Project ovloV

[inchley313]

Bought this car a few months ago and have been having major problems with it!! Every ounce of common sense I have keeps telling me to throw a can of petrol over it and set the f*****g thing on fire but the truth is, it's a fantastic car to drive and I really enjoy it!!!

The car is a 1997 Volvo V40, 2.0CD non turbo with 170,000mi on the clock. I bought the car to go on holiday with back in August for £350. I expected a few little problems but this car has been abused by the previous owner and needs some major work!!

First of all, driving the car home after buying it, I noticed a droning noise coming from the passenger front wheel. As a friend of mine back in Leicester owns his own garage, I decided to leave this until I got there to sort out what I thought was a wheel bearing noise and replace the rear brake pads.

I replaced the wheel bearing as required to find the noise still there so I asked my friend to check it out and it turns out the noise was infact the diff bearings in the gear box

I Managed to locate a 2nd hand gear box for £100 (I wouldn't have been able to do that on the Isle of Man) and took it to my friend to have it fitted. We then found the clutch slave cylinder also gone so had to replace that at the same time. (another £98)

This managed to keep up going for the entire holiday with no further problems.

Once back on the Isle of Man, we were driving home off the boat when, on top of the mountain, the windscreen misted up and wouldn't clear. That coupled with the sweet smell of coolant told me that the heater matrix had gone.

After a bit of advice on http://www.volvoforums.org.uk I found the advice I needed to tackle the job of replacing the heater matrix which involved stripping the entire dashboard out of the car and started a thread on there http://volvoforums.org.uk/showthread.ph ... ght=matrix so I could get help as and when I got stuck and the advice I've had from there has been 1st class and the guys deserve a shout out!!

I'll update as I get the car slowly sorted out.

Jobs left to do:

Finish replacing heater matrix
Replace starter motor
Replace lower coolant hose
replace front brake discs, pads and callipers
replace N/S/F indicator lamp and head lamp

[Nitro]

I have a friend who had a V40, he swore blind he'd never own another Volvo, thing was in the garage more than on the road (problems started at 100k!)

However I have been advised that the S60 D5 is a fantastic car for motorway miles, 260k encounting!

[inchley313]

Tbh, I really like the car and feel it needs saving from the death it was facing. I should know better than to throw money at a 14 year old car with 170k on the clock but I can't explain it!! I love this car and want it back on the road ASAP!!!!

[JayJay]

How did the slave cylinder cost almost as much as the gearbox

I have a friend who had a V40, he swore blind he'd never own another Volvo, thing was in the garage more than on the road (problems started at 100k!)

That's kind of weird, I've got a few friends in the UK (met mostly through another car club there) and there was an explosion of old-Volvo buying, all of them can't compliment the cars enough!

[Nitro]

Perhaps its just the V40?, 2.0l?

[audiodjmp77]

Perhaps its just the V40?, 2.0l?

Should have got a T4 V40 Mate

I think I'll miss mine when I give it back to the lease company when september ends (V50 ES Drive. 1.6 Diesel eco special, it's not a bad engine considering it is a 1.6)
Might have to see if they will let me have the V60 for a weekend when that time comes, or as the present list stands a Sh!troen C4 grand Picasso. (While preparing for a serious shafting for a benefit in kind, and kind being used in the loosest form)

I don't think it will be too much to save it now IMHO. I could say the same with the Celica, but thats 21 Years old and had been imported from Japan and would not trade it for all the tea there (Aside the fact our lass has categorically told me not to, so not all bad) I am waiting for the head gasket to go before I start changing things properly - read as turbo, cooler, fuel rail, pressure regulator, pump.

[inchley313]

How did the slave cylinder cost almost as much as the gearbox

I have a friend who had a V40, he swore blind he'd never own another Volvo, thing was in the garage more than on the road (problems started at 100k!)

That's kind of weird, I've got a few friends in the UK (met mostly through another car club there) and there was an explosion of old-Volvo buying, all of them can't compliment the cars enough!

The slave was brand new from a motor factors as the one on my box and the one on the second hand box were both completely knackered.

[inchley313]

just a quick update, the heater matrix is now out of the car and ready to be replaced. I am currently waiting for a heater matrix to be delivered from one of the guys on http://www.volvoforums.org.uk for a very good price.

I also have a list of parts I need just in case anyone on the island is breaking one for parts or is selling an old one cheap.

- Lower Coolant Hose
- Starter Motor
- N/S/F Headlamp
- N/S/F ABS Sensor
- Front Brake Callipers, Discs & Pads

I'll update this thread as I start putting the car back together and hopefully getting it on the road.

[steeldonkey]

I had to do a heater matrix on a mk3 gti aback in the day, its a s**ty job. Don't envy you one bit mate.

[inchley313]

I just thought I would copy this over from the other forum I'm on to give you an idea of what I'm currently up to!

Just a quick thread to show you all how I'm getting on with the V40 and what work is currently "In Progress"

1. Heater Matrix - Already have a separate thread for this one, http://www.volvoforums.org.uk/showth...=heater+matrix

2. Starter Motor - Solenoid is sticking and requires the unit to be replaced. Will remove old starter and get part number and see if anyone has one to sell

3. N/S/F Headlamp - Due to a crack in the lens, the headlamp unit has started corroding internally and the adjuster is broke. Also, you can see on the pics, the wiring connectors have started melting, would it be wise to replace these? if I'm replacing them, should I just fit P2 headlights?

3. N/S/F Indicator - Again, due to the abuse this car suffered at the hands of it's previous owner, the indicator lamp unit is broken and doesn't stay in it's hole. I was just going to replace the 1 but thanks to pacman67, I now have a nice pair of clear p1.5 indicators on the way to me!! Another reason to chance the headlamps altogether methinks!!

note: Does the front bumper have to be moved to replace the headlamps? I managed to get the drivers one out but got the impression that if the adjuster was in 1 piece, the headlamp would never have come out. Also, the screw under the arch that holds the bumper in place has been rounded off, is there another way around this??

4. Front Brake Calipers, Discs & Pads - Discs are warped due to calipers sticking. Pistons on calipers has corroded due to the rubber boots and the piston being split so definitively require replacement.

5. Replace Lower Coolant Hose - Due to me being an idiot!! I managed to split the bottom hose. To drain the coolant (to replace matrix), I needed to remove the lower hose from the rad and the clip was corroded solid!! Knowing that I needed to replace the clip anyway, I decided to cut it off. Not having a dremell to hand, I took to the clip armed with an angle grinder!! DO NOT REMOVE THE CLIP IN THIS WAY!!!!!!!! The grinder snagged and went straight through the hose!!

6. Spray Front Grille - Not being able to afford an egg crate grill, I decided that I am going to pray mine black. However, all the nuts that hold the grille in place are spinning and not undoing!!

7. Service - Once all the work is complete, I aim to give the car a full service!! Oil + Filter, Volvo Spark Plugs (still have slight misfire to cure!!) Gearbox Oil Change (Replaced gearbox recently and would like to change oil again as I'm not sure that what I used was the right oil) and I'm also going to fit an Induction Kit.

Here are some pics of the work so far!!