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)
Other manuals for D20
2
This manual suits for next models
1
Table of contents
Other Volvo Engine manuals
Volvo
Volvo D12D Operating and installation instructions
Volvo
Volvo D9 series User manual
Volvo
Volvo MD2010 Instruction manual
Volvo
Volvo TD420VE User manual
Volvo
Volvo TAD1240GE User manual
Volvo
Volvo B27A User manual
Volvo
Volvo D13J User manual
Volvo
Volvo D16F Reference manual
Volvo
Volvo B6324S Operating and installation instructions
Volvo
Volvo B 17 User manual
