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Rebuild the strongest, latest generation T5 that drops in. Make whatever changes necessary to setup dual vvt.
Plan
Parts
Goals
Criteria that will guide this project:
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Don’t go all out; get it working and proven. Learn from the past. I can always bore the bottom end in the future
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400whp vanity goal, but same power as old engine (360whp 380wtq) with better powerband is fine. Build the engine internally for 500whp but don’t push it that far. Reliability is more important than big power.
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Opt for aftermarket only where a specific improvement is needed to hit goals
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Genuine Volvo seals everywhere
Decisions & Unknowns
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Which head and block to use based on condition? 2005 block & 2008 head
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Original bores or hone? Dingleball hone bores
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Original rings or new? Original rings
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Original rods or hbeams? K1 H-beam rods
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Original main bearings or new? New standard size Glycomain bearings
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Machine work by Pakes or Zach? Pakes
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How to fit dual cam sensors & wiring? (Factory setup runs into firewall) RNC cam trigger wheels with top-mounted sensors milled and threadedinto cam cover
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Replace valve guides or run original? Run it
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Cam cover coating? Cerakote air cureGlacier Black https://www.cerakote.com/shop/cerakote-coating/C-7600/cerakote-glacier-black
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How to adapt factory oil drain port (standard tap doesn’t fit; try turning down AN fittings)
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How to plug/cap extra water hardline with drain petcock
Tasks
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Pull the crank and inspect main bearings
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Check block and head for major warping before machining all surfaces within 0.1mm warping; usable after resurfacing
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Ball hone cylinders and inspect bore condition
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Drill and tap holes for oil pickup tube ‘06 block has holes alreadyunlike newer ‘08 block
