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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > N54 Turbo Engine / Drivetrain / Exhaust Modifications - 335i > Vishnu/FFTEC: FlexFuel is Finally Here (425+whp dyno and logs)



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      08-10-2012, 01:24 PM   #1
shiv@vishnu
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Vishnu/FFTEC: FlexFuel is Finally Here (425+whp dyno and logs)



N54 users can now have True Flex-Fuel functionality!

What this means that you can now run any mixture of E85 and have the PROcede adjust the tune accordingly. This is made possible by integrating a Siemens Fuel Composition Sensor (aka Flex-Fuel sensor) to the PROcede. With it able to accurately monitor ethanol content, the PROcede will advance ignition advance, enlean AFR targets and raise boost as a function of fuel composition.

The Vishnu/FFTECFlexFuel conversion kit includes:
-FlexFuel Sensor
-Mounting bracket
-Plug-and-play fuel lines
-Plug-and-play wiring harness
-PROcedeFlash DME reflash

The last bit is one of the more interesting components of the system. The reflash removes some of the fuel limitations in the DME. Along with the PROcede's open loop fuel adjustments, fuel system capacity is raised considerably. This means that you won't see maxed out fuel trims or fuel rail pressure codes on the stock turbos. Even running upwards of 20psi. For now, you will need to send your DME to us for the same-day reflashing service. But later, this may change

For more information, you can visit the Flex-Fuel Conversion page on our website HERE. It's still under construction so expect more information to be added over the next few days.

Here is a dyno result running a 60% Ethanol mix (50/50 e85/91oct).

2007 335i 6AT (only DCI+FMIC) No meth. 100% stock exhaust.


Datalogs:









At full boost:
-Fuel trims at full boost are stable in the 10-20% range.
-Ignition advance is in the 12-16 deg range, reducing gradually as IAT increases
-AFR is in the mid to low 12s

Last edited by shiv@vishnu; 08-10-2012 at 02:18 PM.
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      08-10-2012, 01:28 PM   #2
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Here's another dyno results (60% ethanol) from a 2008 6AT with ONLY DCIs. Stock everything else. No meth.

Stock cars routinely make 275whp on this dyno.

And with AFR and Boost logged on our Mustang Dyno:

Last edited by shiv@vishnu; 08-10-2012 at 01:39 PM.
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      08-10-2012, 01:29 PM   #3
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HOLY SHEET.... i gotta ask man... what about n55??? i'm dying out here to try this
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      08-10-2012, 01:32 PM   #4
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E85 appears to be making some great numbers on this platform.
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      08-10-2012, 01:34 PM   #5
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Hey Shiv, is that on the beta E85 maps that are in 5.23 or are these "soon to be released maps"?
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      08-10-2012, 01:35 PM   #6
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SWEET MUTHA!! The N54 and E85!!
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      08-10-2012, 01:37 PM   #7
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These numbers are unreal! Impressive gains indeed
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      08-10-2012, 01:37 PM   #8
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Hi guys- These results are from customers cars running our new FlexFuel conversion kit (fuel composition sensor+DME update+new Procede firmware/maps). I'll have more info to post up later this weekend

BrianNM has been secretly testing a similar set-up for the past couple of weeks as well.

Last edited by shiv@vishnu; 08-10-2012 at 01:47 PM.
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      08-10-2012, 01:42 PM   #9
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incredible results
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      08-10-2012, 01:43 PM   #10
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Interesting stuff!

Nice peak numbers.
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      08-10-2012, 01:44 PM   #11
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So, the first dyno is of two different cars?
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      08-10-2012, 01:48 PM   #12
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2 questions:

1. How did you arrive at 60% ethanol content? Wouldn't 50/50 e85/91 equal = 0.5*85% + 0.5*10% = 47.5% ethanol content?

2. In what gear were the dyno pulls done?
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      08-10-2012, 01:49 PM   #13
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It will be interesting to see what an FBO car can do with this. Between the single turbo, and the E85 developments, there should be some amazing track numbers popping up soon!
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      08-10-2012, 01:51 PM   #14
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Quote:
Originally Posted by GeorgiaTech335coupe View Post
2 questions:

1. How did you arrive at 60% ethanol content? Wouldn't 50/50 e85/91 equal = 0.5*85% + 0.5*10% = 47.5% ethanol content?

2. In what gear were the dyno pulls done?
The fuel composition sensor indicated 60% ethanol content. I suspect our CA91 gasoline has a bit more ethanol in it than advertised. And e85 can have up to 90% ethanol depending on location and season.

All dyno runs were done in 4th gear as usual.

Shiv
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      08-10-2012, 01:55 PM   #15
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Quote:
Originally Posted by pentaxis View Post
It will be interesting to see what an FBO car can do with this. Between the single turbo, and the E85 developments, there should be some amazing track numbers popping up soon!
We have tested this setup on Presidio335xi's FBO car. Unfortunately, it is an XI which means that we can't do any direct apples-to-apples dynojet testing. And also unfortunate is the fact that the clutch is slipping since it was probably making over 500lb-ft of torque with some of the earlier very aggressive maps. He will be getting a new clutch installed soon and we will be able to dyno it once again with the current maps.

That said, I'd expect to see a FBO car making 440-445whp and at least 475lbft of torque at 60% ethanol content.
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      08-10-2012, 01:58 PM   #16
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very interested! patiently waiting for vishnu to take my money and DME!
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      08-10-2012, 02:03 PM   #17
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Absolutely. Insane. Good job Shiv!
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      08-10-2012, 02:06 PM   #18
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Thanks for the kind words guys. This is something that we've been working on for quite some time. It's nice to finally let you guys in on this little secret. It really does make a flexfuel 335i a reality
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      08-10-2012, 02:10 PM   #19
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      08-10-2012, 02:12 PM   #20
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If we have rev 2.5 are we still able to do this? How much for the Flex Fuel upgrade? What about other aspects of the fuel system? I thought for true Flex Fuel capability that certain components (besides the sensor) were required because high levels of ethanol will break down hoses and fuel system components. Is this any risk or issue that we need to accept?

Thanks. Nice work!
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      08-10-2012, 02:18 PM   #21
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So you can successfully run 100% E85 with no side effects? (short of idling issues).
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      08-10-2012, 02:28 PM   #22
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Quote:
Originally Posted by N54_Fan View Post
If we have rev 2.5 are we still able to do this? How much for the Flex Fuel upgrade? What about other aspects of the fuel system? I thought for true Flex Fuel capability that certain components (besides the sensor) were required because high levels of ethanol will break down hoses and fuel system components. Is this any risk or issue that we need to accept?

Thanks. Nice work!
All our development thus far has been on a Rev3. It made the most sense since it has the most i/o channels. With it, one doesn't have to give up other functionality when adding the Flex-Fuel sensor. We may eventually port functionality over to the Rev2.5 but it will require some more work due to limitations. You would have to give up the ability to run PWM meth (which, as we will soon demonstrate) is of significant value when running e85.

As for fuel system compatibility with e85, everything looks good so far. Many people have been running strong e85 mixtures for quite some time. With our testing, we have routinely inspected fuel lines for any signs of premature wear/deterioration and no issues. Not surprising since most modern fuel systems are e85 compatible.
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