Hi there,
i'm rebuilding my 190D and i'm going to get a 605 engine. I removed the electronics so i's mechanical injection ... like a bad man

well, these are my key features to the project

- 605 Engine
- New Turbo
- New Injectors
- New Injection Pump
- New Intercooler
- New exahust system
- New intake

well, for the turbo ,i was thinking on getting an E270CDI variable geometry turbo working. anyone has ideas about how it can be done? I think the wastegate must be replaces with a normal one, the exhaust manifold must be adapted and other little things but what do you think. Should i get a better turbo?

Give me the possibilities for a better "normal" turbo. e300 is better than the e250?

For the injectors and injection pump, what do you think i can upgrade here? bigger capacity injectors from E300 ?
For the pump, should i get a MB Sprinter injection pump and injectors? are they adaptable?

For intercooler i'll go with a custom one, and for the exhaust system a direct line from the turbo. The intake will be taken by a BMC CDA for a E270CDI engine.

Now for you opinions ... and by the way, do you prefer the 2.500 Turbo Diesel 10v or the 2.500 Turbo Diesel 20v ?

Thank you for the help

P.S Sorry for my english, i'm from Portugal so i'm kind of "rusty" when speaking and writing english.

This sort of detailed technical question is best answered by someone over in Europe, since we in North America don't have access to the OM605 engines. I'll assume for now that the OM605 is just an OM606 with one less cylinder, but in any case you'll be doing a lot of plumbing to make it fit (i.e. exhaust, coolant lines, intercooler charge air hoses, etc.).

I believe large horsepower/torque gains can be achieved without modifying the injectors or trying to adapt another type of injection pump. The good folks in Finland have found a way to modify the stock injection pumps with larger fuel delivery elements. They also add a much larger turbo from a truck engine and a huge front mount intercooler to produce approximately 450 hp with the OM603 and close to 500hp with the OM606 engines. You really should discuss your project with them. Try this Finnish forum: http://mersuforum.net/forum/viewforum.php?f=29

Good luck!

I don't really know any world writen there

I don't want 400 hp, they have a lot of lag!!! the car is dead before 3.000rpm.

About the fuel pump, how did they do that?

The Finns claim the power is available right off the line, but their cars do wake up above 3k rpm. Either your variable geometry turbo or another hybrid design could conceivably reduce turbo lag, but you don't really need a larger turbo, so lag wouldn't be an issue anyway. But, you really do need to introduce more fuel into the engine, which requires the internal full load stop be turned up and the governor to be adjusted allowing for higher rpms--your twin cam would really love those high rpms. I think your stock injection pump would be just fine for your purposes. If you do want to really increase power, you could send the pump to Myna Diesel in Finland and they could add the larger pump elements for you. Those guys do lots of pumps for the tractor pulling competitions, so they know what they're doing.

Where were you thinking of mounting the intercooler? Not a lot of room for those in a W201 chassis.

the intercooler would be installed at the front, in the back of the grill.
I'm talkin with a admin of the forum, he's going to help me achieving a good HP with the MO605! ...

Pump, Turbo, intercooler, exhaust manifolds, exhaust line... well, he told me that 200-250HP is easily achieved, 400 is the max, so, 300 would be a good line to get

Good, I see you've connected with Mauri. He's one of the most knowledgable in the business. Good luck!

Yes, i'm talkin' with im!

He really has what it takes!

But damn, 400HP is just too horsies for a engine without giving all sorts of problems.

Just one question ... after various emails exchange with Mauri i have one doubt ... the "useability" of the car. I like a responsive car, and from what i've seen @ dyno's ... the car before 3000 rpm is quite "inexistent" ... so my question, for mountain roads and all that kind of driving ... isn't the finnish way of tuning, a little HardCore? i mean, you enter a corner, if your turbo just boosts before apex, you can be really in bad business!

Well, i'm talkin' but i'm a step away from getting parts from Mauri ... but for a 5 cylinder 2.500 20v turbo diesel.