Originally Posted by Micah / AF1 Rac

Originally Posted by evan717

That is a sweet build. Maybe if I can iron out a few issues I will re-spark my love for the car. How do I fit a 3 bar boost sensor?

Are you guys using the VW sensor? Do you need a pigtail to wire? Open up the sensor hole?

Originally Posted by Legodude

Anyone care to share a resource to increase fuel flow in my injectors??

I've got the turbo hybrid in work, a 400cdi pump, other plumbing improvements.
Got a tunner who's done om642s lined up to do custom stuff.. I'm modding a om648.
My friend build 726 transmissions for kompressor cars.. so what ever we need.
Suspension upgraded and lsd installed.
Looking for 325-360 hp.

Do ppl increase the fuel rail sensor off something newer? 20000 psi vs stock 16000 psi.

Originally Posted by Legodude

Turbo has bigger wheels, much better intercooler, swirl valve free, no mixer in the mixing chamber, bigger high pressure pump, exhaust is larger diameter.

Looking to get 50% more fuel.

Originally Posted by CDIAMG

C30 CDI amg injectors. I believe they are plug and play.

Originally Posted by Micah / AF1 Rac

My daily driver too. Volume of a charge cooler is about as inportant as surface area, the other heat exchangers seems to work well enough with that front brace covering them so I'm a bit undecided there. I have TIG/MIG and a few other welders plus a *****in' plasma cutter, v-bands easy enough. The engineering of the stock turbo couplers has really impressed me though. Recently on eBay.de I saw an all cast aluminum version of the post turbo resonator instead of the plastic ones we have, that got me to thinking...buy two (both were like sub €50) use one as jig, cut ends off other, weld up a few bends of aluminum pipe with about 2% taper, done. Pretty much everyone at work shares same sickness as me, currently the parking lot looks somewhat high brow, non stock Golf TDI, Jetta, Audi 3.0V6 supercharged getting less stock every week, Bentley Turbo R being converted to actually fun power levels, heavily modified Lotus espirit, Honda Beat, Ferrari 308/H23A Honda motor and trans swap...I could go on. We build a few little custom shop projects every year like the turbocharged Moto Guzzi V7 flat track bike featured in Cycle World right now, ALL work is done in house at shop.

My car effectively has no resale value left at 177k miles and using it a thousand miles per week, now it's just a fun commuter toy that gets about a 1000 miles per week put on it. Since it has no resale value left, why not do as many cheap yet effective mods as possible? Document, share etc. I've kept OCD level notes on service and mods and logging and fuel economy for years now. Finally I really can get 38-41mpg full tank averages as long as winds and temps are favorable.

I'm running my car to failure, then I'll probably keep it at ranch as a parts car and take motor parts and mods and transfer to another W211 or similar...would love to do a manual shift strong tranny OM648 as I'm well short of power I can make now often hitting torque limiters at well under 1,600rpm. I think (not totally sure here but math works) that if not for 478 ft/lbs torque limit to protect transmission I could probably get into the 550-600 ft/lbs range pretty easy and with at minimum a 2-4mm increase in compressor wheel and cleaned up resized turbo snail size 300-330 bhp on the AMG injectors would be easy.

I'm betting next round of mods is going to see even lower EGT's, and about 20-25 bhp gain from just my ported manifold and de-resonated intake piping and a light dosing of water/methanol. Even at full power loads I've only barely managed to touch 1200F EGT on very hot days here in hellish Texas. The OM648 seems to be the Toyota Supra/Yamaha 2JZ-GTE of mid sized inline six diesels. Another option on the consideration list is a fully ported and built cylinder head. Like fuel, the more air you trap in the cylinder at intake-close on valves, the more power and fuel economy you get, restrictions taken out of intake allow for same or better power levels at lower EGT/IAT and absolute pressure.

Here is my non flapper intake manifold the day it arrived sea freight from Germany:



The perfect hybrid for an aviation junkie like me, half jet, half piston motor. So on dynolicous app best power runs in last year were 253-262 on two way averages but vastly different atmospheric conditions. 300 bhp seems low hanging fruit...you have seen what the 335/535/X5D diesel BMW folks are getting now even here in USA? Drove a 400-420 bhp 335D recently, cannot honestly say I'm not interested in adding one of those to fleet as they are taking the typical tuetonic depreciation trajectory. After 99.9k miles they are now 12-15k U$D cars. Hmmm.


All the runners have since been ported or at least port matched to new OEM gasket I bought from ID parts at same time



Looks a bit different now, have not decided to polish or paint the final version, just a few welds left before decision time...thoughts? A crinkle ferrar Rosso Corsa red would stand out nicely?




While intake is off I will be doing new Beru 5V glow plugs and walnut shell media blasting of intake ports and valves because putting a cleaned and ported manifold, de-venturied up pipe, non resonator charge piping and such onto a carboned up cylinder head cold side seems sacrilege. Mercedes sold me the wrong glow plugs last time but the Bosch 11V items have caused no issues even when car has been as far north as Colorado or Tahoe...but you gotta pull either glow plugs or injectors to manually rotate crankshaft for media blasting so I'm going with the easy option there. I'm not pulling injectors till one fails or at very least I find a deal I cannot pass up on the AMG items.

We shall see how far stock injectors allow power to rise, I honestly think very close to 300 bhp is possible. Just got to clean up all that other bs first and get the water/meth dialed in. On my land speed race bike (1060cc twin, supercharger, nitrous) water meth was good for 12-15 bhp gain on my Mustange Dyno at 170-190 bhp wheel power.

I guess really with this car I'm at the nothing to lose or be disappointed about stage of ownership...so throw air and fuel at under load like a madman, why not?

This is up pipe to manifold as it came out of box, slightly more carbon than my OEM one. This shows the massive percentage of intake pipe blocked by EGR Venturi:



This is after half an hour with proper porting tools and a few flap wheels used up...welding not done yet in this pic to add water/meth spigot at previous Venturi entry location to up-pipe. This is where the number 1 size nozzle will go since it is post IAT

Originally Posted by DuhStig

Happen to have a part # of the Europe intake manifold?

Originally Posted by turbo97se

A6130900737 is what I installed. They are super cheap from Europe .. Shipping may be more than the manifold in some cases.

Originally Posted by steeven001

Hey guys I got a couple questions

How much boost do you guys see when cruising around 100km/h - 120km/h (62-75mph) on a flat highway and what is your IAT readings at these speeds? Also what is the ambient temperature? And on what tune?

In my car I have an upsolute remap and an egr delete circuit because the map just reduces egr instead of deleting it. I'm seeing between 7-10psi and 45 degrees Celsius IAT with an ambient temperature of 25 degrees Celsius at these speeds.

I have a feeling the egr delete circuit is raising the boost too much while cruising which is also raising my IAT because the intercooler can't keep it cool enough when under constant boost which is lowering my fuel economy because of how hot the air is.

Originally Posted by drewkeen

You need the block off plate there on the back of the head and also a round one in the EGR mix pipe. You will also need to do a coolant bypass on it. You can cut the hoses and connect them with a barb to do this.

I have some of the ones for the back of the head here we cut on a plasma table.

Originally Posted by steeven001

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

Originally Posted by CDIAMG

Figured I'd show off my CDI and hopefully get some motivation to continue and install all the damn parts that are sitting in the garage.
I've owned a few CDIs, About a year ago a found the one.
05 white on black with keyless go/full leather/xenon's/fold down rear seats

Goal was to convert it inside and out to e55amg
Currently has bumpers, rocker panels, calipers and rotors all from e55. Only thing missing is exhaust... Which I have from an 07 e63 and will need to make that fit soon.

Started with this



wow


Has downpipe installed, tcu tune, rebuilt valve body with "shift kit",tq converter dampener and sonax sleeves.

Did the headliner and pillars in same black alcantara from w211 e63... Didn't like the grey cloth over black leather.

Also thank you to everyone who has contributed to this thread as it has been a huge source of help and motivation so far