help with superturbo diesel om 603

[anton]

Im planning top build a really fun street diesel-car wit alot of power. The car is a w201 who is in my garage already. I have build gasoline-turbos before, so Im not totally lost about turboinstalling.

But I woder if it not nessesery to lower the compression when you rising the boost. If its nessesery, how and how much should I lower the compression?

About the pump I have already readed that I should send it over to mynä diesel for rebuild.(anyone who knows the costs?) 7mm elements.... But do I need to do something more with the pump? Exept adjusting it..

The turbo I´m planning to use is a hx50. Cause I have one brand new just waiting to be used. It was first ment to be used to a another project.. A new mainfold will be welded up. No problems there, its the funniest part
40mm external wastegate

The intercooler will be a big one. 480mm width and 500mm high. 60mm thick. 2,5" piping.

The tranny is an 5speed getrag with a sinter clutch (2,3 16v)

4" downpipe to 3" exhaust

And there will be an full-aluninium watercooler and bigger oilcooler.

How hig boost is it able to push the engine, without get major damages. Is it able to push 2bar?

If all these things will be done right, how many horsepowers is it abel to get? At the crank of course.

-Anton

[Mauri H.]

Im planning top build a really fun street diesel-car wit alot of power. The car is a w201 who is in my garage already. I have build gasoline-turbos before, so Im not totally lost about turboinstalling.

But I woder if it not nessesery to lower the compression when you rising the boost. If its nessesery, how and how much should I lower the compression?

No, you do not need to lower the compression.

About the pump I have already readed that I should send it over to mynä diesel for rebuild.(anyone who knows the costs?) 7mm elements.... But do I need to do something more with the pump? Exept adjusting it..

No, you don't need to do anything else after Mynädiesel has worked on the pump. Costs are about 800-1000 €

The turbo I´m planning to use is a hx50. Cause I have one brand new just waiting to be used. It was first ment to be used to a another project.. A new mainfold will be welded up. No problems there, its the funniest part
40mm external wastegate

The intercooler will be a big one. 480mm width and 500mm high. 60mm thick. 2,5" piping.

The tranny is an 5speed getrag with a sinter clutch (2,3 16v)

4" downpipe to 3" exhaust

And there will be an full-aluninium watercooler and bigger oilcooler.

How hig boost is it able to push the engine, without get major damages. Is it able to push 2bar?

Yes, OM603 can handle 2 bar easily, but I wouldn't use much more than that because you might bend a rod or blow you head gasget when using too much boost, 2.2 - 2.3 is the maximum.

If all these things will be done right, how many horsepowers is it abel to get? At the crank of course.

-Anton

You could expect 430 hp or more.

ps. OM603 and W201 means a lot of work.

[anton]

But with my setup, how many hp is this able to? And I don´t find it so hard to get the 603 in the w201. And this evening I have also bought an Mercedes sprinter clutch.

[Mauri H.]

But with my setup, how many hp is this able to? And I don´t find it so hard to get the 603 in the w201. And this evening I have also bought an Mercedes sprinter clutch.

Sprinter clutch will not hold.

Maybe you can get around 430-470 hp, it also depends a lot which type of dynamometer you use.

Well, hard and hard, it is a small room but it can be done. You see the results when you are done

[Hans]

Lycka till med bygget och kom ihåg att lägga upp bilder här på forumet!

Det kommer onekligen att bli jävligt trångt!
Här är några bilder från Jormas( turbospecialist på dettta forum) projekt
http://img.photobucket.com/albums/v296/ ... kti013.jpg
http://img.photobucket.com/albums/v296/ ... kti003.jpg
http://img.photobucket.com/albums/v296/ ... kti002.jpg
http://img.photobucket.com/albums/v296/ ... kti005.jpg

[anton]

If I send the IP away to mynä diesel, do I need all the electrics to the pump? ELR I think its named. Type of electric revcontrol. I don´really know.

Hans: Maybe I´ll take some pictures during the building. There is many forums I´m visiting.

[anton]

Is there anyone who knows the boschnumber for the 7mm elements?

[Mitch H]

I think the 7mm elements are not Bosch. Mynädiesel will sell them to you, I believe the price is around 50 euro each. Having Mynädiesel perform the rebuild on a pump is cheaper than buying the elements and having my local Bosch shop rebuild the pump. You can send a personal message to Antti A. at Mynädiesel through this forum if you have questions about his pump work.

I have a question. Can a clutch and flywheel from a 270CDI Sprinter engine fit on a OM602 and a 2.3-16v transmission? Will this clutch hold 350 ft-lb or 470 Nm?

[rodion]

AFAIK Sprinter 270CDI has only 330Nm. In the C or E-Class the 270CDI has 370Nm. But you do not have much options on clutches because the 270CDIs were the biggest machines, which you could buy with manual gearbox.

cu Rod

[canonballman]

ps. OM603 and W201 means a lot of work.

Can you explain this a bit further please?
-engine mounts?
-cutting/welding the chassis?
-16v getrag gearbox in original place?
-make more room at the front of the car for radiator/IC?

Seems to me that width is not the problem, but LENGTH.....

[canonballman]

Lycka till med bygget och kom ihåg att lägga upp bilder här på forumet!

Det kommer onekligen att bli jävligt trångt!
Här är några bilder från Jormas( turbospecialist på dettta forum) projekt
http://img.photobucket.com/albums/v296/ ... kti013.jpg
http://img.photobucket.com/albums/v296/ ... kti003.jpg
http://img.photobucket.com/albums/v296/ ... kti002.jpg
http://img.photobucket.com/albums/v296/ ... kti005.jpg

Anyone happen to know which make/brand intercooler Jormas is using? And where to get one? Dimensions should be about 40 by 50 cm, when I look at the first picture.
All I can find are FMIC that are just 30 cm in height.....

[Mauri H.]

Lycka till med bygget och kom ihåg att lägga upp bilder här på forumet!

Det kommer onekligen att bli jävligt trångt!
Här är några bilder från Jormas( turbospecialist på dettta forum) projekt
http://img.photobucket.com/albums/v296/ ... kti013.jpg
http://img.photobucket.com/albums/v296/ ... kti003.jpg
http://img.photobucket.com/albums/v296/ ... kti002.jpg
http://img.photobucket.com/albums/v296/ ... kti005.jpg

Anyone happen to know which make/brand intercooler Jormas is using? And where to get one? Dimensions should be about 40 by 50 cm, when I look at the first picture.
All I can find are FMIC that are just 30 cm in height.....

I have one of those for sale. It is 50x60 cm + tanks on both sides. Should say it's big enough

Used for 5000 km, just wash it and it is as good as new.

http://www.mersuforum.net/forum/viewtopic.php?t=44594

[Forced_Induction]

AFAIK Sprinter 270CDI has only 330Nm. In the C or E-Class the 270CDI has 370Nm. But you do not have much options on clutches because the 270CDIs were the biggest machines, which you could buy with manual gearbox.

cu Rod

Wasn't the C30 CDI AMG offered with a manual transmission? It had 540 nm / 398.3 ft lbs of torque.