Wastegate actuator swap for OM602.962? - Page 6 - PeachParts Mercedes-Benz Forum

Brian Carlton · #76 05-03-2008, 09:43 AM

Quote:

Originally Posted by bgkast

I would be hesitant to take the signal from the intake manifold; especially if you are ever going to add an intercooler. You want the wastegate actuator to "see" the pressure the turbo is putting out as quickly as possible, the farther down-stream it is the longer it will take the wastegate to react. The reaction time will be especially slow if there is a whole intercooler that needs to be pressurized before the wastegate reacts.

The time "downstream" is negligible without an intercooler.

With an intercooler, the pressure "downstream" will be slightly less than the pressure at the turbo. However, the pressure that we are interested in is the pressure in the intake manifold, not the pressure at the turbo...........so, in reality.........the signal from the intake manifold is the preferred solution.

pmari · #77 05-03-2008, 10:22 AM

There are two threaded (and plugged) "access ports" ready to go.
More and larger pics....http://www.mindspring.com/~houlihan/merc/banjo.htm

cscmc1 · #78 05-03-2008, 05:05 PM

I ordered the same actuator as gsxr, and was able to modify it in the same way. I installed it today, along with one of BC's EGR delete kits, and drilled/tapped the EGR delete plate for a hose barb to run the actuator. I also removed the EGR housing and pulled the plate out of the butterfly flapper valve and removed the flap actuator altogether. I'll see how this setup works tomorrow, after the RTV silicon in the EGR delete kit cures, and post a follow-up.

Thanks, all, for the excellent ideas and advice in this thread!

cscmc1 · #79 05-13-2008, 10:20 AM

I wanted to post a followup and say that my setup, so far, is working great. And FWIW, the actuator CAN be swapped out w/o removing the turbo. I removed the crossover pipe and EGR housing as I was going to be cleaning and modifying them anyway, and the intake boot from the airbox was removed, so access was a little bit easier. The little circlip that holds the actuator rod on at the wastegate can be tricky to remove, but I finally did get it with just my fingers. This is a messy job (if your car is as dirty as mine), so approach it with patience and ratty attire.

Thanks again GSXR for being the pathfinder on this project!

slimak9 · #80 07-26-2008, 03:34 PM

gsxr,

where you able to locate an actuator for the 300D 2.5's that didn't need to be shortened and still responded to 14psi?

gsxr · #81 07-27-2008, 10:24 PM

Quote:

Originally Posted by slimak9

gsxr, were you able to locate an actuator for the 300D 2.5's that didn't need to be shortened and still responded to 14psi?

Nope. Only the wastegate shown in my photos, which needs the rod shortened. Sure would like to find the "correct" part number though.

pdrayton · #82 08-04-2008, 08:33 PM

WOW! I've been messing with the notorious rat's nest and EDS error codes for what seems like ages! And this sounds awesome!

Only downside I see is if the actuator malfunctions, or if there is a hole in the pressure sensor tube. That would screw things up wouldn't it?

I just paid $127 for a vacuum transducer that didn't solve the problem.... think I'll take it back and buy the pressure actuator and save some money! Yipee!

pdrayton · #83 08-05-2008, 07:51 AM

I've been trying to find that actuator 433489-12. Closest I found is this, from a volvo 740. It looks the exact same, anybody know if it's a goer?

http://www.ipdusa.com/version.asp?strPageHistory=search&numSearchStartRecord=1&P_ID=826&CAT_ID=0&V_ID=1680

pdrayton · #84 08-07-2008, 01:51 PM

The IPD guys can ship that actuator in 45 days... hmmm, not so good.

I finally got the ATP guys to find it by looking up a previous order (thanks Chris). There is some weirdness with the whole thing - doens't have a part number or something. If you want to order one from ATP Turbo, talk to Moe and tell him you want the same thing that Paul Drayton got on order number 281251. Then he'll be able to order it.

HE says the IPD actuator is actually 18psi. The one he's ordering is a 14psi one.

Crazy.

slimak9 · #85 08-10-2008, 11:19 PM

Does anyone know if a turbo from a 603 1987 300D would drop into the 602 1990 300D 2.5? And are the pressures equal?

As we know, the 603 is already pressure operated from the turbo, and I can get one for next to nothing. Plus I have lots of play in my stock 602 one, so its time for a change.

gsxr · #86 08-11-2008, 01:24 AM

No, it's not a direct swap. The flanges are different, the 603 uses a T3, the 602 uses a smaller TB-025. Both are set to 12-14psi of boost. If you put a T3 on the 2.5T, you would likely end up with significant turbo lag, although peak power could increase if you also have the injection pump modified by Myna. This would result in a car that was a real dog until 2500rpm or so, then it would be pretty quick. With the stock injection pump, I think it might be a waste of time to put a T3 on a 602. And it would definitely not be a bolt-on.

What is "lots of play"? The turbine shafts are supported by the oil film, they will normally have a noticeable amount of side to side movement. But it shouldn't move in or out much at all. These turbos don't often fail, other than the shaft movement, why do you think it's bad?

slimak9 · #87 08-11-2008, 02:48 AM

I was getting no pull from the turbo, so when I took it into my indy, he told me the vacuum solenoid needs replacing, but instead of throwing money away on that, I'd like to convert it to a pressure regulated as described above.

He also pulled off the intake hose from the filter housing and showed me how much play there was (not sure if it was side to side OR front to back) I'll check tommorow.

But, since a 603 is not a direct swap, I'll hunt for a 602 OR look to have this one rebult AND converted to a pressure regulated.

pdrayton · #88 08-12-2008, 12:11 PM

I got the 433489 actuator yesterday. Tested it today and it STARTS opening at 14 psi, is fully open at 21psi. Granted, I don't have a very accurate gauge (100psi water pressure gauge) but it is not more than 10% off (tested with another 10psi gauge).

Is that right? Should it only be open at around 20psi? Sounds dangerous. Or maybe I should get a gauge I am fully confident in. I doubt my gauge is that far off.

CI, didn't you say yours starting opening at 10 or something and was completely open at 14psi?

gsxr · #89 08-12-2008, 12:33 PM

Sounds normal. When tested with a Mity-Vac, mine started opening right around 14psi. That is the measurement you're looking for, when the actuator rod first starts to move at all. On the car, it measures 14psi under load on the boost gauge.

The pressure required to move the actuator through its full stroke (21psi, in this case) is irrelevant. Note that the actuator can move a lot farther than the wastegate valve itself can move. I think the valve's full stroke is less than 10mm? I forget...

pdrayton · #90 08-12-2008, 02:03 PM

Thanks GSXR.

How much boost can the 602 handle without extra mods? Stock is 14psi and that's what you're getting with the 433489-12 which starts opening at 14?