Details of my engine mods
When my Volvo 240TI�s engine was getting worn out, I faced the usual dilemma: I wanted a more powerful engine, but I had little money to spend. So I used the same formula when modifying normally aspirated street engines: increase power by using a little more of everything. The new engine is 2345 cc versus 2127 cc of the old one, the compression ratio is 9:1 (as in the European market B23ET), versus the old 7.5:1, while the valves are actuated by an �A� camshaft (from a Canadian car with the carburated B21A engine), vs the conservative �T� of the B21FT. The boost pressure is stock (10.5 psi, 0.7 bar), but as soon as I install a knock-sensor equipped ignition system it will be raised (planning around 12-14 psi).
To reduce costs the ignition, fuel injection systems and the turbo were left as is, the only external modification to the engine is a B23 intake manifold, along with the needed piping (from a 740T).
I wanted as strong a base as possible, so a B23F block was used. I would have preferred a B23FT, but those are scarce and expensive in my area. The only difference is the oil feed and return holes for the turbo, so these had to be custom made. The oil feed comes from an existing port on the back of the head (stock B21FT), while there was a hole drilled on the bottom of the block for the oil return.
Naturally all the usual parts were checked: the crankshaft journals were measured and found to be within spec, so no machining or oversize bearings were needed. The front auxiliary shaft bearing was damaged and it was replaced (make sure to align the oil hole properly!). The small-end bushes were also replaced.
The camshaft was checked in the head for ease of turning (if the head has been overheated before and warped, the camshaft may bind), and the valves and valve guides were checked for wear. These were not in the best of shape, therefore all the valveguides and four valves were renewed.
Costs:
Block $50
Machine shop $200
Pistons (Mahle forged) and bearings $400
Valves $90
Gaskets, etc $200
New injectors $70
Turbo feed hose $40
Miscellaneuos $50
�A� grind camshaft $65
Total $1165
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