I picked up this turbo kit from a junk yard in an old storage van its been sitting 20years it was off of a 1974 240d the only parts left where the Rajay turbo with throttle body bolted on and the exhaust elbow adapter to the stock manifold but i found a 1975 exhaust manifold and a 1971 220d intake manifold here are some pics I'm putting it on a 1980 240d with a 4spd stick for my dad here are some pics of the parts I have so far! so far i have about $170 invested with paint and welding

the two throttle bodies are not pictured because i had to strip out the guts and grind off the excess mettle and they are at the shop next door getting the holes welded up I have also clocked the intake on the turbo inlet downward instead of up wards to go to an air filter note i have to drill and tap two holes in the turbo! I got an oil filter housing off a 617 turbo for my oil supply to the turbo

Looking good. I like that neat setup!

(06-22-2009 05:57 PM)willbhere4u Wrote:  I got an oil filter housing off a 617 turbo for my oil supply to the turbo

all you need to get that working is to swap the back plate off the donor to the filter housing on your car... I accidentally grabbed a N/A engine's oil filter housing (i think thats the same as the 240s) when I was powdercoating a bunch of stuff and didnt realize the oil lines came off of it... anyway, I just swapped the back plate over and installed it... you might wanna swap it over anyway since the filter housing does tend to leak after 20+ years...

The filter housing is used I just put it through the parts washer! there was a fitting in the exhaust elbow I was planing on removing it to install an EGT gauge probe until I realized it was the same fitting here is the probe installed how easy was that!!! here is a pic!

There is no waste gate on this set up it had a small bleed valve on the intake originally I"m going to put on a air compressor pressure regulator in the glove box so I can adjust the bleed in the car while I"m driving! I don't know how well this will work but I'll let you guys know I'm going for 5-6 psi


I'll take more pics as I get it installed and setup and ill make some vids of it running!

my dad likes his 240 4spd and I couldn't talk him into a 617 turbo because It runs to darn good but this will be just as cool
I"m doing a 617turbo and 4spd in my 240d auto. I will compare them when I have finished

Happy fathers day

That's way cool Will! I always wondered if there were Rajay kits out there for MB diesels, I know people used to do that stuff with VW's. Keep us in the know about what it ends up like. You are putting in an EGT gauge, right?

Yea the probe fitting was already there in the exhaust elbow! that pic I just posted is with the probe installed!!! I haven't been able to find anything out about the kit but that it came off a 1974 240d

So now all you need is an IP from a Cummins 4BT, 617 turbo pistons/rods, 617 turbo oil pump, some tweaking of the block to install piston oil squirters, and a VGT and you have a superturbo 616! Might also need a custom camshaft and a bigger crank.

EDIT: Probably a good idea to lower the compression a bit too with a spacer or something..

If it was my car I would! I don't think my dad will go for it i had a hard enough time convincing him to put this kit on

I'm plan on putting a Holset XY on my 617 turbo 240 4spd project with 20 25 psi boost with an inter cooler! I would also like to put bigger elements in the pump as well! I need the AIR first to keep it cool!!!! and need to find some one to grind my cam a bit! and do a little port work i would like 180-200hp and 400-500TQ we will see how the 4spd holds up 2 some abuse it only has 32k miles

back on the kit! I wet to a shop that deals with tubes and hoses and got a fitting for the back of the oil filter housing to adapt it to an-6 to match the turbo oil feed fitting! once I get it mounted and measured they will make me a custom line. I also got a an-10 fitting for the oil return! To fit in the upper oil pan where the stock drain is in the 617 turbo engine I just have to drill and bolt it in! I have to replace the lower oil pan any ways as it is dented but I have a new one and a gasket I will take some pics tomorrow if I get a chance its pretty slick

That is outstanding!

(06-25-2009 11:16 AM)GREASY_BEAST Wrote:  So now all you need is an IP from a Cummins 4BT, 617 turbo pistons/rods, 617 turbo oil pump, some tweaking of the block to install piston oil squirters, and a VGT and you have a superturbo 616! Might also need a custom camshaft and a bigger crank...

That's a pretty cool recipe. A 4bt VE pump on a 616 can be very flexible.

My dad wants to make a knock off of the Callaway 240d turbo with recaro buckets and a momo searing wheel and he wants to get the Callaway decal made for the back shure the turbo kit is different but it would be cool anyways

here are some pics of the oil feed fitting an-6 bolted to the oil filter housing. The return fitting I plan on mounting to the upper oil pan an-10. and the fitting in the intake is going to go to a pressure bleed to set boost pressure

here is a pic of one throttle body done! the intake to the filter on the turbo

well I was doing some research online and found out that road and track tested a turbo kit on a Mercedes 220d September 1973 so I am purchasing that issue off ebay and will ley you know what it say's

That is such a cool kit, can't wait to see it up and running.

here is the article from the September 1973 Road & track! and I believe this to be the same kit I have as the kit was off a 1974 240d it was made in limited production back in the day!

Look at that torque, its almost doing a wheelie!

Wonder if my w123 will do that? On my set up I may add an inter cooler as this car is mine now!!!

Man that is too cool to find the kit and the article, I think there is enough info with all the Merc. diesel guys to do a book on Mercedes Turbo Diesel performance. By the end of the year I will have alot of data from my pyle and F.I. is always working on mad diesel development as well as all of you, maybe we can get some input from the Finn's?

well I got some time today and got some work done installing the turbo kit I got the intake exhaust and turbo installed today! The turbo clears the intake in spots by thousandths of an inch!!! looks like it will all fit like expected! I'm hoping to get it up and working for diesels drag races AUG 2nd at Bandimere in CO

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hay F.I. do you know what has to be done to the car to get it through tech??? for the drag race? I think it needs an overflow boodle for the rad? thanks Will

(07-16-2009 05:11 PM)willbhere4u Wrote:  looks like it will all fit like expected! I'm hoping to get it up and working for diesels drag races AUG 2nd at Bandimere in CO

Thats great! The more that show up the better. I'll have to get hold of Tom Judd and let him know whats going on.

Any info on how you can turn up the fuel? I don't know much about how the pneumatically governed pumps work. If you can find/write a guide I'll put it in with the main adjustment article. EDIT: Never mind, I forgot you've got a W123 240D and not a W115.

Maybe you can get some adjustment direction out of the STT article.

Tom

STT article whats that?

Thats for the M pump. Follow the MW pump guide at the top of the engine subforum.

(07-17-2009 08:02 PM)ForcedInduction Wrote:  Thats for the M pump. Follow the MW pump guide at the top of the engine subforum.

MW n/a pump in a 240D? If so I'd try to swap the governor for a turbo one from the 617a.

Tom

The MW for turbo and non are identical except for the ADA/ALDA. Adjustment of the torque capsule, adjustment/removal of the rack limiter and an ALDA swap are all thats needed to make it the same as a 617a pump -1 cylinder.

cool thanks for the info I just got the intake plumed and the oil filter housing installed and tomorrow I'm going to install the return fitting and new oil pan and work on my exhaust adapter then Monday I'm going to get the feed and return lines made!

Note the hose are temporary for mock up only! just to make sure it all fits

How exciting! Good job so far.

I got the oil return fitting in the upper pan today and the new oil pan! And sorted out the the exhaust adapter tomorrow I'm going to grab the stock air filter housing out of a w115 220d and get the oil feed and return lines made up tomorrow then just got to add oil and filter and see what happens!

I still need to hook up my boost and EGT gauges I will take some more pics and vids for the utube

Well I got the return and feed lines made and got it fired up today I'v got the boost gauge hooked up and it was only making 2 psi boost so iI hooked up a smoke machine no boost leeks but I found an exhaust leak witch I have to fix at the elbow. I'll take some vids soon!

I fixed the exhaust leak and now it will hit 3psi in 1 st gear 6psi in 2nd and 7psi in 3rd before I backed off.
It only gets there up in the high revs? I was hoping it would spool sooner I'll have to double check there are no more leaks I still need to hook up the exhaust and air filter

all I have done to the pump is turn up the ADA what all do I need to add an ALDA? I have a spare mw pump? I'm wondering if I add more fuel if the turbo will spool up faster?

(07-22-2009 02:30 PM)willbhere4u Wrote:  what all do I need to add an ALDA?

Just swap it in place of the ADA.

Quote:I'm wondering if I add more fuel if the turbo will spool up faster?

Much faster.
If the turbo is non-wastegated its going to be somewhat slow to spool.

cool thanks do I also need to remove the rack limiter for the ALDA to work? and will the ALDA add more fuel under boost or just lean it out at idle? I have the ADA full rich now so dose the ALDA have any benefit?

(07-22-2009 10:49 PM)willbhere4u Wrote:  cool thanks do I also need to remove the rack limiter for the ALDA to work?

I'd adjust the torque capsule and adjust the rack limiter. I don't know how well a 616 can handle 110hp (removed rack limiter) without the piston cooling.

Quote:will the ALDA add more fuel under boost or just lean it out at idle?

The alda takes away fuel and gives it back with boost.

Quote:I have the ADA full rich now so dose the ALDA have any benefit?

You must turn up the pump to make more power with the extra air. Since your turbo is slow to spool (non wastegated) you'll probably need an ALDA to limit fuel just to keep EGTs in the safe range.

well with the ADA turned up flat out to 70mph I only hit 950 deg (F) I think I need more fuel the car doesn't feel any faster with the turbo??? it only hit 2-3 psi up till 3500 rpm and it will get to 5-7 near red line? with the ADA turned up I get a nice black puff when I take off but it cleans up quick

it sits at 350 deg at idle

Normal. Thats exactly how my M-Pump was until I turned up the fuel.

Well today I got the exhaust on the car! and partially figured out the air filter I got an old Mercedes oil bath filter housing that I need to convert to a paper filter.

In other news I figured out that the turbo isn't spinning fast enough to get 5 psi boost until the car is at red line with no leaks! I opened a 1/4in leak in the intake manifold and it boost much sooner but not as much up high so I need to bleed it to the right amount to get the turbo in it's efficiency range! bleed a to much not good! To little and it doesn't like that either

What I need is an adjustable bleed valve that closes under pressure gradually so it bleeds until its got good speed and pressure going???

well I got some time today and removed the rack limiter! I also installed a spare set of turbo injectors they are louder! and I tried an ALDA but the care wouldn't even make boost!!! so I put my ADA back on and it has more off the line power but makes no more boost just 5psi at red line? I think the turbo is inefficient??? just to old I need to modify a newer one on to the car later!
I'll take some video later tonight

Did you adjust the torque capsule? (I've got the two-tab sockets if you need them). That will give you more fuel on the top end. Does it smoke much?

I didn't adjust the TC yet! It doesn't smoke much more than it did other day? the turbo injectors nail a bit at idle and cause it to idle rough!

I wish the turbo could hit higher boost numbers 90% of the time it is between 0-3 psi

Here are some pic of the kit finished and tided up a bit! I ended up putting a straight pipe on the car because the exhaust broke between the mufflers last Thursday it sounds interesting now! but makes boost sooner than before! It now hits 5psi in 2nd gear and 7psi in 4th at 70mph! http://www.youtube.com/watch?v=P1WtXc79Ymk

Nice! Hopefully we can run against each other tomorrow!

Are you running a line to the ADA or did you swap an ALDA on?

I put the ALDA on but it wouldn't make boost! not enough fuel to light it off I guess? so I put the ADA back on lots more power!!! I also ran a boost line to the ADA port I don't think that it makes a big difference though! see you at the track!

Well the bleed valve fell off some time on the way home from the race track Sunday so I plugged the hole and now it doesn't need it any more with the rack limiter removed! I also put the stock rebuilt 240 injectors back in and it runs a lot better on the top end!!! and the turbo is now making boost earlier and hitting 8-9 psi at 75-85! Now I need to get a turbo 300d oil cooler and radiator and a new thermostat it's running warm under load up hill 225ish deg F. I should also put in a fan clutch at the same time!

I'm starting to be impressed with this setup as I passed cars all the way up a steep hill on I 25 doing 75-80 mph with 1/4 throttle and I had to let off to keep from going to fast! never done that before!!! also the EGT's never got over 1050 deg F

Found in "Turbochargers" by Hugh Maclnnes.

   
   

I seriously doubt the performance claim is factual, the M117 had 190hp/278tq and thats a big stretch to best even today.
   

wow cool stuff thanks for posting it! the 300d with the same power as the 450se yea right I'll believe it when I see it! that would be impressive by today's standards!!!

http://forums.tdiclub.com/showpost.php?p...stcount=10

very cool project!!!
What about dino? how much hp?

probably about 15-20 hp more than stock! It really need's a new/upgraded injection pump

Where i can buy this pump and what price?
answer please hear http://www.superturbodiesel.com/std/td-t...-1682.html