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Volvo 242 T5 Build Sheet

Category Part Part Type Link
Engine
Volvo T5 engine swap with lots of custom fabrication to make it all fit and function
'98 850 T5 (B5234T) head
lightly ported & matched to RN intake
OEM
'99 S70 T5 (B5234T) block
late version w/ crankcase windows; shimmed liners
OEM
Wiseco 81.5mm pistons & rings
Aftermarket
Maxpeedingrods H-beam connecting rods
139.5mm long, sized for B5234T; w/ ARP bolts
Aftermarket Shop
NA cams
intake 7° ret; exhaust 5° adv.
OEM
960 oil pan, transfer tube & dipstick
pan and transfer tube are shortened & welded; support ribs shaved for crossmember clearance; 10AN oil drain & 1/8NPT oil temp ports added; no modifications to dipstick tube
Modified OEM
'07 S60R intake manifold
plenum shortened to clear S70 steering pump
Modified OEM
ATP Turbo C30 cast exhaust manifold
ceramic coated with Cerakote Air Cure; EGT bung added to collector
Aftermarket
Gates Racing timing belt
T331RB; kevlar-reinforced
Aftermarket
Volvo 260 right side diesel mounts
1272346; used on both sides
OEM
Custom engine mount brackets
bracket drawings available for download
Aftermarket Shop
Mann ProVent 200 oil separator
routed to intake & oil pan with check valve
Universal Shop
Bosch FR7DPP+ spark plugs
OE Volvo plugs direct from Bosch
OEM Shop
Turbo
Turbosmart UltraGate 38mm external wastegate
TS-0551-1012; custom stainless hardlines
Universal Shop
Garrett GTX3067R
ceramic coated .82 A/R turbine housing
Aftermarket
32"x12.5"x3.5" intercooler w/ 2.5" inlet/outlet
for Evo VIII; made by CX Racing; added mounting posts
Aftermarket
Exhaust
3" TIG welded 304 stainless exhaust
with cat & 2 Vibrant mufflers; mandrel bends, no pie cuts
Vibrant 1103 3" oval muffler
mounted behind fuel tank; 5" x 9" x 15" body; 20" overall
Aftermarket Shop
Vibrant 1142 3" ultra quiet resonator
mounted in front of axle; 6.5" x 4.75" x 9.75" body; 13.75" overall
Aftermarket Shop
Magnaflow 3" catalytic converter
Aftermarket Shop
Engine Management & Wiring
MaxxECU Race w/ custom harness, ethrottle; see video for complete details
MaxxECU Race
lambda, knock & EGT monitoring built in
Universal
Custom wiring harness
built from MaxxECU universal harness with Raychem DR-25
Bussmann sealed relay and fuse panel
15305-4-0-4; accepts mini fuses & micro 280 relays
Universal
Saab ethrottle pedal
Hella 6PV 010 946-141
OEM
'07 S60R ethrottle valve
Bosch 30711554
OEM
MAC 4-port boost solenoid
Universal Shop
Cooling
Wider OEM radiator with PWM cooling fan; watch video clip for details
'01 S60 PWM cooling fan
30680547; allows for gradual ramp of fan speed, less shock to charging system; mounting tabs trimmed & deutsch connectors added
Modified OEM Shop
92+ 940 NA radiator
Nissens 8603905; fits 240 using wider set of factory mounting holes + clearancing lower tabs on radiator
Modified OEM
Fuel
E85 flex-fuel system with single in-tank pump
Injector Dynamics id1300x2 fuel injectors
1300cc injectors rated for ethanol
Universal
Modified S70 fuel rail
machined for factory FPR, 6AN inlet, 1/8NPT sender
Modified OEM
'98 S70 T5 3 bar FPR
OEM
Deatschwerks DW300 fuel pump
in-tank pump mounted in original sending unit
Universal Shop
Transmission & Driveline
Getrag 265 5-speed manual swap & Trutrac locking differential; watch video clip for details
Getrag 265 5-speed transmission
found in mid-to-late 80s BMW E24 & E28 with removable bellhousing
OEM
Volvo 960 automatic transmission bellhousing
OEM
Custom adapter plate
connects Getrag 265 trans & Volvo 960 bellhousing
Volvo 850 single-mass flywheel
OEM
BMW E34 M5 clutch disc
Sachs 240mm full-faced organic clutch disc that is strong and easy to drive
OEM
Sachs Racing 707 pressure plate
slight clearancing required to mounting holes
Aftermarket
Tilton 60-1100 clutch release bearing
hydraulic concentric bearing located on transmission input shaft inside of bellhousing; custom teflon braided stainless lines to bulkhead fittings
Aftermarket
E36 M3/E34 M5 giubo
heavy-duty flex disc that matches the Volvo M47 driveshaft bolt pattern
OEM
Lengthened Volvo 240 driveshaft for M47 trans
bolt pattern matches the transmission, but it is too short to reach, so it will need to be lengthened and rebalanced
Modified OEM
J9fab driveshaft support bracket & Volvo 940 bushing
more rigid than OE Volvo 240 driveshaft support bushing
Aftermarket
Modified Getrag 265 shifter bracket
spaced 1.25" from transmission mounting tabs; mounted through 240 floor with e46 M3 trans mount secured in a 8mm hole drilled at rear side of shifter hole
Modified OEM
Garagistic DIY shifter
shift selector, joint & tall lever
Aftermarket
BMW E46 M3 transmission mounts
stiffer rubber mounts with longer stud to clear thick transmission mount arm
OEM
Trutrac torsen locking rear differential
3.73 ring & pinion
Aftermarket
Custom 12 tooth trigger wheel
cut out of 16awg steel and welded to differential carrier
Front Suspension
Thoroughly worked over; watch video clip for details
GAZ Gold adjustable coilovers
better than Koni, Bilstein, BC Racing options
Aftermarket
336lb 8" x 2.5" main springs
Aftermarket
6" hyperco helper springs
Aftermarket Shop
Custom offset strut mounts
inspired by Volvo Group A racecar design; bearings added
Boxed 240 Control Arms
standard 240 control arms with yoshifab reinforced plates welded on
Modified OEM
STS Machining Delrin Control Arm Bushings
Aftermarket
BNE Dynamics Quick Steer Roll Correction
V2 QSRC spacers with adjustable Ackerman
Aftermarket
BNE Dynamics Adjustable Swaybar Endlinks
Aftermarket
STS Machining 28mm drop swaybar
drop gives extra clearance for shortened 960 oil pan
Aftermarket
Rear Suspension
Thoroughly worked over; watch video clip for details
Shortened Volvo 240 trailing arms
cut, overlapped, and welded back together 20mm shorter to center rear axle in fender after lowering ride height
Modified OEM
BNE Dynamics Hybrid torque rods
with Genuine Volvo rubber bushings; adjustment allows you to correct pinion angle after lowering and moving rear axle
Aftermarket
Adjustable 5" spring perches
universal part from Speedway Motors modified with plate welded to base for mounting to trailing arm
Universal
200lb 5" x 9.5" Eibach springs
Universal
5" polyurethane spring pads
reduce noice from springs moving on steel perches
Universal
Gaz adjustable shocks
40mm shorter than stock
Aftermarket
Volvo 240 wagon rear swaybar
slightly less body roll for tradeoff of slightly less rear traction at limit; good for street, maybe not track
OEM
iPd adjustable panhard bar
recenter the axle (left to right) after changing ride height
Aftermarket
Genuine Volvo front trailing arm bushings
always use Genuine Volvo rubber here.
OEM
BNE Dynamics spherical rear trailing arm bushings
maximize traction and handling by allowing full axle articulation; always use spherical or OE rubber bushings here; never use polyurethane in 240 trailing arms.
Aftermarket
Chassis Bracing
The best factory braces + group A inspiration; watch video clip for details
GT firewall braces
1978 Volvo 242 GT factory reinforcement
OEM
Cravingboost strut brace
NLA, limited run inspired by Group A
Aftermarket
iPd lower chassis braces
thicker replica of 1978 Volvo 242 GT lower braces that reinforce between the two control arm mounting points on the chassis and crossmember
Aftermarket
Brakes
6 piston/4 piston calipers on 330mm rotors; watch video clip for details
'04-07 Volvo S60R brake rotors
330mm front and rear
OEM
'05-08 Porsche Cayenne V8 calipers
6 piston front (17z) & 4 piston rear
OEM
17z caliper adapter kit
caliper & brake line adapters designed by Homer; now available through BNE Dynamics
Aftermarket
iPd stainless brake lines
Aftermarket
Bosch Quietcast pads
pads for '05-08 Porsche Cayenne V8
OEM
'94 Ford Mustang master cylinder
Volvo 240 reservoir fits when spaced out with 2x o-rings per port; Mustang reservoir designed to mount on an angle & seeps fluid when mounted horizontally in a 240
OEM
Wheels & Tires
Lightweight BBS wheels in E36 BMW spec adapted to fit
BBS RC305 17x9 ET32
lightweight wheels (17lb each); 5x120 PCD; barrels barely clear 17z calipers
Aftermarket
Motorsporttech hubcentric wheel adapters
mount 5x120 wheels to 5x108 hubs
Aftermarket
Pirelli P Zero Nero GT
245/40R17 square setup
Aftermarket
Interior
Recaro LS-B seats
from mkII VW, black leather & new bolster foam
Modified OEM
BNE Dynamics Recaro Seat Brackets
bolt Recaro seats onto Volvo 240 seat sliders
Aftermarket
Custom door cards
1/4" HDPE + Suede
'87 Volvo 240 dash
flocked using Flock It Kit
Modified OEM
Momo 360mm steering wheel
R-Sport style on hub with 2.5” spacer
Aftermarket
Sound deadening
Rattletrap + closed-cell foam + MLV under black carpet
Universal
Exterior
8" round H4 E-Code headlights
with 12ga relay harness
OEM
GT driving lights in grille
with 12ga relay harness, 100w bulbs
OEM
Volvo #477 Electric Silver paint
repainted in 2006 Volvo S60 color
OEM
Shaved body moulding & trim
beltline moulding, rocker moulding, c-pillar trim & trunk lock all shaved by previous owner
Rolled fenders and widened rear wheel tubs
lips were rolled flat on front and rear fenders; rear tubs were sectioned and pushed out ~1" wider at the back side

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Torque Specifications for Volvo T5 engines

Values are for the B5234T engine used in the Volvo 850 & S70 T5; however, most apply to newer RN engines as well.

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General torque reference

No spec available? Here's a general reference for torque by fastener size.

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