The clutch is slipping! It's going in to the garage on Thursday for the clutch, 300bhp rated so should be good!

Some of you might have seen my dog dish gone wrong thread. https://www.volvoforums.org.uk/showthread.php?t=291869 The garage managed to have issues timing the engine so the gbox was off 3 times.

Fast forwards 100 or so miles and the crank pulley falls off. I suspect the gear was already damaged and the crank pulley bolt one up.

Whilist trying to set the timing I think it's been turned backwards and loosened the bolt.

After reading a thread @ volvo forums (i need to get the link from my laptop) I decided to make a fix using a dowel. The job went smoothly so fingers crossed it's going to be gone. It's not like the engine is turning on the dowell. It's got a big bolt holding it flush.

Here are some pretty pictures.

http://i68.tinypic.com/166ho47.jpg
http://i66.tinypic.com/a3l576.jpg
http://i64.tinypic.com/2wgcay9.jpg
http://i66.tinypic.com/2rr7a7t.jpg


Also cleaned the header tank with soda crystals. WOW look at it now !

Looks good, great job on the dowel.

Thank you.

http://i67.tinypic.com/2w5na5t.jpg

Here you can see how I setup the drill.

http://i66.tinypic.com/244w8b5.jpg

Found all these marks on the crank pulley. Very suspect.


New water pump / cam belt / idler / PS belt / Alternator belt but it's being mounted lower as I intend to install the charge cooler better.

Looks like someone tried to lever the belts on without slackening the adjusters.

Diagonal hammer blows?

Guys something like that I suspect.

I fixed the rear washer on Saturday. I removed the washer bottle from the car and found it very dirty. I used Soda crystals again and it came up nice.

The rear washer pump was dead. I would guess it's siezed and I could not take it apart.

I used one of my spare aftermarket pumps and modded it to fit. The power connector was on the side and touched the wash bottle so chopped off and soldered the wires again. The pump inlet was a tiny bit too small for the sealing ring. I added some heat strink over the inlet and it's nice and snug.

Next I found the line from the front to rear was blocked. The one way check valve was no good so I bridged it. I will need a new valve for this to stop the fluid running back down. It's located behind the side trim in the boot. (UK drives side)

My birthday present from me to me came. Brace bar made from steel but surprising light. I had to mod some studs on the towers with a hammer and it was a tight fit. I know the bolts are wrong ways. I was in a rush to pickup a friend. Not a good idea to rush these things.

The correct B230 turbo throttle turned up which is getting a v-band attached. Shot blasted it clean. Avoided the insides.

Other news . When replacing the cam belt I managed to break a seal on the charge cooler connector. Hopefully it's OK now after some repair.

This weekend I decided that welding a v-band to my throttle was not the cheapest idea and after forking out over £200 on my push bike I decided to fit a silicone joiner between the throttle and first elbow.

The lower alternator bracket has been fitted. The air con version is massive!

Next it's off to get tig welded up.

I have now fitted my old MOMO steering wheel which came as an optional extra from Volvo on my old 480. Looks smart and next is to fit a 555 time for the air bag light.

The charge cooler has been tig welded by a professional and it fits well. It looks like it's resting on the radiator hose but it's not yet mounted on the bracket The pipe work all 51mm turbo outlet then 63mm into the inlet manifold.

Why are the hoses blue? Because I'm fed up buying colours like black when I have loads of cool blue hoses (lol) from the early 2000's . Yes i'd like black for a OEM look but in my 20's blue was way cooler looking. I have grown up since but i'm not wasting money!