Nb's 850 R-esurrection thread

[AndysR]

Got a bit more done today. Hooking up the oil and coolant lines up to the turbo was SO much easier on my old T5 with the engine out on the bench as was re-fitting the turbo heat shield (who the hell designed that thing !) took me till lunchtime just to get that done ! Then finally got the cams back in and the cover sealed down (don't have the correct tool so had to pull all the 10mm bolts down a tad at a time !)



Then used my very home made cam timing tool to time up the cams and fitted the belt.



I fished the cambelt upper cover from amongst the rest of the shrapnel in the boot but was a little concerned at what I found

These are the mounting holes in the upper cover




The cover has basically melted where it contacts the cam-cover, this is not good as it means that the engine has been b@stard hot !. This is starting to give me 'the fear', the previous owner said that prior to selling the car the temperature had got hotter than normal and he had keyed it off to prevent it from overheating and that this was caused by the poor fitment of the radiator by the local garage (it was hanging off admittedly). He then had the head pulled but couldn't afford to have it replaced. Now I didn't find any evidence of head gasket failure but I'm starting to worry about the condition of the bottom end.(the severely rusty oil filter also doesn't suggest it was particularly well cared for !) The car was also MOT'd a month or so before I got it but just removing the front wheel to pull the crank pulley I have seen that the outer C/V boot it torn open, the rack gaiter is split and the track rod end boot is also split, all would be failure points (hmmmm !). Won't know the state of the engine or box till I turn the key, fingers crossed I'm just being paranoid !

Did the oil in the engine smell burnt at all? When I worked at Rover we had a few of the K series engines that had got hot enough to melt the inlet manifold and dipsticks some of them were ok some were not... Fingers crossed your's is ok after all Volvo engines aren't made out of Chocolate, well except the rods maybe... lol

[nobananas]

Never smelt the oil, (dipstick and tube still in the boot lol !). The old Laguna I used to have I bought with a blown head gasket and that had been so hot it had boiled the oil in the sump. !. I risked it because I only needed it for 6 months or so, but I ended up running it for 9 years without problems, hopefully the R will be the same .

[AndysR]

Fingers crossed then

[leet5r]

good work on the rebuild bud , turbo looks well with the porting , what tools did you use for it , might have a go at the spare 1 av got in the bat shed

[nobananas]

good work on the rebuild bud , turbo looks well with the porting , what tools did you use for it , might have a go at the spare 1 av got in the bat shed

Used carbide burrs for the main material removal
(these sort of things, come in various profiles)
http://www.ebay.co.uk/itm/CARBIDE-BU...item3f23f3ae3a

M-R-P did me a good deal on a couple and I also bought a couple more from ebay then smoothed and polished the machining marks out with a combination of drum sanders and flap wheels in a drill.

[nobananas]

Got a little bit done today (and a little done last weekend that I didn't mention !)

Last weekend managed to get the inlet manifold on in between other jobs.



And today did a few little jobs that seemed to take longer than they should !.

The bulkhead mount had definitely seen better days !



So this was replaced with the one I bought of Blackbeast that is practically as new (thanks Steve !)



Then I cleaned and refitted the end plate complete with polybush then there followed an hour or so of poking around under my running T5's bonnet to try and work out where things like the wiring loom should be routed as well as about a dozen other things that I was struggling to place properly ! (the joys of trying to piece together something you didn't take apart !)



I even managed to dig out another top cambelt cover that I didn't realise I had to replace the melted one !



I'm not too far off hearing the big ends knocking (eternal optimist !), I still have to get hold off a better crank pulley and decide whether to put together an RIP kit for it or just get it running on the pipework I've got and sort out the RIP later.

[leet5r]

coming along nicely bud

[martybelfastt5]

fingers crossed mate!!

[Jamest5r]

It will all be fine dont worry, how long till D Day

[Tomcat]

looking really nice mate, I'm sure it'll be ok, wanna come and do my R?...lol..

[nobananas]

It will all be fine dont worry, how long till D Day

Maybe the bank holiday weekend.....maybe !

[nobananas]

looking really nice mate, I'm sure it'll be ok, wanna come and do my R?...lol..

I think I'd rather have yours anyday Tc !

[Tomcat]

No, you wouldn't bud, it's a bloody wreck at the minute,lol.

[nobananas]

No, you wouldn't bud, it's a bloody wreck at the minute,lol.

Yeah but it runs Lol ! You'll get the running issues sorted mate, going to be something cheap and simple I'm sure.

[Tomcat]

Christ I hope so, cant be doing with a money pit,lol.

[nobananas]

Time for an update ! Did a few small jobs last weekend. Had to refit the old crank pulley as I didn't get around to replacing it and used the same locking tool that I used to remove it.

Here is my dodgy home made crank locking tool.



(basically it's an old BMX stunt peg I found in the shed filed down to fit !)

It fits in the crank sensor hole and locks against the sensor teeth. I wasn't particularly happy using the crank sensor housing as it's just a bit of cast alloy but when I was removing the pulley I had a breaker bar with a 12 foot scaffold pole attached to undo the nut so I think the housing is man enough !.

Here is the 'tool' in place.



I then spent a few hours draining out the oil and changing the filter then collecting together all the dodgy bits of silicone hose and joining pipes and tried to cobble together the boost pipes as they had been. This is all temporary at the moment, I just need to hear it run !

The last thing to do before initially starting it was to refit the injectors but some of the seals had been lost so I ordered some last week and luckily they turned up today so got the injectors fitted.

I fitted a cone filter that I had lying around just as a temporary measure and fitted a battery. Then with the injectors in place but not electrically connected I turned her over to get some oil pressure (which thankfully I got !) then refitted the injector plugs and tried to start it. I wasn't actually expecting it to start, I certainly wasn't expecting it to start straight away but it did ! Very tappety, very fast idle but no misfiring and very little exhaust smoke and running !. After a few minutes the lifters quietened down but the idle was still very high but I found a degraded hose going to the charcoal canister causing an airleak and with this replaced she now idles sweetly. Less good was the large water leak from the corner of the radiator but that's easily fixed and at least I only put plain water in it to flush it through so haven't wasted antifreeze.

So here she is running, not too pretty at the moment under the hood with a lot of the pipework being temporary but I'll sort that out.



I'll breath a lot easier after I've driven it and know for definite how healthy the engine and box really is.