Crowley the '92 240

jamesinc · 2024-06-13T01:03:09+00:00

Around 10 years ago, I picked up an '81 244 from @Spac for @powder_hound as a fixer-upper, and this led to Nina finding The Passion for 240 ownership. Aroun...

jamesinc

For what it's worth, if you see a 240 in this dark green pearl colour being parted out, I need panels. The rear left door has massive rot in the bottom of it, as does the driver's door around the side mirror, and the lower front valence has some rust bubbles.

Dont ask me how, I've never seen a '90s 240 with this kind of rot.

jamesinc

Crowley returned tonight, the alternator bushings (Uro PU) had shattered and the alternator was rattling around in the mount.

I also changed the oil, flushed the brakes, and looked into an idle hunting issue and occasional rough idle issue.

I checked the injector fans, they all looked good, and I pressure tested the fuel rail and it sat right on 3 bar so no issues there either.

The ICV was stuck pretty badly, I flushed it out and got it unstuck, but I think there is some internal damage as it still seems to work inconsistently.

I checked the throttle spindle seal and it was brittle so I replaced that too.

I also replaced the distributor cap and rotor, the O2 sensor, and swapped in a spare AMM. Crowley's AMM is fine, it just needed a hit of maf cleaner I think as until recently the PCV was upstream of it.

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Major Ledfoot

jamesinc the alternator bushings (Uro PU) had shattered and the alternator was rattling around

There's been some discussion about this type of thing lately. What's your plan going forward? Solid alloy or delrin, rubber, new polys, or a mixture of two types?

jamesinc

In the last few years I have been using MTC VU482, which are also PU, but softer than Uro and from what I've seen so far much more durable.

jamesinc

On accessory bushings - I need to replenish my stock so I'm doing an IPD order if anyone wants to get in on it and split postage.

jamesinc

Having gone through all the BS of pulling the dash to fix the evaporator, the system still leaks refrigerant, so it appears the evaporator wasn't the source of the leak. Oh well, the evaporator was pretty clogged up with leaves and dirt so it wasn't such a waste of time.

My regular AC guy came round and we crawled over the entire system, and neither of us could find anything fluorescing under the blacklight. However, he noticed some suspicious staining on the condenser.

I borrowed his sniffer and slowly went down every single row of the condenser, and eventually found one spot where I could consistently get a reading. The sniffer is super sensitive, even moving it too fast will set it off, but it only registered the presence of refrigerant in a maybe 5mm x 5mm area of the condenser. So I feel validated that I took the time to methodically go through it row-by-row.

I've ordered a new Nissens condenser + o-rings from Skandix, which should arrive this week. My AC guy is going to come back and charge the system with nitrogen and we will let it stand for 24h to verify the fix, rather than wasting money on R134a (plus it's bad for the environment when it leaks).

Johnno_

jamesinc

Could have done a double deal on the condenser. I've just done a crash course in A/C air conditioning pulling mine apart.

Been through a few of your posts on forum getting tips and tricks.

jamesinc

Johnno_ it was in the last Skandix group-buy! There will be another 💪

Major Ledfoot

jamesinc What are the measurements of the 240's condenser?

Johnno_

Rob, I have my old R12 one out and it is 660mm wide x 390mm high. It is 675mm wide bracket to bracket. Fins are 30mm thick.

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jamesinc

@Major Ledfoot it won't arrive until tomorrow I think.

I went to check Skandix what part number it was (it's unique to 92/93 240s with factory R134a I think), it turns out Skandix have included some already:

https://www.skandix.de/en/spare-parts/interior-temperature/air-conditioner/condenser/condenser-air-conditioner/1021555/

Volvo 3540647 condenser dimensions from Skandix

Johnno_

jamesinc These newer ones have 4 x rubber mounts rather than the 4 x PK screws on the old ones? Looks a lot more solid.

https://www.skandix.de/en/spare-parts/accessories/din-assembly-parts/fasteners/rubber-support/1082916/

jamesinc

Yeah they do, I threw in a fresh set with the order too, figured it was worthwhile.

I think the rubber mounts are to reduce vibrations in rhe condenser?

But generally I agree it is more solid, the whole setup actually seems deliberate, whereas on the earlier 240s, the AC almost feels like an afterthought.

jamesinc

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New condenser is in. My AC guy did a static test of the system with nitrogen and it is confirmed: NO LEAKS

Also, definitely replace the rubber mounts if you do this job. They were all pretty shot, but worse than that the nuts under the rad support were badly seized from rust, I actually had to cut them off with the grinder.

I would recommend also replacing the rubber mounts for the pusher fan, I didn't think to do that but they were as bad as the condenser mounts. I can replace those pretty easily later on so I think I will as I don't want the fan to come loose.

I also solved the low pressure switch problem. The RHD receiver/dryer is NLA (and I have scoured other brands and the aftermarket looking for a compatible substitute but found none). Starting with the LHD receiver from Rockauto, what I did was, I cut the housing off the terminal, then bent the pins 90 degrees. Bosch to their credit are extremely consistent with their connector dimensions and so I just re-crimped the connector to a D-Jet injector terminal and its happy days.

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Anyway the AC is incredible. Absolutely unrelenting cold even sitting in traffic in 30 degree heat.

Evan11509

I’d love to know where you found such nice black trim pieces?

jamesinc

Evan11509 I put up wanted ads on Oz Volvo 😉

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