850R - Seat Restoration

Well, more like an attempt at seat salvaging.

To be honest, there is no way to restore alcantara seats that are 20+ years old. That many years have taken a decent toll on the seats on the 850, as you may have seen they have significant matting of the seat material, as well as a significant rip in the lower drivers seat bolster. The only real fix is to have the seats re-upholstered but on our limited budget that is simply not possible. For this restoration project I tried to see what I can do as cheaply as possible with tools I already had. One of my ideas was to use my Conair Fabric Defuzzer, which can be purchased on Amazon for $12. Its mostly used for clothing, but in practice it seems to remove matted pieces of alcantara from the seats.

The section on the left is after being run over by the defuzzer, and the section on the right (the center piece of the seat) is what the rest of the seat looks like.

Left side after, right side before.

While the material will never look new, I am still happy with the results. From a distance the seats look much better, and this process only took me around 20 minutes to cover both front seats with multiple passes. After this I used Griots interior cleaner on the fresh sections, but the affect was minimal.

All of this begs the question "Who the fuck bought a Volvo wagon and decided that suede / alcantara was the best choice of seat material!?" If the car had been garaged all of its life maybe it would have been ok, but this car was being used constantly as a family hauler and daily driver for almost all of its life. By some miracle the rear seats are almost perfect, and god bless the fact that the steering wheel, armrest, and headliner arent made of the stuff.

850R - Better and Brighter Tail Light Installation

The greatest enemy when working on an older car is time itself. Over time things like rubber and plastic degrade due to exposure to the elements, its just something you cant control. I ran into this issue originally when removing the new taillights that we had purchased from LKQ Greensboro. The 850 Estate that I removed them from had dry, cracking, rear trim. I had hoped that this was a isolated case, but when I went to install the new lights on the 850R I found that the rear plastic on our car was also in a sad state of brittleness. This discovery did not hamper the installation, however I had to take extra care to remove the panel clips and make sure the plastic wasn't being stressed. Unfortunately in this installation I ended up cracking one of the rear speaker grilles.

Removal and installation of the tail lights is a simple process, needing only an 8mm socket, and extension, a small ratchet, and some thin hands. The upper light pieces are very easy to remove, as both of the 8mm bolts are unobstructed by any trim panels or wires, and this piece can be removed only be removing the rear tweeter cover.

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The D pillar cleaned up after removing the upper light assembally.

On the 850 wagon the lower tail light assembly is where the real fun stuff is. To get the the bolts holding the lower section, almost all of the trim pieces around the rear hatch need to be moved. On the drivers side I had a much easier time with this process as many of the clips were already broken or moved already. (I am assuming this is from one of the many rear repairs done by the dealer at some point). To get to these bolts you will certainly need a ratchet extension and some thin hands. Almost all of these bolts you will need to put on and off using your hand so that they do not fall down into the abyss below the light assembly. To make matter worse, the light harness that comes out has a much shorter loom length than the upper light, making it much harder to move it out of the way when trying to grab a bolt.

The new light with the red corner piece installed vs the old piece.

The lower light removed from the drivers side. A lot of junk has built up behind these over the years!

One thing I have to say is that being able to work on a junkyard car before your own is a great learning experience. This process is pretty straight forward, but knowing what tools I needed, and how the lights were attached before hand took out any guess work I had to do when swapping the housings out. The passenger side took me a bit more time as one of the panels that I easily removed on the drivers side was being very stubborn and required me to blindly undo a bolt using my hand instead of the socket. For this job I really recommend that you purchase a magnet-snake tool that can grab any bolts that may fall down into the car during this project.

A comparison shot: new on the left, old on the right.

Overall the project took less than an hour. Even someone with little mechanical skill can get this done. Unfortunately by the time I finished it was already getting dark so the final shots do not accurately show the progression from old to new.

As a note, I would like to mention this will probably be the last update on the 850R until January when Steve and I return from our college winter break. Hopefully then we will be able to work on installing the exhaust as well as the new intake manifold. Do worry though, updates on my personal vehicle (my 2012 S60 R Design) will still be coming over the break. Have a happy holidays!

850R - Junkyard Pulls for Performance & New Rear Lights

As the weather in North Carolina has started its harsh descent into winter, progress has gotten slower on the 850R. Many of the projects still left on the car are either too time consuming, or require a professionals touch (like the interior headliner). We have started working on acquiring parts for a performance upgrade that should give the 850R a bit more power. This process involves using an intake manifold from a naturally aspirated 850, and the throttle body off of a 960. As luck would have it, our local LKQ had both of these cars in (well actually we already knew that from when we had to get the new caliper). Removing the parts was easy, and while Steve and Andrew set about on removing the intake from the 850 wagon, I began the process of removing the tail lights to replace the old, beaten, faded tail lights currently installed on our 850R.

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The rear of the 855 after removing the tail lights.

Removing the intake from the 850 was a standard affair, and while I did not take part in the removal, the process only took about 20-30 minutes. The use of an extremely lengthened wrench was needed to remove some trick bolts, however with the tool kits we brought along we had no issue getting each bolt out.

The naturally aspirated 850 features a larger, higher bore, intake manifold allowing for better airflow over the stock turbo intake manifold.

Working on removing the pieces around the intake manifold for removal.

Our haul of parts from the 850. We are also able to take the ECUs from the engine bay.

With all the parts collected, we moved on to the Volvo 960 that was also in the yard. Thankfully for us the car was only 1 row over, and was almost completely untouched. On this car the only part that we needed was the throttle body. The throttle body from the 960s 6cyl engine has a larger diameter inlet, and will allow us to increase airflow. This increase in air flow from both the new throttle body and intake manifold will create a good starting point for a performance tune on our 850Rs engine. The one down side of this modification will be the need to have the car dyno tuned to properly match the air/fuel ratio. If we can not achieve this, expect to see these parts in the Volvo Parts section of the website!

Steve and Andrew working on removing the throttle body from the 960. 

With the warm patch of weather we should be able to install the new tail lights and interior trim pieces. Stay tuned as we continue to build and work on this amazing project!