Been busy again... New "Ram Air" intake and charge pipe!!!

[Jason]

Well, unfortunatly I haven't been able to come across a D24 NA manifold, and the stock T manifold is not the best setup for high performance with the sissy 1.5" inlet. Basicly what I did here was replicate the NA manifold since I felt the stock inlet was restricting me. Also the flow path of the NA manifold is much better under boost, with the air flow going directly in the manifold, rather than crashing into the top and tumbling around inside. The new charge pipe is mandrel bent 2" to match the compressor outlet. I cut off the snout for the old POS dump valve, and die ground it out to match. Since I didn't have a tig welder handy, I fabbed up a flange and drilled and tapped the manifold to bolt it down with. Here are the pics:
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0010.jpg
Difference between the T4 compressor outlet and the stock inlet pipe that slips into the manifold.
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0012.jpg My crappy connector showing how it was necked down into the manifold.
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0013.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0015.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0028.jpg
weld strip to keep the pipe from slipping out of the connector boot
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0027.jpg

Now its manifold time. After cutting off the stock dump valve flange and some die grinding:
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0018.jpg
Holes drilled and tapped, flange match ported and fitted:
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0020.jpg
Flange welded up with 2" pipe neck:
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0021.jpg
Finnished product, painted high performance RED!!!! To match my porno interior!!!;)
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0022.jpg
New intake setup! MUCH smoother and unrestricted flow path...
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0023.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0024.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/101_0026.jpg

Not so much a difference spooling up, but on its way up from 10 to 15lbs of boost it really comes on hard now. I'll have qtr mile times tomorrow and video!

Jason

[oregon101]

That looks great! Excellent job. Looking forward to your track info.

[IceV_760]

I just can adore the speed you build up your Volvo.
Again, we saw something new.
Is N/A manifolds rare in USA? As i know you guys
wrecked every single 200-series diesel, which were just d24's.

[Jason]

They are pretty rare around where I live, that is diesel volvos in general. They seam to gravitate towards the coasts and I'm in the middle of the US.

I had some free time on my day off and started getting ideas, and thought why not!

Jason

[v8volvo]

Looks great. How did you plug up the hole in the bottom of the manifold where the tube from the turbo used to slide in? You may eventually find that this is the best setup of all, since the D24 NA manifold may have trouble fitting under the 700 hood, and it has that big opening on the back that I would worry about when running big boost.

Now it just needs an intercooler... and injectors... and a manual trans... and a real oil cooler. Then you will have a pretty serious diesel hot rod on your hands. :eek: :cool:

[IceV_760]

and it has that big opening on the back that I would worry about when running big boost.

Now it just needs an intercooler... and injectors... and a manual trans... and a real oil cooler. Then you will have a pretty serious diesel hot rod on your hands. :eek: :cool:

You can just tig-weld that big opening on back with thick aluminium plate.
So its not going to be problem. No injector changing needed by the way,
or can you point me some thread which recommends it?
Sorry little sceptism, but im curious to know if you really change injectors?

I get the idea, with bigger nozzles you can feed more fuel to cylinder in less time
than with smaller, but i havent heard anyone in finland had changed injectors,
just liquid head.

[Jason]

I too have been researching the injector thing. IDI injectors aren't sized differently, it all depends on how much fuel is pushed though it since they pop open. Its not like a TDI injector with a certain size orfice that is enlarged for more power. I have come to find out the different numbered nozzles eg 253 293 only refer to different updates and changes that were made as they revised the design of the injector tips. Whether is was for cleaner combustion, less noise, etc... As the years went on the numbers increased as bosch release new and better tips.

As for the intercooler, I've got that covered with the water/alcohol injection. It is just as effective if not more so since I can tune the injection amount.

Whats really going to step up the performance will be the ARP head studs. This car with 25lbs boost and fuel to match is going to be really mean.

I'm working on the manual. At least I finnaly got a D24T bellhousing and flywheel. I'm wanting to do a T5 swap but my buddy that just bought his 760 may want to sell and its a m46. We may swap and sell his car as an auto. That would be straightforward and when I blow it up I can go to a T5 then.

Whats wrong with the oil cooler? I know its not that big but for how I drive it, I would think its alright. If I was rallycrossing it and under load for a long time I could see doing a larger one, but most of my running is messing with guys on the street or just getting into it for a quick hard run. Hell it holds 8 qts of oil!

Jason

[Jason]

The inlet was plugged with a rubber expandable pipe plug from home depot. I used a nylock nut instead of the big dorky wing nut, and siliconed it in.

Jason

[cuaz64]

Interesing development. About the NA intake manifolds, Tom Bryant is a source of them.

[Jason]

Ya kevin (slobodan on here) had one for me but I was really wanting to get the intake setup better before heading to the track. He wasn't able to get it off, and I also had read that there can be fittement problems because of how tall it is in a 7xx series car. I figure what i have now is pretty damn close to as good as the na manifold.

Jason

[v8volvo]

I too have been researching the injector thing. IDI injectors aren't sized differently, it all depends on how much fuel is pushed though it since they pop open. Its not like a TDI injector with a certain size orfice that is enlarged for more power. I have come to find out the different numbered nozzles eg 253 293 only refer to different updates and changes that were made as they revised the design of the injector tips. Whether is was for cleaner combustion, less noise, etc... As the years went on the numbers increased as bosch release new and better tips.

As for the intercooler, I've got that covered with the water/alcohol injection. It is just as effective if not more so since I can tune the injection amount.

Whats really going to step up the performance will be the ARP head studs. This car with 25lbs boost and fuel to match is going to be really mean.

I'm working on the manual. At least I finnaly got a D24T bellhousing and flywheel. I'm wanting to do a T5 swap but my buddy that just bought his 760 may want to sell and its a m46. We may swap and sell his car as an auto. That would be straightforward and when I blow it up I can go to a T5 then.

Whats wrong with the oil cooler? I know its not that big but for how I drive it, I would think its alright. If I was rallycrossing it and under load for a long time I could see doing a larger one, but most of my running is messing with guys on the street or just getting into it for a quick hard run. Hell it holds 8 qts of oil!

Jason

Jason, interesting stuff about the injectors. If what you say is true, then what is the difference between the normal TD and the "GTD" injector nozzles? I think there must be some possibility of flowing more fuel with the GTD units, since they (along with an intercooler) are the major differences between TD and GTD engines, the latter of which do make significantly more power. I buy what you are saying about many of the number series referring to refinements in nozzle design rather than to fuel flow capability, but I think there is a possibility a larger nozzle could nonetheless exist.

Did you get the M46 D24T bellhousing/flywheel from the guy in Pennsylvania? You may discover that you end up deciding to just stick with the M46 and forget the T5. I have owned both, and the M46 is much nicer to use -- excellent gearing, very smooth-shifting and quiet, and the electronic overdrive is a nice feature. If you run short rearend gearing and use the stronger P-Type OD unit, I doubt it will really ever give you too much in the way of trouble. Remember that the M46 is used behind turbo gas motors that came stock with as much as 200 hp and 190 lb-ft, and they stand up to modified motors making up to about 250 lb-ft. I'll be surprised if you are able to break one with a D24T no matter how much you modify it.

I just hate the oil cooler design, with the hose running up over the valve cover that is hard to bleed and always gets soaked with oil and gets in the way when you are adjusting the valves, and the oil soaked short hose at the back of the head, and the increased stress on the cooling system and the possibility of coolant and oil mixing. Much better to switch to a real external cooler that will keep temps lower and not be as much of a threat to the engine.

You ought to install the MLS headgasket when you do the head studs. Then it will really be unbreakable. :cool:

[IceV_760]

v8volvo, i must disagree. With highly tuned d24t m46 is going to
be rubber, especially 3rd gear. OD isnt a problem.
For Jason, if you want more power, DO that IC assemly,
water/alcohol injection is not so good than intercooler.
You are going to break that engine for nothing if you will use bigger turbo,
high pressures and alot fuel. Just my tips.

[IceV_760]

I mean, you have the heat problem still there, even youve raised power
by freeing additional oxygen when injected water/alchol mix
vaporizes on cylinder. But after all, im going to test before any mods your
inject system, then doing something with it.

[Jason]

The GTD nozzle is the 253 number. I read some posts by Giles (i'm sure you have heard of him, the hot rod pump expert in Canada) and he recomended those over the other numbers. The extra power is probably from the better design. More effecient combustion will of course lead to more power, along with the intercooler. I would suspect the injection pump on the GTD engine has a different stock calibration that pushes more fuel compaired to the calabration of the regular TD pump. Another "injector expert" also confirmed this on the vwdiesel.net forum. I read through the listing of Bosch injector numbers and pretty much the DNOSD numbers just went up as the years went by, which further leads me to believe that they were just changing and improving the design. The Benz injectors may have a larger flow capacity, but the spray angle is wrong.

Jason

[IceV_760]

How did your quarter mile went? I really want to hear. I have soon my intercooler fit done, then running on bench.
I believe and hope its done in 2 or 3 weeks. I know, pretty long but ive been waiting now my really last parts
and they havent come yet. 2,5" thick piping all the way before intake manifold, which is 3". Just the usage of 90 degree angles will restrict air flow,
but its, hell, 1" thicker pipe, that will cover it and more,
also cooler air to engine. Then ill modify my original air-filter box, to take needed air way straigher way.
Are you going to bench your car? Would be really interesting to see
our results with some agreed turbo pressure, like 1bar/14,5psi.
So we could compare intercooler+2,5" piping vs. 2"piping and charge pipe+
water/alcohol injection. I think that would be interesting,
for both of us.