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Actual proper work done today ;D I've got use of Becky's car this week. It's quite a cool barge and Becky seems to find it mildly amusing (as I long as I don't spill oil in it) that the moment I get my hands on it, the back seats go down and it stays as a van for as long as possible. And have now learnt the main failure point of diesels that don't start tends to be the fuel stop solenoid thingy. Three guesses how I learnt this... temp bodge living in the scuttle ;D So last night I loaded up and planned on getting an early start. It didn't happen, obviously, but at least I was already loaded and could go straight to the Volvo I stripped down some of the front end; the later ones have the panels at the front spot welded together but thankfully the earlier 244/245s were bolt together, so I could just remove the top piece for access. Bonnet came off and was incredibly cumbersome when working solo.. Then the radiator and associated hoses. From there it was a case of carefully disconnecting everything and unbolting the engine from the gearbox, draining the oil and undoing the mounts.. Sounds like a 10 minute job when typed up like that! The Hardcore loaner crane got pulled out and the engine attached to it. A bit of 'manual adjustment' was required to get the rubber engine mounts out of the way, and also a bit of a pry between engine and bellhousing to get it sliding off of the splines, so it went surprisingly smoothly Except.. I was working in a flat(ish) garage and a slope out of it. The wheels weren't touching the floor and the support to make it freestanding when stored was doing its best impession of a tent peg I hacksawed it a bit and bent it out and it all started to get much easier. It even stands better when stored now I've bent it. I'll weld it into place next time I'm melting stuff together. Great success! Obligatory 'an engine used to live here' shot I'm quite proud. I've never pulled an engine on my own before, only ever giving other people a hand. Reading Bruce's Mazda thread has shamed me into wanting to finish stuff to a higher standard and with greater attention to detail. I won't get all OCDish though. I only get that with checking I've locked doors.. What that essentially means is more paint. To fix the 'learning curve' mistakes from when we originally painted it last summer, and to do the engine bay, boot and door shuts. This is good, becuase I had a bit of an accident that will need some paint attention. When working in a narrow garage, do not jack your car over so it pushes into the wall. cockflaps I also noticed that one of my headlamps had a stone chip. Arseholes. I'd done a 'I've got to sell the Volvo' sale before coming to my senses and managed to sell off my spare, rare headlamp really cheap. Guess I'll be modifying a pair of 7inch ones instead then.
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...proper medallion man chest wig motoring.
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,028
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Congats on loosing your engine-removing virginity dude ;D Piece of pi$$ really when you get down to it, and hugely enjoyable when the the lump in question finally pops out of the bay Any progress on the hunt for a replacement??
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YAY for popping your engine removal cherry. It's an awesome feeling! Got your text earlier but was in the remotest wilds of Pembrokeshire measuring up totally un-inhabitable properties with a big grin and grand plans....whenever I tried to respond I was met with 'No Service' which actually made me even happier that my efforts to find somewhere remote were working ;D Nice work Dude and very honoured that I could be inspiring you in some way. OCD does have its benefits* Looking forward to the next stages..... * I don't actually have OCD but think it's easier to say I do so people don't question why I am so pedantic about most things
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Figuratively speaking, Iveco engines and 'boxes are ten a penny so finding a replacement isn't a problem. Litteraly speaking, going rate is £450ish, so it's a case of waiting until I've saved more money, or stumble upon something cheap. Whichever comes first Bruce, Your NotOCD reminds me of something that makes me smile.. During the Project X build, at one point the centreline we'd marked on the shell didn't quite line up with one on the chassis, and somebody said 'Whilst Bruce isn't here, why don't we just draw another line'. I won't say who but it made me laugh. I believe we got it to line up properly..
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...proper medallion man chest wig motoring.
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Apr 21, 2011 21:06:45 GMT
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...proper medallion man chest wig motoring.
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Apr 21, 2011 21:10:17 GMT
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AWESOME.
Let the dizzle shizzle commence. Roadtrip to collect? Fancy some company? ;D
Good work Dude.
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Apr 21, 2011 21:18:39 GMT
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Just getting in touch with the seller now so I'll give you a bell tomorrow, Bruce
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...proper medallion man chest wig motoring.
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Apr 21, 2011 21:21:00 GMT
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Text maybe best, I'm out on the road all day Very excited for you.
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kevfromwales
Posted a lot
the conrod's REALLY out the block now!
Posts: 3,909
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Apr 21, 2011 21:26:29 GMT
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I BOURGHT THIS IN THE VIEW TO FIT INTO MY DODGE RAM DAY VAN...BUT IV GOT TO FACE FACTS....ITS TO MUCH TO MAKE IT FIT AS AMERICAN STUFF HAVE THAT MANY TYE BARS STEERING ARMS ID HAVE TO REMAKE THE SUMP...SO SELLING IT.... ^^ gaylord ben, I'm so pleased you have gone this way with the engine choice! - and whitchurch is not a big hop from me at all, so either pop up and say hi - or I'll pop down to whitchurch and give you guys a lift chuffed the iveco love is spreading!
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Almost on the road: b11 sunny breadvan, e36 tds, 325i skidcar,
nearly there: ford f250 tathauler, suzuki alto, u11 bluey
not for a while: ford pop, 32 rails,
not in this lifetime: ruby, '29 hillman
''unfortanatly I'm quite old and scruffy and in need of some loving. my drive shaft needs a new boot....''
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G A R'goyle
Part of things
Bad to the bones Senior citzien
Posts: 115
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Apr 22, 2011 14:44:33 GMT
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Apr 26, 2011 21:37:58 GMT
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Can you get an Iveco Turbodaily engine in the back of a Passat? Yes, but it involves a forklift, a massive metal pole, and a ratchet strap. Can you get it out again on your own with only a crane and a bit of dodgy rope? Yes, but it involves dangling the engine and driving away from it whilst wincing and hoping for the best. ;D Must remember to use a more appropriate vehicle next time.. So I have it, and it's at my unit. I'm trying to split the engine and gearbox and can't figure out why they only come apart by 30mm or so. My best guess is that the clutch release bearing has become seized into place, holding the box to the clutch.. dunno. I guess a big hammer would sort it. Sump looks like it may need some work.. but the crossmember that will be below it can be cut about a bit as there is an additional crossmember across the front that the engine mounts to. I haven't checked the width yet, but it looks easy to modify or replicate Was quite fortunate that the seller wanted to just offload everything.. He included the ali cored rad and intercooler, the prop, the fuel filter mount (return runs to this), front section of the exhaust and a few other bits. It's a 49-12, 2.5 turbo'd and intercooled engine from a recovery truck. The numbers are deciphered as 4.9 tonnes, 120 horsepower. it's actually 116 but I'll allow them those four since there's going to be masses of torque ;D Looking over it, it's been well looked after and only genuine Iveco service parts used. £275 was a bargain
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Last Edit: Apr 26, 2011 21:42:34 GMT by ben711200
...proper medallion man chest wig motoring.
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kevfromwales
Posted a lot
the conrod's REALLY out the block now!
Posts: 3,909
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Apr 26, 2011 21:51:29 GMT
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yay!! - I had to do much sump chopping to mine to get it in, and my front x-member is pretty similar to yours did the bloke include the gearstick??
- kev ps - get the bloke to give you the VIN for the van, it'll make ordering service bits a lot easier - though not as funny as quoting the volvo VIN....
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Almost on the road: b11 sunny breadvan, e36 tds, 325i skidcar,
nearly there: ford f250 tathauler, suzuki alto, u11 bluey
not for a while: ford pop, 32 rails,
not in this lifetime: ruby, '29 hillman
''unfortanatly I'm quite old and scruffy and in need of some loving. my drive shaft needs a new boot....''
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Yep, gearstick is amongst the pile of bits. Good call on the VIN, it totally escaped my mind when I was there. Will figure out how much and where to chop once I've actually got it mocked up, though I have a feeling it will need quite a bit of work.
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...proper medallion man chest wig motoring.
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kevfromwales
Posted a lot
the conrod's REALLY out the block now!
Posts: 3,909
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Apr 27, 2011 11:41:30 GMT
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I pondered dry sumping mine, might be an option to get rid of the sump all together??
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Almost on the road: b11 sunny breadvan, e36 tds, 325i skidcar,
nearly there: ford f250 tathauler, suzuki alto, u11 bluey
not for a while: ford pop, 32 rails,
not in this lifetime: ruby, '29 hillman
''unfortanatly I'm quite old and scruffy and in need of some loving. my drive shaft needs a new boot....''
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Apr 27, 2011 19:09:03 GMT
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I also pondered it, but having looked into how it's done, it's more expense and complication than I'd like.. Afterall, my time with the sump, a grinder and a welder is free and scavenge pumps, oil reservoirs and getting lines made up are not. And with that front crossmember essentially doing the job of the existing one, I can afford to be creative with the existing one. Obviously nothing ridiculous though, it still has to have some structural inregrity. That's the thing though, I can get it out by an 30mm or so but not pull it right off. It's like it's stuck on something but I can't find anything there. Normally I manage with a little prise and then it slides off freely. So, it's come out a bit, and the box spins round the input shaft but it won't pull off? I'm guessing that either the clutch plate or the spigot bearing is stuck to the shaft, and therefore it won't pull through the pressure plate. I had a transit do this once, I had the front of the van off the floor with the crane but it wouldn't budge. I ended up removing all the pressure plate bolts through the starter motor hole (fiddly but do-able) and it fell off. Clutch plate took a hammer to separate from the shaft. It would seem that SOC has the same thinking about my gearbox removal problem that I do. Fortunately, access is pretty good so I'm going to get on that with the bonus bank holiday.
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...proper medallion man chest wig motoring.
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Colonelk
Posted a lot
Posts: 3,740
Club RR Member Number: 83
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Apr 27, 2011 19:18:34 GMT
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Looks like a beast! does it fit height wise in the bay?
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Apr 27, 2011 19:24:02 GMT
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Looks like a beast! does it fit height wise in the bay? Measuring is for losers I'll make it fit if it doesn't want to but it is certainly taller than I anticipated...
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...proper medallion man chest wig motoring.
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Been reading up in the workshop manual.. I haven't gone to check the engine code yet, but a couple of external identifiers suggest this is actually a 2.8 rather than a 2.5. According to the book, the 2.5 has a KKK turbo, and the 2.8 has a Garrett or Mitsubishi. It also suggests that the 2.8 has an electro-mechanical cold start thingy, and the 2.5 does not. I have a Garrett turbo and an electro-mechanical cold start thingy. Frickin' awesome. I've just got 10 or so horsepower for reading the manual ;D
Engine and 'box are now separated. The tunnel is alright, but the bellhousing area will need some manual adjustment, mostly to clear the clutch arm. Ideally I'd like to have found that it can be converted to a hydraulic clutch but it doesn't look like that's going to be the case
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...proper medallion man chest wig motoring.
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B-8-D
Posted a lot
down to one car!!
Posts: 4,038
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Been reading up in the workshop manual.. I haven't gone to check the engine code yet, but a couple of external identifiers suggest this is actually a 2.8 rather than a 2.5. According to the book, the 2.5 has a KKK turbo, and the 2.8 has a Garrett or Mitsubishi. It also suggests that the 2.8 has an electro-mechanical cold start thingy, and the 2.5 does not. I have a Garrett turbo and an electro-mechanical cold start thingy. Frickin' awesome. I've just got 10 or so horsepower for reading the manual ;D Engine and 'box are now separated. The tunnel is alright, but the bellhousing area will need some manual adjustment, mostly to clear the clutch arm. Ideally I'd like to have found that it can be converted to a hydraulic clutch but it doesn't look like that's going to be the case hydraulic conversion can be done easy with a hydraulic bearing of something like a granada diesel or a omeaga.. just need to get the spacing right (measure the old one) and as long as it fits its just a matter of making a conversion plate and a external way of bleading it and conecting the hydraulics.. would save the "arm in the way" shinanigans. si ps cant wait for this to be done.. I thinbg its an excellent conversion. maybe we should have a "diesel conversion stand" at RR11 to spread the love for the dirty oil burners?
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Last Edit: May 1, 2011 17:47:05 GMT by B-8-D
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Steve
Posted a lot
Making progress in small, easy to handle chunks of awesome
Posts: 2,028
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10horses extra just from reading a manual...wish i was that lucky sometimes!
Been a bit of a good news kinda day for both of us then ;D
Crack on then! Want it in and running by dinnertime tomorrow ;D Chop chop!!
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