Does sound familiar , when you think you've just sorted it out and bang something else brakes .
Good luck mate , you'll get there 
850 T-5R Wagon Improvement Thread
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SKIRT & REAR BUMPER:
Looks my right skirt has been repaired at some stage in it's life and the slot for the rectangular plug was missing so I measured and cut the slot out for siad plug.
I've absolutely no idea what this plug does but there's 2 on either skirt.
I also did a rear bumper realignment. Bumper brackets are new but it looks as though the internal bumper foam can sag slightly which in turn causes the bumper to sag. Has anybody else experienced this?
I've managed to insert a wedge at the top of the foam (between foam and inside of bumper)
You can clearly see the difference here:
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Still works for carrying big loads about, although I was super cautious loading/unloading haha
Looks like I need to get reshaping my passenger wiper arm which is nearly colliding with the bonnet when in the home position
The wipers still clear the entire screen as the passenger only lefts where the driver's side has already cleared.
5 days later
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PETROL CAP RELEASE:
My petrol cap release has only worked 50% of the time so I went in to inspect and lubricate so I could then monitor it.
As you can imagine I found some broken clips on my journey so replaced them as I went.
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GCP & SKANDIX ORDERS
I made use of the Black Friday sales, got most parts to finish off jobs I've started. I can start winding down on this mini restoration as I've managed to tick off a lot of items already.
Such items are:
- Door cards & related parts
- Handbrake cable & hardware
- Engine guards (one option has a duct to send cold air up to the turbo)
- Fuel tank gaskets & pipework
- Headlight wiper upgrades
- Misc items that were required
morch_66479 As you can imagine I found some broken clips on my journey so replaced them as I went.
I found it amazing the difference some new pliable fasteners make to the overall 'feel" of the car
morch_66479 Maybe I regret installing the headlight wiper kit. I spent a couple of hours removing and fiddling with the right side motor to try get it rotating the correct way. This involved discovering the correct gear orientations (this took a lot of time and referencing against the left motor)
Admire your tenacity on this, you're a brave man! Usually one of the first things to fail and get deleted. Like you took me ages to work out how to synchronize my rear wiper.
Thanks for the kind words. It's keeping me busy. Another skandix order arrived today too.
The 240 rear wiper issue is something I went through but I resolved it by removing the arm. Then cycling the motor and then reinstalling when in the home position.
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Headlight wiper install has finally been completed after 4 months of:
- sourcing parts
- paint matching,
- returns/repairs
- Skandix & GCP orders to replace worn out parts
- Time haha
I also received & installed a positive battery terminal cover.
morch_66479
Wipers all working on the headlights okay now ?
rado yeah and new T piece valve for the washers and its all good now 
4 days later
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DOOR CARDS, MORE ENGINE MOUNTS & PROTECTION:
My 2 front door cards needed new grab handles, new pins and collars in the dark grey option, along with a pin retaining clip. Also the lower fabric need reattaching.
Front lower engine mount looked in ok condition but replaced it anyway
I ordered 2 sump guards, one is the standard version that fills the entire subframe hole but the other one I took a chance on as there was a difference in deosgn that has an opening and a duct to direct air up to the turbo.
I installed the duct version and works well. This required carefully marking and drilling mounting bolt holes. I purchased the genuine Volvo bolts and washers to fasten the guard.
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HANDBRAKE CABLE:
My rear left handbrake cable sheath was cracked and cable seized. I ordered 2 new cables online with GCP but only discovered after stripping the car that I ordered the sedan version. I'll need to call around to some Volvo mechanics tomorrow in the hopes of sourcing or trading for a set of wagon cables.
Whilst I was in here I finished off installing the spiral wrap in the speed sensors and gave the rear a good vac.
Looks like Volvo superseded the rear brake lines and speed sensor wire retaining clips too:
Tidy work again, thanks for the pics. I do understand replacing a already working indicator cable with one with some functioning spiral sheathing and an OEM clip. Maybe no-one will se it but if you do, it just looks "right'.
morch_66479 I purchased the genuine volvo bolts and washers to fasten the guard
They just seem to fit better don't they?
I really enjoy this thread & I'm hoping top see this beast one day.
Yeah, very much about the details as you can appreciate. Also trying not to forget about the mechanical side of things too though.
Wait for my next post 
I managed to source a black factory T-5R exhaust tip but noticed the the silencer is too short as the tip sits too far forward.
After further investigation I noticed the exhaust pipe hangers are bent back to reach the chassis hangers.
This explains why the tip that came on the car (simmons tip) sat too far forward also.
It turns out that I have a sedan silencer installed and need to source a wagon version.
Just out of curiosity whats the benefits of the ducted sump guard? Is it just to dissipate heat from the turbo?
I had my manifold and turbo exhaust housing black ceramic coated as I removed the factory heat shield when i fitted the latter style R manifold to try and elevate the heat it seems to work well.
I want to re fit the factory heat shield when i Fit the Japanifold i have if I ever pull my finger out.
Eliminate not elevate
morch_66479 It turns out that I have a sedan silencer installed and need to source a wagon version.
Oh that sucks and I can relate 100%
Just bought a brand new steering wheel on GCP Black Friday. It is only good for a '93 air bagged 240.
Johnno_ I fell you, I have made a few mistakes on my journey and must put a few bits up for sale in the coming weeks when i sort my stock out. Car is currently on jack stands and i collect my handbrake cables tomorrow.
