Assembly

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Five-cylinder T5 conversion
Fit a B5234T with a Garrett turbo, custom intake and wiring, retaining the Getrag with a 960 bellhousing and hydraulic clutch.
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Plan
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Parts
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Gallery
Decisions & Unknowns
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Use a 1998 B5234T with H-beam rods, ARP2000 bolts and NA cams. Keep the Getrag 265 and adapt it to a Volvo 960 automatic bellhousing.
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Choose the GTX3067R with a 0.82 A/R housing and ATP C30 manifold. Use an internal hydraulic release bearing instead of an external slave.
Tasks
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Assemble and install
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Shorten and weld the 960 sump and oil transfer tube. Fabricate engine brackets and clearance the sump around the crossmember.
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Modify the S60R intake plenum and S70 fuel rail. Add baffled cam cover vents, oil cooler plumbing and a ProVent return.
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Machine and install with an NTN 6801LU pilot bearing.
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Install and with a single-mass 850 flywheel and M5 disc. Modify the pedal, fit a 260 master cylinder and lengthen the front driveshaft.
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Install and with ceramic coating, custom charge pipes and stainless wastegate control lines.
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Build the MS3x harness with a 55-pin firewall connector, sealed Bussmann fuse box and spare wiring for dual VVT. Set base timing and initial maps.