2006 W164 Mercedes-Benz ML 320 CDI 224HP (OM642) Stage 3 | Intercooler, Hybrid Turbo
2006 W164 Mercedes-Benz ML 320 CDI 224HP (OM642) Stage 3 | Intercooler, Hybrid Turbo
10-29-2023, 06:40 PM
#1
This is my first journey with car modifications. I've got 2006 W164 ML 320 CDI 224KM with OM642
But for me the car weights too much and it's simply too slow. I've been planning to do some budget upgrades, I've got so far 230 km / 140 mi and so far no problems with the car. Running like a new!
I'm looking to get upgraded:
- Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.
- Custom Intercooler it's a must.
- Fuel pump Bosch Cp3 L110 H 0445010029
- 4 bar map sensor A007 153 0028
- DPF Delete
- EGR Delete
- Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
- AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Advice guys on the setup?
This post was last modified: 10-29-2023, 06:41 PM by Tomas51.
Hello,
This is my first journey with car modifications. I've got 2006 W164 ML 320 CDI 224KM with OM642
But for me the car weights too much and it's simply too slow. I've been planning to do some budget upgrades, I've got so far 230 km / 140 mi and so far no problems with the car. Running like a new!
I'm looking to get upgraded:
- Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.
- Custom Intercooler it's a must.
- Fuel pump Bosch Cp3 L110 H 0445010029
- 4 bar map sensor A007 153 0028
- DPF Delete
- EGR Delete
- Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
- AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Advice guys on the setup?
10-30-2023, 06:48 AM
#2
On my W163 I have a hybrid turbo built by Pioneering Performance in the UK. I know at least two companies in Lithuania sell upgraded turbos for the W164, ECU Tuning Kaunas and Turbo Systems.
[*]Custom Intercooler it's a must.
Yes.
[*]Fuel pump Bosch Cp3 L110 H 0445010029
Yes, that will work.
[*]4 bar map sensor A007 153 0028
Yes this is required.
[*]DPF Delete
A must if going for more performance
[*]EGR Delete
Might as well, less things to go wrong.
[*]Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
Not necessary, but it's one less component that can go wrong.
[*]AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Will not fit the OM642 engine. You will need to get different nozzles fitted to the nozzle holders the OM642 engine uses, as it has piezo injectors while every other Mercedes engine apart from the OM629 has solenoids.
Baldur Gislason
[*]Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.
On my W163 I have a hybrid turbo built by Pioneering Performance in the UK. I know at least two companies in Lithuania sell upgraded turbos for the W164, ECU Tuning Kaunas and Turbo Systems.
[*]Custom Intercooler it's a must.
Yes.
[*]Fuel pump Bosch Cp3 L110 H 0445010029
Yes, that will work.
[*]4 bar map sensor A007 153 0028
Yes this is required.
[*]DPF Delete
A must if going for more performance
[*]EGR Delete
Might as well, less things to go wrong.
[*]Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
Not necessary, but it's one less component that can go wrong.
[*]AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Will not fit the OM642 engine. You will need to get different nozzles fitted to the nozzle holders the OM642 engine uses, as it has piezo injectors while every other Mercedes engine apart from the OM629 has solenoids.
Baldur Gislason
10-30-2023, 07:39 AM
#3
(10-30-2023, 06:48 AM)baldur [*]Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.
On my W163 I have a hybrid turbo built by Pioneering Performance in the UK. I know at least two companies in Lithuania sell upgraded turbos for the W164, ECU Tuning Kaunas and Turbo Systems.
[*]Custom Intercooler it's a must.
Yes.
[*]Fuel pump Bosch Cp3 L110 H 0445010029
Yes, that will work.
[*]4 bar map sensor A007 153 0028
Yes this is required.
[*]DPF Delete
A must if going for more performance
[*]EGR Delete
Might as well, less things to go wrong.
[*]Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
Not necessary, but it's one less component that can go wrong.
[*]AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Will not fit the OM642 engine. You will need to get different nozzles fitted to the nozzle holders the OM642 engine uses, as it has piezo injectors while every other Mercedes engine apart from the OM629 has solenoids.
Thanks baldur for fast response. Can you suggest what kind of budget solution should I look for in replacement for AMG nozzle holders from C30? Let's say I will get all from the list above, but the injectors will be the the limiter factor here to push for more power. Everyone I spoke with, said I should go with X5/X6 35d and for less money I would have better performance. But I really like that ML, and the ride quality is in my opinion better.
(10-30-2023, 06:48 AM)baldur [*]Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.
On my W163 I have a hybrid turbo built by Pioneering Performance in the UK. I know at least two companies in Lithuania sell upgraded turbos for the W164, ECU Tuning Kaunas and Turbo Systems.
[*]Custom Intercooler it's a must.
Yes.
[*]Fuel pump Bosch Cp3 L110 H 0445010029
Yes, that will work.
[*]4 bar map sensor A007 153 0028
Yes this is required.
[*]DPF Delete
A must if going for more performance
[*]EGR Delete
Might as well, less things to go wrong.
[*]Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
Not necessary, but it's one less component that can go wrong.
[*]AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Will not fit the OM642 engine. You will need to get different nozzles fitted to the nozzle holders the OM642 engine uses, as it has piezo injectors while every other Mercedes engine apart from the OM629 has solenoids.
Thanks baldur for fast response. Can you suggest what kind of budget solution should I look for in replacement for AMG nozzle holders from C30? Let's say I will get all from the list above, but the injectors will be the the limiter factor here to push for more power. Everyone I spoke with, said I should go with X5/X6 35d and for less money I would have better performance. But I really like that ML, and the ride quality is in my opinion better.
10-30-2023, 08:24 AM
#4
(10-30-2023, 07:39 AM)Tomas51[*](10-30-2023, 06:48 AM)baldur [*]Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.[*]
On my W163 I have a hybrid turbo built by Pioneering Performance in the UK. I know at least two companies in Lithuania sell upgraded turbos for the W164, ECU Tuning Kaunas and Turbo Systems.
[*]Custom Intercooler it's a must.
Yes.
[*]Fuel pump Bosch Cp3 L110 H 0445010029
Yes, that will work.
[*]4 bar map sensor A007 153 0028
Yes this is required.
[*]DPF Delete
A must if going for more performance
[*]EGR Delete
Might as well, less things to go wrong.
[*]Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
Not necessary, but it's one less component that can go wrong.
[*]AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Will not fit the OM642 engine. You will need to get different nozzles fitted to the nozzle holders the OM642 engine uses, as it has piezo injectors while every other Mercedes engine apart from the OM629 has solenoids.
Thanks baldur for fast response. Can you suggest what kind of budget solution should I look for in replacement for AMG nozzle holders from C30? Let's say I will get all from the list above, but the injectors will be the the limiter factor here to push for more power. Everyone I spoke with, said I should go with X5/X6 35d and for less money I would have better performance. But I really like that ML, and the ride quality is in my opinion better.
You will have to speak with diesel shops about the nozzles. Dieselmeken or ECU Tuning Kaunas.
By the way I have a W211 with the OM642 engine that I'm planning to modify, get some horsepower out of. Not sure about the time frame, I'm just driving it around stock right now but no doubt it will end up with 400+ horsepower.
Baldur Gislason
(10-30-2023, 07:39 AM)Tomas51[*](10-30-2023, 06:48 AM)baldur [*]Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.[*]
On my W163 I have a hybrid turbo built by Pioneering Performance in the UK. I know at least two companies in Lithuania sell upgraded turbos for the W164, ECU Tuning Kaunas and Turbo Systems.
[*]Custom Intercooler it's a must.
Yes.
[*]Fuel pump Bosch Cp3 L110 H 0445010029
Yes, that will work.
[*]4 bar map sensor A007 153 0028
Yes this is required.
[*]DPF Delete
A must if going for more performance
[*]EGR Delete
Might as well, less things to go wrong.
[*]Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
Not necessary, but it's one less component that can go wrong.
[*]AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Will not fit the OM642 engine. You will need to get different nozzles fitted to the nozzle holders the OM642 engine uses, as it has piezo injectors while every other Mercedes engine apart from the OM629 has solenoids.
Thanks baldur for fast response. Can you suggest what kind of budget solution should I look for in replacement for AMG nozzle holders from C30? Let's say I will get all from the list above, but the injectors will be the the limiter factor here to push for more power. Everyone I spoke with, said I should go with X5/X6 35d and for less money I would have better performance. But I really like that ML, and the ride quality is in my opinion better.
You will have to speak with diesel shops about the nozzles. Dieselmeken or ECU Tuning Kaunas.
By the way I have a W211 with the OM642 engine that I'm planning to modify, get some horsepower out of. Not sure about the time frame, I'm just driving it around stock right now but no doubt it will end up with 400+ horsepower.
Baldur Gislason
10-30-2023, 03:46 PM
#5
(10-30-2023, 08:24 AM)baldur[*]That sounds great, looking forward for your project.(10-30-2023, 07:39 AM)Tomas51[*](10-30-2023, 06:48 AM)baldur [*]Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.[*]
On my W163 I have a hybrid turbo built by Pioneering Performance in the UK. I know at least two companies in Lithuania sell upgraded turbos for the W164, ECU Tuning Kaunas and Turbo Systems.
[*]Custom Intercooler it's a must.
Yes.
[*]Fuel pump Bosch Cp3 L110 H 0445010029
Yes, that will work.
[*]4 bar map sensor A007 153 0028
Yes this is required.
[*]DPF Delete
A must if going for more performance
[*]EGR Delete
Might as well, less things to go wrong.
[*]Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
Not necessary, but it's one less component that can go wrong.
[*]AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Will not fit the OM642 engine. You will need to get different nozzles fitted to the nozzle holders the OM642 engine uses, as it has piezo injectors while every other Mercedes engine apart from the OM629 has solenoids.
Thanks baldur for fast response. Can you suggest what kind of budget solution should I look for in replacement for AMG nozzle holders from C30? Let's say I will get all from the list above, but the injectors will be the the limiter factor here to push for more power. Everyone I spoke with, said I should go with X5/X6 35d and for less money I would have better performance. But I really like that ML, and the ride quality is in my opinion better.
You will have to speak with diesel shops about the nozzles. Dieselmeken or ECU Tuning Kaunas.
By the way I have a W211 with the OM642 engine that I'm planning to modify, get some horsepower out of. Not sure about the time frame, I'm just driving it around stock right now but no doubt it will end up with 400+ horsepower.
Regarding 320 CDI injectors in ML. I've got a response from one of the tuners "And by the way the standard injector in this car is already quite large ones." and "4bar map, hybrid turbo, pump and intercooler is enough for 370hp." Do you think it is possible with such setup?
(10-30-2023, 08:24 AM)baldur[*]That sounds great, looking forward for your project.(10-30-2023, 07:39 AM)Tomas51[*](10-30-2023, 06:48 AM)baldur [*]Hybrid turbo, I'm looking for P&P so I don't play too much with it. I was thinking about upgraded 777318.[*]
On my W163 I have a hybrid turbo built by Pioneering Performance in the UK. I know at least two companies in Lithuania sell upgraded turbos for the W164, ECU Tuning Kaunas and Turbo Systems.
[*]Custom Intercooler it's a must.
Yes.
[*]Fuel pump Bosch Cp3 L110 H 0445010029
Yes, that will work.
[*]4 bar map sensor A007 153 0028
Yes this is required.
[*]DPF Delete
A must if going for more performance
[*]EGR Delete
Might as well, less things to go wrong.
[*]Swirl Flap Delete (It is necessary or it's just must have in BMW's?)
Not necessary, but it's one less component that can go wrong.
[*]AMG nozzle holder from C30 (It is necessary or I will be stuck with max 300 hp? Looking to do ~350 hp)
Will not fit the OM642 engine. You will need to get different nozzles fitted to the nozzle holders the OM642 engine uses, as it has piezo injectors while every other Mercedes engine apart from the OM629 has solenoids.
Thanks baldur for fast response. Can you suggest what kind of budget solution should I look for in replacement for AMG nozzle holders from C30? Let's say I will get all from the list above, but the injectors will be the the limiter factor here to push for more power. Everyone I spoke with, said I should go with X5/X6 35d and for less money I would have better performance. But I really like that ML, and the ride quality is in my opinion better.
You will have to speak with diesel shops about the nozzles. Dieselmeken or ECU Tuning Kaunas.
By the way I have a W211 with the OM642 engine that I'm planning to modify, get some horsepower out of. Not sure about the time frame, I'm just driving it around stock right now but no doubt it will end up with 400+ horsepower.
Regarding 320 CDI injectors in ML. I've got a response from one of the tuners "And by the way the standard injector in this car is already quite large ones." and "4bar map, hybrid turbo, pump and intercooler is enough for 370hp." Do you think it is possible with such setup?
10-31-2023, 03:50 AM
#7
(10-30-2023, 04:24 PM)baldur Yes you can definitely make over 300hp on the standard injectors, probably 350 or a little more.
Okay, I see well I think that would be enough for me. After 350 HP I think I will put too much stress on the engine, I think it's just not worth it. I want to keep it as daily driver, not floor it on every red light.
(10-30-2023, 04:24 PM)baldur Yes you can definitely make over 300hp on the standard injectors, probably 350 or a little more.
Okay, I see well I think that would be enough for me. After 350 HP I think I will put too much stress on the engine, I think it's just not worth it. I want to keep it as daily driver, not floor it on every red light.
11-02-2023, 09:55 PM
#8
It took a long time for me to figure out where the leak was coming from, just slip up the mesh sock to see. Since then I had it retuned to run front catalysts again, and a little cooler, around ~800F on large hills, no idea what power but is near stock.
With less restrictive manifolds, much larger turbo with good intercooling, and water meth these would probably make some decent power.
The swirl flaps are just another restriction, if removed will be better, at a minimum make sure they are all open and can't close since the linkages break and slip.
Keep an eye out for the accordion metal piece on the manifold growing holes. Even in stock form they can crack due to the regen heat, but with lot more fuel I'm guessing they would be an easy point of failure due to how thin the metal is. I have that engine in a Jeep, and was using a GDE tune with straight pipe (~250hp). Here was after 150k miles frequently towing max load and lots of hills:
It took a long time for me to figure out where the leak was coming from, just slip up the mesh sock to see. Since then I had it retuned to run front catalysts again, and a little cooler, around ~800F on large hills, no idea what power but is near stock.
With less restrictive manifolds, much larger turbo with good intercooling, and water meth these would probably make some decent power.
The swirl flaps are just another restriction, if removed will be better, at a minimum make sure they are all open and can't close since the linkages break and slip.
11-03-2023, 05:23 AM
#9
(11-02-2023, 09:55 PM)WSchotty Keep an eye out for the accordion metal piece on the manifold growing holes. Even in stock form they can crack due to the regen heat, but with lot more fuel I'm guessing they would be an easy point of failure due to how thin the metal is. I have that engine in a Jeep, and was using a GDE tune with straight pipe (~250hp). Here was after 150k miles frequently towing max load and lots of hills:
It took a long time for me to figure out where the leak was coming from, just slip up the mesh sock to see. Since then I had it retuned to run front catalysts again, and a little cooler, around ~800F on large hills, no idea what power but is near stock.
With less restrictive manifolds, much larger turbo with good intercooling, and water meth these would probably make some decent power.
The swirl flaps are just another restriction, if removed will be better, at a minimum make sure they are all open and can't close since the linkages break and slip.
Thanks, will keep that in mind!
(11-02-2023, 09:55 PM)WSchotty Keep an eye out for the accordion metal piece on the manifold growing holes. Even in stock form they can crack due to the regen heat, but with lot more fuel I'm guessing they would be an easy point of failure due to how thin the metal is. I have that engine in a Jeep, and was using a GDE tune with straight pipe (~250hp). Here was after 150k miles frequently towing max load and lots of hills:
It took a long time for me to figure out where the leak was coming from, just slip up the mesh sock to see. Since then I had it retuned to run front catalysts again, and a little cooler, around ~800F on large hills, no idea what power but is near stock.
With less restrictive manifolds, much larger turbo with good intercooling, and water meth these would probably make some decent power.
The swirl flaps are just another restriction, if removed will be better, at a minimum make sure they are all open and can't close since the linkages break and slip.
Thanks, will keep that in mind!
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