1980 BMW M535i

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Here is a note from Peter about his car:

Hi BMW fans,

here is a discription of how I rebuilt and tuned my engine. This engine I made for everyday driving and not for maximum horsepower. I hope that my translation is understandable for everyone. If not - then please correct me.

1980 BMW M535i

Powertrain and turbo system

  • block from 745 turbo: bore 93,6 mm, bore has exactly 90° to the crankshaft line
  • rods are lighter, polished and balanced
  • crankshaft with 88,0mm stroke and balanced
  • pistontop tripple forged in a 120° angle
  • pistontop changed according to my idea (compaction ratio 8,2:1)
  • pistons and rods are balanced with a weight difference of 0,5grams from the first to the sixth piston
  • reduction bush in the oilchannel leading to the cylinderhead for more oilpressure in the block.
  • Fly-wheel made lighter and balanced
  • special rodbearing and crankbearing
  • clutch sintered metal (my clutch had the contact pressure and friction worth from the E39/M5 and this was too weak)
  • smaller gearwheel on the oil-pump
  • cylinderhead from a newer M30 engine because it has bigger channels
  • channels made bigger (like a venturipipe from the inlet manifold to the valveseat) and polished
  • valve seats mill bigger
  • bigger valves: intake 49mm, exhaust 39mm and polished
  • butterfly valve system M5/M88 and a selfmade adapterplate for the 2-valve head
  • cylinderhead on the exhaust side changed for the exhaust manifold system from 745 turbo
  • stronger valve springs fitted according to the camshaft
  • steel camshaft 285° asymmetrical
  • rockets from 745 turbo
  • special cylinder head gasket
  • turbocharger KK 27 with primary and secundary fans for more air volume
  • maximum air pressure 1,0 bar
  • bypass valve changed for regulation (regulation system from Alpina B7 turbo/E28)
  • radiator with a high capacity net and changed water boxes
  • original visco fan swoped with an electrical fan from the 750i
  • water pump with better ballbearings and another paddel wheel (one paddel more)
  • V-belt disc on the waterpump selfmade (diameter 122 mm/aluminum)
  • injection nozzle with copper core (for a faster response time)
  • fuel pressure 3,8 bar
  • thermostat case changed
  • gearbox: ballbearing seats milled bigger for bigger ballbearings, 5th gear ratio 0,81
  • diff: oilcooling selfmade, LSD 75%, ratio 2,93 (selfmade)
  • trigger box programme changed
  • combustion chambers milled hemisphericaly

Wheels / Tires

  • three piece BBS wheels: front 16x9 ET8 and 225/50, rear 16x10 ET11 and 245/45
  • Tires: Pirelli Zero Assimetrico

Suspension

  • dampers: Koni special with stronger bottom valves (adjustable) and shorter pisten rods
  • springs: H&R, pressed ca. 15mm and hardened (center of gravity deeper)
  • adjustable sway bars

Brakes

  • brake discs in the size from the B7/turbo
  • brake servo system from E28/M5