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850: 2.4 Lpt Into A T5 Hole?

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Hi there VS!

 

Please help me get at least one 850 back on the road. Today I have what I'm hoping is not too complicated a question...

 

 

Background:

I have a near-mint (cosmetic) T5 auto wagon with numerous upgrades done to it before overheating. IPD Stage 1, manifold spacer, cat-back exhaust, intake, RIP kit, silicone everywhere, IPD "angel eye" projectors, Volans, sound system, yadda yadda.

 

I had just successfully overtaken an unhappy M3 at about 75mph when I noticed the engine slowing and an impressive plume of steam and smoke behind me. Towed home that night. Overheat cause was found to be cracked plastic water pump impeller :angry: , which broke around the shaft (not radially) and allowed impeller to spin independently of the pulley/shaft. I didn't even know they made plastic ones until I pulled this apart and found the culprit.

 

Through some various screw-ups by a local yard, I am now out $850 (funny it being that number, still seeking refund) for a 2.3L R engine that developed serious rod knock after about 1k miles, still under warranty. Nothing to be done there but take them to small claims court. They've had 6 months to source a replacement for me and the sales guy has stopped returning my calls.

 

Current status:

In a garage, I have the resplendent wagon body on stands with engine and tranny out. The engine is certainly done for, overheat failure was catastrophic. Not looking to use it other than to hold spare bolts for now.

On the street, an 850 GLT (2.4 LPT) with 5-spd and a nearly-dead clutch. The body is fine but faded, interior is rough, and it has electrical (gauges, climate control) problems. Hoping to limp it to the garage IF and ONLY IF you think I can get away with manual swap + throwing all the T5 things around the 2.4 LPT. Am I just asking for trouble?

 

 

What I hope to achieve:

Migrate the 2.4 LPT and its 5-speed into the T5 wagon body. Harness, accessories, plumbing, and turbo all from the T5. Long block, transmission, pedals, shift linkage and shifter from the GLT. Having done one 850 engine swap already, I am comfortable with the mechanical work involved.

 

I'll definitely be consulting the 5-spd swap threads out there for that part of it. My understanding is that it's fine if you have a complete donor vehicle. Space is a concern so I'll be pulling everything from the GLT in one go.

 

I'll need to prep everything with the "new" engine+tranny together as I have to rent or borrow an engine hoist for that step. I have the garage until January 29. Both vehicles will not fit in the garage together, so I'll have to pick the GLT clean of anything useful before hauling it off on a flatbed - all in one go.  Very tempted to do forged crank and rods, but am thinking it maybe isn't necessary. If I went that route the head rebuild and porting would happen pretty definitely. $$$ though. :glare:

 

But will it blend?

 

 

TL;DR

Want to put 2.4 LPT into a T5 ECU/harness/plumbing/turbo/upgrades and nicer body. Also swapping 5-spd over with it. I want your input and advice on what I will need to do for the engine (beyond obvious gaskets, timing kit, seals, and fluids). Is this a square-peg-into-round-hole situation?

 

What else should I take from the GLT engine bay? Is that intake manifold any better than the very clean 2.3 manifold I have on my desk, or is that only NA? Throttle-body?

 

Should I be looking at tearing into the 2.4 to upgrade internals, or will it be OK at a moderately awesome (estimated) 275-300 hp? I doubt I am going the "bigger turbo, m0ar boost" route with this car as FWD is FWD.

 

Will the boost from stock T5 turbo with tune be too much for the 2.4 and its 10.5:1 ratio? Have Forge BOV on that RIP kit.


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