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Well doctor, the transplant was complete. Your volvo is going to live...
I finished hooking up the B20E/M41/Short Driveshaft, HIF6 Carbs, and the other critical engine systems today around 4:30. The engine fired right up after replacing a damaged distributor cap. It initially ran rough, but quickly smoothed off into the nice steady roar of a good motor. It sounds many times better than my old ailing B18B.
Issue #1. It was initially putting A LOT of exhaust out the tailpipe. White in color, but smelling strongly of...exhaust. It seems to have dissipated somewhat but is still present. I'm hoping that this is just the engine burning out all the gunk and fluids that got into it during the long swaping period. It did not do this when it was in the 1800E, so I hope it is just temporary.
Issue #2. The cause of some concern. I've got a B18 hydraulic clutch bellhousing in between the B20 and M41. The clutch has A LOT of travel in it. I adjusted the slave pushrod out almost as far as it could go and got only just enough clutch to shift without grinding gears. I'm suspecting that the issue is due to the different clutch plate on the B20E vs the B18B. I didn't notice that they were different until I already had the B20 in the Amazon.
After the last few days of intensive automotive antics, There's no way that I'm pulling that motor and gearbox out of the car again so soon just to swap the clutch plate. So...
I picked up a couple of extra-long 5 and 6 inch 5/16" grade 8 bolts. I was going to cut off the heads, round down the backside and install one in place of the old pushrod. I did something very similar when I converted to an 1800-style Master Cylinder.
So, should I even have this problem? Is there a problem with this sort of fix?
Issue #3. Wiring up the Overdrive. I've read over the VClassics article on wiring it up. That ought not to be too bad. However, I'm a little confused about the reverse light switch. It was hard to tell but there's already a wire on the reverse light but it seems to be in series with the OD solenoid. Only two wires that come out of the M41 Harness and I thought that one was for the OD solenoid, and the other was for the 4th gear lockout. With everthing installed, I can't see what's what in there anymore. How do I hook up my reverse lights?
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So, other than those two issues, I still need to top off the various fluids, adjust the lifters, adjust the carb mixtures for the new motor, and balance the carbs. Then, unless something new appears, I'm set to enjoy the power and smoothness of my new drivetrain.
Thanks for all the help and advice so far. I could not have performed this switch without you guys.
Jack
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