T3 VW and Mercedes Hybrid Turbocharger - page 1 - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• T3 VW and Mercedes Hybrid Turbocharger by Chestrockwell on 09 Oct, 2009 23:07
• 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.
  
  
• #1 by rabbitman on 09 Oct, 2009 23:36
• Good job on the turbo.
  
  So is you exhaust loud? Like can you have a conversation while cruising at 65mph without yelling? .
  Looks cool, I've never heard of dumping the exhaust in front of the front wheel.
  
  
• #2 by FoXBoXRaCiNG on 10 Oct, 2009 00:09
• That's deadly! That exhaust is intimidating
• #3 by Chestrockwell on 10 Oct, 2009 07:39
• 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.
• #4 by Baron VonZeppelin on 10 Oct, 2009 10:27
• What year range/series/engine size does that MB turbo used on ? I'd like to hunt one or two.
• #5 by truckinwagen on 10 Oct, 2009 10:40
• 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.
• #6 by rallydiesel on 10 Oct, 2009 12:01
• Interesting. Want to build me one? 
• #7 by rallydiesel on 10 Oct, 2009 14:48
• Would you need both cores?
• #8 by Rabbit on Roids on 11 Oct, 2009 09:10
• Quote from: truckinwagen on 10 Oct, 2009 10:40

  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!
• #9 by truckinwagen on 12 Oct, 2009 11:09
• 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.
• #10 by Chestrockwell on 12 Oct, 2009 13:53
• 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
• #11 by RabbitJockey on 12 Oct, 2009 14:14
• how fast do u end up going
• #12 by Chestrockwell on 12 Oct, 2009 17:26
• Let off @ 130kph
• #13 by 87octane on 13 Oct, 2009 14:32
• what was the improvement in low rpm boost start? originally starting boosting when and now it starts boosting what rpm?
• #14 by Chestrockwell on 13 Oct, 2009 22:02
• 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.