PSClub - Hellas :: Επισκόπηση Θ.Ενότητας - 206

PSClub - Hellas

Κινητήρας - 206 - 206 2,2L HDI 16

MEMsound - Δευ 06 Μάρ 2006, 00:47:58
Θέμα δημοσίευσης: 206 - 206 2,2L HDI 16

lybker έγραψε:

well... finally got I the job done - allmost that is:

just wanted to show off some of the progress pics and the first testdrive Smile

..As its such a relief having it done - only need to sort some of the rattle from all the loose bits needed to be boltet on somewhere...

engine:
http://www.efterz.com/lars/206_2.2HDI/2xturbo_01.JPG

diff. bits:
http://www.efterz.com/lars/206_2.2HDI/oilpressure.JPG
http://www.efterz.com/lars/206_2.2HDI/clutch.jpg

day 2:
http://www.efterz.com/lars/206_2.2HDI/206_2.2hdi_day2.JPG

day 3:
http://www.efterz.com/lars/206_2.2HDI/206_2.2hdi_day3.JPG

day 4:
http://www.efterz.com/lars/206_2.2HDI/206_2.2hdi_day4.JPG

first drive video:
http://www.efterz.com/lars/206_2.2HDI/206_2.2hdi_1st_drive.wmv

...off to get it remapped Smile

brz20 - Πεμ 09 Μάρ 2006, 00:44:55
Θέμα δημοσίευσης:

Πολυ καλο θα ελεγα.Αν και θα με βολευαν λιγα περισσοτερα στοιχεια εκτος των φωτογραφιων

tsosmoulis - Δευ 13 Μάρ 2006, 20:56:40
Θέμα δημοσίευσης:

εχει και βιντεακι... Very happy

MEMsound - Παρ 17 Μάρ 2006, 12:33:31
Θέμα δημοσίευσης:

....συνεχεια....

Στην περίπτσωση που δεν έχετε καταλάβει μιλάμε για Biturbo moter... Cool

lybker έγραψε:

...well its not completly legal - but fun Smile

did a new video to show how boost works between the 2 turbos -

you will see at the moment there is so little fuel that I can´t boost the large turbo more than 0,5bar - this results in 1,8bar after its compressed again through the second turbo.

to hint how slow it is to boost: at 2200rpm it delivers 1 bar boost on the small turbo...(when the dials are vertical - it shows 1 bar)

This will of course change as soon as the car is mapped tomorrow Smile

Link: http://www.efterz.com/lars/206_2.2HDI/twin_boost.wmv

lybker έγραψε:

well got it mapped - but some problems arose. Now I have to change some bits to get some decent power Sad

So at the moment its an unsatisfying 195bhp/350nm

Did a small video to indicate how it works at the moment:

http://www.efterz.com/lars/206_2.2HDI/40-200.wmv

should be good once done

oh and yeh wanted to weigh the two engines - but think the diff. is about 20kg or so

τι έγινε!!!!
Που πήγε η μπάλα!!!!

195ps / 350nm

ΑΝΤΕ ΓΕΙΑ!!!!

ultra-one - Παρ 17 Μάρ 2006, 12:59:00
Θέμα δημοσίευσης:

Είδατε το βιντεάκι???

Κάνει 70-120χαω με 3η σε 6δλ..... Shocked

Είμαι περίεργος να το δοκιμάσω στο 1.6 16v να δω πόσο κάνει..... Silly

Μου αρέσει o τύπος που λέει ότι 195bhp είναι "unsatisfying"!!!!!!!!!!!! Shocked

Στα τελευταία βίντεο έπαθα την πλάκα μου!!!
Οι επιταχύνσεις είναι λες και είναι πάνω σε δυναμόμετρο και όχι στο δρόμο!!!!!!! Silly

MEMsound - Παρ 14 Απρ 2006, 19:35:36
Θέμα δημοσίευσης:

Η συνέχεια:

lybker έγραψε:

Well finally got some time to get on with my work:
Update:

Took the engine out today - only way to get to the 2 turbos....

http://www.efterz.com/lars/206_2.2HDI/rebuild/206_no_engine_01.JPG

The thrustbearing on the small turbo gave up 2 days ago - mainly because of the turbine side being to small. So when the larger turbo would go on boost - it would overspool the small turbo...

http://www.efterz.com/lars/206_2.2HDI/rebuild/engine_01.JPG
...thats also why there is so much oil on the back of the engine.

Tomorrow i will do a very short new manifold, and fit the new GT23VNT turbo - yes now it will only be a single turbo again.

Aim is to get some lifetime on the turbos+engine as I want to use it for trackdays - so max 200-210bhp but good torque - as said before...

Also found that the company that resized my injectors made a mistake and didnt increase them as much as I asked for (only got around 10% eventhough I asked for 30%).

Found a new bosch-dealer that will help me - and we will try to increase flow up to 60% - should see some nice powergains then.... Smile

will update you on the next couple of days...

και...

lybker έγραψε:

Update - day2

Finished the manifold - did give me a bit of headacke as I wanted to make it smaller - but that would mean bringing pipe 1+2 and 3+4 together before the main collector - deciding not to do so it got a bit bigger but now its also equal lenghts - should do the trick - allthough not pretty Wink

http://www.efterz.com/lars/206_2.2HDI/rebuild/new_manifold_1.JPG

http://www.efterz.com/lars/206_2.2HDI/rebuild/new_manifold_2.JPG

Also did the wiring for the boostcontrol - will upload the software from a 110bhp 406hdi to get it working.

http://www.efterz.com/lars/206_2.2HDI/rebuild/wiring_01.JPG

http://www.efterz.com/lars/206_2.2HDI/rebuild/wiring_02.JPG

http://www.efterz.com/lars/206_2.2HDI/rebuild/wiring_03.JPG

...need to get the manifold shimmed + will get on working on the new piping / airfilter...

και...

lybker έγραψε:

day 3:

wasn´t happy with my manifold - so decided to change it a bit - the turbo is now closer to the engine - pretty happy with the endresult - now I will put on some powerblanket to reduce boost lag:

http://www.efterz.com/lars/206_2.2HDI/rebuild/new_manifold_again_1.JPG

Also got the rest of the piping done - sadly I haven´t gotten my new TIG welder yet - so have to weld everything with a MIG + argon = crap weldings Sad

http://www.efterz.com/lars/206_2.2HDI/rebuild/new_manifold_again_2.JPG

Also I changed the chip in the ecu. If u look closer you can see the curcuit board that controls the dual - map. the white wire is connected to a switch at my dashboard so I can quickly turn power down to 90bhp if needed Wink

http://www.efterz.com/lars/206_2.2HDI/rebuild/110bhp_software.JPG

Things are taking longer than usual - have been struck by some bad planning, accidents and not having a car to go pick up things I need in, slowed me down.

So I am not sure it will be done by tomorrow as planned - maybe friday Sad

και...

lybker έγραψε:

Didn´t have that much time to work on it today....

fitted the manifold & turbo + the inlet and boostpipes...did the oil feed+return pipes

http://www.efterz.com/lars/206_2.2HDI/rebuild/fitting_engine.JPG

Fitted the engine the first time at 19:00 - found the boostpipe hit the lower front frame on the car - had to remove it 3 times before everything was sorted.

Hope to get more time tomorrow....

και ...the end.... almost ... (γ@μ#μeν# Evil

μπαταρία...)

lybker έγραψε:

Finally got the car finished, but.....

http://www.efterz.com/lars/206_2.2HDI/rebuild/completed.JPG

then found the battery had gone flat... Twisted evil

Should have it running by tonight...

MEMsound - Σαβ 22 Απρ 2006, 09:48:07
Θέμα δημοσίευσης:

lybker έγραψε:

Been a while since my last update - so just a short blurp:

Got the boost control working pretty good, but sometimes it still overboost´s and goes into limp-mode. This has to be sorted on the dyno, before its perfect - as its very sensitive.

Will fit new injectors...again - this time from a mercedes C330 AMG Smile

Wanted injectors that was 60% bigger - but couldn´t find that anywhere yet Sad

normal hdi 2,2L injectors flow 68ml/sek - the AMG injectors flow 97ml/sek - so a increase of 42%, really hope this will be enough.

This will happend on thursday + I will get it remapped, so friday I should have some power-figures and a dyno sheet for you all - keep fingers crossed, that it doesn´t blow on the dyno...hehe

MEMsound - Παρ 28 Απρ 2006, 19:39:21
Θέμα δημοσίευσης:

και λίγη συνέχεια τεχνικού περιεχόμενου:

lybker έγραψε:

Finally got back - with some more knowledge.

Yesterday I went to a bosch testcenter where I could borrow their equipment for flow testing.

So set out to test various conditions:

http://www.efterz.com/lars/206_2.2HDI/rebuild/changing_nozzles.JPG

mercedes C30 AMG vs my old modified injectors:
to my surprise they delivered the same amount: 69mm3/h at 1350bar and 1ms openingtime...
bit wierd as the C30 injectors should have delivered 89mm3/h....hmmm!

modified versus standard 2,2 injectors
Standard injectors was to flow 61mm3/h (not 67-68 as I said above...)
- So only a increase of 13% of flow.

modified versus standard 2,0 injectors
standard 2,0 injectors flow about 50mm3/h BUT........!!!!!

when I fitted the modified injectortips to the 2,0L injectorbody and tested them....they gave 80mm3/h!!! (with the 2,2L hdi body they only gave 69mm3/h) this is an increase of 62% in flowrate for the 2L hdi engine! - explains the good succesrate i had with these injectors Smile

http://www.efterz.com/lars/206_2.2HDI/rebuild/testing_injectors1.JPG
http://www.efterz.com/lars/206_2.2HDI/rebuild/testing_injectors2.JPG

So the final conclusion:
As the the C30 and the modified injector nozzles delivered the exact same amount on the 2,2L injec.body and both delivered more when fitted to the 2,0L injec.body:
The injectorbody has influence on how much flow the injector-tips can deliver....seems the feed-hole inside the 2,2L injectorbody is smaller than the one on the 2L injectorbody = one can never make more power on the 2,2L engine than the 2,0L....unless this feed-hole can be made bigger! (working on that)

So with this new info I now know why I cant get the power I wanted from the 2,2L, so wont go fish for it anymore. But I now know what to do, but not how to....yet. So wont reach my power-aim untill this is solve.

I still got the map on the car adjusted a bit: no smoke and boostcontrol now works + rpm limiter at 5500rpm!

have some small problems still - to long pause on fueldelivery when changing gears, and occationally the ECU goes into fail safe mode

Finally a small video from the dyno:
http://www.efterz.com/lars/206_2.2HDI/rebuild/mapping_206.wmv

will keep on working on solving the limited flowrate of the injectorbody...when I know some more I will share it with you...