w123 - M111 2.2L Turbo
 

Hi all,
Just want to share a project that I have been involved with for the past few years. Originally the car started as 2.0 m102 carb engine, later the engine was swapped with later mercedes m111 EFI and after having some problem with the famous mercedes engine wiring harness and ecu I decided to converted to megasquirt. At first a m45 supercharger was fitted with 0.4 bar of boost after that it was converted to turbo with the following specs
-Vehicle : Mercedes w123 -200 1982
-Engine: Stock Mercedes 2.2L m111.960 4-cylinder engine from w124, 10:1 compression. 0.8 bar of boost

-Megasquirt 2 v3.0, custom wiring harness, 785cc/min delphi injectors, VAG COP wasted spark, gm CLT & IAT sensor, Ford TPS, machined 36-1 trigger wheel on the crankpulley, VVT control, bosch PWM idle valve, k&n filter, MAC boost control, launch control, switchable map.
Walbro 255 and bosch fuel pumps, 2 liter fuel surge tank, sytec FPR.

-Forced induction:
(2014- ???): Holset hx30 turbo, log style exhaust manifold, 40mm wastegate with 7psi spring, 3.5 inch downpipe to 3 inch exhaust pipe with two custom mufflers, small fmic. 0.5-0.8 boost.
(2012-2013): Eaton m45 supercharger from later m111 kompressor engine. 0.4 bar boost.

-Driveline and suspension:
Mercedes 4 speed 722.4 automatic transmission, 3.91:1 welded diff, w126 560sel 2nd gen front brake conversion.

tuning on the dyno
http://i1164.photobucket.com/albums/...psrih8qx6e.jpg

http://i1164.photobucket.com/albums/...psmhtptqdl.jpg

dyno scan:http://i1164.photobucket.com/albums/q564/yazan90/w123/4_zpsqoo2qokm.jpg don't know why it shows 0.9 bar on the paper, but on the datalog it was 0.8 bar

http://i1164.photobucket.com/albums/...psqz1ysck4.jpg

It made 368 nm @3800 rpm and 222 whp @5000 at 0.8bar , it reached the original engine torque which was 210nm@4000 now it's @2400 and the original power with was 150hp@5800 now it's @3200rpm
I'm extremely happy with the result as i know there is more dew to high iat caused by the small intercooler and weather here won't help either .
Also if you look at the graph there is a drop in the torque around 4400 i think that happened because i switch the vvt off at 4300, it will be back on the dyno with more boost and other upgrades.
As for the drive it's really great the torque is instant a bit similar to the supercharge but with more boost, as for the turbo (holset hx30) you won't reach a high hp number but it spool very fast with great sound as plus, in one off the datalog in 4th or 3rd gear i was on full boost at 2700 with 60%tps.
For future upgrade, first a bigger intercooler is a must, and i always wanted to try water injection both pre turbo and after ic. .

Nice.

Do you get any engine cooling trouble from the inter cooler blocking the radiator?

no cooling trouble, as the w123 radiator is pretty big and thick also i got this monster volvo two speed fan. if you see below i got this graph showing datalog for 35 minute drive in 30c weather the coolant temp was at 84c average.

<a href="http://s1164.photobucket.com/user/yazan90/media/w123/cltvstime_zps1vykqssd.jpg.html" target="_blank"><img src="http://i1164.photobucket.com/albums/q564/yazan90/w123/cltvstime_zps1vykqssd.jpg" border="0" alt=" photo cltvstime_zps1vykqssd.jpg"/></a>

That's brilliant - like the intercooler isn't there

This is awesome

so now i got a problem with 722.4 gear box, i'm not sure if the gear has already give up as i read on the net these gearbox don't handle much torque.

The problem is one day on a traffic light the gear is on D position and when it start moving it felt heavy and hardly accelerate, next day when going from the P position to R position the car reverse for few inches and then stop like the handbrake was pulled (or on mercedes pressed!) the same thing happened on L position but not on D,i checked both gear oil and linkage, they looked ok. The day after i drove the car with the same symptoms but when it started to felt heavy, like something is holding the car, i pressed the gas peddle to the floor and it launch like rocket and all the problems went away. What i did after is changing the gear oil and filter, the car drove fine for one day and now i'm having the same problems again.
Any suggestion? or it's the time to install a 722.3 gearbox?

If you are driving "with spirit" fit a 722.3 the 722.4 isn't going to last.

yeah i'm not being easy on her
Actually it snapped one axle and killed one diff

http://i1164.photobucket.com/albums/...psznvynnz1.jpg

Where did the spline go!! this lead to change the diff and the other axle, lesson learned if you want to weld the diff dont close the area from where you should remove the axle C clips

http://i1164.photobucket.com/albums/...psv1pyyltb.jpg

I'm not sure if was a bad diff in the first place

installed a bigger intercooler and change the intercooler pipe from 3inch to 2.5inch as a big pipes are not needed and the new ones fit and give more clearance
difference between intercoolers
http://i1164.photobucket.com/albums/...pscxjcyvo2.jpg

http://i1164.photobucket.com/albums/...pskfmmpzos.jpg
But now i see a raise in engine temperature, nothing serious, maybe because the heat wave we are having this summer here or like what Stretch said.

Also did a test for boost leak found leaks from the intake heater holes!
see my old thread:http://www.peachparts.com/shopforum/performance-paddock/336061-m111-intake-port.html
What i did before is cut them and install them but now they leak from the oring area. I'm going to fill them with titanium repair stick similar to aluminum epoxy as i won't be bother with removing the head and weld the holes

m111 turbo fuel and ignition maps for megasquirt
 

hi do u happen to have the ignition and fuel maps you where running on your megasquirt as i am in the process of doing this to my 190e m111 turbo swap