This article documents the ambitious project of transplanting a Mercedes-Benz Om613 3.2L turbo diesel engine from a 1999 W210 E320 CDI into a 1990 W201 190D. This comprehensive engine swap involved significant mechanical, electrical, and fabrication work to integrate the modern powerplant and its associated systems into the classic chassis.
The Challenge of Modernizing a Classic
The original W201 housed a naturally aspirated OM602 diesel engine and automatic transmission. The goal was to replace this with the significantly more powerful OM613 and its 722.6 automatic gearbox. The project aimed to retain all original controllers from the donor W210, including the complex ESP (Electronic Stability Program) system. This decision, while adding complexity, was crucial for proper transmission function. The swap necessitated integrating various components, including wheel sensors, steering angle sensor, yaw sensor, brake booster with BAS (Brake Assist System), and the ABS (Anti-lock Braking System) unit.
Overcoming Obstacles with Ingenuity
The project involved extensive custom fabrication due to the inherent differences between the donor and recipient vehicles. Key challenges included:
- Wiring Harness Integration: The most time-consuming task involved adapting the W210’s extensive wiring harness to the W201. This required meticulous documentation and careful removal of unnecessary circuits while ensuring compatibility with the W201’s existing systems.
- Steering System Modification: Integrating the ESP required modifying the steering column to accommodate the steering angle sensor. This involved lengthening the steering axle and adapting components from the W210.
- Fuse Box Relocation and Customization: The W201’s fuse box was relocated to create space for the W210’s fuse boxes, demanding careful planning and execution to ensure proper electrical functionality.
- Wiper System Integration: Combining the wiper/washer system of the W201 with the W210’s armature required custom fabrication and precise electrical matching.
- Brake System Upgrade: The braking system was upgraded with larger 4-piston calipers from a Mercedes-Benz C124 to handle the increased power of the OM613. This involved minor modifications to the dust shields.
- Brake Booster and Master Cylinder Swap: The W210’s brake booster, crucial for the BAS system, was ingeniously fitted upside down in the W201’s engine bay to accommodate its sensors. The master cylinder was rotated to fit.
- Engine and Transmission Mounting: Custom engine brackets were fabricated to ensure proper alignment of the OM613 and 722.6 transmission within the W201’s engine bay. Modifications to the longitudinal member were necessary to clear the turbocharger’s VNT (Variable Nozzle Turbine) actuator.
- Rear Differential Adaptation: The W210’s rear differential required significant modification to fit the W201’s rear axle. Sections of the W210 axle were welded onto the W201 axle to accommodate the larger differential housing and its bushings. Access windows were cut in the floor for differential mounting bolts. The final installation resulted in a slight offset of the differential to the right due to space constraints.
A Successful Transformation Powered by the OM613
The project culminated in a running and driving W201 powered by the OM613. The car successfully started and boosted as intended. Despite the challenges, the meticulous planning, custom fabrication, and detailed execution resulted in a unique vehicle blending classic aesthetics with modern diesel performance.
This build demonstrates that with careful planning, perseverance, and access to the necessary tools and resources, seemingly complex automotive projects like an OM613 engine swap can be successfully accomplished.
