The Hacky Throttle Repair That Got Me On The Road Again

Old cars are great. For the nostalgia-obsessed like myself, getting into an old car is like sitting in a living, breathing representation of another time. They also happen to come with their fair share of problems. As the owner of two cars which are nearing their 30th birthdays, you start to face issues that you’d never encounter on a younger automobile. The worst offender of all is plastics. Whether in the interior or in the engine bay, after many years of exposure to the elements, parts become brittle and will crack, snap and shatter at the slightest provocation.

You also get stuck bolts. This was the initial cause of frustration with my Volvo 740 Turbo on a cold Sunday afternoon in May. As I tried in vain to free the fuel rail from its fittings, I tossed a spanner in frustration and I gave up any hope of completing, or indeed, starting the job that day. As I went to move the car back into the driveway, I quickly noticed a new problem. The accelerator was doing approximately nothing. Popping the hood, found the problem and shook my head in resignation. A Volvo 740 Turbo is fitted with a ball-jointed linkage which connects the accelerator cable to the throttle body itself. In my angst, the flying spanner had hit the throttle body and snapped the linkage’s plastic clips. It was at this point that I stormed off, cursing the car that has given me so much trouble over the past year.

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Lazy Hacker Checks Fuel System for Leaks, The Easy Way

Old cars are great. They represent a different time, reflecting the state of society at the point of their design and manufacture, and can charm and delight while also providing useful transport. Except, well… old cars are great, except when they’re not.

With my Volvo 740 hitting its thirtieth birthday and cresting over 200,000 miles, to say its a little worse for wear is an understatement. The turbo dadwagon has suffered transmission issues, and cold starting woes… but most frustrating is the sudden spike in fuel use. After some work, my humble daily driver had slid from using an acceptable 21 miles per gallon, to getting just 15. Add on the fact that the turbocharged engine demands premium fuel, and you can understand my consternation.

Now that I was haemorrhaging cash on a gargantuan weekly fuel bill, I had plenty of motivation to track down the problem. Busy, and eager for a quick solution, I deferred to a mechanic recommended as the local expert in all things Volvo. Sadly, the results were inconclusive — initial appearances were that all the engine’s electronic controls were functioning to specifications, and I was told that it was “probably a bad batch of fuel”.

Unfortunately, several expensive tanks later, sourced from all over town, revealed that the problem was in fact real. With a supposedly reliable report that the fuel mixture was correct, thus ruling out culprits like the oxygen sensor, I began to wonder, was I simply pouring fuel out the tank?

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Volvo Trucks: Kid Tested, Mother Approved

If that looks like a four year old with a remote control driving a full-size dump truck — that’s because it is. As part of their Live Test Series, Volvo made a ridiculous obstacle course, and then let a four year old take the wheel of one of their heavy duty dump trucks. Viral advertising maybe — but too awesome not to share.

And don’t worry, there is a hack involved! The remote control setup in the truck isn’t that polished, and can’t possibly be a commercial “RC kit”. Which means some lucky hacker got to build a remote control system for a freaking dump truck. Consider us jealous.

Surprisingly (or maybe not), the truck seems to withstand everything the four year old throws at it. Including rolling it sideways down a hill, and of course smashing through an entire building. It’s well worth the watch and had us grinning from ear to ear.

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Tricking an Ancient Protocol To Play Tunes

A lot of technological milestones were reached in 2007. The first iPhone, for example, was released that January, and New Horizons passed Jupiter later on that year. But even with all of these amazing achievements, Volvo still wasn’t putting auxiliary inputs on the stereo systems in their cars. They did have antiquated ports in their head units though, and [Kalle] went about engineering this connector to accommodate an auxiliary input.

The connector in question is an 8-pin DIN in the back, which in the days of yore (almost eight years ago) would have been used for a CD changer. Since CDs are old news now, [Kalle] made use of this feature for the hack. The first hurdle was that the CD changer isn’t selectable from the menu unless the head unit confirms that there’s something there. [Kalle] used an Arduino Nano to fool the head unit by simulating the protocol that the CD changer would have used. From there, the left and right audio pins on the same connector were used to connect the auxiliary cable.

If you have a nearly-antique Volvo like [Kalle] that doesn’t have an aux input and you want to try something like this, the source code for the Arduino is available on the project page. Of course, if you don’t have a Volvo, there are many other ways to go about hacking an auxiliary input into various other devices, like an 80s boombox or the ribbon cable on a regular CD player. Things don’t always go smoothly, though, so there are a few nonstandard options as well.

DIY iPhone Mount for a Volvo

[Seandavid010] recently purchased a 2004 Volvo. He really liked the car except for the fact that it was missing some more modern features. He didn’t come stock with any navigation system or Bluetooth capabilities. After adding Bluetooth functionality to the stock stereo himself, he realized he would need a secure location to place his iPhone. This would allow him to control the stereo or use the navigation functions with ease. He ended up building a custom iPhone mount in just a single afternoon.

The key to this project is that the Volvo has an empty pocket on the left side of the stereo. It’s an oddly shaped vertical pocket that doesn’t seem to have any real use. [Seandavid010] decided this would be the perfect place to mount his phone. The only problem was that he didn’t want to make any permanent changes to his car. This meant no drilling into the dash and no gluing.

[Seandavid010] started by lining the pocket with blue masking tape. He then added an additional lining of plastic wrap. All of this was to protect the dashboard from what was to come next. He filled about half of the pocket with epoxy putty. We’ve seen this stuff used before in a similar project. He left a small opening in the middle with a thick washer mounted perpendicular to the ground. The washer would provide a place for an off-the-shelf iPhone holder to mount onto. [Seandavid010] also placed a flat, wooden paint stirrer underneath the putty. This created a pocket that would allow him to route cables and adapters underneath this new mount.

After letting the epoxy putty cure for an hour, he removed the block from the pocket. The stick was then removed, and any gaps were filled in with putty. The whole block was trimmed and smooth down for a more streamlined look. Finally, it was painted over with some flat black spray paint to match the color of the dashboard. An aftermarket iPhone holder allows [Seandavid010] to mount his cell phone to this new bracket. The cell phone holder allows him to rotate the phone into portrait or landscape mode, and even is adjustable to accommodate different sized phones.

Raspberry Pi replaces a Volvo nav system

rpi-replaces-volvo-nav

[Reinis] has a Volvo S80. One of the dashboard features it includes is a 6.5″ LCD screen which periscopes up to use as a navigation system. The problem is that Volvo stopped making maps for it around five years ago and there are no maps at all for Latvia where he lives. So it’s worthless… to you’re average driver. But [Reinis] is fixing it on his own by replacing the system with a Raspberry Pi.

That link leads to his project overview page. But he’s already posted follow-ups on hardware design and initial testing. He’s basing the design around a Raspberry Pi board, but that doesn’t have all the hardware it needs to communicate with the car’s systems. For this he designed his own shield that uses an ATmega328 along with a CAN controller and CAN transceiver. The latter two chips patch into the CAN bus on the car’s On Board Diagnostic system. We didn’t see much about the wiring, but the overview post mentions that the screen takes RGB or Composite inputs so he must be running a composite video cable from the trunk to the dashboard.

 

Car computer requires PIN for ignition

[Ben’s] added some nice goodies to his Volvo in the form of an in-dash computer. The system monitors two pressure sensors for boost and vacuum, as well as reading RPM, O2, and exhaust directly. All of this is tied into the touch interface running on an eeePC 900A. But our favorite feature is that the system requires you to enter a PIN to start the ignition. The forum post linked above is short on details so we asked [Ben] if he could tell us more. Join us after the break for a demonstration video as well as [Ben’s] rundown on the system.

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