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Old 06-08-2005, 10:51 AM   #1
v240tic
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Default B6304 fitted in 242, with pics.

I guess this falls into the performance section, correct me if I'm wrong

I'm putting together the last bits and pieces of this engineswap in DaButcher's '80 242. The B6304 fits like a glove. Here are some pics from the swap.















The engine is mounted using 240 diesel mounts and custom brackets on the engine. A 3rd engine mount will be fitted between the engine and the right strut tower to cope with the torque of the engine.







Notice the piece of 3" exhaust It's a JT superflow system for NA 240's

The tranny is mounted on an early AW30-43 mount, fitted to a sligtly customized crossmember from a 86-> 240 with M47. The gear linkage is a shortened 960 piece, connected to a 240 shifter. Had to lower the crossmember appr. 7mm to clear the shifter housing with the output flange.





The rear end has been swapped for a newer unit, and a truetrack fitted together with a tone ring from a 960 to provide the correct signal for the tranny ECU. The driveshaft is made from the rear part of a 240 unit, and the front part of some 740/940 auto unit, appr. 52cm long. Dropped right in!!!!





The engine and tranny uses the original ECU's, wired into the stock 240 wiring. We decided to use the 960 instrument panel, as the outputs of various sensors are different from the old ones, and the tranny needs a digital output from the speedometer. It will be fitted in a 81-> dashboard with a little bit of cutting and some new trim.





The engine fired right up when everything was hooked up, and after tracing down some vacuum leaks, it now runs smoothly, but a little bit loud as the front part of the exhaust still needs to be sorted out
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Old 06-08-2005, 10:56 AM   #2
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looks awesome! I especially like the garden hose :-)
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Old 06-08-2005, 10:59 AM   #3
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wow, that's not at all unlike what I want to do, adapting the car to be compatible with a newer ECU by swapping instrument clusters, etc. And that motor mount setup should hopefully silence kenny's whining about how twin turbos won't work because of the intrusiveness of the engine mounts
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Old 06-08-2005, 11:07 AM   #4
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Excellent work. That's going to be a fun driver -- smooth and torquey from down low.
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Old 06-08-2005, 11:09 AM   #5
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Quote:
Originally Posted by acbarnett
wow, that's not at all unlike what I want to do, adapting the car to be compatible with a newer ECU by swapping instrument clusters, etc. And that motor mount setup should hopefully silence kenny's whining about how twin turbos won't work because of the intrusiveness of the engine mounts
didn't you say you'd have this done in a month? No wait, 2 weeks. Oh ya I remeber, something to that effect :rolleyes:

Intresting idea of using the 240 mounts. I'd prefer (doing a built turbo'd motor) something that mounts more like Jesus' T6 (like torque rods out as far as possible) to cope with the torque but thats a fine idea as well.

Doug
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Old 06-08-2005, 11:18 AM   #6
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Originally Posted by socalsean
looks awesome! I especially like the garden hose :-)
It's radiator hose, honestly!!! My brother picked it up from the bus garage were he works as a mechanic.
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Old 06-08-2005, 11:21 AM   #7
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That was me, on another computer... I was looking into other engine mounts, but I didn't want to weld into the frames, and the area around the steering is pretty crowded.
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Old 06-08-2005, 11:31 AM   #8
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Quote:
Originally Posted by v240tic
That was me, on another computer... I was looking into other engine mounts, but I didn't want to weld into the frames, and the area around the steering is pretty crowded.
Makes sense to me. Being NA I doubt you'll have an issue (with a third mount).
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Old 06-08-2005, 11:47 AM   #9
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I must smile while I look at theese pictures.
v240tic is the volvogod of Norway!

I am just awaiting for the guy I bought the engine from, to find a part for the engine.
Hopefully, he has it, or it will be some 140$ :(

I have used very many $$$ on this already, so I dont want to use too much more.. lol..
hopefully I can get the paint fixed, etc. Also I might need some spacers, etc.
And like v240tic said above, the exhaust needs custom work in the front, also the car needs a wheel-alignment (it used to be non-servo and non-lowered in the front).

I hope I can drive this "beauty and the beast" in 2-3 weeks!
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Old 06-08-2005, 11:53 AM   #10
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Da/\/\ /\/ - that looks like it just settled right down into its new home.
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Old 06-08-2005, 11:59 AM   #11
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Cool thanks for the pics. Doesn't follow the mounting strategy I envision either as Doug said, but then yours in your car and mine is on a stand so what can I say?
Awesome work.
AC, I never said modding the mount bracket wouldn't fix the twin turbo clearance issue, what I said was it wasn't worth doing. And I still hold that to be true.
Nice thing about using the "upright" 960 brackets is you can put poly mounts for an e30 M3 in there or a whole host of different things since they are stright with a std centered on each end. hehehehe. Buy your motor yet? Buy ANYTHING yet?
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Old 06-08-2005, 12:09 PM   #12
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Quote:
Originally Posted by v240tic
I guess this falls into the performance section, correct me if I'm wrong

I'm putting together the last bits and pieces of this engineswap in DaButcher's '80 242. The B6304 fits like a glove. Here are some pics from the swap.

http://www.vikeboe.com/b6304/IMG_9330.JPG
http://www.vikeboe.com/b6304/IMG_9331.JPG
http://www.vikeboe.com/b6304/IMG_9321.JPG
http://www.vikeboe.com/b6304/IMG_9322.JPG
http://www.vikeboe.com/b6304/IMG_9319.JPG
http://www.vikeboe.com/b6304/IMG_9335.JPG
http://www.vikeboe.com/b6304/IMG_9333.JPG

The engine is mounted using 240 diesel mounts and custom brackets on the engine. A 3rd engine mount will be fitted between the engine and the right strut tower to cope with the torque of the engine.

http://www.vikeboe.com/b6304/IMG_9323.JPG
http://www.vikeboe.com/b6304/IMG_9328.JPG

Notice the piece of 3" exhaust It's a JT superflow system for NA 240's

The tranny is mounted on an early AW30-43 mount, fitted to a sligtly customized crossmember from a 86-> 240 with M47. The gear linkage is a shortened 960 piece, connected to a 240 shifter. Had to lower the crossmember appr. 7mm to clear the shifter housing with the output flange.

http://www.vikeboe.com/b6304/IMG_9329.JPG

The rear end has been swapped for a newer unit, and a truetrack fitted together with a tone ring from a 960 to provide the correct signal for the tranny ECU. The driveshaft is made from the rear part of a 240 unit, and the front part of some 740/940 auto unit, appr. 52cm long. Dropped right in!!!!

http://www.vikeboe.com/b6304/IMG_9316.JPG

The engine and tranny uses the original ECU's, wired into the stock 240 wiring. We decided to use the 960 instrument panel, as the outputs of various sensors are different from the old ones, and the tranny needs a digital output from the speedometer. It will be fitted in a 81-> dashboard with a little bit of cutting and some new trim.

http://www.vikeboe.com/b6304/IMG_9338.JPG

The engine fired right up when everything was hooked up, and after tracing down some vacuum leaks, it now runs smoothly, but a little bit loud as the front part of the exhaust still needs to be sorted out
Beautiful. That fits perfectly and it should be great in terms of power.

This is the kind of thing that many of us in the US would kill to get our hands on, I think... You planning on doing a writeup on the whole thing?
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Old 06-08-2005, 12:10 PM   #13
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Nice work guys!!

Should be a nice runner.

JL
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Old 06-08-2005, 12:13 PM   #14
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damn. I'm impressed. I'd love to see what that thing'll do NA.

The pics are awesome too...esp because it gives us viewpoints from all critical perspectives.

Keep us in the loop and keep up the good work!

Mike
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Old 06-08-2005, 12:15 PM   #15
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nice write up! i can't wait to see the final product!
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Old 06-08-2005, 12:17 PM   #16
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Oh I meant to ask also, what the plan for the cooling fan? Much space in front of the rad or are you going to use a pusher?
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Old 06-08-2005, 12:22 PM   #17
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DaButcher used to have some toyota? electric fan in it while he had the old B19. It clears the timing cover, but I don't know if it will foul the drive belt for the PS and generator when I get it back in place, don't think it will. Anyway, it will be controlled by the ECU of the engine, as it has outputs for controlling a fan relay.
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Old 06-09-2005, 05:54 AM   #18
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Here are some old pictures of my "not so beauty", while it was "less beast".





yes, I think I might have to buy a new fan in the future, as the current one is a single-speed fan.. or, maybe I should run dual fans..

I dont know how the terms of cooling will go, but the radiator is the aluminium one from a volvo 245 automatic (b230a), 1985'.
Some people I talked to, thought that the radiator and fan would do fine..

When I ran it on the b19a, the thermostat switch never worked, so I put it on constant power, via. a relay which I took "control current" from the coil..
Now, as v240tic said, the engine will control it.

* There is no A/C on the engine, and there never will be.
We have natural A/C in Norway.. (The weather)

I also think theese pictures are great
And the work is superb!

I've had some nightmares about the car recently..
Like, one night I woke up, and dreamt that the car was crashed very badly..
lol.. I guess it's because I use all $$ for this car, and I'm a bit scared at times if it will live up to my expectations.
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Old 06-09-2005, 08:44 AM   #19
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What did you use for the oil filter mount, as the oil cooler attatchment on the pan I'm working on pulling is broken off (luckily there is no damage to the pan itself)
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Old 06-09-2005, 09:18 AM   #20
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Great job. I was thinking about this kinda thing once upon a time before I realized I still live in an apartment (At least we are supposed to be out of these ghetto apts by the end of this week)
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Old 06-09-2005, 09:20 AM   #21
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Quote:
Originally Posted by acbarnett
What did you use for the oil filter mount, as the oil cooler attatchment on the pan I'm working on pulling is broken off (luckily there is no damage to the pan itself)
This engine originaly had the old style oil cooler with a remotely mounted radiator, connected to the front of the oil pan, but it was removed when we got the engine and oilpan, and we decided to convert it to the newer style oil cooler. We blocked of the mount for the remote oilcooler in front of the oilpan (you can see the shiny new cover just behind the flywheel), and fitted a watercooled oilcooler from a late 940t, together with the anglebracket from the newer 960 setup. The oilcooler and bracket are fitted with a huge bolt, similar to the ones used with banjo fittings. The watersupply taps into the plumbing to the expansion tank, and into the nipple on the side of the block, which was changed for a later style unit.
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Old 06-09-2005, 09:27 AM   #22
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thanks for the info
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Old 06-09-2005, 11:51 AM   #23
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Quote:
Originally Posted by acbarnett
thanks for the info
yeah, he is the volvogod allright..

This is coming to my house (in red):
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Old 06-09-2005, 12:22 PM   #24
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I have a couple of questions.
What Trans? Auto/Man What kind of trans IE M90 ..
Are you using the Motronic that came with the engine?
From the looks of it an 850 Turbo engine will fit better.
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Old 06-09-2005, 12:33 PM   #25
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Quote:
Originally Posted by turbo16psi
I have a couple of questions.
What Trans? Auto/Man What kind of trans IE M90 ..
Are you using the Motronic that came with the engine?
From the looks of it an 850 Turbo engine will fit better.
The text above cleary states that the original motronic was used.
The clearance of the engine is no problem!
people are running theese engines with twinturbo in scandinavia..
I think there are atleast 5 of them in Norway and some in Sweden too..

The transmission is the one from volvo 960 (auto), as I think is also stated above.
M90 is an manual transmission, but there are no driveshafts that will fit.
Also, the M90 is not as strong as the automatic transmission.

the automatic is electronically controlled, and gears on many factors.
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