E34/E28/E12 Discussion Discuss the E34 (1989 - 1996), E28 (1982 - 1988) and the E12 (1972 - 1981) 5 series models here.

Project Ares: E34 540i/6

Old 08-02-2016, 07:52 PM
New Members
Thread Starter
Join Date: Dec 2014
Location: Prescott, Az
Posts: 5
My Ride: E34 540i/6
Model Year: 1995
Engine: M60B40
Default Project Ares: E34 540i/6

Hey Guys, here's a little build thread on my E34 540i/6. It's my project daily driver that I've been putting together as a fun hot street build, replacing or modifying along the way as I see fit to my own personal tastes.

I picked up the car non-running. It would crank but not fire.

Name:  BeFunky_20141105_172229jpg.jpg
Views: 350
Size:  75.8 KB

Name:  BeFunky_20141018_0920551jpg.jpg
Views: 167
Size:  123.1 KB

The car came with 18 M-parallel copy wheels. The chrome is destroyed on each, so I dismounted the tires and now the wheels are a coffee table in my apartment.

It took me a while but I found that the harmonic damper was installed clocked incorrectly so the DME was sending fuel and spark timing way off into no mans land. Once it was running I took care of a few leaks and then drove it for a year and a half, slowly modifying things along the way.

I made a grill for it:

Name:  20150430_191534.jpg
Views: 133
Size:  668.3 KB

Most BMW enthusiasts hate it, I like it.

Then I traded the wheels off of a junk car that came through my shop.

Name:  11838671_10200827825733818_5084291996228937629_o.jpg
Views: 296
Size:  111.1 KB

Name:  20151112_083130_2.jpg
Views: 159
Size:  188.7 KB

Replaced all of the broke engine & trans mounts for a set of RevShift Poly 95a mounts:

Name:  20151004_092432.jpg
Views: 130
Size:  681.5 KB

Name:  20151004_074312.jpg
Views: 127
Size:  487.8 KB

Name:  20151004_092511.jpg
Views: 132
Size:  631.3 KB

For computer tuning I'm running an Ostrich 2.0 chip emulator installed in a Bosch 404 DME loaded with my own tunes via TunerProRT. I eventually want to get that MAFT-PRO piggyback unit to take primary fueling control as it has wideband O2 AFR tracking capability.

Name:  20160109_090842.jpg
Views: 153
Size:  518.4 KB

Installed some seats:

Name:  12489281_10201285344651505_2652757086259120501_o.jpg
Views: 155
Size:  128.3 KB

After daily driving for 1.5 years it came time to address the clutch, as it was already grabbing at the end of the pedal stroke since day one.

I opt'd to pull the drivetrain, clean things up. Replace & modify a few things.

Name:  20160308_134119.jpg
Views: 133
Size:  669.2 KB

I also wanted to dial in some custom cam timing, and add a few bolt on's while it was out:

Name:  IMG_3705.jpg
Views: 127
Size:  518.0 KB

Name:  IMG_3721.jpg
Views: 126
Size:  683.5 KB

The OE cam timing uses a 246°/242° duration on a 109°ICL with 108°LSA. I advanced intake cams and retarded exhaust cams for a 106°ICL./106°LSA. Nothing drastic, just a little increase in dynamic compression and valve overlap.

Name:  IMG_3741.jpg
Views: 134
Size:  656.0 KB

Spec lightweight single mass flywheel, Spec StageII kevlar clutch:

Name:  IMG_3959.jpg
Views: 137
Size:  695.8 KB

Name:  IMG_3967.jpg
Views: 130
Size:  600.6 KB

Name:  IMG_3955.jpg
Views: 178
Size:  786.4 KB

Name:  IMG_4017.jpg
Views: 138
Size:  622.7 KB

Cleaned up and painted the engine bay/body/frame. Removed ABS pump, installed manual brake bias valve. Removed leaking 540i steering gear, installed 525i steering gear converter to manual steering.

Name:  IMG_4003.jpg
Views: 139
Size:  692.8 KB

Name:  IMG_4046.jpg
Views: 158
Size:  733.8 KB

On the way in those aftermarket headers didn't come close to sitting in the body of the car. So the OE manifolds went back on, after a header wrap treatment.

Name:  IMG_4047.jpg
Views: 159
Size:  757.6 KB

Name:  2016-07-30%2011.27.55.jpg
Views: 147
Size:  243.0 KB

I then tackled the control arms, and then also lowered the front end a bit.

Name:  20160731_192134.jpg
Views: 125
Size:  216.6 KB

Name:  20160801_101550.jpg
Views: 128
Size:  245.0 KB

Name:  2016-08-02%2020.45.01.jpg
Views: 133
Size:  234.6 KB

Name:  2016-08-01%2015.08.49.jpg
Views: 142
Size:  202.0 KB

It's going in for an alignment and to have new exhaust pipes made this week. I'll keep modifying it, and tweaking it. The computer tuning and speed density conversion will take a bit. I have toyed with idea of adding nitrous. But really, the only other major mod I have planned is to rid of the 2.91:1 open rear differential and rebuild it using E46 M3 210mm 3.64:1 gears and limited slip carrier.
Mykk is offline  
Old 04-29-2018, 07:48 AM
New Members
Thread Starter
Join Date: Dec 2014
Location: Prescott, Az
Posts: 5
My Ride: E34 540i/6
Model Year: 1995
Engine: M60B40

A few updates on Project Ares: Replaced a siezed Spec clutch with a Luk clutch. Removed 2.93:1 rear gear for 3.62:1 LSD, Remove Bosch Motronic DME and installed and tuning a DIY EFI called Speeduino after converting the ignition system to a waste spark MSD set up.

Mykk is offline  
Old 04-29-2018, 07:53 AM
New Members
Thread Starter
Join Date: Dec 2014
Location: Prescott, Az
Posts: 5
My Ride: E34 540i/6
Model Year: 1995
Engine: M60B40

Started building a new engine: M62 shortblock, M60B40 heads and cams with M60 double roller timing set up. Eaton M112 supercharger from a Jaguar.

Mykk is offline  
Related Topics
Thread Starter
Last Post
E60 Discussion
11-26-2016 04:49 AM
Tires & Wheels
07-13-2016 11:48 PM
Private Member Classifieds
08-19-2015 09:56 AM
E60 Discussion
08-18-2015 08:35 AM

Thread Tools
Search this Thread
Quick Reply: Project Ares: E34 540i/6

Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.