1996 850 Turbo Wagon White

[Ben850]

I found this car yesterday and paid for it today. $650.00. I will bring it home this Sunday 5-19-13 to begin surgery.

Turbo Wagon 1996.jpg (32.82 KiB) Viewed 2981 times

[Ben850]

Brought the car home yesterday, 5-19-13.
I had to replace all turbo control lines, a PCV elbow and put a clamp on an idle control tube.

Learned turbo control routing.

Along with the MAF I had changed out the day before and the battery I took home to charge overnight, it ran well to drive the 20 miles home.

Safely home.

It will need PCV, Control arms, brakes, tie rods, front tires. All the usual ignored items when someone is running a car to its death.

There are many things I can do before I open the money floodgates. I started today with the grille and some cleaning.

Seems like deja vous

Before.

After.

There was no way I could leave it after blacking the Sedan grille and the results.
I have a list of things to do with parts on hand, and other things that take no money. It should keep me busy for a while and give me a chance to reload the bank account.

[Ben850]

Picked some parts at the yard on 5-22-13. Hood hinges, turbo tubes and hoses that seemed stiff and newer, corner light, MAFs, TCVs, throttle bodies with TPS, ECUs and a few more swappable parts for diagnostics and spares.

I'll have a chance to do some things tomorrow, 5-25-13.
Took a couple side by side shots.

[Ben850]

Today, 5-25-13, I painted the hood hinges that came from a black car and got rid of that pesky gap in the rear part of the hood.
I left the fenders off for now to clean a bit of surface rust from the left fender lip.

After reading the EVAP thread today, I also found a broken connection to the rollover valve and replaced.
The stalling issue after warm up is not yet resolved, but with every part I rule out I know I am getting close.
Ruled out so far:
MAF Swapped with three different clean ones.
TCV Replaced hoses and swapped with another.
TPS Cleaned and swapped throttle body.
103 fuel pump relay, swapped with 2 different.
Grey injection system relay, swapped with known working.
Cleaned PTC.

Tomorrow moving on to fuel pressure regulators. Maybe swap fuel rail and regulator with another I have on hand.

[Ben850]

Successful parts yard trips recently.
All these and more for less than $120.00:

* Tail lights for the wagon, all four upgraded to white glass in the upper turn signals.
* Powered and heated passengers seat. beige leather in excellent condition.
* Drivers side sun visor. The wagons was missing.
* Front and rear Bosch O2 sensors, like new to swap for diagnostics.
* Intercooler with hoses and tubes. ($25.!) Also just in case for diagnostics. Had to grab it while I could.
* Beige leather arm rest

I have to go back there is a '98 XC 70 I want to get more parts from.

Also prepped right front fender since they are off. Currently painting left fender after sanding some surface rust around the inside lip.

Left fender primed.

Right fender rubbed out.

Emblem with 3M molding tape.

Right fender done.

I need to finish the left fender and paint the bumper cover. The rest of the wagon is in great shape.
Rubbing out and a waxing will be it for the exterior.

[Ben850]

While the whole front clip has been off I finally solved the engine stall issue. The final, and persistent cause turned out to be fouled O2 sensors. Today, 6-3-13, after bolting the front end back together, I was able to give it a thorough test drive for the first time. Aside from the issues I was aware of, it ran great.

I finished the front bumper cover with the same EZ-Lip I had attached to the sedan. Having a system for that already made it quick. It is inexpensive, functional and doesn't look bad in my opinion.

Looks familiar.

The sanding and paint work took two days to cure and rub out.

Then adding the EZ-Lip.

Also added '98 XC 70 upper tail lights with white glass and amber bulb.

It was a successful and constructive week and they look good together.

I am happy to have an opportunity to document what began as a junk car given to me by a friend, turned to something that occupies most of my spare time. Now a second one.
I'm not sure what it is about these cars, but it is infectious.

Including photos in my maintenance logs is a helpful means to show, and explain to my friends what it is that I am doing with all my money and spare time.
Thanks again for allowing photos in this thread.

[Ben850]

Yesterday, 6-9-13, Installed control arms and an end link. Front brake pads for now.
Replaced rear right door panel, found window motor unplugged. Easy fix there.
Headlight glass replaced.
Cleaned wheel speed sensors, repaired connector wires.
Drilled out broken bolt on left rotor dust shield to steering knuckle and replaced. Quiet now.

List of goodies to continue with tomorrow. Have new OBD II computer adaptors and software to play with and get running. ECC to swap out. Previous owner unhooked and hardwired a switch to the blower. Aargh.
PCV cleaning and new 5/8 heater line, 1/4 fuel lines to run for it.
Photos to come and more.

[Ben850]

Did the PCV 5-11-13.
It appears it was done at least once with OE Volvo tubes. The stickers were still fairly fresh.

Previously replaced.

The oil separator passage back to the crankcase was not horribly clogged as my sedan was, but could use the attention.

Utilized 5/8" heater hose to PTC, as well as 1/4" thick walled vacuum line from the manifold to PTC.

New lines at PTC nipple.

I came up with the 5/8" hose through the manifold, around under the throttle body.

Between intake #1 and #2.

I like to utilize space when I can. I spend time picking up after myself as well.

I can see where everything is.

[Ben850]

Yesterday, 6-23-13, was a long busy day for the wagon. Hot as well. I lost 5 pounds.
The day before, 6-22-13, was a good day at one of my pick and pull yards. From a '98 XC 70 I grabbed some extremely strong rear hatch dampers, A door strap, front rotors and pads in new condition all of which were installed.
I didn't take shots of the damper install, but the hatch goes and stays up easily.

The old dampers

It doesn't drop on my head anymore.

I was inside the drivers door to change the strap. While digging out broken pieces, I found the window guide crushed in the bottom of the door.
I had prematurely bought one for the Sedan, but found I did not need it. It's a good thing I still had it. Installed it as well.

I also clean what you don't see. There is a lot when PCV systems clog.

Parts rattling inside the door.

Door strap and window guide.

I had some new-in-the-box, Sachs struts and IPD HD spring seats that were intended for the Sedan, but the wagon was in need of the whole shot.

I had an assembly line of parts going on.

New Sachs Super Touring with IPD HD seats.

All buttoned up and ready for a test drive.

I meant to add, I swapped out this non-heated, non-powered seat from the wagon. The tear in the bottom is the only thing bad. I replaced it with the heated non-powered seat from the Sedan, which came from a '96. For the sedan, I installed a heated, powered passengers seat from a '98 XC70 ($50.). I also had to use the seat belt.
This was useful as a very comfortable work chair to do strut surgery.

Under a shade tree in a comfortable seat, on a hot day.

I was very happy to find coated rotors in this condition, with only oxidation where the pads make contact. $10. a side for everything with pads in new condition, no wear at all.
The test drive made the Sedan jealous for giving up its struts. It feels smooth and quiet.
New front tires tomorrow to finalize the front end issues. The present ones are completely bald with threads showing toward the inside. The rears look new. Go figure.

[Ben850]

New front tires were installed 6-25-13. Actually they are changed out Bridgestone Turnza el42 Run Flat Tires (RFT) from a BMW 300 series like new. Great deal.
Installed rear mud flaps, chrome exhaust tip.

EDIT: I forgot, I also installed new plugs 6-29-13.
I used the same Bosch Super Copper Plus 7955 as I did for the Sedan, gapped @ .028

Bosch Super Copper.jpg (82.8 KiB) Viewed 2855 times

It had Champions and the gap was almost .040 on all five plugs.

Bought Roof wing spoiler, Brackets on order. Pictures to come.

To do in the near future:
*The a/c accumulator sprung a whole while charging. Ordering soon.
*Rear brake rotors. Have e-brake kit.
*Oil change.
*Trans drain and fill.