240 GLT saloon restoration project

[Juular]

Originally Posted by 230ina245

"Usually the temp gauge sensor is towards the front of the head, i wonder if the thermotime switch has been replaced at some point with a temp gauge sender? Wouldn't surprise me! "
From memory that shouldn't be possible as they are different sized threads.
The temp gauge is a smaller sender with the bigger thread.
Tim

Correct - I had a chance to pull them both and test them. Thankfully they're OK.

As you can see the threaded sections are different.

[Juular]

So where were we..

We have tyres.


We have a windscreen (and some filler and primer on the welded repairs).






After the initial failure to start I did a basic overhaul of the ignition and injection.

First, new NGK plugs and a cleanup of the distributor cap.

Then, testing the cold start injector. It had no flow with 12V applied, but just needed a clean.



Checked the Auxiliary Air Valve was open.



I also checked that it closed when heated - which it did.

She lives! Almost..

[YOUTUBE]https://youtu.be/uEPCKxMYp5Q[/YOUTUBE]

As you can see, it needed accelerator pedal pushed or it stalled.

With the idle set a little higher, it stayed alive but still wasn't right.

[YOUTUBE]https://youtu.be/1y10QkrZNyA[/YOUTUBE]

Finally, with the air/fuel mix adjusted a little bit leaner, it was much happier.

[YOUTUBE]https://youtu.be/FelL6TOjHNQ[/YOUTUBE]

Some problems remain:

- Occasional hunting, presumably a small vac leak
- Coolant leak
- No vac at the distributor advance port on the throttle
- Brake pedal causing idle to drop

Water pump and seals had seen better days.





Brake booster is shot. It's pushing air down the vac line when you press the pedal, causing the lean mix / stalling.



A friend is giving me one for free that should be in better condition.

Since I am waiting on parts I cracked on and did some other bits while I had the time.

Manifold off.



Throttle body cleaned. The vac ports were blocked.





Flame trap was choked solid.





Took off the PCV and ran carb cleaner through it.



I also had access to test the thermotime switch with the manifold off. Thankfully it behaves as it should - closed circuit when cold, open circuit when dropped into some hot water.



My goal is absolutely for this to be on the road before Christmas.

[Laird Scooby]

All good stuff and you've done a lot of remedial work which will vastly improve things. You'll need to alter the mixture once you get it all back together to be richer again though.

Also you need more carb cleaner and some "encouragement" on the AAV, that's barely open at all, should open a lot more than that when cold!

I'd suggest giviing it a good dose of carb cleaner, sealing it in something airtight and putting it in the fridge (or freezer) for a while to bring the temperature down. Remove and give it some more carb cleaner then back in the fridge/freezer again. Repeat until the improvement in opening stops.
Also giving the slide some "help" with a tin screwdriver towards open will help move the slide and the carb cleaner will remove the goo that's stopping it.

I don't know if they're still available separately but the gauze in the flame trap (yours looks like a dimpled plug in the pics! ) was available new for pennies, maybe PFV has them?

https://www.partsforvolvosonline.com...th=105_919_923

They have, slightly more than pennies now but not a bank-breaker.

Should be all running nicely soon then!

[Juular]

Originally Posted by Laird Scooby

Also you need more carb cleaner and some "encouragement" on the AAV, that's barely open at all, should open a lot more than that when cold!

Good to know thanks, I have never seen one 'open' so didn't know what to expect.

I did give it a good shove with a screwdriver but it felt like it was meeting quite a lot of spring pressure?

[Othen]

Excellent - as ever.

This has been the best thread on the forum for the past year. Well done.

Alan

[Bob Meadows]

The small nut on top of the Auxiliary Valve can be loosened allowing the fibre valve to be adjusted.
The valve can be pushed aside with a small screwdriver to test/indicate the spring tension.
These don't fully open to the point the valve disappears but you should have a clear passageway when cold/
Hope it helps.
Bob.

[Juular]

How's this?

[Steve 940]

Hi Juular,

Wow, just stumbled across your restoration thread, as many others have already commented, you're a much braver man than many of us to undertake such a project, certainly me anyway😀

Seriously though, many congratulations on what you've achieved so far, well deserved, and another Volvo preserved for many years to come let's hope.

Have recently entered the Volvo fold with a '94 940 Wentworth estate 2.0 Turbo that had hardly been used for 10-15 years, first Volvo in 37 years of driving, and as you'd expect, it has some issues, so undergoing a rolling refurb.

Out of interest, what is the blue rust treatment you used on some of your suspension, subframe and fuel tank please??

Probably have a few areas that might benefit from this in months to come, so would be good to have some treatment so I have it to hand when needed.

Cheers
Steve

[Laird Scooby]

Originally Posted by Juular

How's this?

That looks better, see if you can get any improvement on that but that's about twice as far open as it was.

[kiloran]

I'm in awe. Really enjoyable thread to read, your dedication is incredible. That car's lucky to have you.