Building an 'M540' out of an E34 530i 5 speed - Page 7 - BMW M5 Forum and M6 Forums
E34 M5 Discussion 1988-1995 Sedan and Touring

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post #61 of 186 Old 11th October 2013, 06:58 PM Thread Starter
AseanAero
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Stock front exhaust pipes with mufflers weighs 12kg, the Y pipe came in a 13kg

I'm pleased with the result, at normal around town speeds the exhaust is quiet with a nice bass underneath it all

If I did this again I would go slightly smaller on the pipe , 75 to 80mm instead of 110mm, still sorting out a clearance issue, the LHS pipe is touching the LH transmission mount under hard acceleration. I have to make a clearance depression on the pipe a bit deeper (0.5cm at the moment, I'll try 1cm)

The 'butt dyno' says something good has happened, at 90kmh in 3rd gear the front of the 530i lifts noticeably when the accelerator is floored. Throttle response above 4,000rpm has improved.

The exhaust gas leaving the tailpipe at idle is a constant and steady stream , when I put my hand in front of the tailpipes I can't feel any gas pulses.

I did some calculations tonight and the Y pipe has 3 times the capacity of the front pipe it replaced.

Here's a short video taken in a not ideal place to try the exhaust out, lots of traffic around, speed humps etc. It does show you how quiet it is at low rpm. I didn't get above 3,500rpm

+ YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.


I took the 530i through a tunnel tonight at 6,000rpm and it sounded very nice.
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Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

Last edited by AseanAero; 11th October 2013 at 07:04 PM.
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post #62 of 186 Old 12th October 2013, 05:01 AM
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I like the way it kicks now above 5000 rpm !
And the sound above 4500 Rpm is fantastic.

Do You find less torque @ lower Rpm ? Or is it the same ?

It is said that if you line up all the cars in the world end to end, someone would be stupid enough to try and pass them.
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post #63 of 186 Old 12th October 2013, 05:47 AM Thread Starter
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Quote:
Originally Posted by BlueBiturbo View Post
I like the way it kicks now above 5000 rpm !
And the sound above 4500 Rpm is fantastic.

Do You find less torque @ lower Rpm ? Or is it the same ?
Feels much the same down low or a little bit less, it's hardly noticeable, but definitely improved on the top end.

I'll have a better impression after I've driven it some more.

It was a worthwhile mod, makes the car a lot more fun to drive.

Will sound better when the M60B40 goes in, more bass and growl



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

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post #64 of 186 Old 12th October 2013, 03:16 PM Thread Starter
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Taffy (bluebiturbo) had a drive and says there's definitely been an improvement in power and response.

Video shows short runs to 6,000rpm

I wanted something that was quiet at low speed and louder as power was applied and I acheived that so I'm happy.

It's a lot of fun to drive now.

M60B40 next.

+ YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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post #65 of 186 Old 14th October 2013, 10:01 AM Thread Starter
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Somehow the little M60B30 ended up sounding like a Chev big block powered McLaren M8E Can Am , one of my favorite cars by the way.

+ YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

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post #66 of 186 Old 14th October 2013, 03:40 PM Thread Starter
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Exhaust done, onto the engine swap
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Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
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1995 E34 540/5 Project
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post #67 of 186 Old 19th October 2013, 06:39 AM Thread Starter
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I made an interesting discovery this week.

The starter is on the RHS of the engine which means this engine came out of a LHD market (not Singapore as I was told)

We also had some LHD cars imported here into Indonesia over the years.

Not a big deal, I can cut out the casting on the LHS of the engine and make a blank to close the old starter motor mounting point.

Overall the engine looks in good shape, minimal wear on the cams.

I found some aluminium corrosion on the water jacket on the RHS cylinder bank under the intake manifold which is being treated with Alodine (a formulation which inhibits corrosion in Aluminium) and then will be epoxied just in case.

Cam covers are going out for powder coating in gloss black.

The more I work on this engine the more I appreciate the design and build quality, another good engine from BMW.

The M60B40 goes onto the engine stand next week for a check of the internals.

With an almost 200kg weight difference between the 530i (no sunroof, sls, less sound proofing, manual seats) and my M5 the power to weight ratio is very similar with an M60B40 in the 530i chassis.


.
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Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
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1995 E34 540/5 Project

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post #68 of 186 Old 30th December 2013, 09:20 AM Thread Starter
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I've been busy with salvage projects out of Jakarta the last few months and now the M5 is back on the road for alternate daily driver duties I can do some more work on the 540 project

A small step forward is powder coating the valve covers :-)
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1990 E34 M5 S38B36 GA25324
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post #69 of 186 Old 30th December 2013, 10:27 AM
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Quote:
Originally Posted by AseanAero View Post
A small step forward is powder coating the valve covers :-)
You should have never ever power coat these M60 valve covers !!! They are made from Magnesium in order to save some weight and the magnesium when powder coated wraps enough to make your valve cover gasket to leak in no time. !

On my E31 840Ci M62-B44 I had to change the covers on both banks because the previous owner powder coat them and they leaked like crazy…I had to source a set that were 100% original and untouched. Light sand blast to remove the old and chipped paint and then with hi heat/headers Silver paint was applied to match the factory valve cover color.

In my opinion to work on V8 engines is nightmare time consuming !!! After I put my hands on the M60/S62 engine years ago….I realized and appreciate how simple and easy is to work on S38 engines….

Also I hope you did not get the early blocks with the Nikasil problem ! You can check the block # with BMW to get idea witch block you have…

One little scratch on that Cyl Cheese Block and goes buy buy buy block…will require replacement.

You should have started with M62 B44 4.4 Non Vanos engine say from E39 540i.

I hope you have luck with the 4.0L

Regards
Anri

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post #70 of 186 Old 30th December 2013, 10:54 AM Thread Starter
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Quote:
Originally Posted by First e28 M5 View Post
You should have never ever power coat these M60 valve covers !!! They are made from Magnesium in order to save some weight and the magnesium when powder coated wraps enough to make your valve cover gasket to leak in no time. !

On my E31 840Ci M62-B44 I had to change the covers on both banks because the previous owner powder coat them and they leaked like crazy…I had to source a set that were 100% original and untouched. Light sand blast to remove the old and chipped paint and then with hi heat/headers Silver paint was applied to match the factory valve cover color.

In my opinion to work on V8 engines is nightmare time consuming !!! After I put my hands on the M60/S62 engine years ago….I realized and appreciate how simple and easy is to work on S38 engines….

Also I hope you did not get the early blocks with the Nikasil problem ! You can check the block # with BMW to get idea witch block you have…

One little scratch on that Cyl Cheese Block and goes buy buy buy block…will require replacement.

You should have started with M62 B44 4.4 Non Vanos engine say from E39 540i.

I hope you have luck with the 4.0L

Regards
Anri
Thanks for the tip Anri, if they leak I still have an untouched set of valve covers on the B30 still in the car which will fit the B40.

Both engines (and most here) are still Nikasil , we didn't have the sulphur problem like in the USA, my 530 engine has 164,000kms and still going well.

E39 540i ? I think there is one in the country, we're a bit limited to what's available :-)



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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