Mercedes C250TD Wagon - into - C300TD Wagon..

[hario]

Hello I hail from London but my friends live in Redditch and their garage is bigger than mine so I'm gona do the above mentioned swap up there.


This is my W202 C250TD:


It has standard OM605.960 5 cylinder turbodiesel with Bosch M pump, electronically controlled (EDC). See:


I recon the OM606.962 6 cylinder turbodiesel with Bosch M pump, electronically controlled (EDC), will be plug and play because asside from mechanically haveing one extra cylinder, the electronic controller that connects to the ECU and basically controls the throttle (solenoid fly by wire thing) is identical on both pumps, and the connector is exactly the same. So I bought one for £150 from Polish man:


Evidently they are both very similar engines, they actually share part number with pistons/rods/valves/waterpumps etc

And both engines run 19psi stock. All I have to do is make 4" extra room at the front (move rad / IC forward) to accomodate the longer engine. As this shell came in inline 6 guise from the factory with the C36 AMG I recs its possible.

Basically the ECU reads rpms off the flywheel and moves the solenois on the M pumps for throttle, and modulates same boost pressure through a vacuum solenoid controlling the wastegate actuator. So the ECU has no idea how many cylinders the engine has, its just happy in its little closed loop control system.

I've provisionally sold my 605 5 cylinder engine to a guy also for £150 making this project a net £0 but the 606 has a bad alternator and cut oil cooler lines, so I'm going to have to shell out at least £50 to complete the project (excluding oil / filters but who ads them to project budgets..).

More to follow, Swap wweekend is 28th Feb woo.

[hario]

insert quote here

Oh the 605 makes 150hp and the 606 makes 180 stock, which is good because more is more than less.

I've done various other beer-related mods so I'll upload more as and when, just thgouht I might be able to inspire others to do the same as its such a (relatively) easy swap..

[carat 3.6]

[hario]

GOt Mocal oil cooler because the 606 uses one stock. 3/4" lines, going to buyu 4m of hydraulic hose and get some hydraulic people from Pirtec or similar to crimp them together.



Made a decat section to remove the suitcase cat / muffler.



OEM pipe is 60mm OD so I just bought straights bits and 45o bends from ebay, which were sleeved for 60mm pipe. Fit is very good and clamps up nicely so it 'shouldn't' leak..

[hario]

Factory intercooler is tiny, but to fit a bigger one meant the lower radiator support side brackety things has to go so I fabricated new supports from some bits of SS that sit further outboard to clear the boost hoses.

IC is from an Evo 6, £27 from ebay, bit battered but much better than OEM. Sorry about the blue hose, it's all I had.

[mhuk]

I like it. I have a om606 in my w210 on veg oil. Pulls very well.

[hario]

'Complete' cream leather interior for grandad race:





According to Polish man, complete does not include door cards.

How not to remove an oil cooler.

[mhuk]

It's properly worth swapping the glow plugs (Use Beru make) while the inlet is off and cleaning the EGR too. It's not possible IMO to swap the plugs and clean EGR while it's in the car. I found it a total PITA!

O rings (best for veg oil) www.ebay.co.uk/itm/MERCEDES-DIESEL-VITON-FUEL-O-RING-KIT-ORING-E300D-E300TD-C250TD-W202-W124-W210-/121560056203?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item1c4d8b418b

Hard pipes are MB dealer only I found. I did not bother though.

Also for more boost on mine it's possible to do a resister mod. > www.peachparts.com/shopforum/diesel-performance-tuning/275688-easily-cheaply-increasing-boost-e300-turbo-diesel-w210-606-a.html I used the 11K

If you had the money I would also replace the o rings and fuel hard lines at the IP.

[mhuk]

I fitted water injection...

Veg oil install...

Your C class is going to fly with a 6 pot! Mine is pretty rapid for it's size. Very good cars!

[hario]

Ah yes thanks for the reminder! The 606 magically has new glow plugs fitted!! And all EGR hardware has been deleted, and the C250 ECU does not have a MAF sensor so I don't have to fool anything to avoid limp, and its not an MOT fail, neither is a decat, chop chop chop..

O-rings have been replaced with Viteon equivalents for veg compatibility already thanks. Hard lines are fine, and expensive so they can stay" lol. I just pour neat veg into the fuel tank filler when its warm, and don't in winter..

To increase boost I think I will try a bleed valve at the MAP sensor signal, though it night delay fuelling and give too much lag.

For information: 605 flywheel has 5 tags for rpm pickup, 606 has 6, so flywheels have to be swapped to keep OEM ECU happy. Direct swap and so is torque converter.

[carat 3.6]

Wait, your keeping it auto?

[mhuk]

Sounds like you are well on top of things mate. Really liking this build. Tell me more about the EGR delete please. Thanks

[hario]

Feb 9, 2015 19:34:26 GMT carat 3.6 said:

Wait, your keeping it auto?

Yes the OM605 in the W202 and the OM606 in the W210 both came with the 722.6, and share bellohousings, torque converters, and flywheels (appart from the mentioned 5 & 6 tag issue). I will eventually fit a standalone gearbox controller allowing me to also fit a mechanical fuel pump when I go big power but they aren't very cheap.

I would like to go manual, the 6 speed from the C200K is the easiest fit but it's still not very straight forward, and that box is not very strong either.. :/

[hario]

Feb 10, 2015 9:08:06 GMT mhuk said:

Sounds like you are well on top of things mate. Really liking this build. Tell me more about the EGR delete please. Thanks

EGR delete on the c25OTD? Remove valve and fit streight pipe in the gap now there, blank vavuum signal hose, and make blanking plate to fit over the port now gaping in the exhaust manifold.

[carat 3.6]

Feb 10, 2015 9:37:04 GMT hario said:

Feb 9, 2015 19:34:26 GMT carat 3.6 said:

Wait, your keeping it auto?

Yes the OM605 in the W202 and the OM606 in the W210 both came with the 722.6, and share bellohousings, torque converters, and flywheels (appart from the mentioned 5 & 6 tag issue). I will eventually fit a standalone gearbox controller allowing me to also fit a mechanical fuel pump when I go big power but they aren't very cheap.

I would like to go manual, the 6 speed from the C200K is the easiest fit but it's still not very straight forward, and that box is not very strong either.. :/

If you want a manual go for it. I've got that 6 speed in my 124, 508bhp hasn't broke it yet.)

Cool project getting it to run on the om605 ecu though.

[Phil H]

If your sale of the OM605 falls through, I'll have it off you and you can keep the alternator and cooler lines

[mylittletony]

Feb 9, 2015 14:12:39 GMT hario said:

...not an MOT fail, neither is a decat

I think the rules have changed on this, worth checking... It's only a visual check, so no one would notice if you removed the cat internals and fitted a straight pipe in the casing, obviously that would be naughty though.

otherwise, excellent work!

[hario]

Deposit paid on the OM605 but thanks anyway, loads of C250TD's with short MOT's on ebay for dirt all the time if you need one.

Yes mate I'm friendly with the MOT man so hopefully I can get him to record it as an advisory as it's only tested on smoke output.

The plan is to keep it a secret from the ECU so it suspects nothing and keeps going about business as usual..

[hario]

Engine de-wired, theres one loom on the right hand side which drapes over and down the RH side of the engine for sensors and glowers, and a multiplug for the EDC IP.

Engine tranny pulled out,prop is splined into the centre bearing so it just pulls out, then you wander if the prop is ballanced as an assembly and it needs to be assembled in the same orientation then pretend you didn't have that thought..

Then you realise the 605 and 606 EDC IP plugs are completely different and wander how you missed that..

But then you are thankful that the wire colours match up..

[hario]

Don't realise that you have to hold the TQ onto the tranny to stop them seperating while at the same time don't realise that the tranny communicates its ATF to the TQ through the centre spined shaft and it spills everywhere..

Realise your sneaky friend swapped his curse word 3/8 extension for your pro one..

Less than ideal beer/engine ratio going on, must have been before noon..

OM605.960 flywheel and flexdisk, heavy because of inherent unbalance of 5-cyl?

Compared to OM606.962 flexdisk only, doesn't have FW..