Mercedes C250TD Wagon - into - C300TD Wagon..

[hario]

Figureing out the torque converter and flywheel swap fitment took ages, lots of wiggling to seat things, no mechanical interferenced though. (ECU calculated revs from flywheel and the number of pickup tags are different on the 605/606 hence the swap.
Lots of wood for the burner to keep us warm over the weekend!

USed original 605 engine mounts to keep the bellhousing in the same place so we wouldnt have to fab tranny mounts / propshaft length change etxc. It fits, verylong mind..


SHowing 605 EDC plug on right and 606 plug on left, I must stop assuming things are going to fit.. Wire colours matchned up fine tho.

Wired ready for test fire.


I need to compress the vid so I can add it..

[hario]

Its looking very mean my C300...

I can confirm that broccoli-cheese is awesome, sweet potato mash is awesome too.

Getting build up with ancils..

HEater pipes don't line up, heater circ pump fits the turbo, rad hoses need shortening by a few inches, airbox doesn't sit on OEM mounts, rad needs to go forwards 4" even with mech fan and visco coupling in the bin.

But it does all go..

Less than 2" between rad and pulley, something needs to be done!

[hario]

Mostly piped and wired. Had to extend breather beteween rocker and turbo inlet.

Very tight.

Had to space the ARB down about an inch with some bits of rusty box section with too-thin a wall section to be safe, just to be safe.. Hard boost hoses out of the turbo didnt fit, had to be ninja bent and have all brackets thrown in the bin. (and not replaced).

Photo doesn't show proportion but there is about 1/2 - 3/4" of clearance between the two, the sump sits more behind than above the ARB.

Tranny cooler lines shown there do fit but they are tight due to -4" less room.

[hario]

I decided to cut out the inner half of the front X-member for clearance, gave about 2" more fore aft room. Just drilled the spot welds then hacksawed the inner at each end..

Fortunately I have loads of boost hoses spare ferom a job lot I bought for when things like this happen..
Had to go down to 2" Samco for the hotside into IC, rest is 2.5". Clearance levels approaching that of the Ninja again..

Seems legit?


Got to get rid of those stupid blue/red aero fittings..

[hario]

Oh yeah I had to sacrifice the lower bumper mounting brackets, it has 4-off which mount approx at each corner of the rad, the boost hoses now occupy the spsce where the bottom ones were, seems fine though as the bumper is alwo mounted on positively engaged rails on either side wrap around end things..

[hario]

The autobox only has a belden cable, mechanical linkeage to shifter for parking lockout, big multipin plug for ECU and an earth strap so reconnecting was a breese, prop splines are bevelled so that slipped right in also, gigidy.

I'm glad it looks veery OEM!



All thats left to do is refill the autobox and connect 6" of the E300 DP coming out the turbo to the W202 DP, unfortunately the E300 turbo points down more therefore the DP will need some wedges cut out and rewelding to point it up a bit as the W202 has a box and W210 (E300) has a rack. Not a problem but we just ran out of time on the weekend.

[hario]

So now I have a C300TD with 180hp & 250 lb/ft before I've even started tuning! First port of call is to fit a needle bleed valve to the map sensor to fool the ECU into thinking boost is lower thus causing the ECU to hold the wastegate closed to give more beans, though it may delay the detection of onset of boost by the ECU which would then hold off the fuelling causing more lag. Will try and see.

Runs mostly:

<iframe width="1280" height="720" src="https://www.youtube.com/embed/NUgUJ2jkB_M" frameborder="0" allowfullscreen></iframe>

[hario]

For test run connection of the 606 IP wiring into the W202 loom plug

Were properly running out of storage at this point..

[Stu]

Great read, really enjoying this :-)

[gavs1]

Found it, would like to no more on your boost trick, stripped the curse word out of our e300 and God gosh what a new animal, decat done remap was aborted due to ic pipe split, oh and 50 shot dry nos

[hario]

It is simple, because the ECU controls the wastegate, if you bleed off some of the boost signal going to the MAP sensor then the ECU will think the turbo has not achieved desired boost and it will hold the wastegate closed and an overboost situation will occur but the ECU will be unaware.

[hario]

Wrapped the steering box hard pipes with that NASA looking thermal wrap stuff, only cost £10/meter from internets.


Fitted E300 turbo outlet pipe to C250 DP..

Not too much cutting needed.

[hario]

I will have to make a driving video as soon as it passes its MOT (failed on balljoint and indicators not yellow enough).

I have to make this video because depsite the OM606 being standard, it has made the W202 chassis drastically faster, and it lights up the back wheels in anything other than bone dry. This car is now very fast.

I havent turned the boost up yet, more to follow.

[tdipd]

are you able to give us a definitive list of the steps and parts required for such a swap? i'm very keen to do this in the future, but would love to change to a mechanical controlled IP way down the line.

[hario]

Mar 10, 2015 18:58:50 GMT tdipd said:

are you able to give us a definitive list of the steps and parts required for such a swap? i'm very keen to do this in the future, but would love to change to a mechanical controlled IP way down the line.

Hah yes I can do that. I haven't really missed anything apart from having to make some heater pipework up for the rear heater fitting on the block which is in a different place.
I shall add a list.

[hario]

Klack klack klack.. Runs perfectly on the OEM ECU, it had to warm up to unstick that pumped up lifter.

It was about dinner time Saturday at that point, well drunk,  we started disassembly on the Friday night the day before. 

[hario]

So we had some rust issues, 1" drain hole turned into big brown monster, thoughtt it was into a hollow chassis section full of foam and after tearing loads out using pliers I realised it was a rear passenger footwell and I'd ripped out most of the carpet underlay.. LOL

Redoxide red because racecar..

Nice easy patch to do with top access for sure!

[hario]

My latest Redditch car boot haul was £15 for all this!! All Halfords Pro/Advanced, suspiciously good condition..

[hario]

Front spring perch corrosion:


This is caused by poor paint / mastic at the joint, but mine was only corroded on the outside edge! Completely bemused as to how and why its so localised!



Extra drunk careful marking out cuts adhered to here:



Seamed 2mm for the repair



Red because racecar.



Then we realised the grinder shield fits percfectly! Gona use that for patch material next time!!

[hario]

Another MOT fail was the delaminating number plates, so I got some pressed aluminium ones from eBay, £20 delivered for the pair, gives it a kind of euro look:





Tailgate dent was from drunk pushing it around our steep as hell drive. Damn it..