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Test fitting of the manifolds.
First try on the intake manifold saw it sitting on the dipstick tube and the A/C return line that pokes up off the compressor. Several inches away from actually bolting on.
The dipstick tube is pretty easy to bend around, no problem.
The A/C line, a little trickier. It just can't come up off the compressor and drape over the top of the engine any more. I went to a pick-n-pull junkyard on Saturday and looked over a fwe cars, and noticed a fairly late model 940 with different routing on the A/C return line. The compressor and receiver/drier were in the same (relative) spots, but instead of just flopping a long flex line across the motor, this had a hard line that dropped down from the drier, ran along the frame rail to the front, and then over across the engine bay just in front of the crossmember with a flex line, then a short hard line that reaches around and onto the compressor. I snagged that. Test fit - just about perfect. The flex line section might be ever so slightly long on a 240 (I think the frame rals are closer together), and the hard line along the right side of the motor might need a very slight tweak on one place, but really, it slid right in abd bolted right up.
So that leaves one more obstacle:
The power steering reservoir. I'm not sure when Volvo switched between the style with the reservoir on the side of the engine bay vs. these integrated units, but this wasn't going to work. So I got a remote-reservoir style setup from a slightly older 240 in the pick-n-pull. Just snagged all the lines down to the banjo connections on the steering rack. Bolted it all on (still need to mess around with the bracket that holds the reservoir - there's an ABS unit on my car where it was on the earlier car), and finally, the intake manifold fits.
Also, for no particualrly good reason, I snagged a smaller alternator at the PnP too. It was cheap, it bolted right on in place of the original alternator, it's 100A vs. 80A, and it gives me a little more room on the turbo side of the engine bay.
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'63 PV544 rat rod, '93 Classic #1141 245 (now w/16V turbo)
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