Volvo Penta 230, 250, AQ171, 251DOHC, AQ131 Workshop Manual

...
Engine
230, 250, 251DOHC
AQ131, AQ151, AQ171
Workshop Manual
2(0)
C
Safety Precautions .............................................................................. 2
General information............................................................................ 5
Repair instructions ............................................................................. 6
Presentation ........................................................................................ 8
Trouble-shooting Scheme ..................................................................11
1. Overhaul Data...............................................................................12
2. Special Tools ................................................................................20
3. Electrical System .........................................................................23
Wiring Diagram AQ131, AQ151, 230, 250 Alt. 1.........................24
Wiring Diagram 230, 250 Alt. 2..................................................26
Wiring Diagram AQ171, 251DOHC Alt.1. ..................................28
Wiring Diagram 251DOHC Alt. 2 ............................................... 30
4A. Fuel System ..................................................................................3 2
Trouble shooting and Remedies Fuel System ............................32
Overhauling and checking the carburetor...................................33
4B. Renix Ignition System..................................................................38
Trouble-shooting and repair ignition system 251DOHC, AQ171 38
4C. Cylinder Head ...............................................................................44
Removal of teh external components ......................................... 44
4D. Cooling System ............................................................................48
Overhauling the heat exchanger .................................................48
Overhauling the sea water pump ................................................49
Check the thermostat .................................................................. 49
4E. Overhauling the valve system .....................................................50
Overhauling the valve system 230, 250, AQ131, AQ151 ........... 50
Adjusting the valves 230, 250, AQ131, AQ151.......................... 59
Valve system 251DOHC, AQ171. Technical Description...........61
Overhauling the valve system 251DOHC, AQ171......................63
4F. Installing the toothed belt ...........................................................71
Installing the toothed belt 230, 250, AQ131, AQ151 ......................71
Installing the toothed belt 251DOHC, AQ171.................................73
4G. Installing the external components of the Cylinder Head ........74
5. Cylinder Block ..............................................................................78
5A. Removing the external components...........................................78
5B. Overhauling the Crank Assembly ...............................................80
The lubricating oil pump Overhauling..........................................87
5C. Installing the external components ............................................93
Overhauling the oil cooler 250, 251DOHC, AQ151, AQ171........95
Workshop Manual
Index
230, 250, 251DOHC,
AQ131, AQ151, AQ171
Safety Precautions
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.
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 in-
formation 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.
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 oil­soaked 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.
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.
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.
General information
About the workshop manual
This workshop manual contains technical specifica­tion, descriptions and instructions for repairing the standard versions of the following engines 230, 250, 251DOHC, AQ131, A Q151 and A Q171. 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.
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 well­equipped 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 T orques
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
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 proper ties 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 ser vice 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.
Tow 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 mater ial 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.
Presentation
The engines are 4 cylinder gasoline engines. All the engines are equipped with freshwater cooling in combination with seawater cooling. The seawater system is powered by a direct drive impeller pump. The thermostat controlled freshwater system is pow­ered by a circulation pump.
The engines are manufactured with two different product designations. During 1989 Volvo Penta be­gan designating engines based on their cylinder dis­placement according to the ISO norm 8665. The older product designations of AQ131, AQ151 and AQ171 (where the number provided an approximate indication of output) were withdrawn. The new des­ignation 230 replaced AQ131, 250 replaced AQ151and 251DOHC replaced AQ171.
250, AQ151 and 251DOHC, A Q171 are equipped with an oil cooler. 230, AQ131 has a single carburettor and the others have twin carburettors. The exhaust system has seawater cooled exhaust pipes. 230, AQ131 and 250, AQ151 models have an overhead camshaft while 251DOHC, AQ171 has double overhead camshafts with hydraulic valve lift­ers. 251DOHC, AQ171 is a 16 valve engine. 230, AQ131 and 250, AQ151 models have conventional marine ignition systems while 251DOHC, AQ171 has electronic ignition.
The product plate is located on the cylinder block beside the starter motor. The product plate provides the following information;
(1) Product designation, i.e. AQ131D (2) Product number, i.e 867902 (3) Serial number (10 digit) (4) Basic engine, serial number
Product plate
230, AQ131
250, AQ151
251DOHC, AQ171
The sea water cooling system
The fresh water cooling system, thermostat closed
The fresh water cooling system, thermostat open
1 = Sea-water filter 2 = Heat exchanger 3 = Sea-water pump 4 = Oil cooler 5 = Bypass 6 = Thermostat house 7 = Circulation pump
The Cooling System
10
The Lubricating System
The engine lubricating system from strainer to the main gallery
The engine lubricating system from the main gallery to the lubricating points.
1 = Main gallery 2 = Oil pump 3 = Return line 4 = Oil cooler 5 = Oil filter
11
Trouble-shooting Scheme
Main switch open. Battery discharged. Wires broken or fuse blown.
Empty fuel tank, closed fuel cock, clogged fuel filter.
Water or impurities in the fuel.
Faulty spark plugs.
Burned breaker points, moisture in distributor and ignition leads.
Faulty electronic unit 251DOHC, AQ171
Idling speed not adjusted properly. Faulty tachometer.
Boat loaded abnormally.
Growth on boat bottom and sterndrive.
Damaged propeller.
Clogged cooling water intake, oil cooler (250, 251DOHC, AQ151, AQ171) waterjackets. Damaged impeller or thermostat. Too low coolant level in expansion tank
Wrong fuel quality in relation to timing
Toothed belt faulty or not adjusted properly.
Engine does not start
Engine stops
Engine does not reach op­erating speed at full throttle
Engine runs rough or vi­brates abnor­mally
Engine be­comes abnor­mally hot
Fault reason
X
X
X
XX
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
12
1. Overhaul Data
Technical Data 230, 250, 251DOHC AQ131, AQ151, AQ171
General
Type designation ................................................................................. 230, AQ131
Type of engine ..................................................................................... 4 stroke, overhead cam
Speed range full load ........................................................................... 78.3–83.3 r/s (4700–5000 rpm)
Maximum cruising speed .................................................................... 3.33 r/s (200 rpm) lower than the max speed obtained
Compression ratio ............................................................................... 9.7:1
Compression pressure at starter motor speed
1)
.................................. 10–12 kp/cm2 (142–170 psi)
Number of cylinders ............................................................................ 4 in line
Cylinder bore ....................................................................................... 96 mm (3.7795")
Stroke.................................................................................................. 80 mm (3.1496")
Swept volume (displacement) ............................................................. 2.315 dm3 (141.3 in3)
Weight, excluding water and oil, approx. ............................................. 240 Kilos (529.1 lbs)
Idling speed ......................................................................................... 15 r/s (900 rpm)
General
Type designation ................................................................................. 250, AQ151
Type of engine ..................................................................................... 4 stroke, overhead cam
Speed range full load ........................................................................... 80–91.7 r/s (4800–5500 rpm)
Maximum cruising speed .................................................................... 3.33 r/s (200 rpm) lower than the max speed obtained
Compression ratio ............................................................................... 9.7:1
Compression pressure at starter motor speed1).................................. 10–12 kp/cm2 (142–170 psi)
Number of cylinders ............................................................................ 4 in line
Bore..................................................................................................... 96 mm (3.7795")
Stroke.................................................................................................. 86 mm (3.3858")
Swept volume (displacement) ............................................................. 2.49 dm3 (151.9 in3)
Weight, excluding water and oil, approx. ............................................. 250 Kilos (551.2 lbs)
Idling speed ......................................................................................... 15 r/s (900 rpm)
General
Type designation ................................................................................. 251DOHC, AQ171
Type of engine ..................................................................................... 4 stroke, overhead cams
Speed range full load ........................................................................... 83.3–95 r/s (5000–5700 rpm)
Maximum cruising speed .................................................................... 3.33 r/s (200 rpm) lower than the max speed obtained
Compression ratio ............................................................................... 9.7:1
Compression pressure at starter motor speed1).................................. 10–12 kp/cm2 (142–170 psi)
Number of cylinders ............................................................................ 4 in line
Bore..................................................................................................... 96 mm (3.7795")
Stroke.................................................................................................. 86 mm (3.3858")
Swept volume (displacement) ............................................................. 2.49 dm3 (151.9 in3)
Weight, excluding water and oil, approx. ............................................. 289 Kilos (637.15 lbs)
Idling speed ......................................................................................... 15 r/s (900 rpm)
1)
Applies to hot engine, wide open throttle
13
Cylinder block
Material................................................................................................ Cast iron
Bore, standard..................................................................................... 96.00–96.03 mm (3.7795–3.7807")
Bore, oversize 1 .................................................................................. 96.300 mm (3.79133")
Bore, oversize 2 .................................................................................. 96.600 mm (3.80315")
The cylinder bores should be bored at a wear depth of 0.10 mm (0.004 in) (in case the engine has an abnormal oil consumption).
Pistons
Material................................................................................................ Light alloy
3)
Overall height 230, AQ131 .................................................................. 64.7 mm (2.54724")
Overall height 250, 251DOHC, AQ151, AQ171 .................................. 61.7 mm (2.42913")
Height from gudgeon pin center to top of piston
230, AQ131 ......................................................................................... 39.7 mm (1.56299")
Height from gudgeon pin center to top of piston
250, 251 DOHC, AQ151, AQ171 ........................................................ 36.7 mm (1.44488")
Piston clearance, production ............................................................... 0.010–0.030 mm (0.0004–0.0012")
Piston clearance, service.................................................................... max 0.080 mm (0.0031")
Piston, standard dimension ................................................................. 95.980–96.010 mm4) (3.779–3.780")
Piston, oversize 1................................................................................ 96.280–96.290 mm (3.791–3.7909")
Piston, oversize 2................................................................................ 96.580–96.590 mm (3.802–3.803")
3)
Maximum weight difference between pistons in the same engine is 16 grams (0.56 oz).
4)
See the spare parts catalog for all the products.
Piston rings
Piston ring end gap (oil scraper ring)................................................... 0.30–0.60 mm (0.0118–0.0236")
Piston ring end gap (compression ring) ............................................... 0.30–0.55 mm (0.0118–0.0217")
Oversize piston rings 1 ....................................................................... 0.3 mm (0.0118")
Oversize piston rings 2 ....................................................................... 0.6 mm (0.0236")
Compression rings
The upper ring is chromium plated. The low er ring is marked “T OP”.
Number of rings on each piston........................................................... 2
Height, upper ....................................................................................... 1.728–1.740 mm (0.068–0.069")
Height, lower ....................................................................................... 1.728–1.740 mm (0.068–0.069")
Piston ring clearance in groove, upper ................................................ 0.040–0.072 mm (0.0016–0.0028")
Piston ring clearance in groove, lower................................................. 0.040–0.072 mm (0.0016–0.0028")
Oil scraper rings
Number on each piston ....................................................................... 1
Height.................................................................................................. 3.475–3.490 mm (0.1368–0.374")
Gudgeon pins
Full floating pin. Locked at both ends with circlips.
Fit in connecting rod ............................................................................ Light thumb pressure (push fit)
Fit in piston .......................................................................................... Thumb pressure (slide fit)
Standard diameter ............................................................................... 23.0 mm (0.906")
Oversize diameter ............................................................................... 23.05 mm (0.907")
Length ................................................................................................. 65 mm (2.559")
14
AQ131A, 131B, AQ131C, 131D, 151A, 151B, 151C, 151D, 171C, 171D, 171A, 171B 230, 250, 251DOHC
Crankshaft
Crankshaft, axial clearance................................................................. 0.080–0.270 mm 0.080–0.270 mm
(0.0031–0.0106") (0.0031–0.0106")
Main bearing, radial clearance............................................................. 0.024–0.072 mm 0.024–0.064 mm
(0.00094–0.00283") (0.0009–0.0025")
Crank bearing, radial clearance .......................................................... 0.023–0.067 mm 0.023–0.067 mm
(0.00091–0.00264") (0.00091–0.00264")
Straightness, maximum deviation........................................................ 0.025 mm 0.025 mm
(0.00098") (0.00098")
Taper Out-of-roundness
Main bearings Main bearing journals
Out of roundness, max........................................................................ 0.004 mm 0.004 mm
(0.00016") (0.00016")
Taper, max. .......................................................................................... 0.004 mm 0.004 mm
(0.00016") (0.00016")
Standard diameter ............................................................................... 54.987–55.000 mm 62.987–63.000 mm
(2.1648–2.1654") (2.4798–2.4803")
0.25 mm undersize (0,0098") .............................................................. 54.737–54.750 mm 62.737–62.750 mm
(2.1550–2.1555") (2.4700–2.4705")
0.50 mm undersize (0,0197") .............................................................. 54.487–54.500 mm 62.487–62.500 mm
(2.1452–2.1457") (2.4601–2.4606")
Seat width on crankshaft for thrust bearings
Standard.............................................................................................. 31.96–32.00 mm 35.46–35.50 mm
(1.2583–1.2598") (1.3961–1.3976")
Oversize 1........................................................................................... 32.21–32.25 mm
(1.2681–1.2697")
Oversize 2........................................................................................... 32.46–32.50 mm
(1.2780–1.2795")
The main bearings are available in two mak es. The upper and lower main bearing shell on the same pivot must be of the same make. In production matched crankshaft bearing shells are used. The bearing shells are color coded, red, yellow and blue. They are matched in accordance with one of the following alternatives: Alternative 1: Two yellow-marked bearing shells. Alternative 2: One blue-marked and one red-marked bearing shell. The blue-marked shell to be located on the crankshaft and the red-marked shell in the bearing cap. NOTE! Only yellow-mark ed bearing shells are av ailable f or spare parts purposes.
Connecting rods Connecting Rod Bearings Bearing journals
Out of roundness, max........................................................................ 0.004 mm (0.00016")
T aper, max. .......................................................................................... 0.004 mm (0.00016")
Bearing seat width............................................................................... 23.9–26.1 mm (0.9409–1.0276")
Standard diameter ............................................................................... 48.984–49.005 mm (1.9285–1.9293")
0.25 mm undersize (0.0098") .............................................................. 48.734–48.755 mm (1.9187–1.9195")
0.50 mm undersize (0.0197") .............................................................. 48.484–48.505 mm (1.9088–1.9096")
Axial clearance at the piston ............................................................... 0.25–0.45 mm (0.0098–0.0177")
Length, center to center ...................................................................... 152 mm (5.9843")
Max. weight difference between connecting rods in the same engine . 20 grams (0.7055 oz.)
Color code
15
Camshaft
Number of bearings ............................................................................. 5
Bearing, diameter ................................................................................ 29.95–29.97 mm (1.179–1.180")
Radial clearance ................................................................................. 0.030–0.071 mm (0.0012–0.0028")
Maximum............................................................................................. 0.15 mm (0.0059")
Axial clearance (end play)................................................................... 0.1–0.4 mm (0.0039–0.0157")
Camshaft bearings
Camshaft bearing diameter ................................................................. 30.000–30.021 mm (1.1811–1.1819")
Timing gears, Models 230, 250, AQ131, A Q151
Number of teeth, crankshaft gear........................................................ 19
Number of teeth, intermediate shaft gear ............................................ 38
Number of teeth, camshaft gear .......................................................... 38
Number of teeth, toothed belt .............................................................. 123
Timing gears, Models 251DOHC, A Q171
Number of teeth, crankshaft gear........................................................ 19
Number of teeth, intermediate shaft gear ............................................ 38
Number of teeth, camshaft gear .......................................................... 38
Number of teeth, toothed belt .............................................................. 146
Intermediate shaft
Number of bearings ............................................................................. 3
Front bearing diameter......................................................................... 46.975–47.000 mm (1.849–1.850")
Middle bearing diameter ...................................................................... 43.025–43.050 mm (1.694–1.695")
Rear bearing diameter ......................................................................... 42.925–42.950 mm (1.690–1.691")
Radial clearance ................................................................................. 0.020–0.075 mm (0.0008–0.0030")
Axial clearance (end play)................................................................... 0.20–0.46 mm (0.0079–0.0181")
Intermediate shaft bearing diameter in block:
Front................................................................................................. 47.020–47.050 mm (1.851–1.852")
Middle .............................................................................................. 43.070–43.100 mm (1.696–1.697")
Rear ................................................................................................. 42.970–43.000 mm (1.692–1.693")
Changing the bearings NOTE! New bearings must be line bored!
Valves 230, 250, A Q131, A Q151 Inlet
Disc diameter ...................................................................................... 44.0 mm (1.7323")
Stem diameter ..................................................................................... 7.955–7.970 mm (0.3132–0.3138")
Valv e seat angle.................................................................................. 44.5°
Cylinder block seat angle .................................................................... 45°
Seat width in cylinder head.................................................................. 1.3–1.9 mm (0.0512–0.0748")
Exhaust
Disc diameter ...................................................................................... 35.0 mm (1.37795")
Stem diameter ..................................................................................... 7.945–7.960 mm (0.3128–0.3134")
Valv e seat angle.................................................................................. 44.5°
Cylinder block seat angle .................................................................... 45°
Seat width in cylinder head.................................................................. 17–2.3 mm (0.0669–0.0906")
44.5°
44.0
New: 7.955–7.970 (0.3132–0.3138") Min: 7.935 (0.3124")
Inlet valve
16
IMPORTANT! The valves are stellite coated. Therefore they must not be machined, only lapped against the seat!
Clearance when checking:
Cold engine ......................................................................................... 0.30–0.40 mm (0.0118–0.0157")
Hot engine ........................................................................................... 0.35–0.45 mm (0.0138–0.0177")
Clearance when adjusting:
Cold engine ......................................................................................... 0.35–0.40 mm (0.0138–0.0157")
Hot engine ........................................................................................... 0.40–0.45 mm (0.0157–0.0177")
The same clearance for inlet and exhaust valves.
Valve guides (inlet & exhaust) 230, 250, A Q131, A Q151
Length ................................................................................................. 52 mm (2.165")
Inner diameter ..................................................................................... 8.00–8.02 mm (0.275–0.276")
Clearance, valve stem–valve guide, inlet valve................................... 0.03–0.06 mm (0.0012–0.00245")
Clearance, valve stem–valve guide, exhaust valve ............................ 0.04–0.07 mm (0.0016–0.0028")
Clearance, maximum wear.................................................................. 0.15 mm (0.0059")
Valve springs, 230, 250, A Q131, AQ151
Length, unloaded ................................................................................. 45.0 mm (1.772")
Length, loaded 285–325 N (28.5–32.5 kp)........................................... 38.0 mm (1.496")
Length, loaded 725–805 N (72.5–80.5 kp)........................................... 27.0 mm (1.063")
Valves 251DOHC, A Q171 Inlet
Disc diameter ...................................................................................... 34.5 mm (1.358")
Stem diameter ..................................................................................... 6.955–6.970 mm (0.2738–0.2744")
Valv e seat angle.................................................................................. 44.5°
Cylinder block seat angle .................................................................... 45°
Seat width in cylinder head.................................................................. 1.3–1.9 mm (0.0512–0.0748")
Exhaust
Disc diameter ...................................................................................... 31.5 mm (1.240")
Stem diameter ..................................................................................... 6.945–6.960 mm (0. 2734–0.2740")
Valv e seat angle.................................................................................. 44.5°
Cylinder block seat angle .................................................................... 45°
Seat width in cylinder head.................................................................. 1.7–2.3 mm (0.0669–0.0906")
IMPORT ANT! The valves are stellite coated. Theref ore they m ust not be machined, only lapped against the seat.
New: 7.945–7.960 (0.3128–0.3134) Min: 7.925 (0.3120")
35.0
44.5°
New: 6.955–6.970 (0.2738–0.2744") Min: 6.935 (0.2730")
34.5
44.5°
New: 6.945–6.960 (0.2734–0.2740") Min: 6.925 (0.2726")
31.5
44.5°
Inlet valve
Exhaust valve
Exhaust valve
17
Valve clearance, 251DOHC, AQ171................................................... Hydraulic valve tappets, no setting is required
Valve guides (inlet & exhaust) 251DOHC, A Q171
Length ................................................................................................. 55 mm (2.165")
Inner diameter ..................................................................................... 7.00–7.02 mm (0.275–0.276")
Clearance, valve stem–valve guide, inlet valve................................... 0.03–0.06 mm (0.0012–0.0024")
Clearance, valve stem–valve guide, exhaust valve ............................ 0.04–0.07 mm (0.0016–0.0028")
Clearance, maximum wear.................................................................. 0.15 mm (0.0059")
Valve springs 251DOHC, A Q171
Length, unloaded ................................................................................. 43.0 mm (1.6929")
Length, loaded 212–252 N (21.2–25.2 kp)........................................... 37.0 mm (1.45669")
Length, loaded 600–680 N (60–68 kp)................................................. 26.5 mm (1.0433")
Lubricating system
Changing oil, oil capacity , e xcluding filter ............................................ 3.5 dm3 (0.88 Imp gall./1.06 US gall.)
Changing oil, oil capacity , including filter ............................................. 4.0 dm3 (0.99 Imp gall./1.19 US gall.)
Oil pressure at 33.33 r/s (2000 rpm), hot engine ................................. 2.5–6.0 kp/cm2 (35–85 psi)
Lubricating oil, alternative 1 ................................................................. Volvo P enta lubricating oil for gasoline engines
Lubricating oil, alternative 2 ................................................................. Lubricating oil SG
Viscosity ............................................................................................. SAE 20 W/50
Oil filter
Type..................................................................................................... Full flow filter
Lubricating oil pump
Axial clearance.................................................................................... 0.02–0.12 mm (0.0008–0.0047")
Radial clearance (excluding bearing clearance).................................. 0.02–0.09 mm (0.0008–0.0035")
Gear backlash (excluding bearing clearance)..................................... 0.15–0.35 mm (0.0059–0.0138")
Bearing clearance, drive shaft............................................................. 0.032–0.070 mm (0.0013–0.0028")
Bearing clearance, idler shaft .............................................................. 0.014–0.043 mm (0.0006–0.0017")
Length of the relief valve spring at different loads:
Length: Load:
47.6 mm (1.874") No load
32.0 mm (1.26") 40–48 N (4.0–4.8 kp) (29.4–35.2 ft.lbs)
26.0 mm (1.024") 55–67 N (5.5–6.7 kp) (40.3–49.1 ft.lbs)
Fuel system Fuel pump
Type..................................................................................................... Diaphragm
Feed pressure ..................................................................................... 0.15–0.28 kp/cm2 (2–4 psi)
Fuel flow .............................................................................................. 1.6–2.0 liter/minute
(0.35–0.44 Imp.gal/min/0.375–0.475 US gal/min)
18
Carburetor 230, A Q131 AQ131A, 131B AQ131C,131D, 230
Type..................................................................................................... Down draught Down draught
Designation ......................................................................................... Model 44 P AI-5 Model 44 PAI-7
Venturi ................................................................................................. 34 34
Main jet................................................................................................ 165 165
Idling jet ............................................................................................... 65 65
Air jet ................................................................................................... 185 1 8 5
Needle valve ....................................................................................... 1.7 2.0
Float, weight in grams (oz’s)................................................................ 7.3 (0.26) 7.3 (0.26)
Acceleration jet.................................................................................... 70 70
Econostat jet ....................................................................................... 110 11 0
Carburetor 250, A Q151 AQ151A, AQ151B AQ151C, AQ151D , 250
Type..................................................................................................... Down draught Down draught
Designation ......................................................................................... Model 44 P AI-4 Model 44 PAI-7
Venturi ................................................................................................. 31 31
Main jet................................................................................................ 145 145
Idling jet ............................................................................................... 62 62
Air jet ................................................................................................... 185 1 8 0
Needle valve ....................................................................................... 1.5 1.7
Float, weight in grams (oz’s)................................................................ 7.3 (0.26) 7.3 (0.26)
Acceleration jet.................................................................................... 60 60
Econostat jet ....................................................................................... –
AQ171C, A Q171D ,
Carburetor 251DOHC, A Q171 AQ171A, A Q171B 251DOHC
Type..................................................................................................... Down draught Down draught
Designation ......................................................................................... Model 44 P AI-5-6 Model 44 P AI-7
V enturi ................................................................................................. 32 32
Main jet................................................................................................ 147 147
Idling jet ............................................................................................... 65 60
Air jet ................................................................................................... 190 2 0 0
Needle valve ....................................................................................... 1.7 1.7
Float, weight in grams (oz’s)................................................................ 7.3 (0.26) 7.3 (0.26)
Acceleration jet.................................................................................... 70 70
Econostat jet ....................................................................................... –
Electrical system Battery
Grounding............................................................................................ Negative
V oltage ................................................................................................ 12 Volts
Capacity .............................................................................................. 60 Ah
Specific weight of the electrolyte
Fully charged battery........................................................................... 1.275–1.285 grams/cm3 (0.0460–0.0464 lb/cu.in.)
Discharged battery.............................................................................. 1.230 grams/cm3(0.0444 lb/cu.in.)
Starter motor
Output ................................................................................................. 0.8 kW (1.1 hk)
Alternator
Output, maximum Amp (W) ................................................................. 50 (14x50)
Ignition system
Cylinder marking ................................................................................. No 4 closest to the flywheel
Spark plugs 230, 250, AQ131, AQ151 ................................................ Part no 875820-3, Bosch W6DC or its equivalent
Spark plugs, 251DOHC, AQ171 ......................................................... Part no 876077-9, Bosch WR6DC or its equivalent
Spark plug gap .................................................................................... 0.7 mm (0.0276")
19
Distributor 230, 250, A Q131, A Q151
Type..................................................................................................... Breaker point system
Type Bosch JF4 .................................................................................. 0231 178 019
Setting for regular gasoline, min 91 octane RO T :
USA: Ignition setting for regular petrol (RON+MON)/2 = min 87 octane
Basic setting........................................................................................ 6° BTDC (0–14.17 r/s = 0–850 rpm)
Stroboscope setting ............................................................................ 32–36° BTDC (70 r/s = 4200 rpm)
Contact gap ......................................................................................... 0.40 mm (0.01575")
Dwell angle.......................................................................................... 62±3°
Distributor , 251DOHC, A Q171
Type Bosch TVX4, Breakerless system.............................................. A 237 540 079
Setting for regular gasoline, min 91 octane RO T :
USA: Ignition setting for regular petrol (RON+MON)/2 = min 87 octane
Basic setting........................................................................................ 10° BTDC (0–15 r/s = 0–900 rpm)
Stroboscope setting (not adjustable) ................................................... 23–25° BTDC (73.33 r/s=4400 rpm)
Cooling system Thermostat
Type..................................................................................................... Wax thermostat
Starts opening at ................................................................................. 82°C (179.6°F)
Fully open at ........................................................................................ 92°C (197.6°F)
Tightening torques NOTE! Alwa ys tighten the cylinder head bolts when the
engine is cold. The torque v alues are valid f or bolts and nuts being well oiled prior to installation. Parts having been washed should be oiled prior to the assembly.
Tightening torque for cylinder head bolts:
The cylinder head: To be tightened in stages....................................... 1 = 20 Nm (2.0 kpm) (15 ft.lbs.)
2 = 40 Nm (4.0 kpm) (29 ft.lbs.) 3 = Angle tighten through 120° in one operation!
– Replace the cylinder head bolts if they show signs of being
stretched. If a bolt is “stretched” can clearly be seen on the
“waist” of the bolt, which is then elongated. – The cylinder head bolts can be “re-used” max 5 times. Replace the bolts if you feel uncertain on any of these points.
Nm Kpm Ft.lbs.
Main bearings ...................................................................................... 110 11.0 79.5
Crank bearings, 1st stage1)................................................................ 20 2.0 15
2nd stage1)............................................................... through 90°
Flywheel (use new bolts) .................................................................... 70 7.0 51
Spark plugs (do not oil them!).............................................................. 25±5 2.5±0.5 18
Camshaft gear..................................................................................... 50 5.0 36
Intermediate gear ................................................................................ 50 5.0 36
Camshaft bearing cap ......................................................................... 20 2.0 15
Crankshaft, center bolt pulley, stage 1................................................ 60 6.0 43
stage 2................................................ Angle tighten through 60°
1)
Old bolts can be used provided the length does not exceed 55.5 mm (2.185").
20
2. Special T ools
884359-1 Drift for the installation of the seal in the flywheel
housing
885050-5
884596-8
884599-2
884958-0
884959-0
884960-6
884961-4
884967-1
884966-3
884979-6
Drift for the installation of the primary shaft in the flywheel housing
Drift for the installation of the seal in the flywheel housing
Drift for the changing of valve guides 251DOHC , AQ171
Drift for the changing of valve guides 251DOHC, AQ171
Drift for the changing of valve guides 251DOHC, AQ171
Reamer valve guides 251DOHC, AQ171
Cylinder head fixture 251DOHC, AQ171
Stand fixture
Installation tool inlet valve seat 251DOHC, AQ171
Installation tool exhaust valve seat 251DOHC, AQ171
21
9986052-0 Valve com-
pressor
9991426-9
Drift for the installation of support bearing in the fly­wheel
9994090-0
Puller for support bearing in the flywheel
9995021-4 Press tool for the removal and assembly of the
camshaft, AQ131, AQ151, 230, 250
9995022-2
Tool for depressing valve depressors, AQ131, AQ151, 230, 250
9995025-5
Installation tool for the intermediate shaft seal
9995026-3
9995027-1
Pair of pliers for adjustment shims AQ131, AQ151, 230, 250
Drift for the installation of valve guides (inlet), AQ131, AQ151, 230, 250
9988452-0
Digital probe tester
22
9995029-7
9995034-7
9995224-4
9995276-4
9995283-0
9995220-2
9995284-8
9995309-3
1159660-8
Installation tool for valve seats (inlet), AQ131, AQ151, 230, 250
Counterhold for the camshaft gear and intermediate gear
Installation tool for valve seats (exhaust), AQ131, AQ151, 230, 250
Reamer, valve guides AQ131, AQ151, 230, 250
Drift for the installation of sealing in the crankshaft rear end
Removal tool for the crankshaft front seal
Counterhold for crankshaft pulley
Drift for the removal and installation of bushing in the connecting rod
Tensioning tool for the toothed belt AQ171, 251DOHC
9995028-9
Drift for the installation of valve guides (exhaust), AQ131, AQ151, 230, 250
23
3. Electrical System
General
All engines have a single pole electrical system with an AC generator. The engine main wiring is fused with a thermic 40 A automatic fuse.
Ignition system
AQ131, AQ151, 230 and 250 have conventional breaker point ignition systems. See the “Technical Data” for the setting values. AQ171 and 251DOHC are equipped with breakerless electronic ignition systems. The ignition system memory unit has 63 optimal engine speed / ignition values programmed. The ignition points for other engine speeds is calculated based on these locked values. Note! No ignition setting can be carried out on the distributor. The ignition system has the correct set­ting when all components are correctly installed. In order to obtain exact installation there is a certain amount of adjustment possible in the ignition setting sender. All operation based adjustment is stopped. All settings are permanently stored in the control module and are stable because of the absence of mechanicals (breaker points, mechanical ignition setting). The only task of the distr ibutor has is to distribute the current to the spark plugs via the rotor.
Instrumentation
The engines were manufactured with two types of in­strumentation. One earlier type 1 and the later type 2 (for version refer to wiring diagrams). Both the in­strumentation types are equipped with two 8 A fuses for the system voltage (key switch in ignition posi­tion) and start voltage (key switch in start position). Instrumentation type 2 is equipped with 2 connectors for extra power outputs for accessories. One is fused via the 8 A fuse for system voltage and has a maximum permissible voltage output of 5 A (main panel + any flying bridge panel). The other connector has a maximum permissible voltage output of 20 A and is not separately fused (power supply is via the 40 A automatic fuse for the main wiring). There is also a connector for connecting instrument lighting for extra instruments (a fuel gauge for example) fused via the 8 A fuse for system voltage.
Starter motor
There are two versions. VALEO D6RA11 and Hitachi S114-237.
Minimum length of the brushes: VALEO = 14 mm Hitachi = 12 mm.
Generator
The alternating current generator is a 14 V 50 A VALEO. It is equipped with a charge sensor cable (yellow) which is connected to the generator (GEN) B+.
In those cases where the generator is required to charge several batteries (starter and operational bat­teries) the charge sensor cable should be discon­nected from B+ and connected, using a 1.5 mm
2
ex­tension, to the accessory battery + ter minal using a double diode.
Minimum length of the brushes: 8 mm Resistance rotor winding 4,0–6,0 Resistance stator winding 0,11–0,15
24
Wiring Diagram AQ131, AQ151, 230, 250
With Instrument panel alternative 1
1. Oil pressure gauge
2. Temperature gauge, coolant
3. Voltmeter
4. Tachometer
5. Fuel gauge (alternative)
6. Instrument lighting
7. Key switch (B=30, S=50, I=15)
8. Switch, instrument lighting
9. Fuse 8 A
10. Fuse 8 A
11. Generator
12. Starter motor
13. Connector engine–instrumentation
14. Automatic fuse 40A
15. Main switch (option)
16. Batte r y
17. Temperature sensor
18. Oil pressure sensor
19. Distributor
20. Ignition coil
21. Relay
22. Resistor
Cable cross sections
AWG mm
2
16 1.5 13 2.5 10 6.0
8 10.0
Cable colour code
SB = Black PU = Purple LBN = Light brown R = Red GR = Grey LBL = Light blue R/Y = Red/Yellow BN = Brown W = White Y = Yellow
13
25
AQ131, AQ151, 230, 250 ALT. 1
26
Wiring Diagram 230, 250
With Instrument panel alternative 2
1. Tachometer
2. Oil pressure gauge
3. Temperature gauge, coolant
4. Voltmeter
5. Switch, instrument lighting
6. Instrument lighting
7. Key switch (B=30, S=50, I=15)
8. Fuse 8 A
9. Fuse 8 A
10. Contact terminal neutral position switch (option/accessory)
11. Contact terminal safety switch (accessory)
12. Connector instrument lighting accessory
13. Connector power output, maximum 20 A
14. Connector power output, maximum 5 A (main panel + flying bridge panel)
15. Connector, engine–instrumentation
16. Automatic fuse 40A
17. Main switch (option)
18. Batte r y
19. Temperature sensor
20. Oil pressure sensor
21. Distributor
22. Ignition coil
23. Starter motor
24. Relay
25. Generator
26. Resistor
Cable cross sections
AWG mm
2
16 1.5 13 2.5 10 6.0
8 10.0
Cable colour code
SB = Black PU = Purple LBN = Light brown R = Red GR = Grey LBL = Light blue R/Y = Red/Yellow BN = Brown W = White Y = Yellow
27
230, 250 ALT. 2
28
Wiring Diagram AQ171, 251DOHC
With Instrument panel alternative 1
1 . Oil pressure gauge
2. Temp gauge
3. Voltmeter
4. Tachometer
5. Fuel gauge (alternative)
6. Instrument lights
7. Key switch (B = 30, S = 50, I = 15)
8. Switch, instrument lights
9. Fuse 8 Amp
10. Fuse 8 Amp
11. Alternator
12. Starter motor
13. Terminal block
14. Automatic fuse 40 Amp
15. Main switch (optional)
16. Battery (optional)
17. Temp sender
18. Oil pressure sender
19. Distributor
20. Electronic ignition unit
21. Relay
22. Resistor
23. Impulse sender, ignition unit
24. Ground (screw)
25. Solenoid valve
Cable cross sections
AWG mm
2
16 1.5 13 2.5 10 6.0
8 10.0
Cable colour code
SB = Black PU = Purple LBN = Light brown R = Red GR = Grey LBL = Light blue R/Y = Red/Yellow BN = Brown W = White Y = Yellow
13
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