Re: E39 540i exhaust and intake options

[alex.fadeev@xxxxxxxxxxx]

"Hemauer" <shemauer@domain.elided> wrote:
>
> For E39 owners out there I have some ideas as to inexpensive and
> effective intake and exhaust options for the car.
>
> After owning an E36 for a number of years I recently bought a '97
> 540i 6 spd.  As some on the list may have experienced, the aftermarket
> for the E39 seems a bit more limited and more expensive than the E36
> world.

Scott,
Have you checked with Dinan?
They are far from being my favorite performance supplier, but if there is
nothing else out there...

> After researching exhaust options (every comapny wanted big $$$ for a
> simple short pipe, muffler and two tips) I decided to go about designing
> one myself.  I sourced various mufflers and set up a time with a friend
> at a local exhaust shop.  We intended to cut off the stock muffler and
> then test fit various systems to find one I liked.  We cut off the stock
> muffler just behind the rear diff.  Decided to start up the car like this
> just to see how it sounded.  Suprisingly, it sounded great just like
this.
> We simply welded on a rear pipe section and turndown and that was it!
> The car sounds great, no highway drone at all - and all for less than
> $50-$75.

What about the outcome?
How much power/torque did you gain/loose?
Or was that not the purpose of the exercise?

> I also designed a cold air intake system for the car as well.  I used a
> K&N filter with a short section of 3 1/2" pipe and silicone hose to
> connect to the airflow sensor housing.  I then built a sheet metal heat
> shield that fits beween the K&N and the rest of the engine compartment.
> Also installed two 2 1/2" ducts from the front of the car to under the
> K&N to help route cold air.  Also left in place the stock "snorkel" that
> attached to the stock airbox. This also would help route outside air to
> the K&N.  Results were excellent.  I tested the system using some OBDII
> datalogging software.  I monitored the intake air temp sensor and
compared
> this reading to ambient temperatures.  From 20 mph on up the intake temp
> readings were only 2 to 4 degrees above ambient.  (Ambient of 62 deg).
> Temp readings at rest would slowly rise to eventually around 110 deg.

Again, any net gain/loss in HP/torque?
BTW, you do know that K&N does not filter nearly as well as stock paper,
right? Not that it stopped many from extracting that extra few horses out
of their rides (your truly included ;-)
Anyway, here is a JimC article on the subject:
http://www.bonnevillemotorwerks.com/dynocharts/intake/KN/kntest.pdf

> Just some suggestions for those looking to give their E39 a bit of a
kick!!!

Have you considered taking measurements of your shield and publishing the
diagrams, instructions, pics and all on the net?
I'm sure plenty of E39 owners beyond this forum would love to follow your
lead!

good luck,
alex f

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