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

Post by RickHaleParker » Tue Jun 30, 2020 7:32 pm

Set the Air cleaner issue aside until I get the rest together. That way I can measure the space I have to work with.

New issue radiator fan is too thick., Need to come up with a thinner one or some means to move the radiator forward.

In front of the radiator I got 2" where the Intercooler was. Radiator is 4" thick.
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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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volvolugnut
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volvolugnut

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

Post by volvolugnut » Wed Jul 01, 2020 12:04 pm

RickHaleParker wrote:
Tue Jun 30, 2020 7:32 pm

New issue radiator fan is too thick., Need to come up with a thinner one or some means to move the radiator forward.

In front of the radiator I got 2" where the Intercooler was. Radiator is 4" thick.
Aftermarket thin fans?
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 » Wed Jul 01, 2020 12:40 pm

volvolugnut wrote:
Wed Jul 01, 2020 12:04 pm
Aftermarket thin fans?
I hope.

Just ordered a 16" 1730 CFM that is said to be 2.5" thick. Thinking I'll install it on the front of the radiator where the the Intercooler was. AC condenser in front of the fan. That should move the AC service port back to where one can get to it. Fan control module can go where the 2.5L ECM and TCM was. I can use the 2.5L ECM box for mounting the FCM and it's cool system to keep the FCM cool.

Will really open up the front of the engine bay. Mounting a long air box across the top of the engine bay becomes a possibility. Pass the filtered air through a second custom box with the 4.4L TCM mounted on it.
--------
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 » Fri Jul 03, 2020 11:51 am

Ah shoot! Did I forget to grab something else when I got the Engine and Transmission?
Two One connectors and so have not found anyplace they go to.

Edit: Black is MAF.
IMAG0028.jpg
Last edited by RickHaleParker on Fri Jul 03, 2020 12:21 pm, edited 1 time in total.
--------
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 » Fri Jul 03, 2020 12:07 pm

Clearly they do not mate to each other.
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 » Fri Jul 03, 2020 12:40 pm

volvolugnut wrote:
Fri Jul 03, 2020 12:07 pm
Clearly they do not mate to each other.
I solved it. Black MAF, Square goes to the fuse box.
Could not find either at first because the MAF and Airbox are not installed. The cover was on the fuse box.
--------
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 » Fri Jul 03, 2020 1:30 pm

RickHaleParker wrote:
Fri Jul 03, 2020 12:40 pm
volvolugnut wrote:
Fri Jul 03, 2020 12:07 pm
Clearly they do not mate to each other.
I solved it. Black MAF, Square goes to the fuse box.
Could not find either at first because the MAF and Airbox are not installed. The cover was on the fuse box.
Take the rest of the day off. Have a celebratory beer, iced tea, whatever.
volvolugnut
2001 V70 T5, 1986 244DL, 1983 245DL, 1975 245DL, 1959 PV544, multiple parts cars.

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bmdubya1198
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bmdubya1198

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

Post by bmdubya1198 » Fri Jul 03, 2020 4:59 pm

Ah, I was gonna say the black one looked like it was for the MAF sensor. I found similar connectors in the engine bay on my mom's V8, but they go to the injector/coil harness from the looks of it. Engine was too hot to look at it carefully. Glad that was easy enough!
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 » Sat Jul 04, 2020 1:14 pm

The slim fan can in yesterday.

Options:
1. I could mount it on the back side of the Radiator but there would be only 1/2" of clearance between the fan motor and the exhaust manifold. Don't think the fan motor could take the heat.

2. I could mount the fan on the front side of the Radiator. Will require about 1.75" of stand off spacers in addition to the XC90 frame spacer. That will leave about 1/2" between the AC condenser and the back side of the bumper. Would be a good idea to find something to fill the void between the XC90 frame spacer and AC condenser.

The frame spacer is to fill the space where a intercooler would be on a XC90. If I could get my hands on a second one I could double stack them and forgo the standoff spacers. The only other one that I know of is 3 hours away in Oklahoma City OK. It was on the XC90 the engine and transmission came from. I may or may not still be there. I'm not inclined to do six hours of driving to find out.

PS: Can find the same frame in a 2007 - 2014 3.2L XC90.
Last edited by RickHaleParker on Sat Jul 04, 2020 2:40 pm, edited 6 times in total.
--------
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: 4392
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 » Sat Jul 04, 2020 1:21 pm

bmdubya1198 wrote:
Fri Jul 03, 2020 4:59 pm
Glad that was easy enough!
Was looking high and low for the right side Wheel speed sensor connector. Finally figured out the XC90 harness routes it all the way to the headlight then backtracks along side the harness for the sirens. That runs runs contrary to standard engineering practices. Because it requires extra copper with nothing gained.

I going to extract the wires from the harness and route it the S60 route.
--------
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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