Had a little issue on a customers van today, just thought this maybe useful to others in the same boat.
The front to rear coolant pipes on the early T3 syncro 1.9l DG engines have 32mm front to rear coolant pipes.
The syncro pipes that are available on the aftermarket only come in 38mm and they are a different shape.
There are some 32mm pipes available for early 2WD models but due to their shape they foul the fuel tank so they don’t fit either.
So, you have a van sat on your ramp, customer wants it repairing, what do you do?
Okay, pipes off.
We had to enlarge the hole in the chassis that the pipes pass through.
Change the front rubber radiator hoses to ones suitable for 38mm pipes.
We then had to make a flange piece the attach to the engine cooling pipes and then angle them downwards.
We then used some old coolant pipes to step up from 32 to 38mm.
All done, pretty pleased with the outcome.
Sorry, start from the bottom and work up!
Pedal box came out and got some love, good job really as the pedal was properly worn, the clevis pin was toast and all the grease has dried out on the shaft the pedal sits on. All tidy now though along with a fresh FTE (OEM) clutch master and a new 10″ brake servo to complement those dirty great brakes I’ve fitted to slow down the 205R16 tyres I plan to fit.