What is the safe boost limit on E39 530d with stock management?

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  1. What is the safe boost limit on E39 530d with stock management? 
    #1
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    Hey guys,

    Firstly, can we increase output on a diesel turbo engine simply by installing a manual boost controller?

    If so, what safe boost pressure can the stock engine management on the E39 530d appropriately fuel up to on the stock turbo?
     
     

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    There isn't much you are going to gain.
    The ECU has a table of boost pressures inside it, and it will just actuate the turbo to increase or decrease boost to reach the target.
     
     

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    Can you bypass the actuator with a manual boost controller? and would the ECU increase fuel to compensate?
     
     

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    Don't waste your time and money on doing this

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    AFR on a diesel is already on the lean side so no gains from more boost.
    About the limit on that car is 1.5bar with stock map sensor.If you use the 320d 150hp you can use up to 2.3bars.
    Artur Costa
     
     

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    Quote Originally Posted by Jabo View Post
    Can you bypass the actuator with a manual boost controller? and would the ECU increase fuel to compensate?

    I guess you could divide the ECU into two parts, the fueling and the boost. The power comes from the fueling, and at any point, it will be injecting a specific amount of fuel based on things like pedal position and torque limiters.
    Running in parallel to this is the boost side which is increasing or decreasing boost to reach the levels programmed in the ECU.

    The only time you would see more power would be if the ECU holds back a little on the fueling as it might produce some smoke.

    eg.

    Pedal position asks for x mg of diesel,
    Torque limiters will set the maximum mg of diesel to be injected,

    At the same time, it will be working out boost levels and reaching y mbar of boost.

    It will combine these values and see if x mg of diesel is right for the amount of air measured (more boost means more air)

    So as long as it isn't at a torque limiter, and there is enough air, it will inject the same amount of fuel whether you are at 0.8 bar of boost or 1.5 bar of boost.


    Removing the actuator and using something else to control the boost is likely to put the ECU into a limp mode, which activates quite a low torque limiter for safety.

    Getting more air into a diesel doesn't really do a lot, but it allows more fuel to be injected giving more power without smoke.
     
     

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    Thanks for the responses guys. Remap is definitely the way to go!
     
     

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    #8
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    My 1999 model doesn't have a 16 pin OBD-II port in the cabin. Is the ECU flashable through the 20 pin socket in the engine bay?
     
     

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    Quote Originally Posted by Jabo View Post
    Is the ECU flashable through the 20 pin socket in the engine bay?
    yes mate
     
     

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    #10
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    Awesome. My 20 pin to 16 pin OBD adapter arrived today so I'm going to see if my Galletto or MPPS can dump the ECU then find somebody I can send the file to for a tune

    Quote Originally Posted by payno View Post
    yes mate
     
     

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