I made an turbo - e34 540 and megasquirt content

[motorokr718]

This is probably a year late as the car has been boosted since this time last year, but since I finally got it running on the Megasquirt, I figured it's about time. Anyway, about the car....95 540 msport, 6 speed swapped, suspension stuffs, and a turbo. The original plan was supercharger and nitrous, but wheres the fun in that?? Setup is a t3 Bullseye s256, dual pass interfooler, Tial Q and 38mm wg on 5psi, Megasquirt MS3X running full sequential. I used the 88 pin break out board from diy autotune to retain the oem harness and plug. I have some SD 60# injectors waiting to go it, just wanted to get it running well on the MS before I tripled the fuel flow.

Still in the very early stages of tuning, been letting the VE analyze live function in Tunerstudio work its witchcraft in the lower load range. Took it out for the first drive this past Sunday and it felt great. Fuel table is coming together and once it's to where I feel comfortable just getting in and going somewhere, I'll start playing with timing or just bring it to a dyno to get it dialed in. The main goal right now is to just have it read to go for the European Experience in a few weeks.

Here's a few pics for now, I'll post more more soon. Give me a follow on the instagrams if you're into that kinda thing... @abeebe_718

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[someguy2800]

man that must spool just backing out of the driveway! Looks real nice

[dburt86]

V8's and turbos are the most American thing you can do, even if its a German car. Good work you patriot.

[motorokr718]

man that must spool just backing out of the driveway! Looks real nice

It's not too bad haha. I was getting positive pressure around 2500ish previously on a chipped dme. Guessing once i start getting heavy into tuning with the MS I can probably be at full boost by 3k.

V8's and turbos are the most American thing you can do, even if its a German car. Good work you patriot.

I do what I can to support my country

[HotRodBimmer]

Wow that's sexy! Good job, wish I had the skillz!
Hope I can get a closer look at this sucker in Savannah!

[motorokr718]

Wow that's sexy! Good job, wish I had the skillz!
Hope I can get a closer look at this sucker in Savannah!

Admittedly I didn't do all of the fab work, but it was all me and a buddy who has amazing fab skills. But I'll be down there starting Thursday afternoon, staying on Tybee!

[ECSTuning]

Love it! She has to be a handful now.



-James

[motorokr718]

Pre SoWo/EuEx update. Last minute redid some charge piping and mixed some issues. I hadn't been registering boost pressure on my Defi gauge or the MS dash. Car felt sluggish since installing the MS, figured it was just my inexperience with tuning and that it was just crap tuning on my part. It was driveable, and all the numbers were safe, so I was just babying it around. Thought maybe I had a boost leak, so after tearing several things apart, finally discovered the ASC throttle body was stuck shut. fixed that and now the car pulls like a freight train. Still only on 5psi. Will be working with a tuner after EuEx to sort out some tables and really start getting it dialed in.

[SCapelo]

Not even a fully closed throttle body can stop a V8 from taking some boost! Let 'er eat

[motorokr718]

Post EuEx update:

Made if from CHS to savannah and back with relative ease. A few vacuum leaks here and there that caused momentary panics. but all in all a successful trip. Did a lot of tuning while driving around and it's running much more smoothly. Worked on idle timing a lot too and now it idles between 650-700 rpm steadily.

Kills - big turbo vr6 jetta, bolt ons/tune frs, toyed with a b6 s4 but had on of those vacuum leaks and didn't want to get embarrassed

Losses - buddy's rebuilt full bolt ons/tune e36 m3. this is when i discovered i've run out of injector. ran 3 times and it was the same each, i'd hit a wall in second so he'd pull away, short shift into third and just couldnt reel him in. checked the datalog when we got back and was over 85% duty cycle at 3/4 throttle by 3200rpm…at only 3psi of boost. once i was at WOT i was tapped out of fuel and starting to lean out. So if anybody is wondering, 24lb injectors don't really flow much. Time to put in the 60s.

Also picked up a Forge motorposrts boost controller for dirt cheap at the show to use until i feel like wiring in an EBC and modding the MS board.

I'm loving Megasqurit and TunerStudio though. Very user friendly and fairly intuitive. Makes tuning very approachable. May post my fuel and timing tables here for public ridicule/help as i'm still having trouble with cruising and low rpm/high load fueling. Car has the shakes when trying to slowly accelerate in 4,5, and 6th gear at cruising speeds. I think it just need to study the datalogs a little better and take some fuel out, but I don't want to sacrifice lower gear hard acceleration.

[tptrsn]

This is quite the coincidence. I was just sitting and pondering whether I should just order the 88 pin BOB from DIY for my 540 project, when I fired up the F/I forum and happened into your thread. Too much coincidence to ignore, I'm ordering it NOW!!

[motorokr718]

This is quite the coincidence. I was just sitting and pondering whether I should just order the 88 pin BOB from DIY for my 540 project, when I fired up the F/I forum and happened into your thread. Too much coincidence to ignore, I'm ordering it NOW!!

Nice! It definitely made thing a little more of a 'bolt in' affair. i will say that some of the pin holes are too small for some of the wires on the MS harness (Quad spark leads, shielded crank signals) and I soldered those directly to the pin on the DME plug side. if I can dig up the numbered guide I made for myself i'll send it your way. made life easy especially for the injectors and quad spark modules. I wired them Cyl 1-1, 2-2, etc at first when it has to be first to fire - 1, second - 2, etc..

I'm probably going to get a second m60 harness to hack up to get rid of all the now unnecessary plugs and wires. Between the MS, 6 speed swap, ASC delete, and not using ABS hubs, i have 3 computers and probably 20lb of wiring not being used haha

[dburt86]

If your running ms3x, i dont think you need to mod the board. Did you assemble the ECU ur self?

[motorokr718]

@tptrsn reading through your thread i thought i'd share my intercooler solution. Don't know if there's as much space on the e39, but this is 3" piping. it's tight, but it works.





- - - Updated - - -

If your running ms3x, i dont think you need to mod the board. Did you assemble the ECU ur self?

Assembled it myself. I was fairly certain I did. but if not, that would be sweet

-edit- nvm you're totally right. The expansion board is capable of controlling it. guess i have some spare resisitors and diodes now! lol

[tptrsn]

Damn, I can't see your pics!!

Also, it has been a characteristically crazy Monday, so I haven't had a chance to write a proper response back yet from your prior post, but I'm definitely interested in seeing your notes/diagrams. Thank you!

[GazM3]

Sounds like a nice project.
The little 24 lb injectors will run out of capacity pretty quick. If u are using still the maf that will run out next. With the mega squirt u probably don't need to run a maf. For my supercharged 540i project I've just ordered a 809 maf to allow headroom as the 806 maf runs out of capacity even with a voltage reduction of 0.8v around 6000rpm. I have currently enough fuel with 36lb injectors and fuel pressure up to 60psi but will probably go up to the 42lb ones. I have a set of 60lb injectors on standby.

How ow are u going to put the front bar back on. That intercooler looks massive

[motorokr718]

Damn, I can't see your pics!!

Also, it has been a characteristically crazy Monday, so I haven't had a chance to write a proper response back yet from your prior post, but I'm definitely interested in seeing your notes/diagrams. Thank you!

Ya they aren't showing up for me either now. haha. I'll repost them. but ya wen i get home i'll see if i can dig up my notes while i'm putting the 60lb injectors in.

Sounds like a nice project.
The little 24 lb injectors will run out of capacity pretty quick. If u are using still the maf that will run out next. With the mega squirt u probably don't need to run a maf. For my supercharged 540i project I've just ordered a 809 maf to allow headroom as the 806 maf runs out of capacity even with a voltage reduction of 0.8v around 6000rpm. I have currently enough fuel with 36lb injectors and fuel pressure up to 60psi but will probably go up to the 42lb ones. I have a set of 60lb injectors on standby.

How ow are u going to put the front bar back on. That intercooler looks massive

Ya i maxed them out a lot quicker than i thought would. Putting the 60s in this afternoon. I ditched the maf with the megasquirt. Using the built in MAP sensor. What are you using for engine management? I had considered the WAR chip, but didn't want to be limited by the maf and everybody seems to have issues with having to wire in resistors and such.

Bumper is back on. fitment is....subpar, but it's on. I felt bad hacking up the msport bumper, but it was already pretty damaged. i have a 525 bumper i think i'm going to cut up and have a front splitter made onto it.

[GazM3]

I'm using the OEM 404 ecu with the ESS chip and an interceptor computer for fuel only. I have an adjustable fuel pressure regulator. The fuel computer allows me to scale the voltage on the maf. The the ecu sees 4.2v when the maf gets to 5v so the maf can go as high as 5.8v (approx) before I get issues.

I dont want to offset it any it any more hence the 809 maf. I'm tuning on the wideband now with an air fuel gauge. The fuel computer allows me to do tuning in real time while driving so it's quick and easy. I looked at a war chip but u can't tune in real time and the people at miller were not enthusiastic to be on board. I have a spare haltech ecu but I'm wanting to use this on my e24. I'm pretty confident to get a great result with this setup and have no compromise on drivability. It's a full steet car with functioning A/C system.

Once it's running stable on the new maf I'm keen to turn up the wick on this setup. I'll probably end up going smaller again on the pullley (or larger crank pulley) and using an 8 rib belt. I can't see any reason not to up the rpm limiter to 7500 (dudmd) or so as this will suit the centrifugal. Prob not for turbo as the power will drop off I'm pretty confident of seeing 500rwhp on pump fuel with no compromises for daily driven duties.

Ive just run a twin 2.5" exhaust. It sounds orsome and reasonably quiet (ish) at idle and should allow strong horsepower.
These engines are very underrated and inexpensive. If this setup goes well I may do another one for the m3 and go circuit racing again. The s50b32 is very expansive to rebuild where the m60b40 are inexpensive and plentiful. Almost a disposable commodity.

It's nice to see your setup go well. There is something magical about a boosted m60. Maybe it's the noise. Not sure but it's awesome.

[motorokr718]

Well the car decided to ignite itself yesterday...so the engine bay is melted. that's pretty neat.

tptrsn - I'll try and get you my wiring diagram stuff tonight.

[tptrsn]

No hurry I'm afraid. I still have to do the brakes on one of the family haulers before I can get back on the 540.

Did you have an engine fire?

[motorokr718]

No hurry I'm afraid. I still have to do the brakes on one of the family haulers before I can get back on the 540.

Did you have an engine fire?

Yup. not entirely sure what caused it. but it was ablaze within seconds.

[dburt86]

that sucks, good luck man

[GazM3]

Geez. That's awful. Hope u are ok

[motorokr718]

I'm fine, thanks guys. Car is totaled. Battling with insurance over their laughable valuation. Looking for another 540 to swap everything over to or maybe an e30 for a whole new build...

[dburt86]

jesus, really? Pics?