Dokumen - Tips Volvo d24 Engines Repair Manual

7/21/2019 VOLVO D24 Engines Repair Manual
Group21 Engine
Crankshaftear seal, eplacement
S. Grankshaft earseal, eplacement

Special ools: 1801, 112,5203,5208
s?
Removegearbox/transmission
SeeService anual ection (431.

Secure tanermotorwith a bolt.
Manualgearbox:
s2
Remove ressureplate and driven plate
Unscrewpressure late ountingoltscrosswisea
ew
turnsat a ime o prevent arp.
Manualgearbox:
s3
Remove lywhe€l
Automaticgearbox:
Remove arrierplate
Use ockingector 112o prevent ilywheel from mo -
vin g .
s4
Remove rankshaft ear oil seal
Liftout oil sealw ith a screwdrivers ndicated.
Clean nd
http://slidepdf.com/reader/full/volvo-d24-engines-repair-manual 1/96
Group21 Engine
Crankshaftearseal. eDlacement
s6
Installnew oil seal
Assembletandardandle801 nd rift 208.

S me a ro il o n t o se a lin g u r f a ce s n d lip s o n se a l.
P la ce e a lo n d r if ta n d a p n u n t ild r if ta b u t s r a n ksh a f t .
s7
Install f ywheel/carriei plate
Flnrheel manual) ndcarrier late auto) anonlyb e
Usenewbolts, meared ith sealer /N277961,9.

Torque olts o 75 Nm ( 5 5 t lbs).Use ocking ector
5112 o hold lywheeln position.
s8
Automaticgearbox:
Check nstallationmeasurement t carderplate
(To be caffiedout after replacement f carrierptate.)
Place steel ulerbetween arrier l a t eand engine

block.Fulershould est against ngine o gearbox
=la:O,8mn
mountinglange ndshould est gainst oth ides f (ir
A+B flange. urnithrankshaft
coancides n til neo fholesncarrier
steel u er.Measure late
B"with anoutside
caliper quippedor depthmeasurement.
Measuredalue B' + thicknessf steel uler hould
equal 17.2-18.8 mm = 0.667-0.740n. f distances ess
than 17.2m m = 0.677 n use a spacerw asher P/N
1257377'0)etween rankshaft nd carrierplate.
lf carrier late s insralledncorrectlyi.e. nstattarion
measurement s wrong), istanceo torque onve er
caiiierwillbe oo ong. hismaycause arfier l a t e o
crack n d possibly noisewhendriving.
10 4
Group21 Engine
Crankshaftear seal, eplacement
Manualgearbox:
s9
Install drivenplate
l:i Use enteringhaft 203.
Turndiscwith hub acing ut,away rom tywneet.
Manualgearbox
s10
Install pressure late
Tighten olts rosswise few urnsat a time o avoid
s11
Installgearbox/tmnsmission
Donot orget o remove oltsecuring tarter otor,
105
Gtoup 21 Engine
Vibratio n damper, remov ng/instal ng
T. Vibration damper, emoving/installing

SDecial ools: 5187. 5188
Notel Different vibration dampersor D 20 and .

D 2 4 e n g in e s.
D20 D24
T1
Disconnect battery
T2
Jack-up ehicle
T o prevent pillages hen oolantsdrained,aise e-
hicle t ront ight acking oint.Cooanl will hen un
along plashguard n todrip pan.
Place rip panbeneatheftsteerinsod .
( r(
f3
Draincoolant
Unscrew xpansionank ap.
Disconnect
ower adiator ose om adiator n dd r a i n
(Ensines withoul rain aps).
106
Group 21 Engine
Vibration damper, removi ng/i nsta l ng
T4
Disconnect:
co o lin g a n w it h sp a ce r n d p u l e y
- f a n b e lt a n d p o w e r st e e r ir g p L r mp e h -
T5
Bemove vibration dampea

R e mo ve e n t e rb o lt . Use 5 1 8 7 o p r e ve n tp u le y f f o r n
r o t a t in g , n d so cke t 1 8 8 o u n scr e wb o s.
I t ma y b e n e ce ssa r yo t u r n e n g in e ig h t lyso h a t5 ' 1 8 7
r e st so n f a n b e a r in g .
R e mo ve o u r in h e x b o lt s ( 6 mm) .
P u llo f f vib r a t io nd a mp e r .N o t e l C r a n ksh a f t e a r ma y
so me t ime s t ick o vib r a t io nd a mp e r .
T6
Install ibration amper
D a mp e r a no n lyb e iit e d r o n e w a y.P ino n cr a n ksh a f l
g e a r n 1 u st it in vib r a t io n a mp e r .
T o r q u eb o r s t o 2 0 N m 1 1 5 t b s) .
T7
I n st a ll ce n t e r b o lt
S me a r t h r e a d s a n d ma t in g sL r r f a ce it h se a le r P / N
277961L
U sew r e n ch5 1 8 7 r e sl o n co o iin g a n b e a r in g ) t oh o ld
U se w r e n ch 5 ' 1 8 8 o t o r q u e ce n t e r b o lt t o 3 5 0 N m
( 2 5 5 t lb s) .
lmp o r t a n r : o r q u e3 5 0N m a p p lie s n ly f w r e n ch5 1 8 8
is1 8
5 r se
8 . d . so t o r q u e w r e n ch mu st b e in in e w it hw r e n ch
107
Group21 Engine
Vibration dam per, removi ng/instal ing
T8
Install:
- n dp u lle y. ig h le n in g o r q u e
co
9 Nom lin(g7 atnlw
b sit)h sp a ce r
- b e lt o r p o w e r st e e r in g u mp a n d a n b e s
- fadiator. Connect hoses
{))l
T9
Bleeding of cooling system
Disconnectpperhose ro m coldsiart
drip pan beneath oseand hold hose
edge f expansionank.
ti
I
Coolant
S in cea L r min iu ms u se d n t h e e n g in e s, ct iveco r r o
sio n p r o le ct io n s n e ce ssa r yn t h e co o la n t o h e lp p r e -
ve n r co r r o sr o n a ma g e .
U se g e n u in eV o lvo b lu e - g r e e n o o la n l yp e C , d ilu t e d
with cle.n water in propo(ions of 50/50. ,lr l
T h is mixlu r e h e lp s t o p r e ve n t co f t o sio n a n d ir o sl
d a ma g e .
a N e ve r il l t h e co o lin gsyst e mw ilh w a t e ra lo n e .
a T h e co o la n t h o u ld b e ch a n g e d e g u la r ly in c e h e
co r r o sio np r o t e ct ive n t h e co o la n t o se
rl
their effect in time. d d it ive s
N o t e l D o n o t r u n e n g in ew h e n e ve lo f co o a n l a s o w ,
sin ce h ig h lo ca l e mp e r a t u r e s a n r e su ltw h ich ma v
ca u se h e cylin d e .h e a d o cr a ck.
108
Group21 Engine
Vibration damper, removing/installing
srYoorTr tt 3(rc rfrrRfY[rfi rurr *t0 ai otL ^firr or| rfr 0rr
v0rv04v^rsuTYr
artto wrTNtr0r|r lrol\to cooullr Pt
mdd]wF. B e p la cin g co o la n t
i$rPU r LrourorrrGftvoLvo
rc Mollrt ALr0n€ Ar{TrcrL
iPr c A lw a ys u se yp e C b lu e - g r e e n o o a n t . R e me mb e r o
r e p ia ce e ca l P / N1 3 3 1 4 7 3 , 7 )n e xa n sjo na n k f n e ce s-
Typ€ C blue-s.een coolant

A l d ie se l n d p e t r o l 9 a so n e ) e n g in e sma n u f a ct u r e d
sin ce1 9 8 2a r e ile d w it h r yp e C co o t a n t .
710
F ill co o la n t
C a p a cit y:D 2 0 = 8 . 1 ile r s 8 . 6U S
D 2 4 = 9 . 3 it e r s 9 . 8U S
F lu sh o o lin gsyst e mb e f o r ea d d in g n e w co o la n t , e e
Gr o u p2 6 C o o lin gS yst e m.
S e t d a sh b o a r d - e a t e r o n n o l I o ma \ . T L r n o r e n g in e
a n d w a r m- u p o r 5 min u t e s.A d d co o la n td u r in g h is
lime . C o n n e ct o se o co ld st a r td e vice .F ill co o la n t o
mo u t h o f e xp a n sio n a n k ( a b o ve ma x) a n d sc r e w o n
109
21 Engine
U. Enginemounts, eplacement
D ferent brackets or munLal
and automat c gearboxes
U1
Rear nginemount gearbox ount)
N e ce ssa r yo r e mo veg e a r b o xme mb e r o r e mo ve e a r
Ge a r b o xmu st b e u n o a d e dw it h a ja ck d u r in g e p la ce -
,r))
Frontenginemount
U2
rr)l
U n lo a d n g in emo u n t sw n h if t t o o ls 0 3 3 2 x) , 5 0 0 5 a n d
5115.
U3
Left side
T o r e p la ce u b b e r p a d : r e mo ve e n g in e f ir o u n t w n h
u p p e r a n d r o w e rb r a cke r s.
O,r
q
e I
R ig h t sid e
T o r e p la ce u b b e rp a d : r e mo veu p p e rb r a cke l , , u u D -
b e r p a d t o g e t h e . , o n o t r e mo ve o w e r b r a cke r .
D o n o t lig h t e n u p p e r n u l f o r r u b b e r p a d t ] n t i e n g in e
mo u n l is p o sit io n e d .
Group21 Engine
Removingengine
V. Removing ngine
OperationsV1-7
Speci l tools 281 , 5185,51 6
Ensine n dgearbox emoved sa unit
v1
Remove ngine plashguardnddraincoolant
v2
Remove/disconnecti
r positive lead from battery
2 bonnet hood)
3 e xp a n sio n a n k ca p
4 lower radiaior hose from radiator
Auto {operation 5) l
5 o il p ip e f r o m o i co o le r . H o ld co n n e ct o r s n o i
co o e r w ilh a w r e n ch . t f a ccid e n ia s a cke n e d ,
t o r q u e o 6 N m ( 4 . 5 t t b s)
6 u p p e r a d ia t o rh o se r o m e n g in e
7 h o se s o € xp a n sio n a n k a t r a d it o r
8 radiator
t h o se s r o m h e a t e r o n t r o lv a l v e
1 0 h o se r o m va cu u m p u mp -
1rl
Group21 Engine
Removing engine
v3
R e mo ve / d isco n n e ct
A co n n e cio r r o m cllp o n b u lkh e a d f ir e w a )
B t h r o t t le a b L er o m p lle y a n d b r a cke t
F u e llin eco n n e ct io n s
( C E b e lo w ) i
B lo w - c a n , d isco n n e ct n d p lu g e n d s o p r e ve n td r r t
entering fuel system
C su p p ly in e r o m f u e liilt e r r e t u r n in e r o m n je c
t io n p u mp ( a t cla mp )
E p a L e a la v o r p r a h e a lir g svsr P T 0 1 F n o 1 o .
D isco n n e ctw ir e lr o n r ju n ciio n b o x. D isco n f e cl
b la ckw ir e a n d sma I r e dw ir e r o m r e la y.U n scr e w
r e t a in in g cr e w s r o m r e la y.
r e mo vep o w e r st e e r in g u mp f o m e n g in e :s a ck-
i)t a
e n a n d r e mo ve d r ive b e lt f r o m p u r n p . B e mo ve
p rfp sirL brar\e_ 'rd Lpportroy ro 1 F1g -
rta
T ie p u mp t o ch a ssis o p r e ve n ld a ma g e o h o se s.
co o lin g a n w it h sp a ce r
p u l e ya n d a n b e l t s
b e f o r p o w e r sie e r in gp u mp .
v4
Remove/disconnect
2 cr a n kca se r e a t h e r o se
;
3 a ir ilie r co ve . a n d h o se s
a ie f n a t o rw ir in g h a r n e ss:
d lsco n n e ct o t a 9 € r e g ua io r ( o r a t e r n a lo r ) .
il
R e mo ve e la in in gsc. e w s o r wir in g h a r n e sso n
w h e e a r ch a n d p a ce h a r n e ss n e n g in e .
V e h icle s o r S w e d e n :
5 T - se a ru n it o n b u lkh e a d f r e w a ll)
6 e xh a u st ip e r o m f r o n t e xh a u sl r a n chp ip e D 2 0
h a so n ly 1 ma n f o ld ) .
112
Group21 Engine
Removing engine
v5
Draine n g i n eoil
lnstall lug nd washer fter raining il.
- e n g i n emount etaining olts rom rontaxte ross-
L e f t ngine ount: emove u r s r o m rontaxte ross,
Right nginemounti emoveower ui rom ub-
0 Removinge n g i n e
v6
C
s
Remove/disconnect
0 =-€>
- f r o n t e xh a u stp ip e cla mp s
- d isco n n e cl xh a u stp ip e co u p lin g .R e mo ve r o n t e x -
- ( ma n u a l) lu t chca b lea n d g e a r e ve r
- ( a u t o ) e le ct o r o n t r o l r o m se a r b o x/ lr a n sm sio n
{"F sp e e d o me t e r a b le
-'-2" - g e a r b o x f o ssme mb e r . o sit io n j a c k b e n e a t h e a F
;# - d isco n n e ct ir in g .
0
(f
V7
Use iftins ools 8 0 1 , 5 1 8 5at ront) nd5r86 ar e a r ) .

Liftengine nougho unload eftenginemount.
Rertrovenginemount.
Removeack beneath earbox, tidepu e y u n i t f o r
wards nd ifi ourengine.
113
Gtoup21 Engine
Removing engine
X. Removing ngine
Operations 1-3
Specia tools 281 , 5185,5186
E n g in e n d g e a r b o x n st a lle d s a u n it
x1
Position ngine
Use ift ools2810, 1a5 at r o n t ) n d5186 a l ead.
Positionight ide ubbermounton owerbracket.
x2
Install eft enginemount
P la cemo u n t o n f r o n t a xle cr o ssme mb e r n d t ig h t e n
x3
Place a jack beneath gearbox
Makesurehat ubberfoam ad tgear everis orrect-
Insenwiring ntopassengerompartmeni.
Jack-up earbox ntil evel.
Remove lifling tools
Lower ngine nd emoveools.
114
\
Group21 E ngine
Removing engine
x5
Installgear ever
Place ear ever n housing.
P r e s s l a s t i c o l l a ra n d r u b b e r i n g n t o p o s i t i o n . n s t a l l
l o c k i n g .R e c o n n e c l a r i n g .
I n s t a l l r a c k e t o r r e v e r s e e a r d e t e n t .D o n o t t i g h t e n
screws atthis stage since bracketmust be adjusted at a
0
X6
Installnuts tor engine mounts
Leftm ount: utsn iontaxle rossmember.
R i g h tm o u n t : l o w e r n u l o n r u b b e r p a d .
x7
Installgearboxcrossmember
x8
Install n gearbox:
_ gear ever. Make ure hat bushings nd Ojing are
c o e c l l y n s t a l l e d .n s e n e a r e v e l n y o k e , t p i n a n d
t i s h t e n s c r e w A l l e nk e y 4 m r n ) ,s e e n s e t
- p r o p e l l e r h a f t .A l w a y su s e n e w n u t s a n d b o l t s
s p e e d o m e t e r a b l e .S w e d e n :w i r e m u s t b e s e a l e d t
g e a r b o x t o o n f o r m o a x e g u l a t i o n sk i l o m e r e r t a x a ,
115
Group21 Engine
Removing engine
X9
Connect lutchcableand install return spring

I n se r tca b le h f o u g h f lyw h e e l ca sin g a n d co n n e ct o
ln st a ll u b b e r b u f f e r a n d vib r a t io n d a mp e r o n ca b le ,
ma kin gsu r e h a t b u f f e r s f a cin g ig h t w a y.
C o n n e ct e t u r nsP r in g .
A d ju st p la y = 1 - 3 mm. ( 0 . 0 4 - 0 . 1 2n )
A0tomatic gearbox
Attach gear selector to gearbox

x10 DI
xl1
Install ront exhaustpipe
Forstrainjreenstallation,nstrucrionsustbe ol
{))
1 S la cke n w o r e t a in in g b o lt s h o ld in g b r a cke t o
g e a r b o r t r a n smissio n
2 Attach front exhaust pipe fingef tight. Use new
3 T ig h t e n n u t s a n d b o lt s h o ld in g e xh a u st p ip e t o
4 T ig h t e nb o lt h o ld in g r o n t p ip e o b r a cke t
0D
5 T ig h t e nb o lt s h o ld in gb r a cke t o g e a r b o x
6 T ig h t e ncla mp a t e xh a u stp ip e o in t .
Carsforsweden
xl2
Attach T-gearunit to bulkhead firewall)
1',16
Group21 Engine
Removing engine
x13
Connect lternatot wiring harness
Reconnectvoltage regulator.
A t t a chcla mp o n w h e e la r ch .
x14
lnstall air filter cover
Reconnectir inleth o s eand breather o s e o valve
Notethatarrowonnlethose ust oint owa dsm a n i -

fold as ndicated, therwisehosemay be compressed
xl5
Install drive bells and cooling fan
P la ce o w e r st e e r in gp u mp b e ll o n vib r a t io nd a mp e r .
I n st a llf a nb e lt sa n d p u lle y-
Install cooling fan with spacer.Torque to 9 Nm (6 5 ft
lb s) .
T e n sio n a n b e lt s. ltsh o u ld b e p o ssib le t od e p r e ss e l t
5-10 mm on run between fan and alternator, see fig
x16
Installpowe. steeringpump and belt
Negativeead rom battery houldbe connectedo
lower ront etaining olt or pumpmounting racket.
Tension an belts.lt shouldbe possibleo depress elt
F10 mm (0.2-0.4n ) n ce n t e r f r u nbetweenan an d
x17
Connectelay or preheating ystem
C o n n e ct la ckw ir e o t e r min a l 6 o n r e la ya n d r e d w ir e
t o t e r min a l8 5 .
Attach relay to washer reservoir mounting bracket.
R e co n n e ct ir in g t o ju n ct io n b o x.
Secure wires with clamps and reconnect battery-
111
Group21 Engine
Removing engine
x18
Reconnect uel lines
M a k e u r e h a td i r tdo esnot enter uel system.
x19
lug tirewall)
Reconnect on bulkhead
S e cu r e lu g w it h clip .
x20
Reconnect:
- hoses o heater control valve
- h o se o va cu u m p u mp
x21
lnstall radiatorand connecthoses
'.,r
Automatic earbox
m x22
Connectoil pipes o oil cooler
U sea w r e n ch o h o ld co n n e ct o r c n o il co o le r .
T ig h t e n in g o r q u e
C a pn u t s 3 0 Nm ( 2 2 t t b s)
Oil co o le r o n n e ct io n s N m { 4 . 5 t lb s) .
118
Group21 Engine
Bemovingengine
lnstall bonnet/hood
Connect asher ose,
Reconnect ailery
Manualgearbox
x25
Adiust blacket or reversegear detent. lnstall
rubbergaite.
Engagefirst ear.Ad,ustclearance etween ear ever
and detentbrackerto .5-1.5mm (0.020-0.060n ). Use
a feelergauge.
Tighten etainingbolts.
Rechecklearancen s€condgear,
Install ubbergairerboot.
Automaticgeatbox
Check/rdiusigeaa elector
'1.
Checkthat learance etween ositionD andstop
is approximately ameas rom 2 to stop.
2. Adjust by altering engthof controt rod if neces,
Roughadiustment: urn adjusrer t re6r of rod

Fineadiustmenttu n serrared teeve maxvisibte
thread enslh= 35mm).
hcreasing od ength educes tea ance n position
D, and ncreases learancen posjtion2.
After adiusrment:move tever o posirion an d
then o positionP.Repeat heck ccordng o stag
1.
'119
Group 21 Engine
Removing engine
x27
A d d e n g in e o il
C a p a cit yn c u d in g o il f ille r :
D 2 0 = 6 lit r e s { 6 . 3US q u a d s)
=
D 2 4 7 lit r e s { 7 . 4US q u a d s)
Ou a t y: a cco r d in g o A P l, min cC ( o ils w ir h d e sig n a '
lio r s S L / C C . L / C D . l / C Cd r d S r / C D Jl' i r l-s e q L r e .
V isco sily, e e a d ja ce n t ia g r a m.
N o t e lS A E 5 W 5 0 o r S A E2 0 W 5 0 o i l sa r e r e co mme n
dedioruseinextremedrivingconditionswhichinvolve
h ig h o il co n su mp lio na n d h ig h o il ie mp e r a t u r e s . g .
,))
mo u n t a ind r ivin g w it h f r e q u e n td e ce le r a t io n s r f a st
mo t o r w a Y ir ivin g . N o t e h o w e ve r h e lo w e r e mp e r a
x28
Bleeding I coolingsystem
Disconnectpperhose rom coldstartclevice. ace
drip pan beneath oseand hod hose evelw ith top
'rl
edge i expansionank.
Coolant
S in cea lu min iu m s u se d n t h e e n g ln e s, ct iveco r r o ,
sio n p r o t e ct io n s n e ce ssa r yn t h e co o la n t o h e lp p r e -
ve n r co r o s o n o sma g e .
U se g e n u in eV o lvo b lu e g r e e nco o a n l t yp e C , d ilu t e d
w ilh cle a nw a le r n p r o p o r lio n s i 5 0 / 5 0 .
T h is mixlu r e h e lp s t o p r e ve n t co r o sio n a n d f r o st
i l|
a N e ve r i t h e co o l n g syst e mw it h w a t e r a lo n e .
a T h e co o lE n t h o ud b e ch a n g e d e g u la r y in ce h e
co r r o sio np r o t e ct ive cld it ive sn t h e co o la n t o se i,
t h e ir e f f e ct n ih e t ime .
N o t e lD on o t o ne n sin e h e n e ve o i co o la . l s o w sr n ce
h 9 h o ca e mp e r a t u r e sc6ensu r w h ich a yca u se t h e cy n.
I
20
Group 1 Engine
Removtngengine
oftcrrALirv isx rYP $ rArYL

trr$flLr Ain iurr Mro li Dftv^nr|.ocH r 0rr
v0 r r 0 . va r su' r c
AI<'LI/IO COOLAilINPI R e p la cin g co o la n t
roP uPYladR0ur0 wf| F^tr r^r
A lw a ys u se yp e C b lu e ' g r e e n o o la n t .B e me mb e r o
itMfu 0r 0ur0rArr0n r/o'llro
r e p la ce e ca ( P / N1 3 3 1 4 7 3 - 7 )n e xp a n sio n a n k f n e '
T yp e C b lu e - g r e e n o o la n t
A ll d ie se la n d p e t r o ( g a so lin e ) n sin e sma n u f a ct u r e d
sin ce1 9 8 2a r e ille dw it h t yp e C co o la n t .
x29
F ill co o la n t
C a p a cit y:D 2 0 = 8 . 1 it r e s 8 . 6U S q u a r t s)
D 2 4 = 9 . 3 ir r e s 9 . 8U S q u a r t s)
F lu sh o o lin gsyst e mb e f o r ea cld in g e w co o ia n t , e e
Gr o p 2 6 C o o lin gS yst e m.
S e ld d s _ o o d r d' e . r e r . o r r o l o r d \ . T L r r o r e l g r n e
a n d w a r m- u p o r 5 min u t e s.A d d co o la n td u r in g h is
t ime . C o n n e ct o se o co ld st a r td e vice . ill co o la n r o
n r o u t h o f e xp a n si o n a n k ( a b o ve ma x) a n d scr e w o n
x30
Check/adiust niection iming
(rt See nstructionsn page24,c11-20
,4\\
_egt Checkoperation
x31
T u r non engine ndwarmup.

C h e c k f o r o i l a n d c o o aanki a g e s . T o pp i fn e c e s s a r y .
Install ngine pashguard.
121
Group21 Engine
Removing engtne
Coldgea&oxo I oiltemperatures o'C 104'F'.

This emperat re s reached fterapprox,10 minutes dl ns. Automaticgearboxes:
At oi temperatureseLow 0'C eve may be belowM N. x32
Check-top-up oil level
UseATF ype F or G.
Engine ustbe unning ndselectorn position or P.
MI N .96'€
Hot gearbox o I oit temperatlre 90'C ('194'F)
x33
Check/adiust
ld le = 1 2 . 5 1 0 . 8 A : 7 5 0 1 5 0 / min
F a st d le = 8 7 1 1 . 7 s = 5 2 0 0 1 1 0 0 / min
lf n e ce ssa r ye f e r o p a g e 1 2 9 .
E n g in e co n t r o ls lh r o t t le ca b e a n d kick- d o w n a b t e )
( A u t o ) . f n e ce ssa r ye f e r o p a g e 1 7 6 .
lmp o r t a n t r f e n g in eh a s b e e n d isa sse mb d cylin d e r

h e a d b o lt s n u st b e ch e ck ig h ie n e d a f t e r 6 0 0 1 , 2 0 0
ma e s 1 , 0 0 0 - 2 , 0 0 0m) .
r,il)
iIil
a
122
Group 22 Lubricating System
Engine oil, oil filter
Group22 LubricatingSystem
Contents
Operation
E ' 1 g i n e o i , o ;i l t e r . r a p a c e m e n t . . . . . . . . . . Y1 2
O lp . e ssu r e . h e ckilg 71
O l p L m p , g e r e r d l i n f o r r a l r o n . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . z1
22 124
Engineoil, oil filter. replacement
Y1
D20 D2 4
Oil capacity litres
( U S q u a r t s)
E xcl.o il f it e r 5_2 5 . 5 ) 6.2 6.5)
I n cl.o il f ilt e r 6.0 6 . 3 ) 1.O 7 . 4 1
1.0 1.0) 1.0 1.0)
Ouality
A cco r d in go A P I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I.NCC
......... .
Oils with designationsSE/CC,S E/CD,SF/CC nd SF/CD
f u lf il h is r e q u ir e me n l.
T e r n p e r a t u r aenge
{srable mbientemperat'rres)
N o t eS A E1 5 W5 0o r S A E2 0 W5 0o i l sa f e r e co r n me n d e d
f o r u se in e xt r e me d r ivin g co n d it io n sw h ich I n vo t ve
h ig h o il co n su mp t io n n d h ig h o it t e lr lp e r a t u r e s . g .
mo u n t a in d r ivin g w ih t f r e q u e n t d e ce t e r a t io n s f f a st
mo t o r w a y d r ivin g . N o t e h o w e ve r h e t o w e r e mp e r a -
t u r e imit s. )
Y2
Oil filter
Useoil ilterwrench 903 o removeitter.
To nstallfilter,ee nskuclions n itrer.
lf onlyfilteriseplacedi . e . otengineoil),dd0.a itres
( 0 . 8USquarts) f oil.
12 3
Group 22 Lubricating system

Oil pressure, il pump
Oil pressure, hecking

z1
Connect oil pressure gauge to connection for oil

pressure sender
Oil pressuremust be 6t least200kPa 28psi)at 33 r/ s
(2,000min) and8 0 ' C 1 7 6 ' F ) iltemperature.
Relief alve n pumpshould penat 600-700 Pa 8F
99 psi)-
- oil evel
- relief alve n p u m p .
Oil pump
z2
Generalnformation
Oil p a n cannotbe removed rom installed ngine.
Consequenlly t is necessaryo remove ngine o re-
Mark A) on outerp l m p gearmust ace ear over.

Oil p u m p s onlyavailables a complete nir.Spare
partsare howeveravailableor reliefvalve.
(),il
{))r
z3
Reliefvalve
lf o jl p r e ssu r e s n o t a s sp e cif ie d h e ck h a t p lu n g e r
mo ve s r e e lya n d h a t sp r in g s in g o o d co n d it io n .
R e lie f a lve s a cce ssib ler o m b e lo w w it h o il p u mp
h
a in st a lle d .
g T ig h t e n in s o r q u e4 0 Nm ( 3 0 t lb s) .
I
-/)
€-ao Nm
l
12 4
Gtoup 23 Fuel sysf€fi

Contenls
Group23 Fuel ystem
Contents
Op.ration Pag6
't26
Exhaust a s moke ensity, e n e r a l .-.--..... .-
checking ' AA2-10 126
ldle+ fast dle .............. ABl-6 129
Fuel iltsr,drainingwate AC1 130
replacoment.......... AC2 1 30
Injection ump, eneral AE1-14 13',l
altitudeadiustment, SA AD2 132
senlng .'. , " aD3-14 1 33
't36
belt ePlacement....'..., AEl-14
removal .....,.............. 14 0
installation.................. AG1-17 143
Deliverypipes, emoval/installation...... ......... AH1-3 14 8
'149
rePlac€ment AJl-10
Iniectors, alfunctions/checking . .... . ......... AK1_2 151
removal .......,.,............. AK}6 151
'152
installation................... AK7-9
overhaul incl. esting} AL1-10 1 53
Coldstartclevice.,........ Atvtl-2 1 55
Preheating ystem glowplugsl.wiring diagram1979_80. ' AN1 15 6
1981- .......,.,. AO1 158
125
Group23 Fuel system

Exhaustgas density
AA. Exhaustgas density
General
E xh a u st a s smo ked e n sit yg ive sa g o o d n d ica t io n f
t h e co n d it io no f a n e n g in ea n d w h e t h e r h e in je ct io n
p u mp s co r r e ct ly d ju st e d .
S w e d ish r e g u la t io n s st ip u la t e t h a t smo ke d e n sit y
mu st n o t e xce e d . 5 B o schu n it s o r p a sse n g e r a r sa t
t ime o f r e g is t r a t io n n d 4 . 5 B o schu n it s a t t h e a n n u a
S in ce e xh a u st g a s smo ke e missio n s f r o m V o lvo

d ie se ls r e g e n e r a ly lo w e r h a n o t h e rve h icle s r ma y
b e h o u g h tp o ssibe t o in cr e a se n g n e p e r f o r ma n ce y
e n r ich in s h e f u e l a if mixt u r e .
P r o lo n g e d e r ce ssive e n n ch me n l w ill n o t in L r e a se
p o w e r o u t p u t b u t w ill in f a ct r e d u ce se r yice if e o f
e n g in e co n sid e r a b ly.E ve n mo d e r a t e e n r ich me n t o f
f u e l- a irmixt u r ew illsh a r p ly n cr e a se xh a u st a s e m-
r)d
p e r a t u r e s n dco mb u st io n r e ssu r e s, it h o u t a n y co F
r e sp o n d in sp o w e r sa in .
{),1
AA2
Checkingsmoke density
Variousypes f equipment reavailableo measure
smokedensity. efero manufacturers' nstructions
for maintenancendcalibration f equipment.
12 6
Group 23 Fuel system

Exhaustgas density
AA3
Connectextension piece o exhaust pipe
This educesh e iskof ambient iraffectingnstru-
ment robe. ipe imensions: ength 200mm 8in)
in t e r n a ld r a me L e r5 0 mn l2 in ) .S e cu r e it e n t io np ie ce
w it h r u b b e rh o sea n d cla mp s.
Install sample p u m p
Insertprobe nto exhaust ipe,Probemustbe n center
and nserted o 6 depthof not less han 200mm {8in},
otherwise eadingswill be incorect,
H a n g lexible ose rom clamp s llustrated.
Connect ose rom rubber laddero sample ump.
AA5
Check sample pump operation
Engineoff.
Push n pumpplunger ully.Squeezeubber ladder
andcheckmov€ment f pumpplunger.
NotelDonotcover ole n bladder s plungerwillnot
Push n plunger ully after hecking.
AA6
Insert ilter paper n pump
Unscrew overand check hat contact urfaces re
P l6 ce ilt e r p a p e r n o p e n in g a n d t ig h t e n co ve r h a n d
taght.
Position rubb€r seal over cover (to prevent dirt and
moisture from affecting test).
'127
Group23 Fuelsystem
Exhaustgas density
Routehose with rubber bladderto d.ive6 seat

Secure osewith ape.
2 4 2 1 2 4 4nsert
: ose hrough earsidewindow.
245: nserthrough ailgate.
s0 knr/h 30
50
AA8
,)r
Measuresmoke density
Warm-up ngine o normal peratrngemperature,
Driven second ea at50k m / h 3 0mph). lowly u sh
acceLeratore d a l o floorwhileapplyingootbrakeo rit I
maintain onstant 0 km/h.
Note Automaticransmission: o not depress c'
celerator e d a l o s u € han extent hat kick-downs
engaged.
Maintain onstant peed or a few seconds nd
s0 km/h 3 0mph) squeezeubber adder o operale ump.
Note Squeezeubberbladder ard of several e-
condso ensureh a tsample umphasbeen illed.D o
n o tcover ole n rubber ladder.
AA9 l),,
Repeatmeasurements
Removeilter aperrompump.
Depressumpplungeruly and place new ilter
p a p e r n p u mp . A e p o sit io n u b b e r co ve r .
rl,
R e p e a tm e a su r e me n t s cco r d in g o A A 8 .
I
AAlO
Evaluateesult
C a b r a t e e q u ip me n ta cco r d in g o ma n u f a ct u r e r sn -
S mo ked e n sit y o r p a sse n g e r a r s n S w e d e nmu st n o t

e xce e d . 5B o schu n it s a t t ime o f r e g ist r a t io n n d 4 . 5
B o schu n it s a t a n n u a l n sp e clio n .
124
AB. ldle * fast idle

Special ool: 9950
Connect achomeler
UseVolvoMonotesterndadapter 950.
lf Volvo Monotester js not available use photoelectric
rev counter (999 9795,9).
Warm-upengine
Checldadjust idle
12.5 /s (750 /min).
Sealadjustmentscrew and lock nut with paint after
Checldadiust fast idle

87 r/s {5200 /min).
Sealadjustmentscrew and lock nut with paint after

Donot ace ngineonger hannecessary,
Disconnect achomeler.
AB6
Checldadiust ngine controls
Always
i d l e sp e ehecUadjust
d. ngine ontrolsfter diustjng
S e e n st r u ct io n s n p a g e 1 7 6 ,o p e r a t io n s X l- A X g .
AG.Fuel ilter
'),
ACl i
Drain water from fuel tilter
{ ) l1 I
- place d r i pp a nunderneathrain crew 2)
- slacken leed crew 1) couple fturns
- slacken rainscrew 2 ) and retighten hen clean
fuel lows hrough.
- retightenbleedscrew
AC2
Replacement
Special tool: 2903
- Us€strapwrench2903 o remove ilter. Place trap
asnear s possrbleo bdse f lilter, ee ig .
- smear iesel il on new ilterseal t)r
- tightenilterby handuntilseal o ntacts ody. hen
tighten further /4 urn
- sta eflgine nd heckor eaks.lfsealisottight ir
will bedrawn nto uelsystem ndcause oor u n-
ning. i,l
130
Group23 Fuelsystem
Iniection pump, genercl
AD. niection ump,general
AD1
Adiustments which can be carried out on an
installed iniection pump are limited to tho
tollowing:
- adjustingdleand ast dle
- adjustingniectioniming
Formoredetailedepairs ndadjustmentshe pump
mustbe emoved nd ested y speciallytr6in6dsr-
sonnel,na sDecialtest6nch.
Smokedensity egulationsor Sweden

-..rt-T Fuel egulating crew s sealedatfactory.
No 61 uelsupplymay only be checked/adjustedn a
O) r) t6st benchbvtrained Dersonnel,
, vi
131
Group23 tuel system

High altitude adjustment (Legalrcquirement)
Highaltitudeadjustment Legal equirement)
AD2
Environmental rotection gency EPAI efines:
- high altitudeas an €levationexceeding 219metres
(4000 0
- low altitudeas an elevation ower han or equ6l o
1219metres 4000 tl.
a Ondeliveryfromactoryallehiclesareadiustedfor
low altitudes,
a Nswvehiclesoldfor rincipal se t highaltitudes
must be adjusted befor€ bsing delivered o the
custom€ .After adiu tmenta decalmustbe affixed
to the firewall (beside he emissions nformation
decal) ndalso o the njection ump.
a lf v€hicleowner movesfrom low to high altitude
are6, he vehicleshouldbs readjustedorhighalti-
tude driving.
a Vehicles djusted or high altitudesmust bs read_
iusted or low altitudss fvehicle s o be principallv
usedat low altjtudes. h€ hjghaltitudedecalsmust
also be removsdat the same ime,
Thefollowingadiustmentm ust bemade o vehicle or

useat highaltitudos:
Inisction iming: advancsd0.07 mm (0.0028 n) for
every100m (3300 tlincrease n altitudes.
Injected uantitydecreases y 2.3mm3tor each1000
metre ncreasen altitude. his s equivalentto urning
adiustment crew35' counterclockwise.
Injecrion iming Iniectedqutntity

Example: f altitude s 2000metresabove ea evel he Example:f altitudes2000metresaboveseaevel he
lollowing calculations an be made: following alculationsanb e m a d e i
0.85mm is normal setting for 1982-models} ?999^- -r. = rn.
1000
o.ss+ffi*o.oz)=o.ssr. Turn adjustmenl crew70"
H ig h a lt it u d e e t t in g s 0 . 9 9m m
132

lnjection pump,êfting
pump, setting
AD. Iniection
special tool: 5194
Removo ear iming goa. covel
Disconnect cold start devicc

Slacken crew1.Push ever o wa d and rotatesleeve
90'.
Nole Do nottlrn screw2 otherwis€ twillbe nec€ss'
ary o remove old start deviceand rsset t on a test
bench.
Push ev€rbackagainststop.
Tuln ongin€ until cyl. I is at TDc-iniection

Alwaysuse he vibration dampercentrebolt to turn
the engine.
Usea 27 mm socket,
))
IVsrkn p u m pgearshould eopposite a r k nm o u n -
ting bracket.F lywheelat O" mark.
Pl.co dial Indicator in iniection pump

Unscrew and rerhove plug from iniection pump
distributor.
Installholder 5 1 9 4and dial indicator measuring
range -3 mm).S€tgaugetoapprox.2m m.
Gtoup 23 Fuel system

Injection ump,setting
AD7
Set indicator o zer o
Turn ump ear ack lightlyntilm in. eadingegis-
ters ndial ndicator.
Set ndicatoro zero.
AD8
Check ump setting
T u r nenqine lowly lockwise ntilflywheels at'O'
Note f engines urned oo ar t mustbe urned ack

approx.1/4rurnnd hen o'o'markothelwise etting
a)l
Dial ndicator hould how:
.75-0.83 m (0.0295-0.0327
O20 ...................... n)
i: rt
i i:
i'
,55-0.73 m (0.2560 , 0 2 8 7n )
D24 ................ .........
D24USAandCanada 979-1981....... .65-0.73 m
(0.0256-0 287 n )
0l
l"ri 1 1982- ...............
.82-0.90mm
((c) ,
/1,;.<:i:/h
{0.0323 .0354n )
(Vehiclesdjustedor high altitude rivingj efer o
p a g e14)
AD9
Readiustingump
Setting alues: setting:
D20 .............................................
.80mm {0.0315n)
D24..............................................
.70mm {0.0276n)
D24USAandCanada 979-1981................ .70mm
(0.0295n)
,:f-;*il 1 9 8 2 . . . . . . . . . . . . . . . . . ...8. .5m
(0.0335n )
. . .m.
t),
Reading less than specilied:
Slacken umpmounting olts nd urnpump nwards
to obtain orrect alue. ightenmounting oltsa nd
repeat heck f pumpsetting. ,)t
Reading ore hanspecified:
Slackenpump mounting bolts and turn pump I
outwards ntildial ndicator hows pprox:
D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7. 0
. .m . . .0. . 0. .2. .7 6 i n )
. .m
D 2 4 . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . .6. 0. .m . . .0...0. .2. .3 7 i n )
. .m
D24USAandCanada1979-198? ................. .60mm
{ 00 2 5 6 n )
1 9 8 2 ' . . . . . . . . . . . . . . . . . . .7. 5.m . .m
...
(0.0295n )
Then urn p u m p nwards nti specified alue s ob
tained. ightenmounting olts nd echeckump e t'
t |n g ,
Note njecrionu m pmustn o tbe apped r knocked
as hiswill aher ts setting.
134
Group23 Fuelsystem
lnjection pump, sefting
ADlO
Checkpump setting
Turn nginewoturns6ndchecksetting.
Adjust f necessaryccordingo operationDB and
ADl1
Romovedial i ndicator and holder
AD12
Install plug wath new $oal
Tighteningorque Nm (6.5 t lbs).
ADI3
Install rear iming gear covel
AD14
Reconnect cold stsrt dovicg
Press ever orwards and turn sleeve90'. Retighten
Notol Do notturn screw2. otherwise t will be necess-

ary o removecold start d€viceand reset t on a tgst
bench.
Group23 Fuelsystem
lnjection ump belt, replacement
AE. njection ump belt, eplacement

Special ools: 5193, 194, 197, 199, 201
AEl
Remove ear iming gearcover
AE2
Turnengine ntil cyl.1 s al TDC-injection
0,
Always sevibration amper entre oLt o turn
engine. se 7mmso€ket.
n pump ear hould eopposite arknmount-
l\,lark
in9bracket.lywheelt "o".
Lift off pump belt

S ia cke n r lo u n t in g o lt s o r in je ct io np u mp b r a cke t o
r e le a seb e lt e n sio n .T ig h t e n o n e b o lt so t h a t p u mp
r e ma in s n p p e r p o sit io n . {)l}(|
Lift off belt.
0,)
AE4
Remove amshaft earsprocket
H o d sp r o cke t n p o sit io n w it h 5 1 9 9 a n d u n scr e w
sp r o cke tw it h w r e n ch5 2 0 1 .
Take care nol to rolate camshaft.
ln st a ll e n t e rb o lt , h a n d ig h t . t sh o u ld b e p o ssib le o
t u r n sp r o cke t n ca msh a f rw it h o u t ca msh a f t o t a t i n g .
136
I
Group23 Fuelsystem
Injection ump belt, replacement
AE5
Disconnectold start device
S la cke n cr e w1 .P u sh e ve r o r w a r da n d r o t a t e le e ve
90'.
N o t e D o n o t u f n scr e w2 , o t h e r w ise t will b e n cu e ss,
a r y o r e mo veco ld st a r t d e vicea n d r e se t t o n a r e sr
P r e ss e ve r b a cka g a in st t o p .
AE6
Basic-setn iection ump
\j -,74, - Slackenumpmountingolts Alenkey= 6 mm .
ior Alignmarks n pump ndmountingrackety urn,

in g p u mp . R e t ig h t e nmo u n t in g b o lt s.
1E.
AE7
Set dial indicator zero.
Lock pump gear at cyl. 1 iniection using stop
5193
Unscrewand remove plus from injectionp u m p
InslaIholdF5194 no dal indcdror mFasurirs

range 3 mm).Set g a g e o approx. mm.
T u r n pump ge.r c ockwise nti markon g e a r an d
mounting racket oincide.
:i r€g ::3 Then urnp u m pgearback lightly ntil min feading

registers n d al ndicator. et ndicaroro zero.
T u r n p u m pg e a r clockwise ntil marko n gear and
p u m p mounting racket oincide. ockg e a r n this
positionwilh stop5193. lnsert top hroughp u m p
g e a r nlo mounting rackel.)
137

lniection ump belt, replacement
AE8
lnstall belt
Adiust ension y moving oolant ump.
Use a u g e 197o c h e c kension. ttach a u g e o belt
a n dset o 12.5 nits . tretch eltuntilm a r ko n g a u g e
plunger s flushwith sleeve. epress elt strongly
with handand recheck/adiust ension.
AE9
t .- rl|'- Sel pump and tighten camshaft r6ar sprockei
t t | : : r y,.7,v Use 199to old procket.orquewrenchhould ea t
"' 7u ,
" ",, raght ngleso wrench 201 therwiseorquewill b €
Using 1 9 9 ,u r nsprock€t lowly lockwise ntildial

tit
.80mm 0.0315in)
D20 .............................................
.70mm 0.0276n)
D24...-..........................................
D24USAandCanada 9791981 ................ .70m m
1 O qN m (0.0276n)
1982-..........................
.8sm m
(0.0335n)
(Vehices djustedo r high altitude rivinsi e f e r o
p a g e1 3 2 . )
Hoidsprocketn this position nd orqu€bolt o 100
Nm 73ft b s ) . ake are hat amshaft nd procketo
AEl O
Remove top 5193 rom pump gear
AE11
Check ump setting
Turn ngine
wo ullsurns
tion gain.f engine ntil yl.1
urnedoo s atTDC-injec-
ar tmust e urned
backapprox.l/4turn nd hen ozeromarkotherwise
setting ill be ncorrect.
D20 ....................-.................................
.75-0.83 m
(0.0295-0.0327 n)
D24............--..--..--..-.......................
.65-0.73 m
(0.0256 .0287n )
D 24USAandCanada1979-1981 ....... .55-0.73 m
(0.0256-0.0287 n)
1982- ................82-0.90mm
(0.0323-0.0354 n)
Correct eadingr
bolts.Proceed ighten njection ump mounting
o E12.
Incorrecteading: eadjustc€ordingo instructions
138
Gtoup23 Fuelsystem
lnjectionpump belt
Readiusting ump setting:

D20 .............................................
.80m m {0.0315n )
.70mm (0.0276n )
D24 ...................-.........................
D24USAandCanada 979-1981. 7 0m m (0.0276n)
1982 ....... .85m m (0.0335n)
Reading ess han specilied:

Slacken u m pmounting olts n d u r n p u m p nwards
to obtain orre ct alue. ig htenmounting oltsan d
repeat heck f p u m psetting.
Readingm o r e than specilied:

i, Slackenp u m p mounting bohs and turn pump
outwards ntildial ndicator hows pprox:
D20 .............................................
. 7 0m m (0.0276n)
. 6 0mm (0.0237n)
D24 .............................................
D24USAa n dCanada 1979-1981 .................
.60mm
(0.0237n)
1S82- ......0-75 m (0.0295n)
Then u r n p u m p nwards ntilspecified alue s ob-
tained. ighten ounting olts nd echeck ump e r-
trn9,
lmportanll Iniection p hp must not be tapped or

knocked s his will alter is setting,
AE12
Remove ial ndicalor nd holder5194. nstall
plug with new seal.
Tishteningo rque Nm 6.5t bs).
AE13
Press ever orwardand urn sleeve 0'. Retighten
NotelDon o t u r nscrew ,othelwiset will be eoess-

ary o remove oldstartdevice nd reset t o n a r e s r
AE14
Install ear iming gearcover
139
Fuel system
pump, removal
AF. njection ump, emoval

Special ools: 2 x 2901, 193, 199,5201,5204
Disconnect:
h o se s o r co ld st a d d e vice .C la mp h o se sw it h p lie r s
2 9 0 1p r io r o r e mo va
- t h r o t t le a b L e n d kickd o w n ca b le a u t o ) f r o mp u mp
- w ir e f r o m f u e lva lve .
AF2
Remove ear iming g e a r covel
0,il]
0il
AF3
Disconnectu el delivery nd return ines rcm
pump
C e a n co n n e ct io n s h o r o u g h ly b e f o r e d isco n n e ct in g
t h e m. P lu ge n d s o f f u e l lin e s o p r e ve n t d ir t e n t e r in g
140

lnjectionpump, rcmoval
pump pump plunger

Remove acuum and
ffemove ump etajning utsand place umpon
Removelungerr om ylinderead.
AF5
Remove luel delivery pipes
Clean ll connectionshoroughly efore isconnect-
Ingprpes.
Remove ll deliverypipes and p[]g ends o prevent
dirt rom enteringuelsystem.
AF6
(Wti Turn engine until cyl. 1 is at TDc-iniection

Always se vibration amper enter olt o turn
engine. se 7mmsocket.
) lvlarkn pump earshouldeopposite arknmount'
insbracket.lywheelt O".
Lift oft pump belt

Slacken ounting olts or njection umpbrackero
release elt ension. ighten ne bolt s o t h a t pump
remainsn u p p e rposition.
Lift off belt.
141
Group 23 Fuelsystem
lnjection pump, rcmoval
AF8
Remove camshaft rear sprocket
Hold sprocketn positionwith 5199a n d unsctew
sprocketw ith wrench5201.
Take arenot o rotatecamshaft.
Install enter olt,hand ight. t should e possibleo
t u r nsprocket n camshafl ithoutcamshafto tatang.
AF9
Slacken ump gear
Use 193o holdgear ndslacken
5201. emove ut andwasher.
AFlO
Pulloff gear
Use uller 204 nd top 193. uri}
O,il
AF11
-lepftp'= Remove ump
j,,r Z-{ - Remover o n tmounting racketromengine
r //nl Remove ump rom earmounting racketAllen e y
I riqr = 6 mm).
\-

In ect on pump, insta ation
AG. Injectionpump, nstallation

Special ools: 5193, 194, 197, 199,5201
AG1
Position injection pump
Mountp u m pon engine nd securet wilh retaining
boltsandfront ounting racket. onottighten olts
fullyat hisstage.
Alignmark n p u m pwith mark n mounting racket.
Then ighten etaining olts or p u m p mounting
AG2
Install pump geat
Do not orget o place ey n pump axle, nstall ear.
Torquenut to 45 Nm {33 t lbs).

ljse 5193 o hold sprocketand 5201 o tighten nut.
Torque rench houldbe at rightangles o wrenc h
5201, therwise orquewill be ncorre€t.
AG3
Disconnect old start device
Slackencrew .Pushever orward nd otate leeve
90'.
Notol Do notturn screw2, otherwise t will be necess-
ary to removecold start deviceand reset t on a test
Presseverbackagainststop.
14 3
Group23 Fuelsystem
Iniectionpump, installing
AG4
Set dial ndicalor zero.Lock pump gear at cyl. 1
injection using stop 5193
Unscrewand remove plug from injectionpump
I n s r c lh o d e r 5 1 9 4 r d d i d : r d i c d l o rn e a s . r - i n s
range -3 mm).Setgauge o approx. mm.
T u r n p u m pg e a r c ockwise ntil marko n gear an d
mounting racket oincide.
l)il |
T h e n u r np u m pgearback lightly ntilmin reading
registersn dial ndicatof. et ndicatoro z e r o
T u r n p u m p g e a r clockwise ntil mark o n g e a ra nd
pump mountlng racket olncide. ockg e a r n t h i s
lrii
positionwith stop5193. lnsed top hroughpump
gear ntomounting rackel.)
AG5
Installp ump belt
A d ju sl e n sio nb y mo vin g co o la n t p u mp .
U se g a u g e5 1 9 7 o ch e ckt e n sio n - A n a ch a u g e o b e h
a n d se t o 1 2 . 5 n it s.S t r e t chb e lt u n t il ma r k o n g a u g e
p lu n g e f is f lu sh w it h s e e ve .D e p r e ssb e ll st r o n g ly
w it h h a n d a n d r e ch e ck/ a d ju ste n sio n .
AG 6 ,),il|
S e t p u mp a n d t ig h t e n ca msh a f t r e a r sp r o cke t
U se5 1 9 9 o h o d sp r o cke t . o r q u ew r e n chsh o u ldb e a t
r ig h t a n g L e so w . e n ch 5 2 0 1o t h e r w ise o r q u e w i I b e
sing 1 9 9 ,urn sprocket lowlyclockwise ntild al 'f,f

. . . . . (0.031s
D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . 8. .0mm . . . . . . . n)
D 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . 7. .0mm
. . . . . 10.0276
. . . . . . . n)
D24USAandCanada 9791 9 8 1. . . . . . . . . . . . . . 7 . .0.m m
(0.0276 n)
1982 0.85mm
( 0 , 0 3 3 5n )
( V e h ice s a d ju st e d o r h ig h a t it L r d e r ivin g : . e f e r lo
page132
H o ld sp r o cke t n t h is p o sit io n a r d t o r q u e b o lt t o 1 0 0
Nm ( 7 3 f llb s) .T a ke a r e h a tca msh a f t n d sp r o cke t o
AG7
Removestop 5193 rom pump gear
Gtoup 23 Fuel system

lnjection pump, installing
AG8
Check pump setting
T u r nengine wo ull urnsuntilcyl. 1 s at TDC-injec-
tion,again.f e n g i n es urned oo ar t mustbeturned
back pprox. /4 urn and hen o 'O'mark othelwise
setting ill be n correct.

.75-0.83 m (0.0295-0-0327
D20........................ n)
.65-0.73mm 0.256-0.0287in)
D24..........................
D24USAandCanada 9791S81 ....... .65-0.73 m
(0.0256-0.0287 n)
1982- .......-.......
.82-0.90 m
(0.0323-0.0354 n)
Correct eading:Tighten njection ump mounting
bolts.Proceedo AGg.
Incorrecreading: eadjustccordingo instructions
il Readlustingump etting:
Setting alues:
D20 ............................................. . 8 0m m (0.0315n l
. . .m. . .0. ., .0.2. .7 6
D 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7. .0m n)
D24USAandCanada 979-1981................ .70mm
{0.0276n )
1 9 8 2 . . . . . . . . . . . . . . . . . ...8. .5m . . .m.
10.033sn )
Reading ess han specilied:

Slackenpumpmountingboltsandturnpumpinwa
to obtain orreci alue. iqhtenmounting oltsan d
repeat heck f p u m psetting.
Readingmore than spe cifiedi

Slackenp u m p mounting bolts and turn p u m p
outwards ntildial ndicator hows pproxl
D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7. 0
. .m . . .0. . 0
. .m . .2. .7 6 i n )
D24.............................................. .60m m (0.0237n )
O24USAandCanada 9791981 ................60 . mm
(0.0237n )
1982-..................7 . .5. . .m
...
(0.0295n )
T h e n urn p u m p nwards ntilspecified alue s ob,
lained. ighlenmounting olts nd echeck ump et ,
tin9.
lmp o r t . n t I n je ct io n u mp mu sr n o t b e r a p p e do t
kn o cke d s h isw ill a h e r t sse t t in g .
145
Gtoup23 Fuelsystem
lniection ump, instalation
AG9
Remove ial ndicator nd holder5194. nstall
plug with new seal
T iq h t e n in g o r q u e N m ( 6 . 5 t lb s) .
A G lO
Connectcold start device
Press evef orwardand turn sleeve 0'. Retighten
NotelDonot urns c r e w ,otherwiset willb enecess-

ary o removecold start deviceand reset t on a test
AG11
Fill niection umpwith dieselfuel
Onlynecessary f pumphasbeendrained r new
pumpnstalled.ilteruelbefore se. nN
rilil
AG12
Install ear iming gearcover
C la mp w ir in g h a r n e ss o le it sid e r e t a in in g b o h o n
AG13
Reconnectu eldelivery nd return ines
Do not nterchangeonnections.eturnineconnec
tionsaresmaller ndmarkedOUT,
Tighreningorque 5 Nm (18 t. bs).
146
Group23 Fuelsystem
lnjection ump, insta lation
AG14
Reconnectu el delivery ipes
T ig h t e n in g o r q u e 2 5 N m ( 1 8 t lb s) .
(D
AG 15
Install lunger ndvacuumpump
Check rins, eplacefnecessary.
A G1 6
Connect:
- h o se s o co ld st a r td e vice .R e mo ve la mp in g p lie r s
- wire to fuel va ve
- t h r o t t e ca b lea n d kick d o w n ca b le a u t o )
AG17
Set throttle control
S e e n st r u ct io n n p a g e 1 7 6 ,o p e r a t io n s X 1 A X g .

Fueldelivery pipes
AH. Fuel deliverypipes, eplacement
I
Clean ll conneciionshoroughlY ,i
AH2
,l
Remove
- vacuum umpa n dp u m pplunger
Blank ff portsandpipes o prevent n t r yof dirt.

,i
AH3
lnstallation
- connect elivery ipes.
Tighteningorque 5 Nm { ' 1 8t. bs.)
- pump prunger no vacuumpump. C h e cU r e p la ce
O-ring.
- check unction and security.A few
quired b e f o r e pipes are bled and
148
Group23 Fuelsystem
Deliverypipes
AJ. Delivery ipes, eplacementf one or more pipes

(Donotattempto weldor repair amagedueldelivery ipes. a m a g e d ipesm u s tbe replaced.)
()
0
Clean ll connections aretully. low-dry ipes
././
AJ2
Remove acuum ump and pumpplunger
Remove ump retaining olts.Placepump on
w h e e la r ch n d w it h d r a w p lu n g e r r o m cylin d e rh e a d .
AJ3
Mark positionof clampson pipes
L o ca t io n o t cla mp s is imp o a n t . I n co r r e ct ly o -
ca t e d la mp sca n ca u se ib r a t io n sa n d u e l su p p ly
p r o b le msma y r e su lt .
Disconnectll pipes
14 9

Fueldelivery pipes
AJ5
Remove lampssecuringpipe(s) o be replaced
AJ6
Replace ipe
D o n o t ig h t e n co n n e ct io n s t t h is st a g e .
C h e ckp o sit io no f r u b b e r sle e ve n p ip e .
Install lamps
0l)il
AJ8
ighten ipe connections
T ig h t e n in g o r q u e 2 5 N m ( 1 8 t . 1 b s. ) {)il
AJ9
Installp ump plunger nd vacuum ump
C h e ck/ r e p la ce r in g s.
AJ1O
Check operation and leakage
A fewsecondss required efore ipes r eb ed ully
andengine unssmoothly.
150
Group.23 uelsystem
Wectarc
AK. lnjectors
AKl
Malfundions
Listedbelowar6 malfunctionswhich can occur f one
or more ofthe injectors s defective.
- one or more ol cylindsrsknock.
Notsl Donotconfusethiswithbearing lafter Chsck
- overheating
injoctorope16tion
- unevon dle
- blackexhaust moke
- gXCeSSiVeuel COnSumption.
AK2
Checking iniection oper.tion
1. Bun engineat above dle speed
2. Loos6n ap nuts on injoctorsong at a time. wl6p
sbsorping paper around iniectors to prevenr
spillage.
lfenginsspeed cmains onstantor f knocking isap-
pears, ault may be:
- delective njector
- detBctive eatshield
- leakingdoliverypip€.
Removingniectors
usa/c€nad'
333133;315 e82-
S.s spg.ilicatlons or ld€nritic.rtonot injectortyp6.
068130 ol | - .
068130 01K I ulnermsrkets
DN0 SD193 = Usrcanad€1982-
DN = SD 93 = Othermark€ts
Inisctol
{complete} 't51
AK3
Remove ump
acuum ump andpumpplungel
Remove etaining utsand place umpon
Withdrawlungerr om ylinderead.
AK4
Cleandelivery pipe connections
Clean llconnections horoughlyefore isconnect-
ingprpes.
AK5
Disconnectdelivery pipes
Blank ffpo(sandpipeso preventntry forn.
AK6
Remove nlectors
27mmsocket.
R e mo veh e a tsh ie id s r o m cylin d e rh e a d .
Installinginiectors
Position niectors
AK7
{t,,
Remove ootetc. rom sealing urfaces.
Place ewh e a t hieldsn cylinder ead, ee ig.ToF
que niectorso 70 Nm (50 t. bs.).
AK8
Reconnect elivery pipes
T ig h le n in g o r q u e 2 5 N m ( 1 8 t . lb s) .
AK9
Install umpplunger ndvacuum ump
C h e ck/ r e p la ce { in g .
Group23 Fuelsystem
AL. Reconditioningnjectors
U t mo st c e a n lin e ssmu st b e o b se r ve dw h e n w o r kin ow it h in ie ct o r s.
AL1
Disassembly
clean uter udace f injector
U p p e rn o z2 le disassemblenjector. aremustbe aken o ensure
thatp a ( s do not all onto bench r floor. f n o z z l e
needlesdropped t mustn o t be eused
W a sh e r , d t u st s immerse arts n clean iesel uel ass o o nas hey
do not nterchangea s
iD AL2
C le a n in g , ch e ckin g
c e a n a ll p a s w it h cle a nd ie se l u e l
u sen o zzle le a n e r q u ip me n t o cle a nn o zzle e e d le
D - r e p la ced a ma g e d p a r t s. N o zzlen e e d le a n d sle e ve

a r e ma t ch e da n d mu st b e r e p la ce d o g e t h e r .
AL3
Assembly
- wash f f ustproofingompundromnewparts i ih
clean petrol/gasoline
- immerse arts n clean ieselfuel
- assemblenjector. orqueo 70Nm ( 5 0 t. lbs.l.
It W A R N I N GI xt r e me a r emu st b e a ke nw h e n e st , Testing
i n g : r i e c l o r s .S p r a y e l e d s e or o m i n j e c t o r s a t
su ch a h ig h p r e ssu r e h a t il ca n p a ss h r o u g h skin a I n je ct o r ssh o u ld b e t e st e d w ir h c e a n t e st o il o r
f it e r e d d ie se l u e 1 .U n d e r n o cir cu msla n ce sma y
r'f a n d ca u seb lo o d p o iso n in q f in a d ve lt e d ly o in t e d
p e t r o l/ g a so lin e e u se d b e ca u se f t h e r is k o f e x-
OT h e u se o f su it a b le e va cu a t io n e q u ip me n t t o
r e mo ve d ie se l f u me s is la w in ce r t a in co u n n ie s
( in cl.S w e d e n ) .
a lT p o ' t d r t la ct o r s n t e slin g r je clo r s a r e o p e n in g
p r e ssu r e n d w h e t h e r in je ct o r s le a kp r o o f .S p r a y
p a t t e r n n dn o isea r emo r ed if f icu lt t oa sse ss n dd o
n o t g ive a n e xa ct in d ica t io n o f o n d it io no f n je ct o r .
I n je ct o r ma y f u n ct io n sa t isf a ct o r ily ve n t h o u g h
sp r a y p a t t e r na n d n o isea r e o u n d t o b e d o u b t f u l.
Install niector n test equipment

B a n k o f f f u e l r e lu r n p ip e sw it h
r u b b e rp u g s a n d h o se
23 Fuelsystem
AL5
Check praypattern
a u edisengaged).
{Pressure
Pumpever ith hort, uick trokes4 6persecond).
Sprayetshou be airly ompactnd top bruptly.
ln je ct o rmu st n o t d r ip .
i)rl
Check nlection ound

AL6
|l I
(Pressure
sause isensased).
Slowly epresseverul y (1 2 strokes ersecond).
I n je ct o r h o u ld b u z, w h e n f u e l is e mit t e d .
AL7
Check pening ressure
(Pressure
a u eengaged.
S lo w lyd e p r e ss e ve ra n d ch e cko p e n in g p r e ssu r e .
Op e n in g r e ssu r e h e ck a lu e :1 2 - 1 3MP a 1 7 0 0 - 1 8 5 0 Ia
lf in co r r e ct ,e a k e st b € f o r ea d ju slin gp r e ssu r e .
j,:
I
ALA
Leak est
lncrease ressureo 11MPa 1560 si).Maintarnhrs

pressureor 10seconds. uelmustnot drop rom n
eLlors. rro sl rol/ e rshowever cLcplao .
54
Group23 Fuelsystem
Cold start device
L9
Adlusting opening pressure
Settins alue 12.s-13.5 Pa 1780-1920si).
Removenjector rom estequipment. isassemble
injector nd adjustopeninspressure y repiacing
- to ncreasepenn g pressure fit a rhickerw asher.

- to decreasepening ressure fit a hinnerwasher.
0 . 0 5mm change n thicknesss equivalento a p -
prox. kPa 7 psi).
- shims reavailablenfollowing izes:'1.00-1.95 m
a t 0 . 0 5mm ncrements.
Reassemble n jecror. orque o 70 Nm (50 t. lbs.).
D
ALlO
ID Removenjectorrom test equipment
C o ve r n d w it h p r o t e ct ive a p .
T a ke a r en o t o d a ma g en o zze w h e n in st a t , , s , f le c,
AM. Cold start device

AM1
General
C o ld st a d e vice ma y o n t y b e a d ju st e do n a sp e cia l
t e st b e n ch ,w h e n co n n e cle d o in je ct io np u mp .
H o w e ve ra se r vice ch e € k ca n b e ca r r ie d o u t o n a n
in st a le d in je ct io np u mp .
N o t e l f co ldst a r td e vice o e s n o t u n ct io n h e o t o w
i n gw i l l o c c u r
co ld st a t in g d if f icu lt ie s
b lu e w h iie e xh a u st mo ke
- e n g in e w ill n o t st . r r a r r e mp e r a t u r e s e t o w 1 0 "C
( - 1 4 "F ) .
AM2
Operation heck
Me a su r e d le sp e e dw h e n e n g in e s co t d a n d h o t .
C o ld e n g in e ( b e lo w 2 0 "C = 6 8 "F )= a p p r o x. 3 . 3 r / s
( 2 0 0 / min ) mo r e t h a n w . r m e n sin e d t e .
W it h w a r m e n g in e , e ve ro n co d sla r t d e vice n o u t d
n o t co n t a ct e ve r
o n in je ct io np u mp .
ld e sp e e d w a r m e n g in e ) = 1 2 . 5 / s { 7 5 0 / min ) .
155
Group23 Fuelsystem
Preheati g system 1979- 1980
AN. Preheating ystem

1979-1980
&
\5
{)i)
c (1 |
{lll I
rl
A T e mp e r a t u r ea u g e e n d e r
F u e lv a l v e ( s o l e n o i d a l v e ) B F u e l a lve so le n o id a l v e )
ndicator amps or lnslruments C ln d ica lo ra mp s in sir me n t s)
E Glo wp lu g
K C o n n e ct io na n e l n dse r vice u t p u t
Group23 Fuelsystem
Preheating system 1 79 1 80
B D
BL
n*l ;t>t.
++
Y
"\
w:r> Yflo)
\_./
o' BL-Y
BL
Ra
Gtoup23 Fuelsystem
Prcheatingsystem 1981
AO. Preheating ystem

1981
With efiect trom 1981-hodels:
Blocklng felay discontinued since new

control nh incorporares switch which
disengages low p ugs afteren9inenarl,
tr-8to even f contro unii malfunctions.
rl)'rI
{r I
{ul
i,l
T u r n s l g n a l sa n d h a z a r dw a r n i n g i g h l s A T e h p e r a r u f eg a g e s e n d e r
BL B Fue valve (solenoid alve)
SB C Indlcator amps (instrumentsl
GN E G ow pllg
G Connection anel and serv ce outpLt
158
Group23 Fuelsystem
Prehealing ystem1981
W @-* LY \7V
\,-,'
, /
Group25 lntake and exhaust syste.rs
Group25 Intakeand exhaust ystems
Contents
Operation Page
Intake/exhaust
ystems ......................P l-z 161
Exhaust ipeandsilence .....................a 'l 162
D21
160
Group25lntakeand exhaust ystems

Inta ke m an fo Id exh aust m an fo Id
AP. ntakemanifold/exhaust anifold
Sealing ring between intake manilold and in-

take hose
Introduceduly 1 9 8 1 .
Sealing ing sused o prevent il eakager o m n t a k e
manifold hose onnection.
It canalsobe itted o vehiclesmanufacturedefore
J u l y1 9 8 1 .
Note ntake anifold ating udacemust ecleaned
before nstallins e a l . P/N 257809) .
Intake manitold
a Allen crew 6 mm
a T u r ngasket ith green ide acing ylinder ead
a Tighteninso r q u e 5Nm ( 1 8 t. bs.)
Arrowon intakemanifold osemust poinr owards
manifold therwiserankcasereather osemay on,
t a c tb o n n e r hood).
Exhaustm anitold
Always se ew utswhennstatting anifotd.
o rque 5Nm 18 t. bs.)
a Tightening
161
2S ntakeand exhaust vstem
AR. Exhaust ystem
S t if f e n in s ip e o n ly
o n e a r ly 4 5mo d e ls)
D20
Installing complete exhaust system

New eals hould eu s e d hroughoutwhennstall- Follow nstructions elow o ensure tressJreen-
rngnewexhaust ystems. stallationof exhaust yst€m
1.Slackenwo bolts securingmountingbracket o
n e e d nlybe eplacedt damaged. gearboxransmission,
ipes must be inser ted pprox. 0 mm 2. Positionront pipe and ighten utsand botts or
( 1 . 6n) n silencers frontpipe b r a n c h ipe.
Clearanceetween xhaust ipe andbodyshould 3. Tightenetaining olts o rmounting racket- ront
not be iess han 20 mm (0.8 n). Rear ilencers
marked lN". 4. Tighten two bolts securing mounting bracket o
gearboxransmission.
5-Aligncomplete xhausl ystem.
6. Tighten lampsjoiningilencersto ipes.
7. Tighten utsat iont pipe oint.
8. Ensureh a texhaust ystem annot trike ody, d-
just if necessary.
Group 26 C;.jotingsystetil
Contents
Group26 Gooling ystem
Contents
Oporation Pag.
Cooling ystem,tesiing, ASI 164
Coo'ant,gen€ral AT1 '164
AT2_9
ATM2 16 7
16 5
Thermostat,e p1acement,.....,.,.,.,.,...,.,...,.,.......... 16 8
AU2 16 8
Coolanl waterl ump, eplacemsnt. ................. AVl-23 16 9
3,
\ t
Group 26 Cooling system

Testihg, coolant
AS. Coolingsystem esting
as1
Connect esl bump b6twe6n fidiator and oxpansion
tank as shownadiacent.
Increase re$ure and checkopeningpressure l ex-
pansion ank cap.Also ch€cl tor leakag€.
Openins ressure: ype1:6F-85kPa 9.12psi}.Type2
1982)r
100kPa 14psi).
{introduced prins
Pfessureshould remain constant for at least 30
AT. Coolant
ATl
Siocealuminium s us€d n the €ngines, ctivecorro-
sionprotections nec€ssaryn the coolantto help pre-
,@ ventcorrosiondamage.J s€genuineVolvo lue-green
cool6nttypeC, dilutedwith cleanwater n proportions
of 50/50.T his mixturehelos o Drevent orrosionan d
rEr frost damage.N everfillthecoolingsystemwlth water
alone.Thecoolantsholld be chang€d €gularly ince
the corrosionDrotactive dditives n the coolant ose
their effect n timo.
NotelDo not run 6ngin6wh€n evelofcoolanl s ow

sincehigh ocal €mp€ratures an resultwhich may
cau6e he cylinderhead o crack.
oirc ft rllyîsu IYpc li plfy[D ryrsysrr*rT

siyon. r[ io.i iiliiiiii-iia iuii iiiri i[oii-viiiil'du u uL
nLto*m euuiii rroffi-liiuiiTii c iiiiiifvsrri-E
mortcTE0
q rrf y&n
ropuf R0ur{0 ttl] HAtr vr
Topping.up cooling sFtem
Use same tvDe ol coolant a6 befor6. Do not mix
different voes of coolants.
Replacing cool.nt
Alwrys use yp€ C blue-green oolant.Rememberto
replacedecal (P/N 1331473-71n exp6nsion ank if
't€4
Gtoup 26 Cooling systefi

Coolant, replacement
Roplacing coolant
Coolingsystemneednot be ftushedwhen reptacjng
type B coolant blue)with ypeC btue,green,,r nce
these oolants a nbemixed.
However,sincetype (red) ndtype btue,sreen)r e
not mixable t is necessaryo f t u s hcooting ystem
priorto illing ypeC cootant.
Described eloware wo differentmethods or orarn-
jngcoolant,1)wilh tushing nd
2)withoutlushing.
prior o filling ypeC cootant.
(1) Draining oolantwithout flushingcooling

system
AT2
Disconnectbaltery ground lead
AT3
Jack-upvehicle
T o p r e ve n t sp illa g e sw h e n co o la n t is d r a in e d , a ise
ve h iclea t f r o n t r ig h t a ckin g p o in t . C o o t a n tw i t h e n
r u n a lo n g sp la sh g u a r d n t o d r ip p a n .
P la ce r ip p a n b e n e a t h e f t st e e r in g o d .
gJ AT4
Drain coolant
{Nodrain apson engine)
Unscrew xpansionank ap.
Disconnecto wer radiator ose rom radiator nd
Filling
S e eA T lF 1 2 .
165
Group26 Cooling system

Coolant, replacement
Coolant, Eplacement
Draining nd llushing c ooling system
AT5
Dralncooling ystem
Pl6cedrip pan beneath eft sido of enginebehind
splashgu6rd.
Disconnect ower radiator hose from thermostat
nousrng,
Disconnecthoses from heater control valve {on
firewall).Point ower hosedown.
Flushing
4T6
Flusher(pansionank clean
AT7
Flush engine clean
Connect pperheater ose at rearlto ap and lush
engineuntil clearwaterappears t lower (heater)
hose,C ontidueo flush orafurther2 minutes.
16 6
Group26 Coolingsystem
Coolant, eplacement
AT8
Flush heaterclean
Setheater ontrolso MAXheat.
Connectp per ipe o apand lush ntil lear ater
appearsrom ower ipe.
AT9
Reconnect ll hoses
W a t e r h o se r o m t h e r mo st a th o u sin g s co n n e ct e d o
lo w e r p ip e o n h e a t e rco n t r o lva lve .
Filling
ATlO
Bleedingof cooling system
Disconnectp p e rhose rom coldstartdevice. lace
drip pan beneath oseand hold hose evelw ith op
level f expansionank.
AT11
Fill coolant
Capacity: 20 = a.1 itres 8.6USqua(s)
D 24 = 9.3 itres 9.8UScua s ).
Setdashboard eater ontrol o MAX. Add coolant
through xpansionank ap.
only ypec {blue-green}o olants o be used.
T u r non engine nd warm-up or 5 minutes. Expan-
sion ank ap emoved).d dcoolantduringthistime.
Connect ose o cold start device.Fill coolant o
mouthof expansionank abovem a x }and screw n
capagain.
oircrr|| Ytv^rsuyr N i 4fy[0 xyrsysr$4rT

h riosr-
a'" aurT to fN Dftv^TrffocNNorL
;ilgo01",llll"_1T.Y";'**,
voLvo cool rr iyft c.cooirrc sii;-E
'norfcTfo 0 ,.r roe ur rui 40rrDurF H^ f ^rfR rr0 ^1. v0rvo
ifilnr ff L0ur0rANn6lLwoLvo a4 c v^r8Ll JLSoUA pal AT12
vrc rort €ûMorlt fi{lcrL rYPr
Replace decal
Attach ew ypeC decal o expansionank.

Thomostat
AU. Thermostat
AUl
Replacement
- replacehermostat ndseal
- arrowon hermostat ustPoint P
AU2
Testing
lf nec€ssarye st hermostatn hotw€tet
Thermostathould:
- start o op6nat 87'C 188fF)
"87'C -be lully open at 102"C216"F}. in openinggap
= 8 mm 0.3n).
E m
;i02"-CT
16 8
Coolant water) ump
AV. Coolant water)pump, replacement

Specia tools 5187,51 88,5 1 7
ID AV1
ground
Disconnectbattery lead
AV2
Jack-up vehicle
T o prevent pillages /hencoolant s drained, aise
vehicle t ro nt right acking oint.Coolant ill then
runalong plashguardntodriPpan
Place rip panbeneatheftsteeringo d.
AV3
Draincoolant
{No rainaps nensine)
lJnscrewxpansion
ankcap.
D isco n n e cto w e r a d ia t o rh o se r o m r a d ia t o r .D isco n
n e ct o w e r h o se r o m t h e r mo st a t o r co ld st a r t d e vice
Remove
co o lin g a n w it h sp a ce ra n d p u lle y
f a n b e lt sa n d p o w e r st e e r in gp u mp b e lt
f r o n t t imin g g e a r co ve r .
169
Coolant water) pump
AV5
Remove ibrationdamper center bolt
Use 187o prevenl uley rom otating, ndwrench
5188 o un screw olt. t may be necessaryo turn
enqn eslightly o ha(5 1 8 7 ests n an oearing.
AV6
Turnengineapprox. /4 urn anliclockwise
;> U sew . e n ch 5 1 8 7 .
B y u r n in ge n g in e n t iclo ckw ise ,la ck n b e ltw ill mo ve
{ I
'6i io d r ivin gsid e ,ma kin g l e a sie r o r e mo vea n d in st a
}Y
7
AV7
Remove ibration amper
Removebolts arrowed).llen ey mm.
Pull ffvibrationamper. ote rankshafte armay
sometimesticko vibrationampe. { rli
AV8
Removeower iming gearcover
{ Iil
AV9
I
Detachmountingbracket or cooling an and
alternator nd place n one side
Remove ountingolts arrowed)andress racket
110

Coolant waterpump)
AVl0
Mark position ol timing geal belt
Mark belt,camshaft procket nd crankshaft ear.
Mark n rontof a cog.Also denrify utside nd op"
sideof gearbelt.
lmportant
Belt must be titted in exactly same position as
found otherwisevalves may contact pistonsan d
cause erious ngine amage.
AV11
Remove gear beli
Slacken oolantpump mounting bolts and belt.
Coolant ay eakwhen bolts reslackened.
Lift off belt.
AVl2
Remove oolant pump
Removeover anel nd etainingolts or coolant
pump,
Move anelto ne ide nd emove ump, ake are
AV13
Clean
Cleanontacturface orpump ncylinderlock.

offcoolantr om ylinderlock, ear tc. ry
171

water) pump
AV14
Inslall new coolant pump
Grease ewO-ring nd placet on pump.Donot use
permatex r other ypesof sealers.
Movecoverplate o one side and mount p u m p on
eng ne.Pump etaining olts houdonlybeattached
loosely t h l sstage.
AV15
nstall:
- co ve rp la t e e t a in in gb o lt s,
- mo L n lin g b a cke t o r co o lin g a n d lr e r n a t o r .
I
AV16 {rrl
Installg earbelt
Make sure thai belt is fitted in exactly same
position as before
A lig n d e n t if ica t io nma r ks o n b e lt , ca msh a f t p r o cke t {r
a n d cr a n ksh a f t e a r .
I t is e xt . e me ly mp o n a n t t h a t b e lt is fitted in exactly
sa me p o sit io n a s b e f o r e .
T e n sio n b e lt b y mo vin g co o la n t p u mp ( b y h a n d ) .
T ig h t e np u mp mo u n t in g b o lt s.
12
Coolant water)pump
AV17
Install ower gear
oamper iming coverand vibration
Damper an only be fitted n one way. Pin on
cr a n ksh a f t e a r mL r st it in vib r a t io nd a mp e r .
T o . q u e n h e x b o lt s o 2 0 N m { 1 5 r b s) .
AV18
Install center bolts

Smear hreads nd matingsurface ith sealerP/N
0 271961-9.
Usewrench 187 rest n coolins an ournal) o hotd
vibration amper. se wrench 188 o torque e n t r e
bolt1 o350Nm (255 t lbs).
lmportant orque 5 0Nmapplies nly fwrench 18 8
is used.Also torquewrenchm u s t b e i n line wrrn
wrench5184.
AV19
Set belt ension
Turnengine pprox. /4 urn anticlockwise.
djusi
t e n sio nb y mo vin g co o la n t p u mp . U se g a u g e 5 1 9 7 o
ch e ck e n sio n . A t t a ch g a u g e t o b e lt a n d se t t o 1 2 . 5
u n it s.S t r e t ch e ltu n t ilma r ko n g a u g ep lu n g e r s t u sh
D e p r e ss e lt st r o n g ly w it h h a n d a n d r e ch e ck/ a d ju st
AV2O
ln st a ll:
- f r o n t t imin g g e a r co ve r
- co o lin g a n w it h sp a ce ra n d p u lle y.T o r q u eb o lt s o
9 N m (7 t lb s) .
- b e t f o ' p o w e r st F e r : r g p u n p a r d t a n b e t s
- r a d ia t o r C o n n e cl h o se s ( a lso h o se t o co t d sr a r t
Coolant watet)pump
AV21
Bleedingof cooling system

Disconnectpper oserom old tart evice. lace
drippanbeneathose ndholdhose evelwithop
edge f expansiona nk.
AV22
Fill coolant
Capacityi 20= 8.1 itres 8.6USquarts)
D 24 = 9.3 itres 9.8US quarts).
Set dashboard eater ontrol o MAX.Add coolant
through xpansionank ap.Only ypeC blue'gr€en)
coolants o b eused.
T u r non engine ndwarm-up or 5 minutes. Expan-
sion ank ap emoved).ddcoolant uring his ime .
Connect ose o cold start device.Fill coolant o
mouthof expansionank abovemax)andscrewon
capagain,
\rol-iro YP ^hParYtroLsYsT r^RrRosr

oFrcrrr YrvrTsra
srYooArLr 30"c fi$IYLIARtrR ullr r$$ oft v
l/loLvro co0LrNI
r0r uPYIAA 0un0{trN ^rf r^
L AV23
rrcn voLl/o
r$ru 0r Lrour0r
-r0.[ rui $r rourr ^]soN
v ft ir0flt au fior( ^rrc[L w c Replace ecal
A t t a chn e w t yp e C d e ca l o e xp a n sio n a n k. (rrl
114
Group 7 Engine ontrcls
Group27 Engine ontrols
Gontents
Oporation
Engine ontrols, djustment AX1-S
Group 27 Engine controls
AX. Enginecontrols,adjustment
AXl
Disconnect cold start devico
lf engine s cold. cold start device must be discon-
nected riorto sd,ustingenginecontrols.
Slacken crew1.Push eve fo rwa d and rotat€ leeve
90'.
Notel Do notturn screw2, otherwis€ twillbe necess"
ary to removecold start deviceand r€set t on a tesl
AX2
Disconnectink rod from lever on iniection
pump
AX3
Adiust throttl€ cable
Turncablenut untilcable s taul.Position f throttle
drum mustnot be affected, rum mustcontact dle
stop.
AX4
Check ull thlottlc position
Depress ccelerator edal o floor. Throttledrum
should onlactull throttle top.
176
Group27 Enginecontrcls
Eng ne contro s, adju stment
Autontatio transmission,
Adiust kick-down cable
Depressacceleratore dal ofloor, Cable houldmove
approx,52 m (2.05n)betweendleand ullthrottle
Dositions.
Csbl€should be taut in idle position. Distancebet-
weenclipon cableand nut shouldbe 0,25-1.0m m
(0.01-0.04n) .
Reconnectink rod to levei
AX7
Adiust link rod, full throttle position
Turn hrottle rum o fullthrottleposition.
Adiust ength f link odso hat pump ever ontacts
adjustmentcrewor fast dle,
Adiust ink rod, dle position

Release rum so hat it contacts dle stop.
Adjust ink rod balljoint so that injectionpump ever
contacts dlo (low) adjustment crew.
Readiust link rod

Repeat peraiionsX6 and X7 until 0.3 mm {0.012n)
clearancos obtainedbetween hrottle drum and ull
throttleand dle stoos.
Reconnectcold tart deviceas applicable,
lndex
Op€ration Page Opsralion Pago
Blsfc-sEtting6ngin.,,.,.,,.,.,..,..,.,.,.,,.,.,..,.,..
1-21 22 Glowpluss .................................................
N1-AO1 156
f ront.....................................
- -..............1-27 a1 rdfe6poodsdllsinont................................Ax8 177
, . , . , , , , . , . . , . , . ,1. .-,2. 1 8a
9 e n e r a 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. 1
..AD1
a lt it u d e a d ju st me n t U S A . . . . . . . . . . . . . . . . . . . . . . . . . . A'133 D322
r € mo w 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .-.1. .1. . . . . . . . 7
. . .1 s€ttins....................................................... O3-14
imr a 1 | a t io n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. -. .2. 7............ c11-20 24
.lriv€b€lt,rcplac€m€nt............................. El-14 13 6
r e mo va 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . .F. .l-. -1. .1. . . . . . .1. .4. .0.
insrall€rioneasurement. ,,.,---, -,, 58 10 4 inst6llarion,.,..,.,,.,.,.,,.,.,,.,,,,.,..,.,..,.,,.,.,,.,., G1-17 143
Co|dstartdwie......................................... M1-2 155
C o mp r e ssio n t e st , . , . , , . , , . , . , . , , . , , . , , , , . , . , , . , . , , . , . , , A71 - 1 0 ma lf u n ct io n s. . . . . . . . . . . . . . . . . . . . . . . . - - . . . . . . . . . . . . . . . A K 5 l2
'l
r e mo va 1 . . . . . . . . . . . . . . . . . . . . . . . . - - - . . . . . . . . . . . . . . . . . . . . . 45K2H
in st a 1 1 a t io n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K. .7. .-.9. . . . . . . .1. .5. .2.
rephcement...-...........................-.............. V'l-23 169 reconditioningnd esting ................-..... L1-1 I 53
g sn € r a 1 , , , . , . , , , , . , , , , . , , , , , , . , , . , . , , . , , , , . , . , , . , . , , . , . , , .6, 4
.,AT1 ln t a k. ma n if o ld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A6 0P 1
drainins .................................................... T2-4 168 K ick- d o w n ca b | e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A7X 5
d la in in 9 a n d f | o sh in 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A T656- 9
ii11in9.........................................-...........-... T10-12 1A 7 ch e ck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .4. 2 1
. e lie f va lve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 4 23
lestins,.,.,..,.,.,..,.,.,,,,.,.,.,..,.,..,.,.,.,,.,.,..,.,.,, S1 lBt Oif p u mp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .42 2
coolant ...,.,.,..,.,.,.,,.,.,....,.,..,.,.,,,,,,.,.,..,.,.,, T1-12 164
thefmostat,,.:,...,.,,.,.,.,..,.,....,.,,,,.,.,.,,,,.,.,.., Ul-2 168 Preheatinswirinsdiasrans) ................... N1-AO1 156
coo1antpump............................................ V1-23 169 Pllotbsarlns in crankshaft)
r e p la ce me n t . , . . . . , . , , . , . . , . . . . . . , , . , . . . . , . , . . , . , , . , . , , . , .4O1 - 7
tront ,.r,.,..,.,....,.,..,.,.,..,...,..,.,,.,.,....,.,..,.,.,., 1-21 96 Bemovins ngine ...................................... 1-7 111
. . . . . . . . . . . . . . . . . . . . . s1 - 1 1 1 0 3
S if sn co E . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. .2A R i
unscrewin9.-....-......-....-............................ 17 32
differenttypes.,..........,.....-..............-....-.... 9 e n e . a 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - . - -A- -1- - . . . . 12 6
t ig h t € n in 9 , , , , . , . , . . , . , . , , . , . , , . . . . - . . . . - . . 8. , . . . . . - . . . . . .4A... ch e ckin 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. -. 1 . .0. . . . . . . .12
...6 .
r€1i9h16nin9,,,,.,.,,.,.,,.,,,,.,..,.,,.,,,,.,.,,.,.,,.,., 1- 3 57
S p e cia 1 t o o b , , , , . , . , , . , , , , . , , . , . , . . 12
Cylind€rheadsa3ket.................................. 3 45,46 Specilic.tions.................-........................... 3
r € mo v€ 1 , . , , , , . , , , , . , . , , . , . . , . , . . . - . . . . . . . .1. .-.2. . . . . . . . . . .28 -... Swirlch.mboB........................................... 6 43
in sp o ct io n . , . , , . , . , . . , . , , . , , , , . , . . , . , , . , , , ,2. ,0. , . . , . , , . , . ,32 ,, S1 164
o ve f ia u 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .-. 2
. .1. . . . . . . . . .36.. Tsitingcooling y.tsm ..............................
in st a 1 1 a t io n . . . , . , . . , . , . , , , , , , , . , . . , . , , . , , 1 . ,-.3. ,8. , . . . . , . ,45,,,.
r e p la ce me n t . , , , , . , . , , . , . . , . , , , , . , . , , . , . , ,U . ,1. , , , , . , , , , .16
, , .8
t e st in 9 , , . , . , . , , . , , . , . , . , , . , . . , . , , . , . , , , , . , . ,U, . 2
, , . , . , . , , . ,1. ,6, .8
remov6l/insiallation.,.,.......,---,.,..,.,.,,... H1-3 148
r6p14cemeni,,.,..,.,..,.,,.,..,............-............. Jl-10 149
Engh. t € n sio n , . , . , , . , , , , . , . . , . , . . , . . . . , . . . . , . . - . . - . . . . . . . . . . . . . . . .8, K 1 - E
r e mo v6 l. . . . . . . . . . . . . . . . . . . . . . . . - . . . . - . . . . . . . . . . . . . . . . . . . . .1. 1. V 1 - 7 r e p la ce me n t . . . . . . . . . . . . . , . , . . . , . . . - . . , ,A. ,E. ,1. ,-,1. ,4. , . . , .1, ,3L061 - 3 5
in st a 1 1 . t io n . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . .1. - .3. 3 . . . . . . . . .1.1. .4.
Ersin..@nlrols.......................................... V a lve cl6 a r a n @ , a d iu r t me n t . . . . . . . . . . . . . . . . . . . . . 8 1 - 191
X1-9 176
E n g in e , in st a | | a t io n . , , , , . , . . , . , , . , , . . . . . . . . . . . . . . - . . . . . x1 Valve@verlg.sket,.,,.,.,,.,..,.,,.,.,,,,.,.,,.,,,,,, 11 21
1 4- 3 3
110 cle a r a n c€ , g u id s- va lv€ . , . . , . . , . . . . . . . . . - . . . . . . . . . . . F l 6

f r o n t , . , . . , . , . , . . . . . - . . . . . . . - . . . . . . . . . . . . . . - - -2-4- - - , - . . . . 1 1 0 r e p la ce me n t , . . . . . - . . - . . . . - . . . . . . . . . . . . . . , . , . , . . , . , , . , . , . ,7F H
o i1 se a 1 s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . G4
Ensin6oil,filter...........................-..............- 1- 2 12 3
Exhruatmsnifo|d...................................... Pz 161 .eplacement...,.....,.,.,,.,....,..,.,..,.......,,....,.. 13-21 39
E xh . Gr p ip e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. .1. . . . . . . . . . .162 . sn d in g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . - . . . . . . . . . . . . . F8F 1 2
Fue|fi|ter..................................................... C1-2 130 in sp € ct io n . . . . . . . . . . . - , - - - - , - . . . . . . . . . . . . . . . . . . . . . . F 5 3 7
Al-10 126 V.fvostsmsoals ................ G4 42
smokedensity....-.........-............-...............
id f sp e e d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B. .l-. .6. . . . . . . . .1. .2. 9
f u e 1 f i| t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - - -C- '.l-
. .2. . . . . . . .1 3 0 typss'.'.-'.-'.-'.-'.---'.,,,.,..,.,..,.,,.,.,,, G3 42
'1 9
in ja ct io n p u mp . . . . . . . . . . . . . . . . . . . . . . . . . . . .D . .1. .-.A
. .G1
. . . .41
...31 cleahnce,adjustm€nt..................-..-....-... 1*B'l'l
deliv€rypip€s.............-.............................. H1-AJ10 148 c| e a r a n ce , 9 u id e . va 1 ve . . . . . . . . . . . . . . . .1. . . . , . , . . . . . . 36
injectofs .......................-........................-.. K'l-ALl0 15'l sin d in s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 1
. .2. . . . . . . . . .3a
.
co ld st a r t d e vice . . - , , . . - . . . . . . . . . . . . . . . . . .N. .1. .-.2. . . . . . . .1. 5 6
prehe6tingystem,.,..,.,,.,.,,......,,,..,-,,...,,..
N1-AO1 156 remowl,'insta118tion,,.,.,.,,.,,,,.,,.,.,,.,,,,.,.,,.
1-10 106
Fuflthrottl€adiustomont.......-........,,,........Ax7 177
1 9 7 H 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N . . . . . .'156
. . I. -. .A. .Ol ..
r e p la ce me n t . . . . - , , . . . , . . . - , . . . - . . . . - . . - .E
. .1. --.1. .4. '.1. -3, .6. . . . 1 9 8 1 - , , , , . , . , , , , . , . , , . , , , , . , . . , . , . . , . , , , , . , ,O
. , . , , . , . , , . , . 15
, , . ,4.
't78
Fault reing
FaultTracing
Diesel ngines rebasicallyuggedn design nd Analysisof exhaust mokewill provideuseful n-
are designed or long s€rvice ife. formation on determining uel relatedproblems.
Except uringmajorov€rhaul, ost servicings

confin€d o the tuel system.
Gontents
PW
Summary f fauhsymptoms nd easons.... ,
ExamDlesf taults
- Heaw mokeft€r old tart.,...,..,,..,.. A1
- Engine oesnot stan A1
- E n g i n e a n n o tes t o p p e d . . . . . . . . . . . . . . . . . A1
- Eng ne6ta ts o smokeandclatters oavily ftsr splacingu€l njoc'tion ump
- Engine latters eavily fter eplacing r repairingnjectors r fueldeiivery ipes A1
Excessive mok€
- Black moke M
-
- Whitesmoke.
Blue moke A2
A2
A3
Cold start device
Fault racingpr€-heating glow plug)system
- C o m p l e t eh e c kf p r e - h e a t i nygs t e m . . . . . . . . . . . . . . . . . . . . . . . . F T l - F T 5
-Specificault ases. ased n completeh€ck ..,......,.. ...... FT6-FT14 t€
- lndicatoright lluminateshenengines warm .... ..... .. ... ... FT15 Ar0
-Wiring diagrams A11-A14
Fault racing
- Summary
Summaryof fault symptomsandreasons

The aultsvmptoms re isted umericallyccordingo:
-likely occurance,ase n checking nd ogical equence.
EXAMPLE:nder ach ymptom re group f
numbers- o.1wouldbethe irst tem o check,
thenNo.2 and oon,
untilthe SYmptoms
tautthas [--T--J--T--a NOTE:S
NOTE:Startrngsystem Batte starter,
ystem Banery, aner, erc.J
etc.,rs
assumedo be n goodcondition
l""T*.//"1 I
,M
l/, 1-/
fle, (il
krkl'lglf,,ffi
/i
;{ Rels ons for laults {r
Flel system
1 l Fuel alve stopping alve)in he njection ump
2 6 2 5 I Injection umpsucks ir (leakageetween uel ankandpump)
8 5 1 4 3 1 l Fuel ealage leakage etween umpanddelivery ipes r
otherexternaluel eaks)
3 3 5 1 lceor paraffin n fuel ines r fuel ilter wintertime)
7 I 5 8 6 3 5 Injectioniming ncorrect
'10 2 Pre-heatingystem seewiringdiagrams).
6 1 2 Coldstartdevice
12 I 11 9 9 I 1 0 Faulty njection ump
4 7 3 6 6 6 Fuel ilterblocked drain ondensationater)
I 8 4 7 7 10 7 Fuel ines locked

1',I 1 0 6 8 12 6 Faulty njectors
1 2 5 4 Mix up o{ hollowscrews n pump or feedand return ines {
I Incorrectlydjustedor highalt;tude
2 Injection umpbracketoose/damaged
4 lncorrectow idlesetting
8 5 Incorrect igh dlesetting
4 Returnineblocked (
Other aults
3 Enginemounts oose/damaged
2 2 6 1 Air cleaner locked
11 5 1 Exhaustystemblocked
3 Incorrect cceleratorontrol etting
Enginemechanicalaults
5 4 Incorrectil viscosityor cold emperatures
1l 7 13 7 Compressiono w/uneven
12 8 1o 14 8 Incofiect alveclearance
3 Water eakage
2 High ilconsumption
18 0
Fault tracing
-Examples of faults-
Examples f faults
Heavysmoke after cold start Enginecannot be stopped
Poor uelquality. The uelvalve (stopping alve) n the injection
pumpdoesnot close.t is a solenoid alve.
Check he cold start device by checking dle Increase omentarjlyo high enginespeed
speeo, and r y again o switch offthe start key. f this
doesnot helD:
ldlespeed hould e approx.200pm higher
withcoldengine.dlespeed t normal perat- -Vehicles with manurl transmission:
ing emperaturehould e 800 pm. Engage3rd or 4th gear, depress he brake
At normal operating emperature.h e cotd pedat nd eleasehe clutch edal.
start lever should not touch the leveron the
injection ump. -Vehicles with automatic ransmission.
After setting ow dlespeed, heautomatic dle Use he emergency top lever on the injec-
increase evicemust be checked ndadjusted tion pump, ee ll. below.
it necessary. he gap betweencontrol lever
and ball stud should be 12.7mm 0.5")as
Cold start device

12.7mm 0.5") Emergency top level
Enginedoes not start Enginestarts to smoke and clatter

Check he fuel valve (stoppingvalve) in the heavilyafter replacing uel iniection
injection ump.No uelwill reach he njectors pump
if the valve does not open (listen or audibie The njection ump might be nco rectly imed
clickl. or assembled distributor lunger 180. re-
Thevoltage t he uelvalve olenoid ustbe Check basic injection timing. lf correct, try
a t l e a s t 1 0 v o l t s o o p e n h e v a l v e ,a n d anothernjection ump.
minimum volts o remain pen startetmotor
engaged). Engineclatters heavily (sounds ike
bearing ailure) after replacingiepair-
ing iniectorsor fuel delivery pipes
An injectormight have ammed open.The
combustion s out of control when accelerat-
Ing.
Loosen he cap nuts o one injectorat a time.

The compression ressurewill revealvisible
bubblesat the cap nut ot a stuck njector,
Note: Clean ap nuts before oosening
Fauh mcia
Excesgvenoke
Excessive moke
White oxhaustsmokg cont.)
NOTE:
Whiteexhaustsmokeanalsobecaused y wa-
ter eaksnto heexhaust ystem rcylinderhead.
Possibleausesor whitesmoke:
- Pre-heatingystem glowplugs}not perating.
- Low compresson ressure,
Excessiveigsel moke s usually aused y
incompleteombustion.
Rgasons ay be engine ondition,uel or fuel
- Low operatingemperature.
- Defectivenjectors.
(r I
- Late njectioniming.
iniection quipmgnt. rivingand
tionsmayalsocontribute. traflic
requent condi-
cceleralion -Water leakagecylinder eadgasketl.
in city rafficwillcausearge uantites f exhaust
gases.
- Coldstartdevice ot operating. (
I
Excessiveieselsmokeafter cold startmay be
causeo y poorflrel qualityor defective old
startoevrce.
Bluesmoke
Caused y ncompleteombustion ndcontents
oJcondenseduel particles.
Blacksmoke Can lsobecaused y excessiveilconsumption.
ontent n
Caused
the y tooases
exhaust much uel.Thecarbon
becomes oticeable. auses Possibleausesor bluesmoke:
may be: - Late njectioniming.
- Poor uelquality. - Delectivenjectors.
- Dirtyair cleaner insufficienti r supply). - Heat hield ndernjector amaged r missing.
- Excessiveniection.
- Worn njectors.
- High uelconsumption.
- Low operatingemperature.
{,1 I
- lncorrect el.
- Low compressDn ressure,
- Considerableackpressuren exhaust ystem ( rl
{clogging). CAUTION
Becausef the generallyow smoke evel,t may

I
be tholght possibleo increase ngineperfor-
mance y enricheninghe air-fuelm ixture
White smoke However, rolonged xcessive nrichment ill

Occursmainly uringcold starterand s caused not ncrease oweroutputandwill n fact cause
by nsufficientu elsupply.Themoke onsists f unnecessaryn creasednginewear.
condenseduel particles.hecombustionpeed
is ow and he uel particles ave onger ime o Moderateuelmixture nrichment illsharplyn_
condense. creaseexhausl emperatures nd combustion
(cont.l pressuresithoutanycorrespondingowergain.
Fault raciw
Injectors
Ma]functions
Oneor sevoraloftheollowingmalfunctionsan
occur:
-One or several ylinders nock
NOTE:Do not confusowith bearing latter.
Checknjector peration.
- Overheatednging.
- Reduced oweroutput.
- Unevendle.
- Black xhaust moke.
- High uelconsumption.
Checking niector operation

1.
Rln the engine t increaseddlespeed.
2.
Loosenhecapnutsatthe njectorq neat a ime.
Wrapabsorbing aper ound he njectorsto re-
vent uel spill,
lfthe idlespeodemainsstabler f knocking is-

appears,h e ault mightbe:
- defective njector
- defective eatshield
- leaking elivery ipe
For urther est, emovehe njectors nd est n

a test machane.
A3
Fauftnaciry
Cold tdt't evice
Cold start device
Thecoldstart devicec€nonly be t€sted on a test

with tho injectionpump
bench ogether
A simple op€ration est can be performedwath-
out removing he cold start devica rom the
€ngine.
signs of cold start devicemalfunction:

- Cold €ngjnehard to start.
- Enginedoes not start at tempgraturesbelow

-10'C = 14'F.
- Blue-whit€exhaustgas€s.
Operation ch€ck
check dle speedcold and at normaloperating
temperature.
1.
With cold engine, elow 2O'C = 7O'F.engine
idlespeed hould e approx95o rpm(2Oo pm
more hanwarm).
With enginewarm l normal peratangempera-

ture:
- Enginedlespeed houldbe 750 rpm.
- Thecold start device evershouldclear everon

injection ump.
Diesel engine
-Prc-heating system-
Pre-heating yste
Basic peration f system:
-The systemsswitched nwhen hestart ey s urned o driving ositionl).Thepre-heatingime
depends n coolantemperatures.h edashboardndicatorightwill stayon approx.:
1980MODELS 1981 ON
45 seconds t -2O'C = 4'F. 9 seconds t 20'C = 4'F.
25 seconds t 0'C : 32'F. 6 seconds t 0" C : 32'F.
15seconds t +20'C = 68'F. 4 seconds t +20" c = 68" F.
0 s e c o n d st + 5 0 ' C = 1 1 2 " . 0 seconds t +50' c : '112'F.
-The glowplugs emainONapprox.20econdsfterthendicatori ght as oneoutfor1980models
andaoorox.7 econdsor 1981 ndor,.
if -Ihe glowplugs reONwhen hestarter otor perates.heglowplugs re utoutwhenheengine

startsand the stan key s turned back o position l.
-To position pre-
repeata
heating start;ngattempt, he startkey must be urnedback o
system. to switchon the
iif -The system lso omprisesblockingclay n 1980models, n 1981 nd n hisfunctions part fthe
control nit. twill nterruptthelectricali rcuit etweenhecontrol nitand he elayortheglow
plugswhen he alternatortans harging.
Fault racingpre-heating glow plug)system

Relero hewiringdiagrams t rearof manual uring ault racing. he pre-heatingystems an
electrica
s ystem nd hewiring iagramsrenecessarytonderstandndcorrectlytrouble-shootthe
pre-heatrngystem.
Completecheckof pre-heating ystem

(0 ngine houldbe cold (max.4 0 ' C = 100. )
when starting the system check.
startkey o intermediate osition l), hen o
driving position 1ll) o obtain a new cut-in
fthepre-heatingystem hutsOFF,irstturn penoo.
((l
FTl
Connecta est lampacrossglow plug
terminaland ground.
Fault thcing
4low plug system-
Ffz
Check unction of test lamp and
indicator ight (on instrurnentpanel
in vehicle)
CASEA
Indicstor ight OUI
Test light OUT.
-lndicatesfailure at hecontrolunit.SeeFT6.
'*i1 CASEB
Indicator ight ON.
Tesr light OUT.
-lndicates failure at the glow plug relay.Soe
FI8.
CASEC
Indicator ight OUT.
Y9.'P" Te3t ight ON.
-lndicates failure at temperaturesender or
control unit. SeeFTl3.
Indlcator ight ON,

Test ight ON.
-Proceed on FT3,ne) .
Fn|
CheckON-time or indicator ight and
test light.
Turn tart ey o intermediate
o sition )and
then to driving position (ll). ON-time for
indicator ight should be accordingo coolant
temperaturg, ee diagram.
Forengines riorto 1981 est ightatglow plug
terminals should remain ON for approx. 20
secondsaft€r indicator ight is OUT. For
engines1981and ohward he est ightshould
rcmain ON for approx.7 seconds.
ON.tlmo ncorect (too shortli
Try a new control unit, lf ON-tim€ still is too
short, ry a new temperSture ender.
ON-time @roct:
Proceodon FT4,next.
46
-Glow plug system-
FT4
Check operation with starter motor
operating
Test ightshould lluminate.n dicating oltage t
the glow plugs.
voltage Test light OUT:

terminal 50 Starter motor engaged, se the test lamp to
check oltage t erminal 0 (blue ellowwire)of
the controlu nit,
Voltage:
Indicates faultycontrolunit.
No voltagel
Indicates pen circuit betweenconnector nd
(Connectoro cated ndercarpetnext o control

panel e{tsupport).
Test ight ON:

Proceed n FT5,next.
Ft5
Check glow piugs. one by one
Startkey n positionO.
Removethearbetweenheglowplug erminals.
Connecthe test ightacross atteryPLUSand
one glow plug at a time to check hat current
passeshrough he glow Plugs.
Light OUTat one or mo.e glow plugsi

Indicatesaultyglow plug.
Light ON
System heckedOK.
End of completo system check
Fault tacing
- Glow plug sysEm -
FT2, case A
Test ightand ndicatorightshould lluminate.
Indicator ight OUT.

T€st ight OUT.
- lndicatesailure t the controlunit.
Firstcheck hat cut-inperiodhasnot expired r

that coolant emperatures too high.
FT6
Checkvoltageat terminal 15 of the
controlunit (do not disconnecto test).
Blue-red ire.Use est amp o check oltage.t
should lluminate.
(, (
No voltage:
lndicates pen ircuit etweenuseboxandcon-
trol unrt,
Voltage (
Proceedo FT7,next.
Fr7
Checkground erminal31 of the
controlunit
Blackwire. Connect est lamp acrossbattery
PLUS or usebox PLUS erminall nd erminal
31 of the controlunit.
Test ighl shouldlluminate.
No voltag€r
Indicatesault n ground onnection.
Voltage:
Indicatesontrolu nit ailure.
FT2, case B
vollage erminal 6
ndicator ight ON. f
Test light OUT.
Indicatesailure t the glow plug elay.
FT8
Checkvoltageat terminal86 of the (
glow plugrelay
Yellowwire. Use est amp o check oltage. t
should lluminate.
Voltage:
Connecthe est ampacross atteryPLUSand
relayground erminal blackwire).T he est light
should lluminate.
Voltag€: ndicatesaultyglow plug elay.
No voltagg: ndicatesncorrect round onnec
t|on.
No voltage
Proceedo FTg,next.
Fauft aciw
- Glowplug syslem
FT9
Check voltage at terminal G of the
control unit
Bluewire.Use est amp o check oltage. est
lightshould lluminate.
No voltage:faultycontrolunit.
Indicates
Volt.go
Proceed n FTlq next.
voltageerminal 0 FTl O
Check voltage at terminal 30 of the
blocking elay 1980 nly)
Bluewirc. Use est lamp o check or voltage.
Test ightshould lluminate.
No voltage
Indicatespen ircuitnwirebetween ontrct nrr
andblocking elay.
Voltage:
Proceed n FT11,next.
FT11
Check voltage at terminal 87 ol the
blocking elay 1 |80 nly)
Yellow wire. Use est lamp to checkvoltage.
Test ightshould lluminate.
Voltage:
Indicates pencircuit n wire betlveen lockino
relayandglow plug elay.
No voltage Glod<ingrelay does not operatsl:

Proceed n FT12,next.
FT12
Check voltage at terminal 86 of the
voltage erminal 6 blocking relay (1980only)
Blue-yellowwire. Use est lamp to check
voltage.Test ight should lluminate.
No voltage:
Open ircuit n wirebetweenusoboxandblock-
Ing relay.
Voltage:
Connect est lampacrossbattery PLUS fusebox
PLUS}and round erminalS5 fthe blockinge-
lay.Tert lightshould lluminate.
Voltage:
Indicatesauhyblocking elay.
No voltage:
Indicates pencircuit n wire betweenblocking
relayand nstrument anel,
OR
fault n the nstrument rinted ircuit.
-Glow plug system-

FTz,caseC
Indicator ight OUI
Test ight ON.
-lndicates ailureat temperatureender r
control nt.
FTl3
Disconnect ireashboardl
lndicatoright on at temperature ender
h ouldlluminate.
Makesurewire is not inadvertently rounded.
Indicator ight ON:
Indicatesthatcircuitlromemperatureenclerto
indicator ight s correct
AND
a tault in temperature ender, ry a new one.
Indicator ight still OUT:
Proceedo FT14, ext.
(
FT 14
Gheck round
unit onnectiont terminalK
ground
terminalK
of control
Yellowwire. Connect est lamp acrossbattery
PLUS (Jusebox PLUS)and terminal K. Test
(r
light hould lluminate.
Voltage:
Indicates eJectivendicator amp
OR
defective irebetween ontrolunitand ndicator
light
OR
fauh n the instrument rintedcircuit.
No voltage:
lndicates:
-DeJective controlunit
-OR groundedwire between emperature
senderand controlunit.
Indicator ight illuminateswhen engine s warm

Precedingault racingassumedhat engine
t r(
tempe€turewas below40'C = 100"F and hat
the faul ts occuredwithin the low temperature
range. owever,h e ndicatorightcouldalso
illuminatewith enginewarm (at operating ( (
temperature),
FT15
Check emperaturesendercircuit and
temperaturesender
Disconnect ireat emperatureender.G round
it and turn start key to driving position (ll).
Checkndicatoright.
Indicator ight illuminates
Indicates pencircuit n wire betlveen emper-
aturesenderand controlunit
OR
defective ontrolunit.
Indicator ight does not illuminate:
Indicatesaulty emperature ender.
Glow plug system
Diesel 7980
Glow plug system

Diesel1980
Legend:
A Temperature sensor
B Stop valve
C Indicator light
O Sta.t switch
E Glow plug
F Glow plug relay
G Blocking relay
H Control unit
I Fuse box
K Remote starter
pick-up point
Start key ON
Coolant emperature elow +50 C = 122 F
Blockingelay G)isgrounded hrough

voltageregulatorand alternatorcircuit when
alternators not charging.
130836
l-
Glow plug system
Diesel 1980
D
'-i
FT
H
V
{r :1
{, i(
0,,
(
€
b7.18
bTue-
Glow plug system
Diesel 1981
Glow plugsystem
Diesel 981-
Legend:
A Temperature sensor
B Stop valve
C Indic6tor light
D Start switch
E Glow plug
F Glow plug relay
G Remote starter
pick-up point
H Control unit
I Fuse box
Start
Coolantkey ON
emPerature
below +50'C = 122'F
Startermotor op€rating
I33234
q3323?
Glow plug system
Diesel 1981-
W W {
\.<
)i
r- e
F n I
votv0 suPPoRTsotultTAEY
ilEclltt{lCCERTlFlClTlott
8Y THt t| t.A.S.t.
U.S.A. nly)
Yoalr
most mportant
wecid tool

Dokumen - Tips Volvo d24 Engines Repair Manual

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7/21/2019 VOLVO D24 Engines Repair Manual

S. Grankshaft earseal, eplacement

SeeService anual ection (431.

Assembletandardandle801 nd rift 208.

Usenewbolts, meared ith sealer /N277961,9.

Place steel ulerbetween arrier l a t eand engine

T. Vibration damper, emoving/installing

Notel Different vibration dampersor D 20 and .

(Ensines withoul rain aps).

Bemove vibration dampea

Typ€ C blue-s.een coolant

Ensine n dgearbox emoved sa unit

lnstall lug nd washer fter raining il.

- e n g i n emount etaining olts rom rontaxte ross-

L e f t ngine ount: emove u r s r o m rontaxte ross,

Right nginemounti emoveower ui rom ub-

Use iftins ools 8 0 1 , 5 1 8 5at ront) nd5r86 ar e a r ) .

Remove lifling tools

Lower ngine nd emoveools.

Connect lutchcableand install return spring

Attach gear selector to gearbox

Notethatarrowonnlethose ust oint owa dsm a n i -

Roughadiustment: urn adjusrer t re6r of rod

oftcrrALirv isx rYP $ rArYL

(rt See nstructionsn page24,c11-20

T u r non engine ndwarmup.

Coldgea&oxo I oiltemperatures o'C 104'F'.

Hot gearbox o I oit temperatlre 90'C ('194'F)

lmp o r t a n t r f e n g in eh a s b e e n d isa sse mb d cylin d e r

Engineoil, oil filter. replacement

Group 22 Lubricating system

Oil pressure, hecking

Connect oil pressure gauge to connection for oil

Mark A) on outerp l m p gearmust ace ear over.

Gtoup 23 Fuel sysf€fi

Group23 Fuel ystem

Group23 Fuel system

AA. Exhaustgas density

S in ce e xh a u st g a s smo ke e missio n s f r o m V o lvo

Group 23 Fuel system

Push n plunger ully after hecking.

Routehose with rubber bladderto d.ive6 seat

S mo ked e n sit y o r p a sse n g e r a r s n S w e d e nmu st n o t

Group 23 Fuel system

AB. ldle * fast idle

Checldadiust fast idle

Sealadjustmentscrew and lock nut with paint after

Group 23 Fuel system

AD. niection ump,general

Smokedensity egulationsor Sweden

Group23 tuel system

Highaltitudeadjustment Legal equirement)

Thefollowingadiustmentm ust bemade o vehicle or

Injecrion iming Iniectedqutntity

Group 23 Fuel system

Removo ear iming goa. covel

Disconnect cold start devicc

Tuln ongin€ until cyl. I is at TDc-iniection

Pl.co dial Indicator in iniection pump

Gtoup 23 Fuel system

Note f engines urned oo ar t mustbe urned ack

Romovedial i ndicator and holder