hario
Part of things
S202 C300STD
Posts: 421 
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The project is all finished and running, appart from a fault where it gets warmed up and runs fine and adter 20 minutes the engine shuts off and won't restart until its completely cooled down!?!?!
Thoughts and input welcome and appreciated! No faults appear on STAR diags, just shuts off like you've turned the key, no overheating or any other issues, all we have to try it a new rpm sensor.. If that doesn't work then its f&%ed.
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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Congratulations on an amazing and well thought out economy transplant!!! And still with impressive results, over record time!
The cut out problem, I am sure, you will resolve shortly.
I am convinced that your method is the quickest and easiest. A question though... Keeping in mind necessary changes to propshaft, shifter, engine and transmission mountings, etc., I wonder though, if you have moved the engine back, whether it would have improved the car's balance (between front and back)and if the (likely) elimination of space restrictions/problems regarding radiator and coolers, would have been a comparable alternative approach. That of course if there were any room left behind the 605 to start with.
Could there be another solution instead of swopping the flywheels or do I overestimate the possible benefits?
As a remark only, I guess that the cost of a conversion to a stick shift and the gain in fuel consumption would hardly be a cost effective change. Though I believe the majority of us would prefer to do the changing ourselves!
Add my name to those awaiting the step by step guide! I guess quite a few diesel 250's are awaiting wings added.
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1986 Mercedes 200 (W124) (Standard and daily)
1976 Peugeot 404 1800 Stickshift (Standard - awaiting complete resto, engine done)
1984 Ford Cortina (P100) LDV - Cab and chassis restored, interior and glass not fitted, brand new 3 liter engine (last 110kw Sierra XR6 engine fitted and married to 5 speed Toyota Gearbox), load body needed.
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hario
Part of things
S202 C300STD
Posts: 421
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Apr 10, 2015 20:15:16 GMT
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Hi mate thank you very much, I am quite impressed with my own results also..
I used the original 605 mounts to sit the engine as back as originally, there is 5mm between head and bulkhead, he 606 mounts would have sat it 1" forward.
The flywheel was only swapped to keep the original ecu happy with the rpm's, otherwise it would have regulated the idle speed 1/6th slower than it should be (600 not 700). The flywheel didn't affect gearbox mounting at all, the entire transmission is stock, ideally I would have bought a manual c250 to begin with but they are rare, the 6 speed manual and flywheel and clutch from the c220/e220 cdi is a direct swap to the mounts and engine, but I think you need the prop from a manual w202, this option allows a mechanical IP to be fitted and the entire ecu control removed from the running gear, currently I would need a standalone controller for the 722.6 auto.
Regarding your weight distribution issue, to be honest it handles well, it doesn't under steer hardly, and more foot counteracts that anyway, personally it's not worth the effort, and it's most fun on a straight line as it launches like a whore.. Lol. Cutting the front panels for clearance is easy anyway.
Few beers in and I'm writing this on my phone and I can't remember what else you said.. Ha
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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hario
Part of things
S202 C300STD
Posts: 421
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Apr 10, 2015 20:23:55 GMT
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The 6 speed box can be had for £150/200, and the gearbox mount is a direct fit to the chassis, again prop might need to be shortened, but I know a kit car company that will cut and balance to your dims for £80
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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hario
Part of things
S202 C300STD
Posts: 421
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Apr 13, 2015 12:37:58 GMT
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Crank speed sensor was the fault! The only sensor I left on the donor engine god!! Grr I'll make a driving video and scheduled out instructions for the conversion soon. Euro plates and bumper cutouts complete:   |
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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Apr 13, 2015 13:07:25 GMT
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This is mental! Certainly very different to the cars I'm used to seeing.
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hario
Part of things
S202 C300STD
Posts: 421
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Apr 13, 2015 14:25:01 GMT
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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.. What the fook is that Veilside RX7 doing photobombing my photo?!?! Pahah I didn't even see that! |
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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hario
Part of things
S202 C300STD
Posts: 421
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Apr 13, 2015 14:44:13 GMT
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Heat wrapped the downpipe as it passes very close over the steering box now that the turbo is further forward than with stock 605, thw wrap also covers up our shoddy welding, it seems to be some kind of very itchy GRP and was a tenner. DP is now warm to the touch when fully warmed up mind..  Perhaps a clearer shot of how we fitted the Mitsubishi Evo6 intercooler, those hoses may be blue and red and awful but they are genuine junkyard found Samco. I would like to open out the front crossmeber and add air inlets in the bumper, but simple ducting may be just as effective and less visually damaging than bumper holes?  This shows the length of the engine and (poorly shows) the lack of clearance between visco fan mount and radiator.I wonder if the MOT guy will notice it has more cylinders than when he MOT'd it last month.. LOL |
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Last Edit: Apr 13, 2015 14:48:07 GMT by hario
*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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May 15, 2015 20:55:14 GMT
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No news, I take it, means good news on this project...?
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1986 Mercedes 200 (W124) (Standard and daily)
1976 Peugeot 404 1800 Stickshift (Standard - awaiting complete resto, engine done)
1984 Ford Cortina (P100) LDV - Cab and chassis restored, interior and glass not fitted, brand new 3 liter engine (last 110kw Sierra XR6 engine fitted and married to 5 speed Toyota Gearbox), load body needed.
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hario
Part of things
S202 C300STD
Posts: 421
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Aug 26, 2015 16:21:14 GMT
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Yes it's fine, I drove it to Bordeaux from London 2 weeks after my last post. I'm actually in the process of organising a return trip so I can continue the build, with regards to engine tuning and various other small projects: Shell refurbishment, rad-rod looking roof rack, stand-alone gearbox controller, Holset turbo, built pump, big brakes, arb's, line locker, manifold, etc, etc....  |
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Last Edit: Aug 26, 2015 16:22:24 GMT by hario
*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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hario
Part of things
S202 C300STD
Posts: 421
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Sept 15, 2015 13:12:50 GMT
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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. As requested:  Sorry it's a bit late.. |
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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Sept 15, 2015 14:37:01 GMT
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I am sue many are interested in this.
This remains one of my most admired conversions - something that really works AND look factory or at least not shabby! And your results probably prove that the mighty Mercedes should have built this car themselves!
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1986 Mercedes 200 (W124) (Standard and daily)
1976 Peugeot 404 1800 Stickshift (Standard - awaiting complete resto, engine done)
1984 Ford Cortina (P100) LDV - Cab and chassis restored, interior and glass not fitted, brand new 3 liter engine (last 110kw Sierra XR6 engine fitted and married to 5 speed Toyota Gearbox), load body needed.
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hario
Part of things
S202 C300STD
Posts: 421
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Moderate levels of progress   |
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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wow..amazing work in a very short time!
very cool
JP
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I know its spelled Norman Luxury Yacht, but its pronounced Throat Wobbler Mangrove!
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benjy_b
Yorkshire and The Humber
Posts: 409
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If you fancy a manual conversion, I'll sell you all the appropriate items for CHEAP ;-)
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2005 Subaru Forester 2.5XT
1999 BMW E36 318i Touring with OM605 Mercedes Engine
1996 Lada Riva with Honda S2000 Engine
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juggs
Part of things
Posts: 151
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Hey very impressed with this swap, have saw it over on the merc forum think it's great your willing to share the info with others as OM series tuning info is a bit thin on the ground in the UK. I also have a c250, waited like 8 months constant searching to find a manual estate that wasn't rotten beyond repair! As for the boost bleed mod, have you tried this now if so how have you found boost response? I was toying between trying this out or converting my stock gt20 turbo to use a manual pressure driven actuator, not sure how the Ecu would get on having no control??.. Currently it will spike to around 23-24psi & tail off to around 18 with the rack sensor mod. Cold conditions 4th or 5th gear can see 25psi spike which throws the car into limp mode as I presume it see's over boost. Good luck with the rest of your build & if you stick with the electric pump for a while let me know as I have a couple of contacts for people UK/Ireland based who may be able to sort out a tune with raised torque limits & boost cut delete  |
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Last Edit: Feb 2, 2016 9:07:35 GMT by juggs
Currently cut down the fleet, Pulsar gti-r, sierra v6, E36 328i.. currently looking for crude oil...
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hario
Part of things
S202 C300STD
Posts: 421
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Wheel bearing was borked and I don't even have a drive now..   |
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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hario
Part of things
S202 C300STD
Posts: 421
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2006 S500 AMG (w220) brembo calipers fit. just need W203 AMG cdi discs. (330mm)   |
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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hario
Part of things
S202 C300STD
Posts: 421
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OIl cooler (long) and ATF cooler (square) bought   ATF cooler will go in front of OSF wheel similar to stock E300TD engine oil cooler placement. I will have to get creative with that long oil cooler's mounting brackets... |
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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hario
Part of things
S202 C300STD
Posts: 421
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Original idea for the turbo manifold, unfortunantely the runners would stick out too far and interfere with the DP and steering box..  |
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*S202 C300TD Wagon*
Installed:
OM606 & 722.6, Evo6 IC, S600AMG callipers & 345mm rotors. No catz. Leatherish seats.. Rust..
Future:
DIY manifolds & turbo compound build.
Built IP, & some kind of software. Less rust..
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