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)

Specifications
Group 23 Fuel system
GENERAL
020
Firing order ................ ... .............. ............................................... 1.2.4.5.3
02.
1-5-3-6-2-4
Idle ..... .. ....................................................................................... 12 .5 (750)
fast ............................ ... . .. ..................................................... 87.0 (5200) 12.5 (750) ris
(r i min)
87.0 (5200) ris (ri min)
FUEL
Standard .....................................................................................
Ign;tion response (cetane No.) min ......................................... ..
SUl phur content, max. W.p ... ......................................................
FUEL TANK
DIN 51601: CEC-ERF-OI, or
ASTM-o 975-No. 2-0
45
0.5
Capacity ...................................................................................... 60 lit r es (15.8 US galls.)
INJECTION PUMP
Type.............................................................................................
Make and
designation, 020 .. ... ...................................................
024 .................... ... ............................... ..
Volvo PIN (exchange unit) 020 ................................................ ..
024 ..................................................
Injection timing (pump plunger stroke at TOC)
020 ............................................................ .. ................................
024..............................................................................................
024 USA and Canada 1979- 1981 ............................................ ..
1982- ......... .. ............................................
NOTE! High altitude adjustments are
necessary in certain parts
of USA, see
page
132 .
INJECTORS
Make anddesignalion ........... .........................................................
Bosch No. USA/Canada 1
982- .............. .. ....... ... ...............................
Olhermarkels ........................................................... .. ... .
Volvo P IN USA/Canada 1982- ..........................................................
Otherma
rk ets .................... .. ..........................................
Oistr
ibutor type pump
Bosch VE5/1 OF2400 L45
( l45 -1 for aulO vehicles)
Bosch VE6/10 F2400
l32
(l 32-1 for auto vehicles)
5001716-9
5001715-1
Checking mm {ini Setting mm {ini
0.75-().83 mm
(0.0295-0.0327) 0.80 mm (0.0315)
0.65-0.73
mm
(0.256-0.0287) 0.70 mm (0.0276)
0.65-0.73
mm
(0.0256-0.0287) 0.70 mm (0.0295)
0.82-0.90
mm
(0.0323-0.0354) 0.85 mm (0.0335)
Bosch KCA 30S0 271 (44)
068130201 F (201 J)
068130201 (201 K)
1328073-0
1257144-4
Checking
Injectoropening pressure .................................................. MPa 12-13
Setting
12.5-13.5
1778-1920
.................................................... psi 1707-1849
9

Specifications
Nonie s
Make ............................................................................................
Designation USA/Canada 1982- ................................................
..
Othermarkets ...........................................................
VolvoP/N USA/Canada 1982- ................................................
Othermarkets ................................................................
Identification of injectors and nozzles
TIGHTENING TORQUES
Bosch
DNOS D 1930
DNOS D1 93
1328096·1
1542303·1
0681 3 0201F l
068130201 J { US A/ Cana da 1982·
Injector
(complete)
Nm
068190201 l Oth er ma rkets
0681 30 2 01 K {
DN O SO 193 O= USA /Canada 1982-
DN - SO 193 .. other markets
""""
,:tJ~
Nozzle
Injector, in cylinde r head ............................................................ 70
ft. Ibs
52
upper - lower section ................................................... 70
52
Injection pump, pump gear ........................................................ 45 33
70 Nm -52 ft Ib s
10

Specifications
Group 26 Cooling system
GENERAL
Coolant
Since aluminium is used in the engines, active cor ro-
sion
protection is necessary in the coolant to help pre-
vent corrosion damage.
Use
genuine Volvo blue·green coolant type C diluted
with clean water in proportions of 50/50.
This mixture helps to prevent corrosion and frost
damage.
• Never fill the cooling system with water alone.
• The coolant should be changed regularly since
the corrosion protective additives in the coolant
lose their effect in time.
\28 181
Capacity, with manual gearbox ............................................... ..
with automatic transmission .....................................
EXPANSION TANK
D 20 litres lUS quarts)
8.2 (8.7)
8.018.4)
Pressure valve in ca p opens at .................................. Type 1 kPa (psi)
overpressure ............................................................................... 65-8519.2-12.1)
underpressure ............................................. .. ............................ 7 (1.0)
THERMOSTAT
Marking ........................ .............................................................
Starts to open at .........................................................................
Fully open at .. .............................................................................
Opening gap, min .......................................................................
DRIVE BELTS
Designatian (Volvo PI NI
HC38 x975
(9 58354-3)
Type 1
HC38 x1238
(960296·21
HC38 x888
(460431
·5 )
,.----.> ~-
Typa 2
S7 °e
S7 °e (189° F)
102°C (2l6 " F)
a mm (0.3 in)
HC50 x 913
_ ~ ~960 459'6)
2 / '
1 I 5 \
\ I
-""-~'-----'- - - - :- -- /
TIGHTENING TORQUE HC38x800
(958302·1)
Cooling fan ................................................................ ............ ....
Nm
9
'ON
D 24 lit res lUS quarts)
9.4 (9.9)
9.2 (9.7)
Type 2 kPa (psi )
100 (14.2)
7 (1.0)
1Crankshafl pulley
2 Alternator
3 Cooling fan
4 Power steering pump
5 AC compressor
ft. Ibs.
6.6
11

Special tools
Special tools
9 .. Da sc ription -Usa
1801-3 Standard handla: used
with drift 5207 and 5208
2810-3
Lift beam: removinglinstalling engine
2901-0 Cl ampi ng pliars{2xl: clamping water hoseswhen removing injection pump
2903-6
on filt ar wrench
4090-0 Puller: removing pilot bearing
5006-5 Lift br ackat: replaeing front engine mounts
5033-9 Support {lxI: for l ift bracket 5006
5112-1 Locking sector: loeking flywheel
5115-4 Lift hook: used with lift bracket 5006
5185·7
Lift h oo k, front: removinglinstalling engine
5186-5
Lift hook, rear: removin glinstalling engine
5187-3 Wrench:
vibration damper
5188·1 Wrench with extensio n arm: for vibration damper center bolt
5190·7 Gauga:
installing camshaft
5191 ·5 Adapter : connecting pressure gauge
5193-1 Stop : locking injection pump gear
5194·9 Ho ldar : for dial indieator when adjusting injection pump
5195-6 Pliers: removing valve dises
12

Special tools
5191
._m
5191 ,
'"' \J
~
,'" ,Jo
5194 5195
13

Special tools
99'
Description -Use
5196-4 Press tool : for valve tappets
5197-2
Belt ten si on gauge : timing gear belts and pump drive
5199-8 Wrench: front and rear camshaft gears
5200-4 Adapter : installing crankshah front seal and camshaft seals
5201-2 Wrench: center nut
on rear camshah gear and pump gear
5204-6 Puller: pump gear, injection pump
5202-0 Puller: for idler pulley
5203-8 Centering s haft : f or clutch disc
5205-3 Puller: for crankshaft front seal
5207-9
Drift : instslling needle bearing in crankshaft
5208-7 Drift : installing crankshaft rear seal
5233-7 Guide pins , M 11 bolts (4x): installing cylinder head
5234-3 Guide pins, M 12
bolts (4x): installing cylinder head
5235-0
Tool for r emoving guide pins
9950-0 Adapter : engine rpm. Used with Volvo Monotester
14

5202
5207
5235
I
5235
,
,
,
5197
5201
5203
5208
9950
Special tools
5197
/
;~C
\
o I
,-
5199
5204
5233, 5234
o ••
15

Group 27 Engine
Contents
Group 21 Engine Assembly
Contents
In-car
Compression test .. ........ . .. .................. ... .. ... ....... ... ... ... .. ... ................
Valve adjustment .... ... .. .. .. ... . .... .. .... ... .. .. ... ... .. ... .. .. ........ .... ... .... .. ... ....
Basicsetting
of engine .....................................................................
Cylinderhead, removal . .. .. .. ... ....... .. .. ... .. ... ........ .. ...... .. ... .... .. ... ... .....
disassembly ............................................................
cleaning-checking ...................................................
assembly .........
.. ....................... ... ........... .. .... .. ... ......
installing . .. .. ... ....... ... .. .. .. ... .. ... ... .. ... .. ..... .. . .... ... ... .. ... .
tightening torques ...................................................
Drivebelts
(timing gearsand pump) ..... ... .......... .. ... .... .. .. .... .... .. . ... ..
belttension ................ ....................................................
replacement...................................................................
Camshaft, removal ................................................ .. . .... ... .. ... ... .. .... ..
installing .. .. .......... .. ....... .. .. .. .... .. ... .. ... .. ... .. .... .. .... .. ... ... ... ..
Camshaftoil sea Is, replacement, front ............................................
rear .............................................
Pilot bearing in crankshaft, replacement .... .. ... .. ... .... .. .. ... ... ... .. .... .. .
Crankshaft oil seais, replacement, front ... ... .. ... ... .. .............. ... ...... .. .
rear ............................................
Vibration damper, removal, installing
... . ... ... ... .. .... .. .... .. .... .. .
Engine
mounts, replacement .. . .. .. ... ... .. .. ........................................
Replacement of engine
Removal .. .. ... .. .. .. .. .. ... .. .. .. ... .. ... .. .. .. .......... .. ..
Installing .......................................................
16
Operation
Al- l O
81-11
Cl -21
01-20
El-11
Fl-21
Gl- 16
Hl-38
Jl-3
Kl-5
Ll-35
Ml-l1
Nl-27
01-27
Pl-21
01-7
Rl-21
81-11
Tl-l0
U,-4
Vl-7
Xl-33
Page
17
19
22
2B
33
36
41
45
57
5B
60
71
74
B'
BB
94
96
'03
'06
110
11'
114

Group 2 7 E ngine
Compression test
A. Compression test
Special tool: 5191
"' II '"
Al
Oisconnect wire from stop valve on injection
pump
This stops flow of fuel and prevents unnecessary spill-
age.
A2
Remove vacuum pump and pump plunger
A3
Di sconnect fuel delivery pipes
Clean all connections carefully before disconnecling
them.
Disconnect
pipes and plug all connections to prevent
dirt from entering system.
17

Group 27 Engine
Compression test
,,.' ..
4 25Nm
~
• •
"., ..
'J3oIl'
18
A4
Remove injectors
Use 27 mm sockel ( Volvo PIN 1158146).
Lift out heat shields under injeclors otherwise they will
be blown out during compression test.
AS
Connect compression tester
Placea heat sh ield in cylinder head and screw inadapter
.5191 . T
ighlen 10 70 Nm (50 fl lbs).
Connecl compression tester to adapter.
Run engine and re cord compress i on
Compression
New
Min
Max difference between
cy linders
Install i nje ctors
= 3.2 MPa (455 psil
= 2.
4MPa (341 psi)
= 0. 8MPa ( 114ps i)
A6
A7
Place new heat shields in cylinder head, see tig. Install
injectors. T or que to 70 Nm (50 ft. Ibs).
Reconnect deliv ery pipes
Tightening torque 25 Nm (18 ft lbsl.
Reconnect wire to s top valve
Install pump plunger and vac uum pump
Check pump Q·ring, replace if necessary.
AB
A9
AJO
v.
an
r