So I finally got to putting the new motor in the 850 turbo. The original motor spun a rod bearing so i picked up a 220k long block from the fine folks at mr volvo. Found some used Pauter rods, and had some pistons made up by Venolia in a 0.020" oversize and had the block bored and honed. Rebuilt the head, ran low on money and dragged the project on over the past 4 months!

Cleaned everything and assembled the motor with new waterpump, t-belt/tesioner, had the alt. rebuilt (owed a favor), rebuilt the turbo yada yada yada. Swapped the motor into the car over the past few evenings and buttoned it up tonight.

Just as i am checking all clamps, hoses and conectors, I pull the hose off the throttlebody and realised i shat the bed. The throttle body is all gunked up (forgot to clean the intake!) so i pull the t-body off and clean it. Put it back on and notice something just insight inside the manifold, concocted (sp?) a grabbing device and pull out a CHUNK OF STEEL!

I can't even fathom what or where this came from. I distinctly remember shaking the manifold and pooring brakecleaner out of it as i sprayed it down the runners before i was going to hot tank it (never got to). I put a magnet in the intake and came up with nothing. I REALLY don't want to pull the intake off again!

Help feel my pain please )-:

Oh yes I FEEL your pain.

I also know you have this question or uncertainty ... is there more metal in the intake???

I know it is a pain to pull the intake again but I strongly suggest you take it off and make sure. it is probably OK, but if it is not and there is a bit of metal in there .... well there goes your new engine and all the money and parts invested.

I don't know how many times I took apart my last project during construction to make sure it was "just right". Joke was on me, I guess.

Ya ... Matt and I are the experts at - put together - take apart - put together - take apart ....

One advantage of this technique is you become very fast at it

Be thankful you found it before your new motor ingested it! At this stage, taking another day or two to pull the intake apart and give it a good cleaning seems like a worthwhile effort to me!

Sounds like that was one sick old motor!

You know its not that bad at all. I seriously think the chunck fell in the manifold while off because the car had great compression before i pulled it. All that happend was a spun rod bearing causing some journal wear and opening up the rod a bit.

I didn't sleep a wink last night, it's just my luck that when i start the motor something will happen or I will have aquired another problem. I've always considered myself even stephen and i'm $7000 into this car so it just kills me to think i still may not be done.

Man, I can't beleive how depressed i am over this car. Thanks for the support!