W202 OM606 GT2359v+Pro52
W202 OM606 GT2359v+Pro52
Hi STD people.
This is my car, 1994 c220d. I bought it three years ago and since then I have been reading this forum. First I looked for w201 but most of them were rusted, then I found one slightly wrecked w202. Previous owner was taxi company, some extra holes in dashboard and leaking antenna on the roof but underneath it was in pretty good shape. Last year I finally managed to swap the engines and it is running at the moment.
Specs at the moment:
*Engine - OM606.962, stock from W210
*Turbo - Holset HX40
*Gearbox - 722.6 from w211 320cdi
*Pump - mechanical 7.5mm 180cc Dieselmeken with Bosch 044
*Gearbox controller from olefejer
*3" Simons Exhaust
Donor car was 1998 E300td, with 460k km but engine was running perfectly. It was so rusted that I even couldn't use propshaft.
It's pre-facelift, so it came with 722.4. All parts from 2.2d are ridiculously tiny so I also changed propshaft, differential and driveshafts. Front brakes have solid disks, not even air ventilated, I did't know MB even had those.
First I used 604 mounting arms but there was no room for cooling fan, then I changed to 606 arms and now it fits perfectly. Gearbox mounting bracket is modified, propshaft is from w210 and shortened, diff is from w124 and driveshafts are from w210 and shortened.
606 arm on left and 604 arm on right
Propshafts, you can see the differences.
Longer power steering hoses
w210 300td 2.87, W124 3.07 ASD which I use at the moment and tiny 2.2d 3.27
Some new parts
Avantgarde springs from w210
New nozzles
3" exhaust and HX35 super, turbo is sold for now because it was too small.
Cooler 2.5" hoses are from local truck parts store.
First I used gearbox from 300td but 4th and 5th gear started to slip, so I bought 2005 w211 320cdi gearbox and swapped the bellhousing. And yes, I6 320cdi engine has different housing, it was surprise to me also, 220cdi and 270cdi is the same as 606.
3" exhaust finished, tried different zink based coating paints.
And some smaller modifications, like little pipe in cylinder head, ordered 604 one from mb dealer.
606 has long pipe with rubber sealing
And 604 pipe pressed in.
And it goes in. Exhaust and inlet manifolds were stock, just made the flange to fit bigger turbo to genuine manifold.
Latest purchase was gearbox controller from olefejer.
Fantastic work and great pictures!
Thanks, I have some videos also.
First I tried to take max from stock engine, only changes were dieselmeken pump and boost raised to 2 bar, genuine turbo.
https://www.youtube.com/watch?v=_AAr5asdowk
Here I have HX35 Super with stock manofolds, 2,5bar boost. At that moment 4th and 5th gear slipped so it wasn't possible to accelerate with full throttle over 120kmh.
https://www.youtube.com/watch?v=p-uggNTOaa0
And dyno, same HX35 Super with little 8cm housing, 375hp/280kw, 650nm @ 2,5bar
https://www.youtube.com/watch?v=GuXz2MLn5yU
And just some black smoke.
https://www.youtube.com/watch?v=tbU-gSPFiIo
Awesome mate. I love it
w202 with om606 is my next daily
Great pictures...
Is your gearbox still slipping? maybe a few more clutch discs would solve the problem. Also do u have EDC pump or mechanical? Because I read somewhere that is better to cut off fueling when changing gears, and with mechanical pump that wouldn't be possible unless u release the pedal.
(02-02-2015, 02:54 AM)raidaru Is your gearbox still slipping? maybe a few more clutch discs would solve the problem. Also do u have EDC pump or mechanical? Because I read somewhere that is better to cut off fueling when changing gears, and with mechanical pump that wouldn't be possible unless u release the pedal.Not anymore, 300td gearbox was slipping, now 320cdi gearbox is holding fine. Pump is mechanical.
(02-02-2015, 02:54 AM)raidaru Is your gearbox still slipping? maybe a few more clutch discs would solve the problem. Also do u have EDC pump or mechanical? Because I read somewhere that is better to cut off fueling when changing gears, and with mechanical pump that wouldn't be possible unless u release the pedal.Not anymore, 300td gearbox was slipping, now 320cdi gearbox is holding fine. Pump is mechanical.
Just thinking out loud - Modifying the gearbox mounts and shortening the propshaft was the only way to do it instead of moving the radiator and interooler forward by cutting down the front crossmember??
How was the gearbox modified, just drill new holes for the bolts going up into the bodyshell/
Beers, H.
In front of the engine every inch counts, ofcourse you can move the radiator forward but I also needed room for bigger cooler and it fits tight even now. 604 and 606 mounts give movement about 2,5cm. As I said mine was 2,2d and it doesn't matter which mounts I would use, propshaft should be shortened anyway because 722.6 from 300td have bigger and stronger flexidisk and it needs propshaft from 300td which is about 14cm longer.
One possible way to do it might be using 300td front part of propshaft and c250td rear part of propshaft because I had to shorten rear part. If the center connection is same, then it will be straight fit. Then front flexidisk and gearbox triple flange should be changed to 300td one.
I cut gearbox bracket to peaces and welded back together, nothing special.
W202+OM606 is a great combo.
How much did you have backpressure on HX35 @ 2,5bar boost? What about stock[/quote] turbo?
Just thinking out loud, for that power and small turbine the boost is unnecessarily high, I had similar power on my ex 606 with only 1,7bar boost..
(02-02-2015, 05:28 AM)muuris W202+OM606 is a great combo.Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.
How much did you have backpressure on HX35 @ 2,5bar boost? What about stock turbo?
Just thinking out loud, for that power and small turbine the boost is unnecessarily high, I had similar power on my ex 606 with only 1,7bar boost..
(02-02-2015, 05:28 AM)muuris W202+OM606 is a great combo.Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.
How much did you have backpressure on HX35 @ 2,5bar boost? What about stock turbo?
Just thinking out loud, for that power and small turbine the boost is unnecessarily high, I had similar power on my ex 606 with only 1,7bar boost..
Awsome project. Is the exhaust custom made by you or can I go and buy a system somewhere? Id like a 3 or 4" exhaust for my project
(02-02-2015, 07:17 AM)Insane190d Awsome project. Is the exhaust custom made by you or can I go and buy a system somewhere? Id like a 3 or 4" exhaust for my project
I see. Well UK C250TD comes with 722.6 anyway so gearbox & prop can remain the same if everything can move forward with crossmember cut out.
Why not improve wategate-ing to reduce back press?
(02-02-2015, 05:45 AM)erx Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.Yeah, I measured at worst 2,3bar backpressure on completely stock OM605 (boost 1,2 bar) so you can only imagine.. But actually I expected a lot more backpressure with HX35 super. Running around 1,8 bar boost the backpressure should be ok.
Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.
(02-02-2015, 08:24 AM)Hario Why not improve wategate-ing to reduce back press?Enlarging wastegate has only little effect on backpressure and exhaust flow. It's like curing the symptoms, not the illness itself.
(02-02-2015, 05:45 AM)erx Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.Yeah, I measured at worst 2,3bar backpressure on completely stock OM605 (boost 1,2 bar) so you can only imagine.. But actually I expected a lot more backpressure with HX35 super. Running around 1,8 bar boost the backpressure should be ok.
Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.
(02-02-2015, 08:24 AM)Hario Why not improve wategate-ing to reduce back press?Enlarging wastegate has only little effect on backpressure and exhaust flow. It's like curing the symptoms, not the illness itself.
(02-02-2015, 01:19 PM)muurisI was wrong, looked a video from summer and with 2,0bar boost backpressure was 2,9bar, so with 2,5bar boost it was higher. But you didn't try with genuine manifold? You can't compare with stock manifold, it is so small inside, it causes that high backpressure, also little 8cm housing. Stock manifold and small housing is definitely not good combo for 606 STD.(02-02-2015, 05:45 AM)erx Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.Yeah, I measured at worst 2,3bar backpressure on completely stock OM605 (boost 1,2 bar) so you can only imagine.. But actually I expected a lot more backpressure with HX35 super. Running around 1,8 bar boost the backpressure should be ok.
Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.
(02-02-2015, 08:24 AM)Hario Why not improve wategate-ing to reduce back press?Enlarging wastegate has only little effect on backpressure and exhaust flow. It's like curing the symptoms, not the illness itself.
I had ~380ish horses dynoed with two different self-made manifold, two different turbos (GT37xxV and He351Ve) and two different wastegates. The wastegate was the last upgrade of those, and didn't help with high backpressures/choked exhaust flow. Compressors would have been good for more on both turbos. Then changed the turbo and backpressures dropped around 50%
(02-02-2015, 01:19 PM)muurisI was wrong, looked a video from summer and with 2,0bar boost backpressure was 2,9bar, so with 2,5bar boost it was higher. But you didn't try with genuine manifold? You can't compare with stock manifold, it is so small inside, it causes that high backpressure, also little 8cm housing. Stock manifold and small housing is definitely not good combo for 606 STD.(02-02-2015, 05:45 AM)erx Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.Yeah, I measured at worst 2,3bar backpressure on completely stock OM605 (boost 1,2 bar) so you can only imagine.. But actually I expected a lot more backpressure with HX35 super. Running around 1,8 bar boost the backpressure should be ok.
Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.
(02-02-2015, 08:24 AM)Hario Why not improve wategate-ing to reduce back press?Enlarging wastegate has only little effect on backpressure and exhaust flow. It's like curing the symptoms, not the illness itself.
I had ~380ish horses dynoed with two different self-made manifold, two different turbos (GT37xxV and He351Ve) and two different wastegates. The wastegate was the last upgrade of those, and didn't help with high backpressures/choked exhaust flow. Compressors would have been good for more on both turbos. Then changed the turbo and backpressures dropped around 50%
It must be the W211 bellhousing thats different. A W210 320CDI box should be the same correct?
Loving the build so far!
It sounds pretty quiet from the videos with just that one muffler, how loud is it in person? I still haven't decided what to do after the downpipe.
(02-02-2015, 09:20 PM)Mr_Robs It must be the W211 bellhousing thats different. A W210 320CDI box should be the same correct?
Loving the build so far!
It sounds pretty quiet from the videos with just that one muffler, how loud is it in person? I still haven't decided what to do after the downpipe.
(02-02-2015, 09:20 PM)Mr_Robs It must be the W211 bellhousing thats different. A W210 320CDI box should be the same correct?
Loving the build so far!
It sounds pretty quiet from the videos with just that one muffler, how loud is it in person? I still haven't decided what to do after the downpipe.
(02-03-2015, 02:53 AM)erx W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.
It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through.
(02-03-2015, 02:53 AM)erx W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.
It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through.
(02-03-2015, 08:40 AM)Mr_RobsI'm not sure, so they made whole new engine block for w211? I don't want to belive it. V6 came with new box. My box is from 2005 car but on box there was '04. Code is 722.626 which is the same as w210 uses.(02-03-2015, 02:53 AM)erx W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.
It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through.
Yea, they both have the straight six in the 210 and 211 but i think they made changes when the 211 came out. Any chance you know what year car your box came from?
Haha thats awesome . Good to know, i will plan for just one muffler near the back
(02-03-2015, 08:40 AM)Mr_RobsI'm not sure, so they made whole new engine block for w211? I don't want to belive it. V6 came with new box. My box is from 2005 car but on box there was '04. Code is 722.626 which is the same as w210 uses.(02-03-2015, 02:53 AM)erx W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.
It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through.
Yea, they both have the straight six in the 210 and 211 but i think they made changes when the 211 came out. Any chance you know what year car your box came from?
Haha thats awesome . Good to know, i will plan for just one muffler near the back
Hmm i doubt the block is different but is it possible the bellhousing aligns differently? Like the propshafts are different length and the shifter is mounted in a different position? Thats the only explanation i can think of.
On this chart i was looking at there are two listed E320 CDI
#1 is Model 211.022 Engine 642.920 Gearbox 722.902
#2 is Model 211.026 Engine 648.961 Gearbox 722.626
The E220cdi and E270cdi gearboxes are listed as 722.640
(02-04-2015, 02:13 AM)Mr_Robs Hmm i doubt the block is different but is it possible the bellhousing aligns differently? Like the propshafts are different length and the shifter is mounted in a different position? Thats the only explanation i can think of.
On this chart i was looking at there are two listed E320 CDI
#1 is Model 211.022 Engine 642.920 Gearbox 722.902
#2 is Model 211.026 Engine 648.961 Gearbox 722.626
The E220cdi and E270cdi gearboxes are listed as 722.640
(02-04-2015, 02:13 AM)Mr_Robs Hmm i doubt the block is different but is it possible the bellhousing aligns differently? Like the propshafts are different length and the shifter is mounted in a different position? Thats the only explanation i can think of.
On this chart i was looking at there are two listed E320 CDI
#1 is Model 211.022 Engine 642.920 Gearbox 722.902
#2 is Model 211.026 Engine 648.961 Gearbox 722.626
The E220cdi and E270cdi gearboxes are listed as 722.640
Sorry i should have clarified more what i was trying to explain. Yea totally agree there is one V6 and one inline 6, but does the W210 (not listed in my post) have a gearbox code of 722.640 like the 220/270 boxes? Maybe thats why the W211 722.626 from an inline engine doesnt fit?
(02-04-2015, 05:08 PM)Mr_Robs Sorry i should have clarified more what i was trying to explain. Yea totally agree there is one V6 and one inline 6, but does the W210 (not listed in my post) have a gearbox code of 722.640 like the 220/270 boxes? Maybe thats why the W211 722.626 from an inline engine doesnt fit?
(02-04-2015, 05:08 PM)Mr_Robs Sorry i should have clarified more what i was trying to explain. Yea totally agree there is one V6 and one inline 6, but does the W210 (not listed in my post) have a gearbox code of 722.640 like the 220/270 boxes? Maybe thats why the W211 722.626 from an inline engine doesnt fit?
I know for a fact that there is a change in bellhousing and the 220cdi/20cdi and 320cdi are more or less the same engine. What would be good to know is EXACTLY what year they changed this. Me and Mr_Robs have decided that 2001 is a safe year and that's by looking at pictures and that the w211 came in 2002. However it would be good to know more hands on.
With that said. It doesn't matter if it's a 270cdi gearbox or a 320cdi gearbox. Wrong year and it don't fit anyhow.
I was going off of this PDF i found, but this only has information for W211 models.
(02-04-2015, 06:19 PM)Mr_Robs I was going off of this PDF i found, but this only has information for W211 models.
Not arguing at all here with what you found im just trying to find out the strongest gearbox solution for all of us without needing to swap bell housings
(02-04-2015, 06:19 PM)Mr_Robs I was going off of this PDF i found, but this only has information for W211 models.
Not arguing at all here with what you found im just trying to find out the strongest gearbox solution for all of us without needing to swap bell housings
(02-02-2015, 05:32 PM)erx But you didn't try with genuine manifold? You can't compare with stock manifold, it is so small inside, it causes that high backpressure, also little 8cm housing. Stock manifold and small housing is definitely not good combo for 606 STD.
(02-02-2015, 05:32 PM)erx But you didn't try with genuine manifold? You can't compare with stock manifold, it is so small inside, it causes that high backpressure, also little 8cm housing. Stock manifold and small housing is definitely not good combo for 606 STD.
(02-15-2015, 12:36 PM)INC Hice build. Can You post some pictures from low pressure fuel system setup 044 and FPR ?
(02-15-2015, 12:36 PM)INC Hice build. Can You post some pictures from low pressure fuel system setup 044 and FPR ?
Nice.
But I have to say that 044 is needed only if IP has bigger elements, with stock IP it doesn't give any advantage.
Even this way when it's circulating under the bonnet it makes little pressure to return line so all connections and hoses should be sealed tight, first some little return lines between injectors leaked but after I replaced them it's working fine.
(02-19-2015, 08:21 AM)erx Nice.
But I have to say that 044 is needed only if IP has bigger elements, with stock IP it doesn't give any advantage.
Even this way when it's circulating under the bonnet it makes little pressure to return line so all connections and hoses should be sealed tight, first some little return lines between injectors leaked but after I replaced them it's working fine.
(02-19-2015, 08:21 AM)erx Nice.
But I have to say that 044 is needed only if IP has bigger elements, with stock IP it doesn't give any advantage.
Even this way when it's circulating under the bonnet it makes little pressure to return line so all connections and hoses should be sealed tight, first some little return lines between injectors leaked but after I replaced them it's working fine.
Can I ask how you picked up road wheel speed for the 722 controller, was it a hall effect sensor on the propshaft bolts?
Looks really sleeper!
Thanks.
(03-04-2015, 11:11 AM)Hario Can I ask how you picked up road wheel speed for the 722 controller, was it a hall effect sensor on the propshaft bolts?
Looks really sleeper!
Thanks.
(03-04-2015, 11:11 AM)Hario Can I ask how you picked up road wheel speed for the 722 controller, was it a hall effect sensor on the propshaft bolts?
Looks really sleeper!
Thanks.
(04-01-2015, 03:28 PM)jegesmesh Eesti poistele jätad pooled asjad rääkimata/näitamata
(04-01-2015, 03:28 PM)jegesmesh Eesti poistele jätad pooled asjad rääkimata/näitamata
Hey erx, did you manage to fit the original cooling fan between the radiator and water pump??
I need about 10mm more clearance. Did you cut the heatlight mounts to allow the transmission cooler fittings onthe radiator end tank to move forward more? Thanks!"
(04-15-2015, 07:09 AM)Hario Hey erx, did you manage to fit the original cooling fan between the radiator and water pump??
I need about 10mm more clearance. Did you cut the heatlight mounts to allow the transmission cooler fittings onthe radiator end tank to move forward more? Thanks!"
(04-15-2015, 07:09 AM)Hario Hey erx, did you manage to fit the original cooling fan between the radiator and water pump??
I need about 10mm more clearance. Did you cut the heatlight mounts to allow the transmission cooler fittings onthe radiator end tank to move forward more? Thanks!"
(03-31-2015, 02:50 AM)Booster Nice progress on the manifold/car, but my god that has got to be the biggest cone filter I have ever seen! Where is it going to fit? Keep up the great work'
(03-31-2015, 02:50 AM)Booster Nice progress on the manifold/car, but my god that has got to be the biggest cone filter I have ever seen! Where is it going to fit? Keep up the great work'