RS500 Intercooler on 535d BMW
20-08-2009, 11:50 AM
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RS500 Intercooler on 535d BMW
Hi, I used to be on here ages ago but forgot my login
Anyway wondered if anyone can help. i just fitted an AirFlow 70mm core RS500 intercooler into my 535d bmw and now I am getting overheating problems ( well I think I am, I never checked wath the temps were before I installed it
). My coolant temp is higher than i like. Highest I have seen is 101 deg C that was after a good thrashing out of slow corners and a few high speed straights.
I had this setup on my 4x4 cossie years ago with no overheating issues, granted the cooler was only 40 or 50mm thick cant remember now. Has anyone else had problem with the thicker cores?
My car is remapped and running just over 2 bar of boost.
Not sure how to post a pic on here? the cooler has covered around 90% of the radiator.
any help appreciated
Anyway wondered if anyone can help. i just fitted an AirFlow 70mm core RS500 intercooler into my 535d bmw and now I am getting overheating problems ( well I think I am, I never checked wath the temps were before I installed it
). My coolant temp is higher than i like. Highest I have seen is 101 deg C that was after a good thrashing out of slow corners and a few high speed straights.I had this setup on my 4x4 cossie years ago with no overheating issues, granted the cooler was only 40 or 50mm thick cant remember now. Has anyone else had problem with the thicker cores?
My car is remapped and running just over 2 bar of boost.
Not sure how to post a pic on here? the cooler has covered around 90% of the radiator.
any help appreciated
21-08-2009, 03:20 AM
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Try to get some air to the radiator, scoop from fog light opening or something. Are you sure you can't use a less extreme intercooler so it doesn't restrict the radiator flow?
To post a image use upload it to www.imageshack.us then post the link here so we can see what your working with.
To post a image use upload it to www.imageshack.us then post the link here so we can see what your working with.
21-08-2009, 03:40 AM
#4
Whats the spec of your car? ...fitting a 500-sized cooler must be overkill surely?!
You might have to look into fitting extra fans on an over ride switch if its covering so much of the radiator... thats what I had to do on my RS Turbo with my GRS Cooler fitted back in the day.
Cheers,
Grant
You might have to look into fitting extra fans on an over ride switch if its covering so much of the radiator... thats what I had to do on my RS Turbo with my GRS Cooler fitted back in the day.
Cheers,
Grant
21-08-2009, 10:11 AM
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Current Spec, Remapped to around 340-350bhp and 700nm torque with over 2 bar of boost.
To Follow, will be De-cat and remove the Diesel particulate filter, 3" stainless exhaust from turbo back.
Looks like I have solved the problem. I use 2 x 3 " hose either side of the lower fromt grill. Temps are back to normal.
I used to have a cossie where the intercooler covered 100% of the rad with no issues that is one of the reasons I did this.
Could I use a smaller intercooler? Hmmm, exit temps from the turbos is prob around 150 to 200deg c running over 2 bar of boost so my thinking was bigger is better
http://img22.imageshack.us/i/intercooler008.jpg/
http://img22.imageshack.us/i/rs500intercooler008.jpg/
To Follow, will be De-cat and remove the Diesel particulate filter, 3" stainless exhaust from turbo back.
Looks like I have solved the problem. I use 2 x 3 " hose either side of the lower fromt grill. Temps are back to normal.
I used to have a cossie where the intercooler covered 100% of the rad with no issues that is one of the reasons I did this.
Could I use a smaller intercooler? Hmmm, exit temps from the turbos is prob around 150 to 200deg c running over 2 bar of boost so my thinking was bigger is better
http://img22.imageshack.us/i/intercooler008.jpg/
http://img22.imageshack.us/i/rs500intercooler008.jpg/
21-08-2009, 11:09 AM
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remove the DPF? It will smoke like a Biatch mate.
Good luck and look forward to seeing the results.. You do realise your ALREADY at the torque limits of the 'Box
Good luck and look forward to seeing the results.. You do realise your ALREADY at the torque limits of the 'Box
21-08-2009, 11:30 AM
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Mine is not the LCI so I am way above the limits now
If / when it breaks I intend getting it uprated.
It will only smoke if the mapper cant do his job right.
If / when it breaks I intend getting it uprated.It will only smoke if the mapper cant do his job right.
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21-08-2009, 11:54 AM
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WHo has done your map?
21-08-2009, 12:46 PM
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..BS Motorsport..
21-08-2009, 12:55 PM
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Evolve remap,
Yes I cut the old plastic bits that were there already so it forces all the air through the rad.
It does look pretty agressive
Tried it again today as it is really hot up here now. Thrashing around small tight fast bends right down to 20mph upto around 80mph there is 7 of them in a row I saw the temp upto 100 deg c, then onto a long straight from about 10mph upto 120mph temp dropped to 94 deg c. So it still looks like a flow issue.
Some of the top fins that slow the air ( not the core ) are away to get the dunt
Yes I cut the old plastic bits that were there already so it forces all the air through the rad.
It does look pretty agressive
Tried it again today as it is really hot up here now. Thrashing around small tight fast bends right down to 20mph upto around 80mph there is 7 of them in a row I saw the temp upto 100 deg c, then onto a long straight from about 10mph upto 120mph temp dropped to 94 deg c. So it still looks like a flow issue.
Some of the top fins that slow the air ( not the core ) are away to get the dunt
21-08-2009, 01:07 PM
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Evolve remap,
Yes I cut the old plastic bits that were there already so it forces all the air through the rad.
It does look pretty agressive
Tried it again today as it is really hot up here now. Thrashing around small tight fast bends right down to 20mph upto around 80mph there is 7 of them in a row I saw the temp upto 100 deg c, then onto a long straight from about 10mph upto 120mph temp dropped to 94 deg c. So it still looks like a flow issue.
Some of the top fins that slow the air ( not the core ) are away to get the dunt
Yes I cut the old plastic bits that were there already so it forces all the air through the rad.
It does look pretty agressive
Tried it again today as it is really hot up here now. Thrashing around small tight fast bends right down to 20mph upto around 80mph there is 7 of them in a row I saw the temp upto 100 deg c, then onto a long straight from about 10mph upto 120mph temp dropped to 94 deg c. So it still looks like a flow issue.
Some of the top fins that slow the air ( not the core ) are away to get the dunt
21-08-2009, 01:24 PM
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Evolve remap,
Yes I cut the old plastic bits that were there already so it forces all the air through the rad.
It does look pretty agressive
Tried it again today as it is really hot up here now. Thrashing around small tight fast bends right down to 20mph upto around 80mph there is 7 of them in a row I saw the temp upto 100 deg c, then onto a long straight from about 10mph upto 120mph temp dropped to 94 deg c. So it still looks like a flow issue.
Some of the top fins that slow the air ( not the core ) are away to get the dunt
Yes I cut the old plastic bits that were there already so it forces all the air through the rad.
It does look pretty agressive
Tried it again today as it is really hot up here now. Thrashing around small tight fast bends right down to 20mph upto around 80mph there is 7 of them in a row I saw the temp upto 100 deg c, then onto a long straight from about 10mph upto 120mph temp dropped to 94 deg c. So it still looks like a flow issue.
Some of the top fins that slow the air ( not the core ) are away to get the dunt
Also were you running as high a boost level before you fitted the intercooler?
21-08-2009, 02:19 PM
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21-08-2009, 02:25 PM
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Well I didnt actually mean that mr smart arse.....although dependant on if the new intercooler was more efficient than the old one it may indeed increase it by a couple of PSI or so!!!
What I meant was had it been re-mapped to such a high boost level before he fitted the intercooler or was it done afterwards!!!
What I meant was had it been re-mapped to such a high boost level before he fitted the intercooler or was it done afterwards!!!
21-08-2009, 03:17 PM
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for temps I go into the OBC secret menu.
Yes If i was not so thick I would have done some testing before i fitted the cooler. As you say maybe this is normal for this car as it is funny no matter how hard i try i cant get coolant temp to go over 102 deg c
Boost is unchanged. Car was remapped around 10 months ago. Boost on these cars is around 1.8bar standard.
I have asked a guy with an Evolve mapped 535d to do some testing for me so hopfully he will get back to me tonight.
Yes If i was not so thick I would have done some testing before i fitted the cooler. As you say maybe this is normal for this car as it is funny no matter how hard i try i cant get coolant temp to go over 102 deg c
Boost is unchanged. Car was remapped around 10 months ago. Boost on these cars is around 1.8bar standard.
I have asked a guy with an Evolve mapped 535d to do some testing for me so hopfully he will get back to me tonight.
21-08-2009, 03:41 PM
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Tbh mate.....I really wouldnt worry about it then. 102degrees when properly caning it flat out for prolonged lengths of time is fine. Because the coolant system is pressurised it wont boil at 100deg like a kettle would for example.
What does it run at driving normally?
What does it run at driving normally?
21-08-2009, 04:27 PM
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Cruising with light throttle 84 to 86 deg c. Giving it a good thrashing on the open road it goes upto 91 to 94 deg c. It is only is i give it loads at slow speed several times that the temp goes above 100 deg c
21-08-2009, 05:48 PM
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Yeah been there done that
I was just wondering if it was common for temps to be higher with this 70mm core as there must be loads of RS500 intercoolers on here where as non on BMWland
I was just wondering if it was common for temps to be higher with this 70mm core as there must be loads of RS500 intercoolers on here where as non on BMWland
21-08-2009, 05:54 PM
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For the record, my sierra has no cooling issues with a genuine 500 cooler and standard ford rad/fans...
21-08-2009, 05:55 PM
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tbh, if it's going upto 102oc i really woudln't be overly concerned. what difference have you gained with intake temps?
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