Service Manual

Repairs and maintenance

TP 30420/111.88 EngineD20,D24 240 1979- 19 ..

D20,D24
Boththe D 20ancl 24 Dieselengines dealtwilh D in are this manual. The D 20 hasfive cylinders andthe D 24 six. Otherwise the engines similar principle. in are Not6l Differentllywheelsand vibrationdampersar fitted to the dilferentenginetypes.

iffim

itm!r
:i!r-l-l

Volvosare sold in versions adaptedtor different markets. Theseadaptations clepend manyfacon Iors Including ega, taxarion and marker reqJi.e Thismanual may therefore showill!strations and lextwhichdo not applyto carsin yourcountry.

Contents
page

fmportant information ............................... 2 Specitications ........ 3 Special tools ................................... 12 Group Engine 21 assembly ............................................... 16
(Work wilh engine in-ca., replacernentof engrnej

Group22 Lubricating System......................................... 123 Group23 FuelSystem ......................................................... 125 Group25Intake exhaust and systems .............. r60 .. .. Group26Cooling system.................................................. i63 Group27En9inecontro1s.................................................. 175 Appendix"A"Faulttracing............................................. A1

Index178

OrderNo,:TP 30420/1

We reserye right to makealerat ons the

Reprint of'1983 literature without change. OVOLVO NORTHAMERICA CORPORATION

lmportantinformation

CLEANLINESS Dieselinjection dirt systems areoxtremelysensitiveto and foreign m6tter. A special workplace should thereforebe usedfor insoectionofcomoonents.

PLUGS before disconClean fuelIineconnections thoroughly pipes. necting Plug ends of fusl lines etc as each component is removed. notremove Do thessplugsuntilthe compo' nent is reconnected.

Tightening torques
torques will be found in this Two kindsof tighlening th6t a torque 1. Tightento 40 Nm {30ft lbs)indicates wrench mustbe usedIortightening. 2. Tighteningtorque 40 Nm {30 ft lbs) indicatesa guidevalug. Tightening neednot be donewitha Ioroue wrencn.

Specifications

Specifications
Group 20 General

.,o ,o

Engine typedesignation serial and number

S t a m p e do n l e f t s i d e o f e n g i n eb e n e a t h a c u u t r , u m p p v

D 20 Engine
Output DIN.......................... Maxtorque DIN
N u m b e ro f c y l i n d e r s D i s p l a c e m e n t . . . ............ . . W e i g h t , a p p r o x . i n c l . e n g i n e m o u n t s , a l t e f n a r o ra n d s t a r t e r Compression ressuresi p \ew en9ine.................. iVnirnJn ....................... M a x d ; f f e . e n c e b e r w e e n c ye r s . . . . . . . . . . . . . . . . . . . . . . . . . . nd l C o m p . e s s , o r a t r o. . . . .. . . C y l : n d eb o r e . . . . . . . . . . . . . . . . . . r S t r o \ el e n g r h

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

313 114

Specifications

D 24 Engine
OutputDlN MaxtorqueDlN Numberof cylinders ....... Firing order............,,...,... Disp1acement...,,...,,....,... Weight, approx. incl, engine mounts, alternatorand starter pressurss: Compression Newongin.........,,,,,.,...... lvlinimum ................,,...... Maxdiffsrnce between cy1inders ........................... p Com ression ralio .......,, Cylinder bore....,............. Slrokelength 60 kW al 80 r/s 82 hp at 4,800r/min 140Nm at 47 r/s 14.3kpm 6t 2,800r/min 6 1-5-3-6-2-4 2.383dm3{litsr) 1S8{435lbs) MP. 3.2 2.4 0,8 23.0r1 76.5mm = 3.0118 in 86.4mm = 3.4016 in psl 455 313 114

assembly Group21 Engine

CYLINDERHEAD

9;

:.' .,1

.,, \

\|

max 0.5 mm Diagonally

Replace cylinderhadjfwarp xceds spcificalions. may cylihderhadb machinod. Undrno circumst.ncos

Specifications

CYLINDEB HEAD GASKET Thfeedifferentgaskettypesare useddepending pistonprojection on abovecytinderblockface.

G.sket Pistonproiction notches thickness mm linl mm (in) (0.026-{.031 1 ....................1.4 0.67-0.80 )........ {0.0S5) 0.81-0.90(0.032-{1.035)........ 2 ................... 1.5{0.059) (0.036--0.040)........ 0.91-r.02 3 ................... 1.6(0.063)

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

Valve clearances, warm engine

Check Setting mm (in) mm lin) 0.15 {.25 (0.006-{.010) 0.20{0.008) (0.014-0.01 0.35-0.45 8) 0.40(0.016) 0.20-0.30(0.008-0.012) 0.25{0.010) 0.4(F0.50(0.016-0.020) 0.45{0.018) 3.00-4.25 mm in increments 0-05mm of

Do
,lo

0.1299 to 0.1673 in increments 0.0020 in in of in

a u n !

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

r-l[

r]

D24
Checuadjust valvesin following order: 1-5-3-6-2-4

Specifications

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

oo
@o

TIGHIENITVG SEOUENCE CYLIIIDER FOR XEADBOLTS

,Ot rO @@ D20 ,oo @@

lmportlntl slsck6nbotts in revrsa oder when removingcylindsrhad. Removs oiland dirtfrom bolt holes.Oil leftin holswill reducpressure cylinderheadgasket, on Eolt threads and washers must however be oiled, otherwisefrictionalforceswill b6 too grear.

@@o
@@@

@@@ @@)@
Two types ot bolls ars in uset An early type with M 11 threads 6 latertypewith M 12threads. and typis {Later lhr@d6dalong entirl6ngth.l

D24

NGHIENING OFCYLINDER HEADBOLTS

Mtl

M12

Us6 now waahera,convex sid6 upwards, Tlghtnin fiv stages: l50Nm{37ftlbsl 2 ?0 Nm (50ft lbs) 3 90 Nm {65ft lbs} 4 run 6nginuntil oil temperaturo st tast50.C is 1122'Fl 5 90 Nm (65ft lbs) R.lightening - Atler 600-1.200miles (1,000-2.000 km). Engine shouldbe cold or almostcotd.Tighteneachboltsep6ratslyin specifid order,see abovsfio.: L Slackn bol 3(r 2. Torque to 90 lrlm (65 ft tbs)

Us n.u bolb. Not nce$aryto roplac w6shers. Tightenin six stag6s: 1 ao Nm 0 ft lbsl 2 60 Ntn l4a ft lbsl 3 75 Nm {55ft lbs) 4 angle-tightsn l8f in ono movemnrwithout stopping, {Sefigur 6t lower lefi} 5 run nginuntil oil tehperatureis at lerst 50oC lt22 "Fl 6 anglo-tighten in on6 movsmentwithout stop90P

pins.

Rdighl.nlng After 60F1,200mil6(1,000-2,000 Engineshould km). b6 cold or almost cold. Tighten 6ach boll separatolyin spocifidorder, se bovfig.: 1. Angle-tightenbolt 9|r in one movemontwithout stopping.(Seefigure at lower left) Do not shckon boh firf,

Specificalions

20 Nm l1sft lbs)
6\1fl

100Nm (74ft lbs)

@

45 Nm 133 lbs) ft

b0

I l'-

'

i!

D20
(6.5ft lbsl

@ @'
Nm (55 ft tbs) 75 Nm (55 ft lbs)

S m e a r t h r e a d s db o l th e a d o n an c tacl suriaceswilh locking compound(P/N277961-9). Tiqhtening lorque 350 Nn {258ft l b s ) a p p l i 6 s h e n u s i n gs p e c i a l w tool 5188.lf a torque wrench is lsed dirscny on the cenler boll (wiihout 5188), the tiqhlening torqle should be 450 Nm (332ft

350 Nm (258ft lbs)

zbro'\ 1rs tu"t tt

Smear threads wiih compoundP/N277961-9.

Specifications

Gtoup 22 LubricatingSystem
OILCAPACITIES
D20
Excl.oilfilter Incl.oillilter Difference volume,max-min in Litors{US quarts} 5.2 (5.5) 6.0 (6.3) 1.0(1.0)

D24
LitersIUS quarts) 6.2 (6.5) (1.41 7.O 1.0(1.0)

ENGINEOIL
Oua1ity............,,,,,............ min CC Accord'ng API.......................................,,..,....,.:::::::::::::,.::::::: to Oilswith designations SSCC,SE/CD, SF/CC SF/CD and meotthis rquirement VbGosity Tomporaturc rangs (stableambisnttemperatures)

SAE15 W/50orSAE20 w/50 oilsarerscommendd for usein sxtremedrivingconditions which involvehigh oil consumption and high oil temperatures. example, for mountaindriving with frequentdecelrations fast of motorwaydriving. (Notehowoverth lower temperature limits.)

OILPRESSURE
Oil pressurc oil temperature 8O.C (176.F) 33,3r/s at of and kPa 200
psl 28

(2000r/min)min

Oilpressuresensot
Cut-out point,indicator lampgoesout at 15-45 2-6.4

Lubricating pump oil

Reliefvalvopensat...... Rlisfvalvespring,lngthat diffsrentloads ......................... 600-700 85-99

ffiffi8

Long1h Load mm in. N (1.93) L = 49 0 L1= 22 {0.87} 17F195 L2 = 19.8 (0.781 approx.200 (completely compressed)

lbs 0 {39-.44) (45)

Specifications

Group23 Fuelsystem
GENERAL
F i r i no r d e r . . . . . . . . . . . . . . . . . s
ldle

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

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

D24 1-5-3-6-2 4 12.5(750)r/s (r/min) 87.0(5200) (r/min) r/s

:o a,o

FUEL
Standard................ DIN51601r CEC-ERF-Dl, or ASTIM-D 975-No. 2-D 45 0.5

60litres(15.8 galls.) US

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

D24 Volvo P/N{exchange unit)D20 .................... D24 Injeclion timing{purrpprunger slroke TDC, at D20.............................

D24USAandCanada 1979-t98i 1982NOTE! High altitude necessary certain In page132.

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

0i:o

INJECTORS
Ir4akeanddesignation BoschNo. USA,/Canad 1982-

Other markets................... VolvoP/NUSt"/Canada t982-

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

Setting

Checkins lnlector opening pressure . . . . . .................................. ''''. MPa '. . . ....",.- .- . . . . . . . .....,.-....,. psi 1707-1849

12.5-',t3.s 1778,1920

Specifications

Nozzl6s Designation USA"/Canada 1982Othermarkets

Volvo P/N USA,/Canada 1982'

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

,esz. 3::133;3i usarcanlda 5l

068190201 I ^.

oogrrozolxl
ldentiticationot iniectors and nozzles

D N 0 5 D 1 9 30 = U S A / C a n a d s9 8 2 1 D N = S D 1 9 3= o l h e rm a r k t s

Iniector (complete)

TIGHTENING TOROUES
Injector, cylinder in head upper-rowersection...........................::...:.:.:.:.:.:.:::..:: 70 pump,pumpg Iniection 45

Nm 10

ft. lbs 52 52 33

70Nm = 52ft lbs

45 Nm = 33 ft lbs

ti

10

Specifications

Group26 Coolingsystem
GENERAL
Coohnt Since aluminium usedin the engines, is active corrois sion protection necessary the coolantto help pre in ventcorrosion damage. genuine Use Volvoblue-green coolant type C diluted with cleanwater in proponionsof 50/50. This mixture helps to prvenl corrosion and frost

c,il

a a

Neverlill the coolingsystemwith water alone. The coolantshouldbe changed regularly since the corrosionprolective6dditivesin the coolant losethoiref{ect time. in

co
Capacity, manual gearbox with with auiomatic transmission .....,,... D 20litros IUS qlrrts) 8.2 (8.7) 8.0 (8.4) D 24lirresIUS quarts) 9.4{9.9} 9.2{9.7)

EXPANSION TANK
Pressure valve capopens ,,.,.,.,,,,.,,,.,..,....,..... in al Type 1 kPa(psi) 65-85(9.2-12.1) 7 {1.01 Type2 kPa{psi) r00 {14.2) 7 {1.0)

THERMOSTAT

)ijo tt:o

Markin9......................... Starts openat ,....,,.,.. to Fully openal O p e n i ng a p . i n . . . . . . . . . s m

87'C 87'C{189'Fl 102'C l216.Fl 8 mm (0.3in)

DRIVE BELTS
Deslgndion (VolvoP/Nl
HC38xl238 (960296-2) HC38x975 (958354-3)
HC38x888 {460431 s)

3 C o o l i n gr a n 4 Powersteo.ingpump

TIGHTENING TOROUE
C o o l i n gf a n

Hc38x800 (958302-1) 9

Ir. lbs. 6.6

1l

Special tools

Special tools
999 lDdcription-U.s
18Ol-3 | Stand.rd h.ndle: lsed with drift 5207 and 5208

261G3 | Lift be.m: rcmovingfinslalling engin 2901-0lC16mpinsplisrc{2x):clampinswatrhoseswhenremovinsintecrionpump 2903.6 | Oiltlltor wl6Dch 4090-0 | Pullet:removingpilol bearins 5006-5 | Lifi br.ckst: rplacing tronl nsinemounts 5033-9 | Support{2xl: for lilt braclt5006
5112.1 | Loc*ing 6sdo.: locking flywheel

51154 | Lift hook: usedwith ltft bracket 5006 5185-7 | Lift hoolr lronr: removing/inslallins nsin 5186.5 | Lift hoo*, lsar: ,movins,4nstaltins ensine 5147.3 I Wronchr vibrationdEmoer 5188.'l I Wr6nchwith oxt nsionarm: lor vibraliondampercenterbolt 5190-7 | Giuse: instslling camshaft pr6ssur6 5191-5 | Adapter:connoctins ssuse punp sear 51$n I Siop: lockihsinjecrion pump 5194.9 | Holder:for dial indicalor when adjueins injction 5195.5 | PlisB: rcmovinsvalvediscs

Specialtools

5006,5033,5115

5185,5186

5187,5188

5194

5t95

't3

Special tools

999 5196.4 5197"2 5199-8 52004 5201"2 520/t-6 5202-0 5203-8 5205 l'207-t 5204-7 5233-7 523/t3 5235-0 9950-0 P.B3 roolj for valvetappets Balt tonsiong.uqo: timing ge8rbeltsand pump drive Wr3nch: gears front and rearcamshafi Adapter:installing cEnkshaft front sealand camshaft sals g6arand pump gear Wr6mh: centernut on rearcamshafl pump Pullor:pump gear,injction P0llor;for idlr pull6y Centerins sh.ft: for clutchdisc P{ller: for crankshaft front ssl Drift: installing nsedlgbarjnsin crankshaft Drift: installing crankshaft seal rear GuidapiB, M t l bolts {4x):installing cylinderh6ad GuidepiB, M t2 bolG {4x)rinstallins cylind6rh6ad Tool lor removing suide ping Adapter:gnsinelpm. Usedwirh VolvoMonotstBr

't4

Specialtools

5233,5234 9950

9950

Group21 Engine Contents

Assembly Group21 Engine

Contents
In-car
Valveadjustment.,,..,..... Basicsettingof sngine... Cylinder head,removaI disEssembly ................... cleaning-chscking .......... asssmory ........................ insta11ing......................... tightening torquss,....,,... gearsand pump)........................ Drive beltsltiming belttension ....,,,,,,.,.......,, rep1acement.................... Camshaft, rmoval insra11ing......................... Camshaft sea replacemenl, oil ls, Iront.,,,...,,..,,...,,,. Pilotbearing incrankhaft, replacement .......,....,.,.. replacement, front,,..,,...,,...,,.. Crankshaftoil seals, Vibration damper, removal, insta11in9,,..........,....... Engine mounts, rep1acement,,,.,,,.,,....,,...,,...,,...,,...,

Operation
A1-10 B1-11 c1-21 D1-20 E1-11 G1-16 H1-38 K1-5 Ll-35 t\41-11 N1-27 o1-21 P1-21 o1-7 R1-21 s1-11 T1-10

Page
17 19 22 28 33 36 41 45 57 58 60 71 74 81 88 94 96 103 106 110 'r11 '114

u1-4

Replacement engine of
Removal .,...,,.......,...,....,. Insta11in9 ........................

x1-33

Group21 Engine
Compression test

A. Compression test
Specialtool:5191

A1 Disconnectwire lrom stop valve on injection pump

T h i s s t o p sf l o w o f f u e a n d p r e v e n r s ] n n e c e s s a rs p i | t y ase.

A2 Remove vacuumpumpand pump plunger

A3 Disconnect fuel detiverypipes

Cean all connecrions arefu y before disconnecring c D i s c o n f e c ip i p e s a n d p l u g a l l c o n n e d i o n sr o p r e v e n r d i r i f r o n r e n t e r l n gs y s t e m .

11

Gtoup 21 Engina Compression test

44 Removeiniectors P/N Use27 mm socket {Volvo 1158146}. they otherwise will Liftouthat shields undsriniectors tesl. compression beblownout during

A5 testel Connectcompression adapter heatshield incylindr and head screwin Placea 5191. Ighten to 70 Nm {50ft lbs). tester adapter. to connect compression A6
Run engine and record compression Compression Min Max differnce between = 3.2MPa{455psi} = 2.4MPa(341 psi) = 0.8MP.(114 psi)

A7 Installiniectors in new shields cylinder head, seefig. Install Place heat to injectors. Torque 70 Nm (s0 it. lbs).

A8 Reconnect deliverypipes torque Nm(18 lbsl. 25 ft Tightening

A9 Reconnect wire to stop valve

r'.l0 pumP Installpump plungorand vacuum pumpO-ring. Check replace

18

Group 21 Engine Valve adjustment

B. Valveadjustment
Special tools: 5195, 5196

V a l v e l e a r a n c e u s t b e c h e c k e d / a d i u s t e di e rc o m p l e t i o n f r e p a i f s u c ha s g r i n d i n gv a t v e s c r a n k s h a frre p t a c e m e n t c m 6f o s , etc., a n d a l s oa f t e r6 0 G - 1 , 2 0 0 i l e s ( 1 , 0 0 G - 2 , 0 0 0 ) . m km

B1 Removevalve cover B2 Turn engineuntil cyl. 1 is at TDC- injection

A w a y s u s et h e v i b r a t i o nd a m p e rc e n t e rb o l t t o t u r n t h e e n g i n e .2 7 m m s o c k e to r w r e n c h 5 1 8 8 . B o t h c y l i n d e r1 c a m s s h o u l d p o i n l o b l i q u e l yu p w a r d s .

B3
Check valve clearance lor cyl. 1 Checking values Coldensine Exhaust 0.15-0.25 0.0060.010 0.350.45 0.01,t-0.018 0.20-0.30 0.008-0.012 0.400.50 0.016-0.020

Exhaust

a il a !

D20

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

o24
f r I r

Alf

Alt
19

Group21 Engine Valveadjustment

Incorrect clearance (BZBS ) B4 Tum engineapProx.1/4 iurn whensetting mustnot be at top deadcenter Piston piston will valves contact otherwise valveclearance, is deprsssed whentappt

B5 Dopress tappets point inward. using until Turn tappets grooves slightly access discs. to to tappets obtain 5196, depress tool

B6 Removedisc Use5195.

B7 thicknessol disc to be used Calculate whensetting: Valve clarsnces

Cold ngine Exhaust 0.20 0.40 in 0.008 0.016

Exhaust

0.010 0.25 0.018 0.45 Calcuold discwitha micrometer. Measurethicknessof of latethickness new discto be used,seeoverleaf.

20

Gtoup 21 Engine Valve adjustment

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

B8
Position new disc and removepliers Discshouldbe lubricated n d i n s t a l l e d i t h s i z em a r k s a w B9 Check/adjust valve clearanceIor remaining cylinderc Checuadjust following in order: D 20. 1-2-4,5-3 D 24, 1-5-3-6-2-4 lmportantl Do not forget to rotatecrankshafl turn 1/4 before checUadiusting clearance. valve

810 Recheck valve clearance all cylinders for

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

811 lnstall valve covet if Usenew gaskets required.

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

iY:'I,l d.!

21

Group21 Engine Basic setting

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

in are Thefollowingoperations described this sectionl - settingcamshaft positionin rel6tionto crankshaft - settingtensionof drive belts{front and rear) - injection timing. the if, Engines shouldbe basic-set by adjusting pump,it possible obtain the correctinjectiontiming. to is not (Camshaft seningmay havs changed)

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

C2 'l is at TDC - iniection Turn engine until cyl. da Alwaysusethevibration mpercenterbolt to turn ihe engine. 27 mm socketor wrench5188. pointobliquely upwards. I Bothcylinder camsshould Flywheel 0 mark. at

22

Group 21 Engine Basic setting

Lift ofi pump belt Slacken mountingbolts for injectionpump release Tightenone boll so t h a t p u m p belt tensionremains upperposition. in Lift off belt.

a, ,":'trtiiiiiiiiii
c4
Removecamshaftrear sprocket Hold sprocket pos;tion 5199 unscrew in with and nut
with wrenh 5201. Take care not to rotate camshaft.

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

c6
Set belt tension
A d j u s tt e n s i o nb y m o v i n g c o o l a n tp u m p . U s e g a u g e5 1 9 7t o c h e c kb e l t t e n s i o n .A t t a c hg a u g et o b e l t a n d s e t t o 1 2 . 5u n i t s . S t r e t c hb e l i u n t i l m a r k o n g a u g e p t u n g e ri s f t u s hw i t h D e p r e s s e l ts t r o n g l y w i t hh a n da n d r e c h e c U a d j u se n b tl

23

Group 2l Engine

Basic setting

C7 Set camshaft position gaLrge Insert 0.2mm a Place 5190 rearof camshaft. at (0.008 ieelersausebeneath sideof sauseto lefi in) for compensate timinggearclear;nce. position. Camshafi;s now setat correct

C8

Make sure cyl. no. 1 is at top dead center

Check 0 mark on flywheel and adiust necessary. if

)r
C9 Tighten camshaft front sprocket Use5199 prevent to sprocket fromturning. Makesure that camshaft does not turn. Torquecenterbolt to 4s Nm (33ft lbs).

c10
Removegauge 5190 and leeler gauge

cl1 Disconnect cold start device Slacken screw Push 1. lever forward rotate and sleeve
90". Notel Do not turn screw 2 otherwiseit will be necessary removecold startdeviceand resetit on a to

Group 21 Engine Basic setting

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

c12 Basic-set iniectionpump pump mountins (Ailen = 6 mm). bolts key Align S acken pump bracket turning by in and marks pump mounling
Retighten o!ntin9 bolts. m

- v -.t";; .)!\\./.)

-.l\t'-iHi-

.-

-.-

ilo ,,
/:)a>L I

c13
Sel dial indicator zero. Lock pump gear at cyl. 1 injection using stop 5193 Unscrew and removeplug from injection pump dis(range tributor. Install holder5194 dialindicator and 0-3 mm).Setgauge approx. mm. to 2 Turn pump gear clockwise until mark on gear and mo'rntingbracket coincide.

T h e n t u r n p u m p g e a r b a c k s l i g h ty u n t i l m i n - r e a d i n g registers n dial indicator. o Set indicator to zero. T u r n p u m p g e a rc l o c k w i s en l i l m a r k o n g e a ra n d p u m p ! m o u n t i n g b r a c k e tc o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n w i t h s r o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n t o

c14
Install camshaft rear sprocket and belt bo but stil Tighten cenler t by hand, it should be possi_ on b e to turn sprocket camshaft.

25

Group Engine 21
Basic setting

c15
Set belt tension A d j u s tt e n s i o nb y m o v i n g p u m p . U s e g a u g e5 1 9 7t o c h e c kb e l t t e n s i o n . f t a c hg a u g er o A b e l t a n d s e t t o 1 2 , 5u n i t s . S t r e l c hb e l t u n t i m a r k o n g a u g e p t u n g e ri s f t u s hw i r h D e p r e s s e l i s l r o n g l yw i t h h a n da n d . e c h e c U a d j u s r r e n b

c16
Set pump and tighten camshaft rear sprocket U s e5 1 9 9t o h o l d s p r o c k e tT o r q ! e w r e n c hs h o ! d r r ea t . r i g h i a n g l e l o w r e n c h 5 2 0 1 o t h e r w i s et o r q u e w i l l b e U s i n g 5 1 9 9 ,l u r n s p r o c k e ts o w y c l o c k w i s eu n l i l d i a l D 2 0 . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . .0 . . .0. .m. . . . . .. 0.3 1 i5 . 8 .m . : 0 . . n i D 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0...7.0m m. =. 0 . 0 2 7 6n . . ..... . D 2 4 U S A , / C a n a d a 1 9 7 9 1 . . . . . . .. 7 0 m m = 0 . 0 2 7 6 i n 198 0 . 1 9 8 2 - . . . . . . . . . . .0 . 8.5 . m : 0 . 0 3 3 i5 . . .m n H o d s p r o c k e itn t h i s p o s i t i o na n d t o r q u eb o h t o 1 0 0N m ( 7 3f t . l b s ) .T a k ec a r et h a t c a m s h a f i n d s p r o c k e d o n o t a t

c17 Remove stop5193 trom pump gear

ct8
Check pump setting T u r n e n g i n et w o f u l l t u r n s u n r i c y t . 1 i s a t l o p o e d o c e n t e r- i n j e c t i o na g a i n . l f e n g i n e i s t u r n e d r o o r a r r m u s t b e l u r n e d b a c ka p p r o x .1 / 4 1 u r na n d t h e n t o z e r o m a r k o t h e r w i s es e t t i n gw i l l b e i n c o ( e c i . D i a i n d i c a l o rs h o u l d s h o w : O 2 0 . . . . . . . . . . . . . . . . . . 0...7 . .0 . . 3 m m = 0 . 0 2 9 F 0 . 0 3 2 7 i n . .5. 8 D 2 4 . . . . . . . - . . . . . . . . . . . . 0...6.F- . 7 3m m : 0 . 0 2 5 6 - 0 . 0 2 8f7 . . .0 i D 24 USA and canada 1 9 7 F 8 1 . . . . . . . . . . . . . . . .0...6 . - 0 . 7 3 m m = 0 . 0 2 5 60 . 0 2 8 7 i n . .5 1 9 8 2 . . . . . . . . - . . . . . . . . . . . . . . . . 0 . 8 2m m = 0 . 0 3 2 3 - 0 . 0 3 5n 90 i4 Correct reading: Tighren injeciion pump mounting b o l l s .P r o c e e d o C 1 9 . t r n c o f t e c tr e a d i n g : B e a d j u s ta c c o r d i n gr o i n s r r u c t i o n s

26

Group 21 Engine

Cylinderhead,removal pumpsetting: Readlusting

Setting valuesi D 20 ......-.............-....-....................... 0.80 mm = 0.0315 in D 24 .....-....-....-........-....-...-...-....-...... in 0.70 mm = 0-0276 D 2 4 U S A a n d C a n a d a 18 1 . 9. . . . 0 . 7 0 m m : 0 . 0 2 7 6 i n 97. 1982.......... mm = 0.0335 0.85 in

-trnjE+: -i;6't;
$tl

Readinglessthan specified: purnp Slacken mounting boltsandlurn pumpinwards to obtaincorecr value.Tighten mounring boltsand repeat check pumpsetting. of

Beadingmore than specified: pumpmouling Slacken boltsandturnpumpoutwards untildialindicator showsapprox. D 2 0 . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . .m m = 7 00 2 7i 6 ...0. 0. n D 24 ..........................................-...-.. 0.60 mm : 0.0236 in D 24USA,/Canada l97F81............. mm =0.0236in 0.60 1 S 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m = 0 . 0 2 9 Thnturn pump inwards until specified ue is obva tained. Tighten mounting boltsand recheck punrp setting. NotelInjection pumpmustrot betapped knocked or as thiswil altersetting.

c19 Remove dial indicator and holder 5194. lnstall plug with new seal Tishtening torque Nm (6.5 lbs). 9 ft

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

c21 Install valvecoverand timing gearcovers

U s e n e w g a s k e t si f n e c e s s a r y .

/ Qa,s ' zTazzzz

II

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

21

Group21 Engine
Cylinder head, removal

D. Cylinderhead,removal
5201 Specialtools: 5199,

D1
Disconnect negative lead from battery Remove engine splashguard.

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

D3 Disconnect: - exhaust fromfrontbranch pipe pipe

-air filter cover with intake hose and crankcase

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

2a

Group 21 Engine
Cylinder head, removal

D5 Draincoolant from engine

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

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

D7 Remove vacuumpump and pump plunger

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

D8 pipe Remove delivery tuel

C l e a n l l c o n n e c t i o n sh o r o u g h l yb e f o r ed i s c o n n e c t i n g a t p R e m o v e l l p r e s s u r e i p e sa n d p l u g e n d s l o p r e v e n t i n d a f r o m e n t e r i n gf u e l s y s t e m .

29

Group21 Engine
Cylinder head, removal

D9 Disconnect from cylinder head: -wire for temperature gauge sender -wire for glow plugs copper connecting for rearglow plug strip - feturn hosefrom rear iniector - wirefor temperature gauge sender rear cylinder at of

D10
Remove: -timing gearcovers (front+ read

Dl1 Tum engineuntil cyl. 1 is at TDC- injection

A l w a y su s e i h e v i b r a t i o n a m p e r c e n t e r o l t t o t u r n t h e d b 27 mm socket or wrench 5148. B o t h c y l i n d e r ' l c a m s s h o u l d p o i n t o b l i q u e l yu p w a r d s . Flywheelat'0'mark.

D12 Remove retaining screws from belt cover on cylinder head Take carelhat washer innerscrewdoes falldown on nol intolowertiminggearcasecover. (Late typeengines not havethiswasher). do

30

Group21 Engine
Cylinder head, removal

D13 Removebelt from camshaftsprocket

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

D14 Bemovecamshaftfront sprocket

Use5199 holdsprocket posjtion to in whentoosening bolt. IMake surethat camshaft does not rotate. Tap sprocket free it from camshaft. to

D15 Lift off pump belt

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

D16 Removecamshaftrear sprocket

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

31

Group 21 Engine Cylinder head, removal

oo
@o

oo
oo
D20

A,

Ol
Remove cylinder head

D17

o@

T i g h l e n i n g e q u e n c eo r c y l n d e r h e a d b o i s . s f Bolis musl be slackenedln reversesequence.

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

@@,o @o0

o
D24

oo@

ooo
D18 Place cylinder head on wooden blocks Do not restcylincler head

D19 Clean gasket surfaces on cylinderhead and cylinderblock

D20
Check for damage and warp U s e a s t r a i g h te d g e a n d f e e t e rg a u g e . R e p l a c e y i n d e r h e a di f w a r p e x c e e d s : c - l e n g t h w i s e . 5 m m { 0 . 0 2i n ) . 0 - crosswrse .2mm (0.008n). 0 i

0
--:(g=

32

Group21 Engine
Cylinder head, disassembly

N o t e l S m a l l c r a c k s( 0 . s m m = 0 . 0 2i n ) d o n o r w a . r a n r r e p l a c e m e no f c y l i n d e rh e a d s i n c et h e y d o n o t i m p a i r t F o r g a s k e tr e p l a c e m e n t n l y s e e " C y l i n d e r h e a d i n o s t a l l a t i o n "p a g e 4 5 .

E. Cylinder head,disassem bly

E1 Removeintake manifold,exhaust manifold and gasket

E2
Remove injectors R e m o v ed i r l a r o u n d i n j e c t o r s . D i s c o n n e cftu e l l i n e s . B e m o v ei n j e c t o r s , 2 T m s o c k e t .L i f t o u t h e a ts h i e l d s m l r o m c y l i n d e rh e a d .

i I

33

Group21 Engine
Cylinder head, disassembly

E3 Removecamshaftbearingcaps 1 and 4

E4
Remove camshaft bearing caps 2 and 3 placing load on uneven 1o nuts Slacken crosswise avoid

E5
Lift awav camshalt and remove oil seals

E6 Lift out tappets

e N o t e l D o n o t i n t e r c h a n g t a p p e l s .M a r kt a p p e t ss o t h a t i theycan be installedn same position.

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

Group21 Engine
Cylinder head, disassemt'/y

E8 Tap out swirl chambers (6 in punch mm - 0.24 diameter), a Use longnarrow

l e n g t h1 5 0 m m ( 6 i n ) .

{r*,t
E9 valve springsand valves Remove
pans. Do lmportant! not intetchange tool compressor with a special valvesprings Depress

- upper spnngseat - springs

E10 Removesealstrom valve guides tool Use 5219,

D
El1

Removelower valve spring

U s e a p a i r o f e x t e r n a l o c k r i n g pliers with flatjaws.

35

Group Engine 21
Cylinder head, cleaning - inspection

head,cleaning- inspection F. Gylinder

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

F2 Checkcamshaftend float Usea dialindicator. cdp.lorqueto 20Nm Posir ransnaildrd rr"ld redr or

,rb rbs,. n

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

0
F3 Check discs d C h e c kd i s c p l a y . B e p l a c e i s c i f w o r n o r s c o r e d . I n s t a l ln e w d i s c sw i t h n u m b e r sf a c i n g d o w n , l o w a r d s m n . . . 6 . C l e a r a n c e ,e w p a r 1 s . . . . . . . . . . . . . . . . . . . .0...0.1 .- 0 . 0 4 6 m ( 0 . 0 0 0 6 - 0 0 1 8i n ) 0

36

Group21 Engine
Cylinder head. cleaning - inspection

Check tappets P acetappets cylinder in head Check andclearance. fit mm 0.003in) Clearance, newparts 0.025-0.075 (0.001

Check valve springs

8trre

Length 33.9 28_6 18.3 lin) (1.334) (1.126) (0.720) 0 61 17 209-231 {lbs) l0) { 1 51 7 . 5 ) t41 52.2)

Outersprings Length (in) (1.583) 40.2 (1.283) 32.6 (0.878) 22.3 Replacingvalve guides OperationsF 6-8

0 I67-185 433 479

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

F6 Press valveguide out

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

Ptess in new valve guide L u b r i c a t e a l v eg u i d e . v l j s e d r i f t 5 2 1 8 .P r e s si n f r o m c a m s h a f ts i d e . P r e s si n g u i d e u n t i l f l a n g e o n g u i d e c o n t a c t s y l i n d e r c h e a d .I n t h i s p o s i t i o np r e s sf o . c e m u s t n o l e x c e e dl t o n since f ange may break off.

37

Group21 Engine
Cylinder head, cleaning - inspection

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

aftsrvalveguide Valvesand seatsmust be ground-in

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

wr-

F9 Machineg nd intako valvos Edge intake of valve must belessthan mm (0.02 not 0.5
In). lmportant!Exhaustvalves stellitecoated are and must not be groundby machine. Grind-invalveon seatwith grindingpaste.

F10 Mill or grind valv6 seats Grindto 45'. Contact surface{a) must be: -2.0 mm {0.08in) for intakevalve -2.4 mm {0.09in)for sxhaustvalve. ll contactsurfaceis too wide reducareawith a 15q lmponam! Outer diameterof cutter must no! Bxceeo 35,2mm (1.39in) for intakevalve satsand 33.2mm in)for sxhaust valvessats. {1.31

1.5mm {0.00in)

Ftl gap betweendisc and cylinderhead Measuae surfaco Gap= max1.5 mm 10.06 in).
Replace seatand possibly valve if gap is too Iarge. NotelTwo valvstypes are available, G3. see

38

Group21 Engine
Cylinder head, cieaning - inspection

F12

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

.3F{'

'

q.

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

Cfeancombustionchamber

F13

ahF' cleaninS. Toge sealnJsl be clear vis:ole ol v Remove valve seat F14

Mill vave seat, using cutterssuch as Mira {P/N Make to instructions. 9986045). Refer manufacturer's headis not darnaged. surethatseatin cylinde. cleansurfaces thoroughtr. ,rU

Measure diameter of seat recess in cylinder head and of valve seat to Usean internalmicromeier measureseat recess Standard (production version) mm Diameter, recess, (in) seat 37.000 in1ake.................... 37.016 i.1.4561-1.4513) 1.2994) 6 33-000-33.01 11.2992 exhaust................ 37.09(F37.105( 1 . 4 6 0 21 . 4 6 0 8 ) inrake.................... 05 ................ 33.090-33.1 { 1 . 3 0 2 8 - 1 . 3 0 3 3 ) exhausr
mm = 0.00290 041in) Oversize ( r e p l a c e m e nP a r t sv e r s i o n ) t , D a m e t e r ,s e a t r e c e s s m m ( r n J 3. .0 i n 1 a k e . . . . . . . . . . . . . . .7...2 . 0 - 3 7 . 2 1 6 \ 1 . 4 6 4 6 - 1 . 4 6 5 2 1 3 . -. 113411-1 0171 e x h a u s r. . . . . . . . . . . .3.3 - 2 0 03 3 2 1 6 i n t a k e . . . . . . . . . . . . - . . . . . . . 3 73 2 93 0 5 . 7. 0 333 exhausi...............33.290 05 (1.4681-1.4687) (1.3106-1-3112)

b v W h e n r e p l a c i n g a v e s e a l s :t h e i n t e r f e r e n c e e t w e e n h t h e v a l v es e a ta n d i t s b o r e i r t h e c Y l i n d e r e a ds h a l lb e 0.074-0.10smm (0.0029-0.0041in) I e valve sear d am e t e r m u s t b e 0 . 0 7 40 . 1 0 5 m m ( 0 0 0 2 F 0 0 0 4 1 n ) g r e a t e ri h a n t h d i a m e l e ro f t h e b o r e i n t h e c y l i n d e r c h e a d .R e p l a c e y l i n d e rh e a c li f c e a r a n c ei s t o o s m a l i M i l l s e a t r e c e s si f i n t e r f e r e n c es t o o l a r g e . 39

Group21 Engine
Cylinder head, assembly

F16

Heatcylinderhead (212'F). Heat '100'C to

F17 Placenew seat in installationtool

Use drift 5220 for intake valve seats and 5221 for ex-

lr
F18 Cool valve seat
Wear protective gloves and safety glasses. Use liquid carbon dioxide to cool seat down to -70'C (-94"F).

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

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

F21 Grind valvesand mill seats

S e ei n s t r u c t i o n s n p a g e3 8 , o p e r a t i o n s F ] 2 o F

40

Group21 Engine Cylinderhead,assembly

G. Cylinderhead,assembly
New cylinderhead

a Newcylinderheadmust be the sametype as the old. Cylinderheadsdesigned use with lvl 12 for bolts must not be usedwith M '11bolts. Cylinderheadscan be identifiedas follows (see illustration left): at Number series followed B = M 11 by - Numbe.seriesfollowedby C = M 12 LJSA,/Canada has a differenttype of cylin, 1982der head andswirlchamber. Swirlchamber and its boreis 2 mm (0.080 smaller diameter in) in

Newcylinderhead Opetationcl

cl

Installoil ieis and pin studs in cylinderhead punch. Carelully in oiljetsusing brass tap a Note! Turnouterjets pointacross to cylinder head, see fis
lmportantl Check specification ;nd type of cylinder h e a d .M ' 1 2b o l t s m u s t n o t b e u s e d w i r h M 1 1 b o l t s . Differenttype cylinder heads are used for LJSI,/Canada.

G2 Checkvalve stem posilionin relationto camshaft Thismeasurement iscarried to ensure out thatthere is
sufficient adjustment lattitudefor valves. gauge Place with largest 5222 diamter ring,on cylin(Small der he8d. ringis for B 17-B23 engines.) Notel F.ont bearingrecess diameter'is largerthan others.Makesurethat gaugeis positio.ed correctly. Taking eachva,vein tu.n, check that stem doesnot gauge. thishappens, grindvalvestem. conlact lf

Vslve length, mm {in} New Min I n t a k e v a 1 v e . . . . . . . . . . . . . . . . . . . ' ( 4 .4 .2 6 ) 1 0 4 . 3( 4 . 1 0 6 ) 10 1 8 4.11 E x h a u s t v a l v e . . . . . . . . . . . . . . . . ' 1(0 4 . 6 8 i 1 0 4 . 1( 4 . 0 9 8 1

4l

Group2l Engine head,assembly Cylinder G3 Early and late tvpe valves.valve collets (locks) and upper springseats
E a r l yt y p e v a l v e sa n d c o l e t s h a v eo n e l o c k i n gg r o o v e whereas late tYpes have three a O n l y l a t et y p e s a r e a v a i l a b l e s s p a r e p a r l s a C o n s e q u e n t l w h e n i n s t a L l i n g n e w v a l v e ,t h e c o l l e t y w a n d u p p e rs p r i n gs e a l m u s t a l s o b e r e p l a c e d i t h n e w r N e w s p r i n gs e a t sa r e e i r h e r c o p p e c o a t e do r c h r o m e d E a r l yt y p e s a r e b r i g h t o r b l a c k .

I I
I

f(

0
G4 lnstalll - upper flanged sideup. spring seats, va lnstaLl ve stemoil seal. oilseal must wheninstailing Protectivesleeves beused pl.cevalvein cylinder head andplace To install valve, oil protecrive to sleeve stem.use tool 5219 install on seal. abutflange seal, notethattool should

l, (

I
G5 lnstall: inner and outervalvesp.ings

seats and upper spring Two ol lmportantl types valves,

Group21 Engine
Cylinder head. assembly

ra

( .., e,
air
Install swirl chambers C h e c kt h a l s t e e lb a l l i s i n c h a m b e r . L fn o t , i n s t a l ln e w s w i r l c h a m b e f .

G6

M a k e s u r e t h a t b a l l f i t s i n s l o t i n c y l i n d e rh e a c l . a p T down swirl chambers. l m p o r t a n t ! S p e c i a s w i r l c h a m b e r s ( d i f f e r e n td i a 1 m e t e r )f o r U S A / C a n a d a 9 8 2 - .

G7 lnstall: - glowp ugs.Tishtening torque Nm (30ft lbs) 40 (2X). temperature senders Samelypefrontandrear - connecting fange for radiator hose(Allen5 nrm). Install newgasket. Tightening torque Nm (7ft bs). 10 - lfting eyes.

G8 Installtappets with shims Smear iappets andshimswith oil before instaa!on. Number shimsshould on facedown. Check tappets that y slideeasi withoutsticking.

G9 Placecamshaftin cylinderhead Lubricate contact surfaces camshalt bearings. of and Place 5'190 rearof camshafl. al lmportantl Both 9au9e y cams number cylinder for 1 mustpointdiagona up,

43

Group21 Engine
Cylinder head, assenbly

G10 caps2 and 3 Install camshalt

is Install capscorrectly, center off'sel. Holdcam Tighlen nutscrosswise avoiddistortion. to in wilh gauge 5190 rearwhentighten at shaft position gauge Remove 5190. Gl1 Press in new camshaft oil seals Applyoil to oil seals. posilion. Donotpush sealsto in bottom Makesurethat seasare"square",0 GI2 Install camshaft caps 1 and 4 o M d l ec J r e n a r " eL h r J 5 l w i s nfe r c a r s h . l c a p 4 r l s I colrecl.v. G13 Torque all four caps = Torque 20 Nm (15ft lbs). G14 Tap in oil seals to bottom ma 5200 anda plastic lei use adapter ^ 0

G15 Installiniectors
headTurnshieds as shieds in cy inder Place heat new Torque 70 Nm {50ft lbs) ro Screw injectors. in in,ectors fuel Reconnecl deliveyinesbetween
w h i s a c l v i s a b t o c h e c kc o n d i t i o no f i n l e c i o r s h e n e o .econditioning y inder head. See instructions n c page153.

0 0

Gt6 Install exhaust branch pipe and intake mani{old U s e n e w g a s k e t sa n d n u t s . I n s t a l lg a s k e t sc o r r e c t l Y . B r a n c hp i p e g a s k e ts h o u d b e t u r n e d w i t h r a i s e de d g e o u t w a r d s ,f a c i n g b r a n c h p i p e . I n t a k em a n i f o l d g a s k e t s h o | ]d b e l u r n e d w i t h g r e e ns i d e f a c i n gc y l i n d e rh e a d . T i g h t e n i n g o r q u e 2 5 N r n ( 1 8f t l b s ) . l

Group Engine 21
cylinder head, installing

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

?/'--'\r

S--:'l Q4t

)io.iQ

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

H2 lnstall guide pins in cylinder block 5233for blockswith M 11 bolts. 5234for blockswith M 12 bolts. Twoouterpinsholdgasket position. in Cylinderhead is prevented from slidjng and clamaging gasketby two innerpins, lmportantlUse all four pins, locatedas illustratsd.

H3 Install new cylinderhead gasket Thres dil{srnttypes available, aremarked are and with notches. Typeto be fitteddepends pistonheight on above cylinder block. with Uses8megasket type (no,notches) before, as OBEN facing up.

45

Group2l Engine
Cylinder head. installing

Observe dale code on gaskel and packet.Gasket must b e u s e d b e f o r et h i s d a t e . O n l yg a s k e t s i l h c o d eM O o r l a t e rm a y b e u s e do n D 2 4 w

_0

B
D E

I
| MO

r=r98r
2=1982

= 1980

t*
I I

G Sept Oct Nov Dec J L M' 198 p o T o a v o i d i m p a i r i n gs e a L i n g r o p e r t i e s f g a s k e td o n o t o p e n p a c k e tu n t i l g a s k e ti s t o b e u s e d . p d T a k ec a r en o t t o d a r n a g e a c k e ta n d c a L r s e a m a g el o g a s k e t ,( t e f l o ns t r i p ,r u b b e r s e a l ) .

3:
=.-

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

(in} mm {in) notches thicknessmm (0_026-0.031 ................(0.055) 0.67-0.80 I 1.4 ) (0.032-0.03s) ................(0.059) 0.81-0.90 2 1.5 0.9't-1.02(0.036 0.040) 3 ................{0.063) 1.6 rl'

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

46

Group21 Engine
Cylinder head, installing

H6 Position camshaft Selcamshaft lhat number cylinder at injection 1 is so (both pointdiagonally cam lobes should upwards). Prevent from moving with stop 5190. camshaft lmportant!Camshaft must be lockedotherwise valves

Cylinder head bolts T w o t y p e s o f c y l i n d e rh e a d b o t s a r e i n u s e . E a r l yt y p e b o l t s h a v e M 1 1 t h r e a d s T h e s eb o l t sc a n b e . F r e u s e dw i t h n e w w a s h e r s - i tw a s h e r sw i t h c ! p s h a p e f a c i n gu p . L a t et y p e b o l t s h a v e f M1 2 t h r e a d sa l o n g e n t i r el e n g t h . m T h e s eb o t s m u s t n o t b e r e u s e d W a s h e r s a y h o w e v e r

M11

o
i!

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

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

47

Group21 Engine Cylindet head, installing

oooo9/@

D20
H8 Toique cylinderhead bohs adiaTighten boltsoneat a timein orderspecified all proceeding nextstage. csntbofore wjth

@o.r'o'o@@

n a

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

't1s9082

12-sided wrenchP/N 1159082-5

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

Tightenin four stagesl r 40Nm=29filbs 2 60 Nm = 44 ft lbs 3 75 Nm = 55 ft lbs 4 angle-tighten 18{f in one movementwithout stopping.Seeillustration below:

48

Group21 Engine
Cylinder head, installing

H9

Connect copper connecting stdp lor two rear glow plugs

o
rD

H10 Installbolts lor cover H11 Installcamshaftsprocketand belt Pullbeltto ensure it sitscorrectly crankshaft that on
geaf. Placebelt overcamshafi sprocket and position sprocket T i g h t e nc e n t e rb o l t b y h a n d ,b u t i t s h o u l ds t i l b e p o s s i ' bleto turn sprocket n camshaft. o

Hl2

Set belt tension

A d j u s tl e n s i o n b y m o v i n g c o o l i n g p u m p . U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g er o b e t r a n d s e t t o 1 2 . 5u n i t s . S t r e l c hb e l t u n i i l m a r k o n g a u g e p u n g e r i s f u s h w i r h D e p r e s s e h s t r o n gy w i t h h a n da n d . e c h e c U a d j u s t t e n b

H13 Markesure cyl. 1 is at top dead center

C h e c k ' 0 m a r k o n f l y w h e e a n d a d j u s ti f n e c e s s e r y .

Group 21 Engine Cylinder head, installing

H14 gauge gauge Place 0.2mm feeler a beneath 5190 Insert blade beneath sideof gauge compensale left to gear fortiming clearance. mm = 0.008 0.2 in.

Ht5
Tighten camshaft front sprocket Use5199 prevent to spocket from turning. Torquecenterbolt to 45 Nm (33ft tbs).

,)a )e

H16 Removegauge 5190 and feeler gauge

H17 Disconnect cold start device

S l a c k e n c r e w 1 . P u s hl e v e r f o r w a r da n d r o t a l es l e e v e s 90'. N o t ! D o n o t t u r n s c r e w2 o t h e M i s e i t w i l l b e n e c e s s a r y t o r e m o v e c o l ds t a r t d e v i c e n d r e s e ti l o n a t e s t b e n c h . a P r e s sl e v e rb a c k a g a i n s ts t o p .

u)l
i')l

H1a Basic-set injectionpump

p S l a c k e n u m p m o u n t i n gb o l t s ( A l e n k e y = 6 m m ) A l i g n m a r k so n p u m p a n d m o u n t i n gb r a c k e t y t u r n i n g b p u m p . R e t i g h t e n o u n t i n gb o l t s . m

5A

Group 21 Engine Cylinder head. installing

H19

Set dial indicatorzero. Lock pump gear at cyl. I injectionusing stop 5193
pumpdisrri U n s c r e wa n d r e n r o v ep l u g f r o m injection
I n s t a l lh o l d e r5 l 9 4 a n d d i a l i n d i c a t o r( r a n s e0 3 m m ) . S e t g a u g e t o a p p r o x .2 m m . T u r n p u m p g e a r c l o c k w i s eu n t i l m a r k o n g e a r a n d m o u n t i n gb r a c k e t o i n c i d e . c T h e n t u r n p u m p g e a r b a c k s l i g h t l yu n l i l m i n r e a d i n g registers n dial inciicator. o Set indicator o zero. t T u r np u m p g e a rc l o c k w i s e n t i l m a r ko n g e a ra n d p u m p u m o u n t i n g b r a c k e tc o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n w i t h s t o p 5 1 9 3 .( l n s e f ts t o p t h r o u g h p u m p g e a r i n t o

i;;$d

H2A Installcamshaftrear sprocketand belt Tlghten center by hand, it should be possi bolt but still b e to turnsprocket camshaft. on

H21 Set belt tension A d j u s tl e n s i o n b y r n o v i n gp u m p . U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g et o b e t a n d s e t t o 1 2 . 5u n i t s .S t r e t c hb e l t u n t i l m a r k o n g a u g e p l u n g e ri s f l u s hw i t h s l e e v e D e p r e s s e t s t r o n gy w i t h . b h a n d a n d r e c h e c k / a d j u se n s i o n . tt

5l

Group21 Engine
Cylinder head, installing H22 Set pump and tighten camshaftrear sprocket be should al Torquewrench holdsprocket Use5199to torquewl I be otherwise rightangleto wrench5201 ontiL dial slowlvclockwise turn sprocket Using5199, = D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . - .-. . . 0 8 0 m r n 0 0 3 1 5 i n in 0 70mm = 0.0276 .. D 24 ....................... . .. D 24 USAJCanada = .. . . 197981 ........-................ ... 0-70mrn 0 02761n in 0 85mm :0 0335 .. 1982 ............... . . .. bollto 100Nm and in Hold sprockel thisposiiion torque do (73ft lbs). and thatcamshait sprocket not Take care

H23 from pumpgear Remove stop 5193

)a )e

H24 Check pump setting T u r n e n g i n et w o f u l l t u r n s u n i i c y l . 1 i s a t t o p d e a d a c e n t e r- i n j e c t i o n , g a i n .l i e n g i n e i s t u r n e d l o o f a r i t b m u s t b e l L r r n e d a c ka p p r o x .1 / 4 l u r n a n d t h e n t o z e r o m a r k o t h e l w l s es e t i i n gw i l b e i n c o r e c t D i a l i n d l c a t o rs h o u d s h o w : i D 2 0 . . . . . . . . . . . . . . . . . . . . . . . 7.F.0 . 8 3m m : 0 . 0 2 9 5 - 0 . 0 3 2 7n 0 . . i 0 . . D 2 4 . . . . . . . . . . . . . . . . . . . . . . . 6.F.0 . 7 3m m = 0 . 0 2 5 6 0 . 0 2 8 7n D 24 USAand Canada l7 1 9 7 9 - 1 9 8 1. . . . . - . . . . . . 0...6 F 0 . 7 3m r n : 0 . 0 2 5 6 - 0 . 0 2 8 n . . . i4 m 1 9 8 2 - . . . . . . . . . . . . . . . . . . .0 . . .2.- 0 . 9 0 n r = 0 . 0 3 2 3 - 0 . 0 3 5 n . 8. Correct reading: Tighten injectionpump mounting

W'r

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

)a

pumpsetting: Readiusting 0 . . . . :. . . . 0 . . 5 . D2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 8.0 .m.m0 - . .3.1 . . i.n 0.70 = 0.0276 mm D 24..........-....-................................. n

D 2 4 U S A a n d C a n a9 Ta l g S l 0 . 7 0 m m - 0 . 0 2 7 6 i n l cl 9 in 1982.......... mm = 0.0335 0.85

Readinglessthan specified: pumpmouniing bohsandturn pumpanwards Slacken boltsand Tightenmounilng value. to obtaincorrect settn9s. repeat check punrp oi

52

Group21 Engine Cylinderhead.installing Readingmore than specified: pump Slacken mounting and bolts turnpump oulwards

?.i A.EErj

li6t',t

untildialindicator showsapprox: D20.................................................0.70m D 24 ...--...--...--...--...-...--...-................ in 0.60 mm = 0.0236 197F1981 ......-.. mm = 0.0236 0.60 in D 24USA/canada 1 9 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m = 0 . 0 2 9 5 Thenturn pump inwards until specified valueis ob pompsetrained. Tighten mounting boltsand recheck trng. pumpmustnotbetapped knocked Note!lnjection or as thiswill alterits setting.

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

H26 Reconnect cold start device

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

H27 Install valve cover Usenew gaskets necessary. if

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

zz7:@

ta

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

53

Gtoup 2l Engine Cylinder head. installing

H28 Install timing gear covers ({ront and rearl

)liO
H29 Reconnecttuel delivery pipes Iightening torque25 Nm (18ft lbs).

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H30

Reconnect return pipe to rear iniector

H31 plunger Install and vacuumpump

if Check ring,replace necessaryO to Connect vacuum hose(frombrake seruo); pLrmp. H32 lnstall: wireto glow plug -wires to temperature (2 senders X), one at rearand head. onelo leftof cylinder

ilrlO

H33 Connect: lowerradiato. hoseto radiator - 'rpper radiato. hose - hoses coldsiartdevice cylincler for to head andtheF

54

Group 21 Engine Cylinder head, installing

H34 lnstall air Iilter and connecthoses

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

H35
Connectl branch pipe. Use new gaskets. - splashguard

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

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

U s e g e n u i n eV o l v o b u e - g r e e n o o l a n l t y p e C , d i l u t ( c with clean water in propoltions of 50/50. This mixture helps to prevent corrosion and fic a N e v e rf i l l t h e c o o i n g s y s t e mw i t h w a t e r a l o n e s a T h e c o o l a n l s h o u l d b e c h a n g e dr e g u r a , l y r n c et h c o r r o s i o np r o t e c t i v ea d d i t i v e si n t h e c o o l a n t l o s t h e i r e f f e c ti n l i m e . N o t e ! D o n o t r u n e n 9i n e w h e n l e v e lo f c o o l a n ti s l o w . H i g h l o c a t e m p e r a t ! r e sc a n r e s u l i w h i c h m a y c a u s el h e c y l i n d e rh e a d t o c r a c k .

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

0n v Replacing coolant A l w a y s L r s e y p e C b l u e - 9 r e e n o o l a n t .R e m e m b e rt o t c 7 t r e p l a c e e c a l( P / N 1 3 3 1 4 7 3 ) o n e x p a n s i o n a n k i f n e d

rs voLvo coourrrY* c c00rr6sYsitc r0r uP YIAN B0ur0 iALiw^ $ft rYrtc vl|r0rrrus0u^ 2Pt r/oLvo Motrrt ^Nrcn rw c vrc Mot[ r^Lr

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

H37 Fill coolant C a p a c i t y D 2 0 = 8 . 1 l i t e r s( 8 . 6U S q u a r t s ) : D 2 4 = 9 . 3 t i r e r s( 9 . 8u s q u a f t s ) . F l u s hc o o l i n g s y s t e m b e f o r ea d d i n g n e w c o o l a n t ,s e e G r o u p 2 6 C o o l i n gS y s t e m . S e r d c s o o a r d h e d r e rc o n r r o 'r o 1 i . ( . T u r ' r o ' r e n g n a a n d w a r m ' u p f o r 5 m i n u t e s .A d d c o o l a n td u r i n g t h i s t i m e . C o n n e c th o s el o c o l d s t a r td e v i c e .F i l l c o o l a n tt o m o u t h o f e x p a n s i o nt a n k ( a b o v e m a x ) a n d s c r e w o n

!ilo

).iO

H38 Tighten cylinder head bolts is Wa.m-up engine untiloi temperalure at least50'c 1122"F1. pumpwith plunger andva ve cover. Remove vacuum M 11 boltsrlorqueto 90 Nm (6sft lbs) wrlh 90'in M 12bolts:an9le'tighien onemovemenl otrt plrrnp plunger and stopping.Instal

DO

)ilo
Check-tightening of cylinder head bolts

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

56

Group 21 Engine Cylinder head, retorquing

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

J1 pump and plunger Removevalvecover,vacuum

Access to one of cylinder head bolts is restricled by

J2
M 1l bohs = 10hm Allenkey

M 11 bolts:
to Tighten each boh in turn as indicated according bolt 1. Slacken 30' 2. Torque 90 Nm {65ft !bs)to

M11

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

M 12 bolts:
T i g h t e n e a c h b o L ti n t u r n a s i n d i c a t e da c c o r d i n gt o 1. A n g l e t i g h t e n b o l t 9 0 ' i n o n e m o v e m e n tw i t h o u t s i o p p i n g -D o n o t s a c k e nb o l t f i r s t .S e e i l l u s t r a t i o n i n o p e r a t i o nH 3 8 .

M12

o
ut

ooao,@r
D20

@,@o @rO.O

a
D24

0g:@

oQoo@

o o

i.o (o

J3 Installvalve cover,plunger and vacuumpump Check replace necessary. if O-rinq,

57

Group21 Engine
Timing gear belt tension

K. Timing gear belt tension,checking/adiusting

Specialtoal:5197

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

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

r)a

K2 Check belt tension

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

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

r)rI
t), I

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

58

Group21 Engine Timing gear belts,tension

Incorrect belt tension lJnscrew expansion tank cap to release overpressure from coolingsyslem. Tum engineapprox.1/4 turn anticlockwise obtain to slackpart of bslt on driving side. lf this is not done injectionpump settingwill be incorrect. Turn crankshaft with 27 mm socketor 5188. Adjust belt tension to 12.5 units on gauge 5197 by moving pumpmounting coolant bracket.

lf gear belt tension has been adiusled --'-\. Turn engineat le6stoneturn clockwise and check that belttension 12-13unitson tool5197.Adjustif necesis saryaccording operations to K2-3and rechecktension,

Installtiming gear covers

Group21 Engine
Timing gear belts, replacement

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

E n g i n em a y o n l y b e l u r n e d b y m e a n so f v i b r a t i o nd a m p e r . w D o n o t r o l a t ec r a n k s h a f o r c a m s h a f t h e n t i m i n s s e a r b e l t i s r e m o v e do l h e r w i s ev a l v e sm a y s t r i k p i s t o n s t a n o c a u s eo a m a g e .

L1 Disconnect battery

i){ |

L2 Jack-upvehicle when coolantis drained, raise To prevent spillages jacking point. wil vehicle frontright al Coolanl thenrun into alongsplashg!ard drip pan. rod. left Place drip pan beneath steering

')a

L3 Drain coolant l U n s c r e we x p a n s i o n a n k c a p . D i s c o n n e clto w e r r a d i a i o rh o s e i r o m r a c l i a t o r D l s c o n n e clto w e r h o s e f r o n r t h e r m o s t a tf o r c o l d s t a r t ( i d e v i c e n d d r a i nc o o l a n t . E n g i n es w i l h o u t d r a i nl a p s ) a

0)a
,r)
(

L4

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

60

Group 21 Engine Timing gear belts, replacement

-timing gearcovers (front and rear)

L6 Turn engine until cyl. 1 is at TDC - injection totL'n pn9ine ddmpercenterboll AlwalsJre vib ation 5188 or 27 mm socket wrench 'rpwards pointobLiquelY 1 BothcyLindercamsshould
t,

L7 Removevibration dampercenter bolt

f U s e 5 1 8 7 1 o p r e v e n tp u L l e v r o m r o t a l i n g ,a n d s o c k e t 5 1 8 8t o u n s c r e wb o l t . y I t m a y b e n e c e s s a r t o t u r n e n g i n es l i g h t l vs o i h a t 5 1 8 7 r e s t so n f a n b e a f i n g .

Check that cyl. 1 is at TDC - iniection Check'0' nrark flywheel. on Adjust necessary, 5187 turn engine if use to

61

6roup 21 Engine
Timing gear belts, replacement ,

,J r{

L9 Remove vibration damper (6 four Allenscrews mm). Bemove PullotJvibration damper. Note!Crankshaft may gear sometimes stick vibration to damper.

)a
Ll0 Remove lower timing gear cover and belt pump retaining Slacken coolant boltsto release belt tension. Remove belt.

)r;O

Ll1
Replace idle. pulley A l w a y s r e p l a c ep u l l e yw h e n f i t i i n g n e w b e l t . Renrovecenter bolt. W i l h d r a w p l r l l e y| ] s i n g5 2 0 2 . T a p o n n e w p u l l e ya n d i n s t a l l c e n t e r o l t . b

)il4

),lt
Ll2 Removecamshaftrear sprocketand belt
Hold sprocket in position with 5199 and unscrew sprocket ith wrench5201. w T a k e c a r e n o t t o r o l a t ec a m s h a f t .

62

Group21 Engine
Timing gear belts, rcplacement

L13 Lockcamshaftin posilion

Lift valvecovergasket gauge5190at rear of camshaft. Place lnserta 0.2 mm left feelergaugebeneath sideof gaugoto compensate for timinggearclearance. Camshaft now set ai correctposition. is

LI4
Bemove camshaft Iront sprocket Use5199 holdsprocket position to in when loosenins bolts.Tap sprocket free to

Ll5 Install gear belt and camshaft lronl sprocket [4akesurethat belt fits seurely all gears. on Install center bolt,handtight.lt should possible be to turn sprocket camshaft without camshaftrotating. on

L16 Instatl lower timing gear cover and vibration damper Dampercanonlybefitted inoneway. oncrankshaft Pin
g e a r m u s t f i t i n v i b r a t i o nd a m p e r . T o r q u e i n h e x b o l t sr o 2 0 N m ( 1 5 f i l b s ) .

63

Group21 Engine
Timing gear behs, replacement

Ll7 Installcenterbolt
Smearthreads and rnatingsurface with sealerP/N 277961-9. (reston cooling journal) hold Usewrench 5187 fan to vibration damper. LJse wrench5188to lorquecenter bolt to 350 Nm {255ft lbs). lmportantr Torque Nm applies 350 onlyif wrench 5188 is used. Alsotorque wrench mustbein inewithwrench 5184.

L18 Make sure cyl. 1 is at TDC- inlection

C h e c k ' 0 ' m a | k o n f l y w h e e la n d a d j u s ti f n e c e s s a r y .

L19 Set belt tension

A d j u s t t e n s i o nb y m o v i n g c o o l a n tp u m p U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g et o b e l t and set to 12.5 units. S t r e t c hb e l l u n t i l m a r k o n g a u g e p l u n g e ri s i l u s h w i t h D e p r e s s e l ts t r o n g l yw i t h h a n da n d r e c h e c u a d j u s t t e n b

040
L20

Tightencamshaftlront sprocketand remove gauge 5190 Use 5199 prevent to sprocket turning. from (33fi lbs). Torque center to 4s Nm boit
R e m o v eg a u g e 5 1 9 0a n d f e e l e rg a u g e .

64

Group21 Engine Timinggear belrc,replacement

L21 Disconnect cold start device Slacken screw Push 1. leverfoNard and rotate sleeve 90'. Note!Do notturn screw2 otherwise llbenecessary it to remove coldstartdevice and resetiton a testbench, Press backleveragainststop.

-r@
-v2a//J:'

j iP)

L22 pump Basic-set inieciion pump Slacken mounting (Allen = 6 mm). bolts key Align marks pump mounting on and bracket turning by
pump.Retighten ountingbolts. m

L23 Set dial indicator zero. Lock pump gear at cyl. 1

inlection using stop 5193 plugfrom i n j e c t i o np u m p d i s t r i Unscrew rernove and 0 Install holder 5194 and dialindicator {range 3 mm). mm. Setgauge approx.2 to Turn pump gear clockwise until mark on gear and mounting bracket coincide.

Then turn back p!mp gear siightlyuntil min reading registers n dial indicator. o Set indicator to zero. I ! r n p u m p g e a r c l o c k w i s u n t i l m a r ko n g e a ra n d p u m p e m o u n t i n g b r a c k e tc o i n c i d e . o c k g e a r i n t h i s p o s i t i o n L w i l h s t o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n r o

i
65

Group21 Engine Timinggear belts,replacement

L24 lnstall camshaftrear sprocketand belt Tighten center by hand, shoutd possibte bolr it be to turnsprocket camshaft. on

L25 Set belt tension Adjust tension movingpump. by Usegauge5197to check tension.Attachgaugelo belt units. Stretch untilmarkon gauge belt andsetto 12.5 plunger flushwith sleeveis Depress strongly bell withhand andrechecUadjustten-

0la
!

r)

L26 Sel pump and tighten camshaft rear sprocket Use5199ro sprocket. hold Torque wrench should al be rightangles wrench to 5201otheMise torquewiL be Using5199, turn sproket slowlyclockwise until dial

D20....................................-....-.......0.80mm=0.0315in D 24 ................................................. 0.70 mm : 0.0276 in D 2 4 U S A / C a n a d a 11 9 8 1 . . . . . . . . . 0 . 7 0 m m = 0 - 0 2 7 6 i n 979 'I982-.................mm = 0.0335 0-85 in Hold in sprocket thisposition torque to 100Nm and bolt (73ftlbs). Take care thatcamshaft sprocket not and do

d),I

t)r I

L27 Removestop 5193{rom pump gear

66 I

Group 21 Engine Timing gear belts, replacement

L28 Checkpump setting

Turn engine two full turnsuntil cyl. I is at 1opdead lf is center injection, again. engine turnedtoo far it 'l14lurn thento zero and mustbe turnedback approx. markotherwise setting be inconect. will

i-'i

show: Dialindicator should in D 20 ........................... mm = 0.029F0.0327 0.75-0.83 D24........................... 0.650.73mm=0.025F0.0287in D 24 USA,/Canada 0.6F0.73 mm = 0.0256-0.0282in 1S791981 ...........-.... = 1982 ......................... 0.82-0.90mm 0.0323-0.0354in Correcr reading: Tighten injection mounting ts. Probo ceedto 129. to Incorrect readingr Readjust according instructions Radiusling pump setting:

D20.................................................0.80m D 24 ................................................. 0.70 mm : 0.0276 in D 24 USA,/Canada :0.0276in 1979-1981 ....................................... 0.70mm 1982 ...............................................0.85mm:0.0 Reading less than specified: pumpmounting Slacken boltsandturn pumpinwards to obtaincorrect valLreTightenmounting ts and bo repeatcheckof pump settings. Beadingmore than specified:

purnp Slacken mounting bolls turnpumpoutwards and untildialindicto. showsapprox: in D 20 ................................................. 0.70 mm = 0.0276 D 24 ...........--...-...-....-...-........-.......-.. in 0.60 mm = 0.0236 ......... mm = 0.0236 in D 24USp/Canada 1979-1981 0.60 1 9 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m : 0 . 0 2 9 5 Thenturn pump inwards unti specified valueis ob pumpsettained. Tighten rnounting ts andrecheck bo ting. pumpmustnotbetapped knocked Note!lnjection or as thiswill alterits setring.

L29

Bemovedial indicatorand holder 5194.Install plug with new seal Tightening torque Nm{6.5ft lbs). 9

67

Group21 Engine
Timtnggear bells replacement

L30 Reconnect cold start device 90'. Relighlen Press leverforwards and tlrn sleeve 2 it NotelDo turnscrew otherwisewi benecessary not on io reset coldstartdevice a teslbench.

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

t:: I

I'L =%'r LJ:

/ 0 8,5 azzz Trzzz

L32 Installtiming gear covers {front and rearl if Usenew gaskets necessary.

r)r l

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

68

Group21 Engine Timinggear belts,replacement

Bleeding ot cooling system Disconnect upper hose from cold stan dvice.Place drip pan beneathhose 6nd hold hose level with top edge of expansion tank.

Coolant S i n c ea l u m i n i u m i s u s e d i n t h e e n g i n e s ,a c t i v ec o r r o ' sion protection is necessaryin the coolant to help prevent corrosion d6mage, U s e g e n u i n eV o l v o b l u e - g r e e n o o l a n tt y p e C , d i l u t e d c with clean water in proportions of 50/50. This mixture helps to prevent coiiosion and frost Neverfill the cooling system with water alone. T h e c o o l a n ts h o u l db e c h a n g e dr e g u l a r l y i n c et h e c o r s rosion protective additives in the cootant tose their ef-

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

gt srY0Dlr 30pc rLL rfirrfY[ lfifi lurr {a0 t|r Dftvanrl ocN 0[r r0rv0 xY|^rsunr c IroL\no coouNr c c00ut6 TYPI sYsmi$ PRoTOT[o-22.r nr UP R0Ur0 |ALrWAr$Al0 HArr T0 Y&i R|lH V0tV0 RrirPrr u0urDr 0I ar{r6rL rYrt c VALABL! -2?.t \roLrro JusooA -3trCr$PlrBflT0UT[ Slrsori Morltuu {otTttINI|GIL c ^ytc IYr!

Replacing coolant Always usetypc C blue-green coolanr.Remember to replace decal 1331473-7) expansion if ne, on tank 1PlN Type C blue-green coolant All dieseland petrol (gasoline) enginesmanufactured since 1982 filledwith tvDeC coolant. are

Group2l Engine
Timing gear belts, reqlacement

L35 Fill coolant Capacity: 20 = 8.'l lilers (8.6US quarts) D D 24 = 9.3liters {9.8US quarrs). Flush cooling system before adding new coolant, see Group Cooling 26 System. Sel dashboard l_eater contro, max.Turnon engile io and warm-up 5 minutes. for Add coolant duringthis time. Conneclhoseto cold startdevice.Fill coolantto mouth of expansion tank (abovemax) and screw on

70

Group21 Engine
Camshaft, removal

removal M. Gamshaft,
Special tools: 5199, 5201

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

M2 Turn engineuntil cyl. 1 is at TDC- iniection

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

t
M3 Removebelt Irom camshaftsprocket
U n s c r e we x p a n s i o nt a n k c a p 1 0 r e l e a s eo v e r p r e s s u r e from cooling system. S l a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l r t e n s i o n e r .T i g h t e nt w o l o w e r m o u n l i n g b o l t st o a v o i d u n , n e c e s s a r yo s s o f c o o l a n t . l R e m o v eb e l t f r o m c a m s h a f is p r o c k e t .

11

Group21 Engine Camshaft, rcmoval

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

0t
M5 Detachbelt shieldfrom cvlinderhead
Benove two Lpperreldinirgbolrs. Bend out shield to free it from camshaft. lf necessary s l a c k e n o o l a n tp u m p u p p e r b o l t . c K e e ps h i e l di n o u t e r p o s i t i o nw i t h a p i e c eo f w o o d .

I ') r \

M6 Lift off pump belt

S l a c k e nm o u n t i n g b o l t s f o r i n j e c t i o np u m p b r a c k e t o release elttension. b T i g h l e no ' r e b o k s o I h a t p J n p r e m a ' n s l u p p e ' p o s i Lift off belt.

0ta

0ta
,O

, r tuttililiiii,i,
M7

Removecamshaftrear sprocket
Hold sprocket in position with 5199 and s P r o c k ew i l h w r e n c h 5 2 0 1 . t Take care nol to rolare camshaft.

72

Group21 Engine
Camshaft, removal

M8 Removevacuum pump and pump plunger Removepump fetaining nuts and place pump on plunger Withdraw from cy inderhead.

M9
Remove camshafi beadng caps 1 and 4

M10 Remove camshaft bearing caps 2 and 3 placing Slacken crosswise avoid nuts load to uneven on

M11
Lift awav camshaft and removeoil seals

13

Group21 Engine
Camshaft, installing

N. Camshaft, installing
Specialtools: 5 1 5193, 5194, 5195, 5196, 5197, 5199, 5200,5201 90,

0)ia
Place camshaft in cylinder head Lubricate contactsurfaces camshaft of and bearings. gauge5190at rearof camshaft. Place lmportant!Both camsfor number cylinder 1 rnuslpointdiagonally up, seeiig.

0rl

N2 Installcamshaftcaps2 and 3 Install cenrer off set. is capscorrectly, in to warp. Keep camshaft Tighten crosswise avoid nuts
p o s i t i o n i t h g a u g e5 1 9 0a t r e a rw h e n t i g h t e n i n g a p s . c w

0)a

0)a
N3

gauge Remove 5190

Pressin new camshaftoil seals

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

Group21 Engine
Camshaft, installing

N5 Install camshaft caps 1 and 4 cap camshaft 4 sits thrustwasherfor fMak thatthe sure

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

D
20 Nm

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

N8

Installbolts tor belt cover N9

,D D

Installgear belt and camshaftfront sprocket

P u l l b e l t t o e n s u r et h a t i t i s s e a t e dc o r r e c t l y n c r a n k o P l a c eb e l i o v e r c a m s h a f ts p r o c k e t n d i n s t a l ls p r o c k e t a I n s t a l lc e n t e rb o l t h a n d t i g h t . l t s h o u l c lb e p o s s i b l e o r f s p r o c k e t t ou r n o n c a m s h a f w i t h o u t c a m s h a fr o t a t i n g . t t t

Set belt tension A d j u s tt e n s i o nb y m o v i n g c o o l i n g p u m p . U s e g a u g e5 1 9 7 t o c h e c k l e n s i o nA r t a c hg a u g e r o b e t r . a n d s e t t o 1 2 . 5u n i t s . S l f e t c hb e l t u n t i i m a r k o n g a u g e p t u n g e ri s f t u s h w i l h D e p r e s s e l ts t r o n g l yw i t h h a n da n d r e c h e c u a d j u s t t e n , b

75

Group21 Engine
Cafishaft, installing

Make sure cyl. 1 is at TDC if and on Check'0'mark flywheel adiust necessary'

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

N13 Tightencamshaftlront sprocket from use5199 prevent to sprocket lurning. (33ft lbs). Torque center to 45 Nm bolt

0)lI
gauge Remove 5190andfeelergauge

0)a
N15

Disconnect cold start device

Slackenscrew L Push lever forward and rotate s eeve 90'. N o i e l D o n o t t u r n s c r e w 2o t h e r w i s e t w i l l b e n e c e s s a r y i to remove cold start device and reset it on a test bench. P r e s sb a c k l e v e ra g a i n s rs t o p .

16

Group21 Engine camshaft,installing

-@;

N16 Basic-setiniection pump pump mount:ngbolts (Allenkey = 6 mm). Slacken by bracket tuming Atignmarks pumpandmounting on pump.Retighten mountingbolts.

I-@)

).,)- '2-,

N17 Set dial indicator zero. Lock pump gear at cyl. 1

injection using stop 5193 pumpdistri Unscrew and removeplug from injection (range 0-3 hotder 5194 and disl indicator Install gaugeto approx.2 mm. Set until Turn pump gear clockwise moundngbrackt coincjde.

until readrng Thenturn pump gearbackslightly registers dial indicator. on St indicatorto zero. pump Turnpumpgearclockwise untilmark gearand on Lockgearin this position mounting bracket coincide. (lnse( stopthroughpump gearinto with stop 5193. mounting bracket.)

N18 Installcamshaftrear sprocketand belt Tighten center boltsby hand, should possible it be to turnsprocket camshaft. on

Group21 Engine
Cafishaft, installing

N19 St belt tension Adjusttensionby moving pump. Usegauge 5197 check to tension. gauge bett Attach to and set to 12.5units.Stretchbett untit mark on gauge plungeris flush with sleeve. Depress stronglywith handandrechecUaotusr belt ren-

N20 Set pump and tighten camshaftrear sprocket

Use5199to holdsprocket. Torque wrench should at be rightangles wrench5201otherwise to lorquewill be Using5199, turn sprocket slowlyclockwise until dial D20...................-...-...........0.80mm=0.0315in . . D 24..............................-........-......... 0.70 mm : 0.0276 in D 24 USA,/Canada 1979-1981 ......... mm = 0.0276 0.70 in 1982-................. 0.85 mm = 0.0335 in Hold sprocket thisposilion torque to 100Nm in and bolt {73ft lbs).Takecarethat camshaft andsprocket not do

0 I 0
(

N21

Removestop 5193trom pump gear

0),(
N22 Checkpump setting
T u r n e n g i n et w o f u l l l u r n s u n t i l c y l . 1 i s a t t o p d e a d c e n t e r- i n i c t i o n , g a i n .l f e n g i n e i s t u r n e d t o o f a r i t a m u s t b e i u r n e d b a c ka p p r o x .1 / 4t u r n a n d t h e n t o z e r o m a r k o t h e r w i s es e t t i n gw i l l b e i n c o r e c t . D i a l i n d i c a t o r h o u l ds h o w l s D 2 0 . . . . . . . . . . . . . . . . . . . . . . . 7.5.- 0 . 8 3 m 0 . . m D 2 4 . . . . . . . . . . . . . . . . . . . . . . . 6.5.- 0 - 7 3 m 0 . . m D 24 UStuCanada 1 9 7 F 1 9 8 1. . . . . . . . . . . . . 0...6 F 0 . 7 3m m - . 19 8 2 - . . . . . . . . . . . . . . . . . . .0...4 . . - 0 . 9 0 m . .2 m : 0 . 0 2 9 5 0 . 0 3 2 7n i = 0.0256-0.028n i7 = 0.0256-0.028n i7 = 0.0323-0.035n i4

0)' I

Corect reading: Tighten injection pump mounting bolts. Proceed to N23. Incorrect reading: Readjust according to instructions

7A

Group21 Engine Camshaft, installing

Readiusling pump setting: D 20 ..................-...-...-......,............0.0315 0.80 mm = in = D 24..........................,...................... 0.70mm 0.0276in = D 24L,SA,/Canada 197F1981 ......... O.70mm 0.0276in : 1982-....,....,..,.... 0.85mm 0.0335in Reading less than specified: pump mountingbottsand turn pump inwards Slacken to obtain corrsct value. Tighten mounting botts and repear checkof pump settings. Reading less lhan specified: pumpmounting Slacken bolts pumpoutwards andrurn untildialindicator showsapprox: D 20 ........................-...-.................. 0.70 mm = 0.0276 in D 24 ................................................. 0.60 mm = 0.0236 in D 24USA,/Canada =0.0236in 1979-1981 .........0.60mm 1982-................. 0.75 mm = 0.0295 in Then turn pump inwards untit specifiedvatue rs obtained. Tighten mounting botrs andrecheck pumpsetrng, Not!Injection pump mustnot be tappedor knockeo as this will alter its setting.

t@) )]

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

N24 Reconnect cold start device Presslever forwards and turn sleeve90". Retighten Notel Donotturn screw2otherwise itwitt be necessary to resetcold start deviceon a test bench.

79

Group21 Engine
Camshaft, installing

N25

plunger Install and vacuumpump

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

()l
N26 Adiust valveclearance:
S e e o p e r a t l o nB 1 1 1 , p a g e 1 9 . l m p o r t a n t ! V av e c l e a r a n c e u s t b e c h e c k e d f t e r 6 0 0 m a ( 1,200 1iles 1,00G-2,000 ). n km

,l )l

N27 gearcovers (frontand rear) Installtiming

{l|a

0rr 1

80

r
Group 21 Engine Camshaft fronL seal, replacement

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

iD

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

o1

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

t,

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

D
o3
lnstall dial indicator U . s c r e w a n d r e m o v ep l u g f r o m i n j e c t i o np u m p d i s t r i I n s t a l lh o l d e r5 l 9 4 a n d d i a l i n d i c a l o r{ r a n g e0 - 3 m m ) . S e l g a u g el o a p p r o x .2 m m .

Group21 Engine Camshaft front seal,replacement

o4
Turnengine until cyl. 1 is at TDC- iniection
d A l w a y su s et h e v i b r a t i o n ; m p e r c e n t e rb o l t i o t u r n t h e e n g i n e .2 7 m m s o c k e to r w r e n c h 5 1 8 8 . B o t hc y l i n d e r1 c a m s s h o u l d p o i n ! o b l i q u e l y' r p w a r d s . p T u r ne n g i n ea p p . o x .1 / 4t u r n c l o c k w i s e a s t ' 0 'a n d t h e n b a c kt o ' 0 ' a g a i n ,t o o b t a i ns l a c kp E d o f b e l i o n d r i v i n g s i d e .l f t h i s i s n o t d o n e i n j e c l i o np u m p s e t t i n sw i l b e

{)a
o5
Set dial indicator zero G a u g e p o i n t e r m u s t n o t m o v e d u r i n g i n s t a l a t i o no f new oil sea otherwise it wil be necessaryto basic-set e n g i n es i n c e c a m s h a f tw i l l h a v e m o v e d i n r e l a t i o nt o Lfpointe. does not move itsufficesto check/adjustinjec-

0)l

o6
Remove belt from camshaft sprocket U n s c f e we x p a n s i o nl a n k c a p t o r e l e a s eo v e r p r e s s u r e from coo ing system. S a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l t t e n s i o n e r . i g h l e nt w o o w e r m o u n t i n gb o l t s1 o a v o i d u n T n e c e s s a r yo s s o f c o o l a n t . l R e m o v eb e l t f r o m c a m s h a f ts p r o c k e t .

r)il4

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

a2

Group21 Engine
Camshaft front seal, replacement

Detach belt shield from cylinder head Bemove upperreraining two botts. Bend out shield freeit from camshaft. necessary to tf slacken pumpupperbott. coolant Keep shield outerposjtion in with a piece wood. of

Remove camshaft cap 1 and oil seal

ot0
Pressin new camshaft
Oil seal. D o n o t p u s h i n s e a ll o b o t i o m p o s i t i o n .M a k es u r et h a t

seal

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

o12
Press in seal to bottom position Release cover. Useadapter 5200 rap in oil ro

o13
bolts Ior belt cover
014 Install gear belt and camshaft tront sprocket P u l l b e l t t o e n s u r et h a t i r i s s e a t e cc o r e c r l y o n c r a n k l shaft gear. P l a c eb e l t o v e r c a m s h a f r p r o c k e r n d i n s t a i ls p r o c k e t s a I n s t a l c e n t e rb o l t a n d t i g h r e n .l t s h o u t db e p o s s i b t eo r f s p r o c k e t l o u r n o n c a m s h a f t w i t h o uc a m s h a f t o t a r i n g . t t r

Group21 Engine
Camshaft front seal, replacement

015 Set belt tension

A d j u s l t e n s i o nb y m o v i n g c o o l i n gp u m p . U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g e1 0 b e l t a n d s e t t o 1 2 . 5u n i t s . S t r e t c hb e l t u n t i l m a r k o n g a u g e p l u n g e ri s f l u s h w i t h Depressbeit stongly with hand and rechecuadjust ten-

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o16 Makesurecyl.1 is ai TDC
if and adjust necessarv Check'o'mark flywheel on
il

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o17
Tightencamshaftfront sprocket
L J s e 1 9 9t o p r e v e n ts p r o c k e t i o m t u r n i n g . 5 f TorqLrecenter bolr to 45 Nm (33 ft lbs).

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tl t,

o18
Check dial indicator l f p o i n l e r h a s m o v e d f r o m z e r o p o s i t i o n :b a s i c ' s e e n ' t g i n e a c c o f d i n g o o p e r a l i o n sC 1 - 2 1 . t Pointer at zeror Proceed to O19.

Group2l Engine Camshaft trcnt seal,reDlacement

o19
Zoro injection pump and dial indicator is until min reading Slowly tum engineanticlockwise reached di6l indicator. on Set zero.

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o20 Checkpump sefting '0' Slowly turnengine clockwise untilflywheel reaches lfengine isturned toofar must it beturned backapprox. 1/46nd thento 'o' mark otherwise setting willbe incoF
Dialindicator should showl = D 20........................... 0.7F0.83mm 0.0295-0.0327in D 24 ........................... mm = 0.0256-0.0287 0.6F0.73 in D 24 IJS!,/Canada = 197F1981 ................. 0.65-0.73mm 0.0256-0.0287an 1982-......................... mm = 0.0323-0.0354in 0.82-0.90 Correct reading: Iighten injection pump mounting bolts.Proceed O23. to lncorrectrcading: Readjust acco.ding below. to

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021 Check/adjust pump setting D 20 ................................................. 0.80mm = 0.0315in D 24................................................. 0.70mm = 0.0276in D 24USA"/Canada 197F1981 ......... mm = 0.0275in 0.70 1982-................. 0.85mm = 0.0335in

Reading less than specified: pumpmounting Slacken boltsandturn pumpinwards boltsand to oblaincorrect value. Tightenmounting repeatcheckof pump setting,

85

Group21 Engine Camshaft front seal,replacement

Reading more than specitied:

pumpnrounting bolts turnpumpoutwards and Slacken untildialindicator showsapprox. D20.................................................0.70mm=0.0276 in D 24 ................................................. 0.60 rnm= 0.0236 D 24USA,/Canada 1979-1981 ......... mm = 0.0236 0.60 in mm = 0.0295 in 1982-................. 0.75 Thenturn pump inwardsuntilspecified valueis obpumpset' tained. Tighten mounting boltsandrecheck ting. lf it is not possible sei pumpto abovespecifications to laltude. elgiie becaLse ncuffic ad_Jstmelt of ert mustbe basic-set again, since camshaft crankshaft and areprobably oi ine. our pumpmustnotbetapped knocked Note!Injection or as thiswill alterits setting.

o22
Check pump setting Turnengine round twiceandcheck setting,see opera tion O20.Readjust necessary repeat if and check.

o23
Removedial indicatorand holder
L:ri ii ,. _r Lr=

o24
Install plug with new seal Tishtening torque Nm (6.5 bs). 9 ft

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

86

Group21 Engine Camshaltfront seal,replacement

o2
Inslall valve covei Usenw gaskstsif necessary.
see types Twotypesot pin $uds areavailable, fig. Late and hole in gasketis largrto preveni havea spacer, by damage gasket overlightoningto Lat6and earlytype Frts must not b interchanged

ry

08F

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o27
Installfront timing gear cover

a7

Group21 Engine
Camshaft rear seal, rcplacement

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

r)a
Remove: - reart|mrng gearcover.

r)a

P2 Turn engineuntil cyl. 1 is at TDC- iniection

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

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P3 Lift ofi pump belt S l a c k e nm o u n t i n g b o l l s f o r i n j e c t i o np u r n p b r a c k e t o release elt tension. b T i g h l e no n e b o l t s o t h a t p u m p r e m a i n si n u p p e r p o s Litt off be t.

88

Group 21 Engine Camshaft rear seal, replacement

,."! ",iii;iiii;i;
Removecamshaftrear sprocket Holdsprocket position in with 5r99 and unscrew with sprocker wrench 5201.
Note! Take care not to rotete camshaft.

P5 Remove camshaft caD 4 and old oil seal

Press in new oil seal Oil seal. m D o n o t p u s h i n s e a l t o b o t t o m p o s i t i o n . a k es u r e t h a t

Install camshaft caps 1 and 4 Makesurelhat thrLrst washer camshaft 4 sils for cap Tightenins torq!e 20 Nm (15ft bs). P8 Tap in oil seal to bottom Useadapter 5200 and boltfor rearcamshaii sprocket.

P9 Checkcamshaftsetting
C h e c k i t h g a u g e5 1 9 0t h a l c a m s h a f t s c o r r e c t l y e t i n w i s r e l a t i o nt o c r a n k s h a f t . G a u g es h o u l df i t i n g r o o v ei n b a c ke n d o f c r a n k s h a r tl.f n o l , e n g i n e m ' r s t b e b a s i c - s ea c c o r d i n g o o p e r a t i o n s i t c1-21.

89

Group21 Engine
Camshaft rcar seal, replacement

P10 Disconnect cold start device

Slacken screw 1. Push lever foMard and rotate sleeve 90". N o t e ! D o n o t t u r n s c r e w 2 o t h e M i s ei t w i l l b e n e c e s s a r y to remove cold start device and reset it on a test bench. P r e s sb a c kl e v e ra g a i n s ts t o p .

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iniectionpump Basic-set (Allen = 6 mm) pump bolts key Slacken mountins by bracket t'rrning Align marks pump mounting on and pump. mounting bolts. Retighten

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I

P12 Set dial indicator zero. Lock pump gear at cyl. 1 inlection using stop 5193 pumpdistri plugfrom injection Unscrew remove and 0-3 mml. Install holder 5r94and dialindicator {ranse Setgauge approx. mm. to 2 Turn pump sear clockwise until mark on gear and mounling bracket coincide.

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lrt 1

T h e n t u r n p u m p s e a r b a c ks i g h t l y u n t i l m i n r e a d i n g o regislers n dial indicalor. Set indicator o zero. t T u r np u m p g e a rc l o c k w i s e n t i l m a r ko n s e a ra n d p u m p u m o L r n t i n g r a c k e ic o i n c i d e . o c k g e a r i n t h i s p o s i t i o n b L w l t h s t o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n t o m o u n t i n gb r a c k e t . )

90

Group21 Engine Camshaft rear seal,replacement

Installcamshaftrear sprocketand belt

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

Set belt tension by tenslon rnoving Adiust PumP gauge belt to tensionAtlach 5197 check to Usegauge belt units. Stretch untilmarkon gauge andsetto 12.5 plunger flushwith sleeve is tenbelt Depress stronglywith handandrecheck/adjust

P15 Set pump and tighten camshaftrear sprocket

h U s e 5 1 9 9 t oh o l d s p r o c k e t . T o r q u e w r e n cs h o u l db e a t r i g h t a n g l e st o w r e n c h 5 2 0 1 o t h e r w i s et o r q u e w i l l b e

turn spfocket slowlyuntil Using5199, : in 0.80mm 0.0315 D 20 ................................................. mm = 0.0276 in 0.70 D 24 ................................................. in 0.70 1979 ......... mm : 0 0276 D 24USp,/Canada 1981 in 0.85 mm : 0.0335 1982-................. and torqueto 100Nm in Holdsprocket this position (73ftlbs). not sprocketdo Take carethat camshaftand

Removestop 5193from pump gear

Group21 Engine rear seal,replacement Camshaft P17 Checkpump setting

Turn engine two fuLl turns lntil cyl. 1 is ai top dead center injeclion, again. engine turnedtoo tar il lf is must be turnedbackapprox. turn andthento '0' 1/4 markotheMise setting be incorrecl. wilL Dialindicator should show: in D 20 .............-............. mm = 0.0295-0.0327 0.7F0.83 in D 24 ........................... mm = 0.0256-0.0287 0.65-0.73 D 24 USACanada = 1979-1981 ................. 0.73mm 0.0256-0.0287in 0.65 1982-......................... mm = 0.0323-0.0354in 0.82-0.90 Correct reading: Tighten injection pump mounting bolts.Proceed P18. to lncorectreading: Readjust according instructions to

J;'.

pump setting: Readjusting

S e t t i n gv a u e s : i D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0...8.0m m.:. . 0 . 0 3 1 5n . . ..... i D 2 4 . . . - . . . . . . . . . . . . . - . . . . - . . . . . . . . . . . . .0. .7 0. . .m .:. .0 . 0 2 7 6n . ..m .. D 24 USp,/Ca a 'l 979-198'l ......... nad 0.70mm = 0.0276in 1 9 8 2 - . . . . . . . . . . . . .0. .8 5m m : 0 . 0 3 5 i n . .

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

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Beading mofe than specified: pumpmounting Slacken pumpoutwards bolts andturn untildialindicator showsapprox. 020.........................-.......................0.70mm=0.0276in D 24 ............................. -.................. mm = 0.0236 0.60 in D 24USr',/Canada 1S7F1981 .........0.60 = 0.0236 mm in 1982-................. 0.75 mm = 0.0295 in Thentlrn pump inwardsunrilspecified vatuers oo tained. Tighten mo!ntingboltsandrecheck pumpset, ting. pumpmusrnotbetapped knocked NotelInjection or as thiswill alterits setting.

92

Group21 Engine Camschaft rear seal,reDlacement

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

P19 Reconnect cold start device Presslever forwards and turn sleeve90'. Retighten Note!Do notturn screw2 otherwise itwillbe necessary to rsetcold startdeviceon a test bench.

P20
lnstall valve cover Use new gaskets necessary. if

ry

3
P21
Install rcar liming gear covel

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

93

Gtoup21 Engine
Pilot bearing, replacement

O. Pilot bearingin crankshaft, replacement

Specialtools: 1801, 4090.5203,5207

a1
Removegearbox/transmission
S e e S e r v i c em a n u a l s e c t i o n ( 4 3 ) . 4 S e c u r es t a h e r m o l o r w i t h a b o l t .

a2
Removepressureplate and driven plate lJnscrewpressuremounting crosswrse plate bolts arew turns a timeto prevent at warp,

O3
Remove bearing lJseextractor 4090.

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a4

Installbearing
I n s t a l lb e a r i n ga n d s e a l w i t h t e x t o n o u t e r r i n g f a c i n g out. away from flywheei. U s e s t a n d a r dh a n d l e 1 8 0 1a n d d r i f t 5 2 0 7t o t a p i n b e a r i n g u n t i l i t a b u t sc r a n k s h a f l . P r e s s n . s m a l la m o u n to f g r e a s e( 1 . 3 1 . 5 g r a n i ) i n t h e i s p a c eb e y o n dt h e b e a r i n g .

94

Group21 Engine
Pilot bearing. replacement

a5
Installdriven plate
Use centering shafi 5203. Turn driven plate with hub facing out, away from fly-

0
a6
(,

Install pressureplate Tighten boltscrosswise fewturnsar a timero avoid a

a7
Installgearbox Do notforget remove to boltssecuring starter moror.

o
0

95

Gtoup21 Engine Crankshaft tront seal,replacement

R.Crankshaft front seal,replacement

Specialtools:5187,5188,5197,5200,5205

R1 batterv Disconnect R2 Jack-upvehicle

w T o p r e v e n ts p i l l a g e s h e n c o o l a n ti s d r a i n e d , h i c l ea t f r o n t r i g h t j a c k i n gp o i n t .C o o l a n tw i i a l o n g s p l a s h g u a r dn t o d r i p p a n . Place drip pan beneath left steering rod.

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

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{r)

R4

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

96

I I
I I

Group 21 Engine Crankshaft f ra nt seal, replacem ent

R5 Remove vibration damper center bolt pulley ljse 5'187 prevent to from rolating, socket and boh. 5188 unscrew to It maybe necessary turnengine lo slightly that5187 so resls fan be.ring. on

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(D

Turn engine approx. 1/4 turn anticlockwise Usewrench 5187.

if ockwise, slack beltwillmove engine antic Bylurning and inslall to il to drivlng side,making easier remove

Removevibrationdamper Remove four inhexbolts(6 mm).

Pulloff vibration damper. gear NotelCrankshafi may sometimes stick vibration to damper.

R8

Remove lowertiming gearcover

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

9l

Group2l Engine
Crankshaftfront seal, replacement

R10 Mark position oI timing gear belt

f t l a r kb e l t ,c a m s h a f t p r o c k ea n d c r a n k s h a fg e a r .M a r k s t t A i s o i d e r r ' t v o u l s i d ea n d r o p s i d eo f g e a r b a l r .

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

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811 Removegear belt Slackencoolantpumpmounling andbelt. bolrs Cooanr may leakwhenboltsareslackened.

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R12 Removegearon crankshatt and withdraw oilseal use exlractor5205.

9A

Gtoup 21 Engine Crankshaft front seal, replacement

R13 Installnew oil seal and gear on crankshaft

P a c ks p a c eb e t w e e ns e a l i n gl i p s w i t h g r e a s e . P r e s s n n e w s e a l .U s e a d a p t e r5 2 0 0 , i b f a t i o nd a m p e r i v c e n t e rb o l t a n d a l h i c k w a s h e r . Instalgearon crankshaft.

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

R15 Install camshaft gear belt M a k es u r et h a t b e i r i s f i f t e d i n e x a c r t y s a m e o s i t i o na s p A l i g n i d e n t i f i c a t i o n 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 m a n d c r a n k s h a fs e a f . t It is extremely important that belt is fitted in exactry same position as before. T e n s i o nb e l t b y r n o v i n gc o o l a n tp u m p ( b y h a n d ) . T i g h t e np u m p m o u n l i n g b o l t s .

99

Group21 Engine
Crankshaftf ront seaI, replacement

R16 gear cover and vibration lnstall lower timing Dampercan befiitedinoneway. on crankshaft only Pin gearmustfit in vibralion damper. ft Torque inhexbo ts ro 20 Nm 115 lbs).

r))
R17 lnstall center bolt S m e a r t h r e a d s a n d m a t i n g s u r f a c ew i t h s e a l e r P / N 2779619. U s e w r e n c h 5 1 8 7( r e s to n c o o l i n sf a n b e a r i n g ) t o h o l d Use wrench 5188 to lorque center boll to 350 Nm { 2 5 5f t l b s ) . l m p o r t a n t rT o r q u e3 5 0 N m a p p l i e s n l y i f w r e n c h5 1 8 8 o i s u s e d . l s ot o r q u ew r e n c hm u s t b e i n l i n e w i t hw r e n c h A 5188_ I

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R18 Set belt tension T u r n e n g i n ea p p r o x 1 / 4t u r n a n t i c l o c k w i s e . d j u s tt e n A s i o n b y m o v i n g c o o l a n tp u m p . U s e g a u g e5 1 9 7t o c h e c kt e n s i o n . t t a c hg a u g et o b e l t A a n d s e t t o 1 2 . 5u n i t s . D ep r e s sb e h s t r o n g y w i t h h a n da n d r e c h e c k / a d j u s n e n l

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

100

Group21 Engine Crcnkshaft front seal.reDlacement

820
Bleeding ot cooling system Disconnect upper hose from cold start hoseand hold hose drip pan beneath tank, edgeof expansion

Coolant S i n c ea l u m i n i u m i s u s e d i n t h e e n g i n e s ,a c r i v ec o r . o sion protection is necessaryin the coolant to help prevent corrosion damage, Use genuine Volvo blue-green coolant type C. diluted with clean water in proportions of 50/50. This mixture helps to prevent corrosion and frosr damage. N e v e rf i l l t h e c o o l i n g s y s t e m w i t h w a t e r a l o n e . T h e c o o l a n ts h o u l db e c h a n g e dr e g u l a r l y i n c et h e c o r s rosion protective additives in the coolant lose their ef fect in time.

Note!Oonot runengine whenlevetof coolant is low, since high local temperarures can resutr whichmay cause cylinder the headro crack.

srY0oar ,r00crfTEirfLr SuNr rtt ARar Nto otl vrlraf ocr tN otL v0w!]q!!|I$|l!!_L_ fruo wrTi GaNUltr atol,l/o coourr Tyrc c00u|6sysTrri rs ruP YUi [00ND [rLf WrrtiAri0 v0w0 Ur w|lH |lALa
mnM

[$ru ff Lrouror Arrft vrol,vo n* c vAuBrt Jus0ur zrt ,30.cn rrrr muft s^rsoN Morrtau riorTrt ^vtc Arrctt TYr c

Replacing coolant AlwaysusetypeC blue-green coolant. Remember to replace {P/N decal 1331473-7) on expansion if netank Type C blue-green coolant
s A l l d i e s e la n d p e t r o l ( g a s o l i n e ) e n g i n em a n u f a c t u f e d s i n c e1 9 8 2a r e f i l l e d w i t h t y p e C c o o l a n t .

101

Gtoup 21 Engine

front seal,replacement Crankshaft

R21 Fill coolant Capacity: 20= 8.1liters(8.6USquarts) D

D 2 4 = 9 . 1 l i t e r s( 9 . 8U S q u a r t s ) F l u s hc o o l i n g s y s t e m b e f o r ea d d i n g n e w c o o l a n t ,s e e G r o u p 2 6 C o o l i n gS y s t e m . Set dashboard heater conkol to max. Turn on engine a n d w a r m ' u p f o r 5 m i n u t e s .A d d c o o l a n td u r i n g t h i s t i m e . C o n n e c th o s et o c o l d s t a r td e v i c e .F i l l c o o l a n tt o m o u t h o f e x p a n s i o nt a n k ( a b o v e m a x ) a n d s c r e w o n

0trl 1
((

102