Purchased at 141k Miles with Check Engine Light, missing PDC Sensors, AWD issue ( not bothering mine )




Quick to it - want to do a Semi m5 conversion but -
Rwd Conversion - im halfway done
Keep the Auto 6 speed - 8hp later down the line?
Outside M Sport Aesthetics
M5 LSD w/ Axles
M2/M3 Calipers w/ m5 Rotors - documented on youtube
The N54 has been around for quite sometime. I want to stay within OEM parameters so I will be using the Stock turbos. So lets see what we can do with this frankenstein build but to the unseen eyes just looks like a M Sport 535i.
Current config


Rebuilt Turbos
AWD drivetrain is removed but not coded - Front Axles but Hubs still connected, Front Diff, Front Axle - Evans E61 has it documented on how he did his
High Flow Inlets / Outlets - had to massage the Aluminum Coolant Pipe for the O2 Sensors
Catless Down Pipes
3inch Exhaust with Vibrant Resonator, High Flow Cat from Ebay 200 Cell - stinky sometimes - bearable , Using a 3inch Vibrant Muffler with dual tips built in and still drones
^ Anyone that has single exhaust with muffler chime in, i might swap to a valvetronic muffler, be nice to sound like the e90 w/ PE.
TurboSmart BOV
Burger DCI's
XHP Stage 2
MHD Stage 2
Bmw Style 403M Staggered - Wheels little sunkin in, itll do for now, would love to put the m5 multispoke wheels on.
HR Sport Springs Front - did not adjust the air spring settings. Used these chinese shocks for 110 bucks. Feels like coils but was better than blown shocks.
Issues loading pics at the moment but lots of inspiration from Evans car but car needs to be on quieter side and with some bling on it. Right now im dealing with at 4k rpm sounds like a whoopee cushion, im pretty sure its coming from the High Flow Outlet from the clamps for the silicone hose but will confirm.

 

What have I done from when purchased till now - This is Cliffnotes summary version - from October 24 to May 25
- I hate xDrive. On newer Vehicles it works alot better. Technically this is a xI which is different from xDrive. Only because it has no purpose in my Los Angeles, Ca climate. Since this will not see all weather duty, very first thing i did via followed by Evans E61 build. I removed the AWD Components except the Transfer Case because its part of the Transmission. The Coupler on the Transfer Case pops in n out by hand but it has not popped since ownership. I had to drop the Subframe to remove the Front Diff. Front Driveshaft came off with no effort at all with tools. I removed the components connected to the Oil Pan. The Front Axles, I took them apart and installed the Hubs back onto the Front Wheels as it keeps the Bearings in place.
- Sametime I installed Catless Downpipes. The Coolant Pipe had to be massaged to clear the O2 Sensor.
- Had a boost issue. Dont have code in front of me but replaced both Boost Solenoids to start. Car would go into limp mode just from driving esp when cold. Then replaced Vanos Solenoid as there was was fault for the Exhaust side. Pretty sure I have to address the Camshaft Ledges later down the line. I work down the street but after work I have to drive a few miles so only reason why I take it to work. If I drive it to work and turn it off, when I turn it on the evening the car it has a valve tick or hydraulic tick and requires driving for it to go it away so when I have to drive it to work i let the car warm up at my destination and then turn it off. It gets alarming when you hear the ticking, it follows the RPM with the vehicle.
- Put oil additives Marvel Mystery Oil & B12 Fuel Additive.
- I then replaced the Vanos Filters and they were dirty. Since then the limp mode has slowly gone away now and currently doesnt do it anymore.
- Replaced Spark Plugs - were worn! Coils were replaced with Bosch ones previously.
- Transmission felt great and with my previous experience with 6HP car is guessing itself in either auto or stays in gear longer in sport. I did a drain and fill which was a gamble for this mileage but i plan to the mechtronic seals unless i go 8HP first. I installed XHP into Stage 2 and now when its cold has a flare shift from 3-4 when driving at speed. Other than that, Car is driving like a typical n54 e series car.
-I then installed the VRSF Charge Pipe and kept the Diverter Valves for now. I bought DCI's second hand and got those installed. When it came down to the High Flow Inlets I chose the 2" ones because I knew Turbos were on the horizon. The WasteGate Rattle always scared me but boost was still good. towards the end it started to smoke randomly which I will get to that later.
- I installed the High Flow Inlets, I thought I could get away without dropping the Engine slightly. I was horrible wrong. I dropped the subframe, suspended the Engine and still played with it until I had it fitted. I had to loosen the Waste Gate Actuator on the Rear Turbo to put the Hose Clamp in a good Place if for some reason I had to retighten it. Front is a breeze in comparison to the Rear.
- I installed MHD and have it at Stage 2. All that was missing was the Intercooler which I do not have an upgraded one just yet. I might install before summer starts this year.
- Did an Oil Change and used Motul 5w40. Car seems to like it. Car semi went through oil but thats probably related to the Turbos.
- It was time to do the Turbos. I dont do well working upside down or facing up so this took alot longer than anticipated. I did it in 2/3 hour parts after my 8-5. I finished the Turbos with new Turbo Coolant Lines, reused the Oil lines, I cleaned them and found no gunk. If I had to replace them they appeared to be easier than the Coolant Lines in my opinion except for where it meets in the middle. I then installed the VRSF High Flow Inlet. That was a pain in the way. I did a horrible job putting the silicone coupler in the middle for the Outlet and I assume thats where i have the current boost leak. Currently now when i go into boost at 4k I hear a whoopee cushion. I have to do the boost test which I have but have to allocate time for it.
- I then installed a new Charge Pipe that allows for the Turbosmart BOV. I like the noise which I dont really care for. Seemed to help but still have the noise. How things are looking I'll probably have a new Intercooler by the time I do the Boost Test.
- My exhaust issue I have. The car was still muted with the Catless downpipes and a little volume was nice but just like Evan, I went through a few configurations.
1. Catless downpipes and Vibrant 1095. - 3inch inlet with dual outlet with tips - drone is horrible. esp at cruising highway speeds
2. Added Bottle Resonators 1790 after the downpipes and initial thought it worked - in city was better, highway speed, about the same.
3.) Just like Evans E61 - 3inch Exhaust with 1142 Resonator, 200 Cell highflow Cat on Ebay, 3inch Flexpipe for suppport, used the same muffler - has improved but still have that note on highway speed. One thing I noticed, it doesnt really have the high pitch top end noise, more muffled noise. Im really looking into replacing the muffler with a Valvetronic 3inch. Im hoping around town it isnt loud and Im pretty sure with Valve Open, It'll be glorious. Anyone can chime in thatll be great! If there was a way to get the similar sound from the 3 series PE exhaust into this vehicle, I can sleep better at night.

 

Do you have any concerns about the transfer case getting messed up? I was under the impression the front driveshaft spins the lower gear in the transfer case which then slings the oil around in there and without it there might be no lubrication? Maybe doesn't matter, just something that came to mind. On second thought, there's probably enough friction in the clutch pack that the lower gear spins a bit anyway, even without the driveshaft.

 

Theres an actuator that engage and disengages, not worried about it. Car has high miles, not going back..

 

6 Month Check In -
Front end is apart right now, i had low compression in Cyl 6 127psi and the rest were average of 150psi. I had no misfires and check engine light and car pulled nicely. I bought a parts car and the compression on the engine is 185psi consistent and seemed alot healthier so i bit the bullet so this whole budget build is semi out the window. I pulled the turbos off and installing a 6 + 6 compressor blade with a 9 blade turbine. This just moves the power band slightly up and requires a custom tune to optimize. At the same time im putting on the RWD Front Subframe to finish off the RWD Swap. Im in the works with the 8HP Swap but might have to wait until later. Its going to have Bilstein B4 shocks in the meantime but might have Koni Adjustables with HR Sport Springs or M Sport Springs. I want to keep the plush ride. After this hopefully i can do the M Sport Front/Rear Bumper, update the interior and call it a day!