Table Of Contents - Volvo D 20 Service Manual

Table of Contents

Contents3
Lmportant Information4
Cleanliness4
Plugs4
Tightening Torques4
Specifications5
Group 20 General5
Engine Type Designation And Serial Number5
D 24 Engine6
Engine Assembly6
Cylinder Head6
Cylinder Head Gasket7
Gear Belts7
Valve System7
Tightening Sequence For Cylinder Head Bolts8
Tightening Of Cylinder Head Bolts8
Group 22 Lubricating System10
Oil Capacities10
Engine Oil10
Oil Pressure10
Group 23 Fuel System11
Group 26 Cooling System13
Coolant13
Expansion Tank13
Thermostat13
Special Tools14
Compression Test19
Remove Injectors20
Connect Compression Tester20
Run Engine And Record Compression20
Install Injectors20
Valve Adjustment21
Remove Valve Cover21
Basic Setting Of Engine24
Lift Off Pump Belt25
Remove Camshaft Rear Sprocket25
Slacken Camshaft Front Sprocket25
Set Belt Tension25
Set Camshaft Position26
Tighten Camshaft Front Sprocket26
Disconnect Cold Start Device26
Basic-Set Injection Pump27
Install Camshaft Rear Sprocket And Belt27
Set Pump And Tighten Camshaft Rear Sprocket28
Check Pump Setting28
Readjusting Pump Setting29
Reading Less Than Specified29
Reconnect Cold Start Device29
Cylinder Head, Removal30
Drain Coolant30
Drain Coolant From Engine31
Disconnect From Cylinder Head31
Remove Fuel Delivery Pipe31
Remove Belt From Camshaft Sprocket33
Remove Camsahft Front Sprocket33
Remove Cylinder Head34
Check For Damage And Warp34
Cylinder Head ,Disassembly35
Cylinder Head, Cleaning Inspection38
Check Tappets39
Check Valve Springs39
Clean Inside Of Valve Guide40
Machine Grind Intake Valves40
Mill Or Grind Valve Seats40
Grind-In Valves With Paste41
Clean Combustion Chamber41
Head Cylinder Head42
Cool Valve Seat42
Tap-In Valve Seat42
Check Fit Of Valve Seat42
Cylinder Head, Assembly43
New Cylinder Head43
Check Valve Stem Position In Relation To Camshaft43
Install Swirl Chambers45
Install Tappets With Shims45
Place Camshaft In Cylinder Head45
Install Exhaust Branch Pipe And Intake Manifold46
Cylinder Head, Installing47
Clean Holes For Cylinder Head Bolts47
Install Guide Pins In Cylinder Block47
Install New Cylinder Head Gasket47
Date Code48
Piston Height48
Set Cylinder 1 To Tdc48
Position Camshaft49
Cylinder Head Bolts49
Install Cylinder Head Bolts49
Torque Cylinder Head Bolts50
Tighten In Three Stages50
Tighten In Four Stages50
Install Bolts For Cover51
Install Camshaft Sprocket And Belt51
Basic Set Injection Pump52
Reading More Than Specified55
Install Valve Cover55
Reconnect Fuel Delivery Pipes56
Install Plunger And Vacuum Pump56
Install Air Filter And Connect Hoses57
Bleeding Of Cooling System57
Replacing Coolant58
Fill Coolant58
Tighten Cylinder Head Bolts58
Check Tightening Of Cylinder Head Bolts58
Cylinder Head, Retorquing59
M 12 Bolts59
Install Valve Cover, Plunger And Vacuum Pump59
Timing Gear Belt Tension, Checking/Adjusting60
Check Belt Tension60
Check Timing Belt Tension60
Incorrect Belt Tension61
If Gear Tension Has Been Adjusted61
Timing Gear Belts, Replacement62
Disconnect Battery62
Jack Up Vehicle62
Remove Vibration Damper Center Bolt63
Remove Vibration Damper64
Remove Lower Timing Gear Cover And Belt64
Replace Idler Pulley64
Remove Camshaft Rear Sprocket And Belt64
Lock Camshaft In Position65
Remove Camshaft Front Sprocket65
Install Gear Belt And Camshaft Front Sprocket65
Install Lower Timing Gear Cover And Vibration Damper65
Install Center Bolt66
Camshaft, Removal73
Camshaft Installing76
Camshaft Front Seal Replacement83
Set Dial Indicator Zero84
Camshaft Rear Seal, Replacement90
Pilot Bearing In Crankshaft, Replacement96
Crankshaft Front Seal Replacement98
Install New Oil Seal And Gear On Crankshaft101
Install Camshaft Gear Belt101