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1980 Volvo 240 DL 2 door
2.1L with K-Jet - mechanical fuel injection
4 speed manual with electric overdrive
4 wheel disc brakes
Phase 1: June 2012
Get stock engine running and if possible drivable. The car had been sitting for approximately 10 years when I picked it up.
So, after getting the car home I got the power washer out and started cleaning things up.
There was decades of grease and oil from a leaky engine and the car looked like the previous owner hauled hay for a farm in it.
I found that the engine wiring harness had dozens of wires that the insulation was crumbling away from (common problem for Volvo). So my next step was to start sorting out all of the wiring.
Once the wiring was repaired ( I made a new harness to replace the factory one), I was able to figure out that the fuel pumps were not working.
As it turned out, the in tank pump was bad and need to be replaced ($30.00).
The Main (high pressure) pump was just gummed up from years of sitting with fuel in it. I was able to clean it up and get it running again.
Drain and cleaned fuel tank.
New Fuel filter. ($15.00)
New Spark plugs ($4.50)
Used battery installed
After all that – the engine would crank and if I sprayed some starter fluid in the intake, it would run for a few seconds.
Checked the fuel pressure – Still Nothing.
This required removing the intake manifold to get to the fuel distribution block. So, I pulled the injectors and soaked them in Sea Foam while I attempted to clean and rebuild the distribution block.
A new intake manifold gasket ($12.00) and about 12 hours of soaking parts.
The engine will start and if you keep it floored, it kind of runs. Smokes like hell though. After driving it around the driveway and having to restart it a half dozen times I decided I wanted a better injection system.
Phase 2: September 2012
I have been throwing around the idea of changing out the injection system for a electronic fuel injection system, 5.3L GM engine swap, turbos or a Volvo 5 cylinder engine swap. I finally decided to go with a Volvo 6 cylinder engine with twin turbos. The engine I picked is known as a White Block inline T6 (B6284T) which is a 2.8 liter twin turbo from a 1999 Volvo S60.
Follow this project at: Volvo Build