Sjeng
Member
- Joined
- Sep 3, 2017
1988 740 16v
I would like to share the progress of my cars with some people, so I'm making a project thread!
First lets share some of my Volvo history.
I had several whiteblock volvo's, but I have always wanted a RWD Volvo.
Gave the C70 to my GF, and bought myself a 1997 940 (B230fk + M90):
Performed some mods to car had a HY35, coil overs, 3 inch exhaust etc.
Already quite fun to drive! This was my daily driver for a while.
Then I crashed the thing because I did not pay enough attention. (Lucky I survived)
I removed all the good parts (m90, engine, etc) for a new project!
I saw a cheap 1990 940 GLE 16V and bought that:
My original plans with this car were to build a turbo 16V.
Then a couple of months ago I bought a very clean and cheap 1988 740.
I decided that this would become the project car:
Boring b230k:
My plan for the car:
B234 head on B230FK bottom
Turbocharger
Standalone EMS
M90 Gearbox
Coil over suspension
LSD
Additional strengthening of rear suspension
So what has been done so far:
Car is fitted with the coil overs I built for my old 940:
350/225lb/in springs with GAZ shock absorbers.
Also I started with the engine.
Base is a b230FK junkyard engine.
I brought it to the machine shop, had it measured (was ok), honed and decked.
I bought a rebuild kit and rods which were probably hand-forged by some chinese kid.
Let's continue:
First lets go crazy with the wire wheel and get the rust off:
Paint
OK! Let's start assembly:
I measured bearing play for the conrods and crankshaft, everything in spec.
Filed the piston rings. 0.60mm gap for the top ring, little larger for the second. (I believe 0.68)
I cut the valve recess into the stock b230fk pistons, with Josh' jig (Thanks Josh).
Crank, pistons and rods fitted:
Next I removed the B234 from the estate and removed the head.
Started cleaning the head and all the valves.
After this I lapped all the valves:
Brought the head to the machine shop to have it skimmed.
Let's install the valves and springs (ford 4.6).
Let's continue with assembly:
Installed cams, gears and tried the timing belt setup:
Opel 1.6 diesel timing belt with VW golf 2 tensioner.
I bought a KL-Racing crankshaft sprocket with seperate key for the keyway.
This meant my crankshaft damper had to be "modified". I had the perfect file for this, so I made a jig to file the keyway. (some of you are gonna hate me for this ).
Key fits perfectly.
Painted the valve cover and fitted the oil pan: (This is the current status of the engine)
Next on my list is cleaning intake manifold and gearbox, so the engine can go in the car soon.
Fitted new seals to the M90 and cleaned:
For the exhaust manifold my first idea was to use the 16V manifold and mount the turbo on a up-pipe.
I figured out the turbo position on the 940 and made an up-pipe:
However, when I removed the 16V exhaust manifold from the head I saw how much worse this was than the 8V NA manifold. The radii are very short for cyl 2 and 3.
I decided I will build a whole manifold:
12mm thick hand filed/drilled. With beer and good music it was not too bad.
Ports line up nicely with the head.
The rest of the manifold I will build when the engine is in the car.
Next on the list:
- Install clutch/flywheel/intake(need to clean this)/gearbox/
- Remove engine from 740
- Make room/brackets for IC/rad in 740
- Clean engine bay
- Install waterpump/generator/PS to engine
- Install new engine
- Fabricate exhaust manifold
- Fabricate IC piping
- Fabricate DP/Exhaust
- Install fuel pump and EMS
To be continued!
I would like to share the progress of my cars with some people, so I'm making a project thread!
First lets share some of my Volvo history.
I had several whiteblock volvo's, but I have always wanted a RWD Volvo.
Gave the C70 to my GF, and bought myself a 1997 940 (B230fk + M90):
Performed some mods to car had a HY35, coil overs, 3 inch exhaust etc.
Already quite fun to drive! This was my daily driver for a while.
Then I crashed the thing because I did not pay enough attention. (Lucky I survived)
I removed all the good parts (m90, engine, etc) for a new project!
I saw a cheap 1990 940 GLE 16V and bought that:
My original plans with this car were to build a turbo 16V.
Then a couple of months ago I bought a very clean and cheap 1988 740.
I decided that this would become the project car:
Boring b230k:
My plan for the car:
B234 head on B230FK bottom
Turbocharger
Standalone EMS
M90 Gearbox
Coil over suspension
LSD
Additional strengthening of rear suspension
So what has been done so far:
Car is fitted with the coil overs I built for my old 940:
350/225lb/in springs with GAZ shock absorbers.
Also I started with the engine.
Base is a b230FK junkyard engine.
I brought it to the machine shop, had it measured (was ok), honed and decked.
I bought a rebuild kit and rods which were probably hand-forged by some chinese kid.
Let's continue:
First lets go crazy with the wire wheel and get the rust off:
Paint
OK! Let's start assembly:
I measured bearing play for the conrods and crankshaft, everything in spec.
Filed the piston rings. 0.60mm gap for the top ring, little larger for the second. (I believe 0.68)
I cut the valve recess into the stock b230fk pistons, with Josh' jig (Thanks Josh).
Crank, pistons and rods fitted:
Next I removed the B234 from the estate and removed the head.
Started cleaning the head and all the valves.
After this I lapped all the valves:
Brought the head to the machine shop to have it skimmed.
Let's install the valves and springs (ford 4.6).
Let's continue with assembly:
Installed cams, gears and tried the timing belt setup:
Opel 1.6 diesel timing belt with VW golf 2 tensioner.
I bought a KL-Racing crankshaft sprocket with seperate key for the keyway.
This meant my crankshaft damper had to be "modified". I had the perfect file for this, so I made a jig to file the keyway. (some of you are gonna hate me for this ).
Key fits perfectly.
Painted the valve cover and fitted the oil pan: (This is the current status of the engine)
Next on my list is cleaning intake manifold and gearbox, so the engine can go in the car soon.
Fitted new seals to the M90 and cleaned:
For the exhaust manifold my first idea was to use the 16V manifold and mount the turbo on a up-pipe.
I figured out the turbo position on the 940 and made an up-pipe:
However, when I removed the 16V exhaust manifold from the head I saw how much worse this was than the 8V NA manifold. The radii are very short for cyl 2 and 3.
I decided I will build a whole manifold:
12mm thick hand filed/drilled. With beer and good music it was not too bad.
Ports line up nicely with the head.
The rest of the manifold I will build when the engine is in the car.
Next on the list:
- Install clutch/flywheel/intake(need to clean this)/gearbox/
- Remove engine from 740
- Make room/brackets for IC/rad in 740
- Clean engine bay
- Install waterpump/generator/PS to engine
- Install new engine
- Fabricate exhaust manifold
- Fabricate IC piping
- Fabricate DP/Exhaust
- Install fuel pump and EMS
To be continued!
Last edited: