View Full Version : So that's where the boost was going

02-11-2008, 06:48 PM
I came back from Germany last Friday and the 940 got distinctly noisier than it is supposed to be. It's been sounding like a bag of nails when it's started up from cold for a while, and the manifold was leaking badly until the engine warmed up.

Friday the exhaust decided to start blowing, well if the truth be told it cracked where it goes over the axle. So I decided to also tackle the manifold.

This is what I found.


The manifold is badly cracked, it actually appears to just be starting to crack the flange where the manifold joins the head. I've not seen one quite this extensively cracked before.


The turbo housing is cracked, both where it joins the manifold, but also terminally on the waste gate aperture, basically it's toast. You can see the crack at 5 Oclock. I've thought for a while it was losing a a bit of boost, guess I was right.

I guess since it's misbehaved I won't be fitting shiny new tyres to these after all, that'll teach it! New exhaust and cat are on the way, I'm going to get a waste gate housing and manifold tomorrow. It needs to be on the Autobahn again on the 20th of Feb working for a living.


02-11-2008, 07:56 PM
Crikey, that is impressive! We have a couple of 90+s kicking around if you want one. They're not mint, but they're a damn sight better than that one :rofl:



02-11-2008, 09:05 PM
problems one runs into after driving on the autobahn for a extended periods of time.

02-11-2008, 10:14 PM
Was that a 90+ manifold that was ported? If it wasn't that makes sense. Make sure the next one is ported so that might not happen at all. They are very restrictive as they come from Volvo. Putting a ported one on my 82 turbo along with some other changes has finished off my clutch. Only took a few thousand miles to make the clutch slip.

02-11-2008, 11:00 PM
It's true...we took a huge amount of material out of the collector on Ryan's 90+ with a carbide burr, simply to port-match it to the T3.



02-12-2008, 05:14 AM
This one was factory standard. As far as I know this is the first time any of it has been off the car, and it's done nigh on 160K miles, of which 100K was done in the last two and a half years. Mostly fast long distance work. I'll be porting the next one:) I'm also going to clean up the waste gate housing.

Looking at the manifold the turn fron the head into the manifold seems significantly more restricted on number 3 than on any of the other posts, so that will get a touch of the die grinder too. I'll try to remember to post some pics of it before I stuff the whole thing back together. For the moment it's going to be keeping the TD04 13C I don't run increased boost on this car. It just has to work reliably.

02-12-2008, 05:42 AM
Well, there's 10 1/2 hours to go on my Cossie T3/4 (http://my.ebay.co.uk/ws/eBayISAPI.dll?MyeBay&CurrentPage=MyeBaySelling&ssPageName=STRK:ME:LNLK) if you want it. Ask me nicely and I'll even port a 90+ for you!

02-12-2008, 06:58 AM
Well, there's 10 1/2 hours to go on my Cossie T3/4 (http://my.ebay.co.uk/ws/eBayISAPI.dll?MyeBay&CurrentPage=MyeBaySelling&ssPageName=STRK:ME:LNLK) if you want it. Ask me nicely and I'll even port a 90+ for you!

That link doesn't work, it takes me to my ebay selling. I may have a home for that, though not on the daily driver 940.

02-12-2008, 12:02 PM
Those wheels :omg: How much? Two grand?

02-12-2008, 02:15 PM
Those wheels :omg: How much? Two grand?

1600 US Dollars plus shipping, and I'll include a 5th used Polaris as a spare. I have 4 new ones, with 4 new centre caps and a set of used wheel nuts suitable for a 940.

02-12-2008, 03:55 PM
Item number 260209615550

18 minutes to go!:-D

02-12-2008, 06:13 PM
Polaris looks really really nice!! Keep 'em in your living room instead :)

02-14-2008, 04:25 PM
I've now ported a replacement waste gate housing and manifold. First up is the manifold. I massaged the turn on number 3 a bit where the manifold meets the head. It seemed more restrictive than the others. The outlet to the turbo has been enlarged, sharp edges are gone and the runners have been blended to the enlarged new opening.


I then turned my attention to the wastegate, I've opened the aperture for the wasegate flap. The hole is now ovalled.


I've also altered the shape of the escape route for the gasses when the waste gate opens, as well as opening it up where it meets the manifold. If you look at the waste gate opening to the right of the picture, to the rear of that you'll see the bridge between it and the inlet to the turbo wheel. The damn thing still has a crack. It won't affect it working in its current state, and hopefully it won't spread. It's not good, but its the best one I have at the moment. I guess I'm going to be looking for a spare.


I've removed a lot of metal out of the inlet, if you look at the photo below you can see the original also cracked in there