Thought it was about time I put my project up on here! Some of you may have seen it on other forums, so the first few posts of this will involve a lot of pasting..
2007 - how it was just after I bought it and cleaned it up :
The only modifications on the car when I bought it were a Re-map and a BSR stainless steel exhaust.
Here are some pictures I took at the end of January 2008:
February 2008
Next I decided to get the car fully serviced. The car has had two previous owners. The car has been serviced at Kings Volvo in Southampton by the first owner (the garage it was first registered) and then exclusively at BPC Volvo service specialists by the second owner - where it had a brand new engine fitted in 2004.
Here is a list of the work carried out:
1. Complete breather system.
2. Mobil 1 fully synthetic oil & genuine oil filter.
3. Genuine plugs.
4. Genuine Volvo Strut brace.
5. BSR optiflow air filter (induction Kit).
6. n/s fog light & fitting.
7. powerflex poly top mount.
The strut brace is one of the best value for money modifications, really stiffens up the car at the front and stops the car rolling as much when cornering.
Im also pleased with the induction kit which is hardly any louder than standard - except for a nice air sucking noise and a "dump" when changing gear.
May 2008
In May, some of my friends and I headed down to the nurburgring for a holiday. We had a fantastic week and I did several laps with my T-5R. I didn't really time myself, but on my quickest lap I managed just under 10 minutes (9 min 55ish) which I was quite pleased with - not bad for (as then) standard suspension.
I met someone down there from Belgium who also had an Olive T-5R - he took me for a lap of the ring which was under 9 minutes!!! We overtook several Porches, Impreza's etc (**EDIT** Turned out to be JC Viggen..).
My car was fantastic and covered a total of 957 miles and averaging 27 mpg - including the nurburgring laps which brought the average down to 17ish before heading home! The only thing I noticed is that smoke pourred from my pads after I did 4 laps in a row! There was however minimal fading, probably because they were genuine Volvo discs and pads. Goodyear Eagle F1's dont half squeal on most bends!! Grip fairly well though...
Here are a couple of pics:
Fully loaded in Le Shuttle : 5 people, 6 man tent, 5 sleeping bags, 5 peoples clothes etc for a week!
At the camp site.
Queuing for a lap (taken by a friend from the nurburgring cctv).
On the circuit.
Nearly on 3 wheels - shame you can't see it just after this one! :)
Finally, this one which was found on a german photographers website - my car was 5 up at the time!!
Very clean looking motor you have there! And only 2 previous owners with a new engine too!
August 2008
After getting back from the Nurburgring, I had a couple of modifications ready for my car.
Firstly I bought a set of blue samco's from Don at Kalmar Union. I replaced the coolant and turbo hoses. I also bought a forge dump valve and blanking plate from him.
Secondly, I bought a set of GAZ coilovers. Absoluteley fantastic. Outstanding quality, and the car handles like its on rails.
They are fully adjustable and the car can retain its original ride height if desired. Worth the extra money over some of the other brands in my opinion and as a bonus, they are made in England. They are LEDA coilovers, which GAZ bought the design for when LEDA went out of business a few years ago.
Here are some pictures: I will take some more of the car on a sunny day to show how low I have gone.
New hoses and dump valve.
Coilover kit as received.
Fitted.
Slammed!
September 2008
Time for new tyres:
Some lowered pictures :
This one shows the new colour coded panels below the headlights.
BEFORE : Taken before the coilovers were fitted. Also shows front mud flaps.
AFTER : Taken after the coilovers were fitted. Also shows front mud flaps removed.
Nice, very tidy job. Any plans for body styling, colour coding etc?
[quote=martinrpeachey;414245]Nice, very tidy job. Any plans for body styling, colour coding etc?[/quote] Cheers, still a fair bit more to paste :) - its changed a fair bit since the post above!
NOVEMBER 2008
The car has been in for a major service, the work carried out included:
- New lower control arms.
- New front wheel bearings.
- New track rod ends.
- New fuel filter.
- New crank shaft positioning sensor oil seal.
- Tracking and lazer alignment.
- Uprated IPD drop links.
- Oil and filter change (Mobil 1 0w - 40 fully synthetic).
- 2 x Yokohama Parada Spec 2 tyres - I now have a set of 4 on the car.
I also found some S70 door handles on ebay and had them painted in my cars colour!
This shows the difference between a genuine Volvo drop link and the uprated IPD version.
Yokohama Parada Spec 2 road legal!
S70 door handles now colour coded.
Fitted to the car.
The car is now superb to drive. Since owning the car I have replaced almost every suspension and braking component as well as a whole list of other things...
In my opinion the parada spec 2 tyres are leagues better than any other tyre I have used in the dry. In comparison to the last set of tyres I had (Goodyear Eagle F1's) they grip much better than the F1's in the dry, but the F1's are better in the wet.
The S70 door handles were no bother to fit, and in my opinion look much better!
AUGUST 2009
Finished a couple more mods to my car this week. I had all 4 wheels re-furbed in TVR anthracite, I had the side strips on the doors and front wing colour coded to match the car, and I had the grey on the front and rear bumpers restored so that I dont have to smear bumper care on each weekend!
Here is a pic before with the side strips un colour coded and my old wheel colour :
And here are the photos from today :
I think it looks better now!
APRIL 2009
Did the torque arm with poly bushes.
General pic
Ultra racing rear strut brace.
I also bought a complete interior from an 850R owned by a member on another forum. I am really pleased with it as it is almost mint. The base and upright bolsters hold you in much better than the original 850 T-5R seats - almost did my back in changing the seats over though!!
Before :
Stripped interior :
New seats and door cards fitted. Only missing the 850R steering wheel now as I already had the grey gear knob! :
I got these 96 seat belts to match the new ones in the front. Volvo changed them in 96 so my 95 ones didnt match!
I also got this 850R handbrake cover for less than £40 from my main dealers :
Yep, like that. Are you gonna colour code the door trims (that's in the next photo isn't it;)) EDIT Thought so! :)
MAY 2009
Me and my mates have been for another European road trip. 4 countries in 1 day, and of course another visit to the nurburgring:
T4Mark hadn't finished his T4 build in time so he bought a 940 turbo from Ebay.
Here's a couple of pics:
My car
In Belgium
Marks 940 Turbo on the ring. He did a couple of mods to it : 740 turbo alloys with 205/50/15 Hankooks, lowered 40 mm, MBC and he managed around about an 11 minute lap (not timed, but to the nearest minute). Not bad for an ebay special 1991 brick :)
[quote=martinrpeachey;414251]Yep, like that. Are you gonna colour code the door trims (that's in the next photo isn't it;)) EDIT Thought so! :)[/quote] Lol, good timing!
AUGUST 2009
My recent breakdown: I had my car booked in for its MOT, and I hadn't really planned to have much done. My car had been making a few clicking and scraping noises from the front left which was a bit odd but didn't sound or seem to be too serious, so I thought I would leave it until it was up at RT Mechanics to be checked out.
My girlfriend and I set off on a Friday at the beginning of August to go on holiday so we drove to brooklands where we were camping for the weekend. On the way there the noise got louder and louder but we had to get there before 7.30 pm. By the time we arrived, the n/s front brake was binding. I decided not to drive it to RT Mechanics on the Saturday as the problem was getting too serious.
Here's my car on the breakdown truck!
When we arrived at RT Mechanics it was about 3pm and I was lucky enough to be taken out in the Peril (Russ's project car). It was absolutely fantastic! Gives me something to aim for with mine in the future.. :) Thanks again Russ.
Heres a few pics of the problem with mine:
The disc and carrier have changed colour as they got so hot from the binding caliper! It turns out that the noises were from my c.v. joint which was beginning to fail. I had a new c.v. joint fitted, new discs, wheel arch liner, a carrier and also an abs sensor and at the same time I had a few mods carried out!
Carbotech xp8 pads.
IPD uprated anti roll bars on Russ's recommendation.
Brass gear linkage bushes on Russ's recommendation.
I have to say that my car has now been transformed. The car feels like it stops twice as quick with those pads! The work well from cold and are fantastic from hot.
The gear change is now silk smooth - can't believe the difference something so simple makes.
And to leave the best until last.... the IPD arb's are simply amazing! The difference they make even with coilovers already fitted is unbelievable. The stability, grip and feel are now superb. Pleased that Russ convinced me to have them done, didnt realise they would make such a difference as they have.
SEPTEMBER 2009
Me and the lads went over to the Nurburgring again from 17 - 21 September. Great weather and managed to do a few laps. Car was brilliant, never missed a beat.
Thought I would post up a few pics :
At a Belgian petrol station
Next stop in Belgium
At the campsite
On the ring :)
One more shot before heading home
MARCH / APRIL 2010
PART 1
Thought I would post up my next big modification to the car :
I bought from caffyns Volvo :
1 x set of flywheel bolts
1 x set of clutch retaining bolts
1 x clutch slave circlip
1 x rear main seal
2 x drive shaft nuts
2 x litres of genuine gearbox oil
1 x aux belt for no aircon
1 x clutch release bearing
1 x clutch slave cylinder
And a set of Delrin subframe bushes from RT Mechanics :
Barrysc, T4Mark, my other friend Mark and I made a 240 mile round trip to collect the following :
1 x recon gearbox with new bearings and seals etc :
with one of these fitted :) :
An uprated 850R clutch :
All being well, next weekends jobs are to fit all the parts and ditch the heavy old aircon!! Cheers to Barry for the lift to Bournemouth and back (and for walking the gearbox to the car and then to my house single handedly!!)
PART 2
Update for last Sunday :
Barrysc and T4Mark got to my house at 10.30 and we started straight away on stripping bits off the car ready to get the gear box off. They have already done this job on Barrys T-5 so my main roles were bolt removing, nut loosening, tea making and tool passing!
Heres my car with a few bits stripped :
Engine bay is looking a bit less familiar :
Barrysc and T4Mark
Few more bits off :
Engine support on :
Engine bay looking very bare :
AndysR and Jim_S70R came over to see how things were going in the afternoon and by 5pm we actually got to the stage of removing the old box and clutch, but those pictures didnt come out too well so I will take some tomorrow of that stage before I start.
The plan is to crack on with it again tomorrow so I will post an update at some point next week....
PART 3
Started at 11 ish on Sunday, and made quite good progress. Here is an update from Sundays work :
Here is a pic of where we got to last week with the box off:
New rear main seal fitted:
Flywheel re-fitted with the new style bolts:
Gearbox and Quaife fitted:
Subframe back up, engine mounts re fitted, air-con removed etc:
This is where we left it for the day. Just need to bleed the clutch and re-fit all the hoses etc.
PART 4
We managed to get the diff finished on Saturday, im a bit rushed today so heres a brief summary with pictures :
Reblaced my drive shaft boots while off:
Barry working hard:
Looking a bit more complete :
Back together, but will it jump start?
Luckily was all ok :
Here is a pic from Brooklands on Sunday :
The Quaife diff is fantastic. I thought the IPD bars were my best mod until I got this. Grip is incredible and it is almost a joke how early you can put the power on coming out of bends and roundabouts! :)
I will post up how im getting on after a few miles.
APRIL 2010
No updates as such, but did a 140 mile round trip on Monday to the Quaife MSA British Rallycross championship at Lydden Hill and back and the car was absolutely fantastic. The diff really is amazing and the grip is incredible. One of the best things I found with it is that you can enter some corners in a higher gear than usual because you can power round and out of bends at a much higher speed. What was quick cornering before, is now no effort cornering with the Quaife installed!
There were 6 Volvo's competing (4 240's, 1 ph 1 S40 and one ph2 S40 with a 3.0 red block) on Monday, and every race that had a Volvo entry was won by a Volvo. Unfortunately there were no Volvo's in the top class but the racing was excellent as usual.
Here is a pic of my car taken by a photographer who was at the rallycross :
JULY 2010
Thought I would post some pics of my nurburgring trip from 7th - 15th July 2010. Managed to do a few laps and the diff is brilliant, makes so much difference to the car on the track. Up the hill towards the carousel my o/s front wheel would spin for example, with the diff there is no chance of that. Very pleased with the car although I think I need to get a JT racing exhaust as the soundtrack was lacking!
In Belgium on the way down to the ring
In a field below the mini carousel when we went to watch some of the publc trackday
Inside Marks 940, he didnt get his t4 project finished in time (again!) Next time it will be going to the ring!
Various pics of my car on the circuit
And a pic taken on the way home
OCTOBER 2010
Suspension set up :
An update at last! I took the car up to wheels in motion in Chesham, Buckinghamshire as I have heard so many good reviews from so many people. They set up all sorts of performance cars including time attack and drift cars.
First of all the car was put on the ramp and the current alignment, camber, caster etc of the car are displayed :
After analysing the data, they discussed with me the modifications that I had already done and how I plan to use the car : fast road / track use, and then adjustments are made.
The main adjustment was to reduce the camber from 2.5 ish degrees to 1.2 ish degrees which will improve the cars ability to put the power down and it raised the front up by 5mm. The distance between the centre of the wheel and the arch are now 300mm front and rear which I was recommended as a good base set up. After the adjustments are made, the new results are displayed :
Very impressed with the service, knowledge, equipment and value for money - I noticed the difference on the 100 odd mile return trip. Would recommend wheels in motion to anyone, very pleased.
DECEMBER 2010
For the last few weeks I have changed several service items :
Genuine Volvo :
Plugs
Fuel filter
Bougicord leads
Distributor cap
Rotar arm
Car drives much better now, can feel a few more bhp under my right foot!
Also thought I would add a few snow pics :
And the best bit for last :
I dropped my car to RT's on Saturday because this arrived from JT in Sweden :
And this :
Now looks like this :
Picked up my car on 27/12/2010 from RT's with the JT exhaust fitted - it is absolutely awesome and makes the car feel much more torquey, also cant get enough of that sound with the 3" DP. My old exhaust used to pop and bank quietly, but this does a few nice pops and bangs when you lift off the loud pedal :). Couldn't be more pleased, will certainly do me until I decide to go for more power....
Few pics :
On the car :
And a couple from a few locations in York, where I spent new years with my girlfriend and a few friends :
Cheers to www.rtmechanics.co.uk for the exhaust, heat wrapping / fitting & to Scott, Andy & James for helping me make my mind up for which exhaust to go for!!
MAY 2011
I havent done much to the car for a while, until this weekend..
In April I went over to Belgium as one of my friends (JC Viggen from youtube) decided to break his car. I bought his intercooler, reverse flow IC piping, modified radiator mounts etc and 850R boot spoiler..
Heres lots of pics of the parts being fitted :
Barry starting the long task of removing the complete front end
Spoiler off, not a good look!
New spoiler on the left
New spoiler on
New intercooler from Jan's old car
Bare front end
New IC in
Some reverse piping on
Slam panel back in
Looking a bit more complete
Finishing touches!
Done!
A selection of pics from Saturday when we finished fitting all the parts.
And finally a selection of pics after a quick polish today.
MAY 2011 (2)
Had a busy weekend this weekend..
On Saturday I set off early for Santa Pod to take part in the Run What Yer Brung. The journey took 3 hours in total and entry was £10 and a further £25 for unlimited runs. My brother and I went up in my T-5R and we met my mum and dad there who went up in their C70
I watched for a while and then my Dad and I decided to have a go. My first run was a 14.7 second 1/4 mile which I was pretty pleased with. I did a further 7 runs - I some how managed to win 7 out of my 8 runs. The cars I beat included an STI classic Impreza, a Mazda MPS, Mondeo ST220, Alfa V6, my dads C70 x 2.
My best run of the day was :
Reaction time : 0.501 seconds
Total time : 14.573
Terminal speed : 100.52 mph
I was absolutely made up with those times, especially considering I didnt do a particularly agressive start! Here are some pics :
Quick pic after arriving
My Dads C70 T-5 GT
Me vs my Dad
Me vs Mondeo
And there is more....
I took Monday afternoon off to check my AFR's (and as a bonus get rough idea of bhp and torque!).
The best RR local to me is Sumopower in Rye - only an hour or so away from me. Here are a few pics :
One of the ramps
Nice WRC evo
Drift skyline
Eat dinner off floor clean?
Other side of the workshop
My car on the dyno
Very pleased with the results, mte stage 2 combined with my other mods seems to get the max out of the turbo as it starts to run out of puff! AFR's perfect as well - good result!
BHP at the wheels is 260.5 bhp / 304.78 bhp at the flywheel
281 ft lbs of torque at the wheel / 328.77 ft lbs oftorque at the flywheel
Very pleased - been a brilliant weekend.
NURBURGRING TRIP - 10th - 18th JUNE 2011
Went to the ring for a week with a few friends (including T4Mark with his S40 T4). 5th time we have been now so know the route off by heart and can get down there hassle free. Well and truly turned into an annual trip now!
At Folekestone, way too early in the morning! :
Shot on the way down taken from inside Marks T4 :
Trip to the supermarket to get the essentials :
Marks t4 fully loaded, was low enough on coilovers without a boot full of beer! :
Few random parked up shots :
Went to the nurburgring museum on a rainy day :
Most importantly.... Marks T4 on the circuit :
And the reason why mine wasnt :( .... :
Split the big rear engine mount and couldnt risk taking it around. Gives me a good excuse to go back though if nothing else!
Bought one of these after getting back from the Nurburgring :
The mount has been superceeded twice since the original, and the one on my car is the last original mount I haven't already replaced - probably about due to be replaced anyway.
Glad Mark was there to help me fit it otherwise I wouldnt have had a clue how..
Oh dear :
July 2011
Mot now due, 6 days before I get a clicking noise from the o/s front. Had to order one of these :
Volvo no longer do the cv joint separately AFAIK so managed to get this one from Autolec with a 2 year / 24,000 mile warranty. I dont usually buy pattern parts but this looks to be great quality and there was no Volvo alternative..
Nice one Kerry it is a lovey car you have, about time you got this done lol. Not sure why there is a thumbs down on this??
Looks good mate. Thats one hell of a write up youve done there.
[quote=Jim S70R;414285]Nice one Kerry it is a lovey car you have, about time you got this done lol. Not sure why there is a thumbs down on this??[/quote] Cheers Jim, as do you - surprised to see that your project isnt on here?! [quote=smithson007;414292]Looks good mate. Thats one hell of a write up youve done there.[/quote] Cheers mate
Makes me jealous looking at threads like these, i would never get away with spending my cash on tunning :^( amazing car.
[quote=volvokid;414305]Makes me jealous looking at threads like these, i would never get away with spending my cash on tunning :^( amazing car.[/quote] Many thanks for the kind words. Looking at your sig we have a similar choice in cars : An R and a phase 1.5 S40 D.. Cheers Kerry
excellent thread buddy, wicked motor too
I did notice that lol expect you like saloons and i like estates :^) i need to add my new V70R to my sig
Blimey should have had a drum roll for this thread as it's been a long time coming! Well done for finally getting into gear with it... Great car, great guy. It's a pleasure to see you on here Kerry, look forward to seeing the car again in the flesh sometime soon.
[quote=AndysR;414357]Blimey should have had a drum roll for this thread as it's been a long time coming! Well done for finally getting into gear with it... Great car, great guy. It's a pleasure to see you on here Kerry, look forward to seeing the car again in the flesh sometime soon.[/quote] Cheers Andy, about time I re-joined and re-posted up my project since the forum crashed a few years ago now! Pleased to see you didnt "thumb down" my project - unlike your bro lol. Yes, that sounds good, hopefully do another meet sooner rather than later! Kerry
Long time no update....
Done a few things recently. As some people know a certain red 850R was broken for parts so I had to get a few of the good bits that mine didnt have.
Went for these :
Stoptech BBK with carbotech xp8's. Basically big brembo's and 335 mm discs on alloy rotors with alloy carriers.
and these :
Pro race 1.2's 17" by 8.0"
Put quite a bit of time into the calipers, and they came out like this :
My friend (T4Mark) and brother helped me fit them :
Comparison with my old 302's
Came across a broken track rod end, knew something wasn't right!
Very pleased with the end result! Brakes are noticeably better even at low speeds..
Some more pics :
Nice, I'm liking those brakes.
wow mate the car looks fantastic now with the wheels and brakes , wish i stayed on with mine a bit longer lookin at those pics as i wanted the same wheels lol top marks
looking exellent kerry..........
[quote=leet5r;504479]wow mate the car looks fantastic now with the wheels and brakes , wish i stayed on with mine a bit longer lookin at those pics as i wanted the same wheels lol top marks[/quote] Thanks Lee, really pleased with it - still got a few more things planned for it in the future!
spot on mate , keep up the good work , best colour aswell
Had my wheel arches rolled yesterday so that my new wider wheels won't rub, used these guys as they come to you : http://www.archenemy.co.uk
Couldn't have been more impressed with the care taken and the end result. The guy that came out to me was Dan as he was the most local to me, used to work for mclaren and it showed through the care taken. Anyway here are a few pics :
Rear arch rolled.
Completed with sealant to stop it rusting.
Front in progress.
Done!
Here are a few pics today after a proper wash:
fav car on the forum mate , like it a lot
[quote=leet5r;510026]fav car on the forum mate , like it a lot[/quote] only because you had olive 854r lee lol but does look smart
want to swap for a saffy? lol
best car and colour combo m8
i have an s60 t5 in olive green too which i think is quite rare. not seen one in my area ever ,i love the colour of your wheels they go really well with the car what colour is it .do you think 18" pegs would look good with that colour.
[quote=ROZER;510076]i have an s60 t5 in olive green too which i think is quite rare. not seen one in my area ever ,i love the colour of your wheels they go really well with the car what colour is it .do you think 18" pegs would look good with that colour.[/quote] They are anthracite. If you speak to Lepsons or one of the other big wheel re-furbers you can pretty much pick any colour you like. I had my old titans done in TVR anthracite and they looked pretty good! A few people have done their pegs in anthracite and personally I think they look nicer than the standard silver colour. Cheers Kerry
Really great write up again Kerry, loving the big brakes and how they came up after cleaning and repainting.. I bet you're very happy, I nearly painted mine orange lol Scott..
Realised that I havent updated this thread for a while! Heres a mini update consisting mainly of pictures!
Fitted some of these from Sweden :
Put some of this in :
Annual ring trip 2012 :
Couple of friends with Volvo's also made the trip :
Kerry
Similar to the QBM drop links I tried a while back - completely knackered within a year. You must put rubber boots on them ASAP or the grit/dirt will destroy them.
I have no idea how i've not seen this thread before!! I've just sat and read from the top of page 1, and what a great write-up! Lots of inspiration here, thanks very much!
Looking Good,Was good to meet you at Mercedes Benz World to bud. Gav/merc
love this car , would have loved to have kept mine and tryed to to get it somewhere near this spec , everytime a see this it makes me want another , a proper sorted car in every aspect , brackes , wheels , diff , power , suspension , paintwork trim , every thing , not jel or anything like that lol top work kerry bud
[QUOTE=merc85;547995]Looking Good,Was good to meet you at Mercedes Benz World to bud. Gav/merc[/QUOTE] ah yes, car looks alot better in the flesh the pics don't do it justice
[QUOTE=Wobbly Dave;547939]Similar to the QBM drop links I tried a while back - completely knackered within a year. You must put rubber boots on them ASAP or the grit/dirt will destroy them.[/QUOTE] Will look into that, would be a bit dissapointed if they wore out in a year as they were £200! [QUOTE=T5RPete;547993]I have no idea how i've not seen this thread before!! I've just sat and read from the top of page 1, and what a great write-up! Lots of inspiration here, thanks very much![/QUOTE] Thanks for the kind words - glad you enjoyed the read! [QUOTE=merc85;547995]Looking Good,Was good to meet you at Mercedes Benz World to bud. Gav/merc[/QUOTE] You too Gav, will be definitely going to a few more meets once next spring comes around - car will be garaged for 6 months at the end of Nov! [QUOTE=leet5r;548180]love this car , would have loved to have kept mine and tryed to to get it somewhere near this spec , everytime a see this it makes me want another , a proper sorted car in every aspect , brackes , wheels , diff , power , suspension , paintwork trim , every thing , not jel or anything like that lol top work kerry bud[/QUOTE] Cheers Lee, yours was similar to mine in looks at least! I agree with all of that, just need a bit more power once funds allow. Am going to have a break from spending on it for a few months!! [QUOTE=p fandango;548187]ah yes, car looks alot better in the flesh the pics don't do it justice[/QUOTE] Cheers for the compliments
Just got back from the Nurburgring, so thought that I would post up a few pics:
Before I left:
2000 mile oil change (thanks Baz):
On the Nordschleife:
Drive by at brunchen:
[video=youtube_share;UFUjymBPqpg]http://youtu.be/UFUjymBPqpg[/video]
thats prob one of the nicest 850's i seen. yours and deans realy stand out in a crowd.
just read this from start to finish again , awesome car , defo have another in a heart beat
[QUOTE=leet5r;622978]just read this from start to finish again , awesome car , defo have another in a heart beat[/QUOTE]yes one very nice sorted volvo t5r one of the best I have seen along with yours mate wot off set and size wheels are these Kerry do fancy some for my motor
[QUOTE=WOODY T5;622983]yes one very nice sorted volvo t5r one of the best I have seen along with yours mate wot off set and size wheels are these Kerry do fancy some for my motor[/QUOTE] Thanks Woody, yours looks nice as well from what I have seen! The wheels are 17" by 8", not sure on the offset I'm afraid. Video now in HD so that the flame from the exhaust can be seen properly ;) : [video=youtube;WvbY2w_unCI]http://www.youtube.com/watch?v=WvbY2w_unCI[/video]
Great thread and super looking motor... all very interesting! :smile:
Well, I thought that I would bring this thread up to date now that I have made a little progress with the engine build.
Here is how the car stands today:
Bought a set of these (forged H beam con-rods):
Along with all new gaskets, o-rings, bearing sets, piston rings, oil pump, water pump etc etc etc:
Fortunately I managed to obtain a low mileage engine for a low price from a performance Volvo forum, and eventually once I had help available from a good friend we began the long process of stripping down the engine and thoroughly cleaning everything especially oil ways and mating surfaces.
Barry in action!
Then the block went off to our local machine shop for honing. I am missing a lot of pics from around this time (Spring 2015) but I have all of the following progress pics from this year.
Pistons attached to rods:
New rings:
One rod/piston installed:
All pistons/rods installed:
Crank shaft in:
Liquid gasket application:
Intermediate section down:
New oil pump and oil pick up pipe installed:
New water pump on:
Would have bolted the sump on, but missing 2 x o-rings! Will install during the week hopefully and then on to the head strip down next weekend.
O-rings turned up yesterday, so decided to fit the sump. Liquid gasket applied to the intermediate section:
This was then evenly spread out before bolting down the sump to the specified torque setting
And finally, installed the oil cooling jets, new gaskets and backing plates:
That's the bottom end complete! Head strip down commences on Saturday
some good work there bud , glad your keeping the good work going on the car
Cheers Lee. So am I now that I have started with the build! Always planned to and modified the car in every aspect so that it was ready for an engine build and more power. Would be a shame not to finally give the car the extra power that it is crying out for
Looks a nice build out of intrest are you useing a 2.5 bottom end
[QUOTE=nottsgreent5;799449]Looks a nice build out of intrest are you useing a 2.5 bottom end[/QUOTE] Hi, thanks - hopefully the head work will go just as well and then it's the easy job of installing it!.. No I stuck with the standard 2.3 that came from a good 1997/1998 C70 T-5
[QUOTE=Kerry_T-5R;799464]Hi, thanks - hopefully the head work will go just as well and then it's the easy job of installing it!.. No I stuck with the standard 2.3 that came from a good 1997/1998 C70 T-5[/QUOTE] Cool only reason i ask is the shells in a pic says ford 2.5 or volvo im in the process of rebuilding mine and kust made me think lol where did you source the shells from?
Yeah you are right - that's the box for the main bearings and they are all the same. Not sure about the shells though. I ordered the bearings from parts for Volvos online. Very helpful over the phone and got the shells and main bearings from them at the same time. Handy that they were available now that Volvo are stocking less and less parts for our cars! Have you done a thread for yours?
Cheers for the info bud ill give them a call. I havent as yet its somthing i keep meaning to do but never get round to lol
Made a bit more progress with the build:
Cam cover and cams removed
Then began the process of stripping the head completely. All valves were removed:
This left us with a completely stripped head - now at the machine shop for skimming:
Will hopefully get the head back later this week in order to start re-assembling it. In the meantime here is a picture of the old exhaust manifold (left of pic) vs. the S60R manifold (thanks to Tim Williams for sourcing a good one for me) that will be replacing it:
[QUOTE=Kerry_T-5R;799816]Made a bit more progress with the build:
Cam cover and cams removed
Then began the process of stripping the head completely. All valves were removed:
This left us with a completely stripped head - now at the machine shop for skimming:
Will hopefully get the head back later this week in order to start re-assembling it. In the meantime here is a picture of the old exhaust manifold (left of pic) vs. the S60R manifold (thanks to Tim Williams for sourcing a good one for me) that will be replacing it:
[/QUOTE]
Interesting these s60r manifolds when straight out the box they look a bit restricted where the exit to the turbo exhaust housing is in comparisom to the Japanifold as most call it, I'm going to swap from the japan one to the s60r one in my next round of mods to the olive T-5R, but I have opened up the port to the turbo to match my ported angled housing.
standard japanifold ( this one is about to be ground out and will be soon on an Olive 854 T-5r )
IMG_20160415_173541_572 by moleadrian, on Flickr
and my modified s60r manifold (sorry pic quality on both shots is at bit crap compared to my normal shots)
IMG_20160324_100022_540 by moleadrian, on Flickr
Your S60R manifold is certainly Looking good and will be very interesting to see how much difference it makes to yours. Did you grind that out yourself? As for mine, probably not much different to the Japanifold (and definitely not once ground) but certainly a lot better flowing than the one I removed!
[QUOTE=Kerry_T-5R;799834]Your S60R manifold is certainly Looking good and will be very interesting to see how much difference it makes to yours. Did you grind that out yourself? As for mine, probably not much different to the Japanifold (and definitely not once ground) but certainly a lot better flowing than the one I removed![/QUOTE] yep ground both out with a die grinder, carbide burrs for fast metal remove and then stones for a nice smooth finish. The s60r or Japan item are way better than the standard item ( and the s60r is also stamped Japan on the back..:) )
Got this package from Volvo:
S60R Head Gasket, C30 T-5 exhaust manifold gasket, Head Bolts, Valve Stem seals, all new seals and gaskets for the head, timing belt kit, thermostat kit, water temp sensor, spark plugs, rotor arm, distributor cap etc etc
Next, we removed the old valve stem seals. Much harder than it looks..
And managed to fit 2x new Valve Stem seals before calling it a day:
That's it for now. Hopefully get chance to do some more at the weekend
Made some more progress with the engine build over the long weekend:
Ground in the valves:
Fitted all of the remaining valve stem seals and inserted all of the cleaned up/ground in valves :
Refitted all of the valve springs, collets and caps :
Installed 15x hydraulic lifters, but 5 appear to have seized? May need to purchase 5 new ones
S60R head gasket on :
New head (stretch) bolts had their threads coated in oil before installing and tightening in sequence over 3 stages
Leading to this :
Just need to install 5 more hydraulic lifters, cams, cam cover and time it up before I can start thinking about installing it..
If you ever want to chuck it on a Dyno there a Dyno day on the 11th september not too far from you.
[QUOTE=Ettienne;800453]If you ever want to chuck it on a Dyno there a Dyno day on the 11th september not too far from you.[/QUOTE]
Thanks for the info - I may well be up for attending that if all goes to plan.
Today's update >
Thanks to the advice of a helpful forum member, I carefully put the 5x seized hydraulic lifters in the vice and gently released them from their seized positions one by one. Very pleased with the outcome & now they are all installed as follows:
Here is how the (mostly) assembled engine looks now:
Got the cam cover back from the machine shop yesterday - cleaned up and ready to install once I have finished cleaning the camshafts at the weekend:
That's all for now
Cleaned up the last few parts at the weekend:
And last night, put the cams in along with new spark plug o-rings and camshaft oil seals
ending up like this :
[QUOTE=Kerry_T-5R;800763]
ending up like this :
[/QUOTE]
As I scrolled down I thought "Damn, that patio chair is strong!“
Looking good now :)
Haha - does look a bit like the worlds strongest patio chair in that pic! Thanks very much. Few more bits to bolt on and then we can start the task of installing it
Looking good:B_thumb::B_thumb:
[QUOTE=Hybusamini;800770]Looking good:B_thumb::B_thumb:[/QUOTE] Thanks - as do both of your cars :B_thumb:
Made a bit more progress on Saturday :
Got the lower part of the cam belt cover fitted, along with the new cam belt tensioner and new pulley with new bolts for the sake of it.
Then fitted the S40/V50/C30 T-5 exhaust manifold one piece gasket
Had to snip off a small amount from the right hand side that would have blocked a water pipe
S60R exhaust manifold installed
New genuine coolant temperature sensor
Crank pulley wheel installed but not yet torqued up
Was hoping to fit the timing belt as well, but my vice wouldn’t open far enough to compress the damper/tensioner! Hopefully get that sorted this week
Not much progress lately, but got the T-5R out of hibernation ready for its transplant!
And also managed to time up the new engine - now ready for installation.
Hoping to get the old engine out this weekend
You may need to adjust that layered exhaust gasket because the water branch pipe doesn't quite fit otherwise. I know - I have the same one...
[QUOTE=Wobbly Dave;801812]You may need to adjust that layered exhaust gasket because the water branch pipe doesn't quite fit otherwise. I know - I have the same one...[/QUOTE] post 88 ..
At the weekend, it was time to get started on removing the old engine:
Got the car securely jacked up and on axle stands
Front end panels and lights were stripped off in no time at all
Inlet manifold off and ancillaries now accessible
A full team of my friends/family were working flat out by Saturday afternoon!
Next we were ready to lift the engine out. Unbolting the last few items like the fuel lines at the back had taken much longer than expected
The engine was then carefully lifted out - had just enough clearance
Unfortunately the hot side of the turbo has a couple of cracks, but I think that I have now sourced a good replacement from a forum member - just waiting to hear back
And this is how the car stands now. Ordered up yet more parts from Volvo - just items that were perished or looked as though they were past their best. Not surprising to find a few things as the car is 20 years old now. Also ordered up a new starter motor to go with the new alternator that I already purchased.
Few bits and pieces to do this week, and then hopefully we can start thinking about installing the new engine soon
Great work mate. I can't wait to see the finished product.
A cracked turbo exhaust housing is very common due to the heat it handles, even ones I've bought that are supposedly crack free, when cleaned up have been found to have small hair line cracks in them. My old cracked 15g hotside is still running as part of Claymore's current T-5R turbo configuration (unless he's been playing again), so the cracks aren't necessarily detrimental to power generation from what I seen, but if you have one available all the better, are you going to the angled flange item ??
Hi, any chance you could measure the width between the chassis beams please? Ive not got an empty engine bay to look into haha. TIA.
[QUOTE=mitchyboy01;801834]Great work mate. I can't wait to see the finished product.[/QUOTE]
Thanks very much - I am really looking forward to driving it again now!
[QUOTE=MoleT-5R;801837]A cracked turbo exhaust housing is very common due to the heat it handles, even ones I've bought that are supposedly crack free, when cleaned up have been found to have small hair line cracks in them. My old cracked 15g hotside is still running as part of Claymore's current T-5R turbo configuration (unless he's been playing again), so the cracks aren't necessarily detrimental to power generation from what I seen, but if you have one available all the better, are you going to the angled flange item ??[/QUOTE]
That's interesting to know - thanks. I do have a known good one on it's way to me now so will fit it anyway for piece of mind
[QUOTE=Sparkysparks;801852]Hi, any chance you could measure the width between the chassis beams please? Ive not got an empty engine bay to look into haha.
TIA.[/QUOTE]
No problem - I will measure it next time I work on the car
Mini update: got the water branch attached last night - had to take the manifold back off because you can't quite get to one of the water branch bolts! Just need to attach the turbo/turbo hoses and it's ready for install
Awesome, thankyou.
[QUOTE=Sparkysparks;801854]Awesome, thankyou.[/QUOTE] 97cm is the measurement
Weekend progress
On Friday evening after work, we managed to remove the gearbox, clutch and flywheel from my old engine and transfer the oil cooler lines over to the new engine (along with all new oil seals) and a new thermostat :
Saturday afternoon was productive to say the least - Flywheel (with new one use bolts), clutch and gearbox onto the new engine :
Turbo with new seals and DO88 water hoses to replace the old originals :
Ending up with the engine looking like this & ready for install :
Engine being lowered into place :
Located as it should go :
Engine was then bolted down properly :
The turbo hot side wouldn't mate up to the downpipe unfortunately, so that was about as much as we could get done for one day. I didn't realise that there were 2 types of connection on the straight flange turbo hot sides. Hopefully I will be able to get one before the weekend. We still had a bit more time, so fitted all new track rods and ends to go with the new Meyle HD droplinks :
N/S :
O/S :
On Sunday we connected the PCV & bolted on some of the ancillaries that wont restrict access for turbo refitting. New alternator :
New starter motor :
And how the car looked at the end of the weekend :
If we don't have any further problems then it should be back together by the end of next weekend
Made some excellent progress with the car this weekend:
Saturday
Got started in the afternoon:
Luckily we could remember where most things went as it wasn't that long ago since we removed the old engine
Inlet manifold on and clutch bled. Had to replace the clutch pipe that runs under the battery tray as it was looking very corroded. Volvo have now made this a "classic" part so that they can charge a fortune for it! Worth doing though.
And this is how we left it for the day - certainly looking a bit more recognisable as an 850 engine bay..
Sunday
Sunday ended up being fairly straightforward. Sun was out as well which was a welcome change. Managed to get the front end back on and generally worked from the turbo at the back of the engine forwards
Before long it ended up like this:
Filled it up with mineral oil for its first run:
And after an initial non-start (spade plug for starter motor on wrong connector) it fired into life! Ran for 15 minutes on the mineral oil:
Next we put the car back up on the driveway and dropped the mineral oil out and refilled with semi-synthetic 10W/40 for 500 miles of running in
Here's how the car sits now:
Missing a couple of covers, but will tidy up in the week. So far so good - no leaks etc & MOT is on Saturday. Hopefully be able to start driving it after that.
Very good progress Kerry and a relief not have any leaks or niggles. I love the way your car sits on the coilovers and want mine to look like that but I do like the comfy factory ride as well! Decisions.
Great progress!
[QUOTE=mitchyboy01;802542]Very good progress Kerry and a relief not have any leaks or niggles. I love the way your car sits on the coilovers and want mine to look like that but I do like the comfy factory ride as well! Decisions.[/QUOTE] Thanks very much. The coilovers do stiffen the ride somewhat, but I don't use the car as a daily so for my purposes its exactly as I want it. A good drive on a smooth(ish) twisty road always makes you remember why you fitted them! [QUOTE=jdavis;802544]Great progress![/QUOTE] Thanks very much
Awesome! Good work :)
Awesome progress Kerry, looking forward to my passenger ride in it!! Been a while since I set foot in this place, loads to catch up on.
Looks awesome dude
great write up as usual looking great!!!
Bring it along to beaulieu in September, maybe another olive saloon as well