Target Audience:
Volvo owners, independent repair shops, automotive technicians specializing in older Volvo models and diesel engines.
Value Proposition:
Provides essential, manufacturer-level technical data for maintaining, diagnosing, and repairing Volvo vehicles equipped with D20/D24 diesel engines, crucial for preserving these classic vehicles.
Uniqueness:
Focuses on a specific, and somewhat niche, diesel engine series widely used across various Volvo platforms and some other manufacturers in the specified era, offering specialized knowledge.
Engine Focus:
Detailed coverage of the D20 (2.0L) and D24 (2.4L) diesel engines, including inline 4 and 5-cylinder variants.
Diagnostic Tools:
Information likely includes specific diagnostic procedures and parameters relevant to these diesel powerplants.
Historical Relevance:
Essential for owners of classic Volvo vehicles from the late 70s to late 80s, such as Volvo 240 series, 700 series, and Volvo 300 series, which utilized these engines.
Primary Coverage:
Workshop Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics
Estimated Page Count:
High (typical for comprehensive workshop manuals, exact count not specified in product info but expected 500+ pages for full coverage)
Manual Type:
Workshop Service Repair Manual
Language:
English (standard for international service manuals, assumed)
Engine:
D20, D24 Diesel Engines (In-line 4 and 5-cylinder variants)
Fuel System:
Diesel injection systems (Bosch VE, Bosch inline)
Cooling System:
Radiator, thermostat, water pump, hoses, fan
Lubrication System:
Oil pump, oil filter, oil passages, oil pressure
Ignition System:
Glow plug system, starting system
Exhaust System:
Manifolds, pipes, mufflers, catalytic converters (if applicable)
Transmission:
Manual and Automatic Transmissions (specific models used with these engines)
Drivetrain:
Clutch, driveshafts, differentials
Suspension:
Front and rear suspension components, shock absorbers, springs
Steering:
Steering gear, power steering system, steering column
Brakes:
Hydraulic system, calipers, discs, drums, parking brake
Electrical System:
Battery, alternator, starter, wiring diagrams, fuses, relays
Body And Chassis:
Body panels, doors, windows, interior trim, chassis components
HVAC:
Heating, Ventilation, and Air Conditioning systems
Maintenance:
Scheduled maintenance, oil changes, filter replacements, tune-ups
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault codes
Repair:
Step-by-step repair instructions for all major components and systems
Overhaul:
Engine and transmission overhaul procedures, component rebuilds
Installation:
Installation procedures for replacement parts and accessories
Specifications:
Torque specifications, clearances, measurements
Wiring Diagrams:
Detailed electrical system schematics
Depth:
Comprehensive - Covers from basic maintenance to full engine rebuilds and complex electrical diagnostics.
Diagnostic Level:
Advanced - Includes symptom-based troubleshooting charts and component testing procedures.
Repair Detail:
Detailed step-by-step instructions with diagrams and illustrations.
Engine Variants:
D20 (4-cylinder), D24 (5-cylinder)
Displacement D20:
2.0 Liters (approx. 1986 cc)
Displacement D24:
2.4 Liters (approx. 2400 cc)
Bore Stroke D24:
90 mm x 94 mm (approximate, varies by specific D24 variant)
Compression Ratio D24:
Typically around 20.5:1 to 22:1 (varies by specific D24 variant)
Valve Train D24:
Overhead Valve (OHV) with pushrods and rocker arms, driven by a timing belt.
Horsepower D24 Naturally Aspirated:
Typically in the range of 75-85 HP (varies by model year and specific D24 variant)
Torque D24 Naturally Aspirated:
Typically in the range of 105-120 lb-ft (varies by model year and specific D24 variant)
Turbocharged Variants Mention:
D24T and D24TIC models offered turbocharged variants with increased power output (e.g., 100-120 HP).
Injection Pump Type:
Bosch VE (rotary) or Bosch inline injection pumps, depending on the specific engine variant and market.
Glow Plug System:
Pre-heating system essential for cold starts.
Standard Transmission Type:
Manual Transmission (e.g., M46, M47 for Volvo models)
Optional Transmission Type:
Automatic Transmission (e.g., AW71, BW35 for Volvo models)
Clutch Type:
Dry single-plate clutch (for manual transmissions).
Torque Converter:
Used in automatic transmission variants.
Vehicle Platform Association:
Commonly found in Volvo 200 Series (240, 244, 245) and 700 Series (740, 760) models, as well as some Volvo 300 Series models.
Wheelbase:
Varies significantly by Volvo model (e.g., ~2640 mm for 240 series).
Overall Length:
Varies significantly by Volvo model.
Curb Weight:
Varies by model and configuration, typically 1200-1500 kg for vehicles equipped with these engines.
Crash Test Era:
Vehicles from this era have safety standards that differ from modern ratings. Volvo was a pioneer in safety, so expect good performance for its time.
ABS:
Anti-lock Braking System was optional or standard on higher trims and later models in this range.
Seatbelts:
Three-point seatbelts, often with inertia reel.
Airbags:
Driver-side airbags were introduced later in the production run and not universally standard across all models in this range.
Rollover Protection:
Volvo's reputation for strong passenger compartments.
Infotainment Systems:
Basic to mid-range for the era. Likely cassette player, AM/FM radio, possibly a graphic equalizer. No digital displays or modern connectivity.
Driver Assistance Features:
Limited by era. May include features like cruise control on higher trims. ABS was optional on some models.
Connectivity Options:
No modern connectivity (Bluetooth, USB, Wi-Fi). Electrical system focused on core vehicle functions.
Oil Change Interval:
Typically every 5,000-7,500 miles or 6-12 months (refer to manual for exact recommendation).
Fuel Filter Replacement:
Every 15,000-30,000 miles (refer to manual).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on operating conditions (refer to manual).
Timing Belt Replacement:
Critical for D20/D24 engines. Typically every 60,000-100,000 miles or 5-7 years. Failure leads to catastrophic engine damage. Refer to manual for exact interval and procedure.
Engine Oil Type:
API CD or higher specification diesel engine oil. Viscosity: 15W-40 or 10W-30 depending on ambient temperature. Consult manual for precise recommendation.
Engine Oil Capacity D24:
Approximately 5.5 - 6.5 liters (including filter) for the D24.
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors. Typically a 50/50 mix with distilled water.
Transmission Fluid Manual:
GL-4 Gear Oil. Viscosity typically 75W-90 or 80W-90. Consult manual.
Transmission Fluid Automatic:
Dexron II or equivalent ATF fluid (for AW71/BW35).
Head Gasket Failures:
D24 engines are known for potential head gasket failures, especially if overheated or poorly maintained, leading to coolant/oil leaks or loss of compression.
Glow Plug Issues:
Malfunctioning glow plugs can lead to starting difficulties in cold weather.
Timing Belt Wear:
Due to its critical nature, regular inspection and timely replacement of the timing belt are paramount to prevent severe engine damage.
Injection Pump Seals:
Leaking seals on Bosch injection pumps are a common maintenance item.
Turbocharger Issues:
On turbocharged variants (D24T/TIC), issues can include worn turbo bearings or boost leaks.
Volvo Legacy:
Volvo's long-standing reputation for safety, durability, and engineering robustness.
D Series Development:
The D20 and D24 engines were based on Volkswagen's diesel engine designs, notably derived from the EA827 engine family, and were adapted and produced by Volvo for their vehicles.
D24 Introduction:
The D24 five-cylinder diesel was notably introduced in the Volvo 760 in 1982, offering a smoother and more powerful diesel option than many contemporaries.
Manufacturing Locations:
Volvo vehicles were primarily manufactured in Sweden.
Engine Application:
These engines were used in various Volvo models throughout the 1980s, providing an economical and durable diesel option.
Volvo Safety Award:
While not directly for the D20/D24 engine, Volvo vehicles of this period consistently received high marks for safety and durability from automotive publications and safety organizations.
Diesel Engine Reputation:
The D24 gained a reputation for being a robust, albeit not particularly powerful or refined, diesel engine, valued for its fuel economy and longevity when properly maintained.
