Volvo D20 D24 Engine Repairs & Maintenance Service Manual - PDF DOWNLOAD

ServiceManual Repairs and maintenance TP 30420/111.88

EngineD20,D24

240 1979- 19 ..

D20,D24 Boththe D 20anclD 24 Dieselengines aredealtwilhin this manual.

The D 20 hasfive cylindersandthe D 24 six. Otherwise the enginesaresimilarin principle.

Not6l Differentllywheelsand vibrationdampersar€ fitted to the dilferentenginetypes.

iffim

itm!r :i!r-l-l

Volvosare sold in versions adaptedtor different markets.

Theseadaptations clepend on manyfacIors Includingega, taxarionand markerreqJi.e Thismanualmay thereforeshowill!strationsand lextwhichdo not applyto carsin yourcountry.

Contents page

fmportantinformation............................... 2 Specitications ........

3 Specialtools ...................................

12 Group21 Engineassembly...............................................

16 (Work wilh engine in-ca., replacernentof engrnej

Group22 Lubricating System.........................................

123 Group23 FuelSystem.........................................................

125 Group25Intakeandexhaustsystems.............. .. .. r60 Group26Coolingsystem.................................................. i63 Group27En9inecontro1s..................................................

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

A1

Index178

OrderNo,:TP 30420/1

We reseryethe right to makealerat ons

Reprintof'1983literature withoutchange.

OVOLVONORTHAMERICACORPORATION

lmportantinformation

CLEANLINESS Dieselinjectionsystemsareoxtremelysensitiveto dirt and foreign m6tter. A special workplace should thereforebe usedfor insoectionofcomoonents.

PLUGS CleanfuelIineconnections thoroughlybeforedisconnectingpipes.

Plug ends of fusl lines etc as each componentis removed.

Donotremovethessplugsuntilthe compo' nent is reconnected.

Tightening torques Two kindsof tighleningtorqueswill be found in this 1. Tightento 40 Nm {30ft lbs)indicatesth6t a torque wrenchmustbe usedIortightening.

2. Tighteningtorque 40 Nm {30 ft lbs) indicatesa guidevalug.

Tightening neednot be donewitha Ioroue wrencn.

Specifications

Specifications Group 20 General

.,o ,o

Enginetypedesignation andserial number S t a m p e do n l e f t s i d e o f e n g i n eb e n e a t hv a c u u t r ,p u m p

D 20 Engine OutputDIN..........................

Maxtorque DIN N u m b e ro f c y l i n d e r s D i s p l a c e m e n t . . . ............ . .

W e i g h t , a p p r o x . i n c l . e n g i n e m o u n t s , a l t e f n a r o ra n d s t a r t e r C o m p r e s s i o np r e s s u r e s i \ew en9ine.................. iVnirnJn .......................

M a x d ; f f e . e n c e b e r w e e nncdyel r s . . . . . . . . . . . . . . . . . . . . . . . . . .

C o m p . e s s , o r a t r o. . . . .. . .

C y l : n d eb r ore..................

S t r o \ el e n g rh

50 kW ar 80 r/s 68 hp at 4,800r/min 120Nm at 50 /s 12.2kpm at 3,000/min 5 1-2-4-5-3 1.986dm3(liter) '181kg (405lbsl Mpa 3.2 2.4 0.8 23.0:1 76.5mm : 3.0118 in 86.4mm = 3.4016 in

313 114

Specifications

D 24 Engine OutputDlN MaxtorqueDlN Numberof cylinders .......

Firingorder............,,...,...

Disp1acement...,,...,,....,...

Weight, approx. incl, engine mounts, alternatorand starter Compressionpressurss: Newongin€.........,,,,,.,...... lvlinimum ................,,......

Maxdiffsr€nce between cy1inders ...........................

Compressionralio .......,, Cylinder bore....,.............

Slrokelength

60 kW al 80 r/s 82 hp at 4,800r/min 140Nm at 47 r/s 14.3kpm 6t 2,800r/min 6 1-5-3-6-2-4 2.383dm3{litsr) 1S8{435lbs) MP. 3.2 2.4 0,8 23.0r1 76.5mm = 3.0118 in 86.4mm = 3.4016in

Group21 Engineassembly CYLINDERHEAD

9;

Diagonallymax 0.5 mm

Replacecylinderh€adjfwarp €xce€dssp€cificalions.

Und€rno circumst.ncosmay cylihderh€adb€ machinod.

:.' .,1

.,, \

-

\|

psl 455 313 114

Specifications

CYLINDEB HEADGASKET Thfeedifferentgaskettypesare useddependingon pistonprojectionabovecytinderblockface.

G.sket Pistonproi€ction notches thickness mm linl mm (in) (0.026-{.031 ....................1.4 0.67-0.80 1 )........ {0.0S5) 0.81-0.90(0.032-{1.035)........

2 ...................

1.5{0.059) (0.036--0.040)........

0.91-r.02 3 ...................

1.6(0.063)

_o -o VALVESYSTEM V a l v ec l e a r a n c e sc,o l d e n g i n e C o l d e n g i n e= r o o m t e m p e r a t u r e

Check Setting mm (in) mm lin) 0.15{.25 (0.006-{.010) 0.20{0.008) 0.35-0.45(0.014-0.01 8) 0.40(0.016)

Valveclearances, warm engine

Do ,lo

0.20-0.30(0.008-0.012) 0.25{0.010) 0.4(F0.50(0.016-0.020) 0.45{0.018) 3.00-4.25mm in incrementsof 0-05mm

0.1299 in to 0.1673in in increments of 0.0020 in

a u n !

o20 Checldadjust valves 1-2-4-5"3

r-l[

r]

D24 Checuadjustvalvesin following order: 1-5-3-6-2-4

Specifications

TIGHTENINGTOROUES Tight€ningtorquB apply to oiled nuts and bo|Is.Degrsased {washed}parts must b€ oiled prior to

oo @o

TIGHIENITVG SEOUENCE FORCYLIIIDERXEADBOLTS

,Ot rO @@ D20 ,oo @@

lmportlntl slsck6nbotts in rev€rsaoder when removingcylindsrh€ad.

Removsoiland dirtfrom bolt holes.Oil leftin hol€swill reduc€pressureon cylinderheadgasket, Eolt threads and washers must however be oiled, otherwisefrictionalforceswill b6 too grear.

@@o

@

@@@

D24

o

@@@

@@)@

Two types ot bolls ars in uset An early type with M 11 threadsand6 latertypewith M 12threads.{Latertyp€is lhr@d6dalong entir€l6ngth.l

NGHIENING OFCYLINDERHEADBOLTS

Mtl

Us6 now waahera,convex sid6 upwards, Tlght€nin fiv€ stages: l50Nm{37ftlbsl 2 ?0 Nm (50ft lbs) 3 90 Nm {65ft lbs} 4 run 6ngin€until oil temperaturois st t€ast50.C 1122'Fl 5 90 Nm (65ft lbs) R.lightening - Atler 600-1.200miles (1,000-2.000km). Engine shouldbe cold or almostcotd.Tighteneachboltsep6ratslyin specifi€dorder,see abovsfio.: L Slack€nbol 3(r 2. Torque to 90 lrlm (65 ft tbs)

M12

Us€ n.u bolb. Not n€ce$aryto roplac€w6shers.

Tightenin six stag6s: 1 ao Nm €0 ft lbsl 2 60 Ntn l4a ft lbsl 3 75 Nm {55ft lbs) 4 angle-tightsnl8f in ono movem€nrwithout stopping, {Se€figur€ 6t lower lefi} 5 run €ngin€until oil tehperatureis at lerst 50oC lt22 "Fl 6 anglo-tighten90Pin on6 movsmentwithout stop-

pins.

Rdighl.nlng After 60F1,200mil€6(1,000-2,000 km).Engineshould b6 cold or almost cold.

Tighten 6ach boll separatolyin spocifi€dorder, se€ €bov€fig.: 1. Angle-tightenbolt 9|r in one movemontwithout stopping.(Seefigure at lower left) Do not shckon boh firf,

Specificalions

20 Nm l1sft lbs)

100Nm (74ft lbs) @

6\1fl

45 Nm 133ft lbs)

b0

I l'-

'

i!

D20 (6.5ft lbsl

Smearthread a sn db o l th e a dc o n tacl suriaceswilh locking compound(P/N277961-9).

Tiqhteninglorque 350 Nn {258ft l b s ) a p p l i 6 sw h e n u s i n gs p e c i a l tool 5188.lf a torque wrench is lsed dirscny on the cenler boll (wiihout 5188), the tiqhlening torqle should be 450 Nm (332ft

@@' Nm (55 ft tbs)

75 Nm (55 ft lbs)

350 Nm (258ft lbs)

zbro'\ 1rstt tu"t Smear threads wiih compoundP/N277961-9.

Specifications

Gtoup 22 LubricatingSystem OILCAPACITIES Excl.oilfilter Incl.oillilter Difference in volume,max-min

D20

D24

Litors{US quarts} 5.2 (5.5) 6.0 (6.3) 1.0(1.0)

LitersIUS quarts) 6.2 (6.5) 7.O(1.41 1.0(1.0)

ENGINEOIL Oua1ity............,,,,,............ min CC Accord'ngto API.......................................,,..,....,.:::::::::::::,.::::::: Oilswith designations SSCC,SE/CD, SF/CCand SF/CD meotthis r€quirement VbGosity Tomporaturcrangs (stableambisnttemperatures)

SAE15 W/50orSAE20 w/50 oilsarerscommend€d for usein sxtremedrivingconditionswhich involvehigh oil consumptionand high oil temperatures. for example, mountaindriving with frequentdecel€rationsof fast motorwaydriving. (Notehowoverth€ lower temperature limits.)

OILPRESSURE Oil pressurcat oil temperatureof 8O.C(176.F)and 33,3r/s

(2000r/min)min

kPa

psl

200

28

15-45

2-6.4

Oilpressuresensot Cut-outpoint,indicatorlampgoesout at

Lubricatingoil pump Reliefvalv€opensat......

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

600-700

85-99

R€lisfvalvespring,l€ngthat diffsrentloads

ffiffi8

Long1h Load mm in.

N (1.93) L = 49 0 L1= 22 {0.87} 17F195 L2 = 19.8 (0.781 approx.200 (completelycompressed)

lbs 0 {39-.44) (45)

Specifications

Group23 Fuelsystem GENERAL F i r i n os r d e r . . . . . . . . . . . . . . . . . ldle

fast .,.,.....,.,.,.,,.

:o a,o

D24 1-5-3-6-24 12.5(750)r/s (r/min) 87.0(5200)r/s (r/min)

FUEL Standard................

DIN51601rCEC-ERF-Dl, or ASTIM-D 975-No.2-D 45 0.5

60litres(15.8US galls.)

M a k ea n d d e s i g n a t i o n ,D 2 0

D24 VolvoP/N{exchange unit)D20 ....................

D24 Injeclion timing{purrpprungerslrokeat TDC, D20.............................

D24USAandCanada1979-t98i 1982-

0i:o

D20 'l-2-4-5-3 12.5(750) 87.0(5200)

NOTE! High altitude necessaryIn certain page132.

Distributor rypepump BoschVE5/10F2400145 (145'1for autovehicles) BoschVE6/10F2400132 (132-1 for autovehicles) 500't716-9 5001715-1 Checkinsmm lin) Settinsmm {in) 0.75-0.83mm (0.0295-0.0327) 0.80mm (0.0315) 0.65-0.73mm 10.256-0.O2a7J 0.70mm (0.0276) 0.65-0.73mm (0.0256-0.0287) 0.70mm (0.0295) 0.82-0.90mm {0.0323-0.0354} 0.85mm {0.0335)

INJECTORS Ir4akeanddesignation BoschNo. USA,/Canad€ 1982-

Othermarkets...................

VolvoP/NUSt"/Canada t982-

BoschKCA30SD27l (44) 0 68 13020?F (201J) 0 68 130201(201K) 1328073,0 1257t44-4

Checkins lnlectoropeningpressure''''. . . . . . ..................................

MPa '. . . ....",.- .- . . . . . . . .....,.-....,. psi 1707-1849

Setting

12.5-',t3.s 1778,1920

Specifications

Nozzl6s Designation USA"/Canada 1982Othermarkets Volvo P/N USA,/Canada1982'

Bosch DNOSD1930 DN O SD 193 1328096,1 't542303-1

,esz.

3::133;3i 5l usarcanlda 068190201 I ^.

oogrrozolxl

D N 0 5 D 1 9 30 = U S A / C a n a d1s9 8 2 D N = S D 1 9 3= o l h e rm a r k € t s

ldentiticationot iniectors and nozzles

Iniector (complete)

TIGHTENINGTOROUES Nm 10

Injector, in cylinderhead upper-rowersection...........................::...:.:.:.:.:.:.:::..:: 70 pump,pumpg Iniection 45

ft. lbs 52 52 33

70Nm = 52ft lbs

45 Nm = 33 ft lbs

ti

10

Specifications

Group26 Coolingsystem GENERAL Coohnt Sincealuminiumis usedin the engines, activecorrosion protectionis necessaryin the coolantto help pre ventcorrosion damage. genuine Use Volvoblue-green coolanttype C diluted with cleanwater in proponionsof 50/50.

This mixture helps to pr€venl corrosion and frost

c,il

a

Neverlill the coolingsystemwith water alone.

a

The coolantshouldbe changedregularlysince the corrosionprolective6dditivesin the coolant losethoiref{ectin time.

co Capacity, with manualgearbox with auiomatictransmission .....,,...

D 20litros IUS qlrrts) 8.2 (8.7) 8.0 (8.4)

D 24lirresIUS quarts)

Type 1 kPa(psi) 65-85(9.2-12.1) 7 {1.01

Type2 kPa{psi) r00 {14.2) 7 {1.0)

9.4{9.9} 9.2{9.7)

EXPANSIONTANK Pressure valvein capopensal ,,.,.,.,,,,.,,,.,..,....,.....

THERMOSTAT

)ijo tt:o

Markin9.........................

Startsto openat ,....,,.,..

Fullyopenal O p e n i ngsa p .m i n . . . . . . . . .

87'C 87'C{189'Fl 102'Cl216.Fl 8 mm (0.3in)

DRIVEBELTS Deslgndion (VolvoP/Nl HC38xl238 (960296-2) HC38x975 (958354-3) 3 C o o l i n gr a n 4 Powersteo.ingpump

HC38x888 {460431 s)

TIGHTENINGTOROUE C o o l i n gf a n

Hc38x800 (958302-1) 9

Ir. lbs.

6.6 1l

Special tools

Specialtools 999

lDdcription-U.s

18Ol-3 | Stand.rd h.ndle: lsed with drift 5207 and 5208

261G3 | Lift be.m: rcmovingfinslalling engin€ 2901-0lC16mpinsplisrc{2x):clampinswat€rhoseswhenremovinsintecrionpump 2903.6 | Oiltlltor wl6Dch 4090-0 | Pullet:removingpilol bearins 5006-5 | Lifi br.ckst: r€placingtronl €nsinemounts 5033-9 | Support{2xl: for lilt bracl€t5006 5112.1 | Loc*ing 6sdo.: locking flywheel

51154 | Lift hook: usedwith ltft bracket5006 5185-7 | Lift hoolr lronr: removing/inslallins €nsin€ 5186.5 | Lift hoo*, lsar: ,€movins,4nstaltins ensine 5147.3 I WronchrvibrationdEmoer 5188.'l I Wr6nchwith oxt nsionarm: lor vibraliondampercenterbolt 5190-7 | Giuse: instsllingcamshaft 5191-5 | Adapter:connoctinspr6ssur6ssuse 51$n I Siop: lockihsinjecrionpunp sear 5194.9 | Holder:for dial indicalorwhen adjueins inj€ctionpump 5195.5 | PlisB: rcmovinsvalvediscs

Specialtools

5006,5033,5115

5185,5186

5194

5187,5188

5t95

't3

Special tools

999

't4

5196.4 5197"2 5199-8

P.B3 roolj for valvetappets Balt tonsiong.uqo: timing ge8rbeltsand pump drive Wr3nch:front and rearcamshafigears

52004 5201"2 520/t-6

Adapter:installingcEnkshaftfront sealand camshafts€als Wr6mh: centernut on rearcamshaflg6arand pump gear Pullor:pump gear,inj€ctionpump

5202-0 5203-8 5205€

P0llor;for idl€r pull6y Centerinssh.ft: for clutchdisc P{ller: for crankshaft front s€sl

l'207-t 5204-7 5233-7

Drift: installingnsedlgb€arjnsin crankshaft Drift: installingcrankshaftrearseal GuidapiB, M t l bolts {4x):installingcylinderh6ad

523/t3 5235-0 9950-0

GuidepiB, M t2 bolG {4x)rinstallinscylind6rh6ad Tool lor removing suide ping Adapter:gnsinelpm. Usedwirh VolvoMonot€stBr

Specialtools

5233,5234 9950

9950

Group21 Engine Contents

Group21 EngineAssembly

Contents In-car Valveadjustment.,,..,.....

Basicsettingof sngine...

Cylinderhead,removaI disEssembly ................... cleaning-chscking .......... asssmory ........................ insta11ing......................... tightening torquss,....,,... gearsand pump)........................

Drivebeltsltiming belttension ....,,,,,,.,.......,, rep1acement....................

Camshaft, r€moval insra11ing.........................

Camshaftoil seals,replacemenl, Iront.,,,...,,..,,...,,,.

Pilotbearing incrankhaft, replacement .......,....,.,.. front,,..,,...,,...,,..

Crankshaftoil seals,replacement, Vibration damper,removal, insta11in9,,..........,.......

Engine mounts,rep1acement,,,.,,,.,,....,,...,,...,,...,,...,

Operation

Page

A1-10 B1-11 c1-21 D1-20 E1-11

17 19 22 28 33 36 41 45 57

G1-16 H1-38

u1-4

58 60 71 74 81 88 94 96 103 106 110

x1-33

'r11 '114

K1-5 Ll-35 t\41-11 N1-27 o1-21 P1-21 o1-7 R1-21 s1-11 T1-10

Replacementof engine Removal .,...,,.......,...,....,.

Insta11in9 ........................

Group21 Engine Compression test

A. Compressiontest Specialtool:5191

A1 Disconnectwire lrom stop valve on injection pump T h i s s t o p sf l o w o f f u e a n d p r e v e n r st ] n n e c e s s a rsyp i | ase.

A2 Removevacuumpumpand pump plunger

A3 Disconnectfuel detiverypipes C e a n a l l c o n n e c r i o n sc a r e f u y b e f o r e d i s c o n n e c r i n g D i s c o n f e c ip i p e s a n d p l u g a l l c o n n e d i o n sr o p r e v e n r d i r i f r o n r e n t e r l n gs y s t e m .

11

Gtoup 21 Engina Compression test

44 Removeiniectors Use27 mm socket{VolvoP/N1158146}. theywill otherwise Liftouth€atshieldsundsriniectors tesl. beblownout duringcompression

A5 Connectcompressiontestel adapter heatshield incylind€r headandscrewin Placea 5191.Ighten to 70 Nm {50ft lbs). testerto adapter. connectcompression A6 Run engine and record compression Compression Min Max differ€ncebetween

= 3.2MPa{455psi} = 2.4MPa(341psi) = 0.8MP.(114psi)

A7 Installiniectors Placenewheatshieldsin cylinder head, seefig. Install injectors.

Torqueto 70 Nm (s0 it. lbs).

A8 Reconnectdeliverypipes torque25 Nm(18ft lbsl.

Tightening

A9 Reconnectwire to stop valve

r'.l0 Installpump plungorand vacuumpumP CheckpumpO-ring.replace

18

Group 21 Engine Valve adjustment

B. Valveadjustment Special tools: 5195, 5196

V a l v ec l e a r a n c em u s t b e c h e c k e d / a d i u s t e6df i e rc o m p l e t i o no f r e p a i f ss u c ha s g r i n d i n gv a t v e s c, r a n k s h a frre p t a c e m e n t etc., a n d a l s o a f t e r6 0 G - 1 , 2 0 0m i l e s ( 1 , 0 0 G - 2 , 0 0k0m ) .

B1 Removevalve cover B2 Turn engineuntil cyl. 1 is at TDC- injection A w a y s u s et h e v i b r a t i o nd a m p e rc e n t e rb o l t t o t u r n t h e e n g i n e .2 7 m m s o c k e to r w r e n c h 5 1 8 8 .

B o t h c y l i n d e r1 c a m s s h o u l d p o i n l o b l i q u e l yu p w a r d s .

B3 Check valve clearance lor cyl. 1 Checking values Coldensine

a il a !

Exhaust

0.15-0.25 0.0060.010 0.350.45 0.01,t-0.018

Exhaust

0.20-0.30 0.008-0.012 0.400.50 0.016-0.020

D20

C o d e n g i n e= r o o h t e m p e r a l u r e

o24 f r

Alf

I

r

Alt 19

Group21 Engine Valveadjustment

Incorrect clearance (BZBS ) B4 Tum engineapProx.1/4 iurn Pistonmustnot be at top deadcenterwhensetting otherwisevalveswill contactpiston valveclearance, deprsssed is whentapp€t

B5 Dopresstappets pointslightly inward. using untilgrooves Turntappets discs. access to to obtain tappets 5196, depress tool

B6 Removedisc Use5195.

B7 Calculatethicknessol disc to be used whensetting: Valvecl€arsnces Cold €ngine Exhaust

0.20 0.40

in 0.008 0.016

0.010 0.25 0.018 0.45 Calcua micrometer. old discwith Measurethicknessof latethicknessof new discto be used,seeoverleaf.

Exhaust

20

Gtoup 21 Engine Valve adjustment

Erample: is 0.25 lfclearance is 0.20mm andspecified clearance mm then replaceexistingdiscwith one whichis 0.05 Alwaysuse new discs, = 3.0G-4.25 mm 6t inte als Discthicknesses 6vailable of 0.05mm.

B8 Position new disc and removepliers Discshouldbe lubricateda n d i n s t a l l e dw i t h s i z em a r k s B9 Check/adjust valve clearanceIor remaining cylinderc Checuadjust in followingorder: D 20. 1-2-4,5-3 D 24, 1-5-3-6-2-4 lmportantl Do not forget to rotatecrankshafl1/4turn beforechecUadiusting valveclearance.

810 Recheckvalve clearancefor all cylinders R o t a t ee n g i n es e v e r a lt u r n s b e f o r e r e c h e c k i n g .

811 lnstall valve covet if required.

Usenew gaskets

iY:'I,l d.!

T w o i y p e s o f p i n s t o d sa r e a v a i l a b l es e ef i g . L a r e t y p e s have a spacer, and hole in gasket is la.ger to prevent damage to gaskel by ovenightening, L€te and eary type parts must not be imerchanged.

21

Group21 Engine Basic setting

C. Basicsetting of engine Specialtools: 5190,5193,5194,5197,5199,5201

Thefollowingoperationsaredescribedin this sectionl - settingcamshaftpositionin rel6tionto crankshaft - settingtensionof drive belts{front and rear) - injection timing.

Enginesshouldbe basic-setif, by adjustingthe pump,it is not possibleto obtain the correctinjectiontiming.

(Camshaftseningmay havs changed)

C1 Remove: -timing gearcovers{front and rear).

=

C2 'l Turn engine until cyl. is at TDC - iniection Alwaysusethevibrationdampercenterbolt to turn ihe engine.

27 mm socketor wrench5188.

BothcylinderI camsshouldpointobliquelyupwards.

Flywheel at 0 mark.

22

Group 21 Engine Basic setting

Lift ofi pump belt Slackenmountingbolts for injectionpump releasebelt tension-Tightenone boll so t h a t p u m p remainsin upperposition.

Lift off belt.

a, ,":'trtiiiiiiiiii c4 Removecamshaftrear sprocket Holdsprocket in pos;tion with5199andunscrew nut with wren€h 5201. Take care not to rotate camshaft.

C5 Slackencamshafttront sprocket U s e 5 1 9 9r o h o l d s p . o c k e ri n p o s i n o nw h e ' 1l o o s e n i n g b o l t . M a k e s u r e t h a t c a m s h a f id o e s n o l r o l a t e .

Tap sprocket to free it from camshaft.

c6 Set belt tension A d j u s tt e n s i o nb y m o v i n g c o o l a n tp u m p .

U s e g a u g e5 1 9 7t o c h e c kb e l t t e n s i o n .A t t a c hg a u g et o b e l t a n d s e t t o 1 2 . 5u n i t s .

S t r e t c hb e l i u n t i l m a r k o n g a u g e p t u n g e ri s f t u s hw i t h D e p r e s sb e l ts t r o n g l y w i t hh a n da n d r e c h e c U a d j u st el n

23

Group 2l Engine

Basic setting

C7 Set camshaft position Inserta 0.2mm PlacegaLrge 5190at rearof camshaft.

(0.008in) ieelersausebeneathlefi sideof sauseto for timinggearclear;nce. compensate Camshafi;s now setat correctposition.

C8

Make sure cyl. no. 1 is at top dead center Check 0 mark on flywheel and adiustif necessary.

)r C9 Tighten camshaft front sprocket Use5199to preventsprocket fromturning.Makesure that camshaftdoes not turn.

Torquecenterbolt to 4s Nm (33ft lbs).

c10 Removegauge 5190 and leeler gauge

cl1 Disconnectcold start device Slacken screw1. Pushleverforwardandrotatesleeve 90". Notel Do not turn screw 2 otherwiseit will be necessary to removecold startdeviceand resetit on a

Group 21 Engine Basic setting

_--xar-L--.\.'

-.l\t'-iHi-

- v -.t";; -

ilo ,,

-.-

c12 Basic-setiniectionpump pumpmountins bolts(Ailen key= 6 mm).Align S acken pump bracket byturning in pumpandmounling marks R e t i g h t e nm o ! n t i n 9 b o l t s .

.)!\\./.)

.-

/:)a>-

L

I

c13 Sel dial indicator zero. Lock pump gear at cyl. 1 injection using stop 5193 Unscrewand removeplug from injectionpump dis(range0-3 tributor.

Installholder5194 anddialindicator mm).Setgaugeto approx.2 mm.

Turn pump gear clockwiseuntil mark on gear and mo'rntingbracketcoincide.

T h e n t u r n p u m p g e a r b a c k s l i g h ty u n t i l m i n - r e a d i n g r e g i s t e r so n d i a l i n d i c a t o r .

Set indicator to zero.

T u r n p u m p g e a rc l o c k w i s e! n l i l m a r k o n g e a ra n d p u m p m o u n t i n g b r a c k e tc o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n w i t h s r o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n t o

c14 Install camshaft rear sprocket and belt Tightencenlerbo t by hand,but it shouldstil be possi_ on camshaft. b e to turn sprocket

25

Group21 Engine Basic setting

c15 Set belt tension A d j u s tt e n s i o nb y m o v i n g p u m p .

U s e g a u g e5 1 9 7t o c h e c kb e l t t e n s i o n .A f t a c hg a u g er o b e l t a n d s e t t o 1 2 , 5u n i t s .

S t r e l c hb e l t u n t i m a r k o n g a u g e p t u n g e ri s f t u s hw i r h D e p r e s sb e l i s l r o n g l yw i t h h a n da n d . e c h e c U a d j u s r r e n

c16 Set pump and tighten camshaft rear sprocket U s e5 1 9 9t o h o l d s p r o c k e tT. o r q ! e w r e n c hs h o ! d r r ea t r i g h i a n g l e l o w r e n c h 5 2 0 1 o t h e r w i s et o r q u e w i l l b e U s i n g 5 1 9 9 ,l u r n s p r o c k e ts o w y c l o c k w i s eu n l i l d i a l D 2 0 . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . .8.0.m . .m . . .: . .0. .. 0. .3. 1 i5n D 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 . ...7. .0.m . .m . . .= . . 0 . 0 2 7 6i n D 2 4 U S A , / C a n a d a 1 917998 1 . . . . . .0. . 7. 0 m m = 0 . 0 2 7 6 i n 1 9 8 2 - . . . . . . . . . . .0. . 8 . .5.m. m : 0 . 0 3 3 i5n H o d s p r o c k e itn t h i s p o s i t i o na n d t o r q u eb o h t o 1 0 0N m ( 7 3f t . l b s ) .T a k ec a r et h a t c a m s h a f ia n d s p r o c k e d t o not

c17 Removestop5193trom pump gear

ct8 Check pump setting T u r n e n g i n et w o f u l l t u r n s u n r i c y t . 1 i s a t l o p o e d o c e n t e r- i n j e c t i o na g a i n . l f e n g i n e i s t u r n e d r o o r a r r m u s t b e l u r n e d b a c ka p p r o x .1 / 4 1 u r na n d t h e n t o z e r o m a r k o t h e r w i s es e t t i n gw i l l b e i n c o ( e c i .

D i a i n d i c a l o rs h o u l d s h o w : O 2 0 . . . . . . . . . . . . . . . . . . 0. ...7. .5.0. . .8 3 m m = 0 . 0 2 9 F 0 . 0 3 2 7 i n D 24 .......-............0 . ...6. .F. -0 . 7 3m m : 0 . 0 2 5 6 - 0 . 0 2 8i f7 D 24 USA and canada 1 9 7 F 8 1 . . . . . . . . . . . . . . . .0. ...6. .5 - 0 . 7 3 m m = 0 . 0 2 5 60 . 0 2 8 7 i n 1982 ........-................0.8 92 0m m = 0 . 0 3 2 3 - 0 . 0 3 5i n4 Correct reading: Tighren injeciion pump mounting b o l l s .P r o c e e dt o C 1 9 . r n c o f t e c tr e a d i n g : B e a d j u s ta c c o r d i n gr o i n s r r u c t i o n s

26

Group 21 Engine

Cylinderhead,removal pumpsetting: Readlusting Settingvaluesi

-trnjE+: -i;6't;

D 20 ......-.............-....-.......................

0.80mm = 0.0315 in D 24 .....-....-....-........-....-...-...-....-......

0.70mm = 0-0276 in D 2 4 U S A a n d C a n a d a 18917. 9 .....0.70mm:0.0276in 1982-..........

0.85mm = 0.0335 in

$tl

Readinglessthan specified: purnpmountingboltsandlurn pumpinwards Slacken to obtaincorecr value.Tightenmounringboltsand repeatcheckof pumpsetting.

Beadingmore than specified: pumpmoulingboltsandturnpumpoutwards Slacken untildialindicator showsapprox.

D 2 0 . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . .m . .m . 0=. 70 0. 0 2 7i 6n D 24 ..........................................-...-..

0.60mm : 0.0236 in D 24USA,/Canada l97F81.............

0.60mm =0.0236in 1 S 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m = 0 . 0 2 9 Th€nturn pump inwardsuntil specified va ue is obtained.Tightenmountingboltsand recheck punrpsetting.

NotelInjection pumpmustrot betappedor knocked as thiswil altersetting.

c19 Remove dial indicator and holder 5194. lnstall plug with new seal Tishtening torque9 Nm (6.5ft lbs).

c20 Reconnect cold start device Presseverforwardsand turn s l e e v e 9 0 " . R e t i g h t e n

c21 Installvalvecoverand timing gearcovers U s e n e w g a s k e t si f n e c e s s a r y .

/ Qa,s ' zTazzzz II

E

Two types ol pin studs are avaitabte,see tig. LareryDes h € v ea s p a c e r a , n d h o i e i n g a s k e li s l a r g e rt o p r e v e n l d a m a g et o g a s k e rb y o v e r r i g h t e n i n g , Late ard eury type pa.ts musr not be inlerchanged.

21

Group21 Engine Cylinder head, removal

D. Cylinderhead,removal Specialtools: 5199,5201

D1 Disconnect negative lead from battery Removeenginesplashguard.

D2 Disconnect: - e x h a u s tp i p e f r o m g e a r b o xb r a c k e t e x h a u s tp i p e f r o m r e a r b r a n c h p i p e .

D3 Disconnect: - exhaust pipe pipefromfrontbranch -air

filter cover with intake hose and crankcase

D4 Draincoolant R e m o v ee x p a n s i o nt a n k c a p D i s c o n n e clto w e r r a d i a t o rh o s ef r o m r a d i a t o r

2a

Group 21 Engine Cylinder head, removal

D5 Draincoolantfrom engine { E n g i n ei s w i t h o u t a d r a i n c o c k . ) D i s c o n n e co t w e r h o s ef r o m c o l d s t a r td e v i c ea n d d r a i n

D6 Disconnect {rom cylindet head I u p p e r r a d i a t o rh o s e - h o s ef o r c o l d s t a r i d e v i c e .

D7 Removevacuumpump and pump plunger Remove pump retaining nuts and place pump on B e m o v ep l u n g e rf r o m c y l i n d e rh e a d .

D8 Removetuel deliverypipe C l e a na l l c o n n e c t i o n st h o r o u g h l yb e f o r ed i s c o n n e c t i n g R e m o v ea l l p r e s s u r ep i p e sa n d p l u g e n d s l o p r e v e n td i n f r o m e n t e r i n gf u e l s y s t e m .

29

Group21 Engine Cylinder head, removal

D9 Disconnect from cylinder head: -wire for temperature gaugesender -wire for glow plugs copperconnecting stripfor rearglow plug - feturn hosefrom rear iniector - wirefor temperature gaugesenderat rearof cylinder

D10 Remove: -timing gearcovers(front+ read

Dl1 Tum engineuntil cyl. 1 is at TDC- injection A l w a y su s e i h e v i b r a t i o nd a m p e r c e n t e rb o l t t o t u r n t h e 27 mm socket or wrench 5148.

B o t h c y l i n d e r ' l c a m s s h o u l d p o i n t o b l i q u e l yu p w a r d s .

Flywheelat'0'mark.

D12 Remove retaining screws from belt cover on cylinder head Takecarelhatwasheron innerscrewdoes nolfalldown intolowertiminggearcasecover.

(Latetypeenginesdo not havethiswasher).

30

Group21 Engine Cylinder head, removal

D13 Removebelt from camshaftsprocket S l a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l t t e n R e m o v eb e l t f r o m s p r o c k e t .

D14 Bemovecamshaftfront sprocket Use5199to holdsprocket in posjtionwhentoosening bolt. IMakesurethat camshaftdoes not rotate.

Tap sprocketto free it from camshaft.

D15 Lift off pump belt S l a c k e nm o j n t i n s b o l t s f o r i n j e c t i o np u m p re ease belt tension. Tighten one bo t so r e m a a n si n u p p e r p o s i t i o n .

Lift off belt.

D16 Removecamshaftrear sprocket Hold sprocket in position with 5199 and unscrew sprocket with wrench 5201- Take care not to rorate

31

Group 21 Engine Cylinder head, removal

oo

oo

A,

Ol

D20

@o

oo

o@

T i g h l e n i n gs e q u e n c ef o r c y l n d e r h e a d b o i s .

Bolis musl be slackenedln reversesequence.

@@,o

o D24

@o0

o

D17 Remove cylinder head lmportantr Slacken bo ts in reverse sequence to tighle n i n g .( i . e .s t a r ta t 1 2 ( o r 1 4 ) a n d f i n i s h a t 1 - ) L i i i a w a y c y i n d e rh e a d .C h e c k t h a rt e a r g l o w p u g c l e a r s i n j e c t i o np u m p b r a c k e la n d t h a t v a l v e sd o n o t c o n t a c t

oo@

ooo D18

0

Place cylinder head on wooden blocks Do not restcylincler head

D19 Clean gasket surfaces on cylinderhead and cylinderblock

D20 Check for damage and warp U s e a s t r a i g h te d g e a n d f e e t e rg a u g e .

R e p l a c ec y i n d e r h e a d i f w a r p e x c e e d s : - l e n g t h w i s e0 . 5 m m { 0 . 0 2i n ) .

- c r o s s w r s e0 . 2 m m ( 0 . 0 0 8i n ) .

--:(g=

32

0

(

0

(

Group21 Engine Cylinder head, disassembly

N o t e l S m a l l c r a c k s( 0 . s m m = 0 . 0 2i n ) d o n o r w a . r a n r r e p l a c e m e not f c y l i n d e rh e a d s i n c et h e y d o n o t i m p a i r F o r g a s k e t r e p l a c e m e n to n l y s e e " C y l i n d e r h e a d i n s t a l l a t i o n "p a g e 4 5 .

E. Cylinderhead,disassem bly

E1 Removeintake manifold,exhaust manifold and gasket

E2 Remove injectors R e m o v ed i r l a r o u n d i n j e c t o r s .

D i s c o n n e cftu e l l i n e s .

B e m o v ei n j e c t o r s , 2 Tm m s o c k e t .L i f t o u t h e a ts h i e l d s l r o m c y l i n d e rh e a d .

iI

33

Group21 Engine Cylinder head, disassembly

E3 Removecamshaftbearingcaps 1 and 4

E4 Remove camshaft bearing caps 2 and 3 1oavoidplacingunevenloadon nutscrosswise Slacken

E5 Lift awav camshalt and remove oil seals

E6 Lift out tappets N o t e l D o n o t i n t e r c h a n g tea p p e l s .M a r kt a p p e t ss o t h a t t h e y c a n b e i n s t a l l e di n s a m e p o s i t i o n .

E7 Remove {rom cylinder head: - lifting eyes - c o n n e c t i n gf l a n g ef o r w a t e r h o s e ( A l l e n5 m m ) - t e m p e r a t u r es e n d e r s( 2 x ) .

Group21 Engine Cylinder head, disassemt'/y

E8 Tap out swirl chambers Usea longnarrowpunch(6mm - 0.24in diameter), l e n g t h1 5 0 m m ( 6 i n ) .

{r*,t E9 Removevalve springsand valves pans.

Do not intetchange lmportant! tool valvespringswith a specialcompressor Depress

- upperspnngseat - springs

E10 Removesealstrom valve guides Usetool5219,

D El1

Removelower valve spring U s e a p a i r o f e x t e r n a l o c k r i n g plierswith flatjaws.

35

Group21 Engine Cylinder head, cleaning - inspection

F. Gylinderhead,cleaning- inspection

v Checkclearance between va lve g uides and valves Usea di.l indi.alor Usenewvalves(iniakeandexhausl) with endoi va ve slemf ushwith valveguide. = 1.3mm (0.05in).

C earance

V

F2 Checkcamshaftend float Usea dialindicator.

Posiror ransnaildrd rr"ld redrcdp.lorqueto 20Nm

, r bn r b s , .

0

C l e a r a n c e= m a x 0 . 1 5m m ( 0 0 0 6 i n ) R e m o v ec a p a n d c a m s h a f l .

0 F3 Check discs C h e c kd i s c p l a y . B e p l a c ed i s c i f w o r n o r s c o r e d .

I n s t a l ln e w d i s c sw i t h n u m b e r sf a c i n g d o w n , l o w a r d s C l e a r a n c en,e w p a r 1 s. . . . . . . . . . . . . . . . . . . . .0. ...0. .16. .- 0 . 0 4 6m m ( 0 . 0 0 0 6 - 00 0 1 8i n )

36

Group21 Engine Cylinder head. cleaning - inspection

Check tappets P acetappetsin cylinderhead Checkfit andclearance. mm (0.0010.003in) Clearance, newparts 0.025-0.075

Check valve springs

8trre

Length lin) (1.334) (1.126) (0.720)

0 61 17 209-231

{lbs) l0) { 1 51 7 . 5 ) t41 52.2)

Outersprings Length (in) (1.583) 40.2 (1.283) 32.6 (0.878) 22.3

0 I67-185 433 479

{lbs) (0) l3v42l (98-108.3)

33.9 28_6 18.3

Replacingvalve guides OperationsF 6-8

F6 Pressout valveguide U s e d r i f t 5 2 1 8 .P r e s sf r o m c o m b u s t i o nc h a m b e rs i d e .

Ptess in new valve guide L u b r i c a t ev a l v e g u i d e . l j s e d r i f t 5 2 1 8 .P r e s si n f r o m c a m s h a f ts i d e .

P r e s si n g u i d e u n t i l f l a n g e o n g u i d e c o n t a c t sc y l i n d e r h e a d .I n t h i s p o s i t i o np r e s sf o . c e m u s t n o l e x c e e dl t o n since f ange may break off.

37

Group21 Engine Cylinder head, cleaning - inspection

F8 Clean inside of valve guide Use rsamBr5224 Note! Cuttingoil must beusedwhenreaming,

aftsrvalveguide Valvesand seatsmust be ground-in

'-'T-_____________ Gri nding-i n valve6and seats OperationsF 9-12

F9

wr-

Machineg nd intako valvos Edgeof intakevalvemustnotbelessthan0.5mm (0.02 In). lmportant!Exhaustvalves are stellitecoatedand must not be groundby machine.Grind-invalveon seatwith grindingpaste.

F10 Mill or grind valv6 seats Grindto 45'.

Contactsurface{a) must be: -2.0 mm {0.08in) for intakevalve -2.4 mm {0.09in)for sxhaustvalve. ll contactsurfaceis too wide reduc€areawith a 15q lmponam! Outer diameterof cutter must no! Bxceeo 35,2mm (1.39in) for intakevalve s€atsand 33.2mm {1.31in)for sxhaustvalvessats.

1.5mm {0.00in)

Ftl Measuaegap betweendisc and cylinderhead surfaco Gap= max1.5mm 10.06 in).

Replaceseatand possiblyvalve if gap is too Iarge.

NotelTwo valvstypes are available,seeG3.

38

Group21 Engine Cylinder head, cieaning - inspection

F12

Grind-invalveswith paste C l e a nv a l v e st h o r o u s h l y .

.3F{'

q.

'

^s Replacingvalve seats OperctionsF13 21 V a l v eg u i d e sm u s t b e r e p l a c e db e f o r er e p a c _ i n g s e a t s ,s e e F 6 8 , p a g e 3 7 .

Cfeancombustionchamber

F13

Togeol sealnJsl be clearv vis:oleahF' cleaninS. Remove valve seat

F14

Mill vave seat, using cutterssuch as Mira {P/N Make instructions.

9986045).

Referto manufacturer's surethatseatin cylinde.headis not darnaged. cleansurfaces thoroughtr.

,rU

Measure diameter of seat recess in cylinder head and of valve seat Usean internalmicromeierto measureseat recess Standard (production version) mm (in) Diameter, seatrecess, 37.00037.016 i.1.4561-1.4513) in1ake....................

6 33-000-33.01 11.29921.2994) exhaust................

37.09(F37.105( 1 . 4 6 0 21 . 4 6 0 8 ) inrake....................

05 { 1 . 3 0 2 8 - 1 . 3 0 3 3 ) 33.090-33.1 exhausr................ mm = 0.00290 041in)

Oversize ( r e p l a c e m e nPt a r t sv e r s i o n ) , m (rnJ D a m e t e r ,s e a t r e c e s s m 3 7 . i n 1 a k e . . . . . . . . . . . . . . . . . .2. .0 0 - 3 7 . 2 1 6 \ 1 . 4 6 4 6 - 1 . 4 6 5 2 1 1 1 3 4 1 1 - 13 0 1 7 1 e x h a u s r. . . . . . . . . . . .3. .3- -. 2 0 03 3 2 1 6 i n t a k e . . . . . . . . . . . . - . . . . . . . 3 73. 27 9. 300 5 e x h a u s i . . . . . . . . . . . . . . . 3 3 . 239303 0 5

(1.4681-1.4687) (1.3106-1-3112)

W h e n r e p l a c i n gv a v e s e a l s :t h e i n t e r f e r e n c eb e t w e e n t h e v a l v es e a ta n d i t s b o r e i r t h e c Y l i n d e rh e a ds h a l lb e 0.074-0.10smm (0.0029-0.0041in) I e valve sear d am e t e r m u s t b e 0 . 0 7 40 . 1 0 5 m m ( 0 0 0 2 F 0 0 0 4 1 n ) g r e a t e ri h a n t h € d i a m e l e ro f t h e b o r e i n t h e c y l i n d e r h e a d .R e p l a c ec y l i n d e rh e a c li f c e a r a n c ei s t o o s m a l M i l l s e a t r e c e s si f i n t e r f e r e n c ei s t o o l a r g e .

39

Group21 Engine Cylinder head, assembly

F16

Heatcylinderhead (212'F).

Heatto '100'C

F17 Placenew seat in installationtool Use drift 5220 for intake valve seats and 5221 for ex-

lr F18 Cool valve seat Wear protective gloves and safety glasses.

Use liquid carbon dioxide to cool seat down to -70'C (-94"F).

Ft9 Tap-invalveseat N o t e l T h i s m u s t b e d o n e q u i c k l y , w i t h i n 34 s e c o n d s t o avoid temperature loss.

0,r ( F20 Checklit of valve seat M a k es u r e t h a t t h e s e a th a s b o t t o m e dc o r r e c t l ya n d i s s e c u r e .i f n o t , r e p l a c ec y l i n d e rh e a d .

F21 Grind valvesand mill seats S e e i n s t r u c t i o n so n p a g e 3 8 , o p e r a t i o n sF F ] 2

40

Group21 Engine Cylinderhead,assembly

G. Cylinderhead,assembly New cylinderhead

a Newcylinderheadmust be the sametype as the old. Cylinderheadsdesignedfor use with lvl 12 bolts must not be usedwith M '11bolts.

Cylinderheadscan be identifiedas follows (see illustrationat left): Numberseriesfollowedby B = M 11 - Numbe.seriesfollowedby C = M 12 LJSA,/Canada 1982-has a differenttype of cylin, der headandswirlchamber.

Swirlchamberand its boreis 2 mm (0.080in) smallerin diameter

Newcylinderhead Opetationcl

cl

Installoil ieis and pin studs in cylinderhead Carelully tapin oiljetsusinga brasspunch.

Note!Turnouterjetsto pointacross cylinderhead,see fis lmportantl Check specification ;nd type of cylinder h e a d .M ' 1 2b o l t s m u s t n o t b e u s e d w i r h M 1 1 b o l t s .

Differenttype cylinder heads are used for LJSI,/Canada.

G2 Checkvalvestem posilionin relationto camshaft Thismeasurement iscarriedoutto ensurethatthereis sufficientadjustmentlattitudefor valves.

Placegauge5222with largestdiam€terring,on cylinder he8d.(Smallringis for B 17-B23 engines.)

Notel F.ont bearingrecessdiameter'islargerthan others.Makesurethat gaugeis positio.ed correctly.

Takingeachva,vein tu.n, checkthat stem doesnot grindvalvestem. conlactgauge.lf thishappens,

Vslve length, mm {in} New Min I n t a k e v a 1 v e . . . . . . . . . . . . . . . . . . . ' (140.41.286 ) 1 0 4 . 3( 4 . 1 0 6 ) E x h a u s t v a l v e . . . . . . . . . . . . . . . . ' 1(044. .161 8 i 1 0 4 . 1( 4 . 0 9 8 1

4l

I I

Group2l Engine Cylinderhead,assembly G3 Early and late tvpe valves.valve collets (locks) and upper springseats

I

E a r l yt y p e v a l v e sa n d c o l e t s h a v eo n e l o c k i n gg r o o v e whereas late tYpes have three O n l y l a t e t y p e s a r e a v a i l a b l ea s s p a r e p a r l s Consequentlw y h e n i n s t a L l i n ga n e w v a l v e ,t h e c o l l e t a n d u p p e rs p r i n gs e a l m u s t a l s o b e r e p l a c e dw i t h n e w N e w s p r i n gs e a t sa r e e i r h e r c o p p e cr o a t e do r c h r o m e d E a r l yt y p e s a r e b r i g h t o r b l a c k .

f(

0 G4 lnstalll - upperspringseats,flangedsideup. va ve stemoil seal. lnstaLl oilseal mustbeusedwheninstailing Protectivesleeves To installvalve,pl.cevalvein cylinderheadandplace protecrive sleeveon stem.use tool 5219to installoil seal,notethattool shouldabutflangeseal.

l, (

I G5 lnstall: innerand outervalvesp.ings

upperspringseatsand Twotypesol valves, lmportantl

Group21 Engine Cylinder head. assembly

ra

( .., e, air

G6 Install swirl chambers C h e c kt h a l s t e e lb a l l i s i n c h a m b e r .

L fn o t , i n s t a l ln e w s w i r l c h a m b e f .

M a k e s u r e t h a t b a l l f i t s i n s l o t i n c y l i n d e rh e a c l .T a p down swirl chambers. l m p o r t a n t ! S p e c i a s w i r l c h a m b e r s ( d i f f e r e n td i a 1982-. m e t e r )f o r U S A / C a n a d a

G7 lnstall: - glowp ugs.Tishtening torque40 Nm (30ft lbs) (2X).Samelypefrontandrear temperature senders - connecting fange for radiatorhose(Allen5 nrm).

Installnewgasket.

Tightening torque10Nm (7ft bs).

- lfting eyes.

G8 Installtappets with shims Smeariappetsandshimswith oil beforeinstaa!on.

Numberon shimsshouldfacedown.

Checkthattappetsslideeasiy withoutsticking.

G9 Placecamshaftin cylinderhead Lubricate contactsurfaces of camshaltand bearings.

Place9au9e5'190al rearof camshafl. lmportantlBoth camsfor number1 cylindermustpointdiagonay up,

43

Group21 Engine Cylinder head, assenbly

G10 Installcamshaltcaps2 and 3 Installcapscorrectly, centeris off'sel.

Holdcam Tighlennutscrosswise to avoiddistortion. wilh gauge5190at rearwhentighten shaftin position gauge5190.

Remove Gl1 Press in new camshaft oil seals Applyoil to oil seals.

Donotpushin sealstobottomposilion.

Makesurethat seasare"square",0 GI2 Install camshaft caps 1 and 4 M d l ec J r eI n a r " eL h r J 5 l w i s nfeo r c a r s h . l c a p 4 r l s colrecl.v.

G13

^ 0

Torque all four caps Torque= 20 Nm (15ft lbs).

G14 Tap in oil seals to bottom use adapter5200anda plasticma lei

G15 Installiniectors Placenewheatshieds in cy inderheadTurnshieds as Torquero 70 Nm {50ft lbs) Screwin injectors. fuel deliveyinesbetweenin,ectors Reconnecl h i s a c l v i s a be t o c h e c kc o n d i t i o no f i n l e c i o r sw h e n . e c o n d i t i o n i n gc y i n d e r h e a d . S e e i n s t r u c t i o n so n page153.

0 0

Gt6 Install exhaust branch pipe and intake mani{old U s e n e w g a s k e t sa n d n u t s . I n s t a l lg a s k e t sc o r r e c t l Y .

B r a n c hp i p e g a s k e ts h o u d b e t u r n e d w i t h r a i s e de d g e o u t w a r d s ,f a c i n g b r a n c h p i p e . I n t a k em a n i f o l d g a s k e t s h o | ]d b e l u r n e d w i t h g r e e ns i d e f a c i n gc y l i n d e rh e a d .

T i g h t e n i n gl o r q u e 2 5 N r n ( 1 8f t l b s ) .

Group21 Engine cylinder head, installing

H. Cylinderhead,installing Specialtools: 5190,5193,5194,5197,5199.5201,4x 5233,4 x 5234,5235

?/'--'\r

S--:'l Q4t

)io.iQ

H1 Clean holes lor cylindel h6ad bohs Oil and dirt must be removedfrom holes gasketmay leak as a result of insufficienttightening

H2 lnstall guide pins in cylinder block 5233for blockswith M 11 bolts.

5234for blockswith M 12 bolts.

Twoouterpinsholdgasketin position.Cylinderheadis preventedfrom slidjng and clamaginggasketby two innerpins, lmportantlUse all four pins, locatedas illustratsd.

H3 Install new cylinderhead gasket Thresdil{sr€nttypes areavailable, andaremarked with notches.

Typeto be fitteddependson pistonheight abovecylinderblock.

Uses8megaskettype (no,notches)as before,with OBEN facingup.

45

Group2l Engine Cylinder head. installing

Observe dale code on gaskel and packet.Gasket must b e u s e d b e f o r et h i s d a t e .

O n l yg a s k e t sw i l h c o d eM O o r l a t e rm a y b e u s e do n D 2 4

_0

B

c

D E

I

= 1980

r=r98r 2=1982

|

t*

MO

I

G Sept Oct Nov Dec

J L M'

I

198 T o a v o i d i m p a i r i n gs e a L i n gp r o p e r t i e so f g a s k e td o n o t o p e n p a c k e tu n t i l g a s k e ti s t o b e u s e d .

T a k ec a r en o t t o d a r n a g ep a c k e ta n d c a L r s ed a m a g el o g a s k e t ,( t e f l o ns t r i p ,r u b b e r s e a l ) .

3: =.-

l f p i s t o n s ,c o n n e c t i n gr o d s e t c . a r e r e p a c e d , p i s t o n h e i g h lm u s tb e m e a s u r e da, n d g a s k e ct h o s e na c c o r d i n g Piston height above

Gasket

(in} mm {in) notches thicknessmm (0_026-0.031 (0.055) 0.67-0.80 I ................

1.4 ) (0.032-0.03s)2 ................

0.81-0.90 1.5(0.059) 0.9't-1.02(0.036 0.040) 3 ................

1.6{0.063)

I

rl'

H5 Set cylinder1 to TDC F l y w h e e l t i m i n gm a r k a t ' 0 U s e a 2 7 m m s o c k e to r w r e n c h5 ' l 8 8o n v i b r a t i o nd a m p e r c e n t e rb o l t t o t u r n e n g r n e .

46

0

Group21 Engine Cylinder head, installing

H6 Position camshaft Selcamshaft so lhat number1 cylinderis at injection (bothcam lobesshouldpointdiagonally upwards).

Preventcamshaftfrom moving with stop 5190. lmportant!Camshaftmust be lockedotherwisevalves

Cylinder head bolts T w o t y p e s o f c y l i n d e rh e a d b o t s a r e i n u s e .

E a r l yt y p e b o l t s h a v e M 1 1 t h r e a d s T . h e s eb o l t sc a n b e r e u s e dw i t h n e w w a s h e r s -F i tw a s h e r sw i t h c ! p s h a p e f a c i n gu p .

M11

L a t et y p e b o l t s h a v e f M1 2 t h r e a d sa l o n g e n t i r el e n g t h .

T h e s eb o t s m u s t n o t b e r e u s e d W a s h e r sm a y h o w e v e r

o i!

I

Installcylinderhead bolts L u b r i c a t et h r e a d sa n d s l i d i n gs ur f a c eo f w a s h e r s .P l a c e b o l t si n h o e s w i l h o u t g u i d e p i n s .

+ R e m o v eg ! i d e p i n s . U s e t o o l 5 2 3 5 .

I n s t a l lr e m a i n i n gb o l t s .

47

I

Group21 Engine Cylindet head, installing

oooo9/@

D20

@o.r'o'o@@

n a

H8 Toique cylinderhead bohs adiaTightenall boltsoneat a timein orderspecified csntboforeproceeding wjth nextstage.

@@@@@).o@D24 @@@O@lO@,1

't1s9082

12-sidedwrenchP/N 1159082-5

Tightenin threestagesl 150Nm=37ftlbs 270Nm=5rftlbs 390Nm=66ftlbs

48

Tightenin four stagesl r 40Nm=29filbs 2 60 Nm = 44 ft lbs 3 75 Nm = 55 ft lbs 4 angle-tighten18{f in one movementwithout stopping.Seeillustration below:

Group21 Engine Cylinder head, installing

H9

Connect copper connecting stdp lor two rear glow plugs

o rD

H10 Installbolts lor cover H11 Installcamshaftsprocketand belt Pullbeltto ensure thatit sitscorrectly on crankshaft geaf.

Placebelt overcamshafi sprocket and position sprocket T i g h t e nc e n t e rb o l t b y h a n d ,b u t i t s h o u l ds t i l b e p o s s i ' b l e t o t u r n s p r o c k e to n c a m s h a f t .

Hl2

Set belt tension A d j u s tl e n s i o n b y m o v i n g c o o l i n g p u m p .

U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g er o b e t r a n d s e t t o 1 2 . 5u n i t s .

S t r e l c hb e l t u n i i l m a r k o n g a u g e p u n g e r i s f u s h w i r h D e p r e s sb e h s t r o n gy w i t h h a n da n d . e c h e c U a d j u s t t e n -

H13 Markesure cyl. 1 is at top dead center C h e c k ' 0 m a r k o n f l y w h e e a n d a d j u s ti f n e c e s s e r y .

Group 21 Engine Cylinder head, installing

H14 Placea 0.2mm feelergaugebeneathgauge5190 Insertbladebeneath leftsideof gaugeto compensale fortiminggearclearance.

0.2mm = 0.008in.

Ht5 Tighten camshaft front sprocket Use5199to preventspocket from turning.

Torquecenterbolt to 45 Nm (33ft tbs).

,)a )e

H16 Removegauge 5190 and feeler gauge

H17 Disconnectcold start device S l a c k e ns c r e w 1 . P u s hl e v e r f o r w a r da n d r o t a l es l e e v e 90'.

N o t € ! D o n o t t u r n s c r e w2 o t h e M i s e i t w i l l b e n e c e s s a r y t o r e m o v e c o l ds t a r t d e v i c ea n d r e s e ti l o n a t e s t b e n c h .

u)l

P r e s sl e v e rb a c k a g a i n s ts t o p .

i')l H1a Basic-setinjectionpump S l a c k e np u m p m o u n t i n g b o l t s ( A l e n k e y = 6 m m ) A l i g n m a r k so n p u m p a n d m o u n t i n gb r a c k e tb y t u r n i n g p u m p . R e t i g h t e nm o u n t i n g b o l t s .

5A

(

Group 21 Engine Cylinder head. installing

H19

Set dial indicatorzero. Lock pump gear at cyl. I injectionusing stop 5193 pumpdisrri U n s c r e wa n d r e n r o v ep l u g f r o m injection I n s t a l lh o l d e r5 l 9 4 a n d d i a l i n d i c a t o r( r a n s e0 3 m m ) .

S e t g a u g e t o a p p r o x .2 m m .

T u r n p u m p g e a r c l o c k w i s eu n t i l m a r k o n g e a r a n d m o u n t i n gb r a c k e tc o i n c i d e .

T h e n t u r n p u m p g e a r b a c k s l i g h t l yu n l i l m i n r e a d i n g r e g i s t e r so n d i a l i n c i i c a t o r .

S e t i n d i c a t o rt o z e r o .

T u r np u m p g e a rc l o c k w i s eu n t i l m a r ko n g e a ra n d p u m p m o u n t i n g b r a c k e tc o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n w i t h s t o p 5 1 9 3 .( l n s e f ts t o p t h r o u g h p u m p g e a r i n t o

i;;$d

H2A Installcamshaftrear sprocketand belt Tlghtencenterboltby hand,but it shouldstillbe possi b e to turnsprocket on camshaft.

H21 Set belt tension A d j u s tl e n s i o n b y r n o v i n gp u m p .

U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g et o b e t a n d s e t t o 1 2 . 5u n i t s .S t r e t c hb e l t u n t i l m a r k o n g a u g e p l u n g e ri s f l u s hw i t h s l e e v e D . e p r e s sb e t s t r o n gy w i t h h a n d a n d r e c h e c k / a d j u st et n s i o n .

5l

Group21 Engine Cylinder head, installing H22 Set pump and tighten camshaftrear sprocket shouldbe al holdsprocketTorquewrench Use5199to wl I be torque otherwise rightangleto wrench5201 ontiLdial Using5199,turn sprocketslowlvclockwise D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . - .-. . . 0 8 0 m r n= 0 0 3 1 5 i n in 0 70mm = 0.0276 . .. ..

D 24 .......................

D 24 USAJCanada ... 0-70mrn= 0 02761n .. . .

197981 ........-................

0 85mm :0 0335in .. . . ..

1982 ............... in thisposiiionandtorquebollto 100Nm Holdsprockel do not (73ft lbs).Takecarethatcamshait andsprocket

H23 Removestop 5193from pumpgear

)a )e

H24 Check pump setting T u r n e n g i n et w o f u l l t u r n s u n i i c y l . 1 i s a t t o p d e a d c e n t e r- i n j e c t i o n ,a g a i n .l i e n g i n e i s t u r n e d l o o f a r i t m u s t b e l L r r n e db a c ka p p r o x .1 / 4 l u r n a n d t h e n t o z e r o m a r k o t h e l w l s es e t i i n gw i l b e i n c o r e c t D i a l i n d l c a t o rs h o u d s h o w :

W'r

D 2 0 . . . . . . . . . . . . . . . . . . . . .0. . 7. .F. .0 . 8 3m m : 0 . 0 2 9 5 - 0 . 0 3 2 7i n D 2 4 . . . . . . . . . . . . . . . . . . . . .0. . 6. .F. .0 . 7 3m m = 0 . 0 2 5 6 0 . 0 2 8 7i n D 24 USAand Canada 1979-1981 . . . . . . - . . . . . .0 . ...6. F 0 . 7 3m r n : 0 . 0 2 5 6 - 0 . 0 2 8l n7 1 9 8 2 - . . . . . . . . . . . . . . . . . . .0. . .8.2. .- 0 . 9 0m n r = 0 . 0 3 2 3 - 0 . 0 3 5i n4 Correct reading: Tighten injectionpump mounting

I n c o r e c t r e a d i n g rB e a d j u s ta c c o r d i n gt o i n s i r u c i i o f s

pumpsetting: Readiusting :. .0. -. .0.3. .1. .5. i.n.

D2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. ,. 8. .0. .m . .m n 0.70mm= 0.0276 D 24..........-....-.................................

D24USAandCana l 9cTl a9 l g S l 0 . 7 0 m m - 0 . 0 2 7 6 i n in 1982-..........

0.85mm = 0.0335

Readinglessthan specified: pumpmouniingbohsandturn pumpanwards Slacken to obtaincorrectvalue.Tightenmounilngboltsand repeatcheckoi punrpsettn9s.

52

)a

Group21 Engine Cylinderhead.installing Readingmore than specified: pumpmounting Slacken boltsandturnpumpoulwards

?.i A.EErj

li6t',t

untildialindicator showsapprox: D20.................................................0.70m D 24 ...--...--...--...--...-...--...-................

0.60mm = 0.0236 in 197F1981 ......-..

0.60mm = 0.0236 in D 24USA/canada 1 9 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m = 0 . 0 2 9 5 Thenturn pump inwardsuntil specified valueis ob pompsetrained.

Tightenmountingboltsand recheck trng. pumpmustnotbetappedor knocked Note!lnjection as thiswill alterits setting.

H25 Removedial indicator and holder5194.lnstall plug with new seal T'shtening torqueI Nm(6.5ft

H26 Reconnect cold start device

o

Presslever forwards and turn sleeve90'. Retighten Notel Do notturnscrew2 otherwiseitwill be necessary lo resetcold start deviceon a test bench.

H27 Install valve cover Usenew gasketsif necessary.

Two typ6s oj pin srudsareavailable, seetig. Laretypes have a spacer, and hole in gasket is larger to pfevont d a m a g el o g a s k e tb y o v e n i g h t e n i n g , Lale and early rype parts must not be interchanqed,

zz7:@ ta

E

E

Note! Only install a lew nuts since cover is to be rem o v e d l a i e r o n w h e n l i g h t e n i n gc y l i n d e rh e a d b o l t s .

53

Gtoup 2l Engine Cylinder head. installing

H28 Install timing gear covers ({ront and rearl

)liO H29 Reconnecttuel delivery pipes Iighteningtorque25 Nm (18ft lbs).

')rO H30

Reconnectreturn pipe to rear iniector

H31 Installplungerand vacuumpump CheckO ring,replaceif necessaryConnect vacuumhose(frombrakeseruo);to pLrmp.

H32 lnstall: wireto glow plug -wires to temperature senders(2 X), one at rearand onelo leftof cylinderhead.

H33 Connect: lowerradiato.hoseto radiator - 'rpperradiato.hose - hosesfor coldsiartdeviceto cylincler headandtheF

54

ilrlO

Group 21 Engine Cylinder head, installing

H34 lnstall air Iilter and connecthoses A ( o w o n i n l e t h o s em u s t p o i n t t o w a r d si n l e t m a n i f o l d otherwise the crankcase breather hose may contact

H35 Connectl branch pipe. Use new gaskets.

- splashguard

H36 Bleeding ot cooling system upperhosefrom cold startdevice.Place Disconnect drip pan beneathhoseand hold hoseleve with top tank. edgeof expansion

Coolant S i n c ea l u r n i n i u mi s u s e d i n t h e e n g i n e s ,a c t i v ec o r r o s i o n p r o t e c t i o ni s n e c e s s a r iyn t h e c o o a n i h e l pp r e v e n l

D

U s e g e n u i n eV o l v o b u e - g r e e nc o o l a n l t y p e C , d i l u t ( with clean water in propoltions of 50/50.

This mixture helps to prevent corrosion and fic a N e v e rf i l l t h e c o o i n g s y s t e mw i t h w a t e r a l o n e a T h e c o o l a n l s h o u l d b e c h a n g e dr e g u r a , l ys r n c et h c o r r o s i o np r o t e c t i v ea d d i t i v e si n t h e c o o l a n t l o s t h e i r e f f e c ti n l i m e .

N o t e ! D o n o t r u n e n 9i n e w h e n l e v e lo f c o o l a n ti s l o w . H i g h l o c a t e m p e r a t ! r e sc a n r e s u l i w h i c h m a y c a u s el h e c y l i n d e rh e a d t o c r a c k .

Group21 Engine Cylinder head, installing -vroL\Io oflGri[ rtrvArsu sfiD!^r L 30cctfrrifYrrairr iLr|r f$

0n v

voLvo coourrrY* c c00rr6sYsitcrs r0r uPYIAN B0ur0 $ft iALiw^ rYrtc vl|r0rrrus0u^ 2Pt r/oLvo vrc Mot[ r^LrMotrrt^Nrcn rw c

Replacing coolant A l w a y s L r s et y p e C b l u e - 9 r e e nc o o l a n t .R e m e m b e rt o r e p l a c ed e c a l( P / N1 3 3 1 4 7 37 ) o n e x p a n s i o nt a n k i f n e -

Type C blue-green coolant A l l d i e s e la n d p e t r o ( g a s o l i n e e) n g i n e sm a n u f a c t u r e d s i n c e 1 9 8 2a r e f i l l e d w i t h t y p e C c o o a n t .

H37

!ilo

Fill coolant C a p a c i t yD : 2 0 = 8 . 1 l i t e r s( 8 . 6U S q u a r t s ) D 2 4 = 9 . 3 t i r e r s( 9 . 8u s q u a f t s ) .

F l u s hc o o l i n g s y s t e m b e f o r ea d d i n g n e w c o o l a n t ,s e e G r o u p 2 6 C o o l i n gS y s t e m .

).iO

S e r d c s o o a r d h e d r e rc o n r r o 'r o 1 i . ( . T u r ' r o ' r e n g n a a n d w a r m ' u p f o r 5 m i n u t e s .A d d c o o l a n td u r i n g t h i s t i m e . C o n n e c th o s el o c o l d s t a r td e v i c e .F i l l c o o l a n tt o m o u t h o f e x p a n s i o nt a n k ( a b o v e m a x ) a n d s c r e w o n

H38 Tighten cylinder head bolts is at least50'c Wa.m-upengineuntiloi temperalure 1122"F1.

Remove vacuumpumpwith plungerandva ve cover.

M 11 boltsrlorqueto 90 Nm (6sft lbs) wrlhotrt 90'in onemovemenl M 12bolts:an9le'tighien plrrnp plunger and stopping.Instal

DO

)ilo Check-tightening

of cylinder head bolts

lmportantr Bolis must be re torqlecl after 600-1,200 m i l e s ( 1 , 0 0 02 , 0 0 0k r n ) .S e e n e x t p a g e .

56

Group 21 Engine Cylinder head, retorquing

J. Cylinderhead,retorquing To be carried out after 600-1,200miles (1,000-2,000km) on cold or nearlY cold engine

J1 pump plunger and Removevalvecover,vacuum Access to one of cylinder head bolts is restricled by

J2 M 11 bolts:

M 1l bohs = 10hm Allenkey

Tighteneach boh in turn as indicatedaccordingto

M11

bolt30' 1. Slacken 2. Torqueto 90 Nm {65ft !bs)-

11s9082 M 1 2 b o l r s= 1 2 s d e d s o c k e i P / N 1 1 59 0 8 2 - 5 .

M 12 bolts: T i g h t e n e a c h b o L ti n t u r n a s i n d i c a t e da c c o r d i n gt o 1.

A n g l e t i g h t e n b o l t 9 0 ' i n o n e m o v e m e n tw i t h o u t s i o p p i n g -D o n o t s a c k e nb o l t f i r s t .S e e i l l u s t r a t i o n i n o p e r a t i o nH 3 8 .

M12

o

ooao,@r

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D24

D20 ut

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a

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J3 Installvalve cover,plunger and vacuumpump CheckO-rinq,replaceif necessary.

57

Group21 Engine Timing gear belt tension

K. Timing gear belt tension,checking/adiusting Specialtoal:5197

B e l l t e n s i o na f f e c b l n j e c t i o nt i m i n g . F o l l o wb e l o w i n s l r u c t l o n sc a r e f u l t yO . v e r r i g h tb e l t sc a u s ep u e y i o s q ! e a k .

:)rI K1 Remove timing gear covers ({ront and rear}

r)a

K2 Checkbelt tension U s e g a u g e 5 1 9 7 .T e n s i o n s h o L r l db e b e t w e e n 1 2 1 3

A d l u s tt e n s i o n1 o' 1 2 . 5u n i i s b y m o v i n g p u m p m o u n r i n g

r)rI t), I

K3 Checktiming gear belt tension Use gauges197.Tensions h o u l d b e b e t w e e n 1 2 - 1 3

58

Group21 Engine Timing gear belts,tension

Incorrect belt tension lJnscrewexpansiontank cap to releaseoverpressure from coolingsyslem.

Tum engineapprox.1/4 turn anticlockwiseto obtain slackpart of bslt on driving side. lf this is not done injectionpump settingwill be incorrect.

Turn crankshaftwith 27 mm socketor 5188.

Adjust belt tension to 12.5 units on gauge 5197 by movingcoolantpumpmountingbracket.

lf gear belt tension has been adiusled --'-\.

Turn engineat le6stoneturn clockwiseand checkthat belttensionis 12-13unitson tool5197.Adjustif necessaryaccording to operationsK2-3and rechecktension,

Installtiming gear covers

Group21 Engine Timing gear belts, replacement

L. Timinggear belts,replacement Special tools: 5187. 5188,5190, 5193, 5194, 5197, 5199, 5201, 5202

E n g i n em a y o n l y b e l u r n e d b y m e a n so f v i b r a t i o nd a m p e r .

D o n o t r o l a t ec r a n k s h a f ot r c a m s h a f tw h e n t i m i n s s e a r b e l t i s r e m o v e do l h e r w i s ev a l v e sm a y s t r i k €p i s t o n s a n o c a u s eo a m a g e .

L1

i){ |

L2

')a

Disconnect battery

Jack-upvehicle To preventspillageswhen coolantis drained,raise wil thenrun vehicle al frontrightjackingpoint.Coolanl intodrip pan. alongsplashg!ard Placedrip pan beneathleftsteeringrod.

L3 Drain coolant U n s c r e we x p a n s i o nl a n k c a p .

D i s c o n n e clto w e r r a d i a i o rh o s e i r o m r a c l i a t o r D l s c o n n e clto w e r h o s e f r o n r t h e r m o s t a tf o r c o l d s t a r t d e v i c ea n d d r a i nc o o l a n t .( E n g i n ei s w i l h o u t d r a i nl a p s )

0)a ,r)

L4

- c o o l i n gf a n w i i h s p a c e ra n d p u l l e y - f a n b e l t sa n d p o w e r s t e e r i n gp u m p b e l t

60

(

Group 21 Engine Timing gear belts, replacement

-timing gearcovers(frontand rear)

L6 Turn engine until cyl. 1 is at TDC - injection totL'n pn9ine AlwalsJre vib ationddmpercenterboll 27 mm socketor wrench5188 'rpwards 1 camsshouldpointobLiquelY BothcyLinder t,

L7 Removevibration dampercenter bolt U s e 5 1 8 7 1 o p r e v e n tp u L l e vf r o m r o t a l i n g ,a n d s o c k e t 5 1 8 8t o u n s c r e wb o l t .

I t m a y b e n e c e s s a r tyo t u r n e n g i n es l i g h t l vs o i h a t 5 1 8 7 r e s t so n f a n b e a f i n g .

Check that cyl. 1 is at TDC - iniection Check'0'nrarkon flywheel.

Adjustif necessary, use5187to turn engine

61

6roup 21 Engine Timing gear belts, replacement ,

,J r{

s

L9 Remove vibration damper Bemovefour Allenscrews(6 mm).

PullotJvibrationdamper.Note!Crankshaft gearmay sometimes stickto vibrationdamper.

)a Ll0 Remove lower timing gear cover and belt Slacken coolantpump retainingboltsto releasebelt tension.Removebelt.

)r;O

Ll1 Replace idle. pulley A l w a y s r e p l a c ep u l l e yw h e n f i t i i n g n e w b e l t .

Renrovecenter bolt.

W i l h d r a w p l r l l e y| ] s i n g5 2 0 2 .

)il4

T a p o n n e w p u l l e ya n d i n s t a l l c e n t e rb o l t .

),lt Ll2 Removecamshaftrear sprocketand belt Hold sprocket in position with 5199 and unscrew s p r o c k e tw i t h w r e n c h 5 2 0 1 .

T a k e c a r e n o t t o r o l a t ec a m s h a f t .

62

Group21 Engine Timing gear belts, rcplacement

L13 Lockcamshaftin posilion Lift valvecovergasket Placegauge5190at rear of camshaft.lnserta 0.2 mm feelergaugebeneathleft sideof gaugoto compensate for timinggearclearance.

Camshaftis now set ai correctposition.

LI4 Bemove camshaft Iront sprocket Use5199to holdsprocket in position whenloosenins bolts.Tap sprocketto free

Ll5 Install gear belt and camshaft lronl sprocket [4akesurethat belt fits se€urelyon all gears.

Installcenterbolt,handtight.lt shouldbe possible to turn sprocketon camshaftwithout camshaftrotating.

L16 Instatl lower timing gear cover and vibration damper Dampercanonlybefitted inoneway.

Pinoncrankshaft g e a r m u s t f i t i n v i b r a t i o nd a m p e r .

T o r q u e i n h e x b o l t sr o 2 0 N m ( 1 5 f i l b s ) .

63

Group21 Engine Timing gear behs, replacement

Ll7 Installcenterbolt Smearthreadsand rnatingsurfacewith sealerP/N 277961-9.

Usewrench5187(reston coolingfan journal)to hold vibrationdamper.LJsewrench5188to lorquecenter bolt to 350 Nm {255ft lbs). lmportantr Torque350Nm appliesonlyif wrench5188 is used.Alsotorquewrenchmustbein inewithwrench 5184.

L18 Make sure cyl. 1 is at TDC- inlection C h e c k ' 0 ' m a | k o n f l y w h e e la n d a d j u s ti f n e c e s s a r y .

L19 Set belt tension A d j u s t t e n s i o nb y m o v i n g c o o l a n tp u m p U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g et o b e l t and set to 12.5 units.

S t r e t c hb e l l u n t i l m a r k o n g a u g e p l u n g e ri s i l u s h w i t h D e p r e s sb e l ts t r o n g l yw i t h h a n da n d r e c h e c u a d j u s t t e n -

040 L20

Tightencamshaftlront sprocketand remove gauge5190 Use5199to prevent sprocket fromturning.

Torquecenterboitto 4s Nm (33fi lbs).

R e m o v eg a u g e 5 1 9 0a n d f e e l e rg a u g e .

64

Group21 Engine Timinggear belrc,replacement

L21 Disconnect cold start device Slacken screw1. PushleverfoNard and rotatesleeve 90'.

Note!Donotturnscrew2otherwise it llbenecessary to removecoldstartdeviceand resetiton a testbench, Pressbackleveragainststop.

-r@ -v2a//J:'

j iP)

L22 Basic-setinieciion pump pumpmounting Slacken bolts(Allenkey= 6 mm).

Alignmarks onpumpandmounting bracket byturning p u m p . R e t i g h t e nm o u n t i n g b o l t s .

L23 Set dial indicator zero. Lock pump gear at cyl. 1 inlection using stop 5193 Unscrew andrernoveplugfrom i n j e c t i o np u m p d i s t r i Installholder5194and dialindicator{range0 3 mm).

Setgaugeto approx.2mm.

Turn pump gear clockwiseuntil mark on gear and mountingbracketcoincide.

Then turn back p!mp gear siightlyuntil min reading r e g i s t e r so n d i a l i n d i c a t o r .

Set indicator to zero.

I!rn pumpgearclockwisu e n t i l m a r ko n g e a ra n d p u m p m o u n t i n g b r a c k e tc o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n w i l h s t o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n r o

i 65

Group21 Engine Timinggear belts,replacement

L24 lnstall camshaftrear sprocketand belt Tighten center bolrby hand,it shoutdbe possibte to turnsprocket on camshaft.

i

L25 Set belt tension

0la !

Adjusttensionby movingpump.

Usegauge5197to checktension.Attachgaugelo belt andsetto 12.5units.Stretchbeltuntilmarkon gauge plungeris flushwith sleeveDepress bellstrongly withhandandrechecUadjustten-

r)

L26 Sel pump and tighten camshaft rear sprocket Use5199ro holdsprocket.

Torquewrenchshouldbe al rightanglesto wrench5201otheMisetorquewiL be Using5199,turn spro€ket slowlyclockwise until dial

d),I

D20....................................-....-.......0.80mm=0.0315in D 24 .................................................

0.70mm : 0.0276 in D 2 4 U S A / C a n a d a 11997891 . . . . . . . . . 0 . 7 0 m m = 0 - 0 2 7 6 i n 'I982-.................

0-85mm = 0.0335 in Holdsprocket in thisposition andtorqueboltto 100Nm (73ftlbs).Takecarethatcamshaft andsprocket do not

t)r I

L27 Removestop 5193{rom pump gear

66 I

I

Group 21 Engine Timing gear belts, replacement

L28 Checkpump setting Turn enginetwo full turnsuntil cyl. I is at 1opdead center- injection, again.lf engineis turnedtoo far it mustbe turnedbackapprox.'l14lurnandthento zero markotherwise settingwill be inconect.

i-'i

Dialindicator shouldshow: mm = 0.029F0.0327 in D 20 ...........................

0.75-0.83 D24...........................

0.650.73mm=0.025F0.0287in D 24 USA,/Canada 0.6F0.73mm = 0.0256-0.0282in 1S791981...........-.... = 0.0323-0.0354in 1982 .........................

0.82-0.90mm Correcr reading: Tighteninjection mountingbo ts. Proceedto 129. to instructions Incorrect readingrReadjust according Radiusling pump setting:

D20.................................................0.80m D 24 .................................................

0.70mm : 0.0276 in D 24 USA,/Canada 1979-1981 .......................................

0.70mm:0.0276in 1982 ...............................................0.85mm:0.0 Reading less than specified: pumpmountingboltsandturn pumpinwards Slacken to obtaincorrectvalLreTightenmountingbo ts and repeatcheckof pump settings.

Beadingmore than specified:

purnpmountingbollsandturnpumpoutwards Slacken untildialindicto.showsapprox: in D 20 .................................................

0.70mm = 0.0276 D 24 ...........--...-...-....-...-........-.......-..

0.60mm = 0.0236 in ......... in D 24USp/Canada 1979-1981 0.60mm = 0.0236 1 9 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m : 0 . 0 2 9 5 Thenturn pump inwardsunti specified valueis ob pumpsettained.Tightenrnounting bo ts andrecheck ting. pumpmustnotbetappedor knocked Note!lnjection as thiswill alterits setring.

L29

Bemovedial indicatorand holder 5194.Install plug with new seal Tightening torque9 Nm{6.5ft lbs).

67

Group21 Engine Timtnggear bells replacement

L30 Reconnect cold start device Pressleverforwardsand tlrn sleeve90'. Relighlen it wi benecessary NotelDonotturnscrew2 otherwise io resetcoldstartdeviceon a teslbench.

)a L31 Installvalve cover Usenew gaskets if necessary. l w o r y p e s o r p i n s t u d s a r e a v a i l a b l e , s e e f i Lg a t e l y l have a spacer, and ho e ln Oasket s l6r9er to prevenl

]

t:: I

=%'rI'LLJ:

/ 0 8,5 azzz Trzzz

L32

r)r l

Installtiming gear covers {front and rearl if necessary.

Usenew gaskets

),,I L33 lnstall: c o o l i n gf a n w i t h s p a c e ra n d p u e y . T o r q u e b o t s l o 9 Nm (7il lbs) - J a nb e t s a n d p o w e r s l e e r i n gp u m p b e t s . A d j u s t b e t t e n s i o n .l t s f r o ud b e p o s s i be t o d e p r e s st h e b e t s 5 1 0 m m ( 0 . 2 - 04 l n ) b y h a n d .

68

Group21 Engine Timinggear belts,replacement

Bleeding ot cooling system Disconnectupper hose from cold stan d€vice.Place drip pan beneathhose 6nd hold hose level with top edge of expansiontank.

Coolant S i n c ea l u m i n i u m i s u s e d i n t h e e n g i n e s ,a c t i v ec o r r o ' sion protection is necessaryin the coolant to help prevent corrosion d6mage, U s e g e n u i n eV o l v o b l u e - g r e e nc o o l a n tt y p e C , d i l u t e d with clean water in proportions of 50/50.

This mixture helps to prevent coiiosion and frost Neverfill the cooling system with water alone.

T h e c o o l a n ts h o u l db e c h a n g e dr e g u l a r l ys i n c et h e c o r rosion protective additives in the cootant tose their ef-

NotelDonot runenginewhenievelofcoolant is low since high local temperaturescan result which mav causethe cvlinderheadto crack.

srY0Dlr rLL 30pcrfirrfY[ lfifi lurr {a0 t|r Dftvanrl ocNgt 0[r r0rv0xY|^rsunr c IroL\no coouNrTYPI c c00ut6sYsmi$ PRoTOT[o T0-22.r nr UPY&i R0Ur0 R|lH|ALrWAr$Al0 HArrV0tV0 RrirPrr -2?.t 0I u0urDr ar{r6rL\roLrro rYrt c VALABL! JusooA -3trCr$PlrB€flT0UT[ Slrsori ^ytcMorltuu {otTttINI|GIL IYr! c

Replacing coolant Always usetypc C blue-greencoolanr.Rememberto replace decal1PlN1331473-7) on expansion tankif ne, Type C blue-green coolant All dieseland petrol (gasoline)enginesmanufactured since1982arefilledwith tvDeC coolant.

Group2l Engine Timing gear belts, reqlacement

L35 Fill coolant Capacity:D 20 = 8.'l lilers (8.6US quarts) D 24 = 9.3liters{9.8US quarrs).

Flushcoolingsystembeforeaddingnew coolant,see Group26 CoolingSystem.

Sel dashboard l_eater contro,io max.Turnon engile and warm-upfor 5 minutes.Add coolantduringthis time. Conneclhoseto cold startdevice.Fill coolantto mouth of expansiontank (abovemax) and screw on

70

Group21 Engine Camshaft, removal

M. Gamshaft,removal Special tools: 5199, 5201

D D

M1 Remove: - t i m i n g g e a r c o v e r s( f r o n t a n d r e a r l .

M2 Turn engineuntil cyl. 1 is at TDC- iniection

D

A i w a y su s et h e v i b r a t i o nd a m p e rc e n t e rb o l t t o t u r n t h e e n g i n e .2 7 m m s o c k e to r w r e n c h 5 1 8 8 .

B o t hc y i n d e r 1 c a m s s h o u l d p o i n t o b l i q u e l yu p w a r d s .

t M3 Removebelt Irom camshaftsprocket U n s c r e we x p a n s i o nt a n k c a p 1 0 r e l e a s eo v e r p r e s s u r e from cooling system.

S l a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l r t e n s i o n e r .T i g h t e nt w o l o w e r m o u n l i n g b o l t st o a v o i d u n , n e c e s s a r yl o s s o f c o o l a n t .

R e m o v eb e l t f r o m c a m s h a f is p r o c k e t .

11

Group21 Engine Camshaft,rcmoval

M4 Removecamshaftfront sprocket U s e 5 1 9 9t o h o l d s p r o c k e ti n p o s i t i o nw h e n l o o s e n i n g b o k . [ 4 . k e s u r e t h a t c a m s h a f td o e s n o t r o t d t e .

Tap sprocket to free it from camshaft.

0t

(

I\ ' ) r

(

M5 Detachbelt shieldfrom cvlinderhead Benove two Lpperreldinirgbolrs.

Bend out shield to free it from camshaft. lf necessary s l a c k e nc o o l a n tp u m p u p p e r b o l t .

K e e ps h i e l di n o u t e r p o s i t i o nw i t h a p i e c eo f w o o d .

M6 Lift off pump belt S l a c k e nm o u n t i n g b o l t s f o r i n j e c t i o np u m p b r a c k e t o r e l e a s eb e l t t e n s i o n .

T i g h l e no ' r e b o k s o I h a t p J n p r e m a ' n s l u p p e ' p o s i

0ta

Lift off belt.

0ta ,O

, r tuttililiiii,i, M7

Removecamshaftrear sprocket Hold sprocket in position with 5199 and s P r o c k ew t ilh wrench5201.

Take care nol to rolare camshaft.

72

Group21 Engine Camshaft, removal

M8 Removevacuum pump and pump plunger Removepump fetainingnuts and place pump on Withdrawplungerfrom cy inderhead.

M9 Remove camshafi beadng caps 1 and 4

M10 Remove camshaft bearing caps 2 and 3 Slacken nutscrosswise to avoidplacing unevenloadon

M11 Lift awav camshaft and removeoil seals

13

Group21 Engine Camshaft, installing

N. Camshaft,installing Specialtools: 5 190, 5193, 5194, 5195, 5196, 5197, 5199, 5200,5201

0)ia Place camshaft in cylinder head Lubricatecontactsurfacesof camshaftand bearings.

Placegauge5190at rearof camshaft.lmportant!Both camsfor number1 cylinderrnuslpointdiagonally up, seeiig.

0rl

N2 Installcamshaftcaps2 and 3 Installcapscorrectly, cenreris off set. in to avoidwarp.Keepcamshaft Tightennutscrosswise p o s i t i o nw i t h g a u g e5 1 9 0a t r e a rw h e n t i g h t e n i n gc a p s .

0)a

0)a N3

Removegauge5190

Pressin new camshaftoil seals Oil seals.

D o n o t p u s h i n s e a l s t o b o t t o mp o s i t i o n .M a k e s u r e t h a t s e a l sa r e " s q u a r e ' -

Group21 Engine Camshaft, installing

N5 Install camshaft caps 1 and 4 cap4 sits camshaft fMak€ surethatthethrustwasherfor

Torqueall four caps = 20Nm (15ft lbs).

Torque

Tap in oil seals to bottom

D

R € a ro i l s e 6 l : U s e . d a p t e r 5 2 0 0a n d b o l t f o r c a m s h a f t F r o n to i l s e a l rt i s e a d a p t e r5 2 0 0a n d t a p s e a l i n t o p o s i

20 Nm

N8

Installbolts tor belt cover N9

,D

Installgear belt and camshaftfront sprocket P u l l b e l t t o e n s u r et h a t i t i s s e a t e dc o r r e c t l yo n c r a n k P l a c eb e l i o v e r c a m s h a f ts p r o c k e ta n d i n s t a l ls p r o c k e t

D

I n s t a l lc e n t e rb o l t h a n d t i g h t . l t s h o u l c lb e p o s s i b l ef o r s p r o c k e t t ot u r n o n c a m s h a f w t i t h o u t c a m s h a frt o t a t i n g .

Set belt tension A d j u s tt e n s i o nb y m o v i n g c o o l i n g p u m p .

U s e g a u g e5 1 9 7 t o c h e c k l e n s i o nA . r t a c hg a u g e r o b e t r a n d s e t t o 1 2 . 5u n i t s .

S l f e t c hb e l t u n t i i m a r k o n g a u g e p t u n g e ri s f t u s h w i l h D e p r e s sb e l ts t r o n g l yw i t h h a n da n d r e c h e c u a d j u s t t e n ,

75

Group21 Engine Cafishaft, installing

Make sure cyl. 1 is at TDC andadiustif necessary' onflywheel Check'0'mark

Qi

(

0

(

N12 Set camshaftposition P l a c eg a u g e5 1 9 0a t r e a r o f c a m s h a f t I. n s e r ta 0 . 2 m m f e e l e rg a u g e b e n e a t hl e f t s i d e o f g a u g et o c o m p e n s a t e f o r t i m i n g g e a rc l e a r a n c e .

N13 Tightencamshaftlront sprocket fromlurning. use5199to prevent sprocket (33 Torquecenterboltto 45 Nm ft lbs).

0)lI Removegauge5190andfeelergauge

0)a N15

Disconnectcold start device Slackenscrew L Push lever forward and rotate s eeve 90'.

N o i e l D o n o t t u r n s c r e w 2 o t h e r w i s ei t w i l l b e n e c e s s a r y to remove cold start device and reset it on a test bench.

P r e s sb a c k l e v e ra g a i n s rs t o p .

16

Group21 Engine camshaft,installing

-@; ).,)- '2-,

I-@)

N16 Basic-setiniection pump Slackenpump mount:ngbolts (Allenkey = 6 mm). bytuming Atignmarkson pumpandmountingbracket pump.Retightenmountingbolts.

N17 Set dial indicator zero. Lock pump gear at cyl. 1 injection using stop 5193 pumpdistri Unscrewand removeplug from injection Installhotder5194and disl indicator(range0-3 Set gaugeto approx.2 mm.

Turn pump gear clockwiseuntil moundngbrack€tcoincjde.

readrng Thenturn pump gearbackslightlyuntil registerson dial indicator.

S€t indicatorto zero.

Turnpumpgearclockwise untilmarkongearandpump Lockgearin this position mountingbracketcoincide. with stop 5193.(lnse( stopthroughpump gearinto mountingbracket.)

N18 Installcamshaftrear sprocketand belt Tightencenterboltsby hand,it shouldbe possible to turnsprocket on camshaft.

Group21 Engine Cafishaft, installing

N19 S€t belt tension Adjusttensionby moving pump.

Usegauge5197to checktension.

Attachgaugeto bett and set to 12.5units.Stretchbett untit mark on gauge plungeris flush with sleeve.

Depressbeltstronglywith handandrechecUaotusr ren-

N20 Set pump and tighten camshaftrear sprocket

0 I

Use5199toholdsprocket.

Torquewrenchshouldbe at rightanglesto wrench5201otherwise lorquewill be Using5199,turn sprocket slowlyclockwise until dial

0

(

D 2 0 . . . . . . . . . . . . . . . . . . . -. . . . -. . . .- . . . . . . . . 0 . 8 0 m m = 0 . 0 3 1 5 i n D 24..............................-........-.........

0.70mm : 0.0276 in D 24 USA,/Canada 1979-1981 .........0.70mm = 0.0276in 1982-.................

0.85mm = 0.0335 in Holdsprocket in thisposilionandtorqueboltto 100Nm {73ft lbs).Takecarethat camshaftandsprocketdo not

N21

Removestop 5193trom pump gear

0),( N22 Checkpump setting T u r n e n g i n et w o f u l l l u r n s u n t i l c y l . 1 i s a t t o p d e a d c e n t e r- i n i € c t i o n ,a g a i n .l f e n g i n e i s t u r n e d t o o f a r i t m u s t b e i u r n e d b a c ka p p r o x .1 / 4t u r n a n d t h e n t o z e r o m a r k o t h e r w i s es e t t i n gw i l l b e i n c o r e c t .

D i a l i n d i c a t o rs h o u l d s h o w l D 2 0 . . . . . . . . . . . . . . . . . . . . .0. . 7. .5. .- 0 . 8 3m m D 2 4 . . . . . . . . . . . . . . . . . . . . .0. . 6. .5. .- 0 - 7 3m m D 24 UStuCanada 1 9 7 F 1 9 8 1. . . . . . . . . . . . . 0 - ...6. F 0 . 7 3m m 19 8 2 - . . . . . . . . . . . . . . . . . . .0. ...4. .2. - 0 . 9 0m m

: 0 . 0 2 9 5 0 . 0 3 2 7i n = 0 . 0 2 5 6 - 0 . 0 2 8i n 7 = 0 . 0 2 5 6 - 0 . 0 2 8i n 7 = 0 . 0 3 2 3 - 0 . 0 3 5i n 4

Corect reading: Tighten injection pump mounting bolts. Proceed to N23.

Incorrect reading: Readjust according to instructions

7A

0)' I

Group21 Engine Camshaft,installing

Readiusling pump setting: D 20 ..................-...-...-......,............

0.80mm = 0.0315 in D 24..........................,......................

0.70mm= 0.0276in D 24L,SA,/Canada 197F1981.........O.70mm= 0.0276in 1982-....,....,..,....

0.85mm: 0.0335in Reading less than specified: Slackenpump mountingbottsand turn pump inwards to obtain corrsct value. Tighten mounting botts and repearcheckof pump settings.

Reading less lhan specified: pumpmounting Slacken boltsandrurnpumpoutwards untildialindicator showsapprox: D 20 ........................-...-..................

0.70mm = 0.0276 in D 24 .................................................

0.60mm = 0.0236 in D 24USA,/Canada =0.0236in 1979-1981 .........0.60mm 1982-.................

0.75mm = 0.0295 in Then turn pump inwards untit specifiedvatue rs obtained.Tightenmountingbotrsandrecheck pumpsetrng, Not€!Injectionpump mustnot be tappedor knockeoas this will alter its setting.

t@))]

N23 Removedial indicator and holder 5194, Instrll plug with new seal Tishtenins torqueI Nm (6.5ft tbs).

N24 Reconnect cold start device Presslever forwards and turn sleeve90". Retighten Notel Donotturn screw2otherwiseitwitt be necessary to resetcold start deviceon a test bench.

79

Group21 Engine Camshaft, installing

N25

Installplungerand vacuumpump C h e c kO - r i n g ,r e p a c e i f n e c e s s a r y .

()l N26

,l )l

Adiust valveclearance: S e e o p e r a t l o nB 1 1 1 , p a g e 1 9 . l m p o r t a n t ! V av e c l e a r a n c em u s t b e c h e c k e da f t e r 6 0 0 1 , 2 0 0n 1 i l e s( 1 , 0 0 G - 2 , 0 0k0m ) .

N27 Installtiminggearcovers(frontand rear)

{l|a

0rr1

80

r Group 21 Engine Camshaft fronL seal, replacement

o.Camshaftfront seal,replacement Special tools : 5194, 5197, 5199,5204

iD o1

D f r o n l t i n ri n g g e a r c o v e r .

o2 Disconnect cold start device S l a c k e ns c r e w 1 . P u s hl e v e rf o r w a r d a n d r o t a t es l e e v e 90'.

t,

N o r e l D o n o t t u r n s c r e w2 o t h e M i s e i t w i I b e n e c e s s a r y io remove cold start device and resei it on a test bench.

Press back lever against stop.

D o3 lnstall dial indicator U . s c r e w a n d r e m o v ep l u g f r o m i n j e c t i o np u m p d i s t r i I n s t a l lh o l d e r5 l 9 4 a n d d i a l i n d i c a l o r{ r a n g e0 - 3 m m ) .

S e l g a u g el o a p p r o x .2 m m .

Group21 Engine Camshaftfront seal,replacement

o4 Turnengineuntil cyl. 1 is at TDC- iniection A l w a y su s et h e v i b r a t i o nd ; m p e r c e n t e rb o l t i o t u r n t h e e n g i n e .2 7 m m s o c k e to r w r e n c h 5 1 8 8 .

B o t hc y l i n d e r1 c a m s s h o u l d p o i n ! o b l i q u e l y' r p w a r d s .

T u r ne n g i n ea p p . o x .1 / 4t u r n c l o c k w i s ep a s t ' 0 'a n d t h e n b a c kt o ' 0 ' a g a i n ,t o o b t a i ns l a c kp E d o f b e l i o n d r i v i n g s i d e .l f t h i s i s n o t d o n e i n j e c l i o np u m p s e t t i n sw i l b e

{)a o5 Set dial indicator zero G a u g e p o i n t e r m u s t n o t m o v e d u r i n g i n s t a l a t i o no f new oil sea otherwise it wil be necessaryto basic-set e n g i n es i n c e c a m s h a f tw i l l h a v e m o v e d i n r e l a t i o nt o

0)l

Lfpointe. does not move itsufficesto check/adjustinjec-

o6 Remove belt from camshaft sprocket U n s c f e we x p a n s i o nl a n k c a p t o r e l e a s eo v e r p r e s s u r e from coo ing system.

S a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l t t e n s i o n e r .T i g h l e nt w o o w e r m o u n t i n gb o l t s1 o a v o i d u n n e c e s s a r yl o s s o f c o o l a n t .

r)il4

R e m o v eb e l t f r o m c a m s h a f ts p r o c k e t .

{)ila o7 Remove camshaft lront sprocket U s e 5 1 9 9t o h o d s p r o c k e ti n p o s i t i o nw h e n l o o s e n i n g b o t . M a k e s ! r e t h a t c a m s h a f td o e s n o t r o r a r e Tap sprocket to free it from carnshaft.

a2

i

Group21 Engine Camshaft front seal, replacement

Detach belt shield from cylinder head Bemovetwo upperreraining botts.

Bendout shieldto freeit from camshaft. tf necessary slacken coolantpumpupperbott.

Keepshieldin outerposjtionwith a pieceof wood.

Remove camshaft cap 1 and oil seal

ot0 Pressin new camshaft

seal

Oil seal.

D o n o t p u s h i n s e a ll o b o t i o m p o s i t i o n .M a k es u r et h a t

L

Install camshaft cap 1 Torqueto 20 Nm {15ft lbs).

o12 Press in seal to bottom position Release cover.Useadapter5200ro rap in oil

o13 bolts Ior belt cover 014 Install gear belt and camshaft tront sprocket P u l l b e l t t o e n s u r et h a t i r i s s e a t e ccl o r e c r l y o n c r a n k shaft gear.

P l a c eb e l t o v e r c a m s h a f rs p r o c k e ra n d i n s t a i ls p r o c k e t I n s t a l c e n t e rb o l t a n d t i g h r e n .l t s h o u t db e p o s s i b t ef o r s p r o c k e t l ot u r n o n c a m s h a f t w i t h o uct a m s h a f tr o t a r i n g .

Group21 Engine Camshaft front seal, replacement

015 Set belt tension A d j u s l t e n s i o nb y m o v i n g c o o l i n gp u m p .

U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g e1 0 b e l t a n d s e t t o 1 2 . 5u n i t s .

S t r e t c hb e l t u n t i l m a r k o n g a u g e p l u n g e ri s f l u s h w i t h Depressbeit stongly with hand and rechecuadjust ten-

o16 Makesurecyl.1 is ai TDC

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Check'o'mark on flywheeland adjustif necessarv il

o17 Tightencamshaftfront sprocket L J s e5 1 9 9t o p r e v e n ts p r o c k e tf i o m t u r n i n g .

TorqLrecenter bolr to 45 Nm (33 ft lbs).

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o18 Check dial indicator l f p o i n l e r h a s m o v e d f r o m z e r o p o s i t i o n :b a s i c ' s e e t n' g i n e a c c o f d i n gt o o p e r a l i o n sC 1 - 2 1 .

Pointer at zeror Proceed to O19.

I

Group2l Engine Camshafttrcnt seal,reDlacement

o19 Zoro injection pump and dial indicator

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Slowly tum engineanticlockwiseuntil min readingis reachedon di6l indicator.

Set zero.

o20 Checkpump sefting '0' Slowlyturnengineclockwise untilflywheel reaches

d.i inzr r rr

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lfengine isturned toofarit mustbeturned backapprox.

1/46ndthento 'o' markotherwise settingwillbe incoF Dialindicator shouldshowl D 20...........................

0.7F0.83mm= 0.0295-0.0327in D 24 ...........................

0.6F0.73mm = 0.0256-0.0287 in D 24 IJS!,/Canada = 0.0256-0.0287an 197F1981 .................

0.65-0.73mm 1982-.........................

0.82-0.90 mm = 0.0323-0.0354in Correct reading: Iighten injection pump mounting bolts.Proceedto O23. lncorrectrcading: Readjustacco.dingto below.

021 Check/adjust pump setting D 20 .................................................

0.80mm = 0.0315in D 24.................................................

0.70mm = 0.0276in D 24USA"/Canada 197F1981 .........

0.70mm = 0.0275in 1982-.................

0.85mm = 0.0335in

Reading less than specified: pumpmountingboltsandturn pumpinwards Slacken to oblaincorrectvalue.Tightenmountingboltsand repeatcheckof pump setting,

85

Group21 Engine Camshaftfront seal,replacement Reading more than specitied:

pumpnrounting boltsandturnpumpoutwards Slacken untildialindicator showsapprox.

D20.................................................0.70mm=0.0276 in D 24 .................................................

0.60rnm= 0.0236 D 24USA,/Canada 1979-1981 .........

0.60mm = 0.0236 in in 1982-.................

0.75mm = 0.0295 Thenturn pump inwardsuntilspecified valueis obpumpset' tained.

Tightenmountingboltsandrecheck ting. lf it is not possibleto sei pumpto abovespecifications becaLseof ncufficert ad_Jstmeltlaltude. elgiie mustbe basic-set again,sincecamshaft andcrankshaft areprobablyour oi ine. pumpmustnotbetappedor knocked Note!Injection as thiswill alterits setting.

o22 Check pump setting Turnengineroundtwiceandchecksetting,see opera tion O20.Readjust if necessary and repeatcheck.

o23 Removedial indicatorand holder L:ri ii

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o24 Install plug with new seal Tishtening torque9 Nm (6.5ft bs).

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o25 Reconnect cold start device P r e s sl e v e r f o r w a r d s a n d t u r n s l e e v e 9 0 ' . R e t i g h t e n N o t e l D o n o t t u r n s c r e w2 o t h e l w i s ei t w i l l b e n e c e s s a r y 10 reset cold stan device on a lest bench.

86

I

Group21 Engine Camshaltfront seal,replacement

o2 Inslall valve covei Usen€w gaskstsif necessary.

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Twotypesot pin $uds areavailable,seefig. Latetypes havea spacer,and hole in gasketis larg€rto preveni damageto gasketby overlightoningLat6and earlytype Frts must not b€ interchanged

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E o27 Installfront timing gear cover

a7

Group21 Engine Camshaft rear seal, rcplacement

P. Camshaftrear seal,replacement Specialtools: 5190, 5193,5194,5199,52A0,5201

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Remove: - reart|mrnggearcover.

P2 Turn engineuntil cyl. 1 is at TDC- iniection A l w a y su s et h e v i b r a t i o nd a m p e rc e n t e rb o l t t o t u r n t h e

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ljse a 27 mm sockelB o t h c y l i n d e r1 c a m s s h o u l d p o i n t o b l i q u e l yu p w a r d s .

i tl P3 Lift ofi pump belt S l a c k e nm o u n t i n g b o l l s f o r i n j e c t i o np u r n p b r a c k e t o r e l e a s eb e l t t e n s i o n .

T i g h l e no n e b o l t s o t h a t p u m p r e m a i n si n u p p e r p o s Litt off be t.

88

Group 21 Engine Camshaft rear seal, replacement

,."! ",iii;iiii;i; Removecamshaftrear sprocket Holdsprocket in positionwith 5r99 and unscrew withwrench sprocker 5201.

Note! Take care not to rotete camshaft.

P5 Remove camshaft caD 4 and old oil seal

Press in new oil seal Oil seal.

D o n o t p u s h i n s e a l t o b o t t o m p o s i t i o n .m a k es u r et h a t

Install camshaft caps 1 and 4 Makesurelhat thrLrst washerfor camshaft cap4 sils Tightenins torq!e 20 Nm (15ft bs).

P8 Tap in oil seal to bottom Useadapter5200and boltfor rearcamshaiisprocket.

P9 Checkcamshaftsetting C h e c kw i t h g a u g e5 1 9 0t h a l c a m s h a f ti s c o r r e c t l ys e t i n r e l a t i o nt o c r a n k s h a f t .

G a u g es h o u l df i t i n g r o o v ei n b a c ke n d o f c r a n k s h a r tl.f n o l , e n g i n e m ' r s t b e b a s i c - s eai c c o r d i n gt o o p e r a t i o n s c1-21.

89

Group21 Engine Camshaft rcar seal, replacement

P10 Disconnectcold start device Slacken screw 1. Push lever foMard and rotate sleeve 90".

N o t e ! D o n o t t u r n s c r e w 2 o t h e M i s ei t w i l l b e n e c e s s a r y to remove cold start device and reset it on a test bench.

P r e s sb a c kl e v e ra g a i n s ts t o p .

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Basic-setiniectionpump pumpmountins bolts(Allenkey= 6 mm) Slacken byt'rrning bracket Alignmarks onpumpandmounting pump.Retighten mounting bolts.

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P12 Set dial indicator zero. Lock pump gear at cyl. 1 inlection using stop 5193 pumpdistri Unscrew andremoveplugfrom injection Installholder5r94and dialindicator {ranse0-3 mml.

Setgaugeto approx.2 mm.

Turn pump sear clockwiseuntil mark on gear and mounlingbracket coincide.

T h e n t u r n p u m p s e a r b a c ks i g h t l y u n t i l m i n r e a d i n g r e g i s l e r so n d i a l i n d i c a l o r .

S e t i n d i c a t o rt o z e r o .

T u r np u m p g e a rc l o c k w i s eu n t i l m a r ko n s e a ra n d p u m p m o L r n t i n gb r a c k e ic o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n w l t h s t o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n t o m o u n t i n gb r a c k e t . )

90

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Group21 Engine Camshaftrear seal,replacement

Installcamshaftrear sprocketand belt T i g h t e nc e n t e rb o l t b y h a n d , i t s h o u l d b e p o s s i b l et o turn sprocket on camshaft.

Set belt tension Adiusttenslonby rnovingPumP Usegauge5197to checktensionAtlachgaugeto belt andsetto 12.5units.Stretchbeltuntilmarkon gauge plungeris flushwith sleeve tenDepressbeltstronglywith handandrecheck/adjust

P15 Set pump and tighten camshaftrear sprocket U s e 5 1 9 9 t oh o l d s p r o c k e t . T o r q u e w r e n cshh o u l db e a t r i g h t a n g l e st o w r e n c h 5 2 0 1 o t h e r w i s et o r q u e w i l l b e

Using5199,turn spfocketslowlyuntil in 0.80mm: 0.0315 D 20 ................................................. in 0.70mm = 0.0276 D 24 .................................................

0.70mm : 0 0276in 19791981.........

D 24USp,/Canada in 0.85mm : 0.0335 1982-.................

Holdsprocketin this positionand torqueto 100Nm (73ftlbs).Takecarethatcamshaftand not sprocketdo

Removestop 5193from pump gear

Group21 Engine Camshaftrear seal,replacement P17 Checkpump setting

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Turn enginetwo fuLlturns lntil cyl. 1 is ai top dead center- injeclion, again.lf engineis turnedtoo tar il must be turnedbackapprox.1/4turn andthento '0' markotheMisesettingwilLbe incorrecl.

Dialindicator shouldshow: in D 20 .............-.............

0.7F0.83mm = 0.0295-0.0327 mm = 0.0256-0.0287 in D 24 ...........................

0.65-0.73 D 24 USACanada 1979-1981 .................

0.650.73mm= 0.0256-0.0287in 1982-.........................

0.82-0.90 mm = 0.0323-0.0354in Correct reading: Tighten injection pump mounting bolts.Proceedto P18. lncorectreading:Readjust according to instructions

Readjustingpump setting:

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S e t t i n gv a u e s : D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 . ...8. .0.m . .m . . .:. . 0 . 0 3 1 5i n D 2 4 . . . - . . . . . . . . . . . . . - . . . . - . . . . . . . . . . . . .0. . .7. 0 . .m. .m . . .:. .0 . 0 2 7 6i n D 24 USp,/Canada 'l 979-198'l .........0.70mm = 0.0276in 1 9 8 2 - . . . . . . . . . . . . .0. . .8. 5m m : 0 . 0 3 5 i n

Reading less than specified: S l a c k e np u m p m o u n t i n gb o l t sa n d t u r n p u m p i n w a r d s t o o b t a i n c o r r e c tv a l u e . T i g h t e n m o u n t i n g b o t s a n d r e p e a tc h e c ko f p u m p s e t r i n g .

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Beadingmofe than specified: pumpmounting Slacken boltsandturnpumpoutwards untildialindicator showsapprox.

020.........................-.......................0.70mm=0.0276in D 24 .............................

-..................

0.60mm = 0.0236 in D 24USr',/Canada 1S7F1981 .........0.60 mm = 0.0236 in 1982-.................

0.75mm = 0.0295 in Thentlrn pump inwardsunrilspecified vatuers oo tained.

Tightenmo!ntingboltsandrecheck pumpset, ting. pumpmusrnotbetappedor knocked NotelInjection as thiswill alterits setting.

92

Group21 Engine Camschaftrear seal,reDlacement

P18 Removedial indicator and holder 5194. Install plug with new seal T i g h t e n i n gt o r q u e I N m { 6 . 5f t l b s ) .

P19 Reconnect cold start device Presslever forwards and turn sleeve90'. Retighten Note!Do notturn screw2 otherwiseitwillbe necessary to r€setcold startdeviceon a test bench.

P20 lnstall valve cover Use new gasketsif necessary.

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Two Vpes of pin studsareavailsble, seeliq Laietvpes have a spacer, and hole in gasket is 1a.gerlo prevent damaqe to gasket by overtightening Late and early type paris must not be interchanged

3 P21 Install rcar liming gear covel

93

Gtoup21 Engine Pilot bearing, replacement

O. Pilot bearingin crankshaft,replacement Specialtools: 1801,4090.5203,5207

a1 Removegearbox/transmission S e e S e r v i c em a n u a l s e c t i o n4 ( 4 3 ) .

S e c u r es t a h e r m o l o r w i t h a b o l t .

a2 Removepressureplate and driven plate lJnscrewpressure platemounting boltscrosswrse arew turnsat a timeto prevent warp,

O3 Remove bearing

0D{

lJseextractor4090.

(i,t,I a4 Installbearing I n s t a l lb e a r i n ga n d s e a l w i t h t e x t o n o u t e r r i n g f a c i n g out. away from flywheei.

U s e s t a n d a r dh a n d l e 1 8 0 1a n d d r i f t 5 2 0 7t o t a p i n b e a r i n g u n t i l i t a b u t sc r a n k s h a f l .

P r e s si n . s m a l la m o u n to f g r e a s e( 1 . 3 1 . 5 g r a n i ) i n t h e s p a c eb e y o n dt h e b e a r i n g .

94

Group21 Engine Pilot bearing. replacement

a5 Installdriven plate Use centering shafi 5203.

Turn driven plate with hub facing out, away from fly-

0 a6 (,

Install pressureplate Tightenboltscrosswise a fewturnsar a timero avoid

a7 Installgearbox Do notforgetto removeboltssecuring startermoror.

o 0

95

Gtoup21 Engine Crankshafttront seal,replacement

R.Crankshaftfront seal,replacement Specialtools:5187,5188,5197,5200,5205

R1 Disconnectbatterv R2 Jack-upvehicle T o p r e v e n ts p i l l a g e sw h e n c o o l a n ti s d r a i n e d , h i c l ea t f r o n t r i g h t j a c k i n gp o i n t .C o o l a n tw i a l o n g s p l a s h g u a r di n t o d r i p p a n .

Place drip pan beneath left steering rod.

R3 Draincoolant U n s c r e we x p a n s i o nt a n k c a p D i s c o n n e clto w e r r a d i a t o rh o s e f r o m r a c l i a t o r a n d r a i n c o o l . n t . ( E n g i n ei s w i t h o u t d r a i n t a p s ) .

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R4

c o o l i n gf a n w i t h s p a c e ra n d p u l l e y f a n b e l t sa n d p o w e r s t e e r ; n gp u m p b e h - f r o n i t i n r i n gg e a r c o v e r .

I I I I

96

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I

Group 21 Engine Crankshaft f ra nt seal, replacem ent

R5 Remove vibration damper center bolt ljse 5'187to preventpulleyfrom rolating,and socket 5188to unscrewboh.

It maybe necessary lo turnengineslightlysothat5187 reslson fan be.ring.

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Turn engine approx. 1/4 turn anticlockwise Usewrench5187.

slackif beltwillmove Bylurningengineanticockwise, to drivlngside,makingil easierto removeand inslall

Removevibrationdamper Remove four inhexbolts(6 mm).

0

Pulloff vibrationdamper.NotelCrankshafi gearmay sometimes stickto vibrationdamper.

R8

Removelowertiming gearcover

R9 Detach cooling lan mounting bracket and alternatorand placeon one side RemovemoLrntins bohslarrowed)and pressbracket

9l

Group2l Engine Crankshaftfront seal, replacement

R10 Mark position oI timing gear belt f t l a r kb e l t ,c a m s h a f ts p r o c k eat n d c r a n k s h a fgt e a r .M a r k A i s o i d e r r ' t v o u l s i d ea n d r o p s i d eo f g e a r b a l r .

B e l t m u s t b e f i t t e d i n e x a c t l y s a m e p o s i t i o na s b e i o r eo t h e . w i s ev a l v e sm a y c o n l a c rp i s t o n sa n d c a u s es e a o u sd a m a g e .

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811 Removegear belt Slackencoolantpumpmounling bolrsandbelt.Cooanr may leakwhenboltsareslackened.

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(rl R12 Removegearon crankshattand withdraw oilseal use exlractor5205.

9A

Gtoup 21 Engine Crankshaft front seal, replacement

R13 Installnew oil seal and gear on crankshaft P a c ks p a c eb e t w e e ns e a l i n gl i p s w i t h g r e a s e .

P r e s si n n e w s e a l .U s e a d a p t e r5 2 0 0 ,v i b f a t i o nd a m p e r c e n t e rb o l t a n d a l h i c k w a s h e r .

Instalgearon crankshaft.

R14 lnstall: - retaining bolts for cover - m o u n l i n g b r a c k e tf o r c o o l i n g f a n / a l i e r n a t o r .

D

R15 Install camshaft gear belt M a k es u r et h a t b e i r i s f i f t e d i n e x a c r t y s a m ep o s i t i o na s A l i g n i d e n t i f i c a t i o nm a r k s o n b e l t , c a m s h a f ts p r o c k e t a n d c r a n k s h a f st e a f .

It is extremely important that belt is fitted in exactry same position as before.

T e n s i o nb e l t b y r n o v i n gc o o l a n tp u m p ( b y h a n d ) .

T i g h t e np u m p m o u n l i n g b o l t s .

99

Group21 Engine Crankshaftf ront seaI, replacement

R16 gear lnstall lower timing cover and vibration Dampercan onlybefiitedinoneway.

Pinon crankshaft gearmustfit in vibraliondamper.

Torqueinhexbo ts ro 20 Nm 115ft lbs).

r)) R17 lnstall center bolt S m e a r t h r e a d s a n d m a t i n g s u r f a c ew i t h s e a l e r P / N 2779619.

U s e w r e n c h 5 1 8 7( r e s to n c o o l i n sf a n b e a r i n g ) t o h o l d

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Use wrench 5188 to lorque center boll to 350 Nm { 2 5 5f t l b s ) . l m p o r t a n t rT o r q u e3 5 0 N m a p p l i e so n l y i f w r e n c h5 1 8 8 i s u s e d .A l s ot o r q u ew r e n c hm u s t b e i n l i n e w i t hw r e n c h 5188_

R18 Set belt tension T u r n e n g i n ea p p r o x 1 / 4t u r n a n t i c l o c k w i s eA. d j u s tt e n s i o n b y m o v i n g c o o l a n tp u m p .

U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g et o b e l t a n d s e t t o 1 2 . 5u n i t s .

D ep r e s sb e h s t r o n gl y w i t h h a n da n d r e c h e c k / a d j u s n e n

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R19 lnstall: - f r o n t t i m i n g g e a rc o v e r c o o i n g i a n w i t h s p a c e ra n d p u l l e y : T o r q u e b o l t s i o I N m ( 6 . 5f t l b s ) - b e l t f o f p o w e . s t e e r i n gp u n r p a n d f a n b e t s - r a d i a t o rC . o n n e c th o s e s splashguard

100

i

Group21 Engine Crcnkshaftfront seal.reDlacement

820 Bleeding ot cooling system Disconnectupper hose from cold start drip pan beneathhoseand hold hose edgeof expansiontank,

Coolant S i n c ea l u m i n i u m i s u s e d i n t h e e n g i n e s ,a c r i v ec o r . o sion protection is necessaryin the coolant to help prevent corrosion damage, Use genuine Volvo blue-green coolant type C. diluted with clean water in proportions of 50/50.

This mixture helps to prevent corrosion and frosr damage.

N e v e rf i l l t h e c o o l i n g s y s t e m w i t h w a t e r a l o n e .

T h e c o o l a n ts h o u l db e c h a n g e dr e g u l a r l ys i n c et h e c o r rosion protective additives in the coolant lose their ef fect in time.

Note!Oonot runenginewhenlevetofcoolantis low, since high local temperarurescan resutr whichmay causethe cylinderheadro crack.

srY0oar rtt ,r00crfTEirfLr ARar SuNrNto otl vrlraf ocr tN otL v0w!]q!!|I$|l!!_L_ fruo wrTi GaNUltratol,l/o coourr Tyr€c c00u|6sysTrrirs ruPUrYUi [00ND w|lH[rLf WrrtiAri0|lALa v0w0 mnM

[$ru ff Lrouror Arr€ft vrol,vo n* c vAuBrtJus0ur zrt ,30.cn rrrr muft s^rsoN ^vtcMorrtau riorTrt Arrctt TYr€ c

Replacingcoolant AlwaysusetypeC blue-green coolant.Remember to replace decal{P/N1331473-7) on expansion tankif neType C blue-greencoolant s anufactufed A l l d i e s e la n d p e t r o l ( g a s o l i n e ) e n g i n em s i n c e1 9 8 2a r e f i l l e d w i t h t y p e C c o o l a n t .

101

Gtoup 21 Engine

Crankshaftfront seal,replacement

R21 Fill coolant Capacity:D 20= 8.1liters(8.6USquarts) D 2 4 = 9 . 1 l i t e r s( 9 . 8U S q u a r t s ) F l u s hc o o l i n g s y s t e m b e f o r ea d d i n g n e w c o o l a n t ,s e e G r o u p 2 6 C o o l i n gS y s t e m .

Set dashboard heater conkol to max. Turn on engine a n d w a r m ' u p f o r 5 m i n u t e s .A d d c o o l a n td u r i n g t h i s t i m e . C o n n e c th o s et o c o l d s t a r td e v i c e .F i l l c o o l a n tt o m o u t h o f e x p a n s i o nt a n k ( a b o v e m a x ) a n d s c r e w o n

0trl1 ((

102

I