Project 254

As 240 turbo's using the 940 lpt red block engines are get as common as muck I think it's time to take the 240 to the next level ........ T5 it :)

With the help from Steve we went and picked up a OBD1 850 T5 engine with 118k miles.

The first thing I found was the turbo is well passed it's best, but the rest of the engine is Ok it looks like it's had the PCV changed and a service not many miles ago.

The first thing to do is to remove all the bits that are not needed.

http://i1067.photobucket.com/albums/...220_140558.jpg
http://i1067.photobucket.com/albums/...220_140713.jpg

Then bolt on all the bits that are needed.

http://i1067.photobucket.com/albums/...220_151234.jpg
http://i1067.photobucket.com/albums/...220_153520.jpg
http://i1067.photobucket.com/albums/...220_153526.jpg

Looking good Rob, don't suppose you got the gearbox with that engine??

Quote:

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Originally Posted by Nealevo

Looking good Rob, don't suppose you got the gearbox with that engine??

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When we turned up the engine and gearbox was still on the sub frame,

As it would fit in the back of Steve's car we had to break it down to just the engine.

I'll pm you his phone number but he won't post anything.

Nice :D

You going to run a custom sump or fit a modified 960 one?

Quote:

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Originally Posted by Dangerous Dave

Nice :D

You going to run a custom sump or fit a modified 960 one?

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A modified 960 sump :)

Sweeeeet!

Looking forward to future updates :)

Picked this up from the profilers this afternoon before they closed for Christmas.

http://i1067.photobucket.com/albums/...223_134139.jpg

Quote:

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Originally Posted by oblark

Picked this up from the profilers this afternoon before they closed for Christmas.

http://i1067.photobucket.com/albums/...223_134139.jpg

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Gearbox adapter?

What you going to be running?

Quote:

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Originally Posted by Dangerous Dave

Gearbox adapter?

What you going to be running?

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It's a gearbox adaptor so I can use the red block M90 gearbox.

Ah yes, I do like the smoothness of the M90 (well compared to the M47)

Started to countersink the holes in the adaptor plate so it can be bolted to the engine, Did all but 4 as my countersinking bit has now passed it's best so I'll order a new one in the new year.

Did a trail fit of the red block bell housing and all looks ok.

http://i1067.photobucket.com/albums/...226_150828.jpg
http://i1067.photobucket.com/albums/...226_153032.jpg

i dont suppose you got the profile drawing with it too?? :B_thumb:

Quote:

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Originally Posted by craigoodwood

i dont suppose you got the profile drawing with it too?? :B_thumb:

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I gave the profilers the bell housing and they used that to cut the adaptor plate.

The gearbox adaptor plate is finished.

http://i1067.photobucket.com/albums/...227_120058.jpg
http://i1067.photobucket.com/albums/...227_132440.jpg
http://i1067.photobucket.com/albums/...227_133217.jpg

Made a new turbo oil return pipe as the turbo has been "clocked" and the 850 wont fit anymore.

The new pipe was made from a 940 lpt and a 850 oil pipe.

http://i1067.photobucket.com/albums/...103_122351.jpg
http://i1067.photobucket.com/albums/...103_123609.jpg
http://i1067.photobucket.com/albums/...103_130046.jpg
http://i1067.photobucket.com/albums/...103_130417.jpg

The down pipe looks like it could be fun.

http://i1067.photobucket.com/albums/...103_140844.jpg

looking good rob

This little beauty arrived in the post today :)

http://i1067.photobucket.com/albums/...106_183512.jpg

The intercooler you posted a photo of, may I ask if the tubes have internal turbulators, (internal finning)? Or are the tubes "empty"? Thanks.

Some major parts arrived from classic swede during the week so today I was out in the man cave cutting down the sump from a 6 cylinder to a 5 cylinder. Also the oil pick up tube modified to fit.

http://i1067.photobucket.com/albums/...114_112628.jpg
http://i1067.photobucket.com/albums/...116_104204.jpg
http://i1067.photobucket.com/albums/...116_104232.jpg
http://i1067.photobucket.com/albums/...116_121045.jpg
http://i1067.photobucket.com/albums/...116_125317.jpg


Already to be welded.

http://i1067.photobucket.com/albums/...116_153918.jpg

On the engine mount front, the inlet side only has 3 out of 4 bolt holes that line up. But the exhaust side only has 2 out of 4 bolt holes that line up so I'll be fabricating so new engine mounts out some steel plate.

http://i1067.photobucket.com/albums/...115_160314.jpg
http://i1067.photobucket.com/albums/...115_160536.jpg

I purchased the CAD file of lower engine mounts from Homer and had them manufactured from 5mm steel. I wasn't happy with how the upper engine mounts sat so I manufactured them from also 5mm steel. I used a CAD (card aided design) to make the mounts.

http://i1067.photobucket.com/albums/...130_151701.jpg
http://i1067.photobucket.com/albums/...123_153853.jpg
http://i1067.photobucket.com/albums/...123_142816.jpg

Picked the sump and the oil filter bracket from the machine shop this morning.

The sump had to be skimmed as it bent when it was welded. With the aid of some Volvo chemical gasket the sump was fitted and the oil filter bracket was screwed into the sump.

http://i1067.photobucket.com/albums/...130_132701.jpg
http://i1067.photobucket.com/albums/...130_132717.jpg
http://i1067.photobucket.com/albums/...130_135256.jpg
http://i1067.photobucket.com/albums/...130_151305.jpg
http://i1067.photobucket.com/albums/...130_151433.jpg
http://i1067.photobucket.com/albums/...130_151444.jpg

Lol at the card aided design - Thanks for the updates Rob!

The old red block engine and M90 gearbox came out without much grief. The gearbox was removed ready to be fitted to the T5 lump. The adaptor plate was drilled and tapped to the hole pattern of the gearbox. The m90 pivot ball was measured and was 24mm long (RHD side)but the pivot ball from the m47 gearbox was 30mm (LHD side) long so with the aid of 2 8mm washes the pivot ball was the required length of 34mm. Had to grind the corner off the drivers side lower mount so the steering column would miss.

http://i1067.photobucket.com/albums/...211_161913.jpg
http://i1067.photobucket.com/albums/...211_163327.jpg
http://i1067.photobucket.com/albums/...213_125034.jpg
http://i1067.photobucket.com/albums/...213_142742.jpg
http://i1067.photobucket.com/albums/...214_113836.jpg

So today the T5 lump and m90 gearbox was fitted into the car. What a PITA, had to drop the cross member by 40 so the sump could fit over the top. Once passed the cross member it dropped in perfectly and lined up with all the mounts.

http://i1067.photobucket.com/albums/...214_133026.jpg
http://i1067.photobucket.com/albums/...214_152443.jpg

Coming along nicely :)

Thats some gap in front of the engine, the 5 pot can't be much longer than the redblock by the look of it.

Up date time as the car is up and running now :)

Time for a bit of wiring.
http://i1067.photobucket.com/albums/...228_124052.jpg

ECU fitted and wired in.
http://i1067.photobucket.com/albums/...228_132315.jpg

Oil and water lines were made from 10mm hydraulic pipe.
http://i1067.photobucket.com/albums/...227_100446.jpg

3" induction pipes.
http://i1067.photobucket.com/albums/...220_151638.jpg
http://i1067.photobucket.com/albums/...305_171357.jpg

Fuse board relocated to the glove box.
http://i1067.photobucket.com/albums/...305_171421.jpg

2.5" downpipe with lambda and wideband semsors.
http://i1067.photobucket.com/albums/...306_141207.jpg

3" maf and heat shield.
http://i1067.photobucket.com/albums/...306_161537.jpg

Two secondhand struts to be turned into coilovers.
http://i1067.photobucket.com/albums/...312_170354.jpg

Coilovers with brembo calipers and custom 290mm discs.
http://i1067.photobucket.com/albums/...402_154509.jpg

Nice ride height.
http://i1067.photobucket.com/albums/...1_160350_1.jpg

Later type brake reservoir.
http://i1067.photobucket.com/albums/...402_163154.jpg

The old panhard converted to a adjustable one.
http://i1067.photobucket.com/albums/...402_163154.jpg

Bumper removed to add some more air flow.
http://i1067.photobucket.com/albums/...417_113616.jpg
http://i1067.photobucket.com/albums/...417_145310.jpg

Custom power steering fitting.
http://i1067.photobucket.com/albums/...418_165620.jpg

New strut brace and catch tank fitted.
http://i1067.photobucket.com/albums/...424_162123.jpg
http://i1067.photobucket.com/albums/...424_162131.jpg

Strut brace all painted up.
http://i1067.photobucket.com/albums/...430_143636.jpg

http://i1067.photobucket.com/albums/...430_152005.jpg
http://i1067.photobucket.com/albums/...430_152019.jpg

So is it running now? :D

Yep it's up and running.

https://youtu.be/FaB6Fu8upl0

This is looking great Rob, lots of hard work and attention to detail - Particularly like the glove box relocation of the fuse board.

What's left on the list of things to do?

Fair play rob this is great work. I felt pleased with myself for removing rebuilding and refitting a t5 engine but that came from the same car and is nothing like the complexity of this! A t5 lump in a 244 body shell is the perfect combo, it's going to be great fun! I wish I had your skills mate

Had to fit the 16T that I was going to convert to a 19T as the 15G decided to eat its self,

So with the 16T fitted and once I'd fixed the rough running it was time to do some data logging,

For a 16T and white it produces some good boost :)

Attachment 30741

Another awesome thread Rob, great to see the fruits of your efforts

Some tidy work there.

The strut brace is a work of art though. :B_thumb:

Finally got around to having some adaptor rings made so I could fit the chrome centre caps.

http://i1067.photobucket.com/albums/...521_110215.jpg
http://i1067.photobucket.com/albums/...521_121707.jpg
http://i1067.photobucket.com/albums/...521_113400.jpg

Took the 240 t5 to the Winchester classic car & bike breakfast meet on bank holiday monday.

http://i1067.photobucket.com/albums/...530_101226.jpg
http://i1067.photobucket.com/albums/...530_101247.jpg

The 240 has started a bad habit of eating cluthes, the reason for this is the frition plate is hanging off the end of the gearbox imput shaft. To overcome this problem a construction grade disc was bolted to the face of the flywheel then drilled to loose the additional weight of the disc. So the flywheel went from 7 kgs to 10kgs then down to 9 kgs. Just need to get it balanced then I can get it fitted.

Attachment 31412

Attachment 31413

Attachment 31414

I also built a plenum chamber inlet manifold as the throttle was a PITA to get at on the old ME7 manifold.

Attachment 31415

Well the 240 got converted back to the B230FK engine then she was sold.

Attachment 31658

Attachment 31659

Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??

Quote:

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Originally Posted by MoleT-5R

Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??

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Don't worry moley, the work hasn't stopped ;) I'll start a new project thread soon.

Nice one Martin, nice to see that the car is still in the forum, you kept that quiet. ...:mischievo

Quote:

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Originally Posted by MoleT-5R

Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??

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It's full steam ahead on the awd conversion which all starts in just over a weeks time :)