ServiceManual Section 2(21)

Reconditioning

Repairs engine
D20, D24

andmaintenance 1979-19...
D20,D24
Boththe D 20 andD 24 Dieselenginesaredealtwith in thismanual.
TheD 20hasfivecylinders andthe D 24six.Otherwjsethe engines aresimilarin principle.
Notel Differentflywheelsand vibrationdampersare fitted to the differentenginetypes.

1234 c

ltr
innrir
FFFF
||l|t tt
UUUU U

llu!r

Volvosare sold in versionsadaptedfor different

markets, Theseadaptations dependon manyfac-
tors includinglegal,taxationand marketrequire-

Thismanualmaythereforeshowillustrations and
text which do not apply to cars in your country.
 Contents
Page
lmportantinlormation 2
Specifications 3
't6

19
24
29
36
43
46

55
59
65

Index pace 74

This manualdealsexclusivelvwith the overhaulof

lhe engine.For work carriedout on the engine
when fitted in th€ car,and for engineremovaland
installation,pleaserefertotheservicemanualSec-
lion 2{20-22)and Section2123-29).

fP 3022412US
UK/USA
6000.05.83
PRINTEDIN USA

We reservethe right to makealterations

lmportantinformation

CLEANLINESS
Daes€liniection
systemsare extremelvsensitivsto din
and foreignmatter.A specialworkplaceshouldthere-
fore be usedfor insDectionof comoonents.

PI,IJGS
Cl6anfuel lineconnectionsthoroughlybeforediscon-
nectingthem. Plugendsolfu€l linesetc as eachcom-
ponentis removed.Do not removethese plugs until
the componsntis reconnected.

Tighteningtorques
Two kindsoI tighteningtorqueswill be Iound in this
manual
1. Tightento 40 Nm {30ft lbs}indicatesth6t a torque
wench must be usedfor tightening.
2. Tighteningtorque 40 Nm (30It lbsl indicat€s6
guidevalue.Tighteningneed not be done with a
toroue wrench,
 Specifications

Specifications
Group20 General

Enginstypedesignationand serialnumber
Stampedin leftsideofcylinderblockbeneathvacuum

VOLVOtype designation
VW type designation
Specitications

Group21Engineblock
CYLINDERHEAD

0 . 5m m : 0 . 0 2 0 i n

DlasonsllY= max 0.5 mm = 0.020in C.osswis€= max 0.2 mh = 0.008

in

Cylinderhead may not be machined.lt must be

replacediI waro exceodsmaximum.

Cylind.. h..d gskot

Th?6. .lt.rnrilv. s!3k6t!.ro us.d d.p€ndins on hotghrof ptsronabov.cyttnd.r btoct.

Hoightof piston .bov! G!3ket

cvllnd€rblock notchos thickneBs
mm in mm in
0.67-0.80 0.026-0.031 1 1.4 0.055
0.81-0.90 0.032-0.035 2 1.5 0.059
0.91-1.02 0,036-0.040 3 1.6 0.063

Notsl Pistonheight in same enginemust not extend

over mor€ than two classes.Piston height is
measuredat front and b6ck of piston (along
gudgeon/pistonpin).
 Specifications

CYLINDER
BLOCK
Borc Mrrking Pistondiameter Cyliider bore

Standard 651 76.44 3.01r0 76.5'1 3.0122

652 76.49 3.0114 76.52 3.0125
653 76.50 3.0118 76.53 3.0130
OversizeI 676 76.13 3.020s 76.?6 3.0220
{0.25mm = 0.010in) 671 76.74 3.0212 76.77 3.0224
678 76.75 3.O217 76.74 3.0224
Oversize2 701 76.98 3.0307 77.01 3.0318
{0.50mm = 0.020in) 702 76.99
'11.00
3.0311 77.O2 3.0322
703 3.0315 77.O3 3.0326
Oversize3 . . . , . , . . , . , , . . , . . . . . 751 77.48 3.0504 77.51 3.0515
{1.00mm = 0.040in) 752 77.49 3.0508 71.52 3.0519
'77.50
753 3.05r2 77.53 3.0523
Max wear djmension(compared
with normaldiametet 0.04mm 0.016in

PISTONS
Weight(incl.sudseon/piston pin)................. 455-465grammes
Maxweightdeviationbetweenpistonsin sa;; ;;;i;;.:.:.:.:.:. 12 grammes
Overallheighl............... 71.7mm 2.8228in
Heightfrom gudgeon/piston pin centerto piston 41.7mm 1 . 6 4 1i7n
Pistonfloat,new ,,,.,,,.,., 0.03-0.05mm
0 . 1 3m m 0.0051in
Pistondiameter,
seecylinderboretable
Weardimension,max (comp6redwith normaldiameter)........ 0.04mm 0.0016in

P i s r o nd i a m e t e r i m
s e a s u r eadt
Pistonrings right angl€s to gudgeon/
Pistonringgapis measured p i s t o np i n b o r c ,1 5m m ( 0 . 6i n )
ls mm (0.6 in from lower
edgeof cylinded.

Upper Oil scrapel

ring
flng ring
Ring1hickness
.............. 1.730 1.980-1.990 2.975-2.990
0.0681-0.0685 0.0780-0.0783 o . 1 1 7 1 - O . 1 t 7 7
Side clearance
lmeasuredwilh ringonpision),new.................................0.06-0.09 0.05-0.08 0.03-0.06
in 0.0024-0.0035 0.0020-0.0031 0.0012-0.0024
max .,.......,... o.2 0.2 0.15
Ringgap i n 0.0079 0.0079 0.0059
(measured in cylinder,
seefig.),new ................... 0.3 0.5 0.3-0.5 0.25-0.40
i n 0.0r2-0.020 0.012-0.020 0.00980.0157
1.0 1.0 1.0
0.040 0.040 0.040
Gudgeon/pistonpins
F i t ,i n c o n n e c t i n gr o d (closerunningfit)
Lightthumbpressure
Thumbpressure(pushfit)
Specitications

VALVESYSTEM
Valveclearances

Coldengine= engineat roomtemperature

A = exhaustvalves
Checuadiustvalvesin following order:
D 20 = 1-2-4-5-3
D 24 = 1-5"3-6-2-4

Checking Setting

0.20-0.30 0.008-0.0120.25 0.010

0.15-0.25 0.006-0.010 0.20 0.008
0.40-0.50 0.016-0.020 0.45 0.018
0.35-0.45 0.014-0.0r8 0.40 0.016
3.00-4.25
at increments
of 0.05mm
0.012-0.167
at increments
of 0.002in
7.95mm = 0.3129in
3 l m m = 1 . 2 2i n

lmportantlExhaustvalvesare sielllte coated and

mustnol be groundby machine. Grind-invalveon
seatwith grindlngpaste.

32,8mm = 1.2193in
1,5mm = 0.0590in
2,0 mm = 0.747in
l-5 mm = 0,0590in

Intako Exhaust
Valvesealdiameter, standard.,,,.,,,.,,,.----,.-,.,.,.,.,.,........
mm 37.090-37.105 33.090-33.105
1.4602-1.4608 1.3027-1.3033
oversaze I .,,,...,.,.,.,.,.,.,......,...,.......-.,.
mm 37.290-37.305 33.290-33.305
1.4681-1.4687 1.3106-1.3112
Seatwidthin cylinderhead:
diameter,
standard........ 37.000-37.016 33.000-33.016
1.4566-1.4573 1.2992-1.2998
oversize 1 .,.,.,.,.,.,.,.,...,.,.....,.........,.,.,.,...,.,.,.,..,.,.
mm 37.200-37.216 33.200-33.216
1.4645- 1.4651 1.3070-1.3077

6
 Specifications

D+(0,074-0,105
mm)
r-- l:]l
lE-
Note! When replacingvalve seats:the interferencebetlveen
the valveseatand its bore in the cylinderheadshall be 0.074-
0.105mm 10.029-0.041 in).Thatis,valveseatdiametermustbe
0.074-0.105mm greaterthanthe diameterof the borein the
cylinderhead.

Valve guides mm(in)

Len9th,.,.,.,.,.,,,.,.,.,.,.,.,., 36.50-36.75 (1.4370-1.4468)
Innerdiameter.............. 8.000-8.01 5 (0.3r49-0.3155)
Heightabovecylinderheadlowersurlace 40.1-40.5 (1.5787-1.5944)
valvestem-guide
Clearance, (seetig.),new ......... 0.3 (0.018)
1 . 3( 0 . 0 5 1 1 )
Clearanceis measuredwith new valve and with valve stem
flushwith valveguide.

Valvesprings

oE
L€ngth
.fE=
T=
sPrings
Load
N
Length
Outer valvesprings
Load
N
33.9 1.334 0 0 40.2 1.583 0 0
28.6 61-71 32.6 1.243 167-185 3A-42
la.3 o.720 209-231 41-52.2 22.3 0.878 433-479 98-108

Tappets
Diameter,.,.,.,.,.,.,.,.,.,..., 34.950-34.975(1.3759-
1.3769)
Hei9ht............................ 28.0-28.8(1.1023-1.1388)
Clearance,shim-lappet . 0.016-0.046{0.0006-0.0018}
tappei-cylinder head 0.025-0.075(0.0010-0.0029)

Shims ltor aalustinsvalveclearance)

Thickness....,.......,...,..... mm at increments
3.00-4.25 of0.05mm
at increments
0.118-0.167 of 0.002in
Diameter
....................... 30.950-30.975(1.2185-1.2',]94)
 Specifications

TIMINGGEARS

Toothed belts
Belttension (measuredwith tool5197)
checkvalue ..............,.... 12-13
settin9......,...,................ 12.5

Camshaft
Max liftheight, intake 8.5 {0.334)
9.0 {0.354)
Bearingjou rnal diameter,front 31.925-31.950{1.2568-1.2578}
otherc 29.939-29.960(1.1787-1.7351
Bearingclearance.new 0.05-0.10{0.0019-0.0039)
Endclearancs. max 0.15{0.006)

Camshaftsettingis checkedby using gauge5190

Gamshaftbearings
Bearingdi6meter,front.
o
32.000-32.025
{1.2598-1.2608)
otherthree.,.,.,...,.,.,...,.. 30.000-30.021
{1.r811-1.1819)

Crankshaft
IVaxrun-out,tlvocenterbearings 0.06(0.0023)
0.04(0.00151
others..,...,.,...,,.,.,.,.,.,.,...,..........,...,
Crankshaft
endclearance, ngw ........
-................. 0.07-0.18 {0.0027-0.0071)
0.25(0.0098)
Mainbearingclearance, 0.016-0.075 {0.0006-0.002s1
m4x,.................,......,.,.,. 0.16(0.0062)

Connectingrod beaings, sid€ cl€arance,max .... 0.4 (0.0157)

repairingclearancs,new 0.015-0.062{0.0005-0.0024}
m4x.....,...,...,.,.,.,.,.,...,... 0.12(0.0047)
M66sured
withtwo outermainbsaringsin V-blocks.

Mainbearingjournals
Outof round.max 0.003{0.0001) )
Taper,max 0.005{0.0002}

Diamelerstand6rd 58.00(57.955-57,975) mm
2.2A3412.2a16-2.2A241 in
57-75 157.705-57.7251mn
2.2736 12.271A-2.2126t,in
undersize2 57.50(57.455-57.475) mm
2.2539 12,2521-2,25291 in
undersize3 57.25 157.205-27 .2251mm
2.234212.2324-2.23321in

b-
 Specifications

Connectingrod bearingiournals
Outof round,max 0.003(0.0001)
r a o e rm . . . . . :(0.0002)
. a x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :0.00s .....................

Diameter,
standard 47.AOg7.754-47.7741
1 . 8 1 8( 1 . 8 4 0 2 - 1 . 8 8i 1n 0 )
47.55 147.50a-47.52A1mm
1 . 8 7 2(01 . 8 7 0 3
1 . 8 7 1 1i n)
41.30 141.254-47.2741mm
1.8622 {1.8605- 1.8613) in

Main bearingjournals(when grinding)

Width, bearingrecess Badius
Min
Thrustbearingjournal 22.5 23.O 1.0
0.8858 0.9055 0.0393 0.0590
Othermainjournals...... 2t.5 22.0 1.0 1.5
0.8464 0.8661 0.0393 0.0590
rodjournals
Connecting 24.6 25.0 2.O 2.5
0.9658 0.9842 0.0787 0.9442

Connectingrods
O n l y i o b e r e p l a c e di n s e t s
Sideclearance
on crankshaft,rnax................ 0.4mm (0.0157 in)
136mm (5.3543
Lensthbetweencenters.....................................:...:...:.:.:........... in)
Maxweightdeviarionbetweenconnecting rods
In sameengrne 6 grammes

Flywheel
W a r pm
, ax..................... 0.05mm at 150mm diameter
in at 5-90in diameter
0.0019
Specifications

TIGHTENING
TOROUES
Tighteningtorquesapply to oiled nuts and bolts.
Degreased (washed)pans must be oiled prior to

TIGHTENINGSEOUENCEFOR CYLINDERHEAD
oo oo o ,Ol BOTTS
D20
@o oa @ '@-r lhport.nt! slackenbolts in reverseorder wheh
removingcylinderhead.

Bemoveoil anddirtfromboltholes.Oilleftinholeswill
reducepressureon cylinderheadgasket.
Bolt threadsand washersmust howeverbe oiled,
@@a o oorE otherwisefrictional
forceswill be too large.
D24 Twotypesof bolts are in use: An earlytype with lM1l
@oo o ooo threadsanda latertypewith M '12threads.(Latertype
is threadedalongentirelength.)

TIGHTENING HEADBOLTS
OFCYLINDER

Mtl M12
I

Usenew washers,convexside upwards.Tightenin Usen€w bolls. Not necessarvto reDlacewashers.

Tightenin six stages:
1. 50 Nm (37ft lbs) 1. 40 Nm {30ft lbs)
2. 70 Nm (50ft lbs) 2. 60 Nm (44ft lbs)
3. 90 Nm {65ft lbs)
4. run engineuntil oil temperature
1122"F)
is at least50'C
3. 75 Nm (55ft lbs)
4. angle-tighten
ping
180'in one movement withoutstop- Or
5. 90 Nm (65ft lbs) 5. run engineuntil oil temperatureis at least 50"C
Retightsning \'122'F)
6. angle-tighten 90'in one movementwithout stop-
- After 600-1,200miles (1,000-2,000km). Ensine ping
shouldbe cold or almost cold. Tighteneach bolt
separatelyin specified
order,seeabovefig.l Rerightening
1. Slackenbolt30' After 600-1,200miles {1,000-2,000 km}. Engine
2. Torqueto90 Nm (65ft lbs) shouldbe coldor almostcold.
Tighteneachbolt separately in specifiedorder,see
abovefig.l
1. Angle-tighten bolt 90'in one movementwithout
stopping.
Do not sl.cftenbolt tirst.

10
 Specifications

Grankshaftassembly

75 Nm'?r--
5ftlbs
45 Nm3)=
3ftlbs

75 Nm'zr:
5C Tr tOS
350 Nm'l =
258 ft lbs
,-@1
fu >4

20 Nm= *pj 1Threadsand bolt headcontactsurfacetobe smeared

Oruft lbs MI with lockingcompound (P/N277961-9).

n-=
-€
Tightening torque350Nm (258ft lbs)apptres
usingspecial
operationJ4.
tool 5188.Seeinstructions
wnen
on page64,

odttm 2 Usenew bolts.Sh6ar threadswith P/N277961-9.

48 ft lbs
a Thereare2versionsof thrustbearingsr
f langedbear
ingshellsandalsoplainbearingswiththrustbearing
washerhalves.Only flanged bearingsare available
Specitications

Timing gears,cylinderhead

20Nm=15ftlbs
100Nm = 74ft lbs
d

Tighteningsequence:

opg.ation Hg on page5a.

-^@
@,
w
e.rlytype = I groove
latetype = 3 grooves.
Soe operationG3 on page 52.

oooo
 Specifications

Lubricatingsystem

Fo{-r
I
)

------1
+--i"-1
6@,Tf
M6x28
ltll
ta
MGxl8 / M6x103

1 8m m = 0 . 7 1i n
2 8 m m = 1 . 1 0i n
7 5 m m = 2 . 9 5i n
t03 mm = 4.05in
Speclfications

Intakeand exhaustmanifolds

Alwaysusen6wnuts

Coolingsystem
 Specifications

Group22 Lubricatingsystem
Oil pressuresensor
C u t - o u t p o i n t , i n d i c a i o r l a m p g o e s o u t a t . . . . . . . . . . . . . . . . .1. 5
. .-.4. .5.k.P
. .a. . . . . . 2.1-6.4psi

Lubricatingoil pump
Reliefv6lvespring
lengthat differentloads:

Lengrh Load
N lbs

oE
L=49 1.93 0 0
0.87 r79-195 39-44
L,=198 0.74 approx200 45
(completely
compressed)

Group23 Fuelsystem
INJECTION
PUMP
Checkvalue Setting value
timing(pumpplungerstrokearT.0.C.)
Injection mm in
0.75-0.83 0.029-0.033 0.80 0.031
0.65-0.73 0.025-0.029 0.70 o.o27
D 24 USrJCanada
1979-81 0.65-0.73 0.025-0.029 0.70 0.o27
D 24 USrJCanada
1982- 0.82-0.90 0.032-0.035 0.85 0.033

USA - vehiclesup to 198:|must be ad-

iustedfor high allitudo drivingif main use
is above :1000ft {r,219m} |
Refer to appropriateservice manual for

TIGHTENING
TOROUES
Nm ft tbs
lniector,
in cylinder
head...........
70 52
uppeFlower sections... 70 52
pump,pumpgear.......45
Injection 33

l
Special tools

Specialtools

9!9 Dosdiption - Use

1801-3 S t a n d a r dh a n d l e :l s e d w i t h 5 2 0 7a n d 5 2 0 8
2520.8 Stand: lsed with fixture 5206
2903-6 Oil filter wrench

4090.0 P u l l s r :r e m o v i n gp i l o t b e a r i h g
5017-2 Drift: removing/instaling crankshaftbushings
5112-1 L o c k i n gs e c t o f :i o c k i n gf t y w h e e l

5187-3 w r e n c h :v i b r a t i o nd a m p e r
5i8a-1 Wrenchwith exte.sion arh: tof vibrationdampercenierbol (
{
5190-7 G r u g e :i n s t a l l i n gc a m s h a f t
5192-3 Supportfordi.lindicaror:heasuringpistonheight

fr

0)
r)

a<

?"i
5',187,5188
D
5ta2
'16
 Special tools

1001S |CONT.t
SPECTAL
Doscriorion- U.6

; S t o p : l o c k i n si n i e c t i o np u m ps e a f
5194-9 r h e na d i u s t i n si n j e c t i o np u m p
H o l d e r :f o r d i a l i n d i c a t ow
5195-6 Pli.rs: removinsvalve discs

5196-4 Presslool: for valvelappels

5197-2 B 6 l t l o n s i o ng a u g e : t i m i n qg e . r b e l t s a n dp u m pd r i v e
5194-0 Straight odgo: setting T.D.c.for cylinder 1 (flywheelcasi

5't99-8 Wrench:front and rea. camshaltgears

4200-4 A d l p i e r : i n s t a l l i n gc r a n k s h a f rt o n ts e a la n d c a m s h a fsl e a l s
5202-0 P u l l s r :f o r i d l e rp u l l e y

5203.8 crntering shali: for clutch driven plare

5204.6

D 5205.3

5206-l
5207-9
P u l l o r :f o r c r a n k s h a f rt o n ts e a l

O r i t t :i n s t a l l i n gn e e d l eb e a r i n gi n c r a n k s h a f t
5204-t D r i t t :i n s t a l l i n gc r a n k s h a .f e
t a rs e a l

D 5214-6
5219-4
5220-2
D r i l t : r e m o v i n g / i n s t a l l i vnagl v eg o i d e s
r o o l : r e m o v i n g / i n s l a l l i vn ag l v es e a l s
D r i t i : i n s t a l l i n si n r a k ev a l v es e a t

5221-O D r i t t :i n s r a l l i n se x h a u svi a l v es e a t
5222-8 G a l g e :c h e c k i n g v a l v eh e i g h ti n r e l a r i o n
ro camshait
4224-4 R e . m 6 r :v a l v es u i d e

5223.4 G l ' i d ep i n sM 1 1b o t s { 4 x ) : i h s t a l l i n g
cylindeh
r ead
5234.3 G u i d ep i n sM 1 2b o l t s{ 4 x ) : i n s t a l l i n gcylind€h
r ead
5194
5235-0 T o o l if o r r e m o v i n ss u i d ep i n s

o
o 5195

17
Special tools

(
{

(
{

I
0r
0
i.3
5220,5221
 Group21Reconditioningengine
Removing parts

Reconditioning
engine
Specialtools: 1801,2520,2903,490, 5017,5112,5187,5188,5190,5192,5193,5194,5195,5196,5197,5198,5199,
5200,5202,5203,5204,5205,5206,5207,5208,5218,5219,5220,5221,5222,5224,5233 (5234),5235

A. Removingpartsfrom engineblock

A1
Remove:
- wiresfrom startermotor

- rightenginemount
- lransmission.

A2
Mount engine in 3tand 2520with fixture 5206

Remove:
- wiresfrom alternator
- altgrnatorwithmounting bracketarm
- intakemanifold(6 mm Allen)andgasket
- exhaustmanifoldand gaskets,
Gtoup21 Reconditioningengine
Removingparts

A4
Remove:
- valve cover and gaskets
- timing gear covers (front + read.

A5
-
TuIn €ngin6 until cyl. 1 is at TDC iniection
Alwaysusethe vibrationdampercenterbolt to turn

L,sea 27 mm socket.
Bothcylinderl camsshouldpointdiagonally
upwards
and markon pump gearshouldbe oppositeline on
mountingbracket.

46
R€move vibration damper
Use5187to preventpulleyfrom rotating,and wrench
5188to unscrewbolt.
It maybenecessarytoturnengineslightlysothat5l8T
restson fan bearing.

Remove 4 Allenscrews(6 mm).

Pull off vibrationdamper.
Notel Crankshaftge6r may sometimesstjckto vibra-
tiondamper.

20
 Group21Reconditioningengine
Removing pafts

47
nemove:
- lowertiminggearcover
- fan/alternatormounting bracket.

A8
Disconned coolant hoses
Disconnect
hosesfromcoldstartdeviceandheater.

A9
Removevacuum pump with plunger and fuel
delivery pipes
Cleanallconnectionsthoroughly
beforedisconnect-
rns.
Blockoffallportsandconnectionsto
preventdirten-
teringfuelsystem.

410
Remove:
- return and supply fuel lin€s from iniection
pump.
Plugendsto preventdirt ingress.
- fueltilterwithbase
- mountingbracketIo r fuel filter.
Group 21 Reconditioning engine
Bemoving parts

All
Remove wiring hainess
Cut both harnessstr6psat rear of block.
Disconnectwiresfrom temperaturesenders(2x), fuel
valve,oil pressure
senderand No.2 glow plug.
Removeharnessclamps{2x) at bottomof blockand
lift awaywiring harness.

Lift off pump belt

412 0
Slacken mounting pumpbracketto
boltsforinjection
release Tightenoneboltso thatpump
belttension.
remains in upperposition.
Liftoffbelt.
0 (

r'.l3
Removepump gear
Usestop5'lg3to holdgearin positionwhenremoving

0
0
Removegearwith puller5204.

22
 Group 21 Raconditioning engine
Removingpafts

414
Removeiniection pump
Removefrontmountingbracketforpump.

ao#'==
*-,v,-,-,:-
pumptromrearmountingbracket.
Detach
6 mmAllenkeyto removeinnerbolt.
usea long

lr l
)p)
\-

415
Remov€:
- copp€rconnectingstripsfrom glow plugs
- oil dipstickwith tub€

I - rcar pump mounting bracket,

Group 2l Reconditloning engine
Disassembly

B. Disassembling
engine

TIMINGGEARS
B1
Remove timing geal belt and clankshatt gear
Slackencooling pump mounting bolts and belt.
Removebelt and crankshaftgear
CAUTION! Oncethetiminggearbeltis removedneither
the crankshaftnor camshaftmay be turned beforethe
0,t I
cylinder head is removed,otherwisethe valves can
strikethe pistonsandcauseseriousenginedamage.

B2
Removeflonl and rear camshaftsDrockets
H o l dt h e c a m s h a f ii n p o s i t i o nw i t h w r e n c h5 1 9 9 .
l a p I h e l r o n t g e a rt o r e m o v ei t f r o m c a m s h a h .
Note! Takecare not to rotate the camshaft-

Removeidler pulley and plrte

Unscrewand removecenterbolt,
Withdrawpulleyusingpuller5202.
Removecoverplate,

24
 Group 21 Reconditioning engine
Disassefibly

B4
Romovecoolantpump,thormostathousingand
thermostat
Placea drip pan beneathengineand tilt enginelor-
ward to drain coolant.

CYLINDER
HEAD
B5
Removeinieclors
Remove
dirt aroundinjectors.

o Disconnectluellines,
Removeinjectors,(27 mm socket).Lift out heat shields
fromcylind€rhead.

B6

a
@@@o@@

n
@@@@@@
Removecylinder head
lmponantl Slackenbolts in reverses€quenceto
i.e.startat 12(or14)andfinishat l.
tightening.

llluslrutionshowsiight.nlng sequsnc€.Bolts
must be slackenedln reve

a
@@@@@@@

@@@o@@@

Lift 6w6ycylinder head,checkingthat valvesdo not

contactcylinderwalls.
Placecylinderheadon wooden blocksso that it does
not reston valves.Remov6g6sket,

25
Gtoup 21 Reconditloning engine
Disassembly

FLYWHEEI.,
CRANKSHAFT
OILSEALS

B7
Remove pressure plste, driven plate and
flywheel
Unscrew clutch pressure plate mounting bolts
crosswisea fewturns at a time to preventwarp,
Uselockingsector5ll2 to preventftywheelfrom mov-
Ing.

B8
Removehose connector at .oar of block and
crankshaftlear oil seal
Pryout sealwith a screwdriver
placedbetweenseal

B9
Checkpilot bearing
Replace
bearingif damaged.
lJsepu er4O9O

0 (

810
Removeclankshaft front oil seal
Usepuller5205.

26
 Group 21 Reconditioning engine
Disassembly

SUMP,
OILPUMP

81l
Removeoil pressuresenderand lilter
Usestrapwrench2903to removeoil filter.

812
Remove:

- rearsealingflange.

PISTONS,
CONNECTING
BODS
813
Check connecting rod side clearance
Llsea feelergauge.
Clearance = max0.4mm 10.016 in).
lI clearanceis too large,connectingrods must be
replaced.Notethat connectingrods must be replaced

814
Mark pistons

815
Removeridge at top edge of cylinder bore

21
Group 21 Reconditioning engine
Disassembly

816
RemoveNo. 1 piston with connecting.od
Removeconnecting rodcapandbearingshell.
Pushout pistonandconnecting
rod.

Assemble connecting rod,bearingshellsandcapsto

preventinterchangeof parts. Note! casting lugs on
connectingrod and capsmustfacethe sameway.
0 (

lrarkconnectingrod-cap.

(
{,,
817
Bemoveremainingpistonsaad connecting.ods
as above
N o b ! O o n o t i n l e r c h a n g eb e a r i n gs h e l l s .

CRANKSHAFT
818
Remove crankshaft
Checkidentification markson main bearingcaps.
llark as necessary.
Removemainbearingcapsandshells,
Lift awaycrankshaft. (
{
Removebearingshellsfrom cylinderblock.
NotelDo not interchangeb€aringshells.

0 {

28
 Gtoup 21 Reconditioning engine
Cleaning, checking

G.Cleaning,
checkingengine

c1
Cle.n
- cylinder block {piecesot g6skst. mating surfaces,
bearingseats,oilwaysetc).Polishsealingsurfacetor
coolantpump O-ring.
- bor€sfor cylinderhead bolts.and bolts
- polishcylinderboresto rcmovescratchmarksetc
- crankshaft-blow-out oilways
- mainbearingcapsand bearingshells
Checkall partsfor clamageand wear.

k
c2
Mgasurccrankshaft
Ussa micrometerto measure out-of-roundandtaper
of bearingiournals.Measureat severalpoints.
Maxout-of-round :0.003 rr|tn{0.0001
in)
Maxtaper= 0.005mm (0.0002 in),

c3
---o-- 1q-----.-.,,oMoasure cylinder bora

sl Usea dialbo16indicator(50-100mm = 1.95-3.95in).

lveasure diameterA (crosswiselEnd B {lengthwise)at

ol
Boremust not doviateby morethan 0.04mm (0.0016
inlstanytwo points.

;=-@-_.
Group21Reconditioningengine
Cleaning, checking

Cylinder borc is stamped on cylindet block (last 3

figurcs= honinggroup).
lf cylinders are rebored, new bore must be

Kba )i
stampedon side of block.

Marking Piston Bore

{honing- Diamster Diameter
group) mm in mm in
Standard 651 76.48 3.0110 76.51 3.0122
652 76.49 3.01r4 76.52 3.0126
653 76.50 3.01r8 76.53 3.0130
Oversize1 676 76.73 3.0209 76.76 3.O22O

Oversize
677
673
2 701
76.74
16.75
76.98
3.0211 76.77
3.0217 76.7a
3.0307 77.01
3.0224
3.O22a
3.0319
0 (

702 76.99 3.0311 77.02 3.0323

703 77.00 3.0315 77.03 3.0327
Oversizo3 751 77.4a 3.0504 77.51 3.0516 (
752 77.49 3.0508 17.52 3.0520 {
753 77.50 3.0512 77.53 3.0524

c4
Measure piston diametel
Takemeasurements at rightanglesto gudgeon/piston
pin bore,15mm (0.6inlfrom loweredgeof piston.
Diametermust not deviateby more than 0.04mm
in) fromvaluein tableabove.
{0.0016
0 (

0 (

stampedon top of piston.

Diameter

30
 Group21Reconditioningengine
Cleaning, checking

Removepiston rings from piston

L,sepistonringpliers.

c6
Disassemble connecting rods - pistons
Removecirclipsfrom gudgeon/piston pins with a
smalls€rewdriver.Pushoutpinswitha suitable drift.lf
difficult to remove, heat pistons to approx. 60qC
(140"F).

C7
Cleanpistons
Bemove carbondeposits.Usea groove part
cleaneror
of a groundpistonringto cleangrooves.
C8

ID Checkpistons
Check
forcracks,
wearetc.
P i s t o n sw i t h r o u n d e dt o p e d g e sm u s t n o t b e r e u s e d .

)
F ( S i n c aI h i s i s L a u s e ob v d e f e c tv e I n j e c t o r st.h e I n _ e c .
t o r s s h o u l d b e c h e c k e d / r e c o n d i i i o n ea ds w e l . )
il
c9
Measure piston ring side clearance
U s e a f e e l e rg a u g e .
Side clerrrnce mln {inl
Nsw
(in)

. 0 9 ( 0 . 0 0 2 40 . 0 0 3 50) . 2 ( 0 . 0 0 7 9 )
s i o nr i n s . . . . . . . . . . . - . . 0 . 0 6

s i o n r i n 9 . . . . . . . . . . . . . . 0 . 0 5 - 0 .(008. 0 0 2 0 - 0 . 0 0 301,)2 ( 0 . 0 0 7 9 )

0 6 ( 0 . 0 0 1 2 - 0 . 0 0 20 4. 1) 5( 0 . 0 0 6 0 )
r i n g . . . . . . . . . . . . . . . . . . . - . . 0 .00. 3
Group 21 Reconditioning engine
Cleaning, checking

c10
Checkgudgeon/pistonpin lit
Makesure that pin is not loos€ and that bor€ js not

cl1 0
Measure piston ring gap
lJsingan invertedpiston,insertringsin cylinderone
at a time.(Thisensures
thatringstakeup correctposi-
tion.)
Measurering gap15 mm (0.6in)from loweredgeof
cyljnder.
{ I
Usea feelergauge.
Gap
New
lin,

r i n q s . . . . . . . . . , . . . . - . . . . . 0 , 3 - 0 .05, 0 1 1 8 - 0 , 0 1 9 1.0
7 0.0394

r i n g . . . . - . . . . . - . . . . . - . . . . - 0 . 2 5 -00. -04009 8 - 0 , 0 1 5 1.0

7 0.0394

cl2
Clean and check connecting rods
Checkfor wear,cracksetc.Alsocheckthreads.

c13
Check gudgeon/pislon pin tit
P,nmustbe pushtir in smallend. 0 I
t) I
Replacing connecting rod studs (if damaged)
Operations C14-15
c14
Tap out old stud
R e m o v eb e a r i n gc 6 p a n d b e a r i n gs h e l l s .
H o l d c o n n e c t i n gr o d o n a h a r d l e v e l s u r f a c eT
. apstud
o u t w i t h a p l a s r i cm a l l e t .

32
 Group21 Reconditioningengine
CIeaning, checking

c15
Fit new stud
Placenewstudin connectingrod.Tapboltintoposi-
tionwitha plastic
mallet.
Install
cap.Nota!ldentifi€ation
marks.
Placea sockerle.g.12mm)benealhcapandprpssin
studuntilitbottoms.

Replacingconnectingrod bushings
OperationsC16-19

c16
Pressout bushing
Usedrift 5017{narrowend)and a suitabte
socket,
placed
beneath connecting
rod.

cl7
Pressin new bushing
Usedrift5017{wideend)anda suitable placed
socket,
b e n e a t hc o n n e c t i n gr o d .
B u s h i n gs h o u l d b e f l u s h w i t h c o n n e c t i n gr o o .
N o t o ! T o e n s u r e c o r r e c t l u b r i c a t i o n ,i n s t a l l b u s h i n g
I with split diagonallyupwards but not blocking oil

(c
c18
I Drilllubricating
holein bushing
lo lMountconnectingrod in vice protectedby softjawsto
preventdamage.Use6 6 mm (0.24in) drillbit.

c19
Ream bushing
pin musthavea lightpushtit in con-
Gudgeon/piston

33
 I
Group21 Reconditioningengine
Cleaning, checking

c20
Checkconnectingrods
U s e a c o n n e c t i n gr o d a l i g n e r .
C h e c kf o r o u t - o f - t r u ed, i s t o r t i o na n d S J o r m .

Beplacingstarterting gear(manualgearboxonly)
OperctionsC21-22
c (

c21
Removeold ring gear
I (
lMakea punchmark exactlybetweentwo cogs and
oppositeoneof the milledrecesses in flywheel.
Drillthroughringgearwitha 10mm drill.NotelDonot
drillintollywheel.lf
necessarysplitringgearwithcold

Liftoff rins gear.

c22
Installnew ring gear
Place
ringgearin ovenat approx.250'C(480"F).
Checktemperature of solder(40%tin,60%
by means
leadl. (430-450'F)
Soldermeltsat 220-230"C
Cleanmatingsurfaces.
Place ring gear in position, bevelled side lacing
f l y w h e e l .l f n e c e s s a r y t a pr i n g g e a ri n t o p o s i t i o nw i t h a
,l
I
0 (

Oil pump
Operations C23-28
c23
oil pump
Disassemble

Clean and check all pans

Checkfor damage,wearetc.Payspecialattentionto
the half moonshaped segmentand surfac€between
inletandoutletports.
pump must be replacedsinceseparate
lf defective,
partsare not available.
Partsare available
for relief

34
 Group2l Reconditioningengine
Cleaning, checking

c25
Placepumpgearsin housingand checkplay/
backlash
Placelargepumpgearin housingwith{A )up andrhen
installsmallgear.
Checkplay/backlash.
lftoo large,reptace
entirepump.

Install cover

1f c27
Test relief valve spring

Etrs
Load Length

:D Ntb
00
175-195 39
49
22
1.930
0.866
approx.200 45 19.8 0.780(fully

c28
Install relief valve
Checkthat plungermovesfreety.
Installnewcopperwasher,
Tightening torque40 Nm (30fr tbs).

0
Group 21 Reconditioning engine
l
Assembly

D. Assemblingengine
N e w g a s k e t s ,O { i n g s a n d o i t s € a t ss h o u t db e u s e dt h r o u g h o u tw h e n a s s e m b t i n gt h e e n g i n e .

-J^ l)
q\\

D 24: Modifi6d fiantshatt beariDgs

T w ot y p s o t b e a . i n qs h e l l sa r ei n u s e l
0 (

Type 1: Flrng€d typ6 bs.rlng sh6ll, firted to vehictes

w i r he n g i n en u m b e . su pr o C W7 0 9 7 8T. y p el s p a r e sa r e

T y p e2 : F r o ms n g i n en u m b e rC W7 0 9 7 8t:h r u s tw a s h e r
h a l v e sa r e u s e dw i i h s e p a r a t eb e 6 r i n gs h e t t s T
. hese
Ir (

parts are not stocked.

q,,
\y
CRANKSHAFT.
OILSEALS

DI
Install main bearingshells in block and caps
Noterhatonlybearing shetls
onbtocksideareequip-
pedwithlubricatingholes.

D
Lubricatebeadng shells

0,1
D3
Positioncrankshaft
Lubricate
bearingseats.

D4
Installmainbearingcaps
Lubricatebolts.
InstallNo.4 capfirst.
Notel ldentificationnumbers must face towards oil
filterside.No.I capmustfacevibrationdamperend
and No.7 capthe flywheelend.
Tighteneachcap to 65 Nm (47ft tbs).tvlakesurethat
crankshaftcan be rolatedaft€r eachcap is instatted.
 Group21Reconditioningengine
Assembly

D5
Checkcrankshaftendtloat
Usea dialindicatortomeasurethe clearance between
both end positionsof crankshaft.
Endfloat
n e w , , , . , . , . , , , . . . , . , , , , , , , ,0.07-0.18
, , , . , . , . , . .mm
_
(0.0028-0.0071 in)
0.25mm {0.0098 in)

Manual transmission D6
)
Install new pilot bearing
Installbearingwith oil sealandmarkon outerrace
facingout.
Usestandard handlel80landdrift520Ttotap
in bear
ing untilit abutscrankshaft.
Pressin a smallamountofgrease(1.3-1.5
gram)inthe
spacebeyondth€ bearing.

Install rear sealingtlange

(6boltsM6 x 18)

M
Install crankshaltrear oll seal
Assemble standardhandle1801 anddrift5208.
Smear allmatingsurfaceswithoil.
Placesealondriftandtapin untilit abutscrankshaft.

PISTONS,
CONNECTING
RODS

D9
Assemble pistons and connecting rods
Caslinglugs on connecting rod and arrowon top of
pistonmustfacesamedirection.
Insertonesnapringand pressin gudgeon/piston pin
usinga suitabledrift.lfthis is difficult,heatpistonto
approx.60"C{l40oF). Instattothersnapring.
Gtoup21 Reconditioningengine
Assembly

Dl0
lnstallpistonrings
Installringwith springin bottomgroove.
Installoil scraperring.Not€!Makesurethatgapin oil
ringandspringareopposileeachother,seefig.
Insialllowercompression ring,TOPfacingup.
Installuppercompression ring.

Dl1
Turn rings until gaps are l20" apart

,ffi
Nots!Do notrotateoil scraperring.

0r(

Dl2
Installbearingshellsin connectingrod and caps

Dl3
Lubricate cylinder bores, pistons and beaiing
shells

0' (
')(

D14
Turn crankshaftuntil cyl. I crank iournal points
straight down

Dl5
Inslall No. 1 piston in cylinder bore
lJsea pistonringcompresser tool.
Pushin pistonandposition connecting rodoncrank.
Note!Arrowontop of pistonmustpointforwards.

38
T_
Group21Reconditioningengine
Assembly

Dl6
Install connecting .od cap
Checkidentification marks.Castingtugs (arroweo,
mustfaceforwards.Installnew nuts,lubricatecontact

Torqueto 45 Nm {32ft tbs).

i
i
D Install remainingpistons
D17

FollowoperationsD14-Dl6.
Dl8
Checkthat clankshaft can be rotated
Usetwooldflywheelboltsandascrewdriveras
illustr-
atedto rotatecrankshaft.

OILPUMP,SUMP{PAN}

Dl9
Install oil pump
Installpumpwith newoil seal.
Align pump gearon crankshaft flang€.Installthree
bolts (arrowed).Otherbolts will be installedat a later
stage,
Notsl Oil pump bolts are of differentlengths

22mm = 0.87in

I'D 30mm = 1.18

in

D20
I lnstall crankshalttronl oil seal
Packspacebetweensealinglipswith grease.
I TaDin oilsealwith
5200anda olastic mallet.

39
Gtoup2l Reconditioningengine
Assembly

D21
Installoil strainer
Useanewoilsealandnewlockingstraploroil
pump

Tightening
torque10Nm{6.5ft lbs).

Inslallsump
D22
0
N o i e l D i f f e r e n tb o l t l e n g t h sa n d d i m e n s i o n s
R e a re d g e o f s u m p m u s t b e f l u s h w i t h e n g i n e b l o c k .
{ U s ea s t r a i g h te d g e t o c h e c kt h i s . ) {C
A l l o t h e rb o l t s= M 6 x 1 8
2 8 m m = 1 , 1 0i n
7 5 m m = 2 . 9 5i n
1 0 3m m = 4 . 0 5i n

FLYWHEEL,CLUTCH.CARRIERPLATE

D20 D23
,al Installflywheel{manuall,carrierplate(automa,
I ,,Jr
"] ticl

v_-,/ Flywheelcanonly be insralledin one posilionsince

boltsareasymmetrically
D24
,{\
located.
Nots!Suppo( panelon auromatic vehictes.
Usenew bolts,smearedwith seaterP/N27796'l-9.
0 I
/^\ l.\l
ll
1rr11 Use locking sector 5112to prevent crankshaftfrom
rotatingandtorquebotrsro 75 Nm i55 ft tbsl
vt Note! Differenttypes of flywheelstor D 20 and D 24
I
D24
Install clutch
Usecentering shaft5203.
Installdiscwith hubfacingout,awayfromftywneer.

40
 Group21Reconditioningengine
Assembly

D25
Install piessureplate
T i g h t e nb o l t sc r o s s w i s e a
, few turnsat a time to avoid

R e m o v el o c k i n gs e c t o r5 1 1 2a n d c e n t e r i n gs h a f t5 2 0 3 .

MISCELLANEOUS

D26
Reconnect hoses at lear of engine block
UsenewO'rings.

Automatic gearbox

Check installation measurement of carrier plate

{Tobe caried out afterreplacement of carrierplate)
Installation measurement = 17.2-18.8mm (0.667-
0.740in).
(i.e.installation
lf carrierplateis installedincorrectly
measurement is wro.g),distanceto torqueconverter
carrierwillbetoo long.Thismaycausecarrierplateto
crackand possiblynoisewhendriving.

D27
To measure
Placea steelrulerbetweencarier plateand engine
block.Rulershouldrest againstengineto gearbox
mounting flangeandshouldrestagainstbothsidesof
flange.Turr crankshaftuntil one of holesin carrier
platecoincideswith steelruler.MeasureB with an
outsidecaliperequipped for depthmeasurement.

0 A+B=1810,8..

M e a s u r e dv a l u e B p l u s t h i c k n e s so f s t e e lr u l e r s h o u l d
= 1 7 . 2 - 1 8 . 8m m ( 0 . 6 6 7 - 0 . 7 4 0i n ) . l f d i s t a n c ei s l e s s
t h a n 1 7 . 2m m = 0 . 6 7 7i n , p l a c ea s p a c e rw a s h e r { P / N
1 2 5 7 3 7 7 - 0b1e t w e e nc r a n k s h a fat n d c a i i i e r p l a t e .

4l
Gtoup 21 Reconditioning engine
Assembly

D28
Installcoolantpump
Inslalla new O-ring,lubricatedwith grease.
lnstallthe two outerretainingbottsonly,but do not
tightenat thi6 stage.

D29
lnstall
- thermostat,newO-ringandthermostat
housing.AF
row on thermostatmust taceup.

Install
- oil pressure sender,usea newwasher
D30
nl
- oil filter.see instructionson cartridge.

@)
(

DI
D(

42
 Gtoup 21 Reconditioning engine
Cylinder head, disassembly

E. Cylinderhead,disassem
bly

E Clean gaskel sufaces on cylinder head ano

cylinder block.

D D Checkfor damageand warp

lJsea straightedgeandfeeler9auge.
Replace cylinderheadif warpexceeds:
- lengthwise 0.5mm {0.02in)

I D - crosswise0.2 mm (0.008in)

'a et :2.

oJ
Nolol Smallcracks0.5 mm (0.02in) do not warrant
replacement of cylinderheadsincetheydo notimpair
enginefunction.
Forgasketreplacement only see "Cylinderheadin-
on page55.
stallation"

43
Gtoup 21 Reconditioning engine
Cylinder head, d isassem bIy

Removecamshaftbearingcaps1 and 4

E4 {;(
Removecamshaftbearingcaps 2 and 3
Slacken
nutscrosswise
to avoidplacingunev€ntoad

E5((
Lift away camshaftand lemove oil seals

E6
Litt out tappets
Note!Do not interchangetappets.
Marktappetsso
thattheycanbeinsralled
in sameposition.

o(
oOcoto 0t tr6a
12 34 78 I 't0 11 12 )

E7
Remove from cvlinder head:
- lifting eyes
- connecting flangefor coolanthose{Atten5 mm)
- glow plugs
- temperature senders(2 X).

44
 Gtoup21Reconditioningengine
Cylin der head, d isa ssemb Iy

E8
Tap out swirl chambers
Usealongnarrowpunch (0.6mm= 0.24indiameter),
length150mm{6in).

t:
t
--. 1.:{'

a
oa 1a

3: Remove valve spaings and valves

E9

6cl lmportantl Oo not interchangeparts.

Depress tool.
valvespringswith a springcompressor

- retainers
(collet)
- upperspringseat
- springs

Removesealsfrcm valve guides

Usetool5219.

E11
Removelower valve spring washers
lockringplierswithflatjaws.
Usea pairof external

45
Gtoup 21 Reconditioning engine
Cylinder head, cleaning - inspection

F.Cylinderhead,cleaning- inspection

Check clearance between valve guides and

{)l
LJse
a dialindicator.
U s e n e w v a l v e s( i n t a k ea n d e x h a u s t ) w i t he n d o f v a l v e
s t e mf l u s h w i t h v a l v eg u i d e . {)l
C l e a r a n c e= 1 . 3 m m ( 0 . 0 5i n ) .

Checkcamshaftend tloat
Usea dialindicator.
Positioncamshaftand installrearcap.Torqueto 20
Nm (15ft lbs).
Clearance = max 0.15mm {0.006in).
Bemovecap and camshaft,
{

ri
F3
Check discs
Checkdiscplay.Replace discif worn or scored.
lnstalldiscswith numbersfacingdown,towardstap-

0.016-0.046mm
Clearance,newparts.......................
in)
{0.0006-0.0018

46
 6toup 21 Reconditioning engine
Cylinder head, cleaning - inspection

F4
Checktappets
Placetappetsin cylinderhead.
Checkfit andclearance.
Clearance,newpans 0.025-0.075mnl
(0.0010.003in)

o Checkvalvesprings
F5

Eres
Innersp.ings
Length
Iinl N {lbs)
33.9 (1.334) 0 (0)
24.6 (1.126) 67-17 (15-17,5)
18.3 to.72ol 209-231 141-52.21
Outer sptings
Length Load
{in} {lbs)
40.2 {1.583) 0 {0)
32.6 (1.283) 167-185 (38-42)
22.3 (0.878) 433-479 (98-108.3)

Replacingvalve guides
Operations Fo I

F6
Pressout valve guide
Usedrift5218.
Press chamber
fromcombustion side.

-
":-: _t

Pressin new valve guide

Lubricate valveguide.
Usedrift 5218.Pressin from camshaftside.
Pressin guideuntilflangeon guidecontacts cylinder
head.Inthispositionpressforcemustnotexceed'lton
sinceIlangemay breakoff.

41
Group2l Reconditioningengine
Cylinder head, cleaning - inspection

F8
Cleaninsideof valveguide
Usereamer5224.
oil mustbeusedwhenreaming.
NotelCutting
V a l v e sa n d s e a i sm u * b e g r o u n d - i na f t e rv a l v eg u i d e

Grinding-in valves and seats

OpefttionsF9-12
0l
F9
Machinegdnd intakevalves
E d g e o f i n t a k ev a l v e m u s t n o t b e l e s s t h a n 0 . 5 m m
( 0 . 0 2i n ) .
0l
lmDortant!Exhaustvalvesare stellite€oatedand
mustnot be groundby machine.Grind'invalveon
seatwith grindingpaste.

F10
Mill or grind valve seats
Grindto 45'.
Contactsurface(a) must be:
- 2.0mm (0.08in)for intakevalve
- 2.4mm (0.09in) for exhaustvalve.
lf contactsurfaceis too wide reduceareawith a 15" lrl
lmDortantl Ouler diamererof cutter must not exceed
3 5 . 2m m ( 1 . 3 9i n ) f o r i n t a k ev a l v es e a r sa n d 3 3 , 2m m
( 1 . 3 1i n )f o r e x h a u svt a l v es e a l s -
i.il I
Fl1
Measuregap between valve disc and cylinder
1,5mm head surtace
Gap= max1-5mm (0.06in).
R e p l a c es e a t a n d p o s s i b l yv a l v e i f g a p i s t o o l a r g e .
Note! Two valve types are available, see G3.

48
 Group21Reconditioningengine
Cylinder head, cleanlng - inspection

F12
Gdnd-invalveswith paste
Clean
valves
thoroughlyaftergrinding.

G.

Replacingvalve seats
OperationsFl3-21
V a l v es u i d e sm u s tb e r e p l a c e d
b e f o r cr e p l a c i n g
seals.

F13
Clean combustion chamber
Edgeof seatmustbe clearlyvisibleaftercleaning.

Remove valve s€al

Mill valve seat, using cutterssuch as lvlira{P/N
9986045).Referto manufacturer'sinstructions.Make
surethatseatin cylind€rheadis not damaged.
thoroughly,
Cleansurfaces
F15
Measure diameter of seat recess in cylinder
head and ot valve seat
- measureseatrecess.
Usean internalmicrometerto
Standard
{production version}
Diameter. seatrecess, mm (in)
intake.................
37.000-37.o t6 \1.4567-1.4573)
exhaust..............33.000-33.016{1.29921.2998)

I Diameter,seat,
intake.................
37.090-37.105
exh6ust..............
33.090-33.105
{1.4602-1.4608)
{1.30281.3033)
Ovsrsi2e
D+(O,074-OJO5
mm) Partsversion)
{replacement

H Diameter,seatrecess,mm (in)
37.200-31.216
intake................. (t.4646-1.4652\
(1.3071-1
exhaust..............33.200-33216
Diameter, seat,
3077)

intake-................
37.290-37.305{1.4681-1.4687)
33.290-33.305
exhaust.............. (13106-1.3112)

Whenreplacing valveseatsrthe interference between

thevalveseatanditsborein thecylinderheadshallbe
0.074-0.105 mm (0.0029-0.0041 in) i.e. valve seat
diametermustbe 0.074-0.105 mm {0.0029-0.0041 in)
greaterthanthe diameterof the borein the cylinder
head.Replacecylinderhead if interference is too
small.lvlillseat recessif interferenceis too large

49
Group 21 Reconditioning engine
Cylinderhead,assembly

Heat cylinder head

Heatto 100'c (212"F).

Place new seat in installation tool

Fl7 0, (
Use drift 5220 for intake valve seats and 5221 for
exh.ust valveseats.

Fl8
Cool valve seal
Wearprotectiveglovesandsafetyglasses,
Useliquidcarbon to coolseatdownto -70"C
dioxide
(-94"F).

F19
Tap-invalve seat
N o t e l T h i s m u s t b e d o n e q u i c k l y ,w i t h i n 3 - 4 s e c o n d s
to avoid temperature loss.
220

0 I
(

F20
Checktit of valve seat
Makesurethatthe seathasbottomedcorrectly
andis
secure.lf not,replacecylinderhead.

F21
Grind valves and mill seats
on page48,operations
Seeinstructions F9-12.

50
 Group21Recondhioningengine
Cylindet head, assembly

G. Cylinderhead,assembly

New cylinder head

a Newcylinderheadmustbethesametypeastheold.
C y l i n d e rh e a d s d e s i g n e df o r u s e w i t h M 1 2 b o l t s
m u s t n o t b e u s e dw i i h f V 1 1 b o t s .
C y l i n d e rh e a d sc a n b e i d e n t i ife da s f o l l o w s( s e ei l l ! s
t r a l i o na t l e f t ) :
- N u m b e rs e r i e sf o l o w e d b y B = M t l
N u m b e rs e r i e sf o l o w e d b y C : f v l 1 2
U S A J C a n a d1a9 8 2 - h a s a d i f f e r e n tt y p e o f c y l i n d e r
h e a da n d s w i r l c h a m b e r .S w i r l c h a m b e r3 n d i t s b o r e
i s 2 m m ( 0 . 0 8 0i n ) s m a l e r i n d i a m e t e rt h a n o t h e r

New cylinderhead
OperationGl

GI
Installoiljets and pin studsin cYlinderhead
tapin oiljetsusinga brasspunch.
Carefully
NotelTurn outerietstopointacross head,
cylinder see
fig.
and type of cylinder
lmportantlCheckspecification
head.M 12boltsmustnot be usedwith M 11bolts.

O Differenttype cylinderheads are used for IJSAJ

Canada.

G2
Check valve stem position in relation to
camshatt
Thismeasurement
iscarried is
outtoensurethatthere
s u f f i c i e n ta d j u s t m e n tl a t t i t u d ef o r v a l v e s .
Place gauge 5222 with largesl d;€meter rin9. on
c y l i n d e rh e a d .( S m a l l r i n g i s f o r 8 1 7 - 8 2 3 e n s i n e s ) .
N o r e ! F r o n i b e a r i n g r e c e s sd i a m e t e r i s l a r g e r t h a n
o t h e r s .M a k e s u r et h a t g a u g e i s p o s i t i o n e dc o r r e c t l y .
T a k i n ge a c h v a l v e i n t u r n , c h e c k t h a t s t e m d o e s n o t
c o n t a c ig a u g e .l f t h i s h a p p e n s ,g r i n d v a l v e s t e m .

^nC'
51
Group 21 Beconditioning engine
Cylinder head, assembly

Valvelength,mm (in)

Now Min
lntakevalve .........
104.8{4.126) 104.3{4.105)
Exhaustvalve......104.6(4.118) 104.1{4,098)

G3
Early and lat€ type valves, valve collets (locks)
o
and upper spdng s€ats
Earlytype valvesand colletshaveone lockinggroove
wh€roaslatetypes havethr€e.
Only latetypes6re availableas spareparts.
Consequentlywhen installinga new valve,the collet
o
andupperspringseatmustalsobe replac€dwith new

New spring seats are either copper coated or

chromed.Earlytypes ars bright or black.

G4
lnstall:
- upperspring
seats,flanged
sideup. !
lnstall valve stem oil seal.

sleevssmust be usedwhen jnstallingoil

Protective
seal.

placevalve
Toinstallv6lve. incylinderhead andplace
protectivesleev€on stem. use tool 5219to install oil
seal,nolethattoolshouldabutflangeseal,
 Group 21 Beconditioning engine
Cylinder head, assembly

Install:
- i n n e ra n d o u t e rv a l v es p r i n g s

l h p o r t a n t lT w o t y p e so i v a l v e so. p p e r s p r i n g
s e a t sa n d

G6
Install swirl chambers
C h e c kt h a t s t e e lb a l l i s i n c h a m b e r .

i0 l f n o t , i n s t a l ln e w s w i r l c h a m b e r .
N l a k es u r e l h a t b a l l f i t s i n s l o t i n c y l i n d e r h e a d . T a p
down swirl chambers.

p'
l m p o n a n t lS p e c i asl w i r lc h a m b e 6l d i f f e r e ndr i a m e t e r )
i o r U S A / C a n a d1a9 8 2 - .

G7
lnstall:
- slow plugs.Tightening to.que40 Nm (30ft lbs)
- temperature senders(2X).Sametypefrontandrear
- connecting flangefor coolanthose(Allen5 mm).
Installnewgasket.Tighteningtorque10Nm(7fr lbs).
- liftingeyes.
0

G8
Installtappetswith discs
S T e . l a p p a r sa r c ld s . s w r h o r l o e l o r e i r s r d n
. g.
N u m b e ro n d i s c ss h o u l d f a c e d o w n .
C h e c kt h a t t a p p e t ss l i d e e a s i l yw i t h o u t s t i c k i n g .

53
Group21 Reconditioningengine
Cylindet head, assembly

G9
5190
Placecamshaftin cylinder head
Lubricate contactsufaces of camshaft andbearings.
Placegauge5t90at rearof camshaft. lmport.nt!Both
c a m s f o r n u m bceyr l i n d e r m u s t p o i n t d i a g o n a l l y u p ,
seefig.

G10 (
Insiall camshatt caps 2 and 3
Installcapscorrectly,centeris off-set.
Tighten nuts crosswise to avoid distortion. Hold
camshaftin positionwith gauge5190at rearwhen (
tightening€ps.
Removegauge5190.

G11
Press in new camshatt oil seals

Do not push in sealsto bottom position. Make sure

thatsealsare"square".

Install camshatt caps 1 and 4

llake surethatthe thrustwasherfor camshaftcap4
sjts corectly.

Torqueall loua caps f(

= 20Nm(15ft lbs).
Torque
G14
Tap in oil sealsto bottom
U s e s l e e v e5 2 0 0a n d a p l a s t i cm a l l e t .
fl

54
 Group 21 Reconditioning engine
Cylinder head, ircta ing

H. Cylinderhead,installing

Cylindsr hoad gasket

Obs6rv6datecodeon gasketandpacket.Gasketmust
be ussd b€forethis date,
Only gasketswith code MO or later may be us€d on
D 24 engines.

Data Goda
Toavoidimpairing6ealingpropertiesof gasketdo not
op€n packetuntilgasketisto be used,

Month Jan A
Feb B
Mar C
Apr D
May E
June F MO
July G
AUS H
Sept J
oct K
Nov L
Dec @
Year 19@
0 = 1980
1 = 1981
2 = 1942

Takecarenottodsmage packetand caus6damagelo

gasket,(teflonstrip. rubberseal).

Installsametypeof gask€tas bolore{i.e,same no. of

notches),OBENlacing up.
lf pislons,connectingrods etc. are rgplaced,piston
h€ightmu6t be measured,and gasketchosonaccord-
ing to table on page56,
Threedifferonttyp€sofgasketsare available.Typeto
be fitted depends on piston height above cylinder
block.

55
Group21 Reconditioning
engine
Cylinder head, installing

H1
Measurepiston height abovecylinderblockand
select gasket
Pistonheight above G6skst
cylinderblock
mm {in} notches thickness mm
(inl
0.67-0.80(0.026-0.031)1 ...............
r.4 (0.055)
0.81 0.90(0.032-0.035)2 ...............
1.5(0.059)
0.91-1.02(0.036-0.040)3 ...............
r.6 (0.063)

H2 (
Cleanholestor cylinder head bolts
r.6;-\{)-?;- Oilanddirtmustbe r€moved fromholesotheMise
/r_(jQ.]!q gasket
mayleakasa resultof insufficient
tightening

0(

H3
Set cylinder 1 to TDC
Flywheeitimingmarkat'0'.
Use a 27 mm socket or wrench 5188 on vibration
dampercenterboltto turn engine,

{|

Install guide pins in cylinder block

5233for blockswith M 11bolts-
5234for blockswith lvl l2 bolts.
Two outerpinson rightsidehold gasketin position.
Cylinderheadis prevented fromslidinganddamasins
gasketby two innerpinson left.

lmportantllJseall four pins,locatedas illustrated.

 Gtoup 21 Reconditioning engine
Cylinder head, installing

H5
Install new cylinder head gasket
OBEN facingup.

H6
Positioncylinder head
l cylinder
solhatnumber
Firstsetcamshaft isatinjec-
tion (bothcam lobesshouldpointdiagonally up-

Prevent
camshaft
from movingwith stop5190.

lmoortant! Camshaftmust be locked otherwise

valvesmav strike Distons.

Cylinder head bolts

Twotypesof cylinderheadboltsarein use.
EarlytypeboltshaveM ll threads.
Theseboltscanbe
reusedwith new washers.Fitwasherswith cup shape
()
facingup.
M11
Latetypeboltshave[4'12threadsalongentirelength.
These bolts must not be reused. Washers may
howeverbe reused,

o H7
Install cylinder head bolts
{ Lubricate threadsand slidingsurfaceof washers.
Placeboltsin holeswithoutguidepins.

0
Removeguide pins. Usetool 5235,
Installremaining
bolts.

57

L
Group 21 Beconditioning engine
Cylinder head, i nstalli ng

H8
,oo oo @@ Toquo cylindor head bolt3
D20 Tightenallboltsoneatatim6 in ord€r6p6cifi€d
edja-
,9 ,O centbeforeproceedingwith n6xtstage.
@o, @@

@@ @ @ @@@
D24
@@ @ o @@@

M 1l boltr
r159082

ffi M 12 boltt

Allen key10 mm l2-sidedwrsnch P/N 1159082-5

Tightenin thrce stages: Tightsnin fourstages:

1, 50 Nm = 37 ft lbs 1. 40 N|n = 29 ft lbs
2. 70 Nm = 51 ft lbs 2. 60 Nm = 44 ft lbs
3.90 m=66frlbs 3.75Nm=55ftlbs
4, angle-tight6n18C in ons movem€ntwithout dop
pins.

lmpon6ntl Cylinderhead bolts must be torqued lmportant! Cylindsr h€ad bolts must be torqued
againaftertheengineiswarm6d-up. Refertospecifi- 69ainafrertheengineis warmsd-up.Refertospecifi-
cationsin front oI manualfor torqueprocedurcsto cationsin ftont of manuallor torque proceduresto
be usedafterenginehasbeenrun. be usedafterenginshasbs€n run.
 Gtoup 21 Reconditioning engine
Assembly

J. Assembly

0 TIMINGGEAR

J1
lnstall
- coverplate.Do nottightencoolantpumpmounting
boltsfully 6t thisstage
- fan/alternatormounting bracket
- idlerpulley.Tappulleyintopositionandinstallcen-
ter bolt
- crankshaftgear.

Inslall camshaft lront sprocket and gear belt

Ensurethat belt sits correctlyon all gears.Tighten
centerbolt by hand,it should be Dossibleto turn
sorocketon camshaft.

0
e
J3
Install lower timing gear cover and vibration

I $f
dampel
Dampercan only be fitted in one way, Pin on
crankshaftmustfit in vibrationdamper.
Torqueinhexboltsto 20Nm{15ft lbs).

,
Gtoup 21 Reconditioning engine
Assembly

lnstall center bolt

Smearthreadsand matingsurfacewith sealerP/N
277961-9.
Usewrench5187{reston coolingfanjournal)to hold
vibrationdamperand wrench5188to torquecenter
boltto 350Nm (255fr lbs).
lmport.nt!Torque350Nm (255ft lbs)appliesonly if
wrench5188is used.Also,torquewrenchmustbe in
linewith wrench518a.

{
Note! Differentvibration dampersfor D 20 and D 24

D24

J5
Set belt tension
Adjusttensionby movingcoolantpump.
lJsegauge5197to checktension. Attachgaugeto belt
andsetto 12.5units.Stretchbeltuntitmarkon gauge
plungeris flushwith sleeve.
Tightenmountingbolts.Depressbelt stronglywith
handand rechecUadiust tension. 0

J6
Checkthat cyl. 1 is at TDC- iniection
Usetool 5!98.Setgaugeto 25.0.
zeromarkon flywheel shouldcoincidewithzeroof
ruler.AdjustiI necessary.

60
 Group 21 Reconditioning engine
Assembly

ry''!
5190
Lockcamshatt in O-position
Place gauge5190 at rearofcamshaft.Insert
a 0.2mm
feelergaug€ beneath leftsideofgaugetocompensate
for tifting gearclear6nce.

J8
Tighten camshatt frcnt sprocket and r€move
gauge 5190
Use5199to preventsprockettromturning.
Torquecenterboltto 115
Nm {33ft tbs}.
Remove gauge 5190andfeelergauge.

0 Valveadjustment
OperationsJ9-17

J9
Turn engine until cyl. 1 is at TDC- injection
Alwaysuse vibrationdampercenterbolt to turn
engine.
{27mmsocket orwrench51881.
Bothcylinder
1camsshould pointobliquely
upwards.

J10
Checkvalve cleslancetor cyl. 1
Checking values
Coldengine in
Intake.................
0.15-0.25 0.006-0.010
Exhaust.......,.....
0.35-0.45 0.014-0.018

Intake.................
0.20-0.30 0.008-0.012
Exhaust.............
0.40-0.50 0.016-0.020
l f t h e c l e a r a n c ei s a c c o r d i n gt o t h e a b o v e v a t u e st r o o e s
not need to be adjusted.

a
! Al-alfAlaT
rlLrl

l.a:-tA
--
Group 2, Reconditioning engine
Assembly

lncoftec,tclearance lJIl -1 5)

J11
Tum onglns approx.1/4lurn
Pistonmustnot b€ at top deadcenterwhensetting
valveclearance,
othorwiso valveawlllcontactpiston
whentappetis deprcssed.

J12
Dopr$s tappots
Tum lappets until grooves poini slightly inward.
lJsingtool 5194 depresstappetsto obtain accossto
disc.

J13
Ramovedisc
Us€5195.

J14
Calculatesthicknossof di8c to b6 urod
Valv6clearances whensetting:
Coldengino mrr ln
Inrake............,....
0,20 0.008
Exhaust.,...........
0.40 0.016
Warmenglna
Int8k6.................
0-25 0,010
Exhaust.............
0,45 0,018
lvloaaur€thicknessof cold disc with a micrcmeter.
Calculatethickness oI new disc to be used, see
 Group21 Reconditioningengine
Assembly

Example mm tn
lvleasuredvalveclearance............. 0.20 0.55
Specifiedvalveclearance..............
_,915 0.45
-0.05 + 0 . 1 0
4.00
Thickness,o|ddisc......................... 4.00
-0.05 + 0 . 1 0
newdisc ........................
Thickness. 3.95 4.10

Always use new discs. Discthicknessesavailable=

3.00-4.25mm at incrementsof 0.05mm.

J15
Positionnew disc and removepliers
Discshouldbelubricated
andinstalled
withnumbers

J16
Checldadjust valve cleaEnce lor romaining
cylindercin following order
D 20,1-2-4-5-3
D ?l, 1-5-3-6-2-4
lmpoftantlDo notforgetto rotatecrankshaft
1/4turn
beforechecuadjustingvalveclearance.

J17
Recheck valve cleaianc€ tor all cylinders
Rotateenginesev€ralturns beforerechecking.
{2 25,O J18
-
Turn engine until cyl. 1 is .t TDC injedion
Bothcyl.1 camsshouldpojntobliquelyupwards

Usetool 5198.
Set gaugeto 25.0.
Zeromarkon flywheelshouldcoincidewith zeroof
ruler.Adjust if necessary.

63
Gtoup 21 Reconditioning engine
Assembly

. 06 J19
_1"_ Install valve covet
g lf necessaryinstallnewgaskets.
1E Threedifferenttypesof assembliesare in use
\8,/
Pinstudwithoutspacer, gasketstud hole= 6 mm
/ tg,s ' {0.24in) diameter.
z4z Type 2.
Pin stud with spacer,gasketstud hole = 8.5 mm

3g
(0.33in) diameter.
Type 3.
Pin stud without spacer,stud holesin valve cover
arecountersunk, gasketstud holediameter= 8,5
mm {0.33in)diameter.

J20
Install tront timing gear cover
Checkbothtiminggearcoversfor loosepartsetc.
 Group21 Beconditioningengine
lnstalling parts

K. Installingparts on engine

Kl
Install iniectols
Placenewheatshields
in cylinder
head.Turnshields
as illustrated.
Screwin iniectors.Torqueto 70 Nm (50ft lbs).
Reconnectfue! deliverylines betweeniniectors.

!t is advisablsto checkco.dition of injectorcwhen re-

c o n d i t i o n i hcgy l i n d e h
r e a d .S e ei n s t r u c l r o ni sn s e r v i c e
manualsection2(23-291D 20, D 24 engines.

K2
Install pump rear mounting brrcket rnd
dipstick + tube
Slidepumpbrackettothe upperposition andtighten
oneof the bolts,
InstallanewO-ringonoiltube.

K3
lnstall:
- copperconnectors+ leadsbetweenglow plugs.Do
nolscrewonnuton number2glowplugsincewiring
harnessis securedby this nut at a laterstage.
- mountingbracketfor fuelfilter
- fuelfilterand base.

65
Gtoup 21 Reconditioning engine
Installing pafts

INJECTION
PUMP

Removing/installing
Operations
K4-14

K4
Position injection pump
lvlountpumpon engineand secureit with retaining
boltsandfrontmountingbracket.
Donottightenbolts
fullyat thisstage.
Align markin pumpwith markin mouniingbracket.
Thentightenretainingbolrsfor pump - mounting

K5
Install pump geal
Notel Be sureto pla€ekey in pomp shaft.Installgear,

Torquenut to 45 Nm {33ft tbs).

Use5193to holdsprocket and5201totightennut.

K6
Disconnect cold start device
Slackenscrew1. Pushleverforwardand rotatesleeve
90'.
Not6! Do notturn screw2, otherwiseit will be neces-
saryto removecold start deviceand resetit on a test

K7
Set dial indicatol to zelo
Lock pump gear at cyl. 1 inioction using stop
5193
4.irrefl1= Unscrewancl remove plug from iniectionpump
;i,6 rr distributor.
lnstall holder 5194 and diat indicator{measuring
range0-3 mm).Setgaugeto approx.2 mm.
Turn pump g€ar clockwiseuntil mark on gear and
mountingbracketcoincide,
 Group 21 Reconditioning engine
Installing parts

Thenturn pumpgearbackslightlyuntil min reading

r€gisterson dial indicator.Set indicatorto zero.
Turn pump gear clockwiseuntil mark on gear and
pump mounting bracketcoincide.Lock gear in this
positionwith stop 5193.(lnsert stop through pump
ge6r into mountingbracket,)

K8
Install camshaftrear sprocketand timing belt
Tighten centerboltby hand,it shoutdbe possibte
to
turnsprocket on cahshaft,

K9
Set belt tension
Adjusttensionby movingjnjectionpump.
UsegEUge5197to checktension.Attachgaugeto belt
6ndsettol2.5units.Stretch beltuntitmarkongauge
plungerjs flushwith sleeve.
Tighten mounting bolts, Depressbelt strongly with
handand rechecUadi!st tension.

Altitude adjustmentUSA only (Vehiclesup to 19831

Legal requhemsnt Thefollowingadjustment mustbe madeto vehjclefor
EnvironmentalProtectionAgency(EpAldefines: useat highaltitudesl
- highaltitudeasan elsvation exceeding 1219metres Iniestion
{4000f0 timing: advanced0.07 mm (0.0028inl for
every1000m (3300ft) increasein altitude,
Newvehiclessold for princip6luseat high attitudss
must be adjusted before being deljvered to the Injectedqu.ntity decreasedby 2.3 mm3for each10OO
metreincreassin altjtude.
Thisis equivalenttoturning
customer.Afteradjustementa decalmust be affixedto adjustmentscrew
the firewall {besidethe emissionsinformationdecal) 35, anticlockwise,
and6lsoto the injectionpump.
Group21 Reconditioningengine
lnstalling parts

Kl0
Set pump and tighten camshafl rear sprocket
Checkthat ruler519ais setat 25.0andthatflywheel'O'
is flushwith ruler'O'.
Using5199,turn sprocketslowlyclockwiseuntildial

D 20 .............................
0.80mm (0.0315
in)
D 24 .............................
0.70mm (0.0276
in)
D 24 USA and Canada
1979-1981 ....................
0.70mm (0.0276
in)
'1982-
.......-...................
0.85mm (0.0335
in)

Hold sprocketin this positionand torque bolt to

100 Nm {73 ft lbs). Take care that camshaft and
sProcketdo not move.

Kl1
Remove stop 5193 from pump gear
g Zs.o
K12
Check pump setting
Turnenginetwo fullturnsuntilcyl.1 is at TDC- iniec-
tion,again.lfengineis turnedtoofar it mustbeturned
backapprox.l/4turnandthento zeromarkotherwise
settingwill be incorrect.
Dialindicatorshouldshowl
D20...................
0.75-0.83mm(0.0295-0.0327 in)
D24...................
0.65-0.73mm(0.02560.0287in)
D 24 USAand
Canada1979-
0.65-0.73m m (0.0256-0.0287
1981................... inl

0.82-0.90mm (0.0323-0.0354
1982-.................. in)
Correct.eading:Tighteniniectionpump mounting
bolts.Proceed to Kl3.
Inco.rectreading:Readjustaccordingto instructions

R€adiustingpump setting:
D 20 .............................
0.80mm { 0 . 0 3 1i 5n )
0.70mm
D 24 ............................. {0.0276 in)
D 24 USA and Canada
1979-1981....................
0.70mm (0.0276
in)
'1982'...........................
0.85mm (0.0335
in)

Reading less than specified:

Slackenpumpmountingboltsandturnpumpinwards
to obtaincorrectvalue.Tightenmountingboltsand
repeatcheckof pumpsetting.

68
 Gtoup 21 Reconditioning
lnstalling pafts

Readingmore than specitied:

Sl6cksnpump mountingbolts and turn pump
ourwardsuntildi6lindicatorshowsapprox:
D 20 ...................
0.70mm (0.0276in)
D 24 ...................
0.50mm (0.0237in)
D 24 USAand
Canad61979"
1,3-1.61981 ........
0.60mm (0.0237
in)

1982-....0.75mm (0.0295 in)

Thenturn pump inwards until specifiedvalue is ob-
tained.Tightenmountingboltsand recheckpump set,
!ng.

lmportantl Inieclion pump must not be tapped or

knockedas this willalt€r its setting.

Kl3
Renove dial indicator and holder 5194,lnstall
plug with new se.l.
TighteningtorqueI Nm(6.5ftlbs).

Kl4
Install cold start device
Presslever forward and turn sleeve 90'. R€tighten

Nolel Do notturn screw2, otherwiseitwill be neces-

saryto removecold start deviceand rcset it on a test

Kt5
Rehoveruler5198lromcylinderblockreal

K16
lnstall:
- deliverypipes.Tightening torque25 Nm (18ftlbsl
- supplylinestopump.Tight€ning torque25Nm{18ft
tbsl
- returnline from rear iniectorto pump.
- reartimang ge6rcover.(oo not installnut on pump
bracketstud sincewiring harnessmust be attached
at a l6tsr stage).

69
Gtoup21 Reconditioningengine
lnstallingpans

KI7
Installpump plungerand vacuumpump
plunger.
Lubricate plunger
Install in sameposition
as
befofe
{checkwearmarksonendof plungerl.
newO-ringon vacuumpump.Applysealer
Install to
O-ring.

K18
Install alternator and adjusting bracket
D o n o t t i g h t e n r e t a i n i n gb o l t s a t t h i s s t a g e .

Kl9
Attach wiring harness to engine left side
Clampwiringharnessbenealhthermostat housing.
Reconnectwiring.

Tiewiringharnesstoholderforoiltubeandatrearof
cylinderblockas illustrated.
Clampwiringharness to r€taining
boltfor reartiming

70
 Gtoup21Reconditioningengine
lnstallingpans

K20
Attachwiring harnessto engineright side
Clampwiringharness to loweredgeofcylinderblock.
Connectwires to alternatoras follows:
- thickredto B+
- thin redto D+
Slide plasticcoverover B+ wire,

K21
Reconnect coolant hoses to:
- rearofcylinderblock
- thermostathousing

I - connector
on cylinderhead.

K22
Install exhaust manifold
Install new gasketsand use new nuts for exhaust

'o Gasketmust be turned with raised edge outwards,

facingmanifold.
torque25 Nm (18ftlbs).
T'ghtenins

K23
lnstall intake manitold
Installnewgasket.Turngasketwith greensidefacing
4a,
Apply sLrfficientoil to gasketso that it remains ar,
tachedto cylinderhead.
Tighteningtorque25 Nm (18ft lbs).Allen = 6 mm.

K24
Removeengine from stand
Lowerengine to floor, but leave most ofthe weight on
the lifting tool.
Group 21 Reconditioning engine
lnstalling wfts

K25
Installg€orboxandatartormotor
Ch€ckthatguide pins are installed.
Not€differentboltsizes and bolt length8,seefig.
Manualge6rbox: installwasher{g = 4.5mm thick)on
bolts which are installedwith spacer (A). All other
bolts havespringwashers.

4.5mm = 0.18ln
50 mm = 1.97in
70 mm = 2.75ln
75 mm = 2.95in
t00 mm = 3.94in

'12
 Group21Reconditioningengine
Installing parts

K26
Roconnectwites to starter motor
Connect
tl/vothickredwiresrostartermotorandblue/
yellowwireto soleno;d.

K27
Attach right engine mount
Installengine
Referto appropriatemanuallorinstall6tionprocedure.

m m",,
u-ll M11
.irulr
/--\
lmport.nt! Cylinder head boltsmustbe retorqued.fter
theengineiswarmed-up.

1122"FJ.
Followtheprocedure
1. Runengineuntiltheoillemperature

2. M 11 bolts: torque bohsto 90 Nm (66ft lbs).

M 12bolts:angle-tighten
below:
is at l€ast50'C/

bolts90'in onemovement
,ffiir,";J r,ft;i) without stopping.Do not slackenboltsfirst.
Aft€r driving 1000-2000km (600-'1200
inderheadboltsmustbe torquedagain.
miles)the cyl

1tt499
Group2l Reconditioningengine

lndex
Opera- Opera' Page

Altitude adiusrment{USA) Cylinderhead

Bigend bearings remova1 ..,.,.,,,,,.,.,.,.......,.,.,.,.,.,.,... 86 25
seeconnecting rod bearings disassembly.......-......................... E 1 -1 1 43
cleaning, checkin9....................... F1 46
Camshafroil seals w 4 r p , , , . , . , . , . , . . . . . , . , , , . . . , . , . , . , . . . , . , . , , , . , .43
,
i n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . .c.1. .1. -. .1.4. . . . . . . oiljets,instattation 51
4ssemDry......,.,.,.,.,.,.......,.,.,.,.,.,.,. 51
Camshattsprocket,lront insta11ation ................................... H1-8 55
r e m o v a 1 , . , . , . , . , . . . . . . - . , . , . , . , . ,B2
, , . , . , . , . , . , 24
. bolts,t;ghteningtorque ..............H8 58
installation J2 59 bolts,differenttypes ................... H6 57
Camshartsprocket.rear Cylanderh6ad gasket
B2 24 types..,,.,,,.,,,.,,,......,,.,,,, 55
i n s t a l l a t i o n. , . , . , . . . . . . . . _ . , , , , , . , , , , , , , ,K8
,,,., 67 i n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . .H. .5. . . _ . . . . . .51

Camshaft Exhaustmanitold
r e m o v a l. . . , . , . , . , , , , . , . , . . . . . . . . . , . , . , . , . ,E. ,1. ,-.5 43 A3 19
endf|oat ...........-........................... 46 i n s t a l l a t i o n. . . . . . . . . . . . . . . . . . . . . . _ K22 71
i n s l a 1 1 a 1 i o. .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . .G. . .9- -1 3 54
G1114 54
removal...,.,.,.,.,.,.,... B7 26
Clutch lnstallation D23 40
r e m o v a l. , , , , , , , , , . , . , . , . 87 26 ringgear,replacement .,.,.........,., 34
i n s t a 1 1 a t i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . - . . .D24
.... 40
Gudgeonpins
Connecting rod bearings c6
814- 17 21 fit, in piston c10 32
i n s t a 1 1 a r i o n . . . . . . . . . . . . . . . . . . . . .D12-16
. . . . . . . . . . . .38
_. c13 32
installation D9 37
Connectingrods
axialclearance.,,..,..-...-...,.,.,,,.,.,., 27 Ini€ctionpump
remova1 ........................................
B1 6 -1 7 2a remova1,.,.,,,,,.,.,... Al2-14 22
disassembly, piston-conrod ........ c6 31 insrallation,setting......................
K4-.14
studrep1acement.,.,........,...,,.,,,.,, c14-15 32 checkin9.........................K ..1
. .2. . . . . . . . . 68
bushrep1acement ........,.,,,.,,,.,.,.,.
c]6-17 33
inspection .,.,,,,,,.,.,.........,.,.,,,.,.,.,.
c20 34 Iniectionpump belt
assembly, piston-conrod .............D9 37 A.12 22
installation D12-18 38 i n s t a 1 1 a i.i .o. n
................... K8
tension................... K9
Crankshaft
removal.,,,.,.,.,.,... 818 2A Injectionpump gear
I n s p e c t r o n , , . , . , . . . . . . . , . , . , . , . , . , . ,c2 .,........ 29 A',l3 22
i n s t a 1 1 a i i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3
.... 36 i n s t a 1 1 a t i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .K. .5. . 66
D5 37

C.ankshaft oil seal B5 25

rear,remova1,.,.,...,..,.,.,,,,,.,.,.,.,.,..
B8 26 installation K1 65
installation.................................._
07 31
front,removal 810 26 Intake m6nitold
installation D20 39 remova1,.,.,.,.,.,... A3 ,I9
i n s t a l l a t i o n. . . . . . . . . . . . . . . . . . . . . . . . _ . . . . .K23
..... 11
Crankshaftpull€y
B3 24 Main bea.ings
insla11ation
...................................
J1 59 removal...,.,,,,,,,.,,,.,.....,.,.,.,.,.,.,....
818 2a
installation D1-4 36
Cylinderbore

74
 Group21 Reconditioningengine

Opera- p.g. Op€ra- Page

tion tion
Oil filter Swirl ch.mb6rs
remova|,...,...,.,.,...,.....,.,.....,.........
811 27 removal..,.........,.,.,.............,.........
E8 45
insta|1ation...................................
D30 42 installation
................................... 53
Oilie$ lin cylind6rh6.d) Tappets
installation ................................... 51 inspection,,,.,.,.,...,.,.,.,.......,.....,...
F4 41
installation
...................................
G8 53
Oil pump
removal.,...,.,.,.,.,...,.,...,.,...,..........
812 Timing g6ar belt
disassembly/reassembly .,..........c23-24 34 re|noval.....,..............................,.,.
B1 24
anspection.........,.,.,...,...,...,.,.....,..
c25 35 installation.....................,...,.........
J2 59
inst6llation
.,.,.,...,...,.,.,...,,.,,....,..,,
D19 39 tensron.,...,...,...,...........,...,.,.,...,.,.
J5 60
Oil sirainer
remova1,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.
912 27
remova1,.,.,.....,.....,.....,.....,.,...,.....
E9 45
install6tion...,...,..,,...,...,...,...,...,...
D22 40 grinding.......................................
F9-12 4a
Pilot beadng checking/grinding stem ..............G2 51
removal........................................
B9 26 install6tion
...................................
G4-5 52
installation
................................... 37 G9-17 61
rypes-------------------..- G3 52
Pistonpins
seegudgeonprns Valve cov€r gasket
types-..--...-....-...--...-------. J 1 9 64
Pbton rings
c5
remova1,.,...,.......,...,.,.,.,.,.,.,.,.,.,.,. Valv€discs(shims)
gapmeasurement c11 32 checking ....................................... 46
c9
axialc1earance..,......,...,...,...,...,... inst6llation.................................., 53
installation
..,.....,.,.,.,.,.....,........,...
D10-11 38
V.lvs guides
Pistons cl€arance, guide-va1ve,..........,..., Ft 46
removal...,.....,.,.,.,........................
816-17 28 rept8cement...,...,..,,...,..,...,...,.,...,
F6-8 47
disassembly,piston-conrod........ oil seals,remova1.........................
E10 46
diameter,,.,.,..,...,.......,-.,-----,- c4 30 insta11ation...................................
G4 52
assembly. piston-conrod..,...,...,.. D9
insta11ation ................................,.,
D12-17 38
lift hsight ................,.,...,..............
H1 56 grinding................,.,.,..................
F9-12 48
r€p1acement,.,.,.,.,.,.,.,.,...,........,...
F13-21 49
Prcssurc plate
temovat.,.....,.....,.,...,.,.,.,.,.,.,.,...,.,
B7 26 V.lvo 3prings
installation...................................
D25 4l rcmova1,.,.,...,.,...,.,......................, 45
checkin9......................................, 47
Ring geal
insta11ation.....................,...,...,...... 53
c21-22 34

Sump Vibr6tion d.mp€r

rcmovat.....--.,,...,.__---------, 812 A6 20
installation
...................................
D22 40 installation J3 59

75
 National
Institute
for
AUTOMOTIVE
SERVICE
€XCELLENCE I

I
T,OLVO
SUPPOBTSVOIIJI{TANY
MECHANTC
CtnnACAn0il
BYTHtN,I,A,S.E.
(U.S.A.
only)

Your
ftrostimportant
specialtool