Project: Converting 1.8 into a 1.9D

[Matt86]

Righty I'm just starting to get around to doing the prep work on swapping over the 1.8 shell with the diesel one. Won't really kick off until next month as I've got a few tools and parts to get beforehand but though I'd start it off now as any advice on parts to start replacing now before it's in place would be very valuable.

So first up we have the Cat D 1.9D T3











and the reasons behind the bodywork being useless




Although it might not look to bad behind that bumper and under the rear of the car it's a complete mess. Will get a picture up once I start dismantling.


and the lovely shell it's going into








Although the 1.8 is pretty solid it's got the usual VVT issue and the lifters need adjusting which although I'm happy enough to do I prefer diesel engines and considering my annual mileage I'd prefer to have a diesel so sod it

So yeah my plan is literally the entire interior will be moved into the 1.8 including the wiring looms and the engine will be moved out the 1.9 into the 1.8 as well.

[244T]

Goodness me.......

That is quite a project!!!!!


Please keep us informed on your progress!!!!


Best of luck,

[gatos]

I am waiting to see the results Matt, as I am very seriously thinking of doing the same thing with my newly acquired V40. ALready have a spare diesel engine, but I am missing all the looms. I destroyed them a few months ago getting parts for another member

If there are any tools you need, feel free to ask and I can send you some with myHermes. As long as I can have them back when you are done.....

[Matt86]

Thanks Andrew, will do. I'm actually quite looking forward to it. Expect that'll chance halfway through.

Cheers fella. I know I need to get hold of a torque wrench as I haven't even got one lol! All these years without using one... oops! Need to get a universal puller to get the hubs/spindles off and some spring compressors to as i'll swap over the complete suspension if they're different sizes. Going to buy an engine stand as i'll do all the work on the diesel engine and get it spick and span before it goes back in and i'll leave the petrol on it and probably either sell it if someone needs one otherwise it'll be broken for parts. Also going to buy the Volvo timing tool kit to redo all the cam belt system.

Tomorrow I'm planning on draining the fuel tank. Still looking into that, VIDAs method isn't feasible as I haven't got the pump system it recommends. So hoping to find an easier method with the tools I have, don't really want to drop a fuel tank that's 3/4s full!

[gatos]

You can do without a universal puller to remove the driveshafts.

I have two torque wrenches 8-60Nm and 40-200Nm. 36mm hubnut and a balljoint splitter.

Or if it helps, I can get you a Halfords Torque wrench for half the price with my Trade card. They are excellent quality and lifetime guarantee. So feel free to ask what you want.

[Matt86]

Certainly will borrow the balljoint splitter, 36mm hubnut and the smaller torque wrench off you next month if that's alright. I'll deffo be buying a bigger torque wrench through Halfords with you then

I can always come collect them when I come get that exhaust

[GaryS40]

Looking forward to regular updates on this, Matt.

Edit: You could repair your grille with a section of the one from the diesel car, glued into place.

I see you will soon have an electric driver's seat too!

Best of luck, mate.

Gary

[Matt86]

Originally Posted by GaryS40

Looking forward to regular updates on this, Matt.

Edit: You could repair your grille with a section of the one from the diesel car, glued into place.

I see you will soon have an electric driver's seat too!

Best of luck, mate.

Gary

Yeah I'm going to give that a go. That grille on the diesel is completely wrecked as well. Although you can't see quite tell from the picture. The bonnet is actually wedged against the release catch so you need someone to pull the bonnet release and lift the bonnet to release it. Then to pull the grill forward to get to the bonnet release switch as it's stuck in the bottom of the grill.

Oh and yes the seat is heated and electric. Nice change to the cold manual one I have now lol

[gatos]

Originally Posted by Matt86

Certainly will borrow the balljoint splitter, 36mm hubnut and the smaller torque wrench off you next month if that's alright. I'll deffo be buying a bigger torque wrench through Halfords with you then

I can always come collect them when I come get that exhaust

Not a problem Matt.

I bought the 8-60Nm from Halfords and I the bigger 40-200Nm is an RS one. But it is absolutely identical to the Halfords one. When you come over, we can go down to Halfords and get any other bits you might need

[Matt86]

Originally Posted by gatos

Not a problem Matt.

I bought the 8-60Nm from Halfords and I the bigger 40-200Nm is an RS one. But it is absolutely identical to the Halfords one. When you come over, we can go down to Halfords and get any other bits you might need

Coolies cheers fella sounds like a plan.