DESCRIPTION

Page updated 5-Sep-2006
10-11 Hours fitting time, fully reversible.

VF-Engineering chose to supercharge the BMW 540 to increase throttle response and mid-to-top end power with the centrifugal Vortech supercharger. With the stock 4.4 liter motor, power and torque are already substantial. However this upgrade is for the V8 enthusiast who demands more than substantial power. The newfound power makes the 540 more powerful than a stock E39 M5 in many areas of the rpm range. As a daily driver the supercharged 540 is a mild mannered beast waiting for the throttle body to to be flung open. It is easy to slide the back out under full throttle and send the 5 series V8 to speeds way above the limit in a split second. Good brakes and self control are suggested pre-requisites.

When supercharged, the early 96-98 V8 single VANOS (variable intake) M62 engines make approx 10-15 whp less throughout the RPM range when compared to the newer 98-03 double VANOS M62TU engines but make almost identical peak power and torque. This applies to both automatic and manual transmission vehicles.

The 2003 540 6-speed Sport model test vehicle shown in the above images belongs to the head of R&D at VF-Engineering. "The blown 540 is one of my all time favorites. It just eats the freeway when I roll-on to full throttle at any speed."- NS. The supercharged 540 has the looks and refinements one expects from a high-end BMW family car but is a true autobahn terrorist to the unsuspecting eye.

Maintaining the the original BMW quality, smoothness, and reliability were the key factors in the VF design. This is where the GIAC software comes into full play. VF have harnessed reliability of Vortech superchargers and quality of GIAC custom software with their 10 years of supercharging experience and worldwide OEM supply contacts to create the ultimate supercharger system for the ultimate drivers car.

All key components are 100% made in California. This system has been fully road tested and dyno tuned on both the GIAC Mustang MD500AWD and in-house Dynojet 224XLC dynamometers with and without engine load. All stage 1 kits are setup at 6 psi and create as much, if not more power than similar products running greater levels of boost.

VF engineers spent over 12 months software testing the BMW Bosch and Siemens ECUs. Software flash technology and latest BMW file versions have all been employed to provide the cleanest and the most reliable method of software installation. GIAC engineers extensively re-wrote the ECU software using their own binary, assembly and disassembly algorithms written from scratch. Testing the software included extensive road and dyno test cycles, with acceleration and deceleration tests for driveability smoothness and ECU fuel management. All test cars were put through long term full throttle testing in conditions varying from wet cold climates to hot dry Arizona desert temperature for safe-optimal air fuel ratios and knock activity monitoring. Competently-written ECU software has allowed VF to fully explore the potential of the BMW engine, making over 40% more power in most applications.

VF chose to mount the Vortech supercharger with an in-house CNC machined aluminum bracket system. The unit is positioned in line with a bolt-on crank pulley with an additional active OEM tensioner using a dedicated serpentine belt. The key to reliable superchargers sytems is the the active belt tensioner which eliminates belt slip. The supercharger air ducts are custom molded in-house from plastic to give an OEM appearance, quality and fit. The incorporated Bosch boost overrun system is designed for smooth off-throttle cruising and deceleration with clean emissions. The crankcase ventilation system is designed to cope with positive pressure and high flow OEM injectors are supplied to fit as direct replacements without modification to the injector rail.  A removable plastic air box is provided with the K&N induction filter for those who use their vehicles in persistently wet climates.The VF supercharger system remains fully OBD2 compliant and is supported by a 3 year unlimited mileage warranty on the product only. Installation can be performed in approximately 8 hours and is non-intrusive, allowing it to be fully reversible.

The VF Stage 2 development vehicle is aftercooled by integrating a chargecooler into a cast aluminum intake manifold included with the kit to replace the original manifold. This design approach reduces the length of pipework by about 75% required for a remote mounted chargecooler core or air/air intercooler. The simple and compact design make this kit integrate neatly into the V8's engine bay.

Every aspect of this kit has been fully engineered for high quality fitment and highly demanding performance and expectation. VF's in-house horizontal, turning and milling CNC's and plastic molding plant, GIAC's industry reputation and track record, and Vortech's reliability have been fully exploited to create a product with internationally un-rivaled material technology, quality, and performance.    

Not all vehicles respond identically to engine modifications which is why it is important to consider the "delta", or relative power increase, measured on the same dyno before and after modification. Power gains shown by VF have been found to be accurate on test vehicles on 91 octane at sea level, with stock setups (i.e. throttle body, exhaust system, etc.). The GIAC software adapts just as the OEM software and a slight increase in performance may be expected from the use of higher quality fuels such as 93 octane. Power gains may vary according to factors such as altitude or vehicle condition.