N54/N55 Stage 4 Fuel System Build

[Twinz]

This is more to start a discussion amongst those that have done this mod or planning to do it. Lessons learnt/tips etc.

I have done this FUEL-IT + custom mod a few years ago but have not read many that have done it.

So before i post up a technical DIY for archiving purposes just checking what the Eseries N54/N55 enthusiasts have done in this regard.

 

[Jive_E46]

It will be very interesting to see how South Africans fuel their N5x powered machines.

So my question is, does installing Water Methanol Injection take pressure of the fuelling system and does the WMI form part of the Stage 4 Fuel-It system ?

From my understanding WMI can be used to cool down and densify combustion OR it can add octane to the combustion. Assuming that this is the Stage 4 Fuel-It system we’re talking about, does that mean there’s port injection involved or throttle body injection over and above the flex fuel, upgraded LPFP, WMI?

Then again if you’re talking about such a complex fuelling system you’re probably running E85 only which could make WMI redundant.


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[General.Massacre]

IMO,
the Stage4 fueling depending's on your current, or future power levels.
There are a host of fueling options:
Port Injection rail for regular fuel, or E85.
Port Injection for Meth (nozzles tapped to the Intake runners)

Now, with PI, there is alot of options here as well, i know of an EU Z4 running 2 tanks in the boot, one for E85, and the other for Meth.
this allows the daily driving on regular fuel and not wasting E85 for daily, so its only on demand.

Also, Meth has more octane that Ethanol, (only slightly, but its still more). so hving PI Meth in the runners is beneficial to the Octane aspect, but so is having a nozzle in your charge pipe to aid the cooling aspect for lower IAT's. there is loads of threads on this topic for mixes/location etc, so wont go into it here.
But the fitment of PI opens up fueling to a whole new level, even on regular Stg2 Pumps, plus the additional of the Spool Performance HPFP x3/x4 overdrive upgrade pumps now available.

Keep in mind, the upgraded fuel pumps are REALLY only required due to the use of Ethanol. if you using only Pump fuel, and plan to PI your additional fuel by way of meth or E85 via a separate tank, then like me, a stock Fuel pump is still fine (i did 350wkw on stock Pump, with 16T china turbos at 18PSi on Jb4 and Pump BEF and pump fuel) my car has never seen the use of Ethanol in my ownership, and wont use it ever.

This topic can derail a fair bit, as the amount of directions fueling can cover is very expansive, and there will be a lot to cover.

 

[Twinz]

My approach to the DIY will be different from what you said but it does not matter.

I like the questions and ideas being put forward. Gives one a sense of what users are running or planning to do. So post away.

 

[General.Massacre]

My approach to the DIY will be different from what you said but it does not matter.

I like the questions and ideas being put forward. Gives one a sense of what users are running or planning to do. So post away.

Yea i fully understand.
with the vastness of options and explorables when it comes to fueling, and how to set it up, there is countless possibilities.

To name but a few off the top of my head, current options are:
-In-Tank upgraded Fuel Pumps (Bucketed or Bucketless depending on your use)
-Adding Surge Tank
-Port Injection via PI Rail or aftermarket manifold
-Port Meth
-Spool performance x3/x4 helix Overdrive for HPFP
-Flex Fuel configuration
-VTT Single or Double Barrell Shotgun system
-Direct Injection Delete for Regular port injection (not same as Port injected supplemented fueling)

As you said Twinz, your approach will be different to what I said. what one person chooses to do, maybe not work for, or agree with another persons uses or requirements.
So I am actually keen to see how this thread progresses, and it could be a valuable thread for the future.

 

[Dax]

Hi Twinz,

Once again this will be an excellent thread.

When building my car (Well still buzzy) I did not want to do away with the bucket due to my pursuit of a good all round car, Drags, Top end runs and most of all mountain passes.

What I did, kept the stock pump and added 2 x Walbro 450's, I had a custom bracket made to hold pumps (I have a pic) then a nice bracket so that the bucket holds everything in place. (no pic unfortunately)

The pumps are operated by the JB4 (This I don't like)

I am buzzy rebuilding and this time I am going to use a AEM fuel regulator and fit 6AN lines (Feed and return) my aim is to have 75/85 psi consistently feeding the system, this means all pumps will run all the time. The regulator has a 1:1 boost feed but I am not sure I want to use that.

I would trigger the 2 x Walbro 450's from the stock pump's power, this would free up the JB4 and have less wires running up and down the car.

The biggest problem I found was trying to get the fittings for the pumps and trying to get it all in the petrol tank, other than that it worked well.


your thoughts

Thanks

 

[Twinz]

Agree G.M there are so many ways to go about putting together fueling systems and having a clear goal what one wants to achieve is the starting point and of course what the budget is that one is prepared to spend.

Dax you have made some good progress already. I love the bucketless kit in your pic.

Guys, we should all be posting our own fueling technical DIY threads. There is clearly no single method that will suit all purposes and having various options is fantastic. In fact, one could even develop a hybrid kit from the various fueling solutions available.

 

[General.Massacre]

Hi Twinz,

Once again this will be an excellent thread.

When building my car (Well still buzzy) I did not want to do away with the bucket due to my pursuit of a good all round car, Drags, Top end runs and most of all mountain passes.

What I did, kept the stock pump and added 2 x Walbro 450's, I had a custom bracket made to hold pumps (I have a pic) then a nice bracket so that the bucket holds everything in place. (no pic unfortunately)

The pumps are operated by the JB4 (This I don't like)

I am buzzy rebuilding and this time I am going to use a AEM fuel regulator and fit 6AN lines (Feed and return) my aim is to have 75/85 psi consistently feeding the system, this means all pumps will run all the time. The regulator has a 1:1 boost feed but I am not sure I want to use that.

I would trigger the 2 x Walbro 450's from the stock pump's power, this would free up the JB4 and have less wires running up and down the car.

The biggest problem I found was trying to get the fittings for the pumps and trying to get it all in the petrol tank, other than that it worked well.


your thoughts

Thanks

Howsit bud, very nice set up so far. you obviously going with the Bucketed option, however, if you do decide on Bucketless one day, have you heard of the Holley Performance HydraMat kit to add In-Tank?

HydraMat - Holley Performance Products

The amazing HydraMat is a patent-pending fuel reservoir system designed to reduce fuel starvation issues present in hard cornering, acceleration, stopping, inclines, and low fuel conditions.

www.holley.com

they are pretty pricey, but probably one of the best pieces of technology to add to a fuel system, especially for racing when you want to save weight and run the most minimum amount of fuel where possible.

From their site:

"HydraMat​

The amazing HydraMat is a patent-pending fuel reservoir system designed to reduce fuel starvation issues present in hard cornering, acceleration, stopping, inclines, and low fuel conditions."

Over and above this, looking forward to seeing your project gain more headway.

 

[Dax]

Howsit bud, very nice set up so far. you obviously going with the Bucketed option, however, if you do decide on Bucketless one day, have you heard of the Holley Performance HydraMat kit to add In-Tank?

HydraMat - Holley Performance Products

The amazing HydraMat is a patent-pending fuel reservoir system designed to reduce fuel starvation issues present in hard cornering, acceleration, stopping, inclines, and low fuel conditions.

www.holley.com

they are pretty pricey, but probably one of the best pieces of technology to add to a fuel system, especially for racing when you want to save weight and run the most minimum amount of fuel where possible.

From their site:

"HydraMat​

The amazing HydraMat is a patent-pending fuel reservoir system designed to reduce fuel starvation issues present in hard cornering, acceleration, stopping, inclines, and low fuel conditions."

Over and above this, looking forward to seeing your project gain more headway.

interesting, I agree it is expensive but could solve a lot of space issues and make installing very easy if the right connectors are available .

My project is on hold, I bought a block from the USA and they sent the wrong bedplate with.

They have agreed to send another block with correct bedplate but not sure how long this will take.

 

[Dax]

Howsit guys,

I a hopefully going to complete fuel line upgrade this week if I can find all the fittings.

has anyone done a return line and if so where did you fit to the tank?



thank you

 

[Dax]

My planned setup,

1. Fuelit Line from tank to Flex Fuel sensor,
2. From sensor to regulator
3. Y piece after regulator to HPFP and PI
4. Return line from Regulator to Tank
5. In time I will fit a fuel pressure gauge switch to Regulator and have a gauge in the car

What I have also done is blocked off the line into throttle body that comes from the tank (scavenge air line) I will vent this to atmosphere, I believe these stupid things upset the vacuum in the car and with a return line I don't think a breather will be necessary

I will pull vacuum from manifold via a proper one way valve for the Low side oil Catch Can

 

[Twinz]

Love the plans Dax.
Yeah, those are all the things i have done as part of my stage 4+ setup and want to archive in a thread.

Let me see how this week goes to start writing up some.

If you using JB4 or MHD then you dont need a fuel pressure guage in the car because you can read the signal off the app.

 

[Dax]

Thanks Twins,

I would rather monitor Boost, Oil pressure and fuel pressure live on gauges and use JB4 for other critical monitoring

I have ordered one of these for the gauges, a bit old school but I dig it, I will use different gauges

 

[Twinz]

My 335i e90 set up looks like this:

Initially, I wanted to do the Stack gauges for Boost, Nitrous and exhaust gas temp (Egt).



But then settled on these. In the future I may want to go back to nitrous.

1. KW DDC suspension damper control switch
2. Exhaust Billet Automotive custom switch. Lights up when activated.
3. Burnout custom momentary push switch. Lights up when active.
4. Stack analogue boost gauge which also indicates vacuum on startup. Lights up with start up.
5. The housing for the gauges was carbon dipped.