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OM 612 270cdi G-Wagon Torque Monster build
Matthias4x4 Offline
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#1
OM 612 270cdi G-Wagon Torque Monster build
Hello to all common rail specialists here. I need your mind.

I have rebuilt a G Wagon with a 270cdi engine and 722.6 gearbox. Frame and body are now finished. The vehicle should become a daily driver with whom I can also pull trailers. Can smoke black but should not produce a solar eclipse!

Start is an Om612 with original 150 hp with 1.2 bar boost pressure GT2256v turbo and original air water intercooler.

My goal is to get over 200 horsepower (that would have to be about 260 HP on the engine) and a torque of about 500NM that starts in very low engine speeds.

I've already thought a few things about:

1. A Turbocharger with milled compressor wheel. but what?
them original GT2256V or GT2359v I have both but what should I do that gives me a good torque band and still promotes enough air at high engine speeds.

2. Intercooling on air-air with a largest possible cooler I get in the front. (Measurements at 10 degrees outside temperature have shown that
Charge air temperature after 10 seconds full load increases to about 60 degrees and even further - I think that is not optimal).


3rd EGR is closed and the swirl flaps I want to disassemble and close.

4. Change the charge pressure sensor to a 4 bar sensor to avoid any problems with pressure peaks.

5. The topic with the cp3 pump and the injectors does not want to tackle, because I want to test first how much I get out with sofwaremod turbo and intercooler --- or will it not be enough with the modifications.

I hope there are more that have something about the head broke and maybe already built something

I am open to suggestions that have already been tested and grateful
03-22-2019, 04:23 AM
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bqik Offline
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#2
RE: OM 612 270cdi G-Wagon Torque Monster build
Remember that  your 722.6 is not the highest input torque transmission.

I would not recommend going higher than 480Nm.
03-22-2019, 08:36 AM
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Matthias4x4 Offline
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#3
RE: OM 612 270cdi G-Wagon Torque Monster build
Thank you for your answer. I have already taken that into account and built a gearbox of a 400cdi (V8) with a reinforced torque converter. bell housing rebuilt and hole drilled for the rear rotary sensor. I think that can stand it.

but I would like to know how to get there without injectors and CP3, if at all?
03-22-2019, 09:30 AM
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INC Offline
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#4
RE: OM 612 270cdi G-Wagon Torque Monster build
Better look for C30AMG donor car, and swap engine.
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03-23-2019, 01:50 PM
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AlanMcR Offline
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#5
RE: OM 612 270cdi G-Wagon Torque Monster build
(03-23-2019, 01:50 PM)INC Wrote: Better look for C30AMG donor car, and swap engine.
I've thought about that too.  Don't think many were made, and those that were made have probably been flogged pretty vigorously by now.
(This post was last modified: 03-24-2019, 01:13 AM by AlanMcR.)
03-24-2019, 01:12 AM
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Matthias4x4 Offline
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#6
RE: OM 612 270cdi G-Wagon Torque Monster build
Thank you for your help,

I have already built a W463 with om 606 in the past and with Ole contoler he was also quite funny but that is not a daily driver. ninimum 16 liters on om 606 and trailer 20 liters, but it was fun !!
   

Furthermore, I have a en Bus W602 4x4 where an Om605 Superturbo comes in.


I have now come across the Comon rail because the torque is easier to generate from below. I drive with the vehicle about 40000 km a year so that's already in the weight.
And yes it is time that you get old engines from junkyard 612 dispensers cost with gear about 800 euros. So can ever go up a motor and it does not hurt so much in the purse.

On the subject of C30 AMG first are the so rare here in Europe that you can get donations 1000km far to 4000Euro then you have to rebuild the whole engine and what can the standart engine ???? Crankshaft camshafts Injectors Pump and intercooler ECU is different but at these prices.

Many are already starting to build 613 engines and I think that's good (he would also like to do it just because he does not fit into the vehicle)

There must be people who have already worked on the 612.
03-24-2019, 01:18 PM
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AlanMcR Offline
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#7
RE: OM 612 270cdi G-Wagon Torque Monster build
Matthias4x4, that looks exactly like a factory OM606 setup (W463.33x). I have one.
What G did you start with? It must have been a 1997+ I6 engine.
03-25-2019, 12:08 AM
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INC Offline
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#8
RE: OM 612 270cdi G-Wagon Torque Monster build
I bought donor C30AMG, and with standart hardware and stage 1 chip get 282ps and 700nm on dyno. I`m planing swap engine in my G270.
Good turbo cost ~1000eur, AMG injectors 1000eur, HP fuel pump 200eur, better cooler 500..1000eur and many working hours.

C30AMG is cheapest option.

613 is good option, but its not straight fit, and its heavy.
G300TD(OM606.964) & 250GD(OM605.960)Trophy raid
03-26-2019, 03:00 PM
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barrote Offline
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#9
RE: OM 612 270cdi G-Wagon Torque Monster build
Hope u're lucky with it... CDI engines don't las as 606.
I've heard rumours about the D30 612...
FD,
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03-27-2019, 02:37 AM
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Matthias4x4 Offline
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#10
RE: OM 612 270cdi G-Wagon Torque Monster build
i now the good olt engines!!!! I can confirm that.

I have an om612 from a E-class I want to rebuild!
When the cultivation components are selected, it will then be completely in the G vehicle.

until then, I'm on the G-Wagon so that I can confirm the changes.

Question: How does a GT2359v behave from an Om612 to an OM612? with software change. Turbo lag from the bottom revs out ?? more air above? responsiveness ??

Does anyone have experience?
03-27-2019, 05:20 AM
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baldur Offline
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#11
RE: OM 612 270cdi G-Wagon Torque Monster build
(03-27-2019, 02:37 AM)barrote Wrote: Hope u're lucky with it... CDI engines don't las as 606.
I've heard rumours about the D30 612...

My father owns a Sprinter 416CDI (OM612) with 1.3 million km on the odometer, supposedly original bottom end and cylinder head has been replaced once.
Baldur Gislason

03-27-2019, 09:51 AM
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barrote Offline
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#12
RE: OM 612 270cdi G-Wagon Torque Monster build
Un iceland roads... haha. No they do not hold half the 605
For the turbo question i had a 612 engined car with a 2359... in stock fuel it lag a bit
FD,
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03-28-2019, 10:40 AM
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Turbo Offline
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#13
RE: OM 612 270cdi G-Wagon Torque Monster build
my old 270 cdi om612 holded for 790 000km, one injector got open all time and blow a hole in one piston, but I did feed it with 2000bar when it happen...
03-29-2019, 11:55 AM
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Matthias4x4 Offline
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#14
RE: OM 612 270cdi G-Wagon Torque Monster build
to barrote: with stock fuel you mean stock software? or have you modified the software?
04-01-2019, 01:08 AM
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barrote Offline
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#15
RE: OM 612 270cdi G-Wagon Torque Monster build
Stock soft= stock fuel. Unless i miss something,
FD,
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04-01-2019, 04:23 AM
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Matthias4x4 Offline
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#16
RE: OM 612 270cdi G-Wagon Torque Monster build
Thx for info! I try it first with softmod
04-02-2019, 01:38 AM
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Matthias4x4 Offline
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#17
RE: OM 612 270cdi G-Wagon Torque Monster build
(03-26-2019, 03:00 PM)INC Wrote:
I bought donor C30AMG, and with standart hardware and stage 1 chip get 282ps and 700nm on dyno. I`m planing swap engine in my G270.
Good turbo cost ~1000eur, AMG injectors 1000eur, HP fuel pump 200eur, better cooler 500..1000eur and many working hours.

C30AMG is cheapest option.

613 is good option, but its not straight fit, and its heavy.
Hi in the last weeks i sort your advice. I chek all wiring diagramms from w203 c30 cdi and my G Waggon. The engine fitt‘s in SAM Canbus EZS ESL coding all no problem BUT only one! The abs esb unit not accept the ecu (error communication), this means you can not bring the abs,esb to work! And you have the errorlamp always on! If you have a w463 before 2000 it’s possible without issues! The ecu  is immo off with julie emulator (virgin ecu dont bring Sense) gearbox and ecu works together. And its not on the immochip i try 3 different cars! 
Or have anybody a clue?
05-17-2019, 01:54 PM
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INC Offline
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#18
RE: OM 612 270cdi G-Wagon Torque Monster build
(05-17-2019, 01:54 PM)Matthias4x4 Wrote:
(03-26-2019, 03:00 PM)INC Wrote:
I bought donor C30AMG, and with standart hardware and stage 1 chip get 282ps and 700nm on dyno. I`m planing swap engine in my G270.
Good turbo cost ~1000eur, AMG injectors 1000eur, HP fuel pump 200eur, better cooler 500..1000eur and many working hours.

C30AMG is cheapest option.

613 is good option, but its not straight fit, and its heavy.
Hi in the last weeks i sort your advice. I chek all wiring diagramms from w203 c30 cdi and my G Waggon. The engine fitt‘s in SAM Canbus EZS ESL coding all no problem BUT only one! The abs esb unit not accept the ecu (error communication), this means you can not bring the abs,esb to work! And you have the errorlamp always on! If you have a w463 before 2000 it’s possible without issues! The ecu  is immo off with julie emulator (virgin ecu dont bring Sense) gearbox and ecu works together. And its not on the immochip i try 3 different cars! 
Or have anybody a clue?
You see abs data on CAN? Wheel speed and stop lamp switch?
G300TD(OM606.964) & 250GD(OM605.960)Trophy raid
05-21-2019, 02:33 PM
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Matthias4x4 Offline
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#19
RE: OM 612 270cdi G-Wagon Torque Monster build
(05-21-2019, 02:33 PM)INC Wrote:
(05-17-2019, 01:54 PM)Matthias4x4 Wrote:
(03-26-2019, 03:00 PM)INC Wrote: I bought donor C30AMG, and with standart hardware and stage 1 chip get 282ps and 700nm on dyno. I`m planing swap engine in my G270.
Good turbo cost ~1000eur, AMG injectors 1000eur, HP fuel pump 200eur, better cooler 500..1000eur and many working hours.

C30AMG is cheapest option.

613 is good option, but its not straight fit, and its heavy.
Hi in the last weeks i sort your advice. I chek all wiring diagramms from w203 c30 cdi and my G Waggon. The engine fitt‘s in SAM Canbus EZS ESL coding all no problem BUT only one! The abs esb unit not accept the ecu (error communication), this means you can not bring the abs,esb to work! And you have the errorlamp always on! If you have a w463 before 2000 it’s possible without issues! The ecu  is immo off with julie emulator (virgin ecu dont bring Sense) gearbox and ecu works together. And its not on the immochip i try 3 different cars! 
Or have anybody a clue?
You see abs data on CAN? Wheel speed and stop lamp switch?
Yes i see all ! The Abs esp unit work , only the comunication between Enginge ECu and Abs unit not work . i can read all erase all.ect i triet the ecu in other cars top . it´s the same Problem!
05-24-2019, 05:09 AM
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INC Offline
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#20
RE: OM 612 270cdi G-Wagon Torque Monster build
(05-24-2019, 05:09 AM)Matthias4x4 Wrote:
(05-21-2019, 02:33 PM)INC Wrote:
(05-17-2019, 01:54 PM)Matthias4x4 Wrote: Hi in the last weeks i sort your advice. I chek all wiring diagramms from w203 c30 cdi and my G Waggon. The engine fitt‘s in SAM Canbus EZS ESL coding all no problem BUT only one! The abs esb unit not accept the ecu (error communication), this means you can not bring the abs,esb to work! And you have the errorlamp always on! If you have a w463 before 2000 it’s possible without issues! The ecu  is immo off with julie emulator (virgin ecu dont bring Sense) gearbox and ecu works together. And its not on the immochip i try 3 different cars! 
Or have anybody a clue?
You see abs data on CAN? Wheel speed and stop lamp switch?
Yes i see all ! The Abs esp unit work , only the comunication between Enginge ECu and Abs unit not work . i can read all erase all.ect i triet the ecu in other cars top . it´s the same Problem!
Then use can filter from http://www.autokey.com.ua/CAN%20FILTER/canfilter.html

And filter abs fault code in can. Works great.
G300TD(OM606.964) & 250GD(OM605.960)Trophy raid
06-01-2019, 11:12 AM
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