[lawdogg]

Moved from LA up to Northern California, and the ~400 miles of highway (and potholes, some really bad) caused these to come back:

ECM-280A	Front heated oxygen sensor (HO2S), bank 1 - Faulty signal
ECM-400C	Fuel tank System, Leakage - Minor Leak
BCM-0136	Brake pressure sensors 1 & 2 signal outside its permitted range

I am thinking that the O2 sensor is a symptom of the aftermarket downpipe, since VIDA shows it cycling OK (last time I checked) and the code only gets thrown after highway driving.

The fuel tank leakage, that's been bugging me since I did the fuel pump. Not sure how to narrow this down aside from looking for fuel leaks?

The brake pressure one, this was thrown once before back in March and I assumed it was because of a low battery. VIDA shows both brake pressure sensors are working fine. I'm wondering if I've got a loose sensor connection or something.

And finally ... on the drive up I realized that my shocks are probably bad. The car bounces up and down almost as if it has no damping at all, in every mode. In Comfort mode it bounces so badly it hits the bump stops! So ... I am thinking it's time to replace the suspension.

(I have yet to do a SUM cal which I will do but I'm not expecting much...)

I'm looking at getting the Monroe gear from FCP Euro - anyone know of a better place to shop, or any tips or tricks beyond what's already been covered in the forum about a full 4C replacement?

 

[kTaLgsTo]

This was the cheapest place I found them, even with shipping.

https://m.autodoc.co.uk/

Of course, can you beat fcpeuro warranty?

 

[bencrabtree27]

If youre going with brand new 4C I would go FCP, like @kTaLgsTo said, can't beat their warranty. I didnt have the money for new 4C at the time, and the VR was my daily so, I did the resistor mod and put on AWD strut and spring assemblys. I purchased those from 1aauto.

 

[lawdogg]

Thanks guys. Yeah the FCP warranty is pretty appealing. I'm gonna try to get the car up and at least inspect the shocks before buying. But given how my damping is basically 75%+ gone, I'm expecting to see that a lot more fluid has leaked out or some other sign pointing to the need for new shocks.

Adding insult to injury, the AC stopped working. Upon inspection, the compressor is not engaging / spinning. It still doesn't engage if I tap it with a breaker bar (so maybe that means it isn't a clutch issue), and both the 10A fuse and relay in the fuse box are OK (so maybe that means the compressor didn't short out, fingers crossed).

I'll try to figure out if it's getting power via the signal wire next.

 

[lawdogg]

Pulled the trigger on the parts from FCP. Got the whole kits. $2k shipped with their current 5% discount code. Not thrilled about spending so much money but looking forward to getting them in.

 

[lawdogg]

Control arms out and now I'm either going to find a shop that can press the old bushings out / new ones in, or pick up a press and do it myself.

Am so happy to have a rust-free car. The control arms came out so easily, even the ball joints survived (although I did get new ones that I'll install just because it's a good opportunity to do it).

 

[lawdogg]

Also - got my d/s strut apart, lo and behold no bump stop.

Did these cars ever come without front bump stops from the factory?

 

[lawdogg]

Is this the right way to assemble the 4C strut? It's basically how mine came apart but I have a couple questions:

-The red bump stop: my car didn't have one when I took it apart. But, it has little tabs that seem to fit perfectly in the metal plate below the upper spring seat. Also, various diagrams online seem to show the bump stops in place. E.g. #7 in the below. Should I install it?

-There is no lower spring insulator (#32 in the above pic). My car didn't have any on it, and none came in the FCP kit. Do I need one?

For reference, here's my p/s front original (as far as I know) shock in place ... no bump stop, no lower spring insulator.

 

[lawdogg]

Here's the old one lol ... no wonder I was bouncing down the road.

 

[rnkelly]

My understanding is that yes the bump stop fits into that metal plate. I don’t think it’s critical though cause it doesn’t usually stay there, but will do it’s job nonetheless. Personally I would get the insulator too, it would be frustrating to find an annoying noise/squeak and have to redo the whole thing. Good luck!

 

[lawdogg]

So it turns out the V70XC rear bushings won't fit in the R control arms: Volvo Control Arm Bushing - Delphi 8630605

(I had thought they would work from this thread: IPD HD vs OEM Lower control arms?)

These XC bushings are 2.017" OD.

The R control arm bushing ID is 1.985" I.D.

OEM removed bushing left, new XC bushing top. Empty R control arm on right.

This resulted in an aborted press and mushroomed bushing. The control arm sustained some damage as well but I'm hoping I can still use it. Ugh.

Now, need to order bushings that actually fit.

Edit: Went with poly because why not. Volvo Lower Control Arm Bushing Set - Powerflex PFF88-600

 

[lawdogg]

Well, no pics but finally got the car back together with the brand new Monroe 4C shocks, mounts, and good control arm bushings. I also did a ball joint and swapped in a spare p/s axle since my cv boot was torn. I kept the original springs.

WOW! The ride is just incredible now. I can't believe how nice it is. I am very very happy I decided to stick with 4C rather than switching to aftermarket coilovers.

 

[lawdogg]

Before tossing it all in the bin, here's a pic of everything I replaced.

All 4 control arm bushings were torn, one of the front upper strut mounts was torn, and the balljoint boot retaining clip had fallen off, so it was dry and loose. Good riddance. Also, there were no front bump stops to be found. I installed new red ones that came with the FCP kit when I put it all back in. I didn't find I needed to replace any of the sway bar links so I'll keep the ones that came in the FCP kit just in case.

Not pictured is the p/s drive axle. I'm taking it apart to put a new inner CV boot on it ... then this happened.

The retaining clip broke.

So I need to figure out how to (1) squeeze it to slide the inner ball holder off, (2) remove it, and (3) find a replacement clip...

 

[kTaLgsTo]

Rebuilding the axles is A greasy job.
Nice work on the suspension, been there, had the back pain.

 

[lawdogg]

Got it apart, just need to find a replacement circlip.

Looks like the genuine Volvo inner CV boot kit comes with one, although it's a different style: Volvo CV Boot Kit Inner - Genuine Volvo 31256223

Edit: I suspect that kit isn't right, from FCP's own guide it shows that style circlip used in the different tripod-style CV joint: Learn How To Replace Your Volvo Inner CV Joint Boot

So, will keep looking ...

 

[lawdogg]

Found my AC leak ... FMIC poked a hole in the condenser. Doh.

New condenser on the way from FCP.

 

[lawdogg]

New condenser in ... crossing my fingers it holds vacuum before either (a) hunting for leaks again or (b) if it holds, filling up with refrigerant.

 

[chefricky]

I admire your perseverance! You certainly deserve a very fine example R. As for the recharge of the A/c system, charge it up with nitrogen to check it for holding pressure. Then go ahead and charge it. No sense in losing $$$ on refrigerant.

 

[lawdogg]

Instead of charging it with nitrogen, I held it in vacuum overnight and it didn't leak at all.

So, I filled it up (Volvo spec is 1kg of R134a which = 28oz).

No leaks, ICE cold, amazing. Very happy!

 

[ZZZZZZZ]

Somehow I missed all your updates over the last several weeks/months. Great job, and I agree - 4C new and working well (+ all those related things you did) is spectacular. The car rides SO nicely after that. Did the control arm break or did you have to cut it? Looks like a break from that incorrect (larger) bushing being forced.