How'd you Intercool your D24T?

[Benzsc1]

Also just noticed your Cam cover is the other way round to mine on the LT truck my oil filler is at the pump ened of the engines I take it on the Volvo D24 they turned it round for easier access??

Si

[Jason]

Thanks! I don't know if the NA manifold would be much better than the factory IC manifold, its a great upgrade over the stock non ic turbo manifold. You may still gain some power thanks to the longer intake runners and if the inlet facing forward would help you out it may be worth installing. There is a write up on how I built the breather (actually an oil seperator). Its a fuel cap off a early '60s vw bug. I used it just becuase it was the right size and the stamped vw logo looked cool. Since it IS a vw diesel after all, why not!

Jason

[240diesel]

This topic looks nice to me!
I did enjoy the storys i read here.
So i diceded to contribute some pictures / words of my build.
(sorry for my poor language)

The intercooler you're looking at is from a DAF-truck and shortened at top and bottom to fit into my 245.
Because the in-and-outlet-pipes were far to big i made new ones from 65mm aluminium pipe.
I'am lucky my boss bought a brandnew aluminium-weldingequipement so welded everything togheter....



I'm sorry not to have pictures of the sockets i welded on the in-and-outlet of the IC.
This sockets i used later to fit the temperature-sensors i made for measuring the IC-effect.



Also ordered t-bolt clamps for thight fitting.



When finished, i pressurised the IC with 2 bar to be sure the IC withstands the workingpressure of approx.1 bar.
PLEASE BE CAREFULL, WHEN DOING SO PLACE THE IC AT A SAFE PLACE AND DISTANCE BEFORE PRESSURISING THE IC VIA A LONG HOSE.
SO IF THE IC EXPLODES NOBODY GETS HURT!!!!!

Next part, fitting into the car;



The pic. above shows the turbo i started with, now already replaced by a original D24TIC-turbo;





(Above pics from the new turbo)



As you can see on several pictures, the IC won't fit, so i cut out the front plate and placed the IC...



The piping of the IC circuit; i made it from exhaust-pipe 65mm (also VW, comes from brandnew VW LT's wich are
equiped with loadlift so the last meters of exhaustpipe were getting in the way of the lift)



I made The piping (while i was preparing the swap D24 >> D24TIC , (i used the front of my scrapped '87 245 for that purpose.)



I realise that i don't have a picture of the piping to the inletmanifold.....
I only have a bad picture ,you can see the D24TIC manifold, piping stil not powdercoated.

In the next days i will try to add some pictures from that part.

About the IC-effect on the temperature;
When cruising 120 KM/hour the inlet-temp. at the IC (air coming from turbo) is about 95 Celcius, while the outlet air is doing
37 Celcius. (Temp. outside the car is 25 - 30 C)

[Jason]

Man must be nice to be able to pic up a factory IC manifold over there! The NA manifold does work pretty well. Nice job! I too was surprised what a difference the intercooler made, and I just used a cheapo ebay one! I don't have any actual temp data other than from feeling it with my hand, but on a cool night after running the car hard, the inlet is hot and the outlet was a good amount cooler, much more of a difference than I expected. It really helped add some power, especially on hot days when the engine was much more doggy.

Jason

[240diesel]

I just came back of a vacationtrip in Germany (sow only 1 245 D24) and measured the highest temp between the turbo and the intercooler; 120 C it's 248 F.
The intercooler cooled the air back to 37 C / 98 F.
It was a warm day and the volvo was towing a folding caravan, 3 persons and bycilcles on the roof uphill D24TIC at 3000 rpm, 3rd gear, boost about 1 bar.
So this IC seems to be doing a good job.

[Jason]

Sweet, a D24Tic doing some work! Have any pictures of the car with the bikes and trailer on it?

Jason

[Zoupop]

hi im new in this forum and my english is not perfect.

i just buy the 740 d24 turbo of my grand-father but i want to make it intercooler. So is that bether if a I buy a tic manifold,buy an N/A manifold or i keep the manifold same and I do all the modification to fit all the piping??

Thank

[Jason]

Hello and welcome,
I would run either the factory TIC manifold, or the NA manifold. I think the NA manifold has a nicer flowpath, and helps with torque thanks to the longer intake runners built in. If you could find the manifold and piping off a stock TIC car, it would be easier to install. Using the NA manifold will mean you have to make the charge piping.

Jason

[Zoupop]

but can i modify mine? like by making the new in let in front like a N/A one??

[Jason]

You can but there isn't much room there to make the inlet very big. I got a nice performance increase by going to the NA manifold. The na and TIC manifolds aren't all that expensive, and there are many more of these cars and parts over where you are. That stuff should be easy to find.

Jason