1983 245 D24 to D24T

[verdigo]

Im sort of in the middle of this engine swap. Seems like there ar some experienced folks here. Im pretty new to the D24T but have owned a number of old Volvos. I have already done this to my VW Rabbit truck, and the power difference is so much needed just to contend with today's traffic. I have a D24T from an 84 760 which needs oversized pistons in a bad way. Still sorting a source for those out. Im not familiar with the different transmissions but the 245 has a 4 speed with the OD unit. M46 I think. Works but is making some noise. Anyway here is the 245. Solid, no rust, a quarter million miles. The current D24 is tired and runs like a slug trying to get away from a salt shaker.
http://i1000.photobucket.com/albums/af125/verdigo59/Picture002.jpg
Here is the Caddy. Still in progress.
http://i1000.photobucket.com/albums/af125/verdigo59/Picture007.jpg
Here is the D24T beit came out and was tore down
http://i1000.photobucket.com/albums/af125/verdigo59/Picture002-2.jpg

[Slobodan]

D24T sits more upright, and the D24 is slanted a bit.

I found it easier to mod the 240 cross member so my D24T sits almost straight up. but more like in between where the 760 and 240 D24's sit. I did this so I had more room for the compressor to fit. I've heard of people having issues with the turbo fitment when they leave the D24 sitting in the original position in the 240's.

So, I not only had to mod the crossmember but I HAD to use the D24T bell housing for the M46 transmission. the transmission sits at a slant away from me. So the stick leans more towards the passenger, I could mod the shifter holder and rod to sit in the stock location but I don't care. Its fine.

I love my D24T + 240!

[v8volvo]

Where are you located? Somewhere rusty by the looks of that D24T... I have a motor from Pennsylvania that looks similar to yours.

Do you still have the rest of the car the turbo motor came out of? Was it an automatic or a stick? Looks like an auto, I think I see a kickdown cable there, but if it's a stick you might be better off finding a nice 7 series wagon to use as a starting point for the swap. They are nicer cars than 240s, and the motor will fit much better -- you won't have turbo clearance issues, and D24Ts in 700s also have room for a clutch fan up front, easier access to the rear belt, etc, etc. Some people prefer the look and feel of the 240, though, and if you're one of those people nothing I can say will convince you that the 700 is a superior automobile, no matter what the truth may be. :D

If your 760 is a stick and you do want to use the 245 as the car the motor ends up in, you can swap bellhousings and use the 760 trans with the 240 BH. That will solve your noisy tranny issue.

[verdigo]

I was under the impression when I started this project that it would be a straight up swap, and that the externals on the D24, and D24T were the same when it came to the block for transmission mounting and engine mounts as well. The 760 had an automatic trans. Its good to hear these things before I get to work though. I went out and looked at the 240 and I see where there might be a problem with the Turbo clearance.

[Slobodan]

Tell you what, ship the car to me, and I'll put it all together! :)) I love doing these swaps. I get to be creative :) Not a hard task at all.

[verdigo]

Tell you what, ship the car to me, and I'll put it all together! :)) I love doing these swaps. I get to be creative :) Not a hard task at all.

No thanks but will it bolt in at the 240 slant with the NA transmission? I'll deal with the turbo another way if needed.

[Slobodan]

Get a D24T M46 bellhousing. Use it. Use the D24T pass side engine to mount bracket and use the pass side 240 D24 crossmember to mount bracket.
Hack up and chop out a section of crossmember to accomodate the D24T oil pan. Doing this will prop up the engine enough for proper turbo/frame rail clearance. The transmission will sit slanted but its mighty fine. You may need to shim up the transmount to move the transmission up a bit to get the engine to sit more level North/South. View my D24T into 240 thread. You can also check out my Photo gallery. You should be able to see it.

[verdigo]

No. I think I will use the NA oil pan, and weld in an oil return bung for an oil return fitting. Thinkin about trimming that frame rail.

[verdigo]

Where are you located? Somewhere rusty by the looks of that D24T... I have a motor from Pennsylvania that looks similar to yours.

Do you still have the rest of the car the turbo motor came out of? Was it an automatic or a stick? Looks like an auto, I think I see a kickdown cable there, but if it's a stick you might be better off finding a nice 7 series wagon to use as a starting point for the swap. They are nicer cars than 240s, and the motor will fit much better -- you won't have turbo clearance issues, and D24Ts in 700s also have room for a clutch fan up front, easier access to the rear belt, etc, etc. Some people prefer the look and feel of the 240, though, and if you're one of those people nothing I can say will convince you that the 700 is a superior automobile, no matter what the truth may be. :D

If your 760 is a stick and you do want to use the 245 as the car the motor ends up in, you can swap bellhousings and use the 760 trans with the 240 BH. That will solve your noisy tranny issue.

Gonna stay with the 240. The 760 came out of a field in TN. I no longer have the car. Im going ahead and building the turbo motor, and if I have too I may run it for a while as an NA if the turbo gives me much clearance issures. Once I see it in there, I will know more. The older 240s have less junky Volvo plastic to crack up.

[verdigo]

There are lotsof ideas here!!!!!!!!!
but people seem to be very casual with this site!!!!!!!!!!!!!
Any body interested in a joint venture ?
I got some stuff to share

Explain joint venture. To update the thread, I now have a new set of .050 OS pistons and the block is being bored. I plan to post pics of the build. Pistons cost me $95.00 a piece. Took a while to shop and build up the play $$$

[verdigo]

Kobenschmidt .050mm OS. They have oil squirter notches for both D24T, and VW 1.6TD.http://i1000.photobucket.com/albums/af125/verdigo59/Picture006.jpg

[verdigo]

Got my block back crank is still standard. Parts are high $ for this sucker
http://i1000.photobucket.com/albums/af125/verdigo59/Picture008.jpg

[Jason]

Who did you end up finding German piston from for that price?

Jason

[cuaz64]

Who did you end up finding German piston from for that price?

Jason
Maybe with this guy:

http://www.thedubdoctor.com/parts_site/idiparts.html

[Jason]

He must be selling old stock. My cost at work through an importer is almost 100 a piece...

Good deal for sure.

Jason

[verdigo]

Who did you end up finding German piston from for that price?

Jason
Same as you. Could have gotten them cheaper but I procrastinated too long. and the price went up.

[verdigo]

My crank is washed, and polished. This engine had a double ring groove,f but the main and rod bearings had no visable wear at all. The crank is beautiful, solid steel. The thing weighs a ton.

[verdigo]

Got my crank torqued down. 48ft/lbs. Couldn't find a torque spec on the oil squirter bolts, so I used a bit of lock tight, and cranked em down with a 1/4 inch ratchet. http://i1000.photobucket.com/albums/af125/verdigo59/Picture011.jpg

[verdigo]

http://i1000.photobucket.com/albums/af125/verdigo59/Picture019.jpg

[verdigo]

My D24T Head is toast. I am planning on using my D24 Head instead, and was wondering what or if there were any differences in the two other than the cams, (which is suppose to be an up grade). ???

[Jason]

Same thing, assuming it is not a early head for 11mm head bolts. I just finnished taking measurements of my new NA cam, I'll be compairing to my stock TD cam when I take my other engine out and see if it really is any bigger.

jason

[v8volvo]

Supposedly there were some differences in terms of material. The aluminum alloy used for the TD head casting is supposed to be of a slightly different composition to better withstand heat, and the exhaust valves are silicon-filled for better heat transfer as well. Likely not a big deal though unless you are abusing the motor.

The other difference is that the TD head has a coolant flange on the back for connecting to the oil cooler sandwich plate, that the NA D24 head does not have. It wouldn't be hard to pop out the plug back there and drill and tap a hole to make it work, or you could switch to a true oil-to-air heat exchanger using the sandwich plate off a redblock turbo Volvo motor (B230FT). That requires some new lines and some fabricating but it's a good idea for the long term.

A D24 head ought to be fine on the D24T if installed well and used without too much abuse... meaning no huge boost pressures, keep the cooling system in good shape, and make sure you get the timing right (too advanced can be hard on the head in terms of pressures and heat). If you are careful about those things, it will likely do great.

[Jason]

Ahh forgot about the coolant flange. Hadn't heard there was a difference in material though.

Jason

[verdigo]

The NA head has a freeze plug where the coolant flange is on the turbo head. Cool beans, so far so good. Tearing down the NA engine today. I'll be running it as an NA while figuring out the turbo clearance issues.
Dennis

[verdigo]

Money pit.http://i1000.photobucket.com/albums/af125/verdigo59/005.jpg

[verdigo]

The other money pit. http://i1000.photobucket.com/albums/af125/verdigo59/001-2.jpg

[Jason]

I see a nice looking late 50s maybe early 60s bug sitting there in the background... What is it with volvo people having air cooled vws too?? Seems like many pictures I've seen over on turbo bricks have air cooled vws in the background too. Kinda interesting..

As for money pit... I know the feeling, but really it was worth it, the new engine runs SO damn good!

Jason

[verdigo]

The Bug is a 61 Delux Ragtop that belongs to a customer. I'v had more Bugs and Buses than I can remember though. Now Im older and enjoy heat on other parts of my body instead of just my left foot. Oh yeah I like defrosters as well. The 245 will have functioning A/C whenever I get time to finish it up.

[Jason]

I've still got my bug, you've probably seen parts of it in the background in many of my pictures in the garage. Yes heat, a/c, defrost are a big plus... When I was 16 and first driving my bug, I said I would never drive anything but a air cooled VW... Ha! ya right.. I woke up at about 18 and bought a normal car for a daily beater and built a bigger engine for the bug so I could waste the ricers and V8 guys on the weekends...

Jason

[verdigo]

Ah ha. Thats where the vwjunkie handle came from. Here's my air-cooled sign on my shop. http://i1000.photobucket.com/albums/af125/verdigo59/001-3.jpg

[Jason]

Ha! Sweet, we have half a dune buggy frame hanging off the front of our building... Air cooled VWs have always been my primary passion and hobby, but diesels are second place for sure... The whole reason I got the volvo in the first place was because it was a VW diesel engine, and I have had a few diesel jettas and whatnot and knew the fun you could have with them after a little pump work and some extra boost!

My bug was just featured in the Dec issue of Hot VWs.. Thats the REAL money pit there, but man the fun I have with it. Unlike the volvo, its actually fast! lol The volvo is just blasts smoke and makes noise, but its fun for a daily beater.

Jason

[verdigo]

Pictures and progress bump. Not as pretty as Jason's.
http://i1000.photobucket.com/albums/af125/verdigo59/041.jpg
http://i1000.photobucket.com/albums/af125/verdigo59/014.jpg

[verdigo]

It has been a while getting back on this. My turbo fits.
http://i1000.photobucket.com/albums/af125/verdigo59/IMAG0182.jpg

[Grubby]

I have a 245/d24t swap car and I'm loving it. Regarding turbo/frame rail clearance, I just shimmed the pass. side mount up about a half inch or less and it doesn't hit that rail. Works great. Is yours on the road yet?

[verdigo]

Not yet. Should make some progress this weekend. My stock turbo clears the frame rail even with the old mount.

[v8volvo]

Looks nice!

I like your #6 glow plug wiring setup. Certainly would make taking the IP bracket or cylinder head on and off easier. Not that you would want to be planning to do either of those jobs... but if it were to come down to it, not having to struggle with the GP nut and bus bar dance back there would save some time and annoyance for sure. :p

Abe, is your TD 245 on the road now?

[anders]

Wow, with all these 240 D24T swaps I think there will end up being more D24T powered 240's then there are D24T powered 740/760 cars! Looks good.

[verdigo]

240s are tanks. There simple, well designed, and easy to maintain. They are just ugly. Thanks.

[verdigo]

All done except for the intercooler and bumping up the boost. Huge improvement over the old D24. I just nochted the frame for the turbo clearance.