82mm throttle body and 80mm y pipes fitment HELP!
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Senior Member
Joined: Dec 2007
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From: Dago, CA
2003 cl55 (sold)
82mm throttle body and 80mm y pipes fitment HELP!
Have the Mercedes 82mm throttle body and 80mm y pipes. How did you guys get it to fit? It doesn't fit exactly no matter what I tried: rightside up, upside down, no rubber gasket (but I think you need it to stop air leak), etc. Do you just force the thing on there? Any help would be appreciated.
Thread Starter
Senior Member
Joined: Dec 2007
Posts: 472
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From: Dago, CA
2003 cl55 (sold)
The only way I can get it to kinda fit is: No plastic ring piece, gasket inverted, then it slides onto the y pipes. But it is fairly loose. It doesn't really stay in there firmly, the clasps on the y pipes don't clasp and it seems like the rubber gasket could be moved around fairly easily and upset the whole applecart (like a strong pothole or something) and move on the throttle body and allow air in. Or air could still come in where the larger rubber gasket meets up with the y pipes.
I haven't tried it on the car yet, and it may be different once installing and the whole y pipes and tubes are held down, but I'm still not comfortable with it. I can tell it very well may be a problem.
I need a way to clamp that inverted rubber gasket in place so it doesn't move and something to allow a tighter fit of the rubber gasket onto the y pipes without the plastic ring part. Or something on the outside to clamp both the rubber gasket and the y pipes......
Last edited by jicl55; Apr 8, 2010 at 12:53 PM.
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Thread Starter
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Joined: Dec 2007
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From: Dago, CA
2003 cl55 (sold)
A heat shield that could match up with the front somewhere and help seal in the cone filter would be great, but not a lot of space. Of course, I always thought that a custom hood with some huge openings near the throttle body and mated to some pipes would do the trick nicely, but fairly involved and rain just might be your worst nightmare.
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Joined: Jul 2005
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From: London, UK
No longer stock '06 E55, A3 3.2 Quattro, GLE 400d, R107 280SL, Golf Polo
Anyone modify their VRUS "80mm" CF air boxes for the 82 mm TB?
I suppose a gasket attached with sealant to the larger airbox bore should do the trick?
Question is how to get a nice clean circle on the CF air box... guess sanding drum and a good template probably easiest.
The other issue is getting the TB to fit properly onto the s/c adaptor housing and providing enough space for the CF AB to fit on ok. Using an adaptor plate will take up too much space ... need TB to fit flush with S/C housing.
I think for this diff in diam I am not sure its worth this amount of work... and problems.
I suppose a gasket attached with sealant to the larger airbox bore should do the trick?
Question is how to get a nice clean circle on the CF air box... guess sanding drum and a good template probably easiest.
The other issue is getting the TB to fit properly onto the s/c adaptor housing and providing enough space for the CF AB to fit on ok. Using an adaptor plate will take up too much space ... need TB to fit flush with S/C housing.
I think for this diff in diam I am not sure its worth this amount of work... and problems.
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haters crazy
Anyone modify their VRUS "80mm" CF air boxes for the 82 mm TB?
I suppose a gasket attached with sealant to the larger airbox bore should do the trick?
Question is how to get a nice clean circle on the CF air box... guess sanding drum and a good template probably easiest.
The other issue is getting the TB to fit properly onto the s/c adaptor housing and providing enough space for the CF AB to fit on ok. Using an adaptor plate will take up too much space ... need TB to fit flush with S/C housing.
I think for this diff in diam I am not sure its worth this amount of work... and problems.
I suppose a gasket attached with sealant to the larger airbox bore should do the trick?
Question is how to get a nice clean circle on the CF air box... guess sanding drum and a good template probably easiest.
The other issue is getting the TB to fit properly onto the s/c adaptor housing and providing enough space for the CF AB to fit on ok. Using an adaptor plate will take up too much space ... need TB to fit flush with S/C housing.
I think for this diff in diam I am not sure its worth this amount of work... and problems.
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E55
Received your PM, I'll send them out today.
"The other issue is getting the TB to fit properly onto the s/c adaptor housing and providing enough space for the CF AB to fit on ok. Using an adaptor plate will take up too much space ... need TB to fit flush with S/C housing".
Who says you need to use an adapter plate?
"The other issue is getting the TB to fit properly onto the s/c adaptor housing and providing enough space for the CF AB to fit on ok. Using an adaptor plate will take up too much space ... need TB to fit flush with S/C housing".
Who says you need to use an adapter plate?
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From: Texas
2003 CL55
I also have a CF airbox and use the inverted rubber gasket for it.. I also ported the neck of the air box to fit over my 82mm TB and used a die grinder with 2" round sanding tool.. It is not a flat sanding bit but a cylinder sanding bit.. Took about 2mm out of the OD, as I recall but not all the 82mm TB have the same outside diameter.. Mine is a mercedes 82mm and has same 82mm Id but smaller OD lip.. Some of the Bosch are pretty thick on the OD..
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E63 Biturbo, UPD Cold Air induction kit, UPD performance crank pulley and UPD adjustable rear suspension with ride height adjustment.
CL55 UPD Cold Air Boost kit, UPD 3000 stall converter, UPD 77mm SC clutched pulley and beltwrap kit, Custom long tubes, UPD crank pulley , UPD suspension kit, UPD SC pulley, Aux. HE, Trunk tank w/rule 2000 pump, Mezeire pump, UPD 5pc idler set, Aluminum rotor hats.
www.ultimatepd.com
instagram @ultimate_pd
facebook.com/ultimatepd
MBWorld Fanatic!
Joined: Jul 2005
Posts: 3,174
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From: London, UK
No longer stock '06 E55, A3 3.2 Quattro, GLE 400d, R107 280SL, Golf Polo
Received your PM, I'll send them out today.
"The other issue is getting the TB to fit properly onto the s/c adaptor housing and providing enough space for the CF AB to fit on ok. Using an adaptor plate will take up too much space ... need TB to fit flush with S/C housing".
Who says you need to use an adapter plate?
"The other issue is getting the TB to fit properly onto the s/c adaptor housing and providing enough space for the CF AB to fit on ok. Using an adaptor plate will take up too much space ... need TB to fit flush with S/C housing".
Who says you need to use an adapter plate?
MBWorld Fanatic!
Joined: Jul 2005
Posts: 3,174
Likes: 19
From: London, UK
No longer stock '06 E55, A3 3.2 Quattro, GLE 400d, R107 280SL, Golf Polo
I was using the inverted rubber gasket trick had no issues with that but took Amhad`s advice and did the "trim the inner ring" trick and it is a nice clean stock seal now.. Very easy and only had to remove a very small amount of the ring.. This is for my stock air boxes.
I also have a CF airbox and use the inverted rubber gasket for it.. I also ported the neck of the air box to fit over my 82mm TB and used a die grinder with 2" round sanding tool.. It is not a flat sanding bit but a cylinder sanding bit.. Took about 2mm out of the OD, as I recall but not all the 82mm TB have the same outside diameter.. Mine is a mercedes 82mm and has same 82mm Id but smaller OD lip.. Some of the Bosch are pretty thick on the OD..
I also have a CF airbox and use the inverted rubber gasket for it.. I also ported the neck of the air box to fit over my 82mm TB and used a die grinder with 2" round sanding tool.. It is not a flat sanding bit but a cylinder sanding bit.. Took about 2mm out of the OD, as I recall but not all the 82mm TB have the same outside diameter.. Mine is a mercedes 82mm and has same 82mm Id but smaller OD lip.. Some of the Bosch are pretty thick on the OD..
Many, many thanks. 
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Joined: Mar 2009
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From: Knoxville, TN
E55, Supercharged Z4 (sold)
Is the inlet for these a stock 74mm inlet bored to 82mm? Or is it off another car? Seems to me you could use an 82mm throttle body and a custom Y-Pipe made from silcone or perhaps steel/aluminum piping. Any decent fabricator should be able to do that no?
Just thinking out loud. I'm not sure I want to buy an 82mm kit if I can make it "better" fairly easily and cheaper.
Just thinking out loud. I'm not sure I want to buy an 82mm kit if I can make it "better" fairly easily and cheaper.
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Joined: Apr 2009
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E55
Here's the part # for anyone interested; Part Number: 90025K396
Purchased from McMaster.com
10 o-rings come in the package, you need only two for each application. Remove the plastic retainer and rubber seal from the y-pipe, replace with two new quad style o-rings, and assemble.
Note: This is for the MB 82mm throttle being used in conjunction with the 80mm y-pipe.
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'18 AMG GTR, '04 CL55, '04 E55, '03 CLK500, '01 E55,94 E500, '91 190E 2.5-16 EVOII, '86 560SL
Here's the part # for anyone interested; Part Number: 90025K396
Purchased from McMaster.com
10 o-rings come in the package, you need only two for each application. Remove the plastic retainer and rubber seal from the y-pipe, replace with two new quad style o-rings, and assemble.
Note: This is for the MB 82mm throttle being used in conjunction with the 80mm y-pipe.
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E55
Honestly I haven't mic'd the 74mm Y-pipe, but I imagine it is smaller then the 80mm version. I would be hesitant to use anything smaller than the 80mm as there is a slight step going from the y-pipe to the throttle body when using the 80mm version.
That said, If you want to mic it and post the measurements, we might be able to find a solution for you.
That said, If you want to mic it and post the measurements, we might be able to find a solution for you.
MBWorld Fanatic!
Joined: Apr 2009
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E55
Gains would depend on your specific mods, engine health, tune, etc. For comparison, Alan reported about 25hp on a heat soaked motor, iirc.
Also, keep in mind you are actually upgrading from a 78mm(80mm true measurement) when you go this route.
Also, keep in mind you are actually upgrading from a 78mm(80mm true measurement) when you go this route.
