Volvo D20 Manuale utente

Service

Manual

Repairs

and

maintenance

30420/1

11.88

EngineD20,D24

240 1979-

19 ..

D20,D24

Both

the

D20

ancl

24Dieselenginesare

dealtwilhin

thismanual.

TheD20hasfivecylindersandtheD24six.Otherwise

the

enginesaresimilar

principle.

Not6lDifferent

llywheels

andvibrationdampersar€

fitted

tothedilferentenginetypes.

Volvos

aresold in versions

adaptedtor different

markets.These

adaptationsclependonmanyfac-

IorsIncluding

ega,taxarionandmarkerreqJi.e

Thismanualmay

thereforeshowill!strations

and

lext

whichdonotapplytocars

your

country.

iffim itm!r

:i!r-l-l

Contents page

mportantinformation............................... 2

Specitications........ 3

Special

tools ...................................12

Group21Engineassembly...............................................

(Workwilh enginein-ca.,replacernent

of engrnej

Group22LubricatingSystem.........................................

123

Group23FuelSystem.........................................................

125

Group25Intake

andexhaustsystems................ .. r60

Group26

Coolingsystem..................................................

i63

Group27En9inecontro1s..................................................

175

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

Index178

OrderNo,:TP30420/1

reserye

theright

to makealerat ons

Reprint

of'1983literature

without

change.

OVOLVO

NORTH

AMERICA

CORPORATION

lmportant

information

CLEANLINESS

Dieselinjection

systemsareoxtremelysensitiveto

dirt

and foreign m6tter. A special workplace should

thereforebeusedfor insoectionofcomoonents.

PLUGS

CleanfuelIineconnectionsthoroughly

beforediscon-

necting

pipes.

Plug

ends

of fusl linesetcas eachcomponentis

removed.Donotremovethess

plugs

untilthecompo'

nentis reconnected.

Tighteningtorques

Twokindsoftighlening

torqueswillbefoundinthis

1. Tightento40Nm

{30ft

lbs)indicatesth6tatorque

wrenchmustbeusedIortightening.

2. Tighteningtorque40 Nm {30

ft lbs) indicatesa

guidevalug.

Tighteningneednotbedonewitha

Iorouewrencn.

Specifications

Group

20General

.,o

,o Engine

typedesignation

and

serial

number

Stamped

left

side

ofenginebeneath

vacuutr,

pump

Maxtorque

DIN

20Engine

OutputDIN

.......................... 50kW ar80 r/s

68hpat4,800r/min

120Nmat

50/s

12.2kpm

at3,000/min

1-2-4-5-3

1.986

dm3

(liter)

'181

(405lbsl

Mpa

3.2

2.4

0.8

23.0:1

76.5

: 3.0118in

86.4mm

= 3.4016in

Number

ofcylinders

Displacement.........

........

Weight,

approx.incl. enginemounts,altefnaror

and starter

Compressionpressuresi

\ew en9ine..................

iVnirnJn.......................

Maxd;ffe.enceberweencyl

nders..........................

Comp.ess,orratro.....

...

Cyl:nderbore..................

Stro\e

lengr

313

114

Specifications

24Engine

OutputDlN

MaxtorqueDlN

60kWal 80 r/s

82hpat4,800r/min

140Nmat47r/s

14.3kpm

6t2,800r/min

1-5-3-6-2-4

2.383dm3

{litsr)

1S8

{435

lbs)

MP.

3.2

2.4

0,8

23.0r1

76.5mm

= 3.0118in

86.4mm= 3.4016in

Numberofcylinders.......

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

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

Weight,approx.incl,enginemounts,alternator

and starter

Compression

pressurss:

Newongin€.........,,,,,.,......

lvlinimum................,,......

Maxdiffsr€ncebetween

cy1inders...........................

Com

ressionralio.......,,

Cylinder

bore....,.............

Slrokelength

psl

455

313

114

Group

21Engineassembly

CYLINDERHEAD

Replacecylinderh€ad

jfwarp €xce€dssp€cificalions.

Und€rnocircumst.ncos

maycylihderh€adb€machinod.

9- :.' ., - \|

; .,1 ,\

Diagonally

max0.5mm

L-

Specifications

CYLINDEBHEADGASKET

Thfeedifferentgasket

typesareused

dependingonpistonprojection

abovecytinderblock

face.

G.sket

Pistonproi€ction notches

linl thickness

(in)

0.67-0.80

(0.026-{.031

)........

1 ....................1.4

{0.0S5)

0.81-0.90(0.032-{1.035)........2 ...................

1.5

{0.059)

0.91-r.02

(0.036--0.040)........

3 ...................

1.6

(0.063)

-o

,lo

-L

VALVESYSTEM

Valveclearances,

coldengine

Cold

engine

= roomtemperature Check

(in)

0.15{.25

(0.006-{.010)

0.35-0.45

(0.014-0.01

Setting

lin)

0.20

{0.008)

0.40

(0.016)

Valve

clearances,warm

engine

0.1299into0.1673in

inincrements

of0.0020in

0.20-0.30(0.008-0.012)

0.25{0.010)

0.4(F0.50(0.016-0.020)

0.45{0.018)

3.00-4.25mmin increments

of0-05

o20

Checldadjust

valves

1-2-4-5"3

D24

Checuadjustvalvesinfollowingorder:

1-5-3-6-2-4

r-l[ r

]

Specifications

TIGHTENINGTOROUES

Tight€ning

torquB apply

to oilednutsandbo|Is.

grsased

{washed}

parts must b€ oiled prior to De-

NGHIENING

CYLINDERHEADBOLTS

TIGHIENITVG

SEOUENCEFORCYLIIIDERXEADBOLTS

lmportlntl slsck6nbottsin rev€rsa

oder when

removing

cylindsrh€ad.

Removsoiland

dirtfromboltholes.

Oil

left

inhol€swill

reduc€

pressure

oncylinderhead

gasket,

Eolt threads

and washersmust howeverbe oiled,

otherwisefrictionalforces

will b6toogrear.

Twotypesot bolls ars in usetAn earlytypewith M 11

threads

and6later

typewithM 12threads.

{Later

typ€is

lhr@d6dalong

entir€l6ngth.l

Us6now waahera,convex sid6upwards,

Tlght€n

infiv€stages:

l50Nm{37ftlbsl

2 ?0Nm (50

ft lbs)

3 90Nm {65ft lbs}

4 run

6ngin€until

oiltemperaturo

isst t€ast

50.C

1122'Fl

5 90Nm (65

ft lbs)

R.lightening

- Atler 600-1.200miles (1,000-2.000

km). Engine

should

becold

oralmostcotd.

Tighten

eachboltsep6r-

atslyin specifi€d

order,

seeabovsfio.:

L Slack€n

bol 3(r

2. Torqueto 90lrlm (65ft tbs)

Us€n.u bolb. Notn€ce$ary

to roplac€w6shers.

Tighten

insixstag6s:

1 aoNm€0 ft lbsl

2 60 Ntn l4aft lbsl

3 75Nm{55

ft lbs)

4 angle-tightsn

l8f in onomovem€nrwithout

stop-

ping,

{Se€

figur€6tlowerlefi}

5 run€ngin€until

oiltehperatureisatlerst50oC

lt22

"Fl

6 anglo-tighten90Pin on6movsment

withoutstop-

pins.

Rdighl.nlng

After

60F1,200mil€6

(1,000-2,000

km).Engineshould

coldoralmostcold.

Tighten

6achboll separatolyin spocifi€d

order,se€

€bov€fig.:

1. Angle-tighten

bolt 9|r in one movemontwithout

stopping.

(See

figure

atlowerleft)

Donot shckon boh firf,

,Ot rO

D20

,oo

@@@

@@)@

@@o

@@@

D24

Mtl M12

Specificalions

20Nm

6\1fl

I l'- '

l1s

ft lbs)

ro'\ 1rs

tttu"t

100

Nm(74

@lbs)

45Nm133

ft lbs)

Smearthreadsandboltheadcon-

tacl suriaceswilh lockingcom-

pound(P/N

277961-9).

Tiqhteninglorque

350

Nn {258

lbs)

appli6swhenusingspecial

tool 5188.lf a torquewrenchis

lsed dirscnyon the cenlerboll

(wiihout 5188),the tiqhlening

torqle shouldbe450Nm(332

350Nm (258

ft lbs)

Nm (55

ft tbs)

75Nm (55

ft lbs)

Smear threads wiih

compound

P/N277961-9.

(6.5

ft lbsl

D20

@@'

Specifications

OILCAPACITIES

Excl.oilfilter

Incl.oillilter

Difference

involume,

max-min

ENGINEOIL

Oua1ity............,,,,,............

Accord'ngtoAPI.......................................,,..,....,.:::::::::::::,.:::::::

VbGosity

Tomporaturc

rangs

(stable

ambisnttemperatures)

ffiffi8

Gtoup

22Lubricating

System

D20

Litors

{US

quarts}

5.2

(5.5)

6.0

(6.3)

1.0

(1.0)

kPa

200

15-45

Long1h

mm in.

L = 49 (1.93)

L1=22 {0.87}

= 19.8 (0.781

(completely

compressed)

psl

D24

Liters

IUS

quarts)

6.2

(6.5)

7.O

(1.41

1.0

(1.0)

minCC

OilswithdesignationsSSCC,

SE/CD,SF/CCandSF/CD

meotthisr€quirement

SAE15W/50orSAE20

w/50oilsarerscommend€dfor

useinsxtreme

drivingconditionswhichinvolvehig

hoil

consumption

andhigh

oiltemperatures.

for example,

mountain

drivingwith frequent

decel€rationsof fast

motorway

driving.

(Note

howoverth€lower

tempera-

turelimits.)

OILPRESSURE

Oil

pressurc

atoiltemperature

of 8O.C

(176.F)

and

33,3r/s

(2000r/min)min

Oil

pressuresensot

Cut-outpoint,

indicatorlampgoes

out

Lubricating

oilpump

Reliefvalv€opensat...... .........................

600-700

R€lisfvalve

spring,l€ngthatdiffsrentloads

2-6.4

85-99

Load

0lbs

17F195 {39-.44)

approx.

200 (45)

Altri manuali per D20

Questo manuale è adatto per i seguenti modelli

Indice

Altri manuali Volvo Motore

Volvo

Volvo 2001 Manuale utente

Volvo

Volvo B 17 Manuale utente

Volvo

Volvo MB10A Manuale di istruzioni

Volvo

Volvo B 17 Manuale utente

Volvo

Volvo 819 E Manuale utente

Volvo

Volvo D16F Manuale di riferimento

Volvo

Volvo 3TNV76 Istruzioni per l'uso e l'installazione

Volvo

Volvo D5 series Manuale utente

Volvo

Volvo D13 Manuale utente

Volvo

Volvo EPA2007 D13F Manuale utente

Volvo

Volvo XC90 - ANNEXE 951 Manuale utente

Volvo

Volvo TAD650VE Manuale di istruzioni

Volvo

Volvo D20 Manuale utente

Volvo

Volvo D13J Manuale utente

Volvo

Volvo D13H Manuale utente

Volvo

Volvo MD5A Manuale di istruzioni

Volvo

Volvo TAD1240GE Manuale utente

Volvo

Volvo D4 Manuale utente

Volvo

Volvo D1-13 B Manuale di istruzioni

Volvo

Volvo TAMD75P Manuale utente

Volvo

Volvo D13 Manuale utente

Volvo

Volvo TAD734GE Manuale utente

Volvo

Volvo D12D Istruzioni per l'uso e l'installazione

Volvo

Volvo B27A Manuale utente

Manuali Motore popolari di altre marche

Rotax

Rotax 125 senior MAX evo Manuale utente

Kohler

Kohler K361 Manuale utente

MTD

MTD OHV Series Manuale utente

Kohler

Kohler COMMAND CH18-745 Manuale utente

Mercury

Mercury D4.2L D-Tronic Manuale utente

Selve

Selve SE Plus-RC Series Manuale utente

Perkins

Perkins 1206E-E66TA Manuale utente

Skov

Skov DA 174 Manuale

Rossi

Rossi TX11 Series Manuale utente

Siemens

Siemens SIMOTICS T-1FW3 Foglio di istruzioni

AL-KO

AL-KO PRO 350 Manuale utente

MTU

MTU 12 V 4000 Lx4 Manuale utente

Nanni

Nanni N3.30 Manuale di istruzioni

Nanni

Nanni N5.160 CR2 Manuale utente

KSB

KSB SuPreme Series Istruzioni per l'installazione

Hiwin

Hiwin EM1 Series Manuale utente

Rotax

Rotax 912 i series Istruzioni operative

Siemens

Siemens SIMOTICS XP 1MB1 Manuale utente