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VOLVO D24 Engines Repair Manual

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(1)

Crankshaft rear seal, replacement

S. Grankshaft

rear seal, replacement

Special tools: 1801, 5112, 5203, 5208

s ?

Remove gearbox/transmission

See Service manual section 4 (431. Secure staner motor with a bolt.

Manualgearbox:

s2

Remove pressure plate and driven plate

Unscrewpressure plate mounting boltscrosswisea few turns at a time to prevent warp.

Manualgearbox:

Remove flywhe€l

Automaticgearbox: Remove carrier plate Use locking sector 5112 to

v i n g . prevent ilywheel from

mo-s3

s4

Remove crankshaft rear oil seal

Lift out oil seal with a screwdriver as indicated.

(2)

Crankshaft rear seal. reDlacement

s6

Install new oil seal

Assemble standard handle 1801 and drift 5208.

S m e a r o i l o n t o s e a l i n g s u r f a c e s a n d l i p s o n s e a l . P l a c e s e a l o n d r i f t a n d ta p i n u n t i l d r i f t a b u t s c r a n k s h a f t .

s7

Install f lywheel/carriei plate

F l n r h e e l ( m a n u a l ) a n d c a r r i e r p l a t e ( a u t o ) c a n o n l y b e U s e n e w b o l t s , s m e a r e d w i t h s e a l e r P / N 2 7 7 9 6 1 , 9 . T o r q u e b o l t s t o 7 5 N m ( 5 5 ft lbs). U s e lo c k i n g s e c t o r 5 1 1 2 t o h o l d fl y w h e e l i n p o s i t i o n .

s8

Automatic gearbox:

Check installation measurement ot carder plate

(To be caffied out after replacement of carrier ptate.) P l a c e a s t e e l ru l e r between c a r r i e r p l a t e and engine b l o c k . F u l e r should rest against e n g i n e t o g e a r b o x m o u n t i n g f l a n g e a n d should r e s t a g a i n s t b o t h sides o f f l a n g e . T u r n c r a n k s h a f t u n t i l o n e of holes i n carrier p l a t e c o a n c i d e s w i t h steel r u le r . M e a s u r e " B " w i t h a n o u t s i d e c a l i p e r e q u i p p e d f o r d e p t h m e a s u r e m e n t .

M e a s u r e d v a l u e " B ' + thickness o f steel r u l e r s h o u l d equal '17.2-18.8 mm = 0.667-0.740 in. lf distance is less t h a n 1 7 . 2 m m = 0 . 6 7 7 i n u s e a spacer w a s h e r ( P / N 1257377'0) between crankshaft and carrier plate. l f carrier p l a t e i s i n s r a l l e d i n c o r r e c t l y ( i . e . i n s t a t t a r i o n m e a s u r e m e n t j s wrong), d i s t a n c e t o t o r q u e c o n v e e r c a i i i e r w i l l b e to o lo n g . T h i s m a y c a u s e c a r f i e r p l a t e t o c r a c k a n d p o s s i b l y a n o i s e w h e n d r i v i n g .

(ir

A+B =la:O,8mn 104

(3)

l : i

Crankshaft rear seal, replacement

Manualgearbox:

s9

Install driven plate Use centering shaft 5203.

Turn disc with hub facing out, away from ftywneet.

Manualgearbox

s10

Install pressure plate

Tighten bolts crosswise a few turns at a time to avoid

s 1 1

Install gearbox/tmnsmission

Do not forget to remove bolt securing starter notor,

(4)

Vibrati on dam per, remov in g/i nstal I i ng

T. Vibration damper, removing/installing

SDecial tools: 51 87. 5188

Notel Different vibration D 2 4 e n g i n e s . d a m p e r s f o r D 2 0 and i .

D20

D24

T1 Disconnect battery T2 J a c k - u p v e h i c l e T o p r e v e n t s p i l l a g e s w h e n c o o l a n t i s d r a i n e d , r a i s e v e -h i c l e a t f r o n t ri g h t j a c k i n g p o i n t . C o o a n l w i l l t h e n ru n a l o n g s p l a s h g u a r d i n t o d r i p p a n . P l a c e d r i p p a n b e n e a t h l e f t s t e e r i n s r o d . f3 D r a i n c o o l a n t U n s c r e w e x p a n s i o n t a n k c a p . D i s c o n n e c t l o w e r r a d i a t o r h o s e f r o m ra d i a t o r a n d d r a i n ( E n s i n e i s w i t h o u l d r a i n t a p s ) . (

r(

1 0 6

(5)

Vibration da m per, removi ng/i nsta ll i ng

T4 Disconnect:

c o o l i n g fa n w i t h s p a c e r 6 n d p u l e y - fan belt and power steerirg pLrmp

beh-T5 Bemove vibration dampea

R e m o v e c e n t e r b o l t . U s e 5 1 8 7 to p r e v e n t p u l e y f f o r n r o t a t i n g , a n d s o c k e t 5 1 8 8 to u n s c r e w b o t s . I t m a y b e n e c e s s a r y t o t u r n e n g i n e s i g h t l y s o t h a t 5 ' 1 8 7 r e s t s o n f a n b e a r i n g . R e m o v e f o u r i n h e x b o l t s ( 6 m m ) . P u l l o f f v i b r a t i o n d a m p e r . N o t e l C r a n k s h a f t g e a r m a y s o m e t i m e s s t i c k to v i b r a t i o n d a m p e r . T6 Install vibration damper

D a m p e r c a n o n l y b e f i i t e d ir o n e w a y . P i n o n c r a n k s h a f l g e a r n 1 u s t f i t i n v i b r a t i o n d a m p e r . T o r q u e b o r s t o 2 0 N m 115 ft bs). T7 I n s t a l l c e n t e r b o l t S m e a r t h r e a d s a n d m a t i n g s L r r f a c e w i t h s e a l e r P / N 277961 L

U s e w r e n c h 5 1 8 7 {resl on cooiing fan bearing)to hold

U s e w r e n c h 5 ' 1 8 8 to t o r q u e c e n t e r b o l t t o 3 5 0 N m ( 2 5 5 f t l b s ) . l m p o r t a n r : T o r q u e 3 5 0 N m a p p l i e s o n l y if w r e n c h 5 1 8 8 i s | r s e d . A s o t o r q u e w r e n c h m u s t b e i n l i n e w i t h w r e n c h 5 1 8 8 . 1 0 7

(6)

Vibration da m per, removi ng/i nstal ling

1 0 8

T8 Install:

- cooling fan with spacer and pulley. T i g h l e n i n g t o r q u e 9 N m ( 7 f t l b s )

- belt for power steering pump and fan be ts - fadiator. Connect hoses

Bleeding of cooling system

D i s c o n n e c t u p p e r h o s e fr o m c o l d s i a r t d r i p p a n beneath h o s e a n d h o l d h o s e e d g e o f e x p a n s i o n t a n k . T9

{))l

t i

rl

I

Coolant S i n c e a L r m i n i u m i s u s e d in t h e e n g i n e s , a c t i v e c o r r o s i o n p r o l e c t i o n i s n e c e s s a r y i n t h e c o o l a n t to h e l p p r e -v e n r c o r r o s r o n o a m a g e . U s e g e n u i n e V o l v o b l u e - g r e e n c o o l a n l ty p e C , d i l u t e d with cle.n water in propo(ions of 50/50.

T h i s m i x l u r e h e l p s t o p r e v e n t c o f t o s i o n a n d i r o s l d a m a g e .

a N e v e r fi l l t h e c o o l i n g s y s t e m w i l h w a t e r a l o n e . a T h e c o o l a n t s h o u l d b e c h a n g e d re g u l a r l y s i n c e th e

c o r r o s i o n p r o t e c t i v e a d d i t i v e s in t h e c o o l a n t lo s e their effect in time.

N o t e l D o n o t r u n e n g i n e w h e n l e v e l o f c o o a n l a s lo w , s i n c e h i g h l o c a l t e m p e r a t u r e s c a n r e s u l t w h i c h m a v c a u s e t h e c y l i n d e . h e a d to c r a c k .

(7)

srYoorT irtt 3(rc rfrrRfY[ lrfi rurr *t0 ai otL v^firr or| rfr 0rr v0rv0 r4v^rsu TYr c

artto wrTN ctr0r|r lrol\to cooullr nPt

m d d ] w F .

i$rPU 0r Lrouror ArrGft voLvo

rc Mollrt rALr 0n€ Ar{TrcrL fiPr c

Vibration damper, removing/installing

B e p l a c i n g c o o l a n t

A l w a y s u s e ty p e C b l u e - g r e e n c o o a n t . R e m e m b e r t o r e p i a c e d e c a l ( P / N 1 3 3 1 4 7 3 , 7 ) o n e x a n s j o n t a n k if n e c e s

-Typ€ C blue-s.een coolant

A l d i e s e l a n d p e t r o l ( 9 a s o in e ) e n g i n e s m a n u f a c t u r e d s i n c e 1 9 8 2 a r e f i l e d w i t h r y p e C c o o t a n t . F i l l c o o l a n t C a p a c i t y : D 2 0 = 8 . 1 l i l e r s ( 8 . 6 D 2 4 = 9 . 3 l i t e r s (9 . 8 U S U S 710 F l u s h c o o l i n g s y s t e m b e f o r e a d d i n g n e w c o o l a n t , s e e G r o u p 2 6 C o o l i n g S y s t e m . S e t d a s h b o a r d l - e a t e r c o n n o l I o m a \ . T L r n o r e n g i n e a n d w a r m - u p f o r 5 m i n u t e s . A d d c o o l a n t d u r i n g t h i s l i m e . C o n n e c t h o s e to c o l d s t a r t d e v i c e . F i l l c o o l a n t ro m o u t h o f e x p a n s i o n t a n k ( a b o v e m a x ) a n d s c r e w o n 1 0 9

(8)

Engine mounts, replacement

U. Engine

mounts,

replacement

D iferent brackets for mu nLal and automat c gearboxes

U 1 Rear engine mount (gearbox mount)

N e c e s s a r y t o r e m o v e g e a r b o x m e m b e r to r e m o v e re a r

G e a r b o x m u s t b e u n o a d e d w i t h a j a c k d u r i n g r e p l a c e

-U2 Front engine mount

U n l o a d e n g i n e m o u n t s w n h l i f t t o o l s 5 0 3 3 ( 2 x ) , 5 0 0 5 a n d 5 1 1 5 . Left side T o r e p l a c e ru b b e r p a d : r e m o v e u p p e r a n d r o w e r b r a c k e r s . U3 e n g i n e f i r o u n t w n h

I

e

q R i g h t s i d e T o r e p l a c e r u b b e r p a d : r e m o v e upper brackel d , , u r u D -b e r p a d t o g e t h e . , d o n o t r e m o v e to w e r bracker. D o n o t l i g h t e n u p p e r nul for rubber pad t]nti engine m o u n l i s p o s i t i o n e d .

,r))

a

rr)l

O,

'r I

(9)

R e m o v i n g engine

V. Removing

engine

Operations V1-7 Speci al tools : 281 0, 51 85, 51 86 E n s i n e a n d g e a r b o x r e m o v e d a s a u n i t

v 1

Remove

engine

splashguard

and drain coolant

v2

Remove/disconnecti

r positive lead from battery 2 b o n n e t (h o o d )

3 e x p a n s i o n t a n k c a p

4 lower radiaior hose from radiator Auto {operation 5)l 5 o i l p i p e f r o m o i c o o l e r . H o l d connectors on oi c o o e r w i l h a w r e n c h . t f accidenia y s ackened, t o r q u e io 6 N m ( 4 . 5 ft t b s ) 6 u p p e r r a d i a t o r h o s e fr o m e n g i n e 7 h o s e s to € x p a n s i o n t a n k a t r a d i t o r 8 radiator t h o s e s fr o m h e a t e r c o n t r o l v a l v e 1 0 h o s e fr o m v a c u u m p u m p -1 r l

(10)

Removing engine R e m o v e / d i s c o n n e c t 2 3

v3

R e m o v e / d i s c o n n e c t A c o n n e c i o r f r o m c l l p o n b u l k h e a d l f i r e w a ) B t h r o t t l e c a b L e f r o m p ! l l e y a n d b r a c k e t F u e l l i n e c o n n e c t i o n s ( C E b e l o w ) i B l o w - c e a n , d i s c o n n e c t a n d p l u g e n d s t o p r e v e n t d r r t entering fuel system

C s u p p l y i n e f r o m f u e l i i l t e r - r e t u r n li n e ir o m n j e c t i o n p u m p ( a t c l a m p ) E p a L e a l a v f o r p r a h e a l i r g s v s r P T 0 1 F n o 1 o . D i s c o n n e c t w i r e l r o n r j u n c i i o n b o x . D i s c o n f e c l b l a c k w i r e a n d s m a I r e d w i r e f r o m r e l a y . U n s c r e w r e t a i n i n g s c r e w s fr o m r e l a y . r e m o v e p o w e r s t e e r i n g p u m p l f o m e n g i n e : s a c k -e n a n d r -e m o v -e d r i v -e b -e l t f r o m p u r n p . B -e m o v -e p r f p s i r L b r a r \ e _ o ' r d ,L p p o r t \ r o y lr o 1 F 1 g .-T i e p u m p t o c h a s s i s t o p r e v e n l d a m a g e to h o s e s . c o o l i n g fa n w i t h s p a c e r p u l e y a n d fa n b e l t s b e I f o r p o w e r s i e e r i n g p u m p .

i)t a

rta

v4

c r a n k c a s e b r e a t h e r h o s e a i r f i l i e r c o v e . a n d h o s e s a i e f n a t o r w i r i n g h a r n e s s : d l s c o n n e c t v o t a 9 € r e g u a i o r ( o r a t e r n a l o r ) . R e m o v e re l a i n i n g s c . e w s f o r w i r i n g h a r n e s s o n w h e e a r c h a n d p a c e h a r n e s s o n e n g i n e . V e h i c l e s f o r S w e d e n : 5 T - s e a r u n i t o n b u l k h e a d ( f rewall) 6 e x h a u s t p i p e fr o m f r o n t e x h a u s l b r a n c h p i p e lD 2 0 h a s o n l y 1 m a n f o l d ) .

;a

il

1 1 2

(11)

Group 21 Engine

Y

I

Removing engine

0

v5

D r a i n e n g i n e o i l l n s t a l l p l u g .nd washer a f t e r d r a i n i n g o i l .

- engine m o u n t retaining b o l t s f r o m f r o n t axte c r o s s -L e f t e n g i n e m o u n t : r e m o v e n u r s f r o m f r o n t a x t e c r o s s ,

R i g h t e n g i n e m o u n t i r e m o v e l o w e r n u i from

rub-e n g i n rub-e

v6

Remove/disconnect

- front exhaust pipe clamps

- disconnecl e x h a u s t p i p e c o u p l i n g . R e m o v e f r o n t e x -- ( m a n u a l ) c l u t c h c a b l e a n d g e a r ! e v e r - ( a u t o ) selector c o n t r o l fr o m searbox/lransm s s i o n s p e e d o m e t e r c a b l e - gearbox c f o s s m e m b e r . P o s i t i o n a j a c k b e n e a t h g e a F

Removing

0

0

(f

V7 U s e l i f t i n s t o o l s 2 8 0 1 , 5 1 8 5 ( a t front) a n d 5 r 8 6 (a r r e a r ) . L i f t engine e n o u g h l o u n l o a d l e f t e n g i n e m o u n t . R e r t r o v e e n g i n e m o u n t .

R e m o v e j a c k beneath s e a r b o x , s t i d e p u e y unit for w a r d s a n d li f i our engine.

C

s

=-€>

{"F

-'-2"

;#

- disconnect w i r i n g . 1 1 3

(12)

Removing engine

X. Removing

engine

Operations x1-3 Specia I tools : 281 0, 51 85, 51 86 E n g i n e a n d g e a r b o x in s t a l l e d a s a u n i t

x 1

Position

engine

U s e li f t to o l s 2 8 1 0 , 5 1 a 5 ( a t front) and 5186 (al read. P o s i t i o n r i g h t s i d e ru b b e r m o u n t o n o w e r b r a c k e t .

x2

Install left engine mount

P l a c e m o u n t o n f r o n t a x l e c r o s s m e m b e r a n d t i g h t e n

x3

Place a jack beneath gearbox

M a k e s u r e t h a t ru b b e r f o a m p a d a t g e a r l e v e r i s c o r r e c t

-I n s e n w i r i n g in t o p a s s e n g e r c o m p a r t m e n i . J a c k - u p g e a r b o x u n t i l le v e l .

Remove lifling tools

L o w e r e n g i n e a n d r e m o v e t o o l s .

(13)

Group 21 Engine

l

Removing engine

x5

Install gear lever

P l a c e q e a r le v e r in h o u s i n g .

P r e s s p l a s t i c c o l l a r a n d r u b b e r ri n g in t o p o s i t i o n . l n s t a l l l o c k r i n g . R e c o n n e c l w a r i n g .

I n s t a l l b r a c k e t f o r r e v e r s e g e a r d e t e n t . D o n o t t i g h t e n screws atthis stage since bracket must be adjusted at a

(0

X6 Install nuts tor engine mounts

Left mount: nuts in fiont axle crossmember.

R i g h t m o u n t : l o w e r n u l o n r u b b e r p a d .

Install gearbox crossmember

x7

x8

Install on gearbox:

_ gear lever. lMake s u r e t h a t b u s h i n g s a n d O j i n g a r e c o ( e c l l y in s t a l l e d . I n s e n g e a r e v e l in y o k e , f i t p i n a n d t i s h t e n s c r e w ( A l l e n k e y 4 m r n ) , s e e in s e t - propeller s h a f t . A l w a y s u s e n e w n u t s a n d b o l t s s p e e d o m e t e r c a b l e . S w e d e n : w i r e m u s t b e s e a l e d a t g e a r b o x t o c o n f o r m t o t a x r e g u l a t i o n s ( k i l o m e r e r t a x a , 1 1 5

(14)

Removing engine

X9 Connect clutch cable and install return spring

I n s e r t c a b l e t h f o u g h f l y w h e e l c a s i n g a n d c o n n e c t to l n s t a l l r u b b e r b u f f e r a n d v i b r a t i o n d a m p e r o n c a b l e , m a k i n g s u r e th a t b u f f e r is f a c i n g r i g h t w a y . C o n n e c t r e t u r n s P r i n g . A d j u s t p l a y = 1 - 3 m m . ( 0 . 0 4 - 0 . 1 2 i n )

a

A0tomatic gearbox

Attach gear selector to gearbox

x10

{

DI

x l 1 Install lront exhaust pipe

For strainjree installation, instrucrions must be fol

1 S l a c k e n tw o r e t a i n i n g b o l t s h o l d i n g b r a c k e t to g e a r b o r t r a n s m i s s i o n

2 Attach front exhaust pipe fingef tight. Use new

3 T i g h t e n n u t s a n d b o l t s h o l d i n g e x h a u s t p i p e t o 4 T i g h t e n b o l t h o l d i n g fr o n t p i p e to b r a c k e t 5 T i g h t e n b o l t s h o l d i n g b r a c k e t t o g e a r b o x 6 T i g h t e n c l a m p a t e x h a u s t p i p e jo i n t .

{))

a

0Dl

Carsforsweden xl2 Attach T-gear unit to bulkhead (firewall)

(15)

Removing engine

x 1 3

Connect alternatot wiring harness

Reconnect voltage regulator. A t t a c h c l a m p o n w h e e l a r c h .

x14 lnstall air filter cover

R e c o n n e c t a i r i n l e t h o s e a n d b r e a t h e r h o s e t o v a l v e

N o t e t h a t a r r o w o n i n l e t h o s e m u s t p o i n t t o w a r d s m a n i -fold as indicated, otherwise hose may be compressed

x l 5

Install drive bells and cooling fan

P l a c e p o w e r s t e e r i n g p u m p b e l l o n v i b r a t i o n damper. I n s t a l l f a n b e l t s a n d p u l l e y

-Install cooling fan with spacer. Torque to 9 Nm (6 5 ft l b s ) .

T e n s i o n f a n b e l t s . l t s h o u l d b e p o s s i b l e t o d e p r e s s b e l t 5-10 mm on run between fan and alternator, see fig

x16 Install powe. steering pump and belt

Negative lead from battery should be connected to lower front retaining bolt for pump mounting bracket.

Tension fan belts.lt should be possible to depress belt F 1 0 m m ( 0 . 2 - 0 . 4 i n ) in c e n t e r o f r u n b e t w e e n f a n a n d

x 1 7

Connect

relay

for preheating

system

C o n n e c t b l a c k w i r e t o t e r m i n a l 8 6 o n r e l a y a n d r e d w i r e t o t e r m i n a l 8 5 .

Attach relay to washer reservoir mounting bracket. R e c o n n e c t w i r i n g t o j u n c t i o n b o x .

Secure wires with clamps and reconnect

(16)

Removing engine

Reconnect luel lines

M a k e s u r e t h a t d i r t d o e snot enter fuel system.

x18

x19

x20

x21

x22

Reconnect plug on bulkhead (tirewall)

S e c u r e p l u g w i t h c l i p .

Reconnect:

- hoses to heater control valve - hose to vacuum pump

lnstall radiator and connect hoses

Automatic gearbox

Connect oil pipes to oil cooler

U s e a w r e n c h lo h o l d c o n n e c t o r c o n o i l c o o l e r . T i g h t e n i n g t o r q u e C a p n u t s 3 0 N m ( 2 2 ft t b s ) O i l c o o l e r c o n n e c t i o n s 6 N m { 4 . 5 ft l b s ) .

'.,r

m

1 1 8

(17)

Group 21 Engine Bemoving engine

lnstall bonnet/hood Connect washer hose,

Reconnect bailery

Manualgearbox

Adiust blacket for reverse gear detent. rubber gaite.

x25

lnstall

Engagefirst gear. Ad,ust clearance between gear tever and detent brackerto 0.5-1.5 mm (0.020-0.060 in). Use a feeler gauge.

Tighten retaining bolts.

Recheck clearance in s€cond gear, Install rubber gairerboot.

Automaticgeatbox

Check/rdiusi geaa selector

'1.

Checkthat clearance between position D and stop is approximately same as from 2 to stop.

2. Adjust by altering length of controt rod if neces, Rough adiustment: turn adjusrer at re6r of rod Fine adiustment I tu rn serrared steeve (max visibte t h r e a d l e n s l h = 35 mm).

hcreasing rod length reduces ctea rance in position D, and increases clearance in posjtion 2.

After adiusrment: move tever to posirion I and then to position P. Repeat check accord ing to stag e 1 .

(18)

Removing engine

x27

A d d e n g i n e o i l C a p a c i t y i n c u d i n g o i l f i l l e r : D 2 0 = 6 l i t r e s { 6 . 3 U S q u a d s ) D 2 4 = 7 l i t r e s {7.4 US quads) O u a it y : a c c o r d i n g t o A P l , m i n c C ( o i l s w i r h d e s i g n a ' l i o r s S L / C C . S L / C D . S l / C C d r d S r / C D ,J l ' i r l - s e q L r e . V i s c o s i l y , s e e a d j a c e n t d i a g r a m . N o t e l S A E l5 W 5 0 o r S A E 2 0 W 5 0 o i l s a r e r e c o m m e n d e d i o r u s e i n e x t r e m e d r i v i n g c o n d i t i o n s w h i c h i n v o l v e h i g h o i l c o n s u m p l i o n a n d h i g h o i l i e m p e r a t u r e s e . g . m o u n t a i n d r i v i n g w i t h f r e q u e n t d e c e l e r a t i o n s o r f a s t m o t o r w a Y c i r i v i n g . ( N o t e h o w e v e r th e l o w e r t e m p e r a

x28

B l e e d i n g o I c o o l i n g s y s t e m D i s c o n n e c t u p p e r h o s e fr o m c o l d s t a r t c l e v i c e . P a c e d r i p p a n beneath h o s e a n d h o d h o s e le v e l w i t h t o p e d g e o i e x p a n s i o n t a n k .

,))r

a

'rl

Coolant S i n c e a l u m i n i u m is u s e d in t h e e n g l n e s , a c t i v e c o r r o , s i o n p r o t e c t i o n i s n e c e s s a r y i n t h e c o o l a n t to h e l p p r e -v e n r c o r o s o n o s m a g e . U s e g e n u i n e V o l v o b l u e g r e e n c o o a n l t y p e C , d i l u t e d w i l h c l e a n w a l e r i n p r o p o r l i o n s o i 5 0 / 5 0 . T h i s m i x l u r e h e l p s t o p r e v e n t c o r o s i o n a n d f r o s t a N e v e r fi t h e c o o l n g s y s t e m w i t h w a t e r a l o n e . a T h e c o o l E n t s h o u d b e c h a n g e d re g u l a r y s i n c e th e c o r r o s i o n p r o t e c t i v e a c l d i t i v e s i n t h e c o o l a n t o s e t h e i r e f f e c t in i h e t i m e . N o t e l D o n o t r o n e n s i n e w h e n le v e o i c o o l a . l i s l o w s r n c e h 9h loca lemperaturesc6n f e s u r w h i c h m a y c a u s e t h e c y i n .

i l |

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(19)

oftcrrAL firv isx! rYP c $ rArYL

trr$flLr Ain iurr Mro fli Dft v^nr|. ocH ar 0rr v 0 r r 0 $ . v a r s u r ' r c

AI<'LI/IO COOLAilI NPI roP uP Ylad R0ur0 wf| F^tr r^r

itMfu 0r !0ur0r Arr0n r/o'llro

R e m o v t n g e n g i n e R e p l a c i n g c o o l a n t A l w a y s u s e t y p e C b l u e ' g r e e n c o o l a n t . B e m e m b e r t o r e p l a c e d e c a ( P / N 1 3 3 1 4 7 3 - 7 ) o n e x p a n s i o n t a n k if n e ' T y p e C b l u e - g r e e n c o o l a n t A l l d i e s e l a n d p e t r o ( g a s o l i n e ) e n s i n e s m a n u f a c t u r e d s i n c e 1 9 8 2 a r e f i l l e d w i t h t y p e C c o o l a n t .

x29

F i l l c o o l a n t C a p a c i t y : D 2 0 = 8 . 1 l i t r e s (8 . 6 U S q u a r t s ) D 2 4 = 9 . 3 i r r e s (9 . 8 U S q u a r t s ) F l u s h c o o l i n g s y s t e m b e f o r e a c l d i n g n e w c o o i a n t , s e e G r o ! p 2 6 C o o l i n g S y s t e m . S e l d d s _ o o d r d l ' e . r e r . o r rr o l lo r d \ . T L r r o r e l g r n e a n d w a r m - u p f o r 5 m i n u t e s . A d d c o o l a n t d u r i n g t h i s t i m e . C o n n e c t h o s e to c o l d s t a r t d e v i c e . F i l l c o o l a n r r o n r o u t h o f e x p a n s i o n t a n k ( a b o v e m a x ) a n d s c r e w o n

x30

C h e c k / a d i u s t i n i e c t i o n ti m i n g S e e i n s t r u c t i o n s o n p a g e 2 4 , c 1 1 - 2 0

(rt

)

,4\\

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C h e c k o p e r a t i o n T u r n o n e n g i n e a n d w a r m u p . C h e c k f o r o i l a n d c o o a n i e a k a g e s . T o p u p i f n e c e s s a r y . I n s t a l l e n g i n e s p a s h g u a r d . 1 2 1

(20)

Removing engtne

Cold gea&ox o I oiltemperatures 4o'C (104'F'.

This temperat!re ls reached after approx, 10 minutes idl ns. At oi temperatures beLow 40'C leve may be below M N.

M I N . 9 6 ' €

Hot gearbox o I oit temperatlre 90'C ('194'F)

Automaticgearboxes:

x32

Check-top-up oil level Use ATF type F or G.

E n g i n e m u s t b e r u n n i n g a n d s e l e c t o r i n p o s i t i o n N or P.

x33

Check/adiust l d l e = 1 2 . 5 1 0 . 8 r A : 7 5 0 1 5 0 r / m i n F a s t id l e = 8 7 1 1 . 7 ts = 5 2 0 0 1 1 0 0 r/min l f n e c e s s a r y r e f e r to p a g e 1 2 9 .

E n g i n e c o n t r o l s ( l h r o t t l e c a b e and kick-down cabte) ( A u t o ) . l f n e c e s s a r y r e f e r to p a g e 1 7 6 . l m p o r t a n t r lf e n g i n e h a s b e e n d i s a s s e m b e d c y l i n d e r h e a d b o l t s n u s t b e c h e c k ti g h i e n e d a f t e r 6 0 0 1 , 2 0 0 m a e s ( 1 , 0 0 0 - 2 , 0 0 0 k m ) .

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122

(21)

Group 22 Lubricating

System

Contents

E ' 1 g i n e o i , o ; t i l t e r . r a p a c e m e n t . . . .

O l p . e s s u r e . c h e c k i l g

O l p L m p , g e r e r d l i n f o r r a l r o n . . . .

Engine oil, oil filter.

replacement

O p e r a t i o n Y 1 2 7 1

z1

22

Engine oil, oil filter

1 2 4

Y1

Oil capacity litres ( U S q u a r t s ) E x c l . o i l f i t e r I n c l . o i l f i l t e r

Ouality

A c c o r d i n g t o A P I . . . M I N C C Oils with designations SE/CC, SE/CD, SF/CC and SF/CD f u l f i l lh i s r e q u i r e m e n l . D 2 0 D 2 4 5 _ 2 { 5 . 5 ) 6 . 2 (6 . 5 ) 6 . 0 (6 . 3 ) 1 . O t 7 . 4 1 1 . 0 { 1 . 0 ) 1 . 0 ( 1 . 0 ) T e r n p e r a t u r e r a n g e { s r a b l e a m b i e n t t e m p e r a t ' r r e s ) N o t e S A E 1 5 W 5 0 o r S A E 2 0 W 5 0 o i l s a f e r e c o r n m e n d e d f o r u s e i n e x t r e m e d r i v i n g conditions which Invotve h i g h o i l c o n s u m p t i o n a n d h i g h o i t t e l r l p e r a t u r e s e . g . m o u n t a i n d r i v i n g w i h t f r e q u e n t deceterations o f f a s t m o t o r w a y d r i v i n g . (N o t e h o w e v e r rhe tower tempera-t u r e l i m i tempera-t s . ) Y2 Oil filter U s e o i l f i l t e r w r e n c h 2 9 0 3 t o r e m o v e f i t t e r . T o i n s t a l l f i l t e r , s e e in s k u c l i o n s o n f i t r e r . l f o n l y f i l t e r i s r e p l a c e d ( i . e . n o t e n g i n e o i l ) , a d d 0 . a t i t r e s ( 0 . 8 U S q u a r t s ) o f o i l . 1 2 3

(22)

Oil pressure, oil pump

Oil pressure,

checking

Oil pump

z 1

Connect oil pressure gauge to connection for oil pressure sender

Oil pressure must be 6t least 200 kPa (28 psi) at 33 r/s ( 2 , 0 0 0 r m i n ) a n d 8 0 ' C ( 1 7 6 ' F ) o i l t e m p e r a t u r e . R e l i e f v a l v e i n p u m p s h o u l d o p e n a t 6 0 0 - 7 0 0 k P a { 8 F 99 psi)-- oil level - relief v a l v e i n p u m p .

z2

General

information

O i l p a n cannot be removed f r o m i n s t a l l e d e n g i n e . C o n s e q u e n l l y i t i s n e c e s s a r y t o r e m o v e e n g i n e t o r e

-M a r k ( A ) on outer plmp gear must face rear cover. O i l p u m p is only available a s a complete u n i r . S p a r e parts are however available for relief valve.

z3

Relief valve

l f o j l p r e s s u r e i s n o t a s s p e c i f i e d c h e c k th a t p l u n g e r m o v e s fr e e l y a n d t h a t s p r i n g is i n g o o d c o n d i t i o n . R e l i e f v a l v e i s a c c e s s i b l e f r o m b e l o w w i t h o i l p u m p i n s t a l l e d . T i g h t e n i n s t o r q u e 4 0 N m ( 3 0 ft l b s ) .

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124

(23)

Group

23 Fuel

system

Contents

E x h a u s t g a s smoke d e n s i t y , g e n e r a l . . - . - - . . . . .

-checking '

l d l e + f a s t id l e .. . . . Fuel filtsr, draining wate

r e p l a c o m e n t . . . . I n j e c t i o n p u m p , g e n e r a l a l t i t u d e a d i u s t m e n t , U S A s e n l n g . . ' . . , " b e l t re P l a c e m e n t . . . . . ' . . . , r e m o v a l . . . , . . . . . i n s t a l l a t i o n . . . . Delivery pipes, removal/installation ... . ...

rePlac€ment

I n i e c t o r s , m a l f u n c t i o n s / c h e c k i n g . . . . . . . . . . . . r e m o v a l . . . , . , . . . .

i n s t a l l a t i o n . . . . overhaul {incl. testing} Cold start clevice ,.,...

Preheating system (glow plugsl. wiring diagram 1979_80 .. ' 1 9 8 1 - . . . , . , . Op.ration AA2-10 ABl-6 AC1 AC2 AE1-14 AD2 aD3-14 A E l - 1 4 A G 1 - 1 7 AH1-3 A J l - 1 0 AK1_2 AK}6 AK7-9 A L 1 - 1 0 Atvtl-2 A N 1 A O 1 Pag6 't26 126 1 2 9 1 3 0 1 3 0 13',l 132 1 3 3 't36 1 4 0 143 1 4 8 '149 1 5 1 1 5 1 '152 1 5 3 1 5 5 1 5 6 1 5 8 Contenls 125

(24)

Exhaust gas density

AA. Exhaust gas density

General E x h a u s t g a s s m o k e d e n s i t y g i v e s a g o o d i n d i c a t i o n o f t h e c o n d i t i o n o f a n e n g i n e a n d w h e t h e r t h e i n j e c t i o n p u m p i s c o r r e c t l y a d j u s t e d . S w e d i s h r e g u l a t i o n s s t i p u l a t e t h a t s m o k e d e n s i t y m u s t n o t e x c e e d 3 . 5 B o s c h u n i t s fo r p a s s e n g e r c a r s a t t i m e o f r e g i s t r a t i o n a n d 4 . 5 B o s c h u n i t s a t t h e a n n u a I S i n c e e x h a u s t g a s s m o k e e m i s s i o n s f r o m V o l v o d i e s e l s a r e g e n e r a l y l o w e r t h a n o t h e r v e h i c l e s ir m a y b e th o u g h t p o s s i b e t o i n c r e a s e e n g in e p e r f o r m a n c e b y e n r i c h i n s t h e f u e l a i f m i x t u r e . P r o l o n g e d e r c e s s i v e e n n c h m e n l w i l l n o t i n L r e a s e p o w e r output but will in fact reduce seryice life of e n g i n e c o n s i d e r a b l y . E v e n m o d e r a t e e n r i c h m e n t o f f u e l - a i r m i x t u r e w i l l s h a r p l y in c r e a s e e x h a u s t g a s te m -p e r a t u r e s a n d c o m b u s t i o n p r e s s u r e s , w i t h o u t a n y c o F r e s p o n d i n s p o w e r sain.

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AA2 C h e c k i n g s m o k e d e n s i t y V a r i o u s t y p e s o f equipment a r e a v a i l a b l e t o m e a s u r e s m o k e d e n s i t y . R e f e r t o m a n u f a c t u r e r s ' i n s t r u c t i o n s f o r m a i n t e n a n c e a n d c a l i b r a t i o n o f e q u i p m e n t . 126

(25)

AA3 Connect extension piece to exhaust pipe

This reduces the risk of ambient air affecting instru-ment probe. Pipe dimensions: length = 200 mm (8in)

i n t e r n a l d r a m e L e r - 50 mn l2in). Secure e i t e n t i o n p i e c e w i t h r u b b e r h o s e a n d c l a m p s .

I n s t a l l sample pump

Insert probe into exhaust pipe, Probe must be in center and inserted to 6 depth of not less than 200 mm {8in}, otherwise readings will be incorect,

H a n g f l e x i b l e h o s e f r o m clamp a s il l u s t r a t e d . C o n n e c t h o s e f r o m r u b b e r b l a d d e r t o s a m p l e p u m p .

Exhaust gas density

AA5 Check sample pump operation

Engine off. P u s h i n p u m p p l u n g e r f u l l y . Squeeze r u b b e r b l a d d e r a n d c h e c k m o v € m e n t o f p u m p p l u n g e r . N o t e l D o n o t c o v e r h o l e i n b l a d d e r a s p l u n g e r w i l l n o t P u s h i n p l u n g e r f u l l y after c h e c k i n g . AA6 Insert filter paper in pump

Unscrew cover and check that contact surfaces are

P l 6 c e f i l t e r p a p e r i n o p e n i n g a n d t i g h t e n c o v e r h a n d t a g h t .

Position rubb€r seal over cover (to prevent dirt and moisture from affecting test).

(26)

Exhaust gas density R o u t e h o s e w i t h r u b b e r b l a d d e r t o d.ive6 seat S e c u r e h o s e w i t h ta p e . 2 4 2 1 2 4 4 : I n s e r t h o s e t h r o u g h r e a r side window. 2 4 5 : In s e r t t h r o u g h t a i l g a t e .

50

s0 knr/h (30 AA8 M e a s u r e s m o k e d e n s i t y W a r m - u p e n g i n e t o n o r m a l o p e r a t r n g t e m p e r a t u r e , D r i v e i n s e c o n d g e a r a t 5 0 k m / h { 3 0 m p h ) . S l o w l y p u s h a c c e L e r a t o r p e d a l t o f l o o r w h i l e a p p l y i n g f o o t b r a k e t o m a i n t a i n c o n s t a n t 5 0 k m / h . N o t e ! A u t o m a t i c t r a n s m i s s i o n : D o n o t d e p r e s s a c ' c e l e r a t o r p e d a l t o s u € h a n e x t e n t t h a t k i c k - d o w n i s e n g a g e d . M a i n t a i n c o n s t a n t s p e e d f o r a f e w s e c o n d s a n d s q u e e z e r u b b e r b a d d e r t o o p e r a l e p u m p . N o t e ! S q u e e z e r u b b e r b l a d d e r h a r d fo f s e v e r a l s e -c o n d s t o e n s u r e t h a t s a m p l e p u m p has been f i l l e d . D o n o t c o v e r h o l e in r u b b e r b l a d d e r .

,)r

e

rit I

s 0 km/h (30 mph) AA9 Repeat measurements

Remove filter paper from pump.

Depress pump plunger fuly and place a new filter

p a p e r in p u m p . A e p o s i t i o n r u b b e r c o v e r . R e p e a t m e a s u r e m e n t s a c c o r d i n g t o A A 8 . A A l O Evaluate result C a i b r a t e e q u i p m e n t a c c o r d i n g to m a n u f a c t u r e r s i n -S m o k e d e n s i t y f o r p a s s e n g e r c a r s in S w e d e n m u s t n o t e x c e e d 3 . 5 B o s c h u n i t s a t t i m e o f r e g i s t r a t i o n a n d 4 . 5 B o s c h u n i t s a t a n n u a l in s p e c l i o n .

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(27)

AB.

ldle * fast idle

Special tool: 9950

Connect tachomeler

Use Volvo Monotester and adapter 9950.

lf Volvo Monotester js not available use photoelectric rev counter (999 9795,9).

Warm-up engine

Checldadjust idle 12.5 r/s (750 r/min).

Seal adjustment screw and lock nut with paint after

Checldadiust fast idle 87 r/s {5200 r/min).

Seal adjustment screw and lock nut with paint after

D o n o t r a c e e n g i n e l o n g e r t h a n necessary,

Disconnect tachomeler.

AB6 Checldadiust engine controls

Always checUadjust engine controls after adiustjng

i d l e s p e e d .

(28)

AG. Fuel filter

'),{

e

A C l Drain water from fuel tilter

- place a d r i p p a n u n d e r n e a t h d r a i n s c r e w ( 2 ) - slacken b l e e d s c r e w ( 1 ) a c o u p l e o f t u r n s

- slacken d r a i n s c r e w (2 ) a n d r e t i g h t e n w h e n c l e a n f u e l fl o w s th r o u g h .

- retighten bleed screw

AC2 Replacement

Special tool: 2903

- Us€ strap wrench 2903 to remove filter. Place strap a s n e a r a s p o s s r b l e r o b d s e o f l i l t e r , s e e li g .

- smear d i e s e l o i l o n n e w li l t e r s e a l

- tighten I i l t e r by hand until seal c o n t a c t s b o d y . T h e n t i g h t e n a f u r t h e r 1 / 4 t u r n

- sta eflgine a n d c h e c k f o r le a k s . l f s e a l i s n o t t i g h t a i r w i l l b e drawn i n t o fuelsystem a n d c a u s e p o o r run-n i run-n g .

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(29)

Group 23 Fuel system

Iniection pump, genercl

AD. Iniection

pump, general

AD1 Adiustments which can be carried out on an installed iniection pump are limited to tho tollowing:

- adjusting idle and fast idle - adjusting iniection timing

For more detailed repairs and adjustments the pump must be removed and lested by speciallytr6in6d psr-sonnel, on a sDecialtest b6nch.

Smoke density regulations for Sweden Fuel regulating screw is sealed atfactory.

No!61 Fuelsupply may only be checked/adjusted on a t6st bench bvtrained Dersonnel,

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Group 23 tuel system

High altitude adjustment (Legal rcquirement)

High altitude adjustment

(Legal

requirement)

AD2 Environmental Protection Agency (EPAI defines: - high altitude as an €levation exceeding 1219 metres

(4000 f0

- low altitude as an elevation lower than or equ6l to 1219 metres {4000 ftl.

a O n d e l i v e r y f r o m f a c t o r y a l l v e h i c l e s a r e a d i u s t e d f o r low altitudes,

a N s w v e h i c l e s s o l d f o r p r i n c i p a l u s e a t h i g h a l t i t u d e s must be adjusted befor€ bsing delivered to the cu stom€ r. After adiu stment a decalmust be affixed to the firewall (beside the emissions information d e c a l ) a n d a l s o t o t h e in j e c t i o n p u m p .

a lf v€hicle owner moves are6, the vehicle should t u d e d r i v i n g .

a Vehicles adjusted for high altitudes must bs read_ iusted for low altitudss ifvehicle is to be principallv used at low altjtudes. Th€ hjgh altitude decals must also be removsd at the same time,

Thefollowing adiustment must be made to vehicle for u s e a t h i g h a l t i t u d o s :

Inisction timing: advancsd 0.07 mm (0.0028 in) for every 100 m (3300 ftlincrease in altitudes.

Injected quantity decreases by 2.3 mm3tor each 1000 metre increase in altitude. This is equivalentto turning adiustment screw 35' counterclockwise.

from low to high altitude b s r e a d j u s t e d f o r h i g h a l t i

-Injecrion riming

Example: lf altitude is 2000 metres above sea level the lollowing calculations can be made:

0.85 mm is normal setting {for 1982-models}

o.ss+ffi*o.oz)=o.ssr.

H i g h a l t i t u d e s e t t i n g is 0 . 9 9 m m Iniected qutntity E x a m p l e : l f a l t i t u d e i s 2 0 0 0 f o l l o w i n g c a l c u l a t i o n s c a n

?999^

er. = rn.

1 0 0 0

-Turn adjustmenl screw 70"

metresabovesea level the b e m a d e i

(31)

AD. Iniection pump, setting

special tool: 5194

lnjection pump,^efting

is at TDc-iniection

damper centre bolt to turn

Removo rear timing goa. covel

Disconnect cold start devicc

Slacken screw 1. Push lever fo fwa rd and rotate sleeve 90'.

Nole! Do nottlrn screw 2 otherwis€ itwillbe nec€ss' ary to remove cold start device and rsset it on a test bench.

Push lev€r back against stop.

Tuln ongin€ until cyl. I Always use the vibration the engine.

Use a 27 mm socket,

I V s r k i n p u m p g e a r s h o u l d b e o p p o s i t e m a r k I n m o u n -ting bracket. Flywheelat "O" mark.

Pl.co dial Indicator in iniection pump

Unscrew and rerhove plug from iniection pump distributor.

I n s t a l l h o l d e r 5 1 9 4 a n d d i a l i n d i c a t o r (m e a s u r i n g r a n g e 0 - 3 m m ) . S € t g a u g e t o a p p r o x . 2 m m .

(32)

Injection pump,setting

AD7 Set indicator to zero

Turn pump gear back slightly until min. reading regis-ters on dial indicator.

Set indicator to zero.

AD8

Check pump setting

T u r n e n q i n e s l o w l y c l o c k w i s e u n t i l f l y w h e e l i s a t ' O ' N o t e ! l f e n g i n e i s tu r n e d t o o fa r it m u s t b e tu r n e d b a c k a p p r o x . 1 / 4 r u r n a n d t h e n t o ' o ' m a r k o t h e l w i s e s e t t i n g D i a l i n d i c a t o r s h o u l d s h o w : O 2 0 . . . 0 . 7 5 - 0 . 8 3 m m ( 0 . 0 2 9 5 - 0 . 0 3 2 7 i n ) D 2 4 . . . 0 , 5 5 - 0 . 7 3 m m ( 0 . 2 5 6 0 , 0 2 8 7 i n ) D 2 4 U S A a n d C a n a d a 1 9 7 9 - 1 9 8 1 . . . 0 . 6 5 - 0 . 7 3 m m ( 0 . 0 2 5 6 - 0 0 2 8 7 i n ) 1 9 8 2 - . . . 0 . 8 2 - 0 . 9 0 m m { 0 . 0 3 2 3 0 . 0 3 5 4 i n ) ( V e h i c l e s a d j u s t e d f o r h i g h altitude d r i v i n g j re f e r t o p a g e 14) AD9

Readiusting pump setting:

S e t t i n g v a l u e s : D 2 0 .. . . 0 . 8 0 m m {0.0315 i n ) D 2 4 . . . 0 . 7 0 m m {0.0276 i n ) D 2 4 U S A a n d C a n a d a 1 9 7 9 - 1 9 8 1 . . . 0 . 7 0 m m ( 0 . 0 2 9 5 i n ) 1 9 8 2 . . . 0 . 8 5 m m ( 0 . 0 3 3 5 i n )

Reading less than specilied:

S l a c k e n p u m p m o u n t i n g b o l t s a n d tu r n p u m p i n w a r d s t o o b t a i n c o r r e c t v a l u e . T i g h t e n m o u n t i n g b o l t s a n d r e p e a t c h e c k o f p u m p s e t t i n g . R e a d i n g m o r e th a n s p e c i f i e d : S l a c k e n p u m p m o u n t i n g b o l t s a n d t u r n p u m p o u t w a r d s u n t i l d i a l in d i c a t o r s h o w s a p p r o x : D 2 0 . . . 0 . 7 0 m m ( 0 . 0 2 7 6 i n ) D 2 4 . . . - . . . 0 . 6 0 m m ( 0 . 0 2 3 7 i n ) D 2 4 U S A a n d C a n a d a ' 1 9 7 9 - 1 9 8 ? . . . 0 . 6 0 m m { 0 0 2 5 6 i n ) 1 9 8 2 ' . . . 0 . 7 5 m m ( 0 . 0 2 9 5 i n ) T h e n t u r n p u m p in w a r d s u n t i s p e c i f i e d v a l u e is o b t a i n e d . T i g h t e n m o u n t i n g b o l t s a n d re c h e c k p u m p s e t ' t | n g ,

N o t e ! In j e c r i o n p u m p must not be tapped o r k n o c k e d a s th i s w i l l a h e r i t s s e t t i n g .

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(33)

Group 23 Fuel system

lnjection pump, sefting

ADlO Check pump setting

Turn 6ngine twoturns 6nd checksetting.

Adjust if necessary according to operation DB and

A D l 1 Romove dial indicator and holder

AD12 Install plug wath new $oal

Tightening rorque I Nm (6.5 ft lbs).

ADI3 Install rear timing gear covel

A D 1 4 Reconnect cold stsrt dovicg

Press lever forwards and turn sleeve 90'. Retighten

Notol Do notturn screw 2. otherwise it will be necess-ary to remove cold start d€vice and reset it on a tgst bench.

(34)

lnjection pump belt, replacement

AE. lnjection

pump belt, replacement

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

Remove rear timing gear cover

A E l

AE2 Turn engine until cyl. 1 is al TDC-injection Always use vibration damper centre boLt to turn engine. Use 27 mm so€ket.

l\,lark in pump gear should be opposite mark in mount-in9 bracket. Flywheel at "o".

0,1

Lift off pump belt

S i a c k e n r r l o u n t i n g b o l t s fo r i n j e c t i o n p u m p b r a c k e t i o r e l e a s e b e l t t e n s i o n . T i g h t e n o n e b o l t s o t h a t p u m p r e m a i n s in ! p p e r p o s i t i o n .

Lift off belt.

AE4 Remove camshaft rear sprocket

H o d s p r o c k e t i n p o s i t i o n w i t h 5 1 9 9 a n d u n s c r e w s p r o c k e t w i t h w r e n c h 5 2 0 1 .

Take care nol to rolate camshaft.

l n s t a l l c e n t e r b o l t , h a n d ti g h t . lt s h o u l d b e p o s s i b l e t o t u r n s p r o c k e t o n c a m s h a f r w i t h o u t c a m s h a f t r o t a t i n g .

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(35)

Group 23 Fuel system Injection pump belt, replacement

AE5 Disconnect cold start device

S l a c k e n s c r e w 1 . P u s h le v e r fo r w a r d a n d r o t a t e s l e e v e 90'.

N o t e ! D o n o t t u f n s c r e w 2 , o t h e r w i s e it w i l l b e ncuess, a r y t o r e m o v e c o l d s t a r t d e v i c e a n d r e s e t it on a resr

P r e s s l e v e r b a c k a g a i n s t s t o p .

T h e n t u r n p u m p g e a r back s l i g h t l y u n t i l min feading r e g i s t e r s o n d ia l in d i c a t o r . S e t in d i c a r o r t o z e r o . T u r n p u m p g e a r clockwise u n t i l m a r k on gear and p u m p mounting bracket c o i n c i d e . L o c k g e a r in this p o s i t i o n w i l h s t o p 5 1 9 3 . ( l n s e r t s t o p th r o u g h p u m p g e a r i n l o m o u n t i n g b r a c k e l . )

AE6 Basic-set iniection pump

Slacken pump mounting bolts (Al en key = 6 mm ). Align marks on pump and mounting bracket by turn,

i n g p u m p . R e t i g h t e n m o u n t i n g b o l t s .

A E 7 S e t d i a l indicator zero.

L o c k p u m p g e a r at cyl. 1 iniection using stop 5 1 9 3

U n s c r e w and remove plus from injection pump

I n s l a I h o l d F 5 1 9 4 a n o d a l i n d c d r o r { m F a s u r i r s r a n g e 0 3 m m ) . S e t g a ! g e to approx. 2 m m . T u r n p u m p g e . r c ockwise u n t i m a r k o n g e a r and m o u n t i n g b r a c k e t c o i n c i d e .

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(36)

lniection pump belt, replacement

AE8 lnstall belt

A d i u s t t e n s i o n b y moving c o o l a n t p u m p .

U s e g a u g e 5 1 9 7 t o c h e c k t e n s i o n . A t t a c h g a u g e t o b e l t a n d set to 12.5 u n i t s . S t r e t c h b e l t until mark on gauge p l u n g e r i s f l u s h w i t h sleeve. D e p r e s s b e l t s t r o n g l y w i t h h a n d a n d r e c h e c k / a d i u s t t e n s i o n .

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rl|'-" ' t t | : : r y , . 7 , v 7 u r , " " , , AE9 Sel pump and tighten camshaft r6ar sprockei U s e 5 1 9 9 t o h o l d s p r o c k e t . T o r q u e w r e n c h s h o u l d b e a t r a g h t a n g l e s t o w r e n c h 5 2 0 1 o t h e r w i s e t o r q u e w i l l b€ U s i n g 5 1 9 9 , t u r n sprock€t s l o w l y c l o c k w i s e u n t i l d i a l D 2 0 .. . . 0 . 8 0 m m ( 0 . 0 3 1 5 i n ) D 2 4 . . . - . . . 0 . 7 0 m m (0 . 0 2 7 6 i n ) D 2 4 U S A a n d C a n a d a 1 9 7 9 1 9 8 1 . . . 0 . 7 0 m m ( 0 . 0 2 7 6 i n ) 1 9 8 2 - . . . 0 . 8 s m m ( 0 . 0 3 3 5 i n ) ( V e h i c e s a d j u s t e d f o r high altitude d r i v i n s i refer to p a g e 1 3 2 . ) H o i d s p r o c k e t i n this position a n d to r q u € b o l t to 1 0 0 N m ( 7 3 f t l b s ) . T a k e c a r e t h a t camshaft a n d s p r o c k e t d o

tit

1 O q N m AEl O

Remove stop 5193 from pump gear

A E 1 1

Check pump setting

Turn engine two full turns until cyl. 1 is at TDC-injec-tion again. lf engine is turned too far it must be turned backapprox.l/4turn and then to zero markotherwise

s e t t i n g w i l l b e in c o r r e c t . D i a l i n d i c a t o r s h o u l d s h o w : D 2 0 . . . - . . . 0 . 7 5 - 0 . 8 3 m m ( 0 . 0 2 9 5 - 0 . 0 3 2 7 i n ) D 2 4 . . . - - . . - - . . - - . . - . . . 0 . 6 5 - 0 . 7 3 m m ( 0 . 0 2 5 6 0 . 0 2 8 7 i n ) D 2 4 U S A a n d C a n a d a ' 1 9 7 9 - 1 9 8 1 . . . 0 . 5 5 - 0 . 7 3 m m ( 0 . 0 2 5 6 - 0 . 0 2 8 7 i n ) 1 9 8 2 - . . . 0 . 8 2 - 0 . 9 0 m m ( 0 . 0 3 2 3 - 0 . 0 3 5 4 i n ) C o r r e c t r e a d i n g r T i g h t e n i n j e c t i o n p u m p mounting b o l t s . P r o c e e d t o E 1 2 . I n c o r r e c t r e a d i n g : R e a d j u s t a c € o r d i n g t o i n s t r u c t i o n s 1 3 8

(37)

Gtoup 23 Fuel system

i,

lnjection pump belt

R e a d i u s t i n g p u m p setting: D 2 0 .. . . 0 . 8 0 m m {0.0315 i n ) D 2 4 .. . . - . . . 0 . 7 0 m m ( 0 . 0 2 7 6 i n ) D 2 4 U S A a n d C a n a d a 1 9 7 9 - 1 9 8 1 0 . 7 0 m m ( 0 . 0 2 7 6 i n ) 1 9 8 2 . . . 0 . 8 5 m m ( 0 . 0 3 3 5 i n ) R e a d i n g le s s than specilied: S l a c k e n p u m p m o u n t i n g b o l t s a n d tu r n p u m p i n w a r d s t o obtain c o r r e c t v a l u e . T i g h t e n m o u n t i n g b o l t s a n d r e p e a t c h e c k o f p u m p setting. R e a d i n g m o r e than specilied:

S l a c k e n p u m p mounting bohs and turn pump o u t w a r d s u n t i l d i a l in d i c a t o r s h o w s a p p r o x : D 2 0 -. . . 0 . 7 0 m m ( 0 . 0 2 7 6 i n ) D 2 4 ... 0 . 6 0 m m ( 0 . 0 2 3 7 i n ) D 2 4 U S A a n d C a n a d a ' 1 9 7 9 - 1 9 8 1 . . . 0 . 6 0 m m ( 0 . 0 2 3 7 i n ) 1 S 8 2 - . . . 0 - 7 5 m m ( 0 . 0 2 9 5 i n ) T h e n t u r n p u m p in w a r d s u n t i l specified v a l u e is o b -t a i n e d . T i g h t e n m o u n t i n g b o l t s a n d re c h e c k p u m p s e r -t r n 9 , l m p o r t a n l l I n i e c t i o n p ! h p m u s t n o t b e t a p p e d o r k n o c k e d a s t h i s w i l l a l t e r i i s s e t t i n g ,

ID

AE12 Remove dial indicalor and holder 5194. lnstall plug with new seal.

Tishtening torque 9 Nm {6.5 ft lbs).

A E 1 3 P r e s s l e v e r fo r w a r d and turn sleeve 9 0 ' . R e t i g h t e n

N o t e l D o n o t tu r n screw 2 , o t h e l w i s e i t will be reoess-a r y to r e m o v e c o l d s t a r t d e v i c e a n d r e s e t i t o n a r e s r

AE14 Install rear timing gear cover

(38)

lnjection pump, removal

AF. Injection

pump, removal

Special tools: 2 x 2901, 5193, 5199,5201,5204 R e m o v e re a r t i m i n g g e a r c o v e l Disconnect: h o s e s f o r c o l d s t a d d e v i c e . C l a m p h o s e s w i t h p l i e r s 2 9 0 1 p r i o r t o r e m o v a - throttle cabLe a n d k i c k d o w n c a b l e (a u t o ) f r o m p u m p - wire from fuelvalve.

AF2

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AF3 Disconnect fuel delivery and return lines frcm pump

C e a n c o n n e c t i o n s t h o r o u g h l y b e f o r e d i s c o n n e c t i n g t h e m . P l u g e n d s o f f u e l l i n e s to p r e v e n t d i r t e n t e r i n g

(39)

lnjection pump, rcmoval

Remove vacuum pump and pump plunger

ffemove pump retajning nuts and place pump on Remove plunger from cylinder head.

AF5 Remove luel delivery pipes

C l e a n a l l c o n n e c t i o n s t h o r o u g h l y b e f o r e d i s c o n n e c t -I n g p r p e s .

Remove all delivery pipes and p[]g ends to prevent d i r t fr o m e n t e r i n g f u e l system.

AF6 Turn engine until cyl. 1 is at TDc-iniection Always use vibration damper center bolt to turn engine. Use 27 mm socket.

lvlark in pump gearshould be opposite mark in mount' ins bracket. Flywheel at "O".

Lift oft pump belt

S l a c k e n m o u n t i n g b o l t s f o r in j e c t i o n p u m p bracker t o r e l e a s e b e l t le n s i o n . T i g h t e n o n e b o l t so that pump r e m a i n s i n u p p e r p o s i t i o n .

Lift off belt.

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(40)

lnjection pump, rcmoval

AF8 Remove camshaft rear sprocket

H o l d s p r o c k e t i n p o s i t i o n w i t h 5 1 9 9 a n d u n s c t e w sprocket with wrench 5201.

Take care not to rotate camshaft.

I n s t a l l c e n t e r b o l t , h a n d t i g h t . lt s h o u l d b e p o s s i b l e t o t u r n s p r o c k e t o n c a m s h a f l w i t h o u t c a m s h a f t r o t a t a n g .

Slacken pump gear

Use 5193 to hold gear and slacken 5201. Remove nut and washer.

AF9

A F l O

Pull off gear

Use puller 5204 and stop 5193.

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A F 1 1 Remove pump R e m o v e f r o n t m o u n t i n g b r a c k e t f r o m e n g i n e R e m o v e p u m p f r o m r e a r m o u n t i n g b r a c k e t { A l l e n k e y = 6 mm).

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(41)

\-Group 23 Fuel system

AG. Injection pump, installation

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

I n ject i o n pu m p, i n sta I I ati o n

A G 1 Position injection pump

M o u n t p u m p o n e n g i n e a n d s e c u r e i t w i l h r e t a i n i n g b o l t s a n d f r o n t m o u n t i n g b r a c k e t . D o n o t t i g h t e n b o l t s f u l l y a t th i s s t a g e . A l i g n m a r k in p u m p w i t h m a r k in m o u n t i n g b r a c k e t . T h e n ti g h t e n re t a i n i n g b o l t s fo r p u m p - m o u n t i n g A G 2 I n s t a l l p u m p g e a t D o n o t fo r g e t t o p l a c e k e y in p u m p axle, I n s t a l l g e a r . Torque nut to 45 Nm {33 ft lbs).

ljse 5193 to hold sprocket and 5201 to tighten nut. T o r q u e w r e n c h s h o u l d b e a t r i g h t a n g l e s t o w r e n c h 5201, otherwise torque will be incorre€t.

AG3 Disconnect cold start device

Slacken screw 1. Push lever forward and rotate sleeve 90'.

Notol Do notturn screw 2, otherwise it will be necess-ary to remove cold start device and reset it on a test

Press lever back against stop.

(42)

Group

Iniection pump, installing

A G 4 S e t d i a l i n d i c a l o r z e r o . L o c k p u m p g e a r a t c y l . 1 i n j e c t i o n using stop 5193 U n s c r e w a n d r e m o v e p l u g f r o m i n j e c t i o n p u m p I n s r c l h o d e r 5 1 9 4 a r d d i d : r d i c d l o r l n e a s . r - i n s r a n g e 0 - 3 m m ) . S e t g a u g e t o a p p r o x . 2 m m . T u r n p u m p g e a r c o c k w i s e u n t i l m a r k o n g e a r a n d m o u n t i n g b r a c k e t c o i n c i d e . T h e n r u r n p u m p g e a r b a c k s l i g h t l y u n t i l m i n r e a d i n g r e g i s t e r s o n d i a l in d i c a t o f . S e t in d i c a t o r t o z e r o T u r n p u m p g e a r c l o c k w i s e u n t i l m a r k o n g e a r a n d p u m p mountlng b r a c k e t c o l n c i d e . L o c k g e a r in t h i s p o s i t i o n w i t h s t o p 5 1 9 3 . ( l n s e d stop through pump g e a r i n t o m o u n t i n g b r a c k e l . )

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AG5 Install pump belt

A d j u s l t e n s i o n b y m o v i n g c o o l a n t p u m p . U s e g a u g e 5 1 9 7 t o c h e c k t e n s i o n - A n a c h g a u g e to b e h a n d s e t to 1 2 . 5 u n i t s . S t r e t c h b e l t u n t i l m a r k o n g a u g e p l u n g e f i s f l u s h w i t h s e e v e . D e p r e s s b e l l s t r o n g l y w i t h h a n d a n d r e c h e c k / a d j u s t t e n s i o n . A G 6 S e t p u m p a n d t i g h t e n c a m s h a f t r e a r s p r o c k e t U s e 5 1 9 9 t o h o d s p r o c k e t . T o r q u e w r e n c h s h o u l d b e a t r i g h t a n g L e s t o w . e n c h 5 2 0 1 o t h e r w i s e t o r q u e w i I b e

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U s i n g 5 1 9 9 , t u r n s p r o c k e t s l o w l y D 2 0 . . . . D 2 4 . . . . D 2 4 U S A a n d C a n a d a 1 9 7 9 1 9 8 1 c l o c k w i s e u n t i l d ia l 0 . 8 0 m m ( 0 . 0 3 1 s i n ) 0 . 7 0 m m 10.0276 i n ) . . . 0 . 7 0 m m ( 0 . 0 2 7 6 i n ) 1 9 8 2 0 . 8 5 m m ( 0 , 0 3 3 5 i n ) ( V e h i c e s adjusted lor high a titLrde d r i v i n g : . e f e r l o p a g e 1 3 2 )

H o l d s p r o c k e t i n t h i s p o s i t i o n a r d t o r q u e b o l t t o 1 0 0 N m ( 7 3 f l l b s ) . T a k e c a r e t h a t c a m s h a f t a n d s p r o c k e t d o

R e m o v e s t o p 5 1 9 3 f r o m p u m p g e a r

(43)

Gtoup 23 Fuel system lnjection pump, installing

A G 8 C h e c k p u m p s e t t i n g

T u r n engine t w o f u l l t u r n s until cyl. 1 is at TDC-injec-t i o n , a g a i n . l f engine i s turned t o o fa r it m u s t b e t u r n e d b a c k a p p r o x . 1 / 4 t u r n a n d th e n to ' O ' m a r k o t h e l w i s e s e t t i n g w i l l b e in c o r r e c t . D i a l i n d i c a t o r s h o u l d s h o w : D 2 0 . . . 0 . 7 5 - 0 . 8 3 m m ( 0 . 0 2 9 5 - 0 - 0 3 2 7 j n ) D 2 4 . . . 0 . 6 5 - 0 . 7 3 m m ( 0 . 2 5 6 - 0 . 0 2 8 7 i n ) D 2 4 U S A a n d C a n a d a 1 9 7 9 1 S 8 1 . . . 0 . 6 5 - 0 . 7 3 m m ( 0 . 0 2 5 6 - 0 . 0 2 8 7 i n ) 1 9 8 2 - . . . - . . . 0 . 8 2 - 0 . 9 0 m m ( 0 . 0 3 2 3 - 0 . 0 3 5 4 i n ) C o r r e c t r e a d i n g : T i g h t e n in j e c t i o n p u m p mounting bolts. Proceed to AGg.

I n c o r r e c r r e a d i n g : R e a d j u s t a c c o r d i n g t o i n s t r u c t i o n s

i l

Readlusting

pump setting:

S e t t i n g v a l u e s : D 2 0 .. . . 0 . 8 0 m m ( 0 . 0 3 1 5 i n l D 2 4 . . . 0 . 7 0 m m ( 0 , 0 2 7 6 i n ) D 2 4 U S A a n d C a n a d a 1 9 7 9 - 1 9 8 1 . . . 0 . 7 0 m m { 0 . 0 2 7 6 i n ) 1 9 8 2 . . . 0 . 8 5 m m 1 0 . 0 3 3 s i n )

R e a d i n g less than specilied:

S l a c k e n p u m p m o u n t i n g b o l t s a n d t u r n p u m p i n w a r d s t o obtain c o r r e c i v a l u e . T i q h t e n m o u n t i n g b o l t s a n d

r e p e a t c h e c k o f p u m p s e t t i n g .

R e a d i n g m o r e t h a n s p e c i f i e d i

S l a c k e n p u m p m o u n t i n g b o l t s and turn pump o u t w a r d s u n t i l d i a l in d i c a t o r s h o w s a p p r o x l D 2 0 . . . 0 . 7 0 m m ( 0 . 0 2 7 6 i n ) D 2 4 . . . 0 . 6 0 m m ( 0 . 0 2 3 7 i n ) O 2 4 U S A a n d C a n a d a 1 9 7 9 1 9 8 1 . . . 0 . 6 0 m m ( 0 . 0 2 3 7 i n ) 1 9 8 2 - . . . 0 . 7 5 m m ( 0 . 0 2 9 5 i n ) T h e n t u r n p u m p in w a r d s u n t i l s p e c i f i e d v a l u e is ob, l a i n e d . T i g h l e n m o u n t i n g b o l t s a n d re c h e c k p u m p s e t , t i n 9 . l m p o r t . n t ! I n j e c t i o n p u m p m u s r n o t b e r a p p e d ot k n o c k e d a s th i s w i l l a h e r it s s e t t i n g . 1 4 5

(44)

lniection pum p, insta llation

AG9 Remove dial indicator and holder 5194. Install plug with new seal

T i q h t e n i n g t o r q u e I N m ( 6 . 5 ft l b s ) .

A G l O Connect cold start device

P r e s s l e v e f fo r w a r d a n d t u r n s l e e v e 9 0 ' . R e t i g h t e n

N o t e l D o n o t turn screw 2 , o t h e r w i s e i t w i l l be necess-ary to remove cold start device and reset it on a test

A G 1 1 Fill iniection pump with dieselfuel

Only necessary if pump has been drained or new

pump installed. Filter fuel before use.

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A G 1 2 Install rear timing gear cover

C l a m p w i r i n g h a r n e s s lo l e i t s i d e r e t a i n i n g b o h o n

A G 1 3 Reconnect fuel delivery and return lines

D o n o t in t e r c h a n g e c o n n e c t i o n s . R e t u r n l i n e c o n n e c t i o n s a r e s m a l l e r a n d m a r k e d O U T ,

T i g h r e n i n g t o r q u e 2 5 N m ( 1 8 f t . l b s ) .

L

(45)

(D

Reconnect tuel delivery pipes

T i g h t e n i n g t o r q u e 2 5 N m ( 1 8 ft l b s ) .

Install plunger and vacuum pump Check O rins, replace if necessary.

lnjection pu m p, i nsta llation

A G 1 4

AG 15

A G 1 6 Connect:

- hoses to cold start device. Remove clamping pliers - wire to fuel va ve

- thrott e cable and kick down cable (auto)

Set throttle control

S e e in s t r u c t i o n o n p a g e

A G 1 7

(46)

I

,i.

,l'

,il.

Fuel delivery pipes

AH. Fuel delivery pipes, replacement

Clean all conneciions thoroughlY

AH2

AH3

Remove

- vacuum p u m p and pump plunger

B l a n k o f f p o r t s a n d p i p e s t o p r e v e n t e n t r y o f d i r t . C h e c U r e p l a c e l n s t a l l a t i o n - connect d e l i v e r y p i p e s . T i g h t e n i n g t o r q u e 2 5 N m {'18 f t . l b s . ) - pump prunger a n o v a c u u m p u m p . O - r i n g .

- check function and security. A few q u i r e d before pipes are bled and

(47)

Delivery pipes

AJ. Delivery

pipes,

replacement

of one or more pipes

( D o not attempt t o w e l d o r r e p a i r d a m a g e d f u e l d e l i v e r y p i p e s . D a m a g e d p i p e s m u s t b e r e p l a c e d . )

( )

0

. / . /

Clean all connections caretully. Blow-dry pipes

AJ2

Remove vacuum pump and pump plunger

Remove pump retaining bolts. Place pump on

w h e e l a r c h a n d w i t h d r a w p l u n g e r fr o m c y l i n d e r h e a d .

I

I'

I

AJ3 L o c a t i o n o t c l a m p s i s i m p o a n t . I n c o r r e c t l y lo -c a t e d -c l a m p s -c a n -c a u s e v i b r a t i o n s a n d f u e l s u p p l y p r o b l e m s m a y r e s u l t .

Mark position of clamps on pipes

Disconnect all pipes

(48)

Group 23 Fuel system Fuel delivery pipes

AJ5

Remove clamps securing pipe(s) to be replaced

Replace pipe D o n o t t i g h t e n c o n n e c t i o n s a t t h i s s t a g e . C h e c k p o s i t i o n o f r u b b e r s l e e v e o n p i p e . AJ6 Install clamps

0l)il

e

{)il |

Tighten pipe connections

T i g h t e n i n g t o r q u e 2 5 N m ( 1 8 ft . 1 b s . )

Install pump plunger and vacuum pump

C h e c k / r e p l a c e O r i n g s .

AJ8

AJ9

A J 1 O Check operation and leakage

A f e w s e c o n d s i s r e q u i r e d b e f o r e p i p e s a r e b e d fu l l y a n d e n g i n e r u n s s m o o t h l y .

(49)

Group.23

Fuel system

AKl Malfundions

Listed below ar6 malfu nctio ns which can occur if one or more ofthe injectors is defective.

- one or more ol cylindsrs knock.

Notsl Do notconfusethiswith bearing clafter Chsck injoctor ope16tion

- overheating - unevon idle

- black exhaust smoke

- gXCeSSiVe fuel COnSumption.

AK2 Checking iniection oper.tion

1. Bun engine at above idle speed

2. Loos6n cap nuts on injoctors ong at a time. wl6p sbsorping paper around iniectors to prevenr s p i l l a g e .

lfengins speed rcmains constant or if knocking disap-pears, fault may be:

- delective injector - detBctive heat shield - leaking dolivery pip€.

Wectarc

333133;315

i usa/c€nad'

1e82-0 6 8 1 3 1e82-0 2 o l | - . 0 6 8 1 3 0 2 0 1 K I u l n e r msrkets DN 0 SD 193 0 = Usrcanad€ 1982-DN = SD t93 = Other mark€ts

AK. lnjectors

S.s spg.ilicatlons tor ld€nritic.rton ot injectortyp6.

Removing

iniectors

Inisctol

(50)

Group 23 Fuel system

AK3

Remove vacuum pump and pump plungel

Remove pump retaining nuts and place pump on Withdraw plunger from cylinder head.

AK4 Clean delivery pipe connections

Clean all connections thoroughly before disconnect-ing prpes.

Disconnect delivery pipes

Blank off po(s and pipes to prevent entry of orn. AK5 AK6 AK7 AK8 Remove inlectors 27 mm socket. R e m o v e h e a t s h i e i d s fr o m c y l i n d e r h e a d .

iniectors

Position iniectors

{t,,

a

R e m o v e s o o t etc. f r o m s e a l i n g s u r f a c e s . P l a c e n e w h e a t shields i n c y l i n d e r h e a d , s e e fi g . T o F q u e iniectors t o 7 0 N m ( 5 0 f t . l b s . ) .

Reconnect delivery pipes

T i g h l e n i n g t o r q u e 2 5 N m ( 1 8 f t . l b s ) .

Install pump plunger and vacuum pump

C h e c k / r e p l a c e O { i n g .

Installing

152

(51)

Y

Group 23 Fuel system

AL. Reconditioning

injectors

U t m o s t c e a n l i n e s s m u s t b e o b s e r v e d w h e n w o r k i n o w i t h i n i e c t o r s . Disassembly A L 1

iD

D

W A R N I N G I E x t r e m e c a r e m u s t b e t a k e n w h e n t e s t , i n g : r i e c l o r s . S p r a y r e l e d s e o l r o m i n j e c t o r i s a t s u c h a h i g h p r e s s u r e t h a t i l c a n p a s s th r o u g h s k i n a n d c a u s e b l o o d p o i s o n i n q if i n a d v e l t e d l y p o i n t e d c l e a n o u t e r s u d a c e o f i n j e c t o r d i s a s s e m b l e i n j e c t o r . C a r e m u s t b e ta k e n t o ensure t h a t p a ( s do not fall onto bench o r f l o o r . lf n o z z l e n e e d l e i s d r o p p e d i t m u s t n o t be reused

i m m e r s e p a r t s i n c l e a n d i e s e l f u e l as soon as rhey d o n o t in t e r c h a n g e p a s

Install iniector in test equipment

B a n k o f f f u e l r e l u r n p i p e s w i t h r u b b e r p u g s and hose AL2

Testing

a I n j e c t o r s s h o u l d b e t e s t e d w i r h c e a n t e s t o i l o r f i t e r e d d i e s e l f u e 1 . U n d e r n o c i r c u m s l a n c e s m a y p e t r o l / g a s o l i n e b e u s e d b e c a u s e o f t h e r i s k o f e x -O T h e u s e o f s u i t a b l e e v a c u a t i o n e q u i p m e n t t o r e m o v e d i e s e l f u m e s i s l a w i n c e r t a i n c o u n n i e s ( i n c l . S w e d e n ) . a l T p o ' t d r t l a c t o r s in t e s l i n g i r j e c l o r s a r e o p e n i n g p r e s s u r e a n d w h e t h e r i n j e c t o r is l e a k p r o o f . S p r a y p a t t e r n a n d n o i s e a r e m o r e d i f f i c u l t t o a s s e s s a n d d o n o t g i v e a n e x a c t i n d i c a t i o n o f c o n d i t i o n o f i n j e c t o r . I n j e c t o r m a y f u n c t i o n s a t i s f a c t o r i l y e v e n t h o u g h s p r a y p a t t e r n a n d n o i s e a r e f o u n d t o b e d o u b t f u l . U p p e r n o z 2 l e W a s h e r , a d t u s t s C l e a n i n g , c h e c k i n g c e a n a l l p a s w i t h c l e a n d i e s e l fu e l u s e n o z z l e c l e a n e r e q u i p m e n t t o c l e a n n o z z l e n e e d l e - replace damaged parts. Nozzle needle and sleeve

a r e m a t c h e d a n d m u s t b e r e p l a c e d t o g e t h e r .

A L 3 A s s e m b l y

- wash off rustproofing c o m p u n d t r o m n e w p a r t s w i i h c l e a n p e t r o l / g a s o l i n e

- immerse p a r t s i n c l e a n d i e s e l f u e l

- assemble i n j e c t o r . T o r q u e t o 7 0 N m ( 5 0 f t . l b s . l .

It

(52)

Group 23 Fuel system

AL5

Check spray pattern

{Pressure gau ge disengaged).

Pump lever with short, quick strokes (4 6persecond). Spray jet shou d be fairly compact and stop abruptly.

l n j e c t o r m u s t n o t d r i p .

AL6 Check inlection sound

(Pressure sause disensased).

Slowly depress lever ful y (1 2 strokes per second).

I n j e c t o r s h o u l d b u z , w h e n f u e l i s e m i t t e d .

A L 7

Check opening pressure

(Pressure gau ge engaged. )

S l o w l y d e p r e s s l e v e r a n d c h e c k o p e n i n g p r e s s u r e . O p e n i n g p r e s s u r e c h e c k v a l u e : 1 2 - 1 3 M P a ( 1 7 0 0 - 1 8 5 0 l f i n c o r r e c t , l e a k le s t b € f o r e a d j u s l i n g p r e s s u r e . A L A L e a k te s t l n c r e a s e p r e s s u r e r o 1 1 M P a {1560 p s i ) . M a i n t a r n t h r s p r e s s u r e f o r 1 0 s e c o n d s . F u e l m u s t n o t d r o p fr o m in e L l o r s . A r r o s l r o l / e r s h o w e v e r a c L c p l a o e .

i)rl I

|l I

Ia

j,: I

1 5 4

(53)

Group 23 Fuel system

Cold start device

L 9 A d l u s t i n g opening pressure

S e t t i n s v a l u e : 12.s-13.5 M P a ( 1 7 8 0 - 1 9 2 0 p s i ) .

R e m o v e i n j e c t o r f r o m test equipment. D i s a s s e m b l e i n j e c t o r a n d a d j u s t o p e n i n s p r e s s u r e b y r e p i a c i n g

- to increase o p e n i n g p r e s s u r e = fit a rhicker w a s h e r . - to decrease o p e n i n g p r e s s u r e = fit a thinnerwasher.

0 . 0 5 m m c h a n g e i n thickness i s e q u i v a l e n t t o a p -p r o x . 5 k P a ( 7 psi). - shims a r e a v a i l a b l e i n f o l l o w i n g s i z e s : ' 1 . 0 0 - 1 . 9 5 m m a t 0 . 0 5 m m i n c r e m e n t s . R e a s s e m b l e i n j e c r o r . T o r q u e t o 7 0 N m ( 5 0 ft . l b s . ) .

D

ID

Remove injector lrom test equipment A L l O

C o v e r e n d w i t h p r o t e c t i v e c a p .

T a k e c a r e n o t t o d a m a g e n o z z e w h e n i n s t a t i, , s , f l e c ,

AM. Cold start device

A M 1 General

C o l d s t a d e v i c e m a y o n t y be adjusted on a special t e s t b e n c h , w h e n c o n n e c l e d t o i n j e c t i o n p u m p .

H o w e v e r a s e r v i c e c h e € k can be carried out on an i n s t a l e d i n j e c t i o n p u m p .

N o t e l l f c o l d s t a r t d e v i c e does not function the fo tow i n g w i l l o c c u r

c o l d s t a rt i n g d i f f i c u l t i e s b l u e w h i i e e x h a u s t s m o k e

- engine will not st.rr ar remperatures betow 10"C ( - 1 4 " F ) .

AM2

Operation check

M e a s u r e i d l e s p e e d w h e n e n g i n e is cotd and hot. C o l d e n g i n e ( b e l o w 20"C = 68"F) = approx.3.3 r/s ( 2 0 0 r/min) more than w.rm ensine idte.

W i t h w a r m e n g i n e , le v e r on co d slart device snoutd n o t c o n t a c t le v e r o n i n j e c t i o n p u m p .

l d e s p e e d ( w a r m e n g i n e ) = 12.5 r/s {750 r/min).

References

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