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Fred's 1987 Volvo 240 GL Sedan - Notes and Debate 
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Joined: Tue Jan 15, 2008 2:31 pm
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Went down to the garage to tidy up the tools and parts and stuff in case of more minor flooding like the other day, and did exactly that. But while I was there, I couldn't help but do a bit of Nissan and Volvo work. So here's the Volvo stuff:

https://twitter.com/FredCookeNZ/status/ ... 5322578946
https://twitter.com/FredCookeNZ/status/ ... 4152736768
https://twitter.com/FredCookeNZ/status/ ... 0661906432

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The wheel cleaner experiment was interesting. I also sprayed the wheels and abandoned them to future rain for rinsing. Meh.

The puller should work well, but I had to move it to the setting pictured in this post. Time will tell which suits better.

The paint is too green, but hey, good enough for government avoidance work.

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Sun Mar 26, 2017 11:15 am
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Fred wrote:
Game plan for tomorrow is to...

1) Pull the pulley with the puller. In two pieces, if required. :-p
2) New pulley from B230F in with a drop of locktight and some good luck
3) Belts back onto all accessories and tensioned correctly
4) Degrease ATF lines and RHS of trans in search of leak
5) Fire it up and run it for a while watching for the leak

4/5 will not be done if the weather sucks. 1/2/3 will be done regardless.

If the weather is really nice/hot/dry, instead of 12345 I'll do 678910111213 :-p

12345 all done, except 5 was "take it for a drive around the block" and watch for leaks
was afterward, and unsuccessful, due to not being from the tubes I thought it was.
Though they are pretty worn by the bracket, and will need some padding with rubber
of some sort to not rattle and fail. I have to say, it was damn nice to drive it with the
power steering working and the belts not screaming! Almost like a good car! :-D

Current thoughts are to get it a WOF this Saturday coming. For that it'll need at least:

1) Some various small bits of rust tidied up and hidden/fixed.
2) ATF leak fixed or at least disguised long enough to get the WOF
3) Waterblast various bits to remove loose crap and lichen and so forth (entire outside, parts of engine bay, underneath in places)
4) Front sway bar end links, pull rubbers from caravan front end links and install as temp fix
5) Vacuum interior and boot
6) Degrease engine and transmission fully so it at least looks neat and tidy

Not sure what else. That should be it?

Water blasting may incite anger from my loving neighbour, though. Hmmm.

I know! I'll do it in the morning before I go to work, and after he's already left! Win.

Tomorrow the Suzuki may need moving, though. Minor chores on that front, but we'll see.

Will try to focus on 1, 2, 4, 5, and maybe 6, and keep 3, and maybe 6 for a morning effort. Mu ha ha ha.

Then all I have to do is convince WOF man that I'm just going to park it and not drive it pissing oil everywhere... :-)

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Mon Mar 27, 2017 9:22 am
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Tweet tweet, pic pic, almost forgot forgot:

https://twitter.com/FredCookeNZ/status/ ... 3752200192
https://twitter.com/FredCookeNZ/status/ ... 4569077761
https://twitter.com/FredCookeNZ/status/ ... 9154289664
https://twitter.com/FredCookeNZ/status/ ... 0894596096
https://twitter.com/FredCookeNZ/status/ ... 7068037120
https://twitter.com/FredCookeNZ/status/ ... 0290521088
https://twitter.com/FredCookeNZ/status/ ... 9551958016

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Mon Mar 27, 2017 11:34 am
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I was up again at 545am today, had breakfast, packed my bag, had a shower, prepared hose, found end link bushes for front sway bar, neighbour left, wife woke, went out again at 730 and blasted until 8, then packed away the equipment, had a cold shower to remove sweat, and wandered off to work. Tweets coming soon, linked here later.

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Mon Mar 27, 2017 8:49 pm
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Home by 6, got stuck in and did:

0) Found a lonely drop of bright red ATF on one of the two lines only, no where around/above, no where to run from, cept the back of the tube itself, worn through from the trans bracket, yet to be proven
1) Ground and wire brushed and poked at with centre punch all rusty patches in door/bonnet
2) Mixed some bog and gave it a conservative coating on the two bonnet ones, nice work
3) Mixed some more and spread it into the holes in the door above the lock and all around, messy, bumpy, rough
4) Scuffed up the surface of the bonnet two with sand paper
5) Mixed some more and gave them another skim to bring them above flush a little
6) Noticed door bog was still wet, but stiffening up fast, and went over it with fresh softer bog, still rough as guts
7) Worked on sway bar end links installing 740 upper bushes in there and doing an average job of it with no grease and no idea if I was over winding the nut, or under winding it
8) For water proofing in case of rain, and in knowledge of making my future life more painful/harder, dusted the two bonnet bog patches with blue/green top coat, no primer, no sanding, nothing, fuck it, bog is porous and rain is forecast

Did not vacuum the interior.
Did not fix random rust spots in engine bay or bottoms or doors, etc.
Did not waterblast bits of engine bay.
Did not degrease bits of engine bay and driveline. May not bother if the leak is solvable

Plan tomorrow:

Vacuum the interior out
Undo nut on LHS sway bar to see where thread stops and perhaps install grease, then retighten. If greasing and/or good, then do both one by one.
Pick up run to my storage unit and return trip via hotel to fit other wheels for WOF duty.
Visit dad in hospital - shoulder replacement :-o old bugger is more worn out than the 244.

Tweet tweet, pic pic:

This morning:

https://twitter.com/FredCookeNZ/status/ ... 0510715904
https://twitter.com/FredCookeNZ/status/ ... 9906544641
https://twitter.com/FredCookeNZ/status/ ... 8670086148

This evening:

https://twitter.com/FredCookeNZ/status/ ... 4006456320
https://twitter.com/FredCookeNZ/status/ ... 9534635009
https://twitter.com/FredCookeNZ/status/ ... 8256766979
https://twitter.com/FredCookeNZ/status/ ... 6981560320
https://twitter.com/FredCookeNZ/status/ ... 6981560320
https://twitter.com/FredCookeNZ/status/ ... 7614126080
https://twitter.com/FredCookeNZ/status/ ... 8642902016
https://twitter.com/FredCookeNZ/status/ ... 7723530245
https://twitter.com/FredCookeNZ/status/ ... 3141330945

Pics, this morning and evening:

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Tue Mar 28, 2017 10:19 am
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Tonight I:

1) Vacuumed out the interior and boot! Not perfect, but close enough! :-)

2) Retrieved the ATF carrying hard lines from the 940 caravan shell to replace the worn through lines on this 244

No pics of the vacuuming or clean seats/carpet/boot, but you can see the lines in this shot:

https://twitter.com/FredCookeNZ/status/ ... 2964932609

Image

_________________
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Wed Mar 29, 2017 10:28 am
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Tonight I did a few things, but only one tweet.

1) Confirmed leak in ATF line, undid it, removed it and found the hole worn through in the top side from the steel bracket and 29 years.
2) Created new line from 940 line that didn't fit by bending it, rough enough, good enough, doesn't leak, win. Dry as a bone.
3) Took the car for a drive to prove it was working OK. Almost like a good car, now :-)
4) Treated a few bits of surface rust in a few places, engine bay, underneath, etc. Found a few bits beyond treating, but only small, three of them.
5) Wrote a list of things to do tomorrow:

New numbering sequence:

1) Sand and prime/paint bog in door, very rough right now, may need more bogging after initial sanding.
2) Fill three holes in firewall and sill and coat with black so as to be non-visible.
3) Clean up and treat bottoms of doors, smear some filler on there if it'll help with appearances. Black over.
4) Grease and rust-kill and black out the hinges as some are a bit rusty looking/gone.
5) Wipe out all of the door jams with spray cleaner and cloth.
6) Brush/groom rear parcel shelf to bring colour back out in carpet. Re vacuum this bit.

All of this between home time tomorrow and "too late for noise" tomorrow.

WOF attempt Saturday morning first thing. Fingers crossed.

Tweet: https://twitter.com/FredCookeNZ/status/ ... 5679204353

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After this photo a guest came around and I said "I bet I can push a hole in that with my fingernail" and then did. So it's gaping now. :-D

Partially sealed/tide stemmed by contact with the face it wore against! :-D

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Thu Mar 30, 2017 11:19 am
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330pm to 830pm, five hours hard work:

https://twitter.com/FredCookeNZ/status/ ... 3553969152
https://twitter.com/FredCookeNZ/status/ ... 6206855168
https://twitter.com/FredCookeNZ/status/ ... 2925861888
https://twitter.com/FredCookeNZ/status/ ... 8308950016
https://twitter.com/FredCookeNZ/status/ ... 3316757506
https://twitter.com/FredCookeNZ/status/ ... 9000835072
https://twitter.com/FredCookeNZ/status/ ... 2144148480
https://twitter.com/FredCookeNZ/status/ ... 7978776577
https://twitter.com/FredCookeNZ/status/ ... 1469943808
https://twitter.com/FredCookeNZ/status/ ... 5202026498
https://twitter.com/FredCookeNZ/status/ ... 6721531904
https://twitter.com/FredCookeNZ/status/ ... 6733193217
https://twitter.com/FredCookeNZ/status/ ... 6293758981
https://twitter.com/FredCookeNZ/status/ ... 1123765248
https://twitter.com/FredCookeNZ/status/ ... 9486375936
https://twitter.com/FredCookeNZ/status/ ... 6852023299
https://twitter.com/FredCookeNZ/status/ ... 4465538048
https://twitter.com/FredCookeNZ/status/ ... 6366722048
https://twitter.com/FredCookeNZ/status/ ... 5328942081

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Then I came in and went for a feed, returned at 930pm and went out to put away tools,
which I got done inside half an hour, then doing this post took about 15 minutes...

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Fri Mar 31, 2017 10:15 am
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WOF, rego, and it's out on the street like it didn't miss a beat, no longer taking up valuable driveway space!

And as a direct result the V12 fired up and moved over 3m and took up the valuable driveway space! Doh!

Warmed up the V12 and let it heat cycle on the fan a few time, all good, no overheating, no nothing. 300k on it.

Poured a bottle of flush into the sump and ran it at 1500 to 2000 for 10 minutes then let it idle while I figured out the drain bung.

Drained the filthy concoction out of it, quite a few litres all up. Will take a stab at measuring it, and under fill it with lifter cleaner added.

Then a few heat cycles and a bit of local driving at high risk of big fines because: I just have to do it :-D

Then the engine/trans pull begins! That'll take a bit of time, but aiming for scrapping the body within a month or so.

Interior shot from this morning post WOF obtaining: https://twitter.com/FredCookeNZ/status/ ... 9494542336

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Sat Apr 01, 2017 11:28 am
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OK, so the V12 drinks a massive 8 litres of oil! Looked like that much, too! :-o

I have a non-rooted bung for it, now, and will attempt to clean up the sump
threads if necessary tomorrow arvo/evening. Then I'll pour maybe 4 or so
litres and the lifter cleaner into it and ensure it gets oil pressure with that
little, if so, will run it up to temperature and take it for a short drive nearby.

Ha, and while pondering pushing submit, I found this video of a 240 wagon with this engine:

And this photo of a 240 of some other type with this engine, twin turbo: https://www.youtube.com/watch?v=AvdH0LHlpeg

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I also found others thinking the same way I am re sump placement: So far forward it'll miss the rack and subframe all together!

And I found someone saying the swap was easy, the hard part was the EFI. LOL. I've got that covered ;-)

And if the intake manifolds won't fit with the brake booster... I have 12 ITBs for this bastard! :-D

Good stuff. Excited.

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n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Apr 02, 2017 11:09 am
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