Project: Converting 1.8 into a 1.9D

[Matt86]

Well, Looked inside the red V40 today and once or twice thought... God I'm mad. But a tad too late to stop now! LOL! So instead I spent most the afternoon attempting to remove the buggered exhaust which was a mission...

ended up cutting the silencer off completely as I couldn't get to the bolts then found after a little more routing around and looking at the suspension that the silencer was stuck in the suspension and to stop it off.. the support bracket that holds the ARB was bent out of shape too. SO suspension was screwed either way so had to cut the ARB to get it out so I figured (looking at how crap condition the suspension was on the diesel) I need to really look into what parts of the suspension will need swapping around.

THANKFULLY! are digging around on VIDA on going through all the suspension part numbers for the petrol and diesel - The entire rear suspension system is the same on both vehicles including the hubs and rotors and the front suspensions is also the same apart from ONE item... the hubs are different between the diesel and petrol on the front of the suspension but the spindles aren't.

Mind you I'm going by the part numbers assuming that if they were different the part numbers wouldn't be the same.

So I'm please that now I don't have to look at changing the whole suspension system, will make life a lot easier.

[Matt86]

Been a while since I've posted anything on here so thought I'd update....

Not done too much as the rear wheels have been preventing access to a lot of the area, in the mean time I'd taken the fuel pump out of the petrol car and drained the tank and done the same with the diesel.

Also removed all of the exhaust apart from the rear box as the ARB is in the way, exhaust manifold, Air box and unplugged most of the cables in the engine bay. Need to label some cables up so if people need any HT leads or anything I've got them spare and the labelled correctly.

Rear bumper is off as well to give more access to the exhaust and now just need to get the rear wheels off to undo the ARB so the exhaust will come out and can then start removing the fuel system. Fortunately got ONE wheel nut off the rear just need to attempt the other side next but been stopped by the rain.

[Matt86]

Completely removed the exhaust now after dropping the ARB.
Removed the airbox and the battery tray from the engine bay.
Removed the radiator, washer tank, evap tank and disconnected about 50 wires.
Removed both front wings.
Disconnected the internal loom from the engine loom.
Completely removed the internal loom.

Pictures!!!

Rear O/S wheel - Need to replace the shocks here Rust is too far set in!


N/S wing off


Engine bay and radiator less! (Still has the A/C Rad in tho)



O/S wheel arch engine loom has been disconnected from the interior loom here


Inside without a loom!




Misses looked inside the car after I done this today. All she said was that looks much tidier and cleaner - Keep it that way......

[GaryS40]

Originally Posted by Matt86

Inside without a loom!


Misses looked inside the car after I done this today. All she said was that looks much tidier and cleaner - Keep it that way......

You'd struggle driving it around in this state!

Gary

[Matt86]

Well if I stick a wheel on the rear I can go straight. That's about it lol!

[GaryS40]

Originally Posted by Matt86

O/S wheel arch engine loom has been disconnected from the interior loom here

Your Stellars look better than the ones I have in the garage, waiting for a refurb - for winter tyres.

Gary

[Matt86]

lol you haven't seen the rears! They've been ruined getting the locking nuts on the rear off lol

[kieran40]

That's been gutted lol

[Matt86]

Next stage for the interior is some much needed cleaning and putting in the new brake cables and the diesel fuel pump then it's ready for the new wiring and interior.

Although I won't be doing that until I've got the diesel fuel tank in place.

Exterior is a much longer list....

Replace rear shocks
Refurb the brake callipers and replace with new pads and discs.
Remove the fuel system
Remove the engine
Remove engine wiring loom
Remove gearbox and pretty much the whole front suspensions and driveshaft system to swap with the diesels.

Sigh.... The gutting is the worse bit as I keep finding the odd couple bolts that snap off.

[kieran40]

Originally Posted by Matt86

Next stage for the interior is some much needed cleaning and putting in the new brake cables and the diesel fuel pump then it's ready for the new wiring and interior.

Although I won't be doing that until I've got the diesel fuel tank in place.

Exterior is a much longer list....

Replace rear shocks
Refurb the brake callipers and replace with new pads and discs.
Remove the fuel system
Remove the engine
Remove engine wiring loom
Remove gearbox and pretty much the whole front suspensions and driveshaft system to swap with the diesels.

Sigh.... The gutting is the worse bit as I keep finding the odd couple bolts that snap off.

How much money did you find ,between the seat rails and centre console lol,when it rolls under there you've lost it I find it vanishes