Converting My Volvo To Electric Power
Contents
1. Editor Eric Mollerstuen Designer Bryan Cottrell IN THIS ISSUE Converting a Volvo to Electric pg1 Cameron s Turbo build update pg 2 Tune up pg 4 Air Mass Meter Tech Tip pg 10 Also Sale pricing and special offers Promotions expire May 29 2009 Be sure to check out our new website for all new features and news ipdusa com The Volvo suche 800 444 6473 ipdusa com ipd is not affiliated with Volvo North America Corp E se i o E DE O 5g oa alle wE Volume 2 Issue 2 April 2009 The E Volvo By Mike Ahern ipd Customer Ma Ta Wo F Te Converting my Volvo to Electric Power called Solyndra which makes solar panels in Fremont Ca VI y name is Mike Ahern am a process engineer for a company live in West San wanted to get to work without using gasoline Jose about 16 miles from work 100 lbs iP jik not counting the engine were renioved from the car started reading about electric cars and pretty quickly found people do ing it themselves It looked like fun and thought could do it found a company EV America which sold me most of the parts and helped me with a video a manual and assisted with my many phone calls There were many people who told me ought to use a lighter car but love Volvos and their safety will never drive another brand of car decided the added weight of the Volvo2. move the fuel line between the tank pump and the main pump at the inlet of the main fuel pump Put the end of the fuel line in a bucket or container and turn the key on If the pump is working it will start flowing fuel into the bucket If nothing comes out the pre pump is dead Pct Main Fuel Pumps A fuel pump either works or it doesn t Be sure to fault check the wires and the relay before replacing it A repair to the power source is far less expen sive than a misdiagnosed fuel pump These pumps are the same original Bosch pumps that will last as long as the original 200 series All 1975 77 200 700 900 series All 1978 95 240 260 series B21F B27F B28F 1980 83 240 series B21FT 1981 85 240 series B21F B23F B230F 1982 93 700 900 series non turbo B23F B230F 1985 97 700 900 series turbo B230FT 1985 97 700 900 series B230 Regina 1989 91 Prepump Upgrade for 240 Prepump failure is common in the early 240 series cars They work well for the most part and even when they fail and are replaced with a new one they usually run like new It s the K jet cars 1978 84 that are most likely to benefit from a pre pump upgrade It seems that these 240s may have a main fuel pump noise and lack of full power even with a new original style in tank prepump In these cases Volvo has a bulletin outlining the replacement of the original pre pump with a later version that has a higher delivery capacity 3517845 available in our kit
3. Unfortunately this is not a direct replacement pump Modifications are required to the pick up tube The pick up tube must be shortened by 30mm because the pump is that much longer And a clamp is required to secure the pump to the pick up tube Prepump U In Tank Prepumps If your Volvo runs but runs poorly as if it is starving for fuel a common problem area is the prepump in tank fuel pump Another common symptom is that the car will run fine or a full tank but below half a tank it stumbles and bucks and the main pump will usually be rade for 240 Series 1978 85 Prepump conversion kit includes A B C D E and instructions MEK quite noisy A 200 series B20 B21 B21FT B23 B27 1978 83 A 200 series B23 B230 1984 93 A 740 760 series All 1983 85 A 700 series All 1986 87 A 700 900 series B230FT 1986 95 A 940 series B230F B234F 1991 94 B Filter All models 1978 95 C 200 series Fuel tank sender seal ring 1975 93 D In tank prepump hose 1978 95 E Preoump hose clamps All ipdusa com 800 444 6473 83 68 ML1276330 48 08 e ML1389721 51 70 amp ML1389721 51 70 amp M351785 73 20 e M351785 73 20 e ML1389721 51 70 amp MI 9 03 ea MA6 4 58 ea MHIOI6 0 50 ea M21017 0 98 ea M12509 rubber mount isolator for main pump 2 used 1 72 ea MIMIS rubber mount for fuel pump tray 3 used 3 03 ea M6199 main pump KJ etronic 164 72 ea M6199 main pump K Jet w turbo 164 72 ea M61468 main p
4. OEM quality our wire sets include factory style metal end connectors where applicable Each wire set includes spark plug and coil wires as well as dielectric grease used on the plug boots for easy removal at tune up time 240 series 1976 93 spark plug wires by ipd M30 69 95 SALE 62 95 700 900 series Bosch spark plug wires by ipd cam drvn M3ER00B 69 95 SALE 62 95 700 900 series Regina spark plug wires by ipd cam drvn M3EROOR 59 95 SALE 53 95 Original Equipment Spark Plug Wires by Bosch and Bougicord A properly tuned ignition system is one of the most important factors of any engine It will keep your engine running smoothly economically and will deliver the most power The increased heat under the hood may lead to premature degradation of the ignition wires These wires are made by the original equipment supplier to Volvo so you are assured of the best quality in replacement wires Kit w 90 1 wire for A C Complete kit with Bakelite ends Basdh 240 series 1975 B20 ML3E0909 30 30 Kit 2 coil wires both short and long wires included Metal jacketed ends Bourgcorcl 240 series 1976 93 B21 B21FT B23 B230 M3821 55 1 Complete kit cam driven distributor Rubber ends Bougiaord 700 940 series 1985 95 B230 B230FT M35 40 90 REX 1 for coil mounted on driver s side Rubber ends Bougiaord 700 940 series 1989 95 B230 M36 LU Spark Plug Thread Repair Kit If you have a 1976 1995 4 cylinder Volvo with marginal o
5. T use a ratchet or extension to reach the sensor from farther away Our new high leverage f ey long handle oxygen sensor wrench has a flex head joint and a bent handle which gives you P several different positions to attack that hard to reach sensor aD Bosch oxygen sensor socket M788750 24 95 Oxygen Sensor Wrench M7103 22 95 Fuel Injectors and Seal Kits A poor running car that otherwise has a good tune is sometimes hard to diagnose Injectors will flow fuel for many years without wear but as the car gets over 200k miles it may be time to test them Use water to spray around the injectors to test for a bad injector seal A momentary decrease in idle speed indicates that the seals are bad A bad seal will cause a vacuum leak and will cause a lean condition Replace the seals and reset the fuel mixture for best power and economy An engine that is rough at idle but clears up on acceleration may have a worn injector On LH cars just disconnect the injector plug to find the injector that is not firing Replacing it will smooth the idle and give more power on acceleration 240 series B20F 1975 MOBARE K Jetronic injector seals not included 50 00 ea A 240 series B21F B21FT 1976 85 M0OBAR0I5 K Jetronic injector seals not included 54 71 ea B 240 series B21F B21FT 1976 85 M4633864 plastic injector holder insulator for K Jet 6 80 ea 240 series B20 1975 ML2D0200K fuel injector seal kit K Jet all 8 seals 16 00 kit C 240 series B21 B21FT 1
6. precise control of the injected fuel quality the engine burns cleaner and uses less fuel At the same time drivability is im proved easier starting less stalling smoother idling better throttle response no run on after the ignition is shut off Just add a can to a full tank of gas Fuel injection cleaner K jet Fuel System Cleaner MLLIV2007 7 52 SALE 6 77 Formulated for professional use to restore and keep the fuel system in good condition Reduces the CO and HC emissions and prepares the vehicle for a smog test Success fully tested to international CEC standards Can significantly improve cold start difficulties rough idling poor throttle response loss of performance lean surging high exhaust emis sions Add a 500ml can to a full tank of gas to renew the fuel system Fuel system cleaner ipdusa com 800 444 6473 20 02 SALE 18 00 Oxygen Sensor Removal Tools Replacing the oxygen sensor on your Volvo can be a real pain Since it is installed directly in the head pipe or exhaust manifold it will usually be severely rusted or corroded in place The main sensor wires come right out of the center of the sensor so it is not possible to use a Standard socket over the sensor Our oxygen sensor tools both have slots machined in them that allow you to slide them over the wires and onto the sensor for secure removal and installation The oxygen sensor socket tool attaches to a 3 8 square drive so you can _
7. 3 98 MLFR7DC Bosch resistor spark plug 1 95 ea ipdusa com 800 444 6473 K amp N Air Filters This filter has an international reputation for effective service under the most grueling conditions Patented design utilizes surgical cotton in multi layers oiled and sandwiched between wire mesh K amp N filters not only clean the air but also straighten the air flow Your engine is provided with a less turbulent air stream than other popular filtering mediums like paper and foam Under normal conditions cleaning and reoiling is not required until 50 000 miles without loss of efficiency K amp N filters come pre oiled and ready for installation 240 series non turbo 1976 93 240 series turbo 1981 85 700 940 series non turbo 700 940 series turbo 960 90 series Filter care kit oil and cleaner Stock Replacement Air Filters 54 22 78 40 55 36 82 02 59 94 13 52 SALE 48 80 SALE 70 56 SALE 50 00 SALE 73 87 SALE 53 95 SALE 12 17 While there is no replacement for the K amp N filters listed above there is a substitute Try one of our quality paper elements just like the one that your Volvo came with Easy to install and maintain just discard and replace with a new one when needed Check air filter every 10 000 miles Replace it every 30 000 miles or more often in dirty or dusty conditions Original Paper Style Air Filters 240 series 240 series 240 series 240 series turbo 700 940 seri
8. 30 01 ipdusa com 800 444 6473 By Eric Mollerstuen Symptoms An engine with a bad AMM Air Mass Me ter may start and stall or be hard to start it may hesitate under load idle rough or run excessively rich or lean The engine may also hiccup when you quickly step on the throttle Often a dirty or faulty AMM will cause the engine to set a LEAN code and turn on the Check Engine Light If the AMM sensor wire becomes dirty or is contaminated with oil from a plugged flame trap system it will be slow to react to changes in airflow This may cause the AMM to under report airflow to the computer causing the engine to run lean Not only will a faulty AMM cause the en gine to run poorly but it could also do some serious damage to the engine if left alone for too long Often times when the sensor fails it causes the engine to run lean which in creases the temperature of the exhaust gas es which could damage the oxygen sensor the catalytic convertor the turbocharger and even the material inside the mufflers On the other hand sometimes the AMM failing will put the computer into a Limp Home Mode which will make the car run extremely rich This can have a similar effect as a lean con dition but even more damaging Starting in the engine itself extra fuel can wash down the cylinder walls and essentially rinse the protective film of oil off of the walls which in creases friction and can lead
9. 976 85 ML2D0800K fuel injector seal kit K Jet all 8 seals 4 00 kit D 200 700 series B23 B230F FT 1982 95 ML2D0400K fuel injector seal kit LH Jet all 8 seals 19 95 kit 700 series B230FT 1985 89 ML0280150857 LH Jetronic injector seals included 185 00 ea If you re unsure of what type of injectors you need give us a call and we ll make sure you get the right ones for your Volvo Injector seals aren t included except for LH injec tors which include seals Always replace injector seals when replacing an injector Sending Unit Not sure how much fuel is in the tank If your sending unit is original that means that it s reaching it s golden years The common starting to fail symptom is an inaccurate gauge that momentarily pegs at full It might work like this for years and it might not last another week Put an end to uncertainty prevent unwanted rest stops by the side of the road due to an empty tank replace yours now 200 series 1978 93 M1367253 228 39 ipdusa com 800 444 6473 11 Fuel Injection Test Light Here s an inexpensive tester for do it yourselfers Now you can check if individual injec tors are getting the proper voltage Easily plugs into the fuel injector connector Just crank the engine while watching the light If it flashes your injector voltage is okay Bosch style fuel injection test light M3405 6 95 For use on cars with Bosch Electronic LH fuel i
10. ca com htto www electroauto com e Silicon Valley Electric Auto Associa tion http Awww eaasv org Pt Pdt ipdusa com 800 444 6473 IK114X Reviewed by David Guido from Saratoga CA decided to get this kit when my 1988 245 had 120K miles and used every part All high quality at bargan prices I m now about ready to get another one now that have over 200K miles Tune up Time Do it Right The first step to a well balanced relationship between car and driver is a tune up kit from ipd Utilizing original equipment Bosch compo nents where applicable for the best in quality and value our tune up kits offer the ideal platform for efficient performance For those con sidering a complete service makeover our 60 000 mile extended service kits offer the necessary components for a complete service of the engine and drivetrain on your Volvo All of the parts in our kits are OEM quality for the best in performance and fitment For more information on ipd tune up kits their applications or additional maintenance advice give us a call Bosch Tune up Kits Includes distributor cap rotor and spark plugs 240 series B21F 1976 83 MUKI08 17 92 240 series B230F 1985 93 MUKLIA 18 14 240 series white cap B21MPG B23F 1981 84 MUK1I5 22 50 240 series turbo GLT B2IFT B23E 1981 85 MIK1LI9 17 84 240 series B23F 1983 84 MUK1L16 21 49 740 940 series B230F cam driven 1985 95 MUK117 65 25 700 900 seri
11. dling class well above where it is now and get it well on its way to handling with the same panache as much sportier machinery while retaining its Volvo identity You won t believe the improvement and you ll wish you d bought a set sooner If you don t believe us ask anyone who s tried them Sat isfaction Guaranteed period They really are that good THE suspension performance part for any Volvo Anti Sway Bars have been ipd s best seller for over 40 years and represent the most significant return on investment of any product we sell It s often remarked by customers and employees alike that If you only buy one thing ever from ipd it should be Anti Sway Bars for your Volvo Anti Sway Bars will drastically reduce the amount of body roll your car experiences around corners and increase ride comfort to boot All this translates into much more precise handling and control over your Swede with absolutely zero trade off in ride quality All ipd safety anti sway bar packages are built using the finest materials available including high memory 4140 cold rolled chro moly steel lifetime warrantied polyurethane bushings and grommets and premium grade hardware Detailed step by step instructions are included 240 sedans 1977 93 25mm front 22 mm rear Ma6012 328 00 From Matt in Albany OR 245 wagons 1979 93 25mm front 22 mm rear Maso 328 00 This upgrade is the best thing you can do for your 240 GT Turbo amp lowered All 25mm front 25 m
12. e bay The Curtis controller mounted to the adap tor plate near the firewall EV America sent a detailed schematic which made it easy to wire everything up On the right of the picture below is the resistor box This box sends a variable dc voltage to the Curtis Controller which sends pulse width modulated owm voltage 144V to the motor the duty cycle dependent on how far down am pressing the accelerator With electric cars there is a lot of cur rent going through the wires sometimes over 100 amps So you need big wires A neighbor had 1 0 copper welding cable he gave me and used it for most of the cables The lugs for the cables came from Grainger and from work borrowed an electric crimper which made great hex crimps For the battery boxes used aluminum bar stock got from work and a lot of trips to Orchard Supply Hardware for hardware and various fasteners There are four batteries in the engine bay and eight batteries in the trunk The 12 Trojan T1275 lead acid batter ies are wired in series and there are 2 long cables going under the car from the front to the trunk mounted the long cables using the exhaust hangers The 144 V charger bought from Electro Automotive It plugs into a standard 110 VAC outlet and turns itself off when the 12 bat teries are fully charged drive around with 2 long extension cords enabling me to get power from about 100 feet from the car Once got a charge from a pl
13. e in these must have reference works for the home mechanic Haynes manuals have excellent photo sequences for assembling complex parts They re a good value in our book 240 series 1976 93 MAO 19 96 SALE 17 96 100 series 1983 88 M91550 19 96 SALE 17 96 140 series 1982 91 UK version MOLI258 27 96 SALE 25 16 940 series 1990 95 UK version MA3 27 96 SALE 25 16 The Bentley Bible The Bentley has become our number one resource for helping customers with 200 series You ll find a well worn copy on everyone s desk in our customer service department If you have a 240 or even a 260 of any vintage you need this book Bentley is an official factory service manual publisher for Saab Audi and Volkswagen and acknowledges Volvo Cars North America for the extensive use of original Volvo techni cal illustrations which is a huge contributor to the quality and ease of use of this service manual 240 series 1983 1993 MAB 39 95 240 series turbo models 1981 1985 MAPB 39 95 Busted Knuckle Garage Fender Gripper Protec I tor The Fender Gripper clings to painted material and holds tools at a near 90 degree angle impervious to motor oil coolant lacquer thinner brake fluid etc Made from strong PVC material reinforced with nylon mesh soft and cushioned for protection with a non slip finish 1 the Fender Gripper is completely washable An ounce of prevention is better than a pound of touch up paint Dimensions 22 X 34 Fender gripp
14. er M153 19 95 Mechanics Pick Set You can t appreciate how handy these tools are until you ve had them around for awhile For removing injector seals oil seals cam shims retrieving small parts that have found their way into the depths of the engine compartment fishing wires through the firewall the list goes on The angled hook right angle and straight tips are removable to allow the tool to be used in tight spots Knurled anodized aluminum handles and hardened steel tips provide years of service Pick set MIIA 9 95 set SALE 8 95 ipdusa com 800 444 6473 ipd Anti Sway Bars If you know ipd you know that we began pioneering anti sway bar set ups for Volvos more than 40 years ago Did you know we make anti sway bar packages for other vehicles too In some cases the original manufacturer has copied our designs and integrated them into their own production line or we are providing them with our bars as original equipment Think about that Our bars were so superior to the original equipment that they BECAME original equipment Cars continue to evolve and handling characteristics that were once available only on high end exotics are now commonplace We originally developed our anti sway bars to enhance handling perfor mance which they do However these are the same sway bars many Volvo drivers install as safety improvements They ll give your Volvo handling characteristics that put it in a han
15. er normal use this mat can t be ripped yet it can be custom cut with an ordinary pair of scissors or utility knife Plus this mat can be recycled The oil soak mat measures 3 ft x 5 ft Oil soak mat MLR2 19 90 SALE 17 91 Oil Filter Grabbers This tool works great for most Volvo engine compartments It s especially nice for the gw Turbo engine where access is very tight With slotted adjustment for large and small oil filters and a 20 off set you can get at those filters with limited access and still have a good grip and the leverage needed to spin them off Not for plastic cartridge style filters Oil filter grabbers M71011 19 95 SALE 17 95 Magnetic Oil Drain Plug Prevent abrasive particles from recirculating through your oil pump and back into the pressurized system with our magnetic drain plug This plug catches and holds metal par ticles as they drain into the oil pan You ll be able to spot deteriorating engine conditions easily Plug includes a seal ring 4 cylinder all drain plug w seal M2050 4 95 SALE 4 45 960 90 series drain plug w seal M2651 7 95 SALE 7 15 4 cylinder all additional copper seal ring M18818 0 50 SALE 45 960 90 series additional aluminum seal ring M9775 0 45 SALE 45 Not for V6 or diesel Oil Filter Magnet Capture every microspeck of metal that causes engine wear Debris that your oil filter alone might not be able to screen Made of a strong flexible silicone this oil resi
16. es 700 900 series turbo 200 700 series 960 90 series 960 90 series rectangular 11 25 x 8 25 rectangular 13 25 x 9 5 MLAG0886 MLA63505E ML463506M M1277685 M1336397 M1556 M12682 ML13363976 ML133639 M 25 00 8 44 8 80 15 74 8 44 12 00 12 4 8 44 11 50 Part s ending with an E denotes that this is an economy version of this part Part s ending with an M denotes Mahn or Mahle brands ipdusa com 800 444 6473 Mann Oil Filters To our knowledge this is simply the best filter you can buy for the money This filter manufactured by Mann grabbed the number one slot in an oil filter test by the Volvo Club of America Mann is the original supplier of oil filters to Volvo Fits all 1962 98 Volvos except for diesels or V6 1975 98 All models Mann oil filter M35177 4 95 ea Case of 10 Mann oil filter M517 39 50 case 4 cylinder all copper oil pan drain plug seal ring M18818 0 50 ea 960 90 series aluminum oil pan drain plug seal ring M9775 0 45 ea Not for V 6 or diesel Oil Soak Mat This patented leak resistant mat looks like a black rug yet it has the ability to absorb and retain hundreds of hazardous and non hazardous liquids such as oil gasoline diesel fuel hydraulic fluid transmission fluid anti freeze water and more Absorbs up to one gallon of liquid The leak resistant back will not allow the absorbed liquids to soak through to the floor underneath Und
17. es B230FT cam driven 1985 95 MUK118 65 17 700 series B23FT 1984 MIKI20 20 91 Bosch E xtended Service Kits 60 000 mile service Includes rotor cap spark plugs air filter fuel filter oil filter ignition wire kit timing belt flame trap differential gasket oil drain plug injector seals and fuel filter seals on models where needed 240 series B21 1981 82 MIKI08X 103 80 240 series B230 1985 92 MIKIA 105 47 240 series B21FT 1981 85 MUKLISX 109 69 240 series B23F B230 1983 84 MLUKLIGX 108 31 700 940 series B230 1985 92 MUKLI7X cam drvn dist 138 36 700 940 series B230FT 1985 92 MIKI cam drvn dist 140 45 100 940 series B230 1993 95 MIK27X cam drvn dist 150 19 NOTE Two distributor shaft sizes were used on 1985 240 non turbo models you ll have to measure the shaft OD or the rotor ID to ensure you get the correct rotor If you measure 3 8 400 use tune up kit number MLIK114 X rotor 04170 For 9 16 565 use kit number MLIK116 X rotor 04138 Rex Regina cars will require a different coil wire ML6842734 CMe SA AST RCE Di May 16 2009 Gates open at 8 00am et gt D FP 4 Cede Spark Plug Wires by ipd Our custom spark plug wires are made with a high quality 8mm silicone jacket and feature a spiral wound core for maximum electrical efficiency Each wire set is custom designed for each application covering over 40 years of Volvo models Engineered to meet and surpass
18. had a high build up of carbon deposits on and around the valves It also helps protect the fuel system against corrosion and icing Ventil Sauber is suited for both injected and carbureted cars and is safe for cata lytic converters and turbocharged engines Add a 300ml can to your full gas tank Valve cleaner MLLIV200L 6 16 SALE 5 54 Magnetic Pickup Tool with LED Light Flexible magnetic LED pickup tool is great for retrieving those dropped fasteners Strong 4 lb magnet and super bright LED provides the muscle and illumination to see into dark recessed areas to find fasteners that have slipped between fingers Features non slip rub berized handle twist on off switch for LED and super flexible neck 24 inch overall length Magnetic pickup tool with LED light M71010 9 95 SALE 8 95 ipdusa com 800 444 6473 Chilton Manuals This shop manual for Volvo owners covers all models from 1970 to 1989 1800 140 160 240 260 and 700 series If you have a small fleet of Volvos and don t have manuals for them this could be the guide for you Also covers 200 and 700 series diesels and 1989 700 series overlooked by the major repair manual publishers One inch thick and full of useful information All models 1970 89 M913786 23 96 200 700 900 series 1990 93 M amp 3808 23 96 Haynes Repair amp Service Manuals Whether you need tune up information torque specs or step by step guidance through a complex repair it s her
19. he car normally and allow it to warm up to operat ing temperature Pay attention to how the car runs at idle and how it responds when you step on the accelerator Then shut the engine off and disconnect the wide electrical connector plugged into the AMM On turbo cars it is located between the air filter hous ing and the turbo inlet on the passenger side of the engine bay On non turbo cars it is located between the air filter housing and the intake manifold on the drivers side of the engine bay With the plug disconnected start the car and again pay attention to how the engine idles and how it responds when the engine is revved up If there is very little change in the way the engine runs or if the engine runs worse then the sensor is probably not the problem However if the engine seems to run better with the plug disconnected then the AMM is most likely toast In some cases where the sensor has completely failed it is pos sible to unplug the connector which puts the engine in Limp Home Mode and will allow the car to be driven a short distance Driv ing for very long in this mode though could do some damage to the engine such as dis cussed above Jectron Fuel Injection Cleaner Formulated specifically with the K jet CIS injection in mind as used on the 1974 85 Vol VOS Cleans the fuel distributor and injectors to improve starting idle throttle resoonse and mileage Due to improved injection pattern and more
20. iginal manual transmission was mated to the DC motor with an adaptor plate from EV America The clutch was removed the shifting of the car is now done without a Continued on page 3 Gi T h Swap Mest CEIA May 16 2009 Gates open at 8 00am Annual ipd Garage Sale May 16 2009 is when the 26th Annual ipd Garage Sale Swap Meet and Car Show will take place We look forward to this event each year and we re excited to have games prizes giveaways sale pricing on most of our stock and much more Doors will open to the ipd sales desk from 9 00am until 1 00pm and the swap meet and car show has been extended to run until 3 00pm We hope to see you here for this great event Garage Sale is 9 00am to 3 00pm Saturday M ay 16th F or more information on displaying your Volvo or to reserve a swap meet spot call 800 444 6473 or e mail our show coordinator Bud Cowgill at rcowgi ipdusa com By Cameron Daline good deal has changed since Ar last project update have received several packages in the mail lately including one from SHS Perfor mance www shsperformance no contain ing the amazing lightweight adjustable cam gears high flow billet aluminum fuel rail bil let water pump pulley and light weight alu minum auxiliary shaft pulley all in matching anodized blue Efficiency and adjustability is the name of the game here with lighter weight rotating components which will free up that much more tire smok
21. ing power for the engine and adjustability in the cams to eek out every last nano horsepower avail able The fuel rail should open up the bottle neck previously inline with the fuel system and make sure that don t run out of the good juice also received the billet aluminum 16v timing belt tensioner adapter plate from ipd customer Robert Foltz This piece allows me to use the stock b230 style timing belt tensioner but locates it and the auxiliary roller bearing in the proper place and allows the use of an 850 timing belt The beauti ful UPS man brought my lightened and balanced down to 21 pounds flywheel to the door from Knox motorsports www knoxmotorsports us along with a match balanced SPEC Clutch stage Ill pressure plate and custom built clutch disk The disk uses a BMW center section to mate up to the splines on the BMW Getrag transmis sion and a Volvo sized 6 puck racing disk utilizing a high performance carbon copper ceramic friction material Finally picked up the killer stainless steel header from Jonathan over at RSI It utilizes equal length runners for optimum cylinder evacuation and pulse paired technology which helps to even out the pulses from the cylinder head All this plumbed into a twin scroll t 3 turbo flange which when mated to the GT32 turbo just ordered should signifi cantly increase the rate of boost spool up and overall flow There are still several details to take care of on thi
22. ll the fasteners to 20Ibft or you ll have noises coming from under your feet am very happy with them hard braking is met with less nose dive installed the upper CHASSIS not strut tower brace along with these and love the added stiffness to the chassis Rough roads speed bump and driveway curbs feel have been all smoothed out by this upgrade Aside from Turbo swaybars my 245 has a fully stock suspension Even is you re not going to all out performance these are great for making any road easier to drive on Road noise has been cut down alot too due to the chassis not flexing with every bump or uneven surface ipdusa com 800 444 6473
23. m rear MASA 348 00 brick These especially aided in my lowered 242 700 sedans w 4 cylinder non Tubo 1983 86 25mm front 25 mm rear MSS 328 00 efe a ra Srila a E 700 sedans w 6 cylinder non Turbo 1983 87 25mm front 25 mm rear M amp S 328 00 struts There was a night and day difference in 700 sedans w 4 cyl 1987 93 turbo 83 91 25mm front 25 mm rear M ASW3 328 00 handling and much more confidence GET UM 700 wagons 1983 87 25mm front 25 mm rear MASB 368 00 700 wagons w 4 cyl amp Turbo 1988 92 25mm front 25 mm rear Maco 368 00 From Sebastian in New York City 940 sedans w 4 cyl not for SE models 1991 95 25mm front 25 mm rear Macs 328 00 installed the 25mm front and rear ipd swaybars 940 wagons w 4 cyl 1991 95 25mm front 25 mm rear MSM 368 00 bigger is better along with Koni yellow sport 960wagons 1992 00 motre MASB 636800 wagons 1997 94 25mm front 25 mm rear MASB 368 00 struts and shocks This combination turned out to be the ultimate handling package for my non turbo 1987 240DL Literally they have been a real life saver on three different road trips Factory Reproduction Chassis Braces Volvo has offered chassis braces on some GT and European per formance models in the past and we have reproduced them for the budget minded enthusiast Simple firewall to strut housing braces and lower tie bars work to effectively reduce unwanted flex and improve handling response Easy installation in about 30 minutes
24. njection 240 models 1982 93 all 700 and 900 models and all models 1993 and newer K J etronic Fuel Mixture Adjusting Tool Now you can easily adjust the fuel mixture on your K Jet equipped Volvo Over time the fuel mixture can drift out of adjustment causing a decrease in mileage performance and hard starting With the proper manual you can set the mixture for optimum economy and performance Be sure to check for vacuum leaks before making any adjustments right for rich left for lean 200 series non turbo 1974 85 M713256 4 50 ea 200 series turbo 1981 85 M4630 4 00 ea Anti Friction Engine Treatment When a customer tipped us on this product we were admittedly skeptical But after using it in a number of different cars we thought it was great It forms a friction and wear reducing moly film on all internal moving surfaces of the en gine Engines can actually run smoother quieter cooler and more reliably with an extra measure of protection under extreme operating conditions and cold start situations And it mixes with all motor oils even modern synthetics It really does quiet down the engine and make it run smoother Simply add one can to your engine each time you do an oil change for best results Anti friction engine treatment MIMOO 6 97 SALE 6 27 Ventil Sauber Valve Cleaner This gasoline additive removes carbon deposits from valves and combustion chambers especially important in the mid 1980s LH injection cars that
25. osening solder joints internally and causing intermittent contact It sometimes melts the circuit board After you check for spark consider the fuel pump relay as a possible problem area 240 260 series B21 B21FT B27 amp B28 1978 85 fuel pump relay K Jet only IML1349600 1 61 43 ea 240 series B21 B23 1982 84 fuel pump relay LH jet 2 req MLI348657 2 15 50 ea 240 740 940 series 1985 95 fuel pump relay IML3523608 3 43 14 ea 760 760 series turbo 1988 90 fuel pump relay M1362914 42 00 ea 100 900 series auxiliary suppression relay M1322502 22 80 ea 940 series turbo 1991 fuel pump relay M1362914 42 00 ea 960 series 1992 93 fuel pump relay M1362914 42 00 ea 1 Not for 1983 84 with LH jet 2 Two relays on B23 1983 84 LH jet one for main system and one for fuel pump 3 Not for 1988 and later 760 turbos or V6 models or 1991 SE models Bosch Fuel Injection and Engine Management One of our favorite books when it comes to understanding fuel injection on Volvo models manufactured from 1970 to 1998 Packed with original Bosch diagrams and photos this reference guide is considered required reading for anyone who is interested in understand ing and working on the complex injection systems used in Volvo cars Includes comprehen sive coverage of theory and operation troubleshooting diagnosis and test procedures with specifications and a large section on performance issues Close to 200 pages Bosch fuel injection manual M009
26. r damaged spark plug hole threads you can now make a quick professional repair in minutes without removing the cylinder head Kit includes everything needed to permanently repair 2 spark plug holes Works on all B21 B23 and B230 engines Remember that you can reduce the chances of this happening by using a small amount of anti seize compound on the spark plug threads every time the plugs are replaced Kit contains 1 specialized reamer tap 2 thread inserts and locking compound 1976 95 Volvo 4 cyl M3414 39 00 2 pack of extra thread inserts MAIM 5 34 NGK and Bosch Spark Plugs The first suspect in a poor performing engine always seems to be the plugs On overhead cam engines one should expect about 30k miles but as these are getting older they are wearing out sooner too Contaminants such as oil and incorrect fuel mix will shorten the life of a plug dramatically We have been using and selling NGK spark plugs since the seventies because they re the leaders in copper core technology Copper is a great conductor of electricity and heat so copper spark plugs perform well under all extremes and have a large conductor tip for maximum spark area 4 cylinder non turbo 1976 93 MEP S NGK spark plug 1 95 ea 4 cylinder non turbo 1976 93 MMLBPRGES NGK resistor spark plug 1 95 ea Mm turbo 4 cylinder all 1981 93 MLBP7ES NGK spark plug 1 95 ea I turbo 4 cylinder all 1981 93 MLBPR7ES NGK resistor spark plug 1 95 ea 960 series 90 199
27. s project as well as some custom fabrication test fitting and final assembly For example still need to spec a proper shifter for the Getrag transmission and modify the driveshaft to properly mate up to the rear of the Getrag output shaft The transmission cross member needs to have some brack ets welded onio it to fit a transmission mount and properly set the angle of the drivetrain And then there is the wiring and tuning of the engine management system gulp ft ipdusa com 800 444 6473 Update on Cameron s 16V Turbo Wagon Project Nuke performance parts from SHS Performance Lightened and blanced LH2 4 flywheel Continued from page 1 clutch It is not a difficult process once you get the hang of it Mostly just use 2nd and 3rd gears The mount on the motor came from EV America it was made for an S10 pickup had a sheetmetal company in Santa Clara CA called Pega Precision make me the 1 4 plate steel mounts which got me from the mount on the motor to the mount on the car ipd sold me new rubber motor mounts So from the frame of of the car it goes Volvo metal mount Volvo rubber mount Volvo metal mount fabricated mount S10 electric motor mount motor Also from ipd got the sway bar kit for front and back sway bars the beefier rear springs and new rear shocks There is a variable resistor box with a place to attach the throttle cable mounted that on the drivers side in the engin
28. stant magnet withstands temperatures up to 500 F Simply attach it to the outside of your oil filter and let it do the work The super strong rare earth magnet begins working immediately to power clean your oil Your oil and your engine will continue to get cleaner month after month through normal driv ing and proper maintenance The permanent rare earth magnet will never wear out so you ll enjoy a lifetime of protection that goes far beyond conventional mechanical filtration Oil filter magnet ML20004 12 00 SALE 10 80 ipdusa com 800 444 6473 Symptoms Low pitched growling sounds especially in hot weather and when fuel level is low The car also may feel underpowered or even hesitate or misfire The sound will come from the main fuel pump located under the car just in front of the driver s side rear tire Pre Pump By Eric Mollerstuen Troubleshooting Try remov ing the fuse that provides pow er to it usually fuse 5 If the pre pump is functioning the idle should drop about 2 300 rpm when power is cut to the pump If the idle doesn t change the pre pump has probably failed You can also remove the gas cap and listen in the tank when the car is running for a slight humming sound Sometimes the pre pump hose inside the tank will crack or fall apart and this will show up as a poor running condition when the tank nears empty The best way to test the function of the pump is to re
29. to piston ring damage Once the unburnt fuel leaves the Air Mass Meter combustion chamber it can ignite once it comes in contact with the super hot turbo charger increasing temperatures dramati cally This in turn can damage the oxygen sensor as well as melt and plug up the core of the catalytic convertor hampering per formance and possibly damaging the turbo from too much backpressure Diagnosing Depending on which fuel system the car is operating on LH 2 2 LH 2 4 LH 3 1 the engine computer may turn on the check en gine light and store a fault code when the AMM fails This can be very helpful however there are several different fault codes that could indicate a bad sensor some of which may be misleading e 1 2 1 Fault in signal to from air mass meter e 2 2 1 Fuel system compensating for extremely rich or extremely lean air fuel mixture at cruise e 2 3 1 Fuel system compensating for rich or lean air fuel mixture at cruise e 2 3 2 Fuel system compensating for rich or lean air fuel mixture at idle e 3 2 2 Air mass meter hot wire burn off function not working Some of these codes could indicate a faulty oxygen sensor leaky or faulty fuel in jectors or even a vacuum leak So be careful not to assume the AMM right away If there are no fault codes stored and the check engine light doesn t come on there is a simple and pretty effective way of testing the function of the AMM First start t
30. uel gauge sender assembly on 240 and 260 models can be a tough job if you don t have the right tools The difficulty lies in safely removing the large bung nut where all the lines and wiring go into the top of the tank Believe it or not that s the official name for that style of nut It s a large ring with tabs that stick up at 60 degree intervals The problem with using a drift or punch and a hammer is that the top of the fuel tank is only 4 below the floor of the car and the access opening Is so small that you can t get much of an angle to properly engage the tabs This causes the tabs to bend over making it hard to reinstall And if you ever need to open it again it s so mutilated that it s even more difficult if not impossible to remove Our bung nut tool has interlocking tabs that positively engage the bung nut tabs allowing the bung nut to be removed with a 1 4 turn of a 3 8 ratchet The right tool makes this job go much smoother and prevents the bung nut from being damaged No cussing no damage and more important no sparks from hammering steel on steel hence no unexpected loud violent explosions Please note that any time the fuel tank sender assembly is opened the rubber seal ring should be replaced for safety reasons 240 260 series 1978 93 fuel tank bung nut too M5169 24 00 SALE 21 60 Fuel Pump Relays A common failure causing a no start situation is the fuel pump relay The relay overheats over time lo
31. ug in by a soda machine at a minimall There is an accessory battery which got from the local pick n pull It runs the lights wipers brake vacuum pump and the control voltage for the contactors and fans for the electrical components charge it separately with a 12 V charger When need warmth use a hat To legalize it had to go to the Cal DMV First they sent me to the smog referee Once the smog people had verified that it was all electric went back to the DMV and got it legalized If go back one more time can get a carpool lane sticker for the evolvo My daily driver is still a 1990 240 wagon but as the weather gets warmer and the day light gets longer plan to drive the evolvo to work more until hopefully soon it is the daily driver Supposedly if am careful with the battery pack it will be good for 20 000 miles In 2 years ideally the prices on lighter more exotic batteries like lithium ion will come down Results e Range 35 miles between charges e 6 hours to completely charge 12 12V batteries e Total cost to charge 1 32 e Top speed 55 mph e Total time from getting donor car until running all electric 14 months e Total cost for conversion 8000 M ajor tools needed e Engine hoist for removing old engine installing new motor installing batter ies 82 lbs each e Band saw e Drill press e Hand drill e Voltmeter e Crimper tool for battery cables Sources http www ev ameri
32. ump LH J etronic non turbo 164 31 ea M61468 main pump LH non turbo 164 31 ea M6145 main pump LH with turbo 154 39 ea M3507736 in tank main pump ignition coil is square 149 95 ea ML71036 3 x 4 long 2 1 8 x 4 1 8 long Fuel Filters How long has it been since the fuel filter on your Volvo was changed If you re not sure it would be a good idea to replace it at your next oil change or tune up to prevent loss of performance or related problems Under normal conditions it s safe to replace the fuel filter at 30 000 miles or 2 year intervals When changing the filter it is very important to use safe handling procedures and be prepared for fuel spillage Consult the appropriate workshop manual for specifics To ensure a leak free installation always install new copper sealing washers included with most of our filters Also keep in mind that any foreign debris in the output side of the filter or fuel line could cause serious problems in the fuel system It is very important to measure your fuel filter on 1975 80 240 series It s the only way to be sure to get the correct one 200 series 1975 80 K Jet 2 1 8 x4 1 8 long M71Q20 10 08 200 series 1975 80 K Jet 3 x4 long M71 6 19 04 200 700 900 series 1981 97 All gas K amp LH Jet 3 1 8 x4 7 8 long M7089 11 70 200 700 900 series 1977 95 All in tank prepump filter sock MIZE 9 03 Fuel Tank Bung Nut Tool Accessing the pre pump and f
33. was a challenge When considering adding 1000 Ibs of batteries to a car the structural integrity of Volvos make them great candidates for electric conversion have owned 5 Volvos and bought parts for all of them at ipd over the years decided the platform for my con version should be a 240 First purchased a donor car found a 1978 Volvo with a blown engine on craigslist for 150 It had a manual transmission and manual steering would have preferred manual brakes but all 240s had power brakes In ret rospect 4 wheel disc brakes and power brakes are good for stopping a car that ended up 500 Ibs heavier than stock after the electric conversion If you get a car with manual steering you don t have to worry about what will spin the power steering pump Every conversion have seen requires a man ual transmission The coupler and adap tor plate got used the existing manual transmission sent the clutch plate to a machine shop and they mounted the coupler right to it got a 12 V electric vacuum pump on ebay which supplies vacuum for the brake booster My brake booster turned out to be leaky so got another one from the Pick n Pull in San Jose The replacement booster works great After towing the car home started re moving things from the donor car first the radiator then the exhaust then the engine The first new thing put into the car was the 9 inch dc electric motor from Ad vanced Electric DC motors The or
34. with common hand tools and included hardware and instructions A 240 260 series 1979 93 upper tie bars MLIMO 69 95 SALE 62 95 B 240 series All lower chassis te bars MLI350 69 95 SALE 62 95 C 700 940 series upto1995 lower chassis brace M66 59 95 SALE 53 95 ipdusa com 800 444 6473 Truss Design Brace Kits by Cherry Turbo Incredibly strong trussed and triangulated chassis brace kits for 240 700 and 940 series Volvos They are generally recognized by Volvo performance enthu siasts as the most effective at eliminating unwanted chassis flex Constructed of cold rolled steel and powder coated for extremely high strength and a superior finish For best results you should install the upper and lower braces as they are designed as a system AIB 240 series upper lower kit M45 1 2 219 95 SALE 197 95 240 series upper brace MK2483 1 169 95 SALE 152 95 B 240 series lower brace MK1353 2 69 95 SALE 62 95 VD 700 940 series upper lower kit MK7496 249 95 SALE 224 95 C 700 940 series upper brace MK7483 169 95 SALE 152 95 D 100 940 series lower brace M6 99 95 SALE 89 95 1 The upper 240 brace will not fit on cars with the early flat style hood 1975 81 Call for details or visit our website 2 Lower brace may require drilling 1353 Reviewed by Tom Crowells from NE Portland Great product Use patience if you need to drill It took less then 1 hr to install Its very important that you torque a
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