Alex's 360 build thread

ALVO360 · 2018-03-01T00:23:50+00:00

This is where it all began. only 12 days ago on the 24/02/2018. Its had all oils changed, coolant flush leads, plugs, air filter, dizzy cap and rotor, thr...

carnut222

ALVO360;c-150377 wroteBody kit ideas. Using the front and rear bumper to attach fibreglass body kit. I intend to do this way down the track. LS-DIFF is a priority after engine swap. I think I'll get it sprayed in House of kolor - 'Brandy Wine' or Candy Apple.
There's a new Mazda 3 which has come with a beautiful Red. I might even find out what red that is and go for that instead..

Mmmm...I’ll take that beautiful blue wagon. HAIL HYDRA!

ALVO360

Front mount intercooler is on its way!! I just need to sort out the clutch and flywheel...

ALVO360

Thanks to @AshDVS for my camshaft Bung and DVS plate!

ALVO360

ok. My LH2.4 conversion loom has been sent from classic swede!! Dai sent me a wiring diagram that I thought I'd upload here to possibly help any future converts.

I had the orange injectors from a V70 T5 cleaned and flow tested with new o'rings, filters and caps. They're good to go!

ALVO360

jamesinc;c-149626 wrote@ALVO360 you can get a neat kit for that rear cam plug on the head from @AshDVS. It includes a new plug as well as a steel plate that mounts behind the plug to stop it being ejected if you ever get pressure in the crankcase. Fairly inexpensive peace of mind.

Thanks very much for the suggestion!

ALVO360

Ok! Great news. Thanks to @dmc I have a new flywheel on the way. Dished LH2.4 flywheel was ordered from Skandix:
http://www.skandix.de/en/spare-parts/engine/engine-repair/crankshaft/flywheel/1002822/

I've also ordered the pressure plate>>Sachs 3082 204 033 for the dished flywheel. Also know under P/N 1209874

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F352234429717

The clutch used needs to meet the following specs:

Teeth: 24
Hub profile: 18.30x20.4 24N
Diameter: 228mm

I have been advised that the Vauxhall Astra gte 2l 16v use a Clutch disc which meets my requirements. Specifically one which uses the F20 transmission, which I believe were made between 1988-1991.
They are hard to find....thankfully, Ride_on from 300mania has helped me out with some info and told me that Helix Autosport do clutch kits for the Vauxhall Astra, so I gave them a call.

70-4627 organic plate £136.55
76-4627 (5) Paddle plate £166.23

They also said they could do a 6 paddle plate clutch. I went with the organic clutch as it should be fine for my application. I think the above pressure plate and organic clutch will be good for about 400nm which is likely well beyond what I will be producing.

Clutch thickness is 7.6mm which apparently works fine. Any thicker and you require the use if shims between the flywheel and pressure plate...which may require some grinding of the inside of the bellhousing to accommodate.
I hope this helps somebody one day...

egads (she/her)

Great info, sure it will come in handy

ALVO360

**Edited** the correct Oil cooler o'ring for the water cooled housing is NOT green. It's black, has squared edges and the true P/n is: 3547188

carnut222

ALVO360;c-151295 wroteOil cooler o'ring P/n 967343
Oil filter housing to block o'ring P/n 3547188
That green o'ring doesn't seem like its thick enough to seal the oil cooler properly. We will soon find out :anguished:

Sorry I may have missed it earlier in the thread, but that looks like a water-cooled oil cooler? Vs. the 740T (B230FT) type that circulates the oil through an external oil cooler. Interesting. Is the extension housing same as 740T one?

ALVO360

@carnut222 I'm not sure about the variations of oil coolers. Though you are correct about this one being water cooled. The set-up looks like this:

ALVO360

@carnut222 Thank you for your comment. You provoked some thought about the different oil coolers and I have realised that I was given the incorrect oil cooler o'ring. I just had a 1:30am epiphany.

The one I require is Volvo P/n 3547188

ALVO360

I installed the exhaust manifold and the turbo today. I'm just waiting on the D088 hoses for the oil cooler and the clutch and flywheel to arrive. Sadly, the clutch release bearing has been discontinued and is no longer available. More than frustrating...
I just need to do some final touches on the engine and she is ready to go in. I still have to sort out the intercooler piping, wiring and exhaust downpipe...and that pesky release bearing. 2019 and a turbo 360 WILL be on the road tearing up the streets ?

ALVO360

Do88 hoses arrived today. I'll get new clamps soon.

ALVO360

I've just ordered a bunch of parts from this website in the Netherlands:

https://www.volvo340onderdelen.nl/en/

They seem to have 360 parts that I cannot get anywhere else. They have a variety of parts that you wouldn't even think of! Postage appears to be a flat fee of 25 euro and they have parts for most of the classic Volvo's:

Check this grill out!

ALVO360

Volvo 360 release bearing Update:
I have been told that the volvo 940 with the M90 transmission has a similar release bearing, only it's shorter. For reference it's Sachs P/n 3151 189 031.

This is the original:

What you will need to do is put a 3mm spacer between the bellhousing and the clutch fork pivot ball. I'll report back, hopefully with a success story.

Also, the factory pivot ball on the 360 has a nylon cap. My donor car's pivot ball had a disintegrated nylon cap causing serious metal fatigue on the clutch-fork-pivot-ball-socket <---(try say that really fast 5 times!), to the point where the pivot ball had almost worn through the clutch fork completely. This is worth checking and replacing if you are doing anything clutch related.

Here's just a photo I've taken of the clutch fork and release bearing in situ. The pivot ball socket clearly on the left. If you look closely you can see where the socket has split in the centre.

ALVO360

Astra clutch arrived today. 228mm

ALVO360

Pressure plate arrived.

ALVO360

Using grease, a bolt wrapped in tape and a hammer to remove the old "pilot" bearing. As you can see, she's a redblock at heart ♥
(I've heard of people using bread and wet newspaper. It's probably cleaner than using grease...)

ALVO360

And my Oz Volvo stickers also arrived today! One for the Kia and the other for the Subaru ?? just messin'.

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