Advice on 240 turbo

Hi all,

I am new to these forums, but not to Volvo having had fun with a couple of modified 164s some years back.

I've invented some justifications to build a rapid 245 using (probably) a 700 series 2.3 turbo engine, or possibly (if it would fit) the 5cyl turbo from the fwd cars.

I wonder whether the experts out there can help me with some questions:

1. Has anybody in the UK built a 240 turbo, with right-hand-drive, with either 4cyl or 5cyl turbo engine?
2. Can the 5cyl engine be made to mate with any rwd manual Volvo gearbox?
3. I understand that the 4cyl turbo requires an exhaust manifold to be fabricated/modified in order to fit around the steering column on a rhd 240. Or is there a clever combination of existing parts which avoids this? And has anybody out there built/bought such a manifold?
4. Are there any big problems I have missed..?

Next, the tuning. Assuming I end up using a good, second-hand 700 2.3 intercooled turbo motor, what is the best way to achieve about 220-230bhp and 250ftlb with reliability and reasonable fuel consumption. I am thinking:
>IPD cam
>Free-flow exhaust
>Moderately raised boost pressure (remapped ECU or manual control)
>Custom-made high efficiency intercooler

Would this be enough to get my desired power, or would I need to think about enlarging cubic capacity, larger turbo, extra injectors, water injection, etc?

The benefits of your experience would be much appreciated!

Finally, does anybody have for sale a very solid 240 estate they would like to see turned into my dream machine? Manual & fuel injection prefered; GLT spec ideal but not essential. Not urgent... something available over the next couple of months would be fine.

Thanks

John Hughes
Huddersfield, West Yorkshire

[davebslater(uk)]

john ,

there is indeed some RHd 240 turbos out there , a std manifold will fit , the downpipe may need some mods to clear . Check out megasquirt for some fuelling / mapping problems .

Jan at enem cams in sweden has a much better range of cams and would be just as cheap

turbobricks.com would answer most problems youll encounter , email me if you have something specific in mind . I think anything over 250 hp/300ft/lbs torque you will need either an M90 box from a later 940 turbo - or investigate a getrag/T5 swap - in fact just what i have planned

regards dave

Dave,

Thanks for the guidance. Where are you located? (your website link not currently working)

Cheers

John

[davebslater(uk)]

sorry john ,

you can contact me here - dave@dbsvolvos.co.uk

or view my website - www.volvo480sport.co.uk

oh , and to use a 5 cyl would need an m90 from a 6 cyl engine

Hi Dave

We have now bought a 240 so if possible, I'd like to come to see you to discuss the project; would you mind?

Here are my specific questions, so far:

1. Do you know of anybody who has fitted the 5cyl T5 engine in RHD 240? Does the 5 cyl turbo engine need exhaust manifold mods?

2. Do you think the m90 gearbox will require modifications to the transmission tunnel or gear-lever position?

3. I'd like to get some 16 or 17 inch wheels in a design which suit the car. Can alloy wheels from 850/S70 etc models fit the 240 or is the offset wrong? Did any RWD Volvo have a similar design to the GLT but in a bigger size.... 740 turbo perhaps?

4. What would you recommend as a reasonably economical source for uprated dampers and 2 inch lowered springs?

Hope to be able to meet you soon

Thanks

John

[davebslater(uk)]

ok john ,

yes come and meet me for talk about this , sounds like a good project

All 5 stud pattern volvo wheels will fit the PCD , but the offset isnt correct and may need spacers - 7/9 series wheels fit and 16/17 inch wheels were available - dont know how you would get any now apart from a dealer or somebody who has them fitted - gotta to keep a keen eye open .

The T5 engine has been fitted to various cars in sweden , even the 6 cyl has been shoehorned in - the M90 fits without mods to 7/9 series , it may need some_clearance, i doubt it would be serious , and shifter position would need changing.

ive got quite a few bits lying about that would get your motor turboed fairly easily , so when are you coming ?

email me at dave@dbsvolvos.co.uk
mobile 07779456209 , not tonight though since ive left it ni the workshop.

Dave, thanks... I'm busy for a few days, will phone you next wk.

[judgeman]

Hi there

Not sure if this is relevant to you, but was doing some research on Volvo in Oz, and came accross this website. Thought it may give you some more ideas....!

http://www.rsphysse.anu.edu.au/~amh1...gine_swaps.htm

Chris
& Fred - 1988 240 GLT Estate 2.3ltr 165k
VOC member
Previously
Henry - 1996 854 T5 S 134k
Sylvester - 1995 440 SE 2.0ltr 35k
Monty - 1995 440 Si 1.8ltr 70k
Vincent - 1985 340 GL 1.4ltr 144k
The Yellow Peril in Oz - 1982 244 GL 2.3ltr 250k

Opinionated? You better believe it!

[ravennexus]

for the 240 m90 http://forums.turbobricks.com/showthread.php?t=18442

if doing a 5cyl or 6 cyl swap you need to use a M90 from a 6cyl whiteblock engine, also the 5cyl swap will need a shortened 6cyl sump to fit, not sure about engine mounts they bolt into the 700/900 using inline 6 engine mounts but not 240.

i guy is putting a 170hp NA 2.5 20v into a 240 using such. some pics can be seen http://medlem.spray.se/adturbo/photoalbum1.html

[TheJoyOfSix]

Either the downpipe will need to be modified to clear the steering column, or the steering column swapped with one from a non-PAS car. Ravennexus has done the column swap to fit his 16v engine in so he would be good to talk to on that one.

220bhp is acheiveable with ease by using a MBC, airbox mods and a rising rate fuel pressure regulator. I think that an electric cooling fan may be needed to gain room for an intercooler, but don't quote me on that!

Visit www.turbobricks.com for info on getting the most from the engine.