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960 engine swap

MikeHardy

The Sirius/Nova Police
Joined
Nov 29, 2002
Location
northern Wales, UK
started about 11am today. took a couple of breaks and a 2 hour chill at home in the middle. got it out by 7pm and did some tidying.

<a href="http://www.flickr.com/photos/14193327@N02/2671505517/" title="swap01 by minvie2000, on Flickr"><img src="http://farm4.static.flickr.com/3157/2671505517_e23d5a680e_o.jpg" width="1024" height="681" alt="swap01" /></a>

had to take the intake mani as it appears the exhaust with RHD hits the steering colum off and makes it difficult to get to the access hatch for the torque converter bolts so did it through the starter access.

<a href="http://www.flickr.com/photos/14193327@N02/2671505833/" title="swap02 by minvie2000, on Flickr"><img src="http://farm4.static.flickr.com/3293/2671505833_3dcceff3c7_o.jpg" width="1024" height="681" alt="swap02" /></a>


my dad possing with the engine

<a href="http://www.flickr.com/photos/14193327@N02/2672328656/" title="swap03 by minvie2000, on Flickr"><img src="http://farm4.static.flickr.com/3077/2672328656_0ea15c6ea0_o.jpg" width="1024" height="681" alt="swap03" /></a
 
Just a few questions,

How? Why? Where? Who? When? What?

And if not, why not?
 
the why is because it smokes like a steam train when the dipstick is pulled up. actuall worse then a steam train as they have at least have a break between chuffs.

who? my dad and i cause i put a plea for help and no one agreed to come so had to do it ourselves.
 
I bought it, fixed an oil leaks.. changed the oil and re-did the PCV system only to find out on a warm compression test yeilds 165psi on the highest cylinder and 111psi on the lowest. The fact that it smoked, and was the slowst volvo I've ever driven tipped me off.

The car looks like it had excellent care too:
medium.jpg


Timing belt was changed @ 56,000 miles and it was dealer serviced. Plugs were fresh, OEM filter etc. Lived its entire life in LA.

Obviously not all 6 cylinder whiteblocks are this bad, but there are enough not so great stories about these motors smoking and whatnot (keep in mind I'm bitter about it). At least I got the car for cheap!
 
yeah, this engine i've just taken out looks like a idiot has been servicing it. the support bracket from the AC to the alternator was missing (i know this as the new engine has one) all the mani to engine clips had be replaced by hose clips (4 hoses split, hence ally fleks on the 3-4 of the spark plugs). 2 of the fuel rail bolts were missing, mis-matched screws on the fuel rail

the new engine at 110k has none of these problems.
 
i spent a couple of hours today getting the new engine ready to go in. so going back over to put it in and replace all the the rad etc
fitted the alt and bracketry, plus moved her engine wiring loom from her old engine to her new one. didn't want to but the new engine is from a manual so is missing all the multi-plugs for the auto-box
 
started at about 11 today in the rain. got it in and got it bolted to the gear box after about 1.5hours. took a break for soup and toast, finished bolting things up and startined putting everything back. rain stopped during and carried on.

stopped for soup and chocolate ( :) ) before finishing off. runnings nice. could do with a couple of exhaust gaskets but that can wait for another time.
 
yeah it feels much more spritly then her old one. had a bit of a tick at start but it's been along time since the valve lifters in it have seen oil. went away with some warm up driving and trip to redline
 
oh yeah the all important after pic. sorry for the camera phone quality

<a href="http://www.flickr.com/photos/14193327@N02/2680889284/" title="after swap small by minvie2000, on Flickr"><img src="http://farm4.static.flickr.com/3240/2680889284_910dee36dc_o.jpg" width="1024" height="768" alt="after swap small" /></a>

PS spot the zipties turbobricks style
 
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