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Sniperman
03-11-2011, 06:08 PM
I bought a 1992 940 Turbo a couple years ago that had rod knock and Orie and my dad helped me replace the engine a few months back. The donor engine came out of a 1993 760 Turbo stationwagon that I purchased from Craigslist for $300. It had approx. 320,000 miles on it, but passed a compression test and sounded beautiful while running (and it has oil squirters, which is an amazing upgrade!). The project ended up taking a month and a half because of unforeseen problems. We got the new engine into the car and got it almost entirely reassembled. We decided to start the car and she started up beautifully. Then, she completely failed to start. Orie checked the coolant chamber and it was pressurized (not good!). We thought we may have done the headgasket wrong so we ripped the head off. Long story short, we ripped the engine apart twice only to realize the head was improperly surfaced (it had small grooves in it that you could both see and feel with your fingernail). We got the head properly resurfaced and she fired right up! The foglight pictures were taken before and after polishing (my dad read an article in Popular Mechanics on how to do this and was kind enough to help me).

Here are some general pictures of her from before the engine swap:

http://reed.blacklight.net/car/1992_940_Turbo_Fiddletown1.jpg
http://reed.blacklight.net/car/1992_940_Turbo_Fiddletown2.jpg
http://reed.blacklight.net/car/1992_940_Turbo_Fiddletown3.jpg

Here are the pictures chronicling the laborious engine swap project:

http://reed.blacklight.net/car/engineswap/IMG_2067.JPG
http://reed.blacklight.net/car/engineswap/IMG_2069.JPG
http://reed.blacklight.net/car/engineswap/IMG_2070.JPG
http://reed.blacklight.net/car/engineswap/IMG_2071.JPG
http://reed.blacklight.net/car/engineswap/IMG_2072.JPG
http://reed.blacklight.net/car/engineswap/IMG_2073.JPG
http://reed.blacklight.net/car/engineswap/IMG_2074.JPG
http://reed.blacklight.net/car/engineswap/IMG_2075.JPG
http://reed.blacklight.net/car/engineswap/IMG_2076.JPG
http://reed.blacklight.net/car/engineswap/IMG_2077.JPG
http://reed.blacklight.net/car/engineswap/IMG_2078.JPG
http://reed.blacklight.net/car/engineswap/IMG_2079.JPG
http://reed.blacklight.net/car/engineswap/IMG_2080.JPG
http://reed.blacklight.net/car/engineswap/IMG_2081.JPG
http://reed.blacklight.net/car/engineswap/IMG_2082.JPG
http://reed.blacklight.net/car/engineswap/IMG_2083.JPG
http://reed.blacklight.net/car/engineswap/IMG_2084.JPG
http://reed.blacklight.net/car/engineswap/IMG_2085.JPG
http://reed.blacklight.net/car/engineswap/IMG_2086.JPG
http://reed.blacklight.net/car/engineswap/IMG_2087.JPG
http://reed.blacklight.net/car/engineswap/IMG_2088.JPG
http://reed.blacklight.net/car/engineswap/IMG_2089.JPG
http://reed.blacklight.net/car/engineswap/IMG_2090.JPG
http://reed.blacklight.net/car/engineswap/IMG_2091.JPG
http://reed.blacklight.net/car/engineswap/IMG_2092.JPG
http://reed.blacklight.net/car/engineswap/IMG_2093.JPG
http://reed.blacklight.net/car/engineswap/IMG_2094.JPG
http://reed.blacklight.net/car/engineswap/IMG_2095.JPG
http://reed.blacklight.net/car/engineswap/IMG_2096.JPG
http://reed.blacklight.net/car/engineswap/IMG_2097.JPG
http://reed.blacklight.net/car/engineswap/IMG_2098.JPG
http://reed.blacklight.net/car/engineswap/IMG_2099.JPG
http://reed.blacklight.net/car/engineswap/IMG_2101.JPG
http://reed.blacklight.net/car/engineswap/IMG_2102.JPG
http://reed.blacklight.net/car/engineswap/IMG_2103.JPG
http://reed.blacklight.net/car/engineswap/IMG_2104.JPG
http://reed.blacklight.net/car/engineswap/IMG_2105.JPG
http://reed.blacklight.net/car/engineswap/IMG_2106.JPG
http://reed.blacklight.net/car/engineswap/IMG_2107.JPG
http://reed.blacklight.net/car/engineswap/IMG_2108.JPG
http://reed.blacklight.net/car/engineswap/IMG_2109.JPG

Sadly, my AW71 automatic transmission started to immediately fail after this project. So, my next project will be converting my car to an M46 manual transmission (something I've always wanted in this car). I snagged the kit yesterday and am trying to figure out the logistics of the conversion (it's admittedly over my head). I'll keep adding pictures to this thread! =)

-Snipe

amerbritcan
03-11-2011, 08:14 PM
nice, I'm diggin the black. I bet you can't wait to get it to 'nothing's breaking' status.

Sniperman
03-11-2011, 09:51 PM
Thanks! =) I can't *WAIT* to get her mechanically sound, I'm tired of thinking about it!

-Snipe

nice, I'm diggin the black. I bet you can't wait to get it to 'nothing's breaking' status.

shellshock
03-12-2011, 03:22 AM
Awesome man! She'll be good to go for another 300+k miles!

Headlights look good! Have you looked into the ecode swap?

http://carphotos.cardomain.com/ride_images/3/3235/1701/33085850006_large.jpg

HonestJhon
03-12-2011, 03:33 AM
Install torque converter into transmission first, fully seating the driving notches into the trans pump.
THEN put motor in. then bolt converter to flexplate.
thats why the trans died.

Sniperman
03-12-2011, 03:35 AM
Well, the engine has 325,000, and the car has 187,000, so I hope you're right =). I'm unsure what you mean by ecode swap?

EDIT: The headlight on the right is actually plastic, gotta replace that assembly as soon as I find an unbroken glass one at Pick n' Pull (which means I'll likely need to clean another foglight) =P

Thanks,
-Snipe

Awesome man! She'll be good to go for another 300+k miles!

Headlights look good! Have you looked into the ecode swap?

Sniperman
03-12-2011, 03:37 AM
Yep, we most certainly screwed that up, sigh. Why would that kill the transmission out of curiosity? Also, I pray we didn't damage the engine somehow =/

Thanks,
-Snipe

Install torque converter into transmission first, fully seating the driving notches into the trans pump.
THEN put motor in. then bolt converter to flexplate.
thats why the trans died.

HonestJhon
03-12-2011, 03:41 AM
engine will be fine. well, assuming nothing else was wrong, but the transmission will die a quick death if the converter isnt driving the pump, and you try to use it to move the car.
the fluid wont be doing anything.
however, you COULD see if reseating it now will make it work at least until you get the manual swap sorted...
but thats a lot of work (pull the motor out till you have access to the converter) in and of itself.


i think the most annoying part of doing the manual swap (from reading, have not manual swapped myself) is the pedal box. and for me, that'd be just because i HATE going under the dash in the drivers footwell.

HonestJhon
03-12-2011, 03:43 AM
and the ecode swap is to take your measly stock, american style foglight setup and swapping to the much mo betta european style headlights. they have better beam patterns and use the light the bulbs produce more efficiently. I drive a 940 with the american style lights. they suck. lol

Sniperman
03-12-2011, 03:48 AM
I'm amazed the transmission has survived the 6 months since the engine swap then! Hell no on that potential fix, I don't ever want to pull another motor again unless I absolutely have to haha. Yeah, I briefly started pulling a manual pedal box assembly at Pick n' Pull, and if I recall, 5 of the nuts are a complete pain to get to. Luckily I'm a fairly small guy so it's not too uncomfortable for me to work in the driver's footwell =).

Thanks,
-Snipe

engine will be fine. well, assuming nothing else was wrong, but the transmission will die a quick death if the converter isnt driving the pump, and you try to use it to move the car.
the fluid wont be doing anything.
however, you COULD see if reseating it now will make it work at least until you get the manual swap sorted...
but thats a lot of work (pull the motor out till you have access to the converter) in and of itself.


i think the most annoying part of doing the manual swap (from reading, have not manual swapped myself) is the pedal box. and for me, that'd be just because i HATE going under the dash in the drivers footwell.

Sniperman
03-12-2011, 04:00 AM
Can you please show me a picture of the European-style headlights? I'm very curious to see what looks different =)

Thanks,
-Snipe

and the ecode swap is to take your measly stock, american style foglight setup and swapping to the much mo betta european style headlights. they have better beam patterns and use the light the bulbs produce more efficiently. I drive a 940 with the american style lights. they suck. lol

shellshock
03-12-2011, 04:11 AM
Can you please show me a picture of the European-style headlights? I'm very curious to see what looks different =)

Thanks,
-Snipe

The above picture is the Ecodes. They are all glass and have a superior light output than the American units. It takes hardly any work to swap to the ecode setup.

Sniperman
03-12-2011, 04:17 AM
Hmmm, are the wipers optional I hope? I like the looks except those =P

EDIT: Also, what in the world is sticking out of your driver's side headlight trim?

Thanks,
-Snipe

The above picture is the Ecodes. They are all glass and have a superior light output than the American units. It takes hardly any work to swap to the ecode setup.

Clay
03-12-2011, 01:53 PM
Here's my old 940 with its ecode headlights. The headlight wipers ARE optional and you can reuse your headlight trims.

http://i48.photobucket.com/albums/f224/clay92/IMG_3502.jpg

Sniperman
03-12-2011, 05:08 PM
I really like the look of the ones without wipers. My next question: Where in the world can the headlights/assemblies be found? Are they on more modern Volvos at Pick n' Pull, or do I need to find someone on TBricks/Brickboard that's selling a pair? Also, do they take the same headlight bulbs or would I have to replace those too (I'm currently using Silverstars that I like, and they were expensive)?

Thanks!
-Snipe

Here's my old 940 with its ecode headlights. The headlight wipers ARE optional and you can reuse your headlight trims.

rwturbo
03-12-2011, 09:14 PM
ok the motor you put in that came out of the 760 with 300k miles on the car! that motor was put in that car and probably has much lower miles. The motor you pulled and put in came out of a 940 turbo. If you look at the date codes on rear exhaust side of head you will see it is a much newer motor. The 760 would not of had squirters and the type oil cooler that engine has. So congradulations on your purchase. Your car has the correct motor back in it!

Sniperman
03-12-2011, 10:45 PM
The donor car was probably a 940 Turbo stationwagon (Orie probably remembers). The head came from Orie, not the donor car (the donor car's head was in BAD shape). He had a valve job done and had it resurfaced.

-Snipe

ok the motor you put in that came out of the 760 with 300k miles on the car! that motor was put in that car and probably has much lower miles. The motor you pulled and put in came out of a 940 turbo. If you look at the date codes on rear exhaust side of head you will see it is a much newer motor. The 760 would not of had squirters and the type oil cooler that engine has. So congradulations on your purchase. Your car has the correct motor back in it!

orie
03-14-2011, 02:11 AM
The head was out of my 1992 745Ti and in perfect condition. (Well, as perfect as stock castings and reamings are)

The engine was from a 1993 945Ti, and is a "R" block, which was in this case a february 1993 squirter engine (prototype release of the H block from what I can tell). High mileage, but tight and quiet. VERY minimal ridge on all 4 cyls. Decided to leave the bottom end alone for that reason and inexperience/time.

I agree with everyone else on the ecodes, my 945 will have some as soon as it's on the road.

Kinda figured about the torque converter, but couldn't find any good info on removal/installation at the time. I thought your transmission was having trouble before that anyways, Snipe?

Josh
03-14-2011, 02:33 AM
clay you really should have kept that 940.

urbanwheeler
03-14-2011, 02:47 AM
Get another AW71L and stuff it in there so it'll work till you can sort the manual swap. The automatics are dirt cheap for these, and plenty strong.

Mine's probably gonna get either a T5 or getrag next, as M46s are getting too worn out, and both I've had so far have tons of wear issues.

urbanwheeler
03-14-2011, 02:59 AM
Here's my build thread

http://forums.turbobricks.com/showthread.php?t=209845

Sniperman
03-14-2011, 07:17 AM
Thanks for the additional clarification Orie. The transmission was fine before the engine swap if I recall correctly =/.

urbanwheeler: I wish I had the money to pay for a used AW71L and to pay someone to install it (I've yet to replace an automatic transmission, all of my experience is with M46s), but I'm jobless and in bad shape at the moment =(.

-Snipe

The head was out of my 1992 745Ti and in perfect condition. (Well, as perfect as stock castings and reamings are)

The engine was from a 1993 945Ti, and is a "R" block, which was in this case a february 1993 squirter engine (prototype release of the H block from what I can tell). High mileage, but tight and quiet. VERY minimal ridge on all 4 cyls. Decided to leave the bottom end alone for that reason and inexperience/time.

I agree with everyone else on the ecodes, my 945 will have some as soon as it's on the road.

Kinda figured about the torque converter, but couldn't find any good info on removal/installation at the time. I thought your transmission was having trouble before that anyways, Snipe?

orie
03-14-2011, 02:55 PM
Thanks for the additional clarification Orie. The transmission was fine before the engine swap if I recall correctly =/.

-Snipe

Bummer. But I do still wonder if it's just a clogged screen. Since we did a dirty/exposed swap with the xmission just sitting there for a week, some dirt may have gotten in/been jostled around and caught by the screen.

Why wouldn't the transmission pump work right away the way we installed it? I mean, I do remember feeling the torque converter seat.

Sniperman
03-14-2011, 05:29 PM
Impressive urbanwheeler, nice to see she's in good hands =). The farting being caused by the TPS sensor connector is hilarious! =)

-Snipe

Here's my build thread

http://forums.turbobricks.com/showthread.php?t=209845

Sniperman
11-27-2011, 07:14 PM
During the engine swap, we accidentally used too long of a bolt in one of the two bolt holes where the EGR pipe connects to the intake manifold. This ended up severely damaging the bolt hole, and resulted in a vacuum leak. The car was still able to pass smog despite this, but it was causing fluctuations in my idle. We then attempted to thread a slightly larger bolt in and the bolt ended up snapping (naturally). So, I decided to swap the intake manifold with the spare from my 320,000 mile engine donor car while I was at a stand-still with my automatic to manual transmission conversion project.

Here are the photos from the intake swap (I'll post the manual conversion photos soon):
http://reed.blacklight.net/car/intakeswap/IMG_3490.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3491.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3492.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3493.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3494.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3495.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3496.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3497.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3498.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3499.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3500.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3501.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3502.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3503.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3504.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3505.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3506.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3507.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3508.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3509.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3510.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3511.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3512.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3513.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3514.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3515.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3516.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3517.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3518.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3519.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3520.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3521.JPG
http://reed.blacklight.net/car/intakeswap/IMG_3522.JPG

240Psycho
11-27-2011, 07:39 PM
Your car looks like my black 91 944 turbo. I did the m46 swap a year ago and it made the car soo much quicker. However the transmission is now falling apart. If you need any help with the trany swap shoot me a pm.

Sniperman
11-27-2011, 08:01 PM
Right on =). Yeah, my manual swap is already done! It definitely made the car feel MUCH quicker, and it's SOOOOO much more enjoyable to drive! Bummer to hear the M46 is falling apart, I'm not surprised =/. I went through 2 on my old 1985, and also had 2 clutch fork failures within 1.5 years that made me finally give up on the car. Thanks for the offer of help!

-Snipe

Your car looks like my black 91 944 turbo. I did the m46 swap a year ago and it made the car soo much quicker. However the transmission is now falling apart. If you need any help with the trany swap shoot me a pm.