The build starts, 320 cdi with stand alone ecu, twin turbo
The build starts, 320 cdi with stand alone ecu, twin turbo
![[Image: 3.JPG]](https://lh6.googleusercontent.com/-o-1rR9P2zpg/TvDWEdg4bMI/AAAAAAAAAIA/BSJKtmmahG0/s800/3.JPG)
![[Image: 1.JPG]](https://lh5.googleusercontent.com/-iaA-ZN_tKuI/TvDUCdur5WI/AAAAAAAAAHo/pPxWc1DNS9w/s800/1.JPG)
![[Image: OM613.jpg]](https://lh4.googleusercontent.com/-WDi-7X0YR8o/TvDRpzJgz7I/AAAAAAAAAHg/MM_Ck_OkX20/s800/OM613.jpg)
![[Image: 2.JPG]](https://lh6.googleusercontent.com/-GKGHJYsyKwc/TvDVQ_zGIOI/AAAAAAAAAIY/5Xxgtm5Tx9c/s800/2.JPG)
Grand cherokee WK (OM642)
diesel2fast4u
12-20-2011, 03:13 PM #1teaser pics, all details of the build will be posted...
Grand cherokee WK (OM642)
Obsidian black 2001 E320 cdi, 18inch AMG wheels, waiting to be modified!
angryspartan
12-21-2011, 02:10 PM #4this is what its all about! cant wait to see this build!
Obsidian black 2001 E320 cdi, 18inch AMG wheels, waiting to be modified!
Powergoal is 400 HP, so 2 should do with acceptable spoolup
We start with standard compression ratio
Grand cherokee WK (OM642)
diesel2fast4u
12-21-2011, 03:08 PM #5Yes, it's the gtb 2056 vk from volvo.
Powergoal is 400 HP, so 2 should do with acceptable spoolup
We start with standard compression ratio
Grand cherokee WK (OM642)
![[Image: Schermafbeelding%2525202011-12-22%252520....29.37.png]](https://lh4.googleusercontent.com/-dZ1BQ4RKSK4/TvTM6mtJ7EI/AAAAAAAAAIs/GTUeYuhqyKM/s800/Schermafbeelding%2525202011-12-22%252520om%25252018.29.37.png)
![[Image: Schermafbeelding%2525202011-12-22%252520....29.12.png]](https://lh6.googleusercontent.com/-5wzPOef4WIA/TvTM6tRf_DI/AAAAAAAAAIo/oYr039-eEO0/s800/Schermafbeelding%2525202011-12-22%252520om%25252018.29.12.png)
Grand cherokee WK (OM642)
1996 MB SL320 Now OM606 7 mm pump elements (myna), KKD manifold, HE341VE, 3,5" downpipe, 3" exhaust, big IC, 722.6 gearbox controller, also controls (Turbo VNT, EGT, BOOST, EGP.)
That's a Cool build you have going on there, witch controller are you going to use BOSCH ?
1996 MB SL320 Now OM606 7 mm pump elements (myna), KKD manifold, HE341VE, 3,5" downpipe, 3" exhaust, big IC, 722.6 gearbox controller, also controls (Turbo VNT, EGT, BOOST, EGP.)
final manifold design :
![[Image: Schermafbeelding%2525202011-12-25%252520....06.09.png]](https://lh4.googleusercontent.com/-QONtgQw6HXM/Tvdy8Ioo7sI/AAAAAAAAAJM/kZmPwRtxSKM/s800/Schermafbeelding%2525202011-12-25%252520om%25252019.06.09.png)
![[Image: Schermafbeelding%2525202011-12-25%252520....08.21.png]](https://lh5.googleusercontent.com/-QMr5Vkby5Eg/Tvd1Do7L8TI/AAAAAAAAAJY/aoxQpFqPqRY/s800/Schermafbeelding%2525202011-12-25%252520om%25252020.08.21.png)
Grand cherokee WK (OM642)
diesel2fast4u
12-25-2011, 02:04 PM #8no, we are using our own controller, I'll post pics tomorrow.
final manifold design :
Grand cherokee WK (OM642)
![[Image: 2.JPG]](https://lh3.googleusercontent.com/-CIQJCgAIuwA/TvnBvAbBqgI/AAAAAAAAAK0/6JiHHEpxWdE/s800/2.JPG)
![[Image: 3.JPG]](https://lh6.googleusercontent.com/-G2Ee9EQ9MU4/TvnBs2YdVlI/AAAAAAAAAKw/fW9f7HROuvA/s800/3.JPG)
(12-27-2011, 12:19 PM)INC Please post details and price for this controler.
It`s NIRA?
No, develloped & produced in Belgium : It manages as well common rail piezo engines, common rail inductive engines, and pump injectors or UIS injectors engines up to 6 cilinders.
People who want details pm me your email
Stainless steel came in for the manifolds, welding starts thursday
![[Image: Schermafbeelding%2525202011-12-26%252520....32.52.png]](https://lh6.googleusercontent.com/-j9zcbk4Oh7o/Tvj6X27mV2I/AAAAAAAAAJo/VO-k9ao9Spk/s800/Schermafbeelding%2525202011-12-26%252520om%25252023.32.52.png)
Grand cherokee WK (OM642)
diesel2fast4u
12-27-2011, 12:52 PM #11(12-27-2011, 12:19 PM)INC Please post details and price for this controler.
It`s NIRA?
No, develloped & produced in Belgium : It manages as well common rail piezo engines, common rail inductive engines, and pump injectors or UIS injectors engines up to 6 cilinders.
People who want details pm me your email
Stainless steel came in for the manifolds, welding starts thursday
Grand cherokee WK (OM642)
(12-27-2011, 02:52 PM)majesty78 Shall this engine go into an W210 engine bay again?No, I am building 2 that are going in a boat
Why?
Grand cherokee WK (OM642)
diesel2fast4u
12-27-2011, 05:41 PM #13(12-27-2011, 02:52 PM)majesty78 Shall this engine go into an W210 engine bay again?No, I am building 2 that are going in a boat
Why?
Grand cherokee WK (OM642)
Mercedes Benz W210 E-Class 320CDI, lowered 2.5", 18" AMG wheels, Decat, EGR removed, Tumble flaps removed, C30 AMG injectors, 400kpa MAP, Custom GT2566XTV turbo, SW tweaked to 300+hp/750Nm
Ok that's what confused me because with those exhaust manifolds it would cause clearence issues in engine bay I guess....
Mercedes Benz W210 E-Class 320CDI, lowered 2.5", 18" AMG wheels, Decat, EGR removed, Tumble flaps removed, C30 AMG injectors, 400kpa MAP, Custom GT2566XTV turbo, SW tweaked to 300+hp/750Nm
(12-27-2011, 06:05 PM)majesty78 Ok that's what confused me because with those exhaust manifolds it would cause clearence issues in engine bay I guess....Should be interesting to try, if you want I send you measurements
Grand cherokee WK (OM642)
diesel2fast4u
12-28-2011, 05:31 PM #15(12-27-2011, 06:05 PM)majesty78 Ok that's what confused me because with those exhaust manifolds it would cause clearence issues in engine bay I guess....Should be interesting to try, if you want I send you measurements
Grand cherokee WK (OM642)
![[Image: IMAGE_A261C084-F66B-4614-8894-CED62C61D7CC.JPG]](https://lh5.googleusercontent.com/-tB9t1eD7SIk/TwsquG_lkrI/AAAAAAAAAMU/rPd3vgOu4zM/s800/IMAGE_A261C084-F66B-4614-8894-CED62C61D7CC.JPG)
Almost done
![[Image: IMAGE_CAC1E7B9-D090-44F8-85E6-5CC7213CDFD6.JPG]](https://lh4.googleusercontent.com/-YLyjuWdk6Vg/TwsrCzRNWAI/AAAAAAAAAL4/OaUaI0h7Yc4/s800/IMAGE_CAC1E7B9-D090-44F8-85E6-5CC7213CDFD6.JPG)
Intercooler
![[Image: IMAGE_29567357-A900-40AB-87F4-B23A50905B1A.JPG]](https://lh4.googleusercontent.com/-ERu2D_kAUhs/TwsrZePLWHI/AAAAAAAAAMc/Fj86-bYWWmo/s800/IMAGE_29567357-A900-40AB-87F4-B23A50905B1A.JPG)
Anyone has used these china intercoolers? I want to use 2 of them on each engine...
They any good?
Grand cherokee WK (OM642)
diesel2fast4u
01-09-2012, 01:18 PM #16flanges
Almost done
Intercooler
Anyone has used these china intercoolers? I want to use 2 of them on each engine...
They any good?
Grand cherokee WK (OM642)
(01-09-2012, 01:18 PM)diesel2fast4u Intercooler
Anyone has used these china intercoolers? I want to use 2 of them on each engine...
They any good?
I have one
1982 300D Turbo ... 3,6xxlbs, No fan, No AC, Hood Stack, No ALDA, No rear bumper and stuffed front, A/W Intercooled, Injectors by Greezer and HUGE Pre-Chambers with help from OM616 & Simpler=Better, Fuel Cranked up, 60 Trim Compressor wheel, EGT, EMP, Boost 50" Rigid Radius bar on roof Aux tank for a total of 48 Gal Of Diesel! Odyssey PC-1750 Battery in trunk, 27"x8.5"/R14 Maxxis BigHorn Mud Terrains, In June '14 issue of Off Road Mag
AX15 Jeep Trans swap in progress....
Captain America
01-10-2012, 01:01 AM #17(01-09-2012, 01:18 PM)diesel2fast4u Intercooler
Anyone has used these china intercoolers? I want to use 2 of them on each engine...
They any good?
I have one
1982 300D Turbo ... 3,6xxlbs, No fan, No AC, Hood Stack, No ALDA, No rear bumper and stuffed front, A/W Intercooled, Injectors by Greezer and HUGE Pre-Chambers with help from OM616 & Simpler=Better, Fuel Cranked up, 60 Trim Compressor wheel, EGT, EMP, Boost 50" Rigid Radius bar on roof Aux tank for a total of 48 Gal Of Diesel! Odyssey PC-1750 Battery in trunk, 27"x8.5"/R14 Maxxis BigHorn Mud Terrains, In June '14 issue of Off Road Mag
AX15 Jeep Trans swap in progress....
@ Alcaid , you are right & they are water cooled
Grand cherokee WK (OM642)
diesel2fast4u
01-10-2012, 11:16 AM #20@ Hugh , I wonder if they are big enough for +400 HP, otherwise I would use 2 on each engine...
@ Alcaid , you are right & they are water cooled
Grand cherokee WK (OM642)
![[Image: IMAGE_8517063F-B1DF-4271-A864-22E7626EE054.JPG]](https://lh3.googleusercontent.com/-aTBkLuSmluM/Twx52dnpKHI/AAAAAAAAANA/6jLHGoWoPaI/s800/IMAGE_8517063F-B1DF-4271-A864-22E7626EE054.JPG)
one ic manufacturer in china told me that those w/a intercoolers couldn't take seawater...I guess it's the brazing material they use in manufacturing or he was being cautious.
(01-11-2012, 07:44 AM)antonmies one ic manufacturer in china told me that those w/a intercoolers couldn't take seawater...I guess it's the brazing material they use in manufacturing or he was being cautious.
The saltwater MUST be run through a brass/bronze heat exchanger to cool antifreeze/water mixture. There MUST also be zinc sacrificial anodes in the saltwater portion. Then, you can use the coolant to cool the charge air. If used in fresh water, you can "get by" with this setup, but MUST fully examine the intercoler EACH time after it is run !!! That would necessitate an inspection plate & pressure checking/vacuum checking each outing. There are many marine intercoolers that are designed for marine/saltwater use that remove the loss of 2 transfer mediums.
When you use salt water (or anything but distilled water to a point) you WILL have electrolysis between dissimilar metals. That will corrode & eventually lead to porosity of the intercooler & eventual engine damage.
I work on marine engines for a living & see all too commonly that when the Zinc annodes are not replaced on a yearly basis that failure is a certainty.
If I were to use a W/A intercooler, I would surely use a couple zinc sacrificial anodes along with antifreeze/distilled water to help ensure longevity. Also, replacing the sacrificial anodes (even at West Marine prices of under $10.00) on a 6 month schedule (unless proven to be over 75% remaining after said time, then up to a year) MANDATORY for longevity.
Any questions, feel free to ask or PM me...
Ed
yankneck696
01-11-2012, 05:08 PM #23(01-11-2012, 07:44 AM)antonmies one ic manufacturer in china told me that those w/a intercoolers couldn't take seawater...I guess it's the brazing material they use in manufacturing or he was being cautious.
The saltwater MUST be run through a brass/bronze heat exchanger to cool antifreeze/water mixture. There MUST also be zinc sacrificial anodes in the saltwater portion. Then, you can use the coolant to cool the charge air. If used in fresh water, you can "get by" with this setup, but MUST fully examine the intercoler EACH time after it is run !!! That would necessitate an inspection plate & pressure checking/vacuum checking each outing. There are many marine intercoolers that are designed for marine/saltwater use that remove the loss of 2 transfer mediums.
When you use salt water (or anything but distilled water to a point) you WILL have electrolysis between dissimilar metals. That will corrode & eventually lead to porosity of the intercooler & eventual engine damage.
I work on marine engines for a living & see all too commonly that when the Zinc annodes are not replaced on a yearly basis that failure is a certainty.
If I were to use a W/A intercooler, I would surely use a couple zinc sacrificial anodes along with antifreeze/distilled water to help ensure longevity. Also, replacing the sacrificial anodes (even at West Marine prices of under $10.00) on a 6 month schedule (unless proven to be over 75% remaining after said time, then up to a year) MANDATORY for longevity.
Any questions, feel free to ask or PM me...
Ed
I don't like the metal work
2morrow more cutting & welding ...
![[Image: IMAGE_589D1184-A615-4B00-BFD6-F6D220D99239.JPG]](https://lh6.googleusercontent.com/-FJt26vnbJUA/Tw9o59BrCpI/AAAAAAAAANk/27YXj0BI87g/s800/IMAGE_589D1184-A615-4B00-BFD6-F6D220D99239.JPG)
![[Image: IMAGE_B9B5FBFD-3BFC-4EAB-8D0F-537B386D452E.JPG]](https://lh5.googleusercontent.com/-Iuv3dyluDTE/Tw9pEcZEe9I/AAAAAAAAANc/0c30GfIkgwI/s800/IMAGE_B9B5FBFD-3BFC-4EAB-8D0F-537B386D452E.JPG)
Grand cherokee WK (OM642)
diesel2fast4u
01-12-2012, 06:17 PM #24only messed up 2 90° before getting it right
I don't like the metal work
2morrow more cutting & welding ...
Grand cherokee WK (OM642)
![[Image: IMAGE_4ECD5E45-447B-4652-8823-7C56B2FD5587.JPG]](https://lh3.googleusercontent.com/-P57J_Y_W3vY/TxFm4TlsMWI/AAAAAAAAAOI/hSrzYE-pej4/s800/IMAGE_4ECD5E45-447B-4652-8823-7C56B2FD5587.JPG)
![[Image: IMAGE_DB051D0A-8566-42D6-9CE1-177CBB57E0F6.JPG]](https://lh5.googleusercontent.com/-MYH3Ken8iOE/TxSQWHP43BI/AAAAAAAAAO4/WSEY2YQ6Rs0/s800/IMAGE_DB051D0A-8566-42D6-9CE1-177CBB57E0F6.JPG)
![[Image: IMAGE_608E1CD9-370C-4E42-A311-3BA3AAC1892C.JPG]](https://lh3.googleusercontent.com/-vtOO0GV6sLA/TxSQryfzNWI/AAAAAAAAAPs/VITf9uI9KNg/s800/IMAGE_608E1CD9-370C-4E42-A311-3BA3AAC1892C.JPG)
![[Image: IMAGE_8CBAD8CB-01E6-4BCF-B053-F5EF0659C538.JPG]](https://lh6.googleusercontent.com/-lueCQMReHpA/TxSQ3kMTvFI/AAAAAAAAAPQ/46uLgAPlRYI/s800/IMAGE_8CBAD8CB-01E6-4BCF-B053-F5EF0659C538.JPG)
![[Image: IMAGE_4C158912-9EB9-44A4-852C-B0BFDA28DCE1.JPG]](https://lh4.googleusercontent.com/-zkdFGSDiFUw/TxSRDsWJLdI/AAAAAAAAAPY/SnVhTbPo13s/s800/IMAGE_4C158912-9EB9-44A4-852C-B0BFDA28DCE1.JPG)
Grand cherokee WK (OM642)
diesel2fast4u
01-16-2012, 04:32 PM #26manifold welding after alot of cutting
Grand cherokee WK (OM642)
Map
2 x EGT
2 x EMP
Lambda
![[Image: IMAGE_34347185-2C78-4A32-9A8E-47545CAB6D25.JPG]](https://lh5.googleusercontent.com/-jRYMWIPL3Hw/TxS27o5qdNI/AAAAAAAAAQE/h1rIVz7co4I/s800/IMAGE_34347185-2C78-4A32-9A8E-47545CAB6D25.JPG)
Back turbo manifold
![[Image: IMAGE_E7F11F02-2B15-4118-9A9D-387A5D279CE9.JPG]](https://lh3.googleusercontent.com/-8A8ma4tQXsk/TxS3GhIUsUI/AAAAAAAAAQI/ZpKmz8VmRCg/s800/IMAGE_E7F11F02-2B15-4118-9A9D-387A5D279CE9.JPG)
Grand cherokee WK (OM642)
diesel2fast4u
01-16-2012, 07:01 PM #27Senders
Map
2 x EGT
2 x EMP
Lambda
Back turbo manifold
Grand cherokee WK (OM642)
Cut the original manifold & took out the swirl valves
![[Image: IMAGE_AFA611FF-EF92-4292-9BDE-E5EABA20EF97.JPG]](https://lh3.googleusercontent.com/-jCG7HxDZt3g/TxW65mETTXI/AAAAAAAAAQg/d85iNA0gRQ8/s800/IMAGE_AFA611FF-EF92-4292-9BDE-E5EABA20EF97.JPG)
![[Image: IMAGE_33852972-ED5D-464C-9639-E1EBA5506A67.JPG]](https://lh4.googleusercontent.com/-T6N0ko8BiyQ/TxW7GvZs2LI/AAAAAAAAAQU/-m8_B9OsKFs/s800/IMAGE_33852972-ED5D-464C-9639-E1EBA5506A67.JPG)
Grand cherokee WK (OM642)
diesel2fast4u
01-17-2012, 01:23 PM #28Started the intake manifold, EGR
Cut the original manifold & took out the swirl valves
Grand cherokee WK (OM642)
![[Image: IMAGE_90BD8B4C-A3E7-4D58-A476-BC574A35BC5F.JPG]](https://lh5.googleusercontent.com/-JczQbCSCAmY/TxbZIQy1i3I/AAAAAAAAAQ0/L0CokFULQgM/s800/IMAGE_90BD8B4C-A3E7-4D58-A476-BC574A35BC5F.JPG)
Grand cherokee WK (OM642)
diesel2fast4u
01-18-2012, 09:58 AM #29I am not quitting my day job, but getting the hang of it
Grand cherokee WK (OM642)
1982 300D Turbo ... 3,6xxlbs, No fan, No AC, Hood Stack, No ALDA, No rear bumper and stuffed front, A/W Intercooled, Injectors by Greezer and HUGE Pre-Chambers with help from OM616 & Simpler=Better, Fuel Cranked up, 60 Trim Compressor wheel, EGT, EMP, Boost 50" Rigid Radius bar on roof Aux tank for a total of 48 Gal Of Diesel! Odyssey PC-1750 Battery in trunk, 27"x8.5"/R14 Maxxis BigHorn Mud Terrains, In June '14 issue of Off Road Mag
AX15 Jeep Trans swap in progress....
Captain America
01-19-2012, 02:47 AM #30Looking much better!
1982 300D Turbo ... 3,6xxlbs, No fan, No AC, Hood Stack, No ALDA, No rear bumper and stuffed front, A/W Intercooled, Injectors by Greezer and HUGE Pre-Chambers with help from OM616 & Simpler=Better, Fuel Cranked up, 60 Trim Compressor wheel, EGT, EMP, Boost 50" Rigid Radius bar on roof Aux tank for a total of 48 Gal Of Diesel! Odyssey PC-1750 Battery in trunk, 27"x8.5"/R14 Maxxis BigHorn Mud Terrains, In June '14 issue of Off Road Mag
AX15 Jeep Trans swap in progress....
![[Image: Schermafbeelding%2525202012-01-16%252520....16.34.png]](https://lh4.googleusercontent.com/-XqMpkpOE4q8/TxhX-lc5T_I/AAAAAAAAAR8/sVZHfsKEBdU/s800/Schermafbeelding%2525202012-01-16%252520om%25252008.16.34.png)
have some nice info on cdi injectors
1350bar Standard OM 613 injectors tested at 1600bar:
2000 injections 1100 ms = 117gr
With AMG nozzle at 1600 bar:
2000 injections 1100 ms = 204gr
Grand cherokee WK (OM642)
diesel2fast4u
01-19-2012, 12:53 PM #31intercooler design
have some nice info on cdi injectors
1350bar Standard OM 613 injectors tested at 1600bar:
2000 injections 1100 ms = 117gr
With AMG nozzle at 1600 bar:
2000 injections 1100 ms = 204gr
Grand cherokee WK (OM642)
With 90mg/stroke you get about 100Nm per cylinder ;-)
Well... we decided to put the nozzles in & see what is going to happin on the dyno....
Grand cherokee WK (OM642)
diesel2fast4u
01-20-2012, 11:42 AM #33[quote='majesty78' pid='37727' dateline='1327038790']
With 90mg/stroke you get about 100Nm per cylinder ;-)
Well... we decided to put the nozzles in & see what is going to happin on the dyno....
Grand cherokee WK (OM642)
![[Image: IMAGE_8E13D870-240C-4EE6-A8F9-834C0EDCC52D.JPG]](https://lh3.googleusercontent.com/-e_XKfTw5l28/Txr0Me4zrAI/AAAAAAAAASI/8IfVX73yGtU/s800/IMAGE_8E13D870-240C-4EE6-A8F9-834C0EDCC52D.JPG)
![[Image: IMAGE_2452BFC4-7F70-4574-B38B-2B5CDEA2ABF5.JPG]](https://lh4.googleusercontent.com/-VsAW-aYfCyg/Txr0YUhMy9I/AAAAAAAAASQ/3giJFJXvSp4/s800/IMAGE_2452BFC4-7F70-4574-B38B-2B5CDEA2ABF5.JPG)
![[Image: 12%25252019%25253A53%25253A56.jpg]](https://lh4.googleusercontent.com/-iHuT2agaYQ0/Tx7-afvMS7I/AAAAAAAAAWg/-RRQvcZIyHI/s800/12%25252019%25253A53%25253A56.jpg)
I think this is the L110 pump, meaning leftturning 1100mm³ theoretical displacement per pump revolution
I've did some reading about the mods done to these pump, and it seems the US companies are asking up to 1000$ for some really basic mods, which usually are ported feedpump and metering valve.. I didnt found a proof they use bigger bore plunjers or difference E-shaft for more lift
I think this is the L110 pump, meaning leftturning 1100mm³ theoretical displacement per pump revolution
(01-29-2012, 12:57 AM)zeeman I am using the same engine a 2006 in a Street Rod project and need a stand alone computer to make it work, were did you gets yours? I also have a flywheel and bellhousing if you still need them. Is there anyway to use the stock computer?
Stock computer is in my opinion impossible because you would need a bosch wizard to turn off all things in the ECU you don't use in your car that will put the engine in Limp mode.
With EDC15 it was doable but not with EDC16, on top of that you can't run electronic VNT or VGT turbo's with the EDC15.
Pm me your email address
Grand cherokee WK (OM642)
diesel2fast4u
01-29-2012, 03:50 AM #41(01-29-2012, 12:57 AM)zeeman I am using the same engine a 2006 in a Street Rod project and need a stand alone computer to make it work, were did you gets yours? I also have a flywheel and bellhousing if you still need them. Is there anyway to use the stock computer?
Stock computer is in my opinion impossible because you would need a bosch wizard to turn off all things in the ECU you don't use in your car that will put the engine in Limp mode.
With EDC15 it was doable but not with EDC16, on top of that you can't run electronic VNT or VGT turbo's with the EDC15.
Pm me your email address
Grand cherokee WK (OM642)
![[Image: IMAGE_E7741FC7-FA44-492D-B9D2-7D837E21ADC3.JPG]](https://lh6.googleusercontent.com/-nxMIlucjPNk/TybrRBT3yKI/AAAAAAAAAYU/JeBtPSa-TEA/s800/IMAGE_E7741FC7-FA44-492D-B9D2-7D837E21ADC3.JPG)
Cut the intercoolers (thanks Joe)
![[Image: IMAGE_FAADB5B8-CAF2-4ADB-B94E-59C7D521F04C.JPG]](https://lh4.googleusercontent.com/-PBAd1ttIBCs/Tybr1mN3MRI/AAAAAAAAAYs/n1YxXMzgXQc/s800/IMAGE_FAADB5B8-CAF2-4ADB-B94E-59C7D521F04C.JPG)
Core
![[Image: IMAGE_9165E456-F26F-441F-9666-F1E59ACD332E.JPG]](https://lh3.googleusercontent.com/-Clfce709DJE/TybrqZrvN-I/AAAAAAAAAYk/1z6W7OyNmDc/s800/IMAGE_9165E456-F26F-441F-9666-F1E59ACD332E.JPG)
Welded :
![[Image: IMAGE_1BEEEFD5-A94E-4C79-BBB3-26A7A2A69678.JPG]](https://lh4.googleusercontent.com/-A5XThA4Ya7Q/Tybr-3xemuI/AAAAAAAAAY0/BZDNLaCFdz8/s800/IMAGE_1BEEEFD5-A94E-4C79-BBB3-26A7A2A69678.JPG)
Intake ready for welding :
![[Image: IMAGE_BCB97801-994E-42C6-B4F8-15AF93B82692.JPG]](https://lh4.googleusercontent.com/-YltDDB4nFjU/TybsJlbzQUI/AAAAAAAAAY8/gCxCJDlQTDg/s800/IMAGE_BCB97801-994E-42C6-B4F8-15AF93B82692.JPG)
Turbo mock up
![[Image: IMAGE_0E02194C-A7C7-40C9-B01A-616B0D5DEF27.JPG]](https://lh4.googleusercontent.com/-CdBTRWs6T94/TybsemRjfQI/AAAAAAAAAZM/_rVgvQ1QdAM/s800/IMAGE_0E02194C-A7C7-40C9-B01A-616B0D5DEF27.JPG)
![[Image: IMAGE_8270B2D3-C5D8-4A2A-9729-8DFED17E604E.JPG]](https://lh6.googleusercontent.com/-tZFa0hpoS_o/TybsqInrOoI/AAAAAAAAAZU/PSiYnBKl9x0/s800/IMAGE_8270B2D3-C5D8-4A2A-9729-8DFED17E604E.JPG)
![[Image: IMAGE_9771320C-63D9-4B2D-97BC-A1504E67C5FA.JPG]](https://lh4.googleusercontent.com/-Dlt09bSPbc0/Tybs2SQInQI/AAAAAAAAAZc/4RaTn1YMR70/s800/IMAGE_9771320C-63D9-4B2D-97BC-A1504E67C5FA.JPG)
Grand cherokee WK (OM642)
diesel2fast4u
01-30-2012, 02:52 PM #42did some work today
Cut the intercoolers (thanks Joe)
Core
Welded :
Intake ready for welding :
Turbo mock up
Grand cherokee WK (OM642)
What a great project. What wonderful results.
I did, however, notice something that set me wondering.
When building headers, the weld really matters and more welding is generally worse than less welding because of fatigue cracking.
I have always, ALWAYS seen, and been told, a header is welded on the gasket side of the flange. It is never welded on both sides of the flange. The single weld on the gasket side (against the engine block) is then dressed down smooth and the outboard side of the flange is left unwelded.
Those that do weld the outboard side of the flange invariably have a very good looking and stout header -- except it soon cracks miserably from fatigue and vibration.
Now, does that apply here? I can't say. But it does apply in gassers of just about every size.
And I'm certainly not trying to stall your wonderful project. And I'm not saying you will experience abysmal failures. And I'm not saying to yank all that apart and rebuild it, Heavens No! Everything might be just fine.
But if you end up faced with a mysterious cracking problem, you might look into that because it seems to always happen.
toomanydiesels
02-11-2012, 11:00 AM #43I really hope someone corrects me on this, but I absolutely have to mention something.
What a great project. What wonderful results.
I did, however, notice something that set me wondering.
When building headers, the weld really matters and more welding is generally worse than less welding because of fatigue cracking.
I have always, ALWAYS seen, and been told, a header is welded on the gasket side of the flange. It is never welded on both sides of the flange. The single weld on the gasket side (against the engine block) is then dressed down smooth and the outboard side of the flange is left unwelded.
Those that do weld the outboard side of the flange invariably have a very good looking and stout header -- except it soon cracks miserably from fatigue and vibration.
Now, does that apply here? I can't say. But it does apply in gassers of just about every size.
And I'm certainly not trying to stall your wonderful project. And I'm not saying you will experience abysmal failures. And I'm not saying to yank all that apart and rebuild it, Heavens No! Everything might be just fine.
But if you end up faced with a mysterious cracking problem, you might look into that because it seems to always happen.
manifold, watercooled intercooler, oil cooler, and power steering oil cooler . Run with a modified Bosch original ECU. Lot of work avoiding limp mode , but ok now.
I am also running with a heavy flywheel.
Your project are with exhaust direct into the two turboes and dry exhaust after turboes. In my opinion that should create a lot of heat
in the engine room and where are you routing the seawater outlet ?
These 6 cyl engine runs very smooth and well balanced.
Boatbuilder
04-23-2012, 09:36 AM #44Hi, nice project. I have two similar engines in my boat. next friday in the sea for final testing. Runs with Bravo III and watercooled exhaust
manifold, watercooled intercooler, oil cooler, and power steering oil cooler . Run with a modified Bosch original ECU. Lot of work avoiding limp mode , but ok now.
I am also running with a heavy flywheel.
Your project are with exhaust direct into the two turboes and dry exhaust after turboes. In my opinion that should create a lot of heat
in the engine room and where are you routing the seawater outlet ?
These 6 cyl engine runs very smooth and well balanced.
Theturbodave
05-17-2012, 08:47 AM #45Good work man. I had one question on the twin turbo manifolds i have done you have to run a balance tube between manifold or a surge will happen between the turbo due to firing order of the cylinder (2 cylinders fire in one manifold while other one only one fires and the it switchs). Is there something different on the diesel engine. This happens at light loads part throttle. Just asking, keep up the good work u have some good skills.
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