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940 GL fifty shades of grey turbo conversion

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Old Nov 24th, 2020, 13:40   #31
Laird Scooby
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Thank you for that Dave, it is exactly the level of detail I'm looking for in my planning; part of the question was: where does the B21a stop and the AW71 start? - and I'm pleased to find out at this stage that there is some ambiguity over the TC/drive plate junction.

Alan
I'll try to do a bit of cross-referencing on parts later Alan to see what cross-match compatibility there is between the B21A, AW-55, Aw70/71 and their respective driveplates, torque converters etc.

Meanwhile it's walkies time then birthday cake with 5 gravy bones to serve as edible candles!
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Old Nov 24th, 2020, 15:37   #32
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Thank you for that Dave, it is exactly the level of detail I'm looking for in my planning; part of the question was: where does the B21a stop and the AW71 start? - and I'm pleased to find out at this stage that there is some ambiguity over the TC/drive plate junction.

Alan
Researched as promised Alan :

https://www.volvopartswebstore.com/p...4/6842013.html

Scroll down and click the "What this fits" tab - you will get a long list of 240, 740, 760, 940 & 960 models that it fits. Anything up to ~1986 will be B2xX, after will be B2x0X where x is the second digit of the engine size in dl (eg 21 is 2.1L, 23 is 2.3L) and X is the suffix A, E, F etc.

Short version is your existing driveplate/flexplate will be fine to bolt the TC onto.
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Old Nov 24th, 2020, 19:00   #33
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Researched as promised Alan :

https://www.volvopartswebstore.com/p...4/6842013.html

Scroll down and click the "What this fits" tab - you will get a long list of 240, 740, 760, 940 & 960 models that it fits. Anything up to ~1986 will be B2xX, after will be B2x0X where x is the second digit of the engine size in dl (eg 21 is 2.1L, 23 is 2.3L) and X is the suffix A, E, F etc.

Short version is your existing driveplate/flexplate will be fine to bolt the TC onto.
Excellent Dave, many thanks - I’ll study the reference later.

Happy birthday to your dog :-)

Alan
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Old Nov 24th, 2020, 20:38   #34
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So today was a busy one so I didn't get as much done as I would have liked to but I still got a fair amount of work done.

I started doing the cambelt and did the front oil seals but I had forgotten to order a new gasket for the front timing cover so I have had to stop half way through until the gasket arrives.


IMG-20201124-WA0003 by Luke Ryland - Flickr2BBcode LITE

Next job was the rocker cover gasket


IMG-20201124-WA0005 by Luke Ryland - Flickr2BBcode LITE

Nice new gasket and thoroughly cleaned mating faces.


IMG-20201124-WA0016 by Luke Ryland - Flickr2BBcode LITE

I also changed the oil filter while access is very easy


IMG-20201124-WA0013 by Luke Ryland - Flickr2BBcode LITE

Then I did the inlet manifold gasket, I forgot to take a photo of the cleaned up mating faces.


IMG-20201124-WA0020 by Luke Ryland - Flickr2BBcode LITE

New gasket fitted


IMG-20201124-WA0022 by Luke Ryland - Flickr2BBcode LITE

Inlet manifold refitted


IMG-20201124-WA0027 by Luke Ryland - Flickr2BBcode LITE

Then I fitted a used fuel pressure regulator as it was missing, luckily I had one in stock! I replaced the vacuum line for it with a good condition used line as it was very perished.
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Old Nov 24th, 2020, 22:40   #35
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Clean looking engine inside Luke!
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Old Nov 25th, 2020, 17:28   #36
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The gasket for the front timing cover arrived about 12pm so I could crack on with it a bit more.


IMG-20201125-WA0005 by Luke Ryland - Flickr2BBcode LITE


Fitted the gasket and then finished doing the cambelt and torqued everything to spec.


IMG-20201125-WA0009 by Luke Ryland - Flickr2BBcode LITE


IMG-20201125-WA0011 by Luke Ryland - Flickr2BBcode LITE


IMG-20201125-WA0013 by Luke Ryland - Flickr2BBcode LITE


IMG-20201125-WA0025 by Luke Ryland - Flickr2BBcode LITE



IMG-20201125-WA0015 by Luke Ryland - Flickr2BBcode LITE

Used my crank locking tool that my dad made for me, works perfectly.

All back together


IMG-20201125-WA0027 by Luke Ryland - Flickr2BBcode LITE

Then I cleaned the exhaust manifold mating faces and bolted it on, then I replaced the turbo oil drain to block seal and fitted the turbo. I then realised the seal was rubbish as the pipe could easily move in and out plus side to side so I now need to get one of them... genuine I think this time!


IMG-20201125-WA0031 by Luke Ryland - Flickr2BBcode LITE


IMG-20201125-WA0033 by Luke Ryland - Flickr2BBcode LITE


IMG-20201125-WA0036 by Luke Ryland - Flickr2BBcode LITE


20201125_155348 by Luke Ryland - Flickr2BBcode LITE
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Old Nov 25th, 2020, 17:38   #37
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Genuine oil return seal ordered.
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Old Nov 25th, 2020, 18:21   #38
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Looks good!

Are you making it a HPT plus? I have the same B230FK in LPT guise.

James.
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Old Nov 25th, 2020, 19:16   #39
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A lot of good progress there Luke!
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Old Nov 25th, 2020, 19:36   #40
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Looks good!

Are you making it a HPT plus? I have the same B230FK in LPT guise.

James.
Hiya James, it will be getting a manual boost controller set to 10psi and maybe going more once the customer has driven it for a bit and decided if he wants more power or not.

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A lot of good progress there Luke!
Thanks Dave, just got to refit the cleaned out PCV box with new O-ring, oil return seal and refit the turbo again, 850 t5 injectors when they arrive, sump gasket and the clutch.

Oh just waiting for my dad to return with the nut and plate I cut off the EGR pipes welded up to blank off the inlet manifold and exhaust manifold.
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