240 GLT saloon restoration project

[Juular]

Onto the electrics now, before the interior goes back in.

While refitting the wiper motor I sheared off the spindle bolt - it was quite rusty. I had to retap it a size larger (M7)



On refitting, the motor was totally dead. Even giving the pins power straight from the battery resulted in no life.

Inside the motor, the commutator was very corroded.



A good clean up and some lube resulted in a working motor again.



Also cleaned up the earth point since it earths to the scuttle panel metal directly.



The electric windows worked except for the driver's one.

A bit of diagnostics showed the motor was getting power but wasn't moving.



I removed the regulator, held it closed with cable ties and removed the motor.



Inside the motor, same story as the wiper motor. Water ingress has caused corrosion.






A good clean up saw that back in business.



Since I had to cut the wires off the motor (they are soldered in) I replaced the ends with spade connectors.



Now I have fully working windows!

The headlight wiper motors were also dead.



Dismantling showed that they had both suffered the common fault with these, in that the main red gear wheel had seized inside its bearing.



I ran a finger sander through the metal bearing surface and everything went back together nice and smooth.



Before refitting those I gave the lighting a good clean and tidy up, and tested / cleaned all connections.














The horn didn't work, which required removing the wheel and giving the connectors a good clean.



Next up, refitting the dash and centre console so that I could test the remainder of the electrics.







After a lot of tinkering and cleaning of connections the majority of stuff seemed to be working, so I was happy to refit the (cleaned) fuse panel. The back plate needed to be modified as I'd fabricated my own door hinge support bracket and it no longer supported the fuse panel.



Refitted the handbrake cables.



Underlay



Carpet





There is still some snagging to sort out before going further. The reverse lights don't work, which is either the gearbox switch or the wiring underneath the car. That's going to be an entertaining fix.

The stereo doesn't work. It's getting 12v so I'm not sure what the issue is. The backlighting works, but no life from the unit itself. I have a dangling black/orange connector that doesn't seem to go anywhere, so I wonder if that is related?

The driver's seatbelt was also jammed, so a replacement is on order.

Starting to feel like a car again though.

[Othen]

As always, an excellent thread and very interesting.

Well done.

:-)

[Juular]

So close now!

Interior refitted.











Diff refilled.



Brakes finished off.






Rebuilt the master cylinder, since I was going to have to refill the system anyway.



Old



New




I also made an attempt to start it. This is as good as it got unfortunately.

[YOUTUBE]https://youtu.be/vNnaKA890qw[/YOUTUBE]

I have a new set of spark plugs on the way, plus I'll give the distributor a good clean. It sounds like it's getting fuel anyway..

[Othen]

Excellent - almost finished.

I notice the anniversary of the project is this week - you have done very well.

Alan

[Laird Scooby]

Originally Posted by Juular

I also made an attempt to start it. This is as good as it got unfortunately.

[YOUTUBE]https://youtu.be/vNnaKA890qw[/YOUTUBE]

I have a new set of spark plugs on the way, plus I'll give the distributor a good clean. It sounds like it's getting fuel anyway..

Excellent work and progress there as always! Looking forward to seeing an MoT pass in the near future!

That video sounds like the ignition timing is out or there is an air leak between the "sock" on the fuel distributor and throttle body. You could cheat and use some Easystart to prove the ignition system then if it fires, concentrate on the fuel side of things.

[Mark1Stu]

Fantastic work. Puts my tinkering to shame. Good luck finishing it off and do enjoy driving it.

[loki_the_glt]

What did you use to clean up the taillamp assemblies?

[Juular]

Just soapy water then polished with T-cut. A corner of one was a bit rough, I used kitchen cream cleaner on that as it's a little more abrasive, followed by a polish.

[volvo always]

As always a thoroughly interesting read. Love to see it soon with MOT.

Very nice work. Did you change the heater fan while the dash was out?

I had a 240 GLT and never did sort dead heater fan. Not worked for 6 years out of 10!

James

[Juular]

Originally Posted by volvo always

As always a thoroughly interesting read. Love to see it soon with MOT.

Very nice work. Did you change the heater fan while the dash was out?

I had a 240 GLT and never did sort dead heater fan. Not worked for 6 years out of 10!

James

Thanks. No I didn't change the fan, but I did leave the centre console in place so I was able to test it before refitting the dash.