Volvo 5 Cylinder in an E30

[Steve o 77]

Engine is back in the car with the clutch and transmission all installed. I even replaced the selector seal while it was out because I hate doing them in the car.

[eternal24k]

absolutely love this build. A turbo 5 just feels like the best of all worlds. Great work

[Steve o 77]

thanks guys, just trying to help keep this forum thing alive!

Still making progress. Now that the engine is back together I got the adaptor plate installed for good along with the flywheel.

Then I got the transmission clearenced for the starter and crank sensor.


Waiting on a clutch alignment tool so I've been doing some painting. I coated the exhaust parts in Cerakote ceramic coating. That was quite the process as the parts have to be meticulously clean, then you sand blast them, clean again, then paint.

I ended up doing it all myself with the cheap harbor freight outdoor sandblast gun and touch up paint gun. It seems to have come out great, we will see how it holds up.

[Matt@EDC]

Liking this. The Volvo 5-pots and how they make power has always been intriguing so appreciate the in depth pictures.

Fine work sir

[QuiqueUy]

V nice work , i envy your welding skills !

btw, engine look robust af

[Steve o 77]

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.

They're not too bad, they tend to hold pretty good power once you swap out the stock rods. I'm doing this swap mostly for the 5 cyl noise but I think the car will be pretty quick as well.

[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.

[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!

[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]

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

[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]

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.

[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.

[QuiqueUy]

V nice work , i envy your welding skills !

[CubbyChowder]

This is awesome. Nice fab work too!