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Building a 500hp hybrid red-block Volvo engine 
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Did a tiny bit of work on the engine tonight and removed the freeze/welch plugs from it. A few tweets/pics:

https://twitter.com/FredCookeNZ/status/ ... 1850112001
https://twitter.com/FredCookeNZ/status/ ... 9482831872
https://twitter.com/FredCookeNZ/status/ ... 3345427456
https://twitter.com/FredCookeNZ/status/ ... 6359455745
https://twitter.com/FredCookeNZ/status/ ... 8181728256

Image

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Image

Image

Image

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Mon Feb 20, 2017 10:34 am
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More progress, more stripping, still no legs, only a big red block.

Block coolant drain hole fully plugged with rust, poked it out with a screwdriver easily just as I did on the 740 sedan in-car. No big deal:

https://twitter.com/FredCookeNZ/status/ ... 0272405505

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Bare bottom [end] block:

https://twitter.com/FredCookeNZ/status/ ... 9072260099

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And finally for reference, it's these two holes the studs go in:

https://twitter.com/FredCookeNZ/status/ ... 1051238401

Image





Remaining parts on the block are:

1) Head gasket
2) Squirters and fasteners for them
3) Crankshaft
4) Main caps and bolts
5) Two hex bungs in some passage or other
6) Front seals and housing
7) Auxiliary shaft with oil pump drive
8) Stainless bung in lower dizzy hole
9) Flex plate and main bolts attaching it to engine
10) Oil filter threaded tube
11) Two water pump studs
12) Rear main seal and housing
13) head gasket guide tubes
14) Oil pump drive pressed in brass bearing

Figured 14 was too many, and 13 was bad luck, and did a bit more work while counting. :-p

Next up, front and rear seals, flex plate and bolts. Might be time for the table project around then, but so much else to do, I'm just not sure what to do first. Bleh.

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Tue Feb 21, 2017 8:04 am
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Front cover and oil pump drive shaft removed:

Tweet tweet:

https://twitter.com/FredCookeNZ/status/ ... 2158242816

https://twitter.com/FredCookeNZ/status/ ... 8475868161


Pic pic:

Image

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Also tried to remove the two hex bungs and failed. Might have to weld something to them and find fresh replacements. One is for the oil gallery, the other not even sure, might also be oil?

EDIT: Oil seal area on nose of crank and head gasket peeled off:

https://twitter.com/FredCookeNZ/status/ ... 2817611777

https://twitter.com/FredCookeNZ/status/ ... 5862737920

Image

Image

_________________
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FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
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Thu Feb 23, 2017 10:20 am
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And now the top and topsides scraped: https://twitter.com/FredCookeNZ/status/ ... 8906736640

Image






And:

* The front cover gasket removed
* The front cover studs removed

Remaining is:

1) Head gasket guide tubes (keen to leave alone but likely to be removed for honing, I guess)
2) Front cover dowels (keen to leave alone, I see no reason to pull these)
3) Oil pump drive bearing (unsure if this brass item will like caustic/acidic baths, nor how hard it is to press or tap out)
4) Oil pump drive shaft bearings (Unkeen to touch these, but worried about caustic/acidic dips, too)
5) Flex plate/bolts (easy, hopefully, with the right approach of jammed crank vs block with an item)
6) Block-mount dizzy hole plug (keen to leave alone, but may remove gently)
7) Main caps/bolts (already had them out, just need a safe home for these bits and the crank before removal)
8) Crank and bearings (which turns fluidly with almost no effort right now, and seems to have no play. Nice)

Volvo nuts will be consulted on the above uncertain items.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Fri Feb 24, 2017 10:36 am
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Did these this afternoon:

Fred wrote:
1) Flex plate/bolts/spacer (easy, hopefully, with the right approach of jammed crank vs block with an item)
2) Main caps/bolts (already had them out, just need a safe home for these bits and the crank before removal)
3) Crank and bearings (which turns fluidly with almost no effort right now, and seems to have no play. Nice)

The main bearings looked mint, except the one at the nose, which had slight wear in one direction, upward toward belts! And the thrust bearing which had some "crank in crooked during assembly" marks on it. I don't think I did those, but I guess I may have? I wonder if Volvo engineers are that rough? Or if this block is on rebuild number two? Looks original to me, but you never really know until you measure.

Need to figure out what to do with these:

Fred wrote:
1) Head gasket guide tubes (keen to leave alone but likely to be removed for honing, I guess)
2) Front and rear cover dowels (keen to leave alone, I see no reason to pull these)
3) Oil pump drive bearing (unsure if this brass item will like caustic/acidic baths, nor how hard it is to press or tap out)
4) Oil pump drive shaft bearings (Unkeen to touch these, but worried about caustic/acidic dips, too)
5) Block-mount dizzy hole plug (keen to leave alone, but may remove gently)
6) Three hex bungs, two in the main oil gallery ends, and one other, galvanised. (missing from previous list, but not earlier list)
7) Guide tube for number 5 main bearing cap, not present on other caps


I know you can pull the guide tubes out, but you damage them when you do that, so I'm keen to leave them in place if possible and unless I have quality replacements to go back in afterward.

The brass and soft-metal bearings can stay in place so long as I don't get it dunked in a strong mix. Ditto the dizzy hole plug.
Next step will be to weld a washer to each of the bungs, then weld a nut to the washer, then undo using a power bar and socket.

Tweets:

https://twitter.com/FredCookeNZ/status/ ... 3763073024
https://twitter.com/FredCookeNZ/status/ ... 2402584576
https://twitter.com/FredCookeNZ/status/ ... 6943485952

Pics:

Image

Image

Image

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Feb 26, 2017 10:16 am
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Hindsight: Definitely hasn't been rebuilt, the engine was SO dirty on the outside and the gaskets on the front/rear cover were entirely brittle.

Work to be done:

0) Buy some engine part protection spray on lube that won't penetrate the surface and prevent adhesion of gaskets or be too hard to clean
1) Remove gallery bungs by welding on stronger drives
2) Clean front and rear faces to bare metal, and protect
3) Clean deck of remaining head gasket with some gentle process, and protect
4) Clean entire block with water blaster/degreaser/caustic cleaner, then CRC to prevent rust
5) Clean paint from outside with chemicals
6) Debur the interior of the block to aid oil return and avoid hand damage
7) Get it gently honed ready for new pistons and rings
8) Choose a colour, and respray, with zinc primer on first!
9) Mock up all accessories, covers and pulleys with B234F 16v head on there - machine pulley to suit if necessary
10) Buy some quality engine assembly lube - penrite?
11) Reassembly!

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Feb 26, 2017 10:39 am
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Missed one part, didn't see it until tonight, and finalised the plan:

Fred wrote:
1) Head gasket guide tubes/"locating dowels" - we'll see: (likely to be removed for honing)
2) Front and rear cover dowels - not touching
3) Oil pump drive bearing - not touching
4) Auxiliary drive shaft bearings - not touching
5) Block-mount dizzy hole plug - not touching
6) Three hex bungs - welding and removing
7) Guide tube for number 5 main bearing cap - not touching
8) Auxiliary shaft machining hole plug - not touching


Will try to buy some tools and chemicals and so forth this week to get some of the list in the previous post done.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Mon Feb 27, 2017 10:40 am
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Bought a few things for this tonight:

1) Break in / running in oil of the highest Ozzy quality (Penrite 10 tenths)
2) Sta-lube / CRC engine assembly lube in a tube (any good? Seems okay)
3) CRC gasket stripper spray (weak sauce?)
4) Brass bristled BBQ brush (even weaker sauce.)

And put the last two and a fresh razor blade to use to get the block deck a bit cleaner and closer to ready for reassembly. Tweets/pics:

https://twitter.com/FredCookeNZ/status/ ... 0508333059
https://twitter.com/FredCookeNZ/status/ ... 6619302914

Image

Image

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Wed Mar 01, 2017 10:29 am
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Bought a stack more of the running in oil and the for-real PAO/Ester oil today on special. 35% off normal retail. Win. Plenty of that and the race coolant and 80w140 diff oil in stock, now! :-D Photo here because where else?

https://twitter.com/FredCookeNZ/status/ ... 0487176194

Image







Aside from that, I also spent some time on the deck surface tonight and earlier this afternoon, too, with razor blade, CRC, Jif, scotchbright, gasket stripper, and brass wire brush. End result of many repeated gentle processes, a fairly clean and un-scared block deck ready for new gasket and head! :-)

https://twitter.com/FredCookeNZ/status/ ... 0777090048

Image

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sat Mar 04, 2017 11:02 am
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Spent 15 minutes tonight to make myself feel better and scraped most of the gunk off the water pump and front housing face. Wasn't worth taking a photo of, and isn't quite done yet, but closer. Another step in the right direction.

Tomorrow night I'll weld and remove the three bungs. I confirmed the third one is in the coolant gallery. I guess it's the standard water feed for the turbo model. I may or may not need a water feed for my chosen turbo, but it may as well come out and get replaced anyway.

I probably won't take it outside and waterblast the remaining filth off it. Perhaps wednesday night, for that. We'll see.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Mar 05, 2017 12:02 pm
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