Installed a Variable Geometry Turbo off of a 320 CDI with intercooler, and Apex Boost Controller on 87 300SDL. The car flies. builds 1.23 bar of boost at 3000 rpm. Driven this car 7k miles no problems. Runs 80mph barely touching the throttle at .5 - .6 bar boost. I am putting a 560SEL rear end on the car because it revs out at 4000 at 90mph with plenty of throttle left. Boost is instant. Feels like 420SEL from stop. Will send photos soon.

Dude,
Did you do anything to the injection pump? If not it sounds like all you have is more hot air, maybe more efficently but still just hot air.

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Bob D.
Parrish, FL
1 SDL, 1 D, 1 TD, 1 Mog

Yes. Please elaborate. You won't get much praise here without some kind of documented proof, and/or detailed procedural techniques.

You stated E320CDI with intercooler. Does that mean you installed a Variable Nozzle Turbine type turbocharger with the CDI intercooler? How did you manage to plumb the system in? What modifications did you make to have it fit, and what was done to injector pump to take advantage of the extra flow?

If you are making 1.23 bar boost, with a cooler, and equal fueling ratio to match, you should be putting out a lot more power than a 420SEL. A stock turbo on these cars is good for 12 psi and up to 250 hp(with modified IP), from what I've heard.

Please, continue.

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1987 300SDL (324000)

1986 Porsche 951 (944 Turbo) (166000)

1978 Porsche 924 (99000)

1996 Nissan Pathfinder R50 (201000)

Injection pump handles the boost no problem. With a VGT turbo the real gain is with almost instant boost. I used a straight blow thru FMIC Intercooler with Apex Controller, plumbing was not very difficult. I tapped into the vacuum modulator on the transmission to actuate the Variable Vains via the boost controller. Unlike a normal waste gate on a standard turbo the VGT Turbo needs vacuum at idle and low loads to spool up the turbo. In a rlaxed state the vanes are opened for low back pressure which gives less turbine speed for a given amount of exhaust gas. I will post pics tomorrow. Also Justin I don't want praise for this. I mearly posted this incase someone else has thought about doing the same.

Yes, but....

These guys drool over anything with good power. I mean, the fastest S Class diesel sold here in the States gets to 60 mph in 12 - 13 seconds, and only had 148 hp. Those are very meager figures, and many members here seem to be terribly ambitious at getting more power from their diesels.

My SDL has already been modified. Definitely, from the owner that came before me. I have stop watch, GPS, and videos to prove it. I would have a real problem driving a car that requires you to "plan" a passing maneuver on the highway, or even in town.

You have my praise, regardless. Enjoy it.

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1987 300SDL (324000)

1986 Porsche 951 (944 Turbo) (166000)

1978 Porsche 924 (99000)

1996 Nissan Pathfinder R50 (201000)

Sounds sweet. Please post some hi-res pix

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#dieselFLEET
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'97 E300
'99 E300

I tried to submit pics here but my the file size was to big so I made a link for you. http://home.earthlink.net/~saladna

Those pics look cool, but they are too small. Can't really see any details, so I'll have to ask:

What did you use to adapt the turbo to the exhaust manifold?
What did you use to adapt the intercooler piping to the intake manifold?

I've thought of doing the same thing to mine before, but I didn't know a VGT came stock on any Mercedes... which should make things easier. But you never know.

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The stable, er, 1 horse :
1987 190D 2.5 Turbo (running well, and bloody-well better since it's the only car I have now)

What?!?! No independent 0-60mph back to back tests to verify the benefits? No chassis dynamometer tests? No dragstrip ET's? Quite a few will insist that what you have done is useless, ill-conceived and just short of blasphemy. I on the other hand congratulate you. Nice work, thanks for trying and sharing. RT

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When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K

to view the pictures at full resolution just right click on them then choose "view image" and it will show the full res version in the window by itself, then press back to get to the others, and so on.....

That looks neat.....

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-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

Bill Hayllar in Atlanta made the adapter plate from the exhaust manifold to the turbo. Outlet from the turbo comes straight down to the front of the car. I will post more pics showing these details. All in all its not that bad to do. I used steel tubing (I would have preferred aluminum) from the turbo to intercooler to intake (easy to weld and cut).The hardest part was adapting the tubing to the intake manifold, but that turned out to be not that bad. I took 1.4" steel plate cut it to the shape of the manifold inlet using the gasket as a templet, then formed the tubing to the same inner shape as the inlet and welded it togeather. This tube has to be slightly shaped to clear the temp sensors. Polishing all the inner seams was little bit of a pain but well worth it. Mercedes Part Number on the Turbo is 613 096 02 99 (I bought this off of ebay $200 from England) Intercooler is 24x8x4 (available again on ebay). I thought about having it dyno tested but can't justify the expense since I am not selling a kit. I am happy and that is all that counts

Exactly how I wanted to mount a IC on my 300SD.
Did you have to cut/move anything that was stock on the car to get the IC /tubing to fit?

My tubing would have to be tucked high becuase I like going fast on not so flat stuff.

Awesome job though. Very clean setup.

I have never bottomed out on the tubing even on the largest speed bumps. I removed a small vent plate on the frame rail between the bumper and front tire on passenger side. That was all.

Interesting.

Nice that you guys also do some researching, that's always cool.

Better to modificate the intake manifold like this:



Much better flow and saves lots of space. Also looks little better. Of course this is not the best way, it is even more better to bring the pipe to the bottom of the manifold or bring it in 45 dergees instead of 90.

With VGT you can really get much faster response to throttle, but with highly modified IP you can cause much damage with too much torgue on low rews, of course you cannot do that with stock pump and automatic, so don't worry.

One thing, why didn't you just change the controller from vacuum to boost operating. Just take a wastegate from regular turbo, replace the vacuum one with that, and adjust it. Easy and safe.

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Diesels are lazy and they smoke
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