Project 540i NEED ADVICE!!

[///Miami Greg]

Adopt-a-540i? Help! Need advice!! I am in need of some good, solid tech-talk from you guys. I just purchased a ’98 e39 540i six-speed and I would really like to dial this car in without spending stupid money on things like turbo-charging, etc. I’m not trying to gain a bunch of horsepower since I also own two M5’s which serve that purpose. (A ‘00 e39 and a ’95 e34 “euro” with the 3.8L engine and six-speed.)

What I would like to do to the 540i is the following:
Chip, Cold-air intake, Short-shifter, Full OEM M5 aerodynamics, M5 Sport aluminum interior, Suspension, Drilled rotors, Larger brakes (740i? M5? Brembo/Movit?) Exhaust (Any tech advice for converting and installing OEM M5 dual system?)

Note: I already have 19” Racing Dynamics with Yokohamas, so that part is done! My question to everyone is simply this; what else would YOU recommend, and why? I would also like to get feedback on some of the above-mentioned items, like what brand YOU would recommend, why, the cost factor, install do’s and don’ts, and lastly, where to get it at the lowest possible price?

Please either post your response so we all can enjoy it or send me a private email if you prefer. xproskier@netzero.net

Thank you very much!! “I’ll owe ya one!” I plan on posting a story, complete with names of those who deserve some credit as well as a photo of the car when it is complete. Title: “Project 540i” So, look for it soon, and thanks again.

///Miami Greg

[fvicente]

Greg,

I'm in miami as well, and I've done most of that to my 540 already with the exception of the bumpers. send me a pm, I'll be more than happy to show you the car and all the mods.

-felix
'97 540/6 with an AA exhaust, custom chip, m5 brakes, m5 suspension, short shifter, M-Audio subs, yada yada yada

[Greco]

Wow Greg, thats alot of topics there, but here goes.

1) Pre-Vanos 540's (pre-99) for some reason have been known to put down more hp that what was originally claimed by BMW. Personally on my stock 98 540 I managed an impressive 274 rwhp performed on a mustang dynomometer, which would equate to roughly 315hp at the crank, and I'm completely stock. I know of otherpeople getting more close to 280 rwhp on stock 540's as well. With that said, getting close to or a little over 300 rwhp is very possible on your non-vanos equipped 540. I would recommend a baseline dyno test to start with. You can go with a load bearing dyno usch as the mustang dyno or a free spinning dyno such as the dynojet. The dynojet figures difference are between 3.0-3.5% higher. I prefer mustang over dynojet because of the load bearing feature which equates to real road driving.

2) For chips, you can go with Dinan (conservative, expensive), or GIAC, Autothority (more aggressive). If you know the Roadfly board, John(Revhigh) has custom programmed Autothority chips for about $550.

3) CAI, the only one's I know about are Dinan of course, and again Revhigh (john@roadfly.org).

4) The 2 most commonly used are Rogue Engineering and UUC. Either of which I would recommend the use of the Rogue WSR (Weighted Shift Rod) to accompagny the short-shift kit.

5) Suspension, depends on what you are looking for in terms of either performance or appearance.

6) Big brake kits usually come with drilled or slotted rotors. There's Brembo, Movit, Stoptech. All are fantastic kits, but personally unless you are doing track time, does it warrant the expense $2K+ for you?

7) The M5's do not have spare wheel well,s thus the use of dual mufflers. For you to do this on your 540, you would need to get rid of the spare wheel. You can either cut out the floor and replace with M5 floor, or have a body shop hammer it in enough to give clearance for the mufflers. If this bothers you, the body work, then Eisenmann and Hamann are the only 2 manufacturer's that I know that make a quad exhaust for the stock 540's. Though they do not currently have one that fits the M Tech body kit, I know Eisenmann is currently working on a system for the 540's equipped w/ m-technik body kit with quad tips.

Have fun w/ your mods..

[///Miami Greg]

Thanks very much for the great input regarding my '98 540i/6. It's great to read from enthusiasts like yourself and know that there is help out there if one just asks for it!! Regarding the car...do you know if Conforti makes a chip? I had luck with two of my e34 M5's using his chip, and I felt his had slightly more torque than Dinan.

Also, regarding the suspension, I would really like to "can" the car. I know of a company called KW who has M5 coilover suspension systems and I also heard that H&R is coming out with one. For now, I think they only have the sport springs offered though. (I would just like the car to sit as low as possible without looking like a Honda boy-racer.) Any suggestions? Also, do you know if I can use the front AND rear OEM M5 swaybars? Also, what are the mm thickness specs of the f/r OEM bars? And lastly, do you know who makes "thicker" f/r bars?

Once again, thank you for sharing your knowledge. I'm sure you are very busy and I really appreciate it. I look forward to hearing from you soon.

**Please send me a photo of your car if you have one!!

xproskier@netzero.net

Miami Greg

[marinakorp]

I believe that Dinan makes an adjustable rear Sway for the 540.. a bit thicker as well.

I agree on the cross drilled rotors... I am not so sure they offer more performance for the $$$$$ involved


One thing that you will DEFINATELY want to do is remove the Darned CDV... clutch Delay Valve... really makes the manula work better (not present in m class vehicles)

[kreativdesigns]

Does the m5 have a spare at all then? I looked at the eisenmann exhaust and it looked like they kind of jerry rigged it to get across to the other side.

Another question: When they say m-technik bumper is that the factory ///m bumper or is m-technik an aftermarket company. I can't find a website for them anywhere. Thanks for the help.

p.s. this is my first post. You guys are alot more knowledgeable than the guys over at dtm

[marinakorp]

M technic is a FACTORY product... not quite the M (front) ... but CLOSE


NO... the M5 does not have a spare at all

[540is]

checkout http://www.fast540.com

543bhp

[///Miami Greg]

I love the upgrade list. Very impressive, but I think I would need to knock over a bank to buy the car!

I didn't see any tailpipe photos. Did you trim the spare wheel out and install dual duals like an M5, or just go around it with a dual-tipped Dinan?