OM616 turbo pic
 

I'm gonna make this short. A person close to me asked me to look at this 82 240D for sale. Since I have a 240D he thought I should look at it before he invested time and potential money into it. Well the pic speakes for itself. The body and interior need some TLC but the motor..... yeah as you can see it has a 617 turbo on it. I was instantly sold and well he bought the car.


It totally outperforms my car as far as the motor is concerned. My car is in better shape but this thing will do laps around mine. It puts out about 5 pounds of boost with the wastegate disconnected. A total pleasure to drive.

It would spool up a lot quicker with the K26 turbo. The stock 617 air filter would be perfect for that engine.

Looks nice. Would be interesting to see some real data on that car like MPG, 0-60 time etc. Hope it doesn't cook the engine. I wonder if those turbo om 616's in India are modified with piston squirters and Na filled valves.

They are, supposedly. There's a guy on here, Gurkha I think, who knows all about them.

how are they injecting more fuel?

That's not right, it should put out about 25 psi with the wastegate line disconnected. Perhaps the wastegate is stuck open.

Edit: I thought that was a 617 turbo engine. 5 psi is about all I would run in a 616

Its only going to have 4/5 of the possible exhaust volume, even with enough fuel. I'd be amazed if it could touch 20 with extra fuel or 10 with the stock fueling so 5psi sounds about right without any enrichment. The K26 would probably get higher just because of its smaller turbine.

I've been running my 616 turbo for about 1500 miles now, running 6.5psi and getting anywhere from 29.5mpg to 37mpg. The get up and go is sooooo much better then it was before and it even drinks a little less oil since I don;t have to rev it as high.

I can hit over 18psi with the waste gate inoperative, but am very happy with my 6.5.

If I had that intake I would be using the 300dt filter assemble. I get so much noise from my intake and it would be nice to quite it down.

Yep, they got it all, oil squirters, sodium valves, oil cooler and 617 turbo chain driven oil pump and mated to G1-18 5 speed, its quite peppy.

I see it lacks the expansion tank.

Tom W

Try adjusting the rack limiter to the max.

It is also missing the oil cooler. I would recommend installing both for longevity. As Ghurka pointed out, the turbo om616 properly done has all the goods from the om617.95X

I've adjusted the rack limiter a few turns, added an alda and dialed the fuel back down so that I have a good cruise egt of ~700* and max of 1050* on really long uphill full throttle at 75mph. I'm not sure if the oil cooler comment was for me, but I have the stock 240 cooler in place, not as large as a 617 but should be fine. I'll be adding a oil temp sensor later.

With out the added fuel from rack limiter adjustment, the car was just as slow as it was without the turbo.

What about 135bar injectors?

I didn't install 135b injectors. I have the internals to make my stock ones 135 bar, but all I did was pull, clean, and balance mine to ~125bar. When STT made turbo kits for the car they did not say anything about upping the pop pressure of the injectors, but seeing as all turbo cars at set to 135bar from the factory I decided to go middle of the road with 125.

Sounds about right. Auto or stick? You should get a dyno done, it would be interesting to compare to the Force motors version.

Its a stick, and I have plans underway to make a 5 speed fit it, but thats way in the future. It would be nice to have a dyno sheet from it but its silly money to make a run or two so that will have to wait.

I know that the STT kit without intercooler and 8.5psi of boost was making 100hp and 137ft/lbs.

I'm slowly working up to 8.5psi of boost from my 6.5.

Sorry to but in, but what other mods were made to the engine...?

617 turbo pistons? Oil cooling jets? or is it a 'bog-standard 616 with a turbo added etc...?:confused:

Its just a standard 616, there is no need for piston oil squirted and the other turbo specific parts from a 617 unless you want the thing to last a million miles and want to run big boost. I keep the EGT's in check and I'm not trying to get big power from it.

The STT kits are known good for longevity on the 616 and so I just copied what they did.

Interesting.....

So I guess following the same guidelines, you 'could' turbo a N/A 617....;)

I had planned some experiments with an old 615, but never got off the ground due to time etc...

It would be better for me to 'mess' with a 617, as I have three in total, but no Turbo version unfortunately....

Summit to think about for the future. I have to get my 'rebuild' engine into one piece and fit it to the car first:D

I don't see any reason you couldn't turbo an NA 617. The only thing is that you just can't expect to get 500k out of it with your right foot in it all the time like you would with a factory 617 turbo.

You *can* turbo a non-turbo 617, but why would you, when the factory turbo engine is available?

I agree but Alastair is in the UK and the factory turbo 617 was a rare beast over the pond.

I know a lot of Norwegians turbo'd there 617's in the 300GD and they have been going strong for hundreds of thousands of kilometers.

Sure you can turbo the 617 .91Xat low psi. It's higher PSI and RPM that the 617.95X has been modified for. These modifications were performed for the C-111 during testing and build. Even at the final run they still had head issues (high RPM). Without access to a 617.95X I would stick a VNT with a low boost cap. You may not have the 617.95X but you have a *much* better choice of turbos and pricing for them.

Better turbo to mate for the 2.4 is the Garrett T3 or KKK24 from the VW Td's. They spool up much quicker - like around 1800 rpm. You will either have to fabricate an adapter plate as the VW flange is trapezoidial in shape or swap the hot end with a standard T3. I used a T3 on my 2.4. Wastegate comes in at 10psi. I added the pressure relief valve from my VW td intake manifold into a modified 5cyl intake manifold, so to add extra insurance against overboost. All this gets plumbed into an toyota intercooler with adds a 1psi pressure drop, so I'm actually running 9psi. Fueling on the pump increased by 2 turns - EGT on steep grade at full load is 1050 degrees. This is do-able guys.

Do you know what trim T3 the VW's use? I have a T3 with a 50trim from a slaaab, but its a bit big for the 2.4L.
I have been doing a little research on turbos and there size and from looking at other diesel's close to the 240D in displacement and power goal it looks like the turbo I have is a little big on both the exhaust and compressor side but still ok. I have a TD04HL exhaust mated to a 13g compressor that should make boost a little faster as its smaller and sized a bit closer to the other diesels in the table I have put together. I'll try and get the table up sometime so others can see what I have found.

There's a company in the UK that turbo'd the 616 and 617, particularly in trucks and motorhomes. I posted their link on this board some years ago. They also sold something called an 'autoclutch' as I recall.

The VW T3 is a 42 trim.

A T25 might be an even better match.

I think the T25 is still a little big and I don' think they have the T3 flange and that is what my manifold has. The compressor stuff is easy as there are maps all over the place for them, but the exhaust side is a little different.

The T3 from the 300dt has an exhaust wheel with OD of 59mm and ID of 47.95mm

The T25 has an OD of 53mm and an ID of 46mm to 38mm

The TD04HL I have has an OD of 52mm and an ID of 45.6mm, and a TD04 would be better with an OD of 47.2mm and an ID of 40mm.

Newer Diesels, as in the late 90's, with a displacement of about 2.2 to 2.5L and output of 115 to 143hp, use turbos with an exhaust wheel size with an OD of 41mm to 47mm and an ID of 34.75mm to 40mm respectively.

So it would be nice to get a hold of a smaller gt20 (OD 47mm, ID 38mm) or gt17 (OD 44mm, ID 35mm), or a TD04, but that is for the future if I can find a good junk yard one.

The usage of the K&N cone filter on that engine in the pic is also a bad idea, good way to just further the demise of the engine, a proper MB paper filter setup is needed there.

Hi I'm new to forums. I just gotta ask where are you guys buying these intake and exaust manifolds. I found tata diesels in U.K. ebay but they are 2.0L and I'm not sure they would work since they aren't the 2.4L Tata

Tata never had MB OM616 engines in them so nothing from Tata would fit MB engines.

Ok, someone needs to do a show and tell on putting the oil squirters into the 616 engine.. and the other oil pump arrangement Gurka mentioned... is it a bolt in deal like moving a clutch pedal into an auto trans car... holes already there ?

Fitment is almost bolt on, need the parts.

"Almost" meaning lots of machine work and buying very expensive pistons.

Expensive pistons yes... they go for $700 minus rings for four. Machine work, I am trying to guess what that will be?

For installing the squirters? Making a place to bolt them onto and tapping the oil gallery.
For converting to a chain driven oil pump? It can't be done.

Isn't the chain driven oil pump driven off the timing chain pulley? I do understand the implications of putting the squirters.

A separate sprocket on the front of the crank.

http://www.peachparts.com/shopforum/...chmentid=65880

Oil Pump...
 

IF we were looking at turbo-ing a 616, then there is no probs for the oil-pump....

The std. 616 pump is of a smaller capacity than a N/A 617....

Therefore, just fit a N/A 617 pump to the 616 engine....:D

thinking of looking into this for my n/a 617 but what would be the best way to run the oil inlet and return lines to the turbo? car being a 75 300d with oil filter housing at bottom

I would love to turbo Myrtle's 616, but where do I get an exhaust manifold and intake that line up with a 4 Cyl. head? If I can get the manifolds, Im there!!!

Welcome to the forum, hang around here long enough you will be an expert through Osmosis :rolleyes:.

Charlie

with some tig work im sure you could just cut off the extra passages on the 5cyl manifold?

Recycled
 

for new members.