Project: Converting 1.8 into a 1.9D

[MuscleFlex]

Wow! I'm definitely subscribing to this!!!

[skyship007]

Originally Posted by MuscleFlex

Wow! I'm definitely subscribing to this!!!

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!

[Matt86]

Originally Posted by skyship007

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!

I can already tell you it will have the 1.9D added and not have the 1.8 on it

It doesn't need a diesel fuel sticker on it but if I find a decent enough one I will put one on.

[Matt86]

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!

[Matt86]

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!

[malteser]

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

[Matt86]

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.

[malteser]

Originally Posted by Matt86

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.

That will be good going if you get it done in 3 weeks.

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

[GaryS40]

Originally Posted by Matt86

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.

SLATE, SLATE, SLATE!!!!

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

[Matt86]

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