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

[zetor4321]

good luck with the rest i had the opposite of yours brilliant engine and mechanics but a body that could argue with the titanic over how many holes they each had.

mines now bodily back in one piece with many new panels and plates and fully painted 2 coats of hammerite and 2 of underseal.

ive now got the interior to sort out (its had a hard life)

Just picked up some good used door panels and a center dash panel to take a single din stereo.

it was moted 2 week ago and i am using it with virtually no interior but enjoying it (a bit cold but heater does work)

any way hope all goes well and just to say make sure fuel filter is located on tabs (by turning it while pushing up) then lock it with ring, as i couldnt figure out why mine kept leaking !!!

Cheers Dave

[Van1968]

Now for some more..this part of the engine service is the part I really enjoy and I have a couple of people to thank..I will come back to that in a minute...It show you my bits time sorry I mean parts.. I will stop there while the goings good..
check out this little lot..

A thank you goes out to AndyG for advising on what oil to use..especially in this weather and starting issues if its too thick when cold..I bought 5W 30 Fully synthetic..costs more I agree..the benefits are you can leave it in there a tad longer if needed and thanks to AndyG for tipping me on the FORTE ADVANCED DIESEL treatment..I plan to put it in the tank and introduce it in the fuel filter before starting her up following its service.
a few close ups..again forgive me..I feel its important..help others source..I had trouble with two belts because of the condition they were in.
First the belts, GSF came through and a big thanks to Restorationvanman for help with identifying.

timing belt from click4parts

rocker gasket (not cork) and manifold gasket

Thats it for the pictures so far..Here is a summary of costs so far.
Transitpart centre ebay
uplift pump,oil,air and fuel filter, water pump £64.35
Be careful when dealing with them..phone first ask if in stock and don't buy rocker cover gaskets from them..I received a second hand cork one and not the one they advertised..I have yet to complain..keeping my stress down..its chritmas after all.
GSF TAUNTONReally helpful £102.42
rocker gasket, v belt, drive belt, engine oil, gearbox oil, antifreeze, copper slip..plus I got a free gift and a couple of pens..
37245 ltd ebay
Haynes manual £15
canna remember captain
Pocket mechanic manual £10
plgparts ebay
Inlet gasket £6.38 (a little thin for my likeing..will use a little sealant to back it up)
Andrews Coatings Ltd (Nice gentleman..very helpful)
Rust-oleum Ral 9010 White satin combi colour paint 2.5l £53 (Include vat and discount)
Click4parts ebay (Spot on and highly recommend)
Gates power grip Cambelt kit £63.18
Canna remember captain
Forte Diesel Treatment £ 28.40 (for x2 400ml bottles)
Total spend so far....£341.73
Does not include filler and consumables..spray 40+(wd40),rags,blue roll..lets say £50....Not bad to date bearing in mind the work I'm doing.
Thats about it for now...Next plan of action is to make a list of torque settings from the manual and section off the pages I need..hopefully begin putting things back together tomorrow..weather permitting..fingers crossed with that one.
catch you all soon thanks for looking
Tom

[Van1968]

good luck with the rest i had the opposite of yours brilliant engine and mechanics but a body that could argue with the titanic over how many holes they each had.

mines now bodily back in one piece with many new panels and plates and fully painted 2 coats of hammerite and 2 of underseal.

ive now got the interior to sort out (its had a hard life)

Just picked up some good used door panels and a center dash panel to take a single din stereo.

it was moted 2 week ago and i am using it with virtually no interior but enjoying it (a bit cold but heater does work)

any way hope all goes well and just to say make sure fuel filter is located on tabs (by turning it while pushing up) then lock it with ring, as i couldnt figure out why mine kept leaking !!!

Cheers Dave

Thanks Dave for the tip on the fuel filter ..Good luck with the interior on yours.
Havn't been able to do anything since posting last because of the rain... Did manage to invest in a 20l Jerry can from Halfords £30 and I bought a metre of fuel line for the leak off mod.
Tomorrow (Friday) is meant to be a good one..fingers crossed..exciting times ahead
Tom

[Van1968]

Hello again
Today was reasonably productive...
Jobs completed..Timing belt kit fitted, Water pump, Drive and Power Steering Belts and Uplift Pump.

If you havn't done a Timing belt with autotensioner before...be patient and don't pannick ....What do I mean! well what I can tell you is the instructions are fairly easy to understand. However, it can be a tedious task setting the tensioner and ensuring that after the magic two revolutions of the engine..the check mark is where you set it initially..eg just above the lower edge of the cut off part "Gates technical Bulletin 005"...It took me several attempts and embarrasingly more than an hour and some to finally get it right.....All 3 locking pins sit nice...so I'm hoping all is good with the timing..we shall see
Here is a picture of the tensioner and belt in place

I then got to work on the Water pump..I like to put a little gasket sealant with the supplied gasket..just a smearing....

Now fitted

I put the Timing belt cover on

Water pump pulley and Drive belt

Then onto the Power steering Belt

These are the persuading tools I used to help tighten up both Drive belt (Alternator) and Power steering Belt (Pump)..Nice and tight with a little deflection

I was loosing light quite quickly so moved on to fitting the uplift pump..


Now for a Mr Meaner...I have to take the rocker gear off to refit a valve cap from No1 valve..that for some reason (not down to me) has come off/disloged...not only did I discover this..one of the M10 bolts (used for fitting the Rocker Gear) was with it. I only spotted it while taking blue roll pieces out I was using to protect and soak old oil up..so I could rotate the engine during timing belt work...Can't imagine what damage these might have done!!
Here is a previous picture of the rocker gear..notice the missing Bolt..just before the 3 valve

And the wanting to try to escape valve cap...


Jobs left to do...Working from top to bottom
Rocker Gear to take off and refit.
Adjust tappets.
Rocker cover and gasket
Gentle clean/scrape (coke deposits) and vacuum at the same time..cylinder head where (LHS) manifold sits.
LHS Manifold plus gasket
RHS Manifold piece plus gasket
EGR Throttle Housing
Air filter and housing assembly
Fit Fuel delivery lines..(not too tight enough to allow initial air trapped in system to escape)
Renew Injector leak off pipes and Sort Leak off mod
Fuel filter
Oil Filter
Battery tray
Fan blade to clutch unit
Sump Plug and quick check Torque on sump bolts in general (Not sure if I can do the rear ones without having to dismantle stuff..I won't be dismantling)
Gear box oil change
Oil in engine
Radiator plus header tank plus pipe connections
Coolant
Fit Drivers seat
Battery
Get lovely wife to turn over the engine while I wait for Diesel etc to ooze out of the Injector unions....
Tighten up unions...
Pray to The Transit gods..she Starts...

[oldyellar]

very good work mate that van will be runing like a rols royce time your done

[ake]

The loose/missing bolt in the rocker assembly can cause heavy oil smoke when running, so well worth finding and fixing

[Van1968]

Thanks for your comments gents...Rain has stopped play today and doesn't show any signs of giving up....I live very close to those that flooded last time..the river Tone (Taunton) has burst its banks...I have work friends living in Cornwall and Braunton..My thoughts go out to all those who have been caught up...

[Van1968]

Hello again..
Did a bit yesterday and again today....rained all day on monday so used our patio brolly for a bit of shelter.
Here are a few pictures of what I've done...
Brolly is my friend...

Got to work on the rocker gear..all I had to do was loosen off the bolts and gently quided the number 1 valve cap back on. Tightened all up then worked on setting the tappets...in the picture you will notice valves 1 and 6 are fully open (compressed against the spring). Once I done that I mated up the left side part of the manifold and fuel delivery lines (I haven't tightened up the unions on the injectors). Looking carefully you will also notice a black fuel hose..this was used for the leak off mod..more on that later.

leak off mod time and to help others..
The pictures shows the first injector..originally it had an rubber/silicone end cap closing it off.....

I took it off and stuck it on here...number 4 injector (Number 4 injector used to be connected to the T)

I then connected up the new length of fuel line 4mmID to the T...

Finishing it off by connecting to injector 1 as shown

Fitted the fuel filter..not as easy as it seems at first...I filled it up with FORT and deisel..pushed the filter up tight to the housing (not using the locking ring) rotated the filter clockwise until I felt the lugs and then while pushing up I THEN fitted the locking nut...(Thanks Dave)

Rocker cover next and what pleasure that was..especially using a new gasket (no sealant was used as a secondary back up)

The second part of the manifold,,looking clean and ready to breath..

New "fangled "Throttle body and oil breather fitted..you will also notice the egr opening on the exhaust manifold blanked off..

Air filter housing

That was it for yesterday..today I finished off quite a few jobs. Gear box oil change, Oil in engine and bolts on sump checked and tightened.
Refitted the radiator, fan and renewed jubilee clips here and there..header tank on...coolant in (about 10ltrs)..just a quick tip with all bolts fitted I brass wires down and used a gentle smearing of copper slip. I managed to fit the drivers seat back in.
A picture of a happy engine ready to be started.. (taken before coolant in!!)

I had the battery on charge for around 4 hours while pottering around finishing off...I was feeling quite nervous by the time I refitted the battery tray..I had to bite the bullet and go for it..fitted the battery and called on the Mrs to turn the key...this is what happened..

I asked my good lady not to press on the gas..but foot down on the clutch....
We turned the engine for about 20 seconds...no fuel was being delivered through the very slackened unions..stopped for a starter motor rest..
Tried again not pressing on the gas..the clutch peddle yes for about 10 seconds..battery is starting to die on us..stopped again for a motor rest..
Tried for the 3rd time and the battery gave up the ghost...I was hoping for a result of some fashion..
Further observations
no fuel coming through...I thought I heard a light air sounds whistling out of the unions..(but that could be my mind hoping for such ) While where on the subject of air..I have replaced the up lift pump...so could be a while before air is pushed through..I'm not sure here this one is for the experienced members who have been down this road before.
I have a gut feeling I may have overtightened both power steering and alternator belts..both would have an affect on the engine turning over the starter motor was quite warm..not boiling but warmth was there..water pulley was grinding slightly on the crankcase cover...and I recall the engine generally turning over a lot slower than it did before I started working on it.
I have learned that these engines are not easy to start at times...I have put plenty of diesel in with FORTE.
Plan off action...
Recharge the battery..loosen of belts to the original marks I made using tippex..ask my Wife to hold down both Clutch and GAS Peddle while turning the key..take on board and act on any tips I receive from fellow members...Which are most welcome
I'm not going to get stressed I'm sure I'll get it fired up...thanks for looking reading and if you have had this problem before and overcame it..please offer a tip or two...
Happy new year by the way...
Tom

[oldyellar]

Sounds like it aint turning over fast enough have u cracked the injectors u may have a airlock?

[Van1968]

Sounds like it aint turning over fast enough have u cracked the injectors u may have a airlock?

I have cracked the unions connecting to the injectors....very loose indeed finger tight to be exact only on by one turn..blue roll ready for oozing diesel..I agree with you on the speed of the turn over..I have overtightend on both drive belt (water pulley is grinding on the crankcase cover and I have gone over on the original tippex mark I made on the power steering belt (too much tension on crank pulley itself)...both combinations of tightness will affect turn over.. ...not too mention a battery that probably wasn't fully charged. Added to this..I never got my wife to keep foot and stay down on the gas peddle while turning over.

Battery will be getting an overnight charge tonight and I will carry out the much needed belt adjustments etc tomorrow...been at work today...

Thanks for replying..much appreciated ....wish me luck everyone ..I shall pray to the Transit gods ...

Tom

[oldyellar]

beezing firey rag up the intake na just jokin good luck it'll be puring before u know it

[savagesam]

use a bit of easy start

[Van1968]

use a bit of easy start

Thanks for your input.....
I have air from uplift pump to fuel filter (because I have disconnected) and air from fuel filter, air delivery lines to injectors (because of the disconnection)...Easy start is good for giving the engine a start when the system is completely free from air and I had been a normally running engine (Which at the moment it isn't). From what I have read on the forum...engines can rely on the stuff before starting...if I was to use it..Temps would have to be well below freezing and the battery running quite low after I had a go initially at starting her up.

Not done anything today..took some time out...my nippers are still off school..daddy time..you all know how it works...sweet and keep things sweet...I might get a turbo set up for my Birthday..on the 20th ....didn't stop me from thinking about things...tomorrow is the day for playing

Thanks again

Tom

[Van1968]

Hello....
I have tried to get the Van started but without success...I believe all air is out of the system as gradually while my Wife pushed hard down on the gas peddle and turned the key we eventually got fuel coming out of each fuel delivery line...not at at a rapid pace....steady/gently what I would describe as a light dripping..but enough to land on top of the injectors and flick up the residual fuel lying on top of the injector (not sure what I meant to expect...I thought I would witness diesel sputing out at a rate of knots..to the point I need to step back in case I received a face full (If you know what I'm expected to see please let me know)...engine turned over a lot better than last the effort...loosened the belts slightly....however, battery soon ran out of juice....I cleaned all battery terminals before I started work today....not the starter motor end which is only two years old 10/11/2010...might change it though still quite warm and the the cable from battery to starter was warm toward the startermotor end..battery and its' terminals Temps didn't rise...Members on the forum have changed them when finding starting their vans a nightmare...results have been positive....defo going to get a new battery tomorrow...looks like its been through its paces with recharging...This will be my 6th time for a full recharge in less than a month.. I will try again tomorrow with the tired battery and crack open the unions for a further bleed...I am thinking I have to go a little longer with bleeding...I have the uplift pump side of things to consider...Going to get some easystart just to help me get her fired up...if that doesn't work I will be putting out an SOS....I could be looking at a timing issue...

Thats it for now..going to Give Eurocarparts a shout and order a 0-092-S50-100 Bosch 85Ah
Thanks for looking..any tips advice most welcome...

Tom

[ake]

Before you try to start it again, pin it all up and check the timing again. The starter will get warm with prolonged use, that's not a worry. A quick spray of hair spray/ wd40 / brake cleaner into the air intake should help. Easy Start is best avoided if possible it's too harsh, and often causes more harm than good.