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  #1  
Old 03-23-2020, 04:56 PM
v8volvo v8volvo is offline
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Join Date: Jun 2009
Location: Livingston, MT
Vehicle: '86 745, '83 764
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Thumbs up Quarantine Project Thread

While many of us are stuck at home more lately to slow the spread of the coronavirus, thought it would be fun to start a thread where we can share pictures and updates from projects we are working on in our newfound spare time. These might be D24-related, or anything else -- other vehicles, house projects, whatever seems interesting.

I'll start it off. My current project is a 1999 VW T4 Eurovan MV (picture attached) that was diesel-swapped a few years ago by a builder who did a nice job with the conversion, but unfortunately went way overboard with power increases on the engine. This is a little 1.9L engine moving a heavy, tall van, and they tried to compensate for the extra workload by just turning up the fuel and boost, using a set of huge injectors and an aggressive computer chip.

Didn't take long for the poor guy who bought it to blow the engine up climbing a mountain pass, of course. It still starts and runs now, but sounds like no compression on at least one cylinder and a pretty bad tap. Never lost the coolant or oil so hopefully it's rebuildable at least. I'm expecting either a melted or cracked piston, or two, or maybe a badly blown head gasket and/or head. Plans are to refresh the engine (or replace it if this one is too far gone), and get it back down close to stock power output for reliability.

I'm also finally getting started on my Audi Allroad TDI conversion by doing some work preparing the 2004 Passat 2.0L BHW engine that will be going into it. Attached as well are a couple shots of the TDI engine coming out of the donor car last month and one of the Audi eventual swap recipient.

Volvos are temporarily on back burner, but both of them need transmission work or replacements this year, so hopefully give them some attention soon.

What's everyone else working on?
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__________________
86 745 D24T/ZF 340k lifted 2.5"
83 764 D24T/M46 145k
93 Toyota 4x4 pickup 1.9 TDI swapped
04 Audi Allroad 2.0 TDI swap in progress
02 F250 SD 5.4/4R100
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  #2  
Old 03-23-2020, 07:22 PM
ngoma ngoma is offline
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Join Date: Nov 2009
Posts: 796
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Tracking down an intermittent electrical problem. GPs energize intermittently when driving (at least indicated by instrument panel orange GP indicator lamp). First thing to look at for any electrical problem on these cars is the wiring-- Bosch soybean-based biodegradable insulation wiring.

Sure enough found bundles of the degraded insulation wiring at the 4-pin GP relay connector.

Managed to re-insulate, using a mixture of Liquid Tape, electrical tape, and heatshrink tubing. Problem persists so I need to investigate the wire runs further.
Attached Images
File Type: jpg P1030809.JPG (151.0 KB, 6 views)
File Type: jpg P1030815.JPG (141.0 KB, 4 views)
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1985 744 gle d24t
1985 745 gle d24t
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  #3  
Old 03-24-2020, 09:46 AM
v8volvo v8volvo is offline
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Join Date: Jun 2009
Location: Livingston, MT
Vehicle: '86 745, '83 764
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Started pulling things apart on the van last night. Doesn't look too good so far. I was hoping for an outside chance that the engine problems (rapping and thumping noises and a dead miss) could have been a collapsed hydraulic lifter, which sometimes happens to these, but all the lifters are fully pumped up and seem to be working fine.

One thing that is clear right away is that this engine has seen either a huge amount of heat in the cylinder head, or very poor routine maintenance, or both. The inside of the head is coated with black, slimy buildup from polymerized engine oil broken down by too infrequent changes or excess heat exposure from the aggressive state of tune. This does not give me much hope for the condition of the rest of the engine.

Here are some pictures so far, along with some other pictures for comparison to more healthy engines that have seen less abuse (another AHU TDI and my 745's D24T engine -- sadly showing my shattered camshaft from a couple years ago).

See the strong family resemblance between this TDI engine and the D24 engines. They knew they had a good basic design and no need to change it.

Going to pull the head off next and see what that looks like, hopefully later this week.
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File Type: jpg IMG_20180415_154828.jpg (489.0 KB, 14 views)
__________________
86 745 D24T/ZF 340k lifted 2.5"
83 764 D24T/M46 145k
93 Toyota 4x4 pickup 1.9 TDI swapped
04 Audi Allroad 2.0 TDI swap in progress
02 F250 SD 5.4/4R100
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  #4  
Old 03-25-2020, 07:59 PM
v8volvo v8volvo is offline
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Join Date: Jun 2009
Location: Livingston, MT
Vehicle: '86 745, '83 764
Posts: 1,160
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Head is off of my project van and unfortunately it's not good news.

#2 and #3 cylinders are badly scored and have heavy aluminum deposits from the pistons, and #2 piston has visible missing material on the crown. Looks like #3 cylinder might have still been making just enough compression to fire, since it was dry. #2 is the only one that is washed with fuel and obviously was not running. But the pistons and bores in both cylinders are toast. Surprisingly #1 and #4 cylinders look OK. Maybe the outer cylinders naturally run a little cooler. Or I wonder if the piston oil squirters for 2 and 3 could have gotten slightly clogged or leaked pressure, and weren't able to pull out heat as well as the others.

Fortunately the way the engine is positioned in this van the oil pan can be removed easily, as there's no crossmember below it. I think I will drop the pan next and pop the pistons out of all 4. This engine obviously needs to be fully rebuilt and bored, but I have a few used pistons around, and my current thinking is I might try to just clean up the two damaged bores as best I can and put it back together with used parts to get it running well enough to limp along for a little while. That will at least give me a chance to get the van on the road and check out the rest of it, to see if it's worth the work and expense.
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__________________
86 745 D24T/ZF 340k lifted 2.5"
83 764 D24T/M46 145k
93 Toyota 4x4 pickup 1.9 TDI swapped
04 Audi Allroad 2.0 TDI swap in progress
02 F250 SD 5.4/4R100
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  #5  
Old 03-26-2020, 06:48 PM
anders anders is offline
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Join Date: Jul 2010
Location: NW Washington USA
Posts: 792
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I have now started a few projects! The current one is setting up part of my other shop to have all my d24/d24t parts organized into one room. Itís a 22íx10í section just for my d24/d24t parts hoard. I built a section of a wall to close it off from the other part of the building, also set up 18í worth of shelving on one side.
This is a project I have been wanting to do for a while now, having all the stuff organized and out of my shop that I do my work in.
__________________
12mm pump heads, ARP stud kits and GTD nozzles available! http://d24t.com/showthread.php?t=1646
NA intake manifolds and 240 turbo pans for sale.
Need d24 or d24t parts? PM me!
Shipments done on fridays!

1982 242 D24+T/M46- Super pumped! Build thread:
http://www.d24t.com/showthread.php?t=1545
1984 764 D24T/ZF build thread: http://www.d24t.com/showthread.php?t=1734
Diesel parts cars: 82 244,83 244, 84 244, 84 245, 85 745
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  #6  
Old 03-30-2020, 08:56 AM
v8volvo v8volvo is offline
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Join Date: Jun 2009
Location: Livingston, MT
Vehicle: '86 745, '83 764
Posts: 1,160
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Sounds like an upgrade! I'm envious of the space you have, has to be nice to have all that room for work and storage.

I'll add another update here on the work I'm doing, since keeping these updates rolling seems to be helping me stay motivated with this project.

I had to spend a little time stripping down my spare parts TDI engine that is donating a couple used pistons. This came out of a later year TDI and I had picked it up a while ago mainly for some electrical parts I needed for something else (ECU, harness, etc). The engine had a timing belt break at highway speed unfortunately, but otherwise was in decent shape. It is a second generation ALH code 1.9 TDI that has a different external block and head architecture, but the rods, pistons, and a few other internal parts are interchangeable with the earlier type 1Z/AHU TDI engines like the one in this van.

Once I had freed up a couple pistons from the parts ALH (with valve impressions but they measured out OK), I dropped the pan on the van's engine and popped the middle two pistons out. Next, I'm going to do my best with crocus cloth and a hone to get the bores cleaned up as well as they can be, and throw these whacked ALH pistons in and button it all back up.

This engine is now a bit of a science project, running damaged pistons from one engine in another engine's damaged block. Not even going to put on new rings, since I don't have much hope for a great bore seal here either way, just hoping for enough to run and move the van around under its own power for now. Planning to reuse the headbolts this time too, as Tom Bryant always suggests, to add another experiment. Only brand new part going in here will be a head gasket. We'll see how this goes. Best case it runs well enough to get a little use out of it, worst case I hopefully don't have much to lose other than a $20 head gasket and the time I waste messing with it.
Attached Images
File Type: jpg IMG_20200327_234145.jpg (485.4 KB, 10 views)
File Type: jpg IMG_20200328_155958.jpg (647.8 KB, 11 views)
File Type: jpg IMG_20200329_203811.jpg (571.8 KB, 11 views)
__________________
86 745 D24T/ZF 340k lifted 2.5"
83 764 D24T/M46 145k
93 Toyota 4x4 pickup 1.9 TDI swapped
04 Audi Allroad 2.0 TDI swap in progress
02 F250 SD 5.4/4R100
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  #7  
Old 03-31-2020, 07:15 AM
anders anders is offline
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Join Date: Jul 2010
Location: NW Washington USA
Posts: 792
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Yes indeed an experiment! I did something very similar when I was 16. I purchased an 84 f41 Camaro with a 2.8 and 4 speed. Anyways it had a horrible rod knock, being a cheap and experimental high schooler I ended up getting a FWD 2.8 from a Chevrolet car. I didnít realize when I purchased the engine that the blocks between FWD and RWD are different.

I stripped both engines and installed the rotating assembly from the FWD engine into the camaro block. Had a tough time installing the pistons, I found out they were oversized pistons! I didnít want to spend any money on it other then the $45 for the gaskets and the $25 I spent for the FWD engine. I ended up spending hours honing the block to accept the larger pistons!

Got the engine together with all used parts, camaro block and heads, FWD crank, pistons, rods, along with the used bearings and rings. Amazingly the engine actually ran very well, didnít use oil or have much blow by! I was told that the engine would blow up, but it ran for the year I had it, I ended up trading it for a seized up dirt bike.

It was a fun experience, it was the first automotive engine I put together.
__________________
12mm pump heads, ARP stud kits and GTD nozzles available! http://d24t.com/showthread.php?t=1646
NA intake manifolds and 240 turbo pans for sale.
Need d24 or d24t parts? PM me!
Shipments done on fridays!

1982 242 D24+T/M46- Super pumped! Build thread:
http://www.d24t.com/showthread.php?t=1545
1984 764 D24T/ZF build thread: http://www.d24t.com/showthread.php?t=1734
Diesel parts cars: 82 244,83 244, 84 244, 84 245, 85 745
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