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A Box of Throttle Bodies. 3 Inch Turbo Conversion.

How to go faster, stop quicker, and turn harder. Chips, exhaust, larger turbos, bigger/slotted/drilled rotors, high performance brake pads, manual boost controllers, performance shocks/struts/springs, airbox mods and more! Also discussion on HID and Xenon lights, aftermarket foglights and other exterior lighting.
Ben850
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Year and Model: 1996 850 R Wagon
Location: Michigan
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Ben850

A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by Ben850 » Sat Dec 14, 2013 9:55 pm

I will be doing silicone plumbing all around when it gets warmer. I've got the turbo and radiator hoses on hand so far.
While looking for some other odd silicone pieces like the top IAC hose, and expansion tank hoses, I came across the Snabb N/A throttle body adapter hose for turbo intake.
3 inch throttlle body hose.jpg
This one is on its way.
3 inch throttlle body hose.jpg (28.15 KiB) Viewed 1816 times
I now have to do this easy modification.

After doing the N/A throttle plate alteration on my '93 I had a box of throttle bodies and parts. I had recently grabbed a couple turbo throttle bodies for the wagon for throttle position sensor swaps or whatever.
I can easily get an N/A manifold at my pick and pull for $23.00, or I can spend a couple hours grinding the bore to three inches on the present one.

Either way, It is a plan. Today was a snow day so I brought my box of throttle bodies inside to create the appropriate piece for the application.
IMG_2737.JPG
A Box Of Throttle Bodies.
I had a few 3" for my '93 but only one with no vacuum tubes. (what I want) That was an easy choice for the body. I had plenty of the 3" N/A plates with the obstruction but I wasn't looking forward to filing or grinding it off. I did dig up a 960 throttle body with an unobstructed plate, but it had vacuum tubes and the TPS was angled different as well as the throttle linkage arm.

So the choice was simple. Take the throttle plate from the 960 body and install it in the 850 N/A unit.
The hardest part was cleaning the 960 throttle body just to get the plate out. There was a reason the 960 was at the junkyard, it was breathing oil straight. It must have smoked horribly.
IMG_2740.JPG
960 on right with donor plate.
IMG_2741.JPG
Gunk degreaser and Brake cleaner in the house. A little light headed.
IMG_2744.JPG
Getting there.
IMG_2745.JPG
All set looking good.
IMG_2750.JPG
Be sure to spread the screws to lock them.
The thing I learned when modifying the '93 throttle plate was to not forget to lock the plate screws by spreading the shaft of the screw by the slot on the other side.
After a week or so the throttle plate vibrated loose and would stick open and idle at 2,000 rpm unless I tapped the pedal. It was easily fixed but the kind of mistake you make once.

Manifold is next. I would like to get one from the yards so I can take my time over the winter to clean it up and bench assemble things. I know I can find an N/A for $23. and change, so why bother trying to open the bore myself with hand tools.

Edit.: It just occurred to me. This exact setup is what you want on the N/A to improve throttle response. I simply could not find any 960s at the time so I had ground the plastic obstruction by hand with a file.
1993 850 GLT , You wouldn't know it.
1996 850 Turbo Wagon White.
1995 T-5R Black. New work in progress.
1998 V70 XC Cross Country White.
1994 850 N/A Wagon Black.
1997 850 Sedan Black.
1996 850R Wagon White.
1997 850 Sedan Red ( not white or black!)

polskamafia mjl
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polskamafia mjl

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by polskamafia mjl » Fri Feb 21, 2014 8:41 pm

Do you have any more 960 throttle plates around?
'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

Current: 1995 Volvo 850 T-5R Manual - Bringing it back from the brink of death
Previous: 1996 Volvo 850 GLT - Totaled

Ben850
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Joined: Thu Sep 08, 2011 1:53 pm
Year and Model: 1996 850 R Wagon
Location: Michigan
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Ben850

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by Ben850 » Sat Feb 22, 2014 3:09 pm

polskamafia mjl wrote:Do you have any more 960 throttle plates around?
No, not at this time. I saw a 960 last time out at the yards, but I was in a rush or I would have grabbed it.
If the car is still there in a week or so when I might go again, I can grab it if you need one.
1993 850 GLT , You wouldn't know it.
1996 850 Turbo Wagon White.
1995 T-5R Black. New work in progress.
1998 V70 XC Cross Country White.
1994 850 N/A Wagon Black.
1997 850 Sedan Black.
1996 850R Wagon White.
1997 850 Sedan Red ( not white or black!)

polskamafia mjl
Posts: 2631
Joined: Wed Apr 01, 2009 1:10 am
Year and Model: 1995 Volvo 854 T-5R
Location: Hershey, PA
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Poland
polskamafia mjl

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by polskamafia mjl » Sun Feb 23, 2014 5:40 pm

Yes please! Snaab has one but its $24 + shipping and I'm trying to budget for a semi major engine rebuild. If you do pick it up PM me and we can work out a price. I wish I hard a junk yard near my house.
'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

Current: 1995 Volvo 850 T-5R Manual - Bringing it back from the brink of death
Previous: 1996 Volvo 850 GLT - Totaled

Ben850
Posts: 1613
Joined: Thu Sep 08, 2011 1:53 pm
Year and Model: 1996 850 R Wagon
Location: Michigan
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Ben850

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by Ben850 » Sat Mar 15, 2014 7:19 pm

polskamafia mjl wrote:Yes please! Snaab has one but its $24 + shipping and I'm trying to budget for a semi major engine rebuild. If you do pick it up PM me and we can work out a price. I wish I hard a junk yard near my house.
I was at the Yards today and grabbed a couple 960 complete throttle bodies.

PM me if you like, I'll send you one in case you don't catch this thread.
1993 850 GLT , You wouldn't know it.
1996 850 Turbo Wagon White.
1995 T-5R Black. New work in progress.
1998 V70 XC Cross Country White.
1994 850 N/A Wagon Black.
1997 850 Sedan Black.
1996 850R Wagon White.
1997 850 Sedan Red ( not white or black!)

Ben850
Posts: 1613
Joined: Thu Sep 08, 2011 1:53 pm
Year and Model: 1996 850 R Wagon
Location: Michigan
Has thanked: 0
Been thanked: 4 times
United States of America
Ben850

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by Ben850 » Sat Mar 15, 2014 9:34 pm

I did finally get the manifold during the one and only day in January that was suitable to go outside here.

I've bought a few other things along the way. Reconstruction begins Monday and will be added to my maintenance log with photos.
IMG_2771.JPG
There is a bigger pile today.
I have the use of an air tool equipped garage next week.
1993 850 GLT , You wouldn't know it.
1996 850 Turbo Wagon White.
1995 T-5R Black. New work in progress.
1998 V70 XC Cross Country White.
1994 850 N/A Wagon Black.
1997 850 Sedan Black.
1996 850R Wagon White.
1997 850 Sedan Red ( not white or black!)

Ben850
Posts: 1613
Joined: Thu Sep 08, 2011 1:53 pm
Year and Model: 1996 850 R Wagon
Location: Michigan
Has thanked: 0
Been thanked: 4 times
United States of America
Ben850

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by Ben850 » Tue Mar 18, 2014 5:37 am

Your plate is on its way.

I am into my project as of yesterday.

The garage is only down the street but the ECC is not functional at the moment. That will get fixed as well.

The Wagon had no shelter over the winter and it was as cold as -20F here.
I had to order a radiator quickly from FCP because I noticed small drips of anti freeze on both tank areas. The steel piece across the bottom was extremely rusty.
All the hoses will be silicone, and I have a new Aisin water pump coming as well.
Everything has to be done by Friday when the owner of the garage/home comes home.
IMG_2847.JPG
Frost inside the car. It was cold yesterday.
IMG_2849.JPG
Thawing out.
IMG_2851.JPG
Before.
IMG_2861.JPG
Central command. Air hockey table.
IMG_2858.JPG
White injectors soaking in seafoam. Expensive little bath.
IMG_2864.JPG
Where I left off.

Hopefully everything ships on time.
1993 850 GLT , You wouldn't know it.
1996 850 Turbo Wagon White.
1995 T-5R Black. New work in progress.
1998 V70 XC Cross Country White.
1994 850 N/A Wagon Black.
1997 850 Sedan Black.
1996 850R Wagon White.
1997 850 Sedan Red ( not white or black!)

polskamafia mjl
Posts: 2631
Joined: Wed Apr 01, 2009 1:10 am
Year and Model: 1995 Volvo 854 T-5R
Location: Hershey, PA
Has thanked: 10 times
Been thanked: 8 times
Poland
polskamafia mjl

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by polskamafia mjl » Tue Mar 18, 2014 6:40 pm

Looking good so far.
'All my money is gone and I have an old Volvo.' - Bamse's Turbo Underpants

Current: 1995 Volvo 850 T-5R Manual - Bringing it back from the brink of death
Previous: 1996 Volvo 850 GLT - Totaled

Ben850
Posts: 1613
Joined: Thu Sep 08, 2011 1:53 pm
Year and Model: 1996 850 R Wagon
Location: Michigan
Has thanked: 0
Been thanked: 4 times
United States of America
Ben850

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by Ben850 » Thu Mar 20, 2014 10:35 pm

I've been working on it for four days now. I am waiting for the water pump that is late in shipping.

I'll finish the timing belt, water pump, pulleys, tensioner, as well as the serpentine pulleys and belt tomorrow.
IMG_2867.JPG
IMG_2900.JPG
The 3" aluminum intake to turbo makes the air box a snug fit.
IMG_2904.JPG
Almost done. Water pump delivery today.
1993 850 GLT , You wouldn't know it.
1996 850 Turbo Wagon White.
1995 T-5R Black. New work in progress.
1998 V70 XC Cross Country White.
1994 850 N/A Wagon Black.
1997 850 Sedan Black.
1996 850R Wagon White.
1997 850 Sedan Red ( not white or black!)

Ben850
Posts: 1613
Joined: Thu Sep 08, 2011 1:53 pm
Year and Model: 1996 850 R Wagon
Location: Michigan
Has thanked: 0
Been thanked: 4 times
United States of America
Ben850

Re: A Box of Throttle Bodies. 3 Inch Turbo Conversion.

Post by Ben850 » Sat Mar 22, 2014 6:33 pm

I drove it today. It started on the first turn of the key after hooking up the battery last night.

The stock ECU in place took approximately 4 seconds to get used to the new injectors, and the amount of airflow before going into a fairly smooth idle.

I had been using economy mode for the TCM settings because there was never a low end torque problem.
Today I had switched it to sport to have some fun. I originally switched to economy when I had got the car running. the boost scared me while torque steer took me into other lanes from non existent control arm bushings.
I was wanting the spool to last a bit longer and I now know why there is a built in timing delay between the one-two shift. Parts may break.
I plan to swap the 628 module in next week to expect a few more horsepower. ( I believe 18 or so. Right? for 30 seconds at bla... Bla... ) .


IMG_2479.JPG
I hope I have as nice a day this year.
I should have a new documentation from this runway, this year hopefully.

None the less, it will be sub freezing here for another week. Updates.
1993 850 GLT , You wouldn't know it.
1996 850 Turbo Wagon White.
1995 T-5R Black. New work in progress.
1998 V70 XC Cross Country White.
1994 850 N/A Wagon Black.
1997 850 Sedan Black.
1996 850R Wagon White.
1997 850 Sedan Red ( not white or black!)

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