volvo ecodiesel project

[500dollar744ti]

i have aquired a 1984 volvo 240 diesel with the D24.  i am working on turbocharging it for a setup much like the vw ecodiesel jetta.  any tips or tricks for this project?  the plan is to use the manifold and turbo i sourced from a D24T car in conjunction with a 3" thick 12x18 intercooler.  i was hoping i can turn the fuel adjustment on the injector pump up to add a bit more fuel with the boost.

any ideas on what sort of boost my goal should be and what kind of increase in power (if any) can be expected?  currently the motor is rated at 80hp and 103lb/ft of torque.  i know the increase in economy will go along with this but i am really looking for some sort of increase in power..

1) basically what might be expected using a turbo with a large intercooler and my 2.5" 740 turbo downpipe with the n/a injection pump?

2) does anybody know the size of the bolt that is used to hold the oil filter extension housing to the block on the D24T, it is probably similar to something offered on VW models.

3) i have extensively searched this site and after i thought i had put the idea of turboing this car to rest i have been reinvigorated by the success stories i have seen on here of people turbocharging their 1.6 n/a motors.  thanks in advance for any help/tips that you can provide.  

[flapjack]

here's my favorite volvo "smoke tale"
http://vwdiesel.net/phpBB/viewtopic.php?t=1554&highlight=volvo

[rabbid79]

I would not be concerned about the "turbo worthiness" of your 240D.  Back in the early '80s VW turbocharged the naturally aspirated version of that motor to the tune of 180 HP, and put it in their 200+ MPH top speed test car.  So as far as turbocharging it, you should have just as much success as the 1.6 4-cylinder folks, and maybe even more.

You should be able to adjust the output of your pump, but it could be a little smokey when not on boost.  If you could get a turbo pump, or retrofit the LDA top, that would be best.  I see turbo pumps on eBay from time to time for around $150.

As for the bolt size, I believe that engine has a lot in common with the Audi 5-cyl.  (I know oil pumps and such are the same.)  I suggest setting up an account on vag-ag.com (it's free) so you can see all of the VW/Audi part illustrations and part numbers.  In the description for each of the parts, it usually tells you the size of each of the fasteners.  Just pay special attention to the way they have the data formatted.  There's a solid line between the illustration number and the part numbers that makes them look like they don't belong together, but they do.  You'll see what I mean after you play with it a while.  Then go to 1stvwparts.com to look up the part number and price.

[500dollar744ti]

thanks for the constructive input guys... i went to the scrapyard and for $65 i got a turbo, manifold, oil lines, oil filter extension housing, upper section of LDA pump, partial downpipe and other bits from a nice D24T i will need to do this.  i am stoked about the project and it wasn't until i read all of the success stories about those turboing their 1.6 diesel motors that i got the motivation to do this.

[500dollar744ti]

well, i am almost done with it, just need to setup an exhaust, it has way more power than i expected without even touching the injector pump.

i will post some pics and a video in the smoke tales section if it will let me.

[500dollar744ti]

well the video can be found here, the turbo setup is great and it has gobs of power now!

http://forums.turbobricks.com/showthread.php?t=131057

[Vanagoner]

very cool- lots more power than I expected!  hey- does that turbo have the M4 twin-scroll manifold with a T3?

[500dollar744ti]

^^^ whatever is the stock turbo for a d24t, some sort of t3, TA03 maybe? honestly i am not sure, but the turbo wouldn't fit without notching the frame rail a bit, i shoehorned the turbo in there.  i suppose the reason they never offered the motor in a 240 in turbo form is because it didn't fit. it definately has more power, even with the n/a injector pump still.

[Vanagoner]

If it has M4 or M3 on the exhaust casting near the impeller wheel it is a twinscroll.  It sounds in the video like it boosts up ok at modest RPM's.  either that or you are running immodest rpm's in the video!  I have one of these turbos myself (off of a 760TD) and will install it for fun and see how it does.

[Black Smokin' Diesel]

That thing sounds extremely mean!! It's awesome! For sure one of the best V6 sound I've heard.

[Vanagoner]

The D24 is actually a straight 6 VW engine- same bore/stroke etc. as our 1.6 w/2 more cyls.  it was used in VW's commercial trucks in europe, but not brought in here except in the Volvos.

[500dollar744ti]

i just installed a 2.5" downpipe and a 2005 volvo S60R exhuast system that i had kicking around... it is the twin pipe tuned exhuast and actually on my turbodiesel it sounds incredible... i was skeptical but it sounds great.

i will have to get a video of that too.