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+--- Thread: TheDon's OM606 build (/showthread.php?tid=4187)
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TheDon's OM606 build - TheDon - 12-16-2012
Here it is, my official OM606 build thread.
![[Image: 484173_10151097066456534_2068488291_n.jpg]](https://sphotos-b.xx.fbcdn.net/hphotos-snc7/484173_10151097066456534_2068488291_n.jpg)
Here it is, my 606 thats going to eventually go into my W124.
![[Image: 406803_10151098120346534_2025296745_n.jpg]](https://sphotos-a.xx.fbcdn.net/hphotos-ash4/406803_10151098120346534_2025296745_n.jpg)
It has 1 stuck glow plug which I am not too worried about. I'd rather have 5 that I can remove than 1 broken.
Plan of action is to get it running with a 603 pump and all stock running gear and eventually go super turbo.
I will be sticking with my automatic transmission, unless I come across a 5 speed and then I will do that swap as well.
I have sold off the injection pump that was on it and will be getting a 603 pump soon. If my source pulls through it might be a pump from a 3.5L 603.
Plan of action is as follows
Swap 603 pump
Swap 603 oil pan and oil pump pick up or get a V8 sway bar and install that so the oil pan clears
Rewire the glow plug harness so it works with the early W124 style glow plug clips
Figure out how to get the throttle linkage to work
Figure out where to put the coolant reservoir overflow line
Vacuum lines and etc
Coolant hoses for the heater core
AC compressor, do I swap it or not?
fabricate exhaust
Swap spin on fuel filter housing with one from a 603, maybe?
There might be more but right now my main goal is to get the engine running out of the car.
I think I will have to some how connect the oil cooler lines to the input/output so oil isn't spewing everywhere. As well as warming the plugs and how to power the starter.
Other than that It's going to be fun. I'm sure if I was in finland I would have had this thing running and in the car last week!
RE: TheDon's OM606 build - TheDon - 01-06-2013
Ordered an Om603 mechanical injection pump!
RE: TheDon's OM606 build - Simpler=Better - 01-06-2013
(12-16-2012, 02:08 PM)TheDon It has 1 stuck glow plug which I am not too worried about. I'd rather have 5 that I can remove than 1 broken.
keep soaking it with kroil, then heat and an impact
RE: TheDon's OM606 build - TheDon - 01-07-2013
I need a bernzomatic torch then
Side note, what size hose would I need to connect the cooler lines together so I can run the thing
RE: TheDon's OM606 build - Simpler=Better - 01-07-2013
No, you need a BENZ-O-MATIC!!!!!
Pawn shop might have a cheap ignition-less torch head, they're a dime a dozen
I'd use whatever size heater hose works for a short test
RE: TheDon's OM606 build - TheDon - 01-08-2013
Ha, yes a Benz o matic.
I forgot to ask, I have the spin on fuel filter housing from the 606 and the fuel lines on it are different than the 603's. Will I need a 603 fuel filter housing?
RE: TheDon's OM606 build - TheDon - 01-10-2013
I swear it's like waiting for Christmas for this pump to arrive. Saturday I going to my favorite junkyard and getting the front sway bar from the 400E that's sitting there. $15 for a sway bar compared to 200 ish for a 603 pan and oil pump pickup.
RE: TheDon's OM606 build - Bangaway - 01-10-2013
Talk about christmas--I just ordered my 606.962. Five days for shipping--I can't wait that long.
RE: TheDon's OM606 build - TheDon - 01-10-2013
(01-10-2013, 07:00 PM)Bangaway Talk about christmas--I just ordered my 606.962. Five days for shipping--I can't wait that long.
Can't wait to see pics.
RE: TheDon's OM606 build - TheDon - 01-11-2013
I called my dealership contact about a 606 NA throttle linkage assembly and he can get it for me. The entire thing is around $258 but thats every nut and bolt and ball joint and linkage. I just need the three main pieces and If I can get a few detailed shots of the linkage I can most likely get the nuts and bolts I need from my stash or the junkyard. As well as any linkage I may need.
This is one of the key issues to getting the 606 to work in my W124. I saw another project where the guy took an NA linkage and modified it to mount to the turbo intake and cut out the web on the intake so the linkages would fit.
After that its a matter of determening if the bowden cable is long enough (I hope) and mounting it up!
RE: TheDon's OM606 build - maxypriest - 01-11-2013
My writte off w124 606na will be back with me from the insurance assessors next week. I will take some pictures of the linkage, it's dead simple you know.
My car is RHD.
RE: TheDon's OM606 build - Bangaway - 01-11-2013
Hansebanger77 made this video of his throttle linkage. http://www.youtube.com/watch?v=SdUeRgrKgxM
Take lots of pics of what you do.
RE: TheDon's OM606 build - TheDon - 01-12-2013
(01-11-2013, 11:44 PM)Bangaway Hansebanger77 made this video of his throttle linkage. http://www.youtube.com/watch?v=SdUeRgrKgxM
Take lots of pics of what you do.
He's using the NA 606 linkage set up as well as the NA intake (not sure if engine was orignally NA or Turbo but anyways)
I'm hoping for someone to get some nice close up detailed shots. Cross posting on other forums.
I did nab a bunch of linkages from the junk yard today and I'll get more every time I see them just to have them.
RE: TheDon's OM606 build - TheDon - 01-14-2013
While I wait for my pump and to save up to do more to the engine I decided to clean it
![[Image: 734724_10151161500021534_625952516_n.jpg]](https://sphotos-a.xx.fbcdn.net/hphotos-snc6/734724_10151161500021534_625952516_n.jpg)
Before
![[Image: 734116_10151161500296534_227738125_n.jpg]](https://sphotos-a.xx.fbcdn.net/hphotos-prn1/734116_10151161500296534_227738125_n.jpg)
After
Cleaned it with some oven cleaner and degreaser. Trick is to spray the oven cleaner on and let it sit for 10 seconds then wipe it off and hit it with degreaser/water to kill the oven cleaner. Worked great on the block too
RE: TheDon's OM606 build - TheDon - 01-15-2013
Trying to order pieces of the NA 606 throttle linkage and one of the 3 main pieces might be no longer available. It's not one ofthe two easy pieces I could probably bend and make myself. Yargh
Just got the word the piece is NLA. Damn it
RE: TheDon's OM606 build - Simpler=Better - 01-15-2013
Convert to cable driven and just make a bracket. That's my plan for my 617-I lost most of my crap in my move.
RE: TheDon's OM606 build - TheDon - 01-15-2013
The 124 already is cable driven. The issue is throttling the pump and controlling the transmission Bowden cable. If I had a 6 speed laying around it would be cake! But I'm slowly hunting for a manual to stick behind the thing.
RE: TheDon's OM606 build - maxypriest - 01-16-2013
(01-15-2013, 10:41 PM)TheDon The 124 already is cable driven. The issue is throttling the pump and controlling the transmission Bowden cable. If I had a 6 speed laying around it would be cake! But I'm slowly hunting for a manual to stick behind the thing.
I'm planning a similar project, w124,606turbo,e220cdi manual box, kkd, modded pump.... Etc. I've got my written off w124 arriving this Friday (was to be today), I'll be robbing that for parts and probably building a turbo down pipe on it as a jig as here in the uk there is a RHD steering box issue, it's whe the exhaust goes!
This saturday I'm off to see a w210 300td, daily run about till I rob the engine! I test drove it last week and the mechanics are MINT, the engine is like new and pulls really well.100,000 miles with full Merc history.
Watching the dons post and others with interest!
RE: TheDon's OM606 build - TheDon - 01-16-2013
So I got in touch with another dealership and they claim they can get me the part that is missing. They quoted me at $270 for the entire linkage in the diagram, which I do not need since a majority of it is linkages I already have and misc nuts and bolts I have. So I'll shoot them my part numbers I want and hopefully get the entire linkage setup I need.
I just got an email confirming delivery of my injection pump too, but it went to my previous address which is 5 miles down the road.. awesome!
RE: TheDon's OM606 build - Bangaway - 01-16-2013
I decided just to get a complete 606NA with the pump, throttle, manifold, oil filter housing... Will the 606NA oil fliter housing work instead of the 603 oil filter housing? I figure after I search for all these parts and ship them, it would be easier to buy a 606NA and take the parts I need. That's the idea. Now I have two 606s on the way. Christmas twice. My garage is already full of too much stuff. Anybody need a 606NA long block...oh in about 2 months?
RE: TheDon's OM606 build - TheDon - 01-16-2013
If you can make the oil cooler lines work then stick with the stock oil filter housing. I'm going to swap my 603 housing to my 606 block so I can keep the stock oil cooler set up
RE: TheDon's OM606 build - g kosters - 01-16-2013
hey
do you already have a v8 swaybar ?
and will you keep the stock turbo first ?
isnt it better tho stick with manuel first because im planning tho use
the 722 also but dont want tho mess it up before i got the chance tho reinforce it
and a five speed is way cheaper
tho mess up :p
RE: TheDon's OM606 build - TheDon - 01-16-2013
The 400E at my junkyard was scrapped before I got to it. I need a V8 sway bar, i am on the hunt. I am going to stick with the stock turbo first.
It is very hard finding a manual here in the US to bolt up to the engine, especially on my budget.
I got my pump into today.. I opened it up to this
![[Image: 428116_10151164590106534_1937319973_n.jpg]](https://sphotos-b.xx.fbcdn.net/hphotos-ash4/c0.0.403.403/p403x403/428116_10151164590106534_1937319973_n.jpg)
The seller used straw as a damn packing material.. STRAW!!! The ALDA is damaged beyond any form of repair and there is probably straw in the delivery valves and who knows what else happened to the pump while it knocked around in sub standard packing. I'm pissed. I haven't even bothered to lament on how my allergies are now bothering the crap out of me because I wasn't prepared for a box of friggin straw!!!!!!!!!!!
![[Image: 530735_10151164673116534_394264368_n.jpg]](https://sphotos-a.xx.fbcdn.net/hphotos-prn1/530735_10151164673116534_394264368_n.jpg)
Freshly picked from the injection pump patch......And I seemed to have scratched the round thing on the front of the pump, which I have no idea what it is.... I hope it doesn't leak.
RE: TheDon's OM606 build - aaa - 01-17-2013
Eh the scratch shouldn't be a big deal. The o-ring sits before it.
RE: TheDon's OM606 build - Simpler=Better - 01-17-2013
File a claim for a refund. A new ALDA is what, $300?
RE: TheDon's OM606 build - TheDon - 01-17-2013
It was on peaches. He's sending me another ALDA I need to order the new shaft seal for the pump
RE: TheDon's OM606 build - Simpler=Better - 01-17-2013
Well, in the meantime start polishing it. If you IP doesn't have a mirror finish you're doing it wrong
RE: TheDon's OM606 build - TheDon - 01-17-2013
I'll get around to cleaning
Also pissed me off because I specifie for fedex shipping which would be insure for a minim of $200 automatically.
RE: TheDon's OM606 build - MFSuper90 - 01-19-2013
Straw... lol He must have been a farmer
Hell, I'm a farmer and even though we have extra straw laying around, I wouldn't use it as a packing material!!
RE: TheDon's OM606 build - TheDon - 02-10-2013
Bought another part of my project today
![[Image: 538293_10151220267856534_700272287_n.jpg]](https://sphotos-a.xx.fbcdn.net/hphotos-frc1/538293_10151220267856534_700272287_n.jpg)
722.6 5 speed auto... brought it home for $137... not bad!
RE: TheDon's OM606 build - Bangaway - 02-12-2013
Did you get your throttle figured out yet?
RE: TheDon's OM606 build - TheDon - 02-12-2013
nope, still searching for an NA linkage. side note, I need to find a good site to host photos, photobucket and facebook are not exactly the best.
I havent even tested my engine yet. I need a 603 fuel filter housing and something to connect the oil cooler lines together before I can
RE: TheDon's OM606 build - JustPassinThru - 02-12-2013
(02-12-2013, 01:25 PM)TheDon nope, still searching for an NA linkage. side note, I need to find a good site to host photos, photobucket and facebook are not exactly the best...
Didn't you just buy an NA linkage over on PP?
I use tinypic.com
Can't upload a batch of pics at once though, only one at a time, and it makes you type in a Captcha challenge phrase for each one. But tinypic is reliable.
RE: TheDon's OM606 build - majesty78 - 02-13-2013
www.abload.de ;-)
RE: TheDon's OM606 build - TheDon - 02-13-2013
(02-12-2013, 05:30 PM)JustPassinThruStill waiting for pictures of the linkage. The guy says its from a '93 606 but I'm certain we didn't get the 606 until 95. But we shall see(02-12-2013, 01:25 PM)TheDon nope, still searching for an NA linkage. side note, I need to find a good site to host photos, photobucket and facebook are not exactly the best...
Didn't you just buy an NA linkage over on PP?
I use tinypic.com
Can't upload a batch of pics at once though, only one at a time, and it makes you type in a Captcha challenge phrase for each one. But tinypic is reliable.
RE: TheDon's OM606 build - Bangaway - 02-13-2013
The 606 was available in 93. I know that it was always a "'95" in the U.S, though. In other places it was officiallly a "93."
RE: TheDon's OM606 build - TheDon - 02-13-2013
Hopefully its the linkage I need. I even sent him the parts diagram of what I need.
This weekend I am going to mount my pump and hook the oil cooler lines together and see if I can get it started.
RE: TheDon's OM606 build - TheDon - 02-13-2013
![[Image: 5642_10151225492566534_13684440_n.jpg]](https://sphotos-b.xx.fbcdn.net/hphotos-snc6/5642_10151225492566534_13684440_n.jpg)
603 pump installed!
I hope I did it correctly. I lined the pump up to the gear (didn't have the timing basket in place because I do not feel like pulling my vac pump out of my 603 to get the tool and fight with the gasket) and put the center bolt in to pull it into its splines. Then I put the mounting bolts on and put it on loose. Then I used the turnbuckle to line up the hard lines and bolted the pump on then the hard lines.
I did lock the pump with the tool on the bench before installing.
Hopefully Tomorrow I can find some hose at the hose supply house to connect the oil cooler lines together so I can run it once I get the fuel lines. It's slowly but surely coming together.
I also need to get a new charger for my camera so I can use that instead of my iPhone.
RE: TheDon's OM606 build - Druk - 02-14-2013
Not convinced you should time the pump to the previous hard line alignment. The pump should be set to the timing mark with the lock in place and bolted up then the lines fitted to the pump.
RE: TheDon's OM606 build - TheDon - 02-14-2013
I locked the pump prior to installing it.......
RE: TheDon's OM606 build - Druk - 02-14-2013
(02-14-2013, 07:56 AM)TheDon I locked the pump prior to installing it.......
Got that, but then you said you'd used the turnbuckle to align the hardlines before finally tightnening up the bolts? Would that have not changed the pump timing?
RE: TheDon's OM606 build - TheDon - 02-14-2013
(02-14-2013, 08:18 AM)Druk(02-14-2013, 07:56 AM)TheDon I locked the pump prior to installing it.......
Got that, but then you said you'd used the turnbuckle to align the hardlines before finally tightnening up the bolts? Would that have not changed the pump timing?
Shouldn't have changed. Before I adjusted the turnbuckle the chain had slack in it and now it's tight like it was previously. I'll turn it over by hand to make sure nothing binds an if I have to retune the pump later I will.
Stopped by amazon hose to see about making a fitting to connect the oil lines and for $43 they can make one.
But the only thing is the male end of the fitting isn't a half sphere like the original style. They only have a flat face. I suspect that might be an issue.
Is there any other way I can connect the cooler lines? Maybe they can cut the old fittings off and crimp something else on. Ideas?
RE: TheDon's OM606 build - Druk - 02-14-2013
This is what I did. Cut the Merc connectors off and got hydraulic shop to crimp new standard ends on.
Bracket is to support weight of pipes from sagging.
![[Image: turbo047.jpg]](http://i62.photobucket.com/albums/h112/a10ruk/300TD/turbo047.jpg)
RE: TheDon's OM606 build - TheDon - 02-14-2013
Well, I am going with the 603 oil cooler lines once its in my car.
I'm talking about connected them together for running the engine outside of the car without an oil cooler.
Also, whats the story on your fuel lines. Looks like you've got 606 and 603 stuff there.
Got any more pics of your engine compartment? It looks like your oil cooler lines wouldn't interfere with the intake manifold.
RE: TheDon's OM606 build - Druk - 02-15-2013
(02-14-2013, 06:19 PM)TheDon Well, I am going with the 603 oil cooler lines once its in my car.
Understood. Will the lines marry up when it's installed or will you still need to extend them?
(02-14-2013, 06:19 PM)TheDon Also, whats the story on your fuel lines. Looks like you've got 606 and 603 stuff there.
They're a mixture of 606.910 n/a and 606.962 fuel lines. Just what suits the installation. I've also got that extra filter to plumb in yet. whether to have it before or after the lift pump is the next question.
(02-14-2013, 06:19 PM)TheDon Got any more pics of your engine compartment? It looks like your oil cooler lines wouldn't interfere with the intake manifold.
The clamp thingy holds the lines back against the chassis rail and away from the intake. Note they disappear out through the inner wing. This is a 107 conversion. The cooler is re-mounted horizontally behind the front lower spoiler and in front of the rad instead of vertically beside it as per standard. I used the donor W210 radiator so there was no room.
![[Image: turbo051.jpg]](http://i62.photobucket.com/albums/h112/a10ruk/300TD/turbo051.jpg)
![[Image: turbo038.jpg]](http://i62.photobucket.com/albums/h112/a10ruk/300TD/turbo038.jpg)
.
RE: TheDon's OM606 build - TheDon - 02-15-2013
Very cool. I have to go with the 603 lines so they do not interfere with the intercooler plumbing.
I like your build. Very nice
RE: TheDon's OM606 build - TheDon - 02-16-2013
I was looking at my girlfriends W123 today and noticed that the oil cooler lines are very similar to the 606's lines. Check the parts prices at the yard, $12 for an oil cooler. I think I'll just nab the w123's oil cooler and lines and take them home. I'll make it work!
I also removed the injection pump and reinstalled it. Before removal I put the engine at 15 degrees as specified in the manual, removed the pump. I was having an issue with the tool locking to the pin so I made the slot a little bit wider so it would catch(it worked fine on the 606 electronic pump) and then it was locked. Reinstalled and its fine.
Turned the engine over by hand and nothing binds, ive got a ton of compression for sure, and all of the timing marks line up for the pump.
RE: TheDon's OM606 build - Druk - 02-16-2013
(02-16-2013, 11:09 AM)TheDon I was looking at my girlfriends W123 today and noticed that the oil cooler lines are very similar to the 606's lines. Check the parts prices at the yard, $12 for an oil cooler. I think I'll just nab the w123's oil cooler and lines and take them home. I'll make it work!
I think it's the same same cooler as in my pic above? If so, be careful of the union into the cooler cos they're ally and fusion welded and after a while the weld can get brittle so when you put strain on the line nut to undo it fractures off the cooler. Ask me how I know that?
RE: TheDon's OM606 build - TheDon - 02-16-2013
(02-16-2013, 11:58 AM)Druk(02-16-2013, 11:09 AM)TheDon I was looking at my girlfriends W123 today and noticed that the oil cooler lines are very similar to the 606's lines. Check the parts prices at the yard, $12 for an oil cooler. I think I'll just nab the w123's oil cooler and lines and take them home. I'll make it work!
I think it's the same same cooler as in my pic above? If so, be careful of the union into the cooler cos they're ally and fusion welded and after a while the weld can get brittle so when you put strain on the line nut to undo it fractures off the cooler. Ask me how I know that?
I've had two W123's now and I know that the oil cooler does that. I was just going to remove it from the oil filter housing end and leave it all attached.
I also went to the junk yard to find the cooler but they crushed the car, darn. But I did score a non faded and cracked center console wood (shifter surround) for $8. Now all of my wood is crack free and the same shade. I was cruising around on ebay and found a R129 shifter for $99 buy it now or best offer so I tossed in an offer of $50 expecting it to be shot down, only to get it accepted. Crap, should have offered $40. So, I just paid for it
RE: TheDon's OM606 build - mbz123 - 02-18-2013
(02-10-2013, 02:53 PM)TheDon Bought another part of my project today
722.6 5 speed auto... brought it home for $137... not bad!
OKay, I'll bite. How did you accomplish this? Do you normally come across .6's at the yard? And for a measly hundred and change at that? Having one hell of an adventure just trying to hunt down a 4spd for mine.
BTW thanks for the motivation. I gotta get out and clean mine.
D