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Old 09-02-2018, 03:43 AM   #1
H.E
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Default Henrik's Volvo 240 '93 wagon - BMW M52TUB28 Swap

I've always dreamt of a sleeper wagon and one day there was a good offer for one with rust problems of an acceptable magnitude. Here in Estonia, the roads are salted in the winter, that causes massive corrosion problems.


When I bought it, it had tiny summer wheels. Got some 17inch rims and winter tires.


The car had some minor problems with engine running smoothly and at some point eveng getting the cold engine to start. Eventually replaced the O2 sensor and MAF sensor to get it running well. When fixing the small problems I also replaced the exhaust system from the downpipe. While roubleshooting and trying to get it running some casualties were taken.


The idea was to have a reliable sunday cruiser. The way towards this started with rebuilding the entire brake system.
The calipers were extremely rusty. To get them clean, tried electrolysis. Worked like a charm.



Also took the entire rear axle out to get it into parts and clean it for painting and replacing all the bushes, hoses, tubes, parking brake system, shock absorbers, diff oil.




Also got the offset of the 17" wheels changed -40mm and rear widened about 30mm.
http://static3.nagi.ee/i/p/998/76/24969103c8c447_l.jpg

While working on the stance I also cut the OEM springs almost in half. Would not suggest with oem shock absorbers. The ride is not very enjoyable, specially when the roads are not in the best condition. The thought is to have air suspension at some point and then change the shock absorbers to something that fits the stiffness better.


Since the engine was way under-powered and not the smoothest 4-cylinder in the world, I was looking to replace it. Due to Estonian laws and availablily the selection was limited. I would have had a V8, but the prices for manual are quite high. We have here a lot of BMW engines and know-how about turbocharging one.
The final choice was a M52TUB28.


I started with rebuilding the engine. Got everything machined and cleaned. At first I thought I will just make a minor maintanance, but ended replacing almost everything.



While cleaning, I managed to destroy the double-vanos system. Since I have experience in working with VEMS ecu and controlling the double VANOS with infintely variable cam control is quite difficult. I decided to convert this to non-TU engine single-VANOS system. I also wanted to have a more simple manifold, and replaced it to M50B25 manifold, that is a known performance upgrade. I realised that there are a lot of differences between M52B28 and M52TUB28 engines. I had to replace all the cams, modify the vanos unit, close some ports for EGR and Idle control in the head. I also made some turbo oil return ports for bottom-mount turbo install in the future.


While rebuilding the engine, there was a good offer for a GT3071R turbocharger.


Then it was time to take out the old engine, give the engine bay a clean and get the new engine mounted.
The engine is coming from 5.seriers E39 and fits like it is meant to bethere.





After test-fitting everything, I repainted the engine compartment and other items.


The gearbox is a ZF unit that should handle the power. Stirring the gearbox oil with a long stick and short throw.


Since the windsheild wipers were a bit stuck and i anyway had to work on the pedals It made sense to remove the dashboard. When the dashboard is out, it also made sense to do some other works, that are easier.
Ended up with installing an audio amplifier hidden under the dashboard for under-seat subwoofers, installed keyless central locking and some other minor improvements.


This is VERY shortly summarising what has been done. There are a lot of small details
I'm now waiting for the ECU, shortening of the propshaft and finishing all the small bits of the swap.
A long way to go, but hoping to get it running before christmas
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Old 09-06-2018, 09:27 PM   #2
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looks nice I cant wait to see it finished!
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Old 09-06-2018, 10:25 PM   #3
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Well, this looks promising.
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Old 09-11-2018, 06:34 AM   #4
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While waiting for the ECU I can work on some smaller things that need attention.
Took the headlights apart to clean and replace the reflectors. Managed to break most of the plastic adjustment screw connectors. Got new 3D printed. Hoping that it will takee the heat. The material itself should withstand 130c (266f) and 5kg of pressure.



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Old 09-21-2018, 07:56 AM   #5
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Most of the car has been assembled. Some small bits and peices still missing, but nothing major that would stop it from running.


Got the propshaft rebuilt and extended to the correct lenght. Weirdly enough, the propshaft from a volvo fits directly to the bmw large rubber joint and ZF Gearbox.


Also replaced the bottom seat cushion with another from a passenger seat and hopefully fixed the "Gangsta Lean" issue.
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Old 09-21-2018, 09:43 AM   #6
stick70
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Looks awesome! What did that ZF transmission come in originally?
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Old 09-24-2018, 03:45 PM   #7
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awesome progress!
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Old 09-24-2018, 03:56 PM   #8
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Originally Posted by MadDog_945 View Post
awesome progress!
+1 for sure.

Impressed, this will be fun!
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Old 09-27-2018, 02:53 AM   #9
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Looks awesome! What did that ZF transmission come in originally?
This particular gearbox is coming from a 1998 E39 BMW 528i.
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Old 09-27-2018, 08:03 AM   #10
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Looking good! subscribed!
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Old 10-19-2018, 02:42 PM   #11
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Received the ECU. Using VEMS standalone ecu due to the combination of different engine components from M50, M52 and M52TU and plans for running on boost.
Here's a video of the first start, with engine running on 5 cylinders due to a wiring problem that was sorted later.
Everything took way longer than expected... kind of what you could expect with custom build. Had to completely

If anyone has any suggestions about getting the tachometer working in the instrument cluster, all welcome.
I have tried this guide, but did not work. Have to check once again to verify if all is correctly installed.
https://www.youtube.com/watch?v=RT3ZIFuI90I

Going to get a proper tune over the weekend and then go throught the final assembly of the dashboard and doezens of other bits and peices that require some attention. It never ends.
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Old 10-19-2018, 11:54 PM   #12
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Where in Eesti are you? I love that country.
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Old 10-21-2018, 03:24 AM   #13
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In the suburbian area of Tallinn
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Old 10-21-2018, 04:23 AM   #14
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That looks great!!

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