Sampath Gunasekera

Many thanks for your idea iRage But still wish to stick to the tire size recommended by the manufacturer. All 04 tires are in good condition and specially front two tires seems not even done 1000km-2000km. Hence thinking not to spend money on them and have some other cosmetic ideas which will describe soon.

Many thanks for your wishes. Major difference is, if Viva Elite is a Delica van, CS1 is a Rosa bus. Cs 1 is lengthy as 14' 8". Need to handle very carefully. But very spacious and comfortable.

Interior

Engine Bay

Guys, this time it is a ‘Mitsu’. Last weekend I sold my Perodua Viva Elite after using 6 years with 80k at odometer and shifted to well-maintained Mitsubishi Lancer CS1 GLX. I was seeking a well maintained CS2 or CS3 with Automatic Transmission for months, but was not lucky enough. Two JDM units found comparatively well but no service records and might be odometer tampered. On my way, I accidently found this 9 years old girl and could not miss her even she was a CS1. Hence settled with her within a week. This CS1 is a brand new import under permit scheme and registered in 2007 December. Previous two owners were members of the same family and had maintained her with Unit#d Mot#rs and had all service records from the beginning to up to date. (I verified service history with Unit#d Mot#rs before buying and they confirmed everything is genuine) Last owner was a lady and wonder how she looked after this vehicle. Timing belt has been replaced at 45,000km considering the time factor being 6 years. Current odometer is 92,000km. Again three Autolankans were helping me; Trinity, Davy and The Don. Specially CS experts Trinity and Davy gave me very valuable advises and kept following the project. @trinity, @Davy, @The Don Thank you all guys. Here are some photos of her.

Happy B'Day Machan & have a grate one !!! I will send you the B'Day present within this week,hopefully by Friday. (This will reduce my collection by one, but thought you are the best person to have it rather than having with me )

Ok, Well noted Madz. Simply, Original Post Whoring thread - Bloemendal Post Whoring thread 2 - Meethotamulla Post Whoring thread 3 - Karadiyana

Found this old Volvo at my mechanic's place . Engine and gear box replaced with same of L300. Steering wheel from a Toyota. And the best part is dashboard from a Trad Sunny.

Thanks guys.

How old your tiers are? Check for manufactured year and month. No matter you used or not tires, but rubber starts to degrade after some time. How old your tire valves are? Press the valves from your finger to different sides and make sure quality of rubber valve is ok.

Honda Malaysia’s airbag inflator replacement process http://paultan.org/2017/02/13/honda-malaysia-airbag-recall-now-is-the-time-to-act/

Many thanks for your comments. Even I never thought we could complete the job within this limit. I came to know about Asanga when I searched based on Maersk's hint. Before the project I visited Volmec and checked their capability of doing the project. I saw that he was working with few S60s and S80s at that time. According to Asanga, he studied motor mechanic in Singapore and started Volmec after he returned back. I had another option, very famous Volvo mechanic which worked in Swedish also now runs his own workshop. But that gentlemen was very negative on diesel variant when I speak him everytime . Asanga was so positive from the beginning and he already engaged with few diesel units earlier. So I went with Asanga and he completed the job within 2 weeks. (Actually we had to wait for some parts after ordering) . So you visit them and have a look.

Now car runs very smoothly and pulling power got back. Project Cost: Total project cost was around Rs.300,000/= for purchasing the engine + gearbox , shipping , clearing, engine transportation, vehicle transportation, installation donor engine and bring the car up to final stage including all costs. Cost of the work done at Volmec: (Hope this is not violate any forum rules) 1. Engine replacement LKR 18,500.00 2. Injectors cleaning and pressurizing x 4 LKR 11,200.00 3. Injector pump testing and service LKR 8,750.00 4. Re-making of wiring harness LKR 2,350.00 5. Oil seal pack x 4 LKR 12,150.00 6. Timing belt LKR 8,300.00 7. CV boot LKR 1,440.00 8. Mobil diesel oil LKR 5,600.00 9. Radiator cleaning and pressure test LKR 2,150.00 10. Diesel tank cleaning LKR 2,500.00 11. Drive belt LKR 8,500.00 12. Engine service and cleaning LKR 2,500.00 13. Oil filter LKR 1,500.00 14. Power steering oil LKR 850.00 15. Gear box oil 90W LKR 1,500.00 16. Diesel refill LKR 1,000.00 17. A/C refill and service LKR 5,500.00 18. Brake oil flush and refill LKR 3,500.00 19. Interior cleaning LKR 8,000.00 TOTAL LKR 105,790.00 --------------------------------------------------------------------------------------------------- I would like to express my heartiest thank to following gentlemen. (1) Our Moderator Supra Natural & member Crosswind for pushing me to replace a Volvo engine instead of Japanese engine and suggesting me to import used Volvo engine from UK. (2) Our Moderator The Don for finding the correct engine , arranging shipment and guiding me with all instructions. (3) Member Maersk for giving me hint about Volmec. (4) Asanga of Volmec for doing a neat and great job within a short period. Asanga also a Volvo enthusiast from his childhood and he own a Volvo S60. When the technician himself is a car lover, project flows very smoothly with caring nature. (5) All other Autolanka members whom extended me all valuable ideas, instructions and kind support thorough out the project. Volley is handed over to the original owner; my uncle and he is very happy with his pride ride back. It’s a Volvo Cheers!!! Sampath Gunasekera

Ready to roll

Before interior cleaning After interior cleaning (I have observed many Volvos here and Black leather interior is much better than the Beige interior in Volvos with the time being)

After installing the donor engine Installed donor engine after cleaning Engine cover installed

Before installing the donor engine Installing the donor engine

Donor engine installed and connecting of wire harness and other components are processing. Waiting photos from Asanga. Mean while I have some idea for a cosmetic modification with the grill. I always love the grill model offered in 2003-2004 over grill had with 2000 model. As per google searching, both should be in same dimension however need to check physically. 2003/2004 model is rather rare to find a specimen here.

Many thanks for Davy and Kush for your replies. Well noted your point and decided to replace the timing belt with a new one. Asanga also instructed me the same. Yes, Davy you are right. I met very good gentlemen here & we could help each other. While we were searching for an engine for months , The Don also upgraded to "Married" status. Just after he returned back to UK from the wedding ceremony, he re-started searching for an engine. @The Don is my external supervisor of the project whom keep eye on daily progress through Viber . @The Don Thank you very much my friend. . Asanga (Volmec) wish to complete engine installation within a week. I am not in a position to visit the car daily, but Asanga click all important steps and pass me the photos. I will keep the thread updated.

Leather interior is badly affected due to fungal growth and need to clean and apply leather treatment. Car with donor engine

Progress up to date: Removal of old engine Engine bay before cleaning Engine bay after cleaning Old engine with engine cover New Engine (Donor engine)

Car was stationery for few years . Washed her , pumped air to all four tires and car was delivered to Volmec by a car carrier. Expected Job List (1) Removal of old engine , clean the engine bay (2) Check/clean all electrical components/systems (3) Clean and pressurize & test the injectors (4) Edited:Timing belt WILL BE REPLACED. (Before Edit: Old engine had a very new timing belt and it will fix to donor engine) (5) Radiator and water lines to be cleaned (6) Replace all necessary rubber hoses/components (7) Replace some oil seals (8) Install the donor engine (9) Replace all fluids (10) Check brake system (11) Check suspension system and if need replace required parts (12) A/C work (13) Car body - cut and polish job (14) Interior cleaning and leather treatment (15) Registration at RMV Guys, please advise me if anything I have missed here.

Donor Engine (T3 engine - before ship to Sri Lanka) Donor engine is obtained from a V40 (Wagon) car. Engine codes and everything double checked to make assure that we get the same engine model. (There are four engine models used in Volvo S40 Diesels. T,T2,T3 & T4 and our one hold T3 engine) http://www.partinfo.co.uk/files/TB17.pdf We bought T3 engine, gear box, Turbo Unit, AC Compressor, Power Steering Pump, Injector Pump, Injectors, Engine Cover and wiper arms from same car.( It was advertised that if byer requsted, seller can start and show the working engine before breaking the car.) This engine was the one we could find with lowest mileage done; 65K miles. Other all engines were done much higher than that. The Don was so kind to visit and see the engine before ship it. Engine received safely and next step was seeking a competent mechanic. I had two options. First gentleman was much negative on diesel engines. Second option I found was Volmec (Pvt) Ltd at Malambe. Asanga of Volmec was very positive from the beginning and he was already experienced with S40 diesel versions. Selected and decided to go ahead with Volmec.

Something about Volley: Volvo S40 , 1.9 Turbo Diesel 5 Speed Manual Transmission Manufacturing year: Late 2000 (Imported through agents) This is belong to ‘first generation’ of S40 and ‘Phase II’ Engine Model: D4192T3 Some bells and whistles included;

Engine Swap - Volvo S40 Turbo Diesel YOM-2000 (Project Volley - Volley the Naughty Forty) Previous discussion though below link. My sleeping beauty is about to wake up. After waiting for months and months, this is the right time to start the Project Volley. Volley kept silence for about 2 – 3 years at the rear end of the garage. After many ideas, plans, decided to import a used engine with gear box from U.K. My heartiest thanks to Moderator ‘The Don’ whom did spend many hours for seeking a suitable low mileage engine for months and months and helping me form the beginning. Finally engine reached here safely and ready to swap.