Intercooler 3B/ Turbo Project......

[magnus_heydoc]

Background: My rig is a 76 40 series chassis with an 84 3B 5speed. It was completely rebuilt including sleeves when it got the diesel motor about 10 years ago. 6 Years ago it received a 2nd tank above the rear axle and a DIY vegetable oil switching system. It received a TD05-12B turbo from a volvo as well. I actually don't remember which of those projects came first. At any rate it has over 50k kms on grease and turbo. It ran around 14psi and never exceeded 600C on my pyro mounted pre-turbo.

I believe it got quite hot one time. At some point a year or two ago I found "trace" glycol in an oil test. It used approx. 250ml of coolant from the reservoir every couple thousand kms. The coolant in the reservoir was at times discolored to a weird brown/rust color. It still ran fine when I began this project but I expect I have a leaky head gasket or a cracked head. I'd always wanted an intercooler and to go back to the original air canister (from an open cone style air filter) and to add a snorkle. I also needed new fenders so some aluminum fenders are enroute. All this business, some new gaskets for other motor parts and new pre-cups will be performed.

Pictures to follow. Stay tuned if this is your brand of vodka.

 

[magnus_heydoc]

Intercooler:
The rad was moved back 2.5 " and the fan shroud trimmed. The IC is 3" in thickness.

Stock Air Can:
To get the stock air can to fit the turbo had to be 'rolled in' so to speak towards the valve cover. This required adjusting the angle adapter, clocking the turbo, and adjusting the exhaust. My FPHE for heating grease had to be removed from the firewall and relocated.

Head Gasket:
The head was pulled and disassembled. The pics show valves and intake surfaces that have deposits presumably from uncombusted fuel/ SVO. This truck has been running SVO with a two tank system for 6+ years. This would be approx. 80k kms. Things look better than expected in my opinion.

 

[magnus_heydoc]

more pics

Cylinder walls have no more cross hatching but generally look good.

 

[magnus_heydoc]

more pics

The head gasket look perfect. It does not appear to be a bad gasket at all.
It appears all pre-cups have small cracks. Quite common for 3Bs of all sorts.

 

[magnus_heydoc]

more pics

Intake valve 1,3 and 7 and their areas on the head looks reasonable. Intake valve 5 and it's area show moderate deposits. There are deposits on the intake areas on the head for all valves to some degree.
It doesn't appear that running SVO is aggressively ruining the motor.
I noticed the 3rd and 4th injectors were sorta loose when disassembled. Injector tips looked mostly normal as far as I could tell.
More later.

 

[gerg]

Looks like fun. I gotta say though... those are some pretty dirty intake valves.

 

[magnus_heydoc]

I've never had a head off a car/truck so this is a new project for me. I'd be interested to see intake valves from another 3B.
If these intake valves look excessive it's offset by running free fuel worth well over 2k clams per year for the last 6 years. I'm doing this job with a friend but at that rate I could pay someone to do the head work every 6 years or so.
I'm wondering if this look inside should also be posted in the SVO section? Moderators?

 

[fjbj40]

For the mileage the deposits, except for the last one are quite minimal. For the amount of work it is to remove the head I would suggest dropping it off at a shop and get it hot tanked, valves and seats recut and lapped. They will check the head for flatness at the same time.
Get new precups, they should be replaced if cracked. Give them the new precups when you drop off the head as they will more than likely need to be ground down to be flush with the head sealing surface. The specs are in the FSM, IIRC they are supposed to be a couple of thou above or flush.

The precups are easy to remove and install, I use a long thin punch down through the glow plug hole to drive them out. I use a dead blow hammer to drive them in, that easy, but as I said they will need to be ground.

As per you question about porting and polishing that is up to you. I have done it and it does improve some things, it is a pump so if you just clean up the casting marks as in seams in the ports and clean up the corners it will flow more efficiently. HP expectations? Maybe a couple as in 5-10 but it may lower EGT's also. The tunnels are quite rough so any improvement is better than stock. Port matching will gain the most from my experience, it improves throttle response greatly.

Remember, it is a 3B though!

Regards,
Daryl

 

[gerg]

Yeah so the WVO stuff has nothing to do with your intake grime and everything to do with the cleanlyness of the intake air. Im guessing a dirty filter or a K and N filter. The verticle scoring inst bad at all. How was compression? I sent youa PM by the way.
g

 

[magnus_heydoc]

Yup, got it there Super Grover. Thanks. I love Super Grover, he and Letterman. (not the talk show host)
I've been running a K&N open cone style for years. It got really clogged once that the EGTs went up. So both I guess. Lesson learned there. Then I cleaned it more regularly.
I didn't check compression before this job began unfortunately.
Fenders and Intercooler are next while the head is away.

 

[magnus_heydoc]

Fenders and IC fit

The fenders took around 20 bolts per side. It wasn't too bad to fit them until they were level, even and drilled. My running boards needed mounts as well and served for a good solid lower anchor when drilled and bolted.
They'll come off now for paint.

The IC was fitted in front of the rad and plumbing was mocked up.

 

[magnus_heydoc]

Fenders

The fenders are Al from Aqualu in BC. They are very well made and identical to oem except they don't have the braces. They suggest you don't need the braces but we thought they were very flimsy not b/c the fenders were weak but that they only bolted to the truck in a couple places. In my usage I'd be kneeling up on fenders and sometimes standing on them so we added the braces from other oem steel fenders we had laying around. They're very strong and fit well, nice and level etc. Super square.

 

[magnus_heydoc]

security token

I've tried to upload pictures a dozen times or more with little success. It says I somehow lack the right "security token".
I've been successful a few times. It seems oddly random. Any solutions anybody? I've conntacted the admin and they don't really have a solution.

 

[buschmaster86]

maybe a setting on your computer ?

Nice project ! youll be alot more confident when driving with replaced precups !!

if you search for precup glue on this forum there is also nice info about that

 

[magnus_heydoc]

fenders and IC

more pics

 

[magnus_heydoc]

Fender Brace

Fender Braces were deemed necessary and were removed from the old fenders to be added to the new AL fenders.

 

[Chamba]

I heard a rumour that Woody installed hardware to block photos of upside-down Bezels. Maybe that was your trouble with the photos
Great work. One of my mates in Australia intercooled his 3b and put the cooler on top of the engine with a scoop. I like yours better as you don't ruin the lines.
Who thought you needed the old braces? Is that true for all Aqualu fenders?

 

[magnus_heydoc]

I'm not sure about all fenders all I can say is that in our experience around here guys routinely would be kneeling or standing on the fender. There's no way those fenders could stand that kind of use as they'd only be fastened at that hinge under my upside down bezel .......funny man.

Even with the brace, man are they light. If you're in market b/c you've got cheesy rusty fenders these are great. 2 new steel fenders are around 800 clams. 2 new AL fenders are 1300 shipped so I went for it. The Aquala fenders are nearly identical to oem. Really well done.

 

[Chamba]

Luckily mine are clean but my cousin is planning a tub and maybe fenders from them. I've always been very impressed with their stuff. I never thought of leaning on them. AK cracks rather than bends so a very good idea.

 

[magnus_heydoc]

intercooler sizing

Here's some calculations Chris did to help select the proper sized IC


The head and lots of other stuff are back on. Fenders and days and days of plumbing are next.
pics to follow.