1.6td to Volvo b230a...

[axeman]

look back on page 4 of this thread and you will see how i have done it. i bought a bess spigot to join the 2 pipes togeather.

neil

[carpmaster]

Hello
Managed to get a few hours in today. Had a result with the throttle cable..got full throttle, needed to trim the toe off the peddle but job done.fitted the fuel line, heater hoses, brake non return valve..here are a few flicks.
non return valve

completed

heater hoses

fuel line to pump

I have taken taken a flick of the connections to the radiator and i was hoping a fellow member could confirm a yes or no on what i believe there for..
The bottom connection (not connected just resting under the rad) is coolant cooled and is fed to the water pump and the higher connection (connected) is from the thermostat for the coolant to be cooled..thanks in advance for help

coolant pipes marked ready..the one on the left is to be connected to the water pump and the right one to the thermostat.

That's about it for the time being..back to work tomoz...will post more once I've made a more progress..thanks for looking and continued support...
Tom

[ELVIS]

looking good chap- nearly there now

If it was me i would take off the fuel filter and replace with solid line. Less joints etc to fail/go brittle/split. will also protect pump diaphragm.

Put filter before pump under van away from engine, if it leaks its going onto floor and not onto hot engine/engine pay.

how many 'bad luck' stories have you heard of air cooled stuff going up after fuel leak in engine bay?

Keep piccies coming

[carpmaster]

Nice one ELVIS..I will take you up on that advice..As for keeping the piccies coming..no probs.. good for sharing knowledge for fellow members guests alike. I find them a useful tool for refering back..checking what was existing etc..helps when you forget what things used to look like. Electrics on the diesel engine for example..I have flicks ready with all connections..next stage of learning for me..!! I can establish and share what was what and then learn and get rid of what I don't need.
Tom

[gaz f]

I've just read through this whole thread with interest, keep up the good work. This thread will be a good guide for anyone else considering going down the same route. It really does make interesting reading, well done for sticking with it.

[carpmaster]

I've just read through this whole thread with interest, keep up the good work. This thread will be a good guide for anyone else considering going down the same route. It really does make interesting reading, well done for sticking with it.

Thanks for the feedback Gary much appreciated.. Glad you overcame your timing problem..read your post with interest and I liked your videos..something I would like to do when I start my lump for the first time..never published a vid on UTube before..looking forward to that one..
Tom

[carpmaster]

Hello
Just done a whole page of script..went to a spell checker site and returned to my script to find all the work I had done wasn't there.. I will begin again...
I was planning on going to work on the van today but I am feeling a bit crook..suffering from night shift syndrone..totally wiped out. My car (vw golf)is in for an M.O.T tomoz(Mon) and I think the mass air flow meter sensor is u/s..she sounds like she running on 3 cylinders..driving to work yesterday ok..until I went to park at low revs...chug chug..had to drive her hard for about 2 miles before it cleared itself..then it drove decent'sh..anyway..now that I have offloaded that one..I will talk camper stuff..

I have had a mod done on the thermostat housing. I wasn't happy with the natural shape the volvo hose part I bought wanted to take. Without loosing its natural shape and hence cross sectional area of flow and the expansion/overflow spigot at its perpendicular highest point. It would mean chopping more out of the back end..something I wanted to avoid..done enough butchering as it is..other options..(as you all know by now I over think/study stuff from time to time) could include bending it round with a hose former..but they prooved hard to source for the 35-38mm hose.. a group of jubilee clipps forcing a shape could of been adopted, However, the likelyhood of it working is questionable and to be honest would look ugly and unprofessionally desperate. . I was thinking of using a barrel nipple (threaded both sides) and tap into the housing backing it up with locktight and finish it off with a generous amount of magic putty around the joint (plummers use it for sealing leaking pipes..mix two compounds together slap it on and it eventually hardens). A big thanks to my Boss who came through with a local engineering company (Brent Engineering). They were able to weld aliminium and the job they did on it looks impressive..solid and the weld formation looks like it will last for life.
Here is a reminder of the hose I was going to use and the pictures I gave to Brent..Using a bit of imagination you can see that I would have struggled to fit it and at the same gain access for future maintenance/change of coolant/service etc..

pictures I gave to Brent..I also gave them the Vovo hose section to work ideas on..


thermostat housing

running out of line space back in a mo...

[carpmaster]

Hello again
Here is a few pictures of the modded thermostat...gave it a clean up and its looking good....

check out the weld formation..looks up for the job

A look on the inside..had to rub it down for a while..wanted to be sure the thermostat would sit in there without being fould by the heated area formed from the weld.

A look at the spiggots cross sectional area, the internal diameter is 6mm, overall diameter is 16mm.

I am happy with it and looking forward to fitting it on the engine.I will be using the lower section of the Volvo hose..it has a nice bend and if used will help me avoid the distributor and fit into the area/space I have shown measurements shown in the above photos. Hopefully I can still fit the engine lift mount piece..but not over worried..if it doesn't I will look at modding that too!!.
Back in a bit with a list of remaining jobs to do..
Tom

[carpmaster]

A few flicks from yesterday..get them on before I start work..
I managed to complete a couple of jobs..connected the existing main coolant pipe on the Rad and fitted the bracket...Took on ELVIS's suggestion and moved the fuel filter and placed that under the and Van. pottering around doing odds and sods.....
A look at the modded Thermostat..fits sweet as a nut, got to work on sorting a vent/overflow pipe


Thought about overall length and finished diameter (16mm needed to reduce it to 6mm ID) so made a plug/insert using a piece of 6mm pipe.

another angle... it was quite cold yesterday

trimmed it off leaving a little..you never know!!

Made the connection..easy using silicone spray. Job done..looking up for the job and got plenty of length to play with.

A flick showing the space available to me now the thermostat has been done..chuffed..used the volvo hose piece..cut the angle of the dangle off and suits its new home...

direct feed to fuel pump..thanks ELVIS

[carpmaster]

Don't worry all new connections have been jubulee'd up..forgot to mention that..
Here is a flick of the newly sited filter..looks quite pitifull (size) for the engine it has to filter for..

A quick snap of the cill..I knocked it rolling out from under the van with my shoulder..another subject..

Got to work on a piece of 38mm id flexihose and fitted it to the main coolant pipe..and cut down the s/s pipe I had knocked up..needed too a bit long.

s/s pipe with 16mm spigott

The flick of the s/s pipe and the flexipipe..(incase your not sure..connections to be made to the water pump)

That's it on the flick front for a mo...need to go to work..will post later on other stuff i need to do..I know I know..I said that last time.. fell asleep on the settee..Guiness..
Tom

[Aidan]

any news Tom, or have you driven off to sunnier climes ?

[carpmaster]

Hi Aidan
No further news at the mo..Neil emailed me asking the same question. I have wrapped the van up..weather and natural light hasn't helped..I am hoping to do a bit more soon...The project started to wear me down with worries..what if this, what if that...so decided to take a step back. Added to the fact I was made redundant from my previous job (agency). All good now though, I have a job, shift work but pay is good and I signed a perminent contract...happy days..Now that I have settled, I am praying I can get on top of the project once again. Ideally finishing before the end of May..Tax runs out..I really want to avoid having to SORN the van.

Things to do..

Finish off the coolant conections..mount expansion tank..mount exhaust..fit the alternator..fit the gearlever arm..fit the ignition coil..fill and bleed the clutch system...oils for engine and carb...wire it up...stich the back panel up...

I will need a friend for the clutch bleeding, gearlever arm and wiring up...

My Van looking sorry fo itself..not much space to deal with..my landlord is hinting that the Van will need to be moved in the next Month..A building contractor needs the space for his scaffolding towers...No really..I would never have guessed..just about slip a rizzla paper between scaffold and Van..






So hopefully in the next couple of weeks I will be activly posting. Once I have done the bits I can do on my own..I will be asking for a little help, hopefully a club member near by can give me a hand..clutch bleeding, gearlever arm and if possible wiring up...I am looking forward to the day when I hear the engine start.
Catch you all soon..thanks for looking.
Tom

[carpmaster]

Hello

Did a little yesterday..

Thought I would tackle the air intake and mounting the Diesel filter from my Old JX. I used a couple of plastic link pieces,a little gaffa tape x1 bracket/strap fitting and a scrap piece of hose (grey) from work..nice and flexible. Here is a flick of the bits.


After an hour or so deciding where to mount and swapping pieces here and there I went for this...


I used the right angled connection on the end of the engine air intake hose and fitted it to the filter. Air into the filter I fed the Grey hose up through the air void..(copying the principles of the JX set up)..I then connected both both hose and filter using the plastic piece..Gaffa tape just to make sure.


Overall I am happy with the set up, a nice big filter and very easy to get to and change..I have considered moisture being trapped and I plan to allow a weep hole on the lowest point (Grey hose). If I have any problems with the set up when I get the engine going..I have a piper cross jobby I can just slap on just incase.

[carpmaster]

I also managed to fit the alternator, part of the exhaust and oil dip stick..
I have managed to get some scrap metal pieces from work which I plan to use for the raised hatch. Other scrap pieces include a massive bracket ideal for mounting the exhaust and main coolant pipe...
My cordless drill has gone to heavens...so on the look out for one!!! Ebay here we come...

Quick question...Am I ok using a 65Amp battery alongside/with a 55Amp alternator

Catch you soon....
Tom

[silverbullet]

Don't worry about the amperage thing Tom, you're getting battery Amp/hours mixed up with alternator peak output.

Find a bigger Volvo alt. later on.

Glad you're making headway