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Old 10-22-2021, 12:25 PM   #126
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Yeah, that's my job.
yea in alot of ways i wish it was more down and dirty, its more of a mall crawler now
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Old 11-08-2021, 05:57 PM   #127
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Did a few dump runs with the car today, towed a trailer full of gravel on one trip. Weighed the car and suprisingly the car weighs 3320 lbs with a full tank of fuel!
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Old 01-05-2022, 03:37 PM   #128
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Well as exciting as the thrash was to get the car going quickly I have to say this is by far the most boring build I've ever done. Not in a bad way at all really, everything just seems to be working on the car. I've daily driven it for months now and gone on a few road trips with it and nothing is bugging me or breaking. The car has been extremely reliable, ever since I moved the trans controller screen down by the shifter it made accessing the manual shift easier so I put the stock shifter back in. Cruise control have been working with 0 issues, the ac has been working flawlessly. The only thing I have done was install a LOJ heater core bypass block to keep the temps in check. The damn engine doesn't even burn oil even after nearly half a million miles. The car gets so much attention(too much if I'm being honest), and I've had multiple offers on it. It's almost at the point where I want another 240 that has issues so I have one to work on .
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Old 01-05-2022, 05:03 PM   #129
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Go jump it off some dunes?
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Old 01-05-2022, 05:48 PM   #130
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Well as exciting as the thrash was to get the car going quickly I have to say this is by far the most boring build I've ever done. Not in a bad way at all really, everything just seems to be working on the car. I've daily driven it for months now and gone on a few road trips with it and nothing is bugging me or breaking. The car has been extremely reliable, ever since I moved the trans controller screen down by the shifter it made accessing the manual shift easier so I put the stock shifter back in. Cruise control have been working with 0 issues, the ac has been working flawlessly. The only thing I have done was install a LOJ heater core bypass block to keep the temps in check. The damn engine doesn't even burn oil even after nearly half a million miles. The car gets so much attention(too much if I'm being honest), and I've had multiple offers on it. It's almost at the point where I want another 240 that has issues so I have one to work on .
Well, I can just Michael Baker it for you if you'd like.
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Old 01-05-2022, 06:25 PM   #131
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Well, I can just Michael Baker it for you if you'd like.
absolutely not
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Old 01-06-2022, 02:26 AM   #132
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absolutely not
I could Michael Baker it for you if you want
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Old 01-06-2022, 04:20 AM   #133
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I could Michael Baker it for you if you want
absolutely not
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Old 01-06-2022, 12:36 PM   #134
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absolutely not
I am not pornotaco, but I play OmegaDC on TB
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Old 01-06-2022, 12:45 PM   #135
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I could Michael Baker it for you if you want
Lol
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Old 01-06-2022, 01:13 PM   #136
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It's almost at the point where I want another 240 that has issues so I have one to work on .
You could get a 242 and do a 16v Redblock. That should give you plenty to do.
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Old 01-06-2022, 11:14 PM   #137
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I have a few problem childs lol
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Old 01-07-2022, 03:39 AM   #138
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If it's not breaking enough just add power until it does
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Old 01-07-2022, 01:43 PM   #139
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If it's not breaking enough just add power until it does
ill get one of those when i want the engine to run bad and melt the prechambers again haha. ill get a meken if anything
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Old 01-11-2022, 02:32 PM   #140
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Spoke to soon allegedly! The delivery valves in my pump started leaking fuel everywhere. I had a hard/no start the other day. The car usually starts very quickly and it was acting like there was air in the fuel system. Either way I get to work on it! I'm going to do a few minor mods while I'm in there to clean it up. I noticed one of my injector leak off lines was leaking so that will get addressed as well. The previous owner dinged up the barbs pretty bad so I'm suspecting that's my issue. It will be a good time to recheck the injectors as well and inspect the prechambers balls. May go ahead and do glow plugs as well. Easy stuff
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Old 01-17-2022, 06:26 PM   #141
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Ended up getting some unexpected time off due to contracting the Rona. So I tackled the delivery valves today. Got all the seals and crash washers done. Found 2 bores completely drained of fuel so that's actually nice to see. I installed the om603 fuel pump and filter housing and pre filter as well. Just waiting on my fuel line to show up from McMaster Carr later today.







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Old 01-18-2022, 06:40 PM   #142
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Got the om603 lift pump, filter housing and pre filter installed took about 2 minutes of cranking to bleed the pump and the fuel system. Used tygon semi clear diesel hose for everything and copper washers so I deleted all of the o rings that are prone to leak under vibration and age. Turned the idle down to 600rpm with the ac engaged and it smoothed out quiet a bit the rack position also helped fuel milage a little bit it seems.
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Old 01-18-2022, 07:14 PM   #143
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Tygon is the best hose. I used it on the om617, it was nice to watch the air bubbles dance around.
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Old 01-18-2022, 08:14 PM   #144
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Tygon is the best hose. I used it on the om617, it was nice to watch the air bubbles dance around.
Yea the plastic lines are clear for a few months unless you cycle alot of fuel through them and even the factory plastic stuff rubs on everything
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Old 01-24-2022, 01:14 AM   #145
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Final piece of the puzzle for the engine. Got the turbo engine cover. Looks alot better and was super hard to find.

Old

New


Also bought a w124 off face book market place that ran amazingly well. Just grabbed it for a spare engine. It's amazing how much better a 300k Mercedes drives then a 100k Volvo





Cleaned up this thing a bit today. Mulling over what to do with it
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Old 01-28-2022, 07:51 PM   #146
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https://youtu.be/0e6yiqFQgNU

Got the engine running on the stand. Runs great. Steam cleaned it so I wanted to make sure I blew all the crap that may have gotten into the intake out. Waiting on a turbo manifold to show up and going to start stripping the motor down for a reseal. It has the old school head gasket that's leaking a bit. Want to delete the oil heater and make a drain. Funny enough these early n/a engines have no provisions for the turbo feed and drain so I'm going to need to tap into it at a different point
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Old 01-28-2022, 08:02 PM   #147
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That has a really nice sound.
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Old 01-29-2022, 10:07 PM   #148
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That has a really nice sound.
Thanks! Yea it ran extremely well. I'm excited to crack it open. I'm half tempted to send this pump out for modding. It has a rs203 mech pump on it, only year the 606 had a mechanical pump stock. Word has it the cam profile of the pump is the best one for the 606. Luckily they can mod it for turbo use with a external alda system. I'm not sure exactly what I'm going to do with it, I'm looking at a few w124s and it may end up living in one of those after I go through it. I found another one with a 606 that's very clean so I may turbo a the stock engine in that if I get it and see how well it holds up. I dunno I'm all over the place with cars.
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Old 02-09-2022, 04:24 PM   #149
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so here we go with the engine tear down and reseal, i pulled the engine from the e300 and powerwashed it, it came out amazingly well.

before


after



got it stripped down to a long block and as you can see it has the old style vacuum pump. the early style vacuum pumps explode, its not a matter of if, its a matter of when. and when these puppies go they barf the guts straight into the timing chain and pretty much destroy the engine. so its a good idea if you have one of these early ones to just replace it right away if you dont know the history. considering ive parted a few 606s i had a new style timing cover, vacuum pump and oil jet which i will show how to replace here.




ass you can see the injection pump gear has a wave too it. thats where the original vacuum pump bearing rides on and its just a roller bearing. the updated old style ones are sealed and tend to last longer.




the stud next to it has a oil squirter to lubricate the bearing, when doing this swap you need to replace the oil squirter with the late style squirter that only has one oil jet out the side to lubricate the chain and slider. i have found on these the easiest way to get them out is with a slide hammer and some vice grips. you could easily get a dowel puller for it as well but since its not going to be reused you can just gorilla it out.



the updated oil jet seals to the front cover via a o ring so as i said you need to install the new front cover from a 97+



also this is a good time to verify your timing. you can do that with the cams and crank pretty easily these chains do stretch about 5-6 degrees but you can actually work around that by basically retiming the engine and getting the slack in the right spots i have found. but you really should line everything up and lock the motor before doing this because you have to transfer the timing pointer over to the new cover.

i found on these older engines they actually have a om603 crankshaft in them and use a actual woodruff key instead of the spring steel for the crank gear and balancer. much more robust because there are horror stories of people chucking the balancer off with moderate power and a stick shift.



this is the 96+ style




crank molt torque is extremely crucial on this style, people say that the 05-06 cdi bolt is stronger which it is by grade but if you torque it right im sure its fine.

i put the newer style non bolt together balancer on and got the timing pointer situated and pulled the head off. the head and prechambers looked good. the glow plugs were completely siezed so that was interesting removing them, i just used my 3/8 impact to break them loose and get the carbon off of them




the head was in extremely good shape, i cleaned all the carbon out of the ports and removed all the prechambers and gave them a good cleaning and reinstalled them.



after that i copper sprayed the turbo headgasket and installed it and addressed the injection pump.



the car was a one year only mechanical 606 so the cam profile in the pump is very sought after, so i set the timing at 14 degrees ATDC and removed the cruise control motor and removed the rs203 pump to send to diesemeken.



i installed a spare 603 turbo pump from a 3.0, due to the 5.5 elements its not going to make the power a stock 606 makes but for now it will be fine just to get it going



i got a dsl1 on order too, they are pretty cheap and i do want to get into tuning on one, you can squeeze good power out of a stock edc 6mm pump and the drivability is alot better at higher power levels. so we will see what the meken pump ends up on but for now i just have to reshim the injectors and fire it up.
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Old 02-14-2022, 11:52 PM   #150
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Got my turbo and manifold bolted on that I got for cheap on the diesel forums, the turbo to manifold doesn't have a gasket normally but I like to put one there. Lucky enough a Ford 6.7 y pipe gasket is almost a direct fit!





Deleted the fuel thermostat to clean up the lines and leak points. Cut out a thermostat delete out of some steel and bolted it on.





Got my injector shims kit out and shimmed and adjusted the n/a injectors to 135bar as opposed to 115bar the n/a cars had. The nozzles we're firad 314s which seem to be the go to currently. They popped and atomized fine so I left them. Installed the bleed off pipes and installed the oil pump which I forgot to take pictures of.



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