Herman and Operation 30MPG

[callahanoffroad]

Get some oetikers on that PCs hoses so you don’t have to worry about them loosening up, you can buy them cheap at the home store u]in the PEX section



I wonder if you should spring nut that two bolt exhaust flange? Give it the ability to flex a bit to take strain off the joint

That's a great idea on the oetikers!

The bolts are 5/8ths carriage bolts with springs on them between the nut and the cat flange which is the stock setup. Should I put in more springs do you think?

[abscate]

Get some oetikers on that PCs hoses so you don’t have to worry about them loosening up, you can buy them cheap at the home store u]in the PEX section



I wonder if you should spring nut that two bolt exhaust flange? Give it the ability to flex a bit to take strain off the joint

That's a great idea on the oetikers!

The bolts are 5/8ths carriage bolts with springs on them between the nut and the cat flange which is the stock setup. Should I put in more springs do you think?

No, Volvo knows a lot more about exhaust manifolds,and headers than I do.

[callahanoffroad]

Quick update.

Scrubbed the mass airflow sensor connectors (male and female), and did a second tighten on the exhaust manifold and no more codes!

Today or tomorrow is parking brake day. Started looking at head rebuilding options. Looks like I can do it myself for around $250, or buy a rebuilt one for about $500.

Driving this new car around makes me want three features in my car, Android auto, a backup camera and heated seats.

Starting a list to finish the restoration.

[callahanoffroad]

Good morning everyone.

Herman has a new parking brake on his driver's side!

That was more difficult than I thought it would be, but not that difficult overall.

Had some difficulty getting the drum brakes to set correctly and had to redo the procedure several times. Also had some difficulty getting the cable to lay correctly into the center console area. But I finally got it done!

That was my first time ever working with a drum brake.

Unfortunately I didn't take any pictures as Robert DIY's video is perfectly sufficient.

Still doing research on head rebuilding. I rebuilt a Honda head back in '08, and rebuilt some motors in automotive technical school. The idea of engine rebuilding isn't foreign to me. I'm presently leaning towards rebuilding the head myself, and having a machine shop resurface and clean the head. The rest is pretty easy, but time consuming clean up and regasketing work.

One of my friends was joking that with the broken exhaust manifold and the head rebuild that it was the perfect excuse to pull the n/a motor and swap in a turbo motor. Too bad I only have a one car garage

Because I have done so much work I've decided to make a list of what would need to be done to complete Herman's restoration

Engine bay:
- rebuild head,
- replace oil supply gaskets.
- Possibly new engine mounts.
- Fix the blasted cruise control.
Note: I may replace the VVIS head and Intake with a later style single manifold when I do the rebuild.

Fuel System:
- fuel pump,
- return valve,
- fuel level sender,
- top of tank send and return lines,
- return line off of fuel rail,
- fuel filter.

Cooling system:
- thermostat
- heater core line refit.

Brake system: front brake lines

Suspension:
- Delta link bushings,
- replace swaybars with IPD sways and poly bushings,
- replace rear shocks due to age,
- add HD rear springs to handle larger loads,
- IPD poly subframe inserts.

Exterior Body:
- touch up paint,
- replace or fix lower driver side plate under headlight.

Interior:
- repair tearing on driver seat side support,
- new dash bulbs,
- new headliner,
- upgrade speakers.
- Considering adding backup camera, and modern head unit.

Frivolous things I'd love to do:
(None of these are necessary and my wife would never appropriate but I think would be neat additions)
- Pegasus rims
- Add heated seats
- A stock spoiler or E30 spoiler (the back looks naked)
- Retrofit an infrared camera system from a Mercedes or GM (lots of deer where I live)
- install a HUD unit

[callahanoffroad]

Just wanted to report that Herman returned 23 mpg on this most recent tank. He's been sitting at 21mpg for almost the entire winter. Hopefully this trend continues!

Looks like the exhaust leak was causing the engine to run rich, or the pcv was causing backpressure in the engine. Or potentially, both!

[callahanoffroad]

Had a light day at work today and while I save up for the valve stem seals I tinkered on Herman for a bit today.

I've been trying to diagnose the cruise control fault for about a year now. I think I have finally figured it out. The brake cut out switch.

Broken Switch

The mounting tabs were broken on one side causing the switch to always act like it was engaged. Well I guess in this case, unengaged. The switch works but pushing a little rod out when the brake pedal gets engaged. This tells the cruise control to disengage.

I tried to tape it into the resting position by pressing down on the plunger. That unfortunately didn't work. Hahaha. Clutch switch looks good. All the ends of the vacuum lines looked good. The vacuum pump for the accelerator pedal looks good and moves well too. No codes on the ecu so it must be either that switch or a vacuum leak. I've already replaced the cruise control module with a good one. So I think I'll hunt down one of those switches and get my cruise control working again. Golly, wouldn't that be swell?

Watched another video on the thermostat, I can believe I never thought about an easy out to get those bolts out. Hahahaha sometimes I impress myself with my idiocy.

[abscate]

I know you are going to put up the part number so I can check my stash and see if I have one.

If it’s idiocy you want, let me share my latest on an E83 drivetrain....why won’t the cover fit and why is this driveshaft kinked?

[callahanoffroad]

I know you are going to put up the part number so I can check my stash and see if I have one.

If it’s idiocy you want, let me share my latest on an E83 drivetrain....why won’t the cover fit and why is this driveshaft kinked?

https://www.volvopartswebstore.com/prod ... 46505.html

It is PN: 9146505

That drive shaft... It looks about right. Just get some wire hanger on that!

[abscate]

Pm you address and I’ll pop it in the mail if my 1998 is the same

[ZionXIX]

So I decided to try those headlight bulbs you posted about. I found the install to be quite annoying. I had to remove the housing to see what I was doing. I haven't tested them at night yet. My bulbs have the large heatsinks with a cooling fan installed. Should I leave the covers off to prevent overheating? On another note one of my reflectors detached when installing....