Volvo Turbo Powered Mk2 Clio

[TURBO'D CLIO]

Hi all

My names rob, pretty new round here but i thought I'd start a project thread about my latest victim..

Managed to buy a whole volvo 480 turbo for £10, which then gave me a idea of putting it into a clio, then week later i got offered a standard mk2 on a s plate for £200 with a popped lump. Perfect for my volvo lump to sit it..

Been on the project now for a few weeks, got the volvo lump out and cleaned off, also got the clio engine out now aswell but worried if the volvo lump will fit the mk2 clio like it does in the mk1 clios .
Apparantly it's fit like for like into a mk1 clio, just using the rsi drivers engine mount?

Can any one deffo confirm that the volvo lump will fit the mk2 clio's ? Buggered if it don't lol...

Heres a few pics of progress

Donar car


Loom out and finished



Engine out


Standard clio bay


Engine cleaned off and on stand


Rear of engine



Stripped out clio bay ready for cleaning and lump fitted

Comments and advice glady needed...

Rob

[Andrew Cooke]

are you keeping the power steering?

[TURBO'D CLIO]

I was hoping to the pump pipes look almost exactly the same, even look to route much the same..
However if it's as simple as just fitting a manual rack then ill prob just do that a bin a power steering bits.. Is it possible to bolt a rack on the exact same mounts and using the same coloum...

Rob

[Scoff]

It does fit one way or another - I did some wiring work on a guys Volvo conversion that he had in one of those shape Clio's. From memory he had made a front drivers side engine mount that bolted to the head/block and mounted on the inner wing mount that the Clio uses. I think the nicer way would be to use the RSI/ R5 GTX front drivers engine mount which bolts through the subframe instead.

If you go with the RSI / GTX block mount then I don't think the mount will line up with the subframe without a little work. I had to fit one of those mounts to a C1J engine in the same shape Clio again and I remember the subframe being a funny shape around that area (sort of slopes away) - I had to weld in a triangle section that I could bolt the engine mount into. The Vovlo gearbox mounts should fit the same as the old Clio gearbox mounts.

[TURBO'D CLIO]

The engine doesent mount on the sub frame any where, just a stabaliser mounting at the back of the engine i beleave i need a Rsi clio top drivers mounting which basicly goes over the cambelt cover and the mount bolts to that then on to the car..
Gear box mount sits under the battery tray and if i use a renault gear box all mounts will be the same, and finaly there is the back support which bolts on to the gear box and its like a support to stop the gear box and engine tilting back but i can't see that being a problem either if i use the renault gear box...

Was hoping some one would hit me with a pic of a mk2 carrying a volvo turbo lump...

[raj]

hmm, as youve got this volvo lump out maybe you could help me out with my problem
ive got a piece of pipework left to fit but cannot find where they are supposed to fit.!

its the piece in the first pic in this post

[TURBO'D CLIO]

I can prob help you out there mate, I'm at my mates house at the mo so i dont have access to my pic's but im pretty sure i know where that pipe comes from just i need to check it against a pic i have at home....

It looks very similair to the one that goes to the boost ecu but im not sure, like i say i took about 20 pics as i removed the engine from the volvo so there must be one pic that shows that pipe... Ill try me best bud...

[raj]

I can prob help you out there mate, I'm at my mates house at the mo so i dont have access to my pic's but im pretty sure i know where that pipe comes from just i need to check it against a pic i have at home....

It looks very similair to the one that goes to the boost ecu but im not sure, like i say i took about 20 pics as i removed the engine from the volvo so there must be one pic that shows that pipe... Ill try me best bud...

thanks mate, appreciate it im thinking i must have re-piped it back up wrong somewhere? or i just cant figure it out

[TURBO'D CLIO]

thanks mate, appreciate it im thinking i must have re-piped it back up wrong somewhere? or i just cant figure it out

Right I've had a look through the volvo parts book and your pipe looks very much like the one that goes from left hand side of the inlet manifold and joins onto the throttle body, the other T out of it goes to the valve on the charcol canister, on the volvo its under the drivers side wing, u could prob blank it out..

To make things easier for ya down load this volvo parts manual, save a copy to your pc and go to page 103 for the drawing of the vac hoses..
http://volvo480.northernscum.org.uk/...0partsbook.pdf

Hope it help's ya mate...

[TURBO'D CLIO]

are you keeping the power steering?

I wanted to mate, is there any reason why you ask this ? will the lump fit with power steering...

[Andrew Cooke]

I wanted to mate, is there any reason why you ask this ? will the lump fit with power steering...

I was thinking you'd use a subframe mount, not sure which engine mount fits with the PAS pump there. As it is you want to hang it from the head, in which case your pump should be fine.

[TURBO'D CLIO]

On a mk2 clio there is no subframe mounts other than the dog bone mount at the back of the gear box..

Clio is mounted on the drivers wing and under the batt tray...

Are the r 5 turbo's subframe mounted... ?

[Andrew Cooke]

On a mk2 clio there is no subframe mounts other than the dog bone mount at the back of the gear box..

Clio is mounted on the drivers wing and under the batt tray...

Are the r 5 turbo's subframe mounted... ?

yep, you drill a hole, and bolt the mount to the subframe, but with your dogbone rear stabiliser that won't work.

[TURBO'D CLIO]

But i should be ok using the clio rsi engine mount for the drivers side and normal clio gear box mountings shouldnt i....

I despo need a fly wheel if any one can help..

[Andrew Cooke]

some pictures for you from Dialogys, Clio RSI is C579. It looks like your best bet is to go to a scrappies and pull off all the bits you need, otherwise it'll cost you zillions.

[TURBO'D CLIO]

MATE - your a god dam star so badly needed that pic, been hunting and asking for weeks for it and u just drop it in outta no where, you have been a great help all through this build so far and responded to all my topics i started.. Bloody great site to as i also sorted out a fly wheel last night too, things can move along quickly once i get this mount.
Speaking of which..

I need mount number 5 from the first pic
And mount number 25 from pic 2

I also need that program - a must for doing a project like this - wanna sell me a copy bud ?

[Andrew Cooke]

I think you might also want 1 and 15 from the 3rd pic. Your best bet is going to be to find a car in a scrappies, that way you'll get all the bits and pieces, and the bolts too.

plenty of software on ebay:

http://cgi.ebay.co.uk/RENAULT-DIALOG...3A1|240%3A1318

[TURBO'D CLIO]

Ahh but will it work on vista..

[TURBO'D CLIO]

15 is just the mount cover by looks of things..

[Andrew Cooke]

15 is just the mount cover by looks of things..

I think it also covers some of the belt, can't be sure though.

[Andrew Cooke]

Ahh but will it work on vista..

that's the thing about dialogys, it works on such old versions of stuff that you almost have to keep a dedicated machine for it.

[Andrew Cooke]

I've been stripping a 172, not sure if anything would be of use to you, but possibly parts 22 and 23 might be?

[TURBO'D CLIO]

I have a old lap top with windows xp but its pretty much dead, so slow... would that program you got run on vista ? dont say in his listing..

[Andrew Cooke]

I'm pretty sure it won't run on vista.

You might want to have a read of this

http://www.cliosport.net/forum/showthread.php?t=109413

[TURBO'D CLIO]

is this not a better easyer choice

http://cgi.ebay.co.uk/ws/eBayISAPI.d...m=180344921602

[TURBO'D CLIO]

I've been stripping a 172, not sure if anything would be of use to you, but possibly parts 22 and 23 might be?

Looks like that is the front gear box mount, bolts to sub frame and to the box..

My clio don't have one of them, just hangs below the battery and has a dog bone mount at the back of the subframe..

I want a 172 rear beam with disc's and calipers ? lol also might be interested in the gear box..

Talking of which, trying to work out which one to use my 1.4 box is no good it's far to weak to have turbo power running through it, it would explode.
I was thinking clio rsi, or a 16 valver one.. Beleave some one said a 172 box will fit aswell..

But it must line up on the mounts, one on top of the box and the dog bone mount which joins the box to the frame.. Looks like in ur dialogys pic that the 172 has that front mount aswell, Would that mean drilling the frame to take that mounting if i used the 172 box...

Cheers for you help andrew those dialogys are wicked..

[Andrew Cooke]

I have a use for the rear subframe, the front one is available. I'm using the 172 box, driveshafts, brakes etc.

The 172 mount will fit your gearbox, you may already have the hole in your subframe, I'll try and take a pic of that part of the 172 subframe.

I've attached the dialogys page for the RSI alternator.

As to gearbox, all those will fit your engine, you just need to concern yourself with speedo drives, and mounts. I guess anything out of a PH2 clio will fit.

[TURBO'D CLIO]

I'm thinking i would be better with a 172 box... Hmm would i also need the shafts ?

[Andrew Cooke]

some mount pics:

mount on it's own
hole in the 172 subframe
mount sat in place

[TURBO'D CLIO]

I'll check if i have a hole in my subframe mate, if i do then i'll prob just have it off ya... If its cheap.... I'm running outta cash fast

[TURBO'D CLIO]

Finaly a day of progress..

Got my mounts ordered today, one top mount from ebay for £28.99 and the head mount from renault direct which was £44, not to bad really plus these mounts are the only thing holding me up so now i can mount the engine and see how it lines up...

Becasue im missing a strong gear box and clutch and fly wheel im going to wack the auto flywheel back on and bolt my 1.4 box to it, i know i wont have gears and i wont even bother fitting the drive shafts or subframe. I just want the engine on it's two mounts so i can sort out the wiring once and for all ( still working with diagrams but pretty sure ive cracked it) i wanna hear it run and tidy loom up, then ill rip it back out and prob rebuild the engine with new shells and rings, head gasket etc etc...

Fitted new leads and plugs as old one's where shot to bits..


And i started to strip back the renault wiring loom, keeping to one side the wires i need, and to the other side is all the stuff left to be coiled up and put out the way



Sorry about photo quality compared to other i forgot me camera and had to use me phone...

Comments and ideas welcome chaps....

[Andrew Cooke]

why not just build it with the 1.4 box, and the 172 flywheel/clutch. Check where the dowels are in the gearbox, you want the ones that aren't half hanging into the bellhousing. I'm not sure which starter dowel position you need.

[TURBO'D CLIO]

I was thinking about it but if i put it in the car with the auto wheel on then i know the tdc sensor is spot on..
Think about all that wiring i would have to re trace if it didnt start - then to find out it was the fly wheel casuing the prob..

I'm going to use the 172 fly wheel, just want to get the loom in and sorted and hear it run for a few seconds just so i know the wiring is all correct then i can just pop the engine back out and build it proper, when theres no frame and drive shafts etc it will be a 20 min job max..

I was thinking of using the 1.4 box but do you really think it would take the power of the turbo lump.. ? even if it just took standard power for the first 3 moths untill i find a better one..

[TURBO'D CLIO]

I got the 1.4 box off the clio today and every thing lines up against the volvo engine same bolt holes etc...

Andrew - would that 1.4 rt box take the stick of a standard volvo turbo, volvo prob has 40 bhp more and alot more torque..
But if it would do untill i get a proper one sorted then i'd be happy.....

[Andrew Cooke]

I got the 1.4 box off the clio today and every thing lines up against the volvo engine same bolt holes etc...

Andrew - would that 1.4 rt box take the stick of a standard volvo turbo, volvo prob has 40 bhp more and alot more torque..
But if it would do untill i get a proper one sorted then i'd be happy.....

run it for a while, there are no guarantees with any of these boxes, I've run ones from scrapyards with no problems, and spent a fortune on fancy stuff to destroy it in 10 miles.

[James5]

that's the thing about dialogys, it works on such old versions of stuff that you almost have to keep a dedicated machine for it.

I am using Vista but in order to use my Dialogys properly I use Micrsoft Virtual PC in which I have installed Windows 98se on and it seems to do the job pretty well.
Microsoft Virtual PC is a free download.

[Tiny Tim]

I think Beardo's still got his valver front wings and bumper for sale if you want to widen it a little

[TURBO'D CLIO]

Well after alot of thinking, sleeping, measuring and a closer look at the mk1 clio I'm going to stick with my original plans and keep this mk2, it's newer and cleaner than the mk1 and like some one else said MAKE IT FIT lol...

Lot's and lot's of progress today, both mounts turned up from renault today and ANDREW thanks alot for those epc pages helped out no end when i was on the phone to them...

Removed the cam belt, tensioners and metal cam belt cover (inner one) and luckly i had 3 holes in behind my cover ready to take the rsi mounting i was told that some only had 2 so i was well pleased..



I shot of to a nut and bolt war house at lunce time and bought some proper bolts for the mounts, got 3 m10 8 mm head allen bolts for the top mount, and 3 high tensile bolts to hold it all to the head..
I offered the rsi mount up on the head to see where it sat ....




Perfect fit, very tight and no room there but it fits.. I then cut off the crappy surrounding plate that goes around the wing mounting on the car and offered up the rsi top mount to it...


Just got about a inch over hang so that engine is gonna sit close to the inner wing (if it does fit) but I've made a few measurements and all seams good...

I marked where the Rsi mount sits against the cam belt inner cover, some people run them with out covers on but I'm not as I've seen to many cam belts jump teeth, i then cut out the cover and offered it back up to the engine


I then bolted the cover on and re fitted the cam belt and mountings, I am going to fit a complete cambelt kit when its ready to roll but for time being ill just keep what it has while the lump goes in and out the car testing and what not..

Finished item looks quite good i think..




Now the big decider is if it all lines up in the car, this weekend I'm gonna slap the box onto the engine and put it in the car and bolt it all up just to see where it all fits and if it fits... Just hope it all lines up and it dont sit at a slant or summit? I'm pooing meself.. lol

[Andrew Cooke]

shout up if you want the part numbers for any of the items in those drawings, might save you a bit of time at the stealers

[TURBO'D CLIO]

shout up if you want the part numbers for any of the items in those drawings, might save you a bit of time at the stealers

Thanks mate, i think i should be ok as im going to cut my plastic cover to fit around the mount so fingers crossed i can lay off the main stealers for a while..

How ever i think it will fit in ok but the antinator might not clear the slam panel as the bracket sit's up to tall

[Andrew Cooke]

you should be fine, they get all this clutter in the 172

[TURBO'D CLIO]

Hell

That inlet looks like a giant land snail lol, thaz HUGE !!

[James5]

That pic looks familair

you should be fine, they get all this clutter in the 172

[Andrew Cooke]

That pic looks familair

[TURBO'D CLIO]

Wee bit more progress ready to take the lump to (so hope it fits), finally sorted every wire in the loom, all the ones i need from all the ones i dont...
Tested a few just to double check i had the correct wires as haynes diagrams don't add up on the colours but i think i'm pretty much there now...





And all finished, the wires on the top tucked under the washer jet hose are all the ones to be coiled up and put out the way..

[gtmatt]

seems like your cracking on mate , whens the engine going in ? keep us posted

[TURBO'D CLIO]

seems like your cracking on mate , whens the engine going in ? keep us posted

Gonna trial run it tomoz, gonna mount it in with the auto fly wheel and 1.4 manual box from the clio, i wont ave any drive but i will be able to run it and see where the wiring goes then i can tidy all the wires up once and for all..

I'll pop the engine back out again and then prob put rings and shells init and obv do the head gasket and all the other seals at the same time.. Because the engine hangs on mounts i wont bother fitting the frame untill it's ready to move this way it makes it easier to work on it..

Fingers crossed for tomoz hey so hope it fit's

[TURBO'D CLIO]

Load's of progress today....

Got the clio gear box on, had to use auto flywheel for mo as mine is being delivered on monday.. Gear box fitted like for like just had to swap 3 dowls over...



Engine fitted in a treat so pleased, every mount just fitted perfect...



Turbo clears the bulk head by about 1.5"


So knowing that it fitted i thought about hearing it run, i sat there for weeks working out which wires go where so now was the tester...
Looks a mess but i know where I'm going with it, renault ecu on one side and both volvo ecu's on the drivers side, few hoses here and there...




I changed a bit of wiring, i decided to use the clio fuel pump circuit as opposed to the one in the volvo loom, seams to work fine so i might keep it that way...

Comments welcome, and also i'd like to say thanks to every one that has helped me out on this, advice has been great..

[TURBO'D CLIO]

Got a question about carbon canister's ?

The volvo had one tucked under the drivers front wing, it had 3 take off's that went to the manifold and one went to a vac switch on one off the water pipes?

Just to get it running i looped the 2 take off's on the inlet manifold and just blocked the little take off on the water rail, it seamed to run fine and others that have done the conversion just seam to loop it round and block it off..

Is this ok to just blank it off? and what about the switch on the water pipe one pipe from the switch goes to the carbon canister and the other pipe goes to the throttle body ?

Any idea's any one ?

[TURBO'D CLIO]

Got a question about carbon canister's ?

The volvo had one tucked under the drivers front wing, it had 3 take off's that went to the manifold and one went to a vac switch on one off the water pipes?

Just to get it running i looped the 2 take off's on the inlet manifold and just blocked the little take off on the water rail, it seamed to run fine and others that have done the conversion just seam to loop it round and block it off..

Is this ok to just blank it off? and what about the switch on the water pipe one pipe from the switch goes to the carbon canister and the other pipe goes to the throttle body ?

Any idea's any one ?

Still need help with this one and also need help with where to put the 3 ECU's.. I'm moving the battery into the boot to allow more space in the engine bay and I've also binned the big metal bracket that hold the renault ECU around the battery...

I was thinking of making a alloy plate going along the passenger side inner wing where the battery once was, and putting all 3 ecu's in a row... I've checked the lenth of the loom and it seams to be just about long enuf... Not sure where else they can go..

Any body got any idea's ?

Also noticed in the previous post from me i didn't atch say that i had it running, started her up and she went first hit, long way to go but at least it runs...