Post: #151

...or not. Errand day. Did pick up new heater hoses, but forgot car clothing, so didn't go to PnP for a longer brake booster hose. derp

-J

Post: #152

Head is almost removed. Need to drain the cooling system, pull the injector lines off the injectors and the fuel distributor (that way, I don't break or bend them), disconnect the heater hoses, and start removing the head bolts. Then, it's off.

How it sits right now...


Did discover a broken timing cover...


-J

Post: #153

What's the latest on Rolf?

Post: #154

Still in the garage. Been dealing with other things lately. I did do a couple things over the past 24 hours tho. Mainly cosmetic stuff. Replaced the front spoiler with the broken tab with one that was intact, installed some toy bumper Bosch fog lamp brackets, which mount the lamps farther back than they were previously. Tomorrow, after I get done doing some deliveries, I'll spend some time wrenching on it. Need it done this week, since I definitely won't have time to deal with it next week or the week after.



-J

Post: #155

Pardon the mess on the garage floor... Things have been rather disorganized around here lately.

Post: #156

is that a Hoola-Hoop??

Post: #157

Yep, it's a Hula Hulp. Belongs to my niece.

-J

Post: #158

Finally have the head removed. Both valves on #4 are spinning in their seats. Also had a marginal head gasket at #1. Doing a jy run tom'w and going over to swedishiron.com's house to pull some stuff off the old head that's needed for the replacement head. When I get home, I'm doing the water pump and putting the 100 amp Denso in. Sunday, the replacement head goes on and the B21F intake is installed. Gas still smells fresh, so I suspect I'll be ok once the car's back together (tank is full with 92 octane E0 gas).

-J

Post: #159

Nekkid block (fuel lines in ziploc baggies in hopes of controlling some of the odor):



Front of head is together - tensioner will come back off, tho, need to put new tensioner on spring and mounting pin:



Intake side of head, with sensors, etc, installed - I may reuse the B21FT manifold for now, just grind off part of the metal that interferes with the thermal time switch, that way I can get the car going again without clearing everything out to get the B21F intake parts together:



-J

Post: #160

More updates:







Still got a ways to go before it'll run. But, new water pump, and the head's on.

-J

Post: #161

Will Rolf be able to head south this month John?

Post: #162

Pat,

That's the hope. This weekend is when I plan to finish him up and get 'im back on the road. It all depends on if the car runs on all four and the HG seals properly. If it doesn't, then Lars will be making the trip down, and prepwork will be done for a B23FT swap.

-J

Post: #163

Did some stuff over the past few days. Got the exhaust hooked up to the turbo, throttle cable swapped, and started work on reassembling B21F intake.

Need: vacuum lines and Awab clamps for cooling system

Once those are procured, I can put intake manifold on, and start plumbing the turbo, etc.

-J

Post: #164

Noice, gettin' it done!

Post: #165

Yep, slow, but steady progress. Tomorrow morning, I'm going to hit up PnP and grab a bunch of AWABs off the Volvos up there...

-J

Post: #166

What I did this afternoon...

Remaining stuff:

Reconnect CPR and cold start injector
Reinstall oil feed pipe with new gasket
Fill cooling system and check for leaks with engine stationary
Plumb CIS motor
Install intercooler piping and intake piping for turbo inlet
Plumb wastegate
Install fan shroud and fan
Connect throttle cable to pedal and to spool
Charge battery a bit, so engine will crank over @ normal speed - forgot to disconnect battery during head swap

Build up oil pressure, and check to see if the car runs. If it does and runs on all four cylinders, take it for a short drive, come back, and see if the HG is leaking or not. If not, great.

-J

Post: #167

Bring this to IPD?

Post: #168

That is the plan. Now, whether or not it happens, we'll see how the car runs once everything's back together. Worst case scenario, I clean up the other 245, give it an earl change, reinstall the fan shroud, and drive it down instead.

-J

Post: #169

Car is staying up here this time around. Was sent out today to run errands, so I spent the past 2.5 hours working on the car, and it's still not ready to start. So, going to do some repair work on the silver 245, get my stuff loaded up, then head out early Friday.

-J

Post: #170

Progress is still slow. Today, I modified the door latch to 1986-93 specs, using a piece from a 1987 245DL. At the same time, moved the door panel, map pocket, and other parts that I'd saved from the silver 245Ti over from the silver 245GL.

Also discovered that the P-type Saginaw PS pump needs to go byebye, since it's right where the intercooler pipe needs to go with the B21F intake installed. So, will delete that, and plan to install manual rack from black 242 on the car.

In addition to the left rear window mentioned in the other wagon's thread, I'll be picking up an idle adjustment screw assembly off one of the cars at the yard, so I can run that instead of the CIS motor nipple plate, since the intercooler pipe has a nipple for the CIS motor on it already.

-J

Post: #171

No PS, that will be nice.

Post: #172

Got the idle adjustment screw assembly and a t-fitting. Still need to pick up a replacement 4mm allen wrench (was at the hardware store today, but forgot), so I can do some more work on getting this project done.

Plan is to have the car at the Old School Reunion import car show on June 10th in Bothell, WA.

-J

Post: #173

Well, car did have AC. No longer. AC hose was in the way of the intake piping for the K-Jet manifold. There was a charge in the system, but not much.

Everything's been assembled, battery's charging. It does try to start, but sputters, and seems to have a huge exhaust leak post turbo (either that, or the plugs installed in the pulsair holes fell out - unlikely, since it doesn't sound like my old B23E when the pulsair manifold wouldn't seal). Also discovered that the copper washers on the CPR banjo bolts need replacement. A bit of a leak there. Going to replace those, switch back to the old fuel distributor that I pulled when the car failed in February, then figure out the exhaust leak.

In any case, I suspect the car should be out of the garage either tomorrow evening or this weekend. With it moving under its own power.

-J

Post: #174

Well, it did run. For five seconds. Idled at about 800 rpm with the throttle blocked open about 1/3 of the way. Still think part of my issue is the fuel distributor, but wanted to see if I could get it to run without changing stuff over.

Heading down to Tacoma in the next 2-3 days to pick up a spare 079 CPR, as well as a left rear window for the other 245.

-J

Post: #175

Probably doesn't happen very often but I did have a fuel dist. go bad on me once......in a 75 242. It had been sitting for a while.

Any updates on Rolf??