Isuzu C240 powered Series 3

The flywheel should be back from balancing tomorrow, collected the crank bolts yesterday from Patterson Cheney.
I had a good look at the conversion plate last night and it looks like I'll have to remove it this weekend to heli-coil the stripped threads. There is also a large opening at the lower edge of the front of the conversion plate (doesn't seal against the engine). There are tapped holes on the conversion plate so I'm guessing a plate originally fitted there to seal it off, otherwise a water crossing would quickly fill the bellhousing. I'll get some 3mm aluminium today to make a plate and silicon/bolt it in place when re-installing the conversion plate. There is already a small drain hole in the bottom of the conversion plate.

https://www.aulro.com/afvb/images/im...012/06/503.jpgDSCN1200 by Colin Radley, on Flickr


Then I need to order an overhaul kit for the gearbox, any clues to a good supplier in the UK.

Colin

I just collected the flywheel after balancing so hopefully between rain showers at the weekend I can get the starter motor off, remove the conversion plate and sort out the stripped threads.
If I can get the flywheel fitted I'll be starting her up to check she runs OK.


Colin

I've removed the conversion plate and also fitted the ring gear today. I need to source a heli-coil for the starter bolt because it's a different size to the bell housing bolts. I didn't manage to source any aluminium to blank off the lower part of the conversion plate during the week so I'll get this done during next week.

Picture below of the ring gear about to cook on the BBQ (SWMBO complains when they're done in the oven !). Managed to get the temperature up to 180C for about 10mins and the ring gear 'fell' onto the flywheel with a satisfying 'clang'.

https://www.aulro.com/afvb/images/im...012/06/294.jpgDSCN1279 by Colin Radley, on Flickr

Pressure plate side, you can see the balancing holes on the lower RHS. They tie up exactly opposite the porus patch on the other side of the flywheel.

https://www.aulro.com/afvb/images/im...012/06/295.jpgDSCN1282 by Colin Radley, on Flickr



Colin

I've now made up a blanking plate for the lower half of the conversion plate and re-coiled the damaged threads (7 in total).
The conversion plate is back in so that the engine can rest on the crossmember again (has been supported by an axle stand for most of the week.
The starter motor is bolted back in, this was supported on a length of rope while the conversion plate was removed.

https://www.aulro.com/afvb/images/im...012/06/118.jpgDSCN1289 by Colin Radley, on Flickr

Last night I turned up the 3 dowels for the clutch pressure plate, when the holes were drilled in the flywheel they ended up slightly oversize so I had to make stepped dowels. Pressed them into place and the pressure plate drops on perfectly.
Next I'll turn up a clutch alignment tool and then I need something to bolt onto the flywheel that will rest against the chassis so that I can torque the flywheel bolts.

https://www.aulro.com/afvb/images/im...012/06/119.jpgDSCN1291 by Colin Radley, on Flickr


Colin

Lovely bit of work Colin!

Right up my street as well - making things :D

Cheers Charlie

Quote:

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Originally Posted by chazza

Lovely bit of work Colin!

Right up my street as well - making things :D

Cheers Charlie

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Charlie,

That's why I have so many 'projects', problem is when it gets to the straightforward stuff I loose interest and look for a new project.

I made a traditional wooden rocking horse for one of my daughters, lost interest part way through and started another (I like the cutting & carving of the timber), lost interest and have a third underway. I did go back to the first at Christmas and finished the leatherwork so she could ride it but there are two more to finish.

Just got the steel cut for my forge (I already have an anvil).

Then there are the 6 Land Rovers.....

Work is starting to interfere with all the projects.


Colin

Managed to get the flywheel & clutch fitted this weekend (between the rain showers).

Sealed up the blanking plate to stop water ingress.

https://www.aulro.com/afvb/images/im...12/07/1319.jpgDSCN1292 by Colin Radley, on Flickr

Mounted the flywheel and bolted up. I made a brace to bolt onto the flywheel so that I could torque the bolts.

https://www.aulro.com/afvb/images/im...12/07/1320.jpgDSCN1294 by Colin Radley, on Flickr

Fitted the clutch plate after turning up an alignment tool.

https://www.aulro.com/afvb/images/im...12/07/1321.jpgDSCN1298 by Colin Radley, on Flickr

I replaced the fuel filter, bled the injector system, checked the oil (needs replacing) and then found I'd lost the keys. After turning my office upside down, going though all the boxes that came with the vehicle, trying all the keys that I could find they eventually turned up.
Then moved a battery from another vehicle but found it very slow to turn the Isuzu over. Put it on charge for a few hours and tried again, 10 seconds of glowplugs and she fired up, produced lots of black smoke then stopped. I managed to get it started a few times but each time it stopped after a few seconds so I'll have to look at the fuel supply.
I didn't check the sedimenter and maybe I'll bleed the system again.

Colin

Quote:

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Originally Posted by gromit

Managed to get the flywheel & clutch fitted this weekend (between the rain showers). Then moved a battery from another vehicle but found it very slow to turn the Isuzu over.

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This is about where I rang you. :D

Quote:

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Put it on charge for a few hours and tried again, 10 seconds of glowplugs and she fired up, produced lots of black smoke then stopped. I managed to get it started a few times but each time it stopped after a few seconds so I'll have to look at the fuel supply.
I didn't check the sedimenter and maybe I'll bleed the system again. Colin

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Lots of black smoke = overfuelling for startup.
I have passed the info onto Graham about those pieces you wanting to have folded up.

Alex and myself unloaded a 200TDi engine, gearbox and transferbox today.
The loose plan at this stage is to build them into a 2A shorty, now where to find a chassis? Oh yeah that right :D.
.

Just had a quick try to re-start it . It turned over OK but wouldn't fire but I did get the distinct smell of plastic insulation melting.
I remembered the PO had mentioned that there was a new glow plug resistor in amongst the spares supplied with the car. Had a look at the resistor fitted and it had a link wire across the 2 terminals, this wire had melted insulation !

Once I'd removed it I found the resistor had failed and as a temporary measure the link wire had been fitted.
Rather than going through all the spares I found one off a diesel I'd parted out a while ago, fitted that and put the battery back on charge.

I'll try again tomorrow....


Colin

Finally after a few wet evenings I got home a bit early tonight and decided to try again. Phoned the PO on the way home to see if he had any clues.

Turns out the shut off knob when pushed overfuels the motor so with that in mind I bled the system again, installed the freshly charged battery (which had seen about 3 years use on the wife's Territory) and tried to start it.

No smell of burning insulation now but it turned over very slowly, could be the battery but decided to check the leads to the starter motor and found a bad contact from the solenoid to the starter. Fixed that, gave it 10 seconds of glowplugs, pushed in the shut-off knob turned it over (much faster now) and it burst into life and the wifes car beside it disappeared in the biggest cloud of black smoke I've seen from a diesel.....
Kept it overfueled for a few seconds released the knob, the smoke cleared, and it settled down to tickover.
Quickly topped up the water and left Wallit running for a while. Noticed the alternator light stayed on but that may be down to another bad connection.

Phoned up the PO who was absolutely chuffed to bits that it was running again because he'd given up after trying to get a new flywheel made and it stood idle for 3 years.

Coolant flush, oil & filter change and trace the charging problems tomorrow....


Colin