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Discussion Starter #1 (Edited)
Its been 2 FULL weeks since Active Autowerke started working on my M6.

Before I get started, I just wanted to direct anyone interested in my vehicle's cam progress to my previous thread that I started back on December 1st, 2006. This way, you guys can get an overview of the preparation I went through before Active started on my car. Here is the thread:

http://www.m5board.com/vbulletin/showthread.php?t=85676

Even though I asked Active to take photos of the install as it progressed, they were so focused on the job; they didn’t even end up of taking photographs at all! Sorry guys....no pictures! :sad1:

Anyhow.....here are the latest updates on my car thus far:


Using the BMW instructions, the required special tool set, and replacement gaskets I provided, Active began breaking down the engine for the cam upgrade. Shortly after they started, they realized that I never provided them with the instructions for the vanos adjustments required to complete the install! So, they had to do some research and picked up the additional required documentation to continue the job.

The install moved along and the driver’s side cams were pulled and replaced without any issues. But when it came time to pull the final cam on the passenger side, for some reason, the special jig wouldn’t fit over the cam to remove it. Active spent two days between repair books and speaking to some of their contacts at BMW before they came to realize that the 4th cam on my car was never aligned correctly from the factory! Therefore, it couldn’t be removed with the special tools through conventional means.

Here was the email Karl from Active sent to me last week:

"...Scrappy and I are still here working on your car, we did the driver's side cams quite easily, but the passenger side is giving us a warm time. We were here on Tuesday night as well. We are taking our time to check, double check, triple check everything and that is why we are taking so long. The problem we encountered on the passenger side cams was the factory alignment of the exhaust camshaft was off, the jigs would not fit and after trying like 4 times we came to the conclusion that the vanos gears were never aligned properly from the very beginning. So here we are on Wednesday night making our own special tools to take apart the vanos cam helical gears to align them before installing. We are getting somewhere!!......"

GEEZE! This means my car was never running the way it should have been from the very instant I drove it off the lot!

After picking apart a number of dyno runs I located online, I noticed my stock DynoJet dyno pass at 422 to the wheel with the carbon air filters removed was about 10 whp lower than what most of the other M5s & M6s were putting down. Even my latest DynoJet pass at 459 WHP after the SS headers & cats w/ AA ECU seemed a bit off when compared to another M5 with the similar mods.

After discussing this issue over with Active last week on Friday, we figured we may very well see "higher than normal gains" from the cam upgrade since the last dyno pass was run with the incorrect stock cam timing.

So, I waited for the weekend to pass and called Active on Monday late afternoon to see how things were coming along. The car was back together and they were already working on the cam ECU tuning. They said my car put down 448 wheel horsepower on their Mustang dyno! For those of you who don’t know about Mustang dyno statistics, Mustang dyno numbers always show lower HP numbers than DynoJet dynos. If you take a look at my SS Headers/Cats thread at:
http://www.m5board.com/vbulletin/showthread.php?t=79620

You will see my best Mustang dyno run put down 410 hp to the wheels

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The Mods on my car when the 410 hp was produced were:

Carbon air filters removed
Supersprint Headers
Supersprint Cats
AA Header/Cats ECU Tune
(Slightly compromised exhaust cam timing)

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The Mods on my car when the 448 hp was produced were:

Carbon air filters removed
K & N stock filter replacement
Supersprint Headers
Supersprint Cats
AA Cam ECU Tune
3.91 Dinan Differential (doesn’t effect HP)
Schrick Kelleners cams
(Correct exhaust cam timing)

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After my last conversation with Karl on Monday afternoon, he explained to me that my car was running a bit too lean in the midrange and that they are still working on getting the timing and fuel ratios perfect. In addition, they were also working on trying to figure out how to crack the code in the ECU to raise the rev limiter. According to the dyno sheets, Active is certain that if they can get the motor to spin a few hundred more RPM they will squeeze another 5-10 HP out of the car. Raising the rev limiter will cause the RPM on each up shift to fall into a higher more optimal power range when running through the gears under full throttle.

Once Active is done with the tuning on the Mustang dyno, they will run the car over to a DynoJet dyno near their shop and get a final HP number.

Cams and tuning complete…………NEXT...........the M6 goes back to Active immediately to get the Supersprint X-Pipe (with SS resonator) and the Supersprint Sport Mufflers installed. They may touch up the tuning some once the new exhaust components are installed. Lastly, one last trip back to the DynoJet for a Grand Finale pass.

** (Just to let you know, that since my M6's factory cam timing was off, the car was putting down approximately 12 less horsepower to the flywheel than normal. Therefore, my HP conversions were off when I calculated 50 flywheel hp for the Supersprint headers, cats and ECU. In reality, the M5/M6 e60/e63 will put down 40 additional flywheel HP with these upgrades.)
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So all and all, my M6 upgrade components will consist of:

Carbon air filters removed
K & N stock filter replacement
Supersprint Headers
Supersprint Cats
Superprint X-Pipe w/ SS Resonator
Supersprint Sport Mufflers
AA Cam ECU Tune
3.91 Dinan Differential
Schrick Kelleners cams
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I am projecting a DynoJet final number of 490-505 HP to the wheel! With the correction factor applied for drive train loss, my car will be producing between 575 to 592 Flywheel HP!

Final results and initial driving reports coming soon! I will post all the dyno charts once Active is done with the car. Then I am off to the drag strip for some quarter mile runs!

Keith
 

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Nice, go for it....good luck
 

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Wow!!!

Please, please, please take video clips before x-pipe and mufflers. I would like to hear what the beast sounds like before these mods. I am considering the same mods (minus x-pipe and mufflers) but I do not want the thing to sound too obnoxious.

Cheers ///
 

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6speed said:
Wow!!!

Please, please, please take video clips before x-pipe and mufflers. I would like to hear what the beast sounds like before these mods. I am considering the same mods (minus x-pipe and mufflers) but I do not want the thing to sound too obnoxious.

Cheers ///
I agree. Please, PLEASE, some media!!

'Rocket
 

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KeithTa said:
The install moved along and the driver’s side cams were pulled and replaced without any issues. But when it came time to pull the final cam on the passenger side, for some reason, the special jig wouldn’t fit over the cam to remove it. Active spent two days between repair books and speaking to some of their contacts at BMW before they came to realize that the 4th cam on my car was never aligned correctly from the factory! Therefore, it couldn’t be removed with the special tools through conventional means.

Here was the email Karl from Active sent to me last week:

"...Scrappy and I are still here working on your car, we did the driver's side cams quite easily, but the passenger side is giving us a warm time. We were here on Tuesday night as well. We are taking our time to check, double check, triple check everything and that is why we are taking so long. The problem we encountered on the passenger side cams was the factory alignment of the exhaust camshaft was off, the jigs would not fit and after trying like 4 times we came to the conclusion that the vanos gears were never aligned properly from the very beginning. So here we are on Wednesday night making our own special tools to take apart the vanos cam helical gears to align them before installing. We are getting somewhere!!......"
:eek:h:
That is not good! Trusting their assessment, which you have every reason to, means that this technological masterpiece of an engine gets put together wrong?

Good luck, too!
 

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Thanks for being a leader in this area. There may be some motors not put together correctly? That will be too bad for my lease return. Ha.
 

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A fascinating project - it'll be interesting to see how reliable the car is after all that work.

All the best.
 

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While AA is certainly a reputable tuner, I find it very difficult to believe that the cam wasn't assembly properly at the factory. Is it just me or does something not sound Kosher there.....:confused2
 

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wow, that is quite the setup you have there. Those are some pretty impressive #'s. I can't wait to hear what it's like to drive it.
 

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bmwbonehead said:
While AA is certainly a reputable tuner, I find it very difficult to believe that the cam wasn't assembly properly at the factory. Is it just me or does something not sound Kosher there.....:confused2
:dunno:
 

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Intresting, have you talked to some'one @ BMW about this?grrrrrrr
 

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Discussion Starter #15 (Edited)
BostonRocket & 6speed: A few of the guys as Active are telling me the car has a mild "cam" rumble. Almost sounds stock but if you listen closely you can hear the cam somewhat. I will be taking video clips with sound when I pick up the car.

6speed: I didnt add the standard SS X-Pipe, instead I went with the SS Resonator. The SS Resonator is basically the SS X-Pipe with a high flow resonator in the center for a softer exhaust note. I am also going with the SS Sport mufflers which will also carry a milder exhaust note compared to the SS Race Mufflers.

Flyinbysti: I will certainly post an update to this thread with initial driving impressions after the drive home from Active this Friday.

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Once my car is returned, I have a local M6 without carbon air filters lined up for a base line race against my car before he installs Nitrous. Will post video as soon as possible.
 

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Keith...Congrats on the cam job. I will be patiently awaiting the final dyno results.
 

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6speed: I didnt add the standard SS X-Pipe, instead I went with the SS Resonator. The SS Resonator is basically the SS X-Pipe with a high flow resonator in the center for a softer exhaust note. I am also going with the SS Sport mufflers which will also carry a milder exhaust note compared to the SS Race Mufflers.

Thanks for the info. I did not know SS sold an x-pipe with a high flow resonator. Also, did you specify the 90mm tips for the sport mufflers? There is quite a difference in size and they look great!


Cheers ///
 
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