Blackknight530i 530i6 -> M5 Conversion Build Thread - Page 3 - BMW M5 Forum and M6 Forums
E39 M5 and E52 Z8 Discussion 1998-2003 Advertiser's Forum

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post #21 of 116 Old 18th September 2016, 04:35 AM Thread Starter
blackknight530i
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Yesterday, I took the car over to Euro Envy in Concord, NC to have the AC recharged, and while I was there, they let me swap out the exhaust ring seals and rotate the struts (forgot to align the L and R properly when I was putting my suspension together). One thing I noticed was that the passenger side lower spring perch was aligned way off and had actually cut away a good portion of my tire on the inside shoulder.



As you can see, about 1/2" of the inside tread is shaved smooth. I rotated the strut and the perch and it looked like it wouldn't cause any more issues. When leaving the shop, started to drive away and noticed a scraping sound from the tire. Pulled it inside and put it back on the lift and noticed that the perch was still awfully close to the tire. Rotated it a bit to get it off the tire (just the perch, not the strut) and it seemed to clear the tire, so this time I drove off and it seemed fine. The exhaust leak is completely gone now and the car feels great. The lower spring perches on both sides look like they are way too close to the tire though and if I had brand new front tires, it seems like they would rub. I never had this problem with my I6 struts on the same wheels and tires, so I'm not sure what's going on here, unless it's just that the V8 struts sit lower in the spindles and that means the spring perches sit closer to the tires. I'm only running 255/40/19 AS3s though, so that shouldn't be the issue. For whatever it's worth, they aren't rubbing now.

I just got the 7 and my wagon back home today, but I was so exhausted from driving all the way to Raleigh and back today, that I didn't get a chance to change the fuel pump and regulator. I'll try to do it in the morning, but I made the big mistake of filling the tank with gas the other night, so I might have to do some driving before I try to do the pump to save from losing a lot of fuel. Maybe I can take the line loose from the fuel filter and turn the key on to fill up a 5 gallon gas can. That should get it low enough to change the pump ok. I'll feel a lot better about driving the car hard once I know I'm getting enough fuel to the engine, so I want to do this soon.

In other news, I'm getting a loud buzzing from behind the passenger side dash area. I thought maybe it was the fuel pump relay (and it might still be), but it could also be how I tapped off the terminal 15 power for the unloader relay in the ebox. I've never heard this buzzing on any of the other S62 swaps I've done, so it's really got me confused. The only different wiring I've done is the terminal 15 wire tapped off another DME pin, but it's a low current wire, so I wouldn't think it would cause this kind of noise. I've got the EGS power connector from the M54 wiring harness I cut off today while at Brian's that I might try to pull a pin out of so I can wire it properly.

That's it for now. Car's running great otherwise

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log
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post #22 of 116 Old 18th September 2016, 04:43 AM Thread Starter
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Originally Posted by zaid View Post
very nice to see you doing the swap. all the best. you are so fast with it. very nice video of the first start. sounds familiar lol
Thanks Zaid! Yeah, we don't move slow . It was a hellacious 5 days of working on it, but I knew what all needed to be done and how to do it. It was just a lot to cram into a small amount of time. I don't plan to do this job again on an I6 car. it's just too much and I had already done a lot of the prep.

The first start died quickly as it was still building fuel pressure, but the second start was without giving it any gas on the throttle at all. Just a normal start and it purred like a kitten. The new cam position sensors I installed smoothed out the idle amazingly well.

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log
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post #23 of 116 Old 18th September 2016, 05:05 AM
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I installed 4new cps when the engine was out. I had the same buzzing relay with code 01 "fuel relay" and suddenly after few days of driving it stopped buzzing and now I have random hiccups at around 2-3000rpm. Let me know if you solve it. And good luck with every thing. Must be fun smoking other cars on a 530 hahhahha
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post #24 of 116 Old 18th September 2016, 07:37 AM Thread Starter
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Originally Posted by zaid View Post
I installed 4new cps when the engine was out. I had the same buzzing relay with code 01 "fuel relay" and suddenly after few days of driving it stopped buzzing and now I have random hiccups at around 2-3000rpm. Let me know if you solve it. And good luck with every thing. Must be fun smoking other cars on a 530 hahhahha
Interesting, so maybe it's the green relay buzzing. I'm pretty sure that on the M5s, the relay module/relay (for non-US vehicles) is mounted over the battery in the trunk, so maybe we just never hear the buzzing in some cars, but since the relay is behind the glove box on ours, we hear it really loud. I'm going to be retrofitting the black relay module into mine now that I got my e38 back home and see if it gets rid of the buzzing. Since you're having the same issue, I'm betting it's not because of where I tapped into terminal 15 for my unloader relay (this is 525/530 specific).

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log
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post #25 of 116 Old 18th September 2016, 07:41 AM Thread Starter
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So, I spent about 2-2.5 hours tonight doing a writeup for how to swap a S62 into a facelift 525/530/540 and created a new thread for it here:Swap S62 into Facelift E39 525/530/540 . This should cover things from a general standpoint for anyone with a facelift car and is not a step-by-step. It does include a pretty extensive list of parts and procedures required based on model, as well as the wiring changes needed. Hopefully it helps people out.

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log
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post #26 of 116 Old 18th September 2016, 01:01 PM
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Did you mean a 255/40-18? I would bet there is no way to get a 255/40-19 on my car without digging into the spring perch. With the OE diameter 275/35-18s up front (same as OE front size 245/40-18), there isn't a lot of clearance left.

Current stable:

2001 M5 LeMans Blue/Silverstone
Dinan: springs, Konis, rear sway bar;
Ground Control camber plates, Brake ducts opened, Evolve tune,
OE 9.5" rear wheels all around & 275/35-18 Pilot Super Sport


2011.5 M3 sedan 6MT Silverstone, slicktop
Dinan front swaybar, Eibach rear swaybar, pins-out-max-camber-up-front, Michelin PSS street/Nitto NT-01 time trials

2007 328i wagon Silver/gray
2006 330i E90 ZSP 6MT Electric Red/Black
1975 CanAm 125MX2
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post #27 of 116 Old 18th September 2016, 04:59 PM Thread Starter
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Did you mean a 255/40-18? I would bet there is no way to get a 255/40-19 on my car without digging into the spring perch. With the OE diameter 275/35-18s up front (same as OE front size 245/40-18), there isn't a lot of clearance left.
Oops, I mean 255/35/19, LOL. I had 255/40/19 on my 7.

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log
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post #28 of 116 Old 18th September 2016, 05:33 PM
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Oops, I mean 255/35/19, LOL. I had 255/40/19 on my 7.
Spring perch minor rubbing isn't surprising to me then even still. The diameter of that is 26"versus 25.6-25.7" for spec size tires. Hence the radius is up to 0.2" larger. I know on one side the clearance is very tight on my car since ages ago in PS2 days I had to replace a damaged tire, and the only 275/35-18 Tirerack had in stock was an MO version, and it rubbed just enough that I couldn't use it. I ordered a regular PS2 through DT, and like the one on the car at the time, it fit fine.

Current stable:

2001 M5 LeMans Blue/Silverstone
Dinan: springs, Konis, rear sway bar;
Ground Control camber plates, Brake ducts opened, Evolve tune,
OE 9.5" rear wheels all around & 275/35-18 Pilot Super Sport


2011.5 M3 sedan 6MT Silverstone, slicktop
Dinan front swaybar, Eibach rear swaybar, pins-out-max-camber-up-front, Michelin PSS street/Nitto NT-01 time trials

2007 328i wagon Silver/gray
2006 330i E90 ZSP 6MT Electric Red/Black
1975 CanAm 125MX2

Last edited by CSBM5; 18th September 2016 at 05:34 PM.
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post #29 of 116 Old 18th September 2016, 06:44 PM Thread Starter
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It turns out the PO has the springs sitting wrong in the perches. I think they're turned about 180* wrong. I'll have to pull them apart and redo them. Fortunately, my friend let me borrow his Baum Tools spring compressor with adapters for E39 springs from his shop. Should be a simple squeeze, rotate, release. LOL, that's what she said, HAHA.

-Paul
2003 "M5" - S62/420g swap, M5 diff, M5 driveshaft, M5 brakes, M5 Traction Bars, Eibach Sway Bars, UUC Evo3/DSSR, Custom Exhaust,
BMW NBT Retrofit, M5 Gauge Cluster, Hella G4 Bi-Xenon Retrofit, M5 Extended Leather Interior Swap, APEX PS-7s, e60 Hubs, Koni Sports
Coming Soon - M5 Bumpers
530i 6-speed swap build thread

2003 530it6 - M54b30/S6S-420g swap, 3.15 540it diff, e60 SSK, VMR VB2 19" Wheels, M5 Gauge Cluster, Hella G4 Bi-xenon Retrofit, NBT Retrofit, Koni Sports, 540i Brakes

2001 749i6 - Retired and being parted out - M5Board Build Log
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post #30 of 116 Old 18th September 2016, 07:14 PM
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I will be swapping out my broken S62 for another one. Glad to see someone is able to do this on a 5-Series in their own space.
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