I giant project 540i/6 go fast mods..advice please

[psykotic]

Well, after weeks of reading posts and comments I dove in and just did it. Next week I will be installing my brand new:

VF Engineering Stage 1 Supercharger
Rogue Stage 2 Lightened Flywheel and Clutch
Active Auto SSK
3:15 Quaife LSD from "Diffs online"
and
BSW DICE/Speaker upgrade and Sub



First off, I know and have read the varying differences of opinions on which SC or what SSK..etc, to go with. I chose the above for various reasons and am looking for advice.

The car is a 2002 540i/6 with 50,134 miles on it. I have already replaced:
Radiator/Water Pump/Thermostat/Reservoir and all hoses
Valve cover Gaskets
ALL BELTS
and completed Inspection II
I have done a CDV delete, Resonator/Silencer/Muffler delete running a Borla Muffler w/ straight pipes from the CATS.

Is there anything in particular to watch out for? Like ECU removal, or " You know since your in there.........?

The second phase will include a ground up ctrl arm; bushings; rebuild with a set of shocks/springs and thicker sways. These forums have been an excellent source of info and I appreciate any advice. I will be getting a base line Dyno and will do an "after" as well and will post them when the project is complete. Thanks again


*****Edit I will also be replaceing Motor and Tranny Mounts. To easy while im in there >.< *******

[BKphoto]

just get a zionsville cooling system with electric fan and be done with it forever if you are putting this kind of money in it...

[mattmartindrift]

this is how you do it - read, then mod. not post pointless threads like "should I dinan my e39".

[cdb3113]

Nice list. I'd like to see your before/after results. Also, what was your cost on parts?

[RDR-EURO]

Cant wait till you finish your car with all those mods. Maybe once your done. You can give me a ride in your 540! By the way did you buy your supercharger over here in Hawaii or had it shipped from the mainland and who is going to reprogram your ECU for you once you finish installing your Supercharger ?

Thanks,
Ramon

[Mark@EACTuning]

good luck with your upgrades! If you are not looking for overbearing advice and product testimonials I am afraid you came to the wrong forum.

[cdb3113]

Originally Posted by mark@eactuning

good luck with your upgrades!

+1

Originally Posted by mark@eactuning

if you are not looking for overbearing advice and product testimonials i am afraid you came to the wrong forum.

lol

[nc540]

Sounds like it should go like stink! I'd start making my shopping list for a brake upgrade. Remember, BMW upgraded the brakes on M5's for a good reason. They're way more powerful than 540i's. Your car will be, too.

[540ig5]

Yep, suspension and brake upgrades aren't that bad of an idea. Not that you asked for this advice, but i got nothing else smart to say and couldn't keep my mouth shut.

[psykotic]

Suspension overhaul and Brake upgrade are next. "Phase II" Ill try to answer the questions as I saw them.

I would have gone with a Zionville and will be going that route, but when I bought car 3 months ago it had 46,000miles and the guy had just replaced the radiator at 44,000. Then I had to replace the water pump and changed all hoses and belts. So it got bumped to the end of the list. Phase III.

I havent purchased anything here in Hawaii, all mail order Dan at Beastpowers a good guy, though I had to wire payment so he would ship parts to an adress different than my billing. Cant have a SC and Clutch in my Apartment mailbox.

Phase I

Parts total with shipping
$8494.00 BeastPower for the SSK/Clutch/SC/Tranny mounts
$1800 BSW Dice/S1/Sub
$2000 ECS/BAV gaskets/pads/rotors/filters/fluids/Motor Mounts
$1975 Diffs on line 3:15 Quaife LSD-$800 refundable core charge
$850 Dinan TB

$15,119.00 Ouch i paid $13K cash for the damn car lol

VF Engineering will be doing the re-map of the ECU. 36hour turn around.

Phase II ( hopefully around February)

Headers and Highflow cats- Supersprint prolly @7K
Control Arms/wishbones/intergrals/trailing- replace front & Rear @ $1600
Wheel Bearing Front and Rear @ $1000
Dinan Monoball thrust arm bushing $799.99
Springs/Shocks/Sways/Stress- Havent decided just yet which to go with.

Phase III

Zionville Cooling
Brembo Upgrade
19" something

head gaskets and head rebuild-hopefully in prep for stage II S/C

lastly will interior/exterior paint and such Im thinking the Alpina look......oh and cant forget the best go-fast mod yet

chrome dipstick!

more later

[wilman]

i wish i had that much money.. sounds like awesome mods! not cheap things..

[legitsnowe39]

you know your doing something unique (and right? or wrong? lol) when you pay more in mods than the value of the car

sounds good, just hope you follow through, i want to see more "beast" e39's with ridiculous amount of performance mods, because its not often we see them. These threads are so much more interesting than the "oh look i got an m-tech bumper like everyone else thread" (not to say i oppose m-tech bumpers, its a mod thats sensible... that i may even do )

[jamesdc4]

[MartinV]

Thank you for actually making an interesting thread! Not many like these anymore.

Please take lots of pics and some videos of the SC once installed.

I wish you the best of luck!

Mahalo!!!

[chucksrt]

Nice list!!! What if anything do you have done to your car now?

[Gumbi4u]

Originally Posted by psykotic

Well, after weeks of reading posts and comments I dove in and just did it. Next week I will be installing my brand new:

VF Engineering Stage 1 Supercharger
Rogue Stage 2 Lightened Flywheel and Clutch
Active Auto SSK
3:15 Quaife LSD from "Diffs online"
and
BSW DICE/Speaker upgrade and Sub



First off, I know and have read the varying differences of opinions on which SC or what SSK..etc, to go with. I chose the above for various reasons and am looking for advice.

The car is a 2002 540i/6 with 50,134 miles on it. I have already replaced:
Radiator/Water Pump/Thermostat/Reservoir and all hoses
Valve cover Gaskets
ALL BELTS
and completed Inspection II
I have done a CDV delete, Resonator/Silencer/Muffler delete running a Borla Muffler w/ straight pipes from the CATS.

Is there anything in particular to watch out for? Like ECU removal, or " You know since your in there.........?

The second phase will include a ground up ctrl arm; bushings; rebuild with a set of shocks/springs and thicker sways. These forums have been an excellent source of info and I appreciate any advice. I will be getting a base line Dyno and will do an "after" as well and will post them when the project is complete. Thanks again


*****Edit I will also be replaceing Motor and Tranny Mounts. To easy while im in there >.< *******

Originally Posted by mattmartindrift

this is how you do it - read, then mod. not post pointless threads like "should I dinan my e39".

Originally Posted by MartinV

Thank you for actually making an interesting thread! Not many like these anymore.

Please take lots of pics and some videos of the SC once installed.

I wish you the best of luck!

Mahalo!!!

YES!!!! Finally another person who does not mind spending the money for a job done right with the RIGHT mods. This is indeed an interesting thread. Welcome to the forums brother.


I do believe in justified cost and the zionsville is justified in your situation. Obviously you are going to keep her for a bit. Knock that out as well whiule you are at it. If you want to stretch that dollar a bit, just get the aluminum rad and alum expansion tank and be done with it as well with money going towards a proper suspension.


Kudos!

[npvr6]

Originally Posted by psykotic

$15,119.00 Ouch i paid $13K cash for the damn car lol

Wow! This is definitely a top notch setup! I haven't seen anyone do a severe service and mod extravaganza since I became a member on this board!

Originally Posted by psykotic

VF Engineering will be doing the re-map of the ECU. 36hour turn around.

I am sure that VF supplies a nice tune, But I would definitely compare that price from them to a real street tune from a private tuner, I know a very reputable one in New York In case you are in this area!

Originally Posted by psykotic

Headers and Highflow cats- Supersprint prolly @7K

Definitely get high Flow metal cats, Do not buy an ceramic ones, believe it or not the 100$ ones on ebay that are full metal are better than any ones magnaflow can provide. The ceramics will break quickly... Trust me.

Originally Posted by psykotic

head gaskets and head rebuild-hopefully in prep for stage II S/C

I would definitely port and polish the heads while you have them out! Either have a shop do it the proper way and flow test them or write a sweet DIY and have at it with a dremel! But you will definitely see a high HP increase with a port and polish on a forced induction V8

Originally Posted by psykotic

chrome dipstick!

LOL


Good Luck!!

[psykotic]

Still waiting for S/C, Clutch and Diff in the mail maybe its cause Im in Hawaii. BavAuto seems to be the quickest on parts arrival..anyway I spent the last three days in preperation of my big stuff comming in.

Replaced:
Motor Mounts (didnt need really)
Front Rotors (cross/slotted)
all 4 wheel bearings
pads (went with cool carbon)
Rebuit all calipers with brass bushings (steel lines going in this weekend)
Oil Change(Royal Purple)
Valve cover gaskets ( no leaky Yeah!)
Valley Pan & Gaskets (and those hoses and gaskets at the back )
Sparkplugs
and some minor stuff:
washer resevoir pump(PITA gotta pull wheel and fender cover lol)
black out grills
shift knob
Road rash repair on Stock 17" M-pars
all new hub caps with carbon fiber black out stickers ( lol I know)
all new m stickers
Debadged


The guy from Beast gave me a tracking number yesterday for the SC and Clutch kit so hopefully it will be here soon

Great advice everyone thanks, I will definately post the "results". The car has been very cooperative so far, no hick-ups everything has been straight foward easy mechanics work. The damn snap rings on the caliper rebuild probably took the longest lol, i had to shave down the tips on my pliers to fit in the little holes.

More to come >.<

[chucksrt]

have you already done the pre vanos intake manifold?

[camoore]

Originally Posted by psykotic

phase i

parts total with shipping
$8494.00 beastpower for the ssk/clutch/sc/tranny mounts
$1800 bsw dice/s1/sub
$2000 ecs/bav gaskets/pads/rotors/filters/fluids/motor mounts
$1975 diffs on line 3:15 quaife lsd-$800 refundable core charge
$850 dinan tb

$15,119.00 ouch i paid $13k cash for the damn car lol

vf engineering will be doing the re-map of the ecu. 36hour turn around.

phase ii ( hopefully around february)

headers and highflow cats- supersprint prolly @7k
control arms/wishbones/intergrals/trailing- replace front & rear @ $1600
wheel bearing front and rear @ $1000
dinan monoball thrust arm bushing $799.99
springs/shocks/sways/stress- havent decided just yet which to go with.

phase iii

zionville cooling
brembo upgrade
19" something

head gaskets and head rebuild-hopefully in prep for stage ii s/c

lastly will interior/exterior paint and such im thinking the alpina look......oh and cant forget the best go-fast mod yet

chrome dipstick!

more later

dayuuuuuuuuuum!!!!!!

[Jason5driver]

Originally Posted by Gumbi4u

YES!!!! Finally another person who does not mind spending the money for a job done right with the RIGHT mods. This is indeed an interesting thread. Welcome to the forums brother.


I do believe in justified cost and the zionsville is justified in your situation. Obviously you are going to keep her for a bit. Knock that out as well whiule you are at it. If you want to stretch that dollar a bit, just get the aluminum rad and alum expansion tank and be done with it as well with money going towards a proper suspension.


Kudos!

The OP can obviously "do it right" because obviously money is not a problem with the OP...
Sure, anything is possible/ the sky's the limit, 'if' you have the money to do so.... IMO...
I personally prefer to see and listen to guys that have a very limited budget and doing some spectacular things to their cars... (E39dream for example...)
But that's just me...


Thanks!
Jason

[NikosX]

Ever driven an M5?

[newton22]

Originally Posted by NikosX

Ever driven an M5?

The mindset behind modding is that anyone can buy a M5, but how many 540s can give a M5 a run for its money?

[E39bmw]

Here is what I have planned for my m62 (that is unless i swap it out for a 2jzgte)
This project will start next September, but for now im just putting together the parts list:
So far im totaling about 13K for everything.
If i do get all of those parts for the build, ill be running over 700rwhp after going twin turbo (cant decide between TT or supercharger....want TT because not a lot of people have those on their 5series)

Bottom End

Connecting rods:
Arrow Precision - M60 / M62 Con Rod----$2400

Main Studs
ARP - Main Stud Kits for BMW---$150

Pistons
CP Forged - M60 / M62 BMW Piston Set (94mm)---$1550

Oil System Upgrade
VAC - M60 / 62 Oil Pump Upgrade Kit---$200

Sleeves
VAC - Flanged Cylinder Sleeve, 90-94 mm----$1040



Top End

Cams
Schrick - S62 Camshaft Set, 268 / 268 ($2,600 per bank)----$5200

Vavle retainers
M60/M62/S62 Steel Valve Retainers - 32pieces---$300

Lifters
VAC - M60 / M62 Solid Lifter Conversion Kit (32)---- $1500

Valve Springs
VAC - M60 /M62 /S62 High Performance Valve Springs (32 pcs)-----$900

Valves
VAC - M60/M62/S62 Valve Kit (32) (6mm Valve Stem)------ $960

Head Studs
ARP - Performance Head Stud Kits ------ $350

The prices are just a rough estimate and actually if i order them all at the same time, ill get a good discount from VAC website. For now the total is about 13 or 14K which is not all that bad.

Im not doing the build yet, still need a better Job and more money, but have this on my to do list. Also, at the same time ill do the suspension upgrades becasue as many of you know, my suspension is probably in the worst condition then any 5series you have ever seen lol

[jdjg]

Originally Posted by psykotic

Still waiting for S/C, Clutch and Diff in the mail maybe its cause Im in Hawaii. BavAuto seems to be the quickest on parts arrival..anyway I spent the last three days in preperation of my big stuff comming in.

Replaced:
Motor Mounts (didnt need really)
Front Rotors (cross/slotted)
all 4 wheel bearings
pads (went with cool carbon)
Rebuit all calipers with brass bushings (steel lines going in this weekend)
Oil Change(Royal Purple)
Valve cover gaskets ( no leaky Yeah!)
Valley Pan & Gaskets (and those hoses and gaskets at the back )
Sparkplugs
and some minor stuff:
washer resevoir pump(PITA gotta pull wheel and fender cover lol)
black out grills
shift knob
Road rash repair on Stock 17" M-pars
all new hub caps with carbon fiber black out stickers ( lol I know)
all new m stickers
Debadged


The guy from Beast gave me a tracking number yesterday for the SC and Clutch kit so hopefully it will be here soon

Great advice everyone thanks, I will definately post the "results". The car has been very cooperative so far, no hick-ups everything has been straight foward easy mechanics work. The damn snap rings on the caliper rebuild probably took the longest lol, i had to shave down the tips on my pliers to fit in the little holes.

More to come >.<

everything its ok, but why "all new m stickers"???, why??, don´t do it, your car are are not an M5 e39, I think after all this moods you are going to have a better a much better car than the M5 lol....