1.6td to Volvo b230a...

[carpmaster]

The fourth flick working from left to right...
T7a/4 I have connected to the golf mrk 4 header tank..Currently when I turn the key (not starting engine) warning light flashes and then goes out (telling me the level of coolant is OK)...it's meant to flash all the time at the mo..I have no coolant in the system yet! I have connected the two wires up wrong from jx header tank wiring to Mrk4 header tank...Hopfully by swapping them around I will solve the problem.
T7a/2 I have used and connected to the Volvo temp sender. Open to further investigation as I have never had a temp reading.


Here is a flick of the fuse box and connections the van has..had to give it a good dust down..

I havn't messed around with the connections but curious as I am noticed this little puppy tucked away...not easy getting a flick part number
251 919 505 12v 70A..I believe it is for the radiator fan 2nd stage...Another area I need to investigate..when I lost the jx engine last year and it over heated..not once did I hear the Radiator fan kick in!

To finish off I took a flick of the starter motor..One reason is I needed ask a member who has the same to confirm the spade connections..I would like to know what the perpendicular spade connection would be used for...
The red and black wire I have (now) connected to the lower spade horizontal connection I believe is marked 50...its not connected as shown in the photo.

Back in a moment jumping post...

[silverbullet]

On the clutch problem, that amount of free play before the bearing meets the diaphragm looks about right.

Can't comment on the electrics but 0.3 bar is only 5 psi, crank it over some more with the plugs out to get some oil pressure and to fill the filter (easier on the battery and starter if there's no compression!)

[carpmaster]

I am currently suffering from a sore back lower.. I got to cold on saturday when fooling around with wiring..and I was tensed up for what seemed an age..now of course I am paying the price..
Still my winge and moan over..I received some goodies today..some filler for tarting up the holes I have here and there and for the cill area that I need to disguise from the MOT people..I have some steel to patch in with to cover the magnet check..only a short term fix..I know I need to sort it properly..plus wheel arches x2..well she has been sat there for nearly a year not doing anything other than feeling sorry for itself and being dumped on by Seaguls..
I also took delivery of some Vactan 1ltr to help rid the rusty bits..a big thanks to Covkid's write up on painting your van..

One vital piece of kit I received is a new clutch master cylinder hopfully it will solve the problem I currently have with the rock solid pedal.

To finish off for the time being I will leave by saying once I wired up I just had to try....I connected the battery and ...well she wanted to start..but blow me down with a feather..my luck seems to be out of sorts lately..the battery didn't have enough ummpff to give her a good turn over...I was bit naughty..I needed to crank her up by hand before starting her up to build a little oil pressure..I plan to do that when I visit tomorrow...can't wait..battery has been on charge and is fully loaded and ready for action....
I am going to make a couple of changes to the wiring ..I have decided to disconnect the starter to alternator lead and I am going to use a heavier cable from the battery + to the alternator instead..just like the diesel set up was..Plus I plan to sort the solenoid valve connection and tap it into T3/3..Plus I will go over an double check what I have wired upto ....oil and water..ignition coil..etc

Thanks for looking and help
Tom

[axeman]

seams that your getting very close to the finishing keep at it.


neil

[carpmaster]

On the clutch problem, that amount of free play before the bearing meets the diaphragm looks about right.

Can't comment on the electrics but 0.3 bar is only 5 psi, crank it over some more with the plugs out to get some oil pressure and to fill the filter (easier on the battery and starter if there's no compression!)

One of the reasons for choosing 0.3bar from the existing diesel wiring is because the Volvo oil pressure switch ranges between 0.3 and 0.6bar..the other choice would be 0.9Bar for turbo diesel and 1.4 NA diesel..I am not sure at the moment if oil pressures for my van have been calibrated (if indeed at all) to suit a Jx set up...I mention calibration because I am aware both fuel levels and coolant temps can be calibrated/set using resitors..

I plan to crank the engine up tomorrow without the sparks plugs in..
Tom

[carpmaster]

seams that your getting very close to the finishing keep at it.


neil

Thanks Neil...starting to get a little excited..if she starts up tomorrow and runs ok..I will be pushing through the other jobs I need to get out of the way..get her up and ready for an Mot..give her a wash to start with.. If all goes well I could be driving her about next week...fingers crossed...I could do with a turn of fortune...we shall see..
Tom

[carpmaster]

Started the day on a buzz....Cranked the engine up without the spark plugs in about 20 full revolutions..took the cambelt cover off to check I had TD mark on first cylinder...spark plugs back in..cam cover back on...
I then rewired the solenoid and swapped the connections to the header tank...because of the flashing warning light.."mentioned above" ( I checked after switching the ignition on its doing the same..I may have the wrong switch for the header tank I have..

Connected the battery, I then checked all external electrics..lights, indicators, etc etc..all good..horn and wipers doing what they should do...

I then inspected the slave cylinder on the clutch...following a chat with Aidan..as it could be the problem for the solid clutch pedal..I get full pedal action with the bleed nipple undone..and there is a strong possiblity I could have a hydrid set up..as I was inspecting the push rod on the slave cylinder I accidently ripped the rubber bellow....bit of a blow and I have to admit I was cursing rotten words for a while..It is likely I will get a new one as I can't be bothered with the one I have..I will probably send it to Aidan for a post mortem.

feeling slightly annoyed and sorry for myself...I thought I would have a go at turning the engine over..nicely charged up battery..just the job..
Well it turns out that the starter motor I bought from a member is U/S the brushes are loose/knackered name it what you like it struggled to turn the engine and it was desperately sluggish when it tried...I checked all connections and while doing so felt the starter and it was very warm..
It did rain today on and off with a few hailstones..the only thing missing was lightning to strike me down..

I need a boost of cheery upiness..as right now I am truly peed off....If anyone who can help with a Petrol Starter that is in good working order..please give me a shout..I will go on the wanted section and place an SOS for one there (two postings asking is better than one). If I hear the engine start it will do my spirit the world of good..
Tom

[silverbullet]

The bellows is only there to keep dust out, you can live without for a few days. Aidan is snowed under with work, I'd save the postage and put it down to experience. What clutch slave is Neil using?

On the starter: what a bumm3r! I've been there too, took out one that was a bit sluggish and when opened up it was hanging on by a THREAD. Literally!

Once you've got a runner the world will be a different place. Chin up!

[carpmaster]

Thanks Ian for words of encouragement..

A big thanks to Metalmick8y who has come up trumps with a replacement starter and is posting tomorrow..diamond geezer he is too...

As for the slave cylinder I have fallen out with it..I am no longer its friend.....Ordered a replacement from GSF and should be with me in the next couple of days..I dropped Neil a PM asking what slave cylinder type he has.

It will be interesting finding out when I take the old startmotor off what it's like inside...probably similar to the nightmare one you had.
Tom

[axeman]

i will have to have a look under my van and find out exactly which slave cylinder i have, i have not changed it, ie it is the same one that vw put on the the van, but it was an mv engined van to start with. it has always been a bit of a bugger to bleed but the fluid has always dran through.

tough break with the starter, but keep chin up your be there soon.

neil

[carpmaster]

I am still having problems getting the clutch sorted...the starter Motor I bought from metalmick8y turns the engine over however, I havn't been able to start her. The weather hasn't helped..as you all know the Van is outside and has been throughout the project.

I was about to throw the towel in and call it a day following a visit with my wife about the condition of the van in general and wether it was ecomomical to go ahead with the project...The van is going to cost me an arm and leg to get it through its MOT...panels etc because of the rust problems it has. It was decided that it wasn't worth carrying on and I would try an sell it as a project and or break it down and sell the bits to recoup some money towards another van.

I explained my feelings to a chap at work and he said he would come and help me next weekend to try and start it up...he explained that once you hear the engine starting it would give you new hope..and you may decide that you want to go ahead.(having done several projects himself..so speaks from experience)..then we could look at the clutch situation. Feeling a little different but still apprehensive about the whole situation I agreed with him that maybe it will change change my mind...couldn't stop thinking about the fact I will still need to find extra funds to Mot prep it/repair it etc..

Most of you that have followed this thread will have learned by now I do try and grind away the best way I can and on route with club members help often reach my goals (and often including pockets of bad luck to boot)...A big thank you to all that have contribued and that comes from the heart.

Unfortunatly, more bad luck has come my way and it doesn't look like I am going to ever hear the van start..My landlord wants to to move my van from whaere it is because he has development plans and my van is in the way of progress. He left a message on my phone today while I was sleeping from my night shift. He has given me a space in the front of the building however, and here is the final nail in the conversion coffin...I am not allowed to continue to work on the van and I need to remove it from site as soon as possible...

I am stuck for words to describe how I feel...and to make matters worse I have nowhere to go.....

I have since been on the members only forum part and I have two club members that can hopefully take it away... VW Busted..and Billy.what I am going to do from now I don't know..I have to do a night shift tonight..(doesn't help with your emotions feeling dog tired I am supposed to be sleeping now). I will be calling them tonight and see if they can help...I am not allowed to visit websites at work...I will ask my Pippa (wife)to log on here and if there is someone who is in a position to help me out/contact...She will call me at work..

For everyone that has helped todate..thanks again

Tom

[shaka1976]

This is sad reading, I have admired your perseverance throughout the build. You were brave enough to go against the grain by fitting a non VW motor. And then to be doing it outside. You've got my respect what ever you decide to do. I will say that having an engine that starts does give a new enthusiasm and I hope it does for you!

GOOD LUCK!!!

[jed the spread]

Very disappointing, I just noticed this thread is a year old too Shame someone that knows about this conversion cant help you out?

jed

[rich broom]

i have some space that you can store it.. just the other side of wellington.

[silverbullet]

I've walked away from two resto's in the past, there's no shame in it. Yes it hurts at the time, but you get over it. It's only a car after all...

The first when I was working from a leaky council lockup across town, too much ambition and not enough skill or money. Uni was looming, it was never going to get finished.

The second was more recent, I had the skills but not the time and the car only had 4 seats. Not much good when you've got three kids!

With regard to recent comments, the bottom line in this particular situation is that it wouldn't matter what engine was being fitted to what wagon. It's not like it is a unique, never-been-done before, pioneering conversion.
Loads of these have been done before (OK not many in the UK) but it is based on a well-developed kit and all the thinking had been done for the buyer. Yes Tom had a few hiccups with the trans nose mount but that's all part of the game afaics.

The Volvo is a solid basic lump, it's carb and distributor so doesn't get much simpler for a petrol engine. If it's got fresh fuel, Amps to crank it and volts for a good spark (arriving at the correct time) it should start.