d24t overhaul+mods
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/hzJRL7/211226...76761794_o.jpg https://preview.ibb.co/jgdLXn/volvo_d24t.jpg https://thumb.ibb.co/dKP0f7/22688516...39336303_n.jpg https://thumb.ibb.co/kQKY07/19420844...11696357_n.jpg https://thumb.ibb.co/in9Yk7/IMG_0025.jpg |
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. |
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______________________________________________ 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://preview.ibb.co/fjbeQ7/IMG_0033.jpg https://preview.ibb.co/e862dS/IMG_0029.jpg https://preview.ibb.co/iDYtk7/IMG_0028.jpg |
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://preview.ibb.co/d0FsV7/IMG_0040.jpg https://preview.ibb.co/e5Exxn/IMG_0037.jpg https://preview.ibb.co/fTQgOS/IMG_0046.jpg https://preview.ibb.co/ekAFiS/IMG_0048.jpg https://preview.ibb.co/hF3qHn/IMG_0049.jpg https://preview.ibb.co/bFdqHn/IMG_0044.jpg https://preview.ibb.co/dbQFiS/IMG_0043.jpg |
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. |
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_____________________________________________ 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://preview.ibb.co/eyNxiS/IMG_0078.jpg https://preview.ibb.co/jzcoOS/IMG_0077.jpg https://preview.ibb.co/dTbhiS/IMG_0074.jpg https://preview.ibb.co/cLNKxn/IMG_0065.jpg https://preview.ibb.co/nMS8q7/IMG_0064.jpg |
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. |
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________________________________________________ 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://preview.ibb.co/fQUttS/IMG_0097.jpg https://preview.ibb.co/fcsDtS/IMG_0092.jpg https://preview.ibb.co/f1Zhnn/IMG_0089.jpg https://preview.ibb.co/nqp407/IMG_0085.jpg https://preview.ibb.co/dJAzYS/IMG_0083.jpg https://preview.ibb.co/gqANnn/IMG_0098.jpg |
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? |
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____________________________________ Preparing cylinder head to disassemble, clean and inspect: https://preview.ibb.co/d6hFec/IMG_0116.jpg https://preview.ibb.co/hqETzc/IMG_0117.jpg https://preview.ibb.co/k4vqCx/IMG_0121.jpg https://preview.ibb.co/fCFqCx/IMG_0122.jpg https://preview.ibb.co/bFbaec/IMG_0123.jpg |
Those broken GPs are not a welcome sight. Did someone use starting fluid? Where did the pieces go?
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_____________________________ Cylinder head disassembly and cleaning https://preview.ibb.co/mv7Axx/IMG_0127.jpg https://preview.ibb.co/mcJiHx/IMG_0128.jpg https://preview.ibb.co/j9PZPc/IMG_0135.jpg https://preview.ibb.co/k7Hojc/IMG_0138.jpg https://preview.ibb.co/j0E7cx/IMG_0145.jpg https://preview.ibb.co/g0gncx/IMG_0147.jpg https://preview.ibb.co/kfR9qH/IMG_0150.jpg https://preview.ibb.co/hvc4Pc/IMG_0157.jpg https://preview.ibb.co/knSScx/IMG_0160.jpg |
Looks like you got some good injector nozzles. Are you going fit them and POP test them?
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OK then you will want to refurbish the injector internals as well:
HOW-TO: Rebuild Diesel IDI Injectors |
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________________________ 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://preview.ibb.co/isDZsH/IMG_0216.jpg |
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://preview.ibb.co/jFM4u7/AMC_1.jpg https://preview.ibb.co/nMJTMn/AMC_2.jpg |
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. |
Is the mating surface ready for a MLS head gasket? It looks smooth enough in the photos! What did it cost?
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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://preview.ibb.co/ku8yyy/IMG_0237.jpg https://preview.ibb.co/k3cDWJ/IMG_0238.jpg https://preview.ibb.co/kEMOWJ/IMG_0246.jpg https://preview.ibb.co/gbygJy/IMG_0257.jpg https://preview.ibb.co/hCUMJy/IMG_0255.jpg https://preview.ibb.co/nBBe5d/IMG_0258.jpg https://preview.ibb.co/fszoyy/IMG_0260.jpg https://preview.ibb.co/iFviWJ/IMG_0261.jpg |
Interesting. Did you find the remains of the 2 broken oil squirters in the oil pan?
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________________________ 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://preview.ibb.co/jkNxTy/IMG_0272.jpg https://preview.ibb.co/cmcmMJ/IMG_0273.jpg https://preview.ibb.co/bvcaFd/IMG_0266.jpg https://preview.ibb.co/dtfvFd/IMG_0267.jpg https://preview.ibb.co/bQrP8y/IMG_0274.jpg https://preview.ibb.co/fLCmMJ/IMG_0275.jpg |
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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 |
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. |
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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://preview.ibb.co/mi1vqT/block_machinist.jpg https://preview.ibb.co/c8MH4o/block_machinist2.jpg |
More pictures of the machinist shop. First quick wash of the block.
https://preview.ibb.co/hOK2u8/shop3.jpg https://preview.ibb.co/jubhu8/shop.jpg https://preview.ibb.co/fR20go/shop1.jpg https://preview.ibb.co/jR08Z8/shop2.jpg |
I love seeing them freshly painted "John Deere industrial green"
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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://preview.ibb.co/mgWDV0/20181030-192300.jpg https://preview.ibb.co/jT8Sq0/20181030-192420.jpg https://preview.ibb.co/bSRrHf/20181030-192426.jpg https://preview.ibb.co/h4r2OL/20181030-192432.jpg https://preview.ibb.co/hJjNOL/20181030-192254.jpg |
Often the hardest part is rounding up all the necessary parts. Looks like you got past that step. The rest should be easy. :p
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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://i.ibb.co/NNmtchn/thumbnail-20181113-111804.jpg https://i.ibb.co/8Ym5hy7/thumbnail-20181113-111816.jpg |
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://i.ibb.co/jgjPQcL/20181210-234915.jpg https://i.ibb.co/dDM06N6/20181210-234922.jpg |
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://i.ibb.co/5GMGw3p/20181212-212211.jpg https://i.ibb.co/R7zmdz4/20181212-212200.jpg https://i.ibb.co/8rTWK1m/20181212-212217.jpg |
Satisfied how the paint came out, continuing cleaning parts!
https://i.ibb.co/nMBkhdf/20181213-220937.jpg https://i.ibb.co/bd7QGjX/20181214-144043.jpg https://i.ibb.co/dgR4cJm/20181214-160556.jpg https://i.ibb.co/WxvqM94/20181214-165140.jpg |
Good work. Did you renew the o-ring in the heater hose flange at rear of block?
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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://i.ibb.co/QF1PPtL/20190312-000157.jpg https://i.ibb.co/GWwS3Mh/20190312-000355.jpg https://i.ibb.co/GR2y4nr/thumbnail-20190312-122821.jpg https://i.ibb.co/n6QBmK7/thumbnail-20190312-123042.jpg https://i.ibb.co/wgLkbjQ/thumbnail-20190312-123127.jpg |
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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-...-47-26-548.jpg https://i.ibb.co/NTc8mrh/received-1039258726840722.jpg https://i.ibb.co/b3smfwf/received-274768217717045.jpg https://i.ibb.co/2yBS57x/received-768290837169423.jpg https://i.ibb.co/zf3vb48/received-322174886088986.jpg https://i.ibb.co/vJ1sf65/received-571387004009310.jpg https://i.ibb.co/zx9NRcC/received-176351761344846.jpg |
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? |
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My friends made my downpipe in our little shop. it's tig welded with some good grade 316ss 3inch straight pipe Quote:
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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-I...018-155733.jpg https://i.ibb.co/6HRTzwM/194430695-3...26880886-n.jpg |
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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. |
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