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Workshop manual

1. PISTON ClCANANCE Ys cicscctiveecncassseteenesaststicemscdesneesctasenien FOMUIMANKING vcze secs E E detiseavene sfseh heeetavease Piston rings Compression rings QUaAntY cass sis Sole das iaat epee ectcevatp av tin ncenteeh ik tigen Upper compression ring height n e 2nd compression ring height eeen Oil ring QUAN orcs eve sheg radsi ea setae asthe nape tate iaaa sainan He nin a a a AANE Piston ring gap in cylinder Upper compression FING ssiisririnisnssinsnsinrrininieiinsna 2Nd COmpression FING ccceeeeeeeeeeeeeeeeeeeeseeeeeeeeeneeeees Piston ring clearance in groove upper compression FING sesssessesserirrseseernrnnesrnnnnnenennna 2Nd COMPreSSiON NNG x cessics cseeeeetsceusecseseaececdetvevtacevsectse ai a A AE ST A E E E N Gudgeon pins Clearance piston pin connecting rod bush gudgeon pin gudgeon pin hole n s Gudgeon pin diameter ccccceesceeceeeseeesteeeeeeeseeaees Conrod bush int diameter cccscccceceesesteeeeeeeeeeeees Gudgeon pin hole diameter in piston ccceceeeees D2 55 A B C Atmospheric pressure 84 mm 100 mm 2 2 liter 850 25 rpm 3185 15 rpm 23 3 1 gt 27 Bar 1 3 4 2 Clockwise 20 30 0 20 mm Aluminum alloy 87 66 87 74 mm 47 66 47 74 mm 0 038 0 072 mm D2 75 A 4 Turbochargerwith charge air cooler 84 mm 100 mm 2 2 liter 850 25 rpm 3240 15 rpm 23 3 1 gt 27 Bar 1 3 4 2 Clockwise
2. 28 Check that the spaces for the seal on the engine block and crankshaft are clean Apply grease to the sealing edges and fit the seal 1 Apply an even layer of sealant 840 879 around the seal 2 and camshatt 3 Install the plate flywheel according to previous markings the elastic coupling and the flywheel housing tightening torque refer to Technical data Install the heat exchanger Mount the hoses on the heat exchanger and coolant pump Tighten the hose clamps Install the oil pipe to the turbo and charge air cool er only D2 75 Install the turbo only D2 75 Install the sea water pump Install the fuel filter bracket and feed pump tight ening torque refer to Technical data Mount hoses and tighten hose clamps Install the starter motor and alternator together with the front engine mounting Connect the hose to the sea water pump and tight en the hose clamp Install the exhaust pipe Install the electronics box install the connectors and other electrical connections Install the induction silencer Fill with oil refer to Technical data Fill with cool ant refer to Technical data Connect the battery cables Open the fuel taps and the sea cock Start the engine and check carefully that no leakage occurs Group 21 Short block Camshafts and valve lifters inspection Check using a steel ruler 1 that valve lifter contact surface facing the camshaft is convex or f
3. 4 Install new crankshaft seal 5 Center the cover in front of the oil pump NOTE Check that the spring pin in the timing gear cover can engage in the hole in the oil pump cover Turn the cover back and forwards and center it in the mid position The stop arm must be turned and held in place while the timing gear cover is positioned 53 Group 21 Short block 6 Install a new gasket on the timing cover NOTE If the gasket contains a center part this must be cut away Install the timing gear cover with the new gasket Check that the start spring is in position in the timing gear cover and is connected to the regula tor arm link arm Push the regulator arm through the hole in the cylinder block Screw the timing gear cover down 7 Turn the stop arm clockwise and connect to the injection pump Fit the clip NOTE Be careful to ensure that the shim that was placed underneath the injection pump flange is put back before the pump is placed in the block applies when the pump has been removed 8 Tighten the injection pump tightening torque refer to Technical data 9 Fit the key into the crankshaft and install the crankshaft pulley Tightening torque please refer to the Technical Data chapter 10 Connect the fuel hose to the injection pump 11 Check the injection timing crankshaft position in cases where a new complete camshaft has been installed or if a new cylinder block is used O
4. Check the wear of the valve guides refer to Check of valve guides before machining the valve seats Mill the valve seats When machined only re move enough material to give the valve seat the correct shape and a good mating surface Note Do not grind so much that the valve depth ex ceeds the permissible value Please refer to Chang ing the valve seats New valve seats shall be milled down so far that the distance between the cylinder head plane and the valve head surface A is 0 65 0 95 mm Grind the valves in with grinding paste and check contact with marker dye Install the seals valves valve springs spring washers valve cotters and valve caps Refer to Assembly of cylinder head Checking the valve guides Special tools 999 9683 999 9696 Put the cylinder head on the bench and put valves in the valve guides Measure the wear with rocker indicator 999 9683 and magnetic stand 999 9696 Lift each valve about 2 mm from its seat put the measurement tip on the edge of the valve head and check the wear Permissible clearance between valve and valve guide Inlet valve max clearance 0 20 mm Exhaust valve max clearance 0 25mm Note Since the valve guides are machined directly in the cylinder head the cylinder head must be changed when the clearance is too great even when the valve is new Group 21 Short block Overhauling the rocker arm mechanism Special tools 999
5. 14 15 16 D2 75 A with reverser MS25L D2 75 A with reverser MS25L 13 14 15 16 17 D2 75 A with reverser HS25A D2 75 A with reverser HS25A 14 D2 75 A with sail drive 150S Coolant filling Relay box with fuses Heat exchanger Charge air cooler Turbo Oil cooler reversing gear Starter motor Alternator ONOAARYOND 10 11 12 13 14 15 16 Oil dipstick reverser S drive Air filter Air intake Oil dipstick engine Oil filler engine Fuel pump Oil filter Fuel filter Injection pump Design and function D2 75 A with sail drive 150S 17 Sea water pump 18 Cooling water inlet S drive 19 Sea cock S drive 20 Folding propeller 21 Sacrificial anodes 22 Oil drain S drive 15 Design and function 16 Component description Cylinder head The cylinder head is made from specially alloyed cast iron It has replaceable valve seats for inlet and ex haust valves on D2 55 A B C and for exhaust valves on D2 75 A Engine block The cylinder block is cast in one piece from specially alloyed cast iron Flywheel An elastic coupling with a rubber damping element is screwed onto the flywheel The coupling transfers the power to the reverser S drive Timing gear The timing gears comprise both straight cut and heli cal gears The camshaft and sea water pump are driven from the crankshaft gear via an idler gear The engine s lubrica tion pump is integral with the
6. Volvo Penta Coolant Ready Mixed alternatively Volvo Penta Coolant concentrated mixed with pure water according to spec see Coolant Mixing This grade of coolant is the only one that is developed for and approved by Volvo Penta The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency that of fers complete engine protection Using an anti corro sion mixture exclusively is not permitted in Volvo Penta s engines Never use water by itself as the coolant A IMPORTANT Coolant of a suitable chemical for mula must be used all year round This applies even if there is no risk for frost damage so that the engine always has complete corrosion pro tection Future warranty claims on the engine and ancil laries may be rejected if an unsuitable coolant has been used or if the instructions concerning coolant mixing have not been adhered to NOTE The anti corrosive agents become less effec tive after a time which means that the coolant must be replaced see Service schematic The cooling system should be flushed when the coolant is changed please refer to Cooling system Cleaning Volvo Penta Coolant is a concentrated coolant that is to be mixed with water It has been prepared to work best with Volvo Penta engines and offers excel lent protection against frost and cavitation damage plus frost bursting Volvo Penta Coolant Ready Mixed is a ready
7. chapter Ow 50 Group 22 Lubrication system Repair Instructions Checking lubrication oil pressure The lubrication oil pressure can be checked by con necting a manometer with a hose to the connection for the oil pressure switch thread size in cylinder block 1 8 For the correct pressure at operating speed and temperature refer to Technical data If the oil pressure is too high or too low first try re placing the reduction valve and then check the oil pressure again Oil pump Removing oil pump 1 Remove the injection pump 19 Remove the fix ing screws and nuts on the pump Turn the stop le ver clockwise and carefully lift the pump to make the lock clip on the regulator arm accessible Remove the lock clip and free the regulator arm ZN IMPORTANT Be careful when disassembling the injection pump avoid damaging or bending the lever NOTE Retain any shims from beneath the injection pump flange Use the same thickness of shims when re installing unless the camshaft engine block or in jection pump have been changed 2 Remove the pulley use special tool 885 820 and 3 pcs M10x40 mm bolts Remove the timing gear cover Load the stop arm so that the springs on the inside of the housing do not come out of posi tion or spring out 51 Group 21 Short block 3 Remove the idler lock ring Save the sleeve wash er spring and shims Lift away the idler gear complete with cover and
8. Workshop manual a Group 20 23 26 30 2 0 D2 55 D2 75 Marine engine D2 55 A B C D2 75 A Contents Safety Precautions ccccccseceeeeseeeteeeees 2 Valve lifters INSpectO Misaia 47 Genera n maton sesssosscsececescosccssesssesesssscecocsec 5 Valves adjustment 000 eee cece eee e ete eteeteeeeeeeee 49 Flywheel replace ring gear 49 Special tools cccccceccceeesessseeeeeeeseessneeeeees 9 Crankshaft seal rear replace o n 50 Design and function ccccceeeteeeeeeeeee 10 Crankshaft seal front replace cccceeeeeeees 50 Location of engine type S gnS ceee 10 Group 22 Lubrication system Engine introduction s tessa 11 Oil DUMP sessa a a reece rere 51 Component description sseessieeseetesseees 16 Oil Channels Sa secers caceraiticierslocantetatecereratvenenaseatatedute 54 Repair instructions e 23 Oil pump bearing Overhaul 0 0 ee eee eeeeeeeeeeeeeee 55 GENEGIAl E E E A E 23 Group 23 Fuel system Engine fixture f1Xing ssssssssrsrrsstrrsrerrssrerrsseenn 2R SCHON pu Mperssmansnsa e 56 Compression test ccccscceeeeeeeeeeseeeeeteeeeeaes 24 Setting injection timing secsscscssssssssesseeeessssseeeeeee 57 Group 21 Short block Setting the engine speed 59 Short block disassembly 0 0 eee eeeeeeeeeeeeees 25 FSCO DUMP wcscncisicesereie cst nondenvocseeth swensnscueeetvadedeuewenys 60 Inspecting the engine block 29
9. or electrical sparks Never smoke close to the batteries The batteries generate hydrogen gas when charged which forms an explosive gas when mixed with air This gas is easily ignited and highly volatile A spark which can be caused by incorrect battery connection can cause a single spark which is sufficient to cause an explosion with resulting damage Do not move the connections when you attempt to start the engine risk of arcing and do not stand and lean over one of the batteries Always ensure that the Plus positive and Mi nus negative battery cables are correctly in stalled on the corresponding terminal posts on the batteries Incorrect installation can result in serious damage to the electrical equipment Re fer to the wiring diagram Always use protective goggles when charging and handling the batteries Battery electrolyte contains sulfuric acid which is highly corrosive Should the battery electrolyte come into contact with unprotected skin wash off immediately us ing plenty of water and soap If you get battery acid in your eyes flush at once with a generous amount of water and get medical assistance at once Turn the engine off and turn off the power at the main switch es before carrying out work on the electrical system Clutch adjustments must be carried out with the engine stopped The existing lugs on the engine reversing gear should be used for lifting the assembly Always check that the lifting eq
10. 3 with associated oil return pipe only D2 75 4 Remove the electronics box 4 complete with ca bling 5 Remove the starter motor 5 and alternator 6 and front left engine mounting 6 Remove the coolant hoses 7 heat exchanger 8 sea water pump 9 and circulation pump 10 7 Remove the charge air cooler 11 and oil pipe to the turbo only D2 75 25 Group 21 Short block 26 8 Remove 13 oil pressure monitor and oil pressure pipe 12 to the cylinder head 9 Remove the fuel lines 14 between the injection pump fuel filter and feed pump A WARNING Observe the greatest possible cleanliness in work on the fuel system Watch out for fuel spillage diesel oil is hazardous on repeated skin contact 10 Remove the supply pipes 15 between the fuel pump and injectors use the nut on the return fuel line as a counterhold so as not to bend the pipes Remove the fuel supply pipes and put them on a clean dry surface 11 Remove the return fuel pipe 16 and the injectors A IMPORTANT Observe the greatest possible cleanliness to avoid getting dirt in the fuel sys tem Plug the fuel pump and injector connec tions with suitable plugs for example kit number 885510 12 Remove the fuel filter and bracket 17 feed pump 18 and the nipple to the injection pump 13 Remove the injection pump 19 Remove the fix ing screws and nuts on the pump Turn the stop lever clockwise and carefu
11. lines back to the tank 1 Fuel tank 5 Fuel fine filter 2 Primary filter 6 Injection pump 3 Water separator 7 Injectors 4 Feed pump Injection pump The injection pump is an in line flange mounted pump The pump is driven by cams on the engine s cam shaft which operates the pump chambers directly Centrifugal regulator The regulator is mechanical and works with speed sensitive regulator weighs It is mounted on the front of the camshaft gear from where it is also driven The regulator weights operate the injector pump con trol rod via the regulation sleeve a lever and a regula tor arm The engine speed is regulated throughout the entire range from low idle to high idle all speed type 19 Design and function 20 akWwWN Injector nut Injectors Joining piece Compression screw Spring Adjustment shims Injector holder Washer Nut Feed pump The feed pump is driven by an eccentric on the cam shaft rear end The pump on D2 55 A B is also equipped with a manual hand pump Injectors The engines is provided with pintle type injectors Each injector basically consists of a nozzle retainer and a nozzle When the fuel pressure increases to the set value opening pressure the injector needle which is held pressed against its seat by the compression spring is lifted and atomized fuel is injected into the precom bustion chamber of the engine The opening pr
12. mixed coolant 40 Volvo Penta Coolant and 60 water This concentration protects the engine against corrosion cavitation damage and freezing conditions down to 28 C 67 68 Coolant Mixing AN WARNING All glycol is dangerous to human health and ecologically damaging Shall not be consumed Glycol is flammable Z N IMPORTANT Ethylene glycol should not be mixed with other types of glycol Mix 40 Volvo Penta Coolant conc coolant 60 water This mixture protects against internal corrosion cavi tation and frost damage down to 28 C Using 60 glycol lowers the freezing point to 54 C Never mix more than 60 concentrate Volvo Penta Coolant in the cooling liquid since this would give reduced cool ing effect and increase the risk of overheating and frost damage A IMPORTANT Coolant shall be mixed with pure water use distilled de ionized water The wa ter must fulfill the requirements specified by Vol vo Penta see Water quality A IMPORTANT It is extremely important that the correct concentration of coolant is added to the system Mix in a separate clean vessel before filling the cooling system Make sure that the liq uids mix Water quality ASTM D4985 Total solid particles lt 340 ppm Total NArdneSs sssisesisrinissiiss lt 9 5 dH Chloride essea aaa lt 40 ppm Sulfate ei oeae aaa aaa EAEN lt 100 ppm PH VAUS p2ebccstescetecrcseveecscess exedancee
13. 330 9W Cablecolors BL Blue LBL Light blue BN Brown LBN Light brown GN Green GR Gray OR Orange PU Purple R Red SB Black W White Y Yellow Cable cross section in mm is given after the color code on the wiring diagram Cross section not given 1 0 mm Dotted wires not included from Volvo Penta 91 Group 30 Electrical system Instrument panel alternative A without starter switch VOLVO PENTA 5 6789 On 2B Kh GB 6 1 2 3 4 15 1 Instrument illumination Cable colors 2 Tachometere with built in running hours timer extra equip Or blanking plug BL Blue 3 Connector for connecting extra warning display BN Brown optional equipment GN Green 4 Electronic unit alarm GR Gray 5 Warning lamp coolant temperature OR Orange 6 Warning lamp oil pressure PU Purple 7 Charge warning lamp R Red 8 Indication lamp glow plugs _ 9 Starter button Park 10 Press switch Instrument panel On Off Ww White 11 Connector for connecting extra neutral position switch Y Yellow optional equipment 12 Semiconductor diode Cable cross section in mm is given after the color 13 Alarm code on the wiring diagram 14 Tumbler switch Glow Alarm test Acknowledge 15 16 pin connector 92 with starter switch W BL 15 Spring biased Spring biased S 15a15b 3050 19 Cable colors BL Blue BN Br
14. Aluminum alloy 87 66 87 74 mm 47 66 47 74 mm 0 038 0 072 mm SHIBAURA mark inside piston shall when mounted face the fuel pump D2 55 A B C amp D2 75 1 97 1 99 mm 1 47 1 49 mm 3 90 3 98 mm 0 20 0 35 mm 0 20 0 40 mm 0 07 0 11 mm 0 04 0 08 mm 0 02 0 06 mm 0 010 0 027 mm 0 001 0 011 mm 27 996 28 000 mm 28 010 28 021 mm 27 999 28 005 mm 2 1 97 1 99 mm 1 47 1 49 mm 1 3 90 3 98 mm 0 20 0 35 mm 0 20 0 40 mm 0 07 0 11 mm 0 04 0 08 mm 0 02 0 06 mm 0 010 0 027 mm 0 001 0 011 mm 27 996 28 000 mm 28 010 28 021 mm 27 999 28 005 mm 95 Group 20 Technical data D2 55 A B C Cylinder head FAGIQIN E A N E E S E AN 69 7 70 3 mm Valve seat inlet and exhaust iNet diametere Snide enaere a Macc E a 36 35 36 45 mm Exhaust diameter ccccccceeseeceeseeeeceeeeeeeeeeeeeeneeeees 32 35 32 45 mm Mlet Widi enine eSEE a EENE 1 5 2 0 mm Exha st Width cccccessseeceeeeeeeeeetseeeeeeeseeeeeeeesseneeeees 1 9 2 2 mm Crankshaft with bearings Replaceable bearing shells for main and big end bearings Crankshaft end float ccccccccccessseseecececeeeeeeeseeaeeeeees 0 1 0 4 mm Main bearings radial clearance NOW 2 94 side dee ative 0 044 0 102 mm Main bearing journals Diameter in mm bearing journal standard Os 1 258 Be A 67 957 67 970 Big end journals Big end radial clearance 2 eceeeeeeeeeceeeeeeeeeeeeeeeees 0 035 0 085 mm Length of bearing jo
15. Seal rings for the crankshaft camshaft and drive shafts O rings regardless of where they are installed O rings for cylinder liner sealing are almost always made of fluorocarbon rubber Note that seals which have not been subjected to high temperature can be handled normally Special tools Wherever feasible the tool numbers have been punched on the tools AA ect 856 927 884 892 Oza 885 485 885 498 885 820 998 8539 998 9876 999 9683 999 9772 384 9641 998 6485 or 999 2520 856 927 Plastigauge for measuring main and big 981 2519 Multimeter end bearing play 998 8539 Compression tester 697092 Rggulat r tester 998 9876 Dial indicator 885 023 Valve spring compressor 999 5919 Puller seals 885 252 Adapter for testing compression pressure 999 6662 Pressure testing equipment 885 484 Adapter for testing compression pressure 9999179 Wrench for removing fuel oil filters 885 485 Engine fixture for overhaul stand 999 9684 Rocker indicator 885 820 Puller for pulleys 9999696 Magnetic stand 885 822 Magnetic pen 999 9772 Injector tester 885 498 Pressure foot used together with valve 384 9641 Assembly tool for oil pump shaft spring compressor 885 023 998 6485 or 999 2520 Overhaul stand This tool is used with one or more of Volvo Penta s older products Design and function Location of information decals and type plates There are type plates on the engine and transmission marked with identificat
16. each other Make sure that no piston ring gap is placed in line with the gudgeon pin 2 Place the bearing shells in position in the con rods and bearing caps Oil the bearing journals with engine oil 41 Group 21 Short block 7 1 Woodruff key 5 Gear wheel 2 Camshaft 6 Camshaft gear 3 Bearing 7 Regulator sleeve 4 Spacer 42 Check that the markings on the piston crown or inside the piston line up with those on the con rod Use a piston ring compressor and install the pis ton with con rod in its cylinder starting with cylin der no 1 forwards The con rod with the lowest number shall be mounted first in cyl no 1 and the con rod with the highest number closest to the flywheel The con rods shall be turned so that the mark number colorsplash is facing towards the injec tion pump camshaft side Mount the bearing cap and tighten the con rod bolts Tightening torque please refer to the Tech nical Data chapter Bearing caps must be in stalled so that the number markings paint marks on con rod and cap coincide Undamaged con rod bolts do not need to be changed they can be put back again Mount the oil suction pipe and oil strainer Tight ening torque please refer to the Technical Data chapter Use a new O ring Install the sump with a new gasket Tightening torque please refer to the Technical Data chapter Installing the camshaft The parts of the camshaft
17. fuse blows the electrical system can be recon nected by moving the cable to the next fuse connec tor Always first investigate the reason for the over load Relays The starting and glowplug functions are each con trolled by a switching relay These relays are identical and are thus mutually interchangeable Coolant temperature sensor extra equipment Coolant temperature monitor Fuses Starter relay Glowplug relay Charge sensing resistor Engine speed sensor Starter motor Alternator 10 Glowplug 4 pcs 11 Oil pressure sensor extra equipment 12 Oil pressure monitor OWONOANRWDY 74 ONOARWNH Sensor wire yellow 1 5 mm Charge splitter extra equip Alternator Fuse panel extra equip Starter motor Main switch Auxiliary batteries extra equip Starting battery engine Group 30 Electrical system Alternator Voltage regulator with sensor system The voltage regulator on the standard alternator 14V 60A is equipped with a sensor system The sensor system compares the charge voltage be tween the alternator terminals B and B with the voltage across the battery positive and negative termi nals The voltage regulator then compensates for any voltage drop in the cables between the alternator and the batteries by increasing the charge voltage sup plied by the alternator as necessary When delivered from Volvo Penta the sensor system is not activated The c
18. idler gear and is driven by it Regulator weights are suspended on the front of the camshaft gear Design and function Camshaft The camshaft is of conventional design with eight lobes that operate the pushrods and valves Crankshaft The crankshaft is suspended in five main bearings Axial thrust is taken up by separate thrust washers placed on the rear main bearing The crankshaft is statically and dynamically balanced and has induc tion hardened bearing surfaces The front end of the crankshaft has a Woodruff key and the rear end has a flange upon which the flywheel is mounted Main and big end bearings The main and big end bearings comprise steelshells lined with bearing metal The bearings are precision made and are ready to be installed The thrust washers for the crankshaft axial bearings are not available in oversize Con rods The con rods are of I section The small end is drilled for gudgeon pin lubrication Pistons piston rings The pistons are made from aluminum alloy They are fitted with three piston rings chrome plated two compression rings and an oil ring 17 Design and function 18 Cooling system general The engine is fresh water cooled with a closed cooling system The system is divided into two circuits In the inner circuit the fresh watersystem coolant is pumped around by a circulation pump driven via a belt from the crankshaft pulley The fresh water system works
19. in the bearingcap The bearing shells have an oil groove that should be placed in the upper bearing cap Check that the lubrication holes in the upper bearing shells are centered on the oil ducts 3 Oil the bearing and main bearing journal and mount the bearing cap in its correct place The chamfered edge shall face forwards on all bearing caps Group 21 Short block 4 Place the thrust washers in the rearmost bearing cap flywheel side with the oil groove towards the crankshaft Torque the bearing caps please refer to the Technical Data chapter for tightening torque 5 Carefully lift the crankshaft into position in the cyl inder block Note Tape the crankshaft gear before lifting the crankshaft into place to prevent the gear teeth from damaging the front bearing 6 Torque the main bearing caps in the engine block Tightening torque please refer to the Technical Data chapter 7 Check that the end float does not exceed 0 5 mm by using a special tool magnetic stand 999 9696 and dial gauge 998 9876 Mounting pistons in cylinders Note After replacing the crankshaft piston or gud geon pin the weight difference between con rods with piston and piston rings shall not exceed 10 g between cylinders 1 Lubricate the pistons and piston rings with engine oil beside the rings so that the oil finds its way into the piston ring grooves Turn the piston rings so that the ring gaps are displaced 90 from
20. is extremely important that no dirt or other kinds of foreign particles are able to get in since this would otherwise cause malfunctions or shortened repair life Our common responsibility Each engine consists of a large number of collaborating systems and components Any deviation of a component from its technical specification can dramatically increase the environmental impact of an otherwise good engine For this reason it is extremely important that specified wear tolerances are maintained that systems with adjustment facilities are correctly adjusted and that Volvo Penta Original Spares are used for the engine The stated service intervals in the Maintenance Schedule must be observed Some systems such as the components in the fuel system require special expertise and special testing equipment for service and maintenance Some components are sealed at the factory for environmental reasons etc It is only permissible to work on sealed components if you are authorized to do such work Remember that most chemical products incorrectly used damage the environment Volvo Penta recommends the use of biodegradable degreasers whenever engine components are de greased unless otherwise specified in the Service Manual When working aboard a boat be careful to ensure that oils wash residue etc are processed for destruction and are not inadvertently discharged with bilge water into the environment Tightening torque The tighten
21. more than 14 4 V See sections Checking and Fault Tracing the Al ternator and Checking the Regulator Checking the positive battery lead 1 Connect the multimeter between the alternator connection B and the battery positive pole Run the engine at 2000 r p m The voltage drop shall not exceed 0 2 V If the voltage drop ex ceeds this the battery lead connection must be remedied according to Actions below Then perform the test for Check of the negative battery lead 81 Group 30 Electrical system 82 Checking negative battery lead 1 Connect the multimeter between the alternator connections B and battery negative pole 2 Runthe engine at 2000 r p m The voltage drop shall not exceed 0 2 V If the voltage drop ex ceeds this the battery lead connection must be remedied according to Actions Actions WARNING Disconnect power and remove both battery cables before working on the charging circuit If the voltage drop in any of the tests above exceeded 0 2 V the battery leads connections must be removed and cleaned from oxide etc They spray the connec tions with a moisture dispersent contact oil and tight en the connections once more Treat the connections at the battery main switch starter motor alternator glow plug relay and glow plugs Alternator Checking and fault tracing the alternator 1 Remove the alternator s electrical connections Remove
22. neous charging of two independent battery circuits a Volvo Penta charge splitter can be fitted to the stan dard alternator accessory Batteries Never mix up the battery s positive and negative ter minals when fitting batteries Incorrect installation can result in serious damage to the electrical equipment Refer to the wiring diagram The battery poles shall be kept well cleaned and the cable shoes shall always be tightened and well greased to avoid power loss Fast charging of the batteries should be avoided If fast charging must be used the batterycables shall always be disconnected first NOTE Follow the appropriate safety regulations when charging batteries During charging unscrew the cell plugs but leave them in the plug holes Ventilate well especially if the batteries are charged in an enclosed space Always switch off the charging current before the charging clips are removed A WARNING Never expose the battery area to naked flame or electrical sparks Never smoke close to the batteries The batteries generate hydrogen gas when charged which forms an ex plosive gas when mixed with air This gas is easily ignited and highly explosive Always use protective goggles when charging and handling the batteries Battery electrolyte contains sulfuric acid which is highly corrosive Should the battery electro lyte come into contact with unprotected skin wash off immediately using plenty of water and soap If you g
23. oil pump Note the thrust washer behind the oil pump Inspection of oil pump 1 Check that the oil pump s cover and the outer and inner rotors are not worn or damaged 2 Check the clearance A between the inner 1 and outer 2 rotor Max permitted clearance 0 25 mm 3 Check the idler gear bearings and stub axle If necessary these shall be replaced Refer to Oil pump bearing overhaul 52 OANOaRWN Thrust washer Idler wheel with outer rotor Inner rotor Cover for oil pump Shim Spring Spring washer Circlip 5 Group 21 Short block Installing the oil pump Gears that are of importance in the timing gear as sembly are marked as follows Crankshaft gear 1 and idler gear 2 are marked with a punch mark The idler gear 2 and camshaft gear 3 with a punched line in front of a tooth and tooth groove re spectively IMPORTANT The components must be oiled be fore installation IMPORTANT Make sure that the gear wheel markings coincide 1 Install the thrust washer 8 on the idler wheel shaft stub Install the idler gear so that the marks align NOTE Do not turn the crankshaft before the timing gear cover has been installed 2 Install the inner rotor and cover on the oil pump Install shims spring spring washer and lock washer 3 Adjust the oil pump end float to 0 10 0 15 mm Shims are available in thicknesses 0 10 0 15 0 20 and 0 50 mm
24. or a dropped tool can lead in the worst case to personal injury Be careful with hot surfaces exhaust pipes turbos charge air pipes starting heaters etc and hot fluids in pipes and hoses on an engine which is running or which has just stopped Always refit shields that have been removed for service work before starting the engine A Check that the warning or information labels on the product are always clearly visible Replace labels which have been damaged or painted over A Never start the engine without installing the air cleaner filter The rotating compressor turbine in the turbocharger can cause severe injury For eign objects entering the intake ducts can also cause mechanical damage A Never use start spray or similar products as a starting aid They may cause an explosion in the inlet manifold Danger of personal injury A Avoid opening the coolant filling cap when the en gine is hot Steam or hot coolant can spray out and the system pressure will be lost Open the filler cap slowly and release the pressure in the cooling system if the filling cap or tap has to be opened or if a plug or coolant hose has to be re moved when the engine is hot Steam or hot cool ant might spray out in an unexpected direction A Hot oil can cause burns Avoid skin contact with hot oil Ensure that the lubrication system is not under pressure before carrying out any work Never start or operate the engine with the oil fill er cap re
25. pump 12 Check the injection timing crankshaft position in cases where a new complete camshaft has been installed or if a new cylinder block is used Installing cylinder head 1 Clean the cylinder head and cylinder block surfac es Remove any rust and carbon from bolt holes and from the threads on the cylinder head bolts 2 Install the valve lifters Note Install the valve lifters in their original positions 3 Insert the cylinder head gasket with the mark 1 upwards NOTE The new gasket must be of the same thick ness as the old one If a piston con rod crankshaft or engine block has been changed new measurement must be done The height difference between Gasket pistons and cylinder head thickness 0 45 to 0 30 mm 0 4mm 0 29 till 0 20 mm 0 5mm Group 21 Short block Dip them completely even bolt heads in rust pre ventative 116 1346 and let them run off on a net The bolts should have stopped dripping when they are installed otherwise oil cold may well up and be regarded as leakage AN IMPORTANT The bolts are phosphated and 5 13 POS JN 9 a i fe must not be cleaned with a steel wire brush If the cylinder head is painted the contact surfac es for the cylinder head bolts must be free from paint The clamping force in the joint could oth erwise be very poor Check that the dowels guides are fitted to the block Tighten the
26. seal mating surfaces on the crankshaft are not worn or damaged Max wear refer to Technical data Inspection of main and big end bearings Check the main and big end bearing shells and the front crankshaft bush Change worn bearing shells or any with damaged bearing surfaces Group 21 Short block 12_12 Inspection of front crankshaft bush Check the bearing play between the crankshaft journal and the bush Use both internal and external microme ters 1 Measure the bushes inner diameter at points 1 A and 2 Measure in two directions A and B at each point 2 Measure the bearing journal outer diameter and calculate the bearing play difference between pre vious measurement and max diameter of the bearing journal Max bearing clearance please refer to Technical Data Change the bush if the clearance exceeds the permissible value If necessary the crankshaft can be ground to a suitable undersize and the bush replaced with a corresponding oversize Check the bearing play again before the crank shaft is installed if grinding has been performed Replacement of front crankshaft bush 1 Remove the bush from the cylinder block 2 Check that the bush contact surface in the hous ing has no burrs or deformities 3 Mark a line across the hole in the housing and the bush with a marker pen Oil the outside of the bush and the contact surface in the housing 4 Place the bush 1 in
27. tery is not fully charged Sulfated battery A minor case of sulfating can be bro ken down by an additional 10 hours charging Replace the battery if this does not help Load testing the battery The battery acid density may not be less than 1 21 g cm 1 Fix a voltmeter across the battery poles 2 Activate the stop function and run the starter mo tor for about 10 seconds with the glow plugs acti vated and read off the start voltage It should not be less than 9 5 V 3 Check if any of the cells bubble when the starter motor is operated short circuit cell 4 Ifthe voltage is less than 9 5 V or if any of the cells bubble Replace the battery and try again If the voltage is 9 5 V or higher The battery is OK Check the charging voltage see next paragraph Group 30 Electrical system Checking the battery leads Set the multimeter to voltage test and connect the multimeter between the battery s positive and nega tive poles Run the engine at 2000 r p m Read off and note the voltage across the poles The alternator delivers approx 14 0 V Perform the test as follows 1 Connect the multimeter between the alternator connections B and B Run the engine at 2000 r p m The alternator shall deliver 14 0 14 4 V The total voltage drop shall not exceed 0 4 V Voltage drop less than 0 2 V Battery leads OK Voltage drop more than 0 3 V Perform a check of the battery leads The alternator supplies
28. the cylinder housing IMPORTANT Place the bush so that the oil hole is correctly positioned in the cylinder block The oil groove 2 in the bush must be furthest in Tap the bushing in with a suitable mandrel 3 until it lines up with the cylinder block 5 Check that the oil channels are open are pressing in Check also that the inner diameter of the bush is the same as the crankshaft diameter 35 Group 21 Short block 36 Checking the big end bearing clearance Special tools 856 927 The big end bearing radial play can be checked by us ing plastigauge 856 927 as follows 1 Wipe off any oil from the big end bearing and big end journal Apply a piece of plastigauge the same length as the width of the bearing along the big end journal Avoid the oil hole Mount the con rod and bearing cap observe the markings and tighten the conrod bolts Tightening torque please refer to the Technical Data chapter NOTE Do not rotate the con rod or crankshaft during measurement since this spoils the measurement strip 3 Remove the big end cap and measure the width of the pressed out measurement putty at the widest point Use the scale supplied with the plastigauge Max permissible big end bearing clearance please refer to the Technical Data Change the big end bearing if the bearing clearance exceeds the permissible value The big end journal can be ground to an undersize if required anda c
29. timing 2 Turnthe stop arm clockwise and connect the reg ulator arm to the regulator rod on the pump Fit the clip Screw the pump in place 3 Connect the fuel hose and return fuel line to the pump Install the delivery pipes 4 Prime the fuel system and test run the engine Setting injection timing 1 Remove the delivery pipes and return line If the block or the camshaft have been replaced a 0 5 mm shim shall be placed under the injection pump flange when installing 2 Remove the front 1st pressure valve holder Re move the pressure valve and refit the pressure valve holder It is recommended to remove the pump and hold it in an upright position when installing the pres sure valve holder NOTE Be aware of the pump element so as not to damage it 3 Make a drop pipe from i e a scrapped delivery pipe and mount it on the pressure valve holder Place a fuel container under the pressure valve holder drop pipe 57 Group 23 Fuel system 4 Connect a fuel container with stopcock to the inlet of the injection pump It should hold about 0 7 li C ter Use the hose between the fuel filter and the injection pump to connect the fuel container If ev erything is correctly arranged fuel should start to run out of the drop pipe m 5 Turn the crankshaft in normal direction until the SNA piston in cylinder 1 is at TDC the rocker arms on cylinder 1 should overlap normal direction D Move the actuator arm
30. to maximum position N Turn the crankshaft slowly in the normal direction Wow until the flow is 7 drops minute then read off the S LID number of degrees on the crankshaft pulley If the nA XO 4 value read off diverges from the value in technical x data the injection timing must be adjusted Turn the crankshaft another half turn 180 in the A 0 1 mm shim alters the injection timing approx 1 Thicker shims give later timing and thinner shims give earlier timing 8 Refit the pressure valve 58 Actuator arm Adjustment screw low idle Stop screw full throttle Adjustment screw racing speed Adjustment screw max fuel volume Lock nut Group 23 Fuel system Setting the engine speed Check that the accelerator control functions normally i e the actuator arm 1 is pressed against the low idle stop 2 when the accelerator control is at idle and is pressed against the full throttle screw 3 when the ac celerator control is at full throttle Adjust the control if necessary Also check that the air filter is not blocked and that the air inlet is not blocked L IMPORTANT The engine s fuel volume and speed are set at the factory to give highest pow er and least environmental impact These set tings must not be disturbed NOTE Seals on injection equipment may only be bro ken by authorized personnel Seals which have been broken must be re sealed Low i
31. tracing of the battery circuit should be performed in or der to eliminate other possible faults Testing should be performed with the alternator hot Run the engine at 2000 r pm for about 3 minutes before measuring A WARNING The alternators voltage regulators and battery circuit connections may not be dis connected or be disconnected with the engine running Check carefully that the measuring in strument is set to voltage measurement V to avoid short circuiting between the alternators connections 78 Group 30 Electrical system AN WARNING Be extremely careful so that the measurement cables clothes or similar come into contact with the drive beltor pulleys on the engine or alternator when the engine is running Check the tension of the alternator belt and the belt condition Replace the belt if it is cracked worn or oily Adjust the belt tension as required It should be possible to depress the belt approx 10 mm between the pulleys Fault tracing the battery circuit Special tools 9812519 Note that other instruments may use different sym bols for the set measurement function Current loss check 1 Wash the battery with lukewarm water and dry off Remove the battery cables and clean the poles 2 Reconnect the positive pole again 3 Turn off the keyswitch or disconnect power to the instrument panel and all other consumers con nected to the starting battery 4 Setthe multimeter for DC cur
32. with coolant Flush the cooling system clean before new coolant is added Close all drain points and fill up with coolant to the correct level The engine must be stationary when the cooling system is filled and must not be started until the system is vented and completely filled If a heating unit is connected to the engine cooling system the heat control valve should be fully opened and the in stallation vented during filling Check the hoses and joints and rectify any leaks Fill the system slowly Filling must not be done so fast that air locks are formed in the system The air should be allowed to flow out through the filling opening Check the coolant level after the engine has been run for about an hour Top up with coolant as necessary 69 Group 26 Cooling system 70 Checking the coolant level WARNING Do not open the filler cap when the engine is hot except in emergencies Steam or hot fluid may spray out Turn the filler cap to the first stop and allow any ex cess pressure to hiss out before removing the cap completely Top the coolant up as necessary The level should be between the filler opening and the low er edge of the level marker 1 Fit the filler cap If a separate expansion tank is fitted extra equip ment the coolant level shall be between the MIN and MAX marks Coolant temperature too low Low coolant temperature can be caused by e Faulty thermostat e Faulty temperature sensor o
33. 08 mm max 0 02 mm max 0 12 mm max 0 12 mm max 84 2 mm max 84 7 mm max 85 2 mm max 0 06 mm 0 15 mm 0 2 mm max 0 7 mm max 0 2 mm max 0 2 mm 99 Group 20 Technical data Tightening torque in Nm Cylinder h ad sieccieecetssesicgatstidde nel aede aaas a e 100 Main bearings upper to lower bearing CAPS ccccessseceeeeeeeeeeenees 52 main bearing caps to cylinder block hex bolts 52 rear Cap Allen bolt cccceeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeseaes 27 Bigend DEANNGS a eiccccathes eee teeruestuancedtyewesundedereenesieness 52 End plate flywheel housing cceeeeeeseeeeeeteeeeeeeees 25 Flywheel ROUSING c ececcgeeateceesencteee ccd chensteieteees eee 25 IY WINGO E E E 74 Elastic Coupling sseeccccrelsee canis cee anetecens ceeeseneenenceestges eens 22 Adapter plate to flywheel housing eee 22 Strainer ll PUMP esiisasid nana i anie 10 Oil SUMP ciiin nia iaae ae 10 Drain plug Ol SUMP ssecsctiensssneeevctsestacedspebeeebeendereestpteiees 35 Timing gear COWS cacti s2e ccd shane edde cel eanines taian 10 Crankshaft pulley sidesse eai 300 INJSCUOM pump catrien Maret aae aia REAR 15 Bearing block rocker arm Shaft ccseeeeeeeeeees 33 Vae COVEN rocs Shounen ivemeetacees 14 Pressure oil pipe cylinder block cylinder head 12 MIMS CLOS x ceececet iad atte teesecera A eed 64 Delivery PIDOS wesecscncteutecesanectevteentneeds pelea tenaderwestgea
34. 6400 1 Remove the screw from the front edge of the rocker arm shaft Screw an M8 bolt into the rocker arm shaft Grab the bolt with i e a pair of pliers and pull the rocker arm shaft out 2 Disassemble the rocker arm mechanism Remove the rocker arms springs and washers 3 Clean the components Be especially careful with the rocker arm shaft oil channels and the oil holes in the rocker arms 4 Check the wear of the rocker arm shaft with a mi crometer 5 Check that the rocker arm bearing surface is not worn oval Check the clearance between rocker arm and shaft Check that the spherical section of the adjust ment screw is not deformed or worn The threads on the pin and lock nut should be undamaged The lock nut should be in good condition 6 Oil the rocker arm shaft and assemble the various parts Assembly of cylinder head Special tools 885 023 885 498 1 Press the new valve stem seals onto the valve guides Note The seals for the inlet and exhaust valve guides are different The inlet valve seal has a silver spring while the exhaust valve seal s spring is black 2 The valves must be installed in the correct order Oil the valve sfems and install one valve 1 in it s guide Place the valve spring 2 and spring wash er 3 in place and compress the spring with valve spring compressor 885 023 and pressure foot 885 498 Install the valve cotters 4 Be careful when mounting the valves and when com
35. IMPORTANT NOTE are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out For this reason all we can do is to point out the risks which we believe could occur due to incorrect work in a well equipped workshop using work methods and tools tested by us All operations described in the Service Manual for which there are Volvo Penta Special Tools available assume that these tools are used when carrying out the repair Volvo Penta Special Tools have been specifically developed to ensure the most safe and rational working methods possible It is therefore the responsibility of anyone using other tools or other working methods than we recommend to determine that there is no risk of personal injury or mechanical damage or malfunction as a result In some cases special safety precautions and user instructions may be required in order to use the tools and chemicals mentioned in the Service Manual These rules must always be observed so there are no special instructions about this in the Service Manual By following these basic recommendations and using common sense it is possible to avoid most of the risks involved in the work A clean workplace and a clean engine will eliminate many risks of personal injury and engine malfunction Above all when work on fuel systems lubrication systems induction systems turbocharger bearing caps and seals is done it
36. Venting the fuel system cceeseeeeeeeeeeeereeees 61 Upper block plane ceeeeeeeeeeeeeeeeeteeeteneeeeeeees 29 Fuel filter replat ipepe ea aa 63 Cylinder bore sssssnsenssesnineseeeerrnnsereetnnnsneennnn nenene 29 Fuel pre filter drain and replace ccceeeeeees 63 Cylinder head Overhaul ceceeeeeeeeeeeeeseeeeeeees 30 a excite S cse a reece eee errerrereerererr rere act 64 Cylinder head disassembly cccccseeseteeeees 30 Group 26 Cooling system Cylinder head inspection seceeeeeeeeeees 30 Fresh water SYSteM cccccccsssescsssesseseeseeseseeseeeens 67 Valve seat replace 0 essen 31 GOOlAN a AE T Sais veise tigereastte eee 68 Valves and MeN Sets a sreceeibeincoeceeteris Draining COON sseni aas 69 Valve guides check ei is Oe A 32 Filling With Coolant crsnnorsrinssamninniennas 69 Rocker ANTE CMMs I QVAMAUN isisisi 2 Checking the coolant level cceceeeeeeeteetees 70 Cylinder Head Assambiy ae e me Cleaning heat exchanger s s s 71 Crankshaft inspection jae Sanne cela eae 34 Circulation PUMP sises cesses nteeenads 72 Main andbig and bearings inspection PT ahi Sea Water PUMP isiin inansa aiii 73 Crankshaft bush Mont MEPEGNON eissii sa Thermostat eirmis 73 Crankshaft bush front replace s 35 Crank bearing play Check ccccccccscseeeseeseseees 36 Group 30 Electrical system Piston rings inspection and adjustment 37 Des
37. amshaft with associated rocker arms must be replaced 48 inlet Exhaust Firing order 1 3 4 2 Correspondingcylinder 4 2 1 who s valves overlap Group 21 Short block Adjusting valves NOTE The clearances shall never be checked while the engine is running but on a stationary cold engine Valve clearances Inlet and exhaust 0 2 mm 1 Remove the valve cover 2 Turn the engine in normal direction of rotation until no 1 piston is at TDC after the compression stroke The valves on cylinder 4 overlap 3 Check and adjust the valve clearances for cyl no 1 Turn the engine in normal direction of rotation a half turn and check the clearances for cyl no 3 the valves on cylinder 2 overlap Check the clearances for the remaining cylinders in firing order 4 Replace seal Clean the valve cover and install it Test run the engine and check that no oil leakage occurs Replace ring gear on flywheel 1 Mark the flywheel position on the crankshaft sim plifies installation Remove the flywheel 2 Drill a hole or two in a tooth root on the ring gear Crack the ring gear with a chisel at the drilled holes and remove it 3 Clean the ring gear contact surface on the fly wheel with a wire brush 4 Heat up the new ring gear in an oven 120 150 C so that the ring gear is heated evenly 5 Place the heated ring gear on the flywheel and drive into place with a hammer and soft mandre
38. ange of shim thickness of 0 1 mm Checking injectors Spray pattern Special tools 999 9772 1 Pump with injector tester 999 9772 and check the spray pattern The fuel spray should be cone shaped and aligned with the injector center line Fuel drops shall not occur in the spray 2 Check that the fuel spray has a circular cross section Sealing When sealing is checked investigate the fuel leakage which can occur between the injector nozzle seat and the tapered sealing surface in the injector sleeve 1 Dry the injector nozzle so that it is dry 2 Pump the pressure up to about 2 MPa below the opening pressure of the injector please refer to Technical Data Keep the pressure constant for about 10 sec and check that no fuel drips out from the tip of the injector Damp injectors can be approved Fit a protective plug to the injector s pipe connection and over the injector nozzle if it is not to be installed immediately 65 Group 23 Fuel system 66 akWN Injector nut Injectors Joining piece Compression screw Spring Adjustment shims Injector holder Washer Nut Overhauling injectors 1 Clean the injector externally 2 Fix the injector holder in a vise Unscrew the in jector nut and disassemble the injector Note Be careful that the injector nozzle does not fall out during disassembly 3 Pull the injector nozzle out of the injector sleeve and put the components in c
39. are mounted as illustrated Install the front plate A with a new gasket Tight ening torque please refer to the Technical Data chapter Oil the camshaft bearing surfaces and carefully lift the camshaft into place complete with drive gear and regulator weights Note Be careful to avoid damaging the bearings bearing tracks and camshaft lobes Install the camshaft lock washer B in the correct position and tighten it Tightening torque please refer to the Technical Data chapter Thrust washer Idler wheel with outer rotor Inner rotor Cover for oil pump Shim Spring Spring washer Circlip Group 21 Short block Mounting and installation Gears that are of importance in the timing gear as sembly are marked as follows Crankshaft gear 1 and idler gear 2 are marked with a punch mark The idler gear 2 and camshaft gear 3 with a punched line in front of a tooth and tooth groove re spectively 1 Fit the Woodruff key in place and mount the crankshaft gear ZN IMPORTANT The components must be oiled be fore installation ZN IMPORTANT Make sure that the gear wheel markings coincide 2 Install the thrust washer 8 on the idler wheel shaft stub Install the idler gear so that the marks align NOTE Do not turn the crankshaft before the timing gear cover has been installed 3 Install the inner rotor and cover to the oil pump Install shims spring spring washer a
40. as flame 600 700 C diagonally across the seat Let the cylinder heat cool for 3 5 min in the air Then carefully tap the seat out with a mandrel check that the cylinder head is not damaged The valve seat can also be milled out check that the cylinder head is not damaged 2 Carefully clean the valve seat bed in the cylinder head Check the cylinder head for cracks 3 Cool the new seat with dry ice or similar to minus 60 70 C and heat the cylinder head to approx 60 100 C 4 Press the seats into the cylinder head Use a hy draulic press and a suitable mandrel 5 Machine the seats to the correct angle and width Grinding of valve and valve seats Special tools 885 023 885 498 1 Use valve spring compressor 885 023 and pres sure foot 885 498 to remove the valve cotters Remove the valve washers springs and valves Place the parts in the correct order in a valve holder Remove the valve stem seals 2 Clean the components 3 Check valve stem wear Measure the diameter with a micrometer at points II and III Diameter min inlet 6 89 mm Diameter min exhaust 6 84 mm 31 Group 21 Short block w 32 Grind the valves in a valve grinding machine Grind the sealing surface as little as possible just enough to clean it up If the edge of the valve head B after grinding is less than 0 5 mm the valve must be scrapped Equally any valve with a bent valve stem must be scrapped
41. bush out 2 Press the new bush in NOTE Make sure that the oil hole in the bush lines up with the drilling in the con rod Draw a line across the hole in the con rod and the bush with a felt tip pen Check that the oil duct is open after pressing 3 Broach the bush and measure the con rod with an internal dial gauge NANN AES Group 21 Short block Assembling the piston piston rings and con rod Install one of the circlips in the piston Oil the gudgeon pin and con rod bush Heat the piston to approx 100 C Place the piston and con rod so that the marks align The marking on the con rod and the SHIBAURA marking inside the piston must face the same way Slide the gudgeon pin in NOTE It should be possible to slide the gudgeon pin in easily It must not be driven in 4 5 Install the other circlip Check that the con rod is not tight on the gudgeon pin bearing Check the big end bearing clearances Please re fer to Inspecting the crankshaft and Inspecting the main and big end bearings Check the piston ring gap in the cylinder bore and that the rings do not bind in the piston ring grooves Install the piston rings on the pistons using pis ton ring pliers Letters or markings on ring surfac es must always be turned so that the marking fac es upwards Install the oil scraper ring first Put the expansion spring 1 for the oil scraper ring in the lower pis ton
42. cccesst scence a ENRE iae aaia max 0 25 mm Piston rings Piston ring clearance in groove COMPPESSION TINGS 2 sccasissenseriderivavestiverisantsrecsevavencectenays max 0 25 mm Oil Scraper nN gosta ee a AE max 0 15 mm Piston ring gap in Cylinder ceeseeeeeeeeceeeeeeees max 1 0 mm Gudgeon pins Gudgeon pin diameter cccceeeecseeeeeneeeteeeeeteneeees min 27 996 28 000 mm Clearance gudgeon pin conrod bush 000ee max 0 08 mm gudgeon pin gudgeon pin hole max 0 02 mm Cylinder head Enee E E E N max 0 12 mm Engine block Warping head plane cccceecseeeeeeeeeeteseeeeeneeeeesaaees max 0 12 mm PROC aaa apis det vce desta vasa duties e E E Aaa aE eai max 84 2 mm OSIM DiC cei sunsedevestisaaieseasci N max 84 7 mm Omm TDi O cranna iS max 85 2 mm Crankshaft Out of straightness ssoeeeeseeeeseeeereeerrserrnserrnrernrene max 0 06 mm Conrods Straightness max deviation on 100 mm MOASUPECIONGHN s ccesieiecccssters whececedewe rasani 0 15mm Twist max deviation on 100 mm measured length 0 2 mm End float conrod crankshaft cccccceeeeseeeeeeeeeeees max 0 7 mm Bearing clearance Main Deanng ercsi arrau max 0 2 mm Big endbearings essssessssrrrrensrrrrresrrrrnnrnsrnrnnnnsrnnnnns max 0 2 mm Group 20 Technical data D2 75 A min 25 Bar max 0 25 mm max 0 25 mm max 0 15 mm max 1 0 mm min 27 996 28 000 mm max 0
43. ch instrument lighting Switch Alarm test Acknowledge Tachometer with built in running hours timer extra equip Or blanking plug Key switch Alarm Connector for connecting neutral position switch extra equip 16 pin connector 2 pole connector for possible additional panel Cable cross section in mm is given after the color code on the wiring diagram Cross section not given 1 0 mm Group 20 Technical data General Engine designation ccccecccceecessseeneeeeeeeeeeeeeeeeeeeeeees INGOs Of CYIIMOGNS 3 fascte cduess Soecebenpessdecnetitneradands amesevintee ame toes IMOUICTION SYSTE ticcscesesvteccceeteare ania nei Cylinder volume total scssi seisseen snina Power output see sales literature Aling Speed inosan alela E EAE AEE E E E Compression ratio sisemine ang ae Compression pressure at starter motor speed Firing sequence cyl no 4 closest to flywheel Direction of rotation Seen from front s e Max permissible rearwards inclination in operation Max side inclination in Operation eeeeeeeeeeeeeeeeees Valve clearance stationary cold engine inlet and exhaust Weight engine less oil and water eeeeeeeeeeeeeees Max permitted back pressure in exhaust system Pistons MTG rial saisonnier a a AE nE EAA EEEE Height total ants iss cedentersatinetinendticntssiteeecte dnasiacaieneens Height from gudgeon pin center to piston crown
44. cription 0 002 ccececeee cece eect teeeteeeeeeeeeeteeaeaaeeaeeees 74 Piston and cylinder bore inspection and Important information concerning meas rement en 37 the electrical System cesses testes teens 76 Con rods SPECTOR csisasscecrasisininsavedanrasioncwstsinsvnss 38 Fault tracing glow plugs charging system 78 Con rod bush replace c scssessssssessessessesseeseeeseee 38 AMG IM ALON sonene e unease 82 Piston piston rings and con rods installation 39 Starter MOON siiedesdieecsedetiheasieceeetetiacrectsdidls 86 Camshaft Measurement ccccccccsscccesesceseseesesescesees 40 Electrical component ceeeeeeeeeeeeeeeeeeees 89 Timing gear assembly inspection c cccseeeeee 40 Wirngdiagrams ssie iueriiierannn e 92 Crankshaft installation cccccccccceeeeeseeeeeeeeeeees 40 Group 20 Technical data Piston installation in Cylinder ccceceeeeeeee 41 Technical Gata sacscciigssescascicessineccedsdekdecees donde sceedete 96 Camshaft installation ccccccessseeeesseseteeeees 42 Wear tolerances ccccccssssssssssesseeceeeeeeeeeeeeeseeeeeee 100 Cylinder head installation icssceetadncuinesecacncdcenteates 44 Tightening torque eee eect eee eeeeeeeeeeeeee tetas 101 Safety Precautions Introduction This Service Manual contains technical data descrip tions and repair instructions for the Volvo Penta prod ucts or product versions noted in the table o
45. cylinder head bolts in three steps as follows Refer to tightening diagram 1st tightening 30 Nm 2nd tightening 70 Nm Final tightening 100 2 5Nm Install the copper injector washers Install the injectors Tightening torque refer to Technical data Install the pushrods valve caps and rocker arm mechanism with gasket Tightening torque please refer to the Technical Data chapter Install the oil pressure pipe between the block and rocker arm mechanism together with the oil pres sure sensor Install the oil pressure valve Tightening torque please refer to the Technical Data chapter Turn the crankshaft round a couple of rotations Adjust the valve clearances Tightening torque please refer to the Technical Data chapter Install the valve cover Install the injection pump hollow bolt and banjo union with new copper washers Install new copper gaskets and install the return fuel line Tighten the nuts and connect the return pipe Install the delivery pipes tightening torque refer to Technical data Install the glow plugs and power rail Install the circulation pump tightening torque refer to Technical data Clean the sealing ring seat in the cylinder block and the contact surface of the plate Install the rear crankshaft seal 45 Group 21 Short block 19 D2 55 A B D2 55 C amp D2 75 46 18 20 21 22 23 24 25 26 27
46. dle 1 Check that the gap 6 is about 3 mm when the accelerator is in the idle position If necessary Undo locknut 7 and adjust screw 8 to give the correct gap 2 Warm up the engine and check the idle speed with a tachometer refer to Technical data for the correct idle speed 3 Adjust to the correct idle speed with adjusting screw 2 4 Check the gap 3 again as in item 1 Racing speed high idle Warm the engine up and check the racing speed with a workshop tachometer when the engine is unloaded at full throttle please refer to Technical data for cor rect racing speed Adjust the following as necessary 1 Loosen the stop screw 3 so that it does not limit the movement of the actuator arm 1 2 Runthe engine unloaded at full throttle and adjust to the correct racing speed with adjuster screw 4 remember to re seal the screw 3 Adjust stop screw 3 to give a clearance of 0 1 mm between stop screw 3 and the actuator arm 1 when the throttle control is at the full throttle position 59 Group 23 Fuel system 60 NOoORWOND Piston Strainer Valve housing Lid Pump housing Pin Diaphragm Feed pump Removal of the feed pump 1 Clean around the pump 2 Close the fuel taps Loosen the fuel connections from the pump 3 Remove the feed pump from the cylinder block Empty the pump from fuel Disassembly and inspection of the feed pump 1 Check that th
47. e between 450 and 650 mV which is the voltage drop across the diode Any other value indicates a faulty diode 2 Check the other B diodes by moving the positive probe to the other connections 1 2 3 3 Then check the B diodes in the opposite direc tion by reversing the positive and negative probes Perform the same measurements as above The instrument should show a one 1 with these measurements furthest to the left Any other value on the instrument indicates a faulty di ode Group 30 Electrical system Checking B diodes 1 Connect the instruments positive probe to the di ode plate B connection and the instruments neg ative probe to one of the stator windings connec tions 1 2 3 Read off the instrument as previously A normal value should be between 450 and 650 mV Any other value indicates a faulty diode Then check the B diodes in the opposite direction by reversing the positive and negative probes Perform the same measurements as above The instrument should show a one 1 with these mea surements furthest to the left Any other value on the instrument indicates a faulty diode If any of the diodes are faulty the whole diode plate must be replaced Checking D diodes The diode plate s three magnetization diodes are checked in the same way as above 1 Connect the instrument s positive probe to each stator winding connection 1 2 3 and the negative probe to D The voltage drop f
48. e cotters 5 Place the valves in order in a marked valve holder so they can be refitted in their original positions Remove the valve stem seals 2 2 Clean all components Be especially careful with the cylinder head oil and coolant channels 3 Remove any remaining carbon deposit from the cylinder head sealing surface Note A wire brush may not be used for cleaning the cylinder head bolt threads or the underside of the bolt heads Inspecting the cylinder head Cylinder head warping must not exceed the value giv en in Technical data The check should be done with a feeler gauge and a straight edge Measurement is done at six positions A F If warpage above the permissible level is found the cylinder head must be changed If leakage has been found or if the cylinder head has blow lines no spe cial measurement is needed since such a cylinder head will have to be attended to in any case Check the valve seats and check that the studs are firmly seated Inspect the cylinder head for cracks Carefully check the areas around the valve seats and the holes for the injector nozzles 30 Group 21 Short block Changing the valve seats A NOTE On D2 75 only the inlet valve seat can be changed On D2 55 both the inlet and exhaust valve seats can be changed The valve seat should be changed when the distance A measured with a new valve exceeds 1 8 mm 1 Remove the old valve seat by heating it with a g
49. e piston 1 does not bind in the pump housing Note The feed pump s hand pump only functions when the piston is depressed 2 Remove the strainer 2 from the feed pump s inlet pipe and check that it is not restricted by dirt Re install the strainer by pressing it in until a click is heard 3 Check the function in the valve housing 3 before disassembly as follows Suck in the inlet IN and blow in the outlet OUT The function is normal if they seal in both cases 4 Mark the position of the cover 4 valve housing and pump housing 5 5 Remove the screws holding the cover Remove the cover and valve housing 6 Turn the membrane and piston until the pin 6 in the piston is in front of the groove in the pump housing 7 Press in the piston and membrane 7 Press the pin out of the piston and remove the piston mem brane and springs from the pump housing 8 Check that the membrane is undamaged and shows no cracks Assembling the feed pump 1 Assemble the piston 1 membrane 7 and springs in the pump housing 5 Press the piston and membrane together and press the pin 6 into the piston 2 Turn the membrane and piston so that the pin 6 in the piston is not aligned with the groove in the pump housing 3 Install the valve housing 3 and cover 4 accord ing to the previously made marks Tighten the screws D2 55 A B Group 23 Fuel system Priming the fuel system The fu
50. eeeteeeeeeeeeees 0 20 mm Exhaust Valve stem diameter ccccesssccceeeeeeeeeeeeeeeeeeneeeeees 6 94 6 95 mm Valve head 6dGe isaiccinisncnuisaniinedaiieice 0 925 1 075 mm Clearance valve stem valve guide ceeeeeees 0 050 0 075 mm Valve seat angle in cylinder head n e 45 Valve clearance cold engine ccccceeeeeeeeeeeeeeeeeeeees 0 20 mm Valve springs Length UNIOAC OG eese 35 mm with 79 4 N 8 1 kp load 0 0 0 30 4 mm Pushrods Cengih totales a a ien 226 mm Outer diameter isiccssiccivsasisasiecarsseecusessadeescnnancsdibacvenndsaazaas 6 35 mm Rocker arm mechanism Rocker arm shaft diameter eesseeeeneerseerrnrreernnns 14 95 14 97 mm Clearance rocker arm shaft rocker arm bush 0 030 0 093 mm Lubrication system Oil pressure hot engine at operating speed 150 500 kPa Oil pressure UG a ceciece cesasceccteacVecssestinscivaveeecvetevvasssiveceas 50 150 kPa Reduction valve opening pressure eeeeeeeeeeeeeee 245 345 kPa Lubrication oil pump clearance inner outer rotor e 0 01 0 15 mm end float rotor COVES ceccceeeeeeeeeees 0 01 0 15 mm Oilgrade seisseen Riana ar AE Ori NER ANARE ENARA VDS 2 ACEA E5 API CH 4 Viscosity at 5 to 50 0 oo eccecsceccceceessseeeeeeseesaaees SAE 15W 40 SAE 20W 50 Max oil volume incl oil filter no engine in lination Approx ooo eee eee eee eeeteee eee eeeeeteeeeeeeeeeaaees 10 6 liter Min o
51. el system must be primed after a filter change if the fuel tank has been run dry and after a long term stoppage D2 55A B 1 Open the priming screw 1 on the fuel filter Avoid fuel spillage Use i e rags on the priming point 2 Pump fuel up with the hand pump 2 until fuel without air bubbles can be seen Continue pumping and tighten the priming screw at the same time Note If the pump works poorly crank the engine so that the mark on the pulley is at TOP if it is still poor crank the engine another revolution to TOP 3 Normally additional priming is not required Start the engine and check that no leakage occurs 4 Ifthe engine does not start after a short attempt loosen the pressure pipes at the injectors a few turns Hold the injection pump actuator arm in it s max position and crank the engine with the start er motor until fuel leaks from the pressure pipes Tighten the pressure pipe nuts Tightening torque please refer to the Technical Data chapter The glow plugs are activated at the same time as the starter motor You can save the batteries if the starter motor is only used for short periods when priming 61 Group 23 Fuel system 62 D2 55 C D2 75A D2 55C and D2 75A 1 Open the priming screw 1 on the fuel filter Avoid fuel spillage Use i e rags on the priming point Pump fuel up with the hand pump 2 until fuel without air bubbles can be seen Continue pum
52. enoid and can be slid axially on the rotor The starter motor is fitted with a reduction gear which provides a higher torque Removing the starter motor 1 Remove both battery cables 2 Undo the electrical connections from the starter motor 3 Remove the starter motors fixing bolts and lift off the starter motor Group 30 Electrical system Disassembling the starter motor 1 Clean the starter motor externally 2 Remove the solenoid a 3 Remove the protective cover from the rear bearing N casing Remove the locking ring and where fitted BN the shim s A B Remove the rear bearing casing 5 Remove the brush plate Remove the stator hous ing from the gear housing 6 Remove the lever arm that is fitted in the gear housing and the rotor 7 Remove the starter gear that is fitted in the gear housing First remove the locking ring by striking the contact ring with a suitable sleeve 87 Group 30 Electrical system 88 Inspecting the starter motor Fault tracing the starter motor should be left to an au thorized electrical workshop which has the necessary test equipment 1 Test the rotor with regard to winding breakdown and open circuits with the appropriate test equip ment 2 Check that the brushes contact surface on the commutator is even and free from dirt and oil If the commutator is worn or burnt it can be ground with emery paper no 500 or 600 Measure the commutator
53. essure of the injector is determined by the compression spring which is adjustable with shims Fuel filter The fuel filter is discardable The filter insert is a pa per filter Design and function Lubrication system general The engine has a pressurized lubrication system with full flow oil filter Oil pump The lubrication pump is located within the idler gear on the timing gears from where it is also driven The pump is a rotor pump with an inner rotor and an outer rotor eccentrically mounted in relation to each other The inner rotor has one tooth less than the outer rotor The function of the pump is that the volume of the spaces between the inner and outer gears increases and decreases During the first section of the rotation of the inner rotor the volume increases a partial vac uum occurs and oil is sucked into the inlet After about a half rotation the volume is reduced and a pressure occurs which forces the oil out through the outlet 21 Design and function 22 Reduction valve The lubricating oil pressure is limited by a reduction valve The valve is located in the lubricating system just before the oil filter The valve opens with high pressure and allows the oil to flow back into the sump Crankcase breather To prevent over pressure and to separate fuel vapor water vapor and other gaseous combustion products the engine is fitted with clo
54. et battery acid in your eyes flush at once with a lot of water and get medical as sistance at once Group 30 Electrical system Electrical wiring Never make holes in the cables insulation to perform measurements with needles In a corrosive atmo sphere such as a boat it only takes 2 years for a small cable with a needle hole to oxidize off If it is absolutely necessary to make a hole in the in sulation this must be repaired in a suitable way after testing Connection of extra equipment All extra equipment shall be connected to a separate connection box and correctly fused Extra power take offs directly from the instrument panel should be avoided The permitted extra take off is however total ly max 5A applies to all instrument panels together Galvanic corrosion The S drive is electrically isolated from the engine and shall never be used as a grounding plane The S drive has insulation B placed between the adapter plate and the upper gear housing An isolation bush A shall be installed on one of the lower bolts ZN IMPORTANT The S drive shall never be used as a grounding plane or be electrically connect ed with any other equipment i e radio naviga tion equipment rudder bathing steps etc Electric welding Remove the positive and negative cables from the batteries Then disconnect all cables connected to the alternator Always connect the welder earth clamp to the compo nent
55. f con tents Check that you have the correct Workshop Manual for your engine Read the available safety information General Infor mation and Repair Instructions in the Service Manual before you start to do any service work Important In this book and on the product you will find the follow ing special warning symbols AN WARNING Possible danger of personal injury extensive damage to property or serious me chanical malfunction if the instructions are not followed AN IMPORTANT Used to draw your attention to something that can cause damage or malfunc tions on a product or damage to property NOTE Used to draw your attention to important infor mation that will facilitate the work or operation in progress Below is a summary of the risks involved and safety precautions you should always observe or carry out when operating or servicing the engine A Immobilize the engine by turning off the power supply to the engine at the main switch es and lock it them turned off before starting work Set up a warning notice by the helm station A As a general rule all service operations must be carried out with the engine stopped Some work such as adjustments need the engine to be run ning however Approaching an engine which is running is a safety risk Remember that loose clothing or long hair can fasten in rotating parts and cause serious personal injury If work is done adjacent to a running engine a careless movement
56. flushing of the oil channels Z IMPORTANT Check that the oil pressure valve on the right side of the block is removed before removing the crankshaft NOTE Tape the crankshaft gear to protect the bearing surfaces in the block during disassembly 30 Remove the locking screws holding the main bearing caps Lift the crankshaft out carefully complete with caps backwards Inspecting the engine block Upper block plane Check that the upper engine block plane does not have any cracks or other damage Also check that it is not warped in the same way as for the cylinder head Max warpage please refer to Technical Data Change the engine block if it is outside the tolerances Cylinder bore Check that the cylinder bores are not scored or dam aged in other ways Measure the cylinder bores at the upper and lower turning positions for the piston rings app 10 mm and 100 mm below the engine block plane and also in the middle Measurement should be done with an internal dial gauge and both along and transverse to the en gine block A and B Concerning max permitted cylinder diameter see un der Wear tolerances in Technical data 29 Group 21 Short block Cylinder head overhaul 885 498 885 023 Disassembling cylinder head Special tools 885 023 885 498 1 Remove the valves 1 and valve springs 3 Compress the springs with compressor 885 023 together with pressure foot 885 498 and remove the valv
57. h a new gasket 6 Open the sea cock or tap on the S drive Start the engine and check carefully that no leakage occurs Thermostat Replacing the thermostat 1 Turn the main switch off Drain the water from the freshwater system 2 Remove the cover 1 the spacer 2 and lift out the thermostat 3 Remove the rubber ring D2 55 A B Checking the thermostat 1 Check that the thermostat closes completely 2 Heat up water in a container to 75 C 3 Lower the thermostat into the water Check that the thermostat is still closed after 3 5 minutes 4 Raise the temperature to boiling point 100 C Check that the thermostat has opened at least 8 mm after 3 5 minutes Replace the thermostat if it does not fulfill the requirements NOTE If the thermostat does not close completely the engine will run too cold D2 55 C amp D2 75 73 Group 30 Electrical system General The engine is fitted with an AC alternator The system voltage is 12V and the electrical system is single pole The electrical system can include as extra equip ment sensors for monitoring the engine s coolant temperature and oil pressure The electrical system is shown in two ways The wir ing diagram shows wire runs cable cross section and color Fuses The engine is equipped with a fuse block with four fus es 15A One fuse safeguards the electrical system and blows if overloaded the others are spares If a
58. h reverser HS25A D2 55 A B with reverser HS25A 1 Coolant filling 6 Oil cooler reversing gear 11 Fuel pump 2 Heat exchanger 7 Oil dipstick reverser S drive 12 Oil filter 3 Relay box with fuses 8 Air filter Air intake 13 Fuel filter 4 Alternator 9 Oil dipstick engine 14 Injection pump 5 Starter motor 10 Oil filler engine 15 Sea water pump 11 Design and function D2 55 A B with sail drive MS25S Coolant filling Heat exchanger Relay box with fuses Alternator Starter motor Oil dipstick reverser S drive Seon POON 12 10 11 12 13 14 Air filter Air intake Oil dipstick engine Oil filler engine Fuel pump Oil filter Fuel filter Injection pump 11 12 13 14 D2 55 A B with sail drive MS25S 15 16 17 18 19 20 Sea water pump Cooling water inlet S drive Sea cock S drive Folding propeller Sacrificial anodes Oil drain S drive Design and function D2 55 C with sail drive 130S Coolant filling Heat exchanger Relay box with fuses Alternator Starter motor Oil dipstick reverser S drive Noe O NS 10 11 12 13 14 Air filter Air intake Oil dipstick engine Oil filler engine Fuel pump Oil filter Fuel filter Injection pump D2 55 C with sail drive 130S 15 16 17 18 19 20 Sea water pump Cooling water inlet S drive Sea cock S drive Folding propeller Sacrificial anodes Oil drain S drive 13 Design and function
59. hanger insert at any sign of block age slowly increasing coolant temperature NOTE First check clean the seawater filter Also checkthe seawater pump impeller wheel and the sea water intake IMPORTANT Close the sea cocks before work ing on the cooling system 1 Drain the water from the seawater and freshwater systems 2 Disassemble the exhaust manifold together with the heat exchanger 3 Undo the screws and covers at the front and rear of the heat exchanger Pull out the insert 4009 SPO Poog 1 e IEA 4 Flush and clean the insert both internally and ex ternally Also clean the housing If there are loose deposits in the insert cleaning can be performed by passing a suitable steel rod through the tubes in the opposite direction to the water flow NOTE Check that the rod does not damage the tubes 71 Group 26 Cooling system 72 5 Install the insert in the heat exchanger NOTE Be careful to install the insert in the correct position Make sure the hole in the insert aligns with the hole in the housing and that the venting hole is upwards The insert is marked with UP Install the covers on the front and rear ends of the heat exchanger Connect the hose from the sea water pump and tighten the clamp Assemble the exhaust manifold together with the heat exchanger Fill the engine with coolant Open the sea cocks or valve on the S drive and start the engine Check that
60. ieees 23 Pressure valve holder cicccccsccetisecececcatepecsscdacsevextsveacnets 42 Reduction valve ix cactecevscttes ceectes tress ceeetentuns REREN 64 Locking screw max fuel volume cceeeeeeeeeeeeee 15 Locking screw engine speed s 15 GOW PUG sleni E EEEN 18 Qil press re MOMMMOK issnin ara e 18 Coolant temperature MOnItOr sesseeeeseeeeeeeesereeeeeeeeeee 27 Qil pressure SENSO vic schesevasectedetessaccestaceeeeecesteterteeest 18 Coolant temperature Sensor cceceeeeeeeeeeeeeteeeeeeees 18 The tightening torque given is the final tightening torque The cylinder head is to be tightened in three steps in the correct tightening sequence see tightening diagram Oil the threads of the cylinder head bolts with clean oil 100 References to Service Bulletins Group No Date Refers to Notes Notes Notes Report form Do you have any comments or complaints about this manual Please take a copy of this page write your comments on it and send it to us The address is at the bottom We would appreciate it if you were to write in English or Swedish PROTONS TOU CATON eee sc tease Sect E E E Aaa Se te cueateget PUBICATOMINO sisese orr eih Date OF ISSUC Be ceveiccidecccsadicwithsosadscudnecebeded E AE ia iai Suggestion MOTIVATIONS sssaaa OS AB Volvo Penta Technical Information Dept 42200 SE 405 08 G teborg Sweden g00z 80 ysi 6uy 696C Y LL
61. if it has deep grooves in the skirt surface Likewise if the piston has one or more cracks in the gudgeon pin hole If any such damage is found the injection equipment should also be checked Measure the piston diameter with a micrometer at right angles to the gudgeon pin hole and 10 mm from the bottom edge of the piston Then measure the cyl inder bore and calculate the clearance between the cylinder and piston Replace the piston if the clearance exceeds the per mitted or if the piston diameter is less than permitted value 37 Group 21 Short block 38 Inspecting the con rod 1 Check the con rods for cracking straightness and twist before considering changing the gudgeon pin bush Discard the connecting rod if it is cracked bent or twisted Check the wear of the little end with a gudgeon pin If the clearance is correct an oiled gudgeon pin should slide slowly due to its own weight through the bush Use a new gudgeon pin and measure con rod straightness in a fixture Max deviation 0 15 mm for 100 mm measured length Measure any con rod twist Max deviation 0 20 mm for 100 mm measured length Check the end float between the con rod and crankshaft Change the con rod if the end float exceeds 0 035 0 085 mm Also check the con rod bushes Clearance be tween the gudgeon pin A and con rod bush B refer to Technical data Replacing con rod bushes 1 Press the old
62. il channels Clean and flush the oil channels in the engine with cleaning liquid and then with steam or rinsing oil ata pressure of 300 400 kPa in conjunction with a larger engine overhaul Clean the oil pressure pipe between the cylinder block and cylinder head Clean the drilled oil channels in the cylinder block crankshaft and con rods with a cleaning brush 54 Oil pump bearing overhaul Special tools 384 9641 In order to remove the oil pump the timing gear and crankshaft must be removed 1 Drive out the oil pump bearing section 1 located in the engine block Tap it out from inside the crankcase 2 Use tool 384 9641 First screw the tool s guide pin 1 into the engine block Then put the new oil pump bearing 2 into the tool block 3 3 Place the tool block with the bearing in place us ing the guide pin Tap in the bearing until the tool bottoms on the engine block NOTE It is important that the engine block sur face towards the tool is clean and even 55 Group 23 Fuel system Repair Instructions Observe the greatest possible cleanliness in work on the fuel system Injection pump Removing the injection pump NOTE Repair work that requires work on the injection pump and which can change it s settings shall only be performed by a specially trained mechanic who has the necessary equipment at his her disposal All warranties for the engine are forfeit if the seals are broken by una
63. il volume incl oil filter no engine INCIINAtTION approx ooo ee eeeeeeeee ee eeeeeeeeeeeteeeeeeeeeeeeeetaeeees 8 9 liter Note The temperature values refer to constant ambient temperatures Group 20 Technical data D2 75A Gear wheel 3 13 43 43 13 6 955 6 970 mm 0 925 1 075 mm 0 03 0 06 mm 45 0 20 mm 6 94 6 95 mm 0 925 1 075 mm 0 050 0 075 mm 45 0 20 mm 35 mm 30 4 mm 226 mm 6 35 mm 14 95 14 97 mm 0 030 0 093 mm 150 500 kPa 50 150 kPa 245 345 kPa 0 01 0 15 mm 0 01 0 15 mm VDS 2 ACEA E5 API CH 4 SAE 15W 40 SAE 20W 50 10 6 liter 8 9 liter 97 Group 20 Technical data D2 55 A B C Fuel system Injection Sequence i cc s2hec civccchaeteicceecreneltieecee vine inenveen 1 3 4 2 Feed pump max suction height s e 0 8m FOC PIOSSUIC asiata 15 25 kPa Injection pump Injection start crankshaft position cc eeeeeeeeees 22 0 1 b t d c Pump element diameter ccccessccceeeeeeeseeeeeeeeeees 6mm OKC eseese ae vas eaa aaa eaae 7 mm Injectors Opening pressure for checking seeeeesseeeeeeeeeeee 15 2 16 2 MPa Opening pressure when adjusting csceeeeeeeeeee 15 7 MPa Needle valve GiaAMeter ccccceseccceceeseceeeeeeseeeeeenaneeees 4mm Pir QAI Ctl iaeei 1mm JOU AN GIS sacs sits de E E EE T teres ativievsectandance 4 Cooling system EES eee eee eee eee eee eer ee ere reer ee eerere Over pressure closed cooling system Freshwate
64. in all correspondence about an engine The Service Manual is produced primarily for the use of Volvo Penta workshops and service technicians This assumes that people who use the Manual have basic knowledge of marine drive systems and can do the tasks of a mechanical or electrical nature associated with the trade Volvo Penta constantly improves its products so we reserve the right to make modifications without prior notification All information in this manual is based on product data which was available up to the date on which the manual was printed Any material changes introduced into the product or service methods after this date are notified by means of Service Bulletins Spare parts Spare parts for electrical and fuel systems are subject to various national safety requirements such as the US Coast Guard Safety Regulations Volvo Penta Original Spare Parts meet these specifications No damage whatever occasioned by use of non original Volvo Penta spares for the product will be compen sated by the warranty offered by Volvo Penta Certified engines When doing service and repair on emission certified engines it is important to be aware of the following Certification means that an engine type has been checked and approved by the relevant authority The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified engine This makes special demands on service and repair work as follo
65. ing torque for critical joints that shall be tightened with a torque wrench are listed in Specifications Tightening torque and noted in the job descriptions in the book All torque specifications apply to clean screws screw heads and mating faces Torque data stated apply to lightly oiled or dry threads Where grease locking or sealing agents are required for screwed joints this is stated in both the operation description and in Torque Where a particular torque value is not specified for any faste ner the general tightening torque in the table below shall apply The torque specification is a target value and the fastener does not need to be tightened with a torque wrench Dimension Tightening torque Nm Ibf 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 Torque angle tightening With torque angle tightening the fastener is tightened to the specified torque and tightening then continues through a pre determined angle Example for 90 angle tightening the fastener is turned a further 1 4 turn in one sequence after the specified tightening torque has been achieved Lock nuts Disassembled locknuts shall not be re used they shall be replaced by new ones since the locking properties are impaired or lost when the nut is used several times For locknuts with plastic inserts i e Nylock the tightening torque given in the table shall be reduced if the Nylock nut has the same nut height a
66. ion numbers This information must always be used a reference when spare parts are ordered The appearance and location of the type plates is shown below The figures in brackets refer to the location of the identification number on the type plate Engine Productdesignatiorn I cscuretvvsccecesnesteccdedabeseabaces seduced e aaae r see aa eoa a arara aae Senalnumber 2 iraan aa A aE E E a aA Productn Mber 3 ias5cceciuet vance anoion a ageage a a E aaa AEE Certification number 4 sesiis iae aaa aE aa a aah S drive Reverser Product d signation 5 iesse epar a anes Desi en gy ANE wanes A aN RAOT SenalNUMDEF G execs 2s Sessa deeroen eduaceenectec ceneteestesiauedessuce e RAE EAE Eer AAAS REE n AOF PA ATAARE aai PrOGUCE MUMIDGE T srdiserisrii eieae ee aE e OEA SESE EiS Gedrratio 8 en a a e E a ara RA iN Propeller GOSIQGMAUON aastst nen aaa a ERER PEERAA RRE TARERE WOEN TRANSOM ASSEMBLY u Fy XXXX 1 XXXX 5 FA xx xx XXXXXXXXXX 6 XXX XXX 7 Engine and transmission decal VOLV O PENTA XXXXXX 7 No S drive and reversing gear sign EMISSION APPROVED IN ACCORDANCE TO THE BODENSEE SCHIFFAHRTS ORDNUNG ANLAGE C O APPROVALNO XXXXXXXXXX 4 O VOLVO XXXX 1 XXX XXX 3 PENTA XXXXXXXXXX 2 Engine plate 10 Design and function Engine introduction VOLVO PENTA 5 12 13 14 D2 55 A B with reverser MS25L D2 55 A B with reverser MS25L 5 12 13 14 D2 55 A B wit
67. l The ring gear should then cool naturally 6 Clean the contact surfaces on the flywheel and crankshaft Check the rear crankshaft seal Change as necessary 7 Install the flywheel according to previously made marks Tightening torque please refer to the Technical Data chapter 49 Group 21 Short block Replacement of rear crankshaft seal The seal consists of a rubber ring and is accessible once the plate behind the flywheel housing and the elastic coupling flywheel and flywheel housing have been removed Note Mark the flywheel position on the crankshaft simplifies installation 1 Remove the crankshaft rear seal 1 Check that the spaces for the seal on the engine block and crankshaft are clean Apply grease to the sealing edges and install the seal 2 Apply an even layer of sealant 840 879 around the seal 2 and camshaft 3 3 Install the flywheel the elastic coupling the adapter plate and the flywheel housing Tightening torque please refer to the Technical Data chapter Replacement of front crankshaft seal The seal consists of a rubber ring and can be replaced once the crankshaft pulley has been removed Use puller 999 5919 to remove the seal 1 Remove the key and tape over the keyway 2 Apply grease to the new seal and install it with a suitable socket 3 Remove the tape Install the key and crankshaft pulley Tightening torque please refer to the Technical Data
68. lat If the surface is concave change the valve lifter If the valve lifter is worn all across the lifting surface the valve lifter should be scrapped The ditch shows that the lifter has not been turning A dark line on the outside of the valve lifter shows that the surface is not worn on the other hand The condition of the valve lifters determines whether it is necessary to check for camshaft wear Check that the lifting surfaces on the camshaft and the valve lifters do not have large areas of pitting damage Pitting damage can occur for various rea sons The damage is caused when small pieces of metal loosen from the hardened surface Lifters and camshafts with minor pitting damage can be used Pitting damage seldom become worse Check that the camshaft bearing surfaces and cam curves are not abnormally worn Change the camshaft if major damage or wear occurs NOTE When replacing camshaft all valve lifters should be replaced too Guidelines for replacement In normal conditions un evenness may occur on the camshaft lobes in the engine This does not mean that the camshaft has to be changed These marks do not have any negative influence on either engine per formance or durability of the engine and its compo nents The next pages shows examples of acceptable wear and non acceptable wear 47 Group 21 Short block Acceptable wear The camshaft does not need to be changed Unacceptable wear NOTE C
69. leaning petrol gaso line Note Make sure that the injector needles and injector sleeves which belong with each other and fit together are not mixed up if several injectors are cleaned at the same time To avoid mixing up the injectors should be put in an injector stand or in different compart ments 4 Check the injector nozzle thoroughly with a lamp magnifier or nozzle microscope Also check the other components 5 When installing a new nozzle it is important that the conserving oil is cleaned off the injector nee dle and sleeve before the injector is assembled avoid skin contact with the needle s sliding sur face Clean the components in chemically pure petrol gasoline Check that the needle slides in the sleeve with no tendency to bind 6 Dip the injector components in pure Diesel or test ing oil and fit the components together Use the original thickness of adjustment washer s to set the opening pressure 7 Check the opening pressure jet pattern and seal ing in an injector tester Group 23 Fuel system Group 26 Cooling system Fresh water system The freshwater system is the engines internal cooling system that ensures that the engine operates at the correct temperature It is a closed system and must therefore always be filled with a mixture of at least 40 concentrated coolant and 60 water to offer protection from interior corrosion cavitation and frost bursting We recommend that you use
70. lly lift the pump to make the lock clip on the regulator arm accessi ble Remove the lock clip and free the regulator arm Z N IMPORTANT Be careful when disassembling the injection pump avoid damaging or bending the lever NOTE Retain any shims from beneath the injection pump flange Use the same thickness of shims when re installing unless the camshaft engine block or in jection pump have been changed Group 21 Short block 14 Remove the rocker cover power rail and glow plugs 15 Remove the lower part of the rocker cover with in tegrated rocker arm bridge Start by unscrewing the two M6 screws at the outer edge then loosen the rocker arm bridge nuts half a turn at a time until the rocker arms are no longer under load 16 Prepare a stand marked with cylinder numbers If the rocker arms valve caps pushrods and valve lifters are to be re used these must be fitted in their original positions Lift the push rods and valve caps out and put in them in number sequence in the marked stand 17 Loosen the bolts in the opposite tightening se quence refer to Installing cylinder head Re move the cylinder head 18 Remove the valves if these are to be re used they must be fitted in their original positions Spe cial tool magnetic pen part number 885 822 19 Remove the crankshaft sensor flywheel casing and vibration damper NOTE To reduce the risk of damage to the crankshaft sensor
71. moved otherwise oil could be ejected A Stop the engine and close the sea cocks before doing any work on the cooling system A Only start the engine in a well ventilated area When operated in a confined space exhaust fumes and crankcase gases must be ventilated from the engine bay or workshop area A Always use protective glasses or goggles when carrying out work where there is a risk of splin ters grinding sparks acid splashes or where other chemicals are used Your eyes are ex tremely sensitive injury could cause blindness A Avoid getting oil on your skin Repeated expo sure to oil or exposure over a long period can re sult in the skin becoming dry Irritation dryness and eczema and other skin problems can then occur Used oil is more dangerous than fresh oil from a health aspect Use protective gloves and avoid oil soaked clothes and rags Wash regularly es pecially before eating There are special skin creams which counteract drying out of the skin and make it easier to clean off dirt after work is completed Most chemicals intended for the product e g engine and transmission oils glycol petrol gas oline and diesel oil or chemicals for workshop use e g degreasers paints and solvents are hazardous Read the instructions on the product packaging with care Always follow the safety precautions for the product for example use of protective mask glasses gloves etc Make sure that other personnel are
72. n the starter motor Disconnect the engine instrument cable harness connector Disconnect the sea water connection keel cooling connection Remove the exhaust system 6 Close the fuel stopcocks Remove the fuel con nections 7 Disconnect the throttle and gearshift wires Disconnect the propshaft from the reverser Undo the engine mounting pads from the bed and lift the engine out Actions after lifting the engine 1 Clean the engine Z IMPORTANT Remember the following when washing with a power washer Be extremely careful when cleaning to avoid getting water in side engine components When a power washer is used the water jet must never be aimed at seals such as shaft seals joints with gaskets rubber hoses or electrical components 2 Drain the engine oil 3 Remove the reverser if required 23 Repair instructions 24 Engine fixture fixing Special tools 885 485 998 6485 or 856 927 Use fixture 885 485 to attach the engine to overhaul stand 998 6485 or 856 927 The fixture is attached to the right side of the engine as illustrated below NOTE It is important that the instructions regarding number of attachment bolts and sizes are followed to ensure secure engine attachment Bolts required 1 pcs M10 x 35mm 3 pcs M14 x 1 5 x 35 mm Before the engine fixture can be mounted and the en gine attached to the overhaul stand the right front en gine mounting oil dipstick tube oil c
73. nd lock washer 4 Adjust the oil pump end float to 0 10 0 15 mm Shims are available in thicknesses 0 10 0 15 0 20 and 0 50 mm 5 Install a new crankshaft seal 6 Center the cover in front of the oil pump Note Check that the spring pin in the timing gear cover can engage in the hole in the oil pump cover Turn the cover back and forwards and center it in the mid position The stop arm must be turned and held in place while the timing gear cover is positioned 43 Group 21 Short block 44 7 Place anew gasket on the timing gear cover NOTE If the gasket contains a center part this must be cut away Install the timing gear cover with the new gasket Check that the start spring is in position in the timing gear cover and is connected to the regula tor arm link arm Push the regulator arm through the hole in the cylinder block Screw the timing gear cover down 8 Turn the stop arm clockwise and connect to the injection pump Fit the clip NOTE Be careful to ensure that the shim that was placed underneath the injection pump flange is put back before the pump is placed in the block applies when the pump has been removed 9 Tighten the injection pump tightening torque refer to Technical data 10 Fit the key into the crankshaft and install the crankshaft pulley Tightening torque please refer to the Technical Data chapter 11 Connect the fuel hose to the injection
74. no leakage occurs Replacing the circulation pump Removal 1 Drain the coolant from the engine freshwater sys tem 2 Undo the alternator and remove the drive belt Re move the alternator tensioner 3 Remove the rubber hoses to and from the pump 4 Remove the electric connection from the tempera ture monitor 5 Remove the pump s fixing bolts and lift out the pump Fitting 1 Clean the contact surfaces on the pump and cyl inder block Install the coolant pump with a new gasket Fit the tensioner to the alternator Install the rubber hoses to and from the pump Tighten the hose clamps 5 Install the drive belts It should be possible to de press the belt approx 10 mm between the pul leys 6 Reconnect the temperature monitor Fill the engine with coolant Start the engine and check carefully that no leakage occurs Group 26 Cooling system Replacing impeller in seawater pump Close the sea cock or the valve on the S drive before working on the cooling system 1 Remove the end cover of the pump and drain the water from the seawater system 2 Pull and twist out the impeller with water pump piers 3 Clean inside the housing Grease the pump hous ing and the inside of the cover with a little water resistant grease intended for rubber 4 Push in the new impeller with a twisting motion clockwise Install the sealing washer at the outer end of the impeller center 5 Install the cover wit
75. not inadvertently exposed to hazardous chemicals for example in the air Ensure good ventilation in the work place Follow the instructions provided when dis posing of used or leftover chemicals Exercise extreme care when leak detecting on the fuel system and testing the fuel injector noz zles Use eye protection The jet from a fuel nozzle has very high pressure and great pene tration power Fuel can force its way deep into body tissue and cause severe injury Danger of blood poisoning septicemia All fuels and many chemicals are flammable Do not allow naked flame or sparks in the vicini ty Petrol gasoline some thinners and hydro gen gas from batteries are extremely flammable and explosive when mixed with air in the correct ratio No Smoking Ensure that the work area is well ventilated and take the necessary safety precautions before starting welding or grinding work Always ensure that there are fire extin guishers at hand when work is being carried out Make sure that oil and fuel soaked rags and used fuel and oil filters are stored in a safe place Rags soaked in oil can spontaneously ig nite under certain circumstances Used fuel and oil filters are polluting waste and must be hand ed to an approved waste management facility for destruction together with used lubrication oil contaminated fuel paint residue solvents de greasers and wash residue Safety Precautions A Never expose a battery to naked flame
76. onnection has probably been done during engine installation however Connecting the sensor system IMPORTANT Stop the engine and disconnect power with the main switch before working on the electrical system 1 Release the yellow sensor wire from connection B on the alternator 2 Splice the wire yellow 1 5 mm and run it to the batteries Connect the wire to the batteries posi tive pole Charge splitter As extra equipment the engine s standard alternator can be fitted with a charge splitter Two independent battery circuits can in this way be charged at the same time The charge splitter separates the two cir cuits from each other so that the engine s starting battery is kept fully charged even if the accessory batteries are weak or even totally discharged 75 Group 30 Electrical system 76 Important information electrical system IMPORTANT Stop the engine and turn off the power at the main switch es before carrying out work on the electrical system Battery main switch Never break the circuit between the alternator and the battery while the engine is running The main switch es shall therefore never by switched off before the engine has stopped If the circuit is disconnected while running the voltage regulator can be destroyed and the alternator can be seriously damaged The charging circuits must never be re connected with the engine running for the same reason For simulta
77. ons are mentioned in the workshop manual Loctite 572 white color NOTE Loctite is a registered trademark belonging to the Loctite Corporation Permatex is a registered trademark belonging to the Permatex Corporation Repair instructions Safety rules for Fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings for shafts and in O rings for example When fluorocarbon rubber is subjected to high tempe ratures above 300 C hydrofluoric acid can be for med which is highly corrosive Contact with the skin can result in severe chemical burns Splashes in your eyes can result in severe chemical burns If you brea the in the fumes your lungs can be permanently damaged AN WARNING Be very careful when working on engines which have been exposed to high temperatures e g overheating during a seizure or fire Seals must never be cut with a flame torch during disassembly or burned in uncontrolled circumstances afterwards e Always use gloves made of chloroprene rubber gloves for handling chemicals and protective goggles e Handle the removed seal in the same way as corrosive acid All residue including ash can be highly corrosive Never use compressed air to blow anything clean e Put the remains in a plastic jar which is sealed and provided with a warning label Wash the gloves under running water before removing them The following seals are most probably made from fluorocarbon rubber
78. ooler with oil filter and turbo oil pipe D2 75 must be removed from the engine Condition test engine Compression test Special tools 885 484 885 252 and 998 8539 A compression test is done which shows the sealing of the cylinders and valves to assess the condition of the engine in a simple reliable manner e Warm the engine up then stop it e Remove all the injectors and test each of the cylin ders in turn A IMPORTANT Observe the greatest possible cleanliness to avoid getting dirt in the fuel sys tem Plug the connections for the disassembled injectors and fuel pipes The compression pressure shall be read off at normal starter motor speed refer to Technical data Low combustion pressure in all cylinders indicates worn cylinder bores and piston rings If one cylinder has lower compression pressure than the others the reason can be poor valve sealing broken piston rings or a damaged cylinder head gasket Insert adapter nos 885 484 and 885 252 in the injec tor hole Install a compression gauge 998 8539 in the adapter and carry out the compression test Group 21 Short block Short block disassembly Special tools 885 510 885820 885822 Empty the oil and water from the engine Lift the engine with a suitable lifting device Installing the engine fixture please refer to Engine fixture fixing 1 Remove the exhaust bend 1 2 Remove the induction silencer 2 3 Remove the turbo
79. or each diode should be between 450 and 650 mV Then check the D diodes in the opposite direc tion by reversing the positive and negative probes Perform the same measurements as above The instrument should show a one 1 with these measurements furthest to the left Any other value on the instrument indicates a faulty di ode If any of the diodes are faulty the whole diode plate must be replaced 85 Group 30 Electrical system 86 Checking the stator windings Once the diode bridge is removed the stator windings can be measured by setting the multimeter to buzzer position Measure the resistance of each winding NOTE First check the internal resistance of the mea surement wires When measurement of the stator windings is performed the internal resistance of the measurement wires i e 0 109 must be subtracted from the value displayed Measure between all winding connections three mea surements The resistance be 0 10Q Also measure to the alternator body by connecting the instrument in position Q And then measure from each winding to the body The instrument should show a one 1 with these measurements which means infinity If the instrument shows any other value the stator winding is faulty If any of the stator windings are faulty the complete stator ring must be replaced Starter motor General The starter motor is a DC series motor The starter pinion is operated by a control sol
80. orresponding oversize bearing shell fitted The big end bearings are available in two oversizes NOTE After grinding the bearing journals check the bearing clearance again before assembly Group 21 Short block Piston ring inspection and adjustment Remove the piston rings with piston ring pliers 2 Remove the gudgeon pin circlips and remove the gudgeon pin carefully with a suitable mandrel 3 Check that the rings do not bind in the ring grooves 4 Check the piston ring gap Push the ring down be low the lower turning point with a piston Change the piston ring if the gap exceeds 1 0 mm Check the piston ring gap with new rings Please refer to the Technical Data specifications chap ter for measurements In general piston rings should be changed if there is any noticeable wear or out of roundness in the cylinders since the piston rings frequently do not end up in the same positions as they had before disassembly Oil consumption is also of decisive importance for 1 N the point in time when a piston ring change should l be done 5 Check the clearance in the piston ring grooves Roll the ring in its groove in the piston and mea sure the clearance at several points with a feeler gauge Please refer to the Technical Data speci fications chapter for measurements Inspection and measurement of piston and cylinder bore Check the pistons for cracks and worn piston ring grooves Change the piston
81. ostat from 0 to 1 Regulator OK The red and green lamps shall light from 0 As the rheostat is turned the red lamp should go out at 1 Faulty regulator Replace the regulator if the red lamp lights through the whole travel of the rheostat or if it does not light at all Note Point 2 on the tester is not used for this type of regulator 83 Group 30 Electrical system 84 Checking the rotor winding Once the regulator and brushes have been removed it is possible to measure the resistance of the rotor windings Set the measurement instrument to position Q Make sure the probes have good contact with the slip rings The rotor resistance should be 3 0 5 0 Q Also check for grounding faults by measuring between the slip rings and ground Removing the diode bridge In order to check the diode bridge and stator windings the diode bridge should be removed Unsolder the three stator windings Do not use too much heat as this can damage the diodes Undo the nuts note how the nuts and washers are fitted Checking the diode bridge Set the multimeter to position Diode test Be very sure that you have good probe contact for all mea surements Checking B diodes 1 Connect the multimeters positive probe to one of the stator winding s connections 1 2 3 Then connect the instruments negative probe to the di ode plate B connection Read off the instrument A normal value should b
82. own GN Green GR Gray OR Orange R Red SB Black VO Violet W White Y Yellow Cable cross section in mm is given after the color code on the wiring diagram Cross section not given 1 0 mm OONDOP 10 12 13 14 Group 30 Electrical system Instrument panel alternative B Instrument illumination Tachometere with built in running hours timer extra equip Or blanking plug Connector for connecting extra warning display optional equipment Electronic unit alarm Warning lamp coolant temperature Warning lamp oil pressure Charge warning lamp Indication lamp glow plugs Switch instrument lighting Switch Alarm test Acknowledge Key switch Alarm Connector for connecting neutral position switch extra equip 16 pin connection 93 Group 30 Electrical system Spring biased Cable colors 94 BL LBL BN LBN GN GR OR R SB VO W y S 15a15b 3050 19 Blue Light blue Brown Light brown Green Gray Orange Red Black Violet White Yellow of ON COND 10 Ai 12 13 14 15 16 17 18 Instrument panel alternative C BL SB 15 Instrument lighting Voltmeter Oil pressure gauge Coolant temperature gauge Connector for connection of extra warning display extra equip Electronic unit alarm Warning lamp coolant temperature Warning lamp oil pressure Charge warning lamp Indication lamp glow plugs Swit
83. ping and tighten the priming screw at the same time The pump s inlet pipe contains a strainer 3 which normally does not need to be cleaned since the en gine has a fuel pre filter If a pre filter is not fitted poor feed flow can be due to a blocked strainer Note If either of the two O rings 4 are damaged they must be replaced 3 Normally additional priming is not required Start the engine and check that no leakage occurs If the engine does not start after a short attempt loosen the pressure pipes at the injectors a few turns Hold the injection pump actuator arm in it s max position and crank the engine with the starter motor until fuel leaks from the pressure pipes Tighten the pressure pipe nuts Tightening torque please refer to the Technical Data chapter The glow plugs are activated at the same time as the starter motor You can save the batteries if the starter motor is only used for short periods when priming Group 23 Fuel system Fuel filter replace Clean the filter bracket To prevent fuel spill a plastic bag can be pulled over the filter Unscrew the filter Wipe a film of oil on the gasket of the new filter Screw the filter on by hand until it touches the contact surface Then tighten an extra half turn no more Prime the fuel system Deposit the old filter ata waste management facility Start the engine and check that no leakage occurs ZN WARNING Working with or going close
84. ponding properties but of other makes shall be used When sealants and locking fluids are used it is important that the surfaces are free from oil grease paint and rust protection and that they are dry Always follow the manufacturer s instructions for use regarding temperature range curing time and any oth er instructions for the product Two different basic types of agent are used on the engine These are RTV preparations Room Temperature Vulcanizing Used for gaskets sealing gasket joints or coating gaskets RTV is visible when a part has been disassembled old RTV must be removed before resealing the joint The following RTV preparations are mentioned in the workshop manual Loctite 574 Silicone GE RTV1473W Permatex No 3 Volvo Penta 1161099 5 Permatex No 77 Old sealant can be removed using denatured alcohol in all cases Anaerobic agents These agents cure in the absence of air These preparations are used when two solid components such as two cast components are fitted together without a gasket Common uses are also to lock and seal plugs stud threads taps oil pressure monitors etc Hardened anaerobic preparations are glassy and for this reason the preparations are colored to make them visible Hardened anaerobic preparations are highly resistant to solvents and old compound can not be removed On re installation degrease carefully and then apply new sealant The following anaerobic preparati
85. pressing the springs so that the valve stem seals are not damaged Check that the valve cot ters are properly seated 3 Install the valve caps 5 once all the valves are fitted 4 Mount new core plugs if these have been re moved 5 Install the glow plugs Tightening torque please re fer to Technical Data Install the power rail 33 Group 21 Short block 34 Inspecting the crankshaft Clean the crankshaft carefully in all channels after dis assembly and inspect thoroughly to determine if over haul is really necessary 1 Check wear and ovality with a micrometer Mea sure the diameters A A and B B at points 1 and 2 Max permissible taper and ovality in the main and big end journals is 0 05 mm Grind the crank shaft to a suitable undersize dimension if these values are exceeded Bearing shells are available in two oversizes NOTE Check first which oversize bearing shells are available for the engine type in question 2 Measure lengthwise crookedness in the crank shaft runout Lay the crankshaft on a pair of V blocks placed under the front and rear main bear ing journals Alternately the crankshaft can be set up between centers Measurements shall be done on the center main bearing journal s Max lengthwise crookedness runout refer to Wear tolerances If these values are exceeded the crankshaft must be straightened or replaced 3 Check that the crankshaft
86. r instrument e Engine running with low load Coolant temperature too high High coolant temperature warning lamp lights up can be caused by e Blocked sea water inlet or sea water filter e Defective impeller in the sea water pump e Coolant level Too low air in the fresh water sys tem e Slipping or broken drive belt for circulation pump e Faulty thermostat temperature sensor or instru ment e Blocked cooling system e Incorrectly set injection timing on the injection pump e Filler cap gasket does not seal Group 26 Cooling system Coolant losses There are two types of coolant losses e Coolant losses during operation e Coolant losses after stopping a hot engine Coolant losses during operation can be due to a leak ing cooling system or air or combustion gases being forced into the cooling system Checking the pressure valve in the filler cap Special tools 999 6662 1 Drain some of the coolant and connect the pres sure testing device 99 6662 to a nipple or other plugged hole in the cooling system 2 Extend the drain hose from the filler pipe with a hose which ends up in a water filled vessel 3 Increase the pressure and read the pressure gauge when the valve opens water bubbles into the vessel with the drain hose The valve should open at 0 09 MPa 4 Remove the test equipment Install the plug and fill the engine up with coolant Cleaning heat exchanger Clean the heat exc
87. r system volume APprOxX sses 9 5 liter Thermostat Oly seieren daarnaa 1 Thermostat starts opening at eeen 82 4 C fully OPON at iccssectevesscethaviet vende fees AR EE 95 C Thermostat valve lifting height ee eeeeeeeeeeeeeee 8mm Electrical system System voltage 0 2 ceeeeeccceeeecneeeeeneeeeeeneeeteeaeeeeesaeeetesaeees 12V FUSOS oreroraa EE UEA REARS 15A Battery capacity starter battery cceeeeeeeeeeeee 88 Ah Glow plugs rated VONAGE csssecciec cezicits conan cvsdabucnnee aeneae 10 5V CUITOINU iiris ransis ernier aaa inea iar aT Saini 6 9 A Alternator Voltage output at 20 C with Sensor s 14 2 0 15 V without sensor 14 2 0 3 V Max CUON 2 ccettesinctesvaeisctes cesetbvtetiane iea 115A Power ApprOK sess eticed cecedetecetdevedebvcace setae Agncscxsessttceedents 1630 W Suppression Capacitor sisisi ncini idini 2 2 uF Starter motor Starter motor pOwer ANP irsesiisirni awosciisisniniiianii i niii 2 0 kW 98 D2 75 A 1 3 4 2 0 8 m 15 25 kPa 22 0 1 b t d c 6mm 7mm 15 2 16 2 MPa 15 7 MPa 4mm 1mm 4 Over pressure closed cooling system 9 8 liter 1 82 4 C 95 C 8 mm 12V 15A 88 Ah 10 5 V 6 9 A 14 2 0 15 V 14 2 0 3 V 115A 1630 W 2 2 UF 2 0 kW Wear tolerances D2 55 A B C General Compression pressure at starter motor speed min 200 rPM eee eeeeeeeeeeeeeeeteeeeteeeetee min 25 Bar Pistons PISTOMICICAFANCE iiss cies sianne
88. rent measurement 20A Connect the multimeter between the bat tery s negative pole and the negative cable The current loss may not exceed 0 1 A with the keyswitch or instrument panel disconnected If the current loss is greater than 0 1 A Check that no short circuits or leakage occurs at any of the connection points Leakage can occur through dirty or salt encrusted electrical compo nents Clean and check all connection points If the current loss is less than 0 1 A Check the charge status of the battery 79 Group 30 Electrical system 80 Checking charge status Check the charge status with an acid densitometer Measure the acid density of all cells at 25 C Mea surement shall not be done immediately after charging or filling with battery water The acid density of a fully charged battery at 25 C shall be 1 28 g cm Charge the battery if the acid density is less than 1 24 g cm approx 75 charged Charge at 5 6A for 10 hr A WARNING The battery generates hydrogen gas which is easily ignited and highly explosive Never expose the battery to naked flame or electrical sparks Ventilate the battery area well especially after charging Check 2hr after charging If the acid density of the cells is uneven a cell is probably short circuit Replace the battery if the differ ence between cells is 0 04 g cm or more i e 1 28 1 24 g cm If the acid density between cells is even then the bat
89. ring groove with the location dowel A inside both ends of the spring Check that the ends of the expansion spring do not overlap Install the oil scraper ring 2 above the expansion spring Check that the ring gap is displaced 180 from the guide pin Install the ring with the tapered surface 3 in the center piston ring pair so that the marking faces the piston crown Install the upper ring 4 with the marking up wards Check that the ring gaps are displaced 90 from each other 39 Group 21 Short block 40 Measuring the camshaft Cam height inlet and exhaust A 33 7 mm Cam height B for injection pump 41 8 mm Cam height C for feed pump 30 0 mm Change the camshaft if the wear limits have been ex ceeded Inspection of timing gears Special tools 999 9683 Clean the gears and other parts of the timing system and check them carefully Replace gears that are bad ly worn or damaged Check the backlash with feeler gauges or a dial gauge special tool 999 9683 Max permitted backlash 0 25 mm If the backlash exceeds the permitted value then all gears in the tim ing system must be replaced Installing the crankshaft Special tools 998 9876 999 9696 1 Check the cleanliness of the crankshaft drillings and bearing surfaces engine block and bearing caps Check that the bearing shells and their beds do not have any burrs or upsets 2 Place the main bearing shell in position
90. rs Lube oil pressure monitor alarm Contact type Normally open The contacts close if the lube oil pressure in the engine drops below 0 3 0 15 bar Check of the closing point is done with falling pres sure Coolant temperature monitor alarm Contact type Normally open The contacts close if the coolant temperature rises above 95 C 3 C Check of the closing point is done with rising temper ature 89 Group 30 Electrical system 90 Sensor Note Sensors are only supplied together with the De Luxe instrument panel Lubrication oil pressure sensor Resistance checking measured with falling pressure and instrument connected Measured with ohmmeter class 1 at 20 C Pressure Obar 10 3 5Q0 2bar 524 4Q0 4bar 88 4Q0 6bar 124 50 Coolant temperature sensor Resistance checking measured with sensor im mersed in circulating liquid down to the hexagonal screw for 3 minutes with power connected Temp 60 C 134 0 13 5 Q 4 C 90 C 51 2 4 3Q 4 C 100 C 38 5 3 0Q2 4 C Engine 10 O ooo Q 1 Battery 2 Starter motor 3 Alternator 4 Main switch 5 Glow plugs 6 Oil pressure monitor engine 7 Oil pressure sensor 8 Coolant temperature monitor 9 Coolant temperature sensor 10 Fuses 4 pcs max 15A 11 Starter relay 12 Glowplug relay 13 Magnetisation resistance 14 Engine speed sensor Group 30 Electrical system 11 15 1014 5 3 ie
91. s a standard all metal hex nut Reduce the torque by 25 for screw size 8 mm or larger Where Nylock nuts are higher i e the metallic thread is of the same height as a standard hexagonal nut the torque given in the table apply Strength classes Screws and nuts are sub divided into different strength classes Classification is indicated by markings on the screw head A marking with higher number indicates stronger material For example a screw marked 10 9 is stronger than one marked 8 8 For this reason when fasteners are removed it is important that the screws are put back in the correct places when they are re installed If a screw must be replaced check in the spare parts catalogue to make sure the correct screw is used Sealant Several different types of sealant and locking fluids are used on the engine The properties of the preparations differ and they are intended for different strengths of fastener temperature resistance to oil and other chemicals and for the different materials and gap thicknesses found in the engine Repair instructions 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 required In this Service Manual the user will find that each section where these agents are applied in production states which type was used on the engine In service work the same preparations or preparations of corres
92. sed crankcase ventilation Oil filter The filter is a full flow filter which means that all the oil is filtered before it is forced out into the lubrication system The filter element consists of folded filter paper There is a bypass valve A at the base of the filter which opens and allows oil to flow past the filter if the filter insert should become blocked Repair instructions General A condition test should be done before each major service activity if possible to determine the general condition of the engine and discovery any concurrent fault causes A condition test requires the engine to be run so this should be done before the engine or any engine components are disassembled Please refer to Condition test engine Measures before overhaul in boat 1 Remove battery power 2 Clean the outside of the engine NOTE Make sure that wash residue is collected for destruction and does not inadvertently end up in the water Also refer to the warning text under Actions after lifting the engine 3 Work involving the cooling system Close the sea cocks and drain the coolant from the sea water and fresh water systems A WARNING Make sure that all sea water inlets are securely closed so that water cannot find its way in during disassembly of cooling system sub components Actions before lifting the engine from the boat Lift the boat ashore Disconnect battery power remove battery con nection o
93. sveceteseyeetends 5 5 9 Silica acc to ASTM D859 uiios lt 20 mg SiO Iron acc to ASTM D1068 lt 0 10 ppm Manganese acc to ASTM D858 lt 0 05 ppm Conductivity acc to ASTM D1125 lt 500 uS cm Organic content COD acc IS08467 lt 15 mg KMnO I Group 26 Cooling system Draining coolant Stop the engine before draining the cooling system Freshwater system WARNING Do not open the filler cap when the engine is hot except in emergencies Steam or hot fluid may spray out 1 Place a suitable collection vessel beneath the en gine block drain plug 1 and at the heat exchang er drain tap 2 Open the drain plug 1 and drain tap and drain all coolant NOTE Deposit the old coolant at a recycling station for destruction Draining the seawater system WARNING Risk for flooding Close the sea cocks before starting work 1 Close the sea cock 1 or the valve on the S drive Remove the cover 2 from the seawater pump and let the water run out 2 Undo the hose 3 from the seawater pump and seawater filter at the reverser drive and angle them downwards to let the water out 3 Check if there are extra taps plugs at the cooling and exhaust systems lowest points Check carefully that all the water runs out 4 Tighten the hoses and the cover on the seawater pump Bilge pump the boat WARNING Check that there are no leaks in the seawater system Filling
94. the alternator belt Remove the alternator 2 Undo the voltage regulator s connection at the al ternator connection B Unplug the blade connec tors at connections B and D Remove the pro tective cover from the W connection 3 Lever the plastic cover fixing ears from side to side off the alternator Undo the regulator s con nection cables to the diode bridge Use flat pliers or poke the cable shoes out with a screwdriver Do not pull on the cables Group 30 Electrical system Replacing alternator brushes Unscrew the voltage regulator Unscrew the brush holder Check the length of the brushes Replace the brushes if they are 5 mm or shorter The brush and holder are replaced as a unit Unsolder the connection cables and solder on the new with acid free solder Checking the regulator Special tools 884 892 Before performing the test check that the regulator tester battery has the correct voltage Press the Test button and check that the green lamp Batt lights Replace batteries 2 pcs alcaline 9 V if the lamp does not light The batteries are in a compart ment on the underside of the instrument Connect the tester s gray wire to the brush Connect the tester s brown wire to the regulator s yel low and brown wires which are to be held together for the test Connect the tester s black wire to the regulator s black wire Press the Test button and and at the same time turn the rhe
95. this should be removed before the flywheel casing is removed 20 Mark the position of the flywheel on the crank shaft Remove the flywheel 22 Remove the inner flywheel casing and the rear shaft seal 23 Remove the pulley use special tool 885 820 and 3 pcs M10x40 mm bolts Remove the timing gear cover Load the stop arm so that the springs on the inside of the housing do not come out of posi tion or spring out 27 Group 21 Short block 28 24 Remove the idler lock ring Save the sleeve wash 25 er spring and shims Lift away the idler gear complete with cover and oil pump Note the thrust washer behind the oil pump Remove the camshaft and gear Remove the screws from the locking plate the screws are ac cessible through a hole in the camshaft gear Lift out the camshaft complete with gear and regu lator weights NOTE Take care so that bearings journals and cam lobes are not damaged 26 27 Remove the timing gear plate Invert the engine and remove the sump together with the external oil pipe Remove the oil strainer and suction pipe 28 Scrape away the carbon from the top of the cylin ders to simplify disassembly Check that the con rod caps are marked so that they can be reas sembled correctly Remove the con rod caps and push out the pistons Group 21 Short block 29 Remove the oil pressure valve to allow removal of the crankshaft and simplify
96. tive plug to the injector s pipe connec tion and over the injector nozzle if it is not to be installed immediately D Install the new injector Tightening torque please refer to the Technical Data chapter 7 Install the return fuel pipe use the nut underneath the fuel return pipe to avoid kinking the pipe 8 Install the pressure pipes Check that they do not come out of alignment and tighten the nuts Tightening torque please refer to the Technical Data chapter 9 Start the engine and check that no leakage occurs Testing of injectors Testing is done in an injector tester During the test the opening pressure and sealing are the most impor tant things The spray pattern is more difficult to eval uate and does not fully indicate the condition of the nozzle Lv WARNING Be careful when testing injectors avoid getting the fuel jet from an injector on un protected parts of your body The spray has such great penetration power that it can pene trate the skin and cause blood poisoning 64 Group 23 Fuel system Opening pressure With the pressure gauge connected press the injector tester lever down slowly until the injector opens and releases fuel Read off the opening pressure at the opening instant If the value read does not coincide with the specified value the setting must be changed This is done with shims Note The opening pressure increases or decreases by about 1 MPa with a ch
97. to a run ning engine is a safety risk Watch out for rotat ing components and hot surfaces Fuel pre filter draining and replacement of filter insert Draining The fuel pre filter is extra equipment Put a suitable vessel underneath the filter Drain off water and contaminants through the tap plug in the bottom of the filter bowl ZX IMPORTANT Draining should be performed first anumber of hours after stopping Replacing filter insert Close the fuel stop cock on the tank Put a suitable vessel underneath the filter Remove the filter bowl by undoing the screw 1 Emp ty and clean the filter bowl Replace the insert and as semble the bowl Open the stop cock Prime the fuel system Deposit the old filter at a waste manage ment facility Start the engine and check that no leakage occurs Z WARNING Working with or going close to a run ning engine is a safety risk Watch out for rotat ing components and hot surfaces 63 Group 23 Fuel system Injectors Changing the injectors 1 Wash around the injectors 2 Undo the delivery pipes at the injection pump and at the injectors Lift the fuel delivery pipes away together 3 Undo the nut at the top of each injector use the nuts beneath the return fuel line as a counterhold so that the pipes are not bent Lift the return fuel pipe away 4 Unscrew the injectors 1 Use socket L 80 mm Remove the copper washers 2 beneath the injec tors 5 Fit a protec
98. to be welded and as close as possible to the weld site The clamp must never be connected to the engine or in such a way that current can pass through a bearing WARNING After welding is finished the wires to the alternator must be reconnected before the battery cables are reconnected 77 Group 30 Electrical system Repair Instructions Fault finding glow plugs Special tools 9812519 Remove both battery cables Remove the power rail between the glow plugs Measure the resistance of each glow plug to the engine block with an ohmmeter The resistance shall be 1 6 0 16 Q If the instrument shows 0 the glow plug is short circuit and must be re placed 1 Glow wire 5 Nut 2 Jacket 6 Magnesium oxide 3 Seal 7 Insulation 4 Socket 8 Core Replacing glow plugs 1 Remove both battery cables 2 Clean around the glow plugs 3 Undo the connection from the power rail to the glow plug Remove the power rail and unscrew the glow plug 5 Install the new glow plug Tightening torque please refer to the Technical Data chapter 6 Reinstall the power rail and connect the glow plug Install the battery cables Fault tracing the charging system The engines are equipped with a rectified three phase delta coupled alternator of 14V 60A 840W The alternator s designation can be found on a plate on the rear of the alternator Checking and overhauling Before disassembly of the alternator is started fault
99. uipment used is in good condition and has the load capacity to lift the engine engine weight including gearbox if fitted and any extra equipment Use an adjustable lifting beam or lifting beam specifically for the engine to raise the engine to ensure safe handling and to avoid damaging en gine parts installed on the top of the engine All chains and cables should run parallel to each other and as perpendicular as possible in rela tion to the top of the engine If other equipment connected to the engine has altered its center of gravity special lifting devis es may be needed to obtain the correct balance and safe handling Never carry out work on an engine suspended on a hoist Safety Precautions A Never work alone when removing heavy engine components even when using lifting devices such as locking tackle lifts When using a lifting device two people are usually required to do the work one to take care of the lifting device and another to ensure that components are lifted clear and not damaged during the lifting opera tions When you work aboard a boat always make sure that there is enough space for disassembly where you are working with no risk of personal injury or damage to materials Components in the electrical and fuel systems on Volvo Penta products have been designed to minimize the risks of explosion and fire The en gine must not be run in areas where there are explosive materials A A Fuel deliver
100. under pressure thus reducing the risk of boiling if the temperature becomes high If the pressure becomes excessive a pressure valve opens in the filler cap The coolant temperature is regulated by a thermostat The flow in the sea water system is accomplished by a gear driven impeller pump The heat exchanger transfers heat from the coolant to the sea water As extra equipment the engine can be equipped with a separate expansion tank Thermostat The engine is equipped with a thermostat whose sen sor body contains wax When the engine is cold the thermostat closes the way to the heat exchanger Coolant then passes through a by pass pipe back directly to the suction side of the pump As the engine warms up the vol ume of the wax increases and the thermostat progres sively opens the passage to the heat exchanger at the same time as the by pass channel is closed Please refer to the Technical Data chapter for open ing temperatures Sea water pump The sea water pump is driven by the gears in the tim ing gear The impeller pump wheel is made from rub ber and is replaceable NOTE The impeller will be damaged if the pump is run dry Design and function T Fuel system general The fuel is sucked from the fuel tank by the feed pump through a water separator pre filter extra equip and is pressed through a fine filter to the injec tion pump Return fuel from the injectors is fed through return fuel
101. urnal 00 eee ceeeeeeeeeeeeeeeeeeeenneeeeees 17 70 20 60 mm Diameter standard ccccceceeeeeceeeeeeeeeeeeaeeeeeeeseeseeees 51 964 51 975mm Big end journal shells Thickness in MM standard cccceeeeeeeceeeeeeeeeeeeaeeeees 1 482 1 495 Con rods Fitted with replaceable bearing shells Diameter conrod bush bearing position 30 500 30 516 bearing shell bearing position 28 010 28 021 gudgeon pin bush cceeee 28 010 28 021 End float con rod crankshaft cccccssseeeeeeeeseeeeees 0 035 0 085 mm 96 D2 75A 69 7 70 3mm 36 35 36 45 mm 32 35 32 45 mm 1 5 2 0 mm 1 9 2 2 mm 0 1 0 4 mm 0 044 0 102 mm 67 957 67 970 0 035 0 085 mm 17 70 20 60 mm 51 964 51 975mm 1 482 1 495 30 500 30 516 28 010 28 021 28 010 28 021 0 035 0 085 mm D2 55 A B C Camshaft DIV Swiss sicccthentnd A A E Gear wheel Nool beangs saien a auee Geechee 3 Valve timing inlet valves opens b t d C 13 closes a b d c 48 exhaust valves opens b b d c 43 closes a t d c 13 Valves Inlet Valve stem diameter ccccesssccceeeeeeeeeeeeeeeeneneeenees 6 955 6 970 mm Valve head edge ceeesscccceeeeeeeseeeeeeeeeeeneeneeeeenenenenees 0 925 1 075 mm Clearance valve stem valve guide ceeeceeees 0 03 0 06 mm Valve seat angle in cylinder head s n 45 Valve clearance cold engine cccccecee
102. uthorized personnel 1 Wash the injection pump injection pipes and the engine closest to the pump very thoroughly 2 Close the fuel taps Remove the delivery pipes complete Release the fuel hose from the pump Fit protective plugs to all connections 3 Remove the fixing screws and nuts on the pump Turn the stop lever clockwise and carefully lift the pump to make the lock clip on the regulator arm accessible Remove the lock clip and free the regulator arm NOTE Retain any shims gaskets from under the in jection pump s flange when the pump is lifted from the cylinder block 4 Send the pump to an authorized diesel workshop for repair if the workshop does not have specially trained personnel with the necessary testing equipment 56 Group 23 Fuel system Installing the injection pump Check that the pump is free from faults and if neces sary has been tested and approved before installation Do not remove the protective plugs before the pipes are to be connected 1 Insert the injection pump into the cylinder block NOTE Make sure that any shims that were placed under the injection pump flange are in replaced as they were before the pump is installed on the block This normally ensures that the pump settings are cor rect If the camshaft complete or the cylinder block have been replaced then the injection pump settings need adjusting Refer to the next paragraph Setting injection
103. with a dial gauge Max permitted runout is 0 05 mm 3 Check that the insulation is at least 0 2 mm below the commutator surface Correct as necessary 4 Check the straightness of the rotor Set the rotor up between centers and measure the runout of the rotor frame with a dial gauge Max runout 0 08 mm The runout is half of the indicated value 5 Check the starter gear teeth Replace damaged gears Also check the ring gear if the starter gear is damaged Field windings Check with the test instrument that there is no open circuit in the windings Faulty field windings must be replaced Assembling the stator Assembly is the reverse of disassembly Connect and from a 12 V battery to the terminals on the solenoid and check that the starter gear is thrown forward to the gear stop Installing the starter motor 1 Place the starter motor in position on the flywheel housing and tighten it 2 Connect the electrical wiring to the starter motor See wiring diagram for starter motor 3 Connect the battery cables Group 30 Electrical system Electrical components Relay box with fuses The engine is equipped with a fuse block with four fus es 15A One fuse safeguards the electrical system and blows if overloaded the others are spares If a fuse blows the electrical system can be recon nected by moving the cable to the next fuse connec tor Always first investigate the reason for the over load Monito
104. ws e Care and Service intervals recommended by Volvo Penta must be followed e Only Volvo Penta original spare parts may be used e Service to injection pumps pump settings and in jectors must always be performed by an authorized Volvo Penta workshop e The engine must not be converted or modified ex cept for the accessories and service kits that Vol vo Penta has approved for the engine e No installation changes to the exhaust pipe and engine air inlet ducts may be made e Any anti tamper seals on the engine may not be broken by unauthorized persons The general advice in the instruction book about oper ation care and maintenance applies ZN IMPORTANT Neglected or poorly performed care service as well as use of non original spare parts entails that AB Volvo Penta can no longer guarantee that the engine conforms to the certified model Damage injury and or costs which arise from this will not be compensated by Volvo Penta Repair procedures The working methods described in the Service Manual apply to work carried out in a workshop For this rea son the engine is lifted out of the boat and mounted on an engine support Renovation work which does not need the engine to be lifted out can be done in situ with the same work methods unless otherwise specified Warning symbols used in this Service Manual for full explanation of the symbols refer to the section Safety Precautions AN WARNING AN
105. y pipes must not be bent or straight ened under any circumstances Damaged pipes must be replaced Remember the following when washing with a power washer Never aim the water jet at seals rubber hoses or electrical components Never use a power washer for engine cleaning Only use the fuels recommended by Volvo Pen ta Refer to the Operator s Manual Use of fuels that are of a lower quality can damage the en gine On a diesel engine poor quality fuel can cause the control rod to bind and the engine to over rev with resulting risk of damage to the en gine and personal injury Poor fuel can also lead to higher service costs 2006 AB VOLVO PENTA We reserve the right to make modifications without prior notice Printed on environmentally compatible paper General information About this Service Manual This Service Manual contains technical data descrip tions and repair instructions for the standard version of engine unit D2 55 The Service Manual can illustrate tasks done on any of the engines noted above This means that the illustra tions and photographs which clarify certain details might not correspond with other engines in some cases Re pair methods are however in general identical If this is not the case this will be noted and important differenc es will be shown separately The engine designation and engine number are given on a type plate see page 14 The engine designation and number must always be given

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