120D PF tuning plan - Dyno results page 13!!!

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geeto
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120D PF tuning plan - Dyno results page 13!!!

Post by geeto » Thu Jul 26, 2012 8:52 pm

Hey all,

Well i've decided after much deliberation that I will stick with 120D and attempt to get some more power out of her! (I was looking into changing to a 330/335d, but turns out its a bit more expensive than I can afford with a house purchase looming).

This is my current idea, according to lots of internet/forum research:

Current Spec - Standard, 68k full BMW service history

Tuned Spec:

EGR removed with blanking adaptor
Inlet manifold cleaned and swirl flaps removed
Custom 2.5" mandrel stainless steel exhaust with twin tips *Cat Back, 1 silencer*
K&N competition filter
Ecotune custom remap on site with before/after dynos
Gearbox and diff oils changed to OEM spec castrol

All in i'm hoping for a solid 210bhp/440nm - Judging by the Standard car remaps I think this is feasible?

Any other little modifications I can do to improve reliability or performance please say but I think I've covered most of it?

EDIT

Goal achieved with 222bhp / 477nm reached :spotman:

Cheers

Tom
Last edited by geeto on Fri Nov 02, 2012 8:48 pm, edited 4 times in total.
Tom

2006 Sparkling Graphite 120d M sport - All factory extras except sat nav!

- Custom Apexi Front mount IC
- 2.5" Turbo back SS exhaust
- EGR bypass kit
- Swirl flaps removed
- K & N filter
- Ecotune custom remap

222bhp / 477nm

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marco_polo
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Re: 120D PF tuning plan

Post by marco_polo » Thu Jul 26, 2012 9:05 pm

No need for the air filter, the standard one is huge so won't create any pumping loses. Just make sure it's been changed at some point.

I think 210 is quite feasible. Maybe look into additional cooling mods if you're going to spend lots of time 'on it', intercooler or some kind of cold air feed blowing over the turbo?

PM 'RJudgey', he knows far more about M47 tuning than me.
Silver F21 M135i - ManBox - HK - Adaptive + Eibach Pro's - BBS CH-R's - BMWP Drexler LSD - TMC Piggyback - M4 LCA's - aFe Dry Filter

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Re: 120D PF tuning plan

Post by Rjudgey » Fri Jul 27, 2012 12:49 am

Don't get a 2.75" exhaust it's simply not needed that big on this turbo. Which year car is yours and is it Garret vacuum operated turbo or Mitsubishi Electronic turbo?
Now you have couple of options here really for optimal peformance you can go the Decat route and keep stock exhaust system which will keep noise nice and quiet but free up some bhp and torque by having no CAT and getting rid of restrictions, or you can go Decat route with custom 2.5" mandrel bent system but put in a large centre silencer or for more quiet and some more back pressure a small rear box on top as well. I can certainly tell you a Decat with a straight through 2.5" system is not very pleasant!! lol!! The idea of the Decat is to keep the heat away from the Turbo and to also help asist in low rpm pull reducing lag. Personally I'd go with the Decat plus custom 2.5" with big middle silencer which should be similar to when I had a CAT on with the straight through setup nice and quiet when poodling around nice Grrrr when you stuck your foot down.

I'd also go with Intercooler upgrade it keeps the intake air charge nice and cool nearly to ambient temp from my HG motorsport one (not without issues but rectifiable), they're not too pricey and generally well made but fitting is a pain and need a little bit of modifications to get them to work correctly.

The EGR and swirl flaps is a good addition i'd go further though and remove the intake with EGR valve all together and fit a whole new body they aren't that expensive and reasonably easy to adapt and fit.

As for maps well I think you need to go see Will at P-torque or Jason B&W chiptune for a custom map to cater for the EGR removal, Decat, you could go to DMS to be honest I know they're expensive but they're maps are very well done but as your having EGR and Decat I'd imagine Rob would charge a small fortune for custom mapping this probably around £1000 or so but I've had they're base map and to be honest if you had this done and just intercooler fitted you'd be very happy only downside is if you have a heavy right foot you may eat some turbo's don't expect much out of 50k miles. But as I say the DMS map is silky smooth flat torque across the rev range only tailing off as you approach redline and the bhp increases nicely like a petrol engine upto redline where you produce max power, other maps I've seen they're peak bhp and torque is very peaky and tend to be between 2-2500rpm which is great for in gear acceleration and economy but makes full throttle red line experience a little less interesting. But have a chat with Will and Jason have a look at some of their M47 dyno charts I'll try and post my DMS ones so you can compare.

Engines are bomb proof on these cars with 68k miles your only worry is turbo but if it's been looked after should be good for a fair bit of mileage yet! I had 172k very hard miles out of my engine before it started having serious issues but even then the pistons, rods and main bearings were all good. Just make sure you warm up turbo cool it down and change oil every 7-10k miles and gear oil every 3 oil changes same for diff.

If you use BP ultimate you can easily get 210-220bhp and 300-320lbft of torque so with a custom map, EGR bypass, exhaust, decat, and I/C expect 230-240bhp and 320-340lbft torque.

Don't waste money on Air filter in summer use stock Mann filter with the fiber sock removed change every oil service, winter time leave the fiber sock on as it gets wet more often from rain. I did do some air intake mods but they made minimal difference.

I've a fair few maps for mine so have done quite a bit of tinkering I have an ECU flasher as well which is handy so can switch between eco map for commuting and a race map for track days etc. They're not mega money and Jason and will can work with these too. Stan at Ecotune does a similar setup but you can only use his map on his flasher as he doesn't want he maps getting pinched by anyone so they're all encrypted.

If your dowm near me one day your welcome to pop down and have a butchers.
120d Msport, Leather, HK 7 Sound, LED plate lights, Goodyear Assym 2, ECOTUNE I flash, 2.5" Downpipe & Exhaust, EGR gone, Modded air intake/box, HG intercooler, Eibach kit, Eibach ARB, powerflex bushes, M3 wishbones, M3 tension arms, BMWP brakes.

geeto
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Re: 120D PF tuning plan

Post by geeto » Fri Jul 27, 2012 1:58 pm

Thanks for the replies!

Well i'm glad i only need a 2.5" exhaust as its alot cheaper going that route! if i remove the CAT will it still be able to pass the MOT? i understand diesels on have to pass a soot test?

I should have been clearer, i plan to buy and fit a EGR bypass pipe which i think is what you were mentioning? its only £40ish and should allow a clean flow into the inlet manifold.

I'm still trying to figure out how to remove the inlet manifold as its looks fairly complex :( the cleaning part is relatively easy as i will just use seafoam and scrape/burn it out - its excellent stuff!

The car will never see the track, i have a dedicated track toy for that! i didn't think an uprated intercooler would be required at these power levels? i'm happy to be mistaken but i reckon it will cost a fair bit for a bespoke IC :(

my car is an M sport (2006) so im pretty confident i will have a mitsubishi turbo :( which is a shame when it comes to hybrids (i've been reading up on these too!) as they only do garret hybrids as far as i can tell.

the car is due an oil change in 4k miles so i will be aiming to do all this works after the oil change to give her a good chance at producing some decent figures :)

In fairness the car is 90% of the time sat at 70-75 mph on the motorway so its only the weekends/bit of fun once a week where i want that extra grunt (i'm used to higher power cars which is the reason for this quest for power).

In terms of the exhaust, i love the sound of the miltek but its very expensive :(
Tom

2006 Sparkling Graphite 120d M sport - All factory extras except sat nav!

- Custom Apexi Front mount IC
- 2.5" Turbo back SS exhaust
- EGR bypass kit
- Swirl flaps removed
- K & N filter
- Ecotune custom remap

222bhp / 477nm

Rjudgey
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Re: 120D PF tuning plan

Post by Rjudgey » Sat Jul 28, 2012 9:05 pm

The Intercooler is bit pricey but the stock one gets pretty mashed and corroded over a few years, and yes yours is a Mitsi then. I paid about £400 plus tax and shipping I think on the I/C so it's not a huge amount more than a new stock one you get better power and more mpg with it no noticeable drop in lag. The car will pass MOT with Decat it's just a soot test so no smoke and it will pass, yes milltek is pricey and to be honest for the money if you know a good custom exhaust fabricator they'll do just as good a job for less and you won't get a rattly silencer!

If your worried about the MOT keep the CAT just have a custom exhaust mandrel bent 2.5" all the way no silencers it's a nice sound when you are at WOT but at normal speeds it's a smidge louder than stock, I kept mine simple with a stock looking downward tailpipe it's also lighter than the old system by quite a bit too! which is good! If the CAT goes in the future can put a Decat pipe on then.

What's the mileage per year you expect to do?

The inlet manifold isn't that tricky the hardest bit is getting the old vac lines off the swirl flap mechanism i had to cut mine off then reattached it after I got the stuck on bit off, with yours doesn't matter as your blocking it off anyways.

I think a EGR removal, plus swirl flaps, custom exhaust, I/C (up to you), with a good map running BP ultimate would certainly see you upto 220-230bhp and 330-340lbft if the engine and sensors are all healthy.

My DMS map with stock engine with BP ultimate made 210bhp and 300lbft and the power delivery is very very good on this map with peak power at the redline and lots of torque nicely spread across the rev range, this is very important to look at power graphs as I said before many mappers go with big figures but this will be in the midrange with power and torque falling rapidly after 3000rpm.

If you go with all your mods I'd certainly go and see Will at P-torque as he'll be nearby and he'll be able to show you some of his mapping graphs and give you some advice he has many cars that come in with the same engine from eco maps to race maps.

As for track toys yes it's nice luxury to have and having a 29 year old honda weighing 800ish kg's and a 8000rpm screaming 200bhp 4 pot running on pair of Weber DCOE 45's and being held on the ground with some custom GAZ coilovers with 600lb race springs certainly entertains and makes mince meat of anything but super cars is pretty entertaining but the BMW does bring a nice sense of speed plus comfort when on the road not to mention welcome relief at the petrol station! lol! With all the mods I've done when I'm running a ECO map which is about 200bhp and 300lbft I can get a good 55mpg avg from not trying hard 60mpg avg if I really really concentrate and drive like a saint! :0)
120d Msport, Leather, HK 7 Sound, LED plate lights, Goodyear Assym 2, ECOTUNE I flash, 2.5" Downpipe & Exhaust, EGR gone, Modded air intake/box, HG intercooler, Eibach kit, Eibach ARB, powerflex bushes, M3 wishbones, M3 tension arms, BMWP brakes.

geeto
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Re: 120D PF tuning plan

Post by geeto » Mon Jul 30, 2012 7:54 pm

Well I've just ordered my EGR bypass pipe, so that should be with me for the weekend all being well!

I've had a few quotes from local custom exhaust places, for a cat back exhaust they are after £270+vat so £304 all in. seems a bit steep to me? I was hoping more £200-£250 all in to be honest - these prices are for a 2.5" system, with a twin exhaust pipe.

In terms of decat pipes, there's one on Ebay for £130. It reads well but has anyone actually using one? I need to ask what diameter they are using as well.

To be honest for my power levels/usage I can't really justify £300-400 for an inter cooler, it would be nice but not required. I drive around 22,000 miles a year mainly motorway to work and back but I have the weekends which i like to drive 'spirited' when I'm on my own :) in fairness if i could measure the old inter cooler I bet I could get one made out of ally cheaper from a local specialist - its certainly an idea.

But yes the car will be sat at 70-75 for the majority of its life, this is the reason for removing the EGR as it will only cause problems in the future. So the idea being once I've fully cleaned the inlet manifold/removed the EGR it shouldn't block up again!

The plan is still going ahead though, if the EGR bypass arrives before the weekend I'll get the inlet cleaned and the EGR blocked off this weekend, then try to find a place which won't charge me as much for a 2.5" custom exhaust. I have a feeling that £270+vat included a silencer but I'm not 100%, I might give him another ring and see what he can do.

Actually I should order the swirl flaps so I can do it all at once! Does anyone know what size I need for my car?
Tom

2006 Sparkling Graphite 120d M sport - All factory extras except sat nav!

- Custom Apexi Front mount IC
- 2.5" Turbo back SS exhaust
- EGR bypass kit
- Swirl flaps removed
- K & N filter
- Ecotune custom remap

222bhp / 477nm

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Re: 120D PF tuning plan

Post by sonicvanman » Mon Jul 30, 2012 9:00 pm

geeto wrote:
In terms of decat pipes, there's one on Ebay for £130. It reads well but has anyone actually using one? I need to ask what diameter they are using as well.


then try to find a place which won't charge me as much for a 2.5" custom exhaust. I have a feeling that £270+vat included a silencer but I'm not 100%
Hello mate i've been looking at that de-cat but im undecided weather to fit it or not as im still unsure if it will be a problem come MOT time as i dont wana have to refit every year, but would love to get a couple more ponnys out, let me know if you go ahead & how you get on.

as for the exhaust, my custom 2.5" cat back NO silencers cost £400 so that a good price & if its priced with a silencer there isnt any need for any as it isnt loud loud but will allow enough grunt out to make you smile when you boot it.

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Re: 120D PF tuning plan

Post by marco_polo » Mon Jul 30, 2012 9:15 pm

A de-cat shouldn't effect the MOT test, it's only a soot test currently, no 'greenhouse' ( :roll: ) gasses checked.
Silver F21 M135i - ManBox - HK - Adaptive + Eibach Pro's - BBS CH-R's - BMWP Drexler LSD - TMC Piggyback - M4 LCA's - aFe Dry Filter

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Re: 120D PF tuning plan

Post by geeto » Mon Jul 30, 2012 10:02 pm

sonicvanman wrote:
Hello mate i've been looking at that de-cat but im undecided weather to fit it or not as im still unsure if it will be a problem come MOT time as i dont wana have to refit every year, but would love to get a couple more ponnys out, let me know if you go ahead & how you get on.

as for the exhaust, my custom 2.5" cat back NO silencers cost £400 so that a good price & if its priced with a silencer there isnt any need for any as it isnt loud loud but will allow enough grunt out to make you smile when you boot it.
Well I'm not 100% on going for the decat pipe just yet, if the seller can confirm its pipe diameter and its 2.5" i'm interested but if not i'll leave it!

Stan's decat pipe looks gorgeous but for £250+ I just can't justify it to be honest, I don't think the gains are worth that much sadly.

I'm going to give them another ring about the exhaust tomorrow as if they can do it for a little bit cheaper i'll have it :D
Tom

2006 Sparkling Graphite 120d M sport - All factory extras except sat nav!

- Custom Apexi Front mount IC
- 2.5" Turbo back SS exhaust
- EGR bypass kit
- Swirl flaps removed
- K & N filter
- Ecotune custom remap

222bhp / 477nm

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Re: 120D PF tuning plan

Post by sonicvanman » Tue Jul 31, 2012 4:55 pm

marco_polo wrote:A de-cat shouldn't effect the MOT test, it's only a soot test currently, no 'greenhouse' ( :roll: ) gasses checked.
isnt there a visual test coming in?
geeto wrote:Well I'm not 100% on going for the decat pipe just yet, if the seller can confirm its pipe diameter and its 2.5" i'm interested but if not i'll leave it!
let me know if you find out.

cheers

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Re: 120D PF tuning plan

Post by marco_polo » Tue Jul 31, 2012 4:58 pm

Do you mean a visual inspection of whether all the emissions crap is still fitted? I've heard whispers, yes. That would mean EGR deletes are a fail too, in theory.
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Re: 120D PF tuning plan

Post by sonicvanman » Tue Jul 31, 2012 8:56 pm

marco_polo wrote:Do you mean a visual inspection of whether all the emissions crap is still fitted? I've heard whispers, yes. That would mean EGR deletes are a fail too, in theory.
My EGR looks stock so should be ok, i may give the De-cat a go down the line.

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Re: 120D PF tuning plan

Post by danchapman » Tue Jul 31, 2012 9:51 pm

I'll be staying tuned to this thread as its pretty much everything I want to do to mine :)

Sonic, as you've got the egr by-pass, what have you used to blank the connection on the left with the weird jubilee clip on?


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Re: 120D PF tuning plan

Post by sonicvanman » Tue Jul 31, 2012 10:37 pm

danchapman wrote:I'll be staying tuned to this thread as its pretty much everything I want to do to mine :)

Sonic, as you've got the egr by-pass, what have you used to blank the connection on the left with the weird jubilee clip on?
Hello mate this is what i fitted & how it looks & fits
Image

Image

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Re: 120D PF tuning plan

Post by danchapman » Tue Jul 31, 2012 11:40 pm

sonicvanman wrote:
danchapman wrote:I'll be staying tuned to this thread as its pretty much everything I want to do to mine :)

Sonic, as you've got the egr by-pass, what have you used to blank the connection on the left with the weird jubilee clip on?
Hello mate this is what i fitted & how it looks & fits
Image

Image
Cheers matey, did you still get eml errors with that? Where did you buy from?


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