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Volvo 945

S

sunday_driver

Member
Joined
Feb 20, 2023
Hello Volvo friends,

I would like to introduce you to my project Volvo. I bought the vehicle ready to drive cheaply two years ago. This is my third 7/9 Volvo. I only have the car for fun and don't drive it every day.

To the car:
1995 Volvo 945 LPT / B230 FK, M90 transmission

Last year I installed the following setup:
• Rebuilt engine after damage
• H-shaft connecting rod
• 531 head – No mechanical processing
• V-camshaft, original position
• 3-inch mass air flow sensor
• 630 Deka injectors + chips
• KL-Racing intercooler
• 3-inch exhaust system (complete)  rear silencer later changed to 2.5 inches because it was too loud
• Single mass flywheel + sinter clutch + KL-Racing pressure plate
• TD04 16T turbocharger with 15G exhaust side (conical flange)
• Housing ventilation on the cylinder head
• Lowering + rims + bracing
• Air filter box original, but processed
• Walbro fuel pump
• Electronic boost controller

--> At 22 Psi, approx. 260 HP / 440 Nm were measured (petrol/air mixture very rich)

• Currently installing the TD04 22T with slanted exhaust housing
--> Hopefully now more than 300 HP (crankshaft)

Overall the car drives pretty well. The 16T is too small above 5000 rpm, but it was still a lot of fun and overall worked well with my setup. I hope that the 22T delivers significantly more at the upper speeds. I know that there are much better solutions for the turbocharger, but I would like to keep an original look in the enginebay.

Future big plans:
• Conversion to freely programmable control
• Modification of the brake system
• Conversion to BMW transmission

My friend Ludi made a nice video of the dyno - give him a like:

ibb.co

IMG-20221227-144929-s hosted at ImgBB

Image IMG-20221227-144929-s hosted on ImgBB
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Purchase condition
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IMG-20240128-120622-s hosted at ImgBB

Image IMG-20240128-120622-s hosted on ImgBB
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Result of the 100 - 200 km/h measurement
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IMG-20240225-135406-s hosted at ImgBB

Image IMG-20240225-135406-s hosted on ImgBB
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new engine
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IMG-20240720-192339-s hosted at ImgBB

Image IMG-20240720-192339-s hosted on ImgBB
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current condition
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IMG-20241019-151054-s hosted at ImgBB

Image IMG-20241019-151054-s hosted on ImgBB
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The Dyno
Thanks for your interest, more to come soon
 
Last edited:
Hello,

time for an update.

The 22T is in there. Runs well. Boost pressure is available from 2700 rpm. The noticeable torque has increased significantly. Has significantly more power than the 16T.

Unfortunately, since upgrading to 630 injectors, Walbro 255 pump and turbocharger, I've had a loss of power starting at 5000 rpm.

Overall the setup is now worse than before. (before: 440 Bosch + 16T + Bosch pump)

At least if you compare the acceleration times from 100 - 150 km/h.

I suspect that I have ignition knock and the LH is adjusting (ignition timing out, mixture richer).

There were also misfires with the Simens Deka injectors. I now have a 630 Bosch EV6 in it. It runs pretty well without any misfires, but the loss of power over 5000 rpm remains.

I'll report. Greetings!
 
Sticking with a TD04 turbo, you've got a VERY small turbine and it's going to choke it off at higher revs. You can put as big of a compressor as you want, but that restriction in the exhaust will choke out flow, lead to high EBR and potentially cause knock. If you can't get the exhaust out, putting more air in isn't helping.
 
Beyond the above comments, with those kind of changes you also should have a WBO2 controller to monitor AFR's. Could be simply a crap pump delivering insufficient fuel volume to the new setup. Lots of KO parts around, the pump may not be up to the task.
 
I have an AFR controller in it. The values are correct so far. The air mixture sometimes becomes particularly rich at high speeds. It will definitely be because of the knocking. The 4th spark plug looks like it's running lean.

Hopefully the new pump will change that.

I know the 22T brakes on the hot side. It should still be enough for my performance goal. I previously ran a 15G exhaust side. The new exhaust side of the 22T (slanted exit) is an improvement.

Thanks!
 
Hello,

I changed the pump. The original Wolbro works fine. But the drop in performance remained.

Then I converted the injectors and chip to the 440 setup I used previously.
Now it's running properly again. The injectors are definitely running at their limit now.

I now have to take care of another chip for the 630 injectors.

Thanks and greetings!
 
Hello,
I have made further progress on a project. I got a new chip. The settings were significantly leaner in the high speed range.

With 3 bar fuel pressure it now runs very well. As the speed increases, the mixture becomes increasingly rich and levels off at AFR 0.72 - 0.78 at full enginespeed.

The 630 Deka injectors run relatively rough compared to the Bosch ones, but the values are right and it delivers performance.
I estimate that there is now around 280 HP (crankshaft). I drive 1.6 bar boost pressure.

I think the small exhaust side of the 22T and the 2.5 inch exhaust system have reached their limit.

I plan to take a measurement on the dyno in a few days.

Thanks and greetings!
 
Beautiful! Out of curiosity what diameter pipe for your exhaust squiggle? The 2.5" I'm putting on mine is a straight exit and I eventually want to get a squiggle back on it. Would love to find one already made.
 
Hello Volvo friends,

this weekend we finally did a new dyno day. Now I was able to see for the first time what kind of power the 22T can deliver.

I'm very happy with the result, especially considering that I have a 2.5-inch exhaust system underneath, a LH 2.4 with chips, and the original distributor ignition is still in place.

Here is the current setup again:
• Rebuilt engine after damage
• H-shaft connecting rod
• 531 head – No mechanical processing
• V-camshaft, original position
• 3-inch mass air flow sensor
• 630 Deka injectors + chips
• KL-Racing intercooler
• 2.5-inch exhaust system
• Single mass flywheel + sinter clutch + KL-Racing pressure plate
• TD04 22T turbocharger
• Housing ventilation on the cylinder head
• Lowering + rims + bracing
• Air filter box original, but processed
• Walbro fuel pump
• Electronic boost controller

--> At 22 Psi, 305 HP / 450 Nm were measured.

Does the 300 Club still exist?😄



My friend Ludi also made a nice video of the dyno - give him a like:


Ludi's exciting 244 was also on the dyno. With the GTX 3076R, a great result was achieved.

 
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