1.9TDI PD compound sizing

[majesty78]

The turbo setup is almost similar to the Mercedes cars equipped with the OM651 engine up to 204hp from stock.

I owned one of these in a S212 E-class wagon and therefor had plans for upgrading the turbos, but sold the car before I could use the modified turbo.

However there have been various versions of this bi-turbo setup, depending on application and make year.

It has always been a kp39 with K04 combination, the first ones had 3 vacuum actuators on them, controlling
1. Wastegate K04
2. Turbine Bypass
3. Compressor Bypass

Later versions then had only 2 vacuum actuators, as the compressor bypass was made with the common known checkvalve set to a certain opening pressure difference. So on these units you have 2 actuators, controlling
1. Wastegate K04
2. Turbine Bypass

When modifying the turbo, you actually do not need to make the small high pressure stage bigger, so you will not lose down low boost response / time to torque. Only thrust bearing needs to be taken care of.

However, if I remember correctly the low pressure K04 housings are limited in wall thickness for machining to reasonable bigger wheel sizes.

 

[miniCotulla]

The turbo setup is almost similar to the Mercedes cars equipped with the OM651 engine up to 204hp from stock.

I owned one of these in a S212 E-class wagon and therefor had plans for upgrading the turbos, but sold the car before I could use the modified turbo.

However there have been various versions of this bi-turbo setup, depending on application and make year.

It has always been a kp39 with K04 combination, the first ones had 3 vacuum actuators on them, controlling
1. Wastegate K04
2. Turbine Bypass
3. Compressor Bypass

Later versions then had only 2 vacuum actuators, as the compressor bypass was made with the common known checkvalve set to a certain opening pressure difference. So on these units you have 2 actuators, controlling
1. Wastegate K04
2. Turbine Bypass

When modifying the turbo, you actually do not need to make the small high pressure stage bigger, so you will not lose down low boost response / time to torque. Only thrust bearing needs to be taken care of.

However, if I remember correctly the low pressure K04 housings are limited in wall thickness for machining to reasonable bigger wheel sizes.

Do any of these mercedes come with a manual gearbox? You can mask any missing low end/off idle torque with a torque converter especially if the gearbox has more then 6 speeds.

 

[altz1]

From 163 to 246?

Yep, mine was 163hp (V220d) but even v200d and v250d have same setup and same max value, about 250hp. Mine is 7g auto and 4wd.

 

[majesty78]

Do any of these mercedes come with a manual gearbox? You can mask any missing low end/off idle torque with a torque converter especially if the gearbox has more then 6 speeds.

I think some of the light duty vehicels like the Sprinter came with a 6 speed manual gearbox. Its called 711.680 with 240mm clutch system.

Yep, mine was 163hp (V220d) but even v200d and v250d have same setup and same max value, about 250hp.

Not fully correct. The lower power "200d" engines always came with a single VNT turbo setup. Only the 220 and 250 had the Bi-Turbo.

 

[adamss24]

Do any of these mercedes come with a manual gearbox? You can mask any missing low end/off idle torque with a torque converter especially if the gearbox has more then 6 speeds.

Yeah, the sprinter this came off had a 6 speed manual gearbox…shifts well !

 

[adamss24]

MiniCotulla do you have Any updates ? What turbo did you go for in the end ?

 

[miniCotulla]

MiniCotulla do you have Any updates ? What turbo did you go for in the end ?

Parts are coming in. A used engine is already waiting to be rebuilt. The Mercedes supercharger should fit where the fan and power steering pump used to be. Turbo I don't know, I kinda want to go with something for a BMW M57 with V-band connections and electric actuator. I didn't have a chance to talk to my turbo guy yet. But I hope he has time this week.

 

[miniCotulla]

I'm thinking about using a Turbo from the BMW B57 single turbo engine. Does anybody know if this actuator is compatible with EDC15?

BMW PartNr.: 8584219

 

[adamss24]

No bmw actuator that I know uses pwm or the same frequency to work on a edc15/16 ecu, some of our tech savvy fellow members have made hybrid actuators with half bmw/half Mercedes, or used Volvo/mercedes full actuators. All I know the bmw work the opposite way to Audi actuators and they need modifying as per above !
Keep us updated as I am keen what you do with the car/turbo combo andI hope the Results are worth it ! Also gladyou choose to go single turbo, supercharger/turbocharger is a lot of headache to make run right…

 

[miniCotulla]

No bmw actuator that I know uses pwm or the same frequency to work on a edc15/16 ecu, some of our tech savvy fellow members have made hybrid actuators with half bmw/half Mercedes, or used Volvo/mercedes full actuators. All I know the bmw work the opposite way to Audi actuators and they need modifying as per above !
Keep us updated as I am keen what you do with the car/turbo combo andI hope the Results are worth it ! Also gladyou choose to go single turbo, supercharger/turbocharger is a lot of headache to make run right…

My previous post is 1 year old. The supercharger is going on the engine along with a HTD3054B2 Turbosystems turbo.