E46 M3 Project

Author
Discussion

benny.c

3,488 posts

209 months

Sunday 27th April 2014
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It's been fine for me, no issues to speak of. It could be my imagination but I think the car may be ever so slightly less tolerant of pulling away in the wrong gear. Its not something I noticed when it was first mapped though so it's probably not the case. No kangarooing from cold like stock any longer, which is great.

Gibbo205

3,563 posts

209 months

Sunday 27th April 2014
quotequote all
Hi there

For the map, use only Evolve.

I don't have a CSL airbox but to give you an idea, all run on same dyno:-
Car with BMC Filter, Milltek 100 cel cats, Cobra mid-pipe and backbox on Vpower = 336BHP.
Car same as above, same day, but with Evolve map loaded on = 367BHP.

The above was not on Evolve's Dyno, so no way for them to bias the results, practically a clear 30BHP was given by the remap.

I then changed my cobra mid-pipe and backbox back to stock CSL Mid-pipe and M3 backbox, the result was 380BHP, again same dyno, but a different day. However between 2500-3500rpm the car gained 70lb/ft as that Cobra/Top Gear Mid-Pipe was loosing tonnes of loads down power, the M3 mid-pipe has a H Design to it whereas most of the aftermarket ones are just straight pipes which rob you of low/mid range power.

On the day my car made 380BHP, a stock M3 with less miles than mine made 345BHP and a 2006 M3 CS with CSL airbox and Alpha-N map made 384BHP. In short my remap, 100 cel cats have given me 35BHP peak gains with most of these gains all beyond 6000rpm. Compared to the stock M3 I had more power/torque every with no flat spots, but the gains are most noticeable higher up the rev range.

In short Evolve seem to know their S54's and when it comes to mapping they seem to be in their own league. Power wise on an M3, exhaust, intakes forget it, just keep the car well serviced with a good clean filter or a BMC replacement and just get a remap as exhaust, intakes don't net you any power, maybe even a loss. So if you want power remap it or go turbo/supercharger, anything else is a waste of money. BMW got the intake and exhaust spot on it seems, they just left a bit in the ECU, no doubt on purpose due to having a CSL planned at a later date. wink

darreni

3,841 posts

272 months

Sunday 27th April 2014
quotequote all
Gibbo205 said:
Hi there

For the map, use only Evolve.

I don't have a CSL airbox but to give you an idea, all run on same dyno:-
Car with BMC Filter, Milltek 100 cel cats, Cobra mid-pipe and backbox on Vpower = 336BHP.
Car same as above, same day, but with Evolve map loaded on = 367BHP.

The above was not on Evolve's Dyno, so no way for them to bias the results, practically a clear 30BHP was given by the remap.

I then changed my cobra mid-pipe and backbox back to stock CSL Mid-pipe and M3 backbox, the result was 380BHP, again same dyno, but a different day. However between 2500-3500rpm the car gained 70lb/ft as that Cobra/Top Gear Mid-Pipe was loosing tonnes of loads down power, the M3 mid-pipe has a H Design to it whereas most of the aftermarket ones are just straight pipes which rob you of low/mid range power.

On the day my car made 380BHP, a stock M3 with less miles than mine made 345BHP and a 2006 M3 CS with CSL airbox and Alpha-N map made 384BHP. In short my remap, 100 cel cats have given me 35BHP peak gains with most of these gains all beyond 6000rpm. Compared to the stock M3 I had more power/torque every with no flat spots, but the gains are most noticeable higher up the rev range.

In short Evolve seem to know their S54's and when it comes to mapping they seem to be in their own league. Power wise on an M3, exhaust, intakes forget it, just keep the car well serviced with a good clean filter or a BMC replacement and just get a remap as exhaust, intakes don't net you any power, maybe even a loss. So if you want power remap it or go turbo/supercharger, anything else is a waste of money. BMW got the intake and exhaust spot on it seems, they just left a bit in the ECU, no doubt on purpose due to having a CSL planned at a later date. wink
Wow, so a BMC panel filter & remap gave you 35 bhp?

Makes you wonder why BMW went to the trouble of bespoke cams, valves, induction, exhaust, engine management etc on the CSL & only made 360bhp.



Edited by darreni on Sunday 27th April 21:40

mwstewart

Original Poster:

7,696 posts

190 months

Sunday 27th April 2014
quotequote all
On average the E46 M3 makes 320bhp at the flywheel; they are all well under the quoted figure, whereas CSL's are about on target. With all the modifications I am making i.e. cams, exhaust, intake, CSL software, and a remap, I will consider myself lucky if I achieve more than 370.

On average the E46 M3 makes 320bhp at the flywheel; they are all well under the quoted figure, whereas CSL's are about on target. With all the modifications I am making i.e. cams, exhaust, intake, CSL software, and a remap, I will consider myself lucky if I achieve more than 370.

Standard exhaust system removed. This took a couple of hours due to limited access and removal of the under trays etc. The system is obscenely heavy, so much so that the car sits noticeably higher without it fitted!


And on to the reason for removing the standard exhaust: to see exactly why the Supersprint V1 manifolds aren't advertised for RHD cars. The reason I bought the V1's over the RHD suitable V2's is detailed http://www.m3forum.net/m3forum/showthread.php?t=39... - if you don't want to read that, the answer is another 6bhp gain from a set of components already proven to make up to 15bhp.


Here are the V1's next to the standard manifolds.



From start to finish it took 4.5 hours. I was expecting it to be a lot worse given what I'd read online, but it was very straight-forward. Note the blood on the oil feed pipe in the following photo - wrapped knuckles aplenty!


So, what did I find? Well, it's not a case of the manifolds being of a similar design to OEM and the additional diameter impeding on space, they are simply not designed with the standard - quite bulky - RHD steering shaft in mind, which is the bottom shaft in the photo below. The pivot points on the standard shaft are at each end i.e. the rack and the column protruding through the bulkhead.


Here's a photo from under the car showing what I'm up against. The rack spigot can be seen in the lower left of the photo and the column shaft in the upper right.


After some thought - and grovelling around on my back under the car! - I came up with the following layout for a custom steering shaft. The blue circles represent the new positions of the UJs.


I dismantled the standard shaft to experiment with the UJs but found they are far too bulky for this application. Tomorrow I will start looking at alternative UJs and buy in some Hexagonal bar stock to start mocking up the new layout.

Gibbo205

3,563 posts

209 months

Sunday 27th April 2014
quotequote all
darreni said:
Wow, so a BMC panel filter & remap gave you 35 bhp?

Makes you wonder why BMW went to the trouble of bespoke cams, valves, induction, exhaust, engine management etc on the CSL & only made 360bhp.



Edited by darreni on Sunday 27th April 21:40
I also have 100 cel cats, but yes proven. Three M3's ran that day, one stock making 345BHP, mine making 380BHP and a CS with CSL Airbox and evolve alpha N making 384BHP.

So irrelevant if the dyno was over reading my car had 36BHP advantage on same dyno, same day compared to a stock M3. smile

Beedub

1,959 posts

228 months

Sunday 27th April 2014
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Gibbo205 said:
I also have 100 cel cats, but yes proven. Three M3's ran that day, one stock making 345BHP, mine making 380BHP and a CS with CSL Airbox and evolve alpha N making 384BHP.

So irrelevant if the dyno was over reading my car had 36BHP advantage on same dyno, same day compared to a stock M3. smile
I've never seen a stock s54 make 345bhp.... every they always make a little less than advertised power, they dyno you guys were using was reading way high..... s54 making 384bhp without serious work?? no... way.....

anonymous-user

56 months

Sunday 27th April 2014
quotequote all
Do those aftermarket exhaust manifolds actually improve performance? Seems like a LOT of effort (with all the messing around with the steering column routing etc) for what will be a zero or minor gain?


(The MaxyT eye-crometer fails to see significant gains, both manifolds have broadly the same geo and lengths, maybe the aftermarket one has slightly longer primaries, but it looks to be a bit larger dia, so that's cancelled out) Benchmarking the E46 M3 motor many years ago (on a >£1M engine dyno with proper in-cylinder combustion analysis etc) i found that really the limitation was intake limited, in terms of cams, valves and to a lesser degree ports. Once the catalyst and some silence EBP was negated, little improvement could be found from the exhaust system (suggesting BMW had got the OEM part correct in the first place, as you might expect given the specific output). In fact, the only way we made any significant more power was longer duration cams at higher crank speed)

Gibbo205

3,563 posts

209 months

Sunday 27th April 2014
quotequote all
Beedub said:
I've never seen a stock s54 make 345bhp.... every they always make a little less than advertised power, they dyno you guys were using was reading way high..... s54 making 384bhp without serious work?? no... way.....
Irrelevant of dyno a 36BHP difference.

Dyno could have read 325BHP, 361BHP and 365BHP if it makes you feel better.

Dynos are for comparing mods, on that day the two modified cars made 35-40BHP over a stock M3, all serviced and all running Vpower.

Do I believe the dyno is over-reading? Yes!
Do I believe my car has 36BHP more than a stock M3? Yes!

I'd say my car is realistically in the 355-365 region.

As another point of interest I have a race logic box, same place tested and before remap my car was doing 60-100mph in 5.9s and now it's doing it in 5.5s smile

Edited by Gibbo205 on Sunday 27th April 23:45

scarebus

858 posts

173 months

Monday 28th April 2014
quotequote all
Gibbo205 said:
As another point of interest I have a race logic box, same place tested and before remap my car was doing 60-100mph in 5.9s and now it's doing it in 5.5s smile

Edited by Gibbo205 on Sunday 27th April 23:45
In what gear can I ask?

Gibbo205

3,563 posts

209 months

Monday 28th April 2014
quotequote all
All three cars were run in 5th, whereas in hindsight we believe they should of being run in 4th maybe as 6th is not a true gear but an overdrive, is that true?

Still three cars, same testing method, same day, the cars with mod had a clear advantage, irrelevent if the dyno was over-reading.

mwstewart

Original Poster:

7,696 posts

190 months

Monday 28th April 2014
quotequote all
Gibbo205 said:
All three cars were run in 5th, whereas in hindsight we believe they should of being run in 4th maybe as 6th is not a true gear but an overdrive, is that true?

Still three cars, same testing method, same day, the cars with mod had a clear advantage, irrelevent if the dyno was over-reading.
Based on what I've learnt from looking into the S54 I think the dyno was optimistic to the tune of 25bhp, so using that as correctional factor leaves 355 for the modified car - which is good - and 320 for the standard car, which is about what I'd expect.

It's worth noting that standard S54's output anywhere from 315bhp to 335bhp, so it's quite probable you started out towards the higher end of the standard output range.

ezakimak

1,871 posts

238 months

Friday 2nd May 2014
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Max_Torque said:
Do those aftermarket exhaust manifolds actually improve performance? Seems like a LOT of effort (with all the messing around with the steering column routing etc) for what will be a zero or minor gain?


(The MaxyT eye-crometer fails to see significant gains, both manifolds have broadly the same geo and lengths, maybe the aftermarket one has slightly longer primaries, but it looks to be a bit larger dia, so that's cancelled out) Benchmarking the E46 M3 motor many years ago (on a >£1M engine dyno with proper in-cylinder combustion analysis etc) i found that really the limitation was intake limited, in terms of cams, valves and to a lesser degree ports. Once the catalyst and some silence EBP was negated, little improvement could be found from the exhaust system (suggesting BMW had got the OEM part correct in the first place, as you might expect given the specific output). In fact, the only way we made any significant more power was longer duration cams at higher crank speed)
So what you are trying to say, is dyno the car with the new exhaust system to see if its worth the effort of swapping the steering shaft before you go through the headache.

i thought that i read some pages back about the standard steering shaft with the guibo being removed when the Z4MC rack was fitted, yet it looks like the standard M3 shaft is still there.

hondansx

4,590 posts

227 months

Friday 2nd May 2014
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Interesting read about the exhaust mods. I had a CSL a few years ago now and I remember BMSport used my car in a test which was shown in a BMW magazine; i had a Supersprint centre pipe and my car got a better result than another CSL with a full system. As as a result, BMSport then actively talked people out of going for cat back systems.

I was under the impression that Thorney Motorsport supplied RHD Supersprint manifolds; or was it a one off batch?

Regardless, chasing power in a M3 makes no sense to me! In modern terms, it's still not going to be especially quick. CSL airbox is the key step for me; it's all about the noise!

Anyway, the car looks great and nice to see genuine parts being used.

mwstewart

Original Poster:

7,696 posts

190 months

Friday 2nd May 2014
quotequote all
ezakimak said:
So what you are trying to say, is dyno the car with the new exhaust system to see if its worth the effort of swapping the steering shaft before you go through the headache.

i thought that i read some pages back about the standard steering shaft with the guibo being removed when the Z4MC rack was fitted, yet it looks like the standard M3 shaft is still there.
The gains from what I'm doing have been proven many time over the years. +45 bhp average gain and and a transformation of the driving experience.

WRT the Z4M shaft:
mwstewart]img said:
The M3 has a rubber steering Giubo in the UJ linkage that's purpose is to absorb kickback through the wheel, which it does well, however it is at the expense of steering feel. I had read elsewhere on the internet that the solid Z4M coupler is a straight swap, but like a lot of things I read on on the internet, it was incorrect! The spline locating flats on the Z4 part are in completely different orientation to that on the M3.
The above is why the standard shaft and guibo were still on my car.

hondansx said:
Interesting read about the exhaust mods. I had a CSL a few years ago now and I remember BMSport used my car in a test which was shown in a BMW magazine; i had a Supersprint centre pipe and my car got a better result than another CSL with a full system. As as a result, BMSport then actively talked people out of going for cat back systems.

I was under the impression that Thorney Motorsport supplied RHD Supersprint manifolds; or was it a one off batch?

Regardless, chasing power in a M3 makes no sense to me! In modern terms, it's still not going to be especially quick. CSL airbox is the key step for me; it's all about the noise!

Anyway, the car looks great and nice to see genuine parts being used.
Thanks. The modifications are going to make the difference between performance that feels pretty average and performance that starts to feel interesting. The RHD specific Supersprint 'V2' manifolds are 6bhp down on the LHD 'V1' version I have here, which is considerable in NA terms. It is really only the Supersprint parts that are proven to produce the desired results, and their manifolds, cats, and centre section are a well proven 20bhp upgrade which is why remain revered and the best exhaust for the S54/E46.

FYI SS R&D showed that there are zero gains from changing the rear silencer on the E46 M3, except for noise - if that's your thing; the only gains are from the manifolds, cats, and centre section. If your car was compared to another Supersprint equipped car that had the centre and rear silencer, than I would expect the results to be identical. If the other car had a non-SS exhaust, I would almost certainly expect the results to be worse.

Captainawesome

1,817 posts

165 months

Friday 2nd May 2014
quotequote all
This is quite funny, we both bought nearly identical (smg v's manual) cars a few weeks apart.

I've got the carbon box and supersprint lightweight exhaust on order for mine, hopefully be here soon, Also added depo indicators, a panasonic head unit which has a colour change function which I bought purely so it would match the rest of the interior lighting, carbon kidney grilles and a full carbon cube interior kit. I did have CSL wheels and bootlid (copies) but took them off and went back to OEM. I'm up to 50,000 miles now.....guessing yours is nowhere near that. Unfortunately going to be losing my licence for a while soon (damn the S54) sop while she is off the road a set of APs will be fitted up front as despite uprated pad,discs and fluid they still fade very quickly under hard use.

I'm going for the OEM + look too but not quite as detailed as yours. Your work and attention to detail are stunning. Good job.

ETA on the power front...had mine remapped at Evolve (brilliant guys) and she made 327bhp standard which they said was very good and after the map she made 340.7 with no mods whatsoever.erence in how it drives though is crazy. So much more oomph lower down the revs. I can't wait for the airbox and exhaust to go on, I'm hoping for between 360-370bhp but TBH am doing it purely for the noise. I can only imagine how good that drive home is going to be.

Edited by Captainawesome on Friday 2nd May 13:30

mwstewart

Original Poster:

7,696 posts

190 months

Friday 2nd May 2014
quotequote all
Captainawesome said:
This is quite funny, we both bought nearly identical (smg v's manual) cars a few weeks apart.

I've got the carbon box and supersprint lightweight exhaust on order for mine, hopefully be here soon, Also added depo indicators, a panasonic head unit which has a colour change function which I bought purely so it would match the rest of the interior lighting, carbon kidney grilles and a full carbon cube interior kit. I did have CSL wheels and bootlid (copies) but took them off and went back to OEM. I'm up to 50,000 miles now.....guessing yours is nowhere near that. Unfortunately going to be losing my licence for a while soon (damn the S54) sop while she is off the road a set of APs will be fitted up front as despite uprated pad,discs and fluid they still fade very quickly under hard use.

I'm going for the OEM + look too but not quite as detailed as yours. Your work and attention to detail are stunning. Good job.
Cheers!

I remember yours, same mileage too smile Mine's just hit 30k, but I've put I've covered a lot more ground in the previous M3's I've owned. This one is a keeper. I'm looking into AP's for mine at the moment actually.

ezakimak

1,871 posts

238 months

Saturday 3rd May 2014
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Thanks for clearing that up for me.

Will keep watching with interest.

Regards Ryan

ATM

18,406 posts

221 months

Monday 5th May 2014
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I've seen some suspiciously cheap e46 Alcon sets on ebay - I thought they were twice the price of this - http://www.ebay.co.uk/itm/121170065415

I have some AP's on my none-m...


Craigwww

853 posts

171 months

Monday 5th May 2014
quotequote all
Captainawesome said:
ETA on the power front...had mine remapped at Evolve (brilliant guys) and she made 327bhp standard which they said was very good and after the map she made 340.7 with no mods whatsoever.erence in how it drives though is crazy. So much more oomph lower down the revs. I can't wait for the airbox and exhaust to go on, I'm hoping for between 360-370bhp but TBH am doing it purely for the noise. I can only imagine how good that drive home is going to be.
Don't expect much of a power increase from an exhaust and cf airbox. I have a Supersprint system, center section and Evolve cf box + map and I saw 345bhp on their dyno. It's not a power mod, it's for the noise and drive ability.

darreni

3,841 posts

272 months

Monday 5th May 2014
quotequote all
ATM said:
I've seen some suspiciously cheap e46 Alcon sets on ebay - I thought they were twice the price of this - http://www.ebay.co.uk/itm/121170065415

I have some AP's on my none-m...

Those Alcons are front kit only & exclude pads.
Add the rear kit (£1,600) & pads F&R (£4-500) & its the thick end of £4k.