New Exhaust installed on 1990 Volvo 240 wagon.

Here is my new exhaust from the cat converter back.

Replaced door hinge and handle on Driver’s side. 1990 Volvo 240.

This past month I had the hinge area cleaned up and re-welded. A new door handle was also installed.
I lubed everything mechanical inside the door. Lastly, I realigned the door to close perfectly and it all works great as it should. I’m happy with it. Here are photos of the work.

Door removed and cables out.

Door off car.

Preparing to weld.

Weld before cleaning and grinding.

Inside door hinge weld and bolted together.

Cracked around hinge into door bracket.

Old hinge and New hinge.

This bracket inside the foot-well is located behind the fuse bus terminal. The lower door hinge is attached to the body from inside here.

Finished Install

Volvo 240 Stereo system install upgrade, speakers, photos, diagrams.

This install on my YOUTUBE channel.

Volvo harness wiring detail

Pioneer speakers 5 1/2 inch

Pioneer speakers

Stereo On

Stereo head unit installed in upper dash location

Dash speaker access grill in place over antenna

Powered antenna from Autozone - connected

Closer view of grounding bracket with stereo fitted

View through glove compartment at ground bracket behind stereo

Harnesses soldered together

Factory unit removed - harness and antenna wires visible

Wiring harness to Pioneer

Wiring harness adapter to Volvo

Contents from Crutchfield

Added a new Pioneer DEH-3300UB stereo reciever head unit to my car.
Ordered it online from Crutchfield. Requested the wiring harness adapter and plastic dash insert for aftermarket radios. Installation was easy.
I found excellent instructions online and also included in the box from Crutchfield. Here are some photos from the recent installation. Hope this helps other 240 owners who are planning to make this upgrade. The photos show the install work in reverse. Scroll to bottom to see beginning.
The new system sounds seriously improved. It’s louder, cleaner, more punch, more radio stations are being received more clearly, and now I can play CDs, MP3s, USB, Ipod.

Volvo 240 Dash removal detail at Cleanflametrap
Aftermarket radio install 87 Volvo 240
Volvo 240 stereo wiring colors and details

New Headlights and Seats Swapped…yeah!

This past week I finally installed new headlights and swapped the driver/passenger seats.

The headlights are a great improvement over the old. They also have upgraded 9004 halogen bulbs, Sylvania Extras. Just need to fine adjust the aim of each side.

I swapped the seats to have better support on the driver side and adjustable lumbar support. Woo hoo! It was a tight fit but it works. I reworked the wires, springs and foam while the seats were out. Also added reinforcement pressboard underneath. Much more comfy. The passenger side seat now has front and rear height adjustment but no lumbar. It would be great if there were an adjustable seat belt height adjuster on the door pillars and maybe adjustable seat clip receptacles. Yeah, the small cubby in the center console e-brake area is blue, should be black. I’ll either paint it to match or buy a new one on e-bay or one of many volvo owners forums.

Found speaker mount/bases and grills for Volvo 240 front doors.

UPDATE DEC. 6
Hey all.

Thank you for reading my request.

I found bases/mounts and grills HT-204 style from smokeyfan1000 on turbobricks.com forums. Great communication and highly recommended. Glad I posted to several forums. Never know who you’ll find with the right parts at the right time.

Best of success with all your parts needs,

Brandon
Franklin,TN
organicbees@live.com

DEC 12: Installed speaker mounts, speakers and grills in front doors. Pics coming soon.

These allow mounting of 5 1/4″ – 6″ speakers up to a depth of 2 1/2 inches in the door. Dozens of different speakers will now fit. Before, only about 7 models/brands would. I went with some Pioneers TS-G1343R for $50. Sound great. They’ll do for a while. You may like this site if you want to design your own car audio system.
the12volt.com