TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
I was presented with a deal I couldn't pass up and added another wagon to the collection. This is my second E61 and 3rd wagon.

1st E61: https://www.bimmerfest.com/forums/showthread.php?t=908702
E39 Touring: https://www.bimmerfest.com/forums/showthread.php?t=1245562

I have known of this wagon for a while, back when my E61 was stock I used this wagon as inspiration for the M5 front end conversion and as a reference when calculating my wheel offsets and fitment. Funny how it ended up in my possession. I am the 4th owner, California car all it's life, from 60,000 to current 127,000 it was the daily driver for the owner of an automotive shop in Orange County. The wagon presents well, the body is very clean, and mechanically it's solid. There are some small issues to address which will make it a very polished example.

06/2008 Build
127,000
Grey Interior
Comfort Seats
DSP HiFi
Grigio Telesto Paint + Gloss Black Roof
OEM M5 Front End Conversion
Vossen CV3 20x9F 20x10.5R Hankook V12s
Dinan Muffler
COBB Accessport


THE PLAN:
- Address all necessary repairs, maintenance, and preventative maintenance
- Refine fitment
- *********, FMIC, intake. Nothing crazy just letting the motor work more efficiently.
- If the wagon stays AT the I will retrofit a wheel with paddles and run the XHP trans tune.

- If I find a great deal on a manual 535xi donor car then I will execute a manual swap and hopefully a custom grey on black interior (similar to my white E61's interior).


Should be a fun project, here are some pictures,
Evan

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2SyFH7wOL3tGub5JsViF4Vxg0oKvlKGJI0NwFu5fzYXtc9ocWjbTzxswm31QtdJgW6Eab_HT8ZpV-MDXkg=w1304-h978-no.jpg

BvXwZiG4VDyPKsAFA67mzaEf7SUCZ5yB7MPflyUMeyltro33Zg6_gxCkZt-VnG1WVoRdtisisYqJiQtmBQ=w1304-h978-no.jpg

OpX6DQb7yeEaFk9tWrAfwRuK5oIYalhaRDOGdx4xHrmkiNKSijr9t6_jRXo2okjZ0nVeIAfXfoqYDDGq-A=w1304-h978-no.jpg

5LEo0EX0rxRMIIy5EpP1tDfMTvzltzbrF8tz9trXJOmJ9-isXOGBKj8y9VFKVmVlnJcoUgQwFjSE6u3kFg=w1304-h978-no.jpg

vStJg0MQwU9B5Y9RYRfEmV1H4j4PwpNCKrsmlN-swxeOIU7FmeooH2Rd4qj0e1BSLSe8-PXPr80PGbNM_Q=w1304-h978-no.jpg

VnuotsVzXV0D56XRyDrc0E8iZPIyWSR_9xPhmK-j9n6R9B8wfz7i_uFhW_H-XnXDu83nOGR7YiYL1_gSMQ=w1304-h978-no.jpg

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Sa1oYKLqaCrQlAIu5R5qFRqK6qz3JyewMC8IOoI8WCA6Xuftf4WbREukw2J-n2SDeluVAknEhAhyEmfA3Q=w1304-h978-no.jpg

_20vo9lSUAaceOrHavduJ4Zf5IoGF7DG7XzligUcphQ-nmdrIuUF0uRK2T90Teh9_U9vA_x5gKKRGNVKag=w1304-h978-no.jpg
 

TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
The wagon has received various little upgrades and repairs, nothing major but it all adds up!

A dog's dilema ...which wagon?
59MD57p0LdBQ95VIOplHbjn9Jf-r6EhtZ0KOl4Q9xxREZJXXwTTpnye9gS9ZXRUVgL3BFYqoVlk4Qzap_0=w1303-h977-no.jpg


Reconditioned and straightened Dinan muffler
l2qjs7XddnHJPLTzqyREDQTeFZLr7dzCHL_o3WzZwc5FyBoqc5tm_pNq3vtm3TqCNv2mrYDLA7P6_kKkBt_3Mfwk=s977-no.jpg


Updated firmware on the Cobb Accessport, tune was previously set at Stage 1 and I adjusted that to Stage 1 with linear throttle, boost was coming on too hard and was making it unnecessarily hard to drive smoothly.
cVw58kojo7G02nkttjQm9uOahpW9BIS0HzBwNIOVfRMLw701ebT4oXPXaYUBG1ojKUbUP0P__NPEiwqhII=w1303-h977-no.jpg


Phone cradle delete in center console
CFfI_EhO-H2TQs1u5kH25a1pguBis-HZ0YzaM3kp5Y4aW5DGRh9aiVv4rBhOJTtY2rb_TMY3WUkby7uSE0=w1303-h977-no.jpg


After
Evh6I7toMGCyKKaM0XWjBFRArDIp3Xw2V7l8Xqnby2yfvyhgtI7bxR7ADZtTH9OxzpZAk1o5usBOwYN6ZM=w1303-h977-no.jpg


Front Bumper, side mirrors, top of reach bumper and the forward edge of the hood and fenders are all wrapped in clear bra, UV light took it's tool on the hood and fenders so it was removed.
DOldfXen9nUsMOk_DqXVLDolYE6zJ8WeM2DMWaASbxwJXgFU89QIJft3NU1y1kjObD8WSzmEaa999zPOGc=w1303-h977-no.jpg

ZCGlRsP7-VNclMQJRZM-VxHeePYM0tF6Aqc6Ee10GfV-zYCUW97GHyNjN2fqlewuwPuZHfJdovHFYecgUk=w1303-h977-no.jpg


Following clear bra removal the fenders and hood received a clay bar and some Chemical Guys V36.
F-evwYcuVHbs6_5zfnmv4T8Rs6nBeAeYQqw8FPp1rSZzvpdwvIOyv1EPe5tnnXaAEbPFg6knDpVAfYS_Ls=w1303-h977-no.jpg

UcCQJfarGTNNx4Rh2khmrveg_yB66NMjk40k7REF_6snKNpCFQF9T5lMuRRl9wM0nkf3D4hAimszJg2RxI=w1303-h977-no.jpg


Continued with restoring the window trim and roof rails
Before
pwFmcoSRYT8EQNjNHcK1SUyYjGU6D5M6_hKEJV6Hn9XJgtjRO7AW5l1-jiDxUDGBCQCO26FTYy66_lb2kE=w1303-h977-no.jpg


After
4ac3j37vHsbSDyAyhHyWEZ2J934Q0cgVOOGf_R6hdWILtWt8gIslmfZG_iQSjY5oH0eGfxxuIsjCqTCwHc=w1303-h977-no.jpg


Before
qeaZxGU3-7H6jFOFdN18tzUA27SSiAz8fYpsfJPGN7zV3WA_EtUNhLzVf_V3l6rxI7DRvzyNGIKhwiR1U4=w1303-h977-no.jpg


After
RAPMd66aV3qUvnK-rOsIvhmEvJcQuMMGTSlEz3mLV2lJ0eAVrqz-vfRIntSur92o9J7NrTohwR9Ww4qTFM=w1303-h977-no.jpg


Before
9AB9e0Er4PUwPbxZ7KXxN9Hkw9ZFq5rGgSL71g-iDDAIVogCh2APeydDPKNLt2-oj6E1k5GQA0J1nvzpns=w1303-h977-no.jpg


After
QtsiJ2KZe3OureIWdxOl4w4819G0s6KL-L4mgLi6Rk87YUBxV-2EIZpWRkaoZ2sNALm_NoGGmmh_TXhE0M=w1303-h977-no.jpg


Also cleaned up the engine bay, here is a before and after
4GvaE2auiq0OGUsegM46YJaPYKhubXIE_e-kNoMnCSOWCAHAR4snToLLs4yn0U93OfsllZSucglYCBH7HwOMtKB0=s977-no.jpg


Stud conversion and wheel spacers arrived. 10mmF 5mmR
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I took this opportunity to open up the M5 brake ducts
j80jJjH9TEgmmJ_K2FULXwv9d9LMN7uFJY2iHtSIznHSkCsvG2PNV_f6PBsTOt2TO_73ItCI3RGLEoA_BA=w1303-h977-no.jpg


QJCukz8oCR8INs0_5JT4Kwoht2CGfWkCr_amCV4VB6Z9OzAtgKEc3v_0qXD_bKnxQ2Q3lGSdcuh3GfYRKQ=w1303-h977-no.jpg


Front Before
pc3kl0LKcAarTQMluMv_NrwngDngHyD4nDMGEyqj7olSYqNRz3-0qYnn4DexEC-X7U6oc0A-NRpYZPolHM=w1303-h977-no.jpg


Front After
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Rear Before
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Rear After
NP7sIeWMfO8k5FTIwSqOlvBOn646oM9PTIxirEBCPmwfTKnFVXAsACuy4Cck0FDDApdex7RswVO33b1VqU=w1303-h977-no.jpg


Now time for some coilovers...
9oTT--qcO2t_VQ958zpefqNwHHbbEFI6ZifKI6hDgoLX6l1Zt2m_EqJHN08dIpCDHmR1_O6hupz9a51Fm0=w1303-h977-no.jpg
 

TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
Oh my, another one? Nice color
Yes, no REAL need for a 3rd wagon but couldn't pass on the deal so I am going to give it some TLC for a very short period before passing it on to someone else to enjoy. It sure is stunning in person.
Looking good! Have you tried the RWD mod yet (this is sigmond from instagram)?
Not yet but I did just flash XHP Stage 3 last night so I will be trying that out in the near future. I don't really have a use for the RWD mode on this car but I am curious to give it a shot, buying the license "just to try" doesn't make much sense but we will see. I do love testing and collecting my own data.



The wagon has received various little upgrades and repairs, nothing major but it all adds up!

A dog's dilema ...which wagon?
59MD57p0LdBQ95VIOplHbjn9Jf-r6EhtZ0KOl4Q9xxREZJXXwTTpnye9gS9ZXRUVgL3BFYqoVlk4Qzap_0=w1303-h977-no.jpg


Reconditioned and straightened Dinan muffler
l2qjs7XddnHJPLTzqyREDQTeFZLr7dzCHL_o3WzZwc5FyBoqc5tm_pNq3vtm3TqCNv2mrYDLA7P6_kKkBt_3Mfwk=s977-no.jpg


Updated firmware on the Cobb Accessport, tune was previously set at Stage 1 and I adjusted that to Stage 1 with linear throttle, boost was coming on too hard and was making it unnecessarily hard to drive smoothly.
cVw58kojo7G02nkttjQm9uOahpW9BIS0HzBwNIOVfRMLw701ebT4oXPXaYUBG1ojKUbUP0P__NPEiwqhII=w1303-h977-no.jpg


Phone cradle delete in center console
CFfI_EhO-H2TQs1u5kH25a1pguBis-HZ0YzaM3kp5Y4aW5DGRh9aiVv4rBhOJTtY2rb_TMY3WUkby7uSE0=w1303-h977-no.jpg


After
Evh6I7toMGCyKKaM0XWjBFRArDIp3Xw2V7l8Xqnby2yfvyhgtI7bxR7ADZtTH9OxzpZAk1o5usBOwYN6ZM=w1303-h977-no.jpg


Front Bumper, side mirrors, top of reach bumper and the forward edge of the hood and fenders are all wrapped in clear bra, UV light took it's tool on the hood and fenders so it was removed.
DOldfXen9nUsMOk_DqXVLDolYE6zJ8WeM2DMWaASbxwJXgFU89QIJft3NU1y1kjObD8WSzmEaa999zPOGc=w1303-h977-no.jpg

ZCGlRsP7-VNclMQJRZM-VxHeePYM0tF6Aqc6Ee10GfV-zYCUW97GHyNjN2fqlewuwPuZHfJdovHFYecgUk=w1303-h977-no.jpg


Following clear bra removal the fenders and hood received a clay bar and some Chemical Guys V36.
F-evwYcuVHbs6_5zfnmv4T8Rs6nBeAeYQqw8FPp1rSZzvpdwvIOyv1EPe5tnnXaAEbPFg6knDpVAfYS_Ls=w1303-h977-no.jpg

UcCQJfarGTNNx4Rh2khmrveg_yB66NMjk40k7REF_6snKNpCFQF9T5lMuRRl9wM0nkf3D4hAimszJg2RxI=w1303-h977-no.jpg


Continued with restoring the window trim and roof rails
Before
pwFmcoSRYT8EQNjNHcK1SUyYjGU6D5M6_hKEJV6Hn9XJgtjRO7AW5l1-jiDxUDGBCQCO26FTYy66_lb2kE=w1303-h977-no.jpg


After
4ac3j37vHsbSDyAyhHyWEZ2J934Q0cgVOOGf_R6hdWILtWt8gIslmfZG_iQSjY5oH0eGfxxuIsjCqTCwHc=w1303-h977-no.jpg


Before
qeaZxGU3-7H6jFOFdN18tzUA27SSiAz8fYpsfJPGN7zV3WA_EtUNhLzVf_V3l6rxI7DRvzyNGIKhwiR1U4=w1303-h977-no.jpg


After
RAPMd66aV3qUvnK-rOsIvhmEvJcQuMMGTSlEz3mLV2lJ0eAVrqz-vfRIntSur92o9J7NrTohwR9Ww4qTFM=w1303-h977-no.jpg


Before
9AB9e0Er4PUwPbxZ7KXxN9Hkw9ZFq5rGgSL71g-iDDAIVogCh2APeydDPKNLt2-oj6E1k5GQA0J1nvzpns=w1303-h977-no.jpg


After
QtsiJ2KZe3OureIWdxOl4w4819G0s6KL-L4mgLi6Rk87YUBxV-2EIZpWRkaoZ2sNALm_NoGGmmh_TXhE0M=w1303-h977-no.jpg


Also cleaned up the engine bay, here is a before and after
4GvaE2auiq0OGUsegM46YJaPYKhubXIE_e-kNoMnCSOWCAHAR4snToLLs4yn0U93OfsllZSucglYCBH7HwOMtKB0=s977-no.jpg
 
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TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
Stud conversion and wheel spacers arrived. 10mmF 5mmR
dO4RtMduN5-aJluUb-xe9m0h3nrzo-c3I3uHAF8_GME5dvI2rn-lng4lMBPJ3SMxYuM_u7JoMpBh7QDeak=w1303-h977-no.jpg


I took this opportunity to open up the M5 brake ducts
j80jJjH9TEgmmJ_K2FULXwv9d9LMN7uFJY2iHtSIznHSkCsvG2PNV_f6PBsTOt2TO_73ItCI3RGLEoA_BA=w1303-h977-no.jpg


QJCukz8oCR8INs0_5JT4Kwoht2CGfWkCr_amCV4VB6Z9OzAtgKEc3v_0qXD_bKnxQ2Q3lGSdcuh3GfYRKQ=w1303-h977-no.jpg


Front Before
pc3kl0LKcAarTQMluMv_NrwngDngHyD4nDMGEyqj7olSYqNRz3-0qYnn4DexEC-X7U6oc0A-NRpYZPolHM=w1303-h977-no.jpg


Front After
o4lLJbDvHdBfX-atLWLs7SlMzyGCUHF0Rblh0Mg2O1ebGQJ5-J3SxCoWX9m-i5oO0IPDPNK3SedDm7CFFs=w1303-h977-no.jpg


Rear Before
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Rear After
NP7sIeWMfO8k5FTIwSqOlvBOn646oM9PTIxirEBCPmwfTKnFVXAsACuy4Cck0FDDApdex7RswVO33b1VqU=w1303-h977-no.jpg


Now time for some coilovers...
9oTT--qcO2t_VQ958zpefqNwHHbbEFI6ZifKI6hDgoLX6l1Zt2m_EqJHN08dIpCDHmR1_O6hupz9a51Fm0=w1303-h977-no.jpg
 
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TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
Synced up with a local enthusiast who was parting out a few E60 M5s. I was able to get everything for the black interior conversion minus the door cards, seat backs, and lower seat trim. I also picked up a front/lower M5 splash shield in good condition.
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I put all the small plastic trim pieces in the washing machine and after a quick cycle used some interior conditioner and a microfiber towel to clean/dry/condition and they look excellent, better than expected to be honest.
BoQ8jQS98YGlvSDvvJiOQcV50iUICTPomOUf1EKz5J8DP9mi6nuriqg6S8r_Vqr2dHDuzAzGo6dvtfCWOg=w1304-h978-no.jpg

FMas9n1b3Q9QJYUCP31_A20YDKzWbDwyg8m2lx1Hb8nDTj_Whf6WjHxcGiuENHeyscray4mPcegDBxXsLQ=w1304-h978-no.jpg


M5 carpet and splash shield
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Center console
fbgidQ69cyYIiOaAYRhr_-U1rtyMt1sL87FFwYmtEVIAdPx29ewXnz96IaVCSYiIyMUsQr2OF_w1lPKEhs=w1304-h978-no.jpg


Downloaded the XHP Trans Tune Package (Stage 1, 2, 3) and flashed Stage 3 to give it a whirl, it sounds promising as it makes the trans 50-60% more responsive with some other benefits. I need to let adaptations relearn the new tune for ~50 miles before giving it the beans but excited to see the improvements.
7CmEEJymnnajdCUWWb54mzQTpWnaxczNgqYNKCzDqs5HAxCoxIATnSqnTP-P0l5upCM6LDHC5-hMHvGfpg=w1304-h978-no.jpg


Overkill for this TCU flashing but it's nice to know I could completely rewrite/flash a BMW overnight with the modules being help at a perfect 14.2v :) One badass charger.
6P5yrIk9lwSP74xqZJipUU_JS2OUuR6aFphF7-JH5xlTD3GQinLW3ieXZoc0OdJJGxP0YB-u1Y9nNZW_iA=w1304-h978-no.jpg

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I also snagged a lightly used M-sport SSG steering wheel from a 2010 550i w/ 19,000 miles and it looks to be one with Nappa leather so it's essentially an M5 wheel without the tri-color stitching and SSG push/pull paddles as opposed to the SMG pull/pull. I prefer the pull/pull style but the SSG does have 2 benefits: 1: You can drive and shift with one hand 2: If my research is correct retrofitting this only requires running 2 wires from the wheel, 1 to the DME and 1 ground, and some coding to integrate the wheel. XHP claims "instantaneous" paddle response, looking forward to that.
Here is a pic from the eBay listing, little dirty but should clean up nicely.
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TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
Nice weekend for the wagon.

- Cleaned and swapped most black interior pieces (need console, seat trim, and door cards)
- Ran wiring for paddle shifters
- Cleaned and installed nappa leather M sport wheel
- Installed Depo smoked side markers
- Replaced faulty TPMS module
- Installed new OEM roundels
- cleaned and conditioned leather seats
- installed new Bosch spark plugs
- Replaced driver seat belt
- repaired driver door weather stripping
- targeted valves which need cleaning and expansion tank which needs replacing

Stock side marker
BypnYemg7_5wNFrtTxgzMJ9Fg0_OBXNedodglRer8gJQHUajDhr2VCDfzkoMxPqsqvKTRj9Fdad4oSbhwg=w1304-h978-no.jpg


Depo smoked side marker
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You can see the driver seat belt was missing the plastic nub which keeps the buckle from sliding all the way down, it was pretty annoying to reach all the way down to your left hip for the buckle. Seat belt was replaced.
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Had some left over wiring and pins from my manual swap on the white E61 so I built the wiring needed for my paddle shift retrofit
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mRhpXTCzSm-QJIHYVTdjQ1avsFC3GuPVOPMb4C7F8q5tXkCFtChEIXV84N_CSwTpa143kqxMBN6erdOGrA=w1304-h978-no.jpg


One wire to ground and the other to DME box, easy peasy
90bXhXMx50NvJyYye06qJxXG5cayMB3cah8T3wn5LNtSUMjOAzeY-wtuG1G2KZfGRz11AuJB-jLy2wbXVA=w1304-h978-no.jpg


So much room for activities!
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Before
Nb7P2nySITWOluG_NMF6-ZCE2sUKTH9yHDwR5prd7Yu486vCgj1JFxkVXrZ3eBh8CTFGOd-w6IhgGCyYNQ=w1304-h978-no.jpg


During
yiMaz4uVRFGsbOLTppomDfJVRVdJX0QHf5T3g-nJQrn6Q2KzqVnwNjn07QUBGBQ8U2XDa69rozCRjtm_wg=w1304-h978-no.jpg


After
8-p3kqokW1fNzYYiZms7tM-offXrpV03Qf-692XrPp7F0YM-hBqo4tKbi67kkN7NspNlPacciUsVpMHKIg=w1304-h978-no.jpg


With the seats out I took the opportunity to clean them. Horse hair brush, leather cleaner, micro fiber towel, leather conditioner
qeja3U8qsXuG6kXyE4oYIQiA5A8JPcjnx4d1UPv9ySDV3yBpMym2wVpIoGXQZb2Zv9ZdiFyd4_P96BXFyg=w1304-h978-no.jpg


Weather stripping had worked loose
RCX8ZvLrylH6ew84_ZexBY0a5ZhXUmIf_WjE9HDTRqv_Qee88gQuKle2BAsuylh3Xk3Z8BcR4Zzz6DMaTA=w1304-h978-no.jpg


Repaired using the ever so awesome 3M VHB tape


Found a Nappa leather SSG M sport wheel on eBay from a 550i with 19,000 miles, shown left.
hICFQ_Ggrc6Xuwk3oEouVg9RMwTo7FblzfBhl2oRB4uG3mETN2Sk97BfD0VMggaU4N7XoZ1E07l3Wy9buw=w1304-h978-no.jpg


Cleaned up the leather, swapped over the old lower trim (not a fan of M badges) and transferred the buttons
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TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
Mechanic hack, release hood struts to open the hood 90 degrees for better lighting and access.
KO82iT75__q7nx9apGQ_AGb1DflHyY7IHrctu_qmx--E-346_XsrEQwR8KC8IYb18m6SkR2dgbzlb-0M0g=w1304-h978-no.jpg


Took a peak at the valves and they will need to be walnut blasted
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New bosch plugs
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Expansion tank also looks to be nice and toasty, there are some stress cracks and discoloration so I ordered a new one.
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New OEM roundels and RDC (TPMS) module to replace the faulty one.
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For those who got unreasonably upset that I plasti-dipped the old UV damaged roundels, you can now relax and go find something else to stress over
PQMsV7uSTalRuE5_p27qsxQCXQfwiajOYvjy8d1-DbOaV2wnf2YwMzTEaIBmfqZmZVHdMm9q8FJMouZ7a6h7EIzQ=s978-no.jpg
 

TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
The center console I got with the M5 part out was a little rougher than I was hoping with some scrapes, dents, and the leather bubbling/lifting in one area so I sourced some new pads/armrests. Some might consider these a "downgrade" since they are made of the same material as the dashboard and not wrapped i leather but I did the same swap on my white E61 and love them. I like how it matches the texture of the dash but more importantly, it's comfortable, and much more durable than the leather. For a high wear location like the console it makes sense.
BEFORE
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AFTER
7dGlZYoJlzyy0gL_I1d-ZQWT14LzXD_buO4UbeWA54WPY8fzEdlw7p3TbUyzaCZYWj8iTjA90pr3HYSI9w=w1303-h977-no.jpg


I collected and installed the remaining black lower seat trim and rail trim, with it installed the interior has undergone a nice transition, door cards and black seat backs are the only items left to do.

BEFORE
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AFTER
3bWfTQ2L79vWrFzbGY-_sQL9H-E0FjpHAZSvwXBBheFJ_BcBTyuXoCgsSdUmSGEiJp3RLRFPsc9TklRPSw=w1303-h977-no.jpg

vMtaAqiFtIkIj-YX25LsjqdDLp97vvKk6I7r0S9Rkat-VsgtFg_Qkq1_px4PlIqk86AY7YmXk8s_8P46hA=w1303-h977-no.jpg

MhvoajVE1p-vPndtSA-tiMHFsL-k1lubsY4CX9ledFRV57ktkm6ggmITP1crQPwnM6zag16F3NkJvGlroQ=w1303-h977-no.jpg
 
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TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
- Installed H&R Sport springs in the front and lowered the rear via coding.
- Built custom OEM+ rear door panels
- Replaced cooling expansion tank
- Changed oil and oil filter
- Replaced cabin air fliters
- Inspected and cleaned from end with bumper removed
- Adjusted Front Bumper, Headlight, and Hood fitment

Removed front bumper to inspect and clean items. Ended up correcting some of the wiring harness routing.
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Cleaned the fins of the trans cooler and intercooler
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Adjusted headlight brackets and removed RPI scoop.
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Unused metal bracket: 0 OCD: 1
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The old expansion tank clearly had seen some heat sitting above the turbos.
Ue9C_0BlUd2SSwkCf3i8MDE4PJCzCeyLzPMrBZtII_jL2yPDytW9oph303ARSkfjNWRhqbrabhw2RLXOkw=w1304-h978-no.jpg


Oil Change and new Bosch filter
K4sYX7xvQpotCTjK12PFbR2ujDKdSPkpPafFr1es0-KP9JEScC7hoTejlza1bNJoJlmk0vb2wGBr-Dq4AQ=w1304-h978-no.jpg


New cabin filters
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I bought some used black door cards and built some "custom" OEM door cards by transferring over my leather inserts. A nice finishing touch are the Dirac (Individual Audio) speakers grills from an M5 which show off the DSP HiFi woofers behind.

This is my second time doing this project and using a sharp chisel + hammer is about 2-3 times as fast as using a Dremel or cutting tool, plus it's a lot cleaner.
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All plastic rivets cut
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Old leather insert removed
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Speaker grill swapped
is1BtJHpRng9XEe17hWEzipT8t8EId2urqI7LahKITr8JE7NZcQq6lvRCUyNKSdzTUnXJFbJ7shR1N3NFw=w1304-h978-no.jpg


How I reassemble
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Before
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After
_SeHTCBgJ8pusoAAuoYuvSQENPXqn1c20dfK4uJa2XZKOztY6JXoNshbRaMSHHOpHOQfSQH4KnDMawEcXw=w1304-h978-no.jpg


#DETAILS
L-FjoAAZOdCypRXndhI8VnEz3CJRR9Npezn2_qr8iz5egkjtmGdaYIVyYM62VinxVHZGm7QfFwXQ8bpdWg=w1304-h978-no.jpg


Installed some H&R Sport springs up front
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Coded the rear air
e_dg00AtmN6DgekBSZ3g_4RtoKEeAbhiexyitXzl9ArqGydWsomH4ahzadK18ha74yYxqsfIiE7ezyL7BQ=w1304-h978-no.jpg

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dendrobatez

New Member
Feb 13, 2019
1
Thanks for your thread! I am a new owner of an '08 535 wagon and some of this stuff is pretty helpful. It came from the dessert, the trim looked awful and it not 2 days after getting the chemical guys torq DA and compounds did I find this page and I saw how you restored yours. Now the trim looks almost brand new.

Are you planning on leaving the hood insulation off?
 

The Convert

Captain
Jun 4, 2017
1,012
When you’re ready to sell this, hit me up. I may be interested depending on when it ends up being.
 

TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
Nice wagon! #fan
Thanks
Always very satisfying looking at your work
Appreciate that!
Thanks for your thread! I am a new owner of an '08 535 wagon and some of this stuff is pretty helpful. It came from the dessert, the trim looked awful and it not 2 days after getting the chemical guys torq DA and compounds did I find this page and I saw how you restored yours. Now the trim looks almost brand new.
Happy to hear it helped and your wagon is getting some love.
Are you planning on leaving the hood insulation off?
When you’re ready to sell this, hit me up. I may be interested depending on when it ends up being.
I will keep you in mind. I am making lots of progress, hope to have the project wrapped up within a month or so.
 

TwinTurboWagon

Corporal
Nov 7, 2016
107
San Diego
Garage door lights FTW
UmFMagNds13MUcniQpUjoTN2ekBl53GUs31HjPMW5csQrpTzInUq56TWUn8kQVNBMwy-6JliUi6D9TW6Xg=w1303-h977-no.jpg


Previous owner thought the injectors were on their last legs so I decided to dig into my library of lightly used coils and injectors. The original index 7 injectors with many miles were replaced with some index 9 injectors with ~60k on them. Cleaned and refreshed with obligatory seals.
bni6NxzzfFw-9VzM7D26wz1xN8ptyEo0zhX9ihNY_XVa5HeK2vAEd_PU_tTWTwAFblQQUkrOwikw5YKLUA=w1303-h977-no.jpg


Cleaned them good
Htrxa6VY2HLmyJ1sGU9dtDr-mfC49v650QSYVVA-SYhXgnATq16L3xR2NeWlRGFbtk4X7PF9cVGL7crMJQmf_x4A=s977-no.jpg


Real good!
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Ready for install
br_ru-ea_bCb37jS2OyqRlT2aOHkTScq5jslRxrJYL_k4z7iTz24ZdqEH3_TultorvhT4aBXh5bFuNRBsg=w1303-h977-no.jpg


Coding injectors
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Decided to inspect the transfer case actuator.
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Happy to report all looked good. Nice to see BMW addressed the issue on previous actuators by replacing the plastic gears with metal ones, wish they would do the same for their water pump impellers.
md2Z66iao7oeO0ae7c20_hyHz-Msdf9sWeGeevCe47eO8E8JDOtQc0a8IZFn3cascMcHZ2q60k9kTqmJJw=w1303-h977-no.jpg


Cleaned up and repacked with fresh grease
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Guibo was toast, thankfully I had my old XI guibo left over from my RWD conversion. center support bearing looked fine.
0-XXrH3UR9ABQAgohbFcH2WtMnf4JiSZr4F5pDURY5ztMPcaMpaDYlzPYr07b4cFSfwPPhzoO8W9Cbf1SA=w1303-h977-no.jpg


Actuator and guibo reinstalled.
-qUec_02zXogaY5j0lx9lu3ltMHsivdFtIKKE-TdjgxZpaX18v9CZ57eDnvUVw6_EGaHdvEWk0KXXG-wNQ=w1303-h977-no.jpg


Clean as you go
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Cleaned vanos solenoids MAF, easy to do an eliminates potential variables for a rough running motor.
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The small pin arrived so I could connect my steering wheel paddles to the connector in the DME box.
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Easiest coding ever: PADDLES Wert_0 to Wert_1 done
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Driver side mirror had an issue with over extending and retracting, a pretty odd issue which slowly happens over time. I took the easy way out and swapped one of my old side mirrors and transferred the cap.
H1E_rliD3zeAp-o64S7uFzFz_36Qu7zGRIHwazORy0_Eji84oghwsxTPbKq7-276Bs0l60EEnIkd0QGC9A=w1303-h977-no.jpg

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Did more "fun" creature comfort coding with a pint of fine San Diego craft beer.
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Lowered the rear a few more millimeters, this is about as good as the fitment will get on H&R springs.
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