Volvo 240 1UZ Swap

This article is full of information about the 1UZ-FE engine and "tips and tricks" for installing this engine in a Volvo 240. LucaCarMods has developed various parts to simplify the execution of this engine swap and we do our best to add even more products to this range in the future.

1.0 Information about the 1UZ-FE

The 1UZ-FE engine is a 4.0L V8 engine designed by Toyota/Lexus and can be found in cars such as the Lexus LS400. There are multiple types of 1UZ-FE engines, each with its pros and cons.

1.1 1st gen 1UZ-FE

Our swap kit is designed for the 1UZ-FE 1^st generation with a 340e automatic transmission. The reason many people choose the 1^st generation 1UZ-FE engine is because it has the thickest connecting rods of all generations. The advantage of this is that it is possible to mount a turbo and significantly increase power at a later stage. The caveat with this engine is that it has the least power in atmospheric form.

Power: 245hp

Pros: Thicker connecting rods

Cons: Least power

1.2 2nd gen 1UZ-FE

The 2^nd generation 1UZ is almost identical to the 1^st generation in terms of appearance and installation possibilities. However, it has already gained a nice power increase to no less than 265hp. This engine has thinner connecting rods and is therefore less suitable for a turbo conversion.

Power: 265hp

Pros: More power than the 1^st generation

Cons: Thinner connecting rods

1.3 1UZ-FE VVTi

If you want to continue driving naturally aspirated, the VVTi engine is definitely recommended! It produces no less than 290-300hp and also has more torque at lower RPMs due to the VVT and variable intake length.

Please note that all 1UZ-FE VVTi ECUs are equipped with an immobilizer. If you are going to run on the original ECU, always ask for the RFID reader, amplifier, and key so that you can start the engine without problems.

Power: 290hp

Pros: Most powerful 1UZ engine

Cons: Thinner connecting rods and immobilizer

Of course, much more information about the 1UZ-FE engines can be found on the internet. In a nutshell, these are the most important items so that you can make a good choice as to which is best suited for your engine conversion.

2.0 LucaCarMods 1UZ-FE Swap kit for a Volvo 240

As of the time of writing (3-2022), our swap kit to equip the Volvo 240 with a 1UZ engine consists of the following items:

• Engine mounts
• Transmission mount for the Lexus 340e automatic transmission
• Throttle cable adapter kit
• GPS Speedometer adapter
• Fan Shroud Kit (new product 03-2022)
• SHIFTER CABLE BRACKET – 340E AUTOMATIC TRANSMISSION – B&M RATCHET SHIFTER (new product 03-2022)

The plan is to expand this to include more parts in the future to ensure that the swap becomes increasingly plug and play.

2.1 Important: Which 1UZ-FE and Volvo 240 are our parts based on and what do they fit (3-2022 kit)

LCM has developed the 1UZ-FE Volvo 240 swap kit for the following setup:

• Volvo 245 1975 LHD
• Without power steering
• Thin/small brake booster
• 1UZ-FE 2nd gen

This means that the parts we have developed will definitely fit this combination. Through customer feedback, we have now been able to create a good overview of the compatibility of our products.

2.1.1 Engine mounts fit:

• 1UZ Volvo 242, 244, 245 LHD without power steering with small brake booster
• 1UZ / 3UZ – Volvo 242, 244, 245 RHD with power steering with small brake booster

For a left-hand drive 1UZ Volvo 240, the engine mounts need to be modified to provide space for the banjo bolts of the steering rack. It can therefore be made to fit by cutting a small notch out of the engine mounts with an angle grinder.

2.1.2 340^e automatic transmission mount fits:

The Lexus 340^e automatic transmission, as far as we know, fits all 1UZ/3UZ and Volvo LHD/RHD combinations. However, we have heard that with certain combinations, the bolt holes for attachment to the chassis on the mount need to be made slightly larger.

2.1.3 Throttle cable adapter kit fits:

This adapter kit can be used on the 2^nd generation 1UZ engine.

For the 1^st generation 1UZ engine, we had to mount the throttle cable on the other side, but we used the adapter bracket to attach the throttle return spring.

The throttle cable from this kit can be used with some modifications to the original 1UZ throttle cable bracket.

2.1.4 GPS Speedometer adapter

The adapter plate for mounting a GPS speedometer from Alibaba is only suitable for the 1^st generation instrument clusters of a Volvo 240. You can easily check this by looking at the back to see if the original speedometer can be removed.

2.2 Wiring from Phoenix Engine Management

An important aspect of any engine swap is the wiring. For wiring, we always choose to send the wiring harness that comes with the engine, including the ECU, to Phoenix Engine Management in the United Kingdom. They specialize in creating Plug and Play wiring harnesses for a 1UZ using the original ECU. If desired, they can also create a wiring harness for a standalone ECU.

The reason we choose to work with this wiring harness supplier is that we receive a wiring harness with a few loose wires that need to be connected to the Volvo 240. This includes: switched positive, constant positive, charging current control lamp, engine malfunction light, reverse lights, etc.

In short, you get a very neat wiring harness that is easy to connect.

3.0 Converting a Volvo 240 to a 1UZ-FE Volvo 240!

Now that the general information about the 1UZ-FE engine and LCM parts is known, we will go into detail about performing the swap.

For each part, specifics, information such as wiring diagrams, important facts, and tips will be provided. This is therefore not a manual, and the chapters are not always in chronological order.

3.1 Preparations for the 1UZ-FE

3.1.1 The correct serpentine belt for a 1UZ-FE without AC and PS

If you have chosen to remove both the air conditioning (AC) and power steering (PS) from the engine, a specific serpentine belt will need to be installed for the alternator. Instead of using an expensive adapter kit, you can also use the following stretch belt:

This is a GATES K060283SF stretch belt. Please note that you should also order special tools for installing stretch belts. If you don't, there is a very high chance that the serpentine belt will tear.

3.1.2 Removing the viscous fan

The first generation 1UZ engines are equipped with a viscous fan. Due to space constraints and the fact that the viscous fan consumes a considerable amount of power, you can remove it. Information in various places states that the fan is connected to the water pump; this is not the case. The viscous fan can simply be removed.

We have welded an aluminum plate into place for aesthetic purposes.

3.2 Preparing the Volvo 240 fuel system for the 1UZ-FE

The standard fuel supply of a Volvo 240 can be mechanical or with 2 electric fuel pumps. In both cases, it is necessary to remove the original system (except the return line) and install a new fuel system.

3.2.1 In-line fuel pump or in-tank fuel pump

It is logical that a larger fuel pump needs to be installed, as the 4-liter V8 engine demands significantly more fuel under full load than the 2.3-liter 4-cylinder that is usually standard.

For the Volvo 240, you can mount either an in-line pump under the car as the main fuel pump, such as the Bosch 044, or an in-tank pump, such as a Walbro 255L.

When installing an in-line pump under the car, I recommend adjusting the suction tube in the tank so that it has the correct suction height. A pre-filter must also be placed in the suction line before the pump.

Installing an in-tank pump is self-explanatory.

Which one is preferred is up to you. An external pump is easier to access, and an internal pump is often quieter.

3.2.2 Fuel rail connections

The Volvo 240 has a fuel system with a return line, and the 1^st and 2^nd generation UZ engines also have this. This allows you to reuse the Volvo 240's return line by connecting it under the hood to the 1UZ engine's fuel rail.

In a LHD Volvo with the engine installed, the supply side of the fuel rail on the 1UZ is on the driver's side and the return line is on the passenger's side.

To provide both connections with Banjo fittings, you will need 2x M12x1.25 hollow bolts (if you do not wish to use the original fuel pressure regulator) and 2x M12 banjos in the desired hose diameter.

3.3 Sump modifications

As previously mentioned, the sump needs to be modified to enable the installation of the 1UZ-FE.

Modifying a front sump as shown below ensures that the engine clears the steering rack and anti-roll bar. Because the sump is positioned so far forward, you will also need to modify the oil pickup tube.

We've fitted this oil pan with 2 extra baffles to prevent the engine oil from sloshing around too much during cornering. You will also need to fabricate your own dipstick for the top of the oil pan, as the original one will no longer be used.

Shortening and reusing an old dipstick from, for example, a Mazda MX-5 works very well.

3.4 Small brake booster

The 1UZ is a rather wide engine, which causes the valve cover to interfere with the brake booster when using a new type (thick) brake booster. By using the original old type (narrow) Volvo brake booster, you will have approximately 2cm clearance to the 1UZ valve cover.

3.5 Exhaust manifolds

Various types of exhaust manifolds were supplied for the 1UZ engine. Any manifold will fit on the passenger side, but on the driver's side, the steering shaft is in the way.

So far, it has been found that the (2nd gen) 1995 1UZ-FE steel manifolds from an LS400 can be made to fit on both sides. By marking the manifold where it comes into contact with the steering shaft and then "massaging" it there with a good mallet, it can also be made to fit.

The 1994 (1st gen) 1UZ-FE LS400 manifolds definitely do not fit.

If you prefer not to dent your manifolds, the only other option is to make custom manifolds.

At Engine Masters, they did a nice test to see how much difference denting a manifold makes; the difference was negligible. Unfortunately, the video has since been taken offline (probably due to video rights). But here's the photo and a link to the article:
https://bangshift.com/general-news/videos/after-getting-bashed-in-the-comments-for-the-header-bash-episode-engine-masters-takes-a-second-swing-at-the-dented-headers-myth/

3.6 Radiator and cooling system

3.6.1 Coolant connection sizes

The coolant connections on the 1UZ-FE engine have a diameter of 38mm, while the Volvo connections on the radiator are 32mm. The best solution is an aluminum Volvo 240 radiator and then weld aluminum bends onto it so that you only need to use one silicone coupler per side. You can also go directly from the radiator to 38mm without a silicone reducer.

3.6.2 Using Lexus 1UZ-FE Coolant Temperature Sensor with Volvo 240 Instrument Cluster

Normally, you would reuse the Volvo 240 coolant temperature sensor in a swap because the 1UZ sensor and the 240's provide different values.

Someone else who performed the same swap discovered, after much trial and error, that you can use the original 1UZ coolant temperature sensor in combination with a 33 ohm resistor. *At the time of writing, we have not yet tested this ourselves.*

3.6.3 Converting DO88 Volvo 240 Radiator to Electric Fan with an LCM Fan Shroud Kit

With our fan shroud kit, you can easily mount a 356mm Mishimoto Slim Fan to the radiator. You slide the bottom of the shroud into the slots and drill 3mm holes at the top yourself, then secure everything with bolts and locknuts.

The reason you need to secure the holes yourself is that there can be small differences in do88 radiators.

3.6.4 Controlling the electric fan with the Mishimoto Fan Controller kit

By removing the viscous fan, you will need to switch to an electric cooling fan for the radiator. If you connect this directly with a relay and switch, you will always have to monitor the temperature yourself...

Much easier and safer is the Mishimoto Fan Controller kit. With this kit, you can control an electric cooling fan using the included coolant temperature sensor and control unit. On this control unit, you set the desired temperature at which the cooling fan will switch on.

The included sensor has a 1/8 NPT thread.

3.7 Wiring

The wiring connection with the Phoenix Engine Management manual is largely self-explanatory; the switched positive can be tapped from the ignition switch (measure to be sure), the same applies to the start signal and other basic connections. I will therefore not go into this further.

However, a few other things are important.

3.7.1 Install Diodes or LED indicator lights

Replace all indicator lights you'll be connecting, such as the charging system indicator, check engine light, and any other T5 bulbs, with LED versions (available from our webshop) or install a diode. The most important one here is the charging system indicator light.

If you don't, 12V can flow back into the ECU, keeping it energized, preventing you from turning off the engine with the ignition switch. The only solution then is to disconnect the battery terminal. A diode ensures that current can only flow in one direction.

3.7.2 Wiring the instrument panel

In the instrument panel, there are a few things you will probably want to connect:

• Check engine light
• Oil pressure
• Charge light
• Tachometer

From Phoenix Engine Management, you will receive a file indicating which signal to expect on a wire. See photo below.

1. The wire from pin 1 can be directly connected to the 1-pole connection behind the tachometer. The 8-cylinder engine provides a 4-cylinder tachometer signal.
   
   
2. Go to https://www.240turbo.com/240gaugewiring.html and find the correct instrument panel. You will find a photo like the one below:

Given that most old Volvo 240s do not have a check engine light, you can use the Choke Lamp. This illuminates orange and displays CH, which can be interpreted as CHECK.

In this case, you connect the CEL/MIL wire to connector 32, pin 3.

• Coolant temp is also quite straightforward; you can connect it to connector 31, pin 10. (Always double-check the website to ensure this is correct for your model year)
  
  
• Chargelight can be connected to connector 31, pin 4. Always check if connector 31, pin 9 is actually receiving 12V to ensure the charge light will work. (Always double-check the website to ensure this is correct for your model year)
  
  
• Oil Light can be connected to connector 31, pin 11. (Always double-check the website to ensure this is correct for your model year)

Instead of cutting off all connectors and then soldering the wires, you can also use completely new terminals. This ensures a much cleaner finish.

The correct terminals can be ordered here: https://lucacarmods.com/shop/electronica/connectoren-bedrading/connector-contacts/volvo-240-instrument-cluster-stekker-contact-female/

3.7.3 Brake light signal for the automatic transmission

The automatic transmission needs to know when you press the brake pedal. If this is not connected, the engine might push while you are braking.

The brake light signal can be provided by tapping into your brake switch or the control relay that monitors the operation of the lights.

Below is a wiring diagram of the round control module located at the bottom of the steering wheel. With a multimeter, you can easily find the 12V signal here when the brakes are applied.

*Always check if this diagram is correct for the year of your Volvo.

3.7.4 Reverse switch and lighting

The automatic Volvo 240 has a reverse switch mounted near/in the automatic shifter. Remove the automatic shifter/switch and use its wiring to connect the reverse lights.

3.7.5 Neatly installing and grounding 1UZ Ignition Modules

The 1UZ has 2 ignition modules, which must be grounded to the housing during installation. An ideal place to neatly tuck them away is against the firewall with rivnuts.

We use M6 rivnuts in combination with M6x30 hex bolts for mounting the ignition modules. This neatly tucks them away and also provides a ground point for the housing.

3.8 Automatic shifter

The Volvo 240 automatic shifter can be replaced by a B&M 80842 – B&M Pro Ratchet Shifters, which can be ordered from, for example, Summit Racing.

This shifter is not entirely plug and play, but it is one of the better solutions for controlling the Lexus automatic transmission.

I will not explain the installation of the shifter itself in detail, but there are a few important things to know.

• For mounting the cable to the automatic transmission, one of the supplied brackets needs to be modified.
• The gear selector lever on the side of the gearbox must be rotated 180 degrees so that it points downwards.
• The most important thing is that the lever on the gearbox has a center-to-center hole length of 57mm. (always check this yourself with the calculation below the photos)
• Always index the automatic gear stick in the neutral position. The travel from R to P is longer than the others on the 340e automatic transmission.

Below you will find the calculation to determine the length of the 340e automatic transmission arm yourself.

Source: https://www.lextreme.com/forums/threads/1uzfe-auto-box-convert-to-cable-shift-link.10007

– Measure the arc the selector on the gearbox takes from Park to 1st (The a341e goes through 60 degrees).
– Measure the Amount of cable pulled by the shifter from Park to 1st (The outlaw was somewhere around 50mm… I can’t remember exactly)

– Using a bit of maths the formula was as follows:

Arm Length = ((360 / Selector Arc) * Cable Pull) / ( 2 * PI)

Basically I’m working out the radius of a circle, using the length of part of the circumference.

So my formula was:

Arm Length = ((360 / 60) * 50) / ( 2 * PI)
Arm Length = 47.75mm

IMPORTANT: The values I’ve plugged in here are from memory. MEASURE YOURS FIRST!

3.8.1 Bracket for the B&M shift cable

The bracket shown below is a modified B&M bracket to mount the shift cable to the 340e automatic transmission. We have converted this bracket into a 3D CAD drawing so that it can be laser cut.

Our bracket can be found under the heading Volvo 240 1UZ swap or by clicking here.

To be continued

If we encounter other issues or receive questions from customers, these will also be included in this article.

If you have any questions about this swap or our products, feel free to send us an email via the contact form.

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