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The E39 M5 is an iconic performance sedan that has captured the hearts of car enthusiasts around the world. Known for its powerful V8 engine, the M5 has become a popular platform for modifications, particularly turbocharger swaps. This article delves into the process of swapping in BorgWarner turbochargers to push the power output of the E39 M5 to over 550 horsepower.
Understanding the E39 M5 Engine
The E39 M5 is equipped with the S62 engine, a 4.4-liter V8 that produces around 394 horsepower in its stock form. This engine is known for its smooth power delivery and high-revving nature. However, many enthusiasts seek to unlock even more potential through turbocharging.
Why Choose BorgWarner Turbochargers?
BorgWarner turbochargers are renowned for their reliability, efficiency, and power capabilities. They are a popular choice among tuners for several reasons:
- Performance: BorgWarner units can support high horsepower applications.
- Durability: Designed to withstand extreme conditions, making them ideal for performance builds.
- Response: Known for quick spool times, enhancing driving experience.
Preparing for the Turbocharger Swap
Before starting the turbocharger swap, proper preparation is essential. Here are the key steps to ensure a successful installation:
- Research: Understand the specifications of your chosen BorgWarner turbochargers.
- Parts List: Gather all necessary components, including manifolds, intercoolers, and piping.
- Tools: Ensure you have the right tools for the job, including wrenches, sockets, and a torque wrench.
Step-by-Step Installation Process
Step 1: Remove the Stock Components
Begin by removing the stock intake and exhaust components. This includes:
- Intake manifold
- Exhaust manifolds
- Stock air intake system
Step 2: Install the Turbo Manifolds
Next, install the turbo manifolds that will accommodate the BorgWarner turbochargers. Ensure that all bolts are torqued to the manufacturer’s specifications.
Step 3: Mount the Turbochargers
Carefully mount the BorgWarner turbochargers onto the newly installed manifolds. Make sure to use new gaskets to prevent any leaks.
Step 4: Install the Intercooler and Piping
Install the intercooler and connect the piping from the turbochargers to the intercooler. This is crucial for maintaining optimal intake temperatures.
Step 5: Set Up the Fuel System
To support the increased power, upgrade the fuel system. This may include:
- High-flow fuel injectors
- Upgraded fuel pump
- Adjustable fuel pressure regulator
Step 6: Tuning the ECU
After the hardware installation, it’s essential to tune the ECU to handle the new turbo setup. This will optimize performance and ensure reliability.
Expected Performance Gains
With the BorgWarner turbocharger swap, you can expect significant performance gains. Many enthusiasts report achieving power outputs of 550+ horsepower, transforming the E39 M5 into a formidable performance machine.
Potential Challenges
While the turbocharger swap can yield impressive results, there are potential challenges to be aware of:
- Fitment Issues: Ensure that all components fit properly without interference.
- Heat Management: Increased power can lead to higher engine temperatures; consider upgrading cooling systems.
- Reliability: Higher horsepower can stress engine components; regular maintenance is crucial.
Conclusion
The E39 M5 turbocharger swap using BorgWarner units is an exhilarating way to enhance performance. With careful planning and execution, you can transform your M5 into a powerhouse that delivers thrilling driving experiences. Always remember to prioritize safety and reliability in your modifications.