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+--- Thread: 1991 300D (/showthread.php?tid=4514)
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1991 300D - Duncansport - 04-21-2013
Hello all. So ill keep some pictures up of the work im doing to my 300D 2.5..
Plans so far are- Pump to Dieselmeken, holset turbo, inter-cooler, 400E knuckles and brakes, B6 shocks and struts, 5 speed, stereo..
Heres what we've got so far...
Turbo, air box and junk out
Ready for some milling
This V-Band for the EGR is 38MM. The same as a Tial wastegate. Not sure if it will match up. Have one on order so we'll see
Cutting..fun fun
T25 flange gone..
Milled as big as i can make it, in prep for T3 flange
Gross....
Cleaning up for the long trip to Sweden
Stripped front end ready for intercooler fab
Cutting these guys out via the spot welds
Intercooler mounting studs (Volvo control arm bolts turned down and welded in
Mounted!
RE: 1991 300D - aaa - 04-21-2013
Awesome.
RE: 1991 300D - Ksteen2 - 04-22-2013
isn't this a 250DT?
RE: 1991 300D - Duncansport - 04-22-2013
(04-22-2013, 02:08 AM)Ksteen2 isn't this a 250DT?
US calls it a 300D....
RE: 1991 300D - Duncansport - 04-22-2013
Pictures of the turbo....Should be interesting. Ran me $100, so if shes to big for the little OM602 resale should be no sweat...
RE: 1991 300D - Duncansport - 04-27-2013
Got to working on the exhaust manifold this evening.... Pump left for Sweden Wednesday.
T3 Split flange with a divider to split exhaust pauses. Welded onto flange then into manifold. Roughly machined.
Port matching flanges, again only rough machining for now.
All looks well here!
And to finish the night with a a growler of WoodStock Brewery around the fire..
RE: 1991 300D - Duncansport - 04-28-2013
Finished up the split T3 flange porting. Turned down a sweet alternator pulley as a extension pipe for the external waste gate. Manifold DONE!
RE: 1991 300D - MFSuper90 - 04-29-2013
Good idea with the wastegate!
RE: 1991 300D - Duncansport - 04-30-2013
(04-29-2013, 09:38 PM)MFSuper90 Good idea with the wastegate!
Thanks. to bad about the crappy welds i did there....feed cable getting a bit loose on the MIG welder..
Really can't wait to get the pump back and see what this will do..
RE: 1991 300D - Equestrian - 05-05-2013
epic! i have the same car taking some notes!
RE: 1991 300D - Duncansport - 05-18-2013
Well 7 hours of driveing later and i now have a 5speed from a 300E and all of it's related parts, even the center wood!. Pictures to follow...
RE: 1991 300D - Duncansport - 05-23-2013
Decided on using the small .63 on the H1C.....
RE: 1991 300D - Duncansport - 06-09-2013
Dieselmeken Pump came in while i was out camping so i got around to installing it Saturday along with the electric lift pump and fuel pressure regulator (Saab SPG 3.0bar).. Built up a bracket for the turbo and oil return, made up a nice oil feed from steel line . Turned a 12x1.5 to 3/8 FIP on the lathe.
Pump timed and no throttle linkage hooked up. Cranked for 15 seconds and took off like the throttle was pined! Jiggled throttle lever, wouldn't stop, cut fuel pump and blasted with halon. Shut her down quick. Upon check everything seemed ok, Return spring hooked up correctly, linkage rutrns ok to what must be the stop, verify inlet is 3.0 bar, it is. Try to start it again and the damage is done. Exhaust valves meet with Mr. Piston. Boooo. Head coming of this week. I wanted to upgrade the valve springs anyways i guess........
RE: 1991 300D - raysorenson - 06-09-2013
Mother bitch. Sorry to hear.
RE: 1991 300D - Duncansport - 06-10-2013
(06-09-2013, 08:38 PM)raysorenson Mother bitch. Sorry to hear.
Indeed, now to source some valve springs. Feel like i may be into uncharted waters here. Haha
RE: 1991 300D - maxypriest - 06-10-2013
(06-09-2013, 06:19 PM)Duncansport Dieselmeken Pump came in while i was out camping so i got around to installing it Saturday along with the electric lift pump and fuel pressure regulator (Saab SPG 3.0bar).. Built up a bracket for the turbo and oil return, made up a nice oil feed from steel line . Turned a 12x1.5 to 3/8 FIP on the lathe.Fuck, what happened? How come at full throttle?
Pump timed and no throttle linkage hooked up. Cranked for 15 seconds and took off like the throttle was pined! Jiggled throttle lever, wouldn't stop, cut fuel pump and blasted with halon. Shut her down quick. Upon check everything seemed ok, Return spring hooked up correctly, linkage rutrns ok to what must be the stop, verify inlet is 3.0 bar, it is. Try to start it again and the damage is done. Exhaust valves meet with Mr. Piston. Boooo. Head coming of this week. I wanted to upgrade the valve springs anyways i guess........
So far another cracking build!
Max
RE: 1991 300D - Duncansport - 06-10-2013
Fuck, what happened? How come at full throttle?
So far another cracking build!
Max
[/quote]
Still not sure, i think it could be related to inlet pressure, perhaps the check valve in the banjo bolt was stuck and the electric feed pump effectively was dead headed and forced to much fuel? Or something is stuck in the pump. How ever i really doubt that. I verified the shut off valve is hooked correctly and working.
Plan is to crank the engine (once back together) with the injector lines off and the throttle closed and see what sort of fuel flow is coming out of the IP. I will also put the inlet manifold on so at least o can block off the inlet if this happens again.
Really strange stuff, ive been working on theses engine for a long time and i have had pumps on and off many of times. This is my first issue like this. At least it was my own car haha
RE: 1991 300D - Duncansport - 06-18-2013
Well head is just about done, new valve guides, minor bowl porting, new valves, weled up some pitting on head surface and finally the M103 valve springs.
The M103 springs are an exact match as far as size. However the wire diameter is 1mm larger and compressed to 1" they offer almost 100lbs more of pressure..
Should have it ready tomorrow and we'll have attempt two.
RE: 1991 300D - willbhere4u - 06-19-2013
Good luck! It should be sweet with those new valve springs for higher RPM!
RE: 1991 300D - raysorenson - 06-19-2013
New lifters too? They're known for making noise. I've got a '92 602 making a little noise and an '87 603 making a lot of noise.
RE: 1991 300D - Duncansport - 06-19-2013
(06-19-2013, 11:48 AM)raysorenson New lifters too? They're known for making noise. I've got a '92 602 making a little noise and an '87 603 making a lot of noise.
No, they were quiet. Most of the time the noise is made due to the fact that the installed height of the valve stem is to high (due to the valves wearing into the seats with age), that makes the lifter in a slightly compressed state partially blocking off the fill hole and becomes hard for it to fill with oil. Or there just junk
I had about 300,000 on my last WVO 1991 OM602 before i did a head job and my lifter would make some noise in the morning. Before i tossed in new lifters i check the valve stem height and found it an issue. After new valves and head work the noise was never present again. I drove that car to 498,000 before selling it. I only thought of the stem height as an issue because i had seen it before in B202 Saab engines...
RE: 1991 300D - raysorenson - 06-19-2013
Thanks for the info Duncansport.
The shop manual has a specification for "valve disc height" which is 1.7-2.05mm new and can go down to as low as 1.6mm used. This is measured on the combustion chamber side with the head off. Is that how you measured?
RE: 1991 300D - Duncansport - 06-19-2013
(06-19-2013, 02:56 PM)raysorenson Thanks for the info Duncansport.
The shop manual has a specification for "valve disc height" which is 1.7-2.05mm new and can go down to as low as 1.6mm used. This is measured on the combustion chamber side with the head off. Is that how you measured?
In WIS (doc#RA0100601418X) the spec for how valve stem height is measure from the bottom of the camshaft journal to the top of the valve stem. 21.455 is the maximum. M-B made "repair" size valves with different lengths ( three sizes in total) but common practice is to cut the top of the stem.
RE: 1991 300D - Duncansport - 06-26-2013
The old gal started to night after much cranking.. Intercooler piping fabbed up and almost ready for install. Still need to mount the radiator, wire fuel pump, fix the stinking ELR, and a bunch of other BS
http://youtu.be/5X5D-LJZRr8
RE: 1991 300D - willbhere4u - 06-27-2013
sounds good
RE: 1991 300D - Raarasutra - 06-27-2013
That thing sounds fantastic <3
RE: 1991 300D - willbhere4u - 06-28-2013
Is that a Ferrari in your garage?
RE: 1991 300D - Duncansport - 06-28-2013
(06-28-2013, 09:12 AM)willbhere4u Is that a Ferrari in your garage?
Yeah, 1988 328GTS that needs head work.....
First drive tonight..went fairly well for no exhaust, ALDA not hooked up, waste gate opening up at 15psi. All in all tho im fairly happy with the power. I can only think there is more in the barrel once the above is hooked hooked up and tuned...
RE: 1991 300D - willbhere4u - 06-29-2013
Nice please take some videos of the acceleration
RE: 1991 300D - Duncansport - 07-28-2013
Slow go lately on the projects but here are some pictures of the intercooler plumbing and exhaust.
Picture of the removal of the diesel strainer and replacement with the 300E and it's feed hose, both being much larger in size
Turbo to intercooler
Down pipe and exhaust made up
Also made up a boost controller to put pressure on the top of the waste gate to force the boost up. Got 2 bar out of it and it's very awesome. Car looses traction when the boost hits in first and second (major slipping at the 1-2 shift with the 722)
RE: 1991 300D - MFSuper90 - 07-29-2013
Lookin pretty good!
Wish mine had enough power to slip the 722...
RE: 1991 300D - Duncansport - 08-14-2013
Video of a pull away from a stop.
Transmission dying quickly....
http://youtu.be/0jXb5SN9OFY
RE: 1991 300D - willbhere4u - 08-15-2013
cool! You need more line pressure in that 722
RE: 1991 300D - Duncansport - 08-15-2013
(08-15-2013, 12:00 PM)willbhere4u cool! You need more line pressure in that 722
My 722 will be meeting the scrap metal bin in a month or so. Just waiting on the Pressure plate and clutch disc to be finished..
RE: 1991 300D - raysorenson - 08-15-2013
(08-15-2013, 02:41 PM)Duncansport ...waiting on the Pressure plate and clutch disc to be finished..
What are you going with?
RE: 1991 300D - Duncansport - 08-15-2013
(08-15-2013, 05:56 PM)raysorenson(08-15-2013, 02:41 PM)Duncansport ...waiting on the Pressure plate and clutch disc to be finished..
What are you going with?
I have a 300E manual set up for the car, only the drive shaft is the sticking point.
Clutchnet is building a stronger 9" PP and something better for the disc.
RE: 1991 300D - HaavardPYA - 08-16-2013
Is your backpressure and egt`s a little high or is this normal?
RE: 1991 300D - Duncansport - 08-16-2013
(08-16-2013, 05:24 PM)HaavardPYA Is your backpressure and egt`s a little high or is this normal?
Back pressure or "TIP" (turbine inlet pressure) is almost higher or at least 1:1 with boost pressure. As far as EGT im not really sure. It does get up there doing full power pulls..
RE: 1991 300D - Ksteen2 - 08-20-2013
nice work
looks like it got some power also
good to see an american thread with a little new'r engine
RE: 1991 300D - maxypriest - 08-20-2013
(08-14-2013, 09:15 PM)Duncansport Video of a pull away from a stop.
Transmission dying quickly....
http://youtu.be/0jXb5SN9OFY
Thats rather impressive.
Great work - I just cant wait to get my project moving again, stuff like this is inspirational!
RE: 1991 300D - Duncansport - 08-20-2013
(08-20-2013, 06:53 AM)maxypriest(08-14-2013, 09:15 PM)Duncansport Video of a pull away from a stop.
Transmission dying quickly....
http://youtu.be/0jXb5SN9OFY
Thats rather impressive.
Great work - I just cant wait to get my project moving again, stuff like this is inspirational!
Thanks! Kinda wish i had a 606 for the car, or even a 605. But no 605's in the states. But the little 2.5 602 does pretty darn good for what it is.
RE: 1991 300D - Duncansport - 09-10-2013
http://youtu.be/YLRdFlT8lxM
RE: 1991 300D - 1911diesel - 09-10-2013
nice! looks good man keep up the good work!
RE: 1991 300D - Duncansport - 09-11-2013
Fit the H&R touring cup suspension kit, all new rear control arms and front strut mounts. Set of AMG 17x8's.
Here's how it sits now.
RE: 1991 300D - willbhere4u - 09-11-2013
(09-10-2013, 09:21 PM)Duncansport http://youtu.be/YLRdFlT8lxM
did you get the 5spd installed?
RE: 1991 300D - Duncansport - 09-11-2013
(09-11-2013, 11:08 AM)willbhere4u(09-10-2013, 09:21 PM)Duncansport http://youtu.be/YLRdFlT8lxM
did you get the 5spd installed?
No, still waiting for my clutch from clutchnet. That was done with a loving neutral drop :-)
RE: 1991 300D - raysorenson - 09-11-2013
Did you go with a red plate? What disc?
RE: 1991 300D - 1911diesel - 09-11-2013
(09-11-2013, 11:36 AM)Duncansport(09-11-2013, 11:08 AM)willbhere4u(09-10-2013, 09:21 PM)Duncansport http://youtu.be/YLRdFlT8lxM
did you get the 5spd installed?
No, still waiting for my clutch from clutchnet. That was done with a loving neutral drop :-)
F*CK the 722! if you got a 5 speed going in it will give you more motivation to get it in there! lol
RE: 1991 300D - garage - 09-11-2013
WOW!!!
RE: 1991 300D - Jetmugg - 09-11-2013
Very cool project. I have an OM602 turbo in a 190D.
I would like to have Dieselmeken rework my pump in the near future. I had him/them do a VW injection pump for me, and it is top notch.
The worst part is the shipping cost to and from Sweden, however. For my VW pump, Goran sourced a pump for me over there, built it, and shipped it to the USA.
It was cheaper for him to find a donor pump in Sweden than it was to ship my pump from the USA to Sweden.
How was the shipping cost for your 602 pump to and from the USA to Sweden?
Steve.