N57 Bimmer Performance Center N57 Tuning

[phil@BPC]

We are starting to see more and more of this resurface as more N57's are hitting the markets. Back in 2016 we had a customer out of state purchase a brand new 2016 535d at the time and had it shipped to us with less than 10 miles on the odometer. This was our BETA tester to get baseline pulls and start to see what the N57 was capable of.
We performed base line pulls and it ended up making about the same as the e90 M57 with numbers coming in at 238rwhp / 405rwtq. Dyno video below.

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Stage 1 Tune, all emissions still enabled.

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Stage 2, DPF delete with Custom made pipe and scr filter gutted. EGR is deleted in the tune.

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Stage 3, Methanol Injection Installed. We found that with the stock turbos still in place that the turbo tapers off so much boost that a progressive controller is not beneficial and therefore the gains not really able to be seen.
Stage 4, Hybrid turbo w/ meth and upgraded intercooler
The stock turbo was sent out for larger intake and exhaust wheels with proper matching of the housings and we were rewarded with a nice boost curve that was able to keep steady across the rpm band instead of tapering off. Because of the new curve the meth injection was able to help out more but more boost will still be beneficial to the N57 motor.
For max effort a new Wagner intercooler was installed and yielded another 10rwhp.

https://www.flickr.com/photos/161141813@N02/

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Stock graph vs Stage 4

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[fmorelli]

Very nice work, and thanks for sharing this with us. Unfortunately we don't see dyno pulls in each stage. We have a friend with an N57 and a dyno in-house (my guess is, countable # of those and you know who) where the interim dyno results have shown negligible gains on the Wagner (as you show as well) and interestingly enough (unlike the M57) negligible increases from doing ABC deletes. I know you don't have dyno data from above, but you probably have it from other situations and may corroborate or not?

The ABC deletes are really for reliability on the N57. My local BMW dealer, which is pretty large, says most all of the N57s they see are for emissions issues. My 40k miles 535d sport just went in for NOx code (sensor replacement) but 5-weeks later now have a seemingly rare P2002 (SCR efficiency) code which keeps coming back if I reset. I'm going to try to force a regen (I'm shooting in the dark - no idea if it will help) before I go back yet again for more emissions work under warranty. When this car goes out of CPO warranty next spring or blows out of the 80k emissions warranty, I'm afraid the only way to get reliability will be with ABC deletes. Anyone price an SCR for this motor? Cripes it's ridiculous. We've already done a $14k stem to stern fuel system replacement after catastrophic HPFP failure @24k miles.

Killer cars but like M57, emissions components seem to be the devil.

Glad to see the healthy Stage 1 tune numbers, and thanks for sharing. Very encouraging. sixty squared is certainly noticeable!

Filippo

 

[Torgus]

Killer cars but like M57, emissions components seem to be the devil.

Yup! This is my fear with my two 2011 X5 Diesels. I gotta get rid of them.

I had 2 $600 NOX sensors fail at 118k 2k miles before the emissions warranty expired. Got lucky on that one.

 

[fmorelli]

Yup! This is my fear with my two 2011 X5 Diesels. I gotta get rid of them.

I had 2 $600 NOX sensors fail at 118k 2k miles before the emissions warranty expired. Got lucky on that one.

You're not in a state we're ripping all that stuff out is a possible option?

Filippo

 

[Torgus]

You're not in a state we're ripping all that stuff out is a possible option?

Filippo

I am pretty sure I can in MA. I think it's like 3k uninstalled for all the parts x2. Not sure if I want to drop 6-7k just to make the damn things reliable.

 

[fmorelli]

https://www.facebook.com/groups/NABDOG/ ... this group rocks for your M57 ownership. I would dig in there and ask some questions, though note they have a pretty extensive primer they recommend you first read. DieselOps and AARodriguez seem to be the go-to peeps. In the case you decide to sell, it's also a good place to post for sale as people are on the hunt for them.

Filippo

 

[phil@BPC]

Oh my... what do we have here??????????

https://www.flickr.com/photos/158893229@N02/

 

[phil@BPC]

https://www.flickr.com/photos/158893229@N02/

 

[phil@BPC]

https://www.flickr.com/photos/158893229@N02/

 

[fmorelli]

This is where knowing someone with a CNC mandrel bending machine is a beautiful thing!

Filippo

 

[doublespaces]

Oh man, I did not expect to see this. Which BW turbos are those?

 

[phil@BPC]

I believe this is their SXE series

 

[phil@BPC]

https://www.flickr.com/photos/158893229@N02/

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[doublespaces]

Sexy. What is next?

 

[phil@BPC]

There are a few odds and ends to wrap up, install everything check and recheck fitment, then install everything one last time and then it should be ready for the dyno. Ill keep making posts to update everyone as things get completed

 

[fmorelli]

Beautiful work.

Filippo

 

[phil@BPC]

https://www.flickr.com/photos/158893229@N02/

 

[phil@BPC]

https://www.flickr.com/photos/158893229@N02/

 

[phil@BPC]

I've been out for two weeks for my honeymoon. I'll be working to get information and photos to catch up. Bear with me and Ill post what I can
Here are some photos to update the thread:

https://www.flickr.com/photos/158893229@N02/

 

[phil@BPC]

https://www.flickr.com/photos/158893229@N02/

VID

VID
Dyno numbers are 450rwhp and 620ft/lbs. It looks like our next hurdle will be fuel.
We found that the stock exhaust, even modded has to much back pressure so we are making fully custom 3.5in back to split 3in to dual mufflers.