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Mk2 Transit 190 LWB

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Re: Mk2 Transit 190 LWB

Postby PIO » Sat Jul 25, 2015 10:17 pm

Old Engine out, Bay cleaned up, a few area's will need to get some TLC over the winter.

Mk5 Axle (4" Wider) fitted, reckon it fills the arches nicely.

Ready for IFS Swop now....

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Happy to see these Engine mounts as well... Makes life easier...

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Mk5 Axle
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Re: Mk2 Transit 190 LWB

Postby Luke » Sat Jul 25, 2015 10:33 pm

arches look loads better filled like that 8)
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Re: Mk2 Transit 190 LWB

Postby PIO » Sat Jul 25, 2015 10:39 pm

Cheers Luke,

Didn't like the way the wheels previously looks lost in the arches
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Re: Mk2 Transit 190 LWB

Postby RustWidow » Sun Jul 26, 2015 6:29 am

Looks good pio, a lot of work there but it's looking worth it
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Re: Mk2 Transit 190 LWB

Postby PIO » Sun Aug 09, 2015 8:30 am

Complete Mk5 running gear fitted with a 100Ps Engine, Bosch 145 pump and an intercooler off a 115 engine. Adjusted the fuelling yesterday, turned the screw at the back of the pump in 2.5 turns and top screw in 1.5 turns, then slackened of the idle screw to bring things back to normal. Some nice power but the van now stalls at a junction, any ideas before I turn my fuel settings back to standard and start from scratch. Van starts and idles lovely, but stalls when slowing down - Thanks (Pics to follow)
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Re: Mk2 Transit 190 LWB

Postby PIO » Sun Aug 09, 2015 12:34 pm

Decided to take the last few days off and along with my buddy, we made a mad burst on the running gear swop...

I spoke to Oldskooler & Markmex and then we jumped in balls deep. Thankfully it was handier than I initially expected, but defo needed a few beers after it...

Have lots of pics, but will throw up a few of the main ones....

To summarise, we levelled the van, centred the wheel in the wheel arch, levelled the sub frame, made up fillet pieces from 60x60 Box Iron, welded up captive pics and welded these to the chassis legs. We had previously made up a jig to locate the top mounts based on the donor van, so we were then able to bolt this jig to the new fillet pieces so that the top mounts were located in the same Camber/castor position relative to the subframe.

We used the top mounts from the old van and 'mated' them to my van. Cleaned them up and job done.

Made a hybrid steering column from the Mk5/Mk2 and mounted it up. By keeping the Subframe 15 mm lower than intended, it made the steering easier to sort and took the pressure off the steering joints.

While I was at the front, I replaced bushes, bearings, brake pads, discs, calipers, flexi pipes, shocks and top mounts.

Rear axle fitted, springs saddles moved in by 2" either side to make it work. Cant use the rear anti roll bar now and it hits the leaf spring, so going to mod the old front anti roll bar some other day to fit....

Changed shoes, cylinders and make made a Mk5 Cable fit handy enough...

Fitted the Brake load apportioning valve from Mk5 as well...

Had to mod the prop to suit, put Mk5 end on the Mk2 Shaft.

Picked up a new exhaust system from a Mk5 Chassis cab, made that fit with a bit messing with brackets etc....

Engine Swop work worked out handy enough as well....

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Re: Mk2 Transit 190 LWB

Postby Luke » Sun Aug 09, 2015 5:09 pm

neat work there 8) 8)

have you driven it on the road yet :?:
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Re: Mk2 Transit 190 LWB

Postby PIO » Sun Aug 09, 2015 5:55 pm

Cheers Luke, only in a car park, 3Rd Gear only. Next Saturday for a proper road test, must sort the fueling first
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Re: Mk2 Transit 190 LWB

Postby irishtransit » Wed Aug 12, 2015 7:32 pm

nice work.
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Re: Mk2 Transit 190 LWB

Postby PIO » Sun Aug 16, 2015 10:12 pm

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Maiden test drive today to a local show, must say that it has transformed the van... Huge difference in power, the hill to my house was a 2nd/3rd gear hill with the old engine, was able to give it 5th today and she pulled away....

I have two axles, one with a 4.63 ratio and the other with 5.14. I played it safe and fitted the 5.14 Axle, but I will swop this out for the 4.63 axle in the winter. With its current set up, It's crying out for more gears....

Steering is spot on while driving on the road, if I had to be very picky, there is a very slight tight/heavy spot feeling in it, might pull the rack forward 25mm to take some pressure off the UJ's...

Finally, must play with the fuelling and boost a bit. Turned up the max fuel screw 2.75 turns, (Mid-range screw 2.5 turns) but feel she is too smokey under load.

Myself and buddy carried out some 'testing' while driving it last night, with the van in 5th gear at 35MPH, I floored it until it got to 70MPH (Sat Nav) and my buddy in the car behind said he barely see my rear number plate with the smoke...

As soon as I lifted off but kept around 65MPH, the smoke cleared....

Wondering should I back off the max fuel screw by half a turn or see can I bring the boost to 0.9 bar to see can I burn off that excess fuel....

This is not a daily driver, so I'm happy to stretch the turbo's legs every so often...
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Re: Mk2 Transit 190 LWB

Postby MinorMatt » Mon Aug 17, 2015 12:05 pm

I normally do 2 turns on the main screw with standard boost...

Wind the wastegate up a bit to get more boost (1.2 bar is a good place to be)
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Re: Mk2 Transit 190 LWB

Postby PIO » Thu Apr 13, 2017 2:06 pm

Another of my posts that I haven't had time to update, delighted to have it back on the road again...

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Re: Mk2 Transit 190 LWB

Postby irishtransit » Sat Apr 15, 2017 3:45 pm

wow she looks gorgeous.where did ya get the silver and black soundproofing from?
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Re: Mk2 Transit 190 LWB

Postby PIO » Sat Apr 15, 2017 7:52 pm

sounddeadening.co.uk
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