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  1. #81
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    Ettienne's Avatar
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    If you ever want to chuck it on a Dyno there a Dyno day on the 11th september not too far from you.

  2. #82
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    Quote Originally Posted by Ettienne View Post
    If you ever want to chuck it on a Dyno there a Dyno day on the 11th september not too far from you.
    Thanks for the info - I may well be up for attending that if all goes to plan.

    Today's update >

    Thanks to the advice of a helpful forum member, I carefully put the 5x seized hydraulic lifters in the vice and gently released them from their seized positions one by one. Very pleased with the outcome & now they are all installed as follows:



    Here is how the (mostly) assembled engine looks now:



    Got the cam cover back from the machine shop yesterday - cleaned up and ready to install once I have finished cleaning the camshafts at the weekend:



    That's all for now

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

  3. #83
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    Cleaned up the last few parts at the weekend:





    And last night, put the cams in along with new spark plug o-rings and camshaft oil seals



    ending up like this :



    Last edited by Kerry_T-5R; Tuesday 10th May 2016 at 13:35.

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

  4. #84
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    All the ladies love it
    sideways!
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    Quote Originally Posted by Kerry_T-5R View Post
    ending up like this :


    As I scrolled down I thought "Damn, that patio chair is strong!“

    Looking good now

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  6. #85
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    Haha - does look a bit like the worlds strongest patio chair in that pic! Thanks very much. Few more bits to bolt on and then we can start the task of installing it

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

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  8. #86
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    Looking good

  9. #87
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    Quote Originally Posted by Hybusamini View Post
    Looking good
    Thanks - as do both of your cars

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

  10. #88
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    Made a bit more progress on Saturday :



    Got the lower part of the cam belt cover fitted, along with the new cam belt tensioner and new pulley with new bolts for the sake of it.



    Then fitted the S40/V50/C30 T-5 exhaust manifold one piece gasket



    Had to snip off a small amount from the right hand side that would have blocked a water pipe



    S60R exhaust manifold installed



    New genuine coolant temperature sensor



    Crank pulley wheel installed but not yet torqued up

    Was hoping to fit the timing belt as well, but my vice wouldn’t open far enough to compress the damper/tensioner! Hopefully get that sorted this week

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

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  12. #89
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    Not much progress lately, but got the T-5R out of hibernation ready for its transplant!



    And also managed to time up the new engine - now ready for installation.



    Hoping to get the old engine out this weekend

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

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  14. #90
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    You may need to adjust that layered exhaust gasket because the water branch pipe doesn't quite fit otherwise. I know - I have the same one...
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    Join my projecteers tribe - Old Volvos Never Die - They just get faster.

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  15. #91
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    Quote Originally Posted by Wobbly Dave View Post
    You may need to adjust that layered exhaust gasket because the water branch pipe doesn't quite fit otherwise. I know - I have the same one...
    post 88 ..

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
    My Ebay Items http://www.ebay.co.uk/usr/quik.connection

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  17. #92
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    At the weekend, it was time to get started on removing the old engine:



    Got the car securely jacked up and on axle stands



    Front end panels and lights were stripped off in no time at all



    Inlet manifold off and ancillaries now accessible



    A full team of my friends/family were working flat out by Saturday afternoon!



    Next we were ready to lift the engine out. Unbolting the last few items like the fuel lines at the back had taken much longer than expected



    The engine was then carefully lifted out - had just enough clearance



    Unfortunately the hot side of the turbo has a couple of cracks, but I think that I have now sourced a good replacement from a forum member - just waiting to hear back



    And this is how the car stands now. Ordered up yet more parts from Volvo - just items that were perished or looked as though they were past their best. Not surprising to find a few things as the car is 20 years old now. Also ordered up a new starter motor to go with the new alternator that I already purchased.

    Few bits and pieces to do this week, and then hopefully we can start thinking about installing the new engine soon

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

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  19. #93
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    Great work mate. I can't wait to see the finished product.
    Grey 855R Manual. Totally standard.

  20. #94
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    A cracked turbo exhaust housing is very common due to the heat it handles, even ones I've bought that are supposedly crack free, when cleaned up have been found to have small hair line cracks in them. My old cracked 15g hotside is still running as part of Claymore's current T-5R turbo configuration (unless he's been playing again), so the cracks aren't necessarily detrimental to power generation from what I seen, but if you have one available all the better, are you going to the angled flange item ??

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
    My Ebay Items http://www.ebay.co.uk/usr/quik.connection

  21. #95
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    Hi, any chance you could measure the width between the chassis beams please? Ive not got an empty engine bay to look into haha.
    TIA.

  22. #96
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    Quote Originally Posted by mitchyboy01 View Post
    Great work mate. I can't wait to see the finished product.
    Thanks very much - I am really looking forward to driving it again now!

    Quote Originally Posted by MoleT-5R View Post
    A cracked turbo exhaust housing is very common due to the heat it handles, even ones I've bought that are supposedly crack free, when cleaned up have been found to have small hair line cracks in them. My old cracked 15g hotside is still running as part of Claymore's current T-5R turbo configuration (unless he's been playing again), so the cracks aren't necessarily detrimental to power generation from what I seen, but if you have one available all the better, are you going to the angled flange item ??
    That's interesting to know - thanks. I do have a known good one on it's way to me now so will fit it anyway for piece of mind

    Quote Originally Posted by Sparkysparks View Post
    Hi, any chance you could measure the width between the chassis beams please? Ive not got an empty engine bay to look into haha.
    TIA.
    No problem - I will measure it next time I work on the car

    Mini update: got the water branch attached last night - had to take the manifold back off because you can't quite get to one of the water branch bolts! Just need to attach the turbo/turbo hoses and it's ready for install


    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

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  24. #97
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    Awesome, thankyou.

  25. #98
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    Quote Originally Posted by Sparkysparks View Post
    Awesome, thankyou.
    97cm is the measurement

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

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  27. #99
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    Weekend progress

    On Friday evening after work, we managed to remove the gearbox, clutch and flywheel from my old engine and transfer the oil cooler lines over to the new engine (along with all new oil seals) and a new thermostat :



    Saturday afternoon was productive to say the least - Flywheel (with new one use bolts), clutch and gearbox onto the new engine :



    Turbo with new seals and DO88 water hoses to replace the old originals :



    Ending up with the engine looking like this & ready for install :



    Engine being lowered into place :



    Located as it should go :



    Engine was then bolted down properly :



    The turbo hot side wouldn't mate up to the downpipe unfortunately, so that was about as much as we could get done for one day. I didn't realise that there were 2 types of connection on the straight flange turbo hot sides. Hopefully I will be able to get one before the weekend. We still had a bit more time, so fitted all new track rods and ends to go with the new Meyle HD droplinks :

    N/S :



    O/S :



    On Sunday we connected the PCV & bolted on some of the ancillaries that wont restrict access for turbo refitting. New alternator :



    New starter motor :



    And how the car looked at the end of the weekend :



    If we don't have any further problems then it should be back together by the end of next weekend

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

  28. #100
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    Made some excellent progress with the car this weekend:

    Saturday

    Got started in the afternoon:



    Luckily we could remember where most things went as it wasn't that long ago since we removed the old engine



    Inlet manifold on and clutch bled. Had to replace the clutch pipe that runs under the battery tray as it was looking very corroded. Volvo have now made this a "classic" part so that they can charge a fortune for it! Worth doing though.



    And this is how we left it for the day - certainly looking a bit more recognisable as an 850 engine bay..



    Sunday

    Sunday ended up being fairly straightforward. Sun was out as well which was a welcome change. Managed to get the front end back on and generally worked from the turbo at the back of the engine forwards



    Before long it ended up like this:





    Filled it up with mineral oil for its first run:



    And after an initial non-start (spade plug for starter motor on wrong connector) it fired into life! Ran for 15 minutes on the mineral oil:



    Next we put the car back up on the driveway and dropped the mineral oil out and refilled with semi-synthetic 10W/40 for 500 miles of running in



    Here's how the car sits now:



    Missing a couple of covers, but will tidy up in the week. So far so good - no leaks etc & MOT is on Saturday. Hopefully be able to start driving it after that.

    Volvo 850 T-5R manual (Olive) B5234T5 : 305 bhp & a 14.5 sec 1/4 mile @ 101 mph & 2004 Volvo S40 1.9D S Daily driver.
    Ex-Volvo: B4194-T2 (S40 T4).

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