Assembly

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1980 Volvo 242

amelian
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3 photos
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Log
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Spec
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Projects
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APR 25, 2026 · PROJECT COMPLETE
Repaint the 242 in GM Supersonic Blue
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Strip and refinish the car in a full color change to GM Supersonic Blue, replacing the earlier silver metallic finish.
2025
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Found significant internal engine damage after the first drive. Base ignition timing was far too advanced because the TDC mark had been set incorrectly. The engine was removed for inspection and rebuild planning.
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Installed 8-inch round headlights on the 242.
2024
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NOV 14, 2024 · PROJECT COMPLETE
Rebuild the B5234T and convert to MaxxECU
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Rebuild the turbocharged five-cylinder after bottom-end damage, then complete the MaxxECU Race conversion and new engine harness.
2023
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Oil pressure continued to fall until the car could no longer be used. The crank and bearings were replaced in 2024.
2022
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A low-oil event damaged the engine's bottom end after the car returned to use. The damage later led to crank and bearing replacement.
2021
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Drove the 242 to a local cars and coffee event.
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Drove the 242 through southwestern Wisconsin's Driftless Area after the no-start issue was resolved.
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The crank-signal interference during cranking was resolved by cleaning the bellhousing-to-block mating surfaces and running a tap through the threads. The car ran again, and the second batch of break-in oil was changed.
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The baseline tune made 274 whp and 282 wtq. On E85, the engine produced 366 whp and 381 wtq. The shop also installed a wastegate, fuel-pressure sender and fuel pump, rewired the pump, and tuned for varying ethanol content.
2020
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DEC 30, 2020 · PROJECT COMPLETE
Rebuild the five-cylinder engine and refine the driveline
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Rebuild the damaged B5234T bottom end after oil starvation, then refine the engine, transmission adapter, mounts, shifter and fuel system.
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MAR 31, 2020 · PROJECT COMPLETE
Upgrade the front suspension
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Replace the short Koni Race front struts with GAZ Gold coilovers better suited to street use, and refresh the suspension and brake details.
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MAR 8, 2020 · PROJECT COMPLETE
Fabricate a quieter stainless exhaust
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Replace the temporary exhaust with a close-fitting 3-inch stainless system using a catalytic converter and two mufflers.
2019
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The rebuilt five-cylinder engine completed its first drive after the water-pipe O-ring coolant leak was repaired. The initial 15-mile run used break-in oil and limited engine speed and throttle.
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JUL 18, 2019 · PROJECT COMPLETE
B5234T engine rebuild and engine bay repaint
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Repair the damaged five-cylinder engine, prepare a replacement block and refresh the engine bay while the powertrain is apart.
2018
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Measured oil pressure after a 0.035-inch restrictor: 1.8 bar at 1,100 rpm after cold start, 0.75 bar at 800 rpm with hot oil, and about 2 bar at 4,500 rpm. The readings were taken while investigating oil smoke and oil-drain behavior.
2017
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Monitored cooling-system pressure while driving. Pressure stayed around 21 psi with no spikes during changes in rpm or boost. The test was part of diagnosing coolant loss and a coolant-filled cylinder 5 spark plug.
2016
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Drove the five-cylinder 242 about 1,200 miles to Kansas City and back. The car averaged 20.0 mpg on the trip down and 24.2 mpg on the return after cruise tuning.
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Attended the VCOA National Meet at Road America and took part in the Volvo-only autocross on the karting circuit. The 242 recorded the quickest lap in the Volvo autocross.
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SEP 2016 · PROJECT COMPLETE
Five-cylinder turbo engine conversion
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Replace the redblock setup with a turbocharged Volvo five-cylinder while retaining the Getrag 265 transmission and adapting the supporting systems for the 242.
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Repaired stripped cam-cover bolt holes with Keensert inserts and fresh Volvo anaerobic sealant after oil leaked from the cover.
2015
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The B230FT setup produced 246 whp and 268 wtq at 16 psi. The car was running very rich on the dyno, and the result prompted further tuning.
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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.
2014
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Drove the 242 approximately 2,400 miles from Wisconsin to the iPd Garage Sale and back. The car made the trip and completed the return in two long driving days.
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Drove the 242 in a circle for the first time after the engine conversion. The car ran and the driveline and brakes were installed. YouTube clip:
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APR 23, 2014 · PROJECT COMPLETE
B230FT conversion and 242 refresh
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Prepare the 1980 242 GT shell and install a turbocharged B230FT powertrain with refreshed suspension, interior and driveline for regular road use.
 Getrag 265 5‑speed manual transmission
 Getrag 265 5‑speed manual transmission