I’ve been putting off working on the replacement engine for the 242, but have been inspired by others’ progress to resume this project.
The idea is to do a fairly basic rebuild of the B5244T5 2.4l 81mm bore 5 cyl engine I bought a while back. Since initially inspecting it, I found out that this is far from an “A” grade lower mileage engine, and has certainly seen abuse.
Currently it is fully disassembled to clean and inspect everything. Once I verify that the head and block are both straight enough to use after a standard resurfacing, I’ll get moving on this.
I’m keeping the original 81mm bores, and just cleaning them up lightly with a flex hone. The only aftermarket parts I’ll be using are K1 h-beam rods and Glyco sputter bearings for the rods alongside standard main bearings. The head and block will be decked with the correct surface finish for an OE Volvo MLS head gasket and Volvo head bolts.
This is not an all-out build. Trying to strike the right balance of keeping it simple, reliable and cost-effective by only ‘upgrading’ parts that are actually needed. Previous iteration of the engine produced 360whp 380wtq; I’ll be looking for similar from this, but with an even better powerband thanks to VVT, and various improvements on this later engine design.
I have most parts for it sitting here already; just waiting on a machinists straight edge to check for any significant warping.
