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Old 08-25-2012, 02:58 PM   #1
Arn02
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Default Dubbelvla: a 245 with an M50

This will be a blog about putting a BMW M50 engine in a '77 245. I know there are a few 2-serie cars with an M50/52 or even S50/52 (M-Power engines) out there, I just haven't seen a well documented build thread anywhere.
I have a blog on the Dutch Volvolvo forum about this swap already, I just figured I may as well go international. So here goes...

First, the car. Like stated above, it's a '77 245. Yellow on the outside, chocolate brown interior (hence the nickname "Dubbelvla" - too silly to explain in English). I bought it for a very reasonable amount of money as it is a non-runner with some serious rust on the floor, A-pillars and sills. The bodywork itself is pretty solid. Since I'll be engine-swapping it, the non-running part is of no importance. The rust part however will require quite some time and effort. But after (partly and full) restoring several cars over the years, I feel comfortable enough to tackle this problem. Pictures say more than words, but sorry about the crappy quality. After having 5 camera's lost or destoyed in 5 years I nowadays just use an old smart phone to make pictures.






In my work place:








I immediatly started stripping it:












Three doors were beyond repair so I scored three rust-free replacements.




Plus a 242GT front.




Some of the rust issues:





Clean!



More to come!
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Last edited by Arn02; 01-14-2013 at 05:29 PM..
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Old 08-25-2012, 03:14 PM   #2
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The engine I will put in the car is a '91 BMW M50. It's the first of the M5x engines, all have 6 cilinders and 24 valves. The original one does not have VANOS (variable valve timing) which is fine because it makes things easier. However, I did make it a stroker by using the rotating assembly of an '02 M54B30 - in which the Bxx stands for engine volume. The original engine I bought is a M50B25 out of an e34 5-series, now a M50B30. Expected horse power around 220-230.

M54 crank in M50 iron block:






Decked 1mm to increase the cr:




Rebuilding the head:






I chose to use the e36 3-series oil sump since it matches the original Volvo sump best. Test fitted in the car:




Fitting an old M50B20 mock-up block with gear box:








Gearboxes compared. Overall dimensions are the same.

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Old 08-25-2012, 04:08 PM   #3
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The M50 is placed under a 30 degree angle. I decided to make the gear box support first and let the position of the engine itself be determined by it.

The original BMW cross member; useless.




Test-fitting the Volvo cross member.



Which led to:



... and...



And that led to:




Not perfect but fine. At least for now. Time to tackle the front!

Motormount and carrier to be welded on the subframe.








On the passenger side I used an original hole:




I didn't have too much time left that day to make the engine stands, so I decided to mock up the cilinder head, intake manifold and headers.



The headers made clear my effortless passenger side solution was rubbish. Too close for comfort:




There where other problems. The valve cover was hitting a bulge. Since these are only there for RHD models I just cut it away. Will weld it shut later.






The inlet manifold was interfering with the wiring, gas cable and brake booster.






The wiring is not a real problem. The gas cable may be a bit, but the brake booster is! On the above picture you can already see I swapped the flat original BB with a later type BB. However, that led to possible problems with the throttle body and rubber elbow, if the MC was mounted.




So I pulled my collection of BMW BB's from a shelve and did some comparing.



They all but one were rubbish. The BMW 2002 BB has the same bolt pattern and distance to firewall as the Volvo BB. Only the "fork" to the pedal itself needs a bit of customizing.




Paired with a e21 3-series MC it will work perfect. The e21 MC is 20mm in diameter and has three exit holes. If one is blocked it fits next to the strut tower. It has the same thread as Volvo by the way. The fluid reservoir on it has a third exit for a clutch cilinder. I already sourced a 940 CC. Here it is mounted:






Today I continued on the engine mounts.















They need to be finished because I just tacked them for now. Will do so when the engine is out again and I can put them on the bench. They also may need some added strength.

Next step it to put the body in the rotissery so I can start the weldathlon on the floor.

Last edited by Arn02; 08-26-2012 at 03:48 AM..
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Old 08-25-2012, 04:54 PM   #4
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Subscribed.
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Old 08-25-2012, 06:53 PM   #5
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I need that Red Heat poster in my garage.

Do you plan on keeping it N/A or boosting it eventually?
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Old 08-25-2012, 07:00 PM   #6
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Sub'd.

This is going to be interesting.

Keep it up!
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Old 08-25-2012, 07:08 PM   #7
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Volvo already have thin vacuum booster, you do not need to install from bmw..

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Old 08-25-2012, 07:14 PM   #8
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I'll be watching this thread. Nice work so far.
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Old 08-25-2012, 08:44 PM   #9
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Hey, thats my old 245! Ha!

Nice work! Continue..
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Old 08-26-2012, 02:48 AM   #10
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Quote:
Originally Posted by manderino View Post
I need that Red Heat poster in my garage.

Do you plan on keeping it N/A or boosting it eventually?
The car will be a dd. If I were to turbo the 3 liter I'd be around 350hp easy. Too much. By decking the engine I've raised the cr to 11.3. Also, the chassis of the 2-series... Well that rear axle would need to be swapped with something with independent suspension for my liking.
Big beefy Arnold holds watch when I'm not around.

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Volvo already have thin vacuum booster, you do not need to install from bmw..
That one was in the car. It's not the flatness which is the problem, it's the diameter of the thing. A booster is a booster. BMW uses Ate. I believe the 2002ti booster is the same as on a P1800es

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Hey, thats my old 245! Ha!

Nice work! Continue..
Really!? That's nice. I have some questions, I'll pm you.
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Old 08-26-2012, 03:24 AM   #11
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g240 or 260?
on my swap im doing m50 + g240.

Looking good though, Good luck!
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Old 08-27-2012, 02:58 PM   #12
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Interesting thread. Eager to see the results!
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Old 08-27-2012, 03:12 PM   #13
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awesome!!!! i've been wanting to swap a m50 stroker into a 245 for the last few years.

can't wait to see this progress!
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Old 09-03-2012, 03:09 PM   #14
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Good lord, this will be interesting. and so near too!
Where are you wrenching, you found a place near Amsterdam to work? Jelouseeeee!
Also where did you find that GT front... awesome!
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Old 09-03-2012, 03:20 PM   #15
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Hm, never seen your toppa on the Volvolvo. Where in The Dam you at?
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Old 09-04-2012, 02:34 AM   #16
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I'm living in A'dam West (≠ the guy who played Batman) but my workplace is near Abcoude. Will take a bit before one can spot the yellow/brown machine on the streets again.

Very busy with work atm so updates come later.
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Old 09-04-2012, 03:00 AM   #17
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Let me update instead

This is his beautiful 2002:





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Old 09-04-2012, 03:37 AM   #18
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well they dont have any spare workspace for rent next year?
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Old 09-04-2012, 03:54 AM   #19
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zo dat ziet er kicke uit, zowel de bmw en de volvo dan he
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Old 09-04-2012, 04:01 AM   #20
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s14 2002...
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Old 09-04-2012, 04:34 AM   #21
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Nice, nice. Good to see you found a spot so near to the city. I got a space in the Rivierenbuurt, but I cannot wrench too much. Ah well, better then nothing.
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Old 09-04-2012, 04:58 AM   #22
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Ask this guy what booster he's running if the BMW booster don't work http://forums.turbobricks.com/showthread.php?t=257601

What color code is that yellow? I like it
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Old 09-05-2012, 01:01 AM   #23
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oh god an s14 swapped 2002, why are you bothering with the volvo, your life is already complete...
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Old 09-06-2012, 05:30 PM   #24
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Quote:
Originally Posted by Mr.Borrie View Post
well they dont have any spare workspace for rent next year?
No unfortunately.

Quote:
Originally Posted by Mattis View Post
Ask this guy what booster he's running if the BMW booster don't work http://forums.turbobricks.com/showthread.php?t=257601

What color code is that yellow? I like it
Will do if it don't. Color is 128. You gotta love the seventies! ;)

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Originally Posted by mdlimy55 View Post
oh god an s14 swapped 2002, why are you bothering with the volvo, your life is already complete...
You're right, it's a brilliant car. But I love the 245 too. It has some flaws especially in handling, but it has lots of character! Nobody hates a Swede. ;)
The 2002 has a s14b20 at the moment with a ported head, 272/264 cams and Maxx Alpha-N. Next step will be a s14b25 transplant which I have waiting for it. It has 11.5 cr pistons and will get more aggressive cams (think 292/284) and I plan on a 325ix Touring rear end swap (ventilated discs). But that will take place in a year or two. Taking my time, taking my time.

Anyway, a few delayed pics of the welded motor mounts, and some stuff I purchased. Hopefully I can continue the work on the car in a weeks time or so.







I adjusted the subframe to give a small bulge in the oil pan just that little bit more space.




The goodies: US indicator lights, some high beams switches and a NOS 262 6 cil. rev counter I won on ebay for 20,- euro. Hopefully I can make it work with the m50.




A welding job I'm doing finally justified me investing in a chop saw. Cuts through metal like a... indeed!


Last edited by Arn02; 09-06-2012 at 05:36 PM..
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Old 09-06-2012, 08:49 PM   #25
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nice job bud! :-)
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