940 GL fifty shades of grey turbo conversion

[360beast]

Just a little tinker with it this morning.

Fitted the replacement wiper stalk, fitted the ECU, turns out early 940s don't have the cage with security screw holding the ECU in place. This one just had two torx screws and then out it slid.

I've removed the gauge cluster too as the speedo sits at 45mph when the car isn't moving, dry solder joints on the back so that needs repairing... enter Dave.

[360beast]

I've been cracking on with my bathroom renovation today but I did manage to sneak a few minutes to test the thermostat was working, which I'm happy to report it is so I fitted a new seal to it and refitted the housing.


20201127_142331 by Luke Ryland - Flickr2BBcode LITE


20201127_142217 by Luke Ryland - Flickr2BBcode LITE

Also had halfords tyres on the drive come out to me and fitted four new Bridgestone A005 weather control evo tyres. Which also meant that the steel wheel bang on weights were removed from the alloys, only absolute butchers fit bang on weights to alloys!!!


2020-11-27_02-52-49 by Luke Ryland - Flickr2BBcode LITE

Very impressed with the workmanship and the young lad doing it was really nice and easy to talk to.

The ride height looks like an off roader with no engine in the car.

[360beast]

So it turns out that the retro turbo mainshaft support bearing needs the original support bearing removing to use. It came with no instructions and only mentions it below all the legal mumbo jumbo in the website. So if you're like me you just assume it fits with no messing... how wrong I was.

So the gearbox wouldn't fit, had to use an oil stone/whetstone to take 0.035mm off the end of the mainshaft so it would actually fit inside the bearing and then had to remove the original one. Looked online and found a decent bearing puller is in the region of £130-£200 or a chinesium one was £18 delivered from China... I used rubber grease instead

IMG-20201202-WA0011 by Luke Ryland - Flickr2BBcode LITE

I filled behind the bearing with grease until I couldn't push anymore in, then found my 3/8 drive bar was the perfect size to go inside the hole as a tight fit. Then hammer it in and let hydraulic pressure do all the work.


IMG-20201202-WA0017 by Luke Ryland - Flickr2BBcode LITE

I think I filled it about 4 times before it came all the way out


IMG-20201202-WA0022 by Luke Ryland - Flickr2BBcode LITE


IMG-20201202-WA0025 by Luke Ryland - Flickr2BBcode LITE

I ordered a genuine alternator and a p/s belt for it.


2020-12-08_02-41-18 by Luke Ryland - Flickr2BBcode LITE

That's about it really, I've been getting on with a backlog of other jobs that I've been delaying to get a decent chunk of work done on this.

I've ordered new genuine gearbox oil for it too and hopefully in the next few days the engine and gearbox will be in!

[360beast]

Boring update, been getting on with other work... including a Porsche 944 turbo S2 that is having new dampers on the front, track rod ends etc.

Back to the Volvo, absolutely loads of work done... changed the gearbox oil for new genuine stuff and that's it 😂

I was all set to have a whole day on it tomorrow until I got asked this evening to do a job for a mate who needs it doing desperately tomorrow. Also got to do dampers on the rear of a 2006 Ford Fiesta so the 940 has been put on hold, good thing the customer is in no rush for it.

[Laird Scooby]

Originally Posted by 360beast

Boring update, been getting on with other work... including a Porsche 944 turbo S2 that is having new dampers on the front, track rod ends etc.

Back to the Volvo, absolutely loads of work done... changed the gearbox oil for new genuine stuff and that's it 😂

I was all set to have a whole day on it tomorrow until I got asked this evening to do a job for a mate who needs it doing desperately tomorrow. Also got to do dampers on the rear of a 2006 Ford Fiesta so the 940 has been put on hold, good thing the customer is in no rush for it.

Is the dizzy cap better than yours Luke? Sell him a new one and if he wants the original, give him yours!

Only joking, but if memory serves they're the same cap and buying a Volvo one is likely to be cheaper than buying a Porsche one, customers usually appreciate little money saving things like that.

[360beast]

Originally Posted by Laird Scooby

Is the dizzy cap better than yours Luke? Sell him a new one and if he wants the original, give him yours!

Only joking, but if memory serves they're the same cap and buying a Volvo one is likely to be cheaper than buying a Porsche one, customers usually appreciate little money saving things like that.

Haha, mine is only about 10k miles old.

Plus that would mean going in the engine bay of the thing and it looks horrendous in there with no room to work!

It is one of my best mates cars too, don't think he would appreciate it 😂

[Laird Scooby]

Originally Posted by 360beast

Haha, mine is only about 10k miles old.

Plus that would mean going in the engine bay of the thing and it looks horrendous in there with no room to work!

It is one of my best mates cars too, don't think he would appreciate it 😂

Yeah, they're pretty tightly packed in there but i daresay Porsche would want £Loads for a genuine dizzy cap, if i'm right then the Volvo one is just as good (possibly better) and even a genuine Volvo one will be cheaper - you can do a mate a favour but take your brave pills before going under the bonnet!

[230ina245]

Hi
Bit late I know - I've seen those expanding wall bolts used to pull those bearigs out. You know the one's that have a wedge shape at the end that goes in a hole you drill in the wall - when you tighten up the bolt the wedge end expands a metal jacket to tighten against the sides of the hole. Easier to show than explain -https://www.screwfix.com/p/easyfix-shield-anchors-m8-x-70mm-5-pack/9650G?tc=SA9&ds_kid=92700048793290424&ds_rl=124941 3&gclid=EAIaIQobChMI7OG34cLF7QIVDe3tCh34rgwyEAQYBC ABEgIIpvD_BwE&gclsrc=aw.ds
You would have to get the right size of course. Supposed to work a treat, but I've not done it myself.
Tim

[Laird Scooby]

Originally Posted by 230ina245

Hi
Bit late I know - I've seen those expanding wall bolts used to pull those bearigs out. You know the one's that have a wedge shape at the end that goes in a hole you drill in the wall - when you tighten up the bolt the wedge end expands a metal jacket to tighten against the sides of the hole. Easier to show than explain -https://www.screwfix.com/p/easyfix-shield-anchors-m8-x-70mm-5-pack/9650G?tc=SA9&ds_kid=92700048793290424&ds_rl=124941 3&gclid=EAIaIQobChMI7OG34cLF7QIVDe3tCh34rgwyEAQYBC ABEgIIpvD_BwE&gclsrc=aw.ds
You would have to get the right size of course. Supposed to work a treat, but I've not done it myself.
Tim

Nice idea and should work well with the right size anchor!

[360beast]

Well the wet weather has stopped me from getting the engine and gearbox back in so I thought I would get on with the front end polybushing.

Front O/S stripped out


IMG-20201214-WA0016 by Luke Ryland - Flickr2BBcode LITE


IMG-20201214-WA0019 by Luke Ryland - Flickr2BBcode LITE


IMG-20201215-WA0040 by Luke Ryland - Flickr2BBcode LITE

Old bushes removed


2020-12-15_08-33-26 by Luke Ryland - Flickr2BBcode LITE

That's as far as I've gotten with the suspension other than when removing the droplink to refurbish and polybush the nut was very tight. I wire brushed the threaded section and sprayed it with wd40 and it was still very tight so I had to keep working it back and forth, I got it about half off before it sheared off 💩

So I set the engine to TDC as shown on the crank and then refitted the flywheel, torqued the bolts to 70nm with a little bit of threadlock for good measure as they have now been 'used' and refitted the clutch kit and the gearbox.


IMG-20201214-WA0023 by Luke Ryland - Flickr2BBcode LITE


IMG-20201214-WA0021 by Luke Ryland - Flickr2BBcode LITE


20201214_204539 by Luke Ryland - Flickr2BBcode LITE


20201214_204554 by Luke Ryland - Flickr2BBcode LITE