G300 OM606 getting some upgrades

[Leovans]

Having had some cold start issues, I decided to replace my glow plugs. Then I thought I would check my prechambers to make sure they are still good.

Then I thought, while I'm in there, I'll add a few upgrades to my 606.

I don't want extreme amounts of power, just doing a few mild upgrades.

I've already installed the upgraded manual pump with 7.5mm Diesel Meken elements and it's made a big difference. But with all that extra fuel, it now needs some more air.

Enter my new T3 G3077R turbo, Benzforce T3 cast manifold (ceramic coated), Turbosmart Compgate 40 High Pressure waste gate & Turbosmart external boost controller. This should give enough extra air needed to run within safe parameters.

Along with the extra boost, I am also installing stiffer valve springs. It's not really a necessity as I won't be boosting that much, but it can't hurt right?

F-Tune upgraded springs from Benzeforce.

And a few gaskets, valve stem seals etc.

And for those wondering, yes I'll be doing the rear cyclinder block cooling mod at the same time.

I will post some pics when we start the project.

 

[Pete460332]

Did the cold starting improve with new glowplugs?

 

[Leovans]

Did the cold starting improve with new glowplugs?

We have not started yet. We start the project next week. No major issues with the cold start, just the plug light only comes on after one minute and then stays on for at least another minute. And there is a little miss fire for probably 15-20 seconds, then all is good. Resistance on no.3 plug was higher than the rest, and I suspect this is the issue.

 

[Rolf Redecker]

That is far too much effort Leo, just pass the parts on to me...
Intercooler?

 

[Leovans]

That is far too much effort Leo, just pass the parts on to me...
Intercooler?

Nam is too far .
Intercooler is already there. Deon installed it.

 

[Leovans]

I had the manifold ceramic coated.

 

[Leovans]

And of course, we need a little more clean fresh air too.

 

[Alan]

Take it you are not going to drive on dirt roads again?

 

[Leovans]

Take it you are not going to drive on dirt roads again?

I absolutely will. It will go into an enclosed box and I will fit a snorkel.

 

[Pete460332]

Air in the cape is nice and clean still

 

[Leovans]

New turbo. Proudly South African built G3077R from Turbo Direct S.A.. Built it their factory at Denel in Kempton Park.

Ceramic ball bearing, AR63.

Bespoke hybrid combination turbocharger. Forms part of a combination of the GTX30R turbine wheel with 8mm ball bearing cartridge and a modified and upgraded Forged, billet compressor wheel derived from the G-series turbochargers from Garrett.
The compressor housing is also a bespoke unit from a combination of the GTX and G30 housing designs and includes a ported shroud design.
This turbo is a TRUE 600-700HP output. (Not that I will be pushing anywhere near that, so this turbo will be lasting a very very long time)

 

[Rolf Redecker]

It looks very cool Leonardo, keen to know how you arrived at the selection.
Would a turbo (good for 600-700 HP) not be very large to push the amount of air, thus resulting in a lot of inertia and turbo lag on a smallish engine like a 606?
Keep us posted on the project!

 

[Leovans]

It looks very cool Leonardo, keen to know how you arrived at the selection.
Would a turbo (good for 600-700 HP) not be very large to push the amount of air, thus resulting in a lot of inertia and turbo lag on a smallish engine like a 606?
Keep us posted on the project!

I won't be using all those horses. It should spool up quick enough, but I will only know once it's installed. Guys overseas are putting much bigger turbos on, and they do lag a bit.

 

[Leovans]

Upgraded valve spring VS stock. 35% stiffer.

 

[Leovans]

Some progress.

 

[Leovans]

Finally everything is done. happy to report back she is running like a steam train.

Boost is smooth and NO black smoke! Getting 1.47bar MAX boost at the moment.

I have a last few little bits to tinker on, install a Loco Can oil catch can, fine tuning the boost etc, but I am ecstatic with the changes. Well worth it.

 

[Leovans]

Some feedback after two weeks.

All I can say is WOW! It's a totally different car.

Acceleration is very smooth.
Going up hills is a breeze and I can even overtake up a hill now, lol.
Overtaking on flats is a breeze.

One thing getting used too is the ball bearing turbo, it sings a bit. A very high pitched sound. It's not annoying, but you can hear it. I suppose it means the turbo is spooling.

The proper offroad test will come at the end of the month.

I will also be doing a dyno run around about the end of the month to see what power she is actually giving.

I will give some more feedback after that.

 

[Leovans]

Cold start issues solved. Replaced the Glow plug relay with a Hella part from Europe, almost one tenth of the cost of an OEM part and it works perfectly. Happy days.

 

[Rolf Redecker]

Good morning Leo. Could you post the Hella part number please?

 

[Alan]

Leo, is that turbo water cooled seeing it is a ball bearing type?