Re-Volv/Kaplhenke Racing BlockGuard for 2.5L S60R V70R

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A joint project between Re-Volv and Kaplhenke Racing, our revolutionary BlockGuard is designed to solve a major problem which is inherent in the 2.5L block used in the S60R and V70R, cracked cylinders. Heat and vibration are the enemy of open deck engine blocks and they plague the 'R Cars' especially as boost and power levels are increased.

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$799.00

  • Yes ($350)
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Group Buy Pricing:

We have just completed a short run of our BlockGuards and installed them in our core blocks. This way you are able to order a BlockGuard and receive a block (with BlockGuard already installed), crank, and girdle in just a few days without having to wait for machining and installation. These are available for immediate purchase at a discounted price. The price for the BlockGuard is $799 and the core charge for using our block is $350. If you send us back a useable core (block, crank, girdle) we will refund the $350 core charge.

If you would like to purchase one of our blocks with the BlockGuard pre-installed, please choose "YES" on the Block Core button above. If you send us back a usable core, we will refund the $350 back to you at that time.

The background:

The Volvo 5 cylinder motors are great and have proven their strength and reliability over the years. This is mostly true of the B5254T4 used in the S60R and V70R with one major caveat, they frequently crack the cylinder liners.  This often happens with higher boost and power levels, but can also happen with stock tuning and boost levels. Once the cylinder is cracked, the engine is effectively junk.

Volvo employed an open deck design when manufacturing the white block series motors, which has several advantages and disadvantages compared to closed deck motors such as the older red blocks.

The pros: light weight, low manufacturing costs, and excellent cooling 

The cons: low stability, low strength

The factory rotating assembly (crank, rods, and pistons) are very high quality and should support substantial power output if the block was up to the task.   

The existing methods commonly used to reinforce these engines is either shimming the cylinder liners or installing a sleeve kit.  Both can work but have their drawbacks.     Shimming addresses the problem indirectly by supporting the block in the weakest area but the block is still subject to the high stresses that cause the cracking.   Sleeving the block is overly expensive and the cast iron used does not reject heat as well as an aluminum housed sleeve.   

The problem:

The main issues are the engines ability to handle the thermal loads, and the block stiffness.

The B5254T4 can produce a lot of heat, especially with increased power output. Since the stock arrangement can not cope with heavy loads, it allows the engine block to operate in a temperature range where they see a dramatic reduction in strength and the result is eventually the cylinder liner fatigues and cracks.

The open deck design allows the top of the cylinders to float and are only braced by the head gasket and the cylinder head, which is problematic as power levels increase. Between the normal vibrations created in the engine and the thrust force created by the pistons during their normal stroke this will cause a situation where the location of the bore is not stable, making cracks a likely effect.

Our solution:

We had the idea but needed someone who could bring our idea to life. Kaplhenke Racing was our first call and what you see here is the culmination of months of research and revisions. We decided to engineer and manufacture a hybrid solution between sleeving and shimming.   One of the big advantages that you get with the Darton MID sleeve kit is the block receives extra bracing from the design of the sleeve.  We have integrated the same approach into our kit but since our kit is made from aluminum & the factory block is made from aluminum, the thermal expansion rates will be very similar and keep the support consistent as the engine changes temperature.

But just reinforcing the cylinders was not enough for us. We wanted to address the need for increased thermal transfer on high horsepower builds. We went a step further and added cooling fins integrated into the lower half of our support which also function as stiffening ribs. Keeping an open channel at the top of the support allows coolant to flow around the area with the highest thermal load.

The process:

The process starts with an 11 lb bar of billet 6061-T651 aluminum that we CNC machine down to a .7 lb reinforcement plate.

Then we take a bare cylinder block and CNC machine the water channel of the block so that our BlockGuard will fit exactly the same in every single block we manufacture.  

Once the block is machined, we apply an aerospace grade thermally conductive epoxy that mechanically and thermally bonds the reinforcement plate to the engine block. This insures that we have over 99% surface contact between the engine block and reinforcement. By filling all the minor surface variations and microvoids we can achieve a much greater thermal transfer rate from the cylinder to the guard.

Availability:

We have a very small number of blocks that have BlockGuards pre-installed. Information on these is listed above, or you can send us your good block to be machined. Keep in mind that turn-around time on machining your block can be lengthy as we have numerous other projects underway simultaneaously. Please call or email for more information on machining your block.

The purchase price of $895 includes a BlockGuard insert, machining your engine block and installing the BlockGuard insert into your block. It does not include finish machining or shipping.

Test Mule:

2006 S60 T5 M66 - Running Stock Engine Management System

Engine 

  • 2005 B5254T4 (S60R) Block
  • Stock Connecting Rods
  • Stock Pistons
  • New Stock Piston Rings
  • New Stock Bearings

Turbo

  • Precision 5857 Turbo with Billet Compressor Wheel
  • Snabb Ultimate FMIC
  • Snabb Intake Pipe and High Flow Intake

Other Upgrades

  • High flow Fuel Pump
  • Audi S4 MAF
  • 950cc Deatschwerks Fuel Injectors
  • Wavetrac LSD
  • Spec Stage 3+ Clutch and Single Mass Flywheel

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Re-Volv/Kaplhenke Racing BlockGuard for 2.5L S60R V70R

Re-Volv/Kaplhenke Racing BlockGuard for 2.5L S60R V70R

A joint project between Re-Volv and Kaplhenke Racing, our revolutionary BlockGuard is designed to solve a major problem which is inherent in the 2.5L block used in the S60R and V70R, cracked cylinders. Heat and vibration are the enemy of open deck engine blocks and they plague the 'R Cars' especially as boost and power levels are increased.

Write a review