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  1. #141
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    Quote Originally Posted by smithy View Post
    Are you running a 3in maf
    No mate stock 016.....easier to alter chip for fuel cut then under fueling with 3" maf cause injectors arent big enough for it.
    Last edited by artfulflounder; Sunday 22nd June 2014 at 22:24.

  2. #142
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    the rocker cover finishes the engine bay off a treat, excellent !!!!

  3. #143
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    Quote Originally Posted by artfulflounder View Post
    No mate stock 016.....easier to alter chip for fuel cut then under fueling with 3" maf cause injectors arent big enough for it.
    You will be fine with 350cc injectors with standard maf at 3bar.your engine bay does look nice mate
    Last edited by smithy; Sunday 22nd June 2014 at 22:29.

  4. #144
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    New walbro 255 fuel pump fitted, in tank fuel line......what a bugger of a job getting sender unit back into tank.
    Fuel filter changed.

    Volvo 760 proper 2x single din centre console purchased.

    mot booked for today at 11......fingers crossed

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    M-R-P (Monday 7th July 2014)

  6. #145
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    228k and still not broke it!

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    Good luck dude
    19t, greens, 3" inlet, 3" downpipe with race cat, V70R catback, autotech map...

    310.2bhp / 333ft/lb

    2016 Swedish Day UK "Best Modified Swede"
    SOLD

    Got an old discovery now.

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    artfulflounder (Monday 7th July 2014)

  8. #146
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    Good luck, show them your cam cover first, instant pass!

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    artfulflounder (Monday 7th July 2014)

  10. #147
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    Just been catching up on your superb build thread, nice work and super detailed write up makes for an interesting and different read. Keep up the good work and it will be interesting to see what this car will make on the rollers when you've finished it.

    And good luck with the MOT, not that you'll really need luck going by what we can see in the build quality
    Last edited by MoleT-5R; Monday 7th July 2014 at 11:31.

    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
    My Ebay Items http://www.ebay.co.uk/usr/quik.connection

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  12. #148
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    Cheers for the comments guys

    Well got the car back from mot.........

    Can you believe I got an advisory: number plate deteriorated but not likely to be misread.

    What a relief that was.......emmisions little bit high but ecu will still be learning for new injectors so should settle down.

    Can get 3" downpipe and exhaust done now wideband at same time.

    YAY

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    M-R-P (Monday 7th July 2014)

  14. #149
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    Woohoo

    You may now relax your sphincter!
    19t, greens, 3" inlet, 3" downpipe with race cat, V70R catback, autotech map...

    310.2bhp / 333ft/lb

    2016 Swedish Day UK "Best Modified Swede"
    SOLD

    Got an old discovery now.

  15. #150
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    Nice one fella

  16. #151
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    Well done on the pass.


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  17. #152
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    Bit of an update with inclusion of ongoing mods.

    Engine work :
    All legal now but only managed 30 or so miles so far. Boost is set at 10psi currently, presume its the swap from T cam but it comes on strong a little further on and is just starting to take a big breath when it reaches 10psi and falls flat on its face......no fuel cut as yet.
    The induction sound is alot deeper, and definately alot more responsive.
    Got a run to grimsby this weekend so will up boost to 16 or so psi when I get back.
    So at 6 bhp per 1psi increase that'll be approx 36bhp increase.

    Also managed to rig up the temperature probe to air filter to see if the bodged airbox was actually acting as a heat shield.
    comparing previous readings with open cone filter temperature was 14° lower at idle, 9° lower in start stop traffic, as expected pretty much same at 60mph but 7° lower than standard airbox at 60mph.
    So it seems that my free bodge gives me best of both worlds...
    Oh 3° decrease is 1bhp so couple of bhp.lol

    Pick up a standard downpipe adapted to 3" with extra 02 bung this weekend. Going with a 3" side exit system.....nice and short so should help lower back pressure fair amount and help give quick spool....
    That will do engine mods for a while I sort other stuff out.

    Interior Stuff :
    Got a lead on leather interior which will be nice. Torneau cover from andy.
    Window tint for bit of security / privacy for the kids and boot.

    Started adapting standard centre console for dvd player.

    Standard is funny 1.5 din thing



    No good to man or beast so managed to find a proper 2 x single din from a 760



    Started looking for a double din dvd player. Ended up getting side tracked and changed direction and have now started installing a 7" tablet in the double din space as a media player.
    Doing my usual research and have already ordered some of the peripheral items and cables.

    Heres a mock up with a tab of similar size to give you an idea.



    So work is continuing and now I'm mobile will have to get out and meet some of you guys

  18. #153
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    Nice work dude
    19t, greens, 3" inlet, 3" downpipe with race cat, V70R catback, autotech map...

    310.2bhp / 333ft/lb

    2016 Swedish Day UK "Best Modified Swede"
    SOLD

    Got an old discovery now.

  19. #154
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    Had a 300 mile round trip at the weekend......all went well.
    lh2.4 seems to have learnt to new injectors.

    Time to have some fun.

    Gradually upped the boost......this is where this got complicated as I'm new to these fangled turbo things.
    Got to point where I reached a peak of 16psi which dropped to 14/15psi then as revs rised continued to drop to 10/11psi.

    Checked for leaks in the pipe work and inlet....all o.k

    mmmm...more homework.

    CBV :

     A small diameter hose connects between the inlet manifold and the relief valve - changing pressure conditions (vacuum or pressure) will exceed the valves internal spring, and the valve will depending on type either open or close accordingly.
    A CBV or BOV relief valve is forced firmly closed under pressure conditions (turbocharger producing boost ), until such time as a lower pressure condition occurs with throttle lift off or between gear changes. An instant lower pressure condition or  vacuum inside the inlet manifold will then pull the valve open  , momentarily venting boost pressure to atmosphere BOV, or recycled CBV.
     Vacuum (pressure less than atmospheric) is formed in the cylinder bore/s when a piston decends (on intake stroke).  vacuum transfers through the opening and closing inlet valves back into the inlet manifold , and rises when the throttle plate is fully closed.

      Bosch style relief valves are compressor bypass valves , and are  most of the time under engine vacuum (idle, cruise, throttle lift-off), but close firmly under positive (boost) pressure. This  style returns (recycles) the air quietly back to the turbo compressor inlet or air cleaner area.

    Wastegate actuator :

    Internal or external, a wastegate is a boost-controlling device that operates by limiting exhaust gases going through the turbocharger, controlling the maximum boost pressure produced by the turbocharger itself. A wastegate consists of an inlet and outlet port, a valve and a pressure actuator. 

    A pressure actuator, controlled by boost pressure determines whether the wastegate is open or shut. In its resting position, a wastegate is shut, and as the boost pressure builds, force is applied to the actuator. When the boost pressure exceeds the spring value, the actuator will progressively open the wastegate, bypassing some of the exhaust gases therefore maintaining the boost pressure at the set level. To put it simply – a wastegate prevents the boost pressure from climbing indefinitely and consequently blowing the engine.

    Heath robinson strikes again : CBV

    Looked at uprated cbv's but can't stretch to a forge or similar. A dump valve wont work as letting already metered air out to atmosphere screwing up the ecu fueling constants.....so I purchased a new mitzi rebuild kit.....comes with a new thicker reinfored rubber diaphram. I'd also seen the ipd kit that shim the spring, this increases spring pre-load and holding capacity. Basically washers between metal case and spring.
    Recommended usage : 9 - 10 psi 2 shims
    11 - 13 psi 3 shims
    14 - 16 psi 4 shims
    17 - 20 psi 5 shims

    So I added 2 washer into the cbv cover. Thought I'd play it safe.

    Wastegate actuator : : Again please don't hate....but wanted to find what was happening. With no mbc held constant 7psi but couldnt hold above an adjusted 10 psi.
    So I removed the mbc and went on the hunt for a helper spring that connects to end of wastegate arm increasing base pressure.
    Found a collection of various springs and measured basic spring rates. Brake shoe springs come very close to 10 lb.
    once installed quick run showed very stable 11psi peak and constant 10psi.

    Installed mbc and increased to indicated 15psi.....max peak 16/17 psi then held contant 15/14 psi throughout revs.

    So now I need to get a new actuator.....looking at an adjustable kanugawa with prob 10/12 psi base then I can tranfer it to future turbo upgrade. Might possibly stretch to a -31 actuator.

    Got to say even with the little 15g at 16psi its alot of fun
    Last edited by artfulflounder; Thursday 17th July 2014 at 21:15.

  20. #155
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    I only paid about 60 quid for a -34 from turbo technics, nice work btw


    T35, 556Nm/410lbft & 361BHP/317WHP

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  22. #156
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    The boost dropping off could be the TCV duty cycle and is part of the map.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

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    artfulflounder (Thursday 17th July 2014)

  24. #157
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    Quote Originally Posted by oblark View Post
    The boost dropping off could be the TCV duty cycle and is part of the map.
    Dont think the 940 had tcv system ??

  25. #158
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    It was just a thought

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  26. #159
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    Quote Originally Posted by oblark View Post
    It was just a thought
    Its all helpful

    All we get is basic knock sensor that alters ignition and fuel cut when maf is maxed.
    Thats where 012 maf comes in and moves the maf linearity scale upwards allowing more flow.

    No fuel cut so far at 16 psi

    Deserately need wideband fitted before I push things too far. Should be in next couple of weeks when I go 3" exhaust.

  27. #160
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    Quote Originally Posted by artfulflounder View Post
    Tonights update......

    YAY......new bpr7s fitted doubled checked everything and the old girl struck up straight away.
    settled down quickly to a nice steady idle.

    Only ran for a few minutes got to cure exhaust manifold paint.

    dont seem to have any drips but will run for longer next time. I did have to slacken off waterpump and apply bit more upward pressure to seal to head but that seems fine.

    God I am so relieved. ......I was dreading today, thought I'd maybe messed something up and have to strip it all down.
    Bit long winded and its took 7 pages of this thread but I've now done my first ever head gasket change.lol

    big thanks to everyone thats helped along the way, wouldn't have got this far without you



    Very nice mate,great work.

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    artfulflounder (Thursday 17th July 2014)


 

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