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Old 10-30-2015, 09:20 AM   #1
JerryJS8
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Default Olga the Second Revised - 740(SE) Turbo 16V

1991 740(SE) 16v turbo rebuild project


TL;DR Bought car 2004, built car 16v turbo 2006, put car in family care/storage 2008, sold car 2013, bought car back 2015, imported car 2016, still ain't finished rebuilding it in 2017... too much kaputt for german

Long-time member, now getting back into the game after a many year hiatus.

A little bit about me – born in Florida, now living in Germany. Always driven a Volvo, first car was a 89’ 240 that taught me a lot about problem diagnostics and got me on a first name basis with the local pull-a-part. After that I had about 4 or 5 740’s and a 960 that I fixed up and sold mostly to friends and family. Moved to Europe in 2007 and got an introduction to Volvo’s European counterparts with a 480 "sports car" (at least my insurance argued it being one on paper) and a V40 being prime examples of hodge-podge value chain management and minimum viable rust prevention manufacturing that both ended up being sold for export to countries with governments that don’t have as much to say about regulations concerning transport vehicles.

A bit about my project car – bought the car off eBay in 2004 for around 500 dollars with blown turbo seals, cracked rear window and other busted stuff I can’t remember. Best part was that the motor had been laying a nice thick layer of anti-rust film all the way to rear bumper which lead to not having a spot of rust anywhere on the chassis. The name of the car “Olga the Second” comes from it being the second blue 740 sedan I had owned having the same personality of what I would imagine a Swedish lady with a remarkable half-tank construction would be like.

A bit about the project - years before I had started collecting parts for a 16 valve conversion and by the summer of 2006 I had found an SE body kit in the junkyard, fully upgraded the suspension with Bilstien HD’s, IPD 25/25 swaybars, Lesförd lowering springs (only in the front, the back was squatting with em installed), adjustable panhard rod, aluminum control arms, Virgo rims, lockin diff with 4.10 final ratio, 5-angle valve seats and matched porting on the B234 head etc.. Biggest hurdle was of course the exhaust manifold, but after getting through that being the last piece of the puzzle, the project had to be completed.

In the pics below you can see the progress/final result of the car as it stood back in the summer of 2008.

































The moderately sized but responsive 50 trim T3



A bit about the interim - in 2008 I put the car up for sale, but got cold feet about parting with it for good and was able to convince my family to take care of it for a while.

Link to my sales thread just for fun

In 2013 I ended up selling the car to a buddy of mine cause I had moved to Europe and couldn’t fit it in my carryon luggage, and my family was tired of babysitting it.

There the car proved to be quite a headache for him considering the non-standard build that most of you here are familiar with and those typical Volvo electrical issues. Sad to say, the Florida sun wasn’t kind to the paint and daily life took its toll on both the interior and motor. Last year I contacted him to ask how the car was treating him to find out he was putting it up for sale.

My wife knew how much I loved building that project (cause I often would be sitting at my computer looking at pictures of it or other turbobrick projects) and suggested importing it to Germany. Before she could even think about regretting it I told my buddy we’d take it. It was a long wait, but visiting my parents in the spring gave me the chance to get the car road ready to drive it down to Miami and get it on a boat. Here’s the car as I bought it back in Florida.



















And here it is getting off the truck in Germany.





The white hood and door I installed before putting it on the boat for Germany and were from taken from the only 740 in the local junkyards (coincidentally that car also belonged to the former owner). At that point the car didn’t need to look good for shipment, it just needed to be functional.

And now the project “Olga the Second Revised” begins

First things first – blue door. The white hood doesn’t bother me so much, but that ther’ stock-car racing deal ain’t gonna work. So I found some local enthusiasts parting out a blue 740 and had an impromptu party getting to meet the gang while filling up on spare parts.



Next improvement – my current daily driver is a 1989 16v 740 SW which originally comes with the 3” throttle body so I swapped manifolds

After that I converted to an e-fan, but I’ll need to update with a pic of that since I can’t find any on my phone right now…

Dem Eyes so sad – much better with E-Codes

Before



After



In all my (revised)project planning, I decided the turbo is too small, and that before I get a new one, it would only make sense to first have a larger air filter. So what I’m currently up to is fabricating a stock-ish looking airbox to furnish a huge air filter. Bigger box needs moar space, so I relocated the stock wiper fluid reservoir, and relocated the battery to accommodate it.





So my winter project is to fabricate said air filter box, and spiff up the interior with said collected spare interior parts from said cannibalized former enthusiast owned Volvo 740. Before springtime I need to also (re)complete Stage 0 for the import registration in Germany. Meanwhile I’ve been having some fun with some 3-D concepts for a bigger turbo. Someone say EFR 6758 Twin scroll?




Last edited by JerryJS8; 07-05-2017 at 04:39 AM.. Reason: update on history of the car and general presentation -- getting rid of photobucket links
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Old 10-30-2015, 11:16 AM   #2
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What a total sleeper! That's awesome that you get to reconditioning it after the person you sold it to ruined it. There are a few cars I've sold that I wish I could have helped out like that...
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Old 10-30-2015, 11:40 AM   #3
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Thanks!

Just means I get more project for old my project car But I wouldn't go as far as saying he ruined it. Just missing a bit of its old glanz

Last edited by JerryJS8; 10-30-2015 at 04:33 PM..
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Old 10-30-2015, 08:36 PM   #4
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I met the guy who bought this car . He was telling me the story on it. Glad to see its back in good hands and being restored to its former glory.
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Old 10-31-2015, 10:51 AM   #5
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Got to swapping the Virgos to my DD and the Remotecs on the project 744.



Not sure how I like the look of these... but they are 7.5 inches wide, which makes them interesting.

Kinda up in the air on these or a set of Geminis, even though a 225/55 tire would go on Geminis just fine.

Last edited by JerryJS8; 07-05-2017 at 04:40 AM.. Reason: Getting rid of photobucket links
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Old 10-31-2015, 12:10 PM   #6
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keep the remotecs and lower the car.
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Old 10-31-2015, 12:38 PM   #7
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Well the car is lowered already, and with the streets here in town I'd be afraid of going any lower.

Also got these hanging out in the garage.



But the remotecs with new paint are kinda growing on me.

Last edited by JerryJS8; 07-05-2017 at 04:40 AM.. Reason: Getting rid of photobucket links
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Old 10-31-2015, 01:48 PM   #8
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Use the Gems
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Old 10-31-2015, 11:18 PM   #9
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I love those remotecs on the car, but gems are my favorite OEM wheels. Tough choice.
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Old 11-11-2015, 04:22 AM   #10
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Found a good reason to use the Gemini rims.

http://www.volvoforums.org.uk/showthread.php?t=156900

Always aggravated me how quickly a new set of stock rotors started warping...
Hopefully some 302mm brakes will be the end of that.
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Old 11-11-2015, 04:59 PM   #11
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Very nice!
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Old 12-24-2015, 03:41 AM   #12
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Whoa awesome... So im not the only 16v turbo guy in germany anymore? i think we need to phone some day about 16v's n stuff !!
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Old 01-03-2016, 02:33 PM   #13
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Whoa awesome... So im not the only 16v turbo guy in germany anymore? i think we need to phone some day about 16v's n stuff !!
Sounds like a plan! But at the moment you may be the only owner of a registered 16v turbo
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Old 01-03-2016, 03:03 PM   #14
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Senn was one of my favourite people on the board, as you can see from my sig. lol


Good to see it's getting reborn.

Glass sunroof?
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Old 01-03-2016, 04:36 PM   #15
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Glass sunroof?
Yeah, I grabbed a glass sunroof some years ago in a junkyard, should have swapped the headliner as well... I'm missing that optional sliding shade!

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Old 01-19-2016, 10:36 AM   #16
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The mailman brought me a new present today! The car has made it this far on a square-toothed belt...



And since this had been a Florida car probably all its life, this might be the first time it's seen snow!


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Old 01-19-2016, 11:06 AM   #17
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looking good.

I always thought the P80 chassis front calipers would work. Nice cheap upgrade!


also how much for your "old" header?
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Old 01-21-2016, 08:46 AM   #18
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looking good.

I always thought the P80 chassis front calipers would work. Nice cheap upgrade!


also how much for your "old" header?
I got a lot of other stuff to do to get it registered and made into a reliable daily driver before I start on the twin scroll upgrade.

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Old 01-21-2016, 09:03 AM   #19
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let me buy those remotecs!
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Old 01-22-2016, 01:59 AM   #20
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let me buy those remotecs!
Ok, but you also pay shipping from Germany...
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Old 02-15-2016, 05:37 AM   #21
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So, the weather finally got warm enough to be able to work outside, so I took the chance to do some work before the snow rolls back in. Was working on cleaning up the motor from all the oil leaks and replacing the gaskets one by one when my garage neighbor asked why I wasn't just pulling the motor if I had so much on my to-do list.

Me: I don't have a crane to pull the motor.
Him: I do, so now what's your excuse?
Me: ... I need a beer, then I'll be over to get the crane

And so the fun begins...



Nastyness in the engine bay, gotta take car of that before the motor goes back in



Source of nastyness in the engine bay, gotta take care of that before the motor goes back in

--------------------------------------------------------------------------------------

Then I pulled the head to see what the past 10+ years have done to it.





#4 - Nice grooves man...



#3 - More groovyness



#2 - And the song continues



#1 - Ah sweet! No grooves, just rust....

So it's not what was wrong with cyl#1, but what happened to 2,3 and 4... Guess I'll be needing a new block, since I don't think they'll be gone with the next bore up and already running once overbored.

On a side note, this is why we don't like the stock 16v intake on boosted motors





So fortunately I just happen to have a low mileage b230f block laying around the garage. Just needs a light hone and drilling all the oil lines for the turbo.

--------------------------------------------------------------------------------------

Still happy with the exhaust manifold though, held up to a lot of abuse with those ugly welds...







So now I'm ordering gaskets and such, getting my shopping list together. While the weather's cold again, at least I got part of my project in the garage next to the heater

Last edited by JerryJS8; 07-05-2017 at 05:26 AM.. Reason: Getting rid of photobucket links
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Old 02-15-2016, 05:50 AM   #22
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Ask FT-Albert.de for parts... Give him a greet from me ;) Or... No.. dont... Just say to him dass er die Dichtungen nicht knicken soll, damit sie in den umschlag passen ;)

he's the best source for parts in .de

I like the manifold.. What material and dimensions? Selfmade?
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Old 02-15-2016, 06:01 AM   #23
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Ask FT-Albert.de for parts... Give him a greet from me ;) Or... No.. dont... Just say to him dass er die Dichtungen nicht knicken soll, damit sie in den umschlag passen ;)
Funny you said that, look what recently came in the mail...





----------------------------------------------------------------------

Manfold is self made from mild steel elbows and a sheet of old metal I had laying around the shop back then. Cutting out those flanges with an acetalyne torch then rounding em out with a dremel took a good amount of time...

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Old 02-15-2016, 06:08 AM   #24
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HE DIDNT ?!!!!! Gerhard... You Prick!! :D
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Old 02-15-2016, 06:18 AM   #25
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HE DIDNT ?!!!!! Gerhard... You Prick!! :D
Ruhig Blut! I didn't order it from him, some eBay shop out of the UK.
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