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Volvo 245 Wagon KA24DE and Manual Swap (Volvo 245SX

Turbo Bob

Turbo Bob

New member
Joined
Aug 4, 2009
Location
Miami, FL
Volvo 245 Wagon KA24DE and Manual Swap (Volvo 245sx?)

Like the title says, blew up the B230F+T not too long ago, swapping in a KA24DE and manual transmission from a 1995 Nissan 240sx.

Why I picked the KA24DE:
It's cheap and proven, rather compact, and very common
Upgrades for this engine are cheap
Comes with a 5 Speed Manual

250-300 whp should be attainable with a turbo

KA24DE from 1995 Nissan 240sx
5 Speed from 1995 Nissan 240sx
Nissan 240sx Hydraulic Clutch Master/Slave
Manual Pedals from Volvo 240
eBay SR20 Aftermarket Fuel Rails
eBay FPR
eBay T3/T4 Turbo (same one from my B230F+T)
eBay $60 Cast Manifold
eBay Intercooler/Piping

Microsquirt v3 (same one I used on the B230F+T)
GT500 Injectors
LS1 Coils
DIYautotune Trigger wheel 12-1
AEM UEGO X-Series

Custom Hackjob Bob (me) mounts

Driveshaft? IDK
I bought the nissan transmission slip yoke and volvo 240 diff flange yoke, just have to figure out what to do in between


Video:
https://youtu.be/X0zK3n2lonI







 
Last edited:
Looks great. Your engine angle seems a bit off. Stand straight in front and you'll see what I mean
 
The only thing that bothers me about a KA or an SR in a LHD 240 is that the turbo and exhaust all get awfully close to the steering shaft and brake plumbing components. Shouldn't be terrible to figure it out I guess.
 
More updates coming tomorrow.
BIG PROGRESS

Harlard said:
The only thing that bothers me about a KA or an SR in a LHD 240 is that the turbo and exhaust all get awfully close to the steering shaft and brake plumbing components. Shouldn't be terrible to figure it out I guess.
Click to expand...

I will jerry rig some type of heat shield or throw a blankie on the turbo.

Dannyt0186 said:
sick!! i actually used some of your vids to get rolling on my 91 940 turbo wagon.... bummed you sold it. keep up the good work
Click to expand...

Thanks Danny, hope to get more vids up.
I really enjoy making them
 
New Video!
https://youtu.be/8r0xyd87OB8

Lately we got a few things done:
Power Steering!!
Fuel Lines, Rail, FPR, Return
Injectors
Almost all the wiring for Microsquirt
The Ignition coils are in (need to be mounted)
Turbo Lines Drain and Feed
Turbo Glued On
Clutch Pedal/Actuation/Master Cylinder
The downpipe from the B230F+T will work with no modification needed for open downpipe, just need to make a support bracket
Closed up all vacuum lines
All sensors are installed (MAP, CLT, MAT, TPS, Dizzy, WBO2)

The Clutch Pedal has been welded and modified for hydraulic system, system not flushed yet but appears to be actuating properly.
Pedal length must still be extended but will be done after brake pedal has been reinstalled.


What is left including but not limited to:
Bleeding of clutch system
Intercooler/Coldside piping
Testing and verification of microsquirt wiring
Install Trigger Disk in Distributor
Radiator/Hoses/Fan/Relay
Driveshaft
Starter Cable/Alternator Charge Cable
Throttle Cable
Oil/Filter
Maybe wire an Idle Valve? (Possible air con!?!?!?)
 
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