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Volvo 940 GLE Caravan Project - Underway! 
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Joined: Tue Jan 15, 2008 2:31 pm
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Location: Home sweet home!
Exhaust fasteners (various) doused in CRC and to have removal attempted possibly tomorrow.

Rear wheels up on blocks to aid in some room to safely work underneath.

Imperative that I get this to a towable/parkable state very soon. I'm working on it!

Fred.

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Tue Feb 09, 2016 6:21 am
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Location: Home sweet home!
https://twitter.com/FredCookeNZ/status/ ... 5946132480

Exhaust out! Vibrating driveshaft also out and on the ground. Turns out that at least the centre uni joint had been cut and replaced. Balancing may not have been a priority, or the siliconed up hanger bearing may have been to blame?

Fuel system or steering rack next. 740 progress first though.

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Sun Feb 21, 2016 5:36 am
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Location: Home sweet home!
Back to hacking on this very soon, I want the hotel out and the Starlet in, and the Volvo in the driveway, so this has to move! Behind the Volvo, most likely :-D Should be quite the sight!

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n00bs, do NOT PM or email tech questions! Use the forum!
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Tue Mar 08, 2016 6:10 am
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Went out last night in the dark to find out for sure what the screw holding the ABS wheel speed sensor onto the stub axle are, and found this:

https://twitter.com/FredCookeNZ/status/ ... 7392755712

Was pretty dirty before and I had assumed torx due to everything being torx, but it was actually just hex with a little lip to stop the right size fitting into it.

Baby steps :-p

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FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Fri Mar 18, 2016 10:05 pm
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Yesterday afternoon I whipped out the now totally free LHS strut (after removing the ABS wheel speed sensor), and propped up the wheel to look like it was doing its job :-D

https://twitter.com/FredCookeNZ/status/ ... 6362142720

More progress this week coming as I work hard to make space for the hotel to come out, the starlet to go in, the gold Volvo oil pressure job, and the blue Volvo off-street parking!

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FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Mar 20, 2016 10:52 am
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Location: Home sweet home!
An hour and a half tonight and I got the following done:

  • Wiring looms disconnected from engine, unraveled and removed out of the way
  • Fuel hoses disconnected from engine and blocked up so as to keep the rail clean
  • Power steer reservoir drained and removed
  • Feed hose to PS pump retained and redirected to keep things leak-free
  • Lower aircon hose removed from pump and tucked into front of chassis
  • Throttle cable disconnected and moved out of the way
  • Ground straps disconnected and moved out of the way
  • Stole the oil pressure sender/switch from the block for the 240

All that's left to do before the engine can be pulled is:

  • Drain ATF out of the auto slush box and lines
  • Remove or disconnected ATF cooling lines from/to auto slush box
  • Remove the upper pressure line from the PS pump or rack - needs research

Also need to make room for it to come inside afterward.

Fred.

_________________
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FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Thu Mar 24, 2016 4:31 am
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Just realised that my unpleasant intolerant neighbour was out and ducked down to do a couple of more minor but noisy chores:

https://twitter.com/FredCookeNZ/status/ ... 8831594496
https://twitter.com/FredCookeNZ/status/ ... 5959455744

Baby steps! :-p

Once the engine is gone, there's just brake lines and wiring to clear the bay. Underneath is cross member and rack. From the firewall is the steering shaft, dangling, after that.

I'll still want to pump the fuel tank dry and remove the pump setup and tank, but they're not super urgent.

The RHS strut is still in there, too, but that should be easy pickings now, just need to undo the ABS wheel speed sensor, which I might go and dow now, actually... done! Now the strut is ready to come out! Will see if I can have the thing ready for the chop by Tuesday morning. This is the blocker for me keeping both myself and landlord happy.

Fred.

_________________
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FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Thu Mar 24, 2016 5:25 am
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Location: Home sweet home!
Progress by 1:30pm even after a late awakening around 10, and 30 mins lost dropping the wife at Yoga:

ATF drained from the slush box, nice and clean and red, which likely explains why it shifted better than the one in the blue car shifts!
ATF lines and cooler removed.
RHS strut on the ground.
RHS inner guard plastic removed.
Engine mount big nuts removed, both sides.
2/4 rear cross member bolts removed, trans nut removed, 2/4 rear cross member bolts loose
Shifter linkages and wire disconnected and hanging

Just the PS pump top pressure hose to undo, and it seems like it might be a challenge :-( I think it's intentionally locked into the larger nut, but the larger nut doesn't allow the hose to rotate when being undone.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sat Mar 26, 2016 1:28 am
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Location: Home sweet home!
Pics to come. 7:30pm, just came inside from a minimal clean up and tools-away after working on this solidly since this morning. Got a LOT done, and there's not much left to do before the reciprocating saw and demo blade come out!

TODO for tomorrow:

  • Extract A-frame from back of garage behind hotel
  • Pull the brake booster off of the firewall
  • Pump all fuel out of the tank
  • Seal up and move the fuel lines, or remove them entirely
  • Remove the pump and filter assembly
  • Disconnect and remove the brake lines except those to the rear which I will plug up to keep dry/fluid-filled
  • Remove the bonnet and hinge mechanisms (one spring already done)
  • Cut the radiator support out of between the two frame rails and inner guards to make them independent and easier to manage
  • Cut the outer skin of the inner guard about 100mm too long, so as to be able to fold and weld it afterward
  • Cut down the inner guard about 30mm clear of the firewall so as to not damage anything important
  • Cut the frame rails at the shortest path, roughly vertical

Fuel tank can come out another day on a hoist.

That's all of the cutting and removing done, aside from the seats and steering column etc.

Not sure if I'll squeeze this in tomorrow, but:

TODO, the day after? :

  • Mock up the A-frame in place
  • Attach (weld or bolt) the hinge points to the floor or frame rails as appropriate
  • Make a bracket to hold the weight at the middle of the A-frame and on the firewall somewhere
  • Choose a good place to bolt/weld the jockey wheel and attach that
  • Figure out the tail light/headlight wiring and put a trailer plug on that.
  • Change vehicle class and/or new registration for it, "Volvo 940 Caravan"
  • WOF time!
  • Park on street, profit.

Huge day, another huge one tomorrow, but good things to come as a result.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sat Mar 26, 2016 7:45 am
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Location: Home sweet home!
Caravan progress:

https://twitter.com/FredCookeNZ/status/ ... 7799148545
https://twitter.com/FredCookeNZ/status/ ... 6891368448
https://twitter.com/FredCookeNZ/status/ ... 1223224320
https://twitter.com/FredCookeNZ/status/ ... 4033469440
https://twitter.com/FredCookeNZ/status/ ... 1109611522
https://twitter.com/FredCookeNZ/status/ ... 5047345152
https://twitter.com/FredCookeNZ/status/ ... 1937330177
https://twitter.com/FredCookeNZ/status/ ... 7550264320

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Bonus pics from yesterday at the beach:

https://twitter.com/FredCookeNZ/status/ ... 8763337728
https://twitter.com/FredCookeNZ/status/ ... 4186916864
https://twitter.com/FredCookeNZ/status/ ... 8864998400

Image

Image

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What did I do?

CBF thinking about it. Lots though. See old lists vs tomorrow's list, etc.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sat Mar 26, 2016 11:26 am
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