AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Status
Not open for further replies.

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Getting there....

Before::

IMG_0276.jpg


After::

IMG_0331.jpg
 

bgc

Ensign
Joined
Jul 13, 2011
Messages
980
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Wow!
 

ess

Recruit
Joined
Oct 26, 2011
Messages
1
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

I have been considering a 27 seasport that has twin aq151a's. One was just replaced at 1000 hours with a new engine that came with the boat and I suspect the other will need to be replaced as well. Your project is a great inspiration. I have a couple questions:

1. How much will you be into this when it is all said and done?

2. Is it possible to use the fuel injection that came with the motor from the car?

Great project!
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

1. How much will you be into this when it is all said and done?

I'm keeping track of the cost. I'll post it when it's all said and done.

2. Is it possible to use the fuel injection that came with the motor from the car?

I'm not sure.
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

She's in. Next up is final wiring, reinstalling the upper gear housing, and installing both new bellows.

PhotoNov1361749PM.jpg


PhotoNov1344936PM.jpg
 

Mullin

Petty Officer 1st Class
Joined
May 12, 2011
Messages
256
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Nice.
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

I had decided some time ago to put in a thru-hull water pickup for the engine. Normally the water is pumped from the outdrive making it almost the lowest point of the boat where sand and weed is more prevalent. I came up with a three way valve system allowing me to pickup water from the outdrive, thru-hull, or garden hose. Here's what that looks like, along with the brass scupper and valve:

PhotoDec1760834PM.jpg


The center brass fitting is just the quick disconnect receiver I use on the hoses at my house. The scupper position I chose is 2' off the stern and 1' port of center.

PhotoDec18102737AM.jpg


PhotoDec18111942AM.jpg


This will eventually be painted black to match the rest of the bottom:

PhotoDec18121931PM.jpg


In doing this, it no longer makes sense to have the raw pump input line all the way near the back of the engine. So I cut that copper line down to size:

PhotoDec1761214PM.jpg


PhotoDec1762150PM.jpg


I also got the upper gear housing reinstalled with new bellows. I also installed a new shifter/throttle (the other one was worn pretty bad and would slip).
I've got some time off from work coming up, so I hope to get her splashed!
 

rdengil1

Seaman
Joined
Apr 27, 2009
Messages
52
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

I read most of your progress. what was the outcome of the cylinder head and cam from the volvo auto. I have a 131D and thought of changing the head from a 1988 244.
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

I had a valve job done on the auto head when I got it. As for the cam, I'm sticking with the "A" grind that came with it.
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

I made a bracket for the coolant expansion tank. It mounts to an existing bolt on the intake manifold:

PhotoDec2292129AM.jpg


PhotoDec2292135AM.jpg


PhotoDec2292144AM.jpg


The tank ends up in a perfect spot a few inches above the alternator:

PhotoDec2292922AM.jpg
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

I'm running on the trailer and I'm having some trouble with the temp and oil gauges on the boat. The oil gauge is reading just above red. It doesn't have marked increments but I'd say probably reading 20psi (it maxes at 80). The temp gauge just reads well below the lowest temp mark. I was thinking maybe an incompatibility between the senders and the gauges on the boat, since all checked out great when I ran the new engine on the stand.

To check the senders I hooked up the positive side of a multimeter to the battery (+), and the negative side to the sender being tested. With the key off, both read 12V. With the engine idling, the oil pressure sender reads 10.4V. That is a brand new sender, Sierra Part# 18-5899, bought from here. With the engine idling, the temp sensor (port side just below intake for cylinder 2) reads 14.5V. That is the sender that came with the auto engine. There is another connection on the starboard side to the left of the oil filter, that I'm assuming is another temp sensor?

Anyone have any ideas? Further troubleshooting techniques?
 

dennis461

Chief Petty Officer
Joined
Aug 11, 2011
Messages
516
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

HNY

IMHO, I'd check ohms first, not voltage.
Disconnect the sender(sensor) wire.
With cold engine not running.
Measure the resistance from sender terminal to engine ground.
Write down the numbers !

Start engine,
Write down the numbers !
Wait two-three minutes for engine to warm up.
Write down the numbers !


here is a chart to get you started.

http://faria-instruments.com/site_manuals/IS0085E.pdf
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Thanks for the great chart. I measure the resistance and here's what I found...

Temp sensor (in the head on the port side):
Off=1.53 Kohms
On=450 ohms (100*F)
As the engine ran, the 450 ohms continued dropping all the way to 140 ohms as the engine heated up. At that point it seemed like the thermostat may have kicked in because the resistance began climbing again to 165 ohms. As the engine ran warm, the resistance fluctuated in the 158 to 165 ohm range.

Oil sender (starboard side):
Off=242 ohms
On=70 ohms (55-ish psi)
As the engine ran warm, the resistance stayed about the same.
 

dennis461

Chief Petty Officer
Joined
Aug 11, 2011
Messages
516
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

OK, sounds to me like the sensors would work in my boat with original gauges.
My oil sender is at 260 ohms, temperature sender is 2.3 kilo ohms ice cold (NJ).
Could be some one swapped the original gauges.
If it was my boat, i'd mark the gauges when running with a black marker and ignore the other markings.

However, seeing how clean that motor is, I'm guessing you have better ideas...

Reading the gauges is a little tougher as the voltmeter applies voltage to measure ohms, the gauge moves, and it's resistance changes.
My Temperature gauge reads around 23 to 57 ohms.

With engine off, the connection on top of the oil sender reads 7.5 VDC to ground with ignition ON, engine NOT spinning.

Do you have 13.5 VDC at the dashboard or 12 VDC?
It can make a slight difference in where the gauge needles reads on simple systems (non-electronic).
 

74bayliner

Chief Petty Officer
Joined
Aug 23, 2011
Messages
607
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Very nice Paperclip. You didnt do anything with your flywheel and absorber for rust?
I just put mine into EvapoRust from HF for like 10 bucks.. and it cleaned it right up. its been about 2 months and it still has not flash rusted.(pics in my link). good stuff something to check out in the future..

really like your rebuild, something ive noticed working with my AQ130D is i thought i would spend max 1500.. im almost in 2k... im gonna have total 3k into the motor. and people say i could buy a brand new one for close to that but you cannot buy experiance. i have learned so much after this my rebuild its amazing... i actually became a motorhead lol. good luck buddy
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Today was splash day! A beautiful day on the ICW!

PhotoJan05125413PM.jpg


She ran great! We noticed a very small leak in the valve cover gasket. As soon as I saw it, I knew what happened. When I had popped the valve cover to perform the second round of head tightening (it's a two stage tightening sequence), the gasket tore in one spot. I patched it up with some permatex but it clearly didn't do the trick. No biggie at all... the volvo dealership has a new one in stock and I'll have her back on the water tomorrow.
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Installed a new valve cover gasket ($10 at autozone) and took the boat out for another successful test. It runs a comfortable 25 mph at 4400 rpms (the manual indicates recommended max operating rpms of 4800).

PhotoJan0642326PM.jpg


PhotoJan0642331PM.jpg


That's about what I expect for a 21' Bayliner Explorer, a small cabin cruiser with a non-planing style hull (though it does plane). :D
 

Mullin

Petty Officer 1st Class
Joined
May 12, 2011
Messages
256
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Looking good! It was a lot of work but it seems to have worked out really well for you. Are you going to bother changing the prop to get those extra 400 rpm? 25 mph sounds really good for that heavy of a boat, my 19' capri does just 28mph with the same motor (although I am at very high altitude).

Can I ask you for a picture of the thru-hull water pickup for the engine installed and hooked up? My pickup has a small air leak in the outdrive section and this seems like a great way to permanently fix it.
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Are you going to bother changing the prop to get those extra 400 rpm?

It still has more juice past 4400 rpms! I did have it up to 5000 briefly and let it climb to 28mph before backing off since that hull is not made to go that fast. :)

I'll upload some pictures of the pickup and corresponding valve system (installed) shortly.
 

paperklip

Petty Officer 2nd Class
Joined
May 20, 2011
Messages
108
Re: AQ125B Engine Swap with a Marinized B230 Auto Engine from 92 Volvo 240

Can I ask you for a picture of the thru-hull water pickup for the engine installed and hooked up?

The hole:

PhotoDec18102737AM.jpg


The thru-hull strainer:

PhotoDec18111942AM.jpg


Installed, from underneath:

PhotoDec18121931PM.jpg


I built this valve system allowing the raw pump to to draw from 3 different sources of water:

PhotoDec2921610PM.jpg


I put a particulate trap/strainer on the output side to catch any "large" debris. Here it is installed. The rightmost valve connects to the thru-hull fitting. The one in the middle has a quick-disconnect for my garden hose. The left valve connects to the outdrive pickup (as normal).

PhotoDec3042725PM.jpg


I modified (shortened) the copper tube that connects to the raw water pump on the front of the engine and connected a looped hose to the particulate strainer. The loop keeps tension off of the rubber grommet connection to the pump, as those are particularly sensitive.

PhotoDec3042730PM.jpg


The clear tubing lets you see the water flow, and I guess any air bubbles in case of a leak. The thru-hull pickup works great and has no trouble cooling the exchanger at all speeds with no bubbles.
 
Status
Not open for further replies.
Top