Finally got the G-wagon together enough to test drive today! First test drive honestly was a bit disappointing. It ran good but the power seemed lacking. Also lacking was any sign of smoke so after getting it washed I started tinkering with the aneroid. I settled on two turns out. The turbodiesel injection pump we got came with the factory seal on the aneroid adjustment so it sets two turns out from that. It may have more in it but there was a consensus that any more was risking breaking parts in the driveline. I'd guess it picked up 75 ft/lb with the adjustment. Still, the only black smoke is from loading it at a low RPM in the higher gears. I put a gauge on it while tuning and its running 13-15 PSI boost.
I've got the 210 factory intercooler stuffed tight under the bumper. A little trimming was required to fit it. I cut and welded the factory aluminum boost tubing to plumb it in using both factory hoses in different positions.
A Dodge diesel wastegate pod was custom mounted to the original bracket. It is supposed to be rated 22PSI but its not hitting that number, but has gobs of power regardless. So much so, I'm not planning to mess with the wastegate adjustment, which is quite buried and hard to reach.
I used sections of the original 210 exhaust piping to connect to the original exhaust system about 5 ft downstream. I incorporated the spring joint near the turbo and deleted the catalyst. A few heat shields were fabbed to keep exhaust heat off the heater hoses and the air horn setup. The original exhaust is a bit smaller than the 210 piping but again, with the power this thing is making, its not an issue at all.
Keep in mind this isn't an all out, max power, kind of build but it probably now has somewhere around twice as much power as it came with. This isn't a testament to how great the 606 is, rather how much of a turd the 603 non-turbo was.
At this point its just a matter of wrapping up small details. I'm going to be sad when the owner picks it up.
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90 300TE 4-M
Turbo 103, T3/T04E 50 trim
T04B cover .60 AR
Stage 3 turbine .63 AR
A2W I/C, 40 LB/HR
MS2E, 60-2 Direct Coil Control
3" Exh, AEM W/B O2
Underdrive Alt. and P/S Pulleys,
Vented Rear Discs, .034 Booster.
3.07 diffs 1st Gear Start
90 300CE 104.980
Milled & ported head, 10.3:1 compression
197° intake cam w/20° advancer
Tuned CIS ECU
4° ignition advance
PCS TCM2000, built 722.6
600W networked suction fan
Sportline sway bars
V8 rear subframe, Quaife ATB 3.06 diff