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Thread: Project 254

  1. #1
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    Project 254

    As 240 turbo's using the 940 lpt red block engines are get as common as muck I think it's time to take the 240 to the next level ........ T5 it

    With the help from Steve we went and picked up a OBD1 850 T5 engine with 118k miles.

    The first thing I found was the turbo is well passed it's best, but the rest of the engine is Ok it looks like it's had the PCV changed and a service not many miles ago.

    The first thing to do is to remove all the bits that are not needed.




    Then bolt on all the bits that are needed.




    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. #2
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    Looking good Rob, don't suppose you got the gearbox with that engine??

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    Quote Originally Posted by Nealevo View Post
    Looking good Rob, don't suppose you got the gearbox with that engine??
    When we turned up the engine and gearbox was still on the sub frame,

    As it would fit in the back of Steve's car we had to break it down to just the engine.

    I'll pm you his phone number but he won't post anything.

    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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    Nice

    You going to run a custom sump or fit a modified 960 one?
    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

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    Quote Originally Posted by Dangerous Dave View Post
    Nice

    You going to run a custom sump or fit a modified 960 one?
    A modified 960 sump

    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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    Sweeeeet!

    Looking forward to future updates
    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

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    Picked this up from the profilers this afternoon before they closed for Christmas.


    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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    Quote Originally Posted by oblark View Post
    Picked this up from the profilers this afternoon before they closed for Christmas.

    Gearbox adapter?

    What you going to be running?
    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

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    Quote Originally Posted by Dangerous Dave View Post
    Gearbox adapter?

    What you going to be running?
    It's a gearbox adaptor so I can use the red block M90 gearbox.

    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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    Ah yes, I do like the smoothness of the M90 (well compared to the M47)
    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

  15. #11
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    Started to countersink the holes in the adaptor plate so it can be bolted to the engine, Did all but 4 as my countersinking bit has now passed it's best so I'll order a new one in the new year.

    Did a trail fit of the red block bell housing and all looks ok.


    Last edited by oblark; Saturday 26th December 2015 at 17:56.

    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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    i dont suppose you got the profile drawing with it too??

  17. #13
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    Quote Originally Posted by craigoodwood View Post
    i dont suppose you got the profile drawing with it too??
    I gave the profilers the bell housing and they used that to cut the adaptor plate.

    The gearbox adaptor plate is finished.




    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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  19. #14
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    Made a new turbo oil return pipe as the turbo has been "clocked" and the 850 wont fit anymore.

    The new pipe was made from a 940 lpt and a 850 oil pipe.






    The down pipe looks like it could be fun.


    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. #15
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    looking good rob
    "dare to be different"

  22. #16
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    This little beauty arrived in the post today


    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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    The intercooler you posted a photo of, may I ask if the tubes have internal turbulators, (internal finning)? Or are the tubes "empty"? Thanks.

  24. #18
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    Some major parts arrived from classic swede during the week so today I was out in the man cave cutting down the sump from a 6 cylinder to a 5 cylinder. Also the oil pick up tube modified to fit.








    Already to be welded.



    On the engine mount front, the inlet side only has 3 out of 4 bolt holes that line up. But the exhaust side only has 2 out of 4 bolt holes that line up so I'll be fabricating so new engine mounts out some steel plate.



    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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  26. #19
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    I purchased the CAD file of lower engine mounts from Homer and had them manufactured from 5mm steel. I wasn't happy with how the upper engine mounts sat so I manufactured them from also 5mm steel. I used a CAD (card aided design) to make the mounts.





    Picked the sump and the oil filter bracket from the machine shop this morning.

    The sump had to be skimmed as it bent when it was welded. With the aid of some Volvo chemical gasket the sump was fitted and the oil filter bracket was screwed into the sump.







    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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    Lol at the card aided design - Thanks for the updates Rob!


 

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