I'm looking to rebuild a 1993 Volvo 960 3.0 liter 24 valve overhead cam in-line 6 cyclinder engine this winter with the goal of boosting the stock horsepower as much as possible, ie as much as I can afford and find parts for.

This motor is from a wreck and has 114k miles and will replace one in my 93 wagon which will have ~ 200K miles next spring.

I'm planning on the proposed list of modifications shown in order of preference:

Overbore cylinders by .030" or up to .060" if the block will take it.

Oversized headgasket, pistons & rings if I can find them.

New bearings.

Mill, port & polish the head - Overbore to match the cylinders?

5 angle valve grind.

Clean & flow balance injectors.

Overbore the throttle body.

Knife edge the (new) throttle body plate.

Flush mount throttle body plate screws.

Port match intake & exhaust to the block.


The machining & assembly will be done by my local engine rebuilder here in the Phila PA burbs.

I couldn't find any source of a more aggressive cam for instance so I'm sticking with stock.

Can anyone suggest suppliers for the oversized items I will need.

Does anyone have any other suggestions for performance modifications short of a turbo or supercharger or other comments or suggestions?

Thanks.