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Continuation of the 242 16VTi build

@GTJordan so you are field service engineer for Volvo? Very cool. Neat to see the competition for the Countryman BEV. Knowing ze Germans, I doubt the cells will be anywhere near that accessible.
 
In my past years my DSM wanted me go to work for Volvo as a field trouble shooter. I had to quit my job at the dealer before he would tell me that I had the position. This would also mean that I would move to Dallas. Thought long and hard on this but decided the move wouldn’t work. A few years later local mega dealer bought us. He tried to run us like a domestic store. Got the chance to help open a new Acura store. Got paid Friday afternoon and loaded my tools.
 
I am not, what Volvo calls an FTS (field tech), nor RTS (retailer tech support). I'm just a shop foreman at one of Canadas largest dealers. I spend most of my days communicating with RTS about problem cars and trends. With that, plus all the competitions I've attended, I have got to know quite a few of the people there (and it helps that one of my really good friends is our FTS). I've talked to them about moving up to RTS, but it requires a relocation to NJ, SC or Cali. I'm not at a point in my life where I could do that. Our FTS just started and it is the job he has always dreamed of, so I don't see him leaving any time soon.

So I'm at the retailer for a little while longer. Which is fine, I really like where I work and what I do. I'd just like to go up to corporate at some point.
 
Progress slowed. I'm still going out to the garage to do one thing. But nothing really note worthy has happened.

The IC is in the process of being modified.

I've been plugging away on wiring. Trying to get it to a point where I can finally mount it and put the dash/interior in.

I got the yoshi catch can installed. Along with the FPR.

I have two connectors I can't find in my wiring diagram. The harness is from a 92.

I thought this was the brake fluid level connector - but it does not match the wiring colours in the diagram. It is located by the brake booster/strut tower. Two pin. Thoughts?




backsideofdriverstrutresize.jpg



Next unknown, is at the front of the driver side strut tower. It is a three pin connector with only two wires in it (missing one makes me think I removed one of the wires already, and didn't label the connector as I went. Oops. Any idea?


Driverstruttowerresize.jpg


This is where I mounted the Yoshi can.

Yoshicatchmountedresize.jpg



In the hopes of driving the car this year, I decided to skip mounting the PS pump. But with current progress speed, I don't think driving it this year is going to happen. Only two months until the snow is back and I've got a ton to do. I started thinking about putting the P1 pump in the passenger side fender well. Almost how they're mounted in the P1. Will have to cut a hole in the inner fender to make it fit. Not world ending.

Vacation for a week. No progress for a while.

Jordan
 
GTJordan said:
Progress slowed. I'm still going out to the garage to do one thing. But nothing really note worthy has happened.

The IC is in the process of being modified.

I've been plugging away on wiring. Trying to get it to a point where I can finally mount it and put the dash/interior in.

I got the yoshi catch can installed. Along with the FPR.

I have two connectors I can't find in my wiring diagram. The harness is from a 92.

I thought this was the brake fluid level connector - but it does not match the wiring colours in the diagram. It is located by the brake booster/strut tower. Two pin. Thoughts?




View attachment 27997



Next unknown, is at the front of the driver side strut tower. It is a three pin connector with only two wires in it (missing one makes me think I removed one of the wires already, and didn't label the connector as I went. Oops. Any idea?


View attachment 27998
Click to expand...
First connector I don't know. I would think brake fluid level
Second connector goes to a little sub harness to the factory ignition coil. Blue wire is 15 (+12 ign to coil) and white/red is 1 (- at coil)
So blue you could use if you need to have switched ignition under the hood for something, the red and white goes to the tach at the instrument cluster.
 
Neat build, lots of super cool parts coming together. Looking forward to seeing the solution for the intake and intercooler plumbing.
 
I went on vacation. It was a decent time. Have a bunch of house projects to finish up before winter/hockey season starts. Lame. I've resigned myself to not driving the car this year. Too much fabrication is needed.

So here was the first step. Modified IC. My buddy thought it would a pretty simple rectangle to flip once it was cut off. It was not. That cut was then cut into 4 pieces and then welded back into what you see, then back onto the IC.

Modified IC.jpg


Then I figured, it was probably going to cost 1K to have all of the fabrication done. So I might as well pick up a new trade instead of letting someone else have all the fun. This showed up while I was away. There was a mix up and I also have a Mig180 that is getting returned. Anyways. Keeping this unit around

Whatisthisthing.jpg


New thing to learn over winter. Because I have O'So much time during the winter.... not. But it should be fun to learn. I hope.


I actually got a call back today about the radiator and the gas tank- that the guy is going on Vacation next week. He said I'll be one of the first projects in when he returns, and since I had wated so long he will give me a killer deal. We will see what that ends up being.

Anyways, long weekend. Have a few jobs to do this weekend, and then house projects. But I'd really love to tackle that last bit of wiring. Motivation is taking a hit. But once I get going again, I like to make progress.

Jordan
 
Nice one!

One of my dreams is to get a TIG and learn using it as i got quite ok with the MIG. Also got loads of friends that are pro fabs, so it won't be that difficult!

Keep it coming!

ADam
 
Still plugging away..... BUT hockey started for the kids last week. Soon my life will be fully consumed.

So, where to start.

The exhaust manifold I guess. I broke that tap off in the manifold. I was WORRIED about getting it out. I was able to weld a nut to it and remove it though! Then I bought the 8.5mm drill bit and M10 1.5mm tap as a kit and drilled out the holes and tapped them so I could get the M10 Full race inconel studs in. Went way smoother than I expected honestly.

Removed broken tap.jpg

installednewstuds.jpg


With that out of the way. I wanted to start feeling like I'm accomplishing something. So I started with the dash. I ran some dryer venting from the heater box to the vents. They are clamped, then duct taped for more sealing action. And I was bored.

roughinginplumbingandwiring.jpg


I then threw a seat in so I can sit while I tinker with the dash wiring. Note the GT rear "door" card- more on that later. Apparently my cats found the seats (even though they were under blankets) and made a home on them. I might take them to work and have them clean them up for me. I'll never have the patience to clean them to my low standard on my own.

seatneedsaclean.jpg


The GT door cards. I grabbed these from my dads GT parts car. They had some pack rat shit from sitting in a field outside of Kamloops for YEARS. But Kamloops is essentially a desert, so the cards are dry and in nice shape (little water damage on the drivers door lower front edge.

I can't be named GTJordan and NOT have a little GT flair here and there.

GTdoorcards.jpg

I threw my "cluster" in just to see what it looked like. Then I threw in one of the Momo wheels I have. I have a 12" and a 13" Momo wheel. And Honestly, I like the stock 14" the best. I might try and find something in the 14" range. Or maybe I'll just use the factory wheel with a GT horn pad. Who knows. Low on priority list, but it made me feel like progess!


dashroughin.jpg


So. Now for the bad news. The tank cleaning/rad place called. The Ron Davis radiator is trash. Leaks all over. So off to recycling for it. I'll have to use the DO88 rad I have. Good thing I didn't commit to a fan on the Ron Davis rad.
The fuel tank- trashed. Guy was EXTREMELY worried about how thick the rust was. Didn't think there would be much meat left, if it didn't have some pin holes. He said he could dip it and see how bad it is, but if I could find something else, not to bother spending the money. I had another tank SITTING OUTSIDE FOR THE LAST 5 YEARS. The sending unit was just laying over the hole, but I did tape up the fill port (and it was sitting under a table) but man, this thing is a million times nicer than the one I took him. Only a little rust in the swirl pot. I thought this tank was from a carbed car and wouldn't have the swirl pot. But when I removed the sender I found it had a fuel pump on it.... Lucky me! I'm going to get the POR15 fuel tank cleaner and sealant kit and do it myself. Maybe drop the tank off somewhere to get the tar off of it so I can paint it up.


I mounted my maxxecu fuse panel in the glove box. But now that I've done that, I've realized if I ever need to remove the dash/glove box, I'm not going to be able to because wiring is directly connected from panel to battery, switch etc. I think I may just cut the top of the fuse box so I can remove it if needed. The joys of putting things together without instructions eh!
 
Love the GT door cards. Lucky they're in such good shape. Are you going to use manual windows or just plug the crank holes?

I have had a DO88 radiator in my car for probably 9 years and it's never had a single issue (aside from no integrated drain plug but that's a 240 problem in general). You'll be more than happy with it I'm sure.
 
t8fanning said:
Love the GT door cards. Lucky they're in such good shape. Are you going to use manual windows or just plug the crank holes?

I have had a DO88 radiator in my car for probably 9 years and it's never had a single issue (aside from no integrated drain plug but that's a 240 problem in general). You'll be more than happy with it I'm sure.
Click to expand...

I'm going to plug them and use the electric windows. I really did luck out on these. They've probably been in that field for 10 years or longer. I had planned on grabbing the panels from my original GT, but these parts car cards were in much nicer shape. I want to run a GT rear seat also, but the ones at my dads place are covered in pack rat turds. Not keen on pulling them and cleaning them.

I've had this DO88 rad sitting around FOR YEARS. I think I bought it during a group buy (along with the IC) circa 2015 or earlier. I'm sure it will be fine. I'll just have to figure out a brushless fan situation for it. Have all winter to figure that out at this point.

Jordan
 
GTJordan said:
I've had this DO88 rad sitting around FOR YEARS. I think I bought it during a group buy (along with the IC) circa 2015 or earlier. I'm sure it will be fine. I'll just have to figure out a brushless fan situation for it. Have all winter to figure that out at this point.
Click to expand...

Does it have to be brushless?

I use the 740/940/850 electric fan with the Volvo relay and a 740 fan shroud. Easy setup, looks factory, and works well.
 
t8fanning said:
Does it have to be brushless?

I use the 740/940/850 electric fan with the Volvo relay and a 740 fan shroud. Easy setup, looks factory, and works well.
Click to expand...

I was hoping to use PWM control through the maxx to control the fan. But doing so requires a brushless fan. I could possibly use a brushed fan, just harder on the fan control module.
 
brendon_ak said:
Love the progress!

Better hurry, puck drops soon...

Did your kids decide between contact and no contact leagues yet?
Click to expand...

Starting soon?!? Already started! (well, they are in some camps right now) Two weeks in. Real conditioning camp starts in a week, then try outs start late August through Sept. My oldest is going for hitting, but he is a goalie so it doesn't really make a big difference to him. He just don't want to be a bottom tier goalie. But there are 17 goalies this year, and it looks like 7 teams. Some are hoping to make AA or AAA teams elsewhere. I'm already sick of hockey. BUT, I was at the tool shop the other day and I hear a "hey" look up and it is one of the other dads I always talk with. He bought an old car to fix up but doesn't know anything mechanical, but he build welded art sculptures so can weld. So we might help each other out. He bought a 78 Celica that is really rusty, but pretty rare. That is the cool thing about hockey- meeting all these other people from different walks of life.
 
All those toyotas from that era that were sold here and lived their service life here turned to red dust usually in about seven to ten years with all the salt. That is a rare car now. Good luck with the helping out.
 
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