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940 GL fifty shades of grey turbo conversion

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Old Nov 16th, 2020, 17:45   #11
360beast
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The 760 has now gone to it's new home, I believe the Lexus V8 idea has been changed in favour of a T5 engine

Engine is now here and ready to be resealed and cleaned up. I will delete the EGR junk off it too while it is all easily accessible.

It took longer than planned to get the engine off the trailer and in place and the 760 on the trailer and to have a catch up with my mate so no work done on the 940 today sadly.

However tomorrow the engine and gearbox are definitely coming out of the car.


IMG-20201116-WA0008 by Luke Ryland - Flickr2BBcode LITE

Also while emptying the 760 out I found a new genuine Volvo redblock air filter so I fitted that to the turbo air filter box I have for the car.


20201116_101625 by Luke Ryland - Flickr2BBcode LITE

Last edited by 360beast; Nov 16th, 2020 at 17:47.
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Old Nov 16th, 2020, 18:51   #12
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nice and handy to get the pcv box off as well
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Old Nov 17th, 2020, 18:15   #13
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So 3.5 hours later the engine, gearbox and propshaft are out.


20201117_151428 by Luke Ryland - Flickr2BBcode LITE


20201117_151402 by Luke Ryland - Flickr2BBcode LITE


IMG-20201117-WA0027 by Luke Ryland - Flickr2BBcode LITE


IMG-20201117-WA0029 by Luke Ryland - Flickr2BBcode LITE

B200F has been stripped down for all the brackets etc that I need for the B230FK.

The power steering pump pulley is bent! Good thing the B230FK came with a good one.
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Old Nov 17th, 2020, 18:45   #14
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Great progress Luke!
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Old Nov 19th, 2020, 10:17   #15
360beast
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Just a little bit of work done yesterday:

Swapped over the engine mount brackets on the FK engine for the early non hydraulic mount brackets, removed the A/C pump and auxiliary mounting bracket and then fitted the poverty spec alternator only auxiliary bracket. Undoing the auxiliary bracket I skinned a knuckle so I dripped a lot of red stuff on to it 😂 the first of many skinned knuckles I imagine for this job.


IMG-20201118-WA0006 by Luke Ryland - Flickr2BBcode LITE

I noticed the subframe was a bit flakey under the engine mounts so I took them off, wire brushed it down until I could see shiny metal again then painted with waxoyl stonechip, absolutely brilliant stuff.


2020-11-19_09-06-37 by Luke Ryland - Flickr2BBcode LITE


2020-11-19_09-06-22 by Luke Ryland - Flickr2BBcode LITE

Then the radiator mounting "crossmember" was quite flakey too so I did the same on that.


2020-11-19_09-06-52 by Luke Ryland - Flickr2BBcode LITE

But best of all I was like a kid at Christmas! My 12 ton hydraulic press arrived, just got to clear space for it now... for the 4th time in the last two weeks! I can't seem to keep the workshop end of the garage clear!


IMG-20201118-WA0013 by Luke Ryland - Flickr2BBcode LITE


IMG-20201118-WA0015 by Luke Ryland - Flickr2BBcode LITE

I think it will handle suspension bushes just fine!

If anyone needs any bushes, bearings etc. pushing out then let me know as I can now offer this service.
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Old Nov 19th, 2020, 10:46   #16
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Quote:
Originally Posted by 360beast View Post
Just a little bit of work done yesterday:

Swapped over the engine mount brackets on the FK engine for the early non hydraulic mount brackets, removed the A/C pump and auxiliary mounting bracket and then fitted the poverty spec alternator only auxiliary bracket. Undoing the auxiliary bracket I skinned a knuckle so I dripped a lot of red stuff on to it 😂 the first of many skinned knuckles I imagine for this job.


IMG-20201118-WA0006 by Luke Ryland - Flickr2BBcode LITE

I noticed the subframe was a bit flakey under the engine mounts so I took them off, wire brushed it down until I could see shiny metal again then painted with waxoyl stonechip, absolutely brilliant stuff.


2020-11-19_09-06-37 by Luke Ryland - Flickr2BBcode LITE


2020-11-19_09-06-22 by Luke Ryland - Flickr2BBcode LITE

Then the radiator mounting "crossmember" was quite flakey too so I did the same on that.


2020-11-19_09-06-52 by Luke Ryland - Flickr2BBcode LITE

But best of all I was like a kid at Christmas! My 12 ton hydraulic press arrived, just got to clear space for it now... for the 4th time in the last two weeks! I can't seem to keep the workshop end of the garage clear!


IMG-20201118-WA0013 by Luke Ryland - Flickr2BBcode LITE


IMG-20201118-WA0015 by Luke Ryland - Flickr2BBcode LITE

I think it will handle suspension bushes just fine!

If anyone needs any bushes, bearings etc. pushing out then let me know as I can now offer this service.
I'll be sending all my spare arms etc down Luke, or perhaps when we have our Carnforth meet I can give them to you then
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Old Nov 22nd, 2020, 08:25   #17
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Another little update, yesterday the customer came over to have a look at progress and to see his 940 for the first time since buying it!!!

He loves the car luckily and is happy how work is progressing, he has asked if he can help me fit the engine and gearbox back in to the car to see how it all goes in. Which I'm more than happy for as two pairs of hands make refitting easier than one!

So I did the waterpump gasket and seals while he cleaned up the cylinder head exhaust mating faces.


IMG-20201121-WA0001 by Luke Ryland - Flickr2BBcode LITE

All refitted, once again original volvo waterpump and nothing wrong with it.


IMG-20201121-WA0007 by Luke Ryland - Flickr2BBcode LITE

Also swapped over the other engine mount bracket.


IMG-20201121-WA0005 by Luke Ryland - Flickr2BBcode LITE

The plan next week is to get the engine gaskets and seals done, cambelt and tensioner replaced, delete the egr junk, refit the exhaust manifold and turbo, remove the dual mass flywheel, fit the dogdish flywheel, clutch, oil filter, clean out the PCV and clean the whole engine ready to fit Saturday.

Last edited by 360beast; Nov 22nd, 2020 at 08:27.
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Old Nov 22nd, 2020, 09:04   #18
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what an interesting update to a fascinating project thread. Thank you.
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Old Nov 22nd, 2020, 09:55   #19
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Quote:
Originally Posted by 360beast View Post
Just a little bit of work done yesterday:

Swapped over the engine mount brackets on the FK engine for the early non hydraulic mount brackets, removed the A/C pump and auxiliary mounting bracket and then fitted the poverty spec alternator only auxiliary bracket. Undoing the auxiliary bracket I skinned a knuckle so I dripped a lot of red stuff on to it 😂 the first of many skinned knuckles I imagine for this job.

I regard the drawing of blood as a good portent for the job: no blood loss means I got something wrong...

BTW, my other half is a part-time vampire so looks upon fresh blood with relish (usually cranberry).
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Old Nov 22nd, 2020, 10:52   #20
Laird Scooby
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It's all progressing well Luke!
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