300CE Turbodiesel

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300CE Turbodiesel

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pena837

Naturally-aspirated

18

11-22-2012, 03:02 PM #1

i'm rebuilding 300ce -88.

Almost all of the bodywork is done, some little rust fixing still to do and paint job.

[Image: _img900.jpg]

Bilstein Sprint B8 shocks and H&R -30mm springs

[Image: _img900.jpg]

Motor is going to be original om606 turbo with little changes.

[Image: _img900.jpg]

exhaust manifold

[Image: _img900.jpg]

Holset HX55 turbo and 60mm wastegate

[Image: _img900.jpg]

4'' Downpipe and rest of the pipe is going to be 3,5'' with one vibrant resonator

[Image: _img900.jpg]

intake manifold and 8mm herlevi pump.

[Image: _img900.jpg]

All aluminium Griffin radiator and cooler

[Image: _img900.jpg]

pena837

11-22-2012, 03:02 PM #1

i'm rebuilding 300ce -88.

Almost all of the bodywork is done, some little rust fixing still to do and paint job.

[Image: _img900.jpg]

Bilstein Sprint B8 shocks and H&R -30mm springs

Motor is going to be original om606 turbo with little changes.

exhaust manifold

Holset HX55 turbo and 60mm wastegate

4'' Downpipe and rest of the pipe is going to be 3,5'' with one vibrant resonator

[Image: _img900.jpg]

intake manifold and 8mm herlevi pump.

All aluminium Griffin radiator and cooler

Cool

EDH_Performance

Holset

537

11-22-2012, 04:18 PM #2

Cool project!! But why go with a such a big turbo, takes ages to get it to spool....?? Or are you building a 700hp engine?

EDH_Performance

11-22-2012, 04:18 PM #2

Cool project!! But why go with a such a big turbo, takes ages to get it to spool....?? Or are you building a 700hp engine?

pena837

Naturally-aspirated

18

11-22-2012, 11:47 PM #3

to get high hp . We will see how it spools, exhaust housing is not that huge in this turbo, as usual in these sizes, so hopefully it works good . of course it depends how my exhaust manifold etc. works

pena837

11-22-2012, 11:47 PM #3

erling66

SuperDieselVan

294

11-24-2012, 12:48 PM #4

Very nice project Smile

Is the turbo exhaust house 16cm2?
Will it pass inspection with diesel engine in Finland?
Please keep us updated with more photos

erling66

11-24-2012, 12:48 PM #4

Very nice project Smile Is the turbo exhaust house 16cm2?
Will it pass inspection with diesel engine in Finland?
Please keep us updated with more photos

pena837

Naturally-aspirated

18

11-24-2012, 01:46 PM #5

(11-24-2012, 12:48 PM)erling66 Very nice project Is the turbo exhaust house 16cm2?
Will it pass inspection with diesel engine in Finland?
Please keep us updated with more photos

yes it is 16. inspection is not a problem, i just need to have dyno evidence that it doesn't have more than 180hp so i it will pass the inspection with 300e original brakes etc.

pena837

11-24-2012, 01:46 PM #5

(11-24-2012, 12:48 PM)erling66 Very nice project Is the turbo exhaust house 16cm2?
Will it pass inspection with diesel engine in Finland?
Please keep us updated with more photos

yes it is 16. inspection is not a problem, i just need to have dyno evidence that it doesn't have more than 180hp so i it will pass the inspection with 300e original brakes etc.

pena837

Naturally-aspirated

18

11-27-2012, 02:37 AM #6

couple hours in garage yesterday and boost pipes are ready

[Image: _img900.jpg]

pena837

11-27-2012, 02:37 AM #6

couple hours in garage yesterday and boost pipes are ready

[Image: _img900.jpg]

Bangaway

606 Turbo > Porsche Turbo

129

12-02-2012, 02:56 PM #7

What model is that Griffin radiator and cooler?

Bangaway

12-02-2012, 02:56 PM #7

What model is that Griffin radiator and cooler?

Ksteen2

Holset

304

12-03-2012, 05:29 AM #8

Niiice

I'll watch this closely, hope it works smack Wink

If only we could pass inspetions i here in norway with those specs..
to hell with the pottato norwegian state..
had been so easy Wink

Ksteen2

12-03-2012, 05:29 AM #8

Niiice Wink
I'll watch this closely, hope it works smack Wink
If only we could pass inspetions i here in norway with those specs..
to hell with the pottato norwegian state..
had been so easy Wink

pena837

Naturally-aspirated

18

12-07-2012, 02:28 PM #9

(12-02-2012, 02:56 PM)BigAssCFotPrint What model is that Griffin radiator and cooler?

i dont remember the model, called one dealer here in finland and ordered radiator that fits mb w124 Big Grin

somekind DIY, you have to make brackets yourself. and cooler in 450x300 china cooler.

pena837

12-07-2012, 02:28 PM #9

(12-02-2012, 02:56 PM)BigAssCFotPrint What model is that Griffin radiator and cooler?

i dont remember the model, called one dealer here in finland and ordered radiator that fits mb w124 Big Grin

somekind DIY, you have to make brackets yourself. and cooler in 450x300 china cooler.

Bangaway

606 Turbo > Porsche Turbo

129

01-15-2013, 06:58 PM #10

Any updates with the project?

Bangaway

01-15-2013, 06:58 PM #10

Any updates with the project?

pena837

Naturally-aspirated

18

01-22-2013, 02:34 AM #11

no, snowmobile season slows this project in wintertime.

pena837

01-22-2013, 02:34 AM #11

no, snowmobile season slows this project in wintertime.

mantahead

Holset

600

01-22-2013, 07:50 AM #12

hi,
nice project, what size of piping did you use on your exhaust manifold?

mantahead

01-22-2013, 07:50 AM #12

hi,
nice project, what size of piping did you use on your exhaust manifold?

pena837

Naturally-aspirated

18

01-25-2013, 02:43 PM #13

42mm/38mm

pena837

01-25-2013, 02:43 PM #13

42mm/38mm

raysorenson

Superturbo

1,162

01-25-2013, 11:18 PM #14

Great build! Thank you for sharing the intercooler details.

raysorenson

01-25-2013, 11:18 PM #14

Great build! Thank you for sharing the intercooler details.

pena837

Naturally-aspirated

18

10-22-2013, 03:02 AM #15

low boost testing,

http://www.youtube.com/watch?v=vcJGlZb3Q...e=youtu.be

pena837

10-22-2013, 03:02 AM #15

low boost testing,

http://www.youtube.com/watch?v=vcJGlZb3Q...e=youtu.be

mantahead

Holset

600

10-22-2013, 03:21 PM #16

sounds awesome, what do you call low boost? Big Grin

mantahead

10-22-2013, 03:21 PM #16

sounds awesome, what do you call low boost? Big Grin

pena837

Naturally-aspirated

18

10-22-2013, 03:24 PM #17

2,5bar

pena837

10-22-2013, 03:24 PM #17

2,5bar

mantahead

Holset

600

10-22-2013, 04:08 PM #18

mantahead

10-22-2013, 04:08 PM #18

Big Grin

Tito

Holset

354

10-23-2013, 01:06 AM #19

after hearing that it sucks that i can't see any pictures Undecided

This post was last modified: 10-23-2013, 01:06 AM by Tito.

Tito

10-23-2013, 01:06 AM #19

after hearing that it sucks that i can't see any pictures Undecided

pena837

Naturally-aspirated

18

10-23-2013, 01:34 AM #20

http://pena837.kuvat.fi/

there you can find almost all the project pics

pena837

10-23-2013, 01:34 AM #20

http://pena837.kuvat.fi/

there you can find almost all the project pics

MFSuper90

Budget Builder

1,533

10-23-2013, 08:19 AM #21

I couldn't hardly see from the pics, but how does your wastegate bleed off all cylinders with your custom header?

'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler Big Grin

'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted

MFSuper90

10-23-2013, 08:19 AM #21

I couldn't hardly see from the pics, but how does your wastegate bleed off all cylinders with your custom header?

'82 300D -3" straight pipe, ALDA deleted, 3in1 glowshift gauge, HX30, egr-less manifold, A/W intercooler Big Grin

'14 Ram 6.7l cummins -G56 handshaker, wishing it was deleted

EDH_Performance

Holset

537

10-23-2013, 08:27 AM #22

(10-23-2013, 08:19 AM)MFSuper90 I couldn't hardly see from the pics, but how does your wastegate bleed off all cylinders with your custom header?

I saw that too...Not all sylinders goes trough the wg, only cyl 3 and 4!
Pressure drops but not all gasses will be wastegated^^
But it seems like it works, but not ideal Smile

Sometimes you must comprimise due to tight space Big Grin

EDH_Performance

10-23-2013, 08:27 AM #22

(10-23-2013, 08:19 AM)MFSuper90 I couldn't hardly see from the pics, but how does your wastegate bleed off all cylinders with your custom header?

I saw that too...Not all sylinders goes trough the wg, only cyl 3 and 4!
Pressure drops but not all gasses will be wastegated^^
But it seems like it works, but not ideal Smile

Sometimes you must comprimise due to tight space Big Grin

Ksteen2

Holset

304

10-24-2013, 02:55 AM #23

it drains all the cylinder, mabye not in he best way, but its a twin scroll flange, and waste gated from each side, so it should not be a problem ;p

1#
Volvo 940 estate 1995
Originaly a d24tic
Changed to OM606.962 From the old 81 Benz
4" dp, 3,5" stainless from DP out.
8mm dieselmeken pump att 180cc
BW kkk K29 turbo, 15cm hot side
home made flywheel with sachs 765PP and original mercedes 240mm organic disc
6speed cdi box
4,5" humongus cooler
Please wait, loading boost

Ksteen2

10-24-2013, 02:55 AM #23

it drains all the cylinder, mabye not in he best way, but its a twin scroll flange, and waste gated from each side, so it should not be a problem ;p

pena837

Naturally-aspirated

18

02-18-2014, 04:47 AM #24

New intake manifold and boost pipes upgraded to 3''

[Image: _smaller.jpg]

pena837

02-18-2014, 04:47 AM #24

New intake manifold and boost pipes upgraded to 3''

[Image: _smaller.jpg]

maxypriest

Holset

287

02-18-2014, 07:14 AM #25

a work of art

W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs

maxypriest

02-18-2014, 07:14 AM #25

a work of art

W124 om606 HX40 finished and it's a beauty 450bhp/456ft-lbs

willbhere4u

Six in a row make her go!

2,507

02-18-2014, 05:40 PM #26

nice!

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

willbhere4u

02-18-2014, 05:40 PM #26

nice!

1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running

pena837

Naturally-aspirated

18

08-31-2014, 04:34 AM #27

new intake manifold worked good, so good that we found the limits of original rods Big Grin

all rods are bend more or less, and 3rd let go for good, in 4th gear, full gas about 180-200km/h, quite a big bang Big Grin

, still drove it to the garage with 5 cylinders.

Well, new engine is in the garage, lets make it stronger for next summer Wink

pena837

08-31-2014, 04:34 AM #27

[Image: _img900.jpg]

new intake manifold worked good, so good that we found the limits of original rods Big Grin

all rods are bend more or less, and 3rd let go for good, in 4th gear, full gas about 180-200km/h, quite a big bang , still drove it to the garage with 5 cylinders.

Well, new engine is in the garage, lets make it stronger for next summer Wink

mario

TA 0301

70

08-31-2014, 05:20 AM #28

Well if she drove to the garage she is some little trooper as what are the plans now

mario

08-31-2014, 05:20 AM #28

Well if she drove to the garage she is some little trooper as what are the plans now

pena837

Naturally-aspirated

18

08-31-2014, 10:50 AM #29

still thinking what to do, maybe smaller turbo and make it more ''daily driver'' but that would be little boring?? Big Grin

second option is , stronger rods, good main bearing ''girdle'' in bottom end, maybe update cylinder head more, and enjoy some serious power Big Grin

but this option in going to be €€€€€€ so we will see..

This post was last modified: 08-31-2014, 10:51 AM by pena837.

pena837

08-31-2014, 10:50 AM #29

still thinking what to do, maybe smaller turbo and make it more ''daily driver'' but that would be little boring?? Big Grin

second option is , stronger rods, good main bearing ''girdle'' in bottom end, maybe update cylinder head more, and enjoy some serious power but this option in going to be €€€€€€ so we will see..

Keino

GT2256V

151

08-31-2014, 12:49 PM #30

@ how much boost pressure were you driving it after installing new intake manifold? Tongue

Keino

08-31-2014, 12:49 PM #30

@ how much boost pressure were you driving it after installing new intake manifold? Tongue

pena837

Naturally-aspirated

18

08-31-2014, 01:32 PM #31

Only about 2,5bar. I believe the rods bended at earlier tests when boost pressure got up to about 3,5bar (and 7000rpm) After 300km of test with those settings cold starts started to sound bad. When the engine warmed up to normal it did run good and no problems. Then few hundred km more this happened

pena837

08-31-2014, 01:32 PM #31

Hario'

C300TD Wagon (W202)

894

09-01-2014, 07:29 AM #32

Awesome, very well doccumented. and Very skilled fabrication work!

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

Hario'

09-01-2014, 07:29 AM #32

Awesome, very well doccumented. and Very skilled fabrication work!

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

sorin_cel

5fingers on a hand, 5cylinders block

71

09-21-2014, 09:22 AM #33

if the rod got bented, and cylinder block smashed in half, that means it was some SERIOUS POWER over there.i'm curious to know if the 3,5bar boost caused that... Confused

sorin_cel

09-21-2014, 09:22 AM #33

if the rod got bented, and cylinder block smashed in half, that means it was some SERIOUS POWER over there.i'm curious to know if the 3,5bar boost caused that... Confused

pena837

Naturally-aspirated

18

09-27-2014, 01:36 PM #34

I dont think boost alone will make that happen. But HX55's airflow in 3,5bars + 7000rpm + alot of fuel all together can make little too much stress for original rods. Or maybe the earlier head gasket failure had something to do with this but i dont think so, gasket leaked only ''outside'' , when boost pressure raised up, gasket leaked it to cooling system and overpressured it so that radiator cap opened and coolant got out. Atleast i didnt find any signs of coolant in the cylinders when i pulled the head off...

pena837

09-27-2014, 01:36 PM #34

Hario'

C300TD Wagon (W202)

894

09-30-2014, 06:50 AM #35

It's usually revs that overstresses reciprocating parts.

Looks like the conrod let go of the gudgeon pin while trying to decelerate the piston towards TDC..

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

Hario'

09-30-2014, 06:50 AM #35

It's usually revs that overstresses reciprocating parts.

Looks like the conrod let go of the gudgeon pin while trying to decelerate the piston towards TDC..

Installed:
OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. [/i]

mantahead

Holset

600

09-30-2014, 04:48 PM #36

she went with a bang Cool

did the crank survive?

what make are the head studs?

mantahead

09-30-2014, 04:48 PM #36

she went with a bang Cool

did the crank survive?

what make are the head studs?

pena837

Naturally-aspirated

18

10-01-2014, 01:17 AM #37

rod did made little marks in the cranks ''weights'' as you see in the picture.

Head studs are from akracing.fi

pena837

10-01-2014, 01:17 AM #37

rod did made little marks in the cranks ''weights'' as you see in the picture.

Head studs are from akracing.fi

mantahead

Holset

600

10-04-2014, 02:36 PM #38

hi,
what sort of power do you think you had??
was it high rpm that pulled the small end bearings apart and killed the engine?

mantahead

10-04-2014, 02:36 PM #38

hi,
what sort of power do you think you had??
was it high rpm that pulled the small end bearings apart and killed the engine?

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