ATP is an authorized Honeywell/Garrett retailer(distributor?)
http://www.atpturbo.com/

Dave's got the ruler set up so you can compare the rod lengths
(Old and New [and the mods you have to make to the New] )

The ALDA is a fuel compensating device that reacts to Air Pressure...Either
Ambient or "Boost".Basically,When the Turbo raises pressure in the intake
manifold the ALDA "Sees" the rise and increases Fuel Flow Rate.'Cause
without MORE Fuel the "Boost","Doan DO Nuffin."

The intake is #5 in the first Cyrillic Pictogram,the test port will be any
threaded opening with a bolt closing it off.

#103 is the ALDA in the next two diagrams.

Attached Thumbnails

     

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'84 300SD sold
124.128

CI did a great job of answering the other questions, let me know if you need additional clarification. FYI, the tranny shifting is based completely on throttle position. You are doing the right thing by fixing the engine power first, BEFORE messing with the tranny (although it would be a good idea to at least check the vac lines to the trans and make sure they aren't leaking). Additional information on tranny shifting is located in this post.

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Check out my website photos, documents, and movies!

Trying to get a final shopping list together for ATP.

gsxr - is the unit you purchased somewhere on the ATP site? http://www.atpturbo.com/Merchant2/merchant.mvc?Screen=CTGY&Store_Code=tp&Category_Code=WGT1
If not, will they recognize 433489-12 or did they have a different stock #?

and is this the fitting for the manifold port? http://www.atpturbo.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=ATP-FTG-040&Category_Code=ATP-FTG2

and one last question, what diameter hose did you use for the connection?

Thanks for taking the time to write up such a great post on a much needed upgrade!

Klaus

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‘84 300TD “Mountain Goat”
'62 300d Adenauer-350 Chevy - "Max"
'15 VW Passat TDI
'16 Dodge Ram 3500 - Cummins w/6-speed
'68 Mustang fastback
'55 T-bird
‘63 Studebaker Hawk

KK,

http://www.atpturbo.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=ATP-WGT-022&Category_Code=WGT1

This is Almost what you want...Although the Opening pressure (18PSI) is a
little Higher than Specs.(A Boost Controller might correct that) AND the
opening pressure MAY be slightly adjustable by Tweaking the Rod Length.
Ask ATP next time you call.

EDIT:
Corrected by both FI and GSXR (Thanks Guys!)
Opening Wastegate Pressure can Never be Adjusted Downwards!
(So, The 18 PSI model ain't the ticket)

Attached Thumbnails

 

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'84 300SD sold
124.128

Boost pressure can only be increased with a boost controller and rod length.

The wastegate I purchased was not listed anywhere on the ATP website. You have to call or email, and ask for the specific part number I used.


That sure looks like it, yep!


D'oh! I don't remember. I believe I picked up some fuel hose at the local McParts store, both 1/8" and 3/32" ID, and I used the one that fit better. I need to double-check and add that info to one of the photos on my website.


Note that while you can make a wastegate open at a HIGHER pressure than rated (via boost controller), you cannot make it open at a LOWER pressure. So if you use a wastegate rate at 18psi, you'll never get it to open below 18psi. The wastegate I used keeps max boost at 14psi, right at factory spec, no boost controller required.

The intake flap and the EGR actuator were still hooked up even though I had made the conversion to a pressure type wastegate actuator.

Today I have unplugged both intake flap and EGR: now I have a steady 14 psi with any rpm above 2800-3000. And soon after 2000 rpm it gets to 10psi, so it makes all the difference in the world in terms of power!

Now thats a great car to have!

Thanks again GSXR for this thread!

Bye

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BigBen

'98 E300 Turbodiesel 244 000km
RIP '92 300D 2,5 Turbo 632 859,4km due to engine failure

Just finished reading this whole thread and can't wait to make the mod! I have to trouble shoot some rough engine idle and power issues first, but once I get that done, this will be on the top of the squawk list for sure! Thanks for all the great details and pics!

Here is my thread about bad engine idle issues
http://www.peachparts.com/shopforum/diesel-discussion/253990-1990-300-w124-2-5-turbo-running-worse-after-attempted-tune-up-post2218783.html#post2218783

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1990 300D 2.5 Turbo 150k miles
1999 F250 7.3L Powerstroke 225k miles 22mpg
Intro Thread

I figured out my boost issue. The Overboost protection sensor (or what have you) was clogged. Therefore the boost signal for the ALDA was getting interrupted. Now i have a steady 12psi boost and great acceleration.
Questions: Is it bad to unplug the electrical connection to the airflow meter/airbox flap?

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VegStew
1983 300SD 70,000 WVO Powered miles
1990 300D In driveway with Head Off - Cracked

Cool! I keep forgetting that the 90-91 models still had the overboost circuit installed. This was deleted starting in 1992, I believe... it's not present on my '93.


With the pressure wastegate installed, it's irrelevant either way. The airflow meter is there basically for the EGR computer. Won't matter if it's plugged in or not anymore.

All,

Maybe just a coincidence but since the pressure actuator and the EGR blocker plate have been installed I have noticed a drop in idle oil pressure at operating temperature. It hovers just above the 1 but quickly responds to the throttle. I use Rotella 15w40

any feedback appreciated...

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Wayne Jockers
1992 300D

Wayne2970,

1 bar at Idle is Very Good Oil Pressure,and the fact that OP responds instantly
to RPM increase is also Good.
[The FSM says Oil Pressure drop @ idle may go
as low as 0.3 Bar to 0.5 Bar]

(The factory Oil Pressure Gauge in the Instrument Panel is more of a Suggestion
as to what Actual Oil Pressure is in the Engine.It uses electrical resistance from
the Oil Pressure sensor screwed into the backside of the Oil Filter Housing.I am
sure a Bourdon Tube direct measurement gauge[as in the older MB engines]
would show different measurements.)

There is no way your modifications of the devices you list ,would have any
effect on Your Oil Pressure reading, Unless while your were working you've
"Monkeyed Around" with the OP Gauge or the Sender.

You're O.K.

Also check out this thread (The Engines involved have the Mechanical Gauges)
BUT the advice about Oil Filter Shaft O-Rings AND the Shaft/Tube
openings are Valid Points for your OM602 .
oil pressure issue

How Old is your Oil? If you're running the 15W40 Rotella, 3000 Miles is the
MAXIMUM Oil Change Interval.'Lots of Idling And/Or WOT Highway miles and
you should change more often!

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'84 300SD sold
124.128

Following meekly behind the trailblazers here, I just completed installation of the pressure-actuated wastegate on my 1990 300D 124. Performance is underwhelming, 17-18 second 0-60, with a steady 13-14 psi of boost, but better than the intermittent no boost condition I was experiencing before. I removed the turbo to tap in the fitting in the turbo housing and I have a delete kit for the EGR en route from BC. Any suggestions on where to look next for some extra power? There is a large diameter vacuum line that runs up the passenger side with a branch - one side to a vent and the other disappears into the car. Any idea where the other branch might go?

Many thanks for the excellent solution. I wish that I had seen this 4 months ago when my shop replaced the flapper actuator (for sale now ) and made other adjustments to restore the turbo, repairs that were short lived in their effectiveness. I was not looking forward to a return visit. I have three vacuum solenoids if anyone needs parts.

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Rich Mason
Chapel Hill, NC
1990 300D 285k miles
1993 VW Cabriolet converted to 1.6 TD
1985 VW Westfalia 1.6 TD

Some thoughts on what to check:

At what rpm to you achieve 13-14 psi? It should be all in by 2200-2500 rpm under load.

Run a boost gauge right off the ALDA atop the IP to ensure the ALDA is getting the same 13-14 psi.

Have you confirmed a good fuel supply? Clean filters, clear fuel tank vent/no vacuum build-up in fuel tank, etc.

What's the smoke situation when you floor it?

Sixto
87 300D

I will check to see when exactly the boost comes on. I think it is closer to 3k. There is absolutely no smoke out the back under full throttle that I can see in the daylight. Very different from my 1.6 TD vws, which have multiple adjustment and put out smoke commensurate to their power . All the filters are clean and new. I do have leaking IP DV seals, which are to be replaced tomorrow. Thanks for the suggestions.

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Rich Mason
Chapel Hill, NC
1990 300D 285k miles
1993 VW Cabriolet converted to 1.6 TD
1985 VW Westfalia 1.6 TD