Volvo 940/740 MAF Housing

I have purchased a new Volvo 940, first one in 14 years. Back then I only had a stick welder to do stuff and hand tools.

Now I got 3D printers, so when it was time for me to increase power in my 940 Turbo. Injectors and MAF housing will be increased and there is the popular 3" stock housing one can use.

But I figured why not use a 3D printer to both keep the cost down, and to allow a better fitting MAF housing based on the increase of the injector size.

With this, said. You need to use Fusion 360 to get the full use out of this, otherwise you can only print the models that I uploaded. a stock 63mm MAF and a “3 inch" version.

In the Fusion 360 file, you can change one of the User Parameters based on the percentage increase from the stock injectors. Or for chips that was tuned for, for instance the “green injectors”/Bosch 968 injectors along with a 3" MAF.

Which value to change is in the pictures.


Stock mesh filters can not be used in this design, I might update that in the future. But need to find something to replace it with. Which also is adaptable to fit whatever size ends up being used.
Which is why I didn't go with including a stock filter mechanism to lock the filters in place.


These are my recommended settings for print strength;
Material: Basically anything except for PLA
Walls: 8
Top/Bottom: 8
Infill: 35% Gyroid
Support: Normal(auto), style “Snug” (If using OrcaSlicer)
Wall Generator: Arachne (Nozzle size has a wider wall thickness range)
Alternate extra wall (Stronger wall to infill bond)
Walls Printing Order: Inner/Outer/Inner (A quality boost in walls visual and mechanical accuracy)
Seam: Scarf Joint Contour & Hole (In theory should proved with a stronger seam, better accuracy) 
Print at a higher temp than usual, if you are printing 220°C, try 230°C. To make the filament bond better. Should not present any defects like overhangs drooping.
If you can't raise your temps without issues, then slow down your printing. Will not work as good, but it does improve the bonding between the layers more than running it fast, use as little fan as possible if using for instance PLA. None at all preferably.


Initial Release - 2025-03-15;
Not yet tested this, will print it and update if needed.

2025-03-17;
Printed it and did a test run, works without issues on my end as is.

2025-07-23;
- Organized the user parameters in a more meaningful way, new image of it uploaded.
- Added some more parameters and altered old ones, MAF_Diameter, MAF_Percent_Inc, Stock_Injector_Size, New_Injector_Size and Size_Tuning_Baffle. To make things easier and have everything done in the model.
- Changed the dimension that is affected by the “MAF_Equation”, to allow more fexibility for end users. Who doesn't run the stock housing but want to increase their current housing to a larger one.
- Added a “Size Tuning Baffle”, in case you run into a situation that the MAF housing was too big, and instead of printing a whole new housing, you can now insert this baffle. Saves time, filament and money.
- Altered and added more info into each user parameter, the baffle parameter also has tuning steps to get the proper sizing.