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  1. #141
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    It's been a while since I've updated this thread, I've taken up running and have been busy training, over the last year I've completed 2 half marathons and 6 10k's. But due to the Covid-19 out break all races have been either cancelled or postponed so I've been tweaking the map to solve a knock shortly after start up.

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    To solve this problem I've increased the mixture in the warm up tables which sorted the problem.

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    Once warmed up and at full boost all knock had gone, just got a bit of clutch at full boost.

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    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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  3. #142
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    Nice The AWD system can put extra stress on the clutch, I found that with mine Fortunately I fitted the self adjusting clutch and it sorted itself and I dropped the tune a bit to save it.

    What MPG are you getting? I'm trying to tune mine to be less thirsty at cruise but it's not happening.

    I'm hoping during some of this free time I'll get to do some tuning but got other parts to fix first (rear brake caliper stuck, front wishbone, track rod end and so on)
    Last edited by Dangerous Dave; Saturday 4th April 2020 at 22:19.
    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.

  4. #143
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    I saw on your signature that you are running Brembo calipers with S60R brake discs. Did you post any photos of that here? I have a friend doing that at the moment - Brembo but with 350mm disks and he's having issues fitting them on the Midir wheels (18")
    Last edited by Ric@rdo; Tuesday 7th April 2020 at 01:34.

    V70 2.4T5 M66 Summum

  5. #144
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    Still more fettling needed,
    will it never end?
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    Quote Originally Posted by Dangerous Dave View Post
    Nice The AWD system can put extra stress on the clutch, I found that with mine Fortunately I fitted the self adjusting clutch and it sorted itself and I dropped the tune a bit to save it.

    What MPG are you getting? I'm trying to tune mine to be less thirsty at cruise but it's not happening.

    I'm hoping during some of this free time I'll get to do some tuning but got other parts to fix first (rear brake caliper stuck, front wishbone, track rod end and so on)
    I thought that the operation of hydraulic clutches made them all self adjusting.

  6. #145
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    Quote Originally Posted by stribo View Post
    I thought that the operation of hydraulic clutches made them all self adjusting.
    Sorry bud I meant the actual clutch plate is self adjusting. It contains an adjusting ring which compensates for wear in the friction plate.
    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.

  7. #146
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    Up date time.

    I thought it was about time I upgraded the fuel pump as the VXR injectors at 3.8 bar was starting to push the oem fuel pump to it's limit. So I went for a ASNU 340lph fuel pump, the reason I went for this make of pump as there is so many Walbro copies on the market I didn't want to take any chances.

    Had to remove the exhaust, prop, viscous coupling and the wishbone tie rods just to lower the fuel tank down enough to remove the pump, all in all not a bad job just took all day. Once the fuel pump had been changed the 650cc injectors where fitted but as I'm running at 3.8 bar the injectors will run at 720cc. Loaded the figures for the injectors from Dangerous Dave into tunerpro, Looks like I've got the settings pretty close might need a little bit of adjusting.

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    720cc injectors at idle
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    720cc injectors at 50mph
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    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,

  8. #147
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    Nice one bud, glad those figures are close
    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.

  9. #148
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    For the last few months I keep getting the same fault code of EFI-355 (mass air flow senso fault) I've fitted secondhand,aftermarket and even OEM sensors but after a day or two the MIL light comes back on.

    A big thanks to Dangerous Dave for the hex addresses hopefully I've sorted the problem.

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    Whilst doing a steady 60mph up hill the MIL light came on, lucky enough I was data logging the run. The MIL light came on roughly where I've circled on the above picture. I was above the maximum the RPM for MAF threshold but still in the airflow threshold so I've lowered the threshold for airflow from 403kg/hr to 210kg/hr so hopefully that will sort the problem.

    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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  11. #149
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    Some good investigation going on there mate.

    I wonder if the rpm and the air flow min/max are related or separate.
    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.

  12. #150
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    I've had to put the maf problem on the back burner as I've had a more pressing problem.

    The old car started to splutter when the manifold pressure went from vacuum to pressure. At first I thought it was the fuel pump but that checked out ok, then I thought it was the fuel pressure and that checked out ok. So I swapped out the 720cc injectors and fitted the VXR injectors along with the ostrich which has a VXR bin file. Went for test drive and no spluttering so it looks like the 720cc injectors need an overhaul.

    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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  14. #151
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    Hmm interesting. Hopefully a clean will sort it. Let us know how it goes.
    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. #152
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    Had a week off so I thought it was about time I fixed some of the long term problems eg no air being blown on the windscreen. So out came the dash followed by the heater unit, the fault was found to be a very corroded air con evaporator (it had been in the car for the last 24 years) the holes for the evaporator pipes were blocked off with some industrial duct tape. Now it blows air on the windscreen like a hurricane.

    Also while the dash was out the rats nest of wiring was sorted out, the number of wires either not used or running from one side of the car to the other was unreal (all my doing) Now the passengers electric seat is wired into the ancillary circuit (yellow/purple wire) from the ignition switch with a line fuse and the wideband is wired into position 2/start circuit (yellow/blue wire) also through a inline fuse.

    The other job was to swap over the steering column as sometimes when starting the car nothing happens when you go to start it. Also wired in a 12v timer and switch into the lambda warning light

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    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,

  16. #153
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    I can only guess at why you'd want a timer on the lambda light.....
    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.

  17. #154
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    I've been running the VXR bin file for a couple of weeks and all is running fine apart from the fact I'd forgot to change the MAF fault threshold values, This was a bit of blessing as the MIL light came on and I could test the MIL switch.

    The MIL light came on as I lifted to change from 4th to 5th.

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    Also got around to changing the headlining as it was starting to come away from the backing alone the front by the windscreen. It wasn't to bad getting the headlining out it was just getting the foam off of the backing took a bit of time but got it all off with a wire brush, then applied plenty of glue and stuck on the new fake suede foam backed headlining.

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    The finished headlining.

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    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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  19. #155
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    MoleT-5R's Avatar
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    Quote Originally Posted by oblark View Post
    I've been running the VXR bin file for a couple of weeks and all is running fine apart from the fact I'd forgot to change the MAF fault threshold values, This was a bit of blessing as the MIL light came on and I could test the MIL switch.

    The MIL light came on as I lifted to change from 4th to 5th.

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    Also got around to changing the headlining as it was starting to come away from the backing alone the front by the windscreen. It wasn't to bad getting the headlining out it was just getting the foam off of the backing took a bit of time but got it all off with a wire brush, then applied plenty of glue and stuck on the new fake suede foam backed headlining.

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    The finished headlining.

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    Headlining looks lush Rob, bit easier to get in and out of an estate than a Saloon, I've my Gul's to do soon

    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

  20. #156
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    How on earth does the lining come out of the saloon?

    It was bad enough trying to get the one out of my estate through the boot.
    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.

  21. #157
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    Quote Originally Posted by Dangerous Dave View Post
    How on earth does the lining come out of the saloon?

    It was bad enough trying to get the one out of my estate through the boot.
    The same, through the boot, done it once in the donor saloon, not fun but it's the only way I could see.....lol

    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

  22. #158
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    Update time.

    Had a MOT last week and passed with 2 minor defects, 2 driveshaft CV boots split which is a PITA as they are only 2 years old and covered 1500 miles.

    As just about everything has be upgraded I thought it was about time to upgrade the suspension with some BC coilovers.

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    As nice as there look in the box it was about time I fitted them. I started with the rears and I'm glad I did As they were a PITA to set up as there is no room to adjust the shocks. The fronts went in in a matter of minutes compared to the rears and were easy to adjust. The only thing I'd say say is you will need a deep 17mm ring spanner ro do the top shock nut up.

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    I'm still getting the MIL light come on with the same MAF fault code, I've been setting the detection values lower and lower. As the fault code keeps coming in when I change gear from 4th to 5th under load so I've now lowered the detection values to below idle.

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    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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  24. #159
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    Quote Originally Posted by oblark View Post
    Update time.

    Had a MOT last week and passed with 2 minor defects, 2 driveshaft CV boots split which is a PITA as they are only 2 years old and covered 1500 miles.

    As just about everything has be upgraded I thought it was about time to upgrade the suspension with some BC coilovers.

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    As nice as there look in the box it was about time I fitted them. I started with the rears and I'm glad I did As they were a PITA to set up as there is no room to adjust the shocks. The fronts went in in a matter of minutes compared to the rears and were easy to adjust. The only thing I'd say say is you will need a deep 17mm ring spanner ro do the top shock nut up.

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    I'm still getting the MIL light come on with the same MAF fault code, I've been setting the detection values lower and lower. As the fault code keeps coming in when I change gear from 4th to 5th under load so I've now lowered the detection values to below idle.

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    Nice bit of kit you've got yourself for Christmas there Rob, I assume as yours is AWD, that these will fit the P1 V70R AWD phase 2 and 3

    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

  25. #160
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    Quote Originally Posted by MoleT-5R View Post
    Nice bit of kit you've got yourself for Christmas there Rob, I assume as yours is AWD, that these will fit the P1 V70R AWD phase 2 and 3
    The kit is listed to fit V70/S70 AWD from 98 - 00

    I've put some miles on the bc coilovers and I can report back that the ride is a great improvement over old suspension.

    The front have just been fitted and have had the ride height set the dampening is as it was set in the factory.

    The rear suspension in 100% improvement over knackered nivomats with standard springs. The only thing is the ride height is 3/4" difference from one side to the other. The difference is in suspension when there is no weight on hubs. Hopefully it's just a case of loosening off the bushes and resetting them as the bolts through the bushes are on a splindes.

    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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