tuikku

No I did not.


If I understand you right, that kind of reprogramming is not needed.
The original turbo of my car was also VNT.
Newer the less, programming is not a problem here.
We have here a man, who can make such changes in program, that we need, or want.
http://www.turbotec.com/Mika Karala.


In my car, exhaust gas pressure is lower than intake manifold pressure, when the turbo is “on the map”.
So, I have not reach yet the limit of this charger.
Estimated amount of air should be enough for 300hp.
Boost is 2bar max.
There is no smoke at all, now.

Garret does not manufacture AMG 3,0cdi,s turbo 2559 any more.
Compensatory charger is 2359.
The difference is in turbine side of turbo, compressors are equal.

The type of BMW chargers are 2260, and 2556.


Original Mercedes turbos are the best.
They all fits straight to exhaust manifold.
Only a little mods needed to air pipes.
And they works fine, like “originals”, in good ways.

tuikku

http://www.proturbo.fi/

I hope, that it is not too far away....

gaiex

How did you managed to squeeze the intercooler in there!??

Me and my friend LOB are looking to do some similar Mods to our cars (220cdi and 270cdi) Next step is the turbo, and than the intercooler, but we only were looking to put and intercooler similar to the factory one but a little bit bigger, but yours its gigantic!

Did you managed to turn off the EGR valve?

Good project, keep us updated

PS: copy your post to the w203 area also

gaiex

Your 320CDI turbo is like this one? (the one on the right, forgot the electric geometry, I know it must be in vacuum)

VNT 18 (mine), VNT22, VNT23



Do you have better pics of your instalation... turbo, what you say "air line" and "fuel line"??

I want pics

harkgar

The Finns seem to do a lot of diesel engine tuning. Presumably their emission laws are not as ridiculous as North Americans'. They have a tradition of driving fast. Very fast. On loose surface roads.

tuikku

.
EGR is deleted.
In program and also physically blocked the EGR-pipe.
You must block the EGR pipe, when boost is higher than EGP.
Otherwise the boost pressure disappears among the EGR pipe straight to exhaust manifold.


My cars original charger was “electric”.
Better 2359 is the “vacuum” model, because the charge air hose leaves to right way.
Now I have “vacuum” charger with electric motor control.


First you need better injectors.
AMG-injectors are good, in start.
1350bar pressure they give ~55hp/cyl.
1600bar ~65hp.
The difference is therefore so small, because original 1350bar injectors don’t work properly any more in 1600bar pressure.
They don’t give such amount of fuel in spray, that program ask, any more.
It depends from injectors operational principals, my English is not enough to explain it now, maybe later.

The only way to really have more power is very efficient and quick spray, only way.
Bigger turbo, or higher boost, or nothing else would not do that.
You must burn more fuel, “in good order”.

You need chiptuning programmer, a good one, who really understand, what you need, and is capable to it.
This is not "ordinary" chiptuning any more.

Some pictures.

240D 3.0T

You should gut out that cat/trap behind the turbo or replace it with a straight pipe.

gaiex

This is the most Moded CDI I've seen till now!!

What are those wires connected to the Cat? Wich cat did you used, the 320cdi one?

gaiex

I also don't want to do it, more noise and more smoke!! sure it cut performance but... and I want all looking like stock to go to MB to do the services and then they won't notice anything

240D 3.0T

Thats the nature of performance Diesel. If you tune it properly there will not be any smoke.

gaiex

Yes, but It will end to make more smoke without it, and not to speak about the emitions produced!

I will keep it for now

tuikku

.
Cat is empty.
I am not so sure of taking away it.
There are reasons, why it is still there.

“Wires” are:
Exhaust gas temperature.
Exhaust manifold pressure.
Exhaust pipe back pressure.

I have also measured a lot amount of air.
1,7bar……………........................ vs………………...............2.0bar boost.


Red is boost level.
Green is motor rpm.
Yellow is air flow rate, MAF.


Important is the air rate level.
The higher, the better.
Boost is not important at all.
Boost is only a tool to have more air, and not so good tool.

Air flow rate in stock car looks quite different.

gaiex

Backpressure for example

Your cat its not the stock one or is!? I'm thinking in upgrading to the 270cdi for my car in combination with the VNT22 turbo also from an 270cdi

240D 3.0T

Backpressure after the turbo is always bad.

tuikku

You are right.
Try to measure it with different combinations, and you may see something intresting.

As bad is vacuum in turbo intake, or even more harmful.


270cdi turbo is very good for chipped 200/220.
It is very easy to change.
Everything fits, biggest mod are nut between cat bracket and transmission and little adjusting of turbo´s stick.
Turbo peak stopped.
You get some extra pover, couple of hp,because there are less "pumping loss".
It will work "like original", in good ways.
I dont know the right words, hope you understand.

LOB

How you "tuning" the air line, can show us some pictures?
Best regards and congratulations, one more time, for your big project.

When I mounted the new 2260 I will post a dyno test

tuikku

Look the pictures e.g.
Good way to increase the air rate is to change cooler, for instance.

You need much better cooler.
Original is not good.
Intake air temperature rate rises far too high.
System start to limit the fuel rate, when air temperature rises over ~50c level.
With original cooler, temperature rises very quicly above that.
I have measured far over 70c temperatures from chipped cars.

LOB

ahhh ok, when you say air line I thought that you were talking about admission of air.
Have you a scheme with the sizes of you intercooler? Best regards

gaiex

Yes, I was asking for the same thing, do you have the measures of your modded intercooler?

Thanks

harkgar

This is the most beautiful C class diesel I have ever seen. Heavily modified and yet stock looking in the MB garage. I have written to the Finnish company enquiring about the cost of that gigantic intercooler. I wonder if it will fit into my engine bay without major surgery.

Congratulations.

tuikku

Heh, as you can see, I am not sure, even myself, what am I writing.

Air cleaner is still original.
In fact, the whole engine room looks still “stock”, or original.
It is important – for me.

Cooler breadth is 66cm, ~ same as radiator.
High 38,5cm.
Width ~7cm.
Breadth between hoses mid-mid is 85,5cm.
It is important, there is not much space.

LOB

Like this??:


Best regards

tuikku

.
Sorry, my mistake.

Cooler element. 48X38X6cm.
Breadth up 58cm.
Breadth down 66cm.

This size is already enough.
Income air temperature rises only few degrees higher than outside temperature.
It is quite a good result, I am using 2bar boost.

LOB:
What kind of engine do you have ?

LOB

I am thinking put one with more or less this measures... I don't is to have much modifications...
I have a 270Cdi

Best regards

tuikku

.
Aha
1350bar, or 1600bar ?

Here in Finland there is a guy, who can rebuild cdi-injectors.
Very high fuel rate parts.
For me, he make such injectors, which flows ~140mm even with the lower pressure (1350bar)
I have 1600bar in my car.
Fuel rate was measured in very reliable place.
Maybe they are first ever made, I don’t know.
Just for reference, “older” superturbo – pumps gives over 70hp/cyl with 120mm fuel rate.
I haven’t yet fasten them into my car.
So, how they really works, is still a little bit mystery.
But soon…