1982 245 back to life

[zwaechte]

Hi all,

I recently picked up this beautiful burned out 245 that was featured in Jalopnik in 2015. I havent even started it yet and I'm already in love with it. Here's the link: https://jalopnik.com/for-1-495-this-1982-volvo-245-diesel-could-let-you-ve-1742753701

The car has sat since that time and is really showing its age. All i have had a chance to do so far is strip out the old biodiesel setup. The engine in the car is supposed to have bad rings which I believe as it has 265k on the clock, but luckily it came with another engine that is supposed to be better.

My plan for this guy is to get the current engine running and use it to gain some d24 experience. I then plan to swap in the other engine and rebuild the original engine so I can make this vehicle a long term daily. I love the idea of a diesel, manual trans station wagon.

I love the worn exterior look and will be leaving that be aside from some coating some rust spots. The interior is shot though. If any of you know where to find a decent cheap interior around Indiana please let me know!

[Goteborg Vapenfabrik]

Very nice purchase. Looking for a good interior could be as simple as finding a well maintained wrecked 240 wagon that is not very expensive. Collecting the tools for the timing belt changes and injection pump timing may take some searching but recently one member made a couple of the necessary tools for torqueing the crankshaft harmonic balancer screw (bolt). Timing belt maintenance is essential since these are interference engines.

[1982 245]

I plan on making my own tools for the crankshaft holder and the cam bolt wrench. If anyone has any drawings they could send my way I'd appreciate it. If not I can just wing it.

[v8volvo]

Check ngoma's posts in the "D24 Special Tools" sticky, which show photos of the majority of the special tools needed: https://d24t.com/showthread.php?t=1299

Those might get you started on building what you need. The most critical D24-specific tools are the ones related to locking the crankshaft and the pulley counterhold and bent wrench for the rear camshaft pulley bolt (tool numbers 9995187, 9995199, and 9995201). The dial indicator holder (and indicator itself) and the cam locking plate are also highly necessary for any successful work related to the timing system or cylinder head, but those are easily adapted from the very common VW 4-cylinder versions that are dime-a-dozen on ebay.

If you need detailed measurements or photos of the crank locking tool let us know and someone who has the factory tool can probably provide them, or you can measure the inner locking tabs on the harmonic balancer also to get the same result. The tool is designed to engage those tabs to stop the crank. It then rests against the fan bearing bracket in the factory version, but you could just as easily make a longer version that rests against the ground, or the frame rail, etc.

You could also check the Tool Rental section of the forum where members who own the factory tools make them available for loan or rent. I have a full set that I loan out for free, though I do require a very large deposit to ensure I get them back.

Welcome to the board and glad to hear you're going to give it a new lease on life, sounds like a fun project!

[v8volvo]

I noticed the thread I linked above had pictures of all the tools except the crank locking tool (9995187), which is one of the tools you were asking about.

Here are links to a couple of pages that show photos of it and some information, and it looks like Baum does still sell it (for $150 or $104, depending on whether you buy it from their site or from their store on Amazon):
http://volvoturbodiesel.blogspot.com/2006/07/more-tool-stuff-and-pump-shaft-seals.html
http://www.baumtools.com/shop/Volvo/00-General-Purpose-Tools/V5187-CRANKSHAFT-COUNTER-HOLDER#.Xisgz47YrnE
https://www.amazon.com/Baum-Tools-Crankshaft-Counter-Holder/dp/B01A1HAY8O

http://www.baumtools.com/shop/images/v5187_1392762203.jpg

Note also that you need to make sure to use the right torque spec when tightening the crank center bolt after you lock the crank with this tool (or your own fabricated version). Be careful, because there are two different torque specs for this bolt depending on what equipment you are using, and you need to choose the correct one for your situation. The actual torque spec, if using a wrench directly on the bolt, is around 340 ft-lb. YES, this is likely to be tighter than any fastener you have ever encountered before, and yes, it really does need to be AT LEAST that tight when you put it back together, or it'll grenade the engine. And yes, even with that extremely high torque, Volvo also calls for locking compound to be used on this bolt. In case it isn't already clear, it is really critical that this bolt never loosens up. ;)

Since most torque wrenches only read up to around 250 ft-lb, Volvo provides a wrench extension tool that adds about a foot of extra lever length between the bolt and your torque wrench (tool 9995188). When using this extension, a torque wrench reading of 255 ft-lb is called for. In other words, when using this method, you dial up the maximum setting on your 250lb torque wrench, then give a couple of very hard pulls with a breaker bar inserted into the 5188 tool AFTER the torque wrench clicks at 250. But don't misread that 255 spec and think that the bolt itself only needs to be tightened to 255 ft-lb!!! That spec ONLY is valid if you use the 9995188 extension or a similar tool you build yourself. If you are only using a torque wrench and socket directly on the bolt without the extension, the higher 340+ ft-lb spec is what you have to use.

Here's what 9995188 looks like, for reference. It's a 12pt 27mm socket on one end and accepts a 1/2" drive torque wrench on the other.

https://www.picclickimg.com/d/l400/pict/232392529991_/Volvo-9995188-Steckschl%C3%BCssel-Zentralschraube-Riemenscheibe-Kurbelwelle-SW-27.jpg

And here is a helpful image showing how 9995187 and 9995188 are used together:

https://docplayer.net/docs-images/82/85032083/images/3-1.jpg

[19misha72]

I plan on making my own tools for the crankshaft holder and the cam bolt wrench. If anyone has any drawings they could send my way I'd appreciate it. If not I can just wing it.

https://www.drive2.ru/cars/volvo/245/m222/

[19misha72]

Good afternoon. Look at the link. At the bottom you will find a drawing with dimensions for locking the crankshaft. YOU CAN 'T SAVE MONEY ON THE CAMSHAFT BELT . Watch the belt tension. Add an additional fuel filter. Good luck.Michael.Stalingrad.
https://www.drive2.ru/l/545750843857568119/