Conversion 960 B204FT to B234FT

rijk · 09-27-2009, 04:11 PM

Some pictures of my new engine build. The car is a 1993 Volvo 960, imported from Italy. Stock engine is B204FT. After 650k km it needed overhaul. Decided for 2.3 16V turbo. The engine was built by Erland Cox (Staffanstorp, Sweden). The building in was performed by Ulf Persson who did an outstanding job. See for yourself.

My old, mildly modified B204FT (280 hp - 410 Nm) with 18T and tweaked LH2.4. Replacing seals more than once couldn't prevent balanceshafts from polluting my driveway.

Modified induction with ITG airfilter on old engine.

Emerald K3 is very good for my goals. And excellent vfm.

UNIK Sweden made this beauty.

Ported.

ss valves.

SPM conrods, Venolia pistons.

'96 B230 FK block was bored and o-ringed.

Head modified by Erland Cox.

Old studs were replaced.

Installing the Emerald ecu.

Craftsmanship. Constructing the plenum.

Grinding for o-rings

O-ringed

No even length runners but as short as possible. Tested concept with good results for driveability. 2mm stainless.

Nice collector

Test fitting.

What a juwel...

Garrett GT3071-R with 44 mm wastegate from Tial.

EGT sensor signal for Emerald and Stack EGT gauge.

Remote filter adapter.

Bosch 044 fuel pump.

Mounted on bracket with fuel filter.

Festo canister acts as 'shock absorber' for vacuum pulse.

APS bov mounted on bottom of plenum.

Bell IC core for custom IC build.

Waterhose modification.

Piping for watercooling turbo.

Manifold with vacuum lines and Nuke fuel rail. Festo canister mounted on throttle linkage bracket.

New servo pump and dock for remote oil filter.

Accel coil for wasted spark.

Modified outlet turbo.

Oil return hose and engine heater cable.

And this is how it looks.

One very nice part invisible from the outside: beautiful crafted Nuke cam gear, covered by belt cover. Solve that later.
Drove the car back to Holland. Lot of small things still have to be done.
Emerald management (currently replaced) was mapped temporary to get the engine home safe (0.8 bar - 11.5 psi on 95 ron - dyno 417/485 crank). Final mapping will be done later, both on dyno and road.

UPDATE: Bottom picture shows completely rebuilded engine (2016 - due to damage by broken porcelain from spark plug) with:
- New 16V plenum (KLRacing.se).
- Replaced damaged Garrett GT3071R with twin-scroll BorgWarner EFR 7064
- New ceramic coated manifold containing egt-sensor adapter in all four runners.
- For safety reasons renewed all oil lines and Setrab cooler.
- Emerald ecu was replaced by excellent swedish MaxxEcu Race.
-Front and rear suspension replaced by Kaplhenke coilovers.
- Front with Adjustable Strut Mounts
- Luxe Steer
- Quick Steer Roll Correction
- Adjustable control arms
- Multilink renovated - Bushings (a.o Retro Turbo) all around renewed
- Adjustable IRS stay rods
- Stock brakes replaced by V70R Brembo 4-pot calipers and front 330 mm Volvo-discs, rear V70R 4-pot Brembo calipers with custom 320mm AP Racing rotors
- Wilwood adjustable proportioning valve
- M90 was modified by swedish specialist and will hold 500+ Nm
- Short throw shifter from Retro Turbo
- 18x8 wheels Enkei PDC with GoodYear Eagle F1 Asymmetric 3 - 225-40-18.
More pictures to follow.

Other parts: injectors Siemens Mototron 630cc - Box modified M90L2 with Sachs Racing clutch with sinter plate (625 Nm) - ss 3 inch exh system with HJS WRC cat - Setrab 19-row oilcooler - Stack boost gauge - Stack EGT gauge - Stack A/F ratio gauge - SPA oil temp/pressure gauge.

pwschuh · 09-27-2009, 04:37 PM

Very nice set-up. Me likey.

It looks like your Festo vacuum canister is only drawing from one cylinder in the picture you showed. Is that true or do you have another shot that shows how it picks up from all four. That was a bit of a pain for my set-up, mostly because those fittings are not common in the states.

VolvoPunch · 09-27-2009, 04:38 PM

Now that's how it should be done.

Homer · 09-27-2009, 04:49 PM

Nice, that's how i'd do it.
Good use of the MAC valve too. I like the use of the pushlock tubing.

Cojones · 09-27-2009, 04:56 PM

That looks sweet my man!

Turbosteen · 09-27-2009, 04:56 PM

Amazing engine! Can't wait to see the results
Can you make sure my engine gets the same treatment?

740tankDriver · 09-27-2009, 05:02 PM

does it get any more proper than this?

rijk · 09-27-2009, 05:27 PM

Quote:

Originally Posted by 740tankDriver

does it get any more proper than this?

We dutchies like proper.

09-27-2009, 05:30 PM

looks like you've had a very good year.

Cameron · 09-27-2009, 05:58 PM

Nice to see the final pictures posted up here - it looks great! You didn't tell me it was Erland Cox working on the engine, very nice. They must have solved the problem with the v belts they were having?

It really did turn out beautiful - absolutely love it and can't wait to hear your impressions of it after the dyno tuning. Should make some impressive power I'm sure.

volvotech97850 · 09-28-2009, 12:56 AM

Absolutely beautiful.

Hagar17 · 09-28-2009, 12:57 AM

AMAZING! love it. Such a fantastic build.

Oh yeah and I'm jealous!

~~GrandmaSideways~~ · 09-28-2009, 01:07 AM

Holy ****.

Right click
Save As
'Inspiration.jpg'

shaved240 · 09-28-2009, 01:43 AM

nice #'s for low boost

looking forward to seeing the new dyno #s

ricardomotorhead · 09-28-2009, 02:13 AM

Amazing, build, thanks for sharing those amazing pics, did you help with the build as well? or someone else did it all. Wow, I need to find someone in the area, that might be able to help me out do something like this.

JW240 · 09-28-2009, 02:54 AM

very nice!

Mr.Borrie · 09-28-2009, 05:52 AM

wow orrly!

dieselboy · 09-28-2009, 03:42 PM

Intake envy..

thevolvokid · 09-28-2009, 04:52 PM

Very Nice, can't wait for tuned output, pictures of the whole car?

500dollar744ti · 09-28-2009, 05:34 PM

nice setup dude, i like the manifold. how is the Emerald EMS? i've never heard of it but that doesn't mean too much either.

Janspeed · 09-28-2009, 05:42 PM

great craftmanship!

Fivehundred · 09-28-2009, 05:46 PM

Quote:

Originally Posted by 500dollar744ti

nice setup dude, i like the manifold. how is the Emerald EMS? i've never heard of it but that doesn't mean too much either.

http://www.emeraldm3d.com/ run by Dave Walker who is one of the most helpful and knowledgeable guys you're ever likely to meet.

DrvSfly · 09-28-2009, 10:44 PM

Very Nice build!!!!!

Lol@motorsport filter.

switch_351 · 09-29-2009, 12:02 AM

Wow... Me Want!!

rijk · 09-29-2009, 05:00 PM

Quote:

Originally Posted by fivehundred

http://www.emeraldm3d.com/ run by dave walker who is one of the most helpful and knowledgeable guys you're ever likely to meet.

+1

09-27-2009, 04:11 PM	#1
rijk Board Member Join Date: Apr 2004 Location: Netherlands	Conversion 960 B204FT to B234FT Some pictures of my new engine build. The car is a 1993 Volvo 960, imported from Italy. Stock engine is B204FT. After 650k km it needed overhaul. Decided for 2.3 16V turbo. The engine was built by Erland Cox (Staffanstorp, Sweden). The building in was performed by Ulf Persson who did an outstanding job. See for yourself. My old, mildly modified B204FT (280 hp - 410 Nm) with 18T and tweaked LH2.4. Replacing seals more than once couldn't prevent balanceshafts from polluting my driveway. Modified induction with ITG airfilter on old engine. Emerald K3 is very good for my goals. And excellent vfm. UNIK Sweden made this beauty. Ported. ss valves. SPM conrods, Venolia pistons. '96 B230 FK block was bored and o-ringed. Head modified by Erland Cox. Old studs were replaced. Installing the Emerald ecu. Craftsmanship. Constructing the plenum. Grinding for o-rings O-ringed No even length runners but as short as possible. Tested concept with good results for driveability. 2mm stainless. Nice collector Test fitting. What a juwel... Garrett GT3071-R with 44 mm wastegate from Tial. EGT sensor signal for Emerald and Stack EGT gauge. Remote filter adapter. Bosch 044 fuel pump. Mounted on bracket with fuel filter. Festo canister acts as 'shock absorber' for vacuum pulse. APS bov mounted on bottom of plenum. Bell IC core for custom IC build. Waterhose modification. Piping for watercooling turbo. Manifold with vacuum lines and Nuke fuel rail. Festo canister mounted on throttle linkage bracket. New servo pump and dock for remote oil filter. Accel coil for wasted spark. Modified outlet turbo. Oil return hose and engine heater cable. And this is how it looks. One very nice part invisible from the outside: beautiful crafted Nuke cam gear, covered by belt cover. Solve that later. Drove the car back to Holland. Lot of small things still have to be done. Emerald management (currently replaced) was mapped temporary to get the engine home safe (0.8 bar - 11.5 psi on 95 ron - dyno 417/485 crank). Final mapping will be done later, both on dyno and road. UPDATE: Bottom picture shows completely rebuilded engine (2016 - due to damage by broken porcelain from spark plug) with: - New 16V plenum (KLRacing.se). - Replaced damaged Garrett GT3071R with twin-scroll BorgWarner EFR 7064 - New ceramic coated manifold containing egt-sensor adapter in all four runners. - For safety reasons renewed all oil lines and Setrab cooler. - Emerald ecu was replaced by excellent swedish MaxxEcu Race. -Front and rear suspension replaced by Kaplhenke coilovers. - Front with Adjustable Strut Mounts - Luxe Steer - Quick Steer Roll Correction - Adjustable control arms - Multilink renovated - Bushings (a.o Retro Turbo) all around renewed - Adjustable IRS stay rods - Stock brakes replaced by V70R Brembo 4-pot calipers and front 330 mm Volvo-discs, rear V70R 4-pot Brembo calipers with custom 320mm AP Racing rotors - Wilwood adjustable proportioning valve - M90 was modified by swedish specialist and will hold 500+ Nm - Short throw shifter from Retro Turbo - 18x8 wheels Enkei PDC with GoodYear Eagle F1 Asymmetric 3 - 225-40-18. More pictures to follow. Other parts: injectors Siemens Mototron 630cc - Box modified M90L2 with Sachs Racing clutch with sinter plate (625 Nm) - ss 3 inch exh system with HJS WRC cat - Setrab 19-row oilcooler - Stack boost gauge - Stack EGT gauge - Stack A/F ratio gauge - SPA oil temp/pressure gauge. __________________ The B204FT to B234FT conversion http://forums.turbobricks.com/showthread.php?t=182821 Last edited by rijk; 03-30-2021 at 09:05 AM.. Reason: PhotoBucket removed all pictures

09-27-2009, 04:37 PM	#2
pwschuh Rolling... Join Date: Jul 2003 Location: Mid-Atlantic	Very nice set-up. Me likey. It looks like your Festo vacuum canister is only drawing from one cylinder in the picture you showed. Is that true or do you have another shot that shows how it picks up from all four. That was a bit of a pain for my set-up, mostly because those fittings are not common in the states. __________________ "No man would listen to you talk if he didn't know it was his turn next." E. W. Howe

09-27-2009, 04:38 PM	#3
VolvoPunch Board Member Join Date: Sep 2006 Location: Bend, Or	Now that's how it should be done. __________________ smurf244 stole from me.

09-27-2009, 04:49 PM	#4
Homer OEMplus++ Join Date: Aug 2003 Location: San Francisco	Nice, that's how i'd do it. Good use of the MAC valve too. I like the use of the pushlock tubing. __________________ -Jacob: 1990 240 - 5 Cyl Whiteblocked. 2017 allroad - Comfy DD

09-27-2009, 04:56 PM	#5
Cojones Board Member Join Date: Feb 2007 Location: Amsterdam	That looks sweet my man! __________________ S90 Executive

09-27-2009, 04:56 PM	#6
Turbosteen I was born at a young age Join Date: Sep 2008 Location: The Netherlands, Europe	Amazing engine! Can't wait to see the results Can you make sure my engine gets the same treatment? __________________ Philip Project '82 760 16vT \| Amazon \| B204GT \| Feedback \| Husqvarna Nuda 900

09-27-2009, 05:02 PM	#7
740tankDriver Post-Hypnotic Sigma Join Date: Aug 2006 Location: Under your nose.	does it get any more proper than this?

09-27-2009, 05:30 PM	#9
740ATL Guest	looks like you've had a very good year.

09-27-2009, 05:58 PM	#10
Cameron ドクターマリオ Join Date: Dec 2006 Location: Crawling around under the car	Nice to see the final pictures posted up here - it looks great! You didn't tell me it was Erland Cox working on the engine, very nice. They must have solved the problem with the v belts they were having? It really did turn out beautiful - absolutely love it and can't wait to hear your impressions of it after the dyno tuning. Should make some impressive power I'm sure.

09-28-2009, 12:56 AM	#11
volvotech97850 Board Member Join Date: Aug 2006 Location: New Orleans	Absolutely beautiful. __________________ FOR SALE: 1997 850 T-5, Forged rods, pistons, & 6-speed swap

09-28-2009, 12:57 AM	#12
Hagar17 Board Member Join Date: Jun 2005 Location: Victoria BC	AMAZING! love it. Such a fantastic build. Oh yeah and I'm jealous! __________________ Keeping late 80's Swedish metal alive!

09-28-2009, 01:07 AM	#13
~~GrandmaSideways~~ AW71AW71AW71 AW71AW71AW71 Join Date: Dec 2006 Location: Vancouver B.C.	Holy ****. Right click Save As 'Inspiration.jpg'

09-28-2009, 02:13 AM	#15
ricardomotorhead Board Member Join Date: Nov 2007 Location: San Jose	Amazing, build, thanks for sharing those amazing pics, did you help with the build as well? or someone else did it all. Wow, I need to find someone in the area, that might be able to help me out do something like this.

09-28-2009, 05:52 AM	#17
Mr.Borrie The Sneaky F*ing Russian Join Date: Aug 2006 Location: Netherlands	wow orrly! __________________ 760 Turbo 86\|Volvo 360 cup\|Volvo XC90 04\|Volvo C70 C 03\|Porsche 924 79\|BMW 116I cup\| My Seller Feedback

09-28-2009, 03:42 PM	#18
dieselboy Whooty patrol Join Date: Aug 2006 Location: SoCal/ Ramona	Intake envy.. __________________ '82 242t hy35 @28psi, ebay header, big intercooler, microsquirt ecm, rsi stg2 cam, arp headstuds, tremec tko600, 3" exhaust, 13" brembos, coilovers, saabspoiler, 245/40r17s, lots of yoshifab stuff. '12 flex ecoboost "kats" car '93 940 turbo lifted #trophyvo '08 f350 4x4 v10 cclb '97 f-350 4x4 offroad toy '94 4700 dt466 International toterhome build

09-28-2009, 04:52 PM	#19
thevolvokid 142 whore Join Date: May 2007 Location: Oklahoma City, Ok.	Very Nice, can't wait for tuned output, pictures of the whole car? __________________ 90 745 Turbo, tuned by myself made 365 whp completing a 1/4 mile pass at 12.93 @ 105.xx. Not bad for a stock block w/ 265,xxx miles that runs lh 2.4 and ekz

09-28-2009, 05:34 PM	#20
500dollar744ti still rides with MrDoug Join Date: Feb 2007 Location: Falls Church, VA	nice setup dude, i like the manifold. how is the Emerald EMS? i've never heard of it but that doesn't mean too much either. __________________ -Matt 1989 Volvo 744T- 16v turbo, '94 FD-block, RSI pistons/rods, GT35R, Tial 38mm, RFL, MSnS-E, DSM spark, 100lb Delphis, 4.6 springs, Bondo header, Heebspeed intake, Q45 90mm TB, Bosch 044 FP, 12x24x3 ebayIC, w/c t5, Clutchnet 4puck/PP, 4.10 G80, IPD sways, 960 brakes. 1998 Volvo S70 T5m- Stock, 229k 1998 Jeep Cherokee XJ- Stock, 154k 1983 Ford F150- '89 5.0 H.O, C6/4x4, F+R LSD 4.10, 7" lift, 35s. 1990 Cobia San Marino 225 ECS- MCM 350 Mag, GM Bowtie Intake, HR-Titan 19p.

09-28-2009, 05:42 PM	#21
Janspeed Board Member Join Date: Sep 2005	great craftmanship!

Thread Tools
Show Printable Version Email this Page
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode