W124 250 D - OM603 + 716 Gearbox Superturbo Transformation

W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - Printable Version

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W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 07-27-2014

Hi there,

Tomorrow i will start with my Project. Im gonna swap the om602 engine without Turbo to the 603 Turbo Engine and install the 716 Gearbox from 220CDI + Dual Mass flywheel and clutch.

Until Friday i like to get the engine + Transmission ready.

After that it gonna get a 35 Holset + 7mm Pump Elements, Intercooler and a selfmade 3'' exhaust. My goal are 350 WHP The China Holset is already here:

Do you have any ideas for me? Things i have to take a special look at when i change the gearbox and the clutch?

I will Post Pictures tomorrow!

Thanks an lot

Max!

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 07-28-2014

603 Turbo removed from car. Installed Dual Mass Flywheel from 220 CDI. Already mountet air cooled breaks.

Tomorrow i gonna remove om602 and install the Engine.
I hope i dont get big Problems with the 716 Transmission.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - Petar - 07-28-2014

Looks like a fun project.A couple of things.
The 716 doesn't have a cable drive for the speedo.I don't think the dual mass flywheel will handle 350HP

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 07-28-2014

Hi!

Yeah i already got that. I think about building an cable x on my own because its realy expensive.

As far as i know Hansebanger wrote that his dual mass flywheel was able to handle the Power of om603 with 2.5 bar pressure and HX40.

I think have a China Holset here (35) and like to drive 1.8 to 2 bar.

Looks like a better one of the china holsets. I recived it with 0.3mm Shaftplay Radial. I gonna use Liquid Moly Ceratec and oil the shaft realy good. I hope it will work.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 07-29-2014

Soo Today we mounted the 300D Turbo in my car. We also fittet the 716 Gearbox to the engine.

Here i have a question. I have the 716 Gearbox and the clutch oil line for it. Am i able to connect it to my w124 250 D Clutch pump?

Tomorrow we are going to fit the shifting box to the gearbox.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - Petar - 07-29-2014

I have no idea about the clutch master cylinder (that's how it's called :-) ) but this might be helpful for the speedo
http://www.peachparts.com/shopforum/diesel-discussion/312801-mechanical-electronic-speedometer-conversion.html

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 07-30-2014

Gearbox change is now complete. Shift box also modified and installed.

Tomorrow im going to install the shafts.

I also modified the Diesel Pump to 1000 RPM More and 1,25 Turns more Diesel. In Two weeks 7mm Elements and the 35 Turbo will be installed

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - maxypriest - 08-04-2014

Did you extend the gear linkage? If so how did you modify the cable for the left/right gear linkage movement?
This is my current issue!!

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 08-04-2014

I dont modified it.

I made the Aluminium holding bar (to gearbox) 2 cm shorter, also the shift bolt.

_____________________________________________

When i changed the front crankshaft oil seal the shaft holding feather for the flywheel fall into the engine (I dont notice that while assamby)

Oil seal wasnt leckproof and i removed flywheel again. thats what i got:

I hope the timing chain got damage, its the easyst repair.

Do you have any ideas?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 08-22-2014

Is it possible to coonect the Speed Signal from the differential to the digital e500 Speedometer?
I think about to wire a speed hoaler inbetween to get the correct speed

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 08-29-2014

I have everything here now.

3" exhaust pipe, and 600x300x27 intercooler with 2.5" pipe.
The holset 35 i already told you.

I now like to know how mutch fuel i should Set up the Diesel pump. I got 7mm Elements and the bosch store need my Information.

Im a daily driver... What can you recoomand me with that setup? How much Power will be good and okay for the engine?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - Hario' - 09-01-2014

FOr idle / max fuel quantities? I have read on this forum somewhere that was discussed, maybe 15cc/min for idle or something like that. You will have to do some searching. But for max fuel you will adjust that yourself depending on exhaust gas temperature / black smoke under load (max throttle/boost).

In theory you should set your wastegate to make the turbo boost pressure in its most efficient poisition of its compressor map, 'its sweet spot'. Then adjust the fueling for temp/smoke based on that. easier said than done though..

Hope that helps -

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 09-03-2014

Hi

I think the bosch center will know a good fuel load for idle speed.

HX35 on om603...I read that most people drive around 2 Bar pressure. I will try 1.5-2 Bar.

Today i recived my intercooler

I also got a 3" Aluminium Pipe. Im going to build the "Collector" between Engine cylinders and the 2.5" pipe that comes from intercooler.
I think about to build it on "B" because i think on "A" the middle cylinders get the full flow of the gas and 1,2 and 5,6 are not well flowed.
On A, The flow goes straight into the Bigger 3" Pipe and dose not aim into a special cylinder.

What do you think?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - Edian727 - 09-08-2014

if you are worried about flowing to each cylinder equally i would build it like a header with a collector on the end. I guess then the problem would be plenum size but im sure a piece of 3-inch tube would do, as long as it neck down at the end. much more of a bitch to build though, eqaul length and all.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 09-09-2014

Hey!

I found a way do to it, i will post pictures in the next few days.

Now i have a question about the liftpump.

I got the 040 and not 044. Is it possible to modify this lift pump ? Or is it going to be okay with only 7mm elements?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 10-02-2014

I ordered 7,5mm Elements from Dieselmeken. I also changed fuel line in the car from 5mm diameter to 9mm.

Now im thinking about the lift pump. I really like to stay as mechanical as possible and don't want to use electrical 044 Bosch.

Any Ideas? I like to use 120 cmm

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 10-05-2014

no one experience with Dieseleken 7,5mm elements and stock lift pump?

Did anyone changed cars fuel line? I want to replace the 5mm Diameter pipe with a 9mm pipe!

I hope this will make it easyer to pump

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - mbz123 - 10-06-2014

The HP lines? 9mm sounds BIG and pretty sure some maths needs to be done before changing any of those. In addition, mounting and routing is critical too. A lot simpler to just leave that be, wouldn't think those lines are a bottleneck.

9mm doesn't seem too much for the supply/return lines, tho I don't think it's necessary.

Have you done any measurements with the stock lift pump? Procedures are in the FSM. Check to make sure the spring is within spec. You can either fix/modify it or if you can find a suitable replacement spring that would increase flow somewhat, change it out. That's you're best bet if staying mechanical is the goal.

MBZ123

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - raidaru - 10-07-2014

I think original lift pump should be removed, and replaced with an electric one, and a fuel pressure regulator, also an upgrade to the 9-12mm lines should be done, and a high flow fuel filter, those mods are not expensive. You should also order the outside ALDA kit along with the elements from dieselmeken, will help you with the smoke at low rpm/boost. An EGT sensor is also a must have. GL and keep us informed with the project!

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 10-07-2014

Thanks guys! I will think about the ALDA kit, i got my 7,5mm elements today.

@mbz123
I dont mean the HP lines, im taking about the fuel line from the fuel tank --> diesel pump

Yesterday i mounted the big turbocharger. i only have to modify the dieselpump + diesel line and install the Intercooler!

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 10-10-2014

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - winmutt - 10-13-2014

Can you get a pic from the front of the turbo showing the clearance around the sides of the housing? Also from bottom? Would be a huge help. I assume the wastegate is pointing forward?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 10-13-2014

(10-13-2014, 09:32 AM)winmutt Can you get a pic from the front of the turbo showing the clearance around the sides of the housing? Also from bottom? Would be a huge help. I assume the wastegate is pointing forward?

Hi the 35 fits without problems. I only had to mod the Wastgate... I changed the angel a few degrees upwards per using a few shims under the Metal holding bar.

Then i shortened the Corner that stands off a bit and everything was fine. I gonna make a few pictures for you tomorrow.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - winmutt - 10-13-2014

That would be awesome. Sounds like the exact same mod I had to do for my HX30W

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 10-14-2014

Im thinking about buying a Garett or Percision Turbo because i dont trust in my aftermarked "Holset". Anyone who has experience with an GT or Percision with parameters near the HX35? (Max. Airflow, start Spooling RPM)

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 10-29-2014

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - winmutt - 10-29-2014

Thanks for the pic on the HX35. I know what I am getting for xmas!

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 11-07-2014

Changed fuel line from 5mm to 9mm inner diameter. Also changed the prefilter.

Its realy time for mounting the intercooler.. Real black smoke on high RPM. But sill using stock lift pump.
Pump is now set to 130cmm @ 4600 RPM... Could be higher but diesel store said it wasnt possible. Max. fuel at 5200 RPM would be awsome.

Next pump goes to gordan Wink

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - Keino - 11-07-2014

Göran really knows what he is doing, I dont see why you didn't let him build the pump for you?
Economics i guess, but it's worth it. Rolleyes

Got 150cc out of my 7.5mm pump (for om 617)

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 11-25-2014

I used the last two weeks to change the water cooler of my car. As my car original was a 250D it only had the small water cooler mounted. I had to change the mounts of the cooler to get the 300 Turbo inside.

I also weldet the 2.5" Pipe to my intake mainfold so im able to mount my intercooler now. The shop send me a wrong intercooler so i have to wait until i recive the correct one.

_______________________

Actualy my clutch (220 CDI Dual mass Flywheel and clutch) slips through when engine gives full power on 1.5Bar boost.

I bought Single mass flywheel conversion kit from Valeo for Mercedes Sprinter.
I hope this will hold the Power of 300 WHP.

With 220 CDI original 9,5" clutch the power of ~250 HP wasnt a problem, i used a allerady used clutch and i think its broken now because it was to long in use.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 12-05-2014

Intercooler mounted, what do you think Wink

I tryed to turn the compressor upside down but it was extremly tight fit with wastegate and water line from car.

I also mounted 320TE Front Break system Smile

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - Insane190d - 12-05-2014

Looks good. Did the intercooler just like mine, had to take a little metal out by rad support too.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 12-05-2014

Thanks! Yes mounting it was no problem. Now i have to repair my clutch! Yesterday 3. Gear wheelspin on a allmost dry street 2°C Temperatur outside.

Next is Setting Wastegate to 2Bar pressure and installing an electrical fuel pump!

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 01-03-2015

https://www.youtube.com/watch?v=jxLk8Kj3dls&feature=youtu.be

1.5 Bar original prepump.

Speedometer ist almost connected. I only have to connect the ABS sensor at the diff

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - MFSuper90 - 01-04-2015

swatmugga, what head is on your 603?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 02-23-2015

Where can i find this number?

I send my pump to Diesemelken because diesel was leaking into my engine. I got 10 total 10 liter engine oil.
The cause was the prepump 0-ring what was broken.

He also took the pump on the testbench and i got a very annoying result. The german bosch store done shit with my pump.

I noticed big difference after i got pump back.
- Engine has lower idle
- Engine is going better back to idle from higher rpm
- A lot less smoky
- Engine sounds better

Big thank you to göran again!

BTW my china HX35 is still running! Its installed for around 5000km for now. 1,5Bar with big intercooler.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - MFSuper90 - 02-24-2015

It Should be behind the second injector, I was just curious if you still had the #14 casting or not.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - PedroFerreira - 02-24-2015

your egt are good whith that turbo?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 02-26-2015

My head is a 603 016 22 01

EGT okay!

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - MFSuper90 - 02-26-2015

You lucky guy! A #22 head is darn near impossible to find in the US Tongue

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 02-27-2015

Is there a table with the different head numbers ?

I thought there is only:

14 --> poor
16 --> good
17 --> good

i thought i would have a 16 head?!

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - MFSuper90 - 02-27-2015

http://www.superturbodiesel.com/std/showthread.php?tid=6171

The #22 head casting is the newest and supposedly best version of the om603 heads

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - raysorenson - 02-27-2015

The only documentation I can find from MB regarding turbo 603 head updates is this
16: Reinforced water jacket, thicker "baseplate" on intake side, exhaust bolt flutes reinforced, taller front cover/head gasket bolts
17: Further water jacket improvements, lifter guides reinforced. I've seen a couple pics of the cam pushing the lifters out of the head, I suppose this casting fixed that.

Unidentified casting: Additional steam holes were added between the cylinders in 11/92. My 20 head has these. Maybe the 18 head has these, maybe not. My replacement aftermarket head gasket did not come with matching holes, a had to drill my own.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 02-27-2015

Thanks for that info!

I like to drive on with original lift pump because i like to let my car as stock as possible.
On higher RPM its not so good so im going to replace the Spring to a harder one.
This should give a nice update.

Video with working Tacho will follow next week. Im also chaging my clutch and gearbox from 716 604 to 716 654 and my differential from 3.07 to 2.65 one.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - PedroFerreira - 04-28-2015

any uptades?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 05-03-2015

Car is running fine! I will upload an Video in the next few days.

Next plans are to change the spring of the prepump for better high rpm delivery.

I almost fracked the car last week. I had a screw in one of my tires and changed the rear wheels to my stock small 195 wheels.
It was raining and i wanted to drive on highway.
At around 70 KMH in a curve the rear wheels lost grip and i turned myself 360°. I was realy lucky that i didnt crashed into a wall.

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - PedroFerreira - 05-03-2015

how much cc are you using?
next mounth i will start my 300d turbo project,but i dont whant change the automatic gearbox... 100cc of diesel make 260hp on om603?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 05-03-2015

should be an realistic value

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - PedroFerreira - 05-04-2015

can the stock auto gearbox handle 260 hp?

RE: W124 250 D - OM603 + 716 Gearbox Superturbo Transformation - swatmugga - 05-31-2015

Some news for now!

I just bought another OM603 because in need the pump for Görans new 7,5mm Series which can deliver 190 cc (for around 500 PS) It has the 18th head.

I will put the engine into my garage to have a reserve one. Im looking forward to buy an om606 in the next few month.

I realy want to make a video of the power, but currently i dont have mutch time. If someone is interested in my 140 cc Pump feel free to contact me.