My 745T Mods/ Upgrades

[TIPSP]

Since there are no real performance posts for 200/700/900 series cars, I thought I would start one with my experience. This can be a place where all the RWD Volvos Owners can check out for modding ideas, swap build stories, and find places/sites to get RWD Volvo parts (you can probably find most of the sites from the Volvo Resource Thread by s70driver). This might be a dead post since thisis more of a maintenance site, but we'll see how far it can go. And Sorry for all the pics. Here is a quick break down of the mods: Suspension/Brakes: IPD 25mm/25mm swaybars (F/R), Bilstein Heavy Duty shocks/ struts, TME sport springs, Cherry Turbo upper and lower strut braces, IPD poly suspension bushings, Custom poly endlinks, Brembo Rotors, PBR pads, and IPD SS brake lines. Engine/Drive terrain: Stock B230FT with Stock turbo (TD04H-13c), valve adjustment, stage zero, ECU/ICU chips (Fred's Chips), custom CAI, Hard IC pipe, custom 3" Turbo-back Exhaust, and Turbo Logic MBC @ 15psi. Interior/Miscellaneous: Autometer Boost gauge, AEM UEGO controller (wideband), Alpine Hedunit, Blazer Air horns, Custom license plate, 20% window tint, a few IPD stickers/decals, armrest with cup holders, and a new Black interior (Swap from tan to black)! On to a little background......zZzZzzZzZzz My parents bought a 1991 740 turbo wagon (745t) about eleven years ago. When my dad first got her, being he can't drive a stock car, he put IPD swaybars (25mm/25mm F/R), Bilstein heavy duty shocks/struts, and TME sport springs. Then he put on the Cherry Turbo upper and lower strut braces and IPD SS brake lines, and the car was untouched, as far as mods go, for another ten years. I took over the car at the age of 17 and it is still my current ride. It still handles really well, thanks to the suspension upgrades, and I started to put some of my own mods on her. One of the first things I did wasI tookoff that stupid "S" tailpipe (pics below). The next thing I did was a custom CAI (cold air intake). This is a relatively easy mod to do, and it sounds cool and is pretty cheap. You can read about it here. The next thing I add was an Autometer mechanical boost gauge (30hg/30psi), from egauges.com, with an A-Pillar gauge pod from gaugepods.com. Installing the gauges wasn't that hard. You just need to drill a small hole where the wires will pass through the pillar and feed the wires down through the dash. There is a vacuum line already in the lower part of the dash, for the stock boost gauge, which you can tap into, by cutting the hose and connecting them together with the T-fitting that comes with the gauge. After that just wire it up to the headlight switch and find a good ground and you're done. Here is mine: The first time looking at the gauge, I only saw it boosting at 5-7psi (that is the stock setting). I wanted more boost than that, so I went here to get my MBC (manual boost controller) and it only cost $50. (You can also adjust the wastegate, but it is not recommended.) This is probably one of the easiest mods you can do. I would take off the airbox to turbo hose, because it is easier to work with (and since you have that hose off, I would check you turbo shaft for any play). There is a little nipple on compressor side of the turbo which is connected to the wastegate by a little hose about 4in long. You can just cut that hose in the middle and attach the MBC to it (make sure you attach it correctly or it will not work), or you can take that hose off and use the hose supplied with the MBC. After you install it, check for any leaks, and take it for a test drive and watch the boost gauge to see if you are getting solid boost (you should install an aftermarket boost gauge before installing the MBC). I have been running my car for 2 months now at 10-11psi (which is ~30%-60% more boost than stock), and you will really feel the difference from the extra boost. Here is the Hose you can tap into. Here is mine: Please note: that the first thing you should do before any of the engine mods is a stage zero. Here is a Stage Zero list from s70driver: Plugs cap/rotor oil/transflush filter (oil) hoses (the little vac lines) 02 sensors fuel pumps clean injectors clean IC/IC plumbing (Turbo Models ONLY) Air filter plug wires I also installed an Alpine head unit, and Blazer Air horns (Air horns are Hella Tight). Here is the Horns: They are nice and hidden: We also just did some custom Polyurethane bushings endlinks. You can read about it here. That is all that is really been done to her right now, but I have some more stuff I plan on doing. Starting year 2009, I will be putting a custom 2.5in turbo-back exhaust, and I will be ordering what is known by the turbobrick community as Fred's Chip (Hi-Tuning.com). The chips are good for basically any Volvo model with a chippable ECU and EZK, and my car should gain 55hp and 50tq...not to mention better fuel economy when your not mashing the pedal. You can read about them here and you can order them from hereas a group buy. (the group buylink will only work if you are a member of turbobricks.com other wise..you can order them from hituning-usa.com at full retail value). So anyways...Here she is as of today. Exterior shots...Nothing special The paint and lights need to be fixed, but right now I am putting money else where. Interior Shot...Blah Blah Some Engine Shots...Nothing special Sorry the engine is so dirty And here is my current list of mods: Suspension/Brakes: IPD 25mm/25mm swaybars (F/R), Bilstein Heavy Duty shocks/ struts, TME sport springs, Cherry Turbo upper and lower strut braces, IPD poly suspension bushings, Custom poly endlinks, Brembo Rotors, PBR pads, and IPD SS brake lines. Engine/Drive terrain: Stock B230FT with Stock turbo (TD04H-13c), valve adjustment, stage zero, ECU/ICU chips (Fred's Chips), custom CAI, Hard IC pipe, custom 3" Turbo-back Exhaust, and Turbo Logic MBC @ 15psi. Interior/Miscellaneous: Autometer Boost gauge, AEM UEGO controller (wideband), Alpine Hedunit, Blazer Air horns, Custom license plate, 20% window tint, a few IPD stickers/decals, armrest with cup holders, and a New Black interior (Swap tan to black)! I will update this as I do my car, but until then enjoy. If any one has parts they don't need or just laying around collecting dust and is feeling generous, You can donate them to me (kind of tacky, but worth a shot!)

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[tech]

Looks really good so whats next?

[TIPSP]

Thanks Tech

Well...next should be the Turbo-back exhaust and the chips, and the 3in AMM from a 900seires. I am thinking sometime in January. The chips with the exhaust should give me 225+ whp.

I wouldlove to do the Kaplhenke Racing Short Coilover Struts, but that is a good amount of change.
For the engine: A FMIC, the IPD turbo cam and gear sometime in March.

If I could get 250whp out of her I would be happy, and I should hit that with these.....once these cars get to 300whp I heard the rear subframe start to snap.

I am also trying todo this as a"budget build" I plan on buying mostly used parts, but I will try and get some good deals on new parts that I have to buy.

[Sofar.]

I like S-shaped tailpipes. They're very unpretentious.

[TIPSP]

Yeah... I don't know way that "S" pipe bothers me so much, but it just does.
I think the Pipe looks better on the 240's more than the 740's.

I think I will put a nice straighttip when I get the exhaust.

Edit: Updated pictures.

[Typhoon]

Change the exhaust! 2.5" catback with one low restriction muffler is worth an instant 2psi of boost due to the pressure drop across the turbine. It also improves thottle response a little and fuel economy.
My 90 turbo wagon is about where yours is ( I have the 25/25 bars and some sort of adjustable shock in the front), except I haven't fitted my boost controller yet, I have 10psi with the exhaust as is.
By the way, teh chips won't creat that extra power by themselves, you need exhaust and a good tune up as well, plus 14psi boost.
Oh yeah, I have cool Ecode lights and Hydras stock![8D]




Regards, Andrew.

[TIPSP]

ORIGINAL: Typhoon

Change the exhaust! 2.5" catback with one low restriction muffler is worth an instant 2psi of boost due to the pressure drop across the turbine. It also improves thottle response a little and fuel economy.
My 90 turbo wagon is about where yours is ( I have the 25/25 bars and some sort of adjustable shock in the front), except I haven't fitted my boost controller yet, I have 10psi with the exhaust as is.
By the way, teh chips wont creat that extra power by themselves, you need exhaust and a good tune up as well, plus 14psi boost.
Oh yeah, I have cool Ecode lights and Hydras stock![8D]

Regards, Andrew.

Nice ride Andrew.
I have always like the E-code lights. I am suppose toget the exhaust done this month. Which muffler did you go with?
I would also like to change out the IC andIC pipes (which also rob a fewpsi), andthen, with the exhaust,Ishould be at 14psi, which is what the chips are tuned for.
I plan on switching out the turbo, but I am still debating which one to get, I will probably just settle on the typical 15G upgrade. I would love to get a T3/T4E, 50 trim compressor with StageIII (76 trim) turbine wheel, but then I wouldwant to drop in some RSI rods and custom pistons, and maybe run water/ methanolinjection. I do plan on switching to IPDs turbo cam in March.

[TIPSP]

I will be getting the chips in next week and some new corner lights.

I just got new Bridgestone Potenzas RE960AS pole position Tires. They are AWSOME. They still have some of the "baby" rubber, but they still grip/handle very, very well.

[Typhoon]

I had a truck muffler put in the exhaust. They're free flowing and large chambers, so low restriction. Not noisy at all but noticeable when you boot it. I expect to gain some more once I get a decent 2.5" downpipe and large cat convertor in there too. I woundn't change turbos till you finalise cams/exhaust etc. These engines respond very well to chips/exhaust and boost, upgrade the turbo once you KNOW it's holding you back. Same with the stock intercooler, it's already a pretty good piece, replace it when it's a problem. Stock turbo it's not a problem.
I also wouldn't worry about rods or pistons till you start heavily modifying the engine. At the power levels you and I will be seeing it is wasted money. Far better to spend a few dollars on dyno runs at various stages of modifications to check fuel/air ratios and spend teh money on new fuel pumps/ injectors etc. People that break rods/pistons generally are running lean on these engines....
I also have a modified airbox, no baffles/ reducers in the inlets. That made a difference.
I've had the chips in my car for about six months, the car doesn't do a lot of driving, maybe once a week to work when it is raining. My fuel economy is average, but I suspect teh o2 sensor there. In every other respect the chips are excellent. Flat spots eliminated and a much broader torque curve with no running out of power above 4000 rpm.
As my car does a lot of wet weather driving I went with a wet weather tyre:


They're BF Goodrich GForce profilers. Not only are they an outstanding wet tyre but also extremely capable in teh dry.

Regards, Andrew.

[TIPSP]

Yeah.
I got my Wideband just sitting on my desk waiting to be put in.

Side Note:
It turns out I can't get the exhaust this month (F***), so I guess I will wait and see when I can rock my Turbo-back.