Homer's 1990 240 redblock exorcism

[HiSPL]

In a world where people are paying 400 bucks for Ben’s qsrc’s, this doesn’t seem too out of line.

 

[Homer]

A new project is brewing in the garage... an engine!
I'm going for more mid range power, more top end, better response, no burning oil, and least likely of all, no oil leaks.

Engine:
-R head (Dual VVT) - Gotta sort out the cam sensor clearance, prob going to roll my own trigger wheels to use the 850 style cam sensors
-2.4L block - boring out to 2.5 (I know, the horror)
-Mahle motorsport 83mm pistons - sold as a Mk2 Focus RS PN, a shop in the UK had a set sitting on the shelf collecting dust.
-K1 rods
-TSP700 cams and valve springs
-Ported head (TBD)
-E-throttle


Time to retire the VEMS, it's been flawless but I've reached the limit of I/O, I want solid knock control, ethrottle, no soldered on jumper wires, and good documentation.

-Maxxecu Race Gen 2
-Life Racing PDUX2
-New wiring harness


I figure I've gotten more than enough life out of the 2.3L T5 engine in the car. 70k miles under my tutelage plus another 100k when i bought it in 2010 from the Buchkas. It makes good power, runs smooth and burns/leaks a bit of oil. I'll be selling the engine nearly complete when I'm done with this. Might just be great for someone looking to do a whiteblock swap.

Maybe I'll have this done by summer? Idk, trying to keep this at a fun pace. I'll do better to document this I promise.

-Jacob






Rando clean E46 in Pescadero

 

[Harlard]

Sweet.

 

[doucheNozzle]

Nice!
Are you going to shim the block? Blockguard?

 

[DET17]

And what of the $240 transmission? Has the M90 been replaced?

 

[andyb5]

A new project is brewing in the garage... an engine!
I'm going for more mid range power, more top end, better response, no burning oil, and least likely of all, no oil leaks.

Engine:
-R head (Dual VVT) - Gotta sort out the cam sensor clearance, prob going to roll my own trigger wheels to use the 850 style cam sensors
-2.4L block - boring out to 2.5 (I know, the horror)
-Mahle motorsport 83mm pistons - sold as a Mk2 Focus RS PN, a shop in the UK had a set sitting on the shelf collecting dust.
-K1 rods
-TSP700 cams and valve springs
-Ported head (TBD)
-E-throttle


Time to retire the VEMS, it's been flawless but I've reached the limit of I/O, I want solid knock control, ethrottle, no soldered on jumper wires, and good documentation.

-Maxxecu Race Gen 2
-Life Racing PDUX2
-New wiring harness

Awesome, can't wait to see your progress. Can you share more info on the cams / valve springs? I haven't heard of those and would like to keep them in mind for my setup at some point down the road.

Will you be using the Maxxecu pre-terminated engine harness, or building your own?

Staying with the same exhaust manifold / turbo?

 

[blkaplan]

that Maxxrace gen 2 look so sweet. We got the race unit going and i love it. You do use up alot of the I/O in a hurry

 

[Homer]

Nice!
Are you going to shim the block? Blockguard?

No plans for that

And what of the $240 transmission? Has the M90 been replaced?

Still rocking the M90, at some point it'll get swapped with a BMW 6 speed. Not sure when that'll happen.

Awesome, can't wait to see your progress. Can you share more info on the cams / valve springs? I haven't heard of those and would like to keep them in mind for my setup at some point down the road.

Will you be using the Maxxecu pre-terminated engine harness, or building your own?

Staying with the same exhaust manifold / turbo?

TSP700BRC	Duration In Crank Angle: 280 Valve Lift: 10.5

Springs are made for these cams.

Building my own harness.

Same exhaust manifold, I'm waffling on the turbo, it needs rebuilding. The newish G30-660 looks nice.

 

[Harlard]

I’d pick an EFR7163 over a G30 (sorry Duder).

 

[cosbySweater]

Awesome man, The G30-660 is a sweet turbo. I have a g42-1450 going on my V8. They seem to perform really well. Even my old GTX now that I got the car and everything all figured out is a ripper.

 

[Ne7RideR]

Awesome man, The G30-660 is a sweet turbo. I have a g42-1450 going on my V8. They seem to perform really well. Even my old GTX now that I got the car and everything all figured out is a ripper.

>G42-1450 good lord. Can't wait to see what this combo puts down

 

[Homer]

I've settled on a G30-660 a big bonus is not having to modify the downpipe and T3 header flange.


Bought a set of the A.S.S. engine mounts with softer poly bushings, way more clearance for the later style AC compressor and they just bolt in! (later block doesn't work with my homerfab mounts). Driver's side needs a little clearance between the accessory bracket and the mount


Cam sensors, did some digging and the best combo seems to be an RNC trigger wheel (07-13 i think) and just mod the cam cover to accept a ZF/Cherry thread in hall effect sensor (and throw on some thread sealant of course). I want to avoid welding on the cam cover that close to the bearing journal. RNC engines omit the rear cam shaft type seal and just rely on the cam plug.

Trigger wheel PN:
Intake-8658597
Exhaust- 8658598
Sensor: ZF/Cherry - GS100701

 

[Homer]

Sheesh, slow to update here. Parts pile is growing larger. I'm about ready to yank the engine out.

M90 will come out too, GS6-45DZ is going to take its place. I'm thinking of listing the entire driveline including turbo and vems for sale once the new setup is in.

Engine is off at Larry's Power in CT for the full makeover including cnc porting.

Entire hot side will be getting some zirconia exhaust coating (header, turbo, downpipe).

Taking a week off to work on the car in late may. Expect more updates then!

In the meantime, new color scheme.

 

[Alex Buchka]

This sparks joy. Also I don't know how that header hasn't fallen apart yet.

 

[Stiggy Pop]

Sheesh, slow to update here. Parts pile is growing larger. I'm about ready to yank the engine out.

M90 will come out too, GS6-45DZ is going to take its place. I'm thinking of listing the entire driveline including turbo and vems for sale once the new setup is in.

Engine is off at Larry's Power in CT for the full makeover including cnc porting.

Entire hot side will be getting some zirconia exhaust coating (header, turbo, downpipe).

Taking a week off to work on the car in late may. Expect more updates then!

In the meantime, new color scheme.




View attachment 38353

That’s a long distance machine shop visit! Larry’s has done all of the work on my engines/heads over the years. Great guys, really nice work. Can take a while during their busy season and they’re not cheap but worth it.

 

[Homer]

That’s a long distance machine shop visit! Larry’s has done all of the work on my engines/heads over the years. Great guys, really nice work. Can take a while during their busy season and they’re not cheap but worth it.

It sure is a ways away but I didn't feel like messing around hoping a local shop would do it right. Seems like it's worth the wait!

 

[Homer]

Headed back to LA to pick up the transmission. Spent the last few days yanking the old engine/gearbox and doing some cleanup.


Found the source of my oil leak. Guess the seals just aged out.


Installed the new crossmember and mounts, did some engine bay cleaning. Brake parts cleaner overspray is not kind to sellholm stickers


These IPD poly bushings are absolutely trashed after only 4 years (maybe 6k miles if that). The rear control arm bushings were also gone.


Dropped the mockup engine and new trans in, mounts were cake to install. Shifter mechanism needs some noodling over. Clearance between the trans and the drivers side tunnel is tight but nothing worse than the M90.

 

[Homer]

- PDU mounts where the LH 2.4 (and VEMS) mounted.
- ECU shares two firewall panel mounting bolts and i'll drill/tap the mass damper on the panel for the third mounting point.
- Firewall panel got notched so I can remove it without touching the HVAC box.

After I get the mechanical drivetrain bits sorted out I'll hit the wiring harness.
Engine is booked to start moving at the machine shop this monday!

 

[oldschoolvolvo]

Cool! What is the unit below the PDU with the circular connectors?

 

[RvolvoR]

Hmm, hadn’t thought about notching the panel for the AC lines. Are you going to make a patch piece like on the driver side for the wiring harness?