'Best penetrating oil product: Kroil (Or the spray product ) Aero Kroil

Penetrating-Lubricating Oils

800-311-3374

__________________
'84 300SD sold
124.128

I was going to say no need to remove the turbo but I see the T25 wastegate is part of the turbine housing. The T3 in the 603 has a separate wastegate housing.

If you can do it, remove the flap from the shaft. There's no pressing need to since the flap stays open by default. If you remove the actuator but not the flap, wire the flap open.

Sixto
MB-less

2nd on Kroil !

__________________
1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

Okay so I got it freed up with heat... and a grinder... and a hammer. Had to cut off the arm and pound it out and sand down the shafty. it was STUCK. Im also stuck on waiting for parts so heres some pics of whjat ive done.

Gunk that I scraped out of the intake manifold, wtf.



Don't know what this port is for, but it was DEFINETLTY clogged

Egr probably wasn't working very well...



Look at all that space!



Making the EGT adapter (For testing purposes)




Washer and bung



Welding looks sloppy but I needed the material so I could grind down a chamfer



This took a while, lots of blueing and grinding until I got it to fit in there snug.



Then my "sealent". The carbon buildup from the intake manifold. Slobbered it on, clamped in the sensor then blow torched it until it cauterized.




Sensor installed. You can also see the Test plate I put over the egr port, made out of 1/4" steel.

The stuck wastegate flappet.



At this point I realized I had to take off the turbo.




I got it freed up but it was obvious it had to be removed, I could have sat there all day moving it back and forth but it wasn't going to help.

[No the EGR IS the Problem! The Nasty Exhaust gases and debris mix with ANY
form of lubricant (Say the tiny bit that escapes the Valve Cover from the line
that feeds in UpStream of the Turbo's intake) and forms the Nasty paste like
goo that you found all over your intake system.]

The EGR goo will solidify and block Air (Pressure and Vacuum) passages and
sensors everywhere it touches.

__________________
'84 300SD sold
124.128

Yeah, I may be leaving those "test plates" on for a undetermined amount of time

Okay guys, got the turbo all put back together and installed, produces a healthy 14psi under heavy load but egts only get to about 500f, and is still a little doggy. Definitely heading in the right direction!

What's the next step? Fueling?

Do you see about 5psi by 2000rpm if you go heavy off the line? Do you see smoke under load?

There's a laundry list of things to consider including:

- fuel filters
- ALDA signal
- ALDA response
- IP timing
- cam timing/chain elongation

Sixto
MB-less

That port you pointed to needs to be spotless, and connected to the Alda under the intake. The line, and any valves it passes through on the way to the alda need to be clear. This will improve your shifting response also.

__________________
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!

I'll see 5psi pretty much off idle. 14 psi at full load. No smoke at all. Still a 30second 0-60.

I eliminated all those transducers, since they don't go to anything anymore. What are these two vacuum lines for? The one I'm holding has a filter on it..

Will do
If the alda isn't functioning could it cause a 30 second 0-60?

I just removed the alda, oh my god WHAT A DIFFERENCE! My 30 second 0-60 is about 14 now, very, very happy! It will really blow black smoke if you rev it at idle, but only smokes a little on take off. Full throttle nets about 14psi still and maybe 850f on the egts.

I think there is still room for improvement, even though the fuel filters look right out of the box im going to replace them per everyone's suggestion lol

Transmission shifts way better now, not sure why, must have inadvertently fixed a connection.

Off idle acceleration is IMPRESSIVE! Any gains to be seen are defiantly on the top end.

Acceleration is very linear, like a car should be. I've read that is the result of removing the alda.