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OEM airbox swap?

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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454cid
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OEM airbox swap?

Post by 454cid »

Is there a different OEM airbox that would fit my NA 850 that would eliminate the hot air door contraption? I know people have done things like wedge the door open or remove it, but it still leaves that actuator in place. It looks like mine is the older design, not the one that FCP/IPD carries the thermostatic actuator for.

I'm not sure if the vacuum diaphragm works or not. I'd reconnect it all, but my issue is that the vacuum connection at the air box is broken.... not the rubber fitting, but the plastic.

EDIT: In front of me now, and maybe a better situation than I was thinking.... the piece that actually is in the box looks fine, there is/was an intermediate plastic/rubber right angle fitting that's broken. I think the plastic vacuum line is a different diameter (smaller) than the port on the airbox.

I'd still like to eliminate it all, but I'd settle for a fixed hot air system, too.
1996 850
1999 S70 GLT (sold after deer hit)

2010 Ford Focus SE
2006 Cadillac CTS
1996 Mercedes C220
1999 Chevrolet K3500
1969 Buick LeSabre Custom 400

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abscate
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Post by abscate »

I’ve got a couple of these I can send
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
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454cid
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Year and Model: 1996 850
Location: United States
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Post by 454cid »

abscate wrote: 05 Jun 2022, 11:47 I’ve got a couple of these I can send
It looks like I've now broken the other end.... is there a reason not to run a piece of vacuum hose that fits directly onto the connections instead of using the reducing elbows and tiny nylon line?

Also, I notice that applying vacuum to the actuator closes the main air inlet, and opens the hot inlet, but no vacuum allows both to be open partially, which I'm assuming is a malfunction.
1996 850
1999 S70 GLT (sold after deer hit)

2010 Ford Focus SE
2006 Cadillac CTS
1996 Mercedes C220
1999 Chevrolet K3500
1969 Buick LeSabre Custom 400

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abscate
MVS Moderator
Posts: 35331
Joined: 17 February 2013
Year and Model: 99: V70s S70s,05 V70
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Post by abscate »

No reason not to use direct vacuum line. I never understood the fitting/nylon thin , either

I’ll check my supply of air doors for function
Empty Nester
A Captain in a Sea of Estrogen
1999-V70-T5M56 2005-V70-M56 1999-S70 VW T4 XC90-in-Red
Link to Maintenance record thread

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erikv11  
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Post by erikv11 »

You can put in a turbo airbox bottom and get rid of the hot air intake entirely.
'95 854 T-5R, Motronic 4.4, 185k
'98 V70, T5 tune-injectors-turbo, LPT engine, 304k, daily driver
'06 S60 R, 197k
'07 XC70, black, 205k
'07 XC70, willow green, 212k
'99 Camry V6 :shock: 153k
gone: '96 NA 850 210k, '98 NA V70 182k, '98 S70 NA 225k, '96 855 NA 169k

454cid
Posts: 1255
Joined: 6 January 2022
Year and Model: 1996 850
Location: United States
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Post by 454cid »

erikv11 wrote: 12 Jun 2022, 14:40 You can put in a turbo airbox bottom and get rid of the hot air intake entirely.
I read that in a thread someplace on here, but I was having trouble finding one on ebay. It seems there are few designs. Most were what I already have, and there is an early design too. I'll look again, it's been a week.
1996 850
1999 S70 GLT (sold after deer hit)

2010 Ford Focus SE
2006 Cadillac CTS
1996 Mercedes C220
1999 Chevrolet K3500
1969 Buick LeSabre Custom 400

454cid
Posts: 1255
Joined: 6 January 2022
Year and Model: 1996 850
Location: United States
Has thanked: 145 times
Been thanked: 131 times

Post by 454cid »

I've purchased the bottom portion of the airbox from a Turbo car..... still waiting on it. Estimated delivery date was yesterday, but for some reason the USPS decided it needed to go the opposite direction to Indianapolis, and then onto Pittsburgh from there... I'm in Michigan! It's in Detroit today.

Those of you who may have put the Turbo box on an NA car..... did you do anything to the hose fitting on the exhaust header? It's kind of unsightly sticking out with nothing connected to it.
1996 850
1999 S70 GLT (sold after deer hit)

2010 Ford Focus SE
2006 Cadillac CTS
1996 Mercedes C220
1999 Chevrolet K3500
1969 Buick LeSabre Custom 400

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erikv11  
Posts: 11807
Joined: 25 July 2009
Year and Model: 850, V70, S60R, XC70
Location: Iowa
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Post by erikv11 »

Yeah I just left it open, I couldn't think of any alternative. For me it's fine like that but also curious to know if anyone has other ideas.
'95 854 T-5R, Motronic 4.4, 185k
'98 V70, T5 tune-injectors-turbo, LPT engine, 304k, daily driver
'06 S60 R, 197k
'07 XC70, black, 205k
'07 XC70, willow green, 212k
'99 Camry V6 :shock: 153k
gone: '96 NA 850 210k, '98 NA V70 182k, '98 S70 NA 225k, '96 855 NA 169k

454cid
Posts: 1255
Joined: 6 January 2022
Year and Model: 1996 850
Location: United States
Has thanked: 145 times
Been thanked: 131 times

Post by 454cid »

I've considered just removing the shroud, but I fear that it will allow more heat into the engine compartment. I suppose I could remove it (I think it just bolts in place) just to see what there is to see. I have not looked at how the fitting is attached. If it's easily removed, I could possibly make a patch and pop-rivet it in place.

I guess my main focus now is just to get the lower box from USPS..... it's moving at a snails pace for some reason. Hopefully I can just scrub it up, and install it fairly quickly. I've already cleaned under the existing box, although I have been noticing more and more sand in my engine bay..... must be the construction zone I drive through, although most of the work is on the other side of the highway. I may install the new filter that I have. I've kept the filter that was in the car when I bought it, in January, since it looked like it had been replaced not that long ago.

I wonder if my mileage will go up at all. As I mentioned in my earlier posts, the air flap sits half open, half closed, so it's pulling some warm air into the engine.

I suppose I should order some vacuum caps to block the vacuum off at the Christmas tree vacuum fitting. I wonder if there's anything I could install there instead.... I think most of the ports are already capped.
1996 850
1999 S70 GLT (sold after deer hit)

2010 Ford Focus SE
2006 Cadillac CTS
1996 Mercedes C220
1999 Chevrolet K3500
1969 Buick LeSabre Custom 400

454cid
Posts: 1255
Joined: 6 January 2022
Year and Model: 1996 850
Location: United States
Has thanked: 145 times
Been thanked: 131 times

Post by 454cid »

The box arrived. I've scrubbed it with an old toothbrush and degreaser, and am waiting for it to dry.
1996 850
1999 S70 GLT (sold after deer hit)

2010 Ford Focus SE
2006 Cadillac CTS
1996 Mercedes C220
1999 Chevrolet K3500
1969 Buick LeSabre Custom 400

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