08/09/2024
BMW 535d E60
(M57 3.0l Twin Turbo)
Here we have my own toy. I bought this as an upgraded project! Fun is an understatement, like flying an Boeing 767š¤£
This had issues with the cooling system, with it having an EGR & Cooler delete its shortened the capacity of the coolant thus allowing a little more pressure. After it popping the thermostat, coolant spilling out the coolant cap and a main coolant hose swelling like a balloon after minimal boost. I later discovered it was over pressuring enough to pop the radiator, thermostat & water pump. All in that order on the side of the road at different timesš
I spent a lot of time researching this engine, understanding its weak point and of its common issues. I done a Sniffer test (CO2 Leak test within the cooling system which would indicate a headgasket failure or split) and this came back negative!
I wasnāt convinced so I donāt it several times after with the engine at different states and still negative. I decided to deem it as headgasket. Besides going against all Iāve practiced! It was the only explanation to pressurisation within the cooling system. I also had it in my head that I can do major upgrades for more š š šØ.
I was correct to do so, headgasket was split between cylinder 3&4 with what looks like a hairline split, enough to force gases into the cooling system. Head went away for Pressure testing & Skimming, with soda blasting for prettiness. I made upgrades starting with
ā¢New Uprated Timing chain Kit
ā¢Upgraded Valve Springs
ā¢Thicker Sports Headgasket
ā¢Injector Refurb
ā¢Massive intercooler
ā¢Bigger Radiator
And thereās other ones I canāt even rememberš¤£
Finding time to complete this was difficult but we managed after almost 3 months off the road! Now Iām onto upgrading/replacing all suspension at all corners for more rigidity. Bigger turbos to come in and also a High pressure fuel pump upgrade to come also but glad to have her on the roadš
Currently running: 390BHP 730nm
Goal is: 600BHP 1000+nm
New Hybrid Turbos, bigger HP fuel Pump and we are there!!