Deciding between an 02 and 03 540i6, I see the following changes in 03:

Black headliner - don't care about

Revised grill, bumpers - I actually prefer the less aggressive look of the 02's

Different/Better sport suspension - This one is interesting. I'm not asking what the changes are, but can you really tell the difference in everyday driving? Or is it just a trackday kind of thing?

So, anyone who's driven both an 02 and 03 care to comment?

Thanks!

can't say on the difference between the 02 and 06, but the sport suspension is a huge improvement over stock - the non-sport package 528i I drove before the 540i-6 with sport package I ended up buying was a wallowy boat IMO

supark - both 'versions' of cars, the 02 and 03, have sport packages. I agree with you - I wouldn't get a non-sport BMW. I'm just curious if the '03 changes are dramatic.

bump - no one has driven an 02 and 03 and can comment on the suspension?

donno about 02 and 03 sports sus... but I know my non sports sus. drives like a boat but my mate's sports sus. goes like a bimmer!!

I driven both, and I don't know a diff. It's probably just marketing, because US spec sport packages are pretty limited in late e39's & e46's. All they had to do is revise 1 bushing, and say it's new & improved...

The '03 Sport suspension, I think it's referred to as M-Tech or something like that, has at least different springs (prob just spring rates are diff). At best the diff is subtle I believe.
I remembered reading it somewhere, maybe one of the more recent issues of Bimmer magazine where they had the E39 model buying guide. There's lots of good info in there regarding the diff's between model years.

The '03 Sport suspension, I think it's referred to as M-Tech or something like that, has at least different springs (prob just spring rates are diff). At best the diff is subtle I believe.

Yes, the '03 540iA Sport and the '03 540i 6-speed both had the M-Technic II suspension which was different from the '02 models. They also had stock 18" staggered wheels while the '02 models had 17s. I've driven both and didn't notice a major difference in the suspensions. I think I read somewhere (possibly the BMW Fast Facts CD) that the M-Technic II suspension had more aluminum parts than previous suspensions. I think it was to reduce unsprung weight or something to that effect.

Black headliner - don't care about...Revised grill, bumpers - I actually prefer the less aggressive look of the 02's

Looks to me like the '02 fits you better. ;)

Personally, I think the '03 E39 540i/6 is the epitome of the E39 model lineup. I guess that's probably because I drive one! :)

Glad to hear the diff isn't that major.

Snidely - While I do like the look of the 02 more (providing it has the deep-dish style 32's), I may need to lean more toward the 03 for Sirius and DVD nav ability. Of course, 02's are almost $5k cheaper....

The 03 with the M-tech II also has bigger sway bars than the standard sport edition. I dont know if they make much of a differece since I never drove an 02. But I swapped mine out for the M5 ones.

.......Different/Better sport suspension - This one is interesting. I'm not asking what the changes are, but can you really tell the difference in everyday driving? Or is it just a trackday kind of thing?

So, anyone who's driven both an 02 and 03 care to comment?

Thanks!

The difference in handling between 540i sport '02 and M-Technic '03 is totally inconsequantial. Any differences will be attributable to overall mechanical condition, thrust bushing condition, damper (strut/shock) health, tires (type/wear) and suspension overall wear. These variations will definitely be noticeable, but they have zero to do with the model year or M moniker. The M-Technic cars did not have "superior" parts...this is a myth. The difference between sport and non-sport is very significant though.

The '03 rear springs are more progressive, that's all. The springs are worth $200 at a dealer parts counter and the progressive rate change was only to allow more weight change in the rear for passengers and cargo. The earlier cars with more linear, predictable springs will handle better, if anything. If you want to go fast on a track, spend the $700 for Konis because the stock Boge dampers are worthless.

The sport springs are not for track anyway. I run them on track, but their rate is way, way too low for serious duty. Set up street cars like M3 weighing 600# less run 3x higher spring rate for track. In comparison to an M3 or ponycar with stock springs, the 5er will wallow, heave and lean.

The 03 with the M-tech II also has bigger sway bars than the standard sport edition. I dont know if they make much of a differece since I never drove an 02. But I swapped mine out for the M5 ones.

I don't think so. The '97-'03 sport & M-Technic 540i cars all used 25mm/15mm. The 540i never used the bigger 27mm/16.5mm found on the heavier M5 with it's 9.5" rear wheels. Anyway, you can buy 28mm/18mm bar kit for $380 that blows Dinan and OEM M5 away.

Is that $380 kit you are talking about the eibach kit? I want to look into that...Rear I hear is no problem, but about how much would I be looking at to do the front swa bar?

I don't think so. The '97-'03 sport & M-Technic 540i cars all used 25mm/15mm. The 540i never used the bigger 27mm/16.5mm found on the heavier M5 with it's 9.5" rear wheels. Anyway, you can buy 28mm/18mm bar kit for $380 that blows Dinan and OEM M5 away.

So let me ask you a question. Considering you know the e39 better than most since yours does some track duty.

If you don't take it to the track...but still enjoy taking so twisting back roads. What would be the perfect set up for the 540 e39?

Any info is always welcomed. Thanks.

So let me ask you a question. Considering you know the e39 better than most since yours does some track duty.

If you don't take it to the track...but still enjoy taking so twisting back roads. What would be the perfect set up for the 540 e39?

Any info is always welcomed. Thanks.

I'd install Koni's set to 3/4 T from full soft on rear & run factory OEM sport springs or Eibach sport replacement springs. They are very similar.

I'd install Eibach 28/18 swaybars.

I'd run the SAME wheel width front and rear, preferably 9" or 9.5". Three mm spacers from tirerack are generally needed in front, if the wheel offset is optimized for the rear (23-25mm).

I'd install Ground Control Camber Plates in front that are spec'd for OEM non-coil-over setup.

This setup will be optimal for street use & comfort w slot car handling. Ride quality will be similar to stock with less bodyroll, better response and body control with neutral handling.

This is the perfect compromise setup for street.

For track-quality handling, the complete GC coilover setup with stiffest 500+ f/400+ r springs is way superior. A 3750lb 5 series can not maintain composure under aggressive track maneuvers & peak G's with street springs. The car will wallow and pitch some with sport spring rates. Serious sports cars have higher rate springs combined with a lighter chassis. Once you install genuine track rate springs, you need a kidney belt. It just isn't a practical mod for most 5ers used for hauling folks 95% of the time. You're better off going a bit slower in comfort.

I'd install Koni's set to 3/4 T from full soft on rear & run factory OEM sport springs or Eibach sport replacement springs. They are very similar.

I'd install Eibach 28/18 swaybars.

I'd run the SAME wheel width front and rear, preferably 9" or 9.5". Three mm spacers from tirerack are generally needed in front, if the wheel offset is optimized for the rear (23-25mm).

I'd install Ground Control Camber Plates in front that are spec'd for OEM non-coil-over setup.

This setup will be optimal for street use & comfort w slot car handling. Ride quality will be similar to stock with less bodyroll, better response and body control with neutral handling.

This is the perfect compromise setup for street.

For track-quality handling, the complete GC coilover setup with stiffest 500+ f/400+ r springs is way superior. A 3750lb 5 series can not maintain composure under aggressive track maneuvers & peak G's with street springs. The car will wallow and pitch some with sport spring rates. Serious sports cars have higher rate springs combined with a lighter chassis. Once you install genuine track rate springs, you need a kidney belt. It just isn't a practical mod for most 5ers used for hauling folks 95% of the time. You're better off going a bit slower in comfort.

Thanks for the info!!!