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Old 05-06-2007, 11:01 AM
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Originally Posted by vrus View Post
Guys... Finny is one of those very very quiet guys who just happens to know alot more than he leads on.
OR maybe he's an AMG/ex mechanic? Finny's going to autograph his own engine...
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Old 05-06-2007, 11:14 AM
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2002 C230K, 2013 BMW 328, 2015 BMW X5
Damn, that was a great read, and even better, "car ****".

You the man.

E
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Old 05-06-2007, 04:36 PM
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A160 CLASSIC (The Tardis), VW Passat Diesel
awesome shots finny keep them coming... look fwd to seeing it all back together..
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Old 05-06-2007, 06:38 PM
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4 wheeled car.
Originally Posted by Finny View Post
What's "KRK monitors" ??? Computer monitor?
by monitor he meant speakers...
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Old 05-06-2007, 08:31 PM
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03 E55 AMG
Originally Posted by The Godfather View Post
by monitor he meant speakers...
Of course, sitting in the back ground...

-doh.jpg
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Old 05-06-2007, 08:34 PM
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03 E55 AMG
Originally Posted by WishforE55 View Post
look fwd to seeing it all back together..
+1
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Old 05-06-2007, 09:13 PM
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03 E55 AMG
Originally Posted by JamE55 View Post
OR maybe he's an AMG/ex mechanic? Finny's going to autograph his own engine...
No, unfortunately nothing to do AMG.

I used to design & build parts and service small to very large food processing machines from Germany & Switzerland some time ago. These days I run a small computer IT company and Rebuild Pinball machines for fun.

Anyone with basic mechanical skills can rebuild these engines until you hit the bottom end. This is where you obviously require a very skilled engine builder with specialized tools & machines. You can always sub contract these items out and do the final assembly yourself. A little tricky though.

If one dose attempt DIY, make sure you have WIS on hand.
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Old 05-06-2007, 09:24 PM
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Holy Cow, Finny!! YOU GOT NUTS!! I love it! Keep taking pics as you build it back up.
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Old 05-07-2007, 10:11 AM
  #59  
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awesome thread and pics!
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Old 05-07-2007, 04:15 PM
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A160 CLASSIC (The Tardis), VW Passat Diesel
WIS??? Love the see the dyno results when it is all back together and firing.... Did it take long to get the engine out??
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Old 05-07-2007, 09:41 PM
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2005 E55
Damn man! Nice job!

I'm a little freaked by that PCV issue. I have 18K miles on mine. Think it's already like that? Is it too late for the catch can mod?

I can't believe MB designed that so poorly...
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Old 05-08-2007, 12:54 AM
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2003 E55 AMG
Its never too late!

Also, there is a very simple way to clean out deposits from the engine... There are chemicals that you can buy that will do the trick, or just plain old distilled water..

A trick I've used many times in the past is:

- Go for a drive and once you come back pull the airbox off the car so that the TB is exposed. Its important that the car is at operating temperature when you do this.

- Pour some distilled water into a spray bottle

- With a helper in the car, have him rev the car to about 2,000RPM - 2500RPM (just enough to open the throttle plate a bit)..

- Mist the water into the throttle body.. Start off slowly and listen for the idle.. Keep misting into the TB until you go through 8oz of water.

- The water will immediately turn into steam when it enters the combustion chamber and will act as a cleaning solution to remove all the built up gunk.

- This is a benefit that people see who run water injection systems.. not only do you get the cooling effect, but the cleaning effect also.

Originally Posted by Scott in H-town View Post
Damn man! Nice job!

I'm a little freaked by that PCV issue. I have 18K miles on mine. Think it's already like that? Is it too late for the catch can mod?

I can't believe MB designed that so poorly...
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Old 05-08-2007, 03:29 AM
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No longer stock '06 E55, A3 3.2 Quattro, LRD4 HSE, R107 280SL


I neeeed my fix !!!!!

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Old 05-08-2007, 12:20 PM
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03 E55 AMG
Originally Posted by WishforE55 View Post
WIS??? Love the see the dyno results when it is all back together and firing.... Did it take long to get the engine out??
Workshop Information System or something like that. (Software)

About 4 hours to pull it out.
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Old 05-08-2007, 12:26 PM
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03 E55 AMG
Originally Posted by Scott in H-town View Post
Damn man! Nice job!

I'm a little freaked by that PCV issue. I have 18K miles on mine. Think it's already like that? Is it too late for the catch can mod?

I can't believe MB designed that so poorly...
You can find out by inspecting the chamber with a flexible bore scope. Most pro workshops or Aerospace mechanics will have them as there used to inspect inside turbine engines. The locksmith may have one too as they use them to crack safes.

After 18,000 miles or 29,000K's should be nothing like mine so get the catch can ASAP!

Last edited by Finny; 05-08-2007 at 12:30 PM.
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Old 05-10-2007, 09:58 AM
  #66  
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03 E55 AMG
Thumbs up Bypass Throttle Body Anatomy class.

G'day Fellers, here's another update....

There's been much chatter about the super charger by-pass throttle body being open or shut at different times making us paranoid about whether or not we're losing power.

To date... I've never seen a solution that can indicate in real time if this little T/B bludger is open or shut.

I suppose you could shove a stick up there and feel around but it could damage the charger... now we don't want to do that now do we! So I have a more simple solution... stick a magnet inside the by-pass so when the butterfly valve is shut it triggers a normally open reed switch contact closed where you can hook it up to a LED inside the cockpit.

See the following shots on how it was done.

I sourced the reed switch from a Burglar Alarm supply joint. The magnet and reed switch was stuck on with Loctite silicone. A Dremel was used to make a hole in the Butterfly cog. The photos are fairly self explanatory. I'm also going to add the LED to the boost indicator so can I see it all in one spot.

Was checking out Ebay recently and found the induction system of an E55 for 2k USD or landed to my door in Australia for $2850 Ausie Bux which I think is a bargain for a spare charger with all the bells and whistles... See photos... You never know what you'll find. Mmmm SLR Inter-coolers..... "SEARCH"

-55upgrade484.jpg

Engine mounts added and ready for next step...




Bypass Throttle Body. (note: This was off an 03 model, I know there are some that are covered in rubber)


-55upgrade490.jpg

Lid off, just remove the clips that snap off.


-55upgrade491.jpg

Lid exposing position potentiomitor and motor power sockets.


-55upgrade492.jpg

In the closed position.


-55upgrade493.jpg

Open position.


-55upgrade494.jpg

Cog removed, Magnet installed. In open position.


-55upgrade495.jpg

Closed position.


-55upgrade497.jpg

Goo added to Magnet.


-55upgrade498.jpg

Checking clearance.


-55upgrade499.jpg

Open and clearing.


-55upgrade500.jpg

Install cover and snap clips back on.


-55upgrade501.jpg

I closed the valve and positioned the reed switch so that it triggered right on the border of fully shut
then tacked the switch with Super glue then with Loctite silicone.


-55upgrade502.jpg

Continuity test. Open circuit.


-55upgrade504.jpg

Continuity, Closed circuit... Ahh... Beautiful!


-55upgrade507.jpg

All done!



-55upgrade485.jpg

Box from Ebay.


-55upgrade486.jpg

Surprise! one cheep Charger assembly... Cool!


-55upgrade487.jpg

Top condition.


-55upgrade488.jpg

Bum shot. To bad Victors T/B wasn't stuck on here... Dam!


More Later...

Last edited by Finny; 05-10-2007 at 10:02 AM.
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Old 05-10-2007, 10:27 AM
  #67  
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Finny,

Thanks for the pics. It's like watching a master AMG tech at work!

p.s. Incredible detailed pics btw.
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Old 05-10-2007, 10:51 AM
  #68  
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E-ZGO 53hp., 1999 E 430 sport, 2004 E 55, 2008 Tahoe LTZ on 24"s
Excellent post, Have you been reading my mind / old posts. Any way the bypass info is real important. I see the next big step to be much like the larger diesel engines. Goes like this Turbo charger to after cooler to supercharger to inercooler. The bottom end 1200-4500 is on the supercharger then as the turbo comes on the by pass opens, bringing on turbo boost from 4500-6000 and that bypass valve and the control of it is paramount, as it allows greater boost at the high end and reduces the approx 32HP to drive the S/C. Thanks for taking the time to post all the great pics and commentary. You are so on the right track.
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Old 05-10-2007, 11:32 AM
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2003 E55 AMG
Very nice Finny!!!! That is one definitive way of getting some answers.

What would it take to get you to leave Aussie land and come move to the nice cold north?? Would love to have you as a neighbour over here in Toronto.. Just think of all the mad things we could do!!
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Old 05-10-2007, 12:27 PM
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2003 E55
Great stuff!
Finny, can you show us where the bypass throttle valve is attached to the engine?
I assume it's wired to the ECU. What happens if its disconnected? Is it open or closed? I suppose your investigations will show us under what driving conditions its open and closed.
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Old 05-10-2007, 12:36 PM
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No longer stock '06 E55, A3 3.2 Quattro, LRD4 HSE, R107 280SL
What are those two things lying on top of the S/C (in the top condition picture) looks like a vacuum valves or something?
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Old 05-11-2007, 05:42 AM
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03 E55 AMG
Originally Posted by OzE55 View Post
Great stuff!
Finny, can you show us where the bypass throttle valve is attached to the engine?
I assume it's wired to the ECU. What happens if its disconnected? Is it open or closed? I suppose your investigations will show us under what driving conditions its open and closed.
The bypass is sandwiched between the S/C inlet and outlet to the rear just behind the main inlet T/B. You need to remove the whole S/C assembly to access the location.

I wouldn't suggest disconnecting the bypass as it's fully open when disengaged. Would be a good party trick If you really wanted to annoy someone though.

If I discover that there was premature power loss due to bypass activation, I'll then endeavor to correct the problem if any.


Originally Posted by stevebez View Post
What are those two things lying on top of the S/C (in the top condition picture) looks like a vacuum valves or something?
These are little vacuum activated valves used for the start up emissions blower. You know that vacuum cleaner noise you hear when you first start the beast after it's been sitting there for a while? These are part of that system.


Originally Posted by vrus View Post
Very nice Finny!!!! That is one definitive way of getting some answers.

What would it take to get you to leave Aussie land and come move to the nice cold north?? Would love to have you as a neighbour over here in Toronto.. Just think of all the mad things we could do!!
Well I'm doing my best to venture down that way this year, much beaver down that way?
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Old 05-11-2007, 03:03 PM
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03 E55 AMG
Thumbs up Supercharger Anatomy

You've just spent a stack of coin porting your heads to flow all that extra air and you wonder... am I maximizing my investment in the heads only to be choked by supercharger apparatus?

Well there is a little more you can do to improve the induction. Although were fighting over crumbs here, I think that every bit of effort in aiding the flow helps. Read on for my 2 cents worth...


-55upgrade509.jpg
Lets pop off the lid and have a look inside. That freekin clutch is heavy!


-55upgrade506.jpg
Nice helical gears. The one on the right is interchangeable. Mmmm Interesting.


-55upgrade513.jpg
Lets have a look in here too.


-55upgrade508.jpg
Helical macro shots.

-55upgrade510.jpg
-55upgrade511.jpg


-55upgrade507-1.jpg
This one has been pinned to stay.


-55upgrade512.jpg
Just speculating here... Maybe the SLR's gear is larger and the one on the main side smaller as there is more room around the case for improvement?
Interesting though...


-55upgrade514.jpg
Inlet side of rooters


-55upgrade515.jpg
Inlet side of charger. I haven't investigated this part yet but I reckon more meat can come off here.

-55upgrade516.jpg
To the top is the outlet section. Compression occurs down that barrel.

-55upgrade517.jpg
I don't think a bee's dick will fit between there?


-55upgrade518.jpg
Outside of inlet. Yeah... more meat can come off here!


-55upgrade519.jpg
With all the bits off it's surprisingly light.


-55upgrade520.jpg
The next 3 shots show where some flow improvement can be made. The lower outlet lip can have a shave to help flow.


-55upgrade521.jpg
Here is one of the biggest offenders. See that extra meat around the gasket.. Chop Chop.


-55upgrade522.jpg
Next victim... I'm going to shave this too so it matches the out let manifold. Cutting back too much this way is counter
productive because the compression occurs in the barrel above. I'm just going to remove that rectangular bit sticking
out to match the manifold.


-55upgrade523.jpg
Looking from the rear in. The opposite side of that rectangular bit.


-55upgrade524.jpg
Arrow above is the S/C case and the one just below is the outlet manifold. A big Chop Chop here too! 2 or 3mm along this edge.


-55upgrade525.jpg
How they sit together.

Last edited by Finny; 05-11-2007 at 03:12 PM.
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Old 05-11-2007, 03:06 PM
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03 E55 AMG
-55upgrade526.jpg

-55upgrade527.jpg
Chop Chop here!


-55upgrade528.jpg
And here...


-55upgrade529.jpg
Output side.


-55upgrade530.jpg
This is where the positive air pressure out sensor is mounted.


-55upgrade536.jpg
I can't believe the size of that lug mount inside.. Chop Chop!



-55upgrade531.jpg
This is the base of the air temperature out sensors home. Another unnecessary obstruction... Chop Chop!


-55upgrade532.jpg
I think a hole saw and a die grinder should do the trick here.


-55upgrade533.jpg
The other side. Once this is gone, there should be a little more flow gained here.


-55upgrade534.jpg


-55upgrade535.jpg
A little bit of work to be done here too. The intercooler core, the worst offender of all, Chop Chop Chop!!!!


More to come soon...
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Old 05-11-2007, 03:38 PM
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E-ZGO 53hp., 1999 E 430 sport, 2004 E 55, 2008 Tahoe LTZ on 24"s
Thanks Finny,
You should be on Speed Channel, I can see it now "THE FINNY SHOW"
BTW that S/C is clean, is that the E-bay one?
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