Volvo AQ125A, AQ145A, AQ125B, AQ145B Service Manual

4.5 (25)

Workshop Manual

 

C

Engine Unit

 

2(0)

 

 

 

AQ125A, B

AQ145A, B

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.

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.

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.

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 Safety information)

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.

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

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.

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.

7

Presentation

AQ145A

AQ145A

AQ125

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

AQ125

 

22.Draining, sea water

23.Luboil filter

24.Oil cooler (only AQ145A)

25.Draining, sea water

26.Draining, sea water

27.Draining, fresh water

8

Repair Instructions

1.AQ145. Remove the four screws and pull the induction silencer to one side so that it comes free from the evacuation tube (1). AQ125. Remove the cover.

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.

3.Remove the alternator, drive belt, cable harness, ignition coil, main fuse, starter motor, ignition cables and distributor. NOTE! Mark the cables before they are removed.

4.Remove the cooling water pipe (1), and the bracket for the ignition coil (2). Remove the screw

(3) and draw up the dip stick with its tube (4). Then remove the feed pump (5) and the induction pipe (6). NOTE! There are double gaskets plus an 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.

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.

7.Remove the cap and lift out the strainer (1) from the heat exchanger. Then pull up the rubber ring’s tongue (2). The tongue is marked “UP”. The cover

(3)is now loose and can be lifted up. (Not on AQ125.)

8.Pull the heat exchanger’s fresh water section to one side. The fresh water section is mounted on a rubber bushing (1) and the water pipe (2), 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.)

10.Remove the remaining three screws (X) on the heat exchanger and draw it to one side from the circulation pump.

11.Remove the cooling water pipe between the oil cooler and the exhaust pipe. Not on AQ125. Then remove the exhaust pipe.

12.Unscrew the oil filter. Use tool 999 2903 or push a screwdriver through the filter and work it loose. NOTE! Be careful not to spill oil.

11

13.Remove the nut (1) and remove the oil cooler. Only AQ145. Spanner width = 28 mm. Remove the oil pressure

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.

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.

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

Volvo AQ125A, AQ145A, AQ125B, AQ145B Service Manual

17.Remove the circulation pump’s pulley. 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.

19.Remove the crankshaft pulley. Six screws. The spanner width is 10 mm.

20.If the belt’s markings have disappeared the belt is to be marked before it is removed. The marking of the belt is carried out as follows: Make a mark by the camshaft’s pulley marking. Make a mark by the intermediate gear’s marking and two marks on the crankshaft pulley’s marking. Undo 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.

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.

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.

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.

26.Remove the key and pull off the pulley and the inner guideplate 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.

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 crescent 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.

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.

35.Remove the seal (1) from the camshaft. Then undo the tool spindle and release the camshaft. Remove the tool and lift out the camshaft.

36.Remove the screws in the cylinder head. Use hexagonal socket key 10 mm. Lift away the 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.

38.Remove the valves. Use valve spring compressor 884 580.

39.Remove the rubber ring, collets, upper washers, springs, lower washers and valves. Then remove the valve seals from the inlet valve guides. Clean all the parts. Remove carbon deposits from the combustion chamber and the valves.

40.Grind the valves if necessary in a valve grinding machine. The angle is the same for both the 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.

42.Check the flatness of the cylinderhead. Use a steel straight edge.

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.

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").

46.Check the radial play which is 0.030–0.071 mm (0.0012–0.0028").

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).

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").

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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.

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