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Old 06-04-2009, 07:16 PM
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Underhood Intercooler on a 617

I found a blackstone intercooler found on a Saab 900 and set it in place of the stock air filter housing. The stock turbo was clocked so that it exited right into the IC. I took MB air intake hoses from a 560SEL and routed it to the IC to cool it. I had planned on using a inline fan to increase the air flow- but my egt's show it's not needed. I used a Diawoo air filter top which fit neatly over the IC. The exhaust is below the IC so I put a heat shield there and had the turbo wrapped in a blanket. The exhaust manifold is from the pre egr 617 versions which is a bit stronger and flows a bit better, and had it coated similar to jet hot. This stops the gas from expanding and slowing down, plus the EGT temps drop like a rock when you take your foot off the fuel. I'll get 10 psi boost by 2100 rpm, it tops out at 17 psi. The air filter is from a 3.8 GM, and while the cfm is 320- too restrictive- it fits perfectly in place and pulls cold air from the original location. I use a K&N as it flows much better and the valve cover's vapor will quickly coat a paper element. I used a 616 breather as you can see. The IP's been adjusted- fuel limiter, torque control and idle control. Boost gauges and EGT gauges are mounted where the ash tray was. I've installed AAZ two stage injectors with 265 nozzles set at 145 bar. Other mods include a 115 amp alternator, Bosch H4 headlights, vogtland front springs with Bilstein HD shocks, w126 GenII brakes and wheels, an AMG rear wing, a w115 shifter surround and the muffler delete option. H20diesel did the major work, I got the parts, we both did the design.

Last edited by MTUpower; 06-04-2009 at 09:35 PM.
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Old 06-04-2009, 07:50 PM
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Join Date: Jun 2007
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I'm always impressed by how well all that stuff looks squeezed into the engine compartment.

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Old 06-08-2009, 11:45 PM
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Join Date: May 2009
Location: Southern California
Posts: 106
Excellent job! You inspired me to do the same...I went to the local wrecking yard today and I found a Saab 900, someone was nice enough to remove the intercooler and leave it sitting on the engine for me I looked around the ricers and found the exact same Daiwoo air cleaner as you have. So far so good. I will be searching for the exhaust mainfold this coming weekend. Do you have a detail of the intake mod? Will a non turbo intake like Forced uses work? I can weld aluminum, but less work equals more fun time!
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Old 06-09-2009, 09:04 PM
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Join Date: Jul 2007
Location: chicago area, illinois
Posts: 281
what model daewoo did it come off of? i have the saab 900 intercooler also, and how did u mount it to the intake?

1985 mercedes benz 300D turbo diesel
1998 VW GTI VR6
1996 VW GTI 2.0
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