Alright gents,
Following on from my recent Volvo K24 7400 installation in my 3B S2, here is some info and pics of how i went about the conversion.
Firstly i purchased a second hand turbo several years ago, which sat in a cupboard until such time that i was ready to get my head round making it fit neatly, with a reasonable OEM look.
On removing the compressor housing a couple of months back i noticed there was damage to the compressor wheel, serves me right for not checking it out properly when i first bought it.
Anyhow, i choose Turbo Technics for the refurbishment and off it went.
£600 later the turbo returned with a billet compressor wheel, uprated 360 Deg bearing and uprated seal pack.
The exhaust housing i also purchased a few years back as the standard Volvo one is of no use in this application.
The exhaust housing was fitted to the car along with the CHRA and then the compressor housing fitted to see what mods were needed to it.
Stock 3B oil and coolant lines fitted the turbo with relative ease to be fair.
These turbos come with two different compressor housings, a short stubby one with a "V" band fitting and a longer one where the compressor outlet kind of bends rearwards away from the housing.
By chance i purchased the one with the "V band" outlet which turned out to be good luck as it needed very little fettling to make it fit.
Also, due to the very limited space between the compressor inlet and the bonnet catch stay directly beside the drivers headlight, i only had space to fit a 2.5" Cobra head.
In order for the 2.5" Cobra head hose to fit the compressor inlet flange i had to get it machined from 2.75" to 2.5", at the same time this was being done the "V" band connection was machined off and made suitable for a hose to fit on.
The compressor housing utilises an internal bypass valve which is not the best design. It could be used if you so choose but i preferred to opt for the more reliable S2 stock setup. Blanking plugs are available to block off the port, i'll add the link further down. ( Still waiting on mine to arrive from the states!)
So, with the compressor housing machined it was fitted to the turbo, then i set about making the cobra head hose fit. I loosened the gearbox and engine mounts and moved the engine as far back as i could to gain a little more space. With the hose fitted to the turbo it was rubbing the bonnet catch stay, it you look at this stay there is a small bit that can be filed down do give a little more clearance. every mm counts here as it is so tight. I'm still not 100% happy with it but certainly good enough for now.
I purchased a 1" take off fitting which fits on to the Cobra head hose, this allows the DV to recirculate back to the intake. Again i'll add the link for this further down.
I reused the 3B Turbo to intercooler hose, and with a bit of trimming it worked a treat. I also had to order a 45 deg silicone hose and 2" aluminium joiner to complete the turbo outlet to RS2 intercooler hose. So glad i kept the 3B hose after my RS2 conversion last year!
All that was left now was to find a way of connecting the airbox to the Coba head hose.
A 2.5" stainless tight radius elbow was purchased for this and also a silicone reducer to go from the MAF size down to the 2.5" elbow. A small stainless tube was welded on to the side of the elbow to allow the N75 to bleed back.
And that's about it, now that i have completed the conversion i can say it was not too bad. There was a bit of head scratching to find the right Cobra head as the 3" one i bought first of all was just too big, the space between the compressor inlet and bonnet catch would not allow fitment of it. Also plumbing in the DV valve and MAF to Cobra head was a bit of a chew but got there in the end.
Here are links for the materials purchased to make the conversion work.
2.5" Cobra head http://www.do88.co.uk/product_info.p...0de1970529b413
1" take off for DV https://www.ebay.co.uk/itm/Revotec-2...72.m2749.l2649
2" aluminium joiner https://www.ebay.co.uk/itm/Aluminium...72.m2749.l2649
45 Deg silicone hose https://www.ebay.co.uk/itm/Ramair-45...72.m2749.l2649
MAF to Cobra head elbow https://www.ebay.co.uk/itm/Silicone-...72.m2749.l2649
Compressor housing blanking plate http://www.vivaperformance.com/cbv-b...r-v70r-s60-t5/
Prob missed some detail but that's enough typing for now.
Following on from my recent Volvo K24 7400 installation in my 3B S2, here is some info and pics of how i went about the conversion.
Firstly i purchased a second hand turbo several years ago, which sat in a cupboard until such time that i was ready to get my head round making it fit neatly, with a reasonable OEM look.
On removing the compressor housing a couple of months back i noticed there was damage to the compressor wheel, serves me right for not checking it out properly when i first bought it.
Anyhow, i choose Turbo Technics for the refurbishment and off it went.
£600 later the turbo returned with a billet compressor wheel, uprated 360 Deg bearing and uprated seal pack.
The exhaust housing i also purchased a few years back as the standard Volvo one is of no use in this application.
The exhaust housing was fitted to the car along with the CHRA and then the compressor housing fitted to see what mods were needed to it.
Stock 3B oil and coolant lines fitted the turbo with relative ease to be fair.
These turbos come with two different compressor housings, a short stubby one with a "V" band fitting and a longer one where the compressor outlet kind of bends rearwards away from the housing.
By chance i purchased the one with the "V band" outlet which turned out to be good luck as it needed very little fettling to make it fit.
Also, due to the very limited space between the compressor inlet and the bonnet catch stay directly beside the drivers headlight, i only had space to fit a 2.5" Cobra head.
In order for the 2.5" Cobra head hose to fit the compressor inlet flange i had to get it machined from 2.75" to 2.5", at the same time this was being done the "V" band connection was machined off and made suitable for a hose to fit on.
The compressor housing utilises an internal bypass valve which is not the best design. It could be used if you so choose but i preferred to opt for the more reliable S2 stock setup. Blanking plugs are available to block off the port, i'll add the link further down. ( Still waiting on mine to arrive from the states!)
So, with the compressor housing machined it was fitted to the turbo, then i set about making the cobra head hose fit. I loosened the gearbox and engine mounts and moved the engine as far back as i could to gain a little more space. With the hose fitted to the turbo it was rubbing the bonnet catch stay, it you look at this stay there is a small bit that can be filed down do give a little more clearance. every mm counts here as it is so tight. I'm still not 100% happy with it but certainly good enough for now.
I purchased a 1" take off fitting which fits on to the Cobra head hose, this allows the DV to recirculate back to the intake. Again i'll add the link for this further down.
I reused the 3B Turbo to intercooler hose, and with a bit of trimming it worked a treat. I also had to order a 45 deg silicone hose and 2" aluminium joiner to complete the turbo outlet to RS2 intercooler hose. So glad i kept the 3B hose after my RS2 conversion last year!
All that was left now was to find a way of connecting the airbox to the Coba head hose.
A 2.5" stainless tight radius elbow was purchased for this and also a silicone reducer to go from the MAF size down to the 2.5" elbow. A small stainless tube was welded on to the side of the elbow to allow the N75 to bleed back.
And that's about it, now that i have completed the conversion i can say it was not too bad. There was a bit of head scratching to find the right Cobra head as the 3" one i bought first of all was just too big, the space between the compressor inlet and bonnet catch would not allow fitment of it. Also plumbing in the DV valve and MAF to Cobra head was a bit of a chew but got there in the end.
Here are links for the materials purchased to make the conversion work.
2.5" Cobra head http://www.do88.co.uk/product_info.p...0de1970529b413
1" take off for DV https://www.ebay.co.uk/itm/Revotec-2...72.m2749.l2649
2" aluminium joiner https://www.ebay.co.uk/itm/Aluminium...72.m2749.l2649
45 Deg silicone hose https://www.ebay.co.uk/itm/Ramair-45...72.m2749.l2649
MAF to Cobra head elbow https://www.ebay.co.uk/itm/Silicone-...72.m2749.l2649
Compressor housing blanking plate http://www.vivaperformance.com/cbv-b...r-v70r-s60-t5/
Prob missed some detail but that's enough typing for now.
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