1979 Volvo 245 B21F M46

1979 Volvo 245 – Running/Driving Project

ENGINE: B21F Naturally aspirated 2.1l inline 4 with K-jet Fuel Injection and Lambda Sond O2 system

TRANSMISSION: M46 Manual 4 speed with Overdrive

245 DL model in Orange (125-1) and brown/black interior

History

Originally a Pacific NW car (WA). Driven to NC in late 2015 and purchased by current owner. The odometer was not functioning at time of purchase. Prior owner noted that approximately 70-80k miles had been driven since the odometer stopped. This puts approximate mileage at purchase at 180k-190k. Current owner has driven approximately 3k miles since purchase.

The car starts, runs and drives, but is still needing work. Until the engine is warm, throttle response is poor (stutter/miss). Once warm, there is still a prevalent hesitation in the middle RPM range. Suspect either fuel injection or ignition module. This has not been diagnosed. The car is sufficient for local use up to 65-70MPH, but acceleration is slow and power is restricted. Power seems to be better in higher RPM’s.

Ethanol-free fuel is recommended for K-jet, and this car has only run E0 during the current ownership. See “Current Status” for list of remaining items that need attention on this ongoing project.

Current owner has been methodically doing major refurbishment (see below) and no longer has time to dedicate to finishing the work.

Detailed photos of car and parts that are included, here:https://imgur.com/a/SQkMfo6

VIDEO LINKS:

· Driving Video https://www.youtube.com/watch?v=4DaDXKE-CDU

· Hesitation/miss video https://www.youtube.com/watch?v=XxU2l265M00

UnUnderside Video:https://www.youtube.com/watch?v=O2t-Dayre5I

Early 2016: Major work performed: ($1,400 parts)

· Replaced cooling system, including radiator, water pump and hoses. System flushed.

· New 100A alternator installed

· Replaced most ignition components, including Bosch “blue” condenser, IPD wires, spark plugs, and rotor/cap.

· Installed new fuel injectors (Bosch K-Jet)

· Replaced K-jet air intake boot with new OEM

· Replaced exhaust from downpipe back with OEM turbo exhaust. Catalytic converter removed.

· Installed new O2 sensor

· Engine, transmission and differential oil replaced. Note: transmission was filled with synthetic oil rather than transmission fluid. This will need to be replaced.

· Factory wheels refurbished and painted (black)

· Timing belt/tensioner replaced (ContiTech)

· All accessory drive belts replaced

· New valve cover gasket installed

· All vacuum lines and K-Jet hoses replaced

· New fuel pumps (in tank and under body) and fuel filter installed. New primary fuel line (tank to HP pump) installed

· Replaced fuel tank vent hose

Late 2016: Suspension rebuild performed: ($2,800 parts/service)

· Stripped, primed and painted control arms/buckets, rear trailing arms, and strut assemblies

· Installed Superpro Poly bushings throughout (except main Trailing Arm bushings, which were in good condition)

· Installed IPD swaybars – 25mm front, 23mm rear, with new links

· Installed Koni Sport (yellow) dampers x4 and IPD “Sport” springs

· Installed new OEM strut mounts

· Installed new TRW/Meyle tie rod ends and ball joints

· Installed IPD adjustable Torque Rods and Panhard Rod

· Replaced driveshaft U-joints with Moog Premium. Professional balancing performed.

· Replaced all flexible brake lines with new

· Installed MSW mesh alloy wheels with new tires

· Installed OEM air dam

2017: other work performed

· Refurbished grille, headlight buckets and installed new Hella H1/H4 lights

· Replaced turn signals, rear brake lights and reverse lights with LED

· Replaced shifter bushings with brass bushings

· Installed Mazda 3 front seats. OEM seats (needing refurbishing) included in sale.

· Replaced front armrests with used armrests from newer model (better foam)

· Replaced windshield with 1992 sealed windshield. Stripped and painted window area of body

· Stripped/primed/undercoated left rear “buttcheek” rust area

· Stripped/primed minor corrosion in passenger side engine bay

· Removed Carbon canister (used replacement included in sale)

· Removed windshield washer reservoir/pump. New pump needed. Old parts included in sale.

· Replaced Overdrive switch and shifter cover with new

Current Status – Items needing attention

· Engine mounts need to be replaced. New OEM parts included with sale

· Transmission mount needs to be replaced. New mount included with sale

· Driveline needs to be optimized (once new mounts are installed). Torque/panhard adjustments.

· Major tune up needed to troubleshoot/fix low peak power issue. Source could be K-jet, ignition or valves.

· Engine service needed: cam seals (new seals included with sale), valve clearances, etc

· Transmission service needed: Clutch (new OEM clutch kit included), fluid replacement, overdrive unit service

· Left rear “buttcheek” panel needs to be replaced

· Car has an aftermarket stereo – powers on but no sound. This has not been looked into.

· Driver’s seatbelt and rear right seatbelt stick if pulled too quickly and need to be re-lubricated. Slow, easy motion will allow it to pull fully.

· Tailgate wiring needs to be refurbished. The wires inside the hinges are broken (license plate lights). This is causing the “light failure” indicator to illuminate.

· Rear tailgate panel is missing. Replacement needed

· OEM seats need refurbishing if new owner desires to use them in lieu of the Mazda seats

· Installation of headlight relay recommended to avoid potential overheating of headlight switch

· Right rear tailgate strut mounts need to be installed for proper tailgate operation

· Paint is oxidized and would benefit from refurbishment. Numerous areas of clearcoat peeling.

· Major brake service needed. Rotors/pads (new pads included in sale), junction block replacement (new included in sale), possible replacement of master cylinder. System flush & balance.

Parts included with sale:

· Original seats needing refurbishing

· Spare K-jet components (fuel distributor, air plate assembly)

· Electric Fan swap components

· New OEM clutch kit (clutch, pressure plate bolts, pilot bearing & circlip, clutch centering tool)

· New Bosch Quietcast brake pads, shims and caliper guides

· New heater hoses

· G80 Limited Slip Differential 3.73 gearing, unmodified

· New Distributor cap and rotor (Bosch), spark plugs (NGK)

· New Cam seals

· 2x intake gasket (Victor Reinz)

· Volvo Penta AQ141 dual carbs and manifold, modified for use on vehicle

· New K-jet pressure testing kit

· New load resistors for turn signals to eliminate “fast blinking”

· New Emergency Brake Cable

· New window seals (scrapers)

· Used door handles (3)

· Rear armrests (later/upgraded foam)

· Service Manual (Haynes) and numerous factory “Green Book” printouts and electrical diagrams

· Full set of OEM steel wheels with tires

· 8x OEM center caps (2 different styles)

· 3x OEM chrome wheel rings

· Other misc used parts