Only one person requested it but I thought I would share anyway.

This is the first part of the exhaust as it leaves the turbo. Note the one on the bottom is from the CA car as the "neck" is a bit longer.

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__________________
'85 300SD (formerly california emissions)
'08 Chevy Tahoe
'93 Ducati 900 SS
'79 Kawasaki KZ 650
'86 Kawasaki KX 250
'88 Kawasaki KDX200
'71 Hodaka Ace 100
'72 Triumph T100R

These are the two manifolds. The one on the bottom is from the CA car. Note how the port on the intake is higher than on the federal. Also note the exhaust manifold ports. The top is the federal and is vented directly to the turbo. The CA manifold on the bottom vents to the rear directly to the catalyst as you will see on the next pic.

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__________________
'85 300SD (formerly california emissions)
'08 Chevy Tahoe
'93 Ducati 900 SS
'79 Kawasaki KZ 650
'86 Kawasaki KX 250
'88 Kawasaki KDX200
'71 Hodaka Ace 100
'72 Triumph T100R

This is my old CA manifold. I am holding the catalyst in about the same position as it bolts to the manifold. I have a 2x4 bolted to it because in the initial stages I was thinking of making a jig to have a friend weld a pipe to substitute for the catalyst.

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__________________
'85 300SD (formerly california emissions)
'08 Chevy Tahoe
'93 Ducati 900 SS
'79 Kawasaki KZ 650
'86 Kawasaki KX 250
'88 Kawasaki KDX200
'71 Hodaka Ace 100
'72 Triumph T100R

Are you going to keep the stock turbo or use the one that was used on the new manifolds?

Next is the two turbos. Notice the position of the inlet on the CA turbo on the bottom.

Attached Thumbnails

 

__________________
'85 300SD (formerly california emissions)
'08 Chevy Tahoe
'93 Ducati 900 SS
'79 Kawasaki KZ 650
'86 Kawasaki KX 250
'88 Kawasaki KDX200
'71 Hodaka Ace 100
'72 Triumph T100R

These are the turbo to intake manifold housings spearated from the main turbo unit. The one on the right is from the CA car. I was wandering what the thing was on the CA housing? It has a vacuum line attached to it. I guess I will just reposition the CA housing to line up with the federal manifold.

More to come later when I get all my gaskets. The only thing left to show is the new routes for the turbo oil lines.

Attached Thumbnails

 

__________________
'85 300SD (formerly california emissions)
'08 Chevy Tahoe
'93 Ducati 900 SS
'79 Kawasaki KZ 650
'86 Kawasaki KX 250
'88 Kawasaki KDX200
'71 Hodaka Ace 100
'72 Triumph T100R

I guess I should have shown what it looked like before I started.

Notice how the neck of the exhaust comes up higher to meet the rear of the turbo. The large can like thing below the setup is the catalyst. In this setup the air filter is much larger and is behind the passenger headlight because the turbo sits higher. After the swap it will look like everyone else's.

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__________________
'85 300SD (formerly california emissions)
'08 Chevy Tahoe
'93 Ducati 900 SS
'79 Kawasaki KZ 650
'86 Kawasaki KX 250
'88 Kawasaki KDX200
'71 Hodaka Ace 100
'72 Triumph T100R

Vwbuge, I am very interested in how all of this works out for you and what CA components you were able to re-use for your swap. I am most interested if you will be able to re-use your CA turbo. I have been told that you can. My turbo only has about 50K miles on it because it was replaced when the catalyst was replaced during the recall. I am still thinking about doing this swap on my car as well as I plan on holding on to my car unless I come across a nicer low mileage car that I would be able to afford. The photos you took are great. Keep up the great work and I hope you have good success with the swap.

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

Apparently my turbo wasn't hurt by the trap ox before the replacement. I called in the VIN and they didn't tell me it was replaced. I am going to use the CA turbo. I took the few bolts to loosen the housings in the photos. Those housings can be rotated in any position.

Still trying to find out what that thing is on the housing.

__________________
'85 300SD (formerly california emissions)
'08 Chevy Tahoe
'93 Ducati 900 SS
'79 Kawasaki KZ 650
'86 Kawasaki KX 250
'88 Kawasaki KDX200
'71 Hodaka Ace 100
'72 Triumph T100R

I have the same device on my turbo's housing and I also have no idea what it does. My CD FSM doesn't show it nor any of the CA junk.

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

The" thing" on the side is called the . Plug the vacuum line attachment for "off road use".

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The Golden Rule

1984 300SD (bought new, sold it in 1988, bought it back 13 yrs. later)

I was planning on plugging the EGR. But I noticed a vac line from the EGR diaphram and one from that thing go to the electro-vac sensor and then to something else. So I can ****-can the two vac lines associated with the CA turbo? If so maybe I'll just use the housing from the federal turbo.

__________________
'85 300SD (formerly california emissions)
'08 Chevy Tahoe
'93 Ducati 900 SS
'79 Kawasaki KZ 650
'86 Kawasaki KX 250
'88 Kawasaki KDX200
'71 Hodaka Ace 100
'72 Triumph T100R

The air recirculating valve vacuum line is usually plugged at the electro-vac end due to the different size vacuum line fittings at the respective ends. The end at the electro-vac sensor happens to fit a BB perfectly ; the vacuum line end at the air recirculating valve is larger and the BB doesn't close it (00 buckshot may be correct size at that end).

The 1984 300SD (CA version for sure and, and maybe the Federal) has this valve and plugging is commonly done for off-roading as well as the EGR getting a BB and a plate.

The use of the 1985 Fed. housing sounds like the way to go.

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The Golden Rule

1984 300SD (bought new, sold it in 1988, bought it back 13 yrs. later)

Where the pipe from EGR goes into manifold. Tap it and plug it with {pipe tap} and some JB weld. Then where the valve is, get two gaskets and make a steel plate with two hole bolt it down. And you are good to go. This way no EGR or BB. Just blocked of EGR. Of cource this is for Off Road use only. Because removing a smog device is illegal.
I think I have broke every law but gravity any tips?
Looks good.
Charlie

Wouldn't converting a CA version to a Fed version to be used anywhere but in CA be OK in any case? I would think there'd be no harm in that. "S"-canning all the emissions junk is probably the way to go for "off-road" use.

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012