1997 Volvo 850 NA - look what followed me home!

[abscate]

Interior is gorgeous

[ktuuri]

Had a chance to see Neils 850 when I went over to get a few parts off Neil.
It is in very nice shape and will serve someone well for many years to come, when Neil is finished it will be another Volvo saved!
It was Great to meet Neil in the flesh, a true Volvo enthusiast + all round nice guy.!

[scot850]

Thanks for the kind words about the car and me Ken! Pleasure meeting you too.

Well Canada Post management decided to keep the doors open a bit longer to allow my special package from abscate to arrive yesterday. Many thanks again for the help!

I am waiting now for the main parcel from FCP to arrive. It is apparently in the City so maybe tomorrow with a bit of luck!

Can't really do too much more as I need parts from the shipment to complete most of the remaining jobs.

I've added links to the questions I have asked to keep them all under one thread, as it makes it easier to refer to and prevents me having to duplicate. Attached below are issues raised for shift lever issue (not confirmed) preventing starting, some general questions, and a how-to/questions on window guide repair/service.

https://www.matthewsvolvosite.com/forums ... =1&t=76566

https://www.matthewsvolvosite.com/forums ... =1&t=76569

https://www.matthewsvolvosite.com/forums ... =1&t=76557

I am now on yard duty for a couple of days (I foolishly promised to repair some stuff out there!!), so will have to wait on repairing the car further. Also realised I forgot to buy a transmission plug seal ring. It appears that the engine oil pan drain seal is the same part number so
I may use the one for that to allow me to get on with the drive axle repairs first and pick up another next time I'm near the dealer.

It was interesting to see that all the 850's in PnP that I looked at had leaking drain plugs, as is mine. Is this because repair shops are too cheap to replace the seal ring?

Found the antenna mast is stuck so need to add that to the repairs. Good to see that most Volvos (sedans) since about 1980 all used the same one so hopefully a good one out there. New mast from FCP is $52 US - ouch, as with shipping it makes it almost double that! PnP is under $30 CDN, but has the risk of being as bad. Maybe pull a couple and return one if I find a good one.

Forgot to order a fuel filter from FCP and they won't add to orders, so called the local dealer, even discounted it is $65 CDN for a filter!! Wow.
One on the car may be the original as it looks like it has undercoat on it.

LH front window is now working well again with no rattle, but now have a spare guide as it was only the screw that had fallen out.

Neil.

[scot850]

Quick update.

I have removed:

1) The fuel flap door lock as it doesn't work. Tried to directly power it but is seems to be dead. = PnP visit

2) The trunk lock does not work with the key fob. Again removed and tested with 2A trickle charger and not a peep. So guess that is dud too = PnP visit

3) Radio antenna mast only raises one section. Totally seized. Removed and managed to get the old mast out, cleaned out the gear housing and re-filled with fresh lithium grease waiting new mast (or) = PnP visit!! $15 this week CDN (about 12 US) for whole antennas and motor.

Hopefully I will find good used parts but as testing is not easy at PnP will have to chance it. If not, will have to spring for the parts. Expensive!

Today was starting the cleaning out of the wind-shield wiper motor bay in front of the wind-shield. See link below:

https://www.matthewsvolvosite.com/forums ... 35#p409335

Will hopefully get this back together tomorrow in time for the axle (correct) axle seals to arrive if delivered as per UPS notice.

Neil.

[scot850]

So made some progress today. Finished the cabin filter install and also used some silicon between the lower rubber skirt and the metal below it to try to limit any possible water ingress if the drain blocks.

Cleaned all the drains, 3 were good and one was completely blocked. Also cleaned the whole area under the panel covering the wiper motor and lubed the wiper mechanism bushes, before refitting everything. One job completed.

Next removed the air box and associated pipework to the air box and throttle body. Found one of the oil leaks. The flame trap housing was not closed so oil was dripping from the gap. Flame trap was blocked so I have cleaned most of the removed parts, with the plan now to pull the intake to find another leak.

Also removed the top torque mount bracket to take and drop off at Volvo to press in the new bush. Old bush center fell out on removal.

Got a package from FCP today with the replacement (correctly requested) Corteco axle seals. Or so I thought until I opened the 6" cube box to find they have only sent 1!! These guys are seriously dim!!

Off to PnP tomorrow (rain permitting) to try to find various parts I need in the 50% off member sale.

I've added a link below trying to clarify the E-Torx socket size for the wheel bearings:

https://www.matthewsvolvosite.com/forums ... =1&t=76715

Neil.

[scot850]

Spent a fun packed day at PnP and dodged most of the rain, but managed to find all the parts I was looking for. Electric antenna $15 CDN ($12 US), fuel flap lock $5 CDN, and the trunk lock complete assembly $15. Pulled multiples of each as I didn't want to go back again for more.

Bottom line, I now have a good but slow antenna, a working fuel tank lock (both needing re-installed) and still no working lock. Tackled the harness and found at least 3 wires broken where the harness is attached to the inner support structure above the radio antenna. Now the fun will be to repair that!

So hopefully I now have answers to the 3 issues at the rear of the car. I hate electrickery (can't see the stuff until it zaps you!).

Still waiting for the 2nd seal from FCP and hope to make a start dis-assembling the driveline over the weekend.

Some progress again! Feels good.

Neil.

[scot850]

Been a while since I updated this thread.

Still not made much progress (or so it seems). I keep taking stuff a part but nothing goes back together as I am waiting for parts for various repairs.

I'm hoping for a parcel with most of the remaining parts from FCP by mid-week.

I have pulled the intake to work on the oil leaks and discovered poor previous work on the PCV system and flame trap are part of the issues.

This thread covers a chunk of that:

https://www.matthewsvolvosite.com/forums ... =1&t=76855

I am waiting for the short pipe that goes to the middle of the block front from the catch tank to be able to re-assemble. That is in the FCP package.

I am also waiting for a kit service kit for the injectors from a place I have used before, and some of the seals from FCP.

Decided to try to make a quick repair to feel like I have made progress, so tackled the easy job of swapping out the LH drive axle (burst CV boot). Naturally the axle is probably the original so refused to come out of the axle bearing, and also from the transmission. Eventually pulled the bearing mount, lower control arm (wouldn't come out at the ball bearing) and after a huge fight at the transmission the axle eventually came out.

Separating the control arm took a lot more Deep Creep and a large cold chisel to remove it. Then onto removing the axle. Put an axle nut back on and hit is hard with a 4lb hammer and nothing, but did end up damaging the first 1/2" of thread on the axle stub. Found my HV gear puller and attached it to the hub with the support leg on the center of the axle end. It took close to 350ft/lb on my electric driver for the axle to start moving

Found the reason it wouldn't move was a the amount of the binding/locking agent Volvo use on the stub had allowed water to get into the shaft splines generating rust and this became a binding agent.

With the axle removed, replaced the LHS axle seal in the trans, and today spent a fun couple of hours fighting the new axle into the trans. I am painting the caliper bracket and caliper for re-fitting tomorrow. Also loosened the hard brake line from the flexi line and removed the brake. Tomorrow hopefully this side will be back together along with the brakes on the LHS, the I can tackle the RHS. At least there I expect to remove the axle bearing holder, the brake caliper, axle and oil seal. Hopefully I can replace the axle CV boot and have all this back driveline stuff back together by Wednesday. I might have the part then to rebuild the rear wiring harness for the trunk lock, and the antenna mast to allow the re-installation of that and the motor.

Following on with start the re-build of the PCV system. That will leave the water pump, timing belt and serpentine belt, before tackling the rear flexi-hoses and bleeding the brakes. That will them be most of the car back together.

Finally picked up 3/8" ID fuel hose for the brake booster vacuum line from the intake manifold to the booster.

I will then be waiting for the injector kit and the fuel line I ordered to complete the 'known' issues.

Neil.

[scot850]

Very quick update. It lives!!!!

Today, with my sons help, we bled the front brakes and re-connected the battery.

Weird thing was when he went to put the key in the ignition, the hazard lights came on and the engine would not turn over. Completely dead. Panic set in........................!

Calmed down and locked the car with the fob and re-opened, still the same. Locked the car with the key and hazards went out. Tried to start again and on second attempt the car burst into life. Total relief!

I had my son run it up to temperature, and cycle the trans shifter and then switched off. Checked all areas for leaks and my heart sank when I sway oil drips at the front corner near the oil pan bolts behind the oil filter. Checked further up and could see oil all the way up to the PCV area.

I said some words to the Volvo gods, got out some cloths and pokey long sticks to give reach and dried all the oil off. Could just reach my fat arms into the PCV bottom and it was bone dry.

I have re-run the engine after adding another 1 litre of trans fluid (I have already added 3 liters!) and topped of the anti-freeze. So far I am hoping it was just some cleaning fluid I had missed as it is still dry.

Next I will drain the engine oil and drain out as much power steering fluid as I can. Forgot to get new to me wheels and tires balanced so will get those done tomorrow.

Neil.

[Covert]

Nice bit of work here neil, looking forward to more updates !

[scot850]

Thanks, getting there but still finding potential disasters at every turn. These cars drive you nuts eventually!

Neil.