Right now I'm waiting on the intake manifold from Europe that has no swirl flaps ( the part number for that is
A6130900737 )

What application used the manifold without swirl flaps?

 

I think its the 0m613

 

some vans... I have OM613 in my W220, it does have flaps. EPC gives part number above to my ex. W211, only that it had flaps too.

 

Before you try to improve MB design, consider that the ca 50 engineers did the design for a reason. It might have some side effects, like gunk accumulation, but flaps help in engine performance.
For this year Liqui Moly makes intake cleaner, who in easy job should eliminate the problem where is started, so some might try to go this way.
https://www.napaonline.com will find you
Part # : AIC LM20208 what is the cleaner , although NAPA is screwing around with its availability. Call your local NAPA and ask them to order it.
Raise the hell if they don't.

 

Since the intake manifold is taking me about 15 days to deliver, and since my car is down I will be upgrading intercooler !

 

Actual dimensions of the e320 cdi intercooler om648
36 inch from pipe to pipe

 

Barefoot on greasy concrete slab?
Observe the job safety

 

Lmaoooo i was using flips flops lol haha not osha approved

 

was your intercooler full of oil?

 

Not as much actually, maybe a line of oil but not as much!

 

Update on the progress I made on the car, I decided to buy a intercooler which is 27.5 inches long 8.5 inches high and 3 inch thick! It fits perfect! You actually have 1-2 inches of clearance so for the height I think you can fit a 10 inch high intercooler no problem!
For the couplers I’ve gone and bought the high quality couplers from Vibrant Performance so those suckers wont blow out! Vibrant Performance Reinforced Silicone Elbows 2782

 

Update on the progress I made on the car, I decided to buy a intercooler which is 27.5 inches long 8.5 inches high and 3 inch thick! It fits perfect! You actually have 1-2 inches of clearance so for the height I think you can fit a 10 inch high intercooler no problem!
For the couplers I’ve gone and bought the high quality couplers from Vibrant Performance so those suckers wont blow out! Vibrant Performance Reinforced Silicone Elbows 2782 View attachment 2635169 View attachment 2635170

Hi, what intercooler brand is this?
Regards, Mke

 

I had to move the intercooler about 1-2 inches on the left sides from the center as it was touching but it seems very nice!

 

Was able to cut a plate to block the egr port and also welded turbo silencer shut and where the egr goes, in case i need to bring the car to stock look I’ll do this 🤣

 

Thank you for documenting all of this. There are likely several other OM648 owners out there who will really appreciate this, going forward.

 

That’s why I’m doing it! Because others don’t have to suffer to research like I did

 

While I was there 😅, i did a 5 minute motor mount swap since the motor mount is easily accessible. Follow my cdi progress on ig @one_slow_cdi

 

Interested in the build... I have a 2005 E320 CDI and I was wondering with all of these upgrades and deleting, how much of it will it improve the car? Any computer coding needed since more air will be traveling more freely?

 

Yes, the car will need a ecu tune for egr delete since I want it to pass inspection. I’m gonna get the car tuned from marcin, he will be tuning my car for more power. He said Intercooler upgrade, Swirl flap delete, egr delete, turbo silencer delete will upgrade the power from 201 to 270-280 which is awesome 😎.

 

Who is Marcin? I'm not familiar with him, though it sounds like he's a professional modder.

 

He did the tuning for Alex at LegitStreetCars. He's on the w211 tuning facebook group.

 

Took out the silencer from passenger side where it’s mounted to the turbo.


Taking the bolts out is pretty easy!(it probably took me 10-15 minutes) But trying to take out the turbo silencer from the tight engine bay from the bottom took me 30-40 minutes. The only way I was able to take it out was from the gap close to the radiator and close to the alternator.
I guess there is a lot of restriction because of the stupid thing that’s inside. Broke a little bit of the plastic inside for better airflow. I tried taking the 4 bolts holding the thing together and maybe try to install the silencer while is inside the engine bay but since the rubber gasket needs to be installed from the inside part that wouldn’t work so I had to put it back in one piece. Then I had to put the silencer back the same way which also took me about 20 minutes.
Overall I would’ve changed the engine mounts faster than taking out silencer 😞

 

Took out the silencer from passenger side where it’s mounted to the turbo.


Taking the bolts out is pretty easy!(it probably took me 10-15 minutes) But trying to take out the turbo silencer from the tight engine bay from the bottom took me 30-40 minutes. The only way I was able to take it out was from the gap close to the radiator and close to the alternator.
I guess there is a lot of restriction because of the stupid thing that’s inside. Broke a little bit of the plastic inside for better airflow. I tried taking the 4 bolts holding the thing together and maybe try to install the silencer while is inside the engine bay but since the rubber gasket needs to be installed from the inside part that wouldn’t work so I had to put it back in one piece. Then I had to put the silencer back the same way which also took me about 20 minutes.
Overall I would’ve changed the engine mounts faster than taking out silencer 😞
View attachment 2636440 View attachment 2636446 View attachment 2636447 View attachment 2636448

So what happened to the silencer? Did you install a different one or the same?

 

Hi Albab0y:
I would ask a question. To take out the intake manifold you detached various return fuel hoses.
When you re-asembled everythig, did you do something special to purge air from fuel system? or you simply reattached the hoses?
Was it easy to start the car after that?

 

You'll need to turn the key to position two and back off again a bunch of times to get the air out. You can hear it bubbling. Even after just doing injector seals it takes 3-4 cycles before it'll start right up. Otherwise it'll just crank until it times out.

 

For me it was easier to take the hoses out and leave the metal pipe connected with the manifold! Then take it out after I took out the intake manifold. Some of the hoses look pretty old and dry so i may change some hoses “while I was there 🤣”.
I miss my car and actually can’t wait for the part. I bought the manifold for 60$ (Which is way too cheap compared to the mercedes 1200$ quote ) but had to pay shipping +70$ 😞and it still isn’t coming fast

 

After waiting one almost 1 month usps lost my package, i decided to fix the old one and made plugs for the swirl flaps like this :

 

Keep up the good work, and thanks again for posting this adventure!

 

I had to weld the ear back because it was broken and resurfaced the intake manifold for no leaks! Big big important lesson is to drain coolant before you take out the bolts of the intake manifold! My car keeps smoking for a long time because it had went on the egr port ( which is connected to exhaust) when I took it off

 

Same silencer but gutted the inside of it!

 

Interesting! Any changes in the way the car drives now? I do have a 2005 and thinking in tackling this job. Already have a Rocketchip EGR delete tune(stage 1).
Also, since you have installed the new inter-cooler, have you noticed an increase in power as well?

 

Dude the turbo sounds like a dodge cummins, the whistling can be heard a mile away 😍😍. Well I jumped from stock to this so I don’t know how big of a difference a tune without intercooler is hehe. Car is way more powerful! I have some boost problems now but I have to fix a boost leak now! Boost leak is coming from this rubber gasket because I didn’t tighten it enough, it will be fixed no problem l but dude the turbo now is so much louder

 

Here is the video showing you guys how to take the manifold out.