Dieselboost's 524compoundTD

[DieselBoost]

at this time power goal is about 350hp but that engine is very heavily modified.

i just came to home from carage

now there is the 12mm rotorheadpump and i found that my 524TD goes nuts with that

allmost shitted to pants....that power is awesome

when is was taking 191hp from stock ip there was 1.9bar boost...it is too much but time was running out and i was thinking that makes maximum power.. so it was more easy to run with big boost.

now i have 2.0bar boost with 12mm rotorhead...
engine temperature stays under 90C
exhaust temperature stays under 700C
exhaust pressure stays same what the boost is.
i think this is big success from me

now i must buy a new waterhose...again OLD waterhose exploded.....im thinking how stupid i am when i use those

[Zubcho]

Something new about the project?

Can you tell us the detiled list of the parts that you used and some prices of the parts

[DieselBoost]

Something new about the project?

Can you tell us the detiled list of the parts that you used and some prices of the parts

yes i can...not now but soon.

btw... mild engine exploded...

caused by wastegate malfunction boost was about 4bar and headgasket explodet out...

feels little bit stupid because that happened....so next time i will keep eye on gauge...

interesting thig is that my engine last for 15min before explosion...and water temperature was 85-90c so cooling works fine...

ext gas temperature was about 800c-900c

and base engine was stock..


now im changin new gasket and ready to roll again...

at same time im working with super engine....

[Frybrid 524td]

What new head gasket are you using? Anything special or just a stock gasket?

[DieselBoost]

What new head gasket are you using? Anything special or just a stock gasket?

Stock...because i have one spare

mls gasket is good...but for this engine it is too expensive..

my friend 524td engine is now worked over one year with stock gasket.

power is about 200-250hp and boost 2bar

[Zubcho]

4bar COOL

I'm impressed.

[DieselBoost]

Fun with my friend car...(me driving)

1.6bar boost

i can reveal...this car is builded from junkyard/trash parts

turbo is now new...not anymore 3fd..

now there is Garrett t04b/t04e hybrid...ofcourse turbo parts are from junkpile

so littlebit imagination and this you can get for cheap

http://www.youtube.com/watch?v=lIV3v1V7__Q

[DieselBoost]

So... i repaired my junkpile again.

cyliderhead was totally like a corkscrew caused by heat.

but now it is machined again and engine is running good.

there is one stupid thing to change....there is now fuel pump in tank to getting more fuel for ip but hoses are wrong...

pressure is going to re-circulatingline and leaking lot of fuel out.

[CoyoteStarfish]

I hate to make you repeat yourself DieselBoost, but can you go over the modifications you've made to your injection pump again?

I'm getting ready to look for parts to modify my injection pump (12mm head and rotor, 2.8 or 3.2mm cam plate, etc)

[DieselBoost]

I hate to make you repeat yourself DieselBoost, but can you go over the modifications you've made to your injection pump again?

I'm getting ready to look for parts to modify my injection pump (12mm head and rotor, 2.8 or 3.2mm cam plate, etc)

In my ip is cummins 12mm rotorhead.
but there is adjustments wich i cannot tell anything...because guy who made my ip cant tell me anything....secrets....he say.

but use stock cam plate... i use that too. there is only problems if you use steeper plate.

steeper plate fits nicely to low rpm engines like cummins.

just thinking if my ip cant produce fuel amoun what i need, then i will use mb 300tdt ip maded by mynädiesel with 7mm plungers.

[CoyoteStarfish]

From what I understand, as long as you supply enough pressure and volume of fuel you can run larger cam plates without loss of high end power. On a forum for Cummins engines someone suggested that if we could supply enough pressure and volume of fuel with a quality lift pump and fuel regulator we could run 4mm cam plates. That is a little crazy in my opinion, I would be happy with a 2.8/3.2mm plate used in a stock Cummins, and just supply it with adequate fueling.

Also take a look at this:
http://www.youtube.com/watch?v=LbG4INpF0Ks

Looks like a M21 engine with a heavily modified P7100 injection pump, is that what you're thinking of doing?

[DieselBoost]

yes that is roosamaster pump....that guy who own that car wrote me in youtube..

but yes mercedes row ip.

[DieselBoost]

new video in daylight

HERE! http://www.youtube.com/watch?v=3pI6qduZ3jM

[Alleslowbuged]

Hi,

like that "tractor" sound of a M21 with a straight pipe.
Funny, that you also lost a headgasket though a wasetgate problem, i have lost my second headgasket 2 or 3 hour after restart the engine, because a small boostpipe for the bosstcontroller has get a leakage and i have driven on the autobahn with whatever boost pressure.

Did you have shedule to go on the dyno agian, i would really love to know how much power increases through the the 12mm plunger.

I was on the 1/4 mile this weekend, but could not really decrease my toptime, best run was a 15,2s. Did you was on the dragstrip with your bimmer?

@CoyoteStarfish

In summary you have to make 3 major mods on a pump:
1. bigger plunger for faster injection
2. more advance timing for good high rpm power
3. governor mod, for more fuel at higher RPM than 3500

The hardware mods are not that difficult, if you have the necessary tools, but to find a good setup without a test device and/or a lot of experiency will be nearly imossible. I have 10 years of pump experience and still working since last christmas on my vw pump, to find the best hardware combination and a good setup. The last pump change has been finished in 55min between engine stop and start, so you could imaging how often i have dismount the pump since christmas.

Best Regards from germany
Alleslowbuged

[DieselBoost]

i think im not going to dyno in this moment.... because i will use max 1.7bar boost now.

in finland one 324TD e30 has 12mm plunger with 1.6bar boost and 245hp

i was in dragstrip, but fuel liftpump failure ruined that day. so my car was only in parking lot.

but my friend has 15.6sec time with top speed of 159km/h

and....it was rainy day...so no grip untill 4gear

i think it was quite good time for those weather conditions.

[Alleslowbuged]

Hi,

i drive also max. boost pressure of 1.6 - 1.7 bar in my car. Is the gearbox and differential stock in the car of your friend? The top speed of 159 km/h sound really really quick and should bring a time of below 15s, my top speed is arround 135km/h up to 140km/h, either with a differential ratio of 2.93 or with stock ratio of 3.15.

Why don`t go on the dyno with 1.6 bar, i would really love to see the different in peakpower and also in the power curve vs. engine speed.

Best Regards and always a tight headgasket
Alleslowbuged

[DieselBoost]

gearbox are stock (260) but differential is from 520i

time will tell... there is waiting list of months in dyno....so maybe later.

whatever in next summer i have totally new engine. so then we are talking power seriously.

now there is too small turbo, so i cant get more than 250hp.

[DieselBoost]

check out our facebook group Team3fd

there is our cars.

updating is little bit slow, sorry

[altus22]

How much intercooling do you have? Is it water to air or air to air? Do you know what your peak intake temperature is?

[DieselBoost]

How much intercooling do you have? Is it water to air or air to air? Do you know what your peak intake temperature is?

i dont remember measures. (see my project pics)

but less.

ic is custom made for my car. by erikoishitsaus raatikainen who make coolers for racing cars.

he is one of the bestest aluminum welders in finland.

so i dont use china coolers.

but ic is quite large and very effective.

ic is air to air type....i have no use for air to water. only dragcars and pulling tractors have benefit of that type ic

[DieselBoost]

Now we are talking about serious shit...

while im working with my 524TD
in same carage is something else...

it is Mb 190 300superturbodiesel project of my friend.. actually same guy who owns that other 524TD..

in mb is about 400whp now.

this is only mild test drive. we tested it in asphalt and there wasnt any grip when accelerating full power from 80km/t speed with 4th gear.

http://www.youtube.com/watch?v=tOvmMgQt9oI

http://www.youtube.com/watch?v=fAGidcDBK10

[Zubcho]

wow

[DieselBoost]

Okay AGAIN! i must slow down my project...

Out of money

[DieselBoost]

Juts discovered more broken waterhoses from my car

and second irritating thing..... expansion tank pressure cap is not working properly.

i can only say....upper waterhose was like a piece of rock.

anyway...engine is running fine now, only must get new cap for expansion tank and few new hoses.

in next engine.....i will make waterpipes not bloody hoses DAMN THOSE HOSES!!!

[DieselBoost]

attlast winter came.

So i tested my oilburner

-12c temperature, no block heater, summer type diesel, dry fuel system....

http://www.youtube.com/user/boostturbo? ... sAp6Tx-MYY

then strikes summer type diesel

http://www.youtube.com/user/boostturbo? ... rpsbGCdtHU

[Das_Prachtstrasse]

Love the cold start!

[DieselBoost]

Goodbyes for my garage...

so now is the time to leave my loved carage, it was expensive to keep and our team have own place now.

we are buildin new big carage for our team in my friends ranch. old large cowshed is very cool place for our purpose.
there is room for about six cars.

it smells bit a cow doodoo but it doesnt matter

[DieselBoost]

hello.

I fixed few problems.

1. new expansion tank with newer model plastic cap, water overpressure problem is now fixed....new cap works.

2. fuel lift pump cable connection was poor but now it is fixed

3. engine doesnt start. 4h in warm garage + 20litre winter type fuel with 2litre gas and 1dl 2t oil. and there is now block heater.

now engine is running smooth

[DieselBoost]

What happens when our team gets bored?

http://www.youtube.com/watch?v=VsKPssXMeMQ

[DieselBoost]

Finally i got something good stuff in here....
my friend allowed to upload this vid of his 524TD acceleration testing from last summer.

this engine is maded from scrap parts.

http://www.youtube.com/watch?v=aLZBaPKgk_g

[Zubcho]

Pls give as some pics and more info about the upgrades you have made.

[DieselBoost]

Pls give as some pics and more info about the upgrades you have made.

about my car or my friends car?

http://irc-galleria.net/user/Laskeuma/picture/104062814

this is from my friends 524TD

[Zubcho]

Pls give as some pics and more info about the upgrades you have made.

about my car or my friends car?

http://irc-galleria.net/user/Laskeuma/picture/104062814

this is from my friends 524TD

About your car

[DieselBoost]

ok.....

chassis front
-Koni sport adjustable shock absorters with cobra 45mm lowering springs.
-all powerflex urethane bushes
-all arms replaced with new ones

Chassis rear
-Bilstein new stock shock absorters with cobra 35mm lowering springs
-Powerflex urethane main bushes
-differential is from 520i and it is quite short

Engine

M21D24 from 1991 324TD

engine is refurbished, exception block which is opened only for replacing oil pump with new one.

cylinderhead is cleaned and valves and valve seats are machined, surface is machined.
stock head gasket gemented with vht copper gasket gemetn.
stock head studs
stock cam with timing littlebit earlier.

injection pump with cummins 12mm rotorhead and cummins stock cam plate. and many fine tunes by Pp-Diesel
Timing is 1.15mm before tdc

-gearbox stock getrac 260 5
-Clutch sachsracing 240mm(m5) with stock plate
-528i solid flywheel (240mm)

modified intake manifold
Large intercooler and radiator maded by I Raatikainen
(Erikoishitsaus raatikainen)

stock (524TD)exhaust manifold with my fitting flange with exhaust temperature and exhaust pressure outputs.

Turbo
Master Power SUPER 70 F-2 REFLOW
Model: 802315-063
compressor: 56,5mm
compressor a/r: .70
Turbine: 58,5mm
exhaust a/r: .63
flange: T3
power: 350-490hv

3" downpipe and 3" straight pipe

exteriour

-Color Toytota 162
-Rims ? 17" 7" wide
-Tires hankook ventus k110 215R1745
-rear wing from opel ascona c irmscher

so... nothing very special included for this

there is about 200+?????? power now.

These mods with stock injection pump i had 191hp

now.... much more....

superturbo engine is underconstruction....and in ice...... until i get new job....

[DieselBoost]

so..... some people are thinking to get more liftpressure for injection pump....

i got answers from my pump builder....

never exceed casing pressure of injection pump...

[DieselBoost]

damn... my wet dream
I need more money and bigger garage
In some day i will get a "real" diesel car for my diesel performance projects
http://farm4.static.flickr.com/3403/358 ... 4d7f11.jpg

This is little bit too bligbling for me..... maybe race truck look fits better to me

[DieselBoost]

now im working with water/methanol spray system in my 524

only bad thing is that..... im totally broke...

so must use my creativity with this.....and freebie parts

this is my plan...

-two car headlight washer pumps connected in sequence to get about 4bar pressure.
- oil burner nozzle
-pressure Switch
-limit pressure valve
-self maded tank
-flow controller valve

to increasing water pressure i connect hose from turbo to water tank..

when pumps are making 4bar then boost make extra pressure about 2bar in tank..... i got allmost 6bar waterpressure

and nozzle fitted just before intake manifold

im not making this to get more power...... only to get exhausta/burning gasses little bit cooler and engine lasting longer.

[CoyoteStarfish]

If you want pressure...I suggest you don't use vane style fluid pumps designed for flow and volume. I would use compressed air to pressurize a sealed tank of water/methanol using a small and cheap air compressor designed for inflating tires to pressurize a tank with water/methanol inside.

One option, If you fill the tank with 75% mix and leave 25% air and pressurize it to something crazy like 9 or 10(135-140PSI) bar, it should have enough pressure to push the entire charge of mix out of the tank. You can use a fuel pressure regulator to regulate the pressure of mix leaving the tank if you need to.

Second option is more difficult and more expensive, use the same idea as above but leave the compressor attached, wire it up to a pressure shut-off switch that will limit tank pressure to your desired pressure.

[Frybrid 524td]

Methanol injection isn't advisable in an IDI engine based on what I've read. I plan on adding just water injection at some point after turbo, I/C, and head upgrades.

[DieselBoost]

Methanol injection isn't advisable in an IDI engine based on what I've read. I plan on adding just water injection at some point after turbo, I/C, and head upgrades.

Ok..... in finland we have used methanol/water injection for years..... and it works fine.... in our engines..... only point is dont put too much methanol max 30%

[DieselBoost]

If you want pressure...I suggest you don't use vane style fluid pumps designed for flow and volume. I would use compressed air to pressurize a sealed tank of water/methanol using a small and cheap air compressor designed for inflating tires to pressurize a tank with water/methanol inside.

One option, If you fill the tank with 75% mix and leave 25% air and pressurize it to something crazy like 9 or 10(135-140PSI) bar, it should have enough pressure to push the entire charge of mix out of the tank. You can use a fuel pressure regulator to regulate the pressure of mix leaving the tank if you need to.

Second option is more difficult and more expensive, use the same idea as above but leave the compressor attached, wire it up to a pressure shut-off switch that will limit tank pressure to your desired pressure.

only thing is that those small compressors cant take it.

and if you use those HEADLIGHT washer pumps which are larger.... they can make pressure..... one friend told that he has measured allmost 13bar pressure with those.

this system is what im going to make is used largely in here.
and it works.

and allmost all my parts are free.
i just got pressure switch for free.

[CoyoteStarfish]

13 bar...

That is pretty impressive. I say go for it then! Let us know how it turns out.

[DieselBoost]

13 bar...

That is pretty impressive. I say go for it then! Let us know how it turns out.

i will.

[DieselBoost]

I has new parts..... just bought devils own water spray nozzle and pressure limit valve

but no water games for while..... too freezy to play with water

[Frybrid 524td]

Nice! I'm hoping to put a Cooling Mist kit on someday.

[einstein57]

Hay guys. I'm a total newb when it comes to diesels but I'm pretty comfartable boosting m20s. So just to be clear if I want a moddest increase in boost say 1.5 bar i'd just need to put a bigger turbo and a stronger internal wastegate? No bigger injectors or other mods. Sounds like the factory pump will handle the rest with no mods for my power goals.

[DieselBoost]

Hay guys. I'm a total newb when it comes to diesels but I'm pretty comfartable boosting m20s. So just to be clear if I want a moddest increase in boost say 1.5 bar i'd just need to put a bigger turbo and a stronger internal wastegate? No bigger injectors or other mods. Sounds like the factory pump will handle the rest with no mods for my power goals.

yes.... no bigger mods..... only fine tuning with injection pump...

[einstein57]

Awesome. Guess we will find out how much torque an auto can take. Lol

[Frybrid 524td]

Guess we will find out how much torque an auto can take

FWIW I'm planning to swap in some 4HP24 internals into my 4HP22 sometime this summer to beef it up a bit (That and my A clutch pack needs tending to).
http://www.ashcroft-transmissions.co.uk ... oductId=51

[einstein57]

Wow thats a lot of coin. Really its not but its more then i'm willing to spend on a 25 year old transmission. I'm going to do a 5 speed swap and install a 2.93 lsd when the auto finally gives out. Its pretty smooth and has only 150k miles so it may take a while