sutty2006 Posted October 12, 2019 Share Posted October 12, 2019 Aye a fresh head and rest and it’ll fly on. Good work sir. Did you have a straight edge over the cylinder head? scdan4 1 Link to comment Share on other sites More sharing options...
scdan4 Posted October 15, 2019 Author Share Posted October 15, 2019 Another couple of hours trying to affix the sodding turbo drain pipe resulted in "Fuck it" .So I SEP'd it before I lost all will and reason. Send it into supertom. And it caused him some swears. An All Action Hero at work. Doesn't he look happy. He did it though, but the pipes (both of them) turned out to be twisted, so it wasn't a 5 minute job. Made me feel a bit better. ? And then he helped me torque the head on. I must have been looking a bit desperate! Ran out of time today but it's moving forward again. Squirrel2, Dirk Diggler, Tickman and 5 others 8 Link to comment Share on other sites More sharing options...
sutty2006 Posted October 15, 2019 Share Posted October 15, 2019 Yay progress! Link to comment Share on other sites More sharing options...
scdan4 Posted October 15, 2019 Author Share Posted October 15, 2019 Of course it will work, how could it not? Link to comment Share on other sites More sharing options...
scdan4 Posted November 5, 2019 Author Share Posted November 5, 2019 And it does work. Which is lucky as life dictated that it was put straight to work. The Airbag light is on which is looking like needing vol-fcr to diagnose and extinguish . I Am about to stick it christmas list. I’ve got a laptop and lead ready to go and have tried the rip off versions without success but believe the genuine item will do the deeds required (as the official trial version communicates well with the car) Because it’s so specific and software I’ve got a bit of a mental block about buying it. It’s 125 quid so not the end of the world. The abs light is on as well, but that’s because I hit the already fragile Ecu with the engine when reinserting it. A much manlier reason and I’ve got the spares to sort it when I can / care. And I don’t care right now as the new brakes tyres and suspension combo are outrageously awesome and the ecu will be much easier to sort out when there’s not an engine in the bay. Considerately designed car this Volvo, That spanner’s been there 2 weeks! (It’s been put safe now). I managed a couple of hours at the unit this morning. The original block is on the engine stand, lightly cleaned and now lacking shrapnel. So used the the time to pop off the main bearing caps and have a look not quite in focus but hopefully you can see that they’re in great shape for 230k. put them back on using PD150 bolts as they’re stronger, 12.9 rather than 10.9. Hopefully this will matter. 65nm then 90 degrees, “Tom can I borrow your torque wrench?” The beast, previously featured 10mm for scale. It even counts the angle if you use it as a ratchet. Sweet. Don’t Drop It! Whilst it’s a joy to use there is a relief in giving it back. Pow. Done. New gasket as well, dead posh like. Just need to pop the lid on... 27 fixings to hold that ally cover on! Seems unnecessary. And ta da, bottom end done. ? Lacquer Peel, sutty2006, w00dy and 5 others 8 Link to comment Share on other sites More sharing options...
scdan4 Posted November 9, 2019 Author Share Posted November 9, 2019 The gift that keeps on giving... On Thursday the alternator died. Which was a pleasant surprise. Today I fit a new one (well, reconditioned but it actually came with a guarantee and everything). it seems to have a bit of an appetite for alternators, although it’s never had a new replacement, so I cleaned up the mating surfaces well and will renew the earth straps soon. Its a bit buried... Remove power steering pump, glow plug harness, coolant top hose complete with cylinder head barb, vacuum pump, aux belt, aux belt idler and the rocker cover and it just slips out. Refitting is the reverse of removal, as the great book once said. It took about 4 hours start to finish, which I think is a little better than expected. Runs smoother now, which is nice. There’s a bit of time left so I go to nose the abs. All looks ok, box still sealed, wiring still plugged in. The fuse however is toast. 50amp, so not small. Hunt out another one and pop it in. Stand back for a slurp of tea and oh shit fire. Well, no fire but a lot of smoke from the abs unit. I removed the fuse and put that to the top of the do next list. If this car could speak I think it’d be gasping “ffs just let me die you cunt “ ? Drove it home In torrential rain and grinned all the way. warninglight, stonedagain, mrbenn and 5 others 5 3 Link to comment Share on other sites More sharing options...
scdan4 Posted November 17, 2019 Author Share Posted November 17, 2019 Let's have a look at this abs unit then. It should be something small, perhaps all being well I could identify a blown thingy and swap it for a tandy special, fixing the whole shebang for 19p like those delicate clean small handed people on the Internet do... Not sure that this is the time to start learning circuit boards. And it stinks. Defo been a bit hot. For once the hoarding tenancies paid off and I just slapped on the spare. Had a long stern talk to my teenage self, then cleaned the numberplate lights. (but the rozzers can see your number now innit! What about sticking it to the man?) One done. Should make a difference. Still feel like a traitor. (snapped plates, no plates, Maltese plates, m for n and d for p swaps, dogshitted plates, amongst others, and now this. I'm getting old and times are different) And then had to stop for a pause on the way home at the base of the local big hill. So I properly launched it for the first time. And it went like a goodun, holding 16psi on the boost gauge and charging up it. ? It may have been a bit of a pain of late, but I do like this car. Tickman, mrbenn, Lacquer Peel and 2 others 5 Link to comment Share on other sites More sharing options...
Lacquer Peel Posted November 17, 2019 Share Posted November 17, 2019 Have you fitted the big turbo yet? Link to comment Share on other sites More sharing options...
scdan4 Posted November 17, 2019 Author Share Posted November 17, 2019 Not yet, that’s going to go on the block with the stronger bottom end. But life gets in the way. Link to comment Share on other sites More sharing options...
scdan4 Posted November 21, 2019 Author Share Posted November 21, 2019 I tried to go to work today but they were digging up all of the road to the jobsite. A whole estate, no way in or out for a good few hours. What a shame, when I found this out I had to go engine fiddling instead. ?. Spun the block the correct way up on the engine stand, (still loving the engine stand) And cleaned it back with flat mounted wet and dry. ?. Then we went head hunting and looked at the ebay" rebuilt head. " Doesn't look freshly rebuilt does it. Stripped the cam out, and the cam caps were way too tight. But then 10 brand new hydraulic buckets fell out. Cleaned it. Put the straight edge on it and... it needs a skim (just a little one). Bah. I have no monies at the mo for frivolities. Perhaps if I tried harder to get to work...Broke it down and discovered new valve stem seals, hurrah, and 2 stuck valves, boo. Tapped them out with a drift. Ho and indeed hum. Whilst I was in the swing of things I dug out the broken head, just to confirm it was beyond saving. And it definitely is, the amount of damage to the walls of the bucket holes is enough to render it useless. Even if I could get all the buckets out, which I can't. It will be useful as a dummy though to keep the other one tidy for the machine shop. Some progress then. The engine in the car has a dicky injector. This shows on cold starting. MOV_0618.mp4 I've ordered some injector seals and will swap the injector set over to see if that improves it. Can't make it much worse! Coprolalia, Jim Bell, Squirrel2 and 3 others 6 Link to comment Share on other sites More sharing options...
scdan4 Posted December 18, 2019 Author Share Posted December 18, 2019 Brrr. The boost gauge stops the air vent from shutting, which has become a bit of a problem with the cold mornings. It's not quick to warm up, and blows cold air directly at your face until it does. Not the classiest or most invisible of modifications, but hopefully effective! rainagain, Coprolalia, Jim Bell and 2 others 5 Link to comment Share on other sites More sharing options...
scdan4 Posted December 18, 2019 Author Share Posted December 18, 2019 Back brake was dragging very slightly. I'd not have noticed or worried but supertom is good at pointing out shit like that. Popped the pads out and cleaned greased the pins. Pushed the pistons back and they were lovely still (good). All back together no drama. The main point of this is how ace my mansize birthday jack is. Still not bored of using it. ? Slide it under without scrabbling on the floor, check alignment and up up and away. ?. And the best bit is no one can come and demand it back mid job because its mine! sutty2006, paulplom, Coprolalia and 3 others 6 Link to comment Share on other sites More sharing options...
sutty2006 Posted December 18, 2019 Share Posted December 18, 2019 Great stuff. I remember replacing the back brakes when I first had it. Might have even had a rear caliper but can’t remember which side. Enjoy it now, stop pulling it to bits ? Link to comment Share on other sites More sharing options...
scdan4 Posted January 6, 2020 Author Share Posted January 6, 2020 It's still smoking like a northern nan when cold, so swapped the rest of the injectors (so it's now back on the red cars set) and checked the timing.. 0.55 is the magic number. Son of a.... Luckily, for your convenience you can adjust it by moving all of the components pictured. That's 0.55 mm we are searching for... There is no fine adjustment mechanism. Patience little one. Ding dong. ? Thats close enough. Wonder what it will be like in t'mernin The Moog, Shirley Knott, sutty2006 and 3 others 6 Link to comment Share on other sites More sharing options...
Tamworthbay Posted January 6, 2020 Share Posted January 6, 2020 What is the little timing device hiding in there? Looks a very useful tool. And where did you tap into for the boost gauge? Link to comment Share on other sites More sharing options...
scdan4 Posted January 6, 2020 Author Share Posted January 6, 2020 That’s a 40mm dial gauge attached to a VAG3313 (I think) diesel pump tool. Goes up the central port of the injection pump. 0.55mm piston lift is desired at TDC. Zero gauge on approach as you creep the engine over Boost teed into the inter cooler outlet to turbo control valve. Probably not the best place and next time would tee into the MAP sensor feed (by the expansion tank) Jim Bell, Shirley Knott and Tamworthbay 3 Link to comment Share on other sites More sharing options...
Cooper1 Posted January 6, 2020 Share Posted January 6, 2020 Love this. My Dad had the 2.0 B5202s unit in his '98 torslanda. Slow as fook 126hp, but sounded nice reliable as a brick too scdan4 1 Link to comment Share on other sites More sharing options...
Tepper Posted January 6, 2020 Share Posted January 6, 2020 I see you too have had your fair share of headaches at the hands of a 5 pot tdi Volvo - excellent work sir. Very much looking forward to seeing what you can do with the built engine and turbo! scdan4 1 Link to comment Share on other sites More sharing options...
scdan4 Posted January 9, 2020 Author Share Posted January 9, 2020 A smidgen of fettling the new engine has occurred. The manifold turbo flange is an odd size and despite much internetting I could not find out either what size it was or anything to fit it. Got a link pipe that almost fit and was intending on lots of drilling and filling but super Tom decided that that was a shit idea. "go clean them up with a flap disc and get it as hot as you can with a blow torch" says e. ? Is there nothing he can't do? Left it being heated by the blow lamp to even out the cooling stresses. Jolly Good. ? Coprolalia, Tickman, Shirley Knott and 4 others 7 Link to comment Share on other sites More sharing options...
scdan4 Posted January 17, 2020 Author Share Posted January 17, 2020 Clocking the turbo... Aka making it fit with the nozzles pointing the right way. Well, it fits, but oil feed and drain, and snail are all wrong and the waste gate actuator doesn't. So ever so carefully take it to pieces.. Twist everything relative to itself Refit it all pointing the correct way *, make a bracket for the waste gate dodar Looks good and my tape measure says it will fit. ? Oil feed and drain next. Then work out how to attach the exhaust... (*by eye. What's the betting I'll be here again!) w00dy, Coprolalia, Shirley Knott and 6 others 9 Link to comment Share on other sites More sharing options...
scdan4 Posted March 6, 2020 Author Share Posted March 6, 2020 It’s that time of year again. Off to to see the man from the ministry, which provokes some thought, as it was shortly after this last year that it shit itself. It’s had a busy year, engine swap, hgf, new shoes and suspenders, I’ve learned lots. Including just how much more poke there is hidden in these engines. It’s had a cheeky decat, egg blanked, turbo boost max pressure upped a bit and it goes like stink. Comparatively. Bah. Set to be sorted Monday. Probably. I was being grumpy and fucked off that the turbo nutter bastard engine isn’t in it yet, but as it hadn’t even been considered a year ago I think I might be being too hard on myself. Some skills we seek to learn, others we seek to lose. However, A Great Leap forward has been made with tnb engine today though as we now have oil feed to the new turbo. This Has been surprisingly problematic to sort out as the old vag fittings are big, course and chunky, whilst the holset feed hole is smaller, more delicate and in the wrong place. After much farting about I Ended up with SuperTom making an adapter out of 2 other adapters for me. He’s fab but I’m going to prioritise learning to weld to next. #lifegoals Shirley Knott, sutty2006, Coprolalia and 3 others 6 Link to comment Share on other sites More sharing options...
sutty2006 Posted March 6, 2020 Share Posted March 6, 2020 Couple of easy enough failures no? scdan4 1 Link to comment Share on other sites More sharing options...
mrbenn Posted March 6, 2020 Share Posted March 6, 2020 The fuck? An EML isn't a failure on a diesel of this age is it? July 2008 onwards cars IIRC. scdan4 1 Link to comment Share on other sites More sharing options...
Eyersey1234 Posted March 6, 2020 Share Posted March 6, 2020 @mrbenn is right, an EML is only a fail on a diesel from 1st July 2008. scdan4 and mrbenn 2 Link to comment Share on other sites More sharing options...
scdan4 Posted March 7, 2020 Author Share Posted March 7, 2020 Shouldn’t fail on that no. Mr tame mot tester has genuinely had a terrible week and his mind was clearly elsewhere. Not to worry, all under control I am assured. ?. Seems to be a SEP at the moment, which is nice. Supertom is on it. Apparently. mrbenn and Shirley Knott 2 Link to comment Share on other sites More sharing options...
scdan4 Posted March 11, 2020 Author Share Posted March 11, 2020 Ta daaa Another years ticket. Apparently, so the jungle drums say, any warning light on is a hard fail now. I've just stopped caring for 12 months. ? BlankFrank, Tepper, The Moog and 6 others 9 Link to comment Share on other sites More sharing options...
sutty2006 Posted March 11, 2020 Share Posted March 11, 2020 Yup any EML or emissions related warning light on is a failure regardless of age. Glad it’s passed now! scdan4 and mrbenn 2 Link to comment Share on other sites More sharing options...
DaveDorson Posted March 13, 2020 Share Posted March 13, 2020 Don't suppose you've got a spare set of injectors knocking about have you? Apparently it's a bit of an upgrade for the Stanadyne ones in my VW T4 88BHP Link to comment Share on other sites More sharing options...
scdan4 Posted March 13, 2020 Author Share Posted March 13, 2020 I don’t have a spare set, no. You can get nozzles easily of fleabay to make yours bigger, the Volvo has .216 holes which are the biggest standard ones afaik. My limited knowledge says that that pep up needs the turbo as well, and manifold to fit it else it just makes smoke. DaveDorson 1 Link to comment Share on other sites More sharing options...
scdan4 Posted April 13, 2020 Author Share Posted April 13, 2020 Corona cleaning on a bank holiday Monday. Tickman, paulplom, Tepper and 4 others 7 Link to comment Share on other sites More sharing options...
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