Well, I destroyed my car. I am not willing to let it die though! I have a 98' GLT with 226K on it. I will give you the history on what I did and then maybe you guys can crucify me on what I did wrong. My car was blowing a lot of white smoke and the CEL was reading the codes for a faulty wastegate and a faulty PCV valve. Then my exhaust fell off at the Cat so I swapped the exhaust for a full OBX with a 3" downpipe and never added the bung for the SAS. Shortly after I replaced the PCV valve and it did not correct the smoke problem, but during the change I noticed a lot of oil in the turbo. I bought a new turbo, a 16T from CXRacing and swapped that this past weekend. I noticed that the larger fitting for the air line from the PCV to the intake was clogged and cleaned it. Car started and ran smoother than I can ever remember. As I test drove there was a loud pop and the car started to hesitate and almost stall. The car ran fine when I disconnected the MAF, except for the power. I checked all of the vacuum lines and noticed the small one from the PCV to the intake had blown on the elbow at the intake, and the turbo hose to the throttle body had come loose. Fixed all of this and the car ran smooth again. I took it out for a second test drive and gave about 50% throttle and the car took off faster than I had ever felt and I could hear the turbo spooling then the car bucked and I let off the gas. As soon as I let off the motor was clanking like no other sound I have ever heard. It sounds like the pistons are slapping on the valves. I do not have a reader at home to check the codes. Is there a chance that the turbo could have overboosted since I did not check the rest of the vacuum lines to see if they were clogged? Is the turbo too big for the car? I want to make sure that the problem is corrected before I fix the motor and it does it again. I will not be able to check the timing until this weekend to see if the belt slipped. This is going to take me a while to fix so I apologize if I do not get back to anybody right away. Money is tight and I have been working on this in my driveway in the middle of winter.

 

I will bet it boosted to high to fast and bent a rod or 2.
Do you have an aftermarket gauge in the car?

 

I do not have a boost gauge. I think your right about the rods. With the motor having so many miles I dont think it could handle it anyway, the car used to tap a little already. If the turbo did boost too much how do I control that? It did feel like it did.

 

Well first make sure you have all the vacuum lines to and from the boost control valve correct. Sounds like they might not be connected correctly.

 

The two lines that go from the BCV to the turbo were installed backwards. I have looked into rebuilding and replacing, and it does not look cost effective at all to rebuild. I am going to pick up a used engine. What other volvos can I get a motor from?

 

Look for a 850 motor as well as the S70 motor.

 

Am I able to replace it with any 2.4L motor? Does it matter weather or not it was a turbo model? Can I replace it with the 2.3L as long as I replace the ECU? I am just trying to get as many options as possible. I have found a scrap yard that sells any 5cyl motor for $85.

 

You would be better off putting in a 2.3 and getting a T-5 ecu. This way later if you mod it the motor will be able to handle it better.
You should be able to run it with out the T-5 ecu till you can get it.