Volvo 240, d20, d24 Service Manual

Service

Manual

Repairs

EngineD20,D24

and

TP

30420/1

maintenance

11.88

240 1979-

19

..

D20,D24

Both
this manual.

The D 20 has five cylinders and the D 24 six. Otherwise
the

Not6l
fitted

D 20

the

engines are similar

Different

to the dilferent engine types.

ancl D 24 Dieselengines are

in

llywheels

iffim

dealtwilh in

principle.

vibration dampers ar€

and

itm!r

Volvos
markets. These
Iors Including

This manual may
lext

are sold in versions

adaptations clepend on many fac-

ega, taxarion and marker reqJi.e

therefore show ill!strations

which do not apply to cars

adapted tor different

and

in

your

country.

:i!r-l-l

Contents

page

f

mportant information ...............................

Specitications ........

Special

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

Group 21 Engine assembly ...............................................

(Work

wilh engine in-ca., replacernent

of engrnej

Group 22 Lubricating System .........................................

Group 23 FuelSystem .........................................................

Group 25Intake
Group 26

Cooling system ..................................................

and exhaust systems .............. .. .. r60

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

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

Index 178

2
3

16

123
125

i63
175

A1

We

reserye

Reprint

OVOLVO

NORTH

Order No,: TP 30420/1

the right

of'1983 literature

to make alerat

without

AMERICA

CORPORATION

ons

change.

lmportant

information

CLEANLINESS
Diesel injection

and foreign m6tter. A special
therefore be used for insoection ofcomoonents.

systems areoxtremelysensitiveto

workplace should

dirt

PLUGS

Clean fuel Iine connections thoroughly

necting
Plug

removed. Do not remove thess
nent is reconnected.

pipes.

of fusl lines etc as each component is

ends

plugs

before discon-

until the compo'

Tightening torques

Two kinds of tighlening

1. Tighten to 40 Nm
wrench must be used Iortightening.

2. Tightening torque 40 Nm
guidevalug.

Ioroue wrencn.

Tightening need not be donewith a

torques will be found in this

lbs) indicates th6t a torque

{30ft

lbs) indicates a

ft

{30

Specifications

Specifications

.,o

,o

Group

20

General

Engine
number

Stamped

type designation

left

on

side

of engine beneath

and

serial

vacuutr,

pump

D

20 Engine

Output DIN
Maxtorque

Number

Displacement.........

Weight,
Compression pressuresi

\ew

iV nirnJn .......................

Maxd;ffe.enceberweencyl

Comp.ess,or ratro .....

Cyl:nder bore..................

Stro\e

..........................

DIN

ofcylinders

........

approx. incl.

en9ine..................

lengr

h

engine mounts, altefnaror

...

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

and starter

50 kW ar 80 r/s
68 hp at 4,800 r/min

120 Nm at

12.2 kpm
5
1-2-4-5-3

1.986
'181

Mpa

3.2

2.4

0.8

23.0:1

76.5

86.4 mm = 3.4016 in

50 /s

at 3,000 /min

(liter)

dm3

(405lbsl

kg

mm : 3.0118 in

313

114

Specifications

D

24 Engine

OutputDlN
MaxtorqueDlN

Numberof cylinders .......

Firing order ............,,...,...

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

Weight, approx. incl,
Compression

pressurss:

engine mounts, alternator

Newongin€.........,,,,,.,......

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

Maxdiffsr€nce between

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

Com p ression ralio .......,,

Cylinder

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

Slrokelength

and starter

60 kW al 80 r/s

82 hp at 4,800 r/min

140 Nm

14.3 kpm

47

at

r/s

6t 2,800 r/min

6

1-5-3-6-2-4

2.383 dm3
1S8

{435

{litsr)

lbs)

MP.

3.2

2.4

0,8

23.0r1

76.5 mm

=

3.0118 in

86.4 mm = 3.4016 in

psl
455
313
114

CYLINDERHEAD

Diagonally

Group

max 0.5 mm

21 Engine assembly

.,1

:.'

.,

9-

;

­\|

,\

Replace cylinder h€ad
Und€r no circumst.ncos

jfwarp

€xce€ds sp€cificalions.

may cylihder h€ad b€ machinod.

_o

CYLINDEB HEAD GASKET
Thfee different gasket

types are used

depending on

piston projection

Pistonproi€ction notches
mm

0.67-0.80

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

0.91-r.02

above cytinder block

linl

(0.026-{.031

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

G.sket

1

)........

3

Specifications

face.

thickness

(in)

mm

....................1.4

...................

...................

{0.0S5)

1.5

{0.059)
(0.063)

1.6

-o

Do

,lo

VALVESYSTEM

Valve clearances,
Cold

engine = room temperature

Valve

clearances, warm

0.1299 in to 0.1673 in

cold engine

engine

in increments

of 0.0020 in

Check

(in)

mm

0.15 {.25

0.35-0.45

0.20-0.30(0.008-0.012)

0.4(F0.50(0.016-0.020)

3.00-4.25 mm in increments

o20

(0.006-{.010)
(0.014-0.01

Setting
mm

0.20

8)

0.40

0.25{0.010)

0.45{0.018)

lin)

{0.008)
(0.016)

of 0-05

mm

a

u

n

!

r-l[ r

Checldadjust
1-2-4-5"3

]

valves

D24

Checuadjust valves in following order:
1-5-3-6-2-4

Specifications

TIGHTENINGTOROUES

Tight€ning
grsased

{washed}

oo

@o

@@o

@@@

torquB apply

parts

,Ot rO

D20

,oo

Mtl

to oiled nuts and bo|Is.

must b€ oiled

prior

to

@@
@@

@

@@@

D24

o

@@)@

NGHIENING

OF

De-

TIGHIENITVG

lmportlntl
removing

Removs oiland
reduc€

Eolt threads
otherwise frictional forces

Two types
threads
lhr@d6d along

CYLINDER HEAD BOLTS

SEOUENCE FOR CYLIIIDER XEAD BOLTS

cylindsr h€ad.

pressure

and washers

ot bolls ars in

and 6 later

slsck6n botts in rev€rsa

dirtfrom bolt holes.

on cylinder head

will b6 too

uset An early type

type with M 12 threads.

entir€ l6ngth.l

Oil

gasket,

must however be

grear.

M12

oder when

left

in hol€s will

oiled,

with M 1 1

typ€ is

{Later

Us6 now
Tlght€n

l50Nm{37ftlbsl
2 ?0 Nm
3 90 Nm
4 run

5 90 Nm

R.lightening

-

Atler
should
atsly in

L

2. Torque

waahera, convex

in fiv€

(50
{65 ft lbs}

6ngin€ until

1122'Fl

Slack€n

(65

600-1.200 miles

be cold

specifi€d

bol 3(r

to 90 lrlm

stages:

ft lbs)

ft lbs)

or almost cotd.

order,

sid6 upwards,

oil temperaturo

(1,000-2.000

Tighten

see abovs fio.:

(65

ft tbs)

is st t€ast

each boltsep6r-

km).

50.C

Engine

Us€ n.u bolb.
Tighten
1 ao

2 60 Ntn
3 75 Nm

4 angle-tightsn
5 run €ngin€ until
6 anglo-tighten 90P in

Nm

ping,

lt22

in

{Se€

"Fl

Not n€ce$ary

six stag6s:

ft lbsl

€0
l4a ft lbsl

ft lbs)

{55

l8f in

figur€ 6t lower lefi}

oil tehperature is

pins.

Rdighl.nlng

After

60F1,200 mil€6

b6

cold or almost cold.

Tighten
€bov€ fig.:

1. Angle-tighten

6ach boll

stopping.
Do not shckon boh

(See

(1,000-2,000

separatoly in spocifi€d

bolt 9|r in

figure

to roplac€ w6shers.

ono movem€nr without

at lerst 50oC

on6 movsment

one movemont without

lower left)

at

firf,

without stop-

km). Engine should

order, se€

stop-

20 Nm

6\1fl

l1s

ft lbs)

100

Nm

(74

Specificalions

ft@lbs)

45 Nm

133

ft lbs)

b0

l'-

I

i!

(6.5

'

D20

ft lbsl

@@'

Smearthreads and bolt head con­tacl suriaces wilh locking com-

pound (P/N
Tiqhtening lorque

lbs)
tool 5188. lf a torque wrench is
lsed dirscny on the cenler boll

(wiihout
torqle should be 450 Nm

277961-9).

Nn

350

appli6s when using special

5188), the tiqhlening

zb

(258

ro'\

350 Nm

ft

{258

(332

ft

ft lbs)

1rs

tt tu"t

Smear

compound

threads wiih

75 Nm

P/N 277961-9.

Nm

(55

(55

ft lbs)

ft tbs)

Specifications

Gtoup

22

Lubricating

OILCAPACITIES

D20

Litors

Excl.oilfilter
Incl.oillilter
Difference

in volume,

max-min

5.2

6.0

1.0

{US

(5.5)
(6.3)
(1.0)

ENGINEOIL

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

Accord'ng to API .......................................,,..,....,.:::::::::::::,.:::::::

VbGosity

Tomporaturc

(stable

ambisnt temperatures)

rangs

min CC
Oilswith designations SSCC,
meot this r€quirement

System

quarts}

D24

IUS

(6.5)
(1.41
(1.0)

quarts)

Liters

6.2

7.O

1.0

SE/CD, SF/CC and SF/CD

OILPRESSURE

pressurc

Oil

(2000r/min)min

pressuresensot

Oil

Cut-out point,

Lubricating

Reliefvalv€opensat......

at

oil temperature

indicator lamp goes

pump

oil

of 8O.C

out

at

(176.F)

SAE 15 W/50 orSAE 20
use in sxtreme
consumption
mountain
motorway
ture limits.)

and

33,3 r/s

.........................

w/50 oilsare rscommend€d for

d riving conditions which involve hig

and high

driving with frequent

driving.

kPa
200

15-45

600-700

(Note

temperatures.

oil

decel€rations of fast

howover th€ lower

psl
28

2-6.4

85-99

h oil

for example,

tempera-

R€lisf valve

ffiffi8

spring, l€ngth at diffsrent loads

Long1h
mm
L = 49
L1=

22

=

L2

19.8

(completely

compressed)

in.
(1.93)

{0.87}
(0.781

Load

N
0
17F195
approx.

200

lbs
0
{39-.44)

(45)

Specifications

:o

a,o

0i:o

GENERAL

Firins

order.................

ldle

fast

.,.,.....,.,.,.,,.

FUEL

Standard................

Make

and designation,

Volvo P/N
Injeclion

D20.............................

D24

NOTE!

necessary
page

{exchange

timing

USA and

High

In

132.

{purrp

Canada

altitude

certain

INJECTORS

D20

D24

unit) D20

D24

prunger

1979-t98i
1982-

....................

Group 23

slroke at TDC,

Fuel system

D20
'l-2-4-5-3

(750)

12.5
(5200)

87.0

DIN

51601r CEC-ERF-Dl,
ASTIM-D
45

0.5

60litres

Distributor
Bosch
(145'1

Bosch VE6/10
(132-1

500't716-9
5001715-1
Checkins

0.75-0.83
(0.0295-0.0327)

0.65-0.73 mm

10.256-0.O2a7J

0.65-0.73
(0.0256-0.0287)

0.82-0.90 mm
{0.0323-0.0354}

975-No. 2-D

(15.8

rype

VE5/10 F2400

for

auto vehicles)

for auto vehicles)

mm
mm

mm

galls.)

US

pump

F2400

lin)

145
132

D24

1-5-3-6-2

(750)

12.5
(5200)

87.0

or

Settins

0.80 mm

0.70

mm

0.70 mm

0.85 mm

4

(r/min)

r/s

r/s

mm

{in)

(0.0315)
(0.0276)
(0.0295)

{0.0335)

(r/min)

Ir4akeanddesignation
Bosch

No. USA,/Canad€

Other markets...................

Volvo P/N

lnlector

USt"/Canada

opening pressure

1982-

t982-

''''. .

'. . . ...

. . . . ..................................

.",.-

.- . . .

. . . . .....,.-....,.

MPa

psi

Bosch

KCA

30SD 27l
0 68 130 20?
0 68 130

1328073,0

1257
Checkins
1707-1849

201

t44-4

(201

F

(201

(44)

J)

K)

Setting

12.5-',t3.s
1778,1920

Specifications

Nozzl6s

Designation

Volvo

USA"/Canada 1982­Othermarkets

P/N USA,/Canada 1982'

Bosch
DNOSD1930
DN O SD 193

1328096,1

't542303-1

ldentitication

TIGHTENING

Injector, in cylinder

upper-rowersection...........................::...:.:.:.:.:.:.:::..::

Iniection

ot iniectors

TOROUES

head

pump, pump

g

and

nozzles

Iniector
(complete)

Nm

10

70

45

3::133;3i

068190201

usarcanlda

5l

I ^.

oogrrozolxl

DN

0 5D 193

DN = SD 193 = olher mark€ts

0 = USA/Canads

ft. lbs
52

52

33

,esz.

1982-

70 Nm

=

52ft lbs

=

45

Nm

33 ft

lbs

ti

10

Specifications

c,il

co

GENERAL

Group 26

Cooling system

Coohnt

Since aluminium is used in the

protection

sion

vent corrosion damage.

genuine

Use

with clean water in
This mixture helps

Never

a

The

a

the corrosion

lose thoir ef{ect in time.

is

necessary in the coolant to help

Volvo blue-green

lill the cooling system with

coolant should be changed

prolective

proponions

to

coolant type C diluted

pr€venl

6dditives

engines, active corro-

pre

of 50/50.

corrosion and frost

water alone.

regularly since

in

the coolant

)ijo

tt:o

Capacity,

with manual
with auiomatic

EXPANSION

Pressure valve

in cap

gearbox

transmission .....,,...

TANK

opens al ,,.,.,.,,,,.,,,.,..,....,.....

THERMOSTAT

Markin9.........................

Starts

to open at ,....,,.,..

Fully

open al

Openins

DRIVE

Deslgndion

HC38x975
(958354-3)

gap.

min .........

BELTS

(Volvo

P/Nl

HC38xl238
(960296-2)

HC38x888
{460431

s)

D 20litros

(8.7)

8.2
(8.4)

8.0

Type 1 kPa

(9.2-12.1)

65-85
7

{1.01

87'C
87'C

{189'Fl

102'C

l216.Fl

(0.3

8 mm

IUS

(psi)

in)

qlrrts)

D 24lirres

9.4

9.2

Type
r00
7

{1.0)

3 Cooling ran
4 Power steo.ing

{9.9}
{9.7)

2 kPa

{14.2)

IUS

{psi)

quarts)

pump

TIGHTENING TOROUE

Cooling fan

Hc38x800
(958302-1)

Ir. lbs.

9

6.6

1l

Special tools

Special tools

999

18Ol-3

261G3
2901-0

2903.6
4090-0
5006-5 | Lifi br.ckst: r€placing

5033-9 | Support

5112.1 | Loc*ing

51154
5185-7

5186.5 | Lift hoo*, lsar: ,€movins,4nstaltins

5147.3

5188.'l
5190-7 | Giuse: instslling camshaft
5191-5 | Adapter:

51$n

5194.9 | Holder: for dial indicalor when

5195.5 | PlisB:

lDdcription-U.s

Stand.rd h.ndle: lsed with drift 5207 and 5208

|

Lift be.m: rcmovingfinslalling

|
lC16mpinsplisrc{2x):clampinswat€rhoseswhenremovinsintecrionpump
| Oiltlltor wl6Dch

Pullet: removing

|

{2xl:

6sdo.:

| Lift hook: used with ltft bracket 5006

Lift hoolr lronr: removing/inslallins

|
I Wronchr vibration dEmoer

Wr6nch with oxt nsion arm: lor vibralion

I

connoctins

lockihs

Siop:

I

rcmovins valve discs

pilol

bearins

tronl €nsine mounts

for lilt bracl€t

locking

pr6ssur6

injecrion

5006

flywheel

punp

engin€

€nsin€

ensine

ssuse

sear

adjueins

damper center bolt

inj€ction

pump

Specialtools

5006,5033,5115

5185,5186 5187,5188

5194 5t95

't3

Special

tools

999

5196.4
5197"2
5199-8

52004
5201"2
520/t-6

5202-0
5203-8
5205€

l'207-t
5204-7
5233-7

523/t3
5235-0
9950-0

P.B3 roolj for valve
Balt tonsion
Wr3nch:

Adapter: installing cEnkshaft front
Wr6mh: center nut on rear
Pullor:

P0llor; for
Centerins sh.ft: for
P{ller: for

Drift: installing nsedlg
Drift: installing
Guida

Guide
Tool lor
Adapter:

g.uqo:

front and rear camshafi

pump

idl€r
crankshaft front s€sl

piB,

M t l bolts

piB,

M t2 bolG

removing

gnsine

tappets

ge8r

timing

gear,

inj€ction

pull6y

clutch disc

b€arjns in crankshaft

crankshaft rear seal

{4x):
{4x)r

suide

lpm. Used wirh Volvo Monot€stBr

belts and

gears

camshafl

pump

installing
installins cylind6r h6ad

ping

pump

drive

seal and camshaft s€als

g6ar

cylinder

pump gear

and

h6ad

't4

Specialtools

9950

5233,5234

9950

Group 21 Engine
Contents

Group

21 Engine

Contents

In-car

Valveadjustment.,,..,.....

Basicsettingof sngine...
Cylinder head,

Drive beltsltiming

Camshaft, r€moval
Camshaft oil sea ls,

Pilotbearing incrankhaft, replacement .......,....,.,..

Crankshaftoil seals,

Vibration damper, removal, insta11in9,,..........,.......

Engine mounts, rep1acement,,,.,,,.,,....,,...,,...,,...,,...,

removaI

disEssembly ...................

cleaning-chscking ..........

asssmory ........................

insta11ing.........................

tightening torquss,....,,...

gearsand pump)

belttension ....,,,,,,.,.......,,

rep1acement....................

insra11ing.........................

replacemenl,

replacement, front,,..,,...,,...,,..

........................

Iront .,,,...,,..,,...,,,.

Assembly

Operation

A1-10
B1-11
c1-21
D1-20
E1-11

G1-16
H1-38

K1-5
Ll-35
t\41-11
N 1-27

o1-21

P1-21
o1-7

R1-21
s1-11
T1-10

u1-4

Page

17
19
22
28
33
36
41
45
57

58
60

71
74
81
88
94

96

103
106
110

Replacement of engine

Removal .,...,,.......,...,....,.

Insta11in9 ........................

x1-33

'r

11

'114

A.

Compression test

Group 21 Engine

Compression

test

Special

tool:5191

Disconnect

pump

This

stops flow

ase.

wire lrom

offue and

stop valve

prevenrs

t]nnecessary

A1

on injection

spi|-

Remove

Disconnect

Cean all

Disconfeci
diri fronr enterlng

vacuum

fuel detivery pipes

connecrions

pipes

and

pump

system.

and

carefu y before

plug

all connedions

pump

A2

plunger

A3

disconnecring

prevenr

ro

11

Gtoup 21 Engina

Compression

test

Remove iniectors

1158146}.

Use 27 mm socket

{Volvo

Lift out h€at shields undsriniectors
be blown out

during compression

Connect compression

heatshield incylind€r head and screwin

Placea

5191. Ighten to 70
connect compression

P/N

tesl.

testel

Nm

{50

ft lbs).

tester to adapter.

otherwise

44

will

they

A5

adapter

Run engine and record
Compression

Min
Max differ€nce between

Install iniectors

to 70

in

Nm

pipes
Nm

new heat shields

Place
injectors. Torque

Reconnect delivery
Tightening

torque 25

compression

=

3.2MPa{455psi}

=

2.4MPa

=

0.8MP.

(s0

it.

ft lbsl.

head,
lbs).

cylinder

(18

A6

(341

psi)

(114

psi)

A7

seefig. Install

A8

18

Reconnect wire to stop

Install
Check

pump plungor

pump

O-ring. replace

and

valve

vacuum

A9

r'.l0

pumP

B.

Valve

adjustment

Group

Valve

21 Engine

adjustment

Valve

clearance

and also

must be checked/adiusted

after 60G-1,200

miles

Special

(1,00G-2,000

6fier

km).

tools:

5195, 5196

completion of repaifs

Remove

Turn

engine until cyl.

A

ways use the vibration

engine. 27
Both

cylinder 1cams

Check
Checking

valve

such as

values

grinding

valve

cover

mm socket

clearance

vatves,

1 is at TDC - injection

damper

or wrench 5188.

should

lor

crankshafr

center bolt to turn

poinl

obliquely

cyl. 1

reptacement

upwards.

etc.,

B1

B2

the

B3

a

il

a

f r I r

D20

o24

Cold

ensine

Exhaust

Exhaust

Co

d engine

0.15-0.25

0.35

0.45

0.20-0.30

0.40

0.50

=

rooh

temperalure

0.006

0.010

0.01,t-0.018

0.008-0.012

0.016-0.020

!

Alf

Alt

19

Group 21 Engine
Valve adjustment

I nco rrect clea ra nce ( BZBS )

Tum engine

not be at

must

Piston

clearance,

valve
when tapp€t

apProx.

deprsssed

is

1/4
top dead

otherwise

Dopress tappets

grooves

Turn tappets

5196, depress

tool

until

tappets

iurn

center

valves

point

will contact

slightly

to obtain

setting

when

inward. using

access to

discs.

B4

piston

B5

Remove

Use

Calculate
Valve cl€arsnces

Cold

Exhaust

Exhaust
Measurethicknessof

late thickness

disc

5195.

thickness ol

when setting:

€ngine

old discwith

of new

disc to be

0.20

0.40

0.25

0.45

disc to be used,

used

a micrometer.

B6

B7

in

0.008

0.016

0.010

0.018
Calcu-

see overleaf.

20

Gtoup

Valve

21 Engine

adjustment

Erample:

lfclearance is 0.20 mm and specified clearance
mm then replace existing

disc with one which

is 0.25

is 0.05

Always use

Discthicknesses 6vailable

new discs,

=

3.0G-4.25 mm 6t

inte als

of 0.05 mm.

B8

Position new disc and
Disc

should

be lubricated

remove

and installed with size marks

Check/adjust valve clearance Ior remaining cylin­derc

Checuadjust

D

20. 1-2-4,5-3

in following order:

D 24, 1-5-3-6-2-4

lmportantl Do not forget

before

checUadiusting valve clearance.

to rotate crankshafl 1/4 turn

pliers

B9

iY:'I,l

d.!

Recheck

Rotate engine several

valve clearance for

lnstall valve covet
Use new

gaskets if required.

Twoiypes
have a spacer, and
damage to

L€te

and eary type

stods are available see

ofpin

gaskel

hole in

by ovenightening,

parts

all cylinders

turns before rechecking.

fig.

gasket

is la.ger to

must not be imerchanged.

Laretypes

prevent

810

811

21

Group 21 Engine
Basic setting

Basic setting

C.

of engine

Special tools: 5190, 5193, 5194, 5197, 5199, 5201

The following

-

setting camshaft

-

setting

-

injection

Engines should

possible

is not

(Camshaft

operations

tension of

timing.

be basic-set
to obtain

sening may

position in rel6tion

drive belts

havs changed

are described

to crankshaft

and

{front

if, by adjusting

the correct

injection

)

in this sectionl

rear)

pump,

the

it

timing.

C1

Remove:

-timing

Turn engine
Always usethevibration

=

engine.
27
Both cylinder
Flywheel at 0

gear

covers

until cyl.

mm socket or wrench 5188.

I cams should
mark.

and rear).

{front

'l

is at

da mper center

point

C2

TDC - iniection

bolt to turn ihe

obliquely upwards.

22

Group 21

Basic setting

Engine

a,

,":'trtiiiiiiiiii

ofi

pump

belt

belt

tension- Tighten one boll so

position.

pump

that

pump

Lift
Slacken mounting bolts for injection

release
remains in upper

Lift off belt.

Remove camshaft rear sprocket
Hold

sprocket in

with wren€h 5201. Take care not to rotate camshaft.

pos;tion

with 5199 and unscrew nut

c4

Slacken camshaft tront sprocket

Use 5199 ro
bolt. Make sure that camshafi does nol rolate.

Tap

sprocket

Set belt

Adjust

gauge

Use
belt

and set to 12.5

Stretch

Depress

hold

sp.ocker

to free it from camshaft.

tension

tension

beli until

by moving

5197 to check

mark on

belt

stronglywith

units.

posinon

in

coolant

belt tension.

gauge ptunger

hand and rechecUadjusl

whe'1 loosening

pump.

Attach

gauge

is ftush

C5

c6

to

with

ten

23

Group 2l

Basic

setting

Engine

Set camshaft

gaLrge

Place
(0.008

in) ieeler

compensate
Camshafi;s now set at correct

Make sure cyl. no.

Check

0 mark

position

5190 at rear of camshaft.

sause

for timing

on flywheel

beneath lefi side of

gear

clear;nce.

1 is

at top dead center

and adiust if necessary.

Insert a 0.2 mm

position.

C7

sause

C8

to

)r

Tighten
Use 5199 to

that
Torque

Remove

Disconnect

camshaft front

prevent

camshaft does not

center bolt to 4s Nm

gauge

sprocket from

5190 and leeler

cold start device

sprocket

turn.

Slacken screw 1. Push lever

90". Notel Do not
necessary

to

turn screw 2 otherwise it will be

remove

cold start device and reset it on a

C9

turning. Make sure

(33

ft lbs).

c10

gauge

cl1

forward and rotate sleeve

Group

Basic setting

21 Engine

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

'

-.l\t'-iHi-

-.t";;

v

-

ilo ,,

.)!\\./.)

-.-

.-

/:)a>- L I

-

Basic-set iniection
S acken

marks

Retighten mo!ntin9

Sel dial indicator
injection using stop

Unscrew and remove

tributor. Install holder5194

mm). Set

Turn
mo'rnting

pump

pump

in

gauge

pump gear

bracket coincide.

pump

mountins bolts

and mounling

bolts.

zero. Lock

5193

plug

and dialindicator

to approx. 2 mm.

clockwise until mark on

(Ailen

key = 6 mm). Align

bracket by turning

pump

from injection

gear

at cyl. 1

pump
(range

gear

c12

pump

c13

dis­0-3

and

Then turn
registers

Set indicator to
Turn

mounting bracket coincide. Lock
with

Install
Tighten cenler

b e to turn sprocket

pump gear

on

pump

gear

5193.

srop

camshaft

back slight

dial indicator.

zero.
clockwise !nlilmark on

(lnsert

bo t by hand, but

stop through

rear sprocket

on camshaft.

it

y

until min- reading

gear

gear

in

pump gear

and belt

should stil

and

this

pump

position

possi_

be

into

c14

25

Group 21 Engine

Basic

setting

Set belt tension
Adjust tension by

gauge

Use
belt and

Strelch

5197 to check belt

set to 12,5 units.

belt unti mark

moving

on

pump.

tension. Aftach gauge

gauge ptunger

is ftush wirh

c15

ro

Depress beli

slrongly with

hand and .echecUadjusrren

c16

pump

Set
Use 5199 to hold sprocket. Torq!e wrench sho! d rre at

righi angle lo wrench 5201 otherwise torque will be

Using 5199, lurn sprocket s ow y clockwise

D 20 ....-............................................ 0.80 mm : 0.0315 in

D 24 .................................................

D24USA,/Canada1979 1981......... 0.70mm=0.0276in

Ho d sprocket
(73

ft. lbs). Take care that camshafi and sprocket do

and tighten camshaft rear sprocket

unlil dial

0.70 mm = 0.0276 in

1982-................. 0.85 mm: 0.0335 in

position

in

this

and torque boh to 100 Nm

not

Remove

Check
Turn

center - injection
must be
mark

Dia

O20...........................

D 24 .......-..................-

D 24

197F81.....................

1982
Correct

bolls.

rncoftect

stop 5193 trom

pump

engine two

otherwise

indicalor

USA and canada

........-................0.82

Proceed to

setting

full turns

again.

lurned back

setting will

should

reading: Tighren

C19.

reading:

Beadjust

pump gear

unri cyt. 1 is

lf engine is

approx. 1/41urn

be inco(eci.

show:

0.75

0.83mm=0.029F0.0327in

0.6F0.73 mm

0.65-0.73mm=0.0256

0.90 mm
injeciion

according

at lop oedo
turned
and

:

0.0256-0.0287

=

0.0323-0.0354

pump

roo rar r

then to zero

0.0287in

mounting

ro insrructions

c17

ct8

if

in

26

Group 21 Engine

Cylinder head, removal

-trnjE+:

-i;6't;

$tl

Readlusting

Setting valuesi

D 20 ......-.............-....-....................... 0.80 mm = 0.0315 in

D 24 .....-....-....-........-....-...-...-....-...... 0.70 mm

D24USAandCanada1979

Reading
Slacken

to

obtain corecr value.

repeat

check

Beading

Slacken
until dial indicator

D

20.....................

D 24 ..........................................-...-..

D 24USA,/Canada

Th€n turn
tained. Tighten
ting.

Notel

Injection

this wil

pump

less than specified:

purnp

of

more

pump

pump

alter setting.

setting:

1982- .......... 0.85 mm = 0.0335 in

mounting

pump

than

mouling bolts

l97F81

1S82 .................0.75mm=0.0295in

inwards until

mounting bolts

pump

bolts and lurn
Tighten mounring

setting.

specified:

shows approx.

.....................0.70 mm = 0.0276 in

............. 0.60 mm

must rot be tapped or knocked

=

0-0276

81 ......0.70mm:0.0276in

pump

inwards

bolts and

and turn

pump

outwards

0.60 mm : 0.0236 in

specified va ue is ob-

and recheck

=0.0236in

punrp

set-

as

in

/

Qa,s

zTazzzz

II

E

c19

Remove dial indicator and holder 5194. lnstall
plug

with new

Tishtening

seal

torque 9 Nm

(6.5

ft

lbs).

c20

Reconnect cold
Press

ever forwards and turn

start device

sleeve 90". Retighten

c21

Install valve

Use

new

cover

gaskets

and timing

if necessary.

gear

covers

'

Two types
h€ve
damage
Late ard eu ry

pin

ol

studs are

a spacer, and hoie in

gasker

to

by overrightening,

pa.ts

type

musr

avaitabte, see tig.

gaskel

is larger

not be inlerchanged.

Lare ryDes

prevenl

to

21

Group 21 Engine

Cylinder head, removal

D.Cylinder head, removal

Special

tools:

5199, 5201

Disconnect negative lead from battery
Remove engine splashguard.

Disconnect:

-

exhaust
exhaust

pipe
pipe

gearbox

from
from rear branch

D1

D2

bracket

pipe.

Disconnect:

-

exhaust

-air

Drain

Remove expansion tank cap
Disconnect lower radiator hose from radiator

pipe

filter

cover

coolant

from front branch

with intake hose and crankcase

pipe

D3

D4

2a

Group 21 Engine

Cylinder

Drain coolant from engine

{Engine
Disconnect ower hose f rom cold start

Disconnect

-

is without a drain cock.)

{rom cylindet

radiator hose

upper
hose for cold stari

head I

device.

head, removal

D5

device and drain

D6

Remove vacuum

Remove

Bemove

Remove

Clean all connections

Remove
from entering fuel system.

pump

plunger

tuel delivery

allpressure

pump

retaining nuts and

from cylinder head.

pipe

thoroughly

pipes

pump plunger

and

before disconnecting

plug

and

endslo

place pump

prevent

D7

on

D8

din

29

Group 21 Engine

Cylinder

head, removal

Disconnect

-wire

-wire

from cylinder head:

for temperature

glow plugs

for

gauge

sender

copper connecting strip for rear

-

feturn hose from rear iniector

-

wire for temperature

gauge

sender at rear of cylinder

Remove:

D9

glow plug

D10

-timing

gear

covers

(front

+ read

Dl1

Tum

engine until cyl.

Always useihevibration dampercenter boltto turn the

27

mm socket or

Both

cylinder'l cams should

Flywheelat'0'mark.

wrench

1 is

5148.

TDC - injection

at

point

obliquely upwards.

30

Remove retaining screws from belt cover on
cylinder head

Take

carelhat washer on innerscrewdoes nol falldown

into lower timing
(Late

type engines do not have this washer).

gear

case cover.

D12

Remove belt from

Slacken coolant

pump

Group 21 Engine

Cylinder head, removal

camshaft sprocket

mounting bolts

and

belt

D13

ten

Remove

belt

Bemove

Use 5199
bolt.

IMake sure

Tap

sprocket

from

sprocket.

camshaft front

to hold sprocket

sprocket

in

that camshaft does

to free it from

posjtion

not rotate.

camshaft.

D14

when toosening

Lift

Slacken mojntins bolts for
re
remaans in upper

Lift off belt.

Remove camshaft rear

Hold sprocket in
sprocket with wrench 5201- Take

pump

off

ease belt tension. Tighten one bo t so

belt

injection

position.

sprocket

position

with 5199 and unscrew

D15

pump

D16

care not to rorate

31

Group 21
Cylinder

Engine

head, removal

oo

@o

Tighlening
Bolis

musl be slackened

@@,o
@o0

oo

D20

oo

sequence for

o

D24

o

A, Ol

o@

cylnder head
ln reverse

sequence.

oo@

ooo

bois.

Remove
lmportantr

ening.

Liiiawaycy inder head.
injection

Place cylinder
Do not rest

Clean
cylinder block

cylinder head

Slacken bo ts in reverse

(i.e.

start

pump

cylincler head

gasket

(or

12

at

brackel and that valves do not contact

head

surfaces

D17

sequence to tighl-

14) and finish at 1-)

Checkthat rearglowp ug clears

D18

on

wooden blocks

D19

on

cylinder head

and

0

--:(g=

Check
Use

Replace

-

-

for

a straight

cy inder

lengthwise
crosswrse

damage

0.5 mm

0.2 mm

and warp

edge and feeter gauge.

head if

warp exceeds:

in).

{0.02

(0.008

in).

D20

0

0

(

(

32

Group

Cylinder head, disassembly

21

Engine

Notel Small cracks
replacement

For
stallation"

E. Cylinder head,

(0.s

of cylinder head since they

gasket

disassem

replacement

page

45.

bly

=

mm

0.02 in) do nor wa.ranr
do not impair

only see "Cylinder

head in-

Remove
gasket

Remove injectors
Remove
Disconnect
Bemove

lrom cylinder

intake

dirl around injectors.

fuel lines.

injectors,2T mm

head.

manifold,

socket.

exhaust manifold

Lift out heat

shields

E1

and

E2

33

i

I

Group 21 Engine

Cylinder head, disassembly

Remove camshaft bearing caps 1 and 4

Remove camshaft

crosswise

Slacken

nuts

bearing

1o avoid

caps 2 and 3

placing

uneven

E3

E4

load on

Lift awav

camshalt

Lift out tappets

Do not interchange tappels.

Notel

they can be installed

remove oil

and

in same

E5

seals

E6

Mark tappets so that

position.

Remove

-

lifting eyes

-

connecting

-

temperature senders

{rom cylinder

flange

head:

for water hose

(2

x).

(Allen

E7

5 mm)

Group 21 Engine

{r*,t

Tap out swirl

a long

Use

length

Remove

lmportant!
Depress

narrow

150 mm

valve

Do not

valve springs

Cylinder

chambers

punch

(6

in).

springs

and

intetchange

with a

head, disassemt'/y

mm

-

0.24

(6

valves

pans.

special

compressor

E8

in diameter),

E9

tool

D

-

upper

-

springs

spnng

seat

Remove seals trom valve

tool

Use

5219,

E10

guides

Remove lower valve

pair

Use a

of external

spring

lock

ring

pliers

with flat

El1

jaws.

35

Group 21 Engine

Cylinder head, cleaning - inspection

F. Gylinder

head,cleaning

-

inspection

v

Check

Use a di.l indi.alor

new valves

Use
slem f ush with valve

C earance = 1.3 mm

Check camshaft
Use a dial

Posir

,rb

n

Clearance

Remove cap and

ra nce

clea

indicator.

ransnail

or

rbs,.

=

between va lve g uides a nd valves

(iniake

end float

drd

max 0.15

camshafl.

and exhausl) with end oi va ve

guide.

(0.05

in).

rr"ld redr cdp.

(0

mm

006

in)

lorque to

20 Nm

V

F2

0

0

36

Check
Check disc

Install new discs with numbers

Clearance,

discs

play.

new

Beplace disc if worn or scored.

par1s

............................ 0.01 6-0.046

F3

facing down,lowards

mm

(0.0006-0

0018

in)

8trre

Group

Cylinder head.

Check tappets

P

ace tappets
Check fit and clearance.
Clearance, newparts 0.025-0.075

Check valve springs

Length

33.9
28_6

18.3

Outer springs

Length

40.2

32.6

22.3

in cylinder head

lin)
(1.334)

(1.126)
(0.720)

(in)
(1.583)
(1.283)
(0.878)

cleaning - inspection

mm

0
61 17
209-231

0

I67-185

479

433

21 Engine

(0.001

0.003in)

{lbs)
l0)

17.5)

{15

52.2)

t41

{lbs)
(0)

l3v42l
(98-108.3)

guides

Replacing
Operations

Press out valve

Use drift 5218. Press

Ptess in new valve

Lubricate valve
ljse drift

Press in
head. In
since f ange may break

valve

F 6-8

guide.

Press in from

5218.

guide

until

position press

this

guide

from

guide

flange

combustion

camshaft side.

guide

on

fo.ce must nolexceed l ton

off.

chamber side.

contacts cylinder

F6

37

Group 21 Engine

Cylinder head, cleaning - inspection

oil

valve

must

Clean inside of

Use rsamBr 5224
Note! Cutting

Valves and seats must

guide

be used when reaming,

ground-in

be

aftsr valve

F8

guide

'-'T-______________

wr-

G ri nd i n
Operations F 9-1

Machine g nd intako valvos
Edge

In).
lmportant! Exhaustvalves

not be
grinding paste.

Mill or
Grind
Contact surface

-2.0

-2.4
ll contact

lmponam!
35,2 mm
{1.31

g-

i n va lve6 a n d

of intake valve must not be lessthan 0.5 mm

ground

to 45'.

mm
mm

in)for

by machine. Grind-in valve on seatwith

grind

valv6

{a)

in) for

{0.08

in)for sxhaust valve.

{0.09
surface is too wide

Outer diameter

(1.39

in) for intake valve

sxhaust valve

2

seats

must be:

intake valve

seats

are stellite coated and must

reduc€ area with

of cutter

ssats.

must no! Bxceeo

s€ats and

33.2 mm

F9

(0.02

F10

a 15q

38

1.5 mm

{0.00

in)

Measuae
surfaco

Gap

Replace
Notel Two valvs types

gap

=

max 1.5 mm

seat and

between disc

10.06

possibly

cylinder head

and

in).

valve if

are available, see G3.

gap

is

too Iarge.

Ftl

Cylinder

Grind-in

Clean valves thoroushly.

valves with

head, cieaning - inspection

paste

Group

21 Engine

F12

.3F{'

q.

'

^s

Replacingvalve

OperctionsF

guides

Valve
ing seats, see

Cfean combustion chamber
Toge

ol seal

Remove valve seat
Mill vave seat, using cutters such

9986045). Refer
sure that seat in cylinde.

clean surfaces thoroughtr.

Measure

and of

diameter of seat

valve seat

Use an internal

Diameter, seat

in1ake....................

exhaust

................ 33-000-33.01 6 11.2992

seats

13 21

be replaced before

must

F6 8,

page

nJsl be clear

37.

vis:ole ahF' cleaninS.

v

rep ac_

as Mira

to manufacturer's instructions.

head is not darnaged.

recess in cylinder

micromeier to

measure seat

Standard
(production

recess, mm

37.000 37.016

version)

(in)

i.1.4561-1.4513)

F13

F14

{P/N

Make

,rU

head

recess

1.2994)

mm = 0.0029

0 041 in)

inrake....................

exhausr

D ameter, seat

in1ake....................

exhausr

intake............-.......37.290

exhausi...............33.290

When replacing
the valve seat and

0.074-0.10s
meter must
greater
head.

Mill seat

................ 33.090-33.1

..............-- 33.200

mm

ihan th€

Replace cylinder

recess if interference

37.09(F37.105

Oversize
(replacement

(rnJ

recess,

be 0.074 0.105

mm

37.200-37.216
33 216

37.305

33305

va ve seals:

its bore ir the cYlinder

(0.0029-0.0041

diameler of the

heacl if c earance

(1.4602

05

{1.3028-1.3033)

version)

Parts

\1.4646-1.46521

113411-1
(1.4681-1.4687)

(1.3106-1-3112)

the interference

in) I e

(0

mm

002F0

bore in the

large.

is too

between

head shall

valve sear

0041 n)

is too smal

1.4608)

30171

be

d a-

cylinder

39

Group 21 Engine

Cylinder head, assembly

Heat cylinder head

'100'C

Heat

to

Place new

Use drift 5220 for intake

(212'F).

seat in installation

tool

valve seats and 5221 for

F16

F17

ex-

Cool valve seat

protective gloves

Wear

Use liquid carbon dioxide to cool
(-94"F).

Tap-in

NotelThismustbedonequickly,within3
avoid temperature loss.

valve

seat

and safety

glasses.

down

seat

F18

-70'C

to

Ft9

4secondsto

lr

0,r

(

40

Check lit

Make sure that the
secure. if not,

Grind valves

See instructions

of valve seat

replace cylinder head.

and mill seats

on

has

seat

page

bottomed correctly and is

38, operations F F]2

F20

F21

Group 21 Engine

Cylinder head,

assembly

G. Cylinder

head, assembly

New

cylinder head

a New cylinder head

old. Cylinder

bolts

must not be used with

Cylinder heads can

illustration

Number

-

Numbe.

LJSA,/Canada

der head

its bore is

at left):
series followed by B = M 11
series followed

and swirl chamber. Swirl chamber

2 mm

Newcylinderhead
Opetationcl

Install oil

ieis
Carelully tap in oil
Note! Turn outerjets to

fis

lmportantl

head. M

Differenttype

Check specification ;nd

'12

bolts must not be

cylinder heads are used for LJSI,/Canada.

must be the same type as the

heads designed for use with lvl 12

1982- has a different

(0.080

pin

and

jets

'11

M

bolts.

be identified as follows

by C = M 12

type of cylin,

in) smaller in diameter

studs in cylinder head

using

a brass

point

across cylinder head,

used wirh M 11 bolts.

punch.

type of cylinder

(see

and

cl

see

Checkvalve stem

This measurement

sufficient adjustment lattitude for

gauge

Place
der he8d.

Notel F.ont
others. Make sure that

Taking each va,ve in

conlact

Vslve length, mm

Intakeva1ve...................'104.8

Exhaustvalve................'104.6

(Small

gauge.

posilion

in relationto

is carried out to ensure thatthere is

valves.

with largest

5222

ring is for B 17-B 23 engines.)

bearing recess diameter'is larger than

gauge

tu.n, check that stem does not

lf this happens,

{in}

diam€ter ring, on cylin-

positio.ed

is

grind

New Min

(4.126)
(4.118i

valve

104.3

104.1

G2

camshaft

correctly.

stem.

(4.106)
(4.0981

4l

Group 2l Engine
Cylinder

head, assembly

and late

Early
and upper spring

type valves and

Early
whereas

Only late types
Consequently

and upper spring

late tYpes

tvpe valves.

are available

when

seal

seats

colets

have three

instaLling

must also

valve collets

have one

as spare

a new

locking

parls

valve, the collet

be replaced

G3

(locks)

groove

with new

I
I

I

Newspring

Early types

lnstalll

-

upper spring seats,
lnstaLl
Protectivesleeves

To install valve,

protecrive
seal, note that

seats are
are bright

va ve stem oil seal.

sleeve on stem.

eirhercopper

must be used when

pl.ce

tool should abut flange

coated

or black.

flanged side up.

instailing oilseal

valve in cylinder

use tool 5219 to

orchromed

head and

install oil

seal.

f(

0

G4

place

lnstall:

inner and outer

lmportantl

Two types ol

valve sp.ings

valves, upper spring

G5

seats and

l,

I

(

Group 21 Engine

Cylinder head. assembly

ra

(

..,

air

e,

Install
Check thal steel ball is

Lf not, install new swirl chambef.
Make

down swirl chambers.

swirl chambers

in

chamber.

that ball fits in slot in cylinder heacl. Tap

sure

lmportant! Specia swirl chambers

meter)

for

USA/Canada

1982-.

lnstall:

-

glow p

temperature senders

-

connecting fange for radiator hose
Install new

-

lfting

ugs. Tishtening torque 40 Nm

(2X).

Same lype front and

gasket.

Tightening torque 10 Nm

eyes.

(different

(30

ft lbs)

(Allen

5 nrm).

(7

ft bs).

G6

dia-

G7

rear

G8

Install
Smear

Number

Check

tappets

with shims

iappets and

on shims

that tappets

should face down.

slide easi y without

shims with oil before insta

sticking.

a!on.

G9

Place

camshaft

in

cylinder

head

Lubricate contact surfaces of camshalt and bearings.
Place

cams for number 1 cylinder must

5'190 al rear of camshafl. lmportantl Both

9au9e

point

diagona y up,

43

Group 21 Engine

Cylinder

head, assenbly

Install camshalt

Install caps correctly, center
Tighlen nuts crosswise to avoid

position

in

shaft

caps 2 and 3

gauge

wilh

is off'sel.

5190 at

G10

distortion. Hold cam

rear when tighten

Remove

Press in new camshaft oil seals
Apply oil to oil
Do notpush in

seasare"square",0

Install camshaft caps
Mdle

colrecl.v.

Torque all

Torque = 20 Nm

Tap

use adapter

Install

Place new

gauge

5190.

seals.

sealsto

cJre

Inar r"e LhrJ5lwisne

four caps

(15

ft lbs).

in oil seals

to bottom

5200 and

iniectors

heat shie ds

bottom

a

in cy inder head

posilion.

1 and 4

forcarsh.lcap4rls

plastic ma lei

Gl1

Makesurethat

GI2

G13

G14

G15

Turn shie

ds as

^

0

Screw in
Reconnecl

h is aclvisab e to check
.econditioning cy inder
page

Install exhaust branch
Use new

Branch
outwards, facing branch
sho|]

Tightening lorque 25 Nrn

injectors.

fuel delivey

153.

gaskets

pipe

d be lurned with

Torque ro 70

and nuts. Install

gasket

shou

green

ines between

Nm

condition of inleciors

head. See instructions on

pipe

and intake mani{old

d be turned with

pipe.

Intake manifold

facing cylinder head.

side

(18

ft lbs).

ft lbs)

{50

in,ectors

gaskets

raised edge

when

correctlY.

gasket

0
0

Gt6

Group 21 Engine

cylinder head, installing

?/'--'\r

S--:'l

H. Cylinder

Special tools: 5190, 5193,

Q4t

)io.iQ

head,

5194, 5197,5199.5201,4 x 5233, 4 x 5234, 5235

installing

Clean holes lor cylindel

Oil and
gasket

dirt must be removed from holes

may leak as

a result of insufficient

h6ad bohs

H1

tightening

H2

lnstall

5233 for blocks

5234 for blocks with M 12 bolts.

Twoouterpins hold

prevented
inner

lmportantl Use all four

Install

Thres dil{sr€nttypes are available, and are marked with

notches. Type
above cylinder block.

Use s8me
OBEN facing up.

guide pins

with M 11 bolts.

from

pins,

new cylinder

slidjng and clamaging

be fitted depends

to

gasket

in cylinder block

gasket

type

in

pins,

head

(no,

position.

located as

gasket

notches) as

Cylinderhead is

gasket

on

by two

illustratsd.

piston

height

before, with

H3

45

Group 2l Engine

Cylinder

head. installing

Observe dale code on
be used before this date.

gaskets

Only

wilh code MO or later may be used on

gaskel

B

c

D
E

G

Sept
Oct
Nov
Dec

To avoid impairing seaLing

packet

open

Take care

gasket,

until

not to darnage

(teflon

strip,

J
L

M'
198

gasket

is to be

packet

rubber seal).

properties

and

MO

packet.

_0

I

|

Gasket must

=

1980

r=r98r

2=1982

t*

gasket

of

used.

caLrse damage lo

and

D 24

I
I

do not

pistons,

lf

3:

=.-

rl'

heighl must be measured, and

Piston height

mm

0.67-0.80

0.81-0.90

0.9't-1.02(0.036 0.040) 3

connecting

above

{in)

(0_026-0.031
(0.032-0.03s)

rods etc. are rep aced,

gasket

chosen according

Gasket

notches thicknessmm

I ................

)

2 ................

................

1.4

1.5

1.6

piston

(0.055)
(0.059)

{0.063)

(in}

0

I

H5

Set cylinder 1 to TDC

Flywheeltiming mark at
Use a 27 mm

per

center bolt to turn engrne.

socket or

'0

wrench 5'l88 on vibration dam-

46

M11

Group

Cylinder head, installing

Position camshaft
Sel

camshaft so lhat

(both

cam lobes should
Prevent
lmportant! Camshaft must be locked otherwise valves

Cylinder head bolts

Two types of cylinder

Early type bolts have M 11 threads.
reused with new
facing up.

Late type bolts have fM 12 threads along
These bo

camshaft

ts mustnot be

number 1

point

from moving with

head bo ts are in use.

washers- Fit washers with c!p shape

reused Washers

cylinder

diagonally upwards).

These bolts can be

21 Engine

is

injection

at

stop 5190.

entire length.
may however

H6

+

o

i!

I

Install cylinder head

Lubricate
bolts in ho

Remove
Install remaining

threads and

wilhout guide pins.

es

g!ide pins.

sliding su rface of washers. Place

Use tool

bolts.

bolts

5235.

47

I

Group
Cylindet head, installing

21 Engine

oooo9/@

D20

@o.r'o'o@@

@@@@@).o@-

n

@@@O@lO@,1

a

D24

Toique cylinder
Tighten

csnt bofore

't1s9082

bolts one at a time in order specified

all

proceeding

head bohs

wjth

H8

adia-

next stage.

Tighten
150Nm=37ftlbs
270Nm=5rftlbs
390Nm=66ftlbs

in three stagesl

Tighten in four stagesl
r 40Nm=29filbs
2

Nm = 44 ft lbs

60
3 75 Nm = 55 ft lbs
4 angle-tighten 18{f in
ping.

See illustration below:

12-sided

one movement without stop-

wrench P/N 115 9082-5

48

Group 21

Cylinder

Engine

head, installing

o

rD

Connect

copper

connectingH9stdp lor two

glow plugs

Install

Install camshaft
Pull

geaf.
Place belt

Tighten

ble to turn sprocket on camshaft.

bolts lor

cover

sprocket and belt

belt to ensure that it

overcamshafi sprocket

center bolt by hand, but it should stil be

sits correctly on

and

crankshaft

position

rear

H10

H11

sprocket

possi'

Set

belt tension

Adjust lension

gauge

Use
and set to 12.5

Strelch belt

Depress

Marke

Check'0

5197 to

uniil mark on

beh strong

sure cyl.

mark on flywhee

by moving

check tension. Attach gauge

units.

1 is at

cooling

gauge p

ywith

hand and .echecUadjustten-

top dead

and adjust if necessery.

pump.

unger is f

center

Hl2

ro betr

ush wirh

H13

Group 21 Engine
Cylinder head, installing

Place a 0.2 mm feeler
Insert

blade beneath left side of

for timing

Tighten

Use 5199 to

Torque

gear

clearance. 0.2 mm = 0.008 in.

camshaft front

prevent

center bolt to 45 Nm

spocket from turning.

gauge

sprocket

(33

beneath

gauge

ft tbs).

gauge

to compensale

H14

5190

Ht5

,)

a

)e

H16

Remove

Disconnect

Slacken screw 1. Push leverforward and rotale sleeve
90'.

Not€! Do notturn screw 2 otheMise it will be necessary

to removecold

Press lever

Basic-set injection

Slacken

Align marks

pump.

gauge

pump

Retighten mounting bolts.

5190 and

cold start device

startdevice and reset il on a test bench.

back against stop.

pump

mounting bolts

on

pump

mounting bracket by turning

and

feeler

(Alen

gauge

H17

H1a

key = 6 mm)

u)l

i')l

5A

(

Group 21 Engine

Cylinder head. installing

H19

Set dial indicator zero. Lock
injection

Unscrew and renrove

using stop 5193

plug

pump gear

from

injection

at cyl.

pump

I

disrri

i;;$d

Install holder

gauge

Set

pump gear

Turn

mounting

Then

turn

registers on dial inciicator.
Set indicator to zero.

pump gear

Turn
mounting bracket coincide. Lock
with stop 5193.

5l94 and dial indicator

to approx. 2 mm.

clockwise until mark on

bracket coincide.

pump

gear

back slightly unlil min reading

clockwise untilmark on

(lnseft

stop through

(ranse

gear

gear

in this

pump gear

0 3 mm).

gear

and

pump

and

position

into

Install camshaft rear sprocket and belt
Tlghten

center bolt by hand, but it should still be

b e to turn sprocket on camshaft.

Set belt tension

Adjust lension

gauge

Use
and

set to 12.5 units. Stretch belt until mark

plunger
hand and recheck/adjust

is

by rnoving

5197 to

flush with sleeve. Depress

check tension. Attach

pump.

gauge

be t strong y with

tension.

on

H2A

possi

H21

to be t

gauge

5l

Group

Cylinder

21 Engine

head, installing

pump

Set

Use5199to
right angle

and tighten

hold sprocket
to

camshaft

Torquewrench

wrench 5201

rear sprocket

otherwise

torque

should

be al

wl I be

H22

W'r

5199, turn

Using

D 20 ........................-....

24 .......................

D
D 24 USAJCanada
1979 81

1982 ...............

Hold sprockel
(73

........-................

lbs). Take care

ft

sprocket

..

..

in this

Remove stop 5193

Check
Turn engine two

center

must be lLrrned
mark othelwlse

Dial indlcator shou

D 20 ........................... 0.7F0.83

D 24 ...........................

pump

-

D 24 USA and Canada

1979-1981 ......-.......... 0.6F0.73

1982-......................... 0.82-0.90

Correct reading:

setting

full turns unii cyl.

injection, again.

back approx.

setiing wil be

d show:

Tighten injection

slowlv

- .. 0

..

. ..

. ... 0-70mrn

.. .

. . ..

posiiion
that camshait

from

and

pump gear

li engine is turned

1/4lurn and then

incorect

mm

0.6F0.73 mm
mrn : 0.0256-0.0287

mnr = 0.0323-0.0354

clockwise

80mrn

0 70

0 85

torque

and

:0.0295-0.0327
=

ontiL dial

=

0 0315in

mm = 0.0276

=

0 02761n

:0

mm

boll to

sprocket

1 is at top dead

loo far it

0.0256 0.0287

pump

mounting

in

0335 in

100 Nm

do not

H23

H24

to zero

)a

)e

in
in

ln
in

52

Incorect readingr Beadjust according to insiruciiofs

Readiusting

D 20.......................................-.........

D 24 ..........-....-.................................

D 24USAandCanacla l9T9 lgSl 0.70mm-0.0276in

Reading
Slacken

to obtain correct

repeat check oi

pump

less than specified:

pump

setting:

1982- .......... 0.85 mm

value.

sett

bohs
Tighten

n9s.

mouniing

punrp

0,80mm : 0.0315in

0.70 mm = 0.0276

=

0.0335 in

pump

and turn

mounilng

anwards

bolts and

n

)a

?.i

A.EErj

li6t',t

Group 21 Engine

Cylinder

head. installing

Reading more than specified:
Slacken

until dial indicator shows approx:

D20.................................................0.70mm=0.0276in

D 24 ...--...--...--...--...-...--...-................ 0.60 mm = 0.0236 in

D 24 USA/canada

Then
rained. Tighten mounting bolts and recheck
trng.

Note! lnjection
this will

pump

turn

alter

mounting bolts and turn

197F1981 ......-.. 0.60 mm = 0.0236 in

1982 .................0.75mm=0.0295in

pump

inwards until specified value is ob

pump

must not be tapped or knocked as

its

setting.

pump

oulwards

pomp

set-

H25

Remove dial indicator
plug

with new seal

T'shtening

torque I Nm

and

(6.5

ft

holder

5194. lnstall

o

zz7:@

E

ta

E

Reconnect
Press lever forwards

Notel Do

lo reset

Install valve

new

Use

Two
have a spacer, and hole
damage lo
Lale and early

Note! Only install a lew
moved laier on when lightening cylinder

cold start device

and turn sleeve 90'. Retighten

notturn screw 2 otherwise itwill be

cold start device on a test bench.

cover

gaskets

typ6s oj

if necessary.

pin

srudsareavailable,

gasket

by ovenightening,

parts

rype

seetig. Laretypes

gasket

in

must not be interchanqed,

nuts since cover is to be re-

is larger

H26

necessary

H27

pfevont

to

head bolts.

53

Gtoup 2l Engine
Cylinder head. installing

Install timing

Reconnect
Iightening

tuel delivery

torque

gear

25 Nm

covers

pipes

(18

({ront

ft lbs).

and rearl

H28

H29

)liO

')r

O

Reconnect return

Install

Check O
Connect vacuum hose

lnstall:

-wires

plunger

ring, replace if necessary-

wire to
one lo left of cylinder

glow

to temperature

pipe

and vacuum

plug

to rear iniector

pump

(from

brake seruo);

(2

senders

head.

X),

to

at rear and

one

H30

H31

pLrmp.

H32

ilrlO

54

Connect:

lower radiato. hose to radiator

-

'rpper radiato.

-

hoses

for cold siart device to cylincler head and theF

hose

H33

Cylinder head, installing

lnstall air Iilter and connect

A(ow on
otherwise the crankcase

Connectl

-

splashguard

inlet hose must

branch

Bleeding ot cooling

Disconnect

drip

upper hose from cold

pan

beneath hose

edge of expansion

point
breather hose may contact

pipe.

system

and hold hose

tank.

Group

hoses

towards

Use

inlet manifold

new

start device.

21

Engine

H34

H35

gaskets.

H36

Place

leve with top

D

Coolant

Since alurninium is used in the engines,

protection

sion

genuine

Use
with clean water in

This mixture helps

Never fill the coo ing system with water

a

The coolanl should be changed regura,ly srnce th

a

corrosion
their effect in lime.

Note! Do not run en9 ine when level of coolant is
low. High loca temperat!res
may

cause lhe cylinder

is necessary in

Volvo b ue-green coolanl type C, dilut(

propoltions

to

protective

the coo ani help

of 50/50.

prevent

additives in the coolant

corrosion and fic

can

head

to crack.

active corro

alone-

resuli which

prevenl

los

Group 21 Engine

Cylinder

-vroL\Io
sfiD!^r L 30cc tfrrifYrr airr

head, installing

rtrvArsu

ofl Gri[

voLvo coourr

r0r

uP YIAN B0ur0 $ft

r/oLvo

iLr|r f$

rY*

iALi

rYrt

vrc Mot[ r^Lr

c vl|r0rr rus0u^ 2Pt

v

0n

c c00rr6 sYsitc

w^
Motrrt ^Nrcn rw

rs

Replacing coolant

c

Always Lrse type C blue-9reen coolant. Remember
replace decal

Type C blue-green coolant
All diesel and

1982

since

Fill coolant
Capacity:

Flush cooling system before adding
Group 26 Cooling System.

dcs ooard hedrer conrro' ro 1i.(. Tur'r o'r eng

Ser
and warm'up for 5 minutes. Add coolant
time. Connect hose lo cold start device.

mouth of expansion tank

(P/N

1331473

petro

filled with type C coo ant.

are

D 20 = 8.1

=

D 24

9.3 tirers

7)

(gasoline)

(8.6

liters

(9.8

(above

on expansion

engines

quarts)

US

quafts).

us

max) and screw on

tank if ne-

manufactured

new coolant, see

during this

Fill

coolant

to

H37

na

to

!ilo

).iO

Tighten cylinder
Wa.m-up engine until oi temperalure

1122"F1.
Remove vacuum
M 11 boltsr lorque to 90

M 12 bolts:an9le'tighien
stopping.

Check-tightening
lmportantr Bolis must be

miles

Instal

(1,000

head bolts

pump

of cylinder head bolts

2,000 krn). See next

plunger

with

(6s

Nm

90'in one movemenl

re

torqlecl after 600-1,200

is at least 50'c

and

ft lbs)

plrrnp

page.

H38

va ve cover.

wrlh otrt

plunger

and

DO

)ilo

56

Cylinder

Group

head,

21 Engine

retorquing

To be carried out after

M 1l bohs = 10 hm Allen key

J. Cylinder

(1,000-2,000

600-1,200

miles

head,

retorquing

km) on cold

Remove

Access to one of cylinder

M 11 bolts:

Tighten each boh in turn as indicated according

valve cover, vacuum

or nearlY cold

head bolts

engine

pump

and

is restricled by

J1

plunger

J2

to

M 12 bolrs = 12 s ded sockei
P/N 115 9082-5.

o

ut

ooao,@r
oQoo@

M11

11s9082

M12

D20

1. Slacken

2. Torque to 90

M 12

Tighten each

1. Angle tighten bolt 90'
siopping- Do not s acken bolt first. See illustration
in

bolt 30'

bolts:

boLt in turn as

operation

@,@o

Nm

H38.

{65

!bs)-

ft

indicated according

in

movement without

one

a

0g:@

D24

@rO.O

o

o

i.o (o

to

Install valve cover,
Check

O-rinq,

replace if necessary.

plunger

and

vacuum

J3

pump

57

Group

Timing gear

21 Engine

belt

tension

K.

Timing

Bell tension affecb lnjection

gear

timing. Follow below inslructlons

belt tension, checking/adiusting

Special toal:5197

carefulty. Overright

Remove timing

gear

belts cause

covers

({ront

pu

ey io

and

sq!eak.

rear}

K1

:)r

I

r)a

Check belt tension

Use gauge

Adlust

Check timing

gauge

Use

5197. Tension

tension 1o

gear

s197. Tension

'12.5

shoLrld be between

uniis

by moving

belt

tension

should be

K2

12 13

pump

mounring

K3

between 12-13

r)r

I

t),

I

58

--'-\.

Group 21 Engine

gear

Timing

Incorrect belt tension
lJnscrew

from cooling syslem.

Tum engine approx. 1/4 turn
slack

injection
Turn crankshaft with
Adjust belt

moving

gear

lf

Turn engine at le6st one turn clockwise and check that

belttension is 12-13 units on tool5197. Adjust if neces­saryaccording to

expansion tank cap to release

anticlockwise to obtain

part

of bslt on driving side. lf this is not done

pump

setting will be incorrect.

27 mm socket or 5188.

tension to 12.5 units on

coolant

belt tension

pump

mounting bracket.

has

been adiusled

operations

K2-3 and rechecktension,

belts, tension

overpressure

gauge

5197 by

Install timing

gear

covers

Group 21 Engine

Timing

gear

belts, replacement

L. Timing

Special

Do not rolate crankshaft or camshaft

tools: 5187.

Engine may only be lurned by means of

gear

5188, 5190,

when timins

belts, replacement

cause oamage.

ano

5193, 5194,

removed

belt is

sear

Disconnect battery

Jack-up

prevent

To
vehicle al front right

splashg!ard into drip

along
Place drip

5197, 5199, 5201,

vibration damper.

olherwise

vehicle

spillages

pan

beneath left steering

valves may strik€

when coolant is drained, raise

jacking

5202

point.

pan.

Coolanl

wil then run

rod.

pistons

L1 i){

L2

|

')a

Drain coolant

Unscrew
Disconnect lower radiaior hose
Dlsconnect

device and drain coolant.

-

cooling

-fan

expansion lank cap.

lower hose fronr thermostat

fan wiih spacer and

and

power

belts

(Engine

steering

pulley

irom racliator

for cold start

is wilhout

pump

drain laps)

belt

L3

L4

0)a

,r)

(

60

Timing

Group

gear

belts, replacement

21 Engine

t,

-timing

gear

covers

Turn engine
Alwals Jre

vib ation

27 mm socket

Both cyLinder

1 cams

(front

and

1 is at

cyl.

until

ddmpercenterboll

wrench

or

5188

should

rear)

TDC

point

-

injection
totL'n

obLiquelY

'rpwards

L6

pn9ine

Remove

Use 51871o
5188 to

It may be
rests on fan

vibration

prevent

unscrew

necessary

beafing.

Check that cyl.

damper

puLlev

bolt.

to turn

1 is at TDC - iniection

center

rotaling,

from

engine slightlv

Check'0' nrark on flywheel.
Adjust if necessary, use 5187 to turn

bolt

and socket

so

engine

L7

ihat 5187

61

6roup 21 Engine

Timing

-

gear

belts, replacement

,

,J
r{

s

Remove vibration
Bemove

Pull otJ vibration damper. Note!
sometimes

Remove
Slacken coolant

tension.

four Allen screws

stick to vibration damper.

lower timing

Remove belt.

damper

pump

(6

mm).

gear

cover and belt

retaining

Crankshaft

bolts to

gear

release

L9

may

Ll0

belt

)a

)r;O

Replace
Always replace

Renrove
Wilhdraw plrlley

Tap on new

Remove camshaft rear

Hold sprocket
sprocket with wrench 5201.

Take

care not to rolate camshaft.

pulley

idle.

pulley

center bolt.

|]sing

pulley

in

when fitiing new belt.

5202.

and installcenter bolt.

sprocket and belt

position

with 5199

Ll1

)il4

),lt

Ll2

and unscrew

62

left

gear

of

side

sprocket

position

in

Timing

posilion

Lock camshaft

Lift valve cover

gauge

Place

gauge

feeler
for timing

Camshaft is now set ai correct

Bemove camshaft Iront
Use 5199 to hold sprocket

bolts. Tap sprocket to free

in

gasket

5190 at rear of camshaft. lnsert

beneath

gear

clearance.

Group 21 Engine

belts,

rcplacement

a 0.2 mm

gaugo

to compensate

position.

when loosenins

L13

LI4

Install
[4ake
Install

turn sprocket

Instatl

gear

belt and camshaft lronl

sure that belt

center bolt, hand tight. lt should be

lower timing

fits

se€urely on all

on camshaft

gear

without

damper

Dampercanonlybefitted in

gear

must fit in vibration

Torque

inhex bolts ro 20 Nm

oneway.

damper.

sprocket

gears.

camshaft rotating.

cover

(15

and

Pin

fi lbs).

on crankshaft

Ll5

possible

to

L16

vibration

63

Group 21 Engine

Timing

gear

behs, replacement

Ll7

Install

Smear threads and rnating surface with
277961-9.

Use

vibration damper. LJse wrench 5188 to lorque center

bolt
lmportantr

is used. Also torque wrench must be in ine with wrench

5184.

center bolt

wrench
to 350

(rest

5187

Nm

{255

Torque 350 Nm applies only if wrench 5188

on cooling fan

ft lbs).

journal)

sealer

to hold

P/N

L18

Make

Check'0' ma|k on flywheel and

cyl. 1 is at TDC - inlection

sure

adjust if necessary.

L19

Set belt tension

Adjust

tension by moving coolant

gauge

Use
and

Stretch bell until mark on

Depress belt strongly with hand and rechecuadjustten-

5197 to check tension. Attach

to 12.5 units.

set

gauge plunger

pump

gauge

is

ilush

to

belt

with

L20

Tighten camshaft lront sprocket and remove
gauge

Use 5199 to

Torque

Remove

5190

prevent

sprocket from turning.

center boit to 4s Nm

gauge

5190 and feeler

(33

gauge.

fi lbs).

040

64

Group 21 Engine

Timing

Disconnect cold start device

Slacken
90'.

Note!Do notturn screw2 otherwise it llbe necessary
to remove

Press

screw 1. Push lever foNard

cold startdevice and resetit on a test bench,

back lever against stop.

gear

belrc, replacement

rotate

and

L21

sleeve

-r@

-v2a//J:'

j

iP)

Basic-set
Slacken

Align

pump.

Set

inlection using

Unscrew and rernove

Install holder 5194 and dial

gauge

Set
Turn

mounting bracket coincide.

inieciion

pump

marks on

Retighten mounting bolts.

dial indicator zero. Lock

approx.2 mm.

to

pump

gear

pump

mounting bolts

pump

and mounting

stop 5193

plug

from

clockwise

(Allen

key

bracket by turning

pump gear

injection

indicator

until mark on

{range

=

6 mm).

at cyl. 1

pump

0 3 mm).

gear

L22

L23

distri

and

Then turn back

registers
Set indicator to zero.

I!rn

mounting bracket

wilh stop

on dial indicator.

pump

p!mp gear

gearclockwise

coincide. Lock

(lnsert

5193.

stop through

siightly until min reading

until mark

gear

on

gear

in this

pump gear

pump

and

position

inro

i

65

Group 21 Engine
Timing

gear

belts, replacement

lnstall
Tighten

turn

Set belt tension
Adjust tension by moving
Use

and set to
plunger

Depress bell strongly with hand and

camshaft rear

center bolr by hand, it

sprocket on camshaft.

gauge

5197 to check tension.

12.5 units. Stretch belt until mark on

is flush with sleeve-

sprocket and belt

shoutd be

pump.

Attach

L24

possibte

gauge

rechecUadjustten-

to

L25

lo belt

gauge

i

0la

!

r)

L26

pump

Sel
Use5199ro hold sprocket. Torque wrench should be al

right angles to wrench 5201 otheMise torque wiL be

Using 5199, turn spro€ket slowly clockwise until dial

D20....................................-....-.......0.80mm=0.0315in

D 24 .................................................

D24USA/Canada1979

Hold
(73ft

Remove

and tighten camshaft rear sprocket

0.70 mm : 0.0276 in

1981.........0.70mm=0-0276in

'I

982-................. 0-85 mm

position

sprocket

lbs). Take care that camshaft and sprocket do not

in

this

stop 5193

{rom

and torque bolt to 100 Nm

pump gear

=

0.0335 in

L27

d),

I

t)r

I

66

I

I

i-'i

Group 21 Engine

Timing

gear

belts, replacement

L28

Check

Turn

center - injection, again.
must be turned back approx.
mark otherwise setting will be

Dial

D 20 ........................... 0.75-0.83

D24........................... 0.65 0.73mm=0.025F0.0287in

D 24

1S79 1981 ...........-....

1982 ......................... 0.82-0.90mm

Correcr reading: Tighten injection mounting bo ts.
ceed to 129.

Incorrect readingr Readjust according

pump

engine two full turns until cyl. I is at 1op

indicator

USA,/Canada

setting

should

0.6F0.73 mm = 0.0256-0.0282in

lf

show:

engine

is turned too far it

'l14lurn

and then to zero

inconect.

mm = 0.029F0.0327 in

=

0.0323-0.0354in

to instructions

dead

Pro-

Radiusling

D20.................................................0.80mm=0.0315in

D 24 .................................................

D 24

USA,/Canada
1979-1981

1982 ...............................................0.85mm:0.033sin

Reading less than specified:
Slacken

to obtain correct valLre- Tighten mounting bo ts and

repeat

Beading more than specified:
Slacken

until dial indicto. shows approx:

D 20 ................................................. 0.70 mm = 0.0276

D 24 ...........--...-...-....-...-........-.......-.. 0.60 mm = 0.0236 in

D 24 USp/Canada 1979-1981

Then turn
tained. Tighten rnounting bo ts and recheck
ting.

Note! lnjection

this will

pump

....................................... 0.70mm

pump

check of

purnp

pump

alter

setting:

0.70 mm : 0.0276 in

mounting bolts and turn

pump

settings.

mounting bolls and turn

.........

0.60

1982 .................0.75mm:0.0295in

inwards unti specified value is ob

pump

must not be tapped or knocked as

its

setring.

:0.0276in

pump

inwards

pump

outwards

mm = 0.0236 in

pump

set-

in

Bemove
plug

Tightening

dial indicator

with

new

torque

seal

9 Nm

and holder

ft lbs).

{6.5

5194.

L29

Install

67

Group

Timtng

21 Engine

gear

bells replacement

Reconnect cold start
Press lever forwards and tlrn sleeve

device

L30

90'. Relighlen

=%'r

I'L

LJ:

/

azzz

8,5

0

Trzzz

NotelDo not turn screw 2 otherwise

reset

io

Install valve cover

Use new

lworypesorpinstudsareavailable,seefig

have

start device on a tesl

cold

gaskets

a spacer, and ho e ln

necessary.

if

Oasket

it wi benecessary

bench.

s l6r9er to

Latelyl

prevenl

)a

L31

]

t:: I

Installtiming
Use new

lnstall:

cooling
9 Nm

-

Jan be ts and
tension. lt sfrou d be

10 mm

5

gear

gaskets if necessary.

fan with spacer and

(7

il lbs)

power

(0.2-0

4 ln) by hand.

covers

sleering

possib

{front

and rearl

pu

ey. Torque bo

pump

be

e to depress

L32

L33

ts lo

ts. Adjust be t

the be ts

r)r

l

),,

I

68

Timing

gear

Group 21 Engine

replacement

belts,

Bleeding
Disconnect

drip
edge

Coolant

Since aluminium is used in the engines, active corro'
sion
vent

Use
with clean water in

This mixture helps to

Never
The

rosion

ot cooling system

upper hose from

pan

beneath hose

of expansion tank.

protection

corrosion d6mage,

genuine

fill the

coolant

protective

is necessary in

Volvo blue-green coolant type C, diluted

proportions

cooling system with

should be changed

additives

cold

6nd hold

the coolant to

of 50/50.

prevent

coiiosion and

regularly since the

in the cootant

stan d€vice. Place

hose level with top

pre-

help

frost

water alone.

cor

tose their ef-

srY0Dlr rLL
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PRoTOT[o T0

RrirPrr

-3trC

30pc rfirrfY[ lfifi lurr

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-22.r

nr UP Y&i R0Ur0 R|lH

0I u0urDr ar{r6rL

r$PlrB €fl T0UT[ Slrsori ^ytc

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rYrt

c VALABL! JusooA

Morlt uu {otTtt INI|GIL IYr!

gt

-2?.t

0[r

Notel Do not run

low

since high local temperatures can result

which mav cause the

Replacing

c

Always use
replace

coolant

typc C blue-green coolanr. Remember

decal

Type C blue-green coolant
All diesel

and

since 1982 are filled with tvDe C coolant.

engine when ievelofcoolant is

head

on expansion tank if ne,

engines

1331473-7)

1PlN

(gasoline)

petrol

cvlinder

to crack.

to

manufactured

Group 2l Engine

gear

Timing

belts,

reqlacement

Fill

coolant

Capacity:

Flush

Group 26 Cooling
Sel dashboard

and warm-up for
time. Connecl hose

mouth

D 20 = 8.'l

=

D 24

cooling system before adding new

of expansion tank

9.3 liters

System.

l_eater contro, io max. Turn

5 minutes. Add coolant during this

(8.6

lilers

{9.8

to cold start device. Fill coolant to

(above

quarts)

US

quarrs).

US

max)

L35

coolant, see

on engile

and screw on

70

Group 21 Engine

Camshaft, removal

D
D

M. Gamshaft,

Special tools: 5199, 5201

removal

Remove:

-timing

gear

covers

(front

and

M1

rearl.

D

t

Turn engine until cyl. 1 is at TDC

Aiways
engine. 27 mm socket or

Both cy inder 1 cams should

Remove

Unscrew expansion

from cooling

Slacken

sioner. Tighten two lower

necessary loss
Remove belt

the vibration damper center bolt to turn the

use

wrench 5188.

point

obliquely

belt Irom camshaft

tank cap 10 release

system.

coolant

pump

mounting

of coolant.

from camshafi sprocket.

sprocket

bolts and belr ten

mounling bolts

-

iniection

upwards.

overpressure

to avoid un,

M2

M3

11

Group 21 Engine
Camshaft,

rcmoval

Remove camshaft front sprocket

position

Use 5199 to hold sprocket
bok. [4.ke sure that camshaft does not rotdte.

Tap

sprocket

to free it from camshaft.

in

when loosening

M4

Detach belt

Benove two Lpper
Bend

out shield

slacken coolant
Keep

shield

Lift off

Slacken mounting bolts for

release

Tighlen

Lift off belt.

shield

in

pump

belt tension.

o're bok so Ihat

from cvlinder head

reldinirg bolrs.

to free it from camshaft. lf necessary

pump

upper bolt.

position

outer

belt

pJnp

with a

injection

piece

of wood.

pump

bracket to

rema'ns l uppe'posi

M5

M6

0t

I ) r

\'

(

(

0ta

72

,O

,

tuttililiiii,i,

r

Remove

Hold

sprocket

sProcket
Take care

camshaft

wilh wrench

nol to rolare

position

in

rear

sprocket

with 5199

5201.
camshaft.

0ta

M7

and

Remove vacuum
Remove

pump

fetaining nuts and

pump

and

Group 21 Engine

Camshaft,

pump

place pump

removal

plunger

M8

on

Withdraw

Remove camshafi

plunger

from cy inder head.

beadng caps

1 and 4

M9

Remove camshaft bearing caps 2 and 3
Slacken nuts

Lift awav

camshaft and

crosswise to avoid

placing

remove

uneven

oil seals

M10

load

M11

on

13

Group

Camshaft, installing

21 Engine

S

pecial

N. Camshaft, installing

tools : 5 1 90, 51 93, 51 94, 51 95, 51 96, 51 97, 51 99, 5200, 5201

Place camshaft in
Lubricate
Place

cams for

see iig.

Install camshaft caps

Install

Tighten nuts crosswise

position

contact surfaces of

gauge

5190

number 1 cylinder rnusl

correctly, cenrer is off set.

caps

gauge

with

cylinder head

rear

at

to avoid warp. Keep camshaft

5190 at

camshaft and bearings.

of camshaft. lmportant! Both

point

diagonally

2 and 3

rear when tightening caps.

up,

N2

in

0)i

a

0rl

0)a

Remove

Press

Oil

Do

seals are "square'-

gauge

in new camshaft oil seals

seals.

notpush in sealstobottom

5190

position.

0)a

N3

Makesurethat

D

Install camshaft
fMak€ sure

thatthe thrustwasherfor

caps 1 and

Torque all four caps

=

Torque

Tap in oil seals to bottom
R€ar oil se6l: Use

20 Nm

(15

ft lbs).

.dapter 5200 and bolt

Group 21 Engine

Camshaft, installing

4

camshaft

cap 4 sits

for camshaft

N5

,D

20 Nm

Front oil sealr tise adapter 5200

Install

Install

Pull belt to

Place

Install center bolt hand
sprocketto

bolts tor belt cover

gear

belt and camshaft front

ensure that it is seated correctly

beli over camshaft sprocket

tight. lt shoulcl be

turn on camshaft withoutcamshaft

and tap seal into

sprocket

on crank

and install sprocket

possible

rotating.

posi

N8

N9

for

D

Set belt tension
Adjust

tension by

Use gauge
and set to 12.5

Slfetch belt

Depress

5197to

untii mark

belt strongly with

moving cooling

checklension. Artach gaugero

units.

gauge

on

hand and rechecuadjustten,

pump.

ptunger

is ftush

betr

wilh

75

Group 21 Engine

Cafishaft,

installing

Make sure
Check'0'mark

Set camshaft

Place
feeler
for timing

cyl. 1 is at

on

position

gauge

5190 at rear of camshaft. Insert a 0.2 mm

gauge

beneath

gear

clearance.

TDC

flywheel and adiust

left

side of

if necessary'

gauge

to compensate

N12

Qi

0

(

(

Tighten

use 5199 to

Torque center bolt to 45 Nm

Remove

Disconnect

Slacken screw L Push lever

90'.

Noiel Do notturn

to remove

Press

camshaft

prevent

gauge

cold start device

cold start device and reset it

back lever againsr

lront sprocket

sprocket

5190 and

screw2 otherwise it will be necessary

stop.

N13

from lurning.

(33

lbs).

ft

feeler

forward and rotate s eeve

gauge

N15

on a test bench.

0)l

I

0)

a

16

-@;

).,)- '2-,

I-@)

Basic-set iniection
Slacken

Atign marks on

pump.

Set dial indicator zero. Lock
injection using stop 5193

Unscrew and

pump

Retighten

pump

mount:ng bolts

pump

mounting bolts.

remove

mounting bracket

and

plug

from

Group

camshaft,

(Allen

key = 6

pump gear

injection

21 Engine

installing

N16

mm).

by tuming

N17

cyl. 1

at

pump

distri

hotder 5194 and disl indicator

Install

gauge

Set
Turn

moundng brack€t coincjde.

Then turn
registers on

S€t indicator to zero.
Turn

mounting bracket coincide.

with stop 5193.

mounting bracket.)

to approx.

pump gear

pump gear

dial indicator.

pump gearclockwise

2 mm.

clockwise

back slightly

untilmark on

(lnse(

stop

until

gear

Lock

through

(range

0-3

until

gearand pump
in this

pump gear into

readrng

position

Install camshaft rear sprocket and belt
Tighten center bolts by hand, it

turn

sprocket on camshaft.

should

be

N18

possible

to

Group 21

Cafishaft, installing

Engine

S€t belt
Adjust tension

Use

and set to

plunger
Depress

Set

Use 5199to hold
right

tension

by moving

gauge

5197

to check tension.

12.5 units.

is flush
belt

pump

angles to wrench 5201 otherwise lorque

with sleeve.

strongly with hand

and tighten

sprocket. Torque wrench should be

pump.

Attach

Stretch bett untit

and rechecUaotusr

camshaft rear sprocket

gauge

mark on

N19

to bett
gauge

ren-

N20

at

will be

0

I

Using 5199, turn

D20...................-...-..-.

D 24..............................-........-.........

D 24 USA,/Canada 1979-1981

Hold sprocket in

ft lbs). Take care that

{73

Remove

stop

sprocket slowly clockwise until dial

................0.80mm=0.0315in

0.70 mm : 0.0276 in

......... 0.70 mm = 0.0276 in

1982-................. 0.85 mm = 0.0335 in

posilion

this

5193

trom

and torque bolt to 100 Nm

camshaft and sprocket do not

pump

gear

N21

N22

Check

Turn engine
center - ini€ction, again. lf engine is turned too far it
must be iurned back approx. 1/4 turn and then to zero
mark otherwise

Dial indicator

D 20 ...........................

D 24 ........................... 0.65-0-73 mm = 0.0256-0.0287 in

D 24 UStuCanada

197F1981 .............-... 0.6F0.73 mm

1 982-......................... 0.42-0.90 mm

Corect
bolts. Proceed to N23.

Incorrect reading: Readjust according to instructions

pump

setting

full

two

should showl

reading: Tighten injection

lurns until cyl. 1 is at top dead

setting

will be incorect.

0.75-0.83 mm

:0.0295

=

0.0256-0.0287

=

0.0323-0.0354

pump

0.0327 in

mounting

in
in

0

0),(

0)'

I

(

7A

Group 21 Engine

Camshaft, installing

Readiusling
D 20

..................-...-...-......,............

D 24..........................,......................

D 24L,SA,/Canada

Reading less
Slacken

to obtain
repear

check

Reading less lhan specified:

Slacken
until

dial indicator
D 20

........................-...-..................

D 24 .................................................

D 24

USA,/Canada

Then turn
tained.
rng,

Not€!

Injection

this will

pump

197F1981 ......... O.70mm

1982-....,....,..,....

than specified:

pump

mounting botts

corrsct value.

pump

of

pump

mounting

shows

1979-1981

1982-.................

pump

inwards

Tighten

alter its setting.

mounting

pump

setting:

0.80 mm = 0.0315 in

0.70mm = 0.0276in

0.85mm : 0.0335in

and turn

Tighten mounting

settings.

bolts

andrurn

approx:

.........0.60mm

untit

specified vatue

botrs and recheck pump

must

not be tapped

pump

pumpoutwards

0.70 mm = 0.0276

0.60 mm

0.75 mm = 0.0295

or knockeo

=

0.0276in

inwards

botts

=

0.0236 in

=0.0236in

and

in

in

rs ob-

set-

as

t@)

)]

Remove
plug

dial indicator

with

Tishtenins

Reconnect
Press

lever forwards

Notel Do

to

notturn screw2

reset cold start

new seal

torque

I Nm

cold start

device on a test

and holder

(6.5

ft tbs).

device

and turn

otherwise itwitt

sleeve 90". Retighten

N23

5194, Instrll

N24

be necessary

bench.

79

Group

Camshaft, installing

21 Engine

N25

Install

Check O-ring, rep ace if necessary.

Adiust valve clearance:

See operatlon
lmportant!Va ve clearance must be checked after600-

1,200 n1iles

plunger

and vacuum

B1 11,

(1,00G-2,000

page

pump

N26

19.

km).

()l

,l

)l

Installtiming

gear

covers

(front

and rear)

N27

{l|

a

0rr

1

80

r

Group 21 Engine

Camshaft fronL seal,

replacement

iD

D

o.Camshaft

Special tools : 51 94, 51 97,

front seal,

replacement

5199,5204

fronl tinr ing

gear

cover.

o1

t,

D

o2

Disconnect cold start device
Slacken screw 1. Push lever forward and rotate sleeve

90'.
Norel Do notturn

io remove cold start device and resei it on a test bench.
Press back lever against stop.

screw 2 otheMise

it wi I be necessary

o3

lnstall dial indicator
U.screw and remove

Install holder

gauge

Sel

5l94 and dial indicalor

lo approx. 2 mm.

plug

from injection

pump

{range

0-3

distri-

mm).

Group 21 Engine

Camshaft front seal, replacement

o4

-

Turn

engine

Always use the
engine. 27 mm socket or

Both cylinder 1 cams should

Turn

engine app.ox.

back to

side. lf this is not done injeclion

until cyl. 1 is at TDC

vibration d;mper center bolt io turn the

wrench 5188.

'0'

again, to obtain slack

1/4 turn clockwise

poin!

pEd

iniection

past'0'

settins

'rpwards.

and

obliquely

of beli on driving

pump

then

wil be

o5

Set dial

Gauge
new oil sea otherwise it wil be necessary to
engine since camshaft will have moved in relation

indicator zero

pointer

must not move during instalation of

basic-set

{)a

0)l

to

pointe.

Lf

Remove
Unscfew expansion

from
S acken coolant

sioner. Tighlen two
necessary loss

Remove belt

Remove
Use 5199 to ho d

bo t. Make

Tap sprocket to

does not move itsufficesto check/adjust injec-

belt from camshaft

ing

coo

system.

pump

of coolant.

from camshaft sprocket.

camshaft lront sprocket

sprocket in

s!re that camshaft does not rorare

free it from carnshaft.

o6

sprocket

lank cap to release overpressure

mounting

ower mounting bolts 1o avoid

bolts and belt ten-

un

o7

position

when loosening

r)il

4

{)il

a

a2

i

Detach
Bemove
Bend

slacken
Keep

Remove

belt shield
two

out shield

coolant

shield

Camshaft front

from

upper reraining

to free it from

pump

upper bott.

in outer

camshaft

posjtion

cap 1 and

Group 21

seal, replacement

cylinder

botts.

with a piece

head

camshaft.

oil seal

Engine

tf necessary

of wood.

L

Press in new

Oil

seal.

Do not

Install

Torque

Press

Release

push

in seal lo botiom

camshaft

to 20

in seal

cover.

bolts Ior

camshaft

cap 1

Nm

ft lbs).

{15

to bottom

Use adapter

belt cover

seal

position.

position

5200 ro

Make sure that

rap in

oil

ot0

o12

o13

Install
Pull

shaft

Place

Instal

sprocketlo

gear

belt to

ensure that ir is

gear.

belt over camshafr

center

turn on camshaftwithout

belt

and camshaft

seatecl corecrly

sprocker

bolt and tighren.

tront

sprocket

on crank-

and instail sprocket

lt shoutd be

possibte

camshaft rotaring.

014

for

Group 21 Engine

Camshaft front seal, replacement

015

belt

Set

Adjusl tension by moving cooling

Use
and set to 12.5 units.

Stretch belt until mark on

Depress beit stongly with hand and rechecuadju st ten-

tension

gauge

5197 to check tension. Attach

gauge plunger

pump.

gauge

10 belt

is flush with

{r

o16

is ai TDC

Make sure

Check'o'mark on

il

cyl. 1

flywheel and

adjust if necessarv

|0i

(

(

o17

Tighten

LJse 5199 to

TorqLre center bolr to 45 Nm

camshaft

prevent

front sprocket

sprocket fiom

(33

ft lbs).

turning.

{,r

I

Check dial indicator

poinler

lf
gine

Pointer at zeror Proceed to

has moved

accofding to operalions C1-21.

from zero

position:

O19.

o18

basic'set en'

tl

t,

I

ff.n\ |

Camshaft trcnt seal,

Zoro injection

Slowly tum engine
reached on di6l indicator.

Set zero.

Check

pump

pump

and dial

anticlockwise until min

sefting

Slowly turn engine clockwise

Group 2l Engine

reDlacement

o19

indicator

reading is

o20

untilflywheel reaches

'0'

d.i

inzr

ltR\)

r rr

lfengine isturned
1/46nd then to

Dial indicator

D 20...........................

D 24 ........................... 0.6F0.73

D 24 IJS!,/Canada
197F1981

1982-.........................

Correct reading: Iighten
bolts. Proceed

lncorrect

Check/adjust

D 20 .................................................

D 24.................................................

D 24USA"/Canada

rcading: Readjust acco.ding to below.

toofar it must beturned backapprox.

'o'

mark

otherwise setting willbe incoF

should showl

0.7F0.83mm = 0.0295-0.0327in
mm = 0.0256-0.0287 in

................. 0.65-0.73mm

0.82-0.90 mm = 0.0323-0.0354in

injection

to O23.

pump

setting

197F1981 .........

1982-.................

=

0.0256-0.0287an

pump

0.80 mm

0.70 mm = 0.0276in

0.70 mm

0.85 mm = 0.0335in

mounting

=

0.0315in

=

0.0275in

021

Reading less than specified:
Slacken

to oblain correct value. Tighten mounting

repeat

pump

check of

mounting bolts and

pump

setting,

turn

pump

inwards

bolts and

85

Group 21 Engine

Camshaft front

seal, replacement

Reading more than specitied:

pump

Slacken
until dial indicator shows approx.

D20.................................................0.70mm=0.0276in

D 24 ................................................. 0.60 rnm = 0.0236

D 24

USA,/Canada 1 979-1981

Then turn
tained. Tighten mounting bolts and recheck
ting.

lf it is not
becaLse of ncuffic ert ad_Jstmelt
must be basic-set again, since camshaft and crankshaft

probably

are
Note! Injection

this will

nrounting bolts and turn

1982-................. 0.75

pump

inwards until specified value is ob-

possible

our oi ine.

pump

its

alter

setting.

pump

to sei

must not be tapped or knocked as

......... 0.60 mm = 0.0236 in

to above specifications

pump

outwards

mm = 0.0295 in

pump

laltude.

elgiie

in

set'

o22

Check
Turn

tion O20. Readjust if necessary and repeat check.

pump

engine round twice and check setting,see opera

setting

L:ri

ii ,.

_r

Lr=

- i ],r'/nl l

o23

Remove dial indicator

and holder

o24

Install

Tishtening

plug

with new

torque 9 Nm

seal
(6.5

ft bs).

o25

Reconnect cold start device
Press lever forwards and turn sleeve 90'.

Notel Do not turn screw 2 othelwise it will be necessary

10

reset

cold stan

device on a lest bench.

Retighten

{,i

0

(

I

86

I

Inslall valve
Use n€w

gasksts

Group 21 Engine

Camshalt front seal, replacement

o2

covei

if necessary.

/

ry

08F

E

E

Two types ot

'

have a spacer,
damage to
Lat6 and

pin

gasket

early type

are available,

$uds

and hole in

by overlightoning-

must not b€

Frts

gasket

see fig. Late types

is larg€r

preveni

to

interchanged

o27

gear

Install front timing

cover

a7

Group 21 Engine

Camshaft rear seal,

rcplacement

P. Camshaft

Special tools: 51 90, 5193, 5194, 5199, 52A0, 5201

rear seal, replacement

Remove:

-

rear t|mrng

gear

r)a

r)a

cover.

Turn

engine until cyl. 1 is at TDC - iniection

Always use the vibration damper

ljse a 27 mm
Both

cylinder 1 cams should

Lift ofi

Slacken

release

Tighlen

Litt off be t.

sockel-

pump

belt tension.

one bolt so that

belt

mounting bolls for injection

pump

center

point

obliquely upwards.

remains in

bolt to turn the

purnp

bracket to

upper

P2

P3

pos

(la

i

tl

-

88

,."!

",iii;iiii;i;

Group 21 Engine

Camshaft rear

seal,

Remove camshaft rear sprocket

Hold sprocket in

sprocker

Note! Take care not to rotete camshaft.

Remove

with wrench

camshaft caD 4 and

position

with 5r99 and unscrew

5201.

old oil seal

replacement

P5

Press in new oil seal
Oil seal.

(15

ft bs).

position.

make

camshaft cap 4 sils

camshaii sprocket.

sure

that

P8

Do not

Install
Make

Tightenins torq!e

Tap in oil seal to
Use

push

in sealto bottom

camshaft

sure lhat thrLrst washer for

adapter 5200 and bolt for rear

caps 1 and 4

20 Nm

bottom

P9

Check

Check with
relation

Gauge should fit in
nol, engine m'rst be basic-sei according to operations

c1-21.

camshaft setting

gauge

5190 thal camshaft is correctly set in

to crankshaft.

groove

in back end ofcrankshart. lf

89

Group 21 Engine

Camshaft

rcar seal, replacement

P10

Disconnect cold start device

Slacken screw 1. Push lever foMard and
90".

Note! Do notturn screw2 otheMise

to remove cold start device and reset it on a test bench.

Press back lever against stop.

rotate sleeve

it willbe necessary

I

r))l

I

-.-i-rl

1ffi

,}jz{

I //\l

Iro

-=

-

Basic-set
Slacken
Align marks on

pump.

Set dial indicator zero. Lock

inlection using stop 5193

Unscrew and

Install holder 5r94 and dial indicator
Set

Turn
mounling bracket coincide.

iniection

pump

Retighten

gauge

to approx. 2 mm.

pump

sear

remove

pump

(Allen

mountins

pump

mounting bolts.

clockwise until mark on

bolts

mounting bracket

and

pump gear

plug

from injection

{ranse

key

=

pump

6 mm)
by t'rrning

P12

at cyl.

0-3 mml.

gear

1

distri

and

(

))l

I

{rr)

|

lrt

1

90

Then turn

regislers
Set indicator to zero.
Turn

moLrnting brackei coincide. Lock

wlth

mounting bracket.)

pump

on dial

pump gear
stop 5193.

back s ightly until min reading

sear

indicalor.

clockwise untilmark on

(lnsert

stop through

sear

gear

in this

pump gear

pump

and

position

into

Group

Camshaft rear

seal, replacement

Install camshaft rear sprocket and belt

Tighten center bolt by
turn sprocket on camshaft.

Set belt tension
Adiust

and set

tenslon

gauge 5197 to check

Use

to 12.5

plunger
Depress

by rnoving

units. Stretch

is flush
belt strongly

hand, it

tension

with sleeve

with hand and

should

PumP

belt until

be

gauge to belt

Atlach

mark on

recheck/adjust

21 Engine

possible

to

gauge

ten-

pump

Set

Use5199to
right angles to

Using 5199,

D 20 .................................................

24 .................................................

D
D 24USp,/Canada

Hold sprocket

(73ft

and tighten

hold sprocket.Torquewrench

wrench 5201 otherwise

turn spfocket slowly

1979 1981 .........

1982-.................

in this

Take carethat camshaftand

lbs).

Remove stop 5193

camshaft

position

pump

from

rear sprocket

should be at

torque

until

:

0.80mm

0.70

0.70 mm : 0

0.85 mm : 0.0335

and torque

0.0315

mm = 0.0276 in

to 100 Nm

sprocketdo

gear

P15

will be

in

0276 in

in

not

Group 21 Engine

Camshaft

rear seal, replacement

J;'.

P17

Check

Turn engine two fuLl turns lntil cyl.
center - injeclion, again. lf
must be turned back
mark

Dial indicator should show:

D 20 .............-............. 0.7F0.83 mm = 0.0295-0.0327

l

D 24 ........................... 0.65-0.73

D 24 USACanada

1979-1981 ................. 0.65 0.73mm = 0.0256-0.0287in

1982-......................... 0.82-0.90 mm = 0.0323-0.0354in

Correct reading:
bolts. Proceed to P18.

lncorect reading: Readjust according to

pump

otheMise setting wilL be incorrecl.

setting

engine

approx.

Tighten injection

1 is ai top dead

is

turned too

1/4

turn and then to

mm = 0.0256-0.0287 in

pump

tar il

'0'

in

mounting

instructions

Readjusting

Setting va ues:

D 20 ................................................. 0.80

D 24 ...-.............-....-.......................... 0.70 mm : 0.0276

D 24

U Sp,/Ca

Reading
Slacken

to obtain correct value. Tighten mounting bots and

repeat check of

pump

nad

less than specified:

pump

setting:

'l

979-198'l ......... 0.70 mm = 0.0276 in

a

1982-.................

mounting bolts

pump

setring.

and

mm : 0.0315 in

0.85 mm

turn

:0.035in

pump

in

inwards

()){

{!)

a

r)a

Beading

Slacken
until dial indicator

020.........................-.......................0.70mm=0.0276in

D 24
D 24 USr',/Canada

Then
tained.
ting.

Notel Injection

this will

mofe than specified:

pump

mounting

.............................

pump

tlrn

Tighten mo!nting

pump

alter its

setting.

bolts andturn

shows

1S7F1981 .........0.60

1982-.................

inwards

approx.

-..................

unril specified

bolts

musr

not be tapped

pump

outwards

0.60 mm = 0.0236

0.75 mm = 0.0295 in

and recheck

=

mm

0.0236 in

vatue rs

pump

or knocked

in

oo

set,

as

92

21 Engine

Camschaft rear

Group

seal, reDlacement

Remove dial indicator and holder 5194.
plug

with new seal

Tightening torque I Nm

Reconnect
Press lever forwards and turn sleeve

cold start device

{6.5

ft lbs).

90'.

Retighten

P18

Install

P19

ry

r

3

Note!

Do notturn screw 2 otherwise itwillbe necessary

to r€set cold start device

lnstall valve cover

Use new

Two

gaskets

pin

of

Vpes

have a spacer,
damaqe to
Late and

gasket

early type

if necessary.

studsareavailsble,

and hole in

by overtightening

paris

test bench.

on a

gasket

must not

seeliq Laietvpes

is 1a.ger

be interchanged

lo

P20

prevent

Install

rcar

liming

gear

P21

covel

93

Gtoup 21 Engine

Pilot bearing, replacement

Pilot

O.

bearing in

crankshaft,

replacement

Special tools: 1801, 4090.

Remove

See Service manualsection 4
Secure staher molor with a bolt.

Remove

lJnscrewpressure plate

turns at

5203, 5207

gearbox/transmission

pressure plate

mounting

a time to

prevent

(43).

and driven

bolts crosswrse a rew

warp,

a1

a2

plate

Remove bearing
lJse extractor 4090.

Install

Install bearing
out.

Use
aring until it abuts

Press in . small amount
space beyond the bearing.

bearing

and sealwith text

away from flywheei.
standard handle 1801

crankshafl.

of

O3

a4

on outer ring facing

and drift 5207 to tap in be-

grease

(1.3

1.5grani)inthe

0D{a

(i,t,

I

94

0

(,

Install

Use centering

Turn

Install
Tighten

driven

plate

driven

pressure

bolts crosswise

plate

shafi 5203.

with hub

plate

Group 21 Engine

Pilot bearing. replacement

a5

facing out,

away from fly-

a6

a few turns

ar a time ro

avoid

o

0

Install
Do

gearbox

not forget to remove

bolts securing

starter moror.

a7

95

Gtoup 21 Engine
Crankshaft tront seal,

replacement

R.Crankshaft front

Specialtools:

5187,

seal,

5188,5197,5200,5205

replacement

Disconnect

Jack-up

prevent

To

hicle at front right

along splashguard

Place drip

batterv

vehicle

spillages

pan

jacking

beneath left steering

when coolant is drained,

into drip

point.

pan.

Coolant

rod.

R1

R2

wi

Drain coolant

Unscrew expansion

Disconnect lower

cool.nt.

-

(Engine

cooling fan with spacer and
fan belts and
froni tinring

tank cap-

radiator hosefrom

without drain taps).

is

power

steer;ng

gear

cover.

racliatorand

pulley

pump

beh

R3

drain

R4

(r)r

{r)

I

I

96

I

I
I

I

t

I

(0

(D

Group 21 Engine

C ra nkshaft f ra nt

Remove vibration damper center bolt
ljse 5'187 to

5188 to unscrew
It may be necessary lo turn engine slightly so that 5187

resls

on

Turn engine approx. 1/4 turn anticlockwise

Use wrench 5187.

prevent pulley

boh.

fan be.ring.

from rolating, and socket

seal,

repl

acem ent

R5

0

Bylurning
to drivlng side,

Remove vibration
Remove four
Pull

sometimes

Remove lower

engine antic

making il easier

inhex bolts

off vibration damper.

stick to vibration damper.

timing

ockwise, slack

to remove

damper

(6

mm).

Notel Crankshafi

gear

cover

if beltwill

and inslall

gear

move

may

R8

Detach
alternator and

Remove moLrntins bohs

cooling

lan

mounting bracket and

place

on one

side

larrowed)

and

press

R9

bracket

9l

Group 2l Engine

Crankshaft front

seal, replacement

position

Mark

ftlark belt, camshaft sprocket and

oI timing

gear

belt

crankshaft

gear.

R10

Mark

Aiso iderr'tv

Belt must be fitted in exactly
beiore
cause seaous damage.

Remove

Slackencoolantpumpmounling
may

leak when

oulside and ropside of

othe.wise

gear

valves

may conlacr

belt

bolts are slackened.

same

bolrs

gear

balr.

position

pistons

and belt.

as

and

811

Coo anr

|)

rr)r

r)r)

a

I

|

9A

Remove gear
use exlractor

5205.

on crankshatt

and withdraw

(rl

R12

oilseal