1980 Volvo 242GT to:

1980 Volvo 242GT+TiMSnSWB

Step 1 - Install MegaSquirt N Spark

Step 2 - Install Intercooler, Oil Cooler, Teardown for Turbo, and Oil Feed/Return lines

Step 3 - Install Oil Feed/Return, Turbo, Exhaust, Etc.

Step 4 - Rebuild Engine and Find New Turbo

Step 5 - Install Replacement Engine and 15G Turbo

This car was all stock when I got it, with 196,000 miles. My brother in law rescued it from DMV purgatory; it hadn't been registered in several years and about four owners. He got that squared away, jerry-rigged the wiring, put a set of new treads on it, and then sold it to me.

I had no idea what I was getting into with this car... I really wanted a convertible, but that was a no-go from a family standpoint (a new baby and I already have two other two seater cars). This car at least has a sunroof, and it's passin close to a convertible for my needs.

Unfortunately, with only ~100HP, it's a gutless dog. I started with adding an "A" cam (not much of a change from the "B" cam that was already in there!) advancing the timing, and opening up the air intake a little bit. Still too slow. Thus we fast forward to the turbo and intercooler addition (+Ti). See TurboBricks for more info. Somewhere along the line, I lowered it a little bit, replaced the stock springs and struts/shocks with white KYB's from a junkyard and wagon springs, and put in a Recaro seat for the driver. Doing these things made the car feel sportier and more capable, but it still needed more thrust.

After much research, I decided to Megasquirt it. That meant taking the stock K-Jet mechanical fuel injection off and replacing it with the manifold and injectors from a LH (electronic injection) car; in this case an 86 745Ti. This car was the donor for all major pieces of the conversion. This also gave me a chance to repair the rotted stock wiring harness. Once Megasquirt is up and running, I'll roll out MegasquirtNSpark (aka MSnS) and tune it all with a Tech Edge Wideband O2 (WB). That's how we get to 242GT+TiMSnSWB.

Day 1 - removal of K-Jet, cleanup, and wiring repairs:

This shot showcases the grime and rotted wiring.
...including the horribly rotted wiring.
...cleaned everything up, ran new wires, and voila! The orange pigtail from the large gray connector will be run to the Megasqurit ECU once I get that far. Please note - this doesn't work. MS needs a dedicated temp sensor. I got one from an old BMW 5-series that was the same thread as the Thermal Time Switch (below #4 exhaust port), froze, boiled, and put it in the hot tub to get three temp/resistance readings, and updated with EasyTherm. Worked like a charm!

Day two/three (?): installation. I was working like a maniac, didn't really stop to take a lot of photos.

I installed the open-cell GM Intake Air Temperature sensor in the stock K-Jet intake hose. This will be redone when the turbo and intercooler plumbing goes in. I thought I could reuse/shorten the stock Kjet fuel lines; even went so far as to buy and extra set at PickNPull. Unfortunately, you can't push the fittings into the hard plastic fuel lines... so I had to buy bulk fuel injection hose at $3.19/ft.
The intake manifold was already ready already.
Next was to figure out where to mount MS -I chose the passenger side footwell. I then soldered up the wiring pigtail (all the wires from MS to the sensors, injectors, etc) and passed the connector through the hole in the firewall. Here you can see the wires coming out of the firewall to their various destinations. Once all the connections were made, the manifold tightened in place and the constants set with Megatune, I cranked it... and?

It fired right up! I'd heard other people with the same result, but it was still shocking how easily it started. Once I adjusted the idle screw, it idled a little rough, but revved quickly and easily. It's crazy how easy Megasquirt (and the easy availability of OEM EFI components) make a swap like this.

Still to do: Run the MAP hose (conspicuously absent from the above images) and install the Tech Edge WBO2 controller. I also need to sort out what vacuum lines/fittings I will need, and which ones should be plugged.