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Superseded by B21 F- B.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

Petrol/Gasoline engines
USA. Canada and Japan
Ouality
According toAPI ....
.. minSF-
·oil s witn designations SF/CC Bnd SF/CO meet this require-
man!.
Viscosity (stable ambient temperatures)
• -3, - 20
- 22 -4
SAE5
SAE 1OW/4Q
Group 21 Reconditioning engine
Other markets
Quaiity
According to API -1983.
1984 ..
Specifications
.. .... minSP
................ minSF-·
·oUs with designBtions SE, SF, SElCC, SF/CC Bnd SF/CO
meet tnis requirement. Note tnBt SE/CD oil mU lt not b.
uled.
··oil s witn designations SF/CC and SF/CO meet this requi-
remen!.
Viscosity (stabls ambient temperaturesl
- 30 - 20
-10 O 10
20
30
4fJ-C
.' ! ! ! !
-2 2 -4
14
32
rj
86
104""
SAE 5 30
SAE
~40
15
SAE 20W 40
SAE 30
SAE40
1375012
Note: USA, Canada & Japan SAE 15W/40 engine oil is recommended for use in extreme
driving conditions which involve high oil consumption ego mountain driving with frequent
deceleration or fast motorway driving.
Other markets: SAE 15W/40
an ,d SAE 20W/40 oils are recommended.
Note however the 10wer temperature limits.
Oil pump
Axial clearance . .. . . . . . . . . . .. . ....... .
Radialclearance (excluding bearingclearance)
Backlash (excluding bearingclerarance)
.......... .
Bear
ing clearance, drive shah ...... .
idling shaft
Relief valve spring lenglh under different loads
115013
0.02-0.12 mm
0.02-0.09 mm
0.15-0.35 mm
0.032-0.070 mm
0.014-0.043 mm
l.ngth
39.2 mm (1.5445 in)
26.25 mm (1.0343 in)
21.0 mm (0.8274 in)
(0.0008-0.0047)
10.0008-0.0035)
(0.0059-0.0138)
(0.0013-0.028)
(0.OO06-0.0017)
Load
O
46-54 N (10.1-11.9Ib.)
62-78 N (13.6-17.2Ib.)
9

Group 21 Reconditioning engine
Special tools
Special tools
999 Description use
1426-6 Drift : inslalling pilot bearing
2484-7 Centering drift : installing clutch plnte
(early gearbox types)
2520-8 Stand : Used with fixture 5023
4090-0 Extractor: pilot bearing
5017-2 Drift : installing/removing connecting rod bushing
5021-4 Press tool: installing/removing carnshaft
5022-2 Press tool : adjusting valves
5023-0 Fixture: used with stand 2520
5024-8 Sleeve: installing crankshaft front s:eal
5025-5 Sleeve: installing camshaft and int~3rmediate shaft seals
5026-3 PIIers: removing valve tappets
5027·1 Drift: installing intake valve guides
5028·9 Drift : installing exhaust valve guidos
5029·7 Drift : installing intake valve seats
5034-7
Counterhold : crankshaft, intermediate shaft, camshaft
5111·3
5112·1
5160-0
5161·8
5162-6
5163-4
Centering drift : elutch (late gearbox types)
Gear sector: locking flywheel
Reamer
kit : contains 5161, 5162, 5163, 5164 (early type) o
5224 (late type)
Reamer:
for valve guide 051
Reamer: for valve guide 052
Reamer: for valve guide 053
5218-6 Drift : removing valve guide
5219-4 Tool: removinglinstalling valve
guide seals
5220-2 Drift: for checking valve
5222-8 G8Ug8: for checking valve stem lerlgth
5224-4 Reamer: inside (replaees 5164)
5276-4 Press tool: installing erankshaft rear sea I
2484
10
5111
2484
130 351
",,,
2520

Group 27 Reconditioning engine
Special rools
5023 5024,5025
5026
5027,5028
5<)29 5034
130 35 1
131 tIbO
5111 5112
5160,5161,5162,5163
\i
1>'
[...-5219
L , __
5218 5219 5220
I
~
"~. ""
~
r- '
LI unu
5222 5224
5276
11

Group 27 Reconditioning engine
Thread repBirs
A" l"hread repairs
O'"'
FOO D
I •
C
IThread IComplete
Kit, No ,
M 6x l 9985840-9
M 7x l
9985841-7
M8 x l,25 998 5842·5
M 10x 1,5 998 5843·3
M 12 x 1,5
9985844 -1
M
14 x l ,25
9985845-8
1
M 14 x l ,25 998 5846-6
M
14 x 1,5 998 5847-4
M 16 x 1,5 998 5848-2
M
18 x l ,5 998 5849-0
518 "-
18 UNF 9985850 -8
B
IA. Tap
998 5802-9
9985806 -0
998 5810-2
998 5814-4
998 5818-5
998 5823-5
9985826-8
998 5827-6
998 5831·8
998 5833-4
998 5860-7
'Intandad for spark plug threads Ino drilling)
2Use flat·nosed plierior similar tool
3Supplied with installation tool
113 293
B, Tang
breaker
998 5803-7
998 5807-8
9985811-0
9985815 -1
998 5819-3
"
"
"
"
"
"
Af
General
Damaged threads can usually be repaired with thread
inserts,Thread inserts and installation tool are available
from Volvo Parts.
Nate , Some threads can/may not be repaired with
thr ead inserts (refer to the illustration and table for the
part cancerned)
A2
Installation too I
Complete set or separate parts can be ordered from
Volvo Parts,
Supplied
with klt
C, Mandrel D. Crank E,
Tool Thread
inserts 10
998 5804-5 998 5805-2 " 956014-5 +
956015-2
9985808 -6 998 5809-4
.,
948015·3 +
941843-5
998 5812-8 998 5813-6
.,
956018-6 +
956019-4
998 5816-9 998 5817-7
.,
956022-8 +
956023-6
9985820-1 998 5821·9
.,
948094-8 +
948095-5
998 5824-3 998 5825-0
.,
948756-2
998 5824-3
9985825-0
.,
948756-2
998 5828-4 998 5829-2
.,
948758-8
" "
9985832-6
947847-0
" "
9985834-2 947843-9
" "
9985861-5
948755-4
I
"Tool 998 5830-0 is not supplied with complete kit ;)nd should be ordered separately if required.
12

Group 21 Reconditioning engine
Thread repairs
Do not repair these threads
(Threads shown bnlow cannot or must not be repaired)
Cylinder head
Inlet manifold
:0:
All conical threads such as plu!]s and nipples in inlet manifold on all engine types. A few
examples are
shown above.
later type inlet manifoids havo a few unthreaded holes intended for self-tapping screws.
Inlot manifold A-engines
Idle adjustment screw
e 1378D8
A3
1371107
13

Group 21 Reconditioning engine
Thread repairs
Thread repa ir i nsert , drill diameter
Thre ad
M 6x l
M 7Xl
M 8x l .25
M 10
:< 1.5
M 12x l .5
M 14Xl .25
M 14x l .5
M 16Xl .5
M 18 ;< 1.5
5/ S" x 18UNF
Tap smion
Asamer section
Guide
14
A4
Le ngth PIN Drill dia
mm mm
9.0 956014-5 6.3
12.0 956015·2 6.3
10.5 948016-3 7.3
14.0 941843-5 7.3
8.0 956017·8 8.4
11.4 956018·6 8.4
16.0 956019-4 8.4
10.0 956021-0 10.5
15.0 956022-8 10.5
20.0 956023·6 10.5
25.0 956024-4 10.6
12.0 948094-8 12.5
24.0 948095-5 12.5
30 .0 956028-5 12.5
14
.5 948756 -2 14.3
10.0 948758-8 14.5
12.0 947847-0 16.5
13.5 947843·9 18.5
8.0 948755-4 16.4
AS
Repairing spark plug threads
Cylinder head must be removed fi r st . Tap ha le from
inside
to avoid damaging seat for spark plug.
Do not drill the hole. Use tap 9985823 · 5.
Re ·c ut old threads only. Do not cut further inta cylinder
block.
Spark plug bore must not be threaded along
entire length.
Screw in thread insert (PIN 948756-2).

Thread
Thread depth
Drilling depth
Group 27 Reconditioning engine
Thread repairs
Ins1talling thread inserts
Cutting edge
, .~
, ..
Select drill size, tap and insert
Measure length and thread of old hole.
Tap hole
NOTEI Special i nstru c tians for spark plug hales,
see page 14.
A6
A7
Measure depth of hole. Drill out hole to this depth.
Cut the screw thread to such a depth
that the thread
insert makes contact
with fuliv cut screw thread along
its entire length.
Clean the hole.
AB
Assemble installation tool
M6- M1. threads: fit correct mandrel and crank in in ·
stallation tool 998 5830-0.
M16 and coaner threads: usa the appropr iate installa-
tion tool.
15

Group 21 Reconditioning engine
Th read repairs
Mandre'
113 JOO
ll JJOl
'6
A9
Fit thread insert in installation tool
Fit the thread insert in the tool with the tang facing
downwards.
Turn the crank clockwise
until the tang of the thread
insert engages the slot in the crank.
Without pr •• •i ng , screw the thread insert into the man-
drai until the first thread of the insert is flush with the
opening
of the mandrel.
AIO
Install thread insert
Hold the tool vertically above the centre of the hole.
Without pr.s sing, screw in tha thread insert until the
top thread
of the insert is at least 1/2athread below the
working surlace
(O.5 xpitch). The insert must not be
sc rewed in to the bottom otherwise it will not be possi-
ble
to break off the tango
An
Break off tang
M16 - M12 th r. ad .: use the tang breaker supplied with
the installation kil.
M14 and ca.rser thr •• ds: use a pair of flat nosed pliers
to break off the lang do wn wards_
Remove the tang fr
om the hole.

Group 27 Reconditioning engine
Thread repa;rs
Remo"ing thread repairs inserts
130 379
A12
File groove in th read in s ert
Usinga triangularfile make agroovein thetopthread of
the insert, approx. 1/4
of a thread fr om the end. Take
care not to damage the thread holding the insert.
A13
Remove thr ea d ins ert
Insert asharpedge of atriangularscraper in the groove.
Press
downwards and rotate anti-clockwise until the
insert is removed.
A14
Fit new th r ead insert
Clean the hole with a tap and fit a new insert.
17

Group 21 Reconditioning engine
Recondlitioning engine
Special tooIs: 1426,2484,2520,4090,5017,5021, 5022, 5023, 5024, 5025, 5026, 5027, 5028, 5029, 5034,
5111,5112,5160,5161,5162,5163,5218,5219,5220,5222, 5224, 5276.
For the overhaul of the engine it is presumed that the components shown in the illustration below have already
been removed. Also that the engine is moun ted with support 5023 on universal stand 2520.
-~
,
.' , 00
I It _O
. ~~
137555
131110
18
•