I'm familiar with the B230FT'S and volvo's but I'm completely unfamilar with the 960 and all of its idiosyncracies.

Here's the deal.
Just put in a 93 b304 into our 92 960 that had the wonderful porous block. Dreding the big moment I hit the key tonight for the first time and the motor fired up but it runs really rough, on only 4 cyclinders. The 'new' motor had been sitting since may and was said to run like a top when it was removed. Am I missing something really obvious here? Where should I start looking? The catalytic converter lit up like a torch from all of the unburnt fuel. I took out all of the sparkplugs and cleaned them up and but them back in but there was no improvement.

Also, I added six quarts of oil (5.75), as per the manual, and I'm not getting any reading on the stick. None. What's the deal there?

What is the standard procedure for circulating the coolant into a new engine? I was worried that the thermostat wouldn't open because it is not surrounded by water thus overheating the engine.

And I thought it was going to start up and run like a gem.
Please help and thanks in advance.


JS

Thanks to everyone for your suggestions!

Not being familar with these fancy engines I failed to put two and two, or in this case three and three, together. One powerstage was missing from the engine and it didn't occur to me that there might be another one missing. The engine was supposed to be complete. I swapped over the second power stage, hit the key and the engine purred to life. It runs really smooth now.

I added two more quarts of oil and now I've got a reading on my stick.

I kept adding coolant/water while the motor was running and everything seems to be working properly.

Next up: A lap around the block to check for leaks and a little wine to celebrate.
After of course.

Thanks again to everyone.

Jes
88 744t 254k
92 960 105k
91 744 135k

Congrats! :)
--
Chris. Halifax N.S. '91 745Ti, 291K km and '91 745 NA, 385K km.

Hi JS,

Maybe some lifters have collapsed on those cylinders? It's a common problem on the "white block" engines, I've seen it happen several times. How long did you run it for? Did you try revving it up a bit? What oil did you put in? It *may* just be that the lifters need to "pump up" so that the valves start actuating on those cylinders. Did you actually check for spark?
--
Chris. Halifax N.S. '91 745Ti, 291K km and '91 745 NA, 385K km.

Tom Irwin reported something like that a while back. He put a rebuilt head on the old engine block, and compression pressure blew piston rings weakened by an earlier overheating episode, until he had no compression and oil flowed past piston rings. Right now, a Volvo mechanic I know has a like problem with a rebuilt head he put in an 850 (another "white" engine with one less cylinder).

You will need to find out if the non firing cylinders have spark. If that checks out, how is the timing? You may have missed a ground wire somewhere. One that is frequently missed, by me too, once. It is the ground tang near the drivers side engine bracket. Right where the cable bundle passes by. Check for corrosion and tight fitting connectors. Maybe it is running on three cylinders and if that is the case, look at the power stages on the intake manifold. Try swapping them and see if the missing cylinders change. It could also be the ignition relay, located on the drivers side fender, the ignition and injector relays are the same, and right next to each other, swap them and see if you trade a ignition problem for a fuel problem.

A bone dry engine would require 8 quarts of oil initially. 2 remain after an oil change. So maybe that is where the oil is going. Make sure you have the correct dip stick, and that the dip stick tube is fully inserted into the sump.

As far as the coolant is concerned, all I have ever done is fill it up with the top hose off the radiator, wait until it starts to flow out, connect the hose. Turn the heat on to full, start the engine and keep filling with coolant as needed. Reving the engine will blow some of the trapped air out. I might have to fill a few days later with a cup or two.

Good luck

DanR 94 964 270,000 miles (36,000 on the new engine)
--
DanR

DanR

Thanks for your post. Wow. That is a double the oil in my 4 cyclinder.

I think that it is running on 3 cyclinder- 1,3,5 maybe.
Is there more than one power stage? I can see a 'sensor' on the front side of the intake manifold facing the alternator- is this what you are talking about? If so mine was missing when I got the motor and I used the (good) one from the old motor. I don't imagine 92-1993 being different. As for checking spark, is there a particular procedure for this motor with its funny coil packs? I pulled a plug out and laid it on the valve cover and I didn't get anything. So, thinking I found a dead one I checked another but it didn't produce any spark either making me think that I was not checking them correctly.

For the coolant I filled it up from the overflow tank, got about a gallon and a half into and started it up and pour the rest in as it slowly flowed into the radiator/motor.

JS

Yes, there are two power stages, front and back of the manifold. With 2,4,6 not working it is most likely one of those, don't remember which one controls those cylinders. Try cleaning the metal contacts first and see if that fixes it. Testing the individual spark plugs is done just the way you did it. Though pulling the fuses to the fuel pumps first might be in order, just to keep the raw fuel and fumes to a minimum. Narrow it down to the cylinders that are not firing, then swap the power stages, that should move the non firing cylinder to the other set. If cleaning the contacts doesn't help, you most likely will need another power stage. Unless someone else has other thoughts.

DanR 94 964 270,000 miles (36,000 on the new engine)
--
DanR

Since you have just installed this new engine and the front power stage is hooked up(located on the side of the intake facing the alternator)sounds to me the back power stage isn't hooked up this one is on the opisite side of the intake facing the driver.
Good Luck
Poolman