My upgraded fuel system
Thread Starter
Super Member
Joined: Apr 2009
Posts: 837
Likes: 1
From: Tacoma WA
Bicycle
most of what u are doing is over my head and beyond my comprehension so i apologize if this question sounds offensive - im just naive. what exactly r u looking to accomplish with this mod? is there that much to be had power-wise to justify such a seemingly drastic and extensive project? or is it just for fun?
Part 2
Its amazing how one thing leads to another. I'm sure after building an engine you know what I mean. there is no such thing as a drop in fuel pump upgrade and the big bosch's wont fit in the tank, so then that means you have mount them out side, but now the fuel line wont work that way so you have to run new line but the new line wont connect to the rail and now that you by passed the stock pumps the stock fliter and regulator are by passed so that means you need new ones of those. as you see it grows and grows and grows. This is hands down by far the most money spent on a mod to date.
Last edited by sneakyneon; Jul 16, 2010 at 09:21 PM.
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Joined: Aug 2005
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From: Southern Cali (Ontario)
195mm pulley
85mm TB (82 bored)
Short headers that are less than desirable, no cats 3 inch into magnaflows
Some light port matching and blending on the tanks and IC
Water/meth
rear mount water tank
OE tunned (after one flash it was out of fuel)
My CAI has not proved any HP gain but no loss either so if anything its sounds cool!! lol
Crank case Evac
Fuel and more fuel
Intake/SC thermal spacers
I basical do all of the work my self, mostly out of poverty
I have two things that I really want to do, Long tube headers and a quife. Maybe fine tune the tune a bit.
Best pass has been 11.28 @ 128 I think theres more in her now the fuel is done.
85mm TB (82 bored)
Short headers that are less than desirable, no cats 3 inch into magnaflows
Some light port matching and blending on the tanks and IC
Water/meth
rear mount water tank
OE tunned (after one flash it was out of fuel)
My CAI has not proved any HP gain but no loss either so if anything its sounds cool!! lol
Crank case Evac
Fuel and more fuel
Intake/SC thermal spacers
I basical do all of the work my self, mostly out of poverty
I have two things that I really want to do, Long tube headers and a quife. Maybe fine tune the tune a bit.
Best pass has been 11.28 @ 128 I think theres more in her now the fuel is done.
128 is no joke..
what kind of shortys do you have..? thats my next mod for sure.
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shrimp boat
Do you care to elaborate on how you get rid of those valves? I wanted too, but don't know what to do with the holes. Anyway, keep up the good job.
Thread Starter
Super Member
Joined: Apr 2009
Posts: 837
Likes: 1
From: Tacoma WA
Bicycle
A pic is worth....
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Thread Starter
Super Member
Joined: Apr 2009
Posts: 837
Likes: 1
From: Tacoma WA
Bicycle
Its an EGR valve or some other fancy name MB gives it but it take hot exh and recerulates it back into the SC. There are plenty of info on the web about both good and bad with removing a egr valve, The car should throw code but it has not, it maybe its in the tune or mb has a low valve in the ecu and basicaly dose not check?
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Joined: Dec 2006
Posts: 1,124
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From: Florida-Germany-New York
2004 E55,1969 300SEL6.3,2011 ML350 BlueTec Diesel,2005 ML400 CDI
No offence at all!, The answear is 2 parts, On the dyno there was a big dip in power at 4500 to redline, and no matter how much fuel we put at it it the afrs still creeped up. We figured it most lickly was a weak pump. So you say how much power are we taking? Its just a guess, but a rather fast E55 was there the same day and I have a bigger pulley and bigger TB but he had cams and LT and made 60+ more than me wile down low before 4500 our curves were very similar and I made a bit more peak TQ. If it is fuel this should fix it if not than I suspect that my headers are to blame.
Part 2
Its amazing how one thing leads to another. I'm sure after building an engine you know what I mean. there is no such thing as a drop in fuel pump upgrade and the big bosch's wont fit in the tank, so then that means you have mount them out side, but now the fuel line wont work that way so you have to run new line but the new line wont connect to the rail and now that you by passed the stock pumps the stock fliter and regulator are by passed so that means you need new ones of those. as you see it grows and grows and grows. This is hands down by far the most money spent on a mod to date.
Part 2
Its amazing how one thing leads to another. I'm sure after building an engine you know what I mean. there is no such thing as a drop in fuel pump upgrade and the big bosch's wont fit in the tank, so then that means you have mount them out side, but now the fuel line wont work that way so you have to run new line but the new line wont connect to the rail and now that you by passed the stock pumps the stock fliter and regulator are by passed so that means you need new ones of those. as you see it grows and grows and grows. This is hands down by far the most money spent on a mod to date.
Thread Starter
Super Member
Joined: Apr 2009
Posts: 837
Likes: 1
From: Tacoma WA
Bicycle
First let me say that your fabrication and workmanship looks absolutely 1st class. However, I was wondering why an in-line boost pump (ie Bosch o44) in the feed line to the engine rail would not provide adequate flow and pressure? You must have already considered such an option as not to be a solution. My thoughts would be that with the existing dual pumps there should be enough capacity at the pumps themselves. Naturally there will be losses to pressure and flow based on line diameter and length, but that's why I thought a properly placed boost pump could maintain the necessary flow and pressure. What piece of the puzzle am I missing here?
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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
Super install and some great clean work there... 
One thing that has me a little concerned is the proximity of the open +ve lead of the right side pump to the mounting bracket... mbe the photo angle is exaggerating it a touch but mbe a boot to cover the power lead attachment on the pump?
I am curious why others running 550rwp+ have not had this fuel shortage issue... ? Is this mbe not an ECU / tuning thing or fuel line pressure / injector issue?
You got some super mods ...
One thing that has me a little concerned is the proximity of the open +ve lead of the right side pump to the mounting bracket... mbe the photo angle is exaggerating it a touch but mbe a boot to cover the power lead attachment on the pump?
I am curious why others running 550rwp+ have not had this fuel shortage issue... ? Is this mbe not an ECU / tuning thing or fuel line pressure / injector issue?
You got some super mods ...
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Joined: May 2009
Posts: 1,484
Likes: 13
From: Abu Dhabi
C218 CLS63TT PP Edition1, W213 E63S
Its an EGR valve or some other fancy name MB gives it but it take hot exh and recerulates it back into the SC. There are plenty of info on the web about both good and bad with removing a egr valve, The car should throw code but it has not, it maybe its in the tune or mb has a low valve in the ecu and basicaly dose not check?
so it makes the S/C sucks some hot air, and removing them may make the IAT a bit cooler ??
there is no harm in removing them right ?
Super Member
Joined: Aug 2006
Posts: 856
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From: palm beach
CLS55 & CL CK60
Perhaps it is coincidence but I am in the 550+ club and I am having an issue in 3rd and 4th gear WOT that seems like a fuel issue. When I am WOT I get some sort of sputter and have been advised that it may be me running out of fuel. It typically only lasts a short period of time (1/2 second to a full second) and then the resumes its usual power but for that little period of time I am losing power and car seems likes its choking. It will be definitive this week as Jeremy is coming down and it will be on the dyno. Perhaps a fuel system upgrade is in my future.
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Joined: Jan 2007
Posts: 2,597
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From: Kuwait
CLS55 2006, CLS 63S 2015
Perhaps it is coincidence but I am in the 550+ club and I am having an issue in 3rd and 4th gear WOT that seems like a fuel issue. When I am WOT I get some sort of sputter and have been advised that it may be me running out of fuel. It typically only lasts a short period of time (1/2 second to a full second) and then the resumes its usual power but for that little period of time I am losing power and car seems likes its choking. It will be definitive this week as Jeremy is coming down and it will be on the dyno. Perhaps a fuel system upgrade is in my future.
Out Of Control!!
Joined: Feb 2003
Posts: 13,489
Likes: 96
haters crazy
Perhaps it is coincidence but I am in the 550+ club and I am having an issue in 3rd and 4th gear WOT that seems like a fuel issue. When I am WOT I get some sort of sputter and have been advised that it may be me running out of fuel. It typically only lasts a short period of time (1/2 second to a full second) and then the resumes its usual power but for that little period of time I am losing power and car seems likes its choking. It will be definitive this week as Jeremy is coming down and it will be on the dyno. Perhaps a fuel system upgrade is in my future.
MBWorld Fanatic!
Joined: Jan 2007
Posts: 2,597
Likes: 19
From: Kuwait
CLS55 2006, CLS 63S 2015
Member
Joined: Aug 2009
Posts: 191
Likes: 2
13 E63
Very nice work and I understand how one thing led to another in this process.
I have a question on the stock system. Does the stock system have the single feed line to the engine and NO return line?
I understand the stock fuel pressure regulator is located in the tank with the pump. If this is the case, MB decided to comply with the 2005 US EPA mandate to eliminate the fuel return line from the engine. IMHO this is a major flaw in a performance vehicle and a big stress on the fuel delivery components which now have to be limited in the fuel tank. The fuel pressure regulator needs to be at the engine just after the fuel rail and the fuel pump must be allowed to flow constant pressure and volume to provide the needed flow and volume to the engine at pleak loads.
Again, nice work.
We just got ours back from the dealer from a repeated failure of the level sensor leaking and I have started to look into why the E55 is having this problem.
I have a question on the stock system. Does the stock system have the single feed line to the engine and NO return line?
I understand the stock fuel pressure regulator is located in the tank with the pump. If this is the case, MB decided to comply with the 2005 US EPA mandate to eliminate the fuel return line from the engine. IMHO this is a major flaw in a performance vehicle and a big stress on the fuel delivery components which now have to be limited in the fuel tank. The fuel pressure regulator needs to be at the engine just after the fuel rail and the fuel pump must be allowed to flow constant pressure and volume to provide the needed flow and volume to the engine at pleak loads.
Again, nice work.
We just got ours back from the dealer from a repeated failure of the level sensor leaking and I have started to look into why the E55 is having this problem.
Thread Starter
Super Member
Joined: Apr 2009
Posts: 837
Likes: 1
From: Tacoma WA
Bicycle
There is no return from the fuel rail just a single in.
Very nice work and I understand how one thing led to another in this process.
I have a question on the stock system. Does the stock system have the single feed line to the engine and NO return line?
I understand the stock fuel pressure regulator is located in the tank with the pump. If this is the case, MB decided to comply with the 2005 US EPA mandate to eliminate the fuel return line from the engine. IMHO this is a major flaw in a performance vehicle and a big stress on the fuel delivery components which now have to be limited in the fuel tank. The fuel pressure regulator needs to be at the engine just after the fuel rail and the fuel pump must be allowed to flow constant pressure and volume to provide the needed flow and volume to the engine at pleak loads.
Again, nice work.
We just got ours back from the dealer from a repeated failure of the level sensor leaking and I have started to look into why the E55 is having this problem.
I have a question on the stock system. Does the stock system have the single feed line to the engine and NO return line?
I understand the stock fuel pressure regulator is located in the tank with the pump. If this is the case, MB decided to comply with the 2005 US EPA mandate to eliminate the fuel return line from the engine. IMHO this is a major flaw in a performance vehicle and a big stress on the fuel delivery components which now have to be limited in the fuel tank. The fuel pressure regulator needs to be at the engine just after the fuel rail and the fuel pump must be allowed to flow constant pressure and volume to provide the needed flow and volume to the engine at pleak loads.
Again, nice work.
We just got ours back from the dealer from a repeated failure of the level sensor leaking and I have started to look into why the E55 is having this problem.
