1991 Volvo 240 Turbo Estate (picgasm)

Look at the casting date on the exhaust side, if its a 1993 or later block it will more than likely have squirters.

This one's a `95 so it has 13mm rods and squirters. EDIT, the little bulges on the oil gallery there are for the squirters to screw into inside the engine. I think non squirter engines don't have these bulges.




You can drill and tap the gallery from the inside to fit them if its an older block I think, There's a guy on TB who made tools to do it and lends them out if you pay a refundable deposit and postage, infact he's worth speaking to if you want a bulletproof 500hp reliable motor.

The game is afoot gentlemen.

I took the manifold and turbo over to GT today and tried it out.

I ended up hacking the old downpipe off with the grinder so lets just say I'm more committed today than I was yesterday (and I was committed then)




My confidence grew stronger minute by minute.





The turbo easily clears the inner wing.

The downpipe is tricky as the turbo outlet is pretty much right in front of the top end of the centre part of the steering column.




However I have a 740/940 downpipe from Chesh.

I cut the turbo flange end off and roughly cut the angle I wanted, it's turned around a bit to aim it up away from the column.




Then I got some wood and propped up the rest of the DP with ended up roughly where it wants to be at the top.



There is about half an inch clearance on the column, I may make a top mount to prevent any engine movement and so stop the dp hitting the column when the engine is under load.



I will spend half a day tomorrow on it and hopfully get the DP done.



I then rewarded myself by trial fitting the intercooler Chesh got me, its too wide to fit any further forward, between the uprights underneath the slam panel. I had to cut the battery tray as it interfered with the intercooler outlet pipe. (no matter as its too big anyway) I might have to cut more away and move the inboard tray bracket.





I have booked the block in for its machining. I'm taking it in tomorrow and he said it should be ready be the end of the week so I'm hoping I can pick it up on saturday and rebuild the shortblock on sunday.

I will also have to make up a heat shield to protect the brake gubbins and move the brake and clutch lines away from the heat.

Well a good selection of Turbobrickers turned up and helped to get the project moved on.

On Friday night Foggy and I built the shortblock (mostly) ended up staying up till five am getting it done.

Saturday saw the long block partly assembled and the suspension removed from the car we all worked till about 9pm.




Saturday night was spent in the pub.

We got on with things on Sunday and the longblock was almost finished. the suspension was fitted and the engine dropped in.





Jody came and fetched the axle, struts and seats from the 244 (which is now being scrapped) it's looking a sad case as it sits now:-(




Max and James porting out the exhaust manifold to suit the T3.


Roger, Pete and Nick assembling the engine.


Still a bucket load of stuff to do to get it finished, Finish engine install, fit all new brakes and repair the bodywork, but I am determined to see it through as swiftly as possible.

Big massive thanks to


Foggy
Chesh
Roger
Alex
Max
Nick

And Mr and Mrs Blunt for their patience and kindness.

I'm to tired to construct any more sentences so here's a few pics.

Very nice.. very nice indeed!

I have an eaton M90 supercharger that I could use., but for now I just want to run in the new engine and get the car a bit more sorted.

More things happening

This is how it looked the last time I left it (I didn't get to take a pic)




I went over straight after work and cracked on, (Ignore the blue pipe)












Most of the pipes are not fastened as I was just figuring things out. I need to make a bracket for the coolant bottle (came from a 940) and also drill the I/C - Throttle pipe and fit CBV and IAV pipes (I have marked the pipe, but forgot to use my CBV in the mock up and joined the pipes directly together, whoops, nevermind I'm glad I noticed before fabbing). There were problems getting the AMM and filter to fit properly, I have taken out the washer bottle to make more room, as this is an MOT item I will have to fit a tall slim bottle by the radiator (or somewhere else entirely)

I will need to secure the radiator on rubber mounts at the bottom, The intercooler sits very nicely on the radiator mounts, as a result of this the way the rad is in relation to the intercooler (and sitting snug up to it) the brackets (when placed on the rad) don't line up with the holes on the slam panel, I may use parts of the old cars cross member and slam panel to sort this.


Need to find a long bit of pipe and get a breather filter.

and a 104 other things

Coldside pipe with take off for CBV and IAV

great progress suterman! was not expecting it to fly along like this. poor old GLT saloon though. IMO the only volvo that looks nicer than a 240 wagon is the 262Bertone and that wagon is going to look good. inspiring me to keep saving for the aticipated summertime B230FT. have the same B200F that your wagon had at the moment. considering going +T with a 15g or similar on it but it seems like a lot of effort to gather everything needed and then not having much boost to play around with anyways. so for now i keep track of this creation and hopefully find a cheap 940 or 760 as a donor. then theres quite a high chance il like it too much and end up with another volvo.

Mike, you should use this opportunity to ditch the cat. There's no legal reason to have it on there and it strangles the engine.

Let it breathe!

And you know it'll sound nicer too.