Repair instructions and methods The working methods described in the Workshop Man- ual apply to work carried out in a workshop. The engine has been removed from the boat and is installed in an engine fixture. Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working method. Our joint responsibility Every engine consists of many systems and compon- ents that work together. If one component deviates from the technical specifications this can have dramatic con- sequences on the environmental impact of the engine even if it is otherwise in good running order.
It is there- fore critical that the stated wear tolerances are ob- served, that systems which can be adjusted are cor- rectly set up and that only Volvo Penta Original Parts are used on the engine. The stated service intervals in the Maintenance Schedule must be followed. Warning symbols used in this Workshop Manual (for full explanation of the symbols refer to the section; "Safety Precautions") A AL WARNING! I MPORTANT! Some systems, such as the components in the fuel sys- tem, require special expertise and special testing equip- ment for service and maintenance. Some components are factory sealed for environmental and product spe- cific reasons.
Under no circumstances attempt to ser- vice or repair a sealed component unless the service technician carrying out the work is authorized to do so. Note! are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out. Volvo Penta AB can only i ndicate the risks considered likely to occur as a result of incorrect working methods in a well-equipped work- shop using working methods and tools tested by Volvo Penta AB. Bear in mind that most of the chemicals used around boats are harmful to the environment if used incorrectly.
Volvo Penta recommends the use of bio-degradable degreasing agents for all cleaning of engine compon- ents unless otherwise stated in the Workshop Manual. When working onboard a boat make a special point of preventing oil, waste water from washing components entering the bilges ; i nstead remove all such waste for safe disposal at an approved site for destruction. All operations described in the Workshop Manual for which there are Volvo Penta Special Tools available assume that these tools are used by the service techni- cian or person carrying out the repair. Volvo Penta Spe- cial Tools have been specifically developed to ensure as safe and rational working methods as possible.
It is therefore the responsibility of the person or persons us- Tightening torques i ng other than Volvo Penta Special Tools or approved Volvo Penta working methods (as described in a Work- shop Manual or Service Bulletin), to acquaint them- selves of the risk of personal injury or actual mechan- ical damage or malfunction that can result from failing to use the prescribed tools or working method. The correct tightening torques for critical joints which must be tightened using a torque wrench are listed un- der "Technical Specifications - Tightening Torques " and stated in the method descriptions in the Workshop Manual.
All tightening torques apply to cleaned threads, bolt heads and mating surfaces. Tigthening torques stated are for lightly oiled or dry threads. Where grease, I n some cases special safety precautions and user in- structions may be required in order to use the tools and chemicals mentioned in the Workshop Manual. Always follow these precautions as there are no specific in- structions given in the Workshop Manual. l ocking or sealing agents are required for screwed j oints this is stated in both the operation description and i n "Tightening Torques ". Where no tightening torque is stated for a joint use the general tightening torques ac- cording to the tables below.
The tightening torques stat- ed are a guide and the joint does not have to be tight- ened using a torque wrench. By following these basic recommendations and using common sense it is possible to avoid most of the risks i nvolved in the work. A clean work place and a clean engine will eliminate many risks of personal injury and engine malfunction. Above all when working on the fuel system, engine lub- rication system, air intake system, Turbocharger unit, bearing seals and seals it is extremely important to ob- serve the highest standards of cleanliness and avoid dirt or foreign objects entering the parts or systems, since this can result in reduced service life or malfunc- tions.
Dimension Tightening torque Nm ft.Ibs M5 6 4 M6 10 7 M8 25 18 M - 1 0 50 37 M12 80 59 M14 140 103 6