Ryan's 2002 BMW E39 540i Project Car

This is my introduction and project video for my newly (and strangely) acquired 2002 BMW E39 540i/6 sedan.
E39Source website: www.e39source.com
Help support E39Source by donating: www.e39source.com/donate

[@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

[@paolopanetta10011]

one hour and 24 minutes of fun.....going to enjoy this later!

[@18_rabbit]

well... i would not consider that fun, and instead it's simply very interesting. But if i were doing it, not fun, per se.

[@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!

[@e39hamann]

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

[@benm6899]

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

[@Juul380]

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

[@robertc.8684]

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

[@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.

[@rasmuskurten8455]

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

[@adcampo7601]

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

[@E39Source]

Thanks!

[@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. 👍

[@dannyrasulov2942]

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

[@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.

[@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!

[@mikeyeh7646]

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

[@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!

[@DavidVlogz]

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

[@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.

[@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!

[@MrLaschmoove]

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

[@PB200559]

Fantastic video and great looking car now. Great work.

[@marcosfernandeznanita7150]

Awesome guide for my new 528 project, thanks for sharing

[@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!

[@OfficialMichaelKee]

Love everything he's taking about

[@justiceforall007]

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

[@shakealeg88]

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

[@dali_d]

ever saw @M539Restorations ? :D

[@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.

[@gamestree5318]

Bro wood trim is the best, love grandpa spec

[@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.

[@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.

[@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.

[@aydinkov]

Thank you for saving these legends!

[@MasboyRC]

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

[@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!

[@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!

[@1995RangeRover]

Outstanding results!

[@firstlookpro7282]

Nice video Robert!!

[@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!

[@jabbour7]

Any 540i that’s manual is automatically a sport

[@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!

[@ianleach1869]

Great content, very nice work.

[@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.

[@KARiM-G63]

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

[@speedy6238]

good work. I love your perfection!

[@arnaslt1]

I'm exited for this!

[@DK-421]

Great car Ryan!

[@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.

[@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!

[@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….

[@vishachahal7597]

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

[@jonashillmann1606]

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

[@thegenius46m]

Awesome save for an awesome car!

[@xxx_ray]

Love those style 32's!

[@SvennsCarchannel]

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

[@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 :)

[@markolvera2965]

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

[@E39Source]

It's a Christmas miracle!

[@sjs5395]

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

[@globe999]

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

[@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.

[@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.

[@energy99er]

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

[@gustavocobra77]

Nice setup

[@Eric-zt5it]

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

[@E39Source]

Thanks!

[@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.

[@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!

[@bishopkrout6323]

Definitely going to be my next car!

[@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.

[@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.

[@gudalawrence3746]

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

[@cuiivy]

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

[@LogicIsDumb]

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

[@jesussandoval4550]

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

[@jhncvngh]

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

[@deppen123]

nice i love Sterlinggrau Metallic best colour. Got an e39 Touring with that colour and i love it

[@andersn4707]

❤❤❤❤ one of the best cars

[@PursuitMode2011]

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

[@hanafiait4428]

Good job 👍💪

[@GuciTheBulldog1]

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

[@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 :)

[@efirehawk]

Awesome video Ryan, as usual. Are those M-Sport II or whatever they are called shocks the same ones of the M5? Looking for alternatives to the crazy prices of the OE shocks for my car.

[@E39Source]

These are M-Sport I, so notably softer than the M5 and 540i M-Tech. My advice is save up the cash for the Genuines on the M5, nothing else rides as well.

[@Qsannqc]

the great work

[@cacolargo]

Really nice! Where did you get the front and rear bumper? You got them painted? Or you had to do the paint after? Thanks!

[@E39Source]

I acquired the bumpers from my local BMW dealership and then had an auto-body shop paint them.

[@danielprose5878]

Wow ! Greez from Germany !

[@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!

[@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.

[@LittleCrazyBoy666]

Have the same colour 530i. These cars are the best.

[@Maximilian0011]

is it Aspensilber?

[@btfd1337]

What shop do you use for headliner reupholstery? My brother's E46 needs his headliner recovered in North County SD. Great video as always! Cheers

[@E39Source]

AP Upholstery in Miramar.

[@abelucious]

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

[@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.

[@PursuitMode2011]

Ryan is a GOD!!

[@stevecooper6653]

Wow 😮 all those Ms 🤗🤗🤗

[@expressobike]

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

[@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.

[@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.

[@neilbrown5785]

Hi guys! Good content! Does the 540i have a vanos? I thought only the M version has a vanos...

[@E39Source]

The E39 M5 has double-VANOS, meaning variable valve timing on both the intake and exhaust camshafts. The 540i has variable valve timing on the intake cam only, but this is still VANOS.

[@rogerxxe]

Fantastic!!!!!!!

[@markestrada4466]

noticed you use brass bleeder screws, have had mixed reviews about them , wanted your thoughts

[@E39Source]

I use these on all E39s, I think it's a fantastic upgrade that couldn't be much cheaper or easier. No downsides that I have seen unless you don't like the look of the brass.

[@Santi_Mancini]

Awesome video Ryan! For a daily driver, with good compromise between reliability, consumption and performance, would you say the 540i is the best balanced of the E39s or would you good to a 530i or 535i? Thanks

[@E39Source]

The 530i is probably the 'best' E39 blend. I'd say it beats out the 540i due to its reliability and relatively low cost of ownership and maintenance. For my tastes, it lacks power/torque and most of them are short on options/equipment compared to 540is. Since I do all of my own service (and largely enjoy it), I personally prefer the more maintenance intensive 540i.

[@Santi_Mancini]

@@E39Source Thanks Ryan, very interesting PoV! Do I have to understand that the main item to chose between a 530i and a 540i would be the maintenance costs, as it looks like they are expensive on a 540i unless you make them yourself?

[@E39Source]

@@Santi_Mancini This is essentially true. The 540i is a more premium car with better driving dynamics and a lot more power and torque, but it does require more frequent and more expensive maintenance. It all depends on the vehicle you start with though, many E39s are very neglected while others have been cared for properly throughout their lives.

[@manujadesilva22]

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

[@E39Source]

tinyurl.com/ynexc5yf