1.6td to Volvo b230a...

[carpmaster]

The modded Volvo bit..thermostat side


I visited the Van to fit the fuel tank and investigated the connections and traced what coolant pipes were what..It's not the best flick..it shows the bottom connection to the Rad..this connection is coolant from the rad "cooled" to the engine water pump..just to the left and a little higher up is the connection to the rad from the engine (thermostat)..to be cooled.


Here is the space I have available for fitting the tank. The van is sitting nicely on 6tonne jacks...

getting ready for the fit


Struggled a bit and had to drop it a couple of times because of trapping vent pipes..especially the vent to filler neck vent pipe...got there in the end..useful though to have a friend with you..less swear words..naughty ones too!!


In case you were wondering, I did give the underneathe a coat of waxoil....not a pleasant job..drips in the hair and I got one in my ear!!..looks good though an well worth the effort...Once I get the van back on the road I will give the front end a once over.
Always good to show a picture before..

After...

and a flick of the drive shafts and new CV joints and if you look carefully you will see the rear breaklines..this is the area where the back plate on the gearbox mount is fouling...directly underneath the breaklines on the underside of the chassis is where the gearbox mount and rubber fasten on..

[carpmaster]

All I need to do to finish off is fasten together the cover and ring conneted at the top of the filler neck..

I stripped out the old throttle cable and installed the new one..another pain in the backside job..really fiddly gaining access to the throttle linkage connections (under pedal)..easy to loose focus when you struggle with something. I forgot to note where the excisting throttle cable route fed through..the consequence of doing this led me to re route several times before I felt happy..even now I am unsure if it suitable..I havn't fastened the cable so I have the option of re routing it once the engine is in..If I need too!!


Waiting on my friend for news on his pickup..MOT..once he is back on the road I will be transporting the engine over..exciting times ahead. Still to hear about whether the ignition coil I have is up for starting the engine...

Thanks for looking..

Tom

[carpmaster]

I will start with a positive..I have had a nightmare for 3 days...
A big thanks to BigHerb..


I created a blanket out of cloud nine underlay to replace old with new..




Took the engine out ready for the big day!!


on arrival...


I mated up the gearbox and stuck them both under the van and tried to fit it..sadly without success. Through desparation I butchered the rear of the van and I still couldn't get her to fit.
I took home the gearbox mount and gave it a modification... I tried fitting the engine and again it wouldn't fit. here are a few flicks.

[carpmaster]

The front face of the gearbox mount and slanted shape of the chassis (part where the mount bolts onto) is preventing the modified holes to mate up. The only way of creating space for the gearbox to move is by power pressing the beam...not the sort of job I can do!!



There isn't much more to say other than I am unable to carry on with the project. I am under pressure from the landlord to get it off the axles and move it on..No power point..outside getting "pooh" on by seagulls..The van has been sat there for 5 month..and I have cill issues wheer the fridge and cooker used to be.

It is likely I will abandon the project and scrap the van..not sure what I will do with the kit and all the bits and pieces I bought...I'm not concerned really..I have learned a lot and I have made new friends and contacts on route...I am going to look at it as a hobby I couldn't quite resolve because of circumstances beyond my control....even that statement could be argued against!

A big thanks to all members that have helped..it's been a great experience..much appreciated...

Another time maybe..
Tom

[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

How far is the engine going to stick up above the engine lid hole?

jed

Looking at that picture and add the fact that a 2wd engine sits higher than a Syncro It looks like that engine is going to stick right up into the van I dont know if its just the photo but the top of the engine looks to be miles past the engine hatch panel. Any news on just how far it sticks up yet? and how the R&R bed is going to work? I really hope it isnt going to be as bad as it seems.....

jed

Shame that, you could have fitted a nice AAZ ages ago and had a nice holiday with the time and money you have waisted with your new friends. Gutted for you really, I hope the people who have been so forthcoming with advice so far can get you out of this.

jed

[Aidan]

which gearbox mount and which rubber mount are you using ?

[axeman]

tom it should be possible to mount the engine in to a 2wd van with out having to cut the back of the van for the water pump pulley form the resuch that i have done, i dont know about the difference on gbox mounts as aidan has suggested that there may a difference that can get you out of this spot that your in at the moment.
dont get too diss hearted, rember that it should be a pleasure and not a chore. give me a call if i can help

neil

[jed the spread]

tom it should be possible to mount the engine in to a 2wd van with out having to cut the back of the van for the water pump pulley form the resuch that i have done, i dont know about the difference on gbox mounts as aidan has suggested that there may a diffe

rence that can get you out of this spot that your in at the moment.
dont get too diss hearted, rember that it should be a pleasure and not a chore. give me a call if i can help

neil

Your the one who keeps telling this poor bloke it's going to fit, he has just chopped out half the back of his van on your recomendation from the start and spent a bloody fortune via the links you have sent him. Can't you tell him how to sort it?

Looks quite abit less than a pleasure to me at the moment.....

Jed

[lloydy]

Sorry to hear of your troubles, stop now! Go get a gti engine, they are fitted in many cars (8v) not just hot hatches. Would cost you about £150 at the most. AAZ's are thin on the ground now. The gti will give you 30+mph and more power than a dj. You'll have it fitted I'm a day if you still have the diesel bits.
Can't understand why you changed to petrol? And why you went down that engine route?
Pm Elvis he'll tell you how good a gti is.
I hope you can stitch the van back together

[carpmaster]

which gearbox mount and which rubber mount are you using ?

Here you go Aidan..I took it off after work..













Hope this helps. Prt number rubber 2513992058..on the other side 2-220000 153 02

[carpmaster]

Thanks for your support.

I will wait to hear from Aidan on the rubber/gearbox mount.

I have been thinking on the lines of alignment and the times I had both engine and gearbox jammed in (upright).
I grabbed the engine bar and fitted the engine supports on the bar and two plates on the block. I then fitted the blue rubber mounts and held the engine bar up...Something is not right and its been doing my swede in..I can't help but picture the engine sitting as it should do on the supports, meanwhile my gearbox is at an angle..interesting..

just having munch..

[xriss]

it can be done it has been done tom perhaps u might want too cantact this guy..cheers http://www.members.shaw.ca/bilbo/callevan.html" onclick="window.open(this.href);return false;

[carpmaster]

I am at work now for the next 3 days and as you all know I do rubbish shifts. I plan to look at fitting the engine bar and check that everything is ok with alignement. Gearbox and engine..I have had time to reflect on what I saw and recalled how I felt when spying how high the whole set up was and the drive shafts looked quite low in comparison to the gearbox..something not right and its going to be one of them staring at your face situations!!!

I will keep you posted..thanks again for your thought and support.

Tom

[Aidan]

Tom
hi, so that's a diesel 5 speed mounting plate with a diesel rubber mount, now that means that the gearbox will be high in the chassis and maybe the problem, but I don't know what the kit is designed to fit, but I'm thinking if they were designed for converting petrol vans then the expected petrol rubber mount and gearbox end plate might be the solution, I'll look at the lockup on Friday and I'm sure I have petrol 5 speed plate, and I should have a petrol rubber too you can at least try them and see if that gives you room, you need to come down and forward by a bit isn't it

[carpmaster]

Tom
hi, so that's a diesel 5 speed mounting plate with a diesel rubber mount, now that means that the gearbox will be high in the chassis and maybe the problem, but I don't know what the kit is designed to fit, but I'm thinking if they were designed for converting petrol vans then the expected petrol rubber mount and gearbox end plate might be the solution, I'll look at the lockup on Friday and I'm sure I have petrol 5 speed plate, and I should have a petrol rubber too you can at least try them and see if that gives you room, you need to come down and forward by a bit isn't it

Hello Aidan..I do need need to come down and forward (toward the front of the van)..I tried again to fit the engine on thurs without success. The gearbox does sit high and if I can get them to come down and forward by a couple of inches...45mm will do..modified hole distance on GB mount. I should be there.