Anth's Coal grenade

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Anth's Coal grenade

Post by anths » Mon 06 Apr, 2015 4:25 pm

Hello fellow Ozbenz members ,
After a few years of owning my 79 300d I have decided to turbo it........So I began fabricating my own manifold which proved to be tricky due to clearance problems with the automatic gearbox rods and pivots ect ect but I am happy with the final product .
We named the old girl the "Coal grenade" as to how long it will survive who knows so If your purist this project isn't for you

I'm guess I will be needing spares along the way so if you can help out with spare engines or transmission please send me a PM cheers !

A blown head gasket set the mood for this project,
So far I have ported the head where needed , changed springs and cam to a later model which had 80 thou more lift and some other little modification here and there below is a picture of the final placement of the turbo.....

Cheers Anthony

.
final fitment.jpg
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Re: Anth's Coal grenade

Post by julian » Tue 07 Apr, 2015 10:05 am

Mate, great project. There are a few turbo w123 diesels on here.
Do you have a few pictures of the manifold you made?
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Re: Anth's Coal grenade

Post by anths » Tue 07 Apr, 2015 12:04 pm

Basic rundown, manifold, 38mm external wastegate with a To4e Turbo

Cheers Anthony
Last edited by anths on Wed 02 Dec, 2015 7:54 am, edited 1 time in total.

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Re: Anth's Coal grenade

Post by Tony From West Oz » Tue 07 Apr, 2015 3:48 pm

Did you re-use the stock inlet manifold?
Looks like you could add an intercooler fairly easily.
Have you sourced an IP with ALDA? these will allow you to set the correct fueling for the boost you have and not leave black smoke when accelerating up to boost RPMs.
Be sure to add an EGT gauge so you know when the EGTs are too high.

Looks good, let us know how she goes and MORE PIX please

Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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Re: Anth's Coal grenade

Post by anths » Tue 07 Apr, 2015 7:16 pm

G'day Tony,
Yes the manifold I designed retains stock inlet, heater hose

I have the pyro and boost gauge already installed .....Patiently waiting.

gauges.jpg
Will be using the stock "Mw" pump no alda ......

The plans are water /meth injection and eventually a intercooler as well which will take a little planning to fit .

cheers Anthony
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Re: Anth's Coal grenade

Post by anths » Wed 08 Apr, 2015 4:24 pm

G'day all,
I dropped into my local exhaust Guy today and he had half my stuff , the other lengths will be in later this week but atleast the main bends are here and few for the crossover pipe from the turbo to manifold.
rsz_img_20150408_141654.jpg
Cheers Anthony
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Re: Anth's Coal grenade

Post by Mercmad » Thu 09 Apr, 2015 1:47 pm

I look forward to seeing this light off!

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Re: Anth's Coal grenade

Post by pastelgrey300D » Thu 09 Apr, 2015 3:24 pm

Nice plumbing! Also looking forward to the on-road results!

BTW your rear demister and interior light switches are upside down!

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Re: Anth's Coal grenade

Post by anths » Thu 09 Apr, 2015 7:52 pm

[quote="pastelgrey300D"

BTW your rear demister and interior light switches are upside down! [/quote]

Prefer the switches this way personal taste you'll have to ignore it ;)

Picked up my "cool mist" Shurflo methanol pump today, I'm happy with the quality hope it performs well ,I just need to get the other gear for it ......

Still waiting on the rest of the exhaust , no real hurry plenty to do ,I have a discharge or charge problem with my battery which is starting to drive me mad with frustration ,battery is good, alternator has new reg and brushes yet consistently within days of short trips it goes flat so that's my next task !
rsz_img_20150409_181738.jpg
Cheers Anthony
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Re: Anth's Coal grenade

Post by Mercmad » Thu 09 Apr, 2015 8:46 pm

battery discharge is often caused by switches being upside down.you may need to check the switches to make sure they turn off. :computer:

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Re: Anth's Coal grenade

Post by anths » Thu 09 Apr, 2015 9:46 pm

Hi Mercmad
I don't think it is the switches one being interior light and rear demister .
The interior light would be on inside the car and the illumination on the demister would be shining but it doesn't have constant power with ignition off like the interior light switch does.

Cheer Anthony

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Re: Anth's Coal grenade

Post by Bartman4800 » Tue 14 Apr, 2015 7:44 pm

Anthony, you have been Mercmadded.

I.e. he was very much taking the piss....

But I would rotate those switches anyway, it will definitely have an impact on the performance of the reversed input suctional valve

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Re: Anth's Coal grenade

Post by anths » Fri 17 Apr, 2015 3:54 pm

Yeah understand that,
but it got me looking for a possible source of power drain... I have reversed the fuses in their holders and wires to match both switches should be good to go now :dance:
Been busy in my home based shop with other peoples projects so will get back onto the grenade next week
Cheers Anthony

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Re: Anth's Coal grenade

Post by Mercmad » Sat 18 Apr, 2015 12:12 pm

Check that the alternator reg (in the back odf the alternator) isn.t feeding to earth. It may still charge but the diodes can break down with engine heat , but can drain a good battery overnight. Check that the battery is OK,you need, at Least, a DIN88.

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Re: Anth's Coal grenade

Post by anths » Sat 18 Apr, 2015 10:44 pm

G'day mate ,
It has a new reg in it ,was replaced a few months back and the battery is 18mth old.
I suspect in maybe low idle but will check the reg again aswell

Cheers anthony

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Re: Anth's Coal grenade

Post by Tony From West Oz » Sun 19 Apr, 2015 1:02 am

To check alternator function:
1. Check battery voltage with no additional load - should be in the vicinity of 12 - 12.6V
2. Start engine. At idle, battery voltage should rise above 12.6V.
3. Increase engine RPM. Battery voltage should rise, increasing with time and not exceed 14V. A battery which was fairly flat, could take over an hour to reach 13.6 - 14V, depending on vehicle loads in use and alternator capacity.
4. Take car for a half hour run. When you come back, battery voltage at idle should be 13.6 - 14V. A DIN 88 battery should have around 88AH of capacity. This should take an 80A alternator over an hour to recharge from flat, with NO other vehicle electrical loads.
5. Turn headlights on high beam. Increase engine RPM. Battery voltage should not drop below 13.6V Continue adding loads, including demister, fan on high, etc. With engine above 1000 RPM battery voltage should not drop below 13.6V.

While this is not 100% foolproof it does give an indication that the alternator is charging, with enough capacity for the normal loads of the vehicle.

Have fun,

Tony
ps, others may disagree with the voltages I quoted, but I used ballpark figures.
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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Re: Anth's Coal grenade

Post by anths » Sun 26 Apr, 2015 5:55 pm

Cheers Tony I have discovered :
engine start's voltage is around 12.7 this is after a flat battery and being on charge for 1hr, Voltage slowly falls as the engine warms up 12.6-5 but again the battery was flat, whilst running I removed the plug in the back of the alternator....No change .....then give the engine a bigger rev Wooop ! 13.6 volts charging the battery.
Engine revs drop to idle maintains 13.6....

I don't think the alternator is spinning quick enough to excite the fields, I drive the car a lot harder than my wife does so at some point it will be charging, I believe the small trips backwards and forwards with the alternator not adding any charge is the issue , Its a brand new regulator so why does it need's higher rpms to be excited ?

Cheers Anthony

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Re: Anth's Coal grenade

Post by Tony From West Oz » Sun 26 Apr, 2015 9:26 pm

Anthony,

With the engine at idle, the alternator should be charging. Slippage of the drive belt is a possibility.
Is the drive belt correctly adjusted?
The alternator seems to be working, just not spinning fast enough.
Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

anths
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Re: Anth's Coal grenade

Post by anths » Mon 27 Apr, 2015 9:25 am

It is adding charge at idle but only after it's given a "Rev" , If I start from cold it will happily sit there on idle adding no charge what's so ever ?
I haven't heard belt slip , but that doesn't mean it's not happening will check today

Cheers

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Re: Anth's Coal grenade

Post by anths » Tue 28 Apr, 2015 12:44 pm

battery has been replaced under warranty so this should fix the problem !

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Re: Anth's Coal grenade

Post by Tony From West Oz » Tue 28 Apr, 2015 5:47 pm

Check out the voltages again, before start, at idle and at higher RPM. Same rules apply.
Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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Re: Anth's Coal grenade

Post by seventyeight » Tue 28 Apr, 2015 7:34 pm

FWIW, both my NA and turbo engine needed a blip of pedal to get the alternator going after a cold start.
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Re: Anth's Coal grenade

Post by anths » Sat 30 May, 2015 7:33 pm

Building turbo manifolds and other bit's and bobs for other people cars has left me a little time poor, but today I started fitting up the pipework for the grenade , Cheers Anthony
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Re: Anth's Coal grenade

Post by AMG » Sun 31 May, 2015 11:01 am

From my limited memory, the difference in the 617 vs 617a is the piston oil squirters. Or was that 603 and 603a... I can't remember. Anyway, if you're going to run higher boost levels then you'll want them to cool the pistons.

I think the older STT type conversions only ran about 5-6psi. Someone will correct my inaccuracies im sure.
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Re: Anth's Coal grenade

Post by Tony From West Oz » Sun 31 May, 2015 12:57 pm

The 617a had a huge oil pump as well as oil squirters and I believe the valves are different also.
Mine runs at around 0.5 bar (7psi) boost.
From what I have read, providing you don't crank up the fuel too much on the NA IP, then your EGTs should not rise to dangerous levels.

Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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Re: Anth's Coal grenade

Post by Mercmad » Sun 31 May, 2015 3:01 pm

The STT's run to 1 bar at full throttle but they warned owners not to keep it at that for more than few seconds. :laughing6:
The turbo engine block was longer to accommodate the cast in oil supply for the piston squirters. The later engines all came with squiters even if they weren't turboed. but that appears to be more for engine reliability because the engines were built very lightly and to a price.

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Re: Anth's Coal grenade

Post by anths » Sun 31 May, 2015 6:36 pm

That's the whole point of running water meth to control crown and exhaust valve temperatures......

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Re: Anth's Coal grenade

Post by timtams » Sun 31 May, 2015 10:17 pm

loving the thread mate!!!! very keen to follow your lead on this one with my 300d

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Re: Anth's Coal grenade

Post by anths » Mon 01 Jun, 2015 7:52 pm

Finished the new exhaust or "drain" ,It has been painted black and installed since this picture was taken, tmrw I will install the wastegate properly cant find my smaller spring so I will leave this one in.
Cheers Anthony
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Re: Anth's Coal grenade

Post by Tony From West Oz » Mon 01 Jun, 2015 10:40 pm

Comparing the NA 300D, without a muffler, to the Turbodiesel 300D without a muffler, the Turbodiesel is significantly quieter.
I did have a 2 muffler setup fabricated in 2.5" pipe, but I feel that I could have got away with a single expansion chamber in the pipe.
Yours looks great!

Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

anths
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Re: Anth's Coal grenade

Post by anths » Tue 02 Jun, 2015 2:51 pm

G'day tony ,
I might end up putting one in too, a little to much growl, So I went for a drive today close to home , all I can say is high temp paint takes for ever to stop smoking /baking ,smelly stuff, I need suggestion on "OIL" The longer I drive I have noticed the oil pressure dropping on idle at the traffic lights, my temp has remained consistent and hasn't moved off 80 degc even under boost....

Cheers Anthony
Last edited by anths on Wed 02 Dec, 2015 7:56 am, edited 2 times in total.

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Re: Anth's Coal grenade

Post by Tony From West Oz » Tue 02 Jun, 2015 10:07 pm

anths wrote:G'day tony ,
I might end up putting one in a little too much growl, So I went for a drive today close to home , all I can say is high temp paint takes for ever too stop smoking /baking ,smelly stuff, I need suggestion on "OIL" The longer I drive I have noticed the oil pressure dropping on idle at the traffic lights, my temp has remained consistent and hasn't moved off 80 degc even under boost....

Cheers Anthony
Don't worry about oil pressure dropping at idle. so long as it is over 1/2 Bar and rises quickly when the engine revs up, then all is OK. (very little load on wear surfaces at idle) Mine idles around 0.7 Bar and rises to 3Bar when the engine revs to 1kRPM.
Congratulations on making your 300D Turbodiesel
Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

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Re: Anth's Coal grenade

Post by anths » Tue 02 Jun, 2015 10:55 pm

before the conversion I used Valvoline 15w-40 on cold I would have 3 bar and when operating would be around 2-2.5 bar ,after 30 mins driving im at 1bar,only thing I have changed is oil filter and the brand ,which is "Gulf" same15w-40.
Driving temp remains a constant 80 deg c before and after the conversion ,EGT are 480 deg C and slowly climbing with boost but that reading was taken at wide open throttle holding 2nd gear .
Im considering a higher viscosity oil perhaps even a 15-50 or 20-50 , I will have a further play tmrw

cheers anthony

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Re: Anth's Coal grenade

Post by timtams » Wed 03 Jun, 2015 12:12 am

Hey anth,

A few questions about the manifold design. How did you design and make the flange that meets the head and inlet manifold to sit nicely and get a good seal? Would it be hard to duplicate? Would you do it any different?

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Re: Anth's Coal grenade

Post by anths » Wed 03 Jun, 2015 8:19 am

Im a fitter and turner by trade,
I have a small equipped shop at home with Milling machine and lathe , I enjoying the change of pace working on the diesel ,as usually it's turbo /supercharged petrol engines Im throwing spanners at , it is also a little house keeping, using excess bits and bob's kicking about and the need to add more power to catch up to the flow of modern traffic.

To duplicate will depend on your skills and equipment ,It's a custom manifold fabricated by myself to suit my needs, you need to think about the requirement In my case I have 3" mandrel exhaust ,dump pipe,that needs to clear the starter motor and cables, alternator , steering box, transmission lines, powersteering lines, heater hoses , crossmember and the inner guard ,there was no other way for me to do it........There is but that another project !

Good luck Cheers Anthony

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Re: Anth's Coal grenade

Post by timtams » Wed 03 Jun, 2015 10:54 am

It's funny because I'm actually doing it for the same reasons... I've built many cars but this is the first diesel I've done a turbo conversion on.

In regards to the exhaust flange would you be interested in doing another for me and at what cost? Normally I would use the exhaust gasket and have the plates laser cut to suit and work from there but being of this design I thought it may work out that we can come to an arrangement. The pipe work and the rest I'm happy to do myself but it would emulate what you have done here. Even if it was the drawings and measurements you could part with that would definitely help.

I always tend to dive in the deep end and swim like crazy but maybe I don't need to this time lol

Cheers Graeme

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Re: Anth's Coal grenade

Post by anths » Thu 04 Jun, 2015 9:37 am

Don't worry about oil pressure dropping at idle. so long as it is over 1/2 Bar and rises quickly when the engine revs up, then all is OK. (very little load on wear surfaces at idle) Mine idles around 0.7 Bar and rises to 3Bar when the engine revs to 1kRPM.
Congratulations on making your 300D Turbodiesel
Tony[/quote]

G'day Tony, I still feel something isn't right with the oil pressure...Na the car was always good 2.5-3 , simply putting a turbo feed on shouldn't have altered it as much as im seeing , the hotter the engine get the bigger the issue, I replaced the oil which had 45 mins of service 10w-40 and replaced with penrite 20-60, it made vary little difference , so Im going to look at the oil filter next week and turbo feed,

re trace everything which was replaced during the conversion ,oil,filter,feeds ect.
when I tapped the sump I had the pan removed clean as a whistle, no crap white metal ect at all in it so the whole oil issue ahs me stumped ,

Cheers anthony

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Tony From West Oz
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Re: Anth's Coal grenade

Post by Tony From West Oz » Thu 04 Jun, 2015 10:18 pm

Anths,
The oil is running hotter, therefore it will be less viscous and result in a lower oil pressure.
When you rev it to 1000RPM is the pressure pegged at 3 Bar?
If so, then all is well.

Tony
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
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Re: Anth's Coal grenade

Post by anths » Thu 11 Jun, 2015 6:24 pm

Being on holidays gave me time to think about the "grenade" something has changed but what.......then it occurred to me since the Head gasket being replaced the car hasn't been driven on the highway, or has it..?
So it lead me to check the pump timing today and it was way off.....
Starts a lot easier and a lot less nailing , quick run around showed a lot more effort required to raise the water temp and oil pressure is back up......a short test on the highway and the temp was climbing to 90 less than before but I need to take it for a longer drive to confirm it will hold steady.
I certainly haven't cured the problem but a step in the right direction
Cheers Anthony

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Re: Anth's Coal grenade

Post by anths » Sat 27 Jun, 2015 10:24 am

Quick update surprising how this old girl accelerates 75kmhr the power is strong @ 11psi hitting 100kmh very fast. How can anyone go back to N/a is beyond me the car has become such a joy to drive .
Im in the process of upgrading the radiator and making a few changes ,will update with a few more photo's soon.

Cheers Anthony

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Re: Anth's Coal grenade

Post by timtams » Sat 27 Jun, 2015 11:53 am

Any chance you can get some more detailed pictures of the final setup as I want to start mine in the next few weeks. What did you do with the fuelling side of things?

A video of the action would be great :-)

Cheers Graeme

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Re: Anth's Coal grenade

Post by Mercmad » Sat 27 Jun, 2015 3:52 pm

your loss of oil pressure.. How do you feed the turbo? Mine is fed from the main oil gallery on the oil filter ,leading to the main bearings so I get an accurate oil pressure reading. I drop around one bar when hot (90) but normally the engine runs at 85 even in our heat.The only time you need to worry is when the guage reads below 1 at running speed. :pale:

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Re: Anth's Coal grenade

Post by anths » Tue 22 Sep, 2015 4:50 pm

Mercmad ,
my turbo is feed from the same place I made an adaptor to suit the feed,

It's been a while since I have updated the goal grenades progress , I have installed a new custom 3 core aluminium Radiator and external bar and plate transmission cooler, air filter was swapped out to another less restrictive type I had sitting around and gained 8psi in the top end and 3psi down low with this simple change.
Water meth is the next project to be sorted after I get a few more smaller bits and bods done on the car.
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Re: Anth's Coal grenade

Post by 3DB » Mon 02 Nov, 2015 9:48 pm

G'day Anth,

I've just finished reading through this thread and was wondering how the Coal Grenade is going several months on? Did you get the methanol injection fitted? What sort of EGT's did you end up with? Are you leaving everyone in clouds of black smoke at the lights?

Cheers,

3DB
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1976 W123 300D (weekend warrior on biodiesel)
1995 Holden Rodeo 2.8 factory turbo diesel ute (daily driver...also on biodiesel)
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Re: Anth's Coal grenade

Post by anths » Wed 04 Nov, 2015 4:00 pm

G'day all,
The grenade is going well ,it always blown smoke even when N/a I suspect the injectors are next on the list, Fuelling hasn't been touched , boost is 7psi @ 100kmh cruising with EGT around 300 deg before the turbo, under hard load with manual shifting the auto the EGT are no higher than 460 deg c ,Because the turbo is so large general driving only see 4-5 psi Egt around 280 Deg C
Water methanol will be fitted later in the week once the jets have arrived .
Temperature with the new 3 core radiator keeps everything in check

Cheers Anthony

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Re: Anth's Coal grenade

Post by anths » Fri 13 Nov, 2015 6:50 pm

Water meth has been installed and the Old Om617 is showing positive signs with it's addition will up the ratio of meth soon, system runs at 150psi with a 5ltr tank and pump mounted in the boot ,adjustable pressure switch mounted under the dash. Turbo Compressor Housing has been tapped to suit the systems Meth jet's and can be swapped for larger or small sized nozzles depending on fuelling and boost.
I need to tidy up some wiring in the boot and then give this old girl a general tidy up too !
Cheers Anthony
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Re: Anth's Coal grenade

Post by 3DB » Tue 17 Nov, 2015 6:02 pm

All looks great. Those EGTs sound very reasonable too. You should be able to wind the fuel right up now (smoke notwithstanding). Apologies if I missed it somewhere, but what water / methanol kit did you use? Or did you pull components together yourself?

I recently wound the fuel up on my factory turbo diesel ute and get EGTs of up to 600C pulling up long hills - I often have to back off on the way up to the Central Coast as I'd probably get to 700C or more if I kept on the loud pedal. Around town it never gets above 380C though. I wound the fuel up until the smoke was getting a bit much, then pulled back slightly. I left the factory wastgate attached to keep temperatures reasonable at 13 PSI. I'm keen to fit a water/methanol infection kit now too to see if I can wind the boost up a bit. At present torque has increased by 66% and most of it is below 2500 RPM.

I guess smoke off-boost will be an issue for you with the factory diesel pump?

I want a Coal Grenade now! :dance:
3DB
1976 W123 300D (weekend warrior on biodiesel)
1995 Holden Rodeo 2.8 factory turbo diesel ute (daily driver...also on biodiesel)
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Re: Anth's Coal grenade

Post by anths » Wed 25 Nov, 2015 1:08 pm

Have been running racing methanol in the grenade for few weeks, due to transmission problems I have dropped the ratio along with jets and boost, to try and save the clutches, we have also bought another car so the grenade will no longer be needed as much.
I NEED to build a spare engine as this old girl has over 600,000 on it and I can expect it to keep going without a freshen up with the power it's making......
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Re: Anth's Coal grenade

Post by 3DB » Mon 30 Nov, 2015 9:02 pm

Would a manual gearbox handle the power and torque better than the auto? I understand these are comparatively rare and would require some setting up as an auto conversion.

For those of us interested in a project like this that don't have Anth's fitting skills or the $$ for a custom exhaust manifold, would it be a viable prospect to try to source a factory turbo exhaust manifold from a wrecking yard in the US and have it shipped over? Maybe a rebuilt factory turbo injector pump too with the boost variable fuel delivery? Would these items bolt straight up to our NA 617's? An aftermarket turbo should be easy enough to source here, as would all of the intake bits.

It would be nice to have all of the other factory turbo goodies like piston squirters and sodium valves and I looked briefly into importing an entire engine and its seems like you can pick one up from a wrecker (minus manifolds and turbo....a 'long block') for as little ad US$800, but it would be a pretty big gamble and you still need the manifolds. Also its about AU$750 to have it shipped over here.

....but a just a manifold and injector pump to adapt to an AU vehicle?

https://www.youtube.com/watch?v=EnucllbO3Zk
3DB
1976 W123 300D (weekend warrior on biodiesel)
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Re: Anth's Coal grenade

Post by anths » Tue 01 Dec, 2015 4:45 pm

your over thinking it....why would you bother importing one....?

That was the whole idea of this build/thread..... every keyboard mechanic told me the engine wouldn't last ......rubbish 7 -10 psi these engines will be fine provided your EGT are low all day everyday.

How many Nissan and Toyota diesels have been converted from N/a to turbo without any issues plenty , why would a Mercedes om617 diesel be any different..?

I will have to research the gearbox options further.

Cheers anthony

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