My 960 D24TIC2/M46

[Kraftwerk]

I registered on this forum a while ago, but didn't get much time to visit it afterwards, because of chronic lack of time.
Anyway, as promised earlier, this is my '94 960 with D24TIC2 engine and M46 4-direct-speed+overdrive gearbox. Eventhough my overdrive is able to engage in 2nd and 3rd gear as well, which I don't really see as a bad thing, therefore didn't try to fix it, eventhough I read somewhere that it is supposed to engage only in 4th gear.

Anyway, this is (well, was, got a few more in the meantime) my first Volvo passenger car, and I bought it in May 2011., by chance...I was driving around looking for some W123 Mercedes's to buy and saw this sitting in someone's backyard. I really loved the fact that it was so huge and beautifully boxy all-around, eventhough I didn't know at the time that it's quite rare and different from 740's which are so-to-say common.
I knocked on the doors and asked around, it turned out that car is for sale and advertised locally, but with not too much luck, since Volvo isn't something a lot of people is after, and this one had completely dead engine and was in generally poor condition.
About an hour later, tow-truck was there.
Here are some pictures:



(you can see in the background an '87 Mk.2 Passat 1.6TD we used to have as a mule-car back then...it was falling apart and Volvo would have replaced it if it didn't become my daily driver)

I mentioned horrible interior?







The girder was there to stop the tailgate from smashing someone's head, since there were no tailgate shock absorbers:


Got some tires and stuff as well:


And off she went:



To be continued...

[Kraftwerk]

So...the engine was rebuilt immediately:




NOT A TRACE of rust:


More pictures of tearing the engine compartment apart:






To be continued...

[Kraftwerk]

Parts have arrived:












Head and block machined:



And finally:



To be continued...

[Kraftwerk]

After that, it has been a long year of driving the 960 and constantly working on it - if there's any interest in my thread, I will keep posting progress so far...

[jbg]

Originally Posted by Kraftwerk

After that, it has been a long year of driving the 960 and constantly working on it - if there's any interest in my thread, I will keep posting progress so far...

Yes there is interest in this thread! We're always interested in keeping these vehicles on the road. Please keep up the good work!

[Kraftwerk]

Allright then:

Fixed the bumped rear fender:


Took the doors apart and fixed locks and power-windows:


Got missing emblems:


BUT, this one is from an early 760 TD...does anyone have a correct "TURBODIESEL INTERCOOLER" emblem off a 960 for sale?


Ventillation motor was dead, couldn't find a replacement one anywhere, so I bought a whole 960 3.0i for this:


While installing new float:


Old tail-lights:


New:


Already better, right?

[v8volvo]

Добар дан!

Looks fantastic! What is the latest news?

[casioqv]

Awesome car!

[Vomaz]

Love these cars
Please keep up the good work!

[Kraftwerk]

Uh-huh...haven't updated this in a while.

In the mean time, harmonic balancer went to hell causing timing to slip, first a bit, so I saw it as a pump issue, and then it slipped completely and consequently pistons slammed into the valves, resulting in 12 destroyed valves and a never-seen-before DOHC head on a D24TIC.

Pictures:




"Stains" on the pistons were actually only from all the burned fuel, and in the aftermath score was: Forged pistons vs. Valves 1:0.




Kids, do not try building a DOHC head this way at home!

So, after two weeks off the road, sourcing parts, almost-new cam from a wrecked VW LT with super-low mileage, new valves, valve seats - complete head job, another Glasser MLS head gasket, etc, we're back on the road.

Fixing the A/C and installing another, electric, fan in front of the A/C radiator:
(The fan used was engine fan from my parts car)