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
" ,

Connecting rod bearing journals
Out of round , max ................... .. .................................................
Taper, max ..................................................................................
Diameter,standard .....................................................................
undersize l
undersize 2
Taper
Main bearing journals (when grinding)
T hrust bearing journal .................................... ... ................. mm
;"
Other ma in journals ............................................................ mm
;"
Connecting rod journals ..................................................... mm
Connecting rods
Only to be replaced in sets
;"
Side clearance on crankshaft, max .......... ... ............................. ..
length between centers .............................................................
Max weight devi ation between connecting rods
in same
engine ..................................................... ... ...................
Flywheel
Warp, max ...................................... ... .......................... .. ............
Specifications
0.003 (0.0001)
0.005 (0.0002)
47.80/47.758-47.718)
1. 8118 (1.8802-1.8810) in
47.55 (47.508-47.528) mm
1.8720 (1 .8703- 1.8711) in
47.30 (47.258-47.278) mm
1.8622 (1.8605-' .8613) in
,~"
Out-of-round
Width , bearing recess
Min Max
22.5 23.0
0.8858 0.9055
21.5 22.0
0.8464 0.8661
24.6 25.0
0.9658 0.9842
0.4
mm (0.0157 in)
136 mm (5.3543 in)
6 g ramm es
Radius
Min
1.0
0.0393
1.0
0.0393
2.0
0.0787
0.05
mm at 150 mm diameter
0.0019 in at 5.90 in diameter
Mu
1.5
0.0590
1.5
0.0590
2.5
0.9842
9

Specifications
TIGHTENING TORQUES
Tightening torques apply to oiled nuts and bolts.
Degreased (washed) parts must be oiled prior to
assembly.
l)
r
~
m
-m
v
~
o
Il!>
o
El O
D20
e o
o El
D24
o O
0
El
TIGHTENING OF CYLINDER HEAD BOLTS
M 11
1:13531
o 4D
l)
1]) ,
Use 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 ~ F)
5. 90 Nm (65 ft Ibs)
Retightening
- Atter 600-1,200 miles (1,000-2,000 km). Engine
should be eold
or almost eold . Tighten each bolt
separately in specified order, see above fig.:
l. Slacken bolt 30~
2. Torque to 90 Nm (65 ft Ibs)
1371Y
10
TIGHTENING SEQUENCE FOR CYLINDER HEAD
BOLTS
Importanti slacken bolts in reverse order when
removing cylinder head.
Removeoil and
dirt from bolt holes. cilleft in holes will
reduce pressure
on cylinder head gasket.
Bolt threads and washers must however be oiled,
otherwise frietional forees will be too large.
Two types
of bolts are in use: An early type with M 11
threads and a later type with M 12threads. (Later type
is threaded along entire length.)
M12
~&ill , : ,.I\\i
,\11 \\' ;~\(
-
:l iii
- ~
Use new bolts. Not necessary to replace washers.
Tighten in six stages:
1. 40 Nm (30 ft Ibs)
2. 60 Nm (44 ft Ibs)
3. 75 Nm (55 ft Ibs)
4. angle-tighten 180~ in one movement without stop-
ping
5. run engine
until oil temperature is at least 50 ~ C
(122 ~ F)
6. angle- tighten 90~ in one movement without stop-
ping
Retightening
After 600-1,200 miles (1,000-2,000 km). Engine
should be cold or almost cold.
Tighten each bolt separately in specified order, see
above fig.:
1. Angle-tighten bolt 90° in one movement without
stopping.
Do not slacken bolt first.

Specifications
020
024
Crankshaft assembly
,~
€l
350 Nm" =
'lj
....
I
20Nm =
15 fl Ibs
020
024
45 Nm" =
33 fl Ibs
,
75 Nm" =
55 fl Ibs
"
1 Threads and bolt head contact surface to be smeared
with locking compound (P IN 277961-9).
Tightening
torque 350 Nm (258 ft Ibs) applies when
using special too I 5188. See instructions on page 64,
operation J4.
65 Nm -2 Use new bolts. Smear threads with PIN 277961- 9.
48 ft Ibs 3 Use new nuts.
• Thereare2versions of thrust bearings: flanged bear·
ingsheiis and also plain bearingswith thrust bearing
washer halves.
Only flanged bearings are available
as spare parts.
11

Specifications
Timing gears, cylinder head
45 Nm =
33 ft Ibs
~®
12
20 Nm = 15ft Ibs
/
~
~
Valves:
early type'" l groove
late type '" 3 grooves.
See operation G3 on page 52
Tightening sequence:
See page 10 or
operation H8 on page 58.
/
"II"

I!l=oo-h
,
I
~!-.
~II
-@) --JI-H
~-----
r-
(J
-- - -
M6x28
la mm = 0.71 in
28 mm " 1.10 in
75 mm = 2.95 in
103 mm = 4.05 in
Specifications
Lubricating system
t
_..... -
/ MGx75
M6x103
"-
13

Specifications
Intake and exhaust manifoids
Always use new nuts
Cooling system
C
,---0 \
.--dO"",,"-' --: ' \ II
---
14

Specifications
Group 22 Lubricating system
Oil pressure sensor
Cut-out point, indicator lamp goes out at ................................. 15-45 kPa
2.1-6.4 psi
Lubricating oil pump
Relief valve spring length at different loads:
Length Load
mm in N
L=49 1.93 O
L1 = 22 0.87 179-195
L2 = 19.8 0.78 approx 200
(completely compressed)
Group 23 Fuel system
INJECTION PUMP
Injection timing (pump plunger strake at T.D .C.)
D20 .............................................................................................
D24 .............................................................................................
D 24 USA/Canada 1979-81 ........................................................
D 24 USA/Canada 1982- ........................................................... ..
USA -vehicles up to 1983 must be ad-
justed for high altitude driving if main use
is above 4000
ft (1,219 m):
Reter to appropriate service manual
for
adjustment.
TIGHTENING TORQUES
Nm ft Ibs
Injector, in
cylinder head ........... 70 52
upper-Iower sections ... 70 52
Injection pump, pump gear ... ... . 45 33
Check value
mm
;n
0.75-0.83
0.029-0.033
0.65-0.73
0.025-0.029
0.65-0.73
0.025-0.029
0.82-0.90
0.032-0.035
Ibs
O
39-44
45
Setting value
mm
;n
0.80 0.031
0.70 0.027
0.70 0.027
0.85 0.033
'5

Special tools
.99
1801-3
2520-8
2903·6
4090-0
5017-2
5112-1
5187·3
5188·'
5190·7
5192·3
1801
4090
5187, 5188
16
Special tools
Description -Use
Standard handle: used with 5207 and 5208
Stand: used with fixture 5206
011 filter wrench
Puller: removing pilot bearing
Drift:
removing /instalting crankshaft bushings
loeking sector: locking flywheel
Wrench: vibration damper
Wreneh with extension arm: for vibration damper center bol
Gauge: installing eamshaft
Support for dial indieator: measuring piston height
2520
5017
5190
2903
511Z
5192

...
5193·1
5194·9
5195·6
5196·4
5197·2
5198·0
5199·8
5200·4
5202·0
5203·8
5204·6
5205·3
5206·1
5207·9
5208·7
5218·6
5219·4
5220·2
5221·0
5222·8
5224--4
5223·5
5234·3
5235·0
5195
5198
SPECIAL mOLS (CONT.)
Description -Use
Stop: locking injeetion pump gear
Holder: for dial indieator when adjusling injeetion pump
PIIers: removing valve discs
Press tool: for valve tappels
Belt tension gauge: timing gear bells and pump drive
Straight edge: setting T.D.C. for cylinder l (flywheel casin
removed)
Wrench: front and rear camshaft gears
Adapter: installing crankshaft front sea I and camshall sea Is
Puller: for idler pulley
Centering shaft: for clutch driven plate
PuHer:
pump gear
Puller: for crankshaft front sea I
FIxture: for
engine
Drift: inslalling needle bearing in crankshaft
Drift: installing crankshaft rear seal
Drift: removing /inslalling valve guides
Tool: removing/installing valve seals
Drift: installing intake valve seat
Drift: installing exhaust valve seat
Gauge: checking valve height in relation to camshaft
Rearner: valve guide
Guide pins M11 bolts (4 xl: installing cylinder head
Guide pins M12 bolts (4 xl: installing cylinder head
Tool: for remeving guide pins
5196
5199
Special tools
5193
5194
5197
5200
17

Special tools
5202 5203
5205 5206
5208
5220,5221 5222
5233, 5234 5235
18
I
5235
5204
5207
5224
' ..
I ~
..