Bit tricky to see from this photo, but fuel leak at the Kjet distributor (I think) and water leak at dodgy hose clamp at firewall heater core junction. Ironically, didn’t leak before I topped up! Bahaha! Unfortunately ran out of time again..
Jaz's 1985 240GL K-jet wagon project
21 days later
- Edited
Finally got back to the wagon this morning with just enough time to pull the intake manifold and kjet.
PCV seems not to have sealed properly at the o-rings or internal baffle failed, oil everywhere.
Another potential suspected fuel location around throttle body. All back home for cleanup and inspection.
Not much closer, but any progress is good with so much else going on.
2 years later
Such a long time between updates.. much has changed.
One of the challenges of this project has been distance, located at my parents property. Initially 3 hours away, then after we moved house 4 years ago, only 30 minutes. More recently, other challenges presented.
Cancer has a way of re-prioritising everything, as I'm sure many here would understand. We lost my father in early 2022. Still trying to navigate grief. He was pivotal in this project, managing the full engine rebuild, and more, and putting it all back together.
Have recently come back to the wagon project with the goal of getting it operational. Perhaps to sell, perhaps for one of the kids down the track, but certainly to move, as it can't stay where it's been living for so long.
Anyway, more than a few solid hours recently spent replacing the PCV system, and reinstalling the intake and injection system with new throttle body and intake manifold gaskets, and I was hopeful. No luck unfortunately, and another visit was required...that was today.
Have spent some time troubleshooting the usual suspects this morning. Then after checking pump, supply, power, fuses (& bypassing), removing and bypass jumping the fuel pump relay, was able to prime, start and eventually run (not for long). No fuel leaks, so the new throttle body gasket has done the trick there. Trouble seems to be the green fuel pump relay (no additional white one, just the single green one for this era of k-jet). So further troubleshooting awaits...
In the meantime, I'd like to give a quick shout out to @Major Ledfoot and @1971_144GL for moral support and friendship, it's great to have local like-minded friends, and to @jamesinc for the forum and the support it provides for us all. I'm sure for many us these Volvo tinkerings provide a positive contribution to our mental health :)
Dan
some photos to follow...
a month later
Alternative green fuel pump relay did the trick. Still misfiring, exhaust leak (egr) to sort out when time permits, but at least there’s fuel supply now.
4 months later
Just continuing this thread, Dan's wagon has a new owner, me! After being out of the Volvo game for quite a few years I saw his wagon for sale and picked it up as a little project, progress will probably be slow but gradually Im planning on getting it back up to scratch!
Had more than 5 minutes to look at the car today, needs a pretty extensive detail as the pics will show
Plus the bonnet is stuck shut, it was closed with a block of wood under there and it's jammed the latch closed, I thought I knew how to get it open but no dice, can anyone advise me on the best bit to hit with a hammer to get it open?
Twist with a pair of pliers that lever toward the direction of the cable
Normal cable operation is in the direction of the white arrow. Pulling the cable rotates that cam thing around against the lever in the red circle.
What you need to move is the part within the red circle, in the direction of the red arrow.
Major Ledfoot sweet, I'll try and give that a go
Success! I ended up wriggling the grill out so I could access to the latch, after trying to pry the release open with no luck I started to undo the bolts that good the latch to the bonnet and it just popped open, feels like the release is seized shut so I'll get that working again.
Reds on, all the dash lights seem to work, the exterior lights all work too which is impressive.
My jump pack is pretty well past it's use by so not real impressive cranking but it did do some revolutions.
VolDan changed the title to Jaz's 1985 240GL K-jet wagon project .