W126 short body OM606

K26-2

43

06-25-2018, 10:18 PM #2

Sorry about some of these images, the hosting site I used has some autorotation that can't be changed apparently.

The oil filter housing from the om603 has some clearance issues:

[Image: 20180325141955.jpg]

This was alleviated by removing material from the intake tube and housing with a belt sander:
[Image: 20180325144752.jpg]

Now the oil cap can be removed without pulling the intake! Will have to see if I went too thin on the lid though.

A little support is needed to be welded to the OM606 cooling tube to make it work with this housing:
[Image: 20180506204550.jpg]

Injection pump timed, installed along with a new metal impeller water pump:
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Here you can see how far 8 was from the original setting ~14 in the viewing hole:
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The thermostat housings are different, and to use the original hoses I had to use the original smaller om603 one:
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I wanted to retain the original Nippon AC pump from the 350SD. I left it charged and hanging in the engine bay. The base plates for the alternator and AC pump have slight differences between engines:
[Image: 20180508195457.jpg]

Note how one of the alternator plates has clearance on the back for the crank pulley on the OM606. The OM603 version would need slight modification.
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6031550735 right, 6031550435 middle, 6052140239 left . The compressor mounting holes between the E300 and 350SD have different dimensions .
[Image: 20180429110113.jpg]

Here you can see the different nose length on the 2002 S500 V8 alternator vs the late 90s W140 S320 I6 alternator, I6 on the left:
[Image: 20180311172105.jpg]

The S55 transmission took a beating in its accident, but damage appears to be limited to the pan:
[Image: 20180311184846.jpg]

With the E320 bellhousing and new intermediate plate (seal) and better pan installed:
[Image: 20180507175946.jpg]

The output flange on the AMG transmission is 4 finger, while the 2002 V8 version has an exact match 3 finger dimension to the 91 350SD driveshaft.

Here we have some side-by sides of various transmissions:
90s E320 I6 next to original from 350SD and S500:
[Image: 20180213103600.jpg]

300SD -> 350SD -> E320
[Image: 20180311172146.jpg]

300SD ->350SD -> E320 -> S500 -> S55
[Image: 20180311172050.jpg]

For now I just used the torque converter from the E320, hopefully it isn't fried. The S55 had very low miles, pink fluid.
Here are S55 AMG left and S500 flanges:
[Image: 20180514120825.jpg]

The S500 flange is not the same as the E320, this one is much smaller than the 350SD and S500.

Here are the turbos I had out of storage next to each other:
E300 left, 350SD right
[Image: 20180508103713.jpg]

E300 top, S200 bottom
[Image: 20180508103729.jpg]

The pile in the garage is getting excessive:
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Time to pull the body in:
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And now we find out how far off everything is:
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To my amazement, everything lined up like it was designed for this combination.

[Image: 20180517180237.jpg]

Will have to reroute the heater core lines a bit:
[Image: 20180517195433.jpg]

Perfect, that is the 99 E300 pan in the W126
[Image: 20180528173418.jpg]

The DPUK adapter
[Image: 20180612152303.jpg]

Cleaned out the original oil cooler
[Image: 20180528173444.jpg]

And the biggest question of the day, the driveshaft. It fits perfectly with the original flex discs.
Now if these start to fail to frequently, the S500 has much thicker discs that can be used but will require a couple CM removed from the overall shaft length. Time will tell...
[Image: 20180528173343.jpg]

I got lucky and found a 125k mile LSD from a 560SEL at the pull it yourself yard:
[Image: 20180520131814.jpg]

And now there is a company making full aluminum replacement radiators for the gen II W126 diesels:
[Image: 20180403152504.jpg]

The belt is not the same size due to the different accessories. I used a 2153 mm belt for now as it was the closest fit, but a few mm shorter may be needed. The main vacuum tube bolted directly up to the vacuum pump like it was original.

Thats as far as I am now, I still have to do the following:
Build 3" exhaust
Mock up intercooler size and order
Wire everything and install shifter - will be using the Ole controller for the transmission
Extend heater core hoses to their new homes
Build transmission cross member for the 722.6 mount
Boost hoses, gauge, and EGT gauge
Fuel system - I pulled the pumps from the 560SEL and am going to try to use one of them with a external adjustable regulator in the stock gasser location. If that doesn't do a 044.

Right now I am saving up for a new welder as the china welder I have gave up the ghost on the oil filter housing coolant tube. I'll update the thread when I make some more progress...

This post was last modified: 06-25-2018, 11:40 PM by WSchotty.