Now before I begin let me just say that although I am somewhat mechanically inclined, I am certainly not an expert in understanding performance modifications for our E60s nor have I had much experience in this area. I'm just a regular guy who's had extreme mod fever in the last year and am really excited about this performance upgrade just so I can claim to drive alongside the 530s that are out there
What I am in the process of doing with the help of a local BMW shop Bimmersport
and the power and performance dudes over at Active Autowerke
in Miami, is to complete the conversion of the three stage intake manifold from the e60 530i to the e60 525i. This modification should allow the 525 with the N520B30 3.0L engine to achieve 50hp/40tq gains and should increase power to approximately 265hp and 225 lbft tq
. The main differences between the 530i and the 525i are Intake Manifold, Exhaust Resonator, Exhaust Muffler and ECU software. The 525i has provisions for this 3 stage manifold but does not take advantage of this hardware at all. To quote one of our members with whom I discussed this topic last year (Thanks Diamond)...
The 3 stage manifold allows the tune to be much more aggressive at the top end-for peak power which is why it makes more peak HP and higher rpms, but still maintains decent power and driveability in the low-mid range due to the fleixbility of utilizing 3 different intake pathways. If you only have 1 pathway as does the 525/528 then you have to compromise the tune to work at all rpms with that 1 intake pathway. The end result is you cant tune for as much top end power or else you will suffer a big loss down low.. So its a compromise to keep low-mid end acceptable and then put a decent amount of top end power. So its not the 3 stage intake manifold that creates power-but its what that lets you do with the tuning software that creates the power--worthwhile mod for sure
Considering the cost of the modification (although I'm not yet certain of the final total), the performance to $$$ ratio cannot be beat. It will surely be much less expensive than a supercharger install and yield far better performance results than a BMS Power Box, Sprintbooster V2, or RPI scoop. At the end of the day, I will definitely post Dyno results to substantiate the changes we are making.
Let me also say that we are certainly not reinventing the wheel here. There have been discussions in our very own forums regarding this for some time now http://forums.5series.net/topic/1059...1#entry1262524
and I have also been part of these discussions, however to the best of my knowledge non of our members have completed the mod and posted their experience or results in that regard.
In addition, the pioneers of this endeavor seem to have stemmed from our friends over at the e90 forums. e90pilot and issaBMW are members there who provided much of the initial information and detailed explanations of the components, work involved and results. Much of everything I post here in terms of the inception and details of this should be credited to them and others over at the e90 forums. Thanks guys! I'm just following in their footsteps. You can check out forums posts at e90 forums here http://www.e90post.com/forums/showthread.php?t=381371
and here http://www.e90post.com/forums/showthread.php?t=372973
So lets move on....