Volvo 850 engine rebuild and exhaust recommendations

**Bigsi15** · Wednesday 26th August 2015, 00:46

Hi guys
I'm new to here but have been using the forum for info for quite a while now so may I firstly say thank you to everyone who has helped so much without realising it!

Anyhow I'm looking to build up a second t5 engine as a project to hopefully tune and fit into my current 96 850 t5. The details can be found from my thread on t5d5 to save typing it again only iPhone!

http://forums.t5d5.org/topic/29924-v...ntstolerances/

Basically I'm now after people's recommendations for exhaust systems. Seems the general consensus is 3" full system (based on me hopefully fitting a 20t td04 turbo) but they are very expensive. What are everyone's thoughts on 2.5"? Any good systems at either size that anyone could recommend at a reasonable price?

Any other general help/tips from you fonts of knowledge would also be much appreciated

Thanks guys

**nottsgreent5** · Wednesday 26th August 2015, 17:51

Hi buddy see you made it on here get some pics up of your car

**Bigsi15** · Wednesday 26th August 2015, 18:21

Hey buddy! Yeah here for all the help I can get! Lol!

**Bigsi15** · Wednesday 26th August 2015, 18:23

How do I upload from my iPhone?! Lol

**twr** · Wednesday 26th August 2015, 18:26

Photobucket is your friend.

**oblark** · Wednesday 26th August 2015, 19:18

Originally Posted by twr

Photobucket is your friend.

Or a pain in the ar$e

**Bigsi15** · Thursday 27th August 2015, 18:37

**Bigsi15** · Thursday 27th August 2015, 18:47

bores and internals seem good. no lip at all on the bores

**twr** · Thursday 27th August 2015, 18:50

Not the first time ive seen bores on the t5's like that. Look in great shape.

**Bigsi15** · Thursday 27th August 2015, 18:52

**Doingitsideways** · Thursday 27th August 2015, 19:06

Originally Posted by Bigsi15

Blimey, put that somewhere safe before you kick it over, ffs!!

Lovely cross hatching on those bores

**Bigsi15** · Thursday 27th August 2015, 19:27

haha yeah its bound to happen! thought it would be a simple and cheap way to ensure the same valves and springs go back in the same ports in the head. the head seems so clean and valves have no play and arent burnt (just a little carbon and will need a slight grind back in) that i dont want to replace them, they are bloody expensive!

**Bigsi15** · Thursday 27th August 2015, 19:28

**Bigsi15** · Thursday 27th August 2015, 19:28

all of these pics are after no cleaning what so ever, seems very clean for a 19 year old car with 100k miles

**Bigsi15** · Thursday 27th August 2015, 19:30

Originally Posted by nottsgreent5

Hi buddy see you made it on here get some pics up of your car

Just for you

**Bigsi15** · Thursday 27th August 2015, 19:42

Next will be forged rods. Any recommendations? Need to be a good fit preferably with small end (is that the piston joint bits?!) and reasonable price but not crap! Aim is to have a 20t turbo and aim for around 300 to 350 max hp

Thanks in advance

**Bigsi15** · Friday 28th August 2015, 17:06

Sorry to bombard you with posts but also have found a bit more information out regarding the MAF. Is it possible I'm going to need to replace mine with a larger one perhaps from a 960? Do these sorts of things need including in the map? Thanks

**Bigsi15** · Tuesday 1st September 2015, 21:09

Ok update. Went to the machine shop who were impressed with the general internal condition especially the Pistons and bearings. However they mentioned the bores were worn ranging from 4 1000ths to 7 1000ths (I think that's the measurements they gave). This means nothing to me but they said it was getting to the limit of new rings and a bore would be best. This is not an option as I can't afford the larger Pistons etc.

Are these margins as bad as they say or will it run well really? Car apparently only had around 100k miles on an auto

Thanks guys