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Old 11-14-2013, 01:18 PM
Diesel911's Avatar
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Join Date: Sep 2007
Location: Long Beach,CA
Posts: 35,965
Originally Posted by lombrozo View Post
I have endless difficulty installing the U-Tube between the turbo and the stock air filter. I have replaced the rubber gaskets, but they tend to push down into the tube when trying to force it onto the turbo inlet and the air filter.

I would be perfectly happy to hose-clamp a K&N or equivalent filter onto the end of the turbo and be done with it. Any experience with this? Do I need to make an extension hose or size adapter to control temperature or provide a better fit?

I don't care about cold air, better breathing, or looking like a ricer Honda, just want to keep my engine alive forever.

The car is a 1980 300SD W116, 430,000 miles but I put in a used engine 50,000 ago.

Thanks for your ideas
I think there is a few more ways to go with your issue.
I glued the Rubber Seal into the inside of the U-tube with Silicon Sealant. Stuff something into the ID so that it presses against the Tube.

Then I took a sharp Knife and sort enlarged the ID on the end that goes on the Air Filter. I filed off the sharp edges on the Air Filter housing and coated it with STP and shove it on.

You could get another U-tube at the Junk Yard that has a larger ID.

You toss out the Rubber Seal and fill and build up the Area with Silicon Sealant which is much softer when it cures than the Rubber Seal.
In fact you could actually glue the U-tube to the Air Filter Housing with Silicon Sealant.

You could not use the Rubber Seal and wrap the end of the Air Filter Housing with Rubber Electrical Tape. That tape is sticky on both sides and after it sits a bit you cannot peal/unwind that Tape as it sort of fuses together. You would be making your own rubber Seal with it; but the Seal would be attached to the Air Filter Housing.
Once it is built up enough you would need to lube the U-tube ID.

I don't own an SD so I don't know what type of room is available but the below thread is what I did; but for a different reason.
Washable Air Filter and Intake Mod , With Larger Breather

84 300D, 82 Volvo 244Gl Diesel
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Old 11-14-2013, 01:25 PM
mach4's Avatar
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Join Date: Jul 2011
Location: San Diego County, CA
Posts: 2,736
Originally Posted by Zacharias View Post
I am starting to like this whole idea but would prefer to end up with a housing for the filter, a la Mach4's work on his diesel SL (pic attached from another thread).

Any ideas?
I should probably put everything in one place on this, but here are some links to help you along

380SL Diesel Conversion Project
380SL Diesel Conversion Project
380SL Diesel Conversion Project
Cal. Air cleaner or cold air intake?
catch can & cold / hot air intake how to

Keep in mind that the Cali turbo sits quite high compared to the other models, so you may have some fitment issues with a turbo that sits lower on the engine. Also mine is in a 107 chassis not a 123 or 126 so that may present some other issues as well.

I'll bet you could easily adapt the poleshady solution with my housing strategy
Current Stable
  • 380SL (diesel)
  • Corvette C5
  • Manx
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Old 11-15-2013, 07:02 AM
cho's Avatar
cho cho is offline
diesel power
Join Date: Dec 2011
Location: Europe
Posts: 933
how about this one?

I had issues with height after engine conversion so I had to eliminate air setup.
at first I had sprintfilter with proper flow in closed metal housing which was from
technical point all good but I never liked a look so I find another solution

I pulled complete air setup from 1997 E300TD and plunged it in.
it fits perfectly...even the rubber hose had correct diameter for turbo inlet
and exact hole for my hose from oil separator (the hole was for egr sensor
on original setup).

only issue was to manage to make holder for the housing, coupe I have
plenty space so it was not so big issue...


Attached Thumbnails
1980 300SD - Simpler air filter? I can't keep my U-Tube attached-e300tdair.jpg  

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
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