LOB

My turbo arrive this week. Soon I have a dyno I post here

And your new turbo is ready? HP? NM? Which turbo is?

tuikku

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I am glad for you.

Unfortunately, I haven’t still get the new turbo.
Its type is going to be something like GT3067VNT...

I have been very busy.
And my older turbo gives sound now, like dentists drill, or big truck.
Hope it lasts.
I have even not time to concentrate on that.

LOB

GT3067VNT???? That's a huge turbo!!! You will have power at 3500/4000rpm or more later....

240D 3.0T

You are thinking in fixed geometry. A variable turbo that size will have no problem making boost faster than the Garrett T3 did on the old OM617 engines. A GT3788V would be better, that would easily get it into the 450hp range and still spool much quicker than the Holset HX40 commonly used at that power level.

tuikku

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I don’t worry much about turbo lag.
There are couple of ways to make it spool quicker, if need.
Very efficient ways.

The only thing, that little worries me, is that I have already paid it….
Hopefully I really get it some day.

It seems, that with big VNT-chargers problem rather is that they start make pressure too fast.
->Surge.
I don’t even want very quick wakening.
Max torque should be between 3000-3500rpm.
So there must be the point, where engine reach max boost level.
And max power 4000-4500rpm.
It helps to handle the torque.

LOB

You will have 1000/1500 rpm of useful rpms... :S
I like starting at 2000 and end at 4500...

240D 3.0T

I get 7psi of boost and 200ft/lbs of torque at 2200rpm and 100-107hp from 2800-4500rpm. Yeah, not an E320CDI but not bad for a 26 year old engine.

tuikku

The situation of my car is now, that max boost (2bar) comes till ~3000rpm.
It is good level.
You can see it from torque curve.
I have enough low end torque.
Useful revs starts nearby 1000rpm, and last till ~5000rpm.
Look at my earlier posts, and you see, what I mean.

If you want more air to engine, especially to higher revs, where is the need.
You got to have bigger charger(s), there is not any other way.

Smaller charger, and higher boost is not the same thing.
It gives it addition to air mass very early and higher revs it became harmful.

It is very easy to have enough low end torque for these cdi-engines.
Easily you get more, than technics can handle.
So, to have more power, I need enough big charger, that can have more torque (= air) till higher revs, where I need it.
Smaller charger gives more low end torque, and that is not, what I need.
It seems, that whit BIG vnt-charger, it is possible to have enough low end torque and much more air flow to high revs.

I do really hope that I can prove this one day…

Good luck for your experiment.
I am curious...

tuikku

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Finally get it !
It is almost like GT3267, but maybe exhaust side flows better.
Size vs original is ok.
Not too big, should work.

240D 3.0T

Very nice! Where did you get it and what was its original application (vehicle)?

tuikku

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From Fin-turbo.
Not sure about the original engine.
Probably from hino truck, ~7L/~250-300hp.

Original compressor wheel produced too much air and too little pressure.
So it changed.
Exhaust side is original.

There are still a lot work to do.
I start from making new exhaust manifold and oil-flanges.
But it takes some time, I am really busy now at “real” work.

LOB

That's huge!!!

You will need to remove the engine to put there the turbo!!

Good luck.
Best regards

tuikku

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Heh
Not that big.
It is very reasonable size and good form, should fit easily.
Only one machining yet, and I get the oil-flanges to right position.

The original is capable of -> 180hp.
So, the new one should handle 300 horses easily......

LOB

Is being difficult to put a 2260v in my car, I could imagine put this in your car...
It's no easy... My 2260 touch in everywhere... air filter box, starter engine,...

tuikku

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This is already the fourth charger to my car.
So, I have now a little experience about the critical points.

Good luck.

gaiex

Today was a really hot day here 35ºC (not the hottest but...) I plugged my OBD cable and done some readings, specially the intake temperatures.

With 35C air temp, driving normally at fixed speeds (80-120km/h) I had 49C of intake temp! And pushing it in 6th gear to 180-220km/h or pushing a 5th or 4th at lower speeds I had 65-70C, almost of the time 69ºC and some times more than 70ºC!!!

This is too much, for what I know now, after 50ºC the engine begins to cut on diesel and turbo pressure, so... SMOKE!

I definitively need to install my new intercooler that I have waiting at home, but had no time yet, maybe next week I will install it and also the new turbocharger GT2256

tuikku

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Charger is "ready".

tuikku

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I got to do couple of more changes.
Now I am quite pleased.

LOB
This is what I mean right form.
There are space in there, if the charger is right form.
Hope, that I don´t need to eat my words....

tuikku

tuikku

.
This was not particularly "easy birth".

tuikku

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It works !
Quite well, in fact.
Spools enough from "low-revs" and likes high pressures.

Next 4bar map and reprogramming.
Maybe water injection,... some day.

LOB

You are the best :| :|
What a great work, congratulations for it. Your mainfold is amazing... It was you that did it???
I am curious to see the new dyno


My project was a little bit stopped because I am afraid to put the intercooler and the water temperature rises to much... like gaiex car... What you think?
My intercooler was 400x300x76mm

One more thing that I wanted to know... Which is the producer of your wheels? They are light?

Best regards

harkgar

Tuikku,

Your work is truly amazing, taking into account the complexity of the modern engine and car makers' attempts to make their cars tamper proof, for warranty and emission reasons.

Congratulations.

tuikku

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Thank you

Yes, I made myself the manifold and down pipe.
They look terrible, because I had only five days time to all this.
So there was no time for finishing.
If it fits and works, it was good.

I am very pleased for the turbo.
It works fine.
No smoke any more, not at all, it is like modern petrol car.
No matter, how hard I accelerate.
It makes me laughing, when I look it at mirror.
And this moves quite well, even with the "old" program settings.
60-120km/h takes ,5,5-5,7s.

I try to remove intake manifold flaps next weekend.

I haven`t had any cooling problems at all, ever.
The whole cooling system is original.

Only problem is, that temperature rises to "normal" only after hard acceleration.

I have three kind of wheels.
MB-italia, ATP and original light alloy.
None of them is well.
All are too heavy.

One more pic for the turbo.
I had to do very very many little changes on it.
Here it is almost "ready"
Only a couple more mods still, and it fits and works.
This was not so easy job.

harkgar

What is your daytime job, Mr. Tikkui?

Where did you find time to do all this work? From the photos you have a good work area.