Has anyone installed an intercooler on a 300D? I'm thinking about modifying the intake and plumbing in an intercooler while my engine is out, just not sure if it would be worth the effort. Any thoughts?
Zeke

It is not worth the effort if everthing else on the Engine is stock.

Diesel Performance Tuning - PeachParts Mercedes ShopForum

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84 300D, 82 Volvo 244Gl Diesel

I doubt it its possible in a 300D unless you eliminate either the mechanical fan or the AC condensor.

I installed a customized intercooler in my 2000 Dodge Dakota CUMMINS 4bt, 4x4, Crew Cab. It's visiable in this pic:

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daw_two
Germantown, TN

Links:
Sold last car --- 05/2012 1984 300D Light Ivory, Red interior
Cluster Needles Paint
New Old Stock (NOS) parts

Past:
3/2008 1986 300SDL "Coda"
04/2010 1965 190D(c) "Ben"
& many more

There is a guy on the STD turbodiesel performance forum who has rectangular (long/narrow) one mounted on the front chin of a w116 300sd.

One mean looking machine (numerous other mods as well)....

However, as mentioned, the standard line here is that and intercooler will be mostly decorative unless you intend to do significant a boost bump and ALDA crankup.

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

If the engine is out it might be easier for you to do a little tweaking to the governors in the IP (there's a writeup about it on superturbodiesel), then you can adjust the boost up to about 12psi (or a little more if you go with a different turbo) and plumb in an intercooler. Check out air/water intercoolers, they are smaller than traditional air/air and don't require all the giant air piping everywhere, just smaller water lines to a separate radiator.

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1982 300D Turbodiesel, daily driver. Mods so far: Fram 8038 paper filter, 4 brake light mod, Gen II w126 (front) rotors/calipers, boost turned up to 12lbs, non-egr manifolds, water/methanol injection, 4-speed manual
1980 300SD Turbodiesel, project car, nearly ready to hit the street

1974 240D, New paint

sadly that w116 is crushed IIRC....


.

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w126 500SEC gen II euro, powered by OM617 turbo stolen from 84 300SD 2.88 diff,EGR blinded
next wish/project: w114 coupe OM603 powered

I didn't memntion that the engine is married to a WC T5 5-speed and going in a 65 Ranchero. I've had 3 TDI Jettas and miss the milage. As a hot rod guy I really hate commuting with something as ordinary as my Miata and decieded to build a fun milage machine. So far it has 4 wheel disk brakes and AC. The only modifications to the engine would be to increase milage and maybe mild performance. I've owned a 82 300D turbo sedan and the performance was ok even with the 3 speed auto trans, so I figured a figured a 1200lbs lighter car and a efficient 5 speed manual trans ought to be much better. So what I would like to know what reasonible mods will increase milage and maybe a little performance. Thanks, Zeke

Unless someone did a weird tranny swap, that '82 would have come with a 4-speed auto.

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

um... since zero Turbo 300D's came with a manual trans... or went into a ranchero... I'm going with weird tranny swap...

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Very true... I should consider the circumstances, I guess.

I'm curious as to how the WC T5 will be with the OM617! I don't relish the idea of putting non-MB into MB, but if it works out nicely... well, I can't swear what I would do.

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

What happened? He only built it about three years ago.... I am only an occasional visitor to that board.

Pics at: Jesse's hy35 powered w116

R.I.P.

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

Sorry, I have no idea if my 82 had a 3 or 4 speed auto...it was 20 years ago. A OM617 swap is very popular with the 4x4 guys. There are adapeters to add a Toyota,Chevy, Ford, Jeep, AMC or Chrysler transmission behind them. Adapting a late MB 5 speed to the engine was cost prohibitive (way more than our cars are worth, modified or stock). I have maybe $1000 into the convervsion, including new flywheel, clutch, adapter and transmission. If you care about having an original car, you wouldn't consider it, but if you want performance/milage via an overdrive and a huge choice of gear ratios it's something to consider. I've been told the 700R4 conversions are amazing on the OM617 as far as milage and performance gains, but I'm a manual guy. Anyways back to the question, which should apply to a MB or my kit car (as my wife calls it); what would you suggest for mild modifications to the OM617 to increase milage and possibly performance? I do NOT want something that smokes badly like the 4x4 diesel guys. I went that route on one of my Jettas with larger injectors and pump and hated it, but it performed amazing and averaged about 47mpg. My record was 56mpg...takes out a Prius! I'll be interested in what you think.

There was a design flaw in the location of his intake which lead to it sucking in a bunch of water and bending a rod.

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2004 F150 4.6L -My Daily
2007 Volvo XC70 -Wife's Daily
1998 Ford F150 -Rear ended
1989 J-spec 420SEL -passed onto its new keeper
1982 BMW 733i -fixed and traded for the 420SEL
2003 Volvo V70 5 Speed -scrapped
1997 E290 Turbo Diesel Wagon -traded for above
1992 BMW 525i -traded in
1990 Silver 300TE -hated the M103
1985 Grey 380SE Diesel Conversion, 2.47 rear end, ABS -Sold, really should have kept this one
1979 Silver 300D "The Silver Slug" -Sold

Okay, not to beat this to death, but Cho said it was crushed. He crushed that car because of a bent rod?

It is very hard for those of us back northeast in rustland to process the idea of crushing a w116 'cause it needed a motor. That's all.

End of sermon .

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

He bent the rod and then was unable to find a OM617 in his area. So he had it crushed....

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2004 F150 4.6L -My Daily
2007 Volvo XC70 -Wife's Daily
1998 Ford F150 -Rear ended
1989 J-spec 420SEL -passed onto its new keeper
1982 BMW 733i -fixed and traded for the 420SEL
2003 Volvo V70 5 Speed -scrapped
1997 E290 Turbo Diesel Wagon -traded for above
1992 BMW 525i -traded in
1990 Silver 300TE -hated the M103
1985 Grey 380SE Diesel Conversion, 2.47 rear end, ABS -Sold, really should have kept this one
1979 Silver 300D "The Silver Slug" -Sold