project. Volvo V40 T4 Resurrection Shuffle.

[Snake Charmer]

Wash and brush up...........

Fitted the headlights and aftermarket indicators...........

Having a bit of a push reassembling the car with a view to getting an Mot next weekend as our Vectra has died and the Mercedes I was hoping to replace it with failed the Mot. This was supposed to be a toy not a daily. 🙈

[CaptainBoom]

Oh the horror of those plastic clips that fit in the headlight and the bulb carrier pivots on!  I rescued a LH headlight from Pease Pottage scrap yard a few years ago that had unbroken clips and looked brilliant, I put it in the van and drove back home.  Just as I lifted it out of the van, the clip in the corner snapped

I was dead chuffed* as I had pissed away an afternoon in the blistering heat, got covered in shit and now had two crap LH headlights.

I then found a guy on eBay who was selling uprated clips, as I'm guessing you have.  Fitted a pair of them and the problem has gone away... For now

[Snake Charmer]

11 hours ago, CaptainBoom said:

I then found a guy on eBay who was selling uprated clips, as I'm guessing you have.  Fitted a pair of them and the problem has gone away... For now

Yes, £9.90 for two delivered. I have one that survived out of the excellent R/H lamp I bought cheap, must have been kept out of the sun most of its life, all the others shattered like boiled sweets. The headlight was cheap as it had a broken piece showing, part of the indicator was still attached! 👍

Bumper fitting today to see if I need a new one or it has survived the bump from all those years ago. It will then need painting along with the bonnet that seems to have suffered from roof tiles landing on it. A spares car in silver would be ideal but they never turn up at the right time.

Discs and pads to fit all round and a fluid change, tidy the centre caps and polish the wheel nuts then just about Mot time.

 

[Niffleman]

AFAIK the V40 was based on the Mitsubishi Carisma and some Lancer brakes fit, including some from the higher performance versions.  This might be worth a bit of research if you find the standard brakes really disappointing. 

[Snake Charmer]

25 minutes ago, Niffleman said:

AFAIK the V40 was based on the Mitsubishi Carisma and some Lancer brakes fit, including some from the higher performance versions.  This might be worth a bit of research if you find the standard brakes really disappointing. 

I have seen Evo and FTO brake conversions but the parts are getting hard to get. Peugeot 4007 295mm discs and calipers fit drilled to the 4 stud pattern. I might look into those once I have had it on the road a while but there is an engine knock to sort out first.

[Snake Charmer]

I stripped the bumper down and pressure washed it, most of the cheap paintwork the dealer did when it was 15 months old ended up on the drive. It seems to have survived the bump but the 3 piece lip spoiler is a bit rough.

I will use it and get prices for paintwork. I have fitted it without the headlight wipers as one doesn't work and it needs to come back off again. The cloudy fog light cleaned up nicely but the outer glass looks like it has been shotblasted, the broken one I replaced.

Still needs bolting up and adjusting plus the under tray fitting but starting to look quite tidy now. 

[Snake Charmer]

Oh the joys. I decided the bumper was going on properly tonight minus the lip spoiler. Now there's  a straight crash beam the bumper doesn't sit right with the headlights, mostly the left hand side. a bit of pulling about and asking a question on a Faecesbook Volvo page gleaned a photo of the slam panel centre support rib distance from the aircon condenser should be 6-8mm larger so I will have to tease the slam panel out a little with the Epco hydraulic kit at some stage to bring the headlight up. Definitely will not need much but at least I can drive the car with the Shite bumper.

Borrowed a mates C1 for the missus until I can get the Volvo or Mercedes Mot'd, suddenly realised I have 4 Retail Silver cars on the drive, thankfully the Mercedes is Doom & Gloom Blue!

New discs and pads on tomorrow and sort out the fuel level sender with one off the spares Golf if I'm lucky. 

[Snake Charmer]

I was all brave tonight after work, car out, jacked up on 4 stands and wheels off double quick. Beer, look in here and then another beer. Chinese for dinner, beer. Doze. Beer. One caliper and disc off, clean up the sliding faces for the pads, exercise the piston and all back together. Beer. Wheels back on, polish 4 of the wheel nuts as they are stainless wrapped. Why 4? Can't find the soap for the polishing mop. Beer.

Hic.

[Snake Charmer]

Attacked with gusto tonight the front left disc and pad change. Of course I had a beer in hand when entering the workshop, and a pint in the other. No intention of doing the rear pads yet as dinner looms. Found a wee lump of brown polishing soap and attacked my nuts. Lost one round the back of the lathe as I couldn't be bothered to set the bigger mop up.  Realised there was a bigger bar of white soap in the same drawer, better lustre on my nuts.

Disc fitted, gobsmacked at how free everything is after being stood 11 years, no worse than any daily disc and pad change. Pins and pistons slide freely and they are original. I'm in no doubt a strip and re-seal would help but all they are getting is a spider and moth cocoon clearout plus fluid change. I fancy something silly on the front and nearly silly on the rear, likely homebred.

(Naff bit of prep and painting on the centre cap.)

[stuboy]

14 hours ago, Snake Charmer said:

Attacked with gusto tonight the front left disc and pad change. Of course I had a beer in hand when entering the workshop, and a pint in the other. No intention of doing the rear pads yet as dinner looms. Found a wee lump of brown polishing soap and attacked my nuts. Lost one round the back of the lathe as I couldn't be bothered to set the bigger mop up.  Realised there was a bigger bar of white soap in the same drawer, better lustre on my nuts.

Disc fitted, gobsmacked at how free everything is after being stood 11 years, no worse than any daily disc and pad change. Pins and pistons slide freely and they are original. I'm in no doubt a strip and re-seal would help but all they are getting is a spider and moth cocoon clearout plus fluid change. I fancy something silly on the front and nearly silly on the rear, likely homebred.

(Naff bit of prep and painting on the centre cap.)

just out of curiosty what mm are these disc;s?

[Snake Charmer]

11 minutes ago, stuboy said:

just out of curiosty what mm are these disc;s?

I thought they were 285mm but just checked, 281mm. There's a Peugeot/Mitsubishi disc and caliper that goes on at 295mm. S/V40 shared parts with the Mitsubishi Carisma.

[Snake Charmer]

Coco here managed to break something Volvo which appears to be made from Unobtanium, a rear ABS reluctor ring. 

Removing a rear disc, the M6 button head socket cap disc retaining screw started  to round off. Hardly surprising as they are over 20 years old, so I just drilled the head off and decided to use the other hoke Volvo/Mitsubishi decided to place 180° opposite. Being a good Engineer I decided to run an M6 tap through the 20 year old thread. Not much resistance encountered but the tap didn't seem to bottom out. On closer inspection, Coco here had pushed the ABS reluctor ring off the mounting face, so he tried gently returning both parts back to where they should be. Click. Two piece reluctor ring. 

At this point I realised the bloody thing was bolted to the hub. Never mind, order a new one and chalk it up to experience,  share it on tinternet to much ridicule and move on. No chance, disconbloodytinued. Used ones in Poland and Lithuania, loads going to the crusher attached to cars and any new ones showing in Europe over 100 Euros.

A spares car is always a blessing at this point, I don't have one, only for the Golf and stacks of Opel Manta/Ascona spares. And a shed load of 60's Honda spares, none of which ever had ABS.

Ebay after much searching......£24 delivered. £3 shy of 24 pints of Costco Stella.

Of course it wasn't that simple, I had to buy 1/4 of a car in hope the invisible part would be usable, at least I have a spare everything else now I will probably never need and a large chunk of someone else's living room carpet.

I might be able to insure and Mot the car this week. Might. 

[Snake Charmer]

Might be able to Mot this week turned into definitely did. Needs a few bits I knew about and wanted to replace over time  anyway. Biggest disappointment is the clutch slips on boost in third so no visit to the rolling road for a readout, annoying as it didn't do that 11 years ago!

Mercedes, Volvo and Golf Autoshite all on the road. 😎

 

 

[Snake Charmer]

I took it to work last week, goes reasonably well in first and second but where it used to be nice was third and fourth where the clutch slips. The aircon has leaked away too so the lazy old Mercedes is favourite at the moment!

Scoots round corners nicely but would be better with new top mounts and the soft engine mount is knocking over bumps.

I can see this becoming an expensive toy that will need garaging.

[Snake Charmer]

I have now done a total of 46 miles since the Mot due to weddings, work and the Mercedes being too bloody comfy. I must make an effort to take it to work a couple of days each week after spending all that time and money on it!

[Snake Charmer]

Shock horror the missus has pushed the mileage up to 76! In other news I now have a breeding pair.

Armchair critics calm your fur, I didn't tow the new T4 with the old one.

I added 500 miles to the Mercedes.

[Snake Charmer]

Came in tonight to find a scrap of paper with the post for scrap cars. Found another on the rear wiper of the latest addition so the thieving sea nuts have been trespassing and sniffing round checking DVLA as the other is 6 inches away and taxed.

Back garden for that at the weekend then, might scrap the Golf to make space. 

[Minimad5]

Don't be too hasty, they're probably just trying it on & being cheeky.

Always worth having cameras up though 👍

[worldofceri]

What does the  ‘other’ V40 need to get back on the road?

[Snake Charmer]

10 hours ago, Minimad5 said:

Don't be too hasty, they're probably just trying it on & being cheeky.

Always worth having cameras up though 👍

I wouldn’t mind if they just dropped their flyer through the letter box, the extra one on the rear wiper pisses me off as it means they have been nosing around and right up to my bedroom window.

6 hours ago, worldofceri said:

What does the  ‘other’ V40 need to get back on the road?

Head gasket apparently plus a few other faults from sitting several years. I have not had the time to get under it as yet and see if it is worth saving. 

[Snake Charmer]

Had a shift around Friday and moved the spares T4 into the back garden away from prying eyes.

Decided to fit the matching Piano Key trim steering wheel I've had for months, ended up with the steering column in bits to fix the annoying rocking switchgear. A Google search to see if it was a common fault showed all sorts of fixes from self tapping screws, cardboard, toothpicks and superglue. 🙈

I opted for an M5 grubscrew in a redundant screw hole.

A few threads ground off as without removing the switchgear I could not tap the thread full through.

Looks factory!

Old wheel has slightly more pronounced thumb cutouts than the Piano Key wheel.

Also topped up the washer bottle after 75 miles so now wondering if there's a leak.

[Snake Charmer]

The missus has used the car a few times recently and did a tip run. I used it for work today as it had more fuel in than the Mercedes and pushed the total mileage up near 130 since the Mot July last year. Needs a wash. I like the Mercedes too much hence the low mileage. I'm starting to wonder why I have two T4 Volvos and only one Mercedes. 

[Snake Charmer]

I found a spare aerial from the Terrano and thought I would fit it to the Volvo and replace the roof seal at the same time. No such luck as it has an M6 thread and the Volvo is M5. Never mind, I will have to suffer with a spark plug boot on the old one for a while until I can look cool again.

Discovered a small leak from one of the Hatch cable grommets that needs a little rust repair, that can wait until the summer and have a coat of DumDum putty for now.

 

[Snake Charmer]

I laid up the Mercedes for a few days awaiting parts as it is running cool and used the Volvo for work. I really must dive into this car and sort some of the faults out. A new squeak has developed, sounds like rusty exhaust rubbing on a heatshield over bumps and only audible with the radio turned down. I don't remember if the CD player was supposed to eject the CD when switching the engine off but it does now. Engine mount knocking, known problem on 2ltr engines apparently. Strut mounts knocking and steering feels mushy soft. Little end rattle seems more pronounced at gear changes after a recent thrashing.

Why did I lay this car up in 2010? Oh well, the wheels still look good. 

[Snake Charmer]

The other half took the Volvo shopping on Sunday and commented that the rattling was worse, I didn't think anything of it until I moved the car to work on the Mercedes,  God's teeth it's horrendous! I think the VVT has failed, time to SORN for a while and start stripping it down.

[Snake Charmer]

SORNed now. 😔 Moment of madness last night, I bought a modified shed of an S40  with a spare engine. 🙈 I now have 3 Volvos.

[Snake Charmer]

Collection said shed with @bobdisk tomorrow. Banning Bob from taking shaming photos. 

[bobdisk]

We will see, there might be a clandestine camera

[Darling]

we want video...

[Snake Charmer]

9 hours ago, bobdisk said:

We will see, there might be a clandestine camera

A clandestine winch handle would have been nice!! 🤣