I've been sharing my experiment with local diesel club (big trucks), they mentioned two of the key factors to consider is a cold air intake and bigger exhaust. The big exhuast I can fab with my bender. Between the two combination I am told this diesel in my 85 300SD will come to life.

My question is: has anyone done a "Cold Air Intake" MOD, if so care to share what it looks like. did you buy a kit or was it custom fab? Thanks in advance.

You already have a cold air intake, larger exhaust pipes won't help, it is what it is.

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83 SD

84 CD

A bigger exhaust will help- but just removing the muffler will help also. First you need to get more fuel by tweaking the IP. You already have a cold air intake- look at the stock air cleaner set up- it draws cold air from above the pass headlight . This is a "Diesel Performance forum" thread- check there for more info on "modding" your 617.

Check this thread to see what's been done on my 617.

Okay, I might be headed a "rabbit hole", but how does one tweak the IP. I've been trying to identify where to loosen it so I can adjust the timing. I think I found the bolts but I need to verify with experts from here.

I've been adjusting the ALDA to limit fuel due to the HOD system onboard. I would like to get educated on tweaking it, if anything get smarter about it. Thank you.

Go to the Diesel performance section and search for IP modifications and read up.

Once you start down this path reliability and longevity start to become questionable. Vehicles are hard and expensive enough to maintain let alone modify. Start messing with the IP and watch your fuel efficiency go down the toilet.

just sayin

steve a

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Steve A
92 W140 OM603
97 VW Jetta TDI
90 Passat variant TDI 6 speed MT
94 Chevy K1500 6.5TD
05 E320 CDI
+ others

more power can be more fuel efficient, you just have to gear the vehicle for the additional power.
it's why turbo'd vehicles are usually more efficent than N/A vehicles, not due to the turbo as much as due to the gear ratio's tuning the power to MPH bands.
if you bump your car up to 200hp, be sure to put a 2.25 or so rear diff in there.

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

As long as you're not trying one of those "hydrogen generator" kits, if so we're finished here.

Anyway, the truck guys aren't really that knowledgable on your engine. The intake is cold-air as mentioned, and the exhaust is not that restrictive. You could go to a 4" exhaust, throw on a larger CFM filter system, and I doubt you'll pick up 5hp. The turbo and IP aren't going to put any more air and fuel in the system, so you haven't changed anything significant.

Now if you want to add power, it can be done, at a cost. And if you add a larger turbo and larger elements to the IP, then an aftercooler, you'll need a larger intake and exhaust.
http://www.youtube.com/watch?v=TVXLXuUYjvs&feature=related
http://kuvablogi.com/blog/6520/16/

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Gone to the dark side

- Jeff

There is 3 bolts in the Front and 1 Bolt/Nut that attaches to a Bracket at the bottom Rear of the IP that attaches to the Block with 2 short Bolts.

The front of the IP has a Paper Gasket. Sometimes shifting the IP around is not good for that. Mine seeps Oil a little.
If you believe the Manual you need to remove the Oil Filter Housing to Pull the IP to change the Gasket there. Why, I have not changed mine.

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84 300D, 82 Volvo 244Gl Diesel