Volvo D 20 Service Manual

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Service manual (200 pages)

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Contents
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Table of Contents

Contents
Lmportant Information
Cleanliness
Plugs
Tightening Torques
Specifications
Group 20 General
Engine Type Designation and Serial Number
D 24 Engine
Engine Assembly
Cylinder Head
Cylinder Head Gasket
Gear Belts
Valve System
Tightening Sequence for Cylinder Head Bolts
Tightening of Cylinder Head Bolts
Group 22 Lubricating System
Oil Capacities
Engine Oil
Oil Pressure
Group 23 Fuel System
Group 26 Cooling System
Coolant
Expansion Tank
Thermostat
Special Tools
Compression Test
Remove Injectors
Connect Compression Tester
Run Engine and Record Compression
Install Injectors
Valve Adjustment
Remove Valve Cover
Basic Setting of Engine
Lift off Pump Belt
Remove Camshaft Rear Sprocket
Slacken Camshaft Front Sprocket
Set Belt Tension
Set Camshaft Position
Tighten Camshaft Front Sprocket
Disconnect Cold Start Device
Basic-Set Injection Pump
Install Camshaft Rear Sprocket and Belt
Set Pump and Tighten Camshaft Rear Sprocket
Check Pump Setting
Readjusting Pump Setting
Reading Less than Specified
Reconnect Cold Start Device
Cylinder Head, Removal
Drain Coolant
Drain Coolant from Engine
Disconnect from Cylinder Head
Remove Fuel Delivery Pipe
Remove Belt from Camshaft Sprocket
Remove Camsahft Front Sprocket
Remove Cylinder Head
Check for Damage and Warp
Cylinder Head ,Disassembly
Cylinder Head, Cleaning Inspection
Check Tappets
Check Valve Springs
Clean Inside of Valve Guide
Machine Grind Intake Valves
Mill or Grind Valve Seats
Grind-In Valves with Paste
Clean Combustion Chamber
Head Cylinder Head
Cool Valve Seat
Tap-In Valve Seat
Check Fit of Valve Seat
Cylinder Head, Assembly
New Cylinder Head
Check Valve Stem Position in Relation to Camshaft
Install Swirl Chambers
Install Tappets with Shims
Place Camshaft in Cylinder Head
Install Exhaust Branch Pipe and Intake Manifold
Cylinder Head, Installing
Clean Holes for Cylinder Head Bolts
Install Guide Pins in Cylinder Block
Install New Cylinder Head Gasket
Date Code
Piston Height
Set Cylinder 1 to TDC
Position Camshaft
Cylinder Head Bolts
Install Cylinder Head Bolts
Torque Cylinder Head Bolts
Tighten in Three Stages
Tighten in Four Stages
Install Bolts for Cover
Install Camshaft Sprocket and Belt
Basic Set Injection Pump
Reading more than Specified
Install Valve Cover
Reconnect Fuel Delivery Pipes
Install Plunger and Vacuum Pump
Install Air Filter and Connect Hoses
Bleeding of Cooling System
Replacing Coolant
Fill Coolant
Tighten Cylinder Head Bolts
Check Tightening of Cylinder Head Bolts
Cylinder Head, Retorquing
M 12 Bolts
Install Valve Cover, Plunger and Vacuum Pump
Timing Gear Belt Tension, Checking/Adjusting
Check Belt Tension
Check Timing Belt Tension
Incorrect Belt Tension
If Gear Tension Has Been Adjusted
Timing Gear Belts, Replacement
Disconnect Battery
Jack up Vehicle
Remove Vibration Damper Center Bolt
Remove Vibration Damper
Remove Lower Timing Gear Cover and Belt
Replace Idler Pulley
Remove Camshaft Rear Sprocket and Belt
Lock Camshaft in Position
Remove Camshaft Front Sprocket
Install Gear Belt and Camshaft Front Sprocket
Install Lower Timing Gear Cover and Vibration Damper
Install Center Bolt
Camshaft, Removal
Camshaft Installing
Camshaft Front Seal Replacement
Set Dial Indicator Zero
Camshaft Rear Seal, Replacement
Pilot Bearing in Crankshaft, Replacement
Crankshaft Front Seal Replacement
Install New Oil Seal and Gear on Crankshaft
Install Camshaft Gear Belt

Quick Links

1 Tightening Torques
2 D 24 Engine
3 Engine Assembly
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