I have a 3/8" socket set from harbor freight. Had to use the hammer to get the bolts that were retaining the cam. lol Tried it on the cam bolt and it just spun the cam. What I would give for a solid 1/2" 6pt metric set 2-24mm with a locking flex head 75tooth ratchet and some extensions... Sears is on the priority list.

HA FOUND INSTRUCTIONS to remove the cam gear. Genius this guy is!

 

Any progress? Have all the bits ready to ship whenever and I can pay you.

 

DUDE, CWAZYWAZY - Convinced the landlord, who was conveniently on-site today, to let me push the 780 onto a concrete pad!


This means that I can jack it up on stands now! The exhaust manifold and downpipe were worrying me but this will be simple and fast now. The maintenance man here is going to let me borrow his jack stands and floor jack too.

Took a few teaser pics today; as shown below.

DAVE - Haven't forgotten about you! Found 4 alloy taurus rims with tires for $100 cash. A little more than I was looking to spend on steelies but it's the best choice now. Going to make the deal with the guy later on in the week.

 

Looking good. Would I need the thingies between cam and valve (Whatever you call em) to go with the cam?

 

How come it looks like there's oil sitting in the turbo?

 

I'll include the races (retaining parts sitting in the valve cover) and nuts. Spilled some oil while pulling parts and got lazy; just let it sit there. I'll take a video of the turbo and it's function uo close. Guy said it worked great and it shows no shaft play. The impeller spins like it's on bearings.

 

CWAZYWAZY - Notice anything missing? Got all of the nuts off of the exhaust manifold too; along with seperating the downpipe. Going to jack it up tomorrow and pull the exhaust which will allow the manifold to be pulled. I'm really thinking that all of your parts will be out of the car tomorrow. Which leads me to:

DAVE - Need to ship CWAZYWAZY his stuff tomorrow or the day after to get the Taurus Rims. Found a set of 4 with tires for a bill.

 

Turbo - IN PROGRESS
Intercooler + int/rad mounts - CHECK
Ducting - CHECK
ECU/ICU - QUICK PULL, IN PROGRESS. WHERES THE ICU?
exhaust manifold + downpipe - IN PROGRESS
MAF/airbox - CHECK
ballast resistor for injectors - WHAT IS THIS?
injectors, I think the rest of the intake should be the same - CHECK
oil lines for the turbo - IN PROGRESS. WILL THEY CONNECT TO YOUR BLOCK?
camshaft - CHECK

 

ICU, IDK about the 780, if it even has one, or if I can even use it if it does have one. In my car it's on the passenger side of the engine bay next to the washer tank. The ECU should work just fine though.
Ballast resistor - Apparently it's a thingy on the wiring harness for the injectors so the higher voltage from turbo injectors (IDK why) doesn't fry the ECU, or something. I'll ask Turbobricks.
Oil lines, I'm thinking I can just T off the oil pressure sensor but I'll have to drill a hole in the block for the return.

 

I'll investigate the ICU & Ballast Resistor. Thought the ballast resistor was something mounted on the engine bay walls.

The intake is off. Being that this is the Turbo+ (Have you done much research on this Volvo kit?) I think that you may need the intake. It appears that the Turbo+ kit is a set of vacuum lines and ??? else that raises boost above a set RPM from stock boost. There are numerous vacuum lines that I don;t recognize from my 745 on the intake.

I WANT this to work for you man. If you updated your $200 thread with a video of a working turbo conversion on it.... would be $&@%(&! DOPE for the entire community!

Do as much research as you can using the advanced search at every opportunity and let me know what you need. Maybe even make contact with members of various forums that have done the conversion before.

By the way, I do remember being 17 and in High School. (Man I'm getting older being 26.) A turbo conversion would blow hard in the school parking lot with the 5-speed! Rev that brick out and widen eyes!

If you need the intake manifold, which seems like a crucial component with the turbo+ given it's vacuum system and such, let me know.

 

I'll just try and find a 240 turbo ICU for the ignition. Sounds like I will need the manifold, but I asked Turbobricks and I'll let you know what they say.

 

No problem to send you the ICU from the 780. Just need to identify it lol.

Compare previous pictures that I've posted with your manifold. Will look out for an update.

 

Okay, according to Turbobricks my manifold does have provisions for the extra vacuum lines so I should be all set there.

 

Excellent, any word on the ICU & Ballast Resistor?

 

Looks like your ICU is different anyway and the ballast resistor should be on the harness for the injectors, but IDK where.

 

The Turbobricks guys are telling me to convert to the EZK 117 ignition system you have. For that I'll need the ICU and the harness for the ignition system. Apparently swapping to your system is easier than trying to find a 240 turbo system.

 

-Some guy on Turbobricks

 

The injector resistor pack is mounted right above the battery on the inner fender well/apron. So is the powerstage, which you are going to need along with the ICU and harness.

 

If you are plus T-ing your 240, you don't need the ballast resistor. You can get fuel injectors from any 5 cylinder turbo car. 850,S70,V70 C70 turbo models will have injectors that you can use. These are high impedance injectors that do no require a ballast resistor(less wiring to do as well).

 

Hey greenman86, Thank you for posting man. Do you know if they flow higher than the 780 Green Tops? Also, would the ignition system still need to be upgraded to EZK117 with the 780 ECU?

CWAZYWAZY - Check out these goldmines:

Dave's Volvo Engine Wire Harness Page

Wiring Harness Guide | K-Jet.org

If you need the entire harness it's going to be a little while longer and we'll need to talk. Those things are VERY labor intensive to completely remove intact from what I'm seeing. The audio wiring is going to another member already, though it doesn't seem necessary anyway. Could you drop the cam, ecu, injectors, and such into your car now to enjoy those benefits while I pull the rest of the stuff?

Also, as a favor, since we're learning more and more about the specifics of the conversion and the parts list is changing, cool if we keep a running updated list every couple of posts?