Wastegate actuator swap for OM602.962? - Page 12 - PeachParts Mercedes-Benz Forum

Wayfarer · #**166** 02-24-2010, 12:59 PM

Thanks! I re-read the Bently's publishing W124 "Bible" and it says the MB spec is 13.7 psi for the 2.5 turbo boost pressure, so it looks like I am right on the money! These cars are sweet, especially with the rat's nest of uneccessary vacuum lines safely in the trash

.

gsxr · #**167** 02-24-2010, 03:28 PM

Be careful... that Bentley / Ritter book has quite a few errors in it. But, in this case it is correct, boost spec is 0.85-0.95 bar, or approximately 12-14psi.

Johnhef · #**168** 03-21-2010, 10:18 PM

I think I'm finally going to get off my butt and do this swap. I did a 94-95 hood and headlight swap already to it and since my 87 is still out of commision and I'm still driving the 2.5, might as well give it the kick in the pants it needs

Chris_ · #**169** 03-22-2010, 09:04 AM

Does anyone have the link for the thread that contains the circuit board modification to fool the turbo computer into thinking all is well ?

Thankyou

Chris_ · #**170** 03-22-2010, 01:12 PM

In the spirit of helpfulness... and organisation I am including here a summary listing providing the key references to the conversion... I hope this is of help.

Here is the part number and location to purchase the replacement actuator

part number 433489-12

http://www.atpturbo.com/mm5/merchant...Category_Code=

# please note that the rod length will have to be shortened

as a reference this thread :
A : ( post number 133 ) explains the rod length customisation
B: I would highly recommend perusing the entire thread of which the page 9 URL is listed here :
Wastegate actuator swap for OM602.962?

and

for detailed pictures of the parts involved : ( wastegate13.jpg ) for actuator image )
http://www.w124performance.com/images/OM602_intake/

also,

in this same thread : page 10

Wastegate actuator swap for OM602.962?

it is outlined that for the manifold port fitting one should purchase this :

http://www.atpturbo.com/mm5/merchant..._Code=ATP-FTG2

! please note that this fitting is a NPT thread and will certainly work for the self tapped hole on the turbo housing that GSXR implemented but I have yet to confirm that the OE manifold threads used by : VegStew in post # 117... here :
Wastegate actuator swap for OM602.962?

are in fact a match for the 1/8" NPT thread. I will write again when I have confirmed this.

Thank you

1991 W124 300D
1992 W124 300D

compress ignite · #**171** 03-22-2010, 03:58 PM

Chris,

The Biggest reason for enacting this modification is that once it's done
You can IGNORE the EDS (Electronic Diesel System A.K.A. Computer)
The Only Thing the EDS controls after the Modification is Idle speed.
There's No Need to bother with deceiving the EDS anymore!
[Let the little Bugger store codes until it chokes on them...
Will not affect your motoring enjoyment No More.]

Chris_ · #**172** 03-22-2010, 08:49 PM

Ignite,

Good point to be sure, I guess I have spent so many years repairing vehicles to return them to their original condition that I instinctively search for the least invasive methods hence my interest in the circuit board modification as apposed to the pressure style actuator mod. That said the actuator mod will most likely result in the simplest most predictable outcome.

Johnhef · #**173** 03-26-2010, 06:39 PM

Chris- the plug in the manifold is infact a 1/8 NPT thread hole. I'm currently in the middle of doing my swap before I head home from work. Hope it works!

Johnhef · #**174** 03-26-2010, 07:58 PM

well, all is well with the exception of the last piece i went to reattach- the breather vent line- it broke. Trying to figureout a makeshift repair that will work enough to get me home! had a hose in it, but the hood pushed it in too far and caused oil to blow out the dipstick

the newfound acceleration is mindblowing though!

Chris_ · #**175** 03-26-2010, 10:11 PM

John - thanks for the information on the thread size - greatly appreciated. It is nice to see that you are doing the modification also. I have yet to do either one of mine although I just recieved the actuator and fitting from ATP today. I will post results later ... when I get to it.

Thankyou

1991 300D
1992 300D

Johnhef · #**176** 03-28-2010, 01:29 AM

All is well after the first day here, I ended up rtv'ing a cut section of M112 breather cover hose into the VC and pushing the other end over the broken part of the hard plastic tube. I'll order a new one on monday.

gsxr · #**177** 04-05-2010, 12:00 PM

Link to Chris's new thread about low 602 power, even after the wastegate mod:

Fuel Supply (IP) problem on W-124

Chris_ · #**178** 04-05-2010, 11:43 PM

gsxr thankyou for starting a new thread for this issue.

regards

auspumpen · #**179** 04-06-2010, 06:16 AM

Quote:

Originally Posted by gsxr

The 1990-1993 300D, with the 2.5L OM602.962 engine, has the lovely vacuum-operated wastegate, which is controlled by the computer system (EDS). Due to various reasons, I want to convert this to the good ol' pressure-operated wastegate actuator, like on the older OM602.961 (used in the 1987 190D Turbo). Both cars have the Garrett TB-025 turbocharger.

I have a spare actuator from a T3, but I've been told it won't fit the TB-025... and sure enough, it doesn't (the T3 canister is significantly larger). So... does anyone know where I can obtain a pressure-operated actuator for the TB-025? I emailed a half-dozen suppliers of Garrett parts, and so far none have replied. (Update below.)

Also, if anyone can provide the nameplate data from the older 190D-T turbo used on the 602.961, that would be very helpful.

Not sure if this has been covered in this mammoth thread, but the 603 version of the Garrett actuator can be made to fit on the smaller 602 turbo. The canister is physically larger, so you just need to add about 6mm of spacers to get it to sit back a bit and not interfere with the turbine housing. After that, it's just a matter of adjusting the threaded rod to the appropriate length. An 8" section of 2.25" silicone intercooler hose can be used to replace the entire mixer housing, as well. A highly recommended and very satisfying upgrade.

bobodaclown · #**180** 04-10-2010, 07:13 PM

Woo Hoo! Ordered the actuator. Came within a week. Got the M6 X 1 die to thread the rod down a bit and cut about 1/2 inch off the end of the rod.

Removal of the old actuator was pretty easy from below. Drove the front end up on ramps and had pretty good access to the bolts. The top nut (10mm) is a PIA but use long 1/4 inch rod with a swivel and it came out pretty easy. The bottom nut is visible and easy to get to.

The C-clip came right off using a flat blade screwdriver and popped it off.

This actuator operates in reverse of the original. The original is always out (no boost) vacuum is applied and you get boost. The replacement is always in constant boost and is throttled down/controlled by the pressure wastegate.

Installation of the new controller was very easy pre-set rod length to 106-108 mm from base to hole. Pictures are shown earlier. Place wastegate in hole note which way the hose fitting goes. I place mine so it points towards the engine, not the fender. Thread on bottom nut. Attach wastegate actuator eye to the post and attach the C-clip. It should be in the fully engaged position. Don't forget to lock down the adjustment nut.

Thread on the upper nut then fully tighten both nuts. I used a deep socket, swivel and long extension. Tighten up both bolts. That is for the hard part.

For the hose that controls the wastegate I tapped into the ALDA outlet on the manifold. I placed a short hose, T-fitting, to the ALDA, Off the T-fitting to the wastegate controller. The hose that controls the wastegate goes towards the front of the engine follows the old vac lines, then down to the wastegate.

I hooked up a PSI gauge. (It only goes to 10) It did max out a few times heavy on the throttle. PSI spools up quickly and at 1900-2000 RPM, 50 MPH, I'm getting steady 2 PSI of boost with cruise control on pretty smooth road.

So far so good. I'm happy with this mod.
First Picture: Shows hose going to wastegate. Left side of fire wall.
Second Picute: Where I added a T-fitting from the manifold going to the ALDA connector. To feed the wastegate.
Third Picture: Grayish hose I used from the manifold to the wastegate
Forth Picture: Attached to the wastegate.

I'll add some zip-ties to tighten the hose/barb connectors.