2000 Volvo S80 Project (T5 Engine Swap With M56L And Standalone Ems)

[S8ET6]

What state are you in and what's your plan for passing emissions?

Edit: just noticed that you said the car is RHD, so I assume that you're located in a different country than America

[Stefan Mohammed]

Yep, I'm in Trinidad in the West Indies where there are no emissions tests. No OBD-II trickery needed here to keep my car on the road!

[Stefan Mohammed]

[Major Update]: The car has started!

I got back the modified manifold this morning. A new flange was welded onto the manifold and the plenum was cut to allow the throttle linkage to fully open. We added a new 'tank' above the runner where the plenum was cut into to insure we got the necessary airflow.


Modified ME7 Manifold with 80mm Infiniti Q45 throttle body. Note the massive cutout in the plenum to allow the throttle linkage to open an close.


Extra 'tank' added to the plenum to make up for the restriction caused by the cutout for the throttle linkage.

The electrician came around noon and we found that the best place to mount the Haltech EMS was in the 'breakout box' behind the firewall in the engine bay, where the high speed canbus from the dash meets the engine bay. We spent the whole evening wiring it up; we had some problems getting power to the inputs (Coilpacks/Injectors) but we eventually decided to cut out the old power connector for the inputs from the B6294S and wire it up to the B5234T3.

Haltech EMS in its new home

We got some silicone couplers and 3" aluminum pipe to rebuild the throttle inlet tube but we needed an extra straight coupler and a 90* coupler as well, so we were not able to hook up the intercooler to the throttle body. Nonetheless, the tuner came around 7:30 PM and he did some basic engine configuration. The car was able to start on 3 cylinders at first, and start fairly easily at that). We did some troubleshooting and by about 8:45 we were idling fairly smoothly on all 5 cylinders. We set a boost cut at 2 psi and a rev limiter at 3200rpm as there was no boost entering the system.

We need to do some modifications to the fuel system and to some other areas before we could really start to tune the car effectively. The fuel rail has to be made into a return-type system, we need to get an external fuel pressure regulator, we need to hook up the wideband sensor, add the bracket for the throttle cable, drill the firewall for the throttle cable, get an appropriate throttle cable, weld a bracket onto the accelerator pedal, get a step-up solenoid for the A/C system, add an intake air temperature sensor, finish the throttle inlet pipe, fill remaining fluids and bleed the entire system and finally, do a proper road tune.

The D088 intercooler fit nicely into the stock location. The way how the intercooler piping is, we weren't able to route piping further into the radiator stack without having to modify some sheet metal in order to get the intercooler to the front of the car. The A/C system would also need some rerouting to make it work effectively if the intercooler were to be front mounted.

There's still lots of work to be done but the project is finally nearing completion, I can't wait

Oh... one last thing... here's a video of it running :D https://www.facebook.com/photo.php?v=10151651135718294&set=vb.728018293&type=3&theater

P.S. Lucky (ARD) if you're reading this we need to discuss somethings about feeding information to the DIM; the electrician said that he thinks the crank sensor is supposed to be a ground-based trigger but he's getting 2.5v signals on BOTH wires so he didn't want to take the chance to wire the ECU back to the crank sensor to avoid any issues until this is confirmed. We also hooked up the coolant temperature line to the Haltech and to the ECU but the gauge on the DIM is not working; we're not sure if it's a wiring problem or a problem with the CAN data.

[adamdrives]

Enjoying your progress!

[Ihatespeedbumps]

Really nice work here, can't wait to see this thing up and running!

This is the ONLY good use for an S80 with a six cylinder.

[Commander Riker]

Nice work! I never knew one could order part of an S60!

[Stefan Mohammed]

Nice work! I never knew one could order part of an S60!

Thanks! We didn't order it though... I got a friend to purchase a S60 which had rear-side impact and we cut it in half and shipped it into my country.

[Stefan Mohammed]

[General updates and a setback]

So we did a little bit of work today on the car. We identified that the fuel system does in-fact have a return, we removed the driver's side door to run wires and drill holes for grommets for the AEM failsafe wideband AFR gauge that's being installed in the door, cleaned up some of the vacuum lines and Haltech Wiring, and removed the OEM downpipe. I had a fabricator come in today to look at intake manifold and to look at options for a pedal assembly. We quickly identified that we need to reroute the charge-air pipe and identified that the pedal assembly has to be swapped and modified accordingly. The discussion on the throttle linkage took up quite some time so we weren't able to do much more.


My friend Fahim working under the S80, HI FAHIM!


Driver door out of the car while we wire the wideband wires into the door jam

We did however get to install the new Snabb delrin shifter base plate difference - significant difference in shifter feel with 5 minutes of work; it removed most of the mushy feel in the shifter assembly but the shifter still has some mushyness to it, steel shift bushings should help with that.

The problems with the throttle linkage also created another problem. My tuner is flying out of the country for 2 weeks from Sunday and it is now clear that we would not be able to get the car back up by Sunday. The car wouldn't be driveable for at least another two weeks then, so I have to wait for my car a bit more. Nonetheless we would do some pretty nice work in the following weeks to make up for the extra 'free' time we have.

[Correction to previous post: the fuel line does NOT have a return]

[Stefan Mohammed]

[update]

Today we identified some potential solutions to the accelerator pedal assembly, tried to find a convenient place to mount the newly bought AEM fuel pressure regulator, tried to find a place to mount the D088 catch can and installed the back brakes. We didn't get actually didn't mount any hardware as yet but I have some pictures of the brake install. We also modified the DIM (changed gauges over from the S60's DIMs and removed some warning lights that would now be permanently be lit thanks to the Haltech.

The rear brake system is pretty simple: Stoptech Street Performance pads over Powerslot Cryo-Treated 302mm Rotors with stainless steel braided lines. The front is where the big brake (6 piston EST caliper + 330mm 2-Piece Floating X-Drilled + Slotted Rotor) would be installed but I need at least 18" rims for that.

Rear jacked up and ready to be worked on (the fluid leaking below is P/S fluid that leaked from the pump when the wheel was accidentally turned)

View of old, worn and rusty rotors/pads/brake line and a view of my suspension

View of the new rear brake setup

Closeup of SS braided brake lines


My friend Fahim (again) bleeding the brake system

The finished product!!

Modified DIM on the right and donor S60 DIN on the left (guages swapped over, a few LEDs rerouted to the Haltech and a few LEDs removed

My other friend Irfaan (HI IRFAAN!!) crawled up in the foot-well trying to remove the accelerator pedal

[Emiel]

[adamdrives]

Having many friends is helpful

[Stefan Mohammed]

Having many friends is helpful

It sure is!

[Micro update]: I'm sending the accelerator pedal, the intake manifold and the throttle body to the fabricator on about Tuesday so we could finish up the throttle linkage part of the job. All that remains to do after that before road tuning the car is to bleed the clutch, reroute most of the vacuum sources in the car and modify the fuel system. Since we have a lot of time (comparitiviely) before the car starts we plan to do some miscellaneous work as well; install some other chassis braces, tidy up some things that need to be tidied, start the re installation of the interior, etc.

[Brady]

A T5 M56 combined with S80 style...

[Stefan Mohammed]

[update]: Got the return line installed today and we started finishing up the wideband setup. Extremely tired tonight so I'd upload pictures tomorrow.

Quick list of things that still needs to be done:

• Throttle cable has to be modified to have a snap fitting for the firewall
• Accelerator pedal needs to be fabricated
• Intake manifold needs to be modified to have some more vacuum ports and to have a bracket for the throttle cable
• Charge-air pipe needs to be redone
• OEM Fuel Pressure line needs to be modified to have a braided termination for the modified fuel rail
• Return Pipe needs to have fittings installed on it
• Fuel Rail needs to be fitted with new fittings for pressure and return lines
• Wideband needs to be wired in
• A few more vacuum hoses need to be connected
• Fuel pressure regulator bracket needs to be fabricated
• Fuel pressure regulator needs to be installed
• Catch can needs to be installed
• Bung needs to be welded to the downpipe for the wideband (or a custom downpipe has to be made)
• Front/Rear crank seals need to be changed
• Idler Bearing needs to be changed
• Timing belt pulley needs to be changed
• Water pump needs to be changed
• Clutch Master Cylinder + Clutch Slave Cylinder needs to be changed
• Interior needs to be reinstalled
• Powersteering Hard Line needs to be rerouted

As you could probably tell from the list, the engine is leaking a bit of oil, the clutch is giving problems (system looses pressure but doesn't leak fluid, the clutch pedal fails to return to the rest position). The fabricator is confirmed to be coming either on Thursday or Friday of this week to finish up the throttle linkage segment of the build and we should finish the fuel system (minus fittings and the braided line) by Friday night. I have to wait a while before I touch the seals as I'm waiting on parts to be shipped internationally to Trinidad from FCP Euro, via a US-based freight forwarder.

[Stefan Mohammed]

[Pictures from the other night]:

New fuel return line routed behind the OEM pressure line and the fuel filter.

From left to right: Breather line, Pressure Line, New Fuel Return Line.

Fahim modifying the plastic plate that protects the fuel lines under the car.

Reinstalling the protective plate.

Everything done, looks like a factory install to me.

In-tank fuel pump (OEM Pressure line connected at the bottom, the OEM return disconnected [the OEM system has a single line running from the fuel rail back to the pump that Ts off into a return and a pressure fitting at the pump] and the new Return at the right of picture).

Found a grommet located directly behind the right side marker lamp where we could route the vacuum for the wideband failsafe to be installed in the door.

Drilling a hole in the door for a grommet for the wideband connections.

My other friend Kevin only found out that there was a build log of the car on Volvospeed the other night and when he saw pictures of everyone else (except me) he demanded that he gets his own pic on the build thread. So here's a pic of him sitting on the driver seat reading this thread on his phone!

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Tomorrow should be a pretty busy day with the car again. The fabricator is coming to take measurements for the accelerator pedal and for the throttle bracket, we should be mounting the fuel pressure regulator and connecting some remaining lines, make final adjustments to the wideband and door setup and we should also remove the axles and drop the gearbox in preparation for changing out the seals. One way or the other some progress is being made!