Hi guys,

I have posted a few photos of my project here in different treads.
But here I will post all my photos of my high hp OM606 build.
The engine started out as an .910 engine with a stock 5.5mm M pump, and some tweaking was done too it along the way.
The car I started with was an MB w201 2.0D 4-speed 1993 mod.

I drove it a while with the stock Om606.910 engine, it worked very well, but 136hp wasn`t enough
I fitted an Eaton m90 compressor and tuned the stock 5.5mm pump to max, and got out around 170ish hp (dyno papers will come)

This worked very well, and drove with this mod for almost 6monts!
But 170+hp wasn`t enough

So I bought an shorblock OM606.962 from Erling66 on this forum. This engine had 2 badly bent rods, and 1 minor bent rod. So i bought 6 H-profile rods from Sten Parner Motor form sweden. All gaskets, pistonrings+++ was bought. So lets get on with the pictures

Pictures from the first build:

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The setup now is turbo+compressor, and a 7.5mm M-Pump built by Dieselmeken.
Pictures from current build

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Who said turbocharging was easy????

N/A vs Custom turbo manifold

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All pistons, rods where weight balanced to +-0.05grams
Piston rings was also gapped to right measurment.

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Custom flywheel made from a stock om604 motor, with an 6 puck sinterdisk and Sachs racing Bmw e34 preassure plate.








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Main-bearing girdle was made...

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In these days the head is ported! A lot can be done to the channels, speacily the exhaust side
Pictures will come
Stay tuned

Very impressive! Whats that bent rod from?

looks like allot of fun, congrats, and keep up the fun build.

(12-25-2011, 10:55 PM)willbhere4u Wrote: Very impressive! Whats that bent rod from?

Waterlock

make sure you take some good videos of it running

Sten Parner rods with 28mm upper bush

Great thread...great pics...keep it rolling

(12-26-2011, 12:19 PM)jeemu Wrote: Sten Parner rods with 28mm upper bush

Turbo pistons requires 28mm pin yes They was pretty thin in the top! Do you have any bad experience with them?

Hmmm, looks like it is going to be tough for me to get the strongest 606 in Southern Norway But that is cool
Why did you weld the back side of your flywheel?
and what turbo is that?

(12-27-2011, 01:33 PM)erling66 Wrote: Hmmm, looks like it is going to be tough for me to get the strongest 606 in Southern Norway But that is cool
Why did you weld the back side of your flywheel?
and what turbo is that?

Haha, who knows Erling...Time will show!
I had to weld the startertooths to the flywheel bacuase I had to take away so much material, that the startertooths would fall off if haden`t
The turbo is a T70 super, similar to Garrett T-61.. I have a bigger turbo as well, but hope this will do for now

A buddy of mine ran his 606 with hx40 (19ccm turbine) and a 3" downpipe.. that created too much backpressure.. he only got 2,2bars manifoil pressure.. another buddie of mine ran his 603 with 0,5mm smaller pump elements, a little smaller turbine, and 4" downpipe and exhaust, and got 3,5+ bars...
You might concider building a bigger DP... i got myself 2m of straight 4", and 2 mandrel bendt 90's for christmas it turned out to be a beatiful peice of metal in the end, and will help my 605 sing beautiful serenades

Hope those rods hold up. Piston+pin is wery heavy
On my 605 i had 2.7-3.2bar boost and back pressure with 3.5" DP was 1.8-2.2bar

(12-27-2011, 11:47 PM)bad3gakk Wrote: A buddy of mine ran his 606 with hx40 (19ccm turbine) and a 3" downpipe.. that created too much backpressure.. he only got 2,2bars manifoil pressure.. another buddie of mine ran his 603 with 0,5mm smaller pump elements, a little smaller turbine, and 4" downpipe and exhaust, and got 3,5+ bars...
You might concider building a bigger DP... i got myself 2m of straight 4", and 2 mandrel bendt 90's for christmas it turned out to be a beatiful peice of metal in the end, and will help my 605 sing beautiful serenades

Sounds nice, how many hp did you buddy`s OM606 make?
It is plenty room for a bigger DP But i will meausure backpreassure first...

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(12-28-2011, 05:30 AM)jeemu Wrote: Hope those rods hold up. Piston+pin is wery heavy
On my 605 i had 2.7-3.2bar boost and back pressure with 3.5" DP was 1.8-2.2bar

I was a bit afraid for that to happen...The piston are way more heavier than the N/A piston But the rod are strong the other way, so we have to see if it holds together... If it breaks, then I will buy some new stock rods!

Hello,
Silly question but, did u balance the camshaft? cause i did not understood why u weigh piston and rods. other question can´t u guys find steel crown piston´s for these engines? i also want to do some changes of the inside but, thing is camshaft balance is difficult around here, so as some inside custom parts.
regards

(12-28-2011, 07:27 AM)barrote Wrote: Hello,
Silly question but, did u balance the camshaft? cause i did not understood why u weigh piston and rods. other question can´t u guys find steel crown piston´s for these engines? i also want to do some changes of the inside but, thing is camshaft balance is difficult around here, so as some inside custom parts.
regards

I guess you meen crankshaft? I have not balanced it, only the flywheel. I wheight-balanced the pistons and rods because There was a big difference in weight...

yep i meant crankshaft . according to papers there´s no reason to balance crankshaft to rod/piston dynamic forces, unless u want to gain real RPM, and engine smoothness (alias better rev performance) but since u did it outside, don't think it would have too much deterioration vibrations.
i´m curios about the pistons, how can u prevent them from melting? taking account u guys use stock ones?

If original pistons melt you have done something really wrong

(12-28-2011, 02:52 PM)jeemu Wrote: If original pistons melt you have done something really wrong

Haha! So true Jeemu They seems to be very tough

I have ported the head these days, and this is just a test how the exhaust would look like

What about the space between the 2 exhaust ports
My guess is that it creates turbulence and reduced flow. But I have not seen anyone build a manifold with metal to fill the space so maybe it is not a big deal?

Exhaust side be careful, not now remember but there is weak spot on one channel. You can see it at there is ääh how i say, not know word.
Tunnel go side that exhaust channel. Taht can be port thru there.

(12-29-2011, 05:56 AM)jeemu Wrote: Exhaust side be careful, not now remember but there is weak spot on one channel. You can see it at there is ääh how i say, not know word.
Tunnel go side that exhaust channel. Taht can be port thru there.

Thank you jeemu, i`ve just ported on cyl Will be carefull on the other, snd look for thin spots

The head has been ported now, resurfaced and cleaned







A new and longer belt was fitted, and the routing has also been altered...A servopump has also been fitted!



Clutchplate is an 6-puck 240mm without center.

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The block turned out really good With new H-profile rods and a maingirdle for the mainbearings...I have also fitted a 4 layer mls headgasket
The motor runs really nice now and i have driven it many miles now!
Took it out on a ice race this weekend, everything worked like a treat

First start up video It smokes alot because we couldn`t glow all the glowplugs!


Here is some video from the track

Can I ask where you got that clutch puck from?

I Like

(01-18-2012, 04:02 PM)HughF_UK Wrote: Can I ask where you got that clutch puck from?

I Like

http://shop.klracing.se/sv/artiklar/kopp...index.html

Great to see that the Mighty 190 is running again and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms

(01-19-2012, 09:24 AM)erling66 Wrote: Great to see that the Mighty 190 is running again and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms

It was a good block and pistons Erling! I had to have servo on the ice track, it was to hard to steer fast

(01-19-2012, 01:54 PM)EDH_Performance Wrote:

(01-19-2012, 09:24 AM)erling66 Wrote: Great to see that the Mighty 190 is running again and that the engine (I sold you) works fine. But don't you know that power steering is for chickens? Real men have power arms

It was a good block and pistons Erling! I had to have servo on the ice track, it was to hard to steer fast

I know, I am just having fun
You are a fast worker, I am surprised to see the car running already. What's next, install the turbo, intercooler and get a pump with bigger elements? Tomniks 7,5mm or Myna?

The custom manifold and turbo is good to go!
I dont trust the germans or the finnish HAHA...So Gøran aka Dieselmeken is building one for me= 7.5mm elements and lightened gouvenor!
I will fit the header, turbo and intercooler very soon...Mr Eaton is very noisy, so the intercooler+gate will help him be a bit more quiet

Intercooler has been fitted aswell as a big oilcooler:








All was painted black for Ultra Stealth Look

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The valve that is going to bypass the Compressor is made:

Now the turbo is mounted, and all works very good! Fantastic sound and
the car is awsome to drive!

Intercooler and pipes:





Turbo and header:








Now is it just up to Gøran aka Dieselmeken, to supply me with some go-go juice!!!!!!!!!!!!!!!

I like :-)

But you should maybe use some beefier boost hose clamps....

(01-29-2012, 02:22 PM)majesty78 Wrote: I like :-)

But you should maybe use some beefier boost hose clamps....

If they pop off I will Haven`t happend yet.. I have acsess to some really beefy clamps, but they are more expensive than those i have now

Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?

(01-30-2012, 08:51 AM)Booster Wrote: Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

Hi,

I have some more photos of it, if you want to see?
But I made the collector along the way, just started with two runners and mended the others into them. And after that I welded some inside and ported the collector to a smooth finish
The turbo flange made I myself, the Head flange comes from klracing.se.

The power goal is high, I have seen 614hp on stock engines(upgraded valvesprings). And as I also will fit special high duration cams and stiff springs, who knows? I WANT BIG POWER

I will also get my hands on a BMW 330D/530D transmission, these can handle almost 1000nm (does the BMW guys say)

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(01-30-2012, 10:45 AM)Rub87 Wrote: Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?

Haha, agree! I looks better with the headcover on
No, I haven`t made the inlet in the intake for it yet! But I will do that as soon as i get the 7.5mm pump I dont want to take the intake off two times

Maybe one small remark about the plenum. the big planar top surface welded at the corner under 90° will be prone to crakcing because the big surface will vibrate, and then at the 90° edge the weld will start crack from the inside.. I found out the hard way.. its better to bend the 90° on the plate and then weld in a planar section, this way the weld is only loaded on tension.. or you can also weld some studs in the big flat plate to prevent it from flexing

offcourse I see you used some thick aluminum, which also helps.. I used 3mm, but was only running around 1.7 bar, static tested with 6 bar was no problem, but the pulsation inside the plenum made it fail over time

(01-30-2012, 11:26 AM)Rub87 Wrote: Maybe one small remark about the plenum. the big planar top surface welded at the corner under 90° will be prone to crakcing because the big surface will vibrate, and then at the 90° edge the weld will start crack from the inside.. I found out the hard way.. its better to bend the 90° on the plate and then weld in a planar section, this way the weld is only loaded on tension.. or you can also weld some studs in the big flat plate to prevent it from flexing

offcourse I see you used some thick aluminum, which also helps.. I used 3mm, but was only running around 1.7 bar, static tested with 6 bar was no problem, but the pulsation inside the plenum made it fail over time

I see, let`s hope it won`t crack! But it is 10mm alu, so it is pretty strong!

(01-30-2012, 11:13 AM)EDH_Performance Wrote:

(01-30-2012, 08:51 AM)Booster Wrote: Nice build! Do you have any more details on your exhaust manifold? Images of how you made the collector on the turbo flange etc? also the flange on the head side? whats your end power goal? cheers!

Hi,

I have some more photos of it, if you want to see?
But I made the collector along the way, just started with two runners and mended the others into them. And after that I welded some inside and ported the collector to a smooth finish
The turbo flange made I myself, the Head flange comes from klracing.se.

The power goal is high, I have seen 614hp on stock engines(upgraded valvesprings). And as I also will fit special high duration cams and stiff springs, who knows? I WANT BIG POWER

I will also get my hands on a BMW 330D/530D transmission, these can handle almost 1000nm (does the BMW guys say)

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(01-30-2012, 10:45 AM)Rub87 Wrote: Should have come like that from Stuttgart, looking very nice.. do you use the gate after the intercooler to bypass mr Eaton once the turbo is spooled?

Haha, agree! I looks better with the headcover on
No, I haven`t made the inlet in the intake for it yet! But I will do that as soon as i get the 7.5mm pump I dont want to take the intake off two times

Yes please I would love to see as many as possible...

cheers

This is current setup, with the small 5.5mm elements maxed out!

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Yes please I would love to see as many as possible...

cheers

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Here you go mister

I am very impressed with your fast progress, maybe there is nothing else to do in Arendal in the winter than working?
So tell us, how does the engine feel? old engine with Eaton vs new engine with Eaton vs new engine with Eaton and turbo?

Manifold looks good, what have you done about wastegate?

(01-30-2012, 01:36 PM)erling66 Wrote: I am very impressed with your fast progress, maybe there is nothing else to do in Arendal in the winter than working?
So tell us, how does the engine feel? old engine with Eaton vs new engine with Eaton vs new engine with Eaton and turbo?

Old engine vs Mr. Eaton: Very good, powerful engine with N/A characteristics. No "turbo" lag....Had 0.2 bar on idle and 0.9 at around 3000 and up. It was a bit smokey (blue) on cold starts and idle. A bit ruff at idle when cold. And the engine was a bit "choky" at the top of the rpm. It is a good "cheap" way to do it...Stick a Eaton m90 or turbo, and tune the stock 5.5mm pump, and you get around 170-180hp. The car uses around 0.7ltr/10km on higway driving

New engine vs Mr. Eaton: Same as above, but no smoke at coldstarts, smooth idle. A bit more powerful on the top end (the porting helped!)

New engine vs Turbo+Mr. Eaton: Way more power on higher rpm! The intake preassure comes much faster! The exhaust sound is completly different, much better So i can`t wait to get my 7.5mm elements!!!!

awesome stuff , well done ...!!

wish I wasnt away for so long... cant see any of the pics due to bandwidth limitations. If Mr. EDH will send them to me I'll see if I can host them on my domain.

(02-09-2012, 07:45 PM)SurfRodder Wrote: wish I wasnt away for so long... cant see any of the pics due to bandwidth limitations. If Mr. EDH will send them to me I'll see if I can host them on my domain.

It isn`t your bandwith thats wrong, it`s my photobucket account that is full, and I need to pay them more money I will fix it soon, so stay tuned

Dieselmeken pump with large elements is soon on it`s way guys!

Took the turbo off and installed my exhaust temp sensor, just between the ports.


Eksos sonden ligger akkurat imellom begge kanalene rett før impeller.



And some fitting for 4mm coppertubes for exhaust preassure

Now is everything ready for the new pump

EDH Performance pump has left the building. ( also some nice stickers will come with the receipt from Dieselmeken AB )

(02-14-2012, 12:24 PM)dieselmeken Wrote: EDH Performance pump has left the building. ( also some nice stickers will come with the receipt from Dieselmeken AB )

I like it

Since my photobucket is out of order, i can`t oppload any pictures yet.
But many things have been done
A BMW E39 530D manual gearbox has been fitted, and finally the gears holds
The turbo pressure is just 1.9bars and exhaust pressure is 1.8 bar, so still looking good! It smokes a bit still, so more boost is needed...But this is very easy to change

Did some test her the othe day: