Max´s 190D 2,5 Turbodiesel - Printable Version

Max´s 190D 2,5 Turbodiesel - Printable Version

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Max´s 190D 2,5 Turbodiesel - Max - 10-17-2014

Hi,

my Name is Max and i am from Germany.

This is my 190D 2,5 Turbodiesel:

[Image: wMgYUQ_-fmEcBEU_kSWrXF5YtIHYk91Y40tPX-WS...-h203-p-no]

[Image: wMgYUQ_-fmEcBEU_kSWrXF5YtIHYk91Y40tPX-WS...-h203-p-no]

It was an 2.0 N/a Diesel 4-Speed.

I did a complete Swap from a Original 2,5 Turbo inkl. 5-Speed, 3,46 Rearaxle, Dirveshafts, Propshafts etc.....

I also did a rebuild to The Front- and Rearaxle with New Parts, Complete AMG-Package, New Paintjob and Interior...

Also rewelded the whole Front to 190Ee 2,6 Specs.

Link to Picturegallery with 217 Pics Smile

>>>LINK<<<

Mods did to the Engine:

Waterpump from OM605
Turbo from OM606
Max Fuel out of Stockpump (Update on Pump this Winter)
A/A Intercooler

Runs pretty well as Daily Driver. (No Winter Use)

Plans for this Winter:

OM605 + Bigger Turbo
Injectionpump "Update"
6-Speed from 270cdi
More Power Big Grin

Greets

Max

RE: Max´s 190D 2,5 Turbodiesel - raidaru - 10-17-2014

Nice ride brah! Yes, put an om605/606 there, modded pump, big turbo and smoke those AMG fans out there Cool

RE: Max´s 190D 2,5 Turbodiesel - raysorenson - 10-18-2014

Very clean project. Love the color. I have that same radio in 2 cars.

RE: Max´s 190D 2,5 Turbodiesel - orion - 10-20-2014

Nice projekt,

i also swapped to a OM605 from W202 into my W124. The Engine is much better in terms of thermal stabitility an the power delivery is very good with the 605 charger. I have exchanged the original elements for larger 7mm in the 602 pump. Now I have no smoke and a very good response. My first experiences in this season have shown that the motor is stable over 100km with full load.
I will follow your report.

best greetings

RE: Max´s 190D 2,5 Turbodiesel - Max - 10-20-2014

Hi Orion,

until know i had no thermal problems with my 602.

Maybe it´s because the Head is from a OM662 (2,9 Ssangjong)

Max. Temperatur under Full Load was 580° Celsius.

But i agree 605 flows much more than 602, more Power comes easy.

First Setup for the 605 is:

7,5mm Pump + ALDA
Holset HY35 Turbo with 10cm Exhausthousing
2,5" Exhaust

Hoping for 250 - 300 Hp Sleepy

Greets

Max

RE: Max´s 190D 2,5 Turbodiesel - orion - 10-20-2014

I had much more AGT with the 7mm pump on my 602. Last summer i detected more than 640 degrees with 605 charger. After remove the head i found three cracks on it. The engine has run less than 100k kilometers and 4k with tuned setup.
The HY is a good option for 250++ hp on 605. What kind of ALDA will you obstruct, outside?

For my W124 I want to go an other way. Right now i have installed the 5-speed Gearbox with a 3,27 diff. Next time i will swap to 5-speed e-controlled automatic gaerbox and VTG-Charger. I hope for 200 Hp with early torque rise.
We will see

greetings

RE: Max´s 190D 2,5 Turbodiesel - Max - 10-20-2014

Hi,

ALDA will be the Original one so far.

Gearbox will be 6-Speed from 270cdi and 3,07 Rearaxle.

Greets

Max

RE: Max´s 190D 2,5 Turbodiesel - orion - 10-20-2014

I had already read above. The gearbox is a good choise for your racecar, I will only build a tame cruiser Big Grin

Do you mean the control range of the original ALDA is sufficient?

RE: Max´s 190D 2,5 Turbodiesel - olefejer - 10-20-2014

(10-20-2014, 04:04 PM)orion I had already read above. The gearbox is a good choise for your racecar, I will only build a tame cruiser

Do you mean the control range of the original ALDA is sufficient?

Hi Orion
You send me a PM but it look like you have disabled to recieve PM ;-)
you can write me at olefejer@gmail.com

RE: Max´s 190D 2,5 Turbodiesel - orion - 10-20-2014

is done

RE: Max´s 190D 2,5 Turbodiesel - Max - 11-12-2014

First Parts arrive at the Garage Big Grin

6-Speed + Linkage

Holset HX30W Super (Thanks to Alcaid Wink

)

Engine is going to be removed this Weekend.

I also found a 605 for a good Price, just have to pick it up sometimes... Angel

RE: Max´s 190D 2,5 Turbodiesel - Hario' - 11-14-2014

Very nice gearbox, I always wanted the 6-speed. I definitely think you will make 300hp with 7.5 elements!

Now you just need a nice inlet manifold.. Tongue

What are you thinking for exhaust manifold? Ironically I need one/..

RE: Max´s 190D 2,5 Turbodiesel - Max - 11-14-2014

Hi,

i would be happy with 250Hp, more is always better, but we will see waht happens.

Gearbox is brandnew, was a Bargain from Ebay Big Grin

And yes youre right, I definitly need a nice Inletmanifold ;-)

Im not already sure waht to do with the Exhaust Manifold.

For now i think i´ll make an adapter to the Stock Manifold like the one you did.

A Manifold like the ones from KKD would be perfect but they seem not to be available them at the Moment. (At least i cant find them on their Homepage)

RE: Max´s 190D 2,5 Turbodiesel - Hario' - 11-21-2014

I've heard the Turbobandit OM60X manifolds which look like Chinese shit are actually good quality according to the guy on here doing a 606 into 202 swap..

Your IM is nearly ready, just needs a clean and the cutout filling in - Had to be cut for TIG torch clearance unfortunately, it will be filled, blended and should be hardly noticeable!

RE: Max´s 190D 2,5 Turbodiesel - Max - 12-23-2014

Hi,

Some Updates:

- Got the Engine - > Complete Rebuild with new Bearings, Gaskets etc...

- Flywhell and Clutch arrived

- Intakemanifold from Hario arrived

and 1000 other little things... Angel

Some Pictures:

RE: Max´s 190D 2,5 Turbodiesel - muuris - 12-24-2014

Nice project, it will easily make 300hp with those parts. Just measure exhaust manifold pressures and make adjustments so that it won't climb higher than boost.

Another note, get rid of the 605 crank damper, use 2-piece 602 damper instead and use a stop-screw to secure the hub to crank. These have a tendency to loosen the big bolt on damper and as the crank key is very weak, it makes a mess out of both crank head and the damper. Been there, done that. No problems after the stop screw. It's very little effort now when engine is out of the car.

This is a shot of my 605 crank when I removed the damper from a completely stock engine. Too bad I didn't take a shot of the repair job..

RE: Max´s 190D 2,5 Turbodiesel - Max - 12-24-2014

(12-24-2014, 03:24 AM)muuris Another note, get rid of the 605 crank damper, use 2-piece 602 damper instead and use a stop-screw to secure the hub to crank. These have a tendency to loosen the big bolt on damper and as the crank key is very weak, it makes a mess out of both crank head and the damper. Been there, done that. No problems after the stop screw. It's very little effort now when engine is out of the car.

Thanks for the Information, good to know Big Grin

Im going to take care about this, but honestly i never heard of this Failure at the om605´s before.

A 602 2-Pice Damper is laying around Wink

Do you have a picture of the "Stop-Screw" ?

This Enging is going to be more om602 than OM605 Tongue

Oilpan, Enginemounts, Oilfilterhousing, Crankshaft, Injectionpump, vacuum pump, Steeringpump, Fuelfilterhousing, all from OM602 Tongue

Greets

Max

RE: Max´s 190D 2,5 Turbodiesel - muuris - 12-25-2014

(12-24-2014, 07:25 AM)Max Im going to take care about this, but honestly i never heard of this Failure at the om605´s before.

Yeah, I hadn't heard about it either when this first happened to me in my previous OM606. After that I discovered this will happen even to a to bone stock engine at some point and when I got my current OM605, it had already happened to it.

Some pics of the 606. The stock damper. Crank head. A stop screw. Secured OM601/2/3 damper hub with two screws. The stock big bolt covers these.

When making threads, one has to make sure the hub is bottomed, as the threads of the screws will stop the hub both from spinning or moving back-forth.

RE: Max´s 190D 2,5 Turbodiesel - Max - 12-26-2014

Thanks for the Pictures muuris Wink

Now i know waht to do Cool

This Engines seem to have the same Problem with the Intake Camshaftwheel wehn doing higher Revs ... Tongue

RE: Max´s 190D 2,5 Turbodiesel - Max - 01-12-2015

Painted all the Engine Parts.

Also the intake Manifold from Hario Big Grin

RE: Max´s 190D 2,5 Turbodiesel - Hario' - 01-13-2015

Satin black for OEM+ loveliness!

Is the HX super a 9cm2 housing?

RE: Max´s 190D 2,5 Turbodiesel - Max - 01-13-2015

(01-13-2015, 04:38 AM)Hario Is the HX super a 9cm2 housing?

No, its a 6cm2 Housing

Greets

Max

RE: Max´s 190D 2,5 Turbodiesel - Ksteen2 - 01-14-2015

hello, really nice prodjekt.
but I saw one thing, you are using 2,5" exhaust?
thats waaaay to small.
you will gett massive backpressure..
you need atleast 3", and that maybe to small also Smile

just a tip Smile

RE: Max´s 190D 2,5 Turbodiesel - Max - 01-14-2015

(01-14-2015, 05:17 PM)Ksteen2 but I saw one thing, you are using 2,5" exhaust?
thats waaaay to small.

Hi,

thanks for the Tip, i havent bought or build any Exhaustparts for this car yet.

But yes, i think 3" will be the better Way to go.

RE: Max´s 190D 2,5 Turbodiesel - bmartins - 01-18-2015

Wow...perfect!!!
I also own since yesterday a W201 2.5 turbo and i want for now 200hp.
I saw you changed the the water pump from a OM605, why?
I am thinking to get an intercooler, Mercedes GT22v or GT23v and explore my fuel pump to the max to see what i can get....
What do you think?
Keep going...nice project

RE: Max´s 190D 2,5 Turbodiesel - Max - 01-18-2015

(01-18-2015, 05:49 AM)bmartins Wow...perfect!!!
I also own since yesterday a W201 2.5 turbo and i want for now 200hp.
I saw you changed the the water pump from a OM605, why?
I am thinking to get an intercooler, Mercedes GT22v or GT23v and explore my fuel pump to the max to see what i can get....
What do you think?
Keep going...nice project

Better Cooling. OM605 Waterpump has a 72mm impeller, the Stock 602 Pump only has a 69mm. You also have to Change the Waterpump Housing to Fit the 605 Waterpump. (You also have to close 2 Vent Holes in the Houing).

Without bigger Elements the max you will reach is about 150 HP i guess.

Bigger Elements is to most important Thing to Change Big Grin

Yesterday i completed the Engine Rebuild.

RE: Max´s 190D 2,5 Turbodiesel - bmartins - 01-18-2015

GOD!!!!!!!!
Thanks for the advise...
I would love to ride your car when finished...
Ok i am planing to get 6mm elements, Mercedes Vito w639 intercooler, GT23v Mercedes...
For now i just want a bit better performance.....
I read a lot but till now i didn´t get any video about add some fuel to my pump!!!
Here in Portugal the power word is for 1.9 PD VW engines....
Can you explain me the fuel improvement...
thanks..

How much do you get there each 6mm element...?

RE: Max´s 190D 2,5 Turbodiesel - Max - 01-18-2015

(01-18-2015, 05:14 PM)bmartins GOD!!!!!!!!
Thanks for the advise...
I would love to ride your car when finished...
Ok i am planing to get 6mm elements, Mercedes Vito w639 intercooler, GT23v Mercedes...
For now i just want a bit better performance.....
I read a lot but till now i didn´t get any video about add some fuel to my pump!!!
Here in Portugal the power word is for 1.9 PD VW engines....
Can you explain me the fuel improvement...
thanks..

How much do you get there each 6mm element...?

Thanks

I made this Picture for a Friend of mine to show him how to increase the Fuel on his Pump, worked also fine on my 602.

First you have to remove the Cover on the back of the Pump
(Be Careful, about 0,3 Liter of Oil is coming out of there)

1. Mutter lösen = Loosen the nut

2. Remove the screw 1 round (or more)

Should give you more Fuel out of your Stock pump.

(Note, Im no Dieselpump Expert, all Operations at own Risk ;-))

RE: Max´s 190D 2,5 Turbodiesel - bmartins - 01-19-2015

ok...lets test it...thanks

RE: Max´s 190D 2,5 Turbodiesel - Max - 01-23-2015

First Fitting Test of Enginge and Transmission.

Fits Perfect, thank´s to OM602 Oilpan Big Grin

I only noticed that i have to machine down the Sprinter-Flywheel about 2 mm in the Middle. Otherwise it wouldn´´t lay plain on the Crankshaft Dodgy

RE: Max´s 190D 2,5 Turbodiesel - Jetmugg - 01-23-2015

Great project and a clean installation.

I will be curious to see how the shifter works out in location as compared to the original.

Steve.

RE: Max´s 190D 2,5 Turbodiesel - bmartins - 02-08-2015

Great job Max....
I alredy get an OM606 turbo pump to get the 6mm element.
Do you know any table to get my dBosch diesel shop here and make the adjustements?
Keep the job...with pics..
Thanks

(01-23-2015, 02:10 PM)Jetmugg Great project and a clean installation.

I will be curious to see how the shifter works out in location as compared to the original.

Steve.

RE: Max´s 190D 2,5 Turbodiesel - Max - 02-08-2015

(02-08-2015, 05:17 AM)bmartins Do you know any table to get my dBosch diesel shop here and make the adjustements?
Keep the job...with pics..

No i dont know a dieselshop in Germany that does adjustments in Pump.

All the Bosch-Shops is asked here said No to swapping Elements etc....

My Pump arrived @ Dieselmeken for 8mm Upgrade

But with Pics i can help Big Grin

Manifold Adapter + Exhaustpressure Line
Maybe later ill´ get a "real" Exhaust Manifold

Turbocharger in Place

Some Parts for Fuel Lineing and Turbo Oil Feed

Intecooler fitted and mounted.

Gear Linkage for 6-Speed ist ready for w201.

Fits pretty well inside the Car Blush

Propshaft measuring

Parts ready for welding Cool

Speedometer from E500 + Speedoconverter

So long..

Greets

Max

RE: Max´s 190D 2,5 Turbodiesel - Kuisma - 02-08-2015

Awesome project Smile

That engine looks like brand new! Tell me more about those white wheels under the table? Amg aero1? i have set of them too.

RE: Max´s 190D 2,5 Turbodiesel - Max - 02-08-2015

Yes the Wheels under the Table are AMG Aero 1 Monoblock. Best Weehls for 201 Big Grin

Here a Picture from last Summer Cool

RE: Max´s 190D 2,5 Turbodiesel - Max - 03-08-2015

Going to see the Finishline Cool

Pump ist back from Sweden Big Grin

Propshaft ist shortend and rewelded to 110mm Flanges, also new balanced.

Gearbox Linkage in Place.

Oilcooler in Place.

Secured the Inletcam, thanks to STD Forum Big Grin

Pumpe installed and Pump-timing set.

Engine almost done, only a few little Things left to do.

A Pivture before putting the Engine in the Car Sleepy

I also found a Manuel limited Slip Differental form an early 2,3-16v Tongue

3 Weeks till Season stars here in Germany Big Grin

Greets

Max

RE: Max´s 190D 2,5 Turbodiesel - saquzi - 03-09-2015

Beautiful! Very clean engine bay... :p

RE: Max´s 190D 2,5 Turbodiesel - muuris - 03-09-2015

Nice and clean work.

Since you have 8mm pump and that tiny turbine housing, keep fueling really low and watch exhaust temperatures and pressures.

Btw you should consider renewing the vacuum pump while you're at it. That old type can snap the timing chain when it's ball bearing give up and drop their contents. New similar one is safe for years ahead.. or get newer type from 606, that doesn't cause damage when saying goodbye. Check this and this.

RE: Max´s 190D 2,5 Turbodiesel - Max - 03-09-2015

(03-09-2015, 02:59 PM)muuris Nice and clean work.

Since you have 8mm pump and that tiny turbine housing, keep fueling really low and watch exhaust temperatures and pressures.

Btw you should consider renewing the vacuum pump while you're at it. That old type can snap the timing chain when it's ball bearing give up and drop their contents. New similar one is safe for years ahead.. or get newer type from 606, that doesn't cause damage when saying goodbye. Check this and this.

Hi,

Pump ist the new 7,5mm Nr.3 Version Element, Fuel ist set actually to 90cc . EGT & EGP are always monitored ;-)

Yes I know the Problem, Vacumpump ist only 5000 KM old, its a almost brandnew Pierburg.

On my old 602 the Pump died this Way but luckily it didnt harm the Engine.

Found most of the Parts before the Oilpump Intake ^^

RE: Max´s 190D 2,5 Turbodiesel - Ksteen2 - 03-09-2015

awesome build !
it look amazingly good!

RE: Max´s 190D 2,5 Turbodiesel - bmartins - 03-12-2015

Hello again...
Keep going your project.....perfect perfect...

Note.. i already bought 6mm elements and a Gt23v....
90cc is the max, right?

RE: Max´s 190D 2,5 Turbodiesel - Max - 03-12-2015

(03-12-2015, 04:34 PM)bmartins Hello again...
Keep going your project.....perfect perfect...

Note.. i already bought 6mm elements and a Gt23v....
90cc is the max, right?

Yes 90cc at the Moment, but the Pump is able to do about 180cc

RE: Max´s 190D 2,5 Turbodiesel - Max - 03-26-2015

Hi,

making good Progress..

All Oil-Lines are ready.

Air, Fuel & Waterpipes are also ready.

Im only waiting for the correct Glowplugs to be delivered and some Exhaustparts from Sweden Big Grin

Going to fire it up next Week Cool

RE: Max´s 190D 2,5 Turbodiesel - Jetmugg - 03-27-2015

Beautiful work, and fantastic documentation. I am inspired to do similar work to my W201 2.5 turbodiesel (OM602 for now).

Steve.

RE: Max´s 190D 2,5 Turbodiesel - Max - 04-01-2015

It´s alive Big Grin

https://youtu.be/1P88FBG-Ieo

EDIT: Re-Uploaded in proper Quality Rolleyes

Greets

Max

RE: Max´s 190D 2,5 Turbodiesel - Repetitio - 04-01-2015

Nice, looking forward to see a driving video Smile

RE: Max´s 190D 2,5 Turbodiesel - svenr - 04-01-2015

Lot of work done there, its rewarding to see it run first time, nice job.

RE: Max´s 190D 2,5 Turbodiesel - Max - 04-02-2015

Thanks Blush

Getting there to drive it the First Time Cool

RE: Max´s 190D 2,5 Turbodiesel - Hario' - 04-02-2015

Now that looks mean as fook!

RE: Max´s 190D 2,5 Turbodiesel - svenr - 04-02-2015

How its sounds only with downpipe spotwelded on? Big Grin