home register FAQ memberlist calendar

Go Back   Turbobricks Forums > Mechanical > projects & restorations

Reply
 
Thread Tools Display Modes
Old 05-13-2019, 05:02 PM   #26
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Flywheel surface was >cracked< so resurfacing was done and it goes back. Now waiting for new flywheel bolts.

__________________
Volvo 740 Turbo B204GT 1991 >project thread<
It's the oversteer that scares passengers. It's the understeer that scares the driver.
Quote:
Originally Posted by Wren View Post
I would rather push a 240 than drive a V70.
lazy PRV engine? Check >this< out
tomasss is offline   Reply With Quote
Old 05-14-2019, 07:36 PM   #27
nordmaschine
forced instruction
 
nordmaschine's Avatar
 
Join Date: Feb 2012
Location: The Balkans, BiH
Default

M90 conversion, banalce shafts removed... It's really starting to look like my car now, you just need the wheels.

__________________
Jetronic is romantic.
- '94 965 - D̶2̶4̶T̶I̶C̶, then M̶5̶0̶B̶2̶5̶ now OM606.962.
- '90 744 turbo 16 valve LPG - B204GT/M90 - trophy w̶i̶f̶e̶ car.
- '89 764 B280F - Daily barge.
- Various 740's, 940's, 960's and a couple of 760's.
Quote:
Originally Posted by Kjets On a Plane View Post
Whiteblocks
Quote:
Originally Posted by AdmiralSenn View Post
I think I might be too stupid to own a car.
nordmaschine is offline   Reply With Quote
Old 05-15-2019, 02:53 AM   #28
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Quote:
Originally Posted by nordmaschine View Post
M90 conversion, banalce shafts removed... It's really starting to look like my car now, you just need the wheels.
Actually I already have the wheels! I just need to get tires for it, but it's still quite far on the priority list
tomasss is offline   Reply With Quote
Old 05-15-2019, 02:05 PM   #29
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Brand new green giants (0280155968) in!

tomasss is offline   Reply With Quote
Old 05-17-2019, 02:34 AM   #30
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Finally some more parts arrived...

Oil sump tube resealed with double o-rings


Intake removed..


...and phenolic insulation spacer installed


tomasss is offline   Reply With Quote
Old 05-17-2019, 11:21 AM   #31
gj940
Board Member
 
gj940's Avatar
 
Join Date: Jun 2008
Location: Netherlands
Default

Really nice and clean project. Like it!
__________________
Dutch 940 LPT on BBS
gj940 is offline   Reply With Quote
Old 05-21-2019, 05:17 PM   #32
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

After having some >unclarities< about the clutch and pressure plate fitment...today I finally managed to let the B204GT meet the M90!
The pivot ball has been spaced with the washers 4.5mm towards the clutch, all sliding surfaces lubricated and then these two beasts bolted together.
For the clutch and PP I am going with option #2 mentioned >here<, which means clutch from 850GLT (Sachs 86 1862 314 032) and performance PP (Sachs 883082 999763).

Super happy that this is done





tomasss is offline   Reply With Quote
Old 05-23-2019, 08:44 AM   #33
Abe_
Newbie
 
Abe_'s Avatar
 
Join Date: Apr 2018
Location: Belgium
Default

You're making some good progress! I didn't know you need the adaptor from retroturbo to fit the m90... sigh curious to see the next steps!

Abe
Abe_ is offline   Reply With Quote
Old 05-23-2019, 01:30 PM   #34
nordmaschine
forced instruction
 
nordmaschine's Avatar
 
Join Date: Feb 2012
Location: The Balkans, BiH
Default

Quote:
Originally Posted by Abe_ View Post
You're making some good progress! I didn't know you need the adaptor from retroturbo to fit the m90... sigh curious to see the next steps!

Abe
You *can* use adapter, and you will get smoother box with less chatter, but in all essence, what we call M90 is just another 3-axis Getrag and they usually don't use pilot bearings. Some gear chatter is mandatory... I have B204FT 740 with M90 swap and '97 945 Jurbo with single-mass flywheel swap, both done by me, both done circa 120k klicks ago, both used as car recovery trailer tow rigs, neither 3rd-gear-syncro-modded, both holding on just fine to this day...
All it takes is a bit of not being idiot to your car.
nordmaschine is offline   Reply With Quote
Old 05-23-2019, 06:03 PM   #35
okoye
Board Member
 
okoye's Avatar
 
Join Date: Jul 2009
Location: west hartford, ct
Default

You know that wood trim is factory right? Also that pilot isnt needed
__________________
1991 Volvo 940se sedan m90 swapped, 17x10 oz fittistars, Bilsteins.
1994 Volvo 960 turbo b204ft m46

Quote:
Originally Posted by vagabond View Post
no one saw me with my little umbrella and sandpaper though.
okoye is offline   Reply With Quote
Old 05-24-2019, 03:20 AM   #36
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Quote:
Originally Posted by gj940 View Post
Really nice and clean project. Like it!
Thanks!
Quote:
Originally Posted by Abe_ View Post
You're making some good progress! I didn't know you need the adaptor from retroturbo to fit the m90... sigh curious to see the next steps!
Abe
Yeah, as nordmaschine mentioned, it is not absolutely necessary, but it adds some extra safety...and when I am already there with machining the flywheel and other stuff, it makes sense to me to add it.
Quote:
Originally Posted by okoye View Post
You know that wood trim is factory right? Also that pilot isnt needed
The wood trim was complete garbage, cracked, twisted and so...and anyways I don't like the look at all
tomasss is offline   Reply With Quote
Old 05-24-2019, 05:25 AM   #37
rijk
Board Member
 
rijk's Avatar
 
Join Date: Apr 2004
Location: Netherlands
Default Fuel cut-off issues

Hello Tomasss, swapping the M46 for the M90 MKII in my '93 960-B204FT made such an amazing difference. Not only the way the M90 shifts gears so much smoother and more accurate, imo also the gear ratio's really fit the B204GT/FT better. If you encounter any - annoying - fuel cut-off issues on the way caused by the TCU, like I did with my first conversion (after installing the TD04-19T (V70R), 3 inch exhaust system with HJS cat, green tops, ITG air filter etc), I am sure you will tackle this. If not, let me know. Maybe I can help you out. Good luck with the conversion.
__________________
The B204FT to B234FT conversion
http://forums.turbobricks.com/showthread.php?t=182821

Last edited by rijk; 05-24-2019 at 06:35 AM..
rijk is offline   Reply With Quote
Old 05-24-2019, 09:37 AM   #38
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Quote:
Originally Posted by rijk View Post
Hello Tomasss, swapping the M46 for the M90 MKII in my '93 960-B204FT made such an amazing difference. Not only the way the M90 shifts gears so much smoother and more accurate, imo also the gear ratio's really fit the B204GT/FT better. If you encounter any - annoying - fuel cut-off issues on the way caused by the TCU, like I did with my first conversion (after installing the TD04-19T (V70R), 3 inch exhaust system with HJS cat, green tops, ITG air filter etc), I am sure you will tackle this. If not, let me know. Maybe I can help you out. Good luck with the conversion.
Hey Rijk, thanks...I am really hoping in driving the car this summer. Still waiting for some important parts though. Let's see. There shouldn't be any TCU related problem as I have removed it completely
tomasss is offline   Reply With Quote
Old 05-26-2019, 04:59 PM   #39
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Lots of progress today.

- the resealed oil sump went back in
- cleaned up oil pan with new gasket back in
- intake enlarged for the big throttle body from 960
- and the best part...the engine went back in

I have also measured the cylinder compression and it is:

#1 10bar (145psi)
#2 9.5bar (140psi)
#3 9.5bar (140psi)
#4 8.5bar (125psi)

Is that a reasonable status of an engine with 180tkm? This engine is using hydraulic lifters, and the test was without oil...so it could be better once the oil is in...






tomasss is offline   Reply With Quote
Old 06-04-2019, 03:27 AM   #40
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Shifter in and linkage connected

tomasss is offline   Reply With Quote
Old 06-05-2019, 05:28 PM   #41
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Progress with the large 960 throttle body today.

Initially I was following >this< thread but then I had to combine the parts even more because of fitting the TPS.

To summarize it:

From B204FT this is used:
- TPS
- throttle shaft + throttle plate screws
- linkage lever

From 960 this is used:
- throttle body
- throttle plate
- throttle body gasket

Plus there is extra drilling/tapping required into the 960 throttle body as there are no holes for the TPS.

Size comparison


Tapping the 960 throttle body (M4 thread)


B204 TPS mounted into 960 TB


Enlarging the B204 gasket


And finally mounted on the intake
tomasss is offline   Reply With Quote
Old 06-06-2019, 02:45 AM   #42
nordmaschine
forced instruction
 
nordmaschine's Avatar
 
Join Date: Feb 2012
Location: The Balkans, BiH
Default

Any real difference?
nordmaschine is offline   Reply With Quote
Old 06-06-2019, 04:22 AM   #43
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Car is not running yet...still quite some work to be done.
tomasss is offline   Reply With Quote
Old 06-08-2019, 03:37 PM   #44
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Waterjet cut flange arrived so I progressed with the wasted spark install. As I wanted to keep it stealth, the coil is installed where the distributor was originally located (and serves as a distributor plug retainer as well) and the power stage is below it.
The whole flange is then mounted in the original distributor holes using two phenolic spacers to isolate it from heat.
It is tight but sits perfectly. I have some more flanges available by the way...in case anyone is interested. It is 4mm stainless steel.
Also I had to extend the ignition wires by 10cm each. 7mm silicone ignition wires used.





tomasss is offline   Reply With Quote
Old 06-10-2019, 03:16 PM   #45
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Driveshaft with new center rubber support & bearing is back in.
Lower chassis brace back in.
Clutch flushed with new brake fluid, waiting for the pressure bleeder to get rid of the remaining air.
Keyless system installed, new lock actuator into the driver's door added.
Switch to play with the ez116k advance/retard pins 18&19 installed.
Engine harness cleaned up.

During next week I should receive lh/ezk custom remapped chips from Bijlsma Technical Innovations...also my rebuilt turbocharger should arrive soon...more to follow then

Last edited by tomasss; 06-10-2019 at 04:24 PM..
tomasss is offline   Reply With Quote
Old 06-15-2019, 01:56 PM   #46
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Chip swapping time!

Old LH2.4


New LH2.4


New daughterboard ezk with chip & wasted spark board installation
tomasss is offline   Reply With Quote
Old 06-18-2019, 05:03 AM   #47
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

The clutch hydraulics was bled few days ago, no air bubbles anymore.

This is the clutch travel (using 4.5mm pivot ball shims) using the full pedal range - does it look good?

tomasss is offline   Reply With Quote
Old 06-18-2019, 08:35 PM   #48
DET17
Reformed SAABaholic
 
Join Date: Nov 2009
Location: NW Georgia
Default

Quote:
Originally Posted by tomasss View Post
Progress with the large 960 throttle body today.

Initially I was following >this< thread but then I had to combine the parts even more because of fitting the TPS.

To summarize it:

From B204FT this is used:
- TPS
- throttle shaft + throttle plate screws
- linkage lever

From 960 this is used:
- throttle body
- throttle plate
- throttle body gasket

Plus there is extra drilling/tapping required into the 960 throttle body as there are no holes for the TPS.

Size comparison


Tapping the 960 throttle body (M4 thread)


B204 TPS mounted into 960 TB


Enlarging the B204 gasket


And finally mounted on the intake
Nice work Tomasss, I look forward to seeing your results once you have the 744T back "up and running".

My research led me to retain the standard throttle body diameter rather than upsizing to the 960 diameter. I found validation that the standard size would support 350hp and provide much more usable "off idle" transition. The big TB diameter will easily support 400+hp, but it comes at a drivability price. The good news for you.... if the large size disappoints, is that you can retain the 4 bolt flange pattern and return to the smaller size throttle body. I've noted the donor that you will need to find (mine came from Latvia) in my build thread.

Following your progress!
__________________
Project "cheap thrills" build thread: http://forums.turbobricks.com/showth...67#post4211467

Feedback thread: http://forums.turbobricks.com/showthread.php?t=198746
DET17 is offline   Reply With Quote
Old 06-19-2019, 02:55 AM   #49
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Indeed, I kept the original throttle body in case I am not happy with the big one. One of the complaints I had with the previous B204GT was slow throttle response, so this combined with the KL intercooler and some other modifications should improve it.
Also I was able to step up the throttle body tube diameter from 60 to 70mm.
tomasss is offline   Reply With Quote
Old 06-19-2019, 05:11 PM   #50
tomasss
Board Member
 
tomasss's Avatar
 
Join Date: Oct 2008
Location: Leuven, Belgium
Default

Ezk is back in its place, wires for the wasted spark routed through GX12-3 aviation plug (ground + two signals).

tomasss is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


All times are GMT -4. The time now is 02:55 AM.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.