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#1 2012-11-06 15:55:59

Tank&Paul
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From: Nivillac, France
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Tank Blog

http://i280.photobucket.com/albums/kk165/Paul480/TankatHaylingIsland.jpg

Hi. I've owned a 240 Torslanda, 340GL, 850T5 Est, 244GLT, 480Turbo Auto', 240GL Est & an 850 2.5GLT 20v Est. The last two are still with me.

Tank is my 240GL Est with the B200e (2.0ltr K-jet) engine from 1989 & currently has 206,500 miles recorded.

He started life being purchased from Cambridge (Volvo) Garage in Portsmouth & lived  in Clanfield (Nr Petersfield Hants). He was issued the reg' F 991 RBP, but soon was put on to the private
plate AAC 6 X. during this time, he was fully maintained at Cambridge Garage. He was part ex-changed after around 2 years & was issued F 847 SDL. The next owner was a lady police officer who ran Tank upto 2003 & 148,000 miles. Tank was serviced every 6 months by the same mechanic, during this time. December 2003 I asked if 'Tank' was for sale, and shortly after he was mine :D

It was here that my mechanical abilities began to take a sharp rise :lol:  At the same time we were very near to a life changing move to France, having just sold my T5 Tank was to take on the roll of dog mobile, removals van & 5-berth caravan puller!

I carried out the 'usual' on purchase change of oil, plugs, dizzy cap & rotor & then waited for the outcome of an MOT in Feb 04. Tank passed & the only advice given was that the clutch was 'biting high' (something I was aware of & used as a negotiating point on sale).
So as we had a 'clean bill of health', I took him to Swallows Volvo Specialists in Gosport, he had a new clutch fitted, rear oil seal & cambelt change...................


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2012-11-06 15:55:59

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#2 2012-11-06 22:09:48

Tank&Paul
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Re: Tank Blog

July 04 saw us move to France, Tank was loaded to the gunwhales, roof rack, back seat full, 2 dogs in the boot, caravan in tow. Our daughter was navigator & Elaine (swmbo) was in her car (which then was the 480Tub). Journey made no problems.
So onto Tanks next chapter. Re-registration (again :D ) though, this time onto French plates. I had to obtain a certificate of comformity, LHD headlamps & provide various other bits & bobs of paperwork & of course, a French MOT (contrôle technique). This Tank failed on a lower ball joint & brake pads (front) with an advisory that the rear shocks protection had perished (infact it had all but gone). I had the work done here, & later Tank was issued with reg number: http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Engine240044.jpg
..........


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#3 2012-11-07 09:41:45

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Re: Tank Blog

In 2005 we moved into our current home (as per my website). I found that Tank had a groaning noise on cornering & this turned out to be wheel-bearings. Never having done a great deal of car related stuff I had no real idea of what was involved. By chance I met another english couple who were looking for a place to buy & the chap was a mechanic. He fitted new front bearings & also reaction rod bushes (rear) for me. Whilst doing the job he told me that the discs were 'on the limit', and said he'd do them for me. Anyway having watched him dismantle the brakes to do the bearings I decided that I could do it myself & save some cash.  I ordered the bits from GSF & these were bought over by friends. They were all BREMBO stuff. Fitting went well, no major issues. I enjoyed doing it & the knowledge of knowing it was done correctly & the satisfaction was a good feeling. I was hooked! Over the next few months I replaced the water pump, thermostat, hoses & radiator, as well as doing plugs, leads, oil changes, filters etc.
Time rolled by with me carrying on replacing worn out parts 'as & when'. No major issues.
By now it was 2006 & it was Contrôle Technique time again. Tank went in & ..................... failed  . Nothing major though, just track rod ends & an advisory that the rear axle bushes were worn. The latter I learned was the reason I was getting a 'clunk' on take off from time to time.
So track rods from GSF, around £8 each saw Tank being issued with another 2yr CT.
My thoughts were now with this annoying clunk. I read up, and decided that this was not for me.  I was told that a 'simple home made puller' will suffice  . I went to a couple of local garages, they refused the work saying that special Volvo tools are required. This is very typical of a lot of French garages, if it is not Peugeot, Citroen or Renault.................. That said now-a-days this not so much of an issue. Anyway I was still wondering what to do...............


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#4 2012-11-08 11:26:34

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Re: Tank Blog

Then a fantastic 'offer' was received from Mike brace.  Mike informed that he was in the middle of making a purchase in Brittany & needed some accommodation for a weeks visit in order to finalise his land deal. He offered to spend a day doing the rear bushes & giving Tank the once over if I could put him up. Well 'gift' 'horse' & 'mouth'!
Mike & his wife came over that January & I booked a slot in my mates hanger for the day. He showed me how to replace the bushes using poly-inserts, a much easier option & probably longer lasting. He also bought new rear springs (shocks having been done as per earlier post). Basically Mike did one side, talking me through it & I did the other with his 'beady eye' watching. After we finished, he said, "right spin him round so we can get some light under the bonnet you are replacing the cambelt next and I've also bought a dizzy cap, rotor & a set of leads for you". Fantastic. Well we got on with that, finishing around 1900hrs that evening. The work was photgraphed & is now subject of 'how to's
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/SilentBloc6.jpg
:D


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#5 2012-11-09 09:07:37

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Re: Tank Blog

So with those bushes out of the way, the next few months rolled by with not a lot needed. The normal filter & fluid changes were done. I diagnosed a leaking air intake gasket, so replaced it. 4 new tyres were fitted, to some old Volvo 'corona' alloys that I snapped up for a bargain £50 :D .
Then it was Contrôle Technique time again. This time straight through with a couple of minor advisories. Shortly after this I bought a gunsons eezibleed kit & changed the brake fluid, another new 'mission' for me, which went well.
Then between xmas & New Year 08 -09, Tank under took a long drive to Holland. This was us to collect our Xmas prezzy, which was to be Haiyla, a Border Collie pup from a highly rated breeder. During the trip, which was around 1300 miles (made with 3 stop overs) Tank behaved impeccably.
The day after our return, I nipped out for bread & the front off-side wheel bearing failed spectacularly!
http://i280.photobucket.com/albums/kk165/Paul480/Wheelbearing001.jpg
It looked bad as you can see. Removing the outer race revealed it was worse! The inner had welded itself to the axle-stub. The axle stub is part of the strut. Initially I was stumped & quite simply, felt out of my depth..........


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#6 2012-11-14 11:25:32

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Re: Tank Blog

After a bit of a battle I managed to get the outer race and the hub off. The bearing 'rollers' simply fell out leaving the inner race firmly stuck! I tried some 3 legged pullers that I borrowed, but I couldn't get them to grip - they kept slipping off of the stub :rolleyes: So my final attempt was to cut it with my angle grinder. This worked a treat except for the fact that I slipped a little and cut a gouge in the stub itself :(  So any chance of saving the stub axle was now, well & truly 'out of the window):(.

The advice I was given was to 'simply' replace the strut & to swap over the spring & shock. Once again I was feeling a little daunted. Not having a lot of choice I decided to give it go, again following a 'how to' thread & its pics. All was going well until it came to undoing the brake pipes. One came away a treat, the other I discomknackerated :rolleyes: I was then advised that I should have used a brake pipe spanner!

Anyway by this time, once again Mike was on the case. He informed me that his son would make two new pipes (belts & braces) & he had a McPherson strut ready to send out & would loan me a set of spring compressors. Fab!
The package duly arrived complete with a hub & good bearing. Good news then? Well no it wasn't the strut may have been dropped in transit & the top of the tube had been bent in, so the cover that screws into the end would not go in. I took it to  local workshop but the chaps there condemed it as scrap :(

Having sucessfully removed the strut I was feeling a little more confident & decided that the best option was to find a scrap yard & see if I could remove a strut from another car. After quite a few phone calls, I eventually found a yard that confirmed they had a number of 240's from which I could take my pick :D
http://i280.photobucket.com/albums/kk165/Paul480/Scrappy1.jpghttp://i280.photobucket.com/albums/kk165/Paul480/Scrappy2.jpg

I chose the white 240 to be 'the donor'..................


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#7 2012-11-16 07:58:34

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Re: Tank Blog

Strut removal from the scrap yard car went well. Nothing was seized & I left 80€ lighter with the strut complete with shock & spring still attatched:D .

Once home I began to compress the spring for the 'swap over' from my old 'dead' strut. Well I'd seen my borrowed spring compressors in action many a time in pics........... a few minutes of winding, then deciding, 'no I'm not happy with this', unwinding, moving the compressors a bit & winding again & then again getting to 'no not at all happy'........ I decided spring compressors were not for me. I had visions of them slipping off & me receiving a sprung loaded uppercut! Yep I wimped out :rolleyes:

So fully aware that it is not good practice I fitted the scrap yard strut complete with the shock & spring it came with. :/

Re-fitment went well, I repacked the yard bearing with fresh grease &  bled the brakes once again. After a short test drive, during which the wheel was at about the
'1 O'clock position' to go dead ahead, I booked Tank in for another tracking session at Euromaster. The tracking sorted that out & Tank was driving well again & the un-equal shock spring issue did not have any apparent effect.

During this saga, I had taken a few days out to fly back to Derby where I had a few days with my brother & drove back in:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20850/Engine240052.jpg
Volvo 850 2.5 20v GLT aka 'Zeb' - He has proved (touches wood), 4 years on to be a good 850 quids worth!
Zeb was to take over from Tank as our main car, relegating Tank to (mainly) local journeys. This being the reason I was not too concerned about the shock/spring issue - that said replacement of front springs & shocks was added to my list of work required..............

PS: Soz for slipping a none 200 & :o:o a FWD Ovlov pic here:rolleyes:


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#8 2012-11-17 13:42:51

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Re: Tank Blog

During the next few months, Tank developed a leak. For some reason, I put my hand under the floor tray in the rear passenger footwell & found the carpet sodden. No obvious point of ingress. I decided to remove the interior completely, it needed to dry out in any case. So the whole lot came out & I refitted the drivers seat & seat belt fixing. Now I had to wait for rain & see where the water entered. After a few days I found a trickle coming through the grommit which is supposed to form a seal where the bonnet release cable enters the cabin. You can just make out the trickle in this pic:
http://i280.photobucket.com/albums/kk165/Paul480/Wet002.jpg
The trickle did indeed make its way to the rear footwell.
A squidge of auto-silicone was administered & I carried on driving Tank stripped until the next downpour. He stayed dry, so I moved onto refitting. Whilst fitting the rear carpet where it meets the boot floor. I decided to lift the boot floor in order to neatly tuck the carpet in. To my horror I found:
http://i280.photobucket.com/albums/kk165/Paul480/TankRust005.jpg
Nearside.
http://i280.photobucket.com/albums/kk165/Paul480/TankRust006.jpg
Offside.
Pics taken after a clean up with a wire brush.
This looked a bit 'grim' to me. Apparently it is a common point of rust on 240 models & if caught early enough is not terminal..................
I gave each rust point a liberal coating of rust-killer (Kurust) & decided I needed to find myself a welder!
My 'dry Volvo' soon became a wet one again :( This time it was the front passenger footwell. It appeared to be entering through the windscreen seal. As I'd had a screen fitted fairly recently I took it back & asked the chap to check it. He gave me courtesy car & said he'd call. Two days later he phoned to say it was sorted. When I returned he proudly announced that it was not the screen. After he'd played water onto it, he found that all of the drain channels were blocked with leaves & crud, so the area was filling up & leaking through the wiper spindles. He'd removed the wiper motor & cleaned everything up, cleared the channels of crud & off we went, only I found that the wipers now would not 'park'..................


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#9 2012-11-20 12:14:26

Tank&Paul
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Re: Tank Blog

Back at the windscreen fitters :rolleyes: he admitted he was not an auto electrician. Between us we failed to get them to park. Not being particularly electrically minded myself the 'easy option' was to replace the motor. No point it going to the yard, as LHD cars have a different set-up. It just happened that my brother was attending a Volvo club show (he had a short affair with a Volvo 480 Celebration, but that's history now) which had an autojumble on site. He found one for £15 & passed it onto a forum mate who was coming over for his hols'. So dry once again & soon to have 'parking wipers' once more.
Having asked around about welding those holes up, by chance I learned of a self-employed mechanic who came highly recommended. An English chap, who had set up here. On speaking to him, his background was in Mercedes maindealers, before going it alone. I explained about the holes & he asked about the age of 'Tank', at that time he was 21. Steve said, "Mmm on a car of that age a bit of rust has a habit of being more serious than it looks if it is I'll tell you".
A few weeks later, I set off on the 65 or so miles to Steves workshop. On arrival he'd just finished a job & said, "righto I've got an hour before my next job is due so lets give this thing the once over". He'd arranged for his welder to come over too. I'd stripped out the internal trim before leaving home. Steve checked the rust & confirmed that it was the internal floor only that was affected & that the underside of the car was solid. Welder turned up & said he could sort the holes easily enough. Steve found a few issues:
One front brake flexi was 'bulging'. Something I'd missed :rolleyes:
Clutch slave was leaking.
Front bushes were worn.
Of course, he could do the front shocks & springs :D
He was also happy for me to supply the bits & offered a full blast off of the underside & waxoyl type treatment for the cost of 1hrs labour :D
After he'd finished, he said, "This is good I've not seen one for many years close up this would be good for my mobile business that I'm setting up if you want to sell" I declined! ;)


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#10 2012-11-21 16:16:35

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Re: Tank Blog

The drive home was uneventful, despsite learning of that swollen brake hose. Once home I decided not to drive him again until it was replaced. I had already replaced one on the off-side during replacing that sides strut. That was via GSF. I decided, this time I needed one more urgently. So I phoned Ouest-Injection who said they could have one in the following morning, I ordered it. Next morning I collected (in Zeb' the 850). 28€ :rolleyes:  for one flexi-hose! It was an MGA make, not a company I've heard of. Anyway it was fitted & I bled the system once more. I then ordered the remaining 4 hoses from FRF Volvo in Wales!

Shortly after this I read  of a chap who'd found that his 240 had rusted quite badly where the 'lower' body joins the 'upper' body in front of the rear bumper.

I decided that I'd better have a look a mine This is what I found:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyRear002.jpghttp://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyRear003.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyRear005.jpghttp://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyRear007.jpg

Having seen pics of  others, I was pleasantly surprised by how 'good' mine was. Over the next few days & wire-brushed all the loose stuff away. Gave it a coat of Kurust, filled a few small holes with fibre resin (orrible stuff that is too I decided on my first go) & finished it with 2 coats of Hammerite red. Not an exact match by any means, but as it is hidden away behind the bumper, it matters not.

I was quite pleased with my efforts:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyRear011.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyRear012.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyRear013.jpg


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#11 2012-11-22 12:30:31

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Re: Tank Blog

So next on the list was to fit those remaining 4 brakes hoses, as mentioned these were Volvo ones, so now I have 4 of those, one GSF & that MGA one. Once again I did a full bleed, so I must have one of the most flushed through brake systems going by now  :D

I bought a clutch slave cylinder from Brookhouse Volvo parts, no idea what make it was. That was fitted with a new cir-clip & I was able to try my gunsons bleeder out on the clutch system.
 
By now we are upto July 2010, Simon (aka cumbrianmale) arrived with his family for a visit & with him he kindly bought over the front springs, bushes, shocks, a set of engine mounts & a second hand viscous (cooling) fan. These fans give the 'famous' 'Volvo roar' & I was missing mine! The good thing about the system is that the fans fans continue to cool the engine even if they lose the 'viscous factor'. Instead of cutting in & out, they just continue to spin when they fail.

The fan was fitted & Tank had his roar restored :cool: .

Simon & I replaced the engine mounts together. Not too bad a job. Only error during was that I jacked the engine up a little to high & it nudged the clutch fluid reservoir so much that the fluid began to run out. Poor old Simon who was enjoying himself tinkering underneath got a face full  Luckily no damge, it just needed re-sighting & a quick top of fluid.


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#12 2012-11-23 08:59:53

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Re: Tank Blog

As I now had those parts ready to fit, I phoned 'Steve the mec' & made an appointment. Steve wanted to hold the car for about a week, as he was going to do the work during the evenings, due to his now up & running mobile work. So I asked my mate Malcolm if he'd follow me up & bring me back. This was sorted & Steve not wishing to miss out on a chance, offered to give Malcolm's car one of his 'going overs'.

Malcolm has a very nice 1996 Volvo 850 TDI (Audi engine). The follwing week Malcolm & I met up & made our way to Steve's. Once there Steve went under, over, in & took Malcolms car for a short spin. He diagnosed that it needed new wipers :lol: Malcolm was happy! He uses a mechanic local to him, & it appears that he is getting good service.

A week later, Malcolm & I returned. All the mechanical work had been completed, shocks, springs & bushes with no problems. The old fella that did the welding had an issue with his equipment, & the best he could do was to spot weld a plate over that biggest hole in the inner floor before it all conked out :rolleyes: He did apologise & made no charge.

Steve had, obviously done the waxoyl stuff after the welder had tried. He squirted loads of the stuff into the void where the holes were & then emptied two tubs of the stuff onto the underside.

The return drive was fab', Tank had been transformed, no more wallowing ( well wallowyness (fab word :lol: ) was back to 'as new' it is a Volvo 240 after all :lol: ), no more clonking over pot holes & no more graunching. I was happy :cool: .

Once home I decided to fill the remaining holes & in between the spot welds on the plate. I used some  of that Pattex 'chemical metal' & once that had set, two coats of Hammerite were applied. This is how it finished:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyBottomDone1.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/RustyBottomDone2.jpg
Not a professional 'repair' maybe, but a couple of years on, no further nastyness has appeared........ at least internally.... The  two (two yearly) controle techniques  since the 'repair have both times 'advised' on rust underneath, but that it is not at all serious............

Last edited by Tank&Paul (2012-11-23 09:06:07)


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#13 2012-11-25 09:03:01

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Re: Tank Blog

Next on the list was to replace the fuel filter. I had no record of it ever having been done, but guess that it had been replaced at some stage. The one fitted was a Bosch & the replacement was a MANN from GSF.
The old ready for removal:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/FuelFilter002.jpg
& the new securely in place:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/FuelFilter009.jpg

I love the location of the filters on these models, no scrabbling about under the car with manky rusted seized bolts ( like the one I had ready to fit to to Zeb :rolleyes: ).

The Contrôle Technique was looming. I had a good check around Tank & the only thing I found 'in need' was that both of the rubber ring exhaust pipe centre mounts had gone awol. A common matter. I ordered a couple of these & stretched them into place.
Into the CT & about an hour later I had the result, a smiling chappy saying, "C'est bon pour vous monsieur". Tank had passed, with only a couple of minor advisories - drivers door mirror failing, the chassis number in the a-post had deteriorated, rear brakes were 'uneven' (but not enough to fail) & something about the handbrake lever not working correctly. I've not yet worked that last one out, seems as normal as it has ever been to me :lol:

In Jan 11 Tank suffered a failed rear wheel bearing:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/HalfShaft025.jpg
Quite a spectacular fail :rolleyes: Very noisy too, as you can imagine.
To cut a long story short, I went to a scrap yard & removed a 1/2 shaft complete with a bearing. Then regreased it & fitted that to Tank. :D

Shortly after this Tank suffered a melted fuel pump fuse. This particular fuse is a another common weak point if not regularly cleaned. Volvo OE  ceramic fuses are the way to go. Well, I'd fitted aftermarket plastic bodied ones...........I now have ceramic ones, nuff said! :lol:

Moving on, another oil change was  along with a rotor/dizzy clean-up/check & spark plug check.

Then it was PCV time:
A new bit of pipe from the flame trap holder to air intake. Flame trap was removed in 05 by me, as Volvo decided they were not required & removed them as part of servicing. As Tank had been serviced by the same mobile mec' for many years I guess he never knew.....
A few pics: :D
http://i280.photobucket.com/albums/kk165/Paul480/PCV%20240/PCV1.jpg
http://i280.photobucket.com/albums/kk165/Paul480/PCV%20240/PCV2.jpg
Location of the two pipes

http://i280.photobucket.com/albums/kk165/Paul480/PCV%20240/PCV5.jpg
'Bellows' removed - makes it easier to get to the flme trap holder & is a good time to clean the plate & bowl anyway 8-)

http://i280.photobucket.com/albums/kk165/Paul480/PCV%20240/PCV18.jpg
http://i280.photobucket.com/albums/kk165/Paul480/PCV%20240/PCV8.jpg
New flame trap holder with nipple in tact :o  :D Still can't beleive I was clumsy enough to break my old one, should know better by now :rolleyes:

http://i280.photobucket.com/albums/kk165/Paul480/PCV%20240/PCV19.jpg
New holder going in, with new length of pipe attached, ready to be cut to size & look at my shiney clean 'bowl & plate'  :cool:

http://i280.photobucket.com/albums/kk165/Paul480/PCV%20240/PCV16.jpg
Cleaned out connector for the thin pipe to air intake manifold. (I did clean the fat pipe, but failed on the pic  )

Anyway, you get the idea. I have got about 22 pics of the 'full' procedure in my peebucket account.


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#14 2012-11-27 08:31:38

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Re: Tank Blog

14/04/11, I just had to pull in and 'snap' this:D
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/200k.jpg

Go Tank!


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#15 2012-11-27 20:30:55

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Re: Tank Blog

Next for replacing was a very tired looking brake servo hose. I went  for an original part from Pemzec Volvo in Vannes, as these pipes are reinforced for the job.
Here is the old perished pipe:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/db71d9ad.png

And the spangly new one:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/b3a18e5b.png


I used new jubilee type clips instead of the old spring release ones just to be safe. Also when replacing these, it is a good idea to blow down the pipe into the servo to test if the one way valve is good. Tanks' is. Another one is to press lightly on the brake pedal whilst starting up after fitment. You should be able to feel the pedal rise slowly as the vacuum returns.


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#16 2012-11-29 08:32:53

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Re: Tank Blog

Next on the agenda was to replace the in tank fuel pump. I had let Tank run for about 3 years with this pump not working:rolleyes:
Anyway, for the sake of not re-producing stuff that is already here, the procedure for this work can found by following this link: http://volvo200crazy.co.uk/viewtopic.php?id=11

Moving on quickly to summer this year, Smoke in the cabin coming through the vents with a nasty electrical whiff was not in my plans....

I put it down to the fan blower motor. What a nightmare to get to :(

http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0228.jpg

Lots of bits in the boot too.
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0229.jpg
Back seat was 'toppers' too.
The fan motor was not sounding at all healthy  when I tried it without the engine going. Really struggled on speed 1 . Sounded like a strangled duck too.
Having said that, I could not see any signs of obvious heat damage, there was a feint electrical whiff, but that would be there on any old leccy motor.
The noise is the bearing, no doubt there.
Anyway, I ordered a new fan motor from PFV .

I did a re-test on the fan with my spare battery. It ran fine on speed 3. So ran it on speed 1. Okay for a while, then slower and slower till it stopped. Kept it connected to power and it got hotter and hotter and began to pong in that all-telling electrical way... So that confirmed the problem.

I intended to replace the heater matrix too. Thought was whilst its all out....... Anyway trying to find one was not easy. Skandix had them on the shelf, but at £170 I decided they could keep it! Then found 'adrad' (google it) they had them in their online shop, came to £114 delivered to here. Went for it......... then next day got an e-mail saying, 'no longer in stock web-site updated, refund done':(

Another source offered to re-con one for me, but reckoned it'd be more than the Skandix one......... So in the end I decided that the only way forward was to stick the old one back in. It actually looked good & when flushed through, hardly any crud came out.:)

So, onto  the 'rebuild':
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0237.jpg
Fan in its box with the old matrix and wiggled into place.
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0238.jpg
.....and all back together with a toasty warm heater and 'quiet' fan blower.

Contortionism is a must for this type of work & for the next few days I was as stiff as a camel jockeys crotch!! :lol:


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#17 2012-12-01 17:28:18

Tank&Paul
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Re: Tank Blog

& next was onto the timing belt & auxilliary belts. 4 years or 48,000 miles is the norm. Tank had done a mere 25k but months were up to 54 for the cam and about 60 for the three aux jobbies, as I did those with the water pump.

Volvo belts all round this time, last was a Volvo timing belt & Contitech for the aux's.

I also fitted that 'spare' alternator that had been in the boot for about a year (thanks Mike:D). The original one had a noisy bearing. I checked the regulator brushes on the 'new' and they were the Bosch OE ones. But were very well worn down. I swopped them as I had some new ones fitted in Poitiers when Tank conked out on me. Still a lot left on them, HUCO made in germany it is.

http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0240.jpg
The good news was that my 'cheap-ish' 24v Rolson impact driver was just strong enough to remove the 'dreaded' lower crank bolt, and I mean just it took quite a few go's before it gave in.

I set the two 'matched' aux belts so all the writing was lined up (lol) , but when I started up (after spinning by hand plugs out) one of them slipped so had to re-tighten the alt' to get it right & now they are out of alignment DOH :lol: .

Still, main thing was that it was a job well done........ :D

Over the next couple of weeks, those matched belts kept on working loose and began to slip and squeal . I tightened and reset them numerous times.... But no joy . In the end I gave up and whilst my mobile mec' was doing some work on the 850 I asked him if he could see where I was going wrong. He immediately said that I'd never get this belts right as they were too narrow. Looking at the old which I still had they were indeed different. Volvo ones were 9.5 mm and the old Contitech were 10mm . I asked the Volvo supplier and he advised that  he supplied correctly and the Volvo only ever fitted 9.5 mm ones. Anyway, I decided to refit the Contitech ones just to see if it made a difference..... It did they tightened up correctly and never slipped or squealed. I guess that by fitting them back in 08, they have worn the pulleys so they won't accept 9.5's anymore. I ordered a set from GSF they are 10mm by Dayco.
When I removed the 9.5 ones I found that one belt had virtually no teeth left where it had slipped so much!
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0287.jpg
As you can see here!

Last edited by Tank&Paul (2012-12-01 17:42:40)


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#18 2012-12-03 17:35:21

Tank&Paul
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Re: Tank Blog

Tanks dashboard lights had given out after 20 odd years:rolleyes: So I went for a strip of
Surface Mount LEDs......
1) Remove the dash.
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0245.jpg
2) Remove the guage console from the case & drill a lil' ole hole for the wires to exit:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0246.jpg
3) Stick the run of LED's here:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0247.jpg
Which makes them 'invisible' once the case is turned the right way up.
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0248.jpg
5) Refit the guages, the console & wire the LED's into a suitable feed. I used the clocks light live & earth. This means that they will come on with the day run lights as the old bulbs would.
Daytime pic:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0249.jpg
Nightime pic 8-)
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0250.jpg

They do dim on the rheostat too :D

Last edited by Tank&Paul (2012-12-03 17:39:11)


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#19 2012-12-04 10:55:28

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Re: Tank Blog

Once again I let the 'red' slip away from me. Hadn't really noticed until I saw pics of another red one on another forum. Tank was pink :o  :lol:

'He' was like this all over:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0265.jpg

So I set about bringing back the red  :cool: 
This is what I ended up with :D
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0266.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0267.jpg

I used :
1) Ecauto Shampoo
2) Clean Plus 'Lack Reiniger' (a 'paint restorer' which I guess is a 'cutting agent')
3) Ecauto Power Polish
Then after an hour or so,
4) Colonite 476
5) Linseed Oil on the 'black bits'


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#20 2012-12-07 12:43:53

Tank&Paul
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Re: Tank Blog

October 2012 was Controle Tecnique time (Frenchy MOT, which is 2-yearly) Went straight through with a compliment on how good Tank is from M. Le Testeur!

Advisories:
1) DISQUE DE FREIN: Presence de corps gras (ARD ARG) Wasn't  sure on this as direct translation is "Rear Discs presence of a fatty body"  - So I asked on the frenchy forum. The reply I got was basically that there is some sort of grease/oil leaking and getting onto the discs :o Though clearly not enough to make the brakes fail the test.
2) Play in steering wheel at full lock. Another weird one?
3) Minor play in steering rack
4) Dipped beam too low
5) Headlamp reflectors deteriorating ( Quelle surprise!) these were genuine Volvo replacements fitted in 2005!
6) Front tyres wearing very slightly on inner edges (he reckoned this tied in the play in steering rack).
7) Surface rust 'underneath rear'.
8) Battery not correctly fitted (checked on this one and that bit of plastic that 'locks' it in place has gone awol :rolleyes: .
9) Engine oil leak
10) Gearbox oil leak
11) Differential oil leak.


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#21 2012-12-08 12:50:06

Tank&Paul
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Re: Tank Blog

This is the most up to date 'work' on Tank. Replacing the diff' oil. It had been on the 'list' for some time, but always wondered about the easiest way to get the oil 'up' into it once drained. In the past I have used various 'long nozzled squeezy bottles' and lost about as much as I used :/

This time for £8 or so, Amazon supplied this little 'Draper' Pump:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/Photo0307.jpg

It worked a treat, will try it on the gearbox next :cool:

I shall update this from now, as and when I carry out more work:D

Last edited by Tank&Paul (2012-12-08 12:50:55)


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#22 2015-04-26 11:17:17

Tank&Paul
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From: Nivillac, France
Registered: 2012-11-05
Posts: 52
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Re: Tank Blog

I bought myself one of those electric polishers....Silverline make and 'angle-grinder' style. First 'go' went to the one that drives with the 'wrong wheels', I thought it only fair to give 'Tank' some of the same treatment. Very pleased:thumbs_up:

Like 'Zeb' Tank was quite well waxed up, so just gave him one coat of Colly476 to bring back the red once more.
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zpsdd4f49f2.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zpsffe9618f.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps4cf507ae.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zpseb2e2761.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zpsb964cdd6.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps0c934abe.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps735f2f68.jpg
......and yes I've seen the grot in the gutter :roll:


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#23 2015-04-26 11:23:13

Tank&Paul
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From: Nivillac, France
Registered: 2012-11-05
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Re: Tank Blog

So, back in July 2013 Cumbrianmale (VOC forum username) & I fitted an amplifier and loom (with Cm doing the 'working out of wiring) for the radio cassette. Leaving me to 'just' wire in the rear speakers.
I started of trying to source rear door cards with speakers fitted over here on Frenchy Volvo Forums.... but nowt turned up.
That left me with cutting my current door cards, something which I wasnt overly confident to do, lol.
The cards were marked 'where to cut' for 4" speakers, but I had 5.5" which will not go in that location.....
A few weeks later I popped up to visit Mike whilst on his hols here & he cut the cards out for me. The speakers had to go quite well back, so are a little tucked away by the rear seat bolsters.... but still has a 5-6cm gap. Sound is not at all muffled :D . Sound quality is much better & even with my old personal CD player hooked up to the cassette slot (remember those) I could wack the sound up & no distorting. I have an old mp3 somewhere, will have to charge that and try it...

Anyway a few pics to add to my blog:
Door Card Cut:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps09a5670c.jpg
Speakers Fitted, nuts and bolts & a touch of loctite to stop the nuts coming loose:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps4b6de86b.jpg
Speaker and Grill in place:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps6684d31d.jpg
Whilst the door cards were off, some waxoyl type stuff added:thumbs_up:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps2a90be36.jpg
Pulling the wires through:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps09b16650.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zpsd7b7725b.jpg
Wiring into the block from the amp' - we hung the amp way down and out of the way with zip ties:
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zpsce27672b.jpg
And the final 'look':
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/null_zps725966bf.jpg


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#24 2015-04-26 11:38:06

Tank&Paul
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From: Nivillac, France
Registered: 2012-11-05
Posts: 52
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Re: Tank Blog

Jumping along, Oct 2014 was 'Controle Tecnique' time again, (French MOT),  straight through, get in 8-)

http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/CT4_zpsf4cd35b5.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/CT5_zps99c43c14.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/CT1_zps7b9e1efa.jpg
http://i280.photobucket.com/albums/kk165/Paul480/Volvo%20240/CT3_zps71eb6b43.jpg

Advised tyres near to limit. I knew, but waited the outcome. Should have known better :cool:

So, now Tank is wearing 4 Nankangs :rolleyes: that replaced those aging Hankooks. Figure that Tank is car three these days to the 850 & V70 doing mainly short trips they'd 'do'. Gotta say so far no complaints with them at all.:D


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