Potential for OM602?
 

I've been scouring the earth looking for a clean 190D 5-speed (with no luck so far--as expected) but I'm just wondering what kind of power I can expect out of the 5-cylinder once I put a turbo on it & have the IP worked over? Do any exhaust manifolds from the other 5-cylinder turbos bolt up to the OM602 head?

Forgive my ignorance, as I am new to the ways of the 3-pointed star. :o

Don't put a turbo on the non-turbo engine, it can't handle the stress.

Get a 1987 190D 2.5T and put the manual parts in it.

Thanks for the quick reply! I was debating about doing that. I'm assuming that I would need the following:

-trans from W201
-shift linkage
-driveshaft
-pedal cluster
-console surround
-clutch, mastercylinder & slave
-flywheel

Anything else? Will the gasser 5-speed swap right in? Rear ratios different?

You will also need the differential and speedometer. The automatic 2.5T had the highest gear ratio of the 190 series and would make a manual painful to drive.

A gasser tranny will swap, but finding an 86, 88 or 89 2.5 for parts will make the process far more simple.

Great link!

If I'm reading that right, I'd be looking for something in the 3.46 range, correct?

Correct, but the 3.27 would probably work well also.

Actually I did some figuring on this and it wouldn't be that bad. I had a Honda Civic VX which had the longest gearing of any car I've ever had. It took a little getting used to, but after awhile I enjoyed having the low RPMs while driving fast (80mph @ 2300rpm :D). Besides, if I needed to pass somebody, It was just a shift away.
Here's the comparison between the VX and a 190 with a 2.3/2.5 5-speed and the 2.65 diff:

Gear --- 190 -------- VX (this is combined gearing of tranny and diff)
1st --- 10.3615 --- 10.5625
2nd --- 5.7505 ---- 5.72325
3rd --- 3.6305 ----- 3.4645
4th --- 2.65 ------- 2.77225
5th --- 2.067 ------ 2.2815
torque - 165 ------- 100
weight - 2900 ----- 2100
P/W -- 17.57 ------- 21 (power[torque]/weight ratio [less is better])

As you can see, there's not a lot of difference between the two gear sets, but a turbo 190 has a lot better power/weight ratio. So it wouldn't be too bad... just a bit slower off of the line than a 'normal' car. Besides, if it gets too irritating, there's always a 3.07 diff. Let's see, what were the #s on that one:

1st -- 12.0037
2nd -- 6.6619
3rd -- 4.2059
4th -- 3.07
5th -- 2.3946

I hope that helps. :)

RPM's would already be very low with a 3.46 and a 5-speed. 80mph @ 2300rpm would be lugging the engine with that much of a load.

So as long as I got a clean 190D 2.5T and found me a junked 2.3 (non 16V) I'd be good to go?

How strong is the bottom end of the OM602? (i.e., with upgraded hardware how much psi could I feed it?) I'd love to turn it into a beastly daily driver.

THIS would be a better place to answer that.

The limiting factor on these engines is not the engine durability but the injection pump's limited fuel flow capacity.

The problem with using something other than a 2.5 as the manual donor is you will have to cut and reweld the driveshaft to length. Mercedes uses a very unusual flange and tube design so there are very few places that will even touch them.

I've been lurking on there for a few weeks. Finland seems to be the favorite vacation destination for everyone on there!

There are a number of good Bosch shops within the county here, but I understand that Bosch themselves are the ones that might be the limiting factor on modifying the pump.

Yes. All the pumps have 5.5mm plungers which is supposedly good to 180-ish HP. The next size still available from Bosch is 10mm, much too large for the governor to handle in anything but a dedicated drag racer.

Myna-Diesel uses 7mm plungers but they are extremely tight lipped on their source. They may even make them in-house.

There is a Bosch guy in the next county over that makes his own custom plungers for his drag pumps. Hmmm....

the 300d of the 602 era has a 265 rear iirc. with a five speed it would probably be ok but something nearer 300 would be better....the 327 from the 16v would be fine probably.

in the 123 adding a five speed would not be a problem i think but the 124 300d is already very tall geared.

Tom W