2004 E60 535d - Fitting an intercooler.?????

Notices
 

Thread: 2004 E60 535d - Fitting an intercooler.?????

Reply to Thread
Results 1 to 9 of 9
  1. 2004 E60 535d - Fitting an intercooler.????? 
    #1
    BMW Fanatic
    Car Details
    silvasnow's Car Details
    Model of Car:
    535d m sport
    Year of Manufacture:
    2004
    Transmission Type:
    automatic
    Car Body Type:
    saloon

    Join Date
    Mar 2009
    Location
    scotland
    Posts
    30
    Thanks
    0
    Thanked 0 Times in 0 Posts
    Hi guys,

    anyone fitted an intercooler to a e60 535d??. I've enquired before and was told you could not get one. But i came across this...

    http://turborevs.org.uk/vmchk/interc...ooler-kit.html

    The guy told me it can be fitted with some piping mods.....correct??....or would it be a complete nightmare to do.

    cheers
     
     

  2. Remove Advertisements
    BimmerForums.co.uk
    Advertisements
     

  3.  
    #2
    BMW Maestro
    Car Details
    APtuning's Car Details
    Model of Car:
    e46 330D sport
    Year of Manufacture:
    2003
    Transmission Type:
    auto
    Car Body Type:
    saloon

    Join Date
    Dec 2008
    Location
    Rochester, Kent
    Posts
    640
    Thanks
    70
    Thanked 214 Times in 169 Posts
    Try Allard motorsports for Intercoolers. If they don't already make one for your car I'm sure they can custom build and so taking into account the original pipework. Worth a call and the car will like it
     
     

  4.  
    #3
    BMW Crazed
    Car Details
    celica's Car Details
    Model of Car:
    Golf
    Year of Manufacture:
    2005
    Transmission Type:
    DSG
    Car Body Type:
    Hatch

    Join Date
    Jun 2010
    Location
    bristol
    Posts
    208
    Thanks
    71
    Thanked 7 Times in 7 Posts
    theres an ex 535d owner who had a website showing his intercooler and different maps

    not sure if he's a member here, but now has a porsche 4x4, will dig up the web link when i remember what it is
     
     

  5. Remove Advertisements
    BimmerForums.co.uk
    Advertisements
     

  6.  
    #4
    BMW Fanatic
    Car Details
    bookwyse's Car Details
    Model of Car:
    535d sport
    Year of Manufacture:
    2005
    Transmission Type:
    auto
    Car Body Type:
    Touring

    Join Date
    Apr 2011
    Location
    kent
    Posts
    57
    Thanks
    2
    Thanked 26 Times in 21 Posts
    I remember that bloke3 as he was running a sierra rs500 intercooler that fitted with a few adjustments to the pipework.

    Am seriously considering this myself.
     
     

  7.  
    #5
    Bimmer Fan
    Car Details
    chapelhill's Car Details
    Model of Car:
    535D & Ibiza TDI
    Year of Manufacture:
    05 & 03
    Transmission Type:
    Auto & manual
    Car Body Type:
    Saloon & Hatchback

    Join Date
    May 2010
    Location
    Scotland
    Posts
    2
    Thanks
    0
    Thanked 2 Times in 1 Post
    the web site has been updated for his new Porsche but there is still some info on this page showing the intercooler:
    http://www.bmw535d.co.uk/id11.html

    I bought his 535D, bt have it as a second car as I am doing 35k miles a year and cannot afford to use it for that.

    What are you hoping to achieve with a FMIC?

    Regards
    Chapelhill
     
     

  8.  
    #6
    BMW Fanatic
    Car Details
    bookwyse's Car Details
    Model of Car:
    535d sport
    Year of Manufacture:
    2005
    Transmission Type:
    auto
    Car Body Type:
    Touring

    Join Date
    Apr 2011
    Location
    kent
    Posts
    57
    Thanks
    2
    Thanked 26 Times in 21 Posts
    Will be hoping to reduce the charge temps and hence create a denser air to mix with the diesel, thus resulting in more oxygen and a better burn. Thus more powerrrrrrrrrrrrrrrrrrrr.
     
     

  9.  
    #7
    BMW Guru
    Car Details
    TheEnd's Car Details
    Model of Car:
    540
    Year of Manufacture:
    1998
    Transmission Type:
    Auto
    Car Body Type:
    Saloon
    TheEnd's Avatar
    Join Date
    Jun 2010
    Location
    Birmingham
    Posts
    8,979
    Thanks
    478
    Thanked 2,990 Times in 2,440 Posts
    It would produce a cleaner burn, but not necessarily more power.
    It may have an effect, but the main thing is more air, so a cleaner burn and lower temps, which means you can turn a remap up more to get more power.

    Diesels can be thought of as always at wide open throttle, with power controlled by changing the injection quantity.
    Petrol cars are controlled by the amount of air allowed in, diesels are controlled by the amount of fuel let in.
     
     

  10.  
    #8
    Bimmer Fan
    Car Details
    chapelhill's Car Details
    Model of Car:
    535D & Ibiza TDI
    Year of Manufacture:
    05 & 03
    Transmission Type:
    Auto & manual
    Car Body Type:
    Saloon & Hatchback

    Join Date
    May 2010
    Location
    Scotland
    Posts
    2
    Thanks
    0
    Thanked 2 Times in 1 Post
    The stock intercooler does look small but it is deep.

    Getting more charge air in also has the effect of increasing the overall diesel burn rate which tends to increase peak cylinder pressure and increase power a little. I notice this on my Ibiza when the turbo overboost if I am too harsh with the throttle.

    What is the maximum your inlet temperature reaches now?
    The reason I ask is it depends on your driving style.
    The intercooler system has significant thermal mass and the inlet air has relatively little thermal mass. As a rough approximation boosting the air by one bar increases air temp by approx 50 deg C and a chiped 35d runs close to 2 bar.

    On my Ibiza which runs a 2 bar map until I get it upgraded to get to 2.4 bar, on cruising at 30 MPH inlet temp will be about 8 deg above ambient. Cruising at 70 it will rise to approx 12 deg c above ambient (Approx 0.4-0.5 bar).
    If I give the car some beans (2 bar), the temperature will only rise slowly as the intercooler has large thermal mass.( I managed to get it to 28 deg above ambient on an uphill) As you use the boost more your speed will increase which helps to increase the intercooler efficiency.

    I am not sure what is the critical temperature, but I would make a guess in the region of 60 degrees C.

    Unless you are in a hot country and and drive the car seriously hard you may find that your intercooler is actualy doing a good job already.
    Track days and Dynos would be the worst case scenario.

    If the inlet temp is too high the ecu will counter with reduced fuelling and retarded start of injection.

    The higher the maximum boost you use the more there is need for an intercooler. At these higher boost levels some Turbos start putting in a lot of extra heat with little increase in boost density as we are starting to get out the efficient operating profile.

    Next time I take my BMW out I will see if the Torque app (Andoid OBDII diagnostic) can give me some readings, if not i will have to get the kids out with the laptop and INPA.

    I really want to see what the injection duration is at maximum power to see what is left in reserve for fuelling. I have about 37 degrees on my Ibiza which is pretty much the street limit for a diesel.

    I plan at some stage to put an exhaust manifold pressure gauge on so i can see how the efficient the Turbo set up is for my current tune.

    The RS500 intercooler is large and obstructs the main radiator, from which I understand is essential to install some cooling ducts to move air to the back of the intercooler to the radiator.

    Regards
    Chapelhill
     
     

  11. The Following 2 Users Say Thank You to chapelhill For This Useful Post:

    AWY (17-05-2011),Xmak 330d (16-05-2011)

  12.  
    #9
    BMW Crazed
    Car Details
    powerofm's Car Details
    Model of Car:
    M3 Evo
    Year of Manufacture:
    1996
    Transmission Type:
    manual
    Car Body Type:
    saloon
    powerofm's Avatar
    Join Date
    Dec 2009
    Location
    london
    Posts
    145
    Thanks
    8
    Thanked 75 Times in 61 Posts
    I'm sure i read in a magazine that forge have just made an intercooler for the bmw 35 diesel range. Maybe more info on their website. Although the price was very high iirc
    Last edited by powerofm; 17-05-2011 at 12:02. Reason: missed a bit
     
     

Tags for this Thread

View Tag Cloud

Posting Permissions
  • You may post new threads
  • You may post replies
  • You may not post attachments
  • You may not edit your posts