Hello everyone :thumbsup:
It might be worthwhile to post up my current project.
This 638 is a 2000 model, 2.2 cdi turbo. Manual.
It's done 264,000 km.
I'm a carpenter and thought I'd get a van. I don't really need it for work, definitely can do without it, but like the idea of it anyway. I will use it for work and other stuff. The shape and look of the 638 has been alluring me for a while. Sexy to me
I've done quite a few mechanical projects but this is my first diesel ever. Hopefully by the end of this rebuild I will have fair understanding of them and hoping you lot will advise along the way.
Here is a pic I took of it when I got it home. Paid 2 grand to a mate for it not running. He's a close friend that needs some dough so didn't haggle him. Rolled the dice on it, but calculated another engine into the deal. Don't really care how the figures end up. Close enough. Whatever.
It had the usual 4th injector dramas. I re-tapped, reseated and fitted a reco injector. Did the usual checks and bought a new battery.
Wouldn't crank. At. All. Bugger. A few ticks and noises sometimes. Played with the electrics for a few nights after work. Did the starter relay positive feed ecu bypass and still wouldn't crank. Grrr.
Then finally one night it started to turn over. Yayyyy. Well, just a short lived celebrating, because now you could crank it until the cows came home. Wouldn't fire.
Took the plastic intake piping off...and uh oh... water was pouring out the top of the pipe that come up from under the engine and into the left hand side of the plastic plenum thingy. You're joking right? Nope
Undid the rubber hose from the front of that steel under engine air feed from the turbo and fug me. About 5 litres poured out. Crap.
Not real good hey.
My mate had the van sitting out in the open for a couple of years, with none of the inlet plenum thing on it. The bonnet was down but maybe condensation filled it over the years. It baffle us lots. How did all that water go down the turbo inlet with the bonnet down?
So...water must have also collected into those 4 open inlet pipes that feed into the head right? See why it wouldn't crank? Maybe puddles sitting on top of the pistons...
Tried everything to get it to fire. Engine starter, hot air into the intake. Not a single fire. Ever.
So...
:rotfl:
Here we are tonight
Wanna help me totally rebuild this? Start pulling it to bits tomorrow. Planning on a new head, possibly reco turbo, new bearings everywhere, new rings at least (likely pistons, conrods?) rebore, clutch, rubber hoses, reco starter and alternator etc etc.
I love this shape Vito. This will cost more than it will be worth, but so what, I am keeping it.
I had considered just buying a second hand engine for a couple of thousand with a 3 months warranty, but with approx the same money we could rebuild this and it's way more fun and be much better.
It also needs a new windscreen and some other crap to get it road worthy for rego here.
The missus has given me 7 weeks to get it on the road and we'll take it for a 4 day weekend away to test it out.
Wonder if we can make the dead line?
I'll take pics as it gets dismantled. It can't be good. A cup full of water came out first when I drained the sump. Then the most hideous sludge ever.
It might be worthwhile to post up my current project.
This 638 is a 2000 model, 2.2 cdi turbo. Manual.
It's done 264,000 km.
I'm a carpenter and thought I'd get a van. I don't really need it for work, definitely can do without it, but like the idea of it anyway. I will use it for work and other stuff. The shape and look of the 638 has been alluring me for a while. Sexy to me
I've done quite a few mechanical projects but this is my first diesel ever. Hopefully by the end of this rebuild I will have fair understanding of them and hoping you lot will advise along the way.
Here is a pic I took of it when I got it home. Paid 2 grand to a mate for it not running. He's a close friend that needs some dough so didn't haggle him. Rolled the dice on it, but calculated another engine into the deal. Don't really care how the figures end up. Close enough. Whatever.
It had the usual 4th injector dramas. I re-tapped, reseated and fitted a reco injector. Did the usual checks and bought a new battery.
Wouldn't crank. At. All. Bugger. A few ticks and noises sometimes. Played with the electrics for a few nights after work. Did the starter relay positive feed ecu bypass and still wouldn't crank. Grrr.
Then finally one night it started to turn over. Yayyyy. Well, just a short lived celebrating, because now you could crank it until the cows came home. Wouldn't fire.
Took the plastic intake piping off...and uh oh... water was pouring out the top of the pipe that come up from under the engine and into the left hand side of the plastic plenum thingy. You're joking right? Nope
Undid the rubber hose from the front of that steel under engine air feed from the turbo and fug me. About 5 litres poured out. Crap.
Not real good hey.
My mate had the van sitting out in the open for a couple of years, with none of the inlet plenum thing on it. The bonnet was down but maybe condensation filled it over the years. It baffle us lots. How did all that water go down the turbo inlet with the bonnet down?
So...water must have also collected into those 4 open inlet pipes that feed into the head right? See why it wouldn't crank? Maybe puddles sitting on top of the pistons...
Tried everything to get it to fire. Engine starter, hot air into the intake. Not a single fire. Ever.
So...
:rotfl:
Here we are tonight
Wanna help me totally rebuild this? Start pulling it to bits tomorrow. Planning on a new head, possibly reco turbo, new bearings everywhere, new rings at least (likely pistons, conrods?) rebore, clutch, rubber hoses, reco starter and alternator etc etc.
I love this shape Vito. This will cost more than it will be worth, but so what, I am keeping it.
I had considered just buying a second hand engine for a couple of thousand with a 3 months warranty, but with approx the same money we could rebuild this and it's way more fun and be much better.
It also needs a new windscreen and some other crap to get it road worthy for rego here.
The missus has given me 7 weeks to get it on the road and we'll take it for a 4 day weekend away to test it out.
Wonder if we can make the dead line?
I'll take pics as it gets dismantled. It can't be good. A cup full of water came out first when I drained the sump. Then the most hideous sludge ever.