STD Tuning Engine W210 200 CDI, 200-250 HP/ 450-500 Nm

W210 200 CDI, 200-250 HP/ 450-500 Nm

W210 200 CDI, 200-250 HP/ 450-500 Nm

 
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starynovy
Holset

338
12-27-2015, 06:26 AM #51
To sa to sklada, jedna krasa ked je vsetko nove a leskle. Dlho som tu nebol, ale dovod mojho dymenia bol podfukujuci EGR ventil v zatazi, a zadrete vyrive klapky.

Big Grin
[Image: 23.jpg][Image: 24.jpg][Image: 26.jpg]
A tu niekde bol predtym ten EGR bazmek. Auto uz ide ako drak, neporovnatelne.

For others, I had problems with heavy smoke under load too, especially in higher revs. It seems to be common to CDI engines that EGR valve fails somehow. Mine was blowing by gases even when closed. Also those swirl flaps were so gunked up by soot the could not move at all and port was 1/2 of its original size due to build up. Everything cleaned up, flaps torn out and their holes welded up with AC TIG, same for EGR valve body, removed and replaced with plain aluminium tube. Cars goes like when it left factory. Wink

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
12-27-2015, 06:26 AM #51

To sa to sklada, jedna krasa ked je vsetko nove a leskle. Dlho som tu nebol, ale dovod mojho dymenia bol podfukujuci EGR ventil v zatazi, a zadrete vyrive klapky.

Big Grin
[Image: 23.jpg][Image: 24.jpg][Image: 26.jpg]
A tu niekde bol predtym ten EGR bazmek. Auto uz ide ako drak, neporovnatelne.

For others, I had problems with heavy smoke under load too, especially in higher revs. It seems to be common to CDI engines that EGR valve fails somehow. Mine was blowing by gases even when closed. Also those swirl flaps were so gunked up by soot the could not move at all and port was 1/2 of its original size due to build up. Everything cleaned up, flaps torn out and their holes welded up with AC TIG, same for EGR valve body, removed and replaced with plain aluminium tube. Cars goes like when it left factory. Wink


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

tuikku
GT2256V

132
12-27-2015, 06:42 AM #52
(12-26-2015, 08:16 AM)MartinB I think the best way for you is contact Dieselmeken from your country Wink

Maybe Turbo is interested in this case because of is it really possible inrease fuel flow during injector ~40% using ~11% higher pressure without changing parts in there.
155mm is quite a lot.
In 6 cyl mb engine it meas very close to 1000nm torq and 400hp.
I have made a couple of cars with AMG injectors and they needs here 1800bar to rice that level.
tuikku
12-27-2015, 06:42 AM #52

(12-26-2015, 08:16 AM)MartinB I think the best way for you is contact Dieselmeken from your country Wink

Maybe Turbo is interested in this case because of is it really possible inrease fuel flow during injector ~40% using ~11% higher pressure without changing parts in there.
155mm is quite a lot.
In 6 cyl mb engine it meas very close to 1000nm torq and 400hp.
I have made a couple of cars with AMG injectors and they needs here 1800bar to rice that level.

MartinB
OM605 Power

154
12-27-2015, 12:49 PM #53
I also wondered at, that's too much. So..later i will see. Is there big difference in power with head porting?

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
12-27-2015, 12:49 PM #53

I also wondered at, that's too much. So..later i will see. Is there big difference in power with head porting?


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

MartinB
OM605 Power

154
12-27-2015, 01:42 PM #54
Starynovy: Vypadá to hodně dobře, jak tak koukám Smile

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
12-27-2015, 01:42 PM #54

Starynovy: Vypadá to hodně dobře, jak tak koukám Smile


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

tuikku
GT2256V

132
12-27-2015, 04:09 PM #55
(12-27-2015, 12:49 PM)MartinB I also wondered at, that's too much. So..later i will see. Is there big difference in power with head porting?

You don´t need that.
After you get over 400hp from your engine.
Now ~580hp from OM648 and practically no power mods in engine, only stiffer valve springs.
tuikku
12-27-2015, 04:09 PM #55

(12-27-2015, 12:49 PM)MartinB I also wondered at, that's too much. So..later i will see. Is there big difference in power with head porting?

You don´t need that.
After you get over 400hp from your engine.
Now ~580hp from OM648 and practically no power mods in engine, only stiffer valve springs.

MartinB
OM605 Power

154
12-27-2015, 04:18 PM #56
But i have OM611 not 613 Smile

Stiffer valve springs from where?

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
12-27-2015, 04:18 PM #56

But i have OM611 not 613 Smile

Stiffer valve springs from where?


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

MartinB
OM605 Power

154
12-27-2015, 04:20 PM #57
580hp??? What type of turbo? And injectors? It´s incredible performance Wink

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
12-27-2015, 04:20 PM #57

580hp??? What type of turbo? And injectors? It´s incredible performance Wink


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

Turbo
Holset

489
12-28-2015, 03:49 AM #58
(12-27-2015, 04:09 PM)tuikku
(12-27-2015, 12:49 PM)MartinB I also wondered at, that's too much. So..later i will see. Is there big difference in power with head porting?

You don´t need that.
After you get over 400hp from your engine.
Now ~580hp from OM648 and practically no power mods in engine, only stiffer valve springs.

It would in did be very interesting to know what is needed for that out put since that is exactly what I am looking for
Turbo
12-28-2015, 03:49 AM #58

(12-27-2015, 04:09 PM)tuikku
(12-27-2015, 12:49 PM)MartinB I also wondered at, that's too much. So..later i will see. Is there big difference in power with head porting?

You don´t need that.
After you get over 400hp from your engine.
Now ~580hp from OM648 and practically no power mods in engine, only stiffer valve springs.

It would in did be very interesting to know what is needed for that out put since that is exactly what I am looking for

tuikku
GT2256V

132
12-28-2015, 02:50 PM #59
(12-28-2015, 03:49 AM)Turbo
(12-27-2015, 04:09 PM)tuikku
(12-27-2015, 12:49 PM)MartinB I also wondered at, that's too much. So..later i will see. Is there big difference in power with head porting?

You don´t need that.
After you get over 400hp from your engine.
Now ~580hp from OM648 and practically no power mods in engine, only stiffer valve springs.

It would in did be very interesting to know what is needed for that out put since that is exactly what I am looking for

Very big injectors.
Holset hx40 Super
Very big cooler
Stiffer valve springs
Gridle plate + steel bolts crank/c-rod
tuikku
12-28-2015, 02:50 PM #59

(12-28-2015, 03:49 AM)Turbo
(12-27-2015, 04:09 PM)tuikku
(12-27-2015, 12:49 PM)MartinB I also wondered at, that's too much. So..later i will see. Is there big difference in power with head porting?

You don´t need that.
After you get over 400hp from your engine.
Now ~580hp from OM648 and practically no power mods in engine, only stiffer valve springs.

It would in did be very interesting to know what is needed for that out put since that is exactly what I am looking for

Very big injectors.
Holset hx40 Super
Very big cooler
Stiffer valve springs
Gridle plate + steel bolts crank/c-rod

MartinB
OM605 Power

154
12-28-2015, 03:14 PM #60
Stiffer valve springs are from where?

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
12-28-2015, 03:14 PM #60

Stiffer valve springs are from where?


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

Turbo
Holset

489
12-28-2015, 03:40 PM #61
(12-28-2015, 02:50 PM)Well tuikku can you reveal exactly what injector and who make them since I guess this is the ones BSR is using and and how reliable they areBoost?
(12-28-2015, 03:49 AM)Turbo
(12-27-2015, 04:09 PM)tuikku You don´t need that.
After you get over 400hp from your engine.
Now ~580hp from OM648 and practically no power mods in engine, only stiffer valve springs.

It would in did be very interesting to know what is needed for that out put since that is exactly what I am looking for

Very big injectors.
Holset hx40 Super
Very big cooler
Stiffer valve springs
Gridle plate + steel bolts crank/c-rod
Turbo
12-28-2015, 03:40 PM #61

(12-28-2015, 02:50 PM)Well tuikku can you reveal exactly what injector and who make them since I guess this is the ones BSR is using and and how reliable they areBoost?
(12-28-2015, 03:49 AM)Turbo
(12-27-2015, 04:09 PM)tuikku You don´t need that.
After you get over 400hp from your engine.
Now ~580hp from OM648 and practically no power mods in engine, only stiffer valve springs.

It would in did be very interesting to know what is needed for that out put since that is exactly what I am looking for

Very big injectors.
Holset hx40 Super
Very big cooler
Stiffer valve springs
Gridle plate + steel bolts crank/c-rod

tuikku
GT2256V

132
12-29-2015, 12:35 PM #62
.
No
tuikku
12-29-2015, 12:35 PM #62

.
No

Turbo
Holset

489
12-29-2015, 01:12 PM #63
thanks for that gteat information
Turbo
12-29-2015, 01:12 PM #63

thanks for that gteat information

tuikku
GT2256V

132
12-29-2015, 03:47 PM #64
.
You think that I do  not have the right to decide myself, what to tell and not.
Your trouble is that you don´t want to find answers for yourself, always asking.
And asking many times the very same questions.
And to me it seems that you do not still believe, or understand.
It  has not been so easy to me to find solutions to certain things and I am not telling all here just like that.

There is a reason, why I am here.
And it is not economical in any ways.
tuikku
12-29-2015, 03:47 PM #64

.
You think that I do  not have the right to decide myself, what to tell and not.
Your trouble is that you don´t want to find answers for yourself, always asking.
And asking many times the very same questions.
And to me it seems that you do not still believe, or understand.
It  has not been so easy to me to find solutions to certain things and I am not telling all here just like that.

There is a reason, why I am here.
And it is not economical in any ways.

Turbo
Holset

489
12-29-2015, 05:52 PM #65
If you think that I have not search for information and put down a lot of fa... work, well I can tell you that you are badly mistaken, but to often I have find out in the end that the one that claim can not or do not know in the end, the question is now it seam like you belong to that group.

If I am not mistaken you have said a lot of claims you have not stud up for, you forgotten out last e mail? I always has the idea of sharing is going to be in the common good of this forum

simply if you do not want to share perhaps you can give light what you are doing here so I and some other people can understand it because I am in the dark there, but do not worry, I promise you I will never ask you again.
I wish you best of luck in your projects

In the end I apologize to MartinB for putting this here I do not like it but Mr tuikku is not that keen to answer pm or e mails, please MartinB continue with your great project looking forward to read more about it Smile
Turbo
12-29-2015, 05:52 PM #65

If you think that I have not search for information and put down a lot of fa... work, well I can tell you that you are badly mistaken, but to often I have find out in the end that the one that claim can not or do not know in the end, the question is now it seam like you belong to that group.

If I am not mistaken you have said a lot of claims you have not stud up for, you forgotten out last e mail? I always has the idea of sharing is going to be in the common good of this forum

simply if you do not want to share perhaps you can give light what you are doing here so I and some other people can understand it because I am in the dark there, but do not worry, I promise you I will never ask you again.
I wish you best of luck in your projects

In the end I apologize to MartinB for putting this here I do not like it but Mr tuikku is not that keen to answer pm or e mails, please MartinB continue with your great project looking forward to read more about it Smile

Tito
Holset

354
12-30-2015, 02:33 AM #66
I agree man, this forum is for helping each other out. I would never hold back any info/knowledge I have. I learned a lot (everything STD based) from this forum, so I'm would like to help back. What else would you do on here?
This post was last modified: 12-30-2015, 02:35 AM by Tito.
Tito
12-30-2015, 02:33 AM #66

I agree man, this forum is for helping each other out. I would never hold back any info/knowledge I have. I learned a lot (everything STD based) from this forum, so I'm would like to help back. What else would you do on here?

tuikku
GT2256V

132
12-30-2015, 04:12 AM #67
(12-30-2015, 02:33 AM)Tito I agree man, this forum is for helping each other out. I would never hold back any info/knowledge I have. I learned a lot (everything STD based) from this forum, so I'm would like to help back. What else would you do on here?

Tito, a personal question: Have you shared anything here according to cdi tech. ?
Turbo has not ...
I have, a lot.
Basically everything here in this Martin topic I wrote 2011 here.
Can  you find here new information from cdi, what is true and tested and not me wrote ?
Why don´t you just read my writings here and learn something about cdi working principals ...
Perhaps after that even you have something to share, who knows.

There is something I like to share and something I don´t.
It does not make me better, or worst person, it is my right.
You have that right also, I have never ever blamed you that you have not shared here enough knowledge.
Maybe, after spending enough time and money and time and money to this hobby, you might understand my opinion too.
This post was last modified: 12-30-2015, 04:14 AM by tuikku.
tuikku
12-30-2015, 04:12 AM #67

(12-30-2015, 02:33 AM)Tito I agree man, this forum is for helping each other out. I would never hold back any info/knowledge I have. I learned a lot (everything STD based) from this forum, so I'm would like to help back. What else would you do on here?

Tito, a personal question: Have you shared anything here according to cdi tech. ?
Turbo has not ...
I have, a lot.
Basically everything here in this Martin topic I wrote 2011 here.
Can  you find here new information from cdi, what is true and tested and not me wrote ?
Why don´t you just read my writings here and learn something about cdi working principals ...
Perhaps after that even you have something to share, who knows.

There is something I like to share and something I don´t.
It does not make me better, or worst person, it is my right.
You have that right also, I have never ever blamed you that you have not shared here enough knowledge.
Maybe, after spending enough time and money and time and money to this hobby, you might understand my opinion too.

barrote
Superturbo

1,627
12-30-2015, 04:40 AM #68
hello fine people !!! wish u happy new year to all...
if my opinion matters! sometimes giving too much information on a fórum result in "hold back type" acusations. i have been through that.
these days anyone who wich to know about R/D is better PM otherwise we may end up dispersing "out of knowlegde" info. at least is my way.
there are many persons writing in this fórum that is actions and questions resemble very poor knowlegde on the matter... likewise there are people who opens some light in such matters.
CDI despite i have one in my garage, never messed with it yet, reason simple i dont know how to mod the ECU or even hook it to a PC, wich soft app to read it, and all that very importante thing.... that many tend to be left as a second option.
personally what i would like to see here was a post explaining this basic procedure!!!
thanks , and martinB sorry for the highjacking, wich u good luck with the build.

FD,
Powered by tractor fuel
barrote
12-30-2015, 04:40 AM #68

hello fine people !!! wish u happy new year to all...
if my opinion matters! sometimes giving too much information on a fórum result in "hold back type" acusations. i have been through that.
these days anyone who wich to know about R/D is better PM otherwise we may end up dispersing "out of knowlegde" info. at least is my way.
there are many persons writing in this fórum that is actions and questions resemble very poor knowlegde on the matter... likewise there are people who opens some light in such matters.
CDI despite i have one in my garage, never messed with it yet, reason simple i dont know how to mod the ECU or even hook it to a PC, wich soft app to read it, and all that very importante thing.... that many tend to be left as a second option.
personally what i would like to see here was a post explaining this basic procedure!!!
thanks , and martinB sorry for the highjacking, wich u good luck with the build.


FD,
Powered by tractor fuel

MartinB
OM605 Power

154
12-30-2015, 06:06 AM #69
Yes, Tuikku. I have a lot of knowledges from your topics here, mbworld and mersuforum. It is invaluable. And I can understand that some things can be described almost as a patent. I cant remember how many hours i spent for finding and comparing the various parts (engine, brakes, transmission, interior) in EPC. And thats only small part.
This post was last modified: 12-30-2015, 06:30 AM by MartinB.

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
12-30-2015, 06:06 AM #69

Yes, Tuikku. I have a lot of knowledges from your topics here, mbworld and mersuforum. It is invaluable. And I can understand that some things can be described almost as a patent. I cant remember how many hours i spent for finding and comparing the various parts (engine, brakes, transmission, interior) in EPC. And thats only small part.


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

tuikku
GT2256V

132
12-30-2015, 08:03 AM #70
(12-30-2015, 06:06 AM)MartinB Yes, Tuikku. I have a lot of knowledges from your topics here, mbworld and mersuforum. It is invaluable. And I can understand that some things can be described almost as a patent. I cant remember how many hours i spent for finding and comparing the various parts (engine, brakes, transmission, interior) in EPC. And thats only small part.

Thank you Martin, try Mitsub. Evo springs, they fits
tuikku
12-30-2015, 08:03 AM #70

(12-30-2015, 06:06 AM)MartinB Yes, Tuikku. I have a lot of knowledges from your topics here, mbworld and mersuforum. It is invaluable. And I can understand that some things can be described almost as a patent. I cant remember how many hours i spent for finding and comparing the various parts (engine, brakes, transmission, interior) in EPC. And thats only small part.

Thank you Martin, try Mitsub. Evo springs, they fits

MartinB
OM605 Power

154
12-30-2015, 09:04 AM #71
Thank you too. Hopefully, I'll have a complete engine soon. Next i will try 1500bar. But there are too many other things to do. One of them is backlash in gearshift mechanism (solved). In BMW is it simplier and better.
This post was last modified: 12-30-2015, 09:29 AM by MartinB.
Attached Files
Image(s)
       

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
12-30-2015, 09:04 AM #71

Thank you too. Hopefully, I'll have a complete engine soon. Next i will try 1500bar. But there are too many other things to do. One of them is backlash in gearshift mechanism (solved). In BMW is it simplier and better.

Attached Files
Image(s)
       

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

Riverstick
GT2256V

114
01-14-2016, 05:26 PM #72
Great thread. Funny enough, In Ireland, twin turbo 4 cylinder CDI Mercs have a habit of turning the main bearings....in Sprinter vans...leading to oil starvation etc.

Has anyone figured out why this is happening and what is the cure?

Local guys rebuilding these engines normally cut a deeper groove in the bearing caps to prevent this recurring, and tap the bearing tab deeper into it. Anyone got thoughts on this?

" It is far easier to get forgiveness rather than permission"
Riverstick
01-14-2016, 05:26 PM #72

Great thread. Funny enough, In Ireland, twin turbo 4 cylinder CDI Mercs have a habit of turning the main bearings....in Sprinter vans...leading to oil starvation etc.

Has anyone figured out why this is happening and what is the cure?

Local guys rebuilding these engines normally cut a deeper groove in the bearing caps to prevent this recurring, and tap the bearing tab deeper into it. Anyone got thoughts on this?


" It is far easier to get forgiveness rather than permission"

MartinB
OM605 Power

154
01-14-2016, 06:34 PM #73
I think the main problem is that there isn´t oil pressure sensor. So, you don´t know anything about oil pressure. Oil pressure can be measured only by external pressure gauge.

In WIS - At normal operating temperature of the engine oil, the oil pressure in the idling speed range must not drop below 0,3 bar. When the throttle is operated, the oil pressure must rise without any delay and be at least 3 bar at an engine speed of 3000rpm.

min. 0,3 bar in the idling speed....for me - it´s bad. Old OM602 in the idling I see 1,5-2 bar.

I am planning install my own oil pressure gauge because I don´t want to rebuild this engine unnecessarily anymore Wink

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
01-14-2016, 06:34 PM #73

I think the main problem is that there isn´t oil pressure sensor. So, you don´t know anything about oil pressure. Oil pressure can be measured only by external pressure gauge.

In WIS - At normal operating temperature of the engine oil, the oil pressure in the idling speed range must not drop below 0,3 bar. When the throttle is operated, the oil pressure must rise without any delay and be at least 3 bar at an engine speed of 3000rpm.

min. 0,3 bar in the idling speed....for me - it´s bad. Old OM602 in the idling I see 1,5-2 bar.

I am planning install my own oil pressure gauge because I don´t want to rebuild this engine unnecessarily anymore Wink


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

INC
GTA2056V

76
01-15-2016, 11:35 AM #74
(01-14-2016, 05:26 PM)Riverstick Great thread.  Funny enough, In Ireland, twin turbo 4 cylinder CDI Mercs have a habit of turning the main bearings....in Sprinter vans...leading to oil starvation etc.

Has anyone figured out why this is happening and what is the cure?

Local guys rebuilding these engines normally cut a deeper groove in the bearing caps to prevent this recurring, and tap the bearing tab deeper into it.  Anyone got thoughts on this?

Remove DPF and all is OK.

G300TD(OM606.964) & 250GD(OM605.960)Trophy raid
INC
01-15-2016, 11:35 AM #74

(01-14-2016, 05:26 PM)Riverstick Great thread.  Funny enough, In Ireland, twin turbo 4 cylinder CDI Mercs have a habit of turning the main bearings....in Sprinter vans...leading to oil starvation etc.

Has anyone figured out why this is happening and what is the cure?

Local guys rebuilding these engines normally cut a deeper groove in the bearing caps to prevent this recurring, and tap the bearing tab deeper into it.  Anyone got thoughts on this?

Remove DPF and all is OK.


G300TD(OM606.964) & 250GD(OM605.960)Trophy raid

MartinB
OM605 Power

154
01-15-2016, 12:04 PM #75
DPF wasn´t as standard in W210. I don´t have it.

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
01-15-2016, 12:04 PM #75

DPF wasn´t as standard in W210. I don´t have it.


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
01-15-2016, 01:39 PM #76
O.3Bar on hot engine idling? :Big Grin If I ever saw value like that I would assume that the engine is scraped and dead.

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
01-15-2016, 01:39 PM #76

O.3Bar on hot engine idling? :Big Grin If I ever saw value like that I would assume that the engine is scraped and dead.


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
01-15-2016, 02:17 PM #77
Yes. I don't know why is this in WIS :-) I think the lowest safe oil pressure in the idling is about 1 bar.

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
01-15-2016, 02:17 PM #77

Yes. I don't know why is this in WIS :-) I think the lowest safe oil pressure in the idling is about 1 bar.


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

barrote
Superturbo

1,627
01-15-2016, 05:16 PM #78
thats not so simple , the engine might well be with 0.5 bar in idle and when under load does not reach 3bar at 3000 rpm wich is considered to be good enough, and have 1.5 bar in idle and does not reach 3 bar @3k in dry . but in the rest i agree with all of u.

i had i 612 giving birth in my hand , and it spit the rod bearings out, and it did rotate the caps as well. my findings were related with the rods, i found them week in the botom end. compared to a 606 rod they look a lot weeker , but this is me ....
something is week in this engines, caps , rod ends , oil pump , something is .... weeker that the 606´s

FD,
Powered by tractor fuel
barrote
01-15-2016, 05:16 PM #78

thats not so simple , the engine might well be with 0.5 bar in idle and when under load does not reach 3bar at 3000 rpm wich is considered to be good enough, and have 1.5 bar in idle and does not reach 3 bar @3k in dry . but in the rest i agree with all of u.

i had i 612 giving birth in my hand , and it spit the rod bearings out, and it did rotate the caps as well. my findings were related with the rods, i found them week in the botom end. compared to a 606 rod they look a lot weeker , but this is me ....
something is week in this engines, caps , rod ends , oil pump , something is .... weeker that the 606´s


FD,
Powered by tractor fuel

Riverstick
GT2256V

114
01-16-2016, 01:12 AM #79
Yes, you are right. The bottom end of older Mercedes diesel engines rarely gave trouble. The problem of bearings turning in the block only manifested itself as CDI's got older.

I have seen several 4 cylinder engines turn main bearings(always twin turbo).....the odd 5 cylinder engine, but never a 6 cylinder engine.

I am wondering should the crankshaft damper be changed at a certain mileage to prevent this problem occurring, or is it just a weakness in the securing of the bearings in the bearing caps?

I have seen a good few 150bhp om646 engine blocks replaced with OM611 taken from early production W202 & W210 cars. These engines were fitted with the Sprinter ancillary equipment, although the block has to be drilled and tapped for the oil return for the extra turbo. These engines also had the main bearing securing tab modified to give better 'grip' to the bearing caps. The vans were put back into service and never gave trouble afterwards.

My father tells me in the 1960s a certain model Leyland truck engine had this problem of turning the main bearings. The solution was to 'deepen' the securing tabs in the bearing caps when rebuilding the engines, and he says they never gave any further problems. So, maybe not such a new problem after all?

" It is far easier to get forgiveness rather than permission"
Riverstick
01-16-2016, 01:12 AM #79

Yes, you are right. The bottom end of older Mercedes diesel engines rarely gave trouble. The problem of bearings turning in the block only manifested itself as CDI's got older.

I have seen several 4 cylinder engines turn main bearings(always twin turbo).....the odd 5 cylinder engine, but never a 6 cylinder engine.

I am wondering should the crankshaft damper be changed at a certain mileage to prevent this problem occurring, or is it just a weakness in the securing of the bearings in the bearing caps?

I have seen a good few 150bhp om646 engine blocks replaced with OM611 taken from early production W202 & W210 cars. These engines were fitted with the Sprinter ancillary equipment, although the block has to be drilled and tapped for the oil return for the extra turbo. These engines also had the main bearing securing tab modified to give better 'grip' to the bearing caps. The vans were put back into service and never gave trouble afterwards.

My father tells me in the 1960s a certain model Leyland truck engine had this problem of turning the main bearings. The solution was to 'deepen' the securing tabs in the bearing caps when rebuilding the engines, and he says they never gave any further problems. So, maybe not such a new problem after all?


" It is far easier to get forgiveness rather than permission"

barrote
Superturbo

1,627
01-16-2016, 05:12 AM #80
i see , here where i come from in case we suspect caps want to rotate , its easy .... locktite 271 but this has to be done carefully .
the problem is not new and not so uncommon, sometimes may be a cap defect , nevertheless this type of bearing is not supposed to suffer that much twist, thats why i belive some strange thing is happening in there.
just to confirm u spoke abot OM646 main bearings , and what about the rod bearing?

FD,
Powered by tractor fuel
barrote
01-16-2016, 05:12 AM #80

i see , here where i come from in case we suspect caps want to rotate , its easy .... locktite 271 but this has to be done carefully .
the problem is not new and not so uncommon, sometimes may be a cap defect , nevertheless this type of bearing is not supposed to suffer that much twist, thats why i belive some strange thing is happening in there.
just to confirm u spoke abot OM646 main bearings , and what about the rod bearing?


FD,
Powered by tractor fuel

MartinB
OM605 Power

154
02-11-2016, 06:16 PM #81
Finally the engine is in the car. Also gearbox with better gearshift (original but remanufactured by me). Now I have to build new bigger downpipe.
Attached Files
Image(s)
               

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
02-11-2016, 06:16 PM #81

Finally the engine is in the car. Also gearbox with better gearshift (original but remanufactured by me). Now I have to build new bigger downpipe.

Attached Files
Image(s)
               

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
02-12-2016, 03:38 PM #82
Tell me more about modified gearshift if not secret. Angel

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
02-12-2016, 03:38 PM #82

Tell me more about modified gearshift if not secret. Angel


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
02-12-2016, 04:58 PM #83
As I wrote. Original, only remanufactured. Nothing new. I thought, that i will use BMW gearshift. Maybe in the future :-)

Mercedes gearshift is really bad. But in our C180 Kompressor - It´s precise shifting - like BMW, exactly same (Reverse left from first gear).
This post was last modified: 02-12-2016, 07:21 PM by MartinB.

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
02-12-2016, 04:58 PM #83

As I wrote. Original, only remanufactured. Nothing new. I thought, that i will use BMW gearshift. Maybe in the future :-)

Mercedes gearshift is really bad. But in our C180 Kompressor - It´s precise shifting - like BMW, exactly same (Reverse left from first gear).


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

MartinB
OM605 Power

154
02-28-2016, 02:13 PM #84
Today was a first ride after rebuild. I drove rather max 2500rpm.
Attached Files
Image(s)
                   

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
02-28-2016, 02:13 PM #84

Today was a first ride after rebuild. I drove rather max 2500rpm.

Attached Files
Image(s)
                   

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
03-01-2016, 03:34 PM #85
V tom katalizatore pod autom bolo co? Dalsi normalny kat? Ten za turbom som uz prirodzene kuchol ale pod autom sa mi este nechcelo. Big Grin
Ten EGR ventil by som uplne odstranil, zbytocna prekazka v toku vzduchu. Soft si ides robit sam?

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
03-01-2016, 03:34 PM #85

V tom katalizatore pod autom bolo co? Dalsi normalny kat? Ten za turbom som uz prirodzene kuchol ale pod autom sa mi este nechcelo. Big Grin
Ten EGR ventil by som uplne odstranil, zbytocna prekazka v toku vzduchu. Soft si ides robit sam?


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
03-01-2016, 04:56 PM #86
Jojo, další kat. EGR je znefunkčněn a časem bude nahrazen Smile Soft- Zatim si jen tak projíždím origo mapy stažené z internetu. Takže možná časem. Ale jednu úpravu softu už mi dělali a půjdu na další, až to lehce zajedu. Po opravě a seřízení vstřiků na ještě o něco větší dávku to trochu černě kouří Big Grin. Ale i na ty nízké otáčky to jede dost dobře Wink
This post was last modified: 03-01-2016, 04:57 PM by MartinB.

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-01-2016, 04:56 PM #86

Jojo, další kat. EGR je znefunkčněn a časem bude nahrazen Smile Soft- Zatim si jen tak projíždím origo mapy stažené z internetu. Takže možná časem. Ale jednu úpravu softu už mi dělali a půjdu na další, až to lehce zajedu. Po opravě a seřízení vstřiků na ještě o něco větší dávku to trochu černě kouří Big Grin. Ale i na ty nízké otáčky to jede dost dobře Wink


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
03-01-2016, 05:33 PM #87
No ja uz len cakam na flasher a idem do tej mojej herky, mapy som si uz nasiel v hexdumpe. Big Grin  Akurat montujem 550x230 FMIC miesto toho OE vtipu. Stage 1 remap by mal aspon u mna hodit 230PS a 550Nm. V tych vstrekoch ti menili aj spicky? Viem ze tam pasuju z C30CDI.

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
03-01-2016, 05:33 PM #87

No ja uz len cakam na flasher a idem do tej mojej herky, mapy som si uz nasiel v hexdumpe. Big Grin  Akurat montujem 550x230 FMIC miesto toho OE vtipu. Stage 1 remap by mal aspon u mna hodit 230PS a 550Nm. V tych vstrekoch ti menili aj spicky? Viem ze tam pasuju z C30CDI.


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
03-02-2016, 03:06 AM #88
Já mám originál AMG vstřiky Smile Budu potřebovat určitě přidat hodně vzduchu. A co budeš mít za flasher ?

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-02-2016, 03:06 AM #88

Já mám originál AMG vstřiky Smile Budu potřebovat určitě přidat hodně vzduchu. A co budeš mít za flasher ?


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
03-02-2016, 03:32 AM #89
No najlacnejsie tam bude hodit turbo z 270CDI alebo 320 a doladit to.. Zobral som MPPS.

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
03-02-2016, 03:32 AM #89

No najlacnejsie tam bude hodit turbo z 270CDI alebo 320 a doladit to.. Zobral som MPPS.


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
03-02-2016, 04:31 AM #90
Projdi si celý topic. Mam turbo gt2359v :-)

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-02-2016, 04:31 AM #90

Projdi si celý topic. Mam turbo gt2359v :-)


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

MartinB
OM605 Power

154
03-02-2016, 04:19 PM #91
Today on wet asphalt. Driving with 2nd gear and than full throttle from 1500 to 3000 without using clutch - always wheels spinning. Acceleration with 5th/6th gear from low rpm is really good. But now i need more air because of black smoke - remap. Driving with this car giving me a big smile Smile
Attached Files
Image(s)
   

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-02-2016, 04:19 PM #91

Today on wet asphalt. Driving with 2nd gear and than full throttle from 1500 to 3000 without using clutch - always wheels spinning. Acceleration with 5th/6th gear from low rpm is really good. But now i need more air because of black smoke - remap. Driving with this car giving me a big smile Smile

Attached Files
Image(s)
   

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
03-03-2016, 10:29 AM #92
Hod potom nejake video Wink .

Pozeram ze cockove DEPO svetla.. tiez som ich kupil ale tu shitnu cinsku optiku nahradil Hella Evox-R projektormi, radost jazdit v noci.

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
03-03-2016, 10:29 AM #92

Hod potom nejake video Wink .

Pozeram ze cockove DEPO svetla.. tiez som ich kupil ale tu shitnu cinsku optiku nahradil Hella Evox-R projektormi, radost jazdit v noci.


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
03-03-2016, 11:34 AM #93
V noci jsem zatím neměl problém, svítí to pěkně.

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-03-2016, 11:34 AM #93

V noci jsem zatím neměl problém, svítí to pěkně.


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
03-03-2016, 01:13 PM #94
[Image: 10.jpg]

Left DEPO, right Hella projector.. almost the same. Big Grin

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
03-03-2016, 01:13 PM #94

[Image: 10.jpg]

Left DEPO, right Hella projector.. almost the same. Big Grin


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
03-03-2016, 01:37 PM #95
Woow. With xenon or normal H7?

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-03-2016, 01:37 PM #95

Woow. With xenon or normal H7?


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
03-03-2016, 02:01 PM #96
Both with D2S Osram Xenarc Classic.

This is how it looks at night, lights up as any other brand new car with xenon.. LED lights are another story. Smile

[Image: 43.jpg]

Low-Beam

[Image: 44.jpg]

High-beam (Bi-xenon)

[Image: 45.jpg]

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
03-03-2016, 02:01 PM #96

Both with D2S Osram Xenarc Classic.

This is how it looks at night, lights up as any other brand new car with xenon.. LED lights are another story. Smile

[Image: 43.jpg]

Low-Beam

[Image: 44.jpg]

High-beam (Bi-xenon)

[Image: 45.jpg]


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
03-03-2016, 02:41 PM #97
Hmm really nice, but there is problem- originaly i don´t have xenons. In CZ is this big problem.

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-03-2016, 02:41 PM #97

Hmm really nice, but there is problem- originaly i don´t have xenons. In CZ is this big problem.


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

starynovy
Holset

338
03-03-2016, 03:16 PM #98
Here too, patrols will stop you if it looks suspicious. Like if you mount xenon on skoda fabia, 6500K blue as shit and blind everyone. Big Grin  I had xenon in BMW E34, A6 C4, both never mounted xenon from factory but I had 4300K OE like bulbs and good projectors. Patrols never gave me trouble, never asked about it (had it for 4 years). I gladly took the risk, since I almost hit two pedestrians in rain at night. So how you do it is the key.

-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
starynovy
03-03-2016, 03:16 PM #98

Here too, patrols will stop you if it looks suspicious. Like if you mount xenon on skoda fabia, 6500K blue as shit and blind everyone. Big Grin  I had xenon in BMW E34, A6 C4, both never mounted xenon from factory but I had 4300K OE like bulbs and good projectors. Patrols never gave me trouble, never asked about it (had it for 4 years). I gladly took the risk, since I almost hit two pedestrians in rain at night. So how you do it is the key.


-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW

MartinB
OM605 Power

154
03-05-2016, 08:53 PM #99
Sorry for the quality and radio. Not full rpm. 

https://goo.gl/photos/EnW3pu5vV724YUCp7
This post was last modified: 03-06-2016, 01:26 AM by MartinB.

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-05-2016, 08:53 PM #99

Sorry for the quality and radio. Not full rpm. 

https://goo.gl/photos/EnW3pu5vV724YUCp7


W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

MartinB
OM605 Power

154
03-06-2016, 11:29 AM #100
Little measuring:

Max Boost: 1,4 bar
Max Fueling rate: 80 ml

I think the power is like 320CDI or better. After change the oil, I will go to remap  Wink
Attached Files
Image(s)
       

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual
MartinB
03-06-2016, 11:29 AM #100

Little measuring:

Max Boost: 1,4 bar
Max Fueling rate: 80 ml

I think the power is like 320CDI or better. After change the oil, I will go to remap  Wink

Attached Files
Image(s)
       

W210 E200CDI 185kW Manual, W203 C30 CDI AMG 210kW Manual

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