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1995 940 turbo *longterm* daily driver

you didnt tell me this...but sweet!

do you think changing the EZK chip will be necessary? or just the fuel chip?

Stock ezk maps are not too bad if you want to run 1 bar boost or less on a stockish redblock.
For higher pressures (where these cars become fun) I would reduce timing in the highest load cells in order to be safe.

Low loads you can advance a bit for a little more torque and better response.

Have you two (or others) been satisfied with your 19t turbos? I'm hoping that's a 'final' turbo for this car. I'm wanting decent power and good reliability. Did it leave you wanting more, I guess is what I'm asking?

I am currently running a 18T 7cm on my 940. At 1.4 bar it is quite a bit quicker than my C70 T5. Response is good, wide torque curve. Imo it is a very nice, reliable turbo for these engines. Just like you I have a 250k mile engine and it takes it very well.

I have a HY35 10cm right here but am not (yet?) motivated to put it on, because it already is performing very well.

BTW I just buy aliexpress chips. Works like a charm, although they are only one time programmable. But very very cheap.
 
There's no gasket for the cbv between the cover and compressor housing. Just remove the 3 bolts and it comes right off. Hopefully your cbv cover isn't bent. It can happen pretty easily if you have 1 bolt holding the cover on... Best to remove them evenly or hold pressure on the cover until you get the last bolt completely removed. Kinda hard to describe but you'll see once you get in there.
 
Got around to changing the water pump gaskets. Hopefully my leak is gone. Note that it's great to have a second set of hands to lift up on the water pump as you tighten it against the block.

<a href='http://i.imgur.com/GuxkLeW' title=''><img src='http://i.imgur.com/GuxkLeWl.jpg' alt='' title='Hosted by imgur.com' /></a>

Fresh gaskets, but old (sub-10k miles hepu) water pump.

I'm starting to smell a little oil at high rpms/high boost. Probably should start looking at ccv stuffs for that. I imagine it only gets worse with bigger turbo and more boost. A couple other things are starting to need attention now that I've been driving this car every day for a few months now.
 
This is a sick build. I might have to take a road trip down to chuck town after I?m done my trans swap and check it out.

Thanks man. Making these cars have three pedals is the best mood you can do.

So, I've been leaking oil and decided to try and track it down. I spent a couple hours pulling the timing components off followed by ripping the turbo off. Everything went smoothly. So far, I've confirmed a leak at the cam seal. I think I also have a leak at the front main seal cover, although not leaking through the main seal. I had a puddle dripping off the oil filter, which I believe is my main leak, but I haven't felt like getting under their to investigate that further. Here's where I'm at.

<a href='http://i.imgur.com/7mlGQU9' title=''><img src='http://i.imgur.com/7mlGQU9l.jpg' alt='' title='Hosted by imgur.com' /></a>

I'm going to take this opportunity to advance my cam gear a little more. I think the next increment is 5? advanced on the ipd gear, so I'm going to give that a try. Having it all apart presents a nice time to put a 19t together. So, hopefully I can scrounge a few dollars to make that happen.

Until next time...
 
Well, my old lady said I was selfish to even consider buying turbo upgrade stuff at this time of year. We have our second daughter due on January 3rd and of course, Christmas coming up among other priorities. She is right of course, but I did squeeze out some maintenance money. These will hopefully seal everything up again.

<a href='http://i.imgur.com/HZW6FA9' title=''><img src='http://i.imgur.com/HZW6FA9l.jpg' alt='' title='Hosted by imgur.com' /></a>

I am definitely realizing more boost, more power, more problems. I think I need to start looking into a better ccv system.
 
It's been raining the past two days straight, but spent a little time this afternoon tinkering with it. My brother and I got the all the front end seals replaced. The front metal crank seal holder thingy has the thinnest gasket. Getting the old gasket off the front of the block was painstaking. But it went back together smoothly enough.

<a href='http://i.imgur.com/yA9NXpA' title=''><img src='http://i.imgur.com/yA9NXpAl.jpg' alt='' title='Hosted by imgur.com' /></a>

<a href='http://i.imgur.com/aLlgCkK' title=''><img src='http://i.imgur.com/aLlgCkKl.jpg' alt='' title='Hosted by imgur.com' /></a>

I advanced my cam gear 5 degrees this time for a little more low rpm umph. I retimed the engine but left the timing covers off. I'm really trying to ensure and verify I am without leaks.

To get the car running, I need to see where/what is leaking on the turbo side of things. No fittings on the turbo itself are leaking. Oil pressure sender is dry. But oil was leaving puddles dripping off the filter. Just gotta investigate more.

Also, this seems to be a recurring theme in this "build" thread... Luckily, this time, I had a spare. The dowel nub thing was cracked but still connected when I pulled it off. Came off with my finger nail.

<a href='http://i.imgur.com/RVuPLIj' title=''><img src='http://i.imgur.com/RVuPLIjl.jpg' alt='' title='Hosted by imgur.com' /></a>

And my two year old couldn't help but give me this Christmas gift she made me early.

<a href='http://i.imgur.com/eXP2HOo' title=''><img src='http://i.imgur.com/eXP2HOol.jpg' alt='' title='Hosted by imgur.com' /></a>
 
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Today, I reinstalled my 16t and made a new oil return as my cheap "braided stainless AN line" had hardened from baking repeatedly. It was brittle and cracked inside the stainless cover. Also, I realized my fittings were loose in general. Car fired up for the first time in several months. Little Odyssey battery held a charge well enough to crank it. Hoping for leak free cruising for a while.

Gotta recheck things in the morning and get my accessory belts installed. I'm ready to see how the cold weather helps the car, although it's been topping 70 lately. We just had our second daughter so time and money will be scarcer than ever. I had to get this thing back on the road while the baby is still sleeping throughout the day. I don't know how folks with kids do it, at least babies and toddlers.

<a href='http://i.imgur.com/5JDvVLD' title=''><img src='http://i.imgur.com/5JDvVLDl.jpg' alt='' title='Hosted by imgur.com' /></a>

Harper Dempsey Donovan
 
Well, I began putting the accessory belts back on and realized the tensioner bracket had broken the same way for the second or third time.

<a href='http://i.imgur.com/OjdxTku' title=''><img src='http://i.imgur.com/OjdxTkul.jpg' alt='' title='Hosted by imgur.com' /></a>

This car has had these blue poly bushes installed since I bought it. They're quite hard and I wondered if they were to blame but it seems the consensus was that they break regardless of what bushings are used.

https://forums.turbobricks.com/showthread.php?t=346913

<a href='http://i.imgur.com/V0gXWQa' title=''><img src='http://i.imgur.com/V0gXWQal.jpg' alt='' title='Hosted by imgur.com' /></a>

I was able to get another bracket at the junkayrd from the only 7/9 car they had. Surprisingly, there were 5-6 240's including a nice white wagon I saw driving around recently. Saddens me the few around here seem to be dropping like flies.

I put everything else back together and grabbed the keys. After sitting for several months, the Odyssey pc680 battery managed to fire the car up, albeit sluggishly. I took it for a spin. I'm super happy I advanced the cam gear to 5?. I've owned an adjustable cam gear for many years and never run anything other than 2.5? advanced. The adjustment made a noticeable difference. It was fun driving the car again after so long.

I got home and popped the hood. I believe I fixed my major oil leak but still was greeted with this. I've now replaced the water pump gaskets and the cam seal trying to solve this. The cam seal didn't appear to be leaking before and doesn't now. I think the water pump is still leaking but there is definitely oil.

<a href='http://i.imgur.com/KS6Z8HX' title=''><img src='http://i.imgur.com/KS6Z8HXl.jpg' alt='' title='Hosted by imgur.com' /></a>

<a href='http://i.imgur.com/1xAVnYc' title=''><img src='http://i.imgur.com/1xAVnYcl.jpg' alt='' title='Hosted by imgur.com' /></a>

Can the head gasket leak oil? What is the round plug thing behind the tensioner? Any ideas what's leaking oil? There is a small pool on top of that hump.

Besides that, I blew/vacuumed a season's worth of leaves off the car and discovered a small lizard that has taken refuge. Tomorrow should see a good hardy car wash and some more miles for LH to learn.
 
Beautiful baby girl! I’m a grandpa now, and there is nothing finer than baby girls.

In 10 years of fooling with these red blocks I have never seen one of those tensioners fail. Please describe in detail how you tension belts.
 
In 10 years of fooling with these red blocks I have never seen one of those tensioners fail. Please describe in detail how you tension belts.

I'm wondering too. Never had one do that in my 25 years of driving these cars. The skinny tensioner bolt, yes... but snapping that arm, no.

Oh and yeah, daughters rock.
 
yeah, you're going to want to go ahead and throw those junk seals you installed in the trash and then go to the dealer and buy some OEM ones. The elring seals fail with the quickness.
 
Beautiful baby girl! I’m a grandpa now, and there is nothing finer than baby girls.

In 10 years of fooling with these red blocks I have never seen one of those tensioners fail. Please describe in detail how you tension belts.

I'm wondering too. Never had one do that in my 25 years of driving these cars. The skinny tensioner bolt, yes... but snapping that arm, no.

Oh and yeah, daughters rock.

Thanks. Her and her sister are great.

I'm not sure how detailed I can be but I'll try. On that particular tensioner, I would loosen the tensioning lock nut and the nut and bolt that articulates against the bracket. I've never looked up a spec for belt tightness if there is one, but I would add tension with the 10mm long bolt until the belt can be pulled (maybe?) a half inch or so. Not scientific measurement at all, but just a reasonable tightness. I would then tighten the lock nut and the one against the bracket.

I learned in the thread I linked to earlier, that after everything is tight, you're supposed to back off the long 10mm bolt a bit. I gave that a try on reassembly.

yeah, you're going to want to go ahead and throw those junk seals you installed in the trash and then go to the dealer and buy some OEM ones. The elring seals fail with the quickness.

That's unfortunate to hear. I thought elring were among the better aftermarket stuff. If they start leaking, I'll have to spring for the good stuff.

Any idea what could be causing oil to pool up like I showed if not from the cam seal? It starts from that piece on the head and is oily down to the water pump.

Alternator bracket breaking is common but maybe not discussed as you just need to grab another one from the junkyard.

My question was answered in my thread for the most part. I was just curious if I should be worried about my bushings causing it, which apparently isn't the case since folks were breaking them with rubber bushings.

And yeah, there was a single 7/9 car at the junkyard I was able to grab one from. I've been rolling for a few days now. All is well.
 
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A quick spritz of purple power and a borrowed electric pressure washer...

<a href='http://i.imgur.com/vWRgHYE' title=''><img src='http://i.imgur.com/vWRgHYEl.jpg' alt='' title='Hosted by imgur.com' /></a>

<a href='http://i.imgur.com/ZfAAh1N' title=''><img src='http://i.imgur.com/ZfAAh1Nl.jpg' alt='' title='Hosted by imgur.com' /></a>

<a href='http://i.imgur.com/18xrMai' title=''><img src='http://i.imgur.com/18xrMail.jpg' alt='' title='Hosted by imgur.com' /></a>

<a href='http://i.imgur.com/aiqMZNs' title=''><img src='http://i.imgur.com/aiqMZNsl.jpg' alt='' title='Hosted by imgur.com' /></a>

Came out pretty well for the little effort involved. I wish my hood insulator thing looked a bit better but it went back on also.
 
So, I leaned on the nipple at the top of my radiator and broke it while washing the engine bay. I did the most turbobricks-esque of fixes including jb weld and plastic epoxy. It's been holding a week or so without issue, but this morning when I got to work, I noticed a green puddle on the ground. My radiator is leaking from the seam where plastic meets metal, not even from where I broke it. How ironic. I guess it's really time for a new one. I don't want to waste $140 on a new radiator when what I really want is the do88 version, but I don't have $400+ for that... Oh, what to do..

And I just quit my job, starting a business, had my second daughter, etc, etc. So, no extra money laying arond.
 
So, I leaned on the nipple at the top of my radiator and broke it while washing the engine bay. I did the most turbobricks-esque of fixes including jb weld and plastic epoxy. It's been holding a week or so without issue, but this morning when I got to work, I noticed a green puddle on the ground. My radiator is leaking from the seam where plastic meets metal, not even from where I broke it. How ironic. I guess it's really time for a new one. I don't want to waste $140 on a new radiator when what I really want is the do88 version, but I don't have $400+ for that... Oh, what to do..

And I just quit my job, starting a business, had my second daughter, etc, etc. So, no extra money laying arond.

Yeah, I ran into that with my old na 944. The radiator plastic gets really brittle and they just start falling apart.

I *think* this would work, at least for now. Obviously would need a run through the radiator shop. Relatively cheap replacement. :e-shrug:
https://forums.turbobricks.com/showthread.php?t=347209
 
Did you ever get a radiator? Funny thing, I have to run a 240 radiator in my 940 because the I got the wrong NPR intercooler and I have a brand new 940 I have no idea what to do with.
 
Did you ever get a radiator? Funny thing, I have to run a 240 radiator in my 940 because the I got the wrong NPR intercooler and I have a brand new 940 I have no idea what to do with.

I did get a radiator and drove it for a bit. I ended up purchasing a '94 940 turbo wagon that will be getting some of these goodies and others will be sold off. This sedan will likely meet it's untimely demise. Sigh.
 
I did get a radiator and drove it for a bit. I ended up purchasing a '94 940 turbo wagon that will be getting some of these goodies and others will be sold off. This sedan will likely meet it's untimely demise. Sigh.

What a sad ending to a great thread. It went from great fun to cracked radiator to potential death so fast! I learned a lot, and appreciate the effort you took to re-upload all the photos to imgur, as well as link all technical explanation threads. Thank you!!

How is the car now, did you change your mind?
 
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