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

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post #1 of 186 Old 14th August 2013, 04:20 PM Thread Starter
AseanAero
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Building an 'M540' out of an E34 530i 5 speed

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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IMG-20130813-01662.jpg   IMG-20130813-01660.jpg   IMG-20130813-01661.jpg  



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

Last edited by AseanAero; 14th August 2013 at 04:50 PM.
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post #2 of 186 Old 14th August 2013, 04:38 PM Thread Starter
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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.



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project

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post #3 of 186 Old 14th August 2013, 05:28 PM Thread Starter
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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 ?



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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post #4 of 186 Old 15th August 2013, 05:01 AM
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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.

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 #5 of 186 Old 15th August 2013, 12:55 PM
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Quote:
Originally Posted by AseanAero View Post
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.

To///Mba
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post #6 of 186 Old 15th August 2013, 12:59 PM Thread Starter
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Quote:
Originally Posted by Tomba View Post
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 ?



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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post #7 of 186 Old 15th August 2013, 02:48 PM
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You boys are great ........

Love it !

I'm sure that our engineers have a chromoly billet flywheel for that 540i !

D

Better a day as a tiger than a lifetime as a sheep !

91 Sebring 3.6 | E28 UK RHD M5 | E34 UK RHD 3.8 | E34 M5 Touring | E24 M635CSi UK RHD

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post #8 of 186 Old 15th August 2013, 02:57 PM Thread Starter
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Quote:
Originally Posted by davidoli View Post
You boys are great ........

Love it !

I'm sure that our engineers have a chromoly billet flywheel for that 540i !

D
Budget build David :-)



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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post #9 of 186 Old 15th August 2013, 03:00 PM
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Member , Tel ( FinalEdition ) had a lovely 6 speed manual E34 540i with E32 750i LSD for extra acceleration ......

Great fun !

D

Better a day as a tiger than a lifetime as a sheep !

91 Sebring 3.6 | E28 UK RHD M5 | E34 UK RHD 3.8 | E34 M5 Touring | E24 M635CSi UK RHD

www.classicmdautos.co.uk
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post #10 of 186 Old 15th August 2013, 03:02 PM Thread Starter
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Quote:
Originally Posted by davidoli View Post
Member , Tel ( FinalEdition ) had a lovely 6 speed manual E34 540i with E32 750i LSD for extra acceleration ......

Great fun !

D
Good tip on the LSD , thanks David, we get some 750i's come up cheap here with no papers



Tony, Aussie expat in Jakarta Indonesia

1990 E34 M5 S38B36 GA25324
GA25324


1995 E34 540/5 Project
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