Massive intercooler on 535d Toooo much heat
08-29-2009, 04:48 AM
#21
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Originally Posted by paulmc' post='984834' date='Aug 21 2009, 09:49 PM
Bearing in mind my boost is over 2 bar the exit temp of the turbos will be around 200 deg C a massive intercooler can only help.
Once I get the full exhaust and final remap I will rolling road it to see what I have.
Once I get the full exhaust and final remap I will rolling road it to see what I have.
The gearbox and exhaust is the achilles heel of our cars. The gearbox due to 800nm limit and the exhaust due to the cat/dpf that is placed very near the turbos making extreme heat with boost levels +2bars, damaging the turbos and cracking the exhaust header. Which exhaust are you looking for (cat/dpf-back system or turbo-back system)?
08-29-2009, 12:25 PM
#22
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272bhp
I will do a dyno run at some point. Here is run from same map as mine.
Exhaust will be 3" from turbo back. NO DPF or CAT.
The DPF is not close to the turbo it is in the centre section of the 272 car. On the 286 car they are both together in the down pipe.
I did rolling road it a while ago on an independent dyno and got 319.4bhp with a boost hose hanging off. I then got this new remap so 350bhp seems fair
I will do a dyno run at some point. Here is run from same map as mine.
Exhaust will be 3" from turbo back. NO DPF or CAT.
The DPF is not close to the turbo it is in the centre section of the 272 car. On the 286 car they are both together in the down pipe.
I did rolling road it a while ago on an independent dyno and got 319.4bhp with a boost hose hanging off. I then got this new remap so 350bhp seems fair
08-29-2009, 05:38 PM
#23
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Originally Posted by paulmc' post='981844' date='Aug 19 2009, 06:34 AM
In my quest to make my 535d even quicker I just finished fitting an Ford RS500 intercooler. The reuslts are amazing but now my problem is Coolant temperature. As you can see from the pic my intercooler cover 90% of the radiator as a result my coolant temps are going higher than I like.
Driving normal they are 86 -90 dec C ( normal) If i go for a good thrash, conbination of slow speed full throttle pulls and a couple of straights my temp rises to 101 dec C. I cant get it any higher than that but I feel they are just a bit high.
I used to run a cossie with the same setup and never had a n issue with temps so was hoping for the same here, but not so lucky. I think it is the 70mm deep core that is the problem. Great for cooling not so great for the radiator
Any of you guys in the hotter countries know what your coolant temps sit @ or even a fewllow 535d owner in any country just to give me an idea. Yes I should have logged them before I started but a bit late now
I am going to try and duct more air in throught the lower sides if the fron grill where I have drilled out the blanking plates see if that helps.
Any hlep appreciated
Driving normal they are 86 -90 dec C ( normal) If i go for a good thrash, conbination of slow speed full throttle pulls and a couple of straights my temp rises to 101 dec C. I cant get it any higher than that but I feel they are just a bit high.
I used to run a cossie with the same setup and never had a n issue with temps so was hoping for the same here, but not so lucky. I think it is the 70mm deep core that is the problem. Great for cooling not so great for the radiator
Any of you guys in the hotter countries know what your coolant temps sit @ or even a fewllow 535d owner in any country just to give me an idea. Yes I should have logged them before I started but a bit late now
I am going to try and duct more air in throught the lower sides if the fron grill where I have drilled out the blanking plates see if that helps.
Any hlep appreciated
08-30-2009, 12:53 PM
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Good mod and can only help.
If you do dont buy the 70mm core it is just a wee bit too big. 60mm core would be just right. I ordered the 60mm core but they sent the wrong one as it was for the same money I just kept it
If you do dont buy the 70mm core it is just a wee bit too big. 60mm core would be just right. I ordered the 60mm core but they sent the wrong one as it was for the same money I just kept it
08-30-2009, 01:54 PM
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Yes i agree the car can easy make good power with the standard intercooler. If you add the cooler you will get more BHP and Torque. No point if you are going for a safe map.
08-31-2009, 05:43 AM
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Originally Posted by paulmc' post='992537' date='Aug 29 2009, 09:25 PM
272bhp
I will do a dyno run at some point. Here is run from same map as mine.
Exhaust will be 3" from turbo back. NO DPF or CAT.
The DPF is not close to the turbo it is in the centre section of the 272 car. On the 286 car they are both together in the down pipe.
I did rolling road it a while ago on an independent dyno and got 319.4bhp with a boost hose hanging off. I then got this new remap so 350bhp seems fair
I will do a dyno run at some point. Here is run from same map as mine.
Exhaust will be 3" from turbo back. NO DPF or CAT.
The DPF is not close to the turbo it is in the centre section of the 272 car. On the 286 car they are both together in the down pipe.
I did rolling road it a while ago on an independent dyno and got 319.4bhp with a boost hose hanging off. I then got this new remap so 350bhp seems fair
I would like to hear more about your de-cat/dpf exhaust system. Any engine check light? How will you solve the pressure, egt and O2 sensors signals? Any chance to post a vid? I bet that you will see alot of black smoke in your rear.
2.1bar with the right amount of fuel is good for 350bhp. So if it has +2bar, it should be in that level.
08-31-2009, 12:28 PM
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I have not got round to the exhaust yet. I am looking at buying a OBD flasher so I can load various files from my Tuner as he is 500miles away from me. If I go down that route it may take me a while to get the cash for the exhaust.
I agree re EGT going high. I may end up just doing the CAT but only as a last resort.
I also agree re smoke but only while the turbo is spooling up. Why if the AFR is correct will it smoke. I have seen loads of highly tuned Diesel cars with no smoke. Diesel's only smoke when there is not enough air to burn all the fuel.
As for all the sensors my tuner will do that for me. From what I have read it is pretty easy when you know what you are doing. A few adjustments in the file solves the problem.
I agree re EGT going high. I may end up just doing the CAT but only as a last resort.
I also agree re smoke but only while the turbo is spooling up. Why if the AFR is correct will it smoke. I have seen loads of highly tuned Diesel cars with no smoke. Diesel's only smoke when there is not enough air to burn all the fuel.
As for all the sensors my tuner will do that for me. From what I have read it is pretty easy when you know what you are doing. A few adjustments in the file solves the problem.
08-31-2009, 01:02 PM
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My Ride: 2004 E60 530i, 2012 E70 X5 35i
Model Year: 2004
That thing is awesome!! and huge!! Too bad you can't get it in black to blend in more. but wow. crazy! 