Boxy, but good. 1989 Volvo 740
Discussion
When we went to Rustival back in March, I met a guy called Kam Srih, who runs a club called Nordik Rides, who invited me to display the car at a meeting at The Great British Car Journey in Ambergate, Derbyshire
.
Yesterday was the day, so on Friday after I picked my daughter up from school the two of us loaded the car up, brimmed it with shell V-power at the local station and set off on our road trip at about 4pm.
185 miles and 3hrs 40minutes later we rolled into the car park of the Premier Inn at Ripley, the wheels only having stopped turning to wait at a couple of roundabouts, with the fuel guage still showing well over half a tank.
After eating in the McDonalds next door, back in our room I introduced her to the cult classic film 'Tremors' before turning in for the night.
After our all you can eat breakfast, we popped to the local Sainsburys to get some lunch and then headed to the museum.
On the way an F-plate 240 pulled in front of us up ahead. "I bet thats going there" Emily said, and then - "ooh, can you smell that!" just as I noticed a slight bit of blueish smoke as it pulled away that I commented on - "Well, It could have 300k on it for all we know"
The reality, as it turned out, was that the mileage on that car once it was parked up, was 833,269 miles! I think its allowed to smoke a little bit at that age!
I didn't take that many pictures for some reason, but this was taken by a professional photographer (who has kindly given permission for us to use the 'facebook resolution' photos) as we drove in:
and a video with us arriving on youtube:
https://www.youtube.com/watch?v=maAdy9V7Y3s
After a few hours walking around the cars and getting into conversation with some really nice people, we went over to the museum itself.
Smaller than the museum at Gaydon, they still had a lot of cars packed in, and a very good interactive audio tour to take you round the display. We only spent about an hour and a quarter in there, I reckon we'd both have been happy to have had at least another hour to look at all the detail.
The other feature of the museum is that you can - for a fee - actually drive some of the cars there. Definitely one to come back to.
When people started to disperse, with a long drive ahead of us we nipped back to the Sainsburys again to get some more drinks and then I bottled it and refilled the tank again with their Super Unleaded in case the guage had got stuck or something. Turns out it hadn't, and on the run up the car had returned 32.2 mpg!
Another 185 miles back with Emily in charge of the playlist, we only hit a little traffic getting back at a sensible time for tea.
The car ran faultlessly (as expected) with only a moments mild panic when an awful noise started coming from (from my useless directional hearing perspective) the fuel pump area. As it turned out what had actually happened was my water bottle that was lying on the handbrake had shifted position and was squeaking against the centre console!
As I said to Emily (stolen from someone else) "Taking a road trip in a modern car is like going to the football and seeing a 0:0 draw. Taking a roadtrip in something 35 years old is like going to the football and getting to see a 5:5 thriller - the end result is the same but at any point you just never know what is going to happen".
Also rolled over to all the 8's, conveniently enough as we passed through the local industrial estate about 5 miles from home so I could pull into a car park to get a picture.
Only another 744,381 to catch up to that 240!
.
Yesterday was the day, so on Friday after I picked my daughter up from school the two of us loaded the car up, brimmed it with shell V-power at the local station and set off on our road trip at about 4pm.
185 miles and 3hrs 40minutes later we rolled into the car park of the Premier Inn at Ripley, the wheels only having stopped turning to wait at a couple of roundabouts, with the fuel guage still showing well over half a tank.
After eating in the McDonalds next door, back in our room I introduced her to the cult classic film 'Tremors' before turning in for the night.
After our all you can eat breakfast, we popped to the local Sainsburys to get some lunch and then headed to the museum.
On the way an F-plate 240 pulled in front of us up ahead. "I bet thats going there" Emily said, and then - "ooh, can you smell that!" just as I noticed a slight bit of blueish smoke as it pulled away that I commented on - "Well, It could have 300k on it for all we know"
The reality, as it turned out, was that the mileage on that car once it was parked up, was 833,269 miles! I think its allowed to smoke a little bit at that age!
I didn't take that many pictures for some reason, but this was taken by a professional photographer (who has kindly given permission for us to use the 'facebook resolution' photos) as we drove in:
and a video with us arriving on youtube:
https://www.youtube.com/watch?v=maAdy9V7Y3s
After a few hours walking around the cars and getting into conversation with some really nice people, we went over to the museum itself.
Smaller than the museum at Gaydon, they still had a lot of cars packed in, and a very good interactive audio tour to take you round the display. We only spent about an hour and a quarter in there, I reckon we'd both have been happy to have had at least another hour to look at all the detail.
The other feature of the museum is that you can - for a fee - actually drive some of the cars there. Definitely one to come back to.
When people started to disperse, with a long drive ahead of us we nipped back to the Sainsburys again to get some more drinks and then I bottled it and refilled the tank again with their Super Unleaded in case the guage had got stuck or something. Turns out it hadn't, and on the run up the car had returned 32.2 mpg!
Another 185 miles back with Emily in charge of the playlist, we only hit a little traffic getting back at a sensible time for tea.
The car ran faultlessly (as expected) with only a moments mild panic when an awful noise started coming from (from my useless directional hearing perspective) the fuel pump area. As it turned out what had actually happened was my water bottle that was lying on the handbrake had shifted position and was squeaking against the centre console!
As I said to Emily (stolen from someone else) "Taking a road trip in a modern car is like going to the football and seeing a 0:0 draw. Taking a roadtrip in something 35 years old is like going to the football and getting to see a 5:5 thriller - the end result is the same but at any point you just never know what is going to happen".
Also rolled over to all the 8's, conveniently enough as we passed through the local industrial estate about 5 miles from home so I could pull into a car park to get a picture.
Only another 744,381 to catch up to that 240!
Chris1Roll said:
... I spotted this little electical gizmo that I hadn't really acknowledged up till now, and I don't recall seeing on my previous cars:
Now to me, that looks like a solenoid valve attached to the idle speed air circuit. I suspect for idle speed compensation when engaging drive. If that is what it is, it clearly doesn't work but it would be very good to fix.
Starting point I guess would be to undo the allen bolts and remove the whole assembly and drench in carb cleaner.
Anyone know if there is a gasket, or an 'o ring' behind it?
Having some spare time on Friday night, I finally got round to investigating this.Now to me, that looks like a solenoid valve attached to the idle speed air circuit. I suspect for idle speed compensation when engaging drive. If that is what it is, it clearly doesn't work but it would be very good to fix.
Starting point I guess would be to undo the allen bolts and remove the whole assembly and drench in carb cleaner.
Anyone know if there is a gasket, or an 'o ring' behind it?
On hooking my multimeter up to it I discovered it is indeed as I suspected. When the engine is running and the gearbox is in R, D, 2 or 1, then 12v is supplied to the solenoid.
Then I tested the solenoid by unhooking the connections form the car, and putting 12V across it. It clicked, so the solenoid is functioning.
Went and grabbed a 13mm spanner and whipped it out to find it all gummed up as predicted:
After covering it in car cleaner and activating it several times I put it back in - to no discernable difference...
So I decided to remove the whole thing, remove the idle speed screw etc and clean it all out:
There is now a clean patch on my engine!
It is a gasket behind it, which came off in not too bad a condition but once refitted the engine ran like crap and a spray of easy start confirmed air was getting in past the sealing surface (oops!) I didn't have any gasket material left so a cereal box had to do temporarily. I've ordered some more gasket material so will replace asap.
With that in place and a liberal spraying of easy start proving I had no leaks there or anywhere else (tested manifold gasket, injectors etc while I was there) I set the idle (mostly by ear, the rev counter is intermittently leaving the chat at the moment) and gave it a try.
Still no discernable change, the idle still drops in drive, so I'm still on my current setting of ~1050 in P/N and 900 in D/R/etc.
What I didn't do, and will when its not raining, is test putting 12v to it while idling in P and see if the idle increases. It could be that it has been 'working' all this time and the idle drop would be even worse without it.
- *
https://www.amazon.co.uk/dp/B0BS6XV2F6?psc=1&r...
To treat the trim with which was starting to look a little pale. I only had time to do the front bumper, but I was pleased with the result:
If it lasts as promised (and people are reporting that it does) then it'll be worth doing the XC's bumpers too.
- *
It was only 50 minutes away at Haselbury Plucknet so a nice family day out.
They had 176 people who filled in their forms, and I saw a lot more who had just on the seat so probably 200 cars in total.
On arrival my car was lost in a sea of Saabs:
Which is fine, I like Saabs, and the Sonett 3 behind me was wonderful.
As time went on various people came and went and there were a reasonable number of Volvos at various points, including this rather glorious 164E:
Another good day wandering around chatting to different people in the sunshine
chris1roll said:
Still no discernable change, the idle still drops in drive, so I'm still on my current setting of ~1050 in P/N and 900 in D/R/etc.
What I didn't do, and will when its not raining, is test putting 12v to it while idling in P and see if the idle increases. It could be that it has been 'working' all this time and the idle drop would be even worse without it.
This would be my guess, 1050 down to 900 'feels' about right to me.What I didn't do, and will when its not raining, is test putting 12v to it while idling in P and see if the idle increases. It could be that it has been 'working' all this time and the idle drop would be even worse without it.
Well that sucks.
Coming home this evening, I was just thinking about how in 2 days it will be a year since I put the car back on the road.
I was just stopping at some traffic lights and just before coming to a halt the car shuddered and then stalled.
Now it sounds like this:
https://www.youtube.com/watch?v=ZCAwN_O017c
Noise is somewhat reminiscent of what happened back at the end January - that 'fixed itself' - , but this is LOUD!
Certainly turned some heads (for the wrong reasons) coming through the village.
It's weird though, the shudder and stall felt like stopping witout putting the clutch down in a manual, rather than just shutting off, and it restarted ok but needed 2 footed driving to pull away...
Coming home this evening, I was just thinking about how in 2 days it will be a year since I put the car back on the road.
I was just stopping at some traffic lights and just before coming to a halt the car shuddered and then stalled.
Now it sounds like this:
https://www.youtube.com/watch?v=ZCAwN_O017c
Noise is somewhat reminiscent of what happened back at the end January - that 'fixed itself' - , but this is LOUD!
Certainly turned some heads (for the wrong reasons) coming through the village.
It's weird though, the shudder and stall felt like stopping witout putting the clutch down in a manual, rather than just shutting off, and it restarted ok but needed 2 footed driving to pull away...
chris1roll said:
Well that sucks.
Coming home this evening, I was just thinking about how in 2 days it will be a year since I put the car back on the road.
I was just stopping at some traffic lights and just before coming to a halt the car shuddered and then stalled.
Now it sounds like this:
https://www.youtube.com/watch?v=ZCAwN_O017c
Noise is somewhat reminiscent of what happened back at the end January - that 'fixed itself' - , but this is LOUD!
Certainly turned some heads (for the wrong reasons) coming through the village.
It's weird though, the shudder and stall felt like stopping witout putting the clutch down in a manual, rather than just shutting off, and it restarted ok but needed 2 footed driving to pull away...
Oh dear, not fun. Presumably something isn’t quite right in the head. There must be a few of these in scrappies…Is popping another engine in an option? Rather than poking around in existing?Coming home this evening, I was just thinking about how in 2 days it will be a year since I put the car back on the road.
I was just stopping at some traffic lights and just before coming to a halt the car shuddered and then stalled.
Now it sounds like this:
https://www.youtube.com/watch?v=ZCAwN_O017c
Noise is somewhat reminiscent of what happened back at the end January - that 'fixed itself' - , but this is LOUD!
Certainly turned some heads (for the wrong reasons) coming through the village.
It's weird though, the shudder and stall felt like stopping witout putting the clutch down in a manual, rather than just shutting off, and it restarted ok but needed 2 footed driving to pull away...
It's possible that I have already sourced a ~70k mile B200E to drop in.
Chap is going to check it still turns over as it has been sat for a little while (under cover).
That'll be the quickest and easiest way.
I'm asuming its something related to the cambelt snap and valve-piston interface. Its weird because it is still running on all 4 cylinders so it's not like its dropped a valve.
Now I'm waaaay overthinking it and questioning the torque converter or flexplate because of the stall, but I'm sure the sound is coming from the head so I probably just need to go to sleep!
Chap is going to check it still turns over as it has been sat for a little while (under cover).
That'll be the quickest and easiest way.
I'm asuming its something related to the cambelt snap and valve-piston interface. Its weird because it is still running on all 4 cylinders so it's not like its dropped a valve.
Now I'm waaaay overthinking it and questioning the torque converter or flexplate because of the stall, but I'm sure the sound is coming from the head so I probably just need to go to sleep!
Instead of taking the car on a road trip over the Abergwesyn pass today, which was the original plan until about half 7 last night, I've done some investigation.
Checked the timing (OK) and ran it with all the belts off - still rattling.
Revved it a bit and lost a cylinder.
Aha! Something to work with - On removing each of the plug leads in turn it was clear it was cylinder one.
I swapped leads 1+2, same result, cyl 1 weak or inactive dependent on how it felt.
Then I swapped the distributor cap just to be sure, still Cyl 1.
Got Amy to come out and listen to locate the noise and she pointed confidently at No1 area in the head.
Compression test shows cylinder 1 is down to just 120psi, with all others at 180-ish.
Arse!
Once the 'scope had charged up, I'd had something to eat, walked the dog and cut the grass I had another poke about.
Ok so No1 plug looked OK, but a bit more bronzed than the other 3....
No2 Cylinder intake valve for reference:
No1 Cylinder intake valve - where the f
k is the valve guide??
Oh, It's OK, I found it!
My working theory is that it was obviously damaged when the cambelt stripped this time last year, and just fatigued further over time.
At the end of Jan I guess a little bit came off that then found its way out the exhaust without causing too much damage, and then last night a big chunk(s) fell off and knackered it.
'New' engine time then!
If I just swapped the head I'd be worried about the beating that cylinder has taken, and TBH it would both quicker and cheaper in terms of parts to just swap in a second hand engine with some new seals and gaskets etc.
I've not taken the head off at the moment, it'll just make it a bit more awkward to get the engine out, and as it stands if I throw the plugs + injectors back in I can move the car if need be.
Checked the timing (OK) and ran it with all the belts off - still rattling.
Revved it a bit and lost a cylinder.
Aha! Something to work with - On removing each of the plug leads in turn it was clear it was cylinder one.
I swapped leads 1+2, same result, cyl 1 weak or inactive dependent on how it felt.
Then I swapped the distributor cap just to be sure, still Cyl 1.
Got Amy to come out and listen to locate the noise and she pointed confidently at No1 area in the head.
Compression test shows cylinder 1 is down to just 120psi, with all others at 180-ish.
Arse!
Once the 'scope had charged up, I'd had something to eat, walked the dog and cut the grass I had another poke about.
Ok so No1 plug looked OK, but a bit more bronzed than the other 3....
No2 Cylinder intake valve for reference:
No1 Cylinder intake valve - where the f
k is the valve guide??Oh, It's OK, I found it!
My working theory is that it was obviously damaged when the cambelt stripped this time last year, and just fatigued further over time.
At the end of Jan I guess a little bit came off that then found its way out the exhaust without causing too much damage, and then last night a big chunk(s) fell off and knackered it.
'New' engine time then!
If I just swapped the head I'd be worried about the beating that cylinder has taken, and TBH it would both quicker and cheaper in terms of parts to just swap in a second hand engine with some new seals and gaskets etc.
I've not taken the head off at the moment, it'll just make it a bit more awkward to get the engine out, and as it stands if I throw the plugs + injectors back in I can move the car if need be.
chris1roll said:
Is that the blue one with the spoiler?
Looks sensibly priced considering.
I'd feel too guilty taking the engine, drive train and spoiler off it, it deserves a bit more life yet.
Sorry for your loss.
Yup, that's the one. It's probably the least desirable version. Just need it gone really, taking up valuable space. Looks sensibly priced considering.
I'd feel too guilty taking the engine, drive train and spoiler off it, it deserves a bit more life yet.
Sorry for your loss.
Nothing is insurmountable..
I whipped the head off in the week, on the off chance I could get away with just putting a new head on. If that were the case, I would be back on the road by now (pending gaskets getting delivered etc). Alas, it was not to be.
No1 Valve guide is completely missing, and No3 is rattling around on the top of the valve!
Piston is all mangled:
And this bit has almost cracked off the edge and has left a shiny wear mark up the bore:
Head destruction:
So, this is happening:
A 70k mile B200E out of a hearse. It had been sat for a few years outside under a tarp so needed a bit of tarting up, but turned over easily.
It’s a bit heavy! My neighbour and I managed to get it out of the car and onto a trolley, but there is no way we were ever going to get it up the steps and around the back of the house, so it has had to sit in front of my car on the drive and I have had to work on it there when it isn’t raining.
After a bit of dismantling (little win, got all the exhaust nuts off no problem!):
It’s a bit more of a rustblock than a redblock.
I had initially thought about replacing all the oil seals, but on inspection, none of them were leaking and the various costs were mounting up so I have gone for the ‘if it ain’t broke’ method. I may live to regret this. There was historically a substantial leak from the rocker cover, hence the old oil gunge, but the previous owner had replaced this and the engine was oil-tight, so after much wire brushing and Harry and I huffing an entire can of brake cleaner, the engine is back to being a redblock:
Looks good from your house doesn’t it?
I had a bit of a panic - No3 plug was stuck, and despite unwinding 1/8th turn, then back in 1/8th turn etc to get it out, it still brought a little bit of thread out with it and then I couldn’t thread another one back in (So the thread must have come from fairly high up, in theory).
Once I had managed to get the tip of a plug thread inserted square-on, I then spent well over an hour with an oiled, wire brushed plug gradually winding it in and out the tiniest bit at a time, wire brushing it again and again until now I can get a new plug threaded all the way to the seat with just my hand on the socket. Phew! I’ll remember to be very gentle with it going forward.
I then provided a public service entertaining the neighbours and any passers-by on Sunday:
It was encouraging that 3 separate people stopped to say how good it was to see someone actually maintaining their own car.
I managed to get everything stripped off/out of the engine bay, so the engine is now ready to lift out. Everything came apart really easily – cooler lines for the gearbox etc separated without fuss. The advantage of having a copious amount of oil covering things!
I’ve taken the Kjet unit out complete, in theory if I put it onto the new one complete without messing with it, it should all still work:
A bit more painting and tarting up, cleaning all the oil off the wiring loom etc:
As with any project like this, you need to be conscious of scope creep. If I wanted to, I could spend days cleaning up all the K-jet pipes, individual nuts, bolts and brackets etc, but I have to remember this isn’t a restoration, its getting my daily driver back on the road.
Cleaning gunky oil off the engine and harness etc is sensible, but when I picked up the inlet manifold and looked at the sticky stuff in there I realised no good could possibly come from trying to clean that out with the facilities I have, so I think I am at the point now where I need to get everything mounted back on the new engine and pray for at least a few hours good weather next weekend so I can get it in the car.
My only mild concern about the job is making sure I don’t bugger up the torque converter if it slips off the dogs on the pump. Haynes has no info about it at all but I have heard some horror stories. I think I might try and keep the assembly slightly ‘gearbox down’ when mounting it to the new engine.
I whipped the head off in the week, on the off chance I could get away with just putting a new head on. If that were the case, I would be back on the road by now (pending gaskets getting delivered etc). Alas, it was not to be.
No1 Valve guide is completely missing, and No3 is rattling around on the top of the valve!
Piston is all mangled:
And this bit has almost cracked off the edge and has left a shiny wear mark up the bore:
Head destruction:
So, this is happening:
A 70k mile B200E out of a hearse. It had been sat for a few years outside under a tarp so needed a bit of tarting up, but turned over easily.
It’s a bit heavy! My neighbour and I managed to get it out of the car and onto a trolley, but there is no way we were ever going to get it up the steps and around the back of the house, so it has had to sit in front of my car on the drive and I have had to work on it there when it isn’t raining.
After a bit of dismantling (little win, got all the exhaust nuts off no problem!):
It’s a bit more of a rustblock than a redblock.
I had initially thought about replacing all the oil seals, but on inspection, none of them were leaking and the various costs were mounting up so I have gone for the ‘if it ain’t broke’ method. I may live to regret this. There was historically a substantial leak from the rocker cover, hence the old oil gunge, but the previous owner had replaced this and the engine was oil-tight, so after much wire brushing and Harry and I huffing an entire can of brake cleaner, the engine is back to being a redblock:
Looks good from your house doesn’t it?
I had a bit of a panic - No3 plug was stuck, and despite unwinding 1/8th turn, then back in 1/8th turn etc to get it out, it still brought a little bit of thread out with it and then I couldn’t thread another one back in (So the thread must have come from fairly high up, in theory).
Once I had managed to get the tip of a plug thread inserted square-on, I then spent well over an hour with an oiled, wire brushed plug gradually winding it in and out the tiniest bit at a time, wire brushing it again and again until now I can get a new plug threaded all the way to the seat with just my hand on the socket. Phew! I’ll remember to be very gentle with it going forward.
I then provided a public service entertaining the neighbours and any passers-by on Sunday:
It was encouraging that 3 separate people stopped to say how good it was to see someone actually maintaining their own car.
I managed to get everything stripped off/out of the engine bay, so the engine is now ready to lift out. Everything came apart really easily – cooler lines for the gearbox etc separated without fuss. The advantage of having a copious amount of oil covering things!
I’ve taken the Kjet unit out complete, in theory if I put it onto the new one complete without messing with it, it should all still work:
A bit more painting and tarting up, cleaning all the oil off the wiring loom etc:
As with any project like this, you need to be conscious of scope creep. If I wanted to, I could spend days cleaning up all the K-jet pipes, individual nuts, bolts and brackets etc, but I have to remember this isn’t a restoration, its getting my daily driver back on the road.
Cleaning gunky oil off the engine and harness etc is sensible, but when I picked up the inlet manifold and looked at the sticky stuff in there I realised no good could possibly come from trying to clean that out with the facilities I have, so I think I am at the point now where I need to get everything mounted back on the new engine and pray for at least a few hours good weather next weekend so I can get it in the car.
My only mild concern about the job is making sure I don’t bugger up the torque converter if it slips off the dogs on the pump. Haynes has no info about it at all but I have heard some horror stories. I think I might try and keep the assembly slightly ‘gearbox down’ when mounting it to the new engine.
Great work.
Sometimes I struggle with enthusiasm to crack on with the cars... and that's WITH a garage. Total credit to you on a driveway.
Memories as a kid of the old man engine swapping the family 240.
Good luck with the second hand unit. Lovely car.
Sometimes I struggle with enthusiasm to crack on with the cars... and that's WITH a garage. Total credit to you on a driveway.
chris1roll said:
It was encouraging that 3 separate people stopped to say how good it was to see someone actually maintaining their own car.
The irony that it used to moaned at with a car on axle stands in the neighbourhood - now it seems a novelty to be encouraged!Memories as a kid of the old man engine swapping the family 240.
Good luck with the second hand unit. Lovely car.
Very busy weekend just gone.
Borrowed an engine hoist from my local friendly garage, and once the rain stopped, my wife and I got cracking. Next door neighbour helped us move the new engine out into the road and shuffle my car back and forth into position:
I took the opportunity to remove the flex-plate to Torque converter bolts while the engine was stable. Very glad I did that as it would have been a nightmare to do with it all wobbling around. It also required the use of a 16mm swan-necked spanner, which incredibly luckily I had bought one in amongst a bundle of old spanners from a car boot sale just last month. I marked the Flex plate and TC to keep them aligned when back on:
Of course, it then decided to rain, heavily, for the precise amount of time it took to lift out the old engine, but out it came, with a bit of swearing:
And the approx. 6 spots of oil we dropped instantly spread in the rainwater to look like an oil slick, so Mrs1roll was despatched to get some cat litter!
These 7 lumps of Oak my dad had leftover from a job were very useful. To be honest I don’t know quite how we would have done it all without them. I was able to secure the gearbox on these two and draw the old engine off (making sure the Torque converter stayed put).
Then I had the new engine positioned on 4 more, with a piece of 6*3 under the front of the engine to keep it slightly gearbox down, and put the flexplate on the new engine with some blue threadlock on the bolts (yes, I re-used them…. They were 12.8’s and looked fine to me!)
Then, a small miracle, I wire brushed the bellhousing mounting faces, and bolt holes, drove the locating dowels out of the old engine, wire brushed them, lightly greased and re-installed on the new engine. Then my wife and I carried the gearbox round, lined it up, and…it went straight on, perfectly square, first try!
Then, there wasn’t much for it but to try and get it dropped in.
At which point it decided to rain again.
Cue more swearing, while we paused for a while, then went for it:
I had to take the bumper off in order to get enough reach with the hoist – it wasn’t too bad yanking the old one out, but there is no way you’d have been able to push it forward enough when replacing it.
Then I was back to putting it all back together again. I took the opportunity while I had access to wire brush and paint some surface rust on the radiator support, then that was me knackered for the day.
My wife said it seemed easier than she expected, but I doubt she’ll volunteer to do it again in a hurry!
Sunday was the put everything back on again day:
Eagle eyes may spot plain water in the header – this was just for the first start up to check for leaks, then 50% antifreeze once cooled down again:
It was due a service at the start of the month anyway so I already had those bits, but altogether its had:
Exhaust Manifold, Downpipe and Inlet Manifold gaskets. New exhaust manifold nuts
New Plugs, Bougicord leads, Dsitributor Cap and Rotor Arm. New clips for the leads to stop them flapping around.
New waterpump (bit of a story here, but I ended up with a cheapy euro car parts one in order to get the job done, and if anyone needs an SKF pump for the B23E or a 16valve engine (I think) let me know!!)
New earth straps to the head (one had already snapped so replaced both)
Oil Filter, Air Filter, Fuel Filter, Flametrap.
4 litres of ATF (having the gearbox at that angle drained a fair bit more out of the TC. I guess it also stirred up some crap as it made a bit of a ‘whoop’ noise a couple of times but it seems to have quietened down now so finger crossed…not much I could have done about it really)
4 Litres Antifreeze,
4 Litres Oil
New Alternator bushings
And, of course, a new cambelt lol.
Still to do: Front Propshaft U joint, probably the carrier and bearing too, and rear diff oil change. I’ll probably wait a short time to make sure the gearbox has definitely settled down after getting jiggled about first.
And at the moment of truth, after 2*10 seconds of cranking to get the fuel though, it came to life and instantly settled to a nice smooth (for a Kjet redblock!) idle.
Quick test drive into the next town and stopped in the car park to check for leaks and ATF level etc:
https://www.youtube.com/watch?v=da0vjk98yjc
It is considerably quieter and smoother than the old engine ever was. Even when cold, there isn’t the same ‘underlying clatter’ which is very good news. It’s much less ‘droney’ on the motorway too.
This week I’ve done about 175 miles in it already with no issues. I’ve not driven it hard at all yet. Fingers still firmly crossed at this stage, but I think its going to work out OK!
At one point it did look a bit messy, but neighbours and passers by were great. Next door moved his car so I could put the XC there to use as a mobile tool chest, a chap up the road who does his own maintenance too said to knock on his door if I needed another pair of hands, lots of ‘good luck’ etc, and some more people commenting it was good to see someone getting their hands dirty!
https://youtube.com/shorts/CI1MKJjNyrM?si=e14PbXqD...
Borrowed an engine hoist from my local friendly garage, and once the rain stopped, my wife and I got cracking. Next door neighbour helped us move the new engine out into the road and shuffle my car back and forth into position:
I took the opportunity to remove the flex-plate to Torque converter bolts while the engine was stable. Very glad I did that as it would have been a nightmare to do with it all wobbling around. It also required the use of a 16mm swan-necked spanner, which incredibly luckily I had bought one in amongst a bundle of old spanners from a car boot sale just last month. I marked the Flex plate and TC to keep them aligned when back on:
Of course, it then decided to rain, heavily, for the precise amount of time it took to lift out the old engine, but out it came, with a bit of swearing:
And the approx. 6 spots of oil we dropped instantly spread in the rainwater to look like an oil slick, so Mrs1roll was despatched to get some cat litter!
These 7 lumps of Oak my dad had leftover from a job were very useful. To be honest I don’t know quite how we would have done it all without them. I was able to secure the gearbox on these two and draw the old engine off (making sure the Torque converter stayed put).
Then I had the new engine positioned on 4 more, with a piece of 6*3 under the front of the engine to keep it slightly gearbox down, and put the flexplate on the new engine with some blue threadlock on the bolts (yes, I re-used them…. They were 12.8’s and looked fine to me!)
Then, a small miracle, I wire brushed the bellhousing mounting faces, and bolt holes, drove the locating dowels out of the old engine, wire brushed them, lightly greased and re-installed on the new engine. Then my wife and I carried the gearbox round, lined it up, and…it went straight on, perfectly square, first try!
Then, there wasn’t much for it but to try and get it dropped in.
At which point it decided to rain again.
Cue more swearing, while we paused for a while, then went for it:
I had to take the bumper off in order to get enough reach with the hoist – it wasn’t too bad yanking the old one out, but there is no way you’d have been able to push it forward enough when replacing it.
Then I was back to putting it all back together again. I took the opportunity while I had access to wire brush and paint some surface rust on the radiator support, then that was me knackered for the day.
My wife said it seemed easier than she expected, but I doubt she’ll volunteer to do it again in a hurry!
Sunday was the put everything back on again day:
Eagle eyes may spot plain water in the header – this was just for the first start up to check for leaks, then 50% antifreeze once cooled down again:
It was due a service at the start of the month anyway so I already had those bits, but altogether its had:
Exhaust Manifold, Downpipe and Inlet Manifold gaskets. New exhaust manifold nuts
New Plugs, Bougicord leads, Dsitributor Cap and Rotor Arm. New clips for the leads to stop them flapping around.
New waterpump (bit of a story here, but I ended up with a cheapy euro car parts one in order to get the job done, and if anyone needs an SKF pump for the B23E or a 16valve engine (I think) let me know!!)
New earth straps to the head (one had already snapped so replaced both)
Oil Filter, Air Filter, Fuel Filter, Flametrap.
4 litres of ATF (having the gearbox at that angle drained a fair bit more out of the TC. I guess it also stirred up some crap as it made a bit of a ‘whoop’ noise a couple of times but it seems to have quietened down now so finger crossed…not much I could have done about it really)
4 Litres Antifreeze,
4 Litres Oil
New Alternator bushings
And, of course, a new cambelt lol.
Still to do: Front Propshaft U joint, probably the carrier and bearing too, and rear diff oil change. I’ll probably wait a short time to make sure the gearbox has definitely settled down after getting jiggled about first.
And at the moment of truth, after 2*10 seconds of cranking to get the fuel though, it came to life and instantly settled to a nice smooth (for a Kjet redblock!) idle.
Quick test drive into the next town and stopped in the car park to check for leaks and ATF level etc:
https://www.youtube.com/watch?v=da0vjk98yjc
It is considerably quieter and smoother than the old engine ever was. Even when cold, there isn’t the same ‘underlying clatter’ which is very good news. It’s much less ‘droney’ on the motorway too.
This week I’ve done about 175 miles in it already with no issues. I’ve not driven it hard at all yet. Fingers still firmly crossed at this stage, but I think its going to work out OK!
At one point it did look a bit messy, but neighbours and passers by were great. Next door moved his car so I could put the XC there to use as a mobile tool chest, a chap up the road who does his own maintenance too said to knock on his door if I needed another pair of hands, lots of ‘good luck’ etc, and some more people commenting it was good to see someone getting their hands dirty!
https://youtube.com/shorts/CI1MKJjNyrM?si=e14PbXqD...
Edited by chris1roll on Thursday 20th June 17:44
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