Right then.
The air cylinders had a few deep rust spots so decided it was best to replace them since they weren’t too expensive
While waiting for new tanks to arrive the straps got repaired, then the whole lot got painted in zinc
And then black epoxy
The fuel tank straps needed repair as well so i did them at the same time.
Then yesterday came around and the sun was out so we started bolting everything back on.
Fittings from the originals went into the tanks
And the tanks went on the hanger
And there had been an extra feed taken from the air tanks that ran in nylon type of pipe to the back of the chassis and had then just been tied off the seal it up
It didnt go back on but of course that left me with a hole in the valve block so i turned out a quick blank that goes in with an o-ring before the connector
That all back together to continue the theme or air lines we decided to refit the cylinders on the back of the brakes. These house the mechanism for the handbrake and the diaphragm for the foot brakes
We had cleaned up and painted these with some other bits
Held on with a couple of nice clean clenching ring pieces.
Stop sniggering you lot
It was a bit of a pain in the posterior to fit so i ended up taking the lower part of the cylinder off so i could compress everything together on the bench with the aid of some clamps
But in the end they came around to my way of thinking and went back on
The brakes have a bias adjuster that is set off the height of the rear axle or the load in the back of the wagon. the arm was looking awfully crusty and since i had a bit of 8mm stainless knocking about i bashed out a new one.
There it goes
Next up we wanted to make sure everything was sealed properly but that means running the engine but that was missing a rather vital piece of kit known as a fuel tank.
The tank that was on wont be going back on due to a leak several months ago and a deft hand with some fiberglass resin. Disclaimer* not my usual thing but i really wasnt up for welding up a fuel tank that was pouring diesel everywhere.
So we were going to order a replacement but when you get quoted over £400 before vat you start to get other ideas.
The logical solution is to get a second hand one but ideally i would like a plastic one so we don't have this kind of trouble again.
No one makes a plastic tank for a 2000 MAN
but at the end of the day its a wagon so how hard can it be to retrofit one.
So a trip to a breakers relieved us of some pennies and relieved them of a plastic Iveco tank with straps and mounting brackets.
The tank is a bit smaller but the height is pretty close and thats the important bit.
So on it went with the "new" brackets
Now comes the problem.
the pickup and return lines are different sizes and the level sensor is obviously different.
So i removed all that from the iveco tank and stripped it out on the bench
Chucked the cap into the lathe and cut out the center
Then i took a jigsaw and cut the original mounting point out of the old tank.
and that went in the lathe as well for a quick true up and trim
Left with 2 pieces
You can probably see where this is going but there is a twist.
Ya' see the level sensor mounting sits a bit lower in the new tank so a small upstand is called for
And the whole lot gets welded together, excuse the shoddy tig work I'm still getting the hang of it.
Primed and powder coated
And there you go, how to fit a MAN fuel level sensor to a Iveco tank. Not that you ever wanted to know but now you do.
And in answer to your imminent questions, yes it started and yes the air system leaked.
After going round with the soapy water i found a small air leak coming out of the swivel joint on one of the tank connectors so that needs depressurizing and looking at
The air cylinders had a few deep rust spots so decided it was best to replace them since they weren’t too expensive
While waiting for new tanks to arrive the straps got repaired, then the whole lot got painted in zinc
And then black epoxy
The fuel tank straps needed repair as well so i did them at the same time.
Then yesterday came around and the sun was out so we started bolting everything back on.
Fittings from the originals went into the tanks
And the tanks went on the hanger
And there had been an extra feed taken from the air tanks that ran in nylon type of pipe to the back of the chassis and had then just been tied off the seal it up
It didnt go back on but of course that left me with a hole in the valve block so i turned out a quick blank that goes in with an o-ring before the connector
That all back together to continue the theme or air lines we decided to refit the cylinders on the back of the brakes. These house the mechanism for the handbrake and the diaphragm for the foot brakes
We had cleaned up and painted these with some other bits
Held on with a couple of nice clean clenching ring pieces.
Stop sniggering you lot
It was a bit of a pain in the posterior to fit so i ended up taking the lower part of the cylinder off so i could compress everything together on the bench with the aid of some clamps
But in the end they came around to my way of thinking and went back on
The brakes have a bias adjuster that is set off the height of the rear axle or the load in the back of the wagon. the arm was looking awfully crusty and since i had a bit of 8mm stainless knocking about i bashed out a new one.
There it goes
Next up we wanted to make sure everything was sealed properly but that means running the engine but that was missing a rather vital piece of kit known as a fuel tank.
The tank that was on wont be going back on due to a leak several months ago and a deft hand with some fiberglass resin. Disclaimer* not my usual thing but i really wasnt up for welding up a fuel tank that was pouring diesel everywhere.
So we were going to order a replacement but when you get quoted over £400 before vat you start to get other ideas.
The logical solution is to get a second hand one but ideally i would like a plastic one so we don't have this kind of trouble again.
No one makes a plastic tank for a 2000 MAN
but at the end of the day its a wagon so how hard can it be to retrofit one.
So a trip to a breakers relieved us of some pennies and relieved them of a plastic Iveco tank with straps and mounting brackets.
The tank is a bit smaller but the height is pretty close and thats the important bit.
So on it went with the "new" brackets
Now comes the problem.
the pickup and return lines are different sizes and the level sensor is obviously different.
So i removed all that from the iveco tank and stripped it out on the bench
Chucked the cap into the lathe and cut out the center
Then i took a jigsaw and cut the original mounting point out of the old tank.
and that went in the lathe as well for a quick true up and trim
Left with 2 pieces
You can probably see where this is going but there is a twist.
Ya' see the level sensor mounting sits a bit lower in the new tank so a small upstand is called for
And the whole lot gets welded together, excuse the shoddy tig work I'm still getting the hang of it.
Primed and powder coated
And there you go, how to fit a MAN fuel level sensor to a Iveco tank. Not that you ever wanted to know but now you do.
And in answer to your imminent questions, yes it started and yes the air system leaked.
After going round with the soapy water i found a small air leak coming out of the swivel joint on one of the tank connectors so that needs depressurizing and looking at
. so back to the stick.