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Forced Induction Forum Sponsored by Active Autowerke
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Old 07-27-2014, 06:38 PM   #1
GeorgeGG
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E46 330ci Turbo Project

I would like to introduce our new Ongoing project 2005 E46 330ci Turbo
car is built and ECU tuned by us in house, it is running factory MS45 ecu so far at 8psi only.
we spent more than 50 hours working on ECU only.

car is equipped with
Garrett T3/T4 60 Trim turbo
Cast manifold
3" downpipe and Megan racing E46 M3 free flow exhaust
Cometic head gasket 1.7mm
raceware head studs.
stock motor with 141000km on clocks
2.5 / 3" intercooler piping
FMIC
draw through stock MAF
42lb injectors
44mm wastegate
AEM boost and AFR gauges
AEM Water meth injection (for future high boost)
E36 M3 LSD
SPEC Stage 4 clutch kit for 6spd

car is street tuned and First dyno test showed 353WHP (Dyno Dynamics)
there were some minor improvements and fine tuning needed but mainly result was higher than we expected.

car is really nice to drive daily, has very nice sound while cruising and screams crazy under boost (i really love it)

please enjoy some pics and video





















Last edited by GeorgeGG; 07-27-2014 at 06:42 PM.
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Old 07-27-2014, 10:04 PM   #2
Rob43
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It looks like you've done a very nice job on your turbo project, very impressive work. I would like to know why you blocked out your AFR numbers while on the dyno ?



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Nitrous is a little trickier than boost, but it's not the spray that kills motors, it's STUPIDITY!!
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Old 07-27-2014, 10:26 PM   #3
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Nice!!!
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Old 07-27-2014, 10:35 PM   #4
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where did you g to buy the head studs?
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Old 07-28-2014, 12:32 AM   #5
GeorgeGG
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Rob43
when there is AFR shown in video, people realise that they are smart and can talk ****. so no AFR no ****.

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got them from VAC Motorsport
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Old 07-28-2014, 12:45 AM   #6
cosmos328Ci
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Quote:
Originally Posted by GeorgeGG View Post
I would like to introduce our new Ongoing project 2005 E46 330ci Turbo
car is built and ECU tuned by us in house, it is running factory MS45 ecu so far at 8psi only.
we spent more than 50 hours working on ECU only.

car is equipped with
Garrett T3/T4 60 Trim turbo
Cast manifold
3" downpipe and Megan racing E46 M3 free flow exhaust
Cometic head gasket 1.7mm
raceware head studs.
stock motor with 141000km on clocks
2.5 / 3" intercooler piping
FMIC
draw through stock MAF
42lb injectors
44mm wastegate
AEM boost and AFR gauges
AEM Water meth injection (for future high boost)
E36 M3 LSD
SPEC Stage 4 clutch kit for 6spd

car is street tuned and First dyno test showed 353WHP (Dyno Dynamics)
there were some minor improvements and fine tuning needed but mainly result was higher than we expected.

car is really nice to drive daily, has very nice sound while cruising and screams crazy under boost (i really love it)

please enjoy some pics and video
GeorgeGG

Hi GeorgeGG,

As always, I love what you are doing and am always fascinated by your work.
Was your last run with Meth?
What type of fuel were you using? and,
What was your WOT AFR? LOL, it is ok if you do not answer this.

Thanks again GeorgeGG, for sharing your work/hobby with us.



Quote:
Originally Posted by Rob43 View Post
It looks like you've done a very nice job on your turbo project, very impressive work. I would like to know why you blocked out your AFR numbers while on the dyno ?

Rob43

LOL, it would be very interesting to say the least.
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Old 07-28-2014, 06:32 AM   #7
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Quote:
Originally Posted by cosmos328Ci View Post
Hi GeorgeGG,

As always, I love what you are doing and am always fascinated by your work.
Was your last run with Meth?
What type of fuel were you using? and,
What was your WOT AFR? LOL, it is ok if you do not answer this.

Thanks again GeorgeGG, for sharing your work/hobby with us.






LOL, it would be very interesting to say the least.
all runs were done without meth. we installed meth injection to run it on high boost.

fuel is 98RON Octane (US 93/94 i think)

WOT AFR is in 11 range

my pleasure
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Old 07-28-2014, 06:32 AM   #8
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All I know is that makes a decent amount power more then my car at 8.5 psi; I'm guessing it is a bit aggressive in the tune. That being said, it looks very well put together, and very quick. Nice job.

Edit: Also, 7000 RPMs vs 6500 makes a difference.
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93 Octane - 8.5 PSI : 309RWHP on a Superflow / 3XXRWHP on a DynoJet
E85 - ? PSI : ???RWHP on a DynoJet
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Last edited by mdrobnak; 07-28-2014 at 06:38 AM. Reason: Forgot about redline
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Old 07-28-2014, 09:08 AM   #9
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Loving it! More non M turbo cars!
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Old 07-28-2014, 05:03 PM   #10
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Quote:
Originally Posted by GeorgeGG View Post
all runs were done without meth. we installed meth injection to run it on high boost.

fuel is 98RON Octane (US 93/94 i think)

WOT AFR is in 11 range

my pleasure
Thanks George,
You are an absolute testament, the dedication and time put in to this stock internal M54B30 for the out put it has.

The reason i asked was I am looking at retuning my Haltech PS2000 a bit more aggressively.

Cheers
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Old 07-28-2014, 05:22 PM   #11
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This is DAMN awesome. Love seeing people going out of the box and turboing there non M. Any change to be able to tune US based cars. We only have one option here in the states for a turbo non m
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Old 07-28-2014, 05:23 PM   #12
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This is DAMN awesome. Love seeing people going out of the box and turboing there non M. Any change to be able to tune US based cars. We only have one option here in the states for a turbo non m
At least it's not a bad option. Just not an inexpensive one. But that can be said for the platform as a whole.
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93 Octane - 8.5 PSI : 309RWHP on a Superflow / 3XXRWHP on a DynoJet
E85 - ? PSI : ???RWHP on a DynoJet
First SSG MoTeC M150 Powered 330
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Old 07-28-2014, 05:27 PM   #13
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Me and my fab guy / tuner talked about a Turbo kit for my e46. We run into problems with tuning. I wish more than just TT here in the states cracked the stock DME for it.
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Old 07-28-2014, 05:48 PM   #14
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Quote:
Originally Posted by cosmos328Ci View Post
Thanks George,
You are an absolute testament, the dedication and time put in to this stock internal M54B30 for the out put it has.

The reason i asked was I am looking at retuning my Haltech PS2000 a bit more aggressively.

Cheers
what power does your car make? and what setup do u run on what fuel?

Last edited by GeorgeGG; 07-29-2014 at 12:44 AM.
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Old 07-28-2014, 09:36 PM   #15
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Set up

Quote:
Originally Posted by GeorgeGG View Post
what power does your car make? and what setup do u run on what fuel?
Hi GeorgeGG,

M54B30:
357 rwhp on a DynoDynamics - Shootout Mode.
450 Ft/lb

ESS Twinscrew with 16 psi pulley - Haltech ECU shows around 18psi and dyno shows around 16 psi - LOL.
ECU: Haltech PS2000
Injectors: 1000cc
Fuel: E85
Compression: Standard
Engine: standard
Headers: M52TU (standard)
Exhaust: 2.5'' single, 100 cpsi cat and 1 muffler (no name)

AFR: 11.8:1 WOT
Timing: 22 deg (approximate) at WOT and max boost, 6500rpm.

Increased timing from 22 deg but no more increase in power.

Am thinking of leaning the AFR to 12.5 (maybe 12.8) and see how it goes if no engine knock.

ATM car runs great, no glitches, but I know I can get more out of it.

Cheers.
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Old 07-29-2014, 12:39 AM   #16
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looks like that compressor does not flow. E85 / 16-18psi and only 357whp? thats gonna be probably somewhere near red line then?!
on pump gas with bit lower compression on small turbos we get 360-370 @ 14-15psi with less timing and 98 octane.
looks strange to me.
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Old 07-29-2014, 01:49 AM   #17
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Quote:
Originally Posted by GeorgeGG View Post
looks like that compressor does not flow. E85 / 16-18psi and only 357whp? thats gonna be probably somewhere near red line then?!
on pump gas with bit lower compression on small turbos we get 360-370 @ 14-15psi with less timing and 98 octane.
looks strange to me.
Before I touch the tuning I am going to run the throttle intake tube down to the front bumper. (out of the engine bay) Just to see if the air temp makes a difference, as after a few 5 sec WOT Max RPM runs the intake air temp gets up to 75 deg cel. The Twin Screw (TS) gets extremely hot even with the water cooler. (thinking bigger cooler and some thermo fans)

I have Water/Meth injection set up and ready to go to combat the heat being produced by the TS but could not get the controller to work. (have not had time to look at why the pump works and injects, but not on boost control)

Thanks for the info GeorgeGG.
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Old 07-29-2014, 02:00 AM   #18
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Quote:
Originally Posted by cosmos328Ci View Post
Before I touch the tuning I am going to run the throttle intake tube down to the front bumper. (out of the engine bay) Just to see if the air temp makes a difference, as after a few 5 sec WOT Max RPM runs the intake air temp gets up to 75 deg cel. The Twin Screw (TS) gets extremely hot even with the water cooler. (thinking bigger cooler and some thermo fans)

I have Water/Meth injection set up and ready to go to combat the heat being produced by the TS but could not get the controller to work. (have not had time to look at why the pump works and injects, but not on boost control)

Thanks for the info GeorgeGG.
Water/Meth will help a lot to drop intake temps and EGT as well
u can hook it up on ECU so ecu will trigger pump under boost. no additional controllers will be needed

post up results how it goes
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Old 07-29-2014, 03:03 AM   #19
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Quote:
Originally Posted by cosmos328Ci View Post
Before I touch the tuning I am going to run the throttle intake tube down to the front bumper. (out of the engine bay) Just to see if the air temp makes a difference, as after a few 5 sec WOT Max RPM runs the intake air temp gets up to 75 deg cel. The Twin Screw (TS) gets extremely hot even with the water cooler. (thinking bigger cooler and some thermo fans)

I have Water/Meth injection set up and ready to go to combat the heat being produced by the TS but could not get the controller to work. (have not had time to look at why the pump works and injects, but not on boost control)

Thanks for the info GeorgeGG.
I ran mine as your planning, intake temps down to maximum of around 38 degrees Celsius, and at wot and spirited driving, down to around 17 degrees Celsius. Makes a big difference to air intake temps

Edit: air intake, not water/meth.
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Old 07-29-2014, 06:24 PM   #20
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Quote:
Originally Posted by GeorgeGG View Post
Water/Meth will help a lot to drop intake temps and EGT as well
u can hook it up on ECU so ecu will trigger pump under boost. no additional controllers will be needed

post up results how it goes
I don't think the Haltech has progressive injection control which is why I was going to use the OEM controller, eg: start injection at 7 psi and progressively reach max volume at 12 psi. I know the Haltech has RPM, Temp and load control. I will just hook it up to the Haltech and do a dyno run.
I don't have time at the moment, just got back from holidays yesterday and flying back to work for a couple of weeks today.

Results will definitely posted.

Thanks for your time GeorgeGG.

Quote:
Originally Posted by Davew View Post
I ran mine as your planning, intake temps down to maximum of around 38 degrees Celsius, and at wot and spirited driving, down to around 17 degrees Celsius. Makes a big difference to air intake temps

Edit: air intake, not water/meth.
Hi Davew,

Hows the dyno going.

Sorry, PM free now.

Sounds like a nice drop in temp, this will be a definite do asap.

Thanks Davew.
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