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91 940SE aka Project Tweek
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skunked Offline
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91 940SE aka Project Tweek
Couple months back my Uncle mentioned that he had a Volvo in the yard on lien and asked if I wanted it before it was scrapped. It was explained as "RWD, turbo 4cyl with leather that ran and drove fine". I figured what the hell, at least the motor is worth my time and I was in the market for a winter beater anyway.

Few weeks later on his way to Colorado he dropped off the car....... 1991 940SE

[Image: fresh%2520940%252001sm.jpg]
[Image: fresh%2520940%252002sm.jpg]
[Image: fresh%2520940%252003sm.jpg]
Trunk full of shit. Always interesting the story a car full of crap will tell.
[Image: fresh%2520940%252005sm.jpg]
[Image: fresh%2520940%252006sm.jpg]
[Image: fresh%2520940%252007sm.jpg]
[Image: fresh%2520940%252008sm.jpg]
[Image: fresh%2520940%252009sm.jpg]
[Image: fresh%2520940%252010sm.jpg]
[Image: fresh%2520940%252011sm.jpg]

Interior was absolutely nasty as hell dirty however the car only had 135K miles on it so that was a pleasant surprise.

I can't handle a nasty interior so I got to work ripping it out for a full detail.
[Image: fresh%2520940%252012sm.jpg]
[Image: fresh%2520940%252013sm.jpg]
[Image: fresh%2520940%252014sm.jpg]
Quick exterior scrub
[Image: fresh%2520940%252015sm.jpg]
Carpets cleaned and reinstalled with the drivers seat. Disregard the dash, hadn't got that far yet.
[Image: fresh%2520940%252016sm.jpg]
All back together with a new/old stereo installed and the new steering column
[Image: fresh%2520940%252017sm.jpg]
[Image: fresh%2520940%252018sm.jpg]

Some other things I've done:
New engine oil and filter
Installed K&N Air Filter
New Battery
New lamps all around
Installed Stereo
Installed new steering column (original was drilled out)
Clay Bar the paint (needs polishing)

The one thing that would make or break this vehicle was the smog inspection however it passed with flying colors over the weekend. It's now on daily duty, yesterday in the rain was fun......I think it has LSD or a locker in the rear.
[Image: fresh%2520940%252019sm.jpg]
[Image: fresh%2520940%252020sm.jpg]

Here is a list of stuff I need to find and or take care of (no particular order)
Drive-shaft wobble at 5-10mph (have a new center support carrier)
Tires or wheels and tires
Brakes (fronts are warped) and flush fluid
Replace tranny & diff fluid
LF Marker
eggcrate grill
S60 tail lights
Moar Lower (remove nivomats)
Exhaust (sounds like shit now)
Floor Mats
Tow Hitch
Driver door lock is not working
Drivers power seat controls
Blower is screaming
Brake pedal pad
Both front doors need speaker covers replaced
Install RR door trim

This is my first turbo car and my only other volvo besides the 142 so any other helpful suggestions or comments are welcome.


oh and the reason why this car is nicknamed tweak.....I found a couple bags of crystal in the car when I gutted the interior for detailing. Rolleyes

73 Volvo 142
10-23-2012 06:37 PM
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kampman Offline
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RE: 91 940SE aka Project Tweek
Wow, that improved a lot with the detail. I think it'd look super-classy if you put an eggcrate insert in the chrome grille surround-it'd flow a bit better with the rest of the trim on the car.
(This post was last modified: 10-23-2012 07:00 PM by kampman.)
10-23-2012 06:59 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
(10-23-2012 06:59 PM)kampman Wrote:  Wow, that improved a lot with the detail. I think it'd look super-classy if you put an eggcrate insert in the chrome grille surround-it'd flow a bit better with the rest of the trim on the car.

Thanks, it's getting better by the day in fact my wife wants to drive it now that it's cleaned up (she loves Volvo's).

I read about that grill combo somewhere else, probably a good idea given the chrome trim on the bumpers & doors. I just don't like the design of the grill that's on it now.

73 Volvo 142
10-23-2012 07:11 PM
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WindowsBreakerG4 Offline
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RE: 91 940SE aka Project Tweek
Those are really nice cars, and it's 406 blue it looks like. You scored on that! What was wrong with it?

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10-24-2012 02:18 AM
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blu92in99 Away
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RE: 91 940SE aka Project Tweek
Looks good Mat! One thing I noticed in the pics that I didn't see mentioned in the 'to do' list is turning the front strut mounts back around; they're backwards now (top of the strut should be towards the firewall, not pointing forward). The caster angle is way off with them the way they're oriented now.

Also judging by the allen-head tops of those strut inserts; they could be Bilstein HDs.

Stockton Blvd PnP had a couple 960s this past weekend, I bet you could find the tails you're looking for. Wink
10-24-2012 10:09 AM
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skunked Offline
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RE: 91 940SE aka Project Tweek
(10-24-2012 02:18 AM)WindowsBreakerG4 Wrote:  Those are really nice cars, and it's 406 blue it looks like. You scored on that! What was wrong with it?

Other than a dead battery the car ran and drove when I received it. It's a lien car from the tow yard, I think the PO was arrested and didn't have the funds to get it out of the yard.

(10-24-2012 10:09 AM)blu92in99 Wrote:  Looks good Mat! One thing I noticed in the pics that I didn't see mentioned in the 'to do' list is turning the front strut mounts back around; they're backwards now (top of the strut should be towards the firewall, not pointing forward). The caster angle is way off with them the way they're oriented now.

Also judging by the allen-head tops of those strut inserts; they could be Bilstein HDs.

Stockton Blvd PnP had a couple 960s this past weekend, I bet you could find the tails you're looking for. Wink

I had no idea about those struts being 180 out, that's the kinda stuff I don't know since I'm fairly unfamiliar with these cars. The tires have odd wear up front so this may be one reason for that. I'll head out to Stockton Blvd this weekend, thanks for the info.

What springs do you guys recommend for the front? I just need something a little stiffer and obviously shorter.

73 Volvo 142
10-24-2012 12:21 PM
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WindowsBreakerG4 Offline
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RE: 91 940SE aka Project Tweek
I'd cut a coil or a coil and maybe a coil and a half off and see how that does for ya. I'd also consider changing the struts at the same time. If you want it to turn in a bit better do the camber mod. The 960 braces are also a nice cheap upgrade.

Volvo Documents, a growing collection

Karl Buchka Wrote:Matching gasoline is the new matching numbers.

MIKEHOWELLS! Wrote:I think the underlying cause of this is allowing too many N/A users on the board.
10-24-2012 12:51 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
is it a lower chassis brace(s)?

any more info/links on the camber mod?

73 Volvo 142
10-24-2012 01:46 PM
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blu92in99 Away
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RE: 91 940SE aka Project Tweek
Yeah, either cut a coil off the fronts or see if you can pick up a pair of just the front springs (iPd, B&G, Jamex, etc). Since you have IRS out back you're either stuck with the Nivos or converting it to "normal" springs and altered shocks (iPd sells a conversion kit for this). Being a '91 though, you already have a rear swaybar (IRS gold right there!!), locking diff, and possibly a 24mm front swaybar. Score! Smile

The 960 x-member braces...look on TB for threads with pics of them. I have them on mine, and it's easy to describe (basically an L-shaped piece of steel that bolts in and boxes the lower control arm mount on the x-member). They cost about $5/set from PnP, if you don't just pocket them. It is by-far, THE best $5 upgrade you'll ever make on a 7/9.

Camber mod is essentially knocking the forward stud out of the strut mount, rotating the mount as far inward toward the engine as it will turn, then drilling a new hole in the mount for the stud and bolting it back in. There's an official Volvo document on it somewhere out there, as that was their solution for camber adjustments at the dealership back then.
10-24-2012 03:06 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
yes it has the bigger bars.

I want to use the car to tow my 14' fishing boat so I've been bouncing around different ideas with air shocks or maybe even some of those air bags that fit inside the coils.

these are the braces correct?

[Image: IMAG0155.jpg]


I'll add them to the list for this weekends JY roundup

73 Volvo 142
(This post was last modified: 10-24-2012 03:30 PM by skunked.)
10-24-2012 03:30 PM
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blu92in99 Away
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RE: 91 940SE aka Project Tweek
Yup, that's them!

Hang onto that rear swaybar, no IRS before '91 even got one, and the iPd IRS rear bar is only 1mm bigger (not to mention rarer than hen's teeth).

If you're going to use it for towing your 14' fishing boat (aluminum?), I hate to say it but I'd probably stick with the Nivos. The self leveling is nice when they're in good shape. Just my two cents.

I just remembered - Check the differential mount bushing located on the top of the diff housing. That one specifically likes to eat itself up and causes clunks from the rear on accel/decel. Thankfully it's only a ~$35 part.
10-24-2012 03:48 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
I have a clunk now....but it seems more like a clunking wobble. When I grab the driveshaft at the carrier support I can move it around so I ordered a new carrier. I'm going to check out that mount anyway.

The nivo's are tired. The boat is fiberglass but similar size/weight as your typical aluminum fishing boat with minimal tongue weight.

73 Volvo 142
(This post was last modified: 10-24-2012 05:31 PM by skunked.)
10-24-2012 04:08 PM
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miguel.760ti Offline
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RE: 91 940SE aka Project Tweek
Nice score

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'89 240dl - Non-running 240 #3 in krisverde's shop
10-25-2012 05:55 PM
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scottyd Offline
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RE: 91 940SE aka Project Tweek
(10-25-2012 05:55 PM)miguel.760ti Wrote:  Nice score

srsly

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10-26-2012 07:19 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
Scored at the local pick n pull today.
960 tail lights
960 lower braces
Passenger visor with light
E-fan and relay

Installed everything but the e-fan, I'll post some pics on Monday.

73 Volvo 142
10-27-2012 08:39 PM
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WindowsBreakerG4 Offline
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RE: 91 940SE aka Project Tweek
If you swap in a 954 ecu or something like that (I have an EGR 2.4 Turbo ECU) you can just straight up wire the fan controls in. That's what I did and just tied both to trigger the high. Fan rarely comes on with 2.4 it seems and the large late rad.

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Karl Buchka Wrote:Matching gasoline is the new matching numbers.

MIKEHOWELLS! Wrote:I think the underlying cause of this is allowing too many N/A users on the board.
10-28-2012 02:41 AM
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skunked Offline
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RE: 91 940SE aka Project Tweek
(10-28-2012 02:41 AM)WindowsBreakerG4 Wrote:  If you swap in a 954 ecu or something like that (I have an EGR 2.4 Turbo ECU) you can just straight up wire the fan controls in. That's what I did and just tied both to trigger the high. Fan rarely comes on with 2.4 it seems and the large late rad.

I'll have to look into this further, I thought I would use the existing switch on the radiator or use a T fitting with a switch off the lower hose.

Here are some pics from the weekend

The JY score
[Image: fresh%2520940%252021sm.jpg]
960 lower brackets after a run through the parts washer
[Image: fresh%2520940%252023sm.jpg]
[Image: fresh%2520940%252024sm.jpg]
and the new tails
[Image: fresh%2520940%252022sm.jpg]

I read several people talking about how much better the car handled with the braces, to be honest I was skeptical however I was really impressed with how much tighter it feels in the corners now.

73 Volvo 142
(This post was last modified: 10-29-2012 12:25 PM by skunked.)
10-29-2012 12:24 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
Question for you guys.....

I'm starting to notice a smell of exhaust under mild to hard acceleration in the cabin. Obviously some sort of exhaust leak, is there a common place on the manifold or turbo to look at?

73 Volvo 142
12-14-2012 07:10 PM
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WindowsBreakerG4 Offline
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RE: 91 940SE aka Project Tweek
90+ manifolds are known to crack on the back but I've never smelled one from there. Can you hear it leaking? I would look for a manifold gasket leak I think

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Karl Buchka Wrote:Matching gasoline is the new matching numbers.

MIKEHOWELLS! Wrote:I think the underlying cause of this is allowing too many N/A users on the board.
12-14-2012 09:08 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
(12-14-2012 09:08 PM)WindowsBreakerG4 Wrote:  90+ manifolds are known to crack on the back but I've never smelled one from there. Can you hear it leaking? I would look for a manifold gasket leak I think

There is some noise from the top end but it sounds more like valvetrain. The head has paint marks on it from what appears to be a junkyard so it's been off and likely replaced at some point. I'll check the gaskets first.

73 Volvo 142
12-17-2012 05:27 PM
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WindowsBreakerG4 Offline
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RE: 91 940SE aka Project Tweek
I would suspect gasket or hole in the DP maybe

Volvo Documents, a growing collection

Karl Buchka Wrote:Matching gasoline is the new matching numbers.

MIKEHOWELLS! Wrote:I think the underlying cause of this is allowing too many N/A users on the board.
12-18-2012 01:11 AM
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dl242gt Offline
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RE: 91 940SE aka Project Tweek
A bad gasket from the manifold to the head will make a ticking sound which sounds like valve train but isn't. On a red block turbo it's a common place to leak.

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12-27-2012 04:32 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
Thanks for the info, I'm hoping to dig into this over the next week since the holidays are now over.

73 Volvo 142
01-03-2013 05:41 PM
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skunked Offline
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RE: 91 940SE aka Project Tweek
Some other projects have slowed down and the 940 sounds like a tractor so I tore into it tonight. One of the eight exhaust manifold bolts is tight therefore its safe to say the exhaust manifold gasket needs to be replaced. Is it possible to leave the turbo attached to the manifold and gain enough space to remove that gasket?

Also found a coolant leak which apears to either be the pump or the lower hose so I'm thinking it would be in my best interest to replace the T-belt, tensioner, water pump and coolant hoses. I assume I need to remove the crank pulley, is an impact the tool of choice there? I've done plenty of T-belts just not on a Volvo.

73 Volvo 142
02-13-2013 12:48 AM
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Shifted Offline
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RE: 91 940SE aka Project Tweek
Try to tighten first?

When that fails you should be able to do, after unbolting various bits; at least that was my experience on my 745t w/mitsu turbo, did the whole head job with the turbo on.

Re. h/b bolt, impact not recommended.

I use the rope trick, easy safe and fun.

Bullshitters have been keelhauled.
(This post was last modified: 02-13-2013 03:00 AM by Shifted.)
02-13-2013 02:58 AM
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