Johann Posted November 7, 2014 Author Report Share Posted November 7, 2014 I can help you try out COP for M4.4 if you'd like. That is a nice offer. I would be willing to try at a later point. Are you using ME7 cops or the older 960 with external ignitors? I want to have the car up and running sometime next week. For this to happen the stock management setup will be used. AC has been removed from the car so basically there is no conversion needed to run either 4.3 or 4.4. I'm using all the sensors from the stock setup. Stock fuel rail with 395 injectors (@3 bar), 850 style intake with a 20V NA throttle body. Stock idle valve. This style conversion has been done before and works. Quote Link to comment Share on other sites More sharing options...
Commander Riker Posted November 7, 2014 Report Share Posted November 7, 2014 Where you live you do not need AC?? This makes me ask, how many rooms do you have to rent? lol Quote Link to comment Share on other sites More sharing options...
Johann Posted November 7, 2014 Author Report Share Posted November 7, 2014 Where you live you do not need AC?? This makes me ask, how many rooms do you have to rent? lol Temperature is psychological. A the moment it's freaking "water" cold out here. 7 degree C. Roughly 100 miles east from Amsterdam. Only an office building for rent at the moment. Sorry. Quote Link to comment Share on other sites More sharing options...
Zappo Posted November 7, 2014 Report Share Posted November 7, 2014 Where you live you do not need AC?? You really need to get out of Texas once in a while. 4 Quote Link to comment Share on other sites More sharing options...
Johann Posted November 8, 2014 Author Report Share Posted November 8, 2014 Installed crank ventilation and intake plenum. Changed the injectors to blue's. Wanted to do some more today but the steering pump of the T-5R decided to crap out. Exchanged it for better functioning one this afternoon. Quote Link to comment Share on other sites More sharing options...
Midnight Caller Posted November 8, 2014 Report Share Posted November 8, 2014 Sorry to bump in but I couldn't find certain data about this. Some say blue injectors are the same cc as the white ones. Some say they are bigger. There are also ones called "blue giants" What's the truth ? Thank you ! Quote Link to comment Share on other sites More sharing options...
Johann Posted November 8, 2014 Author Report Share Posted November 8, 2014 Sorry to bump in but I couldn't find certain data about this. Some say blue injectors are the same cc as the white ones. Some say they are bigger. There are also ones called "blue giants" What's the truth ? Thank you ! Has been discussed on this forum. Blue's are 395 CC at 3.8 bar. At 3 bar they do closer to 360 CC. White's are 350 CC at 3 bar. Had a set of 5 blue's cleaned and tested at 3 bar and the report said they averaged at 363 CC. Quote Link to comment Share on other sites More sharing options...
Midnight Caller Posted November 8, 2014 Report Share Posted November 8, 2014 Thank you ! The 3.8bar info was what I was missing. At 3 bar they are the same as I knew. Sorry but I couldn't find that and I read all 220 pages of the M4.4 tuning thread. Thank you again and sorry for the off-topic ! Quote Link to comment Share on other sites More sharing options...
Johann Posted November 14, 2014 Author Report Share Posted November 14, 2014 Engine up and running using M4.3, 2 Quote Link to comment Share on other sites More sharing options...
laird Posted November 17, 2014 Report Share Posted November 17, 2014 I still wonder if it wasn't your place I stopped by a few years back. No one was home, but there was a driveway with a few Volvos. I can't even remember how I knew to stop. Did you sell cool Volvo things at some point? Quote Link to comment Share on other sites More sharing options...
Johann Posted November 17, 2014 Author Report Share Posted November 17, 2014 I still wonder if it wasn't your place I stopped by a few years back. No one was home, but there was a driveway with a few Volvos. I can't even remember how I knew to stop. Did you sell cool Volvo things at some point? No pictures taken? I didn't sell cool Volvo things back then. About the swap, Last Friday had the engine up and running mainly because of the voluntary help of a good friend... Early Friday morning I picked up the Trex wheels and TDR rims from the tire guy. Mounted the rear wheels and started adding some parts to the engine bay. Put the radiator back in the car and mounted most of the coolant system hoses and some vacuum stuff. Can't say it was a joy. It was pretty cold in the workplace and didn't feel very excited to work on the car. Sometimes this happens when there is no pressure. Had to bring the 6 wheeler for annual inspection. This was more of a pre inspection. If all turned out OK it could have been certified right away but I knew there were some issues. About an hour later I was back at the shop and it was time for coffee. The doorbell rang, my friend came by and also thought it was time for coffee. He had taken the day off and it looked like he had time to kill.. Little later some visitors came by but when I came back in the canteen my friend wasn't there but his car still parked outside. Went in to the shop to discover huge progress in the engine bay of the SD.. My friend really had time to kill.. Shifter cables, clutch bleeding, driveshafts, exhaust and accessory stuff had already been done earlier in the week but there still was the vacuum puzzle and the intake. The airbox didn't fit above the M66 without modification. We decided to use an open filter for the time being and look at the airbox at a later point. Fuel lines needed to be secured. Some B5244T5's do not have all the bolt holes present for mounting the fuel line mounting brackets. For now we tie wrapped the return line to the feed line which sits pretty secure over the engine. Then there was the intake pipe. About half an hour fiddling with a K24 pipe, a 15G pipe, an alloy pipe, a burner and two hose clamps later there was a provisional intake pipe to mount the 850 LMM. After that it was time to start. And the engine started without fuzz. Pretty disappointing actually. Turned the key and the engine started like it had never been out of the car. No smoke, no sputter, no drama . Idling was OK at first but ran higher a bit later. Turned off the engine and started again and if gave a throttle blip. Could see the throttle cable being pulled without touching the throttle pedal. This had something to do with the CC so we removed the linkage at the throttle pedal to get rid of it. The CC was disabled on this car and apparently enabled again during the rebuild.. Need to check if it's broken or connected wrong. Can be done at a later point. Saturday morning I added the last parts to the car and went for a short test drive. The ECU has been re-flashed with a temporary tune which incorporates the blue injectors and the K24 at lower boost setting. Tried to keep the engine out of boost at this first drive which it managed very well. The engine responds very well to throttle input. The K24 made a slight whistling noise, nothing alarming. Think I must have driven 3 or 4 miles in total. The M66 shifts better than the original setup. Shifter position is OK. Maybe with the reverse at the far right it might have been positioned a bit more to the left. Nothing leaking after the test drive. Yesterday morning I wanted to mount some closed covers under the headlamps. Removed the headlight wipers and had two white covers without the wiper holes but the white color was a huge mismatch so I mounted the original ones again. Also made an attempt to reshape the distribution belt cover to it will fit behind the old accessory belt tensioner. Don't want to drive the car without the cover. To much rain in the coming days and do not want to have it all smudged. Left for a Volvo meeting in the country later in the day so didn't work on the car anymore. Hope to do some more today and have the car back on the road as a DD again. 5 Quote Link to comment Share on other sites More sharing options...
Tommy. Posted November 17, 2014 Report Share Posted November 17, 2014 Nice! Always good to have friends to help push things along. Totally blanking here but CC? Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted November 18, 2014 Report Share Posted November 18, 2014 Nice. I wish I had more uneventful put togethers Nice! Always good to have friends to help push things along. Totally blanking here but CC? Cruise Control. Quote Link to comment Share on other sites More sharing options...
Tommy. Posted November 18, 2014 Report Share Posted November 18, 2014 Nice. I wish I had more uneventful put togethers Cruise Control. Got it. Something I wish I could keep when I swapped mine. Quote Link to comment Share on other sites More sharing options...
Johann Posted November 20, 2014 Author Report Share Posted November 20, 2014 Got it. Something I wish I could keep when I swapped mine. Should be possible to get it functioning again. I believe there is a wiring difference between AT and MT and a clutch switch is needed. Had an issue with the speedometer. The former M56 had a speed sensor, the M66 not. Applied the VSS mod by rerouting the the speed sensor wires to the driver side ABS sensor. Thought I had done a neat job only to discover that it didn't work. Once the car started rolling the engine died. With the new engine an M4.4 ECU was used with modified software for this setup to get going. Swapped the ECU for an M4.3 containing OEM T-5R software and everything worked like it should. Tried several other ECU's including M4.4's and all worked well except the one which initially was in the car. Received another M4.4 ECU today with the same modified software and all it working OK now. Have driven some 30-40 miles with the car so far with and without the speedometer working and want to put some more miles on it first before making more modifications. Most of the goals have been met for the time being. Some minor fixes and improvement still need to be done but basically the setup is OK for now. A small sum of parts, Car: 1994 Volvo 855 2.0 T5 MT. Base engine: 2005+ B5244T5 including long neck K24 turbo OEM mounted. Base gearbox: M66 P2 version. Engine mods, MY2000 B5244S fixed exhaust cam MY2003 B5234T3 fixed intake cam. Intake and exhaust VVT blocking plates. MY1995 B5234FT intake plenum RN port matched. MY2000 crank ventilation canister. MY1995 vent hose to head. Slightly modified B5244T5 PTC hose/pipe to MY1995 PTC MY1994 B5254S throttle body (Including plastic lump) DO88.se silicone coupler to fit TB to late style turbo plumbing. Modified late style turbo to IC pipe to align with K24 neck. - cut, repositioned and welded turbo side hose flange. OEM B5204FT fuel rail including FPR. OEM B5244T5 Blue injectors installed. MY1999-2000 front engine mount. Home made rear engine/M66 mount. TTV-racing lightened single mass flywheel. S60R friction to fit M66 spline - 850R pressure plate. (The verdict still out.. Don't think this is the way to go. Wait and see.) MY1995 accessory bracket holding MY1995 steering pump and alternator. AC pump removed. Short route multi belt. B5244T5 crank pulley. (1 bolt hole of the bracket doesn't align to engine btw) Intake pipe, K24 turbo side, MY1995 850 LMM side. 2.5" alloy pipe in between. (Temporary) Gearbox mods, Shifter pins on gearbox changed to MY1995 850 style 8 mm pins. Modified cable bracket to fit MY1995 850 shifter cables. Quaife LSD. OEM MY1999 C70 2.5T downpipe/converter. OEM IC, AC condensor removed. M4.4 ECU (reflashed) 3 Quote Link to comment Share on other sites More sharing options...
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