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Rölf 2.0, the blue 245 Turbo...
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Blue245Ti Offline
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Post: #1
Rölf 2.0, the blue 245 Turbo...
Got this car on June 26th, 2011 from Patrick Helzer (aka Helrazor/700volts). Your typical 1984.5 245 Turbo with factory intercooler setup and Aw71 in #200 blue metallic. Interior was fairly trashed, upholstery-wise, dash was beginning to crater, etc. Body was straight, though, with only minor rust on the passenger floor, a rusty tailgate, and a small spot of rust on the driver's rocker. Paint was decent, having only clearcoat damage on the hood and at the front of the roof. Car was, alas, adorned with the six legged roof spider thing that's chrome. Yes, someone had added a roof rack and didn't care to even use the OEM hardware. Just drilled holes, and screwed it on with sheetmetal screws.

Car ran fairly decent, but had issues with the Aw71 skipping 2nd gear and slipping into 3rd when accelerating, and slipping in boost if 2nd gear was engaged by the transmission itself. Manually engage 2nd, car would upshift just fine. No problems whatsoever. Engine ran a bit hot and had a surging idle if tranny was in park or neutral. Sometimes would stall as well. Exhaust leak at turbo mating surface of manifold when engine's cold. AC bypassed with iPd kit.

Suspension left lots to be desired (and still to some extent). Front struts are DEAD. Bounce the front end of the car and it continues to bob for a few seconds. Rear shocks are OK. Bushings are worn.

Electrically, the car had a well-worn fuse block with lots of blackened metal, especially on fuse #7, which is where the main pump fuse resides, of course. Power door locks didn't work, driver's power window was dead, heater fan was/is noisy (something's in the passenger side clamshell, rattling against the fan blades when fan is on - doesn't do this if car is parked so passenger side is lower or when turning left), etc. Also, wipers didn't work - exploded pass.side wiper pivot.

So far, what I've done is:

Pre-tranny swap:

Removed roof rack
Fixed wipers with parts from an '87 244DL
Replaced dash with better one
Swapped hydras over with good tires that are balanced
Swapped interior from my old '85 245Ti into the car
Installed E-code 4x6 headlamps and NOS Cibie E-code turn lenses that I had from my previous 245's
Replaced the passenger side taillamp with one from an '89 245DL and modified the driver's taillamp to accept the 3-contact sockets from an '85 or newer car (reason why will be mentioned in a bit)
Fixed the power windows - bad switch for driver's door
Installed my Alpine CD player and Sony 5.25" speakers
Added a cargo guard and an iPd armrest
New plugs, cap, rotor, and wires
ATF flush on Aw71 - didn't help one bit
Installed later fuel/temp gauges without markings to modernize the car a little
Replaced speedometer after replacing needle once already on original speedometer
Swapped a 6500 rpm redline tach in place of 6000 redline tach.
Changed oil
Replaced dead oil pressure sender with one that was leaking - exxon valdez underneath car
Fixed alternator wiring
Replaced oil pressure sender yet again, this time with a Volvo VDO sender (previous was a VW/Audi with longer nipple)
Replaced brake calipers and a couple brake hoses
Bled brakes

Day after brakes were done, it was time to deal with the transmission issues.

Installed very low mileage clutch kit, resurfaced flywheel, M46, driveshaft, etc, with the help of swedishiron.com and drturbo. Car is much better, in that it didn't have slippage issues and is getting reasonable mileage (23-24, instead of 16-18). Also installed a fan shroud, which the car didn't have when I got it. At the time, the idle surge was pretty bad and the exhaust system seemed to be rubbing massively. A few days later, decided to tackle those issues and see if I could get the car to run cooler. Put in an 82 deg C t-stat and discovered that the bracket for the exhaust hangers ahead of the rear axle was touching the body. Loosened up the bolt, then tapped it backward until the exhaust fit right. Fired car back up, noticed it was quieter, but the idle was still going bonkers. Jonathan (swedishiron.com) decided to check the timing. Sure enough, some mechanic had set it at 27 degrees BTDC. We readjusted it to 10 deg BTDC. Much smoother and the car doesn't buck at a certain throttle position.

Since then, I've done some other fixes and upgrades:

Installed iPd rear 25mm sway bar
Partially fixed power door locks - they work, but not from the key, since I wasn't thinking and decided to roll down the window before routing the wiring to the key switch where it normally goes. Broke the switch. At least, I can unlock my door, open it, then pull up on the lock knob to unlock the remaining doors.
Began adding black door handles from a '92 240.

Today, I decided it was time to replace the fuse block that had been cooked for god knows how long and was providing some resistance in the fuel pump circuit, sometimes also creating a no-start condition, like it did prior to the manual transmission swap. The fuse block I had on hand was from an '86 and was white with the painted on wiring legend, which meant nothing would match up if I left the wires going to the 1984 positions. Decided to wire everything up 1985-style and add the rear fog lamp wiring (hence the modded driver's side taillamp assembly and the late model passenger side assembly). Now, I essentially have an '85 245Ti.

Stuff still to be done:

Replace front struts with Billy HD's
Install iPd front sway
Wire up oil temperature and ambient temperature gauges
Wire up front fog lamps
Do bushings
Replace rear shocks with Billy HD's (either used or new)
Replace tailgate with '90+, painted #200 blue metallic
Locate and install better hood
Install '93 power mirrors
Install late model C-pillar covers and rear quarter glass seals

Eventually, the car will get repainted and have the roof rack holes filled, so I don't have to leave the screws in the holes.

Pics of the car will be added in my next post.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-04-2011 12:07 AM
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scottyd Offline
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Post: #2
RE: Rölf 2.0, the blue 245 Turbo...
Pics or ban.

'97 GMC K2500 Suburban 6.5TD - FailBus
'84 245GLT - FailWagon
'92 245DL - The iFixit.com Lemon
'95 850T5R - ButterCup


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09-04-2011 07:33 PM
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Blue245Ti Offline
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Post: #3
RE: Rölf 2.0, the blue 245 Turbo...
Ok, Mr. Dingledangle (yes, re: your 245GT-Turdblow name)... One pic is in my avatar, btw.

On the way to Voodoo Dougnuts from Boring, OR:

[Image: 5899684583_8b51d8fddd_o.jpg]

At home the next evening - rack has been removed and a 240T grille has been installed - car came with a black painted DL/GL chrome grille installed:

[Image: 5879065457_1c6ca2a2a7_o.jpg]

A week later - finally started daily driving the beast, still with the flaky Aw71 and with the Virgos, etc:

[Image: 5917649122_87d68be951_b.jpg]

Side view, taken at the same time as the previous image:

[Image: 5917086447_78fc448fee_b.jpg]

Now with Hydras:

[Image: 6037196728_124b3039c2_b.jpg]

1985 245T leather interior installed:

[Image: 5959723746_450b2ff9a5_o.jpg]

Fog lamps and cargo guard:

[Image: 6037187826_115767e2d2_b.jpg]

Rear shot showing new taillamp on passenger side, 2.5" catback exhaust, and iPd hitch:

[Image: 6037182832_09c8106660_b.jpg]

Suicidal speedo needle. Happened twice, thanks to a very kinky M46 speedo cable connected to an Aw71:

[Image: 6021404894_427c9e7eea_z.jpg]

Transmission issues fixed:

[Image: 6044190901_308b98b21d_z.jpg]

That's what I have for now. I do have a leather cover for the shifter, but find that shifting action is better without, so I only slap the leather cover on when I'm going to a meet.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-04-2011 10:39 PM
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scottyd Offline
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Post: #4
RE: Rölf 2.0, the blue 245 Turbo...
What color blue is that?

'97 GMC K2500 Suburban 6.5TD - FailBus
'84 245GLT - FailWagon
'92 245DL - The iFixit.com Lemon
'95 850T5R - ButterCup


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09-04-2011 10:53 PM
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Blue245Ti Offline
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Post: #5
RE: Rölf 2.0, the blue 245 Turbo...
LOL, it's what your car used to be, before the repaint. #200 Blue Metallic. Same color as Alden's 744Ti.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-05-2011 12:12 AM
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s_r_c Offline
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Post: #6
RE: Rölf 2.0, the blue 245 Turbo...
"Transmission issues fixed..."
Haha.
I need to do that.

Shame about the hacked slicktop, but otherwise looking good.
You doing your 1st-front conversion or keeping it formal with this one?

84 240 Turbo - 71 ID21F - 88 CX Gti?
09-05-2011 12:16 AM
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Blue245Ti Offline
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Post: #7
RE: Rölf 2.0, the blue 245 Turbo...
For now, the car's remaining as is front end-wise. If I find a *mint* Canadian spec #200 front clip, I might swap over and go commando. At that point, I might swap to dual 5.75" rounds like what I've done on the silver '84 245GL. Not sure about the flattie. Kinda tired of sticking out like a sore thumb all the time, so that's kinda why I've kept the car fairly stock looking. Yeah, it'll get fixed sometime in the near future. At least, they're smaller holes, so it's a little less obvious than with the other wagon we own.

Ah, so the 244 is an autotragic? What I'd do is find yourself a decent 1979-82 non-turbo box. It's still a fairly wide ratio box, but the 1-2 canyon is more like a valley than a canyon. I also seem to have less trouble with the synchros on the older non-turbo/non-diesel boxes. My old red '83 245T had the box from my old '82 242T in it. At 275K, it began crunching going into 4th gear from 3rd. Never had that happen before. Tranny was never abused, nor was the engine. The 242 was used by the previous owner as a long-trip car between WA and California and had been well-maintained before I got it. The silver wagon does have issues with its M46. Both 1st and 3rd tend to pop out if you're doing any deceleration. 2nd and 4th, no problems.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-05-2011 12:42 AM
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ButterflyBrakeChecker Offline
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Post: #8
RE: Rölf 2.0, the blue 245 Turbo...
"Have you tried putting some talc in the leather shift boot cover to maybe help improve shift action? that or graphite powder"
-left field

'85 245T+
list of For Sale threads: https://docs.google.com/document/d/1Bvhf...t?hl=en_US
... including a B23FTBig Grin
09-07-2011 02:52 AM
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Blue245Ti Offline
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Post: #9
RE: Rölf 2.0, the blue 245 Turbo...
Yes, I have. It still tends to be a bit on the stiff side. It's mainly because the leather boots tend to dry out a bit as they age, if they aren't kept in nice condition all their lives.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-07-2011 04:17 AM
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Blue245Ti Offline
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Post: #10
RE: Rölf 2.0, the blue 245 Turbo...
Did some stuff to the wagon this evening. Wired up the fog lamps, remounted the AC switch, so it's useable once the AC is recharged, and moved the front plate, since it kept getting mangled in parking lots.

[Image: 6131697123_998bbd9b78_o.jpg]

Yes, lame ass camera phone pic. Real pics will be coming later.

Also added my OVT stickers to the rear quarter windows...

[Image: 6132245184_7e82c377dd_o.jpg]

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-10-2011 01:23 AM
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Blue245Ti Offline
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Post: #11
RE: Rölf 2.0, the blue 245 Turbo...
New tailgate. Still kinda rusty, but much nicer than the previous one. Now have a working power door lock on the tailgate, but need to swap the lock cylinder from the old gate into the new one, and need to do the remaining things mentioned on the flickr page. Too tired to retype stuff...lol...

-J

[Image: 6151724324_9235bf2e66_o.jpg]

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-15-2011 08:46 PM
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Blue245Ti Offline
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Post: #12
RE: Rölf 2.0, the blue 245 Turbo...
Rooftop view with some of the other 245 showing as well...

[Image: 6164677456_8ccd595312_b.jpg]

Pic of both wagons together is linked in my .sig.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-20-2011 03:07 AM
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Redwoodchair Offline
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Post: #13
RE: Rölf 2.0, the blue 245 Turbo...
Nice project, love the blue car.
Reminds me of the 87 245 Blue Mule.
Silver car is sweet too.

All Hat No Cattle.

[Image: volvo_10.jpg]

09-21-2011 02:06 AM
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Blue245Ti Offline
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Post: #14
RE: Rölf 2.0, the blue 245 Turbo...
Thanks, Ken...

Hope this next year's more conducive to your being able to visit Portland at iPd time.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-21-2011 11:44 AM
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Redwoodchair Offline
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Post: #15
RE: Rölf 2.0, the blue 245 Turbo...
Should be able to swing it, we had the grandson's high school graduation this year that threw the timing off.
Not like I would have wanted to show the wrecked car anyways.
Bondo

All Hat No Cattle.

[Image: volvo_10.jpg]

09-21-2011 01:55 PM
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Blue245Ti Offline
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Post: #16
RE: Rölf 2.0, the blue 245 Turbo...
Hehe, could've just called it the work in progress... In any case, hope to see ya up here. BTW: noticed that there's no project thread for the gold wagon...

(edit - figured I should've added these pics)

Did this on the 16th...

[Image: 6154338125_b0c732f197_z.jpg]

[Image: 6154338127_749430d2ef_z.jpg]

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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(This post was last modified: 10-01-2011 03:33 AM by Blue245Ti.)
09-21-2011 10:29 PM
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Blue245Ti Offline
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Post: #17
RE: Rölf 2.0, the blue 245 Turbo...
A fairly uncommon part arrived in the mail today (thanks Fige)...

[Image: 6174266008_59b18d5e33_o.jpg]

It's now mounted properly, although, I did have one of the two screws go flying out onto the driveway as I was trying to get it into its respective hole on the coin tray. Will have to look for it tom'w morning, when it's daylight.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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09-22-2011 11:46 PM
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Blue245Ti Offline
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RE: Rölf 2.0, the blue 245 Turbo...
Spent some time on Thursday evening, replacing a crusty A-pillar antenna wire assembly (rust and corrosion on the metal nut that screws into the body and accepts the antenna mast itself), and replacing a bad bulb on the hazard switch, and the bad bulbs for the heater controls and the top of the center console. Now, the heater controls light up, as do the switches on the console. Much better.

Today, I noticed that my overdrive was insistent on being engaged whenever the car was in 4th gear, and the OD light would keep flashing on and off whenever the car wasn't in 4th. Think there are a couple problems. Firstly, one of the terminals was missing from the wires in the shifter, so it'd keep shorting against the other terminal. Then, after I replaced them, the problem still remained to some extent, making me think either the NOS Lucas OD switch is flaking out (probably - prince of darkness, after all), or the wiring in the shifter is chafing against something metal. Must've gone through eight replacement terminals. Replaced both, since the other one was getting a little worn as well. After getting everything redone, I think it's acted up maybe once. So, there's still something wrong, but, it's not doing it constantly like it was earlier on in the day.

Sold my Nikon F5 camera, so I can finally get the money order to Ken for the R-sport wheel. While waiting for that to arrive, I shall spend time replacing the remaining chrome door handles with the black ones I have from a '92 244, then fix the driver's door power door lock switch, so I can use the key to lock and unlock all the doors. After that's done, I shall swap the '89 240GL black door panels onto the car from the other '84 245, along with the door pockets that were installed on my old '85. If I can source some '93 power mirror joysticks before next weekend, I might also modify the doors for the '93 power mirrors, wire them up, and install them. Will have to see how things go.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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10-01-2011 03:24 AM
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Blue245Ti Offline
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Post: #19
RE: Rölf 2.0, the blue 245 Turbo...
Got the wheel finally. It's now on the car. Pic is in the 5 euro thread. I still haven't had time to get the remaining projects done (more like haven't had the weather - a few days ago, summer left, being replaced by late fall-like weather). So, it was a bit of a surprise to see some sunny weather today. Got the car cleaned out somewhat and prepped for the Volvo meet that happens tom'w. I should have some much more recent pics once I finish the roll of film that's in my Nikon F2AS body, which will be happening tomorrow, most likely.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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10-09-2011 12:32 AM
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Blue245Ti Offline
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Post: #20
RE: Rölf 2.0, the blue 245 Turbo...
A couple digital pics...

View of the wagon with the hood open:

[Image: 6228918964_7b2d444266_z.jpg]

Underhood:

[Image: 6228914958_62602b771e_z.jpg]

More pics coming either tom'w or Tuesday.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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10-09-2011 11:01 PM
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83 flatty Offline
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Post: #21
RE: Rölf 2.0, the blue 245 Turbo...
John your choice of updates and additions for this car are just what it needed, spot on man. And lots of progress here....keep it up. So you found a hood?....same color? Again, bummer about the home depot install method someone took with the chrome spider (trust me it wasn't me). Some good shocks/struts and bushings will really make things right. Did you get a better rear harness with the newer tailgate? Looks like those firewall braces used to be painted the same blue.
10-11-2011 11:47 PM
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Blue245Ti Offline
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Post: #22
RE: Rölf 2.0, the blue 245 Turbo...
Pat,

Yep, found one at the Tacoma yard on an '85 245DL, which will be donating a front spoiler that has both end tabs to the car. Just wish I'd the opportunity to pick up the hood on a drier day. There's an '84 GL at the Tumwater yard that may have a nicer driver's fender, so I may grab that and swap it over.

Yeah, it's annoying. But, hopefully before iPd, I'll have the holes refilled and the roof paint redone so it won't look like there was a rack on it at one time or another. Yeah, I figured it wouldn't have been ya.

The passenger side harness was good. The driver's I had to homebuild. I do have a pair of nice harnesses from an '87 somewhere that I was going to use on the silver '84, but will probably use the driver's side harness on the blue wagon and use the passenger harness on the silver wagon.

The braces were originally Hammerite Sapphire blue. Same color as the cam cover that was on the old 245's B23FT. -> [Image: 3686816884_61baec0f82_z.jpg?zz=1]

Yeah, I think once the suspension is fixed up (still bottoming out at the bottom of the driveway when I back out every time I go somewhere lol), it should be much better. Then, it's just a matter of driving the thing. The Virgos will be fitted with studded snowies, since it looks like I'm getting a second set of Hydras from Jonathan D. for the silver wagon.

BTW: it's time to begin migrating the 744Ti project thread over to here and maybe time to start work on the 242 project thread. I'm not sure how much longer TB's going to be half reliable.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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10-12-2011 12:33 AM
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Blue245Ti Offline
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Post: #23
RE: Rölf 2.0, the blue 245 Turbo...
A few photos from the hood pickup mission:

[Image: 6247670961_ebf5795aa8_z.jpg]

[Image: 6247675019_aaf5760a34_o.jpg]

[Image: 6248198670_5651568e6e_z.jpg]

[Image: 6248203494_2b0c0cdc3b_z.jpg]

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
flickr page
(This post was last modified: 10-20-2011 12:03 AM by Blue245Ti.)
10-16-2011 04:25 AM
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Redwoodchair Offline
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Post: #24
RE: Rölf 2.0, the blue 245 Turbo...
(10-09-2011 12:32 AM)Blue245Ti Wrote:  Got the wheel finally. It's now on the car. Pic is in the 5 euro thread.

-J

Pix?

Did the horn buttons work?

All Hat No Cattle.

[Image: volvo_10.jpg]

10-17-2011 11:01 AM
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Blue245Ti Offline
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Post: #25
RE: Rölf 2.0, the blue 245 Turbo...
In the 5 euro thread is a cameraphone pic. I plan to get some better pics of the interior of the car either today or tomorrow. The right horn button works, left doesn't. Will have that fixed when I eventually get it recovered. Will also switch to an orange thread, so it'll be more like a GT wheel.

-J

1982 242Ti - black, M46. 1985 245Ti - blue, M46. 1989 745Ti - red, Aw71.
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(This post was last modified: 10-17-2011 02:19 PM by Blue245Ti.)
10-17-2011 02:15 PM
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