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Old 11-28-2014, 07:08 PM   #2751
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Numbers matching build.
Waiting on some bearings and crap. I'll see if I can remember all the little fiddly things I've changed.
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Old 12-13-2014, 05:03 AM   #2752
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Making progress. That's enough for tonight.





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Old 12-13-2014, 12:52 PM   #2753
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Lookin good!

I think a year from now looking back, this will be the best decision you ever made.

I picked up a complete 2.3t5 for the bottom end and accessories. Huzzah. That's my once a quarter "I did something" quota. Come work on mine when you're done.
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Old 12-13-2014, 07:44 PM   #2754
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Looking good, Homer..... Will you get this drivable this weekend?
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Old 12-13-2014, 09:34 PM   #2755
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That's the plan. Gotta get all the fiddly bits connected tomorrow and hopefully it starts!
Engine and trans are in as of a few hours ago. Christmas party tonight so I can't plow through it.

I made a heat shield for the exhaust side of the head.



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Old 12-14-2014, 06:41 AM   #2756
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Jacob, hope everything works, without any problems.... :-)
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Old 12-14-2014, 01:01 PM   #2757
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+1!
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http://forums.turbobricks.com/showthread.php?t=247082
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Old 12-14-2014, 02:55 PM   #2758
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How's them fiddly bits coming together?
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Old 12-14-2014, 05:55 PM   #2759
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Slow because there's
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Old 12-15-2014, 03:24 AM   #2760
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Nice work Homer, Makes me almost want to forget about the B234 engine and B204F manifold i have in storage
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Old 12-15-2014, 12:40 PM   #2761
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Got the thing running last night in the pouring rain but I have an oil leak from the main oil feed to the top cam cover. The PO (not Justus) got a little randy with a screwdriver popping the cam cover off and gouged the mating face. I took the high spots down with a flat stone the volvo sealant doesn't want to seal it. It was also compounded with the paint getting soft after the engine warming up and requiring a retorquing of the cam cover bolts. That all turned into a massive rage inducing oil leak.
I did figure out a cam seal tool for the rear of the head so I don't have to pull the engine to fix the leak.
I'm going to fill in the low spot with jb weld and use some toyota FIPG to seal the cam cover. Fingers crossed.
The far right side of the head you can see the gouges just past the oil feed hole.
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Old 12-15-2014, 02:38 PM   #2762
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a massive rage inducing oil leak
Sorry to hear about that dude. I've had my share of experience with those. Over the years I've learned to set down the blunt instruments and just walk away from the project for a day or two whenever the urge to rage-bash new/shiny mechanical bits takes over.

Toyota FIPG is really great stuff. I've used the black and the grey; never had a problem. Permatex Ultra Grey is essentially the same thing if you're in a pinch. I haven't had to use any other type of RTV for automotive engine oil sealing since I discovered these.
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Old 12-15-2014, 02:44 PM   #2763
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Sorry to hear about that dude. I've had my share of experience with those. Over the years I've learned to set down the blunt instruments and just walk away from the project for a day or two whenever the urge to rage-bash new/shiny mechanical bits takes over.

Toyota FIPG is really great stuff. I've used the black and the grey; never had a problem. Permatex Ultra Grey is essentially the same thing if you're in a pinch. I haven't had to use any other type of RTV for automotive engine oil sealing since I discovered these.
I threw my volvo keys, slammed the jack around a bunch but kept far far away from expensive bits. Went home and had a few beers. I'm gonna get back at it this afternoon.
Yep, toob o toyota fipg in the toolbox. I sealed the gearbox up with the orange stuff and bought the black stuff just to have.
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Old 12-15-2014, 02:50 PM   #2764
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Sorry dude. I do know that this thing was sealed with Blue RTV when I got it. I didn't inspect it too much since at the time you were just going to take the valves from it. The grey stuff should work, never used it on a valve cover myself but it does work great on oil pans.

Feel bad now especially since I have 2 other head I could have sent you instead...
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Old 12-18-2014, 12:12 PM   #2765
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Huzzah. So I really think it was just down to the paint on the cam cover.
Finished the 240 last night, changed the oil on the audi too. Got both cars home and the gate to the parking garage was out of order. The 240 had to sit on the street and get snowed on.


So a list of what I did.
-All new rod bearings and #1 crank bearing. The #1 crank and rod bearing had debris in it. The other rod bearings were questionable. Got genuine Volvo bearings. The crank was fine, did a light polish on it.
-RSI Rods (Thanks Justus)
-Cleaned pistons, no pitting or signs of detonation
-New head, 1998 Casting
-New stem seals, lapped valves, skimmed head and hot tanked
-New cam seals, got rid of that leaky elring trash
-Keenserts on the exhaust studs, changed to english 5/16" thread, used ARP studs and A286 silver plated k-nuts
-Tore oil pump down, inspected for wear, new crank, o-ring and pump seal on front, new RMS
-Oil leak repaired between oil pan mating surface. Alex kindly lapped the pan on a granite block.
-Lapped wastegate valve to seat
-Used flat grinding stone to fix the mating surfaces on the wastegate
-Replaced turbo and wastegate fasteners with english threads to use more A286 k-nuts
-Replaced IAC hose
-Replaced PCV hose with oil rated hose
-Replaced chintzy coupler on the upper rad hose with a stainless J bend and silicone couplers
-Replaced broken coil pack connector
-Changed to a 99-01 style thermostat housing with dual ports
-Changed the coolant temp sender to the later style as well, uses a standard bosch cal curve. 850 sensor was never really cal'd correctly. Read high.
-Made a heat shield for between the head and downpipe/header
-Added some heat shrinkable abrasion guard to a few hoses
-Added an input filter cap on the EGT input in the vems, much more stable (see video below, video shows old coolant temp cal)
-Configured the VEMS board to take oil pressure and temp. (Had to swap out a pullup resistor for the oil pressure input, solder some jumpers)
-Updated the bootloader on the VEMS so I can run the latest firmware (hoping for faster sync times and quicker starting)
-Painted the IC piping in the same wrinkle finish as the cam cover.
I think that's it. I really tried my hardest to avoid the "while I'm in there" syndrome.





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Last edited by Homer; 12-18-2014 at 12:33 PM..
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Old 12-18-2014, 02:19 PM   #2766
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I love this swap jacob. Its very inspirational, with the lack of good reblocks at the yards these days, its a very tempting swap
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Old 12-18-2014, 02:24 PM   #2767
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Come over and swap a Whiteblock in my car, Jacob. I'll feed you.
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Old 12-18-2014, 10:30 PM   #2768
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I love this swap jacob. Its very inspirational, with the lack of good reblocks at the yards these days, its a very tempting swap
Much appreciated Erik. Whiteblocks have started to outnumber redblocks at the yard. Now's the time!
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Come over and swap a Whiteblock in my car, Jacob. I'll feed you.
Sounds tempting...
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Old 01-08-2015, 05:14 PM   #2769
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Might be noteworthy but it started right up this morning, the Vems said -18C (-1F)
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Old 01-08-2015, 05:37 PM   #2770
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Might be noteworthy but it started right up this morning, the Vems said -18C (-1F)
Sounds very good Homer!
Are you using the car daily in the wintertime also?

Love the Towers strutbrace, looks really good and carbonfiber pipe is not something you see everyday on a 240
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Old 01-08-2015, 07:01 PM   #2771
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Sounds very good Homer!
Are you using the car daily in the wintertime also?

Love the Towers strutbrace, looks really good and carbonfiber pipe is not something you see everyday on a 240
Thanks! It's not my daily but I'll drive it when the weather permits in the winter. It's a nice contrast from the A4.
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Old 01-31-2015, 01:04 AM   #2772
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One of the chinese ballasts is finally on its way out after 8 years. Figured I'd get a better set this time. New bulbs are on the way as well.


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Old 01-31-2015, 01:14 PM   #2773
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Yeah those ballasts are much much nicer than the China ones!

Grabbed one of these from a BMW at the J/Y, nicely made. The Chine ones are made with so many 'floating' components and other shortcuts, it is a miracle they even survived this long.
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Old 03-08-2015, 01:31 AM   #2774
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Got a few things done today. Beautiful weather.
-Recharged the AC. It's been too cold since I put the engine back in to charge it.


-Installed the new ballasts finally and some OEM++++ stickers. I still need to fix the one busted reflector clip.


-Replaced the borked odo gear, swapped clusters with a much fresher looking one aaaaand fixed the mileage on the odometer. There's also a newish temp compensation board in there. eeeeeeeeee

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Old 03-08-2015, 01:49 AM   #2775
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This is the best stage of a big project: time to relax and do the easy little detailed things that make a big difference. Such satisfy.
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