W202 Wagon build thread - *NOW OM606*

W202 Wagon build thread - *NOW OM606* - Printable Version

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W202 Wagon build thread - *NOW OM606* - Hario' - 08-14-2014

Hello all,

I have been a long time lurker building ideas and designs, nothing physical until now. Bought a 99' W202 Wagon C250TD, because well it looks bad ass! (18" 2004 CLS AMG wheels).

originally wanted to swap a 606 in for instant more power and beans, but alck of space has stopped this happening, next plan was HX35 on ported factory manifold with my adapter, and quick spool valve which is still in developmemt:

Trial fitting on a friends 606 here.

Note v-band is to allow fine tuning of turbo position to clear cam cover and inner wing / elec. heating pump..
I will probably fit a wastegate to the EGR port after opening it up a bit because compounding is the way forward and stock turbo w/external wastegate HP compounded by a LP HX35 will be lovely.

I've shown my cutdown 606 manifold before but here it is in context, being welded this weekend by Hugh_F, I've bought another 606 manifold to make another OM605 converstion one to sell if anyones interested, (allows boost hose to enter from below as per W210.
I have also deleted AC condensor to fit an Evo 6 IC this weekend which I will doccument and share (easy fit), also I have deleted the AC compressor for easy piping from IC to my hybrid manifold - If you do this you will need a shorter belt model 6PK2080 from http://www.camskill.co.uk/ to do this was about £15! Pics of that to follow..
[url=http://s1250.photobucket.com/user/Mercedes_Power/media/image6.jpeg.html][/url]

RE: W202 Wagon build thread - OM605 - mario - 08-14-2014

I like the manifold as would it be possible to just remove the very last two cylinders off it and weld up the plenum chamber after

RE: W202 Wagon build thread - OM605 - Hario' - 08-15-2014

No, the central runner (Cyl.4) has to be removed to keep the last runner to keep the manifold profile for oil filter clearance/removal, I'll add an installed pic this weekend if the rain holds off!

RE: W202 Wagon build thread - OM605 - Stevo-trendy - 08-15-2014

Good work so far mate & nice clean lookin w202 estate !!

RE: W202 Wagon build thread - OM605 - sorin_cel - 08-24-2014

why you want it to look like OEM? any problems at the MOT station? Undecided

RE: W202 Wagon build thread - OM605 - DiseaselWeasel - 08-24-2014

Or maybe he just wants a nice looking engine bay Smile

I too get wrinckled toe nails if I see blue or red silcone hoses and colored wires all over the place...

Make it look nice! Smile

I like this! It's much more work, but it certainly pleases the eye.

RE: W202 Wagon build thread - OM605 - Hario' - 08-26-2014

I like performance tuning where it can almost pass for stock, OEM+1 is the expression over here in the UK..

Tell a lie actually, I needed to remove the crossover boost pipework and EGR equipment to allow clearance for a bigger turbo, and a 606 manifold cut and shit was the easiest and most elagent way of doing it, and because I can and it looks bad ass of course!

RE: W202 Wagon build thread - OM605 - Hario' - 09-22-2014

For those that don't know, the lower radiator support on a W202 is like sheetmetal origami and the hard plastic charge hoses ninja snake around the supports, so to allow big intercooler fitment I had to cut it all abck and fabricate a lower rad support from sheet stainless, see below. Its clude but strong and will never decay.

I basically cut out the support but remounted / positioned the lower face of it which houses the rad / IC mounting lugs, with my stainless origami.

Evo.6 IC install to follow.

RE: W202 Wagon build thread - OM605 - hooblah - 09-22-2014

Nice! You must take me for a spin at some point!

RE: W202 Wagon build thread - OM605 - Hario' - 09-26-2014

FOUnd a few more random build pics.. For OEM exhaust manifold flow I will die grind the aperture out to the 2" ID of the weld-els, its no KKD but it was cheap and easy!

THe v-band obviously won't support the tubo on it's own so before installation i'll fabricate a turbo brace / suppert something that looks like this F1 turbo era one because RACE...

RE: W202 Wagon build thread - OM605 - Hario' - 10-20-2014

Made a start on Mk.2 OM605 manifold cut from OM606 for MAX on this forum, I think painted / powder coated black will give it best OEM as the weld is a big give-away.. lol

Edit: Hmm I'm getting good at that!

RE: W202 Wagon build thread - OM605 - Max - 10-20-2014

(10-20-2014, 10:59 AM)Hario I'm getting good at that!

RE: W202 Wagon build thread - OM605 - Hario' - 11-18-2014

I designed an ALDA for a friends 603 pumped OM606 build, saw this on the Googles and improved upon it:

Used a signle-acting (spring return) pheumatic cylinder I had lying about:

Had to make a slotty-thing for the actuating rod because the cylinder would rotate with the (good) vibrations

As installed, has locking nut adjustment for bottom and top travel, the return spring only holds about 5 psi so will have to add one with a tension adjuster to adjust fuelling increase point to match the holset boost curve..

Hopefully somone gets some inspiration from it.

RE: W202 Wagon build thread - OM605 - Hario' - 11-25-2014

Attempt 2 at OM606 manifold cut down for OM605..

Bead blasting makes a big diffence, black paint or powdercoat will be the finishing touch though.

RE: W202 Wagon build thread - OM605 - Hario' - 12-08-2014

More progress..

Mitsubishi Evo 6 nearly installed, just working out how best to design some non-shit bracketry..

Cremé leather interior as the OEM fabric ones were fucked because previous owner owned/was a dog..
(Shopping for cremé door cards...)

RE: W202 Wagon build thread - OM605 - MrHope - 01-08-2015

Do you now have the adapter on the om605?

RE: W202 Wagon build thread - OM605 - Hario' - 01-09-2015

Nope I am straight-through-ing the exhaust at the moment..

NB. I think it will be laggy so I am looking for a 9cm2 turbine HX35. But as per your g-waggen build thread, without 7.5mm elemens it will be a bit pointless. Lots of lag then only 30-40hp more than normal.. So I will probably start shopping for elements.

RE: W202 Wagon build thread - OM605 - MrHope - 01-09-2015

Ok, i have sent my pump to dieselmeken and we talked about hp and the 6mm will work fine for 200+hp i will not need more it will only cause more trouble for my clutch, the car is heavy.. I think i will start out with the 606 turbocharger..

RE: W202 Wagon build thread - OM605 - Hario' - 02-05-2015

Decided to fit OM606 as it is (mostly) a direct swap onto UK spec C250TD, as I have the 722.6 and the EDC part of the pump is the same, hope it should just plug and play.

Got OM606 from Polish man, he said 'it run till the end', IDK if that means it ran until he took it out or it ran until it exploded.

Anyway it looks nice. Has genuine MB fuel pipe replacement kit fitted, few filter pipes are broke but that looks like all.

The water pump pulley should not be rubbing the crank pulley.. (crashed?)

[Image: water%20pump%20interference.jpg]

Got mocal oil cooler from my old Mini because 605 come with water/oil exchanger.

I will use the OM605 loom and just jump the #6 glow plug lead onto the #5 wire until I get a 606 glow relay.

Also as discussed elsewhere 605 has 5 flywheel tags and 606 has 6 so flywheels have to be swapped to keep OEM C250 tach happy, otherwise it would under read by 16% (ish), more importantly ECU would make EDC idle at 550 rpms (also ish).

Garage space booked for swap end of Feb, woo!

RE: W202 Wagon build thread - OM605 - Hario' - 03-03-2015

The rest of the build and pictorial 'instructions' are here for those who are interested in doing the swap themselves.
http://retrorides.proboards.com/thread/175523/mercedes-c250td-wagon-c300td?page=2#scrollTo=2051432
Looks good though!

RE: W202 Wagon build thread - OM605 - Hario' - 03-04-2015

http://youtu.be/NUgUJ2jkB_M

RE: W202 Wagon build thread - OM605 - raysorenson - 03-04-2015

Probably just a pumped up lifter.

RE: W202 Wagon build thread - OM605 - Ksteen2 - 03-05-2015

it's a lifter, i hade the same problem with my engine..
it's comon when the engine stand still for long.

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 03-10-2015

This is my favourite

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 03-10-2015

Wrapped the steering box hard pipes with that NASA looking thermal wrap stuff, only cost £10/meter from internets.

Fitted E300 turbo outlet pipe to C250 DP..

Not too much cutting needed.

RE: W202 Wagon build thread - *NOW OM606* - Ksteen2 - 03-10-2015

exhaust brake?
hehe, just kidding, is it that limited space on those RHD cars? :o
now I'm happy I have LHD car :p

RE: W202 Wagon build thread - *NOW OM606* - Kalti - 03-15-2015

nice projekt!

and do you want to sell the intake manifold from the om605?

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 03-16-2015

Haa! Exhaust has silencers and catalytic converter removed so not too much restriction, and it is factory 2.5" 63mm anyway. As these are the last to come with a steering box it is quite tight. Plenty space to go upto 3.5" DP but no point on that manifold and microturbo. But the car is much faster now.

RE: W202 Wagon build thread - *NOW OM606* - dcm - 03-18-2015

Nice job, looks factory fitted. I always hoped my 605 would blow up to justify fitting a 606 as a replacement. How much space is there between the engine and radiator?

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 03-19-2015

Thanks! That was always the goal, the HX35 will make it a bit less OEM so I will paint is black I think.

Well I bought this 606 for £150 with the £150 that I sold my 605 for..

I made a bracket to hold the original lower radiator bracket more forward so the radiator sits under the slam panel just like on the C32 AMG. Then you can use the original viscous fan and coupling or a slim electric fan. But if you want a bigger intercooler you will have to relieve the inside of the front crossmember for clearance like I did, by drilling the spot welds and hacksawing down the inside face like I did here, took 50 minutes:

You will also have to make some shoddy ARB mount drop brackets like mine for sump clearance, these lower by 30mm, 50mm would be better IMHO.

RE: W202 Wagon build thread - *NOW OM606* - Ksteen2 - 03-20-2015

looks nice Smile

yeah, i get that :p
with a new manifold you will get the space you want so Wink

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 04-13-2015

(03-18-2015, 02:07 PM)dcm Nice job, looks factory fitted. I always hoped my 605 would blow up to justify fitting a 606 as a replacement. How much space is there between the engine and radiator?

There is about 5mm too little room to fit the OEM viscous fan, so I think I will do more cutting and modifying and move the radiator and intercooler forwards more.

It had a mysterious running problem where it would cut out as if the key was turned off after about 20 minutes of driving or idling.. Puzzled for ages, I thought it might be the RPM sensor as the EDC is unlikely to be faulty and there are no other engine sensors which would affect running.
Cured the problem straight away! WIll make a driving vid next weekend.

Also cut out the bumper for IC flow, should make a duct really, shame the red/blue pipes make it look chav.. Pressed aluminium Euro plates looks good tho, last mod to do it 3k ohm resisitor mod Smile

[Image: 7AA519F9-38FD-4E38-A6AA-5D5C4686E171.jpg]

[Image: 1C9861A8-C222-46F8-80AF-3F632B37AFAA.jpg]

RE: W202 Wagon build thread - *NOW OM606* - dcm - 05-07-2015

I've painted boost pipes black before which has worked ok. Any updates or video?

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 07-24-2015

Just the vid of the first start

https://youtu.be/NUgUJ2jkB_M

it's actually in my parents barn in Bordeaux at the moment as my previous company provided a mandatory company car and I have limited parking space. Fortunately that has now changed and I'll be driving it back to London relatively soon then the 606 can get the STD treatment..

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 08-13-2015

[Image: 5D3C3FF5-05A2-4066-891D-E679C2B04DCE.jpg]

[Image: EA5F3A54-945D-4C14-9580-45A34902BA2D.jpg]

Nice.

RE: W202 Wagon build thread - *NOW OM606* - dcm - 08-16-2015

Looks good, always like the wagon shape. What's your plan for the gearbox?

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 08-28-2015

I'm going to buy an Ole controller as soon as I'm not poor from my house move and job change..

I thought for once I should do a car project in the right order so I am doing some light 'restoration' works, in as far as new (un cracked) tail lights, a rust free tailgate, Frenched (yellowed) side lights like the guy with the white w123 on here somewhere.

Also the radiator n3eeds to move forward another inch to allow me to refit the factory visco fan, as it currently has none. Unfortunately the tranncy cooler in the radiator header tank causes the rad to not fit between the headlights so I have got myself a manual C250TD rad which obviously doesn't have the cooler. So I'm now collecting parts to install an air/oil tranny cooler above the intercooler to allow the rad swap to happen. If that makes sense..?

RE: W202 Wagon build thread - *NOW OM606* - DiseaselWeasel - 08-29-2015

http://www.mymbonline.com/forum/1917848-post1.html - some inspiration Smile

On my coupé I painted the refelctors with yellow light bulb paint. It's been holding up well for 3 years now Smile

(see sig)

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 12-02-2015

I started work on my new exhaust manifold because some peoples on here says my turbo is tiny and my downpipe is shit.

Just proof of concept ovalising 2" x 1.5" reducers with hammer and anvil, I will have to cut down the reducer and bends for cylinders 5 & 6 to clear the down pipe but that is ok.

Will start tacking soon, got to pay for my HY35 also. Got a Tial 38mm wastegate for the HP turbine bypass. I hope it, along with the HY35's internal gate will be enough bypass, I should measure HP turbine differential pressure to establish if that is the case (eventually).

It is more in focus in real life.

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 01-04-2016

Bought a big Mocal cooler to cool the ATF, and will be mounted under driver side wing, behind bumper, opposite where it goes on W124 & W210.

The long thin oil cooler is made by Radtec and should squeeze in the space above the IC, because on UK spec W202's there are horns, wiring and pipes on the other under wing/bumper area (where oil cooler is normally fitted on W210)

The oil cooler has nice and big -12AN fittings which will marry up nicely to the 606's 19mm 3/4" oil cooler hose.

[Image: oil%20cooler%20AN12%20fitting.jpg]

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 01-04-2016

Rumble from NSF wheel bearing so I found a complete low mileage front knuckle for under £20, then had to spend the same again on a BJ splitter set as there is 3 different sizes on the knuckle.

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 01-04-2016

Bought a W220 S500 front caliper to make a start on my big brake upgrade, I can confirm they fit the W202 knuckle and clear the dust shield (only bented it from me splitting BJ's).. They will need 3 or 4mm bolt spacers between the caliper and the knuckles, I'm going to get some machined because mild washers aren't good enough.

That's the stock disc obviously, I need W203 AMG (330mm) discs for a bolt on swap (I think-hope).

Got to make up brake hoses 100mm longer and M10 banjo on the outer.
Does anybody know the thread & fitting type on the inboard bulkhead fitting for the flex onto the hard pipe under the wing?

[Image: w202%20w220%20caliper%201_1.jpg]

Beers.

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 02-01-2016

Moderate levels of progress

[Image: 0931FBB4-B67C-4403-A979-D214103C0878.jpg]

[Image: E5022A5D-3B97-4332-892A-6E734B60F0F9.jpg]

RE: W202 Wagon build thread - *NOW OM606* - sorin_cel - 02-01-2016

Nice start on the manifold Smile

i'm curious if the w220 brakes will fit spot on.

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 02-02-2016

(02-01-2016, 02:56 PM)sorin_cel Nice start on the manifold
i'm curious if the w220 brakes will fit spot on.

Thanks, did too many beers to make real progress.

The w220 caliper fitted the knuckle fine, even the dust shield cleared. Just needs custom hoses and euro spec W203 AMG cdi discs (330mm).

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 02-02-2016

(02-01-2016, 02:56 PM)sorin_cel Nice start on the manifold
i'm curious if the w220 brakes will fit spot on.

Thanks, did too many beers to make real progress.

The w220 caliper fitted the knuckle fine, even the dust shield cleared. Just needs custom hoses and euro spec W203 AMG cdi discs (330mm).

RE: W202 Wagon build thread - *NOW OM606* - sorin_cel - 02-08-2016

i've got w220 4 pot calipers now, but i need discs. apparently the w210 E430 330mm discs should be a straight fit. Try it. Let me know, cheers Undecided

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 02-09-2016

(02-08-2016, 04:56 PM)sorin_cel i've got w220 4 pot calipers now, but i need discs. apparently the w210 E430 330mm discs should be a straight fit. Try it. Let me know, cheers

It is all about the disc offset.

I know C270-320 CDI 2000-2007 have the correct disc offset for w220 calipers onto W202. I am not sure about any others.

Also note the W220 calipers will need a hardened washer between the caliper mount and the steering knuckle to make the caliper sit centred on the disk.

The run out was 4mm I think, so 2mm hardened washers need to be bought or made, let me know if you find some!

RE: W202 Wagon build thread - *NOW OM606* - MartinB - 02-09-2016

I bought W220 S600 Calipers for my W210. These are for 345mm discs Wink

RE: W202 Wagon build thread - *NOW OM606* - Hario' - 02-10-2016

(02-09-2016, 05:23 PM)MartinB I bought W220 S600 Calipers for my W210. These are for 345mm discs

Yep, the S500 ones are 330mm but and loads cheaper here in UK anyway