The brackets re-welded.
Drivers side view.
Underneath.
Tuesday 30 June 2009
Exhaust
Whilst the van was off the road I took the oppertunity to modify the exhaust. Before it exited on the near side, so into the awning if you started up whilst still attached to it. Now it exits offside due to me rotating the silencer 180 and cutting off and welding back on the brackets. I also cut down the tailpipe and left it with a slash cut.
The brackets re-welded.
Drivers side view.
Underneath.
The brackets re-welded.Drivers side view.Underneath.
Sorted, again
Got the radiator fixed as I couldn't find a replacement. £30 cash and it's all back up and running.
Saturday 27 June 2009
It gets better!
The radiator was damaged by the installer and there is a small hole. Excellent, now I need a new rad! BASTARD
Friday 26 June 2009
It's official
A shot of the Smurf TD badge and the new towbar step, to make getting in and out the back a bit easier.
It's in!
Well the TD lump is in. It's been a bit of a nightmare.
I picked up the van and then broke down 3 times on the way home due to coolant leaks. The fitter and used pipes that were too big and squashed them down with jubilee clips so when they got hot the pipes split. By the 3rd break down what water was left in the tank for the sink was gone so I had to make some water ;-)
Once I eventually got home I replace most of the dodgy hoses with samco ones and in the process found the engine was only attached on one side!!!!!
I then had to fabricate and engine mount, joy! Then I had to adjust the clutch which was biting way too high.
When I started the engine cold it smoked like a BAS***D, funny how it was warm when I picked it up, mmmm.
So it's been to an injection specialist as after changing the glow plugs I figured it was pump timing. The timing wasn't far wrong but they advanced it a touch. They then compression tested the engine (I had asked the fitter to do this) and the compression was on the low side and cylinder 6 was very low. Off came the rocker cover to check the valve clearances and sure enough there weren't any (another thing I asked the fitter to do). Now the engine is a bit smokey when it's cold but is sweet as a nut once it's warm. When all this was done they pointed out the fact that the injection pump was completely missing a bracket that supported one end of, it was there when I dropped the engine off to be fitted. The injection guys said the injector pipes would have split if I hadn't supplied them with a bracket from the spare engine I have. At the same time They and I installed the automatic cold start device as the fitter had completely removed it and not even bothered to connect the manual one. All in all I guess you get what you pay for. £400 was pretty cheap for the swap but it's probably cost another £300 since then and about a week of my time. I can't say I'd recommend the fitter to anyone, I just hope I've found all the horrors.................
The turbo ensures it keeps 60-70 on the motorway and helps up the hills. I've added a boost controller to keep the boost at the upper specified limit for now but will increase it once I've added an intercooler.
I've also added some inspection hatches as removing the bonnet to check the oil and water levels was way too much effort, it's bloody heavy!!
Anyway here are some pics.
Almost forgot the cold air beer intake. Helps prevent the K&N airfilter sucking in warm engine air!
I picked up the van and then broke down 3 times on the way home due to coolant leaks. The fitter and used pipes that were too big and squashed them down with jubilee clips so when they got hot the pipes split. By the 3rd break down what water was left in the tank for the sink was gone so I had to make some water ;-)
Once I eventually got home I replace most of the dodgy hoses with samco ones and in the process found the engine was only attached on one side!!!!!
I then had to fabricate and engine mount, joy! Then I had to adjust the clutch which was biting way too high.
When I started the engine cold it smoked like a BAS***D, funny how it was warm when I picked it up, mmmm.
So it's been to an injection specialist as after changing the glow plugs I figured it was pump timing. The timing wasn't far wrong but they advanced it a touch. They then compression tested the engine (I had asked the fitter to do this) and the compression was on the low side and cylinder 6 was very low. Off came the rocker cover to check the valve clearances and sure enough there weren't any (another thing I asked the fitter to do). Now the engine is a bit smokey when it's cold but is sweet as a nut once it's warm. When all this was done they pointed out the fact that the injection pump was completely missing a bracket that supported one end of, it was there when I dropped the engine off to be fitted. The injection guys said the injector pipes would have split if I hadn't supplied them with a bracket from the spare engine I have. At the same time They and I installed the automatic cold start device as the fitter had completely removed it and not even bothered to connect the manual one. All in all I guess you get what you pay for. £400 was pretty cheap for the swap but it's probably cost another £300 since then and about a week of my time. I can't say I'd recommend the fitter to anyone, I just hope I've found all the horrors.................
The turbo ensures it keeps 60-70 on the motorway and helps up the hills. I've added a boost controller to keep the boost at the upper specified limit for now but will increase it once I've added an intercooler.
I've also added some inspection hatches as removing the bonnet to check the oil and water levels was way too much effort, it's bloody heavy!!
Anyway here are some pics.
Almost forgot the cold air beer intake. Helps prevent the K&N airfilter sucking in warm engine air!
Monday 8 June 2009
Hopefully all is well
I got the fitter to ground a wire that was connected to an oil pressure sensor on the original engine that isn't there on the turbo engine. This solved the problem with the oil buzzer going off. He's going to check with a manual gauge that the pressure is within limits and if all is well I'll collect the van Weds or Thurs. I've fleebayed a couple of bits to allow me to mount the sensor from the original engine and a sensor for an oil pressure gauge into the oil filter housing. At the same time I've ordered a turbo boost gauge so I can keep an eye on things. Didn't need the spare engine I got hold of, except for some breather hoses, but at least I have a complete spare for parts. Pretty cheap source of spares at £30, I still can't believe it.
Saturday 6 June 2009
BAD NEWS
The camper isn't finished in time for Volksfest which started yesterday.
The guy finished installing the engine Wednesday morning and I got a call when I was on the train to go pick it up, no oil pressure! It has pressure at low revs but when you accelerate the oil warning buzzer comes on.
He tried swapping the oil pump from the old engine and had the engine back in yesterday, but the problem remains. Bugger
He's still trying to trace the problem but if it comes to it I got hold of another engine for £30 which I dropped to him yesterday morning.
Still, a shame as we've already bought our tickets for Volksfest. We're going to pop along for the day as there's no point in wasting £40.
I have a new drivers seat sitting in my dining room waiting to go in. Hopefully it will fit with not too much work as it's from a transporter, has arm rests too. Also the new table is sitting there, so the sooner we get the van back the sooner we can have out dining room back. I've got a feeling it won't be till the end of next week now :-(
The guy finished installing the engine Wednesday morning and I got a call when I was on the train to go pick it up, no oil pressure! It has pressure at low revs but when you accelerate the oil warning buzzer comes on.
He tried swapping the oil pump from the old engine and had the engine back in yesterday, but the problem remains. Bugger
He's still trying to trace the problem but if it comes to it I got hold of another engine for £30 which I dropped to him yesterday morning.
Still, a shame as we've already bought our tickets for Volksfest. We're going to pop along for the day as there's no point in wasting £40.
I have a new drivers seat sitting in my dining room waiting to go in. Hopefully it will fit with not too much work as it's from a transporter, has arm rests too. Also the new table is sitting there, so the sooner we get the van back the sooner we can have out dining room back. I've got a feeling it won't be till the end of next week now :-(
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