Single Turbo E61 Build

ThatSTe61

New Member
Jan 10, 2019
5
Iowa
Alright I’m hopping back into the forum life, something which I haven’t been a part of since I used to ride motorcycles.

Recently took the plunge and picked up a car I’ve wanted for a long while now. I’ve wanted an E61535xi ever since I ran across several build logs years and years ago.

Well here is my own 2008 535xi with 130xxx miles, that came with its fair share of problems (mostly stemming from improper maintenance). So I’ve decided to refresh the poor thing and give it new life.

First up on the docket was to get all the misfires, codes, and 100k maintenance done. No problem. Water pump, thermostat, VCG, OFHG, Low/High PCV cans, precision raceworks coils, n52 spark plugs, VRSF charge pipe w/tial BOV, and walnut blast.

This initial work was tackled all in one weekend courtesy of an extra set of hands donated by my younger brother.

Along with the initial fixes I decided to go ahead and do a full manual swap while retaining the AWD system since my auto trans is on its way out in inglorious fashion. I have all the components needed Including a beautiful RTD lockout shifter coming my way soon. I settled on a GS653BZ transmission since I couldn’t find a reasonable GSX653DZ transmission that was supposedly the original that came in the manuals. I’ve come to the conclusion that they’re interchangeable and have set those worries aside. Only thing is figuring out the wiring, I’ve read and read and heard from people that it’s not awful...but whatever, any wiring is awful in my opinion lol.

As I am currently a dental student I don’t have much free time on my hands so the trans swap will be coming in March on my spring break, and it will be fully documented. I have been very graciously allowed lift time by a local BMW shop over the course of two weekends to get my setup sorted.

Now bear with me as I figure out the photo situation here and I’ll have photos and documentation to go along with my ramblings.

As the title suggest I am also preparing the wagon for a full single turbo setup, something which not very many (if any at all) have ventured in. As motivation I picked up a Garrett GTX3582R from real st for an amazing price as the heart of my system. The turbo setup will slowly be pieced together over the next year as my pocketbook allows.

This wagon is and will be my daily driver and I will be doing the build in two steps. Initial pump gas setup to try and make 450-500whp and work out all the system kinks, and then a full e50 port injection setup that will try and hit my final power goals of around 650-750whp.

Stick around, I’ll be trying to update this when I can and when I have time to do a little wrenching on “Das Boot.” Input is greatly welcomed. Cheers!
 

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Torgus

Lieutenant
Nov 6, 2016
816
Boston
Are you planning a top mount or bottom single turbo? It should be possible to fit a top mount. Someone mocked up my ACF manifold and there was lots of room iirc. I Don't have the pictures anymore...

@islandroad
 

ThatSTe61

New Member
Jan 10, 2019
5
Iowa
Are you planning a top mount or bottom single turbo? It should be possible to fit a top mount. Someone mocked up my ACF manifold and there was lots of room iirc. I Don't have the pictures anymore...

@islandroad
I’m going too mount for sure. That’s actually great to know, I was looking at an ACF manifold, and the On 3 manifold, I was between the two because of the tight confines on the 5 series chassis.

Currently leaning towards the On 3 kit, since the turbo is a 1.06 AR open T4. But ideally I’d swap the turbine housing down to a .83 AR with a divided T4 for the ACF manifold. I’ve got time to decide since there are pros and cons of each option.
 

Torgus

Lieutenant
Nov 6, 2016
816
Boston
Island road can post the pics up if he still has them and you can see the clearance. I vote ACF but I am biased.
 

ThatSTe61

New Member
Jan 10, 2019
5
Iowa
ah gotcha! I’d love to see that though. I’ll be sure to list my turbo component parts as I pick them up. For now I’m mostly worrying about my manual swap happening in March.
 

AKN54135i

New Member
Aug 18, 2018
5
Alaska
Awesome build plan Mate! I'll be curious to see if the GS653BZ works or not. i've been slowly piecing together awd stuff for my 135i and finding a reasonable GSX653DZ has also been a struggle and really the last piece of the puzzle for me.
 

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