The Volvo Parts, Accessories & Performance Specialists Since 1963 800-444-6473

Cameron Daline

Product Line Specialist
800-444-6473 / 503-257-7500

The Newest Project -- 1978 242 GTX

The newest Volvo orphan to join my stable is this beige 1978 242. I purchased it as a rolling shell from a friend in Spokane, WA a couple months ago and have been tinkering on it ever since. For a full write up on the progress, check out the project thread on Turbobricks by clicking here.

 

Here's what I started with:

 

 

First order of business was to clean it up and mount the new wheels I refinshed specifically for this car - It cleaned up pretty good:

 

 

Next order of business was to pull the old B21 and refinish the engine bay:

 

 

New motor I put together for it is another B230/B234 hybrid engine. This one is staying non-turbo. Shaved the head to up the compression to 10.5:1, H beam rods, B234 pistons. Running it with LH Jetronic 2.2:

 
   

 

 

 Also built some new coilovers for the front and upgraded to vented brakes:

 

 

Finished assembling the new motor, and put it in the car. Also installed the E-Code headlights I imported from Europe:

 

 

And something I splurged on for the car!

 

 

Almost done with the motor install:

 

 

Testing out the function of the newly rebuilt, LED converted R-Sport cluster after I installed it:

 

More to come as I progress further and get the thing running.

 


Previous 16v Turbo Project 245 Info:

Check out the slideshow below for detailed pics of my last project, a 1980 245 that saw a complete makeover. For a more detailed write up you can check out my project thread over at www.turbobricks.com by clicking here

Gallery

Test fittingh the Ishihara-Johnson crank scraper
New RSI internals in the new engine block as seen from the bottom
New engine on the stand
Front of the new engine without the front cover and water pump
New RSI internals in the new engine block
New RSI internals in the new engine block
New RSI internals in the new engine block
Freshly bored
Crank frest back from the machine shop
Looking throught the #1 cylinder on the new engine
View from underneath, looking up the bore showing the adapted BMW oil cooling piston squirters
Crank journals ground down .010 and polished
New RSI rod/pison combo
Block fresh from the machine shop, before I cleaned it and painted it
Top of the new RSI pistons showing rollerwave design and valve reliefs for B234 16v DOHC head
Side of the engine after block was clear coated
Freshly bored
Freshly clear coated
Removing old crusty B21F engine
Removing old crusty B21F engine, and using my devil eyes to stare it into submission
Removing old crusty B21F engine
Out!
What remains after the B21F was pulled.  This car used to be yellow, and when it was painted black, they never touched the engine bay.  Yuck.
Hey look at that!  Much better.
Painted.
Cleaned up wiring
Cleaned up wiring
More pieces installed
Water pump and front cover installed
Oil pump installed and crank scraper fitted
Oil pump installed and crank scraper fitted
Getrag 265 transmissions from e28 chassis BMW - one of which will be installed.
Oil pan fitted
Oil pan fitted
Head back from the machine shop.
Head back from the machine shop.
Head back from the machine shop.
Cometic MLS head gasket
Refinished camshaft cover
More pieces installed
More pieces installed
Oil feed fitting for turbo
New oil return fitting for drainback off of turbo
ARP head stud kit
Head studs installed
Cometic MLS head gasket fitted
Installing the head
Cam box and camshafts installed
Nuke Performance cam gears installed
Prototype belt drive plate fitted
Plate installed with both tensioner pulley and idler pulley installed
Preparing for cam belt test fit
Belt drive system test fit
Belt wrap around cam gears
With tension on the belt
With tension on the belt
LH 2.4 flywheel lightened to 21.45 pounds by Lawrence at www.knoxmotorsports.us
Flywheel
Close up of the 60-2 flywheel pattern on the LH 2.4 flywheel
Spec stage III clutch kit
6 puck Spec clutch disc
Clutch disc & flywheel
Pressure plate & flywheel
Aeromotive adjustable, rising rate fuel pressure regulator and AEM UEGO wideband controller
Transmission adapter plate from RSI (www.r-sport.org) to fit Getrag 265 BMW trans to the new engine
Nuke Performance parts for the new engine from www.shsperformance.no
Nuke Performance Cam gears and fuel rail from www.shsperformance.no
New billet water pump pulley and aux shaft gear from www.shsperformance.no
New intercooler for the new engine
Adapter plate to fit the standard B230 intake manifold to the B234 16v head
Close up view of one of the Nuke Performance cam gears
Back of one of the new Nuke Performance cam gears
New Header from R-Sport International
New header from R-Sport International
Header from R-Sport International
Header from R-Sport International
Header from R-Sport International
Header from R-Sport International
Header from R-Sport International
Link EMS
Time to start studying....
Link EMS Wiring Harness
RSI Getrag adapter plate installed on transmission
Image_290
Image_291
Intake manifold mounted
Intake manifold mounted
View from underneath showing intake manifold mounted with adapter plate from www.yoshifab.com
Starting to look more like an engine...
BMW throwout bearing in modified Volvo clutch fork
Modified Volvo bellhousing attached to BMW Getrag transmission
Volvo clutch fork, BMW release bearing, Volvo bellhousing and BMW Getrag transmission
Another angle of the Volvo/BMW mash-up transmission solution
Fresh paint plus blue accessories = +10 HP!
Transmission assembled
Settled into it's new home
Clearance between the header and strut tower
Another shot showing the clearance between the header and the strut tower
A view from above
Overall view of how the new engine sits
Pulled the engine back out for final dressing of engine
Pulled the engine back out for final dressing of engine
Plenty of clearance for downpipe
More assembled
Flywheel and Spec clutch installed
Getrag transmission installed and whole thing getting ready to be dropped back into the car
Engine/trans rough fitted back into car
Working on the hot side intercooler mounting
Shifter kit from R Sport International (www.rsport.org) to enable using the stock Volvo shifter with the Getrag 265 transmission
Quick test fit of R Sport shifter kit on a spare Getrag
Test fitting the R Sport shifter kit with the Volvo shifter
Spent some time working on integrating the old factory wiring with the new LINK system
Taken from paper to car
New intake manifold
Cold side intercooler routing is now complete. It tucks under the battery tray nicely.
Another picture of the cold side induction piping.
Underside of the new intake manifold showing the nicely hidden vacuum ports
Nuke fuel rail mounted to the new intake manifold
More wiring and fuel plumbing slowly going on
Moved alternator to intake side for more clearance.
Individual coil on plug ignition system
Very basic intake
The new throttle spool from www.yoshifab.com to work with the Yoshifab intake manifold
Getting more complete
750cc injectors from Deatschwerks
Downpipe fabrication in process
New coil cover

Community Comments

Sunday, March 8, 2009 - BEN

Saw the write up on this on Turbobricks and I've got to say it's an awesome build. Keep up the good work Cameron.

Wednesday, March 11, 2009 - ANONYMOUS

It is amazing what money, time, and attention to detail can do. Keep it up. BTW, I am in the process of making LH2.2 block mounted distributors that will fit on a 16V and still retain the hall effect sensor. So the 240 people have even more options on ignition control with a 16v. I wonder, can the NUKE parts be done in black instead of blue? Krona is still falling to the US dollar, yeah!!!! Cheers PJ, fast242 on TB and a long time IPD customer

Thursday, March 12, 2009 - JONATHAN

Looks like a lot of fun, time and money! One quick question: why did you re-use the old oil pump? A new one is cheap insurance, especially on such an expensive build...

Thursday, March 12, 2009 - CAMERON

Jonathan, I made the decision to re-use the old pump only after I took it apart and checked it out/measured clearances to ensure it was still within OEM specs and found that it was. If it proves to not perform as it should it will be replaced. As much of a pain as it is to swap it out later, I will do so if need be. Thanks for the kind words so far guys! -Cameron

Friday, March 13, 2009 - SEAN

How Much Power Are You Aiming For? If You're Aiming For No More Than 400-500HP, I Think The Holset HE351VE, (a variable geometry turbocharger, allowing lower full boost RPM than a conventional turbocharger) turbocharger would be a very good choice, partially because it's common, (comes on many Dodge Ram Cummins Diesels, ie., the 6.7 liter variation) durable, and realativily inexpensive. I have the virtually the same project, and I plan to use this turbocharger.

Sunday, March 15, 2009 - GEOFF

looks great! If i ever make it to Portland Ill race ya pink slips on my stock 122!!! (kidding of course)

Saturday, March 21, 2009 - JOHN FROM VOLVOSPEED

Are those the BBS nebs? This car is amazing, I wish I had a 240 :'( Great job though, love the cleanliness of everything. And of course the 16v head.

Tuesday, March 24, 2009 - OLIVER NEWELL

I'm a Jamaican and I feel that modernizing Volvo from inside out is a great project. I have a 1984 240 Turbo, I'd like to make it better as well. Is it possible.

Thursday, March 26, 2009 - JAKE - A.K.A. TURBO

Currently, i drive a good ol' brick too, and i love to swoon over the pictures of this build. Don't stop!

Friday, March 27, 2009 - MATT ROSA

looking good man

Monday, March 30, 2009 - ROBIN OMALLEY

as an east coast volvo fan we don't see many rust free 240's, but great project. my 945 turbo has greatly benifited from the parts fom ipd and the m46 I put in it.

Wednesday, April 1, 2009 - ERIC GREEN

Cameron- after experiencing the joys of a B234 grenading itself in a 90 745GLE, I recommend yanking that POS motor and installing one of Ross Converse's Ford 5.0 kits with 5-speed. The rest of your build-up looks high-quality. Good work.

Wednesday, April 1, 2009 - REDLINE T5R

Beautiful buildup. I like seeing parts from other suppliers in the mix. IPD has always been a great co. to order from, I've been doing it since 95. Keep up the outstanding work. Good luck with the rest of the car. Redblocks rule!

Friday, April 10, 2009 - HECTOR

nice work, I am working with a volvo 740 with a 16v engine, with manual transmition from a volvo 244. what do you recomend to modify the ECU, microtech?? I have also a .57 turbocharger installed. What I really want is to pull out the more hp that I can.

Wednesday, April 15, 2009 - DSLOANE@TELUS.NET

Being the owner of a 97 V90 with an interferance engine, I am very interested in your fly cut pistons. Does this mod give you running room in the case of belt failure or is it done just to increase the cam lift? I never could understand why Volvo would build an engine that will self destruct. Seems to me that hot rodders have had this figured out for years and fly cut clearance for their high lift cams.

Sunday, May 3, 2009 - MIKE JORDAN SR.

Enjoy watching your buildup. I see you are using Link Plus EMS. I would like some more info. Keep up the good work! Mike Sr.

Saturday, May 23, 2009 - JOE STEVENS

Ahhh crap. I came up to your shop last week, and thought I recognized you from your picture, but didn't get a chance to bs with you about your wagon. Keep up the awesome work, man. Joe (243_phantom on turbobricks)

Thursday, July 9, 2009 - DSLOANE@TELUS.NET

I realize that you get many messages and requests but I really would like an answer to my question re the fly cut pistons. The answer will decide fo me wether to keep the vehicle or sell it. Thanks.

Saturday, July 18, 2009 - ANDREW FROM FLO TOWN

Beautiful work, Cameron, as well as the photography. You've invested so much money, time, and I know TLC in your wagon. I love to see old bricks resurrected, and this is one to be proud of! Thanks for the write up, and for sharing your project with us. Andrew

Monday, July 20, 2009 - CAMERON

DSLOANE - did you get my response via email to your inquiry about the fly cuts in the pistons? Andrew - thanks for the kind words! It's been a lot of work so far and there's still more to be done before it's "done" but I'm loving every minute of it :) -Cameron

Sunday, August 16, 2009 - APRIL ANDERSON

My 1980 Volvo 245 wagon has been my daily driver for over 10 years now. Bought it thinking it would last me the summer with 240,000 at time of purchase. Though mine is now rusty, it is still reliable at 340,000. Have been watching this project from the beginning. I admire the work you're doing on your wagon inside and out. Way to go, Cameron!

Friday, September 4, 2009 - RICHARD L

WAY COOL !!! i'm an up grader of sorts myself ( though mostly just suspension/intake/exhaust related) and love this idea ! keep up the gret work !! one of these days i'll be playing with my 93 240 ( around 200k so far and still going strong thank you !), after the navy i guess.

Tuesday, October 27, 2009 - HAAVARD FORSAA /SHS PERFORMANCE

Looks real cool. And so many great pics of everything. Coooooooooooooooooooooooooooool ;-).

Wednesday, November 11, 2009 - ANDREW ELLIS

Cameron, have you found any options for a Limited Slip Differential? if so, what route are you persuing? I am curious about fitting a LSD to my 1989 240, and was hoping that there were some factory versions used in the RWD volvos before ford took over... any ideas would be awesome.

Sunday, January 24, 2010 - RICHARD STOUD

You are my hero! Do you want to sell the car???? I'll buy it sight unseen! Rich (Keep up the good work!)

Monday, January 25, 2010 - CAMERON

Andrew, I haven't made any decisions on the rear end of the car yet. We'll see how long it takes me to blow up the stock stuff first :) Richard, Thanks for the kind words! Not interested in selling the car just yet - but possibly in a few years, depending on whether or not I get bored of it or want to pursue a new project.

Thursday, February 4, 2010 - BRETT

I'd love to see more detail on the R brake install

Thursday, July 1, 2010 - ERWIN GOPEZ

I love turbobricks! In fact, I own the precursor of the 1991 745SE. I would love to see you succeed so that I can apply what you learned along the way when I rebuild mine. Too bad it still has low mileage at 104000. It takes a lot of OCD (obsessive compulsive disorder), patience, research, money, time, effort, etc. to get to where you are and that makes you my idol. My wife might divorce me, but for a 745SE 16vT???? hmmmm.

Friday, July 16, 2010 - SUPERLEARNMATHNGENTOT

hello guys I just want to say hi

Friday, July 16, 2010 - SUPERLEARNMTHNGEGTOT

I like turtles!

Sunday, August 15, 2010 - GREGORY WARD

Cameron, thank you for taking the time to show me around your domain, I was the guy who was in town and wanted to see where I was buying parts from here in southern California. You showed me the green R project car as well as your awesome 240 wagon. Keep doing what you guy's do!! Do you still have the carbon fiber hoods hiding in the back room for the 70 series? gregorylward 2sbcglobal.net

Wednesday, October 13, 2010 - BRICKBAT

what year is the B230 block that you're using? I've fantasized about doing something like this with my 740, but I've read that B230s from some years are better than those of other years. Also, this is a great thing you're doing. I've become a fan of yours.

Friday, October 15, 2010 - CAMERON

BRICKBAT - thanks for the kind words! The block is an 89 or so B230F block. The 88+ B230 blocks use a rear thrust bearing configuration vs. the center thrust of the 85-87. The 93+ B230s come with piston cooling oil squirters from the factory. I originally searched for a decent core of one of those late blocks, but didn't have luck so I just machined the block I had and adapted oil squirters from a BMW.

Wednesday, March 2, 2011 - EVAN MILLER

I have a 1984 244 GL and I want to restore it and get more power and acceleration, but I don t know where to start. What do you suggest

Friday, October 28, 2011 - MARK JOHNSON

Cameron, Have you done anything recent with your wagon, or are you done for a while?

Friday, November 4, 2011 - CAMERON DALINE

Mark, I can't leave well enough alone and I'm now working on a 1978 242 that I built another 16v hybrid motor for. I'll be updating this page soon with info on the new car!

Tuesday, December 20, 2011 - MARK JOHNSON

Cameron, I don't envy many people, but you have the ideal job, great garage to work on your projects, and a large community of Volvo people to help you find hard to source parts, a 2 year old son, who looks eager to pick up a wrench, and obviously an understanding wife to support/allow you to pursue your illness. Yes, I'm a bit green with jealousy. Please continue, you do inspire many of us, and help the rest of us to dream. Mark

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