DD'ing a Turbo Brick

[flipstah]

Picked up a daily driver last night. Had to get it towed home because registry was closed and I didn't have an extra plate.

Some fun bits:

1991 Volvo 940 Turbo Wagon
Blue
5 seats (6 and 7 are missing)
BOV
RWD

Wagon

Did I mention it was a wagon?

http://i113.photobucket.com/albums/n205/dj_flipster/13872902_10154324958439820_1718005976468108162_n_zpsgqo5ph6r.jpg

Sr. Flipstah waiting in the back, looking at me as if I was a tool.

http://i113.photobucket.com/albums/n205/dj_flipster/13782224_10154324958524820_3694559774076665750_n_zpsijocnvxq.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/13680592_10154325039804820_1482627022932014314_n_zpsly3wsmyh.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/13782203_10154325039779820_1980937315899826774_n_zpssc8seymw.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/13872954_10154325039834820_4946127981587137881_n_zpsiqtfwhq5.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/13882313_10154325039859820_3588135763646658617_n_zpserri7bfj.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/13886333_10154325039844820_2249075614215003459_n_zpsayn0e0tg.jpg

Will I regret buying this land yacht? Maybe. Maybe not.

Who knows? Time to do the basic maintenance and be ski-hill ready.
:bigpimp:

Let the games begin! :drama: :rofl:

[jwslam]

YTMND

[EK 2.0]

Like I said on Insta....



Ayooooooooos pare....I mahal por your coche...

[BokCh0y]

My friend had one of those when we were younger, I used to drive that wagon all the time, was so fun haha.

[eglove]

wtf..why wouldn't you buy just one nice brand new car...

[flipstah]

Originally posted by eglove
wtf..why wouldn't you buy just one nice brand new car...

I'm waiting for the V90 to come out. Looks better than the V60 Polestar out right now, and with V90 Polestar... Mmm.

http://www.volvocars.com/en-ca/cars/new-models/the-new-v90

[G-ZUS]

Ohhh woh

[Darkane]

Is that a wagon?

[mrsingh]

:thumbsup:

[zipdoa]

lol you and I have so much in common... excellent taste my brethren

[vengie]

Lol, AMA must love you when you come renew the memberships for your cars

[mrsingh]

When you told me a Volvo, I was thinking mid to late 90s, front wheel drive. I secretly hoped for a yellow 850R wagon... :clap:

[eglove]

Originally posted by flipstah


I'm waiting for the V90 to come out. Looks better than the V60 Polestar out right now, and with V90 Polestar... Mmm.

http://www.volvocars.com/en-ca/cars/new-models/the-new-v90

That makes more sense. I have some wheels for you ;) 5x108 ooh yeaaa

[A790]

Originally posted by Darkane
Is that a wagon?

[R154]

Don, you are SO weird. And I love it.:love:

[flipstah]

Thanks, peeps! Keep posted on daily maintenance and random shit.


Originally posted by vengie
Lol, AMA must love you when you come renew the memberships for your cars

AMA was so slow to get a tow truck last night. 2 hours. Cool dude though.

I have a go-to tow crew, but they were in Golden last night. They love me lol!


Originally posted by mrsingh
When you told me a Volvo, I was thinking mid to late 90s, front wheel drive. I secretly hoped for a yellow 850R wagon... :clap:

I wanted an 850R in Edmonton, but the price was way too much.


Originally posted by eglove


That makes more sense. I have some wheels for you ;) 5x108 ooh yeaaa

18s though... So big, lah.


Originally posted by R154
Don, you are SO weird. And I love it.:love:

Rofl.

[Neil4Speed]

Originally posted by R154
Don, you are SO weird. And I love it.:love:

:werd:, sometimes I just shake my head... in a good way with a smile.

[LilDrunkenSmurf]

Ahahahahaha

[finboy]

I'm jelly, I love these volvo's, I tried to convince lammer to buy one before he got his DA

[flipstah]

Finding offset information is difficult for the Brick.

They're on awesome winters right now and I don't want to burn through them.

[flipstah]

Maintenance day today! Went to my local Auto Value to gather some items:

Oil + oil filter
Headlight bulb
Rear wiper
Spark plugs
Engine degreaser

http://i113.photobucket.com/albums/n205/dj_flipster/2AD09747-1FD3-4031-B66A-4F16C10C60D6_zpsebhjxxad.jpg

Following recommended weight as upkeep is what keeps the world go round!

,http://i113.photobucket.com/albums/n205/dj_flipster/0D9C2F6C-818A-41C0-9592-C609532C4901_zpsf5pu1vdc.jpg

Head gasket needs work and the last oil was very thin. No way this was a month old oil.

http://i113.photobucket.com/albums/n205/dj_flipster/59F9286D-60F5-4603-9FEE-ACAE30DCC2E6_zpsoeaj9hhz.jpg

Degreaser doing wonders.

http://i113.photobucket.com/albums/n205/dj_flipster/4325EDC5-1A52-4E97-A4ED-9F94BB3FD2E4_zpszhhvkgdb.jpg

Fluid top up:

http://i113.photobucket.com/albums/n205/dj_flipster/D51593F0-9698-4708-8726-FDBCFCF05E83_zps8edbvxx9.jpg

Unplugged the battery and the engine light went away. Yay! Went for a test run and things went well!

http://i113.photobucket.com/albums/n205/dj_flipster/67B32B31-022B-44CB-B758-D32159DF612E_zpsl9bgcvav.jpg

Tomorrow will be interior work and cleaning while ATF and brake fluid flush will be next week!

[G-ZUS]

Nice ride, saw you last night at Shell

[NoPulp]

SO MUCH WANT!
Why can I never find a nice one. I can only find ones that are 1. 400+km or 2.rusty.

[flipstah]

Nice meeting you as well. The V Power made a difference to the low compression turbo lol.

[flipstah]

Originally posted by NoPulp
SO MUCH WANT!
Why can I never find a nice one. I can only find ones that are 1. 400+km or 2.rusty.

I was going to buy one in Abbotsford Friday and drive back Saturday, but was able to snipe this one Wednesday.

I drove this weekend to Vancouver for dinner lmao

[flipstah]

Did some interior work today. Sort of.

Tried to sew a rip, but my needle broke.

http://i113.photobucket.com/albums/n205/dj_flipster/13900287_10154339235039820_5825353809047076465_n_zps5rkjqqmo.jpg

So I changed the stereo instead.

http://i113.photobucket.com/albums/n205/dj_flipster/13882439_10154340569054820_8868809638301754259_n_zpstrrpybx6.jpg

So there's a leak in the car and while investigating, found a weird tube that didn't belong...

http://i113.photobucket.com/albums/n205/dj_flipster/13876244_10154340115384820_6897707253719381666_n_zpsw6lbay85.jpg

You can see how it's an afterthought, touching hardlines

http://i113.photobucket.com/albums/n205/dj_flipster/13895527_10154340115414820_3792692184066115813_n_zpsof2ti1wa.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/13892065_10154340115434820_3507096920667048926_n_zps7ipnyvp4.jpg

Where did it lead?!

http://i113.photobucket.com/albums/n205/dj_flipster/13891914_10154340115469820_809756066948593400_n_zpsgxvoe8ml.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/13891796_10154340115544820_1497582319748123780_n_zpsf2nrigfm.jpg

Some fool rigged a POS catch can/blow-by.

http://i113.photobucket.com/albums/n205/dj_flipster/13876394_10154340115494820_7224766252650798942_n_zpsxtbot9g8.jpg

FML.

Not really sure how to fix this...

[G-ZUS]

Originally posted by flipstah
Nice meeting you as well. The V Power made a difference to the low compression turbo lol.

You too sir, would have loved to stay and chat for a few mins but I was in a hurry LOL

[flipstah]

Who wants to see me put an eBay catch can on it?! :rofl:

[mrsingh]

Originally posted by flipstah
Who wants to see me put an eBay catch can on it?! :rofl:

Do ittt, what is the worst that can happen?...

[LilDrunkenSmurf]

I do.

[flipstah]

I also joined a Volvo forum to gather some parts from other members.

[flipstah]

Does anyone have recommendations on slowing down rust on rear wheel well? It's not bad, but I want to slow it down or stop it.

Cut/weld/respray?

[mr2mike]

Damn, wish I saw this eariler. Got a generic catch can you could have had for really cheap.

Get an industrial sewing needle and you should be able to sew the seat.

[whatthe]

Looks like it should be a fun build, always nice to see something different.

I grabbed a curved needle set from Walmart a while back for a couple of bucks that works great on upholstery. I didn't even use the biggest one in the set and had no issues. For the thread, I used some sewing 'cord' passed down from generations... don't really know how long that thread/cord has been around, but it was the cats meow and stronger than some fishing line.

[flipstah]

Originally posted by mr2mike
Damn, wish I saw this eariler. Got a generic catch can you could have had for really cheap.

Get an industrial sewing needle and you should be able to sew the seat.


Originally posted by whatthe
Looks like it should be a fun build, always nice to see something different.

I grabbed a curved needle set from Walmart a while back for a couple of bucks that works great on upholstery. I didn't even use the biggest one in the set and had no issues. For the thread, I used some sewing 'cord' passed down from generations... don't really know how long that thread/cord has been around, but it was the cats meow and stronger than some fishing line.

Thanks for the tips on the needle. I'll stop by and take a look.

Good thing I paid attention in Home Economics. Cheap fuck, rolling in. :rofl:

Ordered more goodies from eBay and TurboBricks, the local Volvo site for enthusiasts. Apparently, a cupholder armrest was a baller option. BOUGHT.

Gotta check the timing belt next week and still do the fluid changes.

Coils or bags?

[xnvy]

Originally posted by flipstah
Does anyone have recommendations on slowing down rust on rear wheel well? It's not bad, but I want to slow it down or stop it.

Cut/weld/respray? Sand/grind it away then cover it with POR-15? You can pick some up at Napa or even Canadian Tire but not all CT carry it.

[nzwasp]

You will probably want to use upholstery thread for the seat. It will be easier to use than nylon. Its about 3 or 4 times thicker than normal polyester thread, get it from fabricland.

[flipstah]

I learned that leather sewing sucks, and Stiegl doesn't really go well with sewing.

[flipstah]

Weird. The Brick ate through 2-3L of oil from end of July till now. Been monitoring the oil status, and there's no burn (white smoke when cold start, but disappears when warm), catch can is not that full (maybe 1/8 cup?), and there's no gushing leak (just trickles).

WHERE DID IT ALL GO!?

[AndyL]

Check pcv blockage - common turbo volvo issue?

[flipstah]

In Edmonton right now this weekend with the Brick. Ran fine and mileage was decent with half tank usage.

10L/100kms on highway. Pretty decent.

Catch can picked up maybe 400ml from this trip. Do I want to set it up so it recirc back into the oil filler cap or just empty and discard safely?

[J-hop]

So I could be wrong but I don't think you want to plum it back to the oil filler as that is your crankcase pressure ventilation. On my b21ft I had a catch can and then plummed the line to the intake before the turbo (I think the stock intake has a port for that?). In theory that should put the pcv under slight vacuum which I think is what you want. Or vent to atmosphere as a second option.

[flipstah]

Well, the one I have right now is vent to atmosphere, and it's working pretty well.

The previous owner modded the tubing to add an SQV so I don't know if there's a spot for the recirc pre-turbo.

I have to also find out where the oil is being fed for the turbo. There's so many weird things in this car. I love it. :rofl:

The Brick was able to conquer Calgary->Edmonton and back with no issues. Was able to keep up with the traffic and was pretty comfortable on the highway.

However, one of the shocks seem shot because of the floaty handling and also, the condensation from the AC leaks inside the cabin.

EDIT: The car seems to love Rotella5W40 and Shell 91. Got better mileage on this setup vs. 5W30 and Shell 89.

Weird....

[LilDrunkenSmurf]

Shell 91 will have 0% ethanol vs 5% in the 89 (which just mixes 87 and 91 at the pump)

Ethanol burns faster, so the less of it you have, the better the mileage.

[flipstah]

I guess oil viscosity isn't a huge factor in MPG after all

[J-hop]

Originally posted by LilDrunkenSmurf
Shell 91 will have 0% ethanol vs 5% in the 89 (which just mixes 87 and 91 at the pump)

Ethanol burns faster, so the less of it you have, the better the mileage.

I believe also ethanol contains oxygen in its chemical make up. This causes the exhaust gases exiting to have a slightly higher oxygen content than with regular gasoline. Older vehicles that don't have composition sensors therefore think a leaner condition exists and will adjust the fuel tables slightly richer and you end up burning more fuel unnecessarily.

[flipstah]

To-Do List This Weekend:

- Drain and fill ATF (not flush)
- Change Brake Fluid
- Change Power Steering Fluid
- Inspect serpentine/timing belt/water pump
- Inspect brake pads and discs
- Change Valve Cover Gasket
- Find the damn oil trickle
- Diagnose extended cranking (maybe HT leads/ignition coil/fuel system related)
- Aesthetics (valve cover painting/grille refresh)
- Vacuum
- Create crossbars for Thule box

[flipstah]

Completed partial maintenance weekend and this car is a riot to learn stuff on.

- ATF is fine, clean, plentiful and similar situation with the brake fluid. No changes.
- Power steering fluid was brown and murky, so switched it up to the Volvo green splooge.
- Belts looked fine with no cracks
- Brakes are still thick
- Finding the oil trickle is tricky. Still haven't found it,

Checked around the turbo, which meant removing piping around the air filter. Good thing I did, because the air filter is nasty.

http://i113.photobucket.com/albums/n205/dj_flipster/14095844_10154419931229820_5972942348038239682_n_zpsivhdtfee.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/14064280_10154419931269820_8310642220833556038_n_zpsmzlprcli.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/14141728_10154419931774820_9022662559937625421_n_zps4exuqkb6.jpg

Cleaned the baby turbo with some Spray Nine and a toothbrush. Lots of accumulation. There's also an open nipple that I have no idea where it leads to. Looks like a valve for the wastegate?

http://i113.photobucket.com/albums/n205/dj_flipster/14102690_10154419931364820_5575965293164122042_n_zpsyiogvoqx.jpg

While searching for that elusive oil leak, I thought there was an open valve for the PCV. Turns out it was a coolant plug. FML.

Screwed it back in, refilled the coolant and cleaned the garage floor. While that dried up, I detailed the car and refreshed the grille! So many rock chips. Not anymore.

http://i113.photobucket.com/albums/n205/dj_flipster/14054159_10154419931574820_1556060231273762424_n_zpselfp6fvu.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/14079491_10154419931649820_7145577902461640587_n_zpsxhh1z8xv.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/14054081_10154419931904820_2825900524658336238_n_zpsw4n97uxe.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/14089079_10154419931829820_8054594118464253031_n_zps8ca7ba9u.jpg

I found a HBC boost controller in my glove compartment, except I've never used one. Is it necessary?

[whatthe]

Originally posted by flipstah
Completed partial maintenance weekend and this car is a riot to learn stuff on.

Looks like a valve for the wastegate?

While searching for that elusive oil leak, I thought there was an open valve for the PCV. Turns out it was a coolant plug. FML.

Screwed it back in, refilled the coolant and cleaned the garage floor. While that dried up, I detailed the car and refreshed the grille! So many rock chips. Not anymore.

I found a HBC boost controller in my glove compartment, except I've never used one. Is it necessary?

I've never worked on a Volvo, but always nice to read the full deal in the build. Something always happens and to learn from.

Turbo looks like it has an integrated bov/compressor bypass valve for the missing connection. Notice any fluttering when you let off throttle? Given the age, that valve might just be simply pooched at this point. Typically that nipple would just go to a vacuum connection on the intake manifold in between the engine and throttle body.

Boost controller would be 'necessary for fun'/increased boost at some point, but wouldn't install it if you don't have boost gauge, wideband, some experienced help and an idea of boost targets from other Volvo guys.

[J-hop]

^ You are right, the nipple is on the integrated compressor bypass valve (see diagram in this link https://www.volvoclub.org.uk/faq/EngineTurbo.html

If you look at the pics it looks like someone put a hks blow off valve or something so he shouldn't have compressor surge problems.

Leaving that nipple open should be fine as the valve would only open under vacuum.

OP do you notice any performance issues on shifts? The stock ecu fuel maps assume you are recirculating the air from the bypass valve. I think with venting to atmosphere you will be spiking rich on shifts. I ran MS on my Volvo so I never got to test how the stock ecu handled the fuel when venting to atmosphere. So I don't really know if it would affect performance

[flipstah]

Just as I thought. Thanks!

Performance wise, not really sure how to test it. Fuel mileage is roughly 22mpg in the city and 24mpg on the highway or 10L/100km.

The car handled heading to Edmonton and back just fine at awesome speeds.

Go 10psi

[J-hop]

Originally posted by flipstah
Just as I thought. Thanks!

Performance wise, not really sure how to test it. Fuel mileage is roughly 22mpg in the city and 24mpg on the highway or 10L/100km.

The car handled heading to Edmonton and back just fine at awesome speeds.

Go 10psi

Awesome yea I was just thinking if you noticed stumbling on shifts or anything like that

[flipstah]

So the leak is on the left side, which is probably power steering. Time to follow the piping.

Meanwhile, I did this:

http://i113.photobucket.com/albums/n205/dj_flipster/14188651_10154422614324820_3273077272686501693_o_zps3qndt6ao.jpg

[flipstah]

So the leak is at the bell housing, which is a PITA. Going to Valentine Volvo to get it formally diagnosed and quoted.

[prae]

Valentine's kind of a ripoff shop. you might be better off going to a respected independent like "Mr Volvo" or otherwise http://www.mrvolvoplus.ca/

I thought "cancer man" on the forums was a bit of a volvo guy (may be affiliated with one of the aforementioned shops). The guys on calgaryvolvoclub are also super friendly and probably a great resource for you.

[flipstah]

Unfortunately, I need the shuttle service for work and Mr. Volvo can't do weekends.

Otherwise, I definitely would've gone with them.

Just saw Calgary Volvo Club, so I'll check them out. Thanks!

EDIT: Mr. Volvo does overnight drop off so dropping the car off!

[flipstah]

Bought PCV goodies! Yay!

http://i113.photobucket.com/albums/n205/dj_flipster/20160830_132119_zps5l34ftek.jpg

Breathe, my precious.

[flipstah]

Slight snag on the breather box replacement.

Removed the old breather box and added a new one in. The previous owner drilled a tube through the oil breather into their DIY catch can. Hooked up everything again, and car won't hold idle.

Took off BOV; same thing. Replaced the hose that housed the BOV, to an original one, car won't start. Took off silicon hose from turbo to intercooler, and car starts. I control the airflow with my hand and car runs decent. The moment I complete the circuit, it chokes and cuts out. I unplug the MAF sensor near the air filter box and car starts lean. It doesn't like the pressure the turbo is giving so vacuum leak?

[cancer man]

Anytime you need a hand pm me. I have all the tools.

[flipstah]

^Thanks for the offer but was able to solve the vacuum leak. Intake manifold gasket issue, but found a replacement part from NAPA.

Back to stock mode, and running better now. No more hesitation on first gear, and I still get 10psi of boost.

Anyone know street value for a manual boost controller and an HKS SQV?

Some pics of previous owner hackjob. Guess which one is the stock oil breather box lol

http://i113.photobucket.com/albums/n205/dj_flipster/14225572_10154443495994820_5122554011806169654_n_zpsfu2sicke.jpg

http://i113.photobucket.com/albums/n205/dj_flipster/14141543_10154443496554820_8411046498846771385_n_zpsoh5l0y9m.jpg

New hoses, box, many goodies...

http://i113.photobucket.com/albums/n205/dj_flipster/14232972_10154443495824820_4255728052443497438_n_zpskriukjkl.jpg

Goodbye, HKS thing.

http://i113.photobucket.com/albums/n205/dj_flipster/14212139_10154443496684820_3499635943070819559_n_zpsjy27uhbc.jpg

Stock everything!

http://i113.photobucket.com/albums/n205/dj_flipster/14224839_10154449686239820_8353506656406381040_n_zpshwetuf1n.jpg

[whatthe]

Good call on getting the leak fixed... MAF cars definitely hate leaks. I have a few couplers to pressure test piping and then spray on some soapy water, but even then it can be a challenge depending on where the leak is.

The HKS BOV design is still one of the best in my opinion since added pressure really helps the piston seat and isn't nearly as finicky as some other 'quick-acting' types. The main challenge is getting one that isn't an ebay clone. Given the inherent design, the clones can still do fairly well... but I've seen the center smaller valve for lighter throttle releases not function, and also seen them still manage to leak with questionable seating/and springs on the back end. You can work around it a bit, but if you can find a new/used authentic, you'll save yourself a lot of headache. Used clones vs. used authentic don't seem to differ too much in price $80-$150 just because most guys think theirs is authentic. New authentic are in the 400-450 range.

[flipstah]

Don't think I'll verify authenticity. Just throw money at me lol!

I did notice excessive blow-by during cold start, but not sure if it's because it's colder today and/or the change made that happen. Too many factors.

[flipstah]

The brick is running well. I'm bored now. :(

[AndyL]

There's a sexy lil 60s Nissan patrol on Kijiji ;) that'd keep you entertained for years :)

And it's brick shaped!

[whatthe]

Originally posted by flipstah
The brick is running well. I'm bored now. :(


https://cdn.meme.am/instances/55304604.jpg

Not sure about the music, but more boost is a good cure for boredom

[flipstah]

Is it weird I was looking up "Twincharged 940" on Google? :rofl:

I could also upgrade the Mitsubishi turbo to a big one. That's just asking for trouble.

[ercchry]

Where is the air suspension?!

[flipstah]

Originally posted by ercchry
Where is the air suspension?!

No one wants to weld me front struts! :( I also can't find new spindles to mock a setup.

[ercchry]

Sounds like excuses

[Waldi]

Originally posted by flipstah


No one wants to weld me front struts! :( I also can't find new spindles to mock a setup.



Check this board for wealth of info https://www.brickboard.com/, in terms of parts, I used to go to https://www.ipdusa.com/ (it is in Oregon, but they ship here as well). I had 740 turbo wagon and it was the beast brick.

[flipstah]

It's time to dump money in it and make it my own. Only logical thing to do, really.

[flipstah]

My boredom will be rectified by making this wagon a boss ride.

First thing cleared: Finding the elusive third row seats.

http://i113.photobucket.com/albums/n205/dj_flipster/14470517_10154507072729820_2081366569317826825_n_zpsk81mdnnb.jpg

Granted, they're beige but once installed it should be good to go for now. Unless I figure out how to dye vinyl/leatherette.

Got a lot of plans now mwhahahha.

[BerserkerCatSplat]

Originally posted by flipstah
Can anyone recommend a used dealer with a great selection of European cars? The Volvo is leaking way too much and the board has given me notice for it. Cost too much to fix than it's worth.


What's leaking so badly that it's noticeable? Rear main seal?

[flipstah]

Originally posted by BerserkerCatSplat


What's leaking so badly that it's noticeable? Rear main seal?

Head gasket

[BerserkerCatSplat]

Originally posted by flipstah


Head gasket

Wat. Your board somehow noticed you have a bad head gasket? I'm so confused. :rofl: Are you leaking fluids, or just smoking out the parking garage?

[flipstah]

Originally posted by BerserkerCatSplat


Wat. Your board somehow noticed you have a bad head gasket? I'm so confused. :rofl:

It's slowly leaking coolant to the floor, and I noticed that the sides around the head gasket is always wet.

[BerserkerCatSplat]

Having an external coolant leak from a head gasket is pretty uncommon, but I suppose it's possible. Got any pics of the leak?

[flipstah]

I'll msg you. Can we move some of the conversation from here to my build thread? Don't want to de-rail.

[BerserkerCatSplat]

Yeah a mod should do that or something.

[flipstah]

Goodbye! She is sold.