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volvo_d24t 03-05-2018 05:45 PM

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

RedArrow 03-05-2018 06:13 PM

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.

volvo_d24t 03-06-2018 04:53 PM

Quote:

Originally Posted by RedArrow (Post 12406)
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.

yes this thread will be my project and I will try to keep it updated with pictures
______________________________________________

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

volvo_d24t 03-07-2018 10:12 PM

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

ngoma 03-08-2018 10:15 PM

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.

volvo_d24t 03-09-2018 06:40 PM

Quote:

Originally Posted by ngoma (Post 12426)
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.

I will try to keep those thread untouched. Yes previous owner block off the EGR... homemade not even the same bolts lol
_____________________________________________

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

ngoma 03-10-2018 07:12 PM

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.

volvo_d24t 03-12-2018 08:07 PM

Quote:

Originally Posted by ngoma (Post 12437)
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.

well I don't know either, haha! thought it was hydraulic...
________________________________________________

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

RedArrow 03-12-2018 08:59 PM

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?

volvo_d24t 03-17-2018 08:18 PM

Quote:

Originally Posted by RedArrow (Post 12439)
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?

I think I will keep those exhaust and intake valves. They require to be reconditioned as well as the valves seats. I don't know what is the maximum size of a crack but yeah, as you said, greenbook says 0.5mm. I think there is no doubt that they are exceeding the specification, but anyway I will try to put this cylinder head back in service.
____________________________________

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


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