I did it 95 Turbo 606
 

I got a hx35 with a 12 cm housing for free so I decided to put it on my car. Here is my photo album http://s108.photobucket.com/albums/n1/2benchanted/Mercedes%20606%20turbo/ . I also replaced the glow plug harness and went with a full 3" exhttp://%3Ca%20href=%22http://s108.ph...%22%3E%3C/a%3Ehaust.

ok one question
 

I replaced the upper harness and took the battery out. I having problem with central locking system and the alarm is not working. I had the battery out for two days and now have this problem. Any help would be great will great will get more pics of the finished product.

its alive
 

Well I have been driving the last two days and working out the bugs got the door lock issue fixed was a fuse. I have fixed all the air leaks and now am getting 5 lbs boost by 2500 and 15 by 4000. Runs like a new car like to start to turn the pump up.http://i108.photobucket.com/albums/n...o/100_3166.jpg

Awesome work and thanks for posting! I'm surprised nobody has responded yet...

Where did you get the header flange from? Also, what fittings did you use for the turbo drain line?

Is this driving the car down the road? I think the stock turbo for the OM603 in my '87 300TD is EXTREMELY small on the turbine side. I get 11 PSI of boost in park at 5100RPM!!! In second gear, going to 5100RPM, letting off throttle it is 9 PSI at 4500RPM. That's crazy the turbo spools that quick. I can only imagine what the backpressure is. This is also with a straight pipe exhaust ending at the end of the transmission. :evilgrin:

BTW, Get that green coolant out of there and put the proper stuff in!

Yeah I machined the header flange myself I am a journeyman tool and die maker I welded the header and exhaust. The boost is alright while driving it I get 5 psi by 2500 and 15 at 4000 to 4500 so I only have it for a 1000 rpms but she really pulls. Free revving to 4500 in park I can only about 5-6 psi. Driving at 70 I get about 6 psi and she pulls allot better on the hills here in Portland nice big grades to check the torque. I still need to install egt gauge so I can start turning up the pump. Thanks for the tip on the coolant first merc. didn't know there was a diff.

15psi on a na engine is almost certainly asking for trouble. Would like to see how long it lasts. Decent looking exhaust mani, powder coated?

Well the start mileage is 22400 I think it should hold together jemmu said the internals are good for 300 hp. The exhaust is just high temp painted the whole exhaust to hide it under the car will get some video of it running.

Very interesting!! I'm glad someone has installed one of these... The boost numbers are interesting, and I can't wait to see how quick it spools with the pump turned up. :cool:

Would you be interested in selling the flanges and the oval cones?

No prob! :) The proper stuff is either from the dealer ($20/gallon) or Zerex G-05. The only place I know of to get the Zerex is at NAPA... Unfortunately you have to order a whole case of six if they don't have it in stock ($10/gallon). That isn't a big deal for me since I have lots of MB's... dunno if it is for you or not.

I would just keep your EGTs a little lower than what the turbo engine can handle and you should be fine. That's My $.02 anyway!

Header building
 

I have to look into making the flanges I made them when I was deployed and had axes to a machine shop.I have a friend with a shop see what he will charge for the use. I can get the transition cones but they are not perfect require some work to fit. I think the transitions cost 12 each. :D

So this was a non turbo engine that you added a turbo to! Do let the purists hear that. I think it was still mechanical injection in 95, not computer controlled, Right? What did you do for fuel enrichment? How different are the engine internals from the factory turbo models? are you monitoring the egt? how hot does it get? pre turbo or post?

Now the HX35 is a bit on the big side, but there is a way you could get it to spool faster, much faster, since the turbine housing is split. you would need to make a valve, that flips at a certain pressure. If you feed the exhaust pressure / gasses from the second bank of cylinders along with the first bank into the turbine inlet for the first bank, there will be a night and day difference. then at a certain boost level, maybe 7psi , the valve will then send the exhaust gasses / pressure from the second bank of cylinders to the back side of the turbine. kind of a wastegate before the turbine.

This is for a log manifold (Same concept) :
http://www.spracingonline.com/images/products/3643.jpg

It feeds all the pressure into the front half of the turbine to make it spool faster

Yes 95 606 is still mechanical injection so I have not messed with the injection yet have to install egt and wrap the exhaust manifold first. The Fins say it has the oil squirters I know about the pistons and the rods but I am not in search of huge horse power. I talked to a diesel shop here in Portland and they said the Ford banks kit for the early diesel would cause piston skirt scraping. I saw those valves on a turbo forum I could make it for nothing but I wanted to keep the engine divided as far as exhaust pulse goes. I went with the same idea banks uses for the Cummings since we have the same firing order. I have done allot of research on this build I will be adding a air to water intercooler to replace the crossover tube will look almost stock trying to make it that way.

wow, the non turbo block has the oil squirters! thats a great thing, but why? Let us know what you end up doing for fuel, thats the key, other wise you are not making much more power. You might not be looking for big power, but your turbo sure suggests you are! I understand what you mean about the split pulse manifold, I have used that method for years on non M/B gas engines.

The oil squirters are necessary for keeping the piston temperature under control. If the piston temp gets too high cylinder scuffing, increased ring wear, increased blow by, etc occur. On the NA 606, the oil squirters simply squirt oil to the underside of a "normal" diesel piston. On the turbo 606 the oil is squirted into a "cooling galley" (AKA chamber) inside the piston. The oil is sloshed around by the movement of the piston, which increases the heat transfer into the oil.

Long story short, the NA 606 has squirters, but the turbo 606 has squirters and pistons with oil galleys.

I think the NA has weaker rods as well... I'm sure there are other things, but all I know about are the oil squirters.

Call me crazy
 

Yeah the na606 has the weaker rods and pistons. I think the hp goals should be safe for this motor the oil jets help not a big issue as long as you don't do long hill pulls . Also I might look into putting a small shot of propane on it once the stock pump is turned up sort of a kick in the butt to get it spooling faster.:D

That doesn't sound right... my '87 300D with stock turbo doesn't build any boost in park at any RPM, AFAIK. Sounds like you might have something else going on there...?

:blink:

No boost while floored in park at max RPM? Normally, I'd say your wastegate is stuck open, but I know how meticulous you are about your cars, and you have performance figures to verify that the turbo is operating as it should. :confused:

Also, I only have a downpipe and the intake air is not pulled through the fender. That probably has something to do with it. :whistling2: FWIW, my '79 SD makes 5psi of boost at redline in park, and it has a full exhaust on it.

Pretty sweet project. I'm looking forward to seeing how things turn out once you get the fuel turned up a bit. I think it'll probably pin you back in the seat pretty well. ;)

Also, it is normal for these engines to make boost in park and neutral when you rev the engine, and a lack of boost would indicate a problem with the wastegate or fuel enrichment.

I would have sworn there was no boost with no load, I'll double check the next time the car is out of the garage... it's currently in hibernation. :)


I wouldn't expect that to affect things much, but I only have the rear muffler on mine. My engine has the KKK turbo, btw... most have the Garrett.


:boat:

Going strong
 

229000 miles on it now that is over 5000 and not a single problem. I have seen a significant increase in cruising efficiency I see about 34 mpg on avg. and that is with whipping the snot out of it from time to time. Hard to keep your foot out of it with the sound of the turbo and the exhaust. :D

Far out dude! Cool applications. I like very much.:)

Maybe more of these '95s can and will be retro-turboed so's they can get out of their own way.:D
That was the only deficit on their build besides the wiring harness issues as far as I could tell.

The "34 mpg" is outstanding too!

Yes indeed, Very FAR OUT! Is this the same conversion Kartec did a few yrs ago?

Oil line feed
 

Hi,
I have a 1996, and previously had a 99 E300 turbo. The 99 had it's oil feed to the turbo coming out of the side of the block. Does anyone know if the earlier years have that same provision? I just havent felt around on the block yet. If not, Where are you getting your oil feed from?
Please reply

Oil supply
 

I had help from Jeemu he said to just tap the sending unit hole. I pulled the filter housing and tapped it 1/4 28 npt and put a t fitting one side for the sending unit and other for the turbo feed. The sending unit is not pipe thread but will thread into pipe thread and seal with plumbers tape. I had a custom feed line made and it was 34 inches long so I could rout it nice and out of the way.:D

1996 Turbo install coming along, Resonance flap question
 

I remember that someone here on the forum eliminated the resonance flaps, I did as well. I believe I saw that you are able to remove alot of the vacuum line and electrical with no CEL on for the 96, due to not much engine monitoring by the ECM. I think I can cut and cap the electric for the resonace flaps.Anyone know the link for that post,I tried hunting already.

Ok this weekend I turned the stock pump up. All I have to say is nice it goes real good now at least as much of a hp jump from when I put the turbo on it. It now hits 10 lbs of boost by 3000rpm under load. I also turned up max rpm to 5500 and firmed up the shifts to stop the flare that started with the extra power. I have a bad shake from the rear trans mount between 30 and 40. I know my motor mounts are shot just wonder the stock overall height so I can mod my mounts like jeemu.:D

Are you using the stock OM606 injection pump, or a turbo 603 pump?

:kid:

Stock pump it runs good but doesn't have a alda but not much smoke on take off just in black puff and away I go. I can brake torque my 245 with no problem.:D

Update
 

Pump is in Sweden having Dieselmeken work his magic. Just had another present arrive today. H&R bar that should compliment my limo bar.[IMG]http://i108.photobucket.com/albums/n...-46-35_892.jpg[/IMG]

So bigger delivery valves and external ALDA then?

Yes the whole package 7.5 and outside alda I want 300-350 and nice driving habits.

:clap::nos: This is too legit to quit. I was joking about the NOS, but if you want to that'd cool:cool:. Or propane.

Props on the tubing work too; do you know if the exhaust manifold form a 1987 om603 would work?

What is the cost of the Dieselmeken upgrade to your pump?

:zorro:

He said around 925 euro and shipping which should be about 150 euro. Have not got my final price yet.

Excellent info - thanks! That includes the cost of the 7.5mm elements, correct? Is he fabricating his own elements now?

I never heard what happened with development of the infamous 'Floyd' elements (Tomik? on the STD forum)... those sounded promising. Maybe Dieselmeken has somethine equal or better now.

:scooter:

I have a set of "Floyds" in my car. I think Goran improved on Tom's original design.

elements
 

Dieselmeken has made his own design and has finally found a manufacturer to make them up to his quality.

SuperFloyd 8.5 mm is state of the art, 7.5 mm are also still available.

Tom

That is awesome. I think 7.5mm would be plenty for my needs (looking for ~300hp), anything larger might be a bit overkill.

Even with my simple 6mm pump upgrade, I'm finding some unexpected issues. Because the throttle linkage travel is so small at cruising speeds and at light acceleration (i.e., in traffic) this causes issues with cruise control surging, and the transmission upshifting too early. Thus far I haven't been able to fix either problem via adjustments. Maybe Dieselmeken has a way to tweak the power curve vs throttle input to help counteract those issues.

:batman:

my 603a behaves like stock, except way more power and less smoke.
I would not accept any compromise for a daily driver. For further testing I even still run the stock turbo (without excessive EGT). The pump adjustment is at about 25-30% of max. fuel delivery.
So the diameter of elements is more a matter of efficiency than power goal.

Check the (maybe adjustable) linkage levers. If this is o.k. then have the governor adjusted by someone who knows what to do.

The following check will tell you all: open the IP side cover and slowly press the pedal (or linkage), engine NOT running, now you want to see the rack move +- with the pedal. I had a pump with bad adjusted governor and the rack did not move until approx. 50% of pedal but then "jumped" to that position. The rack was not stuck, it was simply bad governor adjustment.

Tom

I need some 7.5MM DV's!

DVs?
or elements?
Who made your current IP (governor setup)?
Who will do the new pump?

Tom

hi Tom

nice to see you on the boards again :)

.

Pump is done and paid for it will be shipped out on Friday. I can't wait putting new bushing in the rear end. I have also installed the new sway bar fits but is kinda close it will work though.

tell us more details:
what elements
which shop
what max. delivery

Tom

Goran worked his magic on the pump he did 7.5 elements added outside alda it is set to 140 cc.

Pump arrived today started install need new gasket for vacuum pump and a banjo fitting for the pump install. I will be getting the gasket tomorrow and then it will be time for a little test drive.

Pump is in
 

I have installed the pump and I am still doing some tuning on my transmission. I have quite a bit of flare on my trans but need to adjust the vacuum modulator. I have had quite of few cars with power but this diesel has some great torque. :D:D:D
I still haven't hooked up the ALDA boost reference and I can't believe how much of a difference this pump has made.

Great thread and build :thumbsup:

Awesome! Maybe we can meet up sometime, I'd love to check it out in person...

:zorro:

We should get together this summer and I could show you the car. Are you still doing the races this might be a easy way to meet up.