d24t overhaul+mods

[volvo_d24t]

my project 1985 volvo 745 d24t

* to-do list *
remove auto trans
remove engine
complete engine overhaul
n/a intake
bigger turbo
head porting
H-beam connecting rod
bosch GTD nozzles + pressure
modded fuel pump
swap m46 transmission 4speed + OD
flywheel and clutch
new starter
new radiator
new water pump
new timing belt
add intercooler
ARP headstuds
MLS gasket
custom driveshaft or find stock front propeller shaft

https://preview.ibb.co/hzJRL7/21122653_10155713226725152_2556127685476761794_o.j pg (https://ibb.co/i128YS)

https://preview.ibb.co/jgdLXn/volvo_d24t.jpg (https://ibb.co/d18yJS)

https://thumb.ibb.co/dKP0f7/22688516_10155883642565152_2720236447739336303_n.j pg (https://ibb.co/dKP0f7) https://thumb.ibb.co/kQKY07/19420844_10155477765870152_5286600979611696357_n.j pg (https://ibb.co/kQKY07) https://thumb.ibb.co/in9Yk7/IMG_0025.jpg (https://ibb.co/in9Yk7)

[RedArrow]

Your plans sound great. I hope you will open a thread here on this forum and share as much as you can.
There used to be a problem with hosting pictures but every post can include 5 standard pictures that you may attach when you post. I found that to be the best option... and all my pictures are still accessible after all these years while others " lost " their linked footage, unfortunately.
Keep dieseling!
Would be nice to update this forum somehow so better quality pictures could be shared VIA THE STANDARD SHARING FUNCTIONS OF THIS FORUM. Maybe moderators could solve that soon. I hope so because for now it isnt possible to add a picture that looks okay and is standard quality.

[volvo_d24t]

Your plans sound great. I hope you will open a thread here on this forum and share as much as you can.
There used to be a problem with hosting pictures but every post can include 5 standard pictures that you may attach when you post. I found that to be the best option... and all my pictures are still accessible after all these years while others " lost " their linked footage, unfortunately.
Keep dieseling!
Would be nice to update this forum somehow so better quality pictures could be shared VIA THE STANDARD SHARING FUNCTIONS OF THIS FORUM. Maybe moderators could solve that soon. I hope so because for now it isnt possible to add a picture that looks okay and is standard quality.

yes this thread will be my project and I will try to keep it updated with pictures
______________________________________________

update #1 : Today I have removed the automatic transmission and few other things... thanks to Anders on this forum for parts I needed, pictures below

Next step: remove engine

https://preview.ibb.co/kunm57/IMG_0031.jpg (https://ibb.co/mRNKQ7)

https://preview.ibb.co/fjbeQ7/IMG_0033.jpg (https://ibb.co/gGBDk7)

https://preview.ibb.co/e862dS/IMG_0029.jpg (https://ibb.co/mhc8JS)

https://preview.ibb.co/iDYtk7/IMG_0028.jpg (https://ibb.co/kXRDk7)

[volvo_d24t]

update #2 : engine removal, unfortunately I missed took a picture when operating the chain block.

Snapped a bolt in exhaust manifold... i don't want to make other threads... will try to extract somehow...
i'll leave you with a Sneak peek of new turbo in pictures below.

https://preview.ibb.co/fAyCV7/IMG_0036.jpg (https://ibb.co/cLD1OS)

https://preview.ibb.co/d0FsV7/IMG_0040.jpg (https://ibb.co/maVgOS)

https://preview.ibb.co/e5Exxn/IMG_0037.jpg (https://ibb.co/cYdPcn)

https://preview.ibb.co/fTQgOS/IMG_0046.jpg (https://ibb.co/ewp83S)

https://preview.ibb.co/ekAFiS/IMG_0048.jpg (https://ibb.co/ggvgOS)

https://preview.ibb.co/hF3qHn/IMG_0049.jpg (https://ibb.co/gajKA7)

https://preview.ibb.co/bFdqHn/IMG_0044.jpg (https://ibb.co/gWzKA7)

https://preview.ibb.co/dbQFiS/IMG_0043.jpg (https://ibb.co/bSzaiS)

[ngoma]

There's bound to be one or two snapped studs or bolts in a project like this. You could try soaking it with penetrating oil and drilling it out with a left-handed bit. Sometimes the counter-clockwise drilling unscrews it.

Looks like someone made an EGR block off plate there.

[volvo_d24t]

There's bound to be one or two snapped studs or bolts in a project like this. You could try soaking it with penetrating oil and drilling it out with a left-handed bit. Sometimes the counter-clockwise drilling unscrews it.

Looks like someone made an EGR block off plate there.

I will try to keep those thread untouched. Yes previous owner block off the EGR... homemade not even the same bolts lol
_____________________________________________

update #3: injection pump removal, vaccum , ect...

made a little dent on the front camshaft sprocket, I dropped it :/ Otherwise , I came to took head off and didn't have the socket at the workshop... dammit.
at least I found manual pedal assembly and master cylinder for m46 swap!


https://preview.ibb.co/migCHn/IMG_0058.jpg (https://ibb.co/k46OOS)

https://preview.ibb.co/eyNxiS/IMG_0078.jpg (https://ibb.co/iqrq3S)

https://preview.ibb.co/jzcoOS/IMG_0077.jpg (https://ibb.co/hR1F3S)

https://preview.ibb.co/dTbhiS/IMG_0074.jpg (https://ibb.co/jsf8OS)

https://preview.ibb.co/cLNKxn/IMG_0065.jpg (https://ibb.co/kwc8q7)

https://preview.ibb.co/nMS8q7/IMG_0064.jpg (https://ibb.co/kJ0iOS)

[ngoma]

Should be able to lightly file the sharp edges from the dented tooth, bet it will be all right.

I'll be interested to see how you fab up the hydraulic clutch-- most of ours are cable operated.

[volvo_d24t]

Should be able to lightly file the sharp edges from the dented tooth, bet it will be all right.

I'll be interested to see how you fab up the hydraulic clutch-- most of ours are cable operated.

well I don't know either, haha! thought it was hydraulic...
________________________________________________

update #4 : engine disassembly

previous owner tried to make a headgasket job on this motor but he did'nt even have the good socket for the head bolts.
He ended up damaging de #1 bolt and didn't go further in his project... lol! Luckly I was able to remove it by driving the M12 socket with a hammer in the head bolt.

Next step: Rebore cylinder with new KS piston

https://preview.ibb.co/fXxtSn/IMG_0110.jpg (https://ibb.co/ezML7n)

https://preview.ibb.co/fQUttS/IMG_0097.jpg (https://ibb.co/ettKYS)

https://preview.ibb.co/fcsDtS/IMG_0092.jpg (https://ibb.co/b1pF7n)

https://preview.ibb.co/f1Zhnn/IMG_0089.jpg (https://ibb.co/iz2rf7)

https://preview.ibb.co/nqp407/IMG_0085.jpg (https://ibb.co/kQwTSn)

https://preview.ibb.co/dJAzYS/IMG_0083.jpg (https://ibb.co/iZWTSn)

https://preview.ibb.co/gqANnn/IMG_0098.jpg (https://ibb.co/cE7P07)

[RedArrow]

Progress... Is it getting new exhaust valves?
What is the maximum size of a crack between valves on these engines that we can try getting away with?
I know greenbook says 0.5mm.
This one looks wider but maybe only because I zoomed in?

[volvo_d24t]

Progress... Is it getting new exhaust valves?
What is the maximum size of a crack between valves on these engines that we can try getting away with?
I know greenbook says 0.5mm.
This one looks wider but maybe only because I zoomed in?

I think I will keep those exhaust and intake valves. They require to be reconditioned as well as the valves seats. I don't know what is the maximum size of a crack but yeah, as you said, greenbook says 0.5mm. I think there is no doubt that they are exceeding the specification, but anyway I will try to put this cylinder head back in service.
____________________________________

Preparing cylinder head to disassemble, clean and inspect:

https://preview.ibb.co/d6hFec/IMG_0116.jpg (https://ibb.co/f1SgKc)

https://preview.ibb.co/hqETzc/IMG_0117.jpg (https://ibb.co/bZtz5H)

https://preview.ibb.co/k4vqCx/IMG_0121.jpg (https://ibb.co/mangKc)

https://preview.ibb.co/fCFqCx/IMG_0122.jpg (https://ibb.co/hsYMKc)

https://preview.ibb.co/bFbaec/IMG_0123.jpg (https://ibb.co/jMhFec)

[ngoma]

Those broken GPs are not a welcome sight. Did someone use starting fluid? Where did the pieces go?

[volvo_d24t]

Those broken GPs are not a welcome sight. Did someone use starting fluid? Where did the pieces go?

Yes, previous owner used starting fluid for cold start. Those broken glow plugs may be caused by bad injector spray or as you said starting fluid...
_____________________________

Cylinder head disassembly and cleaning

https://preview.ibb.co/mv7Axx/IMG_0127.jpg (https://ibb.co/btG3Hx)

https://preview.ibb.co/mcJiHx/IMG_0128.jpg (https://ibb.co/kr0xcx)

https://preview.ibb.co/j9PZPc/IMG_0135.jpg (https://ibb.co/ekL8jc)

https://preview.ibb.co/k7Hojc/IMG_0138.jpg (https://ibb.co/cX2zqH)

https://preview.ibb.co/j0E7cx/IMG_0145.jpg (https://ibb.co/bYhFVH)

https://preview.ibb.co/g0gncx/IMG_0147.jpg (https://ibb.co/jhi0xx)

https://preview.ibb.co/kfR9qH/IMG_0150.jpg (https://ibb.co/mMkfxx)

https://preview.ibb.co/hvc4Pc/IMG_0157.jpg (https://ibb.co/bVYdjc)

https://preview.ibb.co/knSScx/IMG_0160.jpg (https://ibb.co/mL30xx)

[ngoma]

Looks like you got some good injector nozzles. Are you going fit them and POP test them?

[volvo_d24t]

Looks like you got some good injector nozzles. Are you going fit them and POP test them?

Yes and increased opening pressure. Got them from Anders

[ngoma]

OK then you will want to refurbish the injector internals as well:

HOW-TO: Rebuild Diesel IDI Injectors (http://vincewaldon.com/index.php?option=com_content&task=view&id=20&Itemid=28)

[volvo_d24t]

OK then you will want to refurbish the injector internals as well:

HOW-TO: Rebuild Diesel IDI Injectors (http://vincewaldon.com/index.php?option=com_content&task=view&id=20&Itemid=28)

Thank you for the link, very good information in it. I know a local diesel injector shop and I will just make it done by them with the GTD nozzles since i'm not equipped to pop test myself...
________________________

So here's a little update... it's progressing slowly... Expenses I did not really have planned

I went to visit a machinist with my cylinder head. He could repair the cracks and change the seats for $500 ... otherwise the cheapest way would be to simply cut the seats and valves at 45 degrees angle, change the guides and clean the surface of the cylinder head. Another option would be to buy a new KOlBENSCHMIDT cylinder head for $ 1,000 (comes with seats, guides and combustion chambers).

Someone has a metal head gasket part # or link to buy? and for the clutch has it models more powerful than the original one?
____________________________

Resurfacing the flywheel and cleaning the valves on the steel brush:

https://preview.ibb.co/gwipRc/IMG_0215.jpg (https://ibb.co/eFPJKx)

https://preview.ibb.co/isDZsH/IMG_0216.jpg (https://ibb.co/hinusH)

[volvo_d24t]

Found a brand new AMC cylinder head. ( ordered and will arrive in a month)

Anyone have experience with AMC heads?

https://preview.ibb.co/gmFm7S/AMC.jpg (https://ibb.co/e6wF1n)

https://preview.ibb.co/jFM4u7/AMC_1.jpg (https://ibb.co/fXa8Mn)

https://preview.ibb.co/nMJTMn/AMC_2.jpg (https://ibb.co/keGF1n)

[v8volvo]

I put a new AMC head on a project a few years back. Same as the one you showed except I used the complete version, which included cam, lifters, valves, etc.

It worked well and quality seemed great. I sent it to a rebuilder to take apart and check before putting on and it all was good. I would use one again. The original heads are not much to brag about anyway.

[ngoma]

Is the mating surface ready for a MLS head gasket? It looks smooth enough in the photos! What did it cost?

[volvo_d24t]

Is the mating surface ready for a MLS head gasket? It looks smooth enough in the photos! What did it cost?

Yes the surface will be ready for a MLS gasket. it cost me a lot :eek: ... it's a old stock that was on display at a shop in Europe. I don't think AMC produce this cylinder head anymore... they seem very good quality. I will get new valves, stem seal and buckets (lifters).

I pulled the crankshaft out of the block and got the parts ready to be cleaned in a washing machine. Next step, the machinist will measure the bore, and then I'll order the right oversize piston set. The main bearings seem good to re-use..

There was 2 broken oil squirter for the pistons

https://preview.ibb.co/bWH8yy/IMG_0249.jpg (https://ibb.co/hZwOWJ)

https://preview.ibb.co/ku8yyy/IMG_0237.jpg (https://ibb.co/mZRU5d)

https://preview.ibb.co/k3cDWJ/IMG_0238.jpg (https://ibb.co/da5NQd)

https://preview.ibb.co/kEMOWJ/IMG_0246.jpg (https://ibb.co/ck6qBJ)

https://preview.ibb.co/gbygJy/IMG_0257.jpg (https://ibb.co/b6uz5d)

https://preview.ibb.co/hCUMJy/IMG_0255.jpg (https://ibb.co/cw8sQd)

https://preview.ibb.co/nBBe5d/IMG_0258.jpg (https://ibb.co/mea6kd)

https://preview.ibb.co/fszoyy/IMG_0260.jpg (https://ibb.co/dCfHrJ)

https://preview.ibb.co/iFviWJ/IMG_0261.jpg (https://ibb.co/dyYFdy)

[ngoma]

Interesting. Did you find the remains of the 2 broken oil squirters in the oil pan?

[volvo_d24t]

Interesting. Did you find the remains of the 2 broken oil squirters in the oil pan?

No I didn't. lol
________________________

Few more progress, this time on the car. Stripped the interior to see the floors condition. A bit of work needed on the driver floor pan, but overall is clean and solid. There is rust under rear passenger door trim, but a friend gave me another door to replace it. Otherwise, I want to make this wagon my 'first' little camper and do road trips across the America. I will make a homemade interior and customize it over time.

At the same time, I would also like to replace the heater core but it seems a pain to do. Anyone know a good tutorial or have tips for me before I remove everything? lol

https://preview.ibb.co/kaRfgJ/IMG_0264.jpg (https://ibb.co/m0JFFd)

https://preview.ibb.co/jkNxTy/IMG_0272.jpg (https://ibb.co/bA79ad)

https://preview.ibb.co/cmcmMJ/IMG_0273.jpg (https://ibb.co/hAgD1J)

https://preview.ibb.co/bvcaFd/IMG_0266.jpg (https://ibb.co/iVrP8y)

https://preview.ibb.co/dtfvFd/IMG_0267.jpg (https://ibb.co/eQFUad)

https://preview.ibb.co/bQrP8y/IMG_0274.jpg (https://ibb.co/cSa6MJ)

https://preview.ibb.co/fLCmMJ/IMG_0275.jpg (https://ibb.co/htnLgJ)

[ngoma]

I would also like to replace the heater core but it seems a pain to do. Anyone know a good tutorial or have tips for me before I remove everything? lol
Volvo 700/900 Heater Core Replacement (https://www.brickboard.com/FAQ/700-900/HeaterCoreReplacement.htm)

Don't forget the long 1/4" drive socket extensions for getting at those hidden screws on the top of the heater core box, LOL.

Might as well redo the flapper doors adhesive foam weatherstripping insulations while you are in there, LOL

Beware of "project creep." LOL :D

[v8volvo]

Looks like great progress on engine and the new head.

I saw broken piston squirters once before and that was on an engine where someone rebuilt it and used non-turbo pistons, which do not have the notches in the piston skirts to clear the squirters. The skirts had been (crudely) notched by hand with a file or Dremel tool, and on some of them the notches were not deep enough so they chopped the squirter nozzles off. They were found lying in the pan on that motor. The other squirters that had not broken off had dents from contact with the pistons. Any sign on yours (the intact ones) that something similar happened or evidence of "custom" piston modification?

If they broke off on yours a long time ago and the pieces were relatively small they might have found their way into the bottom of the sump and eventually came out during an oil change.

Replacement squirters aren't too hard to find, I may have a few floating around and Anders probably has many also. Definitely want to get six good ones in the engine.

Body looks pretty good for Canada. The 700 series is much more resistant to rust than the 200 or many other cars of the era, no coincidence since Volvo emphasized it. Sounds like it will be a nice car for the road when it's finished.

[volvo_d24t]

Looks like great progress on engine and the new head.

I saw broken piston squirters once before and that was on an engine where someone rebuilt it and used non-turbo pistons, which do not have the notches in the piston skirts to clear the squirters. The skirts had been (crudely) notched by hand with a file or Dremel tool, and on some of them the notches were not deep enough so they chopped the squirter nozzles off. They were found lying in the pan on that motor. The other squirters that had not broken off had dents from contact with the pistons. Any sign on yours (the intact ones) that something similar happened or evidence of "custom" piston modification?

If they broke off on yours a long time ago and the pieces were relatively small they might have found their way into the bottom of the sump and eventually came out during an oil change.

Replacement squirters aren't too hard to find, I may have a few floating around and Anders probably has many also. Definitely want to get six good ones in the engine.

Body looks pretty good for Canada. The 700 series is much more resistant to rust than the 200 or many other cars of the era, no coincidence since Volvo emphasized it. Sounds like it will be a nice car for the road when it's finished.

Thank you for the support I appreciate!! :)

If I don't find any squirters i'll let you know

_____________________________________

Finally the block is at the machinist.

Cylinder walls are fine at first sight. 0,5mm oversize rebore should be enough. Main bearing are fine, but I might change them for the peace of mind. New idler pulley.

https://preview.ibb.co/g60Yc8/block_machinist1.jpg (https://ibb.co/eYQzH8)

https://preview.ibb.co/mi1vqT/block_machinist.jpg (https://ibb.co/dFU4jo)

https://preview.ibb.co/c8MH4o/block_machinist2.jpg (https://ibb.co/d2N1VT)

[volvo_d24t]

More pictures of the machinist shop. First quick wash of the block.

https://preview.ibb.co/hOK2u8/shop3.jpg (https://ibb.co/griTZ8)

https://preview.ibb.co/jubhu8/shop.jpg (https://ibb.co/gw7Y1o)

https://preview.ibb.co/fR20go/shop1.jpg (https://ibb.co/jne2u8)

https://preview.ibb.co/jR08Z8/shop2.jpg (https://ibb.co/crkLgo)

[RedArrow]

I love seeing them freshly painted "John Deere industrial green"

[volvo_d24t]

I love seeing them freshly painted "John Deere industrial green"

It might be a great color for it. I will make my choice once there but this one is in my book.

I left the pistons at my machinist, until 2 weeks the rebore should be done so I will go further.

__________________________________________________ ____
*RECEIVED FEW ITEMS

- 6 PISTONS (0.5MM)
- 6 EXHAUST VALVES
- 6 INTAKE VALES
- 14 STEM SEALS
- 6 INJECTOR HEAT SHIELD
- OIL PAN GASKET
- CAM BELT + IP
- MOTOR/TRANS MOUNT
- 2 CORNER LIGHT
- 2 LOWER LIGHT

https://preview.ibb.co/dumQcf/20181030-123733.jpg (https://ibb.co/ka0U3L)

https://preview.ibb.co/mgWDV0/20181030-192300.jpg (https://ibb.co/ism2OL)

https://preview.ibb.co/jT8Sq0/20181030-192420.jpg (https://ibb.co/hdOGiL)

https://preview.ibb.co/bSRrHf/20181030-192426.jpg (https://ibb.co/ffLwiL)

https://preview.ibb.co/h4r2OL/20181030-192432.jpg (https://ibb.co/fOXWHf)

https://preview.ibb.co/hJjNOL/20181030-192254.jpg (https://ibb.co/mHwDV0)

[ngoma]

Often the hardest part is rounding up all the necessary parts. Looks like you got past that step. The rest should be easy. :p

[volvo_d24t]

Often the hardest part is rounding up all the necessary parts. Looks like you got past that step. The rest should be easy. :p

You're right ahah. I've got 2 broken oil squirters, I am happy to have Tom helping me out with these specific parts I need !

Took pictures at the machine shop few weeks ago. The block is ready at the time I am writing this, I will pick it up next week.

___________________________
Rebore is done, next step: Hooning

https://i.ibb.co/tHqjsgk/thumbnail-20181113-111758.jpg (https://ibb.co/WHk8yZq)

https://i.ibb.co/NNmtchn/thumbnail-20181113-111804.jpg (https://ibb.co/HPxB5vp)

https://i.ibb.co/8Ym5hy7/thumbnail-20181113-111816.jpg (https://ibb.co/QDJN5WK)

[volvo_d24t]

Block is back in my garage . Cleaned it before painting. I am not 100% sure of the color, but more likely a ''beige'' cummins.

Happy holidays and new year to you all!

https://i.ibb.co/xGFDkSp/20181210-231143.jpg (https://ibb.co/FJHKrbS)

https://i.ibb.co/jgjPQcL/20181210-234915.jpg (https://ibb.co/dGHwVdQ)

https://i.ibb.co/dDM06N6/20181210-234922.jpg (https://ibb.co/Fz3bJQJ)

[volvo_d24t]

I could not wait to paint it so I choose a light green ''Detroit'' diesel engine color. Did the engine stand also :p

https://i.ibb.co/d5G6F9t/received-2303715616539382.jpg (https://ibb.co/6Wgbzh8)

https://i.ibb.co/5GMGw3p/20181212-212211.jpg (https://ibb.co/vVwVRWy)

https://i.ibb.co/R7zmdz4/20181212-212200.jpg (https://ibb.co/rv4SN4f)

https://i.ibb.co/8rTWK1m/20181212-212217.jpg (https://ibb.co/n7ZHgxw)

[volvo_d24t]

Satisfied how the paint came out, continuing cleaning parts!

https://i.ibb.co/nMBkhdf/20181213-220937.jpg (https://ibb.co/F4X7GZJ)

https://i.ibb.co/bd7QGjX/20181214-144043.jpg (https://ibb.co/HgXB9Lq)

https://i.ibb.co/dgR4cJm/20181214-160556.jpg (https://ibb.co/nCFM08P)

https://i.ibb.co/WxvqM94/20181214-165140.jpg (https://ibb.co/5MhtSDg)

[ngoma]

Good work. Did you renew the o-ring in the heater hose flange at rear of block?

[volvo_d24t]

Good work. Did you renew the o-ring in the heater hose flange at rear of block?

Not yet, but I will

Received few more parts from Anders (member of the forum). Now I will be able to start the re assembly.
-Crankshaft bearing
-Rod bearing
-ARP headstuds

https://i.ibb.co/TMrZQMt/20190312-000148.jpg (https://ibb.co/ZzN3Qzx)

https://i.ibb.co/QF1PPtL/20190312-000157.jpg (https://ibb.co/kgW44vj)

https://i.ibb.co/GWwS3Mh/20190312-000355.jpg (https://ibb.co/Yc9sTdr)

https://i.ibb.co/GR2y4nr/thumbnail-20190312-122821.jpg (https://imgbb.com/)

https://i.ibb.co/n6QBmK7/thumbnail-20190312-123042.jpg (https://imgbb.com/)

https://i.ibb.co/wgLkbjQ/thumbnail-20190312-123127.jpg (https://imgbb.com/)

[RedArrow]

Good work. Did you renew the o-ring in the heater hose flange at rear of block?

Good point. I forgot that when I refurbed my engine.

[volvo_d24t]

Hello, it's been a while since a posted updates of my project, but here is some new pictures of the on going process since few months ago. Engine and transmission is in the car right now. Now waiting for a m46 output flange to match with the driveshaft that was already in the car with the old ZF auto trans. Then I will take some measurements and send the driveshaft in a shop for shorten... Will have some wiring to do later... BTW is there anybody having a wiring diagrams of the engine?

Thanks,

https://i.ibb.co/Vx3R6hR/Screenshot-2021-10-17-16-47-26-548.jpg (https://ibb.co/jzHmtxm)

https://i.ibb.co/NTc8mrh/received-1039258726840722.jpg (https://ibb.co/8Y1Wdb3)

https://i.ibb.co/b3smfwf/received-274768217717045.jpg (https://ibb.co/SxtyLYL)

https://i.ibb.co/2yBS57x/received-768290837169423.jpg (https://ibb.co/9NjhG96)

https://i.ibb.co/zf3vb48/received-322174886088986.jpg (https://ibb.co/7y3mV1g)

https://i.ibb.co/vJ1sf65/received-571387004009310.jpg (https://ibb.co/K96NBpZ)

https://i.ibb.co/zx9NRcC/received-176351761344846.jpg (https://ibb.co/DWcLCXm)

[ngoma]

Very nicely detailed! Downpipe shows considerable skills-- yours?

Where are you planning to put the boost gauge?

Can't quite tell from your latest photos if your IP includes the LDA (for managing boost fueling)(actually, it cuts excess fueling under no- or low-boost conditions).

The engine wiring schematics I have seen (Haynes, Chilton manuals) are not always that helpful. Luckily the diesel engine wiring itself is not complex. The most complicated area is the GP relay wiring. Is your wiring harness deteriorated to the point it can't be trusted?

[volvo_d24t]

Very nicely detailed! Downpipe shows considerable skills-- yours?

Where are you planning to put the boost gauge?

Will put the gauge inside the cab. maybe on the dash...
My friends made my downpipe in our little shop. it's tig welded with some good grade 316ss 3inch straight pipe

Can't quite tell from your latest photos if your IP includes the LDA (for managing boost fueling)(actually, it cuts excess fueling under no- or low-boost conditions).

Correct. The pump does'nt have a LDA on it. I will try it out.... will have to control the smoke on low boost condition with my right foot.... If it smoke too much I will put a LDA pump... I'll see what it does with load.

The engine wiring schematics I have seen (Haynes, Chilton manuals) are not always that helpful. Luckily the diesel engine wiring itself is not complex. The most complicated area is the GP relay wiring. Is your wiring harness deteriorated to the point it can't be trusted?

I found a part of the wiring diagram in the greenbook. I can share some pictures, these can be very handy. With the wires color and pin # it's not that complicated.

You can go see my profil on imgbb, easier to share. I will try to post the complet rebuild I have in pictures.

https://volvo-d24t.imgbb.com/

https://i.ibb.co/zGk0QMC/thumbnail-IMG-20211018-155733.jpg (https://ibb.co/0hwdm71)

https://i.ibb.co/6HRTzwM/194430695-3794540534008263-8249418341426880886-n.jpg (https://ibb.co/k4gwjB7)

[ngoma]

Correct. The pump does'nt have a LDA on it. I will try it out.... will have to control the smoke on low boost condition with my right foot....
Will be curious to see if you can find a balance. My guess is that if you set for good WOT performance it will smoke excessively during most other conditions. Depends on your plans for usage.

If it smoke too much I will put a LDA pump... I'll see what it does with load.
Since all the LDA "logic" is contained in the IP top cover, you should be able to swap in an LDA top cover and go from there, instead of a full IP swap.

Yeah that deteriorated wiring is a casualty of the Bosch biodegradable wiring Volvo used during those years. You may find additional issues in other parts of the car where the wires are stressed, i.e. the wiring that gets flexed where passes into the doors, etc.

[volvo_d24t]

First time doing 1st and 2nd gear pull since fresh rebuild:

https://youtu.be/Sx6LupJijHc

Few volvo at the shop.
from left to right:
-960 b230ft 16V
-green 940 stock b230f auto
-745 d24t m46
-740 v8 350
-745 d24t auto
https://i.ibb.co/GWGjtnd/253208376-4284559668339678-2303826378695270433-n.jpg (https://ibb.co/2vRBsWF)