Worked for Volvo from 83 to 98 we used to blanked off the egr from new on the vdub powered Volvo 740s
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Swapping sausages - TDI conversion thread
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Swapped the oil pickup and sump, van one is on the left. Little tip - when you fit the new pick up and wonder why it's not quite bolting up right, make sure the old o ring from the removed pick up isn't still in the oil pump housing (ahem)
Chased out the threads for the engine mount then drilled and tapped the third hole from m6 to m8
Now to clock the turbo...undo the four bolts on the cold side housing
Rotate the housing and replace the bolts
So why have I done this? Well... managed to convince Dave that a front mount intercooler is WAY more effective than a top mount interwarmer so it'll make more sense to send the cooler pipes as direct as possible
Needs a tweak to the metal pipework but it's nearly there.Last edited by regcheeseman; 9 July 2017, 12:23 AM.
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Engine in!
Just a test fitting, good job I tried it first as there is a bit of a clearance problem
The intercooler pipe should come out through here, clocking the turbo was a good shout
As I'll have to make some clearance for the turbo, thought I'd better lift the cab floor mat to ensure I am not going to damage something in the process, that's when I discovered another of Dave's dirty little secrets...
Massive long holes between the step and the wing and a massive hole in the step itself
Nasty.Last edited by regcheeseman; 9 July 2017, 12:26 AM.
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While the site has been down there has been action at cheesetowers
Dave bought me a different gearbox and to add to my joy it had some snapped off seized bolts
Oh the joy, two more!
The starter motor came out with two locked nuts on the remaining portion
The gearbox mount resisted heating, penatrating fluid and beating to hell with a big hammer, in the end I had to drill it from 3mm to 10mm in 0.5mm steps - that was fun but at leas the drill stayed straight.
Just to add to my fun, I found some more rust under the battery tray
And cut out
Plated over
Dave also bought me a darkside clutch and flywheel - for some stupid reason it has no TDC mark on it - except this very feint mark
Which turns out isn't even at TDC, so I had to find TDC and punch my own mark - arsehats.
Finally, fitting the sump pan, the last two M6 bolts wouldn't go in, well they would but they wouldnt tighten - because the seal housing has M7 threads.
M7 bolts wont go through the sump holes so I had to take it all off again, drill the holes out and refit. twatbiscuits.
After all this, I took my hate out on the bulkhead with a big hammer
The engine got cleaned
And the engine bay got painted with base and clear
Dave came round tonight and kindly brought me a new gearbox mount ....... that didn't fit.
So I took the two mounts apart and fitted the new bush in the old mount
Then the engine swung neatly into place
Plenty of clearance round the turbo now
Last edited by regcheeseman; 9 July 2017, 12:47 AM.
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Looking good Reg ......... you must come over and do mine at some point
BigBlue looks real good on the outside, but I think I'm going to need to do a little welding, and the engine compartment could do with some TLC now that I've seen that one.
......... I'd think twice before crawling under that van though with those dodgy axle stands !
TURKYeah, baby ! ........ new Multivan 151bhp AHY 'BigBlue' ; ) >> http://www.vwt4forum.co.uk/showthread.php?t=1023689
And ......... Lulu, T4 2.5 TDi short nose 126bhp > http://www.vwt4forum.co.uk/showthread.php?t=276554
The T4 Quad Headlight Project > http://www.vwt4forum.co.uk/showthread.php?t=249064
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Originally posted by TURK View Post......... I'd think twice before crawling under that van though with those dodgy axle stands !
There was some decent progress last night as Dave came over to offer the usual help and receive the usual abuse.
Didn't take any pictures, I'll get some tomorrow.
My plan now is to get it running this weekend.
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