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Old 10-13-2013, 01:21 PM   #1
adomz
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Default Adam's Street 244 GL

As you already might know and see etc, i had a 1989 240 GLT (thread here: http://forums.turbobricks.com/showthread.php?t=224875, that i was planning to swap the b230e with a b230ft that Mr. Chesh had leying around his garage... That never happened, and after quite alot of discussions etc, we have bought a 1991 244 GL with a ****ty and powerless b20e (i think)... So here it all goes!

The part/mod list so far:

Engine:

1998 B230FK with around 183k miles at the time of the swap.
Repainted Block, all cleaned, new gaskets, seals etc. Apart from that - Stock

Head was refurbed when i was planning to do the swap into the GLT, Stem seals replaced, valves relapped, skimmed to clean up the surfaces

Electric fan has been modified to go in the original radiator and a 3 way switch is located in the centre console near Hazard switch. Still not automatic as i never wired it in.

Mocal 13 row oil cooler mounted horizontally behind the grille, in perfect air flow, and plumbed into the original oil to water exchanger via thermostatic sandwich plate.

Turbo is a 16t from a 2004 v70 T5 with a blocked off Recirc valve (i LOVE chatter), Actuator bracket has been made to be able to run it in RWD fashion. Currently running actuator pressure, and when tested on the (closed) road - set at around 1.3 bar. The hot side has been destudded and has a 3 inch V-Band TIG'd onto it to ease the fitting and removing the downpipe. Downpipe has 2 bungs for Wideband and Lambda probes.
Exhaust is a full stainless steel 3 inch turbo back, V-Banded, with a single Box in the rear where the original under the fuel tank box is and comes out as 2x2.5 inch shotguns at an angle.

Stock intercooler, and piping for now. Looking into options about huge IC's and want to upgrade all the piping to 3". <== Already got a huge 600*300*100mm core 780mm intake to outlet intercooler with most of the piping and hoses etc... (can't weait to upgrade that as it is going to improve the driveability and response of the car)

Stock 016 AMM to be replaced with my home made 3" AMM.

I already have a 960 throttle body, just need to get the adaptor plate for it.

Stock injectors. Got clean and tidy Browntops and 4 bar adjustable FPR to go in with a fuel rail adaptor until i can get a proper fuel rail.

Fuel pump is an AEM 320LPH intank and no Inline fuel pump, for now, Which will be updated with a 044 320LPH pump and maybe a surge tank inbetween the two.

Transmission:

M90 adapted for 240 use by making a transmission mount out of the 240 crossmember and 940 Gearbox mount. (the gearbox is still a little bit too high, so it needs to be trimmed down where it sits on the x-member). The prop-shaft has been lengthened by 50mm by a propshaft specialists and repainted etc and the shifter linkage was shortened by 100mm too.

The Clutch is a LuK reboxed Sachs m90 Diesel clutch in a dog dish flywheel.

Suspension:

Stock for now apart from the 95% polybushed. Torque rods are Rose jointed. Axle bushings are original volvo, but i have kaplhenke racing sphearical bearings to go in.The panhard rod is still stock and lacks any rubber in the bushings. This will be addressed whenever i do the suspension.

Front Shocks:

Stock with 40mm Kilen lowering springs for now, but Gaz Coilovers with 8" 500lbs springs and E36 Camber plates are waiting to go in as soon as.

Rear shocks:

Stock, 40mm Kilen lowering springs for now, Gaz shocks adjustable racing shocks with 275lb springs and adjustable perches to go in as soon as i get the springs and perches.

Brakes:

Stock for now. Mintex discs + Pagid front pads and Mintex rear pads. Plans are for Mitsu EVO 6-9 Calipers all round with 336mm XC90 front discs and 330mm s60r rear discs.

Wheels:

Virgo 15x6" with 195/55 Nankang NS2 front and 205/60 unknown ditchfinders rear. Plans: Volk racing F-Zero Winning 17x8 225/45 Front 17x9 245/45 Rear.

Interior:

OMP Knockoff 360mm Deep used to be suede steering wheel, M90 gear stick. Stock cloth front seats, Leather comfy as fook rear GLT seat.

Stack Boost and oil pressure in the original Clock and lower blanked off spaces and a Stack Wideband + Digital Cheapo Volt Meter where the radio used to be.

Radio located in front of the gear shifter.

Hmm... Have i forgotten anything?? Erm... Should be fine!

Cheers, ADam
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Last edited by adomz; 08-28-2015 at 08:22 AM..
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Old 10-15-2013, 02:34 PM   #2
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Right, finally found the time to do the thread number two, as the first one has died the same as the car...

Here's some pics from the other thread to start the things going, and i will try to update everything else that happened and will happen as soon as it happens... As it has been said already, i had the engine at Chesh's place for about two years, and bit by bit was buying all the necessary stuff to swap it into the GLT.

So, the first was the cylinder head, taht had 3 of the 8 exhaust manifold studs snapped, cause someone previously had crossthreaded them.. So, off it went to the workshop for a skim, clean, and reassemble with all new seals and gaskets, relap etc...






Then, it all was built into the engine like so...







Pete (RIP) was trying to adjust the turbo hot side to suit our 13c...









So, really good times has been had, and i really appreciate all that came to help and so on
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Old 10-15-2013, 03:25 PM   #3
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Then, after a little while, i turned up at Chesh's again to finish it all off. I was really surprised when Pete popped the bonnet, and there it is, sitting in the engine bay, just waiting for me lol... It seems that Foggy visited Chesh to give him some morale support and they did their magic and put the engine in! You two are amazing!!



This happened after we extended the MAF wiring and did some more related jobbies! I didn't get a chance to film the first start, as i was too excited lol, but it started no problem with no MAF or Lambda attatched. Great!

Now some pics then...

Had a set of Stack oil pressure and Boost gauges, which are amazing quality!


Also had around 3.5m of 3" stainless tube, some bends, boxes and so on to go on after we're done with the engine.. More of that later... :


Here it is in the car, looking standard as ever lol... Surprises some people of how it is so simple and tidy there...


In the mean time, there has been some stripping down and swapping as the GL came with fabric seats and manual rear windows, so it all had to be taken out of the GLT...



And here's the sad moment, where the GLT has finished it's life in a scrap yard... It was too rusty to be kept and restored as i have no place to do all the work etc...


So, the GL has received the suspension off the GLT, as i had it fully polybushed, and it was lowered on a set of Kilen -40mm springs, also we have fitted the Goodridge braided brake lines as the old ones were shot...



Surprisingly, the GL's suspension was so rusty, that the metal (erm, or should i say rust?) just flaked off and it looked really bad so we just swapped all except the rear axle, as it was noisy and was losing oil...



When i started taking the front struts apart, we discovered a weird weld on plate on the passenger side cup, that the power arm mounts on... Chesh started to get nervous, as he thought that the shell has been badly damaged, and was repaired that way, but....

...but after a long investigation, it became clear, that the plate and the cup is a quite rare Australian strut reinforcement upgrade that you could get directly from Volvo! Thanx for Roger, our oracle for clarifying that! The weld on plate goes all the way round the top of the cup, where it bolts to the chasis using the three 13mm bolts, and on the other end, it is sandwiched between the chasis rail and the subframe... Also you can see the state of the suspension arms in the picture above. Thank God i have Hammerited the GLT ones ages ago when i was swapping the front lowering springs...

After we figured the suspension out and decided that the shell was straight (what a joy that was!) we went in to adjust the 940 downpipe that it would fit the RHD 244!! You lucky sods who got the joy of owning the LHD versions of the car lol...

Here's the space we have to deal with in the RHD wise:

Think it's ok to be fair... Soon we'll try to get the 3" downpipe there! Any ideas?

Cut, Check clearances, reweld!


Here's some adjustments on the ICV as in the end i figured out that it was shot, so i got another one off Adam (340GLT)...


And here's the Comic exhaust solution...


So, i was really happy about the car, not mentioning some stuff i still need to do on it, which includes fitting the Mocal oil cooler, changing the brakes, Spark plugs etc... Most of it is done now, but i have run out of money, so it will be done in a very near future...

Here's how it all looked on the way back from Chesh's, when i went to fill up, and find my way back home, as my phone, which i was using as Satnav, ran out of battery somehow, and i went the wrong way lol...


Next is some other stuff i got for the GL
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Old 10-16-2013, 04:54 AM   #4
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Get 'er done!

Was the GLT really that rusty? It looked pretty solid from afar, but I guess the bad rust isn't always obvious
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Old 10-16-2013, 06:15 AM   #5
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Hey dude. How you been? Well, the glt was bad. All the chasis rails were rusty, loads of rust round the windshield and rear window. The drivers side door hinge mounting points were shot etc... Not really worth it... But now it's a different story. Will need to investigate this shell a bit more soon...
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Old 10-16-2013, 05:14 PM   #6
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So, i had a chat to Adam (340GLT), and we had a deal to use all my exhaust supply, to make use of it...

I had an idea to go straight as possible, under the axle, and come out on the drivers side, as it was different from the original, and i fancied something like that too... But it never happened... Yeah, stuoid Adam (being myself) has ordered the HUGE rear box, that even half of it wouldn't squeeze inbetween the petrol tank and the but cheek :D Ok... Not a problem! A short while later it has been decided to use the original plan, but to come out in the original volvo place but with a bit of me involved...



Yeah... DTM YO!


What would end up something like that...



Oh... And, not forgetting the magician in his world: Adam (340GLT)


And the almost finished produt, which will be finished in the near future when the new, ported turbo is gonna go on with Vband clamps, ported 90+ manifold etc...


So, all in all, i am really pleased how it all worked out as it sounds quiet, but not too quiet, but it is something that other notice, as the ordinary volvos don't sound like that lol :D

Last edited by adomz; 10-16-2013 at 05:25 PM..
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Old 10-16-2013, 05:52 PM   #7
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Have you guus started your own car club yet!!
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Old 10-17-2013, 08:19 AM   #8
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Erm... We're good thanx. Plenty of other clubs i think
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Old 10-19-2013, 07:13 AM   #9
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Some more goodies arrived:



044 knockoff inline pump, AEM intank pump, MANN Filter, Ball joints, Tie rod ends and some other stuff... Should be on the car pretty soon, so will be updated as stuff happens ;)
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Old 10-25-2013, 10:30 AM   #10
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Today i finally managed to swap the Old lambda with the new. Started it up, and wow! Starts half turn, sounds way better, Idles really good. Great!! Really happy with that! Tomorrow and sunday i think i'll try swapping the fuel pumps, so hopefully it all makes a lot of difference in the way it all works. Another fault code that i got today is 3-2-2, which comes to AMM... Will investigate that too

Cheers!
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Old 10-26-2013, 04:07 AM   #11
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Looking good mate, once the running issures are sorted we can get the other turbo and manifold on and make that downpipe.
Adam
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Old 10-26-2013, 08:19 AM   #12
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Yup, will swap the AMM in a few hours today, and then we'll see. Should be ok, i hope. Can't wait till all is done, to see what it can actually do with the ported 16t, finished exhaust, and the 7000 rpm chips

Also noticed some exhaust noises while turning right all the time... I have an idea where it might catch on the body, so would be nice to eliminate those too whenever we do anything

Appreciate your help dude!!

Adam
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Old 10-30-2013, 04:23 PM   #13
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So far so good. After the AMM swap the car seems to run fine. Only one (yes, another) fault code saying 2-3-1* Fuel trim (lambda control) too lean or too rich at part load }If too lean: air leaks, low fuel pressure, bad sensor }Engine stops when starting from cold; high fuel use... The Lambda is two weeks old, so should be good. Apart from that all seems to be good. If the weather allows this weekend i will finally swap the fuel filter and the fuel pumps, so it might fix it and i will be a happy bunny!

Also it now has a rattle from the exhaust. Whenever i turn right, it seems like the exhaust is rubbing somewhere... Now i have found out lol... It does rub on the propshaft... One of the hangers is touching. It happens when the exhaust moves (slips) on the hangers that are on the body and stays there... I moved it all to the right and it seems to be ok for a while till it moves back again... All the vibrations etc... BAD!!! Need a solution for that!

Adam

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Old 02-22-2014, 11:59 AM   #14
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Hello Gents!

It has been long since i have updated this, so i thought that it's time to do it now.

I have been gathering parts for my m90 gearbox swap, and also, the 16t upgrade from my standard 13c, as well as finishing the exhaust, which is lacking the downpipe at the moment. Also i want to put a 4bar fpr, a mocal oil cooler with a possible oil filter relocation, and some other bits and pieces.

At the moment i am struggling to drive the car, as it has a possible boost leak, which i will investigate tomorrow, when i have some time to play around the car. Will take all the boost hoses off and check for some cracksand tears in them. Also, i will need to rewire the intank AEM pump with a thicker wire, as i have removed the original inline pump to be swapped with a 044 inline pump, but for now it will stay on one pump, as i need to source some fittings that fits the outlet of the pump.

I have replaced the fuel filter and the hose that goes from the inline pump to the filter, and the car has been driving faultlessly up until now, when i have discovered that the No4 fuse is heating up as much as you wouldn't be able to touch it. So i think that there is a problem with the wiring, and the way i wired the AEM pump. Also i am looking to replace the "pill" fuse box with something more up to date soon. As i can't stand the original fuses which usually fail.

There will be some pictures of all i will do and already have done since my last post, but i need to sort them out and see what i can use.

Cheers
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Old 02-22-2014, 12:02 PM   #15
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Oh, and now, when i suspect the car to have a boost leak, sometimes the car completely dies while driving. The revs drop to zero, but i can hear the pump run, so it has fuelling, and it pops and bangs too, which would suggest that the problem is not related to the pumps being wired wrong. If i stop, and try to restart the car, it sometimes starts, and dies after a second, and sometimes it just starts as there wouldn't be a problem. Also, if i try starting it in gear, it would start and drive no probs. Anyone have any idea if that would be related to the boost leak?

Cheers again! ;)
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Old 02-23-2014, 11:31 AM   #16
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Right, checked all the hoses, and all seems ok. After a chat to Mr. Chesher, he reminded to check the Turbo actuator arm, and yes, it was not connected to the wastegate flap... Sorted!

Another thing i found out... The engine is knocking!! That completely ruined the day for me as i wasn't expecting any of that. I never overrevved it, the boost was only stock LPT boost, which never exceeded 0.3 bar... Always had oil and never been overheated... well, atleast with me...

New engine is in the horison...

Cya!
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Old 03-25-2014, 06:44 PM   #17
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cool where you get your bushes from?
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Old 03-27-2014, 07:18 AM   #18
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The bushes have been bought on ebay around 5 years ago, they are made by Superpro, so i think you can still find a complete set there.

And here's how the car looks right now sat at Adam's (340GLT) awaiting those minor (well... HUGE) changes to make it awesome!

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Old 03-27-2014, 07:51 AM   #19
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inspring sir! my 244 had some a long way too, same color and all, I just don't haz turbo engine yet. Someday...
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Old 03-27-2014, 11:48 AM   #20
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Thanx man. A really Big update is coming soon, as i have done some stuff i have not posted yet, and also the stuff that is gonna happen soon will change the car dramatically ,so i will keep you all posted ;)

Adam
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Old 03-28-2014, 06:39 PM   #21
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Ok, got some more bits turn up, so here they are....

20x shallow nuts with volvo 240 sizing, and 20x steel nuts for the rims...



Ohh... And those two are water pumps. For the time when i want to play around with water injection. Why 2? I got one delivered, but one of the brackets was broken, so they just sent me the second one and told me not to bother with sending the broken one back lol :D We shall see how it works when time comes

Adam
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Old 04-26-2014, 08:30 AM   #22
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Right boys and girls, time for some update!

The car is at Adam's, and has been the for the past month or so. It needs a new engine, as it is knocking. one of the big ends seems to start knocking when the engine is cold, and the noise disappears when it get warm. So, i decided to swap it with another late b230fk. Surprise surprise, Adam had a 1998 940 in the scrappy with a really nice engine, and also the m90 gearbox, that i was planning to swap beforehand.

So, last weekend, and many weekends beforehand i went up to Adam's to help him with the swap as much as i could. Not a very pleasant thing when the car you are trying to do stuff to is about one and a half hours away from you lol... But it's all good, as long as we can do stuff!

Last monday we gathered to finally take the engine out of the parts car (red 940) and that turned out rather good! We had some bbq, beers, and really good times, which was unexpectedly amusing!

Here's some pics of the said antics...


The bad boy with the very long awaited m90

Dirty bugger...

Also tried some wheels to see the fitment and how the adapters turned out...

A bit more squat...

Suddenly Adam's passed out...

Some conversation and decision making going on here...


Had a great time and done loads!! Shame Adam's ran out of blue roll...

To be continued Tomorrow!

Adam
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Old 04-26-2014, 10:21 AM   #23
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Also forgot to mention, that i have bought a Stack Wideband to see whether it's still going very rich as i had comments of my mate following me on the motorway, that it smells of unburnt fuel... and a Bi-Xennon kit, so i should see where i am going better
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Old 04-26-2014, 02:36 PM   #24
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Those wheels are totally badass!!!!
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Old 04-26-2014, 02:46 PM   #25
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Yeah, liked it too Now it looks kinda lost with the virgos lol :D
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