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Old 01-28-2019, 02:35 PM   #1
tomasss
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Default tomasss's '91 744 B204GT

Picked up 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 but it has a decent body, electric sunroof and that magical thing under the bonnet so I decided to make it my winter project.
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
It's the oversteer that scares passengers. It's the understeer that scares the driver.
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lazy PRV engine? Check >this< out

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Old 01-28-2019, 02:44 PM   #2
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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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Old 01-28-2019, 02:52 PM   #3
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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

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Old 01-28-2019, 02:53 PM   #4
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Looks like a fun project. Homemade AC is.....interesting.
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Old 01-28-2019, 03:02 PM   #5
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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.


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Old 01-28-2019, 03:09 PM   #6
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Quote:
Originally Posted by Pete.M View Post
Looks like a fun project. Homemade AC is.....interesting.
Oh yeah. Especially the electric part


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Old 01-28-2019, 04:58 PM   #7
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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.


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Old 01-28-2019, 05:01 PM   #8
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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.

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Old 01-28-2019, 05:13 PM   #9
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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


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Old 01-28-2019, 05:16 PM   #10
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Found during cleaning. Not sure if it's OEM?

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Old 01-28-2019, 05:19 PM   #11
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My favourite mod. Magnets on the steering cap to catch the metal particles.

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Old 01-28-2019, 06:07 PM   #12
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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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Old 01-28-2019, 08:13 PM   #13
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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.


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Originally Posted by volvo78244 View Post
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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