What to look for in a used D24T

[Wren]

Originally Posted by anders

That will end up being a nice swap, I have thought about doing a swap like that with a V90/S90 sedan. If you don't mind me asking what did you pay for all the parts from the wrecking yard? Keep us posted on the progress!

My cost was about $300.

[anders]

That's a pretty good deal in my opinion.. A local yard wants $500 for a non turbo D24.

[Wren]

Some yards are best avoided. There's a local place that always tells me, "Them Volvo parts are expensive" like they pay more for a Volvo when they buy them by the pound than they do a Chevette. I'm not afraid to leave parts behind if I get a lot of high-priced nonsense from them. I just usually tell them that I'm buying to resell (which is true in most cases) and I can't make any profit buying for full retail.

[ngoma]

So, a 7xx crossmember bolts into a 9xx-series? That would make it too easy!

[Wren]

Originally Posted by ngoma

So, a 7xx crossmember bolts into a 9xx-series? That would make it too easy!

In many ways, the 7's and 9's are essentially the same car.

[v8volvo]

Nice find!

Very good idea to leave the whole drivetrain just assembled as you have it -- for converting the gas car to diesel, fastest and easiest way is to just put the engine and trans in from beneath with the crossmember attached. I just did that same thing converting a 1986 740 turbo gas wagon and found it much faster and more elegant than installing the drivetrain topside. See pictures below.

Also, from the parts car, be sure to get the important parts of the diesel fuel system as well! Most critical is the fuel filler neck assembly. The diesel filler neck is larger and does not have the vapor-catch flap, so that it can admit the larger diesel fill nozzles that stations often use. See picture below for comparison. The fillers are not hard to swap and, IIRC, are shared between sedans and wagons. Grab it regardless.

And yes, you will need the clutch pedal and its bracket, any cruise control vacuum/electrical switches related to the clutch pedal, the clutch cable (though you may want to replace with new), driveshaft with center support bearing and front and rear shaft halves marked to preserve their proper phasing, and most of the under-hood wiring harness bits.

Bummer that someone took the turbo, since they certainly will have trouble using it on anything else. I hope they left the oil supply and return lines attached to the engine? I have a couple of spare D24T turbos in good shape that I would be willing to sell. The irritating part is that whoever stole that turbocharger also stole the turbo-to-downpipe gasket, which is getting hard to find and will not be useful to whoever bought it. Too bad. You will be able to find one with some effort.

Fuel filler comparison, gasser on left, diesel on right. Good idea to get the filler cap from the diesel too. I can describe what I did to modify the fuel lines and venting system from the gas car -- that part is not hard, no need to worry about getting the tank and lines, just the filler. Plus the 960 wagons came with a nice extra large 19-gallon fuel tank anyway... which you will want to keep regardless.


And here is what it looks like installing a D24T drivetrain "module" from below... disconnect the front suspension and steering and it is a piece of cake. I did it without even unhooking the power steering hoses from the donor car.

[Wren]

Originally Posted by v8volvo

Nice find!

Bummer that someone took the turbo, since they certainly will have trouble using it on anything else. I hope they left the oil supply and return lines attached to the engine? I have a couple of spare D24T turbos in good shape that I would be willing to sell. The irritating part is that whoever stole that turbocharger also stole the turbo-to-downpipe gasket, which is getting hard to find and will not be useful to whoever bought it. Too bad. You will be able to find one with some effort.

I thought about that. If I do get a D24T turbo, I'll have to round up that gasket. I was considering putting a slightly upgraded T3 on the engine once I get it going. 115 HP isn't going to be very inspiring in a car that had a 200 HP engine from the factory. In that case, I wouldn't have to worry about the stock downpipe and would weld on a different downpipe to turbo flange.

One fly in the ointment is finding a shifter boot/console for the 960 that will work. I think I can put a later 960 center console in and install a boot. It sure would be easier to use a stock part and I've contacted a couple of guys I know in England who may can help me.

Originally Posted by v8volvo

Fuel filler comparison, gasser on left, diesel on right. Good idea to get the filler cap from the diesel too. I can describe what I did to modify the fuel lines and venting system from the gas car -- that part is not hard, no need to worry about getting the tank and lines, just the filler. Plus the 960 wagons came with a nice extra large 19-gallon fuel tank anyway... which you will want to keep regardless.

The donor car is an '83. Aren't the filler neck/fuel senders different from the early to late cars? I know the '85 740's used a different sender arrangement than the later cars; in the later cars, the fuel filler coupling hose goes directly into the sender while the earlier cars have the fill pipe go into a different part of the tank.

Originally Posted by v8volvo

And here is what it looks like installing a D24T drivetrain "module" from below... disconnect the front suspension and steering and it is a piece of cake. I did it without even unhooking the power steering hoses from the donor car.

Wow, that's crazy! How did you pick up the front of the car? Overhead beam?