850R Project
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19,453 Posts
All MY96-97 850s came with straight flange and the original coolant layout in all markets.
To use the revised turbo coolant layout, you will also need to upgrade to a RN oil pan and P2 coolant pipe. See:
www.swedespeed.com
To use the revised turbo coolant layout, you will also need to upgrade to a RN oil pan and P2 coolant pipe. See:
JaredR's Dad's 1997 Frost Green V70 T5
Me too, love the interior, especially that contrast of the black/birch steering wheel
www.swedespeed.com
Joined
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91 Posts
Parts prepare for Turbo swap
-Turbo TD04HL-16T / 15G Both 16T and 15G turbo will work. You can get one used on ebay. Or you can buy brand new one by Kinugawa or Mamba. They both provide really good CHRA or whole turbo kit with accessories. The exhaust housing port to CHRA on 16T and 15G are same. Early 16T and 15G have same coolant port(in and out on opposite side), it can be a direct swap. The later 16T has angle flange on exhaust downpipe. The even later 16T CHRA has different coolant port(in and out on same side).
I got a used later 16T from ebay
-Oil and coolant lines for later 16T. You need the coolant in and out line. Oil in line. No need oil reture line. You can grab these parts from any 2000s 2.5T engine cars.
Parts prepare for Manual swap
Used Parts
-Transmission I got a transmission from a junk 1999 C70 T5
-Pedals I got one from a junk 850 manual. You can modify one from x70 to 850.
-Shifter assembly 850 and x70 are exact same. I got each one from 850 manual and C70 T5.
-Shifter cables 850 and x70 are exact same. I got used one from C70T5
-Reverse light switch It should be attached to the transmission
-Clutch master cylinder fluid feed hose PN 9157190. This part is discontinued. You need to get one from junk yard.
New Parts
-Flywheel I recommend a new one. Less problem in future. The OEM turbo single mass flywheel is discontinued PN 9454774. You have two option, 1. the non turbo single mass flywheel PN 9454772, These is no difference to the turbo one and you can still buy genuine Volvo part for this one. 2. Aftermarket tubo single mass flywheel from SPEC PN SO13S. This one is 1.3lb lighter than OEM. It comes with pressure plate bolts. I got the SPEC one because it is cheaper than the genuine non turbo SMF.
-850R clutch PN 272218. It can use one both SMF and DMF.
-Clutch master cylinder PN 9163880. It is pain in the butt to remove and install. Just buy a new one then less headache in future.
-Rear crankshaft seal/rear main seal PN 9458178.
-Transmission input shaft seal PN 1381798. 41mm OD
-Axle seals PN 6843481. Need 2.
-Flywheel bolts PN 9454743. Need 10
-Pressure plate bolts PN 959219. Need 6. If you buy the SPEC flywheel then you don't need these.
-Transmission fluid PN 31280771. Need 3. This is genuine Volvo manual transmission oil.
Transmission with internal slave cylinder
-Clutch slave cylinder PN 31259445.
-Clutch hydraulic hose PN 9181324
Other parts
-3502507 “clip”. 4 required, these are used at both the shifter assembly and at the transmission.
-989037 “lock brace” 2 red’d, these are the clips that hold the shifter cables where they attach to the shifter mechanisms on the transmission.
-986417 “washer” 2 req’d, these are used with the above clips.
Price for all new parts from www.volvopartscounter.com
Subtotal
$800.02
Shipping (UPS Ground)
$40.58
Total
$840.60
Price for parts from Ebay
SPEC SO13S Steel Flywheel
ORDER TOTAL US $454.74
High Pressure Turbo TD04HL-16T 8601691
ORDER TOTALUS $254.39
-Turbo TD04HL-16T / 15G Both 16T and 15G turbo will work. You can get one used on ebay. Or you can buy brand new one by Kinugawa or Mamba. They both provide really good CHRA or whole turbo kit with accessories. The exhaust housing port to CHRA on 16T and 15G are same. Early 16T and 15G have same coolant port(in and out on opposite side), it can be a direct swap. The later 16T has angle flange on exhaust downpipe. The even later 16T CHRA has different coolant port(in and out on same side).
I got a used later 16T from ebay
-Oil and coolant lines for later 16T. You need the coolant in and out line. Oil in line. No need oil reture line. You can grab these parts from any 2000s 2.5T engine cars.
Parts prepare for Manual swap
Used Parts
-Transmission I got a transmission from a junk 1999 C70 T5
-Pedals I got one from a junk 850 manual. You can modify one from x70 to 850.
-Shifter assembly 850 and x70 are exact same. I got each one from 850 manual and C70 T5.
-Shifter cables 850 and x70 are exact same. I got used one from C70T5
-Reverse light switch It should be attached to the transmission
-Clutch master cylinder fluid feed hose PN 9157190. This part is discontinued. You need to get one from junk yard.
New Parts
-Flywheel I recommend a new one. Less problem in future. The OEM turbo single mass flywheel is discontinued PN 9454774. You have two option, 1. the non turbo single mass flywheel PN 9454772, These is no difference to the turbo one and you can still buy genuine Volvo part for this one. 2. Aftermarket tubo single mass flywheel from SPEC PN SO13S. This one is 1.3lb lighter than OEM. It comes with pressure plate bolts. I got the SPEC one because it is cheaper than the genuine non turbo SMF.
-850R clutch PN 272218. It can use one both SMF and DMF.
-Clutch master cylinder PN 9163880. It is pain in the butt to remove and install. Just buy a new one then less headache in future.
-Rear crankshaft seal/rear main seal PN 9458178.
-Transmission input shaft seal PN 1381798. 41mm OD
-Axle seals PN 6843481. Need 2.
-Flywheel bolts PN 9454743. Need 10
-Pressure plate bolts PN 959219. Need 6. If you buy the SPEC flywheel then you don't need these.
-Transmission fluid PN 31280771. Need 3. This is genuine Volvo manual transmission oil.
Transmission with internal slave cylinder
-Clutch slave cylinder PN 31259445.
-Clutch hydraulic hose PN 9181324
Other parts
-3502507 “clip”. 4 required, these are used at both the shifter assembly and at the transmission.
-989037 “lock brace” 2 red’d, these are the clips that hold the shifter cables where they attach to the shifter mechanisms on the transmission.
-986417 “washer” 2 req’d, these are used with the above clips.
Price for all new parts from www.volvopartscounter.com
| Item | Part # | Quantity | Amount | Status | ETA |
|---|---|---|---|---|---|
| Master Cylinder | 9181217 | 1 | $166.27 | - | |
| Clutch Kit | 272218 | 1 | $230.64 | - | |
| Slave Cylinder | 31259445 | 1 | $168.77 | - | |
| Hydraulic Lines | 9181324 | 1 | $91.54 | - | |
| Manual Transmission Input Shaft Seal | 1381798 | 1 | $4.86 | - | |
| Manual Transmission Output Shaft Seal | 6843481 | 2 | $20.10 | - | |
| Engine Crankshaft Seal | 9458178 | 1 | $25.00 | - | |
| Clip | 3502507 | 4 | $10.36 | - | |
| Support Cylinder Retainer Clip | 989037 | 2 | $3.42 | - | |
| Valance Panel Washer | 986417 | 2 | $3.42 | - | |
| Clutch Flywheel Bolt | 9454743 | 10 | $30.40 | - | |
| Transmission Oil | 31280771 | 3 | $45.24 | - |
$800.02
Shipping (UPS Ground)
$40.58
Total
$840.60
Price for parts from Ebay
SPEC SO13S Steel Flywheel
ORDER TOTAL US $454.74
High Pressure Turbo TD04HL-16T 8601691
ORDER TOTALUS $254.39
Joined
·
91 Posts
LOLAll MY96-97 850s came with straight flange and the original coolant layout in all markets.
To use the revised turbo coolant layout, you will also need to upgrade to a RN oil pan and P2 coolant pipe. See:
JaredR's Dad's 1997 Frost Green V70 T5
Me too, love the interior, especially that contrast of the black/birch steering wheel
I wasn't finished yet. I know. I alreday got them.
I'm waiting for the manul parts right now.
You don't need a RN oil pan. Change the oil in line and colant in and out line will be enough.
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19,453 Posts
That's not gonna work if you're using a RN water tree.
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91 Posts
NO i'm not using a RN water tree.
The coolant lines are connected with Ruber lines, so it doesn't matter.
The oil in line just need to be different shap.
I'm thinking about the RN water tree and RN oil pan.
However, I cannot find enough information and pictures to support my build.
Joined
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19,453 Posts
That's not going to fit amazingly but ok.
What I linked to is RN water tree and oil pan on my dad's 97 T5.
Joined
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91 Posts
Do you have detail instruction for the RN oil pan swap?
The old 850 has oil cooler line connected to radiator. I have no idea how to modify them.
I also need all the parts number for the ruber hoses.
Thanks
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1,124 Posts
Joined
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91 Posts
Last piece of parts is coming
Shifter assembly
Clutch pedal assembly
I got these 2 from a manual 850
I'm waiting for the parts from www.volvopartscounter.com .
They said that one of the parts is coming form Sweden and need to wait for about 2 weeks.
After that the swap will be begin
For the RN oil pan swap, It can wait. After looking for the price, oil pan swap will out of my current budget.
Shifter assembly
Clutch pedal assembly
I got these 2 from a manual 850
I'm waiting for the parts from www.volvopartscounter.com .
They said that one of the parts is coming form Sweden and need to wait for about 2 weeks.
After that the swap will be begin
For the RN oil pan swap, It can wait. After looking for the price, oil pan swap will out of my current budget.
Joined
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1,124 Posts
Yeah. In my case on my T5, I had a pan and oil cooler on an '04 P2R engine sitting in my garage, so it really wasn't too expensive.
Joined
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19,673 Posts
What? RN pan swap is cheaper than N oil cooler lines by a fair margin AND gets you the option to use the updated pickup.
Joined
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91 Posts
RN pan need new oil cooler, new coolant tree, a lot of new hoses and a set of new seal.
There is also not enough information for the coolant tree modification. So, I don't want to mess around.
Joined
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19,673 Posts
No modification is necessary.
However you’ll have to go that route to use the “late” 16t.
Is well documented, Jared linked you photos step by step of doing that this summer. I actually did that work on the frost. Going to spend more time trying to avoid doing the RN pan swap ect than just doing it one and done and gaining all the benefits of the improved setup
Joined
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91 Posts
Joined
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19,673 Posts
See above, jared linked to his frost build. It’s in his signature either way
Joined
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91 Posts
The current problem I have is the confusing Serpentine Idler Pulley
There are 2 different Serpentine Idler Pulley with completely different parts number shows up.
9146139
www.volvopartswebstore.com
Size diagram
9135699
www.volvopartswebstore.com
Size diagram
According to the size diagram. They are slightly different.
Which one I should buy?
There are 2 different Serpentine Idler Pulley with completely different parts number shows up.
9146139
9146139 - Volvo Accessory Drive Belt Idler Pulley. IDLER | Volvo Parts Webstore, Oak Park IL
Genuine Volvo Part # 9146139 (9146028) - Accessory Drive Belt Idler Pulley. IDLER ROLLER. Fits 850, 960, C70, S70, S90, V70, V70 XC, V90. Ships from Volvo Parts Webstore, Oak Park IL
www.volvopartswebstore.com
9135699
9135699 - Volvo Accessory Drive Belt Idler Pulley. IDLER | Volvo Parts Webstore, Oak Park IL
Genuine Volvo Part # 9135699 - Accessory Drive Belt Idler Pulley. IDLER ROLLER. Fits 850, 960. Ships from Volvo Parts Webstore, Oak Park IL
www.volvopartswebstore.com
According to the size diagram. They are slightly different.
Which one I should buy?
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