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94 850 - No spark after engine swap to 97 engine

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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soulvoid21
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soulvoid21

94 850 - No spark after engine swap to 97 engine

Post by soulvoid21 » Sat Sep 16, 2017 6:35 pm

Hey all, so I've definitely dug myself into a hole here, and I feel I've bitten off a little more than I can chew.

Long story short. I bought a 94 850 turbo, auto, that was swapped to a 97 engine and 5 speed setup. But it was done very sloppily.. Simply cut and destroyed the entire A/C system, it's missing about 5 plastic pieces for the engine bay, around the radiator to hold the relays, etc. The list goes on.

I couldn't help myself but to buy this car and get it out of the idiots hands. I will say, when it ran, it ran very well. But I have had a number of issues with this car.

The engine eventually blew the HG, because I was getting boost surges up to 21psi. That's what the gauge read anyway, not 100% sure if it's accurate.

He did mod the car with most of the standard bolt-ons:
- Angled exhaust housing for turbo and full rebuild
- 3" down pipe, cat-less and straight pipe exhaust
- Big Bore intake manifold
- I believe it has a larger throttle body, not sure what size it is, or what the stock size should be
- IPD turbo control valve
- ARD Orange tune, with O2 delete, etc. And should be tuned for 14psi (what I was told anyway)

There were wires hanging everywhere, plugs that went to nothing, and the full wire harness for the auto trans still intact.. so I figured I should go through, get rid of everything that isn't needed, clean all the connections up and run the wires where they should go.

Well that was 3 years ago, and I just got the car back together today.. Ran out of time and money, so it just sat.

I have everything connected back up, except 1 - 2 pin connection that I cannot find where it goes. Will get more info on the connector tomorrow (wire color, etc), it's too dark now and the car is outside. I wanted to fix the wiring before I continue to the HG, but this isn't proving easy. I did keep everything I removed from the car if I need to go back. The car did run fine before I did this teardown, even with the bad HG, was simply burning antifreeze, there's sparkles in the antifreeze, and had a misfire. Oil and antifreeze are not mixing though, oil looks fine. No metal or anything. I realized that I should have labeled things as I went, but I was already too far into it when that light clicked on. That's my fault, and now I'm paying the price :lol: :lol:

At this point, with a known good Volvo battery, I get a crank but no start. I have good fuel pressure, but I get no spark at the plugs, and nothing at the blue and red wire on the ignition coil with my multimeter. I can't find a good wire diagram to try and trace the wires to make sure I have the right connections at the right sensors. I believe I just have the cam or crank sensor on the wrong plug

Also, I cannot get codes from the car. Body still has the 94 old style pin and LED, but doesn't work, and the OBDII for the 97 engine doesn't link to my scan tool. I can't scan for codes at this point -_- I can get a donor car if I need to redo the harness as well, that wouldn't be an issue. More work than I'd like to do, but if it comes to it.

I know this won't be a walk in the park with a swapped and modded car, and one that was sloppily done. I greatly appreciate any input.
'07 S60 2.5T AWD - 158k - Stock, daily
'94 854 body - '97 850 turbo engine (looking for engine code, the plate is too dirty) - 5 speed swap - basic bolt-on's and ARD Orange tune

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rspi
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rspi

Re: 94 850 - No spark after engine swap to 97 engine

Post by rspi » Sat Sep 16, 2017 9:17 pm

So basically what you are saying here is that you took a running car with a blown head gasket and "cleaned up" the engine bay? Nothing has been replaced? Now it will crank but not give spark?
'95 855 T-5R M, Panther - 22/28 mpg
'98 S70 GLT, Lil' Red 25/32 mpg
--------------------
Volvo's of past: '87 740 GLE, '79 262C Bertone, '78 264, 960's, '98 S70 GLT, '95 850 T-5R YellowVolvo Repair Videos

tryingbe
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tryingbe

Re: 94 850 - No spark after engine swap to 97 engine

Post by tryingbe » Sat Sep 16, 2017 10:12 pm

soulvoid21 wrote: ↑
Sat Sep 16, 2017 6:35 pm

I have everything connected back up, except 1 - 2 pin connection that I cannot find where it goes. Will get more info on the connector tomorrow (wire color, etc), it's too dark now and the car is outside. I wanted to fix the wiring before I continue to the HG, but this isn't proving easy. I did keep everything I removed from the car if I need to go back. The car did run fine before I did this teardown, even with the bad HG, was simply burning antifreeze, there's sparkles in the antifreeze, and had a misfire. Oil and antifreeze are not mixing though, oil looks fine. No metal or anything. I realized that I should have labeled things as I went, but I was already too far into it when that light clicked on. That's my fault, and now I'm paying the price :lol: :lol:


Post pictures.
85 GLH, 367 whp
00 Insight, 72 mpg

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soulvoid21
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soulvoid21

Re: 94 850 - No spark after engine swap to 97 engine

Post by soulvoid21 » Sun Sep 17, 2017 11:36 am

rspi wrote: ↑
Sat Sep 16, 2017 9:17 pm
So basically what you are saying here is that you took a running car with a blown head gasket and "cleaned up" the engine bay? Nothing has been replaced? Now it will crank but not give spark?
Correct. If you had seen this car, you would have done the same thing. Wires were hanging and dragging on the ground, wrap around the cooling fan almost getting cut, about 10 wires zip tied to the coolant hose, etc. I did have to replace quite a bit before the HG even blew. Coolant temp sensor for a running rich condition, crank sensor, fuel filter, brakes, a brake line, spark plugs, distributor, the car was a complete mess. Like I said, I had a lot of issue other than just the HG. It did run before tearing it down, but only after I went through and fix quite a bit.

Nothing has been replaced since I did the rewire. Everything works fine except I'm not getting spark. Wasn't by choice that I left it sit either, just a crappy situation I was forced into.
Last edited by soulvoid21 on Sun Sep 17, 2017 11:41 am, edited 1 time in total.
'07 S60 2.5T AWD - 158k - Stock, daily
'94 854 body - '97 850 turbo engine (looking for engine code, the plate is too dirty) - 5 speed swap - basic bolt-on's and ARD Orange tune

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soulvoid21
Posts: 47
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soulvoid21

Re: 94 850 - No spark after engine swap to 97 engine

Post by soulvoid21 » Sun Sep 17, 2017 11:37 am

tryingbe wrote: ↑
Sat Sep 16, 2017 10:12 pm
soulvoid21 wrote: ↑
Sat Sep 16, 2017 6:35 pm

I have everything connected back up, except 1 - 2 pin connection that I cannot find where it goes. Will get more info on the connector tomorrow (wire color, etc), it's too dark now and the car is outside. I wanted to fix the wiring before I continue to the HG, but this isn't proving easy. I did keep everything I removed from the car if I need to go back. The car did run fine before I did this teardown, even with the bad HG, was simply burning antifreeze, there's sparkles in the antifreeze, and had a misfire. Oil and antifreeze are not mixing though, oil looks fine. No metal or anything. I realized that I should have labeled things as I went, but I was already too far into it when that light clicked on. That's my fault, and now I'm paying the price :lol: :lol:


Post pictures.
I definitely intend to. I just wasn't sure if someone had a complete diagram of the wire harness, with wire colors or pin-out, so I could go over everything before just blindly asking too many questions.
'07 S60 2.5T AWD - 158k - Stock, daily
'94 854 body - '97 850 turbo engine (looking for engine code, the plate is too dirty) - 5 speed swap - basic bolt-on's and ARD Orange tune

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soulvoid21
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soulvoid21

Re: 94 850 - No spark after engine swap to 97 engine

Post by soulvoid21 » Sun Sep 17, 2017 12:04 pm

Attached are the 2 connections that I cannot find the male ends for. I don't remember if they were extras when I started, or if they actually go somewhere.

I was able to use the attached diagram to confirm that I have the cam sensor on the correct connection. So I'm assuming I have the crank sensor on the wrong plug, but don't want to just go swapping things around and get myself into more of a mess.
Attachments
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2017-09-17 13.46.25.JPG
2017-09-17 13.46.15.JPG
2017-09-17 13.46.11.JPG
'07 S60 2.5T AWD - 158k - Stock, daily
'94 854 body - '97 850 turbo engine (looking for engine code, the plate is too dirty) - 5 speed swap - basic bolt-on's and ARD Orange tune

User avatar
soulvoid21
Posts: 47
Joined: Wed Mar 06, 2013 7:32 am
Year and Model: 07 S60 AWD
Location: Berwick, PA
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soulvoid21

Re: 94 850 - No spark after engine swap to 97 engine

Post by soulvoid21 » Sun Sep 17, 2017 12:27 pm

Just checked the fuel injectors and they aren't pulsing either. So my best guess is the crank sensor on the wrong plug.

I have also checked all fuses. Everything's good there.
'07 S60 2.5T AWD - 158k - Stock, daily
'94 854 body - '97 850 turbo engine (looking for engine code, the plate is too dirty) - 5 speed swap - basic bolt-on's and ARD Orange tune

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rspi
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rspi

Re: 94 850 - No spark after engine swap to 97 engine

Post by rspi » Sun Sep 17, 2017 2:10 pm

Most Volvo connectors have ridges that prevent you from plugging them into the wrong item. Also, harness is usually tightly positioned to prevent that as well, hard to mess up, unless someone tries very hard.

A few weeks ago I replaced my cylinder head for a burnt valve. After all was back together the car would not start at all. Key wouldn't even crank also would not push start. Had a bad wire in the manual swap harness. If you are cranking and have no spark, must have another issue. Maybe a bad ground somewhere.

Cam sensor plug is a known weak link, the connector falls apart. Do check to make sure 7 things are connected...
1. Cam sensor
2. Crank sensor
3. Throttle position sensor
4. Idle air control valve
5. Turbo BCS
6. MAF
7. Fuel injector relay.

You may also find a connector for the EGR valve if still installed.
'95 855 T-5R M, Panther - 22/28 mpg
'98 S70 GLT, Lil' Red 25/32 mpg
--------------------
Volvo's of past: '87 740 GLE, '79 262C Bertone, '78 264, 960's, '98 S70 GLT, '95 850 T-5R YellowVolvo Repair Videos

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rspi
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rspi

Re: 94 850 - No spark after engine swap to 97 engine

Post by rspi » Sun Sep 17, 2017 2:11 pm

'95 855 T-5R M, Panther - 22/28 mpg
'98 S70 GLT, Lil' Red 25/32 mpg
--------------------
Volvo's of past: '87 740 GLE, '79 262C Bertone, '78 264, 960's, '98 S70 GLT, '95 850 T-5R YellowVolvo Repair Videos

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erikv11
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erikv11

Re: 94 850 - No spark after engine swap to 97 engine

Post by erikv11 » Sun Sep 17, 2017 3:29 pm

Pretty sure the red one is for EGR, which your 94 harness has but your 97 engine probably doesn't have.
'95 854 T5-R, Motronic 4.4, 185k
'96 855 NA, 145k
'98 S70 NA, 220k (living out west)
'98 V70, T5 tune-injectors-turbo, LPT engine, 285k
'06 S60 R, 165k
'99 Camry V6 :shock: 125k
gone: '96 NA 850 210k, '98 NA V70 182k

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