Brap Brap went the OM606, A 110 build

expanse

Well-known member
USPS surprised me with a delivery last night. New set of XNZ bits show up. "Impact" grade MIC buggers. Did the trick and the head is off. strip down for cleaning, exhaust stud extraction, measurements for a block off plate on the head diesel heater port, valve guide wear check, new stem seals, upgraded springs & retainers.

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t
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yummy
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expanse

Well-known member
Any more updates on this project?

Not much of an update right now. Covid has really tossed a wrench into life up here thats taken months to feel the brunt of.

I started tackling the 5 seized glow plugs two or so months ago so I can strip the head down and send off for some love @ the machine shop, but I've not finished that task yet.

I've also changed platforms from my Defender 110 to a Series 1 with redesigned chassis i'll hand build, defender axles/suspension, and some big tires. Picked this up over the summer for the body work. (frame/axles and rear tub are for sale)
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I also had a few items I've been on the hunt for need rehoming, so this projects budget has somewhat been reallocated to neat-o things like this Schmidt snow blower for the Unimog.

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expanse

Well-known member
11 months later; 2nd kiddo arrived, city code violations, moving to a new shop, pandemic aftershocks with wife's business, childcare meltdown and recovery, and a dozen other dumpster fires.

Now back to the show:

This 606 has exhaust studs made out of some seriously shat metal. I think I got 2 or 3 full studs out, the rest are all hard seized or snapped off, 3 are in deep.

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Bottom bugger was the deepest snap so far.
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Next up, glow plug extraction; 5 out of 6 are seized and need a swift kick
 

expanse

Well-known member
Success. All exhaust studs are out. final 2 were snapped deep but came out easy. Lots of threads to chase and confirm are happy.
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Now the final push to get the head stripped down. Glows #1 through #5 are all seized. Cyl #6 spun right out like normal (joy). So far Cyl #5 is out after some drilling and slide hammer love.
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expanse

Well-known member
Teardown on the head is compete. Exhaust stud holes are all cleaned out and lastly, glow threads all clear.
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Lower end is now torn down and quick visual inspection done. so far so good. Looking like minimal work will be needed. Measuring will be next step.
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Pistons all pulled and torn down and sent through the hot tub. I've yet to check for any bends in the rods or measure anything. visuals look good.
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Everything is getting bagged and boxed in the AM in prep for the shop move. Will be quiet here till I'm moved in and rolling.
 

expanse

Well-known member
Well I'm bored waiting for Nov 1st move in. Packed just about everything so now picking off small tasks around the house, old shop, etc.

Fun little one I took on was stripping down the block of the last few items. A chunk of cast broke off when removing a seized coolant fitting.
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Picked the threads clear, ran a tap through and was able to reestablish them enough I could align the broken chunk.

Whipped out the ol TIG and set off. First time using Blue Demon 5000T. Was happy with how it came out. bit of a wonky spot but it all glued right back together. cleaned threads and all is happy.
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donb

Well-known member
Well I'm bored waiting for Nov 1st move in. Packed just about everything so now picking off small tasks around the house, old shop, etc.

Fun little one I took on was stripping down the block of the last few items. A chunk of cast broke off when removing a seized coolant fitting.

Picked the threads clear, ran a tap through and was able to reestablish them enough I could align the broken chunk.

Whipped out the ol TIG and set off. First time using Blue Demon 5000T. Was happy with how it came out. bit of a wonky spot but it all glued right back together. cleaned threads and all is happy.
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Nicely done. Stuff like this is where the TIG machines are so nice. Didn't know about the 5000T rod - need to file that in the mental future fix pile.
 

expanse

Well-known member
Nicely done. Stuff like this is where the TIG machines are so nice. Didn't know about the 5000T rod - need to file that in the mental future fix pile.
I'd never heard of this rod till I did a few googles. Thought I'd give it a try. 100amps, red band (2% Thoriated), no pre/post heat, no cracking whatsoever. I'm a fan.
 

expanse

Well-known member
Pic of the new shop? Excited for you!

Well i'm finally bringing this one back from the dead. Nearly a year later and all I can say is; what an insane year it's been. Moving, expanding, hiring first employee, supply chain mess, etc etc.

A few of the shop over the past 11-ish months. Construction was endlessly delayed. I finally moved in the week of Christmas 2021. Lift & power drops took months of waiting but finally were wrapped up in March/April '22.

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And the main reason i'm dragging this thread back to life is a '98 E300 is headed my way in the next week or so. half the miles of the original car/engine I purchased.
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Brapp Brapp 2023!
 

expanse

Well-known member
Got a call last night that the transporter would be arriving today and sure enough, the Booger has arrived.
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Refit the airbox and MAF, all but one code cleared (P0715). Took it for a quick rip and engine sounds smooth as butter for 200k on the clock.

I think this may get daily driven this winter before engine is pulled.
 

expanse

Well-known member
The Booger is coming along. Definitely aiming to use as a winter beater after working through a few codes. So far P0715 - 722.6 conductor plate was problematic, quick swap with a new unit, fresh fluids, and a TCM scan & delete. Now out of limp mode and shifts in all gears. P0243 - rotted vac lines needed refresh. last big task in area of dash lights is the SRS light is on.

now waiting on a few bits to fab up an exhaust, fit a new alternator, fix PCV hose. and fresh tires.


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MountainD

Technical Excellence Contributor
How is the reving? I have always been interested in this engine. At first, I thought the higher revs to make power was going to be an issue (with a manual), but frankly to build pressure, the R2.8 makes you rev a bit too... So in the existing--what do you think?

I still think it is an AMAZING engine. If you are in CO at all once done), I would LOVE to see it and take a ride...
 

expanse

Well-known member
How is the reving? I have always been interested in this engine. At first, I thought the higher revs to make power was going to be an issue (with a manual), but frankly to build pressure, the R2.8 makes you rev a bit too... So in the existing--what do you think?

I still think it is an AMAZING engine. If you are in CO at all once done), I would LOVE to see it and take a ride...

TBD on a solid driving report. Been swamped at the shop and getting carried away with picking up some items on my winter project 'buy' list. here's this weeks item.

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I've been going over the car a bit knocking out little issues and figuring out why fuses have been pulled, etc. etc. Big task was figuring out why boost was not coming on. Replaced all the vacuum line rubber ends and reconnected a few lines that fell off. one of the vacuum solenoids kept tossing a code, will see if the new lines resolve the code and get boost back.

SRS light still on. My Autoenginuity Merc 38pin setup can't seem to find any airbag codes stored. more play time needed to see if the code is saved elsewhere else
 

expanse

Well-known member
Had a few hours to burn today. decided to swing by the shop, move trucks around, and get the trusty merc out for a few pulls. Boost is back. fun running trough the gears with no exhaust. bit of a screamer.

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