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850 engine replacement woes (& Updates)

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

This topic is in the MVS Volvo Repair Database » Project: 850 engine replacement woes (& Updates)
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bigdaddylee82
Posts: 302
Joined: 22 December 2009
Year and Model: '95 850 GLT+94 parts
Location: Central Ohio via NW Aarkansas
Been thanked: 1 time

Re: 850 engine replacement woes

Post by bigdaddylee82 »

nightc1 wrote:I have nothing of value to add, but wanted to post that I read through the whole thread today. WOW.

I'm amazed that the end result was a working engine. Not that I know anything about ripping engines out and replacing them (other than reading threads here)... I just think it's amazing to see it go all back together and actually work. It seems like you are really close to having lola running great.

I guess the end result is to look back and figure out what you paid for everything (outside of time). In fact I'm curious about how much you spent.

Anyway thanks for the thread and the subsequent updates. An extra thanks for the pics and the little video... that was cool to see. Keep the updates coming in.
Thanks Nightc1, you really couldn't pay a guy like me a bigger compliment :oops:.

I had guestimated about what I had "invested" in this project, but never sat down to actually figure it. Since you asked I put together a spread sheet to try and figure it out. I had guessed somewhere between $1300 and $1400, and I wasn't too far off.

I have a fairly well equipped shop/garage, for mechanic work anyway. Pretty much the only thing I don’t have is a welder, but I do have plans to remedy that. I have a very good air compressor, and associated air tools i.e. impact, air ratchet, etc. I wouldn’t attempt this with out them. I already had an “adequate” cherry picker/engine hoist, it’s not great but it was free. A full tool box of wrenches, ratchets, sockets, extensions, torque wrench, specialty pliers, etc. Even with all of those tools I still had to purchase some Torx sockets, and I bought good ones, all that I had were twisted, broke, or the wrong size. I bought some Allen/Hex sockets too, would have been near impossible with just Allen wrenches. I bought another set of metric combo wrenches, seems a previous roommate may have moved out with a few. There were a few misc. tools like another pair of vice grips, and a power brake bleeder that I bought just for convenience.

There was a big expense in a radiator that was complete human error, though with the age and mileage of the car it was likely a wise choice to replace it anyway. I bought new brake lines, they were old and worn so they need replaced, I could have attempted to reuse them, which wouldn’t have been wise, and they gave me such a fit trying to take them off to drop the engine that I just cut them, so I defiantly needed new ones. I did cheap out on gaskets, and used Permetex on a lot of stuff; I bought new exhaust manifold gaskets though. Further cheapskate antics were buying heater hose at Lowe’s by the foot and cutting it to fit, yes I buy automotive parts at the hardware store.

There were a few other goof ups, Autozone sold me the wrong O-ring/gasket with my thermostat, too big/thick, which caused my thermostat housing to crack when attempting to torque it down. I had to buy 2 coolant reservoir caps, the first one I bought was abducted by aliens or something.

One thing that got expensive quick was fluids. All new fluids at once, add up quick. I bought oil, trans. fluid, brake fluid, coolant, and some additives like Royal Purple’s Purple Ice, Seafoam, and Marvel Mystery Oil. I went through 2 bottles of blue Loctite, there are a lot of fasteners. Miscellaneous stuff was hose clamps, nuts/bolts, etc. Finally the most important cost was the beer and food I used to entice a few friends to help me with some of the tedious stuff, and things you need 3 hands for.

So it all breaks down like this:


Engine-------------------$370.00 (This is with ~$90 shipping, a smoking deal)
Radiator-----------------$140.00 (Again, I broke it during engine removal)
Timing Belt Kit----------$200.00
Water Pump-------------$34.00
Thermostat--------------$7.00
Thermostat Housing----$20.00 (Broke thanks to Autozone’s Counter Monkeys)
Gaskets------------------$10.00
Heater Hose-------------$10.00 (About 6’ from Lowe’s)
Coolant Reservoir-------$39.00
Coolant Res. Cap--------$12.00 (This is the price of 2)
Front Brake Lines-------$20.00
Aux. Trans Cooler-------$37.00 (Was a quick fix to get the car moved with a patch on the radiator, but I decided to keep it)
Tools----------------------$100.00
Fluids---------------------$118.00
Loctite--------------------$15.00
Food/Beer----------------$40.00 (Shiner Bock For The Win!)
Miscellaneous------------$35.00

Total-----------------------$1,207.00

I wasn’t too far off. I recouped about $40 dollars by recycling my old engine block, sold as “dirty aluminum.”

So there you have it, I have spent about half of the cars KBB Private Party Value to bring it back to life. I’m not sure how economical my decision was, but I think I made a C in Micro Economics anyway, so what do I know.

- Lee

nightc1
Posts: 93
Joined: 1 September 2009
Year and Model: 99'V70 Base 140K+Mi
Location: Alabama, USA

Post by nightc1 »

That was better than I was expecting. $1200 for basically a near new running car.

I think that's a great deal if you like the car and plan on keeping it. Right now I could add up the repairs and servicing needed on my V70 to bring it to near perfect running condition (that is if nothing else were added on)... and just parts, new tires, and stuff... I'd probably be spending a good $800 easy. But $800 on a car I enjoy and that averages around 30mpg on my work commute? Not bad at all. That's less than 2 car payments on my 08 GMC Envoy.

Anyway, great thread... amazing detail on that expense recap :o ... thanks again for posting here.

bigdaddylee82
Posts: 302
Joined: 22 December 2009
Year and Model: '95 850 GLT+94 parts
Location: Central Ohio via NW Aarkansas
Been thanked: 1 time

Post by bigdaddylee82 »

Yeah, my boss' wife said kind of the same thing, "You pretty much got a new car for $1200." That's not how I see it though, I see that I was a bonehead and tried to nurse an overheating engine along in stop and go traffic, which cost me $1200 :lol:. The Volvo motor isn't quite as tolerant to overheating as my old Jeep is, live and learn right.

I started this thread to get help, which I did, and decided to continue it to, give back... I figured by now everyone would want me to shut up though.

I left out some expense earlier, I bought those overpriced E3 spark plugs, and I already had a new-ish cap/rotor and wires, so technically most of it was already bought and installed on the old motor, but there's about another $80. I'm eventually going to get new plug wires, because I pieced them together between the two motors, I managed to destroy a couple plug wires when removing them from the old engine. What can I say I'm special :roll:.

I've still got to buy at least one CV axle, technically I could get by with a boot and grease, but for the amount of work involved, I'm just going to go ahead and replace it. In all likely hood I'll replace both, so there's another $80.

Last night I bought a new PCV system/kit from IPD for $120, and just about an hour ago I bought a throttle plate for a 960 for $15 :twisted: .

So there's about another $300 that has been or will be shortly sank into Lola.

There's all of the front suspension hardware that needs to be addressed too $$$.

Just one pay check at a time. I've always heard that Jeep was an acronym for Just Empty Every Pocket, so what's Volvo stand for :lol: ?

- Lee

writer100
Posts: 207
Joined: 21 August 2009
Year and Model: 940 1994
Location: Los Angeles, California

Post by writer100 »

Lee,

Thanks. I read every word of this string. This was inspirational. I wish I could've been there to see this, as I'm sure I would have learned a lot.

Don't get discouraged -- you're not moving backwards, you are moving forwards.

As I always tell myself after having put $$ into my old car: Just Don't Get into an Accident. Because then the insurance company will give you a ridiculously low settlement, and all your time and money will be gone with the wind.

Keep up the good work.

Alex
1994 Volvo 940: 189,000 miles.
2008 Mustang GT convertible: 10000 miles. The garage queen.

nightc1
Posts: 93
Joined: 1 September 2009
Year and Model: 99'V70 Base 140K+Mi
Location: Alabama, USA

Post by nightc1 »

bigdaddylee82 wrote:I started this thread to get help, which I did, and decided to continue it to, give back... I figured by now everyone would want me to shut up though.
Nah man, this is the kind of good stuff that makes coming to MVS worth it. I may just make this my regular daily haunt.
bigdaddylee82 wrote: Just one pay check at a time. I've always heard that Jeep was an acronym for Just Empty Every Pocket, so what's Volvo stand for :lol: ?
Well... I take it you fully own the car... so... if you paid $1800 for all repairs (shooting slightly over that $300 estimate)... then you drove the car in total for a year... that would mean the equivalent monthly car payment of $150.00. That's not really that bad at all... and you shouldn't be doing the same repairs in the following year so the cost of ownership should go down. Just don't drive it if she starts to overheat :wink:

bigdaddylee82
Posts: 302
Joined: 22 December 2009
Year and Model: '95 850 GLT+94 parts
Location: Central Ohio via NW Aarkansas
Been thanked: 1 time

Post by bigdaddylee82 »

PARTS!!! :o
P7060093.jpg
P7060093.jpg (53.66 KiB) Viewed 1252 times

- Lee

bigdaddylee82
Posts: 302
Joined: 22 December 2009
Year and Model: '95 850 GLT+94 parts
Location: Central Ohio via NW Aarkansas
Been thanked: 1 time

Post by bigdaddylee82 »

Oh, yeah More parts :twisted:!!!
P7060095.jpg
P7060095.jpg (61.95 KiB) Viewed 1252 times
- Lee

MNCO1
Posts: 172
Joined: 22 February 2009
Year and Model: 850 T-5 1997
Location: colorado springs

Post by MNCO1 »

I second that "WOW".

bigdaddylee82
Posts: 302
Joined: 22 December 2009
Year and Model: '95 850 GLT+94 parts
Location: Central Ohio via NW Aarkansas
Been thanked: 1 time

Post by bigdaddylee82 »

Another short update, I made good use of the last collection of parts I got. It's no secret that I took some short-cuts to get the car at least operational and get it moved, yeah, yeah, procrastination. I really ran into more hurdles than I expected simply due to the difference in the two engines.

I hadn't shown any pictures of it, but I believe that I had mentioned having to modify/extend the breather hose from the oil trap to the flame trap on the PCV system. Well this came back to bite me in the butt :oops:.

Turns out on the < '95 models the hose to the flame trap is longer and comes up between two of the intake runners, then over the top of the manifold to the flame trap. The ≥ '95 models the same hose runs under the manifold. I used the PCV system off of my original engine because I knew it was operating correctly, and I had no clue about the system on my new engine. Only after I had the engine in the car and mostly together did I realize the newer PCV system didn't "fit" on the older engine.

So here's how I modified it, this is a bit more of my famous booty fabrication :wink: :
P7080102.JPG
Here you can see the problem, circled in red, the hose got up against the line from the exhaust manifold to the EGR and melted a hole in it:
P7080106.JPG
Which resulted in this oily mess:
P7080097.JPG
After a can of oven cleaner and a good preassure washing, I put the new and proper PCV system on, and hey look I actually used an intake gasket this time :lol: :
P7090120.JPG
I did all of this a couple of weeks ago, and I don't smell burning oil anymore, weird huh?

Also while I had the intake manifold off, I did some Redneck Engineering and got the VVIS on this engine functional. I documented that in the Performance & Mods section of the Forum:
www.matthewsvolvosite.com/forums/viewtopic.php?f=5&t=30281



- Lee
Last edited by bigdaddylee82 on 21 Jul 2010, 22:28, edited 1 time in total.

bigdaddylee82
Posts: 302
Joined: 22 December 2009
Year and Model: '95 850 GLT+94 parts
Location: Central Ohio via NW Aarkansas
Been thanked: 1 time

Post by bigdaddylee82 »

But wait there's more...
P7210100.JPG
I know suspension parts don't have anything to do with engine replacement, but it does kind of follow the whole Johnny Cash theme of this thread... ya know, getting a new car, "One Piece at a Time." :lol:

I've got a new fuel filter floating around in the garage somewhere, and I'm still driving around with a missing CV boot, that's a good idea right? I've just got to bite the bullet and get a new, reman, axle.

I'll have the newest '95/'94 850 there is before long :roll:. I've got another big weekend ahead of me.


- Lee

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