B21F intake progress.......
After lots of head scratching, postulating plans to move this project forward to completion, finally some progress to report.
Last Saturday I decided to fit check the B21EFI intake again, and sort out WHAT vacuum connections would be made where, and to what device. Made a list of the requirements from the old B230FT intake, and then schemed where to make all these same connections to the old (new) intake. There are actually more ports on the B230FT, as one would expect as technology & creature comforts moved forward.
A couple of the nagging challenges were, what throttle cable to use? How to obtain proper AW71 "throttle pressure" using that cable to properly control the AW (when to downshift, how "hard" to shift, etc.). I actually woke up one night and realized, the nearest thing to a proper cable
would have to be the 240 K-Jet cable used on the NA cars. So I searched around for the Volvo P/N, and then found a nice NOS GEMO cable for that application, which was I think 80-82 NON turbo 240. With the old 940 throttle cable removed (a real PITA to extract, you need a special socket type tool to release the plastic snap fingers on the cabin side).... I failed, and just broke mine off. Another piece of serendipity.... a fellow TBer posted in WANTED looking for a 80-82 triple throttle spool for his 240 NA with cruise.... which looked amazingly similar to what I saw in pics of the 740 B23E / B230E in Europa. I contacted him, he provided the source of his NOS part..... and
amazingly that guy had another! That baby arrived in the mail, then the NOS GEMO cable, and I decided to fit check them both:
Viola! The damn thing looks like a perfect solution! Front view, you can see how well it all aligns to the B21F intake:
Well the differences between the 2 and 7/9 start at the firewall. Would it play nice there?
The answer again, is yes:
Looks like I'll need to drill a couple clearance holes for the small attachment screws, and bolt the 240 cable thru from the engine bay to the cabin. No problemo! In fact, I'll chop up the original 940 cable and use that seal piece to close off the cabin from engine fumes.
The last riddle was, the 240 cables have a little pin connector in the cabin side, whereas the 7/9 series has a ball end on the cable which is retained to the pedal assy. So I'd have to customize my 940 pedal, I thought.
THEN I remembered, this past spring I pulled a complete 93 240 throttle pedal and cable from a 100K mile donor (which yielded many parts for my 242 project). I wondered, would it bolt up and play well with a 940?
Amazingly,
again YES:
I was almost laughing now! Turns out the 2 series and 9 series pedal geometry is EXACTLY THE SAME. Bolt hole pattern/diameter, lever length above/below the pivot point, SAME.
I'll be damned! I guess those OVLOV Engineers loved that pedal design geometry so much, they carried it forward into the 7/9 series. Good times are here!
I'll clean up that total install after it's 100% for final assy.,
but the good news is the 240 system drops right into the 7/9 to properly actuate the throttle.
OK, back to vacuum. I was short a couple of connections, and had that pesky "cold start injector hole" to deal with on the Kjet intake. When I measured the "as found" hole, I saw it was just a shade larger than 1/2" ID. I had already located these other connection points to all the original tapped ports on the B21F intake:
What remained was that cold start hole and a non-existent 2nd hole (the last 2 connections I need at the cabin vacuum controls; tiny hose special fitting on the BH230FT intake) and another for my boost/vacuum gauge. A thought occured, tap the 1/2" ID hole for 3/8" pipe and reduce bush to use my stock port for the dash HV control. Turns out the 3/8" NPT uses a 9/16" tap drill..... which I bought from Homer Depot, and provided this:
That passage for the injector cleans up perfect to 9/16", and now I'll tap with my 3/8" pipe tap. Homer Depot also had a brass 3/8" to 1/8" pipe in one bushing. Success again!
The easiest location left for my 1/8" turbo boost/vac. gauge is right here.... the boss is already there, just waiting to D&T:
In summary.... I'm pretty stoked! Got my B21EFI intake throttle cable & spool sorted out, and all the vacuum connections ID'd as well. One I didn't mention, is the AIC port. Nathan welded a 3/8" NPT boss onto the underside of the intake, and I'll drill that thru to the plenum to provide the AIC connection. One future detail to design/execute is HOW to mount the AIC using part of the original mount and rubber mount.
A pretty sweet night in the Underground Swedish Garage