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  #21  
Old 06-21-2020, 10:18 PM
RedArrow RedArrow is offline
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Default Another post to attach 5 more picts

So the engine accessories came off, including the b...tch oil cooler assembly. All waiting to be cleaned up, some for a coat of paint or checkups.

For the oilcooler main oring at the body of the engine, under the 32mm nut, shall I get a new one? What about the turbo piping where the large cotterpin is? Thanks.

The engine was super oily and dirty on the manifold side.
I noticed that one of the exhaust gaskets were not fully seated.

I added diesel fuel in a spraycan and after removing everything I soaked it well abd started the hr long scrubbing with brushes etc.
Even had to use screwdrivers to loosen up dirt in the tight corners. Found rocks and leaves etc behind and above the intake manifold.

After 2 huge and long scrubbing sessions using diesel, I wiped it off and used brake cleaner then started again.
Then dishsoap liquid then 99% alcohol many times. Then (t)aped it and made it ready to receive some 2+1 layers of engine enamel primer then 2+1 coats of paint I described earlier as Rustoleum farm equipm green. I like this tone and decided to have it again. Took long hrs and all dobe by hand. Except wirewheeling that was also some few hrs of work with several profiles of wirewheels (ports taped!). And about 6 large batteries worth of spinning. Sandblasting? Not here...
Was really down to bare metal to do it right.


Before this project the factory green was showing at two spots.

Theres a million tight corners and they need you unless you like rust for later. Oily goo is stuck in the very corners and had to fight it off everywhere.

Cheers
Attached Images
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Last edited by RedArrow; 06-21-2020 at 11:01 PM.
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  #22  
Old 06-21-2020, 10:24 PM
RedArrow RedArrow is offline
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Join Date: Jan 2013
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Default Some rainbow shots and the end of the day.

Today it all dried slower due to weather so I had to have a very long day. Cleaning and preps are real bitch.
Attached Images
File Type: jpg 20200621_213249.jpg (499.8 KB, 8 views)
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  #23  
Old 06-22-2020, 09:09 PM
RedArrow RedArrow is offline
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Join Date: Jan 2013
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Default

I cleaned the idiotic oilcooler mount then I only had two "projects":

Prepared the exhaust manifold for paint (couldnt find the black VHT high heat stuff so I used silver VHT high heat stuff... I prefer them in darker color so it will get resprayed. IDK what their color is coming from factory BTW. Anyone knows? lets see who had a 0mile td brick in the 80s...?
Interestingly this one has a crack at the very same location as my other d24t does. Bottom lip where it is skinny metal.

Same for the valve cover which I decided to have in somewhat glossy high heat black enamel, also later on I will be ordering a new grommet for the top (and a long list of parts).

It's nice that for some reason on this particular engine both were in very good condition. Made life easier... And Mr Wirewheel was the best friend again

That's how I dealt with the bad design EGR mushroom.... didnt have the patience dealing with that tight angle and horrific corrosion so I chopped it off.
I have leftover new studs from previous exhaust/turbo area nightmares on other d24s and I will make a blockoff plate with *copper nuts LOL. That's it.
Attached Images
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File Type: jpg 20200622_212207.jpg (558.3 KB, 4 views)

Last edited by RedArrow; 06-22-2020 at 10:24 PM. Reason: Pics
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  #24  
Old 06-22-2020, 09:18 PM
RedArrow RedArrow is offline
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Join Date: Jan 2013
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Default High heat 500F paint suggested if want it to last. Ask me how I know:)

Less and less rust is good news around this survivor engine.
Attached Images
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File Type: jpg 20200622_232154.jpg (477.7 KB, 8 views)
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  #25  
Old 06-23-2020, 08:07 PM
RedArrow RedArrow is offline
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Default 5pics Monday

Started sanding the intake but didn't have much patience; decided to finish up the pump side instead (makes no sense )

Hours of soaking, scrubbing, sanding, wirewheeling, etc.


Replacing the oil dipstick tube o-rings, top inside tube and bottom one inside block.


Still need to get the pump brackets off too and get them cleaned up.

Each injectors are wearing a finger of a pandemic rubber glove and a cap. Bus bars came off and I also cleaned the outside of the cylinder head, filed off some imperfections and touched it up.

Then wiped the block super clean and prepared it for the enamel primer. It is receiving the farm green color today no matter how late im gonna have to stay up...
and then, finally, the engine paint project will be done...I will then let it cure for multiple days until I get other things cleaned and set up; and prep gaskets, a pump belt etc.
Attached Images
File Type: jpg 20200623_160227.jpg (443.6 KB, 6 views)
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Last edited by RedArrow; 06-23-2020 at 10:03 PM.
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  #26  
Old 06-23-2020, 08:10 PM
RedArrow RedArrow is offline
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Default Pump side of the engine cleared off and done today

Primer layers are on now and i am going outside to spray the green soon.
Attached Images
File Type: jpg 20200623_204553.jpg (746.6 KB, 6 views)
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  #27  
Old 06-23-2020, 08:53 PM
RedArrow RedArrow is offline
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Talking

In the meantime the wagon is eyeballing the engine :'))))))
Attached Images
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File Type: jpg 20200624_001859.jpg (482.5 KB, 6 views)
File Type: jpg 20200624_001906.jpg (356.5 KB, 6 views)

Last edited by RedArrow; 06-23-2020 at 09:53 PM. Reason: Pict
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  #28  
Old 06-24-2020, 10:51 PM
RedArrow RedArrow is offline
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Default Wednesday already?!

Another day passed,

another day on the Volvo stuff...

unfortunately my girl is probably totally fed up
with all this bricking and it is very hard for me to explain it to her
what this dieseling really means to me.
Sometime around 1990 there was a 78 244 2.1 then an 84 d24 244 that started it all and there were bricks and diesels around ever since, VW Golf-s, LT, Volvos etc. Dealing with these cars and engines bring back precious memories and provide joy (not always) and they serve as physical&brain activity too.


So today I continued disassembly (or assembly? ? IDK ) of the d24t that came from the donor 744.

It is actually the perfect pandemic project, well, one of the hundred


Started again playing around the intake manifold and managed to find the power sander to help me out. After doing half of it I gave up. Freaking Volvo should have polished that damn intake at the factory, such a shame they didnt think of it.


On the injector side of the engine,

I took off the taping from bolt heads and cylinder heads.

Cleaned and reinstalled the oil pressure sensor with a new copper washer.

Checked the new o-ring fitment on the dipstick bottom and removed the old oring (was rock hard and broke into 6 pieces as soon as I touched it).
Attached Images
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File Type: jpg 20200624_225910.jpg (393.6 KB, 6 views)

Last edited by RedArrow; 06-24-2020 at 11:22 PM.
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  #29  
Old 06-24-2020, 10:52 PM
RedArrow RedArrow is offline
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Join Date: Jan 2013
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Default PART 2 Wednesday, parts wash, painting, assembly disassembly combo

Several engine other parts again have been removed and soaked, scrubbed, cleaned, sanded, prepared, all properly primered & painted.

Not all of these colors match with the factory/stock colors so no offense.

I did what I thought will look good and harmonize with the rest of the engine. I simply copied what I usually did with other d24s because they came out good and most of the time I happened to like them afterwards.



The oil dipstick tube - semi gloss black enamel

Throttle spool bracket on injection pump - semi gloss black enamel

Vacuum pump - Light silver wheel/rim paint high heat enamel

Joint piping below intake manifold- light silver rim paint enamel (same as above)

Coolant long metal piping that runs behind the intake manifold- semi gloss high heat black

Oil cooler housing - not painted but polished (thinking of a layer of high heat clearcoat but I will leave it as is for now)
Attached Images
File Type: jpg 20200624_213310.jpg (532.2 KB, 3 views)
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File Type: jpg 20200624_205754.jpg (366.8 KB, 3 views)

Last edited by RedArrow; 06-24-2020 at 11:27 PM.
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  #30  
Old 06-24-2020, 10:58 PM
RedArrow RedArrow is offline
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The pump side of the engine:



For the removal of the injection pump and its brackets,

I had to gently torch the two large bolts that are hidden behing the inj pump, there was no other way because they felt totally stuck and corroded.

I made sure to keep all heat away from the pump and the nearly inaccessible bolts finally gave in and loosened.

Then I found my Volvo tool for the removal of the injection pump sprocket rear gearing and it worked like a charm. No, I didnt lose the woodruff key. `Almost doesnt count`.



these are the colors I used after the 2+1 coats of primer dried:



Throttle linkage - glossy black

Inj pump large bracket and small bracket part- glossy black higher heat tolerance enamel

Inj pump sprocket- semi gloss (satin) black enamel


INJECTION PUMP - green color that is called Satin OLIVE made by Rustoleum.

It is a very nice color in my opinion and I was happy to randomly find such color on my shelf.
((I recall using it on the Husquarna 450 dirtbike and it looked really great bc we did camouflage and this was part of the color-combo setup.))

So, the injection pump is now `matchy-matchy` with the rest of the block
which is Farm Equipment green, almost like the color of a John Deere tractor. These two greens go well and the black brackets will normalize the look into something good because the valve cover is also black now. I also wanted the exh manifold black but couldnt find high heat black on my shelf. And since the silver high heat coat has been baked already, I may just leave it silver now.


d24s are tractors afterall, arent they?



After a few layers of the olive, the pump assembly received 3 coats of high heat tolerance clear enamel to make it stand up better to the heat and possible leaks in the area. If any...


About pump fuel leaks.


I have the full reseal kit for the injection pump but I decided to not do anything to it, at all, because this pump appears to be rebuilt by a reputable diesel shop and I havent noticed any leaks when I ran the engine on the stand, also there was no evidence of pump leaks visible anywhere.
So that`s good news.

I also have the 12mm pump head that I bought from one of the professional dieselbrickers via this forum but I decided to not mess with this pump unless necessary later.

Even the cold start device works on this pump and car still had the intact egr setup as well.

So the pump hasnt been opened up
because I didnt want to complicate things and end up with another to-do project. For the time of spraying, all openings had been tightly sealed, used alu foil plus plugs, blue tape and other ways to plug holes such as the unused egr holes, threads, rubber boot, and to save the rebuild info I stickered up their label and also taped off the Bosch manufactuer pump info tab. The only hose that got overspray is the one I want to replace anyway (return side).



Maybe if I had more time and only the pump to deal with, I`d attempt to reseal it if it was necessary but it isnt.
I have enough stuff to do already, it`s been over a week on this engine, many hours every day.


The paint will cure for several days from now on, but soon there will be an engine assembly with the fresher looking AND NOW CLEAN parts.

Everything in the garage is filthy dirty from this d24t alone and let me tell ya this engine wasnt even as dirty as most of them are.
Donor car didnt even have active leaks for example (except valve cover that generously oiled everything below.
Attached Images
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File Type: jpg 20200624_164120.jpg (439.0 KB, 6 views)

Last edited by RedArrow; 06-24-2020 at 11:45 PM.
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