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Old 01-20-2010, 10:18 AM   #1
varg
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Default It lives! Low buck 240DL->240 Turbo swap

Check back often, this thread will be constantly updated as I progress with my modifications.

My month-long engine swap project is finally complete. What was once a slow-as-a-snail-in-molasses 244DL is now a not-as-slow 244 Turbo and is soon to be a decently fast one. As you may remember, I created a thread when I had a catastrophic head gasket failure that took out a couple of rings on my B230. This meant engine replacement was in order, which was bad (because it costs a lot of money) and good (because it was an excellent excuse to make my car faster).

So I bought this, a B21FT with a VX3 cam, port and polish job, B230FT intake and adjustable cam gear. Along with a stock intercooler and 2.5" exhaust system sans downpipe. It was a good deal for the price I paid.




Out with the old and in with the new (to me)



Many little snags along the way, including this pin... Which I swore at for hours before I hammered it in and clamped it the rest of the way out by torquing the surrounding bellhousing bolts down.



And this hole, which I wound up plugging with a bolt out of my 530 head that just so happened to fit. Boy those little snags eat up time...



It took me forever to source intercooler piping as well. I didn't want to spend $180 on high-quality, Made-In-The-USA silicone connectors and then some extra for aluminum piping from my local performance shops so I went to 5 junkyards and finally found 3 of the 4 stock rubber hoses and both metal pipes at the last of the junkyards (go figure)I still couldn't locate a 2" 90 degree bend from turbo to piping for the life of me... It took a week to finally break down and use a piece of pickup truck radiator hose.



I had get creative with the intake due to the extreme space constraints. Between the radiator hose, turbo cooling lines, transmission lines and AC drier, there was no space for a conventional intake. This was the solution, made out of a mix-match of junkyard flex hoses, stock intake piping and a 90 degree pvc bend, routed to half a stock airbox placed behind the bumper.



Just for fun, 2 extra horns were sourced from a junkyard car identical to mine but with less rust were added. As for the loudness... You know Volvo 240s have good horns, instead of having significantly loud horns, my car now has excessively loud horns.



Zip ties all around, the Turbobricks way. I tried to start it, to no avail. The whitebody injectors were too much for the NA ECU.



Blacktop injectors back in... It runs! It's really loud with an open turbo... Weird fuel cutout issue too...


Here's the video of my first test drive with the new motor:


Update 1/25/10
I received a turbo ECU today and installed my (dirty) whitebody injectors. The difference is exponential! It idles smoother, responds faster and will now push you into your seat (above 3,000rpm, that is). Still some tuning and mods to be done, but I'm stoked to finally have the old Swede moving with gusto!
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Last edited by varg; 03-09-2010 at 04:08 PM.. Reason: Update
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Old 01-20-2010, 04:15 PM   #2
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Lookin good! Do please get rid of that chrysler ignition soon. God, i hated that thing.
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Old 01-20-2010, 04:36 PM   #3
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get rid of it and swap to ezk ASAP. like before you drive it.
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Old 01-20-2010, 04:43 PM   #4
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Yeah that ignition system cannot handle boost. DITCH IT.

That could be your "fuel cut" issue.
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Old 01-20-2010, 05:45 PM   #5
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You think? I don't suspect I'm losing spark because the tach drops slowly when it cuts, it doesn't just shoot down to zero. An EZK conversion is out of my price range for now and there are no LH2.2 cars at any of the junkyards around me, so I guess I'll have to deal. I'm saving my pennies for MS anyway, I don't want to blow money on stock engine management components that I'll be ditching as soon as I can afford to get MS started.
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Old 01-20-2010, 06:14 PM   #6
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Beige!
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Old 01-20-2010, 06:46 PM   #7
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sweet swap.

b21ft motor is badass. boost the hell out of.
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Old 01-20-2010, 07:03 PM   #8
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Originally Posted by blkaplan View Post
Beige!

Yes, Beige.

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sweet swap.

b21ft motor is badass. boost the hell out of.

Thanks, I intend to.

Last edited by varg; 05-01-2010 at 04:07 PM..
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Old 01-20-2010, 08:20 PM   #9
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does it drive ok with the chrysler ignition, you know like for factory boost levels, im wondering if its driveable for a little while like that.
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Old 01-21-2010, 05:26 AM   #10
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It runs and drives just fine except for the fact that it cuts out around 1,500-2,000rpm, loses about 1,000rpm, and then continues as if nothing happened. Some of the others suggest that it's the ignition that's doing this. But I doubt it, because it doesn't fit the symptoms of ignition cut IMO.
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Old 01-21-2010, 08:27 AM   #11
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Thats wierd, sounds like a fuel related sort of thing. The injectors are factory NA injectors? What fuel injection are you running, im guessing LH2.2? I just gave away a set of greentops and an LH2.2 fuel computer, I bet it would have been better for you. I do have 2 more LH2.2 fuel computers if you are interested. I have like a very similar setup on my car, and im afraid to +T the car because of the ignition. Can you make a video of the car driving? Pretty much I just need to know if the car is daily driveable on that ignition computer
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Old 01-21-2010, 08:47 AM   #12
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b21ft is the best mang, it deed it.
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Old 01-21-2010, 05:56 PM   #13
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Quote:
Originally Posted by fisky52688 View Post
Thats wierd, sounds like a fuel related sort of thing. The injectors are factory NA injectors? What fuel injection are you running, im guessing LH2.2? I just gave away a set of greentops and an LH2.2 fuel computer, I bet it would have been better for you. I do have 2 more LH2.2 fuel computers if you are interested. I have like a very similar setup on my car, and im afraid to +T the car because of the ignition. Can you make a video of the car driving? Pretty much I just need to know if the car is daily driveable on that ignition computer
Yes, stock injectors, stock NA LH2.2 system. I have some whitebody injectors that are rated at ~36lbs/hr but the ECU can't handle them (mentioned above).

The cutout is fuel related, the injectors stop firing during the cut (verified with noid light), spark is fine all the way to 5,000rpm (the highest I took the engine, may be fine above that, but isn't verified with timing light). It is totally drivable except for the cutting out, I got it into boost for the first time on the way home tonight. I was listening closely for bad noises and heard that turbo spool up, the resulting push was pretty good, felt like I must be at about 150-160hp. PM me about the LH2.2 Turbo computers, I've got a thread in the wanted section for that right now.

Video uploaded, check the OP.
Nevermind about the PM, I already got one from you.

Last edited by varg; 01-21-2010 at 07:13 PM..
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Old 01-21-2010, 06:28 PM   #14
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Nice, maybe the engine will be ok because the compression is lower in a turbo motor and it won't really ping too bad with the chrysler box.
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Old 01-21-2010, 07:27 PM   #15
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IIRC the only reason the Chrysler box is poorly suited for turbo applications is its advance curve and rapidly fluctuating timing, it appears to advance from an oscillating 15 degrees at idle to about 20 by 3,000rpm, I couldn't read the timing mark above that RPM due to the air blasting in my face from the fan.
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Old 01-21-2010, 10:21 PM   #16
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Its a good swap...for a daily driver, i threw an LH 2.2 in my 242 with an aw71 and it was a great driver. Now that drivetrain in is my GF's 242 and its just as awesome. The 240 should have had 150 hp from the factory, it drives like it should have.

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Old 01-25-2010, 04:13 AM   #17
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did u get the fuel computer?
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Old 01-25-2010, 03:10 PM   #18
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UPDATE!

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Originally Posted by fisky52688 View Post
did u get the fuel computer?
Yes I did, and you know what that means!

See OP for new picture, video coming soon
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Old 01-25-2010, 07:07 PM   #19
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i saw the new pic, cool
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Old 02-01-2010, 07:28 PM   #20
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Where'd you get those whitebodies and how much did they set you back?
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Old 02-09-2010, 01:02 AM   #21
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New pictures! I just took these real quick since I washed and waxed the car today. If it had no rust it would look brand new




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Where'd you get those whitebodies and how much did they set you back?
Junkyard, supercharged V6 buick, $3.50/ea (free with deep pocket discount)
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Old 02-09-2010, 01:58 AM   #22
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Garfield ftw.. i haven't seen one of those in a window for like 10 years!
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Old 02-09-2010, 12:55 PM   #23
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Hey mang! Where are you in Florida anyway?
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Old 02-10-2010, 06:49 PM   #24
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Garfield ftw.. i haven't seen one of those in a window for like 10 years!
Yes, Garfield came flying out of the 90s and stuck right on my back window.

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Hey mang! Where are you in Florida anyway?
I'm in the Boynton Beach area.
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Old 02-10-2010, 09:42 PM   #25
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Good work! The car looks great and I'm sure it runs nice and strong. Fun!
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