Boards.ie uses cookies. By continuing to browse this site you are agreeing to our use of cookies. Click here to find out more x
Post Reply  
 
 
Thread Tools Search this Thread
25-05-2014, 17:30   #46
Bigus
Registered User
 
Bigus's Avatar
 
Join Date: Jan 2010
Posts: 4,521
Very nice so far, I wonder is there another alloy engine bracket from another model that would allow you to use the original engine mounts ?
German auto parts in walkinstown behind Brennan's bakery have a load of merc engines with brackets on the shelf,pre export .

Some sort of aluminium heat shield / heat dissipator might be in order to take heat away from the steering box.

That'll be one quick economical car when it's finished. They handle like a sports cars too , compared to later models and some more modern yokes.

Well done
Bigus is offline  
Thanks from:
Advertisement
25-05-2014, 23:40   #47
pryantcc
Registered User
 
Join Date: Nov 2013
Posts: 182
Quote:
Originally Posted by Bigus View Post
Very nice so far, I wonder is there another alloy engine bracket from another model that would allow you to use the original engine mounts ?
German auto parts in walkinstown behind Brennan's bakery have a load of merc engines with brackets on the shelf,pre export .

Some sort of aluminium heat shield / heat dissipator might be in order to take heat away from the steering box.

That'll be one quick economical car when it's finished. They handle like a sports cars too , compared to later models and some more modern yokes.

Well done
Thanks for your interest Bigus!
Thought about swapping brackets, but the existing ones line up so well with the subframe that I'll either move the existing mounts in to meet them or find some off something else and stick them in.

I kept a big lump of heat shielding off the donor car which I'll use to protect the steering box and engine mount.

Hopefully it'll go well, I'm particularly looking forward to the 6 speed manual box.
pryantcc is offline  
26-05-2014, 01:35   #48
commited
Registered User
 
Join Date: Mar 2003
Posts: 2,192
Great project and great progress! While I'm not a massive diesel fan, the OM602/603/605/606 engines are an example of some amazing engineering and if anything goes wrong, cheap enough to throw in a replacement! I know a chap that does a fair bit of work on these engines and he's not a fan of the OM605/606 as the heads can give trouble.
commited is offline  
Thanks from:
27-05-2014, 06:52   #49
pryantcc
Registered User
 
Join Date: Nov 2013
Posts: 182
Quote:
Originally Posted by commited View Post
Great project and great progress! I know a chap that does a fair bit of work on these engines and he's not a fan of the OM605/606 as the heads can give trouble.
Thanks commited, that's the first time I heard that. Have you seen there are guys running 2 and 3 turbos with getting 400 & 500HP from these without changing the internals!?
Do you know what kind of head problems there are and anything I can do in terms of prevention?
pryantcc is offline  
27-05-2014, 07:08   #50
commited
Registered User
 
Join Date: Mar 2003
Posts: 2,192
I had to go and find it, but this came from a chap who has a standard OM603 turbo on the continent:
Quote:
605/606 - I just don't like them. They need revs to work, they have a nasty plastic fuel system and we had countless heads that had to be removed and sent away for a glow plug change at the machine shop. They make big power with a few mods, no doubt. But if power kicks in at 5000RPM it just doesn't do it for me. I want a cruiser, not a race car. All reasons why I opted for the 2 valve engine(s).
Just a note for anyone trying to source an engine to do the same/similar job - the C250TD is another option with manual available as standard, or an OM662 from a Musso - it's basically a OM602 with a larger capacity and turbo and a few other small mods - the only OM602/603 that came here in turbo form. They're both 5 cylinder engines, so a bit shorter which helps when trying to squeeze in engine bays.
commited is offline  
Advertisement
28-05-2014, 16:57   #51
pryantcc
Registered User
 
Join Date: Nov 2013
Posts: 182
Ah, I have heard about guys snapping glow plugs off in the head alright, I thought that you were talking about head gasket/valve gear troubles.

I'm not looking for big power, I'll be using the engine in standard form.
pryantcc is offline  
01-06-2014, 20:31   #52
pryantcc
Registered User
 
Join Date: Nov 2013
Posts: 182
Drive shaft sorted!
The original shaft is used up to the carrier bearing, and it turned out that the splines on the shaft which came with the manual gearbox match it, so my very good friend just shortened the front section of the shaft which belongs to the gearbox. You can see how it was before and how it is now in the photos below.



pryantcc is offline  
08-06-2014, 20:47   #53
 
Join Date: Oct 2012
Posts: 577
Wonderful
Lucky Mercedes to have survived to today without having Nissan diesel thrown in
cabb8ge is offline  
Thanks from:
09-06-2014, 15:13   #54
ho55
Registered User
 
Join Date: Jun 2014
Posts: 1
Hi Pryan, very nice work and an interesting thread. I would be very interested in your wiring information even if preliminary as i am doing something similar with a 606.962.
On comment on your engine mounts - Diesel ones are normally thicker and more absorbing to take the extra vibration of the motor. You may find if you use the old v8 ones too much gets through. But using the diesel ones means raising the motor or dropping the mount point...
ho55 is offline  
Thanks from:
Advertisement
17-08-2014, 22:21   #55
pryantcc
Registered User
 
Join Date: Nov 2013
Posts: 182
A long time since the last update so a long one to catch up! I spent a long time getting the auld Hilux through its test, doing some house alterations, parenting and that kind of thing! A few bits and pieces have still been done on the car. I've made up some brackets to change the old lever/rod operated throttle to a cable one for the throttle position sensor.
This is the new bracket to mount the sensor in the engine bay.





This bracket is fot the other end to hold the outer casing of the cable. Some rustiness in the bacground which will need to be dealt with!



The clutch pedal and master cylinder are in. They are from the gearbox donor clk. The fluid line to the slave cylinder is routed on the inside, but I still have to sort it out on the outside. It connects with a length of flexi hose coming from the gearbox housing.





In other news, I've done some work to get the engine into its final position. My resourceful and very talented engineering friend made a mounting bracket for the gearbox. The OM606 engine is rotated to one side so that is isn't so tall in an engine bay. Although the bell housing on my gearbox fits the engine crank case, the engine the gearbox was attached to mustn't have had the rotation because my gearbox now sits at an angle as you can see in this photo. The steering componenets are horizontal, the bottom of the gearbox is not!





The gearbox bellhousing could be cut and rotated to straighten out the gearbox, but I'm going to just leave it as it is. It doesn't look like it will present any mechanical issues with the build. I'll be crossing my fingers a bit regarding internal lubrication....

Here you can see the new bracket before painting and in its final position in all its glory!







Once the rear of the gearbox was fixed in position, the engine was nudged around the place in order to get the drive shaft to line up correctly in the centre of the carrier bearing:





Now that that's done, it was a case of trying to make sure the engine ends up in the same spot once the new mounts are fitted. So, there are two dots on the sump which line up with two ends of a piece of TIG wire. Once the new mounts are made, the engine should settle back into the same spot. That's the plan anyhow!





That's it, the Engine mounts shipped last Thursday, so once they arrive, it'll be a matter of figuring out how much they will compress under the weight of the engine, and making a mounting plates to suit.
pryantcc is offline  
07-09-2014, 21:06   #56
pryantcc
Registered User
 
Join Date: Nov 2013
Posts: 182
My 6 speed gearbox is from a 2004 CLK. The gear shifter is attached to it by a long aluminium U-shaped bracket which attaches to the rear/top of the gearbox and to the shifter mechanism. It's relatively straight-forward to re-use this whole setup except that I'm a little tight for space, and, more importantly, my gearbox is rotated in relation to the horizontal plane the gear stick should work on. So, if kept standard, the gear lever would be pointing out the driver window instead of straight up. Hopefully the photos will help explain.

The plan ended up with chopping the mounting point off the bracket and welding it back on at an angle. The effect being that the whole brakcet and gear shifter unit is rotated back into the horizontal plane. Since the top of the gearbox is leaning towards the driver's side of the car, but the shifter will be mounted in the middle of the transmission tunnel, it will have to operate at a slight angle rather than straight front to back, but I reckon I'll get used to that pretty quickly. So, photos:

Here's the whole assembly:



And this is how it conects to the gearbox. There's a rubber bush which goes in the bracket, and a pin runs through it to secure it all to the gearbox.



Here you can see the angle which has been introduced.



A little angle grinder action been going on to make a spot for the gear lever. It'll get bigger before it gets smaller, it's too far forward by a couple of inches!
pryantcc is offline  
25-11-2014, 11:44   #57
Meso Harney
Registered User
 
Join Date: Apr 2014
Posts: 75
Hope life hasn't got in the way of the project
Meso Harney is offline  
(2) thanks from:
25-11-2014, 11:52   #58
pryantcc
Registered User
 
Join Date: Nov 2013
Posts: 182
Quote:
Originally Posted by Meso Harney View Post
Hope life hasn't got in the way of the project
Only partially Meso! Things have slowed down a little, but life has got in the way of updating Boards! Work is still well underway. i'll get my finger out and upload a bunch of photos since the camera card is now full!
pryantcc is offline  
25-11-2014, 19:31   #59
Meso Harney
Registered User
 
Join Date: Apr 2014
Posts: 75
Looking forward to it, it's a project I've been interested in from the start, hope things are going well for you
Meso Harney is offline  
28-11-2014, 23:51   #60
pryantcc
Registered User
 
Join Date: Nov 2013
Posts: 182
It's been a long time since I did a proper update. Progress has been slow but there has been progress. I've been doing a lot of wiring and its almost complete now. I built a circuit to replicate some of the essential stuff. It's basically 2 relays, 1 for ECU power and 1 for switching the starter solenoid, and a few fuses for power running to various sensors, etc. I have also mounted the ECU under the dash and run the wiring through the firewall to connect to it. It's not beautiful, but works well and isn't visible without some contortionism to get feet up on the seat and head down into the passenger footwell.


I have also started to strip the interior and I'm glad I did. I found a big hole in the inner sill which was fibreglassed over. Repair should be easy enough given the simple shapes. The outer sills are new.



I also took the bitumen coating off the passenger floors and found a few bits that need patching. Nothing structural nor particularly serious.






The donor car went to the big car graveyard in the sky today. The first and only time this project will ever give me money I got a puncture in the pick-up (screw through the tire) for my troubles.
pryantcc is offline  
Post Reply

Quick Reply
Message:
Remove Text Formatting
Bold
Italic
Underline

Insert Image
Wrap [QUOTE] tags around selected text
 
Decrease Size
Increase Size
Please sign up or log in to join the discussion

Thread Tools Search this Thread
Search this Thread:

Advanced Search



Share Tweet