245 T5 "Matilda"
Posts
Post 811683 by 245TurboT5 on 2017-05-08 20:26:53
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)
[ATTACH=CONFIG]31558[/ATTACH]
Post 811685 by Doingitsideways on 2017-05-08 20:43:58
Love a boosted 245, even better with Whiteblock power! :D
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 :)
Post 811686 by 245TurboT5 on 2017-05-08 21:43:54
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.
Post 811714 by Dangerous Dave on 2017-05-09 21:28:15
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.
Post 811715 by 245TurboT5 on 2017-05-09 21:37:32
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!!!!
Post 811731 by 245TurboT5 on 2017-05-10 17:34:02
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.
Post 812338 by 245TurboT5 on 2017-06-08 13:54:31
This is my old sump:
This is my new sump:
It's a work in progress....
Post 812342 by petrolh34d on 2017-06-08 14:27:46
Are you dry sumping it?
Post 812343 by 245TurboT5 on 2017-06-08 14:39:58
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
Post 812352 by Ettienne on 2017-06-08 21:07:37
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
Post 812353 by 245TurboT5 on 2017-06-08 21:43:10
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!
Post 812554 by 245TurboT5 on 2017-06-23 11:00:28
Ooh, forgot to mention- I picked this up the other day:
Just need to find a 12cm2 turbine housing and external wastegate now. :pimp2:
Post 812565 by M-R-P on 2017-06-24 10:37:13
Interesting project, should be fun getting that huge turbo to behave but it'll be worth it :)
Post 812570 by 245TurboT5 on 2017-06-24 15:04:58
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.
Post 812595 by 245TurboT5 on 2017-06-25 20:50:14
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
Post 812596 by Dangerous Dave on 2017-06-25 21:52:21
Oooh, another Arduino project, I like it :D
Post 812672 by 245TurboT5 on 2017-06-30 08:14:19
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! :eek:
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.
Post 812673 by MoleT-5R on 2017-06-30 08:43:38
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.
Post 812674 by 245TurboT5 on 2017-06-30 09:06:41
I'm more of a hammer and welder type of guy than a capacitor & coding type, so I'm interested to see how this turns out too! :rolleyes2
Post 812675 by Dangerous Dave on 2017-06-30 09:15:36
[QUOTE=245TurboT5;812672]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! :eek:
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.[/QUOTE]
Oh dear, that's not a lot of tolerance at all :(
Post 812679 by 245TurboT5 on 2017-06-30 13:19:27
That's why I think I'm going to go the adapter plate route. At least that way you know it's flat, and if you do break a gearbox you can replace it with another stock one.
The gearbox uses a traditional syle slave cylinder and clutch arm so my initial thoughts are that, with a 10mm adapter plate, I can leave the flywheel in it's stock position and space out the clutch arm by a few mm (law of levers, and all that). Of course, it all depends on how well the clutch splines engage and, if they don't satisfactorily, what the maximum I can space the flywheel out is and have the starter still engage properly. There will be some wiggle room there, as the starter gear is always much wider than the ring gear.
These are just first thoughts, though. I'm sure the plan will have to change many times before I get this finished. In the mean time I'll get the sump finished, join the engine and 'box on any bolts that line up with a 10mm spacer inbetween, and get it in the car so I can at least get the mounts made and all those jobs done that don't cost much but take up so much time whilst I'm saving my pennies for a clutch.
I'll also be able to make a start on the adapter if I get stuck on any jobs due to the M56 casing that Dangerous Dave very kindly donated to me. Thanks Dave, I really appreciate it. :remybussi
Post 813661 by Dangerous Dave on 2017-09-08 23:02:57
My god its almost as big as the engine :D :D
Post 813666 by 245TurboT5 on 2017-09-09 10:07:52
[QUOTE=Dangerous Dave;813661]My god its almost as big as the engine :D :D[/QUOTE]
If you want to make reliable power you don't want to be poncing about with anything that starts with TD04! That turbo is good for 550bhp (not that I'm going to try to make that much) and will run forever. I just wish we could get E85 here.
Post 813669 by 245TurboT5 on 2017-09-09 10:53:26
Definitely, the 240's engine bay is pretty cavernous
Post 814715 by 245TurboT5 on 2017-11-14 20:56:41
.... and then I lost my mojo a bit. This was mainly down to the whole transmission issue- the cut and shut issue, to be precise. Something about it had been bothering me. I put a post on Facebook asking if anyone had a V8 for sale for cheap (my first love has always been the sound and torque of a V8).
Almost instantly a friend offered me a deal I couldn't refuse. Now, with this particular engine there is a known issue in that it will not work in an engine transplant situation due to the canbus and the auto gearbox throwing a wobbler when it can't talk to the body control, traction control, as, etc. & consequently the engine won't crank, let alone fire. Half of this problem can be cured by using a manual gearbox, but this engine has never been sold with one.
As a consequence this engine has been largely overlooked by hot riddles, which is a shame. However, after literally an hour's ceaseless searching I have found a cure. A manual transmission that bolts straight on and that should manage the torque of the V8 with no problems as it's mechanically the same as the BMW one I was going to use to utilise and shut. It requires a custom flywheel, but that is relatively inexpensive from companies such as TTV Racing.
So, the new direction is a V8. Anyone want to buy a load of T5 stuff?
Post 814716 by 245TurboT5 on 2017-11-14 20:59:09
Hint: 
Oh, did I mention it's supercharged?
Post 814717 by Doingitsideways on 2017-11-14 21:07:02
Ooohhh...
Much more interesting :)
Guessing it's Jag based?
Post 814719 by 245TurboT5 on 2017-11-14 21:22:02
Yeah, 4.0 XJR. 370bhp stock.
Mine will be cat-less, have a decent flowing exhaust, upgraded charge cooler or possibly even go intercooler since I have this beastie hanging from the roof of the man-cave:
There's also the more aggressive mapping you get from a standalone tune plus the eventual supercharger pulleys upgrade. 400+bhp is easily achieved with stock reliability.
Post 814743 by Doingitsideways on 2017-11-16 10:11:44
Nice.
Nearly bought an XJR years ago for a good price.
One of my biggest automotive regrets is not buying it. At the same time, I know I'd be homeless now if I did, as the repair bills when it enevitably went wrong would have crippled me.
The noise though... :D
Post 814744 by 245TurboT5 on 2017-11-16 10:49:32
I'll be doing the timing chains and Tensioners whilst I've got it on the engine stand.
Post 814754 by Doingitsideways on 2017-11-17 01:23:58
Very good shout :)
Could be worse, could be an Audi.
Their chain setups look mental
Post 814760 by 245TurboT5 on 2017-11-17 13:00:49
[QUOTE=Doingitsideways;814754]Very good shout :)
Could be worse, could be an Audi.
Their chain setups look mental[/QUOTE]
Yeah, the Audi one does indeed look mental! :shockedbi
Mind you, it's only three chains compared to the Jag's four!
Post 814763 by Dangerous Dave on 2017-11-17 16:44:24
You're not wrong there
[video=youtube;4J03Upu-8Qs]https://www.youtube.com/watch?v=4J03Upu-8Qs[/video]
Post 814764 by 245TurboT5 on 2017-11-18 08:31:11
Oh no it Is 4 chains. My mistake!
Post 814769 by Dangerous Dave on 2017-11-18 18:38:23
[QUOTE=245TurboT5;814764]Oh no it Is 4 chains. My mistake![/QUOTE]
Og yeah, looks like a right ballache of a job :D
Post 815012 by volvomad on 2017-12-19 02:19:29
Thats mad you putting a v8 in the volvo?
Post 815013 by 245TurboT5 on 2017-12-19 06:30:03
Yep. Big lols at volvomad telling me I'm mad :D:nut::crazy::cool:
Post 815022 by claymore on 2017-12-19 16:42:22
I'm very interested in this as I was lead to beleive that it was really hard to get the Jag V8 to work in any other car, I can't remember the reason at the moment. Something to do with the engine not running because it's all canbus controlled.
Post 815025 by 245TurboT5 on 2017-12-19 18:35:52
Yeah, it's because the engine and transmission talks to the body control module, the traction control system, the ABS module, the immobiliser etc. before it will start. Because of this the engine has largely been ignored, which is a shame.
The only way around it is a manual 'box (that Jaguar never fitted to the AJ-V8) and standalone engine management.
Post 815026 by volvomad on 2017-12-19 18:41:32
Lol..Thats gonna be a monster i.d love a 244 again it was a tank cant wait to see this being brought to life meow!!
Post 815027 by 245TurboT5 on 2017-12-19 19:15:01
Don't hold your breath!
Post 815298 by 245TurboT5 on 2018-01-17 18:23:33
I have decided that, due to the fact that it's bloody cold outside work has been largely suspended on the project for a while. In the meantime I've made a website, which I'll update as I get work done. You can find it at the following link https://stinkypantsshepher.wixsite.com/v8volvo240
Post 815304 by martin_r_smith on 2018-01-17 20:01:39
[QUOTE=245TurboT5;815298]I have decided that, due to the fact that it's bloody cold outside work has been largely suspended on the project for a while. In the meantime I've made a website, which I'll update as I get work done. You can find it at the following link https://stinkypantsshepher.wixsite.com/v8volvo240[/QUOTE]
Like it, keep up the good work.
