W124 300E M103 Turbo Project
 

Finaly and with the help of Jayrash, its been a week or so working on it.

-W124 1991 300E at the factory was produced with a manual transimission but when i bought in 1999 it was already converted to automatic.
-Garret T4 Turbo
-Custom hand made exhaust manifold (based on the OEM one)
-W203 Intercooler (from a C230 Kompressor)
-Split second additional injector controller
-Cooligmist Varicool 250psi trunkmount water alcohol injection kit

Ill post some pictures as soon as possible
For now the manifold is done and the turbo is installed.
Working on the intercooler and some piping

And we cant wait to have the car running :) :)
This one should be real good.

While shopping around today i found a rare diff coming from a 190E 2.5 16V with the following part number R1243510608 and a 3.07 ratio. Any ideas if this one will fit on my car?
I also found the front bumper from AMG gen 2 style, OEM in silver color but without the foglights...its for around 300$...

That 2.5-17 diff is a direct fit to your car, and its an ASD (needs oil pressure) unit not LSD, if its clean ill buy it off ur hands, cause the diff i gave you is the same but shorter ratio.

you will need the gen 2 bumper for your IC. :)

but i know a guy he has molds for full gen 2 kit and will cost you 400 for front rear and sides!

I remember reading somewhere that even without the oil pressure (ASD) the 2.5-16v diff has mechanical locking to some extent (if I remember correctly ~ 18%) .....

Chlippo, that exhaust header will work but it'll not be optimal in my opinion, can't you find one from a TD model to modify like I did ?

All ASD units have abt 15% lock up due to the internal friction and design of the clutch packs.

I tried very very very hard to get one from a 300SD but that was impossible.
The TD that were imported to the USA had different manifolds...donno why, maybe for emissions.
That was the best i was able to get...i know its not optimal but i dont really have the choice.
I wish i can get one of those manifolds

Well, as I said this one will work and later on when you start driving the car if it turns out to be a bottle neck you can always rework it :) . What I would do if I had to build the manifold (the easiest way ), would be to separate the front three cylinders from the back three, say the first three primaries go into one secondary pipe and the same for the back three primaries then join the two secondaries at the turbo flange . This is just a suggestion (based on my opinion) which I hope may help in the future if you decide to rework it. Anyway it's good to see another m103 turboed (time we caught up with the beemer crowd :D ), keeping my fingers crossed .

As soon as i can get a manifold from a 300SD like yours i will happily do it.
Now i am working on figuring out how to pass the pipes of the intercooler and so.
I will reiforce the part downside the cis with a fiberglass clone.
I will try to post pictures of the car with the intercooler fixed soon

Here is a turbo diesel manifold for sale. Not sure it's the type you need, and it's for a 5 cylinder engine (but I'm not sure the 300d existed ever as a 6 cyl): http://cgi.ebay.com/ebaymotors/Mercedes-W123-GArrett-T3-turbo-assembly-w-manifold-300_W0QQitemZ190323355862QQcmdZViewItemQQptZMotors_Car_Truck_Parts_Accessories?hash=item2c5027f0d6&_ trksid=p4506.c0.m245

this manifold wont fit the M103. Im sure there is a 6 cylinder one like the manifold joreto uses in his setup. ill post a picture of the famous wanted manifold that isnt available in the usa

You want to look for the manifolds used in the 124 and 126 chassis turbo diesels.

The listed manifold is for a 123 chassis.

Possible that even a 350SD will mate up...

latest update, the intercooler is in its place. The piping is pretty much done. Still the additional injectors and then the first run.
I will post a few pictures of the setup

would the "hot" air that is flowing towards the trubo be the cause of loosing boost at high rpm's? The boost is dropping from 0.5bar to 0.2bar when the car passes 4500 rpm. We thought about the hot air since the turbo is getting most of the air from the engine fan since he is placed behind....

What is the wastgate actuator set at?
Factory setting could be 0.5 bar which would cause it to open and dump boost.