Cross-posted from the BMW thread, but thought it'd be worth a mention here!
Shocker in mattyprice4004 bought another old shed...
A couple of years ago I went on a mission to find a well-specced late E61 535d - mission failed, as most seem to be in rather middling spec with questionable history.
In the end I gave up and settled for this 530d - not quite what I was after, but having the last iteration of the M57 engine along with piezo injectors I was well aware of the tuning potential and decided to take a punt.
Generic scenic eBay photo, with bonus terrible Instagram filter applied by the seller:
It started out life as a relatively high-spec E61 and had 190,000 happy miles of pottering along completely standard - until I thought 'let's see what we can do with this' like an idiot.
First step - move the tasteless CYA plate from my old Mazda 3 MPS over to this (bought when under the influence of many beers; I'm terrible at remembering car registrations. Helps a lot when parking!)
Before picking modifications, I took it to Germany on my annual 'Ring trip - a few laps highlighted that the suspension was pretty tired all round, the brakes weren't really up to much (what a shock) and power-wise it'd be handy to have a few more horses on tap. Obligatory picture, with my rather unimpressed face:
Once home, the shopping began - and it was a heck of a list!
Cue one rather chunky turbo, an R90 fuel pump and various other bits and pieces being thrown at it - followed by lots of attempts to get the damn thing to run properly.
Lots of parts also suffered along the way - as expected several of the plastic boost hose fittings didn't get along very well with their new boosty pal, and promptly exploded.
Same with a few drivetrain components (including the gearbox itself, but we'll get to that...)
Aptly named the 'Big Grey Tw*t' the aim was to create the ultimate Swiss-army knife - a car I can take on my yearly trips to the 'Ring, lug heavy work stuff about with, use daily without having to compromise on comfort (because I'm old) and MPG (well, that didn't work out!) and most of all, appear completely standard to the outside world (everyone loves a sleeper).
She's rough as balls on the outside, but I've never been one for a pristine car.
Mods:
- Turbo Systems Stage 4 HTD3279BB (79mm compressor, 58mm turbine) running 42+psi of boost
- R90 fuel pump
- Stupidly big (and very hard to mount) intercooler
- Custom mapping (2300 bar fuel pressure, which the pump is struggling to keep up with so we'll have to change that soon)
- Full suspension refresh (went standard because the M Sport setup is pretty good IMO) with all OE parts, probably worth more than the car itself
- The usual EGR and DPF removals, because the planet is a bit knackered anyway
- Set of Spyder alloys as the 245s I had on the back just couldn't put any power down at all even with Goodyear Eagle F1 Asymmetric 6 tyres
- XHP Stage 2 gearbox map (and yes, I hate stage tuning as much as everyone else - but that's what they call it)
- Gearbox mechatronic unit fully rebuilt after it had the world's biggest mood on her maiden voyage (all seals, Sonnax ZipKit, new solenoids etc. £££)
Power-wise it ran 390bhp on the last dyno run, however I then found a pretty big exhaust leak from the V band between turbo and manifold along with 3 boost leaks. Once these had been sorted the MAF figures at full boost suggest it's now around 420-430bhp, but I really need to pop it back on the rollers to verify.
It's certainly quick enough for a lardy bus!
One of the non-negotiable aspects of this journey was that the car has to look completely standard on the outside - I've always loved a sleeper (coming from my British cars such as the Rover 620ti and MG ZT260).
Anyway, enjoy. This is what happens when you find a bit of money and combine it with a love of old, crap BMWs.
Here's where we are today. Next week it's booked in for a full detail and paint correction - it'll never be a showroom example, but I feel after the torturous journey I should at least give the outside *some* attention.
I'll post an update with the after pictures - not that I'm expecting miracles!