The M57....BMW's best kept secret

[fmorelli]

The M57 cars are great, though there are not too many of them ... especially if enthusiasts start to figure out that they are the perfect itch to scratch between Daily Driver x Powerstroke Substitute x Crazy Mileage x BMW Handling.

The newer N57 powerplant is amazing. Just now they are coming out with ECU tuning where one can do it remotely (right now it has been a "send in your ECU" deal ... which sucks for several reasons). There are a handful of people playing with the N57. As usual (and contrary to what a lot of people don't seem to understand in the N5x market) is that most of the development happens when the cars get affordable (and often out of production). The $70k buyer market is not the hop-up market. Anyway the N57 cars (535d and X5 35d) were pretty expensive (X5 being around $80k loaded) ... not many 5ers were sold. The motor was never put in a US 3 series. But I am looking forward to seeing what's possible.

Here's an example with nothing but DPF/SCR delete and a tune on an N57 535d. And remember a car like this will still pull well north of 30mpg. (this graph cribbed from a recent Facebook post for the North America BMW Diesel Owners).

There are folks now (like DUDMD Tuning) that are doing N57s with FMIC, charge pipes, intakes, all deletes, etc ... and doing dyno pulls and posting along the way. That motor is a velvet sledgehammer.

Filippo

 

[Itsbrokeagain]

I wasn't aware the N57 was in the 535d. Was considering an F10 for a daily driver at some point.

 

[fmorelli]

You'll be disappointed with how it handles. Based on will Turner's advice I installed AC Schnitzer Springs and H&R sway bars. That fix the handling, at least for daily driving chores. The 8-speed transmission is excellent. The first automatic I've owned, tow vehicles aside.

Filippo

 

[Itsbrokeagain]

For me it would be a daily driver, so those mods may be on the list.

But for now it's working on getting the M57 to play nice in the E39.

 

[ccbsecu]

One of the advantages the N57 535d, is the ability to compensate for the extra weight - it's AWD.

I'd LOVE a M57 335d xDrive

 

[ccbsecu]

So.....big things are happening for the M57 and my build. Until now - only a hybrid option using the oem turbos have been possible. This is an EFR low pressure turbo that’ll be used on a new setup. We will still use the HP oem hybrid to feed the LP turbo. In addition - custom cams, built head, forged internals are part of the build to support the higher power output.

 

[doublespaces]

I just realized, I have no idea how this engine works.

 

[ccbsecu]

@doublespaces - sequential turbo I'll find a stock pic of the OEM turbo set up and post it here.

Smaller (HP) turbo works until the larger turbo (LP) spools and takes over via a change over valve. Really clever actually. We are doing a new cast manifold to support the larger (LP) turbo while still utilizing the change over valve. FWIW - the smaller turbo (HP) makes over 500 wtq before the LP takes over.

With the new set-up - and supporting mods - the engine should be good for 650ish whp and 775-800 wtq, while still getting 40 mpg...

 

[doublespaces]

Nice, so kinda like the 2JZ setup

 

[Itsbrokeagain]

Nice, so kinda like the 2JZ setup

Ehhhhh kinda. A 2JZ has a change over to spool the second turbo, but it's a separate unit on it's own. BMWs setup is what they call compounding, quite common in the diesel scene. The exhaust from the small turbo is routed into the larger turbo to spool it, and the air intake comes in through the larger unit, which is then fed into the smaller compressor before heading off to the intercooler.

Toyotas setup has two separate turbos, one just comes on later in the power band.

 

[98mkiv]

^what he said

....the 2JZ uses a valve and two identical turbos. Basically all the exhaust is diverted through the front turbo until the valve is opened. The Valve is on the exhaust outlet of the 2nd turbo, so when that valve is closed, there is no flow thru that turbo, once it is opened the exhaust flow is shared equally between the turbos. A reed valve sits between the second turbo coldside output so it doesn't spin in reverse - the reed valve prevents the first turbo coldside outlet just venting thru the first (since they Y together).

@ccbsecu - your build is awesome. Actually you've inspired me to (maybe) keep my D. It's a super fun car, but my car is plagued with irritating CEL's, all related to the tight emissions controls.

I'm in California so that might mean I can't do any of this, but there is nothing I'd love to do more than tear off all the emissions controls, strip the whole thing down to the meaningful bits, upgrade the turbos/IC and have fun. I don't see myself going into the motor internals, but could definitely be down with EGR/DPF/SF/etc Delete and bigger turbos.

Aside from my concern about registering it in Cali (how would I pass emissions?) the other thing is the tuning - this ECU is a nightmare. I'm from the 2JZ world and am very familiar with AEM and tuning in general, but I've never once been able to get into this ECU.

I've got questions! lol

 

[ccbsecu]

@98mkiv - deleting in Cali is tough....unless you know a guy, who knows a guy...

@Whitbread is working to develop the manifold and this will open a whole new aspect for these motors. A set of custom profile cams have finally been installed and the results are very positive. ARP studs finally exist....

Tuning options are basically 4 known and validated tuners. On the west coast - DUDMD is the closest to you geographically, but others tune remotely via OBII (JR, Malone, etc).

I hope you decide to keep the car - and can delete the junk causing those CEL’s. It’s really a great platform - and it’s getting better. Check out the North American BMW Diesel Page.

 

[98mkiv]

@ccbsecu - could you update the thread - maybe the first post to add a complete build list with sources? That would be super helpful.

 

[135boost]

i must agree this about 535D n57 engine, it`s amazing engine and that 3 turbo M550d is even better one
hfpf of that 535D powerplant is supporting hp (engine) levels of some 380hp /800nm before it
outran of juice. it`s only 2 piston version 70 or 75cc.

M variant has it`s pump to 92cc so that support fuel quantities up 450hp levels but to swap 2 pistons to 3 require
fuel line mods too... injectors is supporting more before spay time is oven smoke limits,
if i remember right, we tuned wifes 535 to maximize 2000bar and 11 crank degree
time at max speed ans smoke / effiency loss is running away on 14-15 degree.

M variant uses higher pressures too so maybe 480 is possible with it.

 

[135boost]

on turbo sides, those 535D turbos (2012 535 xdrive) is running out of steam on levels 420hp, there is a guy swapped that
m series fuel pump to a 535 to maximize output but if i remember right, he got 411 or 417 hp.

this is why my wife is running only 380hp/800 nm variant

 

[vegasboy]

So you inspired me to go test drive a 2015 535d M sport today. I was very disappointed with the feel of this car. It just feels so disconnected from the road. Maybe a 335d would be a better. The 535d made me feel like I was driving a big marshmallow floating down the road. I couldn’t believe how quite the Diesel engine was though. My wife’s 328i felt like a race car after the test drive in comparison. I was very disappointed with the 535d.

 

[ccbsecu]

So you inspired me to go test drive a 2015 535d M sport today. I was very disappointed with the feel of this car. It just feels so disconnected from the road. Maybe a 335d would be a better. The 535d made me feel like I was driving a big marshmallow floating down the road. I couldn’t believe how quite the Diesel engine was though. My wife’s 328i felt like a race car after the test drive in comparison. I was very disappointed with the 535d.

Yea - the 335d is much better drivers car...can’t say any 5 series (M excluded) would be a choice if you’re looking for that type of drivers feedback.

 

[ccbsecu]

So....things are progressing

 

[Itsbrokeagain]

So you inspired me to go test drive a 2015 535d M sport today. I was very disappointed with the feel of this car. It just feels so disconnected from the road. Maybe a 335d would be a better. The 535d made me feel like I was driving a big marshmallow floating down the road. I couldn’t believe how quite the Diesel engine was though. My wife’s 328i felt like a race car after the test drive in comparison. I was very disappointed with the 535d.

Nothing some suspension bits cant fix

Id throw a set of coilovers on it, keep it near stock ride height and enjoy.

 

[ccbsecu]

Nothing some suspension bits cant fix

Id throw a set of coilovers on it, keep it near stock ride height and enjoy.

Tune, DPF delete, Coilovers, Control arms, LSD....I know a guy who can convert the diff on the low low...He is a vendor in here.

Did you drive a 535xd or just 535d?