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Redline Speed Worx Presents: Saad Racing / Pro EFI Stage 3 Build

56K views 252 replies 48 participants last post by  Vert-igo 
#1 · (Edited)
Redline Speed Worx is proud to present the build thread of our shop E46 M3.

We have been in the the "european repair & performance" community for a number of years now. You may already be familiar with our work in the Audi, VW, Mercedes Benz & Porsche markets and we please invite you to visit our website (www.RedlineSpeedWorx.com), our Flickr Account, as well as our Facebook Page which we do update daily ! We pride ourselves on high end repair work, and do specialize in engine / transmission rebuilds as well as aftermarket turbocharger systems.

If you AREN'T familiar with our work take a moment to check out our "SHOP LIFE" thread here on e46fanatics ! It displays some of the work we have completed over the past few months !

We have FINALLY decided it was time to build a BIG power BMW, and what better platform than that of the E46 M3.

Our Shop M3 will be receiving a complete Saad Racing Stage 3 Turbocharger system. The entire vehicle is currently being overhauled from a complete engine rebuild, drivetrain upgrades, braking system upgrades, suspension overhaul as well as the installation of a complete Pro EFI engine management system.

The first post of this thread will outline the components currently going into the vehicle from Saad Racing as well as Pro EFI.

Precision Turbocharger 6766


Saad_E46_M3_Turbo_4 by Redline Speed Worx, on Flickr


Saad_E46_M3_Turbo_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_Turbo_2 by Redline Speed Worx, on Flickr


Silicone Hose Kit


Saad_E46_M3_Silicone_Couplers_2 by Redline Speed Worx, on Flickr


Pro EFI Engine Management System


Saad_E46_M3_PROEFI_1 by Redline Speed Worx, on Flickr


Saad_E46_M3_PROEFI_2 by Redline Speed Worx, on Flickr


Saad_E46_M3_PROEFI_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_PROEFI_4 by Redline Speed Worx, on Flickr


Saad Racing Exhaust Manifold. Currently being Ceramic Coated


Saad_E46_M3_Mainfold_1 by Redline Speed Worx, on Flickr


Saad_E46_M3_Mainfold_2 by Redline Speed Worx, on Flickr


Saad_E46_M3_Mainfold_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_Mainfold_5 by Redline Speed Worx, on Flickr


Saad_E46_M3_Mainfold_6 by Redline Speed Worx, on Flickr


Saad Racing Intake Manifold. Currently being Thermal Coated


Saad_E46_M3_Intake_Manifold_1 by Redline Speed Worx, on Flickr


Saad_E46_M3_Intake_Manifold_2 by Redline Speed Worx, on Flickr


Saad_E46_M3_Intake_Manifold_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_Intake_Manifold_5 by Redline Speed Worx, on Flickr


Saad Racing / Pro EFI Upgraded Ignition System


Saad_E46_M3_Ignition_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_Ignition_2 by Redline Speed Worx, on Flickr


Saad_E46_M3_Ignition_1 by Redline Speed Worx, on Flickr


Saad Racing Upgraded Fueling System Fully E85 Compatible.


Saad_E46_M3_Fueling_1 by Redline Speed Worx, on Flickr


Saad_E46_M3_Fueling_2 by Redline Speed Worx, on Flickr


Saad_E46_M3_Fueling_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_Fueling_4 by Redline Speed Worx, on Flickr


Saad_E46_M3_Fueling_5 by Redline Speed Worx, on Flickr


Saad_E46_M3_Fueling_6 by Redline Speed Worx, on Flickr


Saad_E46_M3_Fueling_7 by Redline Speed Worx, on Flickr


Saad Racing Front Mount Intercooler


Saad_E46_M3_FMIC_1 by Redline Speed Worx, on Flickr


Saad_E46_M3_FMIC_2 by Redline Speed Worx, on Flickr


Saad_E46_M3_FMIC_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_FMIC_Piping_1 by Redline Speed Worx, on Flickr


Saad_E46_M3_FMIC_Piping_2 by Redline Speed Worx, on Flickr


Saad_E46_M3_FMIC_Piping_3 by Redline Speed Worx, on Flickr
 
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33
#2 · (Edited)
Saad Racing 3.5" Downpipe Assembly w/ WG Recirculation


Saad_E46_M3_Downpipe_1 by Redline Speed Worx, on Flickr


Saad_E46_M3_Downpipe_2 by Redline Speed Worx, on Flickr


Saad_E46_M3_Downpipe_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_Downpipe_4 by Redline Speed Worx, on Flickr


Saad Racing Oil Res


Saad_E46_M3_Engine_Components_3 by Redline Speed Worx, on Flickr


Saad_E46_M3_Engine_Components_4 by Redline Speed Worx, on Flickr


Super High Power Neon GREEN Air Filter !


Saad_E46_M3_Air_Filter_1 by Redline Speed Worx, on Flickr


More to come, stay tuned . . . :pimpin:
 
#3 ·
This seems awesome!! Very interested in this build

I have a question. I have been a lurk trying to learn about all these turbo systems. Love HPF, am waiting to hear more info on Maximum PSI, but really am interested in the SAAD racing turbo. Charlie (M5chas)'s M3 was a monster! The only thing I cannot find is pricing on SAAD racing kits, and the stages they have with power output?

I am on the east coast so having all these shops appear in NJ is only making me want to pull the trigger faster.

Sorry if this jacked your thread a little bit, Good luck with the build!
 
#12 ·
The link you posted does include a 500 hour run-time limit in the installation notes. The exact wording is: "With E26/E85 or Diesel fuel run-time max. 500 h"

That makes me think Bosche expects that it would normally fail sooner.

Seems like the pump only makes sense for temporary uses like testing or tuning an E85 setup.

That reads like incompatible to me too. Good catch.
 
#31 ·
Thanks for the link. Nice story!

Is there an official link that Redline would publish regarding features/failsafes that the ECU provides?

First off ProEFI has built in failsafes that are imbedded into the code so they are always on. For example overboost. With the I boost you have 5 boost curves that are allowable. You can set the overboost amount and time in the software. So lets say that you have a curve that goes from 18 psi to 33 psi from 0 mph to 60 mph. Then if you ever go X amount of boost over your setpoint for Y amount of time, then overboost kicks in. X and Y being adjustable. Overboost will then engage a fuel cut/ ignition cut to save you. Now you can also setup additional thing to happen like the check engine light coming on, nitrous shutting off etc.

ProEFI of course has individual cylinder knock control that again automatically retards timing instantly in the offending cylinder but then you can set it to put on a check engine light, disable nitrous, default to base boost etc when this occurs.

Also built into the code is fuel pressure safety compensation. If the fuel pressure does not rise with boost the ecu automatically adjusts the injector pulse width to keep your a/f's perfect. Then you can setup what else happens with the fault manager like check engine light, disable nitrous, base boost, rev limiter etc.

ProEFI also has a complete OEM style fault manager. IF any sensor goes out of range it can be set to throw a check engine light, engage a revlimiter, disable nitrous, go to base boost or just about anything that you can imagine. These actions can also be set to happen only if the fault occurs, suspected, active, occurred etc. Meaning that you can set the number of times that a sensor has to go out of range to set the fault, below that it would be considered suspected, over that it would be considered occurred. If you set the manager to occurred for example to disable nitrous, then the ecu will not let nitrous activate until the fault is cleared. If you set it to active then the nitrous will only be disable if the fault is active.

You also have curves that you can set for example for oil pressure. If the oil pressure is below what you set by rpm at any point then you can set it to do up to 4 actions from invoke a hard cut, shut you completely down, turn of nitrous, base boost or simply put on a check engine light.

You can do this for pretty much any fault !!

Here is a partial list of the faults that are in the ProEFI.

Boost limit exceeded, brake/clutch pressure high/low, cam edge fault, cam sync fault, crank edge fault, crank sync fault, differential wheel speed exceeded, drive shaft speed exceeded, coolant temp high, EGT high, Electronic throttle body open fault, electronic throttle body sticking, engine over speed, ethanol content low, exhaust back pressure high.low, (1st-6th) gear accel limit exceeded, flex fuel sensor fault, air temp fault or high/low, I boost switch fault, knock sensor fault, map sensor fault, mass air meter fault, nitrous bottle pressure fault or high/low up to 4 bottles, nitrous armed, nitrous engaged, O2 failed lean/rich (two sensors), O2 target not met, oil temp high/low, oil pressure high low, oil temp sensor fault, oil pressure sensor fault, fuel pressure sensor fault, fuel pressure not rising with boost etc, radiator pressure sensor fault, radiator pressure high, batt voltage high/low, TPS sensor fault or out of range, trans temp sensor fault or high/low, trans pressure sensor fault or high/low, turbo speed sensor fault or high, vehicle speed accel limit exceeded, variable cam errors, wastegate pressure sensor high/low.


So therefore if any of these actions happens, you can have it do up to 4 things as a result!!

Also you can get the check engine light to flash codes like OEM as well and the faults are displayed on the can display too.
 
#11 · (Edited)
I was just pointing out that your wording is misleading. Nothing is fully compatible if it has a limited lifespan as stated by the manufacturer. Plenty of 044 failures on E85.

Saad has put together a great kit, but changing the pumps to fuelab or walbro 416s which are 100% E85 compatible with no time limitations would be a prudent move for cars planning on flex fuel. For the extreme cost of these kits, and pumps now designed for E85, doesnt make sense to cut that corner.
 
#18 ·
I also want to add that there is 2 parameters for the fuel pumps. rpm and boost. Both of those limits have to be met for them to turn on. The pump may only run for 3 to 10 seconds when racing and may never turn on when daily driving. As a point of reference, you can get 3500 10 second passes before the Bosch estimated failure. Understand also that Bosch is going to underestimate the longevity to stamp warranty issues.
 
#17 · (Edited)
On a side note, AMAZING kit! Can't wait to see the final build and all the POWER!! Thats a very unique kit with tons of detail! I love how the Intake plenum is made of all billet parts instead of all the shitty cast manifolds! That header looks amazing with all 6 runners merging directly in the flange! Should flow Great!
 
#25 ·
I wouldn't worry about the Bosch 044 fuel pump at all! They are by far the most proven fuel pump on the market and widely used in all applications. I used one on my previous car (daily driven/tracked) and it never once gave me a problem. I also have a lot of friends running Bosch 044's on their E85 Evo's/Supra's/WRX's/etc.. and none have had any fueling issues. A genuine Bosch 044 pump used with a proper filter and clean tank (ie not an old gas tank used with 91 octane gas and then switched to E85 without cleaning..) will last for a very very long time.
 
#28 ·
The ProEFI failsafes are exemplary. In this day and age, with the great options available, we can't imagine running a turbo high compression setup like a E46m turbo without lean protection, fuel pressure protection, etc...

It is one thing if you're running an inexpensive turbo DSM on a series 1 ems, but considering the cost of these cars, engine's, and turbo kits, having an ECU that understands boost and what the parameters should be under boost seems like such an "automatic" necessity.

This kit looks great and I wouldn't worry about those 044's, they're great pumps!
 
#50 ·
A few more pictures of product going into our build

Pauter I beam Forged Connecting Rods w/ ARP Hardware


Pauter_BMW_E46_M3_Rod_1 by Redline Speed Worx, on Flickr


Pauter_BMW_E46_M3_Rod_2 by Redline Speed Worx, on Flickr


Pauter_BMW_E46_M3_Rod_3 by Redline Speed Worx, on Flickr


Pauter_BMW_E46_M3_Rod_5 by Redline Speed Worx, on Flickr


Pauter_BMW_E46_M3_Rod_6 by Redline Speed Worx, on Flickr


Pauter_BMW_E46_M3_Rod_7 by Redline Speed Worx, on Flickr


Pauter_BMW_E46_M3_Rod_8 by Redline Speed Worx, on Flickr
 
#53 · (Edited)
I'd have to spend some time adding components/etc together to make a direct cost comparison.. but a HPF Stage 3 includes quite a few little bells n whistles like the gauges, meth kit, etc..

The best comparison would be a HPF Stage 2.5 vs a Saad Stage 3. The difference being Flex Fuel vs Meth. Saad's flex fuel setup being significantly less than HPF's meth setup. Ignoring that though and just going Stage 2.5 vs Saad Stage 3 without doing the math I think the HPF kit is still cheaper.. and more refined.. Saad builds race cars.. and he's rather good at it.. its just hard to beat the HPF Stage anything kit as far as refinement.. and thats not a knock against Saad, or anyone for that matter.. simply put JP built an incredible turbo setup for HPF and it shows in every nut, bolt and screw..

FSR is not far behind though, after spending some time with them I'm really impressed with their attention to detail.

Source: Been there, done that.. a year and a half ago.

If you're looking for wild, and lots of custom stuff.. I'd go Saad/FSR/ProEFI.
If you're looking for an off the shelf kit that just works and can be installed by just about anyone... I'd go HPF... if you start deviating from the off the shelf setup thats where the HPF kit starts to deteriorate.
 
#54 ·
Might also like to add that HPF also has a proven track record and a database of known problems. If you end up having a problem trouble shooting will more/less be a breeze compared to a more custom kit.

In my opinion all 4 vendors mentioned here build quality stuff, but like with everything in life they all have their good and their bad. It'll be up to what the customer wants in the end and how much they are willing to pay.
 
#69 ·
Perhaps the Saad Racing kit is a bit more expensive than the other available kits but it has been proven to make the most HP. Just look at the trap speeds the cars run in the 1/4 mile. They are 10+ mph than any other cars out there even the HPF orange car! Gotta pay to play guys!
 
#70 ·
Saad Racing stage 1 kit is 9999.99 But the pre rec. is as of "RIGHT NOW" you need a pro-efi which go from 2700-3600, stage 1 does not include a new intake, you can get the stage 2 the only difference is the intake manifold,i Have talked to saad and they currently are working on a DME tune working with jason at pro-efi to try and make the best DME tune.
 
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