Post 456889 by antz on 2012-01-30 19:03:24
Well guys I decided it’s time to run a small project thread for my 2003 V40 T4 Sport NA52 FYU just to document the progress of the car from wreck to respectable motor.
Some of you may remember it from when AL115 owned it briefly and it had, shall we say a few problems resulting from a front end bump in the past that wasn’t repaired to the best standard.
I bought the car roughly 2 years ago for a rather cheap sum due to the previous accident damage and general poor condition of the car. After purchasing it I had the whole car checked over and everything tested by a local well respected local ex-Volvo mechanic where it was given the all clear structurally and mechanically with only a few small issues that I rectified immediately. I cannot say what happened to the car between Al having it and me getting it as I simply don’t know but it seems all the major issues were addressed as they are no longer present, just leaving a whole host of visual and minor issues.
The whole car was filthy inside and out. Pen marks covered the headlining, Previous owners’ dog ate the boot plastics then puked them up. It had no oil or water, PAS pump was shot, brakes were shot, 2 tyres were bald and it was generally looking very sorry for itself.
So I did the following:
Had the whole car checked over for roadworthiness as detailed above – Came back all clear
4x New Toyo T1R tyres
New Genuine Volvo locking wheel nut kit (old ones rounded off)
Renewed whole braking system including callipers, discs, pads & brake lines.
Tracking done
New strut top mounts
New PAS pump & auxiliary belts
Everything checked for water leaks, water usage, oil leaks and oil usage.
Cambelt & pulleys changed & Full service including cabin filter
New battery (old one was far too small for the car)
New Genuine Volvo bonnet cable (Snapped)
Fitted correct bonnet catch (wrong one fitted)
Replaced all wheelarch liner fixings with proper fixings (not random bolts & plugs as used previously)
Fitted a complete set of new boot plastics with lights and boot carpets (to get rid of the chewed/broken bits and dog sick smell)
Fitted all new boot carpets again (a gearbox leaked in the boot one day)
Fitted new heater vent grills (old ones broken)
Fitted various new interior & exterior trim clips that were broken/missing
Found the radio code
Replaced drivers side fog light (Broken)
Replaced front seatbelt trim covers on front seats (were missing)
New windscreen washer bottle (lid was missing)
Replaced interior light trim as it was full of “hands free kit” holes.
Fitted brand new indicator units with correct fixings (not wood screws as held in previously)
Fitted new Genuine Volvo front and rear mudflaps
Fitted a Genuine Volvo front strut brace
Replaced entire stereo system with new Volvo speakers (old ones blew up)
Fitted Genuine Volvo boot tray
Fitted Genuine Volvo bumper protector
Fitted new shorter aerial from Astra Coupe (old one perishing and signal rubbish)
Fitted Genuine Volvo headlight protectors
Fitted a brand new K&N Cone filter & heat shield to replace nasty Ripspeed special filter that was fitted.
Pieced together a complete toolkit (was missing)
Bought a new correct owners handbook & wallet (was missing)
There are other jobs I've done but I can’t remember what they are off the top of my head.
With those jobs out of the way NA52 FYU now rides well, no clonks, drives straight & true, is comfy, doesn’t smell of dog sick, is safe, goes well and is A-OK! It’s served me well for 24k miles so far and now it’s time to turn my attention to the very badly re-sprayed front end as well as adding a few more personal touches to the car.
Few photos from last Summer when I actually took some:
Pre K&N heat shield at this point
First up was a trip to Huddersfield Volvo Spares last weekend to get a full leather interior and door cards. I can’t recommend these guys enough, he was so helpful. It needed a damn good clean which is expected but I wasn’t expecting them to have the built in booster seats, child headrests & centre arm rest with built in cup holders. WOW! So I spent Sunday fitting up as much as I could before the light ran out.
New door cards on car Vs old ones on floor
There’s a couple of trim screw covers which I lost and a door handle trim was cracked so ill pop to the scrapyard at the weekend and get some replacements.
Also it’s time to look at the bad re-spray job so I've managed to source a good used drivers wing in the correct 347/22 Titanium Grey colour. I also bought a good used bonnet in the same colour but unfortunately the courier damaged it in transit. I'm going to try and repair the damaged one before looking for another. I'm also on the look out for a passenger wing in the correct colour. The front bumper Ill spray myself one day but at the moment I want to try and straighten it up so it’s less “pissed” looking. I've got the headlight wipers to go back on & another engine under tray to go on because it was missing.
Stay tuned for more to come....
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Gary.
On the upside my dirt cheap Spectra wheels and unlop winter tyres are bloody ace in the snow. Although it doesnt look i the driveway is a 40degree uphill up get out and it puleld up no problem compared to last winter on Toyo T1R's it couldnt get half way up.
BUT....
I did manage to get my bumper protector off after some silly sod (me) trapped it outside the boot and drove to work for 4 days with it hanging out resulting in one very salty bumper protector.
so washed and re-fitted:
I also discovered it had factory fitted dog guard/cargo net mounts but the guard was missing so I tracked a good used cargo net which arrived today and is now fitted.
Old seat out and lots of muck under here. Also 5p WOO!:
New seat in:
Then I did a temp paint job on my new damaged bonnet and proceeded to fit it. The colour is off due to a previous poor respray but ill address that when I manage to track down a passenger side wing to match the drivers wing I have yet to fit.
Next jobs to do are fit the drivers wing, remove the front bumper, refit headlight wipers, try and striahgten front bumper up when re-fitting and source a passenger wing in the correct colour to finish it off.
And whats wrong with the old wing? Well its had an appauling respray in the past and subsequently there is no paint left on the arch lip as its all fallen off and some kind person left a 3inch long scratch right down the top edge when i was parked at a cafe one day.
And my replacement wing all fitted up. The colour isnt a perfect match to the car from where the last respray blended into the doors but it does match the bonnet and when i get the bumper sprayed it should match that too.
And a good wash later with my summer wheels back on.
Ive worked out my wonky front end is actually due to the bonnet being too high on the drivers side and not anything being bent (phew!) so ill dead with this at the weekend if i get chance.
Next jobs are to source a passenger wing in the correct colour, get the headlight wipers refitted, undertray fitted and respray the black centre piece of the front splitter.( and replace a broken headlight backing which i broke today DOH!)
After:
I got the car up on the ramps and refitted a plastic engine under tray which has been missing since before I bought the car.
Also I gave the front splitter centre section a respray in satin black because the original paint was all chipping off and showing grey primer underneath:
Now my washer bottle level light is constantly on which it wasnt before today so I think ive knocked something. Ill look at that another day though and my bonnet still needs adjusting on the drivers side as its too high but thats a job for another day because I think the bonnet catch is at fault with not enough adjustment in it.
And.....a final shot hiding behind my dads T5 which I also fitted a poly top engine mount on today.
Knackered now.........
And as well as that Ive also replaced all the dash bulbs which have a habit of dying on the S40/V40's but they are about £40 to replace so I took a deep breath and ordered the full lot from PFV
At this point Im nearing the end of my tidy up of the car with the only real job to still do is a dodgy wiring connection on the NSR bumper light that comes on and goes off when it wants and Id like to find a grey passenger wing to complete the front end but I havent sourced a good one yet so thatll get done one day when one turns up.
Hopefully youve enjoyed reading this as much as Ive enjoyed doing it and I hope that I have done some justice in restoring the car to its former glory and hopefully showing that its no longer the troublesome beast she once was.
Thank you for reading, good night. :)