Here is my recap:

I replaced my auto trans with a junk yard transmission and made an error at install which damaged the flywheel. Put in a JY flywheel and reinstalled the transmission today.

When I tried to start the car, it did not want to start. It turned over, but sputtered like it wasn't getting any/enough fuel. Eventually, it did start, but it barely runs. When I press the gas pedal, it stumbles or won't do any better. Checked the O2 sensor (its good), tested the AMM per Haynes and it seems good. I'm trying to run through the various actions of the swap to see if there may be something we may have bumped. The car started and ran normal just prior to the swap.

Incidentally, I did check for loose or disconnected vacuum hoses. I also pulled the spark plug wire one at a time while the engine ran and it made a noticable difference for the worst. I now have an exhaust leak where the pipe connects to the exhaust manifold. Surely that wouldn't be the cause...I appreciate everyone's input.

Trey
--
1993 Volvo 240 219,000 miles

Trey:

When I made this mistake, Sven's Maintainer (I believe) gave me the answer/description of the error I made on our 92 245. Please make sure you are seated before reading on...

What I did was install the flywheel/flex plate with the blocked tone ring hole on the flex plate straight up (12 O'clock)while the crank was at TDC. The flex plate needs to be installed with the blocked hole approximately near the starter with the crank at TDC (aka 9 O'clock). Sorry for the news, but I believe you need to drop the transmission, and re-index the flex plate for correct operation. Your symptoms are identical to what I ran into.

The "tone ring" is around the outside lip of the flex plate and runs very close to the crank position sensor just behind the head. If the flex plate is off by 90 degrees, so is the timing... backfires, stalling, and so on are common with this condition. Sorry, rotating the distributor will not correct the problem. Some have mentioned that the flex plate has arrows on the face marking the UP position when at TDC, but I have not seen them.

I feel your pain. Look at the bright side, if this is the cause, you haven't trashed the engine.

Dang, I hate delivering that news even worse than receiving it....

jorrell
--
92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!

Jorrel, I hate receiving it even more. I mentioned the flywheel swap as I felt it had to do with that. We have become quite adept at removing the transmission. There IS an arrow on the engine side of the flywheel. The old one came off at the 4 o'clock position, so I put the replacement back on in the same fashion. Could one flywheel be indexed differently? I will consult my much-now-owed-plenty-of-time-on-his-vehicle buddy and look at pulling it tomorrow.

Thanks for your help.

Trey
--
1993 Volvo 240 219,000 miles

Don’t ignore the FAQs. There are more similarities than differences. Make sure you are at TDC, triple check, and place the flywheel in the location shown in the link. The two "hole voids" should be near the bottom of the starter opening. This is very clear in the RH photo. With the tranny inspection plate removed, you should be able to check for proper fly wheel alignment, before the tranny removal.

You may find that all LH2.4 with the bell housing mounted crank sensors will be the same, 200,700 and 940s. Not sure but I cannot see why not.

Also, I had a rear seal housing screw vibrate out at 70MPH in a 940. Since, I have been very fond on LockTite 242.

http://brickboard.com/FAQ/700-900/EngineMechanical.htm#FlywheelPositiononReinstallation

Sorry for sending pain like that. One question I forgot to ask was if the flywheel was from the same year/model. If not, sorry, I don't know the differences. Perhaps Sven's Maintainer can pipe up on this one. Before dropping the trans again... ouch, you can verify the issue with a timing light assuming the disti cap and plug wires are in the right orientation/order.

If the flywheel/flex plate came from a pre-LH 2.4 car (I think, please verify this), there may be a compatibility issue with the flywheel.

jorrell

ps. I feel your pain, and if it helps, I'm currently mudding and sanding drywall... misery loves company... want to swap jobs? I'd rather peel four layers of 60's wall paper off a wall rather than do mudding and sanding!
--
92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!

Ok, I'm going back in armed with good information. Jorrel, the flywheel is in fact from an identical year 240 and I would rather pull this transmission two more times than do drywall work.

Thanks for all the info from all you guys. I'll report back with results.

Trey
--
1993 Volvo 240 219,000 miles

I hate to say this, but being a bit claustrophobic in my old age, a trans swap on the ground (like I did the last time) isn't what I call a walk in the park. That being said, drywall work is a nightmare so for me it's an even swap! Let us know what you find!

jorrell

--
92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!

Here's the update -- I removed the transmission, removed and properly set the flywheel with the arrow at 12 o'clock with the #1 cyllinder at TDC. It was way off. Put it all back together (third time, I'm a pro now) and it runs MUCH better! The timing is off a little as it runs a little rough with some valve noise during acceleration. I'm guessing I will need to adjust the timing a little. Do I need to remove the timing belt cover to use a timing light or does Volvo somehow magically make this easier? After a tranny swap, there isn't much that I fear with this car now.

Incidentally, there had been some concern that I may have damaged the transmission during the first installation. So far, so good. It ran and shifted smoothly. Once I get the timing set properly, I will head down to get the state inspection and put some miles on it.

I really appreciate everyone's help. I could not have done this without the resource of experienced Volvo owners at brickboard.

Trey
--
1993 Volvo 240 219,000 miles

The timing is not adjustable on this engine (unless you count the flywheel placement)! If you removed the disti it may be off a tooth, but most likely the plugs are partly fouled from trying to run it with the timing waay off.

It wouldn't hurt to check the timing belt marks just to make sure it didn't jump a tooth as well but only if its really rough.

Great job fixing the issue! I'm still doin' drywall... primer tomorrow!

jorrell
--
92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!