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Fred's 1987 Volvo 240 GL Sedan - Notes and Debate
http://forum.diyefi.org/viewtopic.php?f=3&t=2728
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Author:  ivan141 [ Mon Sep 05, 2016 10:03 am ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

You sure it's a 44-1-1 pattern? 44 hole flywheels are usually 44-2-2 (renix).

Author:  Fred [ Mon Sep 05, 2016 11:08 am ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

I'm 110% sure that you're right! :-D I should have updated this. I have some photos, so I'll put them up now below.

The Volvo book has text that is self contradictory and the diagram clearly shows 22-1 however even with super wide tolerances 22-1 would NOT sync on the engine. 22-2 synced fine and for the purposes of RPM and so forth worked fine. I think I had another bug in the new mode that I want to solve properly, not quickly, that stopped me in my tracks. The pulley didn't help, either, as you could see.

Tools: https://twitter.com/FredCookeNZ/status/ ... 4218366976
PSU: https://twitter.com/FredCookeNZ/status/ ... 4092677120
MAP: https://twitter.com/FredCookeNZ/status/ ... 1422554112
Ready: https://twitter.com/FredCookeNZ/status/ ... 7110504448
Safe: https://twitter.com/FredCookeNZ/status/ ... 2695538689
Pulley: https://twitter.com/FredCookeNZ/status/ ... 3266063360
FUMurphy: https://twitter.com/FredCookeNZ/status/ ... 2655348736
Fortieth: https://twitter.com/FredCookeNZ/status/ ... 6792955904

Inlined, cept last two:

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Author:  Fred [ Wed Sep 07, 2016 12:37 pm ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

A screeny as I shut ULV down to try a new version. This is 300 RPM, no plugs, perfect sync, 22-2 over 180 degrees.

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Two firmware weaknesses visible:

Time tolerance should be reset to its central value on timeout state clear (but not on sync loss).
Steppiness of dwell after cranking stops is due to slow sampling when the engine is not running.

And a nice little linear decay of speed without the plugs in there:

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Author:  Fred [ Sun Mar 12, 2017 11:23 am ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

Never did get back to hacking on the fucked engine with the dodgy new code. Might at some point.

However I have a vague new plan... and I might just go through with it... mu ha ha ha!

And in other news, tonight I decided to test out the wheel cleaning sprays (got two types) on
this old girl, and these are the results: https://twitter.com/FredCookeNZ/status/ ... 4429578241

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Author:  Fred [ Mon Mar 20, 2017 8:33 am ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

Technically I just bought this:

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Though I still have to pick it, and the rest of the car, up, and then get it out of the bloated home and into something lighter and more stylish. :-)

Author:  Fred [ Wed Mar 22, 2017 6:51 pm ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

Booked in and paid for Saturday morning pickup of car transporter trailer! She should be mine, in hand, for real, by the end of Saturday!

Oh shit!

As I look at this car each day, I've taken more of a liking to it. I mean, it's still a rough pile of junk, but I think the wheels suit it in a cruiser V12 kind of way. And the wife digs the colour (inside and out). What else is there? :-p

Finally some motivation to pull the head and try the 16v gear on for size with a RHD (right hand drive, for google) 240 (242 244 245 for google).

No where on the interwebs do I see media, photos, videos, anything, of this being done. All LHD North American and European cars. Nothing UK, Oz, NZ, Jp, that I've seen, anyway.

So tasks in order are something like:

1) Pick up V12 BMW
2) Do burnouts in V12 BMW
3) Pull V12 and all related stuff out of BMW
4) Pull anything valuable off of BMW
5) Scrap bare naked empty forgotten BMW shell
6) Pull 8v head from POS redblock engine
7) Pull 16v head from B234F redblock engine
8) Test fit in 240 engine bay
9) Take many photos of 16v in RHD bay :-p
10) Mock up TD05HR-16G turbo in 240 engine bay
11) Remove rest of POS redblock and related non-useful junk
12) Install V12 engine/trans/etc into 240 engine bay :-D
13) Profit.

Yes, I've noted that 13 is an unlucky number of steps. :-p

Author:  Fred [ Thu Mar 23, 2017 10:26 am ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

Cleared 244 of junk and gear, except the boot which still has an old steering rack and a set of rims in it.

Needs a vacuum, wheels and rack removing, left front door tidied up, bonnet tidied up, front wheels cleaned, pulley swapped, belts back onto power steering pump, and it'd be usable despite the knock.

Oh, and the gastly ATF leak fixing. Not sure what of that will get done as the V12 must go in :-D

And before that the 16v mockup session must occur.

Author:  Fred [ Fri Mar 24, 2017 8:41 am ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

Drama number 1: Got to work yesterday and got an email saying "oh, sorry, your booking isn't available, screw you". Fuck off, HireAce, never again.
Phone call number 1: Independent hire place, didn't have one for my desired time frame, but did have one IF I could have it back by 430pm Saturday. WIN!
Drama number 2: Tow car overheated while trying to park the trailer, details here: viewtopic.php?f=3&t=2627&p=43479#p43479
Solved by Rob/Corbon! <3 Owe you yet another one, mate! THANKS! <3

Dinner has been consumed, and I'm heading for the shower, some GrandTour, then bed for a 6am alarm and 630am departure! Other stuff I got done:

02:07pm <@Fred> sucking in a can of caffiene, then off to get trailer, do chores, come back, move cars, pack car, do more chores, go to sleep, get up early
02:07pm <@Fred> V12 tomorrow :-D
07:41pm <@Fred> 5.5 hours later, I have: picked up trailer, picked up hotel alloys, brought trailer home, parked trailer, overheated stagea, put wheel lock on trailer, abandoned trailer, drove to R33 home, borrowed viscous fan for stagea from skyline, drove back again, removed buggered belts from aircon/ps in 244, removed good belt from main pulley and alternator in 244, removed wheels from boot of 244, stored hotel wheels and volvo wheels behind house neatly, ground surface rust and bubbling paint/bog from 3 spots in 244, 2 in bonnet, one in LHS front door (passenger), reattached stagea to trailer, prepared phone holder and ciggy doubler in stagea, locked stagea for the night, put away tools in garage, prepared things for tomorrow in lounge, and now it's time for a feed, and bed. Yawn. Very tired already.

Not bad for five and a half hours! :-p

Tweets tell the story:

https://twitter.com/FredCookeNZ/status/ ... 1093869569
https://twitter.com/FredCookeNZ/status/ ... 4777843713
https://twitter.com/FredCookeNZ/status/ ... 0161555456
https://twitter.com/FredCookeNZ/status/ ... 7422801921
https://twitter.com/FredCookeNZ/status/ ... 3811462144
https://twitter.com/FredCookeNZ/status/ ... 6151468032

But pictures have a thousand words (each), unlike the tweets with just 140! :-p So:

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Author:  Fred [ Sat Mar 25, 2017 8:35 am ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

Too tired to write more now, but:

https://twitter.com/FredCookeNZ/status/ ... 8288326657
https://twitter.com/FredCookeNZ/status/ ... 6952291328
https://twitter.com/FredCookeNZ/status/ ... 2802330624
https://twitter.com/FredCookeNZ/status/ ... 0605369345
https://twitter.com/FredCookeNZ/status/ ... 8658036739
https://twitter.com/FredCookeNZ/status/ ... 6973334528
https://twitter.com/FredCookeNZ/status/ ... 4123623424
https://twitter.com/FredCookeNZ/status/ ... 8011474946
https://twitter.com/FredCookeNZ/status/ ... 3769966594

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Author:  Fred [ Sun Mar 26, 2017 9:25 am ]
Post subject:  Re: Fred's 1987 Volvo 240 GL Sedan - Notes and Debate

Updates from today on this:

1) Tarp bought and installed
2) Puller bought and assembled
3) Paint and bog bought and pondered

Tweets and pics:

https://twitter.com/FredCookeNZ/status/ ... 0231498753
https://twitter.com/FredCookeNZ/status/ ... 3246674944
https://twitter.com/FredCookeNZ/status/ ... 8611568641

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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

6) power scour the rusty patches and heat the area to fully dry it
7) rust kill the rusty patches if necessary (likely yes)
8) re scour to remove excess rust killer, leaving only firmly attached converted rust
9) bog the door holes with JBWeld, wait 24 hours before overcoating with bog
10) bog the bonnet with fresh polyester bog I bought today
11) sand the bog
12) primer the bog
13) top coat the primer

(make hay while the sun shines! It ain't shinin' tonight... hence 123 aren't already done...)

Also on the menu is a light water blasting of several parts of this thing. There's still lichen/moss on it under the trim strip on the RHS, for eg.

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