Short update

Picked up another trans from a place in Kalamazoo.  It has a 90 day warranty so here's hoping it works this time.  This week we will be taking everything apart, pulling the engine/trans (again), and installing the new (used) transmission. 

Sad face :(

Consensus is that my no-shift issue on the transmission is a broken shift fork.   This is an internal problem on the transmission and cannot be fixed easily.  Since M56 gearboxes have a separate shifter fork for the 1/2 gear pack, it makes sense that 1/2 aren't engaging while the rest of the gears are.  Time to find another transmission. 

Pic update

Updated pics...well, it doesn't look like this right now while I still sort out my transmission issue but gives you an idea:

Intercooler routing, tons more pics but these are the interesting ones

 Wiring for boost gauge, wideband hidden:

EST intake

EST exhaust shortened to fit, about 4" of extra pipe needs to be cut for a trim fit

It lives!

IT RUNS!  Started on the first try.

But (of course there's a but) 1st and 2nd gear aren't engaging now that we dropped the car off jackstands.  3rd, 4th, 5th, and R all "click" when they engage but first and second don't feel like they're connecting.  The shifter feels like jelly and not slotting into place.  I'm really hoping that the cables need to be loosened or something simple like that.  Seems to be a semi common issue for those who do manual swaps that the cables get too tight and out of alignment.

And for some reason during the swap my amplifier/radio harness stopped working? This is why I keep spares around, I guess.

Have many pictures and a video of the first start, but left the camera at the car.  Will try and get those up over the weekend.

Almost there!

Amazingly, the contents of that box were not damaged. 

Got the sheared bolt removed (Thanks again Chuckran Auto Parts) and the downpipe now attached
All intercooler piping routed/cut to fit
Electronic Boost Controller, Air/Fuel wideband, and boost gauge have all been wired and installed

Watch for video of the first start shortly!

Siliconeintakes made right on their screwup and has overnighted me the right parts...intercooler should be run tomorrow, shooting for a Wednesday fire up.

And got this today too, love the Postal Service...I guess they played kickball with my package?

Setbacks :(

Well, this weekend's goal of a fire up didn't materialize.

It turns out that Chuckran Auto Parts (Bridgewater, MA), the place I bought the engine from, removed the stock turbo downpipe incorrectly.  They sheared off a bolt inside the turbo housing and we just discovered this today.  This sheared bolt is preventing my downpipe from being bolted on.  This is exactly the kind of problem I didn't need right now.

On Friday, I also discovered that the intercooler I bought is about 1.5" to tall to be used without cutting the frame support.  Luckily I found another smaller intercooler on the local ricer forum.  It's an Ebay special and the quality is really nothing compared with my Treadstone.  For now it'll do, but I'll definitely be replacing this sometime in the future.

Finally, big thanks to silicone intakes(.com) for sending me the wrong silicone coupler. 

While progress is temporarily stopped for these problems to be dealt with, here's a progress pic for those of you following along.  Hopefully more updates this week.

No pictures this time, but made some real progress over the weekend.

-Got the clutch bled and ready to go
-Eurosport exhaust has been test fit, with some minor modifications it will be on for good.
-Front tie rods and endlinks replaced.

Shooting for an end of the week fire up!

Hard Part is Over

Still a while yet before it's running.  Going to hit it hard this week and next to try and get it finished up.  The hard part is done now though, it's all little stuff from here on in. 

But in other news...got the engine/trans in yesterday.  After installing the 99+ style front engine mount bracket everything dropped right in. 

And my favorite picture of the build so far  :)

Old Engine Extraction: Complete

Old engine has been lifted from its resting place of 13 years.

And added the crucial third pedal.

Engine almost done!

Got some more work done on the motor this week.  Installed new timing components, new OEM rear main seal, and got the R manifold bolted up.  Even though most of the older (98-style) accessories are being retained, I stuck with new style (mechanical) timing components for their longevity (100K service interval vs. 70K on the older style). 

Old timing belt removed...

Old components, including plastic impeller water pump:

New components - metal impeller water pump:

New components installed:

Cleaned up the exhaust ports, installed one of Robbie's single-piece exhaust gaskets, and installed the higher flowing S60R exhaust manifold.  All new studs and lock nuts were used in this step (washers are original, no need to replace those).  I'm still not sure why my exhaust manifold has that pinkish color, but it doesn't matter much either way.

Few photos from work today

The "parts" motor - notice the hole in the block!

The heart of the project - 2000 V70R engine, stripped down and waiting to be reassembled with new seals and hardware

Introduction

I've had my S70 for just over 8 years now.  Being a non-turbo car, however, means that pretty much every modification done so far has been cosmetic or suspension related.  Given this, I decided that I wanted to take the project one step further - and do a turbo engine swap. 

Many of you know that this has been in the works for quite some time, but for those who don't, this thread is here to chronicle the progress made as I complete this project.  First and foremost, big thanks to Matt for donating his garage and help with this project  Also thanks to Tom for picking up the motor for me and shipping it.  Also thanks to everyone else who's been answering my questions as I've been going about this - too many of you to name, but you all know who you are.

GOAL: To have a daily driver putting down about 300 horsepower at the wheels.  This is not a weekend or track day toy so nothing exotic like a built motor.

HARDWARE:  Here's a partial list of what's going into this car.  I'm leaving more minor items and all the maintenance items off the list, but if anyone comes across this thread in the future and has questions about what component was used (IE, OEM v. Aftermarket) feel free to ask.

Engine/Drivetrain:
2000 Volvo V70R 2.4L Motor (95K miles)
Volvo M56H 5-speed manual transmission
Volvo Euro 850R Clutch (PN 272218)
Volvo 19T Turbo
Volvo S60/V70R Exhaust Manifold (PN 30637921)
Volvo/Bosch "Green" Injectors (475cc)
Volvo 98-style intake manifold port-matched to 00 block
Turbosmart Kompact Blow-off Valve with custom piping/recirc parts (Thanks Hussein!)
Bay Valve Service CBV Blanking Plate

Engine Management:
IPD Stage III T5M ECU
Turbosmart Eboost2 Electronic Boost Controller
Auto Meter 3378 Air/Fuel Ratio Gauge
Blitz Illumi-Drive Analog Boost Gauge



Other Performance:
IPD/CJ 3" Stainless Steel Downpipe
EuroSport Tuning 2.5" Cat-Back Exhaust
Simota Carbon True Cold-Air Intake
Treadstone TR8 Front-Mount Intercooler w/2.25" IC Piping
Stylin' Motors Radiator Hoses and Vac Kit
QuickBrick Motorsports Phenolic Intake Manifold Spacer
IPD Front/Rear anti-sway bars

Here are a few pictures.

First, what this car started out as:

What it looks like now: