1998 Volvo: Parts for Rebuilding 5 Cylinder Motor

[RussB]

That is some great info! What is the purpose of the NA manifold upgrade?

The N/A manifolds and throttle body are bigger, allowing more air in. With the 20T turbo and 3" downpipe Will is running that becomes important. To get power you need to get air in and air out

[Big Will]

After discussing it with the machine shop, we settled on that the first 50 miles were especially important and so we drove around Tucson without letting the engine sit in one rpm band for very long, doing some smooth pulls up hills and then letting the car pull vacuum for stretches coming back downhill.

My grandfather used to break in new engines by downshifting (automatic transmission, though it doesn't matter) and not using the brake as much as possible when stopping -- engine braking -- during the first few weeks of ownership. He said it helped distribute wear evenly in the cylinders/pistons/rings. He was an airline mechanic FWIW.

Thanks for adding this to the repair section - I was hoping it would make it there.

Your grandfather clearly knew what he was doing.
Driving the car in the city of Tucson itself helped in terms of constantly needing to shift gears. Probably the worst thing we could have done would have been to just take a 50 mile highway cruise.

Russ - w/ regard to the Ohlins, I know some people who have actually had the lines shortened and I will probably do that when they need to be rebuilt someday (I recently recharged them with nitrogen gas as they were a bit low after 10 years of service). Short of having the line shortened, you can bow the line out toward the front of the car rather than having them run along the brace and that gives you probably 6 inches on each side to bring them away from center.
You could certainly also mount them along the sides of the engine but you would probably have to be a little creative in making a bracket. I imagine on the driver's side, you could mount one inside the heat shield of the intake if you have the EST or IPD ones - there's definitely enough line for that.

[RussB]

I wonder how hot they get? They could be easily checked with one of those infrared temp gauges. I know I check all sorts of things with mine, from brake rotors to roast turkey!

[div4scpro]

Hi,
Saw that you put a DO88 intercooler in during your project. Would really be interested in any details of that install; problems, tips, tricks, etc. Already using your post info for the rear subframe rebuild.
Thanks, Andy

[Big Will]

Hi Andy - sorry just seeing your post as I haven't been on the forums in a while.
Glad the rear subframe info is helpful. I think I replied to you on another forum regarding the bushing you were having trouble finding...any luck?

I have to admit that since the Volvo dealer saved Ben and I some time by removing the lump and reinstalling it on their lift (we then picked it up with a pickup truck and did all the work), the dealership was given the intercooler and rebuilt steering rack and installed them while we were working on the engine. My understanding was that the intercooler was very easy to install and came with everything but the supplied bolts were too long and had to be cut...not sure if that was just a one-time error by do88 or if that's a common issue.

[surfy]

hi Big will
do you have any idea of parts suppler who will supply total parts as you have listed as a rebuild kite?. Im in Australia and having no luck with needs for my 1997 v70 20v non turbo I would like to rebuild . we purchased from new and still going at 380,000km,s but so tired now.
thanks
Graham