My problem yesterday came while working on the blue Volvo wagon. My suspicion was made real when I found that the connection from a wire to the knock sensor was being pressed against by an idle bypass hose, loosening the male connector on sensor. I'm battling a hesitation problem like the gas cuts out quickly while driving above 20 mph. Its also not idling without the help of my gas pedal for the first minute. After the car warms up its good to go.
This wouldn't be the first thing wrong with the car. I've been able to drive the car only a few random weeks that make up a couple months filling in just a little of over two years that I've had it from purchase. In that time I got my first speeding ticket while driving the beast. How could I pass up a car off craigslist when it had so many extras coming with it for free. I figured out after taking off the initial price the net worth of all that was included, some new in the box, I paid about $250-300 for it. It has virtually no rust for a 25 year old car which translated into a worthwhile project. But since that time its had the engine rewired, gas filter replaced 2 times, all exhaust replaced, fuel sending unit and pre pump, torque rod bushings, carpet, plastic molding around windows, shorts in the wiring, new distributor (used), belts, rims, shoot I could keep going but I always forget something. A lot of which are from donor cars. A practical way to recycle.
Yesterdays problem wasn't too bad. I could just simply solder it onto the knock sensor for fear it had come loose. The problem started up again around the time the IAC was removed and cleaned. The hose hitting into the knock sensor was coming from the IAC on its way back to the intake manifold. I moved the connection around and broke it off the knock sensor. You have to have a knock sensor to help the car to calculate its timing and gas to air ratio. I successfully soldered the male connector to the knock sensor but decided it wasn't on their at the correct angle. I heated it up again turning the solder to liquid and causing the male connector to drop nearly out of site at the beginning of a tunnel gong under the oil separation box. After successfully pushing it under the separation box and out of view and out of reach, I knew what had to be done. The new intake manifold gasket was going on the car and in the process I would replace the thermostat sensor under the impossible to reach 4th cylinder intake and reclaim the lost connector by having clear access to the oil separation box.
I had started around 2:30 in the afternoon and before too long half the engine (nearly everything prior to the block) would be disconnected and approaching 6 pm. To take the intake off you have to disconnect the the fuel rail plus gas lines and injectors. Countless vacuum hoses, the one big hose, wire harness connections, multiple ground wires, the throttle cable, and 10 bolts to the manifold. Not an easy 10 bolts like I thought they would be before I started, two would cause me grief with one being lost and a replacement needed. No worries I found one. Once the intake manifold is ready to be removed it becomes clear the main wiring harness will have to be disconnected from the ECU in the passenger foot well and threaded with the FI relays back into the engine compartment and through the multiple vacume hoses, wiring, fuel injectors with the rail. All so I can slide it all down through an opening between intake #3 and #4. I rerouted it around the manifold upon installation.
The gasket was for sure needing replacement which helps to make the job feel worthwhile. The thermostat sensor also in need of a change. I cleaned around the intake holes on the block with a rag and some throttle cleanser. Earlier in the day I had washed the engine with some degreaser focusing on the area where the block meets the intake. Got some of it looking back to silver to match the valve covers new shine from earlier. The intake manifold was dusty and spotted with remains of some kind of fluid. A medium sized wire brush did a great job at getting a fresh silver look. I got a large used piece of cardboard under the intake manifold and sprayed throttle body cleanser through out and cleaned the ports for the fuel injectors. I got it looking pretty good but next time I think the removal of the throttle body will enable me to take the manifold to the car wash and really get the thing inside and out looking new. Next time as in my other Volvo 244 sedan. Notice the 44 sedan and 45 wagon. 240 as in plural for 244 and 245. Just some teaching of the Volvarian language.
The procedure in the manual for reassembly is to just go in reverse. Pretty simple if you can remember everything. I used for the first time a magnet page to hold all the bolts in order which helped. The only real mistake happened right at first. I forgot to check the one lonely bolt that connects to the under middle side of the intake manifold. The other 9 fit up top against the engine this one is bolted to a steal arm reaching up from the engine mount. I had to take all the top bolts off again and remove the intake to get the steal arm about 3 inches towards the intake hose. Once I got the manifold bolted on everything else went pretty quick. The sun was almost down at this point and a good 6 hours of stretching the legs and bending the back into the engine was over. Its been 15 hours since I finished the task and my everything aches. A little harder than the front brakes and rotors I replaced earlier in the week on the 86 244. I got the rotors half off the usual $40 each and the brake pads came from a trunk at the junk yard a few years ago for $15. Today I might change out a fuel pump and try the IAC (Idle Control Valve, helps to regulate the idle speed) from the sedan to try and cure the bad idle at cold start.
video link: Blurt, the new magazine taking the place of Harp. Great reviews and videos online.
The video is of the band fleet foxes. They are the big hype at the moment, opening for Wilco in the coming weeks. Their show this past week got cancelled here near home. Oh well. I like the actual cinema in the film and how it works with the music.
http://www.blurt-online.com/video/view/84/