Volvo D20 User manual

Service Manual
Repairs
and maintenance
TP 30420/1 11 .88
Section 2(20-23.25-27)
Engine D 20. D 24
2401979-19 ..

D 20, D 24
80th the D 20 and D 24 Diesel engines are deall with in
this manual.
The D 20 h as fi ve c ylinders and the D 24 six. Otherwise
the engines are similar in principle.
Note! Different flywheels and vibration dampers are
titted to the different engine typas.
00000
000000
Volvos are sold in versions adapted for different
markets. These adaptations depend on many fae -
ta rs including legal, taxalion and marke! require-
ments.
This manual may therefore show illustrations and
text which do not ap ply to cars in you r coun tr y.
•
•
, ,. .. , •
•

Contents
Page
Important information . ... ... .. .. ... .......................................... 2
Specifications .. . ... ........ ... .. ... .. ... .. ... .... .. .. ... ... ... .. ... .... .. .. .... . 3
Special tools . ......... . .......... ............ .. ............................... ... ... ..... 12
Group21 Engineassembly ............................................... 16
(Work with engine in-car, replacement of engine)
Group22 Lubricating System ........................................ .
Group 23 Fuel System ........................................................ .
Group 251ntake and exhaust systems .. .......... .. ........ .
Group 26 Cooling system ................................................. .
Group27 Enginecontrals ................................................ ..
A d" "A"F I "
ppen IX au t tracmg ............................................ .
Index 178
Order No.: TP 30420/1
We reserve the right lO ma ke alterations
Reprint of 1983 literature without change.
GVOLVO NORTH AMERICA CORPORATION
123
125
160
163
175
Al
1

)?JIt.. ...... ~.
2
Important information
,,. ...
nO'"
" Nm
135020
ClEANLlNESS
Diesel injectionsystemsare extremely sensitive to dirt
and foreign matter . A special workplace should
therefore be used for inspection of components.
PLUGS
Claan fuelline connections thoroughly befora discan-
naeting pipes.
Plug ends of fuel lines etc as each cemponant is
removed. Do not removeIhese plugs unlil the cempo-
nent is reconnected.
Tightening torques
Two kinds of tighte ning torques will be found in this
manual.
l. Tighten to 40 Nm (30 ft Ibsl indicates that a torque
wrench must be used for tightening.
2. Tightening torque 40 Nm (30 ft Ibs) indicates a
guide value. Tightening need not be dona with a
torque wrench.

Specifications
Specifications
Group 20 General
Engine type designatian and serial
number
Stampad on left side of engine beneath vacuum pump
Volvo designatian 133 757
vw designation
D 20Engine
OutputDIN ......................................................................................
Max torqueDIN ........................... .... ..................................................
Numberofcylinders ................................... .. ... ... .............................
Firing
order ......................................................................................
Oisplacement ..................................................... .. ... ... ... .. .................
Weight, approx. incl. engine mounts, alternator and starter
motor ............ .. .................................... .. .... .... ... ... ... ... ........................
Compression pressures:
Newa ngine ......................................................................................
Minimum ........ ... .. ................................ .. .. ... ... ... .. .... .........................
Maxdifference between cylinders .... . ... .... ... . .. .............................. ..
Compression ratio ............ .. .. ... .. ... .. ... ........................ ... ... .... ... .. ... . .. .
Cylinder bore.............. ... .. .. .. .. ............................................ ... ............
Stroke length .....................................................................................
50 kW at 80 r/s
68 hp at 4,800 r/min
120 Nm at 50 r/s
12.2 kpm at 3,000 r/min
5
'·2·4·5·3
'.986 dm
3 (liter)
181 kg (405 Ibs)
Moa
3.2
2.'
0.8
23.0:1
76.5 mm = 3.0 118 in
86.4 mm = 3.4016 in
pSi
'55
313
11.
3

Specifications
D 24Engine
OutputDIN ........................................... ... .. ... ...................................
Maxtorque DIN
Numberofcylinders ....... .. .. .. ... .. ... .. ........................................... .. ....
Firing order ..................... .. ................................ .. .... ... ..
Displacement ................................ .. ... ... ...........................................
Weight, approx. incl. engine mounts, alternator and starter
motor .. .... .. ........ .. .. ... ..................................... .. .. ... .. .. .......................
Compression pressures:
Newengine ............... .. ...... ............................................................
Minimum ............ .. .... .. .. .........................................
Maxdifferencebetweencylinders ................
..
Compressian ratio .. .. ... .. .. .. ............................................
Cylinderbare .. ... .. .. ................................. .. ... .. .................
Stroke length .. ........ ......................................................................... ..
60 kW at 80 rIs
82 hp at 4,800 r/min
140 Nm at 47 rIs
14.3 kpm at 2,800 r/min
6
'-5-3-6-2-4
2.383 dm
J (liter)
198 (435 Ibs)
MP.
3.2
2.4
0,8
23.0:1
76.5 mm = 3.0118 in
86.4 mm = 3.4016 in
psi
455
313
114
Group 21 Engine assembly
CYLINDER HEAD
4
0,5 mm
128 146
Diagonally max 0.5 mm
Replace cylinder head if warp exceeds specificalions.
Under no circumstances
may cylinder head be machined.
r l
0,2 mm
I,
Square max 0.2 mm
128 147

Specifications
CYLINDER HEAD GASKEr
Three different gasket types are used depending on piston projection above cylinder block face.
Gasket
Piston projec1ion notches thickness
mm (in) mm (in)
0.67-O.80(0.026-{1.031) .. .. .... 1 .................. .. 1.4 (0.055)
0.81-0.90(0.032-0.035)......
.. 2 ................... 1.5 (0.059)
0.91-1.02(0.036-0.040)........ 3 ................... 1.6
(0 .063)
5197
Gearbelts
/I~
,
Belt tension (measured with tool 5197)
checkvalue
.. . ... .. ... .. .. .. .. ... ... .. .. .. ... .. ... ... .. .. .. ... ... ... .. ... ... ... ... ... ... ... ..
, , s ,
, , ,
, , \',-
setting ......................................................................................... ..
12-13
12.5 ,If?
VALVESYSTEM
Valve clearances, cold engi ne
Cold engine = room temperature
intakevalves
... .... ...... .. ...................................... ... . ... ..........................
exhaust valves ...........................
.. ................................................... ..
Valve clearances, warm engine
intake valves
... ............................... ................................................ .. .
exhaustvalves ................ ...................................................................
Shims ...... ............... .. ... . ... .............................. .. ....................... ..
0.1299 in to 0.1673 in in increments of 0.0020 in
020
o
Check
mm (in)
0.15-0.25 (0 .006-0.010)
0.35-0.45
(0 .014-0.018)
Setting
mm {in}
0.20 (0.008)
0.40 (0.016)
0.20-0.30 (0.008-0.012) 0.
25 (O.010)
0.40-0. 50 (0.016-0.020) 0.45 (0.018)
3.00-4.25
mm in increments of 0.05 mm
o A
Check/adjust valves in following order:
1-2-4-5-3
I "" intake valves
A '" exhaust valves
024
Checkladjust valves in following order:
1-5-3-6-2-4
y
,
5

Specifications
TIGHTENINGTORQUES
Tightening torques apply to oiled nuts and bolts. De-
greased (washed) parts must be oiled prior to as·
s embly.
r
V o
o
r
~
I!l C!l
1- -
4ll 9
V
'--
o' O'
020
f) o
O
f)
024
l)
01
e
O O ~
O O
O'
TlGHTENINGSEOUENCE FOR CYLINDER HEAD BOL T8
Importentl siaeken bolls in reverse order when
removing cylinder head.
Remove oil and
dirt from bolt holes. Oilleft in holes will
reduce pressure on cylinder head gasket.
Bolt threads and
washers must however be oiled,
otherwise frictional forces
will be too great.
Two types of bolts are in use: An early type with M 11
threads and a latertypewith M 12threads. (Latertype is
threaded along entire length.)
TlGHTENING
OF CYLINDER HEAD BOL T8
M 11
I
Usa new washers, convex side upwards.
Tighten in five stages:
1 50 Nm (37 ft Ibs)
2 70 Nm (50 ft Ibs)
3 90 Nm (65 ft Ibs)
4 run engine until oil temperature is at least 50"C
(122 CF)
5 90 Nm (65 ft Ibs)
Retightening
-After 600-1,200
miles (1,000-2,000 km). Engine
should be cold or almost cold. Tighten each bolt separ-
ately in specified order, see above fig.:
1. SIaeken bolt 30°
2. Torque to 90 Nm (65 ft Ibs)
90 ·
180 ·
IM,!il
6
Use new botts. Not necessary to replace washers.
Tighten in six stages:
1 40
Nm (30 fl Ibs)
2 60 Nm (44 ft Ibs)
3 75 Nm (55 fl Ibs)
4 angle·tighten 180· in one movement without stop-
ping. (See fjgure at lower leftl
5 run engine unlil oil temperature is at lesst SO"C
(122 O F)
6 angle·tighten gO- in one movement without stop-
ping.
Retightenlng
After 600--1,200 miles (1 ,000--2,000 km). Engine should
be c old or almost cold.
Tighten each
bolt separately in specified order, see
above fig.:
1. Angle-tighten bolt gO- in one movement without
slopping. (See figure at lower left)
Do
not siaeken bolt first.
45

20 Nm (15
.; fl Ibsl
\,..\!l ~ ) 1 0.-HL
r
oj/- _JJ:21~
I'
1!
\
9 Nm 16 .5 ft Ibsl
Smear threeds
lecl surfacss ;~~ bolt head con-
pound !PIN 277 locking com-
. 961-9).
Tlghtenin
Ib g torqua 350
si appl" Nm (258 ft
IBS when .
tool 5188 II uSlng speci I
. ato rq 8
usad directly ue wrench is
( . on
th
wIthout 51881 e center bolt
to ' the .
(qua should b lighten ing
(bs). e 450 Nm {332 ft
350 Nm 1258 ft
L Ibsl
r
"'" .®
Je
.,..
20N
m (15 ft IbsJ
~.
20 024
Specifications
• :Jr,0 Nm (74 fl Ibsl
020
024
I]
o
75 N (
j:, m 55 fl Ibs)
Usa new bolls
Smear threads .
compound PIN 277;1~~9. locking
7

Specific8rions
Gr oup 22 Lubricating System
Oll CAPACITIES
Excl. oil filter ............................................................................
Inel. oil filter .............................................................................
Differenee in
volume, max-min ..............................................
E NGINEOll
Quai ity ...................... .................... .. . ... .............
Aeeording
toA PI ..........................................................
Vi sc os it y
- 30
• - 2~
'31_
Te m perature ran gs
(stable am bient temperatures)
-20 -
10
O 10 20 30
I
1 ~
3 ~ 56 I 8 ~
_4 6,
8
SAE owt.30, swl30
I
<
SA[ lm/ t3 0
;.
,
SM: J OWtllO
SAE 15W 50
SAE 2OW l5O
SAE 30
>
I
SAE40
Oll PRESSURE
40 ·C
I
104 oF
Oil pressure at oil tempera ture of 80°C (176° F) and 33.3 r/s
020
liters (US quarts)
5.2 (5.5)
6.0 (6.3)
1.0 (1.0)
min CC
024
li ters (US quarts)
6.2 (6.5)
7.0 (7.4)
1.0 (1.0)
Oils with designations SElCC, SE/CD, SF/CC and SF/CD
meet this requirement
SAE 15 W/50 or SAE 20 W/50 oils are recomme nded for
use in
ext r eme driving eonditions whieh involve high oil
consumption and high oil temperatures, for example,
mountain driving with frequent deeelerations of fast
molorway driving. (Note however the lower tempe r a-
ture limits.)
'Ps
psi
(2000 rI min) min ............. .. .. ............................................................. 200 28
onpressure sensor
Cut-outpoint, indicator l amp goeso u tat ........ .. ... .. ........................ 1&-45
Lubricating oil pump
Reliefvalve opans at ............ .. ........................................................... 600-700
Relief valve spring, fe n gth at different loads l e
ngt h
mm in.
l = 49 ( 1. 93)
L1 :: 22 (0.87)
L2
:: 19.8 (0.78)
(eompletelyeompressed)
8
2-6 .4
85-99
load
N
O
175- 1 95
approx. 200
Ib.
O
(39-441
(45)