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Volvo Penta AQ125A, Workshop Manual

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Volvo Penta AQ125A Workshop Manual Download Page 31

29

80.

Remove the four screws and remove the cover.

81.

Remove the spring, ball and gears. Clean all
parts and replace those damaged or worn.

 82.

Check the spring for the pressure release valve.
Test data:
Length  unloaded

47.6 mm (1.8740")

Length loaded with
44±4 N (4.4±0.4 kp)
(32.43±2.95 lbf.ft.)

32.0 mm (1.260")

Length loaded with
61±6 N (6.1±0.6kp)
(44.96±4.42 lbf.ft.)

26.0 mm (1.024")

 83.

Refit the gear wheels and check the gear flank
clearance which is 0.15–0.35 mm (0.0060–
0.014").

Summary of Contents for AQ125A

Page 1: ...Workshop Manual Engine Unit AQ125A B AQ145A B C 2 0 ...

Page 2: ......

Page 3: ...Cylinders pistons connecting rods crankshaft 25 28 Fuel pump oil cooler lubricating oil pump 28 30 Heat exchanger carburetor flywheel cover 31 33 Assembling Crankshaft pistons lubrication oil pump flywheel 33 35 Oil sump cylinder head camshaft 36 37 Intermediate shaft seals camshaft gear wheel 38 39 Intermediate gear marking timing belt 40 42 Oil pump drive circulation pump valve adjustment 42 46 ...

Page 4: ...r product versions contained in the con tents list Ensure that the correct workshop litera ture is being used Read the safety information and the Workshop Manual General Information and Repair In structions carefully before starting work Important In this book and on the engine you will find the fol lowing special warning symbols WARNING If these instructions are not fol lowed there is a danger of...

Page 5: ...solvent degreasing agents and waste from washing parts Never allow a naked flame or electric sparks near the batteries Never smoke in proximity to the batteries The batteries give off hydro gen gas during charging which when mixed with air can form an explosive gas oxyhy drogen This gas is easily ignited and highly volatile Incorrect connection of the battery can cause a spark which is sufficient ...

Page 6: ...f injury or dam age Components in the electrical system ignition system gasoline engines and fuel system on Volvo Penta products are designed and con structed to minimize the risk of fire and explo sion The engine must not be run in areas where there are explosive materials Always use fuels recommended by Volvo Pen ta Refer to the Instruction Book The use of lower quality fuels can damage the engi...

Page 7: ...This Workshop Manual has been developed primari ly for Volvo Penta service workshops and qualified personnel Persons using this book are assumed to have a grounding in marine drive systems and be able to carry out related mechanical and electrical work Volvo Penta is continuously developing their prod ucts We therefore reserve the right to make chang es All the information contained in this book i...

Page 8: ...e malfunction or a shorter operational life Our joint responsibility Each engine consists of many connected systems and components If a component deviates from its technical specification the environmental impact of an otherwise good engine may be increased signi ficantly It is therefore vital that wear tolerances are maintained that systems that can be adjusted are adjusted properly and that Volv...

Page 9: ...ents have varying properties and are used for different types of jointing trengths operating temperature ranges resistance to oil and other chemicals and for the different materials and gap sizes in the engines To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type is used on the joint where the agents are re quired In this Volvo Penta Servi...

Page 10: ...ft device 10 Steeringarm 11 Fuse box exec USA 12 Serialnumber 13 Fuse exec USA 14 Fuse not USA 15 Fuelpump 16 Sea water pump 17 Grease joint upper steering shaft journal 18 Grease joint drive shaft journal 19 Oil filler cap engine 20 Water filter 21 Heatexchanger 22 Draining seawater 23 Luboil filter 24 Oil cooler only AQ145A 25 Draining seawater 26 Draining seawater 27 Draining freshwater AQ145A ...

Page 11: ...etor 3 Remove the alternator drive belt cable harness ignition coil main fuse starter motor ignition cables and distributor NOTE Mark the cables before they are removed 4 Remove the cooling water pipe 1 and the bracket for the ignition coil 2 Remove the screw 3 and draw up the dip stick with its tube 4 Then remove the feed pump 5 and the induction pipe 6 NOTE There are double gaskets plus an inter...

Page 12: ...2 for the ignition cables The holder is fixed with two guide pins 7 Remove the cap and lift out the strainer 1 from the heat exchanger Then pull up the rubber ring s tongue 2 The tongue is marked UP The cover 3 is now loose and can be lifted up Not on AQ125 8 Pull the heat exchanger s fresh water section to one side The fresh water section is mounted on a rubber bushing 1 and the water pipe 2 whic...

Page 13: ...st pipe on AQ125 10 Remove the remaining three screws X on the heat exchanger and draw it to one side from the circulation pump 11 Remove the cooling water pipe between the oil cooler and the exhaust pipe Not on AQ125 Then remove the exhaust pipe 12 Unscrew the oil filter Use tool 999 2903 or push a screwdriver through the filter and work it loose NOTE Be careful not to spill oil ...

Page 14: ...position After this the insert s channels can be cleaned 15 Remove the saltwater pump and the generator s tensioning bracket The spanner width for the saltwater pump is 10 mm The other screws which hold the cover have a spanner width of 8 mm Check the impeller the key and the packing on the pump s front side plus the sealing ring on the pump s rear side Clean the pump and re place damaged parts 16...

Page 15: ...ed as a complete unit if it has been damaged 19 Remove the crankshaft pulley Six screws The spanner width is 10 mm 20 If the belt s markings have disappeared the belt is to be marked before it is removed The marking of the belt is carried out as follows Make a mark by the camshaft s pulley marking Make a mark by the intermediate gear s marking and two marks on the crankshaft pulley s marking Undo ...

Page 16: ...and the rubber are beginning to separate or if the tread on the timing belt is worn The timing belt is to be changed every five hun dred hours 23 Remove the cross piece from the intermediate gear wheel Check that cross piece is not dam aged Then remove the screw from the carrier Use counterforce 999 5034 Remove the carrier and the pulley Then remove the carrier from the pulley Mild force from the ...

Page 17: ...7 Remove the screws from the sealing flange The flange is also tightened with two of the screws in the oil sump Remove the flange plate and re move the seals Use tool 999 5025 for the small seal and tool 999 5024 for the large seal 28 Unscrew the flywheel cover s four screws and the three screws which hold the protective plate on the underside between the cover and the cylinder block ...

Page 18: ...drive Then lift up the oil pump drive 31 Pull out the intermediate shaft Use the impact tool 999 4030 where necessary NOTE Be care ful to make sure that the intermediate shaft s gearwheel does not damage the bushes in the cylinder block s bearings Cylinder head 32 Remove the valve cover the gasket and the cres cent shaped rubber seal and check the marking on the camshaft bearing caps ...

Page 19: ... the camshaft Use the bear ing cap s nuts The camshaft is held in position with the tool Undo the other four camshaft bear ing caps 35 Remove the seal 1 from the camshaft Then undo the tool spindle and release the camshaft Remove the tool and lift out the camshaft 36 Remove the screws in the cylinder head Use hexagonal socket key 10 mm Lift away the cylin der head and remove the gasket Remove the ...

Page 20: ...580 39 Remove the rubber ring collets upper washers springs lower washers and valves Then remove the valve seals from the inlet valve guides Clean all the parts Remove carbon deposits from the combustion chamber and the valves 40 Grind the valves if necessary in a valve grinding machine The angle is the same for both the ex haust and the inlet valves ...

Page 21: ...round by marking the valve seat face and turning it against the valve seat with light pressure If the marking is not evenly distributed on the whole of the seat leaking valve the valve is ground further and a new check is carried out until the result is satisfactory 44 Check the wear of the valve and the valve guides The play for the inlet valve is 0 030 0 060 mm 0 0012 0 0024 and for the exhaust ...

Page 22: ... too much play in the valve pushers If there are signs of wear on the plain surface of the shim it should be chan ged The play between the shim and the valve presser is 0 009 0 068 mm 0 0004 0 0027 48 Replace the valve pressers in the cylinder head and check that the play is not too much or that they do not stick The play between the valve pressers and the cylinder head is 0 030 0 075 mm 0 0012 0 ...

Page 23: ... tool 999 5028 for the exhaust valves The cylinder head is to be at room tempe rature The pressing force for fitting the valve gui des is to be at least 9000 N 900 kp 2016 lbf If this pressing force is not obtained for the guides the hole is to be reamed and a suitable oversized valve guide is to be fitted Press the guide down until the tool comes up against the cylinder head This gives the guide ...

Page 24: ...rectly so that the thread in the aluminium cylinder head is not damaged The tightening torque is 25 30 Nm 2 5 3 0 kpm 18 4 22 1 lbf ft 53 Remove the locking ring for the bearing on the in put shaft 54 Remove the bearing for the input shaft Use tool 999 4090 Remove the flywheel 55 Remove the sealing flange NOTE Two screws from the sump must also be removed 56 Remove the seal from the sealing flange...

Page 25: ... oil pipe from the cylinder block And from the pipe where neces sary 59 Note that the crankshaft and the crankshaft bear ing caps are numbered Then remove the bearing caps and remove the bearing shells 60 Press out of the pistons from the cylinders Let the pistons fall on a soft surface so that they can not be damaged Then remove the piston rings Use piston ring pliers ...

Page 26: ...n side Remove the main bearing caps 63 Lift out the crankshaft and remove the bearing shells from the block and the bearing caps CLEANING AND INSPECTION 64 Clean and carefully inspect the cylinder block The plugs for channels are to be removed before cleaning Re fit the plugs after cleaning has been completed Tightening torque 1 4 NPTF 20 Nm 2 kpm 14 7 lbf ft 3 8 NPTF 30 Nm 3 kpm 22 1 lbf ft ...

Page 27: ...sification marking 66 Each cylinder liner has a letter which indicates its and pistons class Oversizes indicated by nominal diameter meas urement Pistons 67 Measure the pistons with a micrometer at right angles to the gudgeon pin hole and 6 mm 0 25 from the lower edge Piston diameter standard AQ145 C marked 95 940 95 950 mm 3 7776 3 7780 in D marked 95 950 95 960 mm 3 7787 3 7791 in E marked 95 96...

Page 28: ... NOTE When fitting in a worn cylinder liner the rings must be tested at bottom dead centre since the cylinder liner diameter is at a minimum there 70 Measure the piston ring gap with a feeler gauge Increase the gap with a special file where neces sary The gap for AQ145 is to be Compression rings 0 40 0 65 mm 0 0157 0 0256 in Oil scraper ring 0 30 0 60 mm 0 0118 0 0236 in The gap for AQ125 is to be...

Page 29: ...ole is reamed to the correct dimen sion Use a reamer with a guide ring and make small cuts at a time 73 Press out the small end bush with tool 999 5017 74 Press in the new bushing with tool 999 5017 75 The gudgeon pin is to slide through the hole with light thumb pressure without any appreciable looseness Sliding fit The bush is machined if necessary 76 Check the connecting rods for straightness t...

Page 30: ...rsizes See the technical data Overhauling the oil cooler AQ145 78 Remove the centre screw 1 and remove the end cover 2 and 3 Remove the O rings 4 which remain on the insert Then press out the insert 5 and be careful not to spill oil Clean and blow th rough the insert with compressed air Check that there is free flow in the drain tap 6 Re fit the in sert in the housing and slide on the O rings Re p...

Page 31: ...or worn 82 Check the spring for the pressure release valve Test data Length unloaded 47 6 mm 1 8740 Length loaded with 44 4 N 4 4 0 4 kp 32 43 2 95lbf ft 32 0 mm 1 260 Length loaded with 61 6 N 6 1 0 6kp 44 96 4 42lbf ft 26 0 mm 1 024 83 Refit the gear wheels and check the gear flank clearance which is 0 15 0 35 mm 0 0060 0 014 ...

Page 32: ...arance is 0 02 0 12 mm 0 008 0 0047 85 Lay the ball and the spring in position and refit the cover 86 Refit the strainer and the locking clamp Applies only to the earlier model 87 Fit new sealing rings and press the pipe into posi tion in the pump ...

Page 33: ...he plain pack ing and the other sealing rings Wash and rinse all parts including the expansion tank Check that the insert s channels are free from contamination Use compressed air Change damaged parts As semble the heat exchanger in the opposite order see the picture Use new sealing rings a new packing a new copper washer support ring and O rings NOTE The cover for the seawater strainer is to be l...

Page 34: ...y 92 Disassemble the idling jet 1 and holder 2 for the main jet Unscrew the jet from the holder Blow the jets clean and replace if necessary Unscrew the mixing screw 3 and blow clean the duct Screw 4 locks tight the air cone 5 93 Rotate the throttle shaft 1 and press out the push rod 2 from the lever 3 Then rotate the push rod downwards and disassemble the check valve 4 Blow the check valve clean ...

Page 35: ...mbling Overhauling the flywheel cover 95 Remove the sealing ring 1 in the flywheel cover Check the primary shaft 2 and the bearing 3 If either one is damaged the lock rings 4 are to be undone and the shaft with bearings is to be pressed out Remove the sealing ring 5 and re move the lock ring 6 Replace the damaged parts and then fit the lock ring 6 on the primary shaft and the sealing ring 5 Then p...

Page 36: ...g rods is turned towards the crankcase s starboard side oil filter side Fit the lock rings 100 Fit the piston rings with piston ring pliers The pis ton rings are to be fitted as shown in the picture The upper ring is chromium plated The lower compression ring is marked TOP Turn the pis ton ring so that the gaps are at an angle of 120 from each other 101 Fit the bearing shells in the connecting rod...

Page 37: ...htened 104 Fit a new sealing ring in the rear sealing flange Use tool 999 2817 The sealing ring is to be pressed in sufficiently so that a new wear surface is obtained against the crankshaft Then fit the se aling flange with a new seal against the engine Lubricate the seal s rubber lip and the opposite surface on the crankshaft before fitting Great care must be exercised so that the rubber lip is ...

Page 38: ...108 Lubricate the cylinder head screw threads and the washers then fit and tighten the screws The tight ening force is 90 Nm 9 kpm 66 lbf ft The tight ening is to be carried out in two stages 1 60 Nm 6 kpm 44 2 lbf ft 2 90 Nm 9 kpm 66 lbf ft The screws are to be re torqued after the engine has been warmed up and allowed to cool for 30 minutes When retorquing screws must first be loosened sufficien...

Page 39: ...ed 113 Oil and lay the other three bearing caps in posi tion and fit the nuts for the four bearing caps Tighten them somewhat NOTE The forward bearing cap s surface against the cylinder head is to be painted with sealing fluid before it is fitted Make sure that the seals fit correctly before the front bearing cap is tightened Then remove the tool 114 Oil and fit the last bearing cap Then tighten a...

Page 40: ...ten the screws for the sump The tightening torque is 10 Nm 1 0 kpm 8 0 lbf ft Then check the intermediate shaft s axial clear ance The clearance is 0 20 0 46 mm 0 0079 0 0181 in 118 Fit the crankshaft seal with tool 999 5024 Lubri cate the seal s rubber lip before fitting If the spa cer tube on the crankshaft has not been removed the position for the sealing ring is to be changed so that a new con...

Page 41: ...mshaft The flywheel s groove is to be fixed on the guide pin on the camshaft NOTE The guide plate s bend is to point backwards against the seal 121 Fit the screw the guide plate and the washer and tighten it with a torque wrench Use tool 999 5034 as a counterforce The tightening torque is 50 Nm 5 0 kpm 36 9 lbf ft 122 Paint mineral grease or similar lubricant in the pulley s hub and fit it in posi...

Page 42: ...n the intermediate shaft into position after marking 126 Place the valve cover in position without the gas ket Check that the camshaft s pulley s marking agrees with the marking on the valve cover Then check that the timing belt is in good condi tion NOTE Oil or grease must not be used on the belt Coloured marks stripes are on the belt so that the adjustment can be checked Line up the mark with tw...

Page 43: ...the belt Then tighten the nut 129 Turn the crankshaft clockwise a few degrees This is to take up the backlash between the pul leys NOTE Do not turn the crankshaft anti clockwise otherwise the belt can hop over teeth and alter the adjustment 130 Loosen the nut on the belt tensioner againso that the spring tensions the belt Check that the belt tensioner can move around its shaft Then tighten the nut...

Page 44: ...t intermediate shaft may need to be turned somewhat so that the oil pump drive en gages 133 Fit a new O ring on the cover for the oil pump drive 134 Fit the cover and the brackets for the cooling wa ter pipe NOTE Check first that the cover s pres sure surface which presses against the oil pump drive is not worn ...

Page 45: ...ylinder Both the cams for No 1 cylinder point obliquely upward at equal angles The timing pulley s timing position is 0 NOTE Always turn on the crankshaft s centre screw 138 Measure the valve clearance with a feeler gauge for No 1 cylinder Clearance when checking Cold engine 0 25 0 45 mm 0 010 0 018 in Hot engine 0 30 0 50 mm 0 012 0 020 in adjustment not necessary Clearance when adjusting Cold en...

Page 46: ...t the presser s groove lies over the edge and is accessible with the pliers 141 Remove the shim with pliers 999 5026 142 Measure the thickness of the shim with a micro meter Calculate the thickness of the shim which gives the right clearance Ex Measured clearance 0 30 mm 0 012 in correct clearance 0 40 mm 0 016 in Clearance difference 0 10 mm 0 004 in Measured thickness on the existing shim 3 80 m...

Page 47: ... 884 516 See page 61 144 Oil the new shim and lay it in position 145 Remove tool 999 5022 Turn the cam position in the position for firing on cylinder No 3 Measure the clearance with a feeler gauge and rectify where necessary according to the instructions above Repeat the operations on cylinders No 4 and 2 in the stated order 146 Check the clearance for all the valves NOTE Turn the camshaft a few ...

Page 48: ...ankshaft to the firing position for No 1 cylinder Check this by unscrewing the oil filler cap and seeing how the camshaft s cams are po sitioned and by checking the marking on the pul ley See also point 138 149 Remove the distributor cap 150 Turn the rotor so that the line on it is at 60 from the line on the distributor ...

Page 49: ...akers Fit a new breaker set The contact brea king gap is 0 40 mm 0 016 in Change the con denser 6 at the time by undoing the screw 7 Tighten a new condenser and connect the tab connection and replace the washer Press the ro tor in position and refit the distributor cap NOTE The cam angle is checked and adjusted during test running See Technical Data 154 Fit the oil pressure sender 1 The tightening...

Page 50: ...y The cooling water pipe for AQ125 is connected from the exhaust pipe to the heat exchanger It may be necessary to undo the centre screw 3 in the oil cooler s co ver in order to align the cooling water pipes Then tighten all the screws Tighten nut No 4 as well Fit the engine mountings Make sure that the rub ber bush 5 on the cooling water pipe comes into the right position 158 Oil the lubricating ...

Page 51: ...pipes in the heat ex changer The guide pin 2 is made of rubber At the same time check that the support screw 3 has a plastic sleeve 162 Place an O ring 1 on the expansion tank and fit the thermostat 2 When necessary the opening temperature of the thermostat is checked by lowering it in hot water At a temperature of 82 C 180 F it must begin to open and must be fully open at 92 C 198 F Check that th...

Page 52: ...crew on the cover NOTE If the strainer is incorrectly fitted the cover cannot be screwed in position 165 Fit the fuel pump Use new gaskets Fit the tensio ning bar and the engine mounting with the bracket for the alternator Then tighten the alterna tor in position and fit and tension the belt so that it can be depressed approximately 5 mm 0 2 in with normal thumb pressure 166 Fit the starter motor ...

Page 53: ...ets AQ125 Fit the carburettor to the induction pipe Use new gasket NOTE On engines having main jet 165 and venturi jet 190 installed a spacer washer with a gasket on each side must be instal led between the carburetor and the inlet manifold 170 Fit the fuel pipe between fuel pump and the car buretor Make sure that all sealing washers are fitted 171 AQ145 Fit the rubber rings and place the air filt...

Page 54: ...e 4 ELECTRIC WIRING DIAGRAM INSTRUMENT PANEL ENGINE Position list 1 Key switch with start button 2 Switch for instrument lighting 3 Temperaturegauge 4 Oil pressure warning lamp 5 Tachometer 6 Chargingwarninglight 7 Switch extra 8 Junction box 9 Battery 10 Main switch 11 Starter motor 12 Chargingregulator 13 Alternator 14 Fuse 15 Oil pressure sender 16 Temperaturesender 17 Ignition coil 18 Distribu...

Page 55: ...tivetachometer Boatabnormallyloaded Weed growth on the boat hull and on the outboarddrive Damagedpropeller Blockage in the cooling water intake oil cooler AQ145 cooling jackets heat ex changer Defect impeller or thermostat flu id level too low in the expansion tank The fuel quality is not corresponding to the ignitionsetting Cable Colour Code Marking Colour mm2 A Red 10 6 A Red 5 3 B Light blue 1 ...

Page 56: ...ift for fitting ball bearing in flywheel 9992817 Drift for fitting crankshaft oil seal on enginerearend 9992818 Drift for removing valve guide 9994090 Puller for ball bearing in flywheel 9995017 Drift for removing and fitting bushing in connectingrod 9995021 Press tool for removing and fitting crankshaft ...

Page 57: ...ry 9995023 Fixture for stand 9995024 Drift for fitting crankshaft oil seal 9995025 Drift for fitting intermediary shaft oil seal 9995026 Tool for adjusting spacer 9995027 Drift for fitting valve guide intake 9995028 Drift for fitting valve guide exhaust ...

Page 58: ... mm 3 165 in 71 0 mm 2 795 in Height from gudgeon pin centre to piston top 46 4 mm 1 8268 in 46 0 1 811in Piston clearance 0 05 0 07mm 0 01 0 03mm 0 0020 0 0028in 0 0004 0 0012in Piston standard size 95 940 95 990mm 91 991 92 000mm 3 7772 3 7791in 3 3 6217 3 6220in 4 Piston oversize 1 96 237 96 252mm 92 472 92 487mm 3 7889 3 7894in 3 6406 3 6412in Piston oversize 2 96 537 96 552mm 92 972 92 978mm ...

Page 59: ... 0200 in undersize 62 95 62 96mm 2 4783 2 4787in Mainbearings Diameter standard 63 49 63 52mm 2 4996 2 5008in 0 25 mm 0 0100 in undersize 63 24 63 27mm 2 4898 2 4909in 0 50 mm 0 0200 in undersize 62 99 63 02mm 2 4799 2 4811in BIG END BEARINGS Big end bearing journals Width of bearing recess 24 75 24 85mm 0 9744 0 9783in Diameter standard 53 99 54 00mm 2 1255 2 1260in 0 25 mm 0 0100 in undersize 53...

Page 60: ...alveheaddiameter 44 0 m 1 7323 in Stemdiameter 7 95 7 97mm 0 3130 0 3138in Valve seat angle 45 5 Seat angle in cylinder head 44 75 Seat width in cylinder head 1 7 mm 0 0669 in Clearance warmengine See page 43 Clearance coldengine See page 43 Exhaust Valveheaddiameter 35 0 mm 1 3780 in Stemdiameter 7 92 7 94mm 0 3118 0 3126in Seat valve angle 45 5 Seat angle cylinder head 44 75 Seat width in cylind...

Page 61: ...Length loaded with 40 48 N 4 0 4 8 kp 8 81 10 58 lb 32 0 mm 1 2598 in Length loaded with 55 67 N 5 5 6 7 kp 12 12 14 76 lb 26 0 mm 1 0236 in FUEL SYSTEM Fuel pump Type Diaphragmpump Make Carter Feed pressure 0 15 0 28 kp cm2 2 4 psi Carburetor Type Downdraughtcarburetor Makeanddesignation Solex 44 PAI 4 Venturi 31 34 Mainjet 145 155 165 1 Idlingjet 62 Air jet 185 180 190 1 Needle valve 1 5 1 7 Flo...

Page 62: ... 198 F WEARTOLERANCES Cylinders To be re bored when wear amounts to if engines has abnormaloilconsumption 0 30 mm 0 0118 in Crankshaft Max permissible out of round on main bearing journals 0 05 mm 0 0020 in Max permissible out of round on big end bearing journals 0 07 mm 0 0028 in Max crankshaft end float 0 037 0 147mm 0 0015 0 0058in TIGHTENING TORQUES Tightening torque applies to oiled screws an...

Page 63: ... Designation Thickness mm in 463551 2 Shim 3 55 0 140 463552 3 3 60 0 142 463553 6 3 65 0 144 463554 8 3 70 0 146 463555 12 3 75 0 148 463556 12 3 80 0 150 463557 12 3 85 0 152 463558 12 3 90 0 154 463559 12 3 95 0 156 463560 12 4 00 0 158 463561 8 4 05 0 160 463562 6 4 10 0 162 463563 3 4 15 0 164 463564 2 4 20 0 166 Tightening sequence for cylinder head screws Tightening to be carried out in two...

Page 64: ...d 96 00 96 03 mm 3 7795 3 7898 in Bore oversize 1 96 300 mm 3 7913 in Bore oversize 2 96 600 mm 3 8031 in The cylinder bores are to be rebored when the wear is 0 10 mm 0 004 in if the engine has excessive oil consumption PISTONS Material Light alloy3 Height total 64 7 mm 2 547 in Height from gudgeon pin centre to piston top 39 7 mm 1 563 in Piston clearance 0 010 0 030 mm 0 0004 0 0012 in Piston s...

Page 65: ... Number on each piston 1 Height 3 475 3 490 mm 0 1368 0 1374 in GUDGEON PINS Fully floating Circlips at both ends in piston Fit Connecting rod Close running fit Fit In piston Push fit Diameter standard 23 0 mm 0 9055 in Dimension oversize 23 05 mm 0 9075 in Length 65 mm 2 5591 in CRANKSHAFT Crankshaft end float 0 080 0 270 mm 0 0031 0 0106 in Main bearings radial clearance 0 024 0 072 mm 0 0009 0 ...

Page 66: ...nnectingrod bearing journals Ovality max 0 004 mm 0 0002 in Taper max 0 004 mm 0 0002 in Width of bearing recess 23 9 26 1 mm 0 9409 1 0276 in Diameter standard 48 984 49 005 mm 1 9285 1 9293 in 0 25 mm 0 0100 in undersize 48 734 48 755 mm 1 9187 1 9195 in 0 50 mm 0 0200 in undersize 48 484 48 505 mm 1 9088 1 9096 in End float on piston 0 25 0 45 mm 0 0098 0 0177 in Length centre centre 152 mm 5 9...

Page 67: ...3 070 43 100 mm 1 6957 1 6969 in rear 42 970 43 000 mm 1 6917 1 6929 in REPLACEMENT NOTE New bearings must be line bored VALVES Inlet Valve head diameter 44 0 mm 1 7323 in Stem diameter 7 95 7 97 mm 0 3130 0 3138 in Valve seat angle 44 5 Seat angle in cylinder head 45 Seatwidth in cylinder head 1 3 1 9 mm 0 0512 0 0748 in Exhaust Valve head diameter 35 0 mm 1 3780 in Stem diameter 7 945 7 960 mm 0...

Page 68: ...m 1 0630 in LUBRICATINGSYSTEM Oilchange excl filter 4 5 dm3 I 7 9 UKp 9 5 USp Oilchange incl filter 5 2 dm3 I 9 2 UKp 11 USp Overhaul 5 7 dm3 I 10 UKp 12 USp Oil pressure at 2000 rpm warm engine 2 5 6 0 kp cm2 36 85 psi Oil grade alternative 1 Volvo Penta engine oil for carburetor engines Oil grade alternative 2 Engine oil SE MS alt SF2 Viscosity SAE 10 W 40 Oilfilter Type Full flow filter 2 Oils ...

Page 69: ...of electrolyte Fully charged battery 1 275 1 285 g cm3 0 0460 0 0464 lb cu in Discharged battery 1 230 g cm3 0 0444 lb cu in Starter motor Type Hitachi Output 0 8 kW 1 1 hp Alternator Output max A W 50 14x50 IGNITION SYSTEM Marking of cylinder 4th nearest the flywheel Spark plugs Bosch W6DC or corresponding Spark plug gap 0 7 mm 0 028 in Distributor Distributor Bosch type JF4 0231 178 017 Ignition...

Page 70: ...ow signs of stretching This can be seen at the middle of the bolt where it has been stretched out the bolts can only be re used 5 times Replace the bolts if there is any doubt regard ing these two points Tightening sequence for cylinder head screws Nm Kpm Lbf ft Main bearings 110 11 0 81 Connecting rod bearings1 stage 1 20 2 0 15 stage 2 60 6 0 43 stage 3 angle tighten 90 Flywheel use new bolts 70...

Page 71: ..._ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ______...

Page 72: ..._ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ______...

Page 73: ... this page write your comments down and post it to us The address is at the bottom of the page We would prefer you to write in English or Swedish From Refers to publication Publication no Issued Suggestion reasons Date Name AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden ...

Page 74: ...7739856 8 English 11 1998 ...

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