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Old 02-03-2020, 04:37 PM   #1
kampman
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Default kampman's 245 turbo revival and restothread

It's been about 8 years since I sold my last 240 and I've been looking for another one for a while. This 245 showed up in the orphan thread about a month ago and it caught my attention since it was about 2 hours away from me in southern Ohio. I haven't seen many clean 240s for sale in Ohio in the last few years, to say nothing of turbo cars, so I finally gave into temptation and drove down to check it out this past Saturday. It followed me home and here we are.

It's an '84 model, non-intercooled, with the AW71 and black leather. As far as I can tell it was a WV car for most if not all of its life. A very long time ago TBer John242Ti sent me a link to a blue turbo wagon at the Cincy IAAI auction and the seller confirmed that he bought it from there. I'm almost certain that it's the same car. The seller was originally going to LS swap it but I think he realized it was a rare find and stored it instead. I don't think it's been driven at all since he bought it.

It appears that it got written off after a small underhood fire - I think a fuel line leaked and/or there was a wiring problem. It must have been put out quickly, though. It barely singed the hood blanket and firewall insulation and besides the wiring the only casualties appear to be the dipstick handles and some other plastic bits in that area. The wiring is a bit of a mess but probably salvageable.

The body, though...wow. There's barely a speck of rust underneath. There's no way this car ever saw salt. One of the buttcheeks is crunched in pretty badly and someone cut the mudflap mounts off but that's about the extent of the body issues.

I want to see if I can get the wiring and fuel system cleaned up and get it running on the K-Jet. I also want to get the driver's window to roll up. If that works out then I'll probably leave it alone, I'm not that much of a purist but (wiring aside) it's an extremely original car and there probably aren't many like it left.

So far all I've done is drop the fuel tank for cleaning. I installed a battery and verified that it cranks, but I haven't tried to take it any further. I really don't want to push a bunch of rust through the fuel system (any more than already has been, anyway...)





Nice improvised throttle cable...



Engine bay full of spaghetti...



Ground zero for the crispy stuff:





Popped the oil cap and the cam looks good, oil is very clean.



Doesn't seem like the injector lines have ever been disturbed.



Nice door pockets:



Floorboards are all this clean.



Looking up at the driver's buttcheek and quarter seam, it's perfect:



Inside the trunk well is spotless:

https://i.imgur.com/r8fIE1D.mp4

I already dropped the fuel tank and the metal above is bone dry.

https://imgur.com/nwn47Ai.mp4
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Old 02-03-2020, 04:42 PM   #2
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Awesome score! Looks like a great place to start! I wish my 242 was this clean to start!
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Old 02-03-2020, 10:31 PM   #3
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Great find! Should clean up nicely.
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Old 02-04-2020, 02:07 AM   #4
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Nice score there! Wiring is probably from before replacement harnesses. I had an 83 245 na car that had a home made wire harness.
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Old 02-04-2020, 03:36 AM   #5
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I got a replacement updated harness for you
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Old 02-04-2020, 11:06 AM   #6
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PM'd you Jack.

Took the door apart last night to air things out and see if I could make any headway with the power windows - there was some moisture in the switches and the door card was a little damp, probably from sitting outside with the window down. The moisture barrier (more of an absorber at this point) fell apart at the gentlest touch but it obviously wasn't doing much so no great loss. I'll have to get some poly sheet to replace it. I dried out the switches and cleaned them but it didn't change anything. The only window that works is the passenger rear and it's really slow. I hear the driver's window motor click but that's it. The fuses are good but I probably need to give the contacts a proper cleaning. The battery I'm testing with is weak so I'm going to get a newer one that's a proper fit for this car before trying again. On the upside the heater blower works and it's quiet, most of the interior illumination works, and the speaker surround is still intact and pliable. So much winning.



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Old 02-06-2020, 10:11 AM   #7
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Verified last night that the main plunger in the fuel distributor is stuck - the metering plate can't be lifted upward at all. Not surprising considering how long it's been sitting.
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Old 02-07-2020, 11:16 AM   #8
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Double check the nut under it. If it was tightened down to much it wont allow it to move either. Its the nut that holds the whole piston assembly in fuel block.
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Old 02-09-2020, 08:29 PM   #9
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Got the fuel distributor out this weekend. With better access I found that the plunger will move a little but it's still pretty stuck. I have it marinating in some cleaner to see if I can get it moving without taking it apart or paying someone else to. There was a bunch of varnish on the underside of the FI housing, wonder if someone tried pouring fuel into the air cleaner.

Today I took a little road trip and got a better fuel tank from a local. It's not perfect but it was cheap, it isn't rusty inside, and it came with a much nicer sending unit than the one that was in the car so score. Gonna have to do a little work to adapt the newer sending unit to the return line but I found a fitting in my parts hoard that should work. Glad I didn't throw away all of my 240 stuff.

Everyone's seen this stuff but here it is anyway. I was a little worried about mouse nests in the airbox considering what I've run into in other long-dormant cars but fortunately there were just leaves.





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Old 02-09-2020, 10:39 PM   #10
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Looking good.
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Old 02-10-2020, 02:09 AM   #11
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Take the entire fuel distributor and soak it in something for a couple of days. Then take it apart, clean everything until it is shiny, then clean it some more. Fuel head gaskets are out there, adjustment procedures are out there. Clean the lines, ultrasound clean the injectors. Kjet left standing for a number of years is a biatch, but it's manageable.
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Old 02-10-2020, 12:26 PM   #12
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After reading some instructions I may give rebuilding the distributor a shot, I know the tendency here is to treat it as a black box but it seems like there's much better documentation of the process out there since the last time I had a K-Jet car.

One question - I was looking at the vacuum diagram and comparing it to what's under the hood. In the diagram there's a "delay valve" in one of the lines to the WUR that's missing in my car, both ports are connected to the same vacuum line with a tee. Is the delay valve just a one-way check valve (looks like it) or is it something more elaborate? Is it intended to block vacuum or boost?

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Old 02-11-2020, 12:52 AM   #13
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Chicks dig '84 245's.
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Old 02-11-2020, 01:14 AM   #14
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This may help for the WUR/CPR lines and one-way-valve (not on all WURs): http://forums.turbobricks.com/showthread.php?t=351117
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Old 02-12-2020, 12:39 PM   #15
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Slick. This is a great car to invest the time and effort into!
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Old 02-14-2020, 11:40 AM   #16
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Pouring cleaner into the ports on the fuel distributor didn't have any effect so I got an empty paint can, put the FD in it, and submerged it in mineral spirits. Gonna leave it that way for a few days and see whether it helps.
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Old 02-19-2020, 10:00 PM   #17
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Chicks dig '84 245's.
Yes. Yes they do.
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Old 02-19-2020, 10:33 PM   #18
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Chicks dig '84 245's.

Yeah, I can speak from experience. Went into the garage one day and heard lots of clucking and roostering around on my 245.
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Old 02-19-2020, 11:53 PM   #19
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Took the fuel distributor apart. Seems like someone has been in here before and they weren't careful. There was noticeable copper spray residue on stuff, which isn't so bad, but the scratch above the hole nearest to the camera in the first pic is deep enough to catch my fingernail and there's a big gouge in the flange next to one of the ports (9 o'clock, second pic). I could probably polish out the scratch but I assume the gouge is no bueno as far as trying to rebuild it is concerned. Anyone reading have a good core?




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Old 02-25-2020, 11:46 AM   #20
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After doing some research I guess I could try filling the gouge and scratch with a little dab of JB Weld before polishing the mating surface but I feel like that's a bit sketchy considering the pressures present in the K-Jet system. I bought another fuel distributor on eBay and I'm going to see what kind of shape it's in, I might rebuild it or run it depending on how it looks when it shows up.
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Old 02-28-2020, 10:17 AM   #21
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New to me fuel distributor showed up. It went straight into the mineral spirits bath. It's dirty and the plunger is also stuck but comparing it to the one that came out of the car it's clear that it hasn't been Elroy'd.
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Old 02-28-2020, 09:01 PM   #22
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Nice job starting to go through this thing. I know people say it’s very specialized to work on these cars but great to see to you going right at it!
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Old 02-29-2020, 02:39 PM   #23
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Thanks, I may yet eat my words but I think K-Jet isn’t that weird, it just requires a different diagnostic approach than EFI. Speaking of which I need to get the parts to build the TB K-Jet tester...

The plunger in the replacement fuel distributor already freed up and the bore and ports look clean so I think I’m just going to send it for the time being, if it doesn’t work right I have the rebuild kit in reserve.
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Old 03-03-2020, 10:49 AM   #24
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Pulled the intake manifold and the fuel injectors last night to get a better look at the wiring. I've got my work cut out for me. The wiring definitely suffered the brunt of the damage during the fire. It was nice to get in there with a shop vac and suck up some of the dirt and dust at least.







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Old 03-03-2020, 10:52 AM   #25
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schwoo...glad you are getting that cleaned up.
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