Volvo 850 engine rebuild and exhaust recommendations

[Bigsi15]

Hi guys
I'm new to here but have been using the forum for info for quite a while now so may I firstly say thank you to everyone who has helped so much without realising it!

Anyhow I'm looking to build up a second t5 engine as a project to hopefully tune and fit into my current 96 850 t5. The details can be found from my thread on t5d5 to save typing it again only iPhone!

http://forums.t5d5.org/topic/29924-volvo-850-t5-engine-bearing-measurementstolerances/

Basically I'm now after people's recommendations for exhaust systems. Seems the general consensus is 3" full system (based on me hopefully fitting a 20t td04 turbo) but they are very expensive. What are everyone's thoughts on 2.5"? Any good systems at either size that anyone could recommend at a reasonable price?

Any other general help/tips from you fonts of knowledge would also be much appreciated

Thanks guys

[nottsgreent5]

Hi buddy see you made it on here get some pics up of your car

[Bigsi15]

Hey buddy! Yeah here for all the help I can get! Lol!

[Bigsi15]

How do I upload from my iPhone?! Lol

[twr]

Photobucket is your friend.

[oblark]

Photobucket is your friend.

Or a pain in the ar$e

[Bigsi15]

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[Bigsi15]

bores and internals seem good. no lip at all on the bores

[twr]

Not the first time ive seen bores on the t5's like that. Look in great shape.

[Bigsi15]

29528

[Doingitsideways]

29528

Blimey, put that somewhere safe before you kick it over, ffs!!

Lovely cross hatching on those bores :)

[Bigsi15]

haha yeah its bound to happen! thought it would be a simple and cheap way to ensure the same valves and springs go back in the same ports in the head. the head seems so clean and valves have no play and arent burnt (just a little carbon and will need a slight grind back in) that i dont want to replace them, they are bloody expensive!

[Bigsi15]

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[Bigsi15]

all of these pics are after no cleaning what so ever, seems very clean for a 19 year old car with 100k miles :)

[Bigsi15]

Hi buddy see you made it on here get some pics up of your car

Just for you ;)
29534

[Bigsi15]

Next will be forged rods. Any recommendations? Need to be a good fit preferably with small end (is that the piston joint bits?!) and reasonable price but not crap! Aim is to have a 20t turbo and aim for around 300 to 350 max hp

Thanks in advance :)

[Bigsi15]

Sorry to bombard you with posts but also have found a bit more information out regarding the MAF. Is it possible I'm going to need to replace mine with a larger one perhaps from a 960? Do these sorts of things need including in the map? Thanks

[Bigsi15]

Ok update. Went to the machine shop who were impressed with the general internal condition especially the Pistons and bearings. However they mentioned the bores were worn ranging from 4 1000ths to 7 1000ths (I think that's the measurements they gave). This means nothing to me but they said it was getting to the limit of new rings and a bore would be best. This is not an option as I can't afford the larger Pistons etc.

Are these margins as bad as they say or will it run well really? Car apparently only had around 100k miles on an auto

Thanks guys

[Bigsi15]

29567

one side ground in

[Bigsi15]

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came back nice and clean, just a shame about the bores :( at least it is only the top of them

[Bigsi15]

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After some honing the problem areas can be seen, im hoping this small area wont be enough to affect the engine too much. the machine shop seem to think it will run ok but ideally needs a bore and larger pistons (£600+ at least) so thats a no go for me. engine was always just a 'project' and i never wanted to race it just a bit more welly when needed so i think i may just see how she goes. figure an engine that clean on an auto box shouldnt have been ragged too hard so if people can get half decent tunes on cars with 160k+ miles they cant be too much better inside. shame though as would have liked a fresh engine :(

[oblark]

I got a 109K mile block that was also a auto and it just as worn, a born will wear regardless of what type of gearbox is connected to the engine, it's how often the engine was serviced.

[Bigsi15]

Oblark what did you do with yours? Seems a low mileage to be wearing to the point of nearly needing reboring :(

[oblark]

Oblark what did you do with yours? Seems a low mileage to be wearing to the point of nearly needing reboring :(

I scrapped it :(

[Bigsi15]

Balls

[Dangerous Dave]

Balls
Indeed :(

Not sure what advice to give I'm afraid, I don't know whether shelling out for new main bearings is worth it....

[Bigsi15]

No indeed... Guess until it's built and compression is tested I'm not going to know. Kinda hoping it isn't going to be complete crap! If it is then will have to put the other one back in and start saving I guess!

[Bigsi15]

I think the Haynes manual suggest 4/1000ths is about the acceptable wear limit so at least 4 cylinders are about that just the one which is below that. We will see... Thanks guys

[Bigsi15]

Ok new thought. How would fitting a larger letter piston work? Figure as its only really 1 cylinder that's really worn could I pop an e piston in say rather than the d I have already?

Thanks!

[oblark]

Another option you could consider is to bore it out from 81mm to 83mm making it a 2.4

If you down the the road of boring it out to 2.4 you WILL need a custom map.

[Bigsi15]

Oblark that sounds tempting however I think sourcing pistons and the cost may not be cheap either :(

[oblark]

I have a set of 83mm secondhand pistons tucked away in the garage.

I'm off on holiday tonight for a fortnight so if your interested I'll have a look for them when i get back :)

[Bigsi15]

Ah yes I would be interested thank you. Can you pm me a price and details? Thanks buddy

[Bigsi15]

Are the 83mm bores the same as the r series cars? In which case can you run 139mm rods with those Pistons in my block or do you need te longer ones? Cheers!

[Orca2]

I would deffo bite the bullet and rebore that Si, you are too far in to build back up knowing the bores are a bit suspect, if you factor in the time and hassle of stripping it back to where you are now it makes sense to deal with it now rather than have to return to it, its pretty demoralising too when you build them back up and they arent quite what you had hoped ,
I did it years ago with a Metro turbo, and never again.

[Bigsi15]

Yeah it's a difficult decision :( hopefully if oblark or someone has some larger Pistons at a reasonable cost then I will do it. I just can't justify 600+ pounds for newargwr Pistons and rebore sadly. Thanks for your advice though dude :)

[Orca2]

Good luck with it mate, hopefully someone will have what you need,

[oblark]

The pistons I have are only for the 139mm rods.

You have PM :)

[Bigsi15]

Thanks for that buddy :)