STD Tuning Engine Re: A/W IC install

Re: A/W IC install

Re: A/W IC install

 
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bgkast
VGT-Intercooled

325
02-27-2008, 09:17 PM #1
For this installation I used an "XSPOWER" Aluminum air/water intercooler (from ebay), modified intake manifold, motorcycle radiator (early 80s Honda Goldwing), and Mercedes Aux. water pump wired to a relay to turn on when the key is in the "run" position.

1) Buy a extra manifold and have it modified by cutting off the EGR fitting and having a 2" or larger aluminum barb fitting TIG welded on. (Photos 1 and 2 credited to Brandon314159)
   
   
   

2) Clock the turbo. Loosen the 6 bolts on the back side of the compressor and remove the nuts that hold the manifolds to the head. Separate the turbo compressor from the intake and rotate the compressor housing so that the outlet is pointing vertically

   
This post was last modified: 03-05-2009, 12:51 AM by bgkast.
bgkast
02-27-2008, 09:17 PM #1

For this installation I used an "XSPOWER" Aluminum air/water intercooler (from ebay), modified intake manifold, motorcycle radiator (early 80s Honda Goldwing), and Mercedes Aux. water pump wired to a relay to turn on when the key is in the "run" position.

1) Buy a extra manifold and have it modified by cutting off the EGR fitting and having a 2" or larger aluminum barb fitting TIG welded on. (Photos 1 and 2 credited to Brandon314159)
   
   
   

2) Clock the turbo. Loosen the 6 bolts on the back side of the compressor and remove the nuts that hold the manifolds to the head. Separate the turbo compressor from the intake and rotate the compressor housing so that the outlet is pointing vertically

   

bgkast
VGT-Intercooled

325
02-27-2008, 11:21 PM #2
3) Remove the stock intake manifold.    

4) Install the modified Intake manifold. This is a good time to replace the manifold gasket if it is old.

5) Install the Intercooler. I made some custom brackets to mount the intercooler inlet at a 90* angle to the clocked compressor outlet.
   

6) Connect Intercooler to compressor outlet and modified intake manifold using silicone boots, clamps and tubing as necessary. Note: the O.D. of the stock T3 turbo compressor outlet is 2 1/16"

   
   
This post was last modified: 03-05-2009, 12:56 AM by bgkast.
Attached Files
Image(s)
   
bgkast
02-27-2008, 11:21 PM #2

3) Remove the stock intake manifold.    

4) Install the modified Intake manifold. This is a good time to replace the manifold gasket if it is old.

5) Install the Intercooler. I made some custom brackets to mount the intercooler inlet at a 90* angle to the clocked compressor outlet.
   

6) Connect Intercooler to compressor outlet and modified intake manifold using silicone boots, clamps and tubing as necessary. Note: the O.D. of the stock T3 turbo compressor outlet is 2 1/16"

   
   

Attached Files
Image(s)
   

bgkast
VGT-Intercooled

325
02-27-2008, 11:31 PM #3
7) Install the radiator in front of the engine radiator. You will need to remove the AC condenser.
   

8) Hook up the water lines to the IC, radiator and water pump. You will want to hook the hose from the bottom of the radiator to the lower fitting on the intercooler.

9) Wire up the relay for the water pump. The black and purple wire for the windshield wipers is a good place to attach the relay trigger wire.
   

10) Fill the cooling system for the Intercooler with the same coolant as the engine. Tilt the intercooler if necessary to remove all of the air from inside.

11) Start it up, check for leaks and go for a drive!
This post was last modified: 03-05-2009, 12:57 AM by bgkast.
bgkast
02-27-2008, 11:31 PM #3

7) Install the radiator in front of the engine radiator. You will need to remove the AC condenser.
   

8) Hook up the water lines to the IC, radiator and water pump. You will want to hook the hose from the bottom of the radiator to the lower fitting on the intercooler.

9) Wire up the relay for the water pump. The black and purple wire for the windshield wipers is a good place to attach the relay trigger wire.
   

10) Fill the cooling system for the Intercooler with the same coolant as the engine. Tilt the intercooler if necessary to remove all of the air from inside.

11) Start it up, check for leaks and go for a drive!

HoleshotHolset
Holset

379
03-31-2008, 03:08 PM #4
Are you monitoring IAT's (intake air temperature) at all?

How about EGT's? The drop in IAT's has a pretty significant effect on dropping the EGT's as well. Every setup will vary, of course.

Beers,

Matt

'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
03-31-2008, 03:08 PM #4

Are you monitoring IAT's (intake air temperature) at all?

How about EGT's? The drop in IAT's has a pretty significant effect on dropping the EGT's as well. Every setup will vary, of course.

Beers,

Matt


'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten

bgkast
VGT-Intercooled

325
03-31-2008, 04:23 PM #5
I am not measuring AIT, but my EGTs dropped about 3-400 degrees.
bgkast
03-31-2008, 04:23 PM #5

I am not measuring AIT, but my EGTs dropped about 3-400 degrees.

Telecommbrkr
Soon to be mod'ing......

97
03-31-2008, 07:42 PM #6
...3-400 degrees.

That's cool 8-)

'Jurgen' - 1982 300sd cream paint with palimino MB tex interior. Now running with new cooling systemBig Grin.......discovered oil cooler has pinhole @#$%@Angry Nitrile gloves back on......

'Otto' - 1985 300sd anthracite? grey/silver? with grey leather interior. (heated front seats!!!!Cool ) Euro headlights

Mods are in the works...
Telecommbrkr
03-31-2008, 07:42 PM #6

...3-400 degrees.

That's cool 8-)


'Jurgen' - 1982 300sd cream paint with palimino MB tex interior. Now running with new cooling systemBig Grin.......discovered oil cooler has pinhole @#$%@Angry Nitrile gloves back on......

'Otto' - 1985 300sd anthracite? grey/silver? with grey leather interior. (heated front seats!!!!Cool ) Euro headlights

Mods are in the works...

HoleshotHolset
Holset

379
04-01-2008, 10:20 AM #7
Dropping 3-400°F is awesome! Nice work!
Now you can add more fuel to warm things up again. :twisted:

What kind of EGT's are you seeing now cruising and on a hard pull? (I'm assuming your thermocouple is installed on the exhaust manifold, before the turbine inlet...)

These are some pre-turbo EGT's numbers I like to live by and preach about regarding TDIs and Cummins...
300°F - maximum slow idle temp before shutting engine down
1250°F - maximum sustained temp for periods longer than a minute or two...use good judgement when you're running at this temp for longer than a few minutes...try to figure out WHY you're starting to run 'hot' and make adjustments if necessary.
1500°F - maximum temp for short blasts to 60mph or 1/4-mile runs, back off the soot pedal if you see these temps for more than 15-20 seconds.

Cummins B-series engines are good to about 50psi of boost on the OEM headgasket and head bolts.

The TDI guys start to freak out the minute they see 20psi - my old TDI routinely saw peaks of around 38psi and I didn't see any signs of trouble...but you have to know how to drive and maintain things in order to not do any damage.

Beers,

Matt

'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
04-01-2008, 10:20 AM #7

Dropping 3-400°F is awesome! Nice work!
Now you can add more fuel to warm things up again. :twisted:

What kind of EGT's are you seeing now cruising and on a hard pull? (I'm assuming your thermocouple is installed on the exhaust manifold, before the turbine inlet...)

These are some pre-turbo EGT's numbers I like to live by and preach about regarding TDIs and Cummins...
300°F - maximum slow idle temp before shutting engine down
1250°F - maximum sustained temp for periods longer than a minute or two...use good judgement when you're running at this temp for longer than a few minutes...try to figure out WHY you're starting to run 'hot' and make adjustments if necessary.
1500°F - maximum temp for short blasts to 60mph or 1/4-mile runs, back off the soot pedal if you see these temps for more than 15-20 seconds.

Cummins B-series engines are good to about 50psi of boost on the OEM headgasket and head bolts.

The TDI guys start to freak out the minute they see 20psi - my old TDI routinely saw peaks of around 38psi and I didn't see any signs of trouble...but you have to know how to drive and maintain things in order to not do any damage.

Beers,

Matt


'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten

bgkast
VGT-Intercooled

325
04-01-2008, 11:30 AM #8
Yes, my thermocouple is just before the turbine inlet. You can see some pictures in my pyrometer how to here: <!-- l --><a class="postlink-local" href="http://superturbodiesel.com/std/topic12.html">topic12.html</a><!-- l -->

Cranking up the fuel is next, I just got sidetracked on some rust repair. :|

I have a tough time reaching 900* on a long full load pull with the intercooler
bgkast
04-01-2008, 11:30 AM #8

Yes, my thermocouple is just before the turbine inlet. You can see some pictures in my pyrometer how to here: <!-- l --><a class="postlink-local" href="http://superturbodiesel.com/std/topic12.html">topic12.html</a><!-- l -->

Cranking up the fuel is next, I just got sidetracked on some rust repair. :|

I have a tough time reaching 900* on a long full load pull with the intercooler

HoleshotHolset
Holset

379
04-01-2008, 03:26 PM #9
Excellent - that's just awesome! I love reading about cheap/easy improvements made to cars/engines that the OEMs didn't bother with that have great results. Implementing these improvements on my own vehicles? - pure bliss. 8-)

I've installed probably 30 thermocouples over the years - never really had an install go wrong - knock on cast iron. :geek:
(I have had a few thermocouples and signal amplifiers go bad, though.)

Well done! - 900°F at the turbine inlet on a good pull means you've got quite a bit of room for expansion.

Cheers,

Matt

'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten
HoleshotHolset
04-01-2008, 03:26 PM #9

Excellent - that's just awesome! I love reading about cheap/easy improvements made to cars/engines that the OEMs didn't bother with that have great results. Implementing these improvements on my own vehicles? - pure bliss. 8-)

I've installed probably 30 thermocouples over the years - never really had an install go wrong - knock on cast iron. :geek:
(I have had a few thermocouples and signal amplifiers go bad, though.)

Well done! - 900°F at the turbine inlet on a good pull means you've got quite a bit of room for expansion.

Cheers,

Matt


'07 W211 OM642
'95 W124.131/722.435, 211k - daily driver/Superturbo project - OM606.962 with "M" pump...under construction! (build thread here)
'99 W210.025 - gone, but not forgotten
'94 Dodge/Cummins - gone, but not forgotten

winmutt
bitbanger

3,468
04-01-2008, 03:35 PM #10
BGKast, Got pics of the intake/filter setup with this rig?

1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
winmutt
04-01-2008, 03:35 PM #10

BGKast, Got pics of the intake/filter setup with this rig?


1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42

bgkast
VGT-Intercooled

325
04-05-2008, 01:09 PM #11
Here it is, it's not ideal, but it works:
Attached Files
Image(s)
   
bgkast
04-05-2008, 01:09 PM #11

Here it is, it's not ideal, but it works:

Attached Files
Image(s)
   

winmutt
bitbanger

3,468
04-07-2008, 01:19 PM #12
Ah ok, I didnt see the filter under the AW/IC.


I REAAAAALY like the integrated manifold / awic they have on that Finn superturbo. That shit is hot.

1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
winmutt
04-07-2008, 01:19 PM #12

Ah ok, I didnt see the filter under the AW/IC.


I REAAAAALY like the integrated manifold / awic they have on that Finn superturbo. That shit is hot.


1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42

ForcedInduction
Banned

3,628
09-14-2008, 10:19 AM #13
Speaking of hot, what kind of intercooler water temperatures are you getting in and out of the cooler?
ForcedInduction
09-14-2008, 10:19 AM #13

Speaking of hot, what kind of intercooler water temperatures are you getting in and out of the cooler?

bgkast
VGT-Intercooled

325
09-29-2008, 06:32 PM #14
I'm not sure. From what I remember the inlet hose is cool to the touch, and the outlet is quite a bit warmer. I need to get an infrared thermometer.
bgkast
09-29-2008, 06:32 PM #14

I'm not sure. From what I remember the inlet hose is cool to the touch, and the outlet is quite a bit warmer. I need to get an infrared thermometer.

ForcedInduction
Banned

3,628
03-01-2009, 04:53 AM #15
Any updates? Can you fix the pictures?
ForcedInduction
03-01-2009, 04:53 AM #15

Any updates? Can you fix the pictures?

bgkast
VGT-Intercooled

325
03-05-2009, 12:58 AM #16
Pictures fixed.

Intercooler is still working well.
bgkast
03-05-2009, 12:58 AM #16

Pictures fixed.

Intercooler is still working well.

Tymbrymi
Klatta Klatta

185
03-06-2009, 03:52 PM #17
(03-05-2009, 12:58 AM)bgkast Intercooler is still working well.

Thanks for fixing the pics! Have you had a chance to turn up the fuel yet?

John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!
Tymbrymi
03-06-2009, 03:52 PM #17

(03-05-2009, 12:58 AM)bgkast Intercooler is still working well.

Thanks for fixing the pics! Have you had a chance to turn up the fuel yet?


John Robbins
'05 E320 CDI - 118k - Faaaaaast!! Angel
'87 300TD - 317k - Cracked head... but an OM606 is on the way! Undecided
'79 300SD - 295k - Bad engine = project car!

bgkast
VGT-Intercooled

325
03-09-2009, 12:41 AM #18
No. The car is currently in the garage waiting for me to pull the fender due to some rust I found behind the splash gaurd. Sad
bgkast
03-09-2009, 12:41 AM #18

No. The car is currently in the garage waiting for me to pull the fender due to some rust I found behind the splash gaurd. Sad

 
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