1.6td to Volvo b230a...

[carpmaster]

Mystery pipes under the exhaust side are heater/thermostat bypass and can be teed together for the header tank connection, IIRC from Neil's conversion. Check with the chainsawing one.
Good luck with it, they do sound good when getting the beans "on the hill".
You'll all be needing some "Travolta" badges making up now

Thanks for the support Ian...much appreciated..I will be giving you a call tomorrow about knocking up some engine supports..
Thanks again
Tom

[carpmaster]

Spent a day on the van yesterday and carried out some work on the engine bay..rustolium gel on the rusty bits ready for a coat of undercoat, which, hopefully be sorting at some point tomorrow.

I need to change my fuel lines for new and while doing so make sure my tank and all its connections were upto spec..well I think you might agree I have a problem with this..take a look at this!!



Take a look at the patch repair...flashband The tank underneath looked well looked after..thats waxoil for you..but on top it was covered in silt type mud stuff (I have promised I wont swear)..I reckon my van has been sat in flood water, or has been in a flood, my gearbox had sand/loam deposits on it (aside from the oily stuff)..



now for the other bits the filler neck was shot as were the vent lines and to top it off one of the gravity vent lines had snapped..so I was rather annoyed at yet another set back.



Because of the deposits found on the top of the tank I had a gander underneath and I am looking at several days work cleaning and treating gunk and rust thats found a new home...I will have to check everything...not ideal...but she is 20 odd..so to be expected I suppose.

To finish off on a positive I had some parts delivered..









I wasn't happy with the water pump. I bought on e-bay "new old stock" £17 all in..I will keep it as a reserve but I won't be using it as an exchange for the one on the engine..I am going to invest in an original from Volvo especially following the failure of my Golf's pump a week ago and cost me £300 to sort it..



I did receive a quality water pump gasket set from partsmonster .com..I am tempted to buy a new pump from them..

Researching scrapyards tomorrow and I'm going to be ordering some bits from Baxter's, Total Pipe Solution, RJS ,CAR Builder Solutions, Speedy cables...Skint tomorrow I expect..

A quick look at my engine bar..I measured it and I have 7" from ground to underneath..it looks like I might have a Syncro. I will confirm this with Simon (Spannerboy)..Thanks Aidan..a card is in the post a pleasure taking to you yesterday..
Incidently the kink in it was worse than shown, I took it to work and asked two burley engineers to do their best with the "the monster vice"..it sits flat on the floor and it's straight where needed between the support points..good job considering what it was like...





Catch you all later...Thanks for looking..thanks for all your support...
Tom

[Aidan]

that bar has taken quite a clonk, I have a straight but rusty one spare if required

[silverbullet]

I don't think that's a syncro one from what I can see in the pic - it has short body mounting brackets so is a 2WD one.
Bad luck on the fuel tank, they do collect the muck on top and I'd say yours is the victim of too many seaside visits?
I had to prise loads of tiny stones out from between the tank and the straps, along with a lot of red sand. That's South Africa for you

[axeman]

hi tom here is the water pipe from the water pump i am using the golf header tank mounted as per the photo you have of my van.
the spigot is slightly off set so the hose is not stressed at all.
the water pump would be at the top of the photo,



the small diamiter (6mm) from memory) at the top of the header tank needs to be taped in to the thermostat side main water pipe. i was hunting around the scrap yards and i found a 940 turbo the lower rad pipe (rubber) is perfect as it has a 90degree (ish) bend with a reducing T in line (38mm 6mm 38mm) as the turbo is water cooled. remove this and install it on the t-stat on your engine and conect it to you new water pipe gong to the rad. and the 6mm t to the top of the header tank.

neil

[jed the spread]

I'm sure someone else will ask if I don't, if you're starting with a 1.6TD why isn't a 1.9TDI at the top of the list ?

I am with you Andy, no disrespect to Neil (its something he had to do) but defiantly not for me....

jed

[jed the spread]

Just a little thought, but will that engine fit under the lid on a 2wd van? The engine sits higher on a 2wd doesn't it? It would be awfull to put in all this effort to find out it sticks out at the top as well as the rear. I know you obiously would have measured it before commiting to this engine but the only two vans I have seen these fitted to are dokas.

Jed

[axeman]

Just a little thought, but will that engine fit under the lid on a 2wd van? The engine sits higher on a 2wd doesn't it? It would be awfull to put in all this effort to find out it sticks out at the top as well as the rear. I know you obiously would have measured it before commiting to this engine but the only two vans I have seen these fitted to are dokas.

Jed

the engine will fit in too a 2wd and a camper, the engine hatch will have too be raised up, but with some work to the front gear box mount and the gear linkage you wont have to cut the section of the rear valance away as you can move every thing forward to eneough for the pully to clear the vavence, should be all explained in the distructions. not possible in syncro becouse the gearbox mounts are different along with the small matter of prop etc.

neil

[jed the spread]

How is he going to raise the engine hatch Neil? Am I right in thinking that the top of the engine will be sticking up past the existing hatch level, ie the engine doesn't fit in the engine bay? If this is the case there is going to be some quite involved panel mods going on. Well at least he knows about
it allready, I wonder if it will effect the bed area.....

I will be watching with interest.

Jed

[syncroandy]

There's a complete B230a motor at a scrapper at Gatebeck if anyone in the NW is thinking of this conversion.

[carpmaster]

Hello Everyone

It's been a busy couple of days working on the engine. I have quickly realised that when taking on a project like this..you have to take one step at a time. I found my mind racing with allsorts of info and I was becoming stir crazy..

I decided to concentrate on the engine and cleaning up bits. I gave the gearbox a once over and from it looked like in earlier pictures I think I done a good job. I am sure Aidan will like handling this one!!





I then gave the engine a good clean ready for a coat of paint. I took the Manifold off for a clean and a lick of Black...





A painted manifold

[carpmaster]

I cleaned the block of the best I could..wet and dry plus a small brass brush did it justice...


Time to consider the Aux belts and the Timing belt..






Took a picture of the wiring on the alternator for reference, as I did with the entire loom...purley there for refence and the chance of using a bit!!



Changing the subject briefly..a flick of my gearbox mount..I will need to change this for a petrol..diesel and petrol are different.. I will also have to change my shift lever for a petrol one too. The one on my van is u/s the cup has a chunk out of it.

[carpmaster]

As you all know my fuel tank was knackered...so in with the new..lush...bought from Brickwerks..


Bought some other parts too..I needed a new clutch cable and have to sort the connection...not able to free this one!! I wonder why..


I also received my new throttle cable from you know who...

[carpmaster]

Started working on the Timing belt..read the manual a couple of times..nervous time...patience the key for me..

Took the top cover off..


A look at the water pump and the timing belt Tensioner..


Took the water pump off and the water pipe connected to it...Note the (ignition) timing mark on the crank shaft pulley..


After a bit of head scratching..I had to think of a method of stopping the Crank shaft sprocket from moving when undoing the bolt...Thi is what I came up with. I used the Alternator support as a fixed point and used two pieces of wood to clamp her down...it worked..

The offending bolt


My solution

[carpmaster]

I managed to keep the timing on the marks! all bits removed ready for a clean..

old water pump..going to be replaced





New water pump and head gacket set..




Needed to get the timing belt off..clamped the tensioner spring...