Project: Converting 1.8 into a 1.9D

[Cornishv40]

Wow! What a project to do... good luck with it!

Is there much damage underneath to the o/s/r on the 1.9D?

[skyship007]

Originally Posted by cornishv40

Wow! What a project to do... good luck with it!

Is there much damage underneath to the o/s/r on the 1.9D?

Most of it is just cosmetic, BUT one pic of the back seems to show a fuel leak, so I presume the rear exhaust box was pushed into the tank. Pics of that area would be interesting, as split fuel tanks turn car owners into diesel fans! No idea if the other exhaust boxes also got bent, but a good used fuel tank AND half a rear exhaust system is not cheap and difficult to fit without a car lift. Not sure what a good used bumper would cost, but I can see why it was written off. A new Volvo rear bumper, tank, exhaust and half spray would be two arms and two legs in terms of a fully certified repair.

[Matt86]

Fortunately there are no fuel leaks so I don't believe the tank has taken much damage if any but haven't had chance to inspect the tank will get some decent pictures once moved and start doing some work on it. You are right starship it does look like a leak but there's a recently fresh bit of tarmac right there as well as it's been raining a lot at the time and it's pointing downhill so all that doesn't help! But no leaks thankfully it's got 3/4 of diesel in the tank so gotta get all that drained out! Will be going straight into the Nissan too!

The exhaust mind you is completely dead. The rear box has snapped off between the silencer and the cat I've got that section in the boot lol! and the left hook on the silencer has snapped too so it needs a complete new exhaust - Thankfully Gatos has got one ready and waiting for me so that's replaced already.

Most the damage is hidden behind the bumper. Its chewed up the bodywork behind there and looks a mess - Not cost effective in repairing that at all especially as the damage at the bottom of the C pillar can't really be straightened out and you can't swap the panels like the front wings, Hence why I'm swapping the engines around as well. Had a diesel for so many years and didn't even know much about the V40s or Volvos at the time of getting the petrol one so now I've been able to get hold of a diesel one on the cheap - Even better as the engine is pretty solid as well. Not that I can hear much over the exhaust lol! but all the tests look good just needs a full service which it'll be getting while out of the car.

[Matt86]

Can any 1.9D users let me know how much the oil capacity is for the following pleaaaaaaaaaaaaase!


Oil
Coolant
Gearbox

(Guessing these are the same as petrol engine but be good to know for sure)

Power Steering
Brake Fluid


Thanks!

Finally got confirmation on moving house on Tuesday so can will get the cars moved in due course and can start getting on with this project.

[v40alex]

D4192T3/4 (Phase 2 Diesel)

Oil without filter 4.9l
Oil including filter 5.6l

Coolant 5 litres - 50/50 coolant/water

Gearbox oil - couldn't find in VADIS, gives part number "1161645, Qty X". I think it's 2.1 litres but 0.1 gets left inside so you only need 2 litres.

Also couldn't find power steering fluid amount in VADIS, it only says "fill the reservoir...only ps fluid grades ATF F, G or Dextron D/E Ford Mercon may be used"

Brake/Clutch fluid, again no amount given, says "use Volvo Genuine parts brake fluid (Volvo DOT4+)"

Good luck with the house move

[skyship007]

The info missing from the post above:

Power steering synthetic ATF 0.8 liters (If the rack is drained etc).
It's a no change item according to the LM oil finder.

The brake fluid is listed as 0.45 liters
Listed as 2 year service life and it one of the main reasons why calipers fail. I'm changing it every time the pads are changed, which is around 2 to 3 years.

Gearbox oil total seems to be wrong in every guide, as 2 liters in enough.
LM do have the phase 1 diesel listed as 105,000 km box oil change, so it should be changed every cam belt service.

The coolant is listed as 6.3 liters, BUT I know that a normal drain only needs about 5 max, although the rest might be left in the heater etc. Even LM say contact dealer, so Volvo coolant 50/50 with distilled water only.
I think it's listed as change every 2 years, but mine was very clean after 6 years, so I'm just changing it every cam belt service, when the water pump is supposed to be changed.
The big issue with coolant is not to use the wrong one, or top it up with something different, so if you don't know what was used by the previous owner, it is worth dumping.

[bigboz]

Matt, While the engine is out, have you researched bolting on a bigger blower, or doing any other mods such as gas flowing the head....basically stuff you can do a lot easier when the engine is on a bench?

[Matt86]

Originally Posted by skyship007

The info missing from the post above:

Power steering synthetic ATF 0.8 liters (If the rack is drained etc).
It's a no change item according to the LM oil finder.

The brake fluid is listed as 0.45 liters
Listed as 2 year service life and it one of the main reasons why calipers fail. I'm changing it every time the pads are changed, which is around 2 to 3 years.

Gearbox oil total seems to be wrong in every guide, as 2 liters in enough.
LM do have the phase 1 diesel listed as 105,000 km box oil change, so it should be changed every cam belt service.

The coolant is listed as 6.3 liters, BUT I know that a normal drain only needs about 5 max, although the rest might be left in the heater etc. Even LM say contact dealer, so Volvo coolant 50/50 with distilled water only.
I think it's listed as change every 2 years, but mine was very clean after 6 years, so I'm just changing it every cam belt service, when the water pump is supposed to be changed.
The big issue with coolant is not to use the wrong one, or top it up with something different, so if you don't know what was used by the previous owner, it is worth dumping.

Got no previous history on the Diesel so EVERYTHING is getting checked/changed to make sure it runs perfect.

Originally Posted by bigboz

Matt, While the engine is out, have you researched bolting on a bigger blower, or doing any other mods such as gas flowing the head....basically stuff you can do a lot easier when the engine is on a bench?

I haven't yet no - Not really looked into making any changes to the actual engine just replace the standard parts that need it and give it a clean where it needs it too. I'd end up keeping the engine pretty standard at this point anyway.

[Matt86]

Ok so spent 4 1/2 hours on the car today and removed all the seats, boot liners, carpets, dash and door cards. Still got the ceiling to pull down but can't be arsed to do that section today as I'm knackered and the sun is making it bloody hot inside that car as it's even more like a tin can now!

So pictures! Here's about half way through the removal.






Also once I remove the N/S boot liner I found the CD Changer cable so if anyone is curious:




Then I got some help in the afternoon... he wasn't much help at all though...



and finally got the dash completely removed with the door cards.

[gatos]

Now we are talking........... This is my type of job.... lol

Anyway, just be very very careful with the roof lining. It's bloody hard to remove it without damaging it

Also, have you reconsidered retrofitting Climate control on your car?