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What a thread! :thumbs_up:
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Bloody hell..... Nice project. Something I would love to do on my car too, but I don't have the guts to do so. I am now waiting to see how you sorted out the knocking sound from your engine as per the other thread.
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thx, I will be half way at the end of this post. Still a lot of things has to come off.
Pictures that I missed in previous post. All 4 pistons, just after I removed them, they haven't been cleaned or anything No. 4 is ath the flywheel side, they are in order, as if you are looking at them from the front of the car to the engine bay. http://www.bildites.lv/images/sfmxbeg430htzajej1k.jpg Brake disc comparison http://www.bildites.lv/images/csxxxqijn7l9odikk9aj.jpg ----- Damaged oil pump gears and housing http://www.bildites.lv/images/yaccow4p9iduok0004kt.jpg ----- More cleaning Before http://www.bildites.lv/images/mko2i1srpb6glujnb2xj.jpg and after http://www.bildites.lv/images/hejcblf39dppxyzjnoc7.jpg ------ Sump from the inside, already somewhat cleaned. http://www.bildites.lv/images/w30voswkt0trgrntmsqx.jpg ----- http://www.bildites.lv/images/xkze0tvaslgxvstfxijt.jpg I cleaned engine bay with pressure washer, this is how it looked like the next morning... rusty... http://www.bildites.lv/images/hun5wftyjiwp0rm2dwfo.jpg ------ This is how I tried to remove the engine http://www.bildites.lv/images/x8yjnu7n1t3pavunb77t.jpg and with the little support from fitness ball I did remove the engine :D http://www.bildites.lv/images/4ywpsrevcs537a6xiojw.jpg I removed the engine by moving engine block up and down, side to side and pulling to timing belt side at the same time. After I removed it form the transmission, I just unplugged fitness ball air emmm.. plug so that air can escape and it will slowly deflate... genius idea(at that time) :D:D:D I could just used the car jack, it would have been easier and faster that way :) ----- This is starter or starter motor, this thing is heavy and is attached to gearbox housing, it spins the flywheel so you could get the engine going. http://www.bildites.lv/images/gp7ajr3wxe3mt7vq86t.jpg ----- This is air con compressor, located between radiator and engine itself, just under the generator. I removed this, because air con doesn't work and there is no auxiliary equipment belt attached to it, when I opened it, I saw where the problem was. http://www.bildites.lv/images/vfi4bwrhz5fevy4ftahu.jpg If you can notice, top piston is bent in some angle, it should be like that. http://www.bildites.lv/images/hikto7jxrrrmuz0f7v4p.jpg this is piston emmm housing with 2 pistons damaged beyond repair http://www.bildites.lv/images/3qagou7cyy77kusm0jb.jpg and this makes them compress stuff http://www.bildites.lv/images/yy17vyctpkmtetc2yu1i.jpg http://www.bildites.lv/images/nmki2w0ttfoo31klmp1x.jpg 6 or 7 of these and I can build my own chaingun :D ----- Removing the engine. http://www.bildites.lv/images/42jx48np0c5sq2jdl.jpg http://www.bildites.lv/images/i6xy8m5za11gjdfs6ta7.jpg http://www.bildites.lv/images/nf0m3ynt2204qeukp2.jpg I couldn't remove the crankshaft pulley so I left that on with timing belt. Engine block was sent to nearby engineering the same day for a rebore and oversized pistons. Gearbox without engine http://www.bildites.lv/images/hags7rl7edwh0x3cfrgw.jpg http://www.bildites.lv/images/c885huwi5ol6dxfcinj.jpg Ok, this is half way trough my picture archives few more images and I will be putting engine back together :) |
About one week later I finally got my engine block back, it was pressure cleaned and rebored
http://www.bildites.lv/images/kdlp98vn8id73fclksrn.jpg http://www.bildites.lv/images/sukor9l3pz2tlfu4h1e.jpg ----- All the parts come in one cardboard box..... I was confused dot com ... :D Crankshaft http://www.bildites.lv/images/0j8fpwlfdyhsa76np7r8.jpg http://www.bildites.lv/images/ehzvsy8aypppurnjmb0.jpg http://www.bildites.lv/images/clpkikxh6xtb6sut35zd.jpg ----- Since I haven't removed them before I was going blind from here, I've put old bearings on and matched all the wear and starches on other parts..... Bearings http://www.bildites.lv/images/wacgdga8e6gs9kdxzeal.jpg http://www.bildites.lv/images/74w7srljkncfnrsglgl.jpg http://www.bildites.lv/images/wraaw5253d31aek9dpvw.jpg http://www.bildites.lv/images/wh0sdgybi439p9bid91f.jpg ----- Engine block upside down http://www.bildites.lv/images/w9nbbj0uhal8vxv42rfv.jpg http://www.bildites.lv/images/bacbvm1gqadbwdx6tlc.jpg http://www.bildites.lv/images/v1ulcd1v4ywhmuea8u61.jpg Install piston cooling jets at this stage, or regret your decision later on :) http://www.bildites.lv/images/3hhc9smjqqwy47eb2ou.jpg http://www.bildites.lv/images/nmh9gpcazr5pgbkvxlj.jpg ----- oversized pistons with piston rings already installed http://www.bildites.lv/images/5gwc7xzojrubqm8cqkn8.jpg http://www.bildites.lv/images/v4r5bj232cr2aguyba9.jpg http://www.bildites.lv/images/wuhlt5tqh83i18w77iz.jpg http://www.bildites.lv/images/ozta3hcs8brrya72w6s.jpg cleaning piston rods http://www.bildites.lv/images/onxk01frpwj179jsmc0w.jpg removing old parts with custom made pliers :) http://www.bildites.lv/images/iec66beufw3d81ckwa8.jpg http://www.bildites.lv/images/wwtpt4m7etzyhinu8xz.jpg http://www.bildites.lv/images/7pms1l5ikx502bqtcjpb.jpg ----- I changed crankshaft bearings and piston rod bearings. http://www.bildites.lv/images/soj9wnjvuzy4aby8dxen.jpg http://www.bildites.lv/images/61c1c150rq94knp198dh.jpg http://www.bildites.lv/images/0m7ydql5lt40rf73qepd.jpg http://www.bildites.lv/images/m5jhkxanquhc42o2wrt.jpg http://www.bildites.lv/images/56sml9egisziq4bm4l8v.jpg ----- Chain and gear for oil pump http://www.bildites.lv/images/cles8bltonwbcejqrnpw.jpg ----- making a gasket http://www.bildites.lv/images/x9gabkcrkvcsj18r5tx.jpg http://www.bildites.lv/images/2hark4us06iermf1tf1j.jpg Just in case I will make a guide how to make them :) ----- Almost all parts put together. http://www.bildites.lv/images/98u6tq4a2gwcu1w2tw1w.jpg I had to remove flywheel to make it lighter, so I can lift it from the table and put it on the ground. http://www.bildites.lv/images/girj6vtwjud6vxdjm.jpg http://www.bildites.lv/images/j6kx78y3sidngc4j7z1r.jpg http://www.bildites.lv/images/b8sk38gq364dh9iitrq1.jpg That's not all... there will be more pictures tonight. It just takes a long time to upload them at the moment. At this stage I've done about 90% to get engine running again. I will post more pictures in x40 S1 Articles section as a Guides( I am thinking, there will be at least 3 more guides, maybe more :) ) I don't want to post the same pictures as a guides, so I left few pictures out. Later on I will calculate how much it had cost me, and what parts needed to be changed. It total it took me about one month and 2 weeks to get car running again, all that was done outside, so I had to skip few days due to rain. I am hopping that this will help someone else. Big thanks to: stevo48, Oilydad, andy_d, GMad, Hinckley, steveshaw, Jordie, 960kg, Baffler, Clan, migrator, gatos, littlehomer, v8 rick and others I have forgotten to mention, who has given me advice over last 2 months. :thumbs_up: |
When are you coming to visit me in London. I can offer a lovely Volvo working holiday:):):)
Did you clean the injectors, and if yes, did you disassemble them or not. I have never heard of homemade gaskets by the way. Don't you risk possible leaks in the near future? |
brilliant
you have gone to considerable trouble to photograph and display these pictures for all to see, very much appreciated.
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Quote:
I cleaned them from the outside, just be careful, there are 4 or 5 small holes where diesel is being sprayed inside the cylinder, video on youtube claimed that they can be damaged easily . You don't need to clean it internally as fuel filter should hold back any peace of dirt or debris. But I took the 3rd injector to a local garage for a injector test just to make sure that it is working and not clogged. I just disassembled the top part, nothing else. Those type of gaskets are cheap, easy to make(not if you are doing it for the first few times though :D ) And they are good, I am using it for egr valve, no leaks at all. Every household has materials for this ;) |
This is my first post so please be gentle. Very impressive thread and all done outside in this weather too! As a new member I am very impressed with this forum, very helpful. My car is a 03 V40tdi sport Seems a great car, although only driven it 100 miles home so far. Been preoccupied changing a gearbox in my old faithful Skoda diesel prior to selling it. I previously was always a Mercedes owner but of late the build quality is very poor. So giving Volvo's a chance. |
Cost of repairs for volvo S40:
Turbocharger* 300£ OEM gasket for turbo return pipe(bought this before I find aut about rufe) 15.99£ :@ Rebored cylinders+oversized pistons+2 sets of bearings 630.60£ OEM Piston Cooling jets X4* (discount from Rufe) 106.72£ OEM Bolts and gaskets for sump tank (discount from Rufe) 41.74£ Used Oil pump from Renault Vivaro(they fit in volvos) 30.00£ Labour, removal of 9 studs, change of oil pump, sump gasket, drilling out the studs, new engine oil ..... 268.80£ 2 oil filters from halfords* ~22£ Rough estimate for all the tools that I bought(before that I didn't had any) ~180£ Engine oil since I bought this..... so called car... bought ~45 litres of engine oil so far( in last 10 months since I have this.. car, had a oil leak after rebuilding the engine, Didn't know that there should be a gasket oil was leaking from there) ~163£ <--- I don't believe this number myself, but I have all receipts.. Thermostat* 9.50£ Rear brake fluid pipe change 30.50£ Head gasket set from ebay~30 £ Ok and total cost so far is....:1828.85£ Cost of the car was... 1500£ You gain experience from bad decisions done in the past... Now I know what to look for when you Buy Volvo S40 Phase 2 1.9 TD sport Note: Parts marked with red star(*) are things that I have done myself. |
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