[NC335d]

When I initially began of modding my car, I quickly found about the issues with the leaky seals on the red charge pipe hose coming from the turbos to the FMIC. I was quick to replace the charge pipe with the upgraded version offered by Forge and paired it to the Wagner FMIC I had already had installed and have been running for about 9 months.

Fast forward a couple of months, during which I added hybrid turbos and water/meth injection and I was ready to take the car to the track.

A couple of weeks ago I went to the Rudy's Diesel truck show at the Piedmont Raceway dragstrip where they had an 1/8th mile track. During the first run, the owner of BPC who was driving my car experienced a loud "pop" noise and a sudden reduction in power a 1/4 way down the track. Their were no codes, so at least this was a good thing, jajajaja. Anyways, upon further investigation we came across this.



Bummer, my car was done for the day. It was obvious that this upgraded charge pipe could not handle the boost being pushed through it so we decided to go with slid piping and a much larger FMIC than the Wagner FMIC that was currently installed. I ordered a CX Racing FMIC for the N54 335i, as the one for the 335d did not seem to be available anymore. The largest silicone hose coupling utilized is 1.5" in length secured by T-Clamps.











Temps. have called down quite a bit here, so it is hard to get any comparisons in power since most of the dyno pulls w/ the Wagner were done at higher temps, but the car feels a lot better with the elimination of the airflow restrictions associated with the factory piping.

We will now be able to push this bad boy even harder with higher boost levels than the 40 lbs. we were pushing with the previous setup.

[11_335D]

Very nice setup you got there! With greater than 40lb does BPC recommend an intake manifold upgrade due to its plastic construction or should it hold up? Please post up new dyno videos and graphs.

[NC335d]

Originally Posted by 11_335D

Very nice setup you got there! With greater than 40lb does BPC recommend an intake manifold upgrade due to its plastic construction or should it hold up? Please post up new dyno videos and graphs.

I just picked the car up today and didn't really have time to talk to them about it. Good question on the intake manifold, and I would also be interested in finding that out. I will post on here once I find out.

[rspring]

Was it bolt-in or was fabrication required?

[NC335d]

Originally Posted by rspring

Was it bolt-in or was fabrication required?

Fabrication was required, since everything that could fail (OEM) was replaced. In addition their were some weight saving reductions made to the front bumper assembly and car to accommodate the much larger FMIC.

Here is a picture of the pipe that was fabricated to accommodate the nozzles and sensor for the water/meth setup.

[TDIwyse]

I like the intake pipes.

[DWR]

Originally Posted by NC335d

Here is a picture of the pipe that was fabricated to accommodate the nozzles and sensor for the water/meth setup.

Interesting placement of the injection nozzles relative to the IAT sensor. What was the thought process?

[BEWWWM]

That wagner looks homeless... Upgrade looks good bro!

[rulonger]

Originally Posted by NC335d

When I initially began of modding my car, I quickly found about the issues with the leaky seals on the red charge pipe hose coming from the turbos to the FMIC. I was quick to replace the charge pipe with the upgraded version offered by Forge and paired it to the Wagner FMIC I had already had installed and have been running for about 9 months.

Fast forward a couple of months, during which I added hybrid turbos and water/meth injection and I was ready to take the car to the track.

A couple of weeks ago I went to the Rudy's Diesel truck show at the Piedmont Raceway dragstrip where they had an 1/8th mile track. During the first run, the owner of BPC who was driving my car experienced a loud "pop" noise and a sudden reduction in power a 1/4 way down the track. Their were no codes, so at least this was a good thing, jajajaja. Anyways, upon further investigation we came across this.

Attachment 1305806

Bummer, my car was done for the day. It was obvious that this upgraded charge pipe could not handle the boost being pushed through it so we decided to go with slid piping and a much larger FMIC than the Wagner FMIC that was currently installed. I ordered a CX Racing FMIC for the N54 335i, as the one for the 335d did not seem to be available anymore. The largest silicone hose coupling utilized is 1.5" in length secured by T-Clamps.
...
We will now be able to push this bad boy even harder with higher boost levels than the 40 lbs. we were pushing with the previous setup.

I have contacted Randall at BPC and am in line for a tune/delete in the coming weeks. I want better MPG and to eliminate the probable failure of the emissions equipment (a matter of time, I suppose). However, I had hoped that my only near-term mods would be the delete/tune (Jess' downpipe, block off plates, removal of SCR, tune) and some minor suspension upgrades.

You recommended replacement of the red charge pipe with the Forge one. But that first picture is a bit unnerving. So what pushed you past the limits of the Forge charge pipe? Was it the initial tune or subsequent hybrid turbos?

I ask because I do not want to begin pushing other parts past their limits as my budget is not limitless.

[NC335d]

Originally Posted by rulonger

I have contacted Randall at BPC and am in line for a tune/delete in the coming weeks. I want better MPG and to eliminate the probable failure of the emissions equipment (a matter of time, I suppose). However, I had hoped that my only near-term mods would be the delete/tune (Jess' downpipe, block off plates, removal of SCR, tune) and some minor suspension upgrades.

You recommended replacement of the red charge pipe with the Forge one. But that first picture is a bit unnerving. So what pushed you past the limits of the Forge charge pipe? Was it the initial tune or subsequent hybrid turbos?

I ask because I do not want to begin pushing other parts past their limits as my budget is not limitless.

You will be just fine with the Forge piece based on your goals for your car. I have not heard or seen anybody else have a problem with the Forge CP. I'm pretty much convinced the failure was related to my car's setup and running the much higher boost levels.

The guys at Forge were shocked to say the least when I informed them of what happened. They are sending me a brand new replacement. Couldn't ask for a better response from them, fast, courteous and professional.

[rulonger]

Originally Posted by NC335d

You will be just fine with the Forge piece based on your goals for your car. I have not heard or seen anybody else have a problem with the Forge CP. I'm pretty much convinced the failure was related to my car's setup and running the much higher boost levels.

The guys at Forge were shocked to say the least when I informed them of what happened. They are sending me a brand new replacement. Couldn't ask for a better response from them, fast, courteous and professional.

Since you will not be needing the one they are sending, you can leave it at BPC with my name on it.

In all honesty, if you will not be using the Forge replacement - which I know you will not after seeing the fabricated charge pipe BPC made for your car - I could buy it from you. PM me if you would like to sell it.

[Puerto Rican 335d]

wow NC335d your F'ing blowing the car up LOL. I for one have been using the OEM red hose and plan to replace it, I will give Forge a try since they were replacing yours for free. I had spoken to CX Racing a few years ago and a friend of mines had done the FIRST CX Racing IC on the 335d using the same 335i ic you have but he did some alterations on tubing different than you did . Car was giving him 50 mpg in Florida and btw he did his own piggyback. Hope everything goes well for you

[Chief Orman]

Originally Posted by DWR

Interesting placement of the injection nozzles relative to the IAT sensor. What was the thought process?

ditto on the nozzles...why after the IAT?

the new IC is spectacular!

[NC335d]

Originally Posted by Chief Orman

ditto on the nozzles...why after the IAT?

the new IC is spectacular!

Thanks!

Quite simply, they nozzles were easier to install in that location. It is my understanding that the IAT in the diesel is not utilized for ignition timing etc. where as it is in the gas engine, hence the nozzles are placed before the IAT.

[NC335d]

Originally Posted by Puerto Rican 335d

wow NC335d your F'ing blowing the car up LOL. I for one have been using the OEM red hose and plan to replace it, I will give Forge a try since they were replacing yours for free. I had spoken to CX Racing a few years ago and a friend of mines had done the FIRST CX Racing IC on the 335d using the same 335i ic you have but he did some alterations on tubing different than you did . Car was giving him 50 mpg in Florida and btw he did his own piggyback. Hope everything goes well for you

Amigo, I could def. feel a difference on the butt dyno after switching to the CX Racing IC and the solid piping setup, it feels like the boost is building up a lot faster than before with the old setup. The 17" Apex Arc-8 Conti DWS combo that I just bought for my winter setup kept my traction control light flickering through 3rd gear without even getting on it. Had no option but to switch back to my 19" wheels with the Michelin PSS. I also had to adjust the settings on the water/meth controller where the meth would start spraying at a higher boost level for fear of quenching at lower RPM's.

Have you installed your meth kit yet??

[335duff]

NC335d what apex setup are you running? And what tire size? I was thinking of going for the 17x9 et30 with a 255 square street tire for summer setup and use the stocks for winter, but im unsure if that is ideal. Im also thinking of going to an 18 setup to run the michelin ps2 zp RFT.

[Chief Orman]

Originally Posted by NC335d

Thanks!

Quite simply, they nozzles were easier to install in that location. It is my understanding that the IAT in the diesel is not utilized for ignition timing etc. where as it is in the gas engine, hence the nozzles are placed before the IAT.

NC I am confident that you know more about this topic than I do but when my water meth starts spraying my charge air temperature plummet as one would expect. I am surprised that the lower IAT are not being fed into the DDE in a manner that impacts the ignition parameters. I am with you...it is monumentally easier to do the after the IAT placement but I ended up forcing my mechanic to move them causes I wanted the DDE to adjust for the lower temps.

[DWR]

Originally Posted by Chief Orman

it is monumentally easier to do the after the IAT placement but I ended up forcing my mechanic to move them causes I wanted the DDE to adjust for the lower temps.

Except, we can see it is a custom fabricated pipe, created at a welding table. It may have been easier, but not by much when you consider the total work that went into that pipe.

Since we are told that IAT does not affect BPC's tune, I'll take it as true. There is evidence that it does affect SOI in Jarek's or a stock tune. The affect is real as far as the performance of the engine is concerned. Too bad the tune cannot take advantage of that.

[Puerto Rican 335d]

NC335d haven't installed it yet awaiting my e30 M3 to come out of the shop this week will post pics from the M3 for you guys to droollllll LOL!!

[DWR]

Originally Posted by DWR

Since we are told that IAT does not affect BPC's tune, I'll take it as true. There is evidence that it does affect SOI in Jarek's or a stock tune. The affect is real as far as the performance of the engine is concerned. Too bad the tune cannot take advantage of that.

This comment I made was too cryptic, and could lead to the wrong conclusion. This stuff is complex. If the H2O/meth ratio is dilute, then advance of the start of injection (SOI) is appropriate. We can tell from the HP numbers that NC335d's vehicle is consuming a lot of methanol. At some point, the diesel to methanol ratio requires that the SOI is retarded.

The last sentence of the comment was really about the fact that H20/meth systems are typically minimally integrated with the ECU, diesel or gas. If methanol and H2O could be treated separately as fuel and coolant, control by the DDE really would be possible - with a good deal of programming.

I suspect BPC put the nozzles after the IAT sensor, so that the DDE would not advance SOI. Would not be surprised if some retarding of SOI was in the tune.

[Chief Orman]

Originally Posted by DWR

This comment I made was too cryptic, and could lead to the wrong conclusion. This stuff is complex. If the H2O/meth ratio is dilute, then advance of the start of injection (SOI) is appropriate. We can tell from the HP numbers that NC335d's vehicle is consuming a lot of methanol. At some point, the diesel to methanol ratio requires that the SOI is retarded.

The last sentence of the comment was really about the fact that H20/meth systems are typically minimally integrated with the ECU, diesel or gas. If methanol and H2O could be treated separately as fuel and coolant, control by the DDE really would be possible - with a good deal of programming.

I suspect BPC put the nozzles after the IAT sensor, so that the DDE would not advance SOI. Would not be surprised if some retarding of SOI was in the tune.

DWR what's the optimal configuration in your view? I feel like I have seen plenty of smart people have differing views on where to place the nozzles. So bottom line do we want the IAT reading the reduced temperatures or not?

[DWR]

Originally Posted by Chief Orman

DWR what's the optimal configuration in your view? I feel like I have seen plenty of smart people have differing views on where to place the nozzles. So bottom line do we want the IAT reading the reduced temperatures or not?

Plenty of smart people are trying to acheive different results. Therefore, the idea that there would be an optimal configuration to realize all those results starts with a false premise.
But let me answer the question I think you are really asking. Chief, your setup is fine the way it is.