1981 244 GL High MPG - daughter's first car

[Jack]

Damn dude, nice work! Make sure to hide a rainbow on the diesel bro parts (probably not a good professional decision though)

thanks, getting close to being done.

finally fixed the driver side front light wiring

I rand out of black shrink tubing

finished the positive battery cable ends along with the junction box

new* wire from + to junction box. replaced broken junction box and cover. New connector at end of -

cleaned out the trunk in order to take care of the few surface rust spots

found out the radiator plug to house the fan sensor is leaking. Are replacement gaskets available?

 

[hiperfauto]

OE

Rubber Bushing 1378869 | TascaParts.com

1378869 - Rubber Bushing

www.tascaparts.com

Aftermarket

Radiator Plug & Sensor Seal - 200 700 900 - Aftermarket - Volvo 1378869

>101248 1378869 200 700 900 Aftermarket Plug Radiator Seal Sensor Volvo Vr389

www.ipdusa.com

 

[Jack]

I got busy with other projects on Sunday, yesterday I did 12 hours at work so I was too worn out to do much.
yesterday/today

driver side taillight with mounting studs broken off - Idk how that would happen

I cut off as set from a busted assembly

superglued the studs in place to align them, then I fiberglass reinforced them with some plastic epoxy
not pretty but it works

neutralized the rust and painted it

installed a good trunk gasket and got the lights to work. I need to fix one ground on the license light.

 

[TouzinFish]

Looking good! Never had a 240 with a working trunk light lol, cool that it works on yours.

 

[Jack]

Looking good! Never had a 240 with a working trunk light lol, cool that it works on yours.

Thanks
Usually it's just the bulb. I'll be fixing the hood light next - bulb is good but no power for some reason

today was a shorter work day, 11 hours. Getting up at 6:15 felt like slacking off

I didnt get much done.
Cut out a stock speaker to make grill adapters. This car came with some kickers with aftermarket grills -

I got stock ones from @philski o'flood

started to address the rust under the taillights. I bet Volvo didnt put seam sealer on the outside and water gets trapped under the interior one. I'm just wire wheeling this, putting some rust sealer, a bit of POR (not really a fan of it), seam sealer and paint. This is a problem for a future me to do it right. I crushed cars with less rust
after wire brushings

soaked it in rust converted

Can't really tell from the outside but Im going to make it water proof.

 

[ryanfay]

Evaporust might work good for that since you can pour it on and let it soak

 

[Jack]

Evaporust might work good for that since you can pour it on and let it soak

That’s a good idea, I have some, I’ll wipe it on there in the evening. I’ll wet a paper towel with it and tape plastic over it.

 

[Jack]

Today

I got it to crank but I still need to hook up few wires, distributor, and grounds. I had to bypass fuel pump relay to get gas to the fuel filter. IDK perhaps it has to do with the wiring not all there yet. The old fuel smells so bad!

https://imgur.com/MBu42gv

where do these go?

and ignition wiring -
EDIT - brown goes to knock sensor - not used on 81 and orange wire goes to microswitch. where does the ground go?

 

[302ftw?]

where do these go?

On my car (kjet turbo so fwiw) those look like grounds that get attached to the intake based on wire location. I don't have the one wire thats clipped though, so your results may vary.

 

[Jack]

On my car (kjet turbo so fwiw) those look like grounds that get attached to the intake based on wire location. I don't have the one wire thats clipped though, so your results may vary.

this seems to be the answer https://turbobricks.com/index.php?threads/1981-ground-connection-location.375705/

tried starting it but I was getting no spark, Pulled the distributor out spun it by hand and nothing. I hooked up the old Chrysler rotor and sensor and I got spark. The free distributor from Kjets didnt work... Probably wiring inside. I made a short wiring harness to go from "white cap" connector to the later bosch style.

this worked

https://imgur.com/P0yARFq

 

[Jack]

Battery was dead and after doing a whole bunch of crap around the house

goodbye '64 auto 4 door

I got it to start, then after moving the distributor around, to idle (high idle). Cooling parts are coming in tomorrow and I need to adjust a bunch of junk but it's almost ready to be driven around. Im debating if I should drain the gas or mix in new, there's about 1/3 of the tank left.

https://imgur.com/rrGAZ1u

 

[Harry Tuttle]

Do you know how old that gas is? If you already started it then any damage is already pretty much done. I always drain it and put it in a carbed vehicle. Still would recommend that.

 

[Jack]

Do you know how old that gas is? If you already started it then any damage is already pretty much done. I always drain it and put it in a carbed vehicle. Still would recommend that.

What damage?
At least 4 years old

 

[Harry Tuttle]

I don't have specifics, but it has always been said that old/bad gas is the devil for Kjet. And how about all those cars that "ran when parked" but don't run now? I imagine that deep in the works of the fuel dist there are disgusting things happening. The injectors love to get dirty and spray badly even with the best gas. If I was in your position I would drain that gas and put some fuel system cleaner in with the new. OTOH, if it starts and runs then you may toss the dice and make out.

 

[Jack]

I don't have specifics, but it has always been said that old/bad gas is the devil for Kjet. And how about all those cars that "ran when parked" but don't run now? I imagine that deep in the works of the fuel dist there are disgusting things happening. The injectors love to get dirty and spray badly even with the best gas. If I was in your position I would drain that gas and put some fuel system cleaner in with the new. OTOH, if it starts and runs then you may toss the dice and make out.

That makes sense. I ran the pump prior to starting until clean fuel started to come out.
It didn’t take long, that along with new filter I think I’ll be ok as far as clogs go

Good advice nonetheless. I’m going to drain it, it just make sense.

 

[Jack]

Yesterday/today I replaced the coolant temp bung gasket, transmission fluid, replaced spark plugs, installed seatbelt reminder buzzer - was missing, worked on the rust under driver taillight, drained the old gas.

I was going to set timing and adjust/test the microswitch but the rebuilt starter is acting up, it will click few times then cranks over few times but then nothing happens. The solenoid gets pretty hot right away and then nothing happens with key cycling... so I got to pull for warranty.

Here is some reference/adjustment info about the b21f-mpg