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#1 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Acquired this silver beauty few months back. It was burning oil heavily, not building enough boost and having lots of small issues, so basically sold as a restoration project. I am still not sure why I actually bought it
![]() ![]() Funny part is, I had almost exactly the same car already once years ago. Silver 744 with sunroof and B204GT. So lots of things is now like a dejavu for me. Mainly that part when you have to order engine-specific parts from Volvo ![]() I already went through few rounds of work on it; first round was focused mainly on removing all the homemade wiring, security alarms and things hanging here and there; second round was just a general cleanup to have a reasonably clean car to work on. I will be adding pictures and comments as the work progress goes on, now just an initial pic of the car and the engine bay... ![]() ![]() ![]()
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Volvo 740 Turbo B204GT 1991 >project thread< It's the oversteer that scares passengers. It's the understeer that scares the driver. lazy PRV engine? Check >this< out Last edited by tomasss; 09-07-2019 at 11:05 AM.. |
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#2 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() So, the PLAN:
- rebuild the turbo - replace the saggy nivomats with the IPD conversion kit (Bilstein touring) - new timing belt, all tensioners and belt for the balance pulleys (I want to keep it so far) - wasted spark conversion - KL racing aluminium intercooler - injectors sent for cleaning - TCU mod (to allow higher boost) - professionally made leather wrap for the steering wheel & armrest - full simons stainless steel exhaust - repair the cracked downpipe and exhaust manifold - remove the last pieces of the bloody homemade AC setup ![]() |
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#3 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Turbo.
The original turbocharger in these engines is a variant of Garret T3, model TB0381. After the rebuild shop dismantled the old turbo, they found that the exhaust housing is cracked and it was reasonable to look for some replacement. So it will be compatible better flowing .48 Sierra Cossworth exhaust housing, and the compressor wheel exchanged for its billet aluminium equivalent for faster spool-up. The progress on this I have in a separate thread, so until I have it back I will just add a link: http://forums.turbobricks.com/showthread.php?t=346865 Last edited by tomasss; 01-28-2019 at 03:04 PM.. |
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#4 |
Slow Member
Join Date: Nov 2012
Location: UK
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![]() Looks like a fun project. Homemade AC is.....interesting.
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#5 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() TCU mod.
I followed the description >here< and >here< but realized it's not fully correct...in particular the picture with the resistors is wrong. The resistors below should be changed. ![]() ![]() Last edited by tomasss; 09-07-2019 at 11:06 AM.. |
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#6 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Oh yeah. Especially the electric part
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#7 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Exhaust.
No rocket science here. Went with the 3" Simons chromsteel 024-H7 full set. It is intended to be used with B204FT (with cat) so I had to reuse part of the old pipe to make it fit. No welding required, just cut the appropriate part of the old pipe and use it as a mid-section. The exhaust manifold crack has been welded with nickel filler. The downpipe leak also fixed and secondary o2 bung has been added. Threads re-threaded. Then both sprayed with heat resistant paint. The floor resprayed with zinc spray. ![]() ![]() ![]() ![]() ![]() ![]() ![]() Last edited by tomasss; 09-07-2019 at 11:07 AM.. |
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#8 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Oil pump gear.
Known weak spot on these engines. New type of the pump gear fitted and higher 10.9 strength bolt used. ![]() Last edited by tomasss; 09-07-2019 at 11:08 AM.. |
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#9 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Interior.
First things first. The PO decades ago was probably obsessed with wood. So he fabricated all the door panels and also the dashboard trim / armrest with real wood. The thick layer of clear coat started cracking which is what I ended with. So the door panels has been replaced (I resprayed the grey ones to black, it went surprisingly well), the armrest has been sanded down and recovered with real leather together with the steering wheel (beautiful handmade job by the way). The dashboard trim I just wrapped in black carbon, will see if I will change it to something else in the future. Anything is better than what it was ![]() ![]() ![]() ![]() ![]() ![]() ![]() ![]() Last edited by tomasss; 09-07-2019 at 11:09 AM.. |
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#10 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Found during cleaning. Not sure if it's OEM?
![]() Last edited by tomasss; 09-07-2019 at 11:12 AM.. |
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#11 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() My favourite mod. Magnets on the steering cap to catch the metal particles.
![]() Last edited by tomasss; 09-07-2019 at 11:16 AM.. |
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#12 |
Ring apprentice
Join Date: Aug 2004
Location: Belgium, Gruitrode
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![]() Congrats on the car!
I recently purchased 2 960's with that engine, and they came with quite a few parts. Also had a 740 a few years back, 740 looks better imho. 960 is more modern.
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2019 Peugeot Expert 2005 V70 - 2.4D 1992 740 B230FD 1982 242 B230FK |
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#13 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Good to know. Now I will annoy you with questions all day long
![]() I agree with the 740 look. I love the radical design. For the project car, 960 looks too “normal” to me. Last edited by tomasss; 01-29-2019 at 06:09 AM.. |
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#14 | ||
forced instruction
Join Date: Feb 2012
Location: The Balkans, BiH
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![]() Quote:
I was goint to ask you about that AC... Looks like a jumble of 240 and Mercedes parts. Quote:
That center armrest part was weird, though. Good luck in bringing it back to the road. I have to get mine going too, I miss driving that car...
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Jetronic is romantic. - '94 965 - D̶2̶4̶T̶I̶C̶, then M̶5̶0̶B̶2̶5̶ now OM606.962. - '90 744 turbo 16 valve LPG - B204GT/M90 - trophy w̶i̶f̶e̶ car. - '89 764 B280F - Daily barge. - Various 740's, 940's, 960's and a couple of 760's. |
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#15 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() After obtaining all the parts and tools, finally I had time this weekend to ditch the nivomats and replace the rear springs and shocks with the conversion kit from IPD.
Compressing and fitting the first spring was one hell of work, lots of trials and errors...second spring was then piece of cake ![]() ![]() ![]() ![]() ![]() Last edited by tomasss; 09-07-2019 at 11:17 AM.. |
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#16 |
Board Member
Join Date: Sep 2011
Location: Czechia
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![]() Nice, I´ve found that the simplest way of replacing springs were remove whole arms together with springs
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#17 | |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Quote:
Well for now I have replaced all the pulleys, idlers and belts, so I want to at least give it a shot. I might remove it whenever I fell like. |
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#18 | |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Quote:
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#19 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Antenna time!
Scored a broken antenna on ebay few days ago...so I gave it an overhaul today and replaced the mast. Even small victories deserve celebration ![]() ![]() ![]() Last edited by tomasss; 09-07-2019 at 11:18 AM.. |
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#20 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Picked up the M90L2 during the weekend...gave it a good wash and it landed in my garage today
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#21 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Some progress finally.
Engine went out of the car. M46 removed. Clutch & PP removed, found out my flywheel is bit >tired< In the meantime I have at least removed the rust & repainted the oil pan, when I was there I checked all oil squirters are intact. Also cleaned the oil suction pipe screen. Luckily I also checked the seal at the other end of the oil suction pipe. This seal was completely torn ![]() ![]() ![]() ![]() ![]() ![]() Last edited by tomasss; 09-07-2019 at 11:20 AM.. |
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#22 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Slowly slowly moving forward...
Rear main seal replaced together with the paper gasket, M46 pilot bearing removed and retroturbo pilot bearing with the adapter for M90 installed ![]() ![]() ![]() Last edited by tomasss; 09-07-2019 at 11:20 AM.. |
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#23 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() These days there is some job done almost every evening...
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#24 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() So, after some more thinking I've decided I'll ditch the balance shafts. Originally I wanted the car to be mostly stock, but yeah...for other things I can't resist to modify, so why to keep this system anyways.
Something I can clearly blame turbobricks for ![]() ![]() ![]() ![]() ![]() Last edited by tomasss; 09-07-2019 at 11:22 AM.. |
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#25 |
former PRVert
Join Date: Oct 2008
Location: Leuven, Belgium
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![]() Reached the stage when more assembling than disassembling is to be done
![]() Old mounts ![]() One mount was even completely torn (the screw is wobbling in the metal mount top) ![]() New poly mounts from retroturbo ![]() Also converted the old M46 transmission crossmember mount (on the top) to the M90 transmission (bottom) ![]() Last edited by tomasss; 09-07-2019 at 11:23 AM.. |
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