The initial Packard modifications were done on this engine by changing the main bearings from a copper lead alloy to a silver lead combination and featured indium plating. This had been developed by General Motors' Pontiac Division to prevent corrosion which was possible with lubricating oils that were used at that time. The bearing coating also improved break-in and load-carrying ability of the surface. British engineering staff assigned to Packard were astonished[citation needed] at the suggestion but after tear-down inspections on rigidly tested engines were convinced the new design offered a decided improvement.
The real improvement Packard incorporated into the Merlin was adopting the Wright supercharger drive quill. This modification was designated the V-1650-3 and became known as the "high altitude" Merlin destined for the P-51. The two speed, two stage supercharger section of the -3 featured two separate impellers on the same shaft which were normally driven through a gear train at a ratio of 6.391:1. A hydraulic gear change arrangement of oil operated clutches could be engaged by an electric solenoid to increase this ratio to 8.095:1 in high speed blower position. The high speed gear ratio of the impellers was not as great as the ratio used in the Allison but speed of the impeller alone was not the factor that increased the engine performance at altitude.[clarification needed] The double staging of the compressed fuel/air mixture provided the boost pressure through a diffuser to the intake manifolds which increased the critical altitude of the power plant.
The ability of the supercharger to maintain a sea level atmosphere in the induction system to the cylinders allowed the Packard Merlin to develop 1,210 horsepower (900 kW) at 25,800 feet (7,900 m). The two stage impeller created extreme heating of the fuel/air mixture during the compression process and in order to prevent detonation of the compressed charge, it was necessary to cool the mixture prior to entry into the cylinders. This cooling was accomplished by the casting of an intercooler passage into the wheelcase housing between the first and second stage impellers.
Ethylene glycol coolant was circulated by a pump through this passage to carry off the excess heat generated by the impellers. Without the intercooler the temperature of the charge could be as high as 400 °F (204 °C). The intercooler in itself was not adequate to deal with the high temperature and an additional cooling fin and tube core was placed between the outlet of the blower and the induction manifold to the cylinders. This radiator was known as an aftercooler and served as a reservoir for the system.[clarification needed] The glycol mixture used for the supercharger cooling was independent of the main engine cooling system and used a centrifugal pump driven by the engine to circulate the coolant through an aircraft radiator system at a rate of 30 gallons[clarification needed] per minute.
This combined system reduced the charge temperature to suitable levels. The throttle valves in the updraft carburettor throat were controlled by an automatic boost control through the pilot's linkage to maintain the selected manifold pressure during changes in altitude. These valves were only partially open during ground and low level operation to prevent overboosting of the engine. As air density decreased with an increase in altitude, the throttle valves were moved to an open position by boost pressure corresponding to aircraft altitude. This system provided full power within engine boost limitations up to the critical altitude of 26,000 feet (7,900 m). This was the improvement Packard brought to the Merlin
