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Содержание B27A

Страница 1: ... Service Manual Repairs and maintenance Section 2 21 Reconditioning engine B 27 B 28 260 1975 1983 ...

Страница 2: ...28 is in principle a B 27 with a larger bore 28 27 ce B petrol g Engine type B27A B28A B27E B28E B27F B28F pacity jsoline Model year 1976 1979 1980 1982 1975 1980 1981 1983 1976 1979 1980 1982 Volvos are sold in versions adapted for different markets These adaptions depend on many factors including legal taxation and market requirements This manual may therefore show illustrations and text which d...

Страница 3: ...aning and inspection C 1 41 Assembly D 1 35 Cylinder head reconditioning E 1 26 Assembly cont F 1 33 20 26 38 46 52 Index page 62 r r This manual deals exclusively with the overhaul of the engine For work carried out on the engine when fitted in the car and for engine removal and installation please refer to the separate manuals Order number TP 30447 1 We reserve the right to make alterations ...

Страница 4: ...to specified torque Two types of tightening torques are used in this manu al I Tightening torque 40 Nm 30 ftlbs a torque wrench must be used II Tightening torque 40 Nm 30 ft lbs correct value however it is not necessary to use a torque wrench Specifications Group 20 General Engine serial number and part number Located on a plate in front of the oil filter On B 28 E F 1981 models located on the rea...

Страница 5: ...1 01 mm 3 4646 3 4650 in 3 5826 3 5830 in 2 B marked piston 88 01 88 02 mm 91 01 91 02 mm 3 4650 3 4654 in 3 5830 3 5835 in 3 C marked piston 88 02 88 03 mm 91 02 91 03 mm 3 4654 3 4657 in 3 5835 3 5838 in Liner height above block face 0 16 0 23 mm 0 0063 0 009 in Shims for adjustment of liner height thickness blue paint marking 0 070 0 105 mm 0 0027 0 0041 in white paint marking 0 085 0 120 mm 0 ...

Страница 6: ...arking gudgeon pin 1 Blue 23 514 23 517 mm 0 9257 0 9259 in 2 White 23 511 23 514 mm 0 9256 0 9257 in 3 Red 23 508 23 511 mm 0 9255 0 9256 in MAHLE PISTONS B 27 B 27 A 1976 1979 B 27 E 1975 1978 1979 1980 B27F 1979 1976 1978 Height overall 63 4 mm 62 2 mm 65 3 mm 2 4960 in 2 4488 in 2 5709 in from gudgeon pin centre to piston crown 39 4 mm 38 2 mm 41 3 mm 1 5521 in 1 5039 in 1 6260 in Weight 445 3...

Страница 7: ...3 mm 0 9255 0 9257 in White White 23 507 23 510 mm 0 9254 0 9255 in Red Red 23 504 23 507 mm 0 9253 0 9254 in Piston rings 15 mm Ring gap measured 15 mm 0 6 in from lower edge of cylinder Height mm in mm in 3 mm in Upper compression ring 1 478 1 490 9 0582 0 0587 0 045 0 074 0 0017 0 0029 0 40 0 60 0 0157 0 0236 Lower compression ring 1 978 1 990 0 0779 0 0783 0 025 0 054 0 0009 0 0212 0 40 0 60 0...

Страница 8: ... 006 0 15 0 20 0 006 0 008 0 25 0 30 0 010 0 012 0 30 0 35 0 012 0 014 X X X X X X X Type 2 0 20 0 25 0 008 0 010 0 25 0 30 0 010 0 012 0 30 0 35 0 012 0 014 0 35 0 40 0 014 0 016 X X X Valves mm in 29 5 44 1 7322 7 965 7 980 0 3135 0 3141 26 5 1 0433 Tapered Intake valves 7 975 7 990 0 3139 0 3145 44 5 59 37 iT 1 4566 32 1 2598 Exhaust valves 7 965 7 980 0 3135 0 3141 Valve seats mm in 1 7 2 1 mm...

Страница 9: ... 5944 exhaust 36 9 37 9 1 4527 1 4921 Valve guides are available in three oversizes and are marked with grooves Standard Oversize 1 2 3 Marking No groove 1 groove 2 grooves 3 grooves Reamer for seat 5166 5167 5168 Valve springs Two types of valve springs are in use The springs are colour coded as follows Grey springs B27A 1976 1979 B27E 1975 1978 1979 1980 Sweden Australia B27F 1976 1979 Green spr...

Страница 10: ...t valve clearance on 1st and 6th intake valves to 0 7 mm 0 027 in the intake valves should then open at 1st BTDC 6th BTDC Type 1 7910 245 522 143 or 144 7910 245 412 5 144 0 202 in 5 059 0 199 in 9 3 7 3 Type 2 74 01 269138 74 01269 139 6 004 0 236 in 6 004 0 236 in 9 3 9 3 Type 3 74 01 269 615 74 01 269 616 5 96 0 234 in 5 96 0 234 in 8 3 8 3 Engine type B27 A 1976 1979 B28 A 1980 1981 1982 B27E1...

Страница 11: ...mm Thrust bearing washer thickness standard 2 30 2 35 mm oversized 1 2 40 2 45 mm 2 2 45 2 50 m m 3 2 50 2 55 m m 0 0002 in 0 0003 in 2 7575 2 7583 in 2 7457 2 7465 in 0 0772 0 0774 in 0 0831 0 0833 in 1 1496 1 1 1574 1 1 1614 1 1 1653 1 0 0905 0 0 0944 0 0 0964 0 0 0984 0 1515 in 1594 in 1633 in 1673 in 0925 in 0964 in 0984 in 1003 in Connecting rod bearing journals Out of roundness max 0 007 mm ...

Страница 12: ... time in specified tightening order Retighten according to stages 6 and 7 Tightening sequence for cylinder head bolts o a i i Tightening sequence for main bearings via lower crankcase Main bearings Tighten all nuts in stages 1 30 Nm 22 ft lbs Slacken nut 1 Tighten nut 1 to 30 35 Nm 22 26 ft lbs Angle tighten nut 1 73 77 Slacken and retighten the other nuts in the order specified in stages 2 4 Nm C...

Страница 13: ...m 0 0006 0 0021 in idler shaft 0 015 0 051 mm 0 0059 0 0020 in Relief valve spring length at various loads unloaded 89 5 mm 3 52 in loaded to 88 3 N 8 83 kp 20 lbs 56 5 60 5 mm 2 22 2 33 in Special tools 999 Description use 1426 9 1801 3 2484 7 2520 8 4090 0 5029 7 Drift fitting pilot bearing in crankshaft late type Standard handle used with 5101 and 5953 Centering drift clutch M45 46 gearboxes ea...

Страница 14: ...ntering drift clutch M45 46 gearboxes late type Locking sector locking flywheel Centering drift clutch M50 51 gearboxes Piston support removing gudgeon pin from Mahle piston Used with 5092 Piston support fitting gudgeon pin in Mahle piston Used with 5092 Reamer kit valve guides contains 5164 early type 5224 late type 5166 5167 and 5168 Reamer valve guide seat oversize 1 Reamer valve guide seat ove...

Страница 15: ...p 21 Reconditioning engine Special tools 5103 5108 5109 5111 r 5112 5113 n ggg i U y g 5128 5129 5092 1 5092 2 5092 3 5092 4 5092 5 5092 6 110 214 5128 5129 5165 5166 5167 5168 5192 5218 5220 i 5224 5953 13 ...

Страница 16: ...2 998 5849 0 998 5850 8 Contents of complete kit Tap A 998 5802 9 998 5806 0 998 5810 2 998 5814 4 998 5818 5 998 5823 5 998 5826 8 998 5827 6 998 5831 8 998 5833 4 998 5860 7 Tang B 998 5803 7 998 5807 8 998 5811 0 998 5815 1 998 5819 3 2 2 2 2 2 2 Mandrel C 998 5804 5 998 5808 6 998 5812 8 998 5816 9 998 5820 1 998 5824 3 998 5824 3 998 5828 4 3 3 3 Crank D 998 5805 2 998 5809 4 998 5813 6 998 5...

Страница 17: ...paired for oil filter Connecting rod bearings bolts Cylinder block Timing gear case Adjustment screws Idle adjustment screw Lower section of air fuel control unit B 27 E 1979 B 28 E B 27 28 F Idle adjustment screw Intake manifold B27 B28 All conical threads such as plugs and nipples in intake mani fold also B 28 B 28 A 75 ...

Страница 18: ...8 956023 6 956024 4 948094 8 948095 5 956028 5 948756 2 948758 8 947847 0 947843 9 948755 4 Drill dia mm 6 3 6 3 7 3 7 3 8 4 8 4 8 4 10 5 10 5 10 5 10 5 12 5 12 5 12 5 14 3 14 5 16 5 18 5 16 4 16 Combination tap Tap section Reamer section Guide A5 Repairing spark plug threads Cylinder head must be removed first Tap hole from in side to avoid damaging seat for spark plug Do not drill the hole Use t...

Страница 19: ...l instructions for spark plug holes see page 16 Measure depth of hole Drill out hole to this depth Cut the screw thread to such a depth that the thread insert makes contact with fully cut screw thread along its entire length Clean the hole A8 Assemble installation tool M6 M14 threads fit correct mandrel and crank in in stallation tool 998 5830 0 M16 and coarser threads use the prescribed complete ...

Страница 20: ...lush with the opening of the mandrel AW Install thread insert Hold the tool vertically above the centre of the hole Without pressing screw in the thread insert until the top thread of the insert is at least 1 2 a thread below the working surface 0 5 x pitch The insert must not be screwed in to the bottom otherwise it will not be pos sible to break off the tang AH Break off tang M16 M12 threads use...

Страница 21: ...n the top thread of the insert approx 1 4 of a thread from the end Take care not to damage the thread holding the insert A13 Remove thread insert Insert a sharp edge of a triangular scraper in the groove Press downwards and rotate anti clockwise until the in sert is removed A14 Fit new thread insert Clean the hole with a tap and fit a new insert 19 ...

Страница 22: ...2 5093 5096 5098 5099 5101 5103 5108 5109 5111 5112 5128 5129 5165 5192 5218 5220 5953 Forthe overhaul of the engine it is presumed that the components shown in the illustration below have already been removed Also that the engine is mounted on universal stand 2520 with support 5099 5099 5099 2520 20 ...

Страница 23: ...ley is removed otherwise it will drop into crankcase B2 Remove valve covers timing gear case seal from timing gear case Cover holes in crankcase with e g paper to prevent dirt from entering B3 Check chain wear Check position of belt tensioners If tensioner pin pro trudes by 4 or more notches 8 mm 0 32 chains should be renewed IMPORTANT If chains are replaced sprockets and oil strai ners must also ...

Страница 24: ...ing gear chains Turn each lock 1 4 turn anti clockwise and push in pis ton B6 Remove oil pump sprocket and chain chain tensioners and oil strainers see arrows bent and straight chain dampers camshaft sprockets and chains B7 Remove oil pump with sprocket outer sprocket spacer sleeve early type and key inner sprocket and key If necessary use a puller to remove sprockets 22 ...

Страница 25: ... lift as well Use two bars 0 12 mm length 300 mm and lift off cylinder head as illustrated Place cylinder heads on wooden blocks to prevent da mage BIO Remove cylinder head gaskets guide sleeves use a pair of pliers B11 Fit liner holders 5093 Two per side Liner holders must always be used when cylinder head is removed OIL SUMP LOWER CRAIMKCASE Remove oil sump with gasket oil strainer with O ring s...

Страница 26: ...Use a feeler gauge Clearance new parts 674 0 20 0 38 mm 0 008 0 015 If clearance is too great con rods must be replaced Note that con rods must be replaced in sets 675 Check marking of con rod and cap If necessary mark as follows Cylinder Marking of con early type rod and cap late type Crank webs from rear 1 A 1 1 4 B 2 2 C 3 2 5 D 4 3 E 5 3 6 F 6 676 Remove pistons with con rods and bearings Clea...

Страница 27: ...pressure plate and clutch disc Slacken pressure plate bolts crosswise a few turns at a time to prevent warp flywheel Use locking sector 5112 to prevent engine from rotating rear sealing flange Tap out bearing from flange pilot bearing from crankshaft Use puller 4090 B19 Remove crankshaft main bearings and thrust bearings Check marking of bearing caps mark if necessary Caps are marked 1 4 counting ...

Страница 28: ...in or Mahle B 28 engines Mahle C2 Mahle 7U la to Mahle 8 mm SZZ 4 N f Demolin i 1 II 8 5 mm 11 mm B27F 1976 1978 C3 Measure piston diameter Measure at right angles to gudgeon piston pin bore Diameter must be measured at different heights depending on make and model year All Mahle pistons 8 mm 0 31 in from lower edge B27F 1976 1978 with Demolin pistons 11 mm 0 43 in from lower edge Other Demolin pi...

Страница 29: ...n clearance min 0 025 Piston clearance for new parts max 0 050 B27 Demolin piston 0 090 0 110 mm 0 0035 0 0043 in Mahle piston 0 020 0 040 mm 0 0008 0 0016 in B 28 Mahle piston 0 020 0 040 mm 0 0008 0 0016 in If clearance is too large replace liners piston and gud geon pin These parts are matched and can only be pur chased in kits of six Remove liner if piston liner is to be replaced Proceed to C5...

Страница 30: ...0021 in oil scraper ring fitted 0 009 0 233 mm 0 0004 0 0092 in C9 Measure piston ring gap Insert piston ring in bore one at a time Use an inverted piston to ensure that rings take up correct position Measure gap with ring 15 mm 0 6 in from lower edge Use a feeler gauge Piston ring gap new parts measured in 88 mm 3 4646 in B27 or 91 mm 3 5826 in B 28 cylinder diame ter upper and lower compression ...

Страница 31: ...linder block Remove all plugs before cleaning block Do not remove identification marks for cylinder liners when cleaning Clean sealing surfaces Use a plastic putty knife bearing seats oil and water channels cylinder head bolt holes Check for damage cracks and wear Also check threads on main bearing bolts Re fit plugs using new seals Note Carry out operation C13 before installing block in fixture C...

Страница 32: ...with new type Overflow valve replacement Operations CI5 17 Remove old valve and clean seat Use a screwdriver C15 Important Take care not to damage the oil filter mating surfaces and make sure that dirt does not enter the oil ways C16 Install new parts Install valve with spring facing inwards C17 Tap in washer and secure it Use an 11 mm inner diameter socket Secure washer by making three notches in...

Страница 33: ...undness and taper of crank pins Use a micrometer and take measurements at several diffe rent positions Max out of round 0 007 mm 0 0003 Max taper 0 01 mm 0 0004 Crank pins can be ground to a smaller size see speci fications on page 9 If crankshaft is thought to be out of true check with a dial indicator Support crankshaft by two outer main bearings on a V block Rotate one turn and measure out of t...

Страница 34: ... 7630 Exchange engine 1218098 The above engines may be equipped with early type crankshafts and connecting rods Only parts of the same type may be used together 1 Q 5128 5129 Ttf 5092 1 5092 2 5092 3 5092 4 5092 5 5092 6 C21 Tools required to replace piston or connecting rod 5092 1 Holder 5092 2 Connecting rod support for big end 5092 3 Drift to press out gudgeon pin also used as handle to press i...

Страница 35: ... piston with connecting rod and cap but with out bearing shells in support Arrow on top of piston must point up Press out gudgeon pin Use drift 5092 3 Pistons 4 5 and 6 Connecting rods marked B D and F or 2 4 and 6 Marked 4 5 6 5092 2 C24 Check connecting rods Use an alignment gauge Check out of true twist S form Check bolt threads and replace if necessary see C10 11 C25 Heat connecting rods Insta...

Страница 36: ...ing rod support and connecting rod must be turned in different directions for different pistons connecting rods Gudgeon pin must be pressed in immediately Operation C29 otherwise it may jam halfway Pistons 1 2 and 3 Connecting rods marked A C and E or 1 3 and 5 Marked 1 2 3 v Pistons 4 5 and 6 Connecting rods marked B D and F or 2 4 and 6 t X Marked 4 5 6 5092 2 5092 2 C29 Press in gudgeon piston ...

Страница 37: ... 174 mm L 220 mm 6 85 8 66 IMPORTANT On B 27 engines manufactured up to approx middle of 1976 a bent chain damper with a small mounting is fitted When replacing this type with a late type chain damper late type screws washers and spacers must be fitted In addition two faces on the timing gear case must be ground to make space for the new wider dampers One face must be ground down by 5 mm and the o...

Страница 38: ...aged or worn flywheel must be replaced with ring gear attached Ring gears can be replaced separately New flywheels are rustproofed and should be washed degreased prior to assembly Replacing ring gear Operations C35 39 C35 Heat new ring gear to 230 C 446T Heat in an oven or by oxyacetylene flame If oven is to be used begin heating now With oxyace tylene heat just before installation C36 Drill hole ...

Страница 39: ... ring gear must face fly wheel If necessary tap ring gear until flush Use a brass drift Leave to cool ON 89 5 m m 3 52 in I 88 3 N 19 7 lbs T 56 5 60 5 m m 2 22 2 38 in C40 Clean and inspect oil pump Disassemble and clean oil pump Check for damage and wear and also that relief valve plunger runs smoothly Check that axle is firmly secured to cylinder block Test relief valve in a spring tester Repla...

Страница 40: ... Note The holes in the bearing shells must coincide with the oilways in the engine block Lubricate the bearing shells and studs D2 Locate crankshaft Lubricate bearings Install thrust washer segments Lubricate washers Note the oilways in the two lower segments D3 D4 Install rear main bearing cap with shells and hol der 5096 for main bearing Rear cap is marked 1 Identification number and casting lug...

Страница 41: ...984 0 1003 in D6 Install three remaining main bearing caps with shells Identification numbers2 3and4andthecasting lugson the caps must face forwards Secure front bearing cap with holder 5096 and install nuts on each of the two centre caps CRANKSHAFT REAR SEAL PILOT BEARING D7 Install seal holder Use a new seal Using a straight edge make sure that the holder is flush with the cylinder block D8 Inst...

Страница 42: ... 1801 and drift 5101 Late type inner diameter 15 mm 0 590 Use drift 1426 CYLINDER LINERS D10 Check mating surfaces for shims Check that surfaces in liner and block are clean and free from defects D11 Install no 1 liner without shim Check line up marks and number Install two holder 5093 hand tight D12 Set dial indicator zero position Place dial indicator in outer hole in holder 5192 5094 can also b...

Страница 43: ...stance between top of liner and block should be 0 16 0 23 mm Gap should be as near as possible to 0 23 mm Select a shim which is the same or just under the cal culated thickness Shims are available as follows Colour Thickness Blue 0 070 0 105 mm White 0 085 0 120 mm Red 0 105 0 140 mm Yellow 0 130 0 165 mm Example Max specified gap 0 23 mm Measured gap without shim 0 11 mm Difference 0 12 mm Selec...

Страница 44: ... 1 2 3 and 4 as illustrated Difference between 1 and 2 and 3 and 4 must not ex ceed max 0 04 mm 0 0016 Exchange shims if necessary and re measure according to D17 If new liners are used and difference is too large rotate liners or change positions and re measure D19 Measure liner deck height for 2nd cylinder bank Follow D17 18 Then transfer the two outer holders to the 1st cylinder bank o 0 PISTON...

Страница 45: ...g rod cap Use new nuts lubricate mating surface Torque to 45 50 Nm 33 37 ft lbs Check that crankshaft can be rotated IMPORTANT Marks on connecting rod and cap must match Bearing gap should point rearwards for cylinder 1 2 and 3 forwards for cylinders 3 5 and 6 LOWER CRANKCASE SUMP uide eeve Collar V r iJ J_ i j D25 Check if crankcase is early or late type Late type crankcases are fitted with a col...

Страница 46: ...r block must be flush otherwise distortions may result and cause noise or dama ge 5098 O I I I I I 1 N J I o I I I I D30 Tighten main bearing nuts Tighten in order shown adjacent to 30 Nm 15 ft lbs Re check that lower crankcase lies flush with the rear of cylinder block see D29 D31 Angle tighten main bearing nuts Use protractor 5098 A measuring stand can be used to align the protractor The magneti...

Страница 47: ... new bolts Torque to 45 50 Nm 33 37 ft lbs Use locking sector 5112 to lock the flywheel Auto Note position of support plates Inner plate sho uld be turned with bevel forwards D35 Install clutch driven plate and pressure plate Turn the plate so that the hub faces outwards away from the flywheel Different centering drifts for different types of gearbox es M50 51 drift 5113 M45 46 early type drift 24...

Страница 48: ... deposits from the combustion cham bers and valves Clean valve seats with a grinder to be able to see cracks damage etc Clean gasket mating surfaces Use a plastic scraper and if necessary a fine grade wet abrasive paper Check all parts Visible damage wear etc E3 E4 Check cylinder head for warp Use a straight edge and feeler gauge Warp max 0 05 mm 0 002 in per 100 mm 3 94 in The cylinder head must ...

Страница 49: ... a dial indicator Use new valves and press up 5 10 mm 0 2 0 4 in with finger when measuring The clearance must not exceed max 0 15 mm 0 0059 in E7 Check valve springs The springs are colour coded and two different types are used depending on engine type Colour code GREY GREEN Lenth Load mm in N lbs 47 2 1 86 0 0 40 0 1 57 233 268 52 60 32 2 1 27 521 585 116 131 47 1 1 85 0 0 40 0 1 57 230 266 51 5...

Страница 50: ...d to approx 150C 300 F E12 Cool valve guide to approx 7 0 C 95 F Use liquid carbon dioxide orequivalentto cool the valve guides Wear protective gloves and safety glasses E13 Press in new guide Note This must be done very quickly within 3 4 sees Place the cylinder head on a sloping surface so that the valve guides are vertical Use drift 5108 for intake and 5109 for exhaust valve guides E14 Clean in...

Страница 51: ...cturer s instructions Make sure that the cylinder head is not damaged Clean carefully E17 Measure valve seat diameter in cylinder head and select a new seat of correct size Use an internal micrometer Valve seats are available in three oversizes The interference between the valve seat and recess in the cylinder head must be 0 070 0 134 mm 0 0027 0 0052 in I e the valve seat must be 0 070 0 134 mm l...

Страница 52: ...t has bottomed correctly and is secure If not fit a larger size After valve seat replacement valve seats must be milled and valves ground l 1 7 2 1 mm 0 0669 0 0826 in Intake valve seat Early types 30 Grinding of valves and valve seats Operations E23 24 Machine grind valves Intake valves 29 5 Exhaust valves 44 5 Also grind flush the end of the valve stem Mill or grind valve seats Check valve fit I...

Страница 53: ...rque 12 2 Nm 9 1 5ft lbs E26 Clean and check rocker arm shaft Disassemble only if necessary Place parts in order so that they can be re assembled in the same position The clearance between the rocker arm and shaft is for new parts 0 012 0 054 mm 0 0005 0 0021 in IMPORTANT The rocker arm contact surface on the camshaft is face hardened and must not be ground s Oilway in shaft points downwards The f...

Страница 54: ... sleeves with e g a 3 mm drill This prevents the sleeves from being forced down when the cylinder head is fitted F3 Install cylinder head gasket and cylinder head First remove liner holder 5093 and then the protective paper in the water passages Note Different gaskets for right and left cylinder heads F4 Set camshaft Left side groove in camshaft must point up and No 1 rocker arms should have clear...

Страница 55: ...sleeves Tighten bolts by hand Two different types of cylinder head bolts are in use de pending on the thread length in the cylinder block Late type bolt thread length 27 mm 1 063 in with was her Early type bolt thread length 30 mm 1 181 in without washer Only late type bolts are available as spare parts If late type bolts are used on early type cylinder heads washers must be used the same washers ...

Страница 56: ... F10 Install crankshaft gears and keys Block holes in crankcase to prevent keys from falling in Lubricate parts The mark on the inner gear must face out Note On late types gear and spacer are manufactured in one unit F11 Install new strainers in cylinder block chain tensioners straight chain dampers bent chain dampers Apply locking fluid P N 116 1053 2 to bolts F12 Set crankshaft and left hand cam...

Страница 57: ...tly downwards The groove in the camshaft should point outwards see fig and there should be no clearance between the rock er arms and valve stem tops for No 6 cylinder 1 iT K F15 Install right hand camshaft chain and sprocket Place the chain on the camshaft sprocket with the mark on the sprocket between the two marks on the chain Place the chain on the camshaft sprocket with the mark on the chain o...

Страница 58: ...een rotated the marks for the chains and sprockets do not coincide It is necessary to ro tate the crankshaft a large number of turns to obtain the correct position F19 Install oil pump with sprocket chain and gear Apply locking fluid P N 116 1053 2 to the bolts F20 Remove protective paper Install timing gear case Use new gaskets Smear the four lower bolts with locking fluid P N 116 1056 5 Tighteni...

Страница 59: ...2 to the flywheel casing at the lower bolt RHD vehicles upper bolt Make sure that key in crankshaft does not fall out Tighten nut to correct torque see left 36 mm socket IMPORTANT There are two different types of nuts 160 180 Nm 118 133 ft lbs X 45 mm 240 280 Nm 177 206 ft lbs TIMING SCALE Check adjust only if necessary eg if plate is removed or replaced F23 Remove rear plug in cylinder block 57 ...

Страница 60: ...hole so that it rests on the crankshaft counterweight Press lightly on the drill and turn the crankshaft slowly in the normal direction of rotation until the drill fits into the hole in the counterweight The engine is now set at exactly T D C for cylinder 1 F26 Check adjust timing scale The zero mark on the scale must align exactly with the mark on the pulley F27 Install blocking plug Use a new se...

Страница 61: ... crankshaft to firing position for No 1 cylin der The mark 1 on the pulley should align with the zero mark on the timing scale Both rocker arms for No 1 cylinder should have clearance F29 Check adjust valve clearances Check the following valves in the set position Intake cylinders 1 2 and 4 Exhaust cylinders 1 3 and 6 F30 Turn crankshaft one turn in normal direction to overlap position for No 1 cy...

Страница 62: ...u tor F33 Install gaskets and valve covers Use new gaskets Apply a few spots of sealing com pound P N 116 1026 8 Place only four bolts in each valve cover Do not tighten since the covers are to be removed later on To ensure that the junction between the valve cover cylin der block and timing gear case is fully leak proof a thin coat of silicone P N 116 1048 2 can be applied to the joint Note Do no...

Страница 63: ...B2 F21 B1 F22 B19 C18 19 C20 D1 6 D4 5 Page 46 47 51 25 36 45 22 35 35 54 25 45 24 43 24 24 28 23 28 33 32 32 43 25 39 21 57 21 57 25 31 32 38 38 Cylinder liner classes diameter removal inspection liner height installation Cylinder head gasket installation Cylinder head removal disassembly cleaning checking warp assembly bolts different types installation bolts tightening Flywheel removal inspecti...

Страница 64: ...lation A2 non repairable threads A3 thread inserts A4 drill sizes A4 spark plug threads A5 installation A6 11 removal A12 14 Page 30 30 25 40 26 28 28 35 24 26 26 27 28 32 43 25 45 36 23 51 53 23 45 14 14 15 16 16 16 17 19 Opera tion Page Timing gear chains sprockets wear check B3 21 removal B4 7 22 inspection C33 36 installation F10 19 54 Timing gear cover removal B2 21 installation F20 56 Timing...

Страница 65: ...r r VOLVO SUPPORTS VOLUNTARY MECHANIC CERTIFICATION BY THE N I A S E U S A Only Service literature Your most important special tool ...

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