My Volvo 850 R Saloon

My Volvo 850 R Saloon

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Andysr

Original Poster:

106 posts

174 months

Saturday 4th September 2010
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For a while now during warm up I have noticed a slight whining noise from the power steering pump, at first I could get within 200-300 yards of the house and the noise would go. The said noise then not returning until the car was subject to another cold start after a period of a day or longer. However more recently this noise has become louder and more apparent often lasting for half a mile or so before relinquishing so with my impending Scotland road trip due the time came to renew the pump and a replacement new Volvo item was fitted



Thanks again Russ and team for this one, nice and quiet again :thumbs_up:

Andysr

Original Poster:

106 posts

174 months

Saturday 4th September 2010
quotequote all
Right this last one is me completely up to date now, it's a bit of a read but if your interested please do read on there are some pictures to look at as well....



Now the interesting part, my favourite part, and indeed the part that I know a few people have been wait to hear about,

For sometime now I have been suffering with a very intermittent boosting issue where the cars power delivery, between 3,200 and 4,100 rpm, becomes flat and uninteresting caused by an overboost fault. It has been a suspicion of mine, based on my experience of cars equipped with Mitsubishi turbo chargers, that the turbo itself was to blame but because it was so intermittent the fault was difficult to diagnose at the start of the fault to say the least. However just recently the overboost fault has become more apparent and indeed frustrating detracting from the enjoyment of the car so I it felt time to explore my theory. Especially when the car had started to develop a slight exhaust blow from the manifold area necessitating it’s and the turbo removal to aid inspection.



So off came the manifold and turbo….


It was clear when the manifold was free from the engine that the blow was caused purely by the breakdown of the manifold gasket specifically around the no.1 exhaust port. In the picture below you can see what I mean when I say breakdown….



At this time the turbo was checked to see if my suspicion was correct, indeed it was. Play had developed in the wastegate pivot bushing, the copper bushing which is pressed into the turbocharger exhaust housing had worn through use. As a direct result of the wear the actuator isn’t fully capable of maintaining a consistent boost level due to the wastegate sticking. This is very common on some other Mitsubishi turbo powered cars although not something I have read about or am aware of with the 15g’s and other Mitsubishi turbo equipped Volvo’s before now. It seemed a shame that the turbo had suffered with the excess wear because even at 100,000 miles the turbo internals still appear to be in good shape with no excess play in the shaft or oil consumption/blow by. Never the less I couldn’t have this turbo refitted in it’s current condition as the fault certainly wouldn’t self rectify.

Whilst the turbo was off Russ informed me that the exhaust manifolds can be prone to cracking and guess what mine had done…Yep here a few shots of the manifold outlet area where the turbo mounts.







As you can see the manifold has some minor cracks. If continued use was to occur no doubt some small parts of the manifold could have come away and embedded themselves into my turbo, potentially causing some severe damage to the workings of the turbo. So this left me with a dilemma what direction do I go in? Do I get the wastegate pivot bush replaced along with a seals and bearings rebuild, not necessary but when in Rome, do I source a good second-hand one and wing it, not really my style tbh or do I just fit a bigger turbo. At this point Kerry bought to my attention that TurboTechnics do fettle turbos for some Volvo cars. As luck would have it I have many dealings with TurboTechnics and after a call to a friend there it was all explained. By using the basic 15g Mitsubishi turbo they then machine the turbo to enable the fitting of a compressor wheel from a Garrett T28, along with their own in house uprated actuator and fitting a 360 degree screwed thrust bearing. This means the turbo is then suitable for applications requiring efficient boost levels between 14 and 22 psi and being as the turbo is still essentially a 15g it is a straight fit application.

So I ordered one….







Then I decided that I should really get a replacement manifold to prevent any possible damage to my newly purchased turbo as a result of the earlier mentioned cracking. So would you believe my shock when I found out that the, allegedly, more efficient flowing late V70R and S60R manifold is less to buy new than my original 850 manifold? No? Neither could I.
So I tested the water on a couple of forums for a good 2nd hand item but by the time I had factored in the cost of replacement gaskets etc it worked out more feasible for a new replacement from Volvo. Thanks for the help with that Simon @ FRF spot on job, he managed to get an excellent deal for the cost of the required manifold and gaskets very efficient service there.



So that was the turbo and manifold sorted. But what about the exhaust? I currently have the Ferrita catback system which I have been very pleased with but the Volvo front pipe and cat are inherently quite restrictive as standard and what a perfect compliment a sports cat and 3” downpipe would make to the new turbo and manifold. Now this was the worst and most delaying part of the whole thing, trying to find one. I waited for a while to see if I could source a decatted downpipe but unfortunately as time drew on I decided I didn’t really want to wait too much longer to get the car back. I tried to get either a decat or sport cat variant of the Ferrita downpipe but couldn’t source one anywhere and with Ferrita entering a holiday period I would have to wait for it to be made. I didn’t really know of any other good exhaust suppliers to help me. Russ suggested I looked to JT of Sweden as they do a variety of 3” exhaust downpipes from decatted to 100,200 and 300 cell sports high flow cats. I must confess I was reluctant to consider at first as I had always wanted to get the Ferrita but after doing a few video searches on Youtube and being able to hear Frobes T-5R, as he had recently fitted a JT complete system, at Modified Madness I was sold. Also thanks to Frobes for getting me in touch with JT’s owner whom was able to apply a little gesture of goodwill to the order. On advice from Russ and Mark Shead I decided to go for the JT 3” downpipe with a 200 cell high flow cat not wanting to complicate compatibility of the Ferrita system and JT downpipe I also opted for the complete JT 3” system. This was directly dispatched to Russ for him to heat wrap and fit on arrival, which was very speedy so thanks to JT for the great service. Before and during fitting Russ was able to take a few shots of how the system looked and indeed I was surprised at its size





although to start with I wasn’t too sure of the tailpipe….lol



Obviously as before I had the whole system from the turbo back wrapped, except the cat section



Due to the increase in exhaust bore this has meant I have lost my square tailpipe trim. Although to be honest I think the circular trim is growing on me and I like the way it fits the bumper recess and if all else fails I am sure I can always source a suitable trim if I decide I prefer the square look overall.





By this time I had got the bug to do a bit more to the car. Russ suggested a change of injector to go with the improved turbo and manifold setup to make sure the fuelling was sorted. Russ was able to source on my behalf a set of Bosch green injectors as fitted to an S60R, these injectors were as new and were surplus to the owners requirements so I had them for a very reasonable price. :thumbs_up:

This then left a problem. My car has a Rica which is an off the shelf unmappable item, an excellent upgrade up until now with the standard spec of the car but I wouldn’t be getting the best from my new upgrades unless I could tailor the map to suit. I could get an upgrade for this from Rica but what if I decided to do some more to the car in the future or wanted the very best from what I was doing. The idea of something more flexible was appealing. MTE obviously can be mapped but I understand the only guy who can do this doesn’t live in the UK and therefore isn’t available to do mapping at the drop of a hat. So Russ suggested I take a look at a TurboTuner ECU, for those unfamiliar basically it’s an original Volvo/Bosch ECU that has been modified to allow mapping by anyone with a PC or Laptop via USB. When you purchase the TurboTuner you are supplied with the required software to enable your PC/Laptop to interact with the TurboTuner.





Now I don’t have enough knowledge to entertain mapping a car to it’s full potential and being as Russ had I left it for him to decide how best to map the car. It was at this point that Mark Shead of M.A. Developments got directly involved, for those that don’t know Mark he is responsible for tuning the Sierra Cosworth that can crack over 200 mph. I had occasion a short while back to talk in depth with Mark about tuning and his knowledge blew me away so I thought it rude not to put his knowledge to good use, and he also mapped the Peril so seemed a sensible choice to do my lowly 850.

Well that's all done, I collected the car yesterday and I am absolutely over the moon with it. The exhaust sounds awesome the power delivery is incredible and the drive ability of the car is even better than it was before. So what about fuel consumption? Well here is a shot of the trip computer after 170 miles of keeping up with M25 traffic on a Sunday afternoon..



Obviously not D5 fuel economy but alot better than my PB of 32.1 when it was Rica'd.
Very many thanks to Russ and the RT team, Mark Shead, Kerry T-5R, Frobes and Simon @ FRF motors for all your involvement in this latest work I really can't express to you how happy I am with the car right now :thumbs_up:

I can't wait for my trip to Scotland to really see what she can do fuel consumption wise on a run. :thumbs_up:

So that's me up to date with the project, hopefully the next updates won't be so packed together.

Comments very welcome smile

Edited by Andysr on Saturday 4th September 14:08

macp

4,060 posts

184 months

Saturday 4th September 2010
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Fantastic read and I admire the fact that the mods done so far are very subtle.Well done that man clap

-crookedtail-

1,564 posts

191 months

Sunday 5th September 2010
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Thanks for taking the time to write this up, or at least copying it to this forum for us to read hehe

Enjoyed reading up the progress you've made on the 850 as it now looks amazing. I have always like them and its good to see someone with such a nice example dedicating so much effort to the cause!

Top marks mate, you've earnt yourself a virtual pint drink

Andysr

Original Poster:

106 posts

174 months

Wednesday 8th September 2010
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Thanks for your kind comments smile

RobCrezz

7,892 posts

209 months

Thursday 9th September 2010
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Wow its going really well. Will you get it on the rolling road to see what power it is doing now?

Andysr

Original Poster:

106 posts

174 months

Sunday 12th September 2010
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Hi Rob, thanks for your comments. Yes I do plan to get it rolling roaded soon, not sure when yet but probably within the next few months.

ilovevolvo

1,832 posts

225 months

Friday 1st October 2010
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Andysr said:
Hi Rob, thanks for your comments. Yes I do plan to get it rolling roaded soon, not sure when yet but probably within the next few months.
wink

Bigfatnath

815 posts

209 months

Saturday 2nd October 2010
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Must be the best condition, most looked after 850 r ive ever seen.

I used to see these in white with blue lights on the roof getting spanked down motorway slip roads years ago !.


Thanks for posting....A great read.

SonicHedgeHog

2,539 posts

183 months

Sunday 3rd October 2010
quotequote all
Looks terrific. Makes me want to go and buy a Volvo until I remember how much effort you have put into it. Worth every minute/penny though. Well done.

Welshbeef

49,633 posts

199 months

Sunday 3rd October 2010
quotequote all
Max M4X WW said:
Hi,

Volvo looks like a nice new toy, But..

Your Orion is one of my favourite Fords ever and I've spent ages looking at it at numerous shows!
shame you didn't perk up on my thread orion or
montego which is better. After tens of pages it was generally accepted the Orion was a shockingly bad car and that the Belmont was a far better car which in itself was a dire car.

Anyway OP question for you love the 850r but what's your end game? Guessing keep it for a few years then move on. The list of items needing doing plus the extras does really make me question why not buy a mint 850r one better looked after than doing all the work and possible a lot more cost than buying a better one? Why spend so much of your time with car in garage or planning next work than out enjoyng the car? Sure it's a rare beast but it's never going to be a classic so money and down drain spring to mind.

Still sped on whatever you want BUT I'm guessing you like the car and want to drive it so drive the thing.

MonkeyBusiness

3,937 posts

188 months

Sunday 3rd October 2010
quotequote all
What a great read. Fantastic car and a credit to you.
I love seeing projects like this where there is no way the owner will get the money back on the car - its done purely for the love of the car.

Great stuff.

cosworth330

1,300 posts

238 months

Sunday 3rd October 2010
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Just read through this thread, really good read. We used to have an 850R a long while back now but loved it so much after a couple of years the wife bought a 2yr old V70R (phase 3 the 300bhp one 03 plate) kept that for 4yrs. Now she has a V70 D5 R-Design about 18 months old now,she loves it.
I'm always looking at prices of 850R manuals as i keep thinking of buying one and modding it. I have a E39 M5 facelift which i've had for a year but wouldn't want to part with it for an 850R.
Mark Shead fitted a chip to one of my old Cossie's years ago,he was working out of his parents garage back then !
The quickest 850R i have been in is Elliotts red 850 saloon ( he's sometimes on T5D5 ) that is one quick 850. Also whent out to the Ring last year with some guys from T5D5 and Tim Williams took me for a lap in his white T5 estate, the driver of one of the V10 M5 ring taxis commented after the lap that he couldn't keep up with us ! Just to give you an idea of how quick you can make the 850 and handling/braking, Elliott was doing BTG at the Ring in around 8.10-8.30 constistantly in traffic !

Cheers Simon.

Welshbeef

49,633 posts

199 months

Sunday 3rd October 2010
quotequote all
Amazing fuel economy a 850r does not far off 40mpg yet focus st owners en mass struggle to get mid 20's what gives? Are they just hooners? Or is there a genuine fault with the st and economy which the Volvo overcomes??

jt racing

561 posts

175 months

Sunday 3rd October 2010
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Hey Andy, I have a 850 t5 running the absolute map and a few bits. Have been thinking about doing the heat wrap on the boost hoses for a while now... Did you notice any improvement with it? I did the exhaust a while back on the primera gt and it was a nice difference but just wondering how you found it.

jt racing

561 posts

175 months

Sunday 3rd October 2010
quotequote all
Hi, I have a 850 t5 running the absolute map and a few bits. Have been thinking about doing the heat wrap on the boost hoses for a while now... Did you notice any improvement with it? I did the exhaust a while back on the primera gt and it was a nice difference but just wondering how you found it.

Edited by jt racing on Sunday 3rd October 17:27

Stedman

7,226 posts

193 months

Sunday 3rd October 2010
quotequote all
Welshbeef said:
Amazing fuel economy a 850r does not far off 40mpg yet focus st owners en mass struggle to get mid 20's what gives? Are they just hooners? Or is there a genuine fault with the st and economy which the Volvo overcomes??
The 850/V70R engines are different to the FST (by the way).

I've found the 5 pot turbos not too bad on fuel on a run (40mpg sitting with traffic-OBC). I think Andys is so high as it's been tweaked with quite a big via his turbo tuner ECU.


cosworth330 said:
Cheers Simon.
Who are you on T5D5? smile

Andysr

Original Poster:

106 posts

174 months

Sunday 3rd October 2010
quotequote all
ilovevolvo said:
Andysr said:
Hi Rob, thanks for your comments. Yes I do plan to get it rolling roaded soon, not sure when yet but probably within the next few months.
wink
Get your finger out then wink

Andysr

Original Poster:

106 posts

174 months

Sunday 3rd October 2010
quotequote all
Bigfatnath said:
Must be the best condition, most looked after 850 r ive ever seen.

I used to see these in white with blue lights on the roof getting spanked down motorway slip roads years ago !.


Thanks for posting....A great read.
Cheers, It's not bad, thanks for your kind comments.

Andysr

Original Poster:

106 posts

174 months

Sunday 3rd October 2010
quotequote all
SonicHedgeHog said:
Looks terrific. Makes me want to go and buy a Volvo until I remember how much effort you have put into it. Worth every minute/penny though. Well done.
Cheers unfortunately, as with any older car some effort is required, unless of course your lucky to find one that has already had the effort put in. But they are few and far between these days as rarely people want to spend the money on an older car..

Welshbeef said:

Anyway OP question for you love the 850r but what's your end game? Guessing keep it for a few years then move on. The list of items needing doing plus the extras does really make me question why not buy a mint 850r one better looked after than doing all the work and possible a lot more cost than buying a better one? Why spend so much of your time with car in garage or planning next work than out enjoyng the car? Sure it's a rare beast but it's never going to be a classic so money and down drain spring to mind.

Still sped on whatever you want BUT I'm guessing you like the car and want to drive it so drive the thing.
Not really got an end game tbh bit of a blank canvas with no idea how it will end..
Unfortunately unlike the other more cult cars the Volvo’s tend to get used as family cars and driven, usually into kerbs and things, and if lucky somewhere along the line they get serviced. But that does usually mean they are very rarely low mileage and usually require some form of work especially as they are getting on a bit now. This one was the best I could find at the time it is for this model low mileage and had a good history. However like most older cars things surfaced after buying but I accept that and tbh never looked to make a profit on the car. I love driving the car but I also like everything to work, where some people can cope without the air conditioning not working I must have that sort of thing in good shape otherwise it just annoys me. Unluckily for me this attitude is an expensive one to have with cars but it looks like I am stuck with it.

In respect of driving the car I have now clocked it up to 104,000 miles which works out at 16,000 miles I have covered in the car, most of which I have enjoyed. Most recently I have completed a holiday trip to Scotland and back, details to follow, so it does get used despite the fact it has been off the road a few times in the last 3 years for various bits and pieces. Had the car have been mint factory condition I would have probably done less than half that, as I did in the Orion, for fear of ruining it again just the way I am..

MonkeyBusiness said:
What a great read. Fantastic car and a credit to you.
I love seeing projects like this where there is no way the owner will get the money back on the car - its done purely for the love of the car.

Great stuff.
Thanks for your kind comments, your right I doubt I would get a 1/4 of what I have put into it and it is purely done because I wanted to and I love the car.

cosworth330 said:
Just read through this thread, really good read. We used to have an 850R a long while back now but loved it so much after a couple of years the wife bought a 2yr old V70R (phase 3 the 300bhp one 03 plate) kept that for 4yrs. Now she has a V70 D5 R-Design about 18 months old now,she loves it.
I'm always looking at prices of 850R manuals as i keep thinking of buying one and modding it. I have a E39 M5 facelift which i've had for a year but wouldn't want to part with it for an 850R.
Mark Shead fitted a chip to one of my old Cossie's years ago,he was working out of his parents garage back then !
The quickest 850R i have been in is Elliotts red 850 saloon ( he's sometimes on T5D5 ) that is one quick 850. Also whent out to the Ring last year with some guys from T5D5 and Tim Williams took me for a lap in his white T5 estate, the driver of one of the V10 M5 ring taxis commented after the lap that he couldn't keep up with us ! Just to give you an idea of how quick you can make the 850 and handling/braking, Elliott was doing BTG at the Ring in around 8.10-8.30 constistantly in traffic !

Cheers Simon.
Hi Simon, Thanks for your kind comments, sounds like you have had some nice Volvo’s over the last few years.
I know that these 850’s can be transformed into really quick cars if you are prepared to go for it. Elliot’s car is well known on the Volvo scene and I have seen/heard about his achievements with the car and a 8.10 on the ring isn’t to be laughed at! I have also seen and heard about Tim’s car.

Welshbeef said:
Amazing fuel economy a 850r does not far off 40mpg yet focus st owners en mass struggle to get mid 20's what gives? Are they just hooners? Or is there a genuine fault with the st and economy which the Volvo overcomes??
Might be the way they drive the car, but as stated the engine in mine isn’t the same as the ST engine and being the 2.3 is actually a stronger unit if you want to go down the tuning route. Fuel consumption wise the computer isn’t 100 percent accurate I recently worked out my consumption when on holiday in Scotland and the car achieved 34 mpg overall but that was with luggage and 4 people so still very good but obviously not the 39 mpg that the computer is currently showing. However the consumption of the car is the best it has been since I have owned it which is probably as a result of being able to have the car live mapped meaning it can be setup specifically to give the best on this car, having said that it used to always achieve 27-28 mpg which still sounds better than the ST’s you mentioned.

jt racing said:
Hey Andy, I have a 850 t5 running the absolute map and a few bits. Have been thinking about doing the heat wrap on the boost hoses for a while now... Did you notice any improvement with it? I did the exhaust a while back on the primera gt and it was a nice difference but just wondering how you found it.
Couldn’t say if there was any improvement, I doubt there is much if any tbh. I did it because it was different to what everyone else does under the bonnet. Exhaust wise it’s just something I have always done as it deepens the sound of the exhaust and as a result I prefer the improved sound it gives and apparently it improves the performance but again I couldn’t say if it does this or not tbh but under bonnet heat does appear to have reduced since I have done it which must help for heat soak I guess..