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Old 03-01-2015, 04:44 AM
mytmousemalibu's Avatar
<--- The famed Diesel-8
 
Join Date: Dec 2008
Location: El Dorado, KS
Posts: 359
Chronicle of my OM606 swap!

Well, the journey has finally begun! My 87' 300D is about to be reborn with a new heart, the venerable OM606

As I start this process, I am sitting out a layoff so the project will be a little slower going for funding reasons but none the less, i'm free to take this on now so here we go! I wanted to start a tread to chronicle the processes and procedures to share with everyone and something to look back upon.

This swap has always been a dream of mine but I kinda had been given a push of necessity to go fourth with. I bought the 87' about 4yrs ago off our family owned used car lot. Typical 300D, white/red interior, pretty good condition for age and 230,000 miles. Unfortunately this car had a #14 head on it which I didn't know the relevance of as a OM617 guy at the time. I soon discovered mine had symptoms of a cracked head and found the PO had tried some block sealer in it. It didn't cause too much issue and still ran and drove fine despite the cracked head. I did flush the cooling system very well. Not too long after buying it, a nice muscular 8pt. buck charged out of the ditch on my way home and wiped out the RF fender/hood/lights/etc. So I parked the car for a couple years and drove a couple other cars. I had the 93' 300TE here last year and something in the CIS died. I liked the car a lot but 15mpg sucked and really didn't want to dump money into it. But, its a white W124 just like my 300D, so it donated all the parts to fix my deer wreck and got my baby back on the road! Still running along just fine till last October, a chunk of leak-stop fiber came loose inside the cooling system and solidly plugged the vent hose to the coolant tank. Well, coolant can circulate like that, it formed an air pocket in the head and it about cooked to death. Stupid me, didn't notice the overheat till I just got home one day, i'm pretty good about keeping tabs on my gauges but I missed it. It got hot enough the oil smelled burned. The head is very cracked at that point, massive coolant system overpressure and induced leaks. So, I located and bought an OM606 out of Ohio from a wrecked 99 E300D, 170K miles and got it shipped here just a couple weeks ago. Actually still able to drive the 300D, I ran the cooling system unpressurized and since i'm replacing everything in the cooling system (not about to trust any of it with my new engine), I gave it the water glass/sodium silicate treatment in effort to seal it up and actually it runs reasonably well again, no leakage or overpressure. Just a measure to get by till i'm ready to yank the 603 out.

So I got a very good price on the 606, cheaper than repairing the 603 would be. There was a couple of hiccups though, the injectors were sold off the engine which is ok, I got a good deal on a set of rebuilt injectors done by a Bosch shop with new nozzles and all. The other issue was the valve cover was off and it got a lot of debris in the open head and some surface rust on a few cam lobes. Wasn't too happy about that but the intake ports were so carbon'd up from EGR the head was coming off to get cleaned regardless! I'd never seen an engine so plugged up! Upon head removal, I discovered some light rust in a couple cylinders too. It easily came off with some fine scotch-brite using a cross-hatch motion. I decided to pull the pistons to make sure the rings weren't stuck too. Couple had semi-stuck top rings and all were pretty carbon caked above the top ring land. So now everything will get a good thorough cleaning/decarbon before reassembly and doing some preventative maintenance, T-chain, oil pump chain, chain guides, etc. Good news is the bores and bearings all look like brand new, no noticeable wear. The pistons are in good shape too. Other than absolute filth, the head and valvetrain is all very good too. So it it will be all cleaned and freshened up when its back in one piece!

As for upgrades... Light porting/gasket matching on the head. Maybe a something like a 3-angle valve job. Slightly heavier valve springs. Building my own stainless header. HX35 or HX40 turbo for now. Should be sending my 603 pump to Dieselmeken during or shortly thereafter completion for 7.5 or 8mm pump! I will be running an air-to-water intercooler. Also using the stock intake manifold as a basis for building a new alum. sheetmetal intake. The car already has a 3" exhaust with a Borla muffler but might make some improvements there too!

So, I have a lot of work to do! Enjoy the ride with me!

Pics of the very dirty OM606 below! (the OEM turbo was trashed in the wreck)
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__________________
87' 300D, Currently undergoing an OM606 swap/build! SUPERTURBO!!!
03' 2500HD Dmax + goodies!

82' 300SD, parting out!
93' 300TE 4matic, parting out!
83' 240D Project Cheap Drive
89' 300E, parting out!
74' Datsun 510 wagon
88' RX7 10thAE, 13B track car build soon


Skippy~ As for perception: Drive what you like and can afford. Those who don't like it can supply vacuum to one of your components. LOL

If you need parts, I have some!
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