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240diesel
09-14-2009, 11:16 AM
The story below i wrote in dutch for the dutch volvo240 forum volvolvo
I gave google translations a try and i'am wondering if you all can understand what i ' am trying to tell.
I there are any points of disunderstanding please let me know, then i try to make it clear in other words.....

Since I always like reading the reports of others (preferably with photos) I also will place a story;


My newly built D24TIC engine began to run so irregularly that I began to do some diagnostics (with the help of my colleagues)I am a metal-worker but work for almost 7 years at a local truckshop where we repair DAF trucks, so I learn the diesel job step by step whith the help of them.
First you can (whith the engine running) losen up the injector pipes one at the time, beginning at front working to the end.
This interrupt the fuel supply to that cylinder, "So you switched it off"
Note that the fuel under is under high pressure and can penetrate with ease through your skin and then causing a hefty blood poisoning !
But if you loosen the 17mm pipe-nut with the open spanner you are far enough away to do the job savely.
If the engine it clearly responds to that cylinder is probably nothing wrong.
If you are a little guidance and solves the engine is running noticeably different to that particular cylinder is something going on.
This is only a rough diagnosis but can be useful to first exploration.
If 2 juxtaposition two cylinders located not or hardly react so you can have a head gasket between them beaten by 2 cylinders.

But to me this test was not accurate enough to upset the cylinder sufficiently to appoint.


Be sure that no fuel leaks from the pipes. (see above risk)
Then there is a trick, feel to current engine by hand, turns to all injection pipes.
If all lines equally hard beat (or even soft, whatever you want) can unfortunately distracted.
However, if one of the lines are significantly different "feel" can thus be designated spray sufficiently angry.

In my case it is perfectly tapped, turned out the spray bar 20 to assist vwb the high injection pressure.

So far the diagnostic tips (I hope that you can fiddle ...)

Replacing the nozzle (pipe) can still cause some head crushers.
I have therefore not attempted a step-by-step method to describe but a few more tips that do not (all) to find the books back.

Get more cable from the battery.
First make the environment very clean example with brake cleaner and then compressed to take along all loose connections.
Realize that your open-heart surgery about a run on your motor.Het slightest smudge spray can ruin all!

Remove your vacuum pump, the loose nuts M8 turns on what brand and that the pump would be pushed out by the nokas.
If your engine by hand and the ridge running through some of his lowest place, and the assembled that much easier.
By disconnecting the pump, the stylus pressure that often follows along the ridge to slip out, catch it and REMEMBER HIM NOT TO BE WITH YOU PLACES!



vacuum pump

http://i141.photobucket.com/albums/r66/240diesel/PC010024.jpg



The loosening of the leidingwartels the injectors are still with wrench and 17 mm.
The fuel injection pump is so little, that a key leadership is indispensable.
Even in places with it you can hardly make a stroke so I have an old key leadership on January 1 / 2 "welded cap.
Allows you the whole world .....
If you only want to replace injectors you can choose the leads to the pump and leave the tubes on the side to bend with any violence.
It is often done by some barbarians but I still choose to remove the leadership group as a whole.


Angle 14 + key management

http://i141.photobucket.com/albums/r66/240diesel/PB300014.jpg



Leidingwartels If you want to unscrew the pump is that it might be in for the press valve / check valve in the pump casing is rotating.
To prevent this, I also have a key 14mm entertained, sawed perpendicular and welded together.



fuel diameter

http://i141.photobucket.com/albums/r66/240diesel/pomp2.jpg



The above picture shows the valve that will run your stops him with a 14mm key.



Angle 14

http://i141.photobucket.com/albums/r66/240diesel/PB300013.jpg



If you plug the pipes removed all released holes or tape them off with painter's tape oid




atomizer next br.st. Pump

http://i141.photobucket.com/albums/r66/240diesel/PB300015.jpg



Create a high cap 27mm squeaky clean inside and remove the injectors.



cap 27 in action

http://i141.photobucket.com/albums/r66/240diesel/PB300016.jpg


Near the fuel pump is a piece of extension as shown on the picture VERY useful.
For other uses also!! (Father's Day, Mother's birthday, St. Nicholas, Santa Claus)


articulated extension piece

http://i141.photobucket.com/albums/r66/240diesel/PB300017.jpg


If you've removed the spray with a magnet or hall you lasdraadje perpendicular to the heat shields on the same road and you can see the glow plug.
You should therefore immediately the operation of the glow plugs to control than those without you having to disassemble.
Especially cyl. 5 and 6 are rather difficult to reach.

verstuivergat

http://i141.photobucket.com/albums/r66/240diesel/PB300021.jpg


The purpose of the heat shield is as the name treason, heat and defend the spray to be sealed to the seat bottom of the cup.
Since the shield itself is the combination seat / nozzle must be renewed with each replacement. (Few euros ea.)




The new injectors are ready to mount, one mechanic makes a lick kopervet to the thread, just not the other ......
Make sure you spray the bottom of the needle absolutely not damaged, the crook had heard BOSCH done it myself.


controlled injectors

http://i141.photobucket.com/albums/r66/240diesel/PB260009.jpg


The injectors hear tightened with a torque wrench to be (new heat shield underneath, and not his head).
The moment is 70Nm.


torque wrench

http://i141.photobucket.com/albums/r66/240diesel/PC010022.jpg



If your pipes back-assembled sets you swivels down to 25 Nm, the swivel at the injectors you have let loose even as it bled easily.

Jason
09-14-2009, 03:02 PM
Great write up, great pictures, but the english was a little rough... Without the pictures I think I would have been pretty lost. Is there another translation program that you can try, just to see how it comes out? Unfortunately, I don't think many people on here speak Dutch...

Jason

240diesel
09-15-2009, 12:47 PM
Ha ha i understand what you mean!
When i read the story in english, translated by google i also didn't know what the meaning was of some words or complete phrases.
I will try another program for translations but i think it will be difficult.

The alternativ is to write up directly in the best english i can but it takes me a lot of time, and i don't have much time now so more topics will show up when it's wintertime.

Jason
09-15-2009, 04:23 PM
Thats fine, I appreciate you taking the time to post up what you have. I have more stuff I would like to do to, but now is the time to be getting stuff done on the car while the weather is still nice.

Jason