The stock CIS idle air bypass valve stopped working. I did the tests in the manual to see what wasn't working. The electronics and wiring are fine. In fact I could feel the air valve motor vibrating, trying to work. I took it apart a couple of times seeing if I could free up it's action. No dice there.

My 245 has a 3 wire version that I have not been able to find in the junk yard. So I decided that I could make a manual valve with an adjustment in the cabin. I bought a 3/4" PVC ball valve at the hardware store an placed in in the original location to test the idea. It worked fine. I'd open the hood in the morning to fast idle when the engine is cold. Once the engine was warmed up, it was easy to adjust the valve for a normal idle.

Before using the ball valve, cycle it open and closed a bunch as fast you can operate the valve. This will melt the plastic around the seals a bit and loosen up the action. You will see melted plastic flash around the edges of the opening where the ball is. Drill a hole in one of the handles of the ball valve. The threaded eyelet will bolt into this hole.

I bought 6 feet of hydraulic hose from the from the auto supply (didn't use it all) and ran hose to the space between the brake assist and left fender. Discard or store away the original idle hose. Install a couple of elbows and hose barbs on the ball valve and push the hoses on. Use PVC glue once you establish the orientation of the valve and push rod. Fasten the valve with a cable tie to the left strut tower. Hose clamps were needed at the manifold and throttle body hose connections.

I drilled a hole in the firewall a little larger that the copper rod (I happened to have copper it could be steel or brass).The rod is bent 90 degrees at one end and has a drawer knob screw brazed to the other end.

Install the rod so that the threaded end goes through the firewall into the cabin and through a slot you cut in the felt cover under the dash. It sticks out near the left door jam above the hood release. Screw the drawer knob of your choice into the end. Put a rubber grommet in the eyelet. Poke the bent end of the rod into the grommet of the eyelet and bolt the eyelet into the handle of the valve.

When the engine is cold push the handle in all the way. Adjust as needed for the desired idle speed.
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Mark Mueller, '82 Volvo 245 - Ugly but straight, works good, B21F, Strut brace, electric radiator fan, A cam, Urethane Bushings, Bilstein Sport Shocks, IPD lower springs, Perf Exhaust, 740 10 sp wheels, 2-7/8' stainless exhaust tip adds 20 hp.