Volvo D20 Bedienungsanleitung

Service Manual

Repairs

and maintenance

30420/1

.88

Section

2(20-23.25-27)

Engine

20.

2401979-19

D 20, D

80th

the D

and

Diesel engines are

deall

with

this

manual.

The D

ylinders

and the D

six. Otherwise

the engines

are

similar

principle.

Note!

Different

flywheels

and

vibration

dampers

are

titted

the

different

engine

typas.

00000

000000

Volvos are sold

versions adapted for different

markets. These adaptations depend on

many

fae

rs including legal,

taxalion

and marke! require-

ments.

This

manual

may

therefore

show

illustrations

and

text

which

not

ply

cars

you

coun

•

, •

•

Contents

Page

Important

information .

...

..........................................

Specifications

...

........

...

....

...

....

. 3

Special

tools

.........

..........

............

...............................

...

.....

Group21

Engineassembly

...............................................

(Work

with

engine in-car, replacement

engine)

Group22

Lubricating

System

........................................

Group

23 Fuel

System

........................................................

Group

251ntake

and

exhaust

systems

..........

........

Group

Cooling

system

.................................................

Group27 Enginecontrals

................................................

A d"

"A"F

I "

ppen

au t tracmg

............................................

Index 178

Order No.: TP 30420/1

reserve the right

ke alterations

Reprint

1983 literature

without

change.

GVOLVO NORTH AMERICA CORPORATION

123

125

160

163

175

)?JIt..

......

Important information

,,.

...

nO'"

" Nm

135020

ClEANLlNESS

Diesel injectionsystemsare extremely sensitive

dirt

and

foreign

matter

. A special

workplace

should

therefore be used

for

inspection

components.

PLUGS

Claan

fuelline

connections thoroughly befora discan-

naeting pipes.

Plug ends

fuel lines etc

each cemponant

removed.

not removeIhese plugs

unlil

the cempo-

nent is reconnected.

Tightening

torques

Two kinds

tighte

ning

torques

will

found

this

manual.

Tighten to 40 Nm (30

Ibsl

indicates

that

torque

wrench

must

used

for

tightening.

Tightening

torque

(30

Ibs)

indicates

guide

value.

Tightening

need

not

dona

with

torque

wrench.

Specifications

Group

20 General

Engine

type

designatian and serial

number

Stampad on left side

engine beneath vacuum

pump

Volvo

designatian 133 757

designation

20Engine

OutputDIN ......................................................................................

Max torqueDIN ...........................

....

..................................................

Numberofcylinders

...................................

...

.............................

Firing

order

......................................................................................

Oisplacement .....................................................

...

.................

Weight, approx. incl. engine mounts, alternator and starter

motor

............

....................................

....

...

........................

Compression pressures:

Newa

ngine ......................................................................................

Minimum

........

...

................................

...

....

.........................

Maxdifference

between cylinders

....

...

....

...

..............................

Compression ratio ............

...

........................

...

....

...

Cylinder bore..............

...

............................................

...

............

Stroke length .....................................................................................

kW at 80 r/s

at 4,800 r/min

120

r/s

12.2 kpm at 3,000 r/min

'·2·4·5·3

'.986

3 (liter)

181

(405 Ibs)

Moa

3.2

2.'

0.8

23.0:1

76.5

= 3.0

118

86.4

= 3.4016 in

pSi

'55

313

11.

Specifications

24Engine

OutputDIN ...........................................

...

...................................

Maxtorque

DIN

Numberofcylinders

.......

...

...........................................

....

Firing

order

.....................

................................

....

...

Displacement ................................

...

...........................................

Weight, approx. incl. engine

mounts,

alternator and starter

motor

....

........

...

.....................................

...

.......................

Compression pressures:

Newengine

...............

...... ............................................................

Minimum

............

....

.........................................

Maxdifferencebetweencylinders ................

Compressian ratio

...

............................................

Cylinderbare

...

.................................

...

.................

Stroke length

........ .........................................................................

kW at

rIs

hp at 4,800 r/min

140

at 47 rIs

14.3 kpm at 2,800 r/min

'-5-3-6-2-4

2.383

J (liter)

198 (435 Ibs)

MP.

3.2

2.4

0,8

23.0:1

76.5

= 3.0118 in

86.4

= 3.4016 in

psi

455

313

114

Group

Engine

assembly

CYLINDER HEAD

0,5

128 146

Diagonally

max

0.5

Replace cylinder head if warp exceeds specificalions.

Under no circumstances

may

cylinder head

machined.

r l

0,2

Square max 0.2

128

147

Specifications

CYLINDER HEAD

GASKEr

Three

different

gasket types are used depending on piston projection above cylinder block face.

Gasket

Piston projec1ion

notches

thickness

(in)

0.67-O.80(0.026-{1.031)

.... 1 ..................

1.4 (0.055)

0.81-0.90(0.032-0.035)......

2 ................... 1.5 (0.059)

0.91-1.02(0.036-0.040)........ 3 ................... 1.6

.063)

5197

Gearbelts

/I~

Belt tension (measured

with

tool 5197)

checkvalue

...

, , s ,

, , ,

, , \',-

setting .........................................................................................

12-13

12.5 ,If?

VALVESYSTEM

Valve clearances, cold engi

Cold engine = room temperature

intakevalves

...

....

......

......................................

...

..........................

exhaust valves ...........................

...................................................

Valve clearances, warm engine

intake valves

...

............................... ................................................

exhaustvalves ................ ...................................................................

Shims

......

...............

...

..............................

.......................

0.1299 in to 0.1673

in increments

0.0020 in

020

Check

(in)

0.15-0.25

.006-0.010)

0.35-0.45

.014-0.018)

Setting

{in}

0.20 (0.008)

0.40 (0.016)

0.20-0.30 (0.008-0.012) 0.

(O.010)

0.40-0.

(0.016-0.020) 0.45 (0.018)

3.00-4.25

in increments

0.05

o A

Check/adjust valves in

following

order:

1-2-4-5-3

intake

valves

A '" exhaust

valves

024

Checkladjust valves

following

order:

1-5-3-6-2-4

Specifications

TIGHTENINGTORQUES

Tightening torques

apply

to oiled nuts and bolts. De-

greased (washed) parts

must

be oiled

prior

as·

embly.

V o

I!l

C!l

4ll

'--

o' O'

020

024

O O

TlGHTENINGSEOUENCE

FOR

CYLINDER HEAD BOL

Importentl

siaeken bolls in reverse

order

when

removing cylinder head.

Remove oil and

dirt

from

bolt holes.

Oilleft

holes

will

reduce pressure on cylinder head gasket.

Bolt threads and

washers

must

however

be oiled,

otherwise frictional forces

will

too great.

Two

types

bolts are in use:

early type

with

threads and a

latertypewith

M 12threads.

(Latertype

threaded along entire length.)

TlGHTENING

CYLINDER HEAD

BOL

Usa

new

washers, convex side upwards.

Tighten in five stages:

(37

ft Ibs)

(50 ft Ibs)

3 90

(65 ft Ibs)

4 run engine

until

oil temperature is at least 50"C

(122 CF)

5 90

(65 ft Ibs)

Retightening

-After 600-1,200

miles

(1,000-2,000 km). Engine

should be cold or almost cold. Tighten each bolt separ-

ately in specified order,

see

above fig.:

1. SIaeken bolt 30°

2. Torque to

(65 ft Ibs)

180

IM,!il

Use

new

botts.

Not

necessary

replace washers.

Tighten in six stages:

1 40

(30 fl Ibs)

(44 ft Ibs)

3 75

(55 fl Ibs)

4 angle·tighten 180· in one

movement

without

stop-

ping. (See fjgure at

lower

leftl

5 run engine

unlil

oil temperature is

lesst

SO"C

(122 O

6 angle·tighten

gO-

in one

movement

without

stop-

ping.

Retightenlng

After

600--1,200 miles

,000--2,000 km). Engine

should

be c

old

almost

cold.

Tighten each

bolt

separately in specified order, see

above fig.:

Angle-tighten bolt

gO-

one

movement

without

slopping. (See figure at

lower

left)

not

siaeken

bolt

first.

Nm (15

Ibsl

\,..\!l

)

0.-HL

oj/-

_JJ:21~

9 Nm

Ibsl

Smear

threeds

lecl surfacss

;~~

bolt head con-

pound

!PIN

277

locking

com-

. 961-9).

Tlghtenin

Ib g torqua 350

appl"

(258

IBS

when

tool 5188 II

uSlng

speci

ato

rq 8

usad

directly

wrench

( . on

wIthout

51881

e center bolt

to ' the .

(qua should b lighten

ing

(bs). e 450

{332 ft

350

1258

L Ibsl

"'"

.®

.,..

20N

m (15 ft

IbsJ

024

Specifications

•

:Jr,0

Nm (74

Ibsl

020

024

N (

j:,

Ibs)

Usa

new

bolls

Smear threads .

compound

277;1~~9.

locking

Specific8rions

oup

Lubricating

System

Oll

CAPACITIES

Excl.

oil

filter

............................................................................

Inel. oil

filter

.............................................................................

Differenee in

volume,

max-min

..............................................

NGINEOll

Quai

ity

...................... ....................

...

.............

Aeeording

toA

..........................................................

•

'31_

perature

ran

(stable am

bient

temperatures)

-20 -

O 10

56 I

_4 6,

SAE

owt.30,

swl30

SA[

lm/

SM:

OWtllO

SAE

15W

SAE

2OW

l5O

SAE

SAE40

Oll

PRESSURE

·C

104

Oil pressure at oil

tempera

ture

80°C (176°

and 33.3 r/s

020

liters

(US quarts)

5.2 (5.5)

6.0 (6.3)

1.0 (1.0)

min

024

ters (US quarts)

6.2 (6.5)

7.0 (7.4)

1.0 (1.0)

Oils

with

designations SElCC, SE/CD,

SF/CC

and SF/CD

meet

this

requirement

SAE 15 W/50

SAE

W/50 oils are

recomme

nded for

use in

ext

eme

driving

eonditions

whieh

involve

high

oil

consumption

and

high

oil

temperatures,

for

example,

mountain

driving

with

frequent deeelerations

fast

molorway

driving.

(Note

however

the

lower

tempe

ture

limits.)

'Ps

psi

(2000 rI

min)

min

.............

............................................................. 200 28

onpressure sensor

Cut-outpoint,

indicator

amp

goeso

tat

........

...

........................ 1&-45

Lubricating oil

pump

Reliefvalve opans at ............

........................................................... 600-700

Relief

valve

spring,

gth

different

loads l e

ngt

in.

l = 49 (

93)

(0.87)

19.8 (0.78)

(eompletelyeompressed)

2-6

85-99

load

175-

approx. 200

Ib.

(39-441

(45)

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