OK, I know that at least 60% of you guys know this. But,this post is for the 240 owners that want their car to run for many more years to come, and don't know about this major design flaw that was the death of many a 240. It is critical for the preservation of these great cars to pull the carpets back, and pull the 2 1/2 inch plugs on the inside of both rocker panels, and vacuum all of the leaves and junk that accumulates there, inside the rocker panels. Also, take a coat hanger and probe around as far as you can reach to try to get all of the debris out.

You will be absolutely amazed at all of the junk that accumulates there. The louvers in the cowl have no screens like the 940, and every leaf and other debris will go into those louvers and wind up in your rocker panels. That is where all of the rain and water that gets into those louvers drains, into the rocker panels, and the drips out of the little drain holes in the bottom of the rockers. If the rockers are packed with leaves, it can't drain. My 1991 florida 244 rockers were packed with these small leaves, but somehow the car is totally rust free.

I believe that many, many of the 240's that went to the junk yard prematurely for rust went because of this along with the windshield leaks that rotted out many floorboards. Clean out your rocker panels semi annually, and more often if you park under trees.

Excellent advice! I used a 25 gallon ShopVac when I cleared out my rockers and filled the thing half way with leaves and dirt. It was ugly! The leaves were not only packed into the rockers but about of foot of front fender on either side was filled as well. Opening the floor vent was impossible without being showered in leaves. I was just lucky the car came from Southern California so there was little rain to mix with the mulch in my fenders ;-)

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Don - '89 744ti, '85 Alfa GTV6

Good advice. Just be carefull not to take the paint off with the coat hanager. I'd wrap the end with tape.

Recently I found a small patch of rust where the rocker panel meets the rear wheel arch. It was inside the wheel arch so when I removed the rusty patch, it in effect opened the rocker panel at its tail end. Since it is inside the wheel arch I am planning to keep it open so that air and water can move freely out of the rocker panel. Other side is solid but I think I should drill holes on that side as well.
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DD-1990 240 DL SW M47II FI 3.1 234 K miles

And once you have the rocker panels cleaned out, install Volvo "snow caps" over the vents in front of the windshield... assuming they are still available. With snow caps you can move to a 3+ year clean-out cycle on the rockers.

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

also I think somewhere in the garage I bought a pair of the vent covers that I haven't installed yet.But when I do I will still keep the mesh grille I made up and cover it with the vent covers.The vent covers by themselves will not stop the leaves from blowing in UNDERNEATH the covers in the fall.

Good advice.I did this then I got some black plastic mesh fabric and made my own screen.It is held in place with black electrical tape not too shabby. It actually looks ok on my silver sedan.And I never worry leaves again!