D24 Special Tools

[adamdrives]

Anyone have a compression tester adaptor? PN 5191

[RedArrow]

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.

[adamdrives]

Thank you!

[Louis95]

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

[v8volvo]

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.

[ngoma]

Crank locking tool and pulley bolt wrench torque multiplier:

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

[mrvos]

Originally Posted by ngoma

IP Pulley remover. P/N 9995204 21
Attachment 412

IP Pulley lock pin
Attachment 413

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

[RedArrow]

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.

[ukvolvo]

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

[ukvolvo]

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