boost controller install... - PeachParts Mercedes-Benz Forum

vwbuge · #1 11-04-2003, 12:01 PM

Someone e-mailed me with questions about this. I learned about this myself from others here. I will attempt to make a few posts with pictures to explain what I have done. So far it works good but I haven't "cranked" up the boost yet. I have to install the two o-rings on the turbo as mine are bad. Any other questions/comments are welcomed. Always room for improvement.

First pic of the guage itself inside the cabin. It is a lighted one from JC Whitney and it works well.

vwbuge · #2 11-04-2003, 12:05 PM

This is where I plumbed in for the guage. The arrow points to the banjo bolt at the rear of the manifold. It is hard to see as it is on the other side of the tranny dipstick. ANyway, I just used a t-fitting off this banjo bolt so I can keep all the original lines to the various switches. The line simply runs through the firewall and along to the driver's side where I went through an existing hole into the cabin. I know it looks like Frankenstein but it works.

vwbuge · #3 11-04-2003, 12:07 PM

The last and I thought simplest is the install of the controller itself. THis simply splices into your wastegate hose. The brass piece is the controller. The two arrows point to t-fittings I had to block off.

vwbuge · #4 11-04-2003, 12:13 PM

Like I said I am open for suggestions/comments. I haven't fully adjusted this thing yet. I have just brought the boost back to a "usable" range as my car is form CA and was factory tuned with a very low boost setting. I am now running around 8-9 psi.
ALSO.......The boost guage is a must for this controller. You will be pissing in the dark if you don't have one on.
SECONDLY....You will have to adjust your ALDA to get power. You may make these adjustments and up the boost but will feel no power with out the proper fuel. If you need to adjust or want to know how post it here I will take more pics.

DslBnz · #5 11-04-2003, 02:24 PM

Thanks a lot for the pictures. I just ordered a boost pressure gauge myself today, and I will pick it up tomorrow.

But wait a second. I have the 603 motor. Would the installation complications be a little different?

kerry · #6 11-04-2003, 03:14 PM

I believe I saw a picture where someone mounted the gauge directly into the left center vent hole in the dash.

gsxr · #7 11-04-2003, 03:47 PM

A few comments. First, factory boost spec for the OM617.95x engine is 0.75-0.85 bar (IIRC), which is roughly 11-12psi. So you can safely turn up the boost to that range with NO worries. Second, the ALDA can only do so much. It mostly affects off-the-line (off-idle) power. Definitely try turning it up, BUT, if you don't see a power gain - turn it back down. A proper ALDA setting is turned down (lean) as much as possible without a noticeable power loss, then back up (rich) maybe 1/8 turn. The reason the ALDA can only do so much is because it is still limited internally by the full-load stop screw, inside the injection pump, behind the rear (governor) cover plate. So, to get more power with your new boost, you may need to open up the rear of the pump and richen the full-load screw a bit. Normally you never touch this but as pumps wear and become leaner, it can help out. Also if you add an intercooler, you'll get almost NONE of the benefit without turning up the full-load stop quite a bit (nobody has seemed to figure this out yet who actually installed an intercooler, which is sad.) Here is a small PDF file that shows the full load stop on an OM603 injection pump, which is different than the OM617, but the principle (and general location) is about the same:

http://www.meimann.com/docs/mercedes/Bosch_full_load.pdf

Anyway, on most OM617 cars, turning the boost up and fiddling with the ALDA gets power back to normal (13-14 seconds 0-60 for a 123.133, 1982-1985 300D sedan/coupe). Now if you want it FASTER than that, then you may need to fiddle with the full load stop, and/or intercool the engine - but turning up boost without intercooling is a great way to melt pistons. FYI, my 1984 runs right at 10.5psi boost. One day I pinched off the wastegate hose and did some 0-60 tests. Boost rose to about 15psi max (wow!), but there was ZERO power gain! None, nada, zip, zilch. 0-60 times were identical and there was no seat of the pants increase either. Adjusting the ALDA didn't do anything (I had already tuned it properly, but it had reached the internal limit.)

YMMV, etc... happy tweaking!

DslBnz · #8 11-04-2003, 04:14 PM

Thanks for the great info, Dave!

My SDL is running 0-60 in about high sevens early eights now(and I can prove it). That is better than I would have ever dreamed to achieve (with 3/4 tank of diesel and all my junk too).

Now when I get that custom-made Mosselmann intercooler...,

That's when I'll tweak the internals of my IP.

Unfortunately right now I do not have the $$$$.

As far as tweaking it now? Uh, uh. No way. I am happy with the way it is now. Don't want to risk anything. I plan on driving this car another 200 - 300K miles. Then rebuild the engine and drive it another 600K miles.

Between the two diesels, that will be a long time away!

gsxr · #9 11-04-2003, 04:41 PM

Eh - I hope that's 7's and 8's for 0-60kmh! Spec for the SDL is around 13 seconds for 0-60mph. You have propane injection or something?

On a side note, are you seriously interested in a Mosselman kit? I am, and I need to call Willy in Holland and see if he wants me to send over the USA intake plumbing (EGR mixer housing and the 2 connection pipes), to see if he can make a suitable "USA specific" adapter pipe. His kit only fits Euro engines, as USA engines have a TOTALLY different exhaust manifold & turbo location! (Drat!)

kerry · #10 11-04-2003, 04:44 PM

gsxr:
Are you saying the turbo and manifold are different on Euro 617's? If so, can you describe the differences. I have given thought to putting a turbo engine in my 409d but the space is very tight in the doghouse. Perhaps the Euro version is closer to the block?

DslBnz · #11 11-04-2003, 04:52 PM

Quote:

Originally posted by gsxr
Eh - I hope that's 7's and 8's for 0-60kmh! Spec for the SDL is around 13 seconds for 0-60mph. You have propane injection or something?

On a side note, are you seriously interested in a Mosselman kit? I am, and I need to call Willy in Holland and see if he wants me to send over the USA intake plumbing (EGR mixer housing and the 2 connection pipes), to see if he can make a suitable "USA specific" adapter pipe. His kit only fits Euro engines, as USA engines have a TOTALLY different exhaust manifold & turbo location! (Drat!)

Heh, he... miles per hour, really! I know what specs are, but tell that to my SDL. It doesn't want to listen.

Didn't you ever see my video? First off I hope you have broadband. 1/2 a tank in this one instead of 3/4. D'oh!

Click here

That Mosselman kit sounds awesome, but I right now I am not financially ready for it (I have too many Benzes!). At least it is a possible option. Good project for the future, I say.

#12 11-04-2003, 04:55 PM

Quote:

Originally posted by kerry edwards
I believe I saw a picture where someone mounted the gauge directly into the left center vent hole in the dash.

Thay might have been me

I did not use the ALDA line for the gauge, I used a adaptor that came with the SunPro gauge in the fitting to the lower right of the black arrow at the first picture.

After switching to Mobil1 15W-50 synthetic oil today, I noticed an odd event. My boost gauge usually shows 12psi at full load/throttle but after the oil change it went up to 14psi! Nothing but oil was done to the engine to get this.

gsxr · #13 11-04-2003, 08:47 PM

Kerry - No, sorry, I meant the OM603.96x exhaust is much different between Euro and USA. I believe the 617's are mostly the same, other than the funky 1985 CA version. Here's photos of the 603 setup, Euro and USA:

http://www.meimann.com/images/mercedes/OM603_intake/

82-300td - Yep, it's amazing what a little Mobil synthetic can do for ya, ain't it?

I've never heard of that particular side effect before but it doesn't surprise me. It can take 5-10kmi of using synthetics to get the full benefits, so don't be surprised if your engine runs a bit better still a few thousand miles from now!

DslBnz · #14 11-04-2003, 09:12 PM

Quote:

Originally posted by TheVirginiaDude
You WILL need to add a EGT (exhaust Gas Temprature) guage as it will be darned important, with the IP turned up and under load the temps can soar to unsafe levels, you need a way of seeing just whats happening there,

Sounds like sage advice,