The Jaffa - 1974 144DL

paul0075 · 2017-07-09T08:06:22+00:00

The first thing to do was order up all the service parts for the car. And to get it ready for roadworthy inspection and registration. I used a mix of suppli...

Vee_Que

I installed a slim 940 starter to my 122 with a b20. Worth the effort, Just need the bolts from the 940 too.

paul0075

Vee_Que;112551 wroteI installed a slim 940 starter to my 122 with a b20. Worth the effort, Just need the bolts from the 940 too.

In order to get the bolts out of the 140, you have to drop the gearbox mount / crossmember so they clear the tunnel, but I couldn't do that at home on the ground, so they stayed put and I just used the same model starter as before.

Vee_Que

There is that, I had to drop the crossmember on the 122 as well.

paul0075

Vee_Que;112591 wroteThere is that, I had to drop the crossmember on the 122 as well.

It's a shame the tunnel didn't have a few more cm of space, would make a big difference. Would also open up some possibilities for gearbox swaps :)

paul0075

Pulled the 1985 heater box out of the shed today, so I can begin dismantling it to get the core serviced. Need to test the fan too, hopefully in good condition, and I can have the 4 speed in place of the 3 speed.

Planning to do this tomorrow.

Vee_Que

In this month's practical classics, your cars twin ;)

peterwgpa

Love the colour and interior on this beast

paul0075

My laundry has been turned into Volvo heater box dismantling central.
Core off for servicing and checking tomorrow

Major Ledfoot

peterwgpa;113495 wroteLove the colour and interior on this beast

There was a similar scheme based in light blue, too, instead of orange - I recall seeing a couple of the blue ones in the yard at the original A-Class Dismantlers locale in Revesby back in the mid-eighties.

paul0075;115123 wroteMy laundry has been turned into Volvo heater box dismantling central.
Core off for servicing and checking tomorrow

Excellent. I'll text you on Friday night so we can rip into it on Saturday.

I will bring Shtumpy.

paul0075

After sitting for 6 months and not having a heater and fan for 12 months, I finally started sorting out my 74 144's heater and fan, with the help of @Major Ledfoot who has done it multiple times.

New brushes soldered onto the replacement fan from a late 70s 264. The original had seized. 1985 heater core tested and cleaned professionally. Brand new genuine dash pad (last RHD one left at Volvo storage). New heater tap as well, but non-genuine as there's no stock left anymore.

Jobs to do whilst in this state:
- Reassemble heater box
- Replace all rubber hoses and rubber seals (where available)
- Install new dash pad
- Replace wiper motor
- Clean leaves and dirt out of openings and vent paths
- Run rear speaker wiring
- Run new looms for factory driving lights, front and rear fog lights
- Re-route and re-tie cabling where required. A lot of it was tangled in hoses etc.
- Run loom for extra gauges
- Install factory intermittent wiper controller
- Install headlight reminder buzzer

Found a use for those big IKEA shopping bags. Storage for all the trim and dash sections.

Reassembly will take a few days / weeks depending on my time and the weather (forecast is rain for the rest of the week).

All set up for a big day of dismantling:

IKEA bags for storing all the dashboard panels and trim:

New and old dashboard tops:

Dashboard out:

43 year old heater vent seal vs. 32 year old one. These are NLA:

Heater box in bits, with seized fan motor. Replacement was another Electrolux from a late 70s 264, which I replaced the brushes and wiring loom on.

Jaffa without the dashboard:

gavinh

Big job well done, new dash pad too would love one of them for the 240. I replaced my fan motor afew months ago after not having a fan for about 4 month, how we take it for granted in modern cars

jamesinc

Paul is that a refurbished dash pad or were you lucky enough to find an uncracked original?

Slowbrick

I wish the wiring behind the dash of a 240 was that simple!

Major Ledfoot

jamesinc;115583 wrotePaul is that a refurbished dash pad or were you lucky enough to find an uncracked original?

Paul found an uncracked NOS one hiding in a warehouse. Unfortunately, the thread on one of the permanent nuts which holds the RH demister bracket in place has a dodgy thread, so that just needs a tap run through it to sort out the thread.

Slowbrick;115608 wroteI wish the wiring behind the dash of a 240 was that simple!

Yeah, although the body layout is the same, it makes a difference when there aren't a heap of relays looking for a sensible home. No wonder they integrated the fuse box and relay mounts in the Sevens.

Slowbrick

Yeah the stupid number of relays behind the dash of a 2 just shits me to tears.

paul0075

jamesinc;115583 wrotePaul is that a refurbished dash pad or were you lucky enough to find an uncracked original?

Brand new. Last RHD in Volvo's storage in Sweden from what I was told

paul0075

I reassembled the box and stuck it in the car yesterday. Need to do electrical test then bolt everything up if OK.

paul0075

3 speed replacement fan died after first test. Had to resort to 4 speed.

240 heater box got cracked when I was cleaning it, so a small mod was made to the 140 box to accept a slightly bulkier 4 speed fan.

paul0075

Some progress on the Jaffa today. Of note, the 240 heater pipe firewall plate is not diamond shaped like the 140's one, and I wasn't prepared to make new holes for the screws, but did use the same ones that held the old panel in.

ab1

is that a 2 series heater box? my 164 has a huge amount of unnecessary hoses at the bottom of the heater box rather than just two coming straight out the top like yours

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