Supercharged E34 M60/M62's check in here

[jimmyz66]

The end result is "mo powa". Either turbo, s/c or larger displacement, it is all about the rush of going fast then faster. I respect all forms of power. But, I will take that back of the head slam against the seat headrest any day over exhaust note. That said, I bust a nut every time I hear a Ferrari, Pagani, Lexus LF, old school F1, or most super/hyper cars. It is heaven to my ears.

[GazM3]

I’m looking forward to how you go. I agree power is addictive. The m60/m62 engine is a hidden gem. Any developments beyond the typical bolt on kits is exciting.

[GazM3]

Seems like ages since last update.

All black interior is in with functioning sports seats, now wearing bbs rs, and shadowline trim around the windows. It was running real good in 12psi trim. Decided as u do, to up the envelope and max out the vortech v3, and convert to full e85. All lines replaced and running a walbro 525 fuel pump. I can easily go back to pump fuel with adjusting the FPR but it will be better for engine longevity.

Well got the smaller 2.75” high grip pulley on (originally a std 8 rib 2.95”). Expecting to see 15-16psi. Initially with conversion to e85 had to change all hoses and sort a few leaks. Just in final stages of tuning/setup. Even in the heat of MELBOURNE car feels heaps more torquey but I’m getting a slight ignition breakdown under wot with the few initial bursts of throttle. Just diagnosing whether it’s ignition breakdown, boost leak, or possibly experienceing some valve float. I have my replacement AEM sensor just in the post today so I can run the data logging to verify what’s happening. The car is just way too powerful to road tune with in 2nd gear now and 3rd is too fast. For initial tuning was running my old innovative wideband.

I can can say that at least in the dry those Bridgestone RE71R tyres hook up amazingly well. Car looks so much more purposeful on the rs wheels and rides much better on the konis.

[GazM3]

Still playing. Every time I update this thread moves down about 4 pages.

Had issue with the fuel pump wiring not allowing stable fuel pressure . Now it’s rectified car seems stable. Just sorting the final bits of the tune now. Had also a minor boost leak. Seeing a stable 15-16psi at the peak. E85 is great but only downside is fuel range is abit low now. You are forever chasing where next to fill up and most of the fuel stations that carry e85 shut at 10pm. I’m carrying a spare 20ltr around with me. Once all sorted it should run on pump93 with a simple drop to the fuel pressure.

With the slighly smaller pulley boost comes on notably earlier and much harder than before. I should have car back permanently some time next week. No more mechanical upgrades or development.

Focus will be on making it pretty. It will be a nice change just to enjoy the car rather than upgrading it. Bought it over 4yrs ago with it just needing a little sorting out. Once it’s fully sorted I’ll find a dyno just to see what power it makes as a comparison to other projects. Often you have projects like this and there is no information right at the end. Hopefully I’m not going to be that guy LOL.

[Fatandre]

I think down the road this is much more fun than a turbo.
How about some photos?

[GazM3]

Yes some pics. Should upload some it’s easier on Facebook.

Anyway.

Car has been back with me for a month or so. It’s been very reliable making good consistent power. Done a track day on last Saturday and was a blast the way it pulls. Saw over 240kmh on main straight where the e36 with warmed over s50b32 would pull just on 200kmh. Needs an alloy radiator as coolant was weeping out the plastic tank join. The main issue on the track is crankcase ventilation. Had lots of oil starting to force out the catch can breather pipe after a few laps. Due to the boost it probably needs a vaccum pump to take the pressure out of the crankcase. I’ll trigger it off a Hobbs low boost pressure switch.

Never thought I’d say this but it’s probably too powerful for the racetrack. Power is fine on the street but the track it’s pretty concerning without any safety like a roll cage etc. Am I getting too old? May wind boost back a little if I use it often. Perhaps have to wire up an adjustable pressure switch linked to a solenoid valve to have an in cabin boost dial. Thinking “ladedruck” like the b10 alpine bi-turbo. Posted on the forced induction section but they are no help unless it’s a formula m50 build.

Surely someone else is playing with boost on our platform. It would be nice for someone else to update.

[Creaver]

Are you running an adjustable BOV? Could set it to vent at X boost rather than having the spring only open on vacuum?

[GazM3]

Not sure. I guess I could plumb in a wastegate with whatever spring I want as minimum boost then have a solenoid valve to close it. Like a high/low boost switch. Would be cool to have it variable. A high/low may work though
/

[516SC]

Stock 4.4

https://www.youtube.com/watch?v=UOhHzghf-hY

[GazM3]

Nice quick revs there.


Im still playing with mine also. Its developing up really nicely.
At 12psi it made 315rwkw (422rwhp). Been running it on a 50/50 mix of E85. Had someone locally who can reprogram the ECU which is handy, now has 7500rpm cutout. I fixed some of the boost leaks, put a bit more fuel in for safety at the top end, and it now makes consistant 15-16psi. The car is just nuts on the street, developed well beyond what I thought I would do. Have also plumbed in a wastegate with 7psi spring with a 3 port solienoid valve so I can switch back to full boost in the cabin. It works a treat as the wastegate is before the maf. Even at low boost the car is very fast, and its much more controllable, doesnt even axle tramp. At full boost its a little bit of a handfull to pedal it hard in the corners. My bridgestone RE-71R tyres are now well worn, but still grip reasonably well. Next ill try a set of Yokahama AD08R tyres as the bridgestones dont give much warning before they brake loose!!.

Ive resolved many issues with the crank case vent, being plumbed back to the intake under venturi with a 90deg curved pipe so it gets maximum vacuum. Have new radiatior with aluminuim end tanks, and tidied the engine bay up with a nice M62 engine cover with the better fittings for removal. Id say as a development project its pretty well completed. The only things in the pipeline is to alter cam timing to reduce overlap to hold in the boost better, and a decent set of RHD headers (heat coated) as I'm sure that its restricting power significanty, but the question is does it really need any more!!

The car looks pretty now rolling on some BBS-RS triple step wheels with 18x9 front and 18x10.5 rears. The interior is now black with front sport seats, M5 gauge cluster showing 300kmh & 8000rpm tach. Havent calibrated the tach yet so it reads around 1000rpm too high. Its amusing to see it rev to over 8k on the tacho haha.
Planning to have the headers built around xmas time. Having them built with clerance for the sexy V12 starter motor.

Its good to acutally stop developing and troubleshooting, and just enjoy the car. Ive got heaps of pics and stuff but its annoying to use photobucket but ill try some.

[GazM3]

Ill also do a spec so people who can follow what the setup is rather than sift through all the pages.
To do it properly it takes lots of hidden unknown things, so a full list will probably put people off.

Model: E34 540i (1994 spec)
Trans: Getrag 420g 6 spd
Diff: E32 750i, LSD with 3.15:1 gears
Clutch/ FW: JB racing 280mm (850csi), with custom clutch lining (segmented) and custom pressure plate
Supercharger: Vortech V3 - ex ESS, with 8pk belt system, modified bracket with lateral bracing
SC pulley: 2.75" 8 rib with high grip coating
Crank pulley: 140mm dia ESS, modified with 8pk ribs (1 extra each side)
Blow off valve: Turbosmart Kompact plumb back 25mm
Injectors: Siemens Deka 60 lb/hr capacity
Fuel pump: Walbro 525 in tank E85 compatable
FPR: Turbosmart FPR800 (set to 3.2bar 50/50 e85/ron98, 4 bar full e85)
ECU: factory Bosch 404, with ESS base chip modified with more timing, extra top end fueling, 7500rpm cut by GreshM performance in Brisbane Australia)
MAF: Bosch 809 (porsche turbo 996), with adjustable potentiometer to keep it away from 5v
Wastegate: tial 38mm with 7psi sping, 3 port solenoind for 15-16 psi max boost
Intercooler: 450 x 300, with 76mm pipework - front mounted air/air
Suspension: H&R lowered springs with koni yelllow adjusable shocks
Bushes: Powerflex black series
ARB: Whiteline front and rear adjustable anti roll bars
Camber: Kmac stage 2 top plates with Ireland engineering slotted weld in adjustable bolts set at -3deg front, -2deg rear
Wideband: AEM, with data logging, boost & ethanol content sensor
Wheels: BBS RS-007, rebuilt to 18x9 & 18x10.5
Tyres: Bridgestone RE-71r 245/40/18 & 265/35/18
Misc: E34 M5 gauge cluster, UUC double shear shifter, ZHP weighted knob, and nearly 4 years of sorting with annoyance and frustration included in the package.
Power: 422rwhp @ 12psi boost on dyno dynamics. unknown at 15psi but approx 450ish, severely exhaust heater limited.

Hopefully others can post some stuff. Be nice to know other projects, results, conclusions on other cars. HAHA with most forum projects they get 80-90% to the end and you never hear how they ended up.

[BleedsBlue]

Beautiful, Gary!

Did you ever end up installing our PS pulley, by chance?

[GazM3]

All your products are installed Brent. Underdriven PS pulley along with the fire extinguisher bracket. These pulleys definitely take the stress off the belt system when spinning the engine beyond 7000rpm. The water pump one I got locally also had no adverse cooling effects.

[BleedsBlue]

All your products are installed Brent. Underdriven PS pulley along with the fire extinguisher bracket. These pulleys definitely take the stress off the belt system when spinning the engine beyond 7000rpm. The water pump one I got locally also had no adverse cooling effects.

Great to hear!

What brakes are underpinning this 500hp beast, may I ask?

[GazM3]

The original owner put a set of 4 piston brembos on with 355mm dia disks. All lines are braided with ferodo ds2500 pads and some martini racing RF700 brake fluid. I use the factory rears but may consider upgrading them in the future if more track work is undertaken

[GazM3]

Just recently installed a wastegate with a 3port solenoid to have some in cabin boost control. Low boost is set at 8psi with high boost tops out at 16psi. With low boost it’s very drivable and is much more predictable to drive in the corners

[fo3]

I need to go to Melbourne where the BMWs are

[GazM3]

Thought I'd update this thread as its where most of my posts have been in. Finally after 8yrs of playing with this car ive bitten the bullet and installed a stand-alone ecu. Along the way I've also installed some ceramic coated 4-1 custom headers. It goes rather well, have set it up for flex fuel so i can use any blend of RON98 or e85 i wish, and basically with 2 switchable boost settings being 10psi and 17psi. On 10psi on straight e85 its crazy fast but still controllable. On high boost its just mad with having to feather the throttle in 2nd gear with warmed up Yokohama AD08r tyres. As a safety measure ive locked out high boost unless I have at least E60 in the tank. I've had to gap down the plugs to 0.5mm which is basically 20thou as I was getting just a tiny bit of ignition breakdown on the RHS bank. The coils are a missmatch and have never been replaced in my ownership c. 2014 so Ill go another kick in the financial testices and get a full new set, and a fresh set of spark plugs for good measure before I start using the high boost setting. I have also spent some time getting the clutch right, and the big v12 280mm unit still works on a single plate with only mild compromise to drivability, and the take up point is consistent and perfectly centred.

I've never really owned an analog manual car with this much grunt. You have to adjust your driving methods and feather the throttle for traction, and if you get it right the way it moves off the line from the traffic lights and just obliterates the unsuspecting traffic is something you never get tired of, even as an irresponsible 55yo male. Hope others are still playing with there boosted m60/M62 engines. Mines survived 8 years, 30,000km, numerous burst coolant pipes, an oil cooler pipe rupture, many years of sub-optimal tuning, and years of abuse, with not even as much as a cold start lifter tick to indicate the engine will not last many more years.

[BleedsBlue]

I love it. Thanks for posting as always, Gaz

[dannyzabolotny]

Hope others are still playing with there boosted m60/M62 engines. Mines survived 8 years, 30,000km, numerous burst coolant pipes, an oil cooler pipe rupture, many years of sub-optimal tuning, and years of abuse, with not even as much as a cold start lifter tick to indicate the engine will not last many more years.

I've got a customer with a Dinan supercharged E34 540i/6, while it isn't quite as crazy as yours, it still moves pretty darn well. It's gotten a freshly rebuilt blower, a 3.45 Quaife LSD, JBR LWFW, brand new stock clutch, and a full suspension setup with Broadway Static coilovers all around + Moosehead thrust arm bearings + E31 lower control arms. M5 sway bars and Powerflex subframe bushings round out the handling package.

It gets tracked a lot, about once a month on average. The guy drives it like he stole it every single day, and it actually hangs with much faster/newer cars on the track, like Shelby GT350's and Porsche GT3's. The original M60 is still doing okay at 240,000 miles (~386,000 km), despite being beat on in the Arizona heat with no intercooler.

[GazM3]

Wow it's comforting to know that the integrity of the m60 engine is fine with supercharging. I think the way that the supercharger delivers its power is a little kinder to the engine internals than the top mounted roots style blower or turbocharging.

I've replaced all the coils and some new ngk plugs gapped to 18thou, and I'm getting not ignition breakdown just strong power. I've also finally replaced the long suffering 32mm core radiator with a larger 48mm triple core one, running 2x davis-craig 12" puller thermofans installed low on the radiator to allow a path for the 90deg bend and intake pipe. Coolant runs pretty steady on 1/2 now even if idling for extended periods. Its been wet here in Melbourne for past 5 days so there has been no opportunity to drive it much under load. The only thing to really sort now is the cold starts on E85 are not so easy to do as you are basically trying to start on the 15% gas content. In addition unfortunately i've had to replace an inner barrel on the split bbs rims due to a crack/pothole, not allowing it to hold air, so i'm riding Hobo style with different rims on the front ATM.