STD Other Projects G-wagen , om605 , 6mm , holset

G-wagen , om605 , 6mm , holset

G-wagen , om605 , 6mm , holset

 
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MrHope
GT2256V

112
12-28-2014, 06:14 PM #1
The old 300d (om617) with STT Turbo needs alot of service but if im going to put time and money into it so lets make it wort it.

Engine and gearbox from c250turbodiesel-97
Bigger turbo (will try a holset hx35 with smaller turbin)
Om602 ip with 6mm elements

   

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
12-28-2014, 06:14 PM #1

The old 300d (om617) with STT Turbo needs alot of service but if im going to put time and money into it so lets make it wort it.

Engine and gearbox from c250turbodiesel-97
Bigger turbo (will try a holset hx35 with smaller turbin)
Om602 ip with 6mm elements

   


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

CRD4x4
CompoundSuperTurboDiesel4x4!

399
12-28-2014, 06:29 PM #2
Sounds like a great plan to me!

What transmission are you using?

What's the reputation of the transfercase? Divorced or married?

I only drive a diesel Jeep because I can't find an affordable G-wagen. A LWB hardtop is my dream truck!

I'm looking forward to your progress!

'05 Jeep Liberty CRD - 160k
'06.5 VW Jetta TDI - 230k
'82 MB 300TD - 116k (motor going to raysorenson)
'81 MB 300TD - 195k (parting out)
'71 Jeep DJ5 - diesel conversion project
CRD4x4
12-28-2014, 06:29 PM #2

Sounds like a great plan to me!

What transmission are you using?

What's the reputation of the transfercase? Divorced or married?

I only drive a diesel Jeep because I can't find an affordable G-wagen. A LWB hardtop is my dream truck!

I'm looking forward to your progress!


'05 Jeep Liberty CRD - 160k
'06.5 VW Jetta TDI - 230k
'82 MB 300TD - 116k (motor going to raysorenson)
'81 MB 300TD - 195k (parting out)
'71 Jeep DJ5 - diesel conversion project

MrHope
GT2256V

112
12-29-2014, 03:48 AM #3
I will use the 717.460 5-speed gearbox from c250tdt, the transfercase is divorced with a short shaft inbetween.

I like the lwb to, my next project will be the lwb.

Did remove some stuff yesterday, next is to remove the ip.

[Image: om605utaninsug.jpg]
This post was last modified: 12-29-2014, 03:50 AM by MrHope.

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
12-29-2014, 03:48 AM #3

I will use the 717.460 5-speed gearbox from c250tdt, the transfercase is divorced with a short shaft inbetween.

I like the lwb to, my next project will be the lwb.

Did remove some stuff yesterday, next is to remove the ip.

[Image: om605utaninsug.jpg]


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
12-29-2014, 04:12 PM #4
Made some progress today...

but i didn´t have the workshop manual but im sure its something like this for securing the ip sprocket Angel
[Image: om605securesprocket.jpg]

And pump removed!
[Image: om605pumpremoved.jpg]

Electrical pump that is going to be robbed for 6mm elements.
[Image: om605elpump.jpg]

Alot of stuff im not gonna use...

only the alternator.

[Image: om605junk.jpg]
This post was last modified: 12-29-2014, 04:58 PM by MrHope.

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
12-29-2014, 04:12 PM #4

Made some progress today...

but i didn´t have the workshop manual but im sure its something like this for securing the ip sprocket Angel
[Image: om605securesprocket.jpg]

And pump removed!
[Image: om605pumpremoved.jpg]

Electrical pump that is going to be robbed for 6mm elements.
[Image: om605elpump.jpg]


Alot of stuff im not gonna use...

only the alternator.

[Image: om605junk.jpg]


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
12-31-2014, 01:15 PM #5
Santa came by!
[Image: hx35fender.jpg]

It´s a Holset HX35 specialbulit with a smaller garrett turbine.
And pretreaded 1/8" hole for tempsensor.
[Image: hx35.jpg]

But i will start with the original turbo and when its registered with the engine swap i will start fitting the holset.

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
12-31-2014, 01:15 PM #5

Santa came by!
[Image: hx35fender.jpg]

It´s a Holset HX35 specialbulit with a smaller garrett turbine.
And pretreaded 1/8" hole for tempsensor.
[Image: hx35.jpg]

But i will start with the original turbo and when its registered with the engine swap i will start fitting the holset.


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

bruno_pinho
GT2256V

166
12-31-2014, 02:03 PM #6
Ar63 garrett turbine?
bruno_pinho
12-31-2014, 02:03 PM #6

Ar63 garrett turbine?

muuris
OM605

318
01-01-2015, 05:27 AM #7
The turbo you've chosen is definitely not the best choice. 6mm elements are sensibly good for 230hp, so you'll only need 1bar boost. That's where the compressor is just getting in the sweet spot, so it will be operating at low efficiency all the time, making unnecessary heat and lag.. If the smaller turbine in the HX35 gives "too good" spool, it will also go easily into surge.

If you're going to stick with 6mm, I bet you'll swap for smaller turbo at some point Wink I'd recommend to stick with the turbo you've got and go for 7mm straight away. If 230hp is enough, it comes with less heat than with 6mm. If you'll find at some point that it's not enough, just turn the screw without opening the wallet again.

I'm also driving OM605 only because I couldn't find good enough and affordable G-wagen.. I have similar than HX35-sized BW/Schwitzer turbo and I swapped for smaller turbine too. Then added a supercharger. The low end spool is much more important in a 4x4 than what it is in a normal car, even if you never wheel it. I'd say use the smallest possible turbo that get's you to the power goal of yours.
muuris
01-01-2015, 05:27 AM #7

The turbo you've chosen is definitely not the best choice. 6mm elements are sensibly good for 230hp, so you'll only need 1bar boost. That's where the compressor is just getting in the sweet spot, so it will be operating at low efficiency all the time, making unnecessary heat and lag.. If the smaller turbine in the HX35 gives "too good" spool, it will also go easily into surge.

If you're going to stick with 6mm, I bet you'll swap for smaller turbo at some point Wink I'd recommend to stick with the turbo you've got and go for 7mm straight away. If 230hp is enough, it comes with less heat than with 6mm. If you'll find at some point that it's not enough, just turn the screw without opening the wallet again.

I'm also driving OM605 only because I couldn't find good enough and affordable G-wagen.. I have similar than HX35-sized BW/Schwitzer turbo and I swapped for smaller turbine too. Then added a supercharger. The low end spool is much more important in a 4x4 than what it is in a normal car, even if you never wheel it. I'd say use the smallest possible turbo that get's you to the power goal of yours.

MrHope
GT2256V

112
01-01-2015, 06:20 AM #8
Bruno: i dont remeber what size it was. Wink

Muuris:
I know its a bit to big for the 6mm, but have been looking for somthing inbetween the standard garrett turbo (whitch is werrrry small) and the hx35, i have more mercedes diesels so its not specially bought for the g-wagen project, but im new at this and i was willing to try it.

Do you have any sugestions on a bigger turbo that would do the job?
i have a garret turbo from a 300D STT kit and its alot bigger turbine than the standard garrett turbo originally fitted on the 605

Why does the 6mm produce more heat than the 7mm ?

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-01-2015, 06:20 AM #8

Bruno: i dont remeber what size it was. Wink

Muuris:
I know its a bit to big for the 6mm, but have been looking for somthing inbetween the standard garrett turbo (whitch is werrrry small) and the hx35, i have more mercedes diesels so its not specially bought for the g-wagen project, but im new at this and i was willing to try it.

Do you have any sugestions on a bigger turbo that would do the job?
i have a garret turbo from a 300D STT kit and its alot bigger turbine than the standard garrett turbo originally fitted on the 605

Why does the 6mm produce more heat than the 7mm ?


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

muuris
OM605

318
01-01-2015, 06:43 AM #9
Something like Garrett GT2260 -sized (60mm compressor exducer) would be good for 6mm, the turbine exducer being a bit bigger than compressor inducer.

The heat issue is related to injection duration. 7mm injects the same amount of fuel more quickly, it has more time to burn and will burn more efficiently. The same reason why 605 turbo engine has 6mm elements stock, whereas 602 turbo has 5,5mm. 150hp could be achieved with 5,5mm but it's less stress for engine with 6mm.
muuris
01-01-2015, 06:43 AM #9

Something like Garrett GT2260 -sized (60mm compressor exducer) would be good for 6mm, the turbine exducer being a bit bigger than compressor inducer.

The heat issue is related to injection duration. 7mm injects the same amount of fuel more quickly, it has more time to burn and will burn more efficiently. The same reason why 605 turbo engine has 6mm elements stock, whereas 602 turbo has 5,5mm. 150hp could be achieved with 5,5mm but it's less stress for engine with 6mm.

MrHope
GT2256V

112
01-01-2015, 04:32 PM #10
would the 606 turbo be a better choice? i dont think it looks that much bigger..?

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-01-2015, 04:32 PM #10

would the 606 turbo be a better choice? i dont think it looks that much bigger..?


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

muuris
OM605

318
01-02-2015, 03:23 AM #11
606 K14 turbine exducer and turbine housing are both very small so the turbo is good for only 200hp. But then again, not bad combo with 6mm elements on a G as low-end tq wouldn't suffer..
This post was last modified: 01-02-2015, 03:25 AM by muuris.
muuris
01-02-2015, 03:23 AM #11

606 K14 turbine exducer and turbine housing are both very small so the turbo is good for only 200hp. But then again, not bad combo with 6mm elements on a G as low-end tq wouldn't suffer..

MrHope
GT2256V

112
01-02-2015, 10:43 AM #12
Whats the next step up in turbo after k14? is there a bigger turbo that can handle 250hp?
does mercedes have how about the turbo from a 3,5L 603?

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-02-2015, 10:43 AM #12

Whats the next step up in turbo after k14? is there a bigger turbo that can handle 250hp?
does mercedes have how about the turbo from a 3,5L 603?


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

muuris
OM605

318
01-02-2015, 02:25 PM #13
3.5L 603 turbo isn't really a step up from normal 3.0 turbo. I'd choose a small modern turbo with basically as big turbine housing as possible, as it is small anyways, so it won't hurt spool-up too bad but will help taking it to the limit.

For constant 1 bar boost (PR 2.0) you need 10lbs/min at 2000rpm and 28lbs/min at 5500rpm with good efficiency. Take a look at the attachment, I roughly sketched those numbers for HX35 and GT2860R. You can see that HX35 is off the map until ~3200rpm and hits good efficiency at around 5000rpm. GT28 is on the map at 2200rpm and is on the sweet spot around 3500-5500.

IMO the poor low end of HX35 in this application just isn't justified as there are choices. The power target is moderate and you can build a nice setup with only one conventional turbo. If you were going to boost +2 bar, then the HX35 would be fine as the top end performance would give something back.

Haven't got time now to check but I believe T5 or T5R Volvo has a turbo of the desired "mid-size", although the turbine housing might be a bit small. Also worth checking is HE221W. Personally I'd try GT2359v from 320cdi, but mind you, vnt control needs attention and understanding.
Attached Files
Image(s)
   
muuris
01-02-2015, 02:25 PM #13

3.5L 603 turbo isn't really a step up from normal 3.0 turbo. I'd choose a small modern turbo with basically as big turbine housing as possible, as it is small anyways, so it won't hurt spool-up too bad but will help taking it to the limit.

For constant 1 bar boost (PR 2.0) you need 10lbs/min at 2000rpm and 28lbs/min at 5500rpm with good efficiency. Take a look at the attachment, I roughly sketched those numbers for HX35 and GT2860R. You can see that HX35 is off the map until ~3200rpm and hits good efficiency at around 5000rpm. GT28 is on the map at 2200rpm and is on the sweet spot around 3500-5500.

IMO the poor low end of HX35 in this application just isn't justified as there are choices. The power target is moderate and you can build a nice setup with only one conventional turbo. If you were going to boost +2 bar, then the HX35 would be fine as the top end performance would give something back.

Haven't got time now to check but I believe T5 or T5R Volvo has a turbo of the desired "mid-size", although the turbine housing might be a bit small. Also worth checking is HE221W. Personally I'd try GT2359v from 320cdi, but mind you, vnt control needs attention and understanding.

Attached Files
Image(s)
   

MrHope
GT2256V

112
01-03-2015, 06:27 AM #14
Okey! i will first of all get it running and regstered, then i will try out another turbo.

I have made som pregress to remove the old engine

car looks kind of silly without the front Big Grin

   

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-03-2015, 06:27 AM #14

Okey! i will first of all get it running and regstered, then i will try out another turbo.

I have made som pregress to remove the old engine

car looks kind of silly without the front Big Grin

   


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
01-04-2015, 04:00 PM #15
Did manage to spend a few hours on the g-wagen today!

Feels good to finish the day with removing the old engine!

[Image: om617out.jpg]



And i think i can make this work!
[Image: intercoolerbumper.jpg]
This post was last modified: 01-04-2015, 06:04 PM by MrHope.

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-04-2015, 04:00 PM #15

Did manage to spend a few hours on the g-wagen today!

Feels good to finish the day with removing the old engine!

[Image: om617out.jpg]



And i think i can make this work!
[Image: intercoolerbumper.jpg]


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

Petar
7.5mm M pump

459
01-04-2015, 04:09 PM #16
(01-04-2015, 04:00 PM)MrHope ....

And i think i can make this work!
http://www.lindbergz.com/uploaded/g605/i...bumper.jpg
Is that the stock W202 intercooler ? I didn't know they were that small. Its tiny !! Undecided

Shame on me as i have a W202 and i haven't seen the intercooler yet Shy
Petar
01-04-2015, 04:09 PM #16

(01-04-2015, 04:00 PM)MrHope ....

And i think i can make this work!
http://www.lindbergz.com/uploaded/g605/i...bumper.jpg
Is that the stock W202 intercooler ? I didn't know they were that small. Its tiny !! Undecided

Shame on me as i have a W202 and i haven't seen the intercooler yet Shy

MrHope
GT2256V

112
01-04-2015, 06:07 PM #17
(01-04-2015, 04:09 PM)Petar
(01-04-2015, 04:00 PM)MrHope ....

And i think i can make this work!
http://www.lindbergz.com/uploaded/g605/i...bumper.jpg
Is that the stock W202 intercooler ? I didn't know they were that small. Its tiny !! Undecided

Shame on me as i have a W202 and i haven't seen the intercooler yet Shy

yes, its small or is it the w463 400CDI bumper that is big =)

most standard ic has plastic housing but i like the all alu ones better!

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-04-2015, 06:07 PM #17

(01-04-2015, 04:09 PM)Petar
(01-04-2015, 04:00 PM)MrHope ....

And i think i can make this work!
http://www.lindbergz.com/uploaded/g605/i...bumper.jpg
Is that the stock W202 intercooler ? I didn't know they were that small. Its tiny !! Undecided

Shame on me as i have a W202 and i haven't seen the intercooler yet Shy

yes, its small or is it the w463 400CDI bumper that is big =)

most standard ic has plastic housing but i like the all alu ones better!


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
01-06-2015, 02:51 PM #18
Not the same caliber on w460 and w202 Big Grin
And w460 has the old style locking nut.

[Image: w460vs202flange.jpg]

My cousine made me a simple tool for the lock nut! Cool

[Image: 227349-2292571.jpg]


And had to testfit engine/gearbox, its gonna be a fight between the low mounted turbo and the engine mount.... wonder whos gonna win? Huh

[Image: om605testfit.jpg]

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-06-2015, 02:51 PM #18

Not the same caliber on w460 and w202 Big Grin
And w460 has the old style locking nut.

[Image: w460vs202flange.jpg]

My cousine made me a simple tool for the lock nut! Cool

[Image: 227349-2292571.jpg]


And had to testfit engine/gearbox, its gonna be a fight between the low mounted turbo and the engine mount.... wonder whos gonna win? Huh

[Image: om605testfit.jpg]


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
01-09-2015, 05:21 AM #19
The old garret t3 from the om617 with stt has alot bigger turbine than the newer c250td turbo.
[Image: garrettvsgarrett.jpg]


I had to remove the turbo for clearence... not sure if i will do some kind of adapter to relocate the turbo, or try to relocate the engine mount..
[Image: om605rightside.jpg]

Dont think the geatbox mount will cause any mayor problems... i has 8 diffrent positions to chose from Big Grin

[Image: w460gearboxmount.jpg]
This post was last modified: 01-09-2015, 05:24 AM by MrHope.

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-09-2015, 05:21 AM #19

The old garret t3 from the om617 with stt has alot bigger turbine than the newer c250td turbo.
[Image: garrettvsgarrett.jpg]


I had to remove the turbo for clearence... not sure if i will do some kind of adapter to relocate the turbo, or try to relocate the engine mount..
[Image: om605rightside.jpg]


Dont think the geatbox mount will cause any mayor problems... i has 8 diffrent positions to chose from Big Grin

[Image: w460gearboxmount.jpg]


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

tgg416
K26-2

38
01-10-2015, 05:14 AM #20
I also think a hx35 is way to slow to spool up in a Gwagen.
Dont know the 605 engine but in my 606 a hx30/35 is to late spooling up. The stock 606turbo was very nice in low rpm but got surge halfway. Now the hx30/35 was to big. Its really nice from about 25-2800 and up( I havent a rpm gauge) but on a Gwagen we need tourqe(?) at low rpm. Dont know yet what I will do, I startet a tread about superchargers but because on cost/noise it probobly be a compound.

I also been thinking alot of BD-Diesel diverter valve / spoolup valve.
Try google this, maybe this is something you also should think about ??

Gwagen 460, om606.962. 722.6 Ole Fejer controller++
Gwagen 463, shitty 603,,,,at the moment,,,
Gwagen 463, 270cdi
tgg416
01-10-2015, 05:14 AM #20

I also think a hx35 is way to slow to spool up in a Gwagen.
Dont know the 605 engine but in my 606 a hx30/35 is to late spooling up. The stock 606turbo was very nice in low rpm but got surge halfway. Now the hx30/35 was to big. Its really nice from about 25-2800 and up( I havent a rpm gauge) but on a Gwagen we need tourqe(?) at low rpm. Dont know yet what I will do, I startet a tread about superchargers but because on cost/noise it probobly be a compound.

I also been thinking alot of BD-Diesel diverter valve / spoolup valve.
Try google this, maybe this is something you also should think about ??


Gwagen 460, om606.962. 722.6 Ole Fejer controller++
Gwagen 463, shitty 603,,,,at the moment,,,
Gwagen 463, 270cdi

Hario'
C300TD Wagon (W202)

894
01-10-2015, 03:29 PM #21
'Quick spool valve' I think is what you mean.




Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
Hario'
01-10-2015, 03:29 PM #21

'Quick spool valve' I think is what you mean.





Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]

MrHope
GT2256V

112
01-10-2015, 04:12 PM #22
i rather try a compound turbo setup.. seems fun! =) but stock turbo has to work first for registration so the engine swap gets legal.

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-10-2015, 04:12 PM #22

i rather try a compound turbo setup.. seems fun! =) but stock turbo has to work first for registration so the engine swap gets legal.


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

F.R.A.S
Holset

579
01-12-2015, 06:29 PM #23
Move the engine mount, to get registration you have to make it easy for the inspector to approve you. So no adapters...

Looks good otherwise.

F-tune Performance [Image: V-band_om606.jpg] [Image: GTX3582R.jpg] [Image: gs6-53dz_gearbox.jpg]

I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
F.R.A.S
01-12-2015, 06:29 PM #23

Move the engine mount, to get registration you have to make it easy for the inspector to approve you. So no adapters...

Looks good otherwise.


F-tune Performance [Image: V-band_om606.jpg] [Image: GTX3582R.jpg] [Image: gs6-53dz_gearbox.jpg]

I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.

Alcaid
TA 0301

58
01-13-2015, 03:19 AM #24
(01-02-2015, 02:25 PM)muuris For constant 1 bar boost (PR 2.0) you need 10lbs/min at 2000rpm and 28lbs/min at 5500rpm with good efficiency. Take a look at the attachment, I roughly sketched those numbers for HX35 and GT2860R. You can see that HX35 is off the map until ~3200rpm and hits good efficiency at around 5000rpm. GT28 is on the map at 2200rpm and is on the sweet spot around 3500-5500.

Muuris, you only need a 56mm exducer comp wheel, check out your numbers in a MHI TD04HL-16T compressor map Wink

[Image: 16TMuuris_zps12081c0c.jpg]

This one is available with a 7cm turbine housing that will give you the needed turbine choke flow to max out those 6mm elements, the perfect turbo for this build Smile

Part numbers to look for to find this TD04HL-16T-7cm:

49189-01330
49189-01335
49189-01350
49189-01355
49189-05100
49189-05101
49189-05102
49189-05111
49189-05112

56/43.4mm comp wheel
52/45.6mm turbine wheel
7cm turbine housing

(and please don't buy Chinese junk...)

Regards
Petter
Alcaid
01-13-2015, 03:19 AM #24

(01-02-2015, 02:25 PM)muuris For constant 1 bar boost (PR 2.0) you need 10lbs/min at 2000rpm and 28lbs/min at 5500rpm with good efficiency. Take a look at the attachment, I roughly sketched those numbers for HX35 and GT2860R. You can see that HX35 is off the map until ~3200rpm and hits good efficiency at around 5000rpm. GT28 is on the map at 2200rpm and is on the sweet spot around 3500-5500.

Muuris, you only need a 56mm exducer comp wheel, check out your numbers in a MHI TD04HL-16T compressor map Wink

[Image: 16TMuuris_zps12081c0c.jpg]

This one is available with a 7cm turbine housing that will give you the needed turbine choke flow to max out those 6mm elements, the perfect turbo for this build Smile

Part numbers to look for to find this TD04HL-16T-7cm:

49189-01330
49189-01335
49189-01350
49189-01355
49189-05100
49189-05101
49189-05102
49189-05111
49189-05112

56/43.4mm comp wheel
52/45.6mm turbine wheel
7cm turbine housing

(and please don't buy Chinese junk...)

Regards
Petter

MrHope
GT2256V

112
01-13-2015, 03:37 AM #25
thats a volvo turbo right?

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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-13-2015, 03:37 AM #25

thats a volvo turbo right?


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W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

Alcaid
TA 0301

58
01-13-2015, 03:50 AM #26
Yep, Volvo indeed
Alcaid
01-13-2015, 03:50 AM #26

Yep, Volvo indeed

MrHope
GT2256V

112
01-13-2015, 04:05 AM #27
shouldnt be a problem to find here =)

but is it bigger than the 606 turbo?

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-13-2015, 04:05 AM #27

shouldnt be a problem to find here =)

but is it bigger than the 606 turbo?


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

Alcaid
TA 0301

58
01-13-2015, 04:43 AM #28
It is a newer, smaller wheels = less inertia = quicker on transient response, more efficient design with 360° thrust bearing, and has more turbine flow for peak hp and a perfect matching compressor map. I have never seen the OM606 turbo compressor map so can not say how god of a match it is.
Alcaid
01-13-2015, 04:43 AM #28

It is a newer, smaller wheels = less inertia = quicker on transient response, more efficient design with 360° thrust bearing, and has more turbine flow for peak hp and a perfect matching compressor map. I have never seen the OM606 turbo compressor map so can not say how god of a match it is.

MrHope
GT2256V

112
01-14-2015, 02:30 PM #29
Somewere here the enginebracket has to be.. damn turbo...
   


Heavy duty special Big Grin
   


And offcorse some paint to hide those welds... Cool
   

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-14-2015, 02:30 PM #29

Somewere here the enginebracket has to be.. damn turbo...
   


Heavy duty special Big Grin
   


And offcorse some paint to hide those welds... Cool
   


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

muuris
OM605

318
01-18-2015, 07:16 AM #30
(01-13-2015, 03:19 AM)Alcaid Muuris, you only need a 56mm exducer comp wheel, check out your numbers in a MHI TD04HL-16T compressor map Wink
That would fit this project nicely, if the turbine wheel flows enough (I bet it does).
muuris
01-18-2015, 07:16 AM #30

(01-13-2015, 03:19 AM)Alcaid Muuris, you only need a 56mm exducer comp wheel, check out your numbers in a MHI TD04HL-16T compressor map Wink
That would fit this project nicely, if the turbine wheel flows enough (I bet it does).

01-18-2015, 10:30 AM #31
(01-14-2015, 02:30 PM)MrHope Somewere here the enginebracket has to be.. damn turbo...



Heavy duty special Big Grin



And offcorse some paint to hide those welds... Cool

Hi "VGT enginebracket" http://www.superturbodiesel.com/std/imag.../smile.gif

offroaddieselhu
Attached Files
Image(s)
   
offroaddieselhu
01-18-2015, 10:30 AM #31

(01-14-2015, 02:30 PM)MrHope Somewere here the enginebracket has to be.. damn turbo...



Heavy duty special Big Grin



And offcorse some paint to hide those welds... Cool

Hi "VGT enginebracket" http://www.superturbodiesel.com/std/imag.../smile.gif

offroaddieselhu

Attached Files
Image(s)
   

MrHope
GT2256V

112
01-19-2015, 02:42 PM #32
Got the pump back today!
Special Outside ALDA
Stamped 6mm and 95cc

   


have also started sorting out the oil return pipe, that had the wrong angle due to the new position of turbo just to clear the engine mount.

i think this will work. Cool


   

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-19-2015, 02:42 PM #32

Got the pump back today!
Special Outside ALDA
Stamped 6mm and 95cc

   


have also started sorting out the oil return pipe, that had the wrong angle due to the new position of turbo just to clear the engine mount.

i think this will work. Cool


   


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

Hario'
C300TD Wagon (W202)

894
01-21-2015, 07:16 PM #33
Hello 717 manual gearbox and clutch from the very rare c250td manual car?

It is coming together nicely! Neat oil return pipe mod.




Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
Hario'
01-21-2015, 07:16 PM #33

Hello 717 manual gearbox and clutch from the very rare c250td manual car?

It is coming together nicely! Neat oil return pipe mod.





Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]

MrHope
GT2256V

112
01-22-2015, 02:43 AM #34
yes, its 717.460 probably the strongest bolt on gearbox with 5-speed overdrive.

The oilreturn line had to be changed angle due to the clearance from the engine bracket..

i have now made a bracket and fitted the boost clock to the turbo, it was vaccum controlled before!

is there diffrent spec vaccum clocks? this one just opens a little bit at 2-bar.. maby to strong clock?

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-22-2015, 02:43 AM #34

yes, its 717.460 probably the strongest bolt on gearbox with 5-speed overdrive.

The oilreturn line had to be changed angle due to the clearance from the engine bracket..

i have now made a bracket and fitted the boost clock to the turbo, it was vaccum controlled before!

is there diffrent spec vaccum clocks? this one just opens a little bit at 2-bar.. maby to strong clock?


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

Hario'
C300TD Wagon (W202)

894
01-27-2015, 05:10 PM #35
Stock is 19psi




Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
Hario'
01-27-2015, 05:10 PM #35

Stock is 19psi





Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]

Hario'
C300TD Wagon (W202)

894
01-27-2015, 06:28 PM #36
Also I just found this by accidnt... Might be useful to you gwagen people?

http://fourbyfourclub.com/W460EnginePart...ets605.htm




Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
Hario'
01-27-2015, 06:28 PM #36

Also I just found this by accidnt... Might be useful to you gwagen people?

http://fourbyfourclub.com/W460EnginePart...ets605.htm





Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]

MrHope
GT2256V

112
01-28-2015, 04:13 AM #37
(01-27-2015, 06:28 PM)Hario Also I just found this by accidnt... Might be useful to you gwagen people?

http://fourbyfourclub.com/W460EnginePart...ets605.htm

would probably help someone.
But i have me engine about 70mm furder backwards ,
this helps with :

no need to lengthen the driveshaft
more space for intercooler

but you can probably buy the driveshaft in right length but its $$$ Dodgy

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-28-2015, 04:13 AM #37

(01-27-2015, 06:28 PM)Hario Also I just found this by accidnt... Might be useful to you gwagen people?

http://fourbyfourclub.com/W460EnginePart...ets605.htm

would probably help someone.
But i have me engine about 70mm furder backwards ,
this helps with :

no need to lengthen the driveshaft
more space for intercooler

but you can probably buy the driveshaft in right length but its $$$ Dodgy


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
01-29-2015, 05:01 PM #38
have made some more progress.

wired up the +cable, starter,oil lamp,glowplugs,tempsender..
still ha the alternator to wire.

Made a treaded hole in one of the plugs in the waterchannel to use as the vacumtemp swith for cold start idle.

[Image: tempvacum.jpg]


And the throttle wire had me thinking and trying for a couple of hours!
A 90-degree wire guide from motorbike ( to get under the ip )
automatic transmission kickdown wire (fitted throttle linkage ball)
bike wire guide (throgh firewall)
and welded a bolt ontop of original throttle lever.

ended up with this!
[Image: throttlewirebracket.jpg]

bottom view.. tight fit!
[Image: throttlewirebottomview.jpg]

topview
[Image: throttlewiretopview.jpg]

[Image: throttlewirefirewall2.jpg]

[Image: throttlewirefirewall.jpg]

[Image: throttlepedal.jpg]

Cut the white platic away from this and you will have a relly strong wire lock!
[Image: sany8832.jpg]

also the powersteering cable had to get new threads Cool
[Image: powersteerhose.jpg]
This post was last modified: 02-02-2015, 02:51 PM by MrHope.
Attached Files
Image(s)
                                   

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
01-29-2015, 05:01 PM #38

have made some more progress.

wired up the +cable, starter,oil lamp,glowplugs,tempsender..
still ha the alternator to wire.

Made a treaded hole in one of the plugs in the waterchannel to use as the vacumtemp swith for cold start idle.

[Image: tempvacum.jpg]


And the throttle wire had me thinking and trying for a couple of hours!
A 90-degree wire guide from motorbike ( to get under the ip )
automatic transmission kickdown wire (fitted throttle linkage ball)
bike wire guide (throgh firewall)
and welded a bolt ontop of original throttle lever.

ended up with this!
[Image: throttlewirebracket.jpg]

bottom view.. tight fit!
[Image: throttlewirebottomview.jpg]

topview
[Image: throttlewiretopview.jpg]

[Image: throttlewirefirewall2.jpg]

[Image: throttlewirefirewall.jpg]

[Image: throttlepedal.jpg]

Cut the white platic away from this and you will have a relly strong wire lock!
[Image: sany8832.jpg]

also the powersteering cable had to get new threads Cool
[Image: powersteerhose.jpg]

Attached Files
Image(s)
                                   

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
02-02-2015, 02:40 PM #39
[Image: om605pump.jpg]

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
02-02-2015, 02:40 PM #39

[Image: om605pump.jpg]


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
04-06-2015, 02:29 AM #40
Homemade plug to delete EGR and use the hole for EGT sensor.

[Image: egtadapter.jpg]



Closeup
[Image: egtadapterclose.jpg]


And mounted on engine! EGT sensor install looks kind of professional !
(i wish i could say the same about the boost pipe from turbo to intake....) 80mm to 60mm from 60mm to 50mm.....  Confused
[Image: egtadaptermounted.jpg]
This post was last modified: 04-06-2015, 02:31 AM by MrHope.

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
04-06-2015, 02:29 AM #40

Homemade plug to delete EGR and use the hole for EGT sensor.

[Image: egtadapter.jpg]



Closeup
[Image: egtadapterclose.jpg]


And mounted on engine! EGT sensor install looks kind of professional !
(i wish i could say the same about the boost pipe from turbo to intake....) 80mm to 60mm from 60mm to 50mm.....  Confused
[Image: egtadaptermounted.jpg]


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

Booster
GT2559V

240
04-06-2015, 04:00 AM #41
Your EGT is in the same location as mine, YOURS is much nicer install than mine!!
Booster
04-06-2015, 04:00 AM #41

Your EGT is in the same location as mine, YOURS is much nicer install than mine!!

MrHope
GT2256V

112
04-06-2015, 01:13 PM #42
(04-06-2015, 04:00 AM)Booster Your EGT is in the same location as mine, YOURS is much nicer install than mine!!

Its easy when you have the right machines , hopefully it will work and show the correct temperature.

Anyone know what temp range is ok with this engine/IP/turbo setup?

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
04-06-2015, 01:13 PM #42

(04-06-2015, 04:00 AM)Booster Your EGT is in the same location as mine, YOURS is much nicer install than mine!!

Its easy when you have the right machines , hopefully it will work and show the correct temperature.

Anyone know what temp range is ok with this engine/IP/turbo setup?


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

hents99
GT2256V

157
04-07-2015, 01:12 PM #43
Do you have pictures of cooler when it`s mounted on car. What`s you solution for piping?

I have 400CDI front bumper but I can`t figure how to solve piping issue because I don`t want to cut the car and looks like there is no room for pipes.

I think I`m going to use water to air intercooler.
Coolant radiator behind the bumper and laminova cores into manifold.
hents99
04-07-2015, 01:12 PM #43

Do you have pictures of cooler when it`s mounted on car. What`s you solution for piping?

I have 400CDI front bumper but I can`t figure how to solve piping issue because I don`t want to cut the car and looks like there is no room for pipes.

I think I`m going to use water to air intercooler.
Coolant radiator behind the bumper and laminova cores into manifold.

MrHope
GT2256V

112
04-07-2015, 03:10 PM #44
I havent mounted the intercooler yet, but some cutting has to be done to make it fit.
But Since i have a 605 i did move back the stock radiator so maby i will fit a intercooler infront of the radiator.

I will try to get the car trough auto inspection first, then i will fit intercooler.

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
04-07-2015, 03:10 PM #44

I havent mounted the intercooler yet, but some cutting has to be done to make it fit.
But Since i have a 605 i did move back the stock radiator so maby i will fit a intercooler infront of the radiator.

I will try to get the car trough auto inspection first, then i will fit intercooler.


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

MrHope
GT2256V

112
05-07-2015, 01:27 PM #45
Did buy a 8mm Mynä pump with custom alda "just in case" =)

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
05-07-2015, 01:27 PM #45

Did buy a 8mm Mynä pump with custom alda "just in case" =)


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

muuris
OM605

318
05-08-2015, 12:54 AM #46
Now you'll need another turbo or supercharger Wink
muuris
05-08-2015, 12:54 AM #46

Now you'll need another turbo or supercharger Wink

MrHope
GT2256V

112
05-08-2015, 03:26 PM #47
yes, but i will try the 6mm pump first, have to be as stock as possible during registration

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
05-08-2015, 03:26 PM #47

yes, but i will try the 6mm pump first, have to be as stock as possible during registration


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

muuris
OM605

318
05-11-2015, 05:55 AM #48
(05-08-2015, 03:26 PM)MrHope yes, but i will try the 6mm pump first, have to be as stock as possible during registration


A bit offtopic, but I've always thought that getting MOT/inspection approvals in modified vehicles would be easier to get in Sweden than in Finland. Can't one just bolt in a big turbo, pass emissions test, show a dyno graph of moderate power and call it a day?
muuris
05-11-2015, 05:55 AM #48

(05-08-2015, 03:26 PM)MrHope yes, but i will try the 6mm pump first, have to be as stock as possible during registration


A bit offtopic, but I've always thought that getting MOT/inspection approvals in modified vehicles would be easier to get in Sweden than in Finland. Can't one just bolt in a big turbo, pass emissions test, show a dyno graph of moderate power and call it a day?

MrHope
GT2256V

112
05-12-2015, 05:41 AM #49
biggest problem is that the w460 g-wagen biggest engine is the 300D 88hp and 280E with 154hp and mercedes dont allow any bigger engine than that.

or you can increse tq with 10% and hp with 20% from the cars original engine.

if you register the car as Modified you can get more hp and unlimited tq , as thay just have a limit hp/kg and in that case the gwagen has no problem as its quite heavy! but to do that you have to change the braking system to. and bolt on stuff is not allowed, must be custom made, even if it means put smaller brakes on its ok!! really stupid rule that only proves that someone behind a desk just wanted to make a rule!

.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)
MrHope
05-12-2015, 05:41 AM #49

biggest problem is that the w460 g-wagen biggest engine is the 300D 88hp and 280E with 154hp and mercedes dont allow any bigger engine than that.

or you can increse tq with 10% and hp with 20% from the cars original engine.

if you register the car as Modified you can get more hp and unlimited tq , as thay just have a limit hp/kg and in that case the gwagen has no problem as its quite heavy! but to do that you have to change the braking system to. and bolt on stuff is not allowed, must be custom made, even if it means put smaller brakes on its ok!! really stupid rule that only proves that someone behind a desk just wanted to make a rule!


.
W460 300GD with om605 Turbo 6mm pump Build Thread!
W124 300D 1985 (daily driver)

muuris
OM605

318
05-12-2015, 05:49 AM #50
Right. I'd change some other brakes then tell the inspector they're custom  Big Grin   If not registering as a modified vehicle, how about annual inspections then, will you be changing for stock turbo every time etc?
muuris
05-12-2015, 05:49 AM #50

Right. I'd change some other brakes then tell the inspector they're custom  Big Grin   If not registering as a modified vehicle, how about annual inspections then, will you be changing for stock turbo every time etc?

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