Post 590577 by Palmer on 2013-03-31 00:06:26
I'm going to use this space to document various happenings / doings to my newly acquired 940 diesel. Its a 2.4L straight six turbo diesel intercooler (D24tic)
It started out with me browsing ebay looking at a few motors, when I came across this. I messaged the buy with a cash offer and he accepted. So I filled my mates fuel tank the next morning and set off to Leeds, West Yorkshire.
Few piccies from the ebay add:
Lovely condition seats
Original fire extinguisher!
Arrived in Leeds, looked over the car and accepted the deal, and began the journey home! After stopping off for a much needed Maccies of course! I was driving home mainly by myself as my mate took the wrong turning and nearly ended up in Manchester! Whilst I was on the A1 heading for home. Eventually he caught me up and I had a hoot of a game pulling in front of him and then flooring it so it covered his car in soot. As they say, if you cant smoke em' choke em'! Anyway this game ended with a phone call that described sparks coming from the rear of the car. Needless to say the rest of the journey was spent @ 50mph.
After investigating the next day there was jingle on the rear right wheel. Turns out it snapped the brake pad pin that holds the clip in so the clip was jingling. £3 kit from the local motor factors fixed this.
A few days passed and the car was running lovely, so I decided to clean the engine bay a bit:
And found this!! Trip to the welders needed lol
Anyhoo I didn't really clean the engine as they are generally greasy anyway so I just did around the engine bay and the bulkhead.
Let it dry and set off for my Dads, got down the road and my brakes failed - forcing me to rip up the handbrake to avoid the rear of a learner! Not to self: Handbrake is §§§§§ hot!
After a few days of puzzling and a second hand servo I threw in the towel and rang Steve, who appointed me to the fact the T piece along the servo hose should have a small vac hose in it. DOH! Found it down the back of the engine......
My basic plans for this car are to give it a major clean up, it was a "mobile mechanics" car so it is in dire need of a valet. Lacquer peel has also attacked the front, and seeing as my bro now has his own spraying premises a full respray could be on the cards at a later date. If the parts crop up - manual conversion too!
Sounds the tits!
[video=youtube;lPAqW3r4tAI]http://www.youtube.com/watch?feature=player_embedded&v=lPAqW3r4tAI[/video]
With which came the new intake
Fuel Pump Mods
Turned the fuel screw in a little. Its pictured here with the yellow markings on
Simply wind it in a few turns and tighten the jab nut back up. Obviousely there is an element of danger, being a rotary pump it can "run away" and rev sky high until it pops a piston in ya face! However im still at stock boost, so a few turns just gives it some more oomph. Ill set this up properly, including idle control etc when I up the boost. (Checked the turbo today, no shaft play at all @ 185k miles!!!)
Next I modified the LDA, located on top the pump. The idea is to liven the ole' bus up a bit and make it more driveable / quicker to take off.
Remove the 4 screws on the lid and it will look like this
Carefully peel the rubber diaphragm up and get a finger under the metal disc either side, and gently pull up. Be gentle as if you use too much force, it will knacker the dowel that rides on the fuel pin.
It should then look like this
There is a plastic washer in their, put it somewhere safe, like in the bin!
Take out the fuel pin and look at the mark that's been made by the dowel riding it
Removing the plastic washer allows it to ride all the way to the bottom thus injecting more fuel per (longer) stroke, crank the star wheel (gear like object) down a few turns. This reduces the tension on the diaphragm and allows it to inject more fuel at a lower boost setting. It does increase smoke though. This can be fine tuned with the jab nut / screw on top of the LDA
Before putting the Pin back in, note it is a shaft with an eccentric cone at the lower end. Rotating the pin to the more aggressive side (right had side in the pic) also increases the amount of fuel. It can be ground with a dremel or some sort to make it had a deeper ramp. My opinion is personally, get it done professionally. It needs to be 100% smooth for perfect fuelling and also the tolerances are minute, to an engineering level. So it will be better for performance if you get a pre ground one which is already at the limit, rather than guessing.
Overall: the car is **** hot! I need to fine tune the LDA with the screw on top as its smoking like a trooper on pull off (note: Black smoke = unburnt fuel = waste!)
But yeah, I am impressed with how jusy turning up the fuel makes it more lively. A lot more driveable is the expression id use, less throttle needed to get upto motorway speeds etc. And the auto box seems even more at home @ WOT.
Also, to give an idea of smoke - heres just revving:
[video=youtube;ZgdeRn359Sg]http://www.youtube.com/watch?v=ZgdeRn359Sg&feature=youtu.be[/video]
And in place
Traced the gaskets onto sheet metal and cut them out with a disc cutter
Tidied the edges up with an angle grinder so they fit flush, and then removed the burr with my dremel
Bit of gasket maker and bolted back in place
Set of new discs and pads, drive belts, auto gbox service kit, oil filter and a set of glow plugs.
Will be fitted with an engine flush, new oil, new ATF, and new diff oil.
Also tested this today
Just a mock fitting. Currently its back out and im filling in the right hand side as you can see it slope. Also the finish is pretty poor just a quick splash of paint to bring up any blemishes. Cig lighter will be relocated to the centre console.
I've given the gauge holder to my brother to finish, was getting on my nerves lol
New rear discs + pads
New front discs + pads
Servicing the auto box
The rear diff
Found all 6 glow plugs to be black like this, confirming they were ALL not working one bit! No wonder it sounded rough as §§§§§§§§s on a cold start!
And for those still pondering, this is how you change 5 + 6!!!
It was also the first time id been under Sooty, and I confirm that the MOT it received was in fact more bent that a roundabout! I always had my suspicions because of the battery tray area rust and unsecured tray itself.
Whilst having a nosey I found:
Minor oil leak on the auto box cooler
Almost everything rubber at the front perished (sway bar mounts, bushes etc)
No cat, unsure as to whether it should have one or not
Hole in back box (confirmed by soot EVERYWHERE!!!)
Generally rusty (surface only)
So on the increasing list a manual conversion is confirmed (why fix the leak when its a good excuse!)
And probably some better mounts / bushes etc. The engine also has a massive amount of rocking in it, if you wobble it its like jelly. So probably solid mounts too, been told that's good for power :D
Waxoyl the underneath will also be on the list.
I think its safe to say its been neglected, but its had the "essentials" covered.
Ciao for now :D
Yes, I know its on the passenger side! I can still see it though as I have my seat all the way back.
When I get an EGT gauge I will order a holder that's angled... if I can find one lol
Then I dropped the rear seats, and shampoo'd the whole rear, a job ive been meaning to do:
Whilst doing this I noticed how dirty the head lining was... so I reversed the head of the pipe and shampoo'd that too!!!
Just to give you some idea.... this is a bit I missed; forgot to unclip the sunblind
Massive difference! Its come up so clean!
And this was the water.....
And no matter how much I try, I can never lose my car in a car park.....
Manual conversion is also sat in my garage.... ;)
Sounds awesome!!
[video=youtube;HzSYxq8tuwM]http://www.youtube.com/watch?v=HzSYxq8tuwM&feature=youtu.be[/video]
Also this happened :)
A nice shot through the car
All in all it took me around 4.5 hours. That included:
Shampooing front + rear seats
Shampooing rear carpet
Cleaning + lubing front seat rails
Removing old front carpet and finding a massive puddle of water on the drivers side!
Drying said puddle and fitting new carpet on the front
Chucking the seats back in
Put new mats in :)
The puddle was a heater valve failure in its past (im presuming)... would explain why its just connected with a copper pipe....
The idea was to do the cambelt as well, but I was supplied with the wrong one meaning it all had to be put back together!!... with the old one... so Sooty is whining at having the old one put back on! Hoping to get a new one and have it done this weekend....
Also sooty has a friend :)
So a few 960 type upgrades coming soon!
960 cupholder setup :D
Which resulted in a 960 tailgate + rear lights on Sooty!
also swapped over the boot carpets from the 960 as well as they were unmarked, unstained and generally better
More soon :)
And soon after my drive was a mess... The 960 had a lovely tinted sunroof so I had that too!
And sooty looked a bit bare inside!!
She did look like this:
Even replaced the plastic trim at the front of the windscreen which was a brown pants moment!!
Also changed the gauge set up
Gave her a quick was as shes been a good girl too!
