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E34 540i/6 Project Thread

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    E34 540i/6 Project Thread

    Purchased the car January of this year. I've owned an E30, and a very sweet 5-speed E32 735i (That I regret selling on a daily basis), and now this E34. I hadn't seen too many equipped with a manual transmission, and I've always loved the look of them, so I went and checked it out. Here's one of the pics from the Craigslist ad:

    1995 540i 6-speed manual. 190k miles. Salvage title. (boo)
    The knock-off e36 mirrors didn't fit correctly, the rear bumper was damaged, poorly rattle-canned, and barely hanging on, it couldn't idle cold at all, the M-Sport bumper was damaged, and it had a thick layer of grime all over it. It has evidence of being in multiple collisions. Most of the paint doesn't match period.

    I had never driven a V8 BMW before, and this thing is a blast. Clutch is strong. Radiator, fan clutch, and radiator hoses look brand new. Tires are brand new. Sunroof and power seats/those leg bolster things work. Even with its faults, I had to buy it after I drove it.

    Successfully drove it home about an hour and pressure washed it in 30 degree weather. Still pretty nasty.


    Hit up a U-Pull-It about an hour and a half from me and picked up replacement white bumpers and mirrors from a 525i.





    The cold start has been really rough since I bought it, and the idle has always been rough. Warmed up it's decent, and at speed is great, but even after replacing the missing IAT sensor, valve cover gaskets and spark plugs, things just weren't right.

    So here's what I did:
    1. Replaced PCV with OEM
    2. Installed new hardware on PCV and TB to get rid of those Torx bits
    3. Replaced Intake Manifold Gaskets
    4. Replaced TB gasket
    5. Repair vacuum leaks I found along the way
    6. Cleaned TB
    7. Installed double washers on Intake Manifold gasket tubes








    Broke a knock sensor while pulling the intake off. Couldn't source one locally, so I ended up sanding the plastic down, re-soldering connections, and insulating it. Works fine. No codes. All is good.




    This might've been the source of one of the vacuum leaks..


    Previous owner must've correctly assumed the PCV was leaking, and incorrectly applied some RTV in hopes to stop it. Spoiler: It didn't work


    Check out those trumpets! Pretty weird for a 1995 car.





    Could've taken a lot more pictures, but I was more interested in getting the car back together the same day.

    At the end of the day, I turned the key to prime the fuel system, fired it up, it stumbled for a second (probably due to re-pressuring the rail and stuff) and now has a buttery smooth idle. No check engine light. Revs clean. Sounds wonderful.

    Stay tuned for more...

    #2
    I've been daily driving the car on my short commute without much issue. I had a scare for a moment thinking my car had a knock, but it turned out to be my alternator bearings making noise. In the last couple weeks or so I've replaced/fixed:
    • Oil Pan Gasket (Found an oil pump bolt hanging out in there)
    • Timing Chain Lower Tensioner
    • Oil/filter
    • Fixed glovebox latch and broken trim
    • Cracked headlight assemblies and missing lights - My Euro Smilies were ghetto-rigged, poorly wired, and I was missing a high beam
    • Repainted bumper and front trim
    • Replaced ill-fitting knock-off E36 mirrors with stock
    • Idler pulleys





    Still need to fix/replace:
    • Alternator - it charges and works fine, but makes an annoying noise
    • Seat twists
    • Connections for oil level sensor and fog lights
    • Paint the rear bumper all white (Just got my Tower paint in the mail today)
    • Figure out a random warm misfire

    Comment


      #3
      awesome project! gotta fix that driver door too, somethings going on...

      I have always liked these cars. cool to see you savings this one from death by PepBoys.

      Comment


        #4
        Thanks for the reply!

        I'm on the lookout for a door and a hood. Mine was very poorly repainted and the clearcoat is peeling.

        I'm 99% sure I fixed the warm misfire issue. The wiring to the IAT sensor was precarious, so I installed a new IAT and re-did the wiring. Took it out for a shake-down, with multiple cycles of stopping/on/off, no misfires!

        Comment


          #5
          Looks so clean! Amazing how good e34's look in white!
          Instagram : makeitsnap

          1985 e28 520i

          Comment


            #6
            Well, a business opportunity happened that I couldn't pass up, so all my toys are for sale. Here's the ad for the 540i:

            Comment

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