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940 GLE Auto Turbo system 900

posted by boatfury on Thu Feb 12 08:15 CST 2004
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I have just bought a volvo 940 GLE and everything seemed ok bar the lambda sensor light still on after i put a new one in, anyway i came accross a big hole in the air intake tube just after the air mass meter and just on the other sensor in the other tube, what is that sensor cause it needed a good clean it was nearly blocked. so i replaced the tube and she seems to have lost a lot of torque and occasionally seems to run erratic at low revs and stall. I`ve tried running her with the air mass meter disconected and she just stalls straight off. can anyone help.

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940 GLE Auto Turbo system 900

posted by the kick inside on Thu Feb 12 09:26 CST 2004
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last visit: Thu May 17 09:58 CST 2007

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ok i PRESUME what you mean is that you have a tear in the air intake tube between the AMM and the breather tube fro mthe sump (the approx 3/4" tube runnign over the cyclinder head) I am presumeing that the sensor that is blocked is the sensor that this tube plugs onto that is sort of cast into the main intake tube....

the sensor is temp sensor i believe and i have certainly manually cleaned it out (aka drill bit held in my hand - NOT IN A DRILL -) to ream it out (from memory its about 10mm. if the sensor is blocked you can bet that the whole tube needs cleaning out and you need a new flame trap/breather box assembly (see faq!)

now any tears i nyour turbo duct work wil lcause the mixture to be crap..so get them sorted - that duct work needs to be AIRTIGHT...I am told you can effect good temporary repairs be thoughrly degreasing and duct taping....

basic stuff to do..(see faq)

1. breather box
2. flame trap
3. Clean out hose between flame trap and intake hose
4. Clean/replace hose from flame trap to manafold
5. Clean manafold nipple for hose at 4.
6. clean ALL the turbo duct work out
7. make sure ALL the turbo hoses are airtight
8. clean out throttle body...
9. Repalce airfilter unless you already have done
10. remove foam from inside of top of airbox and check AMM hasnt been blocked with it....

once you have done that..well if its still on then you have an issue and i highly recomend reading the faq...

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940 GLE Auto Turbo system 900

posted by boatfury on Thu Feb 12 09:38 CST 2004
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YES thats the duct and I have replaced it, the bloody thing cost me �51. I have checked that the breather hose is clear, my concern was that the integral sensor that is made of copper was causing the problem. It is since i have cleaned the sensor and replaced the duct that i have gained the lack in torque at the higher revs.
I am also new to the site and do not know what faq`s are, pleasse help

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940 GLE Auto Turbo system 900

posted by the kick inside on Thu Feb 12 10:32 CST 2004
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last visit: Thu May 17 09:58 CST 2007

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go to where it says 'features' and under that drop down you will find the faq (Frequently Asked Questions) for a 700/900 these really should be renamed 'the bible according to steve' - if you need to know it --- its t here...

th lack of torque at high revs would tend to suggest to me you have air loss in the hoses, basically i think you will find that high revs is also high boost levels..if the hoses leak at high levels then the AMM reports an airflow, but not all of it gets to the engine and it runs horribly rich...(possible black smoke out of exhaust!)

finding holes in hoses can be VERY difficult..i suggest removeing ALL the air inlet hoses from the car and cleaning them with gunk or similar & water..whilst doing this you will tend to handle the hoses a lot and find any soft spots...

other issues that would cause it would be incorrectly adjusted waste gate and a blocked, or partially blocked exhaust....

also bear in mind the peak of the power curve on a b230 is about 4k...

now i suspect IF you have cured a issue with a leaking hose..what you could be now seeing is another issue like a low fuel pressure...

see the faq...and do the simple stuff first...as i previously detailed...
btwe whereabouts in the UK are you - im UK based too so you REALLY dont have to tell me about volvo dealer prices...(as i own 2 volvo's...)

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940 GLE Auto Turbo system 900

posted by boatfury on Thu Feb 12 10:42 CST 2004
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Thank`s kick, the sound of exaust blockage could well be the problem may be the cat hey. And thanks the faq is most helpful.

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940 GLE Auto Turbo system 900

posted by the kick inside on Thu Feb 12 10:52 CST 2004
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last visit: Thu May 17 09:58 CST 2007

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np...

hint, if u think it may be the cat there is a plug you can extract just before it...go for a drive..if its better (note not fixed but better!) that indicates a blocked pipe....

note it WILL be noisey!

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940 GLE Auto Turbo system 900

posted by boatfury on Sat Feb 14 07:12 CST 2004
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Cleaned the throttle body and still no joy. i definatly have no leaking hoses and for the life of me i can not find the plug in the exhaust.

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940 GLE Auto Turbo system 900

posted by the kick inside on Sat Feb 14 11:37 CST 2004
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last visit: Thu May 17 09:58 CST 2007

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its a small bolt head thing a couple of inches in front of the cat from memmory - probably covered in rust!...sort of a nipple sticking out of the side of the pipe...

if you still cant locate it you could always actually do a presure test on the exhaust...

1. acquire a sensitive vacume/presure guage (a cheap sorce is to buy a carburator balanceing kit as sold for motorbkies)
2. acquire a balancing kit adaptor for hondas (motorbikes) this should be a brass tube with an m5 thread on the end of it
3. aquire 6 feet of windscreen washer type tube that fits the guage and adaptor
4. aquire some very short m5 bolts
5. aquire an m5 tap...

now drill a m4.5 hole in the exhaust tube before the cat, then one before the mid box, then one before the back box..now plug the back 2 holes with the bolts and screw the adaptor in place before the cat, connect the tube to it and cable tie it in place so it routes into the car under the back door (DONT PINCH THER TUBE!)... now route it in the car to the passenger seat and plug the guage into it...

ok..now you go for a drive with a passenger watching the guage..while you FLOOR it into boost and HOLD it there (I did it at 3.5k rpm and 8lbs boost)..now you will need to do several runs wiht the passenger noting the readings...

now plug that hole and move the adaptor back t o the next hole and repeat and so forth...

Basically what your looking for is IF you get a pressure rise in the exhaust and if it is present in front of one componant but not after it...

so lets say you saw 5 PSI under boost before the cat but 1PSI after it...well your cats stuffed..btu if you saw 4psi before it and 3.5 psi after it...well its likely to be a componant failed later in the exhaust...

couple of words of warning...

1. let every thing cools down lots...dont want to get heat tube hot enough to melt...

2. leave a window open in case you get a leak fro mthe tube into the car...

3. DONT handle the brass adaptor immediately after a run it gets BLOODY HOT!

hope this helps

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940 GLE Auto Turbo system 900

posted by boatfury on Thu Feb 12 11:09 CST 2004
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Excellent i`ll give it a try, the exhaust is blowing white smoke is that a cat problem indication.

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940 GLE Auto Turbo system 900

posted by the kick inside on Thu Feb 12 11:23 CST 2004
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last visit: Thu May 17 09:58 CST 2007

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hmm possibly....if its soaked in unburnt fuel/oil perhaps...

normally WHITE smoke is either condensation drying out, or a coolant getting where it shouldnt....i.e. head gasket etc....could be oil i suppose, but that tends to be more grey than white (or black if theres enough of it!)

hows your coolant level? - does the smoke go away after a bit (like the exhaust drying out?)

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940 GLE Auto Turbo system 900

posted by boatfury on Thu Feb 12 11:27 CST 2004
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I do have a leak at the water pump i haven`t sorted yet, and yes the smoke clears after a few mins.
How difficult is the pump change?

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940 GLE Auto Turbo system 900

posted by the kick inside on Thu Feb 12 11:33 CST 2004
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last visit: Thu May 17 09:58 CST 2007

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see the faq....for the wate pump...not to bad i beleive (havent had to do mine...yet)

if it 'smokes' for the first maybe 2 miles (say 10 mins) then clears i bet its just water comming out of the exhaust....its suprising how long that can take!

Actually if it is doign a lot of that i would BET your exhaust is on the way..2 reaaons...1 all that water = internal rust & colapse...2 sounds like it might be taking the back box (where most of the water is held in the wadding) a while to heat up and clear (possible blockage?)

I repalced my entire exhaust in sections - started by havign the cara 'de cated' - legal in the uk if you are 91 or earlier...then did the rest myself ...cut the back box open for a laugh...it was completely collapsed inside but looked ok from outside...think the back vbox and mid box cost me about �100 third party, the de-cat cost about �70 inc having a cat bypass pipe manufactured...boy did it improve the 'go'

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