More Flair

In Pennsylvania, the state where I live, only the rear of the car requires a license plate. This leaves an empty space in the front for novelty plates and other such things. It’s typical for people restoring old European cars to decide to put a euro-plate of some sort on it. Some look at this as silly and perhaps even a little tacky. I’m not one of those people.

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Changing the Crank Position Sensor

It’s been a bit since my last entry. The weather’s been pretty awful, and Gudrun’s been running pretty well so there honestly hasn’t been a lot of need to do work. There was still that set of codes indicating a malfunctioning crank position sensor, so my next bit of work would be replacing that.

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Central Lock Mechanism Revisited

I live in a pretty safe area and don’t bother to lock my car very often, but when I do I appreciate the central locking feature. One day about a week ago while running some errands I did actually lock my car only to find that the key didn’t seem to want to unlock the other doors when I came back. Central locking not a critical function to me, so I figured something had gone wrong with the janky switch on the lock and that I’d eventually get around to repairing it in the future. However, the next day when I went to start my car I found that the battery had been drained. I immediately suspected the lock switch. Sure enough when I opened up the door panel I found that the little plastic tab that connects the lock to the switch had broken, probably because the action of moving it was too hard. This had left the circuit permanently energized, hence my dead battery.

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Snow Day!

We got an inch or five of snow this past week and Gudrun has done very well. Despite the cover of cold snow she started up and has been driving fantastically. True, the lack of a blower makes defrosting the windshield an issue until the car warms up but other than that I couldn’t be happier. 

New Radio

Now that the original radio was out of the dash it was time to put in a new one. I’m no audiophile, but I do have a few requirement. This is 2020 after all. The car may be old, but the audio system doesn’t need to be. First, there’s no need for a tape deck like the original, or a CD player. An auxiliary in and Bluetooth connectivity will do. I am somewhat cheap, though. I didn’t want to spend a bunch of money. Luckily the date was close to the Black Friday sale time.

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Resetting The SRS Light

A small aside to the previous post, when I reattached the battery to test the horn with the airbag assembly still off the car’s computer registered the missing airbag as a fault. When I got everything back together and started the car my SRS light stayed lit. I was confident that my airbag was fine, so I figured I needed to reset the light. Thanks to a post on swedishbricks.net I learned how to do it, and I’ll share it here too.

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Horn Troubleshooting and Radio Removal

Recently my horn stopped working, and although I seemingly fixed it for a time it eventually stopped again. Since I didn’t have properly sized insulators, I was initially suspicious of the bullet connectors I had used reasoning that they were coming undone due to the vibrations of the running car. On eBay I found someone selling the same model of horn, a Klaxon brand model TR90 “low”, that used spade connectors instead. When it arrived I hooked it but still got no honk. My multimeter told me that I was getting 12 volts at the horn when I pushed the button. Manually grounding the other side of the horn to the car definitely produced a loud, sharp honk. This lead me to believe that the ground wire from the horn to the steering wheel switch. Thus began a day of disassembling a good amount of the dashboard.

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Supernatural

Aside from amateur mechanics one of my guilty pleasures is the TV show Supernatural. For those unfamiliar, it was the continuing story of two brothers who hunt monsters. They managed to keep this show going for 15 seasons with this recent one being the last. After a mid-season production delay due to COVID, the final episodes have aired and the story is now over. I mention all this for one simple reason – in the penultimate episode a 240 wagon was briefly featured front and center.

So I bid farewell to Supernatural and sincerely hope the wagon they smashed up for that episode gets fixed.

She’s Touchy

The new exhaust gasket came sooner than I thought but I didn’t have time (or good weather) to address it until this past weekend. The car stayed up on jacks for a few days. This may become significant later because after I did put the gasket in and let the car down I attempted to start the engine and got nothing but the starter cranking. This made no sense to me since the engine had run just fine a few days earlier. Did being tilted to the side on jacks for a few days somehow upset something? I can’t imagine why that would be, but what else could it be? The engine was running fine just a few days ago and I hadn’t changed anything related to it. Time for diagnostics.

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HONK HONK

The other day I was driving to the store and found myself in that common situation where the guy at the light in front of me was busy looking at his phone and didn’t notice the light change. I went to give him the little “toot toot” horn to refocus him but, to my dismay, found that my horn would not toot. When I got home I took the grill off to get access to the horn and see what the story was. The story was one that has become well known to me: everything was corroded to hell. Verdigris had eaten away at the copper connectors and the plastic insulation around them was falling apart

The horn on my car is a single horn type (some Volvos have two apparently) that connect to the horn switch with two wires that terminate in 3.5mm bullet connectors. Of course the only connectors I had on hand were the 3.9mm type. One trip to Amazon for a small kit of the correct size connectors and a couple of days wait later I was ready to fix it. I made two short pigtails and soldered them to female connectors. These went into the existing connector housing. The insulators that came with the new connectors were nowhere near thick enough to fit the space inside the housing so I ended up wrapping them with vinyl tape about 2 or 3mm thick. I clipped off the existing crappy connectors and soldered the new assembly in their place and zip tied it in place. The result was a working horn. TOOT TOOT!

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Gathered Data

Over the history of this project I’ve found myself searching for bits of information regarding the sorts of materials and fluids that my car uses. I’ve had to comb through a lot of different sources to get this info, so I thought I’d include it here for anyone else who has a similar car and was wondering what sort of brake fluid or engine oil to use. Keep in mind that while this information is probably generally applicable to all 240s (at least all post-85 models) I was always keeping my ’92 model in mind when collating it.

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Yeah, It Was the MAF Sensor

To test my theory that my stalling issue was due to a failed MAF sensor I ordered a replacement. Since original Bosch sensors are pricey and I wasn’t even sure if this was the problem I went with a cheap aftermarket part this time. I know, I know… “Buy Cheap, Buy Twice.” I fully expect this part to die in a few years at which point I will replace it with a better one. Who knows? Perhaps this part will defy the typically shoddy workmanship and QC of these sorts of manufacturers and go the distance. Stranger things have happened.

For the record, the part I bought was made by Bapmic. I looked them up to see where the parts are made and found a corporate website that was doing its level best to look like the homepage of a German manufacturer. A little more digging told a different story. A story where Bapmic, which may have at one point been German, was actually a trademark owned by Shanghai Tongzhi Auto Parts. They also own the brands Topaz and Autopa. So, yeah, one of many cheap Chinese auto part manufacturers. We’ll see how well it does in the long run. I’m just happy that my car is running.

Replacing the Main Fuel Pump

So I was sure that my problem was going to be the fuel pump. I had replaced and tested most everything else I could think of, so what else could it be? Lesson: it can always be something else. So obviously this entry is going to end in disappointment. A new fuel pump did not fix my stalling issue. It did give me an opportunity to try a couple of new things, so it’s worth talking about anyway.

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Fixed the New Wiper Motor

About two years ago I tried to rebuild the original wiper motor with mixed results. In the end I just bought a new motor and that worked fine. For a couple of years. Then one morning I tried out the wipers and nothing happened. I took the motor off and brought it to the work bench for disassembly. Once the stator housing was off and the plastic wiring harness with the brush wires and EM suppression capacitors out of the way it became clear what had happened.

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