W202 220D om604 +P
W202 220D om604 +P
The car was test driven today so it's almost done. However some of you like to see some pictures of the build and some technical info so here goes.
The car is a Mercedes C220D from 1993 with the 2.2-liter n/a om604 and 95hp.
![[Image: 210381-5edd05075a1cd4a533181f34e521c90a.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-5edd05075a1cd4a533181f34e521c90a.jpg)
![[Image: 210381-e4f269214f377bf2ee3f49da682d9acb.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-e4f269214f377bf2ee3f49da682d9acb.jpg)
![[Image: 210381-e688f7a87da8546c5ae820052fc076df.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-e688f7a87da8546c5ae820052fc076df.jpg)
![[Image: 210381-b2f02b0ef1dd339c942ec09961bf9cad.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-b2f02b0ef1dd339c942ec09961bf9cad.jpg)
![[Image: 210381-c5d317a29eb8b2edf8eaeaa6726edbb5.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-c5d317a29eb8b2edf8eaeaa6726edbb5.jpg)
![[Image: 210381-5550b571a519f8525038cdfe213723d0.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-5550b571a519f8525038cdfe213723d0.jpg)
The plan was to make a decent daily out of the old lady.
Said and done I got my self a Injection Pump from the Mercedes Vito with the 2.3-liter turbocharged om601, high RS-number mechanical IP
Sent it of for some adjustments @ Dieselmeken and there is where it all went wrong...
When the pump came back to me it had 8mm elements and was capable of 180cc of fuel. So ditch the plan "decent daily" and start a new one called AWESOME DAILY
Bought myself a couple of items for the car.
Boost control
![[Image: 210381-f1933ea0215ffa0870a976bfbbb61417.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-f1933ea0215ffa0870a976bfbbb61417.jpg)
End muffler
![[Image: 210381-ea3ebdb97af87e37b21ca2e4dc4c0951.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-ea3ebdb97af87e37b21ca2e4dc4c0951.jpg)
Wheel center caps
![[Image: 210381-eb4e59b31eb651e99694f41b7066a552.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-eb4e59b31eb651e99694f41b7066a552.jpg)
Wastegate
![[Image: 210381-07279a82ed4b69622a08b4f4d4a613f6.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-07279a82ed4b69622a08b4f4d4a613f6.jpg)
I'm using a clone GT3076R turbo with a/r 0,63 and a T3-flange.
Started with the manifold
![[Image: 210381-d861231a2bfea674df0b12d18b00c0a6.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-d861231a2bfea674df0b12d18b00c0a6.jpg)
![[Image: 210381-89233921705bfc908d84b1a2a3e735d3.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-89233921705bfc908d84b1a2a3e735d3.jpg)
![[Image: 210381-07e35eac386b335c726e52362962310c.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-07e35eac386b335c726e52362962310c.jpg)
![[Image: 210381-b03b9b284df1fbdbf9db3549c92b8f4f.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-b03b9b284df1fbdbf9db3549c92b8f4f.jpg)
![[Image: 210381-ff6a548ee57e3914be9f0d6c3ed198e9.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-ff6a548ee57e3914be9f0d6c3ed198e9.jpg)
![[Image: 210381-5ed51e483db7af34fec0f36594e07908.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-5ed51e483db7af34fec0f36594e07908.jpg)
Machined and balanced the flywheel, using a Sachs 765 PP and a stock om605 (c250dt) organic clutch.
![[Image: 210381-a3b0f011bf6c31bf34bc643d19787644.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-a3b0f011bf6c31bf34bc643d19787644.jpg)
![[Image: 210381-d97fe0202ad280c35c7f95dd7328fabc.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-d97fe0202ad280c35c7f95dd7328fabc.jpg)
![[Image: 210381-bce36a475d82312911cdbf5755a39c9e.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-bce36a475d82312911cdbf5755a39c9e.jpg)
![[Image: 210381-bb8d900ad873fba3703027c65dfcff92.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-bb8d900ad873fba3703027c65dfcff92.jpg)
Got the turbine housing and manifold back from coating (ceramic coating)
![[Image: 210381-14a973a8e8fbd0622f777963a61c30fd.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-14a973a8e8fbd0622f777963a61c30fd.jpg)
![[Image: 210381-e8ecff026f33bdd3f31daa0e0e420010.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-e8ecff026f33bdd3f31daa0e0e420010.jpg)
Using stock plastic intake so made a little fastening device
![[Image: 210381-7a0132cac6213b65e3a6445ffdbea05b.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-7a0132cac6213b65e3a6445ffdbea05b.jpg)
Engine bay getting together
![[Image: 210381-99be843efe2a51250e0b3c1461289d27.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-99be843efe2a51250e0b3c1461289d27.jpg)
![[Image: 210381-895b54cd8aa8ad59a489c1594a58cfe0.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-895b54cd8aa8ad59a489c1594a58cfe0.jpg)
![[Image: 210381-764d38717d1af3fc4057caa3a616685d.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-764d38717d1af3fc4057caa3a616685d.jpg)
Almost done
![[Image: 210381-afc8cad3099d0bb4e5ff51dd66793665.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-afc8cad3099d0bb4e5ff51dd66793665.jpg)
Exhaust done and car test driven
![[Image: 210381-d9f08ac382f2e32e9b0cfdb65ed8bdd0.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-d9f08ac382f2e32e9b0cfdb65ed8bdd0.jpg)
F-tune Performance
![[Image: V-band_om606.jpg]](http://www.f-tune.se/wp-content/uploads/2015/01/V-band_om606.jpg)
![[Image: GTX3582R.jpg]](http://www.f-tune.se/wp-content/uploads/2015/01/GTX3582R.jpg)
![[Image: gs6-53dz_gearbox.jpg]](http://www.f-tune.se/wp-content/uploads/2015/01/gs6-53dz_gearbox.jpg)
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
For you guys out there in to guns you know that a +P round is a hotter round with more punch and power. That's my om604
The car was test driven today so it's almost done. However some of you like to see some pictures of the build and some technical info so here goes.
The car is a Mercedes C220D from 1993 with the 2.2-liter n/a om604 and 95hp.
The plan was to make a decent daily out of the old lady.
Said and done I got my self a Injection Pump from the Mercedes Vito with the 2.3-liter turbocharged om601, high RS-number mechanical IP
Sent it of for some adjustments @ Dieselmeken and there is where it all went wrong...
When the pump came back to me it had 8mm elements and was capable of 180cc of fuel. So ditch the plan "decent daily" and start a new one called AWESOME DAILY
Bought myself a couple of items for the car.
Boost control
End muffler
Wheel center caps
Wastegate
I'm using a clone GT3076R turbo with a/r 0,63 and a T3-flange.
Started with the manifold
Machined and balanced the flywheel, using a Sachs 765 PP and a stock om605 (c250dt) organic clutch.
Got the turbine housing and manifold back from coating (ceramic coating)
Using stock plastic intake so made a little fastening device
Engine bay getting together
Almost done
Exhaust done and car test driven
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
They are awesome, hahahaha.(01-14-2015, 02:34 PM)Jetmugg F-Tune center caps!!!!!
Must have this item!
Oh yeah, the rest of the car is good too.
Steve.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
I need to know size but I can send you some They are awesome, hahahaha.
(01-14-2015, 02:34 PM)Jetmugg F-Tune center caps!!!!!
Must have this item!
Oh yeah, the rest of the car is good too.
Steve.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
(01-14-2015, 02:41 PM)Hario Aha, very nice superturbo4pot!
A little video a couple of days ago, no mufflers and only downpipe mounted.
Had to fix some minor issues so got this during that.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Thanks mate.
(01-14-2015, 02:41 PM)Hario Aha, very nice superturbo4pot!
A little video a couple of days ago, no mufflers and only downpipe mounted.
Had to fix some minor issues so got this during that.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
I'm going to PM you!
1#
Volvo 940 estate 1995
Originaly a d24tic
Changed to OM606.962 From the old 81 Benz
4" dp, 3,5" stainless from DP out.
8mm dieselmeken pump att 180cc
BW kkk K29 turbo, 15cm hot side
home made flywheel with sachs 765PP and original mercedes 240mm organic disc
6speed cdi box
4,5" humongus cooler
Please wait, loading boost
awesome car F.R.A.S ! its beautiful!
I'm going to PM you!
1#
Volvo 940 estate 1995
Originaly a d24tic
Changed to OM606.962 From the old 81 Benz
4" dp, 3,5" stainless from DP out.
8mm dieselmeken pump att 180cc
BW kkk K29 turbo, 15cm hot side
home made flywheel with sachs 765PP and original mercedes 240mm organic disc
6speed cdi box
4,5" humongus cooler
Please wait, loading boost
(01-14-2015, 05:28 PM)Ksteen2 awesome car F.R.A.S ! its beautiful!
I'm going to PM you!
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Thank you Kent.
(01-14-2015, 05:28 PM)Ksteen2 awesome car F.R.A.S ! its beautiful!
I'm going to PM you!
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
The car is really coming to life with a little extra boost.
Had some leaks so have spend half the day pressure testing and sealing stuff. Did 2,5bar with the tester and now everything is sealed and done. Also checked the boost gauge for accuracy
Only doing 500-degrees Celsius EGT today so I know we're out of fuel. Will adjust the IP tomorrow and do some more testing.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Second test drive today. Boosted 1,2bar yesterday and 1,6bar today.
The car is really coming to life with a little extra boost.
Had some leaks so have spend half the day pressure testing and sealing stuff. Did 2,5bar with the tester and now everything is sealed and done. Also checked the boost gauge for accuracy
Only doing 500-degrees Celsius EGT today so I know we're out of fuel. Will adjust the IP tomorrow and do some more testing.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Have been using a lot of clones before and they usually holds up just fine. It's a big difference in quality on the clones and we have pretty good sources (how ever this is the first turbo like this from our supplier so I have no idea if it will last or not).
Thanks mate.
(01-15-2015, 03:53 PM)rolfts How's that clone holding up? Lovely build!
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Have only been driving 3-4km so far
Have been using a lot of clones before and they usually holds up just fine. It's a big difference in quality on the clones and we have pretty good sources (how ever this is the first turbo like this from our supplier so I have no idea if it will last or not).
Thanks mate.
(01-15-2015, 03:53 PM)rolfts How's that clone holding up? Lovely build!
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Yea it's 3M-dome decals but I have to order the exact size for it to look great. In the case off those already made we measured the inside off the small rim on the edge off the center caps. Inches are really a rough estimate
If I could get a measurement in MM that would be great.It would be possible to mount another engine in this chassis and test it out
but I don't really think that is a good idea.(01-15-2015, 05:04 PM)Jetmugg The car looks good, like a Wolf in Sheep's clothing. Maybe a good place to test a 400HP OM604?
The wheels on my 'Benz are old-school Mille Miglia 5-spokes. 2" center caps. Are the F-Tune center caps adhesive-backed decals?
Steve.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Yea it's a bit of a gentleman racer that goes under the cops radar
Yea it's 3M-dome decals but I have to order the exact size for it to look great. In the case off those already made we measured the inside off the small rim on the edge off the center caps. Inches are really a rough estimate If I could get a measurement in MM that would be great.
It would be possible to mount another engine in this chassis and test it out but I don't really think that is a good idea.
(01-15-2015, 05:04 PM)Jetmugg The car looks good, like a Wolf in Sheep's clothing. Maybe a good place to test a 400HP OM604?
The wheels on my 'Benz are old-school Mille Miglia 5-spokes. 2" center caps. Are the F-Tune center caps adhesive-backed decals?
Steve.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Was going to take the car home but had an oil leak so have to fix that first.
![[Image: 210381-22716cad245c8bdd4b02b895d0255dc5.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-22716cad245c8bdd4b02b895d0255dc5.jpg)
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Third day off testing. Boosting 1,9bar so far and everything looks fine. Car starts to loose grip on third gear and that's great.
Was going to take the car home but had an oil leak so have to fix that first.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Problem is that it is going so much faster then it looks on the camera 
Thanks mate. The little 604 is responding better than I thought on a little boost. Really strong and nice engine!!!
(01-16-2015, 03:32 PM)erling66 Great project and nice to see someone that put some work into tuning the 604
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
I have a video Problem is that it is going so much faster then it looks on the camera
Thanks mate. The little 604 is responding better than I thought on a little boost. Really strong and nice engine!!!
(01-16-2015, 03:32 PM)erling66 Great project and nice to see someone that put some work into tuning the 604
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
(01-16-2015, 03:47 PM)bruno_pinho How many bar makes the wastegate spring?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
1.1bar. Right now I'm only using the top connection to get maximum boost and adjust the boost on the IP.
(01-16-2015, 03:47 PM)bruno_pinho How many bar makes the wastegate spring?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
(01-16-2015, 04:33 PM)F.R.A.S 1.1bar. Right now I'm only using the top connection to get maximum boost and adjust the boost on the IP.
(01-16-2015, 03:47 PM)bruno_pinho How many bar makes the wastegate spring?
Then no longer you use that boost control?
bruno_pinho
01-16-2015, 04:39 PM #18(01-16-2015, 04:33 PM)F.R.A.S 1.1bar. Right now I'm only using the top connection to get maximum boost and adjust the boost on the IP.
(01-16-2015, 03:47 PM)bruno_pinho How many bar makes the wastegate spring?
Then no longer you use that boost control?
(01-16-2015, 04:39 PM)bruno_pinho Then no longer you use that boost control?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
A diesel only boost what you have fuel for. The boost control on a STD is to LOWER the boost to get maximum power (EGT). If letting the turbo boost maximum you will have something like 650-degree Celsius and maximum power is in the range of 850-degree Celsius.
(01-16-2015, 04:39 PM)bruno_pinho Then no longer you use that boost control?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
The om604 has Lucas injectors and not Bosch, same stuff more or less but nice to know.Now I have fitted some upgraded Lucas injectors set @ 160bar, what I can see I have lower EGT by 100-degrees with means a cleaner and more efficient combustion. I also have 0,1bar more boost with nothing else changed. So 2bar even right now.
The car reacts a little better at speed when flooring it. However the differences is really small and for now I have to say that any injectors works equally good. BUT I have not tested this more than 30km (180miles).
Note: We have actually never tested this before and only done what told, fit higher pressure injectors, that's why I had to test
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Have been driving with the stock 115bar injectors till today. Everybody says that the injectors have to be changed so I had to test with the stock ones The om604 has Lucas injectors and not Bosch, same stuff more or less but nice to know.
Now I have fitted some upgraded Lucas injectors set @ 160bar, what I can see I have lower EGT by 100-degrees with means a cleaner and more efficient combustion. I also have 0,1bar more boost with nothing else changed. So 2bar even right now.
The car reacts a little better at speed when flooring it. However the differences is really small and for now I have to say that any injectors works equally good. BUT I have not tested this more than 30km (180miles).
Note: We have actually never tested this before and only done what told, fit higher pressure injectors, that's why I had to test
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
![[Image: 210381-9a4790ddbd2239bf3554968f2ad41deb.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-9a4790ddbd2239bf3554968f2ad41deb.jpg)
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Here it is sitting outside my living room window, the wolf in sheep clothing
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
you said it this time!!!I run a Holley Black clone electric fuel pump because it's easy and some guy told me the Finns have done 700bhp with one. I know absolutely NOTHING about carburettor setups and such so I've been struggling with this for a while now.
Turns out that the Holley Black is made to only give 0,5bar (7psi) off fuel pressure and it don't need a return line. I have a return line
Today I changed the spring that controls fuel pressure in the "Holley" and have an unknown fuel pressure at the moment (will measure later on) and WAOW what a difference
The boost gauge is only good for 2bar (28psi) but I have pressurized the system and know where 2,5bar (35psi) are. However the boost gauge is flicking around like a maniac and I only know I have somewhere between 2,3bar and 3bar.
It's a bit slippery on the roads with 18" and summer tires and we have melted snow on the roads so couldn't test it as hard as I liked.
Ass dyno says 350hp and it's a maniac already
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Alright guys
I run a Holley Black clone electric fuel pump because it's easy and some guy told me the Finns have done 700bhp with one. I know absolutely NOTHING about carburettor setups and such so I've been struggling with this for a while now.
Turns out that the Holley Black is made to only give 0,5bar (7psi) off fuel pressure and it don't need a return line. I have a return line
Today I changed the spring that controls fuel pressure in the "Holley" and have an unknown fuel pressure at the moment (will measure later on) and WAOW what a difference
The boost gauge is only good for 2bar (28psi) but I have pressurized the system and know where 2,5bar (35psi) are. However the boost gauge is flicking around like a maniac and I only know I have somewhere between 2,3bar and 3bar.
It's a bit slippery on the roads with 18" and summer tires and we have melted snow on the roads so couldn't test it as hard as I liked.
Ass dyno says 350hp and it's a maniac already
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Going to the dyno with this? Would be very intersting to see what the "little" engines can do!
DiseaselWeasel
01-23-2015, 02:13 AM #24Carburettors usually have a float & needle pin to shut of fuel supply to the fuel bowl (from which fuel gets sucked into the nozzle/jets of the carb). Hence the fuel pump may not overcome the needle pin. If it would, the engine would severly overfuel (pump pushes fuel into carburettor). Usually they'r membrane pumps, iIRC. You'r probably better off with a different pump. But if it works for now - all good!
Going to the dyno with this? Would be very intersting to see what the "little" engines can do!
The last time i went to my local Scrapyard, a om604 was laying around there "for free" (only Metalprice).
I should have taken it with me....
______________________________________________________________
93´ W124 300TDT -> OM606.962 / RS 203 Dieselmeken 7,5mm 210cc / KKK K14 / Stock Transmission / 2,65 ASD
89´ 190D 2.5 Turbo -> OM605.960 / Dieselmeken 7,5mm 180cc / Holset HX30 Super / 716. 654 6-Speed / 2,87 Rear Axle
Great Build, looks like a perfect Dailydriver ;-)
The last time i went to my local Scrapyard, a om604 was laying around there "for free" (only Metalprice).
I should have taken it with me....
______________________________________________________________
93´ W124 300TDT -> OM606.962 / RS 203 Dieselmeken 7,5mm 210cc / KKK K14 / Stock Transmission / 2,65 ASD
89´ 190D 2.5 Turbo -> OM605.960 / Dieselmeken 7,5mm 180cc / Holset HX30 Super / 716. 654 6-Speed / 2,87 Rear Axle
it's really fast now and the roads are really slippery But everything is alright with both me and the car
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Thanks guys. Dyno is planed but have to sort everything out first. Ran off road today and ended up with a crack in the oil sump it's really fast now and the roads are really slippery
But everything is alright with both me and the car
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
I ask because i am trying to get my friend into STD so he should be OK with only 4 cylinders to start with.
350 ass HP is good but jeemu make 100 per cylinder, just saying
Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]
So is the car called a C200D? Predecessor to the c220cdi.
I ask because i am trying to get my friend into STD so he should be OK with only 4 cylinders to start with.
350 ass HP is good but jeemu make 100 per cylinder, just saying
Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]
100hp/cyl is nothing...
(01-29-2015, 07:29 PM)Hario So is the car called a C200D? Predecessor to the c220cdi.
I ask because i am trying to get my friend into STD so he should be OK with only 4 cylinders to start with.
350 ass HP is good but jeemu make 100 per cylinder, just saying
So guys here is an update for you
Had this C250TDT rear end laying around so welded that diff and mounted it on the 220D
Mmmm, drives hafts didn't fit, had to swap to the 250 ones...
...prop shaft didn't fit so thought of using the rear end of the 250 prop. Naaa didn't fit, the splines where bigger on the 250.
Have to use the entire prop. NO, not that either, the prop don't fit the gearbox.
So I have to cut and weld the last bit of the prop
Easy swap right!!!
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Yes it's called C220D and has a 95hp n/a engine.
100hp/cyl is nothing...
(01-29-2015, 07:29 PM)Hario So is the car called a C200D? Predecessor to the c220cdi.
I ask because i am trying to get my friend into STD so he should be OK with only 4 cylinders to start with.
350 ass HP is good but jeemu make 100 per cylinder, just saying
So guys here is an update for you
Had this C250TDT rear end laying around so welded that diff and mounted it on the 220D
Mmmm, drives hafts didn't fit, had to swap to the 250 ones...
...prop shaft didn't fit so thought of using the rear end of the 250 prop. Naaa didn't fit, the splines where bigger on the 250.
Have to use the entire prop. NO, not that either, the prop don't fit the gearbox.
So I have to cut and weld the last bit of the prop
Easy swap right!!!
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
" It is far easier to get forgiveness rather than permission"
Riverstick
01-30-2015, 05:55 PM #29What an excellent thread. ..That exhaust manifold is a work of art. One question. ...The turbo looks pretty formidable. ..How does the engine perform low down the rim range....Does it spool low down?
" It is far easier to get forgiveness rather than permission"
The turbo is awesome and works great. It feels like a bigger engine really, I have 0,1bar @ 1500rpm and then the boost is climbing slow and nice up to 1bar @ just under 3000rpm and @ 3000rpm I got 2.5bar.
So slow steady build up of boost up to 1bar, then it's just like someone hits you in the back and you get all the boost you could ever need at once. Drivable and fun at the same time.
(01-30-2015, 05:55 PM)Riverstick What an excellent thread. ..That exhaust manifold is a work of art. One question. ...The turbo looks pretty formidable. ..How does the engine perform low down the rim range....Does it spool low down?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Thanks mate.
The turbo is awesome and works great. It feels like a bigger engine really, I have 0,1bar @ 1500rpm and then the boost is climbing slow and nice up to 1bar @ just under 3000rpm and @ 3000rpm I got 2.5bar.
So slow steady build up of boost up to 1bar, then it's just like someone hits you in the back and you get all the boost you could ever need at once. Drivable and fun at the same time.
(01-30-2015, 05:55 PM)Riverstick What an excellent thread. ..That exhaust manifold is a work of art. One question. ...The turbo looks pretty formidable. ..How does the engine perform low down the rim range....Does it spool low down?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Had some problems with the new differential so the solution was to take the driveshafts from the C250tdt and cut the propshaft and weld them together.
Fist I machined a sleeve (56,8mm) that fitted nicely inside the propshaft and then it was just a mater of welding
![[Image: 210381-b676a389e156a6e5ee1d5271ececc109.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-b676a389e156a6e5ee1d5271ececc109.jpg)
![[Image: 210381-8a290ee37a7f7de65093ff67e7fc4d33.jpg]](http://www1.garaget.org/gallery/images/211/210381/210381-8a290ee37a7f7de65093ff67e7fc4d33.jpg)
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Here is some pictures from today.
Had some problems with the new differential so the solution was to take the driveshafts from the C250tdt and cut the propshaft and weld them together.
Fist I machined a sleeve (56,8mm) that fitted nicely inside the propshaft and then it was just a mater of welding
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
(02-02-2015, 02:29 PM)F.R.A.S Here is some pictures from today.
Had some problems with the new differential so the solution was to take the driveshafts from the C250tdt and cut the propshaft and weld them together.
Fist I machined a sleeve (56,8mm) that fitted nicely inside the propshaft and then it was just a mater of welding
Ha, i just did the same thing yesterday. However i didn't use a sleeve. I welded it in the lathe.
Duncansport
02-03-2015, 08:53 AM #32(02-02-2015, 02:29 PM)F.R.A.S Here is some pictures from today.
Had some problems with the new differential so the solution was to take the driveshafts from the C250tdt and cut the propshaft and weld them together.
Fist I machined a sleeve (56,8mm) that fitted nicely inside the propshaft and then it was just a mater of welding
Ha, i just did the same thing yesterday. However i didn't use a sleeve. I welded it in the lathe.
Quote:
I'm going to have to do this soon. I had a custom driveshaft with U-joints (cardans) made and the noise and vibration is awful. I think a U-joint at the trans and a big flex disc at the diff should be a good enough compromise.
raysorenson
02-03-2015, 12:49 PM #33Quote:
I'm going to have to do this soon. I had a custom driveshaft with U-joints (cardans) made and the noise and vibration is awful. I think a U-joint at the trans and a big flex disc at the diff should be a good enough compromise.
(02-03-2015, 12:49 PM)raysorenson I'm going to have to do this soon. I had a custom driveshaft with U-joints (cardans) made and the noise and vibration is awful. I think a U-joint at the trans and a big flex disc at the diff should be a good enough compromise.
Ok Guys, here is the first clip of the car in action.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Yea it's really important things like this works. As you say, it's really awful otherwise.
(02-03-2015, 12:49 PM)raysorenson I'm going to have to do this soon. I had a custom driveshaft with U-joints (cardans) made and the noise and vibration is awful. I think a U-joint at the trans and a big flex disc at the diff should be a good enough compromise.
Ok Guys, here is the first clip of the car in action.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
It's a completely stock om604, not even changed valve springs.
One or a couple of hydraulic lifters are jamming from time to time but it's all good
If it was a petrol car I would say 350bhp easy. But diesel have more torque so I can have less power. Only doing 2.5bar of boost so who knows
If doing the math I have approximately 105-110bhp n/a (95hp with stock IP) so lets agree on 100bhp.
1bar should land me in the region off 200bhp, 2bar 300bhp and 2,5bar 350bhp. If I have 300whp I'm happy.
(02-03-2015, 02:59 PM)erx Excellent work, that exhaust manifold is really looking nice. I'm very interested what power is it making, engine is stock?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Thanks mate.
It's a completely stock om604, not even changed valve springs.
One or a couple of hydraulic lifters are jamming from time to time but it's all good
If it was a petrol car I would say 350bhp easy. But diesel have more torque so I can have less power. Only doing 2.5bar of boost so who knows
If doing the math I have approximately 105-110bhp n/a (95hp with stock IP) so lets agree on 100bhp.
1bar should land me in the region off 200bhp, 2bar 300bhp and 2,5bar 350bhp. If I have 300whp I'm happy.
(02-03-2015, 02:59 PM)erx Excellent work, that exhaust manifold is really looking nice. I'm very interested what power is it making, engine is stock?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
You ever heard about anyone breaking one? I have not...
(02-03-2015, 03:18 PM)erx 300whp from stock 604 is not sounding too healthy I think.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Why not?
You ever heard about anyone breaking one? I have not...
(02-03-2015, 03:18 PM)erx 300whp from stock 604 is not sounding too healthy I think.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
(02-03-2015, 03:21 PM)F.R.A.S Why not?
You ever heard about anyone breaking one? I have not...
(02-03-2015, 03:18 PM)erx 300whp from stock 604 is not sounding too healthy I think.
Something was lost in translation I think, I was just meaning it's more than superb from stock 604.
It's all good mate. Next project is w202 or w203 with om606 (02-03-2015, 03:46 PM)erx Something was lost in translation I think, I was just meaning it's more than superb from stock 604.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
That happens It's all good mate. Next project is w202 or w203 with om606
(02-03-2015, 03:46 PM)erx Something was lost in translation I think, I was just meaning it's more than superb from stock 604.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
What injection pump?
Cheers,
Max
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
maxypriest
02-03-2015, 05:58 PM #41Now that you have turned the fuel pressure up on your Holley black, are you still using the return line or blocked it up?
What injection pump?
Cheers,
Max
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
Dieselmeken 8mm injection pump.
Will build a REAL fuel system soon, just have to figure out the most easy way off doing that with stock fuel lines.
(02-03-2015, 05:58 PM)maxypriest Now that you have turned the fuel pressure up on your Holley black, are you still using the return line or blocked it up?
What injection pump?
Cheers,
Max
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
I'm maxing out the Holley Black. Might be better without return line but I still have mine (factory restriction though).
Dieselmeken 8mm injection pump.
Will build a REAL fuel system soon, just have to figure out the most easy way off doing that with stock fuel lines.
(02-03-2015, 05:58 PM)maxypriest Now that you have turned the fuel pressure up on your Holley black, are you still using the return line or blocked it up?
What injection pump?
Cheers,
Max
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
I have yet to start the car, however have been thinking wether the fuel system is upto it. Sounds like it's ok to begin with.
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
maxypriest
02-04-2015, 01:59 AM #43Thanks for that. I have a dieselmeken 8mm pump on my w124 606 with a real Holley black.
I have yet to start the car, however have been thinking wether the fuel system is upto it. Sounds like it's ok to begin with.
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
If I where to build the fuel system today I would have used the stock lift pump on the IP, route it via the diesel filter to a small (maybe 1-2liter) catch tank and then go Bosch 044 from there to the IP and use a FPR (as supposed to) set at 3bar.
Return line from the IP to the catch tank and return to fuel tank from catch tank. Just as a normal high power fuel system.
That is the most easy way of doing this on our cars that don't have an in-tank pump. If the om60X-engine are in a BMW or similar car there is almost always an in-tank pump and then it's dead easy to just swap that to a beefier pump and be done with it.
(02-04-2015, 01:59 AM)maxypriest Thanks for that. I have a dieselmeken 8mm pump on my w124 606 with a real Holley black.
I have yet to start the car, however have been thinking wether the fuel system is upto it. Sounds like it's ok to begin with.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
It's not worth the trouble really.
If I where to build the fuel system today I would have used the stock lift pump on the IP, route it via the diesel filter to a small (maybe 1-2liter) catch tank and then go Bosch 044 from there to the IP and use a FPR (as supposed to) set at 3bar.
Return line from the IP to the catch tank and return to fuel tank from catch tank. Just as a normal high power fuel system.
That is the most easy way of doing this on our cars that don't have an in-tank pump. If the om60X-engine are in a BMW or similar car there is almost always an in-tank pump and then it's dead easy to just swap that to a beefier pump and be done with it.
(02-04-2015, 01:59 AM)maxypriest Thanks for that. I have a dieselmeken 8mm pump on my w124 606 with a real Holley black.
I have yet to start the car, however have been thinking wether the fuel system is upto it. Sounds like it's ok to begin with.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
(02-02-2015, 02:29 PM)F.R.A.S Here is some pictures from today.
Had some problems with the new differential so the solution was to take the driveshafts from the C250tdt and cut the propshaft and weld them together.
Fist I machined a sleeve (56,8mm) that fitted nicely inside the propshaft and then it was just a mater of welding
I got my prop modified with the correct 6 speed end at a prop shop, they ballanced it too. Cost a fortune! Anyway they also inserted a sleeve. Ballanced too as a whole unit.
I see. Thinking of alternatives I was also going along these lines with an electric lift pump into a swirl pot and running a 044 from that with a RR FPR connected to the plenum.
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
maxypriest
02-04-2015, 04:48 AM #45
(02-02-2015, 02:29 PM)F.R.A.S Here is some pictures from today.
Had some problems with the new differential so the solution was to take the driveshafts from the C250tdt and cut the propshaft and weld them together.
Fist I machined a sleeve (56,8mm) that fitted nicely inside the propshaft and then it was just a mater of welding
I got my prop modified with the correct 6 speed end at a prop shop, they ballanced it too. Cost a fortune! Anyway they also inserted a sleeve. Ballanced too as a whole unit.
I see. Thinking of alternatives I was also going along these lines with an electric lift pump into a swirl pot and running a 044 from that with a RR FPR connected to the plenum.
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
(02-03-2015, 12:49 PM)raysorensonQuote:
I'm going to have to do this soon. I had a custom driveshaft with U-joints (cardans) made and the noise and vibration is awful. I think a U-joint at the trans and a big flex disc at the diff should be a good enough compromise.
FRAS you didn't balance dude?
Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]
(02-03-2015, 12:49 PM)raysorensonQuote:
I'm going to have to do this soon. I had a custom driveshaft with U-joints (cardans) made and the noise and vibration is awful. I think a U-joint at the trans and a big flex disc at the diff should be a good enough compromise.
FRAS you didn't balance dude?
Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]
(02-03-2015, 12:49 PM)raysorenson .....
I'm going to have to do this soon. I had a custom driveshaft with U-joints (cardans) made and the noise and vibration is awful. I think a U-joint at the trans and a big flex disc at the diff should be a good enough compromise.
Did you include a slip joint on the driveshaft ?? The reason being is that the engine is on rubber mounts, the transmission is on rubber mounts and the differential is on rubber mounts. Everything moves a bit. Normally the rubber flex discs absorb the movement but with U joints you are binding everything together you are looking for trouble. FYI my mercedes t1 van,om617 engine, has one u joint at the transmission, a center carrier bearing with a slip yoke and a driveshaft with two u joints between the bearing and the rear axle. It has no noticable vibration.
(02-03-2015, 12:49 PM)raysorenson .....
I'm going to have to do this soon. I had a custom driveshaft with U-joints (cardans) made and the noise and vibration is awful. I think a U-joint at the trans and a big flex disc at the diff should be a good enough compromise.
Did you include a slip joint on the driveshaft ?? The reason being is that the engine is on rubber mounts, the transmission is on rubber mounts and the differential is on rubber mounts. Everything moves a bit. Normally the rubber flex discs absorb the movement but with U joints you are binding everything together you are looking for trouble. FYI my mercedes t1 van,om617 engine, has one u joint at the transmission, a center carrier bearing with a slip yoke and a driveshaft with two u joints between the bearing and the rear axle. It has no noticable vibration.
DO NOT connect boost on the FPR. Turn it to 3bar and leave it there.
(02-04-2015, 04:48 AM)maxypriest I got my prop modified with the correct 6 speed end at a prop shop, they ballanced it too. Cost a fortune! Anyway they also inserted a sleeve. Ballanced too as a whole unit.
I see. Thinking of alternatives I was also going along these lines with an electric lift pump into a swirl pot and running a 044 from that with a RR FPR connected to the plenum.
Hahahaha
No we don't balance in SWITZERLAND Internal joke
(02-04-2015, 07:32 AM)Hario FRAS you didn't balance dude?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Prop looks good.
DO NOT connect boost on the FPR. Turn it to 3bar and leave it there.
(02-04-2015, 04:48 AM)maxypriest I got my prop modified with the correct 6 speed end at a prop shop, they ballanced it too. Cost a fortune! Anyway they also inserted a sleeve. Ballanced too as a whole unit.
I see. Thinking of alternatives I was also going along these lines with an electric lift pump into a swirl pot and running a 044 from that with a RR FPR connected to the plenum.
Hahahaha
No we don't balance in SWITZERLAND Internal joke
(02-04-2015, 07:32 AM)Hario FRAS you didn't balance dude?
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Blew my head gasket
So when ripping the head off what do I do??? Yea I change rods of course
Going to custom make new rod bushings to be able to use the stock 26mm wrist pin.
And I'll build a small catch tank for fuel so I can use a real fuel pump and a FPR and boost 3.2-3.5bar in my little om604
Awesome day in terms of decision making
Only problem is that the car will be stationary for a month or two
or three.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
Alright guys here's an update for you.
Blew my head gasket
So when ripping the head off what do I do??? Yea I change rods of course
Going to custom make new rod bushings to be able to use the stock 26mm wrist pin.
And I'll build a small catch tank for fuel so I can use a real fuel pump and a FPR and boost 3.2-3.5bar in my little om604
Awesome day in terms of decision making
Only problem is that the car will be stationary for a month or two or three.
F-tune Performance
I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.
(02-05-2015, 05:57 PM)F.R.A.S Alright guys here's an update for you.Is the headgasket made from metal or is it soft material like OM603? I really thought that rods go first.
Blew my head gasket
So when ripping the head off what do I do??? Yea I change rods of course
Going to custom make new rod bushings to be able to use the stock 26mm wrist pin.
And I'll build a small catch tank for fuel so I can use a real fuel pump and a FPR and boost 3.2-3.5bar in my little om604
Awesome day in terms of decision making
Only problem is that the car will be stationary for a month or two
Why are you going to use separate catch tank for fuel? I have 044 pump with FPR under the bonnet, fuel lines under the body and fuel tank are stock. I made it like that - fuel comes from tank to 044, after 044 there are FPR and from FPR overflow is not going back to fuel tank but it's running in little circle under the bonnet back to 044. Return line to fuel tank is stock from filter housing. I have fuel pressure 1 bar on idle and about 3 bar on max boost like Dieselmeken recommended. Maybe if I take picture you'll understand what i'm trying to explain.
(02-05-2015, 05:57 PM)F.R.A.S Alright guys here's an update for you.Is the headgasket made from metal or is it soft material like OM603? I really thought that rods go first.
Blew my head gasket
So when ripping the head off what do I do??? Yea I change rods of course
Going to custom make new rod bushings to be able to use the stock 26mm wrist pin.
And I'll build a small catch tank for fuel so I can use a real fuel pump and a FPR and boost 3.2-3.5bar in my little om604
Awesome day in terms of decision making
Only problem is that the car will be stationary for a month or two
Why are you going to use separate catch tank for fuel? I have 044 pump with FPR under the bonnet, fuel lines under the body and fuel tank are stock. I made it like that - fuel comes from tank to 044, after 044 there are FPR and from FPR overflow is not going back to fuel tank but it's running in little circle under the bonnet back to 044. Return line to fuel tank is stock from filter housing. I have fuel pressure 1 bar on idle and about 3 bar on max boost like Dieselmeken recommended. Maybe if I take picture you'll understand what i'm trying to explain.
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