Jason's "built" D24T engine build - Page 6

Jason · #51 11-10-2010, 05:12 AM

Ok, big time update. The engine and trans is out! I took everything out Monday, and started cleaning up the engine compartment, cross member, etc... Spent quite a while with degreaser and the power washer. Also attached are some pictures of cleaned up pieces waiting to be painted for the new engine, and my custom remote oil filter mount with turbo oil inlet tapped into it. All I have left to do is pull the trans off the engine and take a look at it for the 5th gear problem, and see whats up with the clutch. I'm hoping its just oiled from all the leaks from the engine. If its dry, the plate has crapped out and I'll have to send it out to get it rebuilt which will be the next hold up. Plans also include rewiring the main engine harness for a much cleaner look, as well as deleting some of the unused wires like the oil level sender, the boost switch, etc... I hated how the wires were routed, and I want as much of the engine to show as possible, rather than it be covered up with a tangled mess of wires and hoses!

Ha! I should have posted some before pictures, but I'm sure most of you know how oily/grease caked everything is under these engines after 25 years!

Jason

Jason · #52 11-12-2010, 05:43 AM

Got the transmission off the engine, and the clutch off. The p-plate is pretty torn up thanks to that 6 puck clutch. Doesn't seem to have done much to the flywheel though. I would have expected the shoe of a german sachs clutch to be a little harder. It may have been slipping from grease flying out of the needle bearing in the crank, there was some grease type build up on the flywheel side of the disc. With how much material is off the plate though, I'm sure the clamping pressure is down. I'm going to see if clutchnet can rebuild/remachine it. Also, the imput shaft bearing on the T-5 has some play, but its comming apart anyway. Guess I have to find a pilot bearing that actually fits. I'm suprised that the bearing crapped out that quick, with the imput shaft being as short as it is, and the bearing is pretty big. Power steering bracket and pump is on the engine, along with the fan pulley mount, alterantor, and ac brackets. All the parts are cleaned and painted except for the intake manifold which I still need to take off the engine, and the injection pump which I'm taking to work today to rinse off in our clean tank. Dont want to risk getting any crap in it, so I'm not gonna go crazy with the clean up and paint, just get it reasonably clean, and I'll paint the brackets and such. Pics to come!

Jason

Jason · #53 11-12-2010, 06:16 PM

Well here it is... Almost done, all I need to do is mount the turbo and intake manifold. They are still stuck on the old engine. Just about everything else is on... I'm not going to install the injectors and lines untill after its in the car and timed, that way it will turn over more easily so I can crank oil pressure. I'll also install the a/c compressor after its in, it kinda hangs down and is in the way for getting the engine set in I thought... I took some closer up shots so you can see some of the detail. I have ended up taking everything totally apart, the power steering mounting stuff, ac brackets, and also ended up painting some of the hardware black... Alex says its gotten outa hand and will be covered in oil in 15,000 miles anyway...lol I cant help it!

Jason

markbos4 · #54 11-13-2010, 02:10 AM

Looks great man, respect.

Stroked383 · #55 11-13-2010, 07:35 AM

Ha, i knew you'd take some pics last night. i was expecting some turbo/stack pics. Definitely a peice of work. If it runs as good as it looks you wont drive the bug anymore.

Alex

Jason · #56 11-13-2010, 08:57 AM

Ya didn't get to the turbo... I wanted to the get injection pump mounted up so it wouldn't be getting kicked around the garage. I'll probably get the turbo and stuff on today hopefully.

If it runs half as good as it looks it should do some work... But it ins't the bug.

Jason

Jason · #57 11-17-2010, 04:58 AM

Well here are the last couple pics... All done and just waiting for my new clutch to show up. Also a close up detail shot of how the remote mounted oil filter and fittings on the block worked out. A hell of alot more room around the turbo and easily plenty of area for a larger compressor when the time comes.

Jason

Jason · #58 11-19-2010, 04:54 AM

Clutch should be in today. I got the 5th gear problem fixed on the T5, and its ready to go as well. Next pictures should be of the engine getting dropped in. Planning on getting it at least set in the car saturday afternoon after work, and hopefully running this weekend!

Jason

Slobodan · #59 11-21-2010, 10:49 PM

Jason, your new motor is looking NICE! congrats! I can't wait to see the video of its first start up!

v8volvo · #60 11-23-2010, 11:04 PM

Looks awesome.

Two things: one, your drivers side motor mount looks pretty well collapsed -- they need to look straight when they're off the car, if it already looks squished like that without any load on it then it will not last too long on the car. Two, you might want to change the position your injection pump is installed at -- it's best to try to rotate the pump further out, meaning tilt the top more away from the engine. It needs to be at least far enough out that the marks on the pump and the pump bracket line up (looks good that way); and you may even want to set it further out than that. The reason is that if you tilt the pump too far in towards the motor, then the boost enrichment device gets in the way of removing #5 and #6 injectors, and also make for even tighter clearance in there for getting wrenches in to work on glow plugs, etc. Giving yourself a little extra space is a good idea. You'll time it by moving the rear sprocket on the cam anyway, so the pump's position doesn't matter other than making sure you leave space for injector work.

Can't wait to hear how this thing runs.