Volvo D20 Service Manual Download Page 1

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Summary of Contents for D20

Page 1: ...Service Manual Repairs and maintenance TP 30420 1 11 88 Section 2 20 23 25 27 Engine D 20 D 24 2401979 19 ...

Page 2: ...in principle Note Different flywheels and vibration dampers are titted to the different engine typas 00000 000000 Volvos are sold in versions adapted for different markets These adaptations depend on many fae tars including legal taxalion and marke require ments This manual may therefore show illustrations and text which do not apply to cars in your country ...

Page 3: ...engine Group22 Lubricating System Group 23 Fuel System Group 251ntake and exhaust systems Group 26 Cooling system Group 27 Engine contrals A d A F I ppen IX au t tracmg Index 178 Order No TP 30420 1 We reserve the right lO make alterations Reprint of 1983 literature without change GVOLVO NORTH AMERICA CORPORATION 123 125 160 163 175 Al 1 ...

Page 4: ...s thoroughly befora discan naeting pipes Plug ends of fuel lines etc as each cemponant is removed Do not remove Ihese plugs unlil the cempo nent is reconnected Tightening torques Two kinds of tightening torques will be found in this manual l Tighten to 40 Nm 30 ft Ibsl indicates that a torque wrench must be used for tightening 2 Tightening torque 40 Nm 30 ft Ibs indicates a guide value Tightening ...

Page 5: ...IN Numberofcylinders Firing order Oisplacement Weight approx incl engine mounts alternator and starter motor Compression pressures Newangine Minimum Maxdifference between cylinders Compression ratio Cylinder bore Stroke length 50 kW at 80 r s 68 hp at 4 800 r min 120 Nm at 50 r s 12 2 kpm at 3 000 r min 5 2 4 5 3 986 dm3 liter 181 kg 405 Ibs Moa 3 2 2 0 8 23 0 1 76 5 mm 3 0118 in 86 4 mm 3 4016 in...

Page 6: ...tio Cylinder bare Stroke length 60 kW at 80 rIs 82 hp at 4 800 r min 140 Nm at 47 rIs 14 3 kpm at 2 800 r min 6 5 3 6 2 4 2 383 dmJ liter 198 435 Ibs MP 3 2 2 4 0 8 23 0 1 76 5 mm 3 0118 in 86 4 mm 3 4016 in psi 455 313 114 Group 21 Engine assembly CYLINDER HEAD 4 0 5 mm 128 146 Diagonally max 0 5 mm Replace cylinder head if warp exceeds specificalions Under no circumstances may cylinder head be m...

Page 7: ...13 12 5 If VALVESYSTEM Valve clearances cold engine Cold engine room temperature intakevalves exhaust valves Valve clearances warm engine intake valves exhaustvalves Shims 0 1299 in to 0 1673 in in increments of 0 0020 in 020 o Check mm in 0 15 0 25 0 006 0 010 0 35 0 45 0 014 0 018 Setting mm in 0 20 0 008 0 40 0 016 0 20 0 30 0 008 0 012 0 25 O 010 0 40 0 50 0 016 0 020 0 45 0 018 3 00 4 25 mm i...

Page 8: ...in five stages 1 50 Nm 37 ft Ibs 2 70 Nm 50 ft Ibs 3 90 Nm 65 ft Ibs 4 run engine until oil temperature is at least 50 C 122 C F 5 90 Nm 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 90 Nm 65 ft Ibs 90 180 IM il 6 Use new botts Not necessary to replace was...

Page 9: ...a 350 si appl Nm 258 ft IBS when tool 5188 II uSlng speci I atorq 8 usad directly ue wrench is on th wIthout 51881 e center bolt to the qua should b lightening bs e 450 Nm 332 ft 350 Nm 1258 ft L Ibsl r Je 20N m 15 ft IbsJ 20 024 Specifications Jr 0 Nm 74 fl Ibsl 020 024 I o 75 N j m 55 fl Ibs Usa new bolls Smear threads compound PIN 277 1 9 locking 7 ...

Page 10: ...uarts 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 or SAE 20 W 50 oils are recommended for use in extreme driving eonditions whieh involve high oil consumption and high oil temperatures for example mountain driving with frequent deeelerations of fast molorway driving Note however the lower tempera ture limits Ps psi 2000 rImin min 200...

Page 11: ...OTE High altitude adjustments are necessary in certain parts of USA see page 132 INJECTORS Make and designalion Bosch No USA Canada 1982 Olhermarkels Volvo PIN USA Canada 1982 Other markets Oistributor type pump Bosch VE5 1 OF2400 L45 l45 1 for aulO vehicles Bosch VE6 10 F2400 l32 l 32 1 for auto vehicles 5001716 9 5001715 1 Checking mm ini Setting mm ini 0 75 83 mm 0 0295 0 0327 0 80 mm 0 0315 0 ...

Page 12: ...s TIGHTENING TORQUES Bosch DNOSD 1930 DNOSD1 93 1328096 1 1542303 1 0681 30201F l 068130201 J USA Canada 1982 Injector complete Nm 068190201 l Oth er markets 068130 201 K DN OSO 193 O USA Canada 1982 DN SO 193 other markets tJ Nozzle Injector in cylinder head 70 ft Ibs 52 upper lower section 70 52 Injection pump pump gear 45 33 70 Nm 52 ft Ibs 10 ...

Page 13: ...ct in time 28 181 Capacity with manual gearbox with automatic transmission EXPANSION TANK D 20 litres lUS quarts 8 2 8 7 8 018 4 Pressure valve in cap opens at Type 1 kPa psi overpressure 65 8519 2 12 1 underpressure 7 1 0 THERMOSTAT Marking Starts to open at Fully open at Opening gap min DRIVE BELTS Designatian Volvo PINI HC38 x 975 958354 3 Type 1 HC38 x 1238 960296 21 HC38 x 888 460431 5 Typa 2...

Page 14: ...033 9 Support lxI for lift bracket 5006 5112 1 Locking sector loeking flywheel 5115 4 Lift hook used with lift bracket 5006 5185 7 Lift hook front removinglinstalling engine 5186 5 Lift hook rear removinglinstalling engine 5187 3 Wrench vibration damper 5188 1 Wrench with extension arm for vibration damper center bolt 5190 7 Gauga installing camshaft 5191 5 Adapter connecting pressure gauge 5193 1...

Page 15: ...Special tools 5191 _m 5191 J Jo 5194 5195 13 ...

Page 16: ...shah gear and pump gear 5204 6 Puller pump gear injection pump 5202 0 Puller for idler pulley 5203 8 Centering shaft for clutch disc 5205 3 Puller for crankshaft front seal 5207 9 Drift instslling needle bearing in crankshaft 5208 7 Drift installing crankshaft rear seal 5233 7 Guide pins M 11 bolts 4x installing cylinder head 5234 3 Guide pins M 12 bolts 4x installing cylinder head 5235 0 Tool for...

Page 17: ...5202 5207 5235 I 5235 5197 5201 5203 5208 9950 Special tools 5197 C o I 5199 5204 5233 5234 o 15 ...

Page 18: ...t Camshaft rem oval installing Camshaftoil seaIs replacement front rear Pilot bearing in crankshaft replacement Crankshaft oil seais replacement front rear Vibration damper removal installing Engine mounts replacement Replacement of engine Removal Installing 16 Operation Al l O 81 11 Cl 21 01 20 El 11 Fl 21 Gl 16 Hl 38 Jl 3 Kl 5 Ll 35 Ml l1 Nl 27 01 27 Pl 21 01 7 Rl 21 81 11 Tl l0 U 4 Vl 7 Xl 33 P...

Page 19: ...stop valve on injection pump This stops flow of fuel and prevents unnecessary spill age A2 Remove vacuum pump and pump plunger A3 Disconnect fuel delivery pipes Clean all connections carefully before disconnecling them Disconnect pipes and plug all connections to prevent dirt from entering system 17 ...

Page 20: ...ighlen 10 70 Nm 50 fl lbs Connecl compression tester to adapter Run engine and record compression Compression New Min Max difference between cylinders Install injectors 3 2 MPa 455 psil 2 4MPa 341 psi 0 8MPa 114psi A6 A7 Place new heat shields in cylinder head see tig Install injectors Torque to 70 Nm 50 ft Ibs Reconnect delivery pipes Tightening torque 25 Nm 18 ft lbsl Reconnect wire to stop valv...

Page 21: ...ve valve eover 82 Turn engine until eyl 1 is at ToC injection Always use the vibration damper center bolt to tum the engine 27 mm socket or wrench 5188 80th cylinder 1 cams should point obliquely upwards Cheek valve clearanee for eyl 1 Checking values Cold engine Intake Exhaust Warm engine Intake Exhaust mm n 0 15 0 25 0 006 0 010 0 35 0 45 0 014 0 018 0 20 0 30 0 008 0 012 0 40 0 50 0 016 0 020 C...

Page 22: ...Depress tappets Turn tappets until grooves point slightly inward Using tool 5196 depress tappets to oblain access to discs Remove disc Use 5195 Calculate thickness of disc to be used Valve clearances when setting Cold engine mm n Intake 0 20 0 008 Exhaust 0 40 0 016 Warm engine Intake 0 25 0 010 ExhausI 0 45 0 018 B6 B7 Measure thickness of old disc with a micrometer Calcu late thickness of new di...

Page 23: ...lled with size marks facing down 89 Checkl adjust valve clearance for remaining cylin ders Checkladjust in following order D 20 1 2 4 5 3 024 1 5 3 6 2 4 Importanti Do not forget to rolate crankshatt 1 4 turn before checkladjusting valve clearance 810 Recheck valve clearance for all cylinders Rotate engine sevaral turns before rechecking 811 Install valve cover Use new gaskets if required Two typa...

Page 24: ...ts front and rear injection timing Engines should be basic set if by adjusling the pump it is not possible to oblain the correct injection timing Camshaft setting may have changed Cl Remove Valve cover timing gear covers front and rear C2 Turn engine until eyl 1 is at TDe injeetion Always use the vibration damper center balt to turn the engine 27 mm socket or wrench 5188 80th cylinder 1 cams shoul...

Page 25: ...with wrench 5201 Take care not to rotate camshaft C5 Slacken camshaft front sprocket Use 5199 to hold sprocket in position when laosening balt Make sure that camshaft does not rotate Tap sprocket to free il from camshaft C6 Set belt t ension Adjust tension by moving coolant pump Use gauge 5197 to check belt tension Attach gauge to belt and set to 12 5 units Stretch belt unti mark on gauge plunger ...

Page 26: ... eyl no 1 is at top dead center Check O mark on flywheel and adjust if necessary C9 Tighten camshaft front sproeket Use 5199 to prevent sprocket from turning Make sure that camshaft does not turn Torque center bolt to 45 Nm 33 ft Ibs CJO Remove gauge 5190 and feeler gauge Cl1 Disconnect cold start device SIaeken screw 1 Push lever forward and fotate sleeve 90 Nate Do not turn screw 2 otherwise it ...

Page 27: ... and dial indicator range 0 3 mm Set gauge lo approx 2 mm Turn pump gear clockwise unlil mark on gear and mounting bracket coincide Then turn pump gear back slightly unlil min reading registers on dial indicator Set indicator lo zero Turn pump gear clockwise until mark on gear and pump mounling bracket coincide Lock gear in this position with stop 5193 Insert stop through pump gear into mounting b...

Page 28: ...n D 24 USA Canada 1979 1981 0 70 mm 0 0276 in 1982 0 85 mm 0 0335 in Hold sproeket in this position and torque bolt to 100 Nm 73 ft Ibs Take care that camshaft and sproeket do not move C17 Remove stop 5193 from pump gear C18 Check pump setting Tum engine two full tums until eyl 1 is at top dead center injeetion agarn If engine is tumed too far it must be tumed back approx 1 4 turn and then lo zero...

Page 29: ...D 24 0 60 mm 0 0236 in D 24 USA Canada 1979 81 0 60 mm 0 0236 in 1982 0 75 mm 0 0295 in Then turn pump inwards untit specified value is ob tained Tighten mounting balts and recheck pump set ting Notellnjection pump must not be tapped or knocked as this will alter setting C19 Remove dial indicator and holder 5194 Install plug with new seal Tightening torque 9 Nm 6 5 fl Ibs C20 Reconnect cold start ...

Page 30: ...attery Remove engine splashguard Disconnect exhaust pipe from gearbox bracket exhaust pipe from rear branch pipe Disconnect exhaust pipe from front branch pipe Dl 02 03 air filter cover with intake hose and crankcase 11 breather hose 04 Drain coolant Remove expansion tank cap Disconnect lower radiator hose from radiator ...

Page 31: ...t from cylinder head upper radiator hose hose for eold start deviee D6 D7 Remove vacuum pump and pump plunger Aemove pump retaining nuts and place pump on wheelareh Remove plunger from cylinder head D8 Remove fuel delivery pipe elean all eonneetions thoroughly before diseonneeting pipes Remove all pressure pipes and plug ends to prevent dirt from entering fuel system 29 ...

Page 32: ... head 010 Remove valve cover timing gear covers front rear 011 Turn engine until eyl 1 is at TDC injeetion Always use the vibration damper center bolt lo turn the engine 27 mm socket or wrench 5188 80th cylinder 1 cams should point obliquely upwards Flywheel at O mark Remove retaining screws from belt cover on cylinder head 012 Take care that washeron innerscrew does not fall down into lower timin...

Page 33: ...t in position when loosening balt Make sure that camshaft does not rotate Tap sprocket to free il from camshaft 015 Uh off pump belt Slacken mointing balts for injection pump bracket to release belt tension Tighten one bolt so that pump remains in upper position lift off belt 016 Remove camshah rear sprocket Hold sprocket in position with 5199 and unscrew sprocket with wrench 5201 Take care not to...

Page 34: ...rse sequence to tight ening i e start at 12 or 14 and finish at l lift awaycylinder head Check that reargtow plug clears injection pump bracket and that valves do not contact cylinder watts Place cylinder head on wo oden b locks Do not rest cylinder head on vatves Clean gasket surfaces on cylinder head and cylinder block Check for damage and warp Use a straight edge and feeter gauge Reptace cylind...

Page 35: ...do not impair engine function For gasket replacement only see Cylinder head in stallation page 45 E Cylinder head disassembly El Remove intake manifoid exhaust manifold and gasket Allen 6 mm Remove injectors Remove dirt around injectors Disconnect fuel lines E2 Remove injectors 27 mm socket Lift out heat shields from cylinder head 33 ...

Page 36: ...and 3 Slacken nuts crosswise to avoid placing uneven load on camshaft E5 lift away camshaft and remove oit seals E6 lift out tappets Note Do not interchange tappets Mark tappets so that they can be installed in same position Remove from cylinder head lifting eyes connecting flange for water hose Allen 5 mm glow plugs temperature senders 2 XI E7 ...

Page 37: ...mm 6 in Remove valve springs and valves Important Do not interchange parts E9 Depress valve springs with a special compressor tool Remove retainer collet upper spring seat springs valva Remove seals from valve guides Use tool 5219 Remove lower valve spring washers ElD ElI Usa a pair of externat lock ring pliers with flat jaws 35 ...

Page 38: ...d of valve slem flush with valve guide Clearance 1 3 mm 0 05 in F2 Check camshaft end float Use a dial indicator Position camshaft and install rear cap Torque to 20 Nm 15 fl Ibs Clearance max 0 15 mm 0 006 in Aemove cap and camshaft Check discs F3 Check disc play Replace disc if worn or scored Install new discs with numbers facing down towards tappets Clearance new parts 0 016 0 046 mm 0 0006 0 00...

Page 39: ... 40 2 1 583 32 6 11 283 22 3 0 878 Rep acing va ve guides Operations F 6 8 Press out valve guide F5 Load N lbs O lO 67 77 15 17 5 209 231 47 52 2 load N lbs O lO 167 185 38 42 433 479 98 108 3 F6 Use drift 5218 Press from combuSlion chamber side Press in new valve guide Lubricale valve guide Use drift 5218 Press in from camshaft side F7 Press in guide until flange on guide contacts cylinder head I...

Page 40: ... valves are stellite coated and must not be ground by machine Grind in valve on seat with grinding paste Mill or grind valve seats Grind to 45 Contact surface a must be 2 0 mm 0 08 in for intake valve 2 4 mm 0 09 in for exhaust valve FlO If contact surface is too wide reduce area with a 15 cutter Important Guter diameter of cutter must not exceed 35 2 mm 1 39 in for intake valve seats and 33 2 mm ...

Page 41: ...meter to measure seat recess Standard production version Oiameter seat recess mm in intake 37 000 37 016 exhaust 33 000 33 016 Diameter seat intake 37 090 37 105 exhaust 33 090 33 105 Oversize 1 4567 1 4573 1 2992 1 2998 1 4602 1 4608 1 3028 1 3033 replacement parts version Diameler seat recess mm in intake 37 200 37 216 exhaust 33 200 33 216 Diameter seat intake 37 290 37 305 exhaust 33 290 33 30...

Page 42: ...8 Cool valve seat Wear protective gloves and safety glasses Usa liquid carbon dioxide to cool seat down to 70v C 94 F F1 9 Tap in valve seat Nate This must be done quickly within 3 4 seconds to avoid temperature loss F20 Check fit of valve seat Make sure that the seat has bettomed correctly and is secure If not replace cylinder head F21 Grind valves and mill seats See instructiens on page 38 opera...

Page 43: ... tap in oil jets using a brass punch G7 Note Tum outer jets to point across cylinder head see tig Important Check specification and type of cylinder head M 12 balts must not be used with M 11 bolts Different type cylinder heads are used for USA Canada G2 Check valve stem position in relation to camshaft This measurement is carried out to ensure that there is sufficient adjustment lattitude for val...

Page 44: ...d upper spring seat must also ba replaced with new parts New spring seats are either copper coated or chromed Early types are bright or black Install upper spring seats flanged side up Install valve stem oil seal G4 Protective sleeves must be used when installing oil seal To install valve place valve in cylinder head and place protective sleeve on stem Use 1001 5219 to install oil seal nate that t...

Page 45: ... ft Ibs temperature senders 2X Same type front and rear connecting flange for radiator hose Allen 5 mm Install new gasket Tightening torque 10 Nm 7 ft Ibs lifting eyes G8 Install tappets with shims Smear tappets and shims with oil before installation Number on shims should face down Check that tappets slide easily with out sticking G9 Place camshaft in cylinder head Lubricate contact surfaces of c...

Page 46: ...four caps Torque 20 Nm 15 ft Ibsl Tap in oil seals to bottorn Use adapter 5200 and a plastic mallet Install injectors G13 G14 G15 Place new heat shields in cylinder head Turn shields as illustrated Screw in injectors Torque to 70 Nm 50 ft Ibs Reconnect fuet delivey lines between injectors It is advisable to check condition of injectors when reconditioning cylinder head See instructions on page 153...

Page 47: ...e Install guide pins in cylinder block 5233 for blocks with M 11 bolts 5234 for blocks with M 12 balts H2 Two outer pins hold gasket in position Cylinder head is prevented from sliding and damaging gasket by two inner pins Important Use all four pins located as illustrated H3 Install new cylinder head gasket Three different types are available and are marked with notches Type to be fitted depends ...

Page 48: ...not open packet until gasket is to be used Take care not to damage packet and cause damage to 9asket teflon strip rubber seal H4 If pistons connecting rods etc are replaced piston height must be measured and 9asket chosen according 10 lable below Piston height above cylinder block Gasket mm in notches thickness mm in 0 67 0 80 0 026 0 031 0 81 0 90 0 032 0 035 0 91 1 02 0 036 0 040 1 1 4 0 055 2 1...

Page 49: ...rike pistans Cylinder head balts Two types of cylinder head balts are in use Early type balts have M 11threads These balts can be reused with new washers Fil washers with cup shape facing up Late type balts have M 12 threads along entire length These balts must not be reused Washers may however be reused H7 Install cylinder head bolts Lubricate threads and sliding surface of washers Place balts in...

Page 50: ... 51 ft lbs 3 90 Nm 66 ft Ibs 48 O HB Torque cylinder head bolts Tighten all bolts one at a time in order specified adja cent before proceeding with next stage 1159082 Tighten in four stages 1 40 Nm 29 ft Ibs 2 60 Nm 44 ft Ibs 3 75 Nm 55 fl Ibs M 12 bolts 12 sided wrench PIN 115 9082 5 4 angle tighten laOG in one movement wi thout stop ping See illustration below In 101 ...

Page 51: ...d position sprocket and belt Tighten center bolt by hand but it should still be possi ble to turn sprocket on camshaft H12 Set belt tension Adjust tension by moving cooling pump Use gauge 5197 tO check tension Attach gauge to belt and set to 12 5 units Stretch belt until mark on gauge plunger is flush with sleeves Depress belt strong ly with hand and recheckladjust len sion H13 Marke sure cy 1 is ...

Page 52: ... from turning Torque center boll to 45 Nm 33 ft Ibs Remove gauge 5190 and feeler gauge Disconnect cold start device H15 H16 H 17 Slacken screw 1 Push lever forward and rotale sleeve 90 Nate Do not turn screw 2 otherwise il will be necessary to remove caId start device and reset il on a lest bench Press lever back against stop H18 Basic set injection pump Slacken pump mounting bolts Allen key 6 mm ...

Page 53: ... dial indicator Set indicator to lera Turn pump gearclockwise unlil mark on gear and pump mounting bracket coincide Lock gear in this position with stop 5193 Insert stop through pump gear into mounting bracket H20 Install camshaft rear sprocket and belt Tighten center bolt by hand but it should still be possi ble to turn sprocket on camshaft H27 Set belt tension Adjust tension by moving pump Use g...

Page 54: ...l cyl 1 is at top dead center injection again If engine is turned too far il must be turned back approx 1 4 tum and Ihen 10 zero mark otherwise setting will be incorrect Dial indicator should show D 20 0 75 0 83 mm 0 0295 0 0327 in D 24 0 65 0 73 mm 0 025 0 0287 in D 24 USA and Canada 1979 1981 0 65 0 73 mm 0 0256 0 0287 in 1982 0 82 0 90 mm 0 0323 0 0354 in Correct reading Tighten injection pump ...

Page 55: ...apped or knocked as this will alter its setting H25 Remove diaI indicator and holder 5194 Install plug with new seaI Tightening torque 9 Nm 6 5 ft Ibs H26 Reconnect told start device Press lever forwards and tum sleeve 90 Retighten screw 1 Note Do not turn screw 2 otherwise it will be neeessary to reset caId start deviee on a test bench H27 Install valve CDver Use new gaskets if necessary Two type...

Page 56: ...rear injector Install plunger and vacuum pump Check O ring replace if necessary H28 H29 H30 H31 Connect vacuum hose from brake servo to pump H32 Install wire to glow plug _ wires to temperature senders 2 XI one at rear and one to left of cylinder head H33 Connect Iower radiator hose to radiator upper radiator hose hoses for caId start device to cylinder head and ther mastat ...

Page 57: ... hose level with top edge of expansion tank Coolant Since aluminium is used in the engines active corro sion protection is necessary in the coolant help preven corrosion damage Use genuine Volvo blue green coolant type C dilutf with clean water in proportions of SO 50 This mixture helps to prevent corrosian and ff damage Never fill the cooling system with water alone The coolant should be changed ...

Page 58: ... Group 26 Cooling System Set dashboard heater controi to max Turn on engine and warm up for 5 minutes Add coolant during this time Connect hose to cold start device Fill coolant to mouth of expansion tank above max and screw on cap H38 Tighten cylinder head bolts Warm up engine unlil oH temperature is at least 50 c C 122 F Remove vacuum pump with plunger and valve cover M 11 bolts torque to 90 Nm ...

Page 59: ...m pump and plunger Access to one of cylinder head bolts is restricted by pump plunger J2 M11 bolts Tighten each balt in turn as indicated according to below 1 Slacken balt 300 2 Torque to 90 Nm 65 ft Ibs M 12 balts Tighten each balt in turn as indicated according to below 1 Angle tighten balt 900 in one movement without stopping Do not slacken balt first See illustration in operation H38 r 411 e o...

Page 60: ... below instructions carefully Overtight bells cause pulley lo squeak 58 Kl Remove timing gear covers front and rear K2 Check belt tension Use gauge 5197 Tension should be belween 12 13 uniIS If incorrect Adjusl tension to 12 5 units by moving pump mounting braeket K3 Check timing gear belt tension Use gauge 5197 Tension should be between 12 13 units ...

Page 61: ...If this is not done injection pump setting will be incorrect Tum crankshaft with 27 mm socket or 5188 Adjust belt tension to 12 5 units on gauge 5197 by moving coolant pump mounting bracket K4 If gear belt tension has been adjusted Turn engine at least one turn clockwise and check that belt tension is 12 13 units on too15197 Adjust if neces sary according to operations K2 3 and recheck tension K5 ...

Page 62: ...t battery L2 Jack up vehicle To prevent spillages when coolan t is drained raise vehicle at front right jacking point Coolant wil l then run along splashguard inta drip pan Place drip pan beneath left steering rod L3 Drain coolant i Unscrew expansion tank cap I Disconnect lower radiator hose from radiator Disconnect lower hose from thermostat for cold start device and drain coolant Engine is witho...

Page 63: ...rn engine 27 mm socket or wrench 5188 80th cylinder 1 cams should point obliquely upwards Flywheel al O L7 Remove vibration damper center bolt Use 5187 lo prevenl pulley from rotaling and socket 5188 lo unscrew bolt II may be necessary to turn engine slightly so that 5187 rests on fan bearing Check that cVI 1 is at TOC injection Check O mark on flywheel Adjust if necessary use 5187 to turn engine ...

Page 64: ...wer timing gear cover and belt Slacken coolant pump retaining bolts to release belt tension Remove belt Replace idler pullev Always replace pulley when fitting new belt Remove center bolt Withdraw pulley using 5202 rap on new pulley and install center balt Remove camshaft rear sprocket and belt U7 U2 Hold sprocket in position with 5199 and unscrew sprocket with wrench 5201 Take care not to rotate ...

Page 65: ...t sprocket Use 5199 to hold sprocke in position when loosening balts Tap sprocket lo free it from camshaft Install gear belt and camshaft front sprocket Make sure that belt fits securely on all gears U5 Install center bolt hand tight It should be possible to turn sprocket on camshaft without camshaft rotating U6 Install lower timing gear cover and vibration damper Damper can only be fitted in one ...

Page 66: ... be in line with wrench 5188 U8 Make sure evl 1 is at TDC injection Check O mark on flywheel and adjust if necessary U9 Set belt tension Adjust tension by moving coolan pump Use gauge 5197 to check tension Attach gauge to belt and set to 12 5 units Stretch bel unlll mark on gauge plunger is flush with sleeve Depress belt slrongly with hand and recheckladjus ten sion Tighten camshaft front sprocket...

Page 67: ...turning pump Relighlen mounting bolls L23 Set diat indicator zero lock pump gear at cyl 1 injection using stop 5193 Unscrew and remove plug from injection pump distri butor Install holder 5194 and diaI indicalor range 0 3 mm Set gauge to approx 2 mm Turn pump gear clockwise until mark on gear and mounling braeket coincide Then turn back pump gear slightly unlil min reading registers on diaI indica...

Page 68: ...ve Depress belt strong ly with hand and recheck adjust ten sion L26 Set pump and tighten camshaft rear spracket Use 5199 0 hold sprocket Torque wrench should be at right angles to wrench 5201 otherwise torque will be incorrect Using 5199 turn sprocket slowly clockwise until dial indicator shows 0 20 0 80 mm 0 031 5 in 024 0 70 mm 0 0276 in D 24 USA Canada 1979 1981 0 70 mm 0 0275in 1982 0 85 mm 0 ...

Page 69: ... setting D 20 0 80 mm 0 0315 in D 24 0 70mm 0 0276 in D 24 USA Canada 1979 1981 0 70mm 0 0276 in 1982 0 85 mm 0 0335 in Reading less than specified SIaeken pump mounting bolls and lurn pump inwards to obtain correct value Tighten mounting bolts and repeal check of pump settings Reading more than specified Slacken pump mounting bolls and turn pump outwards unlil diaI indicIor shows approx 020 0 70 ...

Page 70: ...kets if necessary Two types of pin studs are available see lig Late types have a spacer and hale in gasket is larger to prevent damage to gasket by overtightening Late and early type parts must nol be interchanged Install timing gear covers front and rear Use new gaskets if necessary Install L32 L33 _ eooling fan with spacer and pulley Torque bolts to 9 Nm 7 fl Ibsl _ fan belts and power steering ...

Page 71: ...ns of 50 50 This mixture hel ps to prevent corrosion and frost damage Never fill the cooJing system with water alone_ The coolant should be changed regularly since the cor rosi on protective additives in the coolant lose their ef feet in time Nate Do not run engine when level of coolant is low since high local temperatures can result which may cause the cylinder head to crack Replacing coolant Alw...

Page 72: ...24 9 3 liters 9 8 US quarts Flush cooling system before adding new coolant see Group 26 Cooling System Set dashboard heater controi to max Tum on engine and warm up for 5 minules Add coolant during this lime Connect hose to cold start device Fill coolant lO mouth of expansion tank above max and screw on cap ...

Page 73: ...ion damper center bolt to turn the engine 27 mm socket or wrench 5188 80th cylinder 1 cams should point obliquely upwards Flywheel at O M3 Remove belt from camshaft sproeket Unscrew expansion tank cap to release overpressure from cooling system Slacken coolanI pump mounting bolts and bell len sioner Tighten two lower mounting bolts to avoid uno necessary loss of coolant Remove belt from camshah sp...

Page 74: ...aining bolts MS Bend out shield to free il from camshah If necessary slacken cooianI pump upper boll Keep shield in outer position wi th a piece of wood M6 lift off pump belt Slacken mounling bolls for injection pump brackel lo release belt tension Tighten one bolt so that pump remains in upper posi tion lift off belt M7 Remove camshaft rear sprocket Hold sprocket in position with 5199 and unscrew...

Page 75: ...ve pump retaining nuts and place pump on wheelarch Withdraw plunger from cylinder head M9 Remove camshaft bearing caps 1 and 4 M10 Remove camshaft bearing caps 2 and 3 Slacken nuls crosswise to avoid placing uneven load on camshaft Ml1 lift away camshaft and remove oil seals 73 ...

Page 76: ...e 5190 at rear of camshaft Important 80th cams for number 1 cylinder must point diagonally up see tig Install camshaft caps 2 and 3 Install caps correctly center is off set N2 Tighten nuts crosswiseto avoid warp Keep camshaft in position with gauge 5190 at rear when tightening caps Remove gauge 5190 Press in new camshaft oil seaIs Oil seaIs N3 N4 Do not push in seals to bottom position Make sure t...

Page 77: ...ts for belt eover N9 Install gear belt and camshaft front sprocket Pull belt to ensure that it is seated correctly on crank shaft gear Place bell over camshaft sprocket and install sprocket and belt Install center balt hand tight It should be possible for sprocket lO turn on camshaftwithoutcamshaft rotating NIO Set belt tension Adjust tension by moving cooring pump Use gauge 5197 to check tension ...

Page 78: ... leh side of gauge to compensate for timing gear clearance Tighten eamshaft front sproeket Use 5199 to prevent sprocket from turning Torque center bolt to 45 Nm 33 ft Ibs Remove gauge 5190 and feeler gauge Diseonnect eold start deviee N13 N14 N15 SIaeken screw 1 Push lever forward and rotate sleeve 900 Note Do not turn screw 2 otherwise it will be necessary to remove cold start device and reset il...

Page 79: ...der 5194 and diaI indicalor range 0 3 mm Set gauge 10 approx 2 mm Tum pump gear clockwise until mark on gear and mounting braeket coincide Then turn pump gear back slight ly unlil min reading registers on dial indicator Set indieator lo zero Turn pump gear clockwise unlil mark on gear and pump mounting brackel coincide lock gear in this position with stop 5193 Insert stop through pump gear inlo mo...

Page 80: ...n D 24 USA Canada 1979 1981 0 70 mm 0 0276 in 1982 0 85 mm 0 0335 in Hold sprocket in this position and torque bolt to 100 Nm 73 ft Ibs Take care that camshaft and sprocket do not move N21 Remove stop 5193 from pump gear N22 Check pump setting Turn engine Iwo full tums unlil cyl 1 is at 10P dead cenler injection again If engine is turned 100 far il must be lurned back approx 1 4 lurn and then to z...

Page 81: ...rds until diaI indicator shows approx 020 0 70 mm 0 0276 in 024 0 60 mm 0 0236 in D 24 USA Canada 1979 1981 0 60 mm 0 0236 in 1982 0 75 mm 0 0295 in Then turn pump inwards until specified value is ob tained Tighten mounting bolts and rech eck pump set ting Note Injection pump must nOl be tapped or knocked as Ihis will alter its setting N23 Remove diaI indieator and holder 5194 Install plug with ne...

Page 82: ...all plunger and vacuum pump Check O ring replace if necessary Adjust valve clearance See operation 81 11 page 19 N25 N26 Important Valve clearance must be checked after 600 1 200 miles 1 000 2 000 km N27 Install timing gear covers front and rear Jt ...

Page 83: ...ld start deviee Slacken screw 1 Push lever forward and rotate sleeve 90 Notel Do not turn screw 2 otherwise it will be necessary to remove cord start device and reset it on a test bench Press back lever against stop 03 Install dial indieator Unscrew and remove plug from injecl ion pump dislri butor Install holder 5194 and diaI indicator range 0 3 mm Set gauge to approx 2 mm 81 ...

Page 84: ...st not move during installation of new oil seal otherwise it will be necessary to basie set engine since camshaft will have moved in relation to crankshaft If pointer does not move it suffices to checkladjust injec tian pump setting 06 Remove belt from eamshaft sproeket Unscrew expansion tank cap to release overpressure from cooting system Slacken coolant pump mounting bolts and belt ten sioner Ti...

Page 85: ... 010 Do not push in seal to bottom position Make sure that seal is square Install camshaft cap 1 Torque to 20 Nm 15 fl Ibs Press in seal to bottom position 011 012 Release cover Use adapter 5200 to tap in oil seaI 013 Install bolts for belt cover 014 Install gear belt and cam shaft front sprocket Pull belt to ensure that it is seated correctly on crank shatt gear Place belt over camshaft sprocket ...

Page 86: ...lunger is flush with sleeve Depress bell slongly with hand and recheckladjust ten sion 016 Make sure cyl 1 is at TOC Check Q mark on flywheel and adjust if necessary Tighten camshaft front sprocket Use 5199 to prevent sprocket from turning Torque center bolt to 45 Nm 33 fl Ibs Check dial indicator 017 018 Jf pointer has moved from zero position basic set en gine according to operations C1 21 Point...

Page 87: ...ator shouId show 020 0 75 0 83 mm 0 0295 0 0327 in 024 0 65 0 73 mm 0 0256 0 0287 in D 24 USA Canada 1979 1981 0 65 0 73 mm 0 0256 0 0287 in 1982 0 82 0 90 mm 0 0323 0 0354 in Correet reading Tighten injeetion pump mounting balts Proeeed to 023 Incorrect reading Readjust aeeording to below 021 Checkladjust pump setting 020 0 80 mm 0 0315 in 024 0 70 mm 0 0276 in D 24 USA Canada 1979 1981 0 70mm 0 ...

Page 88: ...above specifications because of insufficient adjustment latitude engine must be basic set again since camshaft and crankshaft are probably out af line Note Injection pump must not be tapped or knocked as this will alter its setting 022 Check pump setting Turn engine round twice and check setting see opera tion 020 Readjust if necessary and repeat check Remove dial indicator and holder Install plug...

Page 89: ...026 install valve cover Use new gaskets jf necessary Two types of pin studs are available see fig late types have a spacer and hole in gasket is larger to prevent damage to gasket by overtightening Late and early typa parts must not be interchanged 027 Install front timing gear cover 87 ...

Page 90: ...ng gear eover P2 Turn engine until cy 1 is at TOC injection Always use the vibration damper center balt to tum the engine Use a 27 mm socket 80th cylinder 1 cams should point obliquely upwards P3 Lift off pump belt Slacken mounting balts for injection pump bracket to release belt tension Tighten one balt so that pump remains in upper posi tion lift off belt ...

Page 91: ...eal to bottom position make sure that seaI is square P7 Install camshaft caps 1 and 4 Make sure that thrust washer for camshaft cap 4 sits correctly Tightening torque 20 Nm 15 ft Ibs P8 Tap in oil seal to bottom Use adapter 5200 and bolt for rear camshaft sprocket P9 Check camshaft setting Check with gauge 5190 that camshaft is correctly set in relation to crankshaft Gauge should fit in groove in ...

Page 92: ...nting bracket by turning pump Retighten mounting bolls Pl2 Set dial indieator zero Loek pump gear at eyl 1 injection using stop 5193 Unscrew and remove plug from injeclion pump diSlri bulor Inslall holder 5194 and dial indicalor range 0 3 mm Set gauge 10 approx 2 mm Tum pump gear dockwise unlil mark on gear and mounting bracket coincide Then tum pump gear back slightly until min reading registers ...

Page 93: ...ush wil h sleeve Depress belt sl rongly with hand and recheckladjust ten sion P15 Set pump and tighten camshaft rear sprocket Use 5199 to hold sprocket Torque w rench should be at right anglas to wrench 5201 otherwise torque will be incorract Using 5199 lurn sprocket slowly until dial indicator shows D 20 0 80 mm 0 0315 in D 24 0 70 mm 0 0276 in D 24 USA Canada 1979 1981 0 70 mm 0 0276 in 1982 0 8...

Page 94: ...t according lo instructions below Readjusting pump setting Setting valu8s D 20 0 80 mm 0 0315 in D 24 0 70 mm 0 0276 in D 24 USA Canada 1979 1981 0 70 mm 0 0276 in 1982 0 85 mm 0 035 in Reading less than specified Slacken pump mounting balts and turn pump inwards to obtain correcl value Tighlen mounting balts and repeal check of pump setting Reading more than specified Slacken pump mounting balts ...

Page 95: ...lever forwards and tum sleeve 90 Retighten screw 1 Notel Do not tum screw 2 otherwise it will be necessary to reset cold start device on a test bench P20 Install valve cover Use new gaskets if necessary Two typas of pin studs are available see tig Late types have a spacer and hole in gasket is larger to pravent damage to gasket by overtightening Late and early type parts must not be interchanged P...

Page 96: ...ove pressure plate and driven plate 01 02 Unscrew pressure plate mounting bolts crosswisea few turns at a time lo prevent warp Remove bearing Use extractor 4090 Install bearing 03 04 Install bearing and seaI with text on ouler ring facing out away from flywheel Use standard handle 1801 and drift 5207 to tap in be aring unl il il abuts crankshaft Press in a small amount of grease 1 3 1 5 gram in th...

Page 97: ...driven plate Use centering shaft 5203 Turn driven plate with hub fating out away from fly wheel 06 Install pressure plate Tighten balts crosswise a few tums at a time to avoid warp 07 Install gearbox Do not forget to remove bolts securing starter motor 95 ...

Page 98: ...ined raise ve hide at front right jacking point Coolant will then run along splashguard into drip pan Place drip pan beneath left steering rod R3 Drain coolant Unscrew expansion tank cap Disconnect lower radiator hose from radiator and drain coolant Engine is with out drain taps Lower vehicle R4 Remove radiator cooling fan with spacer and pulley fan belts and power steering pump belt front timing ...

Page 99: ...turn anticlockwise Use wrench 5187 R6 By turning engine anticlockwise slack in belt will move to driving side making il easier to rernove and install belt Remove vibration damper Remove four inhex bolts 6 mm R7 Pull off vibration damper Note Crankshaft gear may sometimes stick to vibration damper Remove lower timing gear cover Detach caoling fan mounting bracket and alternator and place on one sid...

Page 100: ... Also identify outside and topside of gear belt Important Belt must be filted in exactly same position as before otherwise valves may centact pistans and cause serious damage Rl1 Remove gear belt Slacken coolant pump mounting balts and belt Coolant may leak when balts are slackened Aemove belt R72 Remove gear on crankshah and withdraw oi seaI Usa extractor 5205 ...

Page 101: ...Install gear on crankshaft R14 Install retaining balts for cover mounting bracket for cooling fanIalternatar R15 Install camshaft gear belt Make sure that bell is fitted in exactly same position as before Align identificalion marks on bell camshaft sprocket and crankshaft gear It is extremely important that belt is fitted in exacIty same position as before Tension belt by moving coolant pump by ha...

Page 102: ...er Use wrench 5188 to torque center balt to 350 Nm 255 fl Ibs Important Torque 350 Nm applies only if wrench 5188 is used Also torque wrench must be in line with wrench 5188 RJB Set belt tension Turn engine approx 1 4 turn anticlockwise Adjust ten sion by moving coolant pump Use gauge 5197 to check tension Attach gauge to belt and set to 12 5 units Depress belt strong ly with hand and recheckladju...

Page 103: ...oportions of 50 50 This mixture helps to prevent corrosion and frost damage Never fill the cooling system with water alone The coolant should be changed regularly since the cor rosi on protective additives in the coolant lose their ef feet in time Nate Do not run engine when level of coolant is low since high local temperatures can result which may cause the cylinder head to crack Replacing coolan...

Page 104: ...024 9 1 liters 9 8 US quarts Flush cooling system before adding new coolant see Group 26 Cooling System Set dashboard heater controi to max Turn on engine and warm up for 5 minutes Add coolant during this time Connect hose to cold start device Fil coolant to mouth of expansion tank above max and screw on cap ...

Page 105: ...olt Manual gearbox SJ S2 Remove pressure plate and driven plate Unscrew pressure plate mounting balts crosswise a few turns at a time to prevent warp Manual gearbox S3 Remove flywheel Automatic gearbox Remove carrier plate Use locking sector 5112 to prevent lIywheel from mo ving S4 Remove crankshaft rear oil seal Lift out oil seal with a screwdriver as indicated S5 Clean and inspect sealing surfac...

Page 106: ...ied out after replacement of carrier plate To measure Place a steel ruler between carrier plate and engine block Ruler should rest against engine to gearbox mounting flange and should rest against both sides of flange Tum crankshatt uniiiane of hales in carrier plate coincides with steel ruler Measure B with an outside caliper equipped for depth measurement Measured value B thickness of steel rule...

Page 107: ... driven plate Use centering shah 5203 Turn disc with hub facing out away from flywheel Manual gearbox SID Install pressure plate Tighten bolts crosswise a few turns at a time to avoid warp SIl Install gearbox transmission Do not torget to remove bolt securing starter motor 05 ...

Page 108: ...ngines Disconnect battery Jack up vehicle T1 T2 To prevent spillages when coolant is drained raise ve hide at front right jacking point Coolant will then run along splashguard inta drip pan Place drip pan beneath left steering rod T3 Drain coolant Unscrew expansion tank cap oisconnect lower radiator hose from radiator and drain coolant Engine is with out drain taps Lower vehicle ...

Page 109: ...ts 6 mm Pull off vibration damper Notel Crankshaft gear may sometimes stick to vibration damper T6 Install vibration damper Damperean only be fitted in one way Pin on crankshaft gear must fit in vibration damper Torque balts 10 20 Nm 15 ft Ibs T7 Install center bolt Smear Ihreads and mating surface with sealer PIN 271961 9 Use wrench 5187 rest on eooling fan bearing to hold vibration damper Use wr...

Page 110: ...e aluminium is used in the engines active corro sion protection is necessary in the coolant to help pre vent corrosion damage Use genuine Volvo blue green coolant type C diluted with clean wa ter in proportions of 50 50 This mixture helps to prevent corrosion and frost damage Never fill the cooling system with water alone The coolant sheuld be changed regularly since the corrosion protective addit...

Page 111: ...ne engines manufactured since 1982 are filled with type C coolant no Fil coolant Capacity D 20 8 1 liters 8 6 US quarts 024 9 3 liters 9 8 US quarts Flush cooling system before adding new coolant see Group 26 Cooling System Set dashboard heater contraI to max Turn on engine and warm up for 5 minutes Add coolant during this time Connect hase to cold start device Fill coolant to mouth of expansion t...

Page 112: ...engine mount Gearbox must be unloaded with a jack during replace menI U2 Front engine mount Unload engine mounlswith lift lools 5033 2 5006 and 5115 U3 Lett side To replace rubber pad remove engine mount with upper and lower brackets U4 Right side To replace rubber pad remove upper brackel and rub ber pad together do nOl remove lower bracke Do not tighten upper nut for rubber pad unlil engine moun...

Page 113: ...onnect 1 positive lead from battery 2 bonnet hood 3 expansion tank cap 4 lower radiator hose from radiator Auto operation 5 V2 5 oil pipe from oif cooler Hold connectors on oil cooler with a wrench If accidentally slackened torque to 6 Nm 4 5 ft Ibs 6 upper radiator hose from engine 7 hoses to expansion tank at raditor 8 radiator 9 hoses from heater controi valve 10 hose from vacuum pump 111 ...

Page 114: ...ew relaining screws from relay F remove power steering pump from engine slack en and remove drive belt from pump Remove pump wi th bracket and support slay from engine Tie pump lo chassis to prevent damage to hoses G cooling fan wi th spacer pulley and fan belts belt for power sleering pump Remove disconnect inlet hose 2 crankcase breather hose 3 air filter cover and hoses 4 alternator wiring harn...

Page 115: ...tic r J 135D5D Remove disconnect front exhaust pipe damps disconnect exhaust pipe coupling Remove front ex haust pipe manual clutch cable and gear lever aula selector controi from gearbox transmission speedameter cable propeller shaft gearbox crossmember Position a jack beneath gear box as support disconnect wiring V7 Use lifting lools 2801 5185 at froni and 5186 al rear Uft engine enaugh to unloa...

Page 116: ...ont and 5186 at rear Position right side rubber mount on lower braeket X2 Install left engine mount Place mount on front axle crossmember and tighten retaining bolts X3 Place a jack beneath gearbox Make sure that rubber foam pad at gear lever is eorreet ly positioned Insert wiring into passenger eompartment Jack up gearbox until level Remove lifting tools Lower engine and rem ove toois X4 ...

Page 117: ... stage Install nuts for engine mounts Lett mount nuts in front axle crossmember Right mount lower nut on rubber pad Install gearbox crossmember Remove jack Install on gearbox X6 X7 XB gear lever Make sure tha t bushings and Q ring are correclly inSlalled Insert gear level in yoke fil pin and tighten screw Allen key 4 mm see inset propeller shaft Always use new nuls and bolts speedometer cable Swed...

Page 118: ...ox XIO Attach gear seleetor to gearbox Xli Install front exhaust pipe For strain free installation instructions must be fol lowed carefully Slacken two retaining balts holding bracket to gearbox transmission 2 Ättach front exhaust pipe finger tight Use new gaskats 3 Tighten nuts and balts holding exhaust pipe to branch pipe 4 Tighten balt hojding front pipe to bracket 5 Tighten balts holding brack...

Page 119: ...ng fan with spacer Torque to 9 Nm 6 5 ft Ibs Tension fan belts It should be possible to depress belt 5 10 mm on run between fan and alternator see fig X16 Install power steering pump and belt Negative lead from battery should be connected to lower front retaining balt for pump mounting bracket Tension fan belts It should be possible to depress belt 5 10 mm 0 2 0 4 in in center of run between fan a...

Page 120: ...firewall Secure plug wilh clip Reconnect hoses to heater controi valve hose to vacuum pump Ihrollle cable Install radiator and connect hoses Automaricgearbox Connect oil pipes to oil cooler Use a wrench lo hold conneclors on oil coole r Tightening lorque Cap nuts 30 Nm 22 ft Ibs Oil cooler connections 6 Nm 4 5 ft Ibs XJB XJ9 X20 X2J X22 ...

Page 121: ...in second gear Install rubbet gaiter boot Automatic gearbox Check adjust gear selector X26 1 Check that clearance between position D and stop is apptoximately same as from 2 to stop 2 Adjust by altering length of controi rad if neces sarv Aough adjustment turn adjustet at rear of rad Fine adjustment turn serrated sleeve max visible thread length 35 mm Jncreasing rad length reduces clearance in pos...

Page 122: ...fast motorway driving Nate however the lower tempera ture limits X28 Bleeding of caoling syst em Disconneet upper hose from eold start deviee Place drip pan beneath hose and hold hose level with top edge of expansion tank Coolant Since aluminium is used in the engines active earro sian protection is necessary in the coolant to help pre vent corrosion damage Use genuine Volvo blue green coolant typ...

Page 123: ... 6 US quarts D 24 9 3 litres 9 8 US quarts Flush cooling system before adding new coolant see Group 26 Cooling System Set dashboard heater contraI to max Turn on engine and warm up fo r 5 minutes Add coolant during this time Connect hose to cold start device Fill coolant to mouth of expansion tank above max and screw on cap X30 Checkl adjust injection timing See instructions on page 24 C11 20 X31 ...

Page 124: ...utomatic gearboxes Check top up oil level Use ATF type F or G X32 Engine must be running and selector in position N or P Checkladjust Idle 12 5 0 8 rIs 750 50 rl min Fast idle 87 1 7 rIs 5200 100 rlmin If necessary refer to page 129 X33 Engine controls throttle cable and kick down cable Auto If necessary refer to page 176 Important If engine has been disassembled cylinder head bolts must be check ...

Page 125: ...C Oils with designatians SE CC SE CD SF CC and SF CD fulfil this requirement 30 20 10 O 10 20 3 0 40 C 2 I 1 2 56 6 1 8 I 4 86 104 oF I SAE Owl3O 5wl3O 1 SA 10W 30 SAE lOW L O SAE 15W 50 SAE 2Ow SO SAJ 30 I SAE40 Nate SAE 15W 50 or SAE 20W 50oils are recommended for use in extreme driving conditions which involve high oil consumption and high oil temperatures e g mountain driving wiht frequent dec...

Page 126: ...illevel for leakage relief valve in pump Oil pump 18 19 Z2 General information OH pan cannot be removed from installed engine Consequently il is necessary to remove engine to re place oil pump Mark 1 on outer pump gear must face rear cover Oil pump is only available as a complete unit Spare parts are however available for relief valve Z3 Relief valve If oil pressure is not as specified check that ...

Page 127: ...ral AEl 14 131 altitude adjustment USA AD2 132 setting AD3 14 133 bett replacement AEl 14 136 removal AF1 11 140 installation AGl 17 143 Delivery pipes removallinstallation AHl 3 148 replacement AJ 1 10 149 Injectors malfunctions checking AKl 2 151 removal AK3 6 151 installation AK7 9 152 overhaul lincl testing AL1 l0 153 Cold start device AMl 2 155 Preheating system glow plugsl wiring diagram 197...

Page 128: ...oke emissions from Volvo diesels are generally lower than other vehicles it may be thought possible to increase engine performance by enriching the fuel air mixture Prolonged excessive enrichment will not increase power output but will in fact reduce service life of engine considerably Even moderate enrichment of fuel air mixture will sharply increase exhaust gas tem peratures and combustion press...

Page 129: ... otherwise readings will be incorrect Hang flexible hose from clamp as illustrated Connect hose from rubber bladder to sample pump Check sample pump operation Engine off AA5 Push in pump plunger fully Squeeze rubber bladder and check movement of pump plunger Nate Do not cover hole in bladder as plunger will not return fully Push in plunger fully after checking AA6 Insert filter paper in pump Unscr...

Page 130: ...t depress ac celerator pedal to such an extent that kick down is engaged Maintain constant speed for a few seconds and squeeze rubber bladder to operate pump Note Squeeze rubber bladder hard for several se conds to ensure that sample pump has been filled Do not cover hole in rubber bladder Repeat measurements Remove filter paper from pump AA9 Depress pump plunger fully and place a new filter paper...

Page 131: ...eck adjust idle 12 5 r s 750 r min AB2 AB3 SeaI adjustment screw and lock nu w ith paint after adjustment Check adjust fast idle 87 r s 5200 r min AB4 Seal adjustment screw and lock nut with paint after adjustment Do not race engine longer than necessary AB5 Disconnect tachameter AB6 Checkladjust engine cantrals Always checkladjust engine con trols after adjusting idle speed See instructions on pa...

Page 132: ...n dean fuel flows through retighten bleed screw Replacement Special tool 2903 AC2 Use strap wrench 2903 to remove filter Place strap as near as possible to base of fi lter see fig smear diesel oil on new filter seal tighten filter by hand until seal contacts body Then tighten a further 1 4 tum start engine and check for leaks Ifseal is not tight air will be drawn into fuel system and cause POOT ru...

Page 133: ... following adjusting idle and fast idle adjusting injection timing For more detailed repairs and adjustments the pump must be removed and tested by specially trained per sonnel on a special test bench Smoke density regulations for Sweden Fuel regulating screw is sealed at factory Notel Fuel supply may only be checkedJadjusted on a test bench by trained persanneI 131 ...

Page 134: ...er adjustment a decal must be affixed to the firewall beside the emissions information deca1 and also to the injection pump If vehicle owner moves from low to high altitude area the vehic1e should be readjusted for high alti tude driving Vehicles adjusted for high alliludes must be read justed for low altitudes if vehicle is to be principally used at low altiludes The high altitude decals must als...

Page 135: ... to remove cold start device and reset it on a test bench Push lever back against stop AD5 Turn engine until cyl 1 is at TDC injection Always use the vibration damper centre balt to turn the engine Use a 27 mm socket Mark in pump gear should be opposite mark in moun ting bracket Flywheel at O mark AD6 Place dial indicator in injection pump Unscrew and remove plug from injection pump distributor In...

Page 136: ...djusted for high altitude driving reter to page 14 AD9 Readjusting pump setting Setting values 020 0 80 mm 0 0315 in 024 0 70 mm 0 0276 in 024 USA and Canada 1979 1981 0 70 mm 0 0295 in 1982 0 85 mm 0 0335 in Reading less than specified Slacken pump mounting bolts and turn pump inwards to obtain correct value Tighten mounting bolts and repeat check of pump setting Reading more than specified SIaek...

Page 137: ...08 and recheck Remove dial indicator and holder Install plug with new seal Tightening torque 9 Nm 6 5 ft Ibs Install rear timing gear cover Reconnect cold start device ADll AD12 AD13 AD14 Press lever forwards and turn sleeve 90 Retighten screw 1 Nate Do not turn screw 2 otherwise it will be necess ary to remove cold start device and reset it on a test bench 135 ...

Page 138: ...ark in pumpgearshould be opposite mark in mount ing bracket Flywheel at O AE3 lift off pump belt Slacken mounting bolts for injection pump braeket to release belt tension Tighten one bolt so that pump remains in upper position Lift off belt AE4 Remove camshaft rear sprocket Hold sprocket in position with 5199 and unscrew sprocket with wrench 5201 Take care not to rotate camshaft Install center bol...

Page 139: ...n ing pum p Retighten mounting bolts AE7 Set dial indieator zero lock pump gear at evl 1 injeetion using stop 5193 Unscrew and remove plug from injection pump distributor Install holder 5194 and dial indicator measuring range 0 3 mm Set gauge to approx 2 mm Turn pump gear clockwise until mark on gear and mounting bracket coincide Then turn pump gear back slightly until min reading registers on dia...

Page 140: ... 1979 1981 0 70 mm 0 0276 in 1982 0 85 mm 0 0335 in Vehicles adjusted for high altitude driving refer to page 132 Hold sprocket in this position and torque balt to 100 Nm 73 ft Ibs Takecare that camshaft and sprocket do not move AE10 Remove stop 5193 from pump gear AEll Check pump setting Turn engine two full turns until cyl 1 is at TDC injec tion again If engine is turned too far it must be turne...

Page 141: ...indicator shows approx 020 0 70 mm 0 0276 in 024 0 60 mm 0 0237 in 024 USA and Canada 1979 1981 0 60 mm 0 0237 in 1982 0 75 mm O 0295 in Then turn pump inwards until specified value is ob tained Tighten mounting balts and recheck pump set ting Importanti Injection pump musl nol be tapped or knocked as Ihis will alter ils setting AE12 Remove diaI indicator and holder 5194 Install plug with new sea ...

Page 142: ...or cold start device Clamp hoses with pliers 2901 prior to removal throttle cable and kick down cable aulo from pump wire from fuel valve AF2 Remove rear timing gear cover AF3 Disconnect fuel delivery and return lines from pump Clean connections thoroughly before disconnecting them Plug ends of fuellines to prevent dir entering fuel system ...

Page 143: ...ing pipes Remove all delivery pipes and plug ends to prevent dirt from entering fuel system AF6 Turn engine until evl 1 is at TDC injection Always use vibration damper center bolt to turn engine Use 27 mm socket Mark in pump gearshould be opposite mark in mount ing braeket Flywheel at O AFl Lift off pump belt Slacken mounting bolts for injection pump bracke to release belt tension Tighten one bolt...

Page 144: ...te camshaft Install center balt hand tight 1t should be possible to turn sprocket on camshaft without camshaft rotating AF9 Slacken pump gear Use 5193 to hold gear and slacken nut with wrench 5201 Remove nut and washer AFlD Pull off gear Use puller 5204 and stop 5193 AFl1 Remove pump Remove front mounting bracket from engine Remove pump from rear mounting bracket Allen key 6mm ...

Page 145: ...en retaining balts for pump mounting bracket AG2 Install pump gear Do not forget to place key in pump axle Install gear washer and nut Torque nut to 45 Nm 33 ft Ibs Use 5193 to hold sprocket and 5201 to tighten nut Torque wrench should be at right angles to wrench 5201 otherwise torque will be incorrect AG3 Diseonnect eold start deviee Slacken screw 1 Push lever forward and rotate sleeve 90 Note D...

Page 146: ...acket AG5 Install pump belt Adjust tension by moving coolant pump Use gauge 5197 to check tension Attach gauge to belt and set to 12 5 uniIS Stretch belt until mark on gauge plunger is flush with sleeve Depress belt strongly with hand and recheckladjust tension AG6 Set pump and tighten camshaft rear sprocket Use 5199 to hold sprockel Torque wrench should be at right angles to w rench 5201 otherwis...

Page 147: ...g 10 instructions below Readjusting pump setting Setting values 020 0 80 mm 0 0315 in 024 0 70 mm 0 0276 in 024 USA and Canada 1979 1981 0 70 mm 0 0276 in 1982 0 85 mm 0 0335 in Reading less than specified Slacken pump mounting balts and lurn pump inwards to obtain correct value Tighten mounting balts and repeat check of pump setting Reading more than specified SIaeken pump mounting balts and turn...

Page 148: ... 2 otherwise it will be necess ary to rem ove cold start device and reset it on a test bench AG11 Fill injection pump with diesel fuel Only necessary if pump has been drained or new pump installed Filter fuel before use AG12 Install rear timing gear cover Clamp wiring harness to left side retaining balt on cover AG13 Reconnect tuel delivery and return lines Do not interchange connections Return li...

Page 149: ...rque 25 Nm 18 ft Ibs Install plunger and vacuum pump Check O ring replace if necessary Connect AG14 AG15 AG16 hoses to cold start device Aemove clamping pliers wire to fuel valve throttle cable and kick down cable auto AG17 Set throttle controi See instruction on page 176 operations AX1 AX9 4 ...

Page 150: ...e vacuum pump and pump plunger delivery pipes Important Blank off ports and pipes to prevent entry of dirt AH3 Installation connect delivery pipes Tightening torque 25 Nm 18 ft Ibs l pump plunger and vacuum pump Checklreplace O ring check function and security A few seconds is re quired before pipes are bled and engine runs smoothly ...

Page 151: ...aced 133 480 AJ Clean all connections carefully Blow dry pipes AJ2 Remove vacuum pump and pump plunger Remove pump retaining balts Place pump on wheelarch and withdraw plungerfrom cylinder head AJ3 Mark position of clamps on pipes Location of clamps is important Incorrectly 10 cated clamps can cause vibrations and tuel supply problems may result AJ4 Disconnect all pipes 149 ...

Page 152: ...connections at this stage Check position of rubber sleeve on pipe Install clamps Tighten pipe connections Tightening torque 25 Nm 1 8 ft Ibs Install pump plunger and vacuum pump Checklreplace O rings Check operation and leakage AJ6 AJ7 AJB AJ9 AJ10 A few seconds is required before pipes are bled fully and engine runs smoothly ...

Page 153: ...injection operation Aun engine at above idle speed AK2 2 Loosen cap nuts on injectors one at a time Wrap absorping paper around injectors to prevent spillage If engine speed remains constant or if knocking disap pears fault may be defective injector defective heat shield leaking delivery pipe Removing injectors See specifications for idant lflcatio n of injecto r typa Jl Injector complete 06813020...

Page 154: ...sconnect ing pipes AK5 Disconnect delivery pipes Blank off ports and pipes to prevent entry of dirt Remove injectors 27 mm sockel Remove heat shields from cylinder head Installing injectors Position injectors Remove soot etc from sealing surfaces AK6 AK7 Place new heat shields in cylinder head see fig Tor que injectors to 70 Nm 50 ft Ibs Reconnect delivery pipes Tightening lorque 25 Nm 18 ft Ibs I...

Page 155: ...lzle eleaner equipment to dean nozzle needle and sleeve replaee damaged parts Nozzle needle and sleeve are matehed and must be replaeed together AL3 Assembly wash off rustproofing compund from new parts with clean petrol gasoline immerse parts in dean diesel fuel assemble injeetor Torque to 70 Nm 50 ft Ibs test injeetors Testing Injeetors should be tested with elean test oil or filtered diesel fue...

Page 156: ...lever fu lly 1 2 strokes per second Injeclor should bUll when fuel is emitted Check opening pressure Pressure gauge engaged All Slowly depress lever and check opening pressure Opening pressure check value 12 13 MPa 1700 1850 psil If incorrect leak test before adjusting pressure leak test Pressure gauge engaged Ory tip of injector AL8 Increase pressure to 11 MPa 1560 psi Maintain this pressure for ...

Page 157: ...ipment Cover end with protective cap AL10 Take care not to damage nOllie when installing injec tor AM Cold start device AM7 General Cold start device may only be adjusted on a special test bench when connected to injection pump However a service check can be carried out on an installed injection pump Note If cold slart device does nol function the follow ing will occur cold startin9 difficulties b...

Page 158: ...enoid valve Indiealor lamps for instruments o BL Y 1980 Colour eod e R red BL blue S6 black y yellow GN green Components A Temperature gauge sender B Fuel valve solenoid valve C Indiealor lamps instruments O Slarling switch E Glow plug F Glow plug relay G Blocking relay H Controi unit I Fuse box K Connection panel and service output ...

Page 159: ...A Y R E c 34 I 32 Group 23 Fuel system Preheating system 1979 1980 D K I Ill481 157 ...

Page 160: ...gs a even if controi unit malfu ImS68G888 ffi 8ma Il i G J 11 f SB f R t Fuse No 13 Turn signals and hazard warning lights Sea belt reminder 158 BL r B V BL R BL 1 1 Colour code A red E BL blue S8 black y vellow GN green c BL R 0 C le R 1 H T I it G 1 I SBl Components A Temperature gauge sender B Fuel valve solenoid valvel C Indicator lamps instruments D Starting switch E Glow plug F Glow plug rel...

Page 161: ...B _ E R BL L 8l BL Y H Group 23 Fuef system Preheating system 7987 8L 8t y R 159 ...

Page 162: ...Group 25 Intake and exhaust systems Contents Group 25 Intake and exhaust systems Contents Operation Intake exhaust systems AP1 2 Exhaust pipe and silencers ARl JJ D24 160 DZO Page 161 162 ...

Page 163: ...itted to vehicles manufactured before July 1981 Note Intake manifold mating surface must be cleaned before installing seaI PIN 1257809 2 APl Intake manifold Allen screw 6 mm Turn gasket with green side facing cylinder head Tightening torque 25 Nm 18 fl Ibs Arrow on intake manifold hose must point towards manifold otherwise crankcase breather hose may con tact bannet hood Exhaust manifold Always us...

Page 164: ...ing pipe only on early 245 modelsl Installing complete exhaust system AR1 Foflow instructions below to ensure stress free in stallation of exhaust system 1 Slacken two bolts securing mounting bracket to gearbox transmission 2 Position front pipe and tighten nuts and bolts for front pipe branch pipe 3 Tighten retaining bolts for mounting braeket front pipe 4 Tighten two bolts securing mounting brac...

Page 165: ... Group 26 Cooling system Contents Cooling syslem lesling Coolani general draining filling Thermostat replacement g Coolant waler pump replacement o I o Operation Page ASl 164 An 164 AT2 9 165 ATlO 12 167 AUl 168 AU 168 AVl 23 169 163 ...

Page 166: ...rrosion damage Use genuine Volvo blue green coolant type C diluted with clean water in proportions of SO 50 This mixture helps to prevent corrosion and frost damage Never fill the cooling system with water alone The coolan should be changed regularly since the corrosion prolective additives in the coolant lose their effect in time Note Do not Tun engine when level of coolant is low since high loca...

Page 167: ...methods for drain ing coolant 1 with flushing and 2 without flushing prior to filling type C coolant 1 Draining coolant without flushing cooling system AT2 Disconnect battery ground lead AT3 Jack up vehicle To prevent spillages when coolant is drained raise vehicle at front right jacking point Coolant will then run alon9 splashguard into drip pan Place drip pan beneath left steering rod Drain cool...

Page 168: ...ine behind splashguard I Disconnect lower radiator hose from thermostat _ lt housing Disconnect hoses from heater controI valve on fi rewall Point lower hose down Flushing AT6 Flush expansion tank clean AT7 Flush engine clean Connect upper heater hose at rear to tap and flush engine until clear water appears at lower heater hose Continue to flush for a furtheT 2 minutes ...

Page 169: ...valve Filling AnD Bleeding of cooling system Disconnect upper hose from cold start device Place drip pan beneath hose and hold hose level with top level of expansion tank ATJ1 FiII coolant Capacity 020 8 1 litres 18 6 US quarts 024 9 3 litres 19 8 US quarts Set dashboard heater controi to MAX Add coolant through expansion tank cap Qnly type C blue green coolant is to be used Turn on engine and war...

Page 170: ...j 8mm r 102 1 lO 168 Replacement replace thermostat and seaI arrow on thermostat must point up Testing If necessary test thermostat in hot water Thermostat should start to open at 87 C 188 F AUl AU2 be fully open at 102 C 216 F Min opening gap 8 mm 0 3 in ...

Page 171: ...t jacking point Coolant will then run along splashguard into drip pan Place drip pan beneath left steering rod Orain coolant No drain taps on engine Unscrew expansion tank cap AV3 Disconnect lower radiator hose from radiator Discon nect lower hose from thermostat fo r cold start device and drain coolant l ower vehicle Remove radiator cooling fan with spacer and pulley fan belts and power steering ...

Page 172: ...clockwise Use wrench 5187 AV6 By turning engine anticlockwise slack in bell will move to driving side making il easier lo remove and install bell AV7 Remove vibration damper Remove 4 balts arrowed Allen key 6 mm Pull off vibration damper Note crankshaft gear may sometimes stick to vibration damper AVB Remove lower timing gear cover AV9 Detach mounting bracket for cooling fan and alternator and pla...

Page 173: ...on as found otherwise al es may contact pistons and cause serious engine damage AVll Remove gear belt Slacken coolant pump mounting bolts and belt Coolant may leak when balts are slackened Lift off belt AV12 Remove coolant pump Aemo e cover panel and retaining balts for coolant pump Move panel to one side and remove pump Take care not to crack panel AV13 Clean Clean contact surface for pump on cyl...

Page 174: ...uld only be attached loosely at this stage AV15 Install cover plate retaining balts mounting bracket for cooling fanIalternatar AV16 Install gear belt Make sure that belt is fitted in exactly same position as before Align identification marks on belt camshaft sprocket and crankshaft gear It is extremely important that belt is fitted in exactly same position as before Tension belt by moving coolant...

Page 175: ...m 255 ft Ibs Important Torque 350 Nm applies only ifwrench 5188 is used Also torque wrench must be in line with wrench 5188 AV19 Set belt tension Turn engine approx 1 4 lurn anticlockwise Adjust tension by moving coolant pump Use gauge 5197 to check tension Attach gauge to belt and set to 12 5 units Stretch belt until markan gauge plunger is flush with sleeve Depress belt strongly with hand and re...

Page 176: ...20 8 1litres 18 6 US qua rIs D 24 9 3 litres 19 8 US quarts Sel dashboard heater contraI lO MAX Add coolant through expansion tank cap Only type C blue green coolant is lo be used Tum on engine and warm up for 5 minules Expan sion tank cap removed Add coolant during this time Connecl hose l o cold start device Fill coolant to moulh of expansion tank above max and screw on cap again AV23 Replace de...

Page 177: ...Group 27 Engine controIs Contents Group 27 Engine controls Contents Operation Engine controis adjustment AXl 9 Page 176 133496 175 ...

Page 178: ... rotate sleeve 90 Nate Do not turn screw 2 otherwise il will be necess arv to rem ove cold start device and reset it on a test bench AX2 Disconnect link rod from lever on injection pump AX3 Adjust throttle cable Turn cable nut unlil cable is taut Position of throttle drum must not be affected drum must contact idle stop AX4 Check full throttle position Depress accelerator pedal to floar Throttle d...

Page 179: ...od to lever Adjust link rod full throttle position Tum throttle drum to full throttle position AX6 AX7 Adjust length of link rad so that pump lever contacts adjustment screw for fast idle AX8 Adjust link rod idle position Release drum so that it contacts idle stop Adjust link rad ball joint so that injection pump lever contacts idle low adjustment screw AX9 Readjust link rod Repeat operations X6 a...

Page 180: ...Idle speed adjustment Injection pump general altitude adjustment USA setting drive belt replacement removal installation lnjectors malfunctions remova l installation reconditioning and testing Intakemanifold Kick down cable Operation AN1 ADl AX8 AD AD2 AD3 14 Cll 20 AE1 14 AF1 11 AG1 17 AKl 2 AK3 6 AK7 9 All lO APl AX5 64 168 166 67 Oil pressure check reliefvalve Z1 64 64 168 69 96 103 32 47 48 57...

Page 181: ...s heavily after replacing fual injection pump Engine datters heavily after replacing or repairing injectors or fuel delivery pipes Excessive smoke Black smoke White smoke o ooooo ooo o o oo oo o ooo o o oo o o o o Blue smoke o o o o o o o o o Injectorso o oo o o o o oo o o o o Cold start device o o o oo o oo o o o o o o o o o Fault tracing pre heating glow plug system Complete check of pre heating...

Page 182: ...Injection pump sucks air tleakage between tuel tank and pump Fuel leakage leakage between pump and delivery pipes or other externai tuelleaksl Ice or paraffin in tuel lines or fuel filter wintertimel Injection timing incorrect Pre heating system see wiring diagrams Cold start device Faulty injection pump Fuel filter blocked drain condensation water Fuellines blocked Faulty injectors Mix up of holl...

Page 183: ...ngaged Engine cannat be stopped The fuel valve stopping valve in the injection pump does not close It is a solenoid valve Increase momentarily to high engine speed and try again to switch off the start key If this does not help Vehieles with manual transmission Engage 3rd or 4th gear depress the brake pedal and release the clutch pedal Vehicles with automatic transmission Use the emergency stop le...

Page 184: ...s have longer time to condense cont White exhaust smake cont NOTE White exhaust smoke can alsa be caused by wa ter leaks inta the exhaust system or cylinder head Possible causes for white smoke Pre heating system glow plugs not operating low compression pressure low operating temperature Defective injectors l ate injection timing Water leakage cylinder head gasket Cold start device not operating B...

Page 185: ...ut Uneven idle Black exhaust smake High fuel consumption Checking injector operation Run the engine at increased idle speed 2 Leasen the cap nuts at the injectors one at a time Wrap absorbing paper round the injectors to pre vent fuel spill If the idle speed remains stable or if knocking dis appears the fault might be defective injector defective heat shield leaking delivery pipe For further test ...

Page 186: ...of cold start device matfunction Cold engine hard to start Engine does not start at temperatures below lO C 14 F Blue white exhaust gases Operation check Check idle speed cold and at normaloperating temperature 1 With cold engine below 20 C 70 F engine idle speed should be approx 950 rpm 200 rpm more than warm 2 With engine warm at normaloperating tempera ture Engine idle speed should be 750 rpm T...

Page 187: ... position IL To repeat astarting attempt the start key must be turned back to position I to switch on the pre heating system The system also comprises a blocking relay on 1980 modeis on 1981 and on this function is part of the controi unit It will interruptthe electrical circuit between the controi unit and the relay for the glow plugs when the alternator starts charging Fault tracing pre heating ...

Page 188: ...cator light ON Test light ON Proceed on FT3 next FTJ Check ON time for indicator light and test light Turn start key to intermediate position I and then to driving position II ON time for indicator light should be according to coolant temperature see diagram For engines prior to 1981 Test light atglow plug terminals should remain ON for approx 20 seconds after indicator li ght is OUT For engines 1...

Page 189: ...y controi unit No voltage Indicates open circuit between connector and controi unit Connector located under carpet next to controi panel left support Test light ON Proceed on FT5 next FT5 Check glow piugs one by one Start key in position O Remove the bar between the glow plug terminals Connect the test light across battery PLUS and one glow plug at a time to check that current passes through the g...

Page 190: ...T7 Check ground terminal 31 of the controi unit Black wire Connect test lamp across battery PLUS or fuse box PLUS terminal and terminal 31 of the controi unit Test light should illuminate No voltage Indicates fault in ground connection Voltage Indicates controi unit failure 128530 FT2 se B voltage terminal 86 Indicator light ON Test light OUT Indicates failure at the glow plug relav Fr8 Check volt...

Page 191: ...y Yellow wire Use test lamp to check voltage Test light should illuminate Voltage Indicates open circuit in wire between blocking relav and glaw plug relav No voltage blocking relav does not operatel 128636 Proceed on FT 12 next voltage terminal 86 1 I I 128636 FT12 Check voltage at terminal 86 of the blocking relay 1980 only Blue vellow w ire Use test lamp to check valtage Test light should illum...

Page 192: ...indicator lamp OR defective wire between controi unit and indicator light OR fault in the instrument printed circuit No voltage Indicates Defective controi unit OR grounded wire between temperature sender and controi unit _______ Indicator light illuminates when engine is warm_______ Al0 Preceding fault tracing assumed that engine temperature was below 40 C 1000 F and that the faults occured withi...

Page 193: ...Starter motor operating D Glow plug system Diesel 1980 Glow plug system Diesel 1980 Legend A Temperature sensor B Stop valve C Indicator light D Start switch E Glow plug F Glow plug relay G Blocking relav H Contral unit I Fuse box K Ramate starter pick up point Start key ON Coolant temperature below 50 C 122 F Engine running iii 130836 A11 ...

Page 194: ... A green E bZue red B c ye ZZO 34 31 ______ _ J r L F A12 u 130837 _______ l 1r 1 Z J G I red 87 85 K 15 T D K b ue bZue blue Hue blue yelLow ...

Page 195: ...ure below 50 C 122 F Glow plug system Diesel 1981 Glow plug system Diesel 1981 Legend A Temperature sensor B Stop valve C I diestor light O Start switch E Glow plug F Glow plug relay G Remote starter pick up point H Contral unit Fuse box Engine running II 133238 A13 ...

Page 196: ...Glow plug system Diesel 1981 A14 E II 133 239 B _ 86 F r bt yeU D ...

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Page 199: ... AS CERTIFIED VOLVO SUPPORTS VOlUNTARY MECHANIC CERTIFICATlON BY THE N I A S E U S A only Service literature Your most Important special tool ...

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Volvo D20, Service Manual

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