Why Force Feed a 540?
The question comes up every time someone considers supercharging an E39 540i: why not just buy an M5? The answer is simple — the 6-speed manual 540i with a supercharger is a different animal than the M5. Same basic platform, significantly more power, and the satisfaction of having built it yourself. The M62TU V8 responds well to forced induction — it's a strong, over-engineered block with plenty of headroom.
ESS Tuning's VT1 kit for the E39 540i was one of the few serious options available — alongside VF Engineering and Dinan. The VT1 used a Vortech centrifugal supercharger with ESS's own ECU calibration, and the result on the M62TU was a reliable, street-driveable power increase that transformed the character of the car without sacrificing everyday usability.
The Engine-Out Decision
Once the decision was made to supercharge, the logical follow-on was: if the engine is coming out anyway for headers and clutch work, this is the time to address the engine bay. A proper detail only goes so far — pulling the engine gives you access to everything behind it, and a freshly painted bay sets the standard for everything that goes back in. The engine came out. The bay was cleaned, prepped, and re-sprayed in Titanium Silver Metallic — matching the exterior. A freshly painted bay raises the standard for everything that goes back in. Then the SuperSprint headers and full exhaust, new clutch, Zionsville aluminum radiator, and ESS VT1 supercharger kit went in together.
Supporting Modifications
A supercharger on a 6-speed car without a clutch upgrade is a recipe for frustration. The new clutch was part of the plan from the start. The SuperSprint headers and full exhaust replaced the stock manifolds and cat-back — the M62TU responds to header work, and with forced induction coming, getting the exhaust side right was essential. The Zionsville aluminum radiator replaced the stock plastic-tank unit — a sensible precaution on a forced induction build and a meaningful upgrade in cooling capacity. The ESS kit then added the supercharger, revised intake, and supporting hardware with an ECU tune to match.
The full build thread is documented on Bimmerfest. This page summarises the project and the results.
A 6-speed 540i with supercharger, headers, new clutch, and a freshly painted engine bay. The full build thread is at Bimmerfest. The car was sold in 2019 to a BMW enthusiast — hopefully still making boost somewhere.