Greg's Gold 1991 240GLE wagon B230FT-to-be

OK so my parents are visiting and my dad is helping get this stalled project back on the road again! We pulled the dash out to make it easier to install the manual pedal box. Marked, then drilled holes for clutch master cylinder, then reinstalled pedal box. Got the clutch master, pipe, bracket, hose and slave installed. Just need to cut the tip off the brake master cylinder reservoir hydraulic feed for clutch and install the rubber hose, then the clutch mechanical and hydraulic system will be done.

Dad's a stickler for cleanliness, so I said great, get the engine cleaned up (I had started some time back). While he did that, I installed the new spark plug heat shields (unfortunately they're not perfectly aligned…guess It's due to manufacturing tolerances?) The new ones have a rolled edge which I assume helps make them stiffer and maybe less of a sharp surface.

New water pump is installed (genuine Volvo - made in UK - purchased maybe 15 years ago?) Also installed the oil pressure sender, new LH2.4 ECU temp sender, swapped gauge temp sender from the 91 240 engine, pulled distributor from 91 240 engine (to be installed on the B230FT). We'll put on a new timing belt and get things aligned, then install the distributor.

Next steps are - swap 91 LH2.4 harness over to B230FT and route extra wire to oil pressure sender, install inlet manifold and new injectors, pull cam cover and put on new seal, and install rear distributor blanking plate + IPD rear cover plate…then I guess new clutch pilot bearing, install flywheel and clutch…heater hoses, engine mount brackets and engine mounts…then about ready to install engine.

Oh, we also got the overdrive wiring re-jigged using the 740T M46 overdrive relay, and I routed the overdrive light wire to the spot for the ABS warning light. Disassembled instrument cluster and cut a green overdrive "5" lens from an earlier cluster to replace the ABS lens on the warning lamp strip. Reassembled cluster and installed a globe in the correct spot.

We don't reinstall the dash until the engine and wiring harness is in as I want to have good access to the wire pass-through when installing as I buggered up the grommet when I removed it (super glue to the rescue). Also installed turbo ECU and have turbo EZK ready to install once engine and harness are in.

So, things are moving along!

jamesinc It's a custom job using a 740 throttle spool/vacuum dashpot/bracket, a late (91-93) 240 cruise stalk and cruise ECU, custom pedal switch brackets, wiring etc. I prefer this setup as it doesn't rely on engine vacuum at all to control the throttle position (it has the separate vacuum pump).

jamesinc Yep 850 pump is the same. Let me know if you need any bits and pieces…I have a large tub of cruise control parts.

ramrod Yep Sam, I believe you were right. I've put a clamp on there, but it probably doesn't really do anything as everything is fairly rigid. James, yeah, probably could just put a bolt in there.

Got a few more things done…mounted the alternator with new bushes, and of course with the oil pressure sender in place the original belt size was too short (alternator touching sender). We had slightly longer (920 mm) belts which just eke by, but I may have to get some longer ones…reason being is if we try to use the original oil cooler lines bracket, that is sandwiched between the alternator bracket and block and will position the bottom of the alternator out the thickness of the bracket (about 2.5 mm) which will tighten up the belts even more. It was a bunch of f**kery to get the alternator bushes and alternator in place and I managed to smash my middle finger nail with the hammer so f**k you alternator and hammer (one of those days…that I remind myself I don't really enjoy working on cars LOL!)

Well, we got the engine in today! Yay! Waiting for clutch fork from GCP, then we'll be ready to put the gearbox in. Progress! We'll start to fit some of the ancillaries etc. in the engine bay and hook up the wiring, fuel hoses etc. while we're waiting for the clutch fork.

Everything looks pretty tight as expected on the turbo side, but hard to say exactly until the gearbox and rear mount are in (currently engine is just sitting with front mounts and a block of wood propping it against the firewall at the back of the cam cover).

Anthony Given I'll probably only drive the car a few times per year, I doubt it will be an issue! I preferred to use a bolt-in solution rather than reinventing the wheel for the sake of getting the project done, given I've had the engine sitting around for over 20 years LOL.

Got the clutch fork from GCP today so have that and throw-out bearing installed on gearbox. Got the clutch plate and clutch cover installed on flywheel, as well as crank sensor bracket and sensor on engine. Removed alloy 740 gearbox mount from back of gearbox and installed 240 mount in its place. I need to measure a cast iron case M46 length just to confirm the gearbox mount is in the same position as on the alloy case M46 as last thing I want is to get the box up into position and find out the mount bracket or cross member needs modification. Trimmed up the foam gear lever surround as the only one available was one for a different gearbox. Doesn't fit great but better than nothing. I can put a bit more insulation around the gear lever once the gearbox is installed if need be. Hopefully tomorrow we'll get the gearbox installed.

Anthony Thanks for the offer but I have one (or more) sitting in the shed as well, so all good. I assume it will be the same, but you know what they say about assumptions! Will report back.

Anthony If anyone asks, they're both the same ~240 mm (nice number! )