We call him Dennis - Volvo T5 powered Super Custom Limited

Apologies if anyone was interested in the Volvo engine conversion and not seen any updates. I'm towards the end of this project now, didn't take many photo's along the way but intend to put some photo's up over the coming days. In the meantime, came across a couple of photo's on the internet of the engine donor when it was still a police car:





More to follow

bye bye 2LT. Ended up selling the original engine on ebay to a guy that ships them out to Africa.

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The original engine had to come out from below, and new engine lifted up from the floor. This was all done during Covid lockdowns, so had to come up with a way of doing this all on my own. New engine being lifted up in to the engine bay by any means possible:

Engine/suspension crossmember had to be modified to clear front of the engine and give clearance for the oil filter. Used Land Rover engine mounts.



It turned out that there was more differences between the Volvo 960 and Toyota Supra automatic gearboxes than anticipated. What I ended up doing was completely stripping both boxes, and built the Volvo one using the Supra output shaft, extension housing and gear selector rod.

The sump fitted to the Volvo V70 engine is designed for FWD application and not suitable for RWD. What they use in these 5 cylinder RWD conversions is the sump from a Volvo 960, but these are 6 cylinder engines which makes the sump 1 cylinder too long....

Needs a section cutting out and welding back together. 6 cylinder sump on left, 5 cylinder on right



Section cut out and bolted to engine, ready for TIG welding back together. Pick up pipe had to be modified also.

Made some adaptors so that I can use Toyota ignition coils. I'd read that the Volvo ones could cause issues when used with aftermarket ECU, and I've used these same coils on another conversion I did. Coils sourced from a Yaris.



I also wanted to use a Toyota alternator (the original Hiace one was unsuitable) and aircon pump. Had to make bespoke brackets to bolt these to the engine, the alternator bracket incorporated the N/S engine mount.



Toyota Avensis aircon pump and Celica alternator bolted to engine(can't recall what car the belt is off, was something obscure):

I changed my mind regarding the intake manifold and decided to use the standard one initially. Did this to save time as everything takes longer than anticipated......

I will revisit this in the future, I have an idea of combined intake manifold and chargecooler.

I welded an adaptor flange to the inlet, so I could bolt a Subaru Impreza 60mm throttle body to it. Chose this throttle body as they're dirt cheap, plentiful and plenty big enough for the power that this engine will be producing. Also welded on some additional brackets so that I could use the standard Hiace throttle cable, a Bosch idle valve and an aftermarket fuel pressure regulator. Decided to paint it wrinkle black, which needs baking on. So obviously I put it in the oven whist the wife was out...... Got away with it  

Not seen this thread before. Awesome work and so very well done. Puts my 30y refresh into the shade. Question above on insurance. My van is with Carole Nash on classic insurance so no accrued NCB but excellent value, I think.

Very interesting conversion Gazt,  i admire your ability and enthusiasm, will cooling be an issue?

frontslide wrote:

Very interesting conversion Gazt,  i admire your ability and enthusiasm, will cooling be an issue?

Just realised I never replied. No, cooling is fine.

Made a cowl to fit on the original radiator so that I can use an electric fan, controlled by the engine ECU.

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Updates are ridiculously slow, apologies.

Original fuel tank had to be modified, as it ran on diesel originally and the tank just had a syphon tube. Needed to incorporate an electric pump within the tank, as external pump are very noisy.

Started to modify the tank:



Flange made for the pump to bolt up to:



All welded in, not all that pretty as struggled to weld to the thin tank:



Pump hanger fabricated to mount the Walbro pump:



All back together with a fresh lick of paint:



The tank actually had top be dropped by about 30mm when fixed back on to the van, to clear the new fuel lines which are made from AN6 pipe.

Additional boss welded to intake manifold to enable fuel pressure regulator to be mounted on fabricated bracket:



Turbo had to be 'clocked' which meant a new wastegate bracket was required:



Stainless exhaust downpipe elbow tig welded to cast turbo flange:



Gear selector rod modified:

State of engine prior to wiring installation:



Start of wiring    :



Relay and fuse holder, which is mounted within battery compartment:



Megasquirt MS3X ECU for the engine, Microsquirt for the auto gearbox and a gubbins to enable the solenoids to work, all of which were also mounted in the battery compartment:

The original mechanical power steering pump wouldn't work, so I've converted it to use an electric pump, from a Vauxhall Astra. Used AN6 lines on the pressure side. All works perfect. No photo's of it installed, but here's the mounting bracket:

This continues to amaze me. Well done!

There are a few recent posts on here about members wanting, contemplating or having to change engines. This seems to be about as complex a job as it’s possible to do and it’s far more advanced than I’d tackle and I’m really hoping to see the results on here. There seems to be modifications on top of modifications but I love how you’ve solved all the problems you’ve encountered and enough brackets for Project Binky!

Please do keep up the posting as it’s fantastic!

LH119V wrote:

This continues to amaze me. Well done!

There are a few recent posts on here about members wanting, contemplating or having to change engines. This seems to be about as complex a job as it’s possible to do and it’s far more advanced than I’d tackle and I’m really hoping to see the results on here. There seems to be modifications on top of modifications but I love how you’ve solved all the problems you’ve encountered and enough brackets for Project Binky!

Please do keep up the posting as it’s fantastic!

Thank you for the kind words. You're correct, this combination of engine and gearbox is about as complex as it gets, and sometimes I do wonder if I've lost my sanity. Has caused many an argument between me and the missus too.....

At this moment in time, despite lack of updates with photo's it is actually running and driving, albeit only up the road and back, and has quite a few teething issues to sort out - mainly with the auto box which I don't have massive amounts of knowledge on.