Hi all!

My trusty 1990 240(automatic) is due for some maintenance and I have a few questions, so any input will be greatly appreciated!

1) I have a vacuum leak somewhere and it appears to involve the PCV valve/hosing. I want to change out the flame trap(and all hosing), the idle speed valve hosing, and the PCV hosing all at the same time. I'm not sure if there is a kit available that includes everything for the flame trap, idle valve AND the PCV hosing. Does anyone have a diagram that lists part numbers, or a parts list that would make this an easy evolution?

2) I want to change out the O2 sensor as well. Does anyone know the best place to get one at a reasonable price?

3) My alternator seems to be on its last leg as well. It is the original unit and has a little over 160k miles on it. At high rpms my lights are beginning to dim a bit so I suspect the brushes are about to go on me. I've read reports that orginal or rebuilt replacements are getting harder to find, so I was considering doing a swap to a GM unit, but I'm not sure what all is entailed in the switch. Are rebuilt units still available, and/or is the swap to a GM unit the best way to go?

Many thanks in advance for your input!

 

There really is no kit per se of which I am aware. The individual parts can be found at Volvo Parts, BMW Parts, European Car Parts | FCPGroton.com
O2 sensors can be purchased there as well. There are at least two schools of thought. There are those who swear by o.e. sensors with the correct connector. Me, I use the cheapest 3 wire sensor I can find and splice the connection. I change O2 sensors every couple of years...they are crucial to proper engine performance.
I've had no issue sourcing alternators; I would begin by checking all my connections including grounds. If you are indeed in need of an alternator, you might consider upgrading to a 100 amp Denso as used in the 91+ 7 and 9 cars. It is a drop in replacement.

 

Thanks for the reply, Swift.

There is a salvage yard near me that specializes in Volvos, so I might try to get me one of the 100 amp units out of a 7 or 9 like you mention.

What I really need though is a diagram of some sort that shows the engine hosing along with part numbers. I have no clue what the names or part numbers are for all of those hoses, and I havent been able to find one here using the search function either. I had considered just buying stock roll hosing and trying to use that, but some of the bends on the factory hoses seems to be there and designed that way for a good reason...heh.

 

for the vacuum and crankcase hoses, pretty much everyone I know uses generic european style hose of the appropriate diameters, cut to fit as needed.

if you really want the Volvo factory parts, you can find diagrams of the various subsystems with the part numbers on TascaParts.com (and order them at a decent discount from dealer list).

 

Check for a book by Robert Bently: The Volvo240 Service Manual. A lot of information in there.

Changing the brushes is not that bad a job, can be done without pulling the alternator. I have a 1990 also, the brushes could have gone longer when I changed them and the slip rings were in good shape and that is with 157,000 on the clock, hopefully yours will be an easy fix.

Congrats on your ride, and good luck. Lots of knowledgeable folks here that will help you. They have me.

Fred

 

Complete flame trap/PCV system kits readily available online. Buy a proper replacement 02 sensor, not a splice and fit one. Also invest in, or borrow an 02 sensor socket.
Alternator brushes and regulator are replaceable (assuming you have a 90 240) and will definitely sort out your problem if it is brushes, but also check alternator belt, if they're loose they can slip under load.

 

C'mon Andrew...the question was "...if there is a kit available that includes everything for the flame trap, idle valve AND the PCV hosing." Find me the kit with all those parts.
As for O2 sensors, I gave fair warning there would be a difference of opinion. I happen to have had good results using ANY 18mm three wire zirconia sensor w/ 2.5 to 6 ohms heater resistance and output voltage of .1 to .9V. I have about 30 that fit that bill in stock and my cost is 18-20 dollars each. I will agree, most folks who make their living working on cars don't like splicing.

 

Which is why I stated that there ar ecomplete flame trap kits available online (note that I specifically did not mention the idle valve).
Like this kit.
88-96 Volvo 240,740, 940 MASTER Flame Trap Kit w/inst | eBay

Buy an idle valve (or just clean the original) and it's everything you need.