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Fred's 1989 Volvo 360 5-door Hatch 
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Emptied the oil that I pulled out of this after the first flush from the drain tray today. A thin bottom layer was bright green.

Last time I took it for a coolant-less drive, though, there was almost no water vapour coming out of the filler cap hole. About what you'd expect from normal blow-by.

And today she became empty-dirty-oil-bottle storage, passenger foot well and passenger seat are chocka with dirty (on the inside) oil bottles ready for disposal after a few hours condensing them into 20l bottles.

130 litres of waste oil now stored much more efficiently, and the garage got a minor clean up in a seldom-accessed location as a result. Win.

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Sun Aug 27, 2017 9:21 am
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Implemented a workaround for a minor issue on the 360: https://twitter.com/FredCookeNZ/status/ ... 2722265088

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Thu Aug 31, 2017 11:04 am
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Picked these up from the delivery-parent today: https://twitter.com/FredCookeNZ/status/ ... 6687892480

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15x6.5 ET34 4x100 PCD, hopefully the offset works for this thing. I think it will. I didn't buy totally blind :-)

They look like this on the front:

TODO

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Sun Sep 17, 2017 1:47 pm
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Car emptied of excess stored junk and filled with empty other stored junk, spare parts migrated to boot space, and ready for putting out on the street for a few weeks: https://twitter.com/FredCookeNZ/status/ ... 2800576512

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Sat Sep 30, 2017 1:47 pm
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Took this for a spin tonight, even managed to find the rev limiter for the first time. A poultry 5500 RPM, or possibly less.

One of my slowest cars, for sure, for now. Later? 300cc more, double the valves, and some reground cams. That ought to do it! https://twitter.com/FredCookeNZ/status/ ... 0713292800

Also upgraded the coolant bottle pressure relief cap from 75kpa to 150kpa (non-genuine, as a test): https://twitter.com/FredCookeNZ/status/ ... 5834091520

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Sat Nov 04, 2017 11:19 am
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On Saturday morning I decided to do the head gasket on this thing. Many tweets and photos since then. No posts due to tired, still working, etc.

TODO: Edit and bump thread...

Saturday started 11am on B234F stripping duties, went and dropped off mrs at Yoga, got back around 1145, started working on the 360 around 1pm, decided to do the HG not long later, turned in just before 4am. A few gaps for dinner and so forth, 14 hours 45 minutes, minus say 2 hours 45 minutes, 12 hours spent, roughly.
First Saturday tweet: https://twitter.com/FredCookeNZ/status/ ... 3333949440
Last Saturday tweet: https://twitter.com/FredCookeNZ/status/ ... 5122237440

Today late start due to late night, wife duties, and sleepiness thereafter. Got going 145pm, solid through to 745pm, supermarket for a while, got back into it 9pm, finished up outside about 1145pm
First today tweet: https://twitter.com/FredCookeNZ/status/ ... 1546103809
Last yet to come, will upload from bus tomorrow. And maybe edit post on the way home or something.

Current state is head torqued down 30nm, 60nm, 90 degrees, which is quite ruthless, even with a big bar. ARP ultra-torque lube made it nice and consistent, though. Win. Chucked 4 socks in the exhaust ports and rested the cam cover over the top and called it a night. Also put the cam gear back on (yet to torque up) and rotated the cam a few times to spread the assembly lube love, and filled the cam valley with fresh oil.

Tomorrow night is all just assembly. Should be able to finish it off and take it for a decent drive if nothing goes horribly wrong.

Would be driving it by now if not for:

Clutch cable without washer and nut embedded in rubber and unreachable
Bad ultra-hard rust scale on lower flange of exhaust manifold and to a lesser extent upper flange of exhaust
Corrosion on head bolts requiring thorough cleaning
Well stuck on gasket from 1989, head and block decks (par for the course, but...)
Two rounded nuts on exhaust manifold requiring die grinding to remove
Two studs coming out of the head requiring cleaning and locktighting into place
Bad alloy corrosion around water pump upper hole requiring hand cleaning with a tiny file
Light rust under/around battery tray, yet to do anything to it, but some time spent thinking about it/cleaning the loose rust up
Me being a fussy OCD perfectionist type and cleaning everything more than necessary

It's 12:45am now, and I'm about to jump in the shower, then hang out the washing that's currently on, process the acid and baking soda in the kitchen, and go to bed, ETA in bed around 145am.

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Sun Nov 12, 2017 12:44 pm
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Filler post for Sunday's tweets. TODO...

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n00bs, do NOT PM or email tech questions! Use the forum!
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Mon Nov 13, 2017 11:31 am
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Got the rest of the photos uploaded this afternoon. Last of yesterday pics/captions posted today was: https://twitter.com/FredCookeNZ/status/ ... 1699826688

Tonight, not too many pics, but got most things reconnected.

Wiring loom needs replugging in.
Exhaust manifold needs installing.
Radiator hoses need cleaning and reconnecting.
Cam belt cover needs refitting, after I see it running again open.
MAF hose needs rehoseclamping on.
A few assorted hoses need poking in where they belong.
Cam cover needs cleaning and torquing down.
Battery needs to be sat back in and hooked up. More work on this later, though, as it's a bit rough under the tray.

Can't think what else. Not much.

Tweets of tonight:

https://twitter.com/FredCookeNZ/status/ ... 2602853377
https://twitter.com/FredCookeNZ/status/ ... 1742883841
https://twitter.com/FredCookeNZ/status/ ... 4117991424

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Might duck out and do a little more now. Hmmm. EDIT: No, went down, realised I couldn't do anything without making excess noise for this time of night. Eyeballed the B234F remains and realised I couldn't lift it by hand in a controlled fashion. Tomorrow night is the ticket.

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Mon Nov 13, 2017 11:36 am
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Wiring loom needs replugging in.
Cam belt cover needs refitting, after I see it running again open.
Battery needs to be sat back in and hooked up. More work on this later, though, as it's a bit rough under the tray.

Fred wrote:
Exhaust manifold needs installing.
Radiator hoses need cleaning and reconnecting.
MAF hose needs rehoseclamping on.
A few assorted hoses need poking in where they belong.
Cam cover needs cleaning and torquing down.

Done. And various other things. Remaining are:

Wiring loom needs replugging in. TPS, Idle, Small2PinRearHead, CHT, Fifth Inj, Four Injs.
Three empty lucar terminals need sorting - one is temp gauge! Other two unused??? Or I forgot?
Fan and water pump pulley need to be installed/belts back on.
Fill engine with straight tap water, for now. Penrite race inhibitor later.
Battery needs to be sat back in and hooked up. More work on this later, though, as it's a bit rough under the tray.
Run engine and warm it up fully, maybe a short gentle drive.
Flush oil, replace filter, refill with fresh oil.
Cam belt cover needs refitting, after I see it running again open.
Reinstall air filter and front pipe.
Reattach and adjust cable clutch.
Use it to collect a couple of car brochures... :-)
Degrease the driveway and put away all of the tools.

Tweets/pics:

https://twitter.com/FredCookeNZ/status/ ... 8820523008
https://twitter.com/FredCookeNZ/status/ ... 8825342976

Image

Image

_________________
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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!


Tue Nov 14, 2017 11:05 am
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Did the last few things tonight, out of order:

Hooked up wiring
Filled with straight water
Fan and pulley and belts back on
Flushed out filthy and sparkly (uh oh) old oil (hoping sparkly from my antics, not some issue, bearings seemed good when checked)
Filled engine and new filter with blend of: 15w40 diesel, 20w50 cheapy, 15w50 PAO/Ester 10 tenths Penrite, 20w50 Amsoil Series 2000 race oil. 3/4 is the junk. Let's call it semi synthetic...
Battery back in.
Penrite race coolant inhibitor in.
Cam cover back on.
Air filter and pipe back on.
Clutch cable end fix for tomorrow.
Make-shift replacement clutch cable end for today.
Heat shield back on the exhaust.

Tweets/pics:

TODO...
First today: https://twitter.com/FredCookeNZ/status/ ... 3270495232
Last today: https://twitter.com/FredCookeNZ/status/ ... 0048823296

TODO list for car:

Get some 95 RON into the tank to decrease/solve the pinging issue. Filled with 98 to average out. Made no difference. Behaviour of car is like timing is too advanced everywhere. Surging on overrun, super crisp response, pinging under load, even light/moderate or tip in. So:
Resolve excess timing issue with regina/rex ECU setup. Priority number one. This is likely how the HG failed the first time.
Replace make-shift clutch adjustment setup for the proper one that I have repaired with RTV and a vice.
Clean the exterior of all the solvent/degreaser/oil overspray/splash that has it looking super dirty right now.
Make ciggy socket work reliably so radar detector can be used and I can get a feel for the car.
Empty 20l bottles from the boot so they don't rattle around while driving.
Replace plugs with something iridium or platinum.
Check leads for resistance/condition, replace coil-to-cap lead if possible/if dubious.
Derust the battery tray area and bolt it back together with s/s fasteners.
Glue the driver's door seal back in place with ADOS or superglue or similar.
Replace diff oil with something much better.
Replace box oil with something much fresher and synchro friendly.
Head rests and rear arm rest are bags of loose dust, replace with cut foam rubber.
Fix rust spot right rear door.
Fix rust inside of rear roof, not yet through.
Find out about lowering and shocks, current shocks are worn out.
Check fitment of 15x6(.5?) alloys on the front and rear.
Get worn out R888 195/50R15 tyres fitted to 15x6(.5?) alloys.
Fit 15 inch alloys with worn out R888s to car :-D
Change brake master cylinder reservoir to offset variety.
FreeEMS the existing engine setup as a baseline.
Build sweet ~200hp 16v 2.3 engine and swap in :-D

Took it out for the fill up with higher octane gas and took a few long exposure shots with the GF1. Some seemed to come out nice.

Zzzzzz time.

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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 Nov 15, 2017 12:08 pm
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