Micah / AF1 Rac

Some pics from morning commute and just looking at what extras I might be doing at 180-200k miles.
Here is speedo, cruise on, at 70mph in normal commute driving



Here you can see boost pressure though in inches of mercury, important thing is delta between barometric and MAP at cruise, and the fuel rail pressure.

I'll be logging a little MAF to see what it does really, at speed.

steeven001

Thanks for sharing your highway boost pressures guys I guess mine is normal.

On another note I was a little curious and opened up the turbo resonator. I removed the baffle inside and reassembled. I don't really notice any difference in noise or lag. I'm thinking to cover the holes in the baffle and reinstall it because it does provide a smoother path for air to flow than having an open area that can cause turbulence.

Anyways here's some pics.

hoski

I was looking into getting AMG injectors for my W211 2.7 cdi om647 and i there is something that raised my concerns. Original AMG injector has a spraying angle @ 156 degrees. Original injector from my engine a6480700187 (same as my buddy's e320cdi om648)has a spraying angle @ 153 degrees. 3 degrees difference is a lot. Wouldn't it create a lot of smoke and melt my pistons after a while?

tuikku

.
They fits and works well.
Proper working demands softing.

hoski

Guys from blacksmoke racing had a problem with amg injectors, they used them for a very short while bc they couldn't get rid of the smoke. I saw they wanted to sell a set shortly after purchase.
They resolved this issue by making new custom pistons and building new injectors based on OEM ones from 320cdi. Non amg.
Tuikku I remember someone saying they couldn't get rid of the smoke with amg injectors until raising boost pressure to something over 2 bar, which means blocking the egr. In some other thread. Wasn't that you? For me it means that fuel is not in proper place in the cylinder and it's not burning right way.

tuikku

.
That car have never ever had amg injectors.
They have always been custom made.
Last season little different, than this one.
I know that engine exactly.

turbo97se

Please come and visit us more frequently here! There are very few people who are knowledgable about our engines here. I think this engine has a lot of potential but not many people interested enough to really push it.

tuikku

.
=> ~580hp from basically stock engine.
=> ~700 with few mods.

turbo97se

Wow! Question is how? Do you have a website with details of how to get there?

My educated guesses are as follows:
1. downpipe and catalytic converter elimination
2. Upgraded (higher flow injectors - AMG? - quite expensive)
3. Upgraded turbo with larger compressor
4. Upgraded high pressure fuel pump?
5. Retune (of course)
6. Upgrade restrictive pressure pipe from turbo to intake.

It would be good if there was somewhere to purchase the parts from as a kit or something like that. If you have website or details, that would be very much appreciated.

My other car is E55 AMG. I am not trying to make my E320 CDI into E55, but it would be nice to do some basic upgrades and still have great fuel economy.

I would be happy enough with 400 HP

Thanks!

tuikku

.
OM648:
Big injectors, far bigger than amg.
CR pump from 400cdi.
Holset 35 billett with 10# exaust housing.
Big cooler
Bigger exhaust pipe

OM642
Modded orig turbo.
bigger cooler
3# downpipe

turbo97se

Could you provide a few more details especially on the injectors? I would like to do this but they also need to have a tune to go with them. Some companies would provide a package.

CR pump from 400 CDI - something like this? https://www.rexbo.eu/teamec/high-pre...00717&at=11460

Holset HX35 would need custom manifold, does anyone sell them?

Can transmission hold all that torque? I expect transmission mods necessary too!

Are there any tuners where you are from that would do packages?

Hope OP doesn't mind this info on this thread.

Cheers

steeven001

I think the problem is finding someone to do the software in North America. And injectors cost an arm and a leg haha

I just got rid of my egr cooler, egr vavle, and the resonator on the left side of the engine. Next step is a bigger intercooler.

Here are a few pics of how I did it. I just used 1/4 inch aluminum plates to make block off plates.

Before - bought this on ebay its actually for an OM613 but is identical to the one on the OM648



After - I ground the lip off flat then had a plate welded on then cut the inside out.



I wrapped up the connector for the egr valve and swirl motor with some plastic bag and ziptied it. With the egr valve removed the engine oil dipstick tube has nothing to bolt to so I ziptied it for now and the coolant hose for the egr cooler I just cut one and joined it up with what I had.


Egr passage block off plate


Charge pipe resonator block off plate

tuikku

Sorry, there are only couple of places here, that do proper big injectors and I do not know, how.
Same about the manifolds, difficult to get them sell abroad.
You are right about the transmission also.
I have done ~400hp cars with orig transmission, but they do not last very long.
Haven¨t get over 400 from V6, always little under.
Straight six with lots of mods is better.
420cdi V8 is the best.

turbo97se

Thanks ... well it looks like this is going to be a pipe dream for the rest of us that do not live where you do. I don't want to have to go through all the custom piping on another project ... but the biggest thing is not having the tuning ability for the larger injectors.

420 CDI is not available in North America.

tuikku

It is shame
My ML420cdi
Orig exept no dpf any more.
Only mod is softw.
About 1100nm/455hp from crank.
Great engine.

isstay

this is the IC I got on my car, no cutting, only two holes for the support bracket bolts. I also have intake w/o flaps (hanging on the wall) but I never replaced it since the OEM one was clean after 100000 miles. OEM fuel pump can be upgraded and it will supply 45% more fuel (this is coming), plus 2000 bar fuel pressure sensor, and then I have to find someone that can tune it.

dulifi

Hello!

This topic is really impulsive. Really cool to see OM646 could reach 250-300hp.
I own a 2008 W204 220cdi with OM646 EVO (170hp). I know it is a bit different with delphi injectors and delphi ECU. With a simple software mod it could reach 200hp, but I want a little more. (around 250hp)

As far as I know the GT2359 from inline 320cdi is fitting well, because the exhaust manifold wasn't changed comapre to OM646. Bigger intercooler is also not a problem.

The question is the injector/injector nozzles. How can I upgrade them? Are the C30cdi (bosch) nozzles compatible? After nozzles shall I install the 400cdi CR pump?

Thank you in advance!

Proctor750

If anyone wants to get in touch with a tuner who is pretty familiar with the CDI engines in North America, check out the guys over at Green Diesel Engineering.
They mainly deal with Jeeps and Sprinters but they did my OM648. They were familiar enough with it to electronically disable the EGR but allow it to operate when coasting for turbo surge protection (normal and regen modes).
They also eliminated the "pre" injection even which "quietens" the injectors a bit.

I got the eco tune but they have "hot" tunes. Perhaps someone where with a custom setup (turbo, pump etc) could reach out to Keith over at GDE and see if he can work with you on a custom tune?

It would be cool if they could even offer a tune for a sort of standardized upgrade kit. Problem is, they only made these cares for 2 years (inline 6) and most of the owners are 90.




As for souping up the injectors or even the pump, why not give Dieselmeken a shout? He appears to be pretty competant with the common rail stuff as well as the mechanical stuff too.

NiTeC

Hello folks...read through this thread - great work tuikku!

I started working on a Holset turbo kit for my T1Ns and wanted to get some feedback...I've gone through a few GT2256 units for both of our vans (OM612 and OM647) for various reasons so it's time to get something a little more robust in there...

Here's the hardware side of the equation:







I'm using the Hx35w to check fitment etc. The choice for turbos is between the Hx30w, Hx35w and Hx40w for T3 flanged units and He200wg and He221w for T25 turbos. I'm currently working on a new flange to adapt the Holset VGT units to this.

This leads me to the turbo control. The 612 uses vacuum and the 647 uses an electronic actuator. I want the turbo control turned off like I did on my Audi, which will allow me to run the stock WG actuators. Obviously this takes away the VNT benefits of the 2256 but it simplifies the system significantly and reduces the cost of the turbo. My tuner is working on getting the turbo control sorted and getting the fuel delivery adjusted. As of right now we've been able to download and start playing with the 647 ECU maps and have done a Stage 1 tune with 10-15% increase of fuel in the lower rpms and EGR delete

The next step is a compound kit to bring the performance closer to a VNT...



here is the stock tune log at WOT







also started working on another compound set from BW but it may be an overkill for the engine...



First impressions of the Stage 1 is the engine is very perky and feels great...GDE claims 180hp on their tune but they haven't really been very helpful with the VNT delete so I'm using my VW/Audi tuner to help with this...the goal for this project is max reliable power from stock hardware and Holset turbo...

JG05CDI

Nice man! Im gonna try to replicate this exactly - was wondering if you or anyone else can chime on exactly what you bought off amazon. Im confused where you say "the bends and tubing' as it just looks like a straight pipe to me but as I look closer at the welds I do kinda see the bends you are talking about. I also noticed the bend on the lh side of the picture is where you'l be putting the sensor? how did you do that?

any help/ tips would be much appreciated - I got my welder buddy ready for the task at hand & am just trying to get all my ducts in a row so we can make this happen

becinko

Hello guys, so happy to find MB Diesel tuners here. I will share with you what have I done

My car is w211 i6 204hp
Kia injector nozzles (just a little bit bigger than AMG)
400CDI fuel pump
Hybrid compressor wheel 65mm 6+6
600/300/76mm Intercooler
EGR physicaly and software removed.
Downpipe 76mm
KN air filter.

When we tune the car at the dyno shows 360hp (engine). Its amazing feeling when more than 850NM kicks you.
I am just now collecting dry nitrous system.

TONIPAPA

hello dear mb friends
can i remove erg pfd and cataluzator on my e 220 194 hp 2016

CDIdreamer

Nice power and mods
From what KIA engine your nozzles? What is potential of your new injectors with NOS?
What rail pressure now? 1800bar?
What turbo pressure with new comp wheel?
You can also put in this turbo AMG turbine wheel, its little bigger and have 10 blades, good for lower EMP at high rpms.

isstay

i have one of those for sale, will post picture. i also have all those parts for sale:

https://mbworld.org/forums/e-class-w...ml#post7304857

hartge6

Hello,,
I would like to ask that someone has put these more advanced injectors E320 v6 cdi 224 ps? .. and was it possible to reprogram the ECU? Does anyone have experience in this regard?

Thanks..