Volvo 745 Pickup + 4.8l V8 conversion

more bits & bobs

Lokar oil dipstick
- need to figure out if the Volvo gauge temp sender will fit in the head port behind the manifold
PXL_20221128_213208403.jpg


Used a modified step coupler to mount the MAF
PXL_20221128_215710680.jpg


PXL_20221128_220635427.jpg


just don't know if it's orientation is critical - the housing has a notch in it, which suggests it is intended to be mounted in a specific position
PXL_20221128_215724775.jpg


rad hose (Gates 23766) is one used by another T/Bricker V8 swap, steam hose will route adjacent to the bung beneath the rad inlet
PXL_20221128_221134297.jpg


mount brackets in place - left side is slightly longer than right side, drivetrain is slightly offset to the right, as apparently is the factory drivetrain
PXL_20221128_220945345.jpg


PXL_20221128_221000845.jpg

PXL_20221128_222254697.jpg
 
center cap decals came, so I bonded those to the 65mm Advanti cap
PXL_20221129_211515209.jpg


swivel elbow AN/NPT Fittings came

PXL_20221129_214518795.jpg


so the plan would be to run the hoses along the frame rail to the firewall, away from the engine
PXL_20221129_224200717.jpg


I have a range of AN fittings I bought/collected to play with the offset exiting the water pump as needed
PXL_20221129_223943984.jpg


This a reference pic of another V8 swap layout - much useful info, however I don't want it to look like this
0qe7RH0.jpg


alternator mount bracket came -
PXL_20221129_220545814.jpg


I bought longer bolts - 140mm - the provided 120mm bolts only go around 1/2" into the block
PXL_20221129_215228226.jpg


PXL_20221129_220842219.jpg
 
Last edited:
Love those wheels!!!

Indeed 😁 - they are the same brand/design as the black ones I've had on my C30 for the past 7 years - the wheels are strong - they have survived all the NY potholes better than any of the factory wheels I have owned.

PXL_20220715_223334276.jpg
 
Last edited:
Test fitting the EMS harness today

PXL_20221130_223013203.jpg


used a C30 hose guide to route the steam vent tube & MAF harness
PXL_20221130_224337616.jpg


MAF connector needs to be modified, needs a notch as marked
PXL_20221130_224354570.jpg


Another C30 HVAC bracket on the backside, to locate & isolate the harness sections from the intake
PXL_20221130_230620367.jpg


PXL_20221130_230635094.jpg


harness is missing the OP sensor connector
PXL_20221130_213008319.jpg


transmission connections & routing - using the plastic X1/9 engine bay harness clamps, and Volvo metal harness clamps. I'm going to sheath the harness where it passes behind the manifold
PXL_20221130_224311184.jpg


PXL_20221130_223021971.jpg


Using an adaptor 16mm to 6AN for the power steering pump, then an -6AN 90º. I'll either mod or make a pressure line to the rack from here
PXL_20221130_223005011.jpg


PXL_20221130_223002000.jpg


Should have enough AC #8 & #10 fittings (90º, 45º & straight) to make the AC lines to the compressor.
PXL_20221130_225043502.jpg



Ideas for heater hose & valve layout
PXL_20221201_001354175.jpg
 
Last edited:
routing wiring, heat sheathing for crank sensor, starter feed & cooler lines
PXL_20221202_200132934.jpg


trans cooler line revision - banjo/6AN fittings to bring the lines in closer
PXL_20221202_182526938.jpg


PXL_20221202_182516376.jpg


drilled & tapped an existing port for the Volvo coolant temp sender - I messed this up initially by tapping to 3/*" NPT,
PXL_20221202_201656434.jpg


and had to put a sleeve in it, and then tap that to M16x1.5 for the sender
PXL_20221202_214530432.jpg

PXL_20221202_215030109.jpg

PXL_20221202_220251131.jpg

notched the MAF connector to fit the MAF
PXL_20221202_205853528.jpg

PXL_20221202_205858474.jpg
 
Small things. Made a M16 - M14 x1.5 adaptor for the oil pressure sender.

Base was a trans cooler fitting from a Volvo radiator, M14 nut braised to the base

PXL_20221203_164929831.jpg


PXL_20221203_174212836.jpg

PXL_20221203_175533179.jpg

One uneventful mod at least
PXL_20221203_180500322.jpg


plugging in the new trans harness seems to have revealed another issue - the socket is not properly attached to the casing anymore - the plug filled up with fluid. Apparently there is a repair solution that presses the connector back up against the underside of the casing to seal the ring again
PXL_20221203_222027385.jpg


modded a 740 plug wire heat shield for the coolant sender - I have my doubts that it will survive in proximity to the manifold without it
PXL_20221203_182640148.jpg


PXL_20221203_183350114.jpg


repair wire 3523813 for Volvo senders
PXL_20221203_183629088.jpg


pulled apart the GM harness to retrieve several wire sets I need - AC compressor, starter trigger & O2 sensors for now

PXL_20221203_212556684.jpg


PXL_20221203_220844692.jpg


PXL_20221203_220903737.jpg


another sender close to the AC compressor plug - I don't know where this came from - looks like the oil pressure sender, but wrong location for that
PXL_20221203_220911005.jpg


Need to run a ground cable from the block to the battery - original was wired for battery on left in bay - it's on the right in mine, so changes will be necessary. I may still need to route the negative cable under the crank, there is no open ground spot on the right side of the block. I need to run. the alternator battery cable as well
PXL_20221203_221805953.jpg


played with the cooler lines a little more - now using a 45º on one to get it to tuck closer in to the casing. Also ground down the edge of a casting bump to allow slightly closer lay
PXL_20221203_201315059.jpg


PXL_20221203_195557477.jpg
 
Last edited:
WIRING: Removed some more Delphi connectors - at this point, I want to cut the loom & have a more modular setup - the idea of unplugging every individual sensor & component, feeding the harness from the pass compartment to the bay isn't going to work for me. I want it like the Fiat, where if need be, I can unplug the harness from the bulkhead & leave it all attached for engine removal.

84 wires to cut & reattach here. 6 or so at the right front, Battery & alternator cables. 2 for eFan control & others I've likely forgotten.

PXL_20221204_201647502.jpg


connectors will be somewhat staggered, I think 2' off the back the motor will be an OK starting point. There's way too much overall length, so I can get rid of some of the trunk while I'm at it
PXL_20221204_201650649.jpg

Much duplication of wire colors - so I'll use the PCM diagrams to cross reference with the standalone harness wiring legend to batch the wires in to identifiable groupings - 2 16pole, 3 14pole, an 8pole, 4pole for the Volvo sensors, and a higher amp 4 pole for the main grounds & starter circuit. I'll need a separate 4-6pole for the AC, & whatever else exits at the front.

c1p1.gif
c1p2.gif
c1p3.gif

c2p1.gif
c2p2.gif
c2p3.gif


I have plenty of sealed connector housing, but 12pole is the largest I've used in the past
PXL_20221204_202009856.jpg


So, I'm going to get more of the 14 & 16 pole Delphi GT150/280 series connectors & terminals used for this gen GM product

PXL_20221204_222359501.jpg
 
Last edited:
Broke down & bought lift hooks - would have cost me more to make my own

PXL_20221205_221019044.jpg


PXL_20221205_221131358.jpg


made the ground cable & alt feed wire - run under the crank using the stock engine harness bracket
PXL_20221205_215646845.jpg

banjo - to AN6 fittings for the power steering rack. Hopefully there is room around the subframe to make this work
PXL_20221205_223227118.jpg

EDIT - based on this pic from jagsthatrun.com, I will likely have to cut the factory lines & weld -6 AN male fittings to the lines

Screen Shot 2022-12-12 at 7.29.44 PM.png
Screenshot 2024-01-12 at 8.29.09 PM.png
 
Last edited:
Cut the harness today. Need to make a start on the bulkhead connections. I'll have to meter out the connections, from here to each device, since many use the same color wires. Once I've mapped them out, I'll group them accordingly.

PXL_20221207_213204242.jpg


Added the Furukawa .250 series terminals for the (30) power from the starter to the EMS. Can handle 35a each.
PXL_20221207_212846746.jpg


PXL_20221207_213015509.jpg


integrated the 3 wires for the 2 Volvo sensors
PXL_20221207_215708045.jpg


Sumitomo TS 090 series for the Volvo sender connections
PXL_20221207_220102655.jpg


have to figure out if I need to integrate the GM neutral safety
PXL_20221207_223323423.jpg
 
Last edited:
Cut the harness today. Need to make a start on the bulkhead connections. I'll have to meter out the connections, from here to each device, since many use the same color wires. Once I've mapped them out, I'll group them accordingly.



Added the terminals for the (30) power from the starter to the EMS




integrated the 3 wires for the 2 Volvo sensors




have to figure out if I need to integrate the GM neutral safety
View attachment 68696

I guess GM does not put the neutral safety switch on the steering column any more. Those were notorious for going intermitent after a few years and you would have to jiggle the gear selector to engage the starter motor.
 
Wiring, wiring. I must be a glutton for punishment

Identified all wires in the loom
PXL_20221210_165051661.jpg

I made a spreadsheet this time, to keep track, using the supplied wiring colors which differ from the factory harness schematics
Screen Shot 2022-12-12 at 12.56.59 PM.png


separated into end user groups
PXL_20221210_195329484.jpg


PXL_20221210_202745375.jpg

crimping new Delphi gt150 & 280 series terminals & adding to housings
PXL_20221211_000503265.jpg


using a Volvo terminal bin for all the Delphi terminals I bought
PXL_20221211_000527524.jpg

body side connectors done. I'll leave all the cable ID until I have the drivetrain side terminated, to verify. I know I get dyslexic.
PXL_20221211_212915116.jpg


Screen Shot 2022-12-18 at 8.34.48 PM.png
 
Last edited:
Been sick with an inner ear infection since last Sunday, finally feeling well enough to get some work done.

Finished up the harness connectors. Rewired the O2 sensors to male, like the original
PXL_20221216_200310168.jpg


Converted the injector plugs to EV1. Didn't like the Delphi-to-EV1 adaptors
PXL_20221216_210138063.jpg


bridge connections for motor / bulkhead done
PXL_20221218_150442918.jpg


PXL_20221219_002518261.jpg
 
My son had sent me several trays of Volvo terminals, the dealer he works at was discarding them (!)
PXL_20221129_005122120.jpg

Since I'm still under the weather with this inner ear infection, I took the time today to dump them out, organize & add my stock to them
PXL_20221219_231630431.jpg
 
HVAC blower motor stopped working on 3 out of 5 speeds today - jiggling the wires at the resistor pack I could get the fan to run at every speed, so I cut all the terminals off & made use of the ones I received from my son :)

contacts in the resistor pack are a little crusty, but all test OK
PXL_20221220_202227691.jpg


I do have a new one stashed, but no need for it yet
PXL_20221220_213212525.jpg


harness terminals not so much - half of them were the old non-reinforced variety also - not good for load circuits
PXL_20221220_201835434.jpg
 
Figuring out ways to use Volvo heater hose quick connect fittings - Dorman 800-416 5/8" elbows work. I can use these to avoid large loops around the back of the motor, along the firewall into the inner fender arera

PXL_20221222_204759242.jpg


PXL_20221222_210453618.jpg


PXL_20221222_210513921.jpg
 
My T5R uses those fittings for the heater. When I replaced my radiator (metal/plastic seam failure), I decided to replace all the hoses including the heater hoses. I got the Volvo connectors from FCP. I did not see the Dorman products back then (~2000).
 
My T5R uses those fittings for the heater. When I replaced my radiator (metal/plastic seam failure), I decided to replace all the hoses including the heater hoses. I got the Volvo connectors from FCP. I did not see the Dorman products back then (~2000).

The brass part is part of the Volvo hose - the receiver (Dorman) would equate to the bulkhead fitting - those were used from 93-00 on the 850 & then the x70 (since those 2 years were essentially a facelift 850)

What I'd ideally like to do is solder the brass male fitting to the heater core ports, and use the elbows right off the bulkhead it's going to be pretty tight back there

this is an example from another LS V8 740

U88Zjkp.jpg
 
Back
Top