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  #31  
Old 04-15-2013, 09:11 AM
Nevadan Nevadan is offline
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Default Engine sounds strong!

I haven't driven the car yet but the engine sounds strong. The head was rebuilt by Portland Aluminum Heads (Thanks Anders!!) and they did some quality work (except for the oil port plugs, but I'm not accusing them). During the process I probably timed the engine 10 times so I fully understand how to do it. I also installed a block heater, transmission mount, driver's side engine mount (I can't find a passenger side mount and will likely get one from Volvo), remote oil cooler (in addition to the stock oil-to-water cooler/heater. I'll get pictures of this once it's all connected), blocked off the EGR exhaust outlet at the manifold, rebuilt the entire engine bay wiring harness, bypassed the altitude compensation mechanism, cleaned the injectors (I'll install new nozzles soon), replaced the airbox thermostat, cleaned the "fuzz" from the exterior of the radiator, replaced all the belts, etc, etc, etc. It was a good learning experience and I feel like I understand this engine now.
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J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg
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  #32  
Old 04-15-2013, 06:35 PM
anders anders is offline
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Wow, you have done lots of work. I will definitely need to watch out for those plugs on the next head I send out, I would of installed it just as you had and had the oil leak, very good to know.
One good thing about all the time you put into it is that you will know how everything is assembled, you should feel more comfortable driving it on trips knowing the ins and outs of the motor and engine bay.
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  #33  
Old 04-15-2013, 09:37 PM
ngoma ngoma is offline
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That's some list! Are you going to use Monark injector nozzles? Do you have a pop tester?
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  #34  
Old 04-16-2013, 07:59 AM
Nevadan Nevadan is offline
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Quote:
Originally Posted by anders View Post
Wow, you have done lots of work. I will definitely need to watch out for those plugs on the next head I send out, I would of installed it just as you had and had the oil leak, very good to know.
One good thing about all the time you put into it is that you will know how everything is assembled, you should feel more comfortable driving it on trips knowing the ins and outs of the motor and engine bay.
It must have been an oversight on their part but I'm so happy with the quality of their work I have no complaints.

I have total confidence in the engine now. I'll put it on the road this weekend and see how it runs!
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J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg
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  #35  
Old 04-16-2013, 08:19 AM
Nevadan Nevadan is offline
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Default Nozzles

Quote:
Originally Posted by ngoma View Post
That's some list! Are you going to use Monark injector nozzles? Do you have a pop tester?
I called Kaia at Mercedes Source and she said they couldn't get the Monark nozzles anymore. I didn't push her too hard but I found a Chinese source, Pyder Power, for the Bosch equivalent to the Monark nozzle. The stock Bosch DNO SD 293 nozzle part number is 0434 250 103. The Bosch number for the Monark nozzle 039 305 138 is 0434 250 138.

The Pyder Power nozzles are shown here: http://www.aliexpress.com/item/Fuel-...507090947.html

They also have the stock 0434 250 103 nozzles available.

I'm going to order 15 nozzles (4 for my 1.6, 5 for my 2.0, and 6 for my 2.4) for $105 including shipping and see how they work. The price is worth the risk and once I get them installed I'll post here.

I do have a good homemade pop tester with a 12" gauge face! I'll post a picture of it here after I do some work this weekend. To get my D24T running I just pulled all the nozzles apart, cleaned them and adjusted the pressure to 2000 - 2200 psi. It wasn't exact but I cleaned up the peeing/leaking nozzles. They don't have perfect spray patterns but they all do spray now and will be good enough until I get the above nozzles.
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J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg

Last edited by Nevadan; 04-17-2013 at 08:18 AM. Reason: changed "of" to "a".
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  #36  
Old 04-16-2013, 08:44 AM
ngoma ngoma is offline
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Kaia at Mercedes Source supplied us a small kit of most useful shims, but we had best luck getting the Monarks from Sean Watts at Hessian Imports.

http://d24t.com/showthread.php?t=550

Anyway, we will be interested to see results from the Pyder Power nozzles, can't complain about the price!
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  #37  
Old 04-21-2013, 07:13 PM
Nevadan Nevadan is offline
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Default Clutch details

One of the administrator's suggested moving this to a new thread. I agree, move it if you can.

Now that the engine sounds good I'm moving on to the clutch. I took several pictures that will be useful to me in the future and to others as well. There will be a few questions scattered in the following posts.

This first picture shows the pressure plate with the Volvo and Fichel-Sachs part numbers on it. Now that it's posted I see it's not so easy to read. The numbers are, Volvo 1340549, Sachs 043082101007.


This picture shows the pressure plate springs with what appears to be a significant amount of wear. Anyone have any input on the useability of this? The Sachs part number is visible in this picture.



This one shows the clutch disk with the part numbers. The Volvo part number is 1220942.

__________________
J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg

Last edited by Nevadan; 04-22-2013 at 12:31 PM.
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  #38  
Old 04-21-2013, 07:22 PM
Nevadan Nevadan is offline
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Default Clutch continued

This one shows the other side of the clutch disk with the splines and spring setup. I've never seen a disk with this type of spring setup. Since I can't seem to find this exact one, will the non-Sachs disks work that don't have this spring setup. I can get them from O'Riley, Autozone or AutohausAZ. There is actually one from AutohausAZ that is the correct one but it's $215.



Next are the throw-out bearing:


This one shows the wear on the bearing that corresponds to the wear on the pressure plate springs. The bearing still appears to be in good condition; it turns freely and has no wear other than on the contact surface with the pressure plate. Is it reusable? I think it is, or at least to be saved for future use.

__________________
J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg

Last edited by Nevadan; 04-21-2013 at 07:32 PM.
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  #39  
Old 04-21-2013, 07:28 PM
Nevadan Nevadan is offline
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Default And finally the pilot bearing and tranny shaft

Here's one of the pilot bearing. Part number from various sites is Kolb 046105313D. Also National F85706. I have not verified the fit on either of these bearings but I will once one of them arrives.



And here's the end of the tranny shaft that rides in the pilot bearing. It has a sleeve over the shaft. Both the sleeve and the pilot bearing appear to be in good condition. Depending on what "clutch kit" or other parts I purchase I might reuse them. I did not research a part number for the sleeve but if someone has it could you please post it here to keep this all in one place.

__________________
J.D. in Reno
1958 Mercedes 180D (rebuilding now)
1985 VW Jetta 1.6TD
1985 Volvo 745 Wagon 2.4TD (sold but still maintain it)
1987 VW Quantum Syncro 2.2 (converting to 2.0TD)
1996 TDI Passat
1997 Chevy 3/4 ton 6.5TD
2006 V10 TDI Touareg

Last edited by Nevadan; 05-02-2013 at 08:42 AM. Reason: Corrected grammar
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  #40  
Old 05-01-2013, 10:09 AM
v8volvo v8volvo is offline
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Default

Wow, impressive progress, you are really blasting through this thing. What made you take the trans off, was the clutch slipping or any other symptoms? Or just to check it out?

I've reused the throwout bearings before -- with success -- though with the amount of wear on the fingers of your diaphragm I wonder if yours may not be 100%. Generally Volvos seem to come with terrific bearings everywhere and bearing failures are pretty unusual. I've got a hunch that this might be because Volvo's car business originally began life as a division of the SKF bearing company -- maybe some of that still runs in the company's blood. Generously-sized, well-designed bearings seem to be the norm -- many of them still supplied by SKF as the OEM.

Watch out on the pilot bearings though -- those are a spot for caution on these because the OEM bearing is NLA from Volvo, and all the aftermarket bearings, the Kolb one included, are a different design with a crappy plastic needle cage and no grease seal (aka junk!). The OEM bearing is made by INA. Even the OEM one isn't the most robust -- perhaps because it's the only bearing on the car that was specced not by Volvo itself, but by VAG.... My hunch anyway. (Compare the little open needle pilot bearing for a D24/T to the large, sealed ball bearing used in a redblock gasser Volvo and you'll see the difference!)

See pictures for comparison:

OEM INA w/ grease seal:


Aftermarket Kolb without seal:


Don't put the crappy kind in, you will regret it! Volvo's decision to discontinue selling the OE bearing is unfortunate... I'm working on a guy's 745 now that had the pilot bearing implode and needs a new one, so I got to work last week on finding a way to get the good bearings. Fortunately I was lucky to get in touch with a source that has access to 19 of them, at $10 apiece plus shipping, I have to order at least 2. They won't come in a Volvo box, but they're the same INA part that Volvo sells in its own package.

Edit - INA number is F-85706, same as your National number, maybe the National product is a reboxed INA too?

I'll be putting together a group order for these, in case anyone else here wants one -- I'll start a thread in the Powertrain section about it shortly, hoping to put in the order this week.

Last edited by v8volvo; 05-01-2013 at 04:49 PM. Reason: INA bearing number
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