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D16C-A/B/C/D MH, D16C-A MG
Group 20: Technical Data
Contents
Safety information ................................................................ 2
General information ................................................................ 5
Technical data:
General ................................................................................ 6
Short block............................................................................ 7
Reciprocating components................................................... 9
Valve mechanism.................................................................. 14
Timing gears.......................................................................... 18
Lubrication system................................................................ 19
Fuel system.......................................................................... 22
Inlet and exhaust system...................................................... 24
Cooling system..................................................................... 26
Electrical system................................................................... 28
Tightening torques................................................................ 30
Tightening diagrams............................................................. 33
Installing seals...................................................................... 45
References to Service Bulletins .......................................... 48
Safety information
Introduction and hot fluids in pipes and hoses on an engine
which is running or which has just stopped.
This workshop manual contains technical data, de- Reinstall all protective parts removed during
scriptions and repair instructions for the Volvo Penta service operations before starting the engine.
products or product versions noted in the table of
contents. Check that you have the correct Workshop
Manual for your engine. Never start the engine with the valve cover re-
Read the available safety information and “General moved. Apart from the risk of spilling oil, there
information” and “Repair instructions” in the workshop is a risk of personal injury. The voltage supplied
manual carefully before you start to do any service to the unit injectors can be as high as 100 V.
work.
2
Group 20 Safety information
Always use protective glasses or goggles when used lubrication oil, contaminated fuel, paint
carrying out work where there is a risk of splin- residue, solvents, degreasers and wash resi-
ters, grinding sparks, acid splashes or where due.
other chemicals are used. Your eyes are ex-
tremely sensitive, injury could cause blindness! Never expose a battery to naked flame
or electrical sparks. Never smoke close to the
batteries. The batteries generate hydrogen
Avoid getting oil on your skin! Repeated exposure gas when charged, which forms an explosive
to oil or exposure over a long period can result in gas when mixed with air. This gas is easily
the skin becoming dry. Irritation, dryness and ec- ignited and highly volatile. A spark, which can
zema and other skin problems can then occur. be caused by incorrect battery connection,
Used oil is more dangerous than fresh oil from can cause a single spark which is sufficient to
a health aspect. Use protective gloves and cause an explosion with resulting damage. Do
avoid oil-soaked clothes and rags. Wash regu- not move the connections when you attempt
larly, especially before eating. There are special to start the engine (risk of arcing), and do not
skin creams which counteract drying out of the stand and lean over one of the batteries.
skin and make it easier to clean off dirt after
work is completed. Always ensure that the Plus (positive) and
Minus (negative) battery cables are correctly
Most chemicals intended for the product (e.g. installed on the corresponding terminal posts
engine and transmission oils, glycol, petrol on the batteries. Incorrect installation can result
(gasoline) and diesel oil) or chemicals for work- in serious damage to the electrical equipment.
shop use (e.g. degreasers, paints and solvents) Refer to the wiring diagram.
are hazardous. Read the instructions on the
product packaging with care! Always follow the Always use protective goggles when charging
safety precautions for the product (for example and handling the batteries. Battery electrolyte
use of protective mask, glasses, gloves etc.). contains sulfuric acid which is highly corrosive.
Make sure that other personnel are not inad- Should the battery electrolyte come into contact
vertently exposed to hazardous chemicals, for with unprotected skin wash off immediately using
example in the air. Ensure good ventilation in plenty of water and soap. If you get battery acid in
the work place. Follow the instructions provided your eyes, flush at once with a generous amount
when disposing of used or leftover chemicals. of water, and get medical assistance at once.
Exercise extreme care when leak detecting Turn the engine off and turn off the power at the
on the fuel system and testing the fuel injector main switch(es) before carrying out work on the
nozzles. Use eye protection. The jet from a fuel electrical system.
nozzle has very high pressure and great pene-
tration power. Fuel can force its way deep into Clutch adjustments must be carried out with the
body tissue and cause severe injury. Danger of engine stopped.
blood poisoning (septicemia).
The existing lugs on the engine/reversing gear
All fuels, and many chemicals, are flamma- should be used for lifting the assembly.
ble. Do not allow naked flame or sparks in the Always check that the lifting equipment used is
vicinity. Petrol (gasoline), some thinners and in good condition and has the load capacity to
hydrogen gas from batteries are extremely lift the engine (engine weight including gearbox,
flammable and explosive when mixed with air in if fitted, and any extra equipment).
the correct ratio. No Smoking! Ensure that the Use an adjustable lifting beam or lifting beam
work area is well ventilated and take the neces- specifically for the engine to raise the engine
sary safety precautions before starting welding to ensure safe handling and to avoid damaging
or grinding work. Always ensure that there are engine parts installed on the top of the engine.
fire extinguishers at hand when work is being All chains and cables should run parallel to
carried out. each other and as perpendicular as possible in
relation to the top of the engine.
Make sure that oil and fuel soaked rags, and If other equipment connected to the engine has
used fuel and oil filters are stored in a safe altered its center of gravity, special lifting devis-
place. Rags soaked in oil can spontaneously es may be needed to obtain the correct balance
ignite under certain circumstances. and safe handling.
Never carry out work on an engine suspended
Used fuel and oil filters are polluting waste and
on a hoist.
must be handed to an approved waste man-
agement facility for destruction, together with
3
Safety information Group 20
Never work alone when removing heavy engine Never use a power washer for engine cleaning.
components, even when using lifting devices Remember the following when washing other
such as locking tackle lifts. When using a lifting components with a power washer: Never aim
device two people are usually required to do the the water jet at seals, rubber hoses or electrical
work, one to take care of the lifting device and components.
another to ensure that components are lifted clear
and not damaged during the lifting operations.
When you work aboard a boat, always make
sure that there is enough space for disassem- Only use the fuels recommended by Volvo Penta.
bly where you are working, with no risk of per- Refer to the Instruction Book. Use of fuels that
sonal injury or damage to materials. are of a lower quality can damage the engine.
Poor fuel can also lead to higher service costs.
Components in the electrical and fuel systems
on Volvo Penta products have been designed to
minimize the risks of explosion and fire. The en-
gine must not be run in areas where there are
explosive materials.
4
General information
5
Technical Data
General
Type designation ................................................. D16C-A/B/C/D MH D16C-A MG
No. of cylinders....................................................... 6
Bore........................................................................ 144 mm (5.669”)
Stroke..................................................................... 165 mm (6.496”)
Swept volume, total................................................ 16.12 dm3 (983.9 in3)
Power ..................................................................... Please refer to the sales literature
No. of valves per cylinder........................................ 4
Direction of rotation (seen from front)..................... Clockwise
Compression ratio.................................................. 17.5:1
Crankcase pressure, normal value,
irrespective of engine speed................................... max. 5 kPa (0.73 psi)
Firing sequence (cyl. No. 6 closest to flywheel)...... 1–5–3–6–2–4
Low idle (propulsion engine)................................... 600 ±10 rpm –
adjustable within the range.................................. 550 –600 rpm –
D16C-500/550/600 (rating 1):
full throttle range.................................................. 1780 –1850 rpm –
D16C-650 (rating 1):
full throttle range.................................................. 1780 –1880 rpm –
D16C-750 (rating 2):
full throttle range.................................................. 1880 –1950 rpm –
High idle:
D16C-A MG............................................................ – 1500 or 1800 rpm
Weight, engine with heat exchanger, without
reverse gear, (dry) approx....................................... 1750 kg (3858 lbs)
6
Group 20 Technical data
Short block
Cylinder head
D16C-A/B/C/D MH D16C-A MG
Cylinder block
Length.................................................................... 1156 mm (45.512”)
Height, upper block plane–crankshaft center (A)... 453 mm (17.835”)
Height, lower block plane–crankshaft center (B).... 120 mm (4.724”)
7
Technical data Group 20
Cylinder liners
D16C-A/B/C/D MH D16C-A MG
Type........................................................................ Wet, replaceable
Height, total............................................................ 288 mm (11.339”)
Cylinder diameter (oversize not available).............. 144 mm (5.669”)
Sealing surface height above block plane.............. 0.15 –0.21 mm
(0.0059–0.0083”)
Number of O-rings, upper liner seal....................... 1
Number of O-rings, lower liner seal........................ 2
Pistons
Gudgeon pins
Diameter................................................................. 63 mm (2.4803”)
8
Group 20 Technical data
Piston rings
D16C-A/B/C/D MH D16C-A MG
Compression rings
Number................................................................... 2
Piston ring clearance in groove:
upper compression ring...................................... Trapezoidal profile
lower compression ring, height........................... 0.07 mm (0.0028”)
max. play (wear allowance).............................. 0.1 mm (0.0039”)
Piston ring gap, measured at ring opening:
upper compression ring...................................... 0.62 mm (0.0244”)
max. ring gap (wear allowance)........................ 0.85 mm (0.0335”)
lower compression ring....................................... 1.1 mm (0.0433”)
max. ring gap (wear allowance)........................ 1.35 mm (0.0531”)
Reciprocating components
Crankshaft
Length.................................................................... 1256 mm (49.449”)
Crankshaft end float 1) ........................................... 0.15 mm (0.0059”)
Main bearings radial clearance 1) ........................... 0.07– 0.14 mm
(0.0028–0.0055”)
Max. permitted ovality on main‑ and big-end
bearing journals...................................................... 0.01 mm (0.0004”)
Max. permitted taper of main‑ and big-end
bearing journals...................................................... 0.02 mm (0.0008”)
Max. runout on center bearing................................ 0.15 mm (0.0059”)
Note. Values apply to oiled components.
1)
9
Technical data Group 20
10
Group 20 Technical data
11
Technical data Group 20
12
Group 20 Technical data
Con rods
D16C-A/B/C/D MH D16C-A MG
Length center – center (D) ..................................... 280 mm (11.0236”)
Marking:
Conrods and bearing caps are marked with
a three-figure number (see figure).
“FRONT” on rod turned....................................... Forwards
Gudgeon pin bushing, internal diameter (E) .......... 63.036–63.046 mm
(2.4817– 2.4821”)
End float, con rod – crankshaft, max. 1) .................. 0.35 mm (0.0138”)
Big end bearings, radial clearance, max. 1) ............ 0.10 mm (0.0039”)
Straightness, max. deviation per 100 mm
(3.937”) measured length....................................... 0.06 mm (0.0024”)
Twist, max. deviation per 100 mm (3.937”)
measured length..................................................... 0.15 mm (0.0059”)
1)
Values apply to oiled components.
Flywheel, installed
Max permitted runout on measured radius 150 mm
(5.905”)................................................................... 0.1 mm (0.0039”)
No. of teeth on starter gear ring.............................. 153
Sensor grooves on flywheel................................... 3 × 18
13
Technical data Group 20
Valve mechanism
Camshaft
D16C-A/B/C/D MH D16C-A MG
Checking camshaft setting:
The check shall be performed with a cold
engine and valve clearance = 0.
Inlet valve for no.1 cylinder shall, at
flywheel position 6° a. t. d. c. have opened............. 1.4 ±0.3 mm
(0.0551 ±0.0118”)
Note. During this check, the timing gear
must be turned in the correct direction
(clockwise seen from the front) to take up all
gear backlash.
NOTE: Do not forget to adjust the valve clear-
ance back to the correct value after the check.
Camshaft bearings
Camshaft bearing thickness, standard................... 1.92 mm (0.0756”)
Oversize dimension:
0.25 mm (0.0098”).............................................. 2.05 mm (0.0807”)
0.50 mm (0.0197”).............................................. 2.17 mm (0.0854”)
0.75 mm (0.0295”).............................................. 2.30 mm (0.0906”)
Diameter, camshaft bearing seat:
Bearings 1 to 7.................................................... 69.97–70.00 mm
(2.7547–2.7559”)
14
Group 20 Technical data
Valves
D16C-A/B/C/D MH D16C-A MG
Head diameter:
Intake................................................................... 49 mm (1.9291”)
Exhaust............................................................... 46 mm (1.8110”)
Stem diameter:
Inlet...................................................................... 10 mm (0.3937”)
Exhaust............................................................... 10 mm (0.3937”)
Valve seat angle:
Intake................................................................... 24.5°
Exhaust............................................................... 44.5°
Seat angle in cylinder head:
Intake................................................................... 25°
Exhaust............................................................... 45°
INLET
EX- HAUST
15
Technical data Group 20
Valve seats
D16C-A/B/C/D MH D16C-A MG
Outer diameter (dimension A), standard:
Intake.................................................................. 52 mm (2.0472”)
Exhaust............................................................... 49 mm (1.9291”)
Outer diameter (dimension A), oversize:
Intake.................................................................. 52.2 mm (2.0551”)
Exhaust............................................................... 49.2 mm (1.9370”)
Height (dimension B):
Intake.................................................................. 7.6 mm (0.2992”) SN 76469 - 6.1 mm
Exhaust............................................................... 7.8 mm (0.3071”) SN 76469 - 6.3 mm
Distance from valve head to cylinder head
plane (check measurement):
Inlet...................................................................... 0.9 –1.4 mm
(0.0354– 0.0551”)
wear tolerance.................................................. max. 1.5 mm (0.0591”)
Exhaust............................................................... 1.4–1.9 mm
(0.0551– 0.0748”)
wear tolerance.................................................. max. 2.0 mm (0.0787”)
If the distance is greater, the valve seat must be
replaced.
NOTE! When the valve seats are changed, the
valves must be changed at the same time.
As spare parts, the valve seats are fully machined
and should not need additional grinding.
16
Group 20 Technical data
Valve guides
D16C-A/B/C/D MH D16C-A MG
Length:
Intake.................................................................. 83.5 mm (3.287”)
Exhaust............................................................... 83.5 mm (3.287”)
Inner diameter:
Intake.................................................................. 10 mm (0.3937”)
Exhaust............................................................... 10 mm (0.3937”)
Height above cylinder head spring plane:
Intake.................................................................. 24.5 ±0.2 mm (0.9646 ±0.0079”)
Exhaust............................................................... 22.5 ±0.2 mm (0.8858 ±0.0079”)
Clearance, valve stem – guide:
Intake.................................................................. 0.025 –0.054 mm
(0.0010–0.0021”)
Wear tolerance.................................................. max. 0.4 mm 1) (0.0354”) 1)
Exhaust............................................................... 0.058 – 0.087 mm
(0.0023–0.0034”)
Wear tolerance.................................................. max. 0.4 mm 1) (0.0354”) 1)
1)
Max. permissible clearance between valve stem and
valve guide: (according to method in “Workshop manual
group 21–26, D16C; Valve guides, inspection”).
Valve springs
17
Technical data Group 20
Timing gears
D16C-A/B/C/D MH D16C-A MG
18
Group 20 Technical data
Lubrication system
D16C-A/B/C/D MH, D16C-A MG:
Oil grade 1) Fuel sulfur content by weight
up to 0.5% 0.5 – 1.0% more than 1.0% 2)
Oil change interval: Reached first in operation
VDS-3 500 hrs. or 12 months. 200 hrs. or 12 months. 100 hrs. or 12 months.
VDS-2 and ACEA E7 3), 4)
VDS-2 and Global DHD-1 3)
VDS-2 and API CH-4 3) 400 hrs. or 12 months. 200 hrs. or 12 months. 100 hrs. or 12 months.
VDS-2 and API CH-4 3)
VDS and ACEA E3 3), 5)
VDS and API CG-4 3), 6) 300 hrs. or 12 months. 150 hrs. or 12 months. 75 hrs. or 12 months.
ACEA: E3 5)
API: CG-4 6) 200 hrs. or 12 months. 100 hrs. or 12 months. 50 hrs. or 12 months.
NOTE: Mineral based oil, as well as fully or semi-synthetic, can be used on condition that it complies with the
quality requirements above.
1)
Lowest recommended oil grade. A lubricating oil with a higher grade can always be used.
2)
With sulfur content >1.0 weight% oils with TBN >15 shall be used.
3)
The lubricating oil shall fulfil both requirements.
4)
ECEA E7 has replaced ACEA E5. ACEA E5 can however be used if oil of this grade is available.
5)
ACEA E3 can be replaced with ACEA E4, E5 or E7.
6)
API CG-4 can be replaced with API CI-4.
All engines:
Select viscosity from adjacent table.
(Temperature values apply to stable outside air tem-
perature).
D16C-A/B/C/D MH
19
Technical data Group 20
D16C-A MG
Lube oil volume
Change volume, including changing three filters,
without regard to engine inclination..................... 55 liters (14.5 US gals)
volume difference min.– max............................... 10 liters (2.6 US gals)
Oil filter
Full-flow filter, number............................................ 2
(tightened ¾ turn after contact)
By-pass filter, number............................................. 1
(tightened ¾–1 turn after contact)
20
Group 20 Technical data
Oil valves
D16C-A/B/C/D MH D16C-A MG
7
5
6
4 3
21
Technical data Group 20
Fuel system
D16C-A/B/C/D MH D16C-A MG
Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with nationally adapted environmental and cold weather requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: Complying with legal requirements in each country.
Low density fuel (city diesel in Sweden and Finland) can cause a loss of up to 5% of power and an increase in fuel
consumption of about 2–3%.
Injection sequence.................................................. 1–5–3–6–2–4
Feed pump
Feed pressure after fuel filter at:
600 rpm............................................................... min. 100 kPa (14.5 psi)
1200 rpm............................................................. min. 280 kPa (40.6 psi)
full load................................................................ min. 280 kPa (40.6 psi)
By-pass valve
Opening pressure................................................... 300–550 kPa (43.5–79.8 psi)
22
Group 20 Technical data
Unit injectors
D16C-A/B/C/D MH, D16C-A MG
23
Technical data Group 20
24
Group 20 Technical data
The exhaust temperatures are measured at duty rating. Temperature of inlet air +27°C (80.6°F) and
exhaust back pressure 10 kPa (1.45 psi / 1019 mm water column / 40.118” water column).
D16C‑A MG (HE/KC)*
Power – ISO Standard Power
1500 rpm................................................................ 215 kPa (31.2 psi) 465°C (869°F)
1800 rpm................................................................ 230 kPa (33.4 psi) 435°C (815°F)
25
Technical data Group 20
Cooling system
D16C-A/B/C/D MH D16C-A MG
General
Type........................................................................ Pressurized, sealed
Pressure cap opens at............................................ 75 kPa (10.9 psi)
Coolant volume, approx.......................................... 56 liters* (14.8 US gals)*
* Note. Incl. heat exchanger (HE).
Thermostat
Type........................................................................ Piston thermostat
Quantity.................................................................. 1
The thermostat starts to open at............................ 84 – 88°C (183– 190°F)
fully open at....................................... 94–98°C (201– 208°F)
Coolant filter
Number................................................................... 1
Coolant pump
Type........................................................................ Belt driven centrifugal pump
Pressure after coolant pump:
1200 rpm............................................................. 150 kPa (21.8 psi) –
1500 rpm............................................................. 220 kPa (31.9 psi) 220 kPa (31.9 psi)
1800 rpm............................................................. 290 kPa (42.1 psi) 290 kPa (42.1 psi)
1900 rpm............................................................. 330 kPa (47.9 psi) –
26
Group 20 Technical data
Coolant
D16C-A/B/C/D MH D16C-A MG
“Volvo Penta Coolant, Ready Mixed”...................... Ready-mixed coolant
Consists of........................................................... 40% ethylene glycol with corrosion inhibiting
additives and 60% water
Protects against freezing down to approx............ –28°C (–18°F)
Alternative:
“Volvo Penta Coolant”............................................. Concentrated coolant
Consists of........................................................... Ethylene glycol + anti-corrosion additives
Color.................................................................... Blue-green
Mixture ratio.........................................................
* IMPORTANT! The concentrated coolant must be 40% 60% –28°C (–18°F)
mixed with clean water. Use distilled – deionized
50% 50% –40°C (–40°F)
water. The water must fulfill the demands specified
in ASTM D4985 (see under heading “Water quality” 60%** 40% –54°C (–65°F)
below).
“Volvo Penta Coolant” (ethylene glycol) must not be
mixed with other types of glycol.
IMPORTANT! A coolant mixture with at least 40%
concentrate (“Volvo Penta Coolant”) shall be used
all year round, even if there is no risk for freezing.
This is to ensure that the engine is adequately pro-
tected against corrosion and cavitation damage.
** Never mix more than 60% concentrate (“Volvo Penta
Coolant”) in the coolant. A higher concentration causes
reduced cooling effect with the risk of overheating and
gives less frost protection.
Concentrated Mix with Provides frost coolant water* protection down
to approx.
Water quality
ASTM D4985:
Total solid particles.............................................. < 340 ppm
Total hardness..................................................... < 9.5° dH
Chloride............................................................... < 40 ppm
Sulfate................................................................. < 100 ppm
pH value.............................................................. 5.5 – 9
Silica (acc. to ASTM D859)................................. < 20 mg SiO2/l
Iron (acc. to ASTM D1068).................................. < 0.10 ppm
Manganese (acc. to ASTM D858)....................... < 0.05 ppm
Conductivity (acc. to ASTM D1125).................... < 500 µS/cm
Organic content, CODMn (acc. ISO8467)............. < 15 mg KMnO4/l
27
Technical data Group 20
Electrical system
D16C-A/B/C/D MH D16C-A MG
System voltage....................................................... 24 V
Battery capacity...................................................... 2 series-connected 12 V, max. 220 Ah
Battery electrolyte density at +25°C (77°F):
fully charged battery............................................. 1.28 g/cm3 (1.24 g/cm3)*
0.0462 lb/in3 (0.0448 lb/in3)*
re-charge battery at.............................................. 1.24 g/cm3 (1.20 g/cm3)*
0.0448 lb/in3 (0.0434 lb/in3)*
* Note. Applies to batteries with tropical acid.
Alternator
Make....................................................................... Bosch
Voltage/max. current capacity................................. 28 V / 80 A
Output, approx........................................................ 2240 W
Starter motor
Make....................................................................... Mitsubishi 24 V / 7 kW
Brush length........................................................... min. 11 mm (0.433”)
Speed sensor
Camshaft (timing gear cover):
distance to toothed wheel, vibration damper....... 1.1 ±0.4 mm (0.0433 ±0.0157”)
Flywheel (flywheel housing):
distance to flywheel............................................. 1.1 ±0.4 mm (0.0433 ±0.0157”)
28
Group 20 Technical data
29
Technical data Group 20
Tightening torques
D16C-A/B/C/D MH D16C-A MG
General tightening torques
Nm (lbf.ft) Angle tightening
M6 standard screw................................................. 10 ±1.5 (7.4 ±1) –
M8 standard screw................................................. 24 ±4 (17.7 ±3) –
M10 standard screw............................................... 48 ±8 (35.4 ±6) –
M12 standard screw............................................... 85 ±15 (62.7 ±11) –
M14 standard screw............................................... 140 ±25 (103.3 ±18) –
M16 standard screw............................................... 220 ±35 (162 ±26) –
30
Group 20 Technical data
31
Technical data Group 20
NOTE! Loosen the unit injector´s fixing yoke before the second tightening.
Second tightening:
Stage 1................................................................ 20 (14.8 ) –
Stage 2................................................................ – 60° ±5°
32
Group 20 Technical data
Tightening diagrams
D16C-A/B/C/D MH, D16C-A MG
Cylinder head
4 5
2 7
1 8
33
Technical data Group 20
40 +/- 3 Nm
Nm (lbf.ft) Angle
Camshaft: tightening
Camshaft and bearing caps in place). Fit a drift to No. 7’s
bearing seat to protect the guide sleeve.
–
Stage 2: (with shorter extra screws). Tighten screws 8 –14.......................... 50 ±10 (36.9 ±5) –
Stage 3: Angle tighten screws 1–7............................................................... – 90° ±5°
Remove extra screws 8–13 and 20. Remove the drift from No. 7’s bearing seat.
34
Group 20 Technical data
35
Technical data Group 20
36
Group 20 Technical data
37
Technical data Group 20
Connections, turbocharger*
Stage 1:
Tighten the screwed joint until it bottoms
(“zero play”).
Stage 2................................................................... 25 ±5 Nm (18.4 ±4 lbf.ft)
* Note. For coolant and lube oil respectively.
Oil cooler
Tightening torque:
Stage 1................................................................... 10 ±4 Nm (7.4 ±3 lbf.ft)
Stage 2*.................................................................. 27 ±4 Nm (20 ±3 lbf.ft)
* Note. Tightening sequence 1 – 2 – 3 – 4 – 1 in stage 2.
38
Group 20 Technical data
Tightening torque:
Lube oil pan............................................................ 24 ±4 Nm (17.7 ±3 lbf.ft)
Drain plug............................................................... 60 ±5 Nm (44.3 ±4 lbf.ft)
39
Technical data Group 20
Tightening torque:
NOTE! The 8.8 screws on the vibration damper
must NOT be reused.
Stage 1................................................................... 35 ±5 Nm (25.8 ±4 lbf.ft)
Stage 2................................................................... 90 ±10 Nm (66.4 ±7 lbf.ft)
Flywheel
40
Group 20 Technical data
Tightening torque:
Stage 1: Tighten all M14 bolts................................ 160 ±20 Nm (118 ±15 lbf.ft)
Stage 2: Tighten all M10 bolts................................ 48 ±8 Nm (35.4 ±6 lbf.ft)
Stage 3: Tighten all M8 screws............................... 24 ±4 Nm (17.7 ±3 lbf.ft)
41
Technical data Group 20
Tightening torque:
Stage 1................................................................... 5 ±2 Nm (3.7 ±1.5 lbf.ft)
Stage 2................................................................... 25 ±5 Nm (18.4 ±4 lbf.ft)
Stage 3................................................................... 52 ±5 Nm (38.4 ±4 lbf.ft)
Fuel pipes
1. Plastic clips
2. Tension strap
3. Rubber clamp
42
Group 20 Technical data
Coolant pump
Tightening torque:
Stage 1*.................................................................. 24 ±4 Nm (17.7 ±3 lbf.ft)
Stage 2*.................................................................. 24 ±4 Nm (17.7 ±3 lbf.ft)
* Note. Tightening sequence: 1– 2– 3– 4– 5–6.
43
Technical data Group 20
Engine cables
*
IMPORTANT! Use only Volvo Penta original tension straps and holders under
the valve cover for clamping the wiring for the unit injectors. These components
have been specially developed to withstand oil and high temperatures.
44
Group 20 Technical data
Installing seals
D16C-A/B/C/D MH, D16C-A MG
Cylinder block, rear
Apply a string of sealant, part No. 1161231* and with a diameter of about 2 mm (0.079”).
* Note. Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).
Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079”).
45
Technical data Group 20
Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079”).
Inlet manifold
Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079”) as illustrated.
46
Group 20 Technical data
The figure shows the joint between the cylinder block and front crankshaft seal cover and the
flywheel housing where sealant (part No. 1161231) shall be applied.
Valve cover
Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079”) to the joint
between the timing gear cover and the cylinder head.
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References to Service Bulletins
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AB Volvo Penta
Technical Information
Dept. CB22000
SE-405 08 Gothenburg
Sweden
7746641 English 01-2018