Super clean motor. Nice work.

Has consideration been made to installing an air to air intercooler? attachment could be made between the compressor outlet and intake inlet. Space is limited in the W124, but perhaps it could be done ?

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85 300D 3 pedal. Current project.
83 300TD (need rear wiper assembly dead or alive)
84 300SD Daily driver
85 300TD almost 400k miles and driven daily.
98 E300D *sold
86 300SDL *sold and made flawless 10 hour journey to new home.

Yep, it's been done. You don't get any more power without turning up the fuel though. And you can max out the fuel delivery without an intercooler, as long as you have an EGT gauge and take your foot out of the throttle when temps get too high. The intercooler should eliminate the need for the EGT gauge and also make the power increase a bit safer though. There's room for a small side-mount IC in the bumper pocket ahead of the right front tire, but plumbing is a challenge. A large front-mount IC can be installed but the bumper must be cut; this only makes sense if you're turning up the power a lot.

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Hello all, I'm about to start to do the conversion to my 124 soon since its starting to warm up. But does anyone have a parts list for the wastegate conversion for the OM602?

Got the list!

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1998 ML-320
1983 SEC 380
1992 300D ~Sold

Could you or anyone else please forward this list to me. Thanks!

Me too please

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Greg

Current
2005 E320 CDI (50k) W211 with OM648
1999 E300D Turbo (133k) W210 with OM606.962
1997 E300D NA (170k) W210 with OM606.912
1991 300D 2.5 Turbo (199k) W124 with OM602
1990 300D 2.5 Turbo (170k) W124 with OM602

I forgot the part number for the "normal" wastegate. I do remember it was from a company out of california. They were very easy to deal with and sent me everything I needed. I believe all in all it was under $100. If I find it, I will post it.

The hardest part is tapping and inserting a metal nipple on the turbo to run a hose to the new wastegate. I took my turbo out of the car, just easier that way. Get it done and dont look back.

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93 300D 2.5 Turbo, Black/Palomino 273K
09 E350 Black/Black 41K

You don't need to remove the turbo to do the swap. Been running with a hose from the manifold. Works well.

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92 300D 2.5L OM602 OBK #59

Total agreement with bobo. What a PITA if you had to remove the turbo to do it.

I also used the intake manifold pressure. If it's good enough for the over-pressure protection circuit I figure it's good enough for the wastegate.

Hi, does anyone have the complete list of parts necessary to do the conversion? Thanks in advance!

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Greg

Current
2005 E320 CDI (50k) W211 with OM648
1999 E300D Turbo (133k) W210 with OM606.962
1997 E300D NA (170k) W210 with OM606.912
1991 300D 2.5 Turbo (199k) W124 with OM602
1990 300D 2.5 Turbo (170k) W124 with OM602

Read the thread.

So I'm about to do this conversion. I thought it'd be easier to tee into the pressure line on the manifold so I'm going to try that route first. I just wanted to be sure I'm using the correct line. There are three ports on the manifold and one already has a hose in it that I *think* leads to the alda?.. whatever the canister is just above the vacuum shutoff. This is a pressure line right? If this is pressure it should be really easy.

As far as the F vacuum connector for removing the transducers- shouldn't I just plug the lines that are removed- the one going to where the egr is (using delete kit) and the other to where vacuum waste gate was (using pressure). In fact, this will eliminate vacuum to the entire passenger side of the car won't it? I can just plug the 4 way just out of the vacuum pump and eliminate that whole run....

Thanks

EDIT: I'm also confused on the original photo with the turbo removed and a hose and a new tap. I'm assuming the hose is going to the new pressure wastegate. However, the wastegate is currently not mounted on the turbo so how is it on the turbo in that picture when I thought the goal was to bolt the replacement one into the same location?

All the ports on the manifold are pressure.

Yes, you can cap the vacuum lines to the passenger side of the engine.

Sixto
87 300D

Maybe I'm just confused I suppose the wastegate must actually be mounted on the turbo and I'm looking at something else. What I'm looking at has vacuum on it and is parallel (roughly) with the egr and controls some kind of valve. I suppose I'll see it all clearly when I take it apart and can see the turbo more clearly.

EDIT: Okay I crawled underneath and saw very clearly the wastegate with its actuator arm so now I'm clear. What is no longer clear is what are the two devices on top to the left of the block that have vacuum going into them? I believe the one towards the passenger compartment is the egr but what is the other?

Yes, the wastegate is mounted on the turbo. crossover valves, one controls the egr the other controls the vacuum control flap vacuum unit. this will be disconnected when you add the pressure actuated wastegate.

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92 300D 2.5L OM602 OBK #59