Volvo AQ125A, AQ145A, AQ125B, AQ145B Service Manual
Workshop Manual
Engine Unit
AQ125A, B
AQ145A, B
C
2(0)
Contents
Safety Precautions ............................................................................................................. 2
General Information ...........................................................................................................5
Repair Instructions ............................................................................................................6
Presentation ....................................................................................................................... 8
Repair Instructions
Disassembling, Overhauling and Inspection
Electrical parts, carburetor ...................................................................................................9
Heating exchanger, exhaust pipe, oil filter.................................................................. 10–11
Oil cooler, sea water pump ............................................................................................... 12
Circulation pump, belt pulley, marking the timing belt ...................................................... 13
Belt tensioner, intermediate pulley, camshaft pulley......................................................... 14
Sealing flange, flywheel cover .......................................................................................... 15
Vibration damper, intermediate shaft ................................................................................ 16
Camshaft........................................................................................................................... 16
Cylinder head valves ..................................................................................................16–18
Valve seats, guides, springs, pushers ........................................................................ 19–22
Flywheel, sealing .............................................................................................................. 22
Lubricating oil pump, pistons, crankshaft.................................................................... 23–24
Cylinders, pistons, connecting rods, crankshaft.......................................................... 25–28
Fuel pump, oil cooler, lubricating oil pump ................................................................. 28–30
Heat exchanger, carburetor, flywheel cover................................................................ 31–33
Assembling
Crankshaft, pistons, lubrication oil pump, flywheel ..................................................... 33–35
Oil sump, cylinder head, camshaft .............................................................................. 36–37
Intermediate shaft, seals, camshaft gear wheel .......................................................... 38–39
Intermediate gear, marking, timing belt ....................................................................... 40–42
Oil pump drive, circulation pump, valve adjustment.................................................... 42–46
Distributor, oil cooler, exhaust pipe, heat exchanger .................................................. 46–48
Lubrication oil filter, sea water pump, expansion tank ................................................ 48–49
Thermostat sea water strainer, alternator.................................................................... 49–50
Starter motor, induction pipe, carburetor ..................................................................... 50–51
Electric wiring diagram ................................................................................................... 52
Fault finding chart ........................................................................................................... 53
Special tools .............................................................................................................. 54–55
Technical data AQ125A, AQ145A............................................................................ 56–60
Valve adjusting kit........................................................................................................... 61
Technical data AQ125B, AQ145B............................................................................ 62–68
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 infor
mation that will facilitate work or operations.
Check that the warning or information decals
on the product are always clearly visible. Replace decals that have been damaged or painted over.
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.
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 engine 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.
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!
2
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.
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.
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.
3
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.
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.
4
General information
About the workshop manual
This workshop manual contains technical specification, descriptions and instructions for repairing
the standard versions of the following engines
AQ125A, B – AQ145A, B. The workshop manual
displays the operations carried out on any of the
engines above. As a result the illustrations and pictures in the manual that show certain parts on the
engines, do not in some cases apply to all the engines listed above. However the repair and service
operations described are the same in all essential
details. Where they are not the same this is stated
in the manual and where the difference is considerable the operations are described separately. Engine designations and numbers are given on the
number plate. The engine designation and number
should be given in all correspondence about the engine.
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 nonoriginal 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
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.
Safety information
)
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 Tightening Torques
Nm lbt.ft
M5 6 4.4
M6 10 7.4
M8 25 18.4
M10 50 36.9
M12 80 59.0
M14 140 103.3
6
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
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. 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.
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 trengths,
operating temperature ranges, resistance to oil and
other chemicals and for the different materials and
gap sizes in the engines.
To ensure service work is correctly carried out it is
important that the correct sealant and locking fluid
type is used on the joint where the agents are required.
7
Presentation
AQ145A
1. Oil dipstick
2. Fresh water tank
3. Filler cap, checking, fresh water
4. Distributor
5. Carburettor, front (AQ125 has only one)
6. Intake air silencer
7. Carburettor, rear
8. Ignition coil
9. Electro-mechanical lift device
10. Steering arm
11. Fuse box (exec. USA)
12. Serial number
13. Fuse (exec. USA)
14. Fuse (not USA)
15. Fuel pump
16. Sea water pump
17. Grease joint, upper steering shaft journal
18. Grease joint, drive shaft journal
19. Oil filler cap engine
20. Water filter
21. Heat exchanger
22. Draining, sea water
23. Luboil filter
24. Oil cooler (only AQ145A)
25. Draining, sea water
26. Draining, sea water
27. Draining, fresh water
AQ145A
AQ125
AQ125
8
Repair Instructions
1. AQ145. Remove the four screws and pull the in-
duction silencer to one side so that it comes free
from the evacuation tube (1). AQ125. Remove the
cover.
3. Remove the alternator, drive belt, cable harness,
ignition coil, main fuse, starter motor, ignition
cables and distributor. NOTE! Mark the cables
before they are removed.
2. Remove the air filters (1), the fuel pipe (2) between the feed pump and the carburetors and
unscrew the carburetors from the induction pipe.
AQ125 has only one carburetor.
4. Remove the cooling water pipe (1), and the
bracket for the ignition coil (2). Remove the screw
(3) and draw up the dip stick with its tube (4).
Then remove the feed pump (5) and the induction
pipe (6). NOTE! There are double gaskets plus an
intermediate washer on the feeder pump. There is
a lifting eye in the induction pipes rear screws.
There are no washers under the lifting eye.
9
5. Remove the thermostat housing and lift out the
thermostat.
NOTE! The forward lifting eye is screwed onto the
thermostat housing.
7. Remove the cap and lift out the strainer (1) from
the heat exchanger. Then pull up the rubber ring’s
tongue (2). The tongue is marked “UP”. The cover
(3) is now loose and can be lifted up. (Not on
AQ125.)
6. Remove and discard the O-ring (1) in the heat exchanger and if necessary, unscrew the holder (2)
for the ignition cables. The holder is fixed with two
guide pins.
8. Pull the heat exchanger’s fresh water section to
one side. The fresh water section is mounted on a
rubber bushing (1) and the water pipe (2), which
seals against an O-ring.
10
9. AQ145. Remove the cooling water pipes between
the seawater pump and the heat exchanger and
between the heat exchanger and the oil cooler.
(Between the heat exchanger and the exhaust
pipe on AQ125.)
11. Remove the cooling water pipe between the oil
cooler and the exhaust pipe. Not on AQ125. Then
remove the exhaust pipe.
10. Remove the remaining three screws (X) on the
heat exchanger and draw it to one side from the
circulation pump.
12. Unscrew the oil filter. Use tool 999 2903 or push a
screwdriver through the filter and work it loose.
NOTE! Be careful not to spill oil.
11
13. Remove the nut (1) and remove the oil cooler.
Only AQ145. Spanner width = 28 mm. Remove
the oil pressure
15. Remove the saltwater pump and the generator’s
tensioning bracket. The spanner width for the
saltwater pump is 10 mm. The other screws
which hold the cover have a spanner width of 8
mm. Check the impeller, the key and the packing
on the pump’s front side plus the sealing ring on
the pump’s rear side. Clean the pump and replace damaged parts.
14. AQ145. If the oil cooler’s channels are to be
cleaned when the exhaust pipe is fitted on the
engine the cooling water pipes (1) and (2) must
be removed. Undo the oil cooler’s screw (3) and
remove the lower cover.
The oil filter is then removed and the centre nut
(4) is loosened so that the oil cooler can be turned
to a horizontal position.
After this the insert’s channels can be cleaned.
16. Undo the cover’s two hexagonal socket screws
(6 mm key) and hexagonal screw (spanner width
10 mm). NOTE! The cover’s upper fixture is fitted
with a guide which means that the cover must be
withdrawn a few millimetres before it is free.
12
17. Remove the circulation pump’s pulley. The spanner width is 10 mm.
19. Remove the crankshaft pulley. Six screws. The
spanner width is 10 mm.
18. Remove the circulation pump. The spanner width
is 10 mm. There are four screws and two nuts
with washers. Discard the plain packing and the
rubber seal. NOTE! The pump is to be changed
as a complete unit if it has been damaged.
20. If the belt’s markings have disappeared the belt is
to be marked before it is removed. The marking of
the belt is carried out as follows: Make a mark by
the camshaft’s pulley marking. Make a mark by
the intermediate gear’s marking and two marks
on the crankshaft pulley’s marking. Undo and remove the nut and washer for the belt tensioner.
13
21. Slacken the belt by depressing the roller against
the spring pressure. Lock the spring by inserting a
3 mm (0.118") pin (e.g. a drill) in the hole on the
pressure pin.
23. Remove the cross piece from the intermediate
gear wheel. Check that cross piece is not damaged. Then remove the screw from the carrier.
Use counterforce 999 5034. Remove the carrier
and the pulley. Then remove the carrier from the
pulley. Mild force from the rear with a wooden
shaft or similar tool may be necessary.
22. Remove the belt tensioner from the shaft (1). The
belt tensioner’s guide pin 2 is now free after
which the belt tensioner is twisted and removed.
Then remove the belt. The shaft (1) can be replaced by unscrewing it from the cylinder head.
The timing belt is to be changed if the cord
re-inforcement and the rubber are beginning to
separate or if the tread on the timing belt is worn.
The timing belt is to be changed every five hundred hours.
24. Remove the pulley from the camshaft. Use counterforce 999 5034. Remove the pulley by hand.
Check that the outer and the inner guide plate’s
edges are not damaged so that these in turn can
damage the belt.
14
25. Remove the centre screw and pull off the carrier
and outer guide plate from the crankshaft.
27. Remove the screws from the sealing flange. The
flange is also tightened with two of the screws in
the oil sump. Remove the flange plate and remove the seals. Use tool 999 5025 for the small
seal and tool 999 5024 for the large seal.
26. Remove the key and pull off the pulley and the
inner guideplate from the crankshaft.
28. Unscrew the flywheel cover’s four screws and the
three screws which hold the protective plate on
the underside between the cover and the cylinder
block.
15
29. Remove the vibration damper’s six screws. Spanner width 13 mm. Carefully remove the vibration
damper from the three guide pins.
31. Pull out the intermediate shaft. Use the impact
tool 999 4030 where necessary. NOTE! Be careful to make sure that the intermediate shaft’s
gearwheel does not damage the bushes in the
cylinder block’s bearings.
30. Remove the cover and the bracket for the oil
pump drive. Then lift up the oil pump drive.
Cylinder head
32. Remove the valve cover, the gasket and the cres-
cent shaped rubber seal and check the marking
on the camshaft bearing caps.
16
33. Remove the centre camshaft bearing cap. Spanner width 1/2". There are spring washers under
the nuts. When necessary use a chisel or similar
tool against the lug as shown by the arrow.
35. Remove the seal (1) from the camshaft. Then
undo the tool spindle and release the camshaft.
Remove the tool and lift out the camshaft.
34. Fit tool 999 5021 on the camshaft. Use the bearing cap’s nuts. The camshaft is held in position
with the tool. Undo the other four camshaft bearing caps.
36. Remove the screws in the cylinder head. Use
hexagonal socket key 10 mm. Lift away the cylinder head and remove the gasket. Remove the
spark plugs.
17
37. Lift up the valve pushers and place them in the
same order as they fit in the cylinder head.
39. Remove the rubber ring, collets, upper washers,
springs, lower washers and valves. Then remove
the valve seals from the inlet valve guides. Clean
all the parts. Remove carbon deposits from the
combustion chamber and the valves.
38. Remove the valves. Use valve spring compressor
884 580.
40. Grind the valves if necessary in a valve grinding
machine. The angle is the same for both the exhaust and the inlet valves.
18
41. Mill or ream the valve seats. The angle is the
same for the exhaust and inlet valve seats.
43. Check that all the valves and the valve seats are
perfectly ground by marking the valve seat face
and turning it against the valve seat with light
pressure. If the marking is not evenly distributed
on the whole of the seat (leaking valve) the valve
is ground further and a new check is carried out
until the result is satisfactory.
42. Check the flatness of the cylinderhead. Use a
steel straight edge.
44. Check the wear of the valve and the valve guides.
The play for the inlet valve is 0.030–0.060 mm
(0.0012–0.0024") and for the exhaust 0.060–
0.090 mm (0.0024–0.0035").
19
45. Replace the camshaft in the cylinder head and
check the axial play which is 0.1–0.4 mm
(0.004–0.016").
47. Check that the shims do not have too much play
in the valve pushers. If there are signs of wear on
the plain surface of the shim it should be changed. The play between the shim and the valve
presser is 0.009–0.068 mm (0.0004–0.0027).
46. Check the radial play which is 0.030–0.071 mm
(0.0012–0.0028").
48. Replace the valve pressers in the cylinder head
and check that the play is not too much or that
they do not stick. The play between the valve
pressers and the cylinder head is 0.030–0.075
mm (0.0012–0.0030").
20
49. Check the valve springs.
Length unloaded 45 mm (1.77")
Length loaded with 300±20 N (67.2±4.48 lbf.)
38 mm (1.50")
Length loaded with 760±40 N (170±8.96 lbf.)
27 mm (1.06")
51. Fit the new valve guides. Use tool 999 5027 for
the inlet valves and tool 999 5028 for the exhaust
valves. The cylinder head is to be at room temperature. The pressing force for fitting the valve guides is to be at least 9000 N (900 kp) (2016 lbf). If
this pressing force is not obtained for the guides
the hole is to be reamed and a suitable oversized
valve guide is to be fitted. Press the guide down
until the tool comes up against the cylinder head.
This gives the guide a height above the valves
spring face around the guide of: 15.5±0.1 mm
(0.610±0.004") for the inlet valve and 18.0±0.1
mm (0.708±0.004") for the exhaust valve.
Changing the valve guides
50. Press up the valve guides with tool 999 2818.
Heat the cylinder head in 60°C (140°F) water.
21
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