My project : Volvo 850 T-5R (Olive)

[leet5r]

just read this from start to finish again , awesome car , defo have another in a heart beat

[WOODY T5]

just read this from start to finish again , awesome car , defo have another in a heart beat

yes one very nice sorted volvo t5r one of the best I have seen along with yours mate wot off set and size wheels are these Kerry do fancy some for my motor

[Kerry_T-5R]

yes one very nice sorted volvo t5r one of the best I have seen along with yours mate wot off set and size wheels are these Kerry do fancy some for my motor

Thanks Woody, yours looks nice as well from what I have seen! The wheels are 17" by 8", not sure on the offset I'm afraid.

Video now in HD so that the flame from the exhaust can be seen properly :

[iancho]

Great thread and super looking motor... all very interesting!

[Kerry_T-5R]

Well, I thought that I would bring this thread up to date now that I have made a little progress with the engine build.

Here is how the car stands today:



Bought a set of these (forged H beam con-rods):



Along with all new gaskets, o-rings, bearing sets, piston rings, oil pump, water pump etc etc etc:





Fortunately I managed to obtain a low mileage engine for a low price from a performance Volvo forum, and eventually once I had help available from a good friend we began the long process of stripping down the engine and thoroughly cleaning everything especially oil ways and mating surfaces.





Barry in action!



Then the block went off to our local machine shop for honing. I am missing a lot of pics from around this time (Spring 2015) but I have all of the following progress pics from this year.

Pistons attached to rods:



New rings:



One rod/piston installed:



All pistons/rods installed:



Crank shaft in:



Liquid gasket application:



Intermediate section down:

[Kerry_T-5R]

New oil pump and oil pick up pipe installed:



New water pump on:



Would have bolted the sump on, but missing 2 x o-rings! Will install during the week hopefully and then on to the head strip down next weekend.

[Kerry_T-5R]

O-rings turned up yesterday, so decided to fit the sump. Liquid gasket applied to the intermediate section:



This was then evenly spread out before bolting down the sump to the specified torque setting





And finally, installed the oil cooling jets, new gaskets and backing plates:



That's the bottom end complete! Head strip down commences on Saturday

[leet5r]

some good work there bud , glad your keeping the good work going on the car

[Kerry_T-5R]

Cheers Lee. So am I now that I have started with the build! Always planned to and modified the car in every aspect so that it was ready for an engine build and more power. Would be a shame not to finally give the car the extra power that it is crying out for

[nottsgreent5]

Looks a nice build out of intrest are you useing a 2.5 bottom end

[Kerry_T-5R]

Looks a nice build out of intrest are you useing a 2.5 bottom end

Hi, thanks - hopefully the head work will go just as well and then it's the easy job of installing it!.. No I stuck with the standard 2.3 that came from a good 1997/1998 C70 T-5

[nottsgreent5]

Hi, thanks - hopefully the head work will go just as well and then it's the easy job of installing it!.. No I stuck with the standard 2.3 that came from a good 1997/1998 C70 T-5

Cool only reason i ask is the shells in a pic says ford 2.5 or volvo im in the process of rebuilding mine and kust made me think lol where did you source the shells from?

[Kerry_T-5R]

Yeah you are right - that's the box for the main bearings and they are all the same. Not sure about the shells though. I ordered the bearings from parts for Volvos online. Very helpful over the phone and got the shells and main bearings from them at the same time. Handy that they were available now that Volvo are stocking less and less parts for our cars! Have you done a thread for yours?

[nottsgreent5]

Cheers for the info bud ill give them a call. I havent as yet its somthing i keep meaning to do but never get round to lol

[Kerry_T-5R]

Made a bit more progress with the build:

Cam cover and cams removed



Then began the process of stripping the head completely. All valves were removed:



This left us with a completely stripped head - now at the machine shop for skimming:



Will hopefully get the head back later this week in order to start re-assembling it. In the meantime here is a picture of the old exhaust manifold (left of pic) vs. the S60R manifold (thanks to Tim Williams for sourcing a good one for me) that will be replacing it:

[MoleT-5R]

Made a bit more progress with the build:

Cam cover and cams removed



Then began the process of stripping the head completely. All valves were removed:



This left us with a completely stripped head - now at the machine shop for skimming:



Will hopefully get the head back later this week in order to start re-assembling it. In the meantime here is a picture of the old exhaust manifold (left of pic) vs. the S60R manifold (thanks to Tim Williams for sourcing a good one for me) that will be replacing it:

Interesting these s60r manifolds when straight out the box they look a bit restricted where the exit to the turbo exhaust housing is in comparisom to the Japanifold as most call it, I'm going to swap from the japan one to the s60r one in my next round of mods to the olive T-5R, but I have opened up the port to the turbo to match my ported angled housing.

standard japanifold ( this one is about to be ground out and will be soon on an Olive 854 T-5r )
IMG_20160415_173541_572 by moleadrian, on Flickr

and my modified s60r manifold (sorry pic quality on both shots is at bit crap compared to my normal shots)
IMG_20160324_100022_540 by moleadrian, on Flickr

[Kerry_T-5R]

Your S60R manifold is certainly Looking good and will be very interesting to see how much difference it makes to yours. Did you grind that out yourself? As for mine, probably not much different to the Japanifold (and definitely not once ground) but certainly a lot better flowing than the one I removed!

[MoleT-5R]

Your S60R manifold is certainly Looking good and will be very interesting to see how much difference it makes to yours. Did you grind that out yourself? As for mine, probably not much different to the Japanifold (and definitely not once ground) but certainly a lot better flowing than the one I removed!

yep ground both out with a die grinder, carbide burrs for fast metal remove and then stones for a nice smooth finish. The s60r or Japan item are way better than the standard item ( and the s60r is also stamped Japan on the back.. )

[Kerry_T-5R]

Got this package from Volvo:



S60R Head Gasket, C30 T-5 exhaust manifold gasket, Head Bolts, Valve Stem seals, all new seals and gaskets for the head, timing belt kit, thermostat kit, water temp sensor, spark plugs, rotor arm, distributor cap etc etc

Next, we removed the old valve stem seals. Much harder than it looks..





And managed to fit 2x new Valve Stem seals before calling it a day:



That's it for now. Hopefully get chance to do some more at the weekend

[Kerry_T-5R]

Made some more progress with the engine build over the long weekend:

Ground in the valves:





Fitted all of the remaining valve stem seals and inserted all of the cleaned up/ground in valves :



Refitted all of the valve springs, collets and caps :



Installed 15x hydraulic lifters, but 5 appear to have seized? May need to purchase 5 new ones



S60R head gasket on :



New head (stretch) bolts had their threads coated in oil before installing and tightening in sequence over 3 stages



Leading to this :



Just need to install 5 more hydraulic lifters, cams, cam cover and time it up before I can start thinking about installing it..