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Keeping a thread for the mechanical refurbishment of a GREAT California car.
I bought a 91 240 about six weeks ago. 84.6k California miles serviced at 2 Volvo repair shops since new. It was purchased at McKevitts VOLVO of Berkeley California which is the 2nd oldest USA VOLVO dealer then later at Ackers VOLVO and spent it’s life in the Bay Area until a Dealer in Arizona bought it & sold it to me. I have tracked down 30 yrs of continuous service records for complete service history.
Below is the parts I ordered today. A mix of RockAuto, EBay , IPDUSA , VPautoparts, Swedish Auto Parts, Auslander Restoration and Amazon.
The mechanic on this Volvo is my Brother in law. He is a Sales Engineer for one of the worlds most respected suppliers of automotive equipment for racing and street performance applications. The company manufactures over 4000 products, from oil pans and oiling systems, to ignition wire, ignition components, valve covers, fuel system equipment, air cleaners, hard-core racing tools, chassis and suspension equipment and numerous other performance parts. The company has an impressive list of customers, ranging from grass-roots racers to top level NASCAR® and NHRA/IHRA race teams.he has over 30yrs of mechanical expertise. He grew up around drag racing and has recently retired from racing after 15yrs of bracket racing in blown alcohol & is transitioning into SCCA racing Needless to say he is immensely qualified as a mechanic on 2200HP motors as well as 114hp inline 4 cylinder Motors. He has remarked that these Volvos are extremely well designed & in his opinion this particular Volvo is completely rust free & in excellent working order.
He will replace/service the below on this Volvo
1) Front/Rear Shocks/rear springs. Bilsteins front/Rear. New Bellows and strut tower mount. 2) Front/Rear Brakes/brake fluid flush. Rubber hose break lines from hard points to caliper R1 Concepts makes Slotted/drilled rotors. All new calipers. 3) Radiator / upper/ lower radiator hoses 4) AT service. Brake clean pan 5) AT mount 6) 2 Engine mounts 7) Alternator / Coil pack 8) Tune up, plugs, cap/rotor, wires, fuel filter/air filter/ two drive belts / grease body fittings on suspension & distributor 9) replace rear tail light harness 10) Replace both head lights 11) replace both front turn signals 12) Replace Rear tail lights 13) Install fixed antenna 14) Sway bar bushings. 15) Thermostat housing / T Stat 16) New Michelin’s ( Went with Hankooks. No Michelin’s available anywhere in USA). 17) Alignment 18) Valve Cover gasket/ 19) Oil Pain gasket. 20) tie rod, ball joints, control arms 21) Dash cover. (Prior dash was cracked) 22) Indash touch screen radio with back up camera / new speakers / door speaker covers 23) REAL leather interior 24) Ceramic window tint 25) when it gets to Florida car will be repainted but with Black gloss 26) removed wiper arms and cleaned / greased spindle 27) Strut anti sway bar from strut tower to strut tower 28) New Belly Engine pan cover from IPDUSA 29) replaced HOSE FLAME TRAP, OIL SEPARATOR BOX, PCV OIL TRAP SEPARATOR, HOSE BREATHER BOX
30) Replaced engine harmonic balancer (3 pulley
31) AC Compressor / Dryer
32) Wiper motor IPD
33) 30yo plus new in box Bosch Fog light kit. Compass series 55 watt
34) Exterior mid line trim new. New scrapper seals around window , wiper arm caps and grommets
35) idler air valve , inlet/outlet hose
36) Coolant temp sensor
37) Wiper motor & grommet to cabin
38) Power antenna of EBay. New mast and greased
Last edited by 91Volvo240survivor; Jan 20, 2022 at 09:06 AM.
My Brother had planned on arriving when sellers Dad shop opened at 7am however after 10 minutes on the road BOTH tires steel belts sprung. Had to wait until 8am until a Uhaul opened up to buy 3 new tires for his dolly
Nice dolly. Power brakes Popped out drive shaft for the tow. Lunch Break. Brother said he had a 1/2 dozen beeps & thumbs up on two hour drive back.
The Tire manufacturer dates are from 2014. The rims were optioned at purchase in that a base would not have come with Diamond Rims. I am doing research now to determine if I can put 215/70/R14 on the 14 x 6” rims. I want to give this the best ride I can and Michelin’s are no where to be found for 195/205. I am not concerned about gas mileage/ straight line performance. Settled on Hankooks All Season
Installing new alternator. The original Bosch alternator still works but I will be driving 1500 miles & want to make absolutely sure I make it
New coil. Looks like the original coil? Bosch Alternator replacing this old work horse Iridium plugs NGK Wires Will add more wire spacers at end. Along with insulation sleeves interesting situation today. The PS pump had been replaced at one time and it’s probably about a 150k to far forward. So they had to use smaller belts. When I put on the correct size they touch! So will get that sorted out tomorrow Power steering pump 150,000 thousandths to far forward. Touching with stock belts. Old belts were thinner Iridium plugs Lastly getting the wipers sorted out. The wipers are very slow. As you can see the motor is recent but the wipers do not work properly. It’s definitely a ground issue. Engineers in 1991 said screw the ground into sheet metal and called it a day so running a ground directly to the battery tomorrow. Also the left wiper arm is one tooth higher than drivers do adjust that and sand them oil each spindle to ensure clean smooth action
Wiper needs a better ground
Last edited by 91Volvo240survivor; Nov 14, 2021 at 06:26 PM.
Night off at the shop tonight as well as Thursday/Friday. Then Wotk all day Saturday/Sunday. Should have progress pictures updates Saturday at 6pm. R1 Concepts did not deliver the Rotors that ordered on 10/29. They sent me pads but no rotors. Then wanted pictures of the pad boxes? Weird. If they don’t have them that would be odd in that I’ve never had an Amazon seller mess up before. Not to worry. eBay actually has black slotted/drilled rotors if R1 doesn’t deliver
R1 Ceramic Pads Shipping confirmation from Amazon Ceramic R1 Pads Ok. R1 Concrpts has sent the front/rear rotors (agsin)
Replacing the Engine Harmonic Balancer. Detected a bit of whine under load with AC on turning Corning. Not PS pump. Removed #1 cylinder spark plug & filled cylinder with rope to halt progression and voila the balancer comes. Old farmer shade tree trick to halt the cylinder to allow the removal of the bolt on HB pulley.
Place rope into #1 cylinder to halt the progression so can turn off the nut holding the harmonic balancer pulley Very worn
31years of patina on original head lights and front marker / turn signal lamps very noticeable in light of day. Replacing all head lights, tail lights and marker light assembly’s. Also replaced radio antenna with OEM antenna fixed. No electrical supply for power antenna.
Sylvanania says 25% brighter over stock head light bulbs and bulbs all around. Definitely will be able to tell during the day the difference with faded/ bleached fixtures. The current headlight lenses are yellow and rear tail lights are bleached
Brand new taillight Passenger side head light is brand new Can totally see the difference! Much safer Look at that bleaching. Wow Look how much brighter the passenger side is ! Wow OEM part from the VPSweden antenna. Decided against running a power antenna to ensure longevity of antenna
The coupe is covered outside but It is raining in CT so my brothers 37 Coupe comes back in doors as the Volvo outside into the cold CT
Back out in the cold rain ! The 37 Coupe in the dry warm garage !
The 37 Coupe was built frame up from ground by my Father in law Dale. Dale was a 7 times national Championship winner in 70’s & 80’s Top Alcohol using a small block Chevy that confounded the Big Blocks of the Day. He had his own Machine shop in CT and produced motors for circle track & recreation alike
Last edited by 91Volvo240survivor; Nov 14, 2021 at 06:47 PM.
Today the intake was removed to gain access to the breather box. Used the kit from IPDUSA. It is my understanding that when the breather box associated mechanicals gum up the crankcase pressure builds up beyond designed limits and pushes out seals causing leaks. So as part of the mechanical restoration of the 30yo Volvo the oil separator box was replaced. The breather box was replaced prior but the mechanic at the time failed to put in an o-ring in place so it puked oil out onto top of the red block for 20yrs. Not enough for the owner to notice but 2 table spoons every a year for 20yrs adds up! Will degrease and clean further.
IPDUSA BREATHER BOX KIT Obviously clogged Brand new breathing Old vs New Breather box New gasket Cleaned internal. Every oil change going forward. I bought 12. Oil will be changed twice per year 15/40 Mobil 1 for upcoming 1500 mile high speed jaunt down 95 to Florida Gulp gulp Magnetic oil plug
Harmonic Pulley on along with belts. Everything under the hood is done on the motor
This is a wearable product. Plenty of load placed on this rubber. Zoom into see the wear vs new. Heck of screech under load prior. All set now.
still need to do
1) Replace Differential Cover. Clean out Diff & seal
2) AT service
3) Fuel filter
4) Mount & Balance tires
5) Front & Rear Rotors, New calipers / pads / brake lines from hard / flush brake fluid
6) rear shocks & springs
7) front struts
8) any worn suspension TDB
9) GT Sway bars from strut towers to fire wall
10) Strut anti sway bar
11) adjust wiper arm
12) Run ground for wiper motor
13) Side markers / front turn signals
14) interior door map pockets
15) Front Grill
16) Alignment
Kinda funny. The drivers door map pocket survived 31years of foot opening & feet swinging out. My brother broke it with his big feet 😂. **** happens.
A big priority is to clean every inch of this VOLVO engine bay from grime. But the under carriage has a wonderful patina of 30yrs of various oil leaks from breather box, valves cover or power steering etc. it’s soaked every inch of the undercarriage and penetrating deeply into seems. While it was on the lift. I blasted the wheel wells and undercarriage with WD40
Last edited by 91Volvo240survivor; Jan 6, 2022 at 07:42 AM.
Fans of Parts-**** your gonna love the below. Enjoy 🤗🤗🤗🤗🤗. Big surprise coming in next the couple of weeks. I am reaching out to Ackers VOLVO and another VOLVO dealer on the CARFAX to secure service receipts. Wish me luck. Really want to see the notes on the 2008 60k Mile service! It had an AT service and rotors & pads all around. Probably a $1400 receipt
Last edited by 91Volvo240survivor; Nov 16, 2021 at 08:27 PM.
Closing in now. List was 32 tasks long. Progress. 💪💪💪💪🏆🔥
Amended list:
1) Replace Differential Cover. Clean out Diff & seal
2) AT service
3) Fuel filter
4) Mount & Balance tires
5) Front & Rear Rotors, New calipers / pads / brake lines from hard / flush brake fluid
6) rear shocks & springs
7) front struts
8) worn suspension. Control arms etc etc etc
9) GT Sway bars from strut towers to fire wall
10) Strut anti sway bar
11)interior door map pockets
12)Front Grill
13)Alignment
Nothing to exciting tonight. Drained rear differential. The rear ended was not leaking after 31years. In American cars the manufacturers use the transmission to control speedo/odometer. In this VOLVO the manufacture places the measuring device in the rear end. I like this way better. The oil removed did not smell or seem dirty. Judging by the CARFAX I see a 60k mile service in the 2000’s at a VOLVO dealer so m ok at likely it was drained and filled ? Tightened the belts some more tonight and torqued down the harmonic balancer. After flushing the PS fluid out a few days ago added topped off PSF
big weekend ahead. Brakes and rear Suspension / springs and front as well. Ordered a blower motor and a resistor for the fan speed. Motor doesn’t work at every selection. Watched a you tube video on the installation and it was not to bad. It needs to be done so it will be
Lucas is an excellent product. Fitting belly pan from IPDUSA Only $25.00. I am going to buy another one and paint it Swedish Blue… Engine compartment is coming alone. Once all the big items are completed will be replacing all the hose cla
Pressure washed both front/rear wheel wells today. 30yrs of brake dust and grime blasted away. Will blast wheel wells with WD40 as well to seal. Just wanted to get the dust out. Pulled into garage to warm. tomorrows jobs. AT filter / fluid , rear springs / shocks / rotors / new calipers. Placed into a 70 degree garage for Sunday.
Last edited by 91Volvo240survivor; Jan 6, 2022 at 07:44 AM.
Coming together now. Nice to see this progress. The rotors , new calipers , brake lines is really Great!
Removing the strut was interesting. Had to make a socket and use a 10mm to get it off The passenger side will take 1/2 the time as drivers Poll is done 💪🔥 Now the great slide over 😂
passenger side is being difficult
Just a weeee bit tight. Wow
Last edited by 91Volvo240survivor; Nov 21, 2021 at 02:24 PM.
New Tires! Hankooks. No Michelin’s anywhere in the USA currently. Hankooks are very nice tire though as well. 70k mile tread warranty and 60lbs higher load than Michelin’s. The Michelin tires that came with the car had 2008 and 2014 manufactured dates. Tread looks new. No dry rot or cracks. The spare tire was the original. 😂. So I swapped out a 2014 Michelin to be the new spare. I also purchased a 25mm spacers. That 1” will make a big difference in stance / appearance.
Just realized I did not post these IPDUSA receipts. The customer service at IPDUSA is really great. Phil is very helpful and I really like the prices on some items.
1991 Volvo 240 California Refurbishment Build
