Documente Academic
Documente Profesional
Documente Cultură
D13
Table of Content
General Information
00-0 General ............................................................................................. 3
Specifications
03-2 Specifications, Engine .................................................................... 9
03-21 Engine ....................................................................................... 32
03-22 Lubrication System ................................................................. 44
03-23 Fuel System .............................................................................. 46
03-25 Inlet and Exhaust System ....................................................... 47
03-26 Cooling System ........................................................................ 48
03-3 Specifications, Electrical .............................................................. 50
Special tools
08-2 Special Service Tools ................................................................... 57
Chemical Products
18-0 General ........................................................................................... 65
General
20-0 Engine Information, General ........................................................ 66
Troubleshooting ................................................................................. 66
Test and Adjustments ....................................................................... 70
Engine
21-0 Engine Complete, General ........................................................... 76
Exposing the Engine ......................................................................... 76
Fitting the Fixture ............................................................................... 89
Engine Disassembly .......................................................................... 95
Engine Assembly ............................................................................. 110
21-1 Cylinder Head .............................................................................. 159
21-3 Cylinder Liner, Pistons ............................................................... 186
21-4 Valve Mechanism ........................................................................ 188
21-5 Timing Gears and Shaft .............................................................. 206
21-6 Crank Mechanism ....................................................................... 211
Fuel System
23-0 Fuel System, General ................................................................. 245
23-3 Fuel Feed Pump and Filter ......................................................... 250
23-7 Injectors and Delivery Pipes ...................................................... 260
Cooling System
Starting System
33-1 Starter Motor ............................................................................... 397
IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.
Repair instructions
Introduction Our mutual responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the
mounted in a holding fixture. Maintenance work is technical specification may dramatically increase the
often carried out on site, in which case – if nothing environmental impact of an otherwise reliable
else is indicated – using the same working methods system. It is therefore critical that the stated wear
as the workshop. tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information . maintenance schedule must be followed.
! DANGER! Some systems, e.g. fuel systems, often require
special expertise and test equipment. A number of
! WARNING! components are factory-sealed, for among other
things environmental reasons. Warranty-sealed
! CAUTION!
components may not be worked on without
authorization to perform such work.
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remember that most chemical products, incorrectly
can be foreseen as service work is carried out in the used, are harmful to the environment. Volvo Penta
most varied of circumstances. We call attention to recommends the use of biodegradable degreasers
risks that may occur due to incorrect handling during whenever components are cleaned, unless otherwise
work in a well-equipped workshop using working specified in the Service Manual. When working
methods and tools tried and tested by us. outdoors, take especial care to ensure that oils and
wash residues etc. are correctly properly for
The service manual describes work operations
destruction.
carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta
Special Tools are designed to ensure the safest and
Tightening torques
most rational working methods possible. It is Tightening torques for vital fasteners that must be
therefore the responsibility of anyone using tools or applied using a torque wrench are indicated in the
working methods other than those we recommend to Service Manual, chapter Tightening torques and in
ensure that no risk of personal injury or mechanical the Manual's work descriptions. All torque indications
damage is present, or that malfunction can result. apply to clean threads, bolt heads and mating faces.
Indicated torque data apply to lightly-oiled or dry
In some cases, special safety regulations and user threads. If lubricants, locking fluids or sealants are
instructions may be in force for the tools and required for fasteners, the correct type will be noted
chemicals mentioned in the Service Manual. These in the job description.
regulations must always be followed, and no special
instructions regarding this are to be found in the
Torque, angle tightening
Service Manual.
When torque/angle tightening, the fastener is
By taking these basic precautions and using common tightened to a specified torque, and tightening then
sense it will be possible to guard against most continues through a pre-determined angle.
elements of risk. A clean workplace and a clean
product will eliminate many risks of personal injury Example: For 90° angle tightening, the fastener is
and malfunction. turned a further 1/4 turn in one sequence, after the
specified tightening torque has been achieved.
Above all, when working on fuel systems, hydraulic
systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.
Illustrations
A lot of illustrations contains standardized symbols and colors. Please refer to the following information to reduce
misunderstandings when working on an engine / transmission using this Workshop Manual.
P0015623
2 Fastenings
(red)
3 Body
(light grey) P0015627
P0015628
Movement Tools
P0015622
P0015625
P0015630
Measurements
P0015631
P0022436
Chemicals Units
P0015695
P0015696
P0015624
Sealant
Safety
P0015698
P0015697
The tube symbol shows how thick layer of sealant to
applicate. These symbols are used when a certain safety related
The clock symbol is used when something needs to equipment is needed.
be done within or after a certain time.
IMPORTANT!
Check bolts which are to be re-installed. Damaged bolts,
e.g. with shear marks under heads must be scrapped.
5
5
7
4
5
2
1
4
3
1 2
6
3
6
6
6
P0012265
Frame reinforcement
24 22 19 18 15 14 11 10 7 6 3 2
23 21 20 17 16 13 12 9 8 5 4 1
P0005220
Timing plate
26 27 28 29
24
25
22
21 23
16
20
19
18
17
15
1 2
4 10
5 11
6 3
12
7
8 13
P0005221
9 14
P0005222
Timing plate
Tighten all bolts in sequence to the following torque: 28 ± 4 Nm (20.65 ± 2.95 lbf ft)
5 1
3 8
7 4
4
2 6
3
3 1
6
5 4
2
3
5
1
7 2
6
5 4 2
1
P0012311
8 9
6 7
2 3
4 5
P0005224
P0005225
Flywheel housing
Tighten all bolts in sequence to the following torque:
M14 bolts 140 ± 20 Nm (103.3 ± 14.75lbf ft)
M10 bolts 48 ± 8 Nm (35.4 ± 5.9 lbf ft)
M8 bolts 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
P0005226
4
5
2 1
P0005290
P0005227
3
Flywheel
6 8
10
4 12
2 14
13 1
11 3
9 5
7
P0005228
Flywheel
stage 1: Tighten the bolts in sequence, as illustrated 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
stage 2: (angle tightening) 120° ± 10°
4 5
6
3
2 7
1 8
P0005229 P0005230
8
5
7
4
9
P0005231 2
Vibration damper:
stage 1: Tighten the bolts in sequence, as illustrated 35 ± 5 Nm (25.81 ± 3.69 lbf ft)
stage 2: Tighten the bolts in sequence, as illustrated 90 ± 10 Nm (66.38 ± 7.38 lbf ft)
NOTICE! The vibration damper 8.8 bolts may not be re-
used.
Cylinder head
36 35 28 27 22 21 15 16 23 24 31 32
13 9 6 1 3 7 11
14 10 4 2 5 8 12
38 37 30 29 18 17 19 20 25 26 33 34
P0005232
1 2 3 4 5 6 7
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
1 6
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
2 7
1 2 3 4 5 6 7
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
3 8
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
4 9
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
5 10
P0005233
Valve adjustment
P0012312
Locking nut, unit injector (1), injector adjuster screw 52 ± 4 Nm (38.35 ± 2.95 lbf ft)
Locking nut (2), valve adjuster screw: 38 ± 4 Nm (28.03 ± 2.95 lbf ft)
Valve Cover
17
13 12 11 10 1 15 16 18
19
14
9 8 7 6 2 3 4 5 20
p0005236
Valve Cover
Tighten the bolts in sequence, as illustrated 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
3 A 1
4 B 2
P0012321
Oil cooler
1 3
4 2
P0005238
A C B
2 3
4 1
D
p0005239
4
3
P0012322
P0012323
p0005241
P0012337
Bolts (1) for adapter incl. fuel pump 24 ± 2 Nm (17.7 ± 1.48 lbf ft)
P0012338
Bolts (1) for fuel pump (installed on adapter) 8 + 2 / – 0 Nm (5.90 + 1.48 / – 0 lbf ft)
A
H
H
F F
H C
H
F
D D
D D
B
F B B
B
H
P0012340
11 10 2 3 6 7
P0012341 12 9 1 4 5 8
Intake Manifold
Torque the bolts 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
M10 plug, inlet manifold 20 ± 3 Nm (14.75 ± 2.21 lbf ft)
Exhaust Manifold
1 3 5 7 9 11
2 4 6 8 10 12
P0012342
Exhaust Manifold with Turbo Valve Housing (only D13B-A/H and inboard engine D13B-C/L, D13C4-A)
Stage 1:
Tighten all the bolts until they make contact (5 ± 1.5 Nm) [3.69 ± 1.11 lbf ft]
Stage 2:
Torque bolts 5, 8 and 6, 7 50 ± 4 Nm (36.9 ± 2.95 lbf ft)
Torque bolts 1, 4 and 9, 12 10 ± 1.5 Nm (7.38 ± 1.11 lbf ft)
Stage 3:
Torque bolts 10 and 11 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 9 and 12 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 2 and 3 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 1 and 4 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 5 and 8 50 ± 4 Nm (36.9 ± 2.95 lbf ft)
Torque bolts 6 and 7 50 ± 4 Nm (36.9 ± 2.95 lbf ft)
Exhaust Manifold (only D13B-B/D/E/F/G/J/K/M/N, D13C1-A, D13C2-A, D13C3-A and IPS engine D13B-C/L,
D13C4-A)
Stage 1:
Tighten all the bolts until they make contact (5 ± 1.5 Nm) [3.69 ± 1.11 lbf ft]
Stage 2:
Torque bolts 1, 4 and 5, 8 and 9, 12 10 ± 1.5 Nm (7.38 ± 1.11 lbf ft)
Stage 3:
Torque bolts 10 and 11 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 9 and 12 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 6 and 7 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 5 and 8 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 2 and 3 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Torque bolts 1 and 4 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Turbo
Turbo – Wastegate valve (only D13B-A/C/G/H/K/L,
D13C2-A, D13C4 twin turbo)
P0018807
Stage 1:
Tighten the nuts in the
sequence illustrated 15 Nm (11.1 lbf ft)
Stage 2:
Tighten the nuts in the
sequence illustrated 60 Nm (44.3 lbf ft)
P0018808
Stage 1:
Tighten the nuts in the
sequence illustrated 15 Nm (11.1 lbf ft)
Stage 2:
Tighten the nuts in the
sequence illustrated 50 Nm (36.9 lbf ft)
P0018809
P0018816 Stage 1:
Tighten the bolts 10 Nm (7.4 lbf ft)
Stage 2:
Loosen the bolts 180°
Stage 3:
Tighten the bolts 10 Nm (7.4 lbf ft)
Engine, General
NOTICE! Because the illustrations 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.
Location of Sensors
Refer to the tightening torques on the following page.
Engine
Technical Data
Engine body
Cylinder head
Max unevenness (bottom surface) 0.1 mm (0.00394 in)
Cylinder block
Length 1052 mm (41.41 in)
Height, upper block plane-crankshaft center 422 mm (16.61 in)
Height, lower block plane-crankshaft center 120 mm (4.72 in)
Cylinder Liner
Type Wet, replaceable
Sealing surface height above block plane 0.15–0.21 mm (0.00591–0.00827 in)
No. of seal rings per cylinder liner 1+3
Piston
Height above cylinder block plane, steel pistons 0.1 (min)–0.7 (max) mm [0.00394–0.0276 in]
No. of ring grooves 3
Front marking Forward pointing arrow
Piston rings
XXX
X
XXX
X
X
X
X
X
p0005201
Compression Rings
Quantity 2
Piston ring clearance in groove:
upper compression ring (trapezoid profile)
lower compression ring 0.09–0.14 mm (0.00354–0.00551 in)
Piston ring gap, measured at ring opening:
upper compression ring 0.40–0.55 mm (0.0157–0.0217 in)
Wear tolerance < 0.65 mm (0.0256 in)
lower compression ring 1.30–1.50 mm (0.0512–0.0591 in)
Wear tolerance < 1.65 mm (0.065 in)
Valve mechanism
Valves
p0005201
p0005203
Valve seats
B
p0005205
R D
p0005206
Valve guides
999 9696
998 9876
p0005207
Length:
Inlet / exhaust 83.5 mm (3.287 in)
Inner diameter:
Inlet / exhaust 8 mm (0.315 in)
Height above cylinder head spring plane:
Inlet / exhaust 24.5 ± 0.2 mm (0.9645 ± 0.00787 in)
Rocker Arm
Wear values
Bearing play (1) max 0.1 mm (0.00394 in)
Roller cam follower, clearance (2) max 0.1 mm (0.00394 in)
Valve springs
Inlet / outlet
Length uncompressed 73.8 mm (2.9055 in)
Engine Transmission
Timing gear wheels
1 Drive gear, crankshaft
2 Intermediate gear: outer gearwheel, inner
gearwheel
3 Intermediate gear (adjustable)
4 Drive gear, camshaft
5 Intermediate gear
6 Drive gear, power steering pump and fuel feed
pump
7 Drive gear, lubrication oil pump
8
8 Seawater pump
P0012463
Camshaft
Camshaft drive gearwheel
No. of bearings 7
Diameter, bearing journals, standard 69.97–70.00 mm (2.755–2.756 in)
Diameter, bearing journals, undersize:
0.25 mm (0.00984 in) 69.72–69.78 mm (2.745–2.747 in)
0.50 mm (0.0197 in) 69.47–69.53 mm (2.735–2.737")
0.75 mm (0.0295 in) 69.22–69.28 mm (2.725–2.728 in)
Permissible wear, entire camshaft profile max 0.1 mm (0.00394 in)
Unit injector, stroke 18 mm (0.709 in)
Wear value
Max end float 0.24 mm (0.00945 in)
Bearing, max permissible radial wear 0.1 mm (0.00394 in)
Camshaft Bearings
Camshaft bearing thickness, standard 1.92 mm (0.0756 in)
Oversize dimension:
0.25 mm (0.00984 in) 2.04 mm (0.0803 in)
0.50 mm (0.0197 in) 2.17 mm (0.0854 in)
0.75 mm (0.0295 in) 2.29 mm (0.0902 in)
Crank Mechanism
Crankshaft
Wear value
Crankshaft end float(1) max 0.4 mm (0.01575 in)
Machining value
Ovality of main bearing journals and connecting rod journal max 0.006 mm (0.0002362 in)
Center main bearing runout max 0.15 mm (0.00591 in)
1) Dimensions refer to greased components.
P0005849
R
C D
B
p0005210
Big-end journals
C A
B
p0005211
Connecting rod
Marking:
201 201
”FRONT” on the connecting rod faces forward.
The connecting rod and bearing caps are
marked in pairs with a three-digit serial number
(see illustration).
201 201
p0005212
Flywheel, installed
Runout, measured radius 150 mm (5.905 in) < 0.20 mm (0.0787 in)
Lubrication System
Technical Data
Oil
Oil change volume 45 liter 11.89 US gals
Oil volume between min and max markings 8 liter 2.11 US gals
Oil Pressure
Operating rpm (above 1400 rpm) 300–550 kPa 43.5–79.8 psi
Cold engine (1400 rpm) –650 kPa –94.3 psi
Low idle (min) min 200 kPa min 29.0 psi
Piston cooling pressure, hot engine (1400 rpm) min 200 kPa min 29.0 psi
Oil temperature
Max oil temperature in oil sump 130 °C 266 °F
Oil filter
Number
Full flow filter 2
Bypass filter 1
Oil valves
1 Thermostat valve, oil
cooler
Opening temperature 105–107 °C
(221–224.6 °F)
2 Safety valve, block
3 Bypass valve, full flow
filter
Spring, free length 69 mm (2.717 in)
Compressed 13–15 N
(2.9–3.4 lbf) 40 mm (1.575 in)
Fuel System
Technical Data
NOTICE! For the below-mentioned values, fuel is
required to fulfill the requirements specified in 03-0,
Fuel and Oils.
Feed pump
Feed pressure at:
600 rpm 100 kPa 14.5 PSI
1200 rpm 300 kPa 43.5 PSI
full load 300 kPa 43.5 PSI
Bypass valve
Opening pressure 300–550 kPa 43.5–79.8 PSI
Unit injector
Pre-load
Tighten the adjuster screw to zero-clearance against
the camshaft. Then turn 4 flats; see illustration.
Cooling System
Technical Data
Pressure cap
p0012569
Thermostat
Number 1
Opening temperature: < 82 °C (179.6 °F)
Coolant
There are two different types of coolant:
Engines manufactured
- between 5/3/2009-6/6/2010 must use Volvo Penta
Coolant.
- from 6/7/2010 must use Volvo Penta Coolant VCS.
IMPORTANT!
Do not mix different kinds of coolant.
Refill quantity
Coolant quantity (engine, radiator and hoses): 60 liter (63.40 quart)
1. ± 1 °C (1.8 °F)
Crankcase sensor
Crankcase pressure, normal value < 1.0 kPa (0.145 PSI)
Read the safety information below and the service manual section About this Workshop manual and Repair
instructions carefully before repair and service work is begun.
!
This symbol is used in the service manual and on the product, to call attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT!
Is used to draw your attention to something that may cause minor damage or a minor
malfunction to the product or property.
NOTICE! Is used to draw your attention to important information that will facilitate the
work or operation in progress.
A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.
Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed when the engine is hot.
As a rule, all service operations must be carried Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.
Be aware of hot surfaces (exhaust pipes, Never start the engine without installing the air
! turbos, charge air pipes, starting heaters etc.) ! filter. The rotating compressor turbine in the
and hot fluids in pipes and hoses on an engine turbocharger can cause severe injury. Foreign
that is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective
careless movement or a dropped tool may in the covers before the engine is started.
worst case lead to personal injury.
Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.
Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. From a such as degreasing agents, paints and
health standpoint, used oil is more dangerous solvents, are injurious to health. Carefully read
than new. Use protective gloves and avoid oil- the instructions on the product packaging!
soaked clothes and rags. Wash regularly, Always follow a product's safety directions, e.g.
especially before eating. Use suitable barrier use of protective mask, glasses, gloves etc.
creams to counteract drying out of the skin and Ensure that other personnel are not exposed to
to aid dirt removal. substances that are injurious to health. Ensure
good ventilation. Handle used and leftover
chemicals in the prescribed manner.
Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.
Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!
Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the sea cock / cooling
water inlet valve before work on the cooling
system is begun.
All fuels, as well as many chemicals, are Make sure that oil, fuel-soaked rags, and used
! flammable. Do not allow open flames or sparks ! fuel and oil filters are stored in a safe manner.
in their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.
Batteries must never be exposed to open Never work alone when removing heavy
! flames or electric sparks. Never smoke in the ! components, even when using lifting devices
vicinity of the batteries; they generate hydrogen such as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.
Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting
a transposition can result in serious damage to equipment used is in good condition and has the
electrical equipment. Refer to the wiring load capacity to lift the engine (engine weight
diagram. including gearbox or extra equipment). For safe
Always use protective goggles when charging handling and to avoid damaging components
and handling the batteries. Battery electrolyte fitted to the top of the engine, the engine must
contains sulfuric acid which is highly corrosive. be lifted with a correctly adjusted lifting boom.
Should the battery electrolyte come into contact All chains or wires must run parallel to each
with unprotected skin, wash it off immediately other and as perpendicular to the engine as
using soap and copious amounts of water. If you possible. If other equipment attached to the
get battery acid in your eyes, flush at once with engine has altered its center of gravity, special
copious amounts of water and seek medical lifting devices may be needed to obtain the
assistance immediately. correct balance for safe handling. Never
perform any work on an engine that is only
suspended from the lifting equipment.
The components in the electrical and fuel Exercise extreme caution when leak-detecting
! systems on Volvo Penta products are designed ! on the fuel system and testing the fuel injector
and manufactured to minimize the risk of fire nozzles. Use eye protection. The jet from a fuel
and explosion. The engine must not be run in nozzle has very high pressure and great
areas where there are explosive materials. penetration power. Fuel can force its way deep
into body tissue and cause severe injury. There
is a risk of blood poisoning (septicemia).
Only use fuels and lubricating oils Never use a high-pressure washer for cleaning
! recommended by Volvo Penta. Refer to the ! the engine.
Operator's Manual for the product in question. Pay attention to the following when using a high-
Use of fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never direct the water jet at
injectors. On a diesel engine, low grade fuel can seals, rubber hoses or electrical components.
cause the control rod to bind and the engine to
over-rev, with the risk of engine damage and
personal injury as a result. Low fuel and oil
grades may result in high service, maintenance
and repair costs.
Fuel delivery pipes must not be bent or When working on the engine; perform leakage
! straightened under any circumstances. Cracks ! and function test as necessary.
may occur. Damaged pipes must be replaced.
P0004337 P0006780
P0002947
P0006822
P0006765
P0006269
P0006793
P0006785
P0007591
P0006779
P0006784
p0004329
p0004330
P0006791
P0004331
P0004332
p0006803
P0006805
P0004349
P0006773 P0001878
P0004580 P0006814
P0006818
P0006816
P0006767 P0002793
P0006806
P0006761
P0006795
P0010363 p0006801
P0001872
P0004276 p0006800
P0010357 P0010358
P0006804
P0010359
P0010361 P0010360
P0010362
P0010365
P0010364
P0006778
p0006802
P0007585
P0006764
P00068115
P0006813
P0006782
P0006792
P0006788
P0006789
P0006786
P0006776
Other Equipment
The following miscellaneous equipment is used when
working on the engine. The equipment can be ordered
from AB Volvo Penta by specifying the number
indicated.
Orig
in
al
P0004344
P0002936 P0002930
P0004343
P0002784
P0001859
P0001879 P0001875
20
0
20
p0013445
P0001881 P0006823
18-0 General
Chemical products
Troubleshooting
Start / stop, symptoms
Engine doesn't start, starter motor is engaged 1
Engine doesn't start, starter motor doesn't engage 2
Engine starts then stops 3
Engine stopped during normal opperation 4
Engine starts but does not stop 5
1 Check: 3 Check:
- Air inlet and air filter - For air in the fuel system
- Fuel feed, from tank to engine (incl. filter) - Fuel feed, from tank to engine (incl. filter)
- Stop device (control and solenoid) - Air inlet and air filter
- Fuel quality and water content - Regulator, injection pump and stop device
for function
2 Check: - Fuel quality and water contentl
- Voltage at the starter motor (during start)
4 Check:
- Voltage on switch (“50”) at starter motor
- For air in the fuel system
- The engine can be turned by hand
- Fuel feed, from tank to engine (incl. filter)
- Starter motor
5 Check: 11 Check:
- Stop switch function - Low coolant level
- Pressure cap on expansion tank
6 Check:
- Seawater intake, filter and hoses
- Hull and propellers for fouling and damage
- Impeller
- Boat weight
- Exhaust pipe for corrosion and leaks
- Fuel feed
- Thermostat
- Air inlet and air filter
- Heat exchanger
- Alternator charging capacity
- Too high engine oil level 12 Check:
- Turbo - Leakage hoses and clamps
- Pressure cap on expansion tank
7 Check:
- Hot water connections
- Air inlet and air filter
- Pressure test the cooling system
- Engine Oil Level
- That the engine does run on all cylinders 13 Check:
8 Check: - Idling speed
- Engine oil, level and consumption - Engine Oil Level
- Coolant, level and consumption - Oil quality (viscosity, fuel concentration)
- Pressure sensor (verify with manometer)
9 Check:
- Flexible engine mounting
14 Check:
- Idling speed is not too low
- Engine Oil Level
- Propeller and propeller shaft deformity
- Oil quality (viscosity, fuel concentration)
- That the engine does run on all cylinders
- Pressure sensor (verify with manometer)
10 Check: 15 Check:
- Thermostat - Leakage hoses and clamps
- Too low load on the engine - Crankcase ventilation function
- Too high heatexchange from cooling water - Oil quality (viscosity)
outlet (e.g. water heaters)
Cold engine
1 Low engine loading
2 Leaky cold start valve (open, same as open
thermostat)
3 Sticking thermostat (open)
Tools:
9988539 Compression meter
9990185 Lifting tool
9998248 Adapter
9998249 Protective sleeve
9998599 Cleaning kit
Removal
1 IMPORTANT!
9998248 Make sure that the area around the unit injectors
is clean before they are removed.
Remove the unit injectors, see Unit Injector,
Replace, page 260 and mount the unit injector
protection (9998249 Protective sleeve). Clean
the copper sleeves as needed with
9998599 Cleaning kit.
2 Fit all(1) adapters (6 pcs), tool 9998248 Adapter,
to the cylinder head and pull them on with the
P0004964 injector retainers.
3 Oil valve caliper, cam shaft ridges and the rocker
bridge.
4 Fit the rocker bridge with 9990185 Lifting tool.
Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft
support bearing. Torque the rocker bridge as
specified in Engine, General, page 29. Use
torque wrench.
5 Install the middle piece and the oil pipe to the
rocker bridge.
6 Check the valve clearance, see Valves and Unit
P0004965
Injectors, Adjustment, page 188, for all valves as
specified in Engine, General, page 29.
P0004964
Installation
14 Mount the unit injectors and new o-rings, see the
Installation section in chapter Unit Injector,
Replace, page 260.
15 Fit the rocker bridge with 9990185 Lifting tool.
Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft
support bearing. Torque the rocker bridge as
specified in Engine, General, page 29. Use
torque wrench.
16 Install the middle piece and the oil pipe to the
rocker bridge.
17 Adjust valves and unit injectors, see Valves and
P0004965
Unit Injectors, Adjustment, page 188.
18 Check and if needed change the valve cover
bearing. Install the valve cover.
19 Re-install the fuel lines. Use new sealings.
20 Vent the fuel system, see Fuel system,
bleeding, page 245.
Tools:
9998339 Manometer
9998493 Hose
9996666 Nipple
1 Connect the nipple with hose and pressure gauge
to the measuring point on the inlet manifold; refer
to Charge Air Pressure, Check, page 327.
2 Compare this pressure with the pressure that can
be read with the VODIA tool; refer to “Workshop
manual, EMS 2”.
If the two measurements show different values,
the pressure sensor is faulty and must be
changed.
IMPORTANT!
If there is oil in charge air pipes and charge air
hoses, the charge air cooler and all pipes and
hoses in the charge air system must be very
thoroughly cleaned inside, before the engine is
started.
IMPORTANT!
Do not use a high pressure power washer.
p0013390
P0012281
Port side
Starboard side
Cable description
The illustrations on the following two show how wire
harnesses and hoses are positioned on the engine.
When changing harness, refer to Cable Trunk,
Change, page 406.
IMPORTANT!
When work on the engine is finished, wire harnesses
and hoses that were removed must be reinstalled
exactly as illustrated. Incorrect installation will result in
vibration damage.
M8x30 (6 pcs)
M8x45 (3 pcs)
Engine Disassembly
Timing Gear, Removal
Cylinder head removed; refer to 21-1, Cylinder
Head, Removal.
Tools:
9993590 Rotation tool
9998511 Lever
9998267 Guide sleeve
1 Remove the front engine mount.
P0010123
P0010157
P0004300
P0010159
P0010160
P0010161
P0010162
P0010163
P0010164
P0010180
P0010181
P0010184
P0010185
P0010153
Pistons, Removal
Tools:
885822 Magnetic pen
1 Remove the carbon uppermost in the cylinder
bore.
Make sure the press tool cannot touch the pistons
when the pistons are removed.
9996966
P0010048
P0010126
P0010127
1
P0010128
P0010129
P0010130
P0012701
P0012702
P0012703
P0010134
9992955
P0010135
P0010136
P0010137
P0010138
Crankshaft, Removal
Tools:
9990114 Puller
9990013 Slide hammer
1 Remove the crankshaft belt pulleys; refer to Drive
Belt, Change, page 358, 32-1, Alternator Belt,
Change.
2 Remove the crankshaft seal holder.
P0010156
P0010165
P0010167
P0010168
P0010169
P0010170
Engine Assembly
Crankshaft, Installation
Tools:
885811 Timing tool
885633 Torque multiplier
885648 Counterhold
9999696 Magnetic stand
9989876 Dial indicator
9998511 Lever
1 Inspect the crankshaft; refer to Crankshaft,
Inspection, page 223.
2 Check that the crankshaft is clean, that all bearing
surfaces are fault free and that the oil channels
are open. Install the crankshaft gear with a new
O-ring. Suspend the crankshaft in a lifting strap;
refer to Crankshaft, Removal, page 107.
Lubricate all bearing surfaces with engine oil.
3 Lower the crankshaft carefully into position. Align
the gearwheel markings with each other.
IMPORTANT!
Make sure that no connecting rod ends up in the
wrong position. The connecting rod separation
planes are very sensitive.
P0010167
P0010171
P0010172
P0010173
P0010174
4 5
6
3
2 7
1 8
P0005230
P0010139
P0010134
P0006964
P0006965
P0010140
P0006967
C Socket
D 9992955 Plate
Pistons, Installation
Tools:
9996966 Press tool
9998531 Piston ring compressor
1 Rotate the crankshaft so that the big end journal
for the piston to be installed ends up as low as
possible.
Remove the two press tools for the liner where
the piston is to be installed.
2 Lift the piston into place with the piston ring clamp
and connecting rod (big end bearing lubricated).
Make sure the piston is facing the right direction
(so that the connecting rod is in the right position
on the crankshaft). Tap down the piston with a
hammer shaft.
Remove the piston ring clamp when the piston is
below it.
Re-install the press tools for the cylinder liner.
Press down the piston so that the connecting rod
touches the crankshaft.
Install the big end bearing caps and align it
precisely with the crankshaft (big end bearing
oiled). Install the bolts.
P0010146
Torque the bolts and check that the crankshaft
can be rotated.
3 Install the remaining pistons the same way.
4 Clean the piston cooling nozzles and check that
they are not damaged.
Install the nozzles using new bolts. Check that the
nozzles are aimed directly at the piston oil cooling
hole.
P0010126
P0010153
P0005221
P0010186
P0010187
P0010186
P0010189
P0010190
P0010191
P0010192
P0010324
P0010193
P0010544
P0010056
P0005224
2 3
4 5
P0005225
P0010159
22 Install the fuel pump with drive unit and new seal.
Install new fuel line seals.
P0004300
P0010157
P0010147
36 Align and fit the oil pipes to the oil line bracket.
IMPORTANT!
The pipe must be pressed firmly into the engine
block. This is made easier when the new seal is
lubricated with VP lubricating oil part # 1698135-8
before installing on the pipe, and by greasing the
hole in the engine block before the pipe is pressed
into place.
Install the pipe with the locking clip.
IMPORTANT!
The pipe must be pressed firmly into the engine
block. This is made easier when the new seal is
lubricated with VP lubricating oil part # 1698135-8
before installing on the pipe, and by greasing the
hole in the engine block before the pipe is pressed
into place.
Install the pipe with the locking clip.
P0012669
105 Install the battery cable connectors and connect
to the starter motor.
106 Install the belt guard and other covers.
Fill the cooling system. Vent and test pressure
again.
Top up engine oil.
Removal
IMPORTANT!
Work on the fuel system demands exceptional
cleanliness.
Install protective plugs in open connections.
All engines
Heat shields removed.
10 D13B-A/B/G/H/J/K only
Remove the clamp securing the wire harness.
Disconnect the PCU harness terminals and
flywheel sensor.
Remove the PCU.
11 D13B-C/D/E/F/L/M/N only
Remove the clamp securing the wire harness.
Disconnect the Power module harness terminals,
the emergency stop switch and flywheel sensor
(3).
Remove the Power module (1) and emergency
stop switch (2).
20 IMPORTANT!
Make sure the camshaft is at TDC.
23 IMPORTANT!
Note the location of the components.
24 IMPORTANT!
Protect the components from knocks and
impacts.
27
CAUTION!
Cutting hazard! Protect your hands!
Installation
38 Clean the mating surface, the cylinder block
sealing surfaces and the cylinder head.
39 Checker liner height; refer to Cylinder Liner,
Installation, page 112.
40 Install a new cylinder head gasket and align it with
the liners.
Tighten the two bolts and washers.
P0012738
47 Timing plate
Tighten the bolts in sequence.
Tightening torque: 28 Nm (20.65 lbf.ft.).
Idler gear
To be tightened according to spec after gear lash
adjustment.
50
CAUTION!
Cutting hazard! Protect your hands!
53 IMPORTANT!
Make sure the camshaft is at TDC on the flywheel
marking.
P0010053
P0010054
Tightening torques
Stage 1: 35 Nm (25.81 lbf.ft.)
Stage 2: (angle tightening) 120° ±5°
IMPORTANT!
The steel washer must be replaced with a new
one every time an injector is installed.
78 D13B-A/B/G/H/J/K only
Install the PCU.
Connect the PCU harness terminals and flywheel
sensor.
Secure the wire harness with clamps.
79 D13B-C/D/E/F/L/M/N only
Install the Power module (1) and emergency stop
switch (2).
Connect the Power module harness terminals,
the emergency stop switch and flywheel sensor
(3).
Secure the wire harness with clamps.
All engines
Install the heat shield.
86 Install the charge air cooler; refer to Front Charge
Air Cooler, Change, page 362.
87 Install the inlet manifold; refer to Intake Manifold,
Change, page 289.
88 Carry out component installation and remove the
engine from the stand. Refer to Engine Fixture,
Removal, page 92.
Finishing off
89 Check engine oil level; top up as necessary.
90 Fill with coolant; refer to Technical
Data, page 48.
91 Open the sea cock.
92 Switch on power.
93 Start the engine and check for any leaks.
IMPORTANT!
The piston and cylinder liner sets are only available as
a single, complete unit.
Cylinder Liner
Measurement of cylinder liner wear can be done with
the liner installed in the cylinder block.
Pistons
5 Check for worn piston ring grooves, damaged
retainer ring grooves, cracks and other damage
to the pistons.
If the piston has deep scratches on its skirt, the
piston (liner kit) must be scrapped. The same
applies if the piston has one or more cracks in the
piston pin hole or in the bottom of the combustion
chamber.
Crack tests must be done using the chalk powder
method.
IMPORTANT!
If the connecting rod or bearing cap are damaged,
change the connecting rod.
3 IMPORTANT!
2 Regarding max. allowed straightness and twist
deviations, refer to Technical Data, page 32.
P0006994 P0006995
P0012534
P0012535
P0012535
P0012536
CAUTION!
Risk of eye injury. Eye protection required.
Option 1
Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990176 Press tool
9996159 Adapter
88800147 Drift
88800062 Drift
Optional tools
Tools:
9992670 Hand pump
Removal
999 2670 980 9729 1 Install tool 9990176 Press tool into the cylinder
980 9726 head retaining bolt holes.
p0003637
Installation
6 Heat the cylinder head with hot water while
cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
IMPORTANT!
Wear protective goggles when pressing.
999 2670 980 9729 7 Press in the valve guide for the inlet valve using
980 9726 tool 88800062 Drift. Press in the exhaust valve
guide using the same tool.
8 Press until the tool bottoms against the cylinder
head plane.
9 Remove the tool from the cylinder head.
999 0176
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
999 6159
Option 2
888 00062
p0011273
Tools:
9992000 Handle
88800147 Drift
88800062 Drift
CAUTION!
Risk of eye injury. Eye protection required.
Removal
NOTICE! Take out the valve guides from beneath the
cylinder head.
Installation
3 Heat the cylinder head with hot water while
cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
CAUTION!
Risk of eye injury. Eye protection required.
4 Tap in the valve guide for the inlet valve using tool
88800062 Drift. Tap in the exhaust valve guide
using the same tool.
5 Tap until the tool bottoms against the cylinder
999 2000 head plane.
6 Repeat the procedure for the remaining valve
guides.
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
Valves, Removal
Alternative 1
Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
P0006996 88800058 Stand
9990174 Drift
9992670 Hand pump
9996159 Adapter
9998246 Drift
Tools:
9990210 Valve spring compressor
Alternative 1
1 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool.
2 Install tool 9996159 Adapter and tool
9998246 Drift (inlet) or tool 9990174 Drift (outlet)
on the hydraulic cylinder. Place the tool in the
holes for the cylinder head retaining bolts.
Tighten the tool nuts.
3 Connect tool 9809726 Pneumatic hydraulic pump
(alternatively 9992670 Hand pump).
4 Press the valve spring washer down and remove
the collets.
Alternative 2
Tools:
9990210 Valve spring compressor
1 Lay the cylinder head on a flat, clean surface.
Make sure the cylinder head is not damaged
when the valves are to be removed.
2 Fit tool 9990210 Valve spring compressor in the
unit injector hole. Fix the tool in the bolt hole for
the unit injector yoke, M10 x 30.
3 Place the moving part of the tool over the valve
spring to be removed. Screw down the “wing nut”
on the tool until the valve washer has been
pressed down so far that the collets can be
removed.
Valves, Installation
Alternative 1
Tools:
9809726 Pneumatic hydraulic pump
9990165 Guide sleeve
9990174 Drift
9990176 Press tool
9990210 Valve spring compressor
9992670 Hand pump
9996159 Adapter
9998246 Drift
88800151 Drift
Tools:
9990210 Valve spring compressor
1 Oil the valve stems and install the valves.
Oil the oil seals.
2 Install tool 9990165 Guide sleeve on the valve
stem and press the new oil seals down over the
valve guides.
P0006998
Alternative 1
3 Install the valve caliper guide pins.
Install the springs and valve spring washers.
Carefully press down the valve spring washer and
install the collets. Use tool 9990176 Press tool
together with 9809726 Pneumatic hydraulic
pump , 9996159 Adapter and 9998246 Drift (inlet)
or 9990174 Drift (outlet), in the same way as for
Valves, Removal.
Alternative 2
Tools:
9990210 Valve spring compressor
1 Alternatively, tool 9990210 Valve spring
compressor may be used instead of the hydraulic
cylinder, in the same way as for Valves, Removal.
P0006997
P0010244
Inlet valve
40
39,5
P0010245
Exhaust valve
Valves, grinding
1 Check dimension (A). If the dimension is greater
than the wear tolerance as specified in Technical
Data, page 32, the valve must be changed.
Tools:
9989876 Dial indicator
9992479 Holder for dial indicator
1 The valve seats must be changed if a satisfactory
seal cannot be obtained or when the distance (A)
exceeds the value stated in the specification;
refer to Technical Data, page 32.
P0007000
IMPORTANT!
Carefully cover the other surfaces on the cylinder head
to prevent any weld spatter from fastening.
P0007001
P0007002
IMPORTANT!
Be careful not to damage the cylinder head.
CAUTION!
Risk of eye injury. Eye protection required.
4 Clean the seat bed carefully and check the
cylinder head for cracks.
5 Measure the diameter of the valve seat bed in the
cylinder head. Determine whether a standard or
oversize dimension valve seat must be used.
Carry out any necessary machining to the valve
P0007003
seat bed; refer to Technical Data, page 32.
P0007004
Removal
1 Disconnect all current to the engine, by switching
off the main switch.
2 Remove the unit injectors; refer to the removal
section in Unit Injector, Replace, page 260.
3 NOTICE! The piston must be at top dead center
when the valves are removed. This is to prevent
the valves from falling down into the cylinder. Use
tool 9993590 Rotation tool.
4 Compress the valve springs for no. 1 cylinder.
Use tool 9990210 Valve spring compressor.
5 Remove the valve washers, valve springs and
collets.
6 Remove the old valve stem seals.
Installation
7 Lubricate the valve stem with engine oil.
Fit tool 9990165 Guide sleeve to the valve stem.
88800151 Thread the new seal on and put it over the
mandrel. Slide tool 88800151 Drift over the valve
stem and tap the seal down carefully with a plastic
mallet.
8 Install the valve springs, valve spring washers
and collets. Carefully tap with a plastic mallet to
make sure the collets end up in the right position.
9 Transfer the valve spring compressor to no. 6
cylinder and repeat the tasks as above. Then
crank the engine so that no.3 and no.4 cylinder
P0011236
are at TDC.
Repeat the procedure. Then continue with
cylinders 2 and 5.
P0007013
Guidelines for replacement
In normal conditions, unevenness may occur on the
surface of engine camshaft lobes. This does not mean
that the camshaft has to be changed. These marks do
not have any negative influence on either engine
performance or the durability of the engine and its
components.
P0003896 P0003899
P0003898 P0003897
P0007018
Flywheel, Indication
Flywheel exposed; refer to Timing Gear,
Removal, page 95.
Tools:
9993590 Rotation tool
9989876 Dial indicator
9999696 Magnetic stand
1 Install 9993590 Rotation tool in order to rotate the
flywheel.
2 Install 9999696 Magnetic stand and 9989876 Dial
indicator with the measuring tip against the
999 9696 flywheel at a measuring radius of around 150 mm
(5.9”).
Rotate the flywheel at least one revolution and
check the min and max deflections on the dial
indicator. The value should not exceed 0.20
mm (0.0079”).
998 9876
3 If the distortion is greater, and this is not the result
of a damaged surface where the dial indicator is
applied, remove the flywheel and check that there
is no waste material or damage to the contact
flange on the flywheel and crankshaft.
Clean the flanges or change the flywheel if it is
damaged.
P0010194
Torque the bolts; refer to Special Tightening
Torques, page 10.
4 Check using the dial indicator and magnetic stand
again.
Remove the tool.
P0006979
P0006980
4 Put the heated gear ring onto the flywheel and tap
it into place with a soft mandrel and hammer.
Leave the gear ring to cool.
P0006981
Sensors, Adjustment
Sensor removed.
Tools:
88800031 Measuring tool
1 If the camshaft sensor needs to be adjusted,
rotate the crankshaft so that one tooth on the
camshaft vibration damper is centered in front of
the sensor hole.
2 Remove any shims beneath the sensor.
Clean the tool's contact surface on the engine.
3 Insert 88800031 Measuring tool without
88800031 tightening the lock screw.
press in the tool firmly so that it is in contact with
the cover. Press in the center part of the tool until
it contacts the gearwheel and tighten the lock
screw.
Rove the tool and inspect the center section
position in its sleeve.
P0010198
P0010219
P0010218
P0010220
Removal
1 Drain the coolant; refer to Coolant,
Draining, page 329.
2 Remove the belt guard; refer to 26-3, Belt
Guard.
3 Remove the belts. For the drive belt, refer to Drive
Belt, Change, page 358.
For the alternator belt, refer to Alternator,
Change, page 394.
4 Remove the automatic belt tensioner.
P0013386
P0004786
6 IMPORTANT!
The oscillation damper may not be exposed to
thrusts or blows.
7 Remove the oscillation damper.
P0014303
P0014304
P0004789
P0004790
Installation
9992000 Handle
9993590 Rotation tool
88800021 Drift.
P0004791
P0004792
P0004793
P0004794
P0004786
P0014304
P0014303
P0013386
Removal
1 Remove the flywheel sensor.
P0004796
P0004795
P0004954
Installation
9990166 Mounting tool
7 NOTICE! Clean the seal seat in the flywheel
housing and the sealing surface on the
crankshaft.
P0004960
P0004957
P0004959
P0004958
13 Offer the flywheel into place and fit the key in the
keyway.
Install one bolt to render the lift safe.
14 Install the remainder of the bolts.
Torque according to specifications: Refer to
General Tightening Torques, page 9.
P0004795
P0004796
Crankshaft, Inspection
The crankshaft is induction hardened.
IMPORTANT!
Crankshaft straightening is not permitted.
5 Check for cracks before and after any grinding.
Magnetic powder testing is used for this test, i.e.
fluorescent powder which is viewed under ultra-
violet light.
Tools:
9990013 Slide hammer
9990114 Puller
9993590 Rotation tool
Removal
1 Fit tool 9993590 Rotation tool.
P0006884
P0013021
P0006970
Installation
7 Lubricate the shaft journal and the new bearing
shells with engine oil.
8 Install the upper bearing shell by turning the
crankshaft using tool 9993590 Rotation tool
against the direction of rotation with the pin in the
oil hole.
P0006972
NOTICE! Remove the pin when done.
P0006974
Removal
1 Remove the oil level sensor connector (1).
Remove the oil filler (2) with attachment and the
oil dipstick (3).
1
P0012707
P00112708
CAUTION!
Cutting hazard! Protect your hands!
P0010536
P0010536
Installation
8 Install the oil pump by meshing the gearwheels
and tightening the bolts.
9 Install the reinforcement plate with new bolts.
CAUTION!
Cutting hazard! Protect your hands!
P0010536
P00112708
P0010147
Tools:
9999179 Extractor oil filter
1 Check that a hose is connected to the drip pan
and is led down to a suitable container.
2 Use 9999179 Extractor oil filter to remove the oil
filter.
3 Check that the filter sealing surfaces are clean.
Lubricate the new filter rubber seals with engine
oil.
Install the filters and tighten them according to the
instructions on the filters.
4 Clean the drip pan.
Reinstall the engine oil drain plug.
5 Fill with engine oil; refer to Technical
Data, page 44.
p0012233
6 Start the engine and check that there is oil
pressure.
Check that no leakage is present.
7 Stop the engine and check the oil level after a
couple of minutes.
Installation
6 Install a new filter bracket.
7 Install new oil filters; refer to Oil filter,
Change, page 231.
8 Install the components (steps 1–3) in reverse
order.
9 Start the engine and check oil system function
and integrity.
10 Switch the engine off and check the oil level.
P0012711
2
P0012712
Installation
7 Move over the parts that are to be reused to the
new bracket.
P0012713
IMPORTANT!
Sealant may absolutely not be used. The use of
sealant may result in engine breakdown.
P0010003
P0010004
P0012714
11 Install the front and rear pipes to the oil cooler with
new seals. Install the hose to the turbocharger
with a new seal.
Install the two oil pipes between the cover (1) and
the oil filter housing.
Install the covers (1 and 2).
P0010334
P0010335
P0010336
P0010334
P0011860
P0010338
P0010339
P0010340
P0011865
1. Screw out the hand pump handle before usage. Fasten the handle
after usage.
p0011863
1
3
p0011864
P0011865
p0011863
p00112239
p0012233
P0012235
p0012233
5 IMPORTANT!
Carefully clean before removal.
Installation
9 Transfer any parts that are to be reused to the
new bracket.
10 Install a new fuel filter.
11 Install the components in the reverse order.
12 Purge the fuel system, refer to the Fuel system,
bleeding, page 245 section.
13 Start the engine and check fuel system integrity.
P0004300
P0010541
P0010543
Installation
8 Install a new O-ring for the pump.
Install the intermediate piece.
P0010542
P0010541
P0010540
P0010539
P0004300
Installation
Removal
1 Remove the ventilation pipe and valve cover.
2 Undo the connectors to the unit injectors and oil
valve.
P0012716
P0012717
P0004965
P0012717
9990006 IMPORTANT!
The seal washer must always be replaced when
installing an injector.
P0001370
999 8249
P0010041
P0010042
Installation
9990156 Adapter
9996400 Slide hammer
9990185 Lifting tool
3883671 Protective sleeve
3883672 Protective sleeve
11 Remove the protective plug for one unit injector
(where necessary use 9990156 Adapter and
9996400 Slide hammer).
9996400
9990156
P0010061
IMPORTANT!
The steel washer must be replaced every time an
injector is installed.
Install the injector and injector yoke. Turn the
injector so that the wiring connections are exactly
opposite the valve springs.
Install the retaining bolt and tighten according to
Special Tightening Torques, page 10.
13 Install the remaining injectors the same way.
P0010062
P0012717
P0012717
P0012716
14
9 8 7 6 2 3 4 5 20
p0005236
Tools:
1159794 Torque wrench
9986173 Puller
9996049 Draining hose
9998250 Sealing ring
9998251 Protection plug
9998580 Protective sleeve
9998599 Cleaning kit
88800196 Drift
88800387 Puller
88800460 Sleeve
IMPORTANT!
Working with the fuel system requests special
cleanliness.
1 Drain the coolant with the aid of a hose, tool
9996049 Draining hose; refer to Coolant,
Draining, page 329.
2 If necessary, remove tool 9998251 Protection
plug.
P0019120
P0019121
Miscellaneous:
- 9998250 Sealing ring, 2 pcs (3)
- Expander (4)
- Sleeve (5)
- Nut (6)
P0019122
P0019123
6 Alternative 1
P0021199
P0021200
P0021201
P0021202
7 Alternative 2
P0019124
P0019125
IMPORTANT!
Tool 9998580 Protective sleeve must be used to
prevent dirt from getting into the fuel duct.
9 Clean the cylinder head walls for the sleeve with
part no. 9808618.
P0007010
P0007011
IMPORTANT!
This must be done so that tool no. 9808617 does
not damage the piston due to its length.
P0007012
IMPORTANT!
The steel gasket supplied with the new sleeve
must be used when installing the unit injector.
Lubricate the O-ring on the sleeve with soapy
water.
IMPORTANT!
Always use a new O-ring.
P0010239
P0003616
P0003617
P0003618
9998250
P0003619
Removal
1 Remove the coolant venting hose (1).
Remove the coolant temperature sensor
connector (2).
IMPORTANT!
It is recommended that a lever is used because
the water pipes can be fixed firmly. Be careful to
avoid the pipes from getting damaged.
Installation
5 Install two new manifold seals. Check that the
manifold's other sealing surfaces are fault free.
All engines
Install the stud connection that attaches to the
cylinder head in front of the manifold.
Install both water connections between the
manifold and water pump. Use new sealings and
lubricate with Forminol.
Install the coolant temperature sensor.
10 D13B-A/C/G/H/K/L, D13C2-A, D13C4-A only
(twin turbocharger)
Clean and check the rear charge air cooler hose
connections and hoses.
Check the pipes where the hoses connect. Make
sure the hose clamps are positioned on the hoses
as illustrated.
IMPORTANT!
The oil return pipe must be pressed firmly into the
engine block. This is made easier when the new
seal is lubricated with VP lubricating oil part #
1698135-8 before installing on the pipe, and by
greasing the hole in the engine block before the
pipe is pressed into place and attached with
locking clip.
IMPORTANT!
The pipe must be pressed firmly into the engine
block. This is made easier when the new seal is
lubricated with VP lubricating oil part #
1698135-8 before installing on the pipe, and by
greasing the hole in the engine block before the
pipe is pressed into place and attached with
locking clip.
15 D13B-A/C/G/H/K/L, D13C2-A, D13C4-A only
(twin turbocharger)
Put the side of the heat shield in position.
P0012669
IMPORTANT!
The main switch must be in the off position before work
is begun.
Removal
1 Remove the cover.
Installation
11 Inspect and clean the sealing surfaces on the
cylinder head and inlet manifold.
P0021213
P0021363
Type B
Tightening torque: 60 Nm (44.3 lbf. ft.)
P0022064
Removal
1 The shield above the rear turbocharger (low
pressure turbocharger) must be removed.
Open the clamp.
P0011910
P0011918
8 Remove the oil return pipe (1) and the tie wrap.
Remove the bottom coolant hose (2).
Installation
11 Inspect and make sure there is no fouling in the
charge air cooler.
Inspect/clean the charge air cooler inlet pipe.
16 Install a tie wrap on the oil return pipe for the top
coolant connection.
P0011918
P0011910
Turbo, Change
D13B-B MP, D13B-D MP, D13B-E MH, D13B-F MG,
D13B-J MP, D13B-M MP, D13B-N MH, D13C1-A MP,
D13C3-A MP
Removal
1 Remove the heat shield and covers, if fitted.
Remove the exhaust pipe.
Installation
10 Transfer any components to the new
turbocharger.
Lift the turbocharger into position and install
spacers and new nuts; refer to Group 25: Inlet and
Exhaust System, page 25.
Tools:
9996666 Nipple
9998339 Manometer
9998493 Hose
1 Clean around the plug (1) and remove it.
Remove the seal washer if it does not come away
with the plug.
P0012245
P0012246
Tools:
22518599 Slide hammer
22632322 Puller
P0018853
WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.
p0011892
p0011893
IMPORTANT!
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have antifreeze properties.
IMPORTANT!
It is extremely important that the correct concentration
and volume of coolant is added to the system. Mix in a
separate clean vessel before filling the cooling system.
Make sure that the liquids mix.
1 Drain the cooling system. Refer to Coolant,
Draining, page 329.
2 Put a hose into the expansion tank filling hole and
flush with clean water, according to specifications
in Technical Data, page 48, until the water
draining out is completely clear.
3 Should there still be some contamination left after
flushing for a long time, cleaning may be done
with coolant. Otherwise, continue as in stage 8
below.
4 Fill the cooling system with 15-20% mixture of
concentrated coolant. Use only Volvo Penta
recommended concentrated coolant mixed with
clean water.
5 Drain the coolant after 1–2 days of operation.
Remove the filler cap and the lower radiator hose
if necessary to increase emptying speed.
To prevent suspended material from settling back
in the system, emptying should be done rapidly,
within 10 minutes, without the engine having
been at a standstill for a long time.
6 Flush the system immediately and thoroughly
with clean hot water to prevent dirt from settling
IMPORTANT!
Filling of coolant must be performed with the engine
stopped. Fill slowly, to allow air to flow out.
IMPORTANT!
Do not let the engine work under load until the
system is vented and completely filled.
6 Stop the engine and let it cool. Check the coolant
level.
7 Top up.
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.
Tools:
3849613 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Replace the filler cap on the expansion tank with
a suitable cover from 3849613 Pressure testing
kit.
Alternative 2
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.
Tools:
9996441 Cover, with connecting nipple
9996662 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Replace the filler cap with 9996441 Cover, with
connecting nipple. Connect 9996662 Pressure
testing kit to the cap. Connect compressed air to
the equipment and open the cock. Adjust the
pressure to 70 kPa (0.7 bar) with the adjuster
knob. Then close the tap.
4 Pressure must not drop for a two minute test
period, for the cooling system to be regarded as
being free from leakage.
5 Release the excess pressure and remove the
pressure testing unit.
6 Check the coolant level in the expansion tank.
Install the regular filler cap.
P0010196
7 Start the engine and check that no leakage
occurs.
Alternative 3
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.
Tools:
9996662 Pressure testing kit
9996049 Draining hose
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
P0010197
6 Remove the compressed air connection. Open
the control valve so that the pressure drops and
shut the cock when coolant runs into the drain
hose.
Remove the drain hose from the engine. Then
remove the drain hose from the test equipment
and empty the coolant from the hose.
Re-install the rubber plug in the engine drain
valve.
7 Check the coolant level in the expansion tank.
8 Start the engine and check that no leakage
occurs.
Removal
1 Close any sea cocks.
2 Empty seawater using the drain tap.
5 Remove the two clamps (1) for the filter drip pan.
Remove the drip pan (1).
Remove the hot water pipe (3) that runs from the
engine.
3 1
2
P0012406
6 Undo the two bolts (1) and remove the oil dipstick
attachment fitting.
Undo the three bolts (2) and remove the reverse
gear oil cooler.
IMPORTANT!
Do not bend the oil hoses too much. They can get
damaged.
CAUTION!
Sharp edges. Wear gloves or use a shop cloth to
protect your hands.
Installation
11 Check that the top bolt at the back of the heat
exchanger is in position.
Do not screw in the bolt too far; a play of around
10 mm (0.39") below the bolt head is advisable.
12 Lift the heat exchanger onto the front attachment
fitting and at the same time guide the rear bolt (2)
into the slot in the rear attachment plate.
Insert the two bottom bolts (1) in the rear
attachment fitting.
Install the pipe and hose and then the front valve
(2).
The valve has a guide pin so that it cannot be
mistaken or turned to face the wrong way.
Install the rear valve (1) and install the narrow
hose at the same time.
This valve also has a guide pin so that it cannot
be mistaken or turned to face the wrong way.
3 1
2
P0012406
Tools:
21461107 Guide pin
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
P0016331
2
CAUTION!
Sharp edges. Wear gloves or use a shop cloth to
protect your hands.
P0016332
4 Mark the top plate (1) and lay it and its unique seal
to one side.
P0016333
P0016334
P0016335
P0016336
P0016337
P0016338
P0016339
P0016340
P0016341
P0016332
P0016331
P0016342
P0016343
P0016344
P0016345
P0016346
P0016348
Thermostat, Change
Drain the coolant so that the level falls below the
thermostat; refer to Coolant, Draining, page 329.
1 Remove the protective covers from the front
turbocharger (1) and remove the front plastic
1
cover (2).
2
P0012279
P0012280
3 Remove the charge air pipe (1) from the inlet pipe
and pull it out from the charge air cooler.
P0012281
12 Install the banjo bolt (1) with new seals and install
the pipe (2) with a new seal.
P0012281
14 Fit the pipe (1) between the charge air cooler and
the expansion tank and the hose (2) from the
thermostat cover.
Use new seals.
1 Install the clamps for the pipes and hoses.
P0012356
15 Add coolant.
Check that no leakage is present.
p0012242
Removal
1 Undo the three bolts that retain the belt tensioner
and return wheel. Remove the unit.
2 Unbolt the return wheel or tensioner, or replace
the complete unit.
P0013386
Installation
3 Install the tensioner complete with attachment.
Align the guide pin on the attachment to the
installation hole and tighten the bolts.
Check the condition of the drive belts.
4 Re-install the belts; refer to Drive Belt,
Change, page 358.
P0005072
Closed thermostat.
P0005073
Open thermostat.
Removal
1 Switch off battery power.
Remove the turbocharger cover.
2 Loosen the attachment frames (1) for the battery
connections.
1
P0011896
1
P0011897
Installation
7 Install the charge air cooler hoses and position
the hose clamps as illustrated to facilitate
tightening.
1
P0011897
1
P0011896
Removal
1 Remove the heat shield and covers, if fitted.
Installation
7 Transfer any necessary components to the new
charge air cooler.
8 Check that the charge air cooler hoses are
undamaged.
Check that the O-rings to the stub connection are
undamaged.
P0011878
P0011879
p0011881
p0011882
P0012259
P0011879
P0011878
p0011881
Removal
1 Close any sea cocks.
2 Remove the pipe between the pump and the heat
exchanger.
p0011881
p0011882
P0012261
P0012262
P0012263
Installation
9 Install a new O-ring on the pump before putting it
in place.
P0012263
p0011881
Tools:
884167 Drift
9994034 Drift
Disassembly
1 Mark the positions of the pipe bends in relation to
the pump housing. Remove the pipe bends.
2 Remove the the seawater pump cover together
with the O-ring. Remove the rubber washer (19)
from the impeller. Pull out the impeller with an
impeller puller.
3 Undo the cam bolt (5). Remove the cam disc (3)
and the wear ring (7).
4 Mark the position of the pump housing in relation
to the bearing housing. Undo the four bolts and
carefully pull out the pump housing. Remove the
pump housing (4), support washer (6) and shaft
seal (8) from the pump shaft.
5 Tap the ceramic ring (9) with rubber cover out
from the pump housing. Use a suitable socket.
6 Remove the deflector ring (10) from the shaft.
Assembly
12 Grease the seal ring (11) with water-resistant
grease (Volvo Penta part # 828250) and tap it into
the bearing housing.
32-1 Alternator
Alternator, Change
Removal
1 Switch off battery power.
2 Remove the belt guard and drive belt.
Installation
6 Check that all four plastic bushings are in place.
1
P0011896
1
P0011896
Installation
8 Connect the fuel pipes with new seals.
PCU, Replace
D13B-A MP, D13B-B MP, D13B-G MP, D13B-H MP,
D13B-J MP, D13B-K MP, D13C1-A MP, D13C2-A MP
Removal
1 Undo the clamp closest to the filter.
Installation
4 Install the harness connectors on the PCU and
screw in the four bolts.
Removal
1 Undo the clamp closest to the filter.
Installation
4 Install the harness connectors on the Power
module and screw in the three bolts.
37-1 Cables
Cable Trunk, Change
In order to replace the wire harness it will be necessary
to remove or undo much of the engine's equipment
first.
If the wire harness is being replaced because of a short
circuit the cause must be remedied before
replacement.
Requirements
• Battery power disconnected.
• Cooling system drained; refer to Coolant,
Draining, page 329.
• All protective covers removed.
• Air filter housing and air filter housing holder
removed.
• Alternator and alternator bracket loosened to allow
outward movement.
• Heat exchanger removed; refer to Heat exchanger,
change, page 335.
• Water pipe between the thermostat and heat
exchanger removed.
• Oil filters removed.
1 Remove the bolt and clamp to the crankcase
ventilation pipe.
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419
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AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
47701522 English 01-2016