Mercedes 190e 2.3-16V Turbo

[jeandersson]

Hello

First of all, Sorry for not speaking or writing German. I'm from Sweden but thought that this forum would be the best one to present my never ending project.

I have been owning this car since the last ten year and it have been a continues project until today. Focus have mainly been with the engine and trying to increase the power.

I will not be bore you with a long technical specification but some of the changes done to the car/engine is:

Aftermarket control system VEMS 3.X
Customs built Exhaust manifold (pulse split down to turbo/WG)
Customs built Intake manifold (8 separate runners, CNC machined)
Cylinder head flow prepped (stainless Ferrea valves, CatCams-Camshafts, Valve guides from BMW M3)
Pistons Wiseco
Connecting rods K1
Chain driven oil pump (Inspiration from EVO)

The car produce 745hp in dyno measured at the rear wheels @ 2.0bar of boost and 7400RPM when control system is in "race mode".

If you find it of interest more pictures and information of the specific parts of the car/engine will follow in later posts

[Henger]

Hello Johann

welcome to our 16V- Forum
Nice car, your project looks very interesting.

LG Fränk

[Nagilum]

Absolutely and the output is impressive. I already have my money-grave and I'm not sure how/if you're able to get TÜV on that car.

Regards
- Nagi

[jeandersson]

Hi again guys

Thanks for the encouraging words. Since you seem to like what you see I will continue to upload some more pictures. Unfortunately I haven't taken to many pictures during the build but I have some.

Today it's time for introducing the intake. The intake are built up by three CNC-machined flanges. One towards cylinder head, one towards plenum chamber and one towards the throttle body. The rest is just aluminium plates, pipes and bends in various dimensions/cuts. As you can see we have choose to keep the runners separated all the way to the bellmount/cone in the plenum. The design of the Bellmount is (freely) based on this study Link to study-PDF

And some pictures:









Any special request for what to show next exhaust manifold, oil pump modification or engine block with pistons/connecting rods?

[Nagilum]

I want to see it all!

Do you plan to make more than one copy of them? ;>

In germany it's very difficult to get one of a kind for reasonable prices, whatever you need. I have some custom parts and would need some more, but... a) they never get produced because people are too busy or b) company want to have it paid in gold (or maybe take your firstborn).

Regards
- Nagi

[jeandersson]

Hello Johann

welcome to our 16V- Forum
Nice car, your project looks very interesting.

LG Fränk

Hi Fränk,

Thanks for inviting me to your forum

[jeandersson]

I want to see it all!

Do you plan to make more than one copy of them? ;>

In germany it's very difficult to get one of a kind for reasonable prices, whatever you need. I have some custom parts and would need some more, but... a) they never get produced because people are too busy or b) company want to have it paid in gold (or maybe take your firstborn).

Regards
- Nagi

Hi Nagi,

Glad that you like what you see. Should have taken some more pictures during the build but I have some more that will follow.

We have no plans of making more copies. Although we have access to CNC-machining and the drawings are already done the production time is to long. First copy of the intake manifold toke about 200-250hrs to produce. Even if reduced to 150hrs for next one, I don't think it will be economically viable to produce the parts other then for oneself.

//Johan

[jeandersson]

Hi again

Today some pictures of the exhaust manifold. Manifold is built in 2"-stainless steel pipes. Pulse splinted all the way down to turbo charger and waste gate. Waste gate is an MVR Tial 44mm and Turbo charger used is BorgWarner S400SX3 with 71mm inducer. Realize that I don't have any pictures from the actual build but only once finished. So you will have to do with these pictures.

Thanks for the previous comments//
Johan

[jeandersson]

Good morning

Today some pictures from the engine build will follow. I just noticed that I can not upload any more pictures to the gallery since there is a limit of 30 pictures. Does anyone have a easy solution?

Don't hesitate to let me know in case that you have any questions or comments. It would just make the thread more alive to have some conversations instead of having a monologue by myself.

Drive safe guys

[Steffen102992]

Hi, I can only say that I'm totally impressed with the work you did....very big respect for this.

Some questions from me:
What will you do with the finished car? (drag race or sleeper on the road?)

And please tell us something about the conrods and Wiseco pistons.
Are these customized for your engine or are they normally designed for another engine?

[jeandersson]

Hi Steffen,

Thanks for your kind comments. I'm happy to hear that you appreciated the work done to the car/engine.

The intention with the car have always been straight forward racing, 1/8 mile and 1/4 mile. Both on the street and drag-strip. A personal goal have been to drive 10.xx on the 1/4 mile. I have not been able to reach that yet. The engine for sure has potential to reach that time but there have been other small things that have stopped me. We don't have many opportunities to test our street cars on the 1/4 mile here in Sweden (maybe 2 per year if willing to drive 400km to the track from were I live). I have also from time to time tried to sell the car. It would be funny to start a new project in some aspect since I have been with this car for about 10 years now.

Pistons are pretty much Wisecos standard pistons for M102-engine. Bore 96.00mm (first oversize) and with compression ratio 9.0:1. I also changed to DLC-coated piston pins after first seasons use. Was no real problem with the standard ones but small wear patterns could be found and I appreciated if I don't have to open the engine for maintenance every winter. Same with connecting rods, they are K1 Technologies standard rods for the 2.3-16v engine. I did however change the bushing in the small end of the connecting rods since K1 refused to completely specify the material used. So I replaced it with bushings made out of JM-material (Johnson Metall). Can't remember which JM-grade but I can look it up in case that anyone is interested. Experience in the past have showed that the material of the small end bushing are of big importance when the power output is increased.

If any one have a solution to the limitation of pictures in the gallery please let me know.

Take care guys!

Hi, I can only say that I'm totally impressed with the work you did....very big respect for this.

Some questions from me:
What will you do with the finished car? (drag race or sleeper on the road?)

And please tell us something about the conrods and Wiseco pistons.
Are these customized for your engine or are they normally designed for another engine?

[Steffen102992]

Hi thanks for your reply!
Very very interesting. I never tried to put a turbo on a NA engine, I always think it ends with a big bang and a lot of wasted money .


For me there's no doubt.... Sweden =Turboland

[Nagilum]

Awesome stuff!

I don't know about any 30 pictures limit, nor did I find anything limiting this. What I could see: I can't push the number of photos per post higher than 10.

Regards
- Nagi

[jeandersson]

You are perfectly correct. Big turbo=Big hole in the engine block (and wallet) Tried it several times until we found the way to reinforce all components and make it withstand the power. But the amount of power you get in relation to the money invested seems to have a pretty good ratio when it comes to turbo charger compared to other methods.

Hi thanks for your reply!
Very very interesting. I never tried to put a turbo on a NA engine, I always think it ends with a big bang and a lot of wasted money .


For me there's no doubt.... Sweden =Turboland

[jeandersson]

Hmm, when I try to upload more pictures to the Gallery I get the following message

"Information
You are not allowed to upload more than 30 images.
Please contact the administrator for more information."

I would like to show you the build of the chain driven oil pump. But for that I would need to upload some more pictures. Any suggestions would be appreciated

Awesome stuff!

I don't know about any 30 pictures limit, nor did I find anything limiting this. What I could see: I can't push the number of photos per post higher than 10.

Regards
- Nagi

[Steffen102992]

Is there no button with "add file" or something like that?
You can find it underneath your text , when you write something new....

In german it's called "Dateianhang hochladen"

[jeandersson]

Hi Steffen,

Thanks for your help trying to assist this confused man

Is it not necessary to first upload the picture to my gallery/personal album here in the forum? All pictures in my posts have previously been uploaded to » Board index ‹ Gallery ‹ Personal albums ‹ jeandersson after that I have copied the links into my post in order to add the pictures and get them published.

Is there no button with "add file" or something like that?
You can find it underneath your text , when you write something new....

In german it's called "Dateianhang hochladen"

[Nagilum]

Nope, you can just attach them to your posts - one after another. IIRC up to 10 or 15 per post.

[jeandersson]

Thanks for all the help. It was new to me that I could upload the pictures direct in the post. So much easier.

Then we can continue the terrorism of the forum with to large and to many pictures.

The following posts will show how we choose to solve the problem with insufficient oil supply after adding oil consumers like turbo, oil sprayers (underneath the pistons) as well as increasing the RPM. The oil pump solution is inspired by what we have seen in EVO-cars and the diesel ones. As you can see from the pictures the mounting bracket and the oil feed line is all home made, while the drive gear is bought from Mercedes using the article numbers from the EVO-cars.

Take care guys

1.jpg

2.jpg

3.jpg

4.jpg

5.jpg

6.jpg

7.jpg

8.jpg

9.jpg

More pictures/post will follow on the same subject

[Exscom]

Hello. Respect!!! Good jobs!!!!