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German 605 s202 t04e undercover Projekt
STDGer Offline
K26-2
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Posts: 42
Joined: Mar 2015
Location: Germany
#1
German 605 s202 t04e undercover Projekt
After my powerfull he 351w 605 sedan build i liked to have a station wagen (dog, own house etc  Big Grin ).

So i bought a 08.97 s202 605 manual with about 352tkm on it.
[Image: IMG-20170722-WA0017.jpg]

But, by the first drive with that original station wagen ive cryd after my white sedan,
so i had to push in a bit more power.

In march i fully rebuild the landing gear.

1st step was to get eeproms into the ecu by a member of our german STD group who build a upgradet map too.

The last month i build a new setup on a donor s202 605 and puted it the last saturday in.

I got a nice t3 flange welded on oem manifold from a friend.
[Image: IMG-20170623-WA0040.jpg]

I think my turbo choice t04e is the biggest one wich will fit in that tight 202 enginge bay by looking oem.
I ve felt like a gynocologist  Big Grin
[Image: 20170711_204308.jpg]
[Image: IMG-20170703-WA0020.jpg]
[Image: IMG-20170703-WA0022.jpg]
But it fits!

First i build the oil feed with included lines from t04e set, but it was scrap and leaky.( see the adaptor on oilfeed)

Now i build the oil feed by stretching the oem one.
[Image: IMG-20170727-WA0045.jpg]

This is the oil return.
[Image: 20170711_204251.jpg]
[Image: 20170711_203123.jpg]
[Image: 20170711_203131.jpg]


I tried to go with oem vaccuum actuator but there was no way to reach 0.5bar :/

UPDATE

Yesterday i swapped to the pressure actuator. Now its about 0.7 bar, and without wastegate pressure line only 1.5 while smoking like a train.
[Image: IMG-20170727-WA0047.jpg]


This is how it looks after implanting all parts on its place.
[Image: IMG-20170715-WA0028.jpg]
[Image: IMG-20170715-WA0026.jpg]
[Image: IMG-20170727-WA0055.jpg]

To get more air in the turbo i changed the restrictive tube between turbo and airbox to pe pipes and opend the hole at the front.
[Image: IMG-20170727-WA0049.jpg]
[Image: IMG-20170727-WA0081.jpg]

Where the fck is my boost Sad
Ive sorted out these opinions:
- high backpressure (its only 1 muffler, but its an aftermarket gas muffler for c280 or c230k and its incredible quite)
- restructive air intake ( oem air intake is for sure not the best opinion, but this build has to keep complete oem style)
- leak in pressure line
- scrap turbo (but bruno pinho got 2.7 bar out of this chinese turbo)


I m grateful for any ideas.

UPDATE

I found out that the muffler was the restrective part with my boost problem. Now it boost easily above 2 bar and spins the weels in 2 gear Cool
Im running now a modded universal stainless muffler
[Image: IMG-20170730-WA0001.jpg]

Last weekend i did a preserve painting to that car too. Its a pu bedline coating with rubber in it.
[Image: IMG-20170722-WA0042.jpg]
[Image: IMG-20170722-WA0037.jpg]
[Image: IMG-20170722-WA0044.jpg]

And this is how the car looks now.
[Image: IMG-20170730-WA0006.jpg]
[Image: IMG-20170730-WA0008.jpg]
[Image: IMG-20170730-WA0010.jpg]
[Image: IMG-20170730-WA0012.jpg]
ex 04. 1997 w202 om605 sedan ,Dieselmeken 7.5mm, 3" exhaust, he351w, 716.657 ca 350+ hp

actual 08. 1997 w202 om605 station wagon, oem edc pump, modded exhaust manifold, t04e turbo, oem pipe 1 silencer wannabe as much as possible
(This post was last modified: 07-31-2017, 07:58 AM by STDGer.)
07-28-2017, 04:20 AM
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STDGer Offline
K26-2
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Posts: 42
Joined: Mar 2015
Location: Germany
#2
RE: German 605 s202 t04e undercover Projekt
Today i orderd a 606 intake gasket. The OEM rubber rings are veryleaky.

The car runs great, But theres another problem wich ive ignored while building.

The temp goes nearly to 100° .
Ive opend the thermostate, But No improvement.
The Radiator is cold in the mittle.

Maybe someone has an idea what i could check too
ex 04. 1997 w202 om605 sedan ,Dieselmeken 7.5mm, 3" exhaust, he351w, 716.657 ca 350+ hp

actual 08. 1997 w202 om605 station wagon, oem edc pump, modded exhaust manifold, t04e turbo, oem pipe 1 silencer wannabe as much as possible
07-31-2017, 08:13 AM
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Fishman Offline
GTA2056V
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Posts: 77
Joined: Apr 2015
Location: Nederland
#3
RE: German 605 s202 t04e undercover Projekt
Where did you buy the bedline coating?
08-01-2017, 04:22 AM
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STDGer Offline
K26-2
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Posts: 42
Joined: Mar 2015
Location: Germany
#4
RE: German 605 s202 t04e undercover Projekt
Its from Horn Tools. Its named herculiner
ex 04. 1997 w202 om605 sedan ,Dieselmeken 7.5mm, 3" exhaust, he351w, 716.657 ca 350+ hp

actual 08. 1997 w202 om605 station wagon, oem edc pump, modded exhaust manifold, t04e turbo, oem pipe 1 silencer wannabe as much as possible
08-01-2017, 06:18 AM
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Fishman Offline
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Posts: 77
Joined: Apr 2015
Location: Nederland
#5
RE: German 605 s202 t04e undercover Projekt
Thanks
08-01-2017, 12:18 PM
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Hario' Offline
C300TD Wagon (W202)
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Posts: 894
Joined: Nov 2011
Location: SW London
#6
RE: German 605 s202 t04e undercover Projekt
The rad is cold but the engine is hot?? is the bleed pipe from the rad to the header tank clear? there is big air pocket in the top of the head if that is not clear or even installed..

Maybe water pump impeller is broke if it is the plastic one? I still didn't over heat when mine was broken in two!

Visco coupling bad? Can you spin the fan easily by hand when it is hot?

Should sit at 78 degrees all the time and go upto 80/85 after a hard drive then idling for abit..



Installed:

OM606/722.6, big IC, W220 brakes.
Planned:
DIY manifold, compound, 722.6 controller, built IP.
[i]Less rust.. 
[/i]
(This post was last modified: 08-01-2017, 01:00 PM by Hario'.)
08-01-2017, 12:59 PM
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STDGer Offline
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Posts: 42
Joined: Mar 2015
Location: Germany
#7
RE: German 605 s202 t04e undercover Projekt
Thanks hario for ur ideas.

Its not the whole rad cold only the area in Front of the Fan.
I rinsed the rad by citus acid . What about scum cummin out of the System. ...
Now, when ich block the Fan, the rad gets hot Smile
But i figured out that theres much air in the System After the acid spooling.
This may be the result from cutting the Front springs.
Today i will install a new thermostat.
Will Report the result Smile

Greetings
ex 04. 1997 w202 om605 sedan ,Dieselmeken 7.5mm, 3" exhaust, he351w, 716.657 ca 350+ hp

actual 08. 1997 w202 om605 station wagon, oem edc pump, modded exhaust manifold, t04e turbo, oem pipe 1 silencer wannabe as much as possible
08-03-2017, 11:53 PM
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seanyt Offline
is300d He351ve
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Posts: 269
Joined: May 2014
Location: Ireland
#8
RE: German 605 s202 t04e undercover Projekt
So hows the map i sent you running now with the 6k rev limit Smile
Making full use of the t04e flow.
08-04-2017, 06:01 AM
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STDGer Offline
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Posts: 42
Joined: Mar 2015
Location: Germany
#9
RE: German 605 s202 t04e undercover Projekt
Ur map is fantastic. Feels like build for that turbo.

But on theute last weekend i crashed the t04e.
It is what it is, Chinese crap.
Im now thinking about a holset hx30 super. But nowhere to find one. That would be nearly the same turbo size but imho is it more durable and will hold the 2 bar continuily
ex 04. 1997 w202 om605 sedan ,Dieselmeken 7.5mm, 3" exhaust, he351w, 716.657 ca 350+ hp

actual 08. 1997 w202 om605 station wagon, oem edc pump, modded exhaust manifold, t04e turbo, oem pipe 1 silencer wannabe as much as possible
08-09-2017, 02:36 AM
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seanyt Offline
is300d He351ve
****


Posts: 269
Joined: May 2014
Location: Ireland
#10
RE: German 605 s202 t04e undercover Projekt
I only suggest 1.5 bar on the chinese turbos.
The turbine wheel can separate on the shaft.
I know you where running it hard. youll get an alternative soon.
08-09-2017, 08:17 AM
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STDGer Offline
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Posts: 42
Joined: Mar 2015
Location: Germany
#11
RE: German 605 s202 t04e undercover Projekt
A little update here.

Blown up the headgasket of my engine and the oilpump.

This was the reason of my heat problems and why the t04e was killed. A pice of the headgasket must hittet the inducer of turbinwheel.

Changed to 605engine of my donor car and puttet in a new t04e.

Also getted a k&n airfilter for oem filterbox and removed the air restrictor at the front.

Now running it with 1.5 bar boost. Spool is not the best, but from 0- 170 it is only 3km/h slower than a new 245hp golf 7 gti performance with is much lighter.

A nice result for a daily i think
ex 04. 1997 w202 om605 sedan ,Dieselmeken 7.5mm, 3" exhaust, he351w, 716.657 ca 350+ hp

actual 08. 1997 w202 om605 station wagon, oem edc pump, modded exhaust manifold, t04e turbo, oem pipe 1 silencer wannabe as much as possible
(This post was last modified: 10-10-2017, 01:13 AM by STDGer.)
10-10-2017, 01:12 AM
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charlysays Offline
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Posts: 95
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Location: West Wales
#12
RE: German 605 s202 t04e undercover Projekt
Looks great! Wish I could fit my T04E into the same spot you did but in the UK the steering box is well in the way!

I'm sending my T04E off to get it built and balanced with a 360 thrust kit. Hopefully it'll then be as reliable as the GT28 from the same Chinese company that I've been using the last 20+k miles!
Could you do some videos with it?

I'm trying to work out how much more lag there's going to be over my GT28 setup

Are you still using the stock IC?
10-10-2017, 05:30 AM
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STDGer Offline
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Posts: 42
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Location: Germany
#13
RE: German 605 s202 t04e undercover Projekt
Hey, nice to have a fan of what i m doing here.

Where do u get such a kit and what would it cost?
Maybe the New one will last longer.
What i could say, there s enough fuel to reach more than 2 bar on that turbo. Spins my 225 17' in 2nd on a dry Road.
At 2k 0.2
At 3k 0.6 bar
At 3.5k 1 bar
At 3.8k 1.5 bar till 6k

Are u sure with ur steeringbox? Theres much space from my turbo to the axle.

I use oem intercooler, But still thinking about WM Injektion or and welding in a 2nd oem intercooler.

I think this is not a favourite trailer setup but its nice to beat some gti guys with that 1k € car Tongue
ex 04. 1997 w202 om605 sedan ,Dieselmeken 7.5mm, 3" exhaust, he351w, 716.657 ca 350+ hp

actual 08. 1997 w202 om605 station wagon, oem edc pump, modded exhaust manifold, t04e turbo, oem pipe 1 silencer wannabe as much as possible
10-10-2017, 02:55 PM
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STDGer Offline
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Posts: 42
Joined: Mar 2015
Location: Germany
#14
RE: German 605 s202 t04e undercover Projekt
ex 04. 1997 w202 om605 sedan ,Dieselmeken 7.5mm, 3" exhaust, he351w, 716.657 ca 350+ hp

actual 08. 1997 w202 om605 station wagon, oem edc pump, modded exhaust manifold, t04e turbo, oem pipe 1 silencer wannabe as much as possible
10-11-2017, 03:02 PM
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charlysays Offline
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Posts: 95
Joined: Apr 2015
Location: West Wales
#15
RE: German 605 s202 t04e undercover Projekt
(10-10-2017, 02:55 PM)STDGer Wrote: Hey, nice to have a fan of what i m doing here.

Where do u get such a kit and what would it cost?
Maybe the New one will last longer.
What i could say, there s enough fuel to reach more than 2 bar on that turbo. Spins my 225 17' in 2nd on a dry Road.
At 2k 0.2
At 3k 0.6 bar
At 3.5k 1 bar
At 3.8k 1.5 bar till 6k

Are u sure with ur steeringbox? Theres much space from my turbo to the axle.

I use oem intercooler, But still thinking about WM Injektion or and welding in a 2nd oem intercooler.

I think this is not a favourite trailer setup but its nice to beat some gti guys with that 1k € car  Tongue

Did you use the oil line supplied with the T04E? I'm not sure I trust it lol, might get another hydraulic line made up.

You can get 360 rebuild kits off ebay for these turbos for 25e or so.
The place which is building mine and balancing it are supplying the kit for £25 which includes just the thrust bearing and new seals I think. They'll VSR balance it then and warranty their work for a year.
I've had no trouble running my GT28 at 1.5-1.7 bar on standard bearings so I'd probably feel happy running up to 2bar on this rebuilt T04E. The weak spot may be the friction weld on the turbine wheel though.
If that falls off... It won't wreck the engine atleast I don't think. Just no boost. Hopefully I could just fit a genuine garret turbine shaft then and have another go!

By the look of it, the T04E could be made to be as responsive as the GT28 on a proper custom manifold. A few people have had spool 500rpm sooner with a DIY manifold vs adapter.

Sounds like you're making a lot more power than me with my GT28 too which I find very exciting, keen to get the T04E on now!
10-18-2017, 04:56 AM
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