ForcedInduction's 1982 300D - Mercedes Forum - Mercedes Benz Enthusiast Forums


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Old 12-17-2010, 06:02 AM
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Lightbulb ForcedInduction's 1982 300D



1982 300D
WDBAB33A0CB008823

USA model
Exterior color code 623- Light Ivory
Interior color code 134- Date MBTex
Engine- OM617.952 (Overhauled 2015/10/04)
Fuel: Stock injection pump adjusted for maximum fueling, DN0SD240/ nozzles set to 140bar
Transmission- 716.210 4-speed manual, Sachs Performance modified clutch (2017/04)
Turbocharger- Holset HE221W (2012/01/15) with a 3-stage mechanical boost controller (2009/07/28), 14.5psi boost
Intake- Modified W115 300D manifold
Air to Water intercooler (2009/09/16), Bosch 0 392 022 002 water pump (2012/04/22) and "Type 117" radiator (2012/04/22)
Air filtration- Fram 8037
Exhaust- Stock with resonator and muffler removed (2009/08/23)
Injection- MW-Pump adjusted to maximum, 240/ injector nozzles set to 140bar (2016/12/09)
Engine Oil- Mobil1 15W-50 synthetic
Filtration- Stock oil filter, Amsoil Ea-BP90 bypass oil filter (2012/04/28), Baldwin BF7591-D (2-micron) secondary fuel filter (2009/04/05)
Cooling- 1-7/8" thick (vs 1-1/4" stock) all-metal radiator (2012/02/01), 1.4bar cap, 6" water pump pulley (2009/07/13), electric fan (2016/10/07)
Brakes- W126 Gen-II 300mm vented front brakes (2010/01/11), slotted rotors (2017/04/22)
2-stage Water/Methanol injection, 1x70cc and 1x300cc nozzles (2010/07/17)
Truck-Lite 27270C LED headlights (2015/05/23)
All LED lighting (2015/12/23)
AL129X 115 amp alternator
Galant front seats
HVAC systems and heater box removed (2009/04/07)
Manual sunroof conversion (2009/04/07)
Battery relocated to the trunk (2009/04/19)
Custom oil cooler hoses based on the 1976 300D (2009/06/30)
Webasto auxiliary heater (2014/10/09)
Viair 380C air compressor, 3 gallon air tank, dual air horns (2015/04/18)

Weight (after weight reduction)
Front: 1940lbs (1740 2009/08/23)
Rear: 1480lbs (1560 2009/08/23)
Total: 3420lbs (3300 2009/08/23)
Balance: 57:43 (53:47)

1/4 mile- [email protected] (2010/08/07)
Dyno- 120hp, 200lb/ft at the rear wheels (2010/07/31)
Dyno- 130hp, 202lb/ft at the rear wheels (2011/08/06)
Dyno- 147hp, 220lb/ft at the rear wheels (2012/08/05)

Engine bay 2015/03/14

Last edited by ForcedInduction; 04-25-2017 at 10:49 PM.
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Old 05-09-2011, 08:27 PM
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Total adjustments for my euro non-turbo M-Pump so far.
Full Load- 6 CCW
Idle, Coarse- 6-1/4 CCW
Max RPM- 3/4 CW
Torque Control- Zero
Idle stabilizer- 2 CCW

I'm waiting to get the Hybrid GT2356V turbo finished, then I will do a dyno run.
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Old 08-08-2011, 04:14 PM
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Old 02-02-2012, 08:56 PM
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New radiator.

The stock core thickness is 1-1/2" while the new is 1-7/8". The new one also has a copper core with brass soldered-on end tanks instead of crimped on plastic tanks.


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Old 04-22-2012, 06:05 PM
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An update to my air-water intercooler system.

I replaced the Bosch heater booster pump with a Bosch 0 392 022 002 intercooler water pump. Its the same Mercedes and Ford use on their water intercoolers.
I replaced the converted stock A/C condenser-radiator with a modified "Type 117" radiator.

The plumbing is vastly improved too. The engine's cooling system is basically stock (except for the radiator, fan pulley and fan) but the expansion tank level sensor port has been tapped for a 3/8 NPT fitting.
The intercooler system is now a semi-closed circuit rather than both systems being somewhat tied together. There is a 1/4" hose between the two systems from the top of the intercooler to the expansion tank. This allows the expansion tank to work for both systems but active flow between the two systems is prevented.

Simple and effective.
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ForcedInduction's 1982 300D-hoses.jpg   ForcedInduction's 1982 300D-rad.jpg  

Last edited by ForcedInduction; 04-22-2012 at 06:10 PM.
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Old 11-29-2012, 03:26 PM
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what exactly did you do with the crank case vent atop the valve cover? A mercedes mechanic says he just runs a line from valve cover to the back so it shoots out by the tail pipe, but I dont like this route as it would make a nasty stain where i park & unnecessarily waste my synthetic oil
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Old 11-29-2012, 03:40 PM
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Its vented straight to the ground. The device on top is a crankcase depression regulator from a VW, it just works as a handy oil separator to reduce vapor.

Routing the pipe to the back is a bad idea. It will have long length of tube and low points where oil can pool, both will cause high crankcase pressure.

I route it to atmosphere to prevent the oil vapor from fouling my intercooler and oozing out the silicone tubes.
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Old 10-09-2014, 03:03 PM
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Since I sold my 240D, which was my winter car, I have installed the Webasto and a Maradyne heater heater!
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ForcedInduction's 1982 300D-dscn2214-webasto.jpg   ForcedInduction's 1982 300D-dscn2222-heater.jpg  
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Old 10-09-2014, 10:14 PM
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Do you have an inter cooler thread in MF or elsewhere?
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Old 10-10-2014, 07:17 AM
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Not really since the initial installation was around the time the fruit-forum and STD-positive forum children started acting up, but I can give you pictures if you like. Beyond the initial installation, most of the work was finding the right circulation pump, radiator and cooling system arrangement.


The cooler is a generic "Type 19". Its PLENTY big for an engine this size and could actually stand to be half as big and still cool well.

I tried using a stock MB heater booster pump but its flow is far too low. I currently use a Bosch pump (p/n 0 392 022 002) that is common to most turbo/supercharged cars/pickups on the market for the last 15 years (Ford and Mercedes especially). Not cheap, but well worth it. Great flow, magnetic drive so there is no shaft seal to leak, quiet and less than 5 amps draw.

The radiator is a generic "Type 117". I tried converting the A/C condenser but it is too restrictive to water flow without using a positive displacement pump (like a marine coolant pump, do not use bilge pumps!). I tried various transmission and hydraulic coolers (both plate and tube tpyes) but they either cooled poorly or had restrictive hose fittings.

The IC water system is always-on, ambient temperature and semi-integrated into the engine coolant system. The cooling circuits are isolated from each other in that no circulation occurs between them. Only a single vent line plumbed into the surge tank where the level sensor would be on later cars is what connects them. This allows the IC system to expand/contract without needing its own pressure cap or surge tank and the engine cooling system hydraulically pressurizes the IC system to prevent boiling or cavitation.
Water flow direction is from the air outlet to the inlet. Total IC water system capacity is a shade over 1 gallon.
Filling is done through removing an upper tube and purging is done by overfilling the engine surge tank, installing a cooling system pressure tester and opening a ventcock on the top intercooler fitting.

Even after a hard run the intake manifold is cool enough to hold, the water outlet line is warm and the water inlet line is nearly ambient.
No electric fan is needed since the engine driven fan is always moving some air at idle.
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Last edited by ForcedInduction; 10-10-2014 at 07:21 AM.
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14, 1982, 1982300d, 300d, air, filter, forced, forcedinduction, fram, fuel, induction, mercedes, mercedesbenz, mile, om617952, pump, weight

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