535xis Restore/build thread
 

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:
https://cimg4.ibsrv.net/gimg/5series...793d58f91f.jpg
https://cimg5.ibsrv.net/gimg/5series...ae35cc8fd6.jpg
https://cimg7.ibsrv.net/gimg/5series...4d38fc4938.jpg
https://cimg0.ibsrv.net/gimg/5series...f9f95d744.jpeg
https://cimg2.ibsrv.net/gimg/5series...ede117082.jpeg
https://cimg8.ibsrv.net/gimg/5series...7ade0e8951.jpg
https://cimg3.ibsrv.net/gimg/5series...4e88a834fb.jpg

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

https://cimg2.ibsrv.net/gimg/5series...3cdeace8a.jpeg
Main seal sludge
https://cimg3.ibsrv.net/gimg/5series...79649c0d4.jpeg
Before diving in
https://cimg8.ibsrv.net/gimg/5series...c3e2d5bdc.jpeg
Belt sucked through crank side of seal

https://cimg0.ibsrv.net/gimg/5series...6b1a86fc6.jpeg
OFHG block was nasty. I think there might of been cross contamination of fluids happening here at some point
https://cimg0.ibsrv.net/gimg/5series...b76e422d1.jpeg
First round of surface cleaning
https://cimg6.ibsrv.net/gimg/5series...c9fb132f3.jpeg
Bought some headlights to restore while waiting on parts
https://cimg7.ibsrv.net/gimg/5series...8cd8597f7.jpeg
Passenger before
https://cimg0.ibsrv.net/gimg/5series...b44c58183.jpeg
Drivers before
https://cimg5.ibsrv.net/gimg/5series...b83dcd6b9.jpeg
As you can see the drivers headlight the car came with was "repaired" in a questionable manner
https://cimg0.ibsrv.net/gimg/5series...a57d53944.jpeg
3m kit worked pretty well
https://cimg4.ibsrv.net/gimg/5series...214110729.jpeg
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
https://cimg9.ibsrv.net/gimg/5series...a2f0f8204.jpeg

https://cimg8.ibsrv.net/gimg/5series...c850bc98e.jpeg
oil collecting everywhere
https://cimg5.ibsrv.net/gimg/5series...958adef33.jpeg
Degreasing the alternator. This was a gamble but it worked out
https://cimg7.ibsrv.net/gimg/5series...09f4a899c.jpeg
FMS. Pretty chewed up
https://cimg3.ibsrv.net/gimg/5series...ddee3fee7.jpeg
https://cimg6.ibsrv.net/gimg/5series...bdb85d84d.jpeg
https://cimg8.ibsrv.net/gimg/5series...f0832d62a.jpeg
https://cimg9.ibsrv.net/gimg/5series...a9704d3a7.jpeg
Had upsize the screws in the seal puller tool to get what was left of the seal out
https://cimg5.ibsrv.net/gimg/5series...6f66a0249.jpeg
Some more belt shreds
https://cimg6.ibsrv.net/gimg/5series...c3962985f.jpeg
This is the eBay tool I used. Worked fine however I'd recommend larger diameter screws

https://cimg3.ibsrv.net/gimg/5series...f294cfb28.jpeg
Restored headlight that was sold
https://cimg9.ibsrv.net/gimg/5series...7e903844a.jpeg
Deteriorated vacuum lines replaced
https://cimg4.ibsrv.net/gimg/5series...5c63c4734.jpeg
Valve cover pulled to inspect for belt pieces in the valvetrain. Found some pieces but none tangled in anything moving
https://cimg4.ibsrv.net/gimg/5series...dd774ab7d.jpeg
https://cimg7.ibsrv.net/gimg/5series...eebc84222.jpeg
Belt piece
https://cimg8.ibsrv.net/gimg/5series...aa590fdb8.jpeg
Belt piece
https://cimg9.ibsrv.net/gimg/5series...3e920b39b.jpeg
Hoping this is normal
https://cimg0.ibsrv.net/gimg/5series...fe3033bf1.jpeg
Cracked vac hose to be replaced

https://cimg8.ibsrv.net/gimg/5series...4ccf6cd06.jpeg
New VTT pcv while cover was off
https://cimg3.ibsrv.net/gimg/5series...94701294d.jpeg
Cleaned things up a little
https://cimg1.ibsrv.net/gimg/5series...9fcdf194e.jpeg
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.



https://cimg8.ibsrv.net/gimg/5series...52267a436.jpeg
https://cimg1.ibsrv.net/gimg/5series...3df40c4a4.jpeg
https://cimg4.ibsrv.net/gimg/5series...7f650d8fd.jpeg
https://cimg7.ibsrv.net/gimg/5series...6bf011422.jpeg
https://cimg9.ibsrv.net/gimg/5series...bd6c0844f.jpeg
https://cimg2.ibsrv.net/gimg/5series...4ed3f4391.jpeg
https://cimg5.ibsrv.net/gimg/5series...0098ead70.jpeg
https://cimg3.ibsrv.net/gimg/5series...97962b8cb.jpeg

Finished up the topside for the time being

https://cimg2.ibsrv.net/gimg/5series...51bcf0335.jpeg
Fully cleaned OFHG block
https://cimg4.ibsrv.net/gimg/5series...394617e63.jpeg
https://cimg7.ibsrv.net/gimg/5series...e3d72be56.jpeg
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.

'https://cimg3.ibsrv.net/gimg/5series...96d161739.jpeg
Mark your steering shaft to get the alignment somewhat right when reinstalling
https://cimg4.ibsrv.net/gimg/5series...a24181cd5.jpeg
Replaced these old motor mounts
https://cimg5.ibsrv.net/gimg/5series...2e837193c.jpeg
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?