Volvo B27A Bedienungsanleitung

•^

ServiceManual

Repairs

andmaintenance

Section2 (21)

Reconditioning

engine

27,

B 28

2601975-1983

books4cars.com

485037thAvenueSouth

Seattle,

WA98118

U.SA

B27A-B27E-B27F-B28A-B28E-B28F

Whatdothesedesignationsmean?

B28E

A= carburettedengine

E= fuelinjectedengine

F= fuelinjectedengine"USAmodels"

The

28isinprinciplea

27witha largerbore.

28(27)=

•

B= petrol

(g«

Enginetype

B27A

B28A

B27E

B28E

B27F

B28F

pacity

jsoline)

Modelyear

1976-1979

1980-1982

1975-1980

1981-1983

1976-1979

1980-1982

Volvosaresoldinversionsadaptedfordifferentmarkets.

Theseadaptionsdependonmanyfactorsincludinglegal,

taxationandmarketrequirements.

Thismanualmaythereforeshowillustrationsandtext

whichdonotapplytocarsinyourcountry.

Group

Reconditioning engine

Contents

Important

information

Specifications

Specialtools

Page

...2

..11

Threadrepairs Operation

1-1414

Reconditioningengine

DisassemblyB 1-19

CleaningandinspectionC 1-41

AssemblyD 1-35

Cylinderhead,reconditioningE 1-26

Assembly(cont.)F 1-33

Indexpage62

Thismanualdealsexclusivelywiththeoverhaulofthe

engine.

Forworkcarriedoutontheenginewhenfittedinthecar,

andforengineremovalandinstallation,pleaserefertothe

separatemanuals.

Ordernumber:TP30447/1

Wereservetherighttomakealterations.

Group

Reconditioning engine

Important information

Importantinformation

Tighteningtorques

Nearlyallofthe

27/28engineismadeofaluminium

alloy.

The

threads

are

tappeddirectlyintothealloy.For

thisreasonitisextremelyimportantthatallofthebolts

aretightenedtospecifiedtorque.

Twotypesoftighteningtorquesareusedinthismanu-

al:

Tighteningtorque40

(30

ftlbs)

= a torque

wrenchmustbeused.

II.

Tighteningtorque

(30

ft.lbs)= correctvalue,

howeveritisnotnecessarytousea torque

wrench.

Specifications

Group20General

Engineserialnumberandpartnumber

Locatedona plateinfrontoftheoilfilter.

28E/F

1981-

models:locatedontherearofthe

right-handcylinder

head,

showsthelastthreedigitsof

thepartnumber.

Group 21 Reconditioning engine

Specifications

Group21Engineblock

CYLINDERHEAD

Height New-

111.07

mm(4.373in)

Max.warpis0.05mmover100mm.

NOTE!

Donotlevela warpedcylinderhead,replaceit.

Cylinderheadgasketthickness

1.14-1.50

(0.045-0.059

in)

CYLINDERBLOCK

Cylinderliners

Pistonsandlinersarematchedsets.

Cylinderlinersaremarkedby1,2 or3 cutsintheupperedgeof

theliner. B27B 27

Bore,

linersmarked1 (A-markedpiston)88.00-88.01mm91.00-91.01mm

(3.4646-3.4650

in)

(3.5826-3.5830

in)

2(B-markedpiston)88.01-88.02mm

91.01-91.02

(3.4650-3.4654in)(3.5830-3.5835in)

3(C-markedpiston)88.02-88.03mm

91.02-91.03mm

(3.4654-3.4657in)(3.5835-3.5838in)

Linerheightaboveblockface

0.16-0.23

mm(0.0063-0.009in)

Shimsforadjustmentoflinerheight:

thickness,bluepaintmarking0.070-0.105mm(0.0027-0.0041in)

whitepaintmarking

0.085-0.120

(0.0033-0.0047

in)

redpaintmarking0.105-0.140mm(0.0041-0.0055in)

yellowpaintmarking0.130-0.165mm(0.0051-0.0064in)

PISTONS

PistonsforB27

Pistonsandlinersarematchedsets.

Twodifferentmanufacturerssupplypistons,seenextpage

forspecifications.

Demolin

Mahle

Group 21 Reconditioning engine

Specifications

DEMOLIN

PISTONS(B27)B27A

1976-1979

B27E1975-1978

B27F 19791976-1978

Height,overall74mm(2.9134in)63.4mm(2.9960in)

fromgudgeonpincentretopistoncrown40mm(1.5748in)39.4mm(1.5512in)

Weight445±3gram

Maxweightdifferencebetweenpistonsinsameengine6 gram

Pistonfloat

0.090-0.110

mm(0.0035-0.0043in)

Pistondiameter,A-markedpistons

87.900-87.910

(3.4606-3.4610

in)

B-markedpistons

87.910-87.920

(3.4610-3.4614

in)

C-markedpistons

87.920-87.930

(3.4614-3.4618

in)

Pistondiameterismeasuredatrightanglestogudgeonpin

boreand:

11mm(0.43in)fromloweredgeofpistonfor

B27F

1976-1978

8.5mm(0.33in)fromloweredgeofoilscraperringforother

engines.

Diameter,gudgeonpinbore:

MarkingpistonMarkinggudgeonpin

1Blue23.514-23.517mm(0.9257-0.9259in)

2White23.511-23.514mm(0.9256-0.9257in)

3Red

23.508-23.511

mm(0.9255-0.9256in)

MAHLEPISTONS(B27)

B 27

1976-1979

B27E

1975-1978

1979-1980

B27F

1979

1976-1978

Height,overall63,4mm62.2mm65.3mm

(2.4960in)(2.4488in)(2.5709in)

fromgudgeonpincentretopistoncrown39.4mm38.2mm41.3mm

(1.5521in)(1.5039in)(1.6260in)

Weight445±3gram

Maxweightdifferencebetweenpistonsinsameengine6 gram

Pistonfloat0.020-0.040mm(0.0008-0.0016in)

Pistondiameter,A-markedpistons87.970-87.980mm(3.4634-3.4638in)

B-markedpistons87.980-87.990mm(3.4638-3.4642in)

C-markedpistons87.990-88.000mm(3.4642-3.4646in)

-ts.

Pistondiameterismeasuredatright-anglestogudgeonpin

bore,

8 mm(0.31in)frombottomedge.

Diameter,gudgeonpinbore:

Marking,

pistonMarking,gudgeonpin

BlueBlue23.510

mm-23.513

(0.9255-0.9257

in)

WhiteWhite23.507-23.510mm

(0.9254-0.9255

in)

RedRed23.504-23.507mm(0.9253-0.9254in)

Group 21 Reconditioning engine

Specifications

PistonsforB28

Pistonsandlinersarematchedsets.

Only

Mahle

pistonsareinuse.

Weight455±3grams

Maxweightdifferencebetweenpistonsinsameengine6 grams

Height,overallA-andF-engines62.8mm(2.4724in)

E-engine65.3mm(2.5709in)

fromgudgeonpincentretopistoncrown

A-andF-engines38.8mm(1.5276in)

E-engine41.3mm(1.6260in)

Pistonfloat

0.020-0.040

(0.0007-0.0015

in)

Pistondiameter,A-markedpistons90.970-90.980mm

(3.5814-3.5818

in)

B-markedpistons90.980-90.990mm(3.5818-3.5822in)

C-markedpistons90.990-91.000mm(3.5822-3.5826in)

Pistondiameterismeasuredatright-anglestogudgeonpin

bore,

8 mm(0.31in)frombottomedge.

Diameter,gudgeonpinbore:

Marking,

pistonMarking,gudgeonpin

BlueBlue

23.510-23.513

mm(0.9255-0.9257in)

WhiteWhite23.507-23.510mm

(0.9254-0.9255

in)

RedRed23.504-23.507mm(0.9253-0.9254in)

Pistonrings

15mm Ringgapmeasured15mm(0.6in)from

loweredgeofcylinder

Height. mm

Upper

compression

ring

1.478-1.490

9.0582-0.0587

0.045-0.074

0.0017-0.0029

0.40-0.60

0.0157-0.0236

Lower

compression

ring

1.978-1.990

0.0779-0.0783

0.025-0.054

0.0009-0.0212

0.40-0.60

0.0157-0.0236

Oilring

2.629-2.731

0.1035-0.1075

0.009-0.233

0.0003-0.0091

0.38-1.45

0.0150-0.0570

Sideclearance(measuredwithringonpiston)mm

Ringgapwhencheckedin91mm(3.5826in)cylinder(B28),

88mm(3.4646in)(B27),seefigmm

Gudgeon(piston)pins

Diameter

Marking,

Marking,piston

gudgeonpin

BlueBlue(1)

23.500-23.497

mm(0.9251-0.9250in)

WhiteWhite(2)23.497-23.494mm(0.9250-0.9249in)

RedRed(3)23.494-23.491mm(0.9249-0.9248in)

Clearanceinconnectingrod0.020-0.041mm

(0.0007-0.0016

in)

piston,

Mahle0.010-0.016mm(0.0003-0.0006in)

Demolin

0.014-0.020mm(0.0006-0.0008in)

Group

Reconditioning engine

Specifications

VALVESYSTEM

Valve

Clearances

(varieswithenginetype)

Valveclearancemm(in)

Intakevalves,coldengine

warmengine

Exhaustvalve,coldengine

warmengine

Enginetype- modelyear

B27A

1976-1979

28A 1980

1981-1982

B27

1975-1978

1979-1980

Sweden+ Australia

1979-1980

Othermarkets

B28E1981-1983

B27

F1976-1979

B28

F1980

1981-1982

Type1

0.10-0.15

(0.004-0.006)

0.15-0.20(0.006-0.008)

0.25-0.30

(0.010-0.012)

0.30-0.35

(0.012-0.014)

Type

0.20-0.25

(0.008-0.010)

0.25-0.30

(0.010-0.012)

0.30-0.35

(0.012-0.014)

0.35-0.40(0.014-0.016)

Valvesmm(in)

29,5°

44(1.7322)

7.965-7.980

(0.3135-0.3141)

26.5

(1.0433)

Tapered

Intakevalves

7.975-7.990

(0.3139-0.3145)

44.5'

59"

(1.4566)

32(1.2598)'

Exhaustvalves

7.965-7.980

(0.3135-0.3141)

Valveseatsmm(in)

1.7-2.1

mm(0.0669-0.0826)

1.3-1.7

(0.0511-0.0669)

Intakevalveseat

Earlytypes Intakevalveseat

Latetypes(venturi

seat):15°

and60°are

correctanglestoreduceseatwidth.

2.0-2.4

mm(0.0787-0.0944)

Exhaustvalveseat

Group 21 Reconditioning engine

Specifications

Note!

Whenreplacingvalveseats:theinterferencebetween

thevalveseatanditsboreinthecylinderheadmustbe

0.070-0.134

mm,(0.0027-0.0052in),i.e.thevalveseatdiame-

termustbe0.070-0.134mmgreaterthanthediameterofthe

boreinthecylinderhead.

Valveseatsareavailableinthreeoversizes.

Valveguides

(in)

Length50.1-51.3(1.2725-1.3030)

Inner

diameter

8.000-8.022

(0.3149-0.3158)

Press-inmeasurementtocylinderheadcontactsurfaceagainst

block:

intake39.5-40.5(1.5551-1.5944)

exhaust36.9-37.9(1.4527-1.4921)

Valveguidesareavailableinthreeoversizes,andaremarked

withgrooves.

Standard

Oversize1

Marking

Nogroove

1groove

2grooves

3grooves

Reamerforseat

5166

5167

5168

/"*

Valve

springs

Twotypesofvalvespringsareinuse.Thespringsarecolourcoded

asfollows:

Greysprings:

B27A

1976-1979

B27E

1975-1978

1979-1980

Sweden+ Australia

B27F

1976-1979

Greensprings:

B28A

1980-1982

B27E

1979-1980

(excludingSweden,Australia)

B28E

B28F

1981-1982

1980-1982

Greysprings:

Length

47.2

40.0

32.2

1.86

1.57

1.27

Load

N(kp)

233-268

(23.3-26.8)

521-585

(52.1-58.5)

lbs.

52-60

116-131

Greensprings:

Length

47.1

40.0

30.0

1.85

1.57

1.18

Load

N(kp)

23.0-26.6

613-689

(61.3-68.9)

lbs.

51-59

137-154

Group 21 Reconditioning engine

Specifications

Rockerarmmechanism

Therockerarmcontactsurfaceagainstthecamshaftissurface-hardenedandmustnotbeground.

Diameter,rockerarmshaft19.959-19.980mm

(0.7857-0.7866

in)

Holediameter,rockerarm19.992-20.013mm

(0.7870-0.7879

in)

Clearance,shaft-rockerarm0.012-0.054mm(0.0005-0.0021in)

TIMINGGEARS

Camshaft

Threetypesofcamshaftswithdifferentliftheights

are

inuse.

Thepartnumberismarkedonthefrontend.

Camshaft

Marking(partnumber),left

right.

Max.liftheight,leftmm

rightmm

Checkofcamshaftsetting(coldengine):

Adjustvalveclearanceon1stand6thintakevalvesto0.7

mm(0,027in),theintakevalvesshouldthenopenat,

1stBTDC

6thBTDC

Type1

7910

245522

(-143or-144)

7910

245412

5.144

(0.202in)

5.059

(0.199in)

9°±3°

7°±3°

Type

01269138

01269

139

6.004

(0.236in)

6.004

(0.236in)

9°±3°

Type3

269615

269616

5.96

(0.234

in)

5.96

(0.234in)

8°±3°

Enginetype

B27

1976-1979

B28

A 1980

1981-1982

B27E1975-1978

1979-1980Sweden4-Australia.

1979-1980

Othermarkets

B28E1981-1983.

B27F

1976-1979.

B28F1980

1981-1982.

Journaldiameter,countingfromfront(alltypes):mm(in)

1st40.440-40.465(1.5921-1.5931)

2nd41.040-41.065

(1.6157-1.6167)

3rd

41.640-41.665(1.6393-1.6403)

4th42.240-42.265(1.6629-1.6639)

Radialplay0.035-0.085(0.0013-0.0033)

Endfloat,new0.070-0.144(0.0027-0.0056)

max0.5(0.0196)

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