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Old 08-14-2019, 07:02 AM   #76
DET17
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Those bent "fender washers" for DP retention would worry me. Why not weld extend the original ~10mm thick plate?
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Old 08-14-2019, 07:20 AM   #77
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You think it will not be able to hold it? It's quite thick stainless steel and it's even folded (so double thickness) on the inner side. I thought for that little amount of stress (just enough to make a seal) it should be ok, but I am open to other thoughts. There is a supporting bracket in the middle of the downpipe too (mounted to the transmission body).
Why not to weld it...well first think I don't have a welder; second thing the gap between one of the bolts and the car body is already very tight with the current solution, I am not sure if it would even fit with welded extension around the bolt...
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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.
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I would rather push a 240 than drive a V70.
lazy PRV engine? Check >this< out
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Old 08-18-2019, 11:37 AM   #78
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Based on the modifications related to the cosworth exhaust housing, I found out that the wastegate doesn't clear the engine block anymore. After some considerations I've decided to shim the whole exhaust manifold using a 16v flange rather than trying to modify such a nice setup that the turbo company made. To achieve that I also needed 1cm longer exhaust manifold studs...









Comparison of the stock IC vs. the full aluminium KL racing intercooler


Which is not exactly direct fit in 740...the front section had to be marked




..and then cut out




test fitting some tubing


and tubing in final configuration


recirc valve connection


the diameter of the original hose was narrowed around the airbox which is not the case now


The airbox itself was emptied inside from any restrictions


Also some progress on the oil separator


then I have started the tubing from the airbox to the turbo...all 80mm, with reusing the heated breather port (the second port is for the recirc valve)




which resulted in this


some more random pics...






Today I made a final order of the last missing hoses, so in week or two I should be able to start the engine again...

Last edited by tomasss; 09-07-2019 at 10:41 AM..
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Old 08-21-2019, 04:19 PM   #79
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Sometimes I feel like being OCD patient... so I was not very happy with the "trumpet" style of the tubing end, but I was not sure how to make a proper beads on the pipe.
Then I found out this neat video and I did exactly the same.



and that allowed me to go from this


to this

Last edited by tomasss; 09-07-2019 at 10:42 AM..
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Old 09-03-2019, 05:27 PM   #80
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Tubing, tubing and more tubing! Almost having dreams about pipes and hoses of all angles and diameters also finished the oil return line from the turbo.

Regular T3 oil return flange


T3 to AN10 adapter


Mounted and test-fitted with the ultraflow hose ends


Using the ptfe hose and ultraflow (torques UK) hose joiners this was created


and this is how it looks all put together


also quite some progress from the top of the engine - hoses going to catch can, external diverter valve are finished, one more pipe (the big one between the turbo and the airbox) to be installed and I will be able to test-start the car

Last edited by tomasss; 09-07-2019 at 10:45 AM..
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Old 09-07-2019, 04:30 AM   #81
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Last 80mm intake pipe arrived yesterday, so here we go...






Last edited by tomasss; 09-07-2019 at 10:35 AM..
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Old 09-07-2019, 05:30 PM   #82
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Engine started today
It was running rough though...very low idle rpm and then it eventually stalled. I've tried to pull the codes but surprisingly no reaction from the jetronic diagnostic socket.
Swapped back the original lh jetronic chip and voila, running fine except being rich because of the greentops. Also diagnostic socket was working.
So it seems I have issue with the BTI lh chip...being checked with the company guy.
On the other hand...I am really happy everything else works...wasted spark ignition, all the new tubing, it is not leaking oil...it was a good day today after all
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Old 09-08-2019, 07:05 AM   #83
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Your oil drain doesn't really look like it's a nice gravity drain from the pics you posted. Might be something to check, or I'm seeing it wrong?
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Old 09-08-2019, 12:30 PM   #84
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Quote:
Originally Posted by reiernumans View Post
Your oil drain doesn't really look like it's a nice gravity drain (...)
You are completely right (and God bless you and turbobricks for that remark ).
I thought the oil return can be basically any shape (as the other side is pressurized so it would push out the oil no matter the shape) but after reading bit more on this topic I understood that the oil return really needs to allow gravity drain.
That in other words means it is not possible to use the AN10 oil return kit from Yoshifab on stock b204ft/gt, as the stock location of the turbo is too low...if I mount the T3 AN adapter the hose end is already below the level of the engine block feed
So yeah...after taking some measurements, I've realized I have no other option than fall back to the stock oil return line I've already removed the Yoshifab press-in adapter (hell of a job) and put the OEM return line in place using a new oring seal and some high temp silicon on the outer side.
Lesson learnt...

Last edited by tomasss; 09-08-2019 at 04:19 PM..
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