I managed to mount my OM603 turbo on my 85 Kalifornistani 300SD. Its not a drop in replacement however. The exhaust scroll is the problem. First you need to twist out the studs and drill out their holes to fit over your exhaust manifold studs. The exhaust scroll places the turbo center section at a different point in space so the oil lines and intake manifold don't line up quite right. The exhaust also doesn't want to line up (we made it though ).

I have about a half inch gap in between my manifold spacer and my compressor housing. For the short term, I have sealed the gap by slicing open a bicycle innertube and wrapping a piece of it around the gap and then wrapping that with duct tape. Its mainly there to keep dirty air from getting sucked in until I have a better solution.

I also don't have a solution for my waste gate actuator yet. I may try a rubber band just to see if boost will build at all.

Sorry no pictures yet, and as for a performance description, a normally aspirated 300SD sucks. Off the line is about the same, but it seems like the car trips and falls on its face soon after. My innertube quick fix works because I draw vacuum of an inch or so of mercury from the air filter.

Note: tested rubber band wastegate controler. It keeps a vacuum from forming but generates no boost because I have a boost leak.

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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

Update: Well I put 3 rubber bands in place of a boost controller and got my first taste of boost with the new turbo. It was only about 1/2 psi but it was much better than pulling a vacuum. I did get it to bump up to 3psi during a shift. I still have too many boost leaks to get a good idea on how well this is going to work.

I still can't find my camera so no pictures yet.

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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

Found my camera.

The first picture is of everything. The second picture is of my latest ugly improvement to the manifold spacer using a plastic conduit size adapter RTV'ed to the outlet of my compressor housing. The third picture shows how far away from the intake manifold things moved and how far back it moved the exhaust down pipe.

I can get 5psi of boost now before the springs can't hold the waste gate closed any longer. Unfortunately the oil return gets in the way of the wastegate actuator linkage.

Attached Thumbnails

     

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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

Looking good!

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RRGrassi


70's Southern Pacific #5608 Fairmont A-4 MOW car

13 VW JSW 2.0 TDI 193K, Tuned with DPF and EGR Delete.

91 W124 300D Turbo replaced, Pressure W/G actuator installed. 210K

90 Dodge D250 5.9 Cummins/5 speed. 400K

nice project..now you just need that intercooler and a pump turn.

Actually I have an intercooler, its just waiting to be installed in my de-Kalifornization project. I just need more time.

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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