W124 250 D - OM603 + 716 Gearbox Superturbo Transformation
W124 250 D - OM603 + 716 Gearbox Superturbo Transformation
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:
![[Image: qjrwsmqzsp2.jpg]](http://www.pic-upload.de/view-24045315/IMAG2938.jpg.html)
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!
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!
![[Image: e49y6x81tkk7.jpg]](http://www.pic-upload.de/view-24059201/IMAG2957.jpg.html)
![[Image: a9tffot9p53.jpg]](http://www.pic-upload.de/view-24059272/VIDEO0129_0000002900.jpg.html)
Tomorrow i gonna remove om602 and install the Engine.
I hope i dont get big Problems with the 716 Transmission.
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.
![[Image: 23qcrgveidp.jpg]](http://www.pic-upload.de/view-24061384/IMAG2938.jpg.html)
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.
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.
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.
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.
http://www.peachparts.com/shopforum/dies...rsion.html
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/dies...rsion.html
![[Image: spygg9rg1rw.jpg]](http://www.pic-upload.de/view-24080855/IMAG3019.jpg.html)
![[Image: m5dfh4yzbb.jpg]](http://www.pic-upload.de/view-24080879/IMAG3021.jpg.html)
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
This is my current issue!!
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
maxypriest
08-04-2014, 08:04 AM #8Did 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!!
W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs
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:
![[Image: qdk63xdb6.jpg]](http://www.pic-upload.de/view-24134198/IMAG3043.jpg.html)
![[Image: 6l8beflwwt2.jpg]](http://www.pic-upload.de/view-24134197/IMAG3037.jpg.html)
I hope the timing chain got damage, its the easyst repair.
Do you have any ideas?
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?
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?
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?
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 -
Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]
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 -
Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]
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
![[Image: csjbnw4ymgm.jpg]](http://www.pic-upload.de/view-24479256/IMAG0018.jpg.html)
![[Image: 8fa7dxpeeb5q.jpg]](http://www.pic-upload.de/view-24479320/IMAG0019.jpg.html)
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?
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?
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.
![[Image: 36fab4el99dt.jpg]](http://www.pic-upload.de/view-24551794/IMAG0108.jpg.html)
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
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
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
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
lost in the diesel universe.............
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!
lost in the diesel universe.............
@mbz123
I dont mean the HP lines, im taking about the fuel line from the fuel tank --> diesel pump
![[Image: p4sbxuqwg9or.jpg]](http://www.pic-upload.de/view-24851525/IMAG0306.jpg.html)
Yesterday i mounted the big turbocharger. i only have to modify the dieselpump + diesel line and install the Intercooler!
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!
![[Image: vulolm23xtcx.jpg]](http://www.pic-upload.de/view-24883261/IMAG0367.jpg.html)
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
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?
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
(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.
(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.
![[Image: yjyunerhe1km.jpg]](http://www.pic-upload.de/view-24928410/IMAG0396.jpg.html)
![[Image: bu6og8pz8txj.jpg]](http://www.pic-upload.de/view-24928411/IMAG0397.jpg.html)
![[Image: ls83ecvme3r9.png]](http://www.pic-upload.de/view-25079200/vlcsnap-2014-10-28-19h27m51s24.png.html)
![[Image: b7s3rh7g3l6.jpg]](http://www.pic-upload.de/view-25185467/IMAG0607.jpg.html)
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
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
![[Image: ypecdofwzfvt.jpg]](http://www.pic-upload.de/view-25374876/IMAG0629.jpg.html)
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.
![[Image: r3125ayamx9q.jpg]](http://www.pic-upload.de/view-25374880/IMAG0691.jpg.html)
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.
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.
?![[Image: xqt1iasoxzz.jpg]](http://www.pic-upload.de/view-25462807/IMAG0784.jpg.html)
![[Image: j8j8eit46cpz.jpg]](http://www.pic-upload.de/view-25462811/IMAG0785.jpg.html)
![[Image: omlo3yr2ycnr.jpg]](http://www.pic-upload.de/view-25462830/IMAG0789.jpg.html)
![[Image: l3wwtxmgpepp.jpg]](http://www.pic-upload.de/view-25462841/IMAG0790.jpg.html)
![[Image: 9rsv6psgxm3l.jpg]](http://www.pic-upload.de/view-25462869/IMAG0737.jpg.html)
![[Image: v2jrvq13sq7f.jpg]](http://www.pic-upload.de/view-25462872/IMAG0743.jpg.html)
![[Image: kra17xdqof7i.jpg]](http://www.pic-upload.de/view-25462873/IMAG0742.jpg.html)
Insane190d
12-05-2014, 09:13 AM #32Looks good. Did the intercooler just like mine, had to take a little metal out by rad support too.
![[Image: h4unxjpypfwy.jpg]](http://www.pic-upload.de/view-25465811/IMAG0798.jpg.html)
![[Image: 3ia6q11abvt1.jpg]](http://www.pic-upload.de/view-25465812/IMAG0803.jpg.html)
1.5 Bar original prepump.
Speedometer ist almost connected. I only have to connect the ABS sensor at the diff
https://www.youtube.com/watch?v=jxLk8Kj3...e=youtu.be
1.5 Bar original prepump.
Speedometer ist almost connected. I only have to connect the ABS sensor at the diff
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.
![[Image: y883ccxkp7o2.jpg]](http://www.pic-upload.de/view-26227874/10997223_555424061226762_1726625999_n.jpg.html)
![[Image: v46ae5r7e6ex.jpg]](http://www.pic-upload.de/view-26227876/11003908_555424064560095_1165971367_n.jpg.html)
![[Image: u1tftqsrnbm.jpg]](http://www.pic-upload.de/view-26227875/11014708_555424051226763_42057147_n.jpg.html)
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.
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.
'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler
'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted
It Should be behind the second injector, I was just curious if you still had the #14 casting or not.
'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler
'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted
The #22 head casting is the newest and supposedly best version of the om603 heads
'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler
'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted
http://www.superturbodiesel.com/std/show...p?tid=6171
The #22 head casting is the newest and supposedly best version of the om603 heads
'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler
'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted
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.
raysorenson
02-27-2015, 01:57 PM #43The 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.
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.
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.
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.
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.
next mounth i will start my 300d turbo project,but i dont whant change the automatic gearbox... 100cc of diesel make 260hp on om603?
PedroFerreira
05-03-2015, 05:37 PM #47how 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?
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.
![[Image: 7sf8qmi5gml.jpg]](http://www.pic-upload.de/view-27212970/IMG-20150530-WA0005.jpg.html)
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.
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.
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