The 160kW to 200kW upgrade option in this entry involves installing a brand-new DME.

Note: as there is zero information from the DME manufacturer/car manufacturer, if MSD81 has successfully/in full amount solved problems with register overflow (well-known issue, noticed at 320.000km and 524.000km), I suggest:

a. before installing the new DME, install the low mileage in CAS. So you will get at least 200’000+ km without register overflow problems;

b. using only the default memory field, don’t perform any “full reflash”, odometer modification or any other “solution”, offered by the chiptuners. 

Ordering of the MSD81. The new DME should be ordered by the owner of the vehicle. The dealer will ask you to show both your personal ID and the registration documents of the vehicle. In addition, you will have to indicate the reason for the DME change and sign all documents certifying that all information and data are true. 

Only the owner of the vehicle can pick up the new DME by presenting the ID.

The price of the DME (Year 2023/2024) is around EUR 1300.

This is what a new DME looks like. 

Today’s task – installation of the new DME:

After connecting the new DME, I opened ISTA to check if the new DME is recognized: 

Here, DME communicates via CAN, but there are error messages:

a. no software data or they are incorrect/inappropriate;

b. no encoding data. 

Let’s see what repair plan is offered by the dealer’s tool:

With the highest priority: the DME programming and encoding problem should be solved – this is logical.

At this moment, the most interesting part of the entry starts. 

From the factory, this current vehicle had the N53B30U0 engine with the power of 160kW installed. Later, I purchased the intake manifold with two DISA valves. In the CAS module, the Power_class was changed from 00H to 02H; the FR was changed to the appropriate (E60; 530i), to increase the power of the engine to 200 kW. CAS allowed the changes in Power_class without any problems, but there were issues with the DME Power_class change. To solve those issues, I had to strain a little – read more here

Now, the main topic – what ISTA will do in this current situation? Possible options:

a. ISTA will read the type of the engine and its Power_class from the VIN/VO databases;

b. ISTA will read the type of the engine from CAS data. 

The second option, of course, would be more pleasant. In the saves of the first option, I will have to rely on the fact that the DME Power_class is locked only when the motor hours reach over 10. Accordingly, there is no problem with changing the Power_class of the completely new DME by using NCS.

ISTA P identification menu 

Here, pay attention to the fields marked with red:

OL = most powerful, 200kW version;

ND71 = E60; 530i (200kW).

It looks like data are taken from CAS – this is good news.

Here, the Replacement procedure is initialized, and the programming and encoding of the DME will be performed. 

Also, in the initial report, we see ND71 and OL records.

Planned ZB release: 7649256. This is interesting because, for example, the last ZB batch for MSD80 was 86XXXXX.

In ISTA, the input of the injector encoding from this GUI is intended, too:

Complete programming of the DME takes around 6 minutes:

Here, are the initial and the programmed ZB of the DME:

DME programming – successful:

Here, is a repeated warning regarding the necessity to input the injector encoding: 

Data input – convenient, much faster than with ISTA D:

Data – entered:

DME Power_class control checks with NCS:

Here – NCS confirms that the engine has OL/the highest power class:

Next steps of the service procedures:

a. the engine in idle is warmed to the work temperature;

b. the flywheel is adapted;

c. the initial fuel mixture (and injector) adaptations, both in Homogeneous and Stratified charge modes, are created.

After creating the adaptations, I checked the performance of DISA with INPA: ../F6/F1/Shift+F4. 

Everything is fine – initially (above 3500 RPM), the small DISA 2 opens (right side of the menu), bar value changes to 67%; above 5000 RPM – the large DISA 1 bar also indicates 67%. Excellent!

First impressions about MSD81 read here.