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Benjamin's W201 OM602 STD Project Car
Benjamin Offline
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#1
Benjamin's W201 OM602 STD Project Car
At first hello to all,

I'm happy to be a member on STD.

I'm Benjamin from Croatia, and I'm working about 3 years on my car.
I would like to introduce my project car that I have rebuild completely from ground off.
To hold me short. Last year I completely rebuild the car from ground off. Inside and outside. Inside it got a black leather 16V interior. And outside you can see.

[Image: zee0l6mt6yb7279cfr.jpg]
[Image: mte4ozdsuxvfzrh0c24e.jpg]

Now I working on a new engine. I have buy a donor car with a 2.5 Turbo Diesel engine.

The engine is now fully rebuildet from ground off. I also modified the pump with 6mm elements from a OM 605 pump. Her in Croatia it's difficult to get bigger elements. STD are not known here. Happily I have good connections I work before in a Mercedes-Benz workshop and I have a friend who repairs Pumps. So we modified the pump with help of Dieselmeken AB Thanks a lot on this place.

The set up is following:
-OM 602 Turbo engine fully rebuilded
-Pump modified with OM605 6mm elements at 75ccm of fuel.
-an IC would be installed to cool air down
-Dog leg 16V 5 speed gearbox
-2.65 diff from the 2.5 TD automatic gearbox
-Flywheel and clutch at first my OEM from the 2.0D it should be OK
-Turbo at the moment OEM one with increased boost to 1.5 bar

My targets:
Daily driver car with around 200-220hp max.
With the OEM turbo 150hp still the engine gona get a few kilometer worked.

Open questions:
-What turbo to use - target 200-220hp? Garret turbos would be easier to get her in Croatia. T3 or T4 or something different...? I have find out that the Holset he221w would be a good choice is that true?
-Making a exhaust manifold - No problem
-Maybe increase fuel ?


Yesterday we have start the car for the first time, her is a short video:
http://www.youtube.com/watch?v=1HJzxWgf218

Thank you all in front.

I hope I will find some useful information's here to go further with my project.
(This post was last modified: 04-09-2013, 05:09 PM by Benjamin.)
04-09-2013, 04:43 PM
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George3soccer Offline
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#2
RE: Benjamin's W201 OM602 STD Project Car
Love your w201. Great job.
Mb 1984 w201 om603 swap.
Mb 1986 w201 190E 2.3-16v
Mb 2004 w203 C230k
04-09-2013, 08:36 PM
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Benjamin Offline
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#3
RE: Benjamin's W201 OM602 STD Project Car
(04-09-2013, 08:36 PM)George3soccer Wrote: Love your w201. Great job.

Thank you I do my best Big Grin
04-10-2013, 04:27 PM
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willbhere4u Offline
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#4
RE: Benjamin's W201 OM602 STD Project Car
Nice looking car

With a decent turbo and a that 6mm injection pump
250hp would be reasonably easy
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-10-2013, 04:45 PM
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Benjamin Offline
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#5
RE: Benjamin's W201 OM602 STD Project Car
(04-10-2013, 04:45 PM)willbhere4u Wrote: Nice looking car

With a decent turbo and a that 6mm injection pump
250hp would be reasonably easy

The only problem is that i dont now what turbo and what turbohousing size i need.

The pump is also modifyed with the 6mm elements. I maybe just need to increase a little bit fuel for the bigger turbo.

I would be happy with around 200-220hp.

I use the car as a daily driver. So I dont wont to go to high hp.
(This post was last modified: 04-11-2013, 08:59 AM by Benjamin.)
04-11-2013, 08:58 AM
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Ksteen2 Offline
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#6
RE: Benjamin's W201 OM602 STD Project Car
I would use a HX35 with 11cm house.
Then You would esaly make 300 hp Wink
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
04-11-2013, 04:25 PM
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Benjamin Offline
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#7
RE: Benjamin's W201 OM602 STD Project Car
(04-11-2013, 04:25 PM)Ksteen2 Wrote: I would use a HX35 with 11cm house.
Then You would esaly make 300 hp Wink

Thats interesting to hear, but for every day its to much i dont now how the other parts would take so much power. I would be happy and fine with 200-220hp.

Some more info what HX35 you prefer. How much blades? Exhaust housing? Air housing?
04-12-2013, 03:43 PM
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willbhere4u Offline
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#8
RE: Benjamin's W201 OM602 STD Project Car
For that kind of power just turn up the boost on the stock turbo It will have better spool characteristics than a bigger one. and should support 18-20psi
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-12-2013, 05:09 PM
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Benjamin Offline
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#9
RE: Benjamin's W201 OM602 STD Project Car
(04-12-2013, 05:09 PM)willbhere4u Wrote: For that kind of power just turn up the boost on the stock turbo It will have better spool characteristics than a bigger one. and should support 18-20psi

The stock one doesent go to 200+hp...with the stock one ist safe to go to about 150hp + the stock one has a few years of usage so i dont think its the best way. I would like to buy a new one thats a little bigger that the stock one.

Thats the info that i have get.
(This post was last modified: 04-13-2013, 05:25 PM by Benjamin.)
04-13-2013, 05:16 PM
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Ksteen2 Offline
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#10
RE: Benjamin's W201 OM602 STD Project Car
the HX35 har a 4" inlet 2,5" outlet on cold side, a T3 flange and 4" exhaust out, the turbo have numerous housings, 9-11-13-15 cm, if you get a 11 cm, you will get a god spool with it, you can search for Holsett HX35 on google, and you get what info you want there Wink
a optimal daliy drive will come from a Dodge RAM 5,9 cummins diesel Wink
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
04-15-2013, 01:57 AM
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upsie Offline
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#11
RE: Benjamin's W201 OM602 STD Project Car
i just want say i love your car !
04-15-2013, 03:19 AM
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Benjamin Offline
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#12
RE: Benjamin's W201 OM602 STD Project Car
(04-15-2013, 01:57 AM)Ksteen2 Wrote: the HX35 har a 4" inlet 2,5" outlet on cold side, a T3 flange and 4" exhaust out, the turbo have numerous housings, 9-11-13-15 cm, if you get a 11 cm, you will get a god spool with it, you can search for Holsett HX35 on google, and you get what info you want there Wink
a optimal daliy drive will come from a Dodge RAM 5,9 cummins diesel Wink

If i go with the HX35 an 11cm housing, is it a problem if i preinstal my new exhaust that was planed to be betwen 2,5 and 3 inch? Is it necessery to go bigger than 3 inch for a 200hp car?

(04-15-2013, 03:19 AM)upsie Wrote: i just want say i love your car !

Thank you... I do my best Smile
(This post was last modified: 04-15-2013, 04:30 AM by Benjamin.)
04-15-2013, 04:28 AM
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majesty78 Offline
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#13
RE: Benjamin's W201 OM602 STD Project Car
2.5" is more than enough for 200-220hp ;-)
Mercedes Benz W210 E-Class 320CDI, lowered 2.5", 18" AMG wheels, Decat, EGR removed, Tumble flaps removed, C30 AMG injectors, 400kpa MAP, Custom GT2566XTV turbo, SW tweaked to 300+hp/750NmBig Grin
04-15-2013, 04:44 AM
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Ksteen2 Offline
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#14
RE: Benjamin's W201 OM602 STD Project Car
use 3", you can get problems with back pressure with smaller Wink
spesialy if you get a bigger pump Wink
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
04-15-2013, 06:29 AM
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willbhere4u Offline
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#15
RE: Benjamin's W201 OM602 STD Project Car
a t3/t4 hybrid would suit it nicely.
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-15-2013, 04:38 PM
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Benjamin Offline
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#16
RE: Benjamin's W201 OM602 STD Project Car
You say 3".

A bigger pump that this one with 6mm elements I dont plan to use. This is absolutly enough for me.

The only plan is to upgrade a turbo. But still doesent now what model?

So 2,5 or 3? I need to check with the workshop do they have tools for a such big pipe in diameter to make angels. This kinde of pipe isnt standart here in Croatia.

Most used are 2.25". All whats bigger then that is a special order. I have meet in the last few days many problems with my build. Hard to find parts what Im looking for.

For exmp. Aluminium 90 degree pipe...doesent exist in Croatia. No one can make it. The only way order over ebay.


Anyone have precise part number of turbos that I should search for?
(This post was last modified: 04-15-2013, 04:52 PM by Benjamin.)
04-15-2013, 04:49 PM
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willbhere4u Offline
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#17
RE: Benjamin's W201 OM602 STD Project Car
look up Garrett t3's they are the most copied turbo out there they came stock on old Mercedes 300d like w123 old Volvo 240's I had one made in to a t3/t4 a few years ago should support 20psi easily
1987 300SDL 6spd manual om606.962 swap project
1985 300td euro 5spd wagon running
04-15-2013, 05:35 PM
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Benjamin Offline
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#18
RE: Benjamin's W201 OM602 STD Project Car
(04-15-2013, 05:35 PM)willbhere4u Wrote: look up Garrett t3's they are the most copied turbo out there they came stock on old Mercedes 300d like w123 old Volvo 240's I had one made in to a t3/t4 a few years ago should support 20psi easily

In this direction I have thik.

Garrett T3 T4 are the most common here. I would be gratefull if i can get a little bit more info... in what direction should i look. Part number.

Im not a turbo guru. I have read articles but the housing of turbos i still complicated to me.. I dont now what size to search for.

Turbine size,Housing size etc...

A little update:

some IC piping

[Image: 0fefdoxp6bsh1ppvp8k.jpg]
[Image: x1g5osbf257m47rr6cp4.jpg]


Hope you like it Smile
(This post was last modified: 04-15-2013, 06:06 PM by Benjamin.)
04-15-2013, 05:52 PM
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Ksteen2 Offline
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#19
RE: Benjamin's W201 OM602 STD Project Car
just find a T3\T4 with an AR.63 exhaust housing, and it will be just perfect Wink
the deal for more power is diesel Wink
u can get 350 Bhp with 6mm elements and HX35 in a OM606, if u get 6mm and a T3/T4 u should be able to gett 250 Wink
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
04-16-2013, 02:54 AM
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Benjamin Offline
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#20
RE: Benjamin's W201 OM602 STD Project Car
Good day today Smile

IC piping finished.
[Image: cv9ygnppwe2pxupax7p.jpg]
[Image: z1r2plnzmadwbudtyxk.jpg]

Rear Big brake upgrade complete.
[Image: f25cx8mmtjc60wldzjns.jpg]

Front Big brake I have upgradet a few weeks ago.
[Image: tv9vcg3jwmkpn6mjc7t.jpg]

@Ksteen2 - Thanks I take a look what can I finde.
04-16-2013, 04:55 PM
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Ksteen2 Offline
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#21
RE: Benjamin's W201 OM602 STD Project Car
how big are the disc's?
what are they from?
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
04-17-2013, 01:44 AM
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Benjamin Offline
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Location: Croatia
#22
RE: Benjamin's W201 OM602 STD Project Car
(04-17-2013, 01:44 AM)Ksteen2 Wrote: how big are the disc's?
what are they from?

W124 E420
but i think ona 300 24V are the same size breakes.

Front are 294mm with 4 Pot calipers.
Rear are 278mm with 2 Pot calipers.
(This post was last modified: 04-18-2013, 07:00 AM by Benjamin.)
04-17-2013, 03:00 AM
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Ksteen2 Offline
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#23
RE: Benjamin's W201 OM602 STD Project Car
is it bigger brakes om a 300TDT? ;o
those are little over 300mm Smile
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
(This post was last modified: 04-18-2013, 02:05 AM by Ksteen2.)
04-18-2013, 02:04 AM
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Benjamin Offline
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#24
RE: Benjamin's W201 OM602 STD Project Car
(04-18-2013, 02:04 AM)Ksteen2 Wrote: is it bigger brakes om a 300TDT? ;o
those are little over 300mm Smile

tdt-s are not common here so i dont now. I now that are existing a older version discs that are a few mm bigger I think 300mm butt they are thinner around 22mm and my 298mm are around 25 or 27 mm.

someone says that the thinner ones had problems with deformation and vibrations. Somewhere I have read this.
(This post was last modified: 04-18-2013, 05:47 AM by Benjamin.)
04-18-2013, 05:46 AM
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raysorenson Offline
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#25
RE: Benjamin's W201 OM602 STD Project Car
I understand the E420's came with 295x22mm or or 294x25mm front discs.

http://www.w124performance.com/docs/mb/W...brakes.pdf
04-18-2013, 06:32 AM
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Benjamin Offline
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#26
RE: Benjamin's W201 OM602 STD Project Car
(04-18-2013, 06:32 AM)raysorenson Wrote: I understand the E420's came with 295x22mm or or 294x25mm front discs.

http://www.w124performance.com/docs/mb/W...brakes.pdf

yes thats correct.I Write the wrong dimensions. 294x25 and 295x22.
04-18-2013, 06:58 AM
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Benjamin Offline
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#27
RE: Benjamin's W201 OM602 STD Project Car
I stuck with the project a little bit.. problems with the cooling system..i wil post pictures an the results after i finish the cooling system...

Another question

What size air filter should I use with the car? I dont use the stock air filter housing. Im thinkig of using something like K&N.

I have found a information that a 500cfm filter should do the thing?

Has someone a good info?
04-22-2013, 06:41 PM
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Benjamin Offline
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#28
RE: Benjamin's W201 OM602 STD Project Car
Good news. Car is running. Cooling system is fixed. The original visco system is throve away and electric fans are installed, also a new oil cooler in the front fender.

a 70mm stainless steel exhaust is installed, and a new K&N filter is installed.

New pictures this weekend.

I'm happy with the performance. The dog leg gearbox out of a 16V works perfectly with the differential
05-03-2013, 03:41 AM
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Benjamin Offline
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#29
RE: Benjamin's W201 OM602 STD Project Car
Some pictures from yesterday...

[Image: 0d0hvpgh5q0taduilbb.jpg]

[Image: nkwsvphgey0to0cs2snz.jpg]

[Image: x6vzpe2gshwk6v6s2.jpg]
05-05-2013, 06:45 PM
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MFSuper90 Offline
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#30
RE: Benjamin's W201 OM602 STD Project Car
Sexyyy Big Grin
I think your current air filter setup should be fine.
Is that a air to water intercooler or air to air?
'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         
05-05-2013, 08:21 PM
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Benjamin Offline
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#31
RE: Benjamin's W201 OM602 STD Project Car
(05-05-2013, 08:21 PM)MFSuper90 Wrote: Sexyyy Big Grin
I think your current air filter setup should be fine.
Is that a air to water intercooler or air to air?

Its a air to air IC.
05-06-2013, 03:40 AM
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TurboWalt Offline
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#32
RE: Benjamin's W201 OM602 STD Project Car
Benjamin,

Great 190 project that you have there! I have a 87 190D Turbo that I'm working on. So far I've installed a 16V body kit, 93 w124 400e front and rear disc brakes, and 7.5 EVOII wheels. I have 16V front and rear seats that will go in it, I will keep the interior color palomino. I plan to install a bigger pump, turbo & intercooler like you are in the process of. Right now I'm undecided on what to do for a transmission. I know the 722.4 probably wont last. Good to hear that 16V dogleg is working for you! Keep up the good work. Your car is inspiration for me to finish mine.

Walt
05-06-2013, 05:19 AM
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Benjamin Offline
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#33
RE: Benjamin's W201 OM602 STD Project Car
(05-06-2013, 05:19 AM)TurboWalt Wrote: Benjamin,

Great 190 project that you have there! I have a 87 190D Turbo that I'm working on. So far I've installed a 16V body kit, 93 w124 400e front and rear disc brakes, and 7.5 EVOII wheels. I have 16V front and rear seats that will go in it, I will keep the interior color palomino. I plan to install a bigger pump, turbo & intercooler like you are in the process of. Right now I'm undecided on what to do for a transmission. I know the 722.4 probably wont last. Good to hear that 16V dogleg is working for you! Keep up the good work. Your car is inspiration for me to finish mine.

Walt

Thanks, I. Appreciate that.

I have use a Dog Leg gearbox out of a 2.5 16V with driveshaft, flywheel and clutch out of my old 2.0D and the differential is out of a 2.5 TD automatic transmission I think it was 2.65.

Works fine for me. Acceleration is great and max speed is around 220km/h. For my use perfectly. Maybe I try another differential to get a comparison.
05-06-2013, 06:09 AM
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Benjamin Offline
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#34
RE: Benjamin's W201 OM602 STD Project Car
Hello,

I'm back after a while. I took a little vacation to relax from the last project.

It's time to go on.

The Benz has got a new flywheel and cluch ugrpade. The old one didn't hold any more. It was too weak. I have make a upgrade to a 228mm cluch.

[Image: dz7r3qpiupgyr1x0f5.jpg]
(This post was last modified: 07-02-2013, 03:48 PM by Benjamin.)
07-02-2013, 03:47 PM
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Simpler=Better Offline
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#35
RE: Benjamin's W201 OM602 STD Project Car
It's beautiful! Your engine bay is immaculate
Newbie-read this: Cheap Tricks
617.952-220k-Getting built up
larsalan Wrote:I guess I need to look at this stupid ass drip shit. What you have to like mess with those elements on the pump? What a fucking hassle. then use some wire to hold the throttle open or some shit?
07-02-2013, 04:04 PM
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Benjamin Offline
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#36
Wink  RE: Benjamin's W201 OM602 STD Project Car
Thank you. I do my best. Smile
07-02-2013, 04:33 PM
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Benjamin Offline
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#37
RE: Benjamin's W201 OM602 STD Project Car
Hello to all,

after I was long time not present on the forum I make a quick post what happens in the meantime.

After installing a new couch the biggest one for a short time it was OK, but not for long after 3000km the cluch starts to slip again. I search for the problem and found it. The problem was the secondary cluch cylinder. The pushing pin was to long I shortened it and now its fine.

After this I got another problem. On Friday evening I was driving (hard style) Smile and unluckily the U-join on the drive shaft broke down.
So now the drive shaft broken we need to re-welding it.

[Image: dt4t24jb20pyqn7kqbc.jpg]

[Image: hj86qu58a4w70prflk6.jpg]S

Stay tuned.
01-20-2014, 02:55 PM
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swampmonkey Offline
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#38
RE: Benjamin's W201 OM602 STD Project Car
(04-13-2013, 05:16 PM)Benjamin Wrote:
(04-12-2013, 05:09 PM)willbhere4u Wrote: For that kind of power just turn up the boost on the stock turbo It will have better spool characteristics than a bigger one. and should support 18-20psi

The stock one doesent go to 200+hp...with the stock one ist safe to go to about 150hp + the stock one has a few years of usage so i dont think its the best way. I would like to buy a new one thats a little bigger that the stock one.

Thats the info that i have get.

i have perhaps 220whp on my om602 with stock turbo, 1.6bar boost at inlet after IC.
beats a 300CE 12valve and 2.3 16v.

7.5mm 180cc pump that i dont fully use. need a better gearbox Tongue
---------------------------------
daily driver
w115 240d 72hp 3.07 rearend
w123 om602 turbo 200whp 7.5mm pump fivespeed 3.07 rearend
+ a few more.
mbturbo.com
01-20-2014, 03:06 PM
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Benjamin Offline
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#39
RE: Benjamin's W201 OM602 STD Project Car
(01-20-2014, 03:06 PM)swampmonkey Wrote:
(04-13-2013, 05:16 PM)Benjamin Wrote:
(04-12-2013, 05:09 PM)willbhere4u Wrote: For that kind of power just turn up the boost on the stock turbo It will have better spool characteristics than a bigger one. and should support 18-20psi

The stock one doesent go to 200+hp...with the stock one ist safe to go to about 150hp + the stock one has a few years of usage so i dont think its the best way. I would like to buy a new one thats a little bigger that the stock one.

Thats the info that i have get.

i have perhaps 220whp on my om602 with stock turbo, 1.6bar boost at inlet after IC.
beats a 300CE 12valve and 2.3 16v.

7.5mm 180cc pump that i dont fully use. need a better gearbox Tongue

Interesting.

You have got my atention =)

We have set my pump with 6mm elements to around 75-80ccm an the stock turbo boosts around 0.9 bar.

I wait for the boost controller to set the boost a little higer and see if we need to add more fuel. I target something around 1.2 bar with stock turbo.

The turbo has some milage so Im a little bit skeptical. Later I maybe get a lightly bigger one.

The only problem are the elements for the fuel pump. Its a bit hard to find bigger here in Croatia.
(This post was last modified: 01-20-2014, 05:05 PM by Benjamin.)
01-20-2014, 05:04 PM
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Ksteen2 Offline
Holset
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Posts: 304
Joined: Sep 2012
Location: East-Norway
#40
RE: Benjamin's W201 OM602 STD Project Car
Looks Like a verry good resault Wink
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
01-26-2014, 02:17 PM
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bmartins Offline
GTA2056V
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Posts: 75
Joined: Apr 2011
Location: Figueira da Foz - Portugal
#41
RE: Benjamin's W201 OM602 STD Project Car
Hello.
When you installed a 2.0d clutch/flywheel single mass, did you changed the 215mm to 228mm?
And after that when it cannot hold the power which set did you installed?
thanks
01-10-2016, 06:13 PM
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Repetitio Offline
GT2256V
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Posts: 134
Joined: Nov 2014
Location: Germany
#42
RE: Benjamin's W201 OM602 STD Project Car
Very nice project Wink
01-14-2016, 02:48 PM
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