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  #61  
Old 04-09-2019, 11:57 AM
ngoma ngoma is offline
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The IP does not rotate smoothly by way of its design. It must overcome tremendous spring pressure at the 3-D cam several times per revolution. Attempting to turn the IP shaft manually you come up against extreme pressure as the rollers climb the cam's ramps, until it wants to spring either back or forwards, to the next or previous "relaxed" zone.

Did you see visible corrosion inside the IP?

Head bolt torquing: Let's make sure you did the correct torquing process in accordance with the head gasket type you installed. By your description, your final step was the 180deg twist. This looks like the process for a MLS head gasket. Is it in fact a MLS headgasket?
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  #62  
Old 04-09-2019, 09:02 PM
HarryCarry HarryCarry is offline
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Vehicle: 1982 240GL
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The IP was very clean inside. My guess is the IP locked up from being dry for so many years. The IP now turns as you described and I think it's dialed in to .80.

I don't know what type of head gasket is installed, but I'll post a photo.


I'm trying to figure out the hard lines now. It would be helpful to know where exactly to hook up the #1 cylinder on the IP. I think it's at the one O' clock position if the pump is positioned with the top parallel to the floor.
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  #63  
Old 04-10-2019, 10:24 AM
ngoma ngoma is offline
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That sure looks like a fiber head gasket. If so, you have two more head bolt tightening sequences to perform.

I can try to take a look later to verify the IP injector hard line clocking position.
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  #64  
Old 04-10-2019, 08:43 PM
RedArrow RedArrow is offline
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Default In case you cant figure it out

A little help to set the hard lines up on the inj pump.
I noticed that any 2 #s (diagonally across ) always sum up as 7, like on properly made dice...



There is a good way to memorize it in case the hard lines got all removed and separated. I find it easy to remember this way:

One can always cheat looking at the intake manifold itself that displays the firing order as 1 5 3 6 2 4
And
Cyl #1 is at 1 o'clock then it is all right there, clockwise...not hard to follow.
Good luck with the setup! In case i ride out to LI this weekend i might be able to visit, what's your zip?
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Last edited by RedArrow; 04-11-2019 at 06:40 AM.
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  #65  
Old 04-11-2019, 04:53 AM
HarryCarry HarryCarry is offline
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Thanks Guys. I'll start working on that this weekend.
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  #66  
Old 04-12-2019, 09:33 AM
19misha72 19misha72 is offline
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Good afternoon. Connecting the tubes to the pump.
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  #67  
Old 04-12-2019, 09:56 AM
19misha72 19misha72 is offline
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Good afternoon. Connecting the tubes to the pump.
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  #68  
Old 04-14-2019, 12:38 AM
19misha72 19misha72 is offline
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http://www.volvotips.com/index.php/2...ervice-manual/
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  #69  
Old 04-14-2019, 07:51 AM
HarryCarry HarryCarry is offline
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RedArrow--Just noticed your comment about riding out to LI. I'm in Huntington 11743. Thank you. That would be great, but unfortunately I work most weekends. We will definitely have to meet up sometime. My father and stepmother live in Bay Ridge, which is in your area I think.

19misha72--Thank you for the photos and link. Those are very helpful.


I left off with wiring the GPs last week. That #6 one is a PITA! Also, the alternator was seized, but got it turning. Hopefully the starter works. If only I had taken pictures of things before taking everything apart 14 years ago. I will start back up Monday and post my results.

One more thing: What kind of gaskets do you guys use for the exhaust flanges? It looks like the old ones were just regular gasket material, not the donut type with springs. I might just get some exhaust gasket material that's suitable and make my own.

Last edited by HarryCarry; 04-14-2019 at 02:41 PM.
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  #70  
Old 04-14-2019, 06:16 PM
ngoma ngoma is offline
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The triangle flange on the downpipe where it connects to the front exhaust pipe section?
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