2.3l turbo prerunner

New member, already have a thread on turboford but going to post here as well. Like the thread says I'm building up a 2.3l turbo prerunner but with a twist..... I'm putting a volvo DOHC on as well. I was going to put it in my 97 regular cab but I really wanted an extended cab for the extra leg room (over 6 foot) and storage space. Well yesterday I found a 98 3.0 with rod knock and I decided to jump on it! Got it for 1000 bucks and i should be able to make double that on my other truck to aid in the project costs. so far I have modified my head already, its ready to go except for the locating pin holds need to be drilled out to match the block size.

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8457.jpg

custom exhaust manifold from a stinger top mount, still needs to be surfaced and change the angle of the t3 flange

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8445.jpg
http://i1258.photobucket.com/albums/ii524/ascentpro/100_8446.jpg

custom intake manifold, may need to be modified a bit more to clear the brake booster

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8450.jpg
http://i1258.photobucket.com/albums/ii524/ascentpro/100_8451.jpg
http://i1258.photobucket.com/albums/ii524/ascentpro/100_8452.jpg

custom 5 bolt to v-flange downpipe adapter, will make for easier turbo removal and exhaust fab

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8443.jpg
http://i1258.photobucket.com/albums/ii524/ascentpro/100_8444.jpg

these are some custom CP pistons, .020 over made to compensate for the volvo chamber size and valve reliefs

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8435.jpg

here is the turbo I'll be strappin on, its a turbonetics t3/t4 hybrid rebuilt by your truly with a 360 thrust bearing and also had a garrett compressor housing

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8437.jpg

this is an adapter I made to run the stock fuel regulator until I pony up for an adjustable one

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8434.jpg

and some knick knacks and doodads for fun

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8442.jpg
http://i1258.photobucket.com/albums/ii524/ascentpro/100_8441.jpg
http://i1258.photobucket.com/albums/ii524/ascentpro/100_8440.jpg

I've got major plans for her just don't want to give the details away too early , I'll post some pics of the truck when I pick her up today.

Picked up a 98 Ranger extended cab, only snapped one pic so far but here she is. does have some unfinished body work on the bed sides but oh well.

http://i1258.photobucket.com/albums/ii524/ascentpro/100_8464.jpg

For anyone interested in the volvo head swap here are some pictures of the difference in bore spacing between the block and head. Custom CP pistons make the valve reliefs big enough so that any piston can be used in any bore and still clear the valves.

Cylinder 1

Cylinder 2

Cylinder 3

Cylinder 4

Ok I have been busy and done a lot recently. I'll just go in order of the pictures I have taken. I picked up a taurus electric fan along with all the wiring off craigslist for 35 bucks. It works great, the only thing I haven't done yet is wire in the A/C request so it stays on with the A/C. Then I will also wire in a switch for highway cruising that will turn it off even with the A/C on.




I also installed a pedal assembly that includes the clutch pedal, right now there is a 3.0l with auto tranny but when I put the 2.3 in I will be installing a manual. Got the pedals from the jy and the tranny off cl.




I ordered a reconditioned crank kit from autozone, they had free shipping at the time so it seemed like the best option. They also told me the brand of bearings included so I knew they weren't chinese crap.




My fabrication abilities were somewhat hindered by the tools I have so after searching craigslist for awhile I finally found a welder I liked for a good deal. Every time I would call someone about a welder they would say it already sold after like 2 hours of being posted. I got mine like an hour after the guy posted the ad.



I customized an exhaust manifold for my application but when I tried fitting the turbo it wouldn't fit because it was angled into the cover. So I added a flange and angled it out so there is about an inch and a half of room between the turbo and the cover.



FINALLY after like 4 or 5 weeks I got my block back from the machine shop and then assembled the short block.







This last pic isn't my most recent, need to take some more. I've modded my tensioner for the timing belt some more and have sealed the cam tower with anaerobic sealer. Right now my oil pan is getting a bung welded in for the oil return on the turbo, also the exhaust manifold is being surfaced at the shop.

My oil pan is back from the weld shop so I bolted it up and filled her up with oil. Then I primed using an electric drill and walla! Oil is coming from the cam tower and out the turbo feed! Then I set up my timing belt and installed new spark plugs.

Volvo power! Thats what's up! Glad you opted for the volvo 16v head.....

Cool!

Now I actually have it timed correctly haha. Here is the front



Now I'm starting to figure out my wiring harness. I have most of it done already, the only problem I really ran into is the 1998 harness (truck I have) the alternator harness is integrated into the engine harness and the 1997 harness (harness I'm using) the alternator is separate. I need to get an alternator harness from a JY or make one from my 3.0 harness.

The sensor on the left is for engine temp to the ECU, the one on the right is the temp sensor for the gauge. This will feed one of the heater hoses, the other comes from the stock position off the water pump.



This is where my oil pressure sender for the stock gauge is located



Here is the same spot just the picture is farther out, the bottom line goes to the head and the top line is the oil feed for the turbo.



I have also been working on a bumper with built in hitch, it is not done yet but is mounted on the truck. I plan to get some 2" tubing, cut 2 sections about 2 or 3 feet long, bend each end 90 degrees, and the weld in on the back of the bumper on either side of the hitch. I also need to get a long flat piece of steel and inch and a half wide to go between the bumper and tailgate to fill the gap. Then I'm going to paint it all black.

You're WAY beyond my capabilities, but I'm a fan of your project.

Glad the FoMoCo ownership of Volvo is paying off in cool "underground" ways, lol.

Curious: what is the visible WELDED seam on lower portion of the head?

Thankyou! 3.slow is out of the truck now and ready for its new heart. The welded portipn on the head is where I added a block of aluminum. The head is somewhat shorter than the block and you eithernhave to weld like I did or plug the rear water holes in the block.you weld it angled down a tad so when you get the head milled it becomes flush with he rest.

It's been a while since I updated my build, I'm really close to starting up this week. Just waiting for some silicone couplers and a few other things.

Here's the truck ready to drop the motor and tranny.



the old 3.slow


motor out of my truck

a quick peak of the interior



motors in!!



the room between motor and fan


coming together




the flex tube for the wastegate



the downpipe, I'm going to wrap it.


this is the rest of the exhaust, just waiting for the clamp to connect it coming in the mail


this is where I added the return fuel line


the turbo I got is water cooled and the ranger had 2 lines coming off the heater lines that went into the intake manifold. They were perfect for connecting to the turbo. The driveshaft for the automatic is too short for the manual trans so I have another coming in the mail. I still have to run 2 more vacuum lines, finish the exhaust, need to fab a plate for the shifter bezel, finish the intake tubing and a few other things. All the wiring but the intake air temp sensor is done. I'm excited to fire her up!

IT STARTS! First try too! Well technically second, the first time the fuel connector came off because I didn't have it in all the way. And I know yall love proof so here it is! I disconnected the MAF because I'm still waiting for some couplers to finish the intake tubing but I wanted to see if it starts. I'm also still waiting on Some exhaust pieces, just running the downpipe right now.

http://s1258.photobucket.com/albums/ii524/ascentpro/?action=view¤t=100_8595.mp4

The truck has been out of commission for awhile, had a little mishap with a timing belt and ended up with bent valves. So I figured it was time to do some upgrades including one piece valves and new followers. Still in progress but here are some pics.

surgery started


continued


here's the problem


figured I'd do some cleaning up while I'm at it.

Took my head in to get guides replaced and have a valve job done, here she is finished.

Pretty clean .. Never thought the Volvo engine would have so much room to work.. Lol