How'd you Intercool your D24T?

[Eli]

*** Please keep this thread uncluttered by keeping discussion to a minimum. I would like this to be a "how to" resource with pics and info only. Thanks, Jason***


Since this is an obvious improvement over stock, and so many people seem interested in this modification, I though I'd start a thread showcasing installs.

I'll start.

The car in question is a '79 245 - D24T+ic. More info can be found Here. (http://www.d24t.com/showthread.php?t=220)

I converted to a D24 N/A intake manifold and N/A valve cover (for oil fill location) Then used an eBay 3" intercooler, eBay 2.5" intercooler piping kit, custom fabbed mounting brackets, Silicone 90 degree bending reducers on intake and turbo outlet, cut down intake hoses from a F150 (for bending reducers) on intercooler. I ran out of pre-bent pieces and had to have the bend under the battery pan done. It is not mandrel, so it will be replaced at some point.

http://i195.photobucket.com/albums/z290/EliMailey/IMG_1377.jpg

http://i195.photobucket.com/albums/z290/EliMailey/IMG_1375.jpg

http://i195.photobucket.com/albums/z290/EliMailey/IMG_1379.jpg

http://i195.photobucket.com/albums/z290/EliMailey/IMG_1381.jpg

I think it turned out pretty nice.

http://i195.photobucket.com/albums/z290/EliMailey/IMG_1575.jpg


How did you do yours??

[Slobodan]

I started off my Intercooler setup with the Gas Audi 5000 Turbo Intercooler, It was allright better than None. I didn't like it or the piping. So I next tried the 240 Turbo intercooler flipped it up side down, and used alot of piping. results slightly lower boost. more boost drop, slightly cooler enging temps. then I tried out the SAAB 9000 Turbo intercooler I saw a better design in the core and end tanks. noticed a bit of performance increase with that..... Then I decided that I was wanting to clean up my setup. Lets just do it right?

I saved up some money, and bought an Ebay same side IC 2.5 in and outs. 3.5 core thickness with a 6x18 lxw.. Mounted it, and reinstalled the stock turbo. WOW huge difference. much more torque with virtually zero pressure drop from this IC.

http://www.d24t.com/picture.php?albumid=1&pictureid=34

http://www.d24t.com/picture.php?albumid=1&pictureid=37

http://www.d24t.com/picture.php?albumid=1&pictureid=38

http://www.d24t.com/picture.php?albumid=1&pictureid=36

And For piping, Its pretty simple. Allthough, I would like to get all 2.5 inch pipings. Hot side is two SAAB 900 IC pipes mated together, then another SAAB pipe with a transition coupler to IC.

Cold side misc 850 turbo piping with a 90 coupler and then I transitions to the N/A manifold.

[Jason]

Here are some teaser pics of the parts I have been collecting. Once my NA manifold is here, I'm going to do it up, assuming its not 12 degrees like it is right now. Its all 3" tubing, and the intercooler is a delta fin 25"x7"x3" Should be a pretty nice setup!


http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0388.jpg

http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0389.jpg

http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0390.jpg

[Jason]

Here it is! My intercooler setup. The cooler is 25x7x3, with 3" inlets and outlets. The tubing is all 3". Yes its bigger than it needs to be, but the NA manifold is a 3" inlet so I figured it might as well all match, and it loooks cool.

If you look closely at the air dam, I cut out the three air intake areas to the full size that is sort of stamped into them. Before there was extra plastic flashing at the bottom and top that made the area about half as big as it could be. It should alow more air flow and most importantly, you can see more of the intercooler! Comming up through by the battery was easy, I cut the thin sheet metal panel behind the headlight just ahead of the battery, and cut into the flat area of the engine compartment that attaches to that just a little bit. There was plenty of space to get the 3" tube up through there. To take the pipe across the front of the engine, I notched out about a 1" deep area of the fan shroud so the tube could fit down in the gap between the engine and radiator. I'm pretty happy with the results, it came out pretty clean!

http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0396.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0397.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0398.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0401.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0402.jpg
http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0413.jpghttp://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0395.jpg

[Jason]

Thanks! Cant wait to install and and really feel the potential of the setup... Its still necked down to 2" at the manifold.

I also forgot to mention the charge pipe to the intercooler. It doesn't show in that pic, but I reclocked the turbo 180 degrees out from where it was, so the outlet was pointing towards the ground (slightly at an angle really). Anway I came off it with a 90 and then forward up to another 90 to the intercooler. Keeps the engine compartment clean and less tubing around the turbo now that its running under the car. This will also leave more room for the compound setup.

The results? Boost is the same, it spools maybe slightly slower on the way up to 10lbs but not much at all. I do get a little turbo bark now when i let off if its making at least 15lbs off boost. Not too good for the turbo but it sounds cool! Also the pull once the turbo spools up is awesome! The butt dyno confirms there is a pretty big difference. I'm pretty sure its not wishfull thinking, it really pulls stronger!

Jason

[Eli]

Awesome work Jason, very clean install.

[Jason]

Thanks, everyone that looks at it now thinks its a 10 sec car when you see the crap on the engine!

Jason

[Jason]

http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/102_0407.jpg

http://i1004.photobucket.com/albums/af168/vwjunkie53/volvo/100_2504.jpg



Well all done, NA manifold is on thanks to Kevin, and its all good silicone boots and stainless T-bolt clamps. What a difference the NA manifold makes WOW. Builds boost faster, has better off boost torque. Great upgrade I wish I did it a while ago. Even without a intercooler it would be a good upgrade!

Check out the burn out vid in the videos section...

Jason

[Slobodan]

That is looking absolutely SICK. Nice work man!

[Benzsc1]

Wow Jason looking hot!! Do I spy a breather set up with a Fuel cap off of a VW Bug on there???

Am really liking how tidy your engine bay is. I am starting to build out my D24TIC am now thinking about sticking with an N/A manifold if what you are saying is right that it really is much better and less restrictive than a standrda D24TIC manifold


Si :)

[Benzsc1]

Also just noticed your Cam cover is the other way round to mine on the LT truck my oil filler is at the pump ened of the engines I take it on the Volvo D24 they turned it round for easier access??

Si :)

[Jason]

Thanks! I don't know if the NA manifold would be much better than the factory IC manifold, its a great upgrade over the stock non ic turbo manifold. You may still gain some power thanks to the longer intake runners and if the inlet facing forward would help you out it may be worth installing. There is a write up on how I built the breather (actually an oil seperator). Its a fuel cap off a early '60s vw bug. I used it just becuase it was the right size and the stamped vw logo looked cool. Since it IS a vw diesel after all, why not!

Jason

[240diesel]

This topic looks nice to me!
I did enjoy the storys i read here.
So i diceded to contribute some pictures / words of my build.
(sorry for my poor language)

The intercooler you're looking at is from a DAF-truck and shortened at top and bottom to fit into my 245.
Because the in-and-outlet-pipes were far to big i made new ones from 65mm aluminium pipe.
I'am lucky my boss bought a brandnew aluminium-weldingequipement so welded everything togheter....

http://i141.photobucket.com/albums/r66/240diesel/leer/P1250002.jpg

I'm sorry not to have pictures of the sockets i welded on the in-and-outlet of the IC.
This sockets i used later to fit the temperature-sensors i made for measuring the IC-effect.

http://i141.photobucket.com/albums/r66/240diesel/leer/P1250003.jpg

Also ordered t-bolt clamps for thight fitting.

http://i141.photobucket.com/albums/r66/240diesel/leer/P2230009.jpg

When finished, i pressurised the IC with 2 bar to be sure the IC withstands the workingpressure of approx.1 bar.
PLEASE BE CAREFULL, WHEN DOING SO PLACE THE IC AT A SAFE PLACE AND DISTANCE BEFORE PRESSURISING THE IC VIA A LONG HOSE.
SO IF THE IC EXPLODES NOBODY GETS HURT!!!!!

Next part, fitting into the car;

http://i141.photobucket.com/albums/r66/240diesel/d24tic/P7230073.jpg

The pic. above shows the turbo i started with, now already replaced by a original D24TIC-turbo;

http://i141.photobucket.com/albums/r66/240diesel/d24tic/P8140089.jpg

http://i141.photobucket.com/albums/r66/240diesel/d24tic/P8140088.jpg

(Above pics from the new turbo)

http://i141.photobucket.com/albums/r66/240diesel/d24tic/P7230075.jpg

As you can see on several pictures, the IC won't fit, so i cut out the front plate and placed the IC...

http://i141.photobucket.com/albums/r66/240diesel/d24tic/P7230076.jpg

The piping of the IC circuit; i made it from exhaust-pipe 65mm (also VW, comes from brandnew VW LT's wich are
equiped with loadlift so the last meters of exhaustpipe were getting in the way of the lift)

http://i141.photobucket.com/albums/r66/240diesel/d24tic/PA010047.jpg

I made The piping (while i was preparing the swap D24 >> D24TIC , (i used the front of my scrapped '87 245 for that purpose.)

http://i141.photobucket.com/albums/r66/240diesel/d24tic/PA020049-1.jpg

I realise that i don't have a picture of the piping to the inletmanifold.....
I only have a bad picture ,you can see the D24TIC manifold, piping stil not powdercoated.

In the next days i will try to add some pictures from that part.

About the IC-effect on the temperature;
When cruising 120 KM/hour the inlet-temp. at the IC (air coming from turbo) is about 95 Celcius, while the outlet air is doing
37 Celcius. (Temp. outside the car is 25 - 30 C)

[Jason]

Man must be nice to be able to pic up a factory IC manifold over there! The NA manifold does work pretty well. Nice job! I too was surprised what a difference the intercooler made, and I just used a cheapo ebay one! I don't have any actual temp data other than from feeling it with my hand, but on a cool night after running the car hard, the inlet is hot and the outlet was a good amount cooler, much more of a difference than I expected. It really helped add some power, especially on hot days when the engine was much more doggy.

Jason

[240diesel]

I just came back of a vacationtrip in Germany (sow only 1 245 D24) and measured the highest temp between the turbo and the intercooler; 120 C it's 248 F.
The intercooler cooled the air back to 37 C / 98 F.
It was a warm day and the volvo was towing a folding caravan, 3 persons and bycilcles on the roof uphill D24TIC at 3000 rpm, 3rd gear, boost about 1 bar.
So this IC seems to be doing a good job.

[Jason]

Sweet, a D24Tic doing some work! Have any pictures of the car with the bikes and trailer on it?

Jason

[Zoupop]

hi im new in this forum and my english is not perfect.

i just buy the 740 d24 turbo of my grand-father but i want to make it intercooler. So is that bether if a I buy a tic manifold,buy an N/A manifold or i keep the manifold same and I do all the modification to fit all the piping??

Thank

[Jason]

Hello and welcome,
I would run either the factory TIC manifold, or the NA manifold. I think the NA manifold has a nicer flowpath, and helps with torque thanks to the longer intake runners built in. If you could find the manifold and piping off a stock TIC car, it would be easier to install. Using the NA manifold will mean you have to make the charge piping.

Jason

[Zoupop]

but can i modify mine? like by making the new in let in front like a N/A one??

[Jason]

You can but there isn't much room there to make the inlet very big. I got a nice performance increase by going to the NA manifold. The na and TIC manifolds aren't all that expensive, and there are many more of these cars and parts over where you are. That stuff should be easy to find.

Jason

[casioqv]

The NA manifolds are going to get hard to find... The TDI guys discovered they can be modified for a TDI, and now they're selling for $150+/each on TDIclub.
http://i204.photobucket.com/albums/bb18/fenwick458/CIMG0224.jpg

[Jason]

Tell them to stay the hell away from our manifolds!!!

What is the manifold on the left??

Jason

[casioqv]

Tell them to stay the hell away from our manifolds!!!

What is the manifold on the left??

Jason

Not sure, but I would guess a VW inline 6 of some sort out of a non-volvo.

[Jason]

Oh I thought this was a picture you took of manifolds you had... Maybe thats a na manifold from a LT truck... It would make sense that its a lower profile since the engine is under the front seat pretty much.

Jason

[casioqv]

Oh I thought this was a picture you took of manifolds you had...

Nah, just grabbed it from tdiclub. More pics:
http://i204.photobucket.com/albums/bb18/fenwick458/IMG_0534.jpg
http://i204.photobucket.com/albums/bb18/fenwick458/IMG_0538.jpg
http://forums.tdiclub.com/showthread.php?t=276296&highlight=d24%2A

[DWL_Puavo]

Quite offtopic, but there's quite plenty of room under LT "hood", the passenger seat sits directly on the plastic engine cover. LT n/a manifold is quite high and has long runners, and as I know, there's only one type of them. It's supposedly higher than any Volvo OEM manifold. BTW - n/a d24 LT -84 car hauling truck with 3 passengers and 800kg race car on top - it takes about 1min 30sec to get to 100kph :)

I have a friend who's cutted LT n/a manifold and welded it into 4-cyl, then cutted the runners and added few aluminium straight and 45 degrees pipes to them to go directly over valve cover, and then attached to some bike's throttle bodies. That's gas engine of course.

Another of my friends cutted the LT manifold onto Seat td, had headwork, methanol injection (with ordinary glass cleaner fluid!), Garrett GT2xxx something turbo, modified VE pump etc. That made 200+ hp and was fun to race with my '87 911 on the 1/4 mile strip - 911 had one second lower ET (15.2 for the seat) but the same end speed 159kph :)

[Zoupop]

where can i get an N/A manifold??And for how much??

thanks

[Jason]

They are on the non turbo D24s.. Not sure what you can get one for where you live, but over here I wouldn't pay more than $50 or so.

Jason

[anders]

My 83 244 now D24TIC.

[michaelovitch]

You need that now !


You have to.
the airflow will say thank you.

http://i685.photobucket.com/albums/vv215/michaelovitch/D24%20NA%20volvo%20245/047.jpg

[chad1966]

Waiting on a few more 45's and some clamps and it will be icered!!!!

[swital]

How to and which intercooler i can mount when i have an A/C ? I think about IC from bmw e60 3.0d

[swital]

I mount IC from BMW E39 530d

http://i.imgur.com/PnX8Lnb.jpg
http://i.imgur.com/k9PbMLZ.jpg
http://i.imgur.com/DJ1SBHv.jpg
http://i.imgur.com/0iUEj58.jpg

http://i.imgur.com/tWxUHEY.jpg

http://i.imgur.com/OoipZKZ.jpg
http://i.imgur.com/jbutO7Q.jpg
http://i.imgur.com/gNnVV9z.jpg
http://i.imgur.com/rqDQUnp.jpg

[ngoma]

I like how the photos really highlight the new plumbing, it really stands out from the rest of the car, almost like it was Photoshopped!

Can you report any performance improvements?

[swital]

First I must go to dyno and check. It's running on 1.2bar, we will see.

The original air box had to removed and changed by a cone.

http://i.imgur.com/6t2ZaeQ.jpg
http://i.imgur.com/xvwzEUl.jpg
http://i.imgur.com/zIjucP1.jpg

[BluevanACD2005]

Good job! :cool:

[S&W 629]

Yeah, great work. I'm going to duplicate you air filter replacement.

[volvo-dennis]

Hi Guys.

I have also Intercooled my D24+T this weekend. I had two options = NA manifold or original D24TIC manifold. I went with the TIC manifold. I thought it would be easier to make all the plumbing, by using that. I also wanted to keep a good airflow in the system, so thats why there are no "sharp" bends.

All the piping is 2", and the intercooler is a universal eBay type.

I'll post some pictures, and let them speak for themselves :)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/020_zpswvpincsb.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/020_zpswvpincsb.jpg.html)
...The eBay Cooler..

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/035_zpsryoldsyj.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/035_zpsryoldsyj.jpg.html)
Right about there...

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/042_zpse6bcga8t.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/042_zpse6bcga8t.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/060_zpsl4bf3ers.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/060_zpsl4bf3ers.jpg.html)
...I decided to keep on doing the green coloured theme.

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/080_zpsqhk5gsib.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/080_zpsqhk5gsib.jpg.html)
Made some brackets for the cooler. They were not made as they were ment to be, because I had to have in mind that there also is an oil cooler in the way.

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/081_zpshrao5u91.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/081_zpshrao5u91.jpg.html)
Old "T" manifold (right) vs. "TIC" manifold (left)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/084_zps0rrh9z8q.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/084_zps0rrh9z8q.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/097_zpsbmotdrf0.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/097_zpsbmotdrf0.jpg.html)
All the piping is just 2" exhaust parts. They will be painted when the pipes are done.

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/105_zpsbhqppxyx.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/105_zpsbhqppxyx.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/107_zpszs9krb0t.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/107_zpszs9krb0t.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/112_zps2wmynwwp.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/112_zps2wmynwwp.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/115_zpsjoxdhdlo.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/115_zpsjoxdhdlo.jpg.html)
Mr. Spoiler was to be modified...

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/126_zpsmuoac83a.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/126_zpsmuoac83a.jpg.html)
What do you think of the "740" writing on the cooler? Too much?..

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/128_zpsoc8zi91u.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/128_zpsoc8zi91u.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/129_zpsuweatzvm.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/129_zpsuweatzvm.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/134_zpshwitrlsr.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/134_zpshwitrlsr.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/135_zpsf9zfiavi.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/135_zpsf9zfiavi.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/133_zpshdc8kkck.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/133_zpshdc8kkck.jpg.html)

http://i1295.photobucket.com/albums/b639/volvo-dennis/Intercooler/130_zpsxaybcnpt.jpg (http://s1295.photobucket.com/user/volvo-dennis/media/Intercooler/130_zpsxaybcnpt.jpg.html)

/Dennis

[ngoma]

Nice work!!! Those pipe bends sure are smooth! Will be interested to see the performance/temperature improvements.

Personally not a fan of extra badging, logos, nameplates, etc. but that is just my preference. You did a clean job on yours.

[BluevanACD2005]

Wow! Nice work for sure!

I do like that green color.

Not really a huge fan of the '740' to be honest, but it's not too flashy either.


Spenser

[volvo-dennis]

Thanks guys for your honest opinions. I have removed the '740', it looks much better now :D

[BluevanACD2005]

I have removed the '740', it looks much better now

You didn't have to do that lol it was just our opinion - Making the car 'yours' and unique is what it's all about!

Spenser

[volvo-dennis]

I know! :) I was in doubt, so thats why I asked you guys ;)

/Dennis

[Brekizer]

Thanks guys for your honest opinions. I have removed the '740', it looks much better now :D

I personally liked it :(

But great job on intercooling it, I think I'm going to do it in the same way.
I would prefer a bigger intercooler but as far as I can see it would be quite a big job with the stock airfilterbox installed.

[Impolvo]

Took some snaking to clear hood and ps pump
And the 262 coolant hoses
https://i.imgur.com/VAAXB9m.jpg

[Impolvo]

Well I upped the boost to 20somethinh
Popped the cap off the na intake rear lol