BMW 325TDS Project Smoke Machine

[mike e30]

Trottle but a mecanical pump would sort all that gayness out

[DaveM-sport]

VGT will make a nice difference. I fitted one to my Defender and it has almost instant power from pretty much idle unlike before where you had to get it wound up to about 2000 before it really got going.

[TorqueWorks]

VGT will make a nice difference. I fitted one to my Defender and it has almost instant power from pretty much idle unlike before where you had to get it wound up to about 2000 before it really got going.

You do the mechanical control way or make an ecu or how?

[TorqueWorks]

Update time.. Tynagh was wet once again had to turn the power right down..

Running the track in reverse presented an interesting challenge, Began using the hydraulic handbrake for the first time and started getting the hang of clipping points too

spent quite a long time in tynagh that week, with a half day karting there on saturday, trackday sunday, and again the following wednesday competing in the inter-universaties competition... anyways, got the car there saturday early... which is extremely rare for us, usually last minute touches happening at 2 in the morning!


been a while since these two ladies were side by side

actually remembered the bumper this time round

few pics of tynagh from various photographers on the day



Owly went doing a bit more land levelling with the front lip & left the bumper behind him


Last thing in the evening, had a bit of a bump with another E36 & pushed in the rear right quarter panel... just as well I completely forgot I had a GoPro with me.


With tynagh not on again until May, we got a move on with testing the Methanol injection this weekend
all the kit setup

small 2.5L tank for now borrowed from another e36, have a 5L tank that was in the car originally as it had headlight washers & a few bits. when its all setup permanently that will be used instead

controller temporarily setup for testing



First methanol trial done with 50/50 methanol/water mix injected at 200psi, no noticable difference with small injector, switched to larger injector (x2 the GPH rating) and began to see mild differences.
Not not much quenching on low boost pressures either, so may be able to start using two injector nozzles together, increase the mix to 75% methanol and continue increasing the injection pressure to 300psi... Its becoming really noticable the boost pressure drops off after 3000-3500rpm so probably a turbo upgrade is the next step before dramatic differences are going to be had

[grange]

Or just pic up m3 running gear lol

[TorqueWorks]

Or just pic up m3 running gear lol

Id expect them comments after page 1... not now!

We had a 328i and a 323i both of which are now soldd on & sliding around tynagh & WGH.. having bought them pretty much to do power comarisons we have a lot more grunt in the diesel, + low running costs.. next up is getting an m3 and matching that for power..

Btw that engine, turbo, intercooler, injectors & diesel pump are still all factory fitted.. its still untouched so a lot more power gain to be had yet

[TorqueWorks]

Right, update

Indirect Injection Fun

Looking at what the guys are at in finland with the M21 engine trying to get better cylinder head flow, raising the headgasket is their way of going about it to get better cylinder head flow from their pre-combustion chambers (Swirl type chambers in the BMW's), that's lowering the compression ratio, but they're compensating by raising the boost pressure

Bit of theory on IDI Engines:
the idea of the pre chamber is air flows into the pre chamber in the compression stroke, the design of them in this engine causes a swirl in the pre chamber, hence the name swirl chamber is also used for this type of indirect injection chamber.. diesel is injected into the swirling air & mixes, that diesel partially ignites in the pre-chamber & creates a pressure that shoves the atomised fuel back into the main chamber. The main chamber is where it meets more air & the main combustion happens during the power stroke.



Looking at the design of the pre chambers in this engine, I think I can achieve a higher head flow by widening the passage to the pre-chamber about 20 to 30 precent, not having to raise the headgasket atall & therefor not really much drop in the existing 22:1 compression. It should help deliver the larger quantities of diesel into the main chamber a lot faster especially under high rpm's (reving to 6000 RPM currently). If it works the engine should be a lot more rev happy, a bit noisier, and with the quantities of diesel we're injecting should burn a lot more of it & develop more power

this could potentially cause dramatically higher combustion temperatures and higher EGT's as a result, but with water/meth injection in place that should lower the combustion temp so everything will be kept under control

pre chamber design

pre chamber position in the head



taking this in mind we removed the spare engine we have for the drifter from the former dog kennel E36 we picked up a few months back. for a bit of experimental head work.


block


cylinder head


6 pre-chambers removed from the head, cleaned a bit & ready to get a go on the milling machine maybe next weekend
the entrance you see, that is going to be enlarged

[TorqueWorks]

Loving this thread. I'm a massive fan of diesels and this stuff is truly fascinating. When your finished here pop over and do my car!

I like the way you think it will ever be actually finished lol

Anyways time for a bit of an update, Have been struggling to find time to get anything done recently with the buildup of coursework & final year project for college, as well as preparing for & attending assesments & Interviews for the Mercedes Formula1 team's Engine & powertrains division. Got through most of the hoops so far & down to final 3 in europe for 2 places with their electrical engineering team.. Would not mind working there #DreamJob

Anyways, the update:
Cylinder head fully stripped down & cleaned, being worked on in cleanroom conditions as you can see :P

soaked everything in a mixture of diesel & petrol for a full week then boiled them, and finally used the die grinder to clean up the valves with steel wool... shiny


even the shite that does build up on the intakes thanks to EGR was dissolved completely



now down to the main job, enlarged pre-chambers on the CNC Milling machie
jig with a face surfaced perpendicular to the angle the entrances were, the reason is that you can set up the jig repeatedly setting this surface horizontal. this ensured every chamber was cut identically and any future chambers can be cut identically too.


after machining


actually noticed slight variations in the casting of the chambers, these are the two that were most different... our cutting was in exactly the same position & precise across all chambers , measure the distance from the side to the casted groove in the pre-chamber and they all varied slightly, measure the distance from the side to the new machined entrance and they are identical.


before & after comparison


wont have time to go at this again until june

[Eoin k]

Fair play is all I've to say!

[TorqueWorks]

Was home from dublin for a few hours earlier today so I attempted something I've been figuring out for a while.... How to give this lady a Remap This older ECU is before the time of the now commonplace plug in remaps, these ladies have to be stripped apart and erased with UV light before programming.. Fuck That! Picked myself up an eprom reader/writer and a few new chips...
and this is what the ECU looks like stripped apart, notice the two chips with the stickers on them, thats actually covering the UV hole for erasing these



chips out, read, and saved to a file then got to the hard bit, figuring out from a bunch of numbers, letters and locations how to distinguish a map from just empty space or other shite you dont need to know about and select it to make it into a 3d graph that can be looked at more visually... Headmelting to say the least, but more interesting than writing my thesis so I managed to figure some of them out
part of the memory dump on one of these eproms... Jibberish to most :P


then eventually you can learn to identify things and get really cool shite to show up, figure out how to convert them from hex to recognisable numbers and edit it... this is my modified torque limiter, one of the most basic maps on the ECU.. as you can see its RPM along the bottom axis, which I have increased from 4250 to 5100 and raised the injection quantity to maximum across the rev range


This is the boost pressure map, remember the boost pressure sensor reads Absolute pressure so 2550 is actually 1.55 Bar boost pressure, this map actually lowers the fuel as the RPM's rise which is probably helping to cause our boost pressure drop


agressively modified... Im not concerned about smoke :P also notice the maximum boost pressure has been raised and the rpms raised




I've flicked around in a lot more of these and fixed them to give me the diesel I want at high revs... Stuck these on the new eeproms earlier and stuck the ECU back into the car and just gave it a quick try... It worked! the car doesnt rev limit anymore it just keeps reving and gives me a wee bit of smoke now without my external chip turned on..... Didnt have time to take it for a spin just yet... but it should prove to be an interesting summer getting the hang of mapping One more week until I get to go back at the other engine too