My 2.5 TDi project

[ColinJack]

Cool copper link pipes on those yellow spots. Did you make them up yourself or buy them?

[FEEZ92]

I bought the copper pipe and cut it to length to fit between the injectors and I soldered in a smaller 4mm pipe into the pipe for no.4 injector to connect to the original fuel system.

Cool copper link pipes on those yellow spots. Did you make them up yourself or buy them?

[ColinJack]

I bought the copper pipe and cut it to length to fit between the injectors and I soldered in a smaller 4mm pipe into the pipe for no.4 injector to connect to the original fuel system.

Cool copper link pipes on those yellow spots. Did you make them up yourself or buy them?

Looks really good. As long as you don't blow the whole thing up in the meantime

Loving this project ... totally mad!

[FEEZ92]

Hi erling
I have reached 6000 on the Di (see one of the earlier videos int the thread)
I love the mercedes engines because they are very easy to get power from

On the Di injectors, there are 5 very tiny holes and they are very restrictive when you try to increase fuel volume per stroke. The "yellow spot" injectors have larger holes so they pass more fuel for the same fuel pressure. This is the main difference between injection systems and tuning Di and IDI engines, the IDI injector has only one big hole and can pass more volume of fuel with less pressure increase.

The exhaust clears to light grey smoke when on boost, I'm hoping it will clear up completely when the Intercooler is fitted. Not the Citroen one, but a universal aluminium intercooler which I will be fitting this week.

I was looking at the Mercedes M45 supercharger for the van, from the W203 petrol, do you think this will be ok to provide enough boost to give some useful torque in the low rev range?
Any advice is greatly appreciated

Hi
I like your project My experience is with Mercedes IDI engines so I am quite new to DI engines. On a IDI engine 6000+ rpm is no problem but I will be surprised if you reach 6000 on the DI. ON the Mercedes IDI we never have to change injectors, the stock ones are good for 100hp+ each I see that you are always talking about changing injectors so I guess the stock ones are quite restrictive
I have a few questions I hope you have time to answer: Does the exhaust clear up when you get boost(any video of your exhaust while driving)? Did you feel some difference with the new injectors? What boost are you running and at what rpm?
Did you install the Citroen IC?
I can try to help you with info on superchargers if you are interested

[FEEZ92]

Thanks, that's why I have spares lol

I bought the copper pipe and cut it to length to fit between the injectors and I soldered in a smaller 4mm pipe into the pipe for no.4 injector to connect to the original fuel system.

Cool copper link pipes on those yellow spots. Did you make them up yourself or buy them?

Looks really good. As long as you don't blow the whole thing up in the meantime

Loving this project ... totally mad!

[James1123]

Feez what intercooler are you going for up front?? what sort of size? any thoughts on pipe work?

I like the look of silicone hoses for the turbo air pipes, any thoughts?

[erling66]

Hi
I consider the Mercedes M45 supercharger too small for a 2,5 DI. your engine use ca 1 liter of air pr turn and the M45 gives 0,67L so if you run it twice as fast as the engine, you will have some boost but not much. So the M62 is a better choice.


You have left to right: M90, M62 and M45(all Eaton).
The M62 on the photo has an electric clutch so that would be a perfect choice. Mercedes and others used it so It should be possible to find used.
I mostly work with the 3.0L mercedes IDI engines and almost everyone use the M90 and run it 2 twice as fast as the engine. That gives ca 0,8-1 bar boost from 1000rpm and up.
There are many other types of superchargers available but often they are very expensive or does not work as well, so most people use the used Eaton M45-M112 superchargers.
To run a supercharger together with a turbo on a diesel engine works quite well but it is a little complicated to hook it up so people only do it if they want a lot of HP or they like the challenge to see if they can make it work.

Different topic: Has anyone tried to drill larger holes in the DI injectors to make them flow more?

[IgorVigor]

the Injector holes are precision drilled so its not a good idea to open them up....

the spray pattern of a Di injector is VERY important!


the 100ps injectors will flow enough for 22psi and 360~380cfm at 4,500rpm....
thats still with a nice smoke haze


anything more than that, and the marine injectors will be needed (still need to get a set for my transit at some point....)
Got a couple of turbo choices for mine

[FEEZ92]

Yeah you can't modify injector holes without specialized equipment. They are extremely tiny, narrower than a hair.

I got an M45 supercharger, it might go better on my W202 Diesel.

Some pics:

[oldyellar]

thats cool as fek needs a modded mk4 grill now

[FEEZ92]

Diff has disintegrated so time to get the welder out I guess

[IgorVigor]

Diff has disintegrated so time to get the welder out I guess

How did you manage to kill the diff?

[FEEZ92]

From doing too much burnouts I guess.
With one wheel spinning it put a lot of stress on the planet gears inside the diff. Also the oil was as thick as grease which obviously didn't help. One of the planet gears broke up and jammed the rest of the operation.......

I welded up the diff today. Pics to follow.......

[FEEZ92]

[robbie.cee]

so it was professionally vandalised then!!

in the last picture, what was it you welded up Feez?

i heard people say the welded up the diff to lock it, but which bits are you locking together?

top thread m8 !