940 GL fifty shades of grey turbo conversion

[360beast]

As the schools have closed I'm on home schooling duties so I have no time to work now, however today I managed to get some time to do some work.

I sucked the old brake fluid out of the reservoir using a syringe and filled with new Dot 4.

Started rewiring the engine bay starting with the fuel injectors.

Changed the sump plug washer and filled the engine with oil.

And then I removed the headlight and set about swapping it over for one where the housing isn't broken and has a known working wiper motor.

Shhhh don't tell my wife I've been fixing cars in the kitchen


IMG-20210120-WA0013 by Luke Ryland - Flickr2BBcode LITE

There are four of these wiper blade stops on the headlights, on with headlights two were missing the plastic end cap so I removed the two from the old unit and fitted them to the new one so it had a complete set.


IMG-20210120-WA0015 by Luke Ryland - Flickr2BBcode LITE


IMG-20210120-WA0017 by Luke Ryland - Flickr2BBcode LITE

I then removed the glass and cleaned it inside and out, then wiped the reflectors on the new unit with a dry cloth to remove dust and debris.


IMG-20210120-WA0019 by Luke Ryland - Flickr2BBcode LITE

I then reassembled it, but before fitting the glass I put a smear of silicone grease over the seal to help rejuvenate it a bit.


IMG-20210120-WA0021 by Luke Ryland - Flickr2BBcode LITE

This is why it was changed


IMG-20210120-WA0023 by Luke Ryland - Flickr2BBcode LITE

How it should be


IMG-20210120-WA0025 by Luke Ryland - Flickr2BBcode LITE

[360beast]

Oh and I've never seen a headlight bulb plug with the retaining clip in place until today


IMG-20210120-WA0027 by Luke Ryland - Flickr2BBcode LITE

[360beast]

My wife finished work a couple of hours early so I seized the opportunity and got some more work done.

I've nearly finished rewiring the engine, just got to fit the oil pressure switch wire, refit the ICV and the plug (found the cause of the hunting idle on B200F to be a seriously dirty ICV) and cut the MAF plug off and extend the wiring to the opposite side of the engine bay.

I then refitted the PCV hose and vacuum line

Checked the coolant level after it has been sat for a few weeks and it is sitting on max nicely so it appears leak free at the moment.

I think I forgot to do an update saying I had refitted the cooling system and the intercooler setup?

So I think the list of jobs to do apart from those mentioned above is as follows:

Fit gear linkage
Fit propshaft to gearbox
Fit propshaft to under floor
Fit downpipe and see if it fits the system that's on the car now
Block up lambda sensor hole in downpipe (this exhaust system has one by the cat)
Make bracket for MAF
Fit cone filter to MAF
Bleed clutch
Refill power steering fluid
Refit headlight
Sort out bonnet not releasing

Then I think it is finished and it can go to my dad to have the welding done!

[Laird Scooby]

Brilliant progress there Luke, especially considering the weather and everything else you've had to deal with thanks to the Kung Flu!

[360beast]

Originally Posted by Laird Scooby

Brilliant progress there Luke, especially considering the weather and everything else you've had to deal with thanks to the Kung Flu!

Thanks Dave I do try my best. I'm just lucky this customer understands as this was meant to be finished by now!

Excuse the appalling photos, my back was in too much pain for me to bother with focused photos haha


IMG-20210121-WA0030 by Luke Ryland - Flickr2BBcode LITE


IMG-20210121-WA0027 by Luke Ryland - Flickr2BBcode LITE


IMG-20210121-WA0025 by Luke Ryland - Flickr2BBcode LITE

[Laird Scooby]

Unless your customer has been on a different planet Luke, he will know all about the wet weather recently! Should be all he needs to understand!

Still excellent progress though!

[360beast]

Headlight and sidelight refitted


20210128_153823 by Luke Ryland - Flickr2BBcode LITE

Choices for the boost gauge mounting


IMG-20210128-WA0010 by Luke Ryland - Flickr2BBcode LITE


IMG-20210128-WA0008 by Luke Ryland - Flickr2BBcode LITE

Finally refitted the M90 selector too and refitted the interior trim


IMG-20210128-WA0004 by Luke Ryland - Flickr2BBcode LITE

[Laird Scooby]

Originally Posted by 360beast

Choices for the boost gauge mounting


IMG-20210128-WA0010 by Luke Ryland - Flickr2BBcode LITE

That one! I think you can get universal pillar-mount pods fairly cheaply although i think i've seen 940-specific pods.

[360beast]

Originally Posted by Laird Scooby

That one! I think you can get universal pillar-mount pods fairly cheaply although i think i've seen 940-specific pods.

The customer has informed me he wants it in the other position, he lives in a dubious part of the country apparently so he wants to draw as little attention to it as possible!

[volvo always]

Good progress. I prefer the more discreet 2nd position. Above looks too boy racer!

James.