Volvo turbo 5 cilinder engine Miata build
Welcome, This page is a build thread of my 1993 mazda miata Volvo 5 cilinder turbo build. Sorted by most recent post
Landrover clutch cilinder
Landrover 19mm master cilinder with internal reservoir
Pressure plate fingers were fitting input shaft sleeve
Wiring Coils, injectos and (rx8) DBW
Shifter and Ebrake setup
Fitting the GS6-53DZ to the Whiteblock pt.2
Chopped both sides. and ready for welding.
Volvo flywheel, BMW X3 Clutchplate, volvo pressure plate, BMW throwout bearing. custom cetering shaft
Chopped both sides. and ready for welding.
Volvo flywheel, BMW X3 Clutchplate, volvo pressure plate, BMW throwout bearing. custom cetering shaft
Chopped both sides. and ready for welding.
Volvo flywheel, BMW X3 Clutchplate, volvo pressure plate, BMW throwout bearing. custom cetering shaft
Chopped both sides. and ready for welding.
Volvo flywheel, BMW X3 Clutchplate, volvo pressure plate, BMW throwout bearing. custom cetering shaft
Chopped both sides. and ready for welding.
Volvo flywheel, BMW X3 Clutchplate, volvo pressure plate, BMW throwout bearing. custom cetering shaft
Chopped both sides. and ready for welding.
Volvo flywheel, BMW X3 Clutchplate, volvo pressure plate, BMW throwout bearing. custom cetering shaft
Chopped both sides. and ready for welding.
Volvo flywheel, BMW X3 Clutchplate, volvo pressure plate, BMW throwout bearing. custom cetering shaft
Chopped both sides. and ready for welding.
Volvo flywheel, BMW X3 Clutchplate, volvo pressure plate, BMW throwout bearing. custom cetering shaft
Fitting the GS6-53DZ to the Whiteblock pt.1
Got a volvo whiteblock automatic transmission bellhousing side (out of an S60?)
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Japanifold dimensions
Japanifold
The turbo setup preview
For future power goals with a built engine in mind I wanted to upgrade the turbo to an Holset HX35. At first I thought this meant i had to make a dit manifold, but after some asking around I found out that (with some drilling, tapping and machining flat) a T3 turbo can be mounted to an original volvo turbo manifold. The specific one being the Japanifold. If only I was smart enough at the junkyard and took it home with me...
Flywheel, Clutch and pressure plate setup
This is one of the hardest parts of the swap for me.
The setup is:
Flywheel: Volvo Whiteblock single mass pressure plate I found at the junkyard. valeo unit
Clutch: BMW specific 240mm clutch stock LUK unit
Pressure plate: Volvo whiteblock single mass flywheel pressure plate Valeo part I found at the junkyard
BMW Gearbox!
I bought this 1 series BMW zf GS6-53DZ gearbox for the swap.
Pros: Very strong (1000Nm+) 6 speed manual. this gearbox will take any abuse I will throw at it
Cons: have to weld on a different bellhousing and the gearing is a little whack for the miata 4.1 diff
First step was to 3D scan it using my Creality CR-Scan ferret!
This model is also on my cults account!
https://cults3d.com/en/3d-model/gadget/gs6-53dz-zf-bmw-gearbox
Testfit painted parts
Cleaning and painting
Painted intake manifold with fuelrail AN6 bungs welded
Oil Routing
Custom oil Sump
Custom oil Sump CAD
Painting the block
Alternator mount shortened and head coolant flow pipe
Volvo Intake manifold with a Rx8 throttlebody which needed some minor modifications. Also plugging the extra fuelrail ports and adding AN fittings
B5244t Engine teardown
Change of plans! Getting a T5 from the junkyard!
A good deal popped up and I decided to get a B5244t engine. The plan is 300 - 400 hp and this would be way easier to fit in the chassis.
Volvo B6284T Engine with Holset HX40 turbo 3D modelled.
Top fitment
To see the fitment at the top of the engine I used the old scan of the hood. The 3D modelled turbo is a Holset HX40, although for the powergoals an Hx35 would be enough. The exact turbo chosen for the build hasn't been decided yet.
The turbo will have to be mounted quite close to the engine because of space restraints and ease of maintanance. This will result in part of the turbo Sticking out of the hood, which I am completely fine with.
The cam gears are the main concern with the fitment at the top. These have to fit under the hood.
Volvo 960 oil pan on the engine. Shown here is a custom tubulair subframe. I still haven't decided if I'm going this route.
Main goal for this 3D model was to see if the front of the pan would fit with the steering rack. In this case it barely fits. Changes to the oil pan will be made to maintain oil capacity.
3D scan of my own Mx5 with subframe and B6284t engine positioned roughly
Volvo 960 RWD oil sump 3D scan
Bram's B6248T with a volvo 960 RWD oil pan. I scanned this one to see how it would fit into the mx-5
Porsche PDK on an Rx7 13B engine
After a CAD dead end I decided to buy a Creality CR-Scan Ferret 3D scanner. This is one of the first 3D scans I did. A Porsche PDK Gearbox and an rx-7 13B rear housing. Scanned it at my internship at the time to digitally testfit an adapterplate.
The top has 40 mm to the heater core assembly
The bottom has 70 mm to the heater core assembly excluding the wiring harness. I suggert removing the heater core assembly before cutting.
A few weeks after the T6 swap idea I was at the local junkyard with Bram to get a single mass flywheel for his T6. Eventually I found myselft with an anglegrinder at the nearest NA Miata which had it's engine removed. Couldn't help no knowing how much space was behind the firewall so I started cutting.
Inspiration picture of a 2JZ swapped miata on youtube. You can see how far they notched the firewall to fit the extra 2 cilinders.
The 3D scan of the Miata engine bay was free online, Not te best resolution scan but enough for rough modeling. The lack of free 3D scans and needing very specific scanned parts ended up being a deciding factor in buying my own 3D scanner.
How it started:
A friend of mine, Bram, bought a B6284T "T6" engine out of a '90s Volvo S80.
He bought the engine to swap in his blue Volvo 245.
Bram showed me how capable the 2.8 Liter engine was and just for fun I 3D modelled the engine in CAD to see if it was possible to fit into an Mx-5.