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JJs Project Thread - 240 GL Estate

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Old Apr 2nd, 2022, 12:59   #101
Othen
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Quote:
Originally Posted by Problemchild1976 View Post
Again - 100% agree

I’m never gonna recoup the money spent but it’s a project/hobby and I’m doing quite a lot with my 12yr old and hoping it gives him some engineering confidence


JJ
... in that case the project will be an absolute bargain, whatever it costs you!


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It’s gonna have cost me about £4k by the time it’s lowered and got the banded steel wheels on so I think that’s a good price for a classic

Yeah that rear panel is a concern - it’s the water that sits in the rubber seal around the boot that’s the culprit

JJ
I must have logged into that VW forum by mistake again :-)

The repair you did is fine if you just want a rough motor car to drive around - but if that is the case £4,000 is a bit steep. The rust will come back in a couple of years, you may have to do a bigger repair then :-)

Alan
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Last edited by Othen; Apr 2nd, 2022 at 13:00. Reason: Spelling error.
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Old Apr 2nd, 2022, 22:21   #102
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Water pump changed in a few hours with help from some small hands

Pretty simple

Drain system

Fan and cowl out

Cam cover off

Release tension on belts with the tensioner

Remove the 6 bolts

Remove the pump and clean the gasket off the face

Fit new pump and do everything else in reverse to put it all back









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Old Apr 3rd, 2022, 12:58   #103
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Made the scabby aerial look a bit better today (free)

Wrapped the broken bit in electrical tape



And when I had enough bulk I used a bit of heat shrink to finish off



JJ
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Old Apr 3rd, 2022, 20:28   #104
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Made the scabby aerial look a bit better today (free)

Wrapped the broken bit in electrical tape



And when I had enough bulk I used a bit of heat shrink to finish off



JJ
A good repair, I like rough engineering like this. Well done.

:-)
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Old Apr 8th, 2022, 23:35   #105
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So I’m getting really bad MPG on the Volvo

£25 of fuel has given me under 60 miles

That’s around 15mpg

The car idles nice but does smell rich

I also struggle to get above 70mph on the motorway (60mph on a hill)

Thoughts oh wise ones??

JJ
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Old Apr 9th, 2022, 09:33   #106
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I've always found the hardest part about refitting the water pump is levering it upwards to compress the upper seal at the same time as tightening all the nuts.
I'm always worried that sliding the pump up the slots in the two studs will disturb the gasket.
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Old Apr 9th, 2022, 09:43   #107
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I've always found the hardest part about refitting the water pump is levering it upwards to compress the upper seal at the same time as tightening all the nuts.
I'm always worried that sliding the pump up the slots in the two studs will disturb the gasket.
Yeah that was a pain

I tightened the top one first (not completely) to make sure that top rubber seal was in the correct place.

It’s hard when some of the studs come out from the block attached to the nut and you only have 1 stud to hang the gasket off haha

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Old Apr 9th, 2022, 11:14   #108
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A light coating of Hylomar on the seal & area (less is more)

A length of wood to lever the pump up on "lightly torqued nuts" seems to work well.
Bob.
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Old Apr 9th, 2022, 11:55   #109
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Originally Posted by Problemchild1976 View Post
So I’m getting really bad MPG on the Volvo

£25 of fuel has given me under 60 miles

That’s around 15mpg

The car idles nice but does smell rich

I also struggle to get above 70mph on the motorway (60mph on a hill)

Thoughts oh wise ones??

JJ
Looks injected going by the flat top manifold.

In that case you probably want to buy / make a fuel pressure gauge and check your system, hot and cold pressures.

Unless it's something obvious like a sticking brake, I'm going to guess that the fuel pressures are off and it's running rich.

Edit : it's also worth checking that the cold start injector isn't stuck on the on position or leaking

Last edited by Juular; Apr 9th, 2022 at 11:58.
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Old Apr 9th, 2022, 12:13   #110
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Originally Posted by Juular View Post
Looks injected going by the flat top manifold.

In that case you probably want to buy / make a fuel pressure gauge and check your system, hot and cold pressures.

Unless it's something obvious like a sticking brake, I'm going to guess that the fuel pressures are off and it's running rich.

Edit : it's also worth checking that the cold start injector isn't stuck on the on position or leaking
Is the cold start injector the one on the top?

It had a new fuel pump before I bought it

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