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After a really bad night with pain and no sleep (still off work sick) I wasnt expecting to achieve much today but then things just sort of clicked for once.
I've worked out that I can use the power steering pump from the 1.9 engine using the 2.4 pulley, this means I only have to change one steer pipe (the pressure feed from the pump)
And while my dilema with the pas belt tensioner continues, I deciede to just fit it all and sort it out at a later date, something I will probably regret looking at the access.
This isnt right though, no wonder it was squealing its tits off. Hopefully a new belt will cure this.
Next problem was the issue with the engine mounting, bare in mind im still new to all things T4. It was confusing me why the engine mounts were so different.
Now I'm not sure if this is a difference between early late T4's or just a difference between 1.9's and 2.4's? but after a quick measure things made more sense.
Late engine mount with 1.9, just over 30cm
Early engine mount with 2.4 approx 27cm
Which explains the 3-4cm difference in the rubber mounts.
Next problem then was the engine mounting of the engine mount, if that makes sense. On the original 2.4 rubber mount the bolt goes through the mount and into a thread on the engine, on the 1.9 the rubber mount is bolted from underneath.
Not a big deal but it was do or die as it was either going to be correct or I was about to screw up the mount on the 2.4,
Out came the drill.....
And the thread was no more.
All bolted up,
Then in the hole it want, was a little faff with the driveshafts but got there in the end. I always tell our apprentices in work that even if it takes time that when rigging an engines/pumps/transmissions etc take the time to get them level or at the right angle they need to be.... didnt take my own advice here really and had to rotate the engine round in situ.
So just electrics and plumbing to sort out now, even though im rushing a little to get it in and running I have got some preventitive maintenance and repairs to do. New glow plugs in while access is (semi) easy and the obvious water leak to repair.
This was leaking from the lower water temp switch but looking at the mess and after inspecting the joint there may be a crack in the housing (just visable aove the top bolt)... more dealys!
And the metal water pipe was looking a little iffy so that got a rub down and lick of paint.
Not sure if I can get down the unit tomorrow so hopefully Wednesday it will be running.
Last edited by 89Rallye; 9 October 2017, 06:38 PM.
Thats the final plan buI for the time being getting it running is priority. I have two bays sapping all my money so i'm on a very tight budget with the T4, Ideally I'm aiming to camper it for under a grand, insulate, carpet, bed/units and a split charge system.
Well that was all the plan, right now im thinking i'd like to drag it outside and burn it to the ground.
Managed to get 3 hours down the unti today but sadly didnt get through todays tick list,
Still waiting on some parts, so todays plan was to sort the fuel, wiring and water hoses then to hopefully test fire it.
This cleaned up well, thanks mainly I think to the wax.
With very little rust to treat.
Fuels lines connected and I replaced the wax that had gone dry and peeled off with a fresh coat of waxoyl
So onto the water pipes next, nothing very exciting but was a little bit of trial and error here mixing 1.9 and 2.4 pipes where required.
Glad I ordered a new one of these, at £6 for a new one I'm going to gather this is a common fault.
Although there isnt much wiring to complete a few things were confusing me until I realised the 1.9 didnt have as many sensors as the 2.4.
Rightly or wrongly I've decided to fit the 1.9td sensors (water and oil) as that way I can retain the later (and better) wiring plugs.
I'm having to extend the loom and theres also a few repairs (and previous botches) to repair along the way.
So with enough wiring in place to attempt a quick cheeky start up... the enthusiam was smacked right out of me..
Attempting to bleed it up and the pump is just pissing fuel from the throttle shaft, it wasnt leaking prior to removal so im assuming I've disturbed something.
Now I cant complain really because I got this engine more or less for free and while its not the end of the world its just another delay and yet another problem to sort.
You know those days were you have a plan of attack all thought out, the simple little jobs that you have to tick off the ever growing list...
and nothing goes right and you come away at the end of the day feeling utterly deflated. This T4 is kicking my arse and patience.
I know the throttle shaft is worn (and leaking) on the pump but I decided to see if I could stick a new seal in to see if I could at least get the engine running.
I didnt take many photos but its a pretty simple case of removing the top of the pump pulling the shaft and changing the o-ring,
Remove the nut on the arm,
This was probably the most difficult thing to do, there is a ring that has to be removed without disturbing the arm on the shaft. Revealing the markings.
when I got it all apart the brass bush is practically oval and the shaft is pretty worn too so I knew my quick fix wouldnt work..... and it didnt, so no running van today.
Then it was underneath to fit the exhaust clamps at the manifold, any tips here more than welcome. I bought the tool, managed to get one on that I could reach around the engine but trying to do the inner one from underneath was a mare then I broke the tool!! and gave up..
I did however get the new upper water flange fitted and finished extending the wiring, all soldered and heat shrinked like it should be.
I have some nice new factory looking conduit it will all go in then installed onto the metal water pipe in the factory location.
Next up I want to try and run the alternator off 1.9 but it was on a later ribbed belt and not a V belt and mounts differently to the block so this may take some head scratching.
Sadly not a very exciting update, I'm pushing to get all the mechanical stuff done so I can get on with the fun stuff but the Fag is pushing back just as hard.
I've been laid up since Saturday with my leg giving me jip again, although when I do get time on the van it feels like its one step forward, three steps back at the moment.
While i've been waiting on parts for the fuel pump I switched my attention back inside.
Two layers of insulation fitted, this was 'gifted' to me and I've had this lot kicking around my garage for about 14 years! glad I held onto it now.
Managed to complete the floor, lots of measuring and only one cock up but will have to live with that.
Finaly lots of parts this afternoon, I was going to leave this job till tomorrow but impatience got the better of me....
Starting to wish I'd left it..
So strip the pump again,
Pull out the old bush,
Old worn spindle with new,
Then I managed to utterly fuck this up! I got the engine started and it was just racing up to full throttle, after attempts to adjust the throttle lever on the shaft it was the same so I opened it back up again and found this.
Not sure how it happened but at this stage I was ready to throw the towel in for the day, then decided rather than wait for the parts I would salvage them from the other (1.9) pump,
My last headache with the engine is the alternator,
Plan is to use the 1.9 alternator which is a ribbed belt on the 2.4 engine which is a V-belt setup. I'm going to this trouble as the early alternator doing have the W terminals etc for the rev counter.
So the V-belt pullet was adapted to fit the 1.9 alternator.
Leaving me with this problem,
I planning on building a CAD (yes the cardboard variety) designed bracket but i'm going to look at a later engine to see what mounts they use,
Last edited by 89Rallye; 19 October 2017, 09:28 PM.
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