Brabus D4 Fitment Instructions.

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Collydog

Member
Joined
Jun 2, 2019
Messages
49
Location
Wiltshire, UK
Car
2001 ML270 CDI, 2001 Mercedes Sprinter 313 CDI, 2004 Mercedes SLK230
Hi All,

I have been a long time researcher now first time poster. To you legends that pass on your fonts of knowledge I salute you. To the Administrators I apologise in advance for any infringement of thread posting procedures.

To the rest your help is also appreciated and I hope others can benefit from this as I hope to.

Right, I recently have come in possession of the Brabus D4 performance enhancement chip part no. 163-634-00. I'm really excited but also frustrated as the original fitment instructions are completely unreadable due to 15 years in a non climate controlled garage. The chip looks immaculate but alas it is only adding performance to my cubby hole at this time.

Please oh please could one of you fine individuals grant me the knowledge to fit power to my steed.

Thanks in advance,
Rob
 
Send an email to [email protected] and ask if he can send a pdf for the fitting instructions for your D4 chip.

Alternatively, this company sell the Brabus Kit for the ML and will email the fitting instructions, although they do state the email is for the Mercedes specialist who will install the kit.
They also state the kit can take up to 1.5hrs to fit? which sounds perhaps beyond the scope of a DIY mechanic.

Brabus PowerXtra Diesel Tuning Kits | Alloy Wheels Direct Ltd
 
Wow thanks AMGeed! I'll let you know how I get on. Is there a place to post the instructions if I get them? As I have scoured the net and have not found a trace.
 
Well the request is in the ether, holding fingers and thumbs for a stroke of luck.
 
I can’t help, but I like your style, both written and choice of chariot. Good luck with fitting it. :thumb:
 
Well Markus proved to be an absolute champion and came through with the Holy grail. Please see attached any other crazy cats who are looking at fitting the Brabus D4. I now need to digest and execute. If I can get a slot between childcare and work I'll get the install done. Thanks again AMGeed.
 
Apologies wrong file, label didn't make sense either way.
 

Attachments

  • Montageanl_D4_Leistungs_Kit_englisch_neu_V00.pdf
    666.6 KB · Views: 48
So, I began this little journey and have come across two stumbling blocks.

1. Before increasing the output of the wagon I just wanted to tidy up a black smoke issue and cleaned the egr and intake manifold with oven cleaner. Excellent results smoke reduced but also checked the turbo at the same time only to find I have excessive play. This explains the noise I'm hearing at 2-3000rpm. So, chip is on hold until new CHRA is fitted.

2. While checking the harness, if you follow the instructions. Red (Brabus) replaces Red/Blue (Original). This is all well and good but unlike all the other wires which have a counterpart (other than Brown which is to earth) in the chip connector, the Red/Blue has no wire to pair up with.

Question do I just slot it into the empty 6th terminal hole and leave it or is it supposed to connect elsewhere I haven't identified yet???

My thoughts are that the Red/Blue wire provides a key signal from the ECU which will now be carried out by the Red (Brabus) wire thus making it redundant. Please let me know if I'm off course.

Cheers,
Rob
 
As an aside the instructions do appear to be a bit A level initially mainly as they don't actually show you what you need to do but if you spend a bit of time in the ECU container it will start making sense. The connectors are numbered from right to left on the ECU as you look at the engine bay and when you remove them you will see that Mercedes were kind enough to number the pins albeit some interpolation is required. I suggest doing one wire colour at a time as it wouldn't be easy to figure out where they go if they are all loose.
 
I like your persistence Rob!

Where in Wiltshire are you based?

David
 
Thanks Bud,

I'm near Melksham. I've had quite a Journey with this wagon probably too long for a single post. A bit of a shame as I solved most issues using this and other forums. Hence why trying to repay the samaritan nature of this community.
 
I'm getting a little runaway up at the moment so may need reigning in but as I need to do a turbo repair. Is it worth looking at an upgrade???

I believe the GT2359V from the 320CDI is a bolt in option. Is there any advice for this mod?

I'm aware I will be exceeding the 300nm rating of my transmission and am content with this as I'm not one for hooning around boy racer style. I like overtaking power and believe cruising speeds will be maintained without downshift thus protecting the transmission.

Will this mod be compatible with the Brabus D4 chip? Just a thought?
 
Hi AnglasIt,

Unfortunately not. I had a look at that video initially but it doesn't show the detail of the fit ie. Wire colour to wire colour matching and it is for the newer 250 as opposed to the 270. The box and harness design is also different.

I have now atleast got the original instructions posted further up and have tidied up my harness as it was looking a little tired so I feel I'm on the right track but just looking for a confirmation from anyone who is more enlightened than I.

Cheers,
Rob
 
Thanks for looking though, it is a real bugger to find any info on this and since that 270cdi was used in so many vehicles I was surprised at how little there is out there on this chip, which got some good reviews. To be fair I think a stage 1 remap is probably the go to option these days and is as cost effective. I'm just trying to use what I have to hand.
 
OK, so I'm now thinking a hybrid rebuild. I appreciate I can't test it as I don't have the bench rig but, I bought this wagon for £250 as a non runner and she definitely is a runner now. So, my threshold for giving anything a go is pretty low.

There are questions I have and haven't been able to answer with a cursory search.

1. Will the Brabus D4 compliment the upgrade or should I really be looking at a remap? (Please say it will)

2. Other than the billet Compressor what else makes up the hybrid? I believe a 360° bearing (whatever that is) and you can also machine the housings somewhat to take larger Compressors and Turbines.

Personally, I want to reuse what I have and if there are gains to be had without going too far off piste that would be preferred. I'm also keen to give something a go as it is a learning journey nonetheless.
 
I'm really enjoying this monologue by the way haha.

I may have found a place near me that can bench test the CHRA and ball bearings may be one of the mods to the hybrid concept I'm keen on. At this time the GT2256V doesn't have a lot of mods available as I think most people jump straight to the GT2359V and get a remap. Still umming and arring as I already have the Brabus chip ready to go.
 
I would just get a good used 2256 turbo from a breakers (lots on eBay) and put the brabus box on as a starter. The cost difference of a hybrid just wouldn't be worth it unless you plan on spending much more on injectors and remaps.
 
Just a note that if you decide to get a 2259, just check that it is vacuum controlled as the later turbos are electronic. They can be converted back easily enough. I've two 2359s in the garage, £50-75 will get a good 2256 or 2359.
 
Hi 91dm,

Thanks for getting back in touch. Yep I've come to the same conclusion. I'm going to do a CHRA replacement as I've been keen to do one anyway for a while.

I plan on tearing into the old CHRA and looking at the potential for a low level conversion. I can get the roller bearing for a GT25 and am marginally convinced with a bit of fab work it will go in. I just need to get eyes on how much material I have to play with. I figured a billet compressor and the rest of a rebuild kit I would have a very efficient standard turbo (dimensions wise atleast). Some VSR balancing then I will look to reinstall. Theoretically, this should compliment the Brabus as the compressor will be 10% more effective. And the ball bearings will just get to the expected datum quicker on spool up. I figured by the time I've tested the current CHRA and Brabus I will be ready for another little mod.

Cheers,
Rob
 

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