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S40 / V40 '96-'04 General Forum for the Volvo S40 and V40 (Classic) Series from 1995-2004. |
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Project: Converting 1.8 into a 1.9DViews : 10569 Replies : 141Users Viewing This Thread : |
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Jul 8th, 2014, 09:10 | #121 |
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Wow! I'm definitely subscribing to this!!!
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Jul 8th, 2014, 09:41 | #122 |
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Yep, it's going to be interesting. I'm wondering if the tail gate badge should be left as V40 1.8i and a 1.9D added afterwards. It might also need a big diesel fuel only sticker near the filler cap!
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2003 V40 1.9TD Mods: Scratches, bent bumpers, raised REAR mats & internal mud guards. SHELL ULTRA 5/40 & LIQUI MOLY CERATEC. Everyone should DYOR (Do Your Own Research) |
Jul 8th, 2014, 11:46 | #123 | |
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It doesn't need a diesel fuel sticker on it but if I find a decent enough one I will put one on. |
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Jul 25th, 2014, 20:49 | #124 |
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Done a few on and off bits after the past few weeks/months, So I'll list everything I've done to date.
Stripped out the interior and rear,Interior and Engine wiring looms from Red car. Stripped the interior, rear and interior looms from the silver and installed into the Red Car Removed the climate control sensors from the silver car and installed into the Red to turn the A/C to climate control. Refitted the interior from the Silver car (Black leather, Heated and electric front seat, Red wood) Removed the rear struts and replaced with nivomats. Fitted genuine Volvo removable towbar. Installed Parrot Phone system and to new HU-1205 and added aftermarket GPS unit. Removed Petrol engine, PAS system, Air Con, Airbox, Battery Tray, Radiators, wiper motors (Basically EVERYTHING in the engine bay) Removed front struts, lower arms, drop links on both sides. Refurbished rear brake calipers Refurbished lower arm balljoint Refurbished Front Struts This is bacially the list of what I've got left to do... Refurb Rear brake carriers Refurb front brakes and carriers Install polyurethane bushes on front ARB Install polyurethane bushes in lower arms Install lower arms Replace inner and outer tie rods Install front Struts Install Drop links Fit Barjo Tailgate and Volvo Metal Dog Guard Clean engine Remove sump and clean out old sludge and refit Clean out EGR carbon build up Install new glow plugs, oil, Air and fuel filters, timing and aux belt kits Replace gearbox oil Install refurbished front and rear calipers/carriers with new discs and pads Replace brake fluid and bleed system Reattach gearbox and install engine Attach PAS with new fluid and bleed system. Install wiper linkage and wipers Install Radiators Install battery tray, fuel filter housing and airbox with new stainless steel clips Check everything is in place and tightened up correctly. Put in new coolant Fill tank with diesel and prime system Start praying and start the engine! Check for leaks and smooth running. Get MOT test and tracking done Once passed get V5c doc Road and Insure Job done! Last edited by Matt86; Jul 25th, 2014 at 20:58. |
Jul 25th, 2014, 20:51 | #125 |
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Stripping the engine down for cleaning today. Found the oil reason and the reason possibly from the EGR because of not a failed O-Ring but because they've used a different bolt on the lower section!!! Grrr! New bolt required.
Found another leak down the back of the block which was water/coolant. Looks like it's coming from the water pump because someone didn't install all the bolts... On the plus side. The turbo is in pretty good nick! |
Jul 25th, 2014, 22:27 | #126 |
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Wow looks like a giant to do list but I'm sure you'll have a great time doing it
A Great project Matt I'd love to do a manual conversion on my T4 but I suspect it will be a minor job compare to yours |
Jul 25th, 2014, 22:43 | #127 |
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That's still a big job in itself there danny! Yeah looks like a long list but I'm saying 3 weeks, Probably be less but by the time I've ordered the parts I need I'll say 3
I'd love to make the Diesel automatic (I expect to get slated now) but it's purely for the benefit of my knee. My left one is shot to pieces so by the end of a 10 minute drive my knee hurts lol, But I've never seen a 1.9D Auto and don't think one is available. |
Jul 25th, 2014, 22:55 | #128 | |
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Funny I done my left knee in 16 years ago, I should have a knee replacement but I just haven't got the time I'll have a spare box at some point I don't think it would be a big job to do if you got a donor car. I think the pedals will be the biggest pain |
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Jul 25th, 2014, 23:11 | #129 | |
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The 'to do' list looks twice the size of the 'done' list! Best o' luck in getting this finished, mate. Never realized you had a busted knee. Well done for getting this far with an injury like that, as you would have been crouching and kneeling most of the time, through this project. Hat off to you, my friend!!!! Gary
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Current car: 2002 V70 2.4T SE Mod's so far: Orpheus alloys, 10.1" android multimedia head unit, Nappa leather rebuilt, wood trimmed m/function steering wheel, Polestar blue and black calipers, Pipe Dynamics custom turbo back stainless steel exhaust, with 200 cell sports cat, R engine and injector rail covers, tinted rear windows. Previous cars: 1982 760 GLE saloon 1989 740 GLE estate 1991 440 S 2003 S40 S - Gone but not forgotten. ☹ 16 non Volvos. |
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Jul 25th, 2014, 23:34 | #130 |
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Too many years playing American football someone took my knee out ended playing career as it was either walk or risk not walking. There's no cartilage in me knee now I should have a knee replacement too Danny but I'm too young for that at the moment want to still be walking at 50 lol
Looks a lot longer but I've listed more detailed to do than done lol plus imagine the length of time removing 2 interiors and looms then installing them lol |
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