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  1. #81
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    Quote Originally Posted by MoleT-5R View Post
    great work Rob, you'll have to keep the tread depths even front and back now to stop the awd wanting to kill itself, unless you where to fit a haldex unit somehow........???? Steve should soon have a spare one knocking about when he breaks that s60r....
    Quote Originally Posted by oblark View Post
    Reference tyres,

    I came across this on an American Web site about the early awd and tyres.

    IF there is a tire circumference difference you use the larger on front. The overrunning clutch in rear of viscous unit lets the rear driveshaft not stress the angle gear. Smaller tires up front will make the rear go slower and the overrunning clutch locks and the angle gear will get loaded and cook out the fluid and it dies.

    On that I've fitted my newest to the front. But I'll keeping an eye on how all 4 wear.
    P1 AWD tyre tread tolerance is 2mm MAX between front and rear axles. As long as you keep within spec, you wind the Transfer box up.

    Quote Originally Posted by oblark View Post
    I had the tracking done which has made a big difference to the steering

    I've done just over a hundred miles in it now, still getting used to the diesel box, I have to remember to change down to 2nd when pulling away from 30 mph if not the engine bogs down and won't pull away.

    The AWD is fantastic it's great powering out of corners a lot earlier than a FWD.

    Here are some photo's from Saturday's Beaulieu meet.

    Attachment 31791
    My only critisism is the awd badge needs to be repositioned to the right so the letter D in AWD is under the R and slightly left. Other than that, she looks fantastic and a credit to you sir!

    See AWD badge position....

    https://s1.cdn.autoevolution.com/ima...70R-1581_5.jpg

    2004 V70R 6spd manual:: Custom JRtuning REMAP @ peak 21psi :: Custom 2.75" exhaust :: TTV SMF + 07 Clutch :: WG 5.0 psi :: Tints :: IPD R gauge Rev.3 :: CFWerks door pod :: Forge CBV + yellow spring :: Windowed stock housing + blue filter :: Powerflex :: Superpro Engine mount :: Brembo Dot 5.1 :: TW FMIC :: Eibach 5mm spacers :: Brembo 330mm drilled discs :: iMiV 'Classic'+ BT :: D2R XENARC 5500k + LED H7 + LED H3 :: VolvoTech CFE OBD-V1 :: See garage for full mod list

  2. #82
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    Interesting thing about the headlights, is that P1 x70 (like from 1997)?
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  3. #83
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    How are you getting on with the apex springs Rob?

    I found them a bit hard on the p2
    19t, greens, 3" inlet, 3" downpipe with race cat, V70R catback, autotech map...

    310.2bhp / 333ft/lb

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  4. #84
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    Quote Originally Posted by M-R-P View Post
    How are you getting on with the apex springs Rob?

    I found them a bit hard on the p2
    There are softer than old springs

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , green injectors, 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,

  5. #85
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    Over the last 4 days I've been removing the 2.3ltr lump and installing the 2.5ltr engine.

    It took 2 evenings after work to remove the old engine.

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    Then on Saturday it was a case of swapping over the flywheel, clutch and gearbox. Once this was done back in it went.

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    Once back in it's just a case of bolting on all the bits and bobs.

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    Then today it's just a case of refitting the drive shafts and the prop, weld on the expansion tank bracket, fill it with fluids and start it,

    Which it did on the first crank, just nee to load on the bin file with the 8% increase in fuelling to allow for the increase in CC

    I tried to upload a video but it won't let me
    Last edited by oblark; Sunday 22nd April 2018 at 19:58.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , green injectors, 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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  7. #86
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    Lovely job

    What maps have you changed for the increase in CC? I'm interested as there isn't much info on the 2.5 tuning
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  8. #87
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    Quote Originally Posted by Dangerous Dave View Post
    Lovely job

    What maps have you changed for the increase in CC? I'm interested as there isn't much info on the 2.5 tuning
    I've found out that I didn't need to increase the injectors values by 8% as I'm running the latest wideband control software.

    I'm running the same 608 bin file with the 2.5 as I was running with the 2.3 but will need to modify the VE map & the TCV load set point file once I've run the engine in.

    The car is running a bit rich on the 2.3 608 bin file so I'll have to back off the injector values a bit.

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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 , green injectors, 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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  10. #88
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    Quote Originally Posted by oblark View Post
    I've found out that I didn't need to increase the injectors values by 8% as I'm running the latest wideband control software.

    I'm running the same 608 bin file with the 2.5 as I was running with the 2.3 but will need to modify the VE map & the TCV load set point file once I've run the engine in.

    The car is running a bit rich on the 2.3 608 bin file so I'll have to back off the injector values a bit.

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    nice work Rob, I'm looking forward to getting to this stage with my next engine.

    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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  11. #89
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    Quote Originally Posted by oblark View Post
    I've found out that I didn't need to increase the injectors values by 8% as I'm running the latest wideband control software.

    I'm running the same 608 bin file with the 2.5 as I was running with the 2.3 but will need to modify the VE map & the TCV load set point file once I've run the engine in.

    The car is running a bit rich on the 2.3 608 bin file so I'll have to back off the injector values a bit.
    Ah ok, I thought you meant increase the values due to the increase in engine size CC
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  12. #90
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    Slowly running the 2.5ltr engine in and trying to dial the injectors in.

    After raising/lowering the injector constant and dead times it was still running rich. So it was back to basics.

    I disabled the STFT and the lambda threshold tables. After a bit of fine tuning of the injector dead times I got the idle AFR's just about spot on.

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    Now it was time to go for a drive to set the injector constant, so at a steady 60mph in 5th I adjusted the injector constant values.

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    So with both the dead times and constant set the STFT was set back to +/- 25 and the lambda threshold was set to 2ms (meaning any load greater than 2ms the lambda does not adjust the AFR)

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    With the STFT and lambda activated the idle AFR has gone up, but still within limits.

    During my drive setting up the injectors I had pull away a bit quickly thanks to some elderly driver who doesn't understand who has right of way on a roundabout.

    Ooopps, 7.40 psi of boost at 20mph.

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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 , green injectors, 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. #91
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    away to start a very similar project. I have a 850 engine and a v70r 2004 engine that I might split to build one engine . hopefully use a holset hx35 turbo with custom tubular manifold .

  15. #92
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    The AFR's have settled down now I been putting miles on the engine.

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    The old red mist came over me when a 08 ST focus pulled up behind me at the lights, didn't give it any welly at first but he tried to stay with me going around the roundabout but he couldn't when on the straight I did give it some welly until I realised I was at a bar of boost so I eased off and he shot passed.

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    3600 rpm at 39% throttle in 3rd gear with 14 psi of boost, if I had given full beans he wouldn't of known what hit him

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , green injectors, 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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  17. #93
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    Finally I've run the engine Had a small problem with the AFR's at 80mph it started running lean so the injector basic adjustment was increased.

    AFR's at 60 mph
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    AFR's at 80 mph
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    Time to have some fun winding the boost up or that's what I thought.

    Whilst doing a boost run at 3600 rpm and boosting at 13.4 psi the engine cut out, just like it had boost cut.

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    Everything from the data log looks OK apart from the TCV target load set point. I'm logging 10.46 whilst the bin target set point is 6.42.
    So I've disabled the boost control part of the bin while I wait for Maarten to get back to me to confirm whether the problem is a bin or a setup fault.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , green injectors, 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. #94
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    Hmm, that is indeed odd.

    Fingers crossed it is something easy to rectify

    I've got to get on with my tuning. Currently trying to get the boost control dialled in.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  20. #95
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    Still try to get to the bottom of my boost cut, After doing some research I've raised the BTC (boost threshold control) from 0.13 to 0.54 as recommended by a guy in the states who is also running the BTC software.

    When the BTC was set to 0.13 the logged TCV was greater than TCV duty cycle table and I think the ECU was just protecting it's self.

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    With the BTC at 0.54 I'm only getting 5-6 psi of boost at 65%+ throttle BUT I've noticed the TCV duty cycle logged was very close to the TCV duty cycle set point, so I've increased the values from 40% throttle and 3000rpm up by 2 so hopefully this will increase my boost. I see me increasing the TCV duty cycle set point up to 20ms+

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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 , green injectors, 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,

  21. #96
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    Have they got back to you regarding this issue? As I understand it this seems to be a problem with the modified boost control routine?
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  22. #97
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    The guy who did the boost control software isn't replying to my emails it looks like venderbreock and his father Piet have disappeared off of the face of the earth.

    I'm hoping my problem is just a case of adjusting the set points in the map, I no of someone else who had problems with venderbreocks software and has had to go back to his old set up.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , green injectors, 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,

  23. #98
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    That's a shame considering you paid for the software. I was a bit disappointed when they announced that there would be a pricing scheme for the mods.

    How are you finding the mods compared to the factory control routines?
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

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    The boost problems continues ...........

    I increased the TCV set points from 10 to 12 and when logging a run I got 12 and 5 psi of boost

    Did some poking around in a couple of bin files with different XDF files I noticed the conversion fact in the BTC threshold as way out. The TCV is meeting its set points but as the conversion fact was out it looks like the ECU wouldn't let the turbo produce boost until it got to 3.51 bar

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    Hopefully that was the problem but I'll find next weekend.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , green injectors, 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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  26. #100
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    Fingers crossed that has fixed the issue!

    Crazy how one equation can cause such problems.
    1996 Olive Green 850 AWD - Forged rods, VXR injectors, 19T, Ostrich 2.0, Arduino data display, Active exhaust control. Follow the project here
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.


 

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