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Old 10-09-2003, 07:40 AM
adamb's Avatar
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Join Date: Jul 2001
Location: Chapel Hill, NC
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Intake, Exhaust Manifold changeout Cali to Federal

I have an 85 300d Cali model and about to change out the intake and exhaust manifold, turbo and entire exhaust system.
I got a 1983 model year intake and exhaust manifold, turbo and brand new header pipe and exhaust system that I'll install this weekend. Does anyone have any interest in any of these parts I'm pulling off my car, to include the exhaust, which is in useable shape? I live in Meridian, MS.
Take care,
Adam Bush

Last edited by adamb; 10-12-2003 at 11:03 PM.
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Old 10-12-2003, 07:30 PM
lietuviai's Avatar
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Join Date: Mar 2003
Location: SW WA
Posts: 5,741
I'm thinking about doing the same conversion on my '85 300D CA model also. Did it work out OK and how much expense did it run you? It's a PIA to get the air filter and it's expensive wherever you go.

84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012
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Old 10-12-2003, 09:23 PM
adamb's Avatar
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Join Date: Jul 2001
Location: Chapel Hill, NC
Posts: 321
What a great night it is!! I just finished up converting my cali model to the older style intake and exhaust manifilds and it works great! The car is faster, with the 0-60 time down to 13.0 from 14.7.
regarding your question about the air filter, cost, etc, I bought the intake and exhaust manifild for 100 bucks from a local foreign car repair shop. I discovered that the turbo is the identical one, except for the valve on the front of the turbo on the air intake side, but this could even be used despite this difference during the conversion. I did put a new turbo cartridge in since I had it all apart anyway and to me it was worth the expence even though the other turbo cartridge spins freely and leaks an average amount of oil for it's age.
I was able to use the same oil feed line - I just influenced it down a little lower and it now works perfectly. The oil drain tube, the upper part, is different, so be sure to get one of those.
Believe it or not, i was able to use my california model air cleaner. All I did was take a hax-saw to the elbow on the bottom of the air cleaner and cut off the 90 degree elbow and was able to use the existing rubber air tube to connect it to the intake of the turbo. The oil breather goes only to the air filter top now, not to the hose after the filter - I just duct taped it closed for a temporary fix. the air filter works nicely and leaves the passenger side of the motor exposed for easy maintenance of things. I bought an entire new exhaust system from the turbo back, as the header pipe is shorter on the converted manifoilds and the exhaust was showing signs of wear. I also put in a new starter solenoid since it was very accessable with the manifolds off.
The one thing I did that will scare people is take my pressure washer to the head and valves with the manifolds off. I couldn't eblieve the junk that came out of the intake valve ports when I pressure washed it - I was in shock. I did make sure to rotate the motor to ensure the valves were closed when I cleaned that particular chamber. After, I blew everything out with the air hose and started her with a bucket under the turbo oil supply line to catch the oil and let her run for 30 seconds with the manifolds off. she ran fine, so then I put the manifolds on and took her for a ride and had a smile on my face the whole time! I hope the fuel economy improves as well, as the older cars have better mileage without ther trap crap.
Have fun,
Adam Bush
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