Hi again. What is the safe maximum boost that i can run with stock old 650k km headstuds and stock internals? I qas thinking of changing the map sensor to the 3 bar boost and boosting to 2.5 bar. Is this possible?

What else will you do, to increase fueling? Boost alone will not make any more power.

Some basic information on tuning up OM646:

http://www.hestec.fi/etusivu/mercedes/v ... 20cdi.html" onclick="window.open(this.href);return false; (In Finnish)

Google-translation:
http://translate.google.fi/translate?sl ... 20cdi.html" onclick="window.open(this.href);return false;

With relatively simple modifications you can get 200 hp and more than 500 Nm.

Sorry for the long delay in answering this post. Thanks for the pointers. The modifications so far,
1. changed the original injectors to the AMG type nozzle.
2. changed the intercooler to lower the blockage and better cooling
3. blocked the EGR by making an aluminum cork for the egr cooler connecting to the egr mixing duct with the shroud.
4. cut out the egr mixing duct.
5. changed out the original turbo (gt1749v) to e270cdi turbo (gt2256v)

The car is now running with increased power but below 2000 rpm there is very little power and smoking. Its makes a lot of power and torque from 2200 to 3700 rpm but seems to run out of diesel above that.

The car now needs a remap/reprogram to make most of the power and get rid of the smoke. I am trying to read the program out from the car but is having difficulty. Will post the program online when it is read out from the ecu.

Once again thanks for all the help.

I also bought a E320cdi turbo gt2359v but is having trouble to modify it to fit the 220 engine. If anyone knows what needs to be done and can post some photos and instructions would be very helpful.

The gt2256v on the 220cdi just died, oil starvation due to the mounting bolts loosening. Need to find a replacement turbo for it. I have been looking at the gtb2260vklr, would it be a good fit or is there a better and cheaper turbo out there?