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2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

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jonesg
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jonesg

Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by jonesg » Sat Jun 20, 2020 8:26 am

I agonize whether to install a cigarette lighter.

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RickHaleParker
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Sat Jun 20, 2020 8:49 pm

Bolted in:
IMAG0003.jpg
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Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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bmdubya1198
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by bmdubya1198 » Sun Jun 21, 2020 8:44 am

Exciting! This is where the fun starts.
2000 V70R Venetian Red/Charcoal M56 Swapped 197k
2003 S60 2.4T Silver/Black 113k
2007 XC90 V8 AWD Sport Titanium Grey/Black 171k
1991 944 Turbo Dark Green/Beige 174k
1992 245 Base White/Beige 249k
2006 BMW 330i
1999 BMW 528i
Sold-
2000 S70 GLT Mystic Silver/Taupe 253k
1993 944 Base Beige/Beige 221k
1998 V70 GLT Black/Beige 199k
1998 S90- Silver/Gray 207k
1995 850 GLT Tropic Green... crushed
2001 S60 2.4T Black/Black 230k
1988 744 Turbo M46 Beige Metallic/Beige 188k

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RickHaleParker
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Mon Jun 22, 2020 8:08 pm

I am using the hard A/C lines from the XC90. The XC90 has two Evaporators. The S60 has only one. I cut off the excess lines figuring I could braze some Aluminum end caps on like I did decades ago. Looked high and low for the end caps. It is like they been vanished from existence. Any alternative ideas or sources for Aluminum end caps?

Small tube is 9.5mm (3/8") Dia. Large tube is 16MM (5/8") Dia.
IMAG0010.jpg
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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RickHaleParker
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Wed Jun 24, 2020 9:23 pm

jonesg wrote:
Sat Jun 20, 2020 8:26 am
I agonize whether to install a cigarette lighter.
Is it like the Paper or Plastic decision ... Electric or Butane?
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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volvolugnut
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volvolugnut

Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by volvolugnut » Thu Jun 25, 2020 1:21 pm

RickHaleParker wrote:
Mon Jun 22, 2020 8:08 pm
I am using the hard A/C lines from the XC90. The XC90 has two Evaporators. The S60 has only one. I cut off the excess lines figuring I could braze some Aluminum end caps on like I did decades ago. Looked high and low for the end caps. It is like they been vanished from existence. Any alternative ideas or sources for Aluminum end caps?

Small tube is 9.5mm (3/8") Dia. Large tube is 16MM (5/8") Dia.

IMAG0010.jpg
Machine your own end caps from Aluminum bar stock. Easy for anyone with a lathe, even a hobby lathe.
volvolugnut
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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RickHaleParker
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Thu Jun 25, 2020 3:56 pm

volvolugnut wrote:
Thu Jun 25, 2020 1:21 pm
Machine your own end caps from Aluminum bar stock. Easy for anyone with a lathe, even a hobby lathe.
I do not have a lathe not even a hobby lathe.

On the small one I found a socket cap screw that self threaded into the tube. However it is steel. I never brazed aluminum to steel so I do not know if that will work out. Thinking about sealing it with Loctite red. Then see if a can find the right size bolt to do the larger one.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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volvolugnut
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volvolugnut

Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by volvolugnut » Thu Jun 25, 2020 5:11 pm

How about this cap from McMaster Carr?

volvolugnut
Attachments
Capture 062420 mc.JPG
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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RickHaleParker
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Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Thu Jun 25, 2020 6:28 pm

volvolugnut wrote:
Thu Jun 25, 2020 5:11 pm
How about this cap from McMaster Carr?
Those are Copper. Copper - Aluminum junctions are highly susceptible to Galvanic corrosion. That green stuff that grows near the soldered joints of Copper water pipes.
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

User avatar
RickHaleParker
Posts: 4374
Joined: Mon May 25, 2015 2:30 pm
Year and Model: See Signature below.
Location: Kansas
Has thanked: 3 times
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RickHaleParker

Re: 2004 S60R B8444S (V8) conversion (Previously : Exhaust Manifold removal.)

Post by RickHaleParker » Thu Jun 25, 2020 6:39 pm

Options:
  • 1. Roll the dice with Loctite red.
    2. Roll the dice with aluminum brazing on Aluminum- Steel.
    3. Abandon the whole idea.
IMAG0021.jpg
--------
Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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