SAVING AND MODIFYING THIS BMW E39 540iT WAGON (6 speed conversion, timing chains and more!)

I have linked a previous video of mine that shows the wiring more in depth for the E39 manual conversion. I have links for other resources that have the coding info of the manual conversion for the 540i wagon and have also included my method of wiring. There are also links to many of the parts I used and needed for the KW Coilovers and the Auto Trans Cooler Delete.

E39 Manual Swap Video with Wiring and Coding Instructions:
   • BMW E39 Manual Conversion (Wiring/Coding I...  

Wiring:
Reverse switch: 1 pin goes to ground, the other pin goes to the cluster( high cluster pin 25 of blue connector, low cluster pin 4 of black connector)

Clutch Switch (New style 4 pin switch that mounts to clutch master cylinder):
Purple/White taps into Purple/White of brake switch
Brown/Black taps into Brown/Black of brake switch
Blue/Black goes to pin 8 of ews wiring
Blue/Brown goes to pin 23 of X60004 (40 Pin connector on DME)

The way I did it to eliminate running wires:
On auto trans cars, pin 6 of ews goes to pin 3 of x70003 (52 pin blue connector on egs/tcu). So I took pin 3 of the EGS connector and ran it to pin 23 of dme X60004 (40 pin connector). And then took out pin 6 of ews connector and ran it to blue/brown of the clutch switch. Pin 6 of ews is no longer needed when the car is converted to manual.

On auto trans cars pin 18 of x70003 (52 pin connector on egs/tcu) goes to pin 3 of x1600 (3 pin purple connector at the gear shifter). So I ran pin 18 wire to the reverse switch wire and pin 3 wire of x1600 to the cluster.

For the reverse switch I cut the two green wires on the auto trans connector and used those to wire to the reverse switch. One of the green wires went to pin 18 wire of x70003 and the other green wire went to a ground.

Additional Wiring Instructions for the 540i Auto with Auto Start:
Ground the original Blue (w/ black stripe) wire at Pin 8 on EWS Connector.
On the X60004 DME 40-pin connector: Remove pin 6 (Black w/ yellow stripe) and pin 40 (Yellow w/ brown stripe) and join/crimp them together.

Coding:
You will need to calculate your ZCS which you can do using Zeko ZCS Calculator found here: https://disk.yandex.ru/d/hYt0UrBN7kcHPA

To run the Zeko app on newer Windows machines you will need to use an emulator like DosBox found here: https://www.dosbox.com/

Here is a great resource that goes over the coding for the swap amongst other things: https://www.bimmerforums.com/forum/sh...

Coilovers:

In order to use KW Coilovers on the 540i you have to use 530i Front Strut Mounts and the associated washers. (2 strut mounts and 2 of each washer) Here are links to each:
https://click.linksynergy.com/deeplin...

https://click.linksynergy.com/deeplin...

https://click.linksynergy.com/deeplin...

https://click.linksynergy.com/deeplin...

Rear Shock Mounts:
https://click.linksynergy.com/deeplin...

Timing Chain Kit:
https://click.linksynergy.com/deeplin...

For Vanos Parts and Procedures:
https://www.beisansystems.com/

Manual Conversion Transmission Cooler Delete Parts:
Expansion Tank Hose: https://click.linksynergy.com/deeplin...

Alternator Cooling Cap: https://click.linksynergy.com/deeplin...

Manual Radiator Drain Plug: https://click.linksynergy.com/deeplin...

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