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1987 Volvo Wagon 240 New Purchase - Difficulties.

Help, Advice, Owners' Discussion and DIY Tutorials on all Volvo's "mid era" rear wheel drive Volvos.

1975 - 1993 240
1983 - 1992 740
1982 - 1991 760
1986 - 1991 780
1990 - 1998 940
1990 - 1998 960
1997 - 1998 V90/S90

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imaitland
Posts: 1
Joined: 21 June 2012
Year and Model: 1987
Location: Detroit, MI

1987 Volvo Wagon 240 New Purchase - Difficulties.

Post by imaitland »

Safe to say I was ignorant buying this car, A Volvo 1987 station wagon. First car, too ignorant to negotiate. 159 000 miles on the broken odometer so i would guess 200,000 Lesson 1. Bring a friend. Whatever. Dealing with it now.

So driving back having bought it from a private seller on Craigslist the timing belt went and I was stranded. Towed to nearest mechanics and charged $100 to diagnose what was already obvious - timing belt. Quote of $300 to fix. $100 for the belt and $200 for the labor. Waited 2 days. Downloaded the very useful instructions here:
http://www.stepbystepvolvo.com/240%20timing%20belt.html
and went to O'Reillys to get the part $20.
Having resolved to do it myself I was making decent headway in the parking lot of the mechanics up until I had to remove the camshaft pulley (step 7 on the guide above) Unlike as in the guide my camshaft pulley only has one large central bolt rather that 4 separate ones. I could not give it enough torque without the whole camshaft pulley rotating, thereafter paid $200 for the mechanic to finish the job ... using an impact gun/wrench he got it off no problem. I was able to drive it home within 1 hour. No problems starting up after being parked at the mechanics for 2 days.
Question 1: How can i get the camshaft pulley off myself without the impact gun? Please see picture 1. I will need to get it off when I check the alternator.
Image

So I got home and the car has a kill switch which I engaged.
Next morning I went to start it up. Starter would go 'Crank' but engine would not fire. I kept trying to get it to start until the battery was obviously out of juice and absolutely nothing would happen when I turned on the ignition.

Thinking that the battery had died because I had left my lights on or something I waited for friends to get home and tried jump starting it with no avail. Friends etc all poking around in the engine, fiddling basically. Finally I remember that I had engaged the kill switch. With juice in the battery from the jump start it started fine!

I am stupid. Anyway. NOW the problem is is I leave the car for an hour or less and it will not start. Sometimes all that happens is the 'beeping' from the seat belt warning flashes. Sometimes not even that. Just soul destroying silence.

It jump started fine just now. I drove for 10mins. Parked. WOuld not start. Came inside to write this. I went out 30 minutes later to check a random hose in the engine that i wanted to ask about. One that seems loose to me. I pulled it off to photograph and put it back on. Decided may as well try to start...started fine?!

Pic of tube here? What is it? Is it supposed to be this loose, it literally almost pops of when i brush it...
Image
Image


Indicating:
I would like to say...
i) We messed something up whilst fiddling...
1) the battery is being drained faster than the alternator can charge it...
2) The alternator is bad.
3) The battery is bad.

BUT - the battery or alternator being bad (essentially not having enough juice to start) does not explain why it sometimes starts (within the hour lets say...and AFTER it has failed to start...)

Maybe...
1) The Earth for the battery is bad. ( I have yet to methodically clean or replace these. I have found the one nearest the battery and the other one against the firewall at the back but I cannot find the third one? Any tips?

It could be a combo of these factors. I am waiting on a multimeter from ebay so I cannot do the usual tests to check the battery ... it does have a sticker on it that says 2/12 which might mean that it was bought this year and is fine?

In the course of my own investigations the following are issues.

1) There is this random wire in the engine. If anyone can tell me what it is supposed to connect to that would be great. In the picture I am pointing to the one end that is connected. Second picture shows general location in the engine.
Image
Image

I have pulled the kill switch along with the frankly suspect radio on my quest to find engine drain.

elsewhere...
1) Missing fuse (see pic 1) Most likely for the heated rear window relay. (see point 2)
Image
2) All the wiring to the rear door has been damaged at the door hinge mechanism.Image
Indicating that all the electronics this end are non-operational...could this be a source for possible drain? If wet the snapped wires are close enough to maybe connect, short, etc.. but then there is that fuse missing which indicates the circuit has been cut...

Any and all advice is much appreciated. For the time being I have disconnected the negative terminal on the battery in order to stop drain and let me start it up. If i can carry on doing this I can confirm that the alternator is OK. If the problems persist I know that it is not battery drain. Once I have done that, let's say 5 or six different trips I will leave the battery connected. If that results in the error occuring I will know that there is a drain or that the battery is bad.

Is there something that I am missing. My understanding of cars is basic. I cannot afford to take it to a mechanic. Thanks.

itguy1010
Posts: 13
Joined: 10 July 2012
Year and Model: 740 B230F 1987
Location: Southeast Michigan

Post by itguy1010 »

Imaitland,

Well, I'm no expert. Just a shade tree Volvo tinkerer but I have been through a fair amount of DIY Volvo procedures and maybe can help with a couple of your questions and certainly some suggestions that have helped me a lot. Since no one has replied, I'll give it a shot...

First, the picture of the pulley is your crankshaft pulley/harmonic balancer not the camshaft pulley. There are many ways to get the center bolt loose and IMO many of them can lead to serious damage to the flywheel. Checkout IPDUSA for a crankshaft pulley immobilizer tool. Yes, its around $45.00 but it makes short work of this problem and safely immobilizes the crankshaft so you can use a torque wrench or breaker bar (probably not a good place to use an air impact gun). IPD is (again, IMO) a decent source for quality Volvo parts and special tools.

I'm not certain about the second set of pics with the vacuum hose that comes off. Kind of looks like its connecting to the Fuel Pressure Regulator but I'm not certain. If the hose is brittle and has lost its elasticity then either replace it or at least cut the end off and put it back on if you have enough extra length.

If there is one source for solid info about working on these older B2XXX series engines and drivetrains its this:

http://www.volvoclub.org.uk/faq/FAQSummary1.html

That site and its various pages of info are like a Volvo bible for me. I know it says 700 series but you will find many similarities between your 240 and the info on those pages.

You may consider getting an actual Volvo Service Manual set for this vehicle. They are pretty reasonable and much more helpful than the Haynes or Chilton manuals. I purchased the latter and its pretty much worthless so I use the link above more than anything else. A good wiring diagram for your model/year is going to be mandatory to deal with the problems you have asked about.

Finally, don't forget about the big box auto stores. They do offer free battery and alternator testing and can help you rule out some electrical issues if you don't have the test equipment or knowledge yourself.

The fact that you tackled the timing belt job seems to indicate that you have some capacity for working on this vehicle. I consider it a labor of love (most of the time) and mine is not a "Primary Transportation Vehicle" although it probably could be. My point is that I accept that I'm going to be wrenching on my baby from time to time and can deal with it. They are reliable cars but at 25 years old they are going to be a little needy at times.


Best luck with yours.

Eric
"There was a time when being crazy meant something... nowadays, everybody's crazy."

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