I getting ready to install a 603.960 into a 95 E300d and would like any advise. I believe I am going to go with a air to water I/C so that I can still have A/C. It looks like I can plumb the intercooler off of the area that the egr valve assembly was.
I have copied the link for injection pump mods so I am going to do these while the engine is out.
I am debating the cost effectiveness of a bigger exhaust also. Some seem to think that the stock piping is ok. I must admit that I have not checked the size of the non turbo exhaust yet.
This car will be a daily driver and my goal right know is to improve the efficiency of the engine. Power,mileage, and drive ability.
thanks ahead for the input Mike

What happened to the original OM606? I'm not sure I understand your comment about plumbing the IC into the EGR port. How will you be rigging up the throttle and transmission shift linkages?

The original has 250k plus miles and broke the vacuum pump and timer.
The 603 and 606 are both cable operated throttle and I am using the 603 transmission that has the same basic transmission as the 606 which is cable operated t/v cable.
If you look at the 603 with a turbo there is an adapter pipe that the egr hooks into. So basically the outlet of the turbo is approx 8-10 inches away from the inlet of the crossover pipe. The 617 has the outlet dump into the intake directly from the turbo.

I'd be interested if you're getting rid of parts off the 606... Particularly the injection pump...:)

I'd be interested if you're getting rid of parts off the 606... Particularly the injection pump...:)

A 95 is going to have the same 5.5mm plungers as the 617 and 60x engines. Only the 98-99 used 6mm.

I have measured the exhaust and it is 2.25 in. any thoughts on it being large enough or should I budget for larger?
I will lose the oxidation catalyst that the 95 has and it looks like the 95 uses a small flow through type front resonator instead of a front muffler.
Has anyone intercooled a 603 yet? I find links about water injection instead of IC. Are the water to air IC on ebay reliable? any experience out there?

The original has 250k plus miles and broke the vacuum pump and timer.
The 603 and 606 are both cable operated throttle and I am using the 603 transmission that has the same basic transmission as the 606 which is cable operated t/v cable.
If you look at the 603 with a turbo there is an adapter pipe that the egr hooks into. So basically the outlet of the turbo is approx 8-10 inches away from the inlet of the crossover pipe. The 617 has the outlet dump into the intake directly from the turbo.

Interesting, apparently the '95 W124 606 has a cable throttle, but the later W210 chassis were all drive-by-wire. Nonetheless, you'll probably have to locate the throttle configuration from an '87 300D/TD, or fab your own.

It sounds like you just want to plumb the IC into the crossover, sans EGR section. Note, it's difficult to attach hoses to the factory turbos found on the early 603 engines, as they have the ARV which gets in the way. The plumbing gets mighty tight if you want to utilize the crossover, so most folks just opt to run with a front mount IC, then plumbed the inlet over to the opposite side of the intake manifold.

I find links about water injection instead of IC. Are the water to air IC on ebay reliable? any experience out there?

Very reliable...

I know of people that solely use water/meth injection and do so without incident.

I am gonna stop in on Friday...so we can discuss :D

Very reliable...

I know of people that solely use water/meth injection and do so without incident.

I am gonna stop in on Friday...so we can discuss :D

I think he meant air to water intercoolers.

As for water injection, there have been some failures in using them as a substitute to intercoolers. For that mater I haven't found a success story where water injection was used in our idi engines as a supplement to intercoolers to lower egts.

For that mater I haven't found a success story where water injection was used in our idi engines as a supplement to intercoolers to lower egts.

I'd consider my run a moderate success. 2hp gain but no noticeable EGT reduction.

but no noticeable EGT reduction.

That's what I'm after and so far I haven't found someone successful in reducing egts.

2hp?? A good stripe kit is worth more than that!!

Any hp improvement wihout increased smoke and EGT is a success IMO.

I'd consider my run a moderate success. 2hp gain but no noticeable EGT reduction.