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  #1  
Old 03-05-2018, 05:45 PM
volvo_d24t volvo_d24t is offline
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Join Date: Oct 2017
Location: Canada
Vehicle: 1985 Volvo 745
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Default 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






Last edited by volvo_d24t; 05-05-2018 at 04:36 PM.
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  #2  
Old 03-05-2018, 06:13 PM
RedArrow RedArrow is offline
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Join Date: Jan 2013
Location: NY
Vehicle: 740
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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.

Last edited by RedArrow; 03-05-2018 at 06:16 PM.
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  #3  
Old 03-06-2018, 04:53 PM
volvo_d24t volvo_d24t is offline
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Join Date: Oct 2017
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Vehicle: 1985 Volvo 745
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Quote:
Originally Posted by RedArrow View Post
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








Last edited by volvo_d24t; 03-09-2018 at 06:43 PM.
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  #4  
Old 03-07-2018, 10:12 PM
volvo_d24t volvo_d24t is offline
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Join Date: Oct 2017
Location: Canada
Vehicle: 1985 Volvo 745
Posts: 23
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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.















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  #5  
Old 03-08-2018, 10:15 PM
ngoma ngoma is offline
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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.
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  #6  
Old 03-09-2018, 06:40 PM
volvo_d24t volvo_d24t is offline
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Vehicle: 1985 Volvo 745
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Quote:
Originally Posted by ngoma View Post
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!













Last edited by volvo_d24t; 03-09-2018 at 06:43 PM.
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  #7  
Old 03-10-2018, 07:12 PM
ngoma ngoma is offline
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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.
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  #8  
Old 03-12-2018, 08:07 PM
volvo_d24t volvo_d24t is offline
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Join Date: Oct 2017
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Vehicle: 1985 Volvo 745
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Quote:
Originally Posted by ngoma View Post
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













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  #9  
Old 03-12-2018, 08:59 PM
RedArrow RedArrow is offline
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Vehicle: 740
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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?
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  #10  
Old 03-17-2018, 08:18 PM
volvo_d24t volvo_d24t is offline
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Join Date: Oct 2017
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Vehicle: 1985 Volvo 745
Posts: 23
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Quote:
Originally Posted by RedArrow View Post
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:









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