Volvo 240 T8 (because V8s and turbos make the best noises)

This is how I bought it




First job the suspension
Made some coilovers for the front and modified the rear suspension to bring it down a bit and make it handle


Sits a lot better and the handling is very good

Next step engine




So old engine out ready to expect the new one and donor car bought

Liking this pal, always loved a volvo. clever man making the coil overs your self

As we move into the fabrication side of things I must add I'm (not a fabricator) I drive lorries
Before that I did spend 25 years in the motor trade in all areas from main dealers/MOT tester/bodyshop fitter etc etc
So I have a good understanding of most things car related but I'm very much a jack of all trades master of none (mainly self tort)

Now I fitted one of there's engines in a BMW E46 for a good friend of mine last year
He works outside his house so doesn't have the use of a welder so he come to me for that bit and he done the rest
And because of that a have a dead 1UZ which he lent to me that I can use for mocking up with
When we did his car we bought an adapter plate to use BMW gearbox and I copied it


So next up was the gearbox and engine mounts I used the Volvo gearbox mount and just modified it
Then made some engine mounts from tube and 5mm steel plate







I wanted to get it sitting as low as possible to miss the servo and also so it lined up with the rear axle better
Now it was at this stage as I was thinking about exhaust manifolds
I came up with the great idea of adding a turbo in the build (this was a financial mistake on my part )
This was on target to be a cheap easy way of getting a good power increase and have one of the best noises in the business
Why oh why do I do it

I'm on all the Volvo Facebook groups what one you on 

Bmw 3.0 diesel 5 speed 

no playing around here.

bookmarked!

Thanks for the interest guys

So on with the build as I said I decided to go down the turbo route
The idea behind this was to make the build more interesting as a finished product and of course extra power
The std non VVTI 1UZ is about 250bhp so a good jump up on the stock 2.0 red block
But I could of got that from a 2.3 turbo red block without to much trouble
As well as that my brother is a bit of a "old cars are curse word type of man" and he thinks his M3 is the best car ever made
So I had to build something that would either embarrass his M3 or at least give it a good run for it's money

I'm using a holset HX40 turbo which I think should do what I need it to with flow/lag etc
And a turbosmart external wastegate


This is the off side manifold as it was being made up
It's the complex side as it need to miss the steering column and go round the engine mounting and the alternator and pas pump





The near side manifold is much simpler I needed it to be as high as possible to leave space to run the exhaust down pipe out

So stripped out the donor car engine/loom/ECU etc







Parts cleaned and painted






The sump was next
Anyone who knows the 1uz engine will be know it comes with either a front bowl sump (LS400) and what is known as a rear bowl sump (soarer)
The rear bowl sump is more a middle bowl so in both cases there of no use for me
So I had to make my own this went tits up as I made a school boy error and measured the gap wrong so the sump was not clearing the crossmember
So I notched the crossmember to accommodate the sump pan
But it was to close to the steering rack for my liking and I wasn't happy with where the turbo return pipe was so engine out and start over with version 2.0



Pressure tested for leaks and painted and more importantly it fits much better