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Sanatarium's 1997 855 T-5 Adventure

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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Sanatarium
Posts: 20
Joined: Sun Apr 19, 2015 10:34 pm
Year and Model: 2010 C30, 97 850 T-5
Location: Phoenix
Has thanked: 3 times
Been thanked: 2 times
Sweden
Sanatarium

Sanatarium's 1997 855 T-5 Adventure

Post by Sanatarium » Mon May 04, 2020 9:35 am

Written June 2015:

Decided to join the club! With the 850 on the verge of becoming a classic car, I really wanted to grab a nice one before they are all gone, or are in such bad shape that they need a full restoration. So I have been hunting for about 3 years to find a good candidate and in Mid-April I finally founds the one!

My needs were, T5 or R, and wagon, and preferably black interior. My intents are road trips, car camping and dogs, and the occasional home depot run. The 850 wagon is the perfect fit.

I have always enjoyed the 5-cylinder whiteblock motor and have owned and worked extensively on several cars with whiteblocks, I fully expect this car to run until a minimum of 300k miles.

Anyway, the car I found is a 1997 850 T-5 Wagon, mystic silver, black leather interior. 109k miles, second owner. The first owner was the grandfather of the second owner! The only problem: it was in Portland. Now, this is not really a problem because I love portland, and jump at the chance to visit, however I live in phoenix, so a 26 hour drive is no joke! So I got a Southwest airlines flight and filled two suitcases with camping gear and tools and brushed up on RobertDIYs videos in case anything went wrong on the car. I flew to Portland on May 6th, completed the sale, had lunch at Deschutes brewery(my favorite!) and hit the road.

Some pictures from the drive:

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Just after purchasing! The owner picked me up from PDX and we made the sale right there in the cell phone lot!

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Downtown Portland after picking up the car

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Of course I had to Swedify the car right away! I happened to have a Dave Barton Swedish Flag decal on me so I put it on the back of the car.

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On the way from Portland to the coast, I found the Evergreen Air and Space Museum, naturally I had to stop!

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Spruce Goose


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I camped all the way down the Oregon coast

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Early morning shot

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Cape Perpetua, great place!

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Klamath River RV Park, another one of my favorites!

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Cruising through Redwoods Natl' Park.

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Anyway, It was a great trip, and I am looking forward to being a long time wagon owner.

At the moment, the car is in my garage getting a full Stage 0 overhaul, PCV, Plugs, Wires, Distributor, Cam Seals, Filters, Oil, etc etc as well as a good deep cleaning of the engine bay. The PCV had been leaking for a long time, but luckily the cam seals were the only thing pushed out, no leaks at the rear main seal observed, hopefully I caught it in time.

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Sanatarium
Posts: 20
Joined: Sun Apr 19, 2015 10:34 pm
Year and Model: 2010 C30, 97 850 T-5
Location: Phoenix
Has thanked: 3 times
Been thanked: 2 times
Sweden
Sanatarium

Re: Sanatarium's 1997 855 T-5 Adventure

Post by Sanatarium » Mon May 04, 2020 9:37 am

Sept 2015:
Did some minor work on the 850. Been driving it every day while the C30 gets pampered in the garage. I had some time though finally to detail the 850, cleaned the interior, clay bar + wax on the exterior, aerospace 303 for all the rubber trim, and meguiars 'ultimate black' I think is what I used on the bumper trim

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Also, I had time to install the IPD poly firewall bushing kit and my one-off aerospace grade upper torque link.

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Sanatarium
Posts: 20
Joined: Sun Apr 19, 2015 10:34 pm
Year and Model: 2010 C30, 97 850 T-5
Location: Phoenix
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Sanatarium

Re: Sanatarium's 1997 855 T-5 Adventure

Post by Sanatarium » Mon May 04, 2020 9:38 am

October 2015:
Well, over the last couple days I overhauled the cooling system on the 850. Replaced all hoses and the heater core, and did the firewall coupler delete. I used the 5/8" gates heater hose that has been suggested in other threads and cut the aluminum heater core hard lines in half. I didn't feel comfortable connecting the heater hose to smooth tubing though so I turned some little beaded tube ends and TIG welded them in place.
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These were the original hoses stamped 10/96 or so. Wow! Those never would have lasted in AZ. This car lived its life in Portland until recently so that is the only thing that saved it.

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New coolant tank and fresh coolant too
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All buttoned up
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Sent from my Nexus 4 using Tapatalk

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Sanatarium
Posts: 20
Joined: Sun Apr 19, 2015 10:34 pm
Year and Model: 2010 C30, 97 850 T-5
Location: Phoenix
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Sanatarium

Re: Sanatarium's 1997 855 T-5 Adventure

Post by Sanatarium » Mon May 04, 2020 9:39 am

March 2016:
Added a new boost gauge, has a greenish backlight that matches the Volvo cluster very well

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Sanatarium
Posts: 20
Joined: Sun Apr 19, 2015 10:34 pm
Year and Model: 2010 C30, 97 850 T-5
Location: Phoenix
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Sanatarium

Re: Sanatarium's 1997 855 T-5 Adventure

Post by Sanatarium » Mon May 04, 2020 9:39 am

Jan 2018:
An updated picture from last year with 17" Pegs, stock suspension. Image

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Sanatarium
Posts: 20
Joined: Sun Apr 19, 2015 10:34 pm
Year and Model: 2010 C30, 97 850 T-5
Location: Phoenix
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Sanatarium

Re: Sanatarium's 1997 855 T-5 Adventure

Post by Sanatarium » Mon May 04, 2020 9:42 am

June 2018:
Small update, Mamba is still waiting on a shipment of 19T compressor housings so I don't have the turbo yet. I did get the KW V2s in after a 7-week wait from germany, they were out of a couple components and had to build a fresh set for me I guess. They came packed very well! Working on the install now. Hope to finish this week. ImageImageImageImage

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Sanatarium
Posts: 20
Joined: Sun Apr 19, 2015 10:34 pm
Year and Model: 2010 C30, 97 850 T-5
Location: Phoenix
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Sanatarium

Re: Sanatarium's 1997 855 T-5 Adventure

Post by Sanatarium » Mon May 04, 2020 9:43 am

Current update: We had a baby last summer and I changed jobs as well, so I haven't had much car time.
Since summer 2018 I have been planning a turbo upgrade and the long term 'form' of the car.
Fall 2018 - Spring 2019 - Parts acquisition
I began researching K24 upgrades as I wanted a direct fit turbo with OEM availability, this is not my primary daily driver but I want to keep it in the neighborhood of daily drivership. The K24 was used on various P2 models including the S60/V70R and some T5 models I believe. It is a well designed turbo that is available, fairly inexpensive, and a great match for the P80 platform.

Parts list:
K24 Turbo Lines:
Oil supply line: OEM 30637731 or Mamba S60R braided oil feed line kit, or build your own, 31439471
https://jjfab.net/turbo-parts/1-volvo-k ... lange.html
I ended up using the Mamba Turbo braided oil line for ease.

Oil supply gasket: 30677842 11994
Oil drain line: 30637732
Oil drain pipe seal: 31251439
Water line: 30713927
Water line until 2004: 8692530
Water line from 2005+: 8692365
Coolant Banjo bolt(2x): 973950
Coolant Copper washer(4x): 11994

Main coolant line to water pump housing seal: 30670570

-K24 Oil drain line is a bolt on
-Oil feed line needs some bending because the pre '99 block has oil "squirt windows" in the way.
-Water line under the turbo needs a bend also, otherwise it touches the engine/tranny mount.
-Stock main water line across back of the engine will not match with the K24 due to compressor housing being larger. Mod original or go for the R/260HP T5 version.
-Custom intake plumbing size needed as well. K24 inlet size 7cm
I opted for the Snabb 850 K24 intake, 960 MAF housing, and an AEM Dryflow 21-2038DK, which is a 3" opening, 6"x8" round filter.

For the exhaust hardware:
Downpipe flange gasket: 30650969
Downpipe Stud(3x): 1357769
Downpipe Nut(3x): 977209
Turbo flange stud(4x): 1336261
Turbo Flange nut(4x): 977209
Turbo flange gasket(1x): 8642450

Here I opted to ceramic coat my IPD downpipe and ceramic coat an R Manifold as well. Also added a wideband sensor bung to the DP.

Exhaust manifold:
Gasket(P1 platform): 8699467 (Do not install upside down!)
Stud: 982667 M8x1.25x50
Washer: 419401
Nut: 985868
Main waterline to block gasket: 1236119

Finally, I opted for the S60R waterline, a bolt on. I had to cap the line that normally goes to the oil pan heat exchanger on the newer models. In case I upgrade to an RN oil pan or RN motor at any point, I left it intact and just welded the end shut with some stainless filler wire.

For supporting mods,
DO88 intercooler and RIP kit
DO88 radiator
Deatschwerks DW200 fuel pump
Bosch Green Injectors

Other misc work:
Repaint front and tear bumper covers
Build 1" lift blocks for rear(KW coils don't sit high enough for my taste. Thinking it's a wagon vs sedan thing)
AEM X-Series wideband
New headlight lens

Here is a photo of the car in spring 2018
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Sanatarium
Posts: 20
Joined: Sun Apr 19, 2015 10:34 pm
Year and Model: 2010 C30, 97 850 T-5
Location: Phoenix
Has thanked: 3 times
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Sanatarium

Re: Sanatarium's 1997 855 T-5 Adventure

Post by Sanatarium » Mon May 04, 2020 9:44 am

Current update:
The K24:

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Last car wash, July 2018
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At this point I stopped driving the 850 and was working 16 hour days on my small business doing steel fab work. Fast forward to June 2019:

Ceramic TBC(thermal barrier coating) for the R Manifold and IPD downpipe
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Mockup, June 2019
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Size comparison with the dirty old 15G. Not the best photo but I will say the K24 is a beast next to the little hairdryer.
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Do88 IC and Radiator sandwich, spring 2020Image


Misc parts to finish off the job
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Finally remembered to take a photo, this is spring 2020 now. Quarantine and furlough time has given me the ability to finish this project!!!
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Turbo and manifold installed
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Greens
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AEM X-Series wideband
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At this point I am actively working with [email protected] on the tune. I have been working with him in planning for almost 2 years, I am sure he was happy to finally get paid when I bought the tune! Big shout out, highly recommend Vast.

Coming together. Vast ECU with boost logging connected, RIP kit, IPD filter still on for now, going to make sure everything works right before moving to the larger MAF housing and filter.
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Vovo
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More to come!

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kallekula
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Year and Model: S70 2000
Location: Orange County, CA
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kallekula

Re: Sanatarium's 1997 855 T-5 Adventure

Post by kallekula » Mon May 04, 2020 11:21 am

Great post man, love all the pictures! 👏
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Sanatarium

BMW 540i 2002
S70 Base 2000
S40 T5 2004.5 (For Sale)

madsking
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Joined: Tue Dec 10, 2019 5:29 am
Year and Model: 96 850 T5
Location: Denmark
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madsking

Re: Sanatarium's 1997 855 T-5 Adventure

Post by madsking » Mon May 04, 2020 11:52 pm

Wonderful

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