Volvo D20 User manual

Service

Manual

Repairs

and

maintenance

30420/1

11.88

EngineD20,D24

240 1979-

19 ..

D20,D24

Both

the

D20

ancl

24Dieselenginesare

dealtwilhin

thismanual.

TheD20hasfivecylindersandtheD24six.Otherwise

the

enginesaresimilar

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

your

country.

iffim itm!r

:i!r-l-l

Contents page

mportantinformation............................... 2

Specitications........ 3

Special

tools ...................................12

Group21Engineassembly...............................................

(Workwilh enginein-ca.,replacernent

of engrnej

Group22LubricatingSystem.........................................

123

Group23FuelSystem.........................................................

125

Group25Intake

andexhaustsystems................ .. r60

Group26

Coolingsystem..................................................

i63

Group27En9inecontro1s..................................................

175

Appendix"A"Faulttracing.............................................

Index178

OrderNo,:TP30420/1

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

Group

20General

.,o

,o Engine

typedesignation

and

serial

number

Stamped

left

side

ofenginebeneath

vacuutr,

pump

Maxtorque

DIN

20Engine

OutputDIN

.......................... 50kW ar80 r/s

68hpat4,800r/min

120Nmat

50/s

12.2kpm

at3,000/min

1-2-4-5-3

1.986

dm3

(liter)

'181

(405lbsl

Mpa

3.2

2.4

0.8

23.0:1

76.5

: 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

313

114

Specifications

24Engine

OutputDlN

MaxtorqueDlN

60kWal 80 r/s

82hpat4,800r/min

140Nmat47r/s

14.3kpm

6t2,800r/min

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

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

linl thickness

(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)

-o

,lo

-L

VALVESYSTEM

Valveclearances,

coldengine

Cold

engine

= roomtemperature Check

(in)

0.15{.25

(0.006-{.010)

0.35-0.45

(0.014-0.01

Setting

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

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

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

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,

,Ot rO

D20

,oo

@@@

@@)@

@@o

@@@

D24

Mtl M12

Specificalions

20Nm

6\1fl

I l'- '

l1s

ft lbs)

ro'\ 1rs

tttu"t

100

Nm(74

@lbs)

45Nm133

ft lbs)

Smearthreadsandboltheadcon-

tacl suriaceswilh lockingcom-

pound(P/N

277961-9).

Tiqhteninglorque

350

Nn {258

lbs)

appli6swhenusingspecial

tool 5188.lf a torquewrenchis

lsed dirscnyon the cenlerboll

(wiihout 5188),the tiqhlening

torqle shouldbe450Nm(332

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}

= 19.8 (0.781

(completely

compressed)

psl

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

Lubricating

oilpump

Reliefvalv€opensat...... .........................

600-700

R€lisfvalve

spring,l€ngthatdiffsrentloads

2-6.4

85-99

Load

0lbs

17F195 {39-.44)

approx.

200 (45)

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