Volvo Penta AQ145A Workshop Manual
  1. Manuals
  2. Brands
  3. Volvo Penta Manuals
  4. Engine
  5. AQ145A
  6. Workshop manual
Volvo Penta AQ145A Workshop Manual

Volvo Penta AQ145A Workshop Manual

Engine unit
Hide thumbs
Table of Contents

Advertisement

Quick Links

Workshop Manual
C
Engine Unit
2(0)
AQ125A, B
AQ145A, B

Advertisement

Table of Contents
loading

Related Manuals for Volvo Penta AQ145A

Summary of Contents for Volvo Penta AQ145A

  • Page 1 Workshop Manual Engine Unit 2(0) AQ125A, B AQ145A, B...

  • Page 3: Table Of Contents

    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...

  • Page 4: Safety Precautions

    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.
  • Page 5 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.
  • Page 6 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.

  • Page 7: General Information

    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-...

  • Page 8: Repair Instructions

    Take special care when working on-board, that oil All procedures for which there are Volvo Penta spe- and waste is taken for destruction and is not acci- cial tools in this Workshop Manual are carried out dentally pumped into the environment with bilge wa- using these.
  • Page 9 In this Volvo Penta Service Manual the user will find Tightening torques-protractor (angle) 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...

  • Page 10: Presentation

    18. Grease joint, drive shaft journal 19. Oil filler cap engine 20. Water filter 21. Heat exchanger AQ125 22. Draining, sea water 23. Luboil filter 24. Oil cooler (only AQ145A) 25. Draining, sea water 26. Draining, sea water 27. Draining, fresh water...

  • Page 11: Repair Instructions

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

  • Page 12: Heating Exchanger, Exhaust Pipe, Oil Filter

    Remove the thermostat housing and lift out the Remove the cap and lift out the strainer (1) from thermostat. the heat exchanger. Then pull up the rubber ring’s tongue (2). The tongue is marked “UP”. The cover NOTE! The forward lifting eye is screwed onto the (3) is now loose and can be lifted up.
  • Page 13 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.

  • Page 14: Oil Cooler, Sea Water Pump

    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.

  • Page 15: Circulation Pump, Belt Pulley, Marking The Timing Belt

    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.

  • Page 16: Belt Tensioner, Intermediate Pulley, Camshaft Pulley

    Slacken the belt by depressing the roller against 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.

  • Page 17: Sealing Flange, Flywheel Cover

    27. Remove the screws from the sealing flange. The Remove the centre screw and pull off the carrier flange is also tightened with two of the screws in and outer guide plate from the crankshaft. the oil sump. Remove the flange plate and re- move the seals.

  • Page 18: Vibration Damper, Intermediate Shaft

    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.
  • Page 19 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.
  • Page 20 Lift up the valve pushers and place them in the 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.

  • Page 21: Valve Seats, Guides, Springs, Pushers

    Mill or ream the valve seats. The angle is the 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.
  • Page 22 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.
  • Page 23 Check the valve springs. Fit the new valve guides. Use tool 999 5027 for the inlet valves and tool 999 5028 for the exhaust Length unloaded 45 mm (1.77") valves. The cylinder head is to be at room tempe- Length loaded with 300±20 N (67.2±4.48 lbf.) rature.

  • Page 24: Flywheel, Sealing

    Refit the valves. 54. Remove the bearing for the input shaft. Use tool 999 4090. Remove the flywheel. 1. Rubber ring 2. Upper valve washer 3. Collets 4. Valve springs 5. Valve stem seal (inlet) 6. Lower valve spring washer Then refit the spark plugs.

  • Page 25: Lubricating Oil Pump, Pistons, Crankshaft

    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.
  • Page 26 63. Lift out the crankshaft and remove the bearing Remove the locking rings for the gudgeon pins shells from the block and the bearing caps. and press the gudgeon pins out. CLEANING AND INSPECTION Clean and carefully inspect the cylinder block. The plugs for channels are to be removed before cleaning.

  • Page 27: Cylinders, Pistons, Connecting Rods, Crankshaft

    Measure the cylinder liners with a special dial in- Pistons dicator. The measurement for greatest wear is Measure the pistons with a micrometer at right carried out immediately below top dead centre angles to the gudgeon pin hole and 6 mm (0.25") and transverse to the engine.
  • Page 28 Piston play in cylinder: 0.05–0.07 mm (0.0020– Measure the piston ring gap with a feeler gauge. 0.0028"). Increase the gap with a special file where neces- sary. a. Piston diameter (A) is measured as stated above. The gap for AQ145 is to be: b.
  • Page 29 Check the play of the gudgeon pin in the piston. 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").

  • Page 30: Fuel Pump, Oil Cooler, Lubricating Oil Pump

    Overhauling the oil cooler (AQ145) Crankshaft Remove the centre screw (1) and remove the end Check the big end bearings and main bearing. cover (2) and (3). Remove the O-rings (4) which Measurement with a micrometer is carried out at remain on the insert.
  • Page 31 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.
  • Page 32 Check the axial clearance. Refit the strainer and the locking clamp. (Applies only to the earlier model). The axial clearance is 0.02–0.12 mm (0.008–0.0047"). Fit new sealing rings and press the pipe into posi- Lay the ball and the spring in position and refit the tion in the pump.

  • Page 33: Heat Exchanger, Carburetor, Flywheel Cover

    Overhauling the heat exchanger. 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.
  • Page 34 Disassemble the idling jet (1) and holder (2) for Remove the gasket (1) and disassemble the the main jet. Unscrew the jet from the holder. needle valve (2). Check that the needle valve Blow the jets clean and replace if necessary. does not bind or is worn (does not seal).

  • Page 35: Assembling

    NOTE! Carefully lubricate the sealing rings before Adjusting the idling screws: they are fitted. Press grease into the lubricating AQ145A. Screw in the screw until it comes into channel (7). contact with the carburetor. Then screw it in a further 3/4 turn.
  • Page 36 Fit the main bearing caps. NOTE! The main bear- 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.
  • Page 37 102. 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.

  • Page 38: Oil Sump, Cylinder Head, Camshaft

    106. Fit a new gasket for the sump on the crankcase. 108. Lubricate the cylinder head screw threads and the Then replace the sump. Tighten all the screws washers then fit and tighten the screws. The tight- except the four nearest the front sealing flange. ening force is 90 Nm (9 kpm) (66 lbf.
  • Page 39 111. Fit tool 999 5021 and depress the camshaft. 113. Oil and lay the other three bearing caps in posi- tion and fit the nuts for the four bearing caps. Tighten them somewhat NOTE! The forward bearing cap’s surface against the cylinder head is to be painted with sealing fluid before it is fitted.

  • Page 40: Intermediate Shaft, Seals, Camshaft Gear Wheel

    117. Fit the front sealing flange (and positioning plate) Transmission with a new gasket. The tightening torque is 10 115. Oil the intermediate shaft bearings. Nm (1.0 kpm) (8.0 lbf. ft.). Then torque tighten the screws for the sump. The tightening torque is 10 Nm (1.0 kpm) (8.0 lbf.ft.).
  • Page 41 119. Fit the intermediate shaft seal with tool 999 5025. 121. Fit the screw, the guide plate and the washer and NOTE! Lubricate the seal’s rubber lip before fit- tighten it with a torque wrench. Use tool 999 5034 ting. Alter the sealing ring’s position in relation to as a counterforce.

  • Page 42: Intermediate Gear, Marking, Timing Belt

    123. Paint mineral grease or similar lubricant in the 125. Turn the intermediate shaft into position after hub on the crankshaft’s pulley. Position the guide marking. plate (turn the bend towards the seal) and fit the pulley on the crankshaft. Then refit the outer plate and the carrier and fit the screws.
  • Page 43 127. Then fit the belt tensioner carefully so that the belt 129. Turn the crankshaft clockwise a few degrees. is not damaged. Turn the belt tensioner so that This is to take up the backlash between the pul- the spring rod (1) can be pushed onto its shaft leys.

  • Page 44: Oil Pump Drive, Circulation Pump, Valve Adjustment

    131. Refit the crankshaft pulley on the carrier. 133. Fit a new O-ring on the cover for the oil pump drive. 132. Fit the oil pump drive. It is possible that the 134. Fit the cover and the brackets for the cooling wa- crankshaft (intermediate shaft) may need to be ter pipe.
  • Page 45 135. Fit a new rubber ring and gasket on the circula- Valve adjustment tion pump. Fit the pump to the engine. Press the 137. Lift off the valve cover. Turn the camshaft to the pump upwards against the cylinder head and position for firing on No.
  • Page 46 139. If the clearance is incorrect the adjustment shims 141. Remove the shim with pliers 999 5026. are to be changed as follows: Turn the valve pusher so that the groove is at right angles to the camshaft’s length. 142. Measure the thickness of the shim with a micro- meter.
  • Page 47 143. The shims are available in different thickness bet- 145. Remove tool 999 5022. Turn the cam position in ween 3.55–4.20 mm (0.140–0.166 in.) at intervals the position for firing on cylinder No. 3. Measure of 0.05 mm (0.02 in.). the clearance with a feeler gauge and rectify NOTE! The shims are to be fitted with the marking where necessary according to the instructions...

  • Page 48: Distributor, Oil Cooler, Exhaust Pipe, Heat Exchanger

    147. Place the gasket and crescent-shaped rubber 149. Remove the distributor cap. seal in position and fit the valve cover. Distributor 148. Turn the crankshaft to the firing position for No. 1 cylinder. Check this by unscrewing the oil filler cap and seeing how the camshaft’s cams are po- 150.
  • Page 49 151. Press the distributor into position in the crankcase Replacing contact breakers and check that the line on the rotor and the line on 153. Remove the distributor cover (1), rotor(2) and the the distributor housing are opposite each other. washer (3).

  • Page 50: Lubrication Oil Filter, Sea Water Pump, Expansion Tank

    155. Place the screws in the exhaust pipe and hang 157. AQ145. Fit the cooling water pipes (1) and (2) be- the gasket in position. NOTE! The marking “UT” is tween the oil cooler and the exhaust pipe and turned outwards. Then fit the pipe to the engine. A heat exchanger respectively.

  • Page 51: Thermostat Sea Water Strainer, Alternator

    159. Fit the pulley on the circulation pump and then 161. Fit a spacer ring and two sealing rings on the ex- the seawater pump. pansion tank’s outgoing water pipe (1) and press in the tank’s guide pin and pipes in the heat ex- changer.

  • Page 52: Starter Motor, Induction Pipe, Carburetor

    163. Connect the cables to the spark plugs. 165. Fit the fuel pump. Use new gaskets. Fit the tensio- ning bar and the engine mounting with the bracket for the alternator. Then tighten the alterna- tor in position and fit and tension the belt so that it can be depressed approximately 5 mm (0.2 in) with normal thumb pressure.
  • Page 53 167. Fit the oil dipstick sleeve in the crankcase. 170. Fit the fuel pipe between fuel pump and the car- NOTE! The bracket for the ignition coil is to be fit- buretor. Make sure that all sealing washers are ted on the flywheel cover’s upper side in the exis- fitted.

  • Page 54: Electric Wiring Diagram

    Cable marking ELECTRIC WIRING DIAGRAM INSTRUMENT PANEL ENGINE Design. Colour Ivory Position list Black 1. Key switch with start 9. Battery Black button 10. Main switch 2. Switch for instrument 11. Starter motor lighting 12. Charging regulator 3. Temperature gauge 13.

  • Page 55: Fault Finding Chart

    Fault finding chart Engine does not Engine runs Engine CAUSE Engines Engine reach correct becomes unevenly or does not stops speed at full abnormally vibrates start throttle or engine abnormally knocking Main switch not connected; discharged battery, break in electrical cables or main switch.

  • Page 56: Special Tools

    Special tools 884580 Valve spring compressor. 9991426 Drift for fitting ball bearing in flywheel. 9992817 Drift for fitting crankshaft oil seal on engine rear end. 9992818 Drift for removing valve guide. 9994090 Puller for ball bearing in flywheel. 9995017 Drift for removing and fitting bushing in connecting rod.
  • Page 57 9995023 Fixture for stand. 9995024 Drift for fitting crankshaft oil seal. 9995025 Drift for fitting intermediary shaft oil seal 9995026 Tool for adjusting spacer. 9995027 Drift for fitting valve guide (intake). 9995028 Drift for fitting valve guide (exhaust). 9995034 Counterhold for camshaft and inter- mediary...

  • Page 58: Technical Data Aq125A, Aq145A

    Technical Data AQ145A, AQ125A General Type designation ..............AQ145A AQ125A Type of operation ..............4 stroke overhead Max. effekt kW ..............99 (135 hp) 84 (115 hp) Max. speed ................91.7 r/s (5500 r/m) 80 r/s (4800 r/m) Max. cruising speed ..............
  • Page 59 AQ145A AQ125A Oil rings Number on each piston ............Height ................... 3.975–3.990 mm 3.978–3.990 mm (0.1565–0.1571 in.) (0.1566–0.1571 in.) Piston ring clearance in groove ..........0.030–0.065 mm 0.030–0.062 mm (0.0012–0.0026 in.) (0.0012–0.0024 in.) GUDGEON PINS Fully floating. Circlips at both ends in piston Fit.
  • Page 60 CAMSHAFT BEARING AQ145A AQ125A Camshaft bearings, diameter ..........30.000–30.021 mm (1.1811–1.1819 in.) Transmission Number of teeth, crankshaft gear .......... Intermediate shaft gear ............Camshaft gear ..............Timing belt ................Intermediate shaft Number of bearings .............. Diameter bearing journal, forward .........
  • Page 61 (I) (10 UKp. 12 USp). Oil pressure at maximum speed warm engine ....... 2.5–6.0 kp/cm (36–87 lbf/in. Oil grade alternative 1 ............Volvo Penta engine oil for carburetor engines Oil grade alternative 2 ............Engine oil SE (MS) Viscosity ................SAE 10 W/40 Oil filter Type ...................
  • Page 62 IGNITION SYSTEM AQ145A AQ125A Marking of cylinder ..............4th nearest the flywheel Spark plugs ................Bosch W6DC or corresponding Spark plug gap ..............0.7 mm (0.028 in.) Distributor Distributor, Bosch type JF4 ..........0231 178 017 Ignition timing. regular gasoline min. 90 octane RON...

  • Page 63: Valve Adjusting Kit

    VALVE ADJUSTING KIT FOR AQ125A, AQ145A Kit No. 884516 The kit is arranged to cover as large an adjustment range as possible and can be added to where necessary from Volvo Penta’s spare parts department. The complete kit (884516) contains the following parts: Part No.

  • Page 64: Technical Data Aq125B, Aq145B

    Technical data AQ145B, AQ125B General Type designation ............AQ145B AQ125B Type of operation ............4 stroke overhead Max. effekt kW (Hp) ............102 (139 hp) 88 (120 hp) Full throttle operation range ..........4800–5500 r/m 4700–5000 r/m Max. cruising speed ............200 r/m (below max.
  • Page 65 AQ145B AQ125B Piston rings Piston ring gap measures in the opening of the ring (oil rings) ................. 0.30–0.60 mm 0.25–0.50 mm (0.0118–0.0236 in.) (0.0098–0.0196 in.) Piston ring gap measures in the opening of the ring (compression ring) ............0.30–0.55 mm (0.0118–0.0217 in.) Piston ring oversize 1 .............
  • Page 66 DISTANCE ON CRANKSHAFT FOR THE THRUST BEARINGS AQ145B AQ125B Standard ................. 31.96–32.00 mm (1.2583–1.2598 in.) Oversize 1 ............... 32.27–32.25 mm (1.2687–1.2697 in.) Oversize 2 ............... 32.46–32.50 mm (1.2780–1.2795 in.) There are two makes of main bearings available. The upper and lower main bearing shells must be of the same make on each journal.
  • Page 67 Intermediate shaft (auxiliary camshaft) AQ145B AQ125B Number of bearings ............Diameter bearing journal, forward ........46.975–47 000 mm (1.8494–1.8504 in.) Diameter bearing journal, centre ........43.025–43.050 mm (1.6939–1.6949 in.) Diameter bearing journal, rear ........42.925–42.950 mm (1.6900–1.6909 in.) Radial clearance ............. 0.020–0.075 mm (0.0008–0.0029 in.) Axial clearance ...............
  • Page 68 Oil pressure at 2000 rpm, warm engine ......2.5–6.0 kp/cm (36–85 psi) Oil grade alternative 1 ............. Volvo Penta engine oil for carburetor engines Oil grade alternative 2 ............. Engine oil SE (MS) alt SF Viscosity ................SAE 10 W/40 Oilfilter Type ................
  • Page 69 FUELSYSTEM AQ145B AQ125B Fuel pump Type ................Diaphragm pump Feed pressure ..............0.15–0.28 kp/cm (2–4 psi) Carburetor Type ................Down draught carburetor Make and designation ............. Solex 44 PAI-4 Venturi ................Main jet ................155 (165) Idling jet ................Air jet ................180 (190) Needle valve ..............
  • Page 70 COOLINGSYSTEM AQ145B AQ125B Thermostat Type ................Wax thermostat Start opening at ............... 82°C (180°F) Fully open at ..............92°C (198°F) TIGHTENING TORQUE Note! Cylinder head should always be torqued when the engine is completely cold. The tightening torques only apply for oiled-in bolts and nuts.
  • Page 71 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________...
  • Page 72 Notes ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ ________________________________________________ Printed in Sweden by Novum Grafiska AB. 98.29000...
  • Page 73 Swedish. From: ....................................................................Refers to publication: ............................Publication no.: ..............Issued: ..............Suggestion/reasons: ..................................................................................................................................................................................................................................................................................................................... Date: ............Name: ............AB Volvo Penta Technical Information Dept. 42200 SE-405 08 Göteborg Sweden...

This manual is also suitable for:

Aq125aAq145bAq125b

Table of Contents