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Matcha: The Green 245

James M

Unknown Member
Joined
May 2, 2017
Location
Davis CA
The car:
1976 Volvo 245 that's been sitting since 2010
B21f with a blown head gasket, reason it was parked
BW55 known for great highway cruising RPM
Power steering and No AC, good thing we have cold California summers….
Brown interior in relatively good shape
Two Cherrybomb glasspacks that need removed
Named Matcha after the tea, i’ve never had it but my girlfriend likes it and says thats the color
Some rust in the hood, cowl and inside the hatch glass, worst of it being up front

<a href="https://ibb.co/7CL4NyY"><img src="https://i.ibb.co/YQwZTjR/20200621-102634.jpg" alt="20200621-102634" border="0"></a>

The plans:
Fix the head gasket
Wax it properly
Get it running well
Restore it to stock
Smog and register it
Fix the rust

Going to be a DD for my girlfriend, along with a roadtrip/camping vehicle because my wagon now has too much oil in the cargo area
I’ve been told I have to keep this one stock, mods are limited to things that help make it more drivable, no turbo unless its a BAR approved swap for highway merging, no manual swap unless I teach her how to drive manual properly.
Also going to be trying to clean up everything I touch, it comes off the car it's getting washed, degreased, painted (if it should be) or otherwise made better then it was before

Very much needs it:
<a href="https://ibb.co/JrbSJpy"><img src="https://i.ibb.co/L9qs7gJ/20200621-131915.jpg" alt="20200621-131915" border="0"></a>

The story:
So i’ve been messing with some BMW stuff with my brother and we needed a transmission, he went down to Vallejo to grab one we found and sends me a snapchat:

<a href="https://ibb.co/HTG1B7j"><img src="https://i.ibb.co/QvYzp94/Screenshot-20200607-135443-Snapchat.jpg" alt="Screenshot-20200607-135443-Snapchat" border="0"></a>

I check the DMV and it's a 76, if it was a 75 I'd be down there with cash in hand in a heartbeat. The next weekend we went back and talked to the owner. It’s been his parents' wagon since new, mom used to drive him to school, dad wouldn’t let him work on it as a kid. He had stories about installing a sedan swaybar to have his mom ask “what did you do to my car...it drives nice” and listed off everything ever done to it. Agreed on a price and to come back next weekend
<a href="https://ibb.co/4pR9B28"><img src="https://i.ibb.co/jDkB7zy/20200613-121624.jpg" alt="20200613-121624" border="0"></a>

Went back today and loaded it up, after 10 years of sitting it’s ready for it to see the road again


<a href="https://ibb.co/35XcYWs"><img src="https://i.ibb.co/Pspgz4Y/20200621-103907.jpg" alt="20200621-103907" border="0"></a>
<a href="https://ibb.co/Fq1PMJg"><img src="https://i.ibb.co/JFTh425/20200621-110507.jpg" alt="20200621-110507" border="0"></a>

Got it back and tore the head off. Pulled the drain plug and out came a couple gallons of milkshake, after popping off the valve cover I was greeted by some nice rust on the cam, seems like it will clean up
<a href="https://ibb.co/rZvwc7W"><img src="https://i.ibb.co/XzVC32w/20200621-135505.jpg" alt="20200621-135505" border="0"></a>

Also found the only 11mm bolts i’ve ever seen on a volvo, why...just why
<a href="https://ibb.co/WtMf5Zy"><img src="https://i.ibb.co/M6t7SrV/20200621-151823.jpg" alt="20200621-151823" border="0"></a>

Got the head off and it looks better than I feared, good looking cylinder bores and no rust (or pictures). Cleaned up the valve cover and head some, going to try rust remover on the exhaust manifold and see what I can do to clean the different aluminum parts.


Also took a swing at the paint, cleans up well with just a wash, I’ll need to wax it as well. Seller said it was repainted once, it shows in a few spots but overall looks nice
<a href="https://ibb.co/N9n5JKg"><img src="https://i.ibb.co/Lxhmc1D/20200621-172320.jpg" alt="20200621-172320" border="0"></a>
<a href="https://ibb.co/LhhLnHf"><img src="https://i.ibb.co/BKKXqFR/20200621-172326.jpg" alt="20200621-172326" border="0"></a>

<a href="https://ibb.co/4Tx51z6"><img src="https://i.ibb.co/zRw06py/20200621-130959.jpg" alt="20200621-130959" border="0"></a>
<a href="https://ibb.co/zXy3nfp"><img src="https://i.ibb.co/GWKZxPy/20200621-131822.jpg" alt="20200621-131822" border="0"></a>

Almost sad it’s not Beige but the green looks great and it should make a good DD, very excited to get it on the road
 
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Nice... The Bw55 (Bw35 is the B18/B20/B30 autotragic) is going to be a bit obnoxious on the highway, tho. I'd either consider swapping the 3.91 out for a 3.54 from a M46 Diesel or B21F-MPG car, or hunt down an Aw70 or 71, then make some brackets to shift the crossmember back one bolt hole per side.

The brackets can be the same thickness as the stock spacers used on the auto cars, just need to be three holes long instead of two. Weld a nut to the third hole. Use norma length bolts in the forward and rearmost bolt holes, and a couple longer bolts in the middle holes to hold the brackets and the crossmember to the frame rails.

The only other things you'd need would be the driveshaft, the shift linkage, shifter assembly and OD wiring, if you plan to retain the lockout function for the overdrive, or just the driveshaft, tranny, shift linkage, a solenoid block off plate, and the brackets, if you don't mind that it will upshift to 4th at all times. Driveplate is the same between the Bw/Aw55 and the Aw7x trannies on cars older than 1989.
 
Cool, another pea green wagon. That's how they're known around here. I have a '75 and it's universally appreciated, by car people and non car people alike. Buff the paint out with a gentle compound, nothing super aggressive, and it should come out great. The color completely changes (darkens) when buffed out.
 
Cool, another pea green wagon. That's how they're known around here. I have a '75 and it's universally appreciated, by car people and non car people alike. Buff the paint out with a gentle compound, nothing super aggressive, and it should come out great. The color completely changes (darkens) when buffed out.

:nod:
I can second this. Still cannot decide which way I like it more... So sometime it is green and other times it is white-ish.
 
Nice... The Bw55 (Bw35 is the B18/B20/B30 autotragic) is going to be a bit obnoxious on the highway, tho. I'd either consider swapping the 3.91 out for a 3.54 from a M46 Diesel or B21F-MPG car, or hunt down an Aw70 or 71, then make some brackets to shift the crossmember back one bolt hole per side.
.

Fixed, thanks for the heads up. I will propibly move to a AW70/71,being at 4,000RPM just to keep up with traffic does not sound fun

The brackets can be the same thickness as the stock spacers used on the auto cars, just need to be three holes long instead of two. Weld a nut to the third hole. Use norma length bolts in the forward and rearmost bolt holes, and a couple longer bolts in the middle holes to hold the brackets and the crossmember to the frame rails.

The only other things you'd need would be the driveshaft, the shift linkage, shifter assembly and OD wiring, if you plan to retain the lockout function for the overdrive, or just the driveshaft, tranny, shift linkage, a solenoid block off plate, and the brackets, if you don't mind that it will upshift to 4th at all times. Driveplate is the same between the Bw/Aw55 and the Aw7x trannies on cars older than 1989.

I should still have most of the shifter assembly and the driveshafts from my wagon when I took out the auto. Gonna have to reread that a few times when I start collecting parts.

Cool, another pea green wagon. That's how they're known around here. I have a '75 and it's universally appreciated, by car people and non car people alike. Buff the paint out with a gentle compound, nothing super aggressive, and it should come out great. The color completely changes (darkens) when buffed out.

I've seen pictures of both your bricks, I'm not copying you a promise.
Towing it back I had two guys in completely restored 50s/60s Alfas honk and give thumbs ups. Defiantly going to get more attention then my other bricks.

Nice score. My girlfriend loves DDing her 245. I hope yours does too! :cool:

She's already quite exited about it. Got a text after work asking not when I would be home but if I was working on the car, she's got her priorities in the right places.

<a href="https://ibb.co/3c5BRCs"><img src="https://i.ibb.co/fHV4DxS/20200621-172426.jpg" alt="20200621-172426" border="0"></a>
Paint looks darker when wet, hopefully the slightly deeper green is what shows up after some polishing. Unfortunately the previous owner bent the hood some between the first time I saw it and when I picked it up. Drivers side has a gap, passengers is alright
 
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Hopefully it's not bent and it's just the hinge. First thing you do on an old Volvo is lubricate all the hinges.

On the trans swap, get the overdrive block out plate. $25 on Ebay. Keep it simple so you can enjoy the car.
 
I was hoping to spend the entire weekend on the car but ended up spending most of it dealing with my brother putting his car in a ditch and his friends car breaking on the drive back. Ended up getting a call at 11:30 friday to get the dolly and drive out to the hills. Long story short a 245 will tow an E30 and carry 8 people at the same time:roll:

On to Matcha! With the few hours I did have on the car we:

Replaced the drivers taillight lens and vacuumed the interior
<a href="https://ibb.co/pLdx2pP"><img src="https://i.ibb.co/VqTtV8N/20200628-143953.jpg" alt="20200628-143953" border="0"></a>
Cleaned the Kjet, unstuck the plunger as recommenced by your favorite local junkman
<a href="https://ibb.co/8NpqxQ8"><img src="https://i.ibb.co/Jm4VpSk/20200628-191214.jpg" alt="20200628-191214" border="0"></a>
<a href="https://ibb.co/fQ658jB"><img src="https://i.ibb.co/Km4kNTR/20200628-192339.jpg" alt="20200628-192339" border="0"></a>
Got the fuel pump working with a few taps of a hammer
<a href="https://ibb.co/PxR0dY8"><img src="https://i.ibb.co/7vHLqzF/20200628-194348.jpg" alt="20200628-194348" border="0"></a>
Drained the old gas(found another 11mm)
<a href="https://ibb.co/746fFXg"><img src="https://i.ibb.co/PQfL8NT/20200628-193019.jpg" alt="20200628-193019" border="0"></a>
Pushed the rest out with the pump revealing some tasty apple juice
<a href="https://ibb.co/B329zdL"><img src="https://i.ibb.co/wghf03y/20200628-194439.jpg" alt="20200628-194439" border="0"></a>
Threw in a spare battery(another damn 11mm!)
<a href="https://ibb.co/jZ3tTZz"><img src="https://i.ibb.co/VpM6tpx/20200628-124438.jpg" alt="20200628-124438" border="0"></a>
Removed and replaced two broken studs from the head, came out pretty easily
<a href="https://ibb.co/Db2F1TQ"><img src="https://i.ibb.co/mBWKRg4/20200628-141115.jpg" alt="20200628-141115" border="0"></a>
Found some more rust under the lifter buckets
<a href="https://ibb.co/ydNC94D"><img src="https://i.ibb.co/Dz1FJrN/20200628-132343.jpg" alt="20200628-132343" border="0"></a>
Lifter buckets themselves came out after some ATF and hammer treatment, valves didn't even close on their own because the buckets where so rusty
<a href="https://ibb.co/R4LDkbV"><img src="https://i.ibb.co/fGmxzFP/20200628-203436.jpg" alt="20200628-203436" border="0"></a>


Gotta pull the valves later this week and check the related components, anyone care to confirm 530 lifter buckets, valve springs and retainers will work on a 160 head?
 
Buckets work fine. The B21FT head that's mated to the B23FT block in my 242 has shim buckets from a 1992 B230F in it. The springs are different on later 160, 398, and all 530 heads. What's called a type 2 spring is used on the later heads. The valves are the same size, tho.
 
Got the head town down, little worse for wear for sure. Two broken springs, lots of rust on 7/8 of them. Valves need cleaned up but seem fine. Gonna have to find the 530 head parts I've got bagged up somewhere.

<a href="https://ibb.co/p4bNSHf"><img src="https://i.ibb.co/Jrm89Yv/20200704-153426.jpg" alt="20200704-153426" border="0"></a>
<a href="https://ibb.co/N6xG1ny"><img src="https://i.ibb.co/7Jv0gN1/20200704-153419.jpg" alt="20200704-153419" border="0"></a>
<a href="https://ibb.co/F5x3Hgq"><img src="https://i.ibb.co/QPbQDrj/20200704-153323.jpg" alt="20200704-153323" border="0"></a>
<a href="https://ibb.co/Zhnkcdp"><img src="https://i.ibb.co/7Gw6rvd/20200704-153317.jpg" alt="20200704-153317" border="0"></a>
<a href="https://ibb.co/3fgmT5K"><img src="https://i.ibb.co/RhRTgG8/20200704-153311.jpg" alt="20200704-153311" border="0"></a>

Head itself is covered in rust, got cracks between all intake and exhaust valves, cylinder 1 is spreading into the ports but the others look contained.

<a href="https://ibb.co/DW7SDNv"><img src="https://i.ibb.co/W5cYWQM/20200704-155133.jpg" alt="20200704-155133" border="0"></a>
<a href="https://ibb.co/By6T25G"><img src="https://i.ibb.co/1rXRGtM/20200704-155134.jpg" alt="20200704-155134" border="0"></a>
<a href="https://ibb.co/qW1DmGh"><img src="https://i.ibb.co/TbhwPXJ/20200704-155233.jpg" alt="20200704-155233" border="0"></a>
 
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With how common and cheap a decent 8v heads still are, I would definitely start with something that hasn't been sitting for so long.
 
Yeah i had a turbo 85 245 that sat needed a head gasket i was told. So i did it. Still has issues. Hmm so did more testing and more testing. Finally found the issue. There was a pin hole in the #4 exhaust port. Yipee so back off the head went.....fun times
 
As recommended I got a new head, well a whole motor but the bottom end is only going in if the current one doesn't do well once it runs. New head is torqued down and I started to build it back up before realizing I misplaced at least one bag of bolts, was using rust remover on them at home, now they are gone.

Real progress came in the form of interior work, old carpet was looking more green then the paint before the washes
<a href="https://ibb.co/19vWP01"><img src="https://i.ibb.co/MR20tgr/IMG-20200726-235515-01.jpg" alt="IMG-20200726-235515-01" border="0"></a>
Pulled it up to reveal some very solid floors, can't wait to get the outside back to this color
<a href="https://ibb.co/qg8xkLc"><img src="https://i.ibb.co/6tSNgcT/IMG-20200726-235519-01.jpg" alt="IMG-20200726-235519-01" border="0"></a>
In went some new carpeting, from a 88 245 so a little different but fits well and looks much nicer
<a href="https://ibb.co/740sDv8"><img src="https://i.ibb.co/m8PfKJ1/IMG-20200726-235517-01.jpg" alt="IMG-20200726-235517-01" border="0"></a>
<a href="https://ibb.co/bJYKQf5"><img src="https://i.ibb.co/8cG7Nhg/IMG-20200726-235521-01.jpg" alt="IMG-20200726-235521-01" border="0"></a>

Tried to add gas but the locking cap doesn't want to unlock,
 
Matcha is back together and running
<a href="https://ibb.co/bHLV1J8"><img src="https://i.ibb.co/xmGbhHR/IMG-20200830-201819-01.jpg" alt="IMG-20200830-201819-01" border="0"></a>

Did'nt get many photos, I need to get a new phone since mine is on it's last legs.
One of reassembly, went well overall. Still needs some vacuum work and an injector Oring, but she runs.
<a href="https://ibb.co/MV4hQYF"><img src="https://i.ibb.co/Xsg4Mhc/20200829-212315.jpg" alt="20200829-212315" border="0"></a>
Had some trouble with the EGR pipe coming out. By trouble I mean the rusty f*cker snapped in half
<a href="https://ibb.co/PhncFqD"><img src="https://i.ibb.co/85prN1Y/20200829-193608.jpg" alt="20200829-193608" border="0"></a>
<a href="https://ibb.co/37w9S3Y"><img src="https://i.ibb.co/HV0fGSp/20200829-193614.jpg" alt="20200829-193614" border="0"></a>
Some booger welds and grinding later its one piece
<a href="https://ibb.co/0QVHJkM"><img src="https://i.ibb.co/4JghNcT/20200829-195045.jpg" alt="20200829-195045" border="0"></a>

Made it around town after sucking down two quarts of transmission fluid, running a little above temp but not overheating, hope to get an air pocket out soon. New tires, a whole bunch of suspension parts and some work here and there should put it back on track.
 
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