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Old 01-09-2021, 08:38 PM   #76
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Took out the old warm up regulator, it's a 128, no vacuum lines going into it and two metallic strips vs one.

The one I bought was a 078, very different inside, just checking the diaphragms were good, both are !

The screen had some mud in it too, now cleaned out !
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Old 01-09-2021, 08:44 PM   #77
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Flame trap cleaning, ended up just using the little screen in the kit I bought. The angle on the vacuum pipe is different on the turbo I guess?

Plugged it up, filled it with a half can of degreaser and washed it out later with hot water.

Big flakes of hardened oil we're falling out of it!
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Old 01-09-2021, 08:51 PM   #78
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Found an intake gasket at the local autozone which was pretty amazing for a 37 yr old car!

I threw the injectors in, but I think I can wait to get the outer sealing I rings before putting everything back together.

I've to replace all the vacuum lines anyways and out of time this week.
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Old 01-09-2021, 09:26 PM   #79
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Just noticing I put the injectors back together incorrectly lol, thankfully I consulted the bently manual !
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Old 01-14-2021, 02:08 PM   #80
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Whipped off the kjet equivalent of a maf?

Gave it a good cleaning with brakcleen.

I'll redo it with fresh gaskets etc but fuel seems to be flowing through at least.

Just want it running, I'll eventually redo the fuel lines too, they're intact but the outer rubber shielding is succumbing to age.

Finally got my injector holder seals, can't be having any unmetered air getting at it !
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Old 01-15-2021, 02:25 AM   #81
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I enjoy watching your progress and giving new life to this 242. Cheers.
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Old 01-16-2021, 12:02 AM   #82
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Quote:
Originally Posted by Vol242vo View Post
I enjoy watching your progress and giving new life to this 242. Cheers.
The car just keeps on giving me stuff to do �� but thanks for the encouragement!

New intake gasket, replaced the thermal switch with a decent used one.

Waiting on a bracket /support for the fuel injection lines, so I decided to whip off the cam cover.

Not a pretty sight, a good bit of surface corrosion on a few lobes, will clean and pray !

New cam is $250 odd but I'd be lying if I said I wanted to throw it at an untested engine!
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Old 01-16-2021, 01:01 AM   #83
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I couldn't help myself, green scotch pad from the kitchen and s ridiculous as mount of pb blaster soakage. All surface stuff thankfully !

Will have to rotate to clean the valves too but it'll be okay I hope !
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Last edited by atomicdeathmonkey; 01-16-2021 at 10:16 AM..
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Old 01-16-2021, 08:45 PM   #84
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After leaving the cover sit overnight and after a good wash I evaluated the cover for a straight polish.

There were some pretty noticeable gouges across the middle and in some corners

Tried to polish through the oxidation but there was some deep pitting I couldn't get past.

20210116_120456 by V G, on Flickr

20210116_124330 by V G, on Flickr

20210116_140544 by V G, on Flickr

It looked alright in full sun but wasn't the finish I'd hoped for, paint it was then.

20210116_140821 by V G, on Flickr

20210116_141253 by V G, on Flickr

20210116_120636 by V G, on Flickr

Had some help about halfway through the process which broke up the tedium waiting for paint to dry!
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Old 01-16-2021, 08:51 PM   #85
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Attention to detail and ocd then came into the equation

20210116_164220 by V G, on Flickr

20210116_164656 by V G, on Flickr

20210116_154554 by V G, on Flickr

20210116_160446 by V G, on Flickr

After a bit of the wire brush on the Dremel.


20210116_175112 by V G, on Flickr
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Old 01-16-2021, 11:25 PM   #86
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Looks fantastic
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Old 01-17-2021, 02:33 AM   #87
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Thanks, now I just have to clean up everything else !
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Old 01-19-2021, 09:15 PM   #88
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Apparently, this is where the oil filter lives - tried a bunch of different tools on it and it won't budge - soaking in pb blaster before I get the heat at it! A thorough bollix of a design if you ask me - a 10th of an inch from the actuator, same from the engine mount - unreal. Ordered a remote filter kit and will break the thing off eventually!

20210118_171138 by V G, Flickr에서

This bracket that carries the injection leads was missing on mine so ebay to the rescue!

20210119_152738 by V G, Flickr에서

Then the last of the parts for a while came in :D

20210119_180842 by V G, Flickr에서

A lot of Kjet stuff off an N/a - some crossover stuff I'll be keeping, should have some n/a kjet stuff up for grabs eventually!

20210119_180917 by V G, Flickr에서

20210119_180849 by V G, Flickr에서

20210119_180907 by V G, Flickr에서
20210119_181022 by V G, Flickr에서
20210119_181249 by V G, Flickr에서
20210119_181044 by V G, Flickr에서

20210119_181613 by V G, Flickr에서

20210119_181619 by V G, Flickr에서

20210119_182029 by V G, Flickr에서

20210119_182417 by V G, Flickr에서

20210119_182746 by V G, Flickr에서
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Old 01-20-2021, 04:01 PM   #89
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Nice work! You're motivating me to continue working on the wagon.
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Old 01-20-2021, 08:25 PM   #90
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I use the oil filter pliers on my turbo cars. No problems getting the filter off... Other wrench that works is the clamp style that has springs and is used with a 3/8" drive ratchet. I would consider putting the remote oil filter bracket behind the fender, in front of the right front tire. That way, it's easy to access, and is far enough away from the turbo and the exhaust to keep the oil cooler than it normally would be. A buddy of mine did that to his '85 245Ti back in 1998.
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Old 01-20-2021, 09:21 PM   #91
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Quote:
Originally Posted by volvowagoon View Post
Nice work! You're motivating me to continue working on the wagon.
Send some of that motivation my way man !!!

Quote:
Originally Posted by John242Ti View Post
I use the oil filter pliers on my turbo cars. No problems getting the filter off... Other wrench that works is the clamp style that has springs and is used with a 3/8" drive ratchet. I would consider putting the remote oil filter bracket behind the fender, in front of the right front tire. That way, it's easy to access, and is far enough away from the turbo and the exhaust to keep the oil cooler than it normally would be. A buddy of mine did that to his '85 245Ti back in 1998.
I think it's probably welded on after sitting so long, I HOPE that's it at least !!!

I tried the handle clamp style, my wee Hazet three-pronged yoke, and then the cup - the last actually wrung the 3/8 drive hole, then popped off!

I'm going to run some oil through it with some engine cleaner in it first-round anyway so may just wait till then and try after it's gone through a heat cycle. Failing that I'll drop it off to pep - boys for a change :D

I hadn't thought of there as a location it sounds like a great idea, thanks man!
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Old 01-20-2021, 09:40 PM   #92
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20210120_155256 by V G, Flickr에서

Got my shiny bracket on today - two m8 x1.25 20mm bolts from home depot and assorted nuts and washers later and it's bet onto the block. the bottom bolt was a tough one to go on and the bracket wasn't too happy with the manifold - didn't seem like a factory fit.

20210120_155502 by V G, Flickr에서

20210120_155505 by V G, Flickr에서

Pcv hose goes through it - had to route it without the protective sheath first - then broke the shagging thing, a litte jb welb later it's all set to go on again. Waiting on my rocker cover gasket to come first.

20210120_162329 by V G, Flickr에서

Next I had to figure out how to arrange the injector lines.

20210120_162431 by V G, Flickr에서

Cleaned up the copper washers - hopefully this will be enough to ensure no leaks!

20210120_173206 by V G, Flickr에서

The banjo bolts were looking a little dirty so cleaned them up, then I polished them because I wanted to stay away from the screens after 10hrs on the laptop!

20210120_174936 by V G, Flickr에서

20210120_180026 by V G, Flickr에서

20210120_181747 by V G, Flickr에서

Looks prettier than it did at least.

Eventually got all the injector lines in their respective places - would probably be a good idea to do that pressure test when everything is accessible!

20210120_183654 by V G, Flickr에서

And that's it until the rocker gasket arrives!

I'm putting off the vacuum system procrastination is strong!
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Old 01-20-2021, 09:57 PM   #93
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20210120_131938 by V G, Flickr에서

Daytime shot
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Old 01-21-2021, 03:19 AM   #94
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Quote:
Originally Posted by atomicdeathmonkey View Post
Send some of that motivation my way man !!!



I think it's probably welded on after sitting so long, I HOPE that's it at least !!!

I tried the handle clamp style, my wee Hazet three-pronged yoke, and then the cup - the last actually wrung the 3/8 drive hole, then popped off!

I'm going to run some oil through it with some engine cleaner in it first-round anyway so may just wait till then and try after it's gone through a heat cycle. Failing that I'll drop it off to pep - boys for a change :D

I hadn't thought of there as a location it sounds like a great idea, thanks man!

Ah, the strap wrench style? Yeah, that one's kinda useless on a 240 Turbo. This is the style I use:
https://www.ipdusa.com/products/6186...ce-tool-w54311


Get it on at a bit of an angle, so the handles stick out some from the cat on the downpipe, then squeeze the ever living daylight out of the filter and loosen it.


Not a problem. Should work better than having it on the firewall.
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Old 01-21-2021, 03:57 PM   #95
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Quote:
Originally Posted by John242Ti View Post
Ah, the strap wrench style? Yeah, that one's kinda useless on a 240 Turbo. This is the style I use:
https://www.ipdusa.com/products/6186...ce-tool-w54311


Get it on at a bit of an angle, so the handles stick out some from the cat on the downpipe, then squeeze the ever living daylight out of the filter and loosen it.


Not a problem. Should work better than having it on the firewall.
Yep that's the one, albeit mine's the harbor freight variant!

Everytime I go near the engine it's been 24hrs of soakage in pb blaster, between that and gratuitous use of red sealant I'm hoping the engine isn't just a boat anchor!
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Old 01-22-2021, 02:29 AM   #96
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20210121_202611 by V G, on Flickr

20210121_202931 by V G, on Flickr

Couldn't stand looking at the metal

Rebadging has commenced, not sure if the sides are right for the year but what I got.

20210121_201353 by V G, on Flickr


20210121_192516 by V G, on Flickr

New gasket - rtv a must apparently - took me some facebook ripping to figure it out - my old one had a full on rtv gasket in the roundy bit :D

20210121_142537 by V G, on Flickr

Aliexpress's finest came through - ordered 3 months ago !

20210121_203252 by V G, on Flickr

Ten centuries of dremel action and filing later
20210122_000629 by V G, on Flickr

20210121_142442 by V G, on Flickr

Oh and I think I've figured out how to remove the plasti-dip hood

20210121_155731 by V G, on Flickr
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Old 01-24-2021, 01:44 AM   #97
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20210123_150407 by V G, on Flickr

Threw the new wur in there - had to add the vacuum stuff - single strip vs the dual bimetallic version

Gave it a quick pressure check by cycling the pumps - seems to be okay it was heading for 70psi before it started pissing out the fittings again so Fingers crossed we're goo d there.

20210123_155138 by V G, on Flickr

Then I went to the dollar store

20210123_174815 by V G, on Flickr

20210123_175002 by V G, on Flickr

20210123_180127 by V G, on Flickr

20210123_183457 by V G, on Flickr

20210123_192144 by V G, on Flickr

20210123_192644 by V G, on Flickr

20210123_183507 by V G, on Flickr

It took about 4 hrs total but it looks like a different car now, the plastic surgery before and afters:

1611463251131-0 by V G, on Flickr

1611463251131-3 by V G, on Flickr

1611463251131-4 by V G, on Flickr

1611463251131-5 by V G, on Flickr

1611463629873-1 by V G, on Flickr

1611463629873-10 by V G, on Flickr

1611463629873-11 by V G, on Flickr

1611463629873-12 by V G, on Flickr

1611463629873-13 by V G, on Flickr

1611463629873-15 by V G, on Flickr

1611463629873-18 by V G, on Flickr

1611463629873-2 by V G, on Flickr

1611463629873-3 by V G, on Flickr

1611463629873-5 by V G, on Flickr

1611463629873-4 by V G, on Flickr

1611463629873-6 by V G, on Flickr

1611463629873-7 by V G, on Flickr

I bought this car because of the lack of rust - the interior was toast and the engine an unknown (still is) but man I had no idea the paint under the plastidip was this good!
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Old 01-24-2021, 12:23 PM   #98
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Waaaaaay better! You’re doing great things to this 242.
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Old 01-24-2021, 01:23 PM   #99
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Thanks a million!

I'm just praying the mechanical work comes together, I don't mind the polishing and cleaning aspects but I'm a total novice with heavier mechanical side of things!

I got it for the learning opportunity as much as anything else!
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Old 01-24-2021, 01:45 PM   #100
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I'm glad there was new paint under there. It was hard to tell. Bringing back to life.
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