My DD- 2003 540iA MSport Topazblau

[tmv]

(If you hate reading, scroll down for some pictures)
I've had my 525i since Jan 2010. All the maintenance are done and it's a good daily driver. However, it's always under-powered as we know. I decide to find an 03 540i MSport someday, as an upgrade and my ultimate daily driver. I am open to any color and any transmission.
One day in Nov 2013, I was browsing the local craigslist ads for 540i Msport and one came up. The asking price was $7.5k with 154k miles and some service records. The car has Dinan CAI, MAF, throttle body, front strut bar, stage 3 engine and transmission software. That Sunday I drove it home with $6k lighter in my pocket. The car is in need of some TLC so that's what it gonna get.

First pic when I got it home.


What have been done so far as I remember:

Fixing window regulators
These are pretty standard. Any E39 (and E53 too) owner should be able to perform this since it's a pretty well-documented problem.

SAP Replace
I bought a used SAP and swap out the old one. Much better but still a little noisy at start up. I'll look into it some more.

Ambient Temp Sensor
I bought aftermarket sensor. What a mistake! It read about 35 degree higher than actual. I try everything without any improvement. Finally, I bought a used OEM one. Work like a charm. Thanks JimLev for the help.

Faded body molding
I use Mother's Back to Black. It's definitely an improvement. I'll keep applying it every month or so.

Replace the peeling rear roundel


Clear coat peeling on roof
I think about having the roof repainted. Then it hit me: I can sand down the peeling and wrap it in gloss black vinyl. I like the black roof any way, so it's a win-win.
Before

After


Valvona wood trim
Remove and swap the wood trim with the Tech Graphite trim from my 525i. I don't like the wood trim at all, even in black interior.

VCG leaking
I bought new VCG gaskets, bolt groomets, and fuel filter from a member on here. He no longer has his E39. Cost me $60 shipped for them all. I replace the fuel filter last week. It still have the original date back in 10/2002.
The internal looks good for being 155k miles



Oil filter housing leaking
After replacing the VCG, I change engine oil. Look like the PO used some over the counter oil filter with inferior O-ring for the housing. It leaks at start up. Put in the Mahle one and it immediately stop leaking.
Running Mobil1 5W-30 with Mahle oil filter now. I change oil and filter every 7.5k miles. No need for another engine oil debate here.

Engine belly pan missing
I bought the M5 belly pan from a member on here too. Paid $125 shipped which I think is a good deal.

Cluster pixel missing
I bought the ribbon, gauge ring and gray faces on eBay. I figure to do them all when I had the cluster apart. The pixel problem is not that bad but I want it fixed before it gets worse.




Red sharpie for the needle.

Finish and back in the car



The car needs interior cleaning. While doing that, I decide to do a 2-tone interior. I grind off the plastic and remove the inserts from door panels and paint it blue to match the car. To reattach, I use small sheet metal screws and washers.



I swap the LED AEs bulbs, license plate bulbs from the 525i. Replace all the interior lights with LED bulbs. I code the Cold Monitoring off, the Comfort Closing feature with key fob, Double Hazard flashing.
I did the fog light to brake light mod for the rear. More brake like is always better to alert the drivers behind me.


3-piece Racing Hart M5
Then I decide to get new wheels for it. The M-Pars wheels are on lots of E39 now and they are no longer special to me. I would rather get something else. I bought a set of refinished Racing Hart M5 18x8.5/9.5 ET17. I am running 245/265 tires on them. I like the fact that I haven't seen another E39 with them. By any chance that I don't want them on my E39 later on, they are dual bolt pattern that can fit on my Z32.



Headlight adjusters
No more point-down headlight. The headlight on my 03 can not be baked open so I used the ship-in-the-bottle method to replace them. Thanks to the write up in the DIY section.

Euro Tilt/Slide with Storage armrest
Well-worth the $110 spent on it.



Cut off the muffler in favor of straight pipe and burnt dual-tips
Save about 50lbs in the rear. I can hear the V8 sing now. It's still very pleasant cruising around town.



The expansion has broken level-indicator. I replace it with new unit and flush the cooling system. It will be refreshed by the summer.

I have no rattle noise at start up, which makes me leave the Timing Chain Tensioner alone. I will check it when doing the Vanos seal this summer. I decide not to replace the ATF and filter at this mileage (156k) There would be more risk than benefit.

After all those works, here it is in its current stage. Plan to have it lower on coilovers this summer, refresh the suspension, Vanos seals replaced.

[TiAgX5]

Looks great.

I've been looking for an E39 ///MSport manual trans for a while.

[Ricky Bobby]

Tam she looks great! Wish it was a stick but they are so hard to find.

Love the two tone interior, and the seats on the E39, I'm sure it is a beautiful daily driver in your neck of the woods.

[ukrcan]

Beautiful car!
e39 is my favourite bmw of all times!

[jljljl]

wow..speechless
so nice!