740 Turbo project from finland

[J4nne_]

Hello D24 forum!

-Introducting the project
Greetings from Finland! I wanted to show you my 740 d24 turbo project. Project started when i bought my volvo. It had been sitting for 3-4years without driving, i decided to take the car and start project. Interior of the car was in very bad condition, its still unfinished, doorpanels etc small stuff is missing. Well the backseats were all moulded because finnish winters are pretty snowy and the car had sitted on the snow. Backseats i could recover just by giving them good clean.
Buying condition

Stock engine

Original spoiler and paint polished


-The motor
This is the part i like the most
Engine was in good shape, it did run just like new so i decided to take it part and make it my base engine for car. This car supposed to be kinda stock but then things went out of handle. I did buy big turbocharger..
Some reason previous owner had builded this engine Na even that it should be stock turbo engine.

I tell you the specs of the engine and drop some pictures
Base engine
-Stock d24t bottom end, oil sprays etc
-Stock rods and pistons
-Ported head (mild porting only)
-stock camsaft (not stock timing for cam )
-Elring metal headgasket
-rebuilded head
Ported head+lapped valves


Turbo and intercooler
-Gt35 Turbo, ar.70 compressor, ar.86 turbine
-Cummins style manifold
-50mm external wastegate
-600x300x76mm intecooler
-740 Na intakemanifold
-2,5” intercoolerpiping
-3” exthaust
Welded manifold



3" pipe

Starting to look something, the turbo looks so big on that picture




Gearbox and diff
-m46 stock gearbox (going to die very soon, some unhealthy sounds :/ )
-Sachs sre 763 clutch with stock plate
-1041 diff with g80 locker
Sre pressureplate


Fuel system
-Prototype injection pump, builded out of three pumps.
-6000rpm pulling
-Modded governor
-12mm disturbor head
-Atm stock camplate (3.1mm lift camplate waiting for some modifications)
-modded pump internal dynamic timing system
-facet external fuelpump'
-basic turned and gringed fuelpin
-Stock injectors, new heads+more pressure

10&12mm plungers

Pump teared apart

Diy fuel pin



Car is pretty angry right now, wheelspin on third gear with normal acceleration. My goal is get 250hp mark breaked on dyno. Spools up pretty good, 3000 pressure goes 0.5bar, 4000 rpm has full 2,0 bar boost.


My future plans are build that engine even more powerful
-prototype intakemanifold
-Heavy ported head, get a grinded cam for that and more agressive valve sprins and three angel valve job.
-Raise boostlevel (valve springs..)
-Modified valves to head
-Try different exhaust manifold, differet collector desing
-Gearbox upgrade
-Compound turbo (BIG MAYBE)




Overall picture of the car



So shortly, D24 with big turbo and aggressive fuelpump Now running 2.0 bars of boost and revs up to 6500rpm.

Because forum allows only 20pics per post PLEASE check my photobucket for more pictures, such as intake manifold and stage 2 headjob-->
http://s1055.photobucket.com/user/Ka...?sort=3&page=1

Feel free to drop some comments or questions, more intresting stuff coming on

[J4nne_]

Here is some pictures about the more aggressive head, i want basically get most out of stock valves. Bigger valves for this head is kinda waste of time and money because you can gain like 2mm more bigger intake

The bowl areas of the head are bit messy and unfinished, like raw cutting has been done. I first port those two ports and then do reference flowtest to them, if they are good im going to use them as guidelines for rest of the head.


I had to get some extra preload to wastegate since the exhaustpressure was creeping that out, did help like hell for spooling. Now port opens naturally at 2 bars


I try to use this custom manifold with that more aggressive head and see results, never seen thiskindof manifold on d24. Basic dual chamber desing.



I did also some modifications for valve cover, didnt like the yellow color because original breather did mess it up so badly. So i welded piece of tube there.


Now it needs only some catchcan type thing. Also i need to get some airfilter.
Enginebay is hot as hell with that engine so i think somekind of cold air setup would not hurt

[ngoma]

Beautiful work on the manifolds!

You are indeed brave to reshape the IP 3-d cam. The fuel pin is easy to understand but how did you know where to go with the 3-d cam?

Sorry about the gearbox but I think you have easy access to the M90 gearbox over there, correct?

[J4nne_]

Originally Posted by ngoma

Beautiful work on the manifolds!

You are indeed brave to reshape the IP 3-d cam. The fuel pin is easy to understand but how did you know where to go with the 3-d cam?

Sorry about the gearbox but I think you have easy access to the M90 gearbox over there, correct?

Well if you mean the 3.1mm camplate, its untouched. Reason why i didn't use that is because it needs different kind of dynamic internal timing setup of the ip. By modificating i meaned that pump itself needs modifications to get it work like should. Fueling is now actually pretty good for the setup in running.

The m90 box for diesel is like piece of gold here, if you find one its highly priced. M90 isnt also "fast" box to shift. I planned to modify bmw zf or getrac gearbox to get box that holds the power and allows quick shifting

[J4nne_]

Well, i get second turbo.

Im going to build compound turbo setup. Secong turbo is from volvo truck, its garret gt45. I need to get smaller exhaust housing for that to suit my needs.
I did some calculations from compressormaps of turbos, they looked okay by working in compound so i picked the turbo.

Also i did some updates to intercooler mounting, its now mounted behind the grill and shorter chargepipes.



Next things to get are
-new manifold for suit different position for gt35
-wastegate setup
-dump pipe form gt35 to 45 and downpipe
-primary and seconday chargepipes
-SMALLER exhaust housing (maybe run existing from only one throat)
-injection pump with that 3.1mm cam

Stay tuned.

[R.Mojica]

very nice work

[1488]

Good job! Post some videos!

[volvo-dennis]

Cool project Looking forward to your next post. Lots of pictures are always a good thing

Dennis

[Fisherman]

I would love to see this thing in a dyno!