124 268 visningar (52 idag)
Uppdaterad 25 december 2017
Skapad 10 februari 2010
Effekt / Vridmoment
330 hk / 470 NmMotor, vxellda och avgassystem
Grundmotor 2.5T lttryck, ombygg till fulltryck,
5 Vxl Getrag 0.8:1 p femman, bakaxel 1031, utv.3,15.Effekt och prestanda (ingende)
Svrt att sga skall ge 330Hk/470nm vid 1.25 bar,
med 1.7 bars laddtryck som nu anvnds knns 1.25 klentChassi
Se "Snabbfakta" under vrigt, eller mer detaljerat under "Framtidsplaner"Flgar, dck och bromsar
Se "Snabbfakta" under vrigt, eller mer detaljerat under "Framtidsplaner"Interir / Inredning
Se "Snabbfakta" under vrigt, eller mer detaljerat under "Framtidsplaner"Bilstereo och multimedia
Description of the project and car in English.
General
The car was bought in a box in Autumn 1990, the renovation had been started by the previous owner, or more accurately he had partly dismantled it in various parts.
The car was dismantled down to the last detail, the body was glass-blasted together with other details such as engine, gearbox, rear-axle, etc, etc.
All parts were painted separately i.e. the body was completely stripped and was put on a special frame with wheels and then rolled in to the paint boot without any masking tape.
The running gear was either replaced or renovated; for example bearings, rubber lists and gaskets, brakes, hoses, complete overhauling of the engine, gearbox and rear-axle etc.
The interior received a new instrument panel, new leather on the front seats, new floor-mats, carpets and new headliner. New chrome-lists on the exterior and newly chromed fenders along with all other chrome details.
The renovation and the re-fitting of the car took place during the winter 91/92 and the car was ready for the road in the summer of 92. It was then used until the autumn of 99 where the project for the change of the engine motor to the 5 cyl. turbo unit was started, during spring 2001 the car was on the road again with the 5cyl engine.
A technical summary of the car is made on the last page.
Certain parts are marked with an * which indicates that further modifications have been made subsequently. These can be found at the end of the document
Change of engine
The engine conversion project was initially considered already in the middle of the 90ies, but the availability of the desired engine was limited, at least from an economically reasonable perspective.
The choice of engine and gearbox had to comply with a number of criteria:
it had to be an original Volvo engine.
it should fit without altering the engine compartment.
have a potential for more than 300 hp.
It would obviously be registered with the base engine (193 hp, 270 Nm), -and it is.
Subsequent engine modifications are not really visible....... :-)
In the following description there are a number of paragraphs with *, these indicates that further modifications have been made and are described in the section titled latest modifications
A complete, crashed, 850AWD LTT -97 with 50000 km on the clock was purchased and engine, gearbox, wiring and control-box was removed. The rest of the car was sold in pieces as spare-parts in order to also provide some finances for the project.
The engine was tested and considered to be fresh and without the need of renovation* at this stage.
Engine, engine mounts.
Since the engine had to be fitted longitudinal and not transversal as in the 850, the first challenge was to re-build an oil-pan from a Volvo 960. It was decided to shorten the oil-pan in order to adjust the size and form to fit against the front cross member. It was a rather time consuming job.
The longitudinal position of the engine also meant that the gearbox and the clutch housing had to be re-modeled to fit the engine. This was made by using one half from the new gearbox and the other half from the old were centered and welded together.
After having fixed the oil-pan and the gearbox everything was ready to be lifted into the car and start constructing the engine mounts. These were fabricated from 12 mm iron-plate and the original engine mounts and shock absorbers on the cross-member was used as an initial fixation point for the final positioning against the engine. The construction and adjustment was not difficult but it does take longer time than what one should think.
Finally it was necessary to also construct a new mount for the gearbox against the original cross-member for the gearbox. This was easy.
Engine block*
The engine block was left standard.
Cylinder head*
The cylinder head was left standard except that the camshaft on the exhaust side was changed to the version from the GLT which has a higher lift.
Intake and exhaust manifold
The intake manifold* was modified by shaving approx. 5 mm. off the packing side in order to ensure sufficient clearance between pipes and inner wheel fender.
The connection point/air inlet for the air control valve was moved to the other side of the air inlet pipe and was extended to make space for the alternator.
A new bracket for the alternator was also fabricated.
The exhaust manifold* was not modified except for a spacer of approx. 20 mm between the
Turbo and the manifold. Again, this was made to ensure sufficient space to the inner wheel fender.
Turbo
TDHL0418T*
To ensure the exhaust in the right direction it was necessary to turn the exhaust side of the Turbo up-side-down as well as twisting the air inlet side to get the right angle.
Exhaust system
The exhaust system consist of 3 pipes, metallic catalyst, two silencers of free flow type.
Cooling system
Original P1800 radiator is used with the only modification being that the top hose connection has been moved to provide a more aesthetic appearance towards the engine.
Inter-cooler
An inter-cooler in aluminum has been modified to fit the space between the radiator and the grill.
Air filter
The air filter is situated in the same place as the original P1800 filter but replaced with a more open KN filter.
Fuel system
The fuel system consist of a Bosch Pump, hoses and pipes are P1800 original.
Fuel injectors are from an R -type.
Engine control system, injection & ignition.
Motronic 4.4 chip-tuned with BSRs stage 3
Since the base engine was equipped with a light-pressure turbo it was necessary to change this and the injector nozzles from the beginning to meet the requirements for BSR stage 3.
Charge pressure with this modification is 1.25 bar which, according to BSR, should give 330 hp and 470 nm torque.
Full function on all sensors and transmitters, ODBII connection point for diagnosis.
Distributor
To avoid the need of modifying the engine compartment there was no other option but to remove the original mechanical distributor. This was replaced with a modified cam-shaft transmitter using a number of logic-boards and transistors to control an ignition- coil for each cylinder. The ignition-coils were taken from a Volvo 960. The engine had to be slightly modified for the ignition-coils to fit the holes for the spark-plugs.
Clutch*
The clutch is an original pressure plate and centre disc.
Drive shaft
The drive shaft is a shortened axle from a Volvo 240/260 which has been balanced and renovated.
Rear-axle
The rear-axle is a 1031 i.e. original P1800 late model except the gearing which has been changed to 3.15 as well as received a diff. brake of centrifugal type.
The spring controlling the speed at which it is engaged was tightened.
The sensors transmitting the speed to the control-box was modified with a number of logic-boards to ensure the correct speed was recorded.
Instruments
The gauges, such as the rev. counter received new internals to suit the data from the engine control-box. The oil temp. gauge was modified to instead display the turbo pressure.
All other instruments remain original and uses standard P1800 sensors installed on the new engine and gearbox.
Gear-box
A 5 speed Getrag gear-box from a Volvo 264, 75&76 was chosen as it is reasonably durable and fitted in this project. It is arguably not the best as the 5th gear is not an overdrive but has a gear ratio of 1:1 which leaves the engine revolutions unnecessary high.
The gear selector from the Getrag box was amended to suit the P1800 body.
Misc.
In addition to the above a number of other technical solutions has been made in regard to the installation of the sensors and transmitters for the Motronic system to ensure a smooth running engine.
Chassis
Road handling
Anti sway-bars from IPD, USA (front 28 mm, rear 19 mm).
Heavy duty shock absorbers from Monroe.
All trailing arms are adjustable via rack & pinion combination enabling fine adjustment of the rear-axle in relation to the chassis.
Brakes*
Original rear brakes, front brakes are ventilated discs and calipers from a Volvo 264.
New brackets for the front calipers was constructed.
Wheels, tires*
Aluminum wheels 100+ 7x15, tires 205/60 -15
Latest modifications:
Engine block
The engine block has been upgraded with new Verdi piston rod's and improved crankshaft ventilation. This was made after 3 standard piston rod's were bent when turbo pressure was 1.4 bar.
Cylinder head.
The cylinder head has been overhauled with all in-/outlet channels polished and adjusted to meet a possible future need if/when fitting modified cam-shafts.
Air intake/Exhaust manifold
The air intake and exhaust manifolds have been modified and adjusted to the cylinder head.
Clutch.
Fixed flywheel (previously rubber suspended) .
The clutch now consist of a stronger pressure plate (570 NM, organic disc)
The disc from a Volvo164 with welded disc center.
Clutch arm and bearing has been reinforced.
Chassis
Complete set of Polyurethane bushings in front and rear suspension.
Turbo/Fuel/control system - 2007/06
Turbo pressure has been increased to 1.7 bar, new progressive fuel regulator, higher fuel base pressure. New turbo TDHL0419T
Wheels & tires - 2007/06
Koyo Magic aluminum wheels with stainless steel rim 8 x 17 , 245/45-17
Brakes - 2008/06
New bigger front brake discs (they are XC90 rear discs), ventilated 305*24mm.
Brake pads are Foredo M1144
Steel braided brake hoses.
Brake calipers are still Girling from Volvo 264.
Power window/central locking/remote start -200903
Power window of universal type modified with auto up/down functionality
Remote central locking of universal type modified to interwork with power window
Remote start, own construction, interworking with central locking and windows
Electric power steering - 201006
Power steering from EZ power steering.
Is a "must" when it come to driving comfort, recommend this...
(www.ezpowersteering.nl)
Summary
This project has been fun and very inspiring and has received considerable attention from many different persons at various occasions. Theres obviously always many new ideas and modifications to be considered. Time will tell if they will materialize.
Quick reference of the modifications
P1800ES, B5254T
General
1800ES 73 with B5254T engine, modified transmission, brakes and road handling.
The objective was to keep the exterior appearance original with no modifications to the body. The drive line, brakes and road handling should match the increase in power.
Drive line:
Engine: B5254T -97
TDHL0419T turbo charger, aluminum inter-cooler.
Verdi steel pistons, polished R-exhaust manifold, polished air intake manifold,
polished cylinder head and modified combustion chambers.
Compression 9.0:1, B5254 GLT exhaust cam-shaft.
Fuel: Bosch pump 0580254984 Max 5Bar, 220 L/H, Malpasi 1:1,2 pressure regulator,
R-injection nozzles 462cc/m, base pressure 3,8 Bar, 98 octane.
Clutch: pressure plate Sachs: 3028999707 (577Nm), organic disc Volvo164 welded centre.
Gearbox: 5 speed Getrag, 0,8:1 on 5th
Rear-axle: 1031, gear ratio 3:15, Diff. brake (centrifugal diff.)
Drive shaft : shortened and balanced from Volvo 240/260.
Wheels & tires: 8x17, 225/45-17
Brakes:
Front: Ventilated Volvo XC90 rear discs (305 mm) and Volvo 260 Girling calipers with M1144 brake pads and steel braided brake hoses.
Rear: Original discs and calipers with M1144 brake pads and steel braided brake hoses.
Road handling:
Shock absorbers: Monroe gas front and rear.
Springs: Front; 16 mm Rear 13 mm
Anti-sway bars: Front; 28mm, Rear; 19mm (IPD, USA)
Polyurethane bushings.
Miscellaneous
Color, Gold, Volvo original (Code 105)
Complete original function concerning engine management and auxiliaries for engine.
Complete 3" exhaust system with Metallic catalyst.
Gauges; rev. counter, tachometer, temp., pressure etc. has been modified to suit the
original P1800 gauges in the instrument cluster.
One electronic ignition coil per cylinder (due to insufficient space for the original mechanical distributor)
Power
At pressure (bar) : (0,40: 193 Hp, 270 Nm)
( 0,80: 250 Hp, 350 Nm)
(1,25: 330 Hp, 470 Nm)
1,70: 330+ Hp, 470+ Nm, today used boostExterir / Styling
Se "Snabbfakta" under vrigt, eller mer detaljerat under "Framtidsplaner"Framtidsplaner
Bygget i med mera detaljer...(ej framtidsplaner som rubriken anger)
Allmnt
Bil kptes i lda hsten 1990, renovering var pbrjad av fregende gare,
eller rttare sagt den var delvis nedplockad i delar.
Bilen plockades ner totalt i minsta detalj, karossen glasblstrades, liksom samtliga vriga detaljer som motor, vxellda, bakaxel, etc.
Alla delar lackerades separat, dvs. karossen var helt ren och rullades in i lackbox med stdben och hjul och inte en enda maskerings tejp satt p vid lackeringstillfllet.
Byte av bilens samtliga slitdelar som t.ex. lager, gummilister, bromsar, slangar, helrenovering av motor, vxellda, bakaxel, mm, mm.
Inredningen fick ny instrument brda, omkldda framstolar och samtliga mattor utbytta samt nytt innertak.
Nya yttre kromlister, omkromning av sttfngare samt alla andra krom detaljer.
Renovering/hopmontering av bilen skedde under vintern 91-92 och togs
i bruk sommaren 1992.
Drefter krdes bil fram till hsten 1999, dr motorbytet till 5 Cyl turbomotor p brjades, vren 2001 var bilen ute p vgen igen.
En sammanstllning p bilens utrustning finns p sista sidan i detta dokument.
Vissa delar r markerade med en * dr har ytterligare modifiering skett och dessa kan utlsas lngre ned i dokumentet.
Motorbyte
Fundering p motorbyte pbrjades redan i mitten av - 90 talet, men tillgngen av den nskade typen av motor var begrnsad, sett ur ett ekonomisk rimligt perspektiv.
Valet av motor vxellda och drivlina hade att antal kriterier:
- Skulle finnas original monterat p ngon Volvo
- Skulle rymmas utan modifiering av motorrum
- Mjlighet till mer n 300 HK
Naturligtvis skulle den vara registrerings besiktigad med grund motorn
(193 Hk, 270 Nm), och de r den.
Motormodifieringar drutver r ju egentligen inte synliga....... :-)
I kommande beskrivning finns i vissa avsnitt ett antal *, med detta
menas att ytterligare modifieringar har skett och beskrivs i avsnittet
Senaste modifieringar
En komplett krockad 850AWD LTT -97 med 5000 mil p mtaren inkptes och motor med kablar och styrsystem demonterades, restan av bilen sldes i delar fr att
finansiera bygget.
Motorn genomgick en konditionstest och bedmdes frisk och sldes behvdes ingen
renovering* av motorn i detta skede.
Motor, Motorfsten
Eftersom motorn skull lngs monteras i bilen s var den frsta utmaningen att
bygga om ett Volvo 960 oljetrg, frutom att korta trget, de enklaste, till att modellera s att de passade mot framvagnsbalken, vilket var ett tidskrvande jobb.
Lngs monteringen innebar ocks att vxelldan och dess kpa skulle anpassas
mot motorn, resultatet vart en halva frn nya vxelldan och en frn
den som tidigare satt p motorn, dessa tv delar centrerades och svetsades ihop.
Efter att oljetrg och vxellda var avklarat var de lge att lyfta i hela paketet och
pbrja byggande av motorfste, dessa fsten tillverkades i 12mm plattjrn och
original motorfsten och motorkuddar p framvagnsbalken fick utgra startpunkt fr
att slutligen ansluta mot motorn, sjlva byggandet och anpassandet av motorfsten var ingen stort problem, dock tar de lngre tid n man kan tro.
Slutligen krvdes ocks ett fste frn vxellda mot vxelldsbalken, vilket var en enkel vning.
Motorblock*
Motorblocket lmnades orrt.
Topp*
Topp lmnades orrt, frutom att kamaxeln p avgassidan r bytt till GLT modell
med ngot hgre lyft.
Insug och Grenrr
Insugs rret* modifierades med att packningsytan mot toppen planades ca 5 mm fr att f tillrckligt stor utrymme mellan rr och innerskrm.
Ingngen/anslutningen fr gasspjllet flyttades frn ena till andra sidan av insugs rret
och frlngdes fr att rymma generatorn.
Nytt generatorfste tillverkades, i samband med modifieringen av insuget.
Grenrret* r inte modifierat frutom att en mellanlggsplatta p ca 20 mm mellan
Turbo och grenrr monterades, detta fr att f tillrckligt med utrymme mellan turbo och innerskrm.
Turbo
TDHL0418T*
Fr att f avgassidan t rtt hll s vndes avgashuset uppochner samt att
turbon vreds p insugs sidan fr att f rtt vinkel.
Avgassystem
Avgassystemet bestr av 3 tums rr, metall katalysator samt tv ljuddmpare av
fullfldestyp.
Kylsystem
Original P1800 kylare anvnds med enda modifiering att vre vattenanslutningen har
flyttats fr att estetiskt passa bttre mot motorn.
Laddluftkylare
Helaluminium laddluftkylare r anpassad fr det utrymme som finns mellan
Vattenkylare och grillen.
Luftfilter
Luftfiltret sitter p samma plats som original P1800 men r utbytt mot ett ppet KN filter.
Brnslesystem
Brnslesystem bestr av en Bosch Pump, slangar och rr r P1800 original
Spridare r av R -modell
Motorstyrsystem insprutning/tndning
Motronic 4.4 chippat med BSRs steg 3
Eftersom att grundmotorn var en lttrycksturbo, s byttes turbo och
spridare redan frn frsta brjan till motsvarande fr vad BSR steg3. frutstter
laddtryck r med denna modifiering r 1.25 bar.
Vilket enligt BSR skall ge 330HK samt 470nm.
Full funktion p samtliga givare och utgngar, ODBII uttag fr diagnostik.
Tndfrdelare
Fr att inte behva modifiera i motorrummet s fanns ingen annan utvg n
att plocka bort den mekaniska tndfrdelaren
Den ersattes med en modifierad kamlgesgivare som fick via ett
antal logiska kretsar och transistorslutsteg styra en tndspole per cylinder.
Tndspolarna togs frn Volvo 960 motorn och modifierades en aning fr
att passa i tndstiftshlen.
Koppling*
Kopplingen bestr original tryckplatta och sinterlamell.
Mellanaxel
Mellanaxeln bestr av en lngdjusterad axel frn Volvo 240/260,
balanserad och renoverad
Bakaxel
Bakaxel r en 1031 d.v.s. original P1800 senare modell, dock r
Utvxlingen bytt till 3.15 samt en diff av slungmodell r installerad.
Fjdern fr vilken hastighet diffen kan g in/ur r uppspnd.
Givare fr hastighet till styrenheten modifierades med hjlp av ett antal
logiska kretar fr att rtt hastighet skall detekteras av styrenheten.
Instrumentering
De invndiga instrumenten ssom varvrknare fick ett nytt innanmte
som passade mot de pulser som styrenheten levererar.
Oljetemp mtaren fick ett nytt innanmte som visar laddtryck istllet.
Övriga instrument r ej modifierade p ngot stt och anvnder P1800
originalgivarna monterade p den nya motorn/vxelldan.
Vxellda
Valet av vxellda fll p den 5 vxlade Getrag lda som fanns originalmonterad
P Volvo 264, 75&76.*
Vxelldan r relativt tlig och passade in i detta bygge, tyvrr kan vl sgas
att 5 vxeln inte r en vervxel utan ger en 1:1 utvxling, varav motorvarvet
blir ondigt hgt.
Spakstllet frn getragldan anpassades s att den passade med P1800 karossen
Övrigt.
Frutom ovanstende finns en rad tekniska lsningar fr placering av styrdon och givare fr Motronicsystemet fr att f en fullt fungerande motor.
Chassi
Vghllning
Krngningshmmare frn IPD i USA fram 28mm, bak 19mm
Frstrkta gas sttdmpare, Monroe
Samtliga lnkarmar r justerbar genom en mutter skruv kombination
detta ger mjlighet att finjustera bakaxeln lge i frhllande till chassi.
Bromsar*
Bak broms r av originaltyp, frambroms bestr av ventilerade Volvo 264 skivor och ok..
Nya distansplattor fr framvagns ok tillverkades i samband med byte.
Flgar, Dck*
Aluminiumflgar 100+ 7x15 dck 205/60 -15
Senaste modifieringar
Motor block
Motorblocket r renoverat med bl.a. nya Verdi stlstakar samt frbttrad vevhus ventilation, detta gjordes efter att 3 st. stakar krktes, laddtrycket var vid de tillfllet
1.4 bar
Topp
Toppen har renoverats samt samtliga in/utlopp kanaler har justerats
fr att kunna mta ett eventuellt kommande behov av modifierade kamaxlar.
Insug/Grenrr
Insug/Grenrr r modifierat och anpassat mot toppmodifieringen.
Koppling
Stumt Svnghjul (tidigare gummidmpat)
Kopplingen bestr nu av kraftigare tryckplatta (570NM, organisk lamell)
Lamellen frn Volvo164, svetsat lamellcentrum
Kopplingsarm/urtrampningslager frstrkt.
Chassi
Polyuretan bussningar i samtliga leder i fram och bakvagn
Turbo/Brnsle/styrsystem - 200706
Laddtrycket har hjts till 1.7 bar, ny progressiv brnsle regulator
hgre brnslegrundtryck.
Turbo TDHL0419T
Dck/flgar - 200706
Aluminiumflgar med Rostfri kant Koyo Magic 8 x 17 , 225/45-17
Bromsar - 200806
Nya strre bromsskivor fram, bromskivorna kommer frn XC90 (bakskivan)
Ventilerade, 305*24 mm
Bromsbelgg av modell Foredo M1144
Stlomspunna bromsslangar.
Bromsok r fortfarande Girling frn Volvo 264
El -fnsterhissar/centralls/fjrrstart 200903
El -fnsterhissar av universaltyp med tillgg fr auto up/down
Centralls av universal typ med auto up styrning av fnsterhissar vid lsning samt fjrrstart/stopp av motor.
Ny vxellda Getdrag typ BMW 265 - 200908
Vxellda med samma styrka, utseende och storlek som fregende Getrag dock med 5 vxeln
som vervxel drmed snks motorvarvet till ca 2000 v/min vid 100 Km/h
Elektrisk servostyrning - 201006
Servostyrning frn EZ power steering.
Är ett lyft nr de gller krkomfort, rekommenderas...
(www.ezpowersteering.nl)'
201406
Byter tillbaka till getrag 1:1 ldan
Summering
Byggande av denna bil har varit skoj och inspirerande, och har rnt mycket intresse
frn mnga personer vid olika tillfllen.
Naturligtvis finns idéer om ytterligare frbttringar/ frndringar om dessa idéer blir verklighet terstr att se.vrigt
Snabbfakta P1800ES, B5254T
Allmnt
1800ES 73 med B5254T, modifierad drivlina, bromsar och vghllning.
Mlet var att utseendemssigt behlla bilen i originalskick samt att ingen modifiering grs i karossen, samt att drivlina, bromsar och vghllning skall matcha effektkningen.
Motorbyte gjort r 1999 - 2000
Drivlina.
Motor: B5254T -97
TDHL0419T turboaggregat, Helaluminium laddluftkylare
Verdi stlstakar, Portat R-grenrr, Portat insug, Portad topp, Modifierade frbrnningsrum.
Kompression 9.0:1, B5254 GLT avgaskam.
Brnsle: Bosch pump 0580254984 Max 5Bar, 220 L/H, Malpasi 1:1,2 tryckregulator,
R-spridare 462cc/m , Grundtryck 3,8 Bar, 98 oktan
Koppling: tryckplatta Sachs: 3028999707 (577Nm), organisk lamell Volvo164 svetsat
centrum.
Vxellda: 5 vxlad, Getdrag, 0.8:1 p femman
Bakaxel: 1031, Utv.3:15, Diffsprr (slungdiff)
Mellanaxel: Lngdanpassad/Balanserad Volvo 240/260 axel
Flgar, dck: 8x17, 225/45-17
Bromsar
Fram: Ventilerade Volvo XC90 bakskivor (305 mm) och
Volvo 264 Girling bromsok och M1144 belgg, stlomspunna slangar.
Bak: Original Skivor och tillhrande bromsok och M1144 belgg, stlomspunna slangar.
Vghllning
Sttdmpare: Monroe gasdmpare fram och bak
Fjdrar: Fram; 16 mm Bak 13 mm
Krngnings hmmare: Fram; 28mm, Bak; 19mm (IPD,USA)
Polyuretan bussningar
Övrigt
Frg, Volvo orginal, Guld metallic (kod 105)
Full original funktion gllande motorstyrning, och kringutrustning fr motor.
Metall katalysator
3" avgassystem hela vgen
Varvrknare, hastighet, temperatur, tryck -mtarfunktioner anpassade till original P18
instrumentering.
Elektronisk tndfrdelare (pga. utrymmesbris), En tndspole per cylinder.
Elhissar & Centralls
Fjrr -start&stopp av motor
Elektrisk servostyrning
Effekt
Vid laddtryck, bar (0,40: 193 Hk, 270 Nm)
(0,80: 250 Hk, 350 Nm)
(1,25: 330 Hk, 470 Nm)
1,70: 330+ HK, 470+ Nm (laddtryck som anvnds fr tillfllet)
