Been busy again... New "Ram Air" intake and charge pipe!!!
 

Well, unfortunatly I haven't been able to come across a D24 NA manifold, and the stock T manifold is not the best setup for high performance with the sissy 1.5" inlet. Basicly what I did here was replicate the NA manifold since I felt the stock inlet was restricting me. Also the flow path of the NA manifold is much better under boost, with the air flow going directly in the manifold, rather than crashing into the top and tumbling around inside. The new charge pipe is mandrel bent 2" to match the compressor outlet. I cut off the snout for the old POS dump valve, and die ground it out to match. Since I didn't have a tig welder handy, I fabbed up a flange and drilled and tapped the manifold to bolt it down with. Here are the pics:
http://i1004.photobucket.com/albums/...3/101_0010.jpg
Difference between the T4 compressor outlet and the stock inlet pipe that slips into the manifold.
http://i1004.photobucket.com/albums/...3/101_0012.jpg My crappy connector showing how it was necked down into the manifold.
http://i1004.photobucket.com/albums/...3/101_0013.jpg
http://i1004.photobucket.com/albums/...3/101_0015.jpg
http://i1004.photobucket.com/albums/...3/101_0028.jpg
weld strip to keep the pipe from slipping out of the connector boot
http://i1004.photobucket.com/albums/...3/101_0027.jpg

Now its manifold time. After cutting off the stock dump valve flange and some die grinding:
http://i1004.photobucket.com/albums/...3/101_0018.jpg
Holes drilled and tapped, flange match ported and fitted:
http://i1004.photobucket.com/albums/...3/101_0020.jpg
Flange welded up with 2" pipe neck:
http://i1004.photobucket.com/albums/...3/101_0021.jpg
Finnished product, painted high performance RED!!!! To match my porno interior!!!;)
http://i1004.photobucket.com/albums/...3/101_0022.jpg
New intake setup! MUCH smoother and unrestricted flow path...
http://i1004.photobucket.com/albums/...3/101_0023.jpg
http://i1004.photobucket.com/albums/...3/101_0024.jpg
http://i1004.photobucket.com/albums/...3/101_0026.jpg

Not so much a difference spooling up, but on its way up from 10 to 15lbs of boost it really comes on hard now. I'll have qtr mile times tomorrow and video!

Jason

That looks great! Excellent job. Looking forward to your track info.

I just can adore the speed you build up your Volvo.
Again, we saw something new.
Is N/A manifolds rare in USA? As i know you guys
wrecked every single 200-series diesel, which were just d24's.

They are pretty rare around where I live, that is diesel volvos in general. They seam to gravitate towards the coasts and I'm in the middle of the US.

I had some free time on my day off and started getting ideas, and thought why not!

Jason

Looks great. How did you plug up the hole in the bottom of the manifold where the tube from the turbo used to slide in? You may eventually find that this is the best setup of all, since the D24 NA manifold may have trouble fitting under the 700 hood, and it has that big opening on the back that I would worry about when running big boost.

Now it just needs an intercooler... and injectors... and a manual trans... and a real oil cooler. Then you will have a pretty serious diesel hot rod on your hands. :eek: :cool:

You can just tig-weld that big opening on back with thick aluminium plate.
So its not going to be problem. No injector changing needed by the way,
or can you point me some thread which recommends it?
Sorry little sceptism, but im curious to know if you really change injectors?

I get the idea, with bigger nozzles you can feed more fuel to cylinder in less time
than with smaller, but i havent heard anyone in finland had changed injectors,
just liquid head.

I too have been researching the injector thing. IDI injectors aren't sized differently, it all depends on how much fuel is pushed though it since they pop open. Its not like a TDI injector with a certain size orfice that is enlarged for more power. I have come to find out the different numbered nozzles eg 253 293 only refer to different updates and changes that were made as they revised the design of the injector tips. Whether is was for cleaner combustion, less noise, etc... As the years went on the numbers increased as bosch release new and better tips.

As for the intercooler, I've got that covered with the water/alcohol injection. It is just as effective if not more so since I can tune the injection amount.

Whats really going to step up the performance will be the ARP head studs. This car with 25lbs boost and fuel to match is going to be really mean.

I'm working on the manual. At least I finnaly got a D24T bellhousing and flywheel. I'm wanting to do a T5 swap but my buddy that just bought his 760 may want to sell and its a m46. We may swap and sell his car as an auto. That would be straightforward and when I blow it up I can go to a T5 then.

Whats wrong with the oil cooler? I know its not that big but for how I drive it, I would think its alright. If I was rallycrossing it and under load for a long time I could see doing a larger one, but most of my running is messing with guys on the street or just getting into it for a quick hard run. Hell it holds 8 qts of oil!

Jason

The inlet was plugged with a rubber expandable pipe plug from home depot. I used a nylock nut instead of the big dorky wing nut, and siliconed it in.

Jason

Interesing development. About the NA intake manifolds, Tom Bryant is a source of them.

Ya kevin (slobodan on here) had one for me but I was really wanting to get the intake setup better before heading to the track. He wasn't able to get it off, and I also had read that there can be fittement problems because of how tall it is in a 7xx series car. I figure what i have now is pretty damn close to as good as the na manifold.

Jason