E320CDI moderate power daily
E320CDI moderate power daily
It also smoked pretty good but previous owner/s did not think much of it obviously. Cause was not bad tuning but faulty EGR valve which leaked exhaust gases into intake at full load. So I did away with whole EGR thing, TIG welded pipe instead and mounted large intercooler. Fairly happy with the result tuned it some more and enjoyed the torque of this engine. Not for long One day luckily few hundred meters from home one cylinder shut down and compresion leaked wildly into crankcase spiting engine oil from every possible hole on engine. At first I tought piston melted but after dissassmebling the engine I found that chip tune, hard driving and EGR causing exhaust temps to rocket into space gave this engine good beating. 6th cylinder was cracked through and all others showed little cracks, no melting just cracking. Simply they went from fairly cold state when cruising into burning hell when gas was slapped and heat cycling destroyed them. Looking for bright side of things the engine got chance to be rebuild and get ready for massive power. ![[Image: 1.JPG]](http://entwicklung.wz.cz/rebuild/1.JPG)
The culprit
![[Image: 5.JPG]](http://entwicklung.wz.cz/rebuild/5.JPG)
Good guy EGR destroying your engine but saves the planet.
![[Image: 7.JPG]](http://entwicklung.wz.cz/rebuild/7.JPG)
![[Image: 8.JPG]](http://entwicklung.wz.cz/rebuild/8.JPG)
Stripped, cleaned, honed and cleaned again.
![[Image: 17.JPG]](http://entwicklung.wz.cz/rebuild/17.JPG)
New main bearings, no.1 was worn and axial bearing the same.
![[Image: 18.JPG]](http://entwicklung.wz.cz/rebuild/18.JPG)
Modified good used pistons, gave it a good read and that combustion bowl ledge which is biggest weakness is there for emisions purpose.. lathe took care of that.
![[Image: 22.JPG]](http://entwicklung.wz.cz/rebuild/22.JPG)
New rings.
![[Image: 25.JPG]](http://entwicklung.wz.cz/rebuild/25.JPG)
Aaand in you go.
![[Image: 27.JPG]](http://entwicklung.wz.cz/rebuild/27.JPG)
Starting to take shape.
![[Image: 32.JPG]](http://entwicklung.wz.cz/rebuild/32.JPG)
Valve job. Shit from EGR got pressed into valve seats causing them to leak.
![[Image: 33.JPG]](http://entwicklung.wz.cz/rebuild/33.JPG)
New oil seals.
![[Image: 36.JPG]](http://entwicklung.wz.cz/rebuild/36.JPG)
Almost done.
![[Image: 40.JPG]](http://entwicklung.wz.cz/rebuild/40.JPG)
Part of power upgrade is fitting big CP3 pump from V8 CDI to up the ability to support high fuel output at much higher pressure than stock engine has.
![[Image: 42.JPG]](http://entwicklung.wz.cz/rebuild/42.JPG)
Reseal that pump and clean it up, dont know where and for how long it sit.
![[Image: 43.JPG]](http://entwicklung.wz.cz/rebuild/43.JPG)
There.. I will have to use some smaller electric cooling fan, original fan will not fit anymore not just becuase of this.
![[Image: 45.JPG]](http://entwicklung.wz.cz/rebuild/45.JPG)
Another big upgrade are injectors from C30AMG with modified master needle lift, should give 50% more fuel than original.
![[Image: 46.JPG]](http://entwicklung.wz.cz/rebuild/46.JPG)
It works.
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
Sooo I aquired this car almost a year ago being one of if not the best diesel engines Mercedes ever produced. Dont bash me with OM606 now, thats for mad race/drift cars but not for eficient daily use. Always had in mind to somehow modify it for more power so I started with remaping it. Soon I found out it was already remaped for ~165kW which explained why it drove so good. It also smoked pretty good but previous owner/s did not think much of it obviously. Cause was not bad tuning but faulty EGR valve which leaked exhaust gases into intake at full load. So I did away with whole EGR thing, TIG welded pipe instead and mounted large intercooler. Fairly happy with the result tuned it some more and enjoyed the torque of this engine. Not for long One day luckily few hundred meters from home one cylinder shut down and compresion leaked wildly into crankcase spiting engine oil from every possible hole on engine. At first I tought piston melted but after dissassmebling the engine I found that chip tune, hard driving and EGR causing exhaust temps to rocket into space gave this engine good beating. 6th cylinder was cracked through and all others showed little cracks, no melting just cracking. Simply they went from fairly cold state when cruising into burning hell when gas was slapped and heat cycling destroyed them. Looking for bright side of things the engine got chance to be rebuild and get ready for massive power.
The culprit
Good guy EGR destroying your engine but saves the planet.
Stripped, cleaned, honed and cleaned again.
New main bearings, no.1 was worn and axial bearing the same.
Modified good used pistons, gave it a good read and that combustion bowl ledge which is biggest weakness is there for emisions purpose.. lathe took care of that.
New rings.
Aaand in you go.
Starting to take shape.
Valve job. Shit from EGR got pressed into valve seats causing them to leak.
New oil seals.
Almost done.
Part of power upgrade is fitting big CP3 pump from V8 CDI to up the ability to support high fuel output at much higher pressure than stock engine has.
Reseal that pump and clean it up, dont know where and for how long it sit.
There.. I will have to use some smaller electric cooling fan, original fan will not fit anymore not just becuase of this.
Another big upgrade are injectors from C30AMG with modified master needle lift, should give 50% more fuel than original.
It works.
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
Nice to see another om648 build
Can you tell more about or develop-"Another big upgrade are injectors from C30AMG with modified master needle lift, should give 50% more fuel than original" or is that secrete stuff?
I a doing a om648 build my self but injectors has been a hard bit since I am trying to locate a appropriate cri2-22/CRI2-25 told build on, and that has been unbelievable hard even if I have have some progress lately
Hi
Nice to see another om648 build
Can you tell more about or develop-"Another big upgrade are injectors from C30AMG with modified master needle lift, should give 50% more fuel than original" or is that secrete stuff?
I a doing a om648 build my self but injectors has been a hard bit since I am trying to locate a appropriate cri2-22/CRI2-25 told build on, and that has been unbelievable hard even if I have have some progress lately
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
Well first off this is W210 hence OM613. I dont think this is secret of any sort. Nozzle size is logical thing, AMG nozzles will give you 15% of fuel above stock nozzle. Real increase comes from injector calibration. Thats when injector builder goes out of bounds and sets needle lift more than BOSCH calls for. This will increase fuel output and decrease life time of injector but screw that. I dont think that I will drive it for another 200-300 000km.
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
so how do you change lift, mechanically or electrically?
the poor thing about c30 injectors is that they will leak quite bad at 1600bar and at 2000bar they will not even open at all.
are you good on injectors?
yes I saw it was om613 since om648 do not have water cooled generator as one thing, so I do not know what got in to me to me to say om648
so how do you change lift, mechanically or electrically?
the poor thing about c30 injectors is that they will leak quite bad at 1600bar and at 2000bar they will not even open at all.
are you good on injectors?
EDIT: Coming to think of that nonsense. Out of fundamental function of that injector it will always open regardles of pressure. It may leak, yes.. but only with damaged ball valves so thats other condition we have remanufactured units.
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
Mechanicaly with shims. Friend is running 200CDI with my software and same HW modifications at 1700Bar and everything opens and delivers power so I dont know where you heard that but it is not true.
EDIT: Coming to think of that nonsense. Out of fundamental function of that injector it will always open regardles of pressure. It may leak, yes.. but only with damaged ball valves so thats other condition we have remanufactured units.
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
Man which did mine injectors is individual and he did not have problem with this, he even suggested some bigger nozzles from Iveco if that wasnt enough.
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
Heh it really depens on who you are talking to but at BOSCH they are really not willing to do such things. Just ask them if they can fit 8mm elements to your M-pump and set governor for 130cc/1000 and you will be surprised by how much "cant be done" answers you get and yet Dieselmeken sold tens if no hundreds of them. Man which did mine injectors is individual and he did not have problem with this, he even suggested some bigger nozzles from Iveco if that wasnt enough.
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
do I understand your right that your guy want to change the DLLA156P1265 nozzle to some Iveco nozzle or do you mean some other injector?
there are some CRIN injectorsd that is way bigger with right injection angel but they are slow in compare to the cri2-22/25
well I have spoken some with Bosch Motorsport and the answer I have received from them make me confused sometimes if I shall cry or laugh many times, but they sure know there stuff but like to have recruits more then some finish guys, no way if you do not have a really really big budget...
do I understand your right that your guy want to change the DLLA156P1265 nozzle to some Iveco nozzle or do you mean some other injector?
there are some CRIN injectorsd that is way bigger with right injection angel but they are slow in compare to the cri2-22/25
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
No I dont, no need for this. With these modified AMG injectors there is enough diesel to destroy gearbox twice.
-------------------------------------------------------------------------------------------------------------------------
Ex: 525tds 130kW, C250TD 160kW, E320CDI 200kW, ML400CDI 230kW, A6 R5TDI 130kW
Now: Q7 V8TDI 240kW, 320d 150kW, 335d 210kW
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
maxypriest
08-04-2016, 11:14 PM #10Very intresting, will watch this closely. Nice rebuild work too :-)
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
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