Greetings from finland.
I just read the topic. Best OM606 has over 3bar boost. Also you asked how to increase fuel flow from pump, What comes to stock pump its quite impossible, only way to increase fuel flow is replacing the elements and you need OM603 IP to OM606. Stock elements are 5.5mm on 603 and 6mm on 606 with 7mm elements you get almost 500hp.

Hey Holset,
What do you mean by "elements" ? Lets say I have the 3.0turbo 12v engine from w124. I have re-worked the whole engine with new parts (stock ones) Now I want to use big turbo, IC and lots of boost. What injectors are the best to get me to 500hp? What exactly needs to be done with the pump? How far is the stock pump good at?300hp ?


Thankyou for any info.

Check this link
http://www.detali.ru/cat/oem_mb2.asp?TP=1&F=124133&M=603%2E960&GA=722%2E317357&CT=M&cat=503&SID=07&SGR=045&SGN=01
it only works with IE
Part number 23 is Pump Element
With stock pump you dont get much over 200hp
IP needs some internal modification, and bigger elements. There is no need to change injectors. Best way to have good ip is sending it to finland.
It will cost nearly 1000€. They made some pumps to Us and sweden.
Stock IP have to send here in finland. Yes i know it aint cheap.

Ok...you made it pretty clear. Lets say the elements are done, what other "internal modifications" needs to be done?
I am basically over sea (from estonia) so the shipping shouldnt be expensive but I would like to do it my self and gather know-how.

How do you later tune the fuel/air ratio? just "but" the pump to the maximum level on injecting fuel and then bring the EGT down with boost pressure?

Holset, thanks for the info. So the 606 can handle 3 bar / 44 PSI with stock internals, stock head bolts and no O-rings for the head?

Is the stock 606 pump hopeless or is it OK with 7mm elements? If possible, I'd like to keep the stock pump so I don't have to fool with converting the electronic system to mechanical. I would like to accomplish all the performance tuning through fuel maps.

On injectors, what do you think of Extrude Honing? We do that to our truck injectors to gain flow and improve atomization.

I'm looking at making 350-400 HP as a goal. Induction system is yet undetermined as it will have to match the output of the IP.

Thanks again!

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

For 44Psi boost, stock ConRods wont handle such amount of boost. Some finnish
owners has changed H-profil conrods, Like Pauter and Arrow etc.. Stock Headbolts will be enough and no need to O-Rings
OM606 stock IP is "Hopeless" Only way to have more power is to change OM603 IP to OM 606. There is no problem with electricity, if you change pump. there is no need to change injectors, and i dont know where might be correct injector, there is many things what must be correct, one is injecting angle.

Thanks again for the information. Is the 603 IP electronic? Is is compatible with the 606 computer? Is the 603 IP a direct, bolt on replacement for the 606 pump?

Due to government emission regulations, OBDII must remain intact and is inspected yearly. Any changes I make must not set any codes and allow OBDII to function normally.

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

But if I tune a 603 engine(the old 12valves)? Just new elements and 35psi of boost with decent turbo and I should be in the 400+ hp range right?

Add a BIG intercooler, transmission that can handle the power and maybe you could.

Thats a must of course.
Whats the most powerful om603 in Finland?

There is a black 190D you can see in some of the videos that are posted on YouTube (the one that raced the C5 Vette). I'm not speaking about the one in the TeamRWD videos, that one has an OM606.

He had numbers down as something like 480 + hp at the crank. But, it was at a screaming (for a diesel) 5700 - 5900 rpm.

__________________
1987 300SDL (324000)

1986 Porsche 951 (944 Turbo) (166000)

1978 Porsche 924 (99000)

1996 Nissan Pathfinder R50 (201000)

The stock 603 IP can only push about another 20% more fuel (approximately), for maybe 180hp. Beyond that, the plunger/elements need to be increased in size. The only way you'll get that done correctly is to send your pump to Myna Diesel in Finland, and it's not cheap. They can modify the pump to your desired power level, anywhere from 200-500hp. These are all mechanical pumps - I don't think we can easily modify the 606.962 fly-by-wire electro-mechanical pumps, but I'm not sure.

You'll need a monster turbo and intercooler, custom exhaust, custom piping for all the intake stuff, transmission mods, and probably need to remove your AC condenser to make room for the intercooler if you want over 300hp. The stock differential is the next weak point (it won't last long under 400hp) but that's an easy upgrade. You'll also need to upgrade the brakes, stock is way too small for 300+hp. The brakes are easy to swap, and pretty cheap as well.

Some photos of assorted SuperTurbo projects are here:
http://www.w124performance.com/images/SuperTurbo/

Some videos are here:
http://www.w124performance.com/movies/Mercedes/SuperTurbos/

__________________
Check out my website photos, documents, and movies!

If mynädiesel is too expencive, you might ask here
highest hp what i know is ~490hp from OM603 and well over 500hp from OM606
Heres fastest finnish diesel

You need Mynädiesel modified IP and huge turbo then you have +400hp
BIG intercooler also is needed.

if emission regulations are tight as you wrote, then there is no way to replace OM603IP to 606