• Hello Guest, welcome to the initial stages of our new platform!
    You can find some additional information about where we are in the process of migrating the board and setting up our new software here

    Thank you for being a part of our community!

Boosting my 96’ 960

960monkey

960monkey

New member
Joined
Jun 13, 2024
Hello! You all have such immense knowledge to share and have been a tremendous help with the information that is not readily available online.

I want to boost my 1996 960 sedan (169,000 miles with routine maintenance and casual driving) with a smaller t5 turbo on stock internals. But before I start ordering parts I wanted to check with you guys and get your feedback. I’m only shooting for 350hp and want to run low boost so I feel like it’s possible if I just do an engine tear down and clean it well but the strength of the rods worry me slightly. I’ve heard that the B230 engine they put in the 240s can handle anywhere from 300-400hp on stock rods and pistons and if Volvo built my I6 24v with similar resilience I feel like I should be good.

Would love to hear yalls thoughts and recommendations on this. Thank you.
 
I'd suggest searching the projects forum, the 960 isn't modded as often as 240s of course. I don't know anything about the strength of that engine, someone here probably does. You might also have to take a look in Swedespeed, might find something good there also.
 
2turbotoys said:
I'd suggest searching the projects forum, the 960 isn't modded as often as 240s of course. I don't know anything about the strength of that engine, someone here probably does. You might also have to take a look in Swedespeed, might find something good there also.
Click to expand...
Thank you
 
The 960 engine has pretty high compression and thin cylinders.
Ypu can swap in the short block from a 99 S80 T6 and have a fairly stout bottom end. As strong as a 2.3 T5 but with 20% more cylinders and valves. The 1999 is the best T6 for a bolt in swap, you can use the 960 head, sump, mounts, oil pan, sensors, accessories, etc.
Then 350 or 400whp is easy.
For an exhaust manifold you can get one from Kangaroo Team, or what my brother did was take 2 5 cyl "R" manifolds, cut them and weld them into a 6 cylinder manifold.
 
Here is the 6 cyl manifold made from 2 "R" manifolds. Really any P2 with a 2.5T has the "R" manifold, it's not exclusive to Rs.
Lots of pre and post heat, TIG welded with 309 filler then flattened on a belt sander. Works like a charm.
You don't want a turbo from a T5 or any turbo from a 5 cyl, every one of them is too small for even a 5 cylinder.
 

Attachments

  • 20240323_224602.jpg
    20240323_224602.jpg
    312.8 KB · Views: 57
244tiCanuck said:
Here is the 6 cyl manifold made from 2 "R" manifolds. Really any P2 with a 2.5T has the "R" manifold, it's not exclusive to Rs.
Lots of pre and post heat, TIG welded with 309 filler then flattened on a belt sander. Works like a charm.
You don't want a turbo from a T5 or any turbo from a 5 cyl, every one of them is too small for even a 5 cylinder.
Click to expand...
244tiCanuck…..you are freaking awesome. As far as pistons and rods go with the T6 bottom end do I just run what’s in the T6 already or swap in what’s left of my original motors rods and pistons?
 
244tiCanuck said:
Here is the 6 cyl manifold made from 2 "R" manifolds. Really any P2 with a 2.5T has the "R" manifold, it's not exclusive to Rs.
Lots of pre and post heat, TIG welded with 309 filler then flattened on a belt sander. Works like a charm.
You don't want a turbo from a T5 or any turbo from a 5 cyl, every one of them is too small for even a 5 cylinder.
Click to expand...
Love the manifold. Good thinking.
 
oldschoolvolvo said:
@244tiCanuck what turbo is your brother using on his T6?
Click to expand...
It's just an ebay special journal bearing GT3076, cast wheel. We welded an elbow to the turbine housing and put a 38mm ebay wastegate on it.
He's just running 6psi on all stock engine management and injectors and stuff, ecu from Aaron at Vast Tuning just showed up so we're gonna get it in there and go to bigger injectors and more boost.
 
244tiCanuck said:
The 960 engine has pretty high compression and thin cylinders.
Ypu can swap in the short block from a 99 S80 T6 and have a fairly stout bottom end. As strong as a 2.3 T5 but with 20% more cylinders and valves. The 1999 is the best T6 for a bolt in swap, you can use the 960 head, sump, mounts, oil pan, sensors, accessories, etc.
Then 350 or 400whp is easy.
For an exhaust manifold you can get one from Kangaroo Team, or what my brother did was take 2 5 cyl "R" manifolds, cut them and weld them into a 6 cylinder manifold.
Click to expand...
Why is 99 the best year for a swap? What changed on the 00/01 S80 T6 engines? I understand that in 02 they got dual VVT.
 
oldschoolvolvo said:
Why is 99 the best year for a swap? What changed on the 00/01 S80 T6 engines? I understand that in 02 they got dual VVT.
Click to expand...
99 still has the mounting provisions for 960 accessories, making it far easier to mount in a RWD. Later engines do not, you are stuck with the RN accessories. Just makes it harder if you want to keep AC and don't want to cobble stuff together. The dual vvt engines were 2.9L engines with 83mm bore, so they're the weaker version. 99 is the sweet spot.
If you're going to do a block saver, the larger bore shouldn't be as much of an issue.
 
You must log in or register to reply here.
Back
Top