Larger intercoolers for sprinters or the lack of

[SkySonner]

Got two sprinters, love them to bits, a 2004 311 and a 2014 316, both LWB, both remapped. I want to take one of them a little further in regards to power..... Normally on a turbo charged engine after a remap I would look at decat/dapfdelete and larger intercooler.

The 2014 van has had dpf removed now and the 2004 van has been decatted (helped in part by a thieving little st).

Upwards and onto larger intercoolers.... Can I find anything on them, I mean anything? No!

Is this because I am the only person that wants there van to go faster or is it because there is a different limiting factor to the performance side of sprinters, don't forget these things use the same engines as mercedes passenger cars, the current 220cdi is around 177bhp standard, my 316cdi is 163bhp standard, what's the difference between the engines, is it a bigger turbo? If not then how does the size of the c220cdi intercooler compare to the one In the sprinters? I bet it's smaller just to confuse the matter?

If anyone here has ever looked into turning there sprinter with more than just a remap I would love to know how you approached it and what the results where?

Lastly if anyone can find any info on uprated intercoolers for sprinters that would make my day

[V12 AMG]

The engine although very similar is different just about everywhere you look between van and passenger car.
Pistons, injectors, gaskets, inlet manifold. The list is pretty endless.

We have an engine from a W210 E class in our 2004 313cdi. The engine in the 210 was originally 150bhp. The van drives in a very different way now. I would be very interested to see the torque curve compared between the 2.
From driving, the van engines seem to have a peak and then no top end whatsoever whereas the passenger engines seem to rev more and have a wider spread of power.

There is someone in the Watford area which has apparently used the turbo, injectors and other pieces (possibly intercooler too) from an I6 320cdi OM613 engine to boost his sprinter up to over 200bhp. I have not seen the van myself, just heard through a reliable friend in the trade.

Obviously the new 250cdi is essentially the same lump with twin sequential turbos. I'm sure if you throw enough money at this problem there asre lots of potential solutions. Shame there is nothing off the shelf to help you out.

[SkySonner]

Thanks for taking the time to reply V12, the vans only Rev to 4000rpm, whereas the passengers car Rev higher, in regards to the dynamic profile of the engines, my older 2004 311 drives much like any other Dreiser, which mid range punch and not much top end. Whereas the 316 2014 seems to love to rev out right to the 4100rpm Rev limit, in fact it's very petrol-sque and the power builds nicely up to the limit.

Injectors are a bit of a no-no, they aren't cheap to buy or to fit. A larger turbo off a different engine might work but I would only get a second hand one on my budget. I would love to chase up the owner of the 200bhp sprinter, find out if he tried a larger intercooler or if that was the limiting factor.

Maybe I need to see what turns off other mercedes will fit the manifold on either of mine as a custom manifold would extra expense. I already tried to make my 316 lighter by ordering it Without a spare wheel, going very basic on spec and omitting options like air con. And deleting the side loading door which saved a whopping 43kilos on top of the 30kg saved by not having the spare tyre, toolkit and spare wheel mounting brackets. And rarely have more £20 in the tank when possible haha.