DOWNLOAD PDF Volvo Penta AQ150, AQ150A, AQ150B Engine Unit Workshop Manual

Workshop Manual

C

Engine unit

2(0)

AQ150, AQ150A, AQ150B

Workshop Manual AQ150, AQ150A, AQ150B

Contents Page Safety precautions ................................................................................................. 2 General Information ............................................................................................... 5 Repair instructions ................................................................................................. 6 Description ............................................................................................................. 8 General ................................................................................................................. 8 Cylinder block ....................................................................................................... 8 Cylinder heads with valves .................................................................................... 8 Crankshaft with bearings ....................................................................................... 9 Camshaft .............................................................................................................. 9 Valve lifters ........................................................................................................... 9 Connecting rods, pistons and piston rings ............................................................. 10 Lubricating system ................................................................................................ 10 Ignition system ..................................................................................................... 11 Fuel system .......................................................................................................... 11 Carburetor ............................................................................................................. 11 Repair instructions ................................................................................................. 12 General overhaul ................................................................................................... 12 Measuring the compression pressure .................................................................... 12 Replacing the thermostat ...................................................................................... 12 Replacing the circulation pump ............................................................................. 13 Disassembling the engine ..................................................................................... 13 Replacing the timing gear cover ............................................................................ 14 Replacing sealing ring, timing gear cover .............................................................. 14 Replacing timing gears .......................................................................................... 15 Valve mechanism ................................................................................................. 15 Intake manifold ..................................................................................................... 16 Valve lifters ........................................................................................................... 16 Camshaft .............................................................................................................. 18 Cylinder heads with valves .................................................................................... 18 Cylinder block ....................................................................................................... 19 Pistons, piston rings and piston pins ..................................................................... 19 Connecting rods .................................................................................................... 20 Measuring radial clearance for big-end bearings .................................................... 21 Measuring radial clearance for crankshaft bearings ............................................... 21 Crankshaft ............................................................................................................ 22 Oil pipe and oil screen ........................................................................................... 22 Oil pump ............................................................................................................... 23 Crankcase ventilation ............................................................................................ 24 Ignition system ..................................................................................................... 24 Fuel system .......................................................................................................... 25 Tools ....................................................................................................................... 29 Specifications ......................................................................................................... 30 Tightening torques ................................................................................................. 35

1

Safety precautions

Introduction This Workshop Manual contains technical data, descriptions and repair instructions for Volvo Penta products or product versions contained in the contents list. Ensure that the correct workshop literature is being used.

Read the safety information and the Workshop Manual “General Information” and “Repair Instructions” carefully before starting work.

Important In this book and on the engine you will find the following special warning symbols.

WARNING! If these instructions are not followed there is a danger of personal injury, extensive damage to the product or serious mechanical malfunction.

IMPORTANT! Used to draw your attention to something that can cause damage, product malfunction or damage to property.

NOTE! Used to draw your attention to important information that will facilitate work or operations.

Below is a summary of the risks and safety precautions you should always observe or carry out when operating or servicing the engine.

Immobilize the engine by turning off the power supply to the engine at the main switch (switches) and lock it (them) in the OFF position before starting work. Set up a warning notice at the engine control point or helm.

Generally, all servicing should be carried out with the engine switched off. Some work (carrying out certain adjustments for example) requires the engine to be running. Approaching a running en-gine is dangerous. Loose clothing or long hair can fasten in rotating parts and cause serious personal injury.

If working in proximity to a running engine, careless movements or a dropped tool can result in personal injury. Avoid burns. Take precautions to avoid hot surfaces (exhausts, turbochargers, charge air pipes and starter elements etc.) and liquids in supply lines and hoses when the engine is running or has been turned off immediately prior to starting work on it. Reinstall all protective parts removed during service operations before starting the engine.

2

Check that the warning or information decals on the product are always clearly visible. Replace decals that have been damaged or painted over.

Engine with turbocharger: Never start the engine without installing the air cleaner (ACL). The rotating compressor in the Turbo can cause serious personal injury. Foreign objects entering the intake ducts can also cause mechanical damage.

Never use start spray or similar to start the engine. The starter element may cause an explosion in the inlet manifold. Danger of personal injury.

Avoid opening the filler cap for engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out. Open the coolant filler cap carefully and slowly to release pressure before removing the cap completely. Take great care if a cock, plug or engine coolant line must be removed from a hot engine. It is difficult to anticipate in which direction steam or hot coolant can spray out.

Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before commencing work on it.

Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected.

Stop the engine and close the sea cock before carrying out operations on the engine cooling system.

Only start the engine in a well-ventilated area. If operating the engine in an enclosed space, ensure that exhaust gases and crankcase ventilation emissions are ventilated out of the working area.

Always use protective goggles where there is a danger of pieces of metal, sparks from grinding, acid or other chemicals being thrown into your eyes. Your eyes are very sensitive, injury can lead to loss of sight!

Avoid skin contact with oil. Long-term or repeated contact with oil can remove the natural oils from your skin. The result can be irritation, dry skin, eczema and other skin problems. Used oil is more dangerous to health than new oil. Use protective gloves and avoid using oil-soaked clothes and rags. Wash regularly, especially before meals. Use the correct barrier cream to prevent dry skin and to make cleaning your skin easier.

Most chemicals used in products (engine and transmission oils, glycol, petrol and diesel oil) and workshop chemicals (solvents and paints) are hazardous to health Read the instructions on the product packaging carefully! Always follow safety instructions (using breathing apparatus, protective goggles and gloves for example). Ensure that other personnel are not unwittingly exposed to hazardous substances (by breathing them in for example). Ensure that ventilation is good. Handle used and excess chemicals according to instructions.

Be extremely careful when tracing leaks in the fuel system and testing fuel injection nozzles.

Use protective goggles! The jet ejected from a fuel injection nozzle is under very high pressure, it can penetrate body tissue and cause serious injury There is a danger of blood poisoning.

All fuels and many chemicals are inflammable.

Ensure that a naked flame or sparks cannot ignite fuel or chemicals. Combined with air in certain ratios, petrol, some solvents and hydrogen from batteries are easily inflammable and explosive. Smoking is prohibited! Ensure that ventilation is good and that the necessary safety precautions have been taken before carrying out welding or grinding work. Always have a fire extinguisher to hand in the workplace.

Store oil and fuel-soaked rags and fuel and oil filters safely. In certain conditions oil-soaked rags can spontaneously ignite. Used fuel and oil filters are environmentally dangerous waste and must be deposited at an approved site for destruction together with used lubricating oil, contaminated fuel, paint remnants, 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 hydrogen gas during charging which when mixed with air can form an explosive gas – oxyhydrogen. This gas is easily ignited and highly volatile. Incorrect connection of the battery can cause a spark which is sufficient to cause an explosion with resulting damage. Do not disturb battery connections when starting the engine (spark risk) and do not lean over batteries.

Never mix up the positive and negative battery terminals when installing. Incorrect installation can result in serious damage to electrical equipment. Refer to wiring diagrams.

Always use protective goggles when charging and handling batteries. The battery electrolyte contains extremely corrosive sulfuric acid. If this comes into contact with the skin, wash immediately with soap and plenty of water. If battery acid comes into contact with the eyes, immediately flush with copious amounts of water and obtain medical assistance.

Turn off the engine and turn off power at main switch(es) before carrying out work on the electrical system.

Clutch adjustments must be carried out with the engine turned off.

3

Use the lifting eyes mounted on the engine/reverse gear when lifting the drive unit.

Always check that lifting equipment is in good condition and has sufficient load capacity to lift the engine (engine weight including reverse gear and any extra equipment installed).

To ensure safe handling and to avoid damaging engine components on top of the engine, use a lifting beam to raise the engine. All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine.

If extra equipment is installed on the engine altering its center of gravity, a special lifting device is required to achieve the correct balance for safe handling.

Never carry out work on an engine suspended on a hoist.

Never remove heavy components alone, even where secure lifting equipment such as secured blocks are being used. Even where lifting equipment is being used it is best to carry out the work with two people; one to operate the lifting equipment and the other to ensure that components are not trapped and damaged when being lifted.

When working on-board ensure that there is sufficient space to remove components without danger of injury or damage.

4

Components in the electrical system, ignition system (gasoline engines) and fuel system on Volvo Penta products are designed and constructed to minimize the risk of fire and explosion. The engine must not be run in areas where there are explosive materials.

Always use fuels recommended by Volvo Penta. Refer to the Instruction Book. The use of lower quality fuels can damage the engine. On a diesel engine poor quality fuel can cause the control rod to seize and the engine to overrev with the resulting risk of damage to the engine and personal injury. Poor fuel quality can also lead to higher maintenance costs.

Observe the following rules when cleaning with high-pressure water jets. Never direct the water jet at seals, rubber hoses or electrical components. Never use a high pressure jet when washing the engine.

General information About the workshop manual This Workshop Manual contains technical data, descriptions, and overhaul instructions for the standard versions of AQ150.

Only the engine model designation are referenced exclusively throughout this Workshop Manual, without the drive/reverse gear. Where there are differences between engine units for the drive and reverse gear versions, the complete designation is stated, e.g.

AQ150A. The engine designation and serial number shall always be given in correspondence to the Service and Parts Department.

The Workshop Manual shows the work procedures carried out on a AQ150 engine equipped with freshwater cooling. The procedures are identical on other versions unless otherwise stated in text or illustrations.

Please note that the illustrations used do not always fully correspond with the other engine version. The abbreviation FWC is used for freshwater cooled engine and SWC is used for sea water cooled engine. The product designation and number should be given in all correspondence about the product.

This Workshop Manual has been developed primarily 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 products.

We therefore reserve the right to make changes. All the information contained in this book is based on product data available at the time of going to print.

Any essential changes or modifications introduced into production or updated or revised service methods introduced after the date of publication will be provided in the form of Service Bulletins.

Replacement parts Replacement parts for electrical and fuel systems are subject to statutory requirements (US Coast Guard Safety Regulations for example). Volvo Penta Genuine parts meet these requirements. Any type of damage which results from the use of non-original Volvo Penta replacement parts for the product will not be covered under any warranty provided by Volvo Penta.

5

Repair instructions The working methods described in the Service Manual apply to work carried out in a workshop. The engine has been removed from the boat and is installed in an engine fixture. Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working method.

Warning symbols occurring in the Workshop Manual (for their meaning see Safety precaution) WARNING! IMPORTANT! NOTE! are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out. For this reason we can only highlight the risks that can arise when work is carried out incorrectly in a well-equipped workshop using working methods and tools developed by us.

All procedures for which there are Volvo Penta special tools in this Workshop Manual are carried out using these. Special tools are developed to rationalize working methods and make procedures as safe as possible. It is therefore the responsibility of any person using tools or working methods other than the ones recommended by us to ensure that there is no danger of injury, damage or malfunction resulting from these.

In some cases there may be special safety precautions and instructions for the use of tools and chemicals contained in this Workshop Manual. These special instructions should always be followed if there are no separate instructions in the Workshop Manual.

Certain elementary precautions and common sense can prevent most risks arising. A clean workplace and engine eliminates much of the danger of injury and malfunction.

It is of the greatest importance that no dirt or foreign particles get into the fuel system, lubrication system, intake system, turbocharger, bearings and seals when they are being worked on. The result can be malfunction or a shorter operational life.

6

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 significantly. It is therefore vital that wear tolerances are maintained, that systems that can be adjusted are adjusted properly and that Volvo Penta Genuine Parts as used. The engine Maintenance Schedule must be followed.

Some systems, such as the components in the fuel system, require special expertise and special testing equipment for service and maintenance. Some components are sealed at the factory for environmental reasons. No work should be carried out on sealed components except by authorized personnel.

Bear in mind that most chemicals used on boats are harmful to the environment if used incorrectly. Volvo Penta recommends the use of biodegradable degreasing agents for cleaning engine components, unless otherwise stated in a workshop manual. Take special care when working on-board, that oil and waste is taken for destruction and is not accidentally pumped into the environment with bilge water.

Tightening torques Tightening torques for vital joints that must be tightened with a torque wrench are listed in workshop manual “Technical Data”: “Tightening Torques” and are contained in work descriptions in this Manual. All torques apply for cleaned threads, screw heads and mating surfaces.

Torques apply for lightly oiled or dry threads. If lubricants, locking fluid or sealing compound are required for a screwed joint this information will be contained in the work description and in “Tightening Torques” Where no tightening torque is stated for a joint use the general tightening torques according to the tables below. The tightening torques stated are a guide and the joint does not have to be tightened using a torque wrench.

Dimension M5 M6 M8 M10 M12 M14

Tightening Torques Nm 6 10 25 50 80 140

lbf.ft 4.4 7.4 18.4 36.9 59.0 103.3

Tightening torques-protractor (angle) tightening Tightening using both a torque setting and a protractor angle requires that first the recommended torque is applied using a torque wrench and then the recommended angle is added according to the protractor scale.

Example: a 90° protractor tightening means that the joint is tightened a further 1/4 turn in one operation after the stated tightening torque has been applied.

Locknuts Do not re-use lock nuts that have been removed during dismantling as they have reduced service life when re-used – use new nuts when assembling or reinstalling. For lock nuts with a plastic insert such as Nylock® the tightening torque stated in the table is reduced if the Nylock® nut has the same head height as a standard hexagonal nut without plastic insert.

Reduce the tightening torque by 25% for bolt size 8 mm or larger. Where Nylock® nuts are higher, or of the same height as a standard hexagonal nut, the tightening torques given in the table apply.

Tolerance classes Screws and nuts are divided into different strength classes, the class is indicated by the number on the bolt head. A high number indicates stronger material, for example a bolt marked 10-9 indicates a higher tolerance than one marked 8-8. It is therefore important that bolts removed during the disassembly of a bolted joint must be reinstalled in their original position when assembling the joint. If a bolt must be replaced check in the replacement parts catalogue to make sure the correct bolt is used.

Sealants A number of sealants and locking liquids are used on the engines. The agents have varying properties and are used for different types of jointing strengths, 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 required.

In this Volvo Penta Service Manual the user will find that each section where these agents are applied in production states which type was used on the engine.

During service operations use the same agent or an alternative from a different manufacturer.

Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturer’s instructions for use regarding; temperature range, curing time and any other instructions for the product.

Two different basic types of agent are used on the engine and these are: RTV agent (Room temperature vulcanizing). Use for gaskets, sealing gasket joints or coating gaskets. RTV agent is clearly visible when a component has been dismantled; old RTV must be removed before the joint is resealed.

The following RTV agents are mentioned in the Service Manual: Loctite® 574, Volvo Penta 840879-1, Permatex® No. 3, Volvo Penta P/N 1161099-5, Permatex® No. 77.

Old sealant can be removed using methylated spirits in all cases.

Anaerobic agents. These agents cure in an absence of air. They are used when two solid parts, for example cast components, are installed face-to-face without a gasket. They are also commonly used to secure plugs, threads in stud bolts, cocks, oil pressure switches and so on. The cured material is glass-like and it is therefore colored to make it visible. Cured anaerobic agents are extremely resistant to solvents and the old agent cannot be removed. When reinstalling the part is carefully degreased and then new sealant is applied.

The following anaerobic agents are mentioned in the Service Manual: Loctite® 572 (white), Loctite® 241 (blue).

NOTE! Loctite® is the registered trademark of Loctite Corporation, Permatex® is the registered trademark of the Permatex Corporation.

7

Description General

Cylinder block

The AQ150, 150A and 150B engines are six cylinder, water cooled, overhead valve units. They are constructed from the same basic engine, a 90° V-6 engine fitted with a two barrel, down-draught carburetor.

The cylinder heads have separate intake and exhaust channels, one for each valve. The crankshaft is carried in four main bearings.

The cylinder block consists of two banks of cylinders, each with three cylinders, and is made of cast iron.

The cylinder liners, which are surrounded by cooling jackets, are drilled directly into the block.

The output is 150 h.p. (SAE) at 4200 r.p.m. The compression ratio is 9:1 and the piston displacement 3.7 litres (225 cu.in.).

Cylinder heads with valves

The engines differ mainly from one another concerning the cooling system. The AQ 150 is fitted with a heat exchanger and is thus fresh-water cooled, while the AQ150A and B engines are sea-water cooled.

Concerning cylinder numbering, see Fig. 4.

The cylinder heads are of cast iron and are bolted on top of the block. Left and right cylinder heads are identical and interchangeable.

The valves have a suspension mounting and the valve guides are cast in the cylinder heads.

The cooling jackets are so constructed that the area adjacent to the spark plugs is also cooled.

Fig. 1 AQ150/200, viewed from the starboard side 1. Outboard drive 2. Transom shield 3. Exhaust manifold elbow (early type) 4. Rocker arm cover 5. Flame arrester 6. Alternator 7. Oil filter 8. Heat exchanger

8

9. Water-cooled exhaust manifold 10. Sump 11. Starter motor 12. Exhaust pipe connection 13. Outlet from by-pass line 14. Cooling water inlet 15. Combined cooling water and exhaust outlet

Crankshaft with bearings

Valve lifters

The crankshaft is steel-forged. It is carried in four main bearings, No. 2 bearing functioning as thrust bearing for taking up end thrust. On each big-end bearing journal there are two connecting rods. The crankshaft has drilled passages for lubricating oil.

The valve system is fitted with hydraulic valve lifters which are located in holes in the block above the camshaft and are operated directly by the camshaft. See Fig. 14.

The replaceable bearing shells for both the big-end and main bearings are steel backed and faced with bearing metal.

Camshaft The camshaft is manufactured of special alloy cast iron and is located between the two banks of cylinders, where it is supported in five steel backed babbit bearings. It is driven by an outside guide type chain.

The camshaft gear is a nylon type ring gear. The crankshaft gear is made of steel.

Oil is fed to all the valve lifters through galleries in the engine lubricating system. An oil cushion then forms under the lifter plunger. See Fig. 5. When the lifter presses the push rod upwards, the check ball closes and the plunger then rests against the oil cushion, which has at the same time a damping function against sudden impacts. At rest position, a spring presses the lifter body against the cam on the camshaft and the plunger on the push rod. The small quantity of oil which leaks out between the body and the plunger is replaced in the resting position, when the engine oil pressure opens the check valve. In this way, the valve lifters eliminate all lash clearances in the valve mechanism even during different operating

Fig. 2 AQ 150 A/200, viewed from the starboard side 1. Outboard drive 2. Transom shield 3. By-pass line for cooling water 4. Exhaust manifold elbow (early type) 5. Rocker arm cover 6. Flame arrester 7. Alternator 8. Oil filter

9. Water-cooled exhaust manifold 10. Front engine mounting 11. Sump 12. Starter motor 13. Exhaust pipe connection 14. Outlet from by-pass line 15. Cooling water inlet 16. Combined cooling water and exhaust gas outlet

9

conditions and temperatures. No adjustment of the valves thus requires to be carried out.

The movement of the valve lifters is transmitted to the rocker arms via the push rods. The arms are made of die-cast aluminium and have wear hats at the contact surfaces for the push rods and valve stems.

Connecting rods, pistons and piston rings The connecting rods are made of dropped-forged steel. The piston pins are moveable in the pistons and are a press fit in the upper end of the connecting rods.

The pistons are made of aluminium alloy and each has two compression rings and an expanding oil control ring. The top compression ring is chromiumplated, this reducing the wear on the cylinder.

Lubricating system The engine is equipped with a force-feed lubricating system. Pressure for discharging the oil comes from a gear-driven pump, which is operated by the distributor shaft gear and is located in the timing gear cover. Oil is drawn from the sump through drilled holes in the crankcase and the timing gear cover by the pump and is then conveyed under pressure to the moving parts of the engine.

The oil filter is fitted in a nipple on the pump housing and is replaceable as a complete unit. Both the relief valve and the by-pass valve are located in the pump.

The by-pass valve opens if the oil filter becomes blocked, so that unfiltered oil then flows into the engine.

Fig. 3 AQ 150 B/200, viewed from the starboard side 1. Outboard drive 2. Transom shield 3. Elevated exhaust manifold elbow (“Riser”) 4. Rocker arm cover 5. Flame arrester 6. Alternator 7. Oil filter

10

8. Water-cooled exhaust manifold 9. Front engine mounting 10. Sump 11. Starter motor 12. Exhaust pipe connection 13. Cooling water inlet 14. Combined cooling water and exhaust gas outlet

Ignition system

Carburetor

The distributor, which is driven by the camshaft with an incline gear, has on the AQ150 engine both a centrifugal and a vacuum governor, while the AQ150A and B only have a centrifugal governor. The governor is built into the rotor. The direction of rotation is clockwise and the firing sequence is 1-6-5-4-3-2. At its lower end, the distributor shaft has a fitting for driving the oil pump pinion.

The engines are provided with a two-barrel, down-draught carburetor produced by Rochester. The carburetor is fitted with an automatic choke device and also a flame arrestor.

Fuel system Fuel is sucked up from the tank by a diaphragm-type pump and is then forced through a filter to the float body of the carburetor. The pump is fitted on the timing gear cover and is driven by an eccentric on the camshaft. The filter is integrally built with the pump.

Fig. 5 Valve lifter

Flywheel

Fig. 4 Cylinder numbering

1. Snap ring 2. Rod seat 3. Oil inlets 4. Plunger 5. Oil feed hole for check ball 6. Check ball retainer 7. Plunger spring 8. Lifter body

11

Repair instructions General overhaul The engine should be tuned up at regular intervals in order to obtain the best running results. The purpose of tuning is to reset all adjustments to the correct values, and to obviate any trouble due to dirt in the sludge trap, deposits on spark plugs. etc, 1. Run the engine warm and check the dwell angle (contact breaker gap), adjusting if necessary. Replace burnt contact breaker points. Check the ignition timing with a stroboscope at the specified setting speed and the vacuum regulator disconnected. For details, see “Specifications”.

dition in order to turn round the engine sufficiently fast. What is most important to watch during this test is the pressure between the cylinders which should be as uniform as possible. The maximum permissible pressure difference between the best and worst cylinders is 25%.

4.

Record the pressure obtained for each cylinder, unless the gauge used is of the self-registering type.

5.

If the values obtained are low or uneven, measuring should be repeated after a small amount of thick oil has been introduced into each cylinder. If the pressure is low in two adjacent cylinders, this probably means that the cylinder head gasket is damaged.

2. Check the distributor cap and clean it. Clean and check the spark plug leads.

3. Check the state of charge of the battery and examine terminals.

4. Clean the fuel pump sludge trap (strainer). Remove the carburetor and blow it clean. Fit the parts.

5. Clean the flame arrester.

6. Check-tighten the intake and exhaust manifold bolts. Check that there are no air leaks at the carburetor.

7. Check that there is no oil leakage.

If the gaskets for the timing gear cover are so compressed that the cover itself makes contact with the cylinder heads, fit new gaskets.

Replacing the thermostat The thermostat housing on the AQ150 and 150B is located at the rear section and on the AQ150A on the front section of the intake manifold. Concerning replacing and testing, see below.

1.

Drain off some of the coolant.

2.

Remove the bolts for the thermostat housing and the necessary hoses. Lift up the housing and take off the thermostat. See Figs. 6, 7 and 8.

8. Measure the compression on all the cylinders.

9. Remove and adjust the spark plugs or replace them with new ones.

10. Check the feed pressure of the fuel pump.

11. Check and adjust the carburetor settings as necessary.

12. Check the fan belt tension.

Measuring the compression pressure 1.

Run the engine until it attains normal operating temperature. Check that the flame arrester is not blocked.

2.

Unscrew all the spark plugs. Open the gas and choke controls fully.

3.

Hold a compression gauge in the spark plug hole for the first cylinder. Turn the engine round with the starter motor until the gauge gives a maximum reading and repeat this procedure on the other cylinders. The battery must be in good con-

12

Fig. 6 Thermostat AQ 150

Replacing the circulation pump 1.

Drain off the coolant. Concerning the drain cocks, see the respective instruction book.

2.

Slacken the alternator (AQ150, AQ150A and 150B) and the sea-water pump (AQ150) sufficiently that the pulleys con be removed. Take off the belts.

3.

Disconnect the circulation pump pulley.

4.

Disconnect the cooling water hoses to the pump.

5.

Unscrew the bolts and remove the pump.

6

Check well the contact surfaces of the pump and the timing gear cover to make sure that they are clean and undamaged.

7.

Installing the circulation pump is carried out in the reverse order to the above. Use a new gasket.

8.

Test run the engine and check for leakage.

Fig. 7 Thermostat AQ 150 A

Disassembling the engine 3.

Replace the thermostat if it is faulty.

4.

Testing: Heat the thermostat in a vessel of water together with a thermometer. The thermostat should begin to open at the temperatures given in the “Specifications”.

5.

Fit the thermostat.

N.B. It is possible to fit the thermostat on the AQ150 engine in the wrong direction. It should be fitted as shown in Fig. 6. Change all the thermostat housing gaskets.

6.

Fit the housing and install the hoses. Fill with coolant (AQ150, fresh-water system).

Fig. 8 Thermostat AQ 150 B.

The disassembling is more or less according to the points given below.

1.

Place the engine on a suitable stand. Check that the oil and coolant (fresh-water system, AQ150) have been drained off.

2.

Remove the alternator, the sea-water pump, also the mounting, the heat exchanger and the expansion tank (AQ150), the fuel filter and the oil filter.

3.

Remove the timing gear cover and the timing gears with chain.

4.

Remove the ignition coil, the carburetor, the rocker arm covers, the rocker arm mechanism, the intake manifold, the push rods, the valve lifters, the camshaft and the exhaust manifold.

5.

Remove the starter motor, the flywheel casing, the vibration damper, the flywheel and the governor with cable cluster (AQ150).

6.

Remove the cylinder heads.

7.

Stand up the engine on its rear end on suitable wooden blocks, so that the crankshaft can rotate freely. Remove the sump, the oil plate and the oil strainer.

8.

Mark the pistons, connecting rods and caps with the respective cylinder number. Concerning cylinder numbering, see under “Cylinder Block” on page 8.

9.

Remove the connecting rod caps. Slide the piston with connecting rod out of the cylinder and refit the respective caps with bearing shells onto the connecting rods to avoid getting them mixed up.

10. Turn the engine upside down. Remove the crankshaft caps and lift out the crankshaft. Refit the caps as above.

13

Cleaning After disassembling, the parts should be thoroughly cleaned. Parts made of steel or cast iron can be washed in a degreasing tank with a caustic soda solution. Light-alloy parts can, however, be damaged by caustic soda, so they should preferably be cleaned with white spirit. Pistons and bearing shells must never be washed in caustic soda solution. Rinse the parts with warm water and blow them dry with compressed air after washing.

2.

Check the sealing surfaces on the block and the casing. These must be clean and free from defects.

3.

Use a new gasket and place the timing gear cover against the block, Check that the guide pins are in the correct position. Screw on the bolts and secure them to the right torque . Concerning the torque, see the “Specifications”.

4.

Lubricate the hub on the vibration damper before fitting the damper. This protects the gasket in the flywheel cover during installation and when the engine is started for the first time.

Clean the oil galleries very thoroughly. Pull them through with a special brush and then blow them out with compressed air. All sealing plugs at the gallery openings in the cylinder block must be removed while cleaning is being done.

Replacing the timing gear cover Removing 1.

Remove the circulation pump. See page 13.

2.

Remove the crankshaft pulley.

3.

Remove the vibration damper. Use a screwdriver or similar tool as a counterhold, when the centre bolt is loosened, by inserting the screwdriver into one of the damper holes and allowing it to rest against the edge of the sump. If the damper is firmly fixed on the shaft, loosen it by striking it with a rubber mallet.

4.

Disconnect the fuel line and fuel pump.

5.

Loosen the distributor cap and move it with the spark plug leads to the one side. Disconnect the primary line to the distributor.

6.

Remove the bolt with the special washer retaining the distributor. Mark the positions of the distributor and rotor before pulling up the distributor.

N.B. From now on the crankshaft and camshaft must not be turned without adjusting the distributor accordingly. See “Fitting the distributor” on page 24.

7.

Loosen the bolts securing the timing gear cover, see Fig. 9.

N.B. Also the two front bolts in the sump.

Fig. 9 Timing gear cover (the arrows point to the bolts)

Replacing the sealing ring in the timing gear cover 1.

Remove the timing gear cover. See above.

2.

Knock out the gasket and washer with a suitable tool.

3.

Fit a new gasket with the ends on top. Drive in a new washer and lock it with a centre punch at least at three points.

4.

Shape the gasket with, for example, the handle of a hammer until it is possible to move the hub on the vibration damper into the gasket.

5.

Fit the timing gear cover. See above.

Fitting Fit the cover in the reverse order to removal and observe the following: 1.

14

Loosen the oil pump cover. One of the bolts will first be accessible when the oil filter has been screwed off. Pack the pump with petroleum jelly free from acid, otherwise there is risk of the pump being unable to suck oil from the sump directly after the moment of starting.

Replacing the timing gears Removing 1.

Remove the timing gear cover. See “Replacing the timing gear cover”.

2.

Remove the front crankshaft oil slinger.

3.

Remove the spark plugs and turn the crankshaft with the help of the vibration damper, for the moment fitted, until the marking on the timing gears are in the position shown in Fig. 10. Remove the vibration damper without altering the gear setting.

If the timing chain dampers are not damaged, it is not necessary to remove them.

4.

Remove the centre bolt with washer on camshaft.

Remove the camshaft distributor drive gear as well as the fuel pump eccentric.

5.

Remove the camshaft gear and crankshaft gear together with the chain. See Fig. 11. When removing, pry alternatively first one gear then the other.

Fig. 11 Removing the timing gears

Valve mechanism Removing 1.

Remove the rocker arm covers.

2.

Slacken the bolts for the caps and lift up the rocker arm shafts with rocker arms and the oil splash plate on the right-hand side.

3.

Lift up the push rods and place them in a numbered stand.

4.

Concerning valve lifters: See “Removing and inspecting valve lifters”.

Fig. 10 Marking on timing gears

Fitting 1.

Fit both timing gears at the same time together with the chain so that the marking on the both gears face opposite each other as shown in Fig. 10.

N.B. When fitting, make sure that the timing chain dampers do not get in the way of the chain.

2.

Fit the eccentric for the fuel pump on the camshaft. The eccentric is fitted with the oil groove facing the timing gear cover. See Fig. 12. Fit the distributor drive gear. Then fit the centre bolt and retaining washer and tighten the bolt with a torque wrench. Concerning the torque, see “Specifications”.

4.

Fit the timing gear cover. See page 14.

5.

Remove the distributor and adjust it to the correct setting. See “Fitting the distributor” on page 24.

Fig. 12 Fitting fuel pump eccentric and distributor drive

15

Fitting 1.

Fit the valve lifters. See “Assembling and installing valve lifters”.

2.

Place the push rods in their respective positions.

Make sure that the lower ends fit correctly into the lifters.

3.

Make sure that the contact surfaces on the bearing brackets are clean.

4.

Fit the rocker arm shafts.

N.B. There is a mark on each shaft to ensure that the lubricating holes will be correctly located. See Fig. 13. The mark on the shaft in the right cylinder bank should face forwards and towards the front valve. The shaft in the left cylinder bank should have the mark facing to the rear and the rear valve.

5.

Fit the bearing bracket bolts. Do not forget the oil splash plate on the two rear bolts in the right cylinder bank. See Fig. 14. Make sure that the push rod ends coincide with the respective rocker arm seat. Tighten the bolts evenly to a torque of 4 kpm (30 lb.ft.).

Fig. 14 1. Oil splash plate 2. Rocker arm cover gasket 3. Intake manifold gasket 4. End gaskets for intake manifold 5. Valve lifter

6. Camshaft

Fitting 1.

Fit new rubber seals on the front and rear edges of the block. See Fig. 14.

2.

Place new metal gaskets against the respective cylinder heads. The gaskets have guides against the heads.

3.

Carefully lower the manifold into position so that the gaskets are not damaged.

N.B. Be careful because it is possible to turn the manifold the wrong way. To avoid making a mistake, see how the thermostat is placed under the heading: “Replacing the thermostat”.

4.

Fit the bolts with the eyelets, etc. Tighten them evenly to a torque of 6 kpm (40 lb.ft.).

5.

Fit the cooling water hoses, the electrical connections and the fuel pipe.

Fig. 13 Marking the rocker arm shaft

Intake manifold Removing 1.

2.

3.

4.

16

Slacken the pipe from the fuel pump to the carburetor and disconnect any electrical connections if necessary.

Disconnect the requisite cooling water hoses and the crankcase ventilation pipe as well as the pipe for the carburetor thermostat housing (AQ150A and B).

Remove the bolts for the intake manifold. Observe here where the engine lifting eyelets (AQ150) and the throttle control attachment are fixed.

Lift up the intake manifold. Check that the manifold contact surfaces against the gaskets on the block are clean and not damaged.

Removing and inspecting the valve lifters 1.

Remove the rocker arm covers, valve mechanism and intake manifold.

2.

Lift out all the valve lifters and place them in a wooden block with numbered holes or similar device.

3.

Disassemble the valve lifters, see Fig. 15, by holding down the push rod seat with a push rod and then removing the snap ring with a suitable tool, e.g., a screwdriver. Then remove the seat and the plunger.

Fig. 15 1. Spring 2. Check valve ball 3. Plunger 4. Snap ring

Fig. 16

5. Push rod seat 6. Ball retainer 7. Valve lifter body

1. Valve lifter body 2. Plunger 3. Tool 884289

If it is difficult to remove the plunger, use tool 884289. Place the lifter in the large opening in the tool. See Fig. 16. As shown in the Figure, hold the bottom of the lifter with the thumb and rap the open end of the tool against a block of wood with just enough force to jar the plunger from the body.

Assembling and installing the valve lifters

1.

Fit the check valve ball together with the spring on the plunger.

4.

Remove the ball retainer, 6 Fig. 15, with the help of pliers.

2.

5.

Place all the parts for each valve lifter where it will not be possible to get them mixed up.

Place the large spring in the recess in the bottom of the valve lifter and then fit the plunger and push rod seat.

3.

Press down the seat and the plunger with a push rod and fit the spring.

6.

Clean all the parts in kerosene, using Cleaning Brush 884290 to clean the bore of the lifter body.

Then dry all the parts, with a clean lint-free cloth, wiping the plunger and body hard with the cloth.

Finally rinse them in kerosene and blow them dry with compressed air.

7.

The parts should now be inspected and the following observed.

a)

Check the lifter body. If the contact surface for the camshaft lobe is excessively worn or damaged in any other way, replace the respective lifters. A lifter body that has been rotating will have a round wear pattern and a non-rotating lifter body will have a square wear pattern. See Fig. 17. Permissible wear depth is 0.5 mm (0.02"). Some wear on the lower part of the body can be considered as normal and generally does not require to be remedied.

Check that there is no scoring as this can cause leakage between the body and the plunger.

b)

Using a magnifying glass inspect the check ball seat of the lifter plunger. If the check ball seat is damaged, or if there are scores and scratches on the outer surface of the plunger, the lifter should be replaced with a new one.

c)

Replace the ball.

d)

Check the remaining parts and replace any if necessary.

Make sure that all the parts are thoroughly cleaned and then fit them in the following order:

Fig. 17 Contact surfaces of the valve lifters 1 and 2. Surfaces not approved 3. Approved rotating lifter 4. Rotating lifter not approved The arrows show the wear edges of the surfaces (max. wear 0.5 mm = 0.02")

17

4.

Protect the assembled lifters until they are fitted in the block.

5.

Check that the valve lifter guide holes in the block are clean and not damaged. Check also the camshaft lobes and lubricate the camshaft and lifter bores with engine oil. Install all the lifters.

Make sure that they slide easily into their guide holes.

6.

Fit the valve mechanism, intake manifold and rocker arm covers.

Fig. 18 Reaming a valve guide

Camshaft Removing 1.

Remove the rocker arm covers and the valve mechanism.

2.

Remove the intake manifold. Lift out the valve lifters.

3.

Remove the timing gear cover. See: “Replacing the timing gear cover”.

4.

Remove the timing gears. See: “Replacing the timing gears”.

5.

Take out the camshaft carefully making sure that the bearings are not damaged by the camshaft lobes.

3.

Measure the clearance between valve stem and guide. Concerning clearances, see “Specifications”. If the stem has excessive clearance in its guide, the guide must be reamed using Reamer 884287. See Fig. 18. This ream has an 0.10 mm (0.004") oversize. Oversize valves are available as spare parts.

4.

Grind the valves in a machine to an angle of 45°.

Excessively worn valves should be replaced with new ones.

5.

Grind the valve seats using an electrically driven grinder or a hand milling cutter. The guide spindle must be securely fixed before the work begins and worn guides are reamed.

Inspect the camshaft and bearings. Slightly scored camshaft bearings can be used if all burr is removed and the surfaces of the camshaft journals are polished. Permissible clearance limits may be 0.038– 0.102 mm (0.0015–0.004").

Note that the camshaft journals have different dimensions. Measuring from the front thus reduces the diameter for each bearing and the corresponding journal by 0.76 mm (0.03").

The seat should be ground until a good sealing surface is obtained. The angle is 45° and the sealing surface width may not exceed 2 mm (0.079"). If the sealing surface is too wide after grinding, it can be reduced by using a 70° and a 20° grinding stone or reamers.

N.B. Grinding the valve and seat raises the height of the stem. As the height from the end of the valve stem to the valve spring seat surface of the cylinder head exceeds 50.17 mm (1 .975"), the functioning of the valve lifters can be affected. In such a case, the valve stem must be ground down or the valve scrapped.

Fitting Fitting of the camshaft takes place in the reverse order to the above. Before fitting, lubricate the bearing surfaces with engine oil and then carefully fit the shaft into position in the block. Concerning the location of the camshaft in the block, see Fig. 14.

6.

Then clean the valves and seats and check that good sealing is obtained.

Cylinder heads with valves Disassembling and reconditioning 1.

Remove the valve springs by first compressing them with valve pliers and removing the valve cotters, after which the pliers are released. Place the valves in order in a stand.

2.

With rotating brushes, clean the valves, the combustion chambers and the ports from carbon and combustion deposits.

Use tool 884304 for cleaning the valve guides.

18

Coat the valve sealing surfaces with a thin layer of fine grinding paste and lap in the valves against their seats.

Assembling 1.

Check that the parts are not damaged and are clean. Test the springs to make sure that they maintain the values indicated in “Specifications”.

2.

Lubricate the parts with engine oil. Fit valves, springs, washers and retainers with the help of the same tools that were used for the disassembling.

N.B. The springs should be turned with the close wound coils toward the cylinder heads. See Fig. 19.

Cylinder block Measuring the cylinder bores The cylinder bores are measured with a special dial indicator. The cylinders should be checked to see if they are out-of-round or tapered. Measuring is carried out at different depths and in both the longitudinal and transverse directions. If the cylinder requires reboring, there are pistons with three different oversizes to chose from. Concerning the wear tolerances for the cylinders and the piston oversize, see “Specifications”.

Fig. 19 Valve springs 1. Close wound coils toward cylinder head

Fitting the cylinder heads 1.

Check that the cylinder heads, the block, the pistons and the cylinder bores are clean.

2.

Install new cylinder head gaskets. Dowels in the cylinder head hold the gasket in position.

N.B. Do not use any extra sealing material on the gaskets. They are coated with a special lacquer to provide good seal, once the parts have warmed up.

3.

Place the cylinder heads in position. Be careful not to damage the gaskets.

4.

Clean the cylinder head bolts and smear their threads with sealer. Fit the bolts and tighten them in the order shown in Fig. 20. The tightening torque is 9–11 kpm (70–75 lb.ft.). Uneven or excessive tightening of the cylinder head bolts can distort the cylinder bores, this causing compression loss and high oil consumption.

Fig. 20 Cylinder head bolt tightening sequence

Reboring cylinders The cylinders are rebored in a special machine, after which they are honed to a fine finish. Before being fitted, the entire cylinder is rinsed in a degreasing tank to remove all grinding residues and impurities.

Before starting the reboring or honing operation, measure all the new pistons. See under the heading: “Measuring the piston”. Then select the smallest piston for the first fitting. If the first piston has excessive clearance, then it is possible to make subsequent correction of the clearance.

When reboring the cylinders, the crankshaft and main bearing caps should be fitted. The caps should also be tightened to the proper torque. See the “Specifications”. Before the pistons are checked for fit, each cylinder bore should be thoroughly cleaned and dried.

Pistons, piston rings and piston pins Measuring the piston Before measuring the piston, clean it thoroughly.

The piston is measured with a micrometer at right angles to the piston pin hole 6.4 mm (1/4") below the oil ring groove. See Fig. 21.

Fig. 21 Measuring the piston 19

Fitting the piston in the cylinder bore 1.

2.

With a cylinder indicator measure the diameter in the bore at right angles to the piston pin and about 50 mm (2") from the upper edge of the bore.

Measure the piston which is to be fitted. See under the heading: “Measuring the piston”. The piston must be 0.020–0.038 mm (0.001–0.0015") less then the cylinder bore.

removed for balancing and weighing. The bosses are shown in Figs. 22–23.

Assembling and fitting the piston and connecting rod 1.

Connecting rods and pistons should be assembled as shown in Figs. 22 and 23. This means that the pistons in the left cylinder bank are turned so that the piston mark faces forwards and the connecting rod and cop marks face to the rear. In the right cylinder bank the piston, connecting rod and cap marks all face forwards.

2.

Press the piston pin into the respective piston and connecting rod. Use drift 9991866 and a suitable counterhold so as not to damage the piston.

N.B. The block and the piston must have the same temperature during the measuring.

Fitting piston rings In a new or rebored cylinder 1.

2.

3.

Insert the piston rings one after the other into the bore. Use a piston in the upside down position so that the ring fits correctly.

Before pressing the piston pin through the respective connecting rod, lubricate it with engine oil to facilitate fitting and to avoid damage to the pin or rod.

Measure the ring gap with a feeler gauge. Concerning the gap, see “Specifications”. If necessary, the gap can be widened with the help of a special file.

Test the piston rings in the respective ring grooves by rolling them in the groove. Fit the piston rings in their grooves and with a feeler gauge measure the clearance between the piston ring and the lower edge on the ring groove. Concerning clearances, see “Specifications”.

In a worn cylinder bore In a worn cylinder bore, the gap should he measured with the piston ring at the bottom dead centre position where the diameter of the bore is smallest.

After assembling the piston and connecting rod, check that the piston rotates easily on the pin.

3.

Fit the piston rings with the help of a pair of piston ring pliers. The ring gaps should be turned in the way shown in Fig. 24. The gap for the resp. piston oil scraper rings should lie on the same side as the oil groove in the lower part of the connecting rod. See Figs. 22–23. The expander ring gap may not coincide with the oil scraper rings.

The side which should be turned upwards is marked with a letter or the word “TOP”. The upper compression ring is chromiumed.

Piston pins Press out the piston pin with the help of drift 9991866 and a suitable counterhold. The pin must be pressed out as it has a tight fit in the connecting rod. The piston pins have no circlips.

If the piston pin hole in the piston is worn in excess of the permissible values, the piston and piston pin must be replaced. As the piston pin has a press fit in the connecting rod, there are no oversize piston pins. The fit is correct when the piston pin meets light resistance when pressed through the hole in the piston with the parts at room temperature.

Fig. 22 Piston in left cylinder bank 1. Oil spurt hole up 2. Boss on rod and cap rearward 3. Notch on piston forward

Connecting rods Straightening Before being fitted, the connecting rods should be checked for straightness, twist and any S-distortion. If necessary, straighten them.

Fig. 23 Piston in right cylinder bank

At the crankshaft end of the connecting rods the rods are provided with bosses where the material can be

1. Oil spurt hole up 2. Boss on rod and cap forward 3. Notch on piston forward

20

Fig. 25 Measuring the radial clearance Fig. 24 Piston ring gap 1. Gap on top compression ring 2. Gap on second compression ring

3. Gap on oil ring 4. Piston pin

4.

Install the upper bearing shell in the connecting rod. Make sure that the bearing surface in the connecting rod is free from dirt, etc. The bearing shell has a tang on the outside which fits into a corresponding recess in the connecting rod.

5.

Lubricate the parts with engine oil and then fit the piston in position in the block with the help of tool 884296.

6.

Install the bearing shell in the cap. Concerning location, see point 4 above. Fit the cap on the connecting rod bolts. Tighten the nuts to a torque of 4–5 kpm (30–35 lb.ft.). Fit all the pistons and connecting rods in the same way.

3.

Remove the bearing cap with bearing shell. The flattened Plastigage will be found adhering to either the bearing shell or the crankpin.

N.B. Do not remove the Plastigage.

4.

Measure the Plastigage at its widest point. Use for this purpose the scale printed on the Plastigage envelope. The scale is in both millimetres and thousandths of an inch and indicates directly the radial clearance in question. See B, Fig. 25.

Concerning radial clearances. see wear tolerances in “Specifications”.

When fitting check that the clearance is the correct one.

N.B. Undersized bearings have a number punched on the outside indicating the degree of undersize. For permissible clearances, see “Crankshaft” in the “Specifications”.

When the piston and rod assemblies are properly installed the marks on the top of the pistons should be pointing forwards. The oil spurt holes in the connecting rods, see 1 Figs. 22–23, should be “up” towards the camshaft.

The conical boss on the connecting rod web and the rib on the edge of the rod cap should be on the same side. See Fig. 22 (2). In the left cylinder bank the ribs should lie rearward. On the right cylinder bank the ribs should lie forwards.

7.

Check the end clearance between the connecting rods on each crankpin using feeler gauges. Concerning clearances, see “Specifications”.

Measuring the radial clearance for big-end bearings The radial clearance is measured with a special measuring wire called Plastigage, Type PG - 1 (green), which has a range of 0.001–0.003" (0.025–0.076 mm). Plastigage is manufactured by Perfect Circle Corporation.

Measuring is carried out according to the following: 1.

2.

Remove connecting rod cap with bearing shell. Wipe oil from the bearing shell and crankpin journal. Blow oil out of the lubricating hole in the crankshaft. This is important because the Plastigage is soluble in oil.

Place a piece of Plastigage lengthwise along the bottom of the bearing shell (lower), see Fig. 25.

Fit the cap and tighten the nuts to the correct torque. See “Specifications”.

Make sure that the caps are not turned in the wrong direction during installation.

N.B. Do not turn the crankshaft with Plastigage in the bearing.

After installing the connecting rod, check that it can be moved back and forth on the crankpin.

Crankshaft bearings The crankshaft bearings consist of two halves or shells where the upper bearing shell has an oil hole with oil groove. See Fig. 26.

Bearings Nos. 1 and 3 are similar. Bearing No. 2 is provided with flanges to take end thrust and thus functions as a thrust bearing. Bearing No. 4 (the rear main bearing) must not be confused with the other bearings.

For this reason, the rear main bearing has its tang on the lower bearing shell displaced in relation to the tang on the Nos. 1 and 3 bearings.

When fitting a new thrust bearing, it should be “lined” up. This is done so that with the bearings fitted and the bolts for the caps lightly tightened (manually), the crankshaft can be moved forwards and backwards as far as the axial clearance permits.

When measuring the main bearings, note the following. a.

Measurement is carried out with the help of Plastigage. See heading: “Measuring the radial clearance for crankshaft bearings”.

b.

Turn the crankshaft so that the oil hole is up to avoid dripping oil on the Plastigage.

c.

If the engine is not upside down, the weight of the crankshaft will influence the results. When measuring with the engine in its normal position, place paper shims in the lower bearing shells of the adjacent bearings to take the weight of the crankshaft off the bearing being measured.

The end play should not exceed 0.076 mm (0.003").

21

Fig. 27 Rear main bearing oil seals 1. Seal against engine block 2. Crankshaft seal

Fig. 26 Engine block seen from underneath 1. Front crankshaft bearing shell 2. Thrust bearing shell 3. Crankshaft bearing shell 4. Rear main bearing shell 5. Rear crankshaft seal, upper part

2.

For sealing against the block, use a seal of the neoprene type, 1 Fig. 27. The seal is somewhat longer than the groove in the bearing cap. Do not cut off a piece of the seal. Allow the upper ends to project over the edge about 1–2 mm (1/16").

Lubricate all the seals before fitting the cap. After the cap has been installed, press down the neoprene seals with a blunt tool in order to ensure good sealing.

d.

Before installing the bearing shells, make sure that the bearing seats and bearings are thoroughly cleaned. Coat, therefore, the bearings with lubricant before installing them. Do not interchange the upper and lower bearing shells. The upper shell has an oil groove in its centre.

3.

e.

When installing a new bearing, the clearance should be 0.010–0.038 mm (0.004–0.0015").

Oversize bearings have a number stomped on or near to the tang. The number indicates the amount of oversize.

Oil pipe and oil screen

f.

Before installing the rear bearing cap, see the heading: “Installing rear bearing oil seals”.

g.

The main bearing bolts should be tightened to a torque of 13–16 kpm (95–120 lb.ft.).

Removing 1.

Remove the sump and oil plate. Clean the parts.

2.

Remove the strainer and the oil pipe and clean them. Blow dry with compressed air. See Fig. 28.

Crankshaft After cleaning the crankshaft measure it. The out-ofroundness on the main bearing and crankshaft bearing pins must not exceed 0.038 mm (0.0015").

Check that the shaft is straight within 0.076 mm (0.003") by indicating it in a V-block.

Installing rear main bearing oil seals 1.

Install the braided fabric bearing seal. Press down the seal into the groove until the ends of the seal do not protrude above the edge more than 1–2 mm (1/16"). See Fig. 27. Cut the ends off with a razor-blade.

On replacing the upper seal half, remove the crankshaft.

22

Fig. 28 Oil strainer and oil pipe

Fitting 1.

Fit the oil pipe. Make sure that the gasket surfaces on the pipe and block are clean and undamaged. Fit on a new gasket. Tighten the bolts to a torque of 0.8–1.2 kpm (6–9 lb.ft.).

2.

Install the strainer.

3.

Fit the oil plate and sump. Tighten the sump bolts evenly.

Fig. 30 Measuring the oil pump gear end clearance

Oil pump Removing and inspecting 1.

Screw off the oil filter.

2.

Remove the screws attaching the oil pump cover assembly to the timing chain cover and take out the oil pump gears.

3.

Wash the parts. Check the gears for wear or scoring, etc. Replace any gears not found to be serviceable.

4.

Disassemble the oil pressure relief valve, see Fig. 29. The oil filter by-pass valve and spring are staked in place and should not be removed.

5.

Check that the valve plunger is not scored or worn and check also the spring to see that it is not excessively worn at the sides. Replace any relief valve spring that is questionable.

6.

Check the valve housing in the cover. The valve plunger should have no more clearance in the housing than an easy slip fit. If any perceptible side shake can be felt, the valve and the cover should be replaced.

7.

Check the filter by-pass valve for cracks, nicks or warping.

Fitting 1.

Lubricate and install the pressure relief valve in the oil pump cover. Tighten the nut to a torque of 4–5 kpm (30–35 lb.ft.).

2.

Install the oil pump gears in the oil pump body.

3.

Measure the clearance of the gears and the pump body surface, without gasket, with a feeler gauge and steel ruler according to Fig. 30. The clearance should be between 0.058–0.147 mm (0.0023–0.0058"). If the clearance is less than 0.045 mm (0.0018"), check the pump body for wear.

4.

After measuring the gear end clearance, remove the gears and pack the gear pocket full of petroleum jelly. This step is very important. Unless the pump is packed with petroleum jelly, it may not be able to suck the oil from the sump directly after the engine has started.

N.B. Do not use ordinary chassis lubricant.

5.

Use a new gasket and fit the cover. Tighten the screws evenly to a torque of 1.1–1.6 kpm (8–12 lb. ft.).

6.

Screw on the oil filter, first making sure that the pump contact surface is clean. Then smear the filter rubber gasket with oil and screw on the filter on the connector nipple until it just touches the contact surface. Then screw it a further 2/3 of a turn.

Fig. 29 Oil pump cover with oil pressure relief valve 1. Valve cap 2. Washer 3. Spring 4. Plunger for relief valve 5. Connection surface for oil filter

23

Crankcase ventilation The crankcase ventilation system on the AQ150 engine differs somewhat from that on the AQ150A and B engines.

On the AQ150 crankcase gases are drawn up through one of the rocker arm covers from where they pass through a hose and into the carburetor throttle body.

The crankcase gases are mixed with fuel-air mixture and drawn into the engine where combustion takes place. The other rocker arm cover is fitted with tightly sealing oil filler caps.

On the AQ150A and B crankcase gases are drawn up from one of the rocker arm covers in the same way as for the AQ150. For the AQ150A and B, however, there is also a ventilator cover with filter on the other rocker arm cover. The crankcase gases are drawn from the left cylinder bank up through the right cylinder bank and then into the carburetor. When the engine is idling, the mixing of these crankcase gases with the fuel-air mixture will influence the idling speed of the engine. For this reason, a positive crankcase ventilator valve is used which automatically restricts the flow of crankcase gases whenever the intake manifold vacuum is high. On the AQ150 engine, this valve is combined with the connection of the breather pipe to the rocker arm cover. The valve is of the diaphragm type. On the AQ150A and B engines, the valve is of another construction, see Fig. 31, and is bolted to the connection nipple in the throttle body. See Fig. 41.

Fig. 32 Distributor and notch for ignition setting (see arrow) 2.

Install the distributor in the position shown in Fig. 33. The rotor should also have the position indicated in the in the figure.

If it is not possible to press down the distributor completely, the reason will be that the recess on the oil pump shaft must be turned so that the distributor shaft can fit into it. So take out the distributor and turn the oil pump shaft with a screwdriver and then reinsert the distributor.

If the ventilator valve becomes clogged, this can cause serious damage to the engine because all crankcase ventilation ceases. Therefore, it is important to check and clean the ventilator valve at regular intervals. Check and clean also the ventilation covers on the AQ150 A and B.

Fig. 33 Rotor in firing position for cylinder No. 1 Fig. 31 Positive crankcase ventilator valve, AQ 150 A and B 1. Spring 2. Plunger 3. Valve body

Ignition system

3.

Fit the bolt and retainer, but do not tighten the bolt as to prevent the distributor body from being turned manually. See Fig. 32.

4.

Connect the primary lead to the ignition coil.

5.

Turn the distributor body clockwise until the contact breaker points just begin to open.

N.B. This must be done very carefully, otherwise it may be extremely difficult to start the engine.

Fitting the distributor 1.

Remove the left rocker arm cover. Turn the crankshaft with the help of a spanner on the centre bolt for the vibration damper until both the valves for cylinder No. 1 are fully closed. Check that the valves are closed even immediately before and after the top dead centre is reached.

The notch on the vibration damper should be at an angle of 5° at the same time. See arrow, Fig. 32.

24

When the engine is started. the ignition timing must be carefully checked with the help of a stroboscope. See: “Adjusting the dwell angle and ignition timing”.

6.

Install the distributor cap and leads. Check the location of the leads in the cop and on the spark plugs. See Fig. 34.

Adjusting the ignition timing First check the dwell angle. See above. The ignition timing should always be adjusted with the help of a stroboscope.

AQ150, AQ150A

AQ150B Fig. 34 Location of spark plug leads seen from front end engine.

A. Cover

1.

Disconnect the vacuum line to the distributor (AQ150).

2.

Lock the attaching bolt so that the distributor can be turned.

3.

Connect the lamp with the high-tension cable to the spark plug in No. 1 cylinder.

4.

Start the engine. Check the idling speed when the engine has become warm. The timing setting should be carried out at 600–700 r.p.m.

5.

Point the lamp to the scale on the timing gear cover and turn the distributor until a 5° pre-firing is obtained.

6.

Tighten the distributor and check that the timing has not been altered. Check also that the speed has not been changed.

7.

Remove the lamp and fit the vacuum line (AQ150).

Fuel system Cleaning the carburetor 1.

Remove the carburetor cover by first disconnecting the control rods for the acceleration pump and choke. Then slacken the bolts retaining the cover and lift it off.

2.

Remove the venturi cluster, 1 Fig. 36, by loosening the three attaching screws. Then slacken the T-shaped retainer which becomes visible when the venturi cluster is removed. Remove the pump discharge spring and the steel discharge check ball.

3.

Remove the float and the needle valve seat with strainer, likewise the acceleration pump.

4.

Remove the two main nozzles as well as the power jet. See Fig. 36.

5.

Take out the return spring and the check ball in the hole for the acceleration pump together with the screen in the pump inlet. See Fig. 36.

6.

Remove the carburetor thermostat body and choke shaft.

7.

Clean the float body and remaining parts in a suitable cleaning fluid. Blow through all the channels and jets with compressed air.

8.

Check the parts for wear and if necessary replace them.

Setting the dwell angle When setting the dwell angle, always follow the instructions of the maker for the dwell angle gauge.

1.

Connect the gauge. Check that it is set for 6 cylinders.

2.

Start the engine. Lift up the opening in the distributor cap. Use a 1/8" hexagon spanner, see Fig. 35, and set the dwell angle at 30°.

3.

Adjust the timing ignition. See below.

Fig. 35 Adjusting the dwell angle A. Internal hexagon spanner 1/8"

25

Fig. 37 Carburetor cover 1. Float 2. Vacuum plunger for power jet 3. Acceleration pump 4. Choke valve 5. Thermostat housing

Fig. 36 Carburetor body 1. Venturi cluster 2. Main jets 3. Carburetor body 4. Return spring, acceleration pump 5. Screen, pump inlet 6. Power jet

Assembling Throttle body 1.

Screw idle mixture adjusting needles and springs into the throttle body until finger tight. Back out the screws one turn as a preliminary idle adjustment.

Carburetor cover 1.

Install the thermostat housing. See Fig. 37. Use a new gasket.

2.

Install the choke shaft and lever for pull rod. See Fig. 38.

3.

Install the choke valve in the choke shaft so that the letters “RP” will face upward. Use new choke valve attaching screws but do not tighten securely until the choke valve is centred. Centre choke valve on choke shaft by holding the choke valve tightly closed. Then slide the choke shaft into obtain a clearance of approx. 0.5 mm (0.020") between the choke trip lever and choke lever and collar assembly. Tighten the choke valve screws securely and make sure that the valve is tightly closed. Stake the screws in place with a centre punch.

NOTE. Do not force the idle needle against its seat or damage may result.

2.

Use a new gasket and install the throttle body on the ball with three screws and lock washers.

Carburetor body 1.

Drop the steel discharge check ball into the discharge hole of the acceleration pump. Install the pump discharge spring. Hold the spring position with a “T” shaped retainer and stake the retainer in place with light blows from a centre punch.

2.

Install the venturi cluster with the gasket. The middle of the three screws should be shorter and should also have a fibre gasket.

3.

Install both the two main nozzles and power jet.

The power jet is provided with a fibre gasket.

4.

Install the small aluminium inlet check ball and return spring in the acceleration pump cylinder.

Insert pump return spring and centre in well by pressing downward with finger.

5.

Install the pump inlet screen in the bottom of the float bowl.

26

Fig. 38 Carburetor 1. Lever for acceleration pump 2. Plunger for acceleration pump 3. Lever for pull rod 4. Lever for choke valve shaft 5. Idle speed screw 6. Connection hole for throttle 7. Pull rod for fast idling 8. Fast idling cam

4.

Install the acceleration pump with lever. See Fig. 37.

5.

Install the needle seat with needle and gasket.

6.

Install the vacuum plunger, see 2 Fig. 37, for the power jet. Lightly stake the plunger retainer washer in place with a centre punch.

7.

Place the gasket on the cover.

8.

Attach the float needle to the float arm and install the needle and float.

9.

Adjust the distance between the gasket and the lower edge (sharp edge) of the float seam at the short end of the float. See Fig. 39. The distance should be 15 mm (0.6"). Bend the float arm according to the arrow on the Figure to adjust the float level .

Check also the location of the float when this is fully open. Measure between the gasket and the bottom of the float according to Fig. 40. The distance should be 48.4 mm (1 .9"). Adjust by bending the tang. See 1 Fig. 40.

Thermostat housing and vacuum valve 1.

Attach the lever in the vacuum valve by inserting the short pin into the hole at the side of the valve and through the hole in the lever.

2.

Install the valve with lever in the thermostat housing. The valve should be turned so that the hole for the lock pin points to the carburetor. The lever is fixed by means of a screw in the throttle shaft.

3.

Install the insulator plate, gasket and cover with thermostat spring.

The cover is attached by means of three screws and retainers. Before tightening the screws, turn the cover clockwise until the choke valve is completely closed. The straight line on the cover at the word “lean” should then point straight upwards. See Fig. 41.

10. Fit the carburetor cover on the float bowl . Make certain that the acceleration pump is properly positioned when the cover is installed.

11. Install the choke rod into the choke lever and fast idle cam. Install the acceleration pump rod. The rod should be locked at its lower end with a retainer. See Fig. 38.

Fig. 41 Carburetor

Fig. 39 Measuring the float level

1. Ventilator valve for crankcase ventilation 2. Connection for sending unit tube to thermostat housing 3. Setting mark for automatic choke 4. Ventilator pipe 5. Carburetor cover 6. Fuel connection 7. Float bowl (carburetor body) 8. Idle mixture screws 9. Throttle body

Adjusting the carburetor Fig. 40 Measuring the float level 1. Stop tang 2. Measuring gauge

All adjustments on the carburetor, except for float adjustments, are made externally. For the float level adjustment, see under the heading “Assembling” on page 26. For the other adjustments, see below.

27

a. Acceleration pump rod adjustment

d. Fast idle adjustment

Back out the idle stop screw and close completely the throttle valve.

The fast idle speed adjustment is controlled by the different cam stages. Provided the idle speed is correctly set and the choke rod properly adjusted, no further adjustment is necessary.

Measure the distance from the top of the flame arrester flange to the upper end of the pump rod. See Fig. 42. The measurement should be 29.4 mm (1.16").

When adjusting bend the pump rod at the arrow in the Figure.

e. Automatic choke If necessary, the automatic choke can be adjusted.

Normally the marking, 3 Fig. 41 , on the cover should point upwards. The thermostat spring inside the cover is then suitably tensioned and this closes the choke valve.

If the automatic choke does not function satisfactorily, this may be due to the spring being incorrectly tensioned. By loosening the three screws, the cover can be turned clockwise or counter clockwise until the best results are obtained.

Fig. 42 Adjusting the carburetor 1. Bend at the arrow

b. Choke unloader adjustment Open the throttle valve fully. The choke valve should then be open sufficiently that the distance according to Fig. 43 between the upper edge of the choke valve and the carburetor cover is 2.8 mm (0.11"). Adjust by bending the unloader tang, 2 Fig. 43.

Fig. 43 Adjusting the carburetor 1. Measuring gauge 2. Tang for choke unloader

c. Idle adjustment Adjust the idling when the engine is at normal operating temperature. Adjust the two idle mixture needle screws alternatively, 8 Fig. 41, until the maximum speed is obtained. Readjust with the idling screw, but conclude by adjusting with the idle mixture needle screws.

28

Tools The following special tools are required for work on the engine.

884287

884289

884290

884296

884304

9991866

Volvo Penta No. GM-No.

Description

884287

J-5830-1

Valve guide reamer. Oversize 0.10 mm (0.0039")

884289

J-4160-A

Tool for removing valve lifter plunger

884290

J-5099

Cleaner brush for valve lifter body

884296

J-5601

Fitting ring for piston

884304

J-8814

Reamer for cleaning valve guide

9991866

–––

Drift for removing and fitting piston pin

29

Specifications General Type designation ................................................................................

Output, h.p. at r.p.m. (SAE) .................................................................

Compression pressure (warm engine and starter motor speed) .....

Compression ratio .............................................................................

Number of cylinders (two banks 90° V-shape) .................................

Cylinder numbering (from front to rear) left cylinder bank .............................................

Right cylinder bank .........................................

Bore ....................................................................................................

Stroke ..................................................................................................

Piston displacement ..........................................................................

Operating speed, max. .......................................................................

Idle speed (warm engine) ..................................................................

Weight, engine unit approx. ...............................................................

AQ150, 150A, 150B 150/4200 11–12 kg/cm2 (160 lb./sq.in.)

9:1 6 1–3–5 2–4–6 95.25 mm (3.750 in.)

86.36 mm (3.400 in.)

3.7 litres (225 cu.in.)

4200 r.p.m.

600–700 r.p.m.

280 kg (506 lb.)

Cylinder block Material ...............................................................................................

Cylinder bore, nominal standard .......................................................

0.010" oversize ..........................................................

0.020" oversize ..........................................................

0.030" oversize ..........................................................

Cast iron 95.250 mm (3.750 in.)

95.504 mm (3.760 in.)

95.758 mm (3.770 in.)

96.012 mm (3.780 in.)

Cylinder heads Material ...............................................................................................

Number ...............................................................................................

Cast iron 2

Pistons Material ...............................................................................................

Piston clearance ................................................................................

Piston diameter, nominal standard ....................................................

0.010" oversize .......................................................

0.020" oversize .......................................................

0.030" oversize .......................................................

Cast alloy iron 0.025–0.038 mm (0.0010–0.0015 in.)

95.225 mm (3.749 in.)

95.479 mm (3.759 in,) 95.733 mm (3.769 in.)

95.987 mm (3.779 in.)

Piston rings Ring gap measured in ring opening: compression ring .................. oil ring ...................................

Oversizes on piston rings ..................................................................

30

0.254–0.508 mm (0.010–0.020 in.)

0.381–0.889 mm (0.015–0.035 in.)

0.508 mm (0.020 in.)

0.762 mm (0.030 in.)

No. 1 Compression ring Marked with letter or “TOP”. Chromium-plated.

Number on each piston .....................................................................

Width ...................................................................................................

Piston ring clearance in groove ........................................................

1 1.994–2.007 mm (0.0785–0.0790 in.)

0.076–0.127 mm (0.003–0.005 in.)

No. 2 Compression ring Marked with letter or “TOP”.

Number on each piston .....................................................................

Width ...................................................................................................

Piston ring clearance in groove ........................................................

1 1.956–1.981 mm (0.0770–0.0780 in.)

0.076–0.127 mm (0.003–0.005 in.)

Oil ring Number on each piston .....................................................................

Type ....................................................................................................

Width ...................................................................................................

Piston ring clearance in groove ........................................................

1 Expanding 4.597–4.750 mm (0.180–0.187 in.)

0.089–0.241 mm (0.0035–0.0095 in.)

Gudgeon pin Floating journalled in piston. Circlips are not fitted.

Fit: In connecting rod ...............................................................................

In piston ..............................................................................................

Diameter .............................................................................................

Press fit Slide fit 23.861–23.868 mm (0.9394–0.9397 in.)

Crankshaft Crankshaft end play ...........................................................................

Main bearing to journal clearance ....................................................

Connecting rod bearing clearance ...................................................

0.102–0.203 mm (0.004–0.008 in.)

0.013–0.053 mm (0.0005–0.0021 in.)

0.051–0.058 mm (0.0020–0.0023 in.)

Main bearings Main bearing journals Diameter, standard ............................................................................ undersize 0.001" ............................................................... undersize 0.002" ............................................................... undersize 0.010" ...............................................................

63.487 mm (2.4995 in.)

63.462 mm (2.4672 in.)

63.437 mm (2.4985 in.)

63.233 mm (2.4895 in.)

Main bearing shells Standard sizes Undersize 0.001" Undersize 0.002" Undersize 0.010"

31

Crankshaft bearings Crankshaft bearing journals Diameter, standard ............................................................................ undersize 0.001" ............................................................... undersize 0.002" ............................................................... undersize 0,010" ...............................................................

50.800 mm (2.0000 in.)

50.775 mm (1.9932 in.)

50.750 mm (1.9980 in.)

50.546 mm (1.9899 in.)

Crankshaft bearing shells Standard sizes Undersize 0.001" Undersize 0.002" Undersize 0.010"

Connecting rods End play at crankshaft (total for both rods) .......................................

0.152–0.356 mm (0.006–0.014 in.)

Camshaft Number of bearings ...........................................................................

Diameter: Bearing journal 1 ..............................................................

Bearing journal 2 ..............................................................

Bearing journal 3 ..............................................................

Bearing journal 4 ..............................................................

Journal clearance in bearings ...........................................................

4 44.577–44.602 mm (1.755–1.756 in.)

43.815–43.840 mm (1.725–1.726 in.)

43.053–43.078 mm (1.695–1.696 in.)

42.291–42.316 mm (1.665–1.666 in.)

0.038–0.102 mm (0.0015–0.0040 in.)

Timing gears Crankshaft drive, number of teeth on gear .......................................

Camshaft gear (nylon), number of teeth ...........................................

20 40

Valve system Rocker arm clearance on shaft .........................................................

Valve lifter diameter ...........................................................................

Valve lifter clearance in crankcase ....................................................

Height from valve stem end to valve spring surface on the cylinder head .............................................................

32

0.043–0.081 mm (0.0017–0.0032 in.)

21.392–21.405 mm (0.8422–0.8427 in.)

0.038–0.076 mm (0.0015–0.0036 in.)

48.895 mm (1.9250 in.)

Valves Intake Head diameter ...................................................................................

Stem diameter ....................................................................................

Valve seat angle .................................................................................

Cylinder head seat angle ..................................................................

Seat width in cylinder heads .............................................................

41.225 mm (1.625 in.)

8.666 mm (0.3412 in.)

45° 45° 1.6 mm (0.0630 in.)

Exhaust Head diameter ...................................................................................

Stem diameter ....................................................................................

Valve seat angle .................................................................................

Cylinder head seat angle ..................................................................

Seat width in cylinder heads .............................................................

34.925 mm (1.3750 in.)

8.654 mm (0.3407 in.)

45° 45° 1.6 mm (0.0630 in.)

Valve guides Not replaceable.

Drift with 0.10 mm (1/64") oversize available.

Clearance valve stem – guide, intake valves .................................. exhaust valves ...............................

0.025–0.089 mm (0.0010–0.0035 in.)

0.038–0.102 mm (0.0015–0.0040 in.)

Valve springs Length – with load .............................................................................

Length – with load .............................................................................

41.6 mm – 29±2.5 kg (1.727 in.–64±5.5 lb.)

32.0 mm – 76±3.0 kg (1.340 in.–164±6.6 lb.)

Lubricating system Oil capacity, incl. oil filter ................................................................... excl. oil filter ..................................................................

Oil pressure at 2400 r.p.m. (warm engine) ........................................

Lubricant ............................................................................................

4.7 litres (8 1/4 Imp. pints = 4 US quarts) 3.8 litres (6 1/2 Imp. pints = 5 US quarts) 2.3 kg/cm2 (33 lb/sq.in.)

Multigrade oil, Service MS SAE 10W-30

Oil filter Type ....................................................................................................

Full flow oil filter

Oil pump Oil pump, type .................................................................................... number of teeth on each gear ..........................................

Gear-driven 8

33

Fuel system Fuel pump Fuel pump, diaphragm type ...............................................................

Min. fuel pressure at carburetor level (idling speed) ........................

AC 0.27 kp/cm2 (4 lb/sq.in.)

Carburetor Type ....................................................................................................

Make and designation .......................................................................

Diameter at throttle flap ......................................................................

Venturi, large ...................................................................................... small ...................................................................................................

Main jet (2) No. ...................................................................................

Idling speed ........................................................................................

Two barrel down draught carburetor Rochester 2GC 36.5 mm (1 7/16 in.)

31.8 mm (1 1/4 in.)

3.2 mm (l/8 in.)

61 600–700 r.p.m.

Electrical system Voltage ...............................................................................................

Alternator, output S.E.V. Motorola ......................................................

Alternator, output Motorola USA ........................................................

Regulator, type ...................................................................................

Control voltage (charging current near zero) ...................................

12 V 450 W 520 W Fully-transistorized 14.4–14.8 V

Ignition system Firing order .........................................................................................

Ignition timing, 92 octane Research Method at 550 r.p.m. (vacuum regulator disconnected) .....................................

Spark plugs ........................................................................................

Spark plug electrode gap ..................................................................

1-6-5-4-3-2 5° before T.D.C. AC 43 S Champion J 10 Y 0,9 mm (1/32 in.)

Distributor Make ...................................................................................................

Breaker contact points, gap ............................................................... contact pressure ..........................................

Dwell angle ........................................................................................

Direction of rotation ............................................................................

Condenser, make and capacity .........................................................

Delco Remy 0.4 mm (0.016 in.)

0.5–0.65 kg (1.10–1.40 lb.)

30° ±1° Clockwise Delco Remy, 18–23 micro-farad

Cooling system Type ....................................................................................................

Capacity, AQ150 (fresh-water cooled) approx. .................................

Pressurized 10 litres (17 1/2 Imp. pints=11.2 US quarts)

Thermostat Begins opening at: AQ 150 ...............................................................

AQ 150A ............................................................

AQ 150B ............................................................

34

60°–63° C (140°–147° F) 54°–55° C (129°–131° F) 76°–78° C (169°–171° F)

Wear tolerances Cylinder To be rebored when wear amounts to (if engine has abnormal oil consumption) .........................................................

To be rebored when out-of-round amounts to (if engine has abnormal oil consumption) ............................................

0.127 mm (0.0050 in.)

0.076 mm (0.0030 in.)

Crankshaft Permissible out-of-round on main bearing journals, max. ...............

Permissible out-of-round on big-end bearing journals, max. ...........

Max. end play for main bearings .......................................................

Max. end play for big-end bearings ...................................................

0.038 mm (0.0015 in.)

0.038 mm (0,0015 in.)

0.076 mm (0.0030 in.)

0.076 mm (0.0030 in.)

Tightening torques Cylinder heads ...................................................................................

Main bearings ....................................................................................

Big-end bearings ................................................................................

Flywheel .............................................................................................

Vibration damper, min. .......................................................................

Crankshaft pulley ...............................................................................

Sump ..................................................................................................

Sump drain plug .................................................................................

Oil pump cover ...................................................................................

Relief valve .........................................................................................

Oil screen in sump .............................................................................

Baffle in sump .....................................................................................

Plugs for oil galleries .........................................................................

Timing gear cover ..............................................................................

Circulation pump ................................................................................

Circulation pump pulley .....................................................................

Intake manifold ...................................................................................

Exhaust manifold ................................................................................

Carburetor ..........................................................................................

Fuel pump ..........................................................................................

Camshaft centre bolt ..........................................................................

Rocker arm covers .............................................................................

Rocker arm shaft bearing brackets ...................................................

Starter motor to cylinder block ...........................................................

Starter motor brace to cylinder block .................................................

Distributor holddown clamp ...............................................................

Spark plugs ........................................................................................

Coupling flywheel – crankshaft .........................................................

kpm 9–11 13–16 4–5.5 7–9 19 2.5–3.5 1.2–1.8 3.5–5 1.1–1.6 3.5–4 0.8–1.2 1.2–1.8 3–4 2.5–3 0.8–1.1 2.5–3 6–7.5 4–5 1.5–2 2.5–3 5.5–7.5 0.4–0.7 3.5–5 4–5.5 1.2–1.8 1.4–2 3.5–5 5.5–7

lb.ft.

65–80 95–120 30–40 50–65 140 17–25 9–13 25–35 8–12 25–30 6–9 9–13 20–30 17–23 6–8 17–23 45–55 30–35 10–15 17–23 40–55 3–5 25–35 30–40 9–13 10–15 25–35 40–50

35

Notes ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... ......................................................................................................................................................................................... .........................................................................................................................................................................................

36

Report form Do you have any complaints or other comments about this manual? Please make a copy of 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 Customer Support Dept. 42200 SE-405 08 Gothenburg Sweden

7721460-9 English 12 2000