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Thread: Project 254

  1. #21
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    The old red block engine and M90 gearbox came out without much grief. The gearbox was removed ready to be fitted to the T5 lump. The adaptor plate was drilled and tapped to the hole pattern of the gearbox. The m90 pivot ball was measured and was 24mm long (RHD side)but the pivot ball from the m47 gearbox was 30mm (LHD side) long so with the aid of 2 8mm washes the pivot ball was the required length of 34mm. Had to grind the corner off the drivers side lower mount so the steering column would miss.







    So today the T5 lump and m90 gearbox was fitted into the car. What a PITA, had to drop the cross member by 40 so the sump could fit over the top. Once passed the cross member it dropped in perfectly and lined up with all the mounts.



    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold

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  3. #22
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    Back in an AWD....Oh the grip!
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    Coming along nicely

    Thats some gap in front of the engine, the 5 pot can't be much longer than the redblock by the look of it.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, cold air con. Follow the project here
    1996 Nautic Blue 850 AWD - The daily, resisting the urge to modify

  4. #23
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    Up date time as the car is up and running now

    Time for a bit of wiring.


    ECU fitted and wired in.


    Oil and water lines were made from 10mm hydraulic pipe.


    3" induction pipes.



    Fuse board relocated to the glove box.


    2.5" downpipe with lambda and wideband semsors.


    3" maf and heat shield.
    Last edited by oblark; Saturday 30th April 2016 at 21:19.

    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold

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  6. #24
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    Two secondhand struts to be turned into coilovers.


    Coilovers with brembo calipers and custom 290mm discs.


    Nice ride height.


    Later type brake reservoir.


    The old panhard converted to a adjustable one.


    Bumper removed to add some more air flow.



    Custom power steering fitting.


    New strut brace and catch tank fitted.



    Strut brace all painted up.




    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold

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  8. #25
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    So is it running now?

  9. #26
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    Yep it's up and running.

    Last edited by oblark; Saturday 30th April 2016 at 21:44.

    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold

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  11. #27
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    This is looking great Rob, lots of hard work and attention to detail - Particularly like the glove box relocation of the fuse board.

    What's left on the list of things to do?

  12. #28
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    Fair play rob this is great work. I felt pleased with myself for removing rebuilding and refitting a t5 engine but that came from the same car and is nothing like the complexity of this! A t5 lump in a 244 body shell is the perfect combo, it's going to be great fun! I wish I had your skills mate

  13. #29
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    Had to fit the 16T that I was going to convert to a 19T as the 15G decided to eat its self,

    So with the 16T fitted and once I'd fixed the rough running it was time to do some data logging,

    For a 16T and white it produces some good boost

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    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold

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  15. #30
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    Another awesome thread Rob, great to see the fruits of your efforts

    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

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  17. #31
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    Some tidy work there.

    The strut brace is a work of art though.
    Silver - 1999 Volvo V70 - 2.5 TDi - Miles: 200,000
    Scrapped: Silver - 1998 Volvo V70 - 2.5 TDi - Miles: 300,000+

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  19. #32
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    Finally got around to having some adaptor rings made so I could fit the chrome centre caps.





    Took the 240 t5 to the Winchester classic car & bike breakfast meet on bank holiday monday.



    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold

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  21. #33
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    The 240 has started a bad habit of eating cluthes, the reason for this is the frition plate is hanging off the end of the gearbox imput shaft. To overcome this problem a construction grade disc was bolted to the face of the flywheel then drilled to loose the additional weight of the disc. So the flywheel went from 7 kgs to 10kgs then down to 9 kgs. Just need to get it balanced then I can get it fitted.

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    I also built a plenum chamber inlet manifold as the throttle was a PITA to get at on the old ME7 manifold.

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    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold

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  23. #34
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    Well the 240 got converted back to the B230FK engine then she was sold.

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    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold

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    kmb (Sunday 9th July 2017),martin_r_smith (Sunday 9th July 2017),MoleT-5R (Tuesday 11th July 2017)

  25. #35
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    Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??

    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

  26. #36
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    Quote Originally Posted by MoleT-5R View Post
    Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??
    Don't worry moley, the work hasn't stopped I'll start a new project thread soon.
    854 T5 - The new project.

    850 tdi - sorely missed.

  27. #37
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    Nice one Martin, nice to see that the car is still in the forum, you kept that quiet. ...

    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

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  29. #38
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    Quote Originally Posted by MoleT-5R View Post
    Sad to see her go Rob, really enjoyed this thread and the top work that has gone into the project, whats next mate ?? push on with the awd project or something else ??
    It's full steam ahead on the awd conversion which all starts in just over a weeks time

    1996 850 - 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, 2.5" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

    1983 240 - M4.4 ECU with COP's, ostrich 2.0, B5234T5 engine, M90 gearbox, green injectors, 3.25 " MAF, 2.5" stainless exhaust, custom strut brace, 2" banded rear rims, brembo front calipers sold


 

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