1991 244 Build Thread by Smokeyfan1000

12 minute(s) of a 720 minute read

Still waiting on the backordered upper steering shaft U Joint, but the hardware for both has come in. Will get those today .



I installed a new flametrap today. Old one was wasn't bad, so soaking it, to clean it and save.

Removed old luftfilter, as it looked like time to change it again. I also vacuumed 4 bugs & their remains from air box.

Then I wiped out the remaining dust in airbox and on the lid with damp towel.

Then I installed a new Mann Luftfilter, p/n C 3483/1.

I also had Discount Tire balance all four of my Michelin 205/60/15 tires on Virgos again as it was time for that too

Odometer milage reads 195,743 miles at time of airfilter , flametrap change and tire balancing.

So, it's now good for the Winter on this deal.

Soon I'll I drain, coolant system, and turn the T Stat so piddle valve is to top, and then flush cooling system with distilled water to remove all old coolant. Then pour in the OEM Volvo Blue Coolant and add distilled water 50/50.

After that I'll install the rack & run tank of gas with Chevron FI Cleaner through the engine.And see how temp gauge does(remember that problem from earlier)

I have ordered the compensator boaard by pass kit from IPD If IC temp gauge acts up I'll install the jumper wire kit.

After all that, I have plugs, dizzy cap & rotor button to install.

Soon I'll I drain, coolant system, and turn the T Stat so piddle valve is to top, and then flush cooling system with distilled water to remove all old coolant. Then pour in the OEM Volvo Blue Coolant and add distilled water 50/50.

After that I'll install the rack & run tank of gas with Chevron FI Cleaner through the engine.And see how temp gauge does(remember that problem from earlier)

I have ordered the compensator boaard by pass kit from IPD If IC temp gauge acts up I'll install the jumper wire kit.

After all that, I have plugs, dizzy cap & rotor button to install.

10-4-2012

Well my order from IPD came today. I now have the IPD Temp Guage Compenstor Board ByPass Kit, and a 5 oz can of Ventil Sauber.

I think I'll end up discovering that my Coolant Temp Gauge in the Instrument Cluster has a " beginning to fail " Compensator Board. I'll drive it first to see if the fan clutch helped any, but doubt it will. I'll by pass the compensating board if needed.

I also received, today, an additional package of P/S Rack Install Hardware that I got ATSCO to send me for free. The hardware kit that came with my ATSCO P/S Rack substituted two bolts and a flat flange style clamp for the additional *U Bolt* like my original P/S rack had.

Now I have two new shiny cadmium plated U Clamps along with shiny new nuts, lockwashers & flat washers. So it'll *all* look new. Was free so why not?

Yesterday all my new upper & lower steering shaft U joint hardware (bolts, nuts and retaining pins) came in as well as several sets of new P/S lines banjo bolts to P/S Rack Copper Seal Washers. All leftovers will be for spares to use later/years from now. I'm planning ahead , so I'm not caught needing a critical part that has gone NLA in 5-10 years.

And also, yesterday I ordered all new T Belt Cover Bolts, as some of mine are rusty and some have rounded/skint up heads on them. I'm hoping I recieve the goldish cadmium plated ones & not the oxide black ones. We'll see.

And I've ordered two pairs (4 total) OEM Volvo Rear Muffler Hangar Rubber "Shackles" as Volvo calls them for my 91 240.

Two to use , & two to have as spares as they'll go NLA in a year or so IMHO. They are on backorder so that's a sign that those parts are soon to be NLA & it isn't very far away. At least I 'll have spares for far into the future use.

I guess my CVOCD is still with me huh?

I also researched my 1991 240 Owners Manual and discovered that Volvo specs ATF Type F fluid , to be used in the 1991 Power Steering System.
Seeing as how I'm installing new/remanned P/S Pump & P/S rack, I figured I'd start off with the correct fluids.

So I returned what I had bought earlier & exchanged it for ATF Type F at my local AutoZone. Now if the Upper Steering Shaft U Joint will arive, I can install the P/S rack...............

Pics below:

10-5-2012

I have been looking into the fan shroud on the car by it's part number. The part number is cast into the fan shroud.

Shroud on my car is 7/8 of an inch shorter than one I pulled off a 88 245 I parted.

NOW...The shorter shroud on the car now is:p/n 3540300

The *1987 245 shroud* part number is: 463303.

BUT .... according to Tasca...this 463303 p/n has been superceeded from p/n 463303 *to p/n 3540300*

LINK> http://www.tascaparts.com/parts/1991...icleid=1287053

Does Volvo figure 7/8" difference in shrouding isn't a big deal?

Or is the n/a shroud NLA, and they're substituting the turbo shroud for the n/a shroud????

Can anyone supply the actual *known* turbo fan shroud part number? Is it indeed 3540300 ?

Tasca is listing a 1984 TURBO Fan shroud as part number 3540300. But no mention if it's Intercooled or non intercooled.
Were all the turbo 240s intercooled after 1982 ??

TASCA also lists this 7/8 " shorter fan shroud for my 91 B230F N/A as superceeding the previous earlier N/A fan shroud

Do you really think I did not measure the difference?

The shroud you have pictured * is NOT the fan shroud* I have .  Also, looks like the intercooler is thicker than 7/8"

My original shroud is *indeed 7/8" shorter * than the older version

The older, and longer fan shroud is NLA and it's part # has been superceed to the shorter one that I have.

If no one can supply proof otherwise....and please do if anyone can..........

The only conclusion I can come to is:

1) Volvo engineers found the 7/8" shorter shroud cooled just as well as the longer one.

2)Or so close that the difference was negligible

3) Volvo saved a penny/a few pennies, by using the later shorter version fan shroud.

4) Volvo shaved a few ounces of weight off the car using the shorter one. (remember all the bolts head sizes they reduced?)

5) This change was most likely done by *the Bean Counters*

NOW FWIW..........

I just bolted on the longer shroud. The difference is indeed negligible just looking at it, IMHO.

I may just leave the longer shroud on. It might help just a tad when sitting for long periods with A/C on.

I took pics of *both* shrouds installed.

I also layed both down (old longer by 7/8" and the one *that was pictured earlier* on my car) beside each other, and took a pic.. Pic of that below:



Pic of previous 7/8" shorter fan shroud installed on car.

Pic of 7/8" *LONGER* fan shroud installed on car.

I would think so too, BUT evidently Volvo thought the shorter does just as well.

Otherwise why would they have changed to the shorter design, and superceeded the part number of the longer shroud, to the part number of the shorter shroud??

I am *assuming* this was a change Volvo made on the later 240s(1991-1993), so I could be wrong........

I'd like for other 1991-1993 240 Volvo Owners to post pics of their N/A radiator shrouds from the same angle as the pics I've posted.  

Just to be *100% sure* we've stumbled upon a late model 240 production change in fan shrouds.

At first I thought it may have been due to the relocation of the P/S reservoir on 91-93 240s. But the longer shroud does not interfere with the later P/S Pump or it's belt.

Until someone can prove otherwise, I can only conclude, that it must have been a bean counter's money and weight saving production change.

One has to also keep in mind, that when the car is traveling down the road, the fan clutch is disengaged much of the time.

So a longer shroud would only be of more help, when sitting still in traffic I would think.....

10-6-2012

A pic of underhood before I did any of the work to it save for plug wires. Shows short shroud with @ 1/2 the fan blades exposed.....

but ya have to look closely to see them as fan's blades are pretty dirty. There is a good view of one blade almost even with the top of lid of the airbox though.

So, at least I am correct about the car having the shorter shroud when I bought it.............

Looks like taking multitudes of pics of your Volvo pays off sooner or later...........

I got bored today. So I piddled on the 240 some. Since I have no new upper steering shaft U joint to install yet......

I cleaned off what little P/S Fluid had run here & there with a gasoline soaked rag.

Then I noticed the underhood light was pretty dirty inside. So....I decided to clean up the underhood light fixture /assembly.(read CVOCD sets in again)

I removed it & cleaned the dirt/dust/ whatever out of it. Looks much better now.

FWIW....., once you remove the light fixture, you can use a sharp thin knife, and use it to get behind the piece of galvanized metal it uses as a blind & reflector, and pop it out by it's center area. This will allow you clean behind it , then just pop it back in.

10-8-2012

Some more of my OEM Volvo parts came in at the dealership today. Went and picked them up. 

Installed all new Outer T-Belt Cover bolts, as some were rusty, These have the later smaller "socket/wrench sized hex heads. So weigh a little less than the old bolts.

SO I presume I shaved a few ounces of weight of the front of the car. (?? because racecar ?? ) LOL

All but two of the below flange screws were galvinized finish, and the other two were a shiny black finish. The blacks ones go in the two center holes of the Outer T Belt Cover, so maybe that's why they're black.

Looks better now .

Outer T Belt Cover Mounting Screws p/ns are:

p/n 985183 flange screw(2)

p/n 982763 flange screw

p/n 982801 flange screw

p/n 985188 flange screw

Also received the new Rear Muffler Rubber "Shackles" as Volvo refers to them as in parts book. 

FWIW they are p/n 1206468 Shackles. Requires two of them.

Then I installed all the parts. Pics below:

This bolt pic below is especially, and just for andrewnance21.

Remember the Kelly's Heroes movie qoute ? Quote:

"There ya go again with the negative waves, have a little faith baby, have a little faith......."

LOL

Muffler "Shackles"...