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#1
12-27-2005, 02:12 AM
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Diesel Hot Roding, Inter Coolers?
Hello
Can anyone tell me if an “inter cooler” or “after cooler” kit is available for the 124, 300D Turbo Diesel? Alternatively any other information about someone who has made one, adapted one from another vehicle, rigged one up etc. and any engine modifications (tuning) necessary to make it all work. Thanks. PD 
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#2
12-27-2005, 03:55 PM
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There is a kit available from Mosselmann, but it's expensive and only gets about 175hp.
You should read this: http://www.***************/forum/showthread.php?t=159 And this: http://www.mersuforum.net/forum/viewforum.php?f=29 You will need an intercooler to exceed stock power. Mauri H turned up his 300D's fuel, it worked fine until summer, then he cracked his head. The Finns say that the stock injection pump can be adjusted for about 30hp per cylinder, beyond that you need major pump modifications. Simply installing an intercooler doesn't help unless you also add fuel. There are 1987 300Ds running around Finland with about 400hp, and 2.5s over 300hp. This requires modified IP, large intercooler, custom manifolds and larger turbo. Porting the head helps too, and you will need to have the tranny modified if you go for a major power increase.
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'79 300SD W116 '86 190E 2.3-16V W201 '92 300D 2.5 W124 '99 E320 4MATIC S210 Last edited by Mitch H; 12-27-2005 at 04:02 PM.
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#3
03-07-2006, 05:44 PM
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Ditto what Mitch said. There is no off-the-shelf, bolt-on kit, for any USA Mercedes diesel. The Mosselman kit is for Euro engines, which have different plumbing. You need to custom fabricate your own intercooler like Casey did (I hope to duplicate his setup someday!)
That said, you can probably get away with maxing out the stock injection pump for a 20-25% power gain, as long as you have an EGT gauge and don't use full throttle for more than 30-60 seconds (varies with ambient temp, etc). I've been experimenting with water/alcohol injection but don't have definitive results yet. It does reduce intake air temps but thus far, it's not nearly as effective as a full intercooler setup. BTW - I have an almost-new pyrometer (EGT gauge) kit for sale. See photos, etc at this link: FS: AutoMeter pyrometer (EGT gauge) 
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