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Old 05-09-2011, 10:40 PM   #16
Boxer2
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sweet, looking forward to seeing it again
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Old 05-17-2011, 08:27 PM   #17
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thanks fellas.

Couple small updates:

Got the coils installed. In the pics they are somewhere between 1/3 - 1/2 way down. I'll probably be running a bit lower, but not gonna be slammed. I still want the car to be driveable. I'll fart around more with them once I get the tires mounted on my 18s. Definitely gonna need a roll in the rear, not sure about the front. Gotta look into borrowing a roller...




On a side note, there was a stupid amount of digging involved to get to the rear mounts





Also got the brakes and clutch bled with help from my buddy.
Everything is working ok but the brakes will probably need to be done again after a test drive, and the clutch feels way light compared to my E36. It's been so long I can't remember how the 540i was before. I'm wondering if my slave is weak/about to take a shit, but everything felt ok while I was rolling it back and forth a few feet inside the garage.

Pulled a bonehead move too; I guess I forgot to tighten the hose clamp on the lower rad hose back when I put the rad in. I'd had the car running several times but this time I was revving it up a bit only to find a green river on the floor when I got out I think I jinxed myself by grabbing this huge bag of sawdust from a neighbour's shop, but it sure came in handy. No harm done to the car.


Finally, I was gonna let it go for now, but I figured with so much of the interior apart already I might as well rip out the nasty old headliner. Kinda cool that it's modular instead of one big piece. Should make it easier to work with when recovering. I found a guy close to home who does boat tops. He was able to order me some foam-back headliner fabric for $20/yard. Lots of colours available but I stuck with as close to the OEM grey as I could find. We'll see how that goes lol.


that's all for now.
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Old 05-20-2011, 01:51 AM   #18
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sick sick job!! Wow.... I don't know what to say. All I need to do with my touring is a 5 spd swap. Don't even think I'd have the balls to do anything else

However I have a problem with the hatch. Not only my hatch lock cylinder is seized (stupid me for not checking before I bought the car), but recently the power lock does not respond in the hatch anymore. So my hatch is permanently locked. All the hatch trim is unremovable from the inside too!

As far as I know this is the hatch relay in the photo. Can you tell me what kinda fuses there are? And did you have any problems with the hatch?

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Old 05-20-2011, 07:45 PM   #19
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^thanks! My hatch has issues too. The lock cylinder/central locking works, but that's the only way to open it as of now. Neither of the switches work, and the wiper is stuck at 10 o'clock.

I read a thread on BFC where a guy said he changed a fuse in the box under the rear seat, driver's side. After that he said his lock started working again, and he was also able to open the glass, which hadn't been working before. I really haven't taken the time to see how it all works; to be honest, it's been the last thing on my list, but I will be looking to sort it out sometime soon. Sorry I can't be of much help at this point.

I'll go out to the garage and poke around in a bit and see if I can find anything out.
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Old 05-20-2011, 08:01 PM   #20
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^thanks! My hatch has issues too. The lock cylinder/central locking works, but that's the only way to open it as of now. Neither of the switches work, and the wiper is stuck at 10 o'clock.

I read a thread on BFC where a guy said he changed a fuse in the box under the rear seat, driver's side. After that he said his lock started working again, and he was also able to open the glass, which hadn't been working before. I really haven't taken the time to see how it all works; to be honest, it's been the last thing on my list, but I will be looking to sort it out sometime soon. Sorry I can't be of much help at this point.

I'll go out to the garage and poke around in a bit and see if I can find anything out.
Check the wiring loom on the right side hinge of the trunk lid.
I had the same problem in my 520iT, first central locking started acting up, then rear window wiper refused to park then release button refused to work.
10 minutes of soldering and everything was working again.


P.S. Awesome project, can wait to see it with the rims on.
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Old 05-20-2011, 08:25 PM   #21
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^thanks! I'll be sure to check it out. I just wanna drive the damn thing already so I'm really hoping it's that simple of a fix in my case.
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Old 05-21-2011, 02:08 PM   #22
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The wiring is the problem!!! Look at BF.C, over 100 threads of hatch issues. I however, am faced with a double whammy, my hatch locking cylinder does not work! It's seized beyond any conceivable measure. I dumped a can of WD-40 and snapped my key in the process. I might just have to buy a new lock cylinder down the road. For now I'll have to live with it.

Let's get back to the wiring.

I mean what kind of heroin were BMW engineers on? My car was a 2 owner car by old men, and also owned by BMW Canada. This clearly was reworked many times! Shrinkwrap, soldering and taping galore.

The problem is that BMW designed the wiring in S-Shape. Every time you open and close the hatch the S shape turns into a Z shape as it is shoved into the tiny crevice. This is unlike a regular trunk harness that has unconstrained movement. Imagine what happens to the harness after a year of opening and closing the hatch, which contains so much! (Apparently dual sunroof operation is related to hatch wiring. Ask me how I know..)





The good news is: Whenever you open a liftgate, the wiring harness does not move, the liftgate operates on simple hinge. Get into the habit of doing that, instead of opening your whole hatch and your wiring harness simply will not get that much wear.

If any of you owned a 90's IBM notebook, they used to have wires going from the screen to the keyboard. And then people were shocked that after 3 years of use their laptop was unusable? This is the same thing, the less you use it the less hacking with the wire harness in the future! I must do this, because if my wires go, I will have to unbolt the latch from the inside to get my hatch up: (I took of the trim on the left-no need! They are just relays, 99% of time they are fine, same with the fuses under rear seat, and hatch microswitches)



Also, check both sides, not just right side, as Sickfinga said. The right side has the wire for the liftgate, the left side has the hatch release.
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Last edited by BMW_7; 05-21-2011 at 05:32 PM.
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Old 05-30-2011, 01:00 AM   #23
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wow impressive Nick, keep it up
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Old 05-30-2011, 04:50 PM   #24
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BMW_7, thanks for posting those pics - easy to see what I'm likely up against.

I should have a nice update soon. Got the headliner done, most of the interior is back together, and should have the rest of the front end and hood back on in a day or two. Then it's off to the ministry for some plates!
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Old 06-01-2011, 09:49 PM   #25
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what is that tool? and where did you get it?
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Old 06-01-2011, 10:41 PM   #26
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what is that tool? and where did you get it?
It is for brake lines/fuel lines. It puts angles on them, you can buy it at princess auto.
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Old 06-01-2011, 10:53 PM   #27
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^bingo. It was less than 10 bucks.
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Old 06-12-2011, 10:54 PM   #28
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The car has now officially entered the shakedown phase. Brought it out for a wash last weekend, got some temp plates and went for a boot. Drove it to work all week and decided it needed a new slave cylinder. Ended up twisting/snapping the hard line after the flex hose this morning while changing it, so I had to make a new one. Didn't take any pics - was too pissed off. I also got my exhaust fixed so no more leaks. Gonna go for an E test tomorrow if I have time.

After babying it all week, I finally wound it out a bit tonight and it's running like a champ. Other than the clutch needing a better bleed, I'm very happy with how things turned out. Hope to get the tires mounted on the RSs this week and get some real pics. Then I have a bunch of small issues to tackle:

ABS light
SRS light
hatch wiring
sloppy front end
rest of interior swap
etc etc...



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Old 06-12-2011, 11:03 PM   #29
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congrats on getting it all running
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Old 06-13-2011, 06:05 PM   #30
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Sloppy front end on an E34!?!?! Never!! Awesome work! I really should have snapped that thing from Rene myself. It was calling my name, but I couldn't pull the trigger. It would look awesome with the 540 lower front lip, and I can't wait to see the rims installed!
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