1978 Volvo 242

What started out as a cosmetic exercise on this 240 ended up finding this and repairing many

here to fore undisclosed problems like...

...a frozen alternator connection...

...rusty air box housing clamps...

...too thick valve shims...

...badly corroded thermostat housing...

...and ultimately a bad engine lower end.

So after all this work in the test drive, the engine bearings failed.

I have never ever seen this happen unless work has been done to the lower end;

and sure enough, that has been the case with this engine.

So back to square one-even further-the engine damage was too great to repair in place...

...the crank shaft was so badly scoped that it needed to come out.  So now we have a clean sheet...

...empty engine bay and a used engine.

Although these engines are bullet proof, we decided to take no chances and at minimum check everything.

What we found was remarkable!

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