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Old 04-16-2019, 02:22 PM   #26
JerryJS8
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Glad to hear the plugs helped out!

The wires you got there:

The blue and black wires with the rubber surrounding is for a temp switch usually mounted in the radiator to controll the e-fan in front of the A/C condensor.

No clue what the other connector is, but it doesn't look like it's ever been used. Could have been intended for the low water sensor in the wiper fluid reservoir?

Keep up the good work! Rust prevention is something worth every minute invested...
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Try to recreate and see what happens, our crystall ball servers are currrently down.
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Old 05-01-2019, 05:20 PM   #27
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Thanks Jerry, the cables are indeed for an electric Fan. They go all the way around to the battery . I removed them becouse i use the fan relais from the later models.




We have good progress the last weeks:


-The 531 head has bigger valves and stronger springs, otherwise stock.
-The engine is assembled and in the car
-Tubo is mounted including oil, water and air connections
-KL-Racing intercooler
-New AN6 fuellines all the way from tank to enginge
-Crankcase ventilation is installed.













The steering rack was leaking and klonking. Now we have a new one.
Made a servo delete plate until i figured out the elctrical servo thing.






And today mock up of the new exhaust system.
70mm (2,75") from turbo to exhaust. 200 cell cat.
The welding will be done from a professional becouse i even had problems to pin the parts together







Oh and the engine is running!
Well, kind of. Its way to rich an unstable spark on cylinder 3.
The rich condition could be caused by the lack of a proper lambda signal.
Further invenstigastions will be made when the exhaust is finished. Its kind of loud without it haha.
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Last edited by DenK; 05-01-2019 at 05:38 PM..
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Old 05-01-2019, 06:16 PM   #28
122power
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What fuel rail is that? Brand, part number?
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Ring,ring,ring

"Hello"

"Do you work on Volvo ...

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Old 05-02-2019, 02:42 AM   #29
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This one:


https://www.ebay.de/itm/Volvo-240-74...wAAOSwf-VWVA~w
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Old 05-03-2019, 05:41 PM   #30
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The steering pump arrived. I chose a pump from a mercedes a-class, they seem to be popular for conversions. It only needs power and a 12V signal to turn it on.

Fabricated a bracket with my massive wig welding skills.

I will mount it near the battery. Used rubber mounts to keep noise low.
More progress tomorrow.

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Old 05-03-2019, 06:29 PM   #31
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Definitely in to see how that pump works out. I'd like to convert .
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Old 05-08-2019, 05:51 AM   #32
DenK
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The power steering conversion is complete.
The pump is mounted on the framerail between alternator and radiator. Plenty of space here and the hose length is short.

The original return line fits perfectly. Just cut it about 10cm and clamp it on the pump connector, wich has 10mm diameter.

For the feed line, I ordered a custom built hydraulic hose with a pressure rating of 200bar. The steering rack end has a M14x1,5 banjo bolt and the pump end M16x1,5 bolt. One connector is rotated 90 degrees. The hose cost around 25€.

The electrical connection couldnt be easier. Just wired the cables directly to the alternator.
Even the wire length was perfect. The Pump will switch on when the Motor is running. It has a standby mode that requires less current when no steering input occurs.
I have not driven the car jet but the feeling in idle is nice.


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Old 05-08-2019, 06:20 AM   #33
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hello from france, very good job and i very like your reveltronics
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Old 05-08-2019, 02:12 PM   #34
JerryJS8
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Wow, I really like the power steering mod. Good job! Excited to hear how it is while driving.
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Old 05-09-2019, 02:38 AM   #35
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I am so excited about this:







Not so excited about the idle behaviour of the motor.
Way too rich and misfire. Above 2000rpm everything is perfectly fine.

I have switched almost every part by now without any effect.


I am afraid that the cam in combination with big valves and 531 head is just a bit too much for stable idle.
It is a KG Trimning KG2T Turbo Cam.

VALVE LIFT IN 10,5
VALVE LIFT OUT 11,9
NOCK ANGLE 114°
DURATION 300°

I think i go back to the VX3 cam.


Has anyone experienced this issue?
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Old 05-09-2019, 06:18 AM   #36
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you buy it or make yourself?
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Old 05-09-2019, 08:04 AM   #37
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If you mean the exhaust, it is selfmade from 70mm (2,75") stainless tubing, 200cell cat and v-band clamps. The tube after cat is reduced to 58mm (2,25") to the standard stainless exhaust system with two mufflers.
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Old 05-11-2019, 01:58 AM   #38
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how mka your head with bigger valve? expansive?
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Old 05-11-2019, 11:33 AM   #39
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Originally Posted by moise View Post
how mka your head with bigger valve? expansive?

I purchased some big valves from volksraceshop in sweden and gave them to the engine shop along with the head and all the other motor bits.
I dont know what the cost would be for only valves.




I drove the car now for a while. Everything is perfectly fine exept for the ****ty idle.
I just ignore it at the moment.
Dialed the boost in at 1,5bar (22psi) and the car pulls nice from 3,5k and hard from 5k to top. This is a completely new thing for me. I am used to peak torque until 4k and not much more after that. The car is clearly faster now but the turbo fun factor is a bit lower.
I`ll give the VX3 Cam a try.


The power steering is okay. The steering is a bit heavier which is nice. But the point when the steering wheel changes direction is a bit too hard. Maybe the fresh rebuilt steering rack needs some time to break in.
After all, i would do it again but maybe with another pump (from Mini Cooper).


Thats what the engine bay looks right now:
The area around the intake is a bit untidy, but that will be better with the new intake and fuelrail.







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Old 05-11-2019, 03:23 PM   #40
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wo kommstn du genau her? haette dir das sonst auch zusammenwiggen koennen
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Old 05-11-2019, 05:05 PM   #41
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Ich komme von ganz weit unten, nähe Ulm.
Da wo es leider fast keine Volvos gibt.


Ich beobachte dein 16V Projekt schon lange, war immer ne Inspiration für mich. Hoffe du bekommst den Wagen bald ordentlich zum Laufen und auf die Strasse.
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Old 05-12-2019, 03:56 AM   #42
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;) schickma hdy per pm, wir haben da sone whatsapp gruppe...

und wieso verkauft brotkasten der lump den oc606 als seine idee!?? na warte!!!1elf
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Old 05-12-2019, 03:58 AM   #43
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i heard a few times that kg2t and bigger valves are no good.. just raise the idle to 1300;)
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Old 05-13-2019, 01:57 AM   #44
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Quote:
Originally Posted by MadDog_945 View Post
und wieso verkauft brotkasten der lump den oc606 als seine idee!?? na warte!!!1elf
Ich kann dir da jetzt nicht jedes mal die Füße küssen.
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Old 05-13-2019, 02:47 AM   #45
MadDog_945
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Ne.. aber ne Quellenangabe is immer gut beim kopieren und klauen ;)

Immerhin geht man nicht einfach zum Teiledealer und bestellt mal eben nen passenden Ölfilter. Da steckt schon ein bisschen Arbeit hinter den als passend zu bezeichnen... :b
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Old 05-13-2019, 04:09 PM   #46
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Quote:
Originally Posted by DenK View Post
Hoffe du bekommst den Wagen bald ordentlich zum Laufen und auf die Strasse.
Die Hoffnung stirbt zuletzt

Krister is secretly planning to get his 940 back on the road and registered as an oldtimer at the same time.
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Old 05-14-2019, 01:49 PM   #47
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fu!!
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Old 05-15-2019, 05:52 PM   #48
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Dyno Time!












Time for 300 badge thingy under my Name?



Oh, on the way home from the dyno session my turbo decided to stop spinning and have a bearing failure. Yeah i love tuning.



Will pull it on the weekend

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Old 05-16-2019, 03:28 AM   #49
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Nice results. Charge pressure?

Bad luck with the turbo man.
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Old 05-18-2019, 06:56 AM   #50
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Boost in that Dynorun was at 1,4-1,5 bar.


I disassembled the Turbo today and it is not too bad.
The turbine wheel left a small mark on the exhaust housing. Everything else is fine.


There are two things that could have caused this:
-I did not install a blow off valve jet.

-I have a kind of lean afr at top end. the afr rise to 12,5 at 6000rpm. See picture below.






But is a new Garrett ballbearing turbo that sensitive?!
I guess a lean mixture and thus high egt damages the exhaust wheel, not the bearing.
The oil feed and return are perfectly fine. The turbo oil filter and restrictor were clean.
Water connections are working, too. Everything in the exhaust tract looks linke new.


Sparkplugs look normal and compression test was good.


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