Ryan's 2002 BMW E39 540i Project Car

[@M539Restorations]

This was a fun watch. Properly refreshed 540i. Great job, Ryan!

[@computiNATEor]

If you’re ever in the San Diego area, definitely reach out! Ryan’s shop is beautiful

[@E39Source]

Thank you so much for the comment! This was a very satisfying project, and I've been driving the 540i far more than I anticipated. And to echo Nate-- we'd love to meet you next time you're back in So-Cal! I hope your 530i project is coming along well!

[@M539Restorations]

@@E39SourceI can imagine, 540i is a great all around package. Thank you for the invite! I'll definitely stop by next time I'm in CA. Touring is back on the road :)

[@computiNATEor]

@@M539Restorations Excellent work on that! I miss my 530i5 so much, even owning an M5 now

[@E39Source]

@@M539Restorations Awesome! Please reach out if you'd like to exchange contacts [e-mail]. :D

[@vestrevekk]

Love this kind of content. Would love if you started having more of this style of videos. I would have something more to watch when m539 restorations havent uploaded :)

[@tbirdboy]

As a 2k 540i owner in Monterey Co. I do very much appreciate your due diligence on your stock of vehicles and not settling for half way measures but displaying complete solutions as it should be. Well done.

[@E39Source]

Thank you!

[@adcampo7601]

I appreciate your attention to detail. Great work. Very satisfying to watch the progress.

[@E39Source]

Thanks!

[@benm6899]

This is going to be a great series, can’t wait for more

[@MrLaschmoove]

I'm learning a lot from Ryan on how to fix my E39 540i

[@dnovello]

Ryan, you crack me up because I was initially thinking this was going to be a relatively long term project; but, then I see the car completely and- nearly instantly transformed. Not too surprised, though. You are a perfectionist with no tolerance for defects

[@E39Source]

I had no intentions of going this far with it initially, but you know how that goes lol.

[@philipdenner8504]

God, i wish someone in Australia had the knowledge and dedication that you do with these BMW's i have an 07 E60 with only 109,000 Kilometers (65,000miles) on the clock and i love it to bits.

[@Icanhazammo]

Nice work Ryan. Impressive to see how far you and your shops skills have progressed in recent years.

[@E39Source]

Thank you Sam! Do you still have your M5?

[@Icanhazammo]

@@E39Source Yes I do! Just rolled over 166k and just passed 4 years of ownership last month. No longer my daily driver, but it's still going very strong. Thanks for asking.

[@82lowe36id]

Great video. What a rescue. You are a wealth of knowledge. I rescued a 2002 525i with 58,000 miles on it for my daughter's first car. It sat outside for a few years here in SE Texas, so it has taken some sun damage. Overall it runs good. I am new to BMW, but admired them as a kid. Was around Audi and Porsche as a kid since my dad was a mechanic on them all my life. Started working on the small issues so far...new battery, leaking valve cover, leaking power sterring hoses, seat twist and new headlights (someone onstalled horrible amazon aftermarkets) and over deep interior cleaning. Plan on doing the water pump, new cooling hoses, thermostat, DISA valve and whatever else I can find as I go. These are amazing cars from what I see so far. Wish I was local to you for sure.

[@E39Source]

Thank you! Great work on the 525i, those are incredibly reliable cars when any effort is made to take care of them. At that mileage, you should get loads of good use out of it!

[@bobcathey8903]

Hello E39 Source! I have a 97' 540iA "100% stock" Alpine White nicely equipped. I spent about 10k in maintenance when I bought it in 2009 with 130k miles on the odometer. Became my daily driver for 30k miles. The biggest investment was a new transmission. Since 2015, I have stored and done minimal maintenance on it. Rust free, 100% stock. Runs great but needs considerable maintenance/refresh. Your videos on this particular project, in my view, are very important to great e39s which are, unfortunately, being overlooked for the great value that they are. Thank you for this video.

[@KelvinR79]

Excellent! So addicted to these types of videos. Makes me want to improve my E39. In fact, ended up buying a replacement door sill for my car while watching the video 😂. Now jumping to watch the E39Source video on how to replace them. Thanks Ryan!!

[@E39Source]

This is what I love to hear! Thanks for watching and Merry Christmas!

[@Porsche_911_Experience]

Just bought a 2001 E39 540i. My first BMW and a 6 speed. Looks just like yours did

[@E39Source]

Welcome to the E39 community!

[@Harry244ful]

37:10 i thought I was the only one that enjoyed listening to that German E39 showcase video while doing DIY! Great video Ryan would love to come and visit if I’m ever stateside. Regards, E46 M3 and 330Ci owner UK.

[@E39Source]

I thought I was! Fantastic. Thanks for the comment, let me know if you ever hit California!

[@shakealeg88]

Best content on the internet, thanks for saving these cars man!

[@dali_d]

ever saw @M539Restorations ? :D

[@rasmuskurten8455]

Cudos to you for the love and care you give these cars! The E39 is definitely peak BMW

[@ianmcwilliam1753]

Impressive work and attention to detail…I’ve Always enjoyed watching your videos especially on maximizing your car’s potential with improvements, upgrades and restoring them to near perfection. Thanks for sharing what you’ve learned. As an owner of 3 older models, 2000m5, 97 540/6 and 91. 850i/6 I can simply watch vids from your channel to get the best diy content.

[@E39Source]

Thank you Ian! You have a wonderful collection of cars there, I'm glad that some of my content has been helpful for you!

[@jaygrosse8365]

I really enjoyed watching this Ryan. Your attention to detail and encyclopedic knowledge of the e39 chassis is inspiring. It’s interesting that you could not find a shop to agree to powder coat your valve covers. I had that done on my car years ago and they still look as good as the day I got them back. My 2003 540i M Sport with a six speed makes me smile every time I drive it. It has developed a small rear main seal leak that isn’t yet dripping but wets the transmission case a bit. Living in Asheville NC is too far away, but otherwise yours would be on the short list of shops I would trust to service my car.

[@E39Source]

Thank you Jay! I was surprised that nobody wanted to do it either, but in hindsight I'm glad I just went with new ones. Sounds like it's time for a road trip!

[@josemedeiros007]

Great video Ryan, I also enjoy watching your KZbin content. I had a battery that was down to 11 volts on my 2001 530i, I also could not get the engine to start by jumping it with my other 530i, and my friends Crown Victoria Police Interceptor with a 300 amp alternator. I put a 1 amp Schumacher battery charger on it, along with my Pulse Tech passive Battery desulfator, for 4 days, and the battery was fully charged, and started the car each week it sat until I could retire it with the State of California Bureau of Automotive Repair as it was rear ended on the freeway and was totaled by the insurance company.

[@MasboyRC]

I really love old bmw model, these models so beautiful.

[@justiceforall007]

Love the black car parked in front of the silver 540i.❤️

[@merlin2627]

Absolute pleasure to watch, and mad with envy! Beautiful 540, wish I had one and that I could take care of it as you do. 👍

[@jkgv1740]

That's a complete overhaul. I have an 02 540i. I won't be able to do all that to it but this video is a real treat.

[@Juul380]

Loved the perfection and information from this video! Looking forward to follow along your 540i

[@lockergnome90087]

Very soothing, seeing a neglected car brought back so nicely. Great work, as per, Ryan. Should make an excellent road trip car, and be reliable now you’ve sorted the usual M62 niggles. Hope 2023 brings continued success and many happy E39 miles.

[@E39Source]

Thank you so much Jake!

[@e39hamann]

Such an awesome transformation in just one video, love that technical graphite trim too.

[@gamestree5318]

Bro wood trim is the best, love grandpa spec

[@aydinkov]

Thank you for saving these legends!

[@professorjr1984]

This was a dope video brotha, solid work! 💪🏼 My friend was gonna junk his 2002 M sport 540i 😭 picked it up for 500, this video got me excited to put some deep work into it and get it back to mint condition

[@dannyrasulov2942]

As always pleasure to hear, and watch your videos👍🏼

[@energy99er]

Really enjoyed watching the whole video, reminds me m539restorations. Good to see another 540/6 saved.

[@adasterdezaster2865]

That strut stand is nice. I wish I had room in my garage for one. One of the things that makes me really nervous is replacing the front struts. I've got a hole in my garage ceiling from a strut mishap a few years back. I'm lucky it didn't hit me in the face. I'd take the headliner and pillars to the same shop that did the rear deck.

[@markolvera2965]

I was just thinking a couple days ago if Ryan had any more videos! Got lucky

[@E39Source]

It's a Christmas miracle!

[@sicelomasuku5554]

My brother I'm here in south Africa owner of excellence automotive PTY Ltd..u already living my dream ..I love cars .. especially bima and merc

[@juanignaciocaino]

Thanks for saving a manual 540i and not turn it into yet another M5 wannabe. Also, the flickering light sometimes it's caused by a diode that's spliced about halfaway from the alternator to the E-box on the terminal 15 wire (or was it terminal 30?) the thinest of the 2 thick wires that goes to the alternator. It's tucked in the bank 2 wire box sometimes. If that diode blows out it ends up taking out the alternator's VR as well. It's worth checking since if that's kaput you'll fry 2, 3 or 4 alternators until you go on a wild chase and figure that out. (ask me how I know lol) Thanks for having helped me for sooo many years of E39 ownership.

[@E39Source]

Thank you for this comment Juan! Thankfully, the replacement alternator fixed the flickering issues a few thousand miles ago. I will certainly keep the diode in mind should this return.

[@robertc.8684]

Very instructive video, beautiful restoration! The cleanest E39 540i 6 Speed I have ever seen. Keep up with the good job 👏🏼

[@DavidVlogz]

Beautiful just purchased a e39 540 for my channel as well can’t wait to see your progress as well

[@ianmcwilliam1753]

As always a very detailed diy video. My crappy internet wouldn’t play the video properly so not sure it you put one in but The low temp thermostat works great with these engines. Extends the cooling systems , plastics and rubber lifespan plus I’m betting the valve cover paint will last longer.

[@E39Source]

I did do a low-temp thermostat a few months after this video when I did the timing chains/guides, and tuned the DME to take full advantage for it!

[@marcosfernandeznanita7150]

Awesome guide for my new 528 project, thanks for sharing

[@andrewduffie]

Great video and cool car, Ryan! Nice to see all of the work you’ve done on it. I’m slowly working my way through most of the items you did on my E39.

[@jabbour7]

Any 540i that’s manual is automatically a sport

[@cuiivy]

if you love an E39, you love it till death.

[@OfficialMichaelKee]

Love everything he's taking about

[@SvennsCarchannel]

That looks great! Wouldn’t at all see it as a less greater car than the M5 🤩

[@dayalanvelan3070]

What am awesome upgrade to a classic German masterpiece. Looking forward for more videos. Keep up the awesome standard of work. Greetings and God bless from South Africa 🙏🏿

[@E39Source]

Thank you for your kind words!

[@soulslinger674]

I'm so glad you got the same car I have. Mines a little different, the bumpers are different, interior has the brushed metal trim parts, it has the automatic trans with the shift select to the left. M sport package with the same rims. I've been working on it 2 years, replacing a lot of parts, trim and engine has been gone through, repainted the valve covers and all gaskets associated with taking those off, including the kit for the intake manifold. I just did the (4) front lower control arms. Fender liners n pork chops replaced. Still chasing a battery discharge and I don't have passenger seat control, 3 windows don't roll down, and my trunk button doesn't work.

[@E39Source]

Sounds like a BMW, a work in progress car! Keep at it, each job is immensely satisfying haha

[@soulslinger674]

@@E39Source it very much is!! I also have an 02 745i I have not started on. I had it flatbed towed home and my main problem with it is since the transmission and emergency brake were disengaged the car won't start, even after putting it back per instructions. I won't be bothering with it until my 540 is done and on the road. I build torpedoes full time so I have to weekend warrior these things. I did get the Bentley book for the 540i, I mostly needed the wiring diagrams to diagnose and put right the things the previous owner(s) improvised on. I want to bring it back to stock condition.

[@mikeyeh7646]

Wow!! Super job Ryan👏👏 what an awesome daily this is! 👌👍🤘

[@KingTerrasDemise]

just bought my first bmw ever. 528 e39 from 98 in vermont green. shes rough but i feel i can save her. thanks for the info

[@E39Source]

Welcome to the community! Good luck with your restoration efforts :)

[@impking5156]

Hi Ryan. Always have fun watching your videos. Really always clean, great work. I like this. I have a tip for you for the black plastic. I use the Koch Chemie Plast Star or Koch Chemie Nano Magic Plast Care. This makes faded black plastics look like new again.

[@E39Source]

Thank you for your comment and kind words! I have since used some 'Back to Black' on various plastic trims with excellent results :)

[@joshuamartin6841]

The attention you give to this car… I’d love for you to “borrow” mine for a month… hell even a week!! I have soooo far to go! But someday… someday….

[@andream959]

Loved this video, thank you for sharing. I always loved the e39, I had 3 in the past, starting with a 525i, a 540i like the one you are restoring and an M5, just one of the more perfect cars for me.

[@KARiM-G63]

Add great value for this ultimate driving mashine ever built 😍❤

[@PB200559]

Fantastic video and great looking car now. Great work.

[@1995RangeRover]

Outstanding results!

[@jhncvngh]

Wow Ryan. Your uploads truly seem to align with my menstrual rhythms 🤩

[@Giggidygiggidy12]

This content is amazing, keep it coming

[@arnaslt1]

I'm exited for this!

[@Charleh-tk2bw]

Hey man I want to say I love your content, when I first started really getting into E39s, your channel was one of the first to show up and have been subscribed since then =D Also I wanted to offer some advice for jumping dead BMWs, it's always best to connect the dead car at its engine bay start assist points too because our old ladies aren't intended to be jumped directly at the battery, it can cause electrical problems like activating the pyrofuse in the positive cable head (usually only activated from an airbag deployment). Also that 540i manual is incredibly rare in the US and Germany and actually if you were to restore it more, I've seen them selling in Germany for as much as 25,000 euro. Again I freaking love your channel man! You're awesome and I look forward always to any videos you upload! =D Happy holidays!

[@E39Source]

Thank you so much for your comment! I generally do jump from the front but I don't believe I'm loosing too much juice by trying the trunk, those are some meaty wires going up to the starter that should carry the amperage no problem.

[@firstlookpro7282]

Nice video Robert!!

[@wernerdanler2742]

Dang, you did a lot to this thing. My 01 e320 needs a lot of those little things done, but I just can't afford to do it anymore. It runs really well, though, so I'm not worried about it. I had a 2003 530i for a while when I lived in San Diego, and I loved the way it drove. I don't understand why BMW couldn't figure out how to put rack and pinion steering on their eight cylinder cars. Happy holidays.

[@E39Source]

I actually prefer the box to the rack, which I know is a hot take. The E39's steering rack always felt artificially heavy and vague to me.

[@LogicIsDumb]

Someone has good taste in music! I hear The Midnight in the background of the shop

[@A6RXN]

Holy crap man, I used to watch you, what? 10/15 years ago??????????? Crazy your voice ain’t changed at all haha brilliant video!

[@DK-421]

Great car Ryan!

[@florinlepadatu5648]

I knew it from the start you will not have the heart to treat this car with lesser attention than your beloved M5. You love this e39's too much and I bet even if it was a 520d you had done it right from head to toes🤗 Well done! Superb ! Again a true inspiration for any e39 lover about how to maintain these gems. I wouldn't delete rear doors sunshades... is a pretty rare option in Europe... I also noticed something different at your fog lights switch... You mentioned about the rattling noise in the front doors when close with the window opened. Could you be a little more specific witch bolt is about perhaps some pics...

[@E39Source]

Thank you for your kind words! If the sunshades added any value and weren't in constant need of expensive repairs, I would have kept them. The US fog light switch is just for fronts, we didn't get rear fogs (though I retrofit them to my M5). The bolt I am referring to is in the clamp that holds the glass to the regulator. It's a T25 or T30 bolt. You may have to adjust the window a touch to cleanly access it. But once you're in there, you can't miss it.

[@GuciTheBulldog1]

It looks good!! Would had preferred to see HOW everything was taken off !!

[@PursuitMode2011]

Ryan is a MASTER MASTER MASTER BMW TECH!!!!!

[@unosec]

beautiful restoration good job

[@ianleach1869]

Great content, very nice work.

[@sjs5395]

Hey Ryan, nice to see new videos. I have an 03’ 525iA I’m selling.

[@thegenius46m]

Awesome save for an awesome car!

[@acsiii110]

Looking fwd to seeing your solution for the broken 'magazine holder' pockets in the rear of comfort seats. The ABS plastic in there shatters and there's no replacements to be had. I reconstructed mine with 'Visabella Speedfix' glue, but I can't see you spending a weekend piecing old ABS fragments back together.

[@E39Source]

Yeah, I'd have no patience for that. I hope to replace these seats with heated black sport seats eventually. For now, they're just going to sag open. At least they both look the same!

[@Eric-zt5it]

Ryan, Love the new vanity plates on your M5🙌 New to me at least

[@E39Source]

Thanks!

[@terrencethorn9237]

It is a special car with the sport package and the 6-speed Getrag trans. These are VERY rare. The style 32 wheels only came on this Model.The parts alone are worth more than you paid for it.

[@vishachahal7597]

It's got E38 comfort seats. really comfy! just swapped E38 sport seats into my E39

[@danielprose5878]

Wow ! Greez from Germany !

[@pyramos5770]

Ich sehe öfter dass bei US Cars die Motorhaube nicht richtig geschlossen ist. Auch hier.(540i) Welchen Grund könnte das haben ? Danke.

[@E39Source]

Während längerer Servicezeiten lasse ich die Haube unverriegelt, um den Zugang zu erleichtern und damit ich die Kabel/Verriegelungen nicht verschleiße.

[@pyramos5770]

@@E39Source Danke vielmals. Diese Anregung werde ich gern übernehmen und auch im Freundeskreis ansprechen. Alles Gute für Sie und nochmals Danke.

[@speedy6238]

good work. I love your perfection!

[@PursuitMode2011]

Ryan is a GOD!!

[@abelucious]

I had one of these, it has the sport package because the windows trim is black not silver.

[@andersn4707]

❤❤❤❤ one of the best cars

[@gustavocobra77]

Nice setup

[@globe999]

Magnificent transformation. Sterling isn't such a bad color ;)

[@expressobike]

Any upgrade on the steering wheel? The rest is impeccable..

[@chrisstrazzulla8962]

Thanks for the informative and entertaining video. I was able to sort my 530i passenger door issue. It was not stuck in the lock positron. I agree with replacing the actuators as preventative maintenance. I am still sorting out my 99 528u sport wagon with 5 speed manual. Are you ever going to restore some touring wagons? Maybe an M5 engine swap? Happy New Year snd thanks for the fantastic videos.

[@E39Source]

If a customer wants a wagon restoration or M5 swap, I'll be all about it! Not really my style though.

[@mnz19921]

The idle rpm on the stock tune was set too low causing diode failure on the alternators.

[@bishopkrout6323]

Definitely going to be my next car!

[@gudalawrence3746]

#team👍🏾b4watching. Great work Ryan as usual.

[@jesussandoval4550]

That is a awesome quick clean up haha you gotta do a touring e39 next

[@hanafiait4428]

Good job 👍💪

[@manujadesilva22]

Where can I get those wheel center-caps ? They look awesome.

[@E39Source]

tinyurl.com/ynexc5yf

[@Reed_Spacer]

What are your thoughts on the German Auto Solutions 1.2 bar coolant cap? Seems like a good upgrade as well to help with the cooling system.

[@E39Source]

I've never had a factory cap fail before, so I just replaced it with a fresh one.

[@Mücke44]

36:36 the german advertisement in the background for the 5 Series so funny 😂

[@j.ianmichel3059]

So I love the E39 M5. Any experience or familiarity with the E39 platform and LS engines swaps? Equal amount of money after all said and done as an M5 or a complete money pit of an idea to try.

[@E39Source]

It's been done before, but it's never something I would ever attempt or recommend. Sure the LS is cheap and powerful, but that's not what the E39 M5 is about. I think the S62 makes the M5 an M5.

[@stevecooper6653]

Wow 😮 all those Ms 🤗🤗🤗

[@acsiii110]

Please tell me how you removed the wood trim from the dash nd front doors. Those grommets in dash with teeth that bite harder into the pins as you pull are diabolical.

[@E39Source]

I used a plastic pry tool and got lucky, these came out fairly easily. I know some are VERY tight, and you usually end up getting the whole grommet out of the dash. Then you have to twist and pry it off the stud to insert it back in the dashboard.

[@acsiii110]

@@E39Source My grommets did not come out. Had feet on the dash I had to pull so hard, and snapped a few studs off. Trim never went back the same. Forced to do damage. Horrible experience.

[@Reed_Spacer]

How did it go with putting in an M5 radiator with a lower temp thermostat? Any check engine lights and how is fitment?

[@E39Source]

No stored codes/warnings whatsoever. Parts fit identically to factory!

[@zburkst2928]

I'd really like to know a ballpark number for auto to manual swap on a 540i

[@hasanmohammed5302]

What screws/screw size do you use to put the plates on? have a hard time to find one that are correct. Thanks.

[@E39Source]

These are the proper E39 license plate screws: tinyurl.com/yr3434dy

[@Reef.Jones.official]

Very nice video, it s calm and interesting. What is the diameter exhaust tips on the black M5 E39 & E60? 3"?? Merry Christmas from France

[@E39Source]

On an E39 I prefer 3 inch, but an E60 can get away with 3.5 or so.

[@onesikm3]

What 20 degree cooler thermostat did you use ? Does it cause any engine warning lights ?

[@E39Source]

This thermostat: tinyurl.com/4m5m335d No check engine light, no codes, just a cooler engine!