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  21.April 2019 20:27:14

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 Thema: C304/OM603 build in USA  (Gelesen 1361 mal)
yitzac1990

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C304/OM603 build in USA
« am: 12.Februar 2019 15:33:26 »
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Guten tag!  I am helping a friend work on his 1975 Volvo c304. I am excited that I can work on such a unique vehicle. We are doing a Mercedes OM603 turbo diesel swap as well as complete new wiring, general cleanup etc. This is what we are starting with:



We moved the engine and some other parts to my shop:



I will try to get more pics of the vehicle.  Hopefully we can have it done before September, I think we would like to do the Tennessee Gambler 500, which is a weekend camping/off-roading trip where each participant uses "crazy" built vehicles and must reach checkpoints, all while picking up trash along the way to help clean up the land.
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yitzac1990

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Re:C304/OM603 build in USA
« am: 12.Februar 2019 15:36:28 »
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Lately  I have been working on the engine, getting it ready to go in.

alternator and pulley bracket installed, with one of the extra needed idler pulleys:



clutch cable attachment installed, had to make a smaller bracket to make up for the fact that those 2 bell housing bolt surfaces do not lie on the same face/plane:



left side of the engine cleaned up and almost ready. still need to figure out the oil cooler lines/fittings.  Does anyone have suggestions on how to convert the lines to AN connections??



EGR block off plate also made:

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yitzac1990

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Re:C304/OM603 build in USA
« am: 12.Februar 2019 15:37:57 »
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exhaust ready for custom 3" piping:



EGR hole in the manifold shut:



"converting" the throttle to cable type system:

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fuhrmi

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Re:C304/OM603 build in USA
« am: 13.Februar 2019 15:53:56 »
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Hey Yitzac,

great project!  cool
How do you solve the problems with the different engine size in terms of space, the engine mount and the position of the gearbox?
Ein Leben ohne Lappländer ist zwar möglich, aber sinnlos...


Nach FEST kommt LOSE
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OlliD

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Cummins R2.8 in c303
« am: 13.Februar 2019 20:49:19 »
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yitzac1990

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Re:C304/OM603 build in USA
« am: 14.Februar 2019 15:42:37 »
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Zitat von: fuhrmi am 13.Februar 2019 15:53:56
Hey Yitzac,

great project!  cool
How do you solve the problems with the different engine size in terms of space, the engine mount and the position of the gearbox?


There is just about 1 company/guy in the world that makes a swap kit for this that I know of:  https://www.smt.nu/volvo-c303-mercedes-benz-300ddt-6-cyl.php

so all the new mounts and adapter plate are included, and the transmission stays in the same place as factory.  There are also a few other modifications you have to make to cables/wires/etc. to make it work
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Re:Cummins R2.8 in c303
« am: 14.Februar 2019 17:22:20 »
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Zitat von: OlliD am 13.Februar 2019 20:49:19
cummins R2.8 conversion  grin
https://m.youtube.com/watch?v=c1FT6wMAY5Q


Didn't take long for my video to post over here!  I Hate writing build threads, so best option is to watch videos as they come.  And since I dont want to hijack this current thread, feel free to PM me.   
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yitzac1990

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Re:C304/OM603 build in USA
« am: 18.Februar 2019 16:09:29 »
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Got the alternator on yesterday.  Was a bit of a job, since the swap kit and parts use the stock Volvo alternator.  But that is an old, weak, 24v alternator, and this new one is a 12v 250 amp alt for a Chevy truck.  Had to make it work!  Still waiting on one pulley that installs just above the alt before I can measure belt length and put a belt on.



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yitzac1990

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Re:C304/OM603 build in USA
« am: 18.Februar 2019 18:25:31 »
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Does anyone have any ideas for a brake master cylinder replacement?  Are there any easy master cylinders that will swap in place of the OEM Volvo C304 master cylinder?  I only found one OEM replacement from a swedish site and it was over $800!!!  I started a new topic in the Brakes section as well...
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hecki28

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Re:C304/OM603 build in USA
« am: 18.Februar 2019 18:42:30 »
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Hallo
What is the problem with the master zylinder? You will get a rubber replacement kid here in the comunity at Friese. Is there any rost in the tube you will spend a lot of time to polish it with oel as I did. For a used one wright a PM to guwolo.

Regards

Christian
« Letzte Änderung: 18.Februar 2019 18:48:34 von hecki28 » Moderator benachrichtigen   Gespeichert
yitzac1990

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Re:C304/OM603 build in USA
« am: 18.Februar 2019 19:00:35 »
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the owner said the brakes were very squishy.  also it has been sitting for a while and may be dirty/rusty on the inside.  We have not taken it apart yet to look inside and see what it looks like, but I would like to know if a replacement is available just in case one is needed.
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hecki28

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Re:C304/OM603 build in USA
« am: 18.Februar 2019 19:34:00 »
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Hallo
I was searching a replacement about 2 years and found only a master zylinder at Tatanka for 800 €. With luck you will find a used one in good condition.

Regards

Christian
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yitzac1990

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Re:C304/OM603 build in USA
« am: 25.Februar 2019 14:49:39 »
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not too much significant progress made lately, but did get some AN10 fittings welded onto the OEM oil cooler lines!  ready for a cooler...

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Re:C304/OM603 build in USA
« am: 26.Februar 2019 15:59:18 »
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Please check your private message box.
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yitzac1990

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Re:C304/OM603 build in USA
« am: 27.Februar 2019 17:51:52 »
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Does anyone know why there are small rubber lines connecting to the front brakes?  What is the purpose?  Where does the rubber hose need to connect to?  Is it just a vent line?

Also, does anyone have any leads on new heater flap door control cables?  The ones on this C304 are rusty/dirty and dont move at all really...
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Re:C304/OM603 build in USA
« am: 28.Februar 2019 19:24:46 »
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Does anyone know if the C304 windshield wiper motors have some kind of relay or timer to make them work together in unison?  Or can they only be operated individually?  The previous owner of this C304 had each wiper on its own manual toggle switch.
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yitzac1990

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Re:C304/OM603 build in USA
« am: 04.März 2019 20:56:51 »
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Havent gotten much noteable work done lately due to being busy with other stuff going on.  I got some heat wrap on the manifold to help cut down on heat in the "bay":



and also cleaned up the vacuum hose routing a bit and simplified it:



hopefully I can drop the fuel tank soon, empty it out, and get ready for diesel fuel and a return system added on.
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Re:C304/OM603 build in USA
« am: 05.März 2019 05:22:44 »
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Hey Yitzac,

your project looks really interesting!
Does the length of the engine fit between gearbox and front axle without major modifications?

Does your om603 have the modified oil lubrication from the g-wagon with  for offroad use?

greetings and good luck!
- aktuell noch Fahrzeuglos, aber an einem c304 interessiert.
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yitzac1990

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Re:C304/OM603 build in USA
« am: 05.März 2019 15:00:00 »
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Zitat von: gh-mobil am 05.März 2019 05:22:44
Hey Yitzac,

your project looks really interesting!
Does the length of the engine fit between gearbox and front axle without major modifications?

Does your om603 have the modified oil lubrication from the g-wagon with  for offroad use?

greetings and good luck!


Hello!  as far as I know it should fit fine.  There are some modifications that need to be made though, that include moving over the parking brake cable, moving over the OEM throttle cable, and relocating the alternator to the driver side of the engine.  Also, the right side motor mount needs to be cut off the frame, trimmed down, and moved back to clear the turbo.

i dont know about a modified oil system, can you provide any more info on this?  We are using modified OEM oil cooler lines and will eventually add in an oil cooler for extra cooling capability.

Thank you!
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Re:C304/OM603 build in USA
« am: 08.März 2019 14:59:52 »
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I got some more work done lately.  Installed an electronic speed sender (I started a thread with this information), made a block-off plate for the OEM fuel pump on the IP, and installed a loop for the oil cooler, just to get it running.  It will be changed out for an oil cooler system later on.





« Letzte Änderung: 08.März 2019 15:01:40 von yitzac1990 » Moderator benachrichtigen   Gespeichert
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