Conversion 960 B204FT to B234FT

[rijk]

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). 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 (now 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 by twin-scroll BorgWarner EFR 7064
- New (to be built) manifold containing four egt-sensors.
- 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 calipers and front 330 mm Volvo-discs, rear V70R Brembo calipers with 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
- 18 inch wheels Enkei PDC with GoodYear Eagle F1 Asymmetric 3 - 235-40-18.
More pictures to follow.

Other parts: injectors Siemens Mototron 630cc - Box 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]

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]

Now that's how it should be done.

[Homer]

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

[Cojones]

That looks sweet my man!

[Turbosteen]

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

[740tankDriver]

does it get any more proper than this?

[rijk]

Originally Posted by 740tankDriver

does it get any more proper than this?

We dutchies like proper.

looks like you've had a very good year.

[Cameron]

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]

Absolutely beautiful.

[Hagar17]

AMAZING! love it. Such a fantastic build.

Oh yeah and I'm jealous!

[GrandmaSideways]

Holy ****.

Right click
Save As
'Inspiration.jpg'

[shaved240]

nice #'s for low boost

looking forward to seeing the new dyno #s

[ricardomotorhead]

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]

very nice!

[Mr.Borrie]

wow orrly!

[dieselboy]

Intake envy..

[thevolvokid]

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

[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.

[Janspeed]

great craftmanship!

[Fivehundred]

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]

Very Nice build!!!!!

Lol@motorsport filter.

[switch_351]

Wow... Me Want!!

[rijk]

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