Evan's E61: Twin Turbo Build Log - Page 4 - Bimmerfest - BMW Forums



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E60 / E61 (2004 - 2010)
BMW 5-Series E60 Sedan was first seen in the Unites States in the fall of 2003 with a 2004 Model Year designation. The E61 wagon followed shortly there after. The E60/E61 5 series is now available as a 528i, 528xi, 535i, 535xi, 550i and a 535xi sports wagon! -- View the E60 Wiki

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  #76  
Old 09-22-2016, 10:50 PM
alisaeed03 alisaeed03 is offline
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Quote:
Originally Posted by ucsbwsr View Post
Some members were inquiring about some of my current projects so I figured it would be best to share a build log on this forum.



A little background on my style: Aesthetics are important to me but not at the expense of function so I do my best to achieve both, if there is a conflict, function wins. "Clean" is always the goal. I love details; details, details, details. Now that I have a garage I do all of my own work, I really enjoy the challenge of solving problems and figuring things out so a late model BMW keeps me busy on this front. When the wagon is broken, I fix it, when it is running 100%, I look for something to modify or break, I am sure many of you can relate. I love to retrofit things and "make them work." I also love having a 550awhp wagon that can run with pretty much anything on the street, while carrying mountain bikes, a dog, and groceries. Function!





Day 1 of the build (September 2013) up to (February 2016) can be seen in the first 30 pages of this thread: http://5series.net/forums/e61-tourin...ve-all-135223/



This thread will continue where that one leaves off.



For those inclined, my Instagram handle is "hoburger"



Evan





Here is a couple introductory pictures of my wagon in current trim:






Was the M5 steering wheel with paddle shifters a direct swap or you had to make changes?

I'm wanting to swap my steering for an m5 paddle steering
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  #77  
Old 09-23-2016, 09:58 AM
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ucsbwsr ucsbwsr is offline
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Quote:
Originally Posted by alisaeed03 View Post
Was the M5 steering wheel with paddle shifters a direct swap or you had to make changes?

I'm wanting to swap my steering for an m5 paddle steering
The wheel itself is a direct swap but the paddles won't work without a wiring harness, I ran one from MotiveMods. Some people claim they can be activated with coding but I can't personally confirm this.

Evan
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #78  
Old 09-23-2016, 10:09 AM
alisaeed03 alisaeed03 is offline
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Originally Posted by ucsbwsr View Post
The wheel itself is a direct swap but the paddles won't work without a wiring harness, I ran one from MotiveMods. Some people claim they can be activated with coding but I can't personally confirm this.



Evan

Thanks for the quick response buddy, I like how the m5 steering feels and i think it might be a little smaller than the e60 sport wheel. I'll check out motivemods
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  #79  
Old 10-03-2016, 10:10 PM
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ucsbwsr ucsbwsr is offline
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Previously my vacuum tanks were held together with zip ties and then zip tied to the ABS hard lines which ran along the firewall. It was a simple and easy solution but was looking for something a little more "legit."


I came up with this setup. After trimming one of the tanks with a dremel and finding the appropriate sized hardware I was able to mount the tanks on the firewall partition which doubles as HVAC ducting.


I was pretty happy how it came out as the bolt was held in place by the partition and acted as a stud.


Mounted


After some more research and some data offered by Doug @Frankenturbo I decided to simplify the setup and run a single tank.


Much more stealth


Also rerouted my ABS/DSC wiring harness along the firewall to keep it away from the engine and heat, prior it was configured in a way that had about 6" exposed in close proximity to the hot-side of the engine and rear manifold.


Oddly enough all of the ABS/DSC lines I ordered from BMW (Germany) cam pre-bent except for the rear 2.


So I had to bent them, a large socket I bought to remove by transmission output flange did the trick.


Not perfect but good enough, much respect to the guys who bend air system hard lines by hand.


Fuel-It upgraded fuel lines, ethanol sensor, and JB4 integration.


I realized there was an oversight on my end with running M5 ABS/DSC hard lines with a non-M5 DSC unit, all but 1 port are in different locations and 2 have different diameters, ~3AN-4AN and ~4AN-3AN. Weeeeeeeeee


Looking into flexible lines with bubble fittings, if I can't find any then I may just build my own hardlines.


On my ABS/DSC connector there were some identical wires which may need to be switched. I pulled up the diagrams in the Bentley manual and made a comprehensive pin-out. My DSC isn't showing up in any coding software so I may have some pics swapped; there are 2 pairs of twisted wires and 1 pair of single wires which are identical so there are 8 potential configurations.

Black boxes designate pins which are not used. Solid lines designate pairs of wires and yellow highlighted pins with dotted lines designate possible swaps.
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats

Last edited by ucsbwsr; 10-03-2016 at 10:15 PM.
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  #80  
Old 10-05-2016, 10:03 AM
mboat mboat is offline
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Looking good, Evan!

Sounds like you may have your hands full with the pin configurations. How is the trans mount design coming? Driveshaft? How close are you being able to finally drive it? I bet you're getting itchy and ready to drive that thing?
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2006 E60 530i N52/6MT - Monaco Blau - Black/Auburn Dakota leather - Premium & Sport Packages 18" TSW Bathurst Rotary Forged wheels, 35% Ceramic Tint, Koni FSD/Eibachs, Bluetooth Audio and Phone - more mods coming...

2007 E60 530i N52/6MT - Monaco Blau - Beige Dakota leather - Premium, Sport, Cold Weather packages - 2013 CIC Retrofit, 2011 Software, CDV Delete, LCI custom headlights, 18" TSW Bathurst Rotary Forged wheels, 35% Ceramic Tint, and Sport Mode. - Gone.
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  #81  
Old 10-06-2016, 10:14 AM
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ucsbwsr ucsbwsr is offline
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Quote:
Originally Posted by mboat View Post
Sounds like you may have your hands full with the pin configurations. How is the trans mount design coming? Driveshaft? How close are you being able to finally drive it? I bet you're getting itchy and ready to drive that thing?
Driveshaft is ready for pick-up. Trans mount will come shortly after. Brakes are getting all the attention right now.

------------------------------------------------------------------------------------------------

First of all big thanks to a fellow forum member Levan (on N54Tech), he was instrumental in getting my PT-CAN system up and running so my DSC module could be recognized, we synced up on Teamviewer and I let him work his magic. Since I have an E61 and am running a DSC module from a RWD E60, since there was never a RWD wagon produced, removing replacing PT73 (wagon) with NW13 (sedan) in the VO gave the DSC the info it wanted to see, VO was not saved in CAS or LMA.

Levan even added some files so that I could control the module via INPA, previously INPA only recognized DSC60 not DSCPP which is what I have. The DSC controls in INPA are in German but that is A-ok with me, I am just happy to have the software at my disposal for diagnostic future diagnostic work.



If you recall on my chicken scratch pin-out: pin #25 and #40 went to X10554 and X10555, after poking around ELE and ELC in the Bentley manual I couldn't find where these points were but I knew X designated them splices or connections.


Here you can see how the DSC and 6AT are connected in PT-CAN


This meant I needed my 6AT wiring harness which I had previously disconnected and hacked up to make my custom wiring harness for the DSC unit, lol. Thankfully I saved the connector and the wires which were not needed, you never know when you might need them!



AT connector in the DME box


Harness plugged in and PT-CAN wires looped (SW/BL and GE)


DSC shows up in UIF! Free LSD!


Coding Setup


Schumacher power supply has a "flash" mode which holds 14.2V stable so I can code for days.


Made the wiring harness into a smaller "key" to keep the DME box tidy.





Realized I never coded my injectors are reinstalling them in the new engine.


Pedals calling my name
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #82  
Old 10-06-2016, 10:22 AM
mboat mboat is offline
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Nicely done!
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2006 E60 530i N52/6MT - Monaco Blau - Black/Auburn Dakota leather - Premium & Sport Packages 18" TSW Bathurst Rotary Forged wheels, 35% Ceramic Tint, Koni FSD/Eibachs, Bluetooth Audio and Phone - more mods coming...

2007 E60 530i N52/6MT - Monaco Blau - Beige Dakota leather - Premium, Sport, Cold Weather packages - 2013 CIC Retrofit, 2011 Software, CDV Delete, LCI custom headlights, 18" TSW Bathurst Rotary Forged wheels, 35% Ceramic Tint, and Sport Mode. - Gone.
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  #83  
Old 10-06-2016, 02:36 PM
etnav382 etnav382 is offline
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They NEVER produced a rwd wagon? Not even outside the US?
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  #84  
Old 11-26-2016, 10:49 AM
Lederhosen Lederhosen is offline
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Inquiring minds want to know

Hi Evan,

Time for an update, inquiring minds want to know. I'm on the tail end of my current project but it's nothing more than an oil change compared to yours. What's the latest and what's next?

Prost

Frank
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  #85  
Old 11-26-2016, 11:03 AM
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Originally Posted by etnav382 View Post
They NEVER produced a rwd wagon? Not even outside the US?
The E61 was offered in Europe in a RWD configuration via 525i, 530i, 550i, 520d, 525d, 530d, 535d, and M5, no RWD offered in the US.

I ran into some issues since I have a wagon but am using a DSC pump from a RWD 528i and coding was interesting since to get the DSC module to integrate into the car we removed wagon from the vehicle order but didn't flash the subsequent modules. Changing the VO was enough for the pump to work but everything else still knows the car as a wagon and works properly.

The M5 DSC pump has two other input sensors: acceleration and yaw, unfortunately those are part of the main wiring harness and although I love to mod my wagon, replacing the that harness does not sound like a fun project.

Quote:
Originally Posted by Lederhosen View Post
Hi Evan,

Time for an update, inquiring minds want to know. I'm on the tail end of my current project but it's nothing more than an oil change compared to yours. What's the latest and what's next?

Prost

Frank
No REAL updates as of now but I hope to have something substantial soon, maybe if everyone is good this year they will get something for Christmas!

Evan
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats

Last edited by ucsbwsr; 11-26-2016 at 11:16 AM.
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  #86  
Old 11-26-2016, 12:47 PM
Lederhosen Lederhosen is offline
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Looking forward

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  #87  
Old 12-26-2016, 03:06 PM
mboat mboat is offline
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So has everyone been good this year?


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2006 E60 530i N52/6MT - Monaco Blau - Black/Auburn Dakota leather - Premium & Sport Packages 18" TSW Bathurst Rotary Forged wheels, 35% Ceramic Tint, Koni FSD/Eibachs, Bluetooth Audio and Phone - more mods coming...

2007 E60 530i N52/6MT - Monaco Blau - Beige Dakota leather - Premium, Sport, Cold Weather packages - 2013 CIC Retrofit, 2011 Software, CDV Delete, LCI custom headlights, 18" TSW Bathurst Rotary Forged wheels, 35% Ceramic Tint, and Sport Mode. - Gone.
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  #88  
Old 12-27-2016, 07:27 AM
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haha YES please.
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  #89  
Old 01-17-2017, 09:16 PM
alisaeed03 alisaeed03 is offline
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I went through your build and I wondering if you happen to know that will the m5 from upper lower control arms are a direct fit for a 2008 535i?


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  #90  
Old 01-17-2017, 09:24 PM
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Originally Posted by alisaeed03 View Post
I went through your build and I wondering if you happen to know that will the m5 from upper lower control arms are a direct fit for a 2008 535i?


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The front suspension is completely different, you will need to run a RWD 535i/M5 front subframe and steering knuckles to use the control arms.

Evan
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #91  
Old 01-17-2017, 09:35 PM
alisaeed03 alisaeed03 is offline
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Originally Posted by ucsbwsr View Post
The front suspension is completely different, you will need to run a RWD 535i/M5 front subframe and steering knuckles to use the control arms.



Evan


Thanks for the quick reply!

Mine is a rwd 2008 535i. Not a Xi.

So it should be a direct swap?


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  #92  
Old 01-18-2017, 11:44 AM
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Originally Posted by alisaeed03 View Post
Thanks for the quick reply!

Mine is a rwd 2008 535i. Not a Xi.

So it should be a direct swap?


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From what I see the front control arms (tension strut and wishbone) are identical between the 535i and M5 so you already have them. Even the hydro bearing in the tension strut is the same.

Evan
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #93  
Old 01-18-2017, 12:35 PM
impac4000 impac4000 is offline
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How is the build going Evan ? Any updates ?
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  #94  
Old 01-18-2017, 12:45 PM
alisaeed03 alisaeed03 is offline
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Originally Posted by ucsbwsr View Post
From what I see the front control arms (tension strut and wishbone) are identical between the 535i and M5 so you already have them. Even the hydro bearing in the tension strut is the same.



Evan


Thanks buddy, I looked it up on realoem and sure enough you're right! Thanks for keeping your build updated, helps a lot.

Next I'm doing m5 rear sway bar.


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  #95  
Old 01-18-2017, 12:56 PM
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How is the build going Evan ? Any updates ?
Nothing good as of yet, hopefully soon. :/
Quote:
Originally Posted by alisaeed03 View Post
Thanks buddy, I looked it up on realoem and sure enough you're right! Thanks for keeping your build updated, helps a lot.

Next I'm doing m5 rear sway bar.
You are welcome. If you can track down a set of RD Sport sways they are superior to the oem M5 units, just FYI if you are going for absolute performance.

Evan
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #96  
Old 01-20-2017, 10:13 PM
alisaeed03 alisaeed03 is offline
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Originally Posted by ucsbwsr View Post
Nothing good as of yet, hopefully soon. :/



You are welcome. If you can track down a set of RD Sport sways they are superior to the oem M5 units, just FYI if you are going for absolute performance.



Evan


Thank you for the info! I looked them up and wow they are more beefed up the m5 oem! I am also looking at the m5 dinan adjustable sways, will decide by Monday.

Cars stripped apart right now...

Installing new turbos, valve cover, oil housing, 7"fmic, inlets, cai, oil catch can, charge pipe, tial bov, and new from control arms, tie rods, and end links.

Any advice on outlets? Is it really worth it?


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  #97  
Old 01-21-2017, 08:53 AM
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ucsbwsr ucsbwsr is offline
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Quote:
Originally Posted by alisaeed03 View Post
Thank you for the info! I looked them up and wow they are more beefed up the m5 oem! I am also looking at the m5 dinan adjustable sways, will decide by Monday.

Cars stripped apart right now...

Installing new turbos, valve cover, oil housing, 7"fmic, inlets, cai, oil catch can, charge pipe, tial bov, and new from control arms, tie rods, and end links.

Any advice on outlets? Is it really worth it?
Outlets are a logical compliment to everything else you have planned and it will also be easier to install them at this point since the turbos are being done. Since they are such a relatively inexpensive mod I would opt for them. Just do research and get the ones which have been proven to be the most reliable, some have poor fitment issues which can lead to melting and compromised performance.

BTW the RD Sport sways are 3-way adjustable in case you over looked that.

Evan
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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  #98  
Old 02-03-2017, 12:48 AM
alisaeed03 alisaeed03 is offline
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Quote:
Originally Posted by ucsbwsr View Post
Nothing good as of yet, hopefully soon. :/



You are welcome. If you can track down a set of RD Sport sways they are superior to the oem M5 units, just FYI if you are going for absolute performance.



Evan


Unfortunately I have dynamic drive so I was told I can't replace the sway bar...


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  #99  
Old 02-11-2017, 08:54 AM
alisaeed03 alisaeed03 is offline
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Thank you Evan for all your help! My car is all done.

I'm installing Bilstein pss10 b14 hopefully in 2 weeks. My pockets are hurting right now haha


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  #100  
Old 02-11-2017, 08:58 AM
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ucsbwsr ucsbwsr is offline
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Originally Posted by alisaeed03 View Post
Thank you Evan for all your help! My car is all done.
Nice, congrats. Time to start your own thread so you don't clutter up my build thread
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N54 Powered M5 Wagon:
- M5 Driveshaft, M5 LSD, M5 Axles, M5 Brakes
- M5 Front End, M5 skirts, M5 Mirrors, M-Tech Rep Rear
- KW V3, RD Sport Sways, UR Strut Braces, Forgestar F14 SDC
- Manual Swap, MFactory SMFW, Spec Stg 3+ Clutch, Shiftteck SSK
- EOS Port Injection Manifold, Fuel-It: Stg 2 LPFP +Ethanol Sensor
- N54B30, JB4, Hexon RR550s, Custom Y-Pipe Inlet, AR DPs, 3" Exhaust, VRSF 7" IC, ER CP, Tial BOV, RB PCV, BMS OCC

E39 540iT:
- OEM Style 167, KW V1
- E38 Contour Seats
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