Volvo 5 Cylinder in an E30

[Steve o 77]

FIRST DRIVE! I finally got that clutch hose in and bled, along with the serpentine belt. Unfortunately the mystery junkyard alternator sounds like it spent the last 30 years on the bottom of the ocean and doesn’t charge, but I was able to take the car around the block.
Its still running hot so likely there’s more air in the cooling system, I might need to add a bleed port. Other than that I can tell it’s gonna rip once I get the tune sorted.

https://youtube.com/shorts/KZyu6Eh7QNA?feature=share

[Steve o 77]

This is so many levels of cool.

Thanks!

Still plugging away. Exhaust is totally done, full 3" stainless system with a straight through muffler for now. I also have an E90 328ix driveshaft installed which will work for now, but it only has like 0.75" of spline engagement on the E36 rear driveshaft section so prior to actually giving it real throttle I'll need to address that. I've also installed a cheap PMC chassis mounted shifter for now. I may go back and fabricate a custom carrier if this one is too loud and annoying.



At this point I'm waiting on a -3AN braided hose that I'm going to use for the clutch and it'll be ready for a first drive!

[DEV0 E30]

This is so many levels of cool.

[Steve o 77]

It’s alive! This is with the exhaust finished back to the diff with no muffler at all. Planning on a straight through style muffler for now but that might change if it gets annoying.

https://youtube.com/shorts/P16bpTiXg84?feature=share

[Steve o 77]

Still going hard on this thing, wiring harness is about 90% done. I started with the Maxxecu flying loom and went from there. Running a flex fuel sensor, VAG coils, converted to speed density obviously, and some other goodies. I even got it to run for a few seconds on ether. Still waiting on one coil connector and need to go get a few feet of fuel hose before I can actually start it up on all 5 cylinders.

[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