For my last auto project for 2006 I installed an air/water intercooler in my 240D. I Have lost about 1 or 2 PSI of boost, which will be regained by installing a boost controller once I have turned up the injection pump. My EGTs have dropped 100 or 150 degrees to 450 F during normal driving. I have not done an extended full power run yet.

Pictures:

1: Honda Goldwing radiator too cool the intercooler
2: Mercedes Aux water pump to circulate the coolant
3: Clocking the turbo

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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

More pictures:

4: Old intake manifold removed
5: Intercooler temporarily in place
6: All installed.

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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

That looks pretty sick, now I wish I had a turbo.
-Zach

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1978 240D Auomatic
Custom Charcoal Gray, Navy MB tex, kenwood/Elemental/Boston/Aura sound,
Shaved antenna and emblems.

1990 Lincoln Town Car, Sleeper/Strip car in progress, 17.75@77mph.

Where did you get that intercooloer and how much did you pay?

Good work. I'd have one as well by now if one eBay seller had not screwed me out of my money and disappeared.

I got it from this fellow here for $120 plus shipping.

http://cgi.ebay.com/ebaymotors/BRAND-NEW-LIQUID-INTERCOOLER-ASSEMBLY-AIR-WATER_W0QQcmdZViewItemQQcategoryZ33742QQhashZitem300063909150QQihZ020QQitemZ300063909150QQrdZ1

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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

I found some data on what happens when you add an intercooler with no fuel adjustment.


(From the Diesel Engine Reference Book, Second edition) Get a copy!!!

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green 85 300SD 200K miles "Das Schlepper Frog" With a OM603 TBO360 turbo ( To be intercooled someday )( Kalifornistani emissons )
white 79 300SD 200K'ish miles "Farfegnugen" (RIP - cracked crank)
desert storm primer 63 T-bird "The Undead" (long term hibernation)

http://ecomodder.com/forum/fe-graphs/sig692a.png

What is BMEP and SFC?

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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

BMEP = Brake Mean Effective Pressure
The average presure on the piston from the top to the bottom of the power stroke which gives you the brake power.

SFC = Specific Fuel Consumption
The amount of fuel used to generate a unit of power. In this case grams of fuel divided by kilowatt hour produced. A lower value means you generate the same amount of power with less fuel or you generate more power for the same amount of fuel.

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green 85 300SD 200K miles "Das Schlepper Frog" With a OM603 TBO360 turbo ( To be intercooled someday )( Kalifornistani emissons )
white 79 300SD 200K'ish miles "Farfegnugen" (RIP - cracked crank)
desert storm primer 63 T-bird "The Undead" (long term hibernation)

http://ecomodder.com/forum/fe-graphs/sig692a.png

Just to share in the goodness - here is my Air to Air unit!
Looks great!
Jake

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You have a V8 in that car correct?

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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

Supercharged Ford V6 if I'm remembering it right.

Yes it's a six....I was 15 when I did the swap...well when my dad taught me how to weld, fabricate, and make what ever you want...

Jake

More Pictures:

Exhaust temps pre-turbo with the intercooler are under 250 F at idle, 450-650 on the freeway, and around 400 around town. I have yet to see 1000F with the intercooler in.

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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

What is considered the "safe" limit for pre-turbine EGTs on these motors?

After looking here and there, I'm feeling like it's time for me to learn to weld aluminum. I've got the steel welding thing down pretty good. I like the Saab 9000 intercooler for it's huge area and it's slim profile. It should leave room for a slimline fan, A/C condenser and radiator and still let the hood close. I just don't care for the Plastic endcaps. I will be running a VNT-25 and don't feel like popping the intercooler. They have all aluminum ones for $700, but for that price I'm inspired to learn al welding and make my own endcaps.

Andrew