Need some help and advice about 1996 t5

[BlackD3vil]

First of all, i want to say hi to the forum since i am a new member i am a proud owner of 1996 850t5.
The car was bought for me by my uncle as a first car. And ofcorse, as any other cars it had and has its problems.

The first was a loud fuel pump. and it was replaced, but it was replaced with a 2004 d5 fuel pump because we had one laying around.
before we changed it the car was boosting lower and it had worse pickup. it was pulling from around 3k rpm, now it starts around 2.2k rpm. and it would die past 5k, now it still pulls and it dosnt lose power in 4th. so i guess i can leave the d5 pump inside.

then i started looking for boost/vacum leaks with a diy smoker and found a huge hole on a hose on the passager side. do you guys know what is this hose used for?. pics bellow

i am trying to get the car to stage 0 so it can be tuned down the road. it will soon be getting a 3" turbo back exhaust
I will also be replacing the fuel/oil/air filters, fluids ,spark plugs,water pump and other service parts

Also. i have been reading about the bosch motronic 4.4 upgrade. and i just want to know, can I use any 97 turbo ecu and just flash an R map on it? or could i eaven flash the 4.3 in my car?

[matt122s]

Hi BlackD3vil and welcome to the site. The hose in the picture goes from the side of the intake manifold to the PTC valve, it's located on the large intake hose/snorkel that goes to the turbo. I think it's part of the PCV system.
Matt

[scot850]

+ 1 to what Matt says. You can sometimes get the hose bend by itself. This is very prone to failing with age, as can many of the rubber pipes at this age. It is worth removing the plastic pipe with the PTC nipple/valve, carefully remove the valve and check it is not blocked. Looking at the amount of gunk at the rotted pipe in your picture it could be blocked. It is part of the PCV/breather system. If you take the plastic turbo input pipe off to clean the PTC it is worth checking the turbo spindle play.

Also check the TCV (Turbo Control Valve). One the 850's it can either be a can or a plastic rectangular part near the intake airbox. There should be 3 pipes going to it. The TCV's start to fail with age and can become lazy to respond not allowing the turbo to spool up fully.

The pipes are very prone to rotting especially at the turbo end. Most folks replace with silicon piping (See IPD for example as a source).

There is a diaphragm on the turbo (CBV compressor bypass valve) which is rubber and can fail with age also. If you suck carefully on the pipe to the TCV that runs to it, if it won't hold a vacuum it is goosed. Good news is on your car you should be able to replace it without removing the turbo.

Fuel pressure should be >43psi at the Schraeder Valve on the fuel injector rail.

Neil.

[Ozark Lee]

I'm not sure what fuel pressure the D5 runs from the electric pump in the fuel tank, hopefully it is the same 43 PSI (3 bar) that the petrol engines use. If you have access to a fuel pressure gauge you might want to check it though. It could be that the Diesel engine takes a higher fuel pressure than the gasoline counterpart and if it is too high the fuel pressure regulator might not be able to handle it. I've not worked with a Volvo diesel but I would guess that they use a mechanical fuel pump to drive the injectors but if they are trying to use the electric pump to drive the injectors it is going to be way too high.

...Lee

[rspi]

As explained, that hose end is part of the PCV system. Unfortunately, if you attempt to replace that end, the small plastic tube that it is connected to will likely break. Test the system and plan on replacing the PCV system.

[BlackD3vil]

Hello guys.
Thank you for all your responses
so the pcv is likley gone and i will need a new one. the problem is i will need to order it online since where i live i prob. will not find it in a store.
i will try to remove the intake and the tubes, sensors and valves and clear them out with a compressor.

unfortunately i dont think I have a fuel pressure sensor, but i may be able to test it at some of my uncles friends.

i will try to do my best. what about the ecu? i was reading the all tuners rejoice thread on volvospeed but i dont realy understand what ecu to use. and how to know if its a 4.4 or 4.3. i know i will need to flash the AC mod so it dosent fry the ac motor . but thats all i know.
Btw my car is the italian version. so its a B5204T. so can i use the 2.3- 2.5 ecu?

[tryingbe]

so its a B5204T. so can i use the 2.3- 2.5 ecu?

Nope, too much fuel and wrong timing (probably)

[BlackD3vil]

so its a B5204T. so can i use the 2.3- 2.5 ecu?

Nope, too much fuel and wrong timing (probably)

so i will not adjust by checking lambda values and stuff?
oh hell. i want do go to 4.4 since the map is twice the size, and i want/need obd2 support. since i wanted to put in a tablet to control music and other features, but i also wanted to connect it to obd2 via bluetooth to have all of my data shown there.
hope i am not stuck with 4.3 and no obd2

[mecheng]

You have the rare 2.0L for Italy only, you can't swap ECUs. I would suggest you check what @Ozark said, these cars are not the type to be using different fuel pumps as they are computer controlled. You could overwhel the fuel pressure regulator.

I noticed the plastic pipe that feeds air to your ECU has holes in it. Clean it with rubbing alcohol and seal it with black electrical tape, or buy a new one.

I find once I clean my engine bay, it is easier to find leaks.

[BlackD3vil]

yeah its the italian version. i will check the fuel pressure soon. the car is not being driven at the moment since its not registerd so no worries.
the fact that i will not be able to swap the ecu SUCKS. . maybe the italian R had the 4.4? or something

Yes the ecu pipe dose have holes in it. and i will be fixing them today. was hoping to find a used one at the jy but no luck.

OOH and yes, thanks to all of you that responded. its nice to be in a helping community