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VOLVO 240 Engines d20 d24 Repairs Manual
VOLVO 240 Engines d20 d24 Repairs Manual
EngineD20,D24
Repairs
and maintenance 240 1979- 19 ..
TP 30420/111.88
D20,D24
Boththe D 20anclD 24 Dieselengines aredealtwilhin
this manual.
The D 20 hasfive cylindersandthe D 24 six. Otherwise
the enginesaresimilarin principle.
Not6l Differentllywheelsand vibrationdampersar€
fitted to the dilferentenginetypes.
iffim itm!r
:i!r-l-l
Thismanualmay thereforeshowill!strationsand
lextwhichdo not applyto carsin yourcountry.
Contents
page
fmportantinformation............................... 2
Specitications
........ 3
Specialtools ...................................
12
Group21 Engineassembly...............................................
16
(Work wilh engine in-ca., replacernentof engrnej
Group22 Lubricating
System.........................................
123
Group23 FuelSystem.........................................................
125
Group25Intakeandexhaustsystems.............. .. .. r60
Group26Coolingsystem..................................................
i63
Group27En9inecontro1s..................................................
175
Appendix"A"Faulttracing.............................................
A1
Index178
OrderNo,:TP 30420/1
Reprintof'1983literature
withoutchange.
OVOLVONORTHAMERICACORPORATION
lmportantinformation
CLEANLINESS
Dieselinjectionsystemsareoxtremelysensitiveto
dirt
and foreign m6tter. A special workplace should
thereforebe usedfor insoectionofcomoonents.
PLUGS
CleanfuelIineconnections thoroughlybeforediscon-
nectingpipes.
Plug ends of fusl lines etc as each componentis
removed. Donotremovethessplugsuntilthe compo'
nent is reconnected.
Tightening torques
Two kindsof tighleningtorqueswill be found in this
Specifications
Group 20 General
.,o
,o Enginetypedesignation
number
andserial
S t a m p e do n l e f t s i d e o f e n g i n eb e n e a t hv a c u u t r ,p u m p
D 20 Engine
OutputDIN.......................... 50 kW ar 80 r/s
68 hp at 4,800r/min
Maxtorque
DIN 120Nm at 50 /s
12.2kpm at 3,000/min
N u m b e ro f c y l i n d e r s 5
1-2-4-5-3
D i s p l a c e m e n t . . . ............ . . 1.986dm3(liter)
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
'181kg (405lbsl
C o m p r e s s i o np r e s s u r e s i Mpa
\ew en9ine.................. 3.2
iVnirnJn ....................... 2.4 313
M a x d ; f f e . e n c e b e r w e e nncdyel r s . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 114
C o m p . e s s , o r a t r o. . . . .. . . 23.0:1
C y l : n d ebr ore.................. 76.5mm : 3.0118 in
S t r o \ el e n g rh 86.4mm = 3.4016 in
Specifications
D 24 Engine
OutputDlN 60 kW al 80 r/s
82 hp at 4,800r/min
MaxtorqueDlN 140Nm at 47 r/s
14.3kpm 6t 2,800r/min
Numberof cylinders ....... 6
Firingorder............,,...,... 1-5-3-6-2-4
Disp1acement...,,...,,....,... 2.383dm3{litsr)
Weight, approx. incl, engine mounts, alternatorand starter
1S8{435lbs)
Compressionpressurss: MP. psl
Newongin€.........,,,,,.,...... 3.2 455
lvlinimum................,,...... 2.4 313
Maxdiffsr€nce between cy1inders ........................... 0,8 114
Compressionralio .......,, 23.0r1
Cylinder
bore....,............. 76.5mm = 3.0118in
Slrokelength 86.4mm = 3.4016in
Group21 Engineassembly
CYLINDERHEAD
:.' -
9- .,, \ \|
.,1
;
Diagonallymax 0.5 mm
Replacecylinderh€adjfwarp €xce€dssp€cificalions.
Und€rno circumst.ncosmay cylihderh€adb€ machinod.
Specifications
CYLINDEB HEADGASKET
Thfeedifferentgaskettypesare useddependingon pistonprojectionabovecytinderblockface.
G.sket
Pistonproi€ction notches thickness
mm linl mm (in)
(0.026-{.031
0.67-0.80 1
)........ ....................1.4
{0.0S5)
2 ...................
0.81-0.90(0.032-{1.035)........ 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 Check Setting
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 mm (in) mm lin)
0.15{.25 (0.006-{.010) 0.20{0.008)
0.35-0.45(0.014-0.01
8) 0.40(0.016)
Valveclearances,
warm engine
0.20-0.30(0.008-0.012)0.25{0.010)
Do 0.1299
in to 0.1673in in increments
of 0.0020
in
0.4(F0.50(0.016-0.020)0.45{0.018)
3.00-4.25mm in incrementsof 0-05mm
,lo
a
u
o20
Checldadjust
1-2-4-5"3
valves
n
!
r-l[ r] D24
Checuadjustvalvesin following order:
1-5-3-6-2-4
Specifications
TIGHTENINGTOROUES
Tight€ningtorquB apply to oiled nuts and bo|Is.De-
grsased {washed}parts must b€ oiled prior to
TIGHIENITVG
SEOUENCE
FORCYLIIIDERXEADBOLTS
oo ,Ot rO @@
D20 lmportlntl slsck6nbotts in rev€rsaoder when
@o ,oo @@ removingcylindsrh€ad.
NGHIENING OFCYLINDERHEADBOLTS
Mtl M12
Us6 now waahera,convex sid6 upwards, Us€ n.u bolb. Not n€ce$aryto roplac€w6shers.
Tlght€nin fiv€ stages:
Tightenin six stag6s:
l50Nm{37ftlbsl
2 ?0 Nm (50ft lbs) 1 ao Nm €0 ft lbsl
3 90 Nm {65ft lbs} 2 60 Ntn l4a ft lbsl
4 run 6ngin€until oil temperaturois st t€ast50.C 3 75 Nm {55ft lbs)
1122'Fl 4 angle-tightsnl8f in ono movem€nrwithout stop-
5 90 Nm (65ft lbs) ping, {Se€figur€ 6t lower lefi}
5 run €ngin€until oil tehperatureis at lerst 50oC
R.lightening lt22 "Fl
- Atler 600-1.200miles (1,000-2.000km). Engine 6 anglo-tighten90Pin on6 movsmentwithout stop-
shouldbe cold or almostcotd.Tighteneachboltsep6r- pins.
atslyin specifi€dorder,see abovsfio.:
L Slack€nbol 3(r Rdighl.nlng
2. Torque to 90 lrlm (65 ft tbs) After 60F1,200mil€6(1,000-2,000 km).Engineshould
b6 cold or almost cold.
Tighten 6ach boll separatolyin spocifi€dorder, se€
€bov€fig.:
1. Angle-tightenbolt 9|r in one movemontwithout
stopping.(Seefigure at lower left)
Do not shckon boh firf,
Specificalions
6\1fl
D20
(6.5ft lbsl
@@'
Smearthread a sn db o l th e a dc o n - Nm (55 ft tbs)
tacl suriaceswilh locking com-
pound(P/N277961-9).
Tiqhteninglorque 350 Nn {258ft
l b s ) a p p l i 6 sw h e n u s i n gs p e c i a l
tool 5188.lf a torque wrench is
lsed dirscny on the cenler boll
(wiihout 5188), the tiqhlening
torqle should be 450 Nm (332ft 75 Nm (55 ft lbs)
350 Nm (258ft lbs)
Gtoup 22 LubricatingSystem
OILCAPACITIES
D20 D24
Litors{US quarts} LitersIUS quarts)
Excl.oilfilter 5.2 (5.5) 6.2 (6.5)
Incl.oillilter 6.0 (6.3) 7.O(1.41
Difference in volume,max-min 1.0(1.0) 1.0(1.0)
ENGINEOIL
Oua1ity............,,,,,............ min CC
Accord'ngto API.......................................,,..,....,.:::::::::::::,.:::::::
Oilswith designations
SSCC,SE/CD,
SF/CCand SF/CD
meotthis r€quirement
VbGosity
Tomporaturcrangs
(stableambisnttemperatures)
OILPRESSURE
kPa psl
Oil pressurcat oil temperatureof 8O.C(176.F)and 33,3r/s
(2000r/min)min 200 28
Oilpressuresensot
Cut-outpoint,indicatorlampgoesout at 15-45 2-6.4
Lubricatingoil pump
Reliefvalv€opensat...... .........................
600-700 85-99
R€lisfvalvespring,l€ngthat diffsrentloads
Long1h Load
ffiffi8
mm in. N lbs
L = 49 (1.93) 0 0
L1= 22 {0.87} 17F195 {39-.44)
L2 = 19.8 (0.781 approx.200 (45)
(completelycompressed)
Specifications
Group23 Fuelsystem
GENERAL
D20 D24
F i r i n os r d e r . . . . . . . . . . . . . . . . . 'l-2-4-5-3
1-5-3-6-24
ldle 12.5(750) 12.5(750)r/s (r/min)
fast .,.,.....,.,.,.,,. 87.0(5200) 87.0(5200)r/s (r/min)
FUEL
:o Standard................ DIN51601rCEC-ERF-Dl,
ASTIM-D
45
975-No.2-D
or
0.5
Distributorrypepump
M a k ea n d d e s i g n a t i o n ,D 2 0 BoschVE5/10F2400145
(145'1for autovehicles)
D24 BoschVE6/10F2400132
(132-1for autovehicles)
VolvoP/N{exchange unit)D20 .................... 500't716-9
D24 5001715-1
Injeclion
timing{purrpprungerslrokeat TDC, Checkinsmm lin) Settinsmm {in)
D20............................. 0.75-0.83mm
(0.0295-0.0327) 0.80mm (0.0315)
0.65-0.73mm
10.256-0.O2a7J 0.70mm (0.0276)
D24USAandCanada1979-t98i 0.65-0.73mm
(0.0256-0.0287) 0.70mm (0.0295)
1982- 0.82-0.90mm
{0.0323-0.0354} 0.85mm {0.0335)
NOTE! High altitude
necessaryIn certain
page132.
0i:o
INJECTORS
Ir4akeanddesignation BoschKCA30SD27l (44)
BoschNo. USA,/Canad€
1982- 0 68 13020?F (201J)
Othermarkets................... 0 68 130201(201K)
VolvoP/NUSt"/Canada
t982- 1328073,0
1257t44-4
Checkins Setting
lnlectoropeningpressure''''. . . . . . ..................................
MPa 12.5-',t3.s
'. . . ....",.- .- . . . . . . . .....,.-....,.
psi 1707-1849 1778,1920
Specifications
Nozzl6s
Bosch
Designation
USA"/Canada
1982- DNOSD1930
Othermarkets DN O SD 193
Volvo P/N USA,/Canada1982' 1328096,1
't542303-1
5l usarcanlda
3::133;3i ,esz.
068190201 I ^.
oogrrozolxl
D N 0 5 D 1 9 30 = U S A / C a n a d1s9 8 2 -
D N = S D 1 9 3= o l h e rm a r k € t s
ldentiticationot iniectors and nozzles
Iniector
(complete)
TIGHTENINGTOROUES
Nm ft. lbs
Injector,
in cylinderhead 10 52
upper-rowersection...........................::...:.:.:.:.:.:.:::..::
70 52
Iniectionpump,pumpg 45 33
45 Nm = 33 ft lbs
ti
10
Specifications
Group26 Coolingsystem
GENERAL
Coohnt
Sincealuminiumis usedin the engines, activecorro-
sion protectionis necessaryin the coolantto help pre
ventcorrosion damage.
Use genuine Volvoblue-green coolanttype C diluted
with cleanwater in proponionsof 50/50.
This mixture helps to pr€venl corrosion and frost
c,il
a Neverlill the coolingsystemwith water alone.
a The coolantshouldbe changedregularlysince
the corrosionprolective6dditivesin the coolant
losethoiref{ectin time.
co
D 20litros IUS qlrrts) D 24lirresIUS quarts)
Capacity,
with manualgearbox 8.2 (8.7) 9.4{9.9}
with auiomatictransmission
.....,,... 8.0 (8.4) 9.2{9.7)
EXPANSIONTANK
Pressure
valvein capopensal ,,.,.,.,,,,.,,,.,..,....,..... Type 1 kPa(psi) Type2 kPa{psi)
65-85(9.2-12.1) r00 {14.2)
7 {1.01 7 {1.0)
THERMOSTAT
Markin9......................... 87'C
tt:o DRIVEBELTS
Deslgndion (VolvoP/Nl
HC38xl238
(960296-2)
HC38x975
(958354-3)
3 C o o l i n gr a n
HC38x888 4 Powersteo.ingpump
{460431 s)
Hc38x800
(958302-1)
TIGHTENINGTOROUE Ir. lbs.
C o o l i n gf a n 9 6.6
1l
Special tools
Specialtools
999 lDdcription-U.s
18Ol-3 | Stand.rd h.ndle: lsed with drift 5207 and 5208
261G3 | Lift be.m: rcmovingfinslalling
engin€
2901-0lC16mpinsplisrc{2x):clampinswat€rhoseswhenremovinsintecrionpump
2903.6 | Oiltlltor wl6Dch
4090-0 | Pullet:removingpilol bearins
5006-5 | Lifi br.ckst: r€placingtronl €nsinemounts
5033-9 | Support{2xl: for lilt bracl€t5006
5112.1 | Loc*ing 6sdo.: locking flywheel
51154 | Lift hook: usedwith ltft bracket5006
5185-7 | Lift hoolr lronr: removing/inslallins
€nsin€
5186.5 | Lift hoo*, lsar: ,€movins,4nstaltins
ensine
5147.3 I WronchrvibrationdEmoer
5188.'l I Wr6nchwith oxt nsionarm: lor vibraliondampercenterbolt
5190-7 | Giuse: instsllingcamshaft
5191-5 | Adapter:connoctinspr6ssur6ssuse
51$n I Siop: lockihsinjecrionpunp sear
5194.9 | Holder:for dial indicalorwhen adjueins inj€ctionpump
5195.5 | PlisB: rcmovinsvalvediscs
Specialtools
5006,5033,5115
5185,5186 5187,5188
5194 5t95
't3
Special tools
999
't4
Specialtools
5233,5234
9950
9950
Group21 Engine
Contents
Group21 EngineAssembly
Contents
Replacementof engine
Removal.,...,,.......,...,....,. 'r11
Insta11in9
........................ x1-33 '114
Group21 Engine
Compression test
A. Compressiontest
Specialtool:5191
A1
Disconnectwire lrom stop valve on injection
pump
T h i s s t o p sf l o w o f f u e a n d p r e v e n r st ] n n e c e s s a rsyp i | -
ase.
A2
Removevacuumpumpand pump plunger
A3
Disconnectfuel detiverypipes
C e a n a l l c o n n e c r i o n sc a r e f u y b e f o r e d i s c o n n e c r i n g
D i s c o n f e c ip i p e s a n d p l u g a l l c o n n e d i o n sr o p r e v e n r
d i r i f r o n r e n t e r l n gs y s t e m .
11
Gtoup 21 Engina
Compression test
44
Removeiniectors
Use27 mm socket{VolvoP/N1158146}.
theywill
otherwise
Liftouth€atshieldsundsriniectors
beblownout duringcompression tesl.
A5
Connectcompressiontestel
Placeaheatshieldincylind€r adapter
headandscrewin
5191.Ighten to 70 Nm {50ft lbs).
connectcompression testerto adapter.
A6
Run engine and record compression
Compression
= 3.2MPa{455psi}
Min = 2.4MPa(341psi)
Max differ€ncebetween
= 0.8MP.(114psi)
A7
Installiniectors
Placenewheatshieldsin cylinder head, seefig. Install
Torqueto 70 Nm (s0 it. lbs).
injectors.
A8
Reconnectdeliverypipes
torque25 Nm(18ft lbsl.
Tightening
A9
Reconnectwire to stop valve
r'.l0
Installpump plungorand vacuumpumP
CheckpumpO-ring.replace
18
Group 21 Engine
Valve adjustment
B. Valveadjustment
Special tools: 5195, 5196
V a l v ec l e a r a n c em u s t b e c h e c k e d / a d i u s t e6df i e rc o m p l e t i o no f r e p a i f ss u c ha s g r i n d i n gv a t v e s c, r a n k s h a frre p t a c e m e n t
etc.,
a n d a l s o a f t e r6 0 G - 1 , 2 0 0m i l e s ( 1 , 0 0 G - 2 , 0 0k0m ) .
B1
Removevalve cover
B2
Turn engineuntil cyl. 1 is at TDC- injection
A w a y s u s et h e v i b r a t i o nd a m p e rc e n t e rb o l t t o t u r n t h e
e n g i n e .2 7 m m s o c k e to r w r e n c h 5 1 8 8 .
B o t h c y l i n d e r1 c a m s s h o u l d p o i n l o b l i q u e l yu p w a r d s .
B3
Check valve clearance lor cyl. 1
Checkingvalues
Coldensine
0.15-0.25 0.0060.010
Exhaust 0.350.45 0.01,t-0.018
0.20-0.30 0.008-0.012
Exhaust 0.400.50 0.016-0.020
D20
a
il 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
a
! Alf
f r
Alt
I r
19
Group21 Engine
Valveadjustment
B4
Tum engineapProx.1/4 iurn
Pistonmustnot be at top deadcenterwhensetting
valveclearance,otherwisevalveswill contactpiston
whentapp€t is deprsssed
B5
Dopresstappets
Turntappetsuntilgroovespointslightly
inward.using
tool 5196,
depress to
tappets obtainaccess
to discs.
B6
Removedisc
Use5195.
B7
Calculatethicknessol disc to be used
whensetting:
Valvecl€arsnces
Cold €ngine in
0.20 0.008
Exhaust 0.40 0.016
0.25 0.010
Exhaust 0.45 0.018
Measurethicknessof old discwitha Calcu-
micrometer.
latethicknessof new discto be used,seeoverleaf.
20
Gtoup 21 Engine
Valve adjustment
Erample:
lfclearance
is 0.20mm andspecified is 0.25
clearance
mm then replaceexistingdiscwith one whichis 0.05
B8
Position new disc and removepliers
Discshouldbe lubricateda n d i n s t a l l e dw i t h s i z em a r k s
B9
Check/adjust valve clearanceIor remaining cylin-
derc
Checuadjust in followingorder:
D 20. 1-2-4,5-3
D 24, 1-5-3-6-2-4
lmportantl Do not forget to rotatecrankshafl1/4turn
beforechecUadiusting valveclearance.
810
Recheckvalve clearancefor all cylinders
R o t a t ee n g i n es e v e r a lt u r n s b e f o r e r e c h e c k i n g .
811
lnstall valve covet
Usenew gaskets
if 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 es e ef i g . L a r e t y p e s
have a spacer, and hole in gasket is la.ger to prevent
damage to gaskel by ovenightening,
iY:'I,l d.!
L€te and eary type parts must not be imerchanged.
21
Group21 Engine
Basic setting
C. Basicsetting of engine
Specialtools: 5190,5193,5194,5197,5199,5201
C1
Remove:
C2
'l
Turn engine until cyl. is at TDC - iniection
Alwaysusethevibrationdampercenterbolt to turn ihe
engine.
=
27 mm socketor wrench5188.
BothcylinderI camsshouldpointobliquelyupwards.
at 0 mark.
Flywheel
22
Group 21 Engine
Basic setting
a,
,":'trtiiiiiiiiii
c4
Removecamshaftrear sprocket
in pos;tion
Holdsprocket with5199andunscrew
nut
with wren€h 5201. Take care not to rotate camshaft.
C5
Slackencamshafttront sprocket
U s e 5 1 9 9r o h o l d s p . o c k e ri n p o s i n o nw h e ' 1l o o s e n i n g
b o l t . M a k e s u r e t h a t c a m s h a f id o e s n o l r o l a t e .
Tap sprocket to free it from camshaft.
c6
Set belt tension
A d j u s tt e n s i o nb y m o v i n g c o o l a n tp u m p .
U s e g a u g e5 1 9 7t o c h e c kb e l t t e n s i o n .A t t a c hg a u g et o
b e l t a n d s e t t o 1 2 . 5u n i t s .
S t r e t c hb e l i u n t i l m a r k o n g a u g e p t u n g e ri s f t u s hw i t h
D e p r e s sb e l ts t r o n g l y w i t hh a n da n d r e c h e c U a d j u st el n
23
Group 2l Engine
Basic setting
C7
Set camshaft position
PlacegaLrge 5190at rearof camshaft.Inserta 0.2mm
(0.008in) ieelersausebeneathlefi sideof sauseto
compensate for timinggearclear;nce.
Camshafi;s now setat correctposition.
C8
Make sure cyl. no. 1 is at top dead center
Check 0 mark on flywheel and adiustif necessary.
)r
C9
Tighten camshaft front sprocket
Use5199to preventsprocket fromturning.Makesure
that camshaftdoes not turn.
Torquecenterbolt to 4s Nm (33ft lbs).
c10
Removegauge 5190 and leeler gauge
cl1
Disconnectcold start device
Slacken
screw1. Pushleverforwardandrotatesleeve
90". Notel Do not turn screw 2 otherwiseit will be
necessaryto removecold startdeviceand resetit on a
Group 21 Engine
Basic setting
c12
_--xar-L--.\.-
' -.l\t'-iHi- Basic-setiniectionpump
- v -.t";; - S ackenpumpmountins bolts(Ailen
key= 6 mm).Align
in pumpandmounling bracket pump
byturning
ilo ,,
-.-
.)!\\./.)
.- /:)a>- L I
marks
R e t i g h t e nm o ! n t i n 9 b o l t s .
c13
Sel dial indicator zero. Lock pump gear at cyl. 1
injection using stop 5193
Unscrewand removeplug from injectionpump dis-
tributor.
Installholder5194 (range0-3
anddialindicator
mm).Setgaugeto approx.2 mm.
Turn pump gear clockwiseuntil mark on gear and
mo'rntingbracketcoincide.
T h e n t u r n p u m p g e a r b a c k s l i g h ty u n t i l m i n - r e a d i n g
r e g i s t e r so n d i a l i n d i c a t o r .
Set indicator to zero.
T u r n p u m p g e a rc l o c k w i s e! n l i l m a r k o n g e a ra n d p u m p
m o u n t i n g b r a c k e tc o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n
w i t h s r o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n t o
c14
Install camshaft rear sprocket and belt
Tightencenlerbo t by hand,but it shouldstil be possi_
on camshaft.
b e to turn sprocket
25
Group21 Engine
Basic setting
c15
Set belt tension
A d j u s tt e n s i o nb y m o v i n g p u m p .
U s e g a u g e5 1 9 7t o c h e c kb e l t t e n s i o n .A f t a c hg a u g er o
b e l t a n d s e t t o 1 2 , 5u n i t s .
S t r e l c hb e l t u n t i m a r k o n g a u g e p t u n g e ri s f t u s hw i r h
D e p r e s sb e l i s l r o n g l yw i t h h a n da n d . e c h e c U a d j u s r r e n
c16
Set pump and tighten camshaft rear sprocket
U s e5 1 9 9t o h o l d s p r o c k e tT. o r q ! e w r e n c hs h o ! d r r ea t
r i g h i a n g l e l o w r e n c h 5 2 0 1 o t h e r w i s et o r q u e w i l l b e
U s i n g 5 1 9 9 ,l u r n s p r o c k e ts o w y c l o c k w i s eu n l i l d i a l
c17
Removestop5193trom pump gear
ct8
Check pump setting
T u r n e n g i n et w o f u l l t u r n s u n r i c y t . 1 i s a t l o p o e d o
c e n t e r- i n j e c t i o na g a i n . l f e n g i n e i s t u r n e d r o o r a r r
m u s t b e l u r n e d b a c ka p p r o x .1 / 4 1 u r na n d t h e n t o z e r o
m a r k o t h e r w i s es e t t i n gw i l l b e i n c o ( e c i .
D i a i n d i c a l o rs h o u l d s h o w :
O 2 0 . . . . . . . . . . . . . . . . . . 0. ...7. .5.0. . .8 3 m m = 0 . 0 2 9 F 0 . 0 3 2 7 i n
D 24 .......-............0 . ...6. .F. -0 . 7 3m m : 0 . 0 2 5 6 - 0 . 0 2 8i f7
D 24 USA and canada
1 9 7 F 8 1 . . . . . . . . . . . . . . . .0. ...6. .5 - 0 . 7 3 m m = 0 . 0 2 5 60 . 0 2 8 7 i n
1982 ........-................0.8 920m m = 0 . 0 3 2 3 - 0 . 0 3 5i n4
Correct reading: Tighren injeciion pump mounting
b o l l s .P r o c e e dt o C 1 9 .
r n c o f t e c tr e a d i n g : B e a d j u s ta c c o r d i n gr o i n s r r u c t i o n s
26
Group 21 Engine
Cylinderhead,removal
pumpsetting:
Readlusting
Settingvaluesi
0.80mm = 0.0315
D 20 ......-.............-....-....................... in
0.70mm = 0-0276
D 24 .....-....-....-........-....-...-...-....-...... in
D 2 4 U S A a n d C a n a d a 18917. 9
.....0.70mm:0.0276in
-trnjE+:
-i;6't;
1982-.......... 0.85mm = 0.0335in
$tl
Readinglessthan specified:
Slackenpurnpmountingboltsandlurn pumpinwards
to obtaincorecr value.Tightenmounringboltsand
repeatcheckof pumpsetting.
c19
Remove dial indicator and holder 5194. lnstall
plug with new seal
Tishteningtorque9 Nm (6.5ft lbs).
c20
Reconnect cold start device
Presseverforwardsand turn s l e e v e 9 0 " . R e t i g h t e n
c21
Installvalvecoverand timing gearcovers
U s e n e w g a s k e t si f n e c e s s a r y .
/ Qa,s '
zTazzzz Two types ol pin studs are avaitabte,see tig. LareryDes
h € v ea s p a c e r a
, n d h o i e i n g a s k e li s l a r g e rt o p r e v e n l
II 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 ,
E Late ard eury type pa.ts musr not be inlerchanged.
21
Group21 Engine
Cylinder head, removal
D. Cylinderhead,removal
Specialtools: 5199,5201
D1
Disconnect negative lead from battery
Removeenginesplashguard.
D2
Disconnect:
- e x h a u s tp i p e f r o m g e a r b o xb r a c k e t
e x h a u s tp i p e f r o m r e a r b r a n c h p i p e .
D3
Disconnect:
- exhaust pipe
pipefromfrontbranch
-air filter cover with intake hose and crankcase
D4
Draincoolant
R e m o v ee x p a n s i o nt a n k c a p
D i s c o n n e clto w e r r a d i a t o rh o s ef r o m r a d i a t o r
2a
Group 21 Engine
Cylinder head, removal
D5
Draincoolantfrom engine
{ E n g i n ei s w i t h o u t a d r a i n c o c k . )
t w e r h o s ef r o m c o l d s t a r td e v i c ea n d d r a i n
D i s c o n n e co
D6
Disconnect {rom cylindet head I
u p p e r r a d i a t o rh o s e
- h o s ef o r c o l d s t a r i d e v i c e .
D7
Removevacuumpump and pump plunger
Remove pump retaining nuts and place pump on
B e m o v ep l u n g e rf r o m c y l i n d e rh e a d .
D8
Removetuel deliverypipe
C l e a na l l c o n n e c t i o n st h o r o u g h l yb e f o r ed i s c o n n e c t i n g
R e m o v ea l l p r e s s u r ep i p e sa n d p l u g e n d s l o p r e v e n td i n
f r o m e n t e r i n gf u e l s y s t e m .
29
Group21 Engine
Cylinder head, removal
D9
Disconnect from cylinder head:
-wire for temperaturegaugesender
-wire for glow plugs
copperconnecting stripfor rearglow plug
- feturn hosefrom rear iniector
- wirefor temperaturegaugesenderat rearof cylinder
D10
Remove:
Dl1
Tum engineuntil cyl. 1 is at TDC- injection
A l w a y su s e i h e v i b r a t i o nd a m p e r c e n t e rb o l t t o t u r n t h e
D12
Remove retaining screws from belt cover on
cylinder head
Takecarelhatwasheron innerscrewdoes
nolfalldown
intolowertiminggearcasecover.
(Latetypeenginesdo not havethiswasher).
30
Group21 Engine
Cylinder head, removal
D13
Removebelt from camshaftsprocket
S l a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l t t e n
R e m o v eb e l t f r o m s p r o c k e t .
D14
Bemovecamshaftfront sprocket
Use5199to holdsprocket in posjtionwhentoosening
bolt. IMakesurethat camshaftdoes not rotate.
Tap sprocketto free it from camshaft.
D15
Lift off pump belt
S l a c k e nm o j n t i n s b o l t s f o r i n j e c t i o np u m p
re ease belt tension. Tighten one bo t so
r e m a a n si n u p p e r p o s i t i o n .
Lift off belt.
D16
Removecamshaftrear sprocket
Hold sprocket in position with 5199 and unscrew
sprocket with wrench 5201- Take care not to rorate
31
Group 21 Engine
Cylinder head, removal
oo oo A, Ol D17
D20 Remove cylinder head
@o oo o@ lmportantr Slacken bo ts in reverse sequence to tighl-
e 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 - )
T i g h l e n i n gs e q u e n c ef o r c y l n d e r h e a d b o i s .
Bolis musl be slackenedln reversesequence. L i i i a w a y c y i n d e rh e a d .C h e c k t h a rt e a r g l o w p u g c l e a r s
i n j e c t i o np u m p b r a c k e la n d t h a t v a l v e sd o n o t c o n t a c t
@@,o o oo@
D24
@o0 o ooo
D18
0
Place cylinder head on wooden blocks
Do not restcylincler
head
D19
Clean gasket surfaces on cylinderhead and
cylinderblock
D20
Check for damage and warp
U s e a s t r a i g h te d g e a n d f e e t e rg a u g e .
R e p l a c ec y i n d e r h e a d i f w a r p e x c e e d s :
- l e n g t h w i s e0 . 5 m m { 0 . 0 2i n ) .
0 (
- c r o s s w r s e0 . 2 m m ( 0 . 0 0 8i n ) .
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 not f c y l i n d e rh e a d s i n c et h e y d o n o t i m p a i r
F o r g a s k e t r e p l a c e m e n to n l y s e e " C y l i n d e r h e a d i n -
s t a l l a t i o n "p a g e 4 5 .
E. Cylinderhead,disassem
bly
E1
Removeintake manifold,exhaust manifold and
gasket
E2
Remove injectors
R e m o v ed i r l a r o u n d i n j e c t o r s .
D i s c o n n e cftu e l l i n e s .
B e m o v ei n j e c t o r s , 2 Tm m s o c k e t .L i f t o u t h e a ts h i e l d s
l r o m c y l i n d e rh e a d .
33
iI
Group21 Engine
Cylinder head, disassembly
E3
Removecamshaftbearingcaps 1 and 4
E4
Remove camshaft bearing caps 2 and 3
1oavoidplacingunevenloadon
nutscrosswise
Slacken
E5
Lift awav camshalt and remove oil seals
E6
Lift out tappets
N o t e l D o n o t i n t e r c h a n g tea p p e l s .M a r kt a p p e t ss o t h a t
t h e y c a n b e i n s t a l l e di n s a m e p o s i t i o n .
E7
Remove {rom cylinder head:
- lifting eyes
- c o n n e c t i n gf l a n g ef o r w a t e r h o s e ( A l l e n5 m m )
- t e m p e r a t u r es e n d e r s( 2 x ) .
Group21 Engine
Cylinder head, disassemt'/y
E8
Tap out swirl chambers
Usea longnarrowpunch(6mm - 0.24in diameter),
l e n g t h1 5 0 m m ( 6 i n ) .
{r*,t
E9
Removevalve springsand valves
Do not intetchange
lmportant! pans.
tool
valvespringswith a specialcompressor
Depress
- upperspnngseat
- springs
E10
Removesealstrom valve guides
Usetool5219,
El1
Removelower valve spring
U s e a p a i r o f e x t e r n a l o c k r i n g plierswith flatjaws.
35
Group21 Engine
Cylinder head, cleaning - inspection
F. Gylinderhead,cleaning- inspection
F2
Checkcamshaftend float
Usea dialindicator.
Posiror ransnaildrd rr"ld redrcdp.lorqueto 20Nm
, r bn r b s , .
0
C l e a r a n c e= m a x 0 . 1 5m m ( 0 0 0 6 i n )
R e m o v ec a p a n d c a m s h a f l .
0
F3
Check discs
C h e c kd i s c p l a y . B e p l a c ed i s c i f w o r n o r s c o r e d .
I n s t a l ln e w d i s c sw i t h n u m b e r sf a c i n g d o w n , l o w a r d s
36
Group21 Engine
Cylinder head. cleaning - inspection
Check tappets
P acetappetsin cylinderhead
Checkfit andclearance.
Clearance, mm (0.0010.003in)
newparts 0.025-0.075
8trre
Length
lin) {lbs)
33.9 (1.334) 0 l0)
28_6 (1.126) 61 17 { 1 51 7 . 5 )
18.3 (0.720) 209-231 t41 52.2)
Outersprings
Length
(in) {lbs)
40.2 (1.583) 0 (0)
32.6 (1.283) I67-185 l3v42l
22.3 (0.878) 433 479 (98-108.3)
Replacingvalve guides
OperationsF 6-8
F6
Pressout valveguide
U s e d r i f t 5 2 1 8 .P r e s sf r o m c o m b u s t i o nc h a m b e rs i d e .
37
Group21 Engine
Cylinder head, cleaning - inspection
F8
Clean inside of valve guide
Use rsamBr5224
Note! Cuttingoil must beusedwhenreaming,
aftsrvalveguide
Valvesand seatsmust be ground-in
F10
Mill or grind valv6 seats
Grindto 45'.
Contactsurface{a) must be:
-2.0 mm {0.08in) for intakevalve
-2.4 mm {0.09in)for sxhaustvalve.
ll contactsurfaceis too wide reduc€areawith a 15q
1.5mm {0.00in)
Ftl
Measuaegap betweendisc and cylinderhead
surfaco
Gap= max1.5mm 10.06
in).
Replaceseatand possiblyvalve if gap is too Iarge.
NotelTwo valvstypes are available,seeG3.
38
Group21 Engine
Cylinder head, cieaning - inspection
F12
Grind-invalveswith paste
C l e a nv a l v e st h o r o u s h l y .
.3F{'
q.
'
^s Replacingvalve seats
OperctionsF13 21
V a l v eg u i d e sm u s t b e r e p l a c e db e f o r er e p a c _
i n g s e a t s ,s e e F 6 8 , p a g e 3 7 .
Cfeancombustionchamber F13
Togeol sealnJsl be clearv vis:oleahF' cleaninS.
37.09(F37.105( 1 . 4 6 0 21 . 4 6 0 8 )
inrake....................
exhausr................ 05 { 1 . 3 0 2 8 - 1 . 3 0 3 3 )
33.090-33.1
Oversize
mm = 0.00290 041in) ( r e p l a c e m e nPt a r t sv e r s i o n )
D a m e t e r ,s e a t r e c e s s m , m (rnJ
i n 1 a k e . . . . . . . . . . . . . . . . . .2. .0 0 - 3 7 . 2 1 6 \ 1 . 4 6 4 6 - 1 . 4 6 5 2 1
3 7 .
e x h a u s r. . . . . . . . . . . .3. .3- -. 2 0 03 3 2 1 6 1 1 3 4 1 1 - 13 0 1 7 1
W h e n r e p l a c i n gv a v e s e a l s :t h e i n t e r f e r e n c eb e t w e e n
t h e v a l v es e a ta n d i t s b o r e i r t h e c Y l i n d e rh e a ds h a l lb e
0.074-0.10smm (0.0029-0.0041in) I e valve sear d a-
m e t e r m u s t b e 0 . 0 7 40 . 1 0 5 m m ( 0 0 0 2 F 0 0 0 4 1 n )
g r e a t e ri h a n t h € d i a m e l e ro f t h e b o r e i n t h e c y l i n d e r
h e a d .R e p l a c ec y l i n d e rh e a c li f c e a r a n c ei s t o o s m a l
M i l l s e a t r e c e s si f i n t e r f e r e n c ei s t o o l a r g e .
39
Group21 Engine
Cylinder head, assembly
F16
Heatcylinderhead
Heatto '100'C
(212'F).
F17
Placenew seat in installationtool
Use drift 5220 for intake valve seats and 5221 for ex-
lr
F18
Cool valve seat
Wear protective gloves and safety glasses.
Use liquid carbon dioxide to cool seat down to -70'C
(-94"F).
Ft9
Tap-invalveseat
N o t e l T h i s m u s t b e d o n e q u i c k l y , w i t h i n 34 s e c o n d s t o
avoid temperature loss.
0,r (
F20
Checklit of valve seat
M a k es u r e t h a t t h e s e a th a s b o t t o m e dc o r r e c t l ya n d i s
s e c u r e .i f n o t , r e p l a c ec y l i n d e rh e a d .
F21
Grind valvesand mill seats
S e e i n s t r u c t i o n so n p a g e 3 8 , o p e r a t i o n sF F ] 2
40
Group21 Engine
Cylinderhead,assembly
G. Cylinderhead,assembly
New cylinderhead
Newcylinderhead
Opetationcl cl
Installoil ieis and pin studs in cylinderhead
Carelullytapin oiljetsusinga brasspunch.
Note!Turnouterjetsto pointacross cylinderhead,see
fis
lmportantl Check specification ;nd type of cylinder
h e a d .M ' 1 2b o l t s m u s t n o t b e u s e d w i r h M 1 1 b o l t s .
Differenttype cylinder heads are used for LJSI,/Canada.
G2
Checkvalvestem posilionin relationto camshaft
Thismeasurement
iscarriedoutto ensurethatthereis
sufficientadjustmentlattitudefor valves.
Placegauge5222with largestdiam€terring,on cylin-
der he8d.(Smallringis for B 17-B23 engines.)
Notel F.ont bearingrecessdiameter'islargerthan
others.Makesurethat gaugeis positio.ed correctly.
Takingeachva,vein tu.n, checkthat stem doesnot
conlactgauge.lf thishappens, grindvalvestem.
4l
Group2l Engine
Cylinderhead,assembly I
G3
Early and late tvpe valves.valve collets (locks)
and upper springseats
I
E a r l yt y p e v a l v e sa n d c o l e t s h a v eo n e l o c k i n gg r o o v e
whereas late tYpes have three
I
O n l y l a t e t y p e s a r e a v a i l a b l ea s s p a r e p a r l s
Consequentlw y h e n i n s t a L l i n ga n e w v a l v e ,t h e c o l l e t
a n d u p p e rs p r i n gs e a l m u s t a l s o b e r e p l a c e dw i t h n e w
N e w s p r i n gs e a t sa r e e i r h e r c o p p e cr o a t e do r c h r o m e d
E a r l yt y p e s a r e b r i g h t o r b l a c k .
f(
G4
lnstalll
- upperspringseats,flangedsideup.
va ve stemoil seal.
lnstaLl
Protectivesleevesmustbeusedwheninstailing oilseal
To installvalve,pl.cevalvein cylinderheadandplace
protecrive sleeveon stem.use tool 5219to installoil
seal,notethattool shouldabutflangeseal.
l, (
I
G5
lnstall:
innerand outervalvesp.ings
upperspringseatsand
Twotypesol valves,
lmportantl
Group21 Engine
Cylinder head. assembly
( .., e, G6
ra 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 .
M a k e s u r e t h a t b a l l f i t s i n s l o t i n c y l i n d e rh e a c l .T a p
down swirl chambers.
l m p o r t a n t ! S p e c i a s w i r l c h a m b e r s ( d i f f e r e n td i a -
m e t e r )f o r U S A / C a n a d a 1982-.
G7
lnstall:
- glowp ugs.Tishtening torque40 Nm (30ft lbs)
temperature (2X).Samelypefrontandrear
senders
- connecting fange for radiatorhose(Allen5 nrm).
Installnewgasket.Tighteningtorque10Nm (7ft bs).
- lfting eyes.
G8
Installtappets with shims
Smeariappetsandshimswith oil beforeinstaa!on.
Numberon shimsshouldfacedown.
Checkthattappetsslideeasiy withoutsticking.
G9
Placecamshaftin cylinderhead
Lubricate
contactsurfaces of camshaltand bearings.
Place9au9e5'190al rearof camshafl.
lmportantlBoth
camsfor number1 cylindermustpointdiagonay up,
43
Group21 Engine
Cylinder head, assenbly
G10
Installcamshaltcaps2 and 3
centeris off'sel.
Installcapscorrectly,
Tighlennutscrosswise to avoiddistortion.
Holdcam
shaftin position
wilh gauge5190at rearwhentighten
gauge5190.
Remove
Gl1
Press in new camshaft oil seals
Applyoil to oil seals.
Donotpushin sealstobottomposilion.
Makesurethat
seasare"square",0
GI2
Install camshaft caps 1 and 4
M d l ec J r eI n a r " eL h r J 5 l w i s nfeo r c a r s h . l c a p 4 r l s ^
colrecl.v.
G13 0
G15
Installiniectors
Placenewheatshieds in cy inderheadTurnshieds as
0
Gt6
Install exhaust branch pipe and intake mani{old
U s e n e w g a s k e t sa n d n u t s . I n s t a l lg a s k e t sc o r r e c t l Y .
B r a n c hp i p e g a s k e ts h o u d b e t u r n e d w i t h r a i s e de d g e
o u t w a r d s ,f a c i n g b r a n c h p i p e . I n t a k em a n i f o l d g a s k e t
s h o | ]d b e l u r n e d w i t h g r e e ns i d e f a c i n gc y l i n d e rh e a d .
T i g h t e n i n gl o r q u e 2 5 N r n ( 1 8f t l b s ) .
Group21 Engine
cylinder head, installing
H. Cylinderhead,installing
Specialtools: 5190,5193,5194,5197,5199.5201,4x 5233,4 x 5234,5235
?/'--'\r H1
S--:'l Q4t )io.iQ Clean holes lor cylindel h6ad bohs
Oil and dirt must be removedfrom holes
gasketmay leak as a result of insufficienttightening
H2
lnstall guide pins in cylinder block
5233for blockswith M 11 bolts.
5234for blockswith M 12 bolts.
Twoouterpinsholdgasketin position.Cylinderheadis
preventedfrom slidjng and clamaginggasketby two
innerpins,
lmportantlUse all four pins, locatedas illustratsd.
H3
Install new cylinderhead gasket
Thresdil{sr€nttypes
areavailable,
andaremarked with
notches. Typeto be fitteddependson pistonheight
abovecylinderblock.
Uses8megaskettype (no,notches)as before,with
OBEN facingup.
45
Group2l Engine
Cylinder head. installing
_0 = 1980
B I r=r98r
c | 2=1982
D
E
MO
t*
Sept
G
J
I
Oct
Nov L
Dec M'
198 I
T o a v o i d i m p a i r i n gs e a L i n gp r o p e r t i e so f g a s k e td o n o t
o p e n p a c k e tu n t i l g a s k e ti s t o b e u s e d .
T a k ec a r en o t t o d a r n a g ep a c k e ta n d c a L r s ed a m a g el o
g a s k e t ,( t e f l o ns t r i p ,r u b b e r s e a l ) .
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
3: h e i g h lm u s tb e m e a s u r e da, n d g a s k e ct h o s e na c c o r d i n g
mm {in)
0.67-0.80(0_026-0.031
)
notches thicknessmm
I ................
1.4 (0.055)
(in}
0
0.81-0.90(0.032-0.03s)2 ................
1.5(0.059)
0.040) 3 ................
0.9't-1.02(0.036 1.6{0.063)
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
Selcamshaftso lhat number1 cylinderis at injection
(bothcam lobesshouldpointdiagonally upwards).
Preventcamshaftfrom moving with stop 5190.
lmportant!Camshaftmust be lockedotherwisevalves
o
i!
I Installcylinderhead bolts
L u b r i c a t et h r e a d sa n d s l i d i n gs ur f a c eo f w a s h e r s .P l a c e
b o l t si n h o e s w i l h o u t g u i d e p i n s .
+
R e m o v eg ! i d e p i n s . U s e t o o l 5 2 3 5 .
I n s t a l lr e m a i n i n gb o l t s .
47
I
Group21 Engine
Cylindet head, installing
oooo9/@
D20
@o.r'o'o@@ H8
Toique cylinderhead bohs
adia-
Tightenall boltsoneat a timein orderspecified
csntboforeproceeding wjth nextstage.
n
a
@@@@@).o@-
D24
@@@O@lO@,1
't1s9082
12-sidedwrenchP/N 1159082-5
48
Group21 Engine
Cylinder head, installing
H9
Connect copper connecting stdp lor two rear
glow plugs
H11
rD Installcamshaftsprocketand belt
Pullbeltto ensure
thatit sitscorrectly
on crankshaft
geaf.
Placebelt overcamshafi sprocket and position sprocket
T i g h t e nc e n t e rb o l t b y h a n d ,b u t i t s h o u l ds t i l b e p o s s i '
b l e t o t u r n s p r o c k e to n c a m s h a f t .
Hl2
Set belt tension
A d j u s tl e n s i o n b y m o v i n g c o o l i n g p u m p .
U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g er o b e t r
a n d s e t t o 1 2 . 5u n i t s .
S t r e l c hb e l t u n i i l m a r k o n g a u g e p u n g e r i s f u s h w i r h
D e p r e s sb e h s t r o n gy w i t h h a n da n d . e c h e c U a d j u s t t e n -
H13
Markesure cyl. 1 is at top dead center
C h e c k ' 0 m a r k o n f l y w h e e a n d a d j u s ti f n e c e s s e r y .
Group 21 Engine
Cylinder head, installing
H14
Placea 0.2mm feelergaugebeneathgauge5190
Insertbladebeneath
leftsideof gaugeto compensale
0.2mm = 0.008in.
fortiminggearclearance.
Ht5
,)a
Tighten camshaft front sprocket
Use5199to preventspocket from turning.
Torquecenterbolt to 45 Nm (33ft tbs). )e
H16
Removegauge 5190 and feeler gauge
H17
Disconnectcold start device
S l a c k e ns c r e w 1 . P u s hl e v e r f o r w a r da n d r o t a l es l e e v e
90'.
N o t € ! D o n o t t u r n s c r e w2 o t h e M i s e i t w i l l b e n e c e s s a r y
t o r e m o v e c o l ds t a r t d e v i c ea n d r e s e ti l o n a t e s t b e n c h . u)l
P r e s sl e v e rb a c k a g a i n s ts t o p .
i')l
H1a
Basic-setinjectionpump
S l a c k e np u m p m o u n t i n g b o l t s ( A l e n k e y = 6 m m )
A l i g n m a r k so n p u m p a n d m o u n t i n gb r a c k e tb y t u r n i n g
p u m p . R e t i g h t e nm o u n t i n g b o l t s .
5A
(
Group 21 Engine
Cylinder head. installing
H19
Set dial indicatorzero. Lock pump gear at cyl. I
injectionusing stop 5193
pumpdisrri
U n s c r e wa n d r e n r o v ep l u g f r o m injection
I n s t a l lh o l d e r5 l 9 4 a n d d i a l i n d i c a t o r( r a n s e0 3 m m ) .
S e t g a u g e t o a p p r o x .2 m m .
T u r n p u m p g e a r c l o c k w i s eu n t i l m a r k o n g e a r a n d
m o u n t i n gb r a c k e tc o i n c i d e .
T h e n t u r n p u m p g e a r b a c k s l i g h t l yu n l i l m i n r e a d i n g
r e g i s t e r so n d i a l i n c i i c a t o r .
S e t i n d i c a t o rt o z e r o .
T u r np u m p g e a rc l o c k w i s eu n t i l m a r ko n g e a ra n d p u m p
m o u n t i n g b r a c k e tc o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n
w i t h s t o p 5 1 9 3 .( l n s e f ts t o p t h r o u g h p u m p g e a r i n t o
i;;$d
H2A
Installcamshaftrear sprocketand belt
Tlghtencenterboltby hand,but it shouldstillbe possi
b e to turnsprocket
on camshaft.
H21
Set belt tension
A d j u s tl e n s i o n b y r n o v i n gp u m p .
U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g et o b e t
a n d s e t t o 1 2 . 5u n i t s .S t r e t c hb e l t u n t i l m a r k o n g a u g e
p l u n g e ri s f l u s hw i t h s l e e v e D
. e p r e s sb e t s t r o n gy w i t h
h a n d a n d r e c h e c k / a d j u st et n s i o n .
5l
Group21 Engine
Cylinder head, installing
H22
Set pump and tighten camshaftrear sprocket
Use5199to holdsprocketTorquewrenchshouldbe al
rightangleto wrench5201 torque
otherwise wl I be
ontiLdial
Using5199,turn sprocketslowlvclockwise
D 2 0 . . . . . . . . . . . . . . . . . . . . . . . . - .-. . . 0 8 0 m r n= 0 0 3 1 5 i n
D 24 ....................... .. . .. 0 70mm = 0.0276 in
D 24 USAJCanada
197981 ........-................ .. . . ... 0-70mrn= 0 02761n
1982 ............... .. . . .. 0 85mm :0 0335in
Holdsprockel in thisposiiionandtorquebollto 100Nm
)a
(73ft lbs).Takecarethatcamshait andsprocket do not
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
Readiusting pumpsetting:
D2 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. ,. 8. .0. .m :. .0. -. .0.3. .1. .5. i.n.
. .m
D 24..........-....-................................. 0.70mm= 0.0276 n
D24USAandCana
l 9cTl a9 l g S l 0 . 7 0 m m - 0 . 0 2 7 6 i n
1982-.......... 0.85mm = 0.0335 in
Readinglessthan specified:
Slackenpumpmouniingbohsandturn pumpanwards
to obtaincorrectvalue.Tightenmounilngboltsand
repeatcheckoi punrpsettn9s.
52
Group21 Engine
Cylinderhead.installing
H25
Removedial indicator and holder5194.lnstall
plug with new seal
T'shteningtorqueI Nm(6.5ft
H26
Reconnect cold start device
o
Presslever forwards and turn sleeve90'. Retighten
H27
Install valve cover
Usenew gasketsif necessary.
53
Gtoup 2l Engine
Cylinder head. installing
H28
Install timing gear covers ({ront and rearl
)liO
H29
Reconnecttuel delivery pipes
Iighteningtorque25 Nm (18ft lbs). ')rO
H30
Reconnectreturn pipe to rear iniector
H31
Installplungerand vacuumpump
CheckO ring,replaceif necessary-
Connectvacuumhose(frombrakeseruo);to pLrmp.
lnstall:
H32
ilrlO
wireto glow plug
-wires to temperaturesenders(2 X), one at rearand
onelo leftof cylinderhead.
H33
Connect:
lowerradiato.hoseto radiator
- 'rpperradiato.hose
- hosesfor coldsiartdeviceto cylincler
headandtheF
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
Disconnectupperhosefrom cold startdevice.Place
drip pan beneathhoseand hold hoseleve with top
edgeof expansiontank.
Coolant
S i n c ea l u r n i n i u mi s u s e d i n t h e e n g i n e s ,a c t i v ec o r r o
s i o n p r o t e c t i o ni s n e c e s s a r iyn t h e c o o a n i h e l pp r e v e n l
D U s e g e n u i n eV o l v o b u e - g r e e nc o o l a n l t y p e C , d i l u t (
with clean water in propoltions of 50/50.
This mixture helps to prevent corrosion and fic
a N e v e rf i l l t h e c o o i n g s y s t e mw i t h w a t e r a l o n e -
a T h e c o o l a n l s h o u l d b e c h a n g e dr e g u r a , l ys r n c et h
c o r r o s i o np r o t e c t i v ea d d i t i v e si n t h e c o o l a n t l o s
t h e i r e f f e c ti n l i m e .
N o t e ! D o n o t r u n e n 9i n e w h e n l e v e lo f c o o l a n ti s
l o w . H i g h l o c a t e m p e r a t ! r e sc a n r e s u l i w h i c h
m a y c a u s el h e c y l i n d e rh e a d t o c r a c k .
Group21 Engine
Cylinder head, installing
H37 !ilo
Fill coolant
: 2 0 = 8 . 1 l i t e r s( 8 . 6U S q u a r t s )
C a p a c i t yD
D 2 4 = 9 . 3 t i r e r s( 9 . 8u s q u a f t s ) .
F l u s hc o o l i n g s y s t e m b e f o r ea d d i n g n e w c o o l a n t ,s e e
G r o u p 2 6 C o o l i n gS y s t e m .
).iO
S e r d c s o o a r d h e d r e rc o n r r o 'r o 1 i . ( . T u r ' r o ' r e n g n a
a n d w a r m ' u p f o r 5 m i n u t e s .A d d c o o l a n td u r i n g t h i s
t i m e . C o n n e c th o s el o c o l d s t a r td e v i c e .F i l l c o o l a n tt o
m o u t h o f e x p a n s i o nt a n k ( a b o v e m a x ) a n d s c r e w o n
H38
Tighten cylinder head bolts
Wa.m-upengineuntiloi temperalure is at least50'c
1122"F1.
Remove vacuumpumpwith plungerandva ve cover.
M 11 boltsrlorqueto 90 Nm (6sft lbs)
90'in onemovemenl
M 12bolts:an9le'tighien wrlhotrt
DO
stopping.Instal plrrnp plunger and
)ilo
56
Group 21 Engine
Cylinder head, retorquing
J. Cylinderhead,retorquing
To be carried out after 600-1,200miles (1,000-2,000km) on cold or nearlY cold engine
J1
Removevalvecover,vacuum pump and plunger
Access to one of cylinder head bolts is restricled by
J2
M 11 bolts:
M 1l bohs = 10hm Allenkey
Tighteneach boh in turn as indicatedaccordingto
M11 1. Slackenbolt30'
2. Torqueto 90 Nm {65ft !bs)-
11s9082
M 1 2 b o l r s= 1 2 s d e d s o c k e i M 12 bolts:
P / N 1 1 59 0 8 2 - 5 .
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
57
Group21 Engine
Timing gear belt tension
B e l l t e n s i o na f f e c b l n j e c t i o nt i m i n g . F o l l o wb e l o w i n s l r u c t l o n sc a r e f u l t yO
. v e r r i g h tb e l t sc a u s ep u e y i o s q ! e a k .
:)rI
K2
Checkbelt tension
U s e g a u g e 5 1 9 7 .T e n s i o n s h o L r l db e b e t w e e n 1 2 1 3
A d l u s tt e n s i o n1 o' 1 2 . 5u n i i s b y m o v i n g p u m p m o u n r i n g
r)rI
t), I
K3
Checktiming gear belt tension
Use gauges197.Tensions h o u l d b e b e t w e e n 1 2 - 1 3
58
Group21 Engine
Timing gear belts,tension
L. Timinggear belts,replacement
Special tools: 5187. 5188,5190, 5193, 5194, 5197, 5199, 5201, 5202
E n g i n em a y o n l y b e l u r n e d b y m e a n so f v i b r a t i o nd a m p e r .
D o n o t r o l a t ec r a n k s h a f ot r c a m s h a f tw h e n t i m i n s s e a r b e l t i s r e m o v e do l h e r w i s ev a l v e sm a y s t r i k €p i s t o n s
a n o c a u s eo a m a g e .
L1 i){ |
Disconnect battery
Jack-upvehicle
L2
')a
To preventspillageswhen coolantis drained,raise
al frontrightjackingpoint.Coolanl
vehicle wil thenrun
alongsplashg!ard intodrip pan.
Placedrip pan beneathleftsteeringrod.
L3
Drain coolant
U n s c r e we x p a n s i o nl a n k c a p .
D i s c o n n e clto w e r r a d i a i o rh o s e i r o m r a c l i a t o r
D l s c o n n e clto w e r h o s e f r o n r t h e r m o s t a tf o r c o l d s t a r t
d e v i c ea n d d r a i nc o o l a n t .( E n g i n ei s w i l h o u t d r a i nl a p s )
0)a
,r) (
L4
- c o o l i n gf a n w i i h s p a c e ra n d p u l l e y
- f a n b e l t sa n d p o w e r s t e e r i n gp u m p b e l t
60
Group 21 Engine
Timing gear belts, replacement
L6
Turn engine until cyl. 1 is at TDC - injection
AlwalsJre vib ationddmpercenterboll totL'n pn9ine
27 mm socketor wrench5188
BothcyLinder1 camsshouldpointobLiquelY 'rpwards
t,
L7
Removevibration dampercenter bolt
U s e 5 1 8 7 1 o p r e v e n tp u L l e vf r o m r o t a l i n g ,a n d s o c k e t
5 1 8 8t o u n s c r e wb o l t .
I t m a y b e n e c e s s a r tyo t u r n e n g i n es l i g h t l vs o i h a t 5 1 8 7
r e s t so n f a n b e a f i n g .
61
6roup 21 Engine
Timing gear belts, replacement
,
,J Remove vibration damper
L9
s PullotJvibrationdamper.Note!Crankshaft
sometimes stickto vibrationdamper.
gearmay
)a
Ll0
Remove lower timing gear cover and belt
Slackencoolantpump retainingboltsto releasebelt
tension.Removebelt.
)r;O
Ll1
Replace idle. pulley
A l w a y s r e p l a c ep u l l e yw h e n f i t i i n g n e w b e l t .
Renrovecenter bolt.
W i l h d r a w p l r l l e y| ] s i n g5 2 0 2 .
T a p o n n e w p u l l e ya n d i n s t a l l c e n t e rb o l t . )il4
),lt
Ll2
Removecamshaftrear sprocketand belt
Hold sprocket in position with 5199 and unscrew
s p r o c k e tw i t h w r e n c h 5 2 0 1 .
T a k e c a r e n o t t o r o l a t ec a m s h a f t .
62
Group21 Engine
Timing gear belts, rcplacement
L13
Lockcamshaftin posilion
Lift valvecovergasket
Placegauge5190at rear of camshaft.lnserta 0.2 mm
feelergaugebeneathleft sideof gaugoto compensate
for timinggearclearance.
Camshaftis now set ai correctposition.
LI4
Bemove camshaft Iront sprocket
Use5199to holdsprocket in position
whenloosenins
bolts.Tap sprocketto free
Ll5
Install gear belt and camshaft lronl sprocket
[4akesurethat belt fits se€urelyon all gears.
Installcenterbolt,handtight.lt shouldbe possible
to
turn sprocketon camshaftwithout camshaftrotating.
L16
Instatl lower timing gear cover and vibration
damper
Dampercanonlybefitted inoneway.
Pinoncrankshaft
g e a r m u s t f i t i n v i b r a t i o nd a m p e r .
T o r q u e i n h e x b o l t sr o 2 0 N m ( 1 5 f i l b s ) .
63
Group21 Engine
Timing gear behs, replacement
Ll7
Installcenterbolt
Smearthreadsand rnatingsurfacewith sealerP/N
277961-9.
Usewrench5187(reston coolingfan journal)to hold
vibrationdamper.LJsewrench5188to lorquecenter
bolt to 350 Nm {255ft lbs).
lmportantr Torque350Nm appliesonlyif wrench5188
is used.Alsotorquewrenchmustbein inewithwrench
5184.
L18
Make sure cyl. 1 is at TDC- inlection
C h e c k ' 0 ' m a | k o n f l y w h e e la n d a d j u s ti f n e c e s s a r y .
L19
Set belt tension
A d j u s t t e n s i o nb y m o v i n g c o o l a n tp u m p
U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g et o b e l t
and set to 12.5 units.
S t r e t c hb e l l u n t i l m a r k o n g a u g e p l u n g e ri s i l u s h w i t h
D e p r e s sb e l ts t r o n g l yw i t h h a n da n d r e c h e c u a d j u s t t e n -
040
L20
Tightencamshaftlront sprocketand remove
gauge5190
Use5199to prevent sprocketfromturning.
Torquecenterboitto 4s Nm (33fi lbs).
R e m o v eg a u g e 5 1 9 0a n d f e e l e rg a u g e .
64
Group21 Engine
Timinggear belrc,replacement
L21
Disconnect cold start device
Slacken
screw1. PushleverfoNard and rotatesleeve
90'.
Note!Donotturnscrew2otherwise it llbenecessary
to removecoldstartdeviceand resetiton a testbench,
Pressbackleveragainststop.
-r@ L22
-v2a//J:' Basic-setinieciion pump
j iP) pumpmounting
Slacken
Alignmarks
bolts(Allenkey= 6 mm).
onpumpandmounting bracketbyturning
p u m p . R e t i g h t e nm o u n t i n g b o l t s .
L23
Set dial indicator zero. Lock pump gear at cyl. 1
inlection using stop 5193
Unscrew andrernoveplugfrom i n j e c t i o np u m p d i s t r i
i
65
Group21 Engine
Timinggear belts,replacement
L24
lnstall camshaftrear sprocketand belt
Tighten center
bolrby hand,it shoutdbe possibte
to
turnsprocket on camshaft.
i
Set belt tension
L25
0la !
Adjusttensionby movingpump.
Usegauge5197to checktension.Attachgaugelo belt
andsetto 12.5units.Stretchbeltuntilmarkon gauge
plungeris flushwith sleeve- r)
DepressbellstronglywithhandandrechecUadjustten-
L26
Sel pump and tighten camshaft rear sprocket
Use5199ro holdsprocket.
Torquewrenchshouldbe al
rightanglesto wrench5201otheMisetorquewiL be
Using5199,turn spro€ket
slowlyclockwise
until dial
D20....................................-....-.......0.80mm=0.0315in
d),I
0.70mm : 0.0276
D 24 ................................................. in
D 2 4 U S A / C a n a d a 11997891 . . . . . . . . . 0 . 7 0 m m = 0 - 0 2 7 6 i n
'I982-.................0-85mm = 0.0335 in
Holdsprocket in thisposition
(73ftlbs).Takecarethatcamshaft
andtorqueboltto 100Nm
andsprocket do not t)r I
L27
Removestop 5193{rom pump gear
66
I
I
Group 21 Engine
Timing gear belts, replacement
L28
Checkpump setting
Turn enginetwo full turnsuntil cyl. I is at 1opdead
center- injection,
again.lf engineis turnedtoo far it
mustbe turnedbackapprox.'l14lurnandthento zero
markotherwise settingwill be inconect.
Dialindicator shouldshow:
i-'i D 20 ...........................
0.75-0.83
D24...........................
mm = 0.029F0.0327
0.650.73mm=0.025F0.0287in
in
D 24 USA,/Canada
0.6F0.73mm = 0.0256-0.0282in
1S791981...........-....
1982 .........................
0.82-0.90mm = 0.0323-0.0354in
Correcr reading: Tighteninjection mountingbo ts. Pro-
ceedto 129.
Incorrect readingrReadjust to instructions
according
L29
Bemovedial indicatorand holder 5194.Install
plug with new seal
Tighteningtorque9 Nm{6.5ft lbs).
67
Group21 Engine
Timtnggear bells replacement
L30
Reconnect cold start device
Pressleverforwardsand tlrn sleeve90'. Relighlen
L31
)a
Installvalve cover
Usenew gaskets
if necessary.
]
l w o r y p e s o r p i n s t u d s a r e a v a i l a b l e , s e e f i Lg a t e l y l
have a spacer, and ho e ln Oasket s l6r9er to prevenl t:: I
/ 0 8,5
azzz Trzzz
=%'rI'LLJ:
L32
Installtiming gear covers {front and rearl
Usenew gaskets
if 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
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 pre-
vent corrosion d6mage,
U s e g e n u i n eV o l v o b l u e - g r e e nc o o l a n tt y p e C , d i l u t e d
with clean water in proportions of 50/50.
This mixture helps to prevent coiiosion and frost
NotelDonot runenginewhenievelofcoolant is
low since high local temperaturescan result
which mav causethe cvlinderheadto crack.
L35
Fill coolant
Capacity:D 20 = 8.'l lilers (8.6US quarts)
D 24 = 9.3liters{9.8US quarrs).
Flushcoolingsystembeforeaddingnew coolant,see
Group26 CoolingSystem.
Sel dashboard l_eater contro,io max.Turnon engile
and warm-upfor 5 minutes.Add coolantduringthis
time. Conneclhoseto cold startdevice.Fill coolantto
mouth of expansiontank (abovemax) and screw on
70
Group21 Engine
Camshaft, removal
M. Gamshaft,removal
Special tools: 5199, 5201
D
M1
D 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
D e n g i n e .2 7 m m s o c k e to r w r e n c h 5 1 8 8 .
B o t hc y i n d e r 1 c a m s s h o u l d p o i n t o b l i q u e l yu p w a r d s .
t
M3
Removebelt Irom camshaftsprocket
U n s c r e we x p a n s i o nt a n k c a p 1 0 r e l e a s eo v e r p r e s s u r e
from cooling system.
S l a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l r t e n
s i o n e r .T i g h t e nt w o l o w e r m o u n l i n g b o l t st o a v o i d u n ,
n e c e s s a r yl o s s o f c o o l a n t .
R e m o v eb e l t f r o m c a m s h a f is p r o c k e t .
11
Group21 Engine
Camshaft,rcmoval
M4
Removecamshaftfront sprocket
U s e 5 1 9 9t o h o l d s p r o c k e ti n p o s i t i o nw h e n l o o s e n i n g
b o k . [ 4 . k e s u r e t h a t c a m s h a f td o e s n o t r o t d t e .
Tap sprocket to free it from camshaft.
0t (
M5
Detachbelt shieldfrom cvlinderhead
I\ ' ) r (
Benove two Lpperreldinirgbolrs.
Bend out shield to free it from camshaft. lf necessary
s l a c k e nc o o l a n tp u m p u p p e r b o l t .
K e e ps h i e l di n o u t e r p o s i t i o nw i t h a p i e c eo f w o o d .
M6
Lift off pump belt
S l a c k e nm o u n t i n g b o l t s f o r i n j e c t i o np u m p b r a c k e t o
r e l e a s eb e l t t e n s i o n .
T i g h l e no ' r e b o k s o I h a t p J n p r e m a ' n s l u p p e ' p o s i 0ta
Lift off belt.
0ta
,O
, r tuttililiiii,i,
M7
Removecamshaftrear sprocket
Hold sprocket in position with 5199 and
s P r o c k ew
t ilh wrench5201.
Take care nol to rolare camshaft.
72
Group21 Engine
Camshaft, removal
M8
Removevacuum pump and pump plunger
Removepump fetainingnuts and place pump on
Withdrawplungerfrom cy inderhead.
M9
Remove camshafi beadng caps 1 and 4
M10
Remove camshaft bearing caps 2 and 3
Slacken to avoidplacing
nutscrosswise unevenloadon
M11
Lift awav camshaft and removeoil seals
13
Group21 Engine
Camshaft, installing
N. Camshaft,installing
Specialtools: 5 190, 5193, 5194, 5195, 5196, 5197, 5199, 5200,5201
0)ia
Place camshaft in cylinder head
Lubricatecontactsurfacesof camshaftand bearings.
Placegauge5190at rearof camshaft.lmportant!Both
camsfor number1 cylinderrnuslpointdiagonally up,
0rl
seeiig.
N2
Installcamshaftcaps2 and 3
Installcapscorrectly,
cenreris off set.
Tightennutscrosswise in
to avoidwarp.Keepcamshaft
p o s i t i o nw i t h g a u g e5 1 9 0a t r e a rw h e n t i g h t e n i n gc a p s . 0)a
0)a
N3
Removegauge5190
N5
Install camshaft caps 1 and 4
surethatthethrustwasherfor
fMak€ cap4 sits
camshaft
D R € a ro i l s e 6 l : U s e . d a p t e r 5 2 0 0a n d b o l t f o r c a m s h a f t
F r o n to i l s e a l rt i s e a d a p t e r5 2 0 0a n d t a p s e a l i n t o p o s i
20 Nm
N8
Installbolts tor belt cover
N9
Installgear belt and camshaftfront sprocket
,D P u l l b e l t t o e n s u r et h a t i t i s s e a t e dc o r r e c t l yo n c r a n k
P l a c eb e l i o v e r c a m s h a f ts p r o c k e ta n d i n s t a l ls p r o c k e t
I n s t a l lc e n t e rb o l t h a n d t i g h t . l t s h o u l c lb e p o s s i b l ef o r
s p r o c k e t t ot u r n o n c a m s h a f w t i t h o u t c a m s h a frt o t a t i n g .
D
Set belt tension
A d j u s tt e n s i o nb y m o v i n g c o o l i n g p u m p .
U s e g a u g e5 1 9 7 t o c h e c k l e n s i o nA
. r t a c hg a u g e r o b e t r
a n d s e t t o 1 2 . 5u n i t s .
S l f e t c hb e l t u n t i i m a r k o n g a u g e p t u n g e ri s f t u s h w i l h
D e p r e s sb e l ts t r o n g l yw i t h h a n da n d r e c h e c u a d j u s t t e n ,
75
Group21 Engine
Cafishaft, installing
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
0 (
f e e l e rg a u g e b e n e a t hl e f t s i d e o f g a u g et o c o m p e n s a t e
f o r t i m i n g g e a rc l e a r a n c e .
N13
Tightencamshaftlront sprocket
use5199to prevent fromlurning.
sprocket
(33
Torquecenterboltto 45 Nm ft lbs).
0)lI
Removegauge5190andfeelergauge
0)a
N15
Disconnectcold start device
Slackenscrew L Push lever forward and rotate s eeve
90'.
N o i e l D o n o t t u r n s c r e w 2 o t h e r w i s ei t w i l l b e n e c e s s a r y
to remove cold start device and reset it on a test bench.
P r e s sb a c k l e v e ra g a i n s rs t o p .
16
Group21 Engine
camshaft,installing
N17
Set dial indicator zero. Lock pump gear at cyl. 1
injection using stop 5193
pumpdistri
Unscrewand removeplug from injection
N18
Installcamshaftrear sprocketand belt
Tightencenterboltsby hand,it shouldbe possible
to
turnsprocket
on camshaft.
Group21 Engine
Cafishaft, installing
N19
S€t belt tension
Adjusttensionby moving pump.
Usegauge5197to checktension. Attachgaugeto bett
and set to 12.5units.Stretchbett untit mark on gauge
plungeris flush with sleeve.
Depressbeltstronglywith handandrechecUaotusr ren-
N20
Set pump and tighten camshaftrear sprocket 0 I
Use5199toholdsprocket.Torquewrenchshouldbe at
rightanglesto wrench5201otherwise
lorquewill be
Using5199,turn sprocket
slowlyclockwise
until dial
0 (
D 2 0 . . . . . . . . . . . . . . . . . . . -. . . . -. . . .- . . . . . . . . 0 . 8 0 m m = 0 . 0 3 1 5 i n
D 24..............................-........-......... 0.70mm : 0.0276 in
D 24 USA,/Canada 1979-1981 .........0.70mm = 0.0276in
1982-................. 0.85mm = 0.0335 in
Holdsprocket in thisposilionandtorqueboltto 100Nm
{73ft lbs).Takecarethat camshaftandsprocketdo not
N21
Removestop 5193trom pump gear
0),(
N22
Checkpump setting 0)' I
T u r n e n g i n et w o f u l l l u r n s u n t i l c y l . 1 i s a t t o p d e a d
c e n t e r- i n i € c t i o n ,a g a i n .l f e n g i n e i s t u r n e d t o o f a r i t
m u s t b e i u r n e d b a c ka p p r o x .1 / 4t u r n a n d t h e n t o z e r o
m a r k o t h e r w i s es e t t i n gw i l l b e i n c o r e c t .
D i a l i n d i c a t o rs h o u l d s h o w l
D 2 0 . . . . . . . . . . . . . . . . . . . . .0. . 7. .5. .- 0 . 8 3m m : 0 . 0 2 9 5 0 . 0 3 2 7i n
D 2 4 . . . . . . . . . . . . . . . . . . . . .0. . 6. .5. .- 0 - 7 3m m = 0 . 0 2 5 6 - 0 . 0 2 8i n
7
D 24 UStuCanada
1 9 7 F 1 9 8 1. . . . . . . . . . . . . 0 - ...6. F 0 . 7 3m m = 0 . 0 2 5 6 - 0 . 0 2 8i n
7
19 8 2 - . . . . . . . . . . . . . . . . . . .0. ...4. .2. - 0 . 9 0m m = 0 . 0 3 2 3 - 0 . 0 3 5i n
4
Corect reading: Tighten injection pump mounting
bolts. Proceed to N23.
Incorrect reading: Readjust according to instructions
7A
Group21 Engine
Camshaft,installing
N23
Removedial indicator and holder 5194, Instrll
plug with new seal
TishteninstorqueI Nm (6.5ft tbs).
t@))]
N24
Reconnect cold start device
Presslever forwards and turn sleeve90". Retighten
79
Group21 Engine
Camshaft, installing
N25
Installplungerand vacuumpump
C h e c kO - r i n g ,r e p a c e i f n e c e s s a r y .
()l
N26
Adiust valveclearance:
S e e o p e r a t l o nB 1 1 1 , p a g e 1 9 .
,l )l
l m p o r t a n t ! V av e c l e a r a n c em u s t b e c h e c k e da f t e r 6 0 0 -
1 , 2 0 0n 1 i l e s( 1 , 0 0 G - 2 , 0 0k0m ) .
N27
Installtiminggearcovers(frontand rear)
{l|a
0rr1
80
r
Group 21 Engine
Camshaft fronL seal, replacement
o.Camshaftfront seal,replacement
Special tools : 5194, 5197, 5199,5204
iD
o1
D
f r o n l t i n ri n g g e a r c o v e r .
o2
Disconnect cold start device
S l a c k e ns c r e w 1 . P u s hl e v e rf o r w a r d a n d r o t a t es l e e v e
90'.
t, N o r e l D o n o t t u r n s c r e w2 o t h e M i s e i t w i I b e n e c e s s a r y
io remove cold start device and resei it on a test bench.
Press back lever against stop.
o3
lnstall dial indicator
U . s c r e w a n d r e m o v ep l u g f r o m i n j e c t i o np u m p d i s t r i -
I n s t a l lh o l d e r5 l 9 4 a n d d i a l i n d i c a l o r{ r a n g e0 - 3 m m ) .
S e l g a u g el o a p p r o x .2 m m .
Group21 Engine
Camshaftfront seal,replacement
o4
Turnengineuntil cyl. 1 is at TDC- iniection
A l w a y su s et h e v i b r a t i o nd ; m p e r c e n t e rb o l t i o t u r n t h e
e n g i n e .2 7 m m s o c k e to r w r e n c h 5 1 8 8 .
B o t hc y l i n d e r1 c a m s s h o u l d p o i n ! o b l i q u e l y' r p w a r d s .
T u r ne n g i n ea p p . o x .1 / 4t u r n c l o c k w i s ep a s t ' 0 'a n d t h e n
b a c kt o ' 0 ' a g a i n ,t o o b t a i ns l a c kp E d o f b e l i o n d r i v i n g
s i d e .l f t h i s i s n o t d o n e i n j e c l i o np u m p s e t t i n sw i l b e
{)a
o5
Set dial indicator zero
G a u g e p o i n t e r m u s t n o t m o v e d u r i n g i n s t a l a t i o no f
0)l
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
o6
Remove belt from camshaft sprocket
U n s c f e we x p a n s i o nl a n k c a p t o r e l e a s eo v e r p r e s s u r e
from coo ing system.
S a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l t t e n -
s i o n e r .T i g h l e nt w o o w e r m o u n t i n gb o l t s1 o a v o i d u n
n e c e s s a r yl o s s o f c o o l a n t .
r)il4
R e m o v eb e l t f r o m c a m s h a f ts p r o c k e t .
{)ila
o7
Remove camshaft lront sprocket
U s e 5 1 9 9t o h o d s p r o c k e ti n p o s i t i o nw h e n l o o s e n i n g
b o t . M a k e s ! r e t h a t c a m s h a f td o e s n o t r o r a r e
Tap sprocket to free it from carnshaft.
a2
i
Group21 Engine
Camshaft front seal, replacement
ot0
Pressin new camshaft seal
Oil seal.
D o n o t p u s h i n s e a ll o b o t i o m p o s i t i o n .M a k es u r et h a t
L
Install camshaft cap 1
Torqueto 20 Nm {15ft lbs).
o12
Press in seal to bottom position
Release
cover.Useadapter5200ro rap in oil
o13
bolts Ior belt cover
014
Install gear belt and camshaft tront sprocket
P u l l b e l t t o e n s u r et h a t i r i s s e a t e ccl o r e c r l y o n c r a n k -
shaft gear.
P l a c eb e l t o v e r c a m s h a f rs p r o c k e ra n d i n s t a i ls p r o c k e t
I n s t a l c e n t e rb o l t a n d t i g h r e n .l t s h o u t db e p o s s i b t ef o r
s p r o c k e t l ot u r n o n c a m s h a f t w i t h o uct a m s h a f tr o t a r i n g .
Group21 Engine
Camshaft front seal, replacement
015
Set belt tension
A d j u s l t e n s i o nb y m o v i n g c o o l i n gp u m p .
U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g e1 0 b e l t
a n d s e t t o 1 2 . 5u n i t s .
S t r e t c hb e l t u n t i l m a r k o n g a u g e p l u n g e ri s f l u s h w i t h
{r (
o16 |0i (
Makesurecyl.1 is ai TDC
on flywheeland adjustif necessarv
Check'o'mark
il
o17
Tightencamshaftfront sprocket
L J s e5 1 9 9t o p r e v e n ts p r o c k e tf i o m t u r n i n g .
TorqLrecenter bolr to 45 Nm (33 ft lbs). {,rI
tl t, I
o18
Check dial indicator
l f p o i n l e r h a s m o v e d f r o m z e r o p o s i t i o n :b a s i c ' s e e
t n'
g i n e a c c o f d i n gt o o p e r a l i o n sC 1 - 2 1 .
Pointer at zeror Proceed to O19.
Group2l Engine
Camshafttrcnt seal,reDlacement
o19
Zoro injection pump and dial indicator
Slowly tum engineanticlockwiseuntil min readingis
reachedon di6l indicator.
ff.n\ | Set zero.
o20
Checkpump sefting
Slowlyturnengineclockwise
untilflywheel '0'
reaches
lfengine
isturned toofarit mustbeturnedbackapprox.
1/46ndthento 'o' markotherwisesettingwillbe incoF
d.i inzr r rr
Dialindicator shouldshowl
ltR\)
0.7F0.83mm= 0.0295-0.0327in
D 20...........................
0.6F0.73mm = 0.0256-0.0287
D 24 ........................... in
D 24 IJS!,/Canada
197F1981 .................
0.65-0.73mm = 0.0256-0.0287an
1982-.........................
0.82-0.90mm = 0.0323-0.0354in
Correct reading: Iighten injection pump mounting
bolts.Proceedto O23.
lncorrectrcading: Readjustacco.dingto below.
021
Check/adjust pump setting
0.80mm = 0.0315in
D 20 .................................................
0.70mm = 0.0276in
D 24.................................................
D 24USA"/Canada 197F1981 0.70mm = 0.0275in
.........
0.85mm = 0.0335in
1982-.................
85
Group21 Engine
Camshaftfront seal,replacement
o22
Check pump setting
Turnengineroundtwiceandchecksetting,see
opera
tion O20.Readjust
if necessary
and repeatcheck.
o23
Removedial indicatorand holder
L:ri ii ,. _r Lr=
o24
{,i (
- i ],r'/nl l Install plug with new seal
Tishtening torque9 Nm (6.5ft bs).
0 I
o25
Reconnect cold start device
P r e s sl e v e r f o r w a r d s a n d t u r n s l e e v e 9 0 ' . R e t i g h t e n
N o t e l D o n o t t u r n s c r e w2 o t h e l w i s ei t w i l l b e n e c e s s a r y
10 reset cold stan device on a lest bench.
86
I
Group21 Engine
Camshaltfront seal,replacement
o2
Inslall valve covei
Usen€w gaskstsif necessary.
E
E
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:
r)a
- reart|mrnggearcover.
P2
Turn engineuntil cyl. 1 is at TDC- iniection
A l w a y su s et h e v i b r a t i o nd a m p e rc e n t e rb o l t t o t u r n t h e
ljse a 27 mm sockel-
(la
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 t o b l i q u e l yu p w a r d s .
i tl
P3
Lift ofi pump belt
S l a c k e nm o u n t i n g b o l l s f o r i n j e c t i o np u r n p b r a c k e t o
r e l e a s eb e l t t e n s i o n .
T i g h l e no n e b o l t s o t h a t p u m p r e m a i n si n u p p e r p o s -
Litt off be t.
88
Group 21 Engine
Camshaft rear seal, replacement
,."!
",iii;iiii;i;
Removecamshaftrear sprocket
in positionwith 5r99 and unscrew
Holdsprocket
withwrench
sprocker 5201.
Note! Take care not to rotete camshaft.
P5
Remove camshaft caD 4 and old oil seal
P9
Checkcamshaftsetting
C h e c kw i t h g a u g e5 1 9 0t h a l c a m s h a f ti s c o r r e c t l ys e t i n
r e l a t i o nt o c r a n k s h a f t .
G a u g es h o u l df i t i n g r o o v ei n b a c ke n d o f c r a n k s h a r tl.f
n o l , e n g i n e m ' r s t b e b a s i c - s eai c c o r d i n gt o o p e r a t i o n s
c1-21.
89
Group21 Engine
Camshaft rcar seal, replacement
P10
Disconnectcold start device
Slacken screw 1. Push lever foMard and rotate sleeve
90".
N o t e ! D o n o t t u r n s c r e w 2 o t h e M i s ei t w i l l b e n e c e s s a r y
to remove cold start device and reset it on a test bench.
P r e s sb a c kl e v e ra g a i n s ts t o p .
I
r))l
I
-.-i-rl
1ffi
-= Basic-setiniectionpump ())l
,}jz{ - pumpmountins
Slacken bolts(Allenkey= 6 mm) I
onpumpandmounting bracketbyt'rrning
P12
Set dial indicator zero. Lock pump gear at cyl. 1
inlection using stop 5193
Unscrew andremoveplugfrom injection pumpdistri
{ranse0-3 mml.
Installholder5r94and dialindicator
{rr)|
Setgaugeto approx.2 mm.
Turn pump sear clockwiseuntil mark on gear and
mounlingbracket coincide.
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
r e g i s l e r so n d i a l i n d i c a l o r .
S e t i n d i c a t o rt o z e r o .
T u r np u m p g e a rc l o c k w i s eu n t i l m a r ko n s e a ra n d p u m p
m o L r n t i n gb r a c k e ic o i n c i d e .L o c k g e a r i n t h i s p o s i t i o n
w l t h s t o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n t o
m o u n t i n gb r a c k e t . )
90
Group21 Engine
Camshaftrear seal,replacement
P15
Set pump and tighten camshaftrear sprocket
U s e 5 1 9 9 t oh o l d s p r o c k e t . T o r q u e w r e n cshh o u l db e a t
r i g h t a n g l e st o w r e n c h 5 2 0 1 o t h e r w i s et o r q u e w i l l b e
Using5199,turn spfocketslowlyuntil
0.80mm: 0.0315
D 20 ................................................. in
0.70mm = 0.0276
D 24 ................................................. in
D 24USp,/Canada 19791981......... 0.70mm : 0 0276in
0.85mm : 0.0335
1982-................. in
Holdsprocketin this positionand torqueto 100Nm
(73ftlbs).Takecarethatcamshaftand not
sprocketdo
P17
Checkpump setting
Turn enginetwo fuLlturns lntil cyl. 1 is ai top dead
center- injeclion, again.lf engineis turnedtoo tar il
must be turnedbackapprox.1/4turn andthento '0'
markotheMisesettingwilLbe incorrecl.
J;'. Dialindicator shouldshow:
0.7F0.83mm = 0.0295-0.0327
D 20 .............-............. in
D 24 ...........................
0.65-0.73 mm = 0.0256-0.0287
in
l D 24 USACanada
1979-1981 0.650.73mm= 0.0256-0.0287in
.................
1982-.........................
0.82-0.90 mm = 0.0323-0.0354in
Correct reading: Tighten injection pump mounting
bolts.Proceedto P18.
lncorectreading:Readjust to instructions
according
r)a
Beadingmofe than specified:
Slacken pumpmounting boltsandturnpumpoutwards
untildialindicator showsapprox.
020.........................-.......................0.70mm=0.0276in
D 24 ............................. 0.60mm = 0.0236
-.................. in
D 24USr',/Canada 1S7F1981 mm = 0.0236
.........0.60 in
0.75mm = 0.0295
1982-................. in
Thentlrn pump inwardsunrilspecified vatuers oo
tained.Tightenmo!ntingboltsandrecheck pumpset,
ting.
NotelInjection pumpmusrnotbetappedor knocked as
thiswill alterits setting.
92
Group21 Engine
Camschaftrear seal,reDlacement
P18
Removedial indicator and holder 5194. Install
plug with new seal
T i g h t e n i n gt o r q u e I N m { 6 . 5f t l b s ) .
P19
Reconnect cold start device
Presslever forwards and turn sleeve90'. Retighten
P20
lnstall valve cover
Use new gasketsif necessary.
r
3
P21
Install rcar liming gear covel
93
Gtoup21 Engine
Pilot bearing, replacement
a1
Removegearbox/transmission
S e e S e r v i c em a n u a l s e c t i o n4 ( 4 3 ) .
S e c u r es t a h e r m o l o r w i t h a b o l t .
a2
Removepressureplate and driven plate
lJnscrewpressure platemounting
boltscrosswrse
arew
turnsat a timeto prevent
warp,
O3
Remove bearing
lJseextractor4090. 0D{
(i,t,I
a4
Installbearing
I n s t a l lb e a r i n ga n d s e a l w i t h t e x t o n o u t e r r i n g f a c i n g
out. away from flywheei.
U s e s t a n d a r dh a n d l e 1 8 0 1a n d d r i f t 5 2 0 7t o t a p i n b e -
a r i n g u n t i l i t a b u t sc r a n k s h a f l .
P r e s si n . s m a l la m o u n to f g r e a s e( 1 . 3 1 . 5 g r a n i ) i n t h e
s p a c eb e y o n dt h e b e a r i n g .
94
Group21 Engine
Pilot bearing. replacement
a5
Installdriven plate
Use centering shafi 5203.
Turn driven plate with hub facing out, away from fly-
0
a6
Install pressureplate
Tightenboltscrosswise a fewturnsar a timero avoid
(,
a7
Installgearbox
Do notforgetto removeboltssecuring
startermoror.
o
0
95
Gtoup21 Engine
Crankshafttront seal,replacement
R.Crankshaftfront seal,replacement
Specialtools:5187,5188,5197,5200,5205
R1
Disconnectbatterv
R2
Jack-upvehicle
T o p r e v e n ts p i l l a g e sw h e n c o o l a n ti s d r a i n e d ,
h i c l ea t f r o n t r i g h t j a c k i n gp o i n t .C o o l a n tw i
a l o n g s p l a s h g u a r di n t o d r i p p a n .
Place drip pan beneath left steering rod.
R3
Draincoolant
U n s c r e we x p a n s i o nt a n k c a p -
D i s c o n n e clto w e r r a d i a t o rh o s e f r o m r a c l i a t o r a n d r a i n
c o o l . n t . ( E n g i n ei s w i t h o u t d r a i n t a p s ) . (r)rI
{r) I
R4
c o o l i n gf a n w i t h s p a c e ra n d p u l l e y
f a n b e l t sa n d p o w e r s t e e r ; n gp u m p b e h
- f r o n i t i n r i n gg e a r c o v e r .
I
I
I
96
I
t
I Group 21 Engine
Crankshaft f ra nt seal, replacem ent
R5
Remove vibration damper center bolt
ljse 5'187to preventpulleyfrom rolating,and socket
5188to unscrewboh.
It maybe necessarylo turnengineslightlysothat5187
reslson fan be.ring.
(0
Turn engine approx. 1/4 turn anticlockwise
(D Usewrench5187.
Removevibrationdamper
four inhexbolts(6 mm).
Remove
Pulloff vibrationdamper.NotelCrankshafi
gearmay
sometimes stickto vibrationdamper.
0
R8
Removelowertiming gearcover
R9
Detach cooling lan mounting bracket and
alternatorand placeon one side
RemovemoLrntins
bohslarrowed)and pressbracket
9l
Group2l Engine
Crankshaftfront seal, replacement
R10
Mark position oI timing gear belt
f t l a r kb e l t ,c a m s h a f ts p r o c k eat n d c r a n k s h a fgt e a r .M a r k
A i s o i d e r r ' t v o u l s i d ea n d r o p s i d eo f g e a r b a l r .
B e l t m u s t b e f i t t e d i n e x a c t l y s a m e p o s i t i o na s
b e i o r eo t h e . w i s ev a l v e sm a y c o n l a c rp i s t o n sa n d
c a u s es e a o u sd a m a g e . |) a
rr)rI
811
Removegear belt
Slackencoolantpumpmounling
bolrsandbelt.Cooanr
may leakwhenboltsareslackened.
r)r)|
(rl
R12
Removegearon crankshattand withdraw oilseal
use exlractor5205.
9A
Gtoup 21 Engine
Crankshaft front seal, replacement
R13
Installnew oil seal and gear on crankshaft
P a c ks p a c eb e t w e e ns e a l i n gl i p s w i t h g r e a s e .
P r e s si n n e w s e a l .U s e a d a p t e r5 2 0 0 ,v i b f a t i o nd a m p e r
c e n t e rb o l t a n d a l h i c k w a s h e r .
Instalgearon crankshaft.
R14
lnstall:
- retaining bolts for cover
- m o u n l i n g b r a c k e tf o r c o o l i n g f a n / a l i e r n a t o r .
R15
A l i g n i d e n t i f i c a t i o nm a r k s o n b e l t , c a m s h a f ts p r o c k e t
a n d c r a n k s h a f st e a f .
It is extremely important that belt is fitted in exactry
same position as before.
T e n s i o nb e l t b y r n o v i n gc o o l a n tp u m p ( b y h a n d ) .
T i g h t e np u m p m o u n l i n g b o l t s .
99
Group21 Engine
Crankshaftf ront seaI, replacement
R16
lnstall lower timing gear cover and vibration
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 I
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
t))r{
Use wrench 5188 to lorque center boll to 350 Nm
{ 2 5 5f t l b s ) .
l m p o r t a n t rT o r q u e3 5 0 N m a p p l i e so n l y i f w r e n c h5 1 8 8
i s u s e d .A l s ot o r q u ew r e n c hm u s t b e i n l i n e w i t hw r e n c h
5188_
R18
Set belt tension
T u r n e n g i n ea p p r o x 1 / 4t u r n a n t i c l o c k w i s eA. d j u s tt e n
s i o n b y m o v i n g c o o l a n tp u m p .
U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g et o b e l t
a n d s e t t o 1 2 . 5u n i t s .
D ep r e s sb e h s t r o n gl y w i t h h a n da n d r e c h e c k / a d j u s n e n rrtttI
(r
I
R19
lnstall:
- f r o n t t i m i n g g e a rc o v e r
c o o i n g i a n w i t h s p a c e ra n d p u l l e y : T o r q u e b o l t s i o
I N m ( 6 . 5f t l b s )
- b e l t f o f p o w e . s t e e r i n gp u n r p a n d f a n b e t s
- r a d i a t o rC. o n n e c th o s e s
splashguard
100
i
Group21 Engine
Crcnkshaftfront seal.reDlacement
820
Bleeding ot cooling system
Disconnectupper hose from cold start
drip pan beneathhoseand hold hose
edgeof expansiontank,
Coolant
S i n c ea l u m i n i u m i s u s e d i n t h e e n g i n e s ,a c r i v ec o r . o -
sion protection is necessaryin the coolant to help pre-
vent corrosion damage,
Use genuine Volvo blue-green coolant type C. diluted
with clean water in proportions of 50/50.
This mixture helps to prevent corrosion and frosr
damage.
N e v e rf i l l t h e c o o l i n g s y s t e m w i t h w a t e r a l o n e .
T h e c o o l a n ts h o u l db e c h a n g e dr e g u l a r l ys i n c et h e c o r -
rosion protective additives in the coolant lose their ef
fect in time.
Note!Oonot runenginewhenlevetofcoolantis
low, since high local temperarurescan resutr
whichmay causethe cylinderheadro crack.
srY0oarrtt ,r00crfTEirfLrARar
SuNrNto otl vrlraf ocr tN otL
v0w!]q!!|I$|l!!_L_
fruo wrTi GaNUltratol,l/o coourr Tyr€c c00u|6sysTrrirs
ruPUrYUi [00NDw|lH[rLf WrrtiAri0|lALa
v0w0
mnM Replacingcoolant
[$ru ff Lrouror
Arr€ft vrol,vo n* c vAuBrtJus0ur zrt
,30.cn rrrr muft s^rsoN ^vtcMorrtau riorTrt
Arrctt TYr€
c AlwaysusetypeC blue-green
coolant.Remember to
replace
decal{P/N1331473-7)
on expansion
tankif ne-
Type C blue-greencoolant
A l l d i e s e la n d p e t r o l ( g a s o l i n e ) e n g i n em
s anufactufed
s i n c e1 9 8 2a r e f i l l e d w i t h t y p e C c o o l a n t .
101
Gtoup 21 Engine
Crankshaftfront seal,replacement
R21
Fill coolant
Capacity:D 20= 8.1liters(8.6USquarts)
D 2 4 = 9 . 1 l i t e r s( 9 . 8U S q u a r t s )
F l u s hc o o l i n g s y s t e m b e f o r ea d d i n g n e w c o o l a n t ,s e e
G r o u p 2 6 C o o l i n gS y s t e m .
Set dashboard heater conkol to max. Turn on engine
a n d w a r m ' u p f o r 5 m i n u t e s .A d d c o o l a n td u r i n g t h i s
t i m e . C o n n e c th o s et o c o l d s t a r td e v i c e .F i l l c o o l a n tt o
m o u t h o f e x p a n s i o nt a n k ( a b o v e m a x ) a n d s c r e w o n
0trl1
((
102