603 to 606 Conversion

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Russ280
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Well I’m maybe 30% of the way through a 603 to 606 swap.

6 months ago I acquired a W124 for next to nothing. 11 months MOT but the ABS light was on so effectively scrap value. Anyway after a bit of fiddling with some connectors that was sorted and I’ve really enjoyed driving it. Even if my wife did call it the old mans car! She actually enjoyed driving it as well.

I’ve used the time to sort a few issue with the engine, glow plugs, service and most importantly by passing all the emission control junk. EGR and other multiple vacuum operated “stuff”. Oh and to drive it like I stole itsmileyThese engines seem to thrive on this and it’s certainly got better and better. It only had 1 previous owner and for the past few years has only been doing 5k miles / year.

Anyway a few weeks ago the 603 finally dies, see photo’s. Not pretty and most of the 8 litres of oil seemed to have dumped themselves on the road outside our house and the drive way. Green Peace have been picketing ever since, no sense of humour some people.

So even though the timing wasn’t great from a time or money perspective (I doubt there is any right time) the swap needed to start.

As I planned a DIY conversion I went the slightly odd path of a non turbo 606. Seemed a simpler choice, a mechanical pump, with a very basic ECU and no RHD turbo complexities. I had driven LEEU/Christo’s non turbo 606 and really liked it. Smooth, refined and quick enough for my purposes. Hopefully more economical as well.

Anyway first snag. Got to swapping the sumps Sunday and the oil pumps are different. The 606 has a oil to water oil cooler direct off the oil pump. The pipes exit through the side of the 606 sump, obviously the G 603 sump doesn’t have this.

So swap the pumps. Nope, different capacities 30mm 603 vs. 37mm 606 and different size sprockets.

Plan B. Get a new 606 pump without the oil cooler outlets. £400+sad

Anyway thanks to Gordon of G Restorations it looks like we’ve solved that one. Hopefully it’s simply a case of swapping the pick up’s (which is a little embarrassing as this needed doing anyway) In my defence it was dark and we were looking at the 2 pumps upside down.

Umm just tried to upload some photo's but no luck. 

Russ280
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Re: 603 to 606 Conversion
stig
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Re: 603 to 606 Conversion

When you swap the pick up/pump end housing, just be careful that everything is aligned properly, You need to let the housing 'fall' in to place so the gears are running absolutely freely, then carefully tighten the bolts without letting it move AT ALL. I've seen someone do this and totally jammed the gears, they said the pump was 'warped', but all I did was loosen the bolts, let it all align properly and it was fine. It is possible to move the housing a fair bit, there are no dowels or spigot to hold things central, just the 4 M6 bolts. I have done it and it was fine, but it's probably not best practice as if there are different wear patterns/size the gears want to 'tip' a bit then they score the end surfaces and lose pressure, this is worst scenario and theoretical of course, should be fine!

Roly
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Re: 603 to 606 Conversion

Russ

I'll be following your conversion closely. I like the 606NA.

Sounds like there are knowledgeable people around to assist. Best of luck

G-Restorations
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Re: 603 to 606 Conversion

Russ280 wrote:

 

Anyway thanks to Gordon of G Restorations it looks like we’ve solved that one. Hopefully it’s simply a case of swapping the pick up’s (which is a little embarrassing as this needed doing anyway) In my defence it was dark and we were looking at the 2 pumps upside down.

Umm just tried to upload some photo's but no luck. 

Happy to help, also a trip to your local scrappy for a 606 turbo water pump housing will spare you having to blank the water cooler pipes off.

Gordon

Russ280
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Re: 603 to 606 Conversion

We have ignitionsmiley

It's taken a while. For various reasons I've barely looked at it for the past month but it's close now.

It needs to go to an exhaust fabricator as the manifold on the 606 is different to the 603.

Then I need to sort out the air intake and filter. Trying to go for near original if possible but for now it's got a chavey looking cone filter but that's OK just to get it usable.

Then it needs an MOT and it'll be back in daily service as my wife's car.

The Accord Type R goes back in to semi retirement (it's fun for a while but 3k miles per month gets expensive and tedious, if you don't drive it at 70%+ it's hard work) and I get the Alfa back.

Happy Days!

Roly
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Re: 603 to 606 Conversion

Russ are you coming to the agm?

Russ280
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Re: 603 to 606 Conversion

I don't think I'll make it Roly. Is it tomorrow?