tuikku

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Little by little....

tjwasiak

It is not that bad. With my brother we are fighting with our W203. Having 5 cylinders in-line and automatic tranny under that bonnet is good if everything works all right. Unfortunately after 220kkm cylinder head was cracked that bad that we have seen nearly 0 compression on 3 cylinders. I was willing to make a complete engine rebuild, but we did just swapped head. 20kkm after that my brother killed the engine. After dismounting it was waiting nearly year to get fixed. We have to grind the block and crankshaft (1st oversize bearings), rework the head (replacing 4 valves). My brother did about 600km with hole in piston on 1st cylinder and with seized 3rd and 5th piston. He was just "refueling" it with clean oil, adding 18l. Unfortunately we have a lot of other troubles with getting it running, for example oil one directional valve/pressure restrictor in timming gear housing. While trying to rebuild it, we took it apart 7 times. Biggest PITA is to connect it with gearbox on the car. Beside it is really easy, or we just got enough experience Now everything is ok, we are just waiting to get AMG nozzles to rebuild our injectors as we found faulty injector to be the reason of the hole in piston.

I have found many interesting information in this thread. I will post mine findings and also ask for some help when it will hit the roads.

I read it is not only nozzles you have to get to make your injectors 100% like AMG. I am curious if our diesel pump and injectors center owner will know the trick...
I have rather big experience in chip-tunning VAG TDI (VP and PD) ECUs, but did not even tried to work on common-rail ECU. I hope I will get it sorted to make big power from our five banger. Hope to see at least 280HP with those injector and proper (probably hybrid) turbocharger if the gearbox will survive it (it is '02 W203 with 5 speed auto tranny). Of course I am not mentioning intercooler and exhaust. I understand your concerns about tuning Mercedes the hard way. Our was nearly 88000 EUR excluding VAT :O And have strange troubles with gearbox from the first moment (no reverse when we were to get it from the dealership). I have an accident when it has half year and since than we have also troubles with rust and "vanishing" body painting

gaiex

Any updates?

tuikku

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Next "potatoe"

tuikku

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The new charger is almost finished.
Original electric control doesnīt work in MB,s.
So, I had to my own solution again.

240D 3.0T

Is that a 2559?

tuikku

No, sorry...

It is 2260 from Audi V6cdi.
Garrettīs newest production.
In Audi, it gives 300hp with 1,5bar max boost, surprisingly smokeless.

tuikku

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Almost ready.
Only downpipes flange missing.

LOB

So tuiki, you already got 300cv?

Tell us what you are doing at your cdi...

tuikku

Sorry LOB, I have been very busy.

Power is still ~250hp.
In fact is is directly 250 between 3800-4800rpm.
And torque is 500nm between 2400-3400rpm.

I donīt know why, yet.
There is some kind of fueling limiter in program, and I cannot find it.
But I am working on it.

I think, that I have already found the same kind of limiter from older box, edc-15.

LOB

If your 250cv are safe, I think that is a great number!! The same with torque.

What you want to say with fueling limiter? It can't put more mg of diesel in cylinders? How you are doing at injector map. Editing the y axis, to have more mg of fuel per rpm or just increase the opening time of it?

limiter of edc15?? what are you talking about??

Best regards
LOB

tuikku

Thatīs it, I donīt need to do anything to injector maps.
And I donīt like to, because, the program donīt work right any more, if it does not know the real amount of fueling.
There is limiter, that prevents the full 100millis coming out.
Same with my car, edc-16.
But I think, that I found it there, too.

I need to wait few days, till my interface come back home, then I can try.

LOB

If you have different injectors... and want more... you have to...

Came to Portugal to talk a little bit and try another file

P.S. You change your admission manifold?

tuikku

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Blue=boost
Red=torque
Black=power

gaiex

CDI powaaa

Good to see that you managed the program, and better yet the last numbers

tuikku

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I would like to had more power...
But maybe I figured now, how it is possible.
The torque curve is good and engine behaves nicely.
No smoke yet, at all.

Luismbmp

Nice power, nice engine, nice, nice, nice, nice

Congratulations tuikku, you made a great work.
I have now in my E220cdi 197hp and 470Nm with a new repro and the gt2256v, but i want more
I had some problems, with much diagnostic test, i found the problem
not the MAF, not the sensor map, not the chip tuner
The problem was the diameter of the wheels, yes it is true made some errors in ECU, and the car when i accelerate, it blocked the power.
Now i make a new repro for a new diametre of wheels, the car are very good now
Next i want buy a AMG injectors for 220 or 240hp and 500Nm

Bye, nice work, it is very good for we learn about your work .

LOB

Hi tuiki... this excel graph looks good. When a dyno at a maha??

Luis, I didn't know that in the ecu can be tuned diameters of wheel. That's a huge discovery

tuikku

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I am quite sure, that this is max result with orig.AMG injectors.
At least, what I am able to.

But I can add more torque.
I tried +540nm, but it was too much for the flywheel.
So, now Iīm driving ~530nm max torq.
...Not a drifting-car, but I like it anyway.

I will try bigger injectors later.

LOB

In what you are thinking?

[ ]

tuikku

I still have the AMG power plus injectors.
They can give more fuel.
If I only find the way to get rid of their horrible noise.
Itīs like few blacksmiths under bonnet.

tuikku

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I have maid some some tests about torque.

270cdi clutch/flywheel can stand 530nm, 2500rpm -> in my car.
~540nm between 2000-2200rpm is too much.
With two biggest gears, flywheel starts to vibrate slightly, clutch doesnīt slip (yet).
So, with this very small limitation everything is ok.

I made also a new exhaust pipe, the "end" part, of it.
Now there is "chamber silencer", hope that the term is right.
The car is quiet and feels better, than very very long time.

gaiex

Any news on the project?

240D 3.0T

Yes, more info please! Any more up to date dyno charts? I can't wait to see a 530+nm torque curve from a 2.0L diesel.

I'm working on building a compound turbo setup right now. Still working on what might be the best low pressure turbo match to my GT2256V.

tuikku

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Hi
This new, "reprogramming hobby" takes more and more time...
I havenīt done practically anything to my own car for a long time.
I donīt even remember anymore, which kind of program I am driving now.
Iīm so busy with the other peoples cars....

Car works ok.
Torque is something between 530-540nm, maybe a bit too much, but I like it that way.