The volvo is gone.

The Volvo went to the scrap yard today. I didn't bother taking any bits off to fleabay. I got £112 so it only cost me £140.46 for a recon engine, pump and turbo, if you include the change I found in the car!

Recon engine

I called the company who re-manufactured the engine today and they confirmed it was a completely re-manufactured engine with reground crank and cam, new pistons and rings, reworked valve and a new pump etc etc. Nice to know it wasn't a half arse job but a complete one. Basically as good as having a brand new engine in 2002. Since then the car it came from has been off the road for a year and a half so having talked to the previous owner I would guestimate the mileage to be an absolute maximum of 50,000 if not more like 30,000.
He used it to drive 8 miles to work and back, so even 365 a year would only be 5840 and for 6 years is 35,000.

Glow plug relay

Ever since driving the van home from installing the new engine the glow plug light has stayed on. I thought this would be another bad earth problem but couldn't find it. I put in a new glow plug relay today and problem solved. Shame all fixes aren't this easy.

Ventilation

Whilst the battery was out due to my split charge relay draining it I found a bit hole in the metalwork. Good news that it was just the rely causing my electrical problem but not such good news in the rust department. I've cut out the entire area to stop it spreading and tomorrow I'll weld in new, Shame as I though the van was rot free.

IT'S IN, AND IT ACTUALLY WORKS

So after 3 days and about 35 hours work the engine is in.
I found a serial number from the engine reconditioning company on the block so I can find out a bit more about it, but as far as I know it was installed in 2002. Even the pump and turbo look new.
It runs beautifully and starts first time with no smoke. The other engine must have been completely buggered because this new one is fast, really fast, well for an LT anyway. A friend of mine has a Transit connect and can't keep up!!! Makes it all worth while.
The glow plug light came on and wouldn't go out on the way home but seems to be coincidence as I replaced the glow plug relay with a spare and all is well.
Before I installed the engine I swapped over all the new parts form the other one as they were spanking new so it has new; cambelt, clutch, serviced injectors, glow plugs, thermostat, water pump, fuel filter, oil filter, aux belt, leak off pipes and fuel pipes.
I also had to swap the fly wheel as the donor was an automatic along with the front pulley/ vibration dampener and spigot bearing.The engine in the Volvo.




Claire helping to disconnect everything.





Ditto.




Finally it's out!



The smurf engine comes out a bit easier.





Almost ready to go in...




Core plug added to rear of engine where Volvo only water pipe was removed.




Test fit of gearbox to make sure clutch is aligned to save misery under the van later. Everything is ready to go in.



The finish product;





At last.


I do seem to have a little bit of vibration, but I think it's to do with the ghetto engine mount.
Also the thermostat seems to be a bit shitty as the engine won't warm up at idle, only when you drive, I'm guessing it's staying open a touch, still, a cheap fix.