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E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #251  
Old 09-06-2012, 09:06 PM
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Additional heat exchanger added to the intercooler driver here around tonight without temps getting over 100F (and this is in the manifold temp.) At boost or not and outside air was 75!

Dyno tomorrow!
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #252  
Old 09-06-2012, 09:12 PM
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Quote:
Originally Posted by LalaRay View Post
Will the power delivery on a Supercharged 540 be at the same Rpm as it was N/A ?
I thought I responded to this sorry man!

Yeah it should be max power just before redline...higher the rpm the higher the boost so max horse power is near the top. Torque curve will be a bit different from NA... As the blower really only starts to boost around 3k below that would like almost stock maybe slightly elevated as even though the intake isn't pressurized it is still be force fed a little as you can see by a reduced vacuum. Peak torque will be a little higher rpm than NA I believe. I will post the runs when I have them should e tomorrow although we are also fixing the base a little to get some of the quirks out I have seen. Car is running great lets see how it goes!
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2001 540i - Orient Blue

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A1 Headers, Random Technology Cats, Eissenmann Exhaust
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  #253  
Old 09-06-2012, 09:25 PM
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Good to hear! Congrats!

I was wondering how much vacuum does the stock engine have at WOT?
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  #254  
Old 09-06-2012, 09:43 PM
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Originally Posted by Flug540 View Post
Good to hear! Congrats!

I was wondering how much vacuum does the stock engine have at WOT?
i have no idea it is around 20inhg idling I think. Some would should chim in and hook up a vacuum gauge on their non SC 540 haha.

Yeah it has been a HUGE project...it is almost done...I have a ton of parts.

I am wondering what sort of IAT the non-intercooled kits are seeing. Just a simple reading from INPA, or something of the like would not do though as the intake air sensor is before the SC on these kits!! I really don't see how they get a good reading. My tuner was very good and we moved it to the manifold. With the water to air intercooler I can turn the pump/fans off...and have seen temps over 150F that was not WOT I got nervous, pulled over and plugged it back in. In this quick test there is also water in the IC it just is moving other than some thermal flowing that may occur. So I am not sure how accurate that is...but I am seeing a 50-60 degree change and this is all without ice in the ice box. Haven't played much with the ice. I am mainly using that tank to increase the volume of water thereby increasing the thermal mass.
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2001 540i - Orient Blue

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  #255  
Old 09-06-2012, 10:00 PM
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Nice temp drop! I'm planning to add an intercooler as well, most likely will be an air-air for me. My car the way it is now tends to detonate on a warmer day if pushed. 100 octane fuel helps (tried once) but it costs almost double

Dinan setup has the IAT sensor in the manifold as well and that's where mine is. I logged the temps before, can't remember what they were, but remember they were surprisingly high considering how cold it was that day. You actually reminded me, I wanted to log some data again, I'll ride with my laptop to work tomorrow and post the temps.

My car idles at around -20psi, if I roll with the throttle completely released, it gets to -25psi. If I remember correctly, it easily gets to 0 with the throttle half open. Just curious how does NA engine compare.

Last edited by Flug540; 09-06-2012 at 10:02 PM.
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  #256  
Old 09-06-2012, 10:14 PM
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Quote:
Originally Posted by Flug540 View Post
Nice temp drop! I'm planning to add an intercooler as well, most likely will be an air-air for me. My car the way it is now tends to detonate on a warmer day if pushed. 100 octane fuel helps (tried once) but it costs almost double

Dinan setup has the IAT sensor in the manifold as well and that's where mine is. I logged the temps before, can't remember what they were, but remember they were surprisingly high considering how cold it was that day. You actually reminded me, I wanted to log some data again, I'll ride with my laptop to work tomorrow and post the temps.

My car idles at around -20psi, if I roll with the throttle completely released, it gets to -25psi. If I remember correctly, it easily gets to 0 with the throttle half open. Just curious how does NA engine compare.
The water to air is a bit more for sure! Air to air should be fine for sure.

Well the issue with this is that unless you swap the intake manifolds (I know the Dinan kit does) with the non-vanos intake you don't have that port for the IAT sensor it covered on my old manifold! I didn't know that Dinan did that and I have the full instruction manual from Dinan and try don't relocate the IAT sensor on the Vanos cars! I am thinking they must have changed that on the vanos cars. The VF and ESS kits I wonder what they do.

I would be interested to see what sort of temps you see...interestingly my temps go down a few degrees as rpm increases.
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2001 540i - Orient Blue

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  #257  
Old 09-07-2012, 05:32 AM
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This is a photo if you are interested of the vanos manifold where the IAT sensor is relocated on mine (and where it is stock on the m60). I would be interested in seeing ht VF and ESS are doing for intake temp compensation...do they just adjust based on the intake temp to the SC based on external conditions and correlate that to an expected charge temp? I see issues with that...like what happens if you just add an aftercooler...the DME wouldn't know the temp is cooler unless it is reprogrammed hmmmmmm.
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2001 540i - Orient Blue

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A1 Headers, Random Technology Cats, Eissenmann Exhaust
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  #258  
Old 09-07-2012, 07:12 AM
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Originally Posted by bricas45 View Post
This is a photo if you are interested of the vanos manifold where the IAT sensor is relocated on mine (and where it is stock on the m60). I would be interested in seeing ht VF and ESS are doing for intake temp compensation...do they just adjust based on the intake temp to the SC based on external conditions and correlate that to an expected charge temp? I see issues with that...like what happens if you just add an aftercooler...the DME wouldn't know the temp is cooler unless it is reprogrammed hmmmmmm.
Yup, that's the same location as M62 only this one comes sealed? Mine was just capped with a bolt. So did you just drill out the seal in the manifold for your IAT? I checked VFE instructions, they say that only 96-98 cars come with the external temp sensor? Apparently BMW did something different after 98? I also remembered that the IAT sensor hole in the stock air filter box is also sealed, I believe, on Vanos cars, is that the case? Where is the IAT sensor then?
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  #259  
Old 09-07-2012, 07:40 AM
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Quote:
Originally Posted by Flug540 View Post
Yup, that's the same location as M62 only this one comes sealed? Mine was just capped with a bolt. So did you just drill out the seal in the manifold for your IAT? I checked VFE instructions, they say that only 96-98 cars come with the external temp sensor? Apparently BMW did something different after 98? I also remembered that the IAT sensor hole in the stock air filter box is also sealed, I believe, on Vanos cars, is that the case? Where is the IAT sensor then?
I have the m62 (non vanos) intake on my car. It too had just a bolt and I bought the m60 IAT sensor and installed. After 98 the IAT sensor is built into the MAF sensor! So we cut those wires and rerouted to the manifold. The manifold in the previous photo is my original vanos manifold I didnt touch that one. Just put in my $50 non-vanos manifold I got off a 740i in the junk yard!! Haha
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  #260  
Old 09-07-2012, 07:50 AM
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I am 99% sure on the vanos kits there is no relocation. They have to be somehow calculating the assumed temp based on the cold air temp.
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A1 Headers, Random Technology Cats, Eissenmann Exhaust
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  #261  
Old 09-07-2012, 10:49 AM
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Finally got to the office, damn traffic. The outside temp was in 62-70 degree range and the intake temp was pretty constant at 176-179 degrees... wow! I'll look at the data in more detail later, but surprisingly RPM change doesn't seem to affect the temp that much, I do see a change, but I expected it to change more. Maybe it's just so darn hot already, it's hard to get any hotter I'll log my back to home trip as well in the evening.
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  #262  
Old 09-07-2012, 11:52 AM
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Hey the 3 of us can be the Boost Brothers
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RK Supercharged @ 501wheel horsepower
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  #263  
Old 09-07-2012, 11:55 AM
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Hey the 3 of us can be the Boost Brothers


Are you getting VFE'd soon?
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  #264  
Old 09-07-2012, 01:04 PM
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Are you getting VFE'd soon?
yea dont think i just got it sitting in the living room for nothing lol. Im working on getting to it, it Should be in No later than the 28th..!
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RK Supercharged @ 501wheel horsepower
Supersprint Headers,
Evolve Alpha N Tune,
CNS lightweight dm flywheel/Spec clutch,
ST coilovers,
Eibach Rear Sway bar/Beast Power Brackets,
Drilled slotted Rotors/Akebono Euro pads,
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  #265  
Old 09-07-2012, 01:30 PM
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Hey the 3 of us can be the Boost Brothers
ha ha! I think I saw your car at bimmerfest...there were chairs around it but no one home when I walked by. Good luck with your kit...as you can see from both Alex and myself it is a great thing to have but comes with a struggle to get there haha.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
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A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #266  
Old 09-07-2012, 01:35 PM
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ha ha! I think I saw your car at bimmerfest...there were chairs around it but no one home when I walked by. Good luck with your kit...as you can see from both Alex and myself it is a great thing to have but comes with a struggle to get there haha.
A struggle for sure, but the reward is great!

Bricas, how did the dyno go?
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  #267  
Old 09-07-2012, 01:49 PM
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some initial dyno runs today some MAF issues with scaler (T9), without prescaler MAF clips at 5.5K rpm. With it we were going lean. Also had some belt slippage! My boost numbers seemed a little low so I am going to take a look at this and put a new belt on, and re-due the leak test. Measured about 5psi at 5.5k...this may be 1-2 psi less than I would expect. (with headers the measured pressure will be less by a few psi... the dinan 6psi kit should measure about 4psi with headers I should have 6-7psi measured or like 9ish without headers). This doesn't mean you loose boost just air flows better (pressure is due the air being forced at a rate faster than the engine can use it)...the air is still there and so is the extra fuel and the power. today we saw about 350rwhp at about 5.5k and redline is at 6750rpm so still a lot to go! will update the next time. following curve looks like it will be in the 420rwhp neighborhood.
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
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A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars

Last edited by bricas45; 09-07-2012 at 01:56 PM.
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  #268  
Old 09-07-2012, 01:52 PM
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A struggle for sure, but the reward is great!

Bricas, how did the dyno go?
yes indeed these things are a dream to drive with boost! Doing this as a custom build is a huge endeavor and having to take baby steps.
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2001 540i - Orient Blue

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A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
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Last edited by bricas45; 09-07-2012 at 01:57 PM.
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  #269  
Old 09-07-2012, 02:00 PM
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Originally Posted by bricas45 View Post
some initial dyno runs today some MAF issues with scaler (T9), without prescaler MAF clips at 5.5K rpm. With it we were going lean. Also had some belt slippage! My boost numbers seemed a little low so I am going to take a look at this and put a new belt on, and re-due the leak test. Measured about 5psi at 5.5k...this may be 1-2 psi less than I would expect. (with headers the measured pressure will be less by a few psi... the dinan 6psi kit should measure about 4psi with headers I should have 6-7psi measured or like 9ish without headers). This doesn't mean you loose boost just air flows better (pressure is due the air being forced at a rate fast than the engine can use it)...the air is still there there and the fuel and the power. today we saw about 350rwhp at about 5.5k and redline is at 6750rpm so still a lot to go! will update the next time. following curve looks like it will be in the 420rwhp neighborhood.
Nice! That's slightly more then I get currently. Hope that intercooler will help to step it up
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  #270  
Old 09-07-2012, 02:05 PM
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Quick screen shot. Blue is NA and the others are some random test runs.
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2001 540i - Orient Blue

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A1 Headers, Random Technology Cats, Eissenmann Exhaust
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Koni Sports, Eibach Springs/Sway Bars
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  #271  
Old 09-07-2012, 06:18 PM
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Do you have a larger image? Also if you haven't done so yet, ask him for the dyno files. I have all mine and it's nice to play around with and compare the runs on your own.

On my way back home the outside temp was around 80 degrees and the intake temp got to 203 toward the end Again, did not see it change as the RPM/load changes. Is that normal? Wonder if my temp sensor became lazy.
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  #272  
Old 09-07-2012, 09:43 PM
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Wow it really compressed that!!! That is really high temp man
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2001 540i - Orient Blue

M5 bumpers, wheels, mirrors
S/C, water/air IC
A1 Headers, Random Technology Cats, Eissenmann Exhaust
3.15 diff, evosport power pullies
Koni Sports, Eibach Springs/Sway Bars
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  #273  
Old 09-08-2012, 11:01 AM
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Originally Posted by bricas45 View Post
Quick screen shot. Blue is NA and the others are some random test runs.
Is the blue NA yours before the SC?
Attached is one of my last dynos.

I believe your IC piping is aluminum? Have you considered going with steel? I was going to go with aluminum originally, but after researching not so sure anymore. Also Dinan pipes are steel.
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  #274  
Old 09-08-2012, 11:05 AM
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Wow it really compressed that!!! That is really high temp man
What temps do you see with the IC?
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  #275  
Old 09-08-2012, 11:17 AM
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Originally Posted by Flug540 View Post
Do you have a larger image? Also if you haven't done so yet, ask him for the dyno files. I have all mine and it's nice to play around with and compare the runs on your own.

On my way back home the outside temp was around 80 degrees and the intake temp got to 203 toward the end Again, did not see it change as the RPM/load changes. Is that normal? Wonder if my temp sensor became lazy.
You should see it fluctuate. Mine wiggles around a little
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