ENGINE MODIFICATION

 

 

Latest Engine tuning:

Engine has recently been pulled down for the 3rd time(explained on page 5) to replace two bent rods,it currently runs OE oversized pistons with OE second hand rods and OE rings.

 

Current tune is 316Hp @ the wheels ~15 to 16psi(red line is lastest tune with twin spray 560cc evo7 injectors)

(blue line was with 2 bent rods,siemens 550cc injectors,slightly less boost with lack of fuel problems)

 

Slotting an exhaust sprocket from another mb engine(5 degress advance/retard)

Results were good given how easy the mod was.

    

Access to adjust it!

     

 

Intake came switch points were optimised by trialing in the full advanced or full retard throughout the rpm range. 

 

 

After having lack of fuel problems it was decided the single spray 550cc seimens injectors may not be atomising correctly into the twin ports,560cc twin spray Evo7 injectors have now been fitted however they required another new fuel rail,suprisingly the result was much more availible fuel.

     

 

 

 

EXTERNAL ENGINE WORK:

 

Custom SM flywheel to replace the DM,OE clutch slipped in 3rd 3000rpm on the first dyno tune so was far from upto the task.

Reused original timing pickup,overall dimensions remain the same as the DM but around 4kg(22%) lighter complete with pressure plate and clutch.

 

            

 

           

 

 

custom kevlar clutch.

 

Swap to N/A belt configuration to eliminate SC belt setup,requires new crank and alternator pullys,alternator relocation braket and aux belt.

            

 

 

Intake manifold:
Billet flange,utilises OE gaskets.

            

 

 

After the flange was hand finshed to suit runner diameter and port size.

 

            

 

Mountings added for FPR etc,fuel mountings were changed to a phenolic material to resist heat transfer to the rail from the head.

            

 

 

Flange and fuel in place,runners onto the flange are extended to give better fitting for the silicone couplers which were nessesary to stop heat transfer and also to make installation and design easy. 

            

 

 

Plenum,a work of art by Jono at PMW.

 

Throttle cable mount and skunk2 68mm TB(OE ~57)

            

 

 

Exhaust manifold,made from thick wall steam pipe,built for strength and durability rather than looks.

            

 

 

 

 

Heat shield wrapped downpipe.

            

 

 

 

3" Exhaust,magnaflow mufflers,Modified C36 Tips(removed baffle to make 2 1/4" inlet)

            

            

            

 

 

Oil in and out from Vito Van M111 front cover,attempt and failed to make the oil feeds on the original.

Custom fittings were made to get the oil in and out,temperary piping fitted while we sort the cooler.

            

 

Cam cover,modified baffle to accomodate the custom vent.

            

 

 

Custom Radiator,vent and window washer tanks.

 

            

 

 

Relocated Heat pump.

 

 

Intake,pipercross filter.

 

 

IC and piping.machined and lobster backed to get correct diameters,looks pretty trick too =).

            

 

 

 

Aeroquip piping.

           

 

Used Motec M400 ECU as we were unable to retune the OE bosch item.Universal loom + sensors.Didnt end up using the bosch coils as we reused the OE.