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Author Topic: T3 VW and Mercedes Hybrid Turbocharger  (Read 9973 times)

October 10, 2009, 02:07:35 am

Chestrockwell

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T3 VW and Mercedes Hybrid Turbocharger
« on: October 10, 2009, 02:07:35 am »
My AAZ has a 1.6 T3 turbo and 1.6 manifold. Giles pump, G60 IC. It ate it's 2nd turbine wheel last week and I don't have any more VW ones so I looked at one of the OM 617 sitting in the shop and they have T3's as well. So I pulled a merc turbo and pulled it apart and it turns out that with a little machining and some grinding I was able to put the merc turbine shaft in the vw housing and merc compressor in the vw housing.

The performance gain is unreal! With the straight VW T3 it would maybe get up to 26psi and the egt would peg to 1400 quick. Now it wraps my 30psi gage waaaaay sooner in the revs probably going to 38psi. The EGT stays below 1300.

The merc compressor housing could have been used in place of the vw one, but the outlet is a bit smaller so I machined the vw one to fit the merc wheel.




On the outside they are the same. I might put the merc on one after opening up the outlet a bit.



The vw hot side housing is smaller port and bore than the merc so I had to open it up. Ended up using lots of layout dye, a cone stone, and a die grinder to get the required clearance. The bores aren't perfect but it doesn't seem to affect much on this.






It also looks like the merc downpipe connection is the same bolt pattern as the vw one. If you had a rect. pattern t3 manifold the merc turbo would be easy to fit with maybe just a little mods to the downpipe.


Assembled hybrid turbo






Also changed is the exhaust; it was 2" to the back now it's 2 1/2" from the turbo to the front wheel no muffler. It sounds sick and I'm sure the cops will love it. Ya I know it looks ricer. It works that's all I really care about. The exhaust was changed and run before the modified turbo was put together. The gains from the modded turbo are observed without any other mods.




Oh ya and I know; it's going to eat T3 bearings and it'll go through trannys ever more too I'm sure. This turbo core has 60000km on new bearings done at the same time as the engine upgrades and bearings are still good.

Also, I attached a 90deg JIC connector to the oil line because the factory vw taper fitting blows goats... and oil.

« Last Edit: November 05, 2012, 03:52:46 am by Chestrockwell »
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Reply #1October 10, 2009, 02:36:23 am

rabbitman

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #1 on: October 10, 2009, 02:36:23 am »
Good job on the turbo. :o

So is you exhaust loud? Like can you have a conversation while cruising at 65mph without yelling? :D.
Looks cool, I've never heard of dumping the exhaust in front of the front wheel.

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Reply #2October 10, 2009, 03:09:09 am

FoXBoXRaCiNG

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #2 on: October 10, 2009, 03:09:09 am »
That's deadly! That exhaust is intimidating :D
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Reply #3October 10, 2009, 10:39:52 am

Chestrockwell

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #3 on: October 10, 2009, 10:39:52 am »
Yes it's fine inside the car can have a conversation no problem. It's a bit louder outside though even at idle.

It's great because the exhaust is mounted to the engine only; not connected to the body at all so the cab is nice and quiet.
« Last Edit: October 10, 2009, 10:41:38 am by Chestrockwell »
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Reply #4October 10, 2009, 01:27:38 pm

Baron VonZeppelin

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #4 on: October 10, 2009, 01:27:38 pm »
What year range/series/engine size does that MB turbo used on ? I'd like to hunt one or two.
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Reply #5October 10, 2009, 01:40:33 pm

truckinwagen

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #5 on: October 10, 2009, 01:40:33 pm »
definitely not a legal exhaust because it exits the car forward of the passenger compartment.
but technically side exits on passenger cars are illegal too.

depends how the cops in your area are, I have been contemplating a hood stack, but don't want to ask for trouble.
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Reply #6October 10, 2009, 03:01:59 pm

rallydiesel

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #6 on: October 10, 2009, 03:01:59 pm »
Interesting. Want to build me one?  ;D
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Reply #7October 10, 2009, 05:48:35 pm

rallydiesel

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #7 on: October 10, 2009, 05:48:35 pm »
Would you need both cores?
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2006 Jetta TDI - gtb1749v, Malone 2, Frank's Titan 2 cam, VR6 clutch....
1991 Jetta TD - sold :(
2001 Golf TDI - Son's
1981 Rabbit - BEW tdi swap project

"ONCE YOU GO CLACK, YOU NEVER GO BACK"
Reply #8October 11, 2009, 12:10:46 pm

Rabbit on Roids

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #8 on: October 11, 2009, 12:10:46 pm »
Quote from: truckinwagen on October 10, 2009, 01:40:33 pm
definitely not a legal exhaust because it exits the car forward of the passenger compartment.
but technically side exits on passenger cars are illegal too.

depends how the cops in your area are, I have been contemplating a hood stack, but don't want to ask for trouble.

hood stack FTW!
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Reply #9October 12, 2009, 02:09:01 pm

truckinwagen

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #9 on: October 12, 2009, 02:09:01 pm »
yeah, but the exhaust is supposed to exit rearward of the passenger compartment, making anything other than out the rear(like the stock exhaust) illegal on cars(pickups can get away with side exit)

being a professional driver, I cant afford to be getting tickets, so I probably wont risk it.
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Reply #10October 12, 2009, 04:53:47 pm

Chestrockwell

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #10 on: October 12, 2009, 04:53:47 pm »
Here's a vid. 1st to 5th. 30psi in 2nd gear. Max 130kph. Before I would be lucky to get to 25psi by 3rd gear. 30 is the last # on my gage. EGT peaks @ 1300.

http://s7.photobucket.com/albums/y254/ccotter_671/Jett/?action=view&current=P1010186.flv
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Reply #11October 12, 2009, 05:14:54 pm

RabbitJockey

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #11 on: October 12, 2009, 05:14:54 pm »
how fast do u end up going
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Reply #12October 12, 2009, 08:26:17 pm

Chestrockwell

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #12 on: October 12, 2009, 08:26:17 pm »
Let off @ 130kph
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Reply #13October 13, 2009, 05:32:20 pm

87octane

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #13 on: October 13, 2009, 05:32:20 pm »
what was the improvement in low rpm boost start? originally starting boosting when and now it starts boosting what rpm?
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Reply #14October 14, 2009, 01:02:14 am

Chestrockwell

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Re: T3 VW and Mercedes Hybrid Turbocharger
« Reply #14 on: October 14, 2009, 01:02:14 am »
Originally I would be lucky to get 8psi in 1st. Now it hits 20 and then 30 in 2nd. I will have to look next time I drive to see what rpm. Look at the video you might be able to make out what it is. The gage is 0-30 in increments of 5psi.
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