OM606 into a W201 - Printable Version

OM606 into a W201 - Printable Version

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OM606 into a W201 - HughF_UK - 05-10-2010

Finally, after a few years searching on and off and not finding anything affordable or near to my home, on saturday I picked up a 90K mile 606 motor for a bargain price, just 70 miles from my house!

Project w201-606 begins. I have all the transmission parts to convert my w201 to manual, except the flywheel and clutch bits... I just need to sort out a turbo capable 603 pump from germany, ship it to finland then get a nice vnt sorted out.

Pics to follow y'all...

Hugh

RE: Got my 606 motor.. Woohoo! - George3soccer - 05-10-2010

congrats, sounds like a mean setup.

RE: Got my 606 motor.. Woohoo! - HughF_UK - 05-19-2010

Ok, so some pics for you all...

[Image: 20100508_003.jpg]

That was on the way home from collecting it...

I've made a start pulling of burnt bits and everything looks good under the rocker cover:

[Image: 20100511_002.jpg]

I even got the glowplugs out without snapping them.

I pulled the injectors and put them on my tester and they seem good as well...

RE: Got my 606 motor.. Woohoo! - Jtn190D - 05-19-2010

Cool good luck with it.

I would love to put a OM605 in my w201 my its just a lot of money.

RE: Got my 606 motor.. Woohoo! - Alastair E - 05-19-2010

IF that engine has been in a fire....

BE VERY VERY CAREFUL!

Hydroflouric Acid!

--From Viton thats used in 'O' rings and other seals....Get that stuff on ya, and amputation is the Only Cure!!

Desparate as I am for 606 I wouldnt touch that motor personally!

RE: Got my 606 motor.. Woohoo! - Rudolf_Diesel - 05-19-2010

(05-19-2010, 03:15 PM)Alastair E IF that engine has been in a fire....

BE VERY VERY CAREFUL!

Hydroflouric Acid!

--From Viton thats used in 'O' rings and other seals....Get that stuff on ya, and amputation is the Only Cure!!

Desparate as I am for 606 I wouldnt touch that motor personally!

I did not know that about the o-rings, but he is right about the acid - NASTY STUFF it goes to the bones and turns them in to mush. It eats the calcium.

RE: Got my 606 motor.. Woohoo! - HughF_UK - 05-20-2010

Thanks for the headsup on the hydrofluoric acid... I know it's super nasty stuff, but had forgotten that it is produced when viton gets burnt!

Bad as it looks, the only thing that is melted/charred is the oil filter top cap, and that has now been replaced. There is a slight charring of the surface of the pas fluid reservoir and the fuel heater.

The plastic hose clips on the IP were a little melted too but I've cut all those off and binned them anyway.

Alastair, did you get my email?

RE: Got my 606 motor.. Woohoo! - GREASY_BEAST - 05-20-2010

Wow, good to know about the viton. Any other deadly surprises we should know about? Maybe it would be good to make a sticky with all the nasty little things that can kill you.

BTW nice engine!

RE: Got my 606 motor.. Woohoo! - HughF_UK - 06-30-2010

Some slight progress... I rebuilt the starter motor and made some new short test leads. Hooked a battery too it and she's cranking over nicely now. Next step, an IP

RE: Got my 606 motor.. Woohoo! - willbhere4u - 06-30-2010

bad ass I want one!

off topic automatic trans fluid is really bad for you it absorbs in to your skin/blood stream almost instantly! It's one of the biggest cause's of cancer in the automotive world!!! or so I've been told

most grease isn't good for you but you have time to clean it off before you have any real problems

RE: Got my 606 motor.. Woohoo! - Alastair E - 06-30-2010

(06-30-2010, 10:04 AM)willbhere4u bad ass I want one!

off topic automatic trans fluid is really bad for you it absorbs in to your skin/blood stream almost instantly! It's one of the biggest cause's of cancer in the automotive world!!! or so I've been told

most grease isn't good for you but you have time to clean it off before you have any real problems

Hmmm.......

I think Ive found one!

A friend has taken some pics of a complete OM.606 Turbo motor, and its looking nice, Its at the other end of the country, so if I can get it at a good price we'll be all set--shipping is prolly gonna cost a few quid!

Good to know about ATF--Didnt know it was That bad, although its well known motor-oil is carcinogenic with extended contact--and, I'm one of those that just Hates wearing those rubber gloves!

Guess any trans. work and Ive gotta!

RE: Got my 606 motor.. Woohoo! - willbhere4u - 06-30-2010

We used ATF on a rag to clean the cylinders in freshly machined engine blocks It will remove dirt form in the metal itself!!!

you can clean until it looks spotless then you used a clean rag and trans fluid and seen how much more crap you get out!

RE: Got my 606 motor.. Woohoo! - HughF_UK - 08-04-2010

I don't want to resurrect this thread unnecessarily but on the topic of viton and HF acid, I was stumbling around our government's health and safety body website and came across this:

http://www.hse.gov.uk/mvr/priorities/fluoroelastomers.htm

RE: Got my 606 motor.. Woohoo! - HughF_UK - 08-13-2010

So, blowby:

http://www.youtube.com/watch?v=G1tuyqidFT8

I'm thinking it needs re-ringing but part of me says stick it in and run it for a bit to see if it's just dampness clearing out?

RE: Got my 606 motor.. Woohoo! - ForcedInduction - 08-13-2010

Thats nothing. The engine sounds great.

RE: Got my 606 motor.. Woohoo! - HughF_UK - 08-13-2010

And here is the part load missing and smokiness I was talking about:

http://www.youtube.com/watch?v=xyIe1-fNaZY

The injectors tested okay on my 1950's CAV tester Smile

but not at part flow, time to get them done along with the pump I think

RE: Got my 606 motor.. Woohoo! - Alastair E - 08-13-2010

Thought you said you had blow-by!

That Aint Blow-by! Nowt wrong there!

As to the smoke--That engine hasnt been run for a bit, been bumped around the country, left outside for a while, prolly turned upside-down when removed--or at the least on its side, Its gonna smoke for a bit anyway!

I'll bet the one I just shoved in the garage today will smoke a fair bit next time its run as it sat on its side in the van from Cardiff to Swansea and overnight--no oil in it though....

As to the miss/shake, dont forget--there is no flywheel on it, only the light ring-gear and flex-plate, the slightest imbalance in power-strokes wont be smoothed out as there's no weight there--no flywheel you see!

I'm sure things would be very different with a proper OM.601 flywheel on there, and a good run with fresh oil under load....

--Having said that, just confirm the injection-timing is correct, 'retarded' timing will make a bit of blue-smoke, depending on how retarded it is....

Diesels LIKE a Load to get all the combustion-chambers good and hot, and often will smoke a little after months of dis-use and no load....

I Saw the vids, but did not Hear them--No speakers--but the other guys reckon it Sounds good....

IF you're really not happy with it, I do know of another one--Trouble is, its in Edinbourgh....

RE: Got my 606 motor.. Woohoo! - HughF_UK - 01-01-2011

So, this project has been steadily emptying my bank account Smile

I have received delivery from Finland of the tubular manifold, hx35 and external wastegate:

[Image: 20101213_001.jpg]

Me and my friend, who happens to run a surface coating business Smile

decided that we should ceramic the manifold and turbine housing, so I made some masking for the turbine housing and then took the turbo apart:

[Image: 20101217_002.jpg]

I have also put the cossy flywheel in the lathe and started machining it:

[Image: 20101218_003.jpg]

So that the Sachs Racing e34 M5 pressure plate will bolt on Smile

That will take the clutch up to 240mm from 228... If I could buy a 240mm friction plate Sad

I have mercedes, LUK and Sachs part numbers for a suitable disk, but they are only available as a whole kit, apart from the main dealer, but then it's £233 just for the disk Sad

RE: Got my 606 motor.. Woohoo! - jeemu - 01-01-2011

Hey. Looking good Cool

Is it really at you cant bought only a cluch disk?
Shit. We could have send that same time on the exhaust Sad

RE: Got my 606 motor.. Woohoo! - HughF_UK - 01-02-2011

Jeemu, it seems that all the suppliers can't buy just the disk, it only comes as a kit. The cheapest kit was the one from LUK which was about 150 euros. But last night on ebay I got a w210 new clutch disk, for £11 Smile

old stock, no box. For that money if it doesn't fit the gearbox or is not 240mm it can go in the trash.

At least it is something to work with to try and get the clutch built up. What I would really like to get is a sprung, full face ceremettallic clutch disk so that it is a bit stronger than the fibre one. Cintered iron would be a bit agressive I think, but from what I have read, the ceremettallic is not aggressive if full face???

RE: Got my 606 motor.. Woohoo! - HughF_UK - 05-16-2011

Ebay finally turned up a clutch disc - the flywheel is nearly back from the shop having the bolt holes all drilled and the face machined.

The manifold and turbo were ceramic coated and are back together and last Friday, Pasi at PP-Diesel started on my pump and injectors. Today I got an email from him saying all is ready to rock and it is chucking out about 90cc's Smile

So perhaps by this weekend I'll be able to run it up Smile

Progress, slow and steady but we're getting there...

RE: Got my 606 motor.. Woohoo! - Riverstick - 05-16-2011

Nice project....I thought your original plan was to send the injector pump over to Myna to be set up?

RE: Got my 606 motor.. Woohoo! - HughF_UK - 05-17-2011

the original plan years ago was to go with a myna pump but then I got in touch with Tomnik and got elements from him with a view to having my local bosch shop do the work.

I became a little concerned that my bosch shop had no experience of building these big power M series pumps so started to look further afield and with shipping being so damn cheap thanks to parcels2go and dhl europlus, I sent all the parts including my injectors, to Pasi.

RE: Got my 606 motor.. Woohoo! - HughF_UK - 05-17-2011

Could a moderator move this to the projects section and rename it something like 'OM606 into W201'?

Cheers!

RE: OM606 into a W201 - Riverstick - 05-17-2011

Sounds good Hugh....How much are Pasi charging for the privilige of waving their magic over your injection system....is it that they are cheaper or more accessable than Myna....or perhaps better?

Do you have a contact details of your ceramic coating friend?....as I have some pistons I'm interested in getting coated.

RE: Got my 606 motor.. Woohoo! - Captain America - 05-18-2011

(01-01-2011, 02:45 PM)HughF_UK So, this project has been steadily emptying my bank account

I have received delivery from Finland of the tubular manifold, hx35 and external wastegate:

Me and my friend, who happens to run a surface coating business decided that we should ceramic the manifold and turbine housing, so I made some masking for the turbine housing and then took the turbo apart:

I have also put the cossy flywheel in the lathe and started machining it:

So that the Sachs Racing e34 M5 pressure plate will bolt on :

That will take the clutch up to 240mm from 228... If I could buy a 240mm friction plate I have mercedes, LUK and Sachs part numbers for a suitable disk, but they are only available as a whole kit, apart from the main dealer, but then it's £233 just for the disk

That is the exact same lathe I used at my last job!!!! Old as shit and not all that accurate with the drill on the right side but she did some good work

RE: OM606 into a W201 - HughF_UK - 05-18-2011

The 1941 Leblond Regal (I think) was sent to the UK under lease-lend in the war. I'm not sure what it was used for during the war, but afterwards it found its way into the local ice rink here in Bournemouth where it spent most of its life, until the early 80's in the maintenance department making/adjusting/repairing refrigeration pipework couplings and stuff.

We've had it since then, broke a gear in the gearbox in the early 90's so contacted leblond with the serial number (hence we know the history) but the new gear was too expensive. It was repaired with weld and file and has been good as new since then.

The tailstock is aweful, the dials on the slides are very small (as are all old lathes) but it is accurate to a thou most of the time Smile

And yes, I know it needs a new power input cable Sad

RE: OM606 into a W201 - Captain America - 05-18-2011

Tailstock! that's the word I was looking for...

Cool to know some history. EVERYTHING about that looks the same and I am sure I read Leblond on it somewhere!

In the stand it has two little cubbys on either side right?

And the dial on top is like a scale right?

Sorry to get so off topic, I just got real excited!

RE: OM606 into a W201 - HughF_UK - 05-19-2011

our stand is slightly different, it only has a cupboard on the left hand side and the dial thing on top is a feeds and speeds calculator dial for various metals.

Smile

RE: OM606 into a W201 - Captain America - 05-19-2011

(05-19-2011, 01:48 AM)HughF_UK the dial thing on top is a feeds and speeds calculator dial for various metals.

Ahh, yes that's what I meant Wink

RE: OM606 into a W201 - HughF_UK - 05-26-2011

The flywheel will be finished tomorrow, the pump and injectors are all back from Finland (a walkaround video will be on youtube soon) and my starter has been rebuilt Smile

Next week we should have a running engine Smile

RE: OM606 into a W201 - HughF_UK - 06-01-2011

Dieselpump business Smile

http://youtu.be/VLjT6nGqMZ4

RE: OM606 into a W201 - Jetmugg - 06-17-2011

Any updates to this project?

SteveM

RE: OM606 into a W201 - HughF_UK - 01-03-2012

Look Smile

Progress...

[Image: 20120103_008.jpg]

Having major downpipe vs steering box issues at the moment Sad

RE: OM606 into a W201 - aaa - 01-03-2012

Did you do anything with your clutch release bearing?

RE: OM606 into a W201 - HughF_UK - 01-03-2012

I don't have one yet - I need to try a standard merc 2.3-16 one along with the release fork...

RE: OM606 into a W201 - 1540 - 04-24-2012

what motor mounts are you using?

RE: OM606 into a W201 - willbhere4u - 04-24-2012

Turn the turbo backwards and run the exhaust forwards?

RE: OM606 into a W201 - Booster - 04-28-2012

Where about's in dorset are you? Must come have a look.

Good project....

RE: OM606 into a W201 - Alastair E - 06-18-2012

(04-24-2012, 02:54 PM)1540 what motor mounts are you using?

At a guess, The original W201 mounts from the original engine...

RE: OM606 into a W201 - JarrusJenkins - 09-23-2013

Anymore on this? Id love to do a w201 with an om606/605

RE: OM606 into a W201 - HughF_UK - 10-10-2013

It's getting compounded with an m112 - currently working out the mount for that

RE: OM606 into a W201 - HughF_UK - 10-10-2013

Been working on converting this w201 to a steering rack (lots of headache) to try and give me some downpipe clearance:

https://plus.google.com/photos/108319227846761721394/albums/5876019903661478625?authkey=CPLFzJS5ntzayQE

I also had to cut up my kkd manifold (sob sob) and move the wastegate, the plumbing for that is nearly complete.

RE: OM606 into a W201 - hooblah - 10-10-2013

Good job Hugh! How long do you think til its up and running?

RE: OM606 into a W201 - HughF_UK - 10-11-2013

Amar,

I'm working on the subframe rebuild at the moment, but once that is done I'll concentrate on the front end again. I've decided on how I'm going to do the plumbing, I just need some time on the CAD to get the mounting plate done for the eaton, then make a new snout.

I'm aiming to have it finished by Retro show '14 for the 190 GTG

RE: OM606 into a W201 - Hario' - 01-23-2014

This thread seems to have stagnated?