DD'ing a Turbo Brick

**flipstah** · 08-20-2016, 07:17 AM

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** · 08-21-2016, 05:06 PM

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** · 08-22-2016, 08:00 AM

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.

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** · 08-23-2016, 06:36 AM

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** · 08-23-2016, 07:58 AM

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

**J-hop** · 08-23-2016, 08:09 AM

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** · 08-23-2016, 08:51 AM

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** · 08-28-2016, 12:04 AM

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.

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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?

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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.

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

**whatthe** · 08-28-2016, 01:12 AM

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** · 08-28-2016, 01:28 AM

^ 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** · 08-28-2016, 06:32 AM

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** · 08-28-2016, 10:20 AM

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** · 08-28-2016, 02:52 PM

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

Meanwhile, I did this:

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**flipstah** · 08-29-2016, 08:47 AM

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

**prae** · 08-29-2016, 11:45 AM

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** · 08-29-2016, 01:10 PM

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** · 08-30-2016, 01:25 PM

Bought PCV goodies! Yay!

Breathe, my precious.

**flipstah** · 09-03-2016, 07:43 PM

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** · 09-03-2016, 11:05 PM

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

**flipstah** · 09-05-2016, 07:52 PM

^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