Post: #1

After being Volvoless for a couple years, I had a desire to sell my MK1 Jetta Coupe diesel and find a clean 240 wagon. On top of that, the Buchka's were labeling me a "dubber" and I wouldn't stand for that. I found this wagon in November 2010 in the Santa Cruz mountains for $1600. It was a 3 owner 300,000 mile car with $15,000+ of service records from local dealerships and Volvo specialty shops. It had the usual problems when I bought it; overdrive wouldn't engage due to faulty wiring, various dash lights out, blown out front seats, missing trim, faded headlights, blown out hatch struts, etc....




After a few junk yard runs, lots of elbow grease, and power wash sessions, I got it to look like this:




The plan is to make it an awesome daily driver with upgrades. We'll see how it goes from here. I have a really solid rust free platform to play with and I'm stoked on the project!

Post: #2

Shortly after buying this wagon I had the opportunity to buy my old engine back from Pat. The engine was originally in my '75 244 (Asher's car now) when I had sold the car to Pat. I guess Pat kept the engine when he sold the car to Asher and offered to sell it back to me. Confused yet?

The engine is a '95 b230ft. I bought it at the San Diego yards about 5 years ago and resealed it. It was a bit greasy and ugly when I got it back from Pat so I spent some time detailing it.




Nothing fancy for now. Stock lower end and head. It's ironic that this engine is mine again :rofl:. The plan is to drop this guy into the wagon and make it look like it came that way from the factory.

Post: #3

In November of last year Vanna's transmission started slipping. Not good. She had been such a reliable car up until this problem surfaced. I had kept the car pretty much stock with the exception of a 25mm IPD front bar and Yoshi Fab upper and lower braces. Since the transmission needed to be replaced I figured that swapping the engine at the same time made perfect sense.


That's Erik (falunbrick) helping me out. I had to remind him about 1,000 times not to scratch my paint. He doesn't give a **** on how his engine bay looks but I do, LOL.


Good bye engine. You served the car well for 300,000 miles.


The new setup.

Get in there!


The transmission is from a '95 Turbo 940. Accumulator modded.

Post: #4

Automagic?

Well everything looks good!

Post: #5

Jeebus that thing is clean Sean! Good job mang!

Post: #6

(04-05-2012 12:11 AM)scottyd Wrote:  Automagic?

Well everything looks good!

Auto is correct.

(04-05-2012 01:35 PM)blu92in99 Wrote:  Jeebus that thing is clean Sean! Good job mang!

Thanks!

Post: #7

Your gonna drive those great mountain roads with an automatic?

Oh well, the car looks great and you can tell it's going to be really nice when you get done. Nice work!

Post: #8

this car has been done for months, now its fast as well

Post: #9

(04-05-2012 05:41 PM)dl242gt Wrote:  Your gonna drive those great mountain roads with an automatic?

Oh well, the car looks great and you can tell it's going to be really nice when you get done. Nice work!

I've got a 2002 for those great mountain roads. A manual may be in the works later this year. Thanks for the compliments.

Post: #10

(04-05-2012 06:22 PM)FalunBrick Wrote:  this car has been done for months, now its fast as well

Shut your mouth.
Coming on the Friday night bike/booze cruise?

Post: #11

just kidding, its honestly a huge letdown

and yes i will be there, i thought you ditched me last night, i was gonna cry....

Post: #12

(04-05-2012 11:00 PM)FalunBrick Wrote:  just kidding, its honestly a huge letdown

and yes i will be there, i thought you ditched me last night, i was gonna cry....

You ditched us last night....good thing we didn't find the boat and are going on another recon mission next week. No excuses this time. We'll have the pirate flag and rigging.

Post: #13

So before I finished dropping the engine in I took care of the efan. I started off with a 740 turbo fan shroud.



I then set an 850 efan into the shroud and marked the mounting holes that needed to be drilled to mount the fan to the shroud. 3 of the 4 holes on the fan mated up to areas on the shroud where holes were easily drilled. The forth hole needed a piece of sheet metal bent at a 90* to make it work. I don't have any photos of this but it's apparent once the fan is inside the shroud.






I then made some spacers out of aluminum tubing to space the fan out from the 740 shroud. Without the spacers the fan would interfere with the radiator. Again, this is apparent once the fan is placed inside the shroud. I used a tubing cutter to make the spacers.



Test fitted with most of the mounting hardware. The sheet metal 90* bracket is absent in these photos.




This is a much cleaner way to mount an efan rather than hacking up the 850 shroud to fit the 240 radiator. I also used the stock 2 speed relay and ecu harness to control the fan. Looks super clean and should be very reliable.

Post: #14

The engine went in but not without lots of cursing, bitching, drinking, and did I mention cursing? The f@cking hydo ram on the hoist started pissing fluid out and couldn't get the engine and trans combo high enough to clear the front end. Our solution.....well to remove the front wheels and lay the sub frame on a jack of course. Unfortunately I don't have any photos of this debacle.... maybe Erik does.

None the less, once the engine was in the harness modifications commenced. Below is a photo of the MAF harness. I cut the MAF harness at the firewall and spliced a 740/940 turbo portion in order to lengthen the harness to meet up with the MAF at its new location.




I used a stock 740 intake hose and needed to remove the windshield washer reservoir due to space limitations. I lucked out and found a turbo intercooler 240 washer reservoir and that will be installed in it's place. You can see in the above photos that the MAF and filter are missing. I needed to figure out something to finish the intake. Getting the MAF and a filter in that space is a bit of a challenge. I've seen some ghetto set ups but I wanted to get something together to make it look clean.

While at the yards I stumbled upon a Dodge Neon with it's hood open. The air box was open and inside was a K&N filter. The outlet was only 2.5" but with a little muscle I stretched it to fit around the MAF. I think I spent $5 on the filter and $15 on the cleaning kit.



I welded a bracket that mounted to the 2 threaded holes on the MAF and 2 factory drilled holes on the inner right fender. This located the MAF and supported the end of the intake and filter. I still need to paint it black.







I think it turned out well.

Post: #15

I also had to cut up the stock 740/940 down pipe. It's being mated to a stock 240 N/A exhaust. I'm using a 90+ exhaust manifold and a .42/.48 T3 turbo. I used a mig welder and a chop saw to make this. It's not pretty but it works. The stock flange on the turbo down pipe matched up with the flange on the 240 N/A exhaust. Since the stock 240 N/A exhaust has a o2 bung near the cat, the 02 bung in the down pipe can be used for a wide band. Nice!



A 3" exhaust will be installed at a later date.

Post: #16

Once the efan, down pipe, and exhaust was sorted, the car was ready to rock. I'm running a gold box EZK and a 940 ecu (don't have the model # handy right now). I'm using high impedance injectors from an early model supercharged Pontiac GTP so I wouldn't need to splice in a resistor pack. I later discovered that these injectors flowed a tad bit less than stock 940 turbo injectors and were later swapped to later model Pontiac GTP injectors which flow slightly more.

Initially I had the dizzy off by a tooth, so Erik beat me with a Swedish stick and fixed it. Thanks bro, I'll try not to doubt you in the future :-P. Once that was fixed the engine ran beautifully. Here are photos of the finished swap. I still need to paint some brackets and install the washer reservoir but for the most part it turned out just like I wanted it to. I broke the radiator outlet during the swap (lame ass plastic end tanks) but scored a metal end tanked Nissens radiator at the yards. I need to repaint that too.

I think the swap looks 100% stock but I'll let you be the judge.







I kept the A/C and power steering. I've also since installed a new belly pan.

Post: #17

that is one clean install and conversion! nice work there sean.

Post: #18

(04-08-2012 10:16 AM)Coupe' de Tat Wrote:  that is one clean install and conversion! nice work there sean.

Thank you Audio King!

Post: #19

Excellent work sir! Fantastic skills.

Post: #20

reminds me so much of my old 244. looks great!

Post: #21

are you going for the BAR legal swap there? jw

Post: #22

(04-09-2012 11:53 PM)slowg35 Wrote:  Excellent work sir! Fantastic skills.

(04-10-2012 07:52 AM)linuxman51 Wrote:  reminds me so much of my old 244. looks great!

Thanks a lot guys!

(04-10-2012 08:51 AM)Coupe' de Tat Wrote:  are you going for the BAR legal swap there? jw

Not too sure yet. I need to get it smogged in November so anything that's "questionable" needs to be easily removed and put back to stock. As of now all I would need to pass is an airbox and the egr reinstalled.

Post: #23

you left off the magical dryur hose!

Post: #24

pull the strut tower lable off a federal car,

Post: #25

Oh and btw you could own 1 million volvos and youd still be a fucking "dubber" in my book.