Hey everyone,

I am new to the e60 and N54 platform but not new to BMW's. I picked up a 2008 535xi that had a bad fms oil leak for super cheap and this will be my thread to document maintenance and build of it. I relied on threads like this to cross reference work so hopefully I can help someone in the future.

The car as I bought it:








The car had a leaking OFHG and degraded the belt. Belt snapped and you guessed it...sucked into the front main seal.


Main seal sludge

Before diving in

Belt sucked through crank side of seal

 

OFHG block was nasty. I think there might of been cross contamination of fluids happening here at some point

First round of surface cleaning

Bought some headlights to restore while waiting on parts

Passenger before

Drivers before

As you can see the drivers headlight the car came with was "repaired" in a questionable manner

3m kit worked pretty well

I ended up restoring the lights that came on the car and selling them for about the same price that I picked up the replacements for

 

oil collecting everywhere

Degreasing the alternator. This was a gamble but it worked out

FMS. Pretty chewed up




Had upsize the screws in the seal puller tool to get what was left of the seal out

Some more belt shreds

This is the eBay tool I used. Worked fine however I'd recommend larger diameter screws

 

Restored headlight that was sold

Deteriorated vacuum lines replaced

Valve cover pulled to inspect for belt pieces in the valvetrain. Found some pieces but none tangled in anything moving


Belt piece

Belt piece

Hoping this is normal

Cracked vac hose to be replaced

 

New VTT pcv while cover was off

Cleaned things up a little

FMS in and VTT seal guard installed

 

So much carbon build-up. I could grab chunks with pliers. I used CRC valve and CRC brake cleaner to clear these up.

 

Finished up the topside for the time being


Fully cleaned OFHG block


Buttoned up the top side. New vac lines, VCG, OFHG, intake gaskets, tb etc

 

I dropped the subframe so I could remove the oil pan and check for belt pieces. It wasn't nearly as hard as some people make it seem. The right tools go a long way like any other job. I wish I took more photos instead of videos because it seems there is a 20mb file limit for uploads.

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Mark your steering shaft to get the alignment somewhat right when reinstalling

Replaced these old motor mounts

pulled plugs, coils, and fuel pump fuse when priming oil system. I think these are factory plugs.

 

So that's where I'm at now. That was a lot at once but now I am caught up and will be able to make some higher quality posts. If anyone has questions on any of the work I'm happy to share my experiences.

Other maintenance performed not pictured:
sway bar end links
oil pan gasket and bolts r2
Serpentine belt and pulleys
Expansion tank
Vac lines
Brake booster line
wiper blades
ch11f replacement
axle seals and nuts
Diff fluid
Fog light assembly replacement

Eldor coils, plugs, Arm DCI, ARM chargepipe, JB4, on the way

 

You did the oil pan with the engine in the car? That's a lot of work on an x-drive - well done. Are you working on a lift, or with the car on jackstands / quickjack?