B21EFI Intake final install; throttle body overhaul
Time for an Xmas update on the project. The throttle body overhaul was delayed as I waited on the Volvo Webstore to deliver the throttle plate attachment screws; they have an unusual feature where they are "V'd" after install, so they will not loosen/fall out. It took 4 weeks to get these screws! I'd previously cleaned the TB in my ultrasonic bath, but waited impatiently for the parts. Here is the finished TB, assembled and ready to attach:
Many thanks to DEK2688 for the tip about this throttle body: it has the smaller TB bore for crisp response, the 4 bolt pattern like the larger 3" 960/850 NA version, and also has the hose barbs for the emission control lines to burn the fumes off the fuel tank. This TB is a little obscure.... came on a 10 valve 850 sold in the UK and Europa; none I believe reached North America. I found this one online in Lithuania, and it only took about 2 weeks to get here.
The winning combination to make this TB play nice with LH2.4 is as follows:
1. the subject 850 TB
2. a B234 throttle plate shaft & throttle plate
3. tap the M4 screws for attachment of the LH2.4 TPS to the casting
4. a K-Jet 240 TB actuation lever (which I welded to the original from the 850 TB for the stop)
This assembly points the LH2.4 TPS downward, so the stock connector will reach. Your must drill & tap the M4 threads into the casting to allow adjustment so the "click" of the TPS occurs when the throttle is closed. I'll be running new hoses to the charcoal canister, as this TB points the barbs towards the firewall. A small price to pay to take care of those fumes in the tank (my tree hugger tendencies coming thru). Here some detailed pics of the components of the hybrid TB:
I reiterate:
you MUST USE the K-Jet TB crank arm, in order for proper function of the linkage with the 240 K-Jet 3 drum (or single drum) spool.
For grins, here is a comparison of the 3 inch NA TB (which can support 400 HP) and the standard 2.5" Turbo TB (which supports 305HP and has crisp throttle response.... you decide):
Fully assembled you can see the throttle actuation with the 240 K-jet spool closed, then fully actuated (to the stop):
Finally, the long awaited l
ast install of the B21EFI intake:
With the intake finally complete, I went back to the 3 inch DP, which needed heat tape wrapping the upper section to prevent heat soak into my AC lines and the dryer/receiver. I used the DEI "titanium wrap", secured with quality Swedish hose clamps. Once the DP was insulated, I connected the previously reviewed bell housing 3" band strap and the V-band up top. Here is the final installed DP, sans O2 sensor which will be installed later:
Next - I'll finalize the custom DP hanger aft of the flex joint which I built to carry the CAT; the exhaust will be roadworthy, so once "Cheap Thrills" is running I'll drive to the local exhaust shop to get a transition pipe from the exit of the CAT to the TME pipes.