Engine rebuild project

[oblark]

Got bored on monday so I decided to take my old engine apart, The bores are showing signs of wear and so are the shell brgs.

I`ve spent the morning steam cleaning all the parts off, then this afternoon phoning around for prices.
I can get a re-bore for £60-80 plus vat but the cost goes through the roof for 0.40mm oversize pistons, £591.10 inc vat plus del from FRF volvo.

Does anyone no of a good company that sells good quaility pistons ???

Before cleaning.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0698.jpg
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0699.jpg
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0700.jpg

After cleaning.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0720.jpg
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0717.jpg
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0718.jpg
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0719.jpg

[PHIL V70R]

watching with intrest sir...

[Jamest5r]

That's the sort of price your looking at im afraid, 81.5mm forged start around that price and go upward's.

£600 plus import tax......http://www.vivaperformance.com/forged-pistons-850-s-c-v70/

[oblark]

With the cost of the pistons, forged rods, shell brgs and gaskets etc this little project mite take a while to complete.

But should be able to take some serious bhp :)

[claymore]

Waw, I'm glad I got my engine for £500 (even though I didn't pay for it)

[merc85]

Arrrrrrrrgh memories lol that Cylinder head brought it all back lol

[p fandango]

i'd buy another block with less wear on it & stick with stock pistons

[Jamest5r]

With the cost of the pistons, forged rods, shell brgs and gaskets etc this little project mite take a while to complete.

But should be able to take some serious bhp :)


At a rough guess i think i paid £380 for forged rods, £500 melhe pistons, plus rebore, belts etc and it all put back together i reckon about 1300 quid i paid and that's about as cheap as your gonna get.

[oblark]

At a rough guess i think i paid £380 for forged rods, £500 melhe pistons, plus rebore, belts etc and it all put back together i reckon about 1300 quid i paid and that's about as cheap as your gonna get.

That`s the sort of figure I was looking at :)

At the end of the day I will end up with a new full rebuilt engine :)

[Jamest5r]

That`s the sort of figure I was looking at :)

At the end of the day I will end up with a new full rebuilt engine :)

Yep thats what ive got and it feels lovely might be able to nudge the high 380's/550's now i have a clutch that wont slip :)

[oblark]

Arrrrrrrrgh memories lol that Cylinder head brought it all back lol

Do you want to port this one ??:)

[Wobbly Dave]

Having just been through the process - I was kinda lucky with the forged pistons - in so much that they came from an abandoned project. 81.5mm forged wiseco pistons cost me 500 quid. The rods (as recommended by Smithy) - K1 technology from Co-ordsport - were 500 ish. Donor engine - is not a problem as you already have one. A local cylinder head specialist refurbished the head & rebuilt the refurbished & rebored block for a very reasonable 1300 quid

HTH

[oblark]

A local cylinder head specialist refurbished the head & rebuilt the refurbished & rebored block for a very reasonable 1300 quid

HTH

The head that was on the engine has 6 bent exhaust valves so I got a refurbed head from Dalhousie and I will rebuild the engine block myself as I`ve done a few in my time :)

[Wobbly Dave]

Super, great - smashin. I would have re-assembled it myself but the VVT cam gave me the wibblies.

[oblark]

Removed the main brg shells today and checked the brgs journals for size.

The brg journals are standard size :smile:

The block has a B stamped on it for the brg classification and I think the crank has a C stamped on it for the brg classification,
So in the Haynes book of lies the brg shells should have a yellow mark on them but I can`t find any marks but I did find some part numbers,

Thrust brg 9146180 and 9135850
Main brgs 9146170 and 9135840

Can someone check/no a web site that lists the part No. to confirm brg sizes :smile:

[Jamest5r]

Removed the main brg shells today and checked the brgs journals for size.

The brg journals are standard size :smile:

The block has a B stamped on it for the brg classification and I think the crank has a C stamped on it for the brg classification,
So in the Haynes book of lies the brg shells should have a yellow mark on them but I can`t find any marks but I did find some part numbers,

Thrust brg 9146180 and 9135850
Main brgs 9146170 and 9135840

Can someone check/no a web site that lists the part No. to confirm brg sizes :smile:

Pault5estate had a load of info on shell's etc from when he done his its a very complicated mine field, mine looked ok so didnt mess lol.

[LiamT4]

Yep thats what ive got and it feels lovely might be able to nudge the high 380's/550's now i have a clutch that wont slip :)

Do you mean 380bhp/550nm? Surely after all that work the engine could take a lot more?

[oblark]

The K24 finally arrived from chad, so after work today I went out into the garage and test fitted the turbo on the engine.
As the S60R manifold is still on the car so I used the old 850 manifold.
Had to re-shape the oil feed pipe as the V70 block doesn`t have the 3 inspection covers for the piston oil injectors.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0758.jpg
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0759.jpg

Also I`ve started to polish the inlet ports.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0725.jpg

[claymore]

looking good mate

[oblark]

Haven`t done much to the engine rebiuld for a while,

Managed to get hold of 4 B4204T5 pistons ( 4 more next month )

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/DSCF4837.jpg

Had some spare time today so I`ve tapped the PCV return hole ready for a 1/4 bsp blank and machined up a plug to go in the main block vent.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0815.jpg

[oblark]

Made the most of the sunshine today and started to paint the head/cam cover

Also drilled a hole in the spark plug cover for the breather

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0837.jpg
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0838.jpg

[oblark]

I cut the flange off of the K24 downpipe, when measured it was found to be 2 7/8
So i took it to work today and bored it out to 3 inches :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0850.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0850.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0851.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0851.jpg.html)

Forgot to mention these arrived last week from Blackbeast, thanks :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0855.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0855.jpg.html)

[oblark]

Had some spare time so I drilled 15 lightning holes flywheel. :)

As soon as I`ve got Pedro`s light weight crank the pair of them will be dynamically balanced.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0857.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0857.jpg.html)

[M-R-P]

Nice work there Rob. It's all coming together nicely ;)

[AndysR]

Nice work, I like the cam cover :smile:

[oblark]

The stainless shim steel arrived this week so had ago shimming the liners,
I managed to two bits of shimming in the gap,
To stop it from coming out the ends where bent over and loctited :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0882.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0882.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0881.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0881.jpg.html)

[claymore]

Nice job mate, that will work nicely

[Jamest5r]

Very neat :)

[t5 pete]

Very nice what grade stainless did you go for the shims.

[oblark]

Very nice what grade stainless did you go for the shims.

The stainless shim is 316,

[M-R-P]

Top work as always mate ;) she's gonna take some big boost when that lump gets fitted. You still got that supercharger? ;)

[oblark]

Top work as always mate ;) she's gonna take some big boost when that lump gets fitted. You still got that supercharger? ;)

Yes and I`m not fitting it :)

[claymore]

Did someone mention Supercharger, wouldn't be an M62 would it?

[oblark]

Did someone mention Supercharger, wouldn't be an M62 would it?

All I now is it came out of a C180 coupe merc :)

[claymore]

All I now is it came out of a C180 coupe merc :)
M45 then.

[oblark]

Been busy out in the man cave for the last few evenings :)

Managed to knock up a 3" stainless downpipe, It fits :)

the welds aren`t to pretty but hold it together :) it will get wrapped in heat wrap tape.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0898.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0898.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0899.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0899.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0905.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0905.jpg.html)

[Jamest5r]

Nice work :) looks bloody tight at one point lol, so when you gonna fit this?

[oblark]

Nice work :) looks bloody tight at one point lol, so when you gonna fit this?

It just clears the steering rack surport by 3/8 inch :)

I`ve still got to get hold of another piston then it`s off to the engineers to be rebored to 2.4

Hopefully will be ready to go in the car later this year :)

[V70 Graham]

Nice work Rob, some great builds should be finished this year.

[Wobbly Dave]

you ditching the rear gearbox mount?

[oblark]

you ditching the rear gearbox mount?

No, it`s under the compressor housing :)

[graemewelch]

Been busy out in the man cave for the last few evenings :)

Managed to knock up a 3" stainless downpipe, It fits :)

the welds aren`t to pretty but hold it together :) it will get wrapped in heat wrap tape.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0898.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0898.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0899.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0899.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0905.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0905.jpg.html)


nice work there. but if id known i could of sorted you a flange rather than cut up a cat

bit cheeky like but do you do much machining. always looking for some one to do a few jobs

[merc85]

Looks flippin good bud :)

[oblark]

nice work there. but if id known i could of sorted you a flange rather than cut up a cat

bit cheeky like but do you do much machining. always looking for some one to do a few jobs

I only had the downpipe to the flexi joint :)

I do abit of basic machining as and when I need to do some and when I`m in the workshop.

If I need anything more complex I know a good machine shop :)

[smithy]

What turbo is that mate

[oblark]

What turbo is that mate

It`s a k24 :)

[Wobbly Dave]

No, it`s under the compressor housing :) I see the rubber part - but usually that's connected to the gearbox via a bracket

this is Paul t5 estates...

http://img.photobucket.com/albums/v16/paulxr4x4/Volvo%20build%20and%20evos/949fd3e2.jpg

[Kingsford G]

Nice work mate.looking forward seeing what it puts out,gotta be well quick and lots of fun with an mbc

[oblark]

I see the rubber part - but usually that's connected to the gearbox via a bracket

this is Paul t5 estates...

http://img.photobucket.com/albums/v16/paulxr4x4/Volvo%20build%20and%20evos/949fd3e2.jpg

As I will using the M66 gearbox I had to make my own rear gearbox mount :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0847.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0847.jpg.html)

[Wobbly Dave]

Aaahh! I wondered why I couldn't see it LOL

[oblark]

I dropped into the machine shop to see if any of the bits & bobs I`m having made where finished,

And this was finished


http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0913.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0913.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0914.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0914.jpg.html)

More to follow :)

[AndysR]

Been busy out in the man cave for the last few evenings :)

Managed to knock up a 3" stainless downpipe, It fits :)

the welds aren`t to pretty but hold it together :) it will get wrapped in heat wrap tape.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0898.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0898.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0899.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0899.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0905.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0905.jpg.html)

Smart work there! Seeing that engne sitting there complete on a subframe really makes me feel good about cleaning the steering rack heat sheild on mine knowing you can't even bloody see it! lol

[oblark]

Finished the downpipe off today and made a tool to lock the cams in place :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0918.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0918.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0919.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0919.jpg.html)

[oblark]

Been busy today doing a few more jobs on the engine, Picked the throttle block from the machine shop during the week so fitted it and the 3" throottle body, with it fitted the linkage was made and welded together. Made the most of the warm weather and sprayed the sump. Also fitted all 5 pistons to the forged rods, A big thanks to Alex (gatos VOC member) for all of the V40 T4 pistons :B_thumb:

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0934.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0934.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0928.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0928.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0931.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0931.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0933.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0933.jpg.html)

[Wobbly Dave]

loving your work.

[claymore]

Looking really good :)

[Tomcat]

Loving this thread, looking forward to seeing it fitted.

[oblark]

Quick update, made a start on the stainless RIP kit, The blue piece of pipe is where the DV mite be going :wink:

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0978.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0978.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0979.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0979.jpg.html)

[stribo]

Looking good Rob, I wish you'd hurry up and finish it, so you can bolt it up to my car. ;)

[oblark]

Looking good Rob, I wish you'd hurry up and finish it, so you can bolt it up to my car. ;)

In your dreams :)

[martybelfastt5]

looking good!!!

[AndysR]

Nice one, making some great progress with it, once question and if I have missed your reasoning I apologise.. Why T4 pistons?

[Wobbly Dave]

I thought it was to lower the compression?

[M-R-P]

The T4 pistons (I can't remember which incarnation) were just the right size to accomodate the bores (can't remember if it's to cope with wear or a rebore).

Coming on nicely there mate. You'll have to do a build video with the A-Team music :)

[oblark]

Nice one, making some great progress with it, once question and if I have missed your reasoning I apologise.. Why T4 pistons?

The reason I'm using second hand t4 pistons is they easy to get hold of and are cheaper than 850 oversize pistons :)

[oblark]

Another quick update,

Haven`t done much seens the last post because I could be bothered but I`ve cut the end off the inlet manifold and sent the stainless top pipe off to be welded.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163536.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163536.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163737.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163737.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163758.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163758.jpg.html)

[Wobbly Dave]

I am beginning to wonder if it would not be easier to convert my ME7 back to a manual throttle - as I am beginning to lose my rag with on-demand systems.

[oblark]

I thought i would update this thread :)

Fitted the RN crank and checked the bearing clearance,

The clearance of the main bearings is between 1-2 thou radial clearance :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/3cf30077-41ae-44e5-a435-64323a8ee293.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/3cf30077-41ae-44e5-a435-64323a8ee293.jpg.html)

[p fandango]

good to hear it fitted with no issues, don't suppose you weigh'd it & your old crank for comparison did you?

[graemewelch]

Another quick update,

Haven`t done much seens the last post because I could be bothered but I`ve cut the end off the inlet manifold and sent the stainless top pipe off to be welded.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163536.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163536.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163737.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163737.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163758.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20130711_163758.jpg.html)


what the end of the manifold cut off for

[oblark]

what the end of the manifold cut off for

The ME7 inlet manifold had to be cut back to allow it to clear the PAS pump

[t5 pete]

what the end of the manifold cut off for

Its because it fouls the power steering pump

[MoleT-5R]

excellent thread, just been back and re-read it, a lot of food for thought, keen to see the results when finished, keep up the good work

[oblark]

I was going to use hylomar on faces of the block to intermediate section and to the sump or would I be better off use a gasket sealant ?

[960kg]

I was going to use hylomar on faces of the block to intermediate section and to the sump or would I be better off use a gasket sealant ?

This is a great thread......very well done and the clarity of the pictures.

We used to use Hylomar in the `60s it was used also by Rolls Royce to assemble there engines and is still the best.

Having said that because the white block is in 5 different sections Volvo`s special adhesive applied with a roller not only seals but acts as a glue and therefore sticks the whole lot together for block strength which will not flex.

Seeing as you have paid out a bit on parts plus all the work it would be silly i think that just for the sake of £30 odd to spoil the efforts.

Especially with the horses i expect this engine will produce you want it as a solid block with no chance of flexing. As you know the two halves of the main and camshaft bearing supports are the actual alloy block and not as old school bearing caps!!

Good luck with what you choose to do.

[p fandango]

Have u ported the head to match the newer me7 manifold?

[oblark]

Have u ported the head to match the newer me7 manifold?

The port shape on the head is the same as the me7 inlet manifold.

The ports in the head will smoothed and polished :)

[iancho]

Really interesting, keep up the good work Rob :smile:

[oblark]

A set of piston rings where ordered today, also phoned FRF and ordered the o rings and gaskets to rebuild the bottom end.

Hopefully it all should arrive by the weekend :)

[Biff]

Glad your going for it rob.
Beast. :)

[oblark]

The piston rings arrived from Germany but the gasket/o rings didn`t :(

The main brg bolts where torqued up then the piston/rods where fitted :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/P1000716.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/P1000716.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/P1000710.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/P1000710.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/P1000723.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/P1000723.jpg.html)

Watch this space as more to follow tomorrow :)

[p fandango]

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/P1000710.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/P1000710.jpg.html)
they look identical to ME7 short skirt pistons, what length rods you running?

http://imagizer.imageshack.us/v2/800x600q90/829/4qox.jpg

[oblark]

The pistons came from 2 x V40 T4 2.0 litre

The rods are 139.5 m/m long

[oblark]

Here is a short video of the rebuild so far.....


http://youtu.be/BhtwuxeF0z0

And here is a preview of what the sngine will look like when finished...

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/P1000729.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/P1000729.jpg.html)

[graemewelch]

looking good. thought you might of went for a 3" down pipe

[oblark]

looking good. thought you might of went for a 3" down pipe

It is a 3" down pipe :)

[graemewelch]

It is a 3" down pipe :)


sorry my mistake. at first glance i thought it was a straight flange. just thought after all the effort thats been put in why would he restrict it with a 2.5" exhaust. ill look closer next time befor opening my mouth

[M-R-P]

Liking the music off the video Rob, and the editing skills are coming on too :)

Keep it up dude ;)

[V70 Graham]

Liking the music off the video Rob, and the editing skills are coming on too :)

Keep it up dude ;)

Wot he said, liking the video mate.

[stribo]

Ooo, shiny, would look good in my C70.;)

[S70T5Chris]

Nice bit of Rob Zombie!! Cool vid mate, keep it coming I say!

[AndysR]

Good to see things kick started again, did (will) you hone the bores or is it all as removed?

[Harvey]

So is a new oil pump on the way as it's missing or just waiting for the gaskets set to turn up.

[oblark]

back by popular demard here is a update on the rebuild.

The head was stripped down for the ports polished and to have valves cleaned and lapped in.
It was then off to the dishwasher for a long hot wash ready for assembly today.

New valve stem seals where fitted, I had to modify a valve spring compressor to get the valve springs out as they sit so far in the head.
Timed up the N/A cams to inlet 2 degrees advance and exhaust 2 dgrees retard, turned the engine over gingerly through 2 revolution of the crank and all was ok :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140126_142825.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140126_142825.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140126_143219.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140126_143219.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140126_142915.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140126_142915.jpg.html)

Just need to get some seals for the turbo and a water pump then it`s finished :)

[merc85]

Looks great buddy well done mate :)

[JT]

looks fantastic! nice work! :B_thumb:

[S70T5Chris]

That is looking fantastic Rob.

[V70 Graham]

Looking good mate, shouldn't be too long now before it's all done.

[abdul]

Very nice keep the good work up

[M-R-P]

Big shiny thingy :)

It'll look great in a modified Honda 400-4 frame ;)

[graemewelch]

looks good. any pics of the head work. its a job ill be doing shortly. a new head is on its way

[Shinsplintz 101]

Really enjoyed this thread - my technical expertise begins & ends atm with changing the boot struts! One day i'll have a bash at rebuilding one of those big oily things, in the mean time it's nice to watch from the side-lines! Liking the satin black look too - nicely understated.

Keep up the good work, all the best, Morgan

[Wobbly Dave]

I hope it runs as good as it looks.

[t5 pete]

back by popular demard here is a update on the rebuild.

The head was stripped down for the ports polished and to have valves cleaned and lapped in.
It was then off to the dishwasher for a long hot wash ready for assembly today.

New valve stem seals where fitted, I had to modify a valve spring compressor to get the valve springs out as they sit so far in the head.
Timed up the N/A cams to inlet 2 degrees advance and exhaust 2 dgrees retard, turned the engine over gingerly through 2 revolution of the crank and all was ok :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140126_142825.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140126_142825.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140126_143219.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140126_143219.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140126_142915.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140126_142915.jpg.html)

Just need to get some seals for the turbo and a water pump then it`s finished :)


Looking great reminds me of when I did mine, im in two minds weather to have the rocker cover powder coated black or weather to just really give it a good clean and light sand to brighten it up to keep the original appearance but if im honest I do prefer it done in black

[Biff]

Looks like I may have to join you & Steve on the engine builds.
Very impressed with the finish on the engine rob, it's better than oe.
Will certainly be using this thread for reference.

[AndysR]

How good does that look! Love the black head/rocker cover look, bet you can't wait to get it fitted and running now with so little left to do :)

[artfulflounder]

Any progress......you got the engine in and running yet?

[AndysR]

What he said ^^^

[dant5r]

https://m.facebook.com/groups/692214850823998

Came across this today on Facebook.

Is this same guy building this engine.

[claymore]

That link makes no sense to me?

[M-R-P]

https://m.facebook.com/groups/692214850823998

Came across this today on Facebook.

Is this same guy building this engine.

yes mate, that's Robs build, half way down the page.

[oblark]

For those who haven`t seen the updates to this project on facebook here they are.

Downpipe and decat pipe made up.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140208_163556.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140208_163556.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143428-1.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143428-1.jpg.html)

The M66 gearbox has been cleaned and painted.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143329.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143329.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143309.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143309.jpg.html)

And the ECU had a switch fitted ready for flashing.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140212_172859.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140212_172859.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140212_173320.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140212_173320.jpg.html)

[p fandango]

looks good, but i can't believe your doing all that work & using a normal T-5 manifold

[oblark]

looks good, but i can't believe your doing all that work & using a normal T-5 manifold

The T5 manifold is just being used to mock up the turbo :) I`ve got a S60R manifold on the car at the moment :)

[p fandango]

The T5 manifold is just being used to mock up the turbo :) I`ve got a S60R manifold on the car at the moment :)
thats ok then ;)

[AndysR]

Looks good so far :)

[smithy]

Looks very nice mate and should push some good power too

[Wobbly Dave]

Loving your work - a word of warning - make sure if you've painted the gearbox that the mating surfaces are paint free. I had that issue & the car wouldn't start/run properly because it interfered with engine earthing.

[artfulflounder]

I'm a miserable git I don't do facebook....so its good to see you're getting on well.

will be good to see the results when you start tinkering with the ecu.

[960kg]

Showing my ignorance here i expect but what gearbox is that as the change levers are different on my `97 M56 manual box??

[M-R-P]

Focus ST gearbox mate ;)

[MoleT-5R]

Rob made his own linkage mounts in this thread a while ago iirc http://www.vpcuk.org/forums/showthread.php?49587-6-speed-gear-upgrade

[stribo]

I recognise that gearbox ;) Good work mate.

[oblark]

Focus ST gearbox mate ;)

Yeah and it`s got volvo cast on the bellhousing :)

[Harvey]

Yeah and it`s got volvo cast on the bellhousing :)

So it's a Volvo gearbox that was fitted to a Ford ST.
This tread makes a good read.

[oblark]

When I brought the gearbox a focus ST gearbox on ebay was around £170 but a gearbox out of a volvo was around £300.

[p fandango]

When I brought the gearbox a focus ST gearbox on ebay was around £170 but a gearbox out of a volvo was around £300.
I picked a focus box up for £50, can't remember who I sold it too

[MoleT-5R]

other than the extra gear (but the same final drive as far as I see), is there any advantage over the 10valve box ? or am I looking at it wrong?

Oh and if anyone see's a awd m66 going for a reasonable sum let me know please

[p fandango]

Oh and if anyone see's a awd m66 going for a reasonable sum let me know please
according to my list there are 4 different ratios (with 3 different fdr's) available in the M66 AWD box, so think you'll have to find the right one to match the diff ratio on your rear axle

[MoleT-5R]

according to my list there are 4 different ratios (with 3 different fdr's) available in the M66 AWD box, so think you'll have to find the right one to match the diff ratio on your rear axle

oh that throws a spanner in the works, I haven't a clue what fdr the V70R is running, but will have to find out what it has, thanks for the heads up

[p fandango]

I haven't a clue what fdr the V70R is running
4.00:1

[partsforvolvos.com]

I read with interest (not often for me) the feature a few issues ago in the voc magazine where somebody fitted a m66 to their d5 to get better motorway consumption.
the thing that intrigued me that I was not aware of was the m66 box apparently has relay control switching for the shift block so you cant select the wrong gears at high speed.
the person who wrote the feature was not able to resolve this, and thought it would be ok if careful when driving.

interested to know, have you heard of this, and do you plan a resolution to it when your box is installed rob?

the engine looks really nice btw

[oblark]

The switch/solenoid is mounted on the gear stick not on the gearbox, so it isn`t a problem :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20130711_162418.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20130711_162418.jpg.html)

[oblark]

downpipe and decat pipe have been heat wrapped :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140222_135953.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140222_135953.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140222_140034.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140222_140034.jpg.html)

[stribo]

Nearly ready to go in my car then ;) Great work mate, can't wait to see your car in action once the new set up's fitted. Any plans for taking it up the strip? Might be the car to knock Dean off the top, and seeing them go head to head would be something I'd love to see.:D

[AndysR]

How's this coming along now Rob? :)

[oblark]

How's this coming along now Rob? :)

Just waiting for my PPI payout then I`ll be ordering the head gasket, head bolts, water pump and timing belt from Volvo

Then it`s just a case of swapping engine/gearboxes over :)

[AndysR]

Nice one :)

[oblark]

As I was cleaning the engine bay today I thought it would be a good time to measure up for the 3.25" maf

I made up a cardboard template to make sure it would fit :)

Just need to get it made out of 3mm aluminium.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140426_163442.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140426_163442.jpg.html)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140426_163546.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140426_163546.jpg.html)

[oblark]

This little lot arrived in the post today :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140514_165544.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140514_165544.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140514_170049.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140514_170049.jpg.html)

Head gasket, head bolts and turbo gaskets/copper washer from FRF Volvo

Water pump, timing belt and damper from PFV

All ordered on Monday, very quick delivery :)

[oblark]

The new MAF mounting plate was picked up today and the ramair filter arrived in the post.

Starting to come together :) just waiting for 3" pipe work to turn up so the MAF to turbo pipe can be made up.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140520_182553.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140520_182553.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140520_182457.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140520_182457.jpg.html)

[smithy]

That look nice mate

[AndysR]

Nice filter, that shouldn't restrict much.. :)

[M-R-P]

Bout time you got rid of that tiny cone filter mate, gonna look sweet under the bonnet with that.

[V70 Graham]

Nice looking bit of kit mate.

[oblark]

Had a spare few hours this afternoon after work so I`ve started to mock the new 3" MAF to turbo pipe.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140522_175914.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140522_175914.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140522_175928.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140522_175928.jpg.html)

It still a little be of tiding up which I`ll do over the weekend :)

[theflyingbrick]

looking good rob,im liking the battery idea....saves moving it to the boot for some more space ;)

[M-R-P]

Shiny shiny :)

[stribo]

Looking good Rob, that's going to sound mean with the new filter.

[Kingsford G]

Had a spare few hours this afternoon after work so I`ve started to mock the new 3" MAF to turbo pipe.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140522_175914.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140522_175914.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140522_175928.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140522_175928.jpg.html)

It still a little be of tiding up which I`ll do over the weekend :)

Thats one nice looking engine bay mate,well done.

[oblark]

Thats one nice looking engine bay mate,well done.

Just wait to this little gem has been fitted :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143428-2.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143428-2.jpg.html)

[Kingsford G]

Just wait to this little gem has been fitted :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143428-2.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143428-2.jpg.html)

Just getting better mate.Is it K24 bolted on it?

[M-R-P]

Just wait to this little gem has been fitted :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143428-2.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140209_143428-2.jpg.html)
Rob, stop posting such filthy porn!

[oblark]

Just getting better mate.Is it K24 bolted on it?

Yeap thats a K24 :)

[Kingsford G]

Yeap thats a K24 :)

I really like k24,quick spool up and smooth.Sorry I didn`t follow this thread,what car is the engine going in?

[oblark]

I really like k24,quick spool up and smooth.Sorry I didn`t follow this thread,what car is the engine going in?

My 850, I went for the K24 as I think it is a under rated as a turbo & not many people are using the K24 in a 850.

[MoleT-5R]

Nice progress Rob, everything seems to be coming together nicely, like the new maf holder and filter

[partsforvolvos.com]

progress looks good rob, carry on!

[martybelfastt5]

looks awsome pitty the bodywork will hide most of it lol

[oblark]

Been busy today in the man cave.

Head gasket, water pump fitted and all timed up just a few little things to finish tomorrow :)

The flywheel is away being balanced once done the engine will be finished, just nned to fit it in the car :)

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140524_132941.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140524_132941.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140524_144408.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140524_144408.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140524_165738.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140524_165738.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140524_165804.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140524_165804.jpg.html)

[Hybusamini]

Looking good m8 keep up the good work :B_thumb::B_thumb:

[oblark]

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140525_124027.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140525_124027.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140525_123730.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140525_123730.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140525_123924.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140525_123924.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140525_123957.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140525_123957.jpg.html)

[AndysR]

Looking good! In fact it's looking awesome, nice work, I like the black rocker cover and twin oil cap set up :)

One question, why no S60R manifold after all the work you've done?

[WOODY T5]

Looking good! In fact it's looking awesome, nice work, I like the black rocker cover and twin oil cap set up :)

One question, why no S60R manifold after all the work you've done?u don't need s60r manifolds mate me not got one :)

[AndysR]

u don't need s60r manifolds mate me not got one :)

Perhaps you should fit one then and get a lower time than you have for the last 3 years ;)

[stribo]

Looking good Rob, when's it going in the car?

[WOODY T5]

Perhaps you should fit one then and get a lower time than you have for the last 3 years ;)might just wait till someone beats me hope there still sale them in 3 years time lol

[oblark]

Looking good Rob, when's it going in the car?

After the flywheel comes back from being balanced so it shoiuld be in the car by the next southern meet :)

[oblark]

Looking good! In fact it's looking awesome, nice work, I like the black rocker cover and twin oil cap set up :)

One question, why no S60R manifold after all the work you've done?

I will be using the RN exhaust & inlet manifolds on the rebuilt engine :)

[claymore]

I will be using the RN exhaust & inlet manifolds on the rebuilt engine :)
It's one of these you want :)


http://i170.photobucket.com/albums/u258/claymore2k/T10%20Projects/10329236_10152120767212479_5272330400397794186_n.j pg (http://s170.photobucket.com/user/claymore2k/media/T10%20Projects/10329236_10152120767212479_5272330400397794186_n.j pg.html)

[stribo]

It's one of these you want :)


http://i170.photobucket.com/albums/u258/claymore2k/T10%20Projects/10329236_10152120767212479_5272330400397794186_n.j pg (http://s170.photobucket.com/user/claymore2k/media/T10%20Projects/10329236_10152120767212479_5272330400397794186_n.j pg.html)

And the space to fit it. :P

[oblark]

The hybrid clutch

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140531_123632.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140531_123632.jpg.html)

Catch tank & crankshaft breath pipework.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140531_143110.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140531_143110.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140531_131520.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140531_131520.jpg.html)
http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140531_131433.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140531_131433.jpg.html)

[stribo]

Nice, that flywheel looks seriously lightened. :)

[oblark]

I thought I would update this thread,

The engine went in about a month ago and I've had a deride of time with it since.

First of all ALL the gaskets, o rings, oil seals and copper washers that where fitted to the engine when it was rebuilt are genuine Volvo parts.

I've spent the last month chasing oil leaks.

First to leak was the rear main seal (I damaged the seal fitting it)
Then turbo drain pipe started to leak a week after the engine was fitted, the oil feed pipe to the turbo was next to leak (it's now on it's 4 set of copper washers) all the cam oil seals have been changed, the 3 covers on the back of the engine for the piston oil cooling jets started leaking last weekend, the dip stick tube, oil pressure switch have all had they seals changed and to top it off the engine started to burn oil after only doing 300ish miles which has filled the exhaust with burnt oil and has knackered the O2 sensor,

I've done a compression test on a hot engine and got a balanced 12 bar, poured some oil in the bores and the readings came up to 16 bar so it looks like the new rings are letting by. As the engine is now burning oil at a hell of a rate I decided to refit the old engine, when I removed the inlet manifold I noticed that they was small puddles of oil on top of the valves which indicates that the valve stem seals are leaking but these a genuine Volvo seals and the head had been overhauled. I'll find out what is at fault when the engine is dismantled either this month or next or when I can be bothered.

So I’m running the old engine with the K24, green injectors, 3.25” maf and 6 speed gearbox. It will be mapped to start to produce boost at 3.5k and full boost at 5.5k.
With the 6 speed box it`s great to drive, 80mph @ 3000 rpm

I see why people loss the love for these car when ever weekend all you're doing is trying to keep them running.

[merc85]

Yep gets tedius mate, you must have spent a small fortune :( Sounds like it should be a Monster of a car just need to get it reliable, I know of a couple of these cars which have Sprung oil leaks running a similar set up (power wise) Were the Valve guides worn on the other engine? were they the original valves from that head?

Hope you get it sorted soon mate

[oblark]

The valve guides where ok with no wear. The head has always been playing on my mind as it could have been a N/A head that has had turbo valves/guides fitted or it`s cracked/porous.

If the bores/pistons are OK then I`m going to get the original head refurbed.

[merc85]

There were 2 different diameter of Valves on the t5's early and late, was just wondering if somehow the incorect size ones were fitted at some point.

[oblark]

This is the thread I started over the valves and the head.

http://www.vpcuk.org/forums/showthread.php?54882-exhaust-valves&highlight=

[Shinsplintz 101]

Real shame that - have been quietly following this thread with interest - lots of hard work & wedge gone into this one. Hope you get it sorted. Keep us posted. Cheers, morgan

[abdul]

Hope u get it sorted

[stribo]

Looked and sounded good yesterday Rob. :D

[960kg]

The valve guides where ok with no wear. The head has always been playing on my mind as it could have been a N/A head that has had turbo valves/guides fitted or it`s cracked/porous.

If the bores/pistons are OK then I`m going to get the original head refurbed.


As you know Rob i always get moaned about for my help or thoughts!.........but sitting from where i am reading your project and what you have done and are still doing those oil seals and gaskets were ok as are the stem seals and guides the problem is Old Pistons in Old Bores..... it does NOT work!!!!........you may have had the T4 pistons fitted to a rebored bore but it will NOT work!

I have built so many engines i can`t remember them all but the only ones that were 100% ok were new rebored blocks with new pistons and that was only for producing 120bhp in the early `70`s!

As you know pistons are not parallel they are tapered a worn piston even more so where do you start the measuring for it to fit !!........some say 10mm down some say at the bottom of the stroke for measuring the block to piston clearance.

There are different grades of piston and bores when new in the factory for fit which only differ by a few thou so how can a used 2nd hand used piston give performance bhp with no problems .......it simply can`t......

The reason your oils seals have failed is because you have too much blowpast which gave you too much pressure in the sump even tho you have modified the PCV.

It is not normal for ALL the seals to go is it especially pucker Volvo?

I don`t know if you have figures but bore is 83.015 and piston should be 82.995 with a running clearance of 0.20mm ( 7 to 8 thou)

Minimum is 4 thou and the max is 11 thou running clearance.

Also did you know that the 1st compression ring is larger than the 2nd compression ring.......did you fit them the wrong way around??

Good Luck

Keith

.................................................. ......................

[t5 pete]

sorry but I must dissagree with you your first paragraph is wrong I know this may suprise you but I actually agree with you just goes to show these old ones still have it

[oblark]

As you know Rob i always get moaned about for my help or thoughts!.........but sitting from where i am reading your project and what you have done and are still doing those oil seals and gaskets were ok as are the stem seals and guides the problem is Old Pistons in Old Bores..... it does NOT work!!!!........you may have had the T4 pistons fitted to a rebored bore but it will NOT work!

I have built so many engines i can`t remember them all but the only ones that were 100% ok were new rebored blocks with new pistons and that was only for producing 120bhp in the early `70`s!

As you know pistons are not parallel they are tapered a worn piston even more so where do you start the measuring for it to fit !!........some say 10mm down some say at the bottom of the stroke for measuring the block to piston clearance.

There are different grades of piston and bores when new in the factory for fit which only differ by a few thou so how can a used 2nd hand used piston give performance bhp with no problems .......it simply can`t......

The reason your oils seals have failed is because you have too much blowpast which gave you too much pressure in the sump even tho you have modified the PCV.

It is not normal for ALL the seals to go is it especially pucker Volvo?

I don`t know if you have figures but bore is 83.015 and piston should be 82.995 with a running clearance of 0.20mm ( 7 to 8 thou)

Minimum is 4 thou and the max is 11 thou running clearance.

Also did you know that the 1st compression ring is larger than the 2nd compression ring.......did you fit them the wrong way around??

Good Luck

Keith

.................................................. ......................

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140710_164259.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140710_164259.jpg.html)

If you look you can make out a puddle of oil on top of the valve heads and where it has come out of the inlet ports.

When I was younger a mate of mine rebuilt his 2 stroke motorbike engine and forgot to refit the rings, it smoked abit but it ran.

[960kg]

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140710_164259.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140710_164259.jpg.html)

If you look you can make out a puddle of oil on top of the valve heads and where it has come out of the inlet ports.

When I was younger a mate of mine rebuilt his 2 stroke motorbike engine and forgot to refit the rings, it smoked abit but it ran.

I understand the 2 stroke bit as that is where i started my tuning engines ,i had the Lambretta GT 200 in 1964 ....it had the hemi head design just like Aston Martin and Jaguar so that is where it all started with me and engines.....the 2 stroke will smoke because of the oil mix in the fuel as it doesn`t have a sump for oil!

Not arguing at all Rob as i know you know your engines etc. but why is there oil on the manifold flange gasket?.......as if it`s on the valve head that is where it should only be!....is the oil coming from the turbo?

You say the comp.test was more when you poured oil in the combustion chamber but surely it would read high if the oil was already there via the valves?

Just remembered when doing my first valve lapping in........i didn`t properly wash away all the grinding paste from the guides and after a few weeks of running the engine did smoke badly as the valve guides had worn out of this world!!

There is a problem ,only hope you find the correct answer without stripping all the time!

[oblark]

The oil was only in the valve ports, the throttle and induction pipes are oil free.

I would have expected the compression reading to come up when oil was added to the bores, the higher the reading with oil over a dry test would indicate the rings are not sealing but as it only increased by 4 bar.

before the engine was removed both the pipes that go to the catch tank where vented to atmosphere and even doing that didn't stop the engine from blowing blue smoke out of the exhaust.

My money is on the head being knackered but I could wrong and have been in the past :)

[FIREBOLT]

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0933.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/IMAG0933.jpg.html)

Did you wire brush the pistons to clean them?

[oblark]

No, they we're cleaned with degreaser then put in dishwasher.

[oblark]

Pulled the head off the smoking engine today and for a engine that has only done 300ish miles f**k me what a state.

A little puddle of oil in the pistons.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140720_105127.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140720_105127.jpg.html)

The head looked like it had done 300k miles.

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140720_105224.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140720_105224.jpg.html)

I`ve pulled a inlet and exhaust valve out of the head and the same out of a spare head I`ve got and measured the valve stem dia, A turbo exhaust valve should be 6.960mm and both of mine are 6.959mm. A n/a exhaust valve is 6.70mm so the head with the n/a ports is a n/a head that has the valve guides machined out to take turbo valves as I`ve not found any imformation to say that ports on the head I used was a turbo head, this was one of the things that was on my mind when building the engine. The valve stem seals where not the greatest of seals on the valve mite look into seeing if I can some tighter fitting ones.

Also the valve springs where a different shape, the tapered ones came from a turbo head,

http://i1067.photobucket.com/albums/u433/oblark/volvo%20850%20t5/Engine%20rebuild%20project/20140720_112253.jpg (http://s1067.photobucket.com/user/oblark/media/volvo%20850%20t5/Engine%20rebuild%20project/20140720_112253.jpg.html)

As the spare turbo head I`ve got has 6 bent exhaust valves I`ll be changing over all 20 valves from one head to another (waiting for the "you can`t do that ......")

[960kg]

As the spare turbo head I`ve got has 6 bent exhaust valves I`ll be changing over all 20 valves from one head to another (waiting for the "you can`t do that ......")

You can do whatever you want to do........but you know yourself deep down "you shouldn`t do it"..........if you want a first class engine that is!

All the time and effort and money you have spent on the engine it is only as good as it`s weakest link!

[partsforvolvos.com]

keep at it rob.
this is an interesting thread, loads of threads on bodywork mods but not that many have good detail on engine rebuilds.

[M-R-P]

Nice to see the Haynes book of lies being put to the use it was designed for - protecting a good table ;)

[oblark]

keep at it rob.
this is an interesting thread, loads of threads on bodywork mods but not that many have good detail on engine rebuilds.

Thanks, I`ll be after some bits & bobs in the next few months :)

[oblark]

Nice to see the Haynes book of lies being put to the use it was designed for - protecting a good table ;)

It was the only flat thing I could find as the valves kept falling over when sttod on the wheelie bin :)

[partsforvolvos.com]

well they stopped doing the Haynes manual plastic protector wallet so the book had to be used .
we christened it the jizz cover ........ pmsl

[stribo]

Surely if you lap the valves in, then there shouldn't be a problem changing them over.

[oblark]

Surely if you lap the valves in, then there shouldn't be a problem changing them over.

The words nail and hammer spring to mind :)

As long as the valve guides aren`t worn to badly then it`s just a case of swapping valves over & lapping them in.

[partsforvolvos.com]

changing valve guides is a pita, you have to heat the head to 180'c to expand it.

[stribo]

The words nail and hammer spring to mind :)

As long as the valve guides aren`t worn to badly then it`s just a case of swapping valves over & lapping them in.

If the valve guides are worn, you'll have a problem whatever valves you put in.

[partsforvolvos.com]

Volvo don't sell guides, but I managed to get some in the past ok.

[960kg]

keep at it rob.
this is an interesting thread, loads of threads on bodywork mods but not that many have good detail on engine rebuilds.


I totaly agree BUT only good engine practices should be detailed and not ones just to save money!

What secondhand valve guide on an 18year old 850 won`t have any wear?....especially a thrashed one which nobody would know of...

If the valves go side to side by too much then it does not matter what valve stems seals you put in they will be worn in miles and let the oil past which it look as though what has happened already.

So now surely the next step is new valve parts?

I have been there and got the T shirt and it don`t work successfully.....the money spent on another set of head bolts and gaskets and time you may as well spend on new valves/guides etc.

But that is only my own opinion!

[Uzulins]

Very nice theread. Thanks Oblark. Loads of useful information.