Volvo Penta Workshop Manual (EN)

FOREWORD This workshop manual contains repair instructions for the 2001, 2002 and 2003 engines . The instructions concerning overhauling describe the most suitable working method using the special tools listed under the heading "Special tools" . Both the engine designation and its serial number must be clearly stated in all correspondence concerning the engine and when ordering parts . We reserve the right to carry out design modifications and, for this reason, the contents of this manual cannot be regarded as binding . AB VOLVO PENTA Technical Publications Department SI UNIT SYSTEM Units according to the international SI system have been used in this book .

The earlier units are given after the SI units . Power is given in kW (kilowatt) Speed is given in rev/s (revolutions per second) earlier unit hp (horse-power) earlier unit rev/min (revolutions per minute) Torque is given in Nm (newton metre) Volume is given in dm 3 (cubic decimetre) earlier unit kpm (kilopond metre) earlier unit l (litre) earlier unit lbf ft (poundfoot) earlier unit Imp . gal (Imperial gallon) earlier unit US gal (United States gallon) Pressure is given in Pa (Pascal) earlier unit kp/cm 2 (kiloponds per square centimetre) earlier unit Ibf/in 2 (pounds per square inch)

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INDEX Components guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISASSEMBLY Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston, piston rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OVERHAUL Disassembling the cylinder head . . . . . . . . . . . . . . . . . . . . . 7 Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Injector sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Injectors . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . 8 Assembling the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . 9 Feed-pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 Sea-water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ASSEMBLY Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . . . . . . . . . 15 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Adjusting the valve clearance . . . . . . . . . . . . . . . . . . . . . . . 17 Checking the injection angle . . . . . . . . . . . . . . . . . . . . . . . . 17 2003 Turbo . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . 21 Fresh water cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Fault tracing scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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COMPONENTS GUIDE 1 . Exhaust elbow 2 . Injectors 3 . Temperature sender 4 . Electrical distribution box 5 . Fuel filter 6 . Alternator 7 . Starter motor 8 . Drainage, cooling water 9 . Feed-pump 10 . Engine serial number 11 . Decompression device 12 . Inlet air silencer 13 . Fuel injection pumps 14 . Oil dipstick 15 . Sea-water pump 8 Halpert@Optonline.net

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DISASSEMBLY Drain off the cooling water and the lubricating oil from the on engine cradle p/n 9992520 and fixture p/n 884837 . If the engine is fresh water cooled, see page 21 . 3 . Remove the fuel filter, the oil filter, the feed-pump, the thermostat housing and the exhaust elbow . Also remove the sea-water pump with its attachment tubes . 1 . Remove the alternator, the tensioner bracket and the starter motor . Remove the connections from the electrical distribution box from the engine and remove the box and the wire harness . 2 . Remove the return fuel line, the fuel pressure lines and the inlet air silencer . Install protection caps on the fuel 4 .

Remove the valve bridge and lift out the push rods . Remove the rubber rings fortheoil pipe . Remove the cylinder head and the valve lifters . Put the lifters on a rack in injection pumps and injectors . Remove the screw holding the lever of the decompression device (1) and pull out the lever . Remove the valve cover . consecutive order, NOTE!Thecylinder head boltsare phosphatised andmustnot becleanedwitha steel brush.

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