Wastegate actuator swap for OM602.962? - Page 30 - PeachParts Mercedes-Benz Forum

engatwork · #**436** 11-26-2012, 04:44 PM

I'll be installing the new wastegate actuator in the one I'm modifying over the next day or so. You will want to plug or remove/seal the vacuum lines going to the passenger side, front fender area.

Gregory · #**437** 11-27-2012, 09:06 AM

Interesting thread. How does it relate to a 1987 190 D, 2.5 w/turbo? I'm having vacuum and low power at high speed issues. The car only smokes when it starts with 3 glow plugs.

gsxr · #**438** 11-27-2012, 01:28 PM

Quote:

Originally Posted by Gregory

Interesting thread. How does it relate to a 1987 190 D, 2.5 w/turbo? I'm having vacuum and low power at high speed issues.

The 87 190D-T already has a pressure wastegate. If you are having power issues at high speed, you may want to post a separate thread, as it's not related to the 1990-1993 wastegate conversion being discussed here...

jpf · #**439** 11-28-2012, 04:17 PM

Quote:

Originally Posted by 300D-91

I did mine to prevent future problems and it was the ideal time since the EGR valve was 99.9% non functional and being removed.

One quick tip, rather than cut & thread the rod I simply installed the nuts from the old unit on the new unit before installing it. This moved the actuator far enough that no cutting was required and allowed some pre-load.

How has this install worked out for you 300D-91 as opposed to the original install by gsxr. It would seem that pressure would reach the actuator quicker by drilling and tapping into the turbo housing. Let me know your thoughts, as I am planning on doing this conversion within the next few days.

JamesDean · #**440** 11-29-2012, 08:05 PM

I pulled my boost gauge out today to see how I was doing. I only saw a peak of like 8-10 psi.

Either
a) controller got bumped and changed
b) gauge is crappy
c) lines are leaky and gauge is inaccurate
d) actually only making 8-10 psi of boost

Hmmm.

sixto · #**441** 11-29-2012, 08:08 PM

e) all of the above

Sixto
87 300D

JamesDean · #**442** 11-29-2012, 08:16 PM

Quote:

Originally Posted by sixto

e) all of the above

Sixto
87 300D

LOL. probably. The question is..is it really that big of deal lol. I'm averaging 33 mpg right now. Would like to jump up 3-4 mpg but probably not going to happen easily, especially with 70-75 mph averages.

Right now what IS worth dealing with is these two noises. One is in a door and goes away after about 20 minutes of driving and the other is this low pitch whistling of wind/air somewhere in the passenger side. Its akin to growling but sounds like wind whisping around something. Not a clue.

gsxr · #**443** 11-30-2012, 10:55 AM

Quote:

Originally Posted by JamesDean

LOL. probably. The question is..is it really that big of deal lol. I'm averaging 33 mpg right now. Would like to jump up 3-4 mpg but probably not going to happen easily, especially with 70-75 mph averages.

I hate to burst your bubble, but 33mpg is darn good. Over the ~30kmi that I owned my 124.128 it averaged right around 30mpg, and the best-ever peak was 33.0mpg, with a few tanks in the 32.x range. The car was fully tuned up (new timing chain, IP timing tweaked, synthetic fluids, etc etc) These numberes were all using the crap low-BTU diesel we get in the PNW, so if you live somewhere with "good" diesel, ~33mpg average is right on target.

There is literally nothing you can do to tweak the motor to get another 3-4mpg. The only thing I can think of that would provide that result (with no other changes) is a 5-speed manual with overdrive 5th gear. My nephew has a .128 with 5-sp and it has gotten ~36mpg on a long freeway trip.

Quote:

Originally Posted by JamesDean

Right now what IS worth dealing with is these two noises. One is in a door and goes away after about 20 minutes of driving and the other is this low pitch whistling of wind/air somewhere in the passenger side. Its akin to growling but sounds like wind whisping around something. Not a clue.

The whistling/air noise... check the felt window channel in the door, look for any loose or misplaced trim, and - I swear - if you have any big chips in the windshield, get them fixed. Our car had a wind noise whistle that I could never track down and then after I had all the stone dings in the windshield repaired, voila! The noise vanished and never returned.

shertex · #**444** 11-30-2012, 11:00 AM

Quote:

Originally Posted by gsxr

I hate to burst your bubble, but 33mpg is darn good. Over the ~30kmi that I owned my 124.128 it averaged right around 30mpg, and the best-ever peak was 33.0mpg, with a few tanks in the 32.x range. The car was fully tuned up (new timing chain, IP timing tweaked, synthetic fluids, etc etc) These numberes were all using the crap low-BTU diesel we get in the PNW, so if you live somewhere with "good" diesel, ~33mpg average is right on target.

There is literally nothing you can do to tweak the motor to get another 3-4mpg. The only thing I can think of that would provide that result (with no other changes) is a 5-speed manual with overdrive 5th gear. My nephew has a .128 with 5-sp and it has gotten ~36mpg on a long freeway trip.

Ditto. I've got two of these cars in excellent condition. I have NEVER seen higher than 32/33 mpg....and that's over a combined 130,000 miles of driving.

JamesDean · #**445** 11-30-2012, 11:33 AM

Look what you guys have done! My bubble, she is dead. You've both burst it to death. LOL.

I almost hit 35 mpg on the last tank, it was darn close. I think with the cruise control FULLY functional it might do it. My foot power usually tips it toward 75-80. I also thought that with non-winter diesel I would do slightly better. I live in North eastern Ohio. I dont think we get nice diesel either.

shertex · #**446** 11-30-2012, 11:36 AM

Quote:

Originally Posted by JamesDean

Look what you guys have done! My bubble, she is dead. You've both burst it to death. LOL.

I almost hit 35 mpg on the last tank, it was darn close. I think with the cruise control FULLY functional it might do it. My foot power usually tips it toward 75-80. I also thought that with non-winter diesel I would do slightly better. I live in North eastern Ohio. I dont think we get nice diesel either.

You must be one of those wacko hyper-milers to get 35+mpg!

JamesDean · #**447** 11-30-2012, 12:01 PM

Quote:

Originally Posted by shertex

You must be one of those wacko hyper-milers to get 35+mpg!

Haha no not that crazy. Creature comforts must stay. My commute is like 99% highway.

Actually tomorrow I'm going to install the 143a alternator. So I can finally use my subwoofer I installed a few weeks back.

On the topic of noises, I've got one in my passenger door that wont quit! If I push on the door panel just above the end of the arm-rest, kind of in-line with the lock plunger it'll stop. But that makes driving awkward, having to lean over the whole time!

shertex · #**448** 11-30-2012, 12:04 PM

Quote:

Originally Posted by JamesDean

On the topic of noises, I've got one in my passenger door that wont quit! If I push on the door panel just above the end of the arm-rest, kind of in-line with the lock plunger it'll stop. But that makes driving awkward, having to lean over the whole time!

Is it perhaps the would trim that's rattling? My 92 was doing that till I wedged some paper in there.

jpf · #**449** 12-01-2012, 08:55 PM

Quote:

Originally Posted by gsxr

Exactly correct. The hard part is installing the new actuator setup, the rest is a breeze.

Well you weren't kidding about the hard part as being installing the new actuator. After I removed all of the emissions vacuum junk and cleaned everything out, I was ready to tackle the actuator. The hardest part was getting the turbo assembly out. What a bear. But, the new actuator is finally installed. Tapped the turbo housing at the inlet port opening and threaded the new 90 1/8 NPT fitting, installed a new 3/16" pressure line from the actuator to the new fitting and put everything back together. I then removed the ALDA and loosened the nut and adjusting screw on top. I opened the adjusting screw all the way out and then turned it in one full turn and locked the nut back down. Re-installed the ALDA and went for a test drive.

Remarkable difference with the performance of my car. Thanks for this thread and all of the information within it. You guys are great.

engatwork · #**450** 12-02-2012, 07:32 AM

I don't remember having to remove the turbo to do the install.