Volvo 5 Cylinder in an E30

[Steve o 77]

While waiting on engine parts I've been working on the intercooler situation. In my quest to not cut up the car at all, and keep the AC, I'm going to put the intercooler where the radiator used to be and space the radiator back. The spacing will be tight to fit the spal 16" slim fan but it should fit with similar clearance as the 24V swaps.

Started with a koyorad tube and fin core and mocked up the end tanks with paper.



then transferred to metal. Huge respect for anyone that makes intercooler tanks, Welding the suuuper thin wall chinesium tubes to the 1/8" plate tanks was extremely challenging for me.









Everything is just kinda wedged in there right now, still need to build mounts. The plan is to build some bolt on brackets that basically extend the stock rad brackets back to support the new radiator location. this whole no cutting/welding on the car thing is a pain!

[MrBurgundy]

Who makes that adapter plate?

[Steve o 77]

Who makes that adapter plate?

PMC motorsports. I got the whole kit from them including a custom flywheel and a stock 535d clutch kit. I like their setup becuase it sandwiches a Volvo flex plate under the flywheel for the starter. I also love that the plate has bolt patterns for basically every bmw trans ever so changing the setup is pretty easy, just need to get a different flywheel depending on which trans you use.

[Tzantushka]

As an E30 tragic and Volvo tragic - this is the best of both!

[e30davie]

pretty neat project.

80s car 5clr turbo. So Its basically an audi group b rally car.

[varg]

Nice. This is one of many engine ideas I thought about over the years but I didn’t give it too much consideration after seeing the sump would be an issue. It is a lot of effort. I like that you’re not cutting the car up, that’s a good constraint to place.

While waiting on engine parts I've been working on the intercooler situation. In my quest to not cut up the car at all, and keep the AC, I'm going to put the intercooler where the radiator used to be and space the radiator back. The spacing will be tight to fit the spal 16" slim fan but it should fit with similar clearance as the 24V swaps.

Started with a koyorad tube and fin core and mocked up the end tanks with paper.

then transferred to metal. Huge respect for anyone that makes intercooler tanks, Welding the suuuper thin wall chinesium tubes to the 1/8" plate tanks was extremely challenging for me.

I don’t envy you there. There are multiple reasons I got a Garrett core, mostly because they flow well, but also that they’re supposedly easier to weld to than chinese cores. I think you will probably need more fan than the slim Spal pulling through that stack. I’d upgrade the condenser fan, my E34 has a similar stack and I bought a $$$ brushless fan for the condenser because AC+Florida+3 core stack is bad news and I had room for only two smaller slim Spal fans between engine and radiator.

[CubbyChowder]

This is awesome. Nice fab work too!

[QuiqueUy]

V nice work , i envy your welding skills !

[Steve o 77]

Nice. This is one of many engine ideas I thought about over the years but I didn’t give it too much consideration after seeing the sump would be an issue. It is a lot of effort. I like that you’re not cutting the car up, that’s a good constraint to place.



I don’t envy you there. There are multiple reasons I got a Garrett core, mostly because they flow well, but also that they’re supposedly easier to weld to than chinese cores. I think you will probably need more fan than the slim Spal pulling through that stack. I’d upgrade the condenser fan, my E34 has a similar stack and I bought a $$$ brushless fan for the condenser because AC+Florida+3 core stack is bad news and I had room for only two smaller slim Spal fans between engine and radiator.

Thanks!

The cooler core was actually quite easy to weld, it was the mandrel bends that I notched into the end tanks that were tough. Next time I'm going to pony up for some quality bends because these thin ones are a pain.

And thanks for the tips on the fan setup, I am definitely ok with upgrading the pusher fan too if needed. It isn't super hot here in Colorado but the altitude is hard on cooling systems.

[Steve o 77]

Intercooler is mostly mounted using the stock lower rad mounts. I’m going to ditch the plastic upper rad mount and make something out of aluminum.

the radiator is also mounted at the bottom. I ended up using some stock holes in the frame rail to hold rivnuts, then made some brackets to support the bottom of the rad. I will add some gussets to the bottom before paint.

[varg]

I like those intercooler mounts using the original rad mounts. In a bit of convergent evolution of my mount ideas I just arrived on something similar for my E34, but mine don't look as nice.

[Steve o 77]

I like those intercooler mounts using the original rad mounts. In a bit of convergent evolution of my mount ideas I just arrived on something similar for my E34, but mine don't look as nice.

Appreciate it! I like to mimmic OEM designs when possible, they seem to know best haha

[Steve o 77]

Most of the engine parts finally arrived so I got it mostly put together.

Started with the bottom end of course.





Once I got the number 1 piston and rod installed I did a quick rotation check and found that the rod was just barely touching the block at the bottom of the bore on one side. A couple minutes with a file and some meticulous cleaning after and all was good to continue.



MLS gasket from a 2004+ 2.4L motor



Head on and torqued to spec with new head bolts

[Steve o 77]

Cam cover gooped up and installed. These motors are weird in that the cam cover doubles as the cam caps so a special tool is needed to compress the cover down prior to installing the 40 M6 (maybe M7?) bolts.



Then the rest kinda flew together. Still waiting on a gasket to install the water pipe and VVT solenoid. Also waiting on the Cerakote to get here so I can coat the exhaust parts prior to install. Also got the fuel rail sorted with -6 fittings for feed and return (this engine was a deadhead style originally)









It's getting there!

[Northern]

I like this swap. I've never actually seen pictures of one of the volvo 5-cyls. I'm surprised with how stout they are, with the split crankcase and cam tray/valve cover combo.

It makes sense why they have the reputation they do.