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1983 Volvo 244 Turbo - The Fun & Unreliable Money Pit

TouzinFish

Active member
Joined
Mar 12, 2017
Location
Boise, Idaho
(Thread Construction in Progress...)

1983 Volvo 244 Turbo
-B21FT / M46
-IPD Lowering Springs
-IPD Sway Bars
-IPD Adjustable Timing Gear
-Intercooler
-Saab APC Boost System
-EFI Intake Manifold
-Terminal 11 Modification
-Catch Can
-2.5" Exhaust by Boise Muffler
-Relocated OD Switch


Formerly owned by: NWVlvTnr
See NWVlvTnr's thread,
here.
 
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January 14, 2021

In January of 2021, I was once again shopping for a Volvo project that I didn't need... because that's what I do best.

Anyway, I'd convinced my wife to let me go look at this:

In person, I was able to confirm that the car did indeed having timing issues, in addition to missing multiple vacuum lines and having the world's loudest belt squeal. Add all of that to excessive backfiring, and the car wasn't ready to handle any sort of test drive. However, the interior was a cool brown tweed, and the M46 was still crisp and notchy. Looking under the car, I saw IPD sway bars and no rust, and in the engine bay was a well-done electric fan conversion.

I was ready to buy the car, but then my phone buzzed, and I looked down to a Facebook Marketplace "suggested for you" ad on my lock screen: a 1983 Volvo 244 Turbo. If that notification had popped up even five minutes later, I would have already bought the white 240 and wouldn't have even been able to consider looking at the Turbo. But at this point in my life, I'd driven other people's turbobricks, but I'd never owned my own turbobrick, so I had to go check it out.

My wife wasn't really surprised when I ditched the 1984 Volvo 244 in favor of a 1983 Volvo 244 for double the price (she reminded me I couldn't even afford it), but she was a good sport and went over with me to check it out.

Did I go look at it in the dark? Yes. Do I encourage that behavior? Probably not. Will I probably do it again someday? Absolutely.

In person, it was apparent that the seller knew absolutely nothing about the car. He didn't know it was a Turbo, or even what a turbocharger was, or even that this was a Volvo 240. He'd been gifted the car for free from someone at his church, and now that it was beginning to have some issues, he was looking to pass it on.

In the dark, here was what I was able to observe...

Aside from a terrible exhaust leak at the manifold and the AFR gauge bouncing all over the place like a caffeinated six-year-old, the car drove pretty well. The inside was filthy and if I could see how trashed the roof's clear coat was at night, then it must have been especially terrible during the day. The tach was anywhere from 600-1100RPM at idle, and the turbocharger didn't really seem to know how much boost to be pushing. I was also a bit bummed to look down and see that someone had popped on a random shift knob, presumably because the overdrive was non-functional and they didn't want to deal with it. However, the car was awesome, and I was sold.

This was back when my wife and I had only been married three months fresh out of college, so money was tight. Spending $1k on the white 240 was already a stretch, but $2k for this Turbo simply wasn't doable. Especially because the seller was firm on his price.

Luckily for me, my wife is awesome at helping me get into unreliable money-pit cars, so she suggested the logical answer: "let's see if he'll accept a deposit to hold the car, and then we'll sell our reliable commuter." And that's exactly what we did. We threw down a $200 deposit and listed our primary car for sale.

Right when we sold our Subaru (seriously, minutes after) I received a text from the seller of the Turbo: apparently he'd taken the car out one last time for old time's sake, and it broke down. So that brought good news and bad news:

The good news: The seller felt bad, and decided to simply let me have the car for what I'd put down as a deposit ($200).

The bad news: I'd just sold our nice car, only to bring home a car that didn't even run.
 
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January 19, 2021

Excited for my newly acquired $200 Volvo 240 Turbo, I wandered out to the seller's apartment to investigate why it wasn't running... this was also the first time I'd seen the car in the daylight.

Taking a quick look in the engine bay, I saw a mounded pile of corrosion on the battery. Even after brushing it all away, the cables were in rough shape. Wiggling them around would get some of the lights to briefly pop on, but the connection wasn't good enough to start the car.

The seller only let me poke around with the car for a few minutes since his landlords had a very strict policy against wrenching on-site. Luckily, he lived pretty close to us, so when the evening passed and traffic thinned out, we used the unkillable 240 to tow it home. Sketchy, but it worked! At this point, my wife was matching my enthusiasm.

Little did I know that this was the first day of the worst love-hate relationship I've ever had with a Volvo.
 
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January 20 - 27, 2021

After dragging the Turbo (the nickname for the car from here on out) home, we were able to finally take a good look at the car the next morning; it quickly became apparent that at some point in this shabby old car's past, the owner knew what they were doing. The first thing I noticed was the intake manifold being different from your normal run-of-the-mill Turbo. This looked like it was from a later LH B230. I'd heard the later manifolds allow better airflow, but that's a bit of a niche thing to know, so I began hunting around for what else the knowledgeable mystery figure of the car's past did. Over the next ten or twenty minutes, I noted the IPD lowering springs, sway bars, intercooler, DIY catch can, full gauges, silicone hoses, and the 2.5" exhaust. Cool!

I also took the time to appreciate how cosmetically different a factory Turbo is than a standard 240: egg-crate grille, black belt trim, black headliner, the trunk badge, the subtle horn stamp, the smaller steering wheel, the Virgos, and the icing on the cake: the GTX headlight trim.

After replacing the battery cables, the Turbo roared to life and ran pretty well, aside from that overly annoying exhaust manifold leak and the AFR gauge having a seizure. I took the car to the gas station and back, still in disbelief I scored it for 200 bucks.

If my wife wasn't cool enough for selling our reliable daily with heated seats in exchange for this pile of garbage, this was her peak moment of cool-ness: understanding that I didn't have a garage or storage shed, she invited me to convert her walk-in closet to my tool storage and mini garage. I'll repeat: my wife invited me to take over her walk-in closet for Volvo parts and tools.
So my first day of ownership involved wrenching on the car after a break-down. Day two should be better, right? Wrong.

I went to start the car, but it wouldn't start. Hmmm. Pulled the fuel line and verified fuel pressure, verified spark at the plugs, checked for clogs in the air intake. With my multi-meter, I poked over the crumbling pile of granola that resembled my wiring harness and called it good enough. I popped off the upper timing cover and the belt looked intact and tight (and I was nicely greeted by an IPD adjustable timing gear), and I couldn't find any issues with the K-Jet.

Being January, it was already dark by the time I got home from work, so I was stuck outdoors, sometimes below zero degrees Farenheit, figuring out why the car wouldn't start. Here's how dark and terrible my usual night was in the engine bay:
 
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January 28, 2021

After a week, I got tired of being cold, working in the dark, working in the snow, and having the occasional knuckle bash be excessively painful compared to summer. So, I called Dennis and had the Turbo towed out to his warm, toasty, blissful shop.
(guest appearance by the rescued 240 and XC70)

There, within about 30 seconds, Dennis pointed out how out-of-tune my ears were, because I didn't hear that the car was turning over suspiciously fast. Without even popping the hood, Dennis put a bet on the timing belt as the culprit for why my car wouldn't run.

We tore into it, and here's what we found...

Do you see it?
How about now?

How about now?

Yes, my timing belt's teeth stripped around the crank on just my second day of ownership.

Being thankful for the warm shop space, I paid Dennis for the space and expertise and decided it would be a good time to address the exhaust manifold leak. Since Boise Muffler welded the Turbo's exhaust as one piece, it was difficult to simply pull the manifold away from the head, so we opted to remove it altogether... what a chore!
 
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January 30 - February 13, 2021

With the exhaust out, we were able to peel away the turbo and manifold to see what we were working with... which unfortunately was three snapped studs in the head of the engine. Sigh.

For the bulk of the day, we tried welding, drilling, extracting, etc etc etc to get the studs out, but the previous owner had been driving for so long with them snapped that they were really buried tight. Additionally, the manifold had developed a warp from the uneven torque distribution through possibly hundreds of heat cycles, which didn't help.

Just for the heck of it, I posted in our local Volvo Facebook group to see if anyone happened to miraculously have a B21FT head that they'd part with, since that would likely be cheaper than having a professional work on the existing head.

To my surprise, someone did! He also had an extra exhaust manifold - perfect!
 
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February 13 - 15, 2021


Dennis took the "new" head to the machine shop to be resurfaced and cleaned while I was at work, and then we met up to remove the existing head from the engine.

Can't beat Swedish steel. The cylinder walls still had the cross-hatching!

While we had the head off, my wife and I chatted and decided it would be a good time to comb through and give the car a proper refresh, so the car received a new alternator, water pump, engine mounts, exhaust hangers, and all engine seals (except for the rear main).

Would that have been a great time to clean the engine bay? Yes, but I was lazy and didn't.

With the car was in a billion pieces, I noticed that the it had a Saab APC system hooked up, and also stumbled onto the modification to Terminal 11 while I was replacing all the fuses and checking the relays. Sweet!

It felt awesome to get the car put back together and ready to roll. Without the exhaust leaks, it sounded amazing. Drove wayyyyy better than before.

The car should be reliable now, right? WRONG.

The day after it was buttoned up, the throttle cable snapped. In a rough part of town. In the rain. 39F degrees outside. Sigh...
 
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February 15 - 25, 2021

After I replaced the throttle cable, I deemed the car reliable enough to drive to work for the first time. After work was also the first time I had to climb through the passenger-side in slacks, a button-up, and tie.

When I bought the car, it didn't have a spare tire, so I thought, "wouldn't it be cool if I had a Virgo as my spare?" I couldn't find a singular Virgo, but I could find a set! The extra set later went on the Frankenwagon.

On day number four or five of driving the car to work, I reached down to turn the rear defroster on, only to be abruptly startled by the car kicking into overdrive. It took a few seconds to process what had just happened, and that's when I noticed the car had two defroster switches. Turns out, the spring-loaded one on the left was actually a relocated overdrive switch! Super cool! I don't know how I never noticed it before. I was especially happy because it meant I got to keep the weighted aluminum shift knob.

After four days of trouble-free driving, the 240 should be reliable now, right? Wrong. Again.

When I was off work, I was wiggling through five lanes of rush-hour traffic in downtown Boise when the car's RPM's started bouncing around as if I had a vacuum leak. By the next stop light, the car died. My intercooler hose had popped off, no biggie. I slipped it back on, made it another half mile, but my RPM's weren't returning to normal. So, for the next two days, I hunted for vacuum leaks with a DIY smoke machine that I built from this Instructables article.

Easier solution: Find a friend who vapes.

Eventually, I found the leak to be a big split in my warm-up regulator (WUR). Probably explained why the car ran particularly terrible when the engine was cold. I had a spare, so no big deal.
(Scrappy making a guest appearance)

With working overdrive and the vacuum issues addressed, the car ran better than ever, so I rewarded myself by taking a late-night drive on a closed course in Mexico :roll:, where I confirmed the car easily held boost and would settle into the 115-120MPH range before the RPM's got too spooky. Not bad for a 1983!
 
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February 26 - March 24, 2021

I had nearly a month of trouble-free driving! Woohoo! A few somewhat noteworthy-ish things that happened over that time span...

Finally gave the Turbo its first bath. From certain angles, the car looked decent!

Instead of properly repainting the roof, I hid the peeling clear coat with a massive metal barnacle.

In a way, I wish I'd followed through with purchasing the white 240 that's at the beginning of this thread - the seller scrapped the car after I passed on it. On a positive note, I was able to snag the IPD sway bars from the junkyard for future shenanigans. I feel like it had way more potential than the scrapyard though. :raincloud:

The more I drove the Turbo, the more I enjoyed the car. No radio or distractions - just simple, analog driving. The pedal feel, shifter feel, and steering all felt great, though the power steering may have been a little over-boosted for my preferences during spirited driving. Exhaust sounded incredible, the engine bay made all the proper turbo noises, and the M46 had a weirdly nice whine to it. After having many 240's, it was crazy how different of a 240 experience this car was.

Ohhhh yeah, it was all coming together. :godlike:
 
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March 25, 2021

My wife, brother, and I had wanted to take a road trip to see the Redwood Forests in California for a while. In March, we finally found time to check that off the bucket list. Since the Turbo had now been rock solid for a month, I convinced them that we should take it! Unfortunately for them, they agreed.

With the fastest route, it would have been just under 10 hours before hitting Crescent City, California, so we decided we'd camp there before heading south on Highway 101 to the thick of the Redwoods. A chunk of this trip was also to enjoy Highway 101 in the Turbo, hence why we went to Crescent City instead of cutting down through Klamath Falls, toward Redding.

Anyway, the route called for us to leave from Boise on I-84 to Ontario, Oregon, where we'd cut off through Vale and Burns on Highway 20, before turning south in Riley and meandering down near Crater Lake to Medford. We decided we'd have dinner in Medford or Grants Pass before continuing on through Cave Junction and into California.

Sounds easy enough, especially in an old K-Jet car with the wiring harness falling apart.

Early on March 25th, we loaded up the trunk and roof basket, packed the spare Virgo, and set off... in the dark, cold, rain. Ironically, the heater decided not to work that morning, so it was miserable from the beginning. Oh, and I forgot to tell my wife and brother that my sunroof leaked... a lot.

We traveled about 30 minutes before running into our first hurdle, just beyond Caldwell, Idaho: a flat tire. No biggie, because I packed that spare Virgo.

From there, the car did great. On the rolling hills with full luggage and an 80MPH speed limit, the Turbo's overdrive and turbocharger went to great use, easily keeping up with modern traffic. We crossed into Oregon and the trip was beginning to look optimistic!

However, we started running into trouble in Burns, Oregon. When we parked for fuel and coffee, I noticed a considerable amount of smoke coming out from the engine bay - yikes! I opened the hood to see a completely ruptured valve cover gasket spewing oil down the side of the engine, onto the exhaust and turbocharger. Nowhere in Burns had a valve cover gasket, so I had to improvise with some RTV gasket maker. Did it work? Not really, but the leak had slowed. So, onward we marched. The K-Jet was handling the elevation changes flawlessly, and aside from the lowering springs being a little harsh on bumps, it was a comfy ride. Between Burns and Riley, I lost the glass from my driver-side mirror, lame.

When we refueled in Silver Lake, the oil leak had returned, this time MUCH worse. Again, I improvised with some RTV gasket maker. This time, it sealed! We hit some pretty roads when we neared Medford, Oregon and even saw some snow, where we once again missed having a heater.

We stopped for dinner in Medford, and luckily nothing was stolen from the roof basket while we ate and relaxed, leaving the car unattended and street-parked in a seemingly rough part of town. Crossing through Grants Pass, Oregon was a breeze, and we began our final push into California!

Shortly after crossing the California border, the car began to act weird. The throttle was cutting in-and-out, and the turbo was misbehaving significantly. The car was acting as though it was cutting fuel at only 3 or 4 PSI on the turbo, making the hilly, winding roads with a full cargo load extremely difficult. We managed to limp along with our hazard lights until we arrived to our campsite, where we parked, set up camp, and decided to deal with the issues the next day.
 
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