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Fred's 1987 16v B234F Powered Volvo 240 GL Sedan 
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Joined: Tue Jan 15, 2008 2:31 pm
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Location: Home sweet home!
Last night's update:
Fred wrote:
Tonight I (all the crossed out items):

4) both engine and trans - refill and add new filter
8) Wire up starter motor and alternator permanently (only finger tight so far)

And later:

1) Find usable TPS and/or throttle with TPS
2) Figure out which COP units to use on it
3) Get throttle cable working, somehow
4) Extend/replace brake booster hose (was duplicated below, deleted below)
5) Make a dizzy hole bung retainer plate - used angle alloy for the 240 wagon - might still have it (or Geoff does?)

Oil in and filter on
refill trans with X litres of ATF, 4 or so should be enough to prevent damage prior to warming up engine later
Starter, alternator, dash temp sensor wiring - find engine loom? merge with car loom?
Plugs out and crank to oil pressure, plugs back in (if clean enough, should be)
reattach with grease between chassis/bracket and on screws
Reconnect ground straps to new engine (did one, not the other)

Items not crossed out not done and on tomorrow's TODO list.

Hmm, may need a pneumatic feed to the engine bay for the 240, too? Not sure. Yes!


Also:

Removed tstat housing to fix or replace
Remounted power steering reservoir
Cleaned, modified, and reinstalled battery tray and bolts with waterproof grease (mentioned above, elaborating)
Connected flame trap up to plenum with silicone vacuum hose
Installed sump drain bung ready for new filter and fresh oil tonight

Tonight:

On car:

Tighten Power Steering fitting
Replace filter on engine
Fill engine with diesel 15w40
Part fill trans with f ATF
Plugs out and crank to oil pressure, plugs back in (if clean enough, should be)
Check dizzy bung and make retainer plate for it if it won't fall in
Connect 240 interior pneumatics to manifold with check valve
Label car-loom ends with functions/figure out loom/list engine connections required

For car:

Dig out pump and filter assembly from caravan
Pick up throttle cable and loom from storage
Find better tstat housing in collection

Pending for weekend:

Starter, alternator, grounds, aircon hoses
Throttle cable
Fuel pump install
Loom hookup
ECU install

To buy:

1/4" to 5/16" brass adaptors (2, probably)
1/4" EFI fuel hose (probably, but perhaps 5/16" is ok, depends)

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Fri Mar 02, 2018 1:43 am
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Last night:

Bought 20l of ATF
Bought 2 feet of 5/16" EFI hose
Tightened the PS fitting
Replaced filter on engine Z9 (big)
Filled with cheap 15w40
Put 4l of ordinary ATF into trans
Washed out plug wells with brakeclean and compressed air
Pulled the plugs
Hooked up enough loom to crank and check for oil pressure (main ground, main power, idiot light sensor)
Cranked and eventually got oil pressure (slow cranking + big filter = took a while) after cranking stops light stayed off for several seconds, so bottom end is good (as you'd expect for low mileage)
Began labeling the car-loom, got 3 end points marked with function
Picked up all 940 caravan loom pieces from storage
Picked up 940 caravan throttle cable from storage
Found clearance issue: balance shaft belt covers touching sway bar - on droop would interfere (didn't notice when I had it up, and no damage, but needs fixing: 10mm alloy plates to be inserted today)

Today: The rest :-D

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Fri Mar 02, 2018 8:15 pm
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Location: Home sweet home!
Today:

Found fuel pump/filter/bracket on shelf
Made custom mounts for filter/pump in same location as stock 240 EFI setup
Analysed and minimised the stock B234F loom
Analysed and minimised the stock B230K loom
Removed bendix ignition ECU
Adapted car to 940 GLE throttle cable and vice versa/got throttle working from pedal
Tested fuel supply line to tank - did not test fuel return line to tank (pending)
Checked that the dizzy bung could only fall out, and not in, need to make retainer like on 240 wagon

Tomorrow morning buy hose adaptors:

5/16 to 3/8 for pump inlet
1/4 to 5/16 for filter outlet
5/16 to 1/4 for rail feed
5/16 to 1/4 for return
and 1m of 1/4" EFI hose
and 1m of 3/8" hose?

Tomorrow's chores:

Go plumbing shopping
Finish fuel system, hoses
Wire up fuel pump and relay (under rear seat)
Check fuel return line for decent flow
Test fuel system before hooking up return
Tighten aircon lines onto pump
Modify OEM VR sensor to extend wires
Label, modify, and install engine loom
Design and install ignition system (probably miata wasted setup, as easy/quick)
Steal hotel ECU, install connectors for it as per sheet
Build configuration up for engine setup
Gain sync cranking and dial in ignition timing
Install radiator, hoses, shroud, fan, coolant
Run engine up, and get idling sustainably leanly
Top up ATF to required level while idling
Attempt to drive :-D

Later chores:

1) Sway bar spacers cut out and installed
2) Tuning
3) Grill reinstalled
4) Boxes of parts out of car

Much later:

G80 install :-p
Skids :-D

Feeling positive, but looking at this list, it'll be a stretch to get it finished before the end of the weekend.

_________________
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FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
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Sat Mar 03, 2018 12:52 pm
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Only moderate progress yesterday:

Went out and bought fuel hose (1/4", 5/16", and 3/8") and barb-to-barb fittings of 3/8" and 3x 5/16" sizes.
Came home and gradually got them all installed, hose clamped, and looking neat/tidy.
Had to cut the 5/16" feed line to insert the pump/filter from the caravan into the circuit.
And clean up the burrs afterward, too. And blow it out with compressed air, too.
Tricked myself into thinking the return line had issues - it didn't, but it got a set of new hose clamps at the tank fitting as a result.
Learned that 240 sedans are ideally designed for an epic fuel system below the parcel shelf in the boot.
Reinstalled the grill.

IE, A long day of not getting much done. Sigh. I blame the wife and em_knaps.

Almost no progress today:

Pottered around the garage tidying stuff up in the dark/quiet - off work with a headache.
Didn't feel up to much at home, either, even after a long sleep in.
Was nice to spend some time with the wife, even if I wasn't feeling my best.

Aside from tidying up in the garage:

I pulled out the spare B234F 16v head and started making the retainer for the dizzy plug.
Needs rivets and more cutting/shaping, but it's in progress. Details: 150mm LOA or a little less, centre to centre M6 fasteners 135mm
With bolts offset to edge on 20mm bar the top edge will go through the centre line of the disk.
IE, needs to be wider. Doing it again I'd make it from 5mm or 6mm plate cut to suit the shape.

Also measured the sway bar mounts for a spacer: 37x92mm (IIRC)

Powered up the fuel pump to check for function, flow, leaks, etc, all good.

Threw a few cable ties on the fuel feed/return lines to keep them neat and together.

Unloaded a set of wheels and two RX7 space saver tyres from the boot (and the spare 240 steering rack yesterday, too).

Found a bunch of ants breeding in the boot, killed them all. Will flea bomb the car before I start using it.

Stored the balance of the caravan wiring looms in the boot, for now.

And the only other thing I did was tighten down the aircon lines onto the aircon pump.

So status after yesterday and today is:

Quote:
Go plumbing shopping
Finish fuel system, hoses

Wire up fuel pump and relay (under rear seat)
Check fuel return line for decent flow
Test fuel system before hooking up return
Tighten aircon lines onto pump
Modify OEM VR sensor to extend wires
Label, modify, and install engine loom
Design and install ignition system (probably miata wasted setup, as easy/quick)
Steal hotel ECU, install connectors for it as per sheet
Build configuration up for engine setup
Gain sync cranking and dial in ignition timing
Install radiator, hoses, shroud, fan, coolant
Run engine up, and get idling sustainably leanly
Top up ATF to required level while idling
NEW: Fill power steering with ATF - currently near dry
NEW: Make dizzy plug retainer plate (in progress!)
Attempt to drive :-D

Later chores:

1) Sway bar spacers cut out and installed
2) Tuning
3) Grill reinstalled
4) Boxes of parts out of car


Which amounts to:

1) Cutting/filing/drilling/riveting some alloy plate/angle
2) Wiring everything up
3) Easy stuff - tuning, fluids, unload car

Hopefully I can push through the alloy tasks tomorrow evening. Leaving wiring / crank sync gain for Wednesday. And first start/tuning on Thursday.

Or something like that.

_________________
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FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
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Mon Mar 05, 2018 8:44 am
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Last night:

Finished the dizzy plug retainer plate (for now) and installed it - easy fitment with tapered wings.
Cleaned up the tstat housing enough to use it and reinstalled it on the engine
Cleaned up the radiator hoses removing white corrosion/coolant stains and hose clamp rust on the outside
Decided to defer sway bar spacers until the engine runs

Tonight I will:

Install radiator and hoses and clean up the steel wind blocking plate more and install that with some paint < semi-final procrastination item
Wiring/ECU/ignition! < only thing that could get in the way is those sway bar spacers, but cutting 9mm alloy plate is not a fun idea either :-D

Which I probably won't 100% finish, but I should get it close enough and can finish it off tomorrow arvo.

Rob will be over tomorrow night and he can hold the camera while I turn the key for first start :-)

_________________
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FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
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Tue Mar 06, 2018 8:57 pm
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Radiator and fan and shroud and mounts and hoses are all in and done up. Extra clamps on the top breather line.

Cleaned radiator core as it was 80% blocked with 30 years of cruft but still in good condition despite that.

Got the loom fully labeled and have a game plan for tomorrow evening.

Should be wired up and hopefully running by the end of the night :-)

Did not cut the alloy spacers, though I may do that first thing tomorrow arvo so that I can drive it if we get it running late at night too late for cutting metal.

_________________
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FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Wed Mar 07, 2018 1:23 pm
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Last night:

No where near what I wanted to get done.

Rob came over and we made a power feed line to the fuel pump including making the connector terminals.

Before that I rinsed/scrubbed the acid/iron-phosphor from the blocker plate and gave it 2 coats of black zinc each side.

I also cleaned and modified the old carby air filter box but the pipes from it don't fit and I can't find the top bracket. It'll block the air from going around the radiator, though.

Also moved the hotel into a corner where it can stay for a while, took it around the block, ripped the firmware from it, and removed the Jaguar for use here.

And today I risk a surprise visit from the landlord with 3 cars outside one on the grass another half blocking the driveway. Sigh.

This is hard work and only because of my living/garage arrangement and the quantity of other projects jammed in here.

One day I'll have a decent workshop, one day...

Tonight loom mods and maybe install of loom, maybe soldering plugs on, etc.

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Thu Mar 08, 2018 8:47 pm
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Location: Home sweet home!
Did some wiring stuff last night, and a bunch more today, nearly ready to start soldering ECU connectors on.

Loom is ready to install, and now only contains

* injectors, 4x control, 1x power
* grounds, 2x independent substantial
* CHT sensor, 2 wires
* PWM idle valve, 2 wires

Temp gauge, oil pressure, VR sensor, IAT, and ignition control are independent loom elements not needed on the intake side of the block.

Knock is pending later development.

Tacho is pending a circuit to drive it as these coils don't handle that.

Key-on power is already feeding the appropriate relays, 3 times power side, with ground ECU controlled, and 1x power side with ground permanent and output controlling the ECU.

Alternator charge wire, starter feed wire, starter solenoid trigger, and excite/dash-light wires all connected.

Coils have relay fed power, and head grounds nearby. Just need to run colour matched signals to them once the injectors are connected up and testable.

Fuel pump has power/ground wires running to it, both need to be terminated in a good ground and a relay power feed.

Tomorrow morning:

* plug in the injector/coolant/idle loom - and route it into the cabin through the grommet potentially removing some outer jacket.
* run the VR sensor wires into the cabin
* colour match the ignition coil numbering vs the injector numbering with near identical wires - label the ECU end of each outer jacket with purpose
* jumper hotel ecu ignition outputs to 5v instead of 12v for now - research real operation later
* connect, route, and splice the oil pressure sensor wire subloom into the old car loom
* connect, with RTV, and ground, and splice the temperature gauge sensor into the old car loom
* connect up and route to cabin the remaining three relays, ECU, FP, Inj
* find an IAT, extend the wiring for it, place it somewhere forward of radiator, and route wiring through to cabin
* configure some firmware for it, probably an old version for starters, so I don't have to think about new features right now
* clear the cam cover valley of any alloy dust with compressed air
* install ignition and ECU relays and dial in timing with plugs out by putting the light loop around the red wire for coil #1
* add fuel pump and injector relays and attempt first start on video with wife on camera, rego and plates covered

Later:

* wideband install
* TPS - current throttle does not have one
* knock sensing

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sat Mar 10, 2018 12:34 pm
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Fred wrote:
* plug in the injector/coolant/idle loom - and route it into the cabin through the grommet potentially removing some outer jacket.
* run the VR sensor wires into the cabin
* colour match the ignition coil numbering vs the injector numbering with near identical wires - label the ECU end of each outer jacket with purpose
* connect coils up to cabin with 4 core like the injector loom

* jumper hotel ecu ignition outputs to 5v instead of 12v for now - research real operation later
* connect, route, and splice the oil pressure sensor wire subloom into the old car loom
* connect, with RTV, and ground, and splice the temperature gauge sensor into the old car loom
* connect up and route to cabin the remaining three relays, ECU, FP, Inj

* find an IAT, extend the wiring for it, place it somewhere forward of radiator, and route wiring through to cabin
* configure some firmware for it, probably an old version for starters, so I don't have to think about new features right now
* clear the cam cover valley of any alloy dust with compressed air
* install ignition and ECU relays and dial in timing with plugs out by putting the light loop around the red wire for coil #1
* add fuel pump and injector relays and attempt first start on video with wife on camera, rego and plates covered


Later:

* wideband install
* TPS - current throttle does not have one
* knock sensing


Today's list smashed. Tomorrow's list yet to be written. Today's success: viewtopic.php?f=55&t=2846

_________________
DIYEFI.org - where Open Source means Open Source, and Free means Freedom
FreeEMS.org - the open source engine management system
FreeEMS dev diary and its comments thread and my turbo truck!
n00bs, do NOT PM or email tech questions! Use the forum!
The ever growing list of FreeEMS success stories!


Sun Mar 11, 2018 11:26 am
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LQFP112 - Up with the play

Joined: Tue Dec 23, 2008 12:20 am
Posts: 113
That's great news all around!

I couldn't quite keep up with your cars lately and trying to read back the past few pages, I only saw hacked up BMW parts. :lol: (I did notice the DOHC engine in between, yes ;) ).

If I'm not mistaken, this is now your first (again) daily FreeEMS-driven ride, isn't it? Anyways, it's gonna be good for FreeEMS and you. :)


Sun Mar 11, 2018 11:39 am
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