1992 745 turbo diesel swap

anders · #1 12-03-2019, 07:23 PM

Well I'm starting a new swap project, I have done several gas to diesel swaps on the 240 series (so easy!) this is actually my first 740 gas to diesel swap..
Here is the rig. It's been in the family for a while, it got overheated and popped the head gasket or cracked the head. So.. The family member decided they didn't want to fix it, so I decided it could use an engine with good power and fuel efficiency. Ideally would like to start off with a turbo gasser as the washer bottle, air filter and battery are on the correct sides for the diesel swap.

anders · #2 12-03-2019, 07:25 PM

Time to get busy! Lots to do, trying to get it done in a few days.

anders · #3 12-03-2019, 07:33 PM

Engine and transmission out! I dropped the engine out with the crossmember because I need to install the diesel crossmember. I had purchased a 1986 744 that I was going to restore as it was my favorite color combo ( black with black interior!) but I found it to be severely rusted when I put it on the lift. So it's being used as the donor for this wagon swap. Here is what has been removed from the 86 744:
Engine crossmember, battery tray, washer bottle, air filter box, transmission, transmission shifter, transmission crossmember, driveshaft, fuel tank filler neck and fuel tank sending unit.

anders · #4 12-03-2019, 07:39 PM

Old b230/AW combo next to the D24T/ZF I will be using. The d24t and zf are not from the 86 donor as I opted for a engine and transmission with low miles. The D24T was a green car company import engine, what's really cool is the engine is a 1992 and so is this wagon! The ZF is from a 84 sedan that was totaled two decades ago.. Transmission has been waiting patiently in my barn for a worthy host.

anders · #5 12-03-2019, 07:48 PM

Yep, the D24T will be using the NA intake, I will also be running a Holset HX30W turbo (44mm,6cm w/MWE) I found that this turbo is an awesome performer in a moderately modified D24T. I do have plans on using a 12mm pump head, 3" exhaust, intercooling, ect.. I have allready installed ARP head studs along with a rebuilt cylinder head.

ngoma · #6 12-03-2019, 10:20 PM

Is that crossmember one of the later reinforced ones?

anders · #7 12-04-2019, 05:21 PM

Quote:

Originally Posted by ngoma

Is that crossmember one of the later reinforced ones?

I believe so, I think all of them are after 1986?

anders · #8 12-04-2019, 05:25 PM

Engine and transmission are bolted in! Along with the driveshaft and radiator. Also a pleasant surprise to find the b230 AC compressor bolt right onto the D24T pump bracket and no modifications needed for the hoses.

anders · #9 12-04-2019, 05:27 PM

Started the engine wiring. Here is what the engine harness looks like before removing the unnecessary wires.

anders · #10 12-04-2019, 05:43 PM

Here is what the harness looks like after removing all the not needed wiring. On the left is the wiring that will not be used, on the right is what will be used. I still need to add an ignition wire, Coolant temp signal for glow plug relay, and tach signal from the alternator.

Started moving battery and washer bottle location. What I found out is I can't use the factory air box from the 1986 744 because of the ABS pump is in the way.. I'm not sure what I will do now, I have several ideas. One of them is to use the battery location alone and use a type 78 battery or similar on the passenger side and then use a universal air filter above the battery and leave the washer bottle in its current location. The second idea is to build a battery tray to go above the washer bottle on the drivers side, the plus to this is I can install a water to air intercooler on passenger side below the airfilter.