2011-12-31
The next step is to swap the engine M102.062 to M111.944. The new engine is from a 1999 year model C200 Kompressor with 141 kW and 270 Nm (and about 100000 miles).

Here are a few pics of the new engine.

2012-02-06
The engine bay looks like this when empty

I took off the double mass flywheel. The flywheel and clutch weighed together about 46 lbs (21 kg). The M102 custom flywheel and the custom clutch weigh about 28 lbs (13 kg) together, so the setup is about 18 lbs (8 kg) lighter. I hope there won't be problems with the idle.

Comparing the two engines:
First the M102

.. then the M111

...and finally the M111 with the M102 flywheel. The starter is from the M111. Everything seems to fit including the TDC sensor.

2012-02-11
The engine build is progressing. Here is the new 90 ampere alternator...

...and here is the flywheel and SRE clutch from the M102 in their new place...

The engine M111 and transmissiion 717.435 fit together fine, this pic is from the right side...

...and the same from the left side with the intake, manifold, injection equipment and the electrical wiring removed

There was no oil pressure sensor in the M111 engine (!), but a M12x1,5 screw can be changed to the M102 sensor. The screw is in a bad spot so I must take off the right engine support to be able to tighten the sensor! The engine front supports are from some diesel engine so far although the best supports should be in models W124 E200 tai E220 which are not so easy to find.

2012-02-12
More pics.
The intake manifold and the fuel rail...

The intake manifold front view...

...and rear view...

...a clöose-up from cyl nr 1 injector...

...and cyl nr 4 injector...

...the throttle plate from the M102 is 58mm and I would like a little bigger one...

2012-02-22
The Volvo 2.56 inch (65mm) throttle plate arrivet, thanks to JuhaU from Volvo Racing Club Finland.
The outer dimension is about 2.9 inches (74mm) and the Volvo TPS should fit the plate shaft. I must tune the throttle casing to make it sit on the intake manifold.

2012-03-03
I lifted the new engine M111 with transmission 717 in the angine compartment for the first time.There is enough room around the engine but the alternator touching the anti roll bar when the front wheels are hanging freely. I must try to fix the problem by changing the position or form of the anti roll bar.

2012-03-04 (Edited 2012-03-06)
When I was fitting the intake manifold the fuel rail touched the valve cover because the injectors are shorter than the original ones. I had to modify the valve cover to make room for the fuel rail screw with a saw and a file.

2012-03-16
The next job was the new throttle plate. I made a flange between the intake manifold and the Volvo 65mm throttle plate. I had to turn the throttle axle 180 degrees to get the TPS in a better position. There was a fair amount of work with the flange with simple hand tools.

The next job is the new throttle linkage. Here I am testing the final position of the intake manifold.

2012-03-23
The throttle linkage is ready. The throttle cable is shortened about 4 inches. The linkage is the original M111 turned upside down and positioned in the cable line.

2012-05-01
The wiring from the ECU and the M111 engine are finally connected. The engine has two wasted spark coils driven by a copy of the Boschin 0 227 100 200 igbition module. The ECU connection include the cam sensor, the cam solenoid, the superchaeger bypass valve and the superchafger solenoid which should be working some day.

2012-05-04
The power steering hose would not fit the new pump. I got help at Mairuen kone ja pultti Oy (Mairue's machine and bolt ltd) where the hose end was modified. There I also found new rubber hoses for the supercharger and the cooling system. Mairue's shop has good spare parts and a good customer service.

2012-05-19
The next thing is to modify the supercharger cover and the intercooler in order to get the pressurized air to the throttle plate.  Here are a few pics of the job. The cold air intake and the SC bypass valve are in position. The radiator is in a lower position and the intercooler higher up to get both in the vcold air stream. Both radiators may get a fan of their own. The hot air will possibly be routed out via a duct in the low pressure region of the hood.

Back to the project start page