Volvo D20 User manual

Service Manual
Repairs
and maintenance
Section 2(21)
Reconditioning
engine
020,024
1979-19 .. .

D 20, 024
80th the D 20 and D 24 Diesel engines are deall with in this manual.
The D 20 has fi"e cylindersand the D 24 six. Dtherwisethe engines are similar in principle.
Natel Different flywheels and vibration dampers are fitted to the different engine types.
020 024
Volvos are sold in versions adapted for different
markets. These adaptations depend on many fae-
tars including legal, taxation and market require-
ments.
This manual may therefore show illustrations and
text which do not apply to cars in your country.
•
128642
•
•l
l

Contents
Important information ..... .... ... .. .................................................................................. ... .
Specifications .............................. ....... ................................................................................ .
Page
2
3
Special tool. .................... ... ....... ....... ... . ... . ... ..... .. .. ... . ........................................................... 16
Reconditioning engine
Removing parts from engine ..................................................
Disassembly ............................ ... .............................................
Cleaning, checking ..................................................................
Aeassembly .............................................................................
Cylinderhead, assembly ..................................... .. .................
cleaning, checking ....................................................
reassembJy ..............................
.. ...............................
installation ................................................................
Installation, (cont.) ..................................................................
Installing parts on engine . ... ...................................................
Index page 74
Operation
Al-15
Bl-18
C l-28
Dl-30
El-l1
Fl -2l
Gl-14
Hl-8
Jl-20
Kl-27
This manual deals exclusively with the overhaul of
the engine. For work carried out on the engine
when
fitted in the ear, and for engine removal and
installation, please reter
to the service manual Sec-
tion 2(20-22) and Section 2(23-29).
TP 30224 /2 US
UK /USA
6000.05.83
PRINTED IN USA
We reser ve the right to make alterations
l.
24
2.
36
43
46
51
55
5.
65
1

2
Important information
,,, . ..
Nm
135020
ClEANLlNESS
Diesel injection systems are extremely sensitive to dirt
and foreign malter. A special workplace should there-
fore be used for inspection of components.
PWGS
Clean fuelline co nn ec tion s thoroughly befare discon -
•
•
necting them. Plug ends of fuellines etc as each com- •
ponent is removed. Do not remove these plugs unl il
the component is reconnected.
Tightening torques
Two kinds of tightening torques will be found in this
manual
1. Ti ghten to 40 Nm (30 fl Ibs) indicates that a torque
wrench must be used for tightening.
2. Tight ening torque 40 Nm (30 ft Ibs) indicates a
guide va lue. Tight en ing need not be done with a
torque wrench.

VW type designation
[
Specifications
Specifications
Group 20 General
_=--=--=- .. J
Engine number
VOLVO type designation
'33 7 51
Engine type designation and serial number
Stamped in left side of cylinder block beneath vacuum
pump.
3

Specifications
Group 21 Engine block
CYLINDER HEAD
0.5 mm = 0.020 in
Diagonally = max 0.5 mm :lO 0.020 in
Cylinder head may not be machined. It must be
replaced if warp exceeds maximum .
Cylinder head gaskat
0.2 mm "" 0.0 08 in
I,
128 141
Crosswise = max 0 .2 mm = 0.008 in
Thrae alternative gaskets are u se d depending on height of piston above cylinder block.
Marked by notch
~
, ,. ".
4
Height of piston above
Gasket
cylinder block
notehes thickness
mm in
mm in
0.67-0.80
0.026-0.031 1 L' 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
Notel Piston height in same engine must not extend
over more than two classes. Pis ton height is
measured
at front and back of piston (along
gudgeon / piston pin).
•

$pecifications
CYLINDER BLOCK
Bore Mark i ng
Piston diameter Cylinder bore
mm
Standard ............ .. .. .. .................. 651 76 .48
652 76.49
653 76.
50
Oversize 1 ................................... 676 76.73
(0.25 mm =0.010 in) 677 76.74
678 76.75
Oversize2 ...................................
701 76.98
(0.50 mm =0.020 in) 702 76.99
703 77.00
Oversize 3
....................
751 71.48
(1.00 mm =0.040 in) 752 77.49
753 77.50
Mo< weaT dimension (compared
with normal diameter)
PISTONS
Weight (inel. gudgeon /piston pin) .............................................
Max
weight deviation between pistons in same engine ...........
Overall height .............................................................................
Height
from gudgeon / piston pin center to piston crown .........
Piston float,
new ............................................ ... . .. .......................
max .........................................................................
Piston diameter, see
cylinder bare table
Wear di
mension, max (compared with normal diameter) ........
;n
mm
3.0110 76.51
3.0114 76.52
3.0118 76 . 53
3.0209 76.76
3.0212 76.71
3.0217 76.78
3.0307 71 . 01
3.0311 77.02
3.0315 77.03
3.0504
77.51
3.0508 77.52
3.0512 77 . 53
0.04 mm
455-465 grammes
12 grammes
71.7 mm
41.7 mm
0.03-0.05 mm
0.13 mm
0.04 mm
;n
3.0122
3.0125
3.0130
3.0220
3.0224
3.0228
3.0318
3.0322
3.0326
3.0515
3.0519
3.0523
0.016 in
2.8228 in
1.6417 in
0.0051 in
0.0016 in
Piston rings
Piston ring gap is measured
15 mm (0.6 in from lower
edge of cylinder).
Piston diameter is measured at
right angles to gudgeon l
piston pin bore, 15 mm (0.6 in)
from lower edge. o
Ring thickness ................... ................................................ mm
Side clearance
(measured
with ring on pisten), new ................................. mm
;n
max ................................ mm
Ring gap
(measured in cylinder, see fig.),
new ................................. mm
;n
max ... .. .. .. . .. .................... mm
Gudgeon/piston pins
Fit, in connecting rad ................. ... ..........................................
in pisten .............................
.. ......................................... .. ... ...
-~
~ t _ J
• ' >O . ..
Upper Lewer Oil seraper
compression
eompression ring
ring ring
1.730 1.980-1.990 2.975-2.990
0.0681 -0.0685 0.0780-0.0783 0.1171 -0.1171
0.06-0.09 0.05-0.08 0.03-0.06
0.0024-0.0035 0.0020-0.0031 0.0012-0.0024
0.2 0.2 0.15
0.0079 0.0079 0.0059
0.3-0.5 0.3-0.5 0.25-0.40
0.012-0.020 0.012-0 .020 0.0098-0.0157
1.0 1.0 1.0
0.040 0.040 0.040
Light thumb pressure (close running fit)
Thumb pressure (push fit)
5

Specifications
VALVE SYSTEM
Valve clearances
D20
Intake va lve, warm engine ...........................................
c
old engine .............................................
Exhaust valve,
warm engine ..................... ... ................
cold engine ..........................................
Shims,thickness ..........................................................
VIIyes
7.97 mm = 0.3137 in
36 mm -1.417 in 0.5 mm = 0.020 in
7.97 mm
. (tlJ)
---..I~~I-_mi". 0.5 mm
Vllye seats
32.8 mm "" 1.2193 in
1.5 mm = 0.0590 in
2.0 mm == 0.787 in
Intake Yllye
,
32.8 nm
Intake YI lye selt
,331, .
\33J!.II
Cold engine = engine at r oo m temperature
= intake valves
A = exhaust valves
Checkladjust valves in foll owing order:
020 = '-2-4-5-3
024 = ' -5-3-6-2-4
Checking Setting
mm
;"
mm
0.20- 0.30 0.
008-0.012
0.25
0.1
5- 0.25 0.006- 0.010 0.20
0.40-0.50
0.016-0.020
0.45
0.35-0.45
0.014-0.018
0.40
3.00-4.25 at increments of 0.05 mm
0.012-0.167 at increments of 0.002 in
7.95 mm = 0.3129 in
31 mm '" 1.22 in
45'
7.95 mm
Exhaust y.lye
;n
0.010
0.008
0.018
0.Q16
131115
Importanti Exhaust valves are stellite coated and
must not
be ground by machine. Grind-in valve on
seat
with grinding paste.
30.4 mm = 1.1968 in
1.5 mm = 0.0590 in
2.4 mm = 0.094 in
30 .4 nm
Exhlust y.lye selt
1:13159
Exhaust
Valve seat diameter , standard ............................................ mm
Intake
37.090-37.105
1.4602 -1. 4608
37.
290-37.305
1.4681- 1.4687
33.090-33.105
1.3027-1.3033
33.290-33.305
1.3106-1.3112
oversize 1 .. ........................................ mm
Seat width in cylinder head:
diameter, standard ..............................................................
mm
oversize 1 ....................................................... ... .. mm
;n
6
37.000-37.016
1.4566-1.4573
37.200-37.216
1. 46 45- 1.4651
33.000-33 .016
1.2992-1.2998
33.200-33.216
1. 3070-1.3071
•

Specifications
1~· (OoO~r00105 mm)
Notel When replacing "al"e seats: the interference between
the
"al"e seat and its bare in the cylinder head shall be 0.074-
0.105 mm (0.029-0.041 ini. That is. "a l"e seat diameter must be
0.074-0.105 mm greater than the diameter of the bore in the
cylinder head. -
......
Valve guides mm (ini :-.
Length ... ...................................................... ... .............................
Innerdiameter ............................................................................
Height abo"e cylinder head
lower surface .............................. ..
Clearance, "al"e stem-guide (see fig.l. new ............................ ..
max ..............................
Clearance is measured
with new "al"e and with "al"e stem
flush
with "al"e guide.
Valve springs
Inner valve springs
Load
N
Ib,
36.50-36.75 (1.4370-1.4468)
8.000-8.015 (0.3 149-0.3155)
40.1 -40.5 (1.5787 -1.59 44)
0.3 (0.018)
1.3 (0.0511)
Outer valve springs
Load
In N
OO M
Ib,
Length
mm
33.9
28.6
18.3
In
1.334
1.126
0.720
O
67-77
209-231
O
15-17.5
47-52.2
Length
mm
40.2
32.6
22.3
1.583
1.283
0.878
O
167-185
433-479
O
38-42
98-108
Tappets
Diameter ........................................................................... .. .
Height........................................................................................
..
Clearance. sh im -tappet ..............................................................
tappet-cylinder head ................................................
Shims (for adjusting "al"8 clearance)
Thickness ...................................................................................
Diameter .....................................................................................
34.950-34.975 (1.3759-1.3769)
28.0-28.8 (1.1023-1.1388)
0.016-0.046 (0.0006-0.00 18)
0.025-0.075 (0.0010-0 .0029)
3.00-4.25 mm at increments of 0.05 mm
0.118-0.167 at increments of 0.002 in
30.950-30.975 (1.2185-1.2194)
7

Specifications
TIMING GEARS
5197
Toothed belts
Belt tension (measured with too I 5197)
checkvalue ............................................................................ 12-13
setting .................................................................................... 12.5
Camshaft
Max lift height, intake ............................................................... ..
exhaust ..................................... .. ....................... 8.5 (0.334)
9.0 (0.354)
,
, ,
( , ,
p--u
, ,
Bearing journal diameter, front ..................................................
others ...............................................
Bearing clearance,
new ....................................... .. ................... ..
End clearance, max ....................................................................
31.925-31.950 (1.2568-l .2578)
29.939-29.960 (1.1787-1.795)
0.05-0. l O(0.0019-0.0039)
0.1510.0061
Camshaft setting is checked by using gauge 5190
Camshaft bearings
Bearing diameter, front .............................................................. 32.000-32.02511.2598-1.2608)
otherthree .................................................... 30.000-30.021 (1.1811-1.1819)
Crankshaft
Max run·out, two center bearings ............................................
others .............................................
Crankshaft end clearance, new ........ .. ........................................
max ..................................................
Main bearing clearance, new .....................................................
max ........................... .. ........................
Connecting rad bearings, side clearance, max .. .......... .. ......... ..
repairing clearance, new ............................... .. ... ........................
max ...............................
.. ...........................
Measured with two outer main bearings in V-blocks.
Main bearing journals
0.06 (0.0023)
0.04 (0.0015)
0.07-0.18 (0.0027-0.0071)
0.25 W.0098)
0.016-0.075 (0.0006-0.0029)
0. 16 (0.0062)
0.4
W.0 1 57)
0.015-0.062 (0.0005-0.0024)
0. 12 (0.0047)
Out
of round, max ...................................................................... 0.003 (0.0001)
Taper, max .................................................................................. 0.005 (0.0002)
Diameterstandard ...................................................................... 58.00 (57.955-57,975) mm
2.283412.2816-2.2824) in
8
undersize1 ................................................................. 57.75(57.705-57.725)mm
2.2736 (2.2718-2.2726) in
undersize 2 ................................................................. 57.50 (57.455-57.475) mm
2.2539 (2.2521-2.2529) in
undersize3 ................................................................. 57.25 (57.205-27.225) mm
2.2342 (2.2324-2.2332) in
~I
/
17
~nJ
" ,