JW's 1991 240 wagon

J2_ said:

Welcome to the polaris club haha

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I just knew you where gonna pop up ans say it

Wagner said:

De aap komt uit de mouw! Real Polaris wheels. A definite upgrade over Virgos. (i have no idea what that means, something with apes possibly )
I vote for silver or white.

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lol! It has nothing to do with apes actually More something to say when after a long time the real cause of something is revealed.
I think I'll go for a little bit darker than the original silver. White would look very good too but i might get tired of cleaning the rims


I received the other 2 rims last week, those look better than the other 2.


The tires are old (2005) and not a great brand so I'll probably go for something better if/when funds allow. 215/50 tires on there now. Please ignore the fact that this wheel is fitted on the wrong side of the car (directional tire)

One very annoying thing is that on 2 rims the previous owner had trouble removing the lockable lug nuts. While welding a nut/bolt to the lock they actually welded into the rim, lodging a pretty big chunk of steel in the rim right next to where the lug nut goes It looks fixable though. I found a local company that specializes in fixing this kind of stuff. A complete wheel refurbishment isn't that expensive there luckily.

oh and i got a set of Lokari inner fenders for the rear wheel wells, i think that they'll stay better with those installed. For the winter the 87 degree t-stat found its way back in the engine bay as well (had 82C in there), i think I'll keep it in there for the summer too, hoping that it improves the fuel efficiency a bit too.

Wow for a second i thought it was Homers car till i saw its an estate.. looking clean JW!

We should start a Polaris club.

Just read through the whole build. Glad to see this car where it is! Looks great.

hey what pressure plate are you running with the m90. i have a projekt like this but my pressure plate was too thick

scottyd said:

Just read through the whole build. Glad to see this car where it is! Looks great.

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Thanks!

jens.s said:

hey what pressure plate are you running with the m90. i have a projekt like this but my pressure plate was too thick

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Everything from a 1995+ 940 Diesel with M90 gearbox, will check numbers later, have pics somewhere.

semi update:
-running LH now for some time with the Ostrich 2.0, works great. rpm limit at ~7000 rpm, mixture is good up to 5500-6000 (.82 Lambda at WOT) but goes to .75 or lower to the limiter. Still surprised at how little the torque tapers off at those rpms, especially considering the sub-optimal mixture.
-got a cruise control set from Homer, some comfort to install this summer (thanks dude!).
-some clunks and driveline vibration issues that need sorting, now the car is back to DD status those things start to annoy fast.
-replaced front brake pads for a set of original Volvo pads and checked the rear brakes, took it easy on the brakes for some time, now back with good stopping power.




Still no progress with the Polaris rims, need to get them ready for use before the Nordschleife meet this summer. Too busy with school/internship ugh.

Fun fun. What cam? Any headwork done? 3" exhaust but mostly stock turbo setup otherwise(on LPG, of course)?

klr142 said:

Fun fun. What cam? Any headwork done? 3" exhaust but mostly stock turbo setup otherwise(on LPG, of course)?

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yeah its a fun DD

short spec list:
-stock, unopened 1991 model B230F, no headwork, 262.000 km
-V cam
-Garrett T3 with 60 trim .42 A/R compressor (a bit bigger than stock T3 but not much) and .63 A/R Cosworth turbine on a ported 90+ and 3" exhaust.
-E85 with 630 cc/min injectors and remapped LH/EZK. I would like to run LPG but road tax would double to ~1200 euro a year (yeah, ~1700$ ).
-currently running 8 PSI, will up the boost when i have the Iveco IC fitted and when the driveline vibrations and some other odds and ends (rear wiper wiring broken in hinge etc) are fixed. It is too easy to up the boost for some extra power, i try to make the most out of the boost i am running before i take the easy way (more boost).

Some update stuff, installed a prototype wasted spark conversion (by Karl Buchka). cross posted to keep this thread up to date.


Re-used a connector from an old copying machine. The 5v/gnd connection is a bit less clean when there is a daughter board in the way for the chip. Wires soldered to the underside, no problem.


Temporary installation, will make wiring pretty/good when I have finalised the mounting position of the coil+powerstage. The coil barely gets hot, the powerstage needs a bit better cooling, it gets a bit hot to the touch after some hard driving.

Impressions:
-engine runs smoother, a bit less agricultural even. Idle and hi-rpm is the most noticeable.
-better torque although my butt-dyno isnt very accurate. Especially hi-rpm+boost where the stock system is lacking.
-need to program the Atmega with the last software version, starting is not 100% ok, needs a few or more tries. Pro-tip: dont park this car in front of uni or anywhere else crowded with people.

My car had good wires from the aspirator, 940 turbo coil, semi fresh Bosch cap+rotor and a Summit MSD box (that I suspect was disfunctional/weak).

Here is some video coverage of last weeks' automotive entertainment:

<iframe width="425" height="349" src="http://www.youtube.com/embed/82t2brpx8WU" frameborder="0" allowfullscreen></iframe>

As said, seems to run better (boost still 0,5 bar in this vid). Oh and it seems like the high load mixture has gotten a bit richer, before it was consistently at lambda .84-.81 (mid rpm-redline) and now it is .81-.78. Better combustion could do such things. Although I can't imagine that stock ignition was lacking so much power that it could have effect on lambda readings. Who knows.

JW240 said:

.

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Is that the correct relay for LH, I thought you'd converted to in essence 940 Turbo spec?

It looks nothing like what you'd find on one of those.

<a href="http://s338.photobucket.com/albums/n413/turbobrickspics/?action=view&current=DSC_6268.jpg" target="_blank"><img src="http://i338.photobucket.com/albums/n413/turbobrickspics/DSC_6268.jpg" border="0" alt="Photobucket"></a>

is CC not always a separate thing, regardless of injection system?

Fivehundred said:

Is that the correct relay for LH, I thought you'd converted to in essence 940 Turbo spec?

It looks nothing like what you'd find on one of those.

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i'm running the 240 Lh 2.4 loom, the cruise control will be completely separate from the engine stuff like boris says. The 940 stuff looks like it is the newer generation, not sure what the differences are.


Updates:

Finally a set of real tires instead of the 2nd hand 15" stuff that i had been using before. That stuff served me well but i wanted something better, especially grip wise..



I got a good deal on a set of brand new Toyo R1R tires sized 225/45ZR17. They guy I got them from bought them for his car but after test fitting he discovere that they were too wide to fit so he ebayed them...
These will be mounted on the Polaris rims when they are restored. I am curious how these tires will be in the rain and on other daily drive stuff (probably fine as long as it doesnt snow/freeze) but i am sure that they will be nice when I go back to the Nordschleife asap hehe. Very happy with this set, i was looking at 4 new tires but most good brands were pushing the limit budget wise..

Mounted the KL-racing underdrive pulley:



The pulley required some grinding to over the crank but nothing serious. I lengthened the tensioner of the alternator a bit to get more clearance for the oil filter but still had to buy shorter belts. While I was there I upgraded the alternator ground and + wire.

Bracket for the Bosch 2x2 coil behind the strut tower:



The wiring for the wasted spark has been cleaned up too and the power stage now resides behind the headlight on the right, looks almost factory now.

Right now the car is still on jackstands, waiting for maybe the Iveco IC and some other smaller things, cleaning up the wiring and such. Cant wait to test the new tires!

Double post fail.

Some pics of the Iveco IC:


After welding up the end tanks.


Used M6 rubber vibration dampers to hold it in place.



Installed. Cold side is a modded original pipe together with a 2.5-3" reducer.


Hotside pipe in progress.


Still have some work here to tidy things up, esp wiring. Had to get the car ready to get to the internship the next day.
Made a gradual transition from the hot side silicone elbow (original Volvo) to 3" from exhaust pipe.

Had another radiator go bad (this one came from a 16V 740), a reminder that I must stop using old crap. Got a new 2nd hand radiator from blabla, still in very good condition. It had a 95C? temp switch and i wired it up to trigger low speed Efan. Works good although I still turn on the fan manually when sitting in a traffic jam etc.

The front shocks seem to have excessive play, had some strange clunks in the front suspension since a few months and always felt some play in the front suspension. Adjusted the wheel bearings, tightened all bolts, no dice, still play. Had it up on the lift last weekend to have some mechanics look at it and they confirmed that the shocks were the culprit. They seem to be quite mushy too. Will give Koni a call this week and make use of the life-time warranty. In the mean time i think i'll use a set of new Bilstein B6/HD that I still have laying around.

Should take some pics, using the Polaris rims from the 760 now. Looks good and the ride is nice too.

whats the point of this? lighter?

Looks good, as seems to be the norm with the things you do.

Envious of those welds seen on the truck intercooler. I bought an AC/DC tig welder myself, and the globs of molten metal between two aluminium parts holding them together that i come up with are not exactly as beatifull as those ones there. Steel is OK, that i can do.

I might have asked this before, but please do remind me again, where does that cooling fan come from? 940?

E-fans from 940, 960 and 850 and the relay can be used