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RHD E60 M5 6 Speed Build Thread

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1.9K views 11 replies 3 participants last post by  mhiscott  
#1 ·
Hey all, very long time lurker, my previous ownership includes E39 M5, I currently own an E92 M3 and a car I would like to introduce below, my E60 M5.

There's a few reasons I wanted the LCI car, I think the interior is significantly nicer than the LCI cars and I prefer the LCI headlights and tail lights.

The release of the LCI car came with the first revision of the S85 too, the following components are upgraded:

  • Updated vanos pump
  • Updated crank gear for the vanos pump
  • Updated Vanos lines
  • Updated Vanos units
  • Updated oil pan with two drain plugs
  • Updated oil squirters


After a bit of a search and wait, in September 2022, a march 2007 build M5 came up for sale, Space Grey, folding seats (such a rare option and I god send in a saloon), under 56k miles but no alcantara roof, no L7 or Individual audio, IA I could always retrofit, the roof, no big deal, slightly high owner count at 6 previous owners, but that can be par for the course with the E60 given their ownership costs, the big thing was that this car had been in a collection for 6 years, with less than 1k miles between MOTs and had a nice folder called, "Mikes Personal Cars".

Having been burned previously with another E60 M5, I took a very cautious route with the car, I had the car inspected by two specialists, who found no fault with the car, a good friend was heading passed the car en route to the Nurburgring, so I tagged along and we planned to make a trip of it.

We arrived at the car and it remains the best condition E60 M5 I've ever seen, the colour is excellent, and I've never gelled with a car so quickly, but as is customary, it does take time to confirm that one hasn't bought a complete ball of ****, and again, I was a bit paranoid when it comes to E60s.

First stop, all seemed well, I did notice that the oil level had dropped from full to 3/4, it put it down to poor timing, the aircon also wasn't working, something I could fix later, usually down to the condenser or cracks in the coolant lines.

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We approached Folkstone and the oil level dropped to 50% from full, representing a further 250ml decline in the reading, at this stage, ones balloon knot starts to pucker.

We continue, we clear 150km from Calais, we're on walkie talkies and we do some tests to try to determine if there's anything wrong with the engine, no sign of smoke, Emmet did make the point that if it was burning it at that rate, he's also expect it to be on his windscreen, "unless it was in the water dues to a head gasket failure".

When I had the car inspected, there was no signs of any oil leaks, the S85 isn't really prone to oil leaks like other BMW engines either.

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We pulled off the motorway, parked the with it's left side on a high curb and tried to see if we had a leak, nothing, I had brought some 10w60 with me, so I figured, best move is to top it up with 500ml, instead of the 750ml it now indicated it wanted and monitor for change. Maybe taking what is considered to be the most unreliable ///M car in history on a 2500km round trip untested is not the smartest move. ¯\(ツ)

Topped it up, monitored it for the next 500km and it remained stable, had to be an oil level sender.

On to the next problem, a sticky brake caliper, something that would need to be sorted before bringing it home.
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After a few phone calls we managed to get the car to The Crown Performance in Adenau, they serviced the car, ordered a new genuine oil level sender from BMW, pulled off and greased the brakes, front and rear.

So, what else would you do with an untested M5 still on its original bearings.... well... laps, this was my first time on the ring, in a car I didn't really know that I hadn't done my usual blanket service routine on, to say I was anxious was an understatement, but while in Rome....


The SMG makes a bit more sense on track, but that's just where it is its least ****, it's never actually good, it's more capable than I had expected.

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Following a fun weekend, the next step was bringing it home for a few months while I decided what I was going to do with it.

Back home
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#2 ·
Now, onto the preventative maintenance, you cannot enjoy these without addressing the failure points, I like learning about my cars so elected to do as much as I could

Never get sick of this view

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Injectors
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Throttle actuators
- Out with the old
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- look at the thickness of the teeth, this wasn't far off ****ting the bed
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- In with the new
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New front disks and pads
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I also had a new brake caliper that I had spare from the M3, so I swapped that over for the sticky one, the brakes felt weird, so I thought it just air, the car was waiting for a green light from Darragh in EverythingMPower so I figured, worst case he could figure it out, more on that later.
 
#3 ·
The call came in December 2022, a gearbox had been sourced

I really didn't want to have to worry about issues with this car, so I tackled every single known failure point proactively on the S85, along with the manual swap, the following parts were fitted to the car.

  • New plugs
  • New coils
  • New fuel filter / lift pump
  • ACL Rod bearings and ARP bolts, they were pretty bad at 60k miles.
  • Sump gasket
  • Engine mounts
  • Oil pump chains and guides
  • High pressure vanos line
  • Low external vanos line
  • High pressure power steering line
  • Low pressure power steering return line
  • New belts and pulleys
  • New water pump
  • New thermostat
  • New coolant temp sender
  • New rear control arms
  • New front thrust arms


Darragh cracking into it
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Box out
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The things nightmares are made of
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Shifter mechanism going in
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Rear suspension refresh
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There wasn't much life left in these
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Transformation complete, the 12th manual swapped E60 M5 by everythingM power.
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I had to bring the car back to Ireland for a short while, I had sold the gearbox, had planned to courier it back but the implications of shipping your own parts are rather frustrating, turns out transporting an SMG box is less hassle that I had thought.

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E60 M5 life
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Back home and the end result
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It's absolutely brilliant and is a totally different car to drive vs the SMG, more engaging, smoother, more efficient (relatively speaking), feels so much like the spiritual successor to the E39 M5, but better, in almost every single way.
 
#4 ·
I hate CCC, it's just crap, an one of the reasons I also wanted an LCI car was that going from CCC to CIC is pretty straight forward, the move to CIC didn't align with the LCI, but thankfully, all the trims and parts to retrofit are plug and play for the most part.

I also wanted carplay, so another mr12volt was ordered.

Some interior stripping
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Placed the mr12volt where the CDC is provisioned to be, this allowed me to use the CDC most connection too, no need to tap into anything
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The controller does just screw into the existing mountings but you have to cut clearance in the console
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New genuine CIC trim surround
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TCU coming out and Combox going in
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This requires a bit of repinning of the existing wires to the CIC connectors, straight forward enough
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Car play and CIC fitted
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You lose the ability to turn of traction control outside of setting DSC under the M button, I like to drive the car in MDM for the most part so wanted a button to disable the DSC, I ordered a new genuine switch panel from the US manual cars

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I changed the VO of the car to LCI, coded it for CIC, clutch to start rather than brake to start.


There was a catch, the audio sounded crap, CCC outputs in high pass, while CIC is flat, so the sound was crap, this only impacts HiFi equipped cars but the amp is simply wrong, there's no real solution outside of finding an LCI CIC HiFI amp, not a big deal as I was going to Individual Audio anyway but couldn't locate a system in time, but I've since located one

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#5 ·
Being a German resident, I explored the option to register the car in Germany, and really using it for road trips and as a summer toy, I have the E92 M3 in Ireland to scratch the ///M itch while I'm here, it also meant that I wouldn't have to face revenue and all the nonsense that comes with that.

Along with the CIC retrofit, I also tried to fix the aircon, there was no gas left, so I ordered a new condenser

The old condenser
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The new one
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Removing the connections is very annoying, there's a steel locating pin that rusts into the old housing, patience, a chisel and a hammer were the only options.

Had the system gassed and tested, it blew perfectly cold air...... more on that later.


I now had to get the car back to Germany, I arranged it around a holiday, I also wanted to get Darragh to go over it, make sure it was OK and also, just check out the clutch as the engagement was a bit tricky, it felt like air, but I tried bleeding it a few times to no real improvement.

Car was fine, there was no issue, he did acknowledge that the clutch feel wasn't great, tried to pressure bleed it which provided a brief improvement but it soon went back to how it was. I have to drop the car back to him at some stage to have it sorted, but he's committed to doing whatever needs to be done to correct it.

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This was during the summer this year, and when we got on the boat, we soon discovered, the aircon wasn't fixed, this specifically during the heat wave in continental Europe. The S85 already pushes a ton of hot air into the cabin, so this made for a pretty sweaty time, 21 degrees in the UK, we hit France, it was 31 degrees and 37 degrees by the time we got toward Cologne.

Did a bit of a road trip, took the car back on the ring, where it was absolutely excellent, an E60 M5 makes a lot of sense when you can spend your day cruising north of 100 mph. Registering it Germany involved a lot of hoops, especially with brexit, but that's where it is now. I'm getting it transported home in December to correct the aircon and sort the audio retrofit.

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#6 ·
I did a few trips in the car, the first 10k km on it was to take it back down to europe and it took everything in it's stride, heading down to Germany it covered 3300 km over the course of 5 days and didn't skip a beat, when it's up to temp, I didn't baby it either.

It's the best road car I've ever owned....

From Snowdonia
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To cruising at 220 kph for roughly 7 hours, going to Stuttgart and back
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To back to back laps.
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The fuel consumption isn't even that bad.
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I ended up registering the car in Germany and kept it for doing road trips. A few shots of the M5 out for a few laps, as always, it was just easy work.

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#7 ·
I brought it back to Ireland in October last year, as there were a few things I wanted to do.

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When I bought the car one thing that was always going to need to be done was an audio upgrade.

There were 4 tiers of systems in the E60

Standard system
  • 2 mid range speakers in the front doors, 2 mid range speakers in the shelf behind the back seat and one base speaker behind each front seat.
  • In total 6 speakers.
  • Amplifier: Main unit only, has 4 x 15 W (@4ohm), 98db from 63Hz, Freq range 50-14000Hz +/-3db

HiFi (676)
  • As above, but also 2 tweeters in the area at the side mirrors and 2 tweeters together with the mid range speakers in the shelf.
  • In total 10 speakers.
  • Amplifier: Main unit with the same wiring as above. Additional unit 2x40w (@2ohm) for the base speakers under the front seats. The unit is found behind the right side panel in the trunk compartment. 104db from 50Hz. Freq range 40-20000Hz +/-3db

HiFi Prologic 7 (677)
  • as HiFi, but also one centre mid range speaker in the center of the dashboard and one mid range speaker in each back door (to create a surround sound)
  • In total 13 speakers
  • Amplifier: One unit for the whole system; 7x40w for tweeters and mid range speakers (@2ohm) and 2x70W (@4ohm) to the base speakers under the front seats. 110db from 40Hz. Freq range 30-20000Hz +/-1,5db

Individual Audio "Dirac" (752)
  • as above, but now with a tweeter to the mid range speaker in the dashboard, and tweeters in the back doors, but mounted coaxially (separated)
  • In total 16 speakers
  • Amplifier: Amplifier with 9 channels with more power (825W) and the "dirac"-technology (active time compensation). 112 db. Freq 18-24000Hz +/- 3db

My car came with option 676 or HiFi. The way this system is wired is that there is a high pass feed directly to the speakers in the front doors and the rear parcel shelf, then a low pass feed to a HK amp in the boot which feeds the subs. The CCC or original idrive system that I upgraded from has a built in pre amp suitable for driving the speakers, which the CIC system does not, so right now, it sounds rubbish. On the LCI equipped cars that had CIC from factory, (2009 on) it was low pass directly to the amplifier and the amp would run all the speakers.

An upgrade was always on the cards and I had bought a full Individual Audio (752) system back in the summer, I had hoped that I would just be able to run the additional speaker wires for the missing components, but it's a complete rewire as the existing loom takes a feed from the front for the subs only and runs the components directly, and I needed to feed from the IA (Individual Audio amp).

Removed the existing loom and ran the new loom. It's painstaking work but this really is something I don't compromise on with cars, it's a must have for me.


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Here the wiring is headunit to speakers apart from the subs for the original system

The older HiFi wiring
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The wiring for individual audio
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Removing the old loom, I took this photo really to just trigger people
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So the route that BMW would take from factory for the loom, which would be installed before the interior, would run up behind the rash, around to the front door, the speaker and then to the rear door, I elected to rather run it along with the existing body loom in the passenger footwell

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New loom in
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Components in
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The coding was pretty simple, remove $676 and add $752 to the VO, FA write the CAS and NFRM, then default code the CIC unit, it all worked, CIC then just pushes audio through the most loop to the amp which drives the speakers.

This was pretty straight forward, just a lot of stripping, but pretty much the same as fitting a home cinema.

There was one snag, the rear door cards for an E60 that isn't equipped for Logic 7 or Individual Audio don't actually have the cutouts on the rear.


I also decided to register the car and keep it in Ireland, elected for a Cork reg as a D reg is too long being prefixed by 120xxx and cork being 4xxxx.

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#8 ·
I managed to come up with a solution for mounting the rear door card speakers.

Take a set of LCI front door cards from any LCI E60/E61, use them as donors to make mountings for the rear door cards, here's how.

Drill out all the plastic fixings to release the leather trim.

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You'll be left with this, which you can throw away.
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Cut the speaker mountings out of the front door inner trim
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Pay dirt!
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Take your rear door cards, the cardboard section is pre cut but the mountings aren't in place.
You need to remove the card, take the passenger facing upper trim off the door so that you can release the T15 screw holding the metal frame on the door card.

Trim the donor speaker mountings to fit into the aperture and then use them as a stencil to mark the cutout of the leather and plastic.
The leather isn't all glued down, so you can then create enough clearance to drill some holes to make mountings for cable ties, which you will use to clamp the bracket with glue.

Cut out and ready for mounting, you need to use the like of a dremel to smooth the surface.
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Secured using hot glue and cable ties
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Secure the outer speaker grill with cable ties onto the original clips, you can't clip them as gluing the mount creates about 3mm excess clearance, this works fine.
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Reassemble the door card with the speaker

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The finished product
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It works perfectly and once fitted looks completely factory, the orientation of the grill is correct because it's mounting is still in reference to the original factory mount.

Full Hifi to factory Individual Audio retrofit complete and it transforms the car, such a nice place to be.

Thats it as far as interior retrofits for this car.
 

Attachments

#9 ·
BMW shifter mechanisms have always been rubbish in terms of feel.

The Autosolutions short shift kits are well proven in the US. I contacted them, they had actually made one before for a US manual E60 M5, the mechanism in the LHD and RHD cars are the same, so after a 3 month lead time, it arrived.

All plastic and rubber is removed from the mechanism, the plastic ball and socket is replaced with a spherical bearing, the selector arm joints are machined with tighter tolerances and the plastic factory bushes are replaced with polyurethane and brass inserts for a tighter tolerance.

Fitting was a bit of a job, exhaust needs to be dropped and the gearbox needs to be lowered slightly for access but what an improvement.

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Before and after:

 
#11 ·
Thank you, there's a few hoops to jump through but its pretty straight forward, there's no real additional headache due to the car being RHD, given Ireland is now the only country in the European Union, we need to be creative in how we bring cars into Ireland, as there's also massive taxes we have to pay on top of vat and duty for UK cars, especially for performance cars.
 
#12 ·
Cool thread! I'm doing the same CIC retrofit with mr12v currently. Hadn't thought about firing the unit in that location and using the adjacent fiber optics. Will do the same! Thanks for the tip!

I couldn't find the brushed trim for a LHD car. I'm about to ship mine off to Germany to have it milled to fit the CIC controller. Still waiting on one of the two e60 controller brackets before I can get the console trimmed as you did.

The individual system retrofit is sick. I have that option in my E92 M3. May have to look into doing the same with my M5....