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  1. #61
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    Quote Originally Posted by pepinosport View Post
    guy from the turbo shop just called to tell me the turbo is FUBAR and that I might as well buy a new one because repairing this one is going to be more expensive.
    Oh dear. A new KKK24 from Volvo is £1300!

    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. #62
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    Why even bother getting a new one?!

    Getting a hybrid replacement will cost less and will give your more driveability ;-)

  3. #63
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    Quote Originally Posted by Vasquez View Post
    Why even bother getting a new one?!

    Getting a hybrid replacement will cost less and will give your more driveability ;-)
    yeah, I know, but then I will want bigger injectors and bigger fuel pump and bigger MAF and... I don't want to spend that much .
    I contacted Turbo Technics to see what are the options. They told me 390GBP for a full refurb, if they're able to source a hot side. My exhaust housing is cracked very close to the turbine and also on the usual spots. And there's no spares...

  4. #64
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    Naaah, no absolute need for all these complementary mods. A respectable tuner will do a remap based on your actual setup.

    Would give you some more headroom in the near future.

    Been there, have a 04 Titanium Grey V70R myself

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    pepinosport (Monday 2nd March 2020)

  6. #65
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    Needs new intercooler too

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  7. #66
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    Use brake cleaner to remove all that oil residue and see if the IC is cracked on the plastic end piece. It's where they commonly fail. Mine had a 3" crack that was hard to see but obviously opened up under boost.

    Pepinosport, can you resize your uploaded images mate. They are way too big and slightly out of focus. Will be almost impossible for phone users to see your pictures

    Replacing the stock IC with an aftermarket FMIC is one of the best mods you can do on these cars for many reasons, here are a few..

    1. Longevity of a true, all aluminium IC with no plastic components.
    2. Aluminium cores are typically larger, so have a greater ability to reduce intake temperatures dramatically.
    3. A true FMIC does not suffer with 'heat soak' unlike the stock IC.
    4. The secondary stock IC has been proven in the past to make little to no difference to intake temps, due to the very small hoses that connect it to the larger core.
    5. Aesthetically pleasing, compared to the stock setup.
    6. Will reduce your intake temperature significantly, track proven to as much as 35*C, thus an immediate noticeable performance increase, especially during warmer weather.

    I highly recommend an aftermarket FMIC.

    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

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    pepinosport (Saturday 7th March 2020)

  9. #67
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    Quote Originally Posted by LeeT5 View Post
    I highly recommend an aftermarket FMIC.
    sorry about the pics, I thought they were automatically resized

    So yeah, the idea was to buy a DO88 FMIC but I kinda ran out of money in between and bought a used OEM for 50€. The original was already repaired and I didn't want to spend money repairing over a reparation

    However, luck was on my side this week and I found a facelift turbo for... 60€! This might give me some room for the FMIC, I have to check numbers...

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    It looks very good, with no cracks. It's currently in the turbo shop being inspected

  10. #68
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    I took the intake housing from the old turbo for the new one. It was actually the only part of the turbo that wasn't damaged

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    Detail of the cracks on the old turbo:

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  11. #69
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    More parts arriving like my ITV (MOT) compliant cat to make a custom dowpipe:

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    Discs and pads. ALL discs 40€ in Autodoc

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    New front dampers with new bumstops and covers and so on...

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    I hope the pics have the correct size now. But yeah, sorry for the potato quality
    Last edited by pepinosport; Saturday 7th March 2020 at 23:31.

  12. #70
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    Here's an interesting thought:

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    I had my 383.000km injectors verified, cleaned and with new microfilters and they are now as good as new.

    I had another set of injectors with half the mileage coming from a friends '05 that cracked a liner. I thought this set would be better, but upon verification at the injection shop they returned uneven values and some injectors were more than 10% off, especially at higher rpm.

    This made me think that all those horror stories about cylinder cracking are more related with a poor maintainance of the injection system rather than the actual block being butter.
    Last edited by pepinosport; Monday 9th March 2020 at 07:43.

  13. #71
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    It wouldn't help cylinder temperatures having uneven fuelling across cylinders. Though there may be allowances built into the mapping to account for some discrepancies/age related "wear"
    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.

  14. #72
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    My 60€ turbo is back from the shop. It was in very good shape but it's had bearings and balancing done:

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    New flywheel fitted:

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    And new... DO88 intercooler

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  16. #73
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    Excellent progress, keep it going!

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    pepinosport (Saturday 21st March 2020)

  18. #74
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    Angle gear on its way to Sweden to be remanufactured by Maskin&Bil.

    Rims sent to paint shop right before the COVID ££££storm, so idk how long it will take to have them back :/
    Will be fitted with new PZero 4 tyres.

    I also went medieval with the angle gear sleeve, but I'm afraid I won't be able to remove it without heat. Can't buy a blow torch because everything is closed

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    Last edited by pepinosport; Monday 23rd March 2020 at 21:44.

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  20. #75
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    I've been a lazy ass and didn't work much lately.

    Angle gear sleeve was finally removed with some heat

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    It was very difficult to push it all the way, I somehow managed to smash the new driveshaft seal with the rubber mallet

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    Clutch and new slave cylinder are in place and gearbox too

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    All four corners have now new discs and pads and new dampers. I found quite difficult to do the rears

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  21. #76
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    I also unsuccesfully tried to swap my saggy driver's seat for the mint facelift one that I have. Seems they are completely different

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    Following with the interior I fitted a rear door panel because mine was broken

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    New centre armrest

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    And fresh steering wheel. I had to remove all the facelft stuff from it

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  22. #77
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    I tried to tidy up the engine bay

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    Removed old exhaust to make room for the TME

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    And today I started with the brake bleeding. The reservoir was really filthy and the fluid was plain gunk

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  24. #78
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    Engine is already in

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    When fitting the intake pipe I found it was fouling with the airbox bracket and making it almost impossible to attach to the IC if already fixed in the TB. This is due to the largest DO88 intercooler. IDK if someone else's had this problem, but I had to cut the bracket with an angle grinder to make some room. I was expecting the DO88 IC to be a more perfect fit than it actually was

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    Tight, but that will do. Still think it will eventually crack

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    Then I bled the clutch and started fitting the rest of ancillaries to find that the OTA pipe doesn't fit because the guys at the turbo shop didn't align the compressor housing properly

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    I broke loose the bolts of the compressor housing half a turn, with the OTA pipe fitted until it dropped, then tightned to the marks I had previously done. I also did marks for the wastegate acutator to check how much it moved. I honestly have no idea if I should touch the adjustment, the leverage angle changed a little bit but unsure if that's enough to make a difference.
    Last edited by pepinosport; Thursday 23rd April 2020 at 22:14.

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  26. #79
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    Looking good!

    Keep the updates coming
    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.

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  28. #80
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    Maybe it's a bit too late for this, since I bought this engine 11 months ago, but with the engine on the car I removed the oil filter -that came with the engine when I bought it- and found this:

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    Tried to ignore it and tossed a new filter and fresh 5w30:



 

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