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Old 05-18-2018, 07:53 AM   #1
MSGGrunt
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Default Lifted coilover 1991 245 Project

I'm the new owner of a 1991 240 automatic wagon. The car has 168,500 miles. Car was originally sold in PA then went to VA, to AZ to Cali, across the country to Nova Scotia, back into the US to NH and now to MA. No accident car fax, odometer is working, but will get new gears before it craps out. The car fired right up even on a cold start. Idled perfectly, no smoke, drove and stopped perfectly on a two hour drive home.

As I do with all my cars it will get a good base-lining including timing belt, water pump, all new belts and hoses, new fluids, complete tune up, etc... The interior is rather filthy, but in good condition. Nothing a bit of time with a shop vac and carpet cleaner won't take care of.

Car was a daily driver up until this past month. I think I got a good deal at $1500.00

Came with all original manuals, original jack and original tool kit.

Clean coat on the hood and roof has "patina'd"

Owners says recent timing belt, but for what they cost I'll replace it.
Rear bushing have all been replace with poly bushing.
Summer and studded winter snow tires included.

Needs:
Blower motor replaced. Ordered.
New door map pockets. Already ordered new ones
Yellowed headlights replaced. New ones are on the way.
Replace the two sun visors and clips. Not easy to find the round mount style.
Rear washer fixed
Some rust around the passenger's rear wheel well fixed. Looks like an earlier repair that has started to bubble.
Antenna not working
Factory radio/cassette missing. An OCD thing, but I loath newer style head units in these older Euro cars. Fortunately AM/FM is fine for my needs.
One front speaker cover needs replacing.
Dash is cracked.
AC system needs to be assessed.

Interior is being cleaned and the carpets re-dyed.
The seats cleaned.
Timing belt, water pump, plugs, dist. cap, rotor, hoses being replaced.
New headlights are on their way.
Attached Images
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1989 BMW E30 325iX 5-speed, 4-door sedan. 156K
1990 Volvo 240 Auto, 4-door sedan. 88K 2-owner car
1991 Volvo 240 Auto, 4-door sedan. 255k 2-owner car
1991 Volvo 245 Auto, 5-door wagon. 158k ??? owners
2000 Audi TT 5-speed, 2-door. 78k 1-owner car
2007 Porsche Cayman S, 6-speed. 42k 1-owner car

Ownership not including me.

Last edited by MSGGrunt; 05-18-2018 at 07:29 PM..
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Old 05-18-2018, 07:54 AM   #2
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Another sub project to my rescue is the interior. Mine was a bit dirty from many years of use, so I removed the center carpet, rear cargo area floor covering, rear carpeted panels and the seats. The carpeted areas were vacuumed, cleaned and then given a coat of Dupli-Color Vinyl & Fabric coating to refresh the faded interior. I will clean and coat the front carpet in place.

The rear vinyl seats were in near perfect condition so those were thoroughly cleaned using Leatherique prepping agent and then treated. The front seats were not in horrible shape, but beyond what a good cleaning could correct. I ordered a seat upholstery kit off EBay and will be recovering those. The driver's seat will probably need a new seat bottom foam. EDIT. It did get a new seat bottom foam and what a difference new foam makes in comfort and support.

https://www.ebay.com/itm/VOLVO-240-2...X%3AIT&_trksid =p2057872.m2749.l2649

I have near perfect cloth front and rear seats and was considering using those instead of recovering the front seat as I like how they match with the cloth of the door panels, but I decided to stay with the vinyl for its added durability.

I have new door map pockets and those will be installed once I clean the door panels.

I will scour my local pick-n-pull for an OEM radio. I know an aftermarket would sound better, have aux input, Bluetooth, etc... but all I care about is having the ability to listen to FM stations when I drive the car and retain the stock original look of the dash.
Attached Images
File Type: jpg DSCN04.jpg (110.9 KB, 168 views)
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File Type: jpg DSCN02.jpg (109.4 KB, 170 views)
File Type: jpg DSCN01.jpg (86.8 KB, 166 views)

Last edited by MSGGrunt; 05-18-2018 at 07:33 PM..
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Old 05-18-2018, 07:55 AM   #3
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Front driver's seat is all apart waiting on the new covers. Boy these were A LOT easier to take apart than BMW E30 sport seats. As I suspected, the bottom foam will need to be replaced. I also found one of the wires to the heating element disconnected so that was fixed. Now just waiting on the covers to arrive.

4 like new door panels that I got out of a low mile wagon at my local pick n pull. I gave them a good cleaning and I can't imagine I could find a nicer set.

Another project is replacing the noisy blower motor. The tutorials and YouTube videos make it look WAY easier than it is. At this point I would have preferred just putting up with a noisy blower. Oh well, too deep into the project now and I already have a new motor.
Attached Images
File Type: jpg DSCN0970.jpg (111.8 KB, 167 views)
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File Type: jpg DSCN1030.jpg (137.0 KB, 166 views)

Last edited by MSGGrunt; 05-18-2018 at 07:34 PM..
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Old 05-18-2018, 07:56 AM   #4
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This afternoon I replaced the severely yellowed headlights with nice new clear ones. I also added a new center Volvo decal to spruce up my semi cracked one.

New taillights are on there way as well. I'm hoping this helps fix my random driver's side light not working.
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Old 05-18-2018, 07:56 AM   #5
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I have some suspension items on the way. The springs are Moog CC217 and from what I have read are a good overload spring for the money. The plan is about a 2 to 3 inch lift with 27" to 28" tires. Re-gearing the rear diff is also part of the plan as I know these larger tires will sap power.
Attached Images
File Type: jpg AMG_CC217_P04_TOP__ra_p.jpg (55.3 KB, 164 views)
File Type: jpg fullsize_7531.jpg (139.9 KB, 168 views)
File Type: jpg fullsize_20313.jpg (74.9 KB, 163 views)
File Type: jpg Rear_Perch_SpringAssembly_1024x1024.jpg (21.0 KB, 161 views)

Last edited by MSGGrunt; 05-18-2018 at 07:36 PM..
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Old 05-18-2018, 07:58 AM   #6
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I ended up going with coil overs in the front as it just seemed easier. I had the stock housings extended 2" and bought 27" tall tires. Every component on the front suspension/brakes are new. I just need to start putting everything back together.
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File Type: jpg DSCN1335.jpg (170.8 KB, 169 views)

Last edited by MSGGrunt; 05-18-2018 at 09:27 PM..
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Old 05-18-2018, 07:58 AM   #7
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While I was waiting for all of the suspension pieces to be made I finished installing the new blower motor unit. Boy, that was no small job. I removed all the carpets front to rear and re-colored them, The front seats were recovered using a vinyl kit, more on that in a separate post, but hence to say I will be using leather in place of vinyl in the future. I replaced a lot of the plastic pieces like the E brake console, B pillar trim, door pockets, etc that had become brittle over the years. The nice thing about black interiors are that they are easy to match if things need to be painted. I am very happy with how nice the car is coming along for being my winter workhorse.
Attached Images
File Type: jpg DSCN1322.jpg (119.2 KB, 169 views)
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File Type: jpg DSCN1351.jpg (142.1 KB, 166 views)

Last edited by MSGGrunt; 05-18-2018 at 07:45 PM..
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Old 05-18-2018, 08:07 AM   #8
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Why can't I post attachments?

Last edited by MSGGrunt; 05-18-2018 at 07:43 PM..
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Old 05-18-2018, 08:42 AM   #9
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Sounds like a great project!
To post pics:
1- you will need to link from a host
2- make a donation and get posting "rights" (but not in off topic). You will be able to post reduced size pics that stay with the thread permanently.
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Old 05-18-2018, 11:09 AM   #10
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Donation made. I assume it may take a bit before rights to post are granted?
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Old 05-18-2018, 11:24 AM   #11
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so interesting reading this stuff. please dont post pictures. This is like going back in time to 1987 internet
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Old 05-18-2018, 11:30 AM   #12
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Quote:
Originally Posted by MSGGrunt View Post
Donation made. I assume it may take a bit before rights to post are granted?
Hopefully you included your screen name?

Also attaching pictures is overrated, most host the pictures elsewhere and direct link them or put them into the picture box in the 'Reply to Thread' posting box header.
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how psi stock cna support?

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Old 05-18-2018, 11:35 AM   #13
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where in western mass?
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Old 05-18-2018, 01:36 PM   #14
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Sounds so cool! The Wife wants her 244 lifted because, why not?
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-My car: White 1991 244, 308k miles. B230F LH2.4, AW70, R134a retro. Thrush glasspack, anthracite refinished Coronas
-Wife's car: White 1990 244DL, T cam, 190k miles.B230F LH2.4, AW70 w/aux cooler, Duracool AC w/condenser fan, purple refinished Virgos, tow hitch, ipd wagon overload springs.
-PSM 2002 Subaru WRX wagon: 120k miles, Perrin TBE, Perrin turbo inlet, intake, and Y-pipe, GrimmSpeed cross pipe.
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Old 05-18-2018, 01:41 PM   #15
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I am in Orange, MA. I lifter it 2" and was able to fit 27" tires all the way around. Pictures to follow once I get that figured out.
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Old 05-18-2018, 07:50 PM   #16
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The engine compartment before and after a good cleaning.
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File Type: jpg DSCN0931.jpg (151.0 KB, 169 views)
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Old 05-18-2018, 07:57 PM   #17
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Tomorrow I start putting the front suspension back together and see how the coil-overs sit. With both the front and rear being height adjustable I am sure with a little trial and error I can get everything sitting level front to rear and side to side. I still need to find longer shocks for the rear. That will take some measuring of the fully compressed vs fully extended lengths and see what is out there.
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Old 05-19-2018, 07:30 PM   #18
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A little progress starting to get the coilovers installed.

I do have a rookie question though, how do I hold the strut shaft from turning while I tighten the top mounting nut?

And yes, I need to run some sort of boot, but the top mount is a different design from OEM and I will have to give this a bit of thought. Or what have others done?

The lower control arms look bad, but the rubber bushings do not appear to be deteriorated. I also already have new tie rod ends ready to install once it is take in for a proper alignment once everything is all back together.
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Old 05-19-2018, 07:45 PM   #19
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This is the wagon that I saw that gave me my inspiration. The intent is to replicate the look and stance of this wagon.
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File Type: jpg uUFwnX2.jpg (84.8 KB, 139 views)
File Type: jpg 1989-Volvo-240-with-a-5.3-L-LSx-V8-06.jpg (133.0 KB, 142 views)
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Old 05-19-2018, 09:25 PM   #20
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Quote:
Originally Posted by Redwood Chair View Post
Hopefully you included your screen name?

Also attaching pictures is overrated, most host the pictures elsewhere and direct link them or put them into the picture box in the 'Reply to Thread' posting box header.
I disagree. There is nothing like "search noob" on a thread a few years old that did not have the picture host maintained. This archival stuff. Lol
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Old 05-21-2018, 02:59 PM   #21
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Quote:
Originally Posted by MSGGrunt View Post
This is the wagon that I saw that gave me my inspiration. The intent is to replicate the look and stance of this wagon.
I built their suspension too :-)
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Old 05-21-2018, 06:50 PM   #22
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Then I went to the right place for my parts I guess. Thanks again.
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Old 05-25-2018, 02:50 AM   #23
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Quote:
Originally Posted by MSGGrunt View Post
I do have a rookie question though, how do I hold the strut shaft from turning while I tighten the top mounting nut?


There is a special tool for that. I've built my own by chopping the top off of a socket and welding a bar to the side. You tighten the nut with the tool while holding the top of the strut shaft with a wrench.


I then got lazy and just used my impact on subsequent iterations.
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Old 05-25-2018, 05:25 AM   #24
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That is brilliant. I will be near a Harbor Freight today and buy a socket to sacrifice. I even have a chop saw that I can use to shorten the socket. I tried the impact gun method and the shaft still spun. I am sure it has a lot to do with the nut being a lock nut.
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Old 05-25-2018, 11:34 AM   #25
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Quote:
Originally Posted by MSGGrunt View Post
I tried the impact gun method and the shaft still spun. I am sure it has a lot to do with the nut being a lock nut.


You have to lower the car back down and get some weight on the strut shaft. It'll usually zip down then.
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