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Quick, easy airbox modification 200 1989

Last Saturday I bought an 89 244 to replace the 88 745 I wrecked a couple months ago. (I really wanted another wagon, but haven't been able to find one that was any good, but that's another story...) The check engine light was on, and one of the codes was for the AMM. I went to replace it, with a known good one, and thought I would check the air filter too. I found that the air thermostat had failed (like they always do) and was stuck in hot air mode. The aluminum duct to the exhaust manifold was still in place, so I decided to solve the problem once and for all. Off with the duct, out with the body of the airbox, to where I could work on it, then it was an easy task to remove the T shaped crossbar that holds the thermostat and flapper, and the elbow for the hot air duct. Now, what to do about that extra hole in the bottom of the airbox??? My first thought was a spray can top, but all the ones I could find were too large in diameter. Some further searching located a small plastic jar, full of hardware, that originally held some sort of condiment (unfortunately, the label had been removed, so I can't tell you the exact product) with a screw-on red plastic lid that was the PERFECT size to be a nice interference fit in the airbox hole. In it went, and back together with it, along with a new filter, one of two (original Volvo, no less) that was in the trunk when i bought the car. Total time spent, including searching for a suitable size plug---approximately 30 minutes.

I then turned my attention to the AMM, and was surprised to find that the screen on the filter side had been torn away at the edge, for about 1/3 the way around, mangled and bent down inside. Any ideas how this happened? The filament was still intact, but I'm not surprised it wasn't working properly. I haven't driven the car yet, so I don't really know how much of a difference it will make---it ran OK on the way home, cruising easily at 70-75 mph, and no major driveability problems.






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New Quick, easy airbox modification [200][1989]
posted by  Blue Horse  on Mon Mar 17 13:56 CST 2008 >


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