Volvo B 17 User manual

Service l\J~anual
Repairs
and maintenance
Section 2 (21)
engine
817 , 819
821 , 823
2401975-1984

817,819.821,823 engines
What do the designations meen?
B 21 E T
l;.Tu,bo
A .. carburetorengine,
K - carburetor
engine
E .., fuel injection engine
F .. fuel injection engine - USA version
21 :z cylinder capacity
8 = petrel (gasoline)
821 ,. basic engine
821A
B 23 = a 821 with larger bore and higher compression
ratia
B 19 _ a B 21 with smaller bore
B 17 = a B 19 with shorte r stroke
This manual covers the following engine types :
Engine
typa
817A
81SA
B 19 K
B
19 E
819ET
821 A
B21E
B21 ET
B 21 F -S'
B21 F_B2
B21 F -9~
B21 FT
B23A
B23E
B 23 F ( lH -Jetronic)
Remarks
Model year
1979- 1984
1977-1984
1984
1917-1984
1982-1984
1975- 1984
1975-1983
1981 -1984
1976-19843
1982
1981 - 1982
1981- 1984
1981 - 1 984
1979-1984
1983-
19 84
'B21 F- S - el system with Bosch ignilion system.
2821 F- B _ LH Jet r onic injection system.
30iscontinued 1982 in
USA & Canada.
Superseded by B21 F- B.
·B 21 F- 9 _ CI system with Chrysler ingition.
Volvos are sold in,versions adapted for different markets.
These
adaptations depend on many faetors including le-
gal, taxatian and
market requirements.
This
manual may therefore show illustrations and text
which do not apply to ears in your country.
•
•
•
•
•
•
•

Group 21 Reconditioning engine
Contents
Important information . ......... .
Specifications
Special too I• ............ ....
Thread repairs ..
Reconditioning engine
Oisassembly .....
Cleaning andinspection ..
Assembly ...... .
Cylinderhead,reconditioning .
Assembly fcont) ...... .
Index page 57
Ope rat ion
A 1- 14
B 1- 13
C 1- 33
01 - 27
E l - 54
F 1- 9
This manual deals exelusively
with the overhaul of
the engine.
For
work earried out on t he engine when finad in the
ear, and
for engine remol/al and installation, please
refer to the separate manuals.
Order
number : TP 30110/2
Supersedes:
TP 30170/1
We reserve tho right to make alterations with out prior
notification.
Contents
Page
2
2
10
12
18
"
23
32
3.
54

Group 21 Reconditioning engine
fmportant i nformat i on
Important information
~ ", ~. -- ~ " ' L ~ ~ - ~ ==l!cn=: rf
Nrn
Tightaning torquas
Two typas of tightening torques are used in this Ma-
nual:
~ I
CYLINDER HEAD
H ei ght .
Min
he ightafterma ch ining
2
1351)20
I. Tightening torque 40 Nm (30 ft.lbs) :: a torque
wrench must
be used.
II. Tightening torque40 Nm (30 ft.lbs) :: correct value,
howeverit is notnecessary to use a torque wrench.
Sp
'
9cifications
Group 20 General
114651
Engina typa dasignation, sarial num-
bar and part numbar
Stamped on a plate on left sida of engine.
1977-models: addition al plats on timing gear cover
showing
la st thres digits of part number.
Group 21 Engine assembly
New 146.1 mm{5.7563 in)
145.6 mm (5 .7366 in)

Group 21 Recondirioning engine
Specificarions
Max d is tortion .....
I I
Na te thatll distortion is greater than 1.0 mm (0.040 in)
lengthwise and0.5 mm (0.020 in) crosswisethecy1inder
head must not be machined but replaced.
mall 0 .5 mm
(0. 020 In) I
I ~ ~' -
10.010 ini
Th~~~~~~ ~ . f . ~~~~~~ ............. . .. 1.3 mm (0.051 in) -- [>--~~::::~~T'
fitted 1.2 mm(0 .047 in) ~ ~
CYLINDER BLOCK
Bore
I • ,
i i
• ,
B17 ,8 19 B21 8 23
.
i
,~~
Standard (marked el
.............................. mm 88.90-88.91 92.00-92.01 96.00-96.01
(i n)
.. .......... mm
(in)
(3.5027-3.5031 ~ (3.6248-3.6252~ (3.7824 - 3.7828~
(marked D) ................ . 88.
91 -88.92 92.01- 92.02 96. 01 -96.02
( 3.5031 -3.5 034 ~ ( 3.6252 - 3.6256~ (3.7828-3.7832~
(marked E) ........... . . .
........ mm 88.92-88.93 92.02-92.03 96.02-96.03
(in)
. mm
(in)
( 3.5034 - 3.5038~ ( 3 . 6256 - 3 . 6260~ (3.7832-3.7836~
(marked G) . 88.94-88.95
92.04-92.05 96.04-96.05
(3.5 042 - 3 .S 047~ (3.6264-3.6268) (3.7840-3.7844)
Oversize 1 ...
2.
.. ....... mm
(in)
. .. mm
(in)
Rebore ifwear exceeds 0.1 mm (0 .004 in) and oi! c onsumption is
very high.
Pistons
A _ Overall height
B '" From gudgeon ( piston ) pin center to crown
89 .29- 89.30 92.5 96.3
(3.5180- 3.S184) (3.6445) (3.7942)
89.67-89.68 93.0 96.6
(3.S33O- 3.5334) (3.6642)
(3 .8060)
e '" Diameter to be measured at right angles 10 gudgeon pin at dislan ce "e" from
bottom of piston
Engine type Weight gms1(oz) Dimension mm
iN
A B C
817 A S30±6 (18.9±0.
2) 75.5 (2.975)
SO.5 (1.9901 7 (0.276)
819 A
5OS ±6 (18.0±0.2) 71 .0 (2.797) 46.0 (1.812) 7
(0 .276)
819 E- 1983 S15± 6 (18,4±0.2) 71.0 (2.797) 46.0 (1.812) 7 (0.276)
'984
S15t 6 (18,4±0.2) 73.9 (2.'91 2) 46.7 (1.640) 7 (0.276)
819 ET S10t 6 (18.2±0.2) 71.0 (2.797) 46.0 (1.812) 7 (0.276)
819 K S15±6 (18A±0.2) 73.9
(2. '912)
46 .7 (1.840) 7 (0.276)
821 AZ
555±6 (19.8tO.2) 71 .0 (2.797) 46.0 (1 .812) 6 (0.236)
B 21 E 555±6 (l9.B ±0.2)
71 .0 (2 .797) 46.0 (1.812) 6 (0.236)
821 ET
535 ±6 (19.1 t O.2) 71.5 (2.81 7) 46 .5 (1.832) 7 (0.276)
821 F
555 ±6 (19.8tO.2) 71.5 (2.81 7) 46 .5 (1.832) 7 (0.276)
B 21 FT
535 ±6 (19.1 t O.2) 71.5 (2.BI7) 46 .5 (1.832) 7 (0.276)
B23A
570 ±7 (2O .4±0.3 76.4 (3 .0 10)
46.4 (1.828) 8 (0 .315)
B23Elypel
555 ±6 (19.8±0.2) 80.4 (3 .168) 46.4
(1 .828) 15 (0 .591)
typa 2
570 ±7 (2O.4 ±. 03 76.4 (3 .0 10) 46 .4 (1.828) 8 (0.315)
B23P
570 ± 7 (20.4±.03 76.4 (3.010) 46,4 (1 .828) 8 (0.315)
I Max weight ditlerence '" same engine _ 12 gms (OA3 Oz)
2Europe 1964- (exel Switzerland, Scandinavl8) medels have high compresslorl pistons,
A- 71.7 rTYTl (2.82 in); 8_48 .7 mm (1.84 in): C",7 mm (0 . 28 in)
lplstons dished on engine numbars 499846, 499890
Piston running clearance mm l[ in)
817A,B19A1E/K,B21A1E/F ............................ . ............... 0.01 -0.04 (0.0004-0.00 1 6)
819 ET ................... 0.03-0.06 (0.0012-0.0024)
821 ET& FT ........... .......... .. 0.02-0.04 (0.0008-0.0016)
823A .. ................ ................. ... 0. 01 - 0.04 (0.0004-0.001 6)
B 23 E type 1 ...... . . . . . . .. 0. OS - 0.07 (0.0020-0.0028)
type 2
...... . . . . . . . . . . . . . . . . . . . .. .. 0.Q1 -0.04 (0.0004-0.0016)
B 23 F ......................................................... 0. 01-0 .04 (0.0004-0.0016)
UJ 551
3

Group 21 Reconditioning engine
Specifications
Piston rings
Piston height, type 1 .
type 2.
Clearance in piston groove ..
Ringgap(see abovefig)
Gudg80n (piston) pins
Fit,in connecting rod ..
in piston ..................... .
Diameter,standard
oversize ..
VALVES
Valve clearance
Inlet and exhaust valves
coldengine
warm engine .......... .
Adjusting shims,thickness
Valv8s mm (in)
44.5·
Valve seats
New U55-7.970
(0.3132-0.3138)
Min 7.935
(0.3124)
1.3-1.9 1.7·2.3
(O.05'0.~·07'0.09)
45 " -=P3 . ~ ~ 45 "
~~
Inlet vllve Illt 11'.1
Exh.ult valvl lelt
4
Measure gap
' ..... ' \( 15 mm (0.59 in) from
~ " ,=_ <! 915 nvn Iower OOge
t (0.5$ In)
Clearance
\\
........... mm
(in)
.nYTl
(in)
... mm
(in)
.. nYTl
(in)
Upper
Lower
Oil
comp.rings comp.rings scraper rings
1.978-1.990 1.978-1.990 4.74
(0.0779-0.0783) (0.0779-0.0783) (0.1866)
1.728- 1.740 1.978-1.990
3.978-3.990
(0.0681 -0.0685) (0.0779-0.0783) (0.1566-0.1571)
0.040-0.072 0.040
-0. 072 0.030-0.062
(0.0016- 0.00
28) (0.0016-0.0028) (0.0012-0.0024)
0.35-0.65 0.35- 0 .5 5 0.25 -0.6 0
(0.014-0.026) (
0.014-0 .022) (0.010- 0.024)
light thumb pressure (dose running fit)
.. ... ...
Thumb pressure (push fit)
. mm (in) 24.00 (0.945)
........ mm (in) 24. 05 (0.947)
Chec:klng
Adjultlng
0.30-0.40 mm 0.35-0.40 mm
(0.012-0.016 in) (0.014-0.016 in)
0.35-0.45 mm 0.40-0.45 mm
(0.014-0.018 in) (0.016-0.018 in)
3.30-4.50 mm (0.1300-0. 1n3 in) in increments of
0.05 mm (0.002 In)
44.5· New 7.945-7.960
New 7.945-7.960
(0.3128-0.3134)
Min 7.925
(0.3120)
New 7.965-7.
(0.3136-0.314
Min 7.945
(0.3128)
'( (0.3128-0.3134)
f'
Min 7.925
(0.3120)
35 ' .' ~=:::::==!:6=~::J1I&
(1.38 in) -
bh.u.t vllvl
A. E, F-enginei
Exhaust valvl
Turbo-engines
1 (0. 63
,.~
Turbo: exh.ust valvel are Stellne.coated and must not be
machined to obtain new surface. They can however be
ground -i n with paste against leat.
Valve seat diameter
Inlet
bhlUlt
standard
mm
46.00 38.00
(n)
(1.8124) (1 .49721
overslza 1
mm
46.25 38.25
(In)
(1.8223) (1.5071)
2 .
mm
46.50 38.50
(in) (1.8321) (1.5169)

D+0 . 17mm (0.0067 in)
Valve guides mm (in)
Length ................... .
Innerdiameter ...
Group 27 Reconditioning eng ine
Specifications
When replacing valve seats the interference between the seat and ils bare
should be 0. 17 mm (0.0067 in) i.e. valve sea! diameter should be 0. 17 mm
(0 .0067 in) greater than diameter 01 bore in cylinder head.
.... rnrn
(in)
...... lTVT1
(in)
Inlet valve
52 Exhaust valve
52
Heightabove upper face of cylinderhead . ... . ...... lTVT1
(2 .0488)
8.000- 8.022
(0 .3152- 0.3161)
15.4-15.6
(0.6068- 0.6146)
0.030- 0.060
0.030-0.060
(0.0012- 0.0021)
0.15
(2.0488)
8.000- 8.022
(0.3152-0.3161)
17.9- 18.1
(0. 7053-0 .7131 )
0.060-0.090
0.060-0.090
(0.0024- 0.0035)
0.15
(in)
Clearance, valve stem -guide (measured with new valve)
new ............ .
max..
.................. mm
(in)
. mm
(in) 10 .0059)
(0 .0059)
Valve guides are available
in
three oversizes, marked
with
Valve springs mm (in)
Typa 1 Type 2
1 15013
Tappets mm (in)
grooves.
M.rklng
Reamer for
seat
Standard
No groove
Qversize 1 1
groov e 5161
2 2 groove 5162
3 3
groove
5163
Note . The force used when pressing in valve guides must be at
least 9000 N (900 kp). Ifthe pressing force used
is lower ,then the
recess
for the guide must be rea med out to the nearest oversize
and a
guide of the corresponding size pressed in.
Type 2 springs are
fltted on following engine types:
- 821 F lH -Jetronic, late types (from 1983-
-
823F
- 819 ET, B 21 ET & 821 FT late type ( from 1984- ).
Type 1 springs are f itted on all other angines typas.
Typel Type2
Length L.oad N (Ob) Length Load N (Ib)
45.0 (1.n)
O 45.5
(1 .79) O
38 .0 (1.50)
280-320
3.00 (1 .50)
280-320
(62-70) (62-70)
27.0 (1.06) 710-790 27.5 (1.08) 702-782
(156-174) (154-172)
Diameter. . . ........... _ ... . .. . 36.975-36.995
/1 .4568- 1.4576)
30- 31 (1.182- 1.221)
0.009-0.064 (0.0004-0.0025)
0.030- 0.075 (0.00.
12 - 0.0030)
-~ ......... . .. . ....... .
Clearance, adjusting sh im to cylinderhead ........ . •.
adjusting
sh im totappet ...... .. .. ..•
Adjusting shims mm (in)
Thickness .
Diameter
..
3. 30-4 .50 (in increments of 0.05)
(0.
1300-0 .1773) (in increments of 0.0020)
32 . 980-33 .0 (1 .2994-1.3002)
5

Group 21 Reconditioning engine
Specifications
TIMING GEARS
Camshaft mm (in)
Engine type
S 17 A, S 19 A
B 19 K
B 19 E 1917-1983
1984
S 19 ET
B 21 A 1975-1983
1984 CH,
Scandinavia
Australia,
Other markets
B 21 E
S 21 ET
B 21 F-5
B 21 F-8
B 21 F -9
S 21 Fl
B 23 A
S 23 E 1919-1980
1981-1982
1983
Canada
Other markets
'984
S 23 F
Bearing journal,
diameter .
Radial elearance, new ....
max ....
Profile
A
L
D
A
T
A
A
L
D
T
B
M
L
T
A
H
K
A
K
A
M
Camshaft
Check values (cold enain;)
max lift he ig ht Valve clearanca
Intake valva should
mm lin}
No. 1 intake valva open at:
All0.51 (0.4131) 0.1 (0.0216)
13 ~ B.T.D.C.ll
B/l0.6 (0.4176) 0.7 (0.0276) 19° B.T.D.C.
0/11.2 (0.4413) 0.7 (0.0276) 15° B.T.D.C.
H/12.0 (0.4728) 0.5 (0.0191) 28'" B.T.D.C.
K/11.95 (0.4708) 0.5 (0.0191) 22.6° B.T.D.C.
1.J9.8 (0.3861) 0.7 (0.0276) 10" B.T.D.C.
MI9.5 inlet 0.1 (0.0276)
3" A.T.D.C.
10.5 exhaust
0.1 (0.0276) 48" B.T.D.C.
TI9 .9 (0.3901) 0.5 (0.0191)
11 ° B.T.D.C.
11975 earlv types: 9.8 mm. 5" B.T.D.C.
29.050-29.070 (1.1 445-1.1454)
0.030-0.071 (0.0012-0.0028)
0.15 (0.0059)
Axial
elearance . . . . .................... .•.
0.1 -0.4 (0.0344-0.0158)
Camshaft bearlngs mm (in)
Bearing diameter .
Inlermediale shaft mm (in)
Diameter,front .. . ................ .
center
rear .
Radial clearance ..
Axial clearance ...
6
30 .000- 30 . 021 (1.1820-1. 1828)
Bearing journal
46 .975-41.000
11.8508-1.85181
43
.025-43.050
1'.6952-1.6962)
42.926-42.950
(1.6912-1.69221
B
ea ring in cylinder
41.020-41.050
(1.8526-1.8538)
43.070-43.100
1.6970-1.6981)
42.970-43.000
(1.6930-1.6942)
0.020-0.075 (0.0008-0.00301
0.20-0.46 (0.0019-0.0181)
t
t

CRANKSHAFT ASSEMBL "f
Crankshatt mm (in)
Max. out-of-true . . ............................. .
Crankshaft, axial clearance, max. . ... ......... .. .
radial clearance (main bearings) .......•.
Big-end bearings, axial clearance ...................•..•..•
radial clearance ... .. .... . . .............. .
Main baaring journals mm (in :)
Out-ofround, max ............ .
Taper, max
.. .......... .
Diameter, standard
.............. .
undersize 1
2 ..
Width on crankshaft for flange bearing shelJ,
standard . .. . .. . . ...... .
oversize1
2 ....
Group 27 Reconditioning engine
0.05 (0.0020)
0.25 (0.0098)
0.028-0.083 (0.0011 -0.0033)
0.15-0.35 (0.0059-0.0138)
0.024-0.070 (0.0009-0.0028)
0.07 (0.0028)
0.05 (0.0020)
63.451 -63.464 (2.5000-2.50 05)
63.197-63.210 (2.4900-2.49051
62.943-62.95612.4800-2.48051
38.960-39.000 11.5350- 1.5366)
39 . 061 -39.101 (1.5390- 1.5406)
39.163-39.203 (1.5430- 1.54
461
Specifications
Taper Out-ol-round
Connecting rod bearing journ'!lls mm (in)
Out-of-round max ..
Taper,max ....
Diameter, standard .................. .
undersize 1
..
2 .. .
Bearing recess widlh ... .
Connecting rods mm (in)
Axial clearance al crankshaft ............................ .
length , centre-centre ......... ........ . .. ..... . .. ..... .
Max.
weight deviation between connecting rods in same
engine
.................. . ..................... .
Flywheel mm (in)
Axialthrow, max ........ .
0.05 (0.0201
0.05 (0.020)
53.987-
54 .000 (2.1271 -2.1276)
53.733-53.746 (2.1171-2.11761
53.479-53.
492 (2.1071 -2.1076)
29.95-30.05 (1.1800-1.1840)
0.15- 0.
35 (0.0059-0.0 138)
145±
0.1 (5 .713±0.0039)
10
gms
0.05 mm!lS0 mm diameter
(0.0020 In/S.9l in diameter)
7

Group 21 Reconditioning engine
Specifications
TIGHTENING TORQUES
The tighteni ng to rques apply to oiled screws, bolts and
nuts. Degreased {washedl parts
must be oiled before
use.
Cylinder head, tightening sequence data
~o , ~ r<7 ~ r' ~ / ~ r ~ I, ~ r ~ , ~ , _________ O
·W'UJM" l UlU
ttrrrrrrr r"j ~
~~I~U~W~!!~!!~. __ ~ ij ~~ _____ ~
Early type
La te t ype
1 - 60 Nm (43 ft.lbs)
2 '"' 110 Nm (80 fUbs)
3 - Run warm . Then allowengine to cool off for about
30 minutes.
1 - 20 Nm
(14 tUbs)
2 "" 60 Nm (43 tUbs)
3 _ Angle-tighten 90".
4 - SIaeken bolt 1 approx. 30". Then tighten to a torque
of 110 Nm (BO ft.lbs) (The bolt must be slackened
first to break the restingstress, otherwise falsetigh-
tening torque will result.
Bolts should be replaced
if center saction shows
signs
of extension. 00 not re-use bolts more than 5
times.
5 = rlQhlen other botts in sequence, see step 4. If
in doubt, fit new bolts.
Main bearings ...
Connecting rod bearings, old bolts
new bolts
Flywheel (use newbolts)
Sparkplugs( no tto be oiled) ...
Camshaftgear ... ........
Intermediateshaft gear ..
Camshaftcap ..
.. .......
Crankshaft,centre bolt pulley ..
"I 3,--,- - ·
O O
O O O O O
8- · 4-2,.--16 - 10
115 U8
T i gh t 8n i nt~ Hqu ence for c ylin de r h e. d bolt.
Nm
.. ...... 11 0
63
70
70
.. .......
20 - 30
50
. .......
50
20
........ .. 165
Group 22 Lubricating system
Gene.al data
Oil capacity, exel oil filter ..
incloil filter.
Max-Min
.......... .
Turbo·engines: add 0.6 I (0.7 US qt) to above il 011 000191' is drained .
Oil pressure at
33 rIs (2000 rImin), warm engine! and newoil filter
8
3.35 I (3 .5 US qt)
3.85 I (4.0 US qt)
1.0 I (1 .1 US qt)
0.25- 0. 60 MPa
35.6-85.3 psj
(
ft.lb s)
80
46
51
51
14-22
36
36
14
119