Things I Learned [Vacuum Lines, Wires & Timing] - W140 OM603.97x "Rod Bender" Engine Swap
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- čas přidán 19. 06. 2020
- In this video I will discuss the intricacies of a 603.97x engine swap. The infamous 'rod bender' which can be solved by replacing with a 3.0L short block (603.960) from a W124.
After sorting the mechanicals (timing) it's time to figure out the vacuum system and the wiring. I recommend taking lot's of pictures before initial disassembly to make your life easier when putting everything back together.
If you have any questions, or you are attempting a project like this of your own, please let me know in the comment section and I would be glad to help in anyway I can :)
The forums are always a great place to start. Odds are someone has already had the same issue as you! - Auta a dopravní prostředky
Great video! Packed with information. I have a 1984 W460 G-Wagon. The garage has just changed the engine to an OM603 from a W124 300D. This is a great reference video!
It is amazing to find a video with just about all the information that I need. I cleaned all of my intake system because of a problematic egr exahust valve and in the process I had to loosen the camshaft retainers and messed with the chain position even if I put some plastic clips to hold the chain onto the cam sprocket and as a result I haven't been able to start the engine.
Im a new owner of a w124 300D turbo with om603 engine, i learned alot from your video. Thx alot man
glad it helped. the w124 are much more straight forward to work on IMO. best of luck
Bro this video made my day, thanks a lot for such valuable insights into the OM603 engine.
Hey your door video helped me! Glad to see u posting!
Glad it helped!
Magyar last name? Egan!
@@HB-sf4xk Igen
excellent video, got some issues with my w140 300sd, this will help, thanks man
cheers! good luck
Awesome work!
great video man! very informative! :) that engine sounds like a real good runner now.... no strange noises :) a video of it driving around and under different loads would be nice. get a listen to that exhaust lol...
Great idea, car is in hibernation for the winter. Furthermore the exhaust is an aftermarket and I am not a fan of the noise it makes, currently looking for a resonator or an OEM exhaust
Congrats very good video. Thanks for share the information
Thanks very good explanation. Very helpful
Glad it was helpful!
Just the information I was looking for... I have a 1993 SD300 with 3.5L... I want to restore it lol
Thunks for info pro
Very nice video but you could explain the pump timing with the Mercedes electronic tool but otherwise it is very well explained. Bravo
You'll want to raise the max RPM on your fuel injection pump - the 3.0 engine can go almost 1000 rpm more than the 3.5. Using the 3.5 engine settings means you'll be down on power.
The W126 and W140 have an electric pump on the trunk for the central locking. Your W140 has a vacuum controlled turbo wastegate. I didn't realize that the W140 does not use the vacuum / boost amplifier for the transmission like the W126!
The black lines are a vent, that go into the cabin. The 2 wire coolant temp sensor in the head is actually 2 sensors in one - one does the gauge, the other hooks up to the glow plug relay. The 2 pin temp sensor on the water outlet is for the climate control, and the single pin temp sensor is for the engine computer.
As far as I know, the W140 does also use vacuum for the transmission. There is a little green nipple that goes to the transmission, along with adjuster knobs for the "force" of each shift. This can be found under the shifter boot in the center console
thanks for video, i fixed my issue on 603 eng w140, at 9 min 30 the wire for RPM indication gauge , it goes from L3 Ring gear speed sensor to N26/2 then to N39 (computer)
Hi, excellent video, I am lost with the vacuum lines, have you any information on the 2 vacuum transducers vacuum line connections. thanks Mal
I dismantled the control panel and needed to arrange the colored wires in their correct place again, socket number 1
Está información vale oro
Me podrías decir si el vacío va directo del motor a la trasmisión o tiene un punto conectado al acelerador
Hoi,good i see this video now , becouse tomorrow or very soon i start remove the cylinderhead from my 350 sd 1992. You have any idea where i can find the step by step info for doiing this? Or the tork s for the bolds. I have to say it is very interesting to know the information you tell about the cars lines and so on. Nice job grts from belgium
hello, great video. could you show each of the vacuum lines? that come from behind the beacon of light to its destination? it has me crazy ... thanks
Wish I could, the W140 does not have the typical 'flying saucer' vacuum line distributor as other Mercs from this era, could you please specify the model you are working on?
Hi how do you prime the diesel pump on this engine as mine does not have a priming pump and now so confused as to how we can get air out of the pump
I'm just now doing this swap with a donor engine with a cracked head and a bad 3.5 with a good head... I hope... anyways we'll see how it goes
Unfortunately for mine its on it final leg, head gasket is blown, and I unfortunately dont have the time to figure out how to replace it, plus i want to replace it with an OM606
Do you know how the vacuum line controls the door lock? Whenever, I shut the driver’s door, it will trigger all doors auto lock. There was once I left my key in the car and I was locked out....😅
I have one, I'm debating on installing a 606 instead of a 603.96x My .971 is starting it's death spiral I believe.
Not familiar with the OM606, it's a little newer model, but I can tell you that if you can find a OM603.960 it's a bulletproof engine known around the world to run for 1 million Km's. They still use them as taxis in the Middle East and Eastern Europe!
I've been working on a 93 300sd. I'm currently having trouble finding a picture of how the fuel lines connect to the tank. Drivers side, where it has two barbs. Any chance you have a diagram or could explain where the return line runs to?
Thanks,
Dustin
Hey Dustin, car is in hibernation at the moment. Send me a private message and we can chat about it.
@@bencesmercedesgarage7479 not exactly sure how to private message through youtube!
@@dustinubbing6722 Looks like you have disabled it on your account. Send me an email at: bence.imre.esztegar@gmail.com
hello thank you for the video. I love. could you help me . I have a vacuum hose that is in a vacuum. I can't find its location
92MB300SD 78,500 miles. Engine runs fine however will not start after shut off until manual STOP lever in engine compartment fully restored to position. It does not reset each time. ? Some fuel leakage in that are just above lever. MB shop recommends replacing Injection pump $$$. Any suggestions?
Im a year late to your comment but I have the same car. Fuel leakage sounds like the copper crush washers in the injection manifold. And your car not shutting off is vacuum, I had the same issue and I had just knocked off a small little vacuum fitting, it took me 4 hours to find but if you shut off the car and listen you can maybe hear a hissing noise.
After timing the IP 15° ATDC do you just put the 17mm back on?
meaning the bolts at the front? yes. they are the ones that hold you IP pump in place
Question for you. I have an 87 om603 in a 124. Just started it with a fresh battery ran for a bit started knocking and stalled out now it doesn’t want to turn over acting like it has a dead battery. Starter crapped out maybe?
Perhaps its a starter....check the serpentine belt, hopefully that's the easiest fix. If you hit the starter with a wrench does it turnover? One last thing that I could think of would be air in your diesel system somewhere.
Bence's Mercedes Garage I haven’t actually hit it with a hammer yet because it tries to spin but is really labored like not even a quarter of a crank turn. I was thinking about pulling my injectors and hoping coolant doesn’t come out. I’m gonna swap a 17 head on and put a 606 head gasket. I just hope it’s not a hydro locked cylinder
@@nicjohn6375 I would recommend first,
Checking if you have good pressure coming from you Injection Pump. You can do this by individually unscrewing the lines coming from the IP pump to each injector [14mm wrench], you should see a pretty violent spray when turning over. Start at the furthest cylinder from the IP pump (#6) and work your way back. This will rule out the air in the system as well and effectively bleed your system.
If you had a blown cylinder head gasket you would know if you were burning coolant, trust me. I've had one before. White smoke and smell.
If your engine isn't even turning over...I would probably assume the starter as well. I don't know what this has to do with your new battery...Is it a OEM Mercedes Battery?
Our other W210 (2.5L Diesel OM605) occasionally suffers from no turn over, specially in very high and low temperatures we've noticed. Likely the starter, but hitting seems to do the trick for the time being.
Bence's Mercedes Garage I’ll try tapping on the starter cuz I’m running a 220GPH lift pump and a smaller back up so 2 lift pumps 1/2” line to the IP w/35psi of FP. but it’s the first fire after 3 years and started right up ran pretty good then developed a knock stalled then when you try to fire it again it just won’t even make a full revolution. I don’t think air in the line would do that. The 14 head also used to blow oil out of the turbo so I’m hoping it didn’t pump all the oil out and lunch the engine on me
@@nicjohn6375 Ah I see, so it's modified. What do you mean by "14 head"?
I thought the reason the 3.5 liter bent rods was due to hydro locking it only takes a table tablespoon of oil or fluid to hydro lock it causing rods to bend. It could be caused by leaking turbo seals or valve stem seals leaking into cylinder and the reason the piston wear the blocking due to the bent rod.
Nooo, luckily this engine never made it to that stage, but the oil burning, noise and lack of compression were clearly pointing to the fact that these cylinders were over bored. Originally the car was sold as a 3.0L with 3.0L pistons, but the block was from the '87 model, being 3.5L.
Sorry, the other way around 3.5 > 3.0
Hello brother, I need your help regarding my 93 Mercedes SD300 Turbo Diesel.
92 have this problem?
If this engine is completely mechanical.. why is there a Vane Air Meter? Maf/Vam
Low oil pressure? You told us, you changed the bearings?
No, I mean't the gauge wasn't reading properly until I switched the wires
Hi can you send me the fan shoud part number. Thanks
Hello, I have not forgotten. Tomorrow I will get under the hood and take a look for you :) Bear with me for one more day.
140 500 06 55 is the shroud
Bence's Mercedes Garage thanks
Bence's Mercedes Garage I order in Mercedes dealer and is not the one . Don’t know can you check the numbers. Thanks
Luis Vazquez I wish i could send you the picture. But this is the same number from my fan shroud cover. Which model car do you have? If you have the W124, it is likely smaller than the one for the W140.
Do you have a WhatsApp account? I would like to contact you if possible. I need help. I have a Mercedes w140 turbo diesel om603 1996
The problem is in the air lines entering the engine. I need an explanation or a picture of how to arrange them correctly because they are arranged incorrectly