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Purple turbo 240D - Printable Version

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RE: Purple turbo 240D - Purplecomputer - 06-27-2012

Holy shit, what a day

after work I got these in the mail

the most important being the oil pan gasket.

[Image: 20120627_193602.jpg]

Then I put on my dirty short and shirt and some working shoes and went at the car.

after about an hour I was able to get the brass fitting that I am using for the return on, it tooks me two days in total for this piece of shit mostly because I made mistakes on where to position it.

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Then I fabricated the return hose that actually goes on the turbo.

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check the length of the hose from the turbo to brass fitting and cut the hose to appropriate size

Then I cleaned the area of dirt, metal shavings and other crap I dont want in the oil/ oil pan and removed the old gasket. The old gasket had to be original becausae is was so worn and was stuck to the pan and took me a lot of force just to get it off, but the new one is nicer Smile

[Image: 20120627_221708.jpg]

I will be taking on the throttle linkage tomorrow!


RE: Purple turbo 240D - ronnie - 06-28-2012

I know what the problem was , you put shoes on, supposed to work barefooted....

Glad you got it together, sometimes simple things have a way of just taking forever and being maddening. I have been working on a boat repair for the last few days that I thought might have taken an hour or two.


RE: Purple turbo 240D - Purplecomputer - 06-28-2012

(06-28-2012, 06:01 AM)ronnie I know what the problem was , you put shoes on, supposed to work barefooted....

Glad you got it together, sometimes simple things have a way of just taking forever and being maddening. I have been working on a boat repair for the last few days that I thought might have taken an hour or two.

i would have workes barefoot but the ground was covered in oil!!

i am glad i got that part done, i was almost about to give up and sell the car as is!!


RE: Purple turbo 240D - JB3 - 06-28-2012

that is a nice brass fitting, very elegant solution.

What is it? Looks like a bulkhead boat tank fitting?

I went with welding a threaded port to me lower oil pan, but this looks way better, ill be going this route instead I think


RE: Purple turbo 240D - Purplecomputer - 06-28-2012

(06-28-2012, 08:40 AM)JB3 that is a nice brass fitting, very elegant solution.

What is it? Looks like a bulkhead boat tank fitting?

I went with welding a threaded port to me lower oil pan, but this looks way better, ill be going this route instead I think

yup, its a bulkhead fitting for a boat. although i cant take credit for this as it was ronnies idea.


RE: Purple turbo 240D - willbhere4u - 06-28-2012

I did almost the exact same thing but I used an an10 bulk head fitting and bolted my return hose to it


RE: Purple turbo 240D - Purplecomputer - 06-28-2012

(06-28-2012, 10:21 AM)willbhere4u I did almost the exact same thing but I used an an10 bulk head fitting and bolted my return hose to it

I had both but i drilled to much, made the hole to big and just went with the brass fitting.

Right now im taking a lunch break, been working on the throttle linkage. Have to remove the old bar that runs across the firewall and weld a few things


RE: Purple turbo 240D - Purplecomputer - 06-28-2012

OKay I am done for the day and I will lose a day tomorrow, I have to work and also go to some family part after work, sucks.

Heres what I did.

I put back the oil pan and Had to remove one of the A/C lines because it was in the way of the turbo return, so I will figure something out but for now it dosnt matter because my A/C is dead.

I figured out how to use the welder today, never used it once in my life and even thought i looks ugly as hell its actually very solid the weld I did, proud of myself!

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Then I tried to figure out the throttle linkage set up, took me a while to get everything in and stuff but its much stiffer now and looks like it will work great althought I did someone manage to let the idle cable go all the way into its sleeve.....

[Image: 20120628_203822.jpg]

Then I removed the injectors becuase I will ultrasonic clean them for now until I can get greazzer to do it professionally.

[Image: 20120628_121440.jpg]

crush washer were also pretty dirty

[Image: 20120628_121455.jpg]


RE: Purple turbo 240D - Simpler=Better - 06-29-2012

For a first weld, that's great. Most people would have burned straight through. If it fails (you know you're going to want to stomp on the accelerator :p) it looks like you could use more heat and a slightly lower wire feed rate. Also, cleaning the surfaces to bare metal before welding, and making sure you have a perfect ground will help a lot. My brother likes to tack weld the ground clamp to the work piece (redneck way I know, but it works)

Are your glow plugs connected with a giant solid wire? That's awesome!


RE: Purple turbo 240D - willbhere4u - 06-29-2012

Make sure you replace the heat shields they are one time use!


RE: Purple turbo 240D - Purplecomputer - 06-29-2012

(06-29-2012, 02:58 PM)willbhere4u Make sure you replace the heat shields they are one time use!

oh yeah! totally forgot about that, Ill pick some up today


RE: Purple turbo 240D - ronnie - 06-29-2012

You will need the seal rings for the pc's too if you (we?) take them out to ream the burn holes.

By the way on the welding, both parts have galvinazation on them so lightly grinding to bare metal will help with a cleaner weld. Good first time try, should hold.


RE: Purple turbo 240D - Purplecomputer - 06-29-2012

(06-29-2012, 04:32 PM)ronnie You will need the seal rings for the pc's too if you (we?) take them out to ream the burn holes.

By the way on the welding, both parts have galvinazation on them so lightly grinding to bare metal will help with a cleaner weld. Good first time try, should hold.

I plan on heading up there sometime in july. Ill let ya know my friend


RE: Purple turbo 240D - Purplecomputer - 06-30-2012

Hey guys so this morning so far I got the throttle linkage all set up, phew!

heres what it looks like trying to re use what I can and not spend money, I tested it and works pretty well. I will need a new idle cable though becuase the one I have is all frayed but for now it is fine.

[Image: 20120630_113524.jpg]

Now, I was taking a look at the air filter housing and I have no Idea what this little opening on the bottom is for!

[Image: 20120630_113512.jpg]

can I just cap this? I hope so I dont really feel like doing any modifications

also I have the ultrasonic cleaner, gonna get to some cleaning today

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hopefully I can tackle the exhaust today


RE: Purple turbo 240D - aaa - 06-30-2012

That's the oil separator, turbo models have that inside the aircleaner. Where are you putting the normal 240d oil separator? If you're keeping the 240d one you can ignore the one in the aircleaner. If you want to use the turbo oil separator then you will have to deal with the different blowby oil drain, you can see the 240d drain is in a totally different spot.


RE: Purple turbo 240D - Purplecomputer - 06-30-2012

(06-30-2012, 11:01 AM)aaa That's the oil separator, turbo models have that inside the aircleaner. Where are you putting the normal 240d oil separator? If you're keeping the 240d one you can ignore the one in the aircleaner. If you want to use the turbo oil separator then you will have to deal with the different blowby oil drain, you can see the 240d drain is in a totally different spot.

oil whaaa? I had no such thing on the original one unless you mean that black hose that went from the valve cover to the intake minifold?

did a little googlin and looks like I have the "old" style or something along those lines so I dont have an oil serperator.


RE: Purple turbo 240D - ronnie - 06-30-2012

Yours does not have the oil seperater, only newer ones. On the 300d air cleaner I just plugged the drain on it. Of course yours being an older engine you may have some oil in the blowby, so you may want to just run the drain to a catch can. It seems like the 300's had two drains in the oil pan. not at home at the moment so can't check that, maybe some else with a 300 will speak up.

Idle cable, in the process of tuning your ip that can be eliminated. As a proper idle can be had without haveing to mess with a manuel adjustment all the time.


RE: Purple turbo 240D - Purplecomputer - 06-30-2012

(06-30-2012, 01:02 PM)ronnie Yours does not have the oil seperater, only newer ones. On the 300d air cleaner I just plugged the drain on it. Of course yours being an older engine you may have some oil in the blowby, so you may want to just run the drain to a catch can. It seems like the 300's had two drains in the oil pan. not at home at the moment so can't check that, maybe some else with a 300 will speak up.

Idle cable, in the process of tuning your ip that can be eliminated. As a proper idle can be had without haveing to mess with a manuel adjustment all the time.

excellent! this is good news. I hate the idle cable, always having to adjust while im driving. I am going to go to a muffler shop today and just have them connect the turbo to the exhaust i have in place. I am so tired of working i would rather pay a few dollars for someone elses labor right now.


RE: Purple turbo 240D - Purplecomputer - 06-30-2012

got a little naughty and decided to start it without the complete exhaust Big Grin

[Image: th_20120630_185023.jpg]

(click for video)

starting it was good because I was able to spot a few oil leaks.


RE: Purple turbo 240D - willbhere4u - 06-30-2012

sounds good!


RE: Purple turbo 240D - Purplecomputer - 07-02-2012

Cars done!

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I still need to install my guages but thats easy. I will do that tonight.

I took the car for a virgin run last night. All is well OIL pressure stays constant, the car is noticably peppier. I removed the exhaust and just left the down pipe for now, With the turbo whistling and the mean exhasust sound it sounds pretty good.

I will be keeping an eye on oil level as it has dropped but I put in two gallons of oil (8 Quarts) So i am assuming thats the oil getting into every nook and crany


RE: Purple turbo 240D - Simpler=Better - 07-02-2012

Now that you have heard it run without an exhaust, you have been tainted. The only solution is a hood stack Big Grin

Time to turn up that pump!


RE: Purple turbo 240D - Purplecomputer - 07-02-2012

(07-02-2012, 08:28 AM)Simpler=Better Now that you have heard it run without an exhaust, you have been tainted. The only solution is a hood stack Big Grin

Time to turn up that pump!

yeah, I can deffinately feel that car needs more fuel.

the idle cable keeps coming loose causing the car to go to a very low idle and my oil pressure drops

also while its still connected the oil pressure drops from 45psi while cruising highway at stop lights its around 30psi, this was also common when i was running it without the turbo. Is this normal for me?


RE: Purple turbo 240D - DeliveryValve - 07-02-2012

Nice Great Job on this!

Your oil pressure seems normal to me.


.


RE: Purple turbo 240D - Purplecomputer - 07-02-2012

(07-02-2012, 01:09 PM)DeliveryValve Nice Great Job on this!

Your oil pressure seems normal to me.


.

great, I always thought I had to stay at 45psi at all times. This makes me less worried


RE: Purple turbo 240D - ronnie - 07-02-2012

Think 10, or 15 is the factory minimum for oil pressure at idle, warmed up. so no worries.

Looks nice.


RE: Purple turbo 240D - Purplecomputer - 07-02-2012

(07-02-2012, 05:10 PM)ronnie Think 10, or 15 is the factory minimum for oil pressure at idle, warmed up. so no worries.

Looks nice.


Woah, Really? Had no idea.

I got the gauges hoooked up. I think my EGT is no good because it always read 1600 degrees on all 6 colors and looks like it read 1200 degrees on teal. I got the glowshift gauges. Boost gauge dosnt work And I think thats becuase I hooked it up wrong. Not sure. Have to read the instructions more carefully.

actually it might be because of a broken wastegate maybe

EDIT:

Okay deffinately hooked up the boost gauge wrong but it powers on and should still show boost but it dosnt....

Another edit:

I honestly have no idea what im doing. I tapped the T that I got from the boost gauge into the line from the wastegate. After some reading everyone is either T'ing into hoses that go into the intake or getting a brass fitting and drilling it into the intake manifold.

Is this true?


RE: Purple turbo 240D - sassparilla_kid - 07-02-2012

Most people use the line that goes to the ALDA, but I guess that isn't really an option for you


RE: Purple turbo 240D - aaa - 07-02-2012

Either way works. It should work fine coming from the compressor housing.

Try cranking up the engine rpm, maybe it only builds boost later.


RE: Purple turbo 240D - sassparilla_kid - 07-03-2012

Is it an electric boost gauge??


RE: Purple turbo 240D - Simpler=Better - 07-03-2012

Let's see some pics of the gauges, model #s, etc.


RE: Purple turbo 240D - Purplecomputer - 07-03-2012

(07-03-2012, 01:58 AM)sassparilla_kid Is it an electric boost gauge??

I think so

(07-03-2012, 08:05 AM)Simpler=Better Let's see some pics of the gauges, model #s, etc.

This is the boost

http://www.glowshiftdirect.com/black-7-color-30psi-boost-vacuum-gauge.aspx

this is the egt

http://www.glowshiftdirect.com/Black-7-Color-1500-F-Pyrometer-EGT-Gauge.aspx

the egt acts funny, it keeps jumping temps all around. Last night though it was weird, looked like it was displaying a correct temp. I was getting around 1200 hard accelerating and around 600 highway. as soon as you change a color it jumps up 200 degrees, change it again and it could drop 300

il take some pictures of the gauges and set up tonight.


RE: Purple turbo 240D - Simpler=Better - 07-03-2012

The boost gauge is mechanical, as long as it's properly hooked up you're good to go.

The pyrometer sounds like you have a poor ground / power supply, make sure you've run a clean ground and a clean hot to the gauge. My guess is that changing colors sucks power down and gives you funky readings. Did you extend the pyrometer sending wires anywhere?


RE: Purple turbo 240D - Purplecomputer - 07-03-2012

(07-03-2012, 10:06 AM)Simpler=Better The boost gauge is mechanical, as long as it's properly hooked up you're good to go.

The pyrometer sounds like you have a poor ground / power supply, make sure you've run a clean ground and a clean hot to the gauge. My guess is that changing colors sucks power down and gives you funky readings. Did you extend the pyrometer sending wires anywhere?

hmm, never thought of that. I ran the ground to the negative terminal on the battery and ran the 12 volt to the ignition fuse, but I think I have it wrong as there is a yellow wire and red. The red goes to the 12v ignition fuse and then the yellow goes to battery, I missed that part. I did the same for the boost gauge

also I feel as if a lot of power is gone to waste since there is a pretty large gap between the turbo outlet and intake manifold. I will get a piece of pipe to extend the manifolds opening and weld it on.

so far two days of driving and no oil leaks which was my number one concern.

heres a list of what I still need to do.

-Finish the exhaust system ( I will be straight piping it all the way to the back)
-Properly install my gauges
-Fix the gap between turbo outlet and intake mani
-Tune IP for more fuel/better performance (I will be visiting my friend Ronnie for that)
- Intall my rear bumper
- I need new tires
- Wash and wax the car Big Grin


RE: Purple turbo 240D - Simpler=Better - 07-03-2012

Did you port match everything when it was off the car? The connecting pipe is pretty meaty, there are theoretical gains to be had if you take the time to transition it. Like this:

[Image: t3coupler.jpg]


RE: Purple turbo 240D - Purplecomputer - 07-03-2012

[quote='Simpler=Better' pid='42786' dateline='1341339243']
Did you port match everything when it was off the car? The connecting pipe is pretty meaty, there are theoretical gains to be had if you take the time to transition

no i didnt, had no idea. do they sell that pipe?


RE: Purple turbo 240D - Simpler=Better - 07-03-2012

Wait, do you not have a connecting pipe in your setup? If you don't have one I can mail you one of my old ones, it's sharp-lipped though. Just takes dremel time to make it smooth like that.


RE: Purple turbo 240D - ronnie - 07-03-2012

Are you missing that piece, should not be any gap? Don't think I have a spare. I did not port match mine, however if you are missing it, and have to put one on, it may well be worth cleaning it up.

Not going to be much boost until it is in, just too much leakage. If everything it air tight, you may get a few pounds to maybe 5 psi boost until more fuel is added.


RE: Purple turbo 240D - Purplecomputer - 07-03-2012

(07-03-2012, 02:44 PM)Simpler=Better Wait, do you not have a connecting pipe in your setup? If you don't have one I can mail you one of my old ones, it's sharp-lipped though. Just takes dremel time to make it smooth like that.

Nope, dont have it. I knew I was doing something wrong..


RE: Purple turbo 240D - Purplecomputer - 07-19-2012

so my car was hit on the side today on the way to get new tires.... Paints all scratched and I have a huge dent on the passenger side rear door. I could always wet sand the scratches out but I dunno how ill get the dent out. Damage is pretty minimal thought.


RE: Purple turbo 240D - Kozuka - 07-19-2012

Hey. you can always get a new door! ^_^

Glad your ok.


RE: Purple turbo 240D - ronnie - 07-19-2012

Bummer. I have an extra rear door, it is dark blue though. Might be better to fix your door unless to bad.

By the way found a dyno close to home, so maybe a little more tuning on mine then I;ll give it a try. $80 for three pulls, and they do diesels.


RE: Purple turbo 240D - Purplecomputer - 07-20-2012

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damage isnt too bad. I could always wet sand the scartch out since its not very deep (what i mean is, it didnt go down to the metal) the ding isnt too bad. I could always try that stupid heater/compressed air trick and work the metal.


RE: Purple turbo 240D - Purplecomputer - 07-20-2012

FML....

I was stuck in traffic when a lady stopped short and i was distracted with the radio and BAM.

Now the front end of my car is completely fucked. The grill is busted, needs to be replaced. The driver side headlight is busted completely and now the bumper is a little messed up.

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RE: Purple turbo 240D - w123love - 07-20-2012

dawwwwww Sad I’m bummed for you man!


RE: Purple turbo 240D - sassparilla_kid - 07-20-2012

Fuuuuu....................... I would have just killed those people. You are having shitty luck these past few days, maybe/hopefully that means you'll get lucky and find some killer deals soon or something


RE: Purple turbo 240D - Purplecomputer - 07-21-2012

(07-20-2012, 08:35 PM)sassparilla_kid Fuuuuu....................... I would have just killed those people. You are having shitty luck these past few days, maybe/hopefully that means you'll get lucky and find some killer deals soon or something

I have my fathers bad luck. Everything that could happens, happens. Im going to repair the car, and I have a gut feeling that maybe i was never supposed to have this car, so I might sell it after the repair and move onto something else. Not sure yet..

ordered a new set of corners and head lights and my buddy ronnie is sending me a new grill monday. So for now Ill just rock on side dot sealed beams and the other side euro's. Im also gonna pull out the fender a lil bit. Any tips are appreciated


RE: Purple turbo 240D - Simpler=Better - 07-21-2012

I have a spare grille. It's not perfect, doesn't have an emblem, but it's your for shipping.


RE: Purple turbo 240D - Purplecomputer - 07-21-2012

(07-21-2012, 11:38 AM)Simpler=Better I have a spare grille. It's not perfect, doesn't have an emblem, but it's your for shipping.

thanks but I already have a replacement on the way. Do you think I should find a fender the same color and replace it? this ones a little shot, might be better to replace it?


RE: Purple turbo 240D - Greazzer - 07-21-2012

Here's the EBAY stuff


NEW Mercedes Euro 123 rear bumper bracket 230 250 280E 240D 300D 280CE
Item Id: 330730591414
End time: Jun-09-12 11:38:39 PDT
Buyer:
blevyone (4)
100.0% Positive Feedback
Member since Jun-22-05 in United States
Location: SC, United States

Listing Status: This message was sent while the listing was active.

Purplecomputer:

Goto DieselGiant and he has a post on replacing a fender