So over the last couple months, Ive run into a biig problem with my 245. Ive got a nasty exhaust leak, In thinking is at the header, because Im not getting any boost whatsoever, Im running super rich, and whenever I start my car up in the morning, I have really mad misfires, Im talking holding revs @ 3k for about a minute. Im running new spark leads, new in-tank pump, I still have a decent air filter, so Im kind of stuck as far as Which problem to address first.

 

Where's the leak? Exhaust leaks are easy to find, they are loud and air comes out! find it and fix it: weld it or change the part before you burn a valve.

 

The leak is at the header, I checked the exhaust, no holes, cracks, soot or anything. I could feel scalding hot air come out around the 3rd or 4th spark plug from the front, so Im almost positive its there. how tough can I expect taking the header off will be since I have a turbo?

 

What do you mean by 'header"? A header usually replaces the exhaust manifold--you can't have both! Pictures?

Doesn't matter, gotta fix it, it's either cracked or a gasket is bad. Either way it has to come off and be sorted. How hard is it? Depends on how much rust and wear there is on the nuts/bolts that have to come off. But be cautious, a broken/stripped nut can ruin your day, and then some! Those exhaust bolts are known for being a bear to remove due to the heat around there, so use 6pt sockets/wrenches, AND heat. Soaking them in PB Blaster etc. may help too, but heat is best! Acetylene torch, you should familiarize yourself with it...

 

My appologies, I believe its an exhaust manifold. It connects straight to the turbo, and my worry was that Id have to take everything apart. Im not sure how to send pictures sorry.

 

the exhaust manifold is the cast iron 4-into-1 piece between the head and the turbo.

 

What does it sound like? An exhaust manifold gasket leak makes a sharp ticking sound.

 

this was the badly cracked manifold off a 7/9 turbo, I think it was my son's former 1991 940SE...



ignore the coolant dribbled all over it, its the X shaped cracks where the 4 pipes join directly across from the turbo.

I ended up finding another manifold from a forum or email list member, as the welders said it couldn't be repaired.

 

you have kjet problems. good luck.

Running really rich a car wont make boost.

 

Your car should still make decent boost with just one blown exhaust manifold gasket. Yeah and it will make a ticking noise.

 

Thanks for all the responses you guys. honestly, it sounds like Im running open exhaust. The ticking noise is there, but the sound is loud, very loud, deep, almost sounds like a low "wuuuuuhh"

The car runs rich, suuuuper rich. I turn it over in the morning, it runs for bit (about 5 seconds), then dies. Every time. Doesnt matter if Im holding the throttle or not. Op Temperature solves the problem. Mostly. Also, my exhaust is blowing clear (no black, blue, or white, thank God.)

I barely get any boost. Maybe 1psi at most, barely breaks into the yellow on the gauge at full open throttle in second gear.

its reassuring to be around people who are sympathetic to the cause lol

 

Time for you to learn kjet if you plan on keeping the car. Running rich can burn out your cat $.

I personally consider kjet obsolete because parts are hard to find and $.

Convert to lh2.2 or 2.4 or learn the ways of kjet!

 

k-jet works wonderfully well when its working, and is very simple... but yeah, volvo abandoned it in the early 80s in favor of EFI, which makes parts hard to come by... my 1990 mercedes is still K-jet (I think Mercedes used it until 1992, my 1993 mbz is HFM-SFI which is a fancier EFI system than LH).

air leaks in the intake path (including around the injectors) tends to make it run lean, while exhaust leaks in the exhaust path upstream from the O2 sensor makes it run rich.

the mercedes KE-jet has a unit they call the EHA or electro-hydraulic actuator, on the side of the fuel distributor... these fail with age, and throw the system way off. I'm sure the volvo k-jet has something equivalent, the EHA's job is to fine tune the fuel pressure, its what the O2 sensor modulates. ok, the 1980 volvo 240 wiring diagram shows a 'control pressure regulator', I bet thats the equivalent piece.

converting a K-Jet car to an LH car would be a massive undertaking. you'd pretty much need a complete engine from a LH turbo 740/940 and transplant everything including the ECU/ICU. AFAIK, there were no turbo 240's with LH. 740/940 dashboard wiring is WAY different so you'd need to do some cobbling, for instance, the 740/940 has the fuel injection/pump main relay in the center console main relay panel, there's no such thing on a 240, so you'll need to wire in a relay socket, probably using one from a LH 240 (its the same relay) and adapt this to the 740/940 engine harness

 

What does control pressure mean? What is a CPR?

Jk.

Learn kjet!

 

Good luck finding tools and fittings to do the proper tests!

If you are at that point you will be a guru and figure out your problems!

Research.

 

I had a 1975 B20 245 before. Kjet isn't easy dude. Parts are old and rare! However, if you learn what does what and your parts are good it will run fine!