Blackknight530i 530i6 -> M5 Conversion Build Thread - Page 4 - BMW M5 Forum and M6 Forums
E39 M5 and E52 Z8 Discussion 1998-2003 Advertiser's Forum

 43Likes
Reply
 
LinkBack Thread Tools Rate Thread Display Modes
post #31 of 105 Old 19th September 2016, 04:45 AM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
Well, I'll have to take the struts off and turn them later as I didn't get time to do it today. I'm hoping I can get to it before Saturday, since I'm taking it to my buddy's shop to correct the steering column alignment to the steering wheel and redoing the alignment. If I make sure the struts/springs are oriented properly, that will help considerably to get it right. I can't believe I didn't check them before installing them. Ugh. I checked the M5 struts that came with my engine a couple years ago and they aren't that different from the Konis, but they are a bit off where they're supposed to be.

In other news, I wired up the oil pressure switch to the ebox and taped it up with BMW (Tesa) tape and it looks like every other wire in the engine bay. I also extended the wires and changed the connector for the aux water pump and taped those up the same. Both look factory now and work great. I still need to run the wires for the servotronic valve and the sport button. I'll likely do the sport button when I get around to swapping my center console and dash to the extended leather ones I have. I want to have the servotronic wired up before VIR October 1st though, so I'll try to do that this week. I cut the connector off the 7 and I just need to run a couple wires from it to the ebox and tape it up.

-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
blackknight530i is online now  
Sponsored Links
Advertisement
 
post #32 of 105 Old 20th September 2016, 05:35 AM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
So, this evening I got a chance to pull the fuel pump and regulator from the e38 and swap them out on the M5. I have a Walbro 255 lph pump, so it took a bit to swap it over, especially since the hanger is different between the e38 and e39. Also, I'll go ahead and say that I hate trying to get the pump lined up with the plastic slot in the tank. It drove me crazy, even though I was sure I noted the orientation when I took the old one out, but apparently not. The regulator just swapped right out into the stock 530i filter/regulator assembly after pulling the retaining clip. Started the car up and took it for a drive and it seemed to accelerate smoother and was able to pull all the way to redline just fine.

While I had the car in the air, I also checked the springs in the lower seats and they aren't that badly oriented as I though. I was able to rotate the springs a bit, but they were only off by maybe 1/2" to 3/4" or so and they actually follow the contours of the spring seat anyways, so I'm not really worried about them.

-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
blackknight530i is online now  
post #33 of 105 Old 22nd September 2016, 10:48 PM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
I have been driving the car a few days now and having the correct fuel pump and regulator has really made driveability improve. There are no hiccups in power and it pulls like a freight train.

While we had the car in the air doing the differential, we noticed that there were some metal pieces in my rear tires (nail and some shrapnel?) I took the car Monday to Discount Tire and they confirmed that the nail, which was about 3/4" from the sidewall, was deep enough to cause a leak when they wiggled it a bit, but we couldn't find anything in the passenger side rear tire, which was quite strange. I rolled the car forward and back several times and they still didn't see anything. I have been wanting to downsize back to 275/30/19s though for a while now, since even with all the fender rolling, I still get some rubbing on deep dips and heavy loads, so I asked if they could replace my rears. They said 1 would definitely be covered, but unless they found something in the other one, I would have to pay for it. They went ahead and ordered them and they just came in this afternoon, so I'll be heading there in a bit to have them swapped out. Fortunately, they haven't been leaking all week, so it hasn't been super urgent. I am hoping that we find that other metal piece in the other rear tire though, because it would be really nice to have both replaced under road hazard coverage.

The car goes into my buddy's shop Saturday morning for the steering column fix and realignment. I was hoping to be able to get the rear struts replaced with the M5 Konis/M5 springs by then, but we'll see. It would have to happen Friday night if it's going to happen.

-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
blackknight530i is online now  
post #34 of 105 Old 24th September 2016, 03:13 PM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
So far, there hasn't been any rubbing, but I haven't loaded the car down with 3 people and luggage yet, so we'll see what happens then. Again, the 285s only rubbed on certain conditions when the back was loaded down and on big dips. I expect now I can go back to using the lower spring perch on the rear Konis if I wanted and still wouldn't have any rubbing. I suppose I could also run lowering springs now and be fine as well.

They couldn't find anything in the right rear tire, so I had to pay for that new one, but the left rear had a nail in it that did get me a new one for free.

-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
blackknight530i is online now  
post #35 of 105 Old 25th September 2016, 05:36 AM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
Got the steering column fixed today and the car realigned with the full sand bag weighting and it rides great. I don't think the steering column made any difference to how the car tracks, but I feel much better knowing that there is some adjustment available on both sides now and that there are more threads in both sides. Now I can finally put my dash back together, but this time I'm swapping everything to the extended leather one, so I need to take more apart to put it back together, LOL.

-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
blackknight530i is online now  
post #36 of 105 Old 25th September 2016, 05:37 AM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
Oh, and I drove around with 2 other people in the car tonight and there is absolutely no rubbing from the back tires, so downsizing to the 275s was a good choice.

-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
blackknight530i is online now  
post #37 of 105 Old 28th September 2016, 05:49 AM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
Really long day today. First I got started with trying to figure out what's causing a clunk from the front end when driving straight over somewhat rough roads.

First I assumed it was the wiring for my xenon fog lights that might be swinging around and hitting the fender liners, but really, they didn't make noise before the swap. I zip tied them anyways, just to test it out. Unfortunately, this didn't fix it.

Next thing I decided to try was replacing the subframe bolts with actual M5 ones. When we did the swap, I had assumed that the I6 bolts would work the same way on the V8 subframe, but I was mistaken. Brian had a bunch of bolts in his collection, so we found some that would work. It turned out, all but 1 were actual 540/M5 subframe bolts. Anyways, I replaced them all and torqued them to spec. Still didn't fix the clunk.

I noticed that when the car was on the ground and I pressed down on either side, I could hear a double-clank sound coming from around the middle of the engine area. I had checked all the control arm bolts, sway bar bolts, steering bolts, etc. for any looseness, but couldn't find anything. I decided to do a quick search and see if anyone else had a clunk like mine. It turns out the first thread I found was from Topaz540i and he described an almost identical issue. His turned out to be the sway bar endlinks and how they were mounted. I think he put the washer in the wrong place. He said once he put the washer between the endlink and the strut attachment point and cranked them down really tight, it fixed his problem. I went to look at mine and sure enough, I had put the washer on the sway bar end, not the strut end. I swapped the bushing to the correct location and cranked it down, but it still didn't fix the clunk. I'm honestly at a loss on this. Someone did mention that when the washer is missing, it allows the threaded part of the endlink to wallow out the hole a bit, so maybe I just need to get new brackets and try that. I did notice that when the wheels are turned to either side, the clunk is gone, so I'm pretty sure it's sway bar related, as it would be loaded during a turn.

Anyways, on to the other stuff I did today. I finally got around to installing the extended leather dash and center console. This is a very time consuming process, but not altogether difficult. The results are pretty amazing. I could have sworn I got the lower driver side dash from Trevor, but I wasn't able to find it in my house, so I may have forgotten to grab it. I'll probably end up having to put the vinyl one in for this weekend's HPDE at VIR, but that's not a big deal. While I had the console out, I decided to run the wiring for the sport button and swapped the switch center for the one from my e38. It has the buttons for heated seats, and my seats are heated, but I need to retrofit the wiring for them. I also decided to wire up the servotronic on the steering box. I cut the connector off the e38 and ran 2 new wires up the tray under the driver side air box, into the bin with the brake master cylinder, then across the firewall in the cowl covering the engine wiring harness and wiper motors, then into the ebox. I did basically the same thing for the oil pressure switch before. With the Tesa tape, it looks factory installed .

The last thing I did was to do the white LED swap into my custom made black face M5 cluster. I had been putting it off for a long time, but since I was taking the whole dash apart anyways, I figured now was as good a time as any. It looks amazing. This is a pic of the one in my wagon, but it looks the same:


-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
blackknight530i is online now  
post #38 of 105 Old 28th September 2016, 06:14 PM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
So, I was able to order new brackets for the sway bars that mount to the steering knuckle and I should have them by Friday afternoon, which means I should be able to get them on before heading to VIR for the weekend. They should be pretty easy to replace. I'm hoping it fixes the clunking, because I'm sure Brian will be happier to ride in my car without it making clunking noises (he's my instructor ).

-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
blackknight530i is online now  
post #39 of 105 Old 28th September 2016, 06:17 PM
CSBM5
M5 Expert (>4000)
 
CSBM5's Avatar
 
Join Date: Aug 2002
Location: Raleigh, NC
Age: 58
Posts: 6,917
Thanks: 1,447
Thanked 1,369 Times in 910 Posts
I would disconnect one end-link and secure it so it doesn't bang around and see if that eliminates the noise as it makes the bar inoperative. If the noise changes and is there in another form, disconnect the other one similarly -- since it may rattle some if it has play even though the bar is inoperative. This should quickly check your theory.

As an instructor, I would never get into a car with a noise issues like this one nor sign off on it's tech inspection. Sorry, just the way it is.

Current stable:

2001 M5 LeMans Blue/Silverstone
Dinan: springs, Konis, rear sway bar, monoball bushings;
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, BFG Rivals autox/Michelin PSS street/Nitto NT-01 time trials

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

Last edited by CSBM5; 28th September 2016 at 06:20 PM.
CSBM5 is online now  
post #40 of 105 Old 28th September 2016, 06:42 PM Thread Starter
blackknight530i
m5board.comoholic (>1000 posts)
 
blackknight530i's Avatar
 
Join Date: Jun 2013
Location: Charlotte, NC
Age: 33
Posts: 1,155
Thanks: 100
Thanked 154 Times in 121 Posts
Quote:
Originally Posted by CSBM5 View Post
I would disconnect one end-link and secure it so it doesn't bang around and see if that eliminates the noise as it makes the bar inoperative. If the noise changes and is there in another form, disconnect the other one similarly -- since it may rattle some if it has play even though the bar is inoperative. This should quickly check your theory.

As an instructor, I would never get into a car with a noise issues like this one nor sign off on it's tech inspection. Sorry, just the way it is.
That was what I was thinking of doing, but after putting the car up on jackstands 3 times yesterday before coming to that conclusion, I figured I would just get the new brackets and do that then.

Brian was there when everything was installed and I'm confident that there is no play in any of the suspension components. The sound is only there when driving straight at low speeds on rough surfaces. When I turn the wheel, it loads the bar and the sound is gone. I plan to have the brackets replaced before heading to VIR though, so I should be good. I know what you mean though Chuck. If I were worried about any play in the suspension/steering, I wouldn't even consider running the car, but I know everything is tight and in good condition. If it's not the sway bar, it's something behind the bumper rattling around, because there's no other suspension/steering components that it could be.

-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
blackknight530i is online now  
Reply

Bookmarks

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the BMW M5 Forum and M6 Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes Rate This Thread
Linear Mode Linear Mode
Rate This Thread:



Similar Threads
Thread Thread Starter Forum Replies Last Post
M6 build thread! moonshiner180 E63 BMW M6 Forum and BMW M6 Convertible | m6board.com 48 5th May 2015 03:15 AM
Yet Another Build Thread Mdirty9 E39 M5 and E52 Z8 Discussion 89 18th July 2014 07:07 AM
m6 build thread :) Sigm6 E63 BMW M6 Forum and BMW M6 Convertible | m6board.com 20 4th May 2014 07:55 AM
M5 F10 to MH5 S Biturbo conversion build thread (pics inside) Manhart Racing F10 M5 Discussion 13 27th January 2013 10:34 PM
English conversion for Alpina Orig Build sheets GaAlpinaowner ALPINABoard.com | BMW Alpina Discussion 6 26th August 2004 11:07 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome