VOLVO D24 Engines Repair Manual

7/21/2019 VOLVO D24 Engines Repair Manual

http://slidepdf.com/reader/full/volvo-d24-engines-repair-manual 1/96

Group21 Engine

Crankshaftear seal, eplacement

S.

Grankshaft ear

seal, eplacement

Special ools: 1801,

112,5203,5208

s?

Remove

gearbox/transmission

SeeService anual ection (431.

Secure tanermotorwith

a bolt.

Manualgearbox:

s2

Remove

ressure

plate

and driven

plate

Unscrewpressure

late

ountingoltscrosswisea

ew

turnsat

a

ime

o

prevent

arp.

Manualgearbox:

Remove

lywhe€l

Automaticgearbox:

Remove arrier

plate

Use ocking

ector

112

o

ving.

prevent

ilywheel

from

mo-

s3

s4

Remove

rankshaft

ear oil

seal

Lift

out oil seal

with a

screwdriver

s ndicated.

Clean

nd



Group21 Engine

Crankshaftearseal.

eDlacement

s6

Installnew

oil seal

Assembletandardandle801 nd ri ft 208.

Smearoi l onto seal ing ur faces nd l ips on seal .

Place ealon dr i f tand ap n

unt i ldr i f tabuts rankshaft .

s7

Install

f ywheel/carriei

plate

Flnrheel

manual)

ndcarrier

late

auto)

anonlybe

Usenewbolts, meared

ithsealer /N277961,9.

Torque ol ts o 75 Nm

(55

t lbs).Use ocking ector

5112 o hold lywheel

n

posit ion.

s8

Automatic

gearbox:

Check nstallation

measurement

t carder

plate

(To

be

caffiedout after replacement

f carrier

ptate.)

Place

steel uler

between arr ier

late

and engine

block.Fuler

should est

against ngine o

gearbox

mounting

lange nd

should est gainst oth

ides f

f lange. urn rankshaftnt i l neofholesncarrier late

coancidesith

steel u er.Measure

B"with anoutside

cal iper

quippedor depth

measurement.

Measured

alue

B'

+

thicknessf

steel uler hould

equal

17.2-18.8

mm

=

0.667-0.740n. f

distances ess

than 17.2

mm

=

0.677 n use

a spacerwasher

P/N

1257377'0)

etween

rankshaft nd carrier

plate.

l f

carr ier

late

s insral led

ncorrect ly

i .e.

nstattarion

measurement

s

wrong),

istanceo torque

onve er

cai i ier

wi l lbe oo ong.

hismaycause

arf ier

late

o

crack

nd

possibly

noisewhendriving.

(ir

A+B

=la:O,8mn

104



Group21 Engine

l : i

Crankshaftear seal, eplacement

Manualgearbox:

s9

Install

driven

plate

Use

entering

haft

203.

Turn

disc

with hub

acing

ut,

away rom

tywneet.

Manualgearbox

s10

Install

pressure

late

Tighten

olts rosswise few urns

at a time o avoid

s11

Install

gearbox/tmnsmission

Donot orget

o remove oltsecuring

tarter

otor,

1 0 5



Gtoup 21 Engine

Vibrati

on dam

per,

remov n

g/i

nstal

ng

T. Vibration

damper, emoving/installing

SDecial ools: 5187. 5188

Notel Different vibration

D 24 engines.

dampersor D 20

and

.

D20

D24

T1

Disconnect battery

T2

Jack-up ehicle

To

prevent

pi l lages hen oolantsdrained,aise e-

hicle t ront ight

acking

oint.

Coo

anl

wi l l hen un

along plashguardntodrip

pan.

Place r ip

pan

beneatheftsteerinsod.

f3

Draincoolant

Unscrew xpansionank ap.

Disconnectower adiator ose om adiatornddrain

(Ensine

s withoul rain aps).

(

r(

1 0 6



Group 21 Engine

Vibration dam

per,

removi

ng/i nsta l ng

T4

Disconnect:

cool ing an

with spacer nd

pul

ey

-

fan

beltand

power

steer i rg

pLrmp

eh-

T5

Bemove vibration dampea

Remove

enter

bol t . Use 5187 o

preventpuley

f forn

rotat ing, nd socket 188 o unscrew

bo s.

I t may be necessaryo

turn engine

ight ly

so hat5'187

rests

on

fan

bear ing.

Remove our inhex bol ts

(6

mm).

Pul lof f v ibrat iondamper.Notel Crankshaft

ear

may

somet imes t ick o vibrat iondamper.

T6

Instal l ibration

amper

Damper

anonlybe

i i ted r oneway.Pin

on crankshaf l

gear

n1ust i t

in v ibrat ion amper.

Torquebo

rs to 2 0 Nm

115

t

bs) .

T7

Instal l

center bol t

Smear threads

and

mat ing

sLrr face i th sealer P/N

277961

L

Usewrench

5187

resl

on cooi ing an

bear ing) tohold

Use wrench 5'188 o torque

center bol t to 350 Nm

(255

t lbs) .

lmportanr: orque

350Nm appl ies

nly f wrench5188

is rsed. sotorquewrenchmustbein inewithwrench

5188.

107



Group

21 Engine

Vibration dam

per,

removi ng/i

nstal ing

1 0 8

T8

Instal l :

-

cool ing anwith spacer

nd

pul ley.

ighleningorque

9 Nm

(7

t lbs)

-

bel t or

power

steer ing

ump

and an be s

-

fadiator. Connect

hoses

Bleeding

of cooling system

Disconnect

pperhose ro m coldsiart

drip

pan

beneath oseand hold hose

edge f expansionank.

T9

{))l

t i

rl

I

Coolant

Sincea Lrminiums used n the engines, ct ivecorro

sion

prolect ion

s necessaryn the coolant o help

pre-

venr corrosron amage.

Use

genuine

Volvo blue-green oolanl ype C, di luted

with

cle.n

water in

propo(ions

of 50/50.

This mixlure

helps to

prevent

cof tosion and i rosl

damage.

a

Never i l l the cool ingsystemwilh wateralone.

a

The coolant houldbe changed egular ly inc e he

corrosion

protect ive

ddi t ives

n the coolant ose

their

effect

in

time.

Notel Do not run enginewhen evelof coo anl as ow,

since high local emperatures an resul twhich mav

cause he cyl inde.head o crack.

,lr

l



Group

21

Engine

srYoorT

rtt

3(rc rfrrRfY[rfi rurr *t0

ai otL ^firr or| rfr 0rr

v0rv04v^rsu

TYr

artto wrTN

tr0r|r lrol\to

cooullr

Pt

m d d ] w F .

i$rPU

r LrourorrrGft

voLvo

rc

Mollrt ALr0n€ Ar{TrcrLiPr

c

Vibration damper,

removing/installing

Beplacing

coolant

Always

use ype

C blue-green

oo ant. Remember

o

repiace ecal P/N1331473,7)n exansjonank f neces-

Typ€

C blue-s.een

coolant

Al diesel

nd

petrol

9aso

ne)engines

manufactured

since1982

are i led with

rype C

cootant.

Fi l l coolant

Capaci ty:

D 20

=

8.1 i lers

8.6

D 24

=

9.3

i ters

9.8

US

US

710

Flush

ool ingsystembefore

adding new coolant ,

ee

Group26 Cool ing

System.

Set dashboard -eater

onnol Io ma\. TLrn

or engine

and warm-up

or 5 minutes.

Add coolantdur ing his

l ime.

Connect ose o

cold star tdevice.Fi l l

coolant o

mouth of expansion

ank

(above

max)

and sc rew on

1 0 9



21 Engine

U. Enginemounts,

eplacement

D ferent

brackets or munLal

and automat c

gearboxes

U1

Rear

nginemount

gearbox

ount)

Necessaryo removegearbox

member

o remove ear

Gearboxmust be un oadedwith

a

jack

dur ing eplace-

U2

Front

engine

mount

Unload nginemountswnh i f t tools

033

2x),5005and

5 1 1 5 .

Left

side

To replace

ubber

pad:

remove

upper

and rower

brackers.

U3

engine

f i rount wnh

I

e

q

Right

side

To replace

ubberpad:

remove

upperbrackel

, ,u uD-

ber

pad

togethe.,

o

not remove

ower

bracker.

Do

not l ighten

upper

nul for rubberpad

t]nt i

engine

mounl is

posi t ioned.

,r))

rr)l

O,

r

0



Group21 Engine

Removing

engine

V. Removing

ngine

OperationsV1-7

Speci l tools 281 , 5185,

51 6

Ensine

nd

gearbox

emoved sa unit

v1

Remove

ngine plashguard

nddraincoolant

v2

Remove/disconnecti

r positive

lead from

battery

2 bonnet

hood)

3

expansion

ank cap

4

lower radiaior

hose from

radiator

Auto

{operation

5) l

5 oi l

p ipe

from oi

cooler .Hold

connectors n oi

coo

er wi lh

a wrench. t f

accidenia s ackened,

torque o

6 Nm

(4.5

t tbs)

6 upper adiatorhose

rom engine

7 hoses

o €xp ansion ank at radi tor

8 radiator

t hoses

rom heater ontrolva lve

10 hose

rom vacuum

pump-

1 r l



Group

21 Engine

Removing

engine

Remove/disconnect

2

3

v3

Remove/disconnect

A

connecior

rom cl lp on bulkhead

f i rewa )

B

throt t le abLe

rom

p l ley

and

bracket

Fuel l ineconnect ions

(C

E below) i

Blow-c

an,

disconnect nd

plug

ends

o

prevent

drr t

entering fuel system

C supply ine

rom fuel i i l ter return ine rom

njec

t ion

pump

(at

clamp)

E

p

aLe

alav

or pra heal i rg

svsrPT

01

Fno

1o.

Disconnect

wire l ronr

junci ion

box.

Disconfecl

blackwire and sma

I redwire rom relay.Unscrew

retaining crews rom relay.

remove

power

steer ing

ump

fom engine:

s ack-

en and

remove dr ive bel t f rom

purnp.

Bemove

p r f p s i r L b r a r \ e _ ' r d L p p o r t r o y r o 1 F 1 g -

Tie

pump

to chassis o

prevenl

damage o hoses.

cool ing

an with spacer

p u l e y

a n d

a n b e l t s

be for

power

sieer ing

pump.

i)t

a

rta

v4

crankcase

reather ose

air

i l ier

cove. and

hoses

a iefnatorwir ing

harness:

dlsconnect o ta9€ reguaior

(or

a

ternalor) .

Remove elainingsc.ews or wir ing harnesson

whee

arch and

p

ace harness n engine.

Vehicles or Sweden:

5

T-searuni t on bulkhead

f

rewal l )

6 exhaust

ipe

rom front exhausl

ranch

pipe

D

20

hasonly

1

man

fold) .

;

il

112



Group21

Engine

Removing

engine

0

v5

Drainengineoi l

lnstal l lug nd washer f ter raining i l .

-

enginemount

etaining ol ts

rom ront

axte ross-

Lef t

ngine ount: emove

urs rom

rontaxte

ross,

Right nginemounti

emoveower ui

rom ub-

engine

v6

Remove/disconnect

-

f ront exhaust

pipe

clamps

-

disconnecl xhaust

pipe

coupl ing.Remove

ront

ex-

-

(manual)

lutchcableand

gear

ever

-

(auto)

elector ontrol rom

searbox/ l ransm

sion

speedometer able

-

gearbox

fossmember. osi t ion

jack

beneath

eaF

Removing

0

0

(f

V7

Use i f t ins ools

801,5185

at

ront)

nd5r86

ar

ear) .

Li f t

engine nough

o unload

eftengine

mount.

Rertrove

nginemount.

Remove

ack

beneath

earbox,

t ide

pu

ey

uni t for

wards

nd i f i

ourengine.

C

s

=-€>

{"F

-'-2"

;#

-

disconnect

i r ing.

1 1 3



Gtoup21 Engine

Removing engine

X. Removing

ngine

Operations 1-3

Specia

tools 281 , 5185,5186

Engine

nd

gearbox

nstal led s a uni t

x1

Position

ngine

Use i f t ools2810, 1a5

at

ront)

nd5186

al

ead.

Posit ionight

ide

ubber

mounton owerbracket.

x2

Install eft

enginemount

Placemount on f ront axle

crossmember nd t ighten

x3

Place a

jack

beneath

gearbox

Makesure

hat

ubberfoam

ad

tgear everis orrect-

Insenwiring nto

passenger

ompartmeni.

Jack-up

earbox

nti l evel.

Remove lifling tools

Lower ngine nd emoveools.

1 1 4



Group21 Engine

\

Removing engine

x5

Install

gear

ever

Place ear ever n housing.

Press

last ic

ol larand

rubber ing nto

posi t ion.

nstal l

lock ing.Reconnecl ar ing.

Instal l racket or reverse

ear

detent.Do not t ighten

screws atthis stage

since

bracketmust

be adjusted at a

0

X6

Installnuts tor engine mounts

Leftmount: utsn iontaxle rossmember.

Rightmount: lower nul

on

rubber

pad.

Install

gearbox

crossmember

x7

x8

Install

n

gearbox:

_

gear

ever. Make ure hat bushings nd Oj ing

are

co ecl ly

nstal led.nsen

ear

evel n

yoke,

t

pin

and

t ishtenscrew

Al len

key 4 mrn),see nset

-

propel ler

haft .Alwaysuse new nuts and bol ts

speedometer

able.Sweden:wire must be sealed

t

gearboxto

onform o ax egulat ions

ki lomerertaxa,

1 1 5



Group21 Engine

Removing engine

X9

Connect lutchcableand install return spring

Insertcable hfough

f lywheel casingand connect

o

lnstal l ubber buf fer and

vibrat iondamper

on cable,

making

sure hat buf fer s

facing ight way.

Connect

eturnsPr ing.

Adjust

play

=

1-3 mm.

(0.04-0.12

n)

A0tomatic

gearbox

Attach

gear

selector

to

gearbox

x10

DI

x l1

Install ront exhaust

pipe

For

strainjreenstal lation,

nstrucrionsust

be ol

1 Slacken wo retainingbol ts holding bracket o

gearbortransmission

2

Attach front exhaust

pipe

fingef tight. Use new

3 Tighten nuts and bol ts holding exhaust

pipe

to

4 Tightenbolt holding ront

pipe

o bracket

5 Tightenbolts holdingbracket o gearbox

6 Tighten

clampat exhaust

pipe

oint .

{))

0D

Carsforsweden

xl2

Attach T-gearunit to

bulkhead

firewall)

1' ,16



Group21 Engine

Removing

engine

x13

Connect

lternatot

wiring harness

Reconnectvoltage

regulator.

At tach

clampon

wheelarch.

x14

lnstall air filter

cover

Reconnect

ir inlet

hoseand breather

ose o

valve

Notethatarrowon

nlethose

ust

oint

owa ds

mani-

fold as ndicated,

therwisehose

may be compressed

x l5

Install drive bells and cooling fan

Place

ower

steer ing

pump

bel l on vibrat ion

damper.

Instal l fanbel tsand

pul ley-

Install cooling fan with spacer.

Torque to 9

Nm

(6

5

ft

lbs) .

Tension an bel ts. l tshould

be

possibleto

depress

el t

5-10

mm

on

run between fan and

alternator, see

fig

x16

Install

powe.

steering

pump

and belt

Negativeead rom battery

houldbe connected

o

lower

ront etaining olt or

pump

mounting racket.

Tension an belts.lt shouldbe

possible

o depress elt

F10 mm

(0.2-0.4

n) n center f runbetweenanand

x17

Connect

elay or

preheating

ystem

Connect lackwire o terminal 6 on relayand red

wire

to terminal85.

Attach relay

to

washer

reservoir mounting bracket.

Reconnect i r ing to

junct ion

box.

Secure wires with clamps and reconnect battery-

1 1 1



Group21 Engine

Removing

engine

Reconnect uel lines

Make

ure hat

di r tdo esnot enter uel system.

x18

x19

x20

x21

x22

Reconnect

lug

on bulkhead

tirewall)

Secure

lug

with

cl ip.

Reconnect:

-

hoses o heater control valve

-

hose o vacuum

pump

lnstall radiatorand

connecthoses

Automatic

earbox

Connect

oil

pipes

o oil cooler

Usea wrench o hold connectorc

n oi l cooler .

Tightening orque

Capnuts

30

Nm

(22

t tbs)

Oi l cooler

onnect ions Nm

{4.5

t lbs) .

' .,r

m

1 1 8



Group21

Engine

Bemoving

engine

lnstall bonnet/hood

Connect asher ose,

Reconnect

ailery

Manualgearbox

Adiust

blacket or

reverse

gear

detent.

rubber

gaite.

x25

lnstall

Engagefirst ear.

Ad,ust

clearance etween

ear

ever

and detent

brackerto .5-1.5

mm

(0.020-0.060

n).

Use

a feelergauge.

Tighten

etainingbolts.

Recheck

learance

n s€cond

gear,

Install

ubber

gairerboot.

Automaticgeatbox

Check/rdiusi

geaa

elector

'1.

Checkthat

learance

etween

osition

D

andstop

is approximately

ameas rom

2 to

stop.

2.

Adjust

by altering

ength

of controt

rod if neces,

Rough

adiustment:

urn

adjusrer t re6r

of rod

Fine

adiustment

tu n serrared

teeve

max

visibte

threadenslh= 35mm).

hcreasing od

ength

educes

tea ance n

position

D, and ncreases

learancen

posjtion

2.

After

adiusrment:

move

tever o

posirion

and

then o

position

P.Repeat

heck

ccordng

o stag

1 .

' 1 1 9



Group 21 Engine

Removing engine

x27

Add eng ine oi l

Capaci tync

uding oi l

f i l ler :

D 20

=

6l i t res

{6.3

US

quads)

D 24

=

7l i t res {7.4US quads)

Oua ty: according o APl, min cC

(oi ls

wirh designa'

l iors

SL/CC.

L/CD. l

/CC

drd Sr/CD

Jl ' i

r l -s eqL

re.

Viscosi ly,

ee adjacent iagram.

NotelSAE

5W 50 or SAE20W

50

oi ls

are

recommen

d e d i o r u s e i n e x t r e m e d r i v i n g c o n d i t i o n s w h i c h i n v o l v e

high oi l

consumpl ionand high oi l iemperatures .g.

mountain

dr iv ing with f re quentdecelerat ions r fast

motorwaY ir iv ing.

Note

however he lower empera

x28

Bleeding

I cool ingsystem

Disconnect

pperhose rom coldstartclevice. ace

drip

pan

beneath oseand hod hose evel

with top

edge i expansion

ank.

,))

'rl

Coolant

Sincealuminium s

used n the englnes, ct ive

corro,

sion

protect ion

s necessaryn the

coolant o help

pre-

venr

coros on osmage.

Use

genuine

Volvo blue green

coo anl type C, di luted

wi lh cleanwaler n

propor l ions

i 50/50.

This mixlure helps

to

prevent

corosion

and

frost

a Never i the

cool ng systemwith water

alone.

a The coolEnt houd

be changed egulary

ince he

corrosion

protect ive

cldi t ivesn the

coolant ose

their ef fect n ihe t ime.

NotelDonot on

ensine hen eve

oi coola. l

s

ow srnce

h

9h

oca

emperaturesc6nesurwhich aycausethecy

n.

i l |

i,

I

20



Group 1 Engine

oftcrrALirv isx rYP

$ rArYL

trr$flLr Ain iurr Mro li Dftv^nr|.ocH r 0rr

v0rr0

.varsu

'r

c

AI<'LI/IO COOLAilINPI

roP uPYladR0ur0 wf| F^tr r^r

itMfu

0r 0ur0rArr0n r/o'llro

Removtng

engine

Replacing coolant

Always use

ype C blue'green oolant .Bemember

o

replace

eca

(P/N

1331473-7)

n expansion ank f ne'

Type

C blue-green oolant

Al l d iesel

and

petro

(gasol ine)

nsinesmanufactured

since

1982are i l ledwith type C

coolant .

x29

Fi l l

coolant

Capaci ty:D 20

=

8.1 i t res

8.6

US

quarts)

D 24

=

9.3

ir res

9.8

US

quarts)

Flush ool ing

systembeforeaclding ew

cooiant , ee

Gro p

26 Cool ingSystem.

S e l

d 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

and warm-up or

5

minutes.

Add coolantdur ing his

t ime. Connect ose

o cold star tdevice. i l l

coolanr o

nrouth

of expansi on ank

(above

max)

and screw on

x30

Check/adiust

niect ion iming

See nstruct ionsn

page

24,c11-20

(rt

)

,4\\

_egt

x31

Checkoperat ion

Turnon engine ndwarmup.

C h e c k f o r o i l a n d c o o a n ia k a g e s . T o p

p i fn e c e s s a r y .

Instal l ngine pashguard.

121



Group21 Engine

Removing

engtne

Cold

gea&ox

o

I oiltemperatures o'C

104'F'.

This emperat re

s reached fterapprox,

10 minutes dl ns.

At oi temperatureseLow 0'C eve may be belowM N.

MIN

.96 '€

Hot

gearbox

o

I oit temperatlre 90'C

('194'F)

Automaticgearboxes:

x32

Check-top-up oil level

UseATF ype F or G.

Engine ustbe unning ndselectorn

posit ion

or

P.

x33

Check/adiust

ld le

=

12.510.8 A

:

750150 /min

Fast dle

=

8711.7

s

=

52001100

/min

l f

necessaryefer

o

page

129.

Engine

controls

lhrot t le

cabe

and kick-down

abte)

(Auto) .

f necessary

efer o

page

176.

lmportantr

f enginehas been disassemb

d cyl inder

head bol ts nust be

check ighienedafter 600 1,200

maes

1,000-2,000

m).

r,il)

iIil

a

122



Group 22 Lubricating

System

Group22

Lubricating

System

Contents

E ' 1 g i n e o i , o ;i l t e r . r a p a c e m e n t . . . . . . . . . .

O

lp.essure.

hecki lg

O l p L m p , g e r e r d l i n f o r r a l r o n . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .

Engine

oi l ,

oi l

f i l ter.

replacement

Operation

Y1 2

71

z1

22

Engine

oil, oil filter

1 2 4

Y1

Oil capacity litres

(US

quarts)

Excl .o i l f i ter

Incl .

o i l

f i l ter

Ouality

Accordingo API . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INCC

Oils

with

designations SE/CC,SE/CD,SF/CC nd SF/CD

ful f i l h is requiremenl.

D 2 0

D24

5_25.5) 6.2 6.5)

6.0

6.3)

1.O

7.41

1 . 0

1 . 0 )

1 . 0

1 . 0 )

Ternperatureange

{srable

mbient

emperat 'rres)

Note

SAE15W50orSAE20W

50oi lsafe recornmended

for

use in

extreme dr iv ing

condit ions

which Invotve

high

oi l consumpt ion

nd high

oi t te l r lperatures

.g.

mountain

dr iv ing wiht

f requent

deceterat ions

f fast

motorway

dr iv ing.

Note

however

he tower

empera-

ture imits.)

Y2

Oil filter

Useoi l i l ter

wrench 903

o removeit ter.

To nstal l f i l ter,

ee nskucl ions

n i trer.

l f onlyf i l ter is

eplaced

i .e.

otengineoi l ) ,

dd0.a i tres

(0.8

US

quarts)

f oi l .

123



Group

22 Lubricating system

Oil

pressure,

il

pump

Oil

pressure,

hecking

Oil pump

z1

Connect oil

pressure gauge

to connection

for

oi l

pressuresender

Oil

pressure

must

be 6t

least200 kPa

28

psi)

at 33

r/s

(2,000

min) and80'C

176'F)

i l temperature.

Rel ief alve n

pump

should penat 600-700 Pa

8F

99

psi)-

-

oi l evel

-

rel ief alve n

pump.

z2

Generalnformation

Oil

pan

cannotbe

removed

rom instal led ngine.

Consequenl lyt is necessaryo remove ngine o re-

Mark

A)

on outer

plmp

gear

must ace

ear over.

Oi lpump s onlyavai lables a complete nir.Spare

parts

are however

availableor relief

valve.

z3

Relief

valve

l f o j l

pressure

s

not as speci f ied heck hat

plunger

moves

reelyand hat spr ing s in

good

condit ion.

Rel ief

alve s accessiblerom below

with oi l

pump

instal led.

Tightenins orque40

Nm

(30

t lbs) .

(),il

{))r

l

h

a

g

I

-/)

€-ao

Nm

124



Gtoup 23

Fuel sysf€fi

Group

23 Fuel

ystem

Contents

Exhaust

as

moke

ensity,

eneral

.-.--. . . . .

. -

checking

'

ldle+ fast

dle

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

Fuel iltsr,draining

wate

r e p l a c o m e n t . . . . . . . . . .

Inject ion

ump, eneral

al t i tudeadiustment,

SA

senlng

. ' . ,

"

belt ePlacement

. . . . ' . . . ,

removal

. . . . . , . . . . . . . . . . . . .

.

instal lat ion.. . . . . . . . . . . . . . . . .

Delivery

pipes,

emoval/installation

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

rePlac€ment

Iniectors,

al funct ions/checking

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

removal

. . . . . . . , . , . . . . . . . . . . . . .

instal lat ion

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

overhaul

incl.

esting}

Coldstartclevice

.,........

Preheating ystem

glow

plugsl.wiring diagram

1979_80

.

'

1981-

.. . . . . . , . , .

Op.ration

AA2-10

ABl-6

AC1

AC2

AE1-14

AD2

aD3-14

AEl-14

AG1-17

AH1-3

AJl-10

AK1_2

AK}6

AK7-9

AL1-10

Atvtl-2

AN1

AO1

Pag6

't26

126

129

130

130

13',l

132

133

't36

140

143

148

'149

1 5 1

1 5 1

'152

153

155

156

1 5 8

Contenls

125



Group 23 Fuel system

Exhaust

gas

density

AA. Exhaust

gas

density

General

Exhaust as

smokedensi ty

gives

a

good

ndicat ion f

the

condit ionof an engine

and whether he in ject ion

pump

s correct ly

djusted.

Swedish regulat ions

st ipulate that smoke

densi ty

must not

exceed .5Boschunits or

passenger

arsat

t ime

of regis trat ion nd 4.5 Bosch

units at the annua

Since

exhaust

gas

smoke

emissions f rom Volvo

diesels

re

general

y

lower han

othervehicles r may

be hought

possib

e

to increase

ng ne

performance

y

enr ichins

he fuel a i f mixture.

Prolonged

ercessive ennchmenl wi l l not inLrease

power

output but wi l l in fact reduce seryice i fe

of

engine considerably.Even

moderateenr ichment of

fuel-air

mixturewi l lsharply

ncrease xhaust

as

em-

peratures

ndcombust ion

ressures,

i thout any

coF

respondins

power

sain.

r)d

{),1

AA2

Checkingsmoke density

Various

ypes f

equipment reavai lableo measure

smokedensity. efer

o manufacturers'nstruct ions

for maintenance

ndcal ibrat ion f equipment.

126




AA3

Connect

extension

piece

o exhaust

pipe

This

educeshe iskof ambient iraffectingnstru-

ment

robe.

ipe imensions:ength 200mm

8in)

internaldrameLer

50

mn

l2in) .Secure i tent ion

piece

with rubberhoseand clamps.

Instal l

sample

pump

Insert

probe

nto

exhaust

ipe,

Probemustbe n

center

and nserted o 6 depthof not less han 200 mm

{8in},

otherwise

eadingswill be

incorect,

Hang

lexible ose rom

clamp s l lustrated.

Connect

ose rom rubber

laddero sample

ump.

Exhaust

gas

density

AA5

Check sample

pump

operation

Engine

off.

Push

n

pumpplunger

ul ly.

Squeezeubber ladder

andcheckmov€ment

f

pumpplunger.

NotelDo

notcover ole n bladder

s

plungerwi l lnot

Push n

plunger

ul ly

after hecking.

AA6

Insert

ilter

paper

n

pump

Unscrew overand check hat contact urfaces re

Pl6ce i l ter

paper

n opening and t ighten cover hand

taght.

Position rubb€r seal over cover

(to

prevent

dirt and

moisture from

affecting test).

'127



Group23

Fuel

system

Exhaust

gas

density

Routehose with rubber bladderto

d. ive6 seat

Secure osewith ape.

2421244:nsert ose hrough earsidewindow.

245: nserthrough ai lgate.

50

s0 knr/h

30

AA8

Measuresmoke density

Warm-up ngine

o normal peratrng

emperature,

Driven second

ea

at50km/h

30

mph).

lowly

ush

acceLerator

edal

o f loorwhi leapplying

ootbrakeo

maintain onstant 0

km/h.

Note Automaticransmission:

o not depress c'

celerator

edal

o su€han extent

hat kick-downs

engaged.

Maintain onstant peed or a

few seconds nd

squeeze

ubber adder o operale

ump.

Note Squeeze

ubberbladder ard of several e-

condso ensurehatsample

ump

hasbeen i l led.Do

notcover ole n rubber ladder.

,)r

rit

I

s0

km/h

30

mph)

AA9

Repeatmeasurements

Removeil ter

aper

rom

pump.

Depress

umpplunger

uly and

place

new

ilter

paper

n

pump.

Aeposi t ion ubbercover.

Repeatmeasurements ccording o AA8.

AAlO

Evaluateesult

Ca brate equipmentaccording o manufa cturersn-

Smokedensi ty or

passenger

ars n Swedenmust not

exceed .5Boschunits

at t ime of

registrat ion

nd

4.5

Bosch

units at annual nspecl ion.

l),,

rl,

I

124




AB.

ldle

* fast idle

Special ool: 9950

Connect

achomeler

UseVolvo

Monotester

ndadapter 950.

lf Volvo

Monotester

js

not available use

photoelectric

rev counter

(999

9795,9).

Warm-upengine

Checldadjust idle

12.5 /s

(750

/min).

Seal

adjustmentscrew and lock nut with

paint

after

Checldadiust fast

idle

87 r/s

{5200

/min).

Seal adjustmentscrew and lock nut with paint after

Donot ace

ngineonger han

necessary,

Disconnect

achomeler.

AB6

Checldadiust

ngine controls

Always hecUadjustngine ontrolsfter diustjng

id le

speed.

See nstruct ions

n

page

176,operat ions

Xl-AXg.




AG.Fuel ilter

'),

ACl

Drain water

from fuel tilter

-

place

dr ip

pan

underneathrain crew

2)

-

slacken leed crew

1)

couple

fturns

-

slacken rainscrew

2)

and

ret ighten hen clean

fuel lows hrough.

-

retighten

bleedscrew

AC2

Replacement

Special tool: 2903

-

Us€strapwrench2903 o remove ilter. Place

trap

asnear s

possrble

o bdse

f

l i l ter,

ee

ig.

-

smear

iesel i l on new i l terseal

-

t ighteni l ter

by handunti lseal o ntacts ody. hen

tighten further /4 urn

-

sta ef lgine nd heckor eaks. l fseal is

ott ight i r

wi l l be

drawn

nto

uelsystem ndcause

oor

un-

n i n g .

i

{ ) l1 I

t)r

i,l

1 3 0



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:

-

adjustingdle

and ast dle

-

adjustingniection

iming

Formoredetailed

epairs ndadjustmentshe

pump

must

be emoved nd ested y speciallytr6in6d

sr-

sonnel,na sDecialtest6nch.

Smokedensity egulations

or Sweden

Fuel egulating crew

s sealedatfactory.

No 61 uelsupply

may only be checked/adjusted

n a

t6st benchbvtrained Dersonnel,

- . . r t -T

O)

r)

,v i

1 3 1



Group23 tuel system

High altitude adjustment

(Legal

rcquirement)

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

Ondel iveryfrom

actoryal lehiclesareadiustedfor

low altitudes,

a

Nswvehiclesoldfor

r incipal

se t highalt i tudes

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 nject ion

ump.

a

lf v€hicle owner moves

are6, he vehicleshould

tude

driving.

a

Vehicles djusted

or high

altitudes

must bs read_

iusted

or low altitudss

fvehicle

s o be

principallv

used

at low altjtudes.

h€hjgh altitude

decals

must

also be

removsdat the same

ime,

Thefollowingadiustmentmust bemade o vehicle or

useat highalt i tudos:

Inisction iming:

advancsd0.07

mm

(0.0028

n) for

every

100m

(3300

tlincrease

n altitudes.

Injected

uantity

decreases y 2.3mm3tor each1000

metre ncreasen altitude. his s equivalentto urning

adiustment crew35' counterclockwise.

from low to high altitude

bs readjustedorhighalt i -

Injecrion iming

Example:

f altitude s 2000metresabove ea evel he

lollowing calculations an be made:

0.85mm is normal setting

for

1982-models}

o.ss+ff i*o.oz)=o.ssr.

High al t i tude et t ing s 0.99mm

Iniected

qutntity

Example:fal t i tude

s2000

fol lowing alculat ionsan

?999^

r. = rn.

1000

--

Turn adjustmenl

crew70"

metresabovesea

evel he

be madei

132



Group

23 Fuel

system

AD. Iniection

pump,

setting

special

tool: 5194

lnjection

pump,^efting

is at TDc-iniection

damper centre

bolt to turn

Removo ear iming goa. covel

Disconnect

cold start devicc

Slacken crew

1.Push ever

o wa d and rotate

sleeve

90'.

Nole Do nottlrn screw

2 otherwis€

twillbe nec€ss'

ary o

remove old start

deviceand

rsset t on a test

bench.

Push ev€r

backagainst

stop.

Tuln ongin€

until cyl. I

Alwaysuse he

vibration

the engine.

Usea 27 mm socket,

IVsrk

n

pumpgearshould

eopposite

ark nmoun-

ting bracket.

Flywheelat

O"

mark.

Pl.co dial Indicator

in iniection

pump

Unscrew and

rerhove

plug

from iniection

pump

distributor.

Instal lholder5194

and dial

indicator

measuring

range -3 mm).S€t

gaugeto

approx.2

mm.

) )



Gtoup

23 Fuel system

Injection

ump,setting

AD7

Set indicator o zero

Turn

ump

ear

ack l ightlynti lmin. eading

egis-

ters

n

dial ndicator.

Set

ndicator

o

zero.

AD8

Check

ump

setting

Turnenqine lowly lockwise nt i l f lywheels at 'O'

Note f engines urned oo

ar t mustbe urned ack

approx.1/4rurnnd hen o'o'markothelwise ett ing

Dial ndicator hould how:

O20 .. . . . . . . . . . . . . . . . . . . . ..75-0.83 m

(0.0295-0.0327

n)

D24 .. . . . . . . . . . . . . . . . . . . . . . . .,55-0.73 m

(0.256

0,0287n)

D24

USAandCanada 979-1981

... . . . .

.65-0.73

m

(0.0256-0

287

n)

1982- . . . . . . . . . . . . . . ..82-0.90mm

{0.0323

.0354n)

(Vehicles

djusted

or high

alt i tude

rivingj efer o

page

14)

AD9

Readiustingumpsetting:

Sett ing alues:

D20 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..80mm

{0.0315

n)

D24... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..70mm

{0.0276

n)

D24

USAandCanada

979-1981... . . . . . . . . . . . . ..70mm

(0.0295

n)

1 9 8 2 . . . . . . . . . . . . . . . . . . . . . . . . .. 8 5m m

(0.0335

n)

Reading less than specilied:

Slacken

ump

mounting ol ts nd urn

pump

nwards

to obtain orrect

alue.

ightenmounting ol tsand

repeat heck f

pump

sett ing.

Reading ore hanspecif ied:

Slacken

pump

mounting bolts and turn

pump

outwards nt i ldial ndicator hows pprox:

D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 0 m m

0 . 0 2 7 6 i n )

D 2 4 . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 6 0 m m

0 . 0 2 3 7 i n )

D24

USAandCanada

1979-198?

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

.60

mm

{0

0256

n)

1 9 8 2 ' . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 5m m

(0.0295

n)

Then urn

pump

nwards nt i specif ied alue s ob

tained. ightenmounting ol ts nd echeck

ump

et'

t |n g ,

Note njecrion

ump

mustnotbe apped

r

knocked

as

hiswi l l aher ts sett ing.

a)

l

0l

i:

rt

i

i :

i '

l " r i 1

((c) ,

/1,;.

<:i:/h

,:f-;*il

t),

,)t

I

1 3 4



Group23 Fuel

system

lnjection

pump,

sefting

ADlO

Check

pump

setting

Turn nginewoturns6ndchecksetting.

Adjust

f necessaryccording

o operationDB

and

ADl1

Romovedial indicator andholder

AD12

Install

plug

wath

new

$oal

Tightening

orque Nm

(6.5

t lbs).

ADI3

Install rear iming gearcovel

AD14

Reconnect cold stsrt dovicg

Press ever orwards and turn sleeve

90'. Retighten

Notol

Do notturn screw2. otherwise t will be necess-

ary o removecold start

d€viceand reset t on a

tgst

bench.



Group23

Fuel

system

lnjection

ump

belt, replacement

AE. njection umpbelt, eplacement

Special ools: 5193, 194, 197,

199, 201

Remove

ear iming

gear

cover

AEl

AE2

Turnengine

nti l cyl.1 s al

TDC-injection

Always

sevibration amper

entre oLt o turn

engine. se

7mmso€ket.

l \, larkn

pump ear

hould eopposite

arknmount-

in9bracket.

lywheelt"o".

0,

Lift off

pump

belt

Siacken

r lount ing ol ts or

in ject ion

pump

bracket o

release

belt ension.Tighten one

bolt so that

pump

remains n

pper posi t ion.

Lift off belt.

AE4

Remove

amshaft earsprocket

Hod

sprocket n

posi t ion

with 5199 and unscrew

sprocketwith wrench

5201.

Take care nol to rolate

camshaft.

lnstal l enterbol t , hand

ight .

t

should

be

possible

o

turn

sprocket n camshafrwithout camshaft otat i ng.

{) l } ( |

0,)

I

136



Group23 Fuel

system

Injection

ump

belt, replacement

AE5

Disconnect

old

start device

Slacken crew1.Push ever orwardand rotate leeve

90'.

Note Do

not ufn screw2,

otherwise t wi l l be

ncuess,

ary o remove

cold

star t deviceand reset

t on a resr

Press ever

backagainst

top.

Then urn

pumpgear

back l ight ly nt i l

min feading

registers

n d al ndicator.

et

ndicaror

o zero.

Turn

pumpgear

clockwise nt i l mark

on

gear

and

pump

mounting

racket oincide. ock

gear

n this

posit ion

wi lh stop5193.

lnsert

top hrough

pump

gear

nlo mounting

rackel.)

AE6

Basic-setniection

ump

Slacken

ump

mountingolts

Al

enkey

=

6 mm

.

Alignmarks

n

pump

ndmounting

rackety urn,

ing

pump.

Ret ightenmount ing

bol ts.

AE7

Set dial

indicator zero.

Lock

pump gear

at cyl . 1 iniect ion using

stop

5193

Unscrew

and remove

plus

from

inject ion

pump

I n s l a I h o l d F

5 1 9 4

n o d a l

i n d c d r o r

m F a s u r i r s

range

3 mm).Set

ga ge

o approx. mm.

Turn

pump

ge.r

c

ockwise nt i markon

gear

and

mounting racket

oincide.

\j

-,74,

-

ior

1E.

:i

r€g ::3

1 3 7




lniection

ump

belt, replacement

AE8

lnstall belt

Adiust ension y moving oolant ump.

Use

auge

197o checkension. t tach

auge

o belt

and

set o 12.5 ni ts . tretch el t

unt i lmarkon

gauge

plunger

s f lushwith

sleeve. epress el t strongly

with handand recheck/adiust

ension.

t

.-

rl|'-

" '

t

t

| :

:

r

y , .7 ,v

7

u ,

"

" , ,

AE9

Sel

pump

and tighten camshaft r6ar sprockei

Use

199to old procket.

orquewrenchhould

eat

raght

ngleso wrench

201 therwiseorquewil l

b€

Using

199,urn

sprock€t lowly lockwise

nti ldial

D20 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.80mm

0.0315in)

D24...-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.70mm

0.0276

n)

D24

USAandCanada

9791981 .. . . . . . . . . . . . . . .

.70mm

(0.0276

n)

1982-.. . . . . . . . . . . . . . . . . . . . . . . . .

.8smm

(0.0335

n)

(Vehices

djustedor

high al t i tude r iv insi

efer o

page

132.)

Hoidsprocketn

this

posit ion

nd orqu€bolt o 100

Nm 73ft bs) . ake are hat amshaftnd procketo

tit

1Oq

Nm

AEl O

Remove

top 5193 rom

pump gear

AE11

Check

ump

setting

Turn ngine

wo ul l urns nti l yl .1 s atTDC-injec-tion gain.fengines urnedoo ar tmust e

urned

backapprox.l /4turn

nd hen o

zeromarkotherwise

sett ing i l l be ncorrect.

Dial ndicator hould

how:

D20 .. . . . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.75-0.83 m

(0.0295-0.0327

n)

D24... . . . . . . . . . -- . .--. .--. .- . . . . . . . . . . . . . . . . . . . . . . .

.65-0.73 m

(0.0256

.0287n)

D 24USAandCanada

1979-1981

... . . . . .55-0.73 m

(0.0256-0.0287

n)

1982- . . . . . . . . . . . . . . .

.82-0.90mm

(0.0323-0.0354

n)

Correct eadingr ighten nject ion ump mounting

bolts.Proceedo E12.

Incorrecteading:

eadjustc€ordingo instruct ions

1 3 8



Gtoup23 Fuel

system

i,

lnjection

pump

belt

Readiust ing

ump

sett ing:

D20 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..80mm

{0.0315

n)

D24 .. . . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . .

.70mm

(0.0276

n)

D24

USAandCanada 979-1981.70mm

(0.0276

n)

1982 .. . . . . . .85mm

(0.0335

n)

Reading ess

han speci l ied:

Slacken

ump

mounting ol ts

nd urn

pump

nwards

to

obtain orre ct alue. ig htenmounting

oltsand

repeat

heck f

pump

sett ing.

Readingmore

than speci l ied:

Slacken

pump

mounting bohs

and turn

pump

outwards

nti ldial ndicator hows pprox:

D20 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..70mm (0.0276n)

D24

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

.60mm

(0.0237

n)

D24

USAandCanada

1979-1981

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

.60mm

(0.0237

n)

1S82- . . . . . .0-75

m

(0.0295

n)

Then

urn

pump

nwards nt i l

specif iedalue s ob-

tained.

ighten ounting ol ts

nd echeck

ump

er-

t r n 9 ,

lmpor tan l l In iect ion

p hp

must no t be tapped

or

knocked

s h is w i l l a l te r is se t t ing ,

AE12

Remove

ial ndicalor nd holder

5194. nstal l

plug

with new

seal.

Tishteningorque

Nm

6.5

t bs).

A E 1 3

Press

ever orward

and urn sleeve 0'. Retighten

NotelDonot urn

screw ,othelwiset

wi l l be eoess-

ary o remove

oldstartdevice nd reset

t on a resr

AE14

Instal l ear iminggearcover

1 3 9



Fuel system

pump,

removal

AF. njection ump, emoval

Special ools: 2

x

2901,

193, 199,5201,5204

Remove ear iming

gear

covel

Disconnect:

hoses or cold stad

device.Clamphoseswith

pl iers

2901

pr ior

o remova

-

throt t le abLe nd kickdown cable

auto) from

pump

-

wire f rom

fuelvalve.

AF2

0,il]

0il

AF3

Disconnectuel del ivery nd return ines rcm

pump

C ean connect ions horoughly beforedisconnect ing

them. Plugends of fuel l ines o

prevent

dir t enter ing

1 4 0




lnjection

pump,

rcmoval

Remove acuum

pump

and

pump plunger

ffemove

ump

etajning

utsand

place ump

on

Remove

lunger

rom yl inder

ead.

AF5

Remove luel

delivery

pipes

Clean

l l connectionshoroughly efore isconnect-

Ing

prpes.

Remove ll delivery

pipes

and

p[]g

ends o

prevent

dirt rom enteringuel

system.

AF6

Turn engine until cyl. 1 is at TDc-iniection

Always se

vibration amper enter olt o turn

engine. se 7mmsocket.

lvlarkn

pump

earshould

eopposite arknmount'

insbracket.lywheelt O".

Lift

oft

pump

belt

Slacken

ounting ol ts or nject ion

ump

brackero

release

elt ension.

ighten ne bolt

so that

pump

remainsn upper

posit ion.

Lift

off belt.

(Wti

)

141



Group

23

Fuel system

lnjection

pump,

rcmoval

AF8

Remove camshaft

rear sprocket

Hold sprocketn posit ionwith 5199and unsctew

sprocketwith wrench5201.

Take are

not o rotatecamshaft.

Instal l enter

ol t ,hand ight.

t

should

e

possible

o

turnsprocketn

camshafl i thoutcamshaft

otatang.

Slacken

ump

gear

Use 193o

hold

gear

ndslacken

5201. emove

ut

and

washer.

AF9

AFlO

Pull

off

gear

Use

uller

204 nd top 193.

uri}

O,il

AF11

Remove

ump

Removerontmounting

racketromengine

Remove

ump

rom earmounting racket

Al len

ey

=

6 mm).

-lepftp'=

j,,r

Z-{

-

r //nl

I

riqr

\-



Group 23 Fuel

system

AG. Injectionpump, nstallation

Special ools: 5193, 194,

197, 199,5201

In

ect

o n

pu

m

p,

in

sta ati on

AG 1

Position injection

pump

Mount

pump

on engine nd securet wi lh

retaining

boltsandfront

ounting racket. onott ighten ol ts

ful lyat hisstage.

Al ignmark n

pump

with mark

n mounting racket.

Then ighten etaining ol ts or

pump

mounting

AG2

Instal l

pump geat

Do not orget o

place

ey n

pump

axle,

nstal l

ear.

Torquenut to 45 Nm

{33

t lbs).

ljse 5193 o hold

sprocketand 5201 o tighten nut.

Torque rench

houldbe at r ightangles 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

device

and

reset t on a test

Presseverbackagainststop.

143



Group

23 Fuelsystem

Iniection

pump,

installing

AG4

Set dial ndicalorzero.Lock

pump gear

at cyl . 1

inject ion

using stop 5193

Unscrewand remove

plug

from inject ion

pump

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 r

n e a s . r - i n s

range -3 mm).Set

gauge

o approx. mm.

Turn

pumpgear

c ockwise nt i l markon

gear

and

mounting racket oincide.

Then urnpumpgearback l ight ly nt i lmin reading

registersn

dial ndicatof. et

ndicatoro zero

Turn

pump gear

clockwise

nti l mark

on

gear

and

pump

mountlng racket

olncide. ock

gear

n th is

posit ion

with stop5193.

lnsed

top hrough

pump

gear

nto

mounting rackel.)

l)i l

|

lrii

AG5

Instal l

pump

belt

Adjusl ension

by moving coolant

pump.

Use

gauge

5197 o checktension-Anach

auge

o beh

and set o 12.5 ni ts.

Stretchbel tunt i l mark on

gauge

plungef

is f lush with s eeve.Depressbel l st rongly

with hand and recheck/adjustension.

AG6

Set

pump

and t ighten camshaft rear

sprocket

Use5199 o ho d sprocket. orquewrench

shouldbeat

r ight angLeso w.ench

5201otherwise orque wi I be

,),i l

|

'f,f

sing

199,urn sprocket lowly

D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D24

USAandCanada 9791981

clockwise nt i ld al

0.80mm

(0.031s

n)

0.70mm

10.0276

n)

. . . . . . . . . . . . . . . . .. 7 0m m

( 0 . 0 2 7 6

n )

1982

0.85mm

(0,0335

n)

(Vehices

adjusted or high a t i tLrde r iv ing: .efer lo

page

132

Hold sprocket n th is

posi t ion

ard torque bol t to 100

Nm

(73f l lbs) .

Take

are hatcamshaft nd sprocket

o

Removestop 5193 rom

pump gear

AG 7



Gtoup

23 Fuel system

lnjection

pump,

installing

AG8

Check

pump

sett ing

Turn

engine

wo ul l urns

unti lcyl .

1 s

at TDC-injec-

t ion,

again.

f

engine

s

urnedoo ar t mustbeturned

back

pprox. /4 urnand hen o 'O'mark othelwise

sett ing i l l be n correct.

Dial ndicator hould how:

D20... . . . . . . . . . . . . . . . . . . . . .

.75-0.83

m

(0.0295-0-0327

n)

D24... . . . . . . . . . . . . . . . . . . . . . . .

.65-0.73mm

0.256-0.0287in)

D24USAandCanada 9791S81... . . . . .65-0.73 m

(0.0256-0.0287

n)

1982- . . . . . . . - . . . . . . .

.82-0.90 m

(0.0323-0.0354

n)

Correct eading:Tighten nject ion

ump

mounting

bolts.Proceed

o AGg.

Incorrecreading: eadjustccordingo instruct ions

i l

Readlusting

ump

etting:

Sett ing alues:

D20 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..80mm

(0.0315

nl

D 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 0m m

0 , 0 2 7 6

n )

D24USAandCanada 979-1981... . . . . . . . . . . . . ..70mm

{0.0276

n)

1 9 8 2 . . . . . . . . . . . . . . . . . . . . . . . . .. 8 5m m

10.033s

n)

Reading

ess han speci l ied:

S l a c k e n p u m p m o u n t i n g b o l t s a n d t u r n p u m p i n w a

to

obtain orreci alue. iqhtenmounting

oltsand

repeat

heck f

pump

sett ing.

Readingmore than spe cif iedi

Slacken

pump

mounting bolts

and turn

pump

outwards nt i ldial ndicator

hows pproxl

D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. 7 0 m m

0 . 0 2 7 6 i n )

D24... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.60mm

(0.0237

n)

O24

USAandCanada 9791981 .. . . . . . . . . . . . . . .

.60mm

(0.0237

n)

1 9 8 2 - . . . . . . . . . . . . . . . . . . . . . . . . . .

. 7 5 m

(0.0295

n)

Then

urn

pump

nwards nt i lspecif ied alue

s ob,

lained. ighlenmounting ol ts

nd

echeck

ump

et,

t i n 9 .

lmport .nt In ject ion ump musr not be rappedot

knocked s hiswi l l aher tsset t ing.

145



Gtoup23 Fuelsystem

lniection

ump,

instalation

AG9

Remove ial ndicator nd holder5194. nstal l

plug

with new seal

Tiqhtening orque Nm

(6.5

t lbs) .

AGlO

Connectcold start device

Press evef orwardand turn sleeve 0'. Retighten

NotelDonot

urnscrew ,otherwise

t wi l l

be

necess-

ary o

remove

cold start deviceand reset t on a test

AG11

Fil l niection

ump

with dieselfuel

Onlynecessary

f

pump

hasbeendrained r new

pump

nstal led.i l teruelbefore

se.

nN

rilil

AG12

Instal l ear

iming

gear

cover

Clamp wir ing harness o le i t s ide retaining boh on

AG13

Reconnect

ueldel ivery nd return ines

Do not nterchangeonnections.eturnineconnec

tionsaresmaller ndmarkedOUT,

Tighreningorque 5 Nm(18 t. bs).

146



Group23 Fuelsystem

(D

Reconnectuel del ivery

ipes

Tightening orque 25 Nm

(18

t lbs) .

Instal l

lunger

ndvacuum

pump

Check

rins, eplacef necessary.

lnjection

u

m

p,

insta

lation

AG14

AG 15

AG16

Connect:

-

hoses

o cold star tdevice.Remove

lamping

pl iers

-

wire

to fuel va ve

-

throt t e cableand kick

down cable

auto)

Set

throttle control

See

nstruct ion n

page

AG17

176,operat ions

X1 AXg.



Group

23 Fuel system

I

,i

,l

,i

Fuel delivery

pipes

AH.

Fuel

delivery

pipes,

eplacement

Clean

ll conneciions

horoughlY

AH2

AH3

Remove

-

vacuum

ump

and

pumpplunger

Blank f f

ports

and

pipes

o

prevent

ntryof

dirt .

ChecUreplace

lnstal lat ion

-

connect el ivery

ipes.

Tighteningorque 5 Nm

{'18

t. bs.)

-

pump prunger

no vacuum

pump.

O-ring.

-

check unction

and security.A few

quired

before

pipes

are

bled and

148



Group23 Fuelsystem

Delivery

pipes

AJ. Delivery

ipes,

eplacementf one or more

pipes

(Do

notattempto

weld

or

repair amagedueldel ivery

ipes.

amaged

ipes

mustbe replaced.)

( )

0

. / . /

Clean l l connections aretul ly. low-dry

ipes

AJ2

Remove acuum

ump

and

pumpplunger

Remove

ump

retaining olts.Place

pump

on

wheelarch nd withdraw

plunger

rom cyl inderhead.

AJ3

Locat ion ot c lamps is impo ant. Incorrect ly

o-

cated lampscan cause ibrat ionsand uel supply

problems

may resul t .

Mark

position

of clampson

pipes

Disconnectl l

pipes

149



Group 23 Fuel

system

Fuel delivery

pipes

AJ5

Remove lampssecuring

pipe(s)

o be replaced

Replace

ipe

Do not

ightenconnect ions

t th is stage.

Check

posi t ion

of rubber

sleeve n

pipe.

AJ6

Instal l lamps

0l)il

{)il

ighten

ipe

connections

Tightening

orque 25 Nm

(18

t. 1bs.)

Instal l

pump

plunger

nd

vacuum

ump

Check/replace

r ings.

AJ8

AJ9

AJ1 O

Check operation

and

leakage

A fewsecondss required efore

ipes

reb ed ul ly

andengine unssmoothly.

1 5 0



Group.23

uelsystem

AKl

Malfundions

Listed

belowar6 malfu

nctionswhich

can occur

f one

or more ofthe

injectors s

defective.

-

one or more

ol cylindsrs

knock.

Notsl Do

notconfusethiswith

bearing

lafter Chsck

injoctorope16tion-

overheating

-

unevon dle

-

black

exhaust

moke

-

gXCeSSiVe

uel

COnSumption.

AK2

Checking

iniection

oper.tion

1. Bun

engine

at above

dle

speed

2. Loos6n

ap nuts

on injoctors

ong

at a time.

wl6p

sbsorping paper

around

iniectors

to

prevenr

spi l lage.

lfengins

speed cmains

onstant

or f

knocking

isap-

pears,

ault

may be:

-

delective

njector

-

detBctive

eat

shield

-

leaking

dolivery

pip€.

Wectarc

333133;315

usa/c€nad'

e82-

068130

ol

| - .

068130

01K

I

ulner

msrkets

DN

0 SD193

=

Usrcanad€ 1982-

DN

=

SD 93

=

Othermark€ts

AK. lnjectors

S.s

spg.ilicatlons

or

ld€nritic.rton

ot

injectortyp6.

Removing

niectors

Inisctol

{complete}

't51



Group 23 Fuel

system

AK3

Remove acuum umpandpumpplungel

Remove

ump

etaining

uts

and

place ump

on

Withdraw

lunger

rom yl inderead.

AK4

Clean

delivery

pipe

connections

Clean l lconnections

horoughlyefore isconnect-

ing

prpes.

Disconnect

delivery

pipes

Blank

ff

po(s

and

pipes

o

prevent

ntry forn.

AK5

AK6

AK7

AK8

Remove

nlectors

27mm

socket.

Remove

heatshieids rom cyl inderhead.

iniectors

Position

niectors

{t,,

Remove oot

etc. rom seal ing urfaces.

Place

ewheat

hieldsn cyl inder ead, ee ig.ToF

que

niectors

o 70 Nm

(50

t. bs.).

Reconnect

elivery

pipes

Tighlening

orque 25 Nm

(18

t.

lbs) .

Instal l

umpplunger

ndvacuum

ump

Check/replace

{ ing.

Installing

2

AK9



Group23 Fuelsystem

AL. Recondit ioning

njectors

Utmost

c eanl inessmust be observedwhen workino

with in iectors.

Disassembly

A L 1

iD

D

WARNINGI

xtreme aremust be

aken

when

est,

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

such a high

pressure

hat i l can

pass

hrough skin

and cause

blood

poisoninq

f inadvel tedly

ointed

clean uter udace

f injector

disassemblenjector.

aremustbe aken o

ensure

that

pa(s

do not al l onto bench

r

f loor.

f nozzle

needle

sdropped

t mustnot

be eused

immerse

arts

n clean iesel uel

assoonas hey

do not nterchange

a

s

Instal l niectorn test equipment

B ank

off fuel relurn

pipes

with

rubber

p

ugs

and hose

AL2

Testing

a

Injectorsshould be te sted wirh c ean test oi l or

f i tered diesel ue1.Under no circumslancesmay

petrol /gasol ine

e used because f the r is k of ex-

OThe use of sui table evacuat ion equipment

to

remove diesel fumes is law in cer tain counnies

( incl .

Sweden).

a lTpo' tdr t lactors n tesl ing

r jeclors

are opening

pressure

nd whether in jector s leakp roof.Spray

pattern

ndnoisearemoredi f f icul t toassess nddo

notgiveanexact indicat ionof ondi t ionof njector .

In jector may funct ion

sat isfactor i ly ven

though

spray

pattern

and

noiseare ound to be doubtful .

Uppernoz2le

Washer, dtusts

Cleaning,

checking

c ean al l pa s with cleandiesel uel

usenozzle

leaner quipment o cleannozzle

eedle

-

replace

damaged

parts.

Nozzleneedle

and sleeve

are matchedand must

be replaced ogether.

AL3

Assembly

-

wash

f f

ustproofing

ompundromnew

parts

i ih

clean

petrol /gasol ine

- immerse arts n clean ieselfuel

-

assemblenjector. orqueo 70Nm

(50

t. lbs. l .

It

r'f



23 Fuel

system

AL5

Check pray

pattern

{Pressure

au e

disengaged).

Pumpever i th

hort,

uick

trokes

4

6persecond).

Spray

et

shou be air ly ompactnd top bruptly.

ln jector

must not dr ip.

AL6

Check nlection

ound

(Pressure

sause

isensased).

Slowly epress

everul

y

(1

2 strokes

er

second).

In jector

hould buz, when fuel is emit ted.

AL7

Check pening

ressure

(Pressure

au e

engaged.

Slowlydepress

everand checkopening

pressure.

Opening

ressure

heck alue:12-13MPa

1700-1850

lf

incorrect ,eak est b€foreadjusl ing

pressure.

ALA

Leak est

lncrease

ressure

o 11MPa

1560

si).

Maintarn

hrs

pressure

or 10seconds. uelmustnotdrop rom

n

eLlors. rro sl rol / e rshowever

cLcplao .

i)rl

|l

I

Ia

j,:

I

5 4



Group23

Fuelsystem

Cold start device

L9

Adlust ing

opening

pressure

Sett ins alue 12.s-13.5 Pa

1780-1920

si).

Remove

njector rom

estequipment. isassemble

injector

nd adjustopenins

pressure

y repiacing

-

to ncrease

penng

pressure

f i t a rhickerwasher.

-

to decreasepening

ressure

f i t

a hinnerwasher.

0.05mm change n

thicknesss equivalento ap-

prox.

kPa

7

psi).

-

shims

reavai lablenfol lowing izes: '1.00-1.95

m

at 0.05mm ncrements.

Reassemblenjecror. orque

o

70

Nm

(50

t. lbs.).

D

ID

AL lO

Removenjector

rom

test equipment

Cover

nd with

protect ive

ap.

Take

arenot o damage

nozze when

instat , ,s , f lec,

AM.

Cold start device

AM1

General

Cold sta

devicemay

onty

be adjusted

on a special

test bench,

when

connecled

o in ject ion

pump.

However

a

serviceche€k

can be

carr ied out

on an

instal

ed in ject ionpump.

Notel

f cold

star tdevice

oes

not unct ion

he o tow

i n gw i l l

o c c u r

cold sta t ingdi f f icul t ies

blue

whi ie

exhaust moke

-

engine

wi l l not

st . r r

ar remperatures

etow

10"C

(-14"F).

AM2

Operation

heck

Measure

dle

speedwhen

engine

s cotd

and hot.

Cold

engine

(below

20"C

=

68"F)

=

approx.3.3

r /s

(200

/min)

more

than w.rm

ensine dte.

With warm

engine,

ever

on co d slar t

device

noutd

not

contact ever

on in ject ionpump.

ld e speed

warm

engine)

=

12.5 /s

{750

/min) .

1 5 5



Group23

Fuelsystem

Preheati g system

1979- 1980

AN.

Preheating

ystem

1979-1980

&

\5

c

{)i)

(1

|

{ll l

I

rl

Fue l

va lve

(so leno id

a lve)

nd ica to r amps or lns l ruments

A Temperature

auge

ender

B Fuel alve

solenoid

a lve)

C lndicaloramps

insir ments)

E Glow

plug

K Connect ionanel ndservice utput



Group

23 Fuel

system

B

Preheatin

g

system 1 79 1 80

D

BL

;t>t.

w:r>

Yflo)

\_./

o'

BL

n*l

++

Y

" \

BL-Y

Ra



Gtoup23 Fuelsystem

Prcheating

system 1981

AO. Preheating ystem

1981

Turn s lgna lsand hazardwarn ing igh ls

With efiect trom 1981-hodels:

Block lng fe lay d iscont inued

since new

cont ro l nh incorporares

swi tch wh ich

d isengages

low

p

ugs

af te ren9 inenar l ,

even f con t ro un i i ma l funct ions.

A Tehperaru fe

ga ge

sender

B Fue va lve

(so leno id

a lve)

C Ind lca to r amps

( inst ruments l

E G ow

p l lg

G Connect ion

ane l

and serv ce

outpL t

rl)'r

I

{r

I

{ul

i , l

B L

S B

G N

tr-8to

1 5 8



Group23 Fuelsystem

Prehealing

ystem1981

W

@-*

LY

\7V

,

/

\,-,'



Group

25 lntake and exhaust

syste.rs

Group25 Intakeandexhaust ystems

Contents

Operation

Intake/exhaustystems

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

Pl-z

Exhaust ipeandsi lence ... . . . . . . . . . . . . . . . . . .a ' l

D21

Page

1 6 1

162

1 6 0



Group25lntake

and exhaust

ystems

AP. ntakemanifold/exhaust anifold

I nta

ke m an fo I d exh au

st m a n fo Id

Exhaust

manitold

Always

se ew

utswhen

nstatting

anifotd.

a

Tightening

orque

5Nm

18

t. bs.)

Seal ing r ing between

intake mani lold

and in-

take hose

Introduced

uly1981.

Seal ing

ing sused o

prevent

i l eakagerom ntake

manifold

hose

onnection.

I t canalsobe i t ted

o vehiclesmanufactured

efore

J u l y1 9 8 1 .

Note ntake

anifold at ing

udacemust ecleaned

beforenstal l ins

eal .

P/N

257809

).

Intake

manitold

a Al len crew

6 mm

a

Turn

gasket

i th

green

ide

acing

yl inder ead

a

Tightenins

orque 5Nm

(18

t. bs.)

Arrowon intake

manifold ose

must

poinr

owards

manifold

therwiserankcase

reatherosemay

on,

tactbonner

hood).

1 6 1



2S ntake

and exhaust vstem

AR. Exhaust ystem

Sti f fenins

ipe only

on ear ly 45models)

New eals hould eused

hroughoutwhennstal l -

rngnewexhaust

ystems.

need

nlybe eplacedt damaged.

ipes

must be inser ted

pprox.

0

mm

(1.6

n) n si lencers

Clearanceetween

xhaust

ipe

andbodyshould

not be

iess han 20 mm

(0.8

n). Rear

i lencers

marked

lN".

Installing

complete

exhaust system

Fol low nstruct ions

elow

o ensure

tressJreen-

stallation

of exhaust

yst€m

1.Slacken

wo bolts

securingmounting

bracket

o

gearbox

ransmission,

2. Posit ion

ront

pipe

and

ighten uts

and botts or

frontpipe

branch

ipe.

3. Tighten

etaining ol ts

ormounting

racket-ront

4. Tighten

two bolts

securing mounting

bracket

o

gearbox

ransmission.

5-Al igncomplete

xhausl

ystem.

6. Tighten lampsjoiningi lencersto ipes.

7. Tighten

utsat iont

pipe

oint.

8. Ensure

hatexhaust

ystem annot

tr ike ody,

d-

just

if necessary.

D20



Group 26

C;.joting

systetil

Group26Gooling ystem

Contents

Cool ing

ystem,tesi ing,

Coo'ant,gen€ral

Thermostat,

ep1acement,. . . . . , . , . , . , . , . . . , . , . . . , . , . . . . . . . . . .

Coolanl

waterl

ump,

eplacemsnt.. . . . . . . . . . . . . . . . .

Oporation

ASI

AT1

AT2_9

A T M 2

AU2

AVl-23

Pag.

164

'164

165

167

168

168

169

Contents

3,

\

t



Group 26 Cooling system

Testihg, coolant

AS.

Coolingsystem

esting

AT. Coolant

as1

Connect esl

bump

b6twe6n fidiator

and

oxpansion

tank as

shownadiacent.

Increase

re$ure

and checkopening

pressure

l ex-

pansion

ank cap.Also ch€cl tor leakag€.

Openins

ressure:

ype1:6F-85kPa

9.12

psi}.

Type2

{introduced

prins

1982)r

100kPa

14

psi).

Pfessure

should remain

constant

for

at

least 30

NotelDo

not run 6ngin6wh€n evelofcoolanl s ow

sincehigh ocal €mp€ratures an resultwhich may

cau6e he cylinderhead o

crack.

ATl

Siocealuminium s us€d n the €ngines,

ctivecorro-

sion

protection

s nec€ssaryn the coolantto help

pre-

ventcorrosiondamage.

Js€

genuineVolvo

lue-green

cool6nttype

C,

dilutedwith

cleanwater n

proportions

of 50/50.This mixturehelos o

Drevent orrosionand

frost damage.Neverfillthe

coolingsystemwlth water

alone.Thecoolantsholld be chang€d €gularly ince

the corrosion

Drotactive

dditives n the

coolant ose

their

effect n timo.

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

1331473-71

n exp6nsion ank if

,@

rEr

oirc ft rlly^isu

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

mortcTE0q

rrf rop

uf

y&n

R0ur{0 ttl] HAtr

vr

't€4



Gtoup 26

Cooling systefi

gJ

Roplacing

coolant

Cooling

system

need

not be ftushed

when

reptacjng

type

B coolant

blue)with

ypeC

btue,green,,rnce

these oolantsanbemixed.

However,sincetype

(red)

ndtype

btue,sreen)

re

not

mixable

t is

necessary

o f tush

cooting

ystem

priorto

i l l ing

ype

C

cootant.

Described

eloware

wo different

methods

or

orarn-

jng

coolant,

1)wi lh

tushing

nd

2)without

lushing.

prior

o f i l l ing

ype

C cootant.

(1)

Draining

oolant

system

Coolant,

replacement

without

flushing

cooling

AT3

Jack-upvehicle

To

prevent

spi l lageswhen

coolant is drained,

aise

vehicleat f ront

r ight

acking

point .

Cootant

wi then

run along

splashguard nto

dr ip

pan.

Place

r ip

pan

beneath

eft steer ing

od.

AT4

Drain coolant

{No

drain

apson engine)

Unscrew

xpansion

ank ap.

Disconnect

ower radiator

ose

rom radiator

nd

Disconnect

baltery

ground

lead

Fil l ing

SeeATlF12.

AT2

1 6 5




Coolant, replacement

Coolant, Eplacement

Draining

nd

llushing cooling system

Dralncooling ystem

Pl6cedrip

pan

beneath eft

splashgu6rd.

Disconnect

ower radiator

nousrng,

AT5

sido of

enginebehind

hose from thermostat

Disconnect

hoses from heater control valve

{on

firewall).Point ower hosedown.

Flushing

Flusher(pansion

ank clean

4T6

AT7

Flush

engine clean

Connect

pperheater ose

at

rearlto ap and lush

engineuntil clearwaterappears t lower

(heater)

hose,

Contidueo flush orafurther2 minutes.

166



Group26 Cooling

system

AT8

Flush heater

clean

Setheater ontrolso MAXheat.

Connectpper

ipe

o apand lush nti l lear ater

appearsrom ower ipe.

AT9

Reconnect

ll hoses

Water

hose rom thermostat

housing s

connected o

lower

pipe

on heater

controlvalve.

Coolant, eplacement

AT12

Fi l l ing

A T l O

Bleedingof cool ing system

Disconnectpperhose rom coldstartdevice. lace

drip

pan

beneath oseand hold hose evelwith op

level

f expansionank.

A T 1 1

Fi l l coolant

Capacity: 20

=

a.1 i tres

8.6

US

qua(s)

D

24

=

9.3 i tres

9.8

US

cua

s).

Setdashboard eater ontrol o MAX. Add coolant

through xpansionank ap.

only ypec

{blue-green}

oolants o be used.

Turn

on engine nd

warm-up

or 5 minutes.

Expan-

sion ank ap emoved).ddcoolantduringthist ime.

Connect ose o cold start device.Fi l l coolant o

mouthof expansionank

above

max}

and

screw n

cap

again.

Replace decal

Attach ew ypeC decal o expansionank.

oircrr|| Ytv^rsu

yr N i

4fy[0 xyrsysr$4rTh riosr-

;ilgo01",llll"_1T.Y";'**,

a'" aurT to

fN Dftv^Trff

ocNNorL

voLvo

cool rr iyft

c.cooirrc

sii;-E

'norfcTfo

0

,.r

roe

ur

rui

40rrD

urF H^ f

^rfR

rr0

^1.

v0rvo

ifilnr

ff L0ur0rANn6lL

woLvo a4

c v^r8Ll

JLSoUA pal

vrc

rort €^uMorlt

fi{lcrL rYPr



Group

26 Cooling system

Thomostat

AU. Thermostat

AUl

Replacement

-

replacehermostat

ndseal

-

arrowon

hermostat

ust

Point

P

AU2

Testing

lf nec€ssaryest hermostatn

hotw€tet

Thermostathould:

-

start

o op6nat 87'C

188fF)

-be

lully open

at 102"C

216"F}.

in opening

gap

=

8 mm

0.3

n).

"87'C

E

;i02"-CT

m

168



Group26 Coolingsystem

ID

AV. Coolant water)pump, replacement

Specia

tools 5187,51

88,5 1 7

Disconnectbattery

ground

lead

Coolant

water)

ump

AV1

AV2

Jack-up

vehicle

To

prevent

pi l lages

/hencoolant

s drained,

aise

vehicle t ro nt

r ight

acking

oint.

Coolant

i l l then

runalong plashguard

ntodriP

pan

Place r ip

pan

beneath

eftsteering

od.

AV3

Draincoolant

{No

rainaps nensine)

lJnscrewxpansionankcap.

Disconnectower adiatorhose

rom radiator .Discon

nect ower hose rom thermostat or cold star t

device

Remove

cool ing an with spacer

and

pul ley

fan bel tsand

power

steer ing

pump

belt

f ront t iming

gear

cover.

1 6 9



Group26 Coolingsystem

Coolant

water)

pump

;>

AV5

Remove ibrat iondamper center bolt

Use 187o prevenl uley rom otat ing, ndwrench

5188 o un screw olt . t may be necessary

o turn

enqnesl ight ly o ha(

5187

ests

n

an

oearing.

AV6

Turn

engineapprox.

/4 urn anl iclockwise

Usew.ench 5187.

By urning

engine nt ic lockwise,lack

n bel twi l l move

io dr iv ingside,making l easier o removeand insta

AV7

Remove ibration amper

Removebolts

arrowed).

l len ey mm.

Pull

f f

vibration

amper. ote rankshaft

ear

may

sometimesticko vibrationampe.

{

(

I

'6i

}Y

7

AV8

{

rli

{ il

I

I

Remove

ower iming

gear

cover

AV9

Detach

mountingbracket or cooling an

and

alternator nd

place

n one side

Remove ountingolts

arrowed)and

ress

racket

1 1 0




Coolant

water

pump)

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

gear

belt.

lmportant

Belt must be titted in exactly same

position

as

found otherwise

valves may contact

pistons

and

cause erious ngine

amage.

Remove

gear

beli

Slacken oolant

pump

Coolant ay eak

when

Lift off belt.

A V 1 1

mounting bolts

and belt .

bol ts reslackened.

AVl2

Remove oolant

pump

Remove

over

anel

nd etainingolts

or coolant

pump,

Move

anelto

ne

ide nd emove

ump,

ake are

AV13

Clean

Cleanontacturfaceorpump ncylinderlock. ry

offcoolant

rom yl inderlock,

ear

tc.

1 7 1



Group 26 Cooling

system

water)

pump

A V 1 4

Inslal l new

coolant

pump

Grease ewO-ring ndplacet on pump.Donot use

permatex

r other ypesof sealers.

Movecover

plate

o one sideand mount

pump

on

engne.Pump

etaining ol ts hou

donlybeattached

loosely

t h lsstage.

AV15

(

I

nstal l :

-

cover

plate

etaining

bol ts,

-

moLnl ing

b

acket or cool ing an

dlrernator .

AV16

Instal l

gear

belt

Make

sure thai belt

is fitted in exactly

same

position

as before

Align dent i f icat ion

marks

on

belt ,

camshaft procket

and crankshaft ear.

{rrl

{r

I t is

ext .emely mponant

that bel t

same

posi t ion

as before.

Tension

belt by moving

coolant

Tighten

pump

mount ing bol ts.

is fitted in exactly

pump

(by

hand).

1 2



Group26 Cooling

system

0

AV17

Instal l ower

iming

gear

coverand vibration

oamper

Damper an only be fi tted n

one

way.

Pin on

crankshaft

ear

mLrst

i t in v ibrat iondamper.

To.que nhex

bolts o

20

Nm

{15

r

bs) .

A V 1 8

Install center bolts

Smear hreads

nd matingsurface i th

sealerP/N

271961-9.

Usewrench

187

rest

n cool ins an

ournal)

o hotd

vibrat ion

amper. se

wrench 188 o torque

entre

bolt1o350Nm

(255

t lbs).

lmportant

orque

50Nma

ppl ies

nly fwrench

188

is

used.Also torque

wrenchmust be in

l ine wrrn

wrench

5184.

AV19

Set belt ension

Turn

engine

pprox. /4 urn

anticlockwise.djusi

tensionby moving

coolant

pump.

Use

gauge

5197

o

check

ension.Attach

gauge

to bel t and set to 12.5

uni ts.

Stretch el tunt i l

markon

gaugeplunger

s

tush

Coolant

water)

pump

hand

and

recheck/adjust

Depress

el t

strongly wi th

AV2O

lnstal l :

-

f ront

t iming

gear

cover

-

cool ing

an with

spacerand

pul ley.

Torque

bolts o

9 Nm

(7

t lbs) .

-

be t fo '

power

stFer:rg

punp

ard tan

be ts

-

radiator

Connecl hoses

(also

hose

to cotd

srar t



Group

26 Coolingsystem

Coolant

watet)pump

AV21

Bleedingof cooling system

Disconnectpper oserom old tart

evice. lace

drip

pan

beneathose ndholdhose evelwithop

edge f expansionank.

AV22

Fill coolant

Capacityi 20= 8.1 i tres 8.6USquarts)

D

24

=

9.3 i tres

9.8

US

quarts).

Set dashboard eater ontrol o MAX.Add coolant

through xpansionank ap.Only ypeC

blue'gr€en)

coolants o beused.

Turnon engine ndwarm-up or 5 minutes.

Expan-

sion ank ap emoved).ddcoolant uring his ime .

Connect ose o cold start device.Fi l l coolant o

mouth

of expansion

ank

above

max)andscrewon

capagain,

AV23

Replace ecal

Attachnew type C

decal o expansion ank.

(rrl

\rol-iro oFrcrrr

YrvrTsraYP ̂ h

ParYtroLsYsT r^RrRosr

srYooAr

Lr

30"c

fi$IYLIARtrRullr

r$$ oft v

l/loLvro co0LrNI

r0r uPYIAA 0un0{trN

^rf r^

L

r$ru 0r Lrour0r

rrcn

voLl/o

-r0.[

rui $r rourr ̂ ]soN

vft ir0flt au fior(

^rrc[L w c

114



Group 7 Engine ontrcls

Engine ontrols,

djustment

Group27 Engine ontrols

Gontents

Oporation

AX1-S



Group 27 Engine

controls

Disconnectink

pump

AX. Enginecontrols,

adjustment

AXl

Disconnect cold

start devico

lf engine s cold. cold

start device must

be discon-

nected

riorto

sd,ustingengine

controls.

Slacken

crew1.Push eve fo

rwa d and rotat€

leeve

90'.

Notel Do notturn screw

2, otherwis€

twillbe necess"

ary to removecold

start deviceand

r€set t on a tesl

AX2

rod from lever on

iniection

AX3

Adiust

throttl€ cable

Turncable

nut 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 onlact

ull throttle top.

176



Group27 Enginecontrcls

Eng ne contro s, adj u stment

Autontatio

transmission,

Adiust kick-down

cable

Depressacceleratoredal

ofloor,

Cable houldmove

approx,52 m

(2.05

n)between

dleand ul l thrott le

Dositions.

Csbl€

should be taut in idle

position.

Distancebet-

ween

cl ipon cableand nut should

be 0,25-1.0mm

(0.01-0.04

n).

Reconnectink rod

to levei

AX7

Adiust link

rod, full throttle

position

Turn

hrottle rum o fullthrottle

position.

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 injection

pump

ever

contacts dlo

(low)

adjustment crew.

Readiust link rod

Repeat peraiions

X6 and X7 until 0.3 mm

{0.012

n)

clearancos obtained

between hrottle drum and ull

throttle

and

dle

stoos.

Reconnectcold

tart deviceas applicable,



Op€ration

Page

Blsfc-sEtting6ngin.,,.,.,,.,.,..,..,.,.,.,,.,.,..,.,..

1-21 22

lndex

Opsralion Pago

Glow

pluss

.................................................N1-AO1 156

rdfe6poodsdllsinont................................Ax8 177

9enera1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AD1

31

alt i tudeadjustmentUSA.. . . . . . . . . . . . . . . . . . . . . . . . .AD232

s€ttins.......................................................O3-14

'133

c11-20 24

.lriv€b€lt,rcplac€m€nt.............................El-14

136

remova1.. . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . - . . . . . . . . . . . . . .F l-11 140

inst6llarion,.,..,.,,.,.,.,,.,.,,.,,,,.,..,.,..,.,,.,.,,.,.,G1-17 143

malfunct ions. . . . . . . . . . . . . . . . . . . . . . . . - - . . . . . . . . . . . . . . .AKl2

5 ' l

remova1.. . . . . . . . . . . . . . . . . . . . . . . - - - . . . . . . . . . . . . . . . . . . . . .4KH52

insta11at ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

K7-9

152

reconditioningnd esting ................-.....L1-1 I 53

lntak.manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AP160

Kick-downcab|e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AX5

77

check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2124

.el iefvalve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2324

Oifpump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2224

Preheatins

wirins

diasrans) ...................N1-AO1 156

Pllot

bsarlns

in

crankshaft)

replacement. , . . . . , . , , . , . . , . . . . . . , , . , . . . . , . , . . , . , , . , . , , . , .O1-74

Bemovins ngine ......................................1-7 111

SifsncoE.. . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ARi

62

insrall€rion easurement.,,.,---, -,,

58

104

Co|dstartdwie.........................................M1-2 155

Compressiontest , . , . , , . , , . , . , . , , . , , . , , , , . , . , , . , . , , . , . , ,A1-107

rephcement...-...........................-..............V'l-23 169

gsn€ra1,, , . , . , , , , . , , , , . , , , , , , . , , . , . , , . , , , , . , . , , . , . , , . , . , , . , . ,AT1

64

drainins ....................................................T2-4 168

dlainin9andf |oshin9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AT5-966

ii11in9.........................................-...........-...

T10-12

1A7

lestins,.,.,..,.,.,..,.,.,,,,.,.,.,..,.,..,.,.,.,,.,.,..,.,.,,

S1 lBt

coolant ...,.,.,..,.,.,.,,.,.,....,.,..,.,.,,,,,,.,.,..,.,.,,T1-12 164

thefmostat,,.:,...,.,,.,.,.,..,.,....,.,,,,.,.,.,,,,.,.,..,Ul-2 168

coo1antpump............................................V1-23 169

tront ,.r,.,..,.,....,.,..,.,.,..,...,..,.,,.,.,....,.,..,.,.,.,1-21 96

.. . . . . . . . . . . . . . . . . . . .s1 -11 103

f ront.....................................- -..............

1-27

, . , . , , , , . , . . , . , . , . . , .1-21

r€mow1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

imra1|at ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27

front , . , . . , . , . , . . . . . - . . . . . . . - . . . . . . . . . . . . . . - - - - - - - , - . . . .

24

Ensin6oil,filter...........................-..............-1-2

Exhruatmsnifo|d

......................................Pz

Exh.Grpipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81

Fue|fi|ter.....................................................C1-2

a1

8a

7 1

unscrewin9.-....-......-....-............................

17

differenttypes.,..........,.....-..............-....-....

t ight€nin9, , , , . , . , . . , . , . , , . , . , , . . . . - . . . . - . . . , . . . . . - . . . . . . . . .8

r€1i9h16nin9,,,,.,.,,.,.,,.,,,,.,..,.,,.,,,,.,.,,.,.,,.,.,1-3

Cylind€rheadsa3ket..................................3

r€mov€1,. , , , , . , , , , . , . , , . , . . , . , . . . - . . . . . . . . . . . . . . . . . . . . . . - . . .1 -2

inspoct ion. , . , , . , . , . . , . , , . , , , , . , . . , . , , . , , , , . , . , . . , . , , . , . , , ,

20

ovef iau1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21

insta11at ion. . . , . , . . , . , . , , , , , , , . , . . , . , , . , , . , . . , . , . . . . , . , , , , .

1-38

remov6l/insiallation.,.,.......,---,.,..,.,.,,...

H1-3

r6p14cemeni,,.,..,.,..,.,,.,..,............-.............

Jl-10

9ene.a1

.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - . - - - - - - . . . .A1

checkin9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Specia1toob,, , , . , . , , . , , , , . , , . , . , . .

Specilic.tions.................-...........................

Swirlch.mboB...........................................6

Tsitingcooling y.tsm ..............................

S1

replacement. , , , , . , . , , . , . . , . , , , , . , . , , . , . , , . , . , , , , . , , , , . , , .U1

test in9, , . , . , . , , . , , . , . , . , , . , . . , . , , . , . , , , , . , . , , . , , . , . , . , , . , . , , .U2

t€nsion, . , . , , . , , , , . , . . , . , . . , . . . . , . . . . , . . - . . - . . . . . . . . . . . . . . . . ,K1-E

8

replacement. . . . . . . . . . . . . , . , . . . , . . . - . . , , . , . , . , , . , . , . . , . , ,L1-350

AE1-14 136

Valvecl6aran@,adiur tment. . . . . . . . . . . . . . . . . . . . .81-119

[email protected],.,,.,.,,.,..,.,,.,.,,,,.,.,,.,,,,,,11 21

clearanc€,guids-valv€. , . . , . . , . . . . . . . . . - . . . . . . . . . . .F l6

replacement, . . . . . - . . - . . . . - . . . . . . . . . . . . . . , . , . , . . , . , , . , . , . ,FH7

oi1sea1s.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G4

2

.eplacement...,.....,.,.,,.,....,..,.,..,.......,,....,..13-21 39

snding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . - . . . . . . . . . . . . .FF12

8

insp€ct ion. . . . . . . . . . . - , - - - - , - . . . . . . . . . . . . . . . . . . . . . .F5

37

V.fvo

stsmsoals ................ G4 42

32

4A

57

45,46

28

32

36

45

148

149

126

126

1 2

3

43

164

168

168

Engh.

remov6l. . . . . . . . . . . . . . . . . . . . . . . . - . . . . - . . . . . . . . . . . . . . . . . . . . . . .V1-7

11

insta11.t ion. . . . . . . . . . . . . . . . . . . - . . . . . . . . . . . . - . . . . . . . . . . . . . . .

1-33 114

Ersin..@nlrols..........................................

X1-9 176

Engine, insta| |at ion. , , , , . , . . , . , , . , , . . . . . . . . . . . . . . - . . . . .x1-33

14

1 1 0

1 1 0

123

161

162

130

smokedensity....-.........-............-...............

Al-10 126

idf speed.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B l-6 129

fue1f i | ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - - - - . . . . . . . . . . .C ' l -2 130

injact ionpump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D1-AG14

131

deliv€rypip€s.............-..............................H1-AJ10 148

injectofs .......................-........................-..K'l-ALl0 15'l

coldstar tdevice. . - , , . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N1-2 156

prehe6tingystem,.,..,.,,.,.,,......,,,..,-,,...,,..N1-AO1 156

Fuflthrottl€adiustomont.......-........,,,........Ax7 177

replacement. . . . - , , . . . , . . . - , . . . - . . . . - . . - . . . . - . . . . . . - , . . . . .E1-14'136

' t78

typss'.'.-'.-'.-'.-'.---'.,,,.,..,.,..,.,,.,.,,, G3

cleahnce,adjustm€nt..................-..-....-...1*B'l'l

c |earance,9uide.va1ve.. . . . . . . . . . . . . . . . . . . , . , . . . . . .1

sindins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-12

remowl,'insta118tion,,.,.,.,,.,,,,.,,.,.,,.,,,,.,.,,.1-10

197H0.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NI-AOl

1981-, , , , . , . , , , , . , . , , . , , , , . , . . , . , . . , . , , , , . , , . , . , , . , . , , . , . , , . , .O

42

'19

36

3a

106

'156

154



A1

A1

A1

A1

M

A2

A2

A3

Cold start device

Fault

racing

pr€-heating

glow

plug)

system

-

Comple teheckf

p re -hea t ing

ys tem. . . .. . . . . . . . . . . . . . . . . . . . . FT l -FT5

-Specific

ault

ases.

ased

n completeh€ck ..,......,.. ......

FT6-FT14

-

lndicatoright l luminates

henengines warm .... ..... .. ... ... FT15

-Wiring

diagrams

t€

Ar0

A11-A14

Fault

Tracing

Diesel ngines rebasicallyugged

n design nd

are designed

or long

s€rvice ife.

Except uringmajor

ov€rhaul, ost servicings

confin€d o the tuel system.

Gontents

Summary f fauhsymptoms nd easons....

,

ExamDlesf taults

-

Heaw

moke f t€ r o l d ta r t . , . . . , . . , , . . , . .

-

Engine oesnot stan

-Eng ine

anno tes topped . . . . . . . . . . . . . . . . .

-

Eng ne6ta ts o smokeandclatters oavily

ftsr splacingu€l njoc'tion

ump

-

Engine latters eavily fter eplacing r repairingnjectors r fueldeiivery

ipes

Excessive mok€

-

Black moke

-

Whitesmoke.-

Blue moke

Analysisof exhaust moke

will

provide

useful

n-

formation on determining uel related

problems.

PW

Fault reing



Fault racing

-

Summary

Summary

of

fault

symptoms

and

reasons

The aultsvmptoms re

isted umerical ly

ccordingo:

-l ikely

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,

unti l the

SYmptoms

NOTE:S

system

Batte

starter,

etc.,

rs

(il

{r

{

(

tautthas

[--T--J--T--a

l""T*./

/"1 I

l/, 1-/fle,

krkl'lglf,,ffi

,M

NOTE:Startrng

ystem

Banery,

aner,

erc.J

assumed

o be

n

good

condition

/ i

;{

Relsons

for laults

Flel

system

Fuel alve

stopping

alve)in he

njection

ump

Injection

ump

sucks ir

(leakage

etween

uel ankand

pump)

Fuel

ealage

leakage

etween

ump

anddelivery

ipes

r

otherexternaluel

eaks)

lce

or

paraffin

n fuel

ines r fuel ilter

wintertime)

Injectioniming

ncorrect

Pre-heatingystem

see

wiringdiagrams).

Coldstartdevice

Faulty njection

ump

Fuel

ilterblocked

drain

ondensation

ater)

Fuel ines locked

Faulty njectors

Mix up o{

hollowscrews n

pump

or feedand return

ines

Incorrectlydjusted

or highalt;tude

Injection

ump

bracket

oose/damaged

lncorrectow

idlesetting

Incorrect

igh dlesetting

Returnineblocked

1

2

8

3

7

'10

6

12

4

I

1',I

6

5

3

I

2

1

7

8

10

2

1

I

3

4

6

5

5

4

11

6

7

8

1

2

l

3

5

8

9

6

7

2

I

1

1

6

10

12

5

8

l

3

9

6

4

2

I

4

5

10

6

7

4

I

5

3

2

11

2

5

6

1

3

1

Other aults

Engine

mounts oose/damaged

Air cleaner locked

Exhaust

ystemblocked

Incorrect ccelerator

ontrol

etting

5

4

1 l

12

7

8 1o

13

14

7

8

3

2

Enginemechanical

aults

Incorrectil

viscosityor cold

emperatures

Compression

ow/uneven

Incofiect alveclearance

Water eakage

High i lconsumption

180



Fault tracing

-Examples

of faults-

Examples

f

faults

Heavy

smoke after cold start

Poor uel

quali ty.

Check he

cold start device by

checking dle

speeo,

ldle

speed hould e

approx.200pm higher

withcold

engine.

dle

speed t normal

perat-

ing emperature

hould e 800 pm.

At normal

operating emperature.

he cotd

start lever

should not touch the lever

on the

injection

ump.

After

setting ow dlespeed, he

automatic dle

increase

evicemust be checked

ndadjusted

it necessary.

he

gap

between

control

lever

and ball stud

should be 12.7mm

0.5")

as

Cold

start device

12.7mm

0.5")

Engine

cannot be stopped

The uelvalve

(stopping

alve) n

the injection

pump

does

not close.t is a solenoid

alve.

Increase omentarj ly

o high enginespeed

and ry again o switch offthe start key. f this

doesnot helD:

-Vehicles

with manurl

transmission:

Engage3rd

or 4th

gear,

depress he brake

pedat

nd elease

he clutch

edal.

-Vehicles

with

automatic ransmission.

Use he

emergency top lever

on

the

injec-

tion

pump,

ee l l . below.

Emergency

top

level

Engine

does not

start

Check he

fuel valve

(stopping

valve) in the

injection

ump.

No uelwill

reach he njectors

if

the valve does not

open

(listen

or

audibie

cl ickl.

Thevoltage

t he uelvalve

olenoid ustbe

a t l eas t

10 vo l ts o open

he

va l ve ,

and

minimum volts

o remain

pen

startetmotor

engaged).

Engine

starts to smoke

and clatter

heavily

after replacing uel

iniection

pump

The njection

ump

might

be nco rectly imed

or assembled

distributor

lunger

180. re-

Check basic injection

timing. lf

correct, try

anothernjection

ump.

Engineclatters heavily

(sounds

ike

bearing

ailure) after replacingi

epair-

ing iniectorsor fuel deliverypipes

An injectormight

have

ammed

open.The

combustion s

out of control when accelerat-

I n g .

Loosen he

cap nuts o one injector

at a time.

The

compression

ressure

will revealvisible

bubbles

at

the

cap nut ot a stuck njector,

Note:

Clean ap nuts

before oosening



Fauh

mcia

Excesgve

noke

Excessive

moke

Excessive

igsel

moke s

usually aused

y

incomplete

ombustion.

Rgasons

ay

be engine ondition,

uel

or fuel

iniection quipmgnt. rivingand traflic condi-

tions

mayalso

contribute.

requent

cceleralion

in city raffic

willcause

arge

uantites

f

exhaust

gases.

White oxhaust

smokg

cont.)

NOTE:

White

exhaustsmokean

alsobecaused

y wa-

ter eaksnto

heexhaust ystem

rcylinderhead.

Possibleauses

or whitesmoke:

-

Pre-heatingystem

glow

plugs}not

perating.

-

Low compresson

ressure,

-

Low operating

emperature.

-

Defectivenjectors.

-

Late njection

iming.

-Water

leakage

cyl inder

ead

gasketl .

-

Coldstartdevice

ot operating.

Bluesmoke

Caused y ncompleteombustion nd

contents

oJcondensed

uel

particles.

Can lsobecaused y excessive

ilconsumption.

Possibleausesor bluesmoke:

-

Late njectioniming.

-

Delectivenjectors.

-

Heat hield nder

njector amaged r missing.

-

High uel

consumption.

-

Low operatingemperature.

CAUTION

Because

f

the

generally

ow smoke

evel,

t may

be tholght

possible

o increase

ngine

perfor-

mance

y enrichening

he air-fuel

mixture

However,

rolonged

xcessive

nrichment

il l

not ncrease

ower

outputand

will n

fact cause

unnecessary

ncreased

nginewear.

Moderate

uelmixture

nrichment

illsharply

n_

crease

exhausl

emperatures

nd combustion

pressuresithoutanycorrespondingowergain.

(r

(

{ ,1

(

I

I

rl

I

Excessive

iesel

causeo

y

poor

start

oevrce.

smokeafter

cold start

may be

flrel

quality

or

defective

old

Black

smoke

Caused y too much uel.Thecarbon

ontent n

the exhaust

ases

becomes

oticeable.

auses

may be:

-

Poor

uel

quali ty.

-

Dirty

air cleaner

insufficient

ir supply).

-

Excessive

niection.

-

Worn

njectors.

-

lncorrect

el.

-

Low compressDn

ressure,

-

Considerable

ackpressure

n exhaust

ystem

{clogging).

White smoke

Occurs

mainly uringcold

starterand s caused

by nsufficient

uelsupply.The

moke onsists f

condensed

uel

particles.

hecombustion

peed

is ow and he

uel

particles

ave onger ime o

condense.

(cont.l

I



Fault

raciw

Injectors

Ma]functions

Oneor sevoralofthe

ollowing

malfunctions

an

occur:

-One

or several

ylinders nock

NOTE:Do

not confuso

with bearing

latter.

Check

njector peration.

-

Overheatednging.

-

Reduced

ower

output.

-

Uneven

dle.

-

Black

xhaust moke.

-

High

uelconsumption.

Checking niector

operation

1 .

Rln

the engine

t increaseddle

speed.

2.

Loosen

he

cap

nuts

atthe njectorq

ne

at a ime.

Wrap

absorbing

aper

ound

he

njectorsto

re-

vent uel spill,

lfthe

idlespeod

emainsstable

r f knocking

is-

appears,he ault mightbe:

-

defective njector

-

defective

eatshield

-

leaking elivery

ipe

For

urther

est, emovehe

njectors

nd est n

a test

machane.

A3



Fauft

naciry

Cold tdt't

evice

Cold start device

The cold start

devicec€n

only be t€sted

on a test

bench ogether

with tho injection

pump

A simple op€ration

est can

be

performed

wath-

out removing

he cold

start devica

rom the

€ngine.

signs of cold

start device

malfunction:

-

Cold €ngjne

hard to start.

-

Engine

does not start at

tempgratures

below

-10'C

=

14'F.

- Blue-whit€exhaustgas€s.

Operation

ch€ck

check

dle speed

cold and

at normal

operating

temperature.

1 .

With cold

engine,

elow

2O'C

=

7O'F.

engine

idlespeed hould eapprox95o rpm(2Oo pm

more

han

warm).

With enginewarm

l normal

peratang

empera-

ture:

-

Enginedle

speed hould

be 750

rpm.

-

The cold

start device

evershould

clear

everon

injection

ump.



Diesel

engine

-Prc-heating

system-

Pre-heating

yste

Basic

peration

f system:

-The

systemsswitched nwhen hestart ey s urnedo driving

osition

l).The

pre-heating

ime

depends n coolantemperatures.hedashboardndicatorightwil l

stayon approx.:

1980MODELS

45

seconds t

-2O'C

=

4'F.

25 seconds t

0'C

:

32'F.

15seconds

t +20'C

=

68'F.

0 seconds

t +50 'C

=

112" .

1981 ON

9

seconds

t

20'C

=

4'F.

6 seconds t 0" C

:

32'F.

4 seconds t

+20"

c

=

68" F.

0 seconds t

+50'

c

:

'112'

F.

if

-The

glow

plugs

emain

ONapprox.20econdsfterthendicatoright as

one

outfor1980models

and

aoorox.7 econdsor 1981 ndor,.

-Ihe

glowplugs

re

ON

when he

starter

otor

perates.he

glowplugs

re utoutwhenheengine

startsand the stan key s turned back o

position

l.

-To

repeata start;ngattempt, he startkey must be urnedback o

position

to switchon the

pre-

heating

system.

-The

system

lso omprisesblockingclay n 1980models, n 1981 nd n hisfunctions

part

fthe

control nit. twi l l nterruptthelectricalircuit etweenhecontrol nitand he elayorthe

glow

plugs

when he alternatortans harging.

Fault

racing

pre-heating

glow

plug)

system

Relero hewiring

diagrams t rearof manual uring ault racing. he

pre-heating

ystems an

electrica

system nd hewiring iagramsrenecessarytonderstandndcorrectlytrouble-shootthe

pre-heatrngystem.

Complete

pre-heating

ystem

iif

(0

check of

100. )

ngine houldbe cold

(max.

40'C

=

when starting the system check.

startkey o intermediate

osit ion

l),

hen o

driving

posit ion

1l l )

o

obtain

a new cut- in

penoo.

fthe

pre-heating

ystem hutsOFF,irstturn

((l

FTl

Connecta est lamp across

glow plug

terminaland

ground.



Fault thcing

4low

plug

system-

Y9.'P"

Ffz

Check

unction

of test lamp

and

indicator ight (on instrurnentpanel

in vehicle)

CASEA

Indicstor

ight

OUI

Test light

OUT.

-lndicatesfailure

at he

controlunit.See

FT6.

CASEB

Indicator

ight ON.

Tesr light

OUT.

-lndicates

failure

at the

glow plug

relay.Soe

FI8.

CASEC

Indicator

ight

OUT.

Te3t

ight ON.

-lndicates

failure

at temperature

sender

or

control

unit. See

FTl3.

Indlcator

ight ON,

Test ight

ON.

-Proceed

on FT3,ne)

.

Fn|

Check

ON-time

or

indicator

ight and

test light.

Turn tart

ey o

intermediate

osition

)

and

then

to driving

position

(l l).

ON-time

for

indicator

ight should

be according

o coolant

temperaturg,

ee

diagram.

Forengines riorto 1981 est ightatglowplug

terminals

should remain

ON for approx.

20

seconds

aft€r indicator

ight

is OUT.

For

engines1981

and 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:

Proceod

on FT4,

next.

'*i1

46



voltage

terminal 50

-Glow

plug

system-

FT4

Check operation

with starter motor

operating

Test ightshould lluminate.ndicating oltage t

the

glow plugs.

Test light OUT:

Starter

motor engaged, se the test lamp

to

check oltage t

erminal

0

(blue

ellow

wire)of

the controlunit,

Voltage:

Indicates faultycontrol

unit.

No voltagel

Indicates pen circuit between

connector nd

(Connector

ocated ndercarpet

next o control

panel

e{tsupport).

Test ight ON:

Proceed n FT5,

next.

Ft5

Check

glow piugs.

one by one

Startkey n

position

O.

Removethearbetweenheglow

plug

erminals.

Connecthe test ightacross attery

PLUS

and

one

glow

plug

at

a time to check hat current

passeshroughhe glow

Plugs.

Light OUTat one or mo.e

glow plugsi

Indicates

aulty

glow

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 control

unit.

Firstcheck hat cut-in

period

hasnot expired r

that coolant

emperatures too high.

FT6

Check

voltageat 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.

( ,

(

(

vol lage

erminal

6

Fr7

Check

ground

erminal31 of the

controlunit

Blackwire. Connect est

lamp acrossbattery

PLUS

or

use

box PLUS erminall nd

erminal

31

of the controlunit.

Test ighl should

lluminate.

No voltag€r

Indicates

ault n

ground

onnection.

Voltage:

Indicatesontrolunit ailure.

FT2, case B

f

ndicator ight

ON.

Test

light OUT.

Indicatesailure

t the

glow plug

elay.

FT8

Check

voltageat terminal86 of the

glow plugrelay

Yellowwire. Use est amp o check

oltage. t

should l luminate.

Voltage:

Connecthe est amp

across

atteryPLUS

and

relay

ground

erminal

black

wire).The est light

should lluminate.

Voltag€:

ndicatesaulty

glow plug

elay.

No voltagg:

ndicatesncorrect

round

onnec

t|on.

No voltage

Proceedo FTg,next.

(



Fauft aciw

-

Glow

plug

syslem

FT9

Check voltage

at terminal G of

the

control unit

Bluewire.Use est amp o

check oltage. est

lightshould lluminate.

No voltage:

Indicates

faultycontrolunit.

Volt.go

Proceed n FTlq

next.

voltage

erminal

0

FTl

O

Check voltage

at terminal 30 of the

blocking elay

1980

nly)

Bluewirc. Use est lamp o

check or voltage.

Test ight

should 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 l luminate.

Voltage:

Indicates pencircuit n wire betlveen lockino

relayand

glow plug

elay.

No voltage

Glod<ing

relay does not operatsl:

Proceed n

FT

12,next.

voltage erminal 6

FT12

Check voltage at terminal 86

of the

blocking relay

(1980

only)

Blue-yel lowwire. Use est lamp to check

voltage.Test ight should lluminate.

No voltage:

Open ircuit n wirebetweenusoboxandblock-

Ing relay.

Voltage:

Connect est lampacrossbattery PLUS

fuse

box

PLUS}and

round

erminalS5 fthe blockinge-

lay.Tert lightshould lluminate.

Voltage:

Indicatesauhyblocking elay.

No voltage:

Indicates

pencircuit n wire between

blocking

relayand nstrument

anel,

OR

fault n the nstrument

rinted

ircuit.



-Glow

plug

system-

FTz,caseC

ground

terminalK

Indicator ight illuminates

when engine s warm

Indicator ight OUI

Test ight

ON.

-lndicates

ailureat temperatureender r

control

nt.

FTl3

Disconnect ire at temperature ender

lndicatoright

on

ashboardlhouldl luminate.

Makesurewire is not inadvertently

rounded.

Indicator ight ON:

Indicatesthatcircuitlrom

emperatureenclerto

indicator

ight s

correct

AND

a tault in temperature ender,

ry

a

new one.

Indicator ight still OUT:

Proceed

o FT14, ext.

FT 14

Gheck round onnectiont terminalK

of control

unit

Yellowwire. Connect

est

lamp across

battery

PLUS

(Juse

box PLUS)and

terminal K.

Test

l ight

hould l luminate.

Voltage:

Indicates

eJectivendicator

amp

OR

defective

irebetween

ontrolunit

and ndicator

l ight

OR

fauh n the

instrument

rinted

circuit.

No voltage:

lndicates:

-DeJective

control

unit

-OR

grounded

wire

between emperature

sender

and control

unit.

Precedingault

racingassumed

hat engine

tempe€ture

was below40'C

=

100"F and hat

the faul ts occured

within the

low temperature

range. owever,

he ndicator

ightcouldalso

i l luminate

with engine

warm

(at

operating

temperature),

FT15

Check emperature

sender circuit

and

temperaturesender

Disconnect

ireat emperature

ender.Ground

it and

turn start key

to driving

position

(ll).

Check

ndicatoright.

Indicator ight illuminates

Indicates pencircuit

n wire betlveen

emper-

aturesenderand control

unit

OR

defective ontrol

unit.

Indicator ight does

not illuminate:

Indicatesaulty

emperature ender.

(

(r

t

(

r(

(



Glow

plug

system

Diesel 7980

Glow

plug

system

Diesel

1980

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

130836

Blocking

elay

G)is

grounded

hrough

voltage regulator

and

alternatorcircuit when

alternators not

charging.



l-

:1

i(

D

Glow

plug

system

Diesel

1980

0,,

{r

{ ,

€

(

i

I

bTue-

'-i

FT

H

V

b7.18



Glow

plug

system

Diesel 1981

Glow

plug

system

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

I 3 3 2 3 4

Start key ON

Coolant

emPerature

below

+50'C

=

122'F

Starter

motor op€rating

q3323?



Glow

plug

system

Diesel 1981-

W

W

{

{

\ .<

)i

r-

F

I

e

n



vot

v0 suPPoRTs

otultTAEY

ilEclltt{lC

CERTlFlClTlott

8Y THt

t| t.A.S.t.

U.S.A.

nly)

Yoalr

most mportant

wecid

tool

VOLVO D24 Engines Repair Manual

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Transcript of VOLVO D24 Engines Repair Manual