volvo — Volvo Penta Workshop Manual Model# 2001 2002 2003(T)

Main bearing journals Diameter, standard 0,250 m m under-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,500 mm under-size- . . . . . . . . . . . . . 59,987-60,000 (2,36169-2,36220 in .) 59,737-59,750 (2,35185-2,35236 in .) 59,487-59,500 (2,34200-2,34252 in .) Main bearing shells Thickness, standard . . . - - . - . . . . . . . . . . . . . . . . . . . . . . . . 2,987-2,997 (0,11760-0,11799 in .) 0,250 mm over-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,112-3,122 (0,12252-0,12291 in .) 0,500 mm over-size . . . . - - - . - . . . . . . . . . . . . . . . . . . . . . . . . .

3,237-3,247 (0,12744-0,12783 in .) Big-end journals Diameter, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47,989-48,000 (1,88933-1,88976 in .) 0,250 mm aver-size --- . . . . . . . . 47,739-47 .750 (1,87949-1,87992 in .) 0,500 m m over-size .- .-- . .- . . . . . . . . . . . . . . . . . . . . . . . . . . . 47,489-47,500 (1,86965-1,87008 in .) Big-end bearing shells Thickness, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,250 mm over-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,500 mm over-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1,478-1,488 (0,05819-0,05858 in .) 1,603-1,613 (0,06311-0,06350 in .) 1,728-1,738 (0,06803-0,06843 in .) Connecting rods Axial clearance at the crankshaft . . . . . . . . . . . . . . . . . . . . . . . 0,15-0,35 mm (0,00590-0,01378 in .) Camshaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radial clearance in bearings . . . . . . . . . . . . Camshaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting height of cams . . . . . . . . . . . .--- .---------- . . .-- . .

0,160-0,300 mm (0,0063-0,01181 in .) 0,020-0,075 mm (0,000787-0,00295 in .) 46,975-47,000 (1,8494-1,85039 in .) 5,48-5,52 mm (0,21575-0,21732 in .) Bushing diameter . . . . . . . . . . . . . . . . . . . . . .------------ . . . 47,02-47,05 mm (1,85118-1,85236 in .) Cylinder head Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special alloy cast iron Inlet valves 20031 Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,4-34,6 mm (1,35433-1 .36220 in .) 35,8-36,0 mm Stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7,955x7,970 mm (0,31319-0,31378 in .) 7,995-7,970 mm Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44°55'-44 ° 85' 29°45'--30 15' Cylinder head seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° 30° Seat width in the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . appr . 1 mm (0,03)37 in .) appr . 1 mm !0 .03)37 in . Clearance, cold/warm engine . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 mm (0,011811 in .) 0 .3 mm (0,011811 in .) Exhaust valves 29,9-30,1 mm (1,14716-1,18504 in .) Stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7,950-7,465 mm (0 .31299-0,31339 in .) Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc diameter . . . . . . . . . . ---- . . . . . . . . . . . . . . . . . . . . . . . . . . . 4°5'-4°85' Cylinder head seat angle - . . - . . . . . . . . . . . . . . . . . . . . . . 45 ° Seat width-in the cylinder head . -- . . . . . . . . . . . . . . . . . . . . . appr . 1 mm (0,03937 in .) Clearance, cold/warm engine ----- . . . . . . . . . . . . .-- . . .--- 0,3 mm (0,011811 in .) Valve guides Length, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 mm (1,49606 in .) Length, outlet valve . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . 38 mm (1,49606 i n .) Inner diameter ------------ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,000-8,015 (0,31496-0,31555 in .) Height above spring-plane of cylinder head . . . . . . . . . . . . . 8,70-9,30 mm (0,34252-0,36614 in .) Valve springs Length, unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42,5 mm (1,67323 in .) Loaded with 170±10 N (17±1 kp) . . . . . . . . . . . . . . . . . . . . . . 32 mm (1 .25984 in .) Loaded with 300±20 N (30±2 kp) . . . . . . . . . . . . . . . . . . . . . . 24 mm (0,94488 in .)