Swapping sausages - TDI conversion thread

[S49]

Worked for Volvo from 83 to 98 we used to blanked off the egr from new on the vdub powered Volvo 740s

[regcheeseman]

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.

[nathaniel_evans]

Nice work !


Sent from my iPhone using Just T4s

[regcheeseman]

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.

[hairyjerry]

that looks like a great bottle opener

[daleydub]

Are you having to cut the bulkhead to make way for turbo?

sent from a t6 (As if am not that sad)

[regcheeseman]

Are you having to cut the bulkhead to make way for turbo?

sent from a t6 (As if am not that sad)

I'm torn between scalloping it out neatly or braying it with a big hammer.....

[daleydub]

A bit of heat and a hammer is probably the easiest option. I been enjoying seeing this engine swap [emoji106]

sent from a t6 (As if am not that sad)

[regcheeseman]

Cleaned up the engine bay ready for paint, the manky rusty brake servo was bugging me so that got stripped as well



Few coats of bilt hamber and then a dusting of satin black on the servo from a rattlecan



Eyeing up for the downpipe, looks nice and simple, plenty of room.

[regcheeseman]

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

[TURK]

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 !



TURK

[regcheeseman]

......... I'd think twice before crawling under that van though with those dodgy axle stands !

Not at all mate, nothing wrong with axle stands, it's all about accessing the risk, employing safe working practices, you'll never catch me doing anything sketchy....


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.

[Dave Sausages]

Not at all mate, nothing wrong with axle stands, it's all about accessing the risk, employing safe working practices, you'll never catch me doing anything sketchy....

Move along, nothing too see...

[Dave Sausages]

You'll notice the reflection of the lesser spotted cocksmoker

[hairyjerry]

have those axle stands and blocks increased the value Mr Sausages?