Repair & Specifications

D16C1 -E, D16C2-E

 Table of Content
General Information
00-0 General ............................................................................................. 3

Specifications
03-0 General Specifications ................................................................... 8
03-2 Specifications, Engine .................................................................. 11
03-21 Engine ....................................................................................... 29
03-22 Lubrication System ................................................................. 38
03-23 Fuel System .............................................................................. 39
03-25 Inlet and Exhaust System ....................................................... 40
03-26 Cooling System ........................................................................ 41
03-3 Specifications, Electrical .............................................................. 42

Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 43

Special tools
08-2 Special Service Tools ................................................................... 44

General
20-0 Engine Information, General ........................................................ 50
Test and Adjustments ........................................................................ 50

Engine
21-0 Engine Complete, General ........................................................... 51
Check and Fault Trace ....................................................................... 52
Fitting the Fixture ............................................................................... 54
Engine Disassembly .......................................................................... 56
Engine Assembly ............................................................................... 62
21-1 Cylinder Head ................................................................................ 72
21-4 Valve Mechanism .......................................................................... 88
21-5 Timing Gears and Shaft ................................................................ 91
21-6 Crank Mechanism ......................................................................... 97

Lubricating and Oil System

22-0 Lubricating and Oil System, General ........................................ 101

Fuel System
23-3 Fuel Feed Pump and Filter ......................................................... 102
23-7 Injectors and Delivery Pipes ...................................................... 108
23-8 Control System, ECM, Data Sets ............................................... 120

Inlet and Exhaust System

25-0 Inlet and Exhaust System, General ........................................... 121
Check and Fault Trace ..................................................................... 121
25-1 Inlet and Exhaust Manifolds ...................................................... 122
25-5 Turbo and supercharger ............................................................. 127
25-7 Crankcase Ventilation ................................................................. 131

Cooling System
26-0 Cooling System, General ........................................................... 132
Check and Fault Trace ..................................................................... 135
26-1 Radiator, Heat Exchanger .......................................................... 136
26-2 Coolant Pump, Thermostat ........................................................ 149

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 26-5 Charge Air Cooler with Connections ........................................ 152
26-6 Sea Water System, Sea Water Pump ......................................... 156

Alternator, Charge Regulator

32-1 Alternator ..................................................................................... 168

Starting System
33-1 Starter Motor ............................................................................... 170
Index ......................................................................................................... 173
References to Service Bulletins ............................................................ 175

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00-0 General
About this Workshop manual
General information Certified engines
The product designation and the serial number and When performing service and repairs on
specification are shown on the engine decal or emission certified engines, it is important to be
type plate. This information must be included in all aware of the following:
correspondence concerning the product.
Certification means that an engine type has been
Volvo Penta is constantly developing its products. checked and approved by the relevant authority. The
All information in this Manual is based on product engine manufacturer guarantees that all engines of
data that was available at the time the Manual was the same type are manufactured to correspond to the
published. certified engine.
This places special demands on service and repair
The working methods described in this manual are work, namely:
based on a workshop scenario where the product is
mounted in a work fixture. Maintenance work is often • Maintenance and service intervals
carried out in situ, in which case - if nothing else is recommended by Volvo Penta must be
indicated - using the same working methods as the complied with.
workshop. • Only replacement parts approved by Volvo
Penta may be used.
The service manual describes work operations
carried out with the aid of Volvo Penta Special • All servicing concerning fuel injection must
Tools, where such have been developed. Volvo Penta always be carried out by an authorized Volvo
Special Tools are designed to ensure the safest and Penta workshop.
most rational working methods possible.
• The engine may not be converted or modified,
In some cases local safety regulations and user except with accessories and service kits which
instructions may be applicable regarding the use of Volvo Penta has approved for the engine.
tools and chemicals mentioned in the service manual. • No changes to the exhaust pipe and engine air
These rules must always be observed, so there are inlet duct installations may be made.
no special instructions about this in the workshop
information. • No warranty seals (where present on the
product) may be broken by unauthorized
Above all, when working on fuel systems, hydraulic persons.
systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept IMPORTANT!
away, as malfunctions or shortened service intervals Neglected or poorly-performed maintenance or
may otherwise result. service and the use of replacement parts not
approved by Volvo Penta, will mean that AB Volvo
Penta no longer guarantees that the engine conforms
Replacement parts to the certified model.
Volvo Penta Original Replacement Parts meet Volvo Penta accepts no responsibility for damage or
national safety requirements. No damage of any kind costs arising as a result of failure to follow the above
caused by the use of replacement parts not approved mentioned standards.
by Volvo Penta will be compensated by any warranty
undertaking.

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00-0 General

Colors used in images

Most images include a highlighted component which is secured by a screw or similar as part of a (light gray)
engine transmission.

NOTICE! Because the images in the maintenance literature are used for different engine variants, certain details
may vary compared to the actual model concerned. The essential information is always correct, however.

Light gray: Chassis

Yellow: Special tool, tools
Blue: Detail in focus
Green: Seals
Red: Mounts e.g. nuts, stripes, clips

P0038817

Other types of symbols used in

the images are divided into the
following categories:
• Safety
• Important
• Cleanliness
• Position
• Movement
• Measured value
• Tools
• Chemicals
• Sealant
• Units

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 00-0 General

Safety information
Read the safety information below carefully before you
start repair or service work.

This symbol is used on the product to let you know that this concerns safety information. Always read such
information very carefully.
Warnings take the following priority:

DANGER!
Indicates a dangerous situation which, if not avoided, will lead to death or serious injury.

WARNING!
Indicates a dangerous situation which, if not avoided, could lead to death or serious personal injury.

CAUTION!
Indicates a dangerous situation which, if not avoided, can lead to minor or significant injury.

IMPORTANT:
Is used to make you aware of something that may cause minor injury or a minor malfunction to the product or
property.
NOTICE! Is used to make you aware of important information that will facilitate the work or operation in progress.

This symbol is used on certain functions to indicate the following:

Before performing this task, theoretical and/or instructor-led training is required. Contact your local training
organization for further information.

This symbol informs you that supplemental information needs to be read. And where necessary information can
be found.

This symbol means Dangerous electrical voltage / General electrical danger.

This symbol is used when a VODIA computer is needed, either for fault tracing, testing or programming.

This symbol is used for facilitation tips when repairing.

A compilation of safety precautions that must be taken and risks which you must be aware of is presented
in the following pages.

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00-0 General

Immobilize the engine by turning off the power Avoid opening the coolant filler cap when
supply with the main switch(es) and lock it the engine is hot. Steam or hot coolant
(them) in the off position before work is begun. may spray out and with a resultant system
Place a warning notice at the main switch. pressure loss.
All maintenance and service must be Never start the engine without the air filter
carried out on when the engine is stopped. in place. The rotating compressor turbine in
Approaching a running engine is a safety risk. the turbocharger can cause severe injury.
Install all protective covers before starting
the engine.
Beware of hot surfaces and hot liquids in pipes When operating in a confined space,
and hoses on an engine that is running or has exhaust pipe fumes and crankcase gases
just been switched off. must be led away from the engine
compartment or workshop area.
Ensure good ventilation.
Make sure that all warning and information Only make connection adjustments with the
decals on the product are always visible. engine switched off.
Replace decals that have been damaged or
painted over.
Avoid getting oil on the skin! Use protective Never start the engine with the valve cover
gloves and avoid oil-soaked clothes and rags. removed. There is a risk of personal injury.

Switch off the engine and disconnect the power Stop the engine before working on the
at the main switches before starting work on cooling system.
the electrical system. Marine engines: Close the sea cock/cooling
water inlet valve before starting work on the
cooling system.
Always wear protective goggles if there is a risk Check that rags soaked in oil or fuel and
of splinters, sparks and splashes from acid or used fuel and oil filters are stored safely.
other chemicals. Oil-soaked rags may ignite spontaneously in
certain conditions.
Never use start gas or similar products as a Never work alone when dismantling heavy
starting aid. components, even if you use lifting
equipment.

Never allow open flames or electrical sparks in Take extreme care when searching for
the vicinity of fuel. Always ensure that there are fuel system leaks and testing fuel injector
fire extinguishers close at hand in the operating nozzles. Wear safety goggles.
area.
Batteries must never be exposed to open Never use a high-pressure washer to clean
flames or electrical sparks. the engine.
Pay attention to the following when using
a high-pressure washer on components
other than the actual engine: Never aim the
water jet at seals, rubber hoses or electrical
components.

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 00-0 General

Always wear protective goggles when charging Only use fuels and lubricating oils as
or handling the batteries. Rinse immediately recommended by Volvo Penta.
with plenty of water and soap if battery
electrolyte comes into contact with unprotected
skin.
If you get battery acid in your eyes, flush at
once with a generous amount of water, and get
medical assistance at once.
The engine must not be operated in areas
where there are explosive materials or gases.

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03-0 General Specifications

03-0 General Specifications

Component location

P0034744

A Air filter
B Turbocharger
C Turbocharger
D Air filter
E Expansion tank, coolant
F Hand pump, drainage engine oil
G Oil filter
H Draining, coolant
I Draining, coolant
J Draining, coolant
K Draining, coolant

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 03-0 General Specifications

P0034745

A Venting, fuel system

B Expansion tank, coolant
C Hand pump, fuel
D Filling, fuel
E Draining, coolant
F Drive belts
G Draining, seawater
H Draining, coolant
I Dipstick, engine oil
J Drainage, engine oil
K Draining, coolant
L Seawater pump
M Fuel filter
N Venting, fuel filter

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03-0 General Specifications

General Tightening Torques

General Tightening Torques
M6 10 Nm
M8 24 Nm
M10 48 Nm
M12 85 Nm
M14 140 Nm
M16 220 Nm

IMPORTANT!
Check screws which are to be re-installed. Damaged bolts
with e.g. shear marks under the heads, must be scrapped.

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 03-2 Specifications, Engine

03-2 Specifications, Engine

Group 21 - Engine
Front Engine Mounting
A 220 Nm
B Step 1: 120 Nm
Step 2: Angle tightening 30°

P0034656

Rear Engine Mounting

A 220 Nm
B Step 1: 120 Nm
Step 2: Angle tightening 30°

P0034653

Main bearing caps

Step 1: 300 Nm
Step 2: Angle tightening 120°

P0034669

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03-2 Specifications, Engine

Big end bearing cap

Step 1: 20 Nm
Step 2: 60 Nm
Step 3: Angle tightening 90°

P0034679

Stiffener frame
Step 1: 65 Nm
Step 2: Angle tightening 60°

P0034659

Flywheel
Step 1: 60 Nm
Step 2: Angle tightening 120°

P0034672

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 03-2 Specifications, Engine

Flywheel Housing
Step 1: M14 screw 160 Nm
Step 2: M10 screw 48 Nm
Step 3: M8 screw 24 Nm
Apply 2 mm sealant P/N 1161231 as shown in the
image.

P0034673

Vibration damper, crankshaft

Step 1: 35 Nm
Step 2: 125 Nm

P0034671

Front crankshaft cover

Apply 2 mm sealant P/N 1161231 as shown in the
image.

P0034658

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03-2 Specifications, Engine

Stage 1: by hand
Step 2: 24 Nm

P0034657

Valve Cover
25 Nm

P0034678

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 03-2 Specifications, Engine

P0034655

Cylinder head
Step 1: 100 Nm
Step 2: Angle tightening 90°
Step 3: Angle tightening 90°

NOTICE! The screws may be re-used max 2 times.

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03-2 Specifications, Engine

Camshaft bearing cap, Rocker arm bridge, screw

P0034654

1 Tightening sequence: 4-15-3-13-5-17-2-11-6-19-1-9-7-20

40 Nm
2 Tightening sequence: 15-13-17-11-19-9-20
60 Nm
3 Tightening sequence: 4-3-5-2-6-1-7
Angle tightening: 90°
4 Tightening sequence: 15-13-17-11-19-9
100 Nm
5 Tightening sequence: 14-12-16-10-18-8
50 Nm
6 Tightening sequence: 20
60 Nm
7 Tightening sequence: 14-12-16-10-18-8-20
Angle tightening: 120°
8 Loosen the screws: 15-13-17-11-19-9
9 Tightening sequence: 15-13-17-11-19-9
50 Nm
10 Tightening sequence: 15-13-17-11-19-9
Angle tightening: 120°

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 03-2 Specifications, Engine

Timing gear plate

Apply 2 mm sealant P/N 1161231 as shown in the
image.

P0037614

P0037615

Step 1: Screws 1 – 25
28 Nm
Step 2: Screw 26
60 Nm

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03-2 Specifications, Engine

Transmission
A Drive wheel, camshaft (incl. oscillation damper):
Step 1: 45 Nm
Step 2: Angle tightening 90°
B Idler gear, adjustable:
Step 1: 35 Nm
Step 2: Angle tightening 120°
C Idler gear, outer bull gear:
24 Nm
D Idler gear, inner:
Apply locking fluid P/N 1161053 to the screws.
Step 1: 25 Nm
Step 2: Angle tightening 110°
E Driving wheel, Crankshaft:
24 Nm
F Driving wheel, PTO, Seawater pump:
200 Nm
G Idler gear:
140 Nm
H Driving wheel, power steering and fuel feed
pump:
100 Nm
P0034670

Valve mechanism, standard

A Adjustment, exhaust:
38 Nm
B Adjustment, exhaust yoke:
38 Nm
C Pre-load, injector:
52 Nm
D Adjustment, intake:
38 Nm

P0034677

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 03-2 Specifications, Engine

Group 22 - Lubrication System

Oil Pan
A 24 Nm
B 60 Nm

P0034667

Oil pump
Step 1: 35 Nm
Step 2: Angle tightening 90°

P0034666

Oil cooler
24 Nm

P0034665

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03-2 Specifications, Engine

Oil pressure pipe

Pipe diameter 12 mm - 80 Nm
Pipe diameter 18 mm - 110 Nm
Pipe diameter 20 mm - 130 Nm
Pipe diameter 22 mm - 170 Nm
Pipe diameter 28 mm - 200 Nm

P0037878

Oil Valves
A Safety valve, lubricating oil pump
10 Nm
B Relief valve
10 Nm
C Control valve, piston cooling
55 Nm
D Opening valve, piston cooling
55 Nm
E Thermostat, oil cooler
10 Nm
F Connection turbo

P0034668
G Overflow valve, bypass filter
55 Nm
H Connection turbo
I Overflow valve, full flow plug
55 Nm

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 03-2 Specifications, Engine

Group 23 - Fuel System

Copper sleeve
Copper sleeve with two grooves requires injectors
with a sealing washer.

P0034664

Injector fastener
Tightening torque when replacing the sleeve:
Step 1: 20 Nm
Step 2: Angle tightening 180°
Step 3: Loosening the screw
Step 4: 25 Nm
Step 5: Angle tightening 90°
Tightening torque when replacing the injector:
Step 1: 25 Nm
Step 2: Angle tightening 90°

P0034662

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03-2 Specifications, Engine

Group 25 - Inlet and Exhaust System

Exhaust manifold
A Step 1: 10 Nm
Step 2: 48 Nm
Step 3: 65 Nm
B 24 Nm

P0034660

Intake manifold
Step 1: Tighten until contact
Step 2: 24 Nm

Step 1: 10 Nm
Step 2: 37 Nm

P0034663

Turbo
A 24 Nm
B Step 1: 20 Nm
Step 2: 48 Nm
Step 3: 85 Nm
C 24 Nm
D 68 Nm

P0034675

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 03-2 Specifications, Engine

Group 30 - Electrical System

Cable description

P0037620

Hot side

P0037618

Cold side

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03-2 Specifications, Engine

P0037619

Top

P0037617

Front side

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 03-2 Specifications, Engine

P0037616

Rear side

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03-2 Specifications, Engine

Technical Data

General

D16C1–E MG/MH
Engine D16C2–E MG/MH
Firing sequence (cyl. no. 6 closest to flywheel) 1-5-3-6-2-4
Idle rpm 550-800 rpm
Speed range, loaded, full throttle 1800/1900 rpm

Cylinder diameter 144 mm

Stroke 165 mm
Cylinder volume 16.12 liters
Cylinder block, type Cast iron blocks, with wet interchangeable cylinder
linings
Engine, without liquids, with cooling system (HE) 1815 kg

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 03-2 Specifications, Engine

Location of Sensors

P0036601

Boost pressure and boost air Oil level

temperature
Tightening torque 10 Nm Pos. D5

Pos. E2
P0037625 P0037627

Coolant level Crankcase pressure

Plug-in type Tightening torque 25 Nm

Pos. C3 Pos. B4

P0037623 P0037633

Sea water pressure and sea water Coolant temperature

temperature Tightening torque 20 Nm
Tightening torque 25 Nm
Pos.N2
Pos. E3
P0037629 P0037632

Fuel pressure sensor Camshaft position

Tightening torque 25 Nm Tightening torque 10 Nm

Pos. E3 Pos. I2

P0037622 P0037626

Oil pressure and oil temperature Flywheel position

Tightening torque 25 Nm Tightening torque 10 Nm

Pos. D3 Pos. I3

P0037628 P0037630

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03-2 Specifications, Engine

Coolant temperature Pressure drop indicator

Tightening torque 25 Nm
Pos. J3
Pos. M3

P0037624 P0037631

Exhaust temperature sensor

Tightening torque 45 Nm

Pos. K3

P0037621

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 03-2 Specifications, Engine

Engine
Cylinder head

P0034836

Max flatness error (base plane) 0.1 mm

Max allowable processing 0

Cylinder Head Bolts

Screw may be re-used 2 times
Thread size M18
Maximum length of screw 188 mm

Cylinder Liner

P0034820

Height above cylinder block plane 0.15 - 0.21 mm

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03-2 Specifications, Engine

Crank Mechanism
Piston

P0034825

Piston, diameter (B) 143.9 mm

Piston installed in engine; height above cylinder block plane 0.0 - 0.6 mm

P0029853

Upper compression ring, piston ring gap (G) at position (L), 0.45 – 0.60 mm
max
2nd compression ring, play in piston ring groove (axial), max 0.09 – 0.14 mm
Oil ring, play in piston ring groove (axially), max 0.06 – 0.11 mm

Con rods
Piston pin diameter 62.99 – 63.0 mm
Piston hole, diameter 63.006 – 63.008 mm

Crankshaft
Axial play 0.10–0.40 mm 1)
1) Dimensions apply to oiled components.

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 03-2 Specifications, Engine

Main bearing journals

P0034818

Standard diameter (D) 118 mm

Max ovality 0.01 mm
Taper, max 0.02 mm
Fillet radius (R) 4.5 mm
Main bearing shell, standard bearing, dimension (T) 2.51 mm

P0029856

Thrust bearing pin, standard bearing, width dimension (X) 49 mm

Thrust bearing, standard bearing, dimension (T) 3.18 mm

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03-2 Specifications, Engine

Main bearing shells

P0034819

Standard bearing, dimension (T) 2.51 mm

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 03-2 Specifications, Engine

Big-end bearing journals

P0029860

Standard diameter (D) 112 mm

Max ovality 0.01 mm
Taper, max 0.02 mm
Fillet radius (R) 4.5 mm

Big-end journal shells

Standard bearing (T) 2.35 mm

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03-2 Specifications, Engine

Con rods

P0029858

Diameter (D1) 116.79 mm

Diameter (D2) 63 mm
Length, connecting rod (L) center measurement between
(D1) and (D2) 280 mm

Flywheel

P0034830

Axial eccentricity (A), max 0.1 mm

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 03-2 Specifications, Engine

Valve mechanism
Camshaft

P0034822

Stubs, diameter 69.97-70.00 mm

Stub, max irregularity 0.05 mm
Axial play camshaft - bearing mode, max 0.35 mm
Camshaft, lift height (H), intake 13.7 mm
Camshaft, lift height (H), exhaust 14.5 mm

Valves

P0034833

Inlet
Valve, seat angle (A1) 25°
Valve seat, seat angle (A2) 25°
Valve clearance, cold engine, setting values 0.3 mm
Outlet
Valve, seat angle (A1) 45°
Valve seat, seat angle (A2) 45°
Valve clearance, cold engine, setting values 0.6 mm

Valve clearance, inlet, diameter 9.945 mm

Valve clearance, outlet, diameter 9.915 mm

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03-2 Specifications, Engine

P0034832

Valve dimensions below cylinder head plane (A), inlet, max 0.9–1.4 mm
Valve dimensions below cylinder head plane (A), outlet, max 1.4–1.9 mm

P0034829

Radial play, inlet, valve/valve guide, max 0.025–0.054 mm

Radial play, outlet, valve/valve guide, max 0.058–0.087 mm

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 03-2 Specifications, Engine

Valve seats

P0034834

Valve seat, inlet, height (H) 6.1 mm

Valve seat, inlet, diameter (D) 52.1 mm
Valve seat, outlet, height (H) 6.3 mm
Valve seat, outlet, diameter (D) 49.1 mm

Position of the valve seat in the cylinder head, inlet, depth

(A) 10.2 mm
Position of the valve seat in the cylinder head, inlet, diameter
(B) 52 mm
Position of the valve seat in the cylinder head, inlet, radius
(R) 0.8 mm
Position of the valve seat in the cylinder head, outlet, depth
(A) 10.2 mm
Position of the valve seat in the cylinder head, outlet,
diameter (B) 49 mm
Position of the valve seat in the cylinder head, outlet, radius
(A) 0.8 mm

Valve springs
Valve spring, length, inlet, unloaded 67.5 mm
Valve spring, length, inlet loaded with 552 N 57 mm
Valve spring, outer, length, outlet, unloaded 69.3 mm
Valve spring, outer, length, outlet, loaded with 93 N 54 mm
Valve spring, inner, length, outlet, unloaded 67 mm
Valve spring, inner, length, outlet, loaded with 465 N 51 mm

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03-2 Specifications, Engine

Lubrication System
Lubricating oil, engine
Oil grade VDS 4.5
Viscosity SAE10W/30 in normal conditions

Oil volume, (including oil filter): 59 liters

Oil volume between min and max markings: 10 liters

Engine Oil Pressure

Lubrication oil pressure, idle, hot engine, min 160 kPa @ 600 rpm
Lubrication oil pressure, operating speed, warm engine, min 270 kPa @ 1900 rpm
210 kPa @ 1200 rpm
Oil temperature, loaded, max 130°C

Thermostat
Thermostat, oil cooler, starts to open 104°C
Thermostat, oil cooler, fully open 116°C

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 03-2 Specifications, Engine

Fuel System
Fuel system
Injection pressure 1700 ± 150 bar
Pressure from feed pump, at idle, min 400 kPa
Pressure from feed pump, operating rpm, min 500 kPa
Max permissible negative pressure to feed pump -65 kPa relative

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03-2 Specifications, Engine

Inlet and Exhaust System

Turbo
Axial play (A) Visual inspection with the wheels not contacting the
housing
Radial play (B), turbine wheel Visual inspection with the wheels not contacting the
housing

P0034831

Charge air pressure

Charging pressure, max rpm/load, air temp 20-25⁰C 297-315 (850hp)
Depends on the power variant

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 03-2 Specifications, Engine

Cooling System
Cooling system
Coolant, type VCS 40/60
Coolant, volume 38 L (engine) + 95 L (radiator)

Opening pressure of the filling cap 100 kPa

Thermostat
Starts to open at 82°C
Fully open at 94°C

Seawater Pump
Capacity 410 L/m

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03-3 Specifications, Electrical

03-3 Specifications, Electrical

Electrical System

System voltage 24 V
Generator, max charging current 110 A

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 05-1 Safety Instructions

05-1 Safety Instructions

Cleanliness requirements

Absolute cleanliness must be observed during all work on lead-free bearings.

Even very small particles have a markedly negative effect, especially on lead-free bearings.
Particles on bearing races during assembly can lead to relatively quickly occurring bearing failures.
The product's service life is directly dependent on the level of cleanliness maintained during service and repair
work.
Lead-free bearings that had been used in operation should not be reused.

Remember to:
• Thoroughly clean the outside of the engine before starting work.
• Keep the immediate surroundings clean while work is in progress (in the vehicle or workshop).
• If possible, make sure no dirt is brought in from outside. For example, close engine compartment ventilation.
Close the doors and such to the workshop workspace.
• Make sure no 'dirty' work takes place in the vicinity, i.e. no forklift driving, spray painting, grinding or welding
etc. nearby.
• Certain spare parts may need to be cleaned before installation.
NOTICE! Bearings may never be washed but must be stored in their packaging until installation.
• Make sure all tools are clean when working.
• Use lint-free gloves and absorbent paper.
• Canned spray-on cleaning agent may be used as necessary, but not on rubber parts.

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08-2 Special Service Tools

08-2 Special Service Tools

Use the following special tools when working on the
engine. The special tools can be ordered from AB
Volvo Penta by specifying the tool number concerned.

827861 Spacer 884167 Drift 885536 Plug 885537 Plug

885539 Plug 885810 Fixture 3849613 Pressure testing kit

9809726 Pneumatic hydraulic

9809729 Hydraulic cylinder 9988539 Compression meter
pump

9989876 Dial indicator 9990006 Puller 9990013 Slide hammer

44 47714221 11-2024 © AB VOLVO PENTA

 08-2 Special Service Tools

9990107 Connection washer 9990114 Puller 9990157 Press tool

9990164 Fixture 9990166 Mounting tool 9990176 Press tool

9992479 Holder for dial

9990192 Puller 9992000 Handle
indicator

9992671 Hydraulic cylinder 9993590 Rotation tool 9996049 Draining hose

47714221 11-2024 © AB VOLVO PENTA 45

08-2 Special Service Tools

9996159 Adapter 9996180 Drift 9996239 Lifting tool

9996394 Support 9996395 Support 9996400 Slide hammer

9996645 Puller 9996662 Pressure testing kit 9996666 Nipple

9996963 Plate 9998248 Adapter 9998249 Protective sleeve

46 47714221 11-2024 © AB VOLVO PENTA

 08-2 Special Service Tools

9998250 Sealing ring 9998251 Protection plug 9998264 Lifting tool

9998339 Manometer 9998493 Hose 9998511 Lever

9999683 Dial indicator (short

9998601 Fixture 9999696 Magnetic stand
probe)

21461107 Guide pin 88800058 Stand 88800064 Drift

47714221 11-2024 © AB VOLVO PENTA 47

08-2 Special Service Tools

88800127 Drift 88800137 Drift 88800151 Drift

88800313 Piston ring

88800352 Lifting tool 88800387 Puller
compressor

88800460 Sleeve 88800501 Mounting tool 88800502 Puller

88800503 Mounting tool 88800513 Drift 88800550 Cleaning kit

48 47714221 11-2024 © AB VOLVO PENTA

 08-2 Special Service Tools

88840300 Plate 88880175 Counterhold 88880176 Guide pin

88880199 Extractor
88880200 Extractor

47714221 11-2024 © AB VOLVO PENTA 49

20-0 Engine Information, General

20-0 Engine Information, General

Test and Adjustments

Cylinder Head, Pressure Testing
Tools:
885537 Plug
9990107 Connection washer
9990164 Fixture
9996662 Pressure testing kit
1 Install the sealing plates with the screws to the
cylinder head and nuts
2 Seal open connections for cooling water.
3 Install the connecting washer to the thermostat
housing and fix it with a vice
4 Activate the pressure test kit, raise the pressure
to 1 Bar.
Check that the pressure has not dropped after 5
minutes.
5

Immerse the cylinder head in water to identify

P0036522 leakage.

NOTICE! Make sure that no dirt gets into the

fuel galleries, since this could damage the unit
injectors.

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 21-0 Engine Complete, General

21-0 Engine Complete, General

Engine, to set TDC
Tools:
9993590 Rotation tool

1 Remove the inspection cover on the timing gear

casing. Turn the engine with P/N 9993590, until
the marking on the flywheel matches the marking
in the timing gear casing.

P0036600

2 Remove the valve cover.

3 Check that the camshaft TDC marking is between
the two lines on the camshaft cover.

P0036599

4 Remove the top timing gear casing and verify

that the reference hole on the timing gear plate is
between the markings on the drive.
5 Fit the upper timing gear casing, refer to Cylinder
Head, Replace, page 72.

P0040772

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21-0 Engine Complete, General

Check and Fault Trace

Cylinder Head, Check
Tools:
9989876 Dial indicator
9992479 Holder for dial indicator
9999683 Dial indicator (short probe)
9999696 Magnetic stand
1 Perform the check with a feeler gauge and a
straight edge.
Max deviation 0.1 mm.

P0035557

2 Valve guides, check

Lift the valve approx 6 mm from the seat.
Max permitted play is:
• Inlet: 0.054 mm
• Outlet: 0.087 mm

P0035560

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 21-0 Engine Complete, General

3 Valve seats, check

The valve seat should be replaced when
dimension (L) exceeds:
• Inlet: 1.4 mm
• Outlet: 1.9 mm

P0035559

4 Valve seat bed, check

Check no cracks are present.
Measure valve seat diameter (D):
• Inlet: 52 – 52.1 mm
• Outlet: 49 – 49.1mm

P0035558

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21-0 Engine Complete, General

Compression Test
Tools:
9988539 Compression meter
9998248 Adapter
9998665 Adapter
• Valve cover removed
• Rocker arm bridge, intermediate piece and injector
removed, refer to Injector, Replace, page 108

NOTICE! The engines are fitted with a ”keystone” type

upper compression ring. This type of ring requires gas
pressure to function optimally.
Measurement results with this type of compression test
can therefore give erroneous indications.

A simpler and more reliable test can be performed with

the VODIA tool.

1 Fit all the adapters to the cylinder head (to avoid

repeated removal/fitting of the rocker arm bridge
and fuel injectors and adjustment of the valve
clearances six times).
2 Add rocker arm bridge and intermediate section,
refer to Injector, Replace, page 108.
3 Crank the engine with the starter motor until the
needle on the compression gauge stops moving
(max. compression value) and read off the value.
Repeat the test on all cylinders.

NOTICE! Do not run the starter motor for more

than 15 seconds at a time, with a rest interval of
a few minutes.
P0041411 4 Remove adapters and re-fit the injectors, refer
toInjector, Replace, page 108.

Fitting the Fixture

Tools:
88800003 Fixture
88800123 Plate

54 47714221 11-2024 © AB VOLVO PENTA

 21-0 Engine Complete, General

1 Remove marked components.

P0036597

2 Attach the fixture and adapter.

P0036598

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21-0 Engine Complete, General

Engine Disassembly
Tools:
9989876 Dial indicator
9990013 Slide hammer
9990114 Puller
9990157 Press tool
9996239 Lifting tool
9996394 Support
9996395 Support
9996645 Puller
9996963 Plate
9998511 Lever
88800313 Piston ring compressor
1 Remove marked parts.

P0036615

2 Remove marked parts.

P0036616

56 47714221 11-2024 © AB VOLVO PENTA

 21-0 Engine Complete, General

3 Remove marked parts.

P0036617

4 Remove marked parts.

P0036618

5 Remove marked parts.

P0036619

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21-0 Engine Complete, General

6 Remove:
• oil pump
• suction pipe
• pressure pipe

P0036620

7 Remove the stiffening plate.

P0036621

8 Remove the piston cooling jet.

P0036622

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 21-0 Engine Complete, General

9 Mark and remove the bearing caps, connecting

rod and piston.

P0036623

10 Pull the cylinder liner out of the block.

Remove the cylinder liner sealing rings.

P0036624

11 Remove the flywheel.

P0036625

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21-0 Engine Complete, General

12 Remove the screws on the back of the casing

P0037635

13 Remove the timing gear casing.

P0036626

14 Remove the transmission wheel.

P0036627

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 21-0 Engine Complete, General

15 Remove the timing gear plate.

P0036629

16 Remove:
• main bearings
• crankshaft

P0036628

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21-0 Engine Complete, General

Engine Assembly

First read the instructions Safety Instructions, page 43.

Tools:
9989876 Dial indicator
9992479 Holder for dial indicator
9998511 Lever
88800313 Piston ring compressor
88840300 Plate

Tools:
1 Install:
• bearing
• crankshaft
NOTICE! Lubricate bearings and crankshaft with
oil.

P0036281

2 Install the main bearing cap.

• Step 1: 300 Nm
• Step 2: Angle tightening 120°

P0036282

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 21-0 Engine Complete, General

3 NOTICE! Apply a bead of sealant P/N 1161231

with a diameter of approx. 2 mm, refer to
illustration.

P0037614

4 Install the timing gear plate.

For tightening torque, refer to Group 21 -
Engine, page 11.

P0036629

5 Install new seals.

P0037638

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21-0 Engine Complete, General

6 Insert transmission wheels according to

numerical order.

NOTICE! Install the double drive (4) so that the

marking matches the markings on the crankshaft
gear (1).

For tightening torque, refer to Group 21 -

Engine, page 11.

P0036634

7 NOTICE! Apply a bead of sealant P/N 1161231

with a diameter of approx. 2 mm, refer to
illustration.

P0036635

8 Install the timing gear casing.

• M8: 24 Nm
• M10: 48 Nm
• M14: 160 Nm

P0036626

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 21-0 Engine Complete, General

9 Install the rear crankshaft seal.

NOTICE! The metal side of the seal ring must

face inward.
Refer to: Crankshaft Seal, Replace
(rear), page 99.

P0036636

10 Install the flywheel.

• Step 1: 60 Nm
• Step 2: Angle tightening 120°

P0036637

11 NOTICE! Apply a bead of sealant P/N 1161231

with a diameter of approx. 2 mm, refer to
illustration.

P0036638

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21-0 Engine Complete, General

12 Install the casing.

Tightening torque: 24 Nm
Install the crankshaft seal; refer to Crankshaft
Seal, Replace (front), page 97.

P0036639

13 Fit the cylinder liner without seal rings. Affix it with

two press tools P/N 9996966.
14 Insert the dial indicator in the retainer. Place
the retainer across the cylinder liner. Zero the
indicator with a couple millimeters of pre-load
against the cylinder block plane.

P0037639

15 Measure the height between the highest point of

the cylinder liner and the plane of the cylinder
block in two different places diagonally to each
other and calculate the average value of the
measurement results.
If the liner height above the block plane is outside
specified tolerances, the liner shelf must be re-
milled and a shim shall be used when installing.

P0037640

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 21-0 Engine Complete, General

16 If the cylinder liner is fitted without shims, an even,

about 0.8 mm thick bead of sealing compound
P/N 1161231 must be placed on the underside of
the cylinder liner collar.
If the cylinder liner is installed with shims, apply
the sealant bead to the cylinder block liner seat.

NOTICE! Do not put the seal around the entire

liner. Leave a 2 mm opening.

NOTICE! Sealant must not be used between the

shims and the cylinder liner collar.

NOTICE! After applying the sealant, the liner

must be installed within 20 minutes. Use pressing
tools P/N 9996966 to hold the liner in place.
P0036641
Apply the included lubricant to the sealing rings
of the liner and install the seals on the lining.

NOTICE! The violet-colored seal must be located

at the bottom of the lining.
17 Insert one of the cylinder head screws and press
the cylinder liner down with a prybar and puller
plate.
Use the appropriate spacer between plate and
prybar. Secure the liner with P/N 9996966 press
tool.

P0036642

18 Lubricate the piston pin and the piston bearing

seat with engine oil and install the connecting rod.
IMPORTANT:

The marking “FRONT” on the connecting rod

and the arrow on the piston must face the same
direction.

P0036643

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21-0 Engine Complete, General

19 Install the piston rings evenly spaced in relation

to each other. The oil ring opening must be
diametrically opposite the opening in the spring.
IMPORTANT:

The marking on the upper piston rings shall face

upwards. The oil ring can be installed in both
directions.

P0037641

20 Tightening torque connecting rod cap:

• Step 1: 20 Nm
• Step 2: 60 Nm
• Step 3: Angle tightening 90°

P0036644

21 Install the piston cooling jets:

Tightening torque: 24 Nm

P0036645

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 21-0 Engine Complete, General

22 Install reinforcing plate:

Tightening torque:
• Step 1: 65 Nm
• Step 2: Angle tightening 90°

P0036646

23 Install:
• oil pump
Tightening torque:
Step 1: 35 Nm
Step 2: Angle tightening 90°
• suction pipe
• pressure pipe
Tightening torque: 200 Nm

P0036620

24 Install marked parts.

P0036619

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21-0 Engine Complete, General

25 Install marked parts.

P0036618

26 Install marked parts.

P0036617

27 Install marked parts.

P0036616

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 21-0 Engine Complete, General

28 Install marked parts.

P0036615

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21-1 Cylinder Head

21-1 Cylinder Head

Cylinder Head, Replace

First read the instructions Safety Instructions, page 43.

Tools:
885810 Fixture
9990006 Puller
9990013 Slide hammer
9990185 Lifting tool
9990192 Puller
9993590 Rotation tool
9996400 Slide hammer
9998249 Protective sleeve
9998251 Protection plug
9998264 Lifting tool
9998601 Fixture
9999683 Dial indicator (short probe)
9999696 Magnetic stand
88800352 Lifting tool

Remove:
• Manifold; refer to Exhaust Manifold,
Replace, page 122.
• Inlet piping, refer to Intake Manifold,
Replace, page 124.
• Heat exchanger; refer to 26-1, Heat exchanger,
Replace.
• Charge air cooler, refer to Charge Air Cooler,
Replace, page 152.
• Expansion tank, refer to 26-0, Expansion Tank,
Replace.
• Thermostat housing/thermostat, refer to
Thermostat, Replace, page 151.
1 Remove the fuel pipes.

P0036474

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 21-1 Cylinder Head

2 Remove water piping and temperature sensors.

P0036475

3 Remove the valve cover.

P0036476

4 Remove:
• connectors to injectors
• cable clips
• screw on the side of the cylinder head
5 Thread the cabling out of the cylinder head.

P0036477

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21-1 Cylinder Head

6 Remove injectors, refer to Injector,

Replace, page 108.

P0036478

7 Remove:
• camshaft sensor
• upper timing gear casing

P0036479

8 Remove the camshaft gear and oscillation

damper.

NOTICE! The oscillation damper is very sensitive

to shocks.

P0036480

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 21-1 Cylinder Head

9 Remove screws in the timing gear plate.

Screw behind the transmission gears is reached
by turning the engine.

P0036481

10 Remove:
• camshaft bearing cap
• camshaft
• bearing brackets

P0036482

11 Remove cylinder head, use 2 pcs P/N 9996239

to lift off cylinder head.

P0036483

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21-1 Cylinder Head

Installation
12 Clean contact surfaces.

P0036484

13 Install a new gasket.

P0036485

14 Apply a string of 2 mm with P/N 1161231 sealant

to the rear edge of the cylinder head.

P0036486

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 21-1 Cylinder Head

15 Install the cylinder head.

Install screws to the transmission side and tighten
the cylinder head firmly against the transmission
plate so that sealant comes into contact.
Tightening torque: 28 Nm, then loosen screws 1
turn.

NOTICE! The cylinder head must not be moved

after this operation.

P0036487

16 Tighten the cylinder head, refer to Group 21 -

Engine, page 11.

P0036488

17 Tighten the screws in the timing gear plate.

Tightening torque: 28 Nm

P0036489

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21-1 Cylinder Head

18 Crank the engine so that the flywheel is set

exactly to zero according to the marking on the
flywheel housing.

P0036490

19 Install:
• bearing brackets
• camshaft
• camshaft bearing cap
Check the marking in the camshaft so that it
is mounted in the TDC, refer to Engine, to set
TDC, page 51.

P0036491

20 Remove the top timing gear casing and verify

that the reference hole on the timing gear plate is
between the markings on the drive.

P0040772

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 21-1 Cylinder Head

21 Install the camshaft gear without the oscillation

damper.
Tightening torque: 10 Nm
22 Loosen the lower screws in the adjustment wheel.
Check that the upper screws are not tightened.
Place a feeler gauge on the pressure side and
press the camshaft gear against the feeler gauge.
23 Tighten the adjuster wheel.
• 35 Nm
• Angle tighten 120°
24 Tighten the camshaft gear.
• 45 Nm
P0036492
• Angle tighten 90°
25 Check the tooth flank play setting. Redo the
above steps if flank play is not correct.
Tooth flank play 0.05-0.15 mm

P0036493

26 Apply an approximately 2 mm string of sealant

P/N 1161231.
Install new gaskets.

P0036494

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21-1 Cylinder Head

27 Install the timing gear casing with 2 screws,

(loosely). The holes for the screws are oblong.
Use tools to press down on the casing.

P0036495

28 Tighten the screws in sequence.

Tightening torque: 27 Nm

P0036496

29 Install the camshaft sensor.

P0036497

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 21-1 Cylinder Head

30 Install injectors, refer to Injector,

Replace, page 108.

P0036478

31 Install the cabling harness.

Apply a 2 mm string of sealant P/N 1161231
on the mating surface between the transmission
casing and cylinder head.

P0036498

32 Refit the valve cover.

P0036499

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21-1 Cylinder Head

33 Install water pipes and temperature sensors.

P0036475

34 Install fuel pipes.

Install:
• Thermostat housing/thermostat, refer to
Thermostat, Replace, page 151.
• Expansion tank, refer to 26-0, Expansion Tank,
Replace.
• Charge air cooler, refer to Charge Air Cooler,
Replace, page 152.
• Heat exchanger; refer to Heat exchanger,
Replace, page 136.
• Inlet piping, refer to Intake Manifold,
Replace, page 124.
P0036474
• Manifold; refer to Exhaust Manifold,
Replace, page 122.

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 21-1 Cylinder Head

Cylinder Head, Overhaul

Tools:
827861 Spacer
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990176 Press tool
9992000 Handle
9992671 Hydraulic cylinder
9996159 Adapter
9996180 Drift
88800058 Stand
88800064 Drift
88800127 Drift
88800137 Drift
88800151 Drift
88880175 Counterhold
88880176 Guide pin
88880199 Extractor
88880200 Extractor

Tools:
1 Position the fixture.

P0036347

2 Remove:
• valve cotters (valve cones)
• spring washer and spring
• valves

P0036346

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21-1 Cylinder Head

3 Place the valves in a stand, to allow reinstallation

in their original positions.

P0029360

4 Holding the puller (A), screw the stick handle into

position.

NOTICE! The tool is identified by the number of

the expander.

P0036359

5 Insert the counterhold and screw the hydraulic

cylinder into position
IMPORTANT:

Stop pumping as soon as the seat loosens.

P0034917

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 21-1 Cylinder Head

6 Cool the valve seat and heat the cylinder head

Install the valve seat.

P0037005

7 Grind valves and valve seats according to

specification, refer to Engine, page 29.

NOTICE! Spare part valves are already

machined, and do not need further grinding.

P0029358

8 Remove the valve stem seals.

P0036351

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21-1 Cylinder Head

9 Press out the valve guides.

NOTICE! Use only nuts on tool 9990176.

P0037006

10 NOTICE! Oil the outside of valve guide with

engine oil before installation.

Press home new valve guides.

P0037007

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 21-1 Cylinder Head

11 Insert a valve and tape the blue-marked area.

Install new valve stem seals.

P0036349

12 Install:
• valve cotters (valve cones)
• spring and spring washer

P0037008

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21-4 Valve Mechanism

21-4 Valve Mechanism

Valves and Injectors, Adjustment
Tools:
9993590 Rotation tool
• Valve cover removed
NOTICE! Markings 1–6 apply to adjustment of inlet
valves, outlet valves and unit injectors.

NOTICE! ! It is important that the line marked on

the camshaft is centered between the marks on the
bearing cap when adjustment is carried out.

1 Crank the engine in the direction of rotation to the

next camshaft marking.

P0038983

2 Adjust the inlet valves and injectors for each

cylinder at the same time.
In this case, camshaft position displays
adjustment of Inlet, outlet and injector rocker
arm cylinder 1.

P0038982

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 21-4 Valve Mechanism

3 Adjust the inlet valve clearance between the

valve yoke and the rocker arm thrust sleeve valve
yoke.
For valve clearance, refer to Engine, page 29.
4 Tighten the lock nut; refer to Group 21 -
Engine, page 11.
5 Check the valve clearance.

P0036609

6 Adjust the unit injector pre-load by loosening the

adjusting screw until clearance is obtained on the
injector.
Adjust the screw until zero clearance.
Tighten the adjusting screw a further 240°.
Tighten the lock nuts; refer to Group 21 -
Engine, page 11.

P0036608

7 Press the yoke down by hand.

At the same time screw the adjusting screw of the
valve yoke down so it rests against the valve stem
and thereafter an additional 60°.

P0036612

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21-4 Valve Mechanism

8 Adjust inlet valve clearance between the valve

yoke and the rocker arm thrust sleeve valve yoke.
For valve clearance, refer to Engine, page 29.
9 Tighten the lock nut; refer to Group 21 -
Engine, page 11.
10 Check the valve clearance.
11 Adjust the remaining valves and unit injectors in
a corresponding way.

P0036606

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 21-5 Timing Gears and Shaft

21-5 Timing Gears and Shaft

Camshaft Bearing Housing,
Replace
The factory-installed bearing housings are machined
together with the cylinder head, and therefore must not
be moved from one cylinder head to another.

Therefore, the first time one or more bearing housings

are replaced, they must all be replaced so that their
positions can be aligned. From then on, bearing
housings may be changed individually since the
replacement part variant differs from the production
variant.

P0036326

The holes for the guide sleeves are oval in the

replacement housings, which allows radial adjustment
of the center bearing housing and axial adjustment of
the front and rear bearing housings.

If replacement housings are installed, number them so

they can be put back in the same place as before, if
they must be removed.

P0036325

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21-5 Timing Gears and Shaft

Gear Ring, Fywheel: Replace

Prerequisite flywheel removed.
1 Drill 1-2 holes in the gap between teeth on the
ring gear.
Split the gear ring using a cold chisel.

P0028593

2 Heat the gear ring.

Tap the gear ring into place using a copper drift.

P0028594

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 21-5 Timing Gears and Shaft

Drive Belts, Replace

1 Alternative 1
Remove the belt protector.

P0037656

2 Replace drive belts.

Check the trailing wheels and tensioners.
Install the belt protector.

P0037654

3 Alternative 2
Remove the belt protector.

P0037655

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21-5 Timing Gears and Shaft

4 Remove the fan guard.

P0037652

5 Replace drive belts.

Check the trailing wheels and tensioners.
6 Install:
• fan guard
• belt protector

P0037653

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 21-5 Timing Gears and Shaft

Flywheel, Replace
Tools:
9993590 Rotation tool
9996239 Lifting tool
1 Remove the sensor.

P0035393

2 Remove the flywheel.

P0035394

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21-5 Timing Gears and Shaft

3 Install the flywheel, tightening torque:

Step 1: 60 Nm
Step 2: 120°

P0035392

4 Install the sensor

P0035393

96 47714221 11-2024 © AB VOLVO PENTA

 21-6 Crank Mechanism

21-6 Crank Mechanism

Crankshaft Seal, Replace (front)
Tools:
88800501 Mounting tool
88800502 Puller

Removal
1 Adjust the arms on 88800501 Mounting tool and
attach the tool.
Setting diameter: use A.
1 Forward: The hooks release
Back: The hooks grip
2 Tension nut
3 Slowly pull the seal off.

P0025163

Installation
Important! The metal side of the seal ring must face
inward.
2 Slide the seal ring onto the tool.
Screw the assembly tool with the seal onto the
crankshaft.
Press the seal in until the cover touches the
bottom. Hold in position for at least 3 seconds.

P0025195

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21-6 Crank Mechanism

3 Reference dimension for a correctly installed

seal.

P0025197

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 21-6 Crank Mechanism

Crankshaft Seal, Replace (rear)

Tools:
88800502 Puller
88800503 Mounting tool
9990166 Mounting tool

Removal
1 Adjust the arms on 88800502 Puller and attach
the tool.
Setting diameter: use C.
1 Forward: The hooks release
Back: The hooks grip
2 Tension nut
3 Slowly pull the seal off.

P0025163

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21-6 Crank Mechanism

Installation
Important! The metal side of the seal ring must face
inward.
2 Slide the seal ring onto the tool.
Screw the assembly tool with the seal onto the
crankshaft.
Press the seal in until the cover touches the
bottom. Hold in position for at least 3 seconds.

P0025171

3 Reference dimensions for a correctly installed

seal.

P0025172

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 22-0 Lubricating and Oil System, General

22-0 Lubricating and Oil System, General

Overview Control Valve
A Relief valve
B Safety valve, lubricating oil pump
C Control valve, piston cooling
D Opening valve, piston cooling
E Thermostat, oil cooler
F Overflow valve, bypass filter
G Overflow valve, full flow filter

IMPORTANT:
For the correct part number and thus the correct opening
pressure on the valves, see Electronic Parts Catalogue
(EPC).
P0036603

IMPORTANT:
The opening pressure and design of the valves
distinguish between standard / remote mounted oil filters.
On remote systems, the overflow valve (G) is located in
the filter holder.

P0036602

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23-3 Fuel Feed Pump and Filter

23-3 Fuel Feed Pump and Filter

Fuel filter, Change
NOTICE! Be prepared to gather up fluid.

Replacement, during operation

Remove the cover.
Loosen the nipple slightly.
Connect a transparent hose.
1 Cut off the fuel flow to one of the filters.
Turn the handle to its end position (A).

NOTICE! The arrow on the handle points towards

the active filter, the opposite filter can be
changed.
2 Remove and install a new filter.
Screw in the filter until it makes contact, then 180
° more.

P0033969

Bleeding, during operation

3 Turn the handle to the bleeding position (B).
4 Screw in the nipple when fuel flows without air
bubbles. Tightening torque: 3.5 Nm
Install the cover.
5 Repeat with the other filter.

6 Set the handle to the operating position (N).

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 23-3 Fuel Feed Pump and Filter

Fuel Feed Pump, Replace

IMPORTANT:
Working with the fuel system requires special
cleanliness.

CAUTION!
The fuel system may be under pressure.
When working on the fuel system, undo a closed
system at the first point with caution.

1 Close the fuel tap.

2 Remove:
• connections
• pump

P0035521

3 Check connecting link.

P0035523

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23-3 Fuel Feed Pump and Filter

4 Install a new seal ring.

Check that the shaft fits in the connecting link.

P0035524

5 Install the pump.

Tightening torque 25 Nm.
6 Attach the connections with new sealing
washers.
Tightening torque 48 Nm.

P0035522

7 Open fuel tap.

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 23-3 Fuel Feed Pump and Filter

Fuel Feed Pressure, Check

Tools:
9996666 Nipple
9998339 Manometer
9998493 Hose
1 Remove a venting nipple and attach the tools.
2 Fuel pressure at idle: min 400 kPa.
Fuel pressure at operating speed: min 500 kPa.

NOTICE! Low feed pressure can be the result of

a blocked fuel filter, a defective overflow valve or
a defective feed pump.

P0036439

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23-3 Fuel Feed Pump and Filter

Fuel System, Drainage

IMPORTANT:
Working with the fuel system requires special
cleanliness.

IMPORTANT:
Clean thoroughly before removal.

Install protective plugs in open connections.

CAUTION!

The fuel system may be pressurized.

When working on the fuel system, exercise caution
when disconnecting the first location in a closed
system.
1 Remove fuel hoses in high pressure pump.

NOTICE! Be prepared to collect fluids.

P0036445

2 Open venting nipples to the filters.

Remove the filters.

P0036446

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 23-3 Fuel Feed Pump and Filter

Fuel system, bleeding

1 Remove the protective cap and connect a
transparent hose to one of the venting nipples.
2 Open the venting nipple. Pump with the hand
pump until fuel that is free from air flows out.
Tighten the venting nipple while fuel is flowing out.
3 Vent the other filter in the same way.

P0036444

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23-7 Injectors and Delivery Pipes

23-7 Injectors and Delivery Pipes

Injector, Replace
Tools:
9998249 Protective sleeve
9998250 Sealing ring
9998251 Protection plug
88800352 Lifting tool
88800550 Cleaning kit

Tools:
IMPORTANT:
Working with the fuel system requires special
cleanliness.

Clean thoroughly before removing.

Install safety plugs in open connections.

CAUTION!
The fuel system may be under pressure.
When working on the fuel system, undo a closed
system at the first point with caution.

• Valve cover removed

1 Remove:
• valve
• pipes
• rocker bridge

P0036538

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 23-7 Injectors and Delivery Pipes

2 Remove the valve yoke, note the positioning, so

that it can be refitted in the same position.

P0035215

3 Remove:
• connector
• fastening caliper

P0035216

4 Remove the injectors.

Put on the protective plug.

NOTICE! Mark the injector locations for refitting.

P0036539

47714221 11-2024 © AB VOLVO PENTA 109

23-7 Injectors and Delivery Pipes

5 Attach a protective plug if a new injector is not to

be mounted immediately.

P0036541

6 Install 2 seal rings to prevent dirt from entering

the fuel ducts.

P0036542

7 Clean the sleeve.

P0036412

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 23-7 Injectors and Delivery Pipes

8 Insert new seals, lubricate with diesel.

P0031708

9 Install the injector, tightening as follows:

1 20 Nm
2 180°
3 Undo the screw
4 25 Nm
5 90°
Install the connector.

P0035214

10

NOTICE! When replacing an injector, a new

injector code must be programmed into the
control unit. The code is on the injector.

P0031707

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23-7 Injectors and Delivery Pipes

11 Install the valve yokes.

Lubricate the valve yokes and camshaft nocks
with engine oil.

P0035215

12

P0035218

13 Install rocker arm bridge, pipe and valve at the

same time.
Tighten the rocker arm bridge until contact,
alternating which screw to avoid bending.

P0036540

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 23-7 Injectors and Delivery Pipes

14 Tightening according to the following steps:

1 40 Nm (screws 4, 15, 3, 13, 5, 17, 2, 11, 6,
19, 1, 9, 7, 20)
2 60 Nm (screws 15, 13, 17, 11, 19, 9, 20)
3 90° (screw 4, 3, 5, 2, 6, 1, 7)
4 100 Nm (screws 15, 13, 17, 11, 19, 9)
5 50 Nm (screws 14, 12, 16, 10, 18, 8)
6 60 Nm (screws 20)
7 120° (screw 14, 12, 16, 10, 18, 8, 20)
8 Loosen screws (15, 13, 17, 11, 19, 9)
9 50 Nm (screws 15, 13, 17, 11, 19, 9)
P0035213
10 120° (screw 15, 13, 17, 11, 19, 9)
15 Perform valve adjustment, refer to 21-4, Valves,
Adjustment
Refit the valve cover.

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23-7 Injectors and Delivery Pipes

Sleeve for unit injector, replace

Tools:
9998250 Sealing ring
9998251 Protection plug
88800387 Puller
88800460 Sleeve
88800513 Drift
88800550 Cleaning kit
• Valve cover removed
• Rocker arm bridge and unit injector removed, refer
to Injector, Replace, page 108.
• Cooling system, emptied.
IMPORTANT!Working with the fuel system requests
special cleanliness.

IMPORTANT!Install safety plugs in open connections.

CAUTION! The fuel system may be pressurized.

Exercise caution when disconnecting the first location
in a closed system.
1 Remove any protective plugs.

P0036666

2 Fit seal rings to prevent dirt from entering the fuel

galleries.

P0036668

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 23-7 Injectors and Delivery Pipes

3 Press down on the puller until it bottoms out

against the injector sleeve.
Tighten the nut until the expander grips the
sleeve.

P0036661

4 Thread the sleeve over and screw on the puller.

Screw on the nut with bearing to extract the
injector sleeve.

P0036660

5 Lift out the tooling and sleeve.

P0036669

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23-7 Injectors and Delivery Pipes

6 Use brushes from the cleaning kit, P/N 88800550

before installing a new sleeve.
Install the protective sleeve in the injector well
and affix it.
Clean the cylinder head walls.

P0030396

7 Clean the sleeve seat.

P0030397

8 Clean the cylinder head wells.

IMPORTANT! Check that the piston is in its lower
position in the cylinder to avoid damage.

P0030398

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 23-7 Injectors and Delivery Pipes

9 Lubricate the tap with engine oil.

P0025230

10 IMPORTANT:

Steel sleeve: Apply activating primer, Loctite

7649 (1). Apply a 2-3 mm string of sealant P/N
1161059 (2).
Copper sleeve: No sealant may be used.

P0030394

11 Put the injector sleeve on the mandrel and

lubricate the O-ring with soapy water.

P0036662

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23-7 Injectors and Delivery Pipes

12 Press down on the mandrel and affix it with the

attachment yoke of the unit injector.
Tightening torque: 80 Nm
13 Drift the tap down through the tip of the sleeve.
Remove the mandrel.

P0036665

14 Remove the sealing rings.

15 Insert injector and rocker arm bridge, refer to
Injector, Replace, page 108.
16 Install the valve cover.
17 Fill coolant, refer to Coolant, Replace, page 132.

P0036668

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 23-7 Injectors and Delivery Pipes

47714221 11-2024 © AB VOLVO PENTA 119

23-8 Control System, ECM, Data Sets

23-8 Control System, ECM, Data Sets

Control Unit, Replace
1 Cut the power.
IMPORTANT:

The system must be disconnected from power

and the starter key(s) must be in position 0
when the engine control unit connectors are
disconnected or connected.

P0036461

2 Remove:
• screws
• connectors
3 Replace control unit.

P0036462

4 Install:
• connectors
• screws
5 Switch power on.

NOTICE! The engine can not be started until

auto-configuration has been performed. Refer to
Service Manual Group 30, Electrical system.

P0036459

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 25-0 Inlet and Exhaust System, General

25-0 Inlet and Exhaust System, General

Check and Fault Trace

Turbocharger, check

Check:
• That no visible external damage to the compressor
wheel/turbine wheel is present.
• Press the turbine wheel/compressor wheel axially
and radiantly while rotating the shaft. No contact
between the turbine wheel or compressor wheel and
their housings may occur.

Bear in mind:
• Oil accumulation in the intake system downstream
of the turbocharger may indicate a worn
turbocharger.
P0034831 • Heavy carbon deposits on the turbine blades may
indicate a worn turbocharger.

47714221 11-2024 © AB VOLVO PENTA 121

25-1 Inlet and Exhaust Manifolds

25-1 Inlet and Exhaust Manifolds

Exhaust Manifold, Replace

Right side
Turbo already removed, refer to Turbo,
Replace, page 127.
1 Remove:
• hose
• manifold

P0034297

2 Replace all gaskets.

P0034298

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 25-1 Inlet and Exhaust Manifolds

3 Attach manifold, tightening torque:

• step 1: 10 Nm
• step 2: 48 Nm
• step 3: 65 Nm
Install hose, tightening torque 24 Nm.

Install the turbocharger.

P0034296

Exhaust Manifold, Replace

Left side
Turbo already removed, refer to Turbo,
Replace, page 127.
1 Remove manifolds.

P0034300

2 Replace all gaskets.

P0034301

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25-1 Inlet and Exhaust Manifolds

3 Attach manifold, tightening torque:

• step 1: 10 Nm
• step 2: 48 Nm
• step 3: 65 Nm

Install the turbocharger.

P0034299

Intake Manifold, Replace

Expansion vessel removed, refer to Expansion Tank,
Replace, page 148

Removal
1 Remove:
• hose
• connector
• Inlet pipe

P0035087

2 Remove:
• bracket
• sensor
• adapter

P0035088

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 25-1 Inlet and Exhaust Manifolds

Installation
3 Replace all seals, apply sealant, P/N 1161231 to
the cylinder head.
Lubricate the sealing rings with vaseline.

P0035089

4 Install:
• sensor
• bracket
• adapter

P0035088

5 Install:
• Inlet pipe
• hose
• connector

P0035087

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25-1 Inlet and Exhaust Manifolds

6 Tightening torque, screw 8.8: 24 Nm.

Tightening torque, screw 10.9: 37 Nm.

P0034663
Install expansion tank.

126 47714221 11-2024 © AB VOLVO PENTA

 25-5 Turbo and supercharger

25-5 Turbo and supercharger

Turbo, Replace

Left side

If turbocharger or EGR breakdown has occurred.

Always ensure that the intake and exhaust systems
are free of metal and oil residues before starting the
engine.
An oil-contaminated SCR / DPF must always be
replaced.
1 Remove:
• air filter
• pipes
• nuts

P0034313

2 Remove:
• hose
• pipes
• nuts

P0034316

47714221 11-2024 © AB VOLVO PENTA 127

25-5 Turbo and supercharger

3 Replace all gaskets.

P0034311

4 Install:
• turbocharger
• nuts (B) tightening torque:
Step 1: 20 Nm
Step 2: 48 Nm
Step 3: 85 Nm
• nut (C) tightening torque:
24 Nm
• pipe (A), tightening torque:
24 Nm
• hose

P0034312

5 Install:
• pipe (A), tightening torque:
24 Nm
• pipe (B) tightening torque:
68 Nm
• nuts (C) tightening torque:
24 Nm
• air filter

P0034314

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 25-5 Turbo and supercharger

Turbo, Replace

Right side

If turbocharger or EGR breakdown has occurred.

Always ensure that the intake and exhaust systems
are free of metal and oil residues before starting the
engine.
An oil-contaminated SCR / DPF must always be
replaced.
1 Remove:
• air filter
• pipes
• hose
• screws
• nuts

P0034308

2 Remove:
• pipes
• screws
• nuts

P0034309

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25-5 Turbo and supercharger

3 Replace all gaskets.

P0034310

4 Install:
• turbocharger
• nuts
• screws
• pipe (A), tightening torque 68 Nm
• pipe (B), tightening torque 24 Nm

P0034306

5 Install:
• nuts (A) tightening torque:
Step 1: 20 Nm
Step 2: 48 Nm
Step 3: 85 Nm
• screws (B), tightening torque:
24 Nm
• pipe (C) tightening torque:
24 Nm
• hose
• air filter

P0034307

130 47714221 11-2024 © AB VOLVO PENTA

 25-7 Crankcase Ventilation

25-7 Crankcase Ventilation

Crankcase Separator, Replace

Removal
1 Remove:
• connections
• crankcase separator

P0034947

Installation
2

P0034948

3 Install:
• crankcase separator
• connections

P0034947

47714221 11-2024 © AB VOLVO PENTA 131

26-0 Cooling System, General

26-0 Cooling System, General

Coolant, Replace
Tools:
9996049 Draining hose
1 Open:
• expansion cap
• drainage plugs
2 Close the drain plugs after draining.

P0035033

3 Fill up with coolant.

P0035032

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 26-0 Cooling System, General

Cooling System, Cleaning

Internal cooling system

WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.

1 Mix cleaning liquid and neutralization liquid

according to the volume of the current cooling
system.
• Cleaning agent: Citric acid (C6H8O7) 30
grams to 1 liter of water (preferably distilled
water).
• Neutralization fluid: Bicarbonate (NaHCo3)
6 grams to 1 liter of water.
2 Drain the cooling system (all draining points and
low-placed hoses etc).
• Fill the cooling system with cleaning agent.
• Run the engine for about 8 hours with
relatively high load (to open the thermostats
fully).
3 Drain the cooling system (all draining points and
low-placed hoses etc).
• Fill the cooling system with neutralization
fluid.
• Run the engine for about 1 hour with
relatively high load.
4 Drain the cooling system (all draining points and
low-placed hoses etc).
• Fill the cooling system with approximately
10% glycol mixture.
NOTICE! Use the correct type of coolant.
Refer to the engine specifications.
• Run the engine for about 2 hours with
relatively high load.
5 Drain the cooling system (all draining points and
low-placed hoses etc).
• Fill the cooling system with ready-mixed
coolant. Refer to the engine specifications.

47714221 11-2024 © AB VOLVO PENTA 133

26-0 Cooling System, General

Cooling System, Pressure Testing

Tools:
3849613 Pressure testing kit
1 Check the coolant level in the expansion tank.
2 Install test pressure kit on the expansion vessel,
pump up pressure to 0.7 bar. The pressure must
not drop during a 5 minute period.

NOTICE! If the pressure drops, check the engine

cooling hoses and connections for leaks.
3 Check coolant level after pressure testing.

P0036605

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 26-0 Cooling System, General

Check and Fault Trace

Charge Air Cooler, Pressure Testing
Tools:
885536 Plug
885539 Plug
3849613 Pressure testing kit
1 Plug the bleed hose.
2 Connect the expander plug to the cooling
connections on the charge air cooler.
3 Pump up a pressure of 1 bar. Pressure must not
fall during a 5 minute period.

NOTICE! If the pressure drops, troubleshoot

the leak with the aid of soapy water around
connections and seals.

P0036604

47714221 11-2024 © AB VOLVO PENTA 135

26-1 Radiator, Heat Exchanger

26-1 Radiator, Heat Exchanger

Heat exchanger, Replace

Removal
1 • Close the sea cock.
• Drain sea water.
• Close drainage.

P0034764

2 • Open the expansion tank cap.

• Drain the coolant.
• Close drainages.

P0034763

3 Remove:
• pipe connections
• the pipe mount
Loosen the screw for the heat exchanger a few
revolutions.

P0034767

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 26-1 Radiator, Heat Exchanger

4 Remove:
• pipe connections
• screws for bracket

P0034768

5 Remove the heat exchanger.

P0034766

Installation
6 Install the heat exchanger.

P0034765

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26-1 Radiator, Heat Exchanger

7 Install:
• screws for bracket
• pipe connections

P0034768

8 Install:
• the screw for the heat exchanger
• the pipe mount
• pipe connections
9 Open the sea cock.
Fill with coolant.

P0034767

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 26-1 Radiator, Heat Exchanger

Heat exchanger, cleaning

Heat exchanger removed; refer to Heat exchanger,
Replace, page 136.

Tools:
21461107 Guide pin

The working method in this description for cleaning

heat exchangers is to look at the changer from the
front, using the three screw holes, as shown in the
image, as the output marking.

IMPORTANT!
Seals and plates must be assembled in a given order
and be turned to face the right way otherwise both
function and watertight integrity will be jeopardized.

P0016330

1 Loosen the screws (1-10) max one revolution.

Continue to loosen each screw in sequence
one revolution at a time until all the screws are
loosened.

P0016331

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26-1 Radiator, Heat Exchanger

2 CAUTION!
Sharp edges. Wear gloves or use a shop cloth to
protect your hands.

Lift off the cover.

3 NOTICE! Mark the plates using a marker pen.

P0016332

4 Mark the top plate (1) and lay it and its unique
seal to one side.

P0016333

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 26-1 Radiator, Heat Exchanger

5 Mark and remove the plates together with their

rubber seals.

P0025054

6 Wash all plates and seals thoroughly under

running water. Use a soft brush.
Make scrupulously sure that there is no dirt
between the rubber seals and the plates.

P0025055

7 Wash the bottom attachment plate.

Check if the seals are to be replaced.

P0016336

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26-1 Radiator, Heat Exchanger

8 Check the oil cooler seals.

Check the water outlet pipe seal.

P0016337

9 Install 21461107 Guide pin in the outer spacer

pipes.

P0025056

10 Install the unique seals according to: Seals for

bottom plate and top plate (three pages ahead in
this section).

P0016339

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 26-1 Radiator, Heat Exchanger

11 NOTICE! The flat sides of the seals must face the

plate.

Install the seals on the other plates. Make sure

that all of the attachment lug seals are properly
positioned.

P0016340

12 Install all cooling plates according to: Cooling

plates and installation order (next page).

Begin with the base plate (A) and seal.

P0016341

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26-1 Radiator, Heat Exchanger

13 Grease the screw threads and the undersides of

the screw heads.
Install the screws except where the guide pins are
located.
Guide the top cover onto the two guide pins.

Tighten the screws to contact.

P0016349

14 IMPORTANT! The screws must be tightened

evenly so that the top cover is pressed down
straight.
Tighten the screws one revolution at a time in
sequence around the cover.

Remove the guide pins once the cover has been

pressed down sufficiently. Install the bushes and
the screws. Tighten the two screws until contact.

Continue to tighten the screws one revolution at

a time in sequence until the cover is completely
pressed down on all spacer pipes.
15 Install the heat exchanger; refer to Heat
exchanger, Replace, page 136.

P0016331

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 26-1 Radiator, Heat Exchanger

Cooling plates and installation sequence

Alternative with 61 plates

A 1 pc bottom plate (61).

The pattern points to the right.
Note the position of the sealed hole.

NOTICE! Unique seals.

B 16 pcs finely patterned cooling plates.

Must be turned so that the pattern on every
second plate points left.
(60, 58, 56 ... 30).

B 15 pcs finely patterned cooling plates.

Must be turned so that the pattern on every
second plate points right.
(59, 57, 55 ... 31)

C 1 intermediate plate (29).

The pattern points to the right.
Note the position of the sealed hole.

D 14 pcs coarsely patterned cooling plates.

Must be turned so that the pattern on every
second plate points left.
(28, 26, 24 ... 2)

D 13 pcs coarsely patterned cooling plates.

Must be turned so that the pattern on every
second plate points right.
(27, 25, 23 ... 3)

E 1 pc top plate (1).

The pattern points to the right.
Note the position of the sealed holes.

NOTICE! Unique seals.

P0025057

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26-1 Radiator, Heat Exchanger

Seals for bottom plate and top plate

This method shows how the seal must be modified to
fit the base plate / top plate.
1 Modify 2 seals to make 1 seal for the base plate /
top plate.

Cut the seal along the dotted line.

P0016343

2 Scrap the upper part of the seal.

P0016344

3 NOTICE! No attachment lugs may be present on

the seals. Cut away the attachment lugs.

Repeat the procedure for more seal halves.

P0016345

4 Place the two cut seal halves facing each other

on the plate.

P0016346

146 47714221 11-2024 © AB VOLVO PENTA

 26-1 Radiator, Heat Exchanger

Image of base plate

5 The seal must be glued using Volvo Penta part
no. 1161277.

Run a strand of glue above and below the join

where the two seal halves meet. Apply glue under
the seal at the points marked. Wipe away excess
glue.

Wait > 30 minutes before installing to give the

glue time to dry.

P0016347

Image of top plate

P0016348

47714221 11-2024 © AB VOLVO PENTA 147

26-1 Radiator, Heat Exchanger

Expansion Tank, Replace

1 Drain coolant, refer to Coolant,
Replace, page 132.
2 Remove:
• hose connections
• expansion tank
3 Install:
• expansion tank
• hose connections

P0035031

4 Fill coolant.

P0035032

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 26-2 Coolant Pump, Thermostat

26-2 Coolant Pump, Thermostat

Coolant Pump, Replace
1 Drain the coolant. Refer to 26-0, Draining the
Cooling System.
2 Remove drive belt protection.
3 Remove the drive belt.
4 Remove:
• connector
• water pump

P0031227

P0031226

47714221 11-2024 © AB VOLVO PENTA 149

26-2 Coolant Pump, Thermostat

6 Install:
• water pump, tightening torque 24 Nm
• connector
7 Install:
• drive belt
• drive belt protection
8 Fill coolant; refer to Coolant, Replace, page 132.

P0031277

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 26-2 Coolant Pump, Thermostat

Thermostat, Replace
Tools:
• Drain coolant; refer to Coolant, Replace, page 132.
1 Remove the thermostat housing.

P0036457

2 Install:
• new gaskets
• thermostat

P0036458

3 Install the thermostat housing.

• Refill with coolant: Refer to Coolant Level, Checking

and Topping Up.

P0036457

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26-5 Charge Air Cooler with Connections

26-5 Charge Air Cooler with Connections

Charge Air Cooler, Replace
1 Drain the cooling system, refer to Coolant,
Replace, page 132.
2 Remove the control panel.

P0036517

3 Remove nuts, 3 pcs.

P0036518

4 Remove:
• hose with hose retainer
• screw in upper bracket

P0036521

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 26-5 Charge Air Cooler with Connections

5 Remove water pipes.

P0036520

6 Remove screw in lower bracket.

P0036519

7 Remove the charge air cooler from the engine,

remove the frame around the charge air cooler.

P0036515

47714221 11-2024 © AB VOLVO PENTA 153

26-5 Charge Air Cooler with Connections

8 Install the gaskets.

P0036516

9 Install:
• charge air cooler
• screws in lower bracket

P0036519

10 Install the hoses

P0036520

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 26-5 Charge Air Cooler with Connections

11 Install:
• screws in bracket
• hose

P0036521

12 Attach nuts.

P0036518

13 Install the control panel.

14 Fill the cooling system, refer to Coolant,
Replace, page 132.

P0036517

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26-6 Sea Water System, Sea Water Pump

26-6 Sea Water System, Sea Water Pump

Seawater Pump, Replace
WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

1 Remove pipe connections.

P0035261

2 Remove the pump.

P0035260

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 26-6 Sea Water System, Sea Water Pump

P0035259

4 Install the pump.

P0035260

5 Install pipe connections.

P0035261

• Open the sea cock.

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26-6 Sea Water System, Sea Water Pump

Seawater Pump, Overhaul

Tools:
884167 Drift

Disassembly
1 Mark the positioning of the bearing housing
against the pump housing.
Remove the bearing halves.

P0035335

2 Remove the cover.

P0035336

3 Remove:
• rubber washer
• seal ring
• impeller

P0035328

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 26-6 Sea Water System, Sea Water Pump

4 Remove:
• cam screw
• cam
• wear ring

P0035341

5 Remove:
• support washer
• shaft seal

P0035340

6 Remove ceramic ring and rubber seal.

P0035330

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26-6 Sea Water System, Sea Water Pump

7 Remove the deflector ring.

P0035342

8 Remove the gear, use the appropriate puller.

P0035327

9 Remove the lock ring.

P0035338

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 26-6 Sea Water System, Sea Water Pump

10 Push the shaft out.

P0035326

11 Remove the bearings, use the appropriate puller.

P0035333

12 Remove seal, use the appropriate socket.

P0035345

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26-6 Sea Water System, Sea Water Pump

Assembly
13 Lubricate seal with P/N 828250, attach seal, use
appropriate washer.

P0035344

14 Fit new lock rings.

Press the bearings into position.

P0035332

15 Install the shaft into the housing.

P0035325

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 26-6 Sea Water System, Sea Water Pump

16 Install the lock ring.

Install the seal ring.

P0035337

17 Install the gearwheel and washer.

Install nut, tightening torque 200 Nm.

P0035327

18 Install the deflector ring.

P0035342

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26-6 Sea Water System, Sea Water Pump

19 Attach the rubber sleeve and ceramic ring.

P0035343

20 Install:
• wear ring (A)
• cam (B)
• screw (C)

P0035339

21 Assemble bearing housing onto pump housing,

observing earlier markup.
Tightening torque 24 Nm.

P0035334

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 26-6 Sea Water System, Sea Water Pump

22 Attach seal and washer.

P0035343

23 Lubricate the impeller and lid with glycerine P/N

828250.
24 Install:
• seal ring
• impeller
• rubber plug
• cover, tightening torque 10 Nm.

P0035329

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26-6 Sea Water System, Sea Water Pump

Seawater Pump, Impeller, Change

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

Removal
1 Remove the cover.

P0035273

2 Remove:
• seal
• impeller, use the appropriate puller

P0035271

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 26-6 Sea Water System, Sea Water Pump

Installation
3 Lubricate the pump housing and the new impeller
with glycerine (part # 3862178).
Install:
• impeller
• seal

P0035272

4 Install the cover, tightening torque 10 Nm

P0035274 Open the sea cock.

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32-1 Alternator

32-1 Alternator
Alternator, Replace
• Drive belts removed, refer toDrive Belts,
Replace, page 93.
• Cut the power.

Removal
1 Remove:
• connector
• cable connections

P0034995

2 Remove the alternator.

P0034994

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 32-1 Alternator

Installation
3 Install the alternator.

P0034994

4 Install:
• connector
• cable connections (A) and (B), tightening
torque 15 Nm

• Drive belts removed, refer toDrive Belts,

Replace, page 93.
• Switch power on.

P0034996

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33-1 Starter Motor

33-1 Starter Motor

Starter Motor, Replace
Cut the power.

Removal
1 Remove cable connections.

P0034998

2 Remove the starter motor.

P0035000

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 33-1 Starter Motor

Installation
3

P0037018

4 Install the starter motor.

P0035000

5 Install:
• cable connection (A), tightening torque 5
Nm
• cable connections (B and (C), tightening
torque 25 Nm

Switch power on.

P0034999

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Index
A General Tightening Torques..................................... 10
About this Workshop manual..................................... 3 Group 21 - Engine.................................................... 11
Alternator................................................................ 168 Group 22 - Lubrication System................................. 19
Alternator, Replace................................................. 168 Group 23 - Fuel System........................................... 21
Group 25 - Inlet and Exhaust System...................... 22
C Group 30 - Electrical System.................................... 23
Camshaft Bearing Housing, Replace....................... 91
Charge Air Cooler with Connections...................... 152 H
Charge Air Cooler, Pressure Testing...................... 135 Heat exchanger, cleaning....................................... 139
Charge Air Cooler, Replace.................................... 152 Heat exchanger, Replace....................................... 136
Check and Fault Trace............................. 52, 121, 135 I
Component location................................................... 8 Injector, Replace..................................................... 108
Compression Test..................................................... 54 Injectors and Delivery Pipes................................... 108
Control System, ECM, Data Sets........................... 120 Inlet and Exhaust Manifolds................................... 122
Control Unit, Replace............................................. 120 Inlet and Exhaust System................................. 40, 121
Coolant Pump, Replace......................................... 149 Inlet and Exhaust System, General........................ 121
Coolant Pump, Thermostat.................................... 149 Intake Manifold, Replace........................................ 124
Coolant, Replace.................................................... 132 L
Cooling System................................................ 41, 132 Location of Sensors.................................................. 27
Cooling System, Cleaning...................................... 133 Lubricating and Oil System, General...................... 101
Cooling System, General....................................... 132 Lubrication System................................................... 38
Cooling System, Pressure Testing......................... 134
Crank Mechanism.............................................. 30, 97 O
Crankcase Separator, Replace.............................. 131 Overview Control Valve.......................................... 101
Crankcase Ventilation............................................. 131 R
Crankshaft Seal, Replace (front).............................. 97 Radiator, Heat Exchanger...................................... 136
Crankshaft Seal, Replace (rear)............................... 99
S
Cylinder Head........................................................... 72
Safety Instructions.................................................... 43
Cylinder Head, Check.............................................. 52
Sea Water System, Sea Water Pump.................... 156
Cylinder Head, Overhaul.......................................... 83
Seawater Pump, Impeller, Change......................... 166
Cylinder Head, Pressure Testing.............................. 50
Seawater Pump, Overhaul..................................... 158
Cylinder Head, Replace........................................... 72
Seawater Pump, Replace....................................... 156
D Sleeve for unit injector, replace.............................. 114
Drive Belts, Replace................................................. 93 Special Service Tools............................................... 44
E Specifications, Electrical........................................... 42
Electrical System...................................................... 42 Specifications, Engine ............................................. 11
Engine................................................................ 29, 51 Starter Motor.......................................................... 170
Engine Assembly...................................................... 62 Starter Motor, Replace........................................... 170
Engine Complete, General....................................... 51 T
Engine Disassembly................................................. 56 Technical Data.......................................................... 26
Engine Information, General.................................... 50 Test and Adjustments............................................... 50
Engine, to set TDC................................................... 51 Thermostat, Replace.............................................. 151
Exhaust Manifold, Replace............................. 122, 123 Timing Gears and Shaft............................................ 91
Expansion Tank, Replace....................................... 148 Turbo and supercharger......................................... 127
F Turbo, Replace............................................... 127, 129
Fitting the Fixture...................................................... 54 Turbocharger, check............................................... 121
Flywheel, Replace.................................................... 95 V
Fuel Feed Pressure, Check.................................... 105 Valve Mechanism..................................................... 88
Fuel Feed Pump and Filter..................................... 102 Valve mechanism..................................................... 35
Fuel Feed Pump, Replace...................................... 103 Valves and Injectors, Adjustment............................. 88
Fuel filter, Change.................................................. 102
Fuel System..................................................... 39, 102
Fuel system, bleeding............................................ 107
Fuel System, Drainage........................................... 106
G
Gear Ring, Fywheel: Replace.................................. 92
General................................................................. 3, 50
General Specifications............................................... 8

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 References to Service Bulletins
Group No. Date Refers to

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