1993 850 GLT White

[Ben850]

Yesterday, 7-26-12, I did the thottle plate modification to rid the obstuction.

I had picked a couple throttle bodies and plates over the months with this modification in mind. I figured I would get around to it eventually. Last week, I found a '94 n/a with the VVIS manifold like mine. So I brought home that throttle body with the same vacuum provisions. A 960 throttle plate was nowhere to be found, so I did the modification to the stock piece.

With enough parts I was able to leave my original throttle body in tact in case I did not like the mod. or any other issues arose.

Manually done with a formica laminate file, I took off the offending material. It took a little less that two hours, but I was taking my time. I had extras in case of mistakes, but I was happy with the first try.

This is another one I should have done sooner, but after the new plugs and wires, I believe the ECU has a consistent group of parameters to deal with. Replacing some old vacuum lines and elbows was another stabilizing compliment.

I did the ECU reset and drove approximately twenty miles, city and highway to let it learn. The throttle response is immediate and even across the powerband now. Anyone who has the VVIS is probably used to the otherwise irritating peaks and valleys.
I am happy with the results and would recommend it. It feels like a normal car.

[Ben850]

On 9-28-12
I had all the intentions of doing the timing belt, water pump and pulley maintanance. It took some time to get all the parts needed for the '93 original belt setup. Upon removing the timing cover, I found the belt and pulleys were upgraded to the 23mm, 148 tooth setup. The timing cover still had the 50,000 mile maintanance suggestion sticker for the '93. There are also two options for the serpentine belt tensioner and pulley.

I had the wrong parts to complete the jobs I had planned for the day. I put on the new serpentine belt, and did a trans drain and fill while the front was on jack stands. I am trying to drain and fill a few more times before winter, as the fluid is still not clean after five times, but the trans is shifting better with each cycle.

I did also install an OBX strut bar I had to get from ebay because I couldn't find it new anywhere. The strut bar is mostly for structural integrity since the unibody has been somewhat compromised from the accident repair.

Today, 10-9-12, I ordered the new parts for the timing belt. I bought the Gates blue belt and both INA pulleys. I won't be doing this job again.(on this car anyway)

[Ben850]

On 10-4-12
I was wanting to change just the oil filter and top off the level after running with Bar's leak rear main seal conditioner for a couple months. I was surprised to find an off brand filter, Tec Select T5675, that I believe is a Chinese made knock-off.
The previous owner had it done by a european specialist shop so I thought it was an original Mann white filter until I took it off.
After priming, and installing a new Mann filter, it fired up with no lifter noise whatsoever, and sounded more smooth and consistent than I've ever heard since owning it. Driving, it also seemed smoother and more reponsive. I'm thinking it has been partially oil starved this whole time. One more down.
I also replaced the cute little ECM filter, that ducts to the front of the radiator. (on a '93 anyway) An inexpensive piece at $6.75 on ebay.
Next week, I will have the new parts to finnish the timing belt job.

[Ben850]

Yesterday, 10-12-12 was a nice day.

I was relieved to finally get the timing belt done before this winter. The belt had been changed at least once before. It had the 23mm 148 tooth belt and pulley system already installed, as opposed to the 1993, 21mm 143 tooth setup. I needed to return parts I had already received, and revise my options. I didn't know that the belt and pulleys were all that was needed to upgrade the belt.
I ordered the best parts I could find. I won't be doing this maintenace again. ( on this car)

I found the hydraulic tensioner was leaking, after doing the slow compression twice to be sure. I did have another on hand that was in fine shape. Truly a lucky pull from another salvage.

I had read all the instructionals and writeups. I was anticipating trouble. I was surprised I had no other trouble than a bad tensioner. I was creative in some areas of tool usage, but for the sake of my log, I will explain that on another thread.

I was pleased when I had pulled the tensioner pin. After rotating the crank two full cycles, (four rotations) the marks all had lined up. A single turn of the key made it a good day.

It was not a bad day. There was also an oil change and filter. I do feel better.

[Ben850]

The VVIS mod was finally done 11-1-12.

I was able to find the time to install the "Yitsbox" last week. I received the modular switch from amsterdam after some IMs to "razorx", ( Yits ) on this site. I did a write-up on the installation in the Performance, Tuning and Aftermarket forum so I won't go into detail here.

https://www.matthewsvolvosite.com/forums ... =5&t=52574

I wanted to add some photos here to my maintanance thread so I can look at it from time to time. I forget all that I have done sometimes.

Yitsbox.jpg (101.33 KiB) Viewed 2778 times

Yitsbox2.jpg (109.5 KiB) Viewed 2778 times

Prepared.jpg (169.51 KiB) Viewed 2778 times

work lights.jpg (131.35 KiB) Viewed 2778 times

Fuse box hole.jpg (112.01 KiB) Viewed 2778 times

Through cowling.jpg (151.3 KiB) Viewed 2778 times

straight run.jpg (134.46 KiB) Viewed 2778 times

Finished Pull.jpg (133.06 KiB) Viewed 2778 times

Coil Terminals.jpg (130.81 KiB) Viewed 2778 times

Coil tap.jpg (108.17 KiB) Viewed 2778 times

Soledoid splice.jpg (126.64 KiB) Viewed 2778 times

Capped and sealed.jpg (120.23 KiB) Viewed 2778 times

Stripped and run.jpg (108.68 KiB) Viewed 2778 times

Phoenix Plug.jpg (112.25 KiB) Viewed 2778 times

In the dash Working.jpg (100.18 KiB) Viewed 2778 times

Between this, and the throttle plate modification, I am beginning to imagine how much fun it must be to drive a turbo version of my car. The throttle response is so immediate now, I hear it might be even quicker than waiting for a turbo to spool-up. Ha.
Either way, it is a blast to drive, and money well spent. Installation was pretty straight forward and around 2 hours, taking my time.

[Ben850]

I picked up a spare instrument cluster from a '94 to install while I do the odometer fix on the original. I have another from a '96 that I was going to use but it uses a different speed sensor.

While I was in there I thought of a quick fix for the edges of the dash pad that were separating above the vents and cluster.
It simply invoves a tube of seal-all and any clamping devices I could come up with.

I also repaired many cracked plastic areas from the air bag deployment.

I was in a rush to button everything back up because I was in a neighbors garage space, but I will give it some more attention when I re-install the cluster. It looks much better already.

[Ben850]

Had a little problem with the ignition system around 12-1-12. The symptom first occurred after I sprayed the undercarriage at the quarter car wash. I figured I got a little water somewhere it shouldn't be. Two days later, it died while driving on a misty rainy night.
I ended up replacing the distributor cap, rotor, still no start. I changed out the cam timing sensor and the coil with salvage parts and it came back to life. I did find a broken connector for the cam timing sensor, but it appeard the wires were not broken. I believe it was the coil in the end as it was the last thing I swapped out.

[Ben850]

On 12-9-12 Did the odometer gear fix, replaced bulbs, and swapped it back in place of the temporary cluster.

The tiny orange spot is the old gear.

Testing and replacing lamps.

Cleaned and ready.

Everything works as it should. I am distracted by the moving numbers now.

[Ben850]

On 12-15-12 I installed Bilstein Touring class rear shocks and mounts. I broke one bolt but it turned out to be an easy fix as the nut popped off the bottom and left a clean hole for a new bolt.

Aside from the broken bolt, it went well. The ride is a world of difference for the better. There were only 170k miles on the old ones.
I will get the front Bilstein TCs in the spring. It is a must at this point after feeling the ride.

[Ben850]

I had done much in the last month to assure driveability.