Palmers 940 D24tic

[Palmer]

I'm going to use this space to document various happenings / doings to my newly acquired 940 diesel. Its a 2.4L straight six turbo diesel intercooler (D24tic)

It started out with me browsing ebay looking at a few motors, when I came across this. I messaged the buy with a cash offer and he accepted. So I filled my mates fuel tank the next morning and set off to Leeds, West Yorkshire.

Few piccies from the ebay add:








Lovely condition seats



Original fire extinguisher!




Arrived in Leeds, looked over the car and accepted the deal, and began the journey home! After stopping off for a much needed Maccies of course! I was driving home mainly by myself as my mate took the wrong turning and nearly ended up in Manchester! Whilst I was on the A1 heading for home. Eventually he caught me up and I had a hoot of a game pulling in front of him and then flooring it so it covered his car in soot. As they say, if you cant smoke em' choke em'! Anyway this game ended with a phone call that described sparks coming from the rear of the car. Needless to say the rest of the journey was spent @ 50mph.

After investigating the next day there was jingle on the rear right wheel. Turns out it snapped the brake pad pin that holds the clip in so the clip was jingling. £3 kit from the local motor factors fixed this.


A few days passed and the car was running lovely, so I decided to clean the engine bay a bit:



And found this!! Trip to the welders needed lol



Anyhoo I didn't really clean the engine as they are generally greasy anyway so I just did around the engine bay and the bulkhead.

Let it dry and set off for my Dads, got down the road and my brakes failed - forcing me to rip up the handbrake to avoid the rear of a learner! Not to self: Handbrake is §§§§§ hot!

After a few days of puzzling and a second hand servo I threw in the towel and rang Steve, who appointed me to the fact the T piece along the servo hose should have a small vac hose in it. DOH! Found it down the back of the engine......



My basic plans for this car are to give it a major clean up, it was a "mobile mechanics" car so it is in dire need of a valet. Lacquer peel has also attacked the front, and seeing as my bro now has his own spraying premises a full respray could be on the cards at a later date. If the parts crop up - manual conversion too!

[Palmer]

Every 940 needs a substantial horn of course.....

Single air horn, ive gone for the stealth look with everything being completely hidden under the headlight / in the bumper



Sounds the tits!

[Palmer]

Installed my catch tank today....



With which came the new intake



Fuel Pump Mods

Turned the fuel screw in a little. Its pictured here with the yellow markings on



Simply wind it in a few turns and tighten the jab nut back up. Obviousely there is an element of danger, being a rotary pump it can "run away" and rev sky high until it pops a piston in ya face! However im still at stock boost, so a few turns just gives it some more oomph. Ill set this up properly, including idle control etc when I up the boost. (Checked the turbo today, no shaft play at all @ 185k miles!!!)

Next I modified the LDA, located on top the pump. The idea is to liven the ole' bus up a bit and make it more driveable / quicker to take off.

Remove the 4 screws on the lid and it will look like this



Carefully peel the rubber diaphragm up and get a finger under the metal disc either side, and gently pull up. Be gentle as if you use too much force, it will knacker the dowel that rides on the fuel pin.

It should then look like this



There is a plastic washer in their, put it somewhere safe, like in the bin!

Take out the fuel pin and look at the mark that's been made by the dowel riding it



Removing the plastic washer allows it to ride all the way to the bottom thus injecting more fuel per (longer) stroke, crank the star wheel (gear like object) down a few turns. This reduces the tension on the diaphragm and allows it to inject more fuel at a lower boost setting. It does increase smoke though. This can be fine tuned with the jab nut / screw on top of the LDA



Before putting the Pin back in, note it is a shaft with an eccentric cone at the lower end. Rotating the pin to the more aggressive side (right had side in the pic) also increases the amount of fuel. It can be ground with a dremel or some sort to make it had a deeper ramp. My opinion is personally, get it done professionally. It needs to be 100% smooth for perfect fuelling and also the tolerances are minute, to an engineering level. So it will be better for performance if you get a pre ground one which is already at the limit, rather than guessing.

Overall: the car is **** hot! I need to fine tune the LDA with the screw on top as its smoking like a trooper on pull off (note: Black smoke = unburnt fuel = waste!)

But yeah, I am impressed with how jusy turning up the fuel makes it more lively. A lot more driveable is the expression id use, less throttle needed to get upto motorway speeds etc. And the auto box seems even more at home @ WOT.

[smithy]

Nice build thread mate keep it going

[c70geoff]

nicely done fella, look forward to seeing how this one progresses

[T5frankie]

why is it not wearing the volans you have?

[Kingsford G]

Nice buy mate and that horn is sick lol

[Palmer]

Cheers guys, im really looking forward to upping the boost muaha!

Volans wont fit without £300 spacers Frankie :/

The horn is epic, lets everyone know of your presence lmao

[Palmer]

Decided to rust proof the areas of the engine bay that are prone to corrosion. Aka the battery area and washer bottle area and chassis legs (I think lol)




Also, to give an idea of smoke - heres just revving:

[M-R-P]

Haha, James Bond will be so proud

Sounds nice. Good work

[T5frankie]

well done mate

[iancho]

Your doing well mate, keep it up !

[Palmer]

Decided to make a bracket to mount the catch tank on so it was more "flush"



And in place

[martybelfastt5]

great write up watching on voc too

[Palmer]

Just realised I never posted the mileage!!

[iancho]

Some serious miles mate... Nice one

[Palmer]

Now, my car has had the EGR system vacuum feed disconnected, to stop it from working, so when in Rome....

EGR solenoid and pipework removed



Traced the gaskets onto sheet metal and cut them out with a disc cutter



Tidied the edges up with an angle grinder so they fit flush, and then removed the burr with my dremel




Bit of gasket maker and bolted back in place

[Rudy]

Good looking project, always had a thing for these volvo's, Had a work car back in 2009 but 2.3 petrol, went side ways like a charm..

Keep up that good work..

[Palmer]

This arrived yesterday



Set of new discs and pads, drive belts, auto gbox service kit, oil filter and a set of glow plugs.

Will be fitted with an engine flush, new oil, new ATF, and new diff oil.

Also tested this today



Just a mock fitting. Currently its back out and im filling in the right hand side as you can see it slope. Also the finish is pretty poor just a quick splash of paint to bring up any blemishes. Cig lighter will be relocated to the centre console.

[1112lewis]

Finally got chance to read through this! You do love the dremel! Best tool ever.