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Service Manual - Designed79.co.uk

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1.
2. B27 E 1975 1978 1979 1980 Sweden and Aus 1979 1980 Other B28 E 1981 1983 B27 F 1976 1979 B 27 F 1980 B27 F 1981 1982 F28 Lag crankshaft to firing position for No 1 cylin er The mark 1 on the pulley should align with the zero mark on the timing scale Both rocker arms for No 1 cylinder should have clearance F29 Check adjust valve clearances Check the following valves in the set position Intake cylinders 1 2 and 4 Sei Exhaust cylinders 1 3 and 6 AS F30 Turn crankshaft one turn in normal direction to overlap position for No 1 cylinder EE The mark 1 on the pulley should align with the zero mark on the scale There should be no clearance be tween the rocker arms and valve stem tops for No 1 cylinder F31 Check adjust valve clearances Check the following valves in the set position Intake cylinders 3 5 and 6 Exhaust cylinders 2 4 and 5 59 Group 21 Reconditioning engine Assembly F32 Turn crankshaft one turn to firing position for No 1 cylinder The mark 1 on the pulley should align with the zero mark on the timing scale The rocker arms for No 1 cylinder should have clearance This is now the correct setting for installing the distribu tor F33 Install gaskets and valve covers Use new gaskets Apply a few spots of sealing com pound P N 116 1026 8 Place only four bolts in each valve cover Do not tight
3. 0 234 in 5 96 0 234 in EE 40 440 40 465 1 5921 1 5931 EE EE 41 040 41 065 1 6157 1 6167 Aco aC dee OKO Seg eee ere Gee RW cu eile Whe ais 41 640 41 665 1 6393 1 6403 Rae SE i FRA aS WS CNRS 42 240 42 265 1 6629 1 6639 Radiat lai eet EE wie Sal NEEN 0 035 0 085 0 0013 0 0033 CR TEN E NAS 0 070 0 144 0 0027 0 0056 JJ 0 5 0 0196 u Group 21 Reconditioning engine CRANK MECHANISM Crankshaft Max run out measured on two centre main bearing journals 0 02 mm Crankshaft and Wot 2 cs psec EEN E d yeasts esse 0 070 0 270 mm clearance main bearings SSES EEN EN 0 038 0 088 mm Crank journals side clearance cersssosneresessssss 0 20 0 38 mm LE Sa teva 0 030 0 080 mm Rear sealing ring diameter standard 79 926 80 000 mm UNGOTSIZAE EE 79 726 79 800 mm Main bearing journals Out of roundness N err cE NEEE TSE 0 007 mm TEEN TT EE 0 01 mm PRUE IRON AIRE EE EE EE 70 043 70 062 mm TTT Sc Soc ren E RTE 69 743 69 762 mm Main bearing shells thickness standard 1 961 1 967 mm OVENS ZOO iis iver assess sie 2 111 2 117 mm Width of crankshaft journal for thrust bearing rear main bearing journal Pi LT EE 29 20 29 25 mm ET Boise ai E EE 29 40 29 45 mm Y SOUPS TTT ERLE OTe Oe POC CUTER ee SOT TTT ETT 29 50 29 55 mm SE 29 60 29 65 mm Thrust bearing washer thickness standard 2 30 2 35 mm oversized 1 5 2 40 2 45 mm EE 2 45 2 50 mm ere AE EEN 2 50 2
4. Assemble con rod cap and bearing shells to prevent interchange of parts Automatic Manual Group 21 Reconditioning engine Disassembly FLYWHEEL CRANKSHAFT Automatic transmission B17 Remove carrier plate Use locking sector 5112 to lock flywheel when bolts are removed rear sealing flange Tap out seal from flange Manual gearbox B18 Remove pressure plate and clutch disc Slacken pressure plate bolts crosswise a few turns at a time to prevent warp flywheel Use locking sector 5112 to prevent engine from rotating rear sealing flange Tap out bearing from flange pilot bearing from crankshaft Use puller 4090 819 Remove crankshaft main bearings and thrust bearings Check marking of bearing caps mark if necessary Caps are marked 1 4 counting from rear IMPORTANT Do not interchange bearing shells and caps 25 Group 21 Reconditioning engine Cleaning checking C Cleaning checking Mahie 8 5 mm 11 mm B27F 1976 1978 Demolin Lpam C1 Check type of piston and cylinder liner Pistons and liners are matched sets based on diameter Three types are available as follows Liner marking Piston marking 1 notch A 2 notches B 3 notches C c2 Check make of pistons B 27 engines Demolin or Mahle B 28 engines Mahle c3 Measure piston diameter Measure at right angles to gudgeon piston pin bore Diameter must be measured at diff
5. P N 1161057 3 and secure with Locktite 43 Group 21 Reconditioning engine Assembly D26 install sleeve and O ring in oil channel D27 Remove main bearing holders and nuts if any of the pin studs is slack torque to 15 20 Nm 11 15 ft lbs D28 Apply sealer Mating surfaces for lower crankcase as well as main bearing caps should be smeared with sealer P N 1161058 1 D29 install lower crankcase Tighten nuts and bolts by hand Align crankcase so that rear edge is flush with cylinder block rear Use a straight edge Check both sides IMPORTANTI Crankcase and cylinder block must be flush otherwise distortions may result and cause noise or dama op D30 Tighten main bearing nuts Tighten in order shown adjacent to 30 Nm 15 ft lbs Re check that lower crankcase lies flush with the r ar of cylinder block see D29 Angle tighten main bearing nuts Use protractor 5098 A measuring stand can be used to align the protractor The magnetic base of the stand should be placed on fixture 5099 and the arm pointed towards the protrac tor Slacken nut 1 Tighten nut 1 to 30 35 Nm 15 27 ft ibs Angle tighten nut 1 to 73 77 Slacken and re tighten remaining nuts in order spe cified above D32 Check that crankshaft rotates Tighten bolts for lower crankcase 4a Group 21 Reconditioning engine Assembly D33 Install splash panel oil strainer with O ring oil sump with gask
6. Tighten to the correct torque in three stages 1 10 Nm 7 ftJbs 2 30 Nm 22 ft lbs 3 60 Nm 44 ft lbs F8 install other cylinder head Install according to C53 65 53 Group 21 Reconditioning engine Assembly 54 F9 Angle tighten cylinder head bolts At the earliest 10 15 minutes after F7 1 Slacken all bolts in order shown adjacent 2 Tighten to a torque of 15 20 Nm 11 15 ft lbs in order shown 3 Angle tighten 113 117 in order shown adjacent Use protractor 5098 The rocker arm bridge can be used as a line of sight IMPORTANTI Bolts must be retightened after engine has cooled r TIMING GEARS i 1 F10 Install crankshaft gears and keys Block holes in crankcase to prevent keys from falling in Lubricate parts The mark on the inner gear must face out Note On late types gear and spacer are manufactured in one unit F11 Install new strainers in cylinder block chain tensioners straight chain dampers bent chain dampers Apply locking fluid P N 116 1053 2 to bolts F12 Set crankshaft and left hand camshaft The key in the crankshaft should point towards the left hand camshaft The groove in the camshaft should point upwards and there should be no clearance between the rocker arms and valve stem tops for No 1 cylinder e e N wr Group 21 Reconditioning engine Assembly F13 Install left hand camshaft chain and sp
7. 55 mm Specifications 0 0007 in 0 0027 0 0106 in 0 0014 0 0034 in 0 0078 0 0149 in 0 0011 0 0031 in 3 1466 3 1496 in 3 1388 3 1417 in 0 0002 in 0 0003 in 2 7575 2 7583 in 2 7457 2 7465 in 0 0772 0 0774 in 0 0831 0 0833 in 1 1496 1 1515 in 1 1574 1 1594 in 1 1614 1 1633 in 1 1653 1 1673 in 0 0905 0 0925 in 0 0944 0 0964 in 0 0964 0 0984 in 0 0984 0 1003 in HO Taper Connecting rod bearing journals Cit Grups NAN 3 0 007 mm di du E EE 0 01 mm e eg EE EN 2 267 52 286 mm TT DEE 51 967 51 986 mm Connecting rod bearing shells thickness standard 1 842 1 848 mm undersized 1 992 1 998 mm Bearing journal width 39 99 40 09 mm Connecting rods End float on crankshaft both con rods fitted 0 20 0 38 mm Length between Centres 146 15 mm Max weight difference between con rods in same engine 2 5 grams Flywheel Ai MON WK EENS as E N 0 05 mm Radial throw max measured at diameter 282 4 mm 0 15 mm Out of roundness 0 0002 in 0 0003 in 2 0577 2 0585 in 2 0456 2 0466 in 0 0725 0 0727 in 0 0784 0 0788 in 1 5744 1 5783 in 0 0078 0 0149 in 5 7539 in 0 0019 in 0 0059 in Group 21 Reconditioning engine Specifications TIGHTENING TORQUES The tightening torques shown below apply to oiled nuts and bolts Degreased washed parts must be oiled prior to
8. arms Slacken bolts in sequence shown adjacent B9 Remove cylinder heads Do not lift cylinder head directly up otherwise cylinder liners may lift as well gt Use two bars 12 mm woer 300 mm and lift off cylinder head as illustrated Place cylinder heads on wooden blocks to prevent da mage 810 Remove cylinder head gaskets guide sleeves use a pair of pliers B11 Fit liner holders 5093 Two per side Liner holders must always be used when cylinder head is removed OIL SUMP LOWER CRANKCASE B12 Remove oil sump with gasket oil strainer with O ring splash panel lower crankcase O ring for oil channels and guide sleeve 23 Group 21 Reconditioning engine Disassembly B13 Install main bearing holder 5096 for two outer bearings a nut for the two centre main bearings This is to prevent the crankshaft main bearings from falling out when the engine is turned PISTONS CONNECTING RODS B14 Check con rod side clearance Use a feeler gauge Clearance new parts 0 20 0 38 mm 0 008 0 015 If clearance is too great con rods must be replaced Note that con rods must be replaced in sets B15 Check marking of con rod and cap if necessary mark as follows ein gagga Marking of con early type Pepe rod and cap late type Crank webs from rear rT tat at 816 Remove pistons with con rods and bearings Clean cylinder liners
9. eeneg B8 cleaning inspection E26 J ie opin ani KAS FS sta E B12 MODON D33 Thread inserts general information Al ee ieee rt A2 non repairable threads A3 thread inserts A4 SU EE A4 spark plug threads AS JJ 6 A6 11 HMO 2 1 Se TR Ai2 14 Page 30 30 25 40 26 28 35 24 26 26 27 28 32 43 25 45 Group 21 Reconditioning engine Index Opera tion Page Timing gear chains sprockets le UE EECH B3 21 POMOVE 22 B4a 7 22 INGHOCHOR E C33 36 J F10 19 54 Timing gear cover RECHNEN del WEE B2 21 installation 5 F20 56 Timing scale checking adjusting F23 27 57 Valve covers TTT ise B2 21 installation oin irei F33 60 Valve guides eys E6 47 replacement 0 655 055 E14 47 oil seals removal E1 46 oil seals installation E25 51 Valve seats RITHM Ee E24 50 replacement Seen E15 22 49 Valve springs TOMOVEL sos ei ners STEEN EE EI 46 E7 47 aA a E25 51 Valves RTE PARE SENE REEN El 46 QUNGING BEE E23 50 installation EES E25 51 DOLDE Aaa se F28 32 59 Vibration damper see Crankshaft pullley 63 5 gt National Institute for AUTOMOTIVE SERVICE EXCELLENCE VOLVO SUPPORTS VOLUNTARY MECHANIC CERTIFICATION BY THE N ILA S E U S A Only Service literature Your most important special tool VOLVO
10. for dirt etc Use the highest measurements for the calculation Example Ist measurement 0 11 mm 2nd measurement 0 08 mm 3rd measurement 0 09 mm Difference between measurements does not exceed 0 05 mm and highest measurement is 0 11 mm D14 Select correct size shim Distance between top of liner and block should be 0 16 0 23 mm Gap should be as near as possible to 0 23 mm Select a shim which is the same or just under the cal culated thickness Shims are available as follows Colour Thickness Bibis EH 0 070 0 105 mm Lu WEE 0 085 0 120 mm 7 KEE EE 0 105 0 140 mm n T ATENE E a e both ton k 0 130 0 165 mm Example Max specified gap Measured gap without shim Select a white shim D15 Install same size shim on all liners Colour marking should face upwards and be visible when liner is installed The tongues B on the inside of the shim should fit into the groove in the liner C D16 Install liner in block Observe liner identification marks as applicable EN Group 21 Reconditioning engine Assembly 42 Di7 Check liner deck height Install four holders 5093 for one bank of cylinders Measure height at three places Difference between va lues must not exceed 0 05 mm 0 0020 Liner height 0 16 0 23 mm 0 0063 0 0091 Exchange shims if necessary D18 Measure difference in height between next liner Mea
11. is removed or replaced F23 Remove rear plug in cylinder block 57 Group 21 Reconditioning engine Assembly F24 Set crankshaft statically 36 mm socket Turn the crankshaft so that the mark forT D C cylinder 1 aligns with the 20 mark on the timing scale Note There are two marks on the pulley 1 T D C cylinder 1 and 2 T D C cylinder 6 A tigen F25 Set crankshaft at T D C cylinder 1 Insert a 8 mm drill 0 315 in jn the blanking plug hole so that it rests on the crankshaft counterweight Press lightly on the drill and turn the crankshaft slowly in the normal direction of rotation until the drill fits into the hole in the counterweight The engine is now set at exactly T D C for cylinder 1 F26 Check adjust timing scale The zero mark on the scale must align exactly with the mark on the pulley F27 Install blocking plug Use a new seal Tightening torque 35 40 Nm 26 30 ft lbs Before proceeding with valve clearance check Camshaft setting must be checked See specifica tions on page 8 58 Group 21 Reconditioning engine Assembly VALVE ADJUSTMENT VALVE COVERS See footnote on page 58 Different clearances for different engine types Valve clearance mm in Type 1 Type 2 cold engin intake 2 0 10 0 15 exhaust 0 004 0 006 in OOS FTO to 0 25 0 30 0 30 0 35 0 010 0 012 in 0 012 0 014 in 1981 1982
12. two centre caps CRANKSHAFT REAR SEAL PILOT BEARING D7 Install seal holder Use a new seal Using a straight edge make sure that the holder is flush with the cylinder block D8 install crankshaft seal Assemble standard handle 1801 and drift 5953 Lubricate the seal and groove Pack grease between the sealing lips Place the seal on the drift see fig Tap in the seal until the drift abuts the crankshaft 39 Group 21 Reconditioning engine Assembly Cars with manual gearbox D9 install new pilot bearing in crankshaft Tap in the bearing until it abuts the crankshaft There are two types of bearings Early type inner diameter 17 mm 0 669 Use stan dard handle 1801 and drift 5101 Late type inner diameter 15 mm 0 590 Use drift 1426 CYLINDER LINERS D10 Check mating surfaces for shims Check that surfaces in liner and block are clean and free from defects D11 Install no 1 liner without shim Check line up marks and number Install two holder 5093 hand tight D12 Set dial indicator zero position Place dial indicator in outer hole in holder 5192 5094 can also be used Rest holder on a flat surface e g cylinder block and set zero Group 21 Reconditioning engine 0 16 0 23 mm Shim Assembly D13 Measure liner height at three different positions as shown adja cen Difference between the three measurements must not exceed 0 05 mm If greater check
13. 029 0 0009 0 0212 Ring gap when checked in 91 mm 3 5826 in cylinder B 28 88 mm 3 4646 in B 27 see po mm 0 40 0 60 0 40 0 60 in 0 0157 0 0236 0 0157 0 0236 Gudgeon piston pins Diameter Marking Marking piston gudgeon pin Blue HI REES White WMG EEN eagles Red Hegle WEEN Clearance in connecting og PEON ANE EE TEE EES 90 990 91 000 mm 3 5822 3 5826 in 23 510 23 513 mm 0 9255 0 9257 in 23 507 23 510 mm 0 9254 0 9255 in 23 504 23 507 mm 0 9253 0 9254 in Ring gap measured 15 mm 0 6 in from Oil ring 2 629 2 731 0 1035 0 1075 0 009 0 233 0 0003 0 0091 0 38 1 45 0 0150 0 0570 23 500 23 497 mm 0 9251 0 9250 in 23 497 23 494 mm 0 9250 0 9249 in 23 494 23 491 mm 0 9249 0 9248 in 0 020 0 041 mm 0 0007 0 0016 in 0 010 0 016 mm 0 0003 0 0006 in 0 014 0 020 mm 0 0006 0 0008 in Group 21 Reconditioning engine Specifications VALVE SYSTEM Valve clearances varies with engine type Valve clearance mm in Type 1 Type 2 Intake valves cold engine 0 10 0 15 0 004 0 006 0 20 0 25 0 008 0 010 warm engine 0 15 0 20 0 006 0 008 0 25 0 30 0 010 0 012 Exhaust valve cold engine 0 25 0 30 0 010 0 012 0 30 0 35 0 012 0 014 warm engine 0 30 0 35 0 012 0 014 0 35 0 40 0 014 0 016 Engine type model year B 27 A 1976 1979 1981 1982 Ta ni a ES AROERI E A 1979 1980 Sweden Australia 1979 1980 Other markets B 28 E 1981
14. 1983 B 27 F 1976 1979 B 28 F 1980 1981 1982 Valves mm in 29 5 44 5 7 945 7 960 7 965 7 980 0 3127 0 3133 0 3135 0 3141 7 965 7 980 7 975 7 990 0 3135 0 3141 0 3133 0 3145 Valve seats mm in 1 7 2 1 mm 0 0669 0 0826 1 3 1 7 mm 0 0511 0 0669 2 0 2 4 mm 0 0787 0 0944 Intake vaive seat Intake valve seat Exhaust valve seat Early types Late types venturi seat 15 and 60 are correct angles to reduce seat width Group 21 Reconditioning engine Specifications dtro 34mm Note When replacing valve seats the interference between the valve seat and its bore in the cylinder head must be 0 070 0 134 mm 0 0027 0 0052 in i e the valve seat diame ter must be 0 070 0 134 mm greater than the diameter of the bore in the cylinder head Valve seats are available in three oversizes Valve guides mm in HIT EE 50 1 51 3 1 2725 1 3030 WinGr Hlp tase 8 000 8 022 0 3149 0 3158 Press in measurement to cylinder head contact surface against block CSRS ray Dna hc 39 5 40 5 1 5551 1 5944 RER Een EE SANSA TM ERT ara ES BREA 36 9 37 9 1 4527 1 4921 ei Valve guides are available in three oversizes and are marked with grooves Marking Reamer for seat Standard No groove Oversize 1 1 groove 5166 2 2 grooves 5167 AR 3 3 grooves 5168 Valve springs Two types of valve springs are in use The springs are colour coded as follows Grey springs Green springs B27
15. 5 Group 21 Reconditioning engine Assembly F17 Turn locks 1 4 turn clockwise F18 Set chain tension Turn the crankshaft round twice Remove the crankshaft nut Note The key in the crankshaft should point upwards to gt prevent it from falling out of its groove br A When the crankshaft has been rotated the marks for the chains and sprockets do not coincide It is necessary to ro tate the crankshaft a large number of turns to obtain the correct position F19 Install oil pump with sprocket chain and gear Apply locking fluid P N 116 1053 2 to the bolts G Pi Y E Ce m F20 Remove protective paper Install timing gear case Use new gaskets Smear the four lower bolts with locking fluid P N 116 1056 5 Tightening torque 10 15 Nm 7 11 ft lbs Cut sides of gaskets flush with cylinder heads 56 Group 21 Reconditioning engine 240 280 Nm 177 206 ft lbs 160 180 Nm 118 133 ft Ibs Assembly CRANKSHAFT FRONT OIL SEAL PULLEY F21 Install new seal in timing gear case Grease the seal Use drift 5103 F22 Install crankshaft pulley Fit locking sector 5112 to the flywheel casing at the lower bolt RHD vehicles upper bolt Make sure that key in crankshaft does not fall out Tighten nut to correct torque see left 36 mm socket IMPORTANT There are two different types of nuts TIMING SCALE Check adjust only if necessary eg if plate
16. 51 gearboxes 5128 7 Piston support removing gudgeon pin from Mahle piston Used with 5092 5129 5 Piston support fitting gudgeon pin in Mahle piston Used with 5092 5165 9 Reamer kit valve guides contains 5164 early type 5224 late type 5166 5167 and 5168 5166 7 Reamer valve guide seat oversize 1 5167 5 Reamer valve guide seat oversize 2 5168 3 Reamer valve guide seat oversize 3 5192 3 Support for dial indicator Measuring cylinder liner height and piston height Also 5094 can be used 218 6 Drift removing valve guides Fitting oil seal on valve guide 5220 2 Drift fitting valve seat exhaust 5224 4 Reamer cleaning valve guides Also 5164 can be used 5953 8 Drift fitting crankshaft rear oil seal Used with 1801 5092 2 5092 3 5092 4 5072 5 5092 6 yoo 5092 as Group 21 Reconditioning engine Special tools 5111 3072 1 5092 7 5092 3 5072 4 5072 5 Se Ae 211 5128 5129 13 Group 21 Reconditioning engine Thread repairs A Thread repairs Al General Adamaged thread can usually be repaired with a thread insert Thread inserts and installation tools are available from Volvo Parts Note Some threads can may not be repaired with thread inserts see next page A2 Installation tools Tools to install thread repair inserts are supplied in kits Some thread inserts are also included in the kits See the table below Note Each tool can
17. A 1976 1979 B28A 1980 1982 B27E 1975 1978 B27E 1979 1980 excluding Sweden Australia 1979 1980 Sweden Australia B27F 1976 1979 B28E 1981 1982 B28F 1980 1982 Tece L me La 47 2 1 86 0 47 1 1 85 0 4 V ks 40 0 1 57 233 268 gra 40 0 1 57 23 0 26 6 ep 23 3 26 8 32 2 1 27 521 585 116 131 30 0 1 18 613 689 137 154 52 1 58 5 61 3 68 9 Group 21 Reconditioning engine Specifications Rocker arm mechanism The rocker arm contact surface against the camshaft is surface hardened and must not be ground Diameter rocker arm shaft 66 19 959 19 980 mm 0 7857 0 7866 in Hole diameter rocker am 19 992 20 013 mm 0 7870 0 7879 in Clearance shaft rocker am 0 012 0 054 mm 0 0005 0 0021 in TIMING GEARS Camshaft neng Camshaft Type 1 79 10 245 522 143 or 144 79 10 245 412 5 144 0 202 in 5 059 0 199 in Check of camshaft setting cold engine Adjust valve clearance on 1st and 6th Intake valves to 0 7 mm 0 027 in the intake valves should then open at B27 E 1975 1978 1979 1980 Sweden Australia 1979 1980 Other markets B 28 E 1981 1983 B 27 F 1976 1979 1981 1982 Journal diameter counting from front all types mm in Type 2 74 01 269 138 74 01 269 139 6 004 0 236 in 6 004 0 236 in Three types of camshafts with different lift heights are in use The part number is marked on the front end Type 3 7401 269615 74 01 269 616 5 96
18. Service Manual Repairs SC and maintenance 260 1975 1983 VOLVO D books4cars com 4850 37th Avenue South Seattle WA 98118 USA B27 A B 27 E B 27 F B 28 A B 28 E B 28 F yl Eet US Ke UI G Di What do these designations mean B28E A carburetted engine E fuel injected engine F fuel injected engine USA models 28 27 capacity B petrol gasoline LC Engine type Model year B27A 1976 1979 B28A 1980 1982 The 8 28 is in principle a B 27 with a larger bore e z d veces B27F 1976 1979 B28F 1980 1982 Volvos are sold in versions adapted for different markets These adaptions depend on many factors including legal taxation and market requirements This manual may therefore show illustrations and text which do not apply to cars in your country I ET G Group 21 Reconditioning engine Contents Contents z Page mporn NO EE EE sia Specifications EEN 2 EE feet NS SERNAME NO AE 11 Operation D TE NEE Al 14 14 Reconditioning engine DARC aise ext ane RNa CERIO SRM We sae EE B1 19 20 Beleeg Eet CIES IEN G mi imi e C1 41 26 ia 511s D1 35 38 Cylinder head reconditioning NNN Ne ei vodka ENKEN va NEE EC E1 26 46 Assembly con EE EEN F1 33 52 Index page 62 This manual deals exclusively with the overhaul of the engine For work carried out on the engine when fitted in the car an
19. acklash eet Bearing play SA EEN EN EE EE E EIENN EIERE 0 17 0 27 mm 0 0066 0 0106 in Bearing play drive shaft isi ikal oi a iada NN 0 015 0 053 mm 0 0006 0 0021 in eller RME SA cease EES Se G IE 0 015 0 051 mm 0 0059 0 0020 in Relief valve spring length at various loads A EE EE 89 5 mm 3 52 in loaded to 88 3 N 8 83 kp 20 Ibs 1 eee ee epee ee 56 5 60 5 mm 2 22 2 33 in Special tools Drift fitting pilot bearing in crankshaft late type Standard handle used with 5101 and 5953 Centering drift clutch M45 46 gearboxes early type Stand used with fixture 5099 Extractor pilot bearing Drift fitting intake valve seat Continued on page 12 Group 21 Reconditioning engine Special tools 5092 5 Combined tools 6 parts removing fitting gudgeon piston pins 5128 and 5129 also required for Mahle pistons 5093 3 Retainer 4 x for cylinder liners 5096 6 Spacer sleeve main bearings 5098 2 Protractor for angle tightening cylinder head bolts and main bearing nuts 5099 0 Fixture for engine Used with 2520 5101 4 Drift fitting pilot bearing in crankshaft early type Used with 1801 5103 0 Drift fitting crankshaft front oil seal 5108 8 Drift fitting valve guide intake 5109 7 Drift fitting valve guide exhaust 5111 3 Centering drift clutch M45 46 gearboxes late type 112 1 Locking sector locking flywheel 5113 9 Centering drift clutch M50
20. ard no groove Oversize 1 1 groove 2 2 grooves 3 3 grooves Ream seat for guide See above table E11 Heat cylinder head to approx 150 C 300 F E12 Cool valve guide to approx 70 C 95 F Use liquid carbon dioxide or equivalent to cool the valve guides Wear protective gloves and safety glasses E13 Press in new guide Note This must be done very quickly within 3 4 secs Place the cylinder head on a sloping surface so that the valve guides are vertical Use drift 5108 for intake and 5109 for exhaust valve guides E14 Clean inner surface of new valve guides Use reamer 5224 Reamer 5164 can also be used Valves and valve seats must be ground in if guide has been replaced Group 21 Reconditioning engine Cylinder head reconditioning 8A j E i ose IXE Valve seat replacement Operations E15 22 Note Valve guides must always be renewed before repla cing seats see E8 14 E15 Clean combustion chambers Clean the surfaces until the edge of the inserted seat is clearly visible E16 Remove valve seat Machine the valve seat Use Mira valve cutter P N 998 6045 5 Follow the manufacturer s instructions Make sure that the cylinder head is not damaged Clean carefully E17 Measure valve seat diameter in cylinder head and select a new seat of correct size Use an internal micrometer Valve seats are available in three oversizes The interference b
21. assembly Tighten all bolts in stages according to below 1 10 Nm 1 kom 7 ft Ibs 2 30 Nm 3 kpm 22 ft Ibs 3 60 Nm 6 kpm 44 ft Ibs 4 Wait 10 15 minutes 5 Slacken bolts 6 15 20 Nm 1 5 2 0 kpm 11 15 ft Ibs 7 Angie tighten to 113 117 8 Warm up engine to operating temperature 9 Cool block 30 minutes 10 Slacken and then retighten bolts one ata time in specified tightening order Retighten according to stages 6 and 7 Main bearings Tighten all nuts in stages 1 30 Nm 22 ft Ibs 2 Slacken nut 1 3 Tighten nut 1 to 30 35 Nm 22 26 ft Ibs 4 Angle tighten nut 1 73 77 5 Slacken and retighten the other nuts in the order specified in stages 2 4 Tightening sequence for main bearings via lower crankcase Nm ft Ibs Cylinder head see below Connecting rod bearings 20 6 0 c cess cree eee een een enact 45 50 33 37 Crankshaft front end 1975 1977 2 2 2 2 ee eee eee eee gee 160 180 118 133 E EE 240 280 177 207 40mm ki 40 mm 1 575 in 45 mm 1 772 in 1975 1977 Nm ft Ibs Camshaft sprocket 212 ise a A EEN EN 70 80 52 66 Flywheel always use new bolts 45 50 33 37 12 2 941 5 VU COUR AO T ERR E O RE 15 11 10 Group 21 Reconditioning engine Specifications Group 22 Lubricating system OIL PUMP ENG TOS eege Eeer Eet ere ieee 0 025 0 084 mm 0 0009 0 0033 in Radial play between cog tip and pump housing JKT DEES 0 110 0 185 mm 0 0043 0 0072 in B
22. be ordered separately nme Contents of complete kit 998 5802 9 998 5803 7 956014 5 956015 2 998 5806 0 998 5807 8 998 5808 6 948015 3 941843 5 998 5810 2 998 5811 0 998 5812 8 956018 6 956019 4 898 5814 4 998 5815 1 998 5816 9 998 5818 5 998 5819 3 998 5820 1 998 5823 5 998 5824 3 998 5826 8 998 5824 3 998 5827 6 998 5828 4 998 5831 8 3 998 5833 4 3 998 5860 7 3 Notes Designed especially for spark plug threads do not drill 2 Use flat nosed pliers or similar tool 2 Supplied with set 4 Tool 998 5830 0 is not supplied with complete kit but may be ordered separately 14 Group 21 Reconditioning engine Thread repairs A3 Do not repair these threads Threads shown below cannot or must not be re paired Nipple for oil filter Connecting rod bearings bolts Cylinder block Adjustment screws Idle adjustment screw Lower section of air fuel contro unit B 27 E 1979 B 28 E B 27 28 F intake manifold B27 B28 Ali conical threads such as plugs and nipples in intake mani fold also B 28 B 28 A Group 21 Reconditioning engine Thread repairs Thread repair insert drill diameter Tod teat Om Iesse M 6x1 956014 5 e Se 956015 2 M 7x1 10 5 948015 3 7 3 14 0 941843 5 7 3 5 88 x 18UNF AS Repairing spark plug threads Cylinder head must be removed first Tap hole from in side to avoid damaging seat for spark plug Do not dr
23. d for engine removal and installation please refer to the separate manuals Order number TP 30447 1 We reserve the right to make alterations Group 21 Reconditioning engine Important information Important information Tightening torques Nearly all of the B 27 28 engine is made of aluminium alloy The threads are tapped directly into the alloy For this reason it is extremely important that all of the bolts are tightened to specified torque Two types of tightening torques are used in this manu al L Tightening torque 40 Nm 30 ft lbs a torque wrench must be used ll Tightening torque 40 Nm 30 ft ibs correct value however it is not necessary to use a torque wrench Specifications Group 20 General Engine serial number and part number Located on a plate in front of the oil filter On B 28 E F 1981 models located on the rear of the right hand cylinder head shows the last three digits of the part number N TA Group 21 Reconditioning engine Specifications Group 21 Engine block CYLINDER HEAD EES New 171 07 mm 4 373 in Max warp is 0 05 mm over 100 mm NOTE Do not level a warped cylinder head replace it Cylinder head gasket thickness 1 14 1 50 mm 0 045 0 059 in CYLINDER BLOCK Cylinder liners Pistons and liners are matched sets Cylinder liners are marked by 1 2 or 3 cuts in the upper edge of the liner B27 B27 Bore liners mar
24. en since the covers are to be removed later on To ensure that the junction between the valve cover cylin der block and timing gear case is fully leak proof a thin coat of silicone P N 116 1048 2 can be applied to the joint Note Do not use too much silicone otherwise it may enter the lubrication system and block the oil channels 60 Group 21 Reconditioning engine Index Camshaft Vu MEET installation Ae Carrier plate Auto e EE EE ODER vu wee ek ENEE ENER EDOR Geen See eege Chain dampers tensioners ue 1 EE different types _ BEEN GASS NES geile tas installation Clutch removal EE EEN ah RK amhugegt Kee g Connecting rod bearings TT EE EES rt LP ae Connecting rods side clearance a A REOR TITLE i KRESCHEL FEPISCOINGHT Ae wee ER WEEK different types 4 s A Kies Crankshaft oil seal SET un NEE inetalletion eene ee e front removal installation DEI Crankshaft pulley e T Ciara N ies Wika eee Crankshaft removal PERRIN 4 66 0 ore dem different typss installation 0 arte end clearance Cylinder block cleaning checking 62 Index Opera Page tion Cylinder liner 46 CHASBOS sia dias i ares als Ci 47 N T A ANES S PETT c4 51 E EEN C5 6 INSPECTION ee oono EE c7 25 E Tele P D10 13 36 installation 5 D14 19 45 Cylinder head gasket Ins
25. erent heights depending on make and model year All Mahle pistons 8 mm 0 31 in from lower edge 8 27 F 1976 1978 with Demolin pistons 11 mm 0 43 in from lower edge Other Demolin pistons 8 5 mm 0 33 in from lower edge of oil ring groove See specifications on pages 4 5 for diameters of new parts Group 21 Reconditioning engine Cleaning checking c4 Measure cylinder diameter Use a dial indicator 50 100 mm 1 97 3 94 in Measure max wear 30 mm 1 18 in from block surfa ce Measure min wear at lower turning point of piston See specifications on page 3 for diameter of new parts Calculate piston clearance Example Cylinder bore measured diameter min 91 010 max 91 035 Piston diameter measured 90 085 90 985 Piston clearances sais iin VE ER N NEEN EA min 0 025 max 0 050 Piston clearance for new parts B 27 Demolin piston 0 090 0 110 mm 0 0035 0 0043 in Mahis Steg es geg a See S 0 020 0 040 mm 0 0008 0 0016 in B28 Mahle piston 0 020 0 040 mm 0 0008 0 0016 in If clearance is too large replace liners piston and gud geon pin These parts are matched and can only be pur chased in kits of six Remove liner if piston liner is to be replaced Proceed to IT C5 Clean mating surface on cylinder block and liner Use a plastic putty knife to avoid damage C6 Mark position of cylinder liner before remov
26. et FLYWHEEL CLUTCH CARRIER PLATE install flywheel manual install carrier plate automatic Flywheel carrier plate can only be installed in one posi tion since bolt holes are asymmetrically located Use new bolts Torque to 45 50 Nm 33 37 ft lbs Use locking sector 5112 to lock the flywheel Auto Note position of support plates Inner plate sho uld be turned with bevel forwards D35 install clutch driven plate and pressure plate Turn the plate so that the hub faces outwards away from the flywheel Different centering drifts for different types of gearbox es M50 51 drift 5113 M45 46 early type drift 2484 M45 46 late type drift 5111 Tighten pressure plate retaining screws crosswise a few turns at a time to avoid distorting the plate 45 Group 21 Reconditioning engine Cylinder head reconditioning 46 E Cylinder head reconditioning tt 860 VU EA EI Remove all parts from cylinder head Take care not to score damage the mating surfaces Note Do not interchange valve parts E2 Clean cylinder head and parts Remove carbon deposits from the combustion cham bers and valves Clean valve seats with a grinder to be able to see cracks damage etc Clean gasket mating surfaces Use a plastic scraper and if necessary a fine grade wet abrasive paper E3 Check all parts Visible damage wear etc E4 Check cylinder head for warp Use a straight edge and fee
27. etween the valve seat and recess in the cylinder head must be 0 070 0 134 mm 0 0027 0 0052 in e the valve seat must be 0 070 0 134 mm larger than the recess in the cylinder head If too small fit a new cylinder head If too large mill the valve seat to correct size Use a valve cutter E18 Heat up cylinder head Approx 100 C 212 F 49 Group 21 Reconditioning engine Cylinder head reconditioning E19 Place new valve seat in correct assembly tool Use 5029 for intake seats and 5220 for exhaust seats E20 Cool valve seat to 70 C Last Use liquid carbon dioxide or equivalent Wear protective gloves and safety glasses E21 Tap in valve seat Note This must be done quickly within 3 4 seconds to avoid temperature loss E22 Check fit of valve seat Make sure that the seat has bottomed correctly and is secure If not fit a larger size After valve seat replacement valve seats must be milled and valves ground Grinding of valves and valve seats Operations E23 24 E23 Machine grind valves Intake valves 29 5 Exhaust valves 44 5 Also grind flush the end of the valve stem E24 Mill or grind valve seats Check valve fit If necessary grind in valves with grinding paste 1 7 2 1 mm i 1 3 1 7 mm 2 0 2 4 mm 0 0669 0 0826 in 0 051 1 0 0669 in 0 0787 0 0944 in Ee KA Intake valve seat Intake valve seat Exhaust valve seat Early types Late types venturi sea
28. hle pistons 5128 Piston support used when pressing out gud geon pin with large bore 6129 Piston support used when pressing in qud geon pin Make sure correct piston is installed B 27 engines Demolin or Mahle pistons B 28 engines Mahle pistons ect TV Group 21 Reconditioning engine Cleaning checking C23 Press out gudgeon piston pin Assemble support tool Use piston support 5092 5 for 5092 3 Demolin pistons and 5128 for Mahle pistons Note that support 5092 2 must be turned different ways for different pistons Pasition piston with connecting rod and cap but with out bearing shells in support Arrow on top of piston must point up Press out gudgeon pin Use drift 5092 3 Pistons 1 2 and 3 Pistons 4 5 and 6 Connecting rods Connecting rods marked B D and F marked A C and E or 2 4 and 6 or1 3and5 C24 Check connecting rods Use an alignment gauge Check out of true twist S form Check bolt threads and replace if necessary see C10 11 C25 Heat connecting rods Install caps on connecting rods but not bearing shells Thera should be approx 1 mm 0 04 clearance be tween connecting rod and cap Place small end on heater and heat to approx 250 C 480 F 33 Group 21 Reconditioning engine Cleaning checking C26 Place piston support and piston in holder 5092 1 Use 5092 6 for Demolin pistons and 5129 for Mahle pis tons Arrow on top of piston mus
29. ill the hole Use tap 998 5823 5 Re cut old threads only Do not cut further into cylinder head Spark plug bore must not be threaded along entire length Screw in thread insert P N 948756 2 Combination tap Tap section Reamer section Guide 16 Group 21 Reconditioning engine Thread repairs Installing thread inserts Thread depth Drilling depth Cc e Drilling depth AG Select drill size tap and insert Measure length and thread of old hole A7 Tap hole NOTE Special instructions for spark plug holes see page 16 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 fully cut screw thread along its entire length Clean the hole A8 Assemble installation tool M6 M14 threads fit correct mandrel and crank in in stallation tool 998 5830 0 M16 and coarser threads use the prescribed complete installation tool Group 21 Reconditioning engine Thread repairs 18 WE HEEN 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 pressing screw the thread insert into the mandrel until the first thread of the insert is flush with the opening of the mandrel A10 Install thread insert Hold the tool vertica
30. inder head gasket and cylinder head First remove liner holder 5093 and then the protective paper in the water passages Note Different gaskets for right and left cylinder heads F4 Set camshaft Left side groove in camshaft must point up and No 1 rocker arms should have clearance Right side groove in camshaft must point out and down Gi X w Fomm Nk 1218127 7 7 aan Early type Late type Engine number Engine number B27A 11374 11375 B27 E F 57276 57277 828 A E F All Ee Sp Se Se S ei 1 _ 3 teat liecas 76 ep G e e i e_ een Group 21 Reconditioning engine Assembly F5 Install rocker arm assembly Use the correct bridge on the right and left sides Brid ges are the same but must face different directions left side circlip must face forwards and right side circlip must face rearwards F6 Clean lubricate and install cylinder head bolts Remove 3 mm drill beneath guide sleeves Tighten bolts by hand Two different types of cylinder head bolts are in use de pending on the thread length in the cylinder block Late type bolt thread length 27 mm 1 063 in with was her Early type bolt thread length 30 mm 1 181 in without washer Only late type bolts are available as spare parts If late type bolts are used on early type cylinder heads washers must be used the same washers as used for late type bolts F7 Tighten cylinder head bolts
31. ing 5128 5129 oe 5092 1 5092 2 5092 3 5092 4 5092 5 5092 6 NEG Demolin Mahle 32 Replacing piston or connecting rod Operations C20 29 C20 General Pistons connecting rods should only be disassembled when replacing pistons liners Once a piston has been removed it may not be used again This is because the piston is deformed when the gudgeon piston pin is removed If a connecting rod is to be removed it is not necessary to disassemble the piston connecting rod since new connecting rods and pistons must be used Liner piston gudgeon pin are supplied in matched sets six Connecting rods are supplied in kits of six Note that all six connecting rods must be replaced at the same time IMPORTANT B 27 E 1975 Engine types 498354 and 498356 up to and incl engine no 7630 Exchange engine 1218098 The above engines may be equipped with early type crankshafts and connecting rods Only parts of the same type may be used together C21 Tools required to replace piston or connecting rod 5092 1 Holder 5092 2 Connecting rod support for big end 5092 3 Drift to press out gudgeon pin also used as handle to press in pin 5092 4 Guide pin used to press in gudgeon pin Additional tools required for Demolin pistons 5092 5 Piston support used when pressing out gud geon pin with large bore 5092 6 Piston support used when pressing in gud geon pin Additional tools required for Ma
32. ing liner Mark position and number of each liner Do not scratch surface 27 Group 21 Reconditioning engine Cleaning checking 8 H C7 Clean and check cylinder liners piston and con rods Clean cylinder bores to remove bright surfaces Remove piston rings with piston ring pliers Scrape out piston ring grooves Check for damage wear cracks out of round gudgeon pin bores threads on connecting rod bolts cs Measure axial play of piston rings Use a feeler gauge Axial clearance new rings upper compression ring 0 045 0 074 mm 0 0018 0 0029 in lower compression ring 0 025 0 054 mm 0 0010 0 0021 in oil scraper ring fitted 0 009 0 233 mm 0 0004 0 0092 in c9 Measure piston ring gap Insert piston ring in bore one at a time Use an inverted piston to ensure that rings take up correct position Measure gap with ring 15 mm 0 6 in from lower edge Use a feeler gauge Piston ring gap new parts measured in 88 mm 3 4646 in B 27 or 91 mm 3 5826 in B 28 cylinder diame ter upper and lower compression rings 0 40 0 58 mm 0 0157 0 0228 in ON Sapar Pi a SEENEN 0 38 1 43 mm 0 0150 0 0563 in 28 Replacing damaged connecting rod boit Operations C10 11 c10 Hammer out old bolt Remove bearing cap and shells Mount connecting rod in vice protected by soft jaws Tap out bolt with a plastic mallet Hold
33. ked 1 A rmarked piston 88 00 88 01 mm 91 00 91 01 mm 3 4646 3 4650 in 3 5826 3 5830 in 2 B marked piston 88 01 88 02 mm 91 01 91 02 mm 3 4650 3 4654 in 3 5830 3 5835 in 3 C marked piston 88 02 88 03 mm 91 02 91 03 mm 3 4654 3 4657 in 3 5835 3 5838 in Liner height above block face 0c eee c eee reeves 0 16 0 23 mm 0 0063 0 009 in Shims for adjustment of liner height thickness blue paint Marking seers rib onesosnpenoserersts 0 070 0 105 mm 0 0027 0 0041 in white paint marking 00 0 0 sastati aats iet asro 0 085 0 120 mm 0 0033 0 0047 in red paint marking isrs sissirsisdssrsssrai 0 105 0 140 mm 0 0041 0 0055 in yellow paint marking Sct RAKES 0 130 0 165 mm 0 0051 0 0064 in PISTONS Pistons for B 27 Pistons and liners are matched sets Two different manufacturers supply pistons see next page for specifications Demolin Mahle Group 21 Reconditioning engine Specifications DEMOLIN PISTONS B 27 B27A 1976 1979 B27E 1975 1978 BZF HIE Ee Ee 1976 1978 Height OVOIGE sos rors cons sau e E A Meese eee HEN 74 mm 2 9134 in 63 4 mm 2 9960 in from gudgeon pin centre to piston crown 40 mm 1 5748 in 39 4 mm 1 5512 in WERNER EE KREE KREE AUER ECKE 4453 gram Max weight difference between pistons in same engine 6 gram PEGG EE THOSE D lte een WEE Een 0 080 0 110 mm 0 0035 0 0043 in Piston dia
34. l mounting is fitted When replacing this type with a late type chain damper late type screws washers and spacers must be fitted In addition two faces on the timing gear case must be ground to make space for the new wider dampers One face must be ground down by 5 mm and the other flush C32 Clean check chain tensioners and chain dam pers Important Do not disassemble tensioners H locking pin falis out complete tensioner must be replaced Check that oilways in chain tensioners do not leak Check dampers for damage and wear Replace parts as necessary 35 Group 21 Reconditioning engine Cleaning checking D es eo Clean check chains and sprockets Check for damage and wear IMPORTANT If damaged replace chains and sprockets to gether Also replace oil strainers behind tensioners C34 Clean check flywheel man gearbox and carrier plate auto Carrier plate with ring gear must be replaced as one unit Damaged or worn flywheel must be replaced with ring gear attached Ring gears can be replaced separately New flywheels are rustproofed and should be washed degreased prior to assembly want 36 Replacing ring gear Operations C35 39 C35 Heat new ring gear to 230 C 446 F Heat in an oven or by oxyacetylene flame lf oven is to be used begin heating now With oxyace tylene heat just before installation C36 Drill hole between two cogs Use a 10 mm 0 4 in drill Hole de
35. ler gauge Warp max 0 05 mm 0 002 in per 100 mm 3 94 in The cylinder head must not be machined but instead replaced if the warp is too great Group 21 Reconditioning engine Cylinder head reconditioning ES Check camshaft end float Position the camshaft and make sure that it turns easi ly Fit the locking fork Measure the end float with a feeler gauge The clearance must not exceed max 0 5 mm 0 020 in Replace the locking fork if the end float is too large Remove the locking fork and camshaft Ee Check valve guide valve clearances Use a dial indicator Use new valves and press up 5 10 mm 0 2 0 4 in with finger when measuring The clearance must not exceed max 0 15 mm 0 0059 in E7 Check valve springs The springs are colour coded and two different types are used depending on engine type Colour Lenth Load code mm in N ibs 47 2 1 86 0 0 40 0 1 57 233 268 52 60 32 2 1 27 521 585 116 131 47 1 1 85 0 0 40 0 1 57 230 266 51 59 30 0 1 18 613 689 137 154 Valve guide replacement Operatons E814 E8 Press out valve guides Use drift 5218 Piace the cylinder head on a sloping surface so that the valve guides are vertical 47 Group 21 Reconditioning engine Cylinder head reconditioning E9 Select a new valve guide one size larger than old one The valve guides are marked with grooves Valve guide Mark Stand
36. lly above the centre of the hole Without pressing screw in the thread insert until the top thread of the insert is at least 1 2 a thread below the working surface 0 5 x pitch The insert must not be screwed in to the bottom otherwise it will not be pos sible to break off the tang All Break off tang M16 M12 threads use the tang breaker in the installa tion kit M14 and coarser threads use a pair of flat nosed pliers to break off the tang downwards Remove the tang from the hole Group 21 Reconditioning engine Thread repairs Removing thread repair inserts Al2 File groove in thread insert Using a triangular file make a groovein the top thread of the insert approx 1 4 of a thread from the end Take care not to damage the thread holding the insert A13 Remove thread insert Insert a sharp edge of a triangular scraper in the groove Press downwards and rotate anti clockwise until the in sert is removed A14 Fit new thread insert H S Clean the hole with a tap and fit a new insert H H 19 Group 21 Reconditioning engine Reconditioning engine Special tools 1426 1801 2484 2520 4090 5029 5092 5093 5096 5098 5099 5101 5103 5108 5109 111 5112 5128 5129 5165 5192 5218 5220 5953 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 mounted on universal stand 2520 with suppor
37. m bottom edge Diameter gudgeon pin bore Marking piston Marking gudgeon pin Blue BEE 23 510 mm 23 513 mm 0 9255 0 9257 in White MER sagt erry Seer re 23 507 23 510 mm 0 9254 0 9255 in Red E Ee 23 504 23 507 mm 0 9253 0 9254 in 4 Group 21 Reconditioning engine Pistons for B 28 Pistons and liners are matched sets Only Mahle pistons are in use Specifications 0 020 0 040 mm 0 0007 0 0015 in 0 970 90 980 mm 3 5814 3 5818 in 90 980 90 990 mm 3 5818 3 5822 in ET E 455 3 grams Max weight difference between pistons in same engine 6 grams Height overall A and F engines 62 8 mm 2 4724 in LI EE miaiciscemecr eects 65 3 mm 2 5709 in from gudgeon pin centre to piston crown Ap and Frongiriae asia ee et 38 8 mm 1 5276 in ane LL ek SA 41 3 mm 1 6260 in PRION HORE seis s ce sricesieseareer AT Piston diameter A marked ptetong eee er sees B marked pistons sert ETK RENE ESA ECH gie C marked pistong eee eee bore 8 mm 0 31 in from bottom edge Diameter gudgeon pin bore Marking piston Marking gudgeon pin Blue BHR ncn sneaeteRr ee I S EE White M tte wl Bed ROG E EE Piston rings Piston diameter is measured at right angles to gudgeon pin lower edge of cylinder Upper Lawer compression compression ring ring 1 478 1 490 1 978 1 990 9 0582 0 0587 0 0779 0 0783 Side clearance measured with ring on piston mm 0 045 0 074 0 025 0 054 in 0 0017 0 0
38. mbling the engine CRANKSHAFT D1 Install main bearing shells in engine block and main bearing cap Make sure that matched pairs are installed together Bearing cap at flywheel end is marked 1 Note The holes in the bearing shells must coincide with the oilways in the engine block Lubricate the bearing shells and studs D2 Locate crankshaft Lubricate bearings D3 Install thrust washer segments Lubricate washers Note the oilways in the two lower segments D4 Install rear main bearing cap with shells and hol der 5096 for main bearing Rear cap is marked 1 Identification number and casting lug on the bearing cap should face forwards Install cap holder and nuts Torque to 40 Nm 30 ft lbs Group 21 Reconditioning engine Assembly D5 Check crankshaft end float Move the crankshaft lengthwise back and forth and measure the clearance with a dial indicator End float a ees A 5 0 070 0 270 mm 0 0027 0 0106 Replace thrust washers if necessary Washers are avail able in the following sizes standard 2 30 2 35 mm 0 0905 0 0925 in OS MN NEE EES 2 40 2 45 mm 0 0944 0 0964 in e EH 2 45 2 50 mm 0 0964 0 0984 in Lo er een 2 50 2 55 mm 0 0984 0 1003 in D6 Install three remaining main bearing caps with shells Identification numbers 2 3 and 4 and the casting lugs on the caps must face forwards Secure front bearing cap with holder 5096 and install nuts on each of the
39. meter A marked pistons 5 5 4 5220008 87 900 87 910 mm 3 4606 3 4610 in B marked pistons 2 87 910 87 920 mm 3 4610 3 4614 in C marked pistons 2 2 0 04 ese e ee eens 87 920 87 930 mm 3 4614 3 4618 in Piston diameter is measured at right angles to gudgeon pin bore and 11 mm 0 43 in from lower edge of piston for B 27F om 1976 1978 8 5 mm 0 33 in from lower edge of oil scraper ring for other engines se Diameter gudgeon pin bore Marking piston Marking gudgeon pin 1 Blue rata E aon SEEM 23 514 23 517 mm 0 9257 0 9259 in 2 WDRO a d MN Eh 4 e HE 23 511 23 514 mm 0 9256 0 9257 in 3 TEE E 23 508 23 511 mm 0 9255 0 9256 in MAHLE PISTONS B 27 B27A 1976 1979 RIFE IRSCH ue ege Eeer 1979 1980 OSA eme gies 1976 1978 Herghtcverall aea ee AE Ee WTA aN 63 4 mm 62 2 mm 65 3 mm 2 4960 in 2 4488 in 2 5709 in NM from gudgeon pin centre to piston crown 39 4 mm 38 2 mm 41 3 mm 1 5521 in 1 5039 in 1 6260 in Met A ERASE AEE OL ISAT TORSTEN A Catt E EES E 445 3 gram Max weight difference between pistons in same engine 6 gram PRO KE en 0 020 0 040 mm 0 0008 0 0016 in A Piston diameter A marked pistons 00 00 0000 02 87 970 87 980 mm 3 4634 3 4638 in B marked WAONE d seer eer ee 87 980 87 990 mm 3 4638 3 4642 in C marked pistons 87 990 88 000 mm 3 4642 3 4646 in Piston diameter is measured at right angles to gudgeon pin bore 8 mm 0 31 in fro
40. piston to prevent damage Group 21 Reconditioning engine Cleaning checking cit Press in new bolt Position bearing cap observe identification marks Place a 12 mm socket beneath cap Press in bolt MIZ bolts EE M25 plug g oi pressure sender adapter for oil dipstick 15 20 Nm 11 15 ft lbs 30 40 Nm 22 30 ft lbs 40 45 Nm 29 33 ft lbs 30 40 Nm 22 30 ft bs 20 30 Nm 15 22 ft lbs C12 Clean and inspect cylinder block Remove all plugs before cleaning block Do not remove identification marks for cylinder liners when cleaning Clean sealing surfaces Use a plastic putty knife bearing seats oil and water channels cylinder head bolt holes Check for damage cracks and wear Also check threads on main bearing boits Re fit plugs using new seals Note Carry out operation C13 before installing block in fixture C13 Check guide pins for gearbox Guide pins must protrude 10 12 mm 0 39 0 47 in from cylinder block lf tubular pins are fitted replace these with solid type P N 1232544 5 Secure pins with locking fluid 29 Group 21 Reconditioning engine Cleaning checking mim C14 Check overflow valve in cylinder block Two types are in use early type without filter late type with filter Early type valves must be replaced with new type heen Overflow valve replacement Ope
41. pth 9 mm 0 385 in IMPORTANT Do not drill into flywheel since it may become out of balance Group 21 Reconditioning engine Cleaning checking C37 Remove ring gear Mount the flywheel in a vice protected by soft jaws Lever off ring gear with a screwdriver It may be neces Sary to split the ring gear above the drilled hole Clean mating surfaces on flywheel C38 Heat new ring gear to approx 230 C 446 F Check temperature with solder 40 tin 60 lead Sol der melts at 220 230 C 428 446 F Install new ring gear Position ring gear IMPORTANT Bevelled side of ring gear must face fly wheel If necessary tap ring gear until flush Use a brass drift Leave to cool ee C40 Clean and inspect oil pump Disassemble and clean oil pump Check for damage and wear and also that relief valve plunger runs smoothly Check that axle is firmly secured to cylinder block Test relief valve in a spring tester Replacement oil pumps are only available as complete units pump body cover gears and relief valve Spare parts for the relief valve are however available Re assemble pump ON 88 3 N 19 7 Ibs C41 Clean and check parts 56 5 60 5 mm 2 22 2 38 in Oil strainer sump lower crankcase valve covers and 3 52 in timing gear case 37 Group 21 Reconditioning engine Assembly 38 D Engine assembly Always use new seals O rings and gaskets when asse
42. rations C15 17 C15 Remove old valve and clean seat Use a screwdriver Important Take care not to damage the oil filter mating surfaces and make sure that dirt does not enter the oil ways C16 install new parts Install valve with spring facing inwards C17 Tap in washer and secure it Use an 11 mm inner diameter socket Secure washer by making three notches in block with a drift 30 Group 21 Reconditioning engine Cleaning checking C18 Clean and check crankshaft main bearing caps and main bearings Clean oilways in crankshaft with a piece of wire and blow clean Also check sealing surfaces on crankshaft IMPORTANT Do not interchange bearing caps and shells Y am c19 Measure crankshaft Measure out of roundness and taper of crank pins Use a micrometer and take measurements at several diffe rent positions Max out otroungd essiri 0 007 mm 0 0003 Was Rm e NEEN IEN rts 0 01 mm 0 0004 Crank pins can be ground to a smaller size see speci fications on page 9 H crankshaft is thought to be out of true check with a dial indicator Support crankshaft by two outer main bearings on a V block Rotate one turn and measure out of true for two centre crank pins Out of true max 0 02 mm 0 0008 in IMPORTANT B 27 E 1975 models may be fitted with early type crankshafts see C20 ae Taper Out of round 31 Group 21 Reconditioning engine Cleaning check
43. rocket Place the chain on the camshaft sprocket with the mark on the sprocket between the two marks on the chain Place the chain on the inner crankshaft sprocket with the mark on the chain opposite the mark on the sprock et Stretch the chain on the pulling side the side against the straight chain damper Position the camshaft sprocket Make sure that the sprocket fits in the groove in the camshaft Install the centre bolt F14 Set crankshaft and right hand camshaft install the crankshaft nut Turn the crankshaft clockwise so that the key points directly downwards The groove in the camshaft should point outwards see fig and there should be no clearance between the rock er arms and valve stem tops for No 6 cylinder F15 Install right hand camshaft chain and sprocket Place the chain on the camshaft sprocket with the mark on the sprocket between the two marks on the chain Place the chain on the camshaft sprocket with the mark on the chain opposite the mark on the sprocket Stretch the chain on the pulling the side against the straight chain damper Install the camshaft sprocket Make sure that the sprock et fits in the groove in the camshaft If necessary rotate the crankshaft slightly Install the centre bolt F16 Tighten both camshaft centre bolts Tighten to a torque of 70 90 Nm 52 66 ft lbs Use a screwdriver as a counterhold placing it between two cogs on the sprocket without holes e 5
44. sure at points 1 2 3 and 4 as illustrated Difference between 1 and 2 and 3 and 4 must not ex ceed max 0 04 mm 0 0016 Exchange shims if necessary and re measure according to D17 If new liners are used and difference is too large rotate liners or change positions and re measure 019 Measure liner deck height for 2nd cylinder bank Follow D17 18 Then transfer the two outer holders to the 1st cylinder bank PISTONS CONNECTING RODS Cylinder Marking of connecting rod and cap Crank webs from rear Group 21 Reconditioning engine Assembly D20 bearing shells in connecting rods and D21 Turn piston rings so that gaps are not in line Note position of oil ring gap D22 Lubricate bearing shells cylinder bores pistons D23 Install piston Use a piston ring compressor tool IMPORTANT Arrow on top of piston must point for wards D24 Install connecting rod cap Use new nuts lubricate mating surface Torque to 45 50 Nm 33 37 ft lbs Check that crankshaft can be rotated IMPORTANT Marks on connecting rod and cap must match Bearing gap should point rearwards for cylinder 1 2 and 3 forwards for cylinders 3 5 and 6 LOWER CRANKCASE SUMP D25 Check if crankcase is early or late type Late type crankcases are fitted with a collar to prevent the sleeve in the oil channel from falling down into the sump For early type crankeases install a new sleeve
45. t 15 and 60 are correct angles to reduce seat width 50 Oilway in shaft points downwards The fiat face must be turned towards the circlip snap ring groove Applies to all four rocker shaft supports A thin spacer B thick spacer Group 21 Reconditioning engine Cylinder head reconditioning E25 Assemble cylinder head Use drift 5218 for valve guide seals Use new gaskets The locking fork should be loosely fitted and not tou ching the camshaft Before fitting check that the spark plugs are clean re place if necessary Electrode gap 0 6 mm 0 024 in Tightening torque 12 2 Nm 9 1 5 ft lbs E26 Clean and check rocker arm shaft Disassemble only if necessary Place parts in order so that they can be re assembled in the same position The clearance between the rocker arm and shaft is for new parts 0 012 0 054 mm 0 0005 0 0021 in IMPORTANT The rocker arm contact surface on the camshaft is face hardened and must not be ground 51 Group 21 Reconditioning engine Assembly F Engine 135 745 52 assembly CYLINDER HEAD Install cylinder heads one at a time i e perform operations F1 7 separately for each cylinder head F1 Turn crankshaft to TDC for cyl 1 F2 install guide sleeves in cylinder block Secure the sleeves with e g a 3 mm drill This prevents the sleeves from being forced down when the cylinder head is fitted F3 Install cyl
46. t 5099 20 Group 21 Reconditioning engine Disassembly B Engine disassembly B1 TIMING GEARS Remove crankshaft pulley 36 mm socket Use locking sector 5112 to prevent engine from rotat ing Pulley key must point upwards when pulley is removed otherwise it will drop into crankcase B2 Remove valve covers timing gear case seal from timing gear case Cover holes in crankcase with e g paper to prevent dirt from entering B3 Check chain wear Check position of belt tensioners If tensioner pin pro trudes by 4 or more notches 8 mm 0 32 chains should be renewed IMPORTANT If chains are replaced sprockets and oil strai ners must also be replaced 21 Group 21 Reconditioning engine Disassembly Slacken camshafts centre bolts Allen key 10 mm If necessary prevent sprocket from rotating with a screwdriver BS Slacken timing gear chains Turn each lock 1 4 turn anti clockwise and push in pis ton B6 Remove oil pump sprocket and chain chain tensioners and oil strainers see arrows bent and straight chain dampers camshaft sprockets and chains e B7 Remove oil pump with sprocket outer sprocket spacer sleeve early type and key inner sprocket and key If necessary use a puller to remove sprockets 22 Group 21 Reconditioning engine Disassembly CYLINDER HEAD Remove rocker arms Mark left and right rocker
47. t point up C27 Piace gudgeon piston pin in tool Immerse in oil C28 Place connecting rod support and connecting rod in holder IMPORTANT Connecting rod support and connecting rod must be turned in different directions for different pistons connecting rods Gudgeon pin must be pressed in immediately Operation C29 otherwise it may jam halfway Pistons 1 2 and 3 Pistons 4 5 and 6 Connecting rods Connecting rods marked B D and F marked A C and E or 2 4 and amp or 1 3and5 Marked 1 2 3 Marked a 5092 2 5092 2 C29 Press in gudgeon piston pin Quickly press down drift by hand until it contacts sup port tool Lift away piston with connecting rod from holder Re move drift and guide pin from gudgeon pin 34 Grind down 5 mm 0 20 in Grind flush thee Group 21 Reconditioning engine Cleaning checking C30 Install piston rings Note position of oil ring gap C31 Check if chain dampers and tensioners are of ear ly or late type Early types must be replaced with new ones IMPORTANT Late type chain tensioners may only be used with late type chain dampers Early type Late type 1 bent chain damper without oilway with oilway 2 chain tensioner 04mm Oz 1 2 mm 0 016 0 047 3 straight chain TEE L 174mm Las 220 mm 6 85 8 66 IMPORTANT On 8 27 engines manufactured up to approx middle of 1976 a bent chain damper with a smal
48. tallation ee F3 22 Cylinder head 35 E DEET B8 11 35 disassembly AOT E E1 54 cleaning checking E2 3 WED Casale TEE dE E4 25 ENUN EE E25 45 bolts different types F6 e EEN Fi 9 24 bolts tightening F7 9 43 Flywheel EE U ITEE TEES OE B18 24 inspection ves 24 ring gear replacement C35 39 28 installation 0 D34 23 Gudgeon pins 28 33 Geng eegen c7 32 reMOval PR C23 32 installation 25 29 43 Lower crankcase D EN oie Ee ITT B12 25 INSBNOHON uereg 025 32 39 Main bearings 21 Eed Eege B19 57 E e OOPP S ege ene D1 6 TT EE D4 5 21 nuts tightening D29 31 57 Oil pump P oann a e 87 25 cleaning checking c40 31 EESE ET F19 32 Oil strainer 38 e H NN B12 38 installation 0 033 29 Page Opera tion Overflow relief valve in cylinder block checking different types C14 replacement NEEN C15 17 Pilot bearing manual TEE B18 Weta RON e erte NEE caine D9 Piston pins see Gudgeon pins Piston rings POMOVEl WE C7 BOA Olay aise CR e EE cg installation C30 Pistons SCHEI ut Mee eebe ee Ae B15 16 types manufacturer Ci 2 diamati 0 55 56 i sae RES c3 TT POENE E C4 C7 replacement C20 29 Ise ES ited ek D20 24 Pressure plate IMMNOVEl EE B18 AOE ae 035 Ring gear replacement ssns i C35 39 Rocker arms RNA

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