Group21 Engine

Crankshaftrear seal,replacement

S. Grankshaftrear seal,replacement
Specialtools: 1801,5112,5203,5208

s?
Removegearbox/transmission
SeeServicemanualsection4 (431.
Securestanermotorwith a bolt.

Manualgearbox:
s2
Removepressureplate and driven plate
Unscrewpressure plate
mounting boltscrosswisea
few
turnsat a timeto preventwarp.

Manualgearbox:
s3
Removeflywhe€l

Automaticgearbox:
Removecarrierplate
Uselocking
sector
5112to prevent ilywheel from mo-
ving.

s4
Removecrankshaftrear oil seal
Liftout oil sealwith a screwdriver
as indicated.

Cleanand
Group21 Engine
Crankshaftrearseal.reDlacement

s6
Installnew oil seal
Assemble standardhandle
1801anddrift5208.
S m e a ro i l o n t o s e a l i n gs u r f a c e sa n d l i p s o n s e a l .
P l a c es e a lo n d r i f t a n d t a p i n u n t i l d r i f t a b u t sc r a n k s h a f t .

s7
Install f lywheel/carriei plate
Flnrheel(manual) andcarrierplate(auto)canonly be

Usenew bolts,smeared with sealerP/N277961,9.

Torqueboltsto 75 Nm (55ft lbs).Uselockingsector
5112to holdflywheelin position.

s8
Automaticgearbox:
Checkinstallationmeasurementot carderplate
(To be caffiedout after replacementof carrierptate.)

Placea steelrulerbetweencarrierplateand engine

block.Fulershouldrest againstengineto gearbox

A+B=la:O,8mn
mounting
flange.
flangeandshouldrestagainstbothsidesof
Turncrankshaft
(ir
untiloneof holesin carrierplate
coancides withsteelruler.Measure "B"with an outside
caliperequipped for depthmeasurement.
Measured value"B' + thickness of steelrulershould
equal'17.2-18.8 mm = 0.667-0.740 in. lf distanceis less
than 17.2mm = 0.677in use a spacerwasher(P/N
1257377'0) betweencrankshaftand carrierplate.
lf carrierplateis insralledincorrectly (i.e.instattarion
measurement js wrong),distance to torqueconve er
caiiierwill betoo long.Thismaycausecarfierplateto
crackand possiblya noisewhendriving.

104
 Group21 Engine
Crankshaftrear seal,replacement

Manualgearbox:
s9
Installdriven plate
l:i Usecentering shaft5203.
Turndiscwith hubfacingout,awayfromftywneet.

Manualgearbox
s10
Install pressureplate
Tightenboltscrosswise a fewturnsat a timeto avoid

s11
Installgearbox/tmnsmission
Do notforgetto removeboltsecuring
starternotor,

105
Gtoup 21 Engine
Vibration damper, remov in g/i nstalIing

T. Vibration damper,removing/installing
SDecialtools: 5187. 5188

Notel Different vibration dampersfor D 20 andi.

D 24 engines.

D20 D24

T1
Disconnect battery

T2
Jack-upvehicle
To prevent spillageswhencoolantis drained, raiseve-
hicleat frontrightjackingpoint.Cooanl will thenrun
alongsplashguard intodrip pan.
Placedrip panbeneathleftsteerinsrod.
( r(

f3
Drain coolant
Unscrew
expansiontankcap.
Disconnect
lowerradiator
hosef romradiator
anddrain

(Ensine
is withouldraintaps).

106
 Group 21 Engine
Vibration dam per, removi ng/i nstall i ng

T4
Disconnect:

c o o l i n gf a n w i t h s p a c e r6 n d p u l e y
- f a n b e l t a n d p o w e r s t e e r i r g p L r m pb e h -

T5
Bemove vibration dampea
R e m o v ec e n t e r b o l t . U s e 5 1 8 7t o p r e v e n tp u l e y f f o r n
r o t a t i n g ,a n d s o c k e t5 1 8 8t o u n s c r e wb o t s .
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 i g h t l ys o t h a t 5 ' 1 8 7
r e s t so n f a n b e a r i n g .
R e m o v ef o u r i n h e x b o l t s ( 6 m m ) .
P u l l o f f v i b r a t i o nd a m p e r .N o t e l C r a n k s h a fgt e a r m a y
s o m e t i m e ss t i c kt o v i b r a t i o nd a m p e r .

T6
Installvibrationdamper
D a m p e rc a n o n l y b e f i i t e di r o n e w a y . P i no n c r a n k s h a f l
g e a r n 1 u s tf i t i n v i b r a t i o nd a m p e r .
T o r q u e b o r s t o 2 0 N m 1 1 5f t b s ) .

T7
Install center bolt
S m e a r t h r e a d s a n d m a t i n g s L r r f a c ew i t h s e a l e r P / N
277961L
U s e w r e n c h 5 1 8 7{ r e s lo n c o o i i n gf a n b e a r i n g ) t oh o l d

U s e w r e n c h 5 ' 1 8 8t o t o r q u e c e n t e r b o l t t o 3 5 0 N m
( 2 5 5f t l b s ) .
l m p o r t a n r :T 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 h 5 1 8 8
i s | r s e dA
. s o t o r q u e w r e n c h m u s t b e i nl i n e w i t hw r e n c h
5188.

107
Group21 Engine
Vibration dam per, removi ng/installing

T8
Install:
- 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 .T i g h l e n i n gt o r q u e
9 Nm (7ft lbs)
- b e l t f o r p o w e r s t e e r i n gp u m p a n d f a n b e t s
- fadiator. Connect hoses

{))l
T9
Bleeding of cooling system
Disconnect upperhosefrom cold siart
drip pan beneathhoseand hold hose
edgeof expansiontank.
ti
I

Coolant
S i n c ea L r m 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 l e c t i o ni s n e c e s s a r yi n t h e c o o l a n tt o h e l p p r e -
v e n r c o r r o s r o no a m a g e .
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 l t y p e C , d i l u t e d
with cle.n water in propo(ions of 50/50. ,lrtl
This mixlure helps to prevent coftosion and irosl
damage.
a N e v e rf i l l t h e c o o l i n gs y s t e mw i l h w a t e r a l o n e .
a T h e c o o l a n ts h o u l d b 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 r o s i o n p 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 e
rl
their effect in time.
N o t e l D o n o t r u n e n g i n ew h e n l e v e lo f c o o a n l a sl o w ,
s i n c e h i g h l o c a l t e m p e r a t u r e sc a n r e s u l t w h i c h m a v
c a u s et h e c y l i n d e .h e a dt o c r a c k .

108
 Group21 Engine
Vibration damper, removing/installing

srYoorTirtt 3(rc rfrrRfY[lrfi rurr *t0 ai otLv^firr or| rfr 0rr

v0rv0r4v^rsuTYrc
artto wrTN ctr0r|r lrol\to cooullrnPt
mdd]wF. Beplacing coolant
i$rPU0r Lrouror
ArrGftvoLvo
rc MollrtrALr 0n€ Ar{TrcrL
fiPr c A l w a y s u s e t y p e C b l u e - g r e e nc o o a n t . R e m e m b e rt o
r e p i a c ed e c a l( P / N1 3 3 1 4 7 3 , 7o)n e x a n s j o nt a n ki f n e c e s -

Typ€ C blue-s.een coolant

A l d i e s e la n d p e t r o l ( 9 a s oi 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 e d w i t h r y p e C c o o t a n t .

710
Fill coolant
C a p a c i t y :D 2 0 = 8 . 1 l i l e r s ( 8 . 6U S
D 2 4 = 9 . 3 l i t e r s( 9 . 8U S
F l u s hc o o l i n gs 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 .
S e t d a s h b o a r dl - e a t e rc o n n o l I o m a \ . T L r n o r e n g i n e
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 t d u r i n g t h i s
l 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 tr 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

109
Group21 Engine
Engine mounts, replacement

U. Enginemounts,replacement
D iferent brackets for mu nLal
and automat c gearboxes

U1
Rearenginemount(gearboxmount)
N e c e s s a rtyo r e m o v eg e a r b o xm e m b e rt o r e m o v er e a r

G e a r b o xm u s t b e u n o a d e dw i t h a j a c k d u r i n g r e p l a c e -

,r))a
Frontenginemount
U2
rr)l
U n l o a de n g i n em o u n t sw n h l i f t t o o l s5 0 3 3( 2 x ) , 5 0 0 5 a n d
5115.

U3
Left side
T o r e p l a c er u b b e r p a d : r e m o v e e n g i n e f i r o u n t w n h
u p p e ra n d r o w e rb r a c k e r s .
O,'rI

I
q
e

Right side
T o r e p l a c er u b b e rp a d : r e m o v eu p p e r b r a c k e d
l ,,uruD-
b e r p a d t o g e t h e . ,d o n o t r e m o v et o w e r b r a c k e r .
Do not lighten upper nul for rubberpad t]nti engine
mounl is positioned.

1t0
 Group21 Engine
Removingengine

V. Removingengine
OperationsV1-7
Special tools: 2810, 5185,5186

Ensineandgearboxremovedas a unit

v1
Removeenginesplashguard
anddraincoolant

v2
Remove/disconnecti
r positive lead from battery
2 b o n n e t( h o o d )
3 e x p a n s i o nt a n k c a p
4 lower radiaior hose from radiator

Auto {operation 5)l

5 o i l p i p e f r o m o i c o o l e r . H o l d c o n n e c t o r so n o i
c o o e r w i l h a w r e n c h . t f a c c i d e n i ay s a c k e n e d ,
t o r q u e i o 6 N m ( 4 . 5f t t b s )
6 u p p e r r a d i a t o rh o s e f r o m e n g i n e
7 h o s e st o € x p a n s i o nt a n k a t r a d i t o r
8 radiator
t h o s e sf r o m h e a t e rc o n t r o l v a l v e
1 0 h o s ef r o m v a c u u m p u m p -

1rl
Group21 Engine
Removing engine

v3
Remove/disconnect
A c o n n e c i o rf r o m c l l p o n b u l k h e a dl f i r e w a )
B t h r o t t l ec a b L ef r o m p ! l l e y a n d b r a c k e t
F u e l l i n ec o n n e c t i o n s
(C E below)i
B l o w - ce a n , d i s c o n n e c a t n d p l u g e n d s t o p r e v e n td r r t
entering fuel system
C s u p p l y i n e f r o m f u e l i i l t e r - r e t u r nl i n e i r o m n j e c
tion pump (atclamp)
E p a L e a l a v f o r p r a h e a l i r g s v s r P T0 1 F n o 1 o .
D i s c o n n e c tw i r e l r o n r j u n c i i o n b o x . D i s c o n f e c l
b l a c kw i r e a n d s m a I r e d w i r e f r o m r e l a y .U n s c r e w
r e t a i n i n gs c r e w sf r o m r e l a y .
r e m o v ep o w e r s t e e r i n gp u m p l f o m e n g i n e :s a c k -
i)t a
en and remove drive belt from purnp. Bemove
p r f p s i r L b r a r \ e _o ' r d , L p p o r \t r o y l r o 1 F 1 g . -
T i e p u m p t o c h a s s i st o p r e v e n ld a m a g et o h o s e s .
c o o l i n gf a n w i t h s p a c e r
p u l e ya n df a n b e l t s
rta
b e I f o r p o w e r s i e e r i n gp u m p .

v4
Remove/disconnect

2 c r a n k c a s eb r e a t h e rh o s e
;a
3 air filier cove.and hoses
a i e f n a t o rw i r i n g h a r n e s s :
d l s c o n n e cvt o t a 9 € r e g ua i o r ( o r a t e r n a l o r ) .
R e m o v er e l a i n i n gs c . e w s f o r w i r i n g h a r n e s so n
il
w h e e a r c h a n d p a c e h a r n e s so n e n g i n e .

V e h i c l e sf o r S w e d e n :
5 T - s e a ru n i t o n b u l k h e a d( f r e w a l l )
6 e x h a u s tp i p ef r o m f r o n t e x h a u s lb r a n c hp i p el D 2 0
hasonly 1 man fold).

112
Y
I Group21 Engine
Removing engine

v5
Drain engineoil
lnstallplug.nd washerafterdrainingoil.

- enginemountretainingboltsfrom frontaxtecross-

Leftenginemount:removenursfromfrontaxte
cross,

Rightenginemountiremovelowernuifromrub-

0 Removinge n g i n e
v6
C Remove/disconnect
s
0 =-€>
- f r o n t e x h a u s tp i p e c l a m p s
- d i s c o n n e c el x h a u s tp i p e c o u p l i n g .R e m o v ef r o n t e x -

- ( m a n u a l )c l u t c h c a b l ea n d g e a r ! e v e r
- ( a u t o )s e l e c t o rc o n t r o lf r o m s e a r b o x / l r a n s ms s i o n
{"F s p e e d o m e t e cr a b l e
-'-2" - g e a r b o xc f o s s m e m b e rP
. o s i t i o na j a c k b e n e a t hg e a F

;# - d i s c o n n e cw
t iring.

0
(f
V7

Useliftinstools2801,5185(atfront)and5r86(arrear).
Liftengineenoughlo unloadleftenginemount.
Rertroveenginemount.
Removejack beneathsearbox,stidepu ey unit for
wardsand lifi our engine.

113
Gtoup21 Engine
Removing engine

X. Removingengine
Operationsx1-3
SpeciaI tools: 2810, 5185,5186

E n g i n ea n d g e a r b o xi n s t a l l e da s a u n i t

x1
Positionengine
Uselift tools2810,51a5(atfront)and5186(al read.
Positionrightsiderubbermounton ower bracket.

x2
Installleft enginemount
P l a c em o u n t o n f r o n t a x l e c r o s s m e m b e ra n d t i g h t e n

x3
Place a jack beneath gearbox
Makesure padatgearleveriscorrect-
thatrubberfoam

Insenwiringintopassengercompartmeni.
gearboxuntillevel.
Jack-up

Remove lifling tools

Lowerengineand removetools.

114
 \
Group21 Engine
Removing engine
l
x5
Installgear lever
P l a c eq e a r l e v e ri n h o u s i n g .
P r e s sp l a s t i cc o l l a ra n d r u b b e rr i n g i n t o p o s i t i o n l.n s t a l l
l o c k r i n g . R e c o n n e cw l aring.
I n s t a l lb r a c k e tf o r r e v e r s eg e a r d e t e n t .D o n o t t i g h t e n
screws atthis stage since bracketmust be adjusted at a

(0
X6
Install nuts tor engine mounts
Leftmount:nutsin fiontaxlecrossmember.
R i g h tm o u n t : l o w e r n u l o n r u b b e r p a d .

x7
Installgearboxcrossmember

x8
Installon gearbox:
_ g e a r l e v e r .l M a k es u r e t h a t b u s h i n g sa n d O j i n g a r e
c o ( e c l l y i n s t a l l e dI.n s e ng e a r e v e li n y o k e ,f i t p i n a n d
t i s h t e n s c r e w ( A l l e nk e y 4 m r n ) , s e e i n s e t
- p r o p e l l e rs h a f t .A l w a y s u s e n e w n u t s a n d b o l t s
s p e e d o m e t ecr a b l e .S w e d e n :w i r e m u s t b e s e a l e da t
g e a r b o x t oc o n f o r mt o t a x r e g u l a t i o n s( k i l o m e r e r t a x a ,

115
Group21 Engine
Removing engine

X9
Connectclutch cableand install return spring
I n s e r tc a b l e t h f o u g h f l y w h e e l c a s i n g a n d c o n n e c tt o

l n s t a l lr u b b e r b u f f e r a n d v i b r a t i o nd a m p e r o n c a b l e ,
m a k i n gs u r e t h a t b u f f e r i s f a c i n g r i g h t w a y .
C o n n e c tr e t u r ns P r i n g .
A d j u s t p l a y = 1 - 3 m m . ( 0 . 0 4 - 0 . 1 2i n )

a
A0tomatic gearbox

Attach gear selector to gearbox

x10 { DI

xl1
Installlront exhaustpipe
Forstrainjree installation,
instrucrions
mustbe fol

{))a
1 S l a c k e nt w o r e t a i n i n g b o l t s h o l d i n g b r a c k e t t o
gearbortransmission
2 Attach front exhaust pipe fingef tight. Use new

3 Tightennuts and bolts holdingexhaustpipe to

4
5
T i g h t e nb o l t h o l d i n gf r o n t p i p e t o b r a c k e t
T i g h t e nb o l t s h o l d i n g b r a c k e t o g e a r b o x
0Dl
6 T i g h t e nc l a m p a t e x h a u s tp i p e j o i n t .

Carsforsweden
xl2
Attach T-gearunit to bulkhead(firewall)

1',16
 Group21 Engine
Removing engine

x13
Connectalternatotwiring harness
Reconnectvoltage regulator.
A t t a c hc l a m p o n w h e e l a r c h .

x14
lnstall air filter cover
air inlet hoseand breatherhoseto valve
Reconnect

Notethatarrowon inlethosemustpointtowardsmani-
fold as indicated,otherwisehosemay be compressed

xl5
Install drive bells and cooling fan
P l a c ep o w e r s t e e r i n gp u m p b e l l o n v i b r a t i o nd a m p e r .
I n s t a l l f a nb e l t s a n d p u l l e y -
Install cooling fan with spacer. Torque to 9 Nm (6 5 ft
lbs).
T e n s i o nf a n b e l t s . l t s h o u l d b e p o s s i b l e t od e p r e s sb e l t
5-10 mm on run between fan and alternator, see fig

x16
Installpowe. steeringpump and belt
Negativeleadfrom batteryshouldbe connectedto
lowerfrontretaining
boltfor pumpmountingbracket.
Tensionfan belts.lt shouldbe possibleto depressbelt
F10 mm (0.2-0.4 in) in centerof run betweenfan and

x17
Connectrelayfor preheating
system
C o n n e c tb l a c kw i r e t o t e r m i n a l8 6 o n r e l a ya n d r e d w i r e
t o t e r m i n a l8 5 .
Attach relay to washer reservoir mounting bracket.
R e c o n n e cwt i r i n g t o j u n c t i o n b o x .
Secure wires with clamps and reconnect battery-

111
Group21 Engine
Removing engine

x18
Reconnectluel lines
Makesurethatdirt doesnot enterfuel system.

x19
Reconnectplug on bulkhead(tirewall)
S e c u r ep l u g w i t h c l i p .

x20
Reconnect:
- hoses to heater control valve
- h o s et o v a c u u m p u m p

x21
lnstall radiatorand connecthoses

'.,r

Automaticgearbox
m x22
Connectoil pipesto oil cooler
U s e a w r e n c h l o h o l d c o n n e c t o r co n o i l c o o l e r .
T i g h t e n i n gt o r q u e
C a p n u t s 3 0 N m ( 2 2f t t b s )
O i l c o o l e rc o n n e c t i o n s6 N m { 4 . 5f t l b s ) .

118
 Group21 Engine
Bemovingengine

lnstall bonnet/hood
Connect
washerhose,

Reconnectbailery

Manualgearbox
x25
Adiust blacketfor reversegear detent. lnstall
rubbergaite.
Engagefirstgear.Ad,ustclearancebetweengeartever
and detentbrackerto0.5-1.5mm (0.020-0.060
in). Use
a feelergauge.
Tightenretainingbolts.
Recheckclearancein s€condgear,
Installrubbergairerboot.

Automaticgeatbox

Check/rdiusigeaaselector
'1.
CheckthatclearancebetweenpositionD and stop
is approximatelysameas from 2 to stop.
2. Adjust by alteringlength of controt rod if neces,

Roughadiustment:turn adjusrerat re6r of rod

FineadiustmentI turn serraredsteeve(maxvisibte
threadlenslh= 35 mm).
hcreasingrod lengthreducesctearancein position
D, and increasesclearancein posjtion2.
After adiusrment:move tever to posirion I and
thento positionP.Repeatcheckaccordingto stage
1.

'119
Group 21 Engine
Removing engine

x27
Add engine oil
C a p a c i t yi n c u d i n g o i l f i l l e r :
D 2 0 = 6 l i t r e s { 6 . 3U S q u a d s )
D 2 4 = 7 l i t r e s { 7 . 4U S q u a d s )
O u a i t y : a c c o r d i n gt o A P l , m i n c C ( o i l s w i r h d e s i g n a '
l i o r s S L / C CS. L/CDS . l / C Cd r d S r / C D, J l ' i r l - s e q L r e .

V i s c o s i l ys, e e a d j a c e n td i a g r a m .
N o t e l S A E l 5 W 5 0 o r S A E2 0 W 5 0 o i l s a r e r e c o m m e n
dedioruseinextremedrivingconditionswhichinvolve
h i g h o i l c o n s u m p l i o na n d h i g h o i l i e m p e r a t u r e se . g .

,))ra
m o u n t a i nd r i v i n g w i t h f r e q u e n t d e c e l e r a t i o n o
s r fast
m o t o r w a Yc i r i v i n g .( N o t e h o w e v e rt h e l o w e r t e m p e r a

x28
BleedingoI cooling system
Disconnect upperhosefrom cold startclevice.
P ace
drip pan beneathhoseand ho d hoselevelwith top
'rl
edgeoi 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 l 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 yi n t h e c o o l a n tt o h e l p p r e -
v e n rc o r o s o n o s m a g e .
U s e g e n u i n eV o l v o b l u e g r e e n c o o a n l t y p e C , d i l u t e d
w i l h c l e a nw a l e r i n p r o p o r l i o n so i 5 0 / 5 0 .
This mixlure helps to prevent corosion and frost
il|

a N e v e rf i t h e c o o l 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 E n ts h o u d b e c h a n g e dr e g u l a r ys i n c et h e
c o r r o s i o np r o t e c t i v ea c l d i t i v e si n t h e c o o l a n t o s e
t h e i r e f f e c ti n i h e t i m e .
i, I
N o t e lD o n o t r o n e n s i n ew h e nl e v e o i c o o l a . li s l o w s r n c e
h 9 h l o c al e m p e r a t u r e s cf6ens u r w h i c hm a y c a u s e t h e ci ny.

r20
 Group21 Engine
Removtngengine

oftcrrAL
firv isx! rYPc $ rArYL
trr$flLr Ain iurr Mrofli Dftv^nr|.ocHar 0rr
v0rr$
0 . v a r s ur ' r c
AI<'LI/IO COOLAilINPI Replacing coolant
roP uP Ylad R0ur0 wf| F^tr r^r
A l w a y s u s e t y p e C b l u e ' g r e e nc o o l a n t .B e m e m b e rt o
itMfu 0r !0ur0rArr0n r/o'llro
r e p l a c ed e c a ( P / N1 3 3 1 4 7 3 - 7o)n e x p a n s i o nt a n k i f n e '

T y p e C b l u e - g r e e nc o o l a n t
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 s 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 dw i t h t y p e C c o o l a n t .

x29
Fill coolant
C a p a c i t y :D 2 0 = 8 . 1 l i t r e s( 8 . 6U S q u a r t s )
D 2 4 = 9 . 3 i r r e 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 e a c l d i n gn e w c o o i a n t ,s e e
G r o ! p 2 6 C o o l i n gS y s t e m .
S e l d d s _ o o d r ld' e . r e r . o rr r o l l o r d \ . T L r r o r e l g r n e
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 t d 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 t d e v i c e .F i l l c o o l a n rr o
n r 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

x30
Check/adiustiniectiontiming

(rt on page24,c11-20
Seeinstructions

,4\\
_egt Checkoperation
x31

Turnon engineandwarm up.

C h e c k f o r o i l a n d c o oeaanki a g e s . T uo pp i fn e c e s s a r y .
Installenginesp ashguard.

121
Group21 Engine
Removing engtne

Coldgea&ox o I oiltemperatures4o'C(104'F'.
Thistemperat!rels reachedafterapprox,10 minutesidl ns. Automaticgearboxes:
beLow40'Cleve may be belowM N.
At oi temperatures x32
Check-top-up oil level
UseATFtype F or G.
in positionN or P.
Enginemustbe runningandselector
MIN .96'€

Hot gearbox o I oit temperatlre 90'C ('194'F)

x33
Check/adiust
l d l e = 1 2 . 5 1 0 . 8r A : 7 5 0 1 5 0 r / m i n
F a s ti d l e = 8 7 1 1 . 7 t s = 5 2 0 0 1 1 0 0r / m i n
l f n e c e s s a r yr e f e rt o p a g e 1 2 9 .
E n g i n e c o n t r o l s ( l h r o t t l ec a b e a n d k i c k - d o w nc a b t e )
( A u t o ) .l f n e c e s s a r yr e f e rt o p a g e 1 7 6 .

l m p o r t a n t r l f e n g i n e h a s b e e n d i s a s s e m be d c y l i n d e r
h e a d b o l t s n u s t b e c h e c kt i g h i e n e d a f t e r 6 0 0 1 , 2 0 0
m a e s ( 1 , 0 0 0 - 2 , 0 0k0m ) .

r,il)

iIila

122
 Group 22 Lubricating System
Engine oil, oil filter

Group 22 LubricatingSystem
Contents
Operation
E ' 1 g i n e o i , ot ;i l t e r . r a p a c e m e n t . . . . . . . . . . Y1 2
O l p . e s s u r ec. h e c k i l g 71
O lpLmp,gererdlinforralron.............................. z1
22 124

Engineoil, oil filter. replacement

Y1
D20 D24
Oil capacity litres
(USquarts)
E x c l .o i l f i t e r 5_2{5.5) 6.2(6.5)
I n c l .o i l f i l t e r 6.0(6.3) 1.Ot7.41
1 . 0{ 1 . 0 ) 1 . 0( 1 . 0 )

Ouality
A c c o r d i n gt o A P I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M
. . .I .N. .C. .C. . . . . .
Oils with designations SE/CC,SE/CD,SF/CCand SF/CD
fulfillhis requiremenl.

Ternperature
range
ambienttemperat'rres)
{srable

N o t eS A E1 5 W5 0 o r S A E 2 0 W5 0 o i l sa f e r e c o r n m e n d e d
f o r u s e i n e x t r e m e d r i v i n g c o n d i t i o n sw h i c h I n v o t v e
h i g h o i l c o n s u m p t i o na n d h i g h o i t t e l r l p e r a t u r e se . g .
m o u n t a i n d r i v i n g w i h t f r e q u e n t d e c e t e r a t i o n os f f a s t
m o t o r w a y d r i v i n g .( N o t e h o w e v e rr h e t o w e r t e m p e r a -
ture limits.)

Y2
Oil filter
Useoil filterwrench2903to removefitter.
To installfilter,
seeinskuclions on fitrer.
lf onlyfilteris
replaced(i.e.notengineoil),
add0.atitres
(0.8US quarts)of oil.

123
Group 22 Lubricating system
Oil pressure,oil pump

Oil pressure,checking
z1

Connect oil pressure gauge to connection for oil

pressure sender
Oil pressuremust be 6t least200 kPa(28 psi)at 33 r/s
(2,000rmin) and80'C(176'F) oiltemperature.
Reliefvalvein pumpshouldopenat 600-700kPa{8F
99 psi)-

- oil level

- reliefvalvein pump.

Oil pump

z2
Generalinformation
Oil pan cannotbe removedfrom installedengine.
Consequenllyit is necessary
to removeengineto re-

Mark(A) on outerplmp gearmustfacerearcover.

Oil pump is only available
as a completeunir.Spare
partsare howeveravailablefor reliefvalve.

(),il)

{))rl
z3
Reliefvalve
l f o j l p r e s s u r ei s n o t a s s p e c i f i e dc h e c k t h a t p l u n g e r
m o v e sf r e e l y a n d t h a t s p r i n g i s i n g o o d c o n d i t i o n .
R e l i e fv a l v e i s a c c e s s i b l ef r o m b e l o w w i t h o i l p u m p
h
a installed.

g T i g h t e n i n st o r q u e 4 0 N m ( 3 0f t l b s ) .

I
-/)
€-ao Nm

124
l
 Gtoup 23 Fuel sysf€fi
Contenls

Group23 Fuelsystem

Contents
Op.ration Pag6
't26
Exhaust gassmokedensity,general..-.--.......-
checking ' AA2-10 126
ldle+ fastidle............... ABl-6 129
Fuelfiltsr, drainingwate AC1 130
replacoment.......... AC2 130
Injection pump,general AE1-14 13',l
altitudeadiustment, USA AD2 132
senlng. .'. ., " aD3-14 133
't36
beltrePlacement .. ...'..., AEl-14
removal . .
......,............. 140
installation ................... AG1-17 143
Deliverypipes,removal/installation ........ ......... AH1-3 148
'149
rePlac€ment AJl-10
Iniectors, malfunctions/checking . . ...... ......... AK1_2 151
removal........,.,............. AK}6 151
'152
installation .................... AK7-9
overhaul{incl.testing} AL1-10 153
Coldstartclevice,.,........ Atvtl-2 155
Preheatingsystem (glow plugsl. wiring diagram 1979_80 .. ' AN1 156
1981-........,.,.AO1 158

125
Group23 Fuel system
Exhaustgas density

AA. Exhaustgas density

General
E x h a u s tg a s s m o k e d e n s i t yg i v e sa g o o d i n d i c a t i o no f
t h e c o n d i t i o no f a n e n g i n e a n d w h e t h e r t h e i n j e c t i o n
p u m p i s c o r r e c t l ya d j u s t e d .
Swedish regulationsstipulate that smoke density
m u s t n o t e x c e e d3 . 5 B o s c hu n i t s f o r p a s s e n g e cr a r s a t
t i m e o f r e g i s t r a t i o na n d 4 . 5 B o s c hu n i t s a t t h e a n n u aI

Since exhaust gas smoke emissions from Volvo

d i e s e l sa r e g e n e r a ly l o w e r t h a n o t h e r v e h i c l e si r m a y
b e t h o u g h tp o s s i be t o i n c r e a s ee n gi n e p e r f o r m a n c eb y
e n r i c h i n st h e f u e l a i f m i x t u r e .
P r o l o n g e de r c e s s i v e e n n c h m e n l w i l l n o t i n L r e a s e
power output but will in fact reduce seryicelife of
e n g i n e c o n s i d e r a b l y .E v e n m o d e r a t e e n r i c h m e n t o f
f u e l - a i rm i x t u r ew i l l s h a r p l y i n c r e a s ee x h a u s tg a s t e m -
r)da
p e r a t u r e sa n d c o m b u s t i o np r e s s u r e sw, i t h o u t a n y c o F
r e s p o n d i n sp o w e r s a i n .

{),1

AA2
Checkingsmoke density
Varioustypesof equipmentareavailableto measure
smokedensity.Referto manufacturers'instructions
for maintenanceandcalibration
of equipment.

126
 Group 23 Fuel system
Exhaustgas density

AA3
Connectextensionpieceto exhaust pipe
Thisreduces
theriskof ambient
airaffecting
instru-
mentprobe.
Pipedimensions:length= 200mm (8in)
i n t e r n a l d r a m e L -e r5 0 m n l 2 i n ) .S e c u r ee i t e n t i o np i e c e
w i t h r u b b e rh o s e a n d c l a m p s .

Install sample pump

Insertprobeinto exhaustpipe,Probemust be in center
and insertedto 6 depth of not lessthan 200 mm {8in},
otherwisereadingswill be incorect,
Hangflexiblehosefrom clampas illustrated.
Connect hosefrom rubberbladderto samplepump.

AA5
Check sample pump operation
Engineoff.
Pushin pumpplungerfully.Squeezerubberbladder
andcheckmov€mentof pump plunger.
NotelDonotcoverholein bladderas plungerwillnot

Pushin plungerfully afterchecking.

AA6
Insert filter paper in pump
Unscrewcoverand checkthat contactsurfacesare

P l 6 c ef i l t e r p a p e r i n o p e n i n g a n d t i g h t e n c o v e r h a n d
taght.
Position rubb€r seal over cover (to prevent dirt and
moisture from affecting test).

'127
Group23 Fuelsystem
Exhaust gas density

Route hose with rubber bladderto d.ive6 seat

Securehosewith tape.
2421244:
Inserthosethroughrearsidewindow.
245:Insertthroughtailgate.

s0 knr/h(30
50

AA8
,)re
Measuresmoke density
Warm-upengineto normaloperatrng temperature,
Drivein secondgear at 50 km/h{30mph).Slowlypush
acceLeratorpedalto floorwhileapplyingfootbraketo rit I
maintainconstant50 km/h.
Note! Automatictransmission: Do not depressac'
celeratorpedalto su€han extentthat kick-downis
engaged.
Maintainconstantspeed for a few secondsand
s0 km/h(30mph) squeeze rubberb adderto operalepump.
Note! Squeezerubberbladderhard fof severalse-
condsto ensurethatsamplepumphasbeenfilled.Do
not coverholein rubberbladder.

AA9 l),,I
Repeatmeasurements
Removefilterpaperfrompump.
pumpplungerfuly and placea newfilter
Depress
p a p e r i n p u m p . A e p o s i t i o nr u b b e r c o v e r .
R e p e a tm e a s u r e m e n t sa c c o r d i n gt o A A 8 .
rl, I

AAlO
Evaluateresult
C a i b r a t e e q u i p m e n ta c c o r d i n gt o m a n u f a c t u r e r si n -

S m o k ed e n s i t yf o r p a s s e n g e cr a r si n S w e d e nm u s t n o t
e x c e e d3 . 5 B o s c hu n i t s a t t i m e o f r e g i s t r a t i o na n d 4 . 5
B o s c hu n i t s a t a n n u a l i n s p e c l i o n .

124
 Group 23 Fuel system

AB. ldle * fast idle

Specialtool: 9950

Connecttachomeler
UseVolvoMonotester
andadapter9950.
lf Volvo Monotester js not available use photoelectric
rev counter (999 9795,9).

Warm-up engine

Checldadjust idle
12.5r/s (750r/min).
Sealadjustmentscrew and lock nut with paint after

Checldadiust fast idle

87 r/s {5200r/min).
Seal adjustmentscrew and lock nut with paint after

Do not raceenginelongerthannecessary,

Disconnecttachomeler.

AB6
Checldadiustengine controls
AlwayschecUadjustenginecontrols
afteradiustjng
idle speed.
S e e i n s t r u c t i o n so n p a g e 1 7 6 ,o p e r a t i o n sA X l - A X g .
Group 23 Fuel system

AG. Fuelfilter

'),{
e
ACl i
Drain water from fuel tilter
{)l1I
- placea drippanunderneath drainscrew(2)
- slackenbleedscrew(1)a coupleofturns
- slackendrain screw(2) and retightenwhen clean
fuelflowsthrough.
- retightenbleedscrew

AC2
Replacement
Special tool: 2903
- Us€strap wrench 2903to removefilter. Placestrap
as nearas possrble ro bdseof lilter,seelig.
- smeardieseloil on newlilterseal
- tightenIilterby handuntilsealcontacts
t)rI
body.Then
tightena further1/4turn
- sta eflgineandcheckfor leaks.lfsealis nottightair
will be drawnintofuelsystemandcausepoorrun-
ning. i,l

130
 Group23 Fuelsystem
Iniection pump, genercl

AD. Iniectionpump,general

AD1
Adiustments which can be carried out on an
installed iniection pump are limited to tho
tollowing:
- adjustingidleandfastidle
- adjustinginiectiontiming
Formoredetailedrepairsandadjustmentsthe pump
mustberemovedandlestedby speciallytr6in6dpsr-
sonnel,ona sDecialtest b6nch.

Smokedensityregulationsfor Sweden
-..rt-T Fuelregulatingscrewis sealedatfactory.
on a
No!61Fuelsupplymay only be checked/adjusted
O) r) t6st benchbvtrained Dersonnel,
,vi

131
Group23 tuel system
High altitude adjustment (Legal rcquirement)

High altitudeadjustment(Legalrequirement)

AD2
EnvironmentalProtectionAgency(EPAIdefines:
- high altitudeas an €levationexceeding1219metres
(4000f0
- low altitude as an elevationlower than or equ6l to
1219metres{4000ftl.

a Ondeliveryfrom factoryall
vehiclesareadiustedfor
low altitudes,
a Nswvehicles soldforprincipaluseat highaltitudes
must be adjusted befor€ bsing deliveredto the
custom€r.After adiustmenta decalmustbe affixed
to the firewall (besidethe emissionsinformation
decal)andalsoto the injectionpump.
a lf v€hicle owner moves from low to high altitude
are6,the vehicleshouldbs readjusted forhigh alti-
tudedriving.
a Vehiclesadjustedfor high altitudesmust bs read_
iustedfor low altitudssifvehicle is to be principallv
usedat low altjtudes.Th€ hjgh altitudedecalsmust
also be removsdat the sametime,

Thefollowingadiustmentmust be madeto vehiclefor

useat highaltitudos:
Inisction timing: advancsd0.07 mm (0.0028in) for
every100m (3300ftlincrease in altitudes.
Injectedquantitydecreasesby 2.3 mm3tor each1000
metreincreasein altitude.This is equivalenttoturning
adiustmentscrew35' counterclockwise.

Injecrionriming Iniectedqutntity
Example:lf altitudeis 2000metresabovesealevelthe Example: lfaltitudeis 2000metresabovesealevelthe
lollowing calculationscan be made: followingcalculations canbe madei
0.85mm is normal setting {for 1982-models} ?999^er.
-- = rn.
1000
o.ss+ffi*o.oz)=o.ssr. Turn adjustmenlscrew70"
H i g h a l t i t u d es e t t i n g i s 0 . 9 9m m

132
 Group 23 Fuel system
lnjection pump,^efting

AD. Iniectionpump, setting

special tool: 5194

Removorear timing goa. covel

Disconnect cold start devicc

Slackenscrew1. Pushleverfo fward and rotatesleeve
90'.
Nole! Do nottlrn screw2 otherwis€itwillbe nec€ss'
ary to removecold start deviceand rsset it on a test
bench.
Pushlev€r backagainststop.

Tuln ongin€ until cyl. I is at TDc-iniection

Always use the vibration damper centre bolt to turn
the engine.
Use a 27 mm socket,
))
IVsrkin pumpgearshouldbe oppositemarkIn moun-
ting bracket.Flywheelat"O" mark.

Pl.co dial Indicator in iniection pump

Unscrew and rerhove plug from iniection pump
distributor.
Installholder 5194 and dial indicator(measuring
range0-3 mm).S€tgaugetoapprox.2mm.
Gtoup 23 Fuel system
Injectionpump,setting

AD7
Set indicator to zero
Turnpumpgearbackslightly regis-
untilmin.reading
tersondialindicator.
Setindicator
to zero.
AD8
Checkpump setting
Turnenqineslowlyclockwiseuntilflywheelis at'O'

Note!lf engineisturnedtoo far it mustbeturnedback

approx.1/4rurn andthento'o'mark othelwisesetting
a),l
Dialindicatorshouldshow:
O 20 .......................
0.75-0.83mm (0.0295-0.0327 in)
ri:frt\
i i:
i'
D24..........................
0,55-0.73
D24USAandCanada1979-1981
mm (0.2560,0287in)
........
0.65-0.73mm
(0.0256-00287in)
0l
l"ri 1 1982-................
0.82-0.90mm
!((c)l,
/1,;. <:i:/h (Vehicles
{0.03230.0354in)

adjustedfor high altitudedrivingjreferto

page14)

AD9
pump setting:
Readiusting
Settingvalues:
D20 ..............................................
0.80mm {0.0315 in)
D24..............................................
0.70mm {0.0276 in)
D24USAandCanada1979-1981 ................. 0.70mm
(0.0295 in)
,:f-;*il 1 9 8 2. . . . . . . . . . . . . . . . . 0. ...8. .5m
(0.0335
. . .m.
in) t), I
Reading less than specilied:
Slackenpumpmountingboltsandturnpumpinwards
to obtaincorrectvalue.Tightenmountingboltsand
repeatcheckof pumpsetting. ,)tI
Reading morethanspecified:
Slackenpump mounting bolts and turn pump
outwardsuntildialindicatorshowsapprox:
D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. ...7. 0
. .m..m. .( .0. . 0 . .2. .7 6 i n )
D 2 4 . . . . . . . . . . - . . . . . . . . . . . . . . . . . .0. . .6. 0. .m . (. .0. .. 0. .2. .3 7 i n )
. .m
D24USAandCanada '1979-198? ................. 0.60mm
{0 0256in)
1 9 8 2 ' . . . . . . . . . . . . . . . .0. . .7. 5.m . .m
...
(0.0295 in)
Thenturn pump inwardsunti specifiedvalueis ob
tained. Tightenmountingboltsandrecheck pumpset'
t |n g ,
Note!Injecrion pumpmustnot be tappedor knocked
asthiswill aherits setting.

134
 Group23 Fuelsystem
lnjection pump, sefting

ADlO
Checkpump setting
Turn6nginetwoturns6ndchecksetting.
Adjustif necessary
accordingto operationDBand

ADl1
Romovedial indicator and holder

AD12
Install plug wath new $oal
Tightening rorqueI Nm (6.5ft lbs).

ADI3
Install rear timing gear covel

AD14
Reconnect cold stsrt dovicg
Presslever forwards and turn sleeve 90'. Retighten

Notol Do notturn screw2. otherwiseit will be necess-

ary to removecold start d€viceand reset it on a tgst
bench.
Group23 Fuelsystem
lnjectionpump belt, replacement

AE. lnjectionpump belt, replacement

Specialtools: 5193,5194,5197,5199,5201

AEl
Removereartiming gearcover

AE2
Turnengineuntil cyl.1 is al TDC-injection
0,1
Alwaysuse vibrationdampercentreboLtto turn
engine. Use27mmso€ket.
in pumpgearshould
l\,lark markin mount-
beopposite
in9bracket.Flywheel
at "o".

Lift off pump belt

S i a c k e nr r l o u n t i n gb 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 ti o
r e l e a s eb e l t t e n s i o n .T i g h t e n o n e b o l t s o t h a t p u m p
r e m a i n si n ! p p e r p o s i t i o n . {)l}(|
Lift off belt.

0,)|

AE4
Removecamshaftrearsprocket
Hod 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 .
Take care nol to rolate camshaft.
l 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 d b e p o s s i b l et o
t u r n s p r o c k e to n c a m s h a f rw i t h o u t c a m s h a f tr o t a t i n g .

136

I
 Group23 Fuelsystem
Injectionpump belt, replacement

AE5
Disconnect
cold start device
S l a c k e ns c r e w1 . P u s h l 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'.
N o t e ! D o n o t t u f n s c r e w2 , o t h e r w i s ei t w i l l b e n c u e s s ,
a r y t o r e m o v ec o l d s t a r t d e v i c ea n d r e s e t i t o n a r e s r

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

AE6
Basic-set
iniectionpump
\j -,74, - pumpmounting
Slacken bolts(Alenkey= 6 mm ).

ior Alignmarkson pumpandmounting bracket

byturn,
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 .
1E.

AE7
Set dial indicator zero.
Lock pump gear at cyl. 1 iniection using stop
5193
Unscrewand remove plus from injectionpump

I n s l a I h o l d F 5 1 9 4a n o d a l i n d c d r o r{ m F a s u r i r s
range0 3 mm).Set ga!geto approx.2 mm.
Turn pump ge.r c ockwiseunti mark on gear and
mountingbracketcoincide.

:i r€g ::3 Thenturn pump gearbackslightlyuntil min feading

registers
on d ial indicator.
Set indicaror
to zero.
Turn pump gear clockwiseuntil mark on gear and
pump mountingbracketcoincide.Lockgear in this
positionwilh stop 5193.(lnsertstop throughpump
gearinlo mountingbrackel.)

137
Group23 Fuel system
lniectionpump belt, replacement

AE8
lnstall belt
Adiusttensionby movingcoolantpump.
Usegauge5197to checktension.Attachgaugeto belt
andsetto 12.5units.Stretchbeltuntilmarkon gauge
plungeris flush with sleeve.Depressbelt strongly
with handand recheck/adiusttension.

AE9
t .- rl|'- Sel pump and tighten camshaft r6ar sprockei
t t | : : r y,.7,v Use5199toholdsprocket.Torquewrench shouldbeat
"' 7 ur ,
" ",, raghtanglesto wrench5201otherwisetorquewill b€

Using5199,turn sprock€tslowlyclockwiseuntil dial

tit
0.80mm(0.0315in)
D20 ..............................................
0.70mm(0.0276
D24...-.......................................... in)
D24USAandCanada1979 1981................. 0.70mm
1 O qN m (0.0276in)
1982-..........................
0.8smm
(0.0335in)
(Vehicesadjustedfor high altitudedrivinsireferto
page132.)
Hoidsprocketin this positionandtorqu€boltto 100
Nm (73ftlbs).Takecarethatcamshaft andsprocket do

AEl O
Removestop 5193from pump gear

AE11
Checkpump setting
Turnengine twofullturnsuntilcyl.1 is at TDC-injec-
tionagain.lf engine
isturnedtoofarit mustbeturned
backapprox.l/4turn andthento zeromarkotherwise
settingwill be incorrect.
Dialindicatorshouldshow:
D20.....................-.................................
0.75-0.83 mm
(0.0295-0.0327 in)
D24............--..--..--..-.......................
0.65-0.73 mm
(0.02560.0287in)
D 24 USAandCanada'1979-1981 .......0.55-0.73mm
(0.0256-0.0287 in)
1982-................
0.82-0.90mm
(0.0323-0.0354 in)
CorrectreadingrTighteninjectionpump mounting
bolts.Proceed to E12.
Incorrectreading:Readjust ac€ording to instructions

138
 Gtoup23 Fuelsystem
lnjectionpump belt

Readiustingpump setting:
D20 ..............................................
0.80mm {0.0315in)
0.70mm (0.0276
D24....................-......................... in)
D24USAandCanada1979-1981 0.70mm (0.0276in)
1982 .......0.85mm (0.0335 in)

Readingless than specilied:

Slackenpumpmountingboltsandturn pumpinwards
to obtaincorrectvalue.Tightenmountingboltsand
repeatcheckof pumpsetting.

Readingmore than specilied:

i, Slackenpump mounting bohs and turn pump
outwardsuntildialindicatorshowsapprox:
0.70mm (0.0276
D20-............................................. in)
0.60mm (0.0237
D24.............................................. in)
ID D24USAandCanada '1979-1981 .................

1S82-.......0-75
0.60mm
(0.0237
mm (0.0295
in)
in)
Thenturn pump inwardsuntil specifiedvalueis ob-
tained.Tightenmountingboltsandrecheck pumpser-
trn9,

lmportanll Iniection p!hp must not be tapped or

k n o c k e da s t h i s w i l l a l t e r i i s s e t t i n g ,

AE12
Removedial indicalorand holder5194.lnstall
plug with new seal.
Tishteningtorque9 Nm{6.5ft lbs).

AE13
Pressleverforwardand turn sleeve90'. Retighten

NotelDo notturnscrew2, othelwiseit will be reoess-

ary to removecold startdeviceand resetit on a resr

AE14
Installreartiming gearcover

139
Group 23 Fuel system
lnjection pump, removal

AF. Injectionpump,removal
Specialtools: 2 x 2901,5193,5199,5201,5204

Disconnect:
h o s e sf o r c o l d s t a d d e v i c e .C l a m p h o s e sw i t h p l i e r s
2 9 0 1p r i o r t o r e m o v a
- t h r o t t l ec a b L ea n d k i c kd o w n c a b l e( a u t o ) f r o mp u m p
- wire from fuelvalve.

AF2
Removerear timing gear covel
0,il]
|

0il4

AF3
Disconnect
fuel deliveryand return linesfrcm
pump
C e a n c o n n e c t i o n st h o r o u g h l y b e f o r e d i s c o n n e c t i n g
t h e m . P l u g e n d s o f f u e l l i n e st o p r e v e n td i r t e n t e r i n g

140
 Group 23 Fuel system
lnjectionpump, rcmoval

Removevacuum pump and pump plunger

ffemovepumpretajning
nutsand placepumpon

plunger
Remove fromcylinder
head.

AF5
Remove luel delivery pipes
Cleanall connections
thoroughlybeforedisconnect-
Ingprpes.
Removeall delivery pipes and p[]g ends to prevent
dirtfrom enteringfuelsystem.

AF6

(Wti Turn engine until cyl. 1 is at TDc-iniection

Alwaysuse vibrationdampercenterbolt to turn
engine. Use27 mm socket.
) in pumpgearshould
lvlark beopposite markin mount'
ins bracket.
Flywheelat "O".

Lift oft pump belt

Slacken mountingboltsfor injectionpumpbracker
to
releasebeltlension.Tightenone bolt so that pump
remainsin upperposition.
Lift off belt.

141
Group 23 Fuel system
lnjection pump, rcmoval

AF8
Remove camshaft rear sprocket
Hold sprocketin positionwith 5199and unsctew
sprocketwith wrench 5201.
Takecarenot to rotatecamshaft.
Installcenterbolt,handtight.lt shouldbe possible
to
turnsprocket on camshaflwithoutcamshaft rotatang.

AF9
Slackenpump gear
Use5193to holdgearandslacken
5201.Removenut andwasher.

AFlO
Pulloff gear
Usepuller5204andstop5193. uri})

O,ill

AF11
-lepftp'= Removepump
j,,r Z-{ - Removefrontmountingbracketfrom engine

r //nl Removepumpfrom rearmountingbracket{Allenkey

I riqr = 6 mm).

\-
 Group 23 Fuel system
Inject ion pump, instaIIati on

AG. Injectionpump, installation

Specialtools: 5193,5194,5197,5199,5201

AG1
Position injection pump
Mountpump on engineand secureit wilh retaining
boltsandfront mountingbracket.
Donottightenbolts
fully at this stage.
Align markin pumpwith markin mountingbracket.
Thentightenretainingbolts for pump - mounting

AG2
Install pump geat
Do not forgetto placekeyin pump axle,Installgear.

Torquenut to 45 Nm {33ft lbs).

ljse 5193to hold sprocketand 5201to tighten nut.
Torquewrenchshouldbe at right anglesto wrench
5201,otherwisetorque will be incorre€t.

AG3
Disconnectcold start device
Slacken
screw1.Pushleverforwardandrotatesleeve
90'.
Notol Do notturn screw2, otherwiseit will be necess-
ary to removecold start deviceand reset it on a test

Presslever backagainststop.

143
Group23 Fuelsystem
Iniection pump, installing

AG4
Set dial indicalor zero. Lock pump gear at cyl. 1
injection using stop 5193
Unscrewand remove plug from injectionpump

I n s r c l h o d e r 5 1 9 4a r d d i d : r d i c d l o rl n e a s . r - i n s
range0-3 mm).Set gaugeto approx.2 mm.
Turn pump gear c ockwiseuntil mark on gear and
mountingbracketcoincide.

l)il |
Thenrurn pump gearbackslightlyuntil min reading
Set indicatorto zero
on dialindicatof.
registers
Turn pump gear clockwiseuntil mark on gear and lrii I
pump mountlngbracketcolncide.Lockgear in this
positionwith stop 5193.(lnsedstop throughpump
gearinto mountingbrackel.)

AG5
Installpump belt
A d j u s l 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 k t e n s i o n - A n a c hg a u g et o b e h
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 f i s f l u s h w i t h s e e v e . D e p r e s sb e l l s t r o n g l y
w i t h h a n d a n d r e c h e c k / a d j u stte n s i o n .

AG6 ,),il|
Set pump and tighten camshaft rear sprocket
U s e5 1 9 9t o h o d s p r o c k e t T . o r q u ew r e n c h s h o u l d b e a t
r i g h t a n g L e st o w . e n c h 5 2 0 1o t h e r w i s et o r q u e w i I b e

Using5199,turn sprocketslowlyclockwiseuntild ial 'f,fI

D 2 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.80 . . . . (0.031s
. . . . .mm . . . . . . . in)
D 2 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.70
. . . . .mm
. . . . 10.0276
. . . . . . . in)
D24USAandCanada1979 1981. . . . . . . . . . . .0. . 7 . .0.m m
( 0 . 0 2 7i 6 n)
1982 0.85mm
( 0 , 0 3 3 5i n )
( V e h i c e s a d j u s t e dl o r h i g h a t i t L r d ed r i v i n g : . e f e r l o
p a g e 1 3 2)
H o l d s p r o c k e ti n t h i s p o s i t i o na r d t o r q u e b o l t t o 1 0 0
N m ( 7 3 f l l b s ) .T a k ec a r et h a t c a m s h a f ta n d s p r o c k e td o

AG7
Removestop 5193from pump gear
 Gtoup23 Fuel system
lnjection pump, installing

AG8
Check pump setting
Turnenginetwo full turnsuntilcyl. 1 is at TDC-injec-
tion,again.lf engineis turnedtoofar it mustbeturned
backapprox.1/4turn andthento'O'mark othelwise
settingwill be incorrect.
Dialindicatorshouldshow:
0.75-0.83mm (0.0295-0-0327
D20........................ jn)
0.65-0.73mm(0.256-0.0287in)
D24..........................
D24USAandCanada1979 1S81........0.65-0.73mm
(0.0256-0.0287 in)
1982-........-.......
0.82-0.90mm
(0.0323-0.0354 in)
Correctreading:Tighteninjectionpump mounting
bolts.Proceedto AGg.
Incorrecr reading:Readjust according to instructions

il pumpsetting:
Readlusting
Settingvalues:
D20 .............................................. 0.80mm (0.0315 inl
. . .m. .(.0. ., .0. 2. .7i 6
D 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. ...7. .0m n)
D24USAandCanada1979-1981 ................. 0.70mm
{0.0276 in)
1 9 8 2. . . . . . . . . . . . . . . . . 0 . ...8. .5m . . .m.
10.033s in)

Readingless than specilied:

Slackenpumpmountingboltsandturnpumpinwa
to obtaincorrecivalue.Tiqhtenmountingboltsand
repeatcheckof pumpsetting.

Readingmore than specifiedi

Slackenpump mounting bolts and turn pump
outwardsuntildialindicatorshowsapproxl
D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. ...7. 0
. .m . .(.0. . 0
..m . .2. .7 6 i n )
D24.............................................. 0.60mm (0.0237 in)
O24USAandCanada1979 1981................. 0.60mm
(0.0237 in)
1 9 8 2 - . . . . . . . . . . . . . . . .0. . 7 . .5.m. .m
...
(0.0295 in)
Thenturn pump inwardsuntil specifiedvalueis ob,
lained.Tighlenmountingboltsandrecheck pumpset,
tin9.

l m p o r t . n t ! I n j e c t i o np u m p m u s r n o t b e r a p p e do t
knocked a st h i s w i l l a h e ri t s s e t t i n g .

145
Gtoup23 Fuelsystem
lniectionpump, installation

AG9
Removedial indicatorand holder5194.Install
plug with new seal
T i q h t e n i n gt o r q u e I N m ( 6 . 5f t l b s ) .

A G lO
Connectcold start device
Presslevefforwardand turn sleeve90'. Retighten

NotelDonotturnscrew2, otherwiseit will be necess-

ary to removecold start deviceand reset it on a test

AG11
Fill iniectionpumpwith dieselfuel
Onlynecessary
pumpinstalled.
if pumphas beendrainedor new
fuelbeforeuse.
Filter nN
rilil|
AG12
Installreartiming gearcover
C l a m p w i r i n g h a r n e s sl o l e i t s i d e r e t a i n i n g b o h o n

AG13
Reconnect
fuel deliveryand returnlines
Do not interchangeconnections. Returnlineconnec
tionsaresmallerandmarkedOUT,
Tighrening torque25 Nm (18ft. lbs).

146
 Group23 Fuelsystem
lnjectionpump, i nstallation

AG14
tuel deliverypipes
Reconnect
T i g h t e n i n gt o r q u e 2 5 N m ( 1 8f t l b s ) .

(D
AG 15
Installplungerand vacuumpump
CheckO rins,replace
if necessary.

A G1 6
Connect:
- h o s e st o c o l d s t a r t d e v i c e .R e m o v ec l a m p i n g p l i e r s
- wire to fuel va ve
- t h r o t t e c a b l ea n d k i c k d o w n c a b l e ( a u t o )

AG17
Set throttle control
S e e i n s t r u c t i o no n p a g e 1 7 6 ,o p e r a t i o n sA X 1 A X g .
Group 23 Fuel system
Fuel delivery pipes

AH. Fuel deliverypipes,replacement

I
Cleanall conneciionsthoroughlY ,i.
,l'
AH2
Remove
- vacuumpumpandpump plunger

Blankoff portsandpipesto prevententryof dirt.

,il
AH3
lnstallation
- connectdeliverypipes.
Tighteningtorque25 Nm {'18ft. lbs.)
- pump prungerano vacuumpump. C h e c U r e p l a c e
O-ring.
- checkfunction and security.A few
quired before pipes are bled and

148
 Group23 Fuelsystem
Deliverypipes

of one or more pipes

AJ. Deliverypipes,replacement
(Donot attemptto weldor repairdamagedfueldeliverypipes.Damagedpipesmustbe replaced.)

()

0
Cleanall connectionscaretully.Blow-drypipes
././

I
AJ2
Removevacuumpump and pump plunger

I' Removepump retainingbolts. Placepump on

w h e e l a r c ha n d w i t h d r a w p l u n g e rf r o m c y l i n d e rh e a d .

AJ3
Mark positionof clampson pipes

L o c a t i o n o t c l a m p s i s i m p o a n t . I n c o r r e c t l yl o -
c a t e dc l a m p s c a n c a u s ev i b r a t i o n sa n d f u e l s u p p l y
p r o b l e m sm a y r e s u l t .

all pipes
Disconnect

149

I
Group23 Fuel system
Fueldelivery pipes

AJ5
Removeclampssecuringpipe(s)to be replaced

AJ6
Replacepipe
D o n o t t i g h t e n c o n n e c t i o n sa t t h i s s t a g e .
C h e c kp o s i t i o no f r u b b e r s l e e v eo n p i p e .

Installclamps

0l)ile
AJ8
Tightenpipe connections
T i g h t e n i n gt o r q u e 2 5 N m ( 1 8f t . 1 b s . ) {)il |

AJ9
Installpump plungerand vacuumpump
Check/replace
O rings.

AJ1O
Check operation and leakage
A few secondsis requiredbeforepipesare b ed fully
andenginerunssmoothly.

150
 Group.23Fuelsystem
Wectarc

AK. lnjectors

AKl
Malfundions
Listedbelowar6 malfunctions which can occur if one
or more ofthe injectorsis defective.
- one or more ol cylindsrsknock.
Notsl Do notconfusethiswithbearingclafter Chsck
injoctorope16tion
- overheating

- unevonidle
- blackexhaustsmoke
- gXCeSSiVe
fuel COnSumption.

AK2
Checking iniection oper.tion
1. Bun engineat aboveidle speed
2. Loos6ncap nuts on injoctorsong at a time. wl6p
sbsorping paper around iniectors to prevenr
spillage.
lfengins speedrcmainsconstantor if knockingdisap-
pears,fault may be:
- delectiveinjector
- detBctiveheatshield
- leakingdoliverypip€.

Removinginiectors

S.s spg.ilicatlonstor ld€nritic.rton ot injectortyp6.

i usa/c€nad'
333133;315 1e82-
0681302ol | - .
068130201K I ulnermsrkets
DN0 SD1930 = Usrcanad€ 1982-
DN= SDt93 = Othermark€ts

Inisctol
{complete} 't51
Group 23 Fuel system

AK3
Removevacuumpump and pump plungel
pumpretaining
Remove nutsand placepumpon

plunger
Withdraw fromcylinder
head.

AK4
Cleandelivery pipe connections
Cleanallconnectionsthoroughly
beforedisconnect-
ingprpes.

AK5
Disconnectdelivery pipes
Blankoffpo(sandpipesto prevent
entryof orn.

AK6
Removeinlectors
27mmsocket.
R e m o v eh e a t s h i e i d sf r o m c y l i n d e rh e a d .

Installinginiectors
{t,,a
AK7
Position iniectors
Removesootetc.from sealingsurfaces.
Placenew heatshieldsin cylinderhead,seefig. ToF
que iniectors
to 70 Nm (50ft. lbs.).

AK8
Reconnectdelivery pipes
T i g h l e n i n gt o r q u e 2 5 N m ( 1 8f t . l b s ) .
AK9
Installpump plungerand vacuumpump
Check/replacO
e {ing.

152
Y
Group23 Fuelsystem

AL. Reconditioning
injectors
U t m o s t c e a n l i n e s sm u s t b e o b s e r v e dw h e n w o r k i n o w i t h i n i e c t o r s .
AL1
Disassembly
cleanoutersudaceof injector
U p p e rn o z 2 l e disassemble injector. Caremustbe takento ensure
that pa(s do not fall onto benchor floor.lf nozzle
needleis droppedit mustnot be reused
W a s h e ra, d t u s t s immersepartsin cleandieselfuel as soon as rhey

pa s
do not interchange

iD AL2
Cleaning, checking
c e a n a l l p a s w i t h c l e a n d i e s e lf u e l
u s e n o z z l ec l e a n e re q u i p m e n tt o c l e a nn o z z l en e e d l e

D - r e p l a c ed a m a g e d p a r t s . N o z z l e n e e d l e a n d s l e e v e
a r e m a t c h e da n d m u s t b e r e p l a c e dt o g e t h e r .

AL3
Assembly
- washoff rustproofing
compundtrom newpartswiih
clean petrol/gasoline
- immersepartsin cleandieselfuel
- assemble Torqueto 70 Nm (50ft. lbs.l.
injector.

It W A R N I N G IE x t r e m ec a r em u s t b e t a k e nw h e n t e s t ,
i n g : r i e c l o r s .S p r a y r e l e d s e ol r o m i n j e c t o ri s a t
s u c h a h i g h p r e s s u r et h a t i l c a n p a s st h r o u g h s k i n
a n d c a u s eb l o o d p o i s o n i n qi f i n a d v e l t e d l yp o i n t e d
r'f
Testing
a I n j e c t o r ss h o u l d b e t e s t e d w i r h c e a n t e s t o i l o r
f i t e r e d d i e s e l f u e 1 .U n d e r n o c i r c u m s l a n c e sm a y
p e t r o l / g a s o l i n eb e u s e d b e c a u s eo f t h e r i s k o f e x -

OThe use of suitable evacuation equipment to

remove diesel fumes is law in certain counnies
( i n c l .S w e d e n ) .
a lTpo'tdrt lactorsin tesling irjeclors are opening
p r e s s u r ea n d w h e t h e r i n j e c t o r i s l e a k p r o o f .S p r a y
p a t t e r na n d n o i s ea r e m o r e d i f f i c u l t t oa s s e s sa n d d o
n o t g i v e a n e x a c t i n d i c a t i o n o fc o n d i t i o no f i n j e c t o r .
I n j e c t o r m a y f u n c t i o n s a t i s f a c t o r i l ye v e n t h o u g h
s p r a y p a t t e r na n d n o i s e a r e f o u n d t o b e d o u b t f u l .

Installiniectorin test equipment

B a n k o f f f u e l r e l u r n p i p e sw i t h r u b b e rp u g s a n d h o s e
Group23 Fuelsystem

AL5
Checkspraypattern
gaugedisengaged).
{Pressure
(4 6persecond).
Pumpleverwithshort,quickstrokes
jetshoud befairlycompact
Spray andstopabruptly.
l n j e c t o rm u s t n o t d r i p .

i)rlI

Checkinlectionsound
AL6
|l I
(Pressure
sausedisensased).
leverful y (1 2 strokes
Slowlydepress persecond).
I n j e c t o rs h o u l d b u z , w h e n f u e l i s e m i t t e d .

AL7
Checkopeningpressure
(Pressure
gaugeengaged.
)
S l o w l y d e p r e s sl e v e ra n d c h e c ko p e n i n g p r e s s u r e .
O p e n i n gp r e s s u r ec h e c kv a l u e : 1 2 - 1 3M P a ( 1 7 0 0 - 1 8 5 0 Ia
l f i n c o r r e c t ,l e a kl e s t b € f o r ea d j u s l i n gp r e s s u r e .

j,: I

ALA
Leak test

lncrease pressure ro 11MPa{1560psi).Maintarnthrs

pressure for 10seconds.Fuelmustnot dropfrom in
eLlors.A rro sl rol/ e rs howeveracLcplao
e.

154
 Group23 Fuelsystem
Cold start device

L9
Adlusting opening pressure
Settinsvalue: 12.s-13.5
MPa(1780-1920psi).
Removeinjectorfrom test equipment.Disassemble
injectorand adjustopeninspressureby repiacing

- to increase
opening pressure = fit a rhickerwasher.
- to decreaseopeningpressure = fit a thinnerwasher.
0.05mm changein thicknessis equivalentto ap-
prox.5 kPa(7 psi).
- shimsareavailable infollowingsizes:'1.00-1.95
mm
at 0.05mm increments.
Reassemble injecror.Torqueto 70 Nm (50 ft. lbs.).

D
ALlO
ID Removeinjectorlrom test equipment
C o v e re n d w i t h p r o t e c t i v ec a p .
T a k ec a r en o t t o d a m a g e n o z ze w h e n i n s t a ti , , s , f l e c ,

AM. Cold start device

AM1
General
C o l d s t a d e v i c e m a y o n t y b e a d j u s t e do n a s p e c i a l
t e s t b e n c h ,w h e n c o n n e c l e dt o i n j e c t i o np u m p .
H o w e v e ra s e r v i c e c h e € k c a n b e c a r r i e d o u t o n a n
i n s t a le d i n j e c t i o np u m p .
N o t e l l f c o l d s t a r t d e v i c ed o e s n o t f u n c t i o nt h e f o t o w
i n gw i l l o c c u r
c o l d s t ar t i n g d i f f i c u l t i e s
b l u e w h i i e e x h a u s ts m o k e
- e n g i n e w i l l n o t s t . r r a r r e m p e r a t u r e sb e t o w 1 0 " C
(-14"F).

AM2
Operationcheck
M e a s u r ei d l e s p e e dw h e n e n g i n e i s c o t d a n d h o t .
C o l d e n g i n e ( b e l o w 2 0 " C = 6 8 " F )= a p p r o x . 3 . 3 r / s
( 2 0 0r / m i n ) m o r e t h a n w . r m e n s i n e i d t e .
W i t h w a r m e n g i n e ,l e v e ro n c o d s l a r t d e v i c es n o u t d
n o t c o n t a c tl e v e ro n i n j e c t i o np u m p .
l d e s p e e d ( w a r m e n g i n e )= 1 2 . 5r / s { 7 5 0 r / m i n ) .

155
Group23 Fuelsystem
Preheating system 1979- 1980

AN. Preheatingsystem
1979-1980

&
\5

{)i)a

c (1 |

{lll I

rl

A T e m p e r a t u rgea u g es e n d e r
F u e l v a l v e ( s o l e n o i dv a l v e ) B F u e vl a l v e( s o l e n o i dvalve)
n d i c a t o rl a m p s f o r l n s l r u m e n t s C l n d i c a l o rl a m p s( i n s i r ! m e n t s )

E G l o wp l u g

K C o n n e c t i o pn a n e la n d s e r v i c eo u t p u t
-Y

Group23 Fuelsystem
Preheating system 1979- 1980

B D
BL
n*l ;t>t.
++
Y
w:r> Yflo)
-\_./

"\

(D
rD

(t
0
o' BL-Y
BL

Ra
Gtoup23 Fuelsystem
Prcheatingsystem 1981

AO. Preheatingsystem
1981

With efiect trom 1981-hodels:

Blocklng felay discontinued since new

c o n t r o l ! n h i n c o r p o r a r e sa s w i t c h w h i c h
d i s e n g a g e sg l o w p u g s a f t e r e n 9 i n e n a r l ,

tr-8to
even if contro unii malfunctions.

rl)'rL
I

{r I

{ul
i,l

T u r n s l g n a l sa n d h a z a r dw a r n i n g l i g h l s A T e h p e r a r u f eg a ! g e s e n d e r
BL B F u e v a l v e ( s o l e n o i dv a l v e )
SB C I n d l c a t o rl a m p s ( i n s t r u m e n t s l

GN E G ow pllg

G C o n n e c t i o np a n e l a n d s e r v c e o u t p L t

158
 Group23 Fuelsystem
Prehealingsystem1981

W @-*"
BLY"\7V
\,-,'
, /
Group 25 lntake and exhaust syste.rs

Group25 Intakeand exhaustsystems

Contents
Operation Page
Intake/exhaust
systems. APl-z
...................... 161
Exhaustpipeandsilence Aa'l
..................... 162

D21

160
l Group25lntakeand exhaustsystems
Inta ke m an ifo Id/exh aust m an i fo Id

AP. Intakemanifold/exhaust
manifold

Sealing ring between intake manilold and in-

take hose
Introduced July 1981.
Sealingringis usedto preventoil leakage
from intake
manifold- hoseconnection.
It canalsobe fittedto vehiclesmanufacturedbefore
J u l y1 9 8 1 .
Note!Intakemanifoldmatingsudacemustbecleaned
beforeinstallinsseal.(P/N1257809 2).

Intake manitold
a Allenscrew= 6 mm
a Turngasketwith greensidefacingcylinderhead
a Tighteninstorque25 Nm (18ft. lbs.)
Arrowon intakemanifoldhosemust poinrrowards
manifoldotherwisecrankcasebreather hosemaycon,
tactbonner(hood).

Exhaustmanitold
Alwaysusenewnutswheninstattingmanifotd.
torque25Nm(18ft. lbs.)
a Tightening

161
6rouD2S lntakeand exhaustsvstem
Exhaust system
AR. Exhaustsystem
D20
a Newsealsshouldbe usedthroughoutwhen install- Followinstructions
rngnewexhaustsystems.
aSteelsealsinflexiblejoinlandexhaustbranchp
needonly be replaced it damaged.
a Exhaustpipes must be insertedapprox.40 mm
(1.6in) in silencers
a Clearance betweenexhaustpipeand bodyshould
not be iessthan 20 mm (0.8in). Rearsilenceris
marked"lN".
S t i f f e n i n sp i p e( o n l y
o n e a r l y2 4 5m o d e l s )
Installing complete exhaust system
below to ensurestressJreein-
stallationof exhaustsyst€m
1.i Slacken
pe two bolts securingmountingbracketto
gearboxtransmission,
2. Positionfront pipe and tightennuts and bottsior
frontpipe- branchpipe.
3. Tightenretaining boltsfor mountingbracket-front
4. Tighten two bolts securing mounting bracketto
gearboxtransmission.
5-Aligncompleteexhauslsystem.
6. Tightenclampsjoining pipes.
silencersto
7. Tightennutsat fiont pipe joint.
8. Ensurethatexhaustsystemcannotstrikebody,ad-
just if necessary.
 Group 26 C;.joting systetil
Contents

Group26 Goolingsystem

Contents
Oporation Pag.
Coolingsystem,tesiing, ASI 164
Coo'ant,gen€ral AT1 '164
AT2_9 165
ATM2 167
Thermostat,
rep1acement,.....,.,.,.,.,...,.,...,.,.......... 168
AU2 168
Coolanl(waterlpump,replacemsnt
................... AVl-23 169

3,
\ t
 Group 26 Cooling system
Testihg, coolant

AS. Coolingsystem testing

as1
Connecttesl bump b6twe6nffidiator and oxpansion
tank as shown adiacent.
Increasepre$ure and checkopening pressureol ex-
pansiontank cap.Also ch€cl tor leakag€.
Openinspressure:Type1:6F-85kPa{9.12psi}.Type2
'1982)r100kPa(14 psi).
{introducedsprins
Pfessure should remain constant for at least 30

AT. Coolant

ATl
Siocealuminiumis us€d in the €ngines,activecorro-
sion protectionis nec€ssaryin the coolantto helppre-
,@ ventcorrosiondamage. lJs€genuineVolvoblue-green
cool6nttypeC,dilutedwith cleanwater in proportions
of 50/50.This mixture helosto Dreventcorrosionand
rEr frost damage.Neverfillthe coolingsystemwlth water
alone.The coolantsholld be chang€dr€gularlysince
the corrosionDrotactiveadditivesin the coolantlose
their effectin timo.

NotelDo not run 6ngin6wh€nlevelofcoolanlis low

sincehigh localt€mp€raturescan resultwhich may
cau6ethe cylinderheadto crack.

oirc ft rlly^isu IYpc li plfy[D ryrsysrr*rT

siyon. r[ io.i iiliiiiii-iia iuii iiiri i[oii-viiiil'du u uL
nLto*m euuiii rroffi-liiuiiTii c iiiiiiifvsrri-E
mortcTE0
rq rrf y&n
ropuf R0ur{0
wttl] HAtrtvr
Topping.up cooling sFtem
Use same tvDe ol coolant a6 befor6. Do not mix
differenttvoes of coolants.

Replacing cool.nt
Alwrys usetyp€ C blue-greencoolant.Rememberto
replacedecal (P/N 1331473-71on exp6nsiontank if

't€4
 Gtoup 26 Cooling systefi
Coolant, replacement

Roplacing coolant
Coolingsystem need not be ftushedwhen reptacjng
type B coolant(blue)withtype C lbtue,green,,srnce
thesecoolants canbe mixed.
However,sincetype A(red)andtypeC (btue,sreen)are
not mixableit is necessarylo ftushcootingsystem
priortofillingtypeC cootant.
Describedbeloware two differentmethodsfor orarn-
jngcoolant,(1)wilhftushingand
{2)withoutflushing.
priorto fillingtypeC cootant.

(1) Drainingcoolantwithout flushing cooling

system

AT2
Disconnectbaltery ground lead

AT3
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 t i s d r a i n e d , r a i s e
v e h i c l ea t f r o n t r i g h t j a c k i n g p o i n t . C o o t a n tw i t h e n
r u n 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 .
P l a c ed r i p p a n b e n e a t hl e f t s t e e r i n gr o d .

gJ AT4
Drain coolant
{Nodraintapson engine)
Unscrew expansiontankcap.
Disconnectlower radiatorhose from radiatorand

Filling
S e eA T l F 1 2 .

165
Group 26 Cooling system
Coolant, replacement

Coolant, Eplacement
Draining.nd llushing cooling system

AT5
Dralncoolingsystem
Pl6cedrip pan beneath left sido of enginebehind
splashgu6rd.
Disconnect lower radiator hose from thermostat
nousrng,
Disconnect hoses from heater control valve {on
firewall).Pointlower hose down.

Flushing

4T6
Flush er(pansiontank clean

AT7
Flush engine clean
Connectupperheaterhose(at rearltotap andflush
engineuntil clearwater appearsat lower (heater)
hose,Contidue to flushtorafurther2 minutes.

166
 Group26 Coolingsystem
Coolant,replacement

AT8
Flush heater clean
Setheatercontrolsto MAXheat.
Connectupperpipeto tapandflushuntilclearwater
appearsfromlowerpipe.

AT9
Reconnectall hoses
W a t e r h o s e f r o m t h e r m o s t a th o u s i n gi s c o n n e c t e dt o
l o w e r p i p e o n h e a t e rc o n t r o l v a l v e .

Filling

ATlO
Bleedingof cooling system
Disconnect upperhosefrom cold startdevice.Place
drip pan beneathhoseand hold hoselevelwith top
levelof expansion
tank.

AT11
Fill coolant
Capacity:D 20 = a.1litres(8.6USqua(s)
D 24 = 9.3litres(9.8UScua s).
Set dashboardheatercontrolto MAX. Add coolant
throughexpansion tankcap.
only type c {blue-green}coolantis to be used.
Turnon engineand warm-upfor 5 minutes.(Expan-
siontankcapremoved). Add coolantduringthistime.
Connecthose to cold start device.Fill coolantto
mouthof expansion tank {abovemax}and screwon
capagain.

oircrr||{Ytv^rsuryr N^i 4fy[0 xyrsysr$4rT

ih riosr-
a'" aurTrto fN Dftv^TrffocNrNorL
;ilgo01",llll"_1T.Y";'**,
voLvo cool rr iyft c.cooirrc sii;-E
'norfcTfor0 ,.r roe ur rui 40rrDurF H^!f {^rfR rr0 !^1. v0rvo
ifilnr ff L0ur0rANn6lLwoLvo a4 c v^r8Ll JLSoUA?pal AT12
vrc irort €^u Morlt fi{lcrL rYPrc
Replace decal
AttachnewtypeC decalto expansion
tank.
Group 26 Cooling system
Thomostat

AU. Thermostat

AUl
Replacement
- replace
thermostatandseal
- arrowonthermostatmustPointuP

AU2
Testing
lf nec€ssarytestthermostatin hotw€tet
Thermostat should:
- startto op6nat 87'C{188fF)
- "87'C+ -be lully open at 102"C{216"F}.
= 8 mm{0.3in).
Min openinggap
Emm
;i02"-CT

168
Y
I
I Group26 Coolingsystem
I Coolant(water)pump

AV. Coolant(water) pump, replacement

SpeciaI tools : 5187, 5188,5 197

ID AV1
Disconnectbattery ground lead
AV2
Jack-up vehicle
To preventspillagesu/hencoolantis drained,raise
vehicleat front rightjackingpoint.Coolantwill then
run alongsplashguard intodriPpan
Placedrip panbeneathleftsteeringrod.

AV3
Draincoolant
{Nodraintapson ensine)
lJnscrew
expansiontankcap.
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 .D i s c o n
n e c t l o w e r h o s e f r o m 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 e

Remove

c o o l i n g f 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 s a n d p o w e r s t e e r i n gp u m p b e l t
front timing gearcover.

169
Group26 Coolingsystem
Coolant lwater) pump

AV5
Removevibrationdamper center bolt
Use5187to prevenlpul ey from rotating,andwrench
5188to unscrewbolt. lt may be necessary to turn
enq ne slightlyso Iha(5187restson lan oearing.

AV6
Turnengineapprox.1/4turn anliclockwise

;> Usew.ench 5187.

B y t u r n i n ge n g i n ea n t i c l o c k w i s es,l a c ki n b e l tw i l l m o v e
{ I
'6i i o d r i v i n g s i d e , m a k i n g i l e a s i e rt o r e m o v ea n d i n s t a

}Y
7
AV7
Removevibrationdamper
Remove 4 bolts(arrowed).Allenkey6 mm.
Pulloff vibration damper. gearmay
Notecrankshaft
sometimes stickto vibration
dampe. { rli
AV8
Removelowertiming gearcover

{ril
I
AV9
I
Detachmounting bracketlor coolinglan and
alternatorand placeon one side
Remove mounting bolts(arrowed)and
pressbracket

110
 Group 26 Cooling system
Coolant(waterpump)

AVl0
Mark position ol timing geal belt
Mark belt,camshaftsprocketand crankshaftgear.
Markin frontof a cog.Alsoidenrifyoutsideandtop"
sideof gearbelt.

lmportant
Belt must be titted in exactly same position as
found otherwisevalves may contact pistons and
causeseriousenginedamage.

AV11
Remove gear beli
Slackencoolant pump mounting bolts and belt.
Coolantmay leakwhen boltsareslackened.
Lift off belt.

AVl2
Removecoolant pump
Removecoverpanelandretaining
boltsfor coolant
pump,
Movepaneltoonesideandremovepump,Takecare

AV13
Clean
Cleancontact forpumponcylinder
surface block.
0ry
offcoolant
fromcylinderblock,gearetc.

171
Group 26 Cooling system
Coolant lwater) pump

AV14
Inslall new coolant pump
Greasenew O-ringand placeit on pump.Do not use
permatexor other types of sealers.
Movecoverplateto one side and mount pump on
engine.Pumpretainingboltsshould only be attached
looselyat thlsstage.

AV15
Install:
- c o v e r p l a t e r e t a i n i n gb o l t s ,
- m o L n l i n g b a c k e tf o r c o o l i n g f a n d l r e r n a t o r .
I

AV16 {rrlI
Installgearbelt
Make sure thai belt is fitted in exactly same
position as before
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
and crankshafg t ear.
{r
I t i s e x t . e m e l yi m p o n a n t t h a t b e l t is fitted in exactly
s a m e p o s i t i o na s b e f o r e .
Tension belt by moving coolant pump (by hand).
T i g h t e np u m p m o u n t i n g b o l t s .

112
 Group26 Coolingsystem
Coolantlwater)pump

AV17
Install lower timing gear cover and vibration
oamper
Dampercan only be fitted in one way. Pin on
c r a n k s h a f gt e a r m L r s tf i t i n v i b r a t i o n d a m p e r .
T o . q u e i n h e x b o l t sr o 2 0 N m { 1 5 f r b s ) .

AV18
Install center bolts
Smearthreadsand matingsurfacewith sealerP/N
0 271961-9.
Usewrench5187{reston coolinsfan journal)ro hotd
vibrationdamper.use wrench5188to torquecentre
bolt1o350Nm (255ft lbs).
lmportant!Torque350Nmappliesonlyifwrench5188
is used.Also torquewrench must be in line wrrn
wrench 5184.

AV19
Set belt tension
I Turnengineapprox.1/4turn anticlockwise.
Adjusi

io
l
t e n s i o nb y m o v i n g c o o l a n t p u m p . U s e g a u g e 5 1 9 7t o
c h e c kt e n s i o n . A t t a c h g a u g e t o b e l t a n d s e t t o 1 2 . 5
u 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 t u s h

D e p r e s sb e l t s t r o n g l y w i t h h a n d a n d r e c h e c k / a d j u s t

AV2O
lnstall:
- front timing gearcover
- c o o l i n g f 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 t o
9 Nm (7ft lbs).
- b e t f o ' p o w e r s t F e r : r gp u n p a r d t a n b e t s
- radiator Connecl hoses (also hose to cotd srart
Group26 Coolingsystem
Coolant(watet)pump

AV21
Bleedingof cooling system
upperhosefromcoldstartdevice.
Disconnect Place
drippanbeneathhoseandholdhoselevelwithtop
edgeof expansion
tank.

AV22
Fill coolant
Capacityi D 20 = 8.1litres(8.6US quarts)
D 24 = 9.3litres(9.8US quarts).
Set dashboard heatercontrolto MAX. Add coolant
throughexpansion tankcap.OnlytypeC (blue'gr€en)
coolantis to be used.
Turnon engineandwarm-upfor 5 minutes.{Expan-
siontankcapremoved). Addcoolantduringthistime.
Connecthose io cold start device.Fill coolantto
mouthof expansion tank (abovemax)and screwon
capagain,

\rol-iro IYPc ^hParYtro

oFrcrrriYrvrTsra rLsYsT!tr^RrRosr
srYooAr nLr -30"cIfi$IYLIARtrRullrr!r$ $ oft v
l/loLvro co0LrNI
r0r uPYIAAR0un0\{trN[^rf r^
L AV23
^rrcn voLl/o
r$ru 0r Lrour0r
-r0.[ i rui $r rourrs^]soN
lvft ir0flt au fior( ^rrc[Lrw c Replacedecal
A t t a c hn e w t y p e C d e c a lt o e x p a n s i o nt a n k . (rrl6

114
 Group27 Enginecontrcls

Group27 Enginecontrols

Gontents
Oporation
Enginecontrols,
adjustment AX1-S
Group 27 Engine controls
Adiustment

AX. Enginecontrols,adjustment

AXl
Disconnect cold start devico
lf engine is cold. cold start device must be discon-
nectedpriorto sd,ustingenginecontrols.
Slackenscrew1.Pushlever fo rward and rotat€sleeve
90'.
Notel Do notturn screw2, otherwis€itwillbe necess"
ary to removecold start deviceand r€set it on a tesl

AX2
Disconnectlink rod from lever on iniection
pump
AX3
Adiust throttl€ cable
Turncablenut until cableis taul.Positionof throttle
drum mustnot be affected,drum mustcontactidle
stop.

AX4
Checktull thlottlc position
Depressacceleratorpedalto floor. Throttledrum
shouldconlactfull throttlestop.

176
 Group27 Enginecontrcls
Engi ne contro ls, adju stment

Autontatio transmission,
Adiust kick-down cable
Depressacceleratorpedaltofloor, Cableshould move
approx,52mm (2.05in)betweenidleandfullthrottle
Dositions.
Csbl€ should be taut in idle position. Distancebet-
weenclip on cableand nut shouldbe 0,25-1.0mm
(0.01-0.04in).

Reconnectlink rod to levei

AX7
Adiust link rod, full throttle position
Turnthrottledrumto fullthrottleposition.
Adiustlengthof linkrodso that pumplevercontacts
adjustment screwIor fastidle,

Adiustlink rod,idle position

Releasedrum so lhat it contactsidle stop.
Adjust link rod balljoint so that injectionpump lever
contactsidlo (low) adjustmentscrew.

Readiust link rod

RepeatoperaiionsX6 and X7 until 0.3 mm {0.012in)
clearancois obtainedbetweenthrottle drum and full
throttleand idle stoos.
Reconnectcoldstart deviceas applicable,
Inclex

lndex
Op€ration Page Opsralion Pago
Blsfc-sEtting6ngin.,,.,.,,.,.,..,..,.,.,.,,.,.,..,.,..
C1-21 22 Glowpluss..................................................
AN1-AO1 156
rdfe6poodsdllsinont................................Ax8 177
f ront.....................................
- - -.............. 01-27 a1
, . , . , , , , . , . . , . ,P. ,1. .-,2. 1 8a
9 e n e r a 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3. .1. . A D 1
a l t i t u d e a d j u s t m e n t U S A . . . . . . . . . . . . . . . . . . . . . . . . . . A1 D322
'133
. . .1. -. .1.1. . . . . . . . .7. .1.
r € m o w 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M s€ttins....................................................... AO3-14
i m r a 1 | a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N
..1 . .-. 2. .7. . . . . . . . . . . . c11-20 24
.lriv€b€lt,rcplac€m€nt............................. AEl-14 136
r e m o v a 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . .A. .F. .l .- -1.1. . . . . . . .1. 4
. .0. .
insrall€rion measurement ,.,,.,----, -,, 58 104 inst6llarion,.,..,.,,.,.,.,,.,.,,.,,,,.,..,.,..,.,,.,.,,.,., AG1-17 143
Co|dstartdwie......................................... AM1-2 155
C o m p r e s s i o n t e s t , . , . , , . , , . , . , . , , . , , . , , , , . , . , , . , . , , . , . , ,1A71 - 1 0 malfunctions........................--...............A 15 K'll2
remova1........................---....................1 . 45K2H
i n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. .K. .7. -. .9. . . . . . . .1. 5 . .2. .
rephcement...-...........................-.............. AV'l-23 169 reconditioning andtesting.................-..... AL1-10 I 53
g s n € r a 1 , , , . , . , , , , . , , , , . , , , , , , . , , . , . , , . , , , , . , . , , . , . , , . , . ,1,6. ,4. , A T 1 l n t a k . m a n i f o l d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .6A0P 1
drainins..................................................... AT2-4 168 K i c k - d o w n c a b | e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .7A7X 5
d l a i n i n 9 a n d f | o s h i n 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1T656- 9
ii11in9.........................................-...........-... AT10-12 1A7 c h e c k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .2. 4 ..21
. e l i e f v a l v e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2. .42 3
lestins,.,.,..,.,.,..,.,.,,,,.,.,.,..,.,..,.,.,.,,.,.,..,.,.,, AS1 lBt O i f p u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 2. .4. 2 2
coolant....,.,.,..,.,.,.,,.,.,....,.,..,.,.,,,,,,.,.,..,.,.,, AT1-12 164
thefmostat,,.:,...,.,,.,.,.,..,.,....,.,,,,.,.,.,,,,.,.,.., AUl-2 168 Preheatins {wirinsdiasrans).................... AN1-AO1 156
coo1antpump............................................ AV1-23 169 Pllotbsarlns{in crankshaft)
r e p l a c e m e n t . , . . . . , . , , . , . . , . . . . . . , , . , . . . . , . , . . , . , , . , . , , .9, 4 .O1-7
tront ,.r,.,..,.,....,.,..,.,.,..,...,..,.,,.,.,....,.,..,.,.,., R1-21 96 Bemovinsengine....................................... V1-7 111
.....................s1-11 103
S i f s n c o E . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 6 . .2. A R i
unscrewin9.-....-......-....-............................ O17 32
differenttypes.,..........,.....-..............-....-.... 9 e n e . a.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - - .A- -A- 1 - - - . . . . 126
t i g h t € n i n 9 , , , , . , . , . . , . , . , , . , . , , . . . . - . . . . -H . .8. , . . . . . - . . . . . .4A
... c h e c k i n 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M . .2. .-.1. .0. . . . . . . .126
....
r€1i9h16nin9,,,,.,.,,.,.,,.,,,,.,..,.,,.,,,,.,.,,.,.,,.,., J1-3 57
Specia1toob,,,,.,.,,.,,,,.,,.,.,.. 12
Cylind€rheadsa3ket.................................. H3 45,46
Specilic.tions.................-........................... 3
r € m o v € 1 , . , , , , . , , , , . , . , , . , . . , . , . . . - . . . . . .o. .1. -. .2. . . . . . . . . . .28-... Swirlch.mboB........................................... G6 43
i n s p o c t i o n . , . , , . , . , . . , . , , . , , , , . , . . , . , , . , ,0, 2
, .0, . , . . , . , , . , . 32
,,, AS1 164
o v e f i a u 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F. .1. .-.2. .1. . . . . . . . .36
... Tsiting coolingsy.tsm ..............................
i n s t a 1 1 a t i o n . . . , . , . . , . , . , , , , , , , . , . . , . , , .H, ,1. ,-.3. ,8. , . . . . , . ,45 ,,,.
r e p l a c e m e n t . , , , , . , . , , . , . . , . , , , , . , . , , . , .A, ,U. ,1. , , , , . , , , , .168 ,,.
remov6l/insiallation.,.,.......,---,.,..,.,.,,... t e s t i n 9 , , . , . , . , , . , , . , . , . , , . , . . , . , , . , . , , , , . ,A. ,U, .2, , . , . , . , , . ,1.6, ,8.
AH1-3 148
r6p14cemeni,,.,..,.,..,.,,.,..,............-............. AJl-10 149
Engh. t € n s i o n , . , . , , . , , , , . , . . , . , . . , . . . . , . . . . , . . - . . - . . . . . . . . . . . . . .5. 8 .,K1-E
r e m o v 6 l . . . . . . . . . . . . . . . . . . . . . . . . - . . . . - . . . . . . . . . . . . . . . . . . .1.1. .1. V 1 - 7 r e p l a c e m e n t . . . . . . . . . . . . . , . , . . . , . . . - . . , ,A. ,E. ,1. -, ,1.4, . , . . , 1 . ,6, 0
36
L1-35
i n s t a 1 1 . t i o n . . . . . . . . . . . . . . . . . . . - . . . . . . . . .X. .1. -3. .3. . . . . . . .1. .1. .4.
Ersin..@nlrols.......................................... V a l v e c l 6 a r a n @ , a d i u r t m e n t . . . . . . . . . . . . . . . . . . . . . 8 1 -1191
AX1-9 176
E n g i n e , i n s t a | | a t i o n . , , , , . , . . , . , , . , , . . . . . . . . . . . . . . - . . . .1. 1 x1 Valve@verlg.sket,.,,.,.,,.,..,.,,.,.,,,,.,.,,.,,,,,, 811 21
4-33
c l e a r a n c € , g u i d s - v a l v € . , . . , . . , . . . . . . . . . - . . . . . . . . . . . F3l6
110 replacement,.....-..-....-..............,.,.,..,.,,.,.3 , .7, F H
f r o n t , . , . . , . , . , . . . . . - . . . . . . . - . . . . . . . . . . . . . . -U- 2
- -4- - - , - . . . . 1 1 0 o i 1 s e a 1 s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. 2. . . . G 4
Ensin6oil,filter...........................-..............- Y1-2 123
Exhruatmsnifo|d....................................... APz 161 .eplacement...,.....,.,.,,.,....,..,.,..,.......,,....,.. F13-21 39
E x h . G r p i p e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. .8. 1. . . . . . . . . . . 162
.. s n d i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . - . . . . . . . . . . . .3. 8F F 1 2
Fue|fi|ter..................................................... AC1-2 130 insp€ction...........-,----,-......................F5 37
AAl-10 126 V.fvostsmsoals................. G4 42
smokedensity....-.........-............-...............
i d fe s p e e d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
. .B
. .l.-.6. . . . . . . . .1. .2. 9
fue1fi|ter...............................-A - -C
- -'.l .-.2. . . . . . . .1 3 0 typss'.'.-'.-'.-'.-'.---'.,,,.,..,.,..,.,,.,.,,, G3 42
'19
i n j a c t i o n p u m p . . . . . . . . . . . . . . . . . . . . . . . . . .A. .D. .1. .- .A. .G. .1. .4. 1. .3 1 cleahnce,adjustm€nt..................-..-....-... B1*B'l'l
deliv€rypip€s.............-.............................. AH1-AJ10 148 c | e a r a n c e , 9 u i d e . v a 1 v e . . . . . . . . . . . . .F . .1. . . . . , . , . . . . . .36
injectofs........................-........................-.. AK'l-ALl0 15'l s i n d i n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F
. .9. .-.1. .2. . . . . . . . .3a
..
c o l d s t a r t d e v i c e . . - , , . . - . . . . . . . . . . . . . . . .A. .N. .1. -. .2. . . . . . . 1. .5 6
prehe6ting system,.,..,.,,.,.,,......,,,..,-,,...,,.. AN1-AO1 156 remowl,'insta118tion,,.,.,.,,.,,,,.,,.,.,,.,,,,.,.,,.
T1-10 106
Fuflthrottl€adiustomont.......-........,,,........Ax7 177
1 9 7 H 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A. .N. .I.-.A . .O. . l. . . . .'156
..
r e p l a c e m e n t . . . . - , , . . . , . . . - , . . . - . . . . - . .A
- .E. .1. - .1. 4
. .'.1. -3,6. . . . . 1 9 8 1 - , , , , . , . , , , , . , . , , . , , , , . , . . , . , . . , . , , , , .A, ,O
. , . , , . , . , , . , .154
,,.,.
't78
 Fault treing

FaultTracing
Dieselenginesarebasically ruggedin designand Analysisof exhaustsmokewill provideusefulin-
are designedfor long s€rvicelife. formation on determiningfuel relatedproblems.

Exceptduringmajorov€rhaul,most servicingis
confin€dto the tuel system.

Gontents
PW
Summaryof fauhsymptomsand reasons..... ,
ExamDles of taults
- H e a ws m o k e
a f t € cr o l ds t a r t . , . . . , . . , , . . , . . A1
- Enginedoesnot stan A1
-Engine c a n n obt es t o p p e d . . . . . . . . . . . . . . . . . A1
- Engine6tartsto smokeandclattershoavilyaftsrrsplacingfu€l injoc'tionpump
- Engineclattersheavilyafterreplacingor repairinginjectorsor fuel deiiverypipes A1
Excessivesmok€
- Blacksmoke M
- Whitesmoke. A2
- Bluesmoke A2
A3
Cold start device.
Fault tracing pr€-heating(glow plug)system
- C o m p l e ct eh e c ok f p r e - h e a t isnygs t e m . . . . . . . . . . . . . . . . . . . . . . . . F T l - F T 5
-Specificfaultcases. basedon complete ch€ck,..,......,........ FT6-FT14 t€
- lndicator lightilluminates whenengine is warm ..... ....... ... ... FT15 Ar0
-Wiring diagrams A11-A14
 Fault tracing
- Summary-

Summaryof fault symptomsand reasons

Thefaultsvmptomsare listednumerically according
to:
-likely occurance,
easein checkingand logicalsequence.
EXAMPLE: Undereachsymptomarea groupof
numbers- No.1wouldbethefirstitemto check,
thenNo.2 andso on,
untilthe SYmptoms
tautthas [--T--J--T--a NOTE:Startrng
S (Batte $aner,
system(Banery, etc., rs
starter,erc.J
in good condition
l""T*./
I /"1/ I
assumed to be

l/,!1-/,M
lfle, (il

krkl'lglf,,ffi
1 l
/i
;{ Rels ons for laults

Flel system
Fuelvalve(stoppingvalve)inthe injectionpump
{r
2 6 2 5 I Injectionpumpsucksair (leakage betweenfuel tankand pump)
8 5 1 4 3 1 l Fuel lealage {leakage between pump and deliverypipesor
otherexternalfuel leaks)
3 3 5 1 lce or paraffinin fuel linesor fuel filter(wintertime)
7 I 5 8 6 3 5 Injectiontimingincorrect
'10 2 Pre-heating system(seewiringdiagrams).

6 1 2 Coldstartdevice
12 I 11 9 9 I 1 0 Faultyinjectionpump
4 7 3 6 6 6 Fuel{ilterblocked(draincondensation
water)

I 8 4 7 7 10 7 Fuellinesblocked
1',I 1 0 6 8 12 6 Faultyinjectors
1 2 5 4 Mix up o{ hollowscrewsin pumpfor feedand returnlines {
I Incorrectlyadjustedfor highalt;tude
2 pump
Injection bracketloose/damaged
4 lncorrectlow idlesetting
8 5 Incorrecthighidlesetting
4 Returnlineblocked (

Otherfaults

3 Enginemountsloose/damaged
2 2 6 1 Air cleanerblocked
11 5 1 Exhaustsystemblocked
3 Incorrectaccelerator
controlsetting

Enginemechanicalfaults
5 4 Incorrect oil viscosityfor coldtemperatures
1l 7 13 7 Compression low/uneven
12 8 1o 14 8 Incofiectvalveclearance
3 Water leakage
2 Highoil consumption

180

Examplesof faults
Heavysmoke after cold start
Poorfuel quality.
Checkthe cold start device by checkingidle
speeo,
ldlespeedshouldbe approx.200rpm higher
with coldengine.ldlespeedat normaloperat-
ing temperature shouldbe 800rpm.
At normal operatingtemperature. the cotd
start lever should not touch the lever on the
injectionpump.
After settinglow idlespeed,the automaticidle
increasedevicemust be checkedand adjusted
it necessary.The gap betweencontrol lever
and ball stud should be 12.7mm(0.5") as
Cold start device
12.7mm(0.5")
Enginedoes not start
Checkthe fuel valve (stoppingvalve) in the
injectionpump.No fuelwill reachthe injectors
if the valve does not open (listenfor audibie
clickl.
Thevoltageat the tuelvalvesolenoidmustbe
a t l e a s t 1 0 v o l t s t o o p e n t h e v a l v e ,a n d
minimumI voltsto remainopen(startetmotor
engaged).
Fault tracing
-Examples of faults-
Enginecannot be stopped
Thefuelvalve (stoppingvalve)in the injection
pumpdoesnot close.lt is a solenoidvalve.
Increasemomentarjly to high enginespeed
and try againto switch offthe start key.lf this
doesnot helD:
-Vehicles with manurl transmission:
Engage3rd or 4th gear, depressthe brake
pedatand releasethe clutchpedal.
-Vehicles with automatictransmission.
Usethe emergencystop lever on the injec-
tion pump,seeill. below.
Emergencystop level
Enginestarts to smoke and clatter
heavily after replacingfuel iniection
pump
The injectionpump might be incorrectlytimed
or assembled(distributorplunger 180. re-
Check basic injection timing. lf correct, try
anotherinjectionpump.
Engineclatters heavily (soundslike
bearingfailure) after replacingirepair-
ing iniectors or fuel delivery pipes
An injectormight have jammed open. The
combustionis out of control when accelerat-
Ing.
Loosenthe cap nutsto one injectorat a time.
The compressionpressurewill revealvisible
bubblesat the cap nut ot a stuckinjector,
Note: Cleancap nuts beforeloosening
 Fauhtmcia
Excesgvesnoke

Excessivesmoke

White oxhaustsmokg(cont.)

NOTE:
Whiteexhaustsmoke canalsobecausedby wa-
ter leaksintotheexhaustsystemorcylinderhead.

causesfor whitesmoke:
Possible
- Pre-heating
system{glowplugs}notoperating.
- Low compressonpressure,
Excessive
incomplete
Rgasons
digselsmokeis usuallycausedby
combustion.
may be enginecondition,fuel or fuel
- Low operatingtemperature.
- Defectiveinjectors.
(r I
iniectionequipmgnt.Drivingand traflic condi- - Lateinjectiontiming.
tionsmay alsocontribute.Frequentacceleralion -Water leakage(cylinderheadgasketl.
in citytrafficwillcauselargequantitesof exhaust
gases.
- Coldstartdevicenot operating. (
I
Excessivedieselsmokeafter cold start may be
causeoby poorflrel quality or defectivecold
start oevrce.
Bluesmoke
Causedby incomplete combustionandcontents
oJ condensedfuel particles.
Blacksmoke Canalsobecausedby excessive oilconsumption.
Causedby too muchfuel.Thecarboncontentin
the exhaustgasesbecomesnoticeable. Causes PossiblecausesIor bluesmoke:
may be: - Lateinjectiontiming.
- Poorfuel quality. - Delectiveinjectors.
- Dirtyair cleaner(insufficient
air supply). - Heatshieldunderinjectordamagedor missing.
- Excessiveiniection.
- Worn injectors.
- High{uelconsumption.
- Low operatingtemperature.
{,1 I
- lncorrectf!el.
- Low compressDn pressure,
- Considerable in exhaustsystem
backpressure ( rl I
{clogging). CAUTION

Because low smokelevel,it may

of the generally
be tholght possibleto increaseengineperfor-
manceby enrichening the air-fuelmixture

White smoke However,prolongedexcessiveenrichmentwill

Occursmainlyduringcold starterand is caused poweroutputandwill in fact cause
not increase
fuelsupply.The
by insufficient smokeconsistsof unnecessary enginewear.
increased
condensed fuel particles.
Thecombustionspeed
is low andthe fuel particleshavelongertime to willsharplyin_
Moderatefuelmixtureenrichment
condense. creaseexhausltemperatures and combustion
(cont.l pressures powergain.
withoutanycorresponding

A2
 Fault traciw

Injectors

Ma]functions
Oneor sevoralofthefollowingmalfunctions
can
occur:
-One or severalcylindersknock
NOTE:Do not confusowith bearingclatter.
Checkinjectoroperation.
- Overheated
enging.
- Reducedpoweroutput.

- Unevenidle.

- Blackexhaustsmoke.

- Highfuel consumption.

Checkinginiector operation
1.
Rln the engineat increased
idlespeed.

2.
Loosenthecapnutsattheinjectorqoneat a time.
Wrapabsorbing paperroundthe injectorstopre-
ventluel spill,

lfthe idlespeodremainsstableor if knockingdis-

appears, the fault mightbe:
- defectiveinjector
- defectiveheatshield
- leakingdeliverypipe

Forfurthertest,removethe injectorsandtest in
a test machane.

A3
 Fauftnaciry
Coldstdt'tdevice

Cold start device

Thecold start devicec€nonly be t€stedon a test

benchtogether with tho injectionpump

A simple op€rationtest can be performedwath-

out removingthe cold start devicafrom the
€ngine.

signs of cold start devicemalfunction:

- Cold €ngjnehard to start.

- Enginedoes not start at tempgraturesbelow

-10'C = 14'F.

- Blue-whit€exhaustgas€s.

Operation ch€ck
check idle speedcold and at normaloperating
temperature.

1.
With cold engine,below 2O'C = 7O'F. engine
idlespeedshouldbe approx 95o rpm (2Oorpm
morethanwarm).

tempera-
With enginewarmal normaloperatang
ture:
- Engineidlespeedshouldbe 750 rpm.

- The cold start devicelevershouldclearleveron

injectionpump.
 Diesel engine
-Prc-heating system-

Pre-heatingsyste
Basicoperationof system:
-The systemis switched
on whenthestartkeyisturnedto drivingpositionll).Thepre-heating
time
dependson coolanttemperatures.
Thedashboard indicatorlightwill stayon approx.:
1980MODELS 1 9 8 1& O N
45 secondsat -2O'C = 4'F. 9 secondsat 20'C = 4'F.
25 secondsat 0'C : 32'F. 6 secondsat 0" C : 32'F.
15 secondsat +20'C = 68'F. 4 secondsat +20" c = 68" F.
0 s e c o n dast + 5 0 ' C = 1 1 2 "F . 0 secondsat +50' c : '112'F.
-The glowplugsremainONapprox.20 seconds lighthasgoneoutfor1980models
aftertheindicator
and aoorox.7secondsfor 1981and or,.

if -Ihe glowplugsareONwhenthestartermotoroperates.
startsand the stan key is turned backto positionll.
Theglowplugsarecutoutwhentheengine

-To repeata start;ngattempt,the startkey must be turned backto positionI to switchon the pre-
heatingsystem.
iif -The systemalsocomprises a blocking
rclayon 1980models, is partofthe
on 1981andon thisfunction
controlunit.lt will interruptthe
electrical thecontrolunitandtherelayfortheglow
circuitbetween
plugswhenthe alternator stanscharging.

Faulttracingpre-heating(glow plug)system
Relerto the wiringdiagramsat rearof manualduringfaulttracing.Thepre-heating
systemis an
electrica
I systemandthewiringdiagrams arenecessarytounderstand andcorrectlytrouble-shootthe
pre-heatrng system.

Completecheck of pre-heatingsystem
(0 Engineshould be cold (max.40'C = 100.F)
when starting the system check.
startkeyto intermediateposition(l),then to
driving position 1ll)to obtain a new cut-in
lfthepre-heating
systemshutsOFF,tirstturn penoo.

((l
FTl
Connecta test lamp acrossglow plug
terminaland ground.
 Fault thcing
4low plug system-

Ffz
Checkfunction of test lamp and
indicator light (on instrurnent panel
in vehicle)
CASEA
Indicstorlight OUI
Test light OUT.
-lndicatesfailure at the controlunit.SeeFT6.

'*i1 CASEB
Indicatorlight ON.
Tesr light OUT.
-lndicates failureat the glow plug relay.Soe
FI8.

CASEC
Indicatorlight OUT.
Y9.'Pi" Te3t light ON.
-lndicates failure at temperaturesender or
control unit. See FTl3.

Indlcatorlight ON,
Test light ON.
-Proceed on FT3,ne) .

Fn|
CheckON-time for indicator light and
test light.
Turnstartkeyto intermediate
position0)and
then to driving position (ll). ON-time for
indicatorlight should be accordingto coolant
temperaturg,see diagram.
Forenginespriorto 1981Testlight at glow plug
terminals should remain ON for approx. 20
secondsaft€r indicator light is OUT. For
engines1981and ohwardthe test lightshould
rcmain ON for approx.7 seconds.
ON.tlmo incorect (too shortli
Try a new control unit, lf ON-tim€ still is too
short,try a new temperSturesender.

ON-time @roct:
Proceodon FT4, next.

46
 -Glow plug system-

FT4
Check operation with starter motor
operating
Testlightshouldilluminate.
indicatingvoltageat
the glow plugs.

voltage Test light OUT:

terminal 50 Starter motor engaged,use the test lamp to
checkvoltageat terminal50 (blueyellowwire)of
the controlunit,

Voltage:
a faultycontrolunit.
Indicates

No voltagel
Indicatesopen circuit betweenconnectorand

(Connector locatedundercarpetnextto control

panelle{t support).

Test light ON:

Proceedon FT5,next.

Ft5
Check glow piugs. one by one
Startkeyin positionO.
Removethe barbetweentheglowplugterminals.
Connectthe test light acrossbatteryPLUSand
one glow plug at a time to checkthat current
passesthroughthe glow Plugs.

Light OUTat one or mo.e glow plugsi

faultyglow plug.
Indicates

Light ON
SystemcheckedOK.

End of completo system check

 Fault tacing
- Glow plug sysEm -

FT2, case A

Testlightand indicatorlightshouldilluminate.

Indicatorlight OUT.
T€st light OUT.
- lndicatesJailureat the controlunit.

Firstcheckthat cut-inperiodhasnot expiredor

that coolanttemperatureis too high.

FT6
Checkvoltageat terminal 15 of the
controlunit (do not disconnect
to test).
Blue-redwire.Usetest lampto checkvoltage.lt
shouldilluminate.
(, (
No voltage:
lndicates opencircuitbetweenfuseboxandcon-
trol unrt,

Voltage (
Proceedto FT7,next.

Fr7
Checkgroundterminal31 of the
controlunit
Blackwire. Connecttest lamp acrossbattery
PLUS(or fuse box PLUSterminalland terminal
31 of the controlunit.
Testlighl shouldilluminate.
No voltag€r
fault in groundconnection.
Indicates

Voltage:
Indicates
controlunit failure.
FT2, case B
vollageterminal86
Indicatorlight ON. f
Test light OUT.
Indicates {ailureat the glow plugrelay.
FT8
Checkvoltageat terminal86 of the (
glow plug relay
Yellowwire. Usetest lampto checkvoltage.lt
shouldilluminate.
Voltage:
Connectthe test lampacrossbatteryPLUSand
relaygroundterminal(blackwire).Thetest light
shouldilluminate.
Voltag€:lndicatesfaultyglow plugrelay.
incorrectgroundconnec
No voltagg: Indicates
t|on.
No voltage
Proceedto FTg,next.
 Faufttaciw
- Glowplug syslem-

FT9
Check voltage at terminal G of the
control unit
Bluewire.Usetest lampto checkvoltage.Test
lightshouldilluminate.

No voltage:
Indicates
a faultycontrolunit.

Volt.go
Proceedon FTlq next.
voltagelerminal30 FTl O
Check voltage at terminal 30 of the
blockingrelay(1980only)
Bluewirc. Use test lamp to checkfor voltage.
Testlightshouldilluminate.

No voltage
Indicates
opencircuitinwirebetweencontrctunrr
and blockingrelay.

Voltage:
Proceedon FT11, next.
FT11
Check voltage at terminal 87 ol the
blockingrelay(1!|80only)
Yellow wire. Use test lamp to checkvoltage.
Testlightshouldilluminate.

Voltage:
Indicatesopencircuitin wire betlveenblockino
relayand glow plugrelay.

No voltage Glod<ing relay does not operatsl:

voltageterminal86
Proceedon FT12,next.
FT12
Check voltage at terminal 86 of the
blocking relay (1980only)
Blue-yellowwire. Use test lamp to check
voltage.Test light should illuminate.
No voltage:
Opencircuitin wire betweenfusoboxandblock-
Ing relay.
Voltage:
Connecttest lampacrossbattery PLUS(fusebox
PLUS}and groundterminalS5ofthe blockingre-
lay.Tert lightshouldilluminate.
Voltage:
Indicates
fauhyblockingrelay.
No voltage:
Indicates open circuitin wire betweenblocking
relayand instrumentpanel,
OR
fault in the instrumentprintedcircuit.
-Glow plug system-
FTz,caseC
Indicatorlight OUI
Test light ON.
-lndicates failureat temperature
senderor
controlunt.
FTl3
Disconnectwire at temperaturesender
light(ondashboardl
lndicator shouldilluminate.
Makesurewire is not inadvertentlygrounded.
Indicatorlight ON:
Indicatesthatcircuitlrom temperature
senclerto
indicatorlight is correct
AND
a tault in temperaturesender,Try a new one.
Indicatorlight still OUT:
Proceedto FT14,next.
(

FT 14
at terminalK
Gheckgroundconnection
ground
terminalK
of control unit
Yellowwire. Connecttest lamp acrossbattery
PLUS (Jusebox PLUS)and terminal K. Test
(r
lightshouldilluminate.
Voltage:
IndicatesdeJectiveindicatorlamp
OR
defectivewire betweencontrolunitandindicator
light
OR
fauh in the instrumentprintedcircuit.
No voltage:
lndicates:
-DeJective controlunit
-OR groundedwire betweentemperature
senderand controlunit.

Indicatorlight illuminateswhen engineis warm

t r(
Preceding fault tracingassumedthat engine
tempe€turewas below40'C = 100"F and that
the faults occuredwithin the low temperature
range.However, the indicatorIightcouldalso
illuminatewith enginewarm (at operating ( (
temperature),
FT 15
Checktemperaturesender circuit and
temperaturesender
Disconnect wire at temperaturesender.Ground
it and turn start key to driving position (ll).
Checkindicator light.
Indicatorlight illuminates:
Indicatesopen circuitin wire betlveentemper-
ature senderand control unit
OR
defectivecontrolunit.
Indicatorlight does not illuminate:
Indicatesfaultytemperaturesender.
-7

Glow plug system

Diesel 7980

Glow plug system

Diesel1980-
Legend:
A Temperature sensor
B Stop valve
C Indicator light
O Sta.t switch
E Glow plug
F Glow plug relay
G Blocking relay
H Control unit
I Fuse box
K Remote starter
pick-up point

Start key ON
Coolanttemperaturebelow +50" C = 122"F

Blockingrelay(G)isgroundedthrough
voltage regulatorand alternatorcircuit when
alternatoris not charging.

130836
 l-
Glow plug system
Diesel 1980

D
'-i
FT
H
V

{r :1
{, i(

0,, (
(
b7.18
€

bTue-

I
 Glow plug system
Diesel 1981-

Glow plugsystem
Diesel1981-
Legend:
A Temperature sensor
B Stop valve
C Indic6tor light
D Start switch
E Glow plug
F Glow plug relay
G Remote starter
pick-up point
H Control unit
I Fuse box

Start key ON
Coolant temPerature
below +50'C = 122'F

Starter motor op€rating

I33234
q3323?
Glow plug system
Diesel 1981-

W W
{

\.<
)i

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Yoalr
most important
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