mygreen300d kirjoitti:
Rebuild cost /difficulty?
Well, it's not cheap. I suggest you ask US prices for parts from mercedesshop.com forum. All the engine internals in Super Turbos are stock MB parts, so no need to locate aftermarket parts to your engine. Just replace worn parts with new stuff.
Turbo upgrade size?
Holset HX 40 is the most common.
Intercooler shape/size and where to mount?
Bigger is better, front mounted air to air IC is the way to go.
http://img.photobucket.com/albums/v296/ ... /keula.jpg
See Mauri H.'s cooler, notice how it goes all the way up to the uppermost fin of radiator grille.
Position of air cleaner?(I know the stock box would be too restrictive, and Ive seen 'em with cone filters)
See pic from konjamiini's car (notice also the IC which is about the same size as Mauri H.'s.)
http://img78.photobucket.com/albums/v29 ... c00130.jpg
I plan on custom exhaust, how big of downpipe and the rest of it?
4" / 3,5" is fine. You also need new exh manifold. See pics from the link (scroll all the way down for exhaust pipe pics).
http://mersuforum.net/forum/viewtopic.php?t=9396
What will I have to do to fuel delivary system?
Remove your injection pump and send it to Mynä-Diesel here in Finland, then install it back to your car when it arrives back to you.
The pumping elements (barrels and plungers) are enlargened from 5,5mm -> 7mm. Also some fiddling with governors etc etc. The fueling amount can be adjusted from outside of the pump. How exactly these modifications are made is not public information, sorry.
I have toyed with the idea of a propane injection setup, but I dont know how to inject it on a diesel like this. I know people have em on their newer diesel pickups. comments on that?
Nobody has propane injection here in Finland. Partly because it's illegal in street use. Why use it anyway if there is a way for enough power using only regular diesel fuel.
I know they made 5speed manuals in europe for these cars, how hard is it to install one on my car?(im not a big fan of auto trannies)
Will my stock rear-end hold up with this beast when Im done?
Some of the Finnish Super Turbos are with auto trans, some with manuals. Original 300 turbodiesel was not offered with manual even here in Europe. There are obvious problems with clutch slipping with almost all of the manual transmission users when using full torque of their Super Turbos (over 500 lbs-ft). AFAIK nobody's found a real cure for this yet (except decreasing the fueling amount of injection pump and thus lowering max torque of the engine). Usage of 2-plate cluthes have been discussed, but they're not very streetable.
Auto trans needs also some strengthening, or it will start to slip. If you want to have boost right from the start, then the torque converter has to be modified for higher stall speed. So far nobody's been able to break a strengthened auto trans.
The differential and half-shafts are quite strong and hold up. Note however that if you don't have limited slip diff and you do one wheel burnouts you have good possibilities to explode your diff. Pic about konjamiini's diff after not-so-succesful burnout
http://img.photobucket.com/albums/v296/ ... c00318.jpg
When buying the car to upgrade it, make sure it is original turbodiesel model. The engine internals, transmission etc (ie. all the critical parts) are stronger than in naturally aspirated 300D.