Karter16's Silbergrau E46 M3 Journal

[Slideways]

Not sure if you have tried them yet, but the 07119905016 bolts won't work on the Karb airbox.

[karter16]

Some of the bits of hardware I was waiting on for the airbox install arrived today.

07119905016 - original silver bolts that hold the two pieces of the airbox together. The black ones that come with the Karbonius look great, but I'm wanting to replicate the original CSL look with the silver hardware.

07119901780 - original bolts that attach the snorkel to the airbox. The Haimus Racing snorkel comes with silver through-bolts and nuts, plus insertable collars to go in the 3D-printed mounting holes. I'm not sure whether the Haimus Racing airbox doesn't have threaded mounts on the airbox, but anyway the Karbonius does. I did a quick test fit and confirmed that using the Haimus collars with the OE bolts works.

07119902626 - original bolts for the MAP sensor to secondary air rail. As George Hill noted some time ago these are too short to fit on my MAP sensor adapter, but with them in hand I was able to confirm that these are DIN7984 spec bolts, and have ordered some M6x18mm DIN7984 bolts which will fit perfectly.

Only item (I think) I'm waiting on now is the CSL dipstick tube. I realised I have a bit of a problem when I went downstairs to find something and couldn't even remember what's in all of the boxes of parts on my shelves. Need the Christmas break to come round so that I can get some of this stuff installed!

[karter16]

Well look what arrived yesterday, less than 6 weeks after I ordered it! I saw a few months ago that Karbonius had made another mold for the CSL replica airbox to speed up production and certainly would seem to have helped!

Can't really say anything about this piece that hasn't already been said. It's spectacularly good. The memory of the cost simply melts away when you hold it in your hand and look at it.

I'm still waiting on the CSL dipstick tube plus a few minor pieces of hardware, but hopeful of having everything by the time the Christmas break rolls around!

In the meantime all these parts continue to clutter up my spare room!

[Bry5on]

It appears you are correct. I checked back in my excel files and indeed they do look the same. Not sure where I got that from..

[karter16]

KF_TIENDE_N_RF are different between euro and CSL tunes that I’m looking at.

Interesting - so the original binary from my car is 211323001901JD54 (appears to be an unlisted variant in the Comprehensive MSS54/MSS54HP DME Information thread) and KF_TIENDE_N_RF is the same as for the 0401PD31 binary.


1901JD54


0401PD31 (CSL)

[Bry5on]

I'm curious - aside from KF_TI_N_RF (which I missed out of the list in my post above) the only other Injection/Ignition tables I see differences in are in the warm-up/cat heating/secondary air pump tables for calculating the warm up factors (which I'll not bother with for now).

I do note that in the US map KF_RF_N_AQ_REL and KF_TIENDE_N_RF differ to the CSL map, however these two are the same between my Euro tune and the CSL tune.

Or I'm missing something 😅

I didn’t modify KF_RF_N_AQ_REL and KF_TIENDE_N_RF are different between euro and CSL tunes that I’m looking at. Just a couple notes

[karter16]

I'll let you walk your way there!

In addition, my euro mullet ended up with several little custom changes in the end, rather than pulling straight from euro maps (US fuel likely cause). It'll be more rewarding for you to chase it yourself I think.

❤️
For sure, ya don't give me the answers! - I'll keep posting here with updates as I work stuff out. Writing things out helps me spot where I'm doing dumb things!


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[Bry5on]

I’ll let you walk your way there!

In addition, my euro mullet ended up with several little custom changes in the end, rather than pulling straight from euro maps (US fuel likely cause). It’ll be more rewarding for you to chase it yourself I think.

[karter16]

There are a few extra tables that needed dialing in for me but that may be in part because the US fuels are different.

I'm curious - aside from KF_TI_N_RF (which I missed out of the list in my post above) the only other Injection/Ignition tables I see differences in are in the warm-up/cat heating/secondary air pump tables for calculating the warm up factors (which I'll not bother with for now).

I do note that in the US map KF_RF_N_AQ_REL and KF_TIENDE_N_RF differ to the CSL map, however these two are the same between my Euro tune and the CSL tune.

Or I'm missing something 😅

[ugaexploder]

Hey - the CSL rail part is now, I believe, ready to go. I haven't published the CAD file yet as a bit reluctant to put it out there without having proven it first (I've test fitted it and all seems well, but haven't proven it in operation yet). If you're keen to give it a go let me know and I can send you the CAD file :-)


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sweet! i’m in no rush at the moment to install the csl intake so i’ll wait to hear your results with them first to see if you decide to make any improvements or revisions. really excited to see the results and the iterating work with the tune

[karter16]

always love the updates, what's happening with the csl rail part by the way?

Hey - the CSL rail part is now, I believe, ready to go. I haven't published the CAD file yet as a bit reluctant to put it out there without having proven it first (I've test fitted it and all seems well, but haven't proven it in operation yet). If you're keen to give it a go let me know and I can send you the CAD file :-)


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[ugaexploder]

always love the updates, what’s happening with the csl rail part by the way?

[karter16]

Happy iterating! Once you're in the weeds, keep posting your notes here regarding where it works well and where it doesn't. There are a few extra tables that needed dialing in for me but that may be in part because the US fuels are different.

Thanks! I'm looking forward to it! Yes will definitely keep this updated with how I go - just need the rest of the parts to arrive now!


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[Bry5on]

Happy iterating! Once you’re in the weeds, keep posting your notes here regarding where it works well and where it doesn’t. There are a few extra tables that needed dialing in for me but that may be in part because the US fuels are different.

[karter16]

This weekend I spent a bit of time finishing up the first cut of my CSL clone tune.

Essentially I'm making my own clone along the lines of the approach Bryson has taken with his Mullet Tune, but doing it myself for the entertainment/learning value. All credit to Bryson for pioneering this approach, I'm basically just building my own version of what he's already done. If you haven't read up already I highly recommend following along in his journal.

When I do the swap, I'm going to do it in two stages.

Stage 1: Flash the car with the base CSL tune. This will give me a baseline datum point and is a known configuration to start with and ensure that the install has been successful.

Stage 2: Flash the car with V1 of my customised tune. This is a starting-point tune which blends Ignition, Injection and VANOS tables from my current Euro M3 tune with the CSL tune. The hope is that this will be an improvement on the base CSL tune and a starting point for iterative fine tuning.


(I'm getting in to a bit of detail now, so those who know more about this than me will be able to point out my mistakes :-))


Scope

• For a vehicle with MSS54HP DME (not modified for flap)
• Vehicle is running a Euro tune
• Vehicle has a CSL airbox conversion using a MAP sensor (OE 1.0 Bar so no conversion factor required)
• Vehicle is MSS54HP so does not require IAT conversion factor

For Stage 1 I'm starting with Terra's 0401 PD31 Full binary. This binary is a modified version of the 0401 full binary with support for the non-CSL boot loader, error codes, etc. I'll be loading this full binary at the time that I do the install. I'll then be flashing the CSL tune (partial binary) as well. There are a number of changes to be made to the original 0401 PD31 partial.

1. Change 0xE002 from 00 to 01 to make the partial work with Terra’s modified full binary (support for the non-CSL boot loader)
2. Enable Alternator light over canbus
3. Set non-CSL cam offsets
4. Set CSL intake flap control to always be open
5. Disable DTC 124 (CSL flap)

I used TunerPro to make the above changes to the partial, and now have this saved ready to go when I do the airbox install.


For Stage 2 I then took the partial I'd just generated and then added the modified ignition, injection and VANOS maps that I'd prepared. The preparation of these maps were of course the bulk of the work.

The merging of the maps is an interesting maths challenge. For this first version I took the following approach:

1: Take the standard M3 and CSL tables and interpolate both tables to allow for direct comparison.
2: Compare the difference between the tables (allowing for any conversion adjustments between the two)
3: I then manually applied a mask to blend the 2 tables together into the output table.
4: We then finish up with a nice optimisation problem. Finding the x-axis points that best describe the table as a whole and thus minimising the error. The M3 tune tables tend to have more x-axis points in the lower half of the RPM range and the CSL tune tends to have more in the upper half. This of course means that you can't just use all of the x-axis points from both maps. Ideally I would dust off my very rusty Matlab skills and write something to do it, however for now I simply added some calculations in the sheet to identify absolute change, rate of change, inflection points, etc. and then rank them by importance, this made it fairly straightforward to more manually identify the most important x-axis values to bring across.


The VANOS maps in particular are quite fascinating. There is a very significant difference in the lower RPM range between the M3 Euro and CSL tunes (example of the difference in the exhaust maps below). It's easy to see why cars with standard cams struggle so much in the lower RPM ranges with the CSL map.



Methodically working through these maps took me a reasonable amount of time (although to be honest a lot of that was diving into researching various topics to help make sure I understood correctly.

The end result was updates to the following maps:

KF_TI_N_RF_VL: Fuel Injection Full Throttle
KF_TI_N_RF: Fuel Injection Duration
KF_TZ_VL: Ignition Full Throttle
KF_TZ_GRUND: Ignition Ground
KF_TZ_MIN: Ignition Minimum
KF_TZ_LL: Ignition Idle
KF_EVAN1_SOLL: Intake Target
KF_EVAN1_SOLL_KATH: Intake Target Cold
KF_EVAN1_SOLL_DMAX: Intake Target Max Deviation
KF_AVAN1_SOLL: Exhaust Target
KF_AVAN1_SOLL_KATH: Exhaust Target Cold

KF_TZ_MIN and KF_TZ_LL are the ones that concern me most. For both I've erred on the side of taking the values from the CSL map, as for KF_TZ_MIN at least they appear to be more conservative. and for KF_TZ_LL it is different enough that I can't be sure there aren't changes in the 0401 program that interpret this map differently. I'll find out I guess when I get the tune running.


It's worth noting that once I have the tune up and running I'll also be doing the VE map tuning process described here.


Oh and the Haimus Racing snorkel arrived today. Well packaged and in a lovely soft bag. It seems to be a fairly nice piece. You can certainly see it's 3D printed when you look at it closely, and there is evidence of printing errors in places. The exterior has been post-processed to a fairly nice finish, and unless you look closely it looks good. It also feels nice and light for its size, but seems sturdy. All in all I'm ambivalent about it given the price (especially with shipping to NZ) (that said I haven't actually looked into how much it would cost to get one printed from CAD file), but it will look pretty nice in the engine bay I think once all is done.