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Thread: Turbo E39 Project v2

  1. #1
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Turbo E39 Project v2

    Took a break from the forums for a bit but I'm back with another E39 project.

    Some of you guys may remember my past turbo E39:


    https://www.bimmerforums.com/forum/s...bo-E39-project

    This time around I'm not looking for 800whp, nor am I going with an engine swap.
    It's simple...

    Stock M54
    Cast manifold
    3076
    Have fun

    The car is a 2002 530i M Sport with a manual




    Last edited by M5Hunter; 09-23-2021 at 01:30 PM.

  2. #2
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    my brother's ti
    awesome. I'm curious to see how much boost the m54 intake manifold can handle. anyone on here know?

  3. #3
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    I have put 16# as read on gauge through mine.
    04R 3l 6 sp VF SC, custom ducting, alphaN, 2.62 pulley, multiport WMI,Severn Tuning(Pokeybritches), Tial BPV,Ceramic header, magnaflow section 1, SS race muffler/y-pipe, megan mounts,42 design catch can, CDV delete ,custom strut bar,3.91 LSD, H&R bars, Hotchkis links.Eibach Pro Kit,Koni Yellows.Megan camber arms. Carbon interior,SSK,UUC lines.CF aero. Poly bushings.

  4. #4
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    E36 Turbo, E39 M5
    Excited to follow along with the project!
    93 325is: obd2 M52, 22rpd tuned, 6266, RSI manifold, 555whp on 18psi

  5. #5
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Strapped the car down for some stock baseline pulls.

    Untitled

    Untitled

    After that I installed the DKM twin disc clutch

    Untitled

    Pulled the stock exhaust manifolds and just got new gaskets in today to put the SPA on.

  6. #6
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    1999 BMW 328iS
    Solid baseline, will you be using the stock ECU?

  7. #7
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Quote Originally Posted by takasauras View Post
    Solid baseline, will you be using the stock ECU?
    Yes, intending to use stock DME. Pursuing a couple options now.

  8. #8
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    '99 528iT
    Following. Plan to do this to my car down the road, currently supercharged.

    Let me know how the DKG twin disk is, I have the Hopwood Motorsports twin disk in my car, feels like stock and I quite like it.
    2.jpg
    Last edited by carcrazyethan; 10-18-2021 at 12:59 PM. Reason: adding bit about the clutch setup
    '89 535i/5 Zinnober
    an 4Runner

  9. #9
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    Which manifold are you using that fits the m54 in the e39?

  10. #10
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    Quote Originally Posted by DSTX17 View Post
    Which manifold are you using that fits the m54 in the e39?
    https://spaturbousa.com/products/bmw...0a9c9262&_ss=r

    This. Out of stock right now, but I believe TRM tuning has them in stock right now.
    '89 535i/5 Zinnober
    an 4Runner

  11. #11
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Quote Originally Posted by carcrazyethan View Post
    Following. Plan to do this to my car down the road, currently supercharged.

    Let me know how the DKG twin disk is, I have the Hopwood Motorsports twin disk in my car, feels like stock and I quite like it.
    Have put quite a few miles on the clutch now and it seems to be really good.
    I'm glad I went this route.

  12. #12
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    Nice!

    Permission to spoil the results? Saw the dyno graphs on facebook, freaking awesome!
    '89 535i/5 Zinnober
    an 4Runner

  13. #13
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Quote Originally Posted by carcrazyethan View Post
    Nice!

    Permission to spoil the results? Saw the dyno graphs on facebook, freaking awesome!
    Thanks! The numbers the car put down were right at my expectations for the current setup.
    Its got a 10psi spring in the wastegate with no boost controller at all. Car holds 10-10.5psi all the way to 6500rpm.

    Thanks to Jules at BeRacing for the tuning service. I'm very glad he was recommended to me and he has exceeded my expectations in ability and customer service.

    There are a few improvements that I already have in the works which includes a better turbo inlet as its currently got a tiny filter directly on the turbo which is smashed against the stock motor mount.
    Ultimately I'd like to get to 400 reliably(as possible).

    Coming from higher horsepower builds, I was a bit concerned with my turbo choice. The 3076 is little but seems to pack a decent punch while building positive pressure at 2000rpm.
    Even if its not a powerhouse, it provides a great soundtrack to my driving experience.








    Last edited by M5Hunter; 12-30-2021 at 11:22 AM.

  14. #14
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    '99 528iT
    And I hear full boost is at 2800. Bet it feels freaking awesome.

    Sound clips?
    '89 535i/5 Zinnober
    an 4Runner

  15. #15
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    e85 ?
    engine bay photos ?

  16. #16
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Currently on Pump 93

    I put a little more spring in the wastegate and bumped boost up to 13psi.
    My very intelligent tuner has requested I go back to a lighter spring, but I can't currently hear that legitimate concern.


    Just installed the new Street Driven Industries E39 turbo engine mount arm. Had clearance to run a full 4" turbo inlet.
    https://streetdrivenindustries.com/c...otor-mount-arm








    Hopefully after some tune adjustments I can get it back on the dyno and shoot for 400/400 through a stock exhaust.
    I'm unsure if, or how long the headgasket will hold up but I may have picked up a spare M54 as well, just in case...
    Last edited by M5Hunter; 04-19-2022 at 10:45 AM.

  17. #17
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    I recall from the old days that NickG at TT offered an M54 turbo kit but for some reason there was a power difference between early and late cars. Not sure if this was the result of an engine limitation or an ECU limitation.

    Have not read much from PEI330 lately, but I recall he was continuing to explore M54 limits as recently as a couple of years ago and listing here.

    E39 is a comfortable cruiser. I liked my 528i, but at at the point now in life where I want either a modern car or a classic car. The 20 year old daily driver needs more attention than I want to give it and is not modern enough for me. I still have my E36 M3 Turbo as a hot rod but it is only occasionally driven and needs some restoration in order for me to continue enjoying it — I am debating whether to go forward or not but probably will. Also have a 2002 that I am restoring but that really is a classic and also won’t be driven much. I had an E90 M3 as my daily driver for 10 years and it was pretty good but I sold it last year and bought an F90M5.

  18. #18
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    Cool car, nice and simple. the e39 530D is the best car i've ever owned.

    From what i've read is that the M54 can take quite a beeting, there is one guy on insta making 500+whp on a fully stock engine (stock headbolts, stock gasket).
    I think 13psi should be fine

  19. #19
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Strapped the car back on the dyno and made some pulls at 12-13psi.
    Ended the evening right at the goals I had set.



    400/400, super quiet through a stock muffler and full boost at 2800 RPM.
    It's far from the quickest car I've owned, but it is everything I love about a E39 with no compromise.
    I've got a better/wider tire setup on the way and I'm sure the differential will see some attention next.

  20. #20
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    Looks like it spools pretty quickly!

  21. #21
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    E46iT- Coma E36- RIP E34
    Holy shit I want this car!! Nice job!!

  22. #22
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    Very cool setup


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  23. #23
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    Quote Originally Posted by pbonsalb View Post
    Have not read much from PEI330 lately, but I recall he was continuing to explore M54 limits as recently as a couple of years ago and listing here.
    I'm still around, and the car is too. It's just in pieces, and I've been too busy to put it back together.

    I keep in contact with Jules @ BeRacing on a regular basis, he's doing stuff I wish was around 15 years ago.

  24. #24
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Did a few more upgrades over the last couple months.

    Wavetrac LSD
    Aquamist methanol injection
    Custom made catch can
    Boost controller









    Made it back on the dyno and played with the boost controller a bit.
    Running at spring pressure(12psi) untill 4500RPM then ramping boost in up to about 21psi.
    I'm keeping mid-range boost on a leash in hopes to keep the stock rods in the block for as long as possible.




  25. #25
    M5Hunter is offline Still has a E39 Supporting Vendor
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    Turned it up a little more for fun.
    This run was ramping boost in after 3800rpm up to 27lbs.
    The little 3076 is really working.
    Still attempting to keep the stock rods inside the block for the time being.


    7F601A94-8041-4FC2-96BC-4313A925DE3C.jpg

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