STD Other Projects W463 G-class OM606 + HE351W

W463 G-class OM606 + HE351W

W463 G-class OM606 + HE351W

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Jambo
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08-18-2015, 07:30 AM #51
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(08-18-2015, 06:34 AM)hents99 Yes. 606 turbo manifold is different. I`m using 606 non-turbo intake manifold because I can`t find a place where to mount intercooler and piping. I don`t want to cut original details. That`s why.

Would love to go that route but no NA manifolds here. Seem to be very difficult to find even online.
Jambo
08-18-2015, 07:30 AM #51

(08-18-2015, 06:34 AM)hents99 Yes. 606 turbo manifold is different. I`m using 606 non-turbo intake manifold because I can`t find a place where to mount intercooler and piping. I don`t want to cut original details. That`s why.

Would love to go that route but no NA manifolds here. Seem to be very difficult to find even online.

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minim
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08-18-2015, 09:09 AM #52
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I just need the laser cut holders and the specifications on the laminova coolers and I can order the rest/weld it myself if you cannot sell complete unit. The manifold isn't very different. Should be possible to weld a plenum that have space for laminova on the turbo aswell.

If you PMed me your VIN number I can check what axle you are using and what you need from the datacard of the vehicle and my document with lenghts of the axles. I have to short mine by 2.5cm but my local driveshaft shop said it was impossible to short it in..  

I kept updating my thread on a Norwegian forum but since there was so little activity here I didn't update but I can do that if it is helpful.  You could check this Norwegian G wagon forum with google translate Smile

Another thing. I found out that the only parts  that differs on the rear engine mount/gear mount is the bracket that goes onto the frame so by replacing this with bracket from a 463 with stock 606 should make everything correct but it doesn't look like a big deal to fabricate something. The only thing I worry about is the angle of the 722.6 gearbox. If I push it up so the gearbox is level then the output flange from the 722.6 will be a lot higher up than the in going flange on the transfer case. I'm not sure this is a problem since there is CV-joints on the axle but I'm tempted to order factory mount/bushing just to be sure I get it properly done. The bracket was €160 so I haven't decided yet if I'm gonna go original or custom make something.. (for the record, I did not see if the bracket fit on my frame but would surprise me if frame was different) 
This post was last modified: 08-18-2015, 09:28 AM by minim.
minim
08-18-2015, 09:09 AM #52

I just need the laser cut holders and the specifications on the laminova coolers and I can order the rest/weld it myself if you cannot sell complete unit. The manifold isn't very different. Should be possible to weld a plenum that have space for laminova on the turbo aswell.

If you PMed me your VIN number I can check what axle you are using and what you need from the datacard of the vehicle and my document with lenghts of the axles. I have to short mine by 2.5cm but my local driveshaft shop said it was impossible to short it in..  

I kept updating my thread on a Norwegian forum but since there was so little activity here I didn't update but I can do that if it is helpful.  You could check this Norwegian G wagon forum with google translate Smile

Another thing. I found out that the only parts  that differs on the rear engine mount/gear mount is the bracket that goes onto the frame so by replacing this with bracket from a 463 with stock 606 should make everything correct but it doesn't look like a big deal to fabricate something. The only thing I worry about is the angle of the 722.6 gearbox. If I push it up so the gearbox is level then the output flange from the 722.6 will be a lot higher up than the in going flange on the transfer case. I'm not sure this is a problem since there is CV-joints on the axle but I'm tempted to order factory mount/bushing just to be sure I get it properly done. The bracket was €160 so I haven't decided yet if I'm gonna go original or custom make something.. (for the record, I did not see if the bracket fit on my frame but would surprise me if frame was different) 

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Jambo
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08-19-2015, 12:51 AM #53
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minim, I bought a gearbox mount yesterday as it is different on the manual box. It has two bolts at an angle at the back instead of one hole in the vertical plane. Will see how much I have to modify the crossmember to align output flange with input flange as closely as possible. I can no longer use the CV propshaft, so want everything aligned as close as possible.

Have you got pictures?
Jambo
08-19-2015, 12:51 AM #53

minim, I bought a gearbox mount yesterday as it is different on the manual box. It has two bolts at an angle at the back instead of one hole in the vertical plane. Will see how much I have to modify the crossmember to align output flange with input flange as closely as possible. I can no longer use the CV propshaft, so want everything aligned as close as possible.

Have you got pictures?

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minim
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09-04-2015, 06:03 AM #54
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I got some of the axle here. The longest is the stock 350 axle and the shortest is from a 300 with 606+722.6 stock. Tried to attach the photos from my phone but not sure if it works. Maybe this can help you with the axle also hents99

Edit; the file is to large to be added. If you need the photo hents99 please let me know and I'll upload it when I am at a computer.
This post was last modified: 09-04-2015, 06:09 AM by minim.
minim
09-04-2015, 06:03 AM #54

I got some of the axle here. The longest is the stock 350 axle and the shortest is from a 300 with 606+722.6 stock. Tried to attach the photos from my phone but not sure if it works. Maybe this can help you with the axle also hents99

Edit; the file is to large to be added. If you need the photo hents99 please let me know and I'll upload it when I am at a computer.

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hents99
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09-05-2015, 05:49 PM #55
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Thanks!

I`m going to use custom shaft and joints.

If somebody wants I can make more of these.


.....something about project.... well...car was in paint shop because I wanted different color. It was there from March to mid August. But quality was very low and now two weeks ago I decided to try another paint shop....And start from beginning. 
This post was last modified: 09-05-2015, 05:58 PM by hents99.
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hents99
09-05-2015, 05:49 PM #55

Thanks!

I`m going to use custom shaft and joints.

If somebody wants I can make more of these.


.....something about project.... well...car was in paint shop because I wanted different color. It was there from March to mid August. But quality was very low and now two weeks ago I decided to try another paint shop....And start from beginning. 

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Jambo
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10-13-2015, 12:38 AM #56
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Bump, any new developments?

I will post mine once I have the outcome. Mainly to do with flange angles of new 6 speed.
Jambo
10-13-2015, 12:38 AM #56

Bump, any new developments?

I will post mine once I have the outcome. Mainly to do with flange angles of new 6 speed.

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hents99
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10-19-2015, 04:58 AM #57
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New propeller shaft. Custom made shaft. 

I can produce more of them if somebody wants. Much more cheaper than original part. Replacing A4634100502 part. 

[Image: DSC_0168.jpg]
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hents99
10-19-2015, 04:58 AM #57

New propeller shaft. Custom made shaft. 

I can produce more of them if somebody wants. Much more cheaper than original part. Replacing A4634100502 part. 

[Image: DSC_0168.jpg]

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INC
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10-20-2015, 10:05 AM #58
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Don`t use thous rubber boots. They will exploud when you drive more than 140km/h.

Use only original plastic boot from G-wagen.
G300TD(OM606.964) & 250GD(OM605.960)Trophy raid
INC
10-20-2015, 10:05 AM #58

Don`t use thous rubber boots. They will exploud when you drive more than 140km/h.

Use only original plastic boot from G-wagen.

G300TD(OM606.964) & 250GD(OM605.960)Trophy raid

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Jambo
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10-21-2015, 04:30 AM #59
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What CV's did you use? I also looked into this and only found a Jeep CV that could be used. Porsche also has some but they have a huge backing plate.
Both are also only 6 hole. Flanges will also need to be fabricated.

PS. I would also be careful with those boots.
This post was last modified: 10-21-2015, 05:18 AM by Jambo.
Jambo
10-21-2015, 04:30 AM #59

What CV's did you use? I also looked into this and only found a Jeep CV that could be used. Porsche also has some but they have a huge backing plate.
Both are also only 6 hole. Flanges will also need to be fabricated.

PS. I would also be careful with those boots.

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hents99
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10-21-2015, 05:28 AM #60
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Flanges are with 6 bolt pattern. Everything fits.

I had very similar boots on stock prop shaft.

Here is stock one:
http://www.metcomp.com.pl/media/produkty...80USsM.jpg


Edit: We will see what's happening. I'm going to try it.
This post was last modified: 10-21-2015, 05:29 AM by hents99.
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hents99
10-21-2015, 05:28 AM #60

Flanges are with 6 bolt pattern. Everything fits.

I had very similar boots on stock prop shaft.

Here is stock one:
http://www.metcomp.com.pl/media/produkty...80USsM.jpg


Edit: We will see what's happening. I'm going to try it.

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INC
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10-21-2015, 02:44 PM #61
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Original have plastic boot, your is made from rubber. You take rubber boot from shaft that is connected to wheel. This shaft rotate ~4 times slower (depends on Your differential ratio + transfer case ratio)  than propellershaft betwean gearbox and transfer case.
G300TD(OM606.964) & 250GD(OM605.960)Trophy raid
INC
10-21-2015, 02:44 PM #61

Original have plastic boot, your is made from rubber. You take rubber boot from shaft that is connected to wheel. This shaft rotate ~4 times slower (depends on Your differential ratio + transfer case ratio)  than propellershaft betwean gearbox and transfer case.

G300TD(OM606.964) & 250GD(OM605.960)Trophy raid

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minim
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10-21-2015, 04:30 PM #62
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did you use oil pump and sump from your old 3.5liter OM603 btw? i do but someone told me that the pump didn't fit properly om the OM606 engine so I got worried. I didnt see any problems with it.
minim
10-21-2015, 04:30 PM #62

did you use oil pump and sump from your old 3.5liter OM603 btw? i do but someone told me that the pump didn't fit properly om the OM606 engine so I got worried. I didnt see any problems with it.

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hents99
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10-04-2016, 11:57 AM #63
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Update. G-wagen is running.  

I have mechanical pump with 7mm elements + HE351W.  
I`m going to install Dieselmeken 7.5mm elements to standard OM606 pump and control it with Baldur`s controller. 

At the moment rear tire is pure black all the time. Hope to solve this problem with controller. Otherwise heavy G-wagen runs good. Tranny seems to be the weakest part Smile  ( small NAG)


New lightweigh door hinges installed. 7075 billet aluminum Smile 

Some pics:


[Image: 75669-Photo_03-10-2016_12_45_36.jpg]

[Image: 82669-Photo_03-10-2016_12_48_03.jpg]

[Image: 62926-Photo_03-10-2016_12_47_46.jpg]

[Image: 22798-Photo_03-10-2016_12_47_15.jpg]

[Image: 76689-Photo_03-10-2016_13_00_03.jpg]
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hents99
10-04-2016, 11:57 AM #63

Update. G-wagen is running.  

I have mechanical pump with 7mm elements + HE351W.  
I`m going to install Dieselmeken 7.5mm elements to standard OM606 pump and control it with Baldur`s controller. 

At the moment rear tire is pure black all the time. Hope to solve this problem with controller. Otherwise heavy G-wagen runs good. Tranny seems to be the weakest part Smile  ( small NAG)


New lightweigh door hinges installed. 7075 billet aluminum Smile 

Some pics:


[Image: 75669-Photo_03-10-2016_12_45_36.jpg]

[Image: 82669-Photo_03-10-2016_12_48_03.jpg]

[Image: 62926-Photo_03-10-2016_12_47_46.jpg]

[Image: 22798-Photo_03-10-2016_12_47_15.jpg]

[Image: 76689-Photo_03-10-2016_13_00_03.jpg]

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hents99
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10-21-2016, 08:29 AM #64
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Some pics of engine bay.

[Image: 24463-Photo_21-10-2016_14_32_55.jpg]

[Image: 82765-Photo_21-10-2016_14_33_05.jpg]

[Image: 47759-Photo_21-10-2016_14_32_59.jpg]
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hents99
10-21-2016, 08:29 AM #64

Some pics of engine bay.

[Image: 24463-Photo_21-10-2016_14_32_55.jpg]

[Image: 82765-Photo_21-10-2016_14_33_05.jpg]

[Image: 47759-Photo_21-10-2016_14_32_59.jpg]

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bigblue
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10-29-2016, 04:56 AM #65
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(10-21-2016, 08:29 AM)hents99 Some pics of engine bay.
...

[Image: 47759-Photo_21-10-2016_14_32_59.jpg]

That swap is a piece of art.  How is the laminova setup working?  I tried to see where you plumbed the water lines and radiator.  All I can see is they go towards the firewall.  Where did you package the radiator? Were you able to still retain your air conditioning condenser since you don't have a front mount air-air IC?
1999 w210 e300
2006 w211 e320 cdi
2003 VW jetta ALH
2004 VW r32 PD150
bigblue
10-29-2016, 04:56 AM #65

(10-21-2016, 08:29 AM)hents99 Some pics of engine bay.
...

[Image: 47759-Photo_21-10-2016_14_32_59.jpg]

That swap is a piece of art.  How is the laminova setup working?  I tried to see where you plumbed the water lines and radiator.  All I can see is they go towards the firewall.  Where did you package the radiator? Were you able to still retain your air conditioning condenser since you don't have a front mount air-air IC?

1999 w210 e300
2006 w211 e320 cdi
2003 VW jetta ALH
2004 VW r32 PD150

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hents99
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10-29-2016, 06:08 AM #66
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Laminova setup seems working. I have temperature sensors before and after cooler but not connected yet. 

I don`t have A/C anymore. I didn`t have W463 A/C pump mounting bracket. Engine came from W210. Steering box hit the A/C pump if it`s from W210. 
Maybe installing it later. 

Cooler coolant tank is under drivers side fender.  Water lines were tricky part and hidden under the intake. 

Radiator:

[Image: DSC_0308.jpg]

[Image: DSC_0309.jpg]
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hents99
10-29-2016, 06:08 AM #66

Laminova setup seems working. I have temperature sensors before and after cooler but not connected yet. 

I don`t have A/C anymore. I didn`t have W463 A/C pump mounting bracket. Engine came from W210. Steering box hit the A/C pump if it`s from W210. 
Maybe installing it later. 

Cooler coolant tank is under drivers side fender.  Water lines were tricky part and hidden under the intake. 

Radiator:

[Image: DSC_0308.jpg]

[Image: DSC_0309.jpg]

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hents99
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10-29-2016, 06:19 AM #67
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[Image: 76378-Photo_23-10-2016_14_08_34.jpg]

[Image: DSC_0423.jpg]

[Image: DSC_0434.jpg]

[Image: DSC_0432.jpg]

[Image: 42957-DSC_0359.JPG]

[Image: 86727-DSC_0370.JPG]

G55K + G300TD

[Image: 48562-DSC_0377.JPG]


Cleaned EDC pump and parts. Dieselmeken 7.5mm elements will be installed. 

[Image: Photo-28-10-2016-22-27-12.jpg]

[Image: Photo-28-10-2016-22-41-12.jpg]

[Image: Photo-29-10-2016-00-28-22.jpg]

[Image: Photo-29-10-2016-00-28-03.jpg]


7075 anodized alloy parts....Fuel inlet flange. M14x1.5 threaded. 

[Image: 23454-Hendrik20161029_084418.jpg]

Fuel pump block off plate: 

[Image: 79379-Hendrik20161029_084229.jpg]
This post was last modified: 10-29-2016, 07:20 AM by hents99.
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hents99
10-29-2016, 06:19 AM #67

[Image: 76378-Photo_23-10-2016_14_08_34.jpg]

[Image: DSC_0423.jpg]

[Image: DSC_0434.jpg]

[Image: DSC_0432.jpg]

[Image: 42957-DSC_0359.JPG]

[Image: 86727-DSC_0370.JPG]

G55K + G300TD

[Image: 48562-DSC_0377.JPG]


Cleaned EDC pump and parts. Dieselmeken 7.5mm elements will be installed. 

[Image: Photo-28-10-2016-22-27-12.jpg]

[Image: Photo-28-10-2016-22-41-12.jpg]

[Image: Photo-29-10-2016-00-28-22.jpg]

[Image: Photo-29-10-2016-00-28-03.jpg]


7075 anodized alloy parts....Fuel inlet flange. M14x1.5 threaded. 

[Image: 23454-Hendrik20161029_084418.jpg]

Fuel pump block off plate: 

[Image: 79379-Hendrik20161029_084229.jpg]

------------------------------------------------------------------------
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hents99
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10-31-2016, 09:00 AM #68
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And the reason why I have this G wagen...and brown color...

[Image: 77973-Photo_31-10-2016_15_40_44.jpg]

[Image: 24424-Photo_31-10-2016_15_41_01.jpg]

[Image: 45525-Photo_31-10-2016_15_41_41.jpg]
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hents99
10-31-2016, 09:00 AM #68

And the reason why I have this G wagen...and brown color...

[Image: 77973-Photo_31-10-2016_15_40_44.jpg]

[Image: 24424-Photo_31-10-2016_15_41_01.jpg]

[Image: 45525-Photo_31-10-2016_15_41_41.jpg]

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atypicalguy
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11-17-2016, 08:27 PM #69
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Are you still selling N/A om606 laminovas manifolds? I would like to have one for my w124 like sultzi. Thanks.
atypicalguy
11-17-2016, 08:27 PM #69

Are you still selling N/A om606 laminovas manifolds? I would like to have one for my w124 like sultzi. Thanks.

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hents99
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11-20-2016, 05:23 AM #70
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At the moment no.
New OEM intake manifolds are out of stock. Only cross over pipes are stocked items. I`m developing totally new intake manifold for OM606 instead of machining used ones.

[Image: Photo-18-11-2016-19-21-03-1024x768.jpg]


700kPa Map sensor. New fuel inlet flange with M14x1.5mm thread. 7075 alloy. And cover plate for original feed pump.   I made more sets if somebody interested. 

[Image: Photo-18-11-2016-19-32-27-1024x768.jpg]

[Image: Photo-18-11-2016-19-20-06-1024x768.jpg]
This post was last modified: 11-20-2016, 05:26 AM by hents99.
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hents99
11-20-2016, 05:23 AM #70

At the moment no.
New OEM intake manifolds are out of stock. Only cross over pipes are stocked items. I`m developing totally new intake manifold for OM606 instead of machining used ones.

[Image: Photo-18-11-2016-19-21-03-1024x768.jpg]


700kPa Map sensor. New fuel inlet flange with M14x1.5mm thread. 7075 alloy. And cover plate for original feed pump.   I made more sets if somebody interested. 

[Image: Photo-18-11-2016-19-32-27-1024x768.jpg]

[Image: Photo-18-11-2016-19-20-06-1024x768.jpg]

------------------------------------------------------------------------
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hents99
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01-06-2017, 05:28 AM #71
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Some fresh pics:

[Image: Photo-03-10-2016-12-46-28-1024x768.jpg]

[Image: 63794-IMG_0686.JPG]

[Image: Photo-05-01-2017-19-51-29-1024x768.jpg]

[Image: Photo-05-01-2017-19-51-23-1024x768.jpg]

[Image: Photo-06-01-2017-10-52-14-1024x768.jpg]

[Image: Photo-06-01-2017-10-52-18-1024x768.jpg]

[Image: Photo-06-01-2017-10-52-30-1024x768.jpg]

[Image: Photo-05-01-2017-19-51-51-1024x768.jpg]
------------------------------------------------------------------------
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hents99
01-06-2017, 05:28 AM #71

Some fresh pics:

[Image: Photo-03-10-2016-12-46-28-1024x768.jpg]

[Image: 63794-IMG_0686.JPG]

[Image: Photo-05-01-2017-19-51-29-1024x768.jpg]

[Image: Photo-05-01-2017-19-51-23-1024x768.jpg]

[Image: Photo-06-01-2017-10-52-14-1024x768.jpg]

[Image: Photo-06-01-2017-10-52-18-1024x768.jpg]

[Image: Photo-06-01-2017-10-52-30-1024x768.jpg]

[Image: Photo-05-01-2017-19-51-51-1024x768.jpg]

------------------------------------------------------------------------
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martymcfly
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10-15-2018, 09:10 PM #72
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(10-04-2016, 11:57 AM)hents99 Update. G-wagen is running.  

I have mechanical pump with 7mm elements + HE351W.  
I`m going to install Dieselmeken 7.5mm elements to standard OM606 pump and control it with Baldur`s controller. 

At the moment rear tire is pure black all the time. Hope to solve this problem with controller. Otherwise heavy G-wagen runs good. Tranny seems to be the weakest part Smile  ( small NAG)
How is the throttle response with this turbo setup? Did you ever produce a turbo kit?
I've been looking at the variable vein turbos and this is one of the only real write up i've found. 
Thanks
martymcfly
10-15-2018, 09:10 PM #72

(10-04-2016, 11:57 AM)hents99 Update. G-wagen is running.  

I have mechanical pump with 7mm elements + HE351W.  
I`m going to install Dieselmeken 7.5mm elements to standard OM606 pump and control it with Baldur`s controller. 

At the moment rear tire is pure black all the time. Hope to solve this problem with controller. Otherwise heavy G-wagen runs good. Tranny seems to be the weakest part Smile  ( small NAG)
How is the throttle response with this turbo setup? Did you ever produce a turbo kit?
I've been looking at the variable vein turbos and this is one of the only real write up i've found. 
Thanks

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g wizz
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10-17-2018, 11:37 AM #73
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ihents99

f your going to use that he351 i suggest you also use a "prioritized external waste gate" fabbed into your manifold, and a big one at that. the exhaust housing on those cummins turbos is pretty small and restrictive and the internal wg is also small even the cummins guys drill their wgs larger.  they do make power but also alot of drive pressure so thats something to think about.

you can also go bigger on both compressor and turbine on this turbo. pure, cheeta, fleece, pretty sure they all do this to these turbos.

also its more important to move air than it is to build boost. but equally that applies to the exhaust, hence why i say the external wg.

both your vehicles are awesome by the way.
g wizz
10-17-2018, 11:37 AM #73

ihents99

f your going to use that he351 i suggest you also use a "prioritized external waste gate" fabbed into your manifold, and a big one at that. the exhaust housing on those cummins turbos is pretty small and restrictive and the internal wg is also small even the cummins guys drill their wgs larger.  they do make power but also alot of drive pressure so thats something to think about.

you can also go bigger on both compressor and turbine on this turbo. pure, cheeta, fleece, pretty sure they all do this to these turbos.

also its more important to move air than it is to build boost. but equally that applies to the exhaust, hence why i say the external wg.

both your vehicles are awesome by the way.

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