D24 Special Tools
 

Here are some photos and brief descriptions of D24 Special Tools.

For working on IP, IP belt, IP timing, Cogged cam pulley, Injector lines:
Attachment 404

From top to bottom:

Dogleg 17mm offset wrench w/ 1/2" socket for torque wrench. Easier wrenching of rear cam pulley and IP pulley nuts. Volvo tool P/N reads 9995201
Attachment 405

Cam pulley holder. Holds cam pulley stationary while tightening/loosening nut. Also rotates pulley on camshaft to adjust IP timing.
Attachment 406

Closeup of P/N 9995199 21 AF-1134
Attachment 407

Injector line wrench. Should be able to reach all of them with this wrench! Hazet tool P/N 4560
Attachment 408

IP Pulley remover. P/N 9995204 21
Attachment 412

IP Pulley lock pin
Attachment 413

Not specifically a Volvo special tool, but very useful, when necessary. For removing the IP shaft seal (and possibly other similar seals).

Lisle Shaft Type Seal Puller 58430
http://www.lislecorp.com/uploads/pro...274B4B65EC.jpg

Are any special tools used for the 1.6 liter VW engines the same as those used for the D24? I found this kit http://www.partsplaceinc.com/product...aspx?sku=17821

Timing tools are the same.

Hazet 2574-1 back scratcher & tappet depressor. My only one where the self made version truly sucked.

Droid autocorrect really really thought I wanted to call it 'hazel'

Anybody have the part number or link to the crankshaft holder, or what tools specifically interchange between the VW 1.6 and the D24?

Tools
 

This blog listed a few of the d24 tools, including Volvo part numbers.
http://www.upshiftblog.net/2012/02/i...ming-belt.html

Scroll down to see there is the `Greenbook` ready to download, in 3 parts (if needed). (`Service Manual Repairs and maintenance, D20, D24`)

Lots of `tool-talk` here too: http://volvoturbodiesel.blogspot.com/ with pics & part #s.

Thanks for the links. I found the first one very useful in cross referencing part numbers and was able to find some of the tools through tasca.

I can get the tools for the same or possibly cheaper than Tasca...

hi Mike
 

re I can get the tools for the same or possibly cheaper than Tasca..

hi again Mike

do you know where to get, or can get tool 5201? that is the final tool I need for my belt change on D24

thanks and regards JM

Anyone have a compression tester adaptor? PN 5191

compression tester adapter
 

If you walk into Harbor Freight, you will see a diesel compression tester kit with several adapters, including the one you need for the d24, d24t. It was around $26 for the entire kit. It is sold in a red color flat hard-case.

There was one 5191 tool listed on ebay recently, for 9.99 plus some shipping. Idk if it is still listed or not.

Dont fully trust the results unless you`ve just adjusted the valves to specifications.

Thank you!

Hey new to page, didn't see this mentioned, EWK makes a kit with special tools for the D24. found it on amazon for $52

EWK Diesel Engine Timing Tools Set Tool Kit for VW Audi Volvo
Part number: EB0126

Thanks for the post and welcome to the board. :)

That tool set will give you a few things you can use but unfortunately it does not include most of the tools required for timing belt replacement, etc. Since this question comes up frequently due to the wide availability and low cost of kits like these (and the fact that they are incorrectly advertised as being suitable for Audi and Volvo engines), I will describe in detail what is in this kit, which is designed for the 4 cylinder VW diesel engine rather than the 5 and 6 cylinder versions, and which parts will and will not help you.

If you were working on a 1.6 or 1.9L pre-TDI 4-cylinder diesel in a Volkswagen or small Audi, a kit like this would give you almost everything you needed for one of those (minus the dial indicator). If you are working on a larger Audi or VW with the 2.0L 5-cylinder diesel, a VW Eurovan with the 2.4L 5-cylinder diesel, or a Volvo with the 2.4L 6-cylinder D24 or D24T diesel, a couple of the tools in this kit would be usable although they would require some adaptation. The remainder of the tools from the 4-cylinder tool kit would be incompatible with the 5 and 6 cylinder engines, and meanwhile some of the tools that are required for the 5 and 6 cylinder engines are not present in this kit.

Usability of the parts INCLUDED in this kit (and other commonly found 4 cylinder kits similar to it):
- the 4 cylinder style holder and rod for the dial indicator in this kit is shorter so you would need to remove the vacuum pump to use it
- the cam locking plate would be usable with modification (you would have to grind material off the ends of the cam locking plate to make it clear the rear valve cover studs on the D24/5cyl)
- the IP locking dowel would be too long for use on a Volvo (hit the firewall) but you could shorten it to fit in the case where you needed one. This is also generally not useful or needed on the 5 and 6 cylinder engine since the proper method for setting timing is different than the 4-cylinder version which does not have a rear timing belt. On the 5 and 6 cylinder engine it is only useful when *removing* the injection pump.
- the 2-pin spanner wrench for the 4 cylinder belt tensioner is not used on the 5/6cyl belt setup, which sets timing belt tension with the water pump position rather than a dedicated tensioner pulley (what that spanner is designed for).

Items NOT included in this kit that are necessary for a D24:
- for most timing related work you would also need at minimum the crank pulley locking tool and the cam counterhold tool (9995187 and 9995199 from the info on the first page of the thread).
- it would help to have the cam bolt offset wrench extension and the longer dial indicator holder and rod, but you could manage without them if you had to (shorter VW 4cyl versions of the holder and rod are usable, again if you remove the vacuum pump for clearance)

In short a kit like this would give you some useful or partially useful pieces depending on what work you needed to do, but you'd be getting some things you don't need and missing some things you do need. It can be cheaper and easier to buy the pieces you need individually, or fabricate them, or borrow some or all from members here.

The one thing you don't want to do is get it all torn down thinking you have everything you need, and then discover you're missing a critical tool to get it back together and running again.

Tool Rental Master List thread is here in case you need it.

Crank locking tool and pulley bolt wrench torque multiplier:

https://www.d24t.com/showpost.php?p=13358&postcount=5

Do you know the diameter of the pulley lock pin? And maybe the length.

I will be making it so to eliminate a few iterations :D

You can measure it yourself, through the IP sprocket you will see the other hole that the pin will plug on the pump.

I can measure for you in a few mins too.

but, you can use a nice deep socket that is perfectly tight in there. give me a few mins...

Update.
The tool on top is the Volvo one
The one below is made by Matra

The length without the head is 35mm

The thickness is 15.4mm on the Matra VW tool and only 15.1 on the V tool but that has been actively used for decades by an old d24 builder. There's more than 0.3mm wear in his 90 year old elbows.

These tools are not showing up at all over here (uk)

Please say someone has a list available these days for t belt and ip belt/ timing?

Or a supplier to try? I really want to assemble my own set and do the job right

The more i hunt the more desperate i become.

I can make the timing pin for the pump myself as it seems like a 15.4mm x 35mm shaft. But the rest i am struggling for.

What is the absolute minimum needed for timing belt set up to correct spec? I keep been told to mark up and go for it by volvo specialists here, but that will not guarantee a correct factory set up to start improving from.

And injection pump belt and timing

Again what is the bare minimum needed for set up? Clock with correct sleeve, rear pulley locking pin and?

Is there any drawings out there people have seen or current sources i could order from?

This is a urgent job no doubt for any new owner and we all need sources of info and tools to keep them going. Most of the green book and other links on the D24 are also dead i found personally.

I could arrange a batch run in the UK easily enough if i could get some sizes to produce drawings from

The bare minimum is all, EXCEPT for the IP pulley locking pin!

Special tools for IP Timing
5201 Dogleg wrench for pulley bolts. If there is space (not in 240), can get by with common 17mm offset box end wrench, but won't be able to get torque reading.

5199 Pulley wrench. Need, but can make a reasonable facsimile.

5194 Dial indicator holder/extension. Need, these are currently found on ebay.

Dial indicator. Need


Special tools for TB R/R, camshaft timing
ALL the above, plus:
5187 Crank damper holder (counterhold). Need. Forum members have made before, search threads for details. There are also recent threads about a currently available version from the EU.

5188 Crank pulley center bolt wrench. Need. Forum members have made before, search threads for details.

(See link in post #16 in this thread for illustration of the above two special tools)

5190 Camshaft alignment bracket. Need. Supposedly can make one out of a brass door hinge.

That is bad and dangerous advice, and you are right to not accept it.

It's the same philosophy that has resulted in so many of these engines being destroyed by "Volvo specialists" over the decades :rolleyes:, who then blame the failure on the engine rather on themselves for deliberately sabotaging it despite having the proper instructions right in front of them. Sad and irritating to hear people still repeating the old misinformation even now -- at one time in the past threatening the assets and finances and safety of regular folks who owned these cars as their main transportation, and today in reference to an antique car of which very few remain.

Anyway glad to hear that you dismissed those recommendations. :cool:

Assembling the full set of factory-version tools is no small task, requiring significant time and money, unless you are lucky enough to encounter a Volvo dealer or independent shop wishing to offload its full set, or find them piece by piece (or even every now and then all together) on ebay. You can try those methods, but they're often not out there at the exact moment you need them.

However, as ngoma alluded, there are good substitutes for most or all of the factory tools at very low cost, if you are willing to use a little creativity and work smart. Thanks to the fact that these are really Audi engines not Volvo engines, the Volvo-specified tools can often be subbed with much more common Audi/VW equivalents, IF you know what you're looking for and don't get tripped up by loosely worded advertisements for tools that might not work. (Main key there is understanding that the 4-cylinder versions of the engines use their own different equipment/procedures and are not compatible. The stuff you need will be called out for the FIVE CYLINDER 2.0L, 2.4L, 2.5L Audi/VW diesel and TDI engines, not the fours.)

But stuff that works is out there cheap, and better yet, many of those substitutes should be even more easily found on your side of the pond where the VW/Audi relatives of the engines are extremely common.

Here are some of the known simple recipes:

9995187 crankshaft counterhold: you can use a commonly found version for a 2.5L TDI 5cylinder as found in Audi cars and VW Transporter trucks. It requires a very slight modification that you can accomplish with an angle grinder in about five minutes, to create a second open section opposite the existing one (D24T crank pulley has two locking lugs to engage with the tool where as the 2.5TDI has only one). See discussion posts and ebay links on page 3 of this thread from member jetfiremuck who has done this. The tool will cost you just a few pounds. https://d24t.com/showthread.php?t=2116&page=3

9995188 wrench extension: you can make one by welding a 27mm socket onto the end of a piece of flat steel, and on the other end adding something to attach a torque wrench to (such as a large nut to accept another socket). The length of the piece of flat steel and the spacing from the wrench attachment to the welded socket would be critical, so if you plan to make one, tell us and someone will measure the correct distance for you. You could also get away without this tool IF YOU HAVE A TORQUE WRENCH THAT READS UP TO 350 FT-LB to use directly on the front crankshaft bolt. If not, you need to obtain or make the tool. There is probably also a cheap Audi version of this out there as well, more research required but probably not hard to find if you can find some service literature for a 2.5TDI Audi/VW engine which will undoubtedly call out a special tool number.

Dial indicator and holder and rod (9995194), and locking plate for back of camshaft (9995190): as ngoma noted, these are easily substituted. Both common on ebay for very cheap. These are the only two tools where the ubiquitous 4 cylinder versions work just fine, though you will need to remove the vac pump for space using the 4cyl version of the dial indicator setup (easy to do). Slight modification of the 4cyl cam locking plate sometimes required for clearance to the two rear valve cover studs, 15 seconds with a bench grinder.

Also the 5190 plate appears to be included in that 23GBP ebay tool set linked in the other thread mentioned earlier. Here it is again: https://www.ebay.com/itm/VW-2-4-2-5-...8AAOSwnHBdHx6C

You could buy that tool set, and then also another commonly seen cheap set intended for the 4cyl engines, and between the two of them you would have 90% of what you need (along with a bunch of stuff that you don't need but oh well).

D24 greenbooks are online. Will look for links, we should have one stickied anyway. Try looking for mirrors of the old k-jet.org as a place to start.

The biggest advice of all: don't let lack of the tools either cause you to become discouraged and decide not do the timing belt job, OR cause you to do it but attempt to cut corners or work without the right equipment/info. Everything you need is out there, cheap, and easy to get if you know where and how to look. ;)

So did you read the "mark up and go for it" as marking the positions of the rotating parts with whiteout or something? Agreed, not likely to produce satisfactory results.

Caveat here, knowing that torque wrench readings are not accurate at the ends of the scale-- the 350 ft-lb should be near the middle of the scale. 100 - 500 or 100 - 700 ft-lb torque wrenches do exist, 4 - 5 feet long, easily costing $400 - 600 or more. :eek: Maybe make friends with somebody who works at the bus barn? :D Wonder if a Torque Multiplier could work?

Yeah.

Sometimes referred to as the "M&P" method -- meaning "mark and pray" :eek:

Pray to which God? Who knows, as the prayers are always ignored. :p

On the 200 series D24 diesels there is not sufficient space between the radiator cross member and the pulley to fit a torque wrench on the 27 mm crankshaft screw. The special tool is required. On the 700 series D24T engines there may be enough space for a torque wrench if the radiator is removed. 900 series D24T intercooled should be very close to 700 in spacing.

This is exactly the info i needed ThankYou. I am crossing my fingers for some luck as i was talking to a old retired diesel specialist yesterday and he claims he still has all the tools FOR SALE :)

Fingers crossed he comes back this weekend and im on the right path

Mick

Good news. :) Just be sure the stuff you get is relevant to the 5 and 6 cylinder diesel (as used in Audi cars, VW LT heavy trucks, and Volvo cars, but NOT in small VW cars such as Golf, Passat, Jetta). Again you want to watch out for people who may be confused and think the 4 cylinder stuff is what you are looking for, since although the techniques for those engines are similar in principle they use mostly different equipment for the timing jobs. As noted above, there are a couple of things in the 4-cylinder "kit" that will be useful (cam locking bar and the IP dial indicator/holder/rod), but the rest of the tools for the 4cyl would not be useful to you on a Volvo, and more importantly it would lack some things you do need.

However, if he really does have the correct 6cyl stuff then you've lucked out as this is the best/easiest way to get hands on the tools in one shot. :cool:

For the sake of accurate info in this sticky thread, I realized I should have clarified this statement a little more. It's not necessarily true that the so-called mark-and-pray method could "never" work. There is always the theoretical chance that the cam and IP timing happens to land in the correct range by pure lucky accident (or successful prayers??).

Also, for someone who knows EXACTLY what/how/why they are doing, AND who is using several of the special tools/techniques to thoroughly check their work before and after, it is possible to do certain repair procedures without stepping through the entire full timing system disassembly/re-timing process. Examples of this are replacement of the front timing belt idler pulley and of the water pump in cases where the timing belt is not yet due to be replaced and is being retained. Many of us here have done those procedures carefully but successfully with the help of paint marks and the like, and managed to save a little bit of time on the job in the end.

**HOWEVER, to achieve success with those methods, one has to also check IP-to-crank timing before disassembly using the dial indicator, and then re-check it after reassembly, confirming it is exactly the same. AND one must be fully prepared and equipped to continue through the full re-timing process IF the timing ends up at all different. Therefore it doesn't save you from still needing to have all the tools on hand and needing to be ready and able to use them, and it doesn't make the work any simpler. To the contrary you need *more* experience and knowledge of the standard procedure to be able to use alternative procedures without jeopardizing the engine. You do it to speed up your work a little bit while reaching the same confirmed result, NOT because you don't have the equipment/technique and are seeking to cut corners that could compromise the result.

Nonetheless, if you do it right, it's a viable practice. But the key is realizing that to safely go off-script with timing work is HARDER and more demanding of skill and nuance, not less. The issue is that most of the time in the real world, the folks trying to cut corners are the same folks who have little or no experience / no interest in learning, and therefore don't actually understand the standard methods, nor the underlying reasons for those methods, nor the risks they are taking in deviating from those methods, incorrectly believing it will make the job easier. Lack of understanding + "alternative techniques" = where we see big problems occur, over and over again. ;)

The folks recommending or practicing the "just mark it up and go" attitude are the ones that fall in this last category and are the most serious troublemakers. (and who often create plenty of trouble for themselves too, when they bugger up the job and create problems they cannot solve despite a customer's reasonable expectations that they do so!)

For someone going through the timing job for the first time, it is NEVER a good idea to attempt anything besides the full standard method, using the full set of tools detailed in this thread or appropriate substitutes for those tools.

I purchased a online manual and ended up with vida it seems. The section on d24s sadly mentions tensioning the belt via the water pump. That means its for a early engine doesn't it? Sadly no matter what year i select i only get the guide with this set up.
.

It is lovely and detailed though so i can share a copy anytime someone wants it :)

Glad i have a later engine as the early seems even more work


Mick

Could try here
https://ozvolvo.org/archive/

and here
http://www.volvotips.com/

A bit tedious, not very well organized. If you got vadis to work, you already have demonstrated superior abilities. :D

You are correct, your setup should have the separate tensioner pulley-- a more elegant evolutionary development.

Unless i am been useless there is not a drop of info left on d24 timing on those sites.

Oz volvo only had timing guiides for petrols and volvo tips goes round and round in circles when you select the d24 timing info.It just loops back to a 240 manual sadly. Must be a missing file.



What would be the best way to post the timing belt for earlier engines up? I may aswell share it as i have the full vida guide. Its where some of the black and white pics on here ce from it seems

Mick

I have just spent a bit time copying the relevant pages for d24's in the injection and timing belt manuals i have been given a lend of.

I believe in helping everyone out and keeping old knowledge circulating SO...

Will happily share them :D but have a issue.... i dont like been sued so i need to remove the company name from the bottom and can not edit pdfs myself.

Could someone, a mod perhaps edit the files for me if i email them over? They are all individual pages too so if combined would be better. There is only 10 pages there so its no mamooth task. Free version on adobe etc wont allow editing. I was lucky to be able to select the area for scan and get one page at a time.

There's a pre 93 timing belt guide, post 93 timing belt guide

And injection timing for d24t up to 82 as the book was old (not sure if procedure is the same across all years, hoping so)

All with diagrams and tools needed



Mick

That is a generous offer, thank you!

Sent you a PM with my email address, feel free to send them to me and I will see what I can do, or if I can't get them fixed up, then I'll take the lawsuit risk and post them as they are. I don't think anyone is likely going to come after us for sharing info about ancient old Volvos here in 2021.

Parts Diagrams
 

Also, Parts Diagrams (Parts Lists). Sometimes more helpful than service manuals.

https://www.gcp.se/en/catalogues/

@ukvolvo I would also really appreciate it if you could send them over. I'm about o approach the same daunting job and any bit of information helps.

Re special tools, I found this one which looks suspiciously similar to volvo nr 5188: https://www.ebay.de/itm/372568724385

Anyone here used it for the job?

I have emailed over the details to v8volvo so i suspect a link will arrive on here soon :D If not i can always email my originals over. That tool does look interesting. All i have acquired so far is a adapter for pump timing physical tool wise. The kit from ebay will do the camshaft plate and crank locking tool so just some pins and the torque tools for camshaft pulley and crankshaft to go.

Mick

Can someone please post a picture of Volvo tool 5190 ( The camshaft allignement bracket) with its thickness.
Scribe around it with a pencile to a white paper and mark the measurement of atleast one side please,