617 IP Full Load Stop Adjustment Procedure - Page 6 - PeachParts Mercedes-Benz Forum

#76 06-21-2005, 03:29 AM

Quote:

Originally Posted by h2odiesel

Brandon,
Here is a pic of my test setup with a ford probe/ mazda MX6 intercooler

How difficult was it plumbing into your stock intake?
Mine is at a very tricky angle and I had to clamp a hose to the outside (not sure how well it is going to hold)
I found out a way to get my Audi IC in there. Just have to put a fan or two on it probably. I am not really a big fan of complex ductwork...it covers up too much stuff :-p

h2odiesel · #77 06-22-2005, 06:23 AM

Hey Brandon,
I re-clocked the compressor side of the turbo and used the original O-ring tube to connect to the manifold. I was planning to eventually weld this connection. I made a small L shaped bracket that bolted to the turbo and went under the first hose clamp to retain the tube. I also had to put a small dent in the tube that passes over the turbo and grind down the casting on the compressor housing where one of the retaining bolts go through. I was able to reclock the turbo with out removing it by using a thin cutoff wrench to access the bolts and by loosening the exhaust mainifold nuts and prying the turbo away from the intake. I also recall having the oil feed line loose. Keep up the good work!

#78 06-22-2005, 06:35 AM

Quote:

Originally Posted by h2odiesel

Hey Brandon,
I re-clocked the compressor side of the turbo and used the original O-ring tube to connect to the manifold.

I am thinking of looking for another intake manifold (that hooks to the engine) so that I can modify it and dump the air out in a different location (and use the stock air cleaner)
I would like to use my stock air cleaner becuase it works so well and also has the oil seperator built into it.
With the stock setup and the reclocked turbo housing, the air tube (where it hooks onto the manifold) can only come out in one direction and thus always gets in way of the turbo air inlet bendy tube from the air cleaner.

I will take some pictures tomorrow assuming my new turbo fan/housing fits.

Brandon

#79 06-22-2005, 04:26 PM

Quote:

Originally Posted by Brandon314159

I am thinking of looking for another intake manifold (that hooks to the engine) so that I can modify it and dump the air out in a different location (and use the stock air cleaner)

I'm using a W115 300D intake. It's opening is about 4" higher than the stock manifold. I mostly used it for space to mount the intake heater but it gives more working room around the turbo also.

boneheaddoctor · #80 06-22-2005, 05:38 PM

Quote:

Originally Posted by 82-300td

I'm using a W115 300D intake. It's opening is about 4" higher than the stock manifold. I mostly used it for space to mount the intake heater but it gives more working room around the turbo also.

Thats a great idea.......I need to see what they look like.....hopefully they are not restrictive internally.

mdisav · #81 06-22-2005, 09:53 PM

Impressive work Brandon!!

I just plumbed an audi TT intercooler in my 124 603. I snuck it under the right headlight. I have installed a boost and egt gauge where the ash tray was. I also turned up the full load stop one turn. I did adjust it two turns and the idle did not return well. So I went to one turn with a good power increase and no effect on the idle. Before the intercooler and full load adjustment 0-60mph was 10 secs. That was with alda tweaked, rear muffler removed and catalytic converter hollowed out. Afterwards
0-60mph was 9 secs. That is with 100% biodiesel. I have found that my 0-60 times were low 9s with dino diesel before intercooler. I will have to run a tank of dino and check the times now.

What is the acceptable limit for egt for the 603 and 617 motors?

I am currently at 1200F with full pedal in third with 14psi boost.

Before intercooler I was 1100F. After intercooler I was 1000F. And after intercooler and full load adjustment 1200F.

Thanks!!

H2O2 · #82 06-22-2005, 10:16 PM

How are you measuring those 0-60mph figures--with a stopwatch, or? My OM603 with the full load screw turned out 1.75 CCW and a medium sized FMIC has reduced 0-60 speeds to 8.25secs--as verified by a G-Tech Pro accelerometer. My EGTs haven't exceeded 1100F. I'm running a Bio mixture of somewhere between B-20 and B-40 right now. Any pics of that Audi TT IC install?

mdisav · #83 06-22-2005, 10:44 PM

I am doing them with a stop watch. I just ordered the G-tech pro so I will get some more exact numbers soon. I have to take some pics and see if I can get them up here. I just may be able to do that tomorrow. How about some pics of yours?

H2O2 · #84 06-22-2005, 11:01 PM

All the gory details can be found here , but the interesting stuff begins around page 13. The installed FMIC can be seen here .

gsxr · #85 06-23-2005, 12:21 AM

Quote:

Originally Posted by mdisav

I am doing them with a stop watch. I just ordered the G-tech pro so I will get some more exact numbers soon. I have to take some pics and see if I can get them up here. I just may be able to do that tomorrow. How about some pics of yours?

Yes yes... photos please! Also, what are the dimensions of the Audi IC? What years/models are valid donors? If this fits under the stock bumper I'm interested...

Side note: did you adjust the '2b' screw behind the ELR, or adjust the external throttle linkages?

#86 06-23-2005, 12:24 AM

Quote:

Originally Posted by boneheaddoctor

Thats a great idea.......I need to see what they look like.....hopefully they are not restrictive internally.

3-4-5 get plenty of airflow. #1-2 are not in a great direction for flow, I had to grind down the internal ridge a bit. Even still, they won't be the best runners.

boneheaddoctor · #87 06-23-2005, 08:24 AM

I got my repairparts from Engatwork yesterday in the mail.....Tonight I'll put the delivery valve in the car...and then I will be back to tweaking mine.

#88 06-23-2005, 09:05 AM

I experimentally put an IC on my 300SD and took it for a little test spin.
I think the problem with the intake port being in a bad spot is really holding back my potential. I want to find another one and modify it to suit the application better.
I really like the idea of using the stock air cleaner setup and this intake manifold just flat out prevents it.

As far as results, I think the air filter that I temporarily put on there didn't allow enough air to flow and thus the turbo never made than about 7psi boost.
I also changed my compressor turbine/housing due to my other one getting damaged. In this replacement, I happened to upgrade to a slightly larger fan/housing (same brand and bolted right up). The input and output of the compressor housing/fan setup are slightly larger on this one as compared to stock.

I am thinking until I find another intake and perhaps a water/air IC...I am going to take this experiment off and keep it simple for now. I just need my benz to get me around for the moment...tinkering is later when I don't have prospective road trips planned

Anyone want me to post a picture?
I used the sizeable Audi intercooler and did nothing more than move a single water tube slightly lower on the passenger side (heater).

gsxr · #89 06-23-2005, 09:57 AM

Brandon, it's highly unlikely that your air filter is causing any restriction, unless you're using something off a garden tractor.

It's more likely that the plumbing is responsible for the pressure loss, and/or not enough fuel, and/or the wastegate needs adjustment. Was the car making more boost before the IC install? All you should need is 10-12psi at the manifold...

mdisav · #90 06-23-2005, 01:10 PM

I do not know what year my intercooler is but I imagine the audi TT intercoolers probably did not change much. It measures approx. 13"width x 8" height. I did not touch the adjustment in the ELR or the linkage and it idles and returns to idle normally. It also had a normal cold start this morning. That is with 1 turn. Here are my pictures.

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