W202 OM606 GT2359v+Pro52

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erx

w202 om606

323

01-31-2015, 07:06 PM #1

some extra holes in dashboard and leaking antenna on the roof but underneath it was in pretty good shape. Last year I finally managed to swap the engines and it is running at the moment.

Specs at the moment:

*Engine - OM606.962, stock from W210
*Turbo - Holset HX40
*Gearbox - 722.6 from w211 320cdi
*Pump - mechanical 7.5mm 180cc Dieselmeken with Bosch 044
*Gearbox controller from olefejer
*3" Simons Exhaust

Donor car was 1998 E300td, with 460k km but engine was running perfectly. It was so rusted that I even couldn't use propshaft.

[Image: IMG_4283modified.jpg]

This post was last modified: 04-24-2018, 02:33 PM by erx.

erx

01-31-2015, 07:06 PM #1

Hi STD people.
This is my car, 1994 c220d. I bought it three years ago and since then I have been reading this forum. First I looked for w201 but most of them were rusted, then I found one slightly wrecked w202. Previous owner was taxi company, Big Grin some extra holes in dashboard and leaking antenna on the roof but underneath it was in pretty good shape. Last year I finally managed to swap the engines and it is running at the moment.

Specs at the moment:

*Engine - OM606.962, stock from W210
*Turbo - Holset HX40
*Gearbox - 722.6 from w211 320cdi
*Pump - mechanical 7.5mm 180cc Dieselmeken with Bosch 044
*Gearbox controller from olefejer
*3" Simons Exhaust

Donor car was 1998 E300td, with 460k km but engine was running perfectly. It was so rusted that I even couldn't use propshaft.

[Image: IMG_4283modified.jpg]

raidaru

TA 0301

65

01-31-2015, 07:17 PM #2

nice ride! what engine mounts did u use? also after u swaped the engine, u didn't have to move the transmission a little backwards?u have manual or auto?

lost in the diesel universe.............

raidaru

01-31-2015, 07:17 PM #2

nice ride! what engine mounts did u use? also after u swaped the engine, u didn't have to move the transmission a little backwards?u have manual or auto?

lost in the diesel universe.............

erx

w202 om606

323

02-01-2015, 07:44 AM #3

Propshafts, you can see the differences. Big Grin

Longer power steering hoses

[Image: DSC_0073_zps89326ee9.jpg]

w210 300td 2.87, W124 3.07 ASD which I use at the moment and tiny 2.2d 3.27

[Image: IMG_5021_zpsffe2303d.jpg]

Some new parts

Avantgarde springs from w210

New nozzles

3" exhaust and HX35 super, turbo is sold for now because it was too small.

Cooler 2.5" hoses are from local truck parts store.

First I used gearbox from 300td but 4th and 5th gear started to slip, so I bought 2005 w211 320cdi gearbox and swapped the bellhousing. And yes, I6 320cdi engine has different housing, it was surprise to me also, 220cdi and 270cdi is the same as 606.

3" exhaust finished, tried different zink based coating paints.

And some smaller modifications, like little pipe in cylinder head, ordered 604 one from mb dealer.
606 has long pipe with rubber sealing

And 604 pipe pressed in.

And it goes in. Exhaust and inlet manifolds were stock, just made the flange to fit bigger turbo to genuine manifold.

Latest purchase was gearbox controller from olefejer.

This post was last modified: 02-01-2015, 08:50 AM by erx.

erx

02-01-2015, 07:44 AM #3

It's pre-facelift, so it came with 722.4. All parts from 2.2d are ridiculously tiny so I also changed propshaft, differential and driveshafts. Front brakes have solid disks, not even air ventilated, I did't know MB even had those.
First I used 604 mounting arms but there was no room for cooling fan, then I changed to 606 arms and now it fits perfectly. Gearbox mounting bracket is modified, propshaft is from w210 and shortened, diff is from w124 and driveshafts are from w210 and shortened.

606 arm on left and 604 arm on right

[Image: DSC_0048_zpse8d2a778.jpg]

Propshafts, you can see the differences. Big Grin

[Image: IMG_4895_zpsfccbfa3e.jpg]

[Image: IMG_4891_zpsae9b6207.jpg]

Longer power steering hoses

[Image: DSC_0073_zps89326ee9.jpg]

[Image: DSC_0030v_zps53666d71.jpg]

[Image: DSC_0031v_zps8b9f6ae3.jpg]

[Image: DSC_0033v_zps0fd36771.jpg]

w210 300td 2.87, W124 3.07 ASD which I use at the moment and tiny 2.2d 3.27

[Image: IMG_5021_zpsffe2303d.jpg]

[Image: IMG_5019_zpse93ea2ff.jpg]

Some new parts

Avantgarde springs from w210

New nozzles

3" exhaust and HX35 super, turbo is sold for now because it was too small.

Cooler 2.5" hoses are from local truck parts store.

First I used gearbox from 300td but 4th and 5th gear started to slip, so I bought 2005 w211 320cdi gearbox and swapped the bellhousing. And yes, I6 320cdi engine has different housing, it was surprise to me also, 220cdi and 270cdi is the same as 606.

3" exhaust finished, tried different zink based coating paints.

And some smaller modifications, like little pipe in cylinder head, ordered 604 one from mb dealer.
606 has long pipe with rubber sealing

And 604 pipe pressed in.

And it goes in. Exhaust and inlet manifolds were stock, just made the flange to fit bigger turbo to genuine manifold.

Latest purchase was gearbox controller from olefejer.

maxypriest

Holset

287

02-01-2015, 05:49 PM #4

Fantastic work and great pictures!

W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs

maxypriest

02-01-2015, 05:49 PM #4

Fantastic work and great pictures!

W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs

erx

w202 om606

323

02-01-2015, 06:49 PM #5

Thanks, I have some videos also.

First I tried to take max from stock engine, only changes were dieselmeken pump and boost raised to 2 bar, genuine turbo.
https://www.youtube.com/watch?v=_AAr5asdowk

Here I have HX35 Super with stock manofolds, 2,5bar boost. At that moment 4th and 5th gear slipped so it wasn't possible to accelerate with full throttle over 120kmh.
https://www.youtube.com/watch?v=p-uggNTOaa0

And dyno, same HX35 Super with little 8cm housing, 375hp/280kw, 650nm @ 2,5bar
https://www.youtube.com/watch?v=GuXz2MLn5yU

And just some black smoke.
https://www.youtube.com/watch?v=tbU-gSPFiIo

erx

02-01-2015, 06:49 PM #5

F.R.A.S

Holset

579

02-02-2015, 02:08 AM #6

Awesome mate. I love it Smile

w202 with om606 is my next daily Big Grin

Great pictures...

F-tune Performance [Image: V-band_om606.jpg]

I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.

F.R.A.S

02-02-2015, 02:08 AM #6

Awesome mate. I love it Smile

w202 with om606 is my next daily Big Grin

Great pictures...

F-tune Performance [Image: V-band_om606.jpg]

I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.

raidaru

TA 0301

65

02-02-2015, 02:54 AM #7

Is your gearbox still slipping? maybe a few more clutch discs would solve the problem. Also do u have EDC pump or mechanical? Because I read somewhere that is better to cut off fueling when changing gears, and with mechanical pump that wouldn't be possible unless u release the pedal.

lost in the diesel universe.............

raidaru

02-02-2015, 02:54 AM #7

lost in the diesel universe.............

erx

w202 om606

323

02-02-2015, 03:53 AM #8

(02-02-2015, 02:54 AM)raidaru Is your gearbox still slipping? maybe a few more clutch discs would solve the problem. Also do u have EDC pump or mechanical? Because I read somewhere that is better to cut off fueling when changing gears, and with mechanical pump that wouldn't be possible unless u release the pedal.

Not anymore, 300td gearbox was slipping, now 320cdi gearbox is holding fine. Pump is mechanical.

This post was last modified: 02-02-2015, 03:59 AM by erx.

erx

02-02-2015, 03:53 AM #8

(02-02-2015, 02:54 AM)raidaru Is your gearbox still slipping? maybe a few more clutch discs would solve the problem. Also do u have EDC pump or mechanical? Because I read somewhere that is better to cut off fueling when changing gears, and with mechanical pump that wouldn't be possible unless u release the pedal.

Not anymore, 300td gearbox was slipping, now 320cdi gearbox is holding fine. Pump is mechanical.

Hario'

C300TD Wagon (W202)

894

02-02-2015, 04:49 AM #9

Just thinking out loud - Modifying the gearbox mounts and shortening the propshaft was the only way to do it instead of moving the radiator and interooler forward by cutting down the front crossmember??
How was the gearbox modified, just drill new holes for the bolts going up into the bodyshell/

Beers, H.

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

Hario'

02-02-2015, 04:49 AM #9

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

erx

w202 om606

323

02-02-2015, 05:01 AM #10

In front of the engine every inch counts, ofcourse you can move the radiator forward but I also needed room for bigger cooler and it fits tight even now. 604 and 606 mounts give movement about 2,5cm. As I said mine was 2,2d and it doesn't matter which mounts I would use, propshaft should be shortened anyway because 722.6 from 300td have bigger and stronger flexidisk and it needs propshaft from 300td which is about 14cm longer.

One possible way to do it might be using 300td front part of propshaft and c250td rear part of propshaft because I had to shorten rear part. If the center connection is same, then it will be straight fit. Then front flexidisk and gearbox triple flange should be changed to 300td one.

I cut gearbox bracket to peaces and welded back together, nothing special.

This post was last modified: 02-02-2015, 05:16 AM by erx.

erx

02-02-2015, 05:01 AM #10

muuris

OM605

318

02-02-2015, 05:28 AM #11

W202+OM606 is a great combo.

How much did you have backpressure on HX35 @ 2,5bar boost? What about stock[/quote] turbo? Big Grin

Just thinking out loud, for that power and small turbine the boost is unnecessarily high, I had similar power on my ex 606 with only 1,7bar boost..

muuris

02-02-2015, 05:28 AM #11

W202+OM606 is a great combo.

How much did you have backpressure on HX35 @ 2,5bar boost? What about stock[/quote] turbo? Big Grin

Just thinking out loud, for that power and small turbine the boost is unnecessarily high, I had similar power on my ex 606 with only 1,7bar boost..

erx

w202 om606

323

02-02-2015, 05:45 AM #12

(02-02-2015, 05:28 AM)muuris W202+OM606 is a great combo.

How much did you have backpressure on HX35 @ 2,5bar boost? What about stock turbo?

Just thinking out loud, for that power and small turbine the boost is unnecessarily high, I had similar power on my ex 606 with only 1,7bar boost..

Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high. Big Grin

Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.

This post was last modified: 02-02-2015, 05:47 AM by erx.

erx

02-02-2015, 05:45 AM #12

(02-02-2015, 05:28 AM)muuris W202+OM606 is a great combo.

How much did you have backpressure on HX35 @ 2,5bar boost? What about stock turbo?

Just thinking out loud, for that power and small turbine the boost is unnecessarily high, I had similar power on my ex 606 with only 1,7bar boost..

Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high. Big Grin

Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.

Insane190d

GT2256V

170

02-02-2015, 07:17 AM #13

Awsome project. Is the exhaust custom made by you or can I go and buy a system somewhere? Id like a 3 or 4" exhaust for my project

Insane190d

02-02-2015, 07:17 AM #13

Awsome project. Is the exhaust custom made by you or can I go and buy a system somewhere? Id like a 3 or 4" exhaust for my project

erx

w202 om606

323

02-02-2015, 07:24 AM #14

(02-02-2015, 07:17 AM)Insane190d Awsome project. Is the exhaust custom made by you or can I go and buy a system somewhere? Id like a 3 or 4" exhaust for my project

It's custom made from universal parts, you can see pipes and resonator on the picture above. I made it by myself, just cut and weld.

This post was last modified: 02-02-2015, 07:25 AM by erx.

erx

02-02-2015, 07:24 AM #14

(02-02-2015, 07:17 AM)Insane190d Awsome project. Is the exhaust custom made by you or can I go and buy a system somewhere? Id like a 3 or 4" exhaust for my project

It's custom made from universal parts, you can see pipes and resonator on the picture above. I made it by myself, just cut and weld.

Hario'

C300TD Wagon (W202)

894

02-02-2015, 08:24 AM #15

I see. Well UK C250TD comes with 722.6 anyway so gearbox & prop can remain the same if everything can move forward with crossmember cut out.

Why not improve wategate-ing to reduce back press?

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

Hario'

02-02-2015, 08:24 AM #15

I see. Well UK C250TD comes with 722.6 anyway so gearbox & prop can remain the same if everything can move forward with crossmember cut out.

Why not improve wategate-ing to reduce back press?

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

muuris

OM605

318

02-02-2015, 01:19 PM #16

(02-02-2015, 05:45 AM)erx Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.
Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.

Yeah, I measured at worst 2,3bar backpressure on completely stock OM605 (boost 1,2 bar) so you can only imagine.. Big Grin

But actually I expected a lot more backpressure with HX35 super. Running around 1,8 bar boost the backpressure should be ok.

(02-02-2015, 08:24 AM)Hario Why not improve wategate-ing to reduce back press?

Enlarging wastegate has only little effect on backpressure and exhaust flow. It's like curing the symptoms, not the illness itself.

I had ~380ish horses dynoed with two different self-made manifold, two different turbos (GT37xxV and He351Ve) and two different wastegates. The wastegate was the last upgrade of those, and didn't help with high backpressures/choked exhaust flow. Compressors would have been good for more on both turbos. Then changed the turbo and backpressures dropped around 50% Big Grin

muuris

02-02-2015, 01:19 PM #16

(02-02-2015, 05:45 AM)erx Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.
Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.

Yeah, I measured at worst 2,3bar backpressure on completely stock OM605 (boost 1,2 bar) so you can only imagine.. Big Grin

But actually I expected a lot more backpressure with HX35 super. Running around 1,8 bar boost the backpressure should be ok.

(02-02-2015, 08:24 AM)Hario Why not improve wategate-ing to reduce back press?

erx

w202 om606

323

02-02-2015, 05:32 PM #17

(02-02-2015, 01:19 PM)muuris
(02-02-2015, 05:45 AM)erx Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.
Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.
Yeah, I measured at worst 2,3bar backpressure on completely stock OM605 (boost 1,2 bar) so you can only imagine.. But actually I expected a lot more backpressure with HX35 super. Running around 1,8 bar boost the backpressure should be ok.

(02-02-2015, 08:24 AM)Hario Why not improve wategate-ing to reduce back press?
Enlarging wastegate has only little effect on backpressure and exhaust flow. It's like curing the symptoms, not the illness itself.

I had ~380ish horses dynoed with two different self-made manifold, two different turbos (GT37xxV and He351Ve) and two different wastegates. The wastegate was the last upgrade of those, and didn't help with high backpressures/choked exhaust flow. Compressors would have been good for more on both turbos. Then changed the turbo and backpressures dropped around 50%

I was wrong, looked a video from summer and with 2,0bar boost backpressure was 2,9bar, so with 2,5bar boost it was higher. But you didn't try with genuine manifold? You can't compare with stock manifold, it is so small inside, it causes that high backpressure, also little 8cm housing. Stock manifold and small housing is definitely not good combo for 606 STD.
I was planning biturbo but nut sure which turbos to choose, at the moment I have HX40 with 16 housing, I will try this with custom made manifold. You can see that hx35 super is really small compared to hx40.

[Image: 10850769_10203656984401955_900121380_n_zpsvkeayazx.jpg]

[Image: 10863677_10203656984841966_416052055_n_zpshtocpra3.jpg]

This post was last modified: 02-02-2015, 06:37 PM by erx.

erx

02-02-2015, 05:32 PM #17

(02-02-2015, 01:19 PM)muuris
(02-02-2015, 05:45 AM)erx Backpressure was 3 bar with hx35 super, don't know with stock turbo but I think it was high.
Did you have stock exhaust manifold and what turbo did you use with 1,7bar? I think it was a lot bigger than 8cm hx35 super.
Yeah, I measured at worst 2,3bar backpressure on completely stock OM605 (boost 1,2 bar) so you can only imagine.. But actually I expected a lot more backpressure with HX35 super. Running around 1,8 bar boost the backpressure should be ok.

(02-02-2015, 08:24 AM)Hario Why not improve wategate-ing to reduce back press?
Enlarging wastegate has only little effect on backpressure and exhaust flow. It's like curing the symptoms, not the illness itself.

I had ~380ish horses dynoed with two different self-made manifold, two different turbos (GT37xxV and He351Ve) and two different wastegates. The wastegate was the last upgrade of those, and didn't help with high backpressures/choked exhaust flow. Compressors would have been good for more on both turbos. Then changed the turbo and backpressures dropped around 50%

Mr_Robs

GT2256V

124

02-02-2015, 09:20 PM #18

It must be the W211 bellhousing thats different. A W210 320CDI box should be the same correct?

Loving the build so far!

It sounds pretty quiet from the videos with just that one muffler, how loud is it in person? I still haven't decided what to do after the downpipe.

Mr_Robs

02-02-2015, 09:20 PM #18

erx

w202 om606

323

02-03-2015, 02:53 AM #19

(02-02-2015, 09:20 PM)Mr_Robs It must be the W211 bellhousing thats different. A W210 320CDI box should be the same correct?

Loving the build so far!

It sounds pretty quiet from the videos with just that one muffler, how loud is it in person? I still haven't decided what to do after the downpipe.

W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.

It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through. Big Grin

This post was last modified: 02-03-2015, 02:54 AM by erx.

erx

02-03-2015, 02:53 AM #19

(02-02-2015, 09:20 PM)Mr_Robs It must be the W211 bellhousing thats different. A W210 320CDI box should be the same correct?

Loving the build so far!

It sounds pretty quiet from the videos with just that one muffler, how loud is it in person? I still haven't decided what to do after the downpipe.

Mr_Robs

GT2256V

124

02-03-2015, 08:40 AM #20

(02-03-2015, 02:53 AM)erx W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.

It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through.

Yea, they both have the straight six in the 210 and 211 but i think they made changes when the 211 came out. Any chance you know what year car your box came from?

Haha thats awesome Big Grin

. Good to know, i will plan for just one muffler near the back Wink

Mr_Robs

02-03-2015, 08:40 AM #20

(02-03-2015, 02:53 AM)erx W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.

It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through.

Yea, they both have the straight six in the 210 and 211 but i think they made changes when the 211 came out. Any chance you know what year car your box came from?

Haha thats awesome Big Grin

. Good to know, i will plan for just one muffler near the back Wink

erx

w202 om606

323

02-03-2015, 08:53 AM #21

(02-03-2015, 08:40 AM)Mr_Robs
(02-03-2015, 02:53 AM)erx W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.

It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through.

Yea, they both have the straight six in the 210 and 211 but i think they made changes when the 211 came out. Any chance you know what year car your box came from?

Haha thats awesome . Good to know, i will plan for just one muffler near the back

I'm not sure, so they made whole new engine block for w211? I don't want to belive it. V6 came with new box. My box is from 2005 car but on box there was '04. Code is 722.626 which is the same as w210 uses.

This post was last modified: 02-03-2015, 08:57 AM by erx.

erx

02-03-2015, 08:53 AM #21

(02-03-2015, 08:40 AM)Mr_Robs
(02-03-2015, 02:53 AM)erx W210 and W211 share basicly the same engine, I think they are the same. Box is from straight 6cyl not V6, V6 came with newer 722.9.

It's louder than stock muffler but not too noisy. Some people have asked if there's something wrong with muffler or is it rusted through.

Yea, they both have the straight six in the 210 and 211 but i think they made changes when the 211 came out. Any chance you know what year car your box came from?

Haha thats awesome . Good to know, i will plan for just one muffler near the back

Mr_Robs

GT2256V

124

02-04-2015, 02:13 AM #22

Hmm i doubt the block is different but is it possible the bellhousing aligns differently? Like the propshafts are different length and the shifter is mounted in a different position? Thats the only explanation i can think of.

On this chart i was looking at there are two listed E320 CDI
#1 is Model 211.022 Engine 642.920 Gearbox 722.902
#2 is Model 211.026 Engine 648.961 Gearbox 722.626

The E220cdi and E270cdi gearboxes are listed as 722.640

This post was last modified: 02-04-2015, 02:19 AM by Mr_Robs.

Mr_Robs

02-04-2015, 02:13 AM #22

erx

w202 om606

323

02-04-2015, 03:14 AM #23

(02-04-2015, 02:13 AM)Mr_Robs Hmm i doubt the block is different but is it possible the bellhousing aligns differently? Like the propshafts are different length and the shifter is mounted in a different position? Thats the only explanation i can think of.

On this chart i was looking at there are two listed E320 CDI
#1 is Model 211.022 Engine 642.920 Gearbox 722.902
#2 is Model 211.026 Engine 648.961 Gearbox 722.626

The E220cdi and E270cdi gearboxes are listed as 722.640

I think you are confused mate. Wink

If you google these two models you'll see that #1 is V6 and as you wrote it came with new generation 722.9 7g-tronic.

erx

02-04-2015, 03:14 AM #23

(02-04-2015, 02:13 AM)Mr_Robs Hmm i doubt the block is different but is it possible the bellhousing aligns differently? Like the propshafts are different length and the shifter is mounted in a different position? Thats the only explanation i can think of.

On this chart i was looking at there are two listed E320 CDI
#1 is Model 211.022 Engine 642.920 Gearbox 722.902
#2 is Model 211.026 Engine 648.961 Gearbox 722.626

The E220cdi and E270cdi gearboxes are listed as 722.640

I think you are confused mate. Wink

If you google these two models you'll see that #1 is V6 and as you wrote it came with new generation 722.9 7g-tronic.

sorin_cel

5fingers on a hand, 5cylinders block

71

02-04-2015, 03:46 PM #24

0-100 in 4-5 sec, that's mad Smile

sorin_cel

02-04-2015, 03:46 PM #24

0-100 in 4-5 sec, that's mad Smile

Mr_Robs

GT2256V

124

02-04-2015, 05:08 PM #25

Sorry i should have clarified more what i was trying to explain. Yea totally agree there is one V6 and one inline 6, but does the W210 (not listed in my post) have a gearbox code of 722.640 like the 220/270 boxes? Maybe thats why the W211 722.626 from an inline engine doesnt fit?

This post was last modified: 02-04-2015, 05:08 PM by Mr_Robs.

Mr_Robs

02-04-2015, 05:08 PM #25

erx

w202 om606

323

02-04-2015, 05:39 PM #26

(02-04-2015, 05:08 PM)Mr_Robs Sorry i should have clarified more what i was trying to explain. Yea totally agree there is one V6 and one inline 6, but does the W210 (not listed in my post) have a gearbox code of 722.640 like the 220/270 boxes? Maybe thats why the W211 722.626 from an inline engine doesnt fit?

Ok.

I don't know where your information is from but all of them have different boxes on w210, maybe on w211 chassis 2.2cdi and 2.7cdi share the same box.

722.699 W 5 A 330 C220CDI, E220CDI, E200CDI 202.193, 210.006, 206, 210.007
722.634 W 5 A 580 E270 CDI 210.016, 216, 616
722.626 W 5 A 580 E320CDI, S320CDI 210.026, 226, 220.026

Copied this from another forum

722.600 W 5 A 330 C230, E300, E320 202.023, 083, 210.020, 210.037, 237
722.601 W 5 A 330 E250 DIESEL 210.010, 210.610
722.602 W 5 A 330 SLK200, C200, E200, CLK200 170.435, 202.020, 080, 210.035, 235, 208.335, 435
722.603 W 5 A 330 C180, C220, E220, C200, E200 202.018, 078, 202.121, 182, 210.004, 202.122, 0180, 210.003
722.604 W 5 A 330 SL280, S280, C280 129.058, 140.028, 202.028
722.605 W 5 A 330 SLK230K, SL320, S320, C230K, E320, C200K, CLK200K, CLK230K, E200 170.447, 129.063, 140.032, 033, 202.024, 210.055, 202.025, 082, 208.345, 445, 208.347, 447, 210.045, 245
722.606 W 5 A 330 C280, E280, SL280, E280T 202.028, 089, 210.063, 129.059, 210.663
722.607 W 5 A 330 E320, CLK320, SL320 210.065, 265, 208.365, 129.064
722.608 W 5 A 330 S300 TURBO, E300 TURBO 140.135, 210.025, 225
722.612 W 5 A 330 C250 TURBO 202.128, 188
722.613 W 5 A 330 E290 TURBO 210.017, 217, 617
722.614 W 5 A 330 C220CDI, E220CDI 202.133, 193, 210.006, 206, 606
722.615 W 5 A 330 C200, E200, CLK200 202.081, 210.035, 235, 208.335, 435
722.616 W 5 A 330 SLK200K, SLK230K, C200K, CLK200K, E200K 170.444, 170.449, 202.087, 208.344, 444, 210.048, 248
722.617 W 5 A 330 S280 220.063
722.618 W 5 A 330 S320 220.065, 165
722.620 W 5 A 580 S500, SL500 140.050, 051, 070, 129.067
722.621 W 5 A 580 S600, SL600 140.056, 057, 076, 129.076
722.622 W 5 A 580 S420 140.042, 043, 063
722.623 W 5 A 580 E430, CLK430 210.070, 270, 208.370
722.624 W 5 A 580 SL500 129.068, 210.074, 274
722.625 W 5 A 580 E420 210.072, 272
722.626 W 5 A 580 E320CDI, S320CDI 210.026, 226, 220.026
722.627 W 5 A 580 E50 AMG 210.072
722.628 W 5 A 580 CL580 215.378
722.629 W 5 A 580 C36 AMG 202.028
722.631 W 5 A 580 E43 AMG 202.033, 093
722.632 W 5 A 580 S430 220.070, 170
722.633 W 5 A 580 S500 220.075, 175
722.634 W 5 A 580 E270 CDI 210.016, 216, 616
722.635 W 5 A 580 S500 220.075, 175
722.636 W 5 A 580 E55 AMG, CLK55 210.074, 274, 208.374
722.661 W 5 A 300 ML270 CDI 163.113
722.662 W 5 A 300 ML320 163.154
722.663 W 5 A 400 ML430 163.172
722.664 W 5 A 300 E320 4MATIC 210.082, 282
722.665 W 5 A 300 E280 4MATIC 210.081, 281
722.666 W 5 A 400 ML55 AMG 163.174
722.669 W 5 A 400 E430 4MATIC 210.083, 283
722.697 W 5 A 330 C250 TD 202.128, 1883
722.698 W 5 A 330 C240, E240 202
722.698 W 5 A 330 C240, E240 202.026, 086, 210.061, 261
722.699 W 5 A 330 C220CDI, E220CDI, E200CDI 202.193, 210.006, 206, 210.007

erx

02-04-2015, 05:39 PM #26

(02-04-2015, 05:08 PM)Mr_Robs Sorry i should have clarified more what i was trying to explain. Yea totally agree there is one V6 and one inline 6, but does the W210 (not listed in my post) have a gearbox code of 722.640 like the 220/270 boxes? Maybe thats why the W211 722.626 from an inline engine doesnt fit?

F.R.A.S

Holset

579

02-04-2015, 05:39 PM #27

I know for a fact that there is a change in bellhousing and the 220cdi/20cdi and 320cdi are more or less the same engine. What would be good to know is EXACTLY what year they changed this. Me and Mr_Robs have decided that 2001 is a safe year and that's by looking at pictures and that the w211 came in 2002. However it would be good to know more hands on.

With that said. It doesn't matter if it's a 270cdi gearbox or a 320cdi gearbox. Wrong year and it don't fit anyhow.

F-tune Performance [Image: V-band_om606.jpg]

I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.

F.R.A.S

02-04-2015, 05:39 PM #27

F-tune Performance [Image: V-band_om606.jpg]

I can help you out with all your manual transmission, clutch, flywheel, intake and exhaust manifold issues.

Mr_Robs

GT2256V

124

02-04-2015, 06:19 PM #28

I was going off of this PDF i found, but this only has information for W211 models.

Overview of major assemblies.pdf
Size: 20.18 KB / Downloads: 1,335

Not arguing at all here with what you found im just trying to find out the strongest gearbox solution for all of us without needing to swap bell housings Smile

Mr_Robs

02-04-2015, 06:19 PM #28

I was going off of this PDF i found, but this only has information for W211 models.

Overview of major assemblies.pdf
Size: 20.18 KB / Downloads: 1,335

Not arguing at all here with what you found im just trying to find out the strongest gearbox solution for all of us without needing to swap bell housings Smile

erx

w202 om606

323

02-05-2015, 03:04 AM #29

(02-04-2015, 06:19 PM)Mr_Robs I was going off of this PDF i found, but this only has information for W211 models.

Not arguing at all here with what you found im just trying to find out the strongest gearbox solution for all of us without needing to swap bell housings

Ok, for 2.2cdi there are two different gearboxes, 722.699 and 722.640 which is the same 2.7 uses, did you notice why they used 2.7 box on 2.2? 722.699 is rated to 330nm but from 2005 or 2006 model have new 2.2 engine which is producing 125kw and 400nm. So it needed stronger gearbox because engine exceeded rated 330nm. Later they all came with 722.9. So this should be clear that 2.2cdi, 2.7cdi and 606 share the same housing pattern.
2.7cdi and 3.2cdi boxes are both rated to 580nm, so if you don't want to hustle with housing swapping, 2.7 box is the way to go.

I don't want to argue also, just want to make thing clear. That's what forums are for, to find answers for different opinions. Smile

This post was last modified: 02-05-2015, 05:01 AM by erx.

erx

02-05-2015, 03:04 AM #29

(02-04-2015, 06:19 PM)Mr_Robs I was going off of this PDF i found, but this only has information for W211 models.

Not arguing at all here with what you found im just trying to find out the strongest gearbox solution for all of us without needing to swap bell housings

muuris

OM605

318

02-05-2015, 09:05 AM #30

(02-02-2015, 05:32 PM)erx But you didn't try with genuine manifold? You can't compare with stock manifold, it is so small inside, it causes that high backpressure, also little 8cm housing. Stock manifold and small housing is definitely not good combo for 606 STD.

I don't totally agree, the effect of turbo is way greater than that of the manifold. I also tried the third turbo (almost HX50-size) with stock manifold without wastegate and it gave same power as with my custom manifold (450hp) so the backpressure couldn't have been high (didn't measure). The difference was that the spoolup was a lot worse with stock manifold.

He351Ve (which has HX40 super compressor) gave 402hp at best with good manifold due to backpressure being about 3bar even with big wastegate (~2,2bar boost).

muuris

02-05-2015, 09:05 AM #30

(02-02-2015, 05:32 PM)erx But you didn't try with genuine manifold? You can't compare with stock manifold, it is so small inside, it causes that high backpressure, also little 8cm housing. Stock manifold and small housing is definitely not good combo for 606 STD.

Hario'

C300TD Wagon (W202)

894

02-05-2015, 10:21 AM #31

erx I decided to copy you a little bit hope you don't mind.. Ps thanks for the swap info!

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

Hario'

02-05-2015, 10:21 AM #31

erx I decided to copy you a little bit hope you don't mind.. Ps thanks for the swap info!

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

INC

GTA2056V

76

02-15-2015, 12:36 PM #32

Hice build. Can You post some pictures from low pressure fuel system setup 044 and FPR ?

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

INC

02-15-2015, 12:36 PM #32

Hice build. Can You post some pictures from low pressure fuel system setup 044 and FPR ?

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

erx

w202 om606

323

02-18-2015, 01:24 PM #33

(02-15-2015, 12:36 PM)INC Hice build. Can You post some pictures from low pressure fuel system setup 044 and FPR ?

Sure, stock lift pump is replaced by 044 and FPR, all other lines are stock. Two little hoses to FPR are from intake manifold and fuel pressure is regulated by boost. Working principle of that system is exactly the same as stock lift pump has but its' fuel amount and pressure is many times greater. I run 1bar at idle and about 3bar at max boost like Dieselmeken recommended.

And the same thing on scheme.

This post was last modified: 02-18-2015, 01:26 PM by erx.

erx

02-18-2015, 01:24 PM #33

(02-15-2015, 12:36 PM)INC Hice build. Can You post some pictures from low pressure fuel system setup 044 and FPR ?

And the same thing on scheme.

INC

GTA2056V

76

02-18-2015, 02:55 PM #34

Thanks for photo and schematic. What FPR You use? 044 is original Bosch, or copy? I have EDC 8mm Dieselmeken pump and feel that original system not working good.

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

INC

02-18-2015, 02:55 PM #34

Thanks for photo and schematic. What FPR You use? 044 is original Bosch, or copy? I have EDC 8mm Dieselmeken pump and feel that original system not working good.

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

erx

w202 om606

323

02-18-2015, 05:06 PM #35

044 is genuine Bosch and FPR is cheap chinese Tomei.

erx

02-18-2015, 05:06 PM #35

044 is genuine Bosch and FPR is cheap chinese Tomei.

Mr_Robs

GT2256V

124

02-19-2015, 05:30 AM #36

Thanks for that diagram and pictures Erx! I bought the same setup for my 606 swap, genuine 044 and ebay FPR.

Cheers!

Mr_Robs

02-19-2015, 05:30 AM #36

Thanks for that diagram and pictures Erx! I bought the same setup for my 606 swap, genuine 044 and ebay FPR.

Cheers!

erx

w202 om606

323

02-19-2015, 08:21 AM #37

Nice.

But I have to say that 044 is needed only if IP has bigger elements, with stock IP it doesn't give any advantage.
Even this way when it's circulating under the bonnet it makes little pressure to return line so all connections and hoses should be sealed tight, first some little return lines between injectors leaked but after I replaced them it's working fine.

erx

02-19-2015, 08:21 AM #37

Nice. Smile

But I have to say that 044 is needed only if IP has bigger elements, with stock IP it doesn't give any advantage.
Even this way when it's circulating under the bonnet it makes little pressure to return line so all connections and hoses should be sealed tight, first some little return lines between injectors leaked but after I replaced them it's working fine.

erx

w202 om606

323

02-19-2015, 05:50 PM #38

......

This post was last modified: 04-24-2018, 02:34 PM by erx.

erx

02-19-2015, 05:50 PM #38

......

Mr_Robs

GT2256V

124

02-20-2015, 03:18 PM #39

(02-19-2015, 08:21 AM)erx Nice.

But I have to say that 044 is needed only if IP has bigger elements, with stock IP it doesn't give any advantage.
Even this way when it's circulating under the bonnet it makes little pressure to return line so all connections and hoses should be sealed tight, first some little return lines between injectors leaked but after I replaced them it's working fine.

For sure! I have 8mm 200cc dieselmeken pump. Ahh yes good tip, i will check all of the old factory lines in the engine bay.

Car looks great even if it cant move Big Grin

Mr_Robs

02-20-2015, 03:18 PM #39

(02-19-2015, 08:21 AM)erx Nice.

But I have to say that 044 is needed only if IP has bigger elements, with stock IP it doesn't give any advantage.
Even this way when it's circulating under the bonnet it makes little pressure to return line so all connections and hoses should be sealed tight, first some little return lines between injectors leaked but after I replaced them it's working fine.

For sure! I have 8mm 200cc dieselmeken pump. Ahh yes good tip, i will check all of the old factory lines in the engine bay.

Car looks great even if it cant move Big Grin

Hario'

C300TD Wagon (W202)

894

03-04-2015, 11:11 AM #40

Can I ask how you picked up road wheel speed for the 722 controller, was it a hall effect sensor on the propshaft bolts?
Looks really sleeper!
Thanks.

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

Hario'

03-04-2015, 11:11 AM #40

Can I ask how you picked up road wheel speed for the 722 controller, was it a hall effect sensor on the propshaft bolts?
Looks really sleeper!
Thanks.

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

erx

w202 om606

323

03-04-2015, 11:43 AM #41

(03-04-2015, 11:11 AM)Hario Can I ask how you picked up road wheel speed for the 722 controller, was it a hall effect sensor on the propshaft bolts?
Looks really sleeper!
Thanks.

You mean for olefejer controller? No need for that, it gets all information from gearbox, no need for extra sensors. Just one big round plug to gearbox and that's all. You can see engine rpm and speed on display.

This post was last modified: 03-04-2015, 11:45 AM by erx.

erx

03-04-2015, 11:43 AM #41

(03-04-2015, 11:11 AM)Hario Can I ask how you picked up road wheel speed for the 722 controller, was it a hall effect sensor on the propshaft bolts?
Looks really sleeper!
Thanks.

erx

w202 om606

323

03-12-2015, 06:15 PM #42

Started with new manifold, need to make wastegate tubing and then finally weld it all together. It will not be easy. Big Grin

Previous manifold which I used with HX35 super.

This post was last modified: 03-12-2015, 06:18 PM by erx.

erx

03-12-2015, 06:15 PM #42

Started with new manifold, need to make wastegate tubing and then finally weld it all together. It will not be easy. Big Grin

Previous manifold which I used with HX35 super.

erx

w202 om606

323

03-30-2015, 04:10 PM #43

Manifold is spot welded and now it needs to be welded around.

LSD coupling for s400cdi differential, still looking for driveshafts. I have driveshafts from s400cdi but outer joints don't fit to w202 flanges so I'm not sure which outer joints I will use.

And some new parts

[Image: 11063213_10204324259443414_507568555_n_zpshvxxuih6.jpg]

erx

03-30-2015, 04:10 PM #43

Manifold is spot welded and now it needs to be welded around.

LSD coupling for s400cdi differential, still looking for driveshafts. I have driveshafts from s400cdi but outer joints don't fit to w202 flanges so I'm not sure which outer joints I will use.

And some new parts

Booster

GT2559V

240

03-31-2015, 02:50 AM #44

Nice progress on the manifold/car, but my god that has got to be the biggest cone filter I have ever seen! Where is it going to fit? Keep up the great work'

Booster

03-31-2015, 02:50 AM #44

Nice progress on the manifold/car, but my god that has got to be the biggest cone filter I have ever seen! Where is it going to fit? Keep up the great work'

jegesmesh

Naturally-aspirated

15

04-01-2015, 03:28 PM #45

Eesti poistele jätad pooled asjad rääkimata/näitamata Big Grin

MB 250D W124 OM602.982 2.9 swap '92 5 SPEED MANUAL
MB E320 CDI W211 '04

jegesmesh

04-01-2015, 03:28 PM #45

Eesti poistele jätad pooled asjad rääkimata/näitamata Big Grin

MB 250D W124 OM602.982 2.9 swap '92 5 SPEED MANUAL
MB E320 CDI W211 '04

erx

w202 om606

323

04-01-2015, 03:45 PM #46

(04-01-2015, 03:28 PM)jegesmesh Eesti poistele jätad pooled asjad rääkimata/näitamata

Eesti poisid on siin lehel Big Grin

: http://foorum.turboclub.ee/viewtopic.php?f=5&t=13155

erx

04-01-2015, 03:45 PM #46

(04-01-2015, 03:28 PM)jegesmesh Eesti poistele jätad pooled asjad rääkimata/näitamata

Eesti poisid on siin lehel Big Grin

: http://foorum.turboclub.ee/viewtopic.php?f=5&t=13155

jegesmesh

Naturally-aspirated

15

04-01-2015, 04:40 PM #47

Hea küll

Ma rohkem MB klubis tegev.

MB 250D W124 OM602.982 2.9 swap '92 5 SPEED MANUAL
MB E320 CDI W211 '04

jegesmesh

04-01-2015, 04:40 PM #47

Hea küll Big Grin Ma rohkem MB klubis tegev.

MB 250D W124 OM602.982 2.9 swap '92 5 SPEED MANUAL
MB E320 CDI W211 '04

Hario'

C300TD Wagon (W202)

894

04-15-2015, 07:09 AM #48

Hey erx, did you manage to fit the original cooling fan between the radiator and water pump??
I need about 10mm more clearance. Did you cut the heatlight mounts to allow the transmission cooler fittings onthe radiator end tank to move forward more? Thanks!"

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

Hario'

04-15-2015, 07:09 AM #48

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

erx

w202 om606

323

04-15-2015, 11:12 AM #49

(04-15-2015, 07:09 AM)Hario Hey erx, did you manage to fit the original cooling fan between the radiator and water pump??
I need about 10mm more clearance. Did you cut the heatlight mounts to allow the transmission cooler fittings onthe radiator end tank to move forward more? Thanks!"

I have visco and cooling fan like it came from w210. Radiator is also on it's original place, nothing is moved. I use engine mounting arms from 606, if you use arms from 605 it will sit 2,5cm forward.

erx

04-15-2015, 11:12 AM #49

(04-15-2015, 07:09 AM)Hario Hey erx, did you manage to fit the original cooling fan between the radiator and water pump??
I need about 10mm more clearance. Did you cut the heatlight mounts to allow the transmission cooler fittings onthe radiator end tank to move forward more? Thanks!"

erx

w202 om606

323

04-22-2015, 05:05 PM #50

(03-31-2015, 02:50 AM)Booster Nice progress on the manifold/car, but my god that has got to be the biggest cone filter I have ever seen! Where is it going to fit? Keep up the great work'

Yes, it was big and it didn't fit, just a little too long. Big Grin

So I got another one, a little shorter but with bigger diameter.

Finished the manifold.

Manifold sandblasted and 3,5" downpipe

Some new gaskets

Innovative EGT gauge kit

And it's running.

erx

04-22-2015, 05:05 PM #50

(03-31-2015, 02:50 AM)Booster Nice progress on the manifold/car, but my god that has got to be the biggest cone filter I have ever seen! Where is it going to fit? Keep up the great work'

Yes, it was big and it didn't fit, just a little too long. Big Grin

So I got another one, a little shorter but with bigger diameter.

Finished the manifold.

Manifold sandblasted and 3,5" downpipe

Some new gaskets

Innovative EGT gauge kit

And it's running.

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