volvo D24T diesel, it's running

[scopefrfd]

Does anyone know if vw made a metal headgasket for the 2.4 6 cylinder diesel engines.  I'm rebuilding a D24T and I'd like to get a metal HG if possible

[itzdshtz]

I don't think so, maybe the Volvo guys know

[745 turbogreasel]

I think the metal one was designed as a service replacement part because so many of the lesser ones blew out...
Hard to find, but it does exist.

You might be able to get some info here... http://lists.subtend.net/mailman/listinfo/d24

[piper109]

Volvo does have a steel head gasket.  I understand it is only available from Volvo dealers and costs over $200.   I can be peeled to get the correct thickness.   It is reputed to last longer than the others and can be reused.

[scopefrfd]

$200 is a crazy price for a MLS HG.....that's like when vw use to charge over $125 for a G60 MLS HG....then Reinz sold the same exact HG for $40 aftermarket.  If it was $100 I'd buy one...but I picked up a Reinz volvo HG for $40.  They're good for 150K, so I went that route.

[scopefrfd]

Total seal rings installed...ported and polished head is done....just waiting for the tranny mainshaft seals to come in and I think it may be in a week or so.  

I found a really nice heat exchanger that I'm going to use as an intercooler.  It's a water to air unit...the sucker has to weigh atleast 20lbs and it has a copper heat exchanger.  

Need to change the intake do a standard D24 style.  If anyone wants to post pics I can send pics of the engine and the progress.

[745 turbogreasel]

PM sent...
What did you do for a headgasket?

[scopefrfd]

I went with the stock Reinz HG....I know the metal HG is an upgrade but I've personnally never have had trouble with the Reinz fiber HG.  I only plan on running 20psi of boost so it should be ok.   The price the dealer charges for the metal HG is quite frankly robbery, over $170 difference in price.  I took the money saved on the HG and bought total seal rings.

Just put new nozzles in and pop tested them...all around 155bar.   Going to set the timing at 1.00mm.  I want to put the whole engine in complete so I'm going to time out the pump while it's on the engine stand.

Going to re-seal the pump this week...the pump did not leak but I don't want to take the chance of seal failure once it's in.

[RabbitJockey]

i have a volvo td :^(  rwd and more potential wheee

[scopefrfd]

Well the pump is resealed...while I was in there I removed the intermediate spring and shimmed the governor so it puts a light preload on the main spring.  hat'll give me some more fuel up top in the rpm band.  

I also adjusted the star wheel...I was able to turn it down 3 full turns.  I rotated the aneroid pin so it will be able to give more fuel and removed the plastic stop/bushing so the pin will have more total travel.  

I've emailed some pics out...hopefully they'll get posted

[745 turbogreasel]

[scopefrfd]

thanks for posting the pics

...engine is in the car..should be running hopefully by the end of the weekend.  I just need to figure out the wiring harness as some a**hole stole my laptop computer bag with my laptop, camera, and volvo green shop manuals.

If anyone has the volvo D24T shop manuals for sale please email me.

[745 turbogreasel]

This may help with the wiring:
http://photos1.blogger.com/blogger/2157/1425/1600/g11.jpg

More excerpts from the greenbook here:
http://volvoturbodiesel.blogspot.com/

Thanks Ross, and too bad you beat me on the greenbooks lot  

[IRoll]

That is just beautiful. Nice work.

      If you don't mind, would you share with us where you got your parts? and thereabouts how much this rebuild cost?

      Thank you very much. Good luck.

                  -Eli

[scopefrfd]

Well, it's running...the engine started right up in 20F weather...let the engine warm-up and did the 1st retorque.  I have to say there is virtually no blow-by pressure coming out of the valve cover.  I think the total seal rings are doing there job.  

I had to delete the volvo 740 gas oil to air cooler as it was a real pain getting it in there and mounted properly.  I'm going back to the vw unit.  I have a larger oil/water oil cooler from and audi S4 and the volvo air/oil unit.  I'm installing an oil temp gauge..if the original oil cooler can't do the job...I'll upgrade to the larger audi unit..if that doesn't keep the oil temps in check..then I'll switch over to the volvo air to oil unit.  I also  installed a 80C/176F thermostat so that should help keep the oil temps from rising excessively.  

Hopefully it'll be on the road in a week or so.