29 replies to this topic

[volvoluvin]

Hey all,
Couple weekends from now I will be swapping out my 15t for a 16t and building a new DP to hook up to the EST exhaust. I want to make sure I have all the "sundry" parts with me so we can get it done in a day.

Currently, I have:

1. New Turbo w/ all nec lines - Check
2. EST Exhaust
3. New Flange for Turbo DP connection - Check
4. Stainless piping for DP
5. New Cat - Check
6. WB connections - Check
7. Gaskets?? - What Gaskets will I need?
8. Bolts?? - Will I need/suggest replacing Turbo exhaust housing bolts
9. Anything else?

Thanks for any help

Cheers
-Phil

[BlackT5]

You don't need any gaskets.

How are you going to mate your new downpipe to the EST exhaust? You'll need to get some sort of transition from 3" to 2.5".

So you've got 3 o2 bungs?

Studs on the turbo are M8x1.25, you'll probably want new ones since the old ones tend to get siezed in there. Grab some nuts too

[volvoluvin]

You don't need any gaskets.

How are you going to mate your new downpipe to the EST exhaust? You'll need to get some sort of transition from 3" to 2.5".

So you've got 3 o2 bungs?

Studs on the turbo are M8x1.25, you'll probably want new ones since the old ones tend to get siezed in there. Grab some nuts too

Thanks for the help.

Why would I need 3 o2 bungs?

We are going to do the reducing at the flange as the DP will be 2.5"

And I will for sure get some bolts...

[NGB]

Thanks for the help.

Why would I need 3 o2 bungs?

We are going to do the reducing at the flange as the DP will be 2.5"

And I will for sure get some bolts...

2.5" DP is silly. At least do 3" until after the cat.


You have two O2 sensors and might want to put a Wideband O2 in at a later date. Hence 3 bungs.

[volvoluvin]

2.5" DP is silly. At least do 3" until after the cat.


You have two O2 sensors and might want to put a Wideband O2 in at a later date. Hence 3 bungs.

Call me silly then...just doing a 2.5"

That's not a bad idea about the 3rd bung...we'll see how I feel. I have zero plans for a WB in this car, but maybe someone else in the future might...

My other Volvo is for crazy stuff, this is a gentle DD built for reliability and a bit of fun here and there.

Thanks
-Phil

[Auburn T5]

Anytime you run more boost than volvo gives you from the factory, it's HIGHLY recommended that you use a wideband meter to monitor the AFR's.

[volvoluvin]

Anytime you run more boost than volvo gives you from the factory, it's HIGHLY recommended that you use a wideband meter to monitor the AFR's.

Completely agreed, but I'm not turning up the boost. Just replacing the turbo with something a little more better...

[Auburn T5]

Uhh....

[volvoluvin]

Uhh....

As in confused as to why I wouldn't turn the wick up?

[Auburn T5]

among other things. The 15t doesn't make squat for boost. running the same amount from a 16t is not worth the trouble of doing the swap. If you're not going to be running 17~18 psi with a decent tune, you're wasting time/money IMO.

[volvoluvin]

among other things. The 15g doesn't make squat for boost. running the same amount from a 16t is not worth the trouble of doing the swap. If you're not going to be running 17~18 psi with a decent tune, you're wasting time/money IMO.

Ahh I C...

So, the information missing here is that my 15g is stock, tired and old...so why replace it with another 15g. I managed to snag a great deal on a relatively new 16t, so it goes in it's place, and I was already replacing the DP/exhaust system as this one is dead.

You need to understand my goals...my goals aren't massive HP, in fact, stock HP is fine by me. But, as things break/wear out, I'm going to "upgrade" the pieces but with only +1 improvement levels over stock. I.E. Shocks go, bilstiens and new springs go in; CBV wear's out, replace with HD one from IPD; IC piping is dead, so updgrade to RIP kit; etc...etc...

If I was looking for 300hp, I'd be the first to do all the big mods, just look at my 245, but lesson's learned on my 245 will keep me away from the crazy stuff on this car.

Cheers
-Phil

[BlackT5]

15g not 15t

[volvoluvin]

15g not 15t

/ninja edit...thx

[Geevs]

Don't forget the coolant and oil to top up what's leaked from the turbo swap.

In case you change your mind about the dp size, I have brand new uncut 3" mandrel s/s J-bend with 15" extension and 3" to 2.5" s/s reducer. I was planning to use this to build a custom downpipe but I just bought an angled OBX downpipe for a lot less than it would cost me to custom build the dp.

[volvoluvin]

Don't forget the coolant and oil to top up what's leaked from the turbo swap.

In case you change your mind about the dp size, I have brand new uncut 3" mandrel s/s J-bend with 15" extension and 3" to 2.5" s/s reducer. I was planning to use this to build a custom downpipe but I just bought an angled OBX downpipe for a lot less than it would cost me to custom build the dp.

Thanks for the reminder about the coolant and oil...appreciate it. I'll probably do an oil change at the same time anyway.

And I appreciate the offer, but I've already purchased the 2.5" flange from CJ, as well as the 2.5" piping/cat...etc...again, appreciate the offer though.

cheers
-Phil

[Geevs]

No prob - glad to help a local VSer. Your friend doing a TIG weld?

[volvoluvin]

So we did the swap on the weekend, and I can say that a 15g to a 16t is far from a straight swap...maybe I didn't word my post correctly at the beginning, but no one hinted at the issues we would be faced with while doing the swap.

Nothing we couldn't overcome of course, but jees...I thought someone might mention that the oil feedline on the 16t would need to be swapped with the 15g one, and that driver side coolant line would have to be swapped from the 15g to the 16t and a longer rubber coolant line adopted, and have an 1" cut out of the steal portion of the feed in order for it to clear the engine mount...Also needed to bend the 16t's passenger side coolant line to meet up with the original location...Oh ya...and the oil return line from the 15g would need to swap to the 16t...maybe this is all common sense to everyone, but it would have been nice to know before hand...oh well...experience is always expensive, so there ya go...a quick right up for someone who's planning on doing this with their 1995 T5-R...

And oh ya...we built a kick ass DP...


And the new turbo + DP + EST Exhaust combo makes for a nice big difference in the butt dyno...

[Aequitas_Veritas]

So we did the swap on the weekend, and I can say that a 15g to a 16t is far from a straight swap...maybe I didn't word my post correctly at the beginning, but no one hinted at the issues we would be faced with while doing the swap.

Nothing we couldn't overcome of course, but jees...I thought someone might mention that the oil feedline on the 16t would need to be swapped with the 15g one, and that driver side coolant line would have to be swapped from the 15g to the 16t and a longer rubber coolant line adopted, and have an 1" cut out of the steal portion of the feed in order for it to clear the engine mount...Also needed to bend the 16t's passenger side coolant line to meet up with the original location...Oh ya...and the oil return line from the 15g would need to swap to the 16t...maybe this is all common sense to everyone, but it would have been nice to know before hand...oh well...experience is always expensive, so there ya go...a quick right up for someone who's planning on doing this with their 1995 T5-R...

i didnt have any of those issues going from a 15g to 16t, they are nearly identical so how could you have all those problems?

[volvoluvin]

Damn great question...?? Was yours a 1995 T5-R?

Maybe the 16t I bought had wierd feedlines on it? Maybe the manifold is different on the 95? I dunno man...but there was no freakin' way on earth it was a straight fit...btw...I'm not whining, I'm just making sure my account is written up...

[Aequitas_Veritas]

Damn great question...?? Was yours a 1995 T5-R?

Maybe the 16t I bought had wierd feedlines on it? Maybe the manifold is different on the 95? I dunno man...but there was no freakin' way on earth it was a straight fit...btw...I'm not whining, I'm just making sure my account is written up...

yeah, actually it was a 95 T5R, then later a 96R, and never had that problem. Worst thing I had to do was to swap the exhaust housings so that my downpipe would still fit. I literally pulled all the lines and DP away, took off the turbo, swapped exhaust housings, put the 16t in and hooked everything back up.