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Old 02-01-2020, 10:04 PM   #126
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Decided to make this an arts & craft weekend after I noticed some broken paint & surface rust forming under the right-side hood hinge. Broke the 12mm bolts loose two weeks ago so all I had to do was take it apart and get to work.



Cleaned off the area, gave it a few primer coats, and topped it off with some Rustoleum white I had laying around. The paint match is not perfect, but it's better than letting it rust.







Gave some other parts a few coats of paint while I was there. The touch-up job on the core support isn't very good, so I'll have to redo that one.







Hopefully I didn't bend the "good" hinge but the hood looks fairly level and well-supported. We'll find out when I put it back together.



I assure you that this is safe!



The rubber sleeve for the positive cable-to-starter mount showed up from Volvo Classic via Culver City Volvo. Now I can finish up the battery cables and move the car into the garage for the long-awaited timing belt/water pump/cooling service. And I suppose changing out the fuel filter now that the new banjo bolt arrived.
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Old 02-09-2020, 08:37 PM   #127
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More parts purchased! I drove down to LA and plucked these out of a 131k mile 240 that was tagged on the right rear. They're solid, but have room for improvement: both sides have small tears in the rear vinyl & need a good cleaning and the pass. side may need new foam or a spring rewelded (I can feel something metal almost poking through), but the all-important upper bolsters are as mint as they look.

I can theoretically build one "perfect" seat from the two. Sure, I could have just bought the nice gray seats from the Craigslist seller but they wouldn't match the theme I'm going for. The power of self-delusion strikes again!



Having seen enough slapstick comedies I wonder if the cigarette burns by the driver-side crotch area played a part in this car's demise.



I also grabbed a rear-lower seat cushion that was conveniently taken out by someone else but not purchased. It'll need a dab of fabric glue and some cleaning and it will look just fine. I have a brand-new rear upper cover in storage.

Also picked up a piece of front trim should I need a replacement in the future. You never know.

If you're in SoCal, the car is at U-Pick Auto Parts off Alameda, but seeing as the entire front end has been removed, I figure you guys knew of it already.
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Old 02-09-2020, 10:37 PM   #128
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The one nice thing about cigarette burns, well if there is a bright side of it, is that it melts the fabric and prevents from more tearing...Bust out the needle and thread and you can make it disappear. Only way to do it right is remove the skins and stitch it from the inside so you can hide/protect the tie off knots. While they’re off and inside out, throw them in the washer.
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Old 02-13-2020, 04:04 AM   #129
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Finally blocked out some time to install the positive cable. It's literally the reverse of disassembly but made better with that gawd-awful mess of extensions and u-joints I had a few pages ago. If you lose the little 13mm nut that holds the cable on the starter, go get yourself a pack of M8x1.25 from your favorite store.

Would have gone faster had I not tried to install that spade connector backwards. CleanFlameTrap got me sorted on how that's oriented so now that's all buttoned up. Time to fire it up tomorrow! Battery's been kept nice and charged through the winter in a warm garage on a tender.

Hopefully I can get the hinge back on and then wheel it into the garage so I can't use 20 mph winds or "it's dark out" to talk my way out of stuff. Also, fewer trips in & out of the garage for tools would be nice. Less cat pee to wash off.
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Old 02-19-2020, 10:22 PM   #130
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When I serviced the PCV on my 940 I forgot to tighten that damn alternator nut. I drove it to the gas station and the nut vibrated off and the wire became disconnected. I drove there fine on battery alone (headlights and all) but after I fueled up I couldn't get it started, so I called for help. While I waited, I popped the hood and noticed the loose alternator wire. Luckily I had some zip ties in the door panel! A zip tie makes an okay m8x1.25 nut on the fly if you cinch it up snug! After the jump start, I headed to ace hardware and just guessed it's size and pitch knowing it's metric. Any error could cost me 22 cents. what's the worst that could happen? Perks of being a machinist was that I guessed thread and pitch correctly. Had to mention that since you had an issue with it too. ;)

Moral of the story is always keep a pack of zip ties in the vehicle!

Nice seat score! As far as your opinion on slapstick comedies, Yeah? Well, you know. That's just like uh... Your opinion man...
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Old 02-20-2020, 03:17 AM   #131
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I plugged the battery in, started the car, and it coughed to life after four months asleep. It seemed to choke quite a bit but it ran pretty well on the 3/4 sitting in the tank with the new cables and a strong battery.

That's when I noticed the puddle by the front wheel. The fuel filter fitting that I had broken loose was now compromised so I was greeted with a nice puddle of fuel there. Oh, that's probably why the engine seemed to struggle... Guess I know what I'm doing this weekend - time to break in that shiny new breaker bar.

That makes it story #3 of mine that involves fuel leaking out of a motor vehicle. Two of them involve this car. One involves a home-brew race car that was hauled to west Texas in the back of a U-Haul on a trip that I used to dodge jury duty and came back to Sacramento with a bent chassis.

I also learned that the power mirrors still work, so that was nice.

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When I serviced the PCV on my 940 I forgot to tighten that damn alternator nut. I drove it to the gas station and the nut vibrated off and the wire became disconnected. I drove there fine on battery alone (headlights and all) but after I fueled up I couldn't get it started, so I called for help. While I waited, I popped the hood and noticed the loose alternator wire. Luckily I had some zip ties in the door panel! A zip tie makes an okay m8x1.25 nut on the fly if you cinch it up snug! After the jump start, I headed to ace hardware and just guessed it's size and pitch knowing it's metric. Any error could cost me 22 cents. what's the worst that could happen? Perks of being a machinist was that I guessed thread and pitch correctly. Had to mention that since you had an issue with it too. ;)

Moral of the story is always keep a pack of zip ties in the vehicle!

Nice seat score! As far as your opinion on slapstick comedies, Yeah? Well, you know. That's just like uh... Your opinion man...
These cars are a great exercise in problem solving. I always have to use my brain to figure out how this ought to go together. I guess it's time to include some zipties in my emergency kit.

Last edited by snailmale; 02-20-2020 at 05:23 AM..
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Old 02-23-2020, 06:57 PM   #132
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My roommate and I got the hood hinge back on. Surprise surprise - it's not seized, but it's still sitting a little high in the back.



My regimen of long soaks in PB Blaster followed by bathing it in white lithium grease didn't seem to do it any harm. Coated the other hinge's pivots with white lithium as well, so they're both nice & quiet.

The fuel filter 19mm still refuses to come off with a breaker bar, so I guess it's time to buy an electric impact.
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Old 02-28-2020, 10:43 PM   #133
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No amount of coaxing could get that banjo off, so I guess I'll leave that for a professional (along with the brake flush and k-jet fine-tuning) before I do something ridiculous. At least I could clean out the debris in & around the bracket.

Next I guess is the long awaited waterpump & timing belt service or the equally long awaited PCV replacement.
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Old 03-01-2020, 10:21 PM   #134
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Hmm... maybe the PCV isn't as bad shape as I thought if some oil is to be expected in the intake. I'll be monitoring it.

http://forums.turbobricks.com/showthread.php?t=300158

In other news I JB-welded the throttle adjustment back together.
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Old 03-03-2020, 12:12 AM   #135
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Couldn't bear to leave it out in the elements any longer as weather & available daylight kept me from working on it. Now I can work on it whenever I have free time instead of when the sun's out. It's a tight squeeze, but my measurements were correct and it fits in the garage. It's actually 1" narrower than my Mazda Miata.
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Old 03-04-2020, 12:53 AM   #136
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Started breaking down the intake manifold for the oil trap replacement. As expected, this job is much much easier now that I'm doing it in the garage with light & warmth and no cats to pee on my car. I can also charge my light, have a beer, and not have to run in and out for tools.



Cut the petrified vacuum hose for the one-way HVAC check valve off. No, seriously, that stuff felt like it was molded with how hard it was, but nothing beats the box cutter used with extreme care. I still have some spare hose left from another repair so that's easy. Bag and tag the little pieces (t-junction).



My cheater bar and PB blaster made taking the 12 & 13mm off so easy. I took extreme care not to disturb the fuel lines outside of the one that plugs into the IM itself shown above. The nuts are 13mm. The long bolts are 12mm.



Today's goal was to break the nuts & bolts loose. Objective mostly achieved. I'll need a long-handled 13mm wrench and more pb blaster for the nut holding the bracket near the firewall. Also some new copper washers for the (I want to say 10mm?) fuel line.

Looks like a Dave Barton harness may be in my future. The wire insulation by the big bracket at the firewall has seen better days.
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Old 03-10-2020, 01:33 AM   #137
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Well my hand's pretty mangled after a fall because my town does not expect its residents to actually use the sidewalks. Still, I'm not one to let that stop me from working on things.

The intake manifold fasteners are off and been through one full blast of brake-cleaner. One of the studs came off and now I regret using the needlenose to hold 'em since it chewed up a bit of the threads. Should have just pulled it out in the first place as the FB group suggested and put it back in later. Also remembered to pull the 12mm holding the vertical support to the block.



Meanwhile I pulled the PCV hose and its PVC junction out. Cap looks nice and full of life, but good god that hose is packed with more goop than Gwyneth Paltrow setting up shop in a town full of rich yuppies.



Some throttle body cleaner and distilled water got most of the junk out. I'll go back in with Q-tips tomorrow night.

Also, as I was taking the stud out I did some math: if the fuel filter was replaced at 240,000 miles in April 2009 and the timing belt at 213,000 miles, this means that the belt has been in the car for over ten years, so it's ripe for replacement. Might mean that the weird hiccup when flooring it was it jumping timing...
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Old 03-27-2020, 10:22 PM   #138
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Now that the state of California has me working at home, I did some cleaning with the intake manifold removed (that IAC bracket had me confused as to why it wasn't coming out).

Before:



In progress:



I was pretty happy to see the original red paint mostly intact under all that. The intake manifold is also getting a fairly detailed clean too, but I'll get pictures of that another time. Many rags died to make this engine look good again and many more will be consumed.
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Old 03-31-2020, 03:44 AM   #139
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More cleaning!



Then I remembered why I was doing all this in the first place - to replace the oil trap.



OK just a little more cleaning.



Hard to see, but the one on the right has seen better days. It also lacks the O-ring that the Volvo dealer reminded me to order.



This was the easiest repair I've done on this car. It took me longer to clean the bolts than it did to fit the new oil trap in.

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Old 04-04-2020, 05:26 PM   #140
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Scrubbing bubbles is a helluva parts cleaner. Much faster than brake cleaner or even soapy water.



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Old 04-04-2020, 06:16 PM   #141
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Gotta love a clean engine.
Great work mate!
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Old 04-05-2020, 05:00 PM   #142
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You would have to be crazy to fix up an old car...

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Old 04-05-2020, 06:35 PM   #143
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Quote:
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You would have to be crazy to fix up an old car...

Who said anything about fixing? I prefer to think of it as "breaking with extra steps".
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Old 04-11-2020, 04:00 PM   #144
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Just received my new Dave Barton harness and iPd goodies just before my imagination led to me buying even more parts...
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Old 04-17-2020, 04:07 AM   #145
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Gradually reassembling it. Changed the idle bypass gaskets - those looked pretty ripe.








Picking up new 13mm nuts & washers and flushing coolant in the morning. Still debating if I should order a new timing belt tensioner, but we'll find out soon enough. I think the answer will be "yes".
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Old 05-01-2020, 08:31 PM   #146
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Back to work! After a frustrating week I finally attempted a cooling system flush.

After flooding my garage trying to put a garden hose in the top, I gave up and just popped off the 10mm holding the thermostat in, slid the entire thermostat + hose assembly out of the way, and stuck the hose into the cylinder head opening. The car was still in pieces which meant I couldn't use my flush treatment, so I just kept flushing it until only water came out in what I'm told is a "two-stage" flush.

Lots of green with a slight oily sheen. Black stuff came out into the drain pan. There was a bit of penetrating oil that splashed into the pan when I sprayed down the fan studs, so maybe that's what's up.

For those of you curious about coolant ratings check back in every now-and-then: they send cars here for hot-weather testing so let's see how well this Peak coolant holds up.
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Old 05-13-2020, 01:56 AM   #147
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Heater hoses changed and heater core refilled with Peak.






Vacuum lines pulled off fuel distributor. Hopefully I have the orientation of the one-way valve just right!





I was planning on using my new drill & a cup brush to do some cleaning but got pulled away to deal with some life & work business. Blah.
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Old 05-20-2020, 01:30 AM   #148
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Got a few vacuum lines mocked up. Clamps will be added once I verify that the 1-way valve is pointed the right way. This was just to check fit.



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Old 05-27-2020, 04:11 AM   #149
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New vacuum lines are in and so is the thermostat. A combo of hand-sanding and judicious use of a cup brush cleaned everything up nicely. It's hand-tight for now in the event I need extra room to fish out the wiring harness or something. This is making slow progress, but it's better than nothing.





The thermostat housing and the lifting hook cleaned up very well. It was around this point that hand-sanding stuff got boring and I had the perfect excuse to buy a drill/driver kit.



Lots of corrosion, nothing serious.




Last edited by snailmale; 05-27-2020 at 04:22 AM..
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Old 05-27-2020, 10:43 AM   #150
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Looking really good man, lots of work but so worth it after each part is cleaned.
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