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Test: 1979 Volvo 242

amelian
5 photos
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Log
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Spec
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Projects
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APR 2026 · PROJECT COMPLETE
GM Supersonic Blue color change
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Strip and refinish the car in GM Supersonic Blue, including the full exterior color change.
2025
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The damaged engine was disassembled far enough to identify the foreign object that caused the internal damage. The B5244T5 refresh is the next engine work.
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AUG 2025 · PROJECT COMPLETE
Interior carpet and seat refresh
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Remove the seats and carpet, repair the rust beneath the sound insulation, replace a torn seat diaphragm and refit dyed low-mileage carpet.
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Significant internal damage was found after the head-gasket repair. A TDC mark error had left base ignition timing substantially advanced. The engine was slated for removal for further inspection.
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2025 · PROJECT COMPLETE
Eight-inch round headlight conversion
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Install the 8-inch round headlights and refresh the headlight plastic.
 Round H4 headlights
 Round H4 headlights
2024
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The rebuilt engine started after the MaxxECU installation.
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NOV 14, 2024 · PROJECT COMPLETE
Five-cylinder rebuild and MaxxECU conversion
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Refresh the engine after worn bearings and convert the engine management from Megasquirt to MaxxECU Race, then reinstall the engine.
 MaxxECU Race engine management
 MaxxECU Race engine management
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Replaced the head gasket after it failed on the first drive following the engine rebuild and MaxxECU conversion.
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The first drive took place after the engine rebuild and MaxxECU installation. The head gasket failed after the drive.
2023
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Oil pressure continued to decrease, eventually preventing the car from being used.
2022
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An oil-starvation event damaged the engine bottom end. The crankshaft and bearings were later replaced during the next engine rebuild.
2021
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Drove through the Driftless Area and attended a Cars & Coffee event after resolving the crank-signal interference.
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The engine would not start because starter noise interfered with the crank-sensor signal. Cleaning the block and bellhousing mating surfaces and chasing the threads restored starting.
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Dyno tuning at Kelly Moss Road & Race produced 366 whp and 381 wtq on E85, with boost peaking around 21 psi. The baseline tune produced 274 whp and 282 wtq. The shop installed a Turbosmart 38 mm external wastegate, fuel pump and fuel pressure sender, and rewired the fuel pump. The car later developed a no-start condition.
 Turbosmart 38 mm external wastegate
 Fuel pump
 Fuel pressure sender
 Turbosmart 38 mm external wastegate
 Fuel pump
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Installed the flex-fuel sensor and restored the original-size battery with a factory battery tray and bracket before taking the car in for dyno tuning.
 GM ethanol content sensor
 Volvo 240 factory‑size battery tray and bracket
 GM ethanol content sensor
 Volvo 240 factory‑size battery tray and bracket
2020
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DEC 30, 2020 · PROJECT COMPLETE
Second five-cylinder bottom-end rebuild
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Rebuild the five-cylinder bottom end after the oil-starvation damage, bore the block for 81.5 mm pistons and prepare the fuel system for E85.
 Getrag 265 to Volvo 960 bellhousing adapter plate
 E85‑rated fuel lines
 Nissens 92+ 940 naturally aspirated radiator
 Injector Dynamics ID1300x2 fuel injectors
 E85‑rated fuel filter
 Getrag 265 to Volvo 960 bellhousing adapter plate
 E85‑rated fuel lines
+7
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MAR 31, 2020 · PROJECT COMPLETE
GAZ Gold front coilover upgrade
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Replace the shortened Koni Race struts with GAZ Gold coilovers and refresh the front suspension and brakes.
 GAZ Gold front coilover struts
 GAZ Gold front coilover struts
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MAR 8, 2020 · PROJECT COMPLETE
Stainless three-piece exhaust system
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Replace the temporary exhaust with a close-fitting 3-inch 304 stainless system using three V-band sections, a catalytic converter and two Vibrant mufflers.
 3‑inch 304 stainless exhaust system
 3‑inch 304 stainless exhaust system
+8
2019
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AUG 2019 · PROJECT COMPLETE
GAZ rear shock replacement
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Replace the rear Koni Race shocks with GAZ adjustable dampers to improve street ride quality.
 GAZ adjustable rear shocks
 GAZ adjustable rear shocks
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The 242 was photographed during a summer outing. The car was shown in its silver finish after the engine-bay repaint.
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First drive after the rebuilt engine was installed. The car covered about 15 miles on break-in oil with engine speed below 4,000 rpm and throttle below 60 percent.
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JUL 18, 2019 · PROJECT COMPLETE
Forged five-cylinder rebuild and engine-bay repaint
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Replace the damaged five-cylinder block with a machined 1999 T5 block, 81.2 mm Wiseco pistons and H-beam rods, and repaint the engine bay in Volvo 477 Electric Silver Metallic.
+5
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JAN 6, 2019 · PROJECT COMPLETE
Leather seat upholstery and bolster refresh
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Recover the Recaro LS-B front seats and stock 242 rear seat in charcoal black leather and replace the front lower bolster foam.
 Charcoal black leather seat covers
 Recaro LS‑B front seats
 Charcoal black leather seat covers
 Recaro LS‑B front seats
+3
2018
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Compression readings were even across the cylinders but appeared slightly low. The engine was warm rather than fully hot and the battery turned it over slowly.
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Checked oil pressure after the turbo oil restrictor. With hot oil, pressure was 0.75 bar at 800 rpm and about 2 bar at 4,500 rpm.
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2018 · PROJECT COMPLETE
Cylinder-head replacement and turbo oil-return repair
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Repair the failed cylinder-head gasket, prepare a replacement head and revise the turbo oil-return system to address oil consumption.
+6
2017
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Monitored cooling-system pressure while driving. Pressure stayed near 21 psi without spikes. Coolant was found on the number 5 piston after the test.
2016
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Drove roughly 1,200 miles to Kansas City with the five-cylinder setup. Fuel economy was 20.0 mpg on the way down and 24.2 mpg on the return after cruise tuning.
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Attended the VCOA National Meet with a group of 242s and recorded the quickest lap in the Volvo-only autocross on the karting circuit.
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The five-cylinder turbo engine fired for the first time.
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Stripped cam-cover bolt holes caused an oil leak after the whiteblock conversion. Keenserts and fresh Volvo anaerobic sealant repaired the threads. The IAC hoses were also replaced with silicone hose.
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2016 · PROJECT COMPLETE
Five-cylinder turbo conversion
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Replace the B230FT with a turbocharged five-cylinder whiteblock and adapt the Getrag 265 to the Volvo 960 bellhousing. Fabricate the engine mounts, clutch hydraulics, fuel rail, charge plumbing and wiring needed for the conversion.
 Volvo 960 bellhousing
 Garrett GTX3067R turbocharger
 Volvo 960 bellhousing
 Garrett GTX3067R turbocharger
+7
2015
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The car recorded 246 whp and 268 wtq at about 16 psi. The mixture was very rich, so further tuning and boost work were needed.
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Drove the 242 to the Eurowerks show in Minneapolis. The car received the Sleeper award and Broadway Auto Tech's Favorite award.
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JUL 2015 · PROJECT COMPLETE
Koni Race suspension and rear geometry
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Refine the 240 suspension with Koni Race dampers, higher-rate front springs, shortened trailing arms and adjustable rear links.
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Drove the 242 to the VCOA Midsommar meet in Hannibal, Missouri.
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Had the 242 aligned at a BMW dealer. The alignment improved the way the car drove, with additional caster adjustment still needed.
2014
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Drove roughly 2,400 miles from Wisconsin to the iPd Garage Sale in Portland. The car completed the trip and returned home without problems.
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MAY 2014 · PROJECT COMPLETE
B230FT and Getrag 265 conversion
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Convert the rolling 242 shell into a usable, street-driven car with the 95 B230FT and Getrag 265. Prepare the engine bay and supporting systems for reliable long-distance driving.
 Getrag 265 5‑speed transmission
 S60R 330 mm brake rotors
 2005 Porsche Cayenne V8 front brake calipers
 Getrag 265 5‑speed transmission
 S60R 330 mm brake rotors
+6
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Drove the car in a circle for the first time. It was running lean and the oil-filter lines were leaking while vacuum leaks were being checked.