d24t overhaul+mods

volvo_d24t · #1 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.

ngoma · #2 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 · #3 03-09-2018, 06:40 PM

Quote:

Originally Posted by ngoma

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!

ngoma · #4 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 · #5 03-12-2018, 08:07 PM

Quote:

Originally Posted by ngoma

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

RedArrow · #6 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 · #7 03-17-2018, 08:18 PM

Quote:

Originally Posted by RedArrow

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: