New Volvo c304 owner new engine swap/ camp rig project

Volvo TGB and 30X (303/304/306) mods and resto work, news, resources and non-technical stuff
tmoney
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New Volvo c304 owner new engine swap/ camp rig project

Post by tmoney »

Hey Guys!

I've never been great at this but I figured I will probably need some help from you guys during this build!
I am starting my first ever build thread!!

Here it is my 1975 Volvo C304 aluminum body 6x6. I ultimately want to build an offroad go anywhere camping vehicle that I can maybe touch 15-19mpg and 65 cruise speed (hopefully more)
So far I have decided I want to do a few updating mods like power steering(either electric or hydraulic), Disc brakes, possibly do a 4link with the suspension and coil overs. I would also like to change the vacuum actuators on the lockers to air powered. Right now what I am trying to decide on is which power plant I will be using.

Some of the top candidates I am thinking right now is...

Isuzu 4bd1t
Mercedes OM648
Cummins 6bt (I dont think this will fit)
Cummins R2.8 (new Crate motor)

Let me know your guys thoughts!

Thanks for your feedback!
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dokatd
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by dokatd »

I am slowly working on the R2.8 option. I mostly need to gather the dimensions from a B40 so I can draw up the adapter plate in SolidWorks. Just not a huge priority for me at the moment. I will probably buy the engine early 2019 I would guess.
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GadgetPhreak
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by GadgetPhreak »

I'm currently in the middle of installing that engine in my FJ40. Along the way I've been evaluating putting one in my Pinzgauer Image

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dokatd
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by dokatd »

Pinz would be a heck of an install for the 2.8. Volvo would be vastly easier that’s for sure.
dokatd
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by dokatd »

I have had several long discussions about the R2.8 swap. Several of those conversations have been with the Cummins repower division. I have all the R2.8 Cad information I need, but now I need the Volvo side for the transmission. I have a shop to CMM the transmission or possibly the back of the engine (probably better to use a B20 to fit CMM table). So the only hold up is getting a block in my hands without pulling my personal B30 from my 303 or my B20 from my boat. Anyone have something on hand?
dokatd
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by dokatd »

Minor update, I secured a bell housing and will be taking it up to the CMM shop this coming week. By end of the week I should have the bel housing adapter drawn up accurately. I have already drawn it fully based on caliper measurements and all looks great so far. Just have to adjust once I get the CMM measurements. So far this appears to be a very simple swap in relative terms. Maybe not cheap, but it’s a potentially very sweet setup. If anyone is legitimately interested this is a good time to speak up. At the moment I have two trucks to potentially convert and would be willing to consider having more adapters cut at the same time.
Jim Molloy
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by Jim Molloy »

Tmoney,

Congratulations on picking up what appears to be a solid AluZn TGB13. You might wish to make contact with Ozzie Pleasant as he is in the process of completing a camper conversion on his TGB13.

Raredog.dk has also done a very nice job on their TGB13.

I am curious as to how you plan to achieve the 65mph cruise speed. That is FAST for a Volvo C-series 6x6! Larger diameter tires? Swapping out the three original R&P sets for faster (either TGB11 or after market) units? Replacing the portal gear sets? Replacing the original 4 speed trans with something with O/D? Swapping engine with one with much higher maximum rpm? Combination of some or all of the above? Just curious.

I am steadily working on making our 1975 non-AluZn TGB1314 ambulance more livable. It certainly runs more economically since replacing the defunct original B30A with a Mercedes OM617A. For the sake of reliability, we have chosen to not add additional HP and I really enjoy the off-highway climbing ability of the stock gearing and tire size. The only time our TGB1314 would see 65mph would be on a trailer like yours being puled by a pickup like yours.

We look forward to seeing the details of your build.
Take care.

Jim Molloy
Waldersee Farm
Sheridan, Oregon
http://www.northwestmogfest.com
tmoney
Canada
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by tmoney »

So I bought a wrecked 2005 Mercedes E 320 CDI

Its got the OM648 mercedes engine

To get that cruise speed I plan to swap the R&P to the T-Max 4x4 Malaysia they will give me a 5.32 axle ratio

The 722.6 transmission has an OD gear of .83

and 37 or 38" tires should give me a 65mph@2600 rpm



I plan to swap to the W5A580 version of the 722.6 with the 4x4 and I would like to adapt an LT230 xfer case.


The hard part is going to be a stand alone trans controller and stand alone ecu. (gotta love the electronics)
Those R&P are $500 per axle so not too bad.

Love that cummins 2.8! I should be much less in my swap than the 9k buy in price of that bad boy... Otherwise I would have probably chose that. Car will arrive in a couple of weeks ill take more pictures then!
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tmoney
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by tmoney »

Jim how did the om617A turn out? Do you think the om648 will fit just fine? It seems wide with that intake but I have been preparing myself to have to do a custom intake
Jim Molloy
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by Jim Molloy »

Tmoney,
Sounds like you have a well thought out plan. I believe there is a fellow in eastern Europe who was making 5.00:1 R&P sets for the TGB as well. Blanking on his name right now but I know he is active on the Facebook TGB and C303 page. I believe he also sells a race-tested disc brake conversion as well. With maximum HP being reached at 4200 rpm on the OM648, the cruise speed of 65mph@2600rpm will give you the fastest TGB on the planet at WOT.

The OM617A is an easy fit. It is rotated 13 degrees toward the passenger side so the large oil filter housing stands vertical. The only other engine modification is to the oil sump drain. New hole is drilled and threaded bung installed to have a drain at the new lowest spot of the sump. The newer OM engines have a far more industrial angular faceted outward appearance in keeping with TGB bodywork as well as greater horsepower and torque. The SMT kit to install the OM603 does require some minor body floor panel trimming. I have now idea about the newer MB diesel offerings.

I look forward to following your build as it progresses.
Take care.

Jim Molloy
Waldersee Farm
Sheridan, Oregon
http://www.northwestmogfest.com
tmoney
Canada
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by tmoney »

I am definitely excited to get cracking on it!

Mostly concerned about two things at this point...

A: I did not get measurements of the motor before I bought the wrecked E 320... I just assumed that they were the same or very close in size to the 606 that I know has already been swapped (so I hope it does fit.. or if not I will have to make it fit)

B: Once I get it to fit I am concerned about the electronics on this engine and the fact that it is a bit rare and not a huge aftermarket base and not a huge following or help on tweaking it to run. (Might have to go with a completely stand alone computer and that could get costly and put a major damper on the whole project)


If any of you know a Mercedes guru who would have a good insight on how to setup the electronics on this motor please let me know!
Jim Molloy
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by Jim Molloy »

The diesel guru closest to me is most familiar with the OM61X and later OM60X powerplants.
You may find someone here: https://www.facebook.com/search/top/?q= ... SEARCH_BOX
There is always BenzWorld

Best wishes.
Jim
Jim Molloy
Waldersee Farm
http://www.northwestmogfest.com
tmoney
Canada
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by tmoney »

Car arrived last weekend. Engine is out and on the garage floor. Moved the rest of the mercedes to the back yard to continue to rob parts from it.

C304 has now taken its place in the driveway.

With a little push from the c303 the 6x6 now sits in the dressing room where she will be stripped down to the bare frame (hopefully tomorrow!)

I drove the mercedes around for a few days before putting her under the wrench, and i was impressed! When I babied it around town the computer was reading 38mpg and it had plenty of power to boot.

I am extremely excited about the project and I hope I can find all the information and resources to complete the swap from the electronics standpoint. I suppose if I cant get it done ill be looking for an om617
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dokatd
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by dokatd »

My R2.8 is on its way. Excited to get my hands on it and see what surprises I run into fitting it.
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TechMOGogy
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Re: New Volvo c304 owner new engine swap/ camp rig project

Post by TechMOGogy »

dokatd wrote: Sun Jan 06, 2019 7:03 pm My R2.8 is on its way. Excited to get my hands on it and see what surprises I run into fitting it.
Will be watching for the build thread on this as that engine looks great!
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