Tom's Mk5 (2000) 150s SWB 2.5L 76ps Project

[Van1968]

Hello everyone...
I have been pottering around.....I've owned the van for approx 25days and with all its faults I have fallen in love... Wife doesn't need to know.
Call me old fashioned (45 in Jan) I am a great believer in preserving and making the most of what you've got....
I started with underneath by wire brushing scraping allsorts of nasties, gunk and more gunk...treated surface rust with VACTAN..most of the factory underseal protection had weathered/worn away so by hand I painted/covered with Waxoil. One thick healthy coat...used approx 3L.

I then got to work on the arches and whatever else I could find...Decided to take the seats out..glad I did! Here are a few pictures.
In case your wondering the black patches is the work of VACTAN...Highly recommend this stuff...
Drivers side..

Passenger side with small filler repairs to the step and arch. I know I will have to get the welder out and stick fresh steel in the future....I am confident I will be ok for a few years as I have caught and treated the rot just in time. (looks worse than it is!)

I have water coming in through the engine bay bulk head...probably got a couple of rot holes allowing it in..once I start on the engine I can get better access and deal with whatever lies beneath
Here is the repair I did to the step..not finished yet

Now for the rest of the treated and filled bits..remember underneath has now been filled as well as treated with Waxoil..so should get a couple of years before Mr MOT pokes a hard sharpy thing through and fails it..


Here is a picture showing My rust bashing friend...

Now for the outside..wheel arches 70% had already been filled..I tidied up using a grinder and filling in sharp edges...coated with a red oxide primer..not the most glamourous..but sealed for now..

Offside view of the van...the rear arch area where the mud flaps are mounted had rotted out so I practically rebuilt it using s/s shim steel and filler. Short term I know..but should do for good couple of years (I need to practice with the welder I have first before new panels and bits are introduced)

I will be giving it a paint job to make it look less like a van from a travellers site..Going to use a Combi colour RAL and roller it on. Not sure on colour..lets get this winter over with first.
Overall I am pretty chuffed with the work I have done...I have caught the nasty bits just in time, and what I have caught I have treated and treated some more. I will be getting new arches etc..need to save up first and make the most of what I have know.
Now for the mechanical side of things...

The engine has from early inspection has never had its belts changed...I have only drove it 10miles since buying..I won't be driving until the engine has had a major service....The drive was sluggish and following inspection I can understand why...
Lots of oil has leaked on the block from the rocker cover.(hopefully not head gasket)...sump gasket appears to be failing...power steering rack (section between the front wheels) is saturated in oil.(hopefully the rear crank seal is ok.
From reading the forum a good service will bring a smile to my face...(I plan to change oil,fuel,air filters,all belts, water pump,thermostat, uplift pump, sump gasket,rockercover gasket. Sort out the tappets, however..never done this before so a link showing this would be most helpful..I believe there is one on this forum for a 2.0l engine..is there one for a 2.5L.
I want to clean the engine first and determine the engine code..I have feeling its a 4HC..I have researched where to go for parts but I don't feel happy..please can you recommend a member who trades, alternatively can you offer a good contact for me to call today if pos so I can get things rolling. Thanks in advance guys..I have tried Transit Parts UK...Asked for a price 10days ago...still waiting.. has anyone used Transit parts centre as you know both trade on ebay.
My local Ford dealer is as usful as a choclate cod piece and showed no interest atall...12 year old van...we need to order your parts and ther are several different belt set ups..cock..plus really expensive...I will pay top prices for cam belts..Other parts I can get too easily I will go on recomendations. I am not a cheap skate..just like the next man when it comes to making a saving..I have a wife and two children
Couple of pictures to ease the burden of my constant dribble
part of the sump with oil doing its thing

not the best picture..notice the oil build up on the rack

Rocker cover area

I believe I have a bosch pump..i think it is either a 626 or 624..I canna remember captain..this is the fuel filter..how easy is it to take these off manual covers a different style to mine!

Thats it for the time being..Going to take the rad out and bits off so I can get better access to cleaning...so long as the rain holds off...just starting to recover from a bad cold...first in two years...don't like it and my wife wants me to keep warm and stuff..
Thanks for looking and any help, advice, happy stories etc...all welcome
Tom

[BigMonty]

Welcome Tom.
Looks like you have a good base to start with.
I will be going the same way with the paint job on my mk4 when the weather gets better. Best compare notes.

[oldyellar]

I will be giving it a paint job to make it look less like a van from a travellers site..

Most likely to see a Couple new vans and pickups in area's like that

[Van1968]

Welcome Tom.
Looks like you have a good base to start with. Thanks...I thought so too, one of the reasons for taking the risk in buying it...
I will be going the same way with the paint job on my mk4 when the weather gets better. Best compare notes. I have a couple of links to share on this from a another forum...one is a whole thread on folks painting there own van and another selling a DVD (approx £10) covering all aspects of rolling. Plus a good source for Combi colour Ral Paints. The results are pretty damm good and compare well with spray techniques..

[Van1968]

I will be giving it a paint job to make it look less like a van from a travellers site..

Most likely to see a Couple new vans and pickups in area's like that

Your quite right..how foolish of me to demonise..

[oldyellar]

I will be giving it a paint job to make it look less like a van from a travellers site..

Most likely to see a Couple new vans and pickups in area's like that

Your quite right..how foolish of me to demonise..

van looks awryt btw get it turbo'd

[Van1968]

Hello again...did a little more between showers....
Firstly, a big thank you to Guy for posting this topic, much appreciated.. viewtopic.php?f=18&t=56801

Number one job was to strip things down so I could get to the rocker cover. With Interesting results..

I removed the air filter and housing..I am guessing that the van has not seen or felt a decent service for a long long time..here goes
one dirty filter

A picture of the all too familiar bannana manifold and the engine I have at the moment

Got to work on the EGR side of business..pretty clogged up...I was not impressed and I am already thinking I want rid of this EGR setup. The exhaust has a CAT convertor Fitted...ridding the EGR I believe won't effect the emissions (MOT) to Failure.
Took a little persuasion but I got there..going to put a plate on this..copy the gasket... Now I have access to the rocker cover.


First half of the manifold off...check out these deposits...made me cough looking at it (I do have a nasty cold at the mo )

Probably take all associated parts off (egr related)..block off...clean off the gunge in the manifold...either that or swap it for a different set up banging a Turbo on at the same time...still early doors...one thing for sure I won't be leaving the other side untouched..its got to be taken off and cleaned..If I do a job...it has to be right. I don't have tools that will allow me to undo the bolts...I will have to take the pump off first...not ideal I know...but I can't be having that crap potentially dropping into a newly serviced engine. More importantly I suffer from doing a proper job syndrone...Leaving it is not an option.

The awkward side I am unable to undo.

I got to work on taking the rad out..front grill easy...front bumper..complete nightmare..drilled out the torx heads on the flanks (up and under inside wings) as they had complety siezed..rusted over...can't really introduce heat!! well you could if you want to make a front bumper sacrifice.
Bled the system..fortunatley have a drain off tap bottom right as you face the front..took the header tank cap off undid the valve and out it came...needed a wee during the process..can't think why . One definate positive...no oil smell/deposits were present in the coolant..although it did look week and old. (Kittens are safe )
The radiator is original..date stamp sticky on the side and not too bad condition wise...good for a few more years...or if I am struck with some good fortune..I will change it for new.

here is a picture of the business end..it all begins..I have a 32mm spanner that fits the nut..but at the mo dont have a ratchet strap..so for the moment I took a leaf from Guy..thanks dude and went for the fan blades.

without the blade on

a quick look at the poor condition of both drive belt and power steering aux belt. beggers belief..
drive belt..the best bits

Aux power steering belt

Unfortunately the heavens opened again and I was suffering from the cold (Soft lad that I am ) so had to call it a day.
I plan to research the forum again..I noticed a section on part numbers and folks who sell parts..so I will be getting in touch.
Back to work tomorrow to begin my shifts..two days/two nights on the bounce....
Thanks for looking..all views, advice, mechanical I have done it tips, funny stories etc are most welcome.
Tom

[Van1968]

Thanks for your feed back I think she is worth the effort..the more you put in the more you get out...and you live longer..got something to do with your life..and its fun too...
van looks awryt btw get it turbo'd [/quote]
Something I have been looking at....I might buy a complete unit and take the head off and associated parts..so long as I can get the intercooler parts to go with as part of the deal...I missed out on a rare 115ps...no carriage offered..I do have my eyes on a couple of units on ebay...probably look out for members selling.

[oldyellar]

minnor mat, andyg, dieselhead123 and fezz99 are the boys to c about turbo'n your van if you clean them banannas out the van will defo breath better

[Van1968]

minnor mat, andyg, dieselhead123 and fezz99 are the boys to c about turbo'n your van ---Thanks pal I will look these guys up...I take it they deal in parts etc or have upgraded their engines ..either way, knowledge is power ...

if you clean them banannas out the van will defo breath better

defo on the case once I get my shifts out of the way...in the meantime I will study up on removing the pump and research the forum for turbo topics...Thanks again
Tom

[Van1968]

Hello again...I'm back
Had a few days here and there and a couple of dry ones..so did a little more.

Because of the heavy rain of late I was concerned about a manmade hole in the roof and the runoff gutters being filled with silicone sealant.

The gutter were a pain in the rear to clear out but after several hours managed to clear both sides. The two holes in the roof have now been filled. In case your wondering a chap used to live in the van and had a wood burner installed...I didn't get that when I bought the van unfortunately. Here are a couple of pictures.
First the gutters and evidence of silicone filling them

something for the rain to run down..and not actually overflow into the top of the sliding door....I won't bore you with an offside shot..but you get the general idea.

I then got to work on the roof..check out what I discovered once I took this off

this suprised me..I thought there was just one

After several hours of scraping, sanding down and accepting the fact I looked odd on a ladder by the average Jo walking..driving by I did this.
I used 0.5mm s/s shim sheet (RS COMPONENTS sell shim of various sizes..really handy). I bonded it on using Araldite..just the job.

I then mixed up some fibre glas filler and covered it over..dont have a picture of that...but it looks a proper job with no leaks
Back in a minute..off to say night to my nippers..

[Van1968]

If you recall I was contemplating on taking the fuel pump off to get access to the left side of the manifold..I wasn't happy with the amount of diposits made from the EGR set up..

I decided to take of both sets of fuel lines, fuel filter and mounting bracket and I sacrificed a 13mm spanner by cutting it in half and using an 11mm spanner connect through its eye as a lever..the first bolt you face on this side of the manifold is the most tricky..It was a lot easier using my newly invented "L" shaped spanner.. (I will be investing in some Crescent shaped ones..My birthday is coming up..might chuck out a few hints ). Once I had removed the fuel lines I could get access to the remaining bolts. Still tricky to undo..I am not the tallest bloke in the world..so my ballerena tiptoe and grunting skills were brought into action. I eventually got there together with a very bruised forearm and an egg on my head..

I took of the EGR Valve and associated parts and placed the complete manifold in a dustbin...soaked for a 5 days in bio washing powder...it didn't shift it..but what this method did do was soften it...I have never seen gunge like it before...all I kept thinking about when I checked out the texture and muck still in there..was seagulls and other wildlife that had been caught in oil disasters....Here is a picture of the water emptied and the manifold pieces feeling sorry forethemselves.

I then took a useful tip from a friend at work and bought 6 bottles of washing up liquid. Got some cleaning bits together and a s/s rod (slightly bent on the tip) I tapped m6 threads so I could fasten a pipe cleaning brush on it..yet another little invention that prooved its worth. Here are a couple of pictures...I like to share so please forgive the simplicity....

I quickly realised this was going to take me a while to do..and it did.. I used a scraper to begin with..slowly bring out sludge where I could reach..then I reached for the kitchen sink...be warned cover everything immediately around you with old towels (too cold to do it outside I'm a light weight..quite literally ..my wife is a good one and I promised I would bleach down and make her a cup of tea afterwards ) 5 bottles of washing up liquid, a can of 40+ spray and just on pipe cleaner (the white one in the picture) plus a tidy up of the outsides with sandpaper (heavy grt and brass brush....these are the results. Boy am I happy
first the EGR Throttle body minus its bits and pieces.

another view showing the inlets and outlet holes etc I will have to cap off.

Now for the best picture and a pleasing one too..

Not bad or what...

[Van1968]

Once I had all things looking clean..I quickly manufactured a piece of steel to cap of the EGR connecting pipe (the one which travels from the exhaust manifold to EGR throttle body), I also made one for the exhaust manifold connection..I used a gasket as a guide..not shape for shape..its not on show and I am happy with something that fits.

another view..I made two the same..The other one fits *exhaust manifold) just as snug..

Now it was time for the remaining holes to be filled..where the butterfly flap was, inlets/outlets for the EGR Valve itself. The best option I had was use some nuts and bolts plus a little gasket sealant under the washers. Not the most handsome of solutions..but all is good and they look like they will do the job.

another view

inside..not much really affecting air intake (except the filter )

The sealant I have used and will be using for the gaskets I fit..good stuff too.

[Van1968]

So far so good..I hope your enjoying the read
Now that the manifold etc is sorted I could carry on stripping down the engine. I began with the rocker cover and made sure before I started work I covered up all oriffices with cut offs from gloves I use (you would argue I don't with the previous pictures..I just got some more..make your hands sweat a little..but realy are good at saving time cleaning your hand and nails afterwards ). I was shocked when it came to undoing the rocker cover bolts..each one I could undo with my hands...explains the reason why (probably..lets hope!) the reason for all the oil around the steering rack and sump areas. I don't think the cover gasket has ever been changed, modern ones now are "rubber ones"..the one I took off was cork and really manky indeed. Another observation was some tappets after a good rub down with rags looked as though they havn't seen any adjustment.
**Never adjusted tappets before if you offer a link or post from the forum on the subject I would be most grateful** I have a manual which i'm not bad at following...
Here are a couple of pictures.

the other side...

[Van1968]

I then got to work on the front part of things...taking the front cover ran smoothly with one mr meaner..adjacent to the automatic tensioner is a bolt that is tricky to get out because of fan pulley being there..access is impossible if you havn't got the tool to do it. The problem I had was I am not strong enough to undo the 32mm nut and hold a ratchet strap at the same time...I tried but failed miserably...(I will get it off at some point when I find my blow torch and a friend to help!) I overcame the problem by taking off the water pump pulley and taking out the bolts fastening the fan pulley. Undoing this allowed for more space for fitting the torx piece..pushing the pully toward the engine. I then got a set of mole grips..gripped the torx piece that undid the rest and hey presto (can't remember size)..you need the water pump pulley out of the way else you won't be able to turn the grips.
I set the timing pins in..quite tricky for the main one..after about two attempts I hit home.

to the left of the autotensioner was the home of the offending bolt.

I have since removed the water pump in readiness for new..caution..even though you have drained the system..remaining water will want to let you know its around! I bagged nuts bolts etc up in there individual bags..ready for refitting...(Ignore the fact part of the manifold is there..when I was soaking them I began working on the front)