494 replies to this topic

[Zappo]

Ok, I finally have the car on the road.

Started 2 weeks ago and had hopped to get the whole thing done in a weekend. Turned out not to be the case.
Technically it started 4 years ago when I first started to collect the parts.











Last pic of this engine in the car.



Uh, got a few white blocks here, and some other engines as well. Oh, and some toys.




The crew working.






Its out!




Uh, needed some modification to fit.




Here is why.


More pics to come and possibly a time lapse video if I can get the size down.

Here are the specs on the engine,

1996 B5234T5 “850R” Main Block (2.3l)
OS1 (.020”) Cylinder Walls
Eagle H-Beam 139.5mm Forged Connecting Rods
ARP 2000 Rod Bolts
Diamond Racing OS1 (.020”) Teflon Coated Pistons
Decked Block
850R Cylinder Head–Ported/Polished–5 Angle Valve Job–20 New Valves/Valve Seals
Volvo S60R Exhaust Manifold (Ported/Polished)
Volvo 850R Intake Manifold (Ported/Polished/Powdercoated)
Volvo 960 3” Throttle Body
Garrett 3076R .82a/r Ball Bearing Turbo with AN Oil/Cooling Lines
ATP Turbo Ultimate Internal Wastegate
Tial 50mm Blow Off Valve
Siemens 630cc Injectors
Stainless steel, Mandrel bent, VBand, Polished, Tig Welded Downpipe
Aluminum, Mandrel bent, , Tig Welded, Polished Intercooler Pipes

Some of you should recognize the engine.

Manual swap at the same time. 98 M56H with Quaife LSD installed.
Turbo Tuner is managing the whole thing.

[gdizzle]

Congrats George!

[Johann]

Nice job!

[Zappo]

We got the engine back in the car the same day, but didn't get it close enough to fire up the engine until the next day. That is when we ran into the big problem. After bleeding the slave cylinder on the clutch, it would blow out the seal. It would rip the seal in 2. After destroying several slaves, we gave up on that issue to do research.

The engine fired right up, but only ran for about 15 seconds before dying. It had 2 issues. First was there wasn't an IAC connection on the pipe going to the throttle body. The car will run without it if you unplug it, but it is nice to have. The other issue is the tune I had in there was set for 465cc injectors and it now had 630cc, so it was too rich. Easy to fix with TT, but we called it a day because of the clutch issue.

Danny wasn't free for another 2 weeks, so the car sat and Mitch's place until yesterday. All research pointed to a release arm problem, so we had to drop the engine out again. In the mean time I got the intake pipe modified so the IAC would work.

Dropped engine, pulled it off the subframe and seperated the transmission off. Clutch installed correctly, arm installed correct. Brian figured out the problem was the clutch arm was hitting the bell housing before it would fully disengage the transmission. That was enough to pop the seals. The cause ended up being the pivot ball for the arm was too short and was missing a spacer. There was another manual sitting there and that is how we figured out it was missing something. 2 washers later and it was now at the correct height.
Put everything back together and back in the car, bleed the clutch and it was working!

About 8 hours of work to install 2 washers. The transmission is from a 98 and since that was a transition year to the internal slave, this could have been an internal slave trans so it never actually had an arm attached, although when I bought the transmission it came with an arm.

Ok, it is going to be a bit before I post anything else because I am going to go drive the car some more. I have to get that engine broken in!

Big thanks to all who have helped with this, especially Danny for helping the whole time and doing the "skilled" labor, Mitch for his help and the use of his shop, Brian for figuring out my big problem and his help yesterday. Carson also helped out. NWC team effort, as usual.

[bergmjs]

Are you missing the little plastic ball cap that goes on the pivot point?
As discussed here: http://volvospeed.co...4067-pivot-pin/

Video showing the difference in that thread:

[fivex84]

What kind of power are looking to put down with that 3076R?

[Zappo]

What kind of power are looking to put down with that 3076R?

Not sure. It should do 400 easily, but I am not really after monster power. The 3076 might be too big for my needs, but I will have to see how this tunes.

Are you missing the little plastic ball cap that goes on the pivot point?

Interesting. This may be the case. I had 2 arms and pretty sure that wasn't on either. Mitch had one also and I didn't see one on his. One of the arms I have came out of a working trans along with the rest of my swap parts.

[Oreo931]

Awesome George

[maciekb2002]

it looks like your specs are almost the same as mine.
I can tell you that 0.63 ar housing will work better for you .
You not gonna like turbo lag
Also if you using 850R clutch it will start to slip quickly
Have fun
Enjoy HP

Edited by maciekb2002, 08 May 2011 - 11:37 PM.

[sconeman]

Are you missing the little plastic ball cap that goes on the pivot point?
As discussed here: http://volvospeed.co...4067-pivot-pin/

I can say for sure that I'm missing it. I could've sworn something went there. Oh well hopefully I won't have to pull the tranny out.


Looks great! So you amassed parts for 4 years huh? it must feel great to get it installed finally.

[herz3mc]

Looks great George - can't wait to see it out on the track.

[Zappo]

it looks like your specs are almost the same as mine.
I can tell you that 0.63 ar housing will work better for you .
You not gonna like turbo lag
Also if you using 850R clutch it will start to slip quickly

I do have an R clutch. I will see how it goes.

I figured the .82 was a bit big, but it all came with the engine. I may swap it at some point depending on how it works out.

Looks great! So you amassed parts for 4 years huh? it must feel great to get it installed finally.

The transmission I bought over 4 years ago and has just been sitting in my garage. Most of the swap parts I got about 20 months ago. TT last August and LSD in October. Engine has been around for a few months also, but that allowed me time to buy the stuff i needed to make it fit.

[Zappo]

More pictures.


About ready to go in. Downpipe doesn't have a flex in it, so I have one right behind it.


Engine in, the first time.




Pictures from today.


Haven't installed any of the covers yet since I am still wiring up my Zeitronix to the new engine.


Downpipe has turned gold on me. I have exhaust wrap and a heat shield to go on, but I still need a bung welded onto the DP for the EGT probe.

[bergmjs]

Yea, the little plastic ball is only held onto the arm by 2 really thin plastic clips, so after 15 years of use it just falls out as soon as the compression of the arm is relieved.

Everything else looks beautiful though.

[JMK33]

Holy smokes, lookin good. Cant wait to hear this thing

[B Mac]

George that looks awesome! I wanted that motor so bad, it's just too pretty . Congrats.

[exexpat]

Beautiful and you did the manual swap! How long has that trans sat in your garage?

[sconeman]

oh snap! this is the TKI engine?! you lucky dog

[mdlimy]

ahhh you finally snagged josh's motor
now buy the cop upgrade for TT to top it all off
i am now envious of your car, have fun with autox with that .82ar, but the 1/4mile times are gonna be something to look forward too
congrats

[Zappo]

oh snap! this is the TKI engine?! you lucky dog

After 7 months of teasing me with it, I had to buy.