Parts Catalog Accessories Catalog How To Articles Tech Forums
Call Pelican Parts at 888-280-7799
Shopping Cart Cart | Project List | Order Status | Help




Go Back   PeachParts Mercedes ShopForum > Technical Information and Support > Diesel Discussion > Diesel Performance Tuning

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 10-20-2006, 02:48 AM
bgkast's Avatar
Rollin' on 16s
 
Join Date: Dec 2005
Location: Vancouver WA
Posts: 6,528
Installing an Air/Water intercooler

Installing an Air/Water intercooler will be my next project. I finished installing a boost gauge and pyrometer today so I can get some baseline measurements before I put in the intercooler. I am using a generic ebay air/water unit that I got for $125, and a Honda Goldwing radiator to cool the water. After the intercooler is installed I plan to turn up the full load setting on the injection pump, and turn up the boost to get boost and EGT back to the levels I have before intercooling.

Pictures are the ebay intercooler and the radiator test fitting. Hood will close with a slight shave of the rear of the grill to clear the cap.
Attached Thumbnails
Installing an Air/Water intercooler-intercooler.jpg   Installing an Air/Water intercooler-icrad.jpg  
__________________
1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
Reply With Quote
  #2  
Old 10-20-2006, 03:35 AM
sailor15015's Avatar
Reverse lights! Score!
 
Join Date: Apr 2005
Location: Norman, Oklahoma
Posts: 1,184
Excellent! I've almost bought one of those intercoolers several times. I can't wait to see how you get it plumbed. I like the motor cycle radiator idea. I just got my a/c working so I don't think I'll be so willing to ditch the condensor.
__________________
Seth

1984 300D 225K
1985 300D Donor body
1985 300D Turbo 165K. Totaled. Donor Engine. It runs!!!
1980 300SD 311K My New Baby.
1979 BMW 633csi 62K+++? Dead odo
Reply With Quote
  #3  
Old 10-20-2006, 03:51 AM
bgkast's Avatar
Rollin' on 16s
 
Join Date: Dec 2005
Location: Vancouver WA
Posts: 6,528
Here is where the intercooler will be installed:
Attached Thumbnails
Installing an Air/Water intercooler-mercedes-intercooler-size.jpg  
__________________
1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
Reply With Quote
  #4  
Old 10-20-2006, 03:54 AM
sailor15015's Avatar
Reverse lights! Score!
 
Join Date: Apr 2005
Location: Norman, Oklahoma
Posts: 1,184
Are you going to modify the intake manifold any?
__________________
Seth

1984 300D 225K
1985 300D Donor body
1985 300D Turbo 165K. Totaled. Donor Engine. It runs!!!
1980 300SD 311K My New Baby.
1979 BMW 633csi 62K+++? Dead odo
Reply With Quote
  #5  
Old 10-20-2006, 04:27 AM
bgkast's Avatar
Rollin' on 16s
 
Join Date: Dec 2005
Location: Vancouver WA
Posts: 6,528
I got a spare manifold off of ebay that I will have a 2.5 inch fitting welded to.
__________________
1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
Reply With Quote
  #6  
Old 10-20-2006, 03:42 PM
sixto's Avatar
smoke gets in your eyes
 
Join Date: Jun 2000
Location: SF Bay Area
Posts: 19,752
I was thinking of fitting one of these in place of the crossover pipe in a 603 -

http://www.cynikal.net/~mike/celica_first_photos/source/5.html

Fit the radiator ahead of a front wheel similar to where a 300SDL has the oil cooler.

Sixto
93 300SD
Reply With Quote
  #7  
Old 10-20-2006, 03:44 PM
sixto's Avatar
smoke gets in your eyes
 
Join Date: Jun 2000
Location: SF Bay Area
Posts: 19,752
Better pic -

http://www.cynikal.net/~mike/celica_first_photos/source/8.html

Sixto
93 300SD
Reply With Quote
  #8  
Old 10-21-2006, 08:00 PM
sixto's Avatar
smoke gets in your eyes
 
Join Date: Jun 2000
Location: SF Bay Area
Posts: 19,752
Is it possible to use the refrigerant line between the evaporator and compressor to cool the IC or IC radiator? Seems like on a day hot enough to warrant AC you can use the wasted 'coolness' to help the IC.

Sixto
93 300SD
Reply With Quote
  #9  
Old 10-21-2006, 08:05 PM
ForcedInduction
Guest
 
Posts: n/a
You would loose much more power running the A/C compressor than could be gained from intercooling. The F-150 Lightning prototype tried that....
Reply With Quote
  #10  
Old 10-21-2006, 08:08 PM
sixto's Avatar
smoke gets in your eyes
 
Join Date: Jun 2000
Location: SF Bay Area
Posts: 19,752
Agreed, but when you have the AC on anyway? Isn't that 364 days a year in Houston and Atlanta? When it's cool enough to not use AC, it's cool enough to not augment the IC.

Sixto
93 300SD
Reply With Quote
  #11  
Old 10-21-2006, 09:02 PM
bgkast's Avatar
Rollin' on 16s
 
Join Date: Dec 2005
Location: Vancouver WA
Posts: 6,528
The problem with these cars is most intercooler spots are taken up by the AC condenser. It is easier to find a spot for a small radiator though than a air/air intercooler. My Air/water radiator resides where the AC would be though.

Progress so far: Not much. I have ordered all of the components. Now I play the waiting game. Did some painting on the radiator yesterday though:
Attached Thumbnails
Installing an Air/Water intercooler-dsc00934.jpg  
__________________
1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
Reply With Quote
  #12  
Old 11-02-2006, 12:27 AM
bgkast's Avatar
Rollin' on 16s
 
Join Date: Dec 2005
Location: Vancouver WA
Posts: 6,528
Update:

I have found all of the parts that I will need to complete the system, however I still need to have my spare intake manifold modified. I made up some brackets to mount the radiator today and mocked up the system. Take a look:
Attached Thumbnails
Installing an Air/Water intercooler-ic1.jpg   Installing an Air/Water intercooler-ic2.jpg  
__________________
1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
Reply With Quote
  #13  
Old 11-10-2006, 01:57 AM
bgkast's Avatar
Rollin' on 16s
 
Join Date: Dec 2005
Location: Vancouver WA
Posts: 6,528
I have decided on a different orientation of the intercooler to simplify the piping system. The compressor will now hook directly to the intercooler through a 90 degree elbow. The outlet will hook to the modified intake manifold through a 8 inch long 2.5 inch dia aluminum pipe with a 45 degree bend in the middle. unfortunately now I need to buy new silicone fittings. It's hard to get much work on the setup done when it gets dark at 4:30.
Attached Thumbnails
Installing an Air/Water intercooler-icnew.jpg  
__________________
1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine
Reply With Quote
  #14  
Old 11-10-2006, 02:04 AM
ForcedInduction
Guest
 
Posts: n/a
It's pretty different from the approach I'll be using. But, my plan will stay under wraps until I'm done...
Reply With Quote
  #15  
Old 11-10-2006, 03:33 AM
PanzerSD's Avatar
Schießenstern
 
Join Date: Jan 2006
Location: Saskatchewan Canada
Posts: 2,351
Has anyone ever tried to use a scirocco radiator itself as an intercooler? seal off the cap neck and (maybe use a NEW rad) and flow air thru it..
__________________
RIP: 80 300SD
RIP: 79 450SEL
2002 E430 4matic (212,000km)

____________________________
FACEBOOK:
PANZER450
Reply With Quote
Reply

Bookmarks

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On




All times are GMT -4. The time now is 10:55 PM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2017, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0
Copyright 2011 Pelican Parts - Posts may be archived for display on the Peach Parts or Pelican Parts Website -    DMCA Registered Agent Contact Page