ovloV V40 and it's Fails!!

[inchley313]

Just a quick thread to show you all how I'm getting on with the V40 and what work is currently "In Progress"

1. Heater Matrix - Already have a separate thread for this one, http://www.volvoforums.org.uk/showth...=heater+matrix

2. Starter Motor - Solenoid is sticking and requires the unit to be replaced. Will remove old starter and get part number and see if anyone has one to sell

3. N/S/F Headlamp - Due to a crack in the lens, the headlamp unit has started corroding internally and the adjuster is broke. Also, you can see on the pics, the wiring connectors have started melting, would it be wise to replace these? if I'm replacing them, should I just fit P2 headlights?

3. N/S/F Indicator - Again, due to the abuse this car suffered at the hands of it's previous owner, the indicator lamp unit is broken and doesn't stay in it's hole. I was just going to replace the 1 but thanks to pacman67, I now have a nice pair of clear p1.5 indicators on the way to me!! Another reason to chance the headlamps altogether methinks!!

note: Does the front bumper have to be moved to replace the headlamps? I managed to get the drivers one out but got the impression that if the adjuster was in 1 piece, the headlamp would never have come out. Also, the screw under the arch that holds the bumper in place has been rounded off, is there another way around this??

4. Front Brake Calipers, Discs & Pads - Discs are warped due to calipers sticking. Pistons on calipers has corroded due to the rubber boots and the piston being split so definitively require replacement.

5. Replace Lower Coolant Hose - Due to me being an idiot!! I managed to split the bottom hose. To drain the coolant (to replace matrix), I needed to remove the lower hose from the rad and the clip was corroded solid!! Knowing that I needed to replace the clip anyway, I decided to cut it off. Not having a dremell to hand, I took to the clip armed with an angle grinder!! DO NOT REMOVE THE CLIP IN THIS WAY!!!!!!!! The grinder snagged and went straight through the hose!!

6. Spray Front Grille - Not being able to afford an egg crate grill, I decided that I am going to pray mine black. However, all the nuts that hold the grille in place are spinning and not undoing!!

7. Service - Once all the work is complete, I aim to give the car a full service!! Oil + Filter, Volvo Spark Plugs (still have slight misfire to cure!!) Gearbox Oil Change (Replaced gearbox recently and would like to change oil again as I'm not sure that what I used was the right oil) and I'm also going to fit an Induction Kit. (wanting moooaaarr noise!!!!!!!)

Also, I am waiting for a friend of mine to let me know if he still has some after market 17" wheels from a Prelude knocking around in his garage!! They are the same PCD and offset and will also be free if he can find them!!

Here are some pics of the work so far!!

[pphilpot]

Originally Posted by inchley313

5. Replace Lower Coolant Hose - Due to me being an idiot!! I managed to split the bottom hose. To drain the coolant (to replace matrix), I needed to remove the lower hose from the rad and the clip was corroded solid!! Knowing that I needed to replace the clip anyway, I decided to cut it off. Not having a dremell to hand, I took to the clip armed with an angle grinder!! DO NOT REMOVE THE CLIP IN THIS WAY!!!!!!!! The grinder snagged and went straight through the hose!!

This made me laugh as I would have thought about this approach too. Instead, on my '97 V40 I just ended up popping a second clip right next to the original rusting one, and crossed my fingers.

[inchley313]

If you use a ratchet and a 7mm socket, it comes straight off!! however, 7mm was the only socket I could NOT find at the time of removal!!

[DWM]

Originally Posted by inchley313

Does the front bumper have to be moved to replace the headlamps? I managed to get the drivers one out but got the impression that if the adjuster was in 1 piece, the headlamp would never have come out. Also, the screw under the arch that holds the bumper in place has been rounded off, is there another way around this??

I have had the passenger side one out without removing the bumper. Undo the nuts and wiggle it towards the middle of the car to free the side of the headlight from the holes by the indicator. Then put your knee on the bumper and push down boldly, and at the same time wiggle the headlight out with your hands. My experience was that it's one of those things that looks as if it is going to be quite impossible until it finally manages to clear the top edge of the bumper and you go Phew. (I couldn't lower my bumper either, because of non-captive captive nuts.)

Edit: now I've looked at your pics I no longer understand and feel I must have misunderstood. You've clearly got the passenger side headlight out?!

[inchley313]

Don't know why i have said drivers, you are right and i clearly have the passenger one out. my mistake

[inchley313]

Got some parts arrive over the last couple of days thanks to pacman67 and gatos!!

Time to get working on the old girl again.

[andy_d]

psst
hose clips n angle grinders,, not the best mix ,,, *ducks,, also being a "smarty pants" and using a dremel type tool with a cut off wheel, does Exactly the same thing,, but the cut into the pipe is smaller ,yet more annoying as its only a Small cut/chop/nick But you stil have to drain the system, replace the hose + clip + refill,, ,,,,

[rublehousen]

rusty jubilee clips that are seized up or rounded off? i always use a pair of vise grips and just grip the whole screw casing part. twist it left,right,up,down and around several times and they usually just come apart. id have had it off before you had got the grinder and extenson lead out :-)

[inchley313]

Originally Posted by rublehousen

rusty jubilee clips that are seized up or rounded off? i always use a pair of vise grips and just grip the whole screw casing part. twist it left,right,up,down and around several times and they usually just come apart. id have had it off before you had got the grinder and extenson lead out :-)

Where is the fun in that!!! PASS ME THE GRINDER!!!!!! I'm a bit rough me!!

[rublehousen]

next time dont forget to gaffa tape the grinder to a broom handle first, that way you can keep well away from those nasty sparks...