My '91 744 B204GT project - Page 10

tomasss · 12-12-2020, 04:42 AM

Well, my friend works in a printing shop, so she managed everything

thanks for the template!
How did I find out? I've recently bought a new calibrated Proxxon small torque wrench, and there was bit of overlap of the torque ranges between that one and the big wrench. So just out of curiosity I was wondering "how precise this old no-name wrench actually is?"

Sjeng · 12-13-2020, 05:17 AM

Good you caught it now.
Engine looks nice.

What did you do with the ring gaps?

MadDog_945 · 12-13-2020, 09:15 AM

Yeah! I'm very curios about the ringgap

tomasss · 12-13-2020, 05:04 PM

For the ring gaps...well I just followed the technical list from Traum pistons. 0.58mm for the 1st/2nd compression ring and 0.38mm for the oil rings.

Other than that...engine is coming together!

Volvo sealant applied with the PU roller, hopefully it will be approved this time

Hydro lifters in

Camshafts in

Cam cover installed & Bosch coil for the wasted spark mounted & leads connected

And timing belt installed

Sjeng · 12-13-2020, 05:29 PM

Does that coil bracket position give you enough room in relation to the firewall?
I looked at this as an option in my 740 but didn't seem to work.

tomasss · 12-13-2020, 05:49 PM

Yes...it is tight fit but it works, there is about 5mm gap. It should be fine with the PU engine mounts.

http://forums.turbobricks.com/showpo...0&postcount=44

tomasss · 12-14-2020, 06:26 PM

Day off today...so garage time from the early morning

Wastegate preload adjusted

Exhaust manifold + turbo mounted & oil lines connected

Prepping the intake side (phenolic spacer)

Intake mounted

Off the engine stand, loaded on the engine crane; flywheel mounted

Clutch...

...and pressure plate

Mated with M90

and all together going back in

Voila...it's end of the day and the engine is back where it is supposed to be

dopski · 12-18-2020, 12:41 PM

Whohaa great succes. Near completion. Do u wait for a fisrt start for 2021 ;)?

tomasss · 12-30-2020, 07:11 PM

Quote:

Originally Posted by dopski

Whohaa great succes. Near completion. Do u wait for a fisrt start for 2021 ;)?

Not sure! I've returned from travelling trip few days ago, since then I am working on it again...so I still have full tomorrow. Lets see!

tomasss · 12-30-2020, 08:22 PM

Quote:

Originally Posted by MadDog_945

nice, curios if it works better..

Well, it doesn't fit...and neither would have fitted the KL Racing one. The issue is that the threaded hose coupler from the clutch master cylinder is specific for b234/b204 engines, so the hose has to have a really long thread at that end, as it goes first through a bracket, then nut, then the coupler...

That is not the case for neither of the aftermarket hoses. So I am thinking about just replacing the hose with new OEM one. It was already working even with the old OEM hose, so that seems as the easiest solution. I am also in contact with a company that makes the custom hoses...

reiernumans · 12-31-2020, 08:16 AM

If you call your local Goodridge dealer I'm positive they'll be able to make you something. Or you could bring your old stuff to a local hydraulics supplier and have them make something for you.

tomasss · 01-06-2021, 05:17 PM

Quote:

Originally Posted by reiernumans

If you call your local Goodridge dealer I'm positive they'll be able to make you something. Or you could bring your old stuff to a local hydraulics supplier and have them make something for you.

Well, I've contacted three (one in UK and two in DE) and only one was able to supply the long threaded end. It's the link below, fitting types 551 and 553. The hose is ordered so I'll give a feedback afterwards

https://www.probrake.de/Custom-steel...specifications

tomasss · 01-06-2021, 05:23 PM

Other than that, I've replaced the automatic timing belt tensioner (just to be sure - it was probably still the original one), filled the fluids and was about to try starting. Unfortunately it seemed I have a dead starter, not even clicking. So I have started investigating and during that process I damaged the starter solenoid while torqueing down the positive cable nut

New starter solenoid is on the way, so hopefully in few days. But after this I still measured the exciter wire of the solenoid and during starting there is only 7V, that looks to me like a possible root cause...

tomasss · 01-07-2021, 06:38 PM

Starter motor extracted, solenoid separated...to my surprise it seems the carnage was not caused primarily by torqueing down the cable nut, but it was already cracked before and this was just the last drop. While searching for used starters yesterday on ebay, I found several ones with the same damage. Well brand new solenoid is on the way so I think I made the right decision

tomasss · 01-08-2021, 03:33 PM

Heatshield applied to protect the undercoating...I am wondering if it will last

ZVOLV · 01-08-2021, 03:58 PM

You are motivating me to make progress on my B234FT build.

tomasss · 01-08-2021, 05:52 PM

Quote:

Originally Posted by ZVOLV

You are motivating me to make progress on my B234FT build.

I am getting lots of motivation in other threads so I'm glad the circle is enclosed then!

tomasss · 01-11-2021, 06:48 PM

So I was having the same issue as described >here< (not enough current causing voltage drop and the solenoid not closing completely).

Fixed by adding the relay solution

(black one starter relay, grey one is just the coil for the wasted spark tacho)

ZVOLV · 01-15-2021, 06:56 AM

I do not agree with your method of adding a relay to the starter circuit. That makes more points of failure. You have excessive resistance somewhere in the circuit. I am going to guess at terminal crimps, ignition switch, or connectors. Always measure power circuits with a test lamp. 7V on a meter won't illuminate a lamp; you found a problem. However, you could have 12v on a meter, but not an illuminated test lamp. (one strand of wire can show 12v on a meter, but won't operate a component)-- To find poor connections, perform a loaded voltage drop test with your meter.

That pink anaerobic liquid gasket is TOUGH to lay down properly. I used a foam paint roller. Your layer of pink goop LOOKS thin; you MAY SEE A LEAK. I put TOO MUCH pink goop on my oil pump/front crank seal plate and fouled the oil pump relief valve open and lost oil pressure.

tomasss · 01-17-2021, 07:35 PM

Yep, I see your point about more points of potential failure. True. I might change it back in the future and debug it more if there is time and energy...

The sealant I think just LOOKS thin. Once I've put the two halves together, there was very little extra sealant being pushed out all around equally. Soon I'll know

tomasss · 01-17-2021, 07:41 PM

So to summarize the clutch hose issue: for b204ft/gt the standard HEL hose for Volvo 740 turbo doesn't fit, also the KL Racing hose doesn't fit. The issue is that the OEM hose has twice as long thread of the hose end on the master cylinder side.

The solution is custom made hose, I bought it from probrake (https://www.probrake.de/Custom-steel...specifications), made in Germany and certified by Dekra. Fitting types 551 and 553. The hose length 43cm.

To make sure it doesn't collide with the steering I made an extra bracket that holds it away from it.

tomasss · 01-18-2021, 06:50 PM

Starter solenoid replaced, so hopefully starting trial at the end of the week

tomasss · 01-21-2021, 05:49 PM

Brakes and clutch bled today, I was expecting that after replacing the brake master cylinder it will take a lot of fluid but bench bleeding it in advance helped a lot...just few bubbles and I was done.
Also attempt to start the car was done, but the battery is suddenly dead...falls below 6v while cranking

So tomorrow again, new battery is on the way.

tomasss · 02-01-2021, 05:37 PM

New battery has been installed, and after fixing some small issues with the oil pump not >priming<, the historic moment came...

FIRST START! IT'S ALIVE!!!

I can't even express how happy I am. I've also measured the compression and it's 8.5bar on all cylinders even before the rings are seated, so it should be even better later.

rijk · 02-02-2021, 06:09 AM

Mooi moment. Gefeliciteerd, Tomass!

12-13-2020, 09:15 AM	#228
MadDog_945 Våga Vägra 8V Join Date: Apr 2006 Location: Lower Saxony	Yeah! I'm very curios about the ringgap __________________ '93 945 B234FT Build '93 245 Racecar

01-08-2021, 03:58 PM	#241
ZVOLV <Master Tech> Join Date: Nov 2002 Location: California	You are motivating me to make progress on my B234FT build. __________________ No Start Thread

01-15-2021, 06:56 AM	#244
ZVOLV <Master Tech> Join Date: Nov 2002 Location: California	I do not agree with your method of adding a relay to the starter circuit. That makes more points of failure. You have excessive resistance somewhere in the circuit. I am going to guess at terminal crimps, ignition switch, or connectors. Always measure power circuits with a test lamp. 7V on a meter won't illuminate a lamp; you found a problem. However, you could have 12v on a meter, but not an illuminated test lamp. (one strand of wire can show 12v on a meter, but won't operate a component)-- To find poor connections, perform a loaded voltage drop test with your meter. That pink anaerobic liquid gasket is TOUGH to lay down properly. I used a foam paint roller. Your layer of pink goop LOOKS thin; you MAY SEE A LEAK. I put TOO MUCH pink goop on my oil pump/front crank seal plate and fouled the oil pump relief valve open and lost oil pressure. Last edited by ZVOLV; 01-15-2021 at 07:02 AM..

02-02-2021, 06:09 AM	#250
rijk Board Member Join Date: Apr 2004 Location: Netherlands	Mooi moment. Gefeliciteerd, Tomass! __________________ The B204FT to B234FT conversion http://forums.turbobricks.com/showthread.php?t=182821

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12-13-2020, 05:17 AM	#227
Sjeng Board Member Join Date: Sep 2017	Good you caught it now. Engine looks nice. What did you do with the ring gaps?

12-13-2020, 05:04 PM	#229
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	For the ring gaps...well I just followed the technical list from Traum pistons. 0.58mm for the 1st/2nd compression ring and 0.38mm for the oil rings. Other than that...engine is coming together! Volvo sealant applied with the PU roller, hopefully it will be approved this time Hydro lifters in Camshafts in Cam cover installed & Bosch coil for the wasted spark mounted & leads connected And timing belt installed

12-13-2020, 05:29 PM	#230
Sjeng Board Member Join Date: Sep 2017	Does that coil bracket position give you enough room in relation to the firewall? I looked at this as an option in my 740 but didn't seem to work.

12-13-2020, 05:49 PM	#231
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Yes...it is tight fit but it works, there is about 5mm gap. It should be fine with the PU engine mounts. http://forums.turbobricks.com/showpo...0&postcount=44

12-14-2020, 06:26 PM	#232
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Day off today...so garage time from the early morning Wastegate preload adjusted Exhaust manifold + turbo mounted & oil lines connected Prepping the intake side (phenolic spacer) Intake mounted Off the engine stand, loaded on the engine crane; flywheel mounted Clutch... ...and pressure plate Mated with M90 and all together going back in Voila...it's end of the day and the engine is back where it is supposed to be

12-18-2020, 12:41 PM	#233
dopski Board Member Join Date: Oct 2008 Location: Rotterdam	Whohaa great succes. Near completion. Do u wait for a fisrt start for 2021 ;)?

12-31-2020, 08:16 AM	#236
reiernumans Board Member Join Date: Jan 2014	If you call your local Goodridge dealer I'm positive they'll be able to make you something. Or you could bring your old stuff to a local hydraulics supplier and have them make something for you.

01-06-2021, 05:23 PM	#238
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Other than that, I've replaced the automatic timing belt tensioner (just to be sure - it was probably still the original one), filled the fluids and was about to try starting. Unfortunately it seemed I have a dead starter, not even clicking. So I have started investigating and during that process I damaged the starter solenoid while torqueing down the positive cable nut New starter solenoid is on the way, so hopefully in few days. But after this I still measured the exciter wire of the solenoid and during starting there is only 7V, that looks to me like a possible root cause...

01-07-2021, 06:38 PM	#239
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Starter motor extracted, solenoid separated...to my surprise it seems the carnage was not caused primarily by torqueing down the cable nut, but it was already cracked before and this was just the last drop. While searching for used starters yesterday on ebay, I found several ones with the same damage. Well brand new solenoid is on the way so I think I made the right decision

01-08-2021, 03:33 PM	#240
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Heatshield applied to protect the undercoating...I am wondering if it will last

01-11-2021, 06:48 PM	#243
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	So I was having the same issue as described >here< (not enough current causing voltage drop and the solenoid not closing completely). Fixed by adding the relay solution (black one starter relay, grey one is just the coil for the wasted spark tacho)

01-17-2021, 07:35 PM	#245
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Yep, I see your point about more points of potential failure. True. I might change it back in the future and debug it more if there is time and energy... The sealant I think just LOOKS thin. Once I've put the two halves together, there was very little extra sealant being pushed out all around equally. Soon I'll know

01-17-2021, 07:41 PM	#246
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	So to summarize the clutch hose issue: for b204ft/gt the standard HEL hose for Volvo 740 turbo doesn't fit, also the KL Racing hose doesn't fit. The issue is that the OEM hose has twice as long thread of the hose end on the master cylinder side. The solution is custom made hose, I bought it from probrake (https://www.probrake.de/Custom-steel...specifications), made in Germany and certified by Dekra. Fitting types 551 and 553. The hose length 43cm. To make sure it doesn't collide with the steering I made an extra bracket that holds it away from it.

01-18-2021, 06:50 PM	#247
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Starter solenoid replaced, so hopefully starting trial at the end of the week

01-21-2021, 05:49 PM	#248
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	Brakes and clutch bled today, I was expecting that after replacing the brake master cylinder it will take a lot of fluid but bench bleeding it in advance helped a lot...just few bubbles and I was done. Also attempt to start the car was done, but the battery is suddenly dead...falls below 6v while cranking So tomorrow again, new battery is on the way.

02-01-2021, 05:37 PM	#249
tomasss former PRVert Join Date: Oct 2008 Location: Leuven, Belgium	New battery has been installed, and after fixing some small issues with the oil pump not >priming<, the historic moment came... FIRST START! IT'S ALIVE!!! I can't even express how happy I am. I've also measured the compression and it's 8.5bar on all cylinders even before the rings are seated, so it should be even better later.