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  1. #21
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    Quote Originally Posted by MoleT-5R View Post
    amazing these small changes that you would not normally even think about, these awd's really are a different breed...!!
    Indeed!

    I have another to add to the list. Whilst browsing the Volvo tech manual I found an article on torque steer. Apparently you have to measure the gap between the engine subframe and each driveshaft. If the difference between sides is any bigger than a 5mm (I think) then the gearbox mount on the N/S can be adjusted to eliminate/reduce the torque steer.

    Trying to find the procedure again.

    Found it:

    Last edited by Dangerous Dave; Friday 26th June 2015 at 01:11.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  3. #22
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    MoleT-5R's Avatar
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    Quote Originally Posted by Dangerous Dave View Post
    Indeed!

    I have another to add to the list. Whilst browsing the Volvo tech manual I found an article on torque steer. Apparently you have to measure the gap between the engine subframe and each driveshaft. If the difference between sides is any bigger than a 5mm (I think) then the gearbox mount on the N/S can be adjusted to eliminate/reduce the torque steer.

    Trying to find the procedure again.

    Found it:

    yet another very useful bit of info, will be checking Olive's clearence's when her engine comes out this weekend.........hopefully

    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/sch/moleadrian...p2047675.l2562

  4. #23
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    So now I'm cleaning up the subframe, gearbox and angle gear.

    Decided to crack open the angle gear as I have some new oil to go in it (and I'll be replacing all the seals in it, might as well). Inside I found 2-3mm of baked on and sludgy oil, bearings are clogged up but still move. Must be as a result of the heat from the engine and exhaust which are in close proximity to it. Trying to find a chemical which can remove the baked on oil, have some products but need something to get inside the bearings...

    Having some trouble cracking the output shaft nut, gonna have to break out the big bar and a bigger vice. The manual says it's torqued to 180nm

    Piccies of the sludge


    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  6. #24
    Gearbox Killer
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    how many mile had this angle gear unit done and do they recommend regular oil changes or is this item another filled for life by Volvo job...??

    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/sch/moleadrian...p2047675.l2562

  7. #25
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    It has done around 160k, think it is on the service schedule, I'll have to look it up in a bit.

    It's pretty much cleaned up now, though I had to scrub hard, that dried on stuff is a b*tch to move.

    Managed to crack the pinion nut, had to make up a bar with some pins to hold it.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  9. #26
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    Coming along
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    Cars : 2009 VW Passat CC 140 CR & 2015 VW Golf R. Uploaded Albums. Past Statuses (Or is that Stati?). Past Posts.

  10. #27
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    Angle gear is all cleaned up and has new seals and oil

    Now to do the gearbox...



    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  12. #28
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    Gearbox is finished....

    Took longer than planned as some fool forgot to put the magnet back in the bottom so had to split it again, clean off and reapply the sealant.

    \

    Now to crack on with the engine subframe
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  13. #29
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    Little update, had to cut the back of the engine to make sure the angle gear doesn't foul on the block (see pic some posts further up)



    Not bad considering I only used an angle grinder (Pedro would be proud )
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  15. #30
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    Quote Originally Posted by Dangerous Dave View Post
    Angle gear is all cleaned up and has new seals and oil

    Now to do the gearbox...



    nice to be able to see the internals as the Haynes book of lies would never entertain showing us important stuff like this

    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/sch/moleadrian...p2047675.l2562

  16. #31
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    Got some more done...

    Engine subframe cleaned off and painted


    bits added


    Swapped out the 19T on the V70 for its original 16T, only took 2 hours to swap the turbos over. I forgot how quick the 16T spools.

    Fitted 19T to the engine. For some reason FRF sent me 4 turbo oil return bottom seals and 4 upper gaskets (two the same and two different)


    Also fitted the VXR injectors.

    Apart from fitting the flywheel and new clutch (can't whilst it is on the engine stand), it's all ready to back together and in the car, which should happen sometime next week (hopefully). Then I'll move onto sorting out some issues created by leaving the car standing for so long (some interior bits need attention, I've got an S80 steering wheel to fit and I think I'll flush/check the fuel system).

    More to come...
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  18. #32
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    Has been some time since the last update, have had a crappy couple of months unfortunately.

    Anyway, I finally got an engine hoist and had our Overlord build it for me (thanks Santa).

    Fitted the new clutch, quite a difference to the old one, the friction plate is thicker plus about 5mm wider. Should last a bit longer


    Fitted the rest of the components to the subframe and put it on the dolly I made to move it around.


    Engine on


    Lifted the car up


    Engine is now in, just need to connect everything, fit the new radiator, put the driveshafts in and fill the gearbox with oil. Have got a wideband lambda sensor to fit too, getting the existing sensor out was a nightmare as it was really stuck in there (plus I forgot to remove it before I put the engine in ).
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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    claymore (Sunday 13th December 2015),craigoodwood (Saturday 10th October 2015),Jamest5r (Friday 9th October 2015),jamesy12345 (Friday 9th October 2015),LeeT5 (Saturday 16th April 2016),MoleT-5R (Friday 9th October 2015)

  20. #33
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    Quote Originally Posted by Dangerous Dave View Post

    Anyway, I finally got an engine hoist and had our Overlord build it for me (thanks Santa).
    I hung myself off it as well so we know it's good for 2 tonnes
    Any suggestions, information, complaints or grievances relating to this forum please feel free to contact us, talk to a mod or administrator

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  22. #34
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    Quote Originally Posted by Dangerous Dave View Post

    Have got a wideband lambda sensor to fit too, getting the existing sensor out was a nightmare as it was really stuck in there (plus I forgot to remove it before I put the engine in ).
    Are you replacing your original Lambda sensor with a wide band sensor? this confuses me?
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  23. #35
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    Quote Originally Posted by claymore View Post
    Are you replacing your original Lambda sensor with a wide band sensor? this confuses me?
    what colin said^^

    wouldn't you need a narrow-band output for the ECU....

    this piece of kit can take a wideband input & turn it into a narrowband output http://www.efi-parts.co.uk/index.php?productID=173

    A bit pricey though

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  25. #36
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    Quote Originally Posted by jamesy12345 View Post
    what colin said^^

    wouldn't you need a narrow-band output for the ECU....

    this piece of kit can take a wideband input & turn it into a narrowband output http://www.efi-parts.co.uk/index.php?productID=173

    A bit pricey though
    Or purchase the software from Maarten which uses a wideband sensor to control the ecu.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, ostrich 2.0 , green injectors, K24 turbo, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

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  27. #37
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    Quote Originally Posted by claymore View Post
    Are you replacing your original Lambda sensor with a wide band sensor? this confuses me?
    Yep. Saves me having another hole added.

    Quote Originally Posted by jamesy12345 View Post
    what colin said^^

    wouldn't you need a narrow-band output for the ECU....

    this piece of kit can take a wideband input & turn it into a narrowband output http://www.efi-parts.co.uk/index.php?productID=173

    A bit pricey though
    Yes, very pricey.....

    I bought a DIY wideband controller from the USA which does all the narrowband conversion/heater control and is a very cheap alternative:
    http://www.14point7.com/products/slc-free

    The Bosch LSU4.9 lambda sensor arrived this morning

    I got the DIY kit some months ago, it's built and just needs the wiring adding to it.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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  29. #38
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    Also had a problem with the starter motor. Managed to break the connector off the solenoid, must have been brittle. Upon opening the starter motor it seems all the grease has dried up so it is getting an overhaul.

    Fortunately I think I have a spare solenoid.

    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  30. #39
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    very nice! Hmmm the thought of an AWD is appealing. Sadly my days of having a huge workshop are now over and all work is down in the road under a brolly
    My experience of engine paint (from my days of restoring/tuning REAL Minis - not the fake rubbish imitation things) is that it BAKES on after a few days!!
    One pic looks like you've fitted a mountain bike wheel to the crank pulley!!
    http://www.vpcuk.org/forums/image.php?type=sigpic&userid=11614&dateline=143983  7674

    2004 - V70 D5 estate - POS waste of money dead and useless
    2001 - V70 T5 P2 -DEAD, bushes, handbrake etc etc
    2002 - C70 T5 - DEAD steering rack, handbrake etc etc
    1997 - V70 T5 ex -armed response unit - killed by a skip lorry, gone but not forgotten
    Next on shopping list - V70R!!!!! (saving hard)

  31. #40
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    Quote Originally Posted by Dangerous Dave View Post
    Have finally got the old engine out the car. Started stripping the AWD components and gearbox off. I've forgotten how heavy the gearbox is (the real reason is I'm not a fit as I was a few years ago).



    Whilst draining the oil out the engine I noticed some machining on the intermediate section of the block. Seems this is to accommodate the angle gear (not even a fingers width clearance when in situ), so looks like I've got to get Pedro down with his angle grinder to attack the block

    Looks like they've taken a lot off the bolt hole (compared to the other one on the right and on the new engine)
    so this is the 2.5 lpt engine?? youve not still got it kicking bout hve you??


 

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