VOLVO 240 Engines d20 d24 Repairs Part 1

ServiceManual
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
Volvosare sold in versions adaptedtor different

markets. Theseadaptations clependon manyfac-
Iors Includingega, taxarionand markerreqJi.e
Thismanualmay thereforeshowill!strationsand
lextwhichdo not applyto carsin yourcountry.
Contents
page
fmportantinformation............................... 2
Specitications
........ 3
Specialtools ...................................
12
Group21 Engineassembly...............................................
16
(Work wilh engine in-ca., replacernentof engrnej
Group22 Lubricating
System.........................................
123
Group23 FuelSystem.........................................................
125
Group25Intakeandexhaustsystems.............. .. .. r60
Group26Coolingsystem..................................................
i63
Group27En9inecontro1s..................................................
175
Appendix"A"Faulttracing.............................................
A1
Index178
OrderNo,:TP 30420/1
We reseryethe right to makealerat ons
Reprintof'1983literature
withoutchange.
OVOLVONORTHAMERICACORPORATION
lmportantinformation
CLEANLINESS
Dieselinjectionsystemsareoxtremelysensitiveto
dirt
and foreign m6tter. A special workplace should
thereforebe usedfor insoectionofcomoonents.
PLUGS
CleanfuelIineconnections 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
1. Tightento 40 Nm {30ft lbs)indicatesth6t a torque

wrenchmustbe usedIortightening.
2. Tighteningtorque 40 Nm {30 ft lbs) indicatesa
guidevalug. Tightening neednot be donewitha
Ioroue wrencn.
Specifications
Specifications
Group 20 General
.,o
,o Enginetypedesignation
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.
Removsoiland dirtfrom bolt holes.Oil leftin hol€swill

reduc€pressureon cylinderheadgasket,
Eolt threads and washers must however be oiled,
otherwisefrictionalforceswill b6 too grear.
@@o @ @@@
D24 Two types ot bolls ars in uset An early type with M 11
@@@ o @@)@
threadsand6 latertypewith M 12threads.{Latertyp€is
lhr@d6dalong entir€l6ngth.l
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
100Nm (74ft lbs)

20 Nm l1sft lbs) @
6\1fl
45 Nm 133ft lbs) '

I l'-
b0 i!
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)
zbro'\ 1rstt tu"t

Smear threads wiih
compoundP/N277961-9.
Specifications
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)
SAE15 W/50orSAE20 w/50 oilsarerscommend€d for

usein sxtremedrivingconditionswhich involvehigh oil
consumptionand high oil temperatures. for example,
mountaindriving with frequentdecel€rationsof fast
motorwaydriving. (Notehowoverth€ lower tempera-
ture limits.)
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
a,o 60litres(15.8US galls.)
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
70Nm = 52ft lbs
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
)ijo Startsto openat ,....,,.,..

Fullyopenal
O p e n i ngsa p .m i n . . . . . . . . .
87'C{189'Fl
102'Cl216.Fl
8 mm (0.3in)
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
5196.4 P.B3 roolj for valvetappets

5197"2 Balt tonsiong.uqo: timing ge8rbeltsand pump drive
5199-8 Wr3nch:front and rearcamshafigears
52004 Adapter:installingcEnkshaftfront sealand camshafts€als
5201"2 Wr6mh: centernut on rearcamshaflg6arand pump gear
520/t-6 Pullor:pump gear,inj€ctionpump
5202-0 P0llor;for idl€r pull6y
5203-8 Centerinssh.ft: for clutchdisc
5205€ P{ller: for crankshaftfront s€sl
l'207-t Drift: installingnsedlgb€arjnsin crankshaft
5204-7 Drift: installingcrankshaftrearseal
5233-7 GuidapiB, M t l bolts {4x):installingcylinderh6ad
523/t3 GuidepiB, M t2 bolG {4x)rinstallinscylind6rh6ad
5235-0 Tool lor removing suide ping
9950-0 Adapter:gnsinelpm. Usedwirh VolvoMonot€stBr
't4
Specialtools
5233,5234
9950
9950
Group21 Engine
Contents
Group21 EngineAssembly
Contents
In-car Operation Page

A1-10 17
Valveadjustment.,,..,..... B1-11 19
Basicsettingofsngine... c1-21 22
Cylinderhead,removaI D1-20 28
disEssembly ................... E1-11 33
cleaning-chscking .......... 36
asssmory ........................ G1-16 41
insta11ing......................... H1-38 45
tightening torquss,....,,... 57
Drivebeltsltiminggearsand pump)........................
belttension ....,,,,,,.,.......,, K1-5 58
rep1acement.................... Ll-35 60
Camshaft,r€moval t\41-11 71
insra11ing......................... N1-27 74
Camshaftoil seals,replacemenl, Iront.,,,...,,..,,...,,,. o1-21 81
P1-21 88
Pilotbearing
incrankhaft,replacement .......,....,.,.. o1-7 94
seals,replacement,
Crankshaftoil front,,..,,...,,...,,.. R1-21 96
s1-11 103
Vibration
damper,removal,
insta11in9,,..........,....... T1-10 106
Enginemounts,rep1acement,,,.,,,.,,....,,...,,...,,...,,..., u1-4 110
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
Incorrect clearance (BZBS )
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
Alwaysuse new discs,

Discthicknesses = 3.0G-4.25
6vailable mm 6t inte als
of 0.05mm.
B8
Position new disc and removepliers
Discshouldbe lubricateda n d i n s t a l l e dw i t h s i z em a r k s
B9
Check/adjust valve clearanceIor remaining 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
Thefollowingoperationsaredescribedin this sectionl

- settingcamshaftpositionin rel6tionto crankshaft
- settingtensionof drive belts{front and rear)
- injectiontiming.
Enginesshouldbe basic-setif, by adjustingthe pump,it
is not possibleto obtain the correctinjectiontiming.
(Camshaftseningmay havs changed)
C1
Remove:
-timing gearcovers{front and rear).
C2
'l
Turn engine until cyl. is at TDC - iniection
Alwaysusethevibrationdampercenterbolt to turn ihe
engine.
=
27 mm socketor wrench5188.
BothcylinderI camsshouldpointobliquelyupwards.
at 0 mark.
Flywheel
22
Group 21 Engine
Basic setting
Lift ofi pump belt

Slackenmountingbolts for injectionpump
releasebelt tension-Tightenone boll so t h a t p u m p
remainsin upperposition.
Lift off belt.
a,
,":'trtiiiiiiiiii
c4
Removecamshaftrear sprocket
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
D 2 0 . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . .8.0.m . .m. . .: . .0. .. 0. .3. 1 i5n

D 2 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0
. ...7. .0.m
. .m. . .=. . 0 . 0 2 7 6i n
D 2 4 U S A , / C a n a d a 1 917998 1 . . . . . .0. . 7. 0 m m = 0 . 0 2 7 6 i n
1 9 8 2 - . . . . . . . . . . .0. . 8 . .5.m. m : 0 . 0 3 3 i5n
H o d s p r o c k e itn t h i s p o s i t i o na n d t o r q u eb o h t o 1 0 0N m
( 7 3f t . l b s ) .T a k ec a r et h a t c a m s h a f ia n d s p r o c k e d
t o not
c17
Removestop5193trom pump gear
ct8
Check pump setting
T u r n e n g i n et w o f u l l t u r n s u n r i c y t . 1 i s a t l o p o e d o
c e n t e r- i n j e c t i o na g a i n . l f e n g i n e i s t u r n e d r o o r a r r
m u s t b e l u r n e d b a c ka p p r o x .1 / 4 1 u r na n d t h e n t o z e r o
m a r k o t h e r w i s es e t t i n gw i l l b e i n c o ( e c i .
D i a i n d i c a l o rs h o u l d s h o w :
O 2 0 . . . . . . . . . . . . . . . . . . 0. ...7. .5.0. . .8 3 m m = 0 . 0 2 9 F 0 . 0 3 2 7 i n
D 24 .......-............0 . ...6. .F. -0 . 7 3m m : 0 . 0 2 5 6 - 0 . 0 2 8i f7
D 24 USA and canada
1 9 7 F 8 1 . . . . . . . . . . . . . . . .0. ...6. .5 - 0 . 7 3 m m = 0 . 0 2 5 60 . 0 2 8 7 i n
1982 ........-................0.8 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.
Beadingmore than specified:

Slacken pumpmoulingboltsandturnpumpoutwards
untildialindicator showsapprox.
D 2 0 . . . . . . . . . . . . . . . . .......... . . . . . . . . . . . . .m . 0=. 70 0. 0 2 7i 6n
. .m
D 24 ..........................................-...-.. 0.60mm : 0.0236 in
D 24USA,/Canada l97F81............. 0.60mm =0.0236in
1 S 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m = 0 . 0 2 9
Th€nturn pump inwardsuntil specified va ue is ob-
tained.Tightenmountingboltsand recheck punrpset-
ting.
NotelInjection pumpmustrot betappedor knocked as
thiswil altersetting.
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
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
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:
-timing gearcovers(front+ read
Dl1
Tum engineuntil cyl. 1 is at TDC- injection
A l w a y su s e i h e v i b r a t i o nd a m p e r c e n t e rb o l t t o t u r n t h e
27 mm socket or wrench 5148.

B o t h c y l i n d e r ' l c a m s s h o u l d p o i n t o b l i q u e l yu p w a r d s .
Flywheelat'0'mark.
D12
Remove retaining screws from belt cover on
cylinder head
Takecarelhatwasheron innerscrewdoes
nolfalldown
intolowertiminggearcasecover.
(Latetypeenginesdo not havethiswasher).
30
Group21 Engine
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
Hold sprocket in position with 5199 and unscrew
sprocket with wrench 5201- Take care not to rorate
31
Group 21 Engine
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
Checkclearance between va lve g uides and valves

Usea di.l indi.alor
V
Usenewvalves(iniakeandexhausl)
with endoi va ve
slemf ushwith valveguide.
C earance = 1.3mm (0.05in).
F2
Checkcamshaftend float
Usea dialindicator.
Posiror ransnaildrd rr"ld redrcdp.lorqueto 20Nm
, r bn r b s , .
0
C l e a r a n c e= m a x 0 . 1 5m m ( 0 0 0 6 i n )
R e m o v ec a p a n d c a m s h a f l .
0
F3
Check discs
C h e c kd i s c p l a y . B e p l a c ed i s c i f w o r n o r s c o r e d .
I n s t a l ln e w d i s c sw i t h n u m b e r sf a c i n g d o w n , l o w a r d s
C l e a r a n c en,e w p a r 1 s. . . . . . . . . . . . . . . . . . . . .0. ...0. .16. .- 0 . 0 4 6m m

( 0 . 0 0 0 6 - 00 0 1 8i n )
36
Group21 Engine
Cylinder head. cleaning - inspection
Check tappets
P acetappetsin cylinderhead
Checkfit andclearance.
Clearance, mm (0.0010.003in)
newparts 0.025-0.075
Check valve springs
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 .
Ptess in new valve guide

L u b r i c a t ev a l v e g u i d e .
l j s e d r i f t 5 2 1 8 .P r e s si n f r o m c a m s h a f ts i d e .
P r e s si n g u i d e u n t i l f l a n g e o n g u i d e c o n t a c t sc y l i n d e r
h e a d .I n t h i s p o s i t i o np r e s sf o . c e m u s t n o l e x c e e dl t o n
since f ange may break off.
37
Group21 Engine
Cylinder head, cleaning - inspection
F8
Clean inside of valve guide
Use rsamBr5224
Note! Cuttingoil must beusedwhenreaming,
aftsrvalveguide
Valvesand seatsmust be ground-in
'-'T-_____________ Gri nding-i n valve6and seats

OperationsF 9-12
F9
wr- Machineg nd intako valvos
Edgeof intakevalvemustnotbelessthan0.5mm (0.02
In).
lmportant!Exhaustvalves
are stellitecoatedand must
not be groundby machine.Grind-invalveon seatwith
grindingpaste.
F10
Mill or grind valv6 seats
Grindto 45'.
Contactsurface{a) must be:
-2.0 mm {0.08in) for intakevalve
-2.4 mm {0.09in)for sxhaustvalve.
ll contactsurfaceis too wide reduc€areawith a 15q
lmponam! Outer diameterof cutter must no! Bxceeo

35,2mm (1.39in) for intakevalve s€atsand 33.2mm
{1.31in)for sxhaustvalvessats.
1.5mm {0.00in)
Ftl
Measuaegap betweendisc and cylinderhead
surfaco
Gap= max1.5mm 10.06
in).
Replaceseatand possiblyvalve if gap is too Iarge.
NotelTwo valvstypes are available,seeG3.
38
Group21 Engine
Cylinder head, cieaning - inspection
F12
Grind-invalveswith paste
C l e a nv a l v e st h o r o u s h l y .
.3F{'
q.
'
^s Replacingvalve seats
OperctionsF13 21
V a l v eg u i d e sm u s t b e r e p l a c e db e f o r er e p a c _
i n g s e a t s ,s e e F 6 8 , p a g e 3 7 .
Cfeancombustionchamber F13
Togeol sealnJsl be clearv vis:oleahF' cleaninS.
Remove valve seat F14

Mill vave seat, using cutterssuch as Mira {P/N
9986045).Referto manufacturer's Make
instructions.
surethatseatin cylinde.headis not darnaged.
cleansurfaces
thoroughtr.
,rU
Measure diameter of seat recess in cylinder head
and of valve seat
Usean internalmicromeierto measureseat recess
Standard
(production version)
Diameter,seatrecess, mm (in)
37.00037.016 i.1.4561-1.4513)
in1ake....................
exhaust................
33-000-33.016 11.29921.2994)
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
i n t a k e . . . . . . . . . . . . - . . . . . . . 3 73. 27 9. 300 5 (1.4681-1.4687)

e x h a u s i . . . . . . . . . . . . . . . 3 3 . 239303 0 5 (1.3106-1-3112)
W h e n r e p l a c i n gv a v e s e a l s :t h e i n t e r f e r e n c eb e t w e e n
t h e v a l v es e a ta n d i t s b o r e i r t h e c Y l i n d e rh e a ds h a l lb e
0.074-0.10smm (0.0029-0.0041in) I e valve sear d 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
a Newcylinderheadmust be the sametype as the

old. Cylinderheadsdesignedfor use with lvl 12
bolts must not be usedwith M '11bolts.
Cylinderheadscan be identifiedas follows (see
illustrationat left):
Numberseriesfollowedby B = M 11
- Numbe.seriesfollowedby C = M 12
LJSA,/Canada 1982-has a differenttype of cylin,
der headandswirlchamber. Swirlchamberand
its boreis 2 mm (0.080in) smallerin diameter
Newcylinderhead
Opetationcl cl
Installoil ieis and pin studs in cylinderhead
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.
Vslve length, mm {in}

New Min
I n t a k e v a 1 v e . . . . . . . . . . . . . . . . . . . ' (140.41.286 ) 1 0 4 . 3( 4 . 1 0 6 )
E x h a u s t v a l v e . . . . . . . . . . . . . . . . ' 1(044. .161 8 i 1 0 4 . 1( 4 . 0 9 8 1
4l
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
Torque all four caps

Torque= 20 Nm (15ft lbs).
G14
Tap in oil seals to bottom
use adapter5200anda plasticma lei
G15
Installiniectors
Placenewheatshieds in cy inderheadTurnshieds as
Torquero 70 Nm {50ft lbs)

Screwin injectors.
Reconneclfuel deliveyinesbetweenin,ectors
h i s a c l v i s a be t o c h e c kc o n d i t i o no f i n l e c i o r sw h e n
0
. e c o n d i t i o n i n gc y i n d e r h e a d . S e e i n s t r u c t i o n so n
page153.
0
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
Observe dale code on gaskel and packet.Gasket must

b e u s e d b e f o r et h i s d a t e .
O n l yg a s k e t sw i l h c o d eM O o r l a t e rm a y b e u s e do n D 2 4
_0 = 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
=.- Piston height above Gasket
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
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
M11 r e u s e dw i t h n e w w a s h e r s -F i tw a s h e r sw i t h c ! p s h a p e
f a c i n gu p .
L a t et y p e b o l t s h a v e f M1 2 t h r e a d sa l o n g e n t i r el e n g t h .
T h e s eb o t s m u s t n o t b e r e u s e d W a s h e r sm a y h o w e v e r
o
i!
I Installcylinderhead bolts
L u b r i c a t et h r e a d sa n d s l i d i n gs ur f a c eo f w a s h e r s .P l a c e
b o l t si n h o e s w i l h o u t g u i d e p i n s .
+
R e m o v eg ! i d e p i n s . U s e t o o l 5 2 3 5 .
I n s t a l lr e m a i n i n gb o l t s .
47
I
Group21 Engine
Cylindet head, installing
oooo9/@
D20
@o.r'o'o@@ 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
Tightenin threestagesl Tightenin four stagesl

150Nm=37ftlbs r 40Nm=29filbs
270Nm=5rftlbs 2 60 Nm = 44 ft lbs
390Nm=66ftlbs 3 75 Nm = 55 ft lbs
4 angle-tighten18{f in one movementwithout stop-
ping.Seeillustrationbelow:
48
Group21 Engine
H9
Connect copper connecting stdp lor two rear
glow plugs
o Installbolts lor cover

H10
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
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
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
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
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
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
Removestop 5193from pumpgear

H23
)e
H24
Check pump setting
T u r n e n g i n et w o f u l l t u r n s u n i i c y l . 1 i s a t t o p d e a d
c e n t e r- i n j e c t i o n ,a g a i n .l i e n g i n e i s t u r n e d l o o f a r i t
m u s t b e l L r r n e db a c ka p p r o x .1 / 4 l u r n a n d t h e n t o z e r o
m a r k o t h e l w l s es e t i i n gw i l b e i n c o r e c t
D i a l i n d l c a t o rs h o u d s h o w :
D 2 0 . . . . . . . . . . . . . . . . . . . . .0. . 7. .F. .0 . 8 3m m : 0 . 0 2 9 5 - 0 . 0 3 2 7i n
D 2 4 . . . . . . . . . . . . . . . . . . . . .0. . 6. .F. .0 . 7 3m m = 0 . 0 2 5 6 0 . 0 2 8 7i n
D 24 USAand Canada
W'r 1979-1981 . . . . . . - . . . . . .0 . ...6. F 0 . 7 3m r n : 0 . 0 2 5 6 - 0 . 0 2 8l n7
1 9 8 2 - . . . . . . . . . . . . . . . . . . .0. . .8.2. .- 0 . 9 0m n r = 0 . 0 3 2 3 - 0 . 0 3 5i n4
Correct reading: Tighten injectionpump mounting
I n c o r e c t r e a d i n g rB e a d j u s ta c c o r d i n gt o i n s i r u c i i o f s )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
Readingmore than specified:

pumpmounting
Slacken boltsandturnpumpoulwards
untildialindicator showsapprox:
D20.................................................0.70m
0.60mm = 0.0236
D 24 ...--...--...--...--...-...--...-................ in
D 24USA/canada 197F1981 ......-.. 0.60mm = 0.0236 in
?.i A.EErj 1 9 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m = 0 . 0 2 9 5
Thenturn pump inwardsuntil specified valueis ob
li6t',t rained.
trng.
Tightenmountingboltsand recheck pompset-
Note!lnjection pumpmustnotbetappedor knocked as

thiswill alterits setting.
H25
Removedial indicator and holder5194.lnstall
plug with new seal
T'shteningtorqueI Nm(6.5ft
H26
o
Presslever forwards and turn sleeve90'. Retighten
Notel Do notturnscrew2 otherwiseitwill be necessary

lo resetcold start deviceon a test bench.
H27
Install valve cover
Usenew gasketsif necessary.
Two typ6s oj pin srudsareavailable, seetig. Laretypes

have a spacer, and hole in gasket is larger to pfevont
d a m a g el o g a s k e tb y o v e n i g h t e n i n g ,
Lale and early rype parts must not be interchanqed,
zz7:@
ta
E Note! Only install a lew nuts since cover is to be re-
E m 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
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
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
-vroL\Io oflGri[ rtrvArsu

sfiD!^r L 30cctfrrifYrrairr iLr|r f$ 0n v
voLvo coourrrY* c c00rr6sYsitcrs
r0r uPYIAN $ft iALiw^
B0ur0
Replacing coolant
r/oLvo rYrtc vl|r0rrrus0u^ 2Pt
vrc Mot[ r^LrMotrrt^Nrcn rw c A l w a y s L r s et y p e C b l u e - 9 r e e nc o o l a n t .R e m e m b e rt o
r e p l a c ed e c a l( P / N1 3 3 1 4 7 37 ) o n e x p a n s i o nt a n k i f n e -
Type C blue-green coolant

A l l d i e s e la n d p e t r o ( g a s o l i n e e) n g i n e sm a n u f a c t u r e d
s i n c e 1 9 8 2a r e f i l l e d w i t h t y p e C c o o a n t .
H37 !ilo
Fill coolant
: 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
Check-tightening of cylinder head bolts

lmportantr Bolis must be re torqlecl after 600-1,200
m i l e s ( 1 , 0 0 02 , 0 0 0k r n ) .S e e n e x t p a g e .
56
Group 21 Engine
Cylinder head, retorquing
J. Cylinderhead,retorquing
To be carried out after 600-1,200miles (1,000-2,000km) on cold or nearlY cold engine
J1
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
o ooao,@r @,@o a 0g:@

D20 D24
ut oQoo@ @rO.O o o i.o (o
J3
Installvalve cover,plunger and vacuumpump
CheckO-rinq,replaceif necessary.
57
Group21 Engine
Timing gear belt tension
K. Timing gear belt tension,checking/adiusting

Specialtoal:5197
B e l l t e n s i o na f f e c b l n j e c t i o nt i m i n g . F o l l o wb e l o w i n s l r u c t l o n sc a r e f u l t yO
. v e r r i g h tb e l t sc a u s ep u e y i o s q ! e a k .
:)rI
Remove timing gear covers ({ront and rear}

K1
r)a
K2
Checkbelt tension
U s e g a u g e 5 1 9 7 .T e n s i o n s h o L r l db e b e t w e e n 1 2 1 3
A d l u s tt e n s i o n1 o' 1 2 . 5u n i i s b y m o v i n g p u m p m o u n r i n g
r)rI
t), I
K3
Checktiming gear belt tension
Use gauges197.Tensions h o u l d b e b e t w e e n 1 2 - 1 3
58
Group21 Engine
Timing gear belts,tension
Incorrect belt tension

lJnscrewexpansiontank cap to releaseoverpressure
from coolingsyslem.
Tum engineapprox.1/4 turn anticlockwiseto obtain
slackpart of bslt on driving side. lf this is not done
injectionpump settingwill be incorrect.
Turn crankshaftwith 27 mm socketor 5188.
Adjust belt tension to 12.5 units on gauge 5197 by
movingcoolantpumpmountingbracket.
lf gear belt tension has been adiusled

Turn engineat le6stoneturn clockwiseand checkthat
--'-\. belttensionis 12-13unitson tool5197.Adjustif neces-
saryaccording to operationsK2-3and rechecktension,
Installtiming gear covers

Group21 Engine
Timing gear belts, replacement
L. Timinggear belts,replacement
Special tools: 5187. 5188,5190, 5193, 5194, 5197, 5199, 5201, 5202
E n g i n em a y o n l y b e l u r n e d b y m e a n so f v i b r a t i o nd a m p e r .
D o n o t r o l a t ec r a n k s h a f ot r c a m s h a f tw h e n t i m i n s s e a r b e l t i s r e m o v e do l h e r w i s ev a l v e sm a y s t r i k €p i s t o n s
a n o c a u s eo a m a g e .
L1 i){ |
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 gearcovers(frontand rear)
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 .
Check that cyl. 1 is at TDC - iniection

Check'0'nrarkon flywheel.
use5187to turn engine
Adjustif necessary,
61
6roup 21 Engine
,
,J Remove vibration damper
L9
r{ Bemovefour Allenscrews(6 mm).
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
Installholder5194and dialindicator{range0 3 mm).

Setgaugeto approx.2mm.
Turn pump gear clockwiseuntil mark on gear and
mountingbracketcoincide.
Then turn back p!mp gear siightlyuntil min reading

r e g i s t e r so n d i a l i n d i c a t o r .
Set indicator to zero.
I!rn pumpgearclockwisu e n t i l m a r ko n g e a ra n d p u m p
w i l h s t o p 5 1 9 3 . ( l n s e r ts t o p t h r o u g h p u m p g e a r i n r o
i
65
Group21 Engine
Timinggear belts,replacement
L24
lnstall camshaftrear sprocketand belt
Tighten center
bolrby hand,it shoutdbe possibte
to
turnsprocket on camshaft.
i
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
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
Radiusling pump setting:

D20.................................................0.80m
0.70mm : 0.0276
D 24 ................................................. in
D 24 USA,/Canada
1979-1981 0.70mm:0.0276in
.......................................
1982 ...............................................0.85mm:0.0
Reading less than specified:

Slackenpumpmountingboltsandturn pumpinwards
to obtaincorrectvalLre-
Tightenmountingbo ts and
repeatcheckof pump settings.
Beadingmore than specified:

Slacken purnpmountingbollsandturnpumpoutwards
untildialindicto.showsapprox:
0.70mm = 0.0276
D 20 ................................................. in
0.60mm = 0.0236
D 24 ...........--...-...-....-...-........-.......-.. in
D 24USp/Canada 1979-1981 ......... 0.60mm = 0.0236 in
1 9 8 2. . . . . . . . . . . . . . . . . 0 . 7 5 m m : 0 . 0 2 9 5
Thenturn pump inwardsunti specified valueis ob
tained.Tightenrnounting bo ts andrecheck pumpset-
ting.
Note!lnjection pumpmustnotbetappedor knocked as
thiswill alterits setring.
L29
Bemovedial indicatorand holder 5194.Install
plug with new seal
Tighteningtorque9 Nm{6.5ft lbs).
67
Group21 Engine
Timtnggear bells replacement
L30
Pressleverforwardsand tlrn sleeve90'. Relighlen
NotelDonotturnscrew2 otherwise it wi benecessary

io resetcoldstartdeviceon a teslbench.
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

Disconnectupper hose from cold stan d€vice.Place
drip pan beneathhose 6nd hold hose level with top
edge of expansiontank.
Coolant
S i n c ea l u m i n i u m i s u s e d i n t h e e n g i n e s ,a c t i v ec o r r o '
sion protection is necessaryin the coolant to help 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
Neverfill the cooling system with water alone.

T h e c o o l a n ts h o u l db e c h a n g e dr e g u l a r l ys i n c et h e c o r
rosion protective additives in the cootant tose their ef-
NotelDonot runenginewhenievelofcoolant is
low since high local temperaturescan result
which mav causethe cvlinderheadto crack.
srY0DlrrLL 30pcrfirrfY[ lfifi lurr {a0 t|r Dftvanrl ocNgt 0[r

r0rv0xY|^rsunr c
IroL\no coouNrTYPI c c00ut6sYsmi$
PRoTOT[oT0-22.r nr UPY&i R0Ur0 R|lH|ALrWAr$Al0 HArrV0tV0
Replacing coolant
RrirPrr
0I u0urDr
ar{r6rL\roLrro rYrt c VALABL!
JusooA -2?.t
-3trCr$PlrB€flT0UT[
Slrsori^ytcMorltuu {otTttINI|GIL
IYr! c Always usetypc C blue-greencoolanr.Rememberto
replace
decal1PlN1331473-7)on expansiontankif ne,
Type C blue-green coolant

All dieseland petrol (gasoline)enginesmanufactured
since1982arefilledwith tvDeC coolant.
Group2l Engine
Timing gear belts, reqlacement
L35
Fill coolant
Capacity:D 20 = 8.'l lilers (8.6US quarts)
D 24 = 9.3liters{9.8US quarrs).
Flushcoolingsystembeforeaddingnew coolant,see
Group26 CoolingSystem.
Sel dashboard l_eater contro,io max.Turnon engile
and warm-upfor 5 minutes.Add coolantduringthis
time. Conneclhoseto cold startdevice.Fill coolantto
mouth of expansiontank (abovemax) and screw on
70
Group21 Engine
Camshaft, removal
M. Gamshaft,removal
Special tools: 5199, 5201
D
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
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
Pressin new camshaftoil seals

Oil seals.
D o n o t p u s h i n s e a l s t o b o t t o mp o s i t i o n .M a k e s u r e t h a t
s e a l sa r e " s q u a r e ' -
Group21 Engine
N5
surethatthethrustwasherfor
fMak€ cap4 sits
camshaft
Torqueall four caps

Torque= 20Nm (15ft lbs).
Tap in oil seals to bottom
D R € a ro i l s e 6 l : U s e . d a p t e r 5 2 0 0a n d b o l t f o r c a m s h a f t
F r o n to i l s e a l rt i s e a d a p t e r5 2 0 0a n d t a p s e a l i n t o p o s i
20 Nm
N8
Installbolts tor belt cover
N9
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
Make sure cyl. 1 is at TDC

Check'0'markonflywheel andadiustif 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
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
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
-@; Basic-setiniection pump

N16
).,)- '2-, Slackenpump mount:ngbolts (Allenkey = 6 mm).
I-@) Atignmarkson pumpandmountingbracket

pump.Retightenmountingbolts.
bytuming
N17
injection using stop 5193
pumpdistri
Unscrewand removeplug from injection
Installhotder5194and disl indicator(range0-3

Set gaugeto approx.2 mm.
Turn pump gear clockwiseuntil
moundngbrack€tcoincjde.
Thenturn pump gearbackslightlyuntil readrng

registerson dial indicator.
S€t indicatorto zero.
Turnpumpgearclockwise untilmarkongearandpump
mountingbracketcoincide. Lockgearin this position
with stop 5193.(lnse( stopthroughpump gearinto
mountingbracket.)
N18
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
Readiusling pump setting:

0.80mm = 0.0315
D 20 ..................-...-...-......,............ in
0.70mm= 0.0276in
D 24..........................,......................
D 24L,SA,/Canada 197F1981.........O.70mm= 0.0276in
0.85mm: 0.0335in
1982-....,....,..,....

Slackenpump mountingbottsand turn pump inwards
to obtain corrsct value. Tighten mounting botts and
repearcheckof pump settings.
Reading less lhan specified:

Slacken pumpmounting boltsandrurnpumpoutwards
untildialindicator showsapprox:
D 20 ........................-...-..................
0.70mm = 0.0276 in
D 24 .................................................
0.60mm = 0.0236 in
D 24USA,/Canada 1979-1981 .........0.60mm =0.0236in
0.75mm = 0.0295
1982-................. in
Then turn pump inwards untit specifiedvatue rs ob-
tained.Tightenmountingbotrsandrecheck pumpset-
rng,
Not€!Injectionpump mustnot be tappedor knockeoas
this will alter its setting.
N23
Removedial indicator and holder 5194, Instrll
plug with new seal
TishteninstorqueI Nm (6.5ft tbs).
t@))]
N24
Presslever forwards and turn sleeve90". Retighten
Notel Donotturn screw2otherwiseitwitt be necessary

to resetcold start deviceon a test bench.
79
Group21 Engine
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
Lfpointe. does not move itsufficesto check/adjustinjec-
o6
Remove belt from camshaft sprocket
U n s c f e we x p a n s i o nl a n k c a p t o r e l e a s eo v e r p r e s s u r e
from coo ing system.
S a c k e nc o o l a n t p u m p m o u n t i n g b o l t s a n d b e l t t e n -
s i o n e r .T i g h l e nt w o o w e r m o u n t i n gb o l t s1 o a v o i d u n
n e c e s s a r yl o s s o f c o o l a n t .
r)il4
R e m o v eb e l t f r o m c a m s h a f ts p r o c k e t .
{)ila
o7
Remove camshaft lront sprocket
U s e 5 1 9 9t o h o d s p r o c k e ti n p o s i t i o nw h e n l o o s e n i n g
b o t . M a k e s ! r e t h a t c a m s h a f td o e s n o t r o r a r e
Tap sprocket to free it from carnshaft.
a2
i
Group21 Engine
Camshaft front seal, replacement
Detach belt shield from cylinder head

Bemovetwo upperreraining botts.
Bendout shieldto freeit from camshaft.
tf necessary
slacken
coolantpumpupperbott.
Keepshieldin outerposjtionwith a pieceof wood.
Remove camshaft cap 1 and oil seal
ot0
Pressin new camshaft seal
Oil seal.
D o n o t p u s h i n s e a ll o b o t i o m p o s i t i o n .M a k es u r et h a t
L
Install camshaft cap 1
Torqueto 20 Nm {15ft lbs).
o12
Press in seal to bottom position
Release
cover.Useadapter5200ro rap in oil
o13
bolts Ior belt cover
014
Install gear belt and camshaft tront sprocket
P u l l b e l t t o e n s u r et h a t i r i s s e a t e ccl o r e c r l y o n c r a n k -
shaft gear.
P l a c eb e l t o v e r c a m s h a f rs p r o c k e ra n d i n s t a i ls p r o c k e t
I n s t a l c e n t e rb o l t a n d t i g h r e n .l t s h o u t db e p o s s i b t ef o r
s p r o c k e t l ot u r n o n c a m s h a f t w i t h o uct a m s h a f tr o t a r i n g .
Group21 Engine
Camshaft front seal, replacement
015
Set belt tension
A d j u s l t e n s i o nb y m o v i n g c o o l i n gp u m p .
U s e g a u g e5 1 9 7t o c h e c kt e n s i o n .A t t a c hg a u g e1 0 b e l t
a n d s e t t o 1 2 . 5u n i t s .
S t r e t c hb e l t u n t i l m a r k o n g a u g e p l u n g e ri s f l u s h w i t h
Depressbeit stongly with hand and rechecuadjust ten-
{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-.................

Slackenpumpmountingboltsandturn pumpinwards
to oblaincorrectvalue.Tightenmountingboltsand
repeatcheckof pump setting,
85
Group21 Engine
Camshaftfront seal,replacement
Reading more than specitied:

Slacken pumpnrounting boltsandturnpumpoutwards
D20.................................................0.70mm=0.0276
0.60rnm= 0.0236
D 24 ................................................. in
D 24USA,/Canada 1979-1981 0.60mm = 0.0236
......... in
0.75mm = 0.0295
1982-................. in
Thenturn pump inwardsuntilspecified valueis ob-
tained. Tightenmountingboltsandrecheck pumpset'
ting.
lf it is not possibleto sei pumpto abovespecifications
becaLseof ncufficert ad_Jstmeltlaltude. elgiie
mustbe basic-set again,sincecamshaft andcrankshaft
areprobablyour oi ine.
Note!Injection pumpmustnotbetappedor knocked as
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
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.
Twotypesot pin $uds areavailable,seefig. Latetypes

havea spacer,and hole in gasketis larg€rto preveni
/ '
08F damageto gasketby overlightoning-
ry Lat6and earlytype Frts must not b€ interchanged
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;
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
Press in new oil seal

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

Makesurelhat thrLrst
washerfor camshaft
cap4 sils
torq!e 20 Nm (15ft bs).

Tightenins
P8
Tap in oil seal to bottom
Useadapter5200and boltfor rearcamshaiisprocket.
P9
Checkcamshaftsetting
C h e c kw i t h g a u g e5 1 9 0t h a l c a m s h a f ti s c o r r e c t l ys e t i n
r e l a t i o nt o c r a n k s h a f t .
G a u g es h o u l df i t i n g r o o v ei n b a c ke n d o f c r a n k s h a r tl.f
n o l , e n g i n e m ' r s t b e b a s i c - s eai c c o r d i n gt o o p e r a t i o n s
c1-21.
89
Group21 Engine
Camshaft rcar seal, replacement
P10
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
IroI //\l Alignmarks

pump.Retighten mountingbolts.
P12
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

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

Adiusttenslonby rnovingPumP
Usegauge5197to checktensionAtlachgaugeto belt
andsetto 12.5units.Stretchbeltuntilmarkon gauge
plungeris flushwith sleeve
ten-
Depressbeltstronglywith handandrecheck/adjust
P15
Set pump and tighten camshaftrear sprocket
U s e 5 1 9 9 t oh o l d s p r o c k e t . T o r q u e w r e n cshh o u l db e a t
r i g h t a n g l e st o w r e n c h 5 2 0 1 o t h e r w i s et o r q u e w i l l b e
Using5199,turn spfocketslowlyuntil
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
Removestop 5193from pump gear

Group21 Engine
Camshaftrear seal,replacement
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
Readjustingpump setting: ()){

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

S l a c k e np u m p m o u n t i n gb o l t sa n d t u r n p u m p i n w a r d s
t o o b t a i n c o r r e c tv a l u e . T i g h t e n m o u n t i n g b o t s a n d
r e p e a tc h e c ko f p u m p s e t r i n g .
{!)a
r)a
Beadingmofe than specified:
Slacken pumpmounting boltsandturnpumpoutwards
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
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
Presslever forwards and turn sleeve90'. Retighten
Note!Do notturn screw2 otherwiseitwillbe necessary

to r€setcold startdeviceon a test bench.
P20
lnstall valve cover
Use new gasketsif necessary.
Two Vpes of pin studsareavailsble, seeliq Laietvpes

have a spacer, and hole in gasket is 1a.gerlo prevent
damaqe to gasket by overtightening
ry Late and early type paris must not be interchanged
r
3
P21
Install rcar liming gear covel
93
Gtoup21 Engine
Pilot bearing, replacement
O. Pilot bearingin crankshaft,replacement

Specialtools: 1801,4090.5203,5207
a1
Removegearbox/transmission
S e e S e r v i c em a n u a l s e c t i o n4 ( 4 3 ) .
S e c u r es t a h e r m o l o r w i t h a b o l t .
a2
Removepressureplate and driven plate
lJnscrewpressure platemounting
boltscrosswrse
arew
turnsat a timeto prevent
warp,
O3
Remove bearing
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.
Bylurningengineanticockwise, slackif beltwillmove

to drivlngside,makingil easierto removeand inslall
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
D Install camshaft gear belt

M a k es u r et h a t b e i r i s f i f t e d i n e x a c r t y s a m ep o s i t i o na s
A l i g n i d e n t i f i c a t i o nm a r k s o n b e l t , c a m s h a f ts p r o c k e t
a n d c r a n k s h a f st e a f .
It is extremely important that belt is fitted in exactry
same position as before.
T e n s i o nb e l t b y r n o v i n gc o o l a n tp u m p ( b y h a n d ) .
T i g h t e np u m p m o u n l i n g b o l t s .
99
Group21 Engine
Crankshaftf ront seaI, replacement
R16
lnstall lower timing gear cover and vibration
Dampercan onlybefiitedinoneway. Pinon crankshaft

gearmustfit in vibraliondamper.
Torqueinhexbo ts ro 20 Nm 115ft lbs).
r))
R17
lnstall center bolt
S m e a r t h r e a d s a n d m a t i n g s u r f a c ew i t h s e a l e r P / N 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
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

VOLVO 240 Engines d20 d24 Repairs Part 1

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VOLVO 240 Engines d20 d24 Repairs Part 1

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ServiceManual

Volvosare sold in versions adaptedtor different

We reseryethe right to makealerat ons

1. Tightento 40 Nm {30ft lbs)indicatesth6t a torque

Removsoiland dirtfrom bolt holes.Oil leftin hol€swill

100Nm (74ft lbs)

45 Nm 133ft lbs) '

zbro'\ 1rstt tu"t

SAE15 W/50orSAE20 w/50 oilsarerscommend€d for

a,o 60litres(15.8US galls.)

70Nm = 52ft lbs

)ijo Startsto openat ,....,,.,..

5196.4 P.B3 roolj for valvetappets

In-car Operation Page

Incorrect clearance (BZBS )

Alwaysuse new discs,

Thefollowingoperationsaredescribedin this sectionl

-timing gearcovers{front and rear).

Lift ofi pump belt

D 2 0 . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . .0. . .8.0.m . .m. . .: . .0. .. 0. .3. 1 i5n

Beadingmore than specified:

-timing gearcovers(front+ read

27 mm socket or wrench 5148.

Checkclearance between va lve g uides and valves

C l e a r a n c en,e w p a r 1 s. . . . . . . . . . . . . . . . . . . . .0. ...0. .16. .- 0 . 0 4 6m m

Check valve springs

Ptess in new valve guide

'-'T-_____________ Gri nding-i n valve6and seats

lmponam! Outer diameterof cutter must no! Bxceeo

Remove valve seat F14

i n t a k e . . . . . . . . . . . . - . . . . . . . 3 73. 27 9. 300 5 (1.4681-1.4687)

a Newcylinderheadmust be the sametype as the

Vslve length, mm {in}

Torque all four caps

Torquero 70 Nm {50ft lbs)

Observe dale code on gaskel and packet.Gasket must

=.- Piston height above Gasket

Cylinder head bolts

Tightenin threestagesl Tightenin four stagesl

o Installbolts lor cover

Removestop 5193from pumpgear

Readingmore than specified:

Note!lnjection pumpmustnotbetappedor knocked as

Notel Do notturnscrew2 otherwiseitwill be necessary

Two typ6s oj pin srudsareavailable, seetig. Laretypes

-vroL\Io oflGri[ rtrvArsu

Type C blue-green coolant

Check-tightening of cylinder head bolts

o ooao,@r @,@o a 0g:@

K. Timing gear belt tension,checking/adiusting

Remove timing gear covers ({ront and rear}

Incorrect belt tension

lf gear belt tension has been adiusled

Installtiming gear covers

-timing gearcovers(frontand rear)

Check that cyl. 1 is at TDC - iniection

r{ Bemovefour Allenscrews(6 mm).

Installholder5194and dialindicator{range0 3 mm).

Then turn back p!mp gear siightlyuntil min reading

Radiusling pump setting:

Reading less than specified:

Beadingmore than specified:

NotelDonotturnscrew2 otherwise it wi benecessary