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1984 245 GLT Intercooler Turbo and parts haul!

intothelabyrinth

Active member
Joined
Mar 20, 2012
Location
Bowling Green, KY
Not that I needed another project, but I just could not pass this one up! I have just acquired an 84 Intercooler Turbo, many new parts to restore it with, and an old guy's lifetime parts stash. This will be my first foray into kjet turbo. I plan to keep the car pretty stock, but would love to turn the boost up. The story is that he got the car and planned his overhaul in the mid 90s, that turbo is a brand new water cooled unit he got from IPD in 1996. Then he just never got around to it, and now he is too old, and moving states. Everything has been put up really nice, most things in sealed ziplock bags with desiccant, and then in tubs. Many of the used parts were stored like this and put up 20 to 30 years ago and are in amazing shape! The car has had a new tank installed on it. I plan to just start going through it all. Putting back the correct pumps, and rebuilding the fuel system. I will rebuild the WUR and Fuel distributor. I appreciate any feedback, or advice!

 
Super sweet pick up ! Howd you find out about this car? Was it a facebook find or just a guy down the street type of deal ? Looks likes its in good hands ! Congrats!
 
Super sweet pick up ! Howd you find out about this car? Was it a facebook find or just a guy down the street type of deal ? Looks likes its in good hands ! Congrats!
It was a fb marketplace deal. He was 4.5 hours away. I initially went up there to buy a m46 from him for my other 84. We hit it off and he showed me the collection. This was late fall, and he was about to go spend the winter in his new home, returning in spring to continue cleaning out his house. I stewed on it, staying staying in touch with him, sending him updates on the 84 I was putting together. At a certain point I realized I had to make it happen, and called dibs lol. His ad said "dedicated Volvo nut needed."
 
Yes, I can see why you want to put it back together stock. It's a really nice project and the performance stuff is always there. Although one of my pet peeves is to change the cam. To either an A or B cam if you want the most affordable improvement. Makes the engine power band like a normal fun car. The T cam with a 3.73 rear just runs out of steam way too fast for fun driving.
 
Anybody want to shoot the shit about how I should be hooking up this turbo? Do I need a BOV? What about the stock crap with the boost light and that solenoid and stuff? I think I just want to hook it up with the manual boost controller I have. I am reading everything I can find and looking at diagrams, but I have never hooked an old school turbo up with kjet and a b21 before so I am a little out of my element. I'm pretty sure this turbo does not have an internal CBV.
 
The plan is this.
vac-B21FT.jpg


I'll either not hook up the overpressure switch, or I will try to adjust it higher to like 16psi. The boost enrichment switch will get hooked up, and the pressure differential switch will get hooked up. For the wastegate, I'll run a MBC between the vacuum port on the turbo, and the wastegate actuator. I will start out probably just hooking it up without the MBC to see how everything goes. Once I have it running like that I will try to increase the boost. There will be a line to the distributor as well as 2 the charcoal canister. There will be a vacuum line to the HVAC controls. There will be the brake booster Vacuum line. I think I have my mind wrapped around it now. I have a vacuum/pressure pump to test my switches, and to test the distributor. There's also the one large line that goes to the pre turbo intake pipe and to the PCV system. I am installing an actual boost gauge, and an innovate AFR gauge as well so I can really see how things are working and hopefully be able to get this thing tuned correctly!
 
I've tried that adjustment of the pressure switch. Thankfully I had more than one. The first one I tried to adjust I destroyed while trying to remove the plug of sealing epoxy. The next one I was able to get the stuff out and turn it up. It didn't seem to adjust after I got it to 14psi. So that's where it stayed on my car. The old kjet boost switch mod was to get one from a Saab. Then you can adjust the pressure higher and it has a normally open and normally closed set of contacts in the switch.
 
The car fires right up and idles beautifully. Will rev a little, but breaks up. I looked at the o2 sensor voltage and I swear it was at battery voltage. I will do some more testing on that deal, but it kinda sounds to me like a dead short in my lambda ecu or something. My system relay is powering up the 2 wires that go to the ecu and to the frequency valve. That's about as far as I have looked it it yet, but something is def wrong there!
 
Lambda ecu has no ground. Constant idle ecu does from the passenger side firewall connector. From what I can see lambda ecu gets it there too, but the 2 black wires go off under the dash to the drivers side. I gotta chase those down. That's at least the main issue.
 
those two black wires seem like the two grounds that go to the intake manifold. Don't connect them together. they each have their own bolt on the manifold. You had an open circuit with no grounds and that means you measured the applied voltage of 12v.

Glad it's running!
 
Yes, once I found the 2 black wires where they come in through the main grommet there on DS of engine bay it was easy to see the 2 empty spots where they were supposed to be hooked up on the manifold. Then I had continuity to ground from the ecu connector and it all just started working immediately. I am really close now. I am installing an AFR gauge, and graduated boost gauge on it, setting base idle, CO, and dwell, and going through he lights and brakes this weekend. I should be ready for a ride over to the county clerk Monday to get it inspected and registered!
those two black wires seem like the two grounds that go to the intake manifold. Don't connect them together. they each have their own bolt on the manifold. You had an open circuit with no grounds and that means you measured the applied voltage of 12v.

Glad it's running!
 
I unplugged the o2 sensor and dwell was reading solid at 43. I turned the CO screw on the distributor until it was reading slightly richer than stoich on my wideband. Then plugged in the o2 and dialed it into the 42-50 swinging back and forth range. I tested the boost enrichment hobbs switch, it seemed to work and will ground the terminal 7 on the lambda ecu when tested, although it seems to need more pressure than it should to do it. I wired up a switch to apply ground to terminal 7 manually and tried boosting, but still as boost builds towards 5psi, it is only reading about 13.5 AFR. I think it must be detonating if I try to push it further so I let off. If I baby it and keep it at 5 psi and under it rides fine. I need to smoke test my intake to rule out any leaks. I got the car registered and have a plate on it now, I'm ready to ride to cars and coffee this Saturday, but I really can't wait to get it rich enough under boost to do a little ripping!
 
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