Don Terrill’s Speed-Talk

Hi,

My Name is Emre. I'm 33 years old Electro-Mechanical Engineer, I live in Istanbul / Turkey, I have a 1.9Lt 4 Cylinder Diesel Car "Alfa Romeo 159". Now I'm upgrading it from 150HP to 300HP. Last month I register this forum to learn something about Intake manifold design and I made it in my CNC machine. Thank you very much all of you,

Now I'm making the exhaust manifold and putting bigger Turbo. New Turbo is GTB2060VKLR from Mercedes 350CDI engine. And It it water cooled.

As you see the position for my idea. And I've checked oil pipes are higher than oil return to crankcase. And very near to Oil Pressure out from the engine block. But when I look at the original position of the turbo on 350 CDI, Oil enter and Oil exit, Water Input are from bottom of the turbo, which is parallel to the ground. But My Turbo position is perpendicular to the ground and parallel to engine block. As you see from picture. What do you think? Does it work? Some say it must positioned face to ground as designed in first place.

Also you may find my hand drawing of New Engine placement, I have to move the battery in front of the car. I don't want to put it to boot. Now the problem is the size. I cannot seem to fit it. My original battery is 60Ah-610CCA lead-Acid battery.
I find Optima Battery In Turkey, RedTop or YellowTop, 55Ah-765CCA AGM battery which can fit perfectly but In Winter I'm afraid of this would not help at all. My Tuner says put 75Ah-855CCA battery and it would be perfect. What do you say about it?

Thank you in advance.

Nice work! Love seeing projects like this.

You want the oil drain as big and as close to the 6 O'clock position as possible. The farther you stray the more problems you will encounter with oil backing up. If there is no other way the use of a scavenge pump would be necessary. Water lines aren't as critical and can usually be run for best fit.

Those battery specs look ok to me for cold weather starts. Possibly a little less reserve capacity?

Turbo Oil return is on higher position than engine return. Do I still need a pump before return to engine block

After viewing your air intake/runner drawings, may I suggest that you perform a CFD analysis of the velocity profiles going into each runner. Use about 7 kPa pressure differential between the air inlet and the runner exits to the cylinder head.

I suspect you will see that the #1 runner will have a reduced air flow (will run rich) and the #4 cylinder will have a increased air flow (run lean, detonation possible).

If what I suspect is true, you should modify the design of the air inlet (air "scoop") until the mass flow and velocity profiles are similar.


You may want to consider one of these batteries if you need a small battery with high cranking amps.
http://www.odysseybattery.com/extreme_b ... specs.aspx

https://youtu.be/6F_MmKlDHzI
https://youtu.be/TsLNKzCZq80
https://youtu.be/K5nXah6dFGM
https://youtu.be/sPF-95GL17A





In Last Picture, you may see, I've tried to smooth the way to 1.cylinder. Also you are right It is not perfect but you should see original manifold. I believe that I run 3 cylinder only. It is a turbo car, So I did not force it to match more than %5