A Rescued 93 240 Wagon

[Hodginsa]

Ongoing To Do List:

Maintenance/Required:
- Stage 0 (Oil, fuel, air, filters)
- Oil Leak
- Get Gauge Cluster/Install
- Reinstall all Interior Pieces
- Replace Leaky Booster
- Starter
- Proper Battery Tie Down
- Front Brakes
- Rear Brakes
- Rear Hard Brake Lines are Crushed (wtf)
- Front Left Caliper (super rusty but working/not leaking)
- Fuel Leak (Fuel filter)
- Trans Leak(Gasket?)
- New Tires
- New fuel sender unit(looks crusty AF) & lock ring + fuel hoses
- Timing belt (or just swap engine)
- Fix Azev Wheel Lug Seats (Damaged)
- Auto locks being weird
- Sticky Idle Valve: Replaced

Optional:
- Pop out kick dents
- Install new radio (stock volvo missing code)
- Fix or remove AC (TBD) Removed!

Performance/Fun:

- Install rebuilt B230FT with GT35R
- Install T5 Trans + Hydraulic Clutch
- MS(have harness and box already) or Turbo ECU/EZK
- Brake upgrade
- Scope Bosch 124 Dwell
- Scope AIC PWM
- Scope Injector Deadtime

Long story short, this car was abandoned at a Volvo repair shop near me. I've known the owner of the shop for a long time and occasionally get work done there on my V70(he also has like 5 storage containers full of 80-90s car parts, but that's another story). The shop after like 20 years didn't have their lease renewed, so they have to move, and with it all of their cars and parts. So to make things easy he was getting rid of some stuff, and I asked about this car(which was destined to have parts removed from it the rest of its life) and he said I could take it. Unfortunately didn't have the ownership, hence the part out destiny.

So I got a uhaul trailer with my suburban and picked it up!

The dash was partially ripped apart, someone cut off the catalytic converter and put two dents in the front and rear driver fenders with a kick, key is missing, no cluster(the shop had it but I couldn't get ahold of them while moving), but otherwise the body is in good shape, and everything around here rusts to nothing, so this is basically perfect IMO. My plan was to cut it up for stuff for my 242, but after seeing how there were no holes at all I decided to get it back on the road.

Turns out it even has IPD sways on it.

Had to swap the ignition part which is really fun! And throw in a starter which I just stole off the 242 since its a shell right now. Band clamped some cat from a F150 and a new o2 sensor. Finally got it to fire up. Ebay'd a gauge cluster.

I spent awhile trying to talk to the shop to get the original owner to bring the ownership, or find the guy, to no avail I wrote an an affidavit of the situation and managed to get the ownership transferred over into my name. It was at the auto shop for nearly a year I think, and at my shop for a few months with no contact.

I threw some new brakes on the front and put the Azev Type As from the 242 I've had sitting for 10 years on it. Not too bad!

This will be the fun car for awhile, so I can figure out what to do with the 242. Might slap the built B230FT and T5 in it at some point if I get bored.

 

[blkaplan]

welcome back!

 

[Hodginsa]

welcome back!

Thanks! I was eyeing the BNE store the other day. The wagon might fill my project car void for awhile.

 

[Hodginsa]

Brake booster was hissing when pressing the pedal and causing a vacuum leak, and I had one sitting around so I popped it in. Its an ABS car so its easier to move the master out of the way I think. Pull the gauge cluster again... Makes it easier to see some stuff. Luckily the dash is still in a few pieces from when I bought it.

For some reason the brake pedal wasn't touching the brake light switch anymore, and I couldn't see a way to adjust the switch(or be bothered to figure it out) so 3d printing to the rescue. Just a little plastic spacer pushed on.

This is a pedal assembly I had to in the shop I used to mock up, and why I couldn't see any adjustability.

A little vacuuming of the usual 240 chair crumbs.

Then I discovered where the fuel leak was. The fuel filter rusted through (I'm sure no rust got into the system ) - this is why you always buy Bosch.

Waiting on parts....

 

[towerymt]

Then I discovered where the fuel leak was. The fuel filter rusted through (I'm sure no rust got into the system ) - this is why you always buy Bosch.


Waiting on parts....

BTDT, '92, pinhole. I guess you didn't read my thread, you should have these parts on the shelf already

240 - Kids....change your fuel filter...

...or else it will one day leave a puddle on the ground and you'll have to deal with it ASAP. I've had this car nearly 10 years and have put about 110,000 miles on it. I've never touched the fuel filter until today. It rusted through. 1992....240,600 miles...don't know if/when it was ever...

www.turbobricks.com

Hope yours comes apart easily. Mine wasn't toooooo bad.

 

[Hodginsa]

BTDT, '92, pinhole. I guess you didn't read my thread, you should have these parts on the shelf already

240 - Kids....change your fuel filter...

...or else it will one day leave a puddle on the ground and you'll have to deal with it ASAP. I've had this car nearly 10 years and have put about 110,000 miles on it. I've never touched the fuel filter until today. It rusted through. 1992....240,600 miles...don't know if/when it was ever...

www.turbobricks.com

Hope yours comes apart easily. Mine wasn't toooooo bad.

Hahaha, yeah there is a bit of rust... got everything I should need to replace, including new banjo bolts, but I think it will come apart intact. I've been surprised so far I haven't stripped anything.

Liked your idea of the running list of stuff to do. Updated first post.

 

[towerymt]

Cool!

Other thing I like to do is take a photo of the odometer every 1,000 miles, then put that down along with the date (photo just records date, dont care about the actual pic). And note maintenance & mods in a running timeline. Helped me keep track of rate of miles driven. Things like tires & brake pads.....when did I last change those???

I closed this thread and just use it for my own records keeping, but I'll do the wagon project thread the same way: https://turbobricks.com/index.php?threads/1992-244-f-t-daily-driver.217941/

 

[Hodginsa]

Cool!

Other thing I like to do is take a photo of the odometer every 1,000 miles, then put that down along with the date (photo just records date, dont care about the actual pic). And note maintenance & mods in a running timeline. Helped me keep track of rate of miles driven. Things like tires & brake pads.....when did I last change those???

I closed this thread and just use it for my own records keeping, but I'll do the wagon project thread the same way: https://turbobricks.com/index.php?threads/1992-244-f-t-daily-driver.217941/

Thats awesome. This gave me an idea. Throw together a microcontroller with a gps and monitor distance traveled and running hours and automatically log it to a spreadsheet every time it connects to wifi (this is the kind of custom stuff I do for work/fun). It could even have a button set for oil changes/brakes and other maintenance items to automatically log those things as well. It could sit in the glove box or just hidden under the dash somewhere and just give it switched 12V. Basically a maintenance logger for older vehicles. Hmm, who wants one?

 

[Hodginsa]

Fuel Filter Replaced.

Then went to fix my wheels... So I guess the stock 240 lugs taper did not fit right with my Azev's - I don't remember this happening before but maybe I was using virgo lugs. Anyway, these lugs didn't seat right and the dig into the aluminum, dumb mistake by me but need to fix it.

See all the aluminum chips?

So I took a wheel hub I had around and stuck it in my Bridgeport. Knocked out one of the studs and centered it over the hole.

The first automotive stuff I've done since I've had the machines.

I took a 60 degree single flute and cleaned up all of the holes. They still had a small groove in one part but they seat much better now. Added some new lugs that have a wider cone. Since I set it up with a hub, I could just rotate and cut the next one without dialing it in again.

These look much nicer, and don't self clearance.
Whats interesting is the rear wheels have steel inserts in them, but these two don't.

I finally brought it home today.

 

[Hodginsa]

Wouldn't turn over this morning. Added a little torque to the starter solenoid nut and it started, but whole stud wiggles a little even though its tight. So might be damaged internally? Otherwise starts great.

Anyway! power locks would randomly make the solenoid noise when the door was jiggled. There's your problem!

Surprised no fuses blew.

 

[Hodginsa]

I might be thinking about putting the built B230FT and the T5 I have out of my 242 in this. Really thinking hard. There was a flat flywheel on it that had a nice layer of rust on it from sitting. Always wanted to try out Evapo-rust so I figured this would be a good test.

Who needs a sandblaster?

 

[blkaplan]

I love evaporust, that stuff is great.

 

[blkaplan]

The dealer should be able to get you the radio code if you need it.

 

[towerymt]

Dang. I need to try that on the bottom of the doors on my 244.

 

[Hodginsa]

The dealer should be able to get you the radio code if you need it.

Is it based on the VIN? I have a feeling its not the original radio to the car. It had an aftermarket one in it at some point.

Dang. I need to try that on the bottom of the doors on my 244.

I know.. I want to dunk the whole 242 in it. It doesn't mess with paint or other stuff so its not like an caustic acid bath, only deals with the rust. There is a method of dampening a rag or paper towel in it and putting it on the surface.

 

[blkaplan]

Is it based on the VIN? I have a feeling its not the original radio to the car. It had an aftermarket one in it at some point.



I know.. I want to dunk the whole 242 in it. It doesn't mess with paint or other stuff so its not like an caustic acid bath, only deals with the rust. There is a method of dampening a rag or paper towel in it and putting it on the surface.

I havent done it, i think its based on vin... there maybe a serial number on the radio you can use as well.

 

[Hodginsa]

I was digging through my 242 parts bins and decided to swap in the tach, and some gauges. Who needs a radio anyway(ill figure something out.) Out with the cluster again!

Thought I lost my wideband, but nope! Still need to wire these up.

Left the V70 at the shop again.

 

[Hodginsa]

I removed the temperature compensation board because my temp gauge wasn't working(wasn't moving at all). Now I'm just wondering if the car wasn't getting hot enough. I think the thermostat is stuck open. Measured the temp and it only got to 50C. Mind you it was only between the fins but the gauge seems to corroborate that fact.

Had to re-tap this hole, trying to get the interior back together but missing hardware, so I started a list on Mcmaster Carr. Its weird having the right tools around.

I let my ADHD take over today after I found a spare GLT steering wheel I had around. So I swapped it out in the wagon. I don't trust that old airbag anyway, and it had been disconnected since I got the car. Had to swap the clock spring and hub cover thing as well.

and repaired a wire.

Horn still doesn't work. There are some funny wiring things going on in this car. The overhead light goes ON when the door is closed but the switch still works. Still getting a slight gas smell but I don't see any leaks. I think its from the filler cap, the tube where it threads on looks bent, and I'm wondering if the fumes are coming in through the rear vent on the wagon. Its a faint smell when driving. Pretty much completely goes away when idling or not moving.

 

[Hodginsa]

Welcome back to the evaporust Channel.

I'm blown away by this, the spring back actually works again. The hood pop is a little sensitive, and that combined with the secondary latch having to be manual pushed back so it would catch made me a little nervous. So a quick ultrasonic clean, then Evaporust, the spring literally looks brand new, no pitting. And it works!

I could put it back in and be perfect, but functionally its perfect now, so thats good enough.

 

[Hodginsa]

3d Printed a test TPS adapter for the 850 TPS before I machine one.

had to notch one of the edges a little.

Ill post the cad files on GrabCad once its finalized so anyone can make one.