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606 conversion questions - Printable Version

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606 conversion questions - matfield - 02-28-2016

Hi Lads,

I'm in the middle of putting a 606 into my Defender 110, and after today its looking like its going to be a lot easier then originally thought!

   


I have a few questions:

What is the stock boost pressure the 606 runs at?

I currently have a Stainless 2.5" exhaust with Powerflow muffler. There is aprox 1 metre of pipe between the turbo and muffler. What would the disadvantages be of running a 3" downpipe into the 2.5" muffler and rear section, as opposed to running a full 3" exhaust with muffler?

Is there an in tank lift pump in a W210 or is the fuel system all located in the engine compartment? What kind of fuel pressure is required for standard 177bhp tuning?

Thanks

Mat

RE: 606 conversion questions - baldur - 02-28-2016

I believe the stock boost pressure is around 0.9 bar. The lift pump is located on the side of the injection pump.

RE: 606 conversion questions - matfield - 02-28-2016

Thanks Baldur!

Slowly coming together!

Mat

RE: 606 conversion questions - seanyt - 02-28-2016

They run 1bar then drop to 0.8 in the upper revs
Fuel is gravity feed to the pump. Then mechanical lift pump from there.
I believe the lift pump is good at running more then stock power also.

RE: 606 conversion questions - LongOldLandy - 02-29-2016

Nice project Matt!

I'm currently putting the same engine into my 130. May I ask what chassis that is?

Mine was originally a V8 and it looks as though the chassis mounts are way too far forward.

What is your plan ref. injection pump? Are you going manual pump or keeping the electronic control?

Cheers

Sam

RE: 606 conversion questions - matfield - 02-29-2016

It's a 200tdi chassis, and I'm sticking with the electronic pump, and Baldur's ECU. I'm also sticking with the 722.6 and Ole Fejer's gearbox controller as well, they are both amazing pieces of engineering, and the fine tuning that's possible with the software is brilliant!

RE: 606 conversion questions - LongOldLandy - 02-29-2016

(02-29-2016, 05:58 AM)matfield It's a 200tdi chassis, and I'm sticking with the electronic pump, and Baldur's ECU. I'm also sticking with the 722.6 and Ole Fejer's gearbox controller as well, they are both amazing pieces of engineering, and the fine tuning that's possible with the software is brilliant!

That would make sense as the 200 mounts are further back afaik. Ah well, I'll have to have a play with the MIG.

I'm going a similar setup with the 722.6 and Ole ECU - but will be using a Dieselmeken 7.5mm pump. I just know that once it's in and running, I'll want more power! Although I understand the electronic pump is capable of 250-ish bhp with a simple remap and enough boost.

Will be following this with interest, my conversion will kick off properly in the next couple of weeks.

RE: 606 conversion questions - 50harleyrider - 02-29-2016

Wow-sounds similar to my F150 conversion. Have you checked oil pan to differential clearance? Looks like you have from the photo. Are you planning a divorced Tcase setup? (hopefully your Defender already has one). You'll need to if you plan on using a 2wd 722.6. I'm using the stock w210 722.6 2wd tranny and a Ford NP205 (all gears no chain) divorced Tcase setup with driver's side drop to match my front diff location. I've got a Dieselmeken 7.5 M-pump but at first thanks to Baldur's ecu, I'm gonna stick with the stock or something similar turbo and the stock E-pump. Should be able to easily get 200HP and still get great fuel mileage. Put a fat Viton fuel line from the tank and you'll be fine with no lift pump and compatible with biodiesel. The IP supply pump should be sufficient. I've run up to 180 hp with 1.9 tdi engines without any lift pump. Green beers!!

RE: 606 conversion questions - matfield - 02-29-2016

Hi 50harleyrider,

I was planning on doing a divorced transfer case, but the 722.6 is only 115mm from the mating face of the transfer case. I've removed the rear mount from the auto box and I plan on removing the 3 bolt flange from the back of the 722.6, machining it down and welding the a Land Rover flange to end, to use an input adapter for the transfer case.

Then I'm going to make an adapter to use the rear mount face of the 722.6, where the factory mount would be, and use the Land Rover gearbox mount, and bolt it up to the transfer case as the Land Rover gear box would. Once its all tightened up, and the adapter I make is strong enough, we should be all good.

The plan is to have the 722.6 mate up in such a way, that if I ever have to change the gearbox, or want to upgrade to the 580NM variant, I can just unbolt, remove what was the 3 bolt flange, and reconnect to the new gearbox.

RE: 606 conversion questions - 50harleyrider - 03-01-2016

So you're actually 'marrying' a 'divorced' setup? Nothing like 'unholy' matrimony! Get some more photos up here. I guess you are eliminating any differential longitudinal movements between the tcase and tranny so no slip splines required? Don't forget to consider the same longitudinal movements through the engine mounts which could be an issue if you lock the tranny/tcase tight to the frame. Cheers and St Patty's green beers!

RE: 606 conversion questions - 50harleyrider - 03-01-2016

So you're actually 'marrying' a 'divorced' setup? Nothing like 'unholy' matrimony! Get some more photos up here. I guess you are eliminating any differential longitudinal movements between the tcase and tranny so no slip splines required? Don't forget to consider the same longitudinal movements through the engine mounts which could be a vibration/binding issue if you lock the tranny/tcase tight to the frame. Cheers and St Patty's green beers!

RE: 606 conversion questions - Hario' - 03-01-2016

The standard lift pump is mechanically driven by the IP, I don't think syphon fuel feed is good for power, doesn't the 200tdi use a tank lift pump?

My 606 peaks at 19psi stock fyi.

RE: 606 conversion questions - matfield - 03-01-2016

The 200tdi has an engine mounted lift pump. I've no problem getting a stand alone electric fuel pump, and running a new feed to it if required.

I am going to be going with a "married" transfer box set up. I've just had a very interesting conversation with a man in a shed about the same, and it's looking very promising!

Ill start a project thread soon

RE: 606 conversion questions - baldur - 03-01-2016

I have run 1.5 bar on the stock OM606 turbo, works okay but it chokes around 4500 revs.

RE: 606 conversion questions - 50harleyrider - 03-02-2016

(03-01-2016, 11:35 AM)baldur I have run 1.5 bar on the stock OM606 turbo, works okay but it chokes around 4500 revs.
Baldur, Are you still good with starting our conversions with your ecu and the stock turbo and E-Pump? The OP seems to be thinking like me and I can live with 4500 max for now. I'll be ordering my ecu soon as I am seriously extracting the mechanicals/wiring out of the donor w210 now.

RE: 606 conversion questions - LongOldLandy - 03-02-2016

Good spooling, approx 200-250bhp and max of 4500 rpm sounds fine for my needs at the moment. Once I figure out the optimal turbo set up for a fast spooling 300bhp then it will change - but the stock KKK turbo should be good for a while I hope!

RE: 606 conversion questions - baldur - 03-02-2016

(03-02-2016, 06:06 AM)50harleyrider
(03-01-2016, 11:35 AM)baldur I have run 1.5 bar on the stock OM606 turbo, works okay but it chokes around 4500 revs.
Baldur, Are you still good with starting our conversions with your ecu and the stock turbo and E-Pump? The OP seems to be thinking like me and I can live with 4500 max for now. I'll be ordering my ecu soon as I am seriously extracting the mechanicals/wiring out of the donor w210 now.

Yes absolutely. The vacuum controlled turbo is no problem, you just need to have the vacuum solenoid that comes with it.

RE: 606 conversion questions - matfield - 03-06-2016

One more question: does anyone know the power steering pump line pressure to the steering rack?

Thanks

Mat

RE: 606 conversion questions - seanyt - 03-06-2016

http://www.superturbodiesel.com/std/showthread.php?tid=6614

RE: 606 conversion questions - matfield - 03-06-2016

Thanks Sean,

When I used the Google site: search I still didn't find that!

RE: 606 conversion questions - seanyt - 03-06-2016

I only found it cause I posted in it. Smile

RE: 606 conversion questions - fire-host - 03-09-2016

722.6 to LR Output flange Wink

   

RE: 606 conversion questions - fire-host - 03-09-2016

The OM606 steering pump will run the LR steering box fine. Slightly higher pressure than normal, but no problems Smile.

RE: 606 conversion questions - fire-host - 03-09-2016

Divorced set-up.

   

RE: 606 conversion questions - matfield - 03-09-2016

That's good news re the PAS pump. I still have to take the pump apart to remove the SLS portion so I'll have a look at the spring anyway Smile

How did you find the alternator sat in relation to the steering box?

RE: 606 conversion questions - LongOldLandy - 03-09-2016

(03-09-2016, 04:57 AM)fire-host Divorced set-up.

Nice!! Any more pictures of the bracketry and mountings on the LT230?

RE: 606 conversion questions - LongOldLandy - 03-09-2016

(03-09-2016, 05:03 AM)matfield That's good news re the PAS pump. I still have to take the pump apart to remove the SLS portion so I'll have a look at the spring anyway Smile

How did you find the alternator sat in relation to the steering box?


I had to remove mine, was right where the PAS box is.

[Image: 20160305_220613295_iOS.jpg]

[Image: 20160305_220440799_iOS.jpg]

When I do my engine mounts, the passenger side one will incorporate an alternator bracket to place it where the Air-Con pump was originally.

RE: 606 conversion questions - matfield - 03-09-2016

Yeah, it won't fit there either, too close to the chassis, and the belt routing would be an issue.

Might be able to use a 300tdi alternator and a Subaru bolt through tensioner/idler pulley

RE: 606 conversion questions - LongOldLandy - 03-09-2016

(03-09-2016, 07:48 AM)matfield Yeah, it won't fit there either, too close to the chassis, and the belt routing would be an issue.

Might be able to use a 300tdi alternator and a Subaru bolt through tensioner/idler pulley

You must be mounting the engine further to the LH chassis rail than me then, as I have a nice big space down there for the alternator.

RE: 606 conversion questions - fire-host - 03-09-2016

Can see the alternator in its Merc OEM position here. All fine!

   

RE: 606 conversion questions - LongOldLandy - 03-09-2016

(03-09-2016, 08:30 AM)fire-host Can see the alternator in its Merc OEM position here. All fine!

Hmm, might have to have another play in that case!

Have you got any more pictures of your divorced LT230 set-up?

What did you use for the LT230 input, was it a rakeway remote input shaft by any chance?

RE: 606 conversion questions - matfield - 03-09-2016

I think it depends on what your original engine was, what transmission tunnel and bulkhead you have, and where the engine mounts are.

I have a galvanised chassis, so the original engine mounts are my reference point, as I'm not about to go cutting and welding the sealed chassis.

I think with the right engine mounts and bushes the alternator should work. I know I have about 4 inches I can come up at before I start to interfere with bonnets and transmission tunnels so we'll see what happens.

Thanks for the replies!