Just bought an OM606.... Probably somewhat worn out, but it can't be beat for the price. Especially since I just found out that the #14 head on my 300TD is cracked.

http://cgi.ebay.com/ebaymotors/ws/eBayIS...0523360144

I'm thinking this should be a pretty easy swap since I already have an OM603 in there... Other than the normal stuff associated with an engine swap, I've listed stuff that needs to be done to adapt the OM606 into the wagon.

• Change mounting arms
• Adapt exhaust to turbo
• Find an air filter for intake
• Figure out how to control the vacuum wastegate
• Rig up a throttle linkage & bowden cable
• Replace IP with mechanical one from OM603 (for now! )
• Replace PS pump with tandem pump from wagon.
  

What else am I missing?

I still can't believe I actually bought one of these! Especially for $625!!

You dog! Hey, I'll buy the IP off that engine if you wan't to sell it! I need a spare to work on while I get the other hot rodded. I also have a pump from an OM603.970 if that will help you. I paid $300+ for it but I'd trade you for the 606 pump. I also have 7mm elements and a guy lined up who could swap them into a pump for you. They belong to Tomnik so you'd have to arrange a price with him.

Oh, and I think you might have to swap oil pans and oil filter housings with the 603 as well...

C'mon, help a brother out!

(12-10-2009 02:50 PM)Tymbrymi Wrote:  

• Change mounting arms
• Adapt exhaust to turbo
• Find an air filter for intake
• Figure out how to control the vacuum wastegate
• Rig up a throttle linkage & bowden cable
• Replace IP with mechanical one from OM603 (for now! )
• Replace PS pump with tandem pump from wagon.
  

What else am I missing?

I still can't believe I actually bought one of these! Especially for $625!!

Use those om603 engine mountings.
Change wastegate clock bressure type modell.

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(12-10-2009 04:01 PM)E300TSC Wrote:  Oh, and I think you might have to swap oil pans and oil filter housings with the 603 as well...

Why those should change?

Looks like a killer deal! The swap shouldn't be to bad since the suspension pump is external and not a head casting like earlier engines. The hardest issue I can think of would be the intercooler install. Everything else should be cake since the block is basically the same as the existing 603.

(12-10-2009 04:59 PM)jeemu Wrote:  Why those should change?

I read in another post about some clearance issues with certain chassis.

(12-10-2009 02:50 PM)Tymbrymi Wrote:  Just bought an OM606....

awesome man! I'd love to have a place to store all the projects in my head! this is one of 'em...

(12-10-2009 04:01 PM)E300TSC Wrote:  You dog! Hey, I'll buy the IP off that engine if you wan't to sell it! I need a spare to work on while I get the other hot rodded. I also have a pump from an OM603.970 if that will help you. I paid $300+ for it but I'd trade you for the 606 pump. I also have 7mm elements and a guy lined up who could swap them into a pump for you. They belong to Tomnik so you'd have to arrange a price with him.

Sorry, but I'm going to keep the pump. I have a spare 606 pump as well (that one cost $250) that I'm going to keep laying around for the exact same purpose you are. I'm actually thinking about just using the electronic pump and not fooling with the mechanical one. I am horrible at rigging mechanical things, much less a throttle linkage!! I know how to actuate the rack solenoid, and how to read the rack position sensor. When the engine comes in, I'm going to try and get it running without any feedback (ie, not monitoring rack position). There will be videos. Hopefully I won't blow it up just after I get it!!!

(12-11-2009 02:38 AM)SurfRodder Wrote:  awesome man! I'd love to have a place to store all the projects in my head! this is one of 'em...

I'm very lucky at the moment... Check out the "shop" (1,000 sqft storage unit) my roommate and I are renting. It is absolutely amazing the difference having a shop makes compared to my carport. We've got a heater, don't have to spend 20 mins setting up and then another 20 mins for packing up, workbenches , a stereo (with amp'd car sub :cool, a recliner, and a sleeper sofa for those really late nights.

http://www.youtube.com/watch?v=u0GTjOOnU0E

jeemu, thanks for the confirmation the 603 mounts will work! If you don't mind me asking, how much did your awesome 605 manifold cost, does KKD make a 606 version, and how can I go about getting one?

(12-11-2009 09:34 AM)Tymbrymi Wrote:  jeemu, thanks for the confirmation the 603 mounts will work! If you don't mind me asking, how much did your awesome 605 manifold cost, does KKD make a 606 version, and how can I go about getting one?

Hello. KKD make manifold also OM606
Here is e-mail adress http://www.kkdmotorsport.com/yhteystiedot.html

(12-11-2009 09:34 AM)Tymbrymi Wrote:  Check out the "shop" (1,000 sqft storage unit) my roommate and I are renting. It is absolutely amazing the difference having a shop makes compared to my carport.

That's awesome man! I was looking into cheap places for auction in the desert out here just to store most of my projects. I never pulled the trigger 'casue they were all about a 2 hour drive away, but for about 15K for a 1/4 acre, house and garage, it was almost too good to pass up. I have to look into the shop route though cause wit ha couple of like minded buddies and the economy killing off small businesses, they're bound to be several around.

(12-11-2009 09:34 AM)Tymbrymi Wrote:  jeemu, thanks for the confirmation the 603 mounts will work! If you don't mind me asking, how much did your awesome 605 manifold cost, does KKD make a 606 version, and how can I go about getting one?

Hi. Now KKDMotorsport have photos on om606 exhaustmanifold
Pretty cool
http://kkdmotorsport.kuvat.fi/kuvat/pako...ium%29.JPG

http://kkdmotorsport.kuvat.fi/kuvat/pako...ium%29.JPG

(12-14-2009 06:21 PM)jeemu[/quote' Wrote:  Now KKDMotorsport have photos on om606 exhaust manifold

*drool* I just sent an email to KKD.... we'll see how much it is and how much shipping costs!!

Looks like they have a set for the 601 and 603 as well.

I checked two months ago they wanted 800 euro and don't think that included shipping. I am working on the flanges for the split man. should have them finished by next week. Then will start welding up the pipes might do a log style like banks does for Cummings. I have a hx35 with a no12 hotside hoping it will spool real nice on my 606.

(12-14-2009 08:16 PM)Tymbrymi Wrote:  *drool* I just sent an email to KKD.... we'll see how much it is and how much shipping costs!!

Gah!!! It is expensive!! To be fair, it is very high quality work. You have to pay to play I guess.

Manifold: 550€
22% VAT: 121€
Shipping: 80€
-----------------
Total 751€

AKA $1100 USD

If it was $600 or so the check would be in the mail already, but $1100 can buy a LOT of my time. Then again, I will probably be spending a LOT of my time making the electronic controls for this thing. If my tax refund is the same as last year I MIGHT get it.

Going to look into how much the materials cost... that may surprise me and it may turn out that this isn't that bad of a deal.

Hello. Talk to Kkd.

KKD wrote: Sorry guys, but in Finland everything is so much more expensive. Materials, gases, tools, and the price level. I knew in advance that I cant sell you a quality exhaust kits, country price difference. easy to compare, for example the price of gasoline. 1.31e liter here. How much do you pay for it: D
603 & 606 Series 550e pay here and they will go quite nicely.
kkdmotorsport make top quality exhaust turbo kits .....
thanks

My budget for a custom header is $1000. What's quoted here is not too bad but I bet you can get someone in the states to fab up something just as nice for less.

(12-15-2009 01:05 PM)jeemu Wrote:  KKD wrote: Sorry guys, but in Finland everything is so much more expensive. Materials, gases, tools, and the price level. I knew in advance that I cant sell you a quality exhaust kits, country price difference. easy to compare, for example the price of gasoline. 1.31e liter here. How much do you pay for it: D

Yeah, I knew the price was coming, but it still was a bit of a shock. I think it is a fair price for all the work that is put in it, but I just don't want to spend money

I looked around some, and I think it'd be $200 for tubing, $100 for misc flanges (maybe more depending on who I can find to make the 606 flange), and then all the misc supplies. So max of $400 - $500 if I did it all myself. That doesn't include any of my time though. I've spent a max of maybe 20 minutes welding, but I do have access to a NICE ($9k) welder at work. Since I haven't done any welding I'd have to learn and screw up many many times before I could make something half as good as KKD's manifold.

I am going to try and get the 606 engine running with the electronic governor, and I'll make a decision after that. For all I know I may have just bought a bad engine

E300TSC, how much less? I like the fact that KKD has made a lot of manifolds that work with the OM60x engines... All the little quirks have probably been worked out so they're less likely to crack, etc. That being said, if it is half as much....

EDIT: The engine was supposed to have shipped today.... so it should be here Thursday or Friday!!

Well, I'd almost convinced myself to get it... then I was welcomed home with a $400 medical bill. So I'll be using the itty bitty stock turbo for a while.

Anybody know of an upgrade that will work with relatively little modification? What is the flange?

Nice grab of that motor. You going to pick it up or have it shipped?


That shop is great! Even a place to lounge and jam on the guitar while taking a break!




.

(12-16-2009 11:07 AM)Tymbrymi Wrote:  Well, I'd almost convinced myself to get it... then I was welcomed home with a $400 medical bill. So I'll be using the itty bitty stock turbo for a while.

Anybody know of an upgrade that will work with relatively little modification? What is the flange?

Good score with the engine

I am going to take some photos of the engine today, and will get some of the flange in particular. It is a odd shape from memory, and you could weld on a t3, etc, flange of your choice to the manifold.

The entry to the manifold's flange is very small as well, which is great for gas velocity, but poor for any type of performance over stock.

The stock turbo probably runs with the wastegate open most of the time (hence the need for a vacuum operated actuator) for, the turbine housing looks like it is for a 1.5L engine! Turbine drive pressure would be interesting to watch whilst the engine is under load.

(12-16-2009 11:39 AM)DeliveryValve Wrote:  You going to pick it up or have it shipped?

Shipped... Cost $250 for the shipping, which is what the fuel costs for a trip up there. Funny thing is shipping 2nd day freight was cheaper than shipping it slower. The engine should be here tomorrow!

(12-16-2009 11:57 AM)Tymbrymi Wrote:  .....Funny thing is shipping 2nd day freight was cheaper than shipping it slower. The engine should be here tomorrow!

Maybe you got the Holiday rate!



.

(12-16-2009 11:57 AM)DervTuning Wrote:  The stock turbo probably runs with the wastegate open most of the time (hence the need for a vacuum operated actuator) for, the turbine housing looks like it is for a 1.5L engine! Turbine drive pressure would be interesting to watch whilst the engine is under load.

What is the turbo model and how big/small is the housing A/R?

It's here! Unfortunately, they took the starter off.... So I'm going to have to find one in order to test it outside the car. Anybody have one cheap? I really don't want to play "swap the starter" between this and the wagon.

It is very dirty, but the leaks are from the typical places (valve cover, etc). Funny thing is the turbo has NO play at all.


   

   

(12-18-2009 01:23 PM)Tymbrymi Wrote:  It's here! Unfortunately, they took the starter off.... So I'm going to have to find one in order to test it outside the car. Anybody have one cheap? I really don't want to play "swap the starter" between this and the wagon.

It is very dirty, but the leaks are from the typical places (valve cover, etc). Funny thing is the turbo has NO play at all.

Nice. There the project starts Couple days and its in engine bay in super motor

Nice! It appears you do not need the turbo and flange photos any more

I bought a used starter yesterday for $50, and it's sitting in the back of the truck waiting for me to install it. So now all I need to do is figure out how I want to wire up the starter, glow plugs, and the electronic pump. I have a manual PWM controller that can control up to 30A, which is what I'll use to try and get the engine running.

Turns out the engine didn't come with the PS pump, A/C compressor, etc (I knew about the lack of alternator). So I can't use a belt for the water pump. Any ideas on how to keep the engine cooled besides duct taping a hose to the engine? I imagine I need to remove the thermostat and duct tape the hose to the lower intake correct?

(12-18-2009 03:38 PM)jeemu Wrote:  Couple days and its in engine bay in super motor

I don't know about that fast! I'm not exactly the fastest guy in the world... but it is one hell of a good starting point!

http://www.youtube.com/watch?v=_B6SWMmlpnA

It is incredible how a mere manifold is more expensive than an engine.

Excellent find - I see they have other W210/OM606.962 parts up for sale as well.

This is sort of related - as for cooling...I've found that I can drive around with NO engine driven fan at all with my W210/OM606.962.

Been doing it since Septemberish when my engine driven fan flew apart and tore a hole in my radiator. It's so much quieter to drive and I picked up what seems like an immediate and easy 2-3mpg...of course, it had to get cold out and then we got winter fuel...wrecking the mileage.

In these colder ambient temps, the engine never EVER gets above 80°C - just like it should. In warmer ambient temps, the electric fans kick on and she cools down very fast - they move a LOT of air.

I'm not convinced I'll be able to run like this in the hot summer weather - but my plans are to add an electric fan on the engine side of the radiator.

Beers,

Matt

John, Casey (Zeitgeist) is already blazing this trail for you... many details are in this thread here:

http://www.benzworld.org/forums/w124-e-c...-s124.html

(12-15-2009 12:37 PM)Tymbrymi Wrote:  

(12-14-2009 08:16 PM)Tymbrymi Wrote:  *drool* I just sent an email to KKD.... we'll see how much it is and how much shipping costs!!

Gah!!! It is expensive!! To be fair, it is very high quality work. You have to pay to play I guess.

Manifold: 550€
22% VAT: 121€
Shipping: 80€
-----------------
Total 751€

AKA $1100 USD

If it was $600 or so the check would be in the mail already, but $1100 can buy a LOT of my time. Then again, I will probably be spending a LOT of my time making the electronic controls for this thing. If my tax refund is the same as last year I MIGHT get it.

Going to look into how much the materials cost... that may surprise me and it may turn out that this isn't that bad of a deal.

Actually VAT is not charged when a company sells outside EU, so that would be 550e+shipping. so that would be around 910USD (exch rate back here is 1.44usd/1€).
The guy is an artist with metal works and takes high pride of what he does.
We are close friends and work together with him a lot: I sell the turbos etc and he makes the manifolds

(01-06-2010 06:52 PM)antonmies Wrote:  Actually VAT is not charged when a company sells outside EU, so that would be 550e+shipping. so that would be around 910USD (exch rate back here is 1.44usd/1€).
The guy is an artist with metal works and takes high pride of what he does.
We are close friends and work together with him a lot: I sell the turbos etc and he makes the manifolds

That doesn't sound so bad, pretty good price for custom made manifold.
Of course there's always the option to by cheap chinese paper manifold that cracks on first rev

Finally got around to hooking everything up to test the engine out... and she runs!! Controlling this electronic pump is going to be a MAJOR pain. I can get the engine to run just fine.... at full throttle. I'm using a PWM driver that a friend had laying around, and for whatever reason, I can't make the engine idle. I'm hoping the sensitivity of the driver isn't all that high. I'm going to take my spare OM606 pump back to work to figure out if it's the driver circuit or just the way the rack behaves that is making things difficult.

I think I need to make a rack position sensor monitoring circuit and hook it up to my wagon (uses the same style sensor as the OM606 pump) to see how the rack behaves with the mechanical governor.

Here's a video of some attempts I made today. I almost got it to idle once!!!

http://www.youtube.com/watch?v=SD18u6XLIpY

She runs!!

http://www.youtube.com/watch?v=mwIQ1UIuh6k

Now that I know it is possible for the engine to idle, and a slow human being can get it to idle, I have faith that I can make a controller for it that will actually work!! Now I just need to actually make it. I also need to clean the engine and fix all the fuel & oil leaks!