fastwagonhawaii Posted February 19, 2011 Report Share Posted February 19, 2011 FWD pan is still in place. There's ~3" clearance with the front axle. I don't expect oil pickup issues because cornering G's in a FWD exceed acceleration G's in an Opel (I think..) not wth that motor in it... : ) Quote Link to comment Share on other sites More sharing options...
Johann Posted February 28, 2011 Author Report Share Posted February 28, 2011 Update, Since the OEM alternator bracket didn't fit anymore decided to change the already finished motor mount and add some connections for the alternator and the pulley bracket. Measurements were copied from the OEM mount The motor mount itself is in place of where the AC pump normally is mounted. Also made a gearbox mount using most of the parts of the Borg Warner AT mount. Because the whole combo is shorter compared to the V8-BW and also mounted lower in the chassis I decided to sort of brace it in to place. No fancy curvy artwork at the moment. The M90 mount, The "Brace" And the mount as it currently is fitted, Will make something smoother at a later time. For now it is strong enough to do the job. ME7 intake with 850 TB and idle motor. Part of the downpipe, Alternator and tensioner fitted, Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 28, 2011 Report Share Posted February 28, 2011 Very nice work! It's always a pleasure to look at your fabrication work. :) Quote Link to comment Share on other sites More sharing options...
Asko Posted March 1, 2011 Report Share Posted March 1, 2011 How nice, a second Opel with a T5 engine in the Netherlands!!! However I think yours will be on the road much sooner. Quote Link to comment Share on other sites More sharing options...
Johann Posted March 16, 2011 Author Report Share Posted March 16, 2011 Update, With most of the big changes finished the progress appears to be lesser by the day.. Lots of things done which can hardly be noticed. Had issues with the placement of the shifter shaft in relation to a cross bar in the chassis. Gave me a huge headache. Couldn't really picture the whole setup so I decided to cut a part out of the floor and just start fabricating something to get a bit overview of the whole situation. Many hours and lots of fun wit the CNC milling machine later something had materialized although a tad over engineered.. But it works for now. Had the drive shaft lengthened, 120 mm, and it fits like a glove. Decided to use a Saab intercooler for now, It looks pretty stealth IMO. Something less stealth, Made a dummy "steering pump" using an old Unorthodox underdrive crank pulley to maintain the stock belt routing and to make use of the stock belt tensioner. Used a 5PK1230 belt instead of a 6PK because the only load is the alternator. Exhaust is mostly done. 2.5" turbo back with a stock Volvo S60 T5 midpipe section including silencer or muffler or whatever it is. Hope it sounds truck like. 13G plumbing all in place except for one coolant hose. Still need to make a connection for the heater and the turbo to the main coolant pipe. Although many hardware changes still need to be done I decided to install most of the ECU wiring this week. This because I can't make up my mind which way to route everything and with all the wires connected to the engine I hope it will show which routing will be better. Also thinking about relocating both battery's. There's a main battery plus a battery for the wrench and I think it will be nicer to mount them side by side underneath the cabin. Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted March 17, 2011 Report Share Posted March 17, 2011 Coming along! Are you using a Volvo EMS, or standalone? Quote Link to comment Share on other sites More sharing options...
gdizzle Posted March 17, 2011 Report Share Posted March 17, 2011 awesome stuff, Johann. Quote Link to comment Share on other sites More sharing options...
Karl Buchka Posted March 17, 2011 Report Share Posted March 17, 2011 Something less stealth, Made a dummy "steering pump" using an old Unorthodox underdrive crank pulley to maintain the stock belt routing and to make use of the stock belt tensioner. Used a 5PK1230 belt instead of a 6PK because the only load is the alternator. This seems like a needlessly complicated/ugly solution. I was in the same position when I swapped a B5234T in my 242. I just removed the idler and shifted the tensioner down: I re-used the top power steering mount hole and drilled a new hole above the alternator. Anyway, this looks like an awesome project. You always do very nice work and it's a pleasure to see your updates. Quote Link to comment Share on other sites More sharing options...
Johann Posted March 17, 2011 Author Report Share Posted March 17, 2011 Dayum.. You know I never ever thought of removing that plastic idler pulley.. :blink: Quote Link to comment Share on other sites More sharing options...
Johann Posted March 17, 2011 Author Report Share Posted March 17, 2011 Coming along! Are you using a Volvo EMS, or standalone? PS, for making the engine work I decided to use the Link ECU which was in the C30. The C30 will receive a newer type Link G4 Xtreme standalone. Talking about the C30, Also received a Bell intercooler for the C30 , Very nice quality. Size is 600w x 140h x 110d Quote Link to comment Share on other sites More sharing options...
Guest Asko Posted March 17, 2011 Report Share Posted March 17, 2011 This seems like a needlessly complicated/ugly solution. I was in the same position when I swapped a B5234T in my 242. I just removed the idler and shifted the tensioner down: I re-used the top power steering mount hole and drilled a new hole above the alternator. Anyway, this looks like an awesome project. You always do very nice work and it's a pleasure to see your updates. What kind of belt did you use? Quote Link to comment Share on other sites More sharing options...
B Mac Posted March 17, 2011 Report Share Posted March 17, 2011 How come we don't have cool guys like you on this side of the pond.....Awesome work J. Always nice to see your work. Quote Link to comment Share on other sites More sharing options...
Karl Buchka Posted March 17, 2011 Report Share Posted March 17, 2011 What kind of belt did you use? 5PK560 if I remember correctly, but don't take my word for it. Quote Link to comment Share on other sites More sharing options...
Johann Posted March 27, 2011 Author Report Share Posted March 27, 2011 Slowly progressing. The engine ECU wiring is finished. Finding a nice route was the hardest part because despite the size of the car there isn't that much room to hide stuff. Wiring now runs from the back of the engine underneath the driver side through the wheel well in to the cabin the underneath the dash to the center console. Only have one picture of the engine side loom before is was soldered to the ECU side of the loom, Like mentioned the engine will use COP's because there isn't space for a distributer at the back of the engine. The head used on this engine doesn't have all the COP bolt holes present and is missing one bolt hole for the COP ground wires. Cylinder number 1 doesn't have a bolt hole for whatever reason but it did have a larger casted in hole at that spot. Threaded the hole managed to fabricate a small adapter thingy part to make it work. Also because this engine has some ridges with two bolt holes casted in for the old style upper engine mount the cylinder 5 coil needs to be rotated. Not really happy with the outcome because it will be difficult to fit a cover. Picture shows vent hose running between cylinder 1 and 2 but has been replaced with a type which runs between cylinder 2 and 3 now. Connected for this setup, Crank trigger Cam trigger MAP IAT TPS CLT TCV Knock1 Knock2 Idle control valve Wideband oil pressure sender 5 x injectors 5 x coils Engine will be running full sequential. Hope to finish the wiring in the coming week. Relay/Power still needs to be done. Also dash needs to be changed but didn't look in to that yet. Had a couple of fuel lines made, Exhaust needs hangers. Lambda still needs to be placed but a local tuning shop lost their wideband while having a car on the dyno and asked if they could borrow mine for the coming days, hope to have it back this week so it can be installed. In the mean time.. Killed a beemer Spring time sunshine, took a couple of pics of the cars, Attended a Volvo meeting yesterday but didn't have a running or road legal Volvo available so I decided to show up with some Volvo parts instead, And someone asked about the SD7's progress... Well.. Not much Quote Link to comment Share on other sites More sharing options...
Asko Posted March 29, 2011 Report Share Posted March 29, 2011 ME7 intake with 850 TB and idle motor. Isn't your throttle cable pointing the wrong direction? To the front of the car? The alternator mounting and the belt tensioner of the early v70 also fit without modification. Anyway, I like your manufacturing skills! Quote Link to comment Share on other sites More sharing options...
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