Whenever I would complain to my dad that something was broken, his first question always was "Have you checked to make sure it's plugged in?" He was able to magically fix a lot of broken things simply by asking that question. :p

:D Nice find, funny that's all it was after everything else. Goes to show us. I think the white smoke threw us all off. But maybe just enough fuel makes it past the shutoff plunger to make a tiny bit of smoke, even when that solenoid is not powered. No excuses, we shouldn't have overlooked it!

Glad you got it going, nice work. :cool:

Good opportunity while it's out of the car to refresh any old tired hoses, maybe the timing belts, etc... AND maybe any repairs to the old and probably crumbling wiring harness, which may have been the reason for no power making it to that IP solenoid. ;)

Forgot to say, in a 240, it's tremendously easier to change out the IP main seal while the engine is out of the car. In-car, it's right up against the firewall, no access. Actually should say it's impossible. So get the tool, and change out the seal while you have the engine out. Inspect the shaft carefully and clean off any stubborn buildup off the riding surface before installing the new seal. Make sure you get the right size seal.

Some pics after reinstall... and it fires right up... gotta hook up clutch cable, upper timing cover, thermostat, heater core hoses need to be replaced, and fill it with coolant, need to do the brakes and take it for a drive!

With a leaky IP main shaft seal? :confused:

Good afternoon. Never give up, the VOLVO D24 will thank you.
WATCH the CAMSHAFT BELT ( cheap belt breaks).
Good luck !

Yes it’s a small dribble out of the injection pump shaft seal. Not as bad as I originally thought. But yes, still searching for a seal kit for the injection pump and the timing belt... now dealing with the front right brake caliper that’s seized and won’t let loose of the rotor...

Are you planning to do all the seals or just the main shaft seal?

If the answer to ngoma's question above is "yes" then the seal kit you need is Bosch DGK126. Should be on the shelf at any fuel injection rebuilder or easily found on ebay, so should not take you too much work to find. Make sure you get Bosch parts and not a cheap knock-off set, though. And you need the 17mm shaft seal which DGK126 should have. Watch out, as some other kits look similar but come with a 20mm shaft seal instead.

Replacing the rest of the seals is a finicky task though. It is a good idea to be sure you know exactly what you are planning to do before you take it apart, since you only get one chance to make the reference notes you will need in order to get it back together correctly where it will run the engine again. ;) Not rocket science by any stretch but set aside some time to do it carefully. And keep everything surgically clean -- you probably know that already.

The shaft seal by comparison takes some finesse but is no different in principle than doing any crank or camshaft seal. Still plenty of opportunity to have it go wrong, but the good part is it only goes together one way, unlike the rest of the pump.

Moving this thread to "Help! My car died!" forum because it is 95% pertains to getting the engine running again.