1.6td to Volvo b230a...

[carpmaster]

when your smiling ....... your smiling ....let the whole world smile with yoooou.....

Thanks Ian for doing these...they look up for the job..can't wait to have a feel of me new shiny shinies..

Nice pics too..and comments...you got the feel for the thread..made me laugh...

Thanks again..

Tom

[carpmaster]

Hello again
been a busy day today running around sorting the s/s coolant pipes I need..Found a place close by and should be ready in the next couple of weeks. Visited a volvo dealer/scrapper and the chap there was very helpful..He loaned me a wiring diagram for rigging up the electrics for the ignition system. I picked up a what is termed a runon valve..earlier in the post I couldn't get hold of one for the love of money..until today..for a tenner..sweet.

Earlier in the post I had set up the fly wheel and linked the gerabox up..only to discover checking through the manual..(fool that I am) I tighten up the flywhell bolts in a circular pattern rather than a diagonal..and being an amateur restorer/engine swapping man I made a fundamental error in allowing the fly wheel to move whilst tighting the bolts.. As a consequence of my foolishness I messed up all the timing etc etc. A lessoned learned and I won't be doing that again in a hurry. If you don't approach this part of the work in a methodical way..you are likely to cause distortion in both flywheel and clutch assembly....I got to work and sorted it..it meant stripping everything down and buying new bolts etc..

Here are a few flicks..you all know I like my pictures..tell a thousand words..thanks for looking..

[axeman]

ho tom i have been mega busy at the moment i will take a photo of my air filter and post it up soon.

neil

[carpmaster]

Thanks Neil...

[carpmaster]

Sorry about that folks..had to have some munch..here is a flick of the fly wheel and the number sequence I decided to do..70Newtons is the torque setting on these and I used my faithful G Clamps and a bit of timber to stop it from moving..did the trick and I was really chuffed..

Here is a flick of the bolts I used..in the middle you will notice two little bits of pipe ends..If you recall I was having a bit of a flappy/worry on about two coolant pipes I was unable to Identify. I have since learned that I don't need them. The engine came from Sweden..those two pipe were connected to an intermediate/pre heater setup for extreme weather conditions. The water in the block was pre heated using this method..if that makes sense. I have since blocked them off...the fittings are at the top of the photo.


undid and made my sticky numbers


All done and this time I got it right..locktight was also used


Put the clutch and cover assembly on in the same fashion and covered her up to help prevent dusty stuff getting in...I have decided not to mate the gearbox up..purely down to the logistics of transporting it..big ole lump when combined..

[carpmaster]

I then got to work on the gear linkage arm and newly purchased shifter..Thanks Aidan for sorting..I was meant to be doing a sweet little deal with Aidan..swapsy for a petrol for a diesel..transpires..VW Heritage had packaged it up incorrect and I had a diesel in the first place..didn't stop me from posting it to Aidan..reminds me of something else I posted and didn't have too..


Painted the linkage arm and left her to dry..


As you know Silverbullet (Ian) manufactured my engine supports. Excellent job too..A little modification on the right support was needed..thanks Neil for the heads up on that..I didn't realise it gave you an oil leak on the sump. I tried a test fit and sure enough the support fould the sump by about 3mm..not a lot you might think..but the bottom of the support was too tight for my liking..so I got to work on it and ground out a small bevel shape..added a washer underneath and bingo..Take a gander...



I bought two gearbox mounts from a nice chap in Wales..very helpful too..I will be contacting him soon as I need a 6 pin control unit (ignition amplifier)..more on that a little later.


I thought a picture of both supports shown "dry" built would be useful..you never know...another member might be interested in carrying out this type of conversion...

Here is the right side..


The left side


Just painting the pieces for further protection and thats them sorted. Thanks again Ian..

When you embark on a project like this...soooo many thing are bouncing around in your head and on occasions you decide to take a breather and try something different!! I took a look at the exhaust section I got as part of the conversion package and thought I would give it a dry run fix..if you get my drift..I am glad I did...I found I could fix 2 of the 3 nuts..the 3rd nut would not tighten as it was fouling the weld..Out with the grinder and I very carefully smoothed it off...Job done, I can now fit all three with ease. I would have been saying a few swear words if I was underneath the van and I come accross the problem then.
Its not the best photo I have taken to date...so apologies for that.

[carpmaster]

I mentioned a little earlier about seeing a Volvo man "Steve"..what a refreshing chap he was too..loads of enthusiasum...Steve loaned me a service manual book with distructions on the ignition set up..take a look at the info. I quickly learned when I got home that I need a 6 pin/slot control unit (ignition amplifier). I have a seven pin..bummer. On a positive I also learned that I dont need a Ballast resistor..electronic ignition.. Rapid learning curve..All I need to find out now is the coil I have..can it be used without a ballast resistor..I hope so..Still waiting on GSF to answer my email...not unless a fellow member can ease my worries either way.


I also mentioned that I bought a runon valve. The concept here is the device helps prevent vapour lock in the Carb. When the engine is running air travels through the valve and when the ignition is turned off it stops the air and hence the engine from running on. I might not need it..its still early days and I am still getting to grips with the concept of the whole relationship of air and how a carb behaves etc.... I am happy I have the option..I can try running the engine without it and see how it goes, alternatively I could set it up as it was. I have been given two solutions by two good Volvo engine people..it's down to me to find what suits the set up I have..we shall see

Here is a flick of the both runon valves..the one on the left was the original..the right was what I got today.

[carpmaster]

You may recall Neil (Axeman) posting a couple of flicks of his coolant set up showing the connections I needed to do to complete the system. On the thermostat side a piece of coolant pipe with a spigot vulcanised to the main pipe was needed..I got one..unfortunatly I hunted high and low for a scappy one..without success..Had to dig deep and buy this from Volvo in Taunton..not cheap..but worth it..


As you all know I needed a new fuel tank..the other one was shot through. I have been preparing it for install. I have since given it two coats of hammerite and one of waxoil protection..sticky ole stuff that. I plan to fit it tomorrow..fingers crossed..here is a couple of pictures.
waxoiled


Bits and pieces together..new grommets..looking good


A quick look at what would be the return feed..Not needed on this project.


That's about it for the time being...not much to purchase..coolant, clutch fluid, braid fuel pipe for the tank..I got the wrong size(I think I reached a 5th part in the incorrect buy list ) battery to starter cable...If any one can help speed things up...if you have a battery to starter loom you want to sell..give away I am all ears.

Once again thanks for looking..thanks for the support...
Tom

[axeman]

hi tom this is the part from the golf k jet system that i was talking about but i see that you have the corect volvo part coming from the card too the air filter



and this is where i have put my air filter, its a temporary untill i figure out a better (more water tight location)



neil

[carpmaster]

Cheers for that Neil

I have been looking at the Pipercross filters and K&N..looks like you have a carbon fibre finished one, retains the coolness of the air a little better..I expect it sounds well lush when you press on the gas.... As for keeping yours dry..what about incorporating/forming a splash guard..it could possibly act as a ram air system and protect at the same time. just toying with ideas myself..forgive me if I am doing the suck eggs thing!!

My s/s coolant pipes have been made I pick them up tomorrow after work.. Rain stopped play last week, so wasn't able to fit the fuel tank..

I will be posting again in a few days..one more night shift and the re birth begins...

Thanks again Neil

Tom

[t25adict]

well its time i should go to sleep... shouldnt have read the hole thread... but i have.

the more i read the more i think the volvo engine may stay in my tristar
we shall see.. loads of welding to do first.

interesting to see another volvo engine being fitted.

only pitty is mine s mated to and auto box..

[carpmaster]

well its time i should go to sleep... shouldnt have read the hole thread... but i have.

the more i read the more i think the volvo engine may stay in my tristar
we shall see.. loads of welding to do first.

interesting to see another volvo engine being fitted.

only pitty is mine s mated to and auto box..

I am glad you enjoyed the post...I can't comment on how the engine feels pushing the van..Neil describes the drive as the "NUTS".

I have grown quite fond of the red lump and I reckon it will serve the van well..I plan to do miles and as Neil says it's a solid engine "lessed stressed".

Keep yours..you know it will be worth it..parts are ready available..good luck with the decision making!!

Tom

[carpmaster]

Hi
Been busy pottering around in the Garage and fitting the new fuel tank...not easy on your jack and very limited space.

I gave the engine mounts a lick of paint and the downpipe got a quick once over.

hanging up...gable ties coming in handy!!


A few flick of the down pipe..Made the error of painting in hammerite first..wasn't happy with the max temp of 25 deg'sC..Scraped it all off and gave it a lick of engine enamel..looks lush.


Prep the end for a sleeve and link for the gsxr cans I treated myself ..both bought of the mighty ebay. Thanks Neil for that info.


A sneaky look at the business end!!


Two cans I got..one is from a gsxr 750 street fighter and the other a gsxr 1000..

[carpmaster]

I then got to work on renewing the water and oil temp switches..refitting and sourcing the parts was the easy bit. The next step is to learn how to wire them up..

old V new

water temp switch fitted..the blue vacuum pipe is blocking off a valve used fas part off the EGR system..The oil switch flick is poor..



I then concentrated on the new coolant pipes and modded the section of pipe from Volvo to fit on the thermostat side.

[carpmaster]

Another angle

I need to get some larger reducers and bits to compensate for the slight increase in diameter..The ID is meant to be 38mm and I have about 40mm and the pipe itself is touching 45mm..take a look at the vernier readings...thinking about 41mm silicone connections for fitting to the end..nice tight fit.