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  1. #1
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    245 T5 "Matilda"

    Well, I've finally started this project. Matilda (1992 240SE estate) is in the newly extended man-cave ready to have her heart transplant.

    I've got a B5234T3 to go in her and have provisionally got a whiteblock M90 to go behind it.

    The plan is as follows:

    fit engine and 'box

    Add huuuge intercooler

    Make intake and exhaust manifolds

    add some engine management

    Enjoy!

    Plus all the other little jobs, of course, like making an exhaust, wiring everything up, cooling, etc, etc.

    The eventual plan is to run loads of boost with a Holset HX35 or similar, but since my budget is miniscule I'll start off with the stock 16T for now (with added boost pressure)

    If anyone is expecting a fast paced build then look elsewhere! Work, family and financial commitments mean that this will get done as and when I have the time and money to continue, and used parts will be sourced to keep costs down where safe & feasible. For example, rather than buy huge injectors I could, since I need to make a manifold anyway, have two banks of stock injectors. Anyway, the engine and 'box are coming out tomorrow and all the parts are for sale if anyone wants anything (a lot of it is already sold)

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  2. The Following 5 Users Say Thank You to 245TurboT5 For This Useful Post:

    claymore (Tuesday 9th May 2017),expolicev70t5 (Wednesday 10th May 2017),kmb (Wednesday 10th May 2017),LiamT4 (Tuesday 9th May 2017),petrolh34d (Tuesday 9th May 2017)

  3. #2
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    All the ladies love it
    sideways!
    Doingitsideways's Avatar
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    Love a boosted 245, even better with Whiteblock power!

    However, I think you may have the wrong engine, looking at the one on the stand there. Does look nice though with the white rocker cover

  4. #3
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    Lol! The original plan was to +T first and T5 later, but an impromptu internet search brought up a whiteblock M90 and so it seemed daft to do the job twice. The +T engine is what you see in the foreground of the picture. That will most likely get scrapped.

  5. #4
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    Back in an AWD....Oh the grip!
    Dangerous Dave's Avatar
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    I was in the same boat with my engine rebuild, time + money + family meant it took 4 years to get it back on the road and I still haven't finished with it.

    You going to beef up the internals of the T5 engine? Some forged rods would be a good idea if you're planning a mahoosive turbo in future.
    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

  6. #5
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    Eventually it'll have decent rods and a big turbo. For now, sadly, budget dictates that it retains it's 16T and stock rods. Still, with a little extra boost it'll have 300bhp, and that's almost three times the stock engine's power!

    In the mean time, I've acquired a Jeep Grand Cherokee to help me familiarise myself with the projected fuel consumption. I'm so glad I don't have to commute!!!!

  7. #6
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    Well, today's progress has been slow but sure. I've stripped all the gubbins off the whiteblock and removed the sump. I've then photographed it and asked a laser cutting company to quote me for a flange in mild steel. I'm also on the lookout for a manifold flange so I can start building the header.
    Last edited by 245TurboT5; Wednesday 10th May 2017 at 20:01.

  8. #7
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    So, this arrived today- another piece of the puzzle. 6 speed BMW 'box from a 130i. You can get the same 'box from a 330i. Obviously, the M Sport gear knob is worth a few bhp.








    Just need an old 960 auto bellhousing or knackered FWD 'box to chop up now. Anyone got one near Blackpool?

  9. #8
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    This is my old sump:



    This is my new sump:



    It's a work in progress....

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  11. #9
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    Diesel power!
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    Are you dry sumping it?
    Silver - 1999 Volvo V70 - 2.5 TDi - Miles: 200,000
    Scrapped: Silver - 1998 Volvo V70 - 2.5 TDi - Miles: 300,000+

  12. #10
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    No, that's just more expense & hassle, but I have some weld-on AN-10 fittings that I will use to give it a remote oil filter setup. That's another advantage over using a shortened 960 sump, as the filter isn't easy to get to in a RWD layout

  13. #11
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    855r 6sp lives
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    Make sure you pop up some good pics, I've got everything for a rwd conversion on a 240 / 740 etc but the bmw box looks interesting

  14. #12
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    Will do. I like to blog stuff when I'm doing a project and haven't been able to find a thread detailing this conversion on an English speaking forum, so am hoping it will help others in the future. So far it's looking like I'll need to shorten the prop 2", use a whiteblock clutch cover and at the moment it's looking like I'll have to use an unsprung BMW or puck style clutch plate, but hopefully I'll be able to find a sprung one. It wouldn't be fun if it was too easy!

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  16. #13
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    Bit more work on the sump yesterday- I got the flange cut out and the fittings for the remote oil filter welded on. Will hopefully get a bit more done today, but there are other jobs that need doing around the house.
    :-(



    Think the wife might go ever so slightly mental when she sees the state of the tumble dryer:










  17. #14
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    Ooh, forgot to mention- I picked this up the other day:



    Just need to find a 12cm2 turbine housing and external wastegate now.

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  19. #15
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    228k and still not broke it!

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    Interesting project, should be fun getting that huge turbo to behave but it'll be worth it
    19t, greens, 3" inlet, 3" downpipe with race cat, V70R catback, autotech map...

    310.2bhp / 333ft/lb

    2016 Swedish Day UK "Best Modified Swede"

  20. #16
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    I want to run 2 bar of boost eventually, which is where a Holset is at it's most efficient. At the risk of boring everyone, we Brits are terribly conservative with our turbo sizes, which leads to excessive exhaust back pressure. At best, this means you're not making as much power as you should be for the boost you're running, or at worst, you'll blow your engine up. With a 12cm2 turbine housing this be fully spooled 4-4.5k and boosting way before that.
    Last edited by 245TurboT5; Saturday 24th June 2017 at 15:08.

  21. #17
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    A new alternative to Megasquirt for the adventurous amongst us. It's open source, has nothing to do with MS before all the haters start, and will do 5 cylinder with an extra ignition output soldered onto the board. It's also very cheap, which is a bonus. I bought the board, a vr conditioner board and an Arduino Mega to power it for 22! Looks like it's going to cost about 70 to populate the board and then you need a MAP sensor and other engine sensors of your choice.

    https://speeduino.com/wiki/index.php/Speeduino

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  23. #18
    New Identity
    Back in an AWD....Oh the grip!
    Dangerous Dave's Avatar
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    Oooh, another Arduino project, I like 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

  24. #19
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    Well, having talked to some Swedes who have done the 6 speed conversion by cutting and welding the bellhousing it emerges that many who do it find problems. One guy told me he had a 0.013" misalignment that destroyed his transmission!

    Since I don't have machine shop facilities I have been persuaded that an adapter plate is way to go. Hopefully I can avoid the pitfalls of super heavy flywheels, etc. with a clutch arm pivot extension. Either way, it'll be an interesting project in itself, and will be fully documented.

  25. #20
    Gearbox Killer
    aiming for the 13's again...
    MoleT-5R's Avatar
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    I'm reading this thread with much interest in the engine management system and where you get to with this, I know Dave is a big Arduino fan, keep up the posts this is a great project.

    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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