I need some help to modify a OM602A

[Heckflosse]

Hello from Vienna!

After driving a 200D for 2 years, I want power!
And you guys are the best specialist's I can ask.
I just bought a 250D Turbo, year 88 with automatic transmission.
I was thinking of mounting a big Intercooler and maybe a bigger turbocharger.
How much HP do you think I can expect with the original injectionpump (of course I will screw her up) ?
What things do I have to take care for modifying?
Ther is a sensor on the intake-manifold which controls too much preasure. How do I uninstall it? Does the engine think that it has too much pressure if I take the cable off, or the opposite?

Thank you very much in advance!

[nokileka]

Hello!

I was thinking of mounting a big Intercooler and maybe a bigger turbocharger.
How much HP do you think I can expect with the original injectionpump (of course I will screw her up) ?

150-160hp

What things do I have to take care for modifying?

Adjust the transmission for increased torque.

Ther is a sensor on the intake-manifold which controls too much preasure. How do I uninstall it? Does the engine think that it has too much pressure if I take the cable off, or the opposite?

Connect pressure from turbo directly to the pump.

[Heckflosse]

Thank you Nokileka for your kind reply

To adjust the transmission would probably mean, so set the adjustment on a harder shifting, or?

And to connect the pressure cable with the injectionpump would make the pump reactin faster. Right?

But there is an electric cable on the intake manifold that is connectet to a pressure-control to lower decrease injection. What should I do with this?

Thank you very much!

[nokileka]

Thank you Nokileka for your kind reply

To adjust the transmission would probably mean, so set the adjustment on a harder shifting, or?

And to connect the pressure cable with the injectionpump would make the pump reactin faster. Right?

But there is an electric cable on the intake manifold that is connectet to a pressure-control to lower decrease injection. What should I do with this?

Thank you very much!

Most probably transmission starts slipping with gear changes, since torque from the engine increases. There's a adjustment screw on the drivers side of the transmission. Remove rubber cab and pull out adjustment dial. By turning it clockwise increases pressure and makes shifts more firm.

Ignore the electrics, just route pressure from turbo or intake manifold to the pump. Follow original hoses and you'll find the pressure box on the top of the pump.

[Heckflosse]

Most probably transmission starts slipping with gear changes, since torque from the engine increases. There's a adjustment screw on the drivers side of the transmission. Remove rubber cab and pull out adjustment dial. By turning it clockwise increases pressure and makes shifts more firm.

I just turned the transmission on softer because it was so extremely hard, and it shifted only after 3.000Rpm. But I adjusted it on the metall connection from gas to the transmission which leads over the engine-head. Now it shiftes softer, but I have the feeling, that it is slipping while driving.
Are you sure my gearbox has also this adjusting toolon the bottom left side?
I'm afraid I will have to try a lot to find the perfect settings

Ignore the electrics, just route pressure from turbo or intake manifold to the pump. Follow original hoses and you'll find the pressure box on the top of the pump.

Ahh I see. Doing this shortcut, the electronic will not have any Influence on pressure or inhjection right?
Where would you reccomend me to connect the pressure line from turbo to injection pump? Because I also want to install a "boost controll" and if it would have the same line, it might be influenced by the boost controll wheel.

Thank you very much as usual

[veskola]

Hello, let's try with the picture, it illustrade how i have done in my W638 car.



And there is this "over pressure control system"


There is some vacuum line (green), some wires (yellow) and air flows from intake manifold (red) to the pump (blue). I just disconnect all and everything and it works well now.

[Heckflosse]

Thank you very much for your great help.
I think now I see through.

By the way... Does anybody know's, how much minä-diesel is asking for the injectionpump upgrade to 7mm? (5 cylinders)

[veskola]

By the way... Does anybody know's, how much minä-diesel is asking for the injectionpump upgrade to 7mm? (5 cylinders)

I don't know exact price today, but 4 elements is about 700 € and 6 element is about 1000 €, so i think 5 could be 850 €...but it depends about the condition of the pump, becase the fix all what is needed to get pump in good shape.

[Heckflosse]

So. Now it ist done. I increased the power of my old 250 Turbo.
But there is one thing that I'm wondering.
Can it be, that the maximum adjustment to the full load screw is only 2 Turns?
I tried to turn it 2,5 turns out, and suddenly the engine was running with 3.000 turns idle. My turbo has the electoning idle and I turned idle RPM down. But it is allways wunning up to 3.000 rpm.
Is there any solution to this problem?

What really surprised me is the fact, that the car is almost not smoking.
Maybe because I drive it with 100% veggie oil.

[veskola]

There is a picture of the pump with electrically adjustable idle:

http://www.mersuforum.net/forum/viewtop ... 256#300256
http://www.nic.fi/~danes/w638_2/jutut/pic/p0241.jpg

Did you unscrew that "Tyhjäkäynti" screw found under the red cylinder. If not do it now. Unscrew us much as you unscrew that fully load screw (in the picture "Syöttöruuvi") or as much it opens.

Opening of full load screw 2,5 turns works fine in the OM601 engine after we unscrew that "Tyhjäkäynti" and also we screw in that "Tyhjäkäynnin hienosäätö" screw (fine adjustment of idle). This fine tune screw is easy to maintain later when the engine running to get idle rpm to be correct.

Hope these hints helps you...

[Heckflosse]

Thank you for your fast reply!

Aaahhh! I didn't know ther ist this screw under the red plate.
So if the upper screw is for fine tuning, it will be more important to unscew Tyhjäkäynti. I hope it will work bekause I really get the taste of horsepower with this engine.
It makes so much fun to drive, especially after I put 200D plate on my car

[veskola]

Thank you for your fast reply!

Aaahhh! I didn't know ther ist this screw under the red plate.
So if the upper screw is for fine tuning, it will be more important to unscew Tyhjäkäynti. I hope it will work bekause I really get the taste of horsepower with this engine.
It makes so much fun to drive, especially after I put 200D plate on my car

Yes "Tyhjäkäynti" is the most important screw to open (also), and feel free to open more that full load screw, about 2,5 to 3 turns should be ok.

[Heckflosse]

Hello!

Please I need our help again!

I want to get more Power than the 2 1/2 Turns I screwed the full load screw out.
I screwed out Tyhjäkäynti for 2 1/2 Turns and then it got stuck.
It was most I could screw Tyhjäkäynti out.
But it didn't change anything. When I wanted t turn out the foll load screw,
the engine whent up to 4000/upm.

How can I lower the idle to turn out the full oad screw to the max?

Thank you very much in advance!