Workshop Manual C

Engine Unit 2(0)

AQ125A, B
AQ145A, B
 Contents

Safety Precautions ............................................................................................................. 2

General Information ........................................................................................................... 5
Repair Instructions ............................................................................................................ 6
Presentation ....................................................................................................................... 8

Repair Instructions
Disassembling, Overhauling and Inspection
Electrical parts, carburetor ...................................................................................................9
Heating exchanger, exhaust pipe, oil filter .................................................................. 10–11
Oil cooler, sea water pump ............................................................................................... 12
Circulation pump, belt pulley, marking the timing belt ...................................................... 13
Belt tensioner, intermediate pulley, camshaft pulley ......................................................... 14
Sealing flange, flywheel cover .......................................................................................... 15
Vibration damper, intermediate shaft ................................................................................ 16
Camshaft ........................................................................................................................... 16
Cylinder head valves .................................................................................................. 16–18
Valve seats, guides, springs, pushers ........................................................................ 19–22
Flywheel, sealing .............................................................................................................. 22
Lubricating oil pump, pistons, crankshaft .................................................................... 23–24

Cylinders, pistons, connecting rods, crankshaft .......................................................... 25–28

Fuel pump, oil cooler, lubricating oil pump ................................................................. 28–30

Heat exchanger, carburetor, flywheel cover ................................................................ 31–33

Assembling
Crankshaft, pistons, lubrication oil pump, flywheel ..................................................... 33–35
Oil sump, cylinder head, camshaft .............................................................................. 36–37
Intermediate shaft, seals, camshaft gear wheel .......................................................... 38–39
Intermediate gear, marking, timing belt ....................................................................... 40–42
Oil pump drive, circulation pump, valve adjustment .................................................... 42–46
Distributor, oil cooler, exhaust pipe, heat exchanger .................................................. 46–48
Lubrication oil filter, sea water pump, expansion tank ................................................ 48–49
Thermostat sea water strainer, alternator .................................................................... 49–50
Starter motor, induction pipe, carburetor ..................................................................... 50–51

Electric wiring diagram ................................................................................................... 52

Fault finding chart ........................................................................................................... 53

Special tools .............................................................................................................. 54–55

Technical data AQ125A, AQ145A ............................................................................ 56–60

Valve adjusting kit ........................................................................................................... 61

Technical data AQ125B, AQ145B ............................................................................ 62–68

1
Safety Precautions
Introduction
Check that the warning or information decals
This Workshop Manual contains technical data, de-
on the product are always clearly visible. Re-
scriptions and repair instructions for Volvo Penta
place decals that have been damaged or paint-
products or product versions contained in the con-
ed over.
tents list. Ensure that the correct workshop litera-
ture is being used.
Read the safety information and the Workshop
Manual “General Information” and “Repair In- Never use start spray or similar to start the
structions” carefully before starting work. engine. The starter element may cause an ex-
plosion in the inlet manifold. Danger of person-
al injury.
Important
In this book and on the engine you will find the fol-
lowing special warning symbols.
Avoid opening the filler cap for engine coolant
WARNING! If these instructions are not fol- system (freshwater cooled engines) when the
lowed there is a danger of personal injury, ex- engine is still hot. Steam or hot coolant can
tensive damage to the product or serious me- spray out. Open the coolant filler cap carefully
chanical malfunction. and slowly to release pressure before remov-
ing the cap completely. Take great care if a
IMPORTANT! Used to draw your attention to cock, plug or engine coolant line must be re-
something that can cause damage, product moved from a hot engine. It is difficult to anti-
malfunction or damage to property. cipate in which direction steam or hot coolant
can spray out.
NOTE! Used to draw your attention to important infor
mation that will facilitate work or operations.

Hot oil can cause burns. Avoid skin contact

Below is a summary of the risks and safety precau- with hot oil. Ensure that the lubrication system
tions you should always observe or carry out when is not under pressure before commencing
operating or servicing the engine. work on it. Never start or operate the engine
with the oil filler cap removed, otherwise oil
Immobilize the engine by turning off the power could be ejected.
supply to the engine at the main switch
(switches) and lock it (them) in the OFF posi-
tion before starting work. Set up a warning no-
tice at the engine control point or helm. Stop the engine and close the sea cock before
carrying out operations on the engine cooling
Generally, all servicing should be carried out system.
with the engine switched off. Some work (car-
rying out certain adjustments for example) re-
quires the engine to be running. Approaching
a running engine is dangerous. Loose clothing Only start the engine in a well-ventilated area.
or long hair can fasten in rotating parts and If operating the engine in an enclosed space,
cause serious personal injury. ensure that exhaust gases and crankcase
If working in proximity to a running engine, ventilation emissions are ventilated out of the
careless movements or a dropped tool can re- working area.
sult in personal injury. Avoid burns. Take pre-
cautions to avoid hot surfaces (exhausts, tur-
bochargers, charge air pipes and starter
elements etc.) and liquids in supply lines and Always use protective goggles where there is
a danger of pieces of metal, sparks from
hoses when the engine is running or has been
grinding, acid or other chemicals being thrown
turned off immediately prior to starting work
into your eyes. Your eyes are very sensitive,
on it. Reinstall all protective parts removed
injury can lead to loss of sight!
during service operations before starting the
engine.

2
Avoid skin contact with oil. Long-term or re- Never allow a naked flame or electric sparks
peated contact with oil can remove the natural near the batteries. Never smoke in proximity
oils from your skin. The result can be irrita- to the batteries. The batteries give off hydro-
tion, dry skin, eczema and other skin prob- gen gas during charging which when mixed
lems. Used oil is more dangerous to health with air can form an explosive gas – oxyhy-
than new oil. Use protective gloves and avoid drogen. This gas is easily ignited and highly
using oil-soaked clothes and rags. Wash regu- volatile. Incorrect connection of the battery
larly, especially before meals. Use the correct can cause a spark which is sufficient to cause
barrier cream to prevent dry skin and to make an explosion with resulting damage. Do not
cleaning your skin easier. disturb battery connections when starting the
engine (spark risk) and do not lean over bat-
Most chemicals used in products (engine and teries.
transmission oils, glycol, petrol and diesel oil)
and workshop chemicals (solvents and paints) Never mix up the positive and negative bat-
are hazardous to health Read the instructions tery terminals when installing. Incorrect instal-
on the product packaging carefully! Always lation can result in serious damage to electri-
follow safety instructions (using breathing cal equipment. Refer to wiring diagrams.
apparatus, protective goggles and gloves for
example). Ensure that other personnel are not Always use protective goggles when charging
unwittingly exposed to hazardous substances and handling batteries. The battery electrolyte
(by breathing them in for example). Ensure contains extremely corrosive sulfuric acid. If
that ventilation is good. Handle used and ex- this comes into contact with the skin, wash
cess chemicals according to instructions. immediately with soap and plenty of water. If
battery acid comes into contact with the eyes,
All fuels and many chemicals are inflammable. immediately flush with copious amounts of
Ensure that a naked flame or sparks cannot water and obtain medical assistance.
ignite fuel or chemicals. Combined with air in
certain ratios, petrol, some solvents and hy- Turn off the engine and turn off power at main
drogen from batteries are easily inflammable switch(es) before carrying out work on the
and explosive. Smoking is prohibited! Ensure electrical system.
that ventilation is good and that the necessary
safety precautions have been taken before Use the lifting eyes mounted on the engine/re-
carrying out welding or grinding work. Always verse gear when lifting the drive unit.
have a fire extinguisher to hand in the work- Always check that lifting equipment is in good
place. condition and has sufficient load capacity to
lift the engine (engine weight including reverse
Store oil and fuel-soaked rags and fuel and oil gear and any extra equipment installed).
filters safely. In certain conditions oil-soaked
rags can spontaneously ignite. Used fuel and To ensure safe handling and to avoid damag-
oil filters are environmentally dangerous waste ing engine components on top of the engine,
and must be deposited at an approved site for use a lifting beam to raise the engine. All
destruction together with used lubricating oil, chains and cables should run parallel to each
contaminated fuel, paint remnants, solvent, other and as perpendicular as possible in rela-
degreasing agents and waste from washing tion to the top of the engine.
parts.
If extra equipment is installed on the engine
altering its center of gravity, a special lifting
device is required to achieve the correct bal-
ance for safe handling.

Never carry out work on an engine suspended

on a hoist.

3
 Never remove heavy components alone, even Always use fuels recommended by Volvo Pen-
where secure lifting equipment such as se- ta. Refer to the Instruction Book. The use of
cured blocks are being used. Even where lift- lower quality fuels can damage the engine. On
ing equipment is being used it is best to carry a diesel engine poor quality fuel can cause the
out the work with two people; one to operate control rod to seize and the engine to overrev
the lifting equipment and the other to ensure with the resulting risk of damage to the engine
that components are not trapped and damaged and personal injury. Poor fuel quality can also
when being lifted. When working on-board en- lead to higher maintenance costs.
sure that there is sufficient space to remove
components without danger of injury or dam-
age.

Components in the electrical system, ignition

system (gasoline engines) and fuel system on
Volvo Penta products are designed and con-
structed to minimize the risk of fire and explo-
sion. The engine must not be run in areas
where there are explosive materials.

4
General information
About the workshop manual
This workshop manual contains technical specifi-
cation, descriptions and instructions for repairing
the standard versions of the following engines
AQ125A, B – AQ145A, B. The workshop manual
displays the operations carried out on any of the
engines above. As a result the illustrations and pic-
tures in the manual that show certain parts on the
engines, do not in some cases apply to all the en-
gines listed above. However the repair and service
operations described are the same in all essential
details. Where they are not the same this is stated
in the manual and where the difference is consider-
able the operations are described separately. En-
gine designations and numbers are given on the
number plate. The engine designation and number
should be given in all correspondence about the en-
gine.
This Workshop Manual has been developed primari-
ly for Volvo Penta service workshops and qualified
personnel. Persons using this book are assumed to
have a grounding in marine drive systems and be
able to carry out related mechanical and electrical
work.
Volvo Penta is continuously developing their prod-
ucts. We therefore reserve the right to make chang-
es. All the information contained in this book is
based on product data available at the time of going
to print. Any essential changes or modifications in-
troduced into production or updated or revised ser-
vice methods introduced after the date of publica-
tion will be provided in the form of Service Bulletins.

Replacement parts
Replacement parts for electrical and fuel systems
are subject to statutory requirements (US Coast
Guard Safety Regulations for example). Volvo Pen-
ta Genuine parts meet these requirements. Any
type of damage which results from the use of non-
original Volvo Penta replacement parts for the prod-
uct will not be covered under any warranty provided
by Volvo Penta.

5
Repair instructions
The working methods described in the Service Man-
Our joint responsibility
ual apply to work carried out in a workshop. The en-
gine has been removed from the boat and is in- Each engine consists of many connected systems
stalled in an engine fixture. Unless otherwise stated and components. If a component deviates from its
reconditioning work which can be carried out with technical specification the environmental impact of
the engine in place follows the same working an otherwise good engine may be increased signi-
method. ficantly. It is therefore vital that wear tolerances are
Warning symbols occurring in the Workshop Man- maintained, that systems that can be adjusted are
ual (for their meaning see Safety information) adjusted properly and that Volvo Penta Genuine
Parts as used. The engine Maintenance Schedule
WARNING! must be followed.
Some systems, such as the components in the fuel
IMPORTANT! system, require special expertise and special test-
ing equipment for service and maintenance. Some
NOTE! components are sealed at the factory for environ-
are not in any way comprehensive since it is mental reasons. No work should be carried out on
impossible to predict every circumstance under sealed components except by authorized personnel.
which service work or repairs may be carried out. Bear in mind that most chemicals used on boats are
For this reason we can only highlight the risks that harmful to the environment if used incorrectly. Vol-
can arise when work is carried out incorrectly in a vo Penta recommends the use of biodegradable de-
well-equipped workshop using working methods and greasing agents for cleaning engine components,
tools developed by us. unless otherwise stated in a workshop manual.
All procedures for which there are Volvo Penta spe- Take special care when working on-board, that oil
cial tools in this Workshop Manual are carried out and waste is taken for destruction and is not acci-
using these. Special tools are developed to rational- dentally pumped into the environment with bilge wa-
ize working methods and make procedures as safe ter.
as possible. It is therefore the responsibility of any
person using tools or working methods other than
the ones recommended by us to ensure that there is
Tightening torques
no danger of injury, damage or malfunction resulting
from these. Tightening torques for vital joints that must be
In some cases there may be special safety precau- tightened with a torque wrench are listed in work-
tions and instructions for the use of tools and chem- shop manual “Technical Data”: “Tightening Torques”
icals contained in this Workshop Manual. These and are contained in work descriptions in this Man-
special instructions should always be followed if ual. All torques apply for cleaned threads, screw
there are no separate instructions in the Workshop heads and mating surfaces. Torques apply for light-
Manual. ly oiled or dry threads. If lubricants, locking fluid or
sealing compound are required for a screwed joint
Certain elementary precautions and common sense
this information will be contained in the work de-
can prevent most risks arising. A clean workplace
scription and in “Tightening Torques” Where no
and engine eliminates much of the danger of injury
tightening torque is stated for a joint use the general
and malfunction.
tightening torques according to the tables below.
It is of the greatest importance that no dirt or for- The tightening torques stated are a guide and the
eign particles get into the fuel system, lubrication joint does not have to be tightened using a torque
system, intake system, turbocharger, bearings and wrench.
seals when they are being worked on. The result
can be malfunction or a shorter operational life. Dimension Tightening Torques
Nm lbt.ft
M5 6 4.4
M6 10 7.4
M8 25 18.4
M10 50 36.9
M12 80 59.0
M14 140 103.3

6
Tightening torques-protractor (angle) In this Volvo Penta Service Manual the user will find
that each section where these agents are applied in
tightening
production states which type was used on the en-
Tightening using both a torque set- gine.
ting and a protractor angle requires During service operations use the same agent or an
that first the recommended torque is alternative from a different manufacturer.
applied using a torque wrench and
then the recommended angle is add- Make sure that mating surfaces are dry and free
ed according to the protractor scale. from oil, grease, paint and anti-corrosion agent be-
Example: a 90° protractor tightening fore applying sealant or locking fluid. Always follow
means that the joint is tightened a the manufacturer’s instructions for use regarding;
further 1/4 turn in one operation af- temperature range, curing time and any other in-
ter the stated tightening torque has structions for the product.
been applied. Two different basic types of agent are used on the
engine and these are:
RTV agent (Room temperature vulcanizing). Use for
gaskets, sealing gasket joints or coating gaskets.
Locknuts
RTV agent is clearly visible when a component has
Do not re-use lock nuts that have been removed been dismantled; old RTV must be removed before
during dismantling as they have reduced service life the joint is resealed. Old sealant can be removed
when re-used - use new nuts when assembling or using methylated spirits in all cases.
reinstalling. For lock nuts with a plastic insert such Anaerobic agents. These agents cure in an absence
as Nylock® the tightening torque stated in the table of air. They are used when two solid parts, for ex-
is reduced if the Nylock® nut has the same head ample cast components, are installed face-to-face
height as a standard hexagonal nut without plastic without a gasket. They are also commonly used to
insert. Reduce the tightening torque by 25% for bolt secure plugs, threads in stud bolts, cocks, oil pres-
size 8 mm or larger. Where Nylock® nuts are high- sure switches and so on. The cured material is
er, or of the same height as a standard hexagonal glass-like and it is therefore colored to make it vis-
nut, the tightening torques given in the table apply. ible. Cured anaerobic agents are extremely resist-
ant to solvents and the old agent cannot be re-
moved. When reinstalling the part is carefully
Tolerance classes degreased and then new sealant is applied.

Screws and nuts are divided into different strength

classes, the class is indicated by the number on the
bolt head. A high number indicates stronger materi-
al, for example a bolt marked 10-9 indicates a high-
er tolerance than one marked 8-8. It is therefore im-
portant that bolts removed during the disassembly
of a bolted joint must be reinstalled in their original
position when assembling the joint. If a bolt must be
replaced check in the replacement parts catalogue
to make sure the correct bolt is used.

Sealants
A number of sealants and locking liquids are used
on the engines. The agents have varying properties
and are used for different types of jointing trengths,
operating temperature ranges, resistance to oil and
other chemicals and for the different materials and
gap sizes in the engines.
To ensure service work is correctly carried out it is
important that the correct sealant and locking fluid
type is used on the joint where the agents are re-
quired.

7
Presentation
AQ145A AQ145A

AQ125

1. Oil dipstick
2. Fresh water tank
3. Filler cap, checking, fresh water
4. Distributor
5. Carburettor, front (AQ125 has only one)
6. Intake air silencer
7. Carburettor, rear
8. Ignition coil
9. Electro-mechanical lift device
10. Steering arm
11. Fuse box (exec. USA)
12. Serial number
13. Fuse (exec. USA)
14. Fuse (not USA)
15. Fuel pump
16. Sea water pump
17. Grease joint, upper steering shaft journal
18. Grease joint, drive shaft journal
19. Oil filler cap engine
20. Water filter
21. Heat exchanger
22. Draining, sea water
AQ125
23. Luboil filter
24. Oil cooler (only AQ145A)
25. Draining, sea water
26. Draining, sea water
27. Draining, fresh water

8
Repair Instructions

1. AQ145. Remove the four screws and pull the in- 3. Remove the alternator, drive belt, cable harness,
duction silencer to one side so that it comes free ignition coil, main fuse, starter motor, ignition
from the evacuation tube (1). AQ125. Remove the cables and distributor. NOTE! Mark the cables
cover. before they are removed.

4. Remove the cooling water pipe (1), and the

bracket for the ignition coil (2). Remove the screw
(3) and draw up the dip stick with its tube (4).
Then remove the feed pump (5) and the induction
pipe (6). NOTE! There are double gaskets plus an
2. Remove the air filters (1), the fuel pipe (2) be- intermediate washer on the feeder pump. There is
tween the feed pump and the carburetors and a lifting eye in the induction pipes rear screws.
unscrew the carburetors from the induction pipe. There are no washers under the lifting eye.
AQ125 has only one carburetor.

9
5. Remove the thermostat housing and lift out the 7. Remove the cap and lift out the strainer (1) from
thermostat. the heat exchanger. Then pull up the rubber ring’s
NOTE! The forward lifting eye is screwed onto the tongue (2). The tongue is marked “UP”. The cover
thermostat housing. (3) is now loose and can be lifted up. (Not on
AQ125.)

6. Remove and discard the O-ring (1) in the heat ex- 8. Pull the heat exchanger’s fresh water section to
changer and if necessary, unscrew the holder (2) one side. The fresh water section is mounted on a
for the ignition cables. The holder is fixed with two rubber bushing (1) and the water pipe (2), which
guide pins. seals against an O-ring.

10
9. AQ145. Remove the cooling water pipes between 11. Remove the cooling water pipe between the oil
the seawater pump and the heat exchanger and cooler and the exhaust pipe. Not on AQ125. Then
between the heat exchanger and the oil cooler. remove the exhaust pipe.
(Between the heat exchanger and the exhaust
pipe on AQ125.)

10. Remove the remaining three screws (X) on the 12. Unscrew the oil filter. Use tool 999 2903 or push a
heat exchanger and draw it to one side from the screwdriver through the filter and work it loose.
circulation pump. NOTE! Be careful not to spill oil.

11
13. Remove the nut (1) and remove the oil cooler. 15. Remove the saltwater pump and the generator’s
Only AQ145. Spanner width = 28 mm. Remove tensioning bracket. The spanner width for the
the oil pressure saltwater pump is 10 mm. The other screws
which hold the cover have a spanner width of 8
mm. Check the impeller, the key and the packing
on the pump’s front side plus the sealing ring on
the pump’s rear side. Clean the pump and re-
place damaged parts.

14. AQ145. If the oil cooler’s channels are to be

cleaned when the exhaust pipe is fitted on the
engine the cooling water pipes (1) and (2) must
be removed. Undo the oil cooler’s screw (3) and
remove the lower cover. 16. Undo the cover’s two hexagonal socket screws
The oil filter is then removed and the centre nut (6 mm key) and hexagonal screw (spanner width
(4) is loosened so that the oil cooler can be turned 10 mm). NOTE! The cover’s upper fixture is fitted
to a horizontal position. with a guide which means that the cover must be
After this the insert’s channels can be cleaned. withdrawn a few millimetres before it is free.

12
17. Remove the circulation pump’s pulley. The span- 19. Remove the crankshaft pulley. Six screws. The
ner width is 10 mm. spanner width is 10 mm.

18. Remove the circulation pump. The spanner width 20. If the belt’s markings have disappeared the belt is
is 10 mm. There are four screws and two nuts to be marked before it is removed. The marking of
with washers. Discard the plain packing and the the belt is carried out as follows: Make a mark by
rubber seal. NOTE! The pump is to be changed the camshaft’s pulley marking. Make a mark by
as a complete unit if it has been damaged. the intermediate gear’s marking and two marks
on the crankshaft pulley’s marking. Undo and re-
move the nut and washer for the belt tensioner.

13
21. Slacken the belt by depressing the roller against 23. Remove the cross piece from the intermediate
the spring pressure. Lock the spring by inserting a gear wheel. Check that cross piece is not dam-
3 mm (0.118") pin (e.g. a drill) in the hole on the aged. Then remove the screw from the carrier.
pressure pin. Use counterforce 999 5034. Remove the carrier
and the pulley. Then remove the carrier from the
pulley. Mild force from the rear with a wooden
shaft or similar tool may be necessary.

22. Remove the belt tensioner from the shaft (1). The
belt tensioner’s guide pin 2 is now free after
which the belt tensioner is twisted and removed.
Then remove the belt. The shaft (1) can be re-
placed by unscrewing it from the cylinder head.
The timing belt is to be changed if the cord 24. Remove the pulley from the camshaft. Use coun-
re-inforcement and the rubber are beginning to terforce 999 5034. Remove the pulley by hand.
separate or if the tread on the timing belt is worn. Check that the outer and the inner guide plate’s
The timing belt is to be changed every five hun- edges are not damaged so that these in turn can
dred hours. damage the belt.

14
25. Remove the centre screw and pull off the carrier 27. Remove the screws from the sealing flange. The
and outer guide plate from the crankshaft. flange is also tightened with two of the screws in
the oil sump. Remove the flange plate and re-
move the seals. Use tool 999 5025 for the small
seal and tool 999 5024 for the large seal.

26. Remove the key and pull off the pulley and the 28. Unscrew the flywheel cover’s four screws and the
inner guideplate from the crankshaft. three screws which hold the protective plate on
the underside between the cover and the cylinder
block.

15
29. Remove the vibration damper’s six screws. Span- 31. Pull out the intermediate shaft. Use the impact
ner width 13 mm. Carefully remove the vibration tool 999 4030 where necessary. NOTE! Be care-
damper from the three guide pins. ful to make sure that the intermediate shaft’s
gearwheel does not damage the bushes in the
cylinder block’s bearings.

Cylinder head
30. Remove the cover and the bracket for the oil 32. Remove the valve cover, the gasket and the cres-
pump drive. Then lift up the oil pump drive. cent shaped rubber seal and check the marking
on the camshaft bearing caps.

16
33. Remove the centre camshaft bearing cap. Span- 35. Remove the seal (1) from the camshaft. Then
ner width 1/2". There are spring washers under undo the tool spindle and release the camshaft.
the nuts. When necessary use a chisel or similar Remove the tool and lift out the camshaft.
tool against the lug as shown by the arrow.

34. Fit tool 999 5021 on the camshaft. Use the bear- 36. Remove the screws in the cylinder head. Use
ing cap’s nuts. The camshaft is held in position hexagonal socket key 10 mm. Lift away the cylin-
with the tool. Undo the other four camshaft bear- der head and remove the gasket. Remove the
ing caps. spark plugs.

17
37. Lift up the valve pushers and place them in the 39. Remove the rubber ring, collets, upper washers,
same order as they fit in the cylinder head. springs, lower washers and valves. Then remove
the valve seals from the inlet valve guides. Clean
all the parts. Remove carbon deposits from the
combustion chamber and the valves.

38. Remove the valves. Use valve spring compressor 40. Grind the valves if necessary in a valve grinding
884 580. machine. The angle is the same for both the ex-
haust and the inlet valves.

18
41. Mill or ream the valve seats. The angle is the 43. Check that all the valves and the valve seats are
same for the exhaust and inlet valve seats. perfectly ground by marking the valve seat face
and turning it against the valve seat with light
pressure. If the marking is not evenly distributed
on the whole of the seat (leaking valve) the valve
is ground further and a new check is carried out
until the result is satisfactory.

42. Check the flatness of the cylinderhead. Use a 44. Check the wear of the valve and the valve guides.
steel straight edge. The play for the inlet valve is 0.030–0.060 mm
(0.0012–0.0024") and for the exhaust 0.060–
0.090 mm (0.0024–0.0035").

19
45. Replace the camshaft in the cylinder head and 47. Check that the shims do not have too much play
check the axial play which is 0.1–0.4 mm in the valve pushers. If there are signs of wear on
(0.004–0.016"). the plain surface of the shim it should be chan-
ged. The play between the shim and the valve
presser is 0.009–0.068 mm (0.0004–0.0027).

46. Check the radial play which is 0.030–0.071 mm 48. Replace the valve pressers in the cylinder head
(0.0012–0.0028"). and check that the play is not too much or that
they do not stick. The play between the valve
pressers and the cylinder head is 0.030–0.075
mm (0.0012–0.0030").

20
49. Check the valve springs. 51. Fit the new valve guides. Use tool 999 5027 for
Length unloaded 45 mm (1.77") the inlet valves and tool 999 5028 for the exhaust
Length loaded with 300±20 N (67.2±4.48 lbf.) valves. The cylinder head is to be at room tempe-
38 mm (1.50") rature. The pressing force for fitting the valve gui-
des is to be at least 9000 N (900 kp) (2016 lbf). If
Length loaded with 760±40 N (170±8.96 lbf.)
this pressing force is not obtained for the guides
27 mm (1.06") the hole is to be reamed and a suitable oversized
valve guide is to be fitted. Press the guide down
until the tool comes up against the cylinder head.
This gives the guide a height above the valves
spring face around the guide of: 15.5±0.1 mm
(0.610±0.004") for the inlet valve and 18.0±0.1
mm (0.708±0.004") for the exhaust valve.

Changing the valve guides

50. Press up the valve guides with tool 999 2818.
Heat the cylinder head in 60°C (140°F) water.

21
52. Refit the valves. 54. Remove the bearing for the input shaft. Use tool
1. Rubber ring 999 4090. Remove the flywheel.
2. Upper valve washer
3. Collets
4. Valve springs
5. Valve stem seal (inlet)
6. Lower valve spring washer
Then refit the spark plugs.
NOTE! Make sure that the spark plug thread
screws in correctly so that the thread in the
aluminium cylinder head is not damaged. The
tightening torque is: 25–30 Nm (2.5–3.0 kpm)
(18.4–22.1 lbf. ft.)

55. Remove the sealing flange. NOTE! Two screws

from the sump must also be removed.

53. Remove the locking ring for the bearing on the in-
put shaft.

56. Remove the seal from the sealing flange with tool
999 2817.

22
57. Undo the screws and remove the oil sump. Then 59. Note that the crankshaft and the crankshaft bear-
remove the two screws in the lubricating oil pump ing caps are numbered. Then remove the bearing
and lift out the pump with the pipe. caps and remove the bearing shells.

58. Remove the rubber ring for the oil pipe from the 60. Press out of the pistons from the cylinders. Let
cylinder block (And from the pipe where neces- the pistons fall on a soft surface so that they can-
sary). not be damaged. Then remove the piston rings.
Use piston ring pliers.

23
61. Remove the locking rings for the gudgeon pins 63. Lift out the crankshaft and remove the bearing
and press the gudgeon pins out. shells from the block and the bearing caps.

CLEANING AND INSPECTION

64. Clean and carefully inspect the cylinder block.
The plugs for channels are to be removed before
62. Note that there are markings for the main bearing cleaning. Re-fit the plugs after cleaning has been
caps. The bearing caps are marked 1–5 from the completed. Tightening torque:
transmission side. Remove the main bearing 1/4 NPTF – 20 Nm (2 kpm) (14.7 lbf. ft.)
caps. 3/8 NPTF – 30 Nm (3 kpm) (22.1 lbf ft.)

24
65. Measure the cylinder liners with a special dial in- Pistons
dicator. The measurement for greatest wear is
carried out immediately below top dead centre 67. Measure the pistons with a micrometer at right
and transverse to the engine. The measurement angles to the gudgeon pin hole and 6 mm (0.25")
for minimum wear is carried out at bottom dead from the lower edge.
centre.
Piston diameter standard. AQ145
Standard cylinder diameter. AQ145 (C-marked): 95.940–95.950 mm (3.7776–3.7780 in.)
(C-marked): 96.00–96.01 mm (3.7795–3.7799 in.) (D-marked): 95.950–95.960 mm (3.7787–3.7791 in.)
(D-marked). 96.01–96.02 mm (3.7799–3.7503 in.) (E-marked): 95.960–95.970 mm (3.7780–3.7783 in.)
(E-marked): 96.02–96.03 mm (3.7803–3.7807 in.) (G-marked): 95.980–95.990 mm (3.7787–3.7791 in.)
Oversize I: 96.300 mm (3.7973 in.) Oversize I: (0.3–96.245): 96.237–96.252
II: 96.600 mm (3.8031 in.) (0.0118–3.7892): 3.7889–3.7894"
II: (0.6–96.545): 96.537–96.552
Standard cylinder diameter. AQ125 (0.0236–3.8010): 3.8007–3.8013"
(D-marked): 92.01–92.02 mm (3.6224–3.6228 in.)
(G-marked): 92.03–92.04 mm (3.6232–3.6236 in.) Piston diameter standard. AQ125
Oversize I: 92.500 mm (3.6417 in.) (D-marked). 91.990–92.000 mm (3.6216–3.6220 m.)
II: 93.000 mm (3.6614 in.) (G-marked). 92.020–92.030 mm (3.6228–3.6232 in.)
Oversize I: (0.5–92.480): 92.474–92.492
(0.0196–3.6409): 3.6407–3.6414 in.)
II: (1.0–92.980): 92.977–92.992
(0.394–3.6606): 3.6605–3.6611 in.)

Classification marking
66. Each cylinder liner has a letter which indicates its
and pistons class.
Oversizes indicated by nominal diameter meas-
urement.

25
68. Piston play in cylinder: 0.05–0.07 mm (0.0020– 70. Measure the piston ring gap with a feeler gauge.
0.0028"). Increase the gap with a special file where neces-
a. Piston diameter (A) is measured as stated sary.
above. The gap for AQ145 is to be:
b. The cylinder diameter is measuredat several Compression rings: 0.40–0.65 mm (0.0157–0.0256 in.)
places crosswise to the engine and 30 mm Oil scraper ring: 0.30–0.60 mm (0.0118–0.0236 in.)
(1.2") (B) from block face and downwards to
bottom dead centre (C). The gap for AQ125 is to be:
c. Calculate the piston’s maximum and minimum Compression rings: 0.35–0.55 mm (0.0138–0.0217")
clearances. (Deduct piston diameter to get cy-
Oil scraper ring: 0.25–0.40 mm (0.0098–0.0157")
linder liner’s maximum and minimum dia-
meters).

71. Measure the piston ring gap by rolling the piston

Piston rings rings in the groove. Check the play at several
69. Insert piston rings, one after the other, in the liner. points with a feeler gauge. The play is:
Use an inverted piston to fit the ring in the correct Compression rings: 0.040–0.072 mm (0.0016–0.0028")
position. Oil scraper ring: 0.030–0.062 mm (0.0012–0.0024")
NOTE! When fitting in a worn cylinder liner, the
rings must be tested at bottom dead centre since
the cylinder liner diameter is at a minimum there.

26
72. Check the play of the gudgeon pin in the piston. 74. Press in the new bushing with tool 999 5017.
The play is correct when the gudgeon pin can be
pushed through with light hand pressure.
(Accurate running fit).
The gudgeon pins are available oversized 0.05
mm (0.0019"). If the gudgeon pin hole in the pis-
ton is worn so that an oversize gudgeon pin is
needed the hole is reamed to the correct dimen-
sion. Use a reamer with a guide ring and make
small cuts at a time.

75. The gudgeon pin is to slide through the hole with

light thumb pressure without any appreciable
looseness. (Sliding fit). The bush is machined if
necessary.

73. Press out the small end bush with tool 999 5017.

76. Check the connecting rods for straightness, tor-

sion and possible s-bends. Use a connecting rod
straightener. Nuts and screws are to be replaced
when overhauling.

27
Crankshaft Overhauling the oil cooler (AQ145)
77. Check the big end bearings and main bearing. 78. Remove the centre screw (1) and remove the end
Measurement with a micrometer is carried out at cover (2) and (3). Remove the O-rings (4) which
several points around the circumference and remain on the insert. Then press out the insert (5)
lengthwise. The ovality of the main bearing jour- and be careful not to spill oil. Clean and blow th-
nals must not exceed 0.07 mm (0.0028") and on rough the insert with compressed air. Check that
the connecting rod journals 0.05 mm (0.0019"). there is free flow in the drain tap (6). Re-fit the in-
The conicity should not be greater than 0.05 mm sert in the housing and slide on the O-rings. (Re-
(0.0019") for any of the journals. If the dimensions place O-rings where necessary). Re-fit the end
lie in the vicinity of or exceed the stated values for cover and tighten them with the centre screw. Re-
wear the crankshaft should be re-ground to the place the O-ring (7) if it is damaged. Check and
nearest undersize. Suitable bearing shells are replace the O-ring (8) where necessary.
available for two undersizes. See the technical
data.

Overhauling the lubrication oil pump

79. Remove the pipe from the pump, remove the lock-
ing clamp and remove the strainer. NOTE! The
strainer cannot be disassembled on the later mo-
del.

28
80. Remove the four screws and remove the cover. 82. Check the spring for the pressure release valve.
Test data:
Length unloaded 47.6 mm (1.8740")
Length loaded with
44±4 N (4.4±0.4 kp)
(32.43±2.95 lbf.ft.) 32.0 mm (1.260")
Length loaded with
61±6 N (6.1±0.6kp)
(44.96±4.42 lbf.ft.) 26.0 mm (1.024")

83. Refit the gear wheels and check the gear flank
81. Remove the spring, ball and gears. Clean all clearance which is 0.15–0.35 mm (0.0060–
parts and replace those damaged or worn. 0.014").

29
84. Check the axial clearance. 86. Refit the strainer and the locking clamp. (Applies
The axial clearance is 0.02–0.12 mm only to the earlier model).
(0.008–0.0047").

85. Lay the ball and the spring in position and refit the 87. Fit new sealing rings and press the pipe into posi-
cover. tion in the pump.

30
Overhauling the heat exchanger.
88. Remove the two screws (1) and remove the strai-
ner housing (2) from the heat exchanger housing
(3). Discard the sealing rings (4) and (5). Then re-
move the four screws in the heat exchanger’s co-
ver. Pull out the insert (6) and cover (7) from the
heat exchanger housing. Put the spacer ring (8) in
a safe place. Remove the cover from the insert.
NOTE! Remove the support ring (9) which can re-
main in the bottom of the housing. Remove the
bottom screw (10) on the insert. Discard the cop-
per seal, the O-ring on the insert, the plain pack-
ing and the other sealing rings. Wash and rinse all
parts including the expansion tank. Check that the
insert’s channels are free from contamination. Use
compressed air. Change damaged parts. As-
semble the heat exchanger in the opposite order,
see the picture. Use new sealing rings, a new
packing, a new copper washer, support ring and
O-rings.
NOTE! The cover for the seawater strainer is to be
lubricated on the inside. Remove the rubber
washer A and the sealing disc B. Distribute grea-
se evenly with a brush on the inside of the cover.
Then replace the sealing disc and the rubber
washer and screw the cover in position.

Overhaul and inspection of carburetor

89. Remove the 4 screws (1) and lift off the upper part
of the carburetor.

31
90. Remove the gasket (1) and disassemble the 92. Disassemble the idling jet (1) and holder (2) for
needle valve (2). Check that the needle valve the main jet. Unscrew the jet from the holder.
does not bind or is worn (does not seal). Replace Blow the jets clean and replace if necessary.
if necessary. Unscrew the mixing screw (3) and blow clean the
duct. Screw (4) locks tight the air cone (5).

91. Lift out the float tube and check that it is tight. If
the float is not tight the float level will be wrong.
Unscrew the emulsifying jet (1) and the accelera- 93. Rotate the throttle shaft (1) and press out the push
tion jet (2). NOTE! The gasket. Check and clean rod (2) from the lever (3). Then rotate the push rod
with compressed air. Replace worn or damaged downwards and disassemble the check valve (4).
parts if necessary. Blow the check valve clean and the strainer.
Clean and blow the carburetor and its ducts. Then
re-fit the check valve and strainer. NOTE! Do not
forget the copper washer. Rotate the throttle shaft
somewhat and press the push rod into the lever.

32
 Overhauling the flywheel cover
Assembling 95. Remove the sealing ring (1) in the flywheel cover.
Check the primary shaft (2) and the bearing (3). If
94. Fit the idling jet (1), main jet (2)and mixing screw either one is damaged the lock rings (4) are to be
(3). NOTE! Copper washer on the main jet. Then undone and the shaft with bearings is to be
fit the emulsifying jet (4), acceleration jet (5) and pressed out. Remove the sealing ring (5) and re-
gasket (6). Place the float in the float housing and move the lock ring (6). Replace the damaged
put on a new gasket (8) and screw on the upper parts and then fit the lock ring (6) on the primary
part of the carburetor housing. Loosen the nut (9) shaft and the sealing ring (5). Then press the
and remove the levers. The spring can then be re- bearing brackets (3) on the primary shaft (2).
placed. Press the shaft with bearing in the flywheel cover.
Fit the lock rings (4) and the sealing ring (1).
Adjusting the idling screws: NOTE! Carefully lubricate the sealing rings before
AQ145A. Screw in the screw until it comes into they are fitted. Press grease into the lubricating
contact with the carburetor. Then screw it in a channel (7).
further 3/4 turn.
AQ125A. 1 1/4 turn.

Adjusting the venting screws:

AQ145A. Screw the venting screw right in. Then
screw it out 1 turn.
AQ125A. 1 turn.

Assembling
96. Put the main bearing shells in position in the
block and the caps. If a spacer tube which has
been removed is to be refitted, it is to be reversed.

33
97. Fit the main bearing caps. NOTE! The main bear- 99. Refit the pistons and the connecting rods so that
ing caps are numbered 1–5 counted from the the marks on the pistons point forward in the en-
transmission end. Oil the screws’ threads. Tighten gine when the figure marking on the connecting
with a torque wrench. The tightening torque is rods is turned towards the crankcase’s starboard
110 Nm (11 kpm), (80 ft.lbf.) side (oil filter side). Fit the lock rings.

100. Fit the piston rings with piston ring pliers. The pis-
ton rings are to be fitted as shown in the picture.
The upper ring is chromium-plated. The lower
compression ring is marked “TOP”. Turn the pis-
ton ring so that the gaps are at an angle of 120°
from each other.

98. Check the axial clearance which is 0.037–0.147

mm (0.0014–0.0058").

101. Fit the bearing shells in the connecting rods and

the bearing caps. Oil the cylinder liners, pistons
and big end bearings. Check that the markings on
the pistons are directed towards the transmission
cover when the piston is fitted in the cylinder. Use
piston ring compressor.

34
102. Fit the big end bearings so that the markings on 104. Fit a new sealing ring in the rear sealing flange.
the cap agree with markings on the connecting Use tool 999 2817. The sealing ring is to be
rods. Oil the threads and tighten with a torque pressed in sufficiently so that a new wear surface
wrench. The tightening torque is: 63 Nm (6.3 is obtained against the crankshaft. Then fit the se-
kpm). (46.4 lbf. ft.). NOTE! When fitting new aling flange with a new seal against the engine.
screws the tightening torque is 70 Nm (7.0 kpm). Lubricate the seal’s rubber lip and the opposite
(51.6 lbf. ft.). Then check that the crankshaft can surface on the crankshaft before fitting. Great care
be turned. must be exercised so that the rubber lip is not
damaged by the edge of the crankshaft or turned
inside-out so that the spring jumps out of position.
Cut off protruding parts on the seal.

Oil pump
103. Fit a new sealing ring on the pipe for the oilpump. 105. Protect the inside of the flywheel with Tectyl or
Where necessary also change the sealing ring at similar fluid and refit the flywheel. The tightening
the other end of the pipe. Fit the pump. Make sure torque is 70 Nm (7 kpm) (51.6 lbf. ft.). Fit the bear-
that the seals are not damaged. The pump is to ing for the ingoing shaft with tool 999 1426 and
mate properly with the crankcase before the then refit the washer and the lock ring for the
screws are tightened. bearing.

35