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Flat hood is a nice look.
Any reason you're getting Bilstein Touring instead of Sport? Sport would seem to be in character for a 242 and the ride is still excellent. Either way, I think you will love the shocks.
Do you have the IPD sway bars already? They are excellent.
A freer flowing exhaust should give you quicker throttle response. Losing the cat and using a (loud) straight-through muffler like a Magnaflow Race with a mandrel-bent 2.5 in. system would be optimum, but it might be noisier than you want. The IPD system is mandrel-bent, but it has a stupid crimp where it goes over the axle. Never understood why they did that.
A performance cam could significantly increase your hp, esp. at higher rpms. I know, more $$. Next tax refund? It would take fuller advantage of your upgraded airflow.
I don't think a different fuel filter alone would increase performance as long as it's clean. Maybe a Kenne Bell Boost-a-pump and bigger injectors would combine with a cam to really wake things up, but this would decrease mileage as well. Dunno - I don't have a Volvo motor in my Volvo. More $$, of course.
Sorry, I got carried away with the hot rodding. For improved mpg and performance, I'd 1st make sure everything was running like it should. 02 sensor and other tune-up items can make a big difference. <20mpg sounds kinda low; I get 16-23mpg with my built V8 (300+ hp).
One more thing, if you're not already using it: a good synthetic oil will increase your mpg and performance over dino, besides reducing wear.
--
'84 "285" rice-eater with lotsa hp & performance goodies
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