1991 244 Build Thread by Smokeyfan1000

7 minute(s) of a 720 minute read

I've been taking some scrap metal & parts to scrap metal yard, and while going through my parts I found another set of Bosch Volvo Horns.

You may recall, some time ago, I moved the existing horns from behind the grille, and mounted those on driver's side, behind the bumper. 

I also had recently scored some corrugated wire sheathing from a parts car recently.

I also found apiece of 3/16" strap metal for an extension bracket to mount them with in the garage....

I had a spare set of horn wire rubber boots too, and I had enough wire connectors & yellow & black wire...

And luckily I save old Volvo bolts, and found a decent looking 8mm-1.25 bolt around 30mm long, to fasten the bracket in the bumper shock absorber mounting hole in the chassis. And a 8mm-1.25 x 25mm long and a flat washer, lock washer & nut for it,to mount the horn's brackets to the newly made bracket..... I also had extra stock Volvo horn mounting brackets that they come with.
SO.....AND ..THEREFORE.... 

I decided I'd install *a second set of horns*, and mount them behind the *passenger side* , and behind the bumper ala 940 style too.

This gives me TWO Bosch horns  on *each side of the car*, for a total of *four horns*

AND lots more decibels of "don't you pull out in front of me/get the hell outta my way" sound.

Maybe the *bluehairs* will hear me now?

I ran the wires for the second set of horns behind the grille along with the other wiring that is already there "stock". Used the 12 gauge yellow and 14 gauge black wire I already had....and ran it in the corrugated sheathing. Used a few tie wraps to hold it in place. Wired the harness to the 1st set of horns, and over to the new *2nd* set of horns.








Test fitted,...cut to proper length,.... rounded the edges of... and drilled the bracket,.... then painted it with Rustoleum Gloss Black.....



I used some extra spare Volvo thin metal brackets that the horn comes from Volvo mounted with and stacked them... 4 on one horn and three on the other horn so they'd be stronger, and more resistant to flexing. The horns are mounted very solidly now. And after wiring and mounting the horns, this is what I have....

10-5-2013

Well...when I installed the Bosch horns on the driver's side, & behind the bumper some time ago, I used a bracket I felt was thinner than Iliked. But at the time it was all I had.

I had enough of the bracket material that I used yesterday on the Passenger side horn mounting, that I could use the remainder to replace the "too thin one" on driver's side. Plus the driver's side bracket would then match the passenger's side bracket for a more uniform appearance. (CVOCD)

I also wanted to use more "leaf brackets" of the Volvo thin metal brackets per horn than I did previously.

One horn had 2 leafs, the other 3 leafs. The horn with two leafs seemed to vibrate at certain RPMs while accelerating for some strange reason. At least I think that is what I've been hearing...we'll see.

So I found some more 'leafs, and painted all the leafs, and placed 3 leafs on each horn. painted the thicker mounting bracket, then mounted it all on the driver's side of the car, behind the bumper.

Pics:
The Too Thin one.



Comparison of the "too thin bracket" and the new thicker one as used on pass side yesterday.



Painted "horn bracket leafs", and main bracket






And the final installation of driver's side horns.

12-18-2013

1:14 PM

215505 miles I changed the oil . Castrol Edge w/ Titanium Full Synthetic in 10W30 weight

Next oil change is *due* at 219,005, or thereabouts

FWIW I grossly overshot this oil change. The oil I drained out has/had 6175 miles on it. And I had to add a quart of oil during that 6175 mile interval.

One quart in 6175 miles is not bad oil consumption for a 215,000 mile n/a redblock engine IMHO.

I found out that Advance Auto parts is carrying MANN oil filters now. But had to order one for my 240 (p/n W917) Took next day @ 8:00 Am for it to arrive. Pricey at $11.52 total, but I was already there to buy the Castrol Edge w/ Titanium 10w30 oil, so I went for it.

I was already 8*rossly* overdue for an oil change anyway. Next time I'll order from FCPG or buy at Maxwell Volvo as I usually do.

It is the new style MANN Oil filter with the "hand grip crimping" on the canister. I'm praying it does not develop a pressure leak like has been recently reported with these new style filters Mann is selling.
We'll see............

A new Bosch dizzy cap and rotor button are on the way from FCPG, and already have the new Bosch Super Plus Copper plugs.....so tune up in a week or so....

Hopefully this week I can remove the old WP/Alt, P/S, A/C V belts, and clean all the pulleys with CRC Brakleen and install the new V belts I have at the ready.

Some time ago the P/S pressure hose was not properly torqued,(my bad) and P/S fluid had to be rinsed off with GUNK. The GUNK caused the V belts to squeel badly. The noise of them has been driving me nuts too.

12-18-2013

BTW, forgot to mention that the new Windshield Wiper arm mounting posts *rubber grommet seals* seemed to have stopped the majority of the downpour of rain water that was running down the entire fuse box, and out of the fusebox via the bottom of the fusebox door and running onto the floorboard & floormat.

I though this note might be helpful to others who have been experiencing the same problem

Well this new style Mann oil filter is leaking per as others has stated.

Funny the last old style *non hand grip crimped canister*mann filter I used did not leak at all.

Off to the dealership...................