Why not try and rehab the original clutch with some toyota viscous fluid. That was the reason it wasn't engaging at temp. It's an easy fix and works great. Might be why your used clutch isn't engaging as well.

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1987 300TDT 278K My Addiction (Going Going Gon...)

2001 Volvo V70 (New Ride)

Hey Bob, I have not needed to mess with the aux. fan operation as I live in New England where it would seldom be needed, and therefore have only a cursory familiarity with its system and controls.

That being said after looking at the 124 ETM, I'd guess the first step would be to find the power connector and with a 12V DC source verify the aux. fan functionality, assuming that it works it would be logical to then test the K9 Auxiliary Fan Relay. This would be done by finding the three pole coolant temp 105/115C switch, this is the switch with three wires connected to it, find the brown/green stripe wire, when this wire is connected to ground it should operate the K9 Auxiliary Fan Relay in the fuse box which in turn should cause the fan to operate. If the fan operates with this wire connected to ground the K9 relay is in working order. The way the switch can be checked would be to get the engine temp up above 105C and the verify with either an Ohm meter or a test light that with coolant temp above 105C the terminal to which the brown/green stripe wire is connecting to Ground.

If you verify that the fan operates with power connected and you've verified that the Auxiliary Fan Relay is operational it would be a fairly simple matter to run a wire from the disconnected brown/green stripe wire to one pole of a toggle switch in the cabin an then from the other switch pole to ground. That way you could operate the aux. fan at full power as needed.

Here are a couple of threads that sort of deal with auxiliary fans in 124 cars that might be of some help, you can also search under "gsxr" as Dave is very knowledgeable with these cars and this issue, good luck!

http://www.peachparts.com//shopforum/showthread.php?t=252895&highlight=auxiliary+fan+switch&page=2

W124 92 300D OM602 Aux Fan Question/Trouble Shooting


P. S. if you have not already carefully checked and cleaned the connections for fuse number #7(8amp) for the K10 Auxiliary Fan Pre-resistor Relay and more importantly fuse #D(16 amp) for the K9 Auxiliary Fan Relay

I intend to rehab the old one in the near future, but I need to drive my car now

Can't the 603 fan be used with the 103 clutch?

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Gone to the dark side

- Jeff

The fan will bolt to the clutch!

The clutch I assume is designed for a particular direction of rotation as it sports a direction of rotatoin indicator arrow on it. As I understand it the design of these fluid clutches include a spiral fluid passage which I'd assume have rotational directions with respect to the application rotational directions. I don't think there has been anything but anecdotal information about an M103 clutch functioning on an OM603 as designed. To know for certain someone would have to direct heated air at the clutch's bimetal strip in situ and then do the same with the other type clutch and compare and contrast any differences.

With the price for replacement OM603 cylinder heads being what they are, experimenting on the road under real world conditions seem "pennywise pound foolish", no?

M103 viscous clutch on the left, OM603 on the right.

Attached Thumbnails

   

ok, original chipped om606 fan reattached to the om606 fan clutch. we'll see how it goes.

i did not test out the parts you mentioned, billybob. I'll give it a go tomorrow.

thanks to all.

[QUOTE=bob_98sr5;2284491]i did not test out the parts you mentioned, billybob. I'll give it a go tomorrow.[QUOTE]

I only mentioned testing of the parts as a way to confirm or disprove the contention that the CCW rotating M103 viscous clutch was a suitable functional replacement for the CW rotating OM603 viscous clutch, although the method of directing heated air from a heat gun to the bimetal strip would be the only way I can think of to get the viscous clutch to actually operate as designed.

happy to report this morning that i did my usual drive to work (with nearly identical atmospheric/weather conditions) that the 0m606 fan clutch w/ the original om606 fan performed without issues. on the fwy drive, the temp was barely a tick above 80C. after that 25 min drive, i exited and at every stop at idle, the temp i estimate around 85C, never past 90C.

a big thanks to all for all the help in this thread. I'll be posting more pics later esp the tool design

How about the 603 fan on the 606 clutch then? Has to be better for the clutch and bearings than a broken/out-of-balance 606 fan.

__________________

Gone to the dark side

- Jeff