Section 2 (211 7401760 1985-19.

Section 2 (211
Reconditioning
engine
B 200, B 230
7401760 1985-19.
.
B 200, B 230
What do the designations mean?
B23OET
l+
IT :
Turbo
try
{
U
I
\/
I
v
I
This manual covers the following engine types:
Engine type
Model year
B2OOK
198*
I
Y
A=
carburetor engine (constant-pressure type
carburetor.
for instance Pierburg 175
CDUS)
K : carburetor engine (jet type carburetor, for
instance Solex-Cisac)
E : fuel injection engine
F = fuel injection engine
23O
:
B2OOE
B 2OO ET
B23OA
B23OK
-
USA version
B23OE
B 230 ET
cylinder volume
B23OF
=
petrol (gasoline)
B 230 :
B 200 =
B 230 FT
basic engine
a B 230 with smaller cu in. displacement
Volvos are sold in versions adapted for different markets. These adaptations
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.
Volvo owners planning to export their ca(s) to another country should investigate the applicable safety and exhaust emission requirements. ln some
cases it may be impossible to comply with these requirements.
Group 21 Reconditioning engine
Contents
Contents
Pagc
)
lmportant information
2
Specifications
2
.
Special tools
!
11
Operation
A 1-14
Thread repairs
Reconditioning engine
Disassembling
Cleaning and checking
Assembling
20
....:.
81-17
C 1-31
D 1-24
E 1-5
E 6-24
Cylinder head, disassembling .
cleaning and checking
assembling
Assembling(cont.) .
E 35-51
F1-12
It
l
c
lndex page 60
This manual deals exclusively with the overhaul of
the engine. For work carried out on the engine
when installed in the car, and for engine removal
and installation, please refer to the appropriate
manual.
Order number: TP
3Og2711
We reserve the right to make alterations
without prior notification.
1986, VOLVO CARS OF NORTH AMERICA,
A Division of Volvo North America Corporation
@
14
21
26
34
41
43
50
56
Group 21 Reconditioning engine
I
m po rta
nt
i
nfo rm ati
o
n, S pecificati o ns
lmportant information
Tightening torques
Two types of tightening
torques are used
manual:
in
this
l.
Tightening torque 40
wrench must be used.
ll.
Tightening torque 40 Nm (30 ft lbs). Correct
value, hcwever, it is not necessary to use a tor-
N.
(gO
ft lbs). A torque
que wrench.
The Specifications section includes torque only for
those parts which must be tightened with a torque
wrench.
Do not use sealing compound when repairing Turbo
engines.
The sealing compound may get into the engine lubri-
cating system and clog the oil channels in the turbo-
{
I
com presso r.
it
ft)i
Specifications
Group 20 General
LABELS
Type plate
On panel above right side headlamp.
Shows, among other things, identification number
(type designation).
ldentification plate (type designation)
Scandinavia: Plate on upper, rear stay in luggage
compartment.
USA, Canada: Plate located on top left of dashboard.
Other markets: No plate.
I
I
Group 21 Reconditioning engine
Specifications
USA/Canada
€YV1DX884XE1 ooooooe
1
Engine type
23:8200K
24:8200E
Others
YV
Decoding of identification number
{type designation}
7
26:
81:
0426
-T
Model year code letter
F=
G:
1985
1986
B 200 ET
B230A
83:8230K
84:B230E
I
86:B230ET
87:8230FT
Engine
88:8230F
Engine serial number and part number
l
Stamped in left side of engine (behind distributor on
B 230 A).
On the timing gear case is a label showing engine
type, Part Number and serial number.
lililr
ililrililililt ililil lilillililt
iilillt
499858
illlil llilililillill ililil IilililIlil
Be30
F
NR: 305
4ggB5g
D
b
4c53
Group 21 Engine assembly
l
CYLINDER HEAD
Height ... New : 146.1 mm (5.752in],
Min after machining : 145.6 mm (5.732 in)
Group 21 Reconditioning engine
Specifications
Maxdistortion
.....
NOTE that if distortion is greater than 1.0 mm (0.04 in)
lengthwise and 0.5 mm (0.02 in) crosswise the cylinder
head must not be machined but replaced.
Thickness of gasket:
New..
Fitted .
....mm
... mm
I
1.3(0.051 in)
l1
tl
il
1.2(0.047in1
II
il
CYLINDER BLOCK
Bore
Standard marked
mm
(in)
mm
(in)
mm
(in)
mm
(in)
mm
(in)
.... mm
(in)
C
marked D
Oversize
marked
E
marked
G
1
2 .....
B 200
88.90-88.91
B 230
96.00-96.01
(3.5000-3.5004)
88.91-88.92
(3.5004-3.5008)
88.92-88.93
(3.5008-3.5012)
88.94-88.95
(3.5016-3.5020)
(3.7795-3.7799)
96.01-96.02
(3.7799-3.7803)
96.02-96.03
(3.7803-3.7807)
96.04-96.05
(3.781 1-3.7815)
88.29
'(3's154)
88.67
(3'5303)
96.3
(3.7914)
96.6
(3.8031)
{
I
Rebore if wear exceeds 0.1 mm (0.004 in) and oil consumption
is abnormal.
PISTONS
A=
B
C
=
=
piston height
piston height from gudgeon (piston) pin centre to crown
measure diameter at right angles to gudgeon (piston) pin at distance
C
from bottom of piston
(
Engine
Cornpres-
type
sion ratio
B 200
8.5
10.0
B 230
8.7
9.0
9.8
10.3
Dimension, mm (in)
Weight
grams (oz)
440+7
(15.5+0.25)
440+7
(15.5+0.25)
c
A
B
67.7
aoa
(2.665)
69.9
41 .9
Q.752\
(1
540+7
(19.0+0.25)
535+7
(18.87 +0.25)
535+7
(18.87+0.25)
535+7
64.7
(18.87+ 0.25)
Q.5472\
39.7
(1.5630)
39.7
(1.5630)
39.7
(1.5630)
39.7
( 1 .5630)
(1
12.54721
64.7
12.54721
64.7
12.5472\
64.7
.s63)
.650)
13.4
I
(0.53)
13.4
(0.53)
7
(0.28)
7
(0.28)
7
(0.28)
7
(0.28)
NOTE:
1
Max weight difference for pistons in same englne is 16 grams {0.56 oz).
Piston running clearance
82001985
82001986-,8230.
Axial clearance, connecting rod to piston
.....
.
mm(in)
....mm(in)
...
. mm (in)
0.010-0.027 (0.0004-0.001
0.003-0.030 (0.0001-0.001
0.25-0.45 (0.001 -0.01 8)
1 )
2)
Group 21 Reconditioning engine
Specifications
Piston rings
Measure ring $ap
15 mm (0.6 in) from
lower edge of cylinder.
129 520
Height
.....
mm
(in)
Upper
Lower
oit
compr. ring
compr. ring
scraper ring
1.728-1.740
(0.0681-0.0685)
1.72V1.740
3.47$-3.490
(0.0681-0.0685)
(0.1
0.060-0.092
(0.0024-0.0036)
0.060-0.092
(0.0024-0.0036)
0.030-0.062
(0.0012-0.0025)
0.040-0.072
(0.0016-0.0028)
0.020-0.055
(0.0008-0.0022)
0.030-0.065
(0.0012-0.0025)
0.30-0.50
(0.012-0.020)
0.30-0.55
(0.012-0.022)
0.30-0.55
(0.012-0.022)
0.30-0.55
0.25-0.50
(0.010-0.020)
0.30-0.60
(0.012-0.0221
(0.012-0.0241
CLarance in piston groove, measured with ring on piston
B
200
....
mm
(in)
t
B 230
mm
Ring gap, measured
in cylinder, cylinder diam.
{in)
88.9, resp.
96.0 mm
B 200
mm
(in)
mm
'(in)
B 230
Piston pin
Light thumb pressure
(close running fit)
Thumb pressure (push fit)
Fit, in connecting rod
in piston
Diameter, standard
Length,
368-0.1 374)
. mm (in)
. mm (in)
.. .. . mm (in)
.. ... mm (in)
oversize
B 200 .
B 230 .
23.00 (0.9055)
23.05 (0.9075)
60 (2.36)
65 (2.s6)
VALVE SYSTEM
Valve clearance
D
Checking
lnlet and exhaust valves
cold engine
warm engine
I
.. . mm (in)
mm (in)
Adjustingshims,thickness
........
mm
(in)
Adjusting
0.30-0.40 (0.012-0.016) 0.35-0.40 (0.01,t-0.016)
0.35-0.45 (0.014-0.018) 0.40-0.45 (0.016-0.018)
3.30-4.50 in increments of 0.05 mm
(0.1300-0.1772) in increments of 0.002 in
IMPORTANT: Valves are Stellite coated and must not be
machined, only ground-in with paste against seat, according to method in op E 28, page 48.
Valves
7.955-7.970 mm (0.3132-0.3138 in)
7.935
mm
.03124 in)
New: 7.945-7.960 mm (0.3128-0.3134 in)
Min: 7.925 mm (0.3120 in)
Exhaust valve (not Turbo)
Group 21 Reconditioning engine
Specifications
New: 7.945-7.960 mm (0.3128-0.3134 in)
Min: 7925 mm (0.3120 in)
New: 7.965-7.980 mm (0.3136-0.3142 in)
Min: 7.945 mm (0.3128 in)
CAUTION! The exhaust valves on Turbo engines
are sodium filled. Discarded valves must not be
mixed with ordinary scrap iron until after sodium
content has been removed.
Exhaust valve, Turbo engines
Valve
1,1-1,9 r{n =
L7-2.3
0,051-0,075"
0
nn
=
(
.066-0 , 091"
I
Valve seat diameter
standa rd
oversize
mm {in)
mm (in)
mm (in)
1
2 ....
lnlet valve seat
Exhaust valve seat
46.00 (1.8110)
46.25 (1.82091
46.50 (1.8307)
38.00 (1.4960)
38.25 (1.5059)
38.50 (1.5157)
p+e,tzmfit
l+r
tlNG:---.:=NI
N\E--..-.'-'.-.
NOTE! When replacing valve seats, the interference between the seat and its bore should be 0.17
mm : 0.0067 in. That means that the valve seat
diameter should be 0.17 mm : 0.0067 in greater
=N
than diameter of bore in cylinder head.
I
Valve guides
Length
mm (in)
lnnerdiameter....
........
mm
(in)
Height above upper face of cylinder head
mm
(in)
Clearance, valve stem
newvalve)
max.
.
lnlet valve
Exhaust valve
52 (2.0471
52
8.000-8.022
{0.3150-0.3158)
15.4-15.6
(0.6063-0.6142)
8.000-8.022
(0.3150-0.3159)
0.030-0.060
(0.0012-0.0024)
0.060-0.090
(0.0024-0.0035)
0.15 (0.006)
0.1
(2.0491
17.9-18.1
(0.7047-0.71261
to valve guide (measured with
........
mm
(in
)
.. . mm (in)
Vaive guides are avaiiable in three oversizes, marked
with grooves.
Standard
Oversize
1
2
3
Marking
No groove
l groove
5 (0.006)
Reamer
for seat
51 61
2 grooves
5162
3 grooves
51
63
NOTE! The force used when pressing in valve
guides must be minimum 9000 N : approx. 20,000
lbs. lf the pressing force is lower, then the recess
for the guide must be reamed to the nearest over-
U
I
Group 21 Reconditioning engine
Specifications
There are two types of valve springs.
w
\
432,5
Ttr
FaEl
-1
::,:
:
5,
:,
!->-
.<
Type
Length,
ts---->
w
;
Type 2
TETFT=
tY
ir;
)
--)
l>=-.)
c\-r-<_>
.J/
)
B 230 A, K, E and ET
Type 2 is used on: B 2OO ET
B 230 F and FT
a'=<a---=->--)
a<--- ,--->
r<,
,rO"
Type 1 is used on: B200KandE
i-
l--?
l+i
Tappets
j=E
Type 2
1
Load,
N (lbs)
Length,
mm (in)
mm {in)
Load,
N (lbs)
45.0
0
(1.771
(0)
45.5
(1.7s1
0
(0)
38.0
(1.50)
27.0
(1.06)
280-320
38.0
28A420
(62-701
(1.50)
162-701
71|J-.790
( 1 56-1 74)
27.5
(1.08)
702-782
(Valve depressors)
Diameter
Height
mm
mm
mm
. . mm
..
. . . . ..
Clearance, shim to tappet
tappet to cyl. head
Adjusting shim
Thickness
36.975-36.995 (1.4557-1.4565)
30-31 (1.18-1.22\
0.009-0.064 (0.0004-0.0025)
0.030-0.075 (0.001 2-0.0030)
(in)
(in)
(in)
(in)
(for valve clearance)
3.30-4.50 in increments of 0.05 mm
(0.1300-0.1772) in increments of 0.002 in
.. . .. . mm (in)
Diameter
32.980-33.000 (1.2984-1.2992\
mm (in)
+
)
(154-1721
camshaft is marked with
a letter on rear end.
TIMING GEARS
Gamshaft
Engine type
)
Check values (cold engine)
Camshaft
Marking
Max lift height
Valve clearance
mm (in)
No. 1 inlet valve
lnlet valve should
open at:
mm (in)
B2OOK
B2OOE
B 2OO ET
10.35 (0.407)
11.37 (0.4481
T
9.9 (0.390)
B23OA
B23OK
B23OE
A
X
B 230 ET
A
10.5 (0.413)
10.65 (0.419)
11.37 (0.44e1
10.5 (0.413)
B23OF
M
inlet 9.5 10.374]'
exh. 10.5 (0.413)
9.9 (0.390)
B 230 FT
* btdc
:
before top dead centre; atdc
:
0.7 (0.028)
0.7 (0.028)
0.7 (0.028)
0.7
0.7
0.7
0.7
0.7
0.7
0.7
after top dead centre; bbdc
=
(0.028)
(0.028)
(0.028)
(0.028)
(0.028)
(0.028)
(0.028)
8'
1
btdc
1" btdc
7" btdc
13'btdc
10'btdc
1
1" btdc
13'btdc
6'atdc
44'bbdc
4'
before bottom dead centre;
btdc
Group 21 Reconditioning engine
Specifications
Camshaft (cont.)
Bearing journal, diameter
Radial clearance,
new
max.
.
Axial clearance ..
...
.. . mm (in)
..
..
mm (in)
mm (in)
mm (in)
......
mm(in)
.
..
.
29.950-29.970, (1.1 791-1.1799)
0.030-0.071, (0.001 2-0.0028)
0.15 (0.006)
0. 1-0.4, (0.00rt-0.01 6)
Camshaft bearings
Bearingdiameter
30.000-30.021 (1.181 1-1.1819)
lntermediate shaft
Diameter,
front
mm
.
(in)
mm
(in
rear..
...
)
mm
(in)
Radial clearance . .
Axial
.. .. . mm (in)
clearance...
.....mm(in)
Bearing journal
Bearing in cylinder
block
46.975-47.OOO
47.020-.47.050
(1.8512-1.85241
43.070-43.1 00
(1.8494-1.8504)
43.02H3.050
(1.6939-1.6949)
(1.6957-1.6969)
42.92H2.950
42.970-43.000
(1.6900-1.6909)
(1.6917-1.6929)
0.020-0.075, (0.0008-0.0030)
0.20-0.46 (0.008-0.020)
CRANKSHAFT ASSEMBLY
{
I
Taper
Crankshaft
Max. out-of-true
Crankshaft:
Axial clearance,
(in)
max.
Radialclearance (main bearings)
Conn. rod bearings, radial clearance ....
......
0.025 (0.01)
mm (in)
mm {in)
mm (in)
0.080-0.270 (0.0032-0.01 06)
mm (in)
mm (in )
0.004 (0.00016)
0.004 (0.00016)
2 (0.000F0.0028)
0.023-0.067 (0.0009-0.0026)
0.424-0.07
Main bearing journals
Out-of-round,max..
....
Taper, max.
Diameter:
..
..
mm
sta nda rd
(in)
undersize1.....
mm
(in)
undersize 2
Bearing
mm
(in)(in)
,"."r"f*idth
...
mm (in)
Width on crankshaft for flange bearing shell
mm
mm
mm
standard
oversizel ....
oversize2 ....
(in)
(in)
(in)
Out-of-round
55 (s4.987-55.000)
654 (2.1 648-2,1 6541
54.75 (54.737-54.750)
2.1
2.1
55s
(2.1
54.50 (54.487-54.500)
2.1 457 (2.1 451-2.1 457 I
22.9-25.1 (0.902-0.988)
31.96-32.00 (1.258-1.260)
32.21-32.25 (1.268-1.2701
32.4A+2.50 (1.278-1.280]'
Main bearings are made by two different manufactur-
ers. Upper and lower bearing halves in a bearing
should be from the same manufacturer.
At manufacture, sized bearing halves are used. They
are colour coded, red-yellow-blue. They are according
to one of the following alternatives:
Type 1 Both bearing halves marked yellow.
Type 2 One bearing half marked blue and one red. The
bearing half marked blue is located in the connecting
rod and the red one in the cap.
Q
Colour code
1S
tll
(
550-2.1 555)
Note. that for Spare Parts only yellow marked bearings are used.
(
Group 21 Reconditioning engine
Specifications
Connecting rod bearing journals
US measurements
Out-of-round, max.
.
Taper, max.
Diameter, standard
.
........
........
.....
.. ... ..
....
2 ....
Bearingrecesswidth.
undersizel
mm
mm
mm
mm
mm
mm
0.004
0.004
49.00 (48.984.-49,005)
48.75 (48.73+-48.7551
48.50 (48.484.-48.505)
0.00016 in
0.00016 in
1.9291 in (1.9285-1.9293)
1.9193 in (1.9187-1.9203)
1.9094 in (1.9088-1.9096)
23.9-26.1
0.92t-1 .03 in
0.25-0.45
0.001-0.018 in
152
5.98 in
20
0.7 oz
Connecting rods
Axial clearance at crankshaft
Length, centre to centre
Max. weight deviation between connecting rods in
b
Y
same
engine
..
mm
mm
..
. grams
Flywheel
Axial throw, max.
.
0.02 mm/1 00 mm diameter
(0.0008 inl4 in diameter)
b
v
TIGHTENING TOROUES
The tightening torques apply to oiled screws, bolts and
nuts. Degreased (washed) parts must be oiled before
use.
Cylinder head, tightening stages:
1=2ONm15ftlbs
2 = 60Nm45ftlbs
3 = Angle-tighten 90'
l
-
Y
Replace bolts if center section shows signs of extension.
Do not reuse bolts more than 5 times.
lf in doubt, fit new bolts.
Y
Tightening sequence for cylinder head bolts
Mainbearings
.....
Connecting rod bolts* first stage
second stage
Flywheel (use new bolts) .
Spark plugs (not to be oiled)
Camshaftgear
.
....
lntermediate shaft gear
Camshaftcaps
.....
Crankshaftcentre boltfirststage
.
secondstage.
* Old bolts can be reused if length does not exceed 55.5 mm (2.185 in).
Nm
ft
110
20
ang le-tighten 90"
70
80
14
lbs
50
25+5
18+4
50
50
20
60
35
35
14
angle-tighten 60'
45
Group 21 Reconditioning engine
Specifications
Group 22 Lubricating system
Engine oil
Oil Capacity*, excl. oil filter
incl. oil filter
litres
litres
litres
.
Max.-Min. difference
*Turbo: add 0.6 I (0.7 US qt) if oil cooler is drained.
Oil pressure at 33 r/s
f
:
3.35 (3.5 US qts)
3.85 (4.0 US qts)
1.0 (1.1 US qt)
2,000 rpm, warm engine and new oil
ilter
MPa
(psi)
0.25-0.60 (36-85)
OIL OUALITY
AccordingtoAPl
x Oils
...
...
min.SF*
Volvo does not recommend the use
with designations SF/CC and SF/CD comply.
of
{
sup-
plementary oil additives because of potential dam-
age to engine.
VISCOSITY (stable ambient temperatures)
I
Other markets (not USA, Canada and Japan)
USA, Canada and Japan
14 32 50 68 86
-3p -2O -1O O 10 20 30
-22 -4 14 32 sO 68 86
1040F
40
104
NOTE! For use in extreme driving conditions which involve high oil consumption, e.g.
mountain driving with frequent decelerations or fast motorway driving, SAE 15W40
!
I
(20Wl4}l oils are recornmended. Note, however, the higher temperature range.
(
Oil pump
Axial
clearance...
clearance)
Backlash (excl. bearingclearance)
Bearing clearance, drive shaft
idling shaft
Radial clearance (excl. bearing
Relief valve spring length under different loads:
.....mm(in)
..
.. . mm (in)
.....
mm (in)
mm (in)
. mm (in)
0.02-0.12 (0.0008-0.0047)
0.02-0.09 (0.0008-0.0035)
0. 1 5-0.35 (0.006-0.01 4)
0.032-0.070 (0.001 3-0.0280)
0.01
4.-0.043 (0.0006-0.001 7)
Length, mm (in)
39.2 (1.s4)
26.25 (1.0341
EEE
129 453
21.0 (0.83)
Load, N (lbs)
0
46-54 (10-121
62-78 (13.6-17.21