540 mods and SC build

Intercooler came in!!!

Ran a pressure leak test.... Wow she leaks like crazy! Both gaskets at throttle body I am replacing. Leaked all around those. Didn't hear many other leaks besides those.

Just used this set up and sprayed the vacuum lines and manifold with soapy water. It bubbled well where leaks were. Worked very well.

I also had to replace the big o-ring at the TB. Used the same method as you and found it bubbling there. But the boost problem was not resolved after I fixed this and a couple other leaks. Finished my smoke machine today, will see if I can find more leaks.

Originally Posted by 540alex

I also had to replace the big o-ring at the TB. Used the same method as you and found it bubbling there. But the boost problem was not resolved after I fixed this and a couple other leaks. Finished my smoke machine today, will see if I can find more leaks.

Any luck with the vacuum leak check I would be interested to see where you are loosing pressure.

Did you do leak test directly into the throttle body to eliminate the SC system as culprit? Did you tune the BOV? Could that be bypassing early?

Dang torx bolts snapped off on me when I went to remove front plate last night I had to drill and extract 2 of them to get the cover off. And one the torx bit snapped off in the bolt! Not happy about that will be replacing all with a more standard bolt tonight.

Working on autos is always like opening up a can of worms.

Originally Posted by bricas45

Any luck with the vacuum leak check I would be interested to see where you are loosing pressure.

Did you do leak test directly into the throttle body to eliminate the SC system as culprit? Did you tune the BOV? Could that be bypassing early?

Dang torx bolts snapped off on me when I went to remove front plate last night I had to drill and extract 2 of them to get the cover off. And one the torx bit snapped off in the bolt! Not happy about that will be replacing all with a more standard bolt tonight.

Working on autos is always like opening up a can of worms.

I haven't got a chance to smoke test it yet. Before I tested from the SC inlet. BOV is a possibility, but I don't believe it has a big leak at least when the engine is off and I'm not sure how to properly tune it. It does leak a little bit past the adjustment screw though, but I don't think it's major. What I really want to do is try my "new" Bosch BOV, but I have to find reducers that will work with it. It has both sides at 25mm diameter (roughly 1"), one side needs to connect with a straight reducer to 45mm pipe (1 3/4") and the other needs a 90 degree elbow reducer to 39mm (1 1/2"). The elbow should not be a problem, but the straight ones I see online are all 3" to 4" long and what it needs is about 7". I want to avoid any additional adapters, so not sure yet what/where to find this thing. Any idea?

Those torx bolts are something else indeed. I had fun time trying to tighten the one in the bottom left corner. I also thought of replacing mine with a hex head, but I if I remember correctly, it gave me an impression that the space is too tight for it.

I know what you mean by a can of worms That's a big part of why it took me months to get it back together and I'm still at it It now makes sense why your mechanic would call you and tell you there is a number of other things wrong with your car besides the one you actually brought it in to have fixed. They weren't kidding!

Originally Posted by 540alex

I haven't got a chance to smoke test it yet. Before I tested from the SC inlet. BOV is a possibility, but I don't believe it has a big leak at least when the engine is off and I'm not sure how to properly tune it. It does leak a little bit past the adjustment screw though, but I don't think it's major. What I really want to do is try my "new" Bosch BOV, but I have to find reducers that will work with it. It has both sides at 25mm diameter (roughly 1"), one side needs to connect with a straight reducer to 45mm pipe (1 3/4") and the other needs a 90 degree elbow reducer to 39mm (1 1/2"). The elbow should not be a problem, but the straight ones I see online are all 3" to 4" long and what it needs is about 7". I want to avoid any additional adapters, so not sure yet what/where to find this thing. Any idea?

Those torx bolts are something else indeed. I had fun time trying to tighten the one in the bottom left corner. I also thought of replacing mine with a hex head, but I if I remember correctly, it gave me an impression that the space is too tight for it.

I know what you mean by a can of worms That's a big part of why it took me months to get it back together and I'm still at it It now makes sense why your mechanic would call you and tell you there is a number of other things wrong with your car besides the one you actually brought it in to have fixed. They weren't kidding!

Not sure about connecting the Bosch valve that is the one VF and ESS use on their kits. It very well could be that your BOV is tuned to open at ~3psi and you may not have a vacuum leak at all. I would try playing with the settings. Tune to one extreme look at pressure WOT, tune other way, and step up. I think mine came with a tuning process.

Can you take adjustment screw off and use Teflon tape on threads?

Again run leak test directly into throttle body to eliminate SC system. And then start attaching parts and make your way to filter. I think starting with filter is just too many variables. Or if you want to just test the SC system cap the inlet to throttle body and pressurize from filter. Maybe even plug off the connections to the BOV.

Originally Posted by bricas45

Not sure about connecting the Bosch valve that is the one VF and ESS use on their kits. It very well could be that your BOV is tuned to open at ~3psi and you may not have a vacuum leak at all. I would try playing with the settings. Tune to one extreme look at pressure WOT, tune other way, and step up. I think mine came with a tuning process.

Can you take adjustment screw off and use Teflon tape on threads?

Again run leak test directly into throttle body to eliminate SC system. And then start attaching parts and make your way to filter. I think starting with filter is just too many variables. Or if you want to just test the SC system cap the inlet to throttle body and pressurize from filter. Maybe even plug off the connections to the BOV.

Good tips, I'll try. I was just too lazy to remove the front S/C pipe that connects to the TB, it's a pain to remove, but I guess I'll have to.

Originally Posted by 540alex

Good tips, I'll try. I was just too lazy to remove the front S/C pipe that connects to the TB, it's a pain to remove, but I guess I'll have to.

Also on silicone couplers sometimes using hairspray at the joints will make a better seal.

Think I am going to mount water/air radiator in my trunk. This was recommended to me by several folks and will save space and fab work of putting behind bumper! Will look at doing this tonight.

Originally Posted by bricas45

Think I am going to mount water/air radiator in my trunk. This was recommended to me by several folks and will save space and fab work of putting behind bumper! Will look at doing this tonight.

That's interesting, I'm not sure I would want to lose any of my trunk space though.

Mounted in trunk

Originally Posted by 540alex

That's interesting, I'm not sure I would want to lose any of my trunk space though.

I hardly use my trunk, mine doesn't fold down. I may build something to cover it when I need to put things in back.

I have about 2 inches of spacers behind it and the back seat wall.

Originally Posted by bricas45

I hardly use my trunk, mine doesn't fold down. I may build something to cover it when I need to put things in back.

I have about 2 inches of spacers behind it and the back seat wall.

Mine also doesn't fold down... Hmmm, something to think about. It doesn't seem to take too much space.

Just ordered HPS reducers for the Bosch BOV. I figured I'll just have the steel pipe extended to fit directly to the regular length reducer, shouldn't be too difficult. The thing is though I just had my pipes powder coated, going to have to redo this pipe again...

Originally Posted by 540alex

Mine also doesn't fold down... Hmmm, something to think about. It doesn't seem to take too much space.

Just ordered HPS reducers for the Bosch BOV. I figured I'll just have the steel pipe extended to fit directly to the regular length reducer, shouldn't be too difficult. The thing is though I just had my pipes powder coated, going to have to redo this pipe again...

I didn't initially intend on doing this so I don't have the hoses for it yet. I will probably go to home depot today and pick up some more hose and try to figure a way to run the hoses to the front bumper. I am going to remove the break air vents and run the IC pipes there with the IC just behind the grille on the M5 bumper. It is about the perfect size to fit like this. Probably going to have a local shop do it as I want it done soon and it would take me forever to do the piping haha

So dinan runs 30lb injectors at 5bar. I could run 42lb injectors at 3.5bar. This would amount to same flow.

I have both sets of injectors, car has 3.5bar fpr and I have the 5bar fpr sitting at home.

Any recommendations on which setup? Seems to me that if I run lower pressure that reduces strain on lines.

Originally Posted by bricas45

So dinan runs 30lb injectors at 5bar. I could run 42lb injectors at 3.5bar. This would amount to same flow.

I have both sets of injectors, car has 3.5bar fpr and I have the 5bar fpr sitting at home.

Any recommendations on which setup? Seems to me that if I run lower pressure that reduces strain on lines.

Its the fuel pump that determines the pressure in the fuel lines and not the injectors.

Originally Posted by bricas45

So dinan runs 30lb injectors at 5bar. I could run 42lb injectors at 3.5bar. This would amount to same flow.

I have both sets of injectors, car has 3.5bar fpr and I have the 5bar fpr sitting at home.

Any recommendations on which setup? Seems to me that if I run lower pressure that reduces strain on lines.

The pressure in the rail actually does not change, in my setup it is still around 55 psi. You need a high flow fuel pump to ensure the fuel supply at the same pressure with larger injectors.

Originally Posted by 540alex

The pressure in the rail actually does not change, in my setup it is still around 55 psi. You need a high flow fuel pump to ensure the fuel supply at the same pressure with larger injectors.

The Dinan kit replaces the 3.5bar with a 5bar FPR for my MY not yours? I already have a high flow pump.

Originally Posted by franka

Its the fuel pump that determines the pressure in the fuel lines and not the injectors.

I am not referring to the injectors setting the pressure. The 30lb and 42lb are assumed at 43.5psi. What I am referring to the fuel pressure regulator. If you change this the pressure in the line should change to the regulator value.

I believe I will go with the 42lb injectors as I do not plan on going with the Dinan tune. I have someone local and with the headers and running 8psi of boost I think the 30lb injectors would be on the low side.

I just ran some calculations and I know someone doing a similar setup got 440whp (517bhp). If I run ~50psi at fuel rail to get that power I would need the 42lb. The 30lb injectors can only support 380bhp where the 42lb can support 500bhp.

Not sure how incredibly accurate that is as I am running ~355bhp now on 19lb stock injectors!

Ok gave in and having a fab shop make the rear endplate. Took forever to find one that would do it.

Also scheduled time to have tubing and rest of custom stuff done. Also this is at the dyno shop that will be doing the dyno tune. So they will fab it then do the tune so hopefully in 2 weeks it will be done! I have the 3.48" pulley but think since I am going for the custom tune I will go straight to the 3.33" pulley for tune.

Today I removed anything that would be in the way of the intercooler. Air dam, aux fan they are gone for the time being. Once I have the intercooler installed I will get another fan smaller to replace the aux fan. It is amazing how much stuff was lodged in between the fan and the radiator!!! Had to shop vac out over 2 hand fulls of leaves and such.

When do you expect to finish? I'm lovin the progression of this thread. Your 540i will pretty much be an M5 after the supercharger, I'd love to do this to my car but I'm afraid it'd be too much strain on the engine and I'm short on funds lol

Originally Posted by DinanBimmer

When do you expect to finish? I'm lovin the progression of this thread. Your 540i will pretty much be an M5 after the supercharger, I'd love to do this to my car but I'm afraid it'd be too much strain on the engine and I'm short on funds lol

My 540 naturally aspirated put down the same torque as an M5 (370lb-ft) was still about 40-50hp away though...8psi should should solve that and then some though haha

I think it will be done by mid December. The tuner is supposed to be amazing so I am excited about that. Yeah if you start modding your bimmer be careful. It is addictive and expensive...but rewarding still.

I can't wait to have it done the car is a mess at the moment haha.

Removed items and oil distribution block with hose.

Originally Posted by bricas45

Removed items and oil distribution block with hose.

She's comin along