1994 Volvo 480 Turbo : Restoration & Diary
Discussion
1994 Volvo 480 Turbo
Some of my other cars have been well received on here so I thought i'd "port" over my 480 journey from the 480 forum. Apologies to those members and the duplication if they are also PH readers.
It's a journey not yet completed even after 10 years. It's a story of woe, self torture and a test of will power. It's the struggle to proceed when you have long since crossed into vehicle negative equity. Throwing good money after bad based purely on nostalgia.
The last time the 480 Turbo got Shed of the Week was a while ago. 11 years ago in fact. The comments are a mixed bag and it's certainly a Marmite car.
Those that seem to love them, really love them.
Yes, I understand the 480 was a bit of a damp squib in places. Not as well built as a Scirocco. Not as powerful as a GTE. Not as reliable as a Prelude. It existed in a strange niche together with the Honda Aerodeck. It was criminally underdeveloped by Volvo - the Dutch / Swedish divide was strong and it was deprived in many areas. It remained largely unchanged in its entire 9 year production run.
Not withstanding, childhood dreams can cloud judgement and if we all restored profitable E-Types - then the world would be a very dull place.
To this day I still think that certain elements are super cool and it still holds a very special place in my heart. I still get excited by pop-up headlights and LCD instruments.
So on that basis, here's the story (so far) on what was my dream car at Middle School.
Background
I came from a Volvo family. My Grandad had multiple 340 models, my Dad had a 240. Our closest family friends had a 760GLE.
It all started in 1991 with THIS very brochure that I still have today. I was 12 years old. I went with my father to Pollendines of Frinton - a Volvo main dealer at the time - to look at a used 240 Estate. In the middle of the showroom was a black 480 Turbo, illuminated by down-lighters, looking absolutely amazing. All I could do was take a brochure, that very brochure, and pour over it cover to cover, as only an impressionable 12 year old lad can do. I saw it as the coolest car in the world. Pop-up lights, digitalised LCD instruments, a Turbo gauge and with door key-holes that lit up...
I promised myself that one day I would own this car.
The search properly started in 2012. The criteria was ‘simple’. It had to be :
• The Turbo.
• Black, or red. Possibly white.
• Manual transmission.
• Good history / provenance.
• Standard, or at least easily-revertible to standard.
I will make a slight admission and say that the Turbo version is a somewhat flawed concept in the advantages it brings. The complexities of turbocharging, additional electric water pumps for the turbo, inflexibility of turbo lag, greater reliability concerns and all for what… 10 bhp extra over the ES? It’s all rather silly. But I was 12, I had the brochure, the Turbo was always marketed as the range topper and it had that badge (in that gorgeous font) on the back…
Back then HowManyLeft listed a worryingly low amount of taxed manual Turbos, so the odds of finding one were tough. Incidentally, these figures have bottomed further (2023).
. 
A shocking decrease in numbers. I turned endless cars down like this. Many were sacrificed for Renault 5 Turbo conversions.
I looked at four in four years. I was outbid on ebay for two of them, one I had to let go as the owner was a complete moron and the penultimate Turbo I looked at in Cambridge had no provenance whatsoever – no owners manual, not even one old mot.
February 2016 I had my standard eBay daily notification saying new results found for “Volvo 480”. Finally, a car ticking all the boxes! Owned for 9 years, black manual Turbo, with good history, invoice folder and glovebox literature. I sent the owner a message and scheduled to see the car Saturday before bidding closed on the Sunday.
The week dragged by, Saturday came and I drove from St. Neots to Newport in Wales. The car was ideal. It had its faults, sure, but it was a tremendous foundation to build upon. I was in a fortunate position that a week had gone by and the item still had no bids at £850. Bearing in mind four years had passed and I’d lost two already to the eBay bidding farce, I wasn’t loosing another. I had prepared an envelope of cash, waved it under the sellers nose and he took it off the auction site.
And so I drove it home February 2016 with a smile from ear to ear, genuinely! The speedo didn’t work which made it interesting. The radio said ‘CODE’, the sunroof was broken, the passenger heated seat wasn't working and the all-important "info-centre" was so dark it was barely readable. The driver’s seat was torn, a front fog light was cracked and the paint was very orange-peely in places. The rear lights, predictably, were absolutely awful. The front daytime running lights were cracked and held together with Sellotape. They were also the incorrect brightness when illuminated. The tyres were of a dubious Chinese brand and the alloy wheels were getting pretty scabby. The spare wheel well was full of water, obviously. The high level brake light was falling off, the roof lining was sagging and the combined boot/fuel cap release lever broke in my hand. However, if you overlook all that, I was driving a car that pulled well, drove really nicely, stopped well and felt, you know, genuine.
• A pit stop on the way home in the pouring rain at Slough McDonalds. She was looking good… but only in the dark!
My plan was a rolling resto. A "fix-on-the-go" car much like my Mk2 GTi.
That would of been the case, but in late 2016 I lost my house and garage. In damage preservation I stashed my cars, bikes and tools with friends and the 480 went into storage, unfortunately outside.
Only in 2019 was I in a position to think 480 again and time hadn't been kind...
Getting it ready for the garage... full underside pressure wash to see what we are working with...
3 years, six months and 15 days since purchase and finally it went in the garage.
Initial bodywork assessment not good... couldn't believe the deterioration in nearly four years. Cars do not like sitting about.
This was no longer a "rolling resto". This car needed some serious attention. Either she was scrapped and I look for another - with now less than 25 taxed - or this was a full-on restoration.
For better or worse, I chose the latter.
It was going to be a struggle from the outset. Parts availability in most cases is non-existent. Ford dumped all their 400 series parts as soon as they could. Lighting, trim, electronics and powertrain all have crippled support.
You really have to invest the effort; such as trawling eBay for "new old stock"... harvest those being broken... repair or engineer your way out of problems or consult some of the dedicated members on the 480 Club Europe forum - an excellent resource.
I will try and author these up to the present day. I do hope you enjoy.
• Chapter 1 - Body
• Chapter 2 - Suspension
• Chapter 3 - Brakes
• Chapter 4 - Steering & Driveline
• Chapter 5 - Engine
• Chapter 6 - Fuel & Exhaust
• Chapter 7 - Dashboard
• Chapter 8 - Paint
• Chapter 9 - First Fit
• Chapter 10 - Second Fit
• Chapter 11 - Interior
• Chapter 12 - In-Car Entertainment (ICE)
• Chapter 13 - Lighting
• Chapter 14 - Finishing Touches
Some of my other cars have been well received on here so I thought i'd "port" over my 480 journey from the 480 forum. Apologies to those members and the duplication if they are also PH readers.
It's a journey not yet completed even after 10 years. It's a story of woe, self torture and a test of will power. It's the struggle to proceed when you have long since crossed into vehicle negative equity. Throwing good money after bad based purely on nostalgia.
The last time the 480 Turbo got Shed of the Week was a while ago. 11 years ago in fact. The comments are a mixed bag and it's certainly a Marmite car.
Those that seem to love them, really love them.
Yes, I understand the 480 was a bit of a damp squib in places. Not as well built as a Scirocco. Not as powerful as a GTE. Not as reliable as a Prelude. It existed in a strange niche together with the Honda Aerodeck. It was criminally underdeveloped by Volvo - the Dutch / Swedish divide was strong and it was deprived in many areas. It remained largely unchanged in its entire 9 year production run.
Not withstanding, childhood dreams can cloud judgement and if we all restored profitable E-Types - then the world would be a very dull place.
To this day I still think that certain elements are super cool and it still holds a very special place in my heart. I still get excited by pop-up headlights and LCD instruments.
So on that basis, here's the story (so far) on what was my dream car at Middle School.
Background
I came from a Volvo family. My Grandad had multiple 340 models, my Dad had a 240. Our closest family friends had a 760GLE.
It all started in 1991 with THIS very brochure that I still have today. I was 12 years old. I went with my father to Pollendines of Frinton - a Volvo main dealer at the time - to look at a used 240 Estate. In the middle of the showroom was a black 480 Turbo, illuminated by down-lighters, looking absolutely amazing. All I could do was take a brochure, that very brochure, and pour over it cover to cover, as only an impressionable 12 year old lad can do. I saw it as the coolest car in the world. Pop-up lights, digitalised LCD instruments, a Turbo gauge and with door key-holes that lit up...
I promised myself that one day I would own this car.
The search properly started in 2012. The criteria was ‘simple’. It had to be :
• The Turbo.
• Black, or red. Possibly white.
• Manual transmission.
• Good history / provenance.
• Standard, or at least easily-revertible to standard.
I will make a slight admission and say that the Turbo version is a somewhat flawed concept in the advantages it brings. The complexities of turbocharging, additional electric water pumps for the turbo, inflexibility of turbo lag, greater reliability concerns and all for what… 10 bhp extra over the ES? It’s all rather silly. But I was 12, I had the brochure, the Turbo was always marketed as the range topper and it had that badge (in that gorgeous font) on the back…
Back then HowManyLeft listed a worryingly low amount of taxed manual Turbos, so the odds of finding one were tough. Incidentally, these figures have bottomed further (2023).
. A shocking decrease in numbers. I turned endless cars down like this. Many were sacrificed for Renault 5 Turbo conversions.
I looked at four in four years. I was outbid on ebay for two of them, one I had to let go as the owner was a complete moron and the penultimate Turbo I looked at in Cambridge had no provenance whatsoever – no owners manual, not even one old mot.
February 2016 I had my standard eBay daily notification saying new results found for “Volvo 480”. Finally, a car ticking all the boxes! Owned for 9 years, black manual Turbo, with good history, invoice folder and glovebox literature. I sent the owner a message and scheduled to see the car Saturday before bidding closed on the Sunday.
The week dragged by, Saturday came and I drove from St. Neots to Newport in Wales. The car was ideal. It had its faults, sure, but it was a tremendous foundation to build upon. I was in a fortunate position that a week had gone by and the item still had no bids at £850. Bearing in mind four years had passed and I’d lost two already to the eBay bidding farce, I wasn’t loosing another. I had prepared an envelope of cash, waved it under the sellers nose and he took it off the auction site.
And so I drove it home February 2016 with a smile from ear to ear, genuinely! The speedo didn’t work which made it interesting. The radio said ‘CODE’, the sunroof was broken, the passenger heated seat wasn't working and the all-important "info-centre" was so dark it was barely readable. The driver’s seat was torn, a front fog light was cracked and the paint was very orange-peely in places. The rear lights, predictably, were absolutely awful. The front daytime running lights were cracked and held together with Sellotape. They were also the incorrect brightness when illuminated. The tyres were of a dubious Chinese brand and the alloy wheels were getting pretty scabby. The spare wheel well was full of water, obviously. The high level brake light was falling off, the roof lining was sagging and the combined boot/fuel cap release lever broke in my hand. However, if you overlook all that, I was driving a car that pulled well, drove really nicely, stopped well and felt, you know, genuine.
• A pit stop on the way home in the pouring rain at Slough McDonalds. She was looking good… but only in the dark!
My plan was a rolling resto. A "fix-on-the-go" car much like my Mk2 GTi.
That would of been the case, but in late 2016 I lost my house and garage. In damage preservation I stashed my cars, bikes and tools with friends and the 480 went into storage, unfortunately outside.
Only in 2019 was I in a position to think 480 again and time hadn't been kind...
Getting it ready for the garage... full underside pressure wash to see what we are working with...
3 years, six months and 15 days since purchase and finally it went in the garage.
Initial bodywork assessment not good... couldn't believe the deterioration in nearly four years. Cars do not like sitting about.
This was no longer a "rolling resto". This car needed some serious attention. Either she was scrapped and I look for another - with now less than 25 taxed - or this was a full-on restoration.
For better or worse, I chose the latter.
It was going to be a struggle from the outset. Parts availability in most cases is non-existent. Ford dumped all their 400 series parts as soon as they could. Lighting, trim, electronics and powertrain all have crippled support.
You really have to invest the effort; such as trawling eBay for "new old stock"... harvest those being broken... repair or engineer your way out of problems or consult some of the dedicated members on the 480 Club Europe forum - an excellent resource.
I will try and author these up to the present day. I do hope you enjoy.
• Chapter 1 - Body
• Chapter 2 - Suspension
• Chapter 3 - Brakes
• Chapter 4 - Steering & Driveline
• Chapter 5 - Engine
• Chapter 6 - Fuel & Exhaust
• Chapter 7 - Dashboard
• Chapter 8 - Paint
• Chapter 9 - First Fit
• Chapter 10 - Second Fit
• Chapter 11 - Interior
• Chapter 12 - In-Car Entertainment (ICE)
• Chapter 13 - Lighting
• Chapter 14 - Finishing Touches
Edited by jay-kay-em on Saturday 16th November 20:45
Such a great carMy dad had a non turbo one of these in 1994.
J808AWP. Sadly scrapped in the early 2000's.
We absolutely loved it and it was affectionately called Arnie. I have very fond memories of it, especially the individual rear seats and big centre arm rest thing. And flip up headlights! It went well all things considered and looked like nothing else on the road. I can't wait to see what you do with this one.
J808AWP. Sadly scrapped in the early 2000's.
We absolutely loved it and it was affectionately called Arnie. I have very fond memories of it, especially the individual rear seats and big centre arm rest thing. And flip up headlights! It went well all things considered and looked like nothing else on the road. I can't wait to see what you do with this one.
Owned a 2.0 manual 480ES with a previous girlfriend - both were fabulous fun 
Still think about getting another 480 - I loved the details around the car, so much so that I fitted the 480ES Voltmeter and oil pressure meter into the ashtray of my M635CSi.
Pop up lights, individual real seats, info centre, heated seats and a hot hatch - all winning.
Still think about getting another 480 - I loved the details around the car, so much so that I fitted the 480ES Voltmeter and oil pressure meter into the ashtray of my M635CSi.
Pop up lights, individual real seats, info centre, heated seats and a hot hatch - all winning.
In for this.
In 94 I bought an 88 1.7 480ES. I drove it to Luxembourg when I moved here in 98 and gave it for spares, gratis, a year later….. I really didn’t want the hassle of either driving it back to the UK for its MoT, or registering it in Luxembourg. It had too many faults.
ETA: F935 RHN
In 94 I bought an 88 1.7 480ES. I drove it to Luxembourg when I moved here in 98 and gave it for spares, gratis, a year later….. I really didn’t want the hassle of either driving it back to the UK for its MoT, or registering it in Luxembourg. It had too many faults.
ETA: F935 RHN
Edited by RC1807 on Thursday 14th December 07:24
Wow a blast from the past, can't remember the last time i saw one in the flesh. Well done for saving it, very futuristic car at the time. My dad had a black 480 as a stop gap when someone went into the back of his 760GLE estate, pretty sure it was a cooking model 2.0ES rather than the turbo. He's 6ft 2 and i remember giggling to myself as a lad how squished he was behind the wheel after driving larger cars (mostly BM 5 series).
Went from this to a Renault Safrane, then back to a V40.
Good luck with it.
Went from this to a Renault Safrane, then back to a V40.
Good luck with it.
I shall follow this thread looking through the back of my hand.. 
I had a '92 480 Turbo back in the day (and used the forum mentioned above!). It was an 'interesting' car but plagued with iffy electrics and that horrible clutch cable that would eventually snag/tear.
I think the later cars were supposed to be better but I didn't go back for seconds.
Best of luck with the resto!
I had a '92 480 Turbo back in the day (and used the forum mentioned above!). It was an 'interesting' car but plagued with iffy electrics and that horrible clutch cable that would eventually snag/tear.I think the later cars were supposed to be better but I didn't go back for seconds.
Best of luck with the resto!
Edited by Hammerhead on Wednesday 13th December 11:50
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