The Flying Moose - Project 855 T5-R (Attempt 2!)

[Nealevo]

Copy cat

[The Flying Moose]

Firstly before anyone says anything (Especially the clean man mr Evans!) its flithy I know, a combination of the demise of the D5 and living in the countryside isnt too compatible with keeping the car as clean as I'd like.

Just a couple of shots of the new egg crate grill on with Volvo slash from 850. Also a pic to show where the LPG filler was installed. Really pleased with how it runs on gas, barely notice a difference and pootling around you cant tell at all. Local BP garage does LPG at 49.9p a litre and has an LPG loyalty scheme where you always get money off leading to 10p off 39.9p a litre cant be bad eh?

Also while at Pete's man cave we noticed the front springs had been installed upside down so thats another job to do!

[t5 pete]

Glad it'd all working fine for you and yes them springs need doing

[Doingitsideways]

Ffs, who's been working on this car?!

Nice positioning with the filler there

[Nealevo]

I was in your area today, lowersoft, March swaffham and Wisbech, and noticed a lot of farm machinery places selling LPG, it's always cheaper there.

I'll let you off the cleaning as my car is filthy from today's jaunt in the sticks.

Also your exhaust hanger is broke from the pics

[The Flying Moose]

I was in your area today, lowersoft, March swaffham and Wisbech, and noticed a lot of farm machinery places selling LPG, it's always cheaper there.

I'll let you off the cleaning as my car is filthy from today's jaunt in the sticks.

Also your exhaust hanger is broke from the pics

Why didnt you say??? I'm in Swaffham and could have caught you!

Yeah thanks the exhaust hanger did break, I fitted a repair hanger but when we removed it to fit the copper pipe for LPG I forgot to re-position it correctly and just bolted it back on.

Another little job to do

[The Flying Moose]

So little update time.

Been a busy few nights sorting the old girl out with various bits and bobs and prepping her for the dyno day.

Sadly as with all things volvo not everything has gone to plan, but it wasnt snowing like the last clutch I did on Frankies drive

Replaced:
1. Clutch
2. Rear Main oil seal (old one was leaking just a tad!)
3. Painted calipers black from red
4. Replaced oil cooler clips
5. Replaced oil cooler block mount o-rings and retainer
6. New front pads
7. Oil change and filter (5k/6 month interval)
8. Gearbox oil renewed with 75w90
9. New clutch slave retaining circlip

Clutch was kindly donated by Neal and was as good as new with loads of meat left, the old clutch had started to slip in third and fourth under WOT (although I've seen worse on inspection).

Once it was all back together I was delighted to find the clutch pedal operated, gears engaged and is now very light indeed.

The negative... well it starts and runs but not well, lumpy and rough. Bizzarely it sounds ok under the engine idle, awful and the rear and seems to mis when you move off. Needless to say a day fault finding tomorrow!

[The Flying Moose]

Well what a bloody bugger!

Let it cool off for a few days but its back to step 1 again, damn rear main oil seal (new I might add!) is leaking already. Lovely puddle under the car. Looks like its all getting dropped again. Loosing faith! Its never straighforward with a damned volvo is it!?!

[martin_r_smith]

ouch!! I feel your pain mate, i'm sure theses cars are sent as a mental test. At least you still have a few weeks before shakey to get it done.

[The Flying Moose]

ouch!! I feel your pain mate, i'm sure theses cars are sent as a mental test. At least you still have a few weeks before shakey to get it done.

Oh I plan on completing it much sooner...

Trip to the Volvo dealers today for a new RMS. Spent a couple of hours on it this afternoon. O/S/F Shaft removed, all under box bolts removed, coolant drained, top pipework and cabling etc all off.

Tomorrow all that remains is the top gearbox bolts, top mount, and N/S/F shaft out and shes ready to drop the box again. Hopefully should have all afternoon tomorrow to work on it again, its amazing how fast you work when its cold and you only have a driveway!


Leak of new seal as below, last time I use a patent part...



Genuine part no for those interested.

[MoleT-5R]

Good luck and I hope you get it sorted with the genuine part, it's no fun having to do a job like that twice.

[The Flying Moose]

SHE LIVES!!!

Well after a painstaking eternity (feels that way) the new clutch, release bearing and rear main seal are now fitted once more. Better still this time no oil leak

Solved the lumping running, took about half hour to find. Injector one had no power and a broken line. New bit of cable soldered in and hey presto!

Took her for a spin and the clutch is lovely, very light indeed and its driving very well too.

Only negative, and there always is with a volvo is a small coolant leak has developed. Its only minor (not draining header) but is enough to need doing asap. Ill get under and inspect tomorrow, I suspect one of the heating/bulkhead coolant pipes is to blame looking at the location.

New patent part leaking



New Genuine RMS fitted in very easily



Fingers crossed solve coolant leak and get her on the dyno this weekend.

[The Flying Moose]

Im now at wits end! I've had various bits apart countless times today and inspected and replaced various hoses including the turbo to block coolant line which I suspected. I finally thought I'd cracked it, took it for a 20+ mile drive checking header tank half way... all ok. Anyhow parked up at home and drip, drip, drip header tank draining again.

Only one pipe left to replace between block and bulkhead although on inspection it looked ok.

[Ettienne]

Heater hoses and turbo return were shagged on the Gul and olive

[Ettienne]

You've got to come to the Dyno I've bought a selection of lady biscuits (I mean bourbons) lol

[Doingitsideways]

Those daft clips on the bulkhead pipes aren't broken are they?

Either that, or the o-rings gone flat?

[S70T5Chris]

You've got to come to the Dyno I've bought a selection of lady biscuits (I mean bourbons) lol

Bourbons are lady biscuits?! ££££, strictly Hobnobs from now on then

[The Flying Moose]

You've got to come to the Dyno I've bought a selection of lady biscuits (I mean bourbons) lol

Dont worry I'm determined!!!

Those daft clips on the bulkhead pipes aren't broken are they?

Either that, or the o-rings gone flat?

Not sure mate, its definately not the turbo coolant line now as new pipe and elbow have been fitted from a spare I had in the garage, Only left is matrix to block line. Its definately not been stretched etc as was removed when clutch was fitted but I'm going to pop out shortly and take it off and inspect more closely again.

[MoleT-5R]

glad to hear the oil leak is sorted and you like the new clutch, Is the water dripping ?? or is the expansion just draining down, as the system loses any airlocks in the system, that didn't come out when the coolant was refilled, Mine is a right bitch to bleed and always needs a top up or 2 whenever the coolant has been dropped.

[The Flying Moose]

glad to hear the oil leak is sorted and you like the new clutch, Is the water dripping ?? or is the expansion just draining down, as the system loses any airlocks in the system, that didn't come out when the coolant was refilled, Mine is a right bitch to bleed and always needs a top up or 2 whenever the coolant has been dropped.

The tank was drainng as the coolant fell out the bottom roughly centre to N/S/f of the engine.

Anyhow finally I think I'm there! Last hose replaced, late night trip to halfords in the volford and found some suitable diameter hose. Re-filled system, Been for a quick blast out (about ten miles) and its all dry. Ill go for a proper drive to prove it tomorrow.

Culprit below, as you can see halfords was busy and I started to question why the hell I was still faffing this late.

Highlighted item on VADIS was to blame.