harkgar

What is the best way to gut the cat? Presumably the procedure is easier than cutting it off?

240D 3.0T

Replacing them with a straight pipe section is the best. No chance of leftover material coming loose and rattling in your muffler and they are not damaged in case they need to be reinstalled.
The down side is if you have visual inspections in Canada, you may fail.

Second best is (with the exhaust out of the car) cutting an access patch at a point not easily visible when the exhaust is installed and gutting it. They remain in place for inspections but are free flowing.

Third best is just using a long rod and ramming the honeycomb out of it.

Rob CL

I second this option. It requires a little more time and effort to remove and replace the exhaust component. The benefit is knowing you've cleaned the unit completely and as 240 said, it will pass a visual inspection.

I applied this method to my DPF. While it has generated soft codes in the ECU, throttle power has not been impaired. -The CAT is next.

harkgar

and long live Chairman Mao (only if he drives a Freedom Diesel)!
Thank you 240. The cat is going to get shafted one way or the other, some day.

harkgar

Sorry guys.

The late Chairman Mao died in the seventies fortunately. No more long living for the preserved mummy.

His body was not properly embalmed and started to mature and smell so the Red Guards had to soak him again in some stronger chemical solution. The embalmer and his family were all shot, I suspect.

I know this bit of trivia has nothing to do with nice MB cars.

diesel2fast4u

I decided to get rid of the tiny turbo first...

Well there is good news, there is 265HP version now of the OM642 and this has an 2260VKLR, water cooled & ball bearing

This turbo should be ok for 300 to 330 HP.
I read a little higher about upgrading the injectors, NO NEED , they are big, piezo injectors.

I sourced a brand new turbo, here we go...

It's not exactly plug & play ...

Turbo mount is different

New vs old, new turbo mount has a hole for the watercooling




Water outlet in the turbo



Plugged the bottem water feed an tapped a new one in the turbo mount



Tapped into the block to feed water to the turbo



Blocked the EGR & It fits :

DubVBenz

Awesome! How's the ECU going to treat this? How will it adapt?

diesel2fast4u

It's not going to adapt, reprogram is needed

diesel2fast4u

Resonator empty :


Cat empty :



And dpf empty :



changed the water feed line :

fishinbama

Whoaaaa, this is awesome. Please give all details.

diesel2fast4u

Well, it's in & running :

First impression, without the DPF, Cat & resonator it moans a little rougher, also inside.


It started right up but trowed alot of codes, going into limp & engine check light because of the dpf not seeing any difference in pressure. So we fool the computer.

EGR delete is done, without deleting this the turbo makes no boost.

We start to understand the bosch EDC16 better.

My tuner found the boost, rail pressure & torque limiters.

When driving max torque we saw on the computer was 490nm.

Current tuning is very mild, more coming !

gaiex

I wrote my questions above.

PS: I removed my DPF and replaced it with a simple straight pipe and left only the little resonator after the turbo.

diesel2fast4u

(I can do some research to see where in the CLS the water outlet is going...)
Looking at the turbo mount & turbo there will be some special piping from the factory.
As long as the water is going from the cold side of the radiator to the warm side it's ok. We took water just after the water pump in the cilinder wall and I inject the hot side right after the thermostat were it goes to the radiator. There is the little hose that goes to the fill can, I just splitted and put a T there.

(so since your block on the turbo mount doesn't have water outlet there you done a "plug" on the new turbo mount to receive the water rigth?)
Yes, here is were I blocked it :


And here I drilled & tapped the new mount for the water to enter :



(where in the block is this, and there was the outlet on the block or you made one?)
Left side first cilinder, I made it.

(you simply blocked it on the exchaust pipe with a sheet of metal? I was to do this for a while, but I don't know how the EGR system is going to react since the EGR is water cooled also!)

I simply blocked, but also deleted in the ECM because otherwise you won't have turbo pressure since the engine tries to make EGR when you start it.

PS: I removed my DPF and replaced it with a simple straight pipe and left only the little resonator after the turbo.

I had resonator, cat & DPF all empty now.
What did you do with the pressure lines that messure before & after DPF?
I made it empty & put back to pass the car control here, nobody can see that it is empty. Then we fooled the DPF sensor by blocking 1 side.

These are the only 2 codes it's trowing in the ECM, not putting on the engine checklight. the glowplug ones I have to look into, they have nothing to do with the turbo

How many km you drive with the straight pipe? does it not try regenerate the DPF?

gaiex

I have bought the pipe of the non DPF version and connected the pressure lines and sensors. This way it can read all the data the same way.
I drived 15000km without the DPF and stock ECU, no error code except for the low pressure read from the pressure reader, but no safe mode.
Now I have the DPF electronically turned off and some other tweeks on the ECU

PS: Don't you worry about the EGR block, do you know how it works and temps that it turn on the water circuit on the EGR cooler, or it's all the time ON? Or you have sorted it out electronically?

diesel2fast4u

Ok, well that pipe doesn't exist for my car, looks good.
Ik think you now my tuner Rub87, we are looking to turn of the DPF electronically but we have a hard time finding the address, if you could help with that

I didn't look into the EGR how it works, just blocked it with a plate & turned it off in the ECM

You have any dyno numbers?

gaiex

I don't know Rub87, and about DPF I'm depending on my chip-tuning guy and only he have the knowledge

I also don't have dyno numbers yet, since I didn't went there yet. We are doing some tests on the road and doing some logs to fine tune it, then I will go to the dyno.

DubVBenz

Is there anything you can install that would temporarily bypass the DPF and be able to swing it back into place? I ask, because I live in an area with tight emission controls, and I'd like to bring the DPF back online during my annual emissions inspection.

diesel2fast4u

Where do you live? What are the emmisions demanded?
I don't believe they can measure in the exhaust if your DPFis there. Visually yes, that's why we just empty

gaiex

And they know the car have DPF?
There are models that DPF is not standard!

diesel2fast4u

Here in Belgium they now, It's on the papers.

But there is no way they can measure

gaiex

Here in the inspection they can measure the amount of particuls, if superior than 0,0005 or something like that it does not have DPF but for the inspection what count is the smoke and other values.

DubVBenz

I live in Virginia, outside of Washington DC which has fairly strict emissions standards. If they can't measure it based upon the sensors on your car, they'll likely hook something up to it to sniff the exhaust (I think).

gaiex

That's what they do here, they don't connect nothing to the car, only hook a sensor to the exhaust and measure gases and particles.

DubVBenz

They will rely on sensors, unless a code is being thrown. If there was a way for me to disable the DPF and trick the sensors without a code, I could probably circumvent it.

diesel2fast4u

No problem to trick the sensor, or to switch it off in the program