Rich T5 Project!

[RichT4]

Old 850 how dare you lol get a new block and you will be back up and running in no time as with any car/project there all here to test us.
what are your plans for the car you could possibly look out for a 2.4 bottom.end kkk turbo and that should see 300+

Sorry lol, frustration was aimed directly at 'him'.

I'm looking into a new block ATM, turbo wise I haven't got a clue. Might start with forged internals providing I can afford it.

[AndysR]

Well I'm not in my right mind, I fancied a challenge and a challenge is what I have taken on.
I don't know anyone who would want to chuck money at an old 850 but it seems quite obvious that we are all insane...right?!

Cheek! Mines not even out the teens yet

You spend your money on what makes you happy so sod what the audience think, I'd cut my losses and wack an entirely different lump in there preferably for a known good source and that will hopefully save you a host of future issues due to the fault with the original engine

[M-R-P]

Rich - quickest way around this is source another 2003-on T5 engine and stick it back together. The later 2.3 T5 lump has the stronger bottom end any way. If you get a 2.4 block you'd need to do a few mods and get a custom map straight away as there's a few differences. Use whatever ancillaries you have that work to save a few quid, source the rest through the forums and you're laughing.

Then you can move on to the fun stuff

[RichT4]

Rich - quickest way around this is source another 2003-on T5 engine and stick it back together. The later 2.3 T5 lump has the stronger bottom end any way. If you get a 2.4 block you'd need to do a few mods and get a custom map straight away as there's a few differences. Use whatever ancillaries you have that work to save a few quid, source the rest through the forums and you're laughing.

Then you can move on to the fun stuff

Isn't mine the later T5 engine?
I won't be getting the 2.4 block.

[hemihusky]

man sucks to hear about the engine. but will look forward to seeing what you do with it! and hey my 850 hasnt been that bad. its only eaten a water pump. aux belt tentioner. timing belt tentioner. whole radiator. turbo. and a catalist!

[RichT4]

Every evening this week I have been coming home from work to take more of the car apart bit by bit.
Through every back breaking turn of the breaker bar I have finally got the engine in a position to be removed.
In the process I have discovered pockets of rust on the vehicle which are going to be taken care of before she gets back together.

Thankfully I have sourced a bottom end to replace this buggered one, just waiting on a call back for the price of it.

I have been thinking about up rating the pistons etc... But have decided against it this time round. I will possibly uprate the bushes and replace a majority of the seals so I have a running engine.

Instead I will keep the damaged block, my plan being that I rebuild it over time with uprated bits and make it stronger, that way I will replace it when the time comes

Here's some photos for your viewing pleasure:







Also I have finally made a list of parts she will need for her to be rebuilt.

2x suspension struts
2x droplinks
4x hub pivot bolts
Replacement inlet manifold pipe
Replace cover behind cambelt
Head gasket kit
Head bolts
Cambelt kit
Water pump
Brake fluid
Gearbox oil
Inter cooler
O ring seal for turbo oil feed return pipe

[stribo]

I'd add strut top mounts to that list, yours are buggered.

[RichT4]

I'd add strut top mounts to that list, yours are buggered.

Lol, I'll probably just replace the entire strut

[M-R-P]

If the bottom end you've found is from a post-2002 (preferably 2003) car, it'll have the stronger bottom end in it any way so, unless you're thinking of exceeding 320+bhp, you'll not need to worry about rods.

I'm pleased to see another plodder getting some TLC Rich (even if I think you're a bit mad for doing it ) Keep it up dude and if I can help in any way, gimme a shout.

[RichT4]

Took the cylinder head apart today and found 7 exhaust valves and 9 inlet valves bent.
Explains the tapping somewhat. Will use another drill to confirm tomorrow though.

Also cleaned up the n/s wheel arch and put rust killer on it, followed up by some hammerite paint.
Before:



After:

[RichT4]

So, removal of the engine has started:





My garage is too full!!!


The only question I do have is relating to the fuel pipe behind the engine.
I had to cut it off by the block as I couldn't release it where you are supposed to.
How can I release the pipe??? So frustrating!

[RichT4]

Been spending the last few days cleaning up the chassis legs and painting some bits red. To subtly match in with what I'm planning

[stribo]

Good work mate, good to see you've made some progress.

[Harvey]

Good to see you getting on with it,not a very good start to volvo ownership.

I guess you will be getting a complete engine now you found out the head's valves been damaged,I guess it will save the cost of a gasket kit.

[RichT4]

Good to see you getting on with it,not a very good start to volvo ownership.

I guess you will be getting a complete engine now you found out the head's valves been damaged,I guess it will save the cost of a gasket kit.

Nope, defiant as always I'm going down the more expensive route.
Will be buying a used cylinder head and doing some cool stuff with that before it goes back on.

Just had fun removing this bugger! After days of occasional hitting, spraying with wd40 and using the cutting sockets I finally win!!
My man strength, 1925degC of heat and the cutting socket finally got it undone! And here it is, a little worse for wear.




I have also changed the main oil seal/diff seal, and swapped flywheels over onto the new block.

[M-R-P]

Might be worth fitting a new DMF or even a lightweight fly rather than an old one mate. If it let's - go, it'll be a gearbox off job again to sort.

[JamesT5]

And this is an 04 plate where Volvo had supposedly 'ironed out' all the failures and made improvements.

I thought I'd been unlucky with my T5 but this takes the biscuit! Well done for sticking with it, you'll have one hell of a motor when your done and it should be an absolute monster if you spend a little and uprate the internals.

[JamesT5]

By the way Rich, you have my sympathy on this.

Plus the Trolls will be along shortly to tell you how to rebuld your engine, all in bold highlight writing of course, and how you should just scrap the car and save yourself the money. Just ignore them; I do.

[RichT4]

Might be worth fitting a new DMF or even a lightweight fly rather than an old one mate. If it let's - go, it'll be a gearbox off job again to sort.

I have been considering this, might have to pass on it this time though.

And this is an 04 plate where Volvo had supposedly 'ironed out' all the failures and made improvements.

I thought I'd been unlucky with my T5 but this takes the biscuit! Well done for sticking with it, you'll have one hell of a motor when your done and it should be an absolute monster if you spend a little and uprate the internals.

Fingers crossed I can come across some funds soon, more I have then the more I can do with it.

[claymore]

By the way Rich, you have my sympathy on this.

Plus the Trolls will be along shortly to tell you how to rebuld your engine, all in bold highlight writing of course, and how you should just scrap the car and save yourself the money. Just ignore them; I do.

You just can't stop yourself can you, and you wonder why so many people dislike you and that there is a whole Facebook page dedicated just to you.