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Discussion Starter #1 (Edited)
Firstly I'd like to ask the mods to indulge me in this thread as I think the best minds on the planet when it comes to my 'M540' project are on this forum.

Six months ago I bought an Indonesian assembled (German manufactured CKD kit) 1995 530i 5 speed manual to take the daily driver duties off my M5 (which doesn't like being stuck in Jakarta traffic jams)










It's been overall a great car for my 40km daily commute, reasonable power, good fuel economy , ok handling and brakes BUT there's lots of room for improvement.

So far I've focused on restoring the 530s power (it went like a 520 when I got it) and we traced that to an incorrectly adjusted throttle cable which was only giving 75% travel on the throttle body and some exhaust mods.

I want a bit more power and I don't want to go EDC but an 'almost' M540 including M5 bumpers etc.

The Indonesian assembled 530i's ALREADY HAVE the M5 style side skirt and M5 rear plastic number plate surround from the factory

I removed the 2 front mufflers, emptied all the glass packing from the centre muffler and installed a used E34 M5 muffler from GA25331 when Taffy put an Eisenmann race muffler on his M5. The exhaust now sounds great and the 530i seems to have more pull at higher speeds. Next step on the exhaust is some collector / expansion chambers and a crossover pipe where the 2 front mufflers used to be.

Some new Toyo T1R 235 and 255 R18s going on at the end of the month.

Finally after patiently waiting I've picked up an M60B40 (nikasil) engine out of an 840 coupe (automatic trans ex Singapore) and I intend to initially just bolt it in and run it with the 530i's 5 speed.

The engine isn't 100% complete but most of the parts from the M60B30 are the same (injectors are there, ICV is missing) so most of the bits from the existing B30 I can use.

A couple of immediate questions

1. The MAF is a different part number, will the B30 MAF work on the B40 or is this a must change item ?

2. The flywheel between the B30 and the B40 are a different part number (PN) and also the B40 flywheel is 1kg heavier, is this a big problem ? All other hardware for the flywheel are the same PN.

3. Will the B30 DME work on the B40 ?

The 530i will get suspension parts from my M5 stock including some front struts , used springs out of my M5 (as I want to put new OEM springs in).

The brakes will also be renewed and or upgraded.

The 530 is a nice car and some tweaking I should be able to get 290 to 300hp out of the 540 with a chip and exhaust mods which would make it a nice DD and as a 'disposable BMW' I won't get upset when a motorcycle puts a scratch on it. I really have a lot of fun driving it each day, usually with my window open to listen to the V8.

Future plans are a 6 speed trans, LSD and a gear ratio change (lower ratio). Taffy has plans to build an E30 M3 replica but a 4 door with an E39 M5 V8 and trans so I could be tempted to go S62B50 later.

We don't know of any genuine E34 540s in Indonesia

Thoughts , comments and suggestions please.
 

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Discussion Starter #2 (Edited)
Taffy , you've driven the 530i , what do you think of it ?

I'm really happy with the exhaust note, no booming and a real V8 sound except for a pop when decelerating through 1,900rpm with the throttle closed (I'll put a video up on the weekend)

I think it will be a great little project.
 

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Discussion Starter #3
Would something like a Dinan 540 chip solve the ECU problem as the ECUs are different part numbers and 540 specific ?
 

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I like the sound of the V8 now that the exhaust is already modified. Good throttle response compared from the day You bought it.
 

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Would something like a Dinan 540 chip solve the ECU problem as the ECUs are different part numbers and 540 specific ?
ECU hardware is the same. You should be able to swap EPROM from a 540i (manual) car and it should work.
Auto and manual calibrations are slightly different (idle speed setpoints, etc).
If interested I have an Alpina chip for that ecu available (B10 4.0 V8). Also lots of parts (Alpina camshafts, a MAF)
PM if interested.
 

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Discussion Starter #6
ECU hardware is the same. You should be able to swap EPROM from a 540i (manual) car and it should work.
Auto and manual calibrations are slightly different (idle speed setpoints, etc).
If interested I have an Alpina chip for that ecu available (B10 4.0 V8). Also lots of parts (Alpina camshafts, a MAF)
PM if interested.
Hi Tomba, yes I'm interested , I'll send you a PM

What are the characteristics of the B10 chip ?
 

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Discussion Starter #11 (Edited)
I think the M60 is a great little V8 , it loves to rev, it has a typical BMW power band ok under 4,000rpm but the fun happens from 4,000rpm to redline.

The old pushod V8s I had I would normally drop down 1 gear for overtaking , in the 530 I drop down 2 gears or whatevers necessary to get 4,000rpm

When I bought the 530 I said to Taffy I'm going to keep it stock but the temptation is too great to make it better.


.
 

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I am sure you will need both the 540 maf and ECU/chip.

The flywheel/clutch assy will bolt on directly without any issues. My friend had a normal auto 540 and transplanted the flywheel, clutch, gearbox, diff, propshaft from a 530 to make it a manual. For some weird reason, the 540i 6 speed uses a 265mm clutch whereas the 530 and almost all other BMWs use a 240mm item. My Friend's 540 with the 530 geartrain lasted quite good, until he took it on a track where after the clutch was not so good anymore. My point being, that if you can moderately behave, it will last just fine with the smaller 530 item.

I have also fitted a 3.15 LSD from an e32 750iL to my 540i 6 speed individual and it makes the car feel much better even though it makes NO difference whatsoever on all out acceleration
 

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Discussion Starter #19 (Edited)
Not convinced.


Getrag 260/5 BMW E34 M60

1st 3.83
2nd 2.2
3rd 1.4
4th 1
5th 0.81
Final drive 3.07

Getrag 280/5 BMW E34 M5

1st 3.51
2nd 2.08
3rd 1.35
4th 1
5th 0.81
Final drive 3.91

The M5 has the same overdrive but 700rpm more redline (6,500 vs 7,200). I don't need a super high top speed on the 540i project. The current 3.07 rear gear ratio is too lazy even as a daily driver.

I agree a 3.45 would be a better compromise but there's a 3.91 sitting ready outside. Try it out for a few months.

.
 

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Your ratios are wrong for the M60 5 speed. 5th is 1:1 ratio.

I have driven a 540 6 speed with a 3.64 LSD from the manual 535 and to be honest, I didn't like it at all.

The B40 is an engine that can be driven in a very relaxed manner and wringing it's neck the whole time feels wrong. It feels as if you are constantly stirring the gears, since I am used to change up @ 2000 rpm in mine while driving in normal conditions.

I just dont think it suits the nature of the 540.

I think the optimal ratio for the 6 speed would have to be a 3.23
 
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