Project 535i Turbo Started

[TCD]

Today we dynoed a bone stock 1992 5 speed 535i. Results were 170/182 at the wheels. Motor is totally healthy. Hopefully this time next week we'll dyno it with a turbo.
Todd
http://www.turbochargingdynamics.com

[Craig]

Cool, can't wait to see the numbers Todd. For a reference point mine made 180/195 corrected with a chip as the only mod.

[Incantation]

Nice.. I am eager to see the results. I would like to buy a kit like this for my e34.

What is the maximum amount of hp/torque you can make without any internal mods on the m30 engine? (in like-new condition)

[George M]

it will be quick to be sure...the question is how long will it last. Presume you are keeping your 9:1 pistons. Hope you have a good engine managment set up and provide plenty of fuel, not too quick a spark and not too much boost. Be sure to let us know what the set up parameters are...intercooler?...engine controller?...new injectors/fuel regulator/pump?...etc.
Good Luck,
George

[TCD]

8.5:1 is considered ideal compression ratio for boost so 9:1 is suitable. We'll initially run 10-11psi non intercooled and then more intercooled. We'll be using the stock engine management with a RRFPR and MSD BTM. This combo has proven reliable in our m30b34 cars for up to 17/18psi. The car will get 30lb injectors and likely a 255lph in tank fuel pump. The only part that we see failure on is a tired headgasket. We have not seen any mechancal failures.
Todd

[George M]

how many cars have you boosted to 17/18 psi with stock 9:1 compression and modified versus replaced engine management?...far from a recipe for any sort of engine life. You gonna run a knock sensor?
Even running 10-11 psi'ed non intercooled with 9:1 compression WILL shorten the engine life and seriously tax an aging head gasket. As a benchmark, the factory 745i turboed M-30 in E-23 cars runs dished pistons dropping compression to 8:1 and less boost than that...a decent baseline to crib off of for engine durability. More boost + more compression = less engine life. Not in of itself a big deal if the car is a Sunday driver that sees low miles. For a daily driver...be prepared for a lot of garage time.
George

[TCD]

how many cars have you boosted to 17/18 psi with stock 9:1 compression and modified versus replaced engine management?...far from a recipe for any sort of engine life. You gonna run a knock sensor?
Even running 10-11 psi'ed non intercooled with 9:1 compression WILL shorten the engine life and seriously tax an aging head gasket. As a benchmark, the factory 745i turboed M-30 in E-23 cars runs dished pistons dropping compression to 8:1 and less boost than that...a decent baseline to crib off of for engine durability. More boost + more compression = less engine life. Not in of itself a big deal if the car is a Sunday driver that sees low miles. For a daily driver...be prepared for a lot of garage time.
George

George,
We don't plan on running 17/18psi with the 9:1 motor. 13/14psi is a safe limit. Anytime you double the HP of an engine you'll shorten it's life. I have 15+k on my junkyard motor running 15+psi in the past year without zero engine failures! I drive it harder than anyone on this board ever dreamed about running a car!

The 745i is not a good comparison. BMW was extremely conservative and built the motor combo to last 400k. We are not doing that.

A turbo is the ultimate daily driver. It adds absolutely zero stress to the engine in all normal driving scenarios!

Todd

[George M]

OK Todd. Without zero engine failures?....does that mean you had multiple engine failures?...kidding. You aren't too far off base...until your last sentence.
George

[TCD]

You aren't too far off base...until your last sentence.


I am basing my opinion on our actual testing but I'll admit it only amounts to 45k miles.

Todd

[George M]

I applaud your ingenuity Todd to retrofit a turbo to your M-30...good stuff and best of luck. Be sure to post your set up for us want-to-be's.
George

[albundy]

Todd,

Was looking at the dyno results for the stock 535i. Is it correct that the RWHP hp is less than 140 for that engine? I dynoed my M52 (stock 2.8 motor) and got more than 160hp. The quoted hp by the manufacturer lists the 535i having more hp than the M52 motor (211 vs 193). Of course now with further mods and a chip I got more than 170hp at the wheels.

Rgds

[Craig]

Are you referring to the 535i dyno in this thread? If so, it looks like it was 170rwhp. If you are looking at a different discussion about a 535i, remember the E28 M30 (Todd is mostly an e28 guy) is rated at 182hp at the flywheel, which would be right around 140rwhp or so.

[Robin-535im]

Today we dynoed a bone stock 1992 5 speed 535i. Results were 170/182 at the wheels. Motor is totally healthy. Hopefully this time next week we'll dyno it with a turbo.
Todd
http://www.turbochargingdynamics.com

Can you post it or mail it to me?

robin.ritter*NOSPAM*@ngc.com - remove the *NOSPAM* of course.

Thanks!

[Robin-535im]

Cool, can't wait to see the numbers Todd. For a reference point mine made 180/195 corrected with a chip as the only mod.

Per my earlier post a few days ago, I'm trying to pool whatever dyno results we may have on the board. If you would send me a copy I'd really appreciate it - I'm going to assemble them and talk to Bruno about posting them on his site.

Thanks,

Robin

[Craig]

Per my earlier post a few days ago, I'm trying to pool whatever dyno results we may have on the board. If you would send me a copy I'd really appreciate it - I'm going to assemble them and talk to Bruno about posting them on his site.


I don't have a scanner, but the peak numbers were 180rwhp and 195rwtq. I'll see if I can try taking a picture of it with a digital camera and sending that to you, if it works.

[TCD]

535i Dyno Sheet (http://groups.msn.com/_Secure/0PgANA3QQT9QmdX2bCgCYjkF12tDIkw6qyG*IJWO*3dxjCUn6W brfP0r35iLND4LmQAMD3xmCnLIKrdwreSei3vYMHy8XUpNC/535.BMP?dc=4675474670009959579)


Car made 169.5/182.2 on the first run. For fun we took out the air filter and it made 166/180. The really interesting part is that it made the a/f ratio a whole point richer! The undirected airflow must open the AFM door more than the air coming through the filter.

We have the manifold, turbo and downpipe mounted. The a/c lines are in the way of course but we should have the car running by the end of the week. Pictures coming tomorrow.

Todd

[Robin-535im]

I don't have a scanner, but the peak numbers were 180rwhp and 195rwtq. I'll see if I can try taking a picture of it with a digital camera and sending that to you, if it works.