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