Volvo D20 User manual

Service
Manual
Repairs
and
maintenance
TP
30420/1
11.88
EngineD20,D24
240 1979-
19 ..

D20,D24
Both
the
D20
ancl
D
24Dieselenginesare
dealtwilhin
thismanual.
TheD20hasfivecylindersandtheD24six.Otherwise
the
enginesaresimilar
in
principle.
Not6lDifferent llywheels
andvibrationdampersar€
fitted
tothedilferentenginetypes.
Volvos
aresold in versions
adaptedtor different
markets.These
adaptationsclependonmanyfac-
IorsIncluding
ega,taxarionandmarkerreqJi.e
Thismanualmay
thereforeshowill!strations
and
lext
whichdonotapplytocars
in
your
country.
iffim itm!r
:i!r-l-l

Contents page
f
mportantinformation............................... 2
Specitications........ 3
Special
tools ...................................12
Group21Engineassembly...............................................
16
(Workwilh enginein-ca.,replacernent
of engrnej
Group22LubricatingSystem.........................................
123
Group23FuelSystem.........................................................
125
Group25Intake
andexhaustsystems................ .. r60
Group26
Coolingsystem..................................................
i63
Group27En9inecontro1s..................................................
175
Appendix"A"Faulttracing.............................................
A1
Index178
OrderNo,:TP30420/1
We
reserye
theright
to makealerat ons
Reprint
of'1983literature
without
change.
OVOLVO
NORTH
AMERICA
CORPORATION

lmportant
information
CLEANLINESS
Dieselinjection
systemsareoxtremelysensitiveto
dirt
and foreign m6tter. A special workplace should
thereforebeusedfor insoectionofcomoonents.
PLUGS
CleanfuelIineconnectionsthoroughly
beforediscon-
necting
pipes.
Plug
ends
of fusl linesetcas eachcomponentis
removed.Donotremovethess
plugs
untilthecompo'
nentis reconnected.
Tighteningtorques
Twokindsoftighlening
torqueswillbefoundinthis
1. Tightento40Nm
{30ft
lbs)indicatesth6tatorque
wrenchmustbeusedIortightening.
2. Tighteningtorque40 Nm {30 ft lbs) indicatesa
guidevalug.
Tighteningneednotbedonewitha
Iorouewrencn.

Specifications
Specifications
Group
20General
.,o
,o Engine
typedesignation
and
serial
number
Stamped
on
left
side
ofenginebeneath
vacuutr,
pump
Maxtorque
DIN
D
20Engine
OutputDIN
.......................... 50kW ar80 r/s
68hpat4,800r/min
120Nmat
50/s
12.2kpm
at3,000/min
5
1-2-4-5-3
1.986
dm3
(liter)
'181
kg
(405lbsl
Mpa
3.2
2.4
0.8
23.0:1
76.5
mm
: 3.0118in
86.4mm
= 3.4016in
Number
ofcylinders
Displacement.........
........
Weight,
approx.incl. enginemounts,altefnaror
and starter
Compressionpressuresi
\ew en9ine..................
iVnirnJn.......................
Maxd;ffe.enceberweencyl
nders..........................
Comp.ess,orratro.....
...
Cyl:nderbore..................
Stro\e
lengr
h
313
114

Specifications
D
24Engine
OutputDlN
MaxtorqueDlN
60kWal 80 r/s
82hpat4,800r/min
140Nmat47r/s
14.3kpm
6t2,800r/min
6
1-5-3-6-2-4
2.383dm3
{litsr)
1S8
{435
lbs)
MP.
3.2
2.4
0,8
23.0r1
76.5mm
= 3.0118in
86.4mm= 3.4016in
Numberofcylinders.......
Firingorder............,,...,...
Disp1acement...,,...,,....,...
Weight,approx.incl,enginemounts,alternator
and starter
Compression
pressurss:
Newongin€.........,,,,,.,......
lvlinimum................,,......
Maxdiffsr€ncebetween
cy1inders...........................
Com
p
ressionralio.......,,
Cylinder
bore....,.............
Slrokelength
psl
455
313
114
Group
21Engineassembly
CYLINDERHEAD
Replacecylinderh€ad
jfwarp €xce€dssp€cificalions.
Und€rnocircumst.ncos
maycylihderh€adb€machinod.
9- :.' ., - \|
; .,1 ,\
Diagonally
max0.5mm
L-

Specifications
CYLINDEBHEADGASKET
Thfeedifferentgasket
typesareused
dependingonpistonprojection
abovecytinderblock
face.
G.sket
Pistonproi€ction notches
mm
linl thickness
mm
(in)
0.67-0.80
(0.026-{.031
)........
1 ....................1.4
{0.0S5)
0.81-0.90(0.032-{1.035)........2 ...................
1.5
{0.059)
0.91-r.02
(0.036--0.040)........
3 ...................
1.6
(0.063)
Do
a
u
n
!
_o
-o
,lo
-L
VALVESYSTEM
Valveclearances,
coldengine
Cold
engine
= roomtemperature Check
mm
(in)
0.15{.25
(0.006-{.010)
0.35-0.45
(0.014-0.01
8)
Setting
mm
lin)
0.20
{0.008)
0.40
(0.016)
Valve
clearances,warm
engine
0.1299into0.1673in
inincrements
of0.0020in
0.20-0.30(0.008-0.012)
0.25{0.010)
0.4(F0.50(0.016-0.020)
0.45{0.018)
3.00-4.25mmin increments
of0-05
mm
o20
Checldadjust
valves
1-2-4-5"3
D24
Checuadjustvalvesinfollowingorder:
1-5-3-6-2-4
r-l[ r
]

Specifications
TIGHTENINGTOROUES
Tight€ning
torquB apply
to oilednutsandbo|Is.
grsased
{washed}
parts must b€ oiled prior to De-
NGHIENING
OF
CYLINDERHEADBOLTS
TIGHIENITVG
SEOUENCEFORCYLIIIDERXEADBOLTS
lmportlntl slsck6nbottsin rev€rsa
oder when
removing
cylindsrh€ad.
Removsoiland
dirtfromboltholes.
Oil
left
inhol€swill
reduc€
pressure
oncylinderhead
gasket,
Eolt threads
and washersmust howeverbe oiled,
otherwisefrictionalforces
will b6toogrear.
Twotypesot bolls ars in usetAn earlytypewith M 11
threads
and6later
typewithM 12threads.
{Later
typ€is
lhr@d6dalong
entir€l6ngth.l
Us6now waahera,convex sid6upwards,
Tlght€n
infiv€stages:
l50Nm{37ftlbsl
2 ?0Nm (50
ft lbs)
3 90Nm {65ft lbs}
4 run
6ngin€until
oiltemperaturo
isst t€ast
50.C
1122'Fl
5 90Nm (65
ft lbs)
R.lightening
- Atler 600-1.200miles (1,000-2.000
km). Engine
should
becold
oralmostcotd.
Tighten
eachboltsep6r-
atslyin specifi€d
order,
seeabovsfio.:
L Slack€n
bol 3(r
2. Torqueto 90lrlm (65ft tbs)
Us€n.u bolb. Notn€ce$ary
to roplac€w6shers.
Tighten
insixstag6s:
1 aoNm€0 ft lbsl
2 60 Ntn l4aft lbsl
3 75Nm{55
ft lbs)
4 angle-tightsn
l8f in onomovem€nrwithout
stop-
ping,
{Se€
figur€6tlowerlefi}
5 run€ngin€until
oiltehperatureisatlerst50oC
lt22
"Fl
6 anglo-tighten90Pin on6movsment
withoutstop-
pins.
Rdighl.nlng
After
60F1,200mil€6
(1,000-2,000
km).Engineshould
b6
coldoralmostcold.
Tighten
6achboll separatolyin spocifi€d
order,se€
€bov€fig.:
1. Angle-tighten
bolt 9|r in one movemontwithout
stopping.
(See
figure
atlowerleft)
Donot shckon boh firf,
@@
@@
oo
@o
,Ot rO
D20
,oo
@@@
@@)@
@@o
@@@
@
D24
o
Mtl M12

Specificalions
20Nm
6\1fl
I l'- '
i!
l1s
ft lbs)
zb
ro'\ 1rs tttu"t
100
Nm(74 ft
@lbs)
45Nm133 ft lbs)
b0
Smearthreadsandboltheadcon-
tacl suriaceswilh lockingcom-
pound(P/N
277961-9).
Tiqhteninglorque
350
Nn {258 ft
lbs)
appli6swhenusingspecial
tool 5188.lf a torquewrenchis
lsed dirscnyon the cenlerboll
(wiihout 5188),the tiqhlening
torqle shouldbe450Nm(332 ft
350Nm (258 ft lbs)
Nm (55
ft tbs)
75Nm (55
ft lbs)
Smear threads wiih
compound
P/N277961-9.
(6.5
ft lbsl
D20
@@'

Specifications
OILCAPACITIES
Excl.oilfilter
Incl.oillilter
Difference
involume,
max-min
ENGINEOIL
Oua1ity............,,,,,............
Accord'ngtoAPI.......................................,,..,....,.:::::::::::::,.:::::::
VbGosity
Tomporaturc
rangs
(stable
ambisnttemperatures)
ffiffi8
Gtoup
22Lubricating
System
D20
Litors
{US
quarts}
5.2
(5.5)
6.0
(6.3)
1.0
(1.0)
kPa
200
15-45
Long1h
mm in.
L = 49 (1.93)
L1=22 {0.87}
L2
= 19.8 (0.781
(completely
compressed)
psl
28
D24
Liters
IUS
quarts)
6.2
(6.5)
7.O
(1.41
1.0
(1.0)
minCC
OilswithdesignationsSSCC,
SE/CD,SF/CCandSF/CD
meotthisr€quirement
SAE15W/50orSAE20
w/50oilsarerscommend€dfor
useinsxtreme
drivingconditionswhichinvolvehig
hoil
consumption
andhigh
oiltemperatures. for example,
mountain
drivingwith frequent
decel€rationsof fast
motorway
driving.
(Note
howoverth€lower
tempera-
turelimits.)
OILPRESSURE
Oil
pressurc
atoiltemperature
of 8O.C
(176.F)
and
33,3r/s
(2000r/min)min
Oil
pressuresensot
Cut-outpoint,
indicatorlampgoes
out
at
Lubricating
oilpump
Reliefvalv€opensat...... .........................
600-700
R€lisfvalve
spring,l€ngthatdiffsrentloads
2-6.4
85-99
Load
N
0lbs
0
17F195 {39-.44)
approx.
200 (45)

Specifications
Group23
Fuelsystem
GENERAL
:o
a,o
Firins
order................. D20
'l-2-4-5-3
12.5
(750)
87.0
(5200)
DIN
51601rCEC-ERF-Dl,
or
ASTIM-D
975-No.2-D
45
0.5
D24
1-5-3-6-2
4
12.5
(750)
r/s
(r/min)
87.0
(5200)
r/s
(r/min)
ldle
fast
.,.,.....,.,.,.,,.
FUEL
Standard................
Make
anddesignation,
D20
D24
60litres
(15.8
US
galls.)
Distributor
rype
pump
Bosch
VE5/10F2400
145
(145'1
for
autovehicles)
BoschVE6/10
F2400
132
(132-1
forautovehicles)
500't716-9
5001715-1
Checkins
mm
lin)
0.75-0.83
mm
(0.0295-0.0327)
0.65-0.73mm
10.256-0.O2a7J
0.65-0.73
mm
(0.0256-0.0287)
0.82-0.90mm
{0.0323-0.0354}
VolvoP/N
{exchange
unit)D20
....................
D20.............................
D24
Injeclion
timing
{purrp
prunger
slrokeatTDC,
D24
USAand
Canada
1979-t98i
1982-
Settins
mm
{in)
0.80mm(0.0315)
0.70
mm
(0.0276)
0.70mm
(0.0295)
0.85mm
{0.0335)
NOTE!
High altitude
necessary
In certain
page
132.
0i:o
Bosch
No.USA,/Canad€
1982-
INJECTORS
Ir4akeanddesignation Bosch
KCA
30SD27l(44)
06813020?
F
(201
J)
068130
201
(201
K)
1328073,0
1257
t44-4
Checkins
1707-1849
Othermarkets...................
VolvoP/N
USt"/Canada
t982-
''''..
......................................
MPa
'......
.",.-
.- ...
.........,.-....,.
psi
Setting
12.5-',t3.s
1778,1920
lnlector
openingpressure

Specifications
Nozzl6s Bosch
DNOSD1930
DNOSD193
1328096,1
't542303-1
Iniector
(complete)
Nm
10
Designation
USA"/Canada1982-
Othermarkets
VolvoP/NUSA,/Canada1982'
3::133;3i
5l usarcanlda
,esz.
068190201
I ^.
oogrrozolxl
DN
05D193
0= USA/Canads
1982-
DN
= SD193 = olhermark€ts
ldentitication
ot iniectors
andnozzles
TIGHTENING
TOROUES
Injector,incylinder
head
upper-rowersection...........................::...:.:.:.:.:.:.:::..::
Iniection
pump,pump
g
70Nm
= 52ftlbs
70
45
ft. lbs
52
52
33
45
Nm= 33ft lbs
ti
10

Specifications
Group26
Coolingsystem
GENERAL
Capacity,
withmanual
gearbox
withauiomatic
transmission.....,,...
EXPANSION
TANK
Coohnt
Sincealuminiumisusedinthe
engines,activecorro-
sion
protection
isnecessaryinthecoolantto help
pre
ventcorrosiondamage.
Use
genuine
Volvoblue-green
coolanttypeCdiluted
withcleanwaterin proponions
of 50/50.
This mixture helpsto pr€venl corrosionand frost
a Never lill thecoolingsystemwith
wateralone.
a The coolantshouldbechanged
regularlysince
thecorrosion
prolective
6dditives
inthe coolant
losethoiref{ectintime.
c,il
co
Pressurevalve
incap
opensal,,.,.,.,,,,.,,,.,..,....,.....
D20litrosIUS
qlrrts)
8.2
(8.7)
8.0
(8.4)
Type1kPa
(psi)
65-85
(9.2-12.1)
7 {1.01
87'C
87'C
{189'Fl
102'C
l216.Fl
8mm
(0.3
in)
D24lirres
IUS
quarts)
9.4
{9.9}
9.2
{9.7)
Type
2 kPa
{psi)
r00
{14.2)
7 {1.0)
)ijo
tt:o
THERMOSTAT
Markin9.........................
Starts
toopenat,....,,.,..
Fully
openal
Openins
gap.
min.........
DRIVE
BELTS
Deslgndion
(Volvo
P/Nl HC38xl238
(960296-2)
HC38x975
(958354-3) 3Coolingran
4 Powersteo.ing
pump
Ir.lbs.
6.6
HC38x888
{460431
s)
TIGHTENINGTOROUE Hc38x800
(958302-1)
9
l'
Coolingfan
1l

Specialtools
Specialtools
999 lDdcription-U.s
18Ol-3 | Stand.rd h.ndle: lsed with drift 5207and 5208
261G3 | Liftbe.m: rcmovingfinslalling
engin€
2901-0
lC16mpinsplisrc{2x):clampinswat€rhoseswhenremovinsintecrionpump
2903.6 | Oiltlltorwl6Dch
4090-0 | Pullet:removing
pilolbearins
5006-5 | Lifibr.ckst:r€placing
tronl€nsinemounts
5033-9 | Support
{2xl:
forlilt bracl€t
5006
5112.1 | Loc*ing 6sdo.: lockingflywheel
51154 | Lifthook:usedwithltftbracket5006
5185-7 | Lifthoolrlronr:removing/inslallins
€nsin€
5186.5 | Lifthoo*,lsar:,€movins,4nstaltins
ensine
5147.3 I WronchrvibrationdEmoer
5188.'l I Wr6nchwith oxt nsionarm:lor vibralion
dampercenterbolt
5190-7 | Giuse:instsllingcamshaft
5191-5 | Adapter:
connoctins
pr6ssur6
ssuse
51$n I Siop:lockihs
injecrion
punp sear
5194.9 | Holder:fordialindicalorwhen
adjueins
inj€ction
pump
5195.5 | PlisB:
rcmovinsvalvediscs

Specialtools
5006,5033,5115
5185,5186 5187,5188
5194 5t95
't3

Specialtools
999
5196.4
5197"2
5199-8
52004
5201"2
520/t-6
5202-0
5203-8
5205€
l'207-t
5204-7
5233-7
523/t3
5235-0
9950-0
P.B3rooljforvalve
tappets
Balttonsion
g.uqo:
timing
ge8r
beltsand
pump
drive
Wr3nch:
frontandrearcamshafi
gears
Adapter:installingcEnkshaftfront
sealandcamshafts€als
Wr6mh:centernuton rear
camshafl
g6ar
and
pumpgear
Pullor:
pump
gear,
inj€ction
pump
P0llor;foridl€r
pull6y
Centerinssh.ft: forclutchdisc
P{ller:forcrankshaftfronts€sl
Drift:installingnsedlg
b€arjnsincrankshaft
Drift:installing
crankshaftrearseal
Guida
piB, M t l bolts
{4x):
installing
cylinder
h6ad
Guide
piB, M t2 bolG
{4x)r
installinscylind6rh6ad
Toollor removingsuide ping
Adapter:
gnsine
lpm.UsedwirhVolvoMonot€stBr
't4

Specialtools
5233,5234
9950
9950

Group21Engine
Contents
Contents
In-car
Valveadjustment.,,..,.....
Basicsettingofsngine...
Cylinderhead,
removaI
disEssembly...................
cleaning-chscking..........
asssmory........................
insta11ing.........................
tighteningtorquss,....,,...
Drivebeltsltiming
gearsandpump)
........................
belttension....,,,,,,.,.......,,
rep1acement....................
Camshaft,r€moval
insra11ing.........................
Camshaftoilseals,
replacemenl,
Iront.,,,...,,..,,...,,,.
Pilotbearingincrankhaft,replacement.......,....,.,..
Crankshaftoilseals,
replacement,front,,..,,...,,...,,..
Vibrationdamper,removal,insta11in9,,..........,.......
Enginemounts,rep1acement,,,.,,,.,,....,,...,,...,,...,,...,
Replacementof engine
Removal.,...,,.......,...,....,.
Insta11in9........................
Group
21Engine
Assembly
Operation
A1-10
B1-11
c1-21
D1-20
E1-11
G1-16
H1-38
K1-5
Ll-35
t\41-11
N1-27
o1-21
P1-21
o1-7
R1-21
s1-11
T1-10
u1-4
x1-33
Page
17
19
22
28
33
36
41
45
57
58
60
71
74
81
88
94
96
103
106
110
'r
11
'114

Group21Engine
A.Compressiontest
Special
tool:5191
Compression test
A1
Disconnect
wire lrom stop valve on injection
pump
This
stopsflow
offue and
prevenrs
t]nnecessary
spi|-
ase.
Remove
vacuum
pump
and
pump
plunger
A3
Disconnect
fueldetiverypipes
Cean all connecrions
carefu
y before
disconnecring
Disconfeci
pipes
and
plug
allconnedions
ro prevenr
dirifronrenterlng
system.
A2
11

Gtoup21Engina
Compression
test
44
Removeiniectors
Use27mmsocket
{Volvo
P/N
1158146}.
Liftouth€atshieldsundsriniectors
otherwise
they
will
beblownout
duringcompression
tesl.
A5
Connectcompression
testel
Placea
heatshieldincylind€rheadandscrewin
adapter
5191.Ightento70
Nm
{50
ft lbs).
connectcompression
testertoadapter.
A6
Runengine and record
Compression
Min
Maxdiffer€ncebetween
Installiniectors
Place
newheatshields
injectors.Torque
to70
Reconnectdelivery
Tightening
torque25
compression
=
3.2MPa{455psi}
=2.4MPa (341
psi)
=
0.8MP.
(114
psi)
A7
in cylinderhead,
seefig. Install
Nm (s0 it. lbs).
A8
pipes
Nm
(18
ftlbsl.
A9
Reconnectwireto stopvalve
Install
pumpplungor
and
Check
pump
O-ring.replace
r'.l0
vacuum
pumP
18