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+--- Thread: OM 648 TURBO RETROFIT (/showthread.php?tid=613)
OM 648 TURBO RETROFIT - MB TECH - 08-18-2009
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.
RE: OM 648 TURBO RETROFIT - ForcedInduction - 08-18-2009
Holes can be drilled into the fenderwell metal if you can't get the tubes to go up the side of the engine.
RE: OM 648 TURBO RETROFIT - MB TECH - 08-18-2009
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)
RE: OM 648 TURBO RETROFIT - willbhere4u - 08-18-2009
ah its been lightened good start to a race car!!! lol the glass is half full
RE: OM 648 TURBO RETROFIT - MB TECH - 08-18-2009
(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!
RE: OM 648 TURBO RETROFIT - benztek - 08-18-2009
Make sure you check that turbo. The few 648 turbos that I have warrantied have had alot of shaft play.
RE: OM 648 TURBO RETROFIT - winmutt - 08-18-2009
(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!
RE: OM 648 TURBO RETROFIT - MB TECH - 08-18-2009
(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.
RE: OM 648 TURBO RETROFIT - benztek - 08-20-2009
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.
RE: OM 648 TURBO RETROFIT - MB TECH - 08-20-2009
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.
RE: OM 648 TURBO RETROFIT - willbhere4u - 08-20-2009
keep us updated and take some pic! What kind of boost numbers do you plan on pushing?
RE: OM 648 TURBO RETROFIT - MB TECH - 08-21-2009
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.
RE: OM 648 TURBO RETROFIT - MB TECH - 08-25-2009
Here are some pics of the 648 turbo to 617 project. Will have more pics soon.
RE: OM 648 TURBO RETROFIT - tantank79 - 08-25-2009
What is that intercooler from?
RE: OM 648 TURBO RETROFIT - MB TECH - 08-25-2009
early 2000 c230 sport (203 chassis with 271 engine)
RE: OM 648 TURBO RETROFIT - tomnik - 08-25-2009
This looks like the same turbo that I have installed in my SD. Should be a GT23. Pics in the VTG installation thread.
Tom
RE: OM 648 TURBO RETROFIT - winmutt - 08-25-2009
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.
RE: OM 648 TURBO RETROFIT - MB TECH - 08-25-2009
I will check when I get home tonight
RE: OM 648 TURBO RETROFIT - ForcedInduction - 08-25-2009
(08-25-2009, 09:39 AM)winmutt Looks like a GT2256V.
Its a 2359, the compressor housing is right.
RE: OM 648 TURBO RETROFIT - MB TECH - 08-26-2009
That is correct it is a 2359
RE: OM 648 TURBO RETROFIT - MB TECH - 08-31-2009
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?
RE: OM 648 TURBO RETROFIT - ForcedInduction - 08-31-2009
I cut off the flare and o-ring parts of the return tubes and pressed a 3/4" low-pressure hydraulic hose between them.
RE: OM 648 TURBO RETROFIT - MB TECH - 09-01-2009
great thanks, I will try something similar.
RE: OM 648 TURBO RETROFIT - tomnik - 09-01-2009
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.
RE: OM 648 TURBO RETROFIT - MB TECH - 09-03-2009
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.
RE: OM 648 TURBO RETROFIT - willbhere4u - 09-03-2009
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
RE: OM 648 TURBO RETROFIT - winmutt - 09-04-2009
Can I have your electronic actuator?
RE: OM 648 TURBO RETROFIT - Tymbrymi - 09-04-2009
(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
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.
RE: OM 648 TURBO RETROFIT - MB TECH - 09-05-2009
(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.
RE: OM 648 TURBO RETROFIT - Tymbrymi - 09-05-2009
(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!!
RE: OM 648 TURBO RETROFIT - MB TECH - 09-09-2009
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.
RE: OM 648 TURBO RETROFIT - willbhere4u - 09-09-2009
wow that's quite the hood!!! cool front mount inter cooler!
RE: OM 648 TURBO RETROFIT - MB TECH - 09-10-2009
thanks, the hood was a result of a few beers and a rivet gun, I think it turned out good.
RE: OM 648 TURBO RETROFIT - larryratcliff - 09-13-2009
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.
RE: OM 648 TURBO RETROFIT - willbhere4u - 09-13-2009
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!
RE: OM 648 TURBO RETROFIT - MB TECH - 09-14-2009
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
RE: OM 648 TURBO RETROFIT - benztek - 09-14-2009
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.
RE: OM 648 TURBO RETROFIT - MB TECH - 09-14-2009
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.
RE: OM 648 TURBO RETROFIT - benztek - 09-14-2009
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?
RE: OM 648 TURBO RETROFIT - MB TECH - 09-14-2009
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.
RE: OM 648 TURBO RETROFIT - Tymbrymi - 12-01-2009
So how goes the progress?
RE: OM 648 TURBO RETROFIT - MB TECH - 12-02-2009
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.
RE: OM 648 TURBO RETROFIT - Tymbrymi - 01-26-2010
Any more updates?
RE: OM 648 TURBO RETROFIT - MB TECH - 01-26-2010
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.
RE: OM 648 TURBO RETROFIT - ForcedInduction - 01-26-2010
Using a t-clamp or worm clamp?
RE: OM 648 TURBO RETROFIT - MB TECH - 01-27-2010
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.
RE: OM 648 TURBO RETROFIT - Tymbrymi - 01-27-2010
(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
RE: OM 648 TURBO RETROFIT - HoleshotHolset - 01-28-2010
(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
RE: OM 648 TURBO RETROFIT - MB TECH - 01-28-2010
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.
RE: OM 648 TURBO RETROFIT - mike-81-240d - 08-16-2010
I spy HID's...