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  1. #2201
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    Again with COVID and time passing away - my thoughts on where I am going next. There is boost creep. I originally thought the SBC was playing up so at some expense I replaced the twin solenoid controller. Makes no difference. Boost is uncontrolled above 5K and peaks out around 1.7 bar. Thankfully the engine appears strong enough to take it.

    I still have an AFR bung to fit. My main thoughts now are towards boost control. I don't think I want to change the exhaust manifold - not after all that work and money, to fit something with an external w/g fitting. e.g. http://swedenexhaust.se/en/volvo/198...rial-mildsteel plus I am not sure this would clear the brake booster on a LHD car. TBH boost creep was never an issue I'd thought I'd have to face. I can either port the W/G hole further and increase the flapper size? or fit an intercept between the manifold and the gtx, with some kind of v-band flange or feed pipe to an external w/g.
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  2. #2202
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    MoleT-5R's Avatar
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    Quote Originally Posted by Wobbly Dave View Post
    Again with COVID and time passing away - my thoughts on where I am going next. There is boost creep. I originally thought the SBC was playing up so at some expense I replaced the twin solenoid controller. Makes no difference. Boost is uncontrolled above 5K and peaks out around 1.7 bar. Thankfully the engine appears strong enough to take it.

    I still have an AFR bung to fit. My main thoughts now are towards boost control. I don't think I want to change the exhaust manifold - not after all that work and money, to fit something with an external w/g fitting. e.g. http://swedenexhaust.se/en/volvo/198...rial-mildsteel plus I am not sure this would clear the brake booster on a LHD car. TBH boost creep was never an issue I'd thought I'd have to face. I can either port the W/G hole further and increase the flapper size? or fit an intercept between the manifold and the gtx, with some kind of v-band flange or feed pipe to an external w/g.
    I'm assuming that you think the wastegate is not allowing enough exhaust gases to by-pass the turbine, thus boost creeps up uncontrolled, is the the wastegate actually opening fully under pressure conditions ?? is the start point of the wastegate set correctly and is it sprung correctly for your application ?? finally if you back off the wastegate set load at rest, does this improve/reduce the boost creep or make it worse, or even have no effect at all ?? Worth having a play with the wastegate with a mittyvac and seeing how it's operating and open. Also playing with the setting on the rod may help (reducing it's load at rest), as it costs nothing but a bit of time in the grand scale of things and may help point you in the right direction or even possibly even solve the issue. Good luck Dave hope you find these ideas useful.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  3. #2203
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    Quote Originally Posted by MoleT-5R View Post
    I'm assuming that you think the wastegate is not allowing enough exhaust gases to by-pass the turbine, thus boost creeps up uncontrolled, is the the wastegate actually opening fully under pressure conditions ?? is the start point of the wastegate set correctly and is it sprung correctly for your application ?? finally if you back off the wastegate set load at rest, does this improve/reduce the boost creep or make it worse, or even have no effect at all ?? Worth having a play with the wastegate with a mittyvac and seeing how it's operating and open. Also playing with the setting on the rod may help (reducing it's load at rest), as it costs nothing but a bit of time in the grand scale of things and may help point you in the right direction or even possibly even solve the issue. Good luck Dave hope you find these ideas useful.
    I have tested the car with the wastegate flap wired fully open to prove the boost creep, which is self evident. I have played around with different settings and used the mittyvac I bought recently to ensure that the SBC was working properly (generating a false pressure into the SBC solenoid to check that it is releasing the boost) and to ensure that the pretention on the W/g actuator was correct. I definitely have boost creep, because above 5K even with the flapper wired fully open it made over 1.5 bar boost.
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  4. #2204
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    MoleT-5R's Avatar
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    Quote Originally Posted by Wobbly Dave View Post
    I have tested the car with the wastegate flap wired fully open to prove the boost creep, which is self evident. I have played around with different settings and used the mittyvac I bought recently to ensure that the SBC was working properly (generating a false pressure into the SBC solenoid to check that it is releasing the boost) and to ensure that the pretention on the W/g actuator was correct. I definitely have boost creep, because above 5K even with the flapper wired fully open it made over 1.5 bar boost.
    It would seem that the wastegate is under spec for your application as it's still driving the turbine to give 1.5 bar of boost even when fully open, is there a larger option one for your turbo?? as it seems a bit undersize compared to the turbine housing in one of your earlier pics in your thread.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  5. #2205
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    Scrub that as I've just been further back in your thread and can clearly see the hole is in the GTX turbine housing and not on the wastegate as I had assumed, that said it does seem a very small hole for all those gases to by-pass the turbine when your hard on the loud pedal and the wastegate is trying to control the boost, could the hole diameter be increased to give a bit more control when the flap is open, just a thought....

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  6. #2206
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    Ade - I looked at these and this also was my first reaction. For a kick off the zircotec coating has been set into the hole. So my plan now is to remove the GTX and see how much the hole can be increased without replacing the flapper and clear out the blue out of the hole.
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  7. #2207
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    That hole looks smaller than a factory TD04HL turbo wastegate.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
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    2004 Sapphire Black S60 D5 - The new daily hack.

  8. #2208
    Gearbox Killer
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    MoleT-5R's Avatar
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    Quote Originally Posted by Dangerous Dave View Post
    That hole looks smaller than a factory TD04HL turbo wastegate.
    It does look tiny for such a large turbo tbh.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
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  9. #2209
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    How was this build so far? Its been weeks since the last upgrade.

  10. #2210
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    Been years more like. I am in the process of moving house. The turbo needs to come off. And I can't really do this until after the house move. Betsy is going to stay with my FIL in Wales very soon.

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  11. #2211
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    Been years more like. I am in the process of moving house. The turbo needs to come off. And I can't really do this until after the house move. Betsy is going to stay with my FIL in Wales very soon.

    Sent from my SM-N950F using Tapatalk
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  12. #2212
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    Volvos never die - they just live off old ones.
    I used the opportunity to have some long overdue paintwork done on Betsy. Windscreen has been removed to sort the rust around the apperture particularly at the top n/s corner of the A pillar. Also the massive wart of rust pushing through the ns rear quarter has been sorted. I got hold of a donor quarter from someone breaking a C70 coupe. I sent him some spot weld drilling tools and he got me most of the quarter. My repair shop guy in Telford took what he needed from the donor panel to essentially replace most of area under the crease line. I've also had the bonnet and rear bumper redone for cosmetic damage, so she'll look like a new car when I get her back.Name:  244750042_10159709604367328_2972972020906139355_n.jpg
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    Volvo ABS ECU Repair
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  13. The Following 2 Users Say Thank You to Wobbly Dave For This Useful Post:

    JT (Saturday 9th October 2021),MoleT-5R (Saturday 9th October 2021)

  14. #2213
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    Ah she'll look lovely. That's one of the things on the list for my green beast, respray.
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.
    2004 Sapphire Black S60 D5 - The new daily hack.

  15. #2214
    Gearbox Killer
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    MoleT-5R's Avatar
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    As above, she'll look lovely..... especially flying through the highlands and also as above I need a respray to, but on Gul.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
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