STD Tuning Engine OM 648 TURBO RETROFIT

OM 648 TURBO RETROFIT

OM 648 TURBO RETROFIT

 
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MB TECH
GT2559V

188
08-18-2009, 08:28 AM #1
I am currently in the process of installing a turbo from an OM648 engine onto the 300TD, with this I also am using an intercooler from a 2004 C class kompressor (front mount about 3ft long), I have the intercooler mounted and am looking for some ideas for the ducting to the turbo and intake obviously using the shortest amount of piping. Not sure if anyone out there has utilized a front mount of this configuration but I am open to any suggestions.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-18-2009, 08:28 AM #1

I am currently in the process of installing a turbo from an OM648 engine onto the 300TD, with this I also am using an intercooler from a 2004 C class kompressor (front mount about 3ft long), I have the intercooler mounted and am looking for some ideas for the ducting to the turbo and intake obviously using the shortest amount of piping. Not sure if anyone out there has utilized a front mount of this configuration but I am open to any suggestions.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

ForcedInduction
Banned

3,628
08-18-2009, 11:21 AM #2
Holes can be drilled into the fenderwell metal if you can't get the tubes to go up the side of the engine.
ForcedInduction
08-18-2009, 11:21 AM #2

Holes can be drilled into the fenderwell metal if you can't get the tubes to go up the side of the engine.

MB TECH
GT2559V

188
08-18-2009, 12:05 PM #3
Ya thats what I was thinking about doing, of course since mine is a former Wisconsin car I can just push a hole through the inner fenders (NO DRILLING REQD ON RUST HAHAHA)

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-18-2009, 12:05 PM #3

Ya thats what I was thinking about doing, of course since mine is a former Wisconsin car I can just push a hole through the inner fenders (NO DRILLING REQD ON RUST HAHAHA)


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

willbhere4u
Six in a row make her go!

2,507
08-18-2009, 12:53 PM #4
ah its been lightened good start to a race car!!! lol the glass is half full

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
08-18-2009, 12:53 PM #4

ah its been lightened good start to a race car!!! lol the glass is half full


1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

MB TECH
GT2559V

188
08-18-2009, 01:09 PM #5
(08-18-2009, 12:53 PM)willbhere4u ah its been lightened good start to a race car!!! lol the glass is half full



My thoughts exactly!

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-18-2009, 01:09 PM #5

(08-18-2009, 12:53 PM)willbhere4u ah its been lightened good start to a race car!!! lol the glass is half full



My thoughts exactly!


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

benztek
MASTER TECH

61
08-18-2009, 04:04 PM #6
Make sure you check that turbo. The few 648 turbos that I have warrantied have had alot of shaft play.
benztek
08-18-2009, 04:04 PM #6

Make sure you check that turbo. The few 648 turbos that I have warrantied have had alot of shaft play.

winmutt
bitbanger

3,468
08-18-2009, 04:22 PM #7
(08-18-2009, 01:09 PM)MB TECH
(08-18-2009, 12:53 PM)willbhere4u ah its been lightened good start to a race car!!! lol the glass is half full



My thoughts exactly!

It's got natural speed holes!

1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
winmutt
08-18-2009, 04:22 PM #7

(08-18-2009, 01:09 PM)MB TECH
(08-18-2009, 12:53 PM)willbhere4u ah its been lightened good start to a race car!!! lol the glass is half full



My thoughts exactly!

It's got natural speed holes!


1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42

MB TECH
GT2559V

188
08-18-2009, 04:54 PM #8
(08-18-2009, 04:04 PM)benztek Make sure you check that turbo. The few 648 turbos that I have warrantied have had alot of shaft play.

I did check this one and it is in excellent condition virtually no play, It has 120K on it and just the electronic actuator took a dump. Thanks for the heads up.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-18-2009, 04:54 PM #8

(08-18-2009, 04:04 PM)benztek Make sure you check that turbo. The few 648 turbos that I have warrantied have had alot of shaft play.

I did check this one and it is in excellent condition virtually no play, It has 120K on it and just the electronic actuator took a dump. Thanks for the heads up.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

benztek
MASTER TECH

61
08-20-2009, 10:08 AM #9
I have replaced several for the same reason. I just have not been able to convice myself to do the fabrication work to mount one up if it has any play in the shaft.
benztek
08-20-2009, 10:08 AM #9

I have replaced several for the same reason. I just have not been able to convice myself to do the fabrication work to mount one up if it has any play in the shaft.

MB TECH
GT2559V

188
08-20-2009, 12:07 PM #10
Ya I wouldnt either if this one had play, The fab work is a little more than what I wanted to do but its been slow at the shop so it keeps me busy.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-20-2009, 12:07 PM #10

Ya I wouldnt either if this one had play, The fab work is a little more than what I wanted to do but its been slow at the shop so it keeps me busy.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

willbhere4u
Six in a row make her go!

2,507
08-20-2009, 08:13 PM #11
keep us updated and take some pic! What kind of boost numbers do you plan on pushing?

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
08-20-2009, 08:13 PM #11

keep us updated and take some pic! What kind of boost numbers do you plan on pushing?


1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

MB TECH
GT2559V

188
08-21-2009, 11:51 AM #12
I have been taking plenty of pics, not sure of the boost pressure, im looking more for a more efficient turbo and adding the intercooler for lower intake temps. I drive the car from Mississippi to Wisconsin alot and im trying to push a little more economy. Plus my factory turbo was starting to sound like it was coming apart.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-21-2009, 11:51 AM #12

I have been taking plenty of pics, not sure of the boost pressure, im looking more for a more efficient turbo and adding the intercooler for lower intake temps. I drive the car from Mississippi to Wisconsin alot and im trying to push a little more economy. Plus my factory turbo was starting to sound like it was coming apart.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
GT2559V

188
08-25-2009, 07:26 AM #13
Here are some pics of the 648 turbo to 617 project. Will have more pics soon.
Attached Files
Image(s)
                   

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-25-2009, 07:26 AM #13

Here are some pics of the 648 turbo to 617 project. Will have more pics soon.

Attached Files
Image(s)
                   

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

tantank79
T3-45

109
08-25-2009, 07:44 AM #14
What is that intercooler from?

-Brian

1983 300TD
1982 240D
1981 280TE
tantank79
08-25-2009, 07:44 AM #14

What is that intercooler from?


-Brian

1983 300TD
1982 240D
1981 280TE

MB TECH
GT2559V

188
08-25-2009, 07:55 AM #15
early 2000 c230 sport (203 chassis with 271 engine)

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-25-2009, 07:55 AM #15

early 2000 c230 sport (203 chassis with 271 engine)


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

tomnik
Holset

587
08-25-2009, 08:12 AM #16
This looks like the same turbo that I have installed in my SD. Should be a GT23. Pics in the VTG installation thread.

Tom
This post was last modified: 08-25-2009, 08:31 AM by tomnik.
tomnik
08-25-2009, 08:12 AM #16

This looks like the same turbo that I have installed in my SD. Should be a GT23. Pics in the VTG installation thread.

Tom

winmutt
bitbanger

3,468
08-25-2009, 09:39 AM #17
Looks like a GT2256V. Can you confirm? If it is do you want to make another adapter for me? pm price if it is a gt2556v.

1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
winmutt
08-25-2009, 09:39 AM #17

Looks like a GT2256V. Can you confirm? If it is do you want to make another adapter for me? pm price if it is a gt2556v.


1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42

MB TECH
GT2559V

188
08-25-2009, 10:07 AM #18
I will check when I get home tonight

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-25-2009, 10:07 AM #18

I will check when I get home tonight


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

ForcedInduction
Banned

3,628
08-25-2009, 09:58 PM #19
(08-25-2009, 09:39 AM)winmutt Looks like a GT2256V.

Its a 2359, the compressor housing is right.
ForcedInduction
08-25-2009, 09:58 PM #19

(08-25-2009, 09:39 AM)winmutt Looks like a GT2256V.

Its a 2359, the compressor housing is right.

MB TECH
GT2559V

188
08-26-2009, 08:08 AM #20
That is correct it is a 2359

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-26-2009, 08:08 AM #20

That is correct it is a 2359


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
GT2559V

188
08-31-2009, 12:42 PM #21
Almost finished with the project, have a question though. Anyone who has installed a different turbo on their 617, what type of configurations did you use for the oil return line?

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
08-31-2009, 12:42 PM #21

Almost finished with the project, have a question though. Anyone who has installed a different turbo on their 617, what type of configurations did you use for the oil return line?


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

ForcedInduction
Banned

3,628
08-31-2009, 08:36 PM #22
I cut off the flare and o-ring parts of the return tubes and pressed a 3/4" low-pressure hydraulic hose between them.
ForcedInduction
08-31-2009, 08:36 PM #22

I cut off the flare and o-ring parts of the return tubes and pressed a 3/4" low-pressure hydraulic hose between them.

MB TECH
GT2559V

188
09-01-2009, 06:48 AM #23
great thanks, I will try something similar.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
09-01-2009, 06:48 AM #23

great thanks, I will try something similar.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

tomnik
Holset

587
09-01-2009, 08:46 AM #24
I made it with a flex SS piece. Important for me was that I put a small tube into the original drain tube and another larger one as kind of cap in touch with the o-ring of the drain tube.

   
tomnik
09-01-2009, 08:46 AM #24

I made it with a flex SS piece. Important for me was that I put a small tube into the original drain tube and another larger one as kind of cap in touch with the o-ring of the drain tube.

   

MB TECH
GT2559V

188
09-03-2009, 01:56 PM #25
Ended up using steel braided line for feed and return, I started it up last night and so far no leaks. We will see how it holds up.
Attached Files
Image(s)
   

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
09-03-2009, 01:56 PM #25

Ended up using steel braided line for feed and return, I started it up last night and so far no leaks. We will see how it holds up.

Attached Files
Image(s)
   

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

willbhere4u
Six in a row make her go!

2,507
09-03-2009, 07:18 PM #26
looks good keep us up to date! like the blue paint I did mine red! but it peeled off as it was only good 2 500deg I need to re do it with some 1000deg paint

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
09-03-2009, 07:18 PM #26

looks good keep us up to date! like the blue paint I did mine red! but it peeled off as it was only good 2 500deg I need to re do it with some 1000deg paint


1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

winmutt
bitbanger

3,468
09-04-2009, 08:49 AM #27
Can I have your electronic actuator?

1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
winmutt
09-04-2009, 08:49 AM #27

Can I have your electronic actuator?


1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42

Tymbrymi
Klatta Klatta

185
09-04-2009, 10:32 AM #28
(09-04-2009, 08:49 AM)winmutt Can I have your electronic actuator?

He said the actuator took a dump, which is why he got the turbo. I need to find one of those since I have an actuator off of my GT2056 Angel

edit: Looks good MB Tech!!! Keep up the good work! I may have to try and come down this weekend and partake in some shenanigans. Wink
This post was last modified: 09-04-2009, 10:34 AM by Tymbrymi.

John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!
Tymbrymi
09-04-2009, 10:32 AM #28

(09-04-2009, 08:49 AM)winmutt Can I have your electronic actuator?

He said the actuator took a dump, which is why he got the turbo. I need to find one of those since I have an actuator off of my GT2056 Angel

edit: Looks good MB Tech!!! Keep up the good work! I may have to try and come down this weekend and partake in some shenanigans. Wink


John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!

MB TECH
GT2559V

188
09-05-2009, 06:15 AM #29
(09-04-2009, 08:49 AM)winmutt Can I have your electronic actuator?

Ya that is correct, the actuator did take a dump, I took it upon myself to look into why it failed and I found that inside are a series of plastic type material gears and one of them just stripped out (not sure exactly why it did that, I was thinking maybe excessive heat that the gears cannot take.) either way this was about 4 months ago and I did throw the pieces out. If I come across another I will let you know.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
09-05-2009, 06:15 AM #29

(09-04-2009, 08:49 AM)winmutt Can I have your electronic actuator?

Ya that is correct, the actuator did take a dump, I took it upon myself to look into why it failed and I found that inside are a series of plastic type material gears and one of them just stripped out (not sure exactly why it did that, I was thinking maybe excessive heat that the gears cannot take.) either way this was about 4 months ago and I did throw the pieces out. If I come across another I will let you know.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

Tymbrymi
Klatta Klatta

185
09-05-2009, 01:40 PM #30
(09-05-2009, 06:15 AM)MB TECH ...either way this was about 4 months ago and I did throw the pieces out. If I come across another I will let you know.

If you would be so kind as to be on the lookout for another GT23 with bad actuator that would be much appreciated!! Angel

John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!
Tymbrymi
09-05-2009, 01:40 PM #30

(09-05-2009, 06:15 AM)MB TECH ...either way this was about 4 months ago and I did throw the pieces out. If I come across another I will let you know.

If you would be so kind as to be on the lookout for another GT23 with bad actuator that would be much appreciated!! Angel


John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!

MB TECH
GT2559V

188
09-09-2009, 07:56 PM #31
Got it running! Still have a few things to get finished including a painted valve cover that I just finished. But it runs great I have been driving it since Monday afternoon and the response is incredible and EGTs are staying down. Also the engine temp is under control with the new 1600cfm aux fan.
Attached Files
Image(s)
               

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
09-09-2009, 07:56 PM #31

Got it running! Still have a few things to get finished including a painted valve cover that I just finished. But it runs great I have been driving it since Monday afternoon and the response is incredible and EGTs are staying down. Also the engine temp is under control with the new 1600cfm aux fan.

Attached Files
Image(s)
               

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

willbhere4u
Six in a row make her go!

2,507
09-09-2009, 08:42 PM #32
wow that's quite the hood!!! cool front mount inter cooler!

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
09-09-2009, 08:42 PM #32

wow that's quite the hood!!! cool front mount inter cooler!


1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

MB TECH
GT2559V

188
09-10-2009, 07:47 PM #33
thanks, the hood was a result of a few beers and a rivet gun, I think it turned out good.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
09-10-2009, 07:47 PM #33

thanks, the hood was a result of a few beers and a rivet gun, I think it turned out good.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

larryratcliff
Unregistered

15
09-13-2009, 01:20 PM #34
How many psi of boost do you expect from this upgrade. I have been contemplating how the vw 2.0 is able to produce such amazing hp and torque numbers and it seems that the biggest part of the equation is boost.

My second question is how to match a mechanical pump to additional boost levels. I am still a bit of diesel noob but it sure seems that mechanical pump issues from gas burners would apply to diesels too. Can you send off a mechanical pump and have it re-calibrated for additional boost levels?

It looks to me that if the 3.0 mercedes was running around 1 bar it would be a serious beast since it looks like the stock boost is about 1/3 of that.
larryratcliff
09-13-2009, 01:20 PM #34

How many psi of boost do you expect from this upgrade. I have been contemplating how the vw 2.0 is able to produce such amazing hp and torque numbers and it seems that the biggest part of the equation is boost.

My second question is how to match a mechanical pump to additional boost levels. I am still a bit of diesel noob but it sure seems that mechanical pump issues from gas burners would apply to diesels too. Can you send off a mechanical pump and have it re-calibrated for additional boost levels?

It looks to me that if the 3.0 mercedes was running around 1 bar it would be a serious beast since it looks like the stock boost is about 1/3 of that.

willbhere4u
Six in a row make her go!

2,507
09-13-2009, 08:18 PM #35
well a diesel runs cooler the leaner it get so adding boost won't hurt it as much as adding fuel!

the real power to be had is by adding fuel! but to keep EGT's under control you need to add more air (boost) to keep it nice and cool!

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
willbhere4u
09-13-2009, 08:18 PM #35

well a diesel runs cooler the leaner it get so adding boost won't hurt it as much as adding fuel!

the real power to be had is by adding fuel! but to keep EGT's under control you need to add more air (boost) to keep it nice and cool!


1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

MB TECH
GT2559V

188
09-14-2009, 05:49 AM #36
That is true, I have not determined the max boost of this turbo since my piping blew off around 25psi, So I have been keeping it around 10psi max. See the entire reason for this upgrade for me was a more efficient setup with better response (not more power) I use this car as a daily driver and I run it on many long road trips so I am trying to squeeze some more fuel economy out of it and run a bit cooler. I am sure if I did the (removing of the rack limiter modification) I would gain quite a bit more power but right now that is not the goal. Maybe in the future, so for now the 123 wagon just looks fast hahaha

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
09-14-2009, 05:49 AM #36

That is true, I have not determined the max boost of this turbo since my piping blew off around 25psi, So I have been keeping it around 10psi max. See the entire reason for this upgrade for me was a more efficient setup with better response (not more power) I use this car as a daily driver and I run it on many long road trips so I am trying to squeeze some more fuel economy out of it and run a bit cooler. I am sure if I did the (removing of the rack limiter modification) I would gain quite a bit more power but right now that is not the goal. Maybe in the future, so for now the 123 wagon just looks fast hahaha


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

benztek
MASTER TECH

61
09-14-2009, 12:21 PM #37
How did you connect to that intercooler? That one has the click in style hoses correct? I have that same intercooler but I havent come across a solution yet.
benztek
09-14-2009, 12:21 PM #37

How did you connect to that intercooler? That one has the click in style hoses correct? I have that same intercooler but I havent come across a solution yet.

MB TECH
GT2559V

188
09-14-2009, 12:42 PM #38
All I did was order silicone adapters large enough to stretch over the quick connect area to the smooth part and tightened them down with t bolt clamps. No leaks yet and going on week #2 of driving it back and forth to work.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
09-14-2009, 12:42 PM #38

All I did was order silicone adapters large enough to stretch over the quick connect area to the smooth part and tightened them down with t bolt clamps. No leaks yet and going on week #2 of driving it back and forth to work.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

benztek
MASTER TECH

61
09-14-2009, 01:16 PM #39
Thanks. I had thought about doing that but cutting off the quick disconnect area. Glad to see it up and running. What kind of control are you using for the vanes?
benztek
09-14-2009, 01:16 PM #39

Thanks. I had thought about doing that but cutting off the quick disconnect area. Glad to see it up and running. What kind of control are you using for the vanes?

MB TECH
GT2559V

188
09-14-2009, 02:49 PM #40
as of right now a zip tie holding it on the low side (mainly to get some mileage on it and testing for leaks) I am working on something that will allow me to control from inside the car and switch it so the throttle controls it. On long road trips I would like to be able to turn the boost down for better mileage. I will keep my progress up to date on here.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
09-14-2009, 02:49 PM #40

as of right now a zip tie holding it on the low side (mainly to get some mileage on it and testing for leaks) I am working on something that will allow me to control from inside the car and switch it so the throttle controls it. On long road trips I would like to be able to turn the boost down for better mileage. I will keep my progress up to date on here.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

Tymbrymi
Klatta Klatta

185
12-01-2009, 04:53 PM #41
So how goes the progress? Smile

John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!
Tymbrymi
12-01-2009, 04:53 PM #41

So how goes the progress? Smile


John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!

MB TECH
GT2559V

188
12-02-2009, 08:03 AM #42
I have been driving the car daily since september and no problems at all, with the boost turned down (8-10psi) I notice better response and better fuel economy. Still playing with ideas of controlling the turbo from inside the cabin - nothing yet.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
12-02-2009, 08:03 AM #42

I have been driving the car daily since september and no problems at all, with the boost turned down (8-10psi) I notice better response and better fuel economy. Still playing with ideas of controlling the turbo from inside the cabin - nothing yet.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

Tymbrymi
Klatta Klatta

185
01-26-2010, 04:11 PM #43
Any more updates? Angel

John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!
Tymbrymi
01-26-2010, 04:11 PM #43

Any more updates? Angel


John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!

MB TECH
GT2559V

188
01-26-2010, 05:56 PM #44
Still running strong, have some issues when boosting 15psi for long periods of time the hose pops off the intake manifold. I got a hold of an other manifold that I will modify and then swap out. Other than that everything is good.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
01-26-2010, 05:56 PM #44

Still running strong, have some issues when boosting 15psi for long periods of time the hose pops off the intake manifold. I got a hold of an other manifold that I will modify and then swap out. Other than that everything is good.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

ForcedInduction
Banned

3,628
01-26-2010, 08:45 PM #45
Using a t-clamp or worm clamp?
ForcedInduction
01-26-2010, 08:45 PM #45

Using a t-clamp or worm clamp?

MB TECH
GT2559V

188
01-27-2010, 06:20 AM #46
all T clamps, but where I am on the intake manifold it is tapered so if you tighten too much it walks off. It works fine for now until I come up with something for the other manifold.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
01-27-2010, 06:20 AM #46

all T clamps, but where I am on the intake manifold it is tapered so if you tighten too much it walks off. It works fine for now until I come up with something for the other manifold.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

Tymbrymi
Klatta Klatta

185
01-27-2010, 10:49 AM #47
(01-26-2010, 05:56 PM)MB TECH Still running strong, have some issues when boosting 15psi for long periods of time the hose pops off the intake manifold. I got a hold of an other manifold that I will modify and then swap out. Other than that everything is good.

Nice! I need to come down there sometime and check it out Smile

John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!
Tymbrymi
01-27-2010, 10:49 AM #47

(01-26-2010, 05:56 PM)MB TECH Still running strong, have some issues when boosting 15psi for long periods of time the hose pops off the intake manifold. I got a hold of an other manifold that I will modify and then swap out. Other than that everything is good.

Nice! I need to come down there sometime and check it out Smile


John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!

HoleshotHolset
Holset

379
01-28-2010, 05:15 PM #48
(08-21-2009, 11:51 AM)MB TECH I drive the car from Mississippi to Wisconsin alot and im trying to push a little more economy.

Care to share what part of WI? I'm a proud resident of America's Dairyland...work in Madison - live up "Nort" a ways.

Beers,

Matt

'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
01-28-2010, 05:15 PM #48

(08-21-2009, 11:51 AM)MB TECH I drive the car from Mississippi to Wisconsin alot and im trying to push a little more economy.

Care to share what part of WI? I'm a proud resident of America's Dairyland...work in Madison - live up "Nort" a ways.

Beers,

Matt


'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten

MB TECH
GT2559V

188
01-28-2010, 05:38 PM #49
Worked in Madison at the benz dealership for about 2 years and grew up in Milwaukee area. just moved down here to the south last year.

1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

MB TECH
01-28-2010, 05:38 PM #49

Worked in Madison at the benz dealership for about 2 years and grew up in Milwaukee area. just moved down here to the south last year.


1979 450SEL 6.9 - stock

1960 220SE
111 tube chassis car/undergoing full restoration. Body work in progress. Merging with a 1996 S500 (119 engine, 722.6 trans, and both subframes)

2005 S55 AMG - stock

1999 SLK230 Kompressor - stock

2006 SLK55 AMG - stock

mike-81-240d
more like mike-84-300d now

427
08-16-2010, 05:39 PM #50
I spy HID's...

1981 Mercedes 300TD Lowered 4 speed manual Holset HX30 
mike-81-240d
08-16-2010, 05:39 PM #50

I spy HID's...


1981 Mercedes 300TD Lowered 4 speed manual Holset HX30 

 
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