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Old 11-05-2012, 11:12 PM   #1
jeKrieg8087
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Default vacuum hose routing diagram....

I need help....

I cannot for the life of me, find a correct vacuum hose routing diagram for my 1987 245 DL wagon, B230F (?) motor, automatic OD transmission. I say '245 DL because that's what the ID plate says it is on the passenger fender well; the badge on the tailgate says its a 240 DL. WHY?
I am concerned about 3 vacuum lines: 2 of them are located on the intake side of the TB; one is a hard black plastic tube about 1/4" with short pieces of rubber hose on each end. This one is hooked to the TB and goes to the charcoal canister. The other vacuum line is missing all together, but all the diagrams I have looked at so far (1986 B230F motor) show it going to the charcoal canister too. (see below: NOTE ***)
The 3rd vacuum line is located on the inboard side of the intake manifold, close to the head. Brass nipple fitting attached to a large hose, 3/8" X 4" long; has a round white and black thing (?) at the end of the hose; it then goes into a white reduction coupling. A hard black plastic line then goes about 6" and stops; Its burnt/broken off at this point and goes nowhere. Any help as to where it goes?

Anyone here own a Volvo, year and model like mine, that can give me the correct routing for the vacuum lines?

Most of the information I have found covers the 240/245 DL up till 1986, then skips 1987 altogether and goes into 88 and newer. Why is this? Something the swedes do just to mess with us?

There are several dead end vacuum lines all across the firewall; one small line, where the heater hose goes into the car through the firewall; another one, larger goes in through the firewall on the drivers side close to the hood hinge. Both of these vacuum lines are torn/cut off and go nowhere. In a box in the cargo area with all the other spare parts I have found, is a large round (4" dia) vacuum modulator (?) with 2 ports; one says vacuum the other I cant read cause its rubbed/scrapped off. Its mounted to a metal angle mount with a paper tag that says: 'mounts to firewall above heater hose'.

I bought this Volvo cause I needed a Wagon type vehicle and the price was right; I didn't know it would bee this difficult, just trying to locate information for it. Unbelievable!

help?

NOTE *** I went out to look again, and I found a vacuum hose lying next to the frame rail (drivers side) going nowhere, just lying there. It comes off the charcoal canister just below where the hard plastic vacuum line is and its about 3' long. Could this be the other vacuum line, missing off the TB?
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Old 11-06-2012, 01:21 AM   #2
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the badge on the tailgate says its a 240 DL. WHY?
Because they changed the naming convention. The older models were 24X with X being the number of doors. 2 door, 4 door, 5 door (wagon). It IS a 240 DL, but it is also a 245 DL. This can cause some problems when talking to parts people, who will claim that a certain model doesn't exist.

I am concerned about 3 vacuum lines: 2 of them are located on the intake side of the TB; one is a hard black plastic tube about 1/4" with short pieces of rubber hose on each end. This one is hooked to the TB and goes to the charcoal canister. The other vacuum line is missing all together, but all the diagrams I have looked at so far (1986 B230F motor) show it going to the charcoal canister too. (see below: NOTE ***)
Yes, those two lines on the driver side, top, of the TB go to the charcoal canister. Not a big deal unless you're in California or anywhere with stringent emissions.

The 3rd vacuum line is located on the inboard side of the intake manifold, close to the head. Brass nipple fitting attached to a large hose, 3/8" X 4" long; has a round white and black thing (?) at the end of the hose; it then goes into a white reduction coupling. A hard black plastic line then goes about 6" and stops; Its burnt/broken off at this point and goes nowhere. Any help as to where it goes?
Without a picture, which is surely worth a thousand words at a time like this, I would venture a guess that it is the climate control system vacuum source.


Anyone here own a Volvo, year and model like mine, that can give me the correct routing for the vacuum lines?

You will thank yourself later, if you buy a Bentley manual today. It has a nice picture and description of the EEC (Evaporative Emission Control) system. Also, visit kjet.org and download the Greenbooks relevant to your car. These are the repair manuals Volvo used in-house. But for now the picture you seek is on this website:
http://www.volvoclub.org.uk/faq/Engi...injection.html
Scroll to the bottom of the page.
Also look at the rest of the site:
http://www.volvoclub.org.uk/faq/FAQSummary1.html
There is plenty of other good information. These Volvo cars are all quite similar, and not very complicated.

Most of the information I have found covers the 240/245 DL up till 1986, then skips 1987 altogether and goes into 88 and newer. Why is this? Something the swedes do just to mess with us?
Most information you find will not be grouped by year, but rather engine control systems and type of engine.

There are several dead end vacuum lines all across the firewall; one small line, where the heater hose goes into the car through the firewall;
Most likely for the climate control.

another one, larger goes in through the firewall on the drivers side close to the hood hinge.

Most likely for a cruise control system.

Both of these vacuum lines are torn/cut off and go nowhere. In a box in the cargo area with all the other spare parts I have found, is a large round (4" dia) vacuum modulator (?) with 2 ports; one says vacuum the other I cant read cause its rubbed/scrapped off. Its mounted to a metal angle mount with a paper tag that says: 'mounts to firewall above heater hose'.
Yes, that's where it mounts. I have one too, although in a box somewhere. Most of those parts are for the cruise control system. The black thing was a vacuum amplifier if I remember correctly.

I bought this Volvo cause I needed a Wagon type vehicle and the price was right; I didn't know it would bee this difficult, just trying to locate information for it. Unbelievable!
help?

Please read through this site, and these:
http://volvo2.homestead.com/
http://www.sonic.net/~zipzippy/volvo...240%20faq.html
http://www.volvowiringdiagrams.com/
http://www.ifixit.com/Device/1986-1993_Volvo_240
http://www.ohio.edu/people/ridgely/Volvo_docs/
http://forums.turbobricks.com/showthread.php?t=158981
http://forums.turbobricks.com/showth...ght=pcv+system
http://www.swedishautoparts.com/240/FAQs.html
http://cleanflametrap.com/

NOTE *** I went out to look again, and I found a vacuum hose lying next to the frame rail (drivers side) going nowhere, just lying there. It comes off the charcoal canister just below where the hard plastic vacuum line is and its about 3' long. Could this be the other vacuum line, missing off the TB?
That's pretty funny, because I found the same thing in my car, just sort of dangling like you described. Yes, it goes to the charcoal canister.
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Old 11-06-2012, 05:13 PM   #3
jeKrieg8087
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Quote:
Originally Posted by whispacloud View Post
the badge on the tailgate says its a 240 DL. WHY?
Because they changed the naming convention. The older models were 24X with X being the number of doors. 2 door, 4 door, 5 door (wagon). It IS a 240 DL, but it is also a 245 DL. This can cause some problems when talking to parts people, who will claim that a certain model doesn't exist.

I am concerned about 3 vacuum lines: 2 of them are located on the intake side of the TB; one is a hard black plastic tube about 1/4" with short pieces of rubber hose on each end. This one is hooked to the TB and goes to the charcoal canister. The other vacuum line is missing all together, but all the diagrams I have looked at so far (1986 B230F motor) show it going to the charcoal canister too. (see below: NOTE ***)
Yes, those two lines on the driver side, top, of the TB go to the charcoal canister. Not a big deal unless you're in California or anywhere with stringent emissions.

The 3rd vacuum line is located on the inboard side of the intake manifold, close to the head. Brass nipple fitting attached to a large hose, 3/8" X 4" long; has a round white and black thing (?) at the end of the hose; it then goes into a white reduction coupling. A hard black plastic line then goes about 6" and stops; Its burnt/broken off at this point and goes nowhere. Any help as to where it goes?
Without a picture, which is surely worth a thousand words at a time like this, I would venture a guess that it is the climate control system vacuum source.


Anyone here own a Volvo, year and model like mine, that can give me the correct routing for the vacuum lines?

You will thank yourself later, if you buy a Bentley manual today. It has a nice picture and description of the EEC (Evaporative Emission Control) system. Also, visit kjet.org and download the Greenbooks relevant to your car. These are the repair manuals Volvo used in-house. But for now the picture you seek is on this website:
http://www.volvoclub.org.uk/faq/Engi...injection.html
Scroll to the bottom of the page.
Also look at the rest of the site:
http://www.volvoclub.org.uk/faq/FAQSummary1.html
There is plenty of other good information. These Volvo cars are all quite similar, and not very complicated.

Most of the information I have found covers the 240/245 DL up till 1986, then skips 1987 altogether and goes into 88 and newer. Why is this? Something the swedes do just to mess with us?
Most information you find will not be grouped by year, but rather engine control systems and type of engine.

There are several dead end vacuum lines all across the firewall; one small line, where the heater hose goes into the car through the firewall;
Most likely for the climate control.

another one, larger goes in through the firewall on the drivers side close to the hood hinge.

Most likely for a cruise control system.

Both of these vacuum lines are torn/cut off and go nowhere. In a box in the cargo area with all the other spare parts I have found, is a large round (4" dia) vacuum modulator (?) with 2 ports; one says vacuum the other I cant read cause its rubbed/scrapped off. Its mounted to a metal angle mount with a paper tag that says: 'mounts to firewall above heater hose'.
Yes, that's where it mounts. I have one too, although in a box somewhere. Most of those parts are for the cruise control system. The black thing was a vacuum amplifier if I remember correctly.

I bought this Volvo cause I needed a Wagon type vehicle and the price was right; I didn't know it would bee this difficult, just trying to locate information for it. Unbelievable!
help?

Please read through this site, and these:
http://volvo2.homestead.com/
http://www.sonic.net/~zipzippy/volvo...240%20faq.html
http://www.volvowiringdiagrams.com/
http://www.ifixit.com/Device/1986-1993_Volvo_240
http://www.ohio.edu/people/ridgely/Volvo_docs/
http://forums.turbobricks.com/showthread.php?t=158981
http://forums.turbobricks.com/showth...ght=pcv+system
http://www.swedishautoparts.com/240/FAQs.html
http://cleanflametrap.com/

NOTE *** I went out to look again, and I found a vacuum hose lying next to the frame rail (drivers side) going nowhere, just lying there. It comes off the charcoal canister just below where the hard plastic vacuum line is and its about 3' long. Could this be the other vacuum line, missing off the TB?
That's pretty funny, because I found the same thing in my car, just sort of dangling like you described. Yes, it goes to the charcoal canister.
Although it may not sound right, I have spent considerable time on the internet and in the local library trying to find anything concerning the 1987 245 DL wagon, BEFORE I bought it. I ran into many dead ends, just as I have here I am afraid. most of references you list I have downloaded or been at already. I strongly disagree with your statement that I would find my year and model Volvo spec's. There is no mention of the year 1987 in any of over 25 sites I have been to as of this morning. I blame no one single person place or thing; but I really wonder if somewhere in a cold dank Nordic abode in Sweden, an old gnarly retired engineer is chuckling at this very moment. I wanted something different when I bought this 245 DL....and I got it, alright!
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Old 11-06-2012, 06:18 PM   #4
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Nothing you describe is in anyway unique to your model year and body style.

I am concerned about 3 vacuum lines: 2 of them are located on the intake side of the TB; one is a hard black plastic tube about 1/4" with short pieces of rubber hose on each end. This one is hooked to the TB and goes to the charcoal canister. The other vacuum line is missing all together, but all the diagrams I have looked at so far (1986 B230F motor) show it going to the charcoal canister too. (see below: NOTE ***)

These go to the charcoal canister, one is on the intake side of and the other is on the engine side.


The 3rd vacuum line is located on the inboard side of the intake manifold, close to the head. Brass nipple fitting attached to a large hose, 3/8" X 4" long; has a round white and black thing (?) at the end of the hose; it then goes into a white reduction coupling. A hard black plastic line then goes about 6" and stops; Its burnt/broken off at this point and goes nowhere. Any help as to where it goes?

This hose goes to the Vacuum resevoir inside the dash. It enters the firewall above the valve cover on the passenger side. The round white and black thing is a check valve.
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Old 11-07-2012, 03:36 AM   #5
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.....will note those facts and locations you have mentioned. In the morning I plan to replace all the rubber lines with new ones; hopefully, I will then be able to start the car and see how it runs.

....btw...the gas tank has several gallons of year old gas in it. Any safe way to remove it without removing the tank? Just about gave myself a hernia getting the fuel filter off yesterday. those fittings must have been tightened with an impact wrench. I thought I would try and siphon the bad fuel out thru the fuel line that goes into the tank from the fuel pump.
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Old 11-07-2012, 08:34 AM   #6
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Quote:
Originally Posted by jeKrieg8087 View Post
Although it may not sound right, I have spent considerable time on the internet and in the local library trying to find anything concerning the 1987 245 DL wagon, BEFORE I bought it. I ran into many dead ends, just as I have here I am afraid. most of references you list I have downloaded or been at already. I strongly disagree with your statement that I would find my year and model Volvo spec's. There is no mention of the year 1987 in any of over 25 sites I have been to as of this morning. I blame no one single person place or thing; but I really wonder if somewhere in a cold dank Nordic abode in Sweden, an old gnarly retired engineer is chuckling at this very moment. I wanted something different when I bought this 245 DL....and I got it, alright!
all right..CALM DOWN....*READ* the post "whispacloud" spent the time trying to help
you....
please note the "Volvo Do" (pronounced "doh" - Nihon for *WAY*) is to identify changes
and not specific "models"....the ENGINE series / the TRANS series / and FUEL
MANAGEMENT (including the IGNITION) computer control and command SYSTEMS
are *CROSS PLATFORM* (w/a LOT of commonalities with the "other SERIES of
Volvo cars" beginning with MUCH OLDER sedans etc. and rolling right along to the
7xx and 9xx cars....)

the sites he provided are a GOOD STARTING POINT for your *EDU /EDIFAcation* in
Volvo land....
for *specific info on YOUR CAR* go to : http://www.volvowiringdiagrams.com/?...ing%20Diagrams
and download the *1987 240 WIRING DIAGRAMMES* which are YEAR AND MODEL
SPECIFIC.....
this is the JOY of the older 240's - LOTS OF STUFF SWOPS OVER and makes
"keeping them on the road a bit easier" than say trying to fettle a 1987 Toyota or
Honda when the *factory* has done RUNNING PRODUCTION CHANGES and
then DISCARDED those for the "new 1989 Corivicla EX"....once you've played
the parts game a bit you'll come to appreciate the fact that you CAN stuff
a turbo motor in your 1987 if you really want to (and you can find the parts readily
enough that you can KEEP IT RUNNING long after you've accomplished the
uprate!)

the only "conspiracy" here is the "cable / zip tie, JB Weld / duktape" mindset that
a LOT of the Camp TBrix folk adhere to...you can make a "BRICK FLY" and stick
like glue for not a lot of do$h *and* have a boatload of fun doing it...all courtesy
of Volvo and their penchant for making tough / reliable TWEAKABLE
machinery....

welcome to the place where *IT CAN BE DONE*!
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Old 11-07-2012, 09:38 PM   #7
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.....I can see that its beginning to look like this Volvo project of mine will have some humoristic moments after all. Just the nomenclature 'Swedishbrick' is enough to bring a chuckle to the dowerist of budding Volvo enthusiast such as myself.
I spent most of this morning going thru the engine wiring that has 'biodegraded' under and around the front of the engine, behind the harmonic balancer fastened to several wire loom clamps. so far, the small wire that hooks to the alternator is broken and 'butt' connected 3 times within 4' of space using 3 different color and gauge of wire. I am surprised this car hasn't burnt to the rims already!
I now believe I have found the reason why the RED battery light (on the dash cluster) is on after I hook up the battery and probably why it goes out after I have started the car on previous attempts. I have already re routed 2 wires in a small 1/4' crinkle loom across the back firewall and over the passenger side inner fender to the alternator and oil sender. Now that I have confirmed the wires correct color I can eliminate them from the harness under the front of the motor.
I asked previously but will remit again, can I replace the heavy gauge BLUE rectangular wire that goes from the starter to the alternator with an 8 or 10 gauge RED wire? This BLUE one is cracking and falling apart (biodegrading I guess) and needs replacing. I have one (8 gauge RED) already made up to switch with the bad BLUE wire.
I have cleaned every ground wire I have found so far and replaced most of the brittle vacuum hoses with new....a considerable task I might add for a novice Volvo 'newbie'. There are several vacuum lines that still go 'nowhere' but i aint done workin yet; hopefully I will locate their origins and fix them too.
I have just received my missing flame trap hose that goes to the air intake tube in front of the TB and will put it where it belongs later this evening.

I still have to empty the gas tank of old 'varnished' gas; any suggestions as to how I can do this task WITHOUT removing the tank? I have limited tools and I am already disabled, so no sense in adding to my pain and misery, right? I'm thinking that I can just siphon the gas thru the gas line between the filter and the tank....that make sense? I already have the back of the wagon jacked up on railroad ties (got no jack stands) so the angle is right for drainage, I think. But I need a second opinion here from a 'brickhead' (?) I believe is what an expert in Volvo-oligy is called here?
I need to drain out the bad gas so I can install a new fuel filter; almost got a hernia getting the old one off. What do they use to put these filters on with....an air wrench? whew....
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Old 11-07-2012, 10:21 PM   #8
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TrickMick....

went to the site you recommended; but its for wiring diagrams!!!!

I need 1987 245 DL Wagon VACUUM DIAGRAMS !!!

there are plenty of vacuum diagrams for 200 series Volvos up to 1986 and 1988 & newer.....but some genius left out the 1987 year and model series Volvo all together!!!
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Old 11-07-2012, 10:26 PM   #9
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....My daughter, bless her heart, just called me and informed me that she has ordered the Bentley manual for my Volvo!

ahhhh....be still my heart. finally a reference that comes from the source.

damn well better had......for $65 bucks and change it better serve tea and biskits too!
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Old 11-07-2012, 11:07 PM   #10
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'86 and '88 will have the same vacuum hose routing as an '87. '85 through '88 models are pretty much identical in this regard.

Post a few pictures and we can tell you where everything goes.
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Old 11-07-2012, 11:54 PM   #11
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greenbooks on www.kjet.org and www.volvowiringdiagrams.com will have vacuum routing. Just have to look. They are all downloadable as well, so take the time to DL them because they are invaluable.

FCP groton also has the complete diagnostic tech manuals on DVD ROM.
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Old 11-08-2012, 09:03 AM   #12
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Quote:
Originally Posted by jeKrieg8087 View Post
TrickMick....
went to the site you recommended; but its for wiring diagrams!!!!
I need 1987 245 DL Wagon VACUUM DIAGRAMS !!!
there are plenty of vacuum diagrams for 200 series Volvos up to 1986 and 1988 & newer.....but some genius left out the 1987 year and model series Volvo all together!!!
I was *trying* to lead you to the discovery that there are *SOME* VERY SPECIFIC
information sources dedicated to the "1987 Volvo"

the fuel and ignition systems are also "shared" across platforms and model years
so you have to "get yopurself up to speed" (and the fastest way to do THAT is go
and BROWSE the various URL's provided..

one of your fellow TBirckers set up and maintains the "Kjet outfit" @
http://www.k-jet.org/documents/greenbooks/200-series/

and another set up the "wiring diagrammes" @ http://www.volvowiringdiagrams.com/

there are SEVERAL *Volvo specific websites extant*
volvospeed
brickspeed
Matthews Volvosite
brickboard
Swedish Embassy
cleanflametrap.com
USF USW.....

wire your car as you see fit ... *DOCUMENT WHAT YOU'VE DONE!!
(I *strongly suggest* a lose leaf LOGBOOK for info archive use)
MY 1991 244, SWMBO's 1991 244, and the family hauler 1993 245
*ALL* have uprated wiring in the charging circuit and ALTERNATOR GROUND
(goes from the alt case to the engine block...VERY IMPORTANT!!)

pulling the large hose that comes from the fuel tank to the "bracket w/pump
and filter" under the drivers butt *SHOULD* let drain off the nasty fuel ...
(and *YES* the filters can be a bugger!..that stupid little PLASTIC LINE
between the pump and the filter is OFT SHREDDED trying to remove the
filter due to corrcion and "overzealous torque application to the fittings (you
HAVE NOW been WARNED...

I see youhave been introduced to the "crinkly smoked wiring harness" already...
COMMON up to 1988 or so - once fixed...good to go for a LONG while!

wilkommen to the world of *who'n'ell did THAT to this car??*
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Old 11-08-2012, 04:34 PM   #13
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....I unfortunately do not have the capability to take or send photos, but wish I could! I have re looked at Dave Bartons web site vacuum diagrams for the 86' Volvo 240/245 DL and there are still 2 vacuum lines that are not mentioned that I cannot find sources for. 1 is on the inboard side of the TB manifold. its a larger vacuum hose, almost looks like one of the heater hoses. Its about 4" long and has a black & white vacuum pot on the end via a reducer fitting. It then reduces even more down to a piece of black plastic tube, about 1/4 ". that piece is about 6: long and is sealed on the end via what looks like a soldering iron; its burnt and crimped over.

...I did find a reference about the heater vacuum lines in the dash; the article mentions a source line coming into the dash from the engine via a black & white vacuum pot and/or a vacuum Servo canister. the #2 line i mentioned above has a black & white vacuum pot in the line. There also is a round black vacuum Servo canister mounted in the firewall just above where the heater hoses go into the firewall. I traced the 1 line that is hooked up to the Servo canister and it goes into the firewall on the drivers side via a rubber grommet. The Servo canister is about 5" or 6" in diameter with 2 ports; one marked 'Vacuum' the other 'Servo'. there is an electrical connector wired into it also, but as yet I have not located where in the dash it goes to.

So.....to date all I now need to get this wagon running is some way to eliminate the bad gas from the tank, without removing it, and a little luck!

Is there an easy way to remove the old varnished gas from the tank WITHOUT pulling the tank out of the car? i an 63yrs old without many tools and disabled so I need all the help I can get.
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Old 11-08-2012, 04:49 PM   #14
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I have a "solid state" electric fuel pump that I use to shuffle fuel out of tanks into
"cans" for use in the "yard machinery"....
http://www.amazon.com/gp/product/B00...FG9E1K2MBSHA7B (google for a better deal)

w/a length of fuel line stuffed down the filler neck you can drain a tank in 15 minutes or so (I use a spare 12 Volt
battery to power up the FACET pump....works a treat and you don't have to crawl around on the deck
(I'm an "older guy" w/a LOT of "busted bits" so I defer to EASE over grunt EVERYTIME!

does any of THIS look familiar??
http://www.volvopartswebstore.com/sh...=0&modelYear=0

Last edited by TrickMick; 11-08-2012 at 04:57 PM.. Reason: added cruise illustration
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Old 11-08-2012, 10:10 PM   #15
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Quote:
Originally Posted by jeKrieg8087 View Post
... 1 is on the inboard side of the TB manifold. its a larger vacuum hose, almost looks like one of the heater hoses. Its about 4" long and has a black & white vacuum pot on the end via a reducer fitting. It then reduces even more down to a piece of black plastic tube, about 1/4 ". that piece is about 6: long and is sealed on the end via what looks like a soldering iron; its burnt and crimped over. ...
That's probably the vacuum fitting and line which is supposed to go through the firewall to the HVAC vacuum reservoir under the dashboard. When you push on and release the three buttons for cabin, windshield and recycle air do you here the vents work and the air movement change with the blower running?
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Old 11-09-2012, 05:50 PM   #16
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YES........

Most definately; at least its a start. It shows me where the heater vent supply vacuum line originates (that big hose from the intake manifold) anf quite possibly the cruise control vacuum too. The diagram is a little confusing due to it not showing the size of the vacuum lines in ENGLISH inches! All of the pieces are in the storage bins located in the back of the wagon, including new vacuum hose!!

....as for the removal of the bad gas from my gas tank, I will have to locate someone with a suction pump as I do not have one.

thank you TrickMick and everyone else for the helpful information
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Old 11-09-2012, 06:27 PM   #17
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FYI, all 240 DL/GL (not GLT or T's) from '83-93 have the same vacuum lines and routing, B23 and B230 engines.

All cars have the vacuum hose routing posted on a label either on the panel across the front or on the strut tower. If yours is missing, take a look at any other 240 for the label.
One difference is cars with the Chrysler ign have a line that runs to the ign unit on the passenger inner fender wall, all else is the same.

Cruise control aside, the lines are:

Idle bypass hoses, from intake tube to IAC to intake manifold, 12 mm
Crankcase Breather hose to Flame trap, 12 mm
Flame trap hose to Intake tube, 12 mm
Flame trap body to intake manifold, 4.5 mm
Brake booster to intake, 3/8"
Intake manifold to check valve 3/8" (then to HVAC vacuum ballast 3mm)
TB to Charcoal canister, 7 mm
TB to Charcoal canister, 3 mm
Intake manifold to FPR, 4.5 mm
Intake manifold to Ign unit, 4.5 mm (Chrysler ign only)

That line from the intake to the check valve that is capped off should go through the firewall to the passenger side of the center console to the vacuum ballast. This is a 3 mm or 1/8" line. It is common for one of the vacuum diaphram motors in the dash to leak, causing a virtual intake leak to the motor causing it to run lean, which is probably why yours was capped off. Use a hand pump and gage to test at the inlet side of the ballast before connecting this line back up as the car won't run well. Find the leak and cap that one line only or fix the vacuum motor. That being said, the most common one to leak is the one for the air recurculation damper which is behind the air box against the firewall and can only be replaced by removing the dash. If that one leaks I would just cap the line and leave it in re-circ mode all the time. (I did!)
The small line missing at the TB should go to the check valve on the top of the charcoal canister, also 3mm.
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Old 11-10-2012, 04:59 AM   #18
jeKrieg8087
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Originally Posted by vvpete View Post
FYI, all 240 DL/GL (not GLT or T's) from '83-93 have the same vacuum lines and routing, B23 and B230 engines.

All cars have the vacuum hose routing posted on a label either on the panel across the front or on the strut tower. If yours is missing, take a look at any other 240 for the label.
One difference is cars with the Chrysler ign have a line that runs to the ign unit on the passenger inner fender wall, all else is the same.

Cruise control aside, the lines are:

Idle bypass hoses, from intake tube to IAC to intake manifold, 12 mm
Crankcase Breather hose to Flame trap, 12 mm
Flame trap hose to Intake tube, 12 mm
Flame trap body to intake manifold, 4.5 mm
Brake booster to intake, 3/8"
Intake manifold to check valve 3/8" (then to HVAC vacuum ballast 3mm)
TB to Charcoal canister, 7 mm
TB to Charcoal canister, 3 mm
Intake manifold to FPR, 4.5 mm
Intake manifold to Ign unit, 4.5 mm (Chrysler ign only)

That line from the intake to the check valve that is capped off should go through the firewall to the passenger side of the center console to the vacuum ballast. This is a 3 mm or 1/8" line. It is common for one of the vacuum diaphram motors in the dash to leak, causing a virtual intake leak to the motor causing it to run lean, which is probably why yours was capped off. Use a hand pump and gage to test at the inlet side of the ballast before connecting this line back up as the car won't run well. Find the leak and cap that one line only or fix the vacuum motor. That being said, the most common one to leak is the one for the air recurculation damper which is behind the air box against the firewall and can only be replaced by removing the dash. If that one leaks I would just cap the line and leave it in re-circ mode all the time. (I did!)
The small line missing at the TB should go to the check valve on the top of the charcoal canister, also 3mm.
Ok......lets do this one from the first one you listed.....you are listing 10 possible vacuum hoses and the origins and ends; of those you have listed, I have checked all but 2, those being: #6 the 3/8" hose from the intake manifold to a B & W check valve (?) which has a black plastic line that's capped off. You say it should go to a HVAC vacuum Ballast? Is that the same as the vacuum Servo tank that is mounted to the firewall above were the heater hoses enter it? The info sites that TrickMick listed show the hose routing that I have most of. I have several more pieces of plastic vacuum chambers in the back of the wagon that are listed in those references. #9 on your list has a vacuum line from the intake manifold to the FPR. whats that?

the rest of your list i have covered, i think. I will no doubt double check several times before I fire her up.

I mentioned above about several plastic pieces i still have to re install; there is 1 thats kind of bell shaped and mounts to the vacuum servo bracket on the firewall. TrickMicks reference site info has the diagrams but where this bell shaped plastic vacuum device is shown, there is only 1 vacuum line coming off a ' T ' from another vacuum source. There is no other vacuum line exiting the 'bell'. what didn't I see?

....btw; I do have the Chrysler ignition, and that vacuum line i have already checked out as it travels with the wiring harness under the front of the motor.

thanks for the help too....
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Old 11-10-2012, 12:13 PM   #19
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Originally Posted by vvpete View Post
Cruise control aside, the lines are:

Intake manifold to check valve 3/8" (then to HVAC vacuum ballast 3mm)

That line from the intake to the check valve that is capped off should go through the firewall to the passenger side of the center console to the vacuum ballast.
There was the answers.

"Is that the same as the vacuum Servo tank that is mounted to the firewall above were the heater hoses enter it?"
No, read above again

I would forget about the HVAC (Heating, Ventilation and Air Conditioning) and the Cruise Control lines for now as they are not essential to operting the motor. Cap off at the manifold where they would be connected
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Old 11-10-2012, 06:04 PM   #20
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Done deal........thanks again.
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Old 11-10-2012, 09:57 PM   #21
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When you get the wagon running properly you'll find it to be a good work horse. It's too bad that the previous owner messed up all the vacuum system, and who knows what else.
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Old 11-17-2012, 11:54 PM   #22
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When you get the wagon running properly you'll find it to be a good work horse. It's too bad that the previous owner messed up all the vacuum system, and who knows what else.
well, i went out to do some more work on the car today and to my surprise, another little problem has raised it little head. The wagon has a roof rack on it; looks stock. The back 2 mounting legs have 2 machine bolts in each leg (4 all together) holding the rack to the wagons roof. Seems the Arizona heat has struck again; all 4 bolts have pulled up and out of the roof leaving 4 large holes, about 1/2" in diameter. The mounts are totally rotted away; looks like some sort of rubber material, cant really tell as all thats left is the machine screw screwed into a metal fitting.

Local Volvo dealer has no idea what i was trying to describe to him but assured me that they didn't carry any parts to fix it. I couldn't find an appropriate place here on the forum to ask how to fix this new problem, so i thought I would ask here. Anyone had this happen to their 245 wagons roof rack? maybe there is an aftermarket kit to plug the holes, after removing the roof rack?

I went down to home depot looking for some kind of a plug but had no luck. i believe there are 10 holes altogether. I am open to any suggestions.......
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Old 11-18-2012, 12:03 AM   #23
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http://www.ipdusa.com/products/5421/...-hole-plug-kit
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Old 11-18-2012, 08:24 AM   #24
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Originally Posted by jeKrieg8087 View Post
YES........

Most definately; at least its a start. It shows me where the heater vent supply vacuum line originates (that big hose from the intake manifold) anf quite possibly the cruise control vacuum too. The diagram is a little confusing due to it not showing the size of the vacuum lines in ENGLISH inches! All of the pieces are in the storage bins located in the back of the wagon, including new vacuum hose!!

....as for the removal of the bad gas from my gas tank, I will have to locate someone with a suction pump as I do not have one. thank you TrickMick and everyone else for the helpful information


If your gonna replace the fuel filter why not just use the fuel pump to drain the old fuel ??
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Old 11-18-2012, 09:32 PM   #25
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If your gonna replace the fuel filter why not just use the fuel pump to drain the old fuel ??
Some little prick stole my new Die Hard battery the 3rd night after i brought it home. i got it handled though.....having my room mate drop the tank for me. i checked the wires going to the sender unit (really ?) and they are as bad as the engine compartment wires were, before i re did them.
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