Volvo Penta D1-30A Workshop Manual
Volvo Penta D1-30A Workshop Manual
Volvo Penta D1-30A Workshop Manual
Contents
1
Table of contents
2
Safety information
In this book and on the product you will find the follow- Never use start spray or similar products as a
ing special warning symbols. starting aid. They may cause an explosion in
the inlet manifold. Danger of personal injury.
WARNING! Warns for the risk of personal injury,
major damage to product or property, or serious Avoid opening the coolant filling cap when the
malfunctions if the instruction is ignored. engine is hot. Steam or hot coolant can spray
out and the system pressure will be lost. Open
IMPORTANT! Is used to call attention to things the filler cap slowly, and release the pressure in
which could cause damage or malfunctions to the cooling system if the filling cap or tap has to
product or property. be opened, or if a plug or coolant hose has to be
removed when the engine is hot. Steam or hot
NOTE! Is used to call attention to important informa- coolant might spray out in an unexpected direc-
tion, to facilitate work processes or operation. tion.
Below is a summary of the risks involved and safety
precautions you should always observe or carry out Hot oil can cause burns. Avoid skin contact with
when operating or servicing the engine. hot oil. Ensure that the lubrication system is not
under pressure before carrying out any work.
Make it impossible to start the engine by cutting Never start or operate the engine with the oil fill-
system current with the main switch(es)and lock er cap removed, otherwise oil could be ejected.
it (them) in the off position before starting ser-
vice work. Set up a warning notice by the helm Stop the engine and close the sea cocks before
station. doing any work on the cooling system.
As a general rule all service operations must be Only start the engine in a well- ventilated area.
carried out with the engine stopped. Some When operated in a confined space, exhaust
tasks, such as adjustments, need the engine to fumes and crankcase gases must be ventilated
be running, however. Approaching an engine from the engine bay or workshop area.
which is operating is a safety hazard. Remem-
ber that loose clothing or long hair can fasten in Always use protective glasses or goggles when
rotating parts and cause serious personal injury. carrying out work where there is a risk of splin-
ters, grinding sparks, acid splashes or where
other chemicals are used. Your eyes are ex-
tremely sensitive, injury could cause blindness!
3
Safety information
Avoid getting oil on your skin! Repeated expo- Batteries must never be exposed to open
sure to oil or exposure over a long period can re- flames or electric sparks. Never smoke close to
sult in the skin becoming dry. Irritation, dryness the batteries. The batteries generate hydrogen
and eczema and other skin problems can then gas when charged, which forms an explosive
occur. Used oil is more dangerous than fresh oil gas when mixed with air. This gas is easily ignit-
from a health aspect. Use protective gloves and ed and highly volatile. A spark, which can be
avoid oil soaked clothes and rags. Wash regu- caused by incorrect battery connection, can
larly, especially before eating. There are special cause a single spark which is sufficient to
skin creams which counteract drying out of the cause an explosion with resulting damage. Do
skin and make it easier to clean off dirt after not move the connections when you attempt to
work is completed. start the engine (risk of arcing), and do not
stand and lean over one of the batteries.
Most chemicals intended for the product (e.g.
engine and transmission oils, glycol, petrol (gas- Always ensure that the Plus (positive) and Mi-
oline) and diesel oil) or chemicals for workshop nus (negative) battery cables are correctly in-
use (e.g. degreasers, paints and solvents) are stalled on the corresponding terminal posts on
hazardous. Read the instructions on the product the batteries. Incorrect installation can result in
packaging with care! Always follow the safety serious damage to the electrical equipment. Re-
precautions for the product (for example use of fer to the wiring diagram.
protective mask, glasses, gloves etc.). Make
sure that other personnel are not inadvertently Always use protective goggles when charging
exposed to hazardous chemicals, for example in and handling the batteries. Battery electrolyte
the air. Ensure good ventilation in the work contains sulfuric acid which is highly corrosive.
place. Follow the instructions provided when dis- Should the battery electrolyte come into contact
posing of used or leftover chemicals. with unprotected skin wash off immediately us-
ing plenty of water and soap. If you get battery
Exercise extreme care when leak detecting on acid in your eyes, flush at once with a generous
the fuel system and testing the fuel injector noz- amount of water, and get medical assistance at
zles. Use eye protection. The jet which comes once.
from a fuel injector has very high pressure and
considerable penetrationability. Fuel can force Turn the engine off and turn off the power at the
its way deep into body tissue and cause severe main switch(es) before carrying out work on the
injury. Danger of blood poisoning (septicemia). electrical system.
All fuels, and many chemicals, are flammable. Clutch adjustments must be carried out with the
Do not allow naked flame or sparks in the vicini- engine stopped.
ty. Petrol (gasoline), some thinners and hydro-
gen gas from batteries are extremely flammable The existing lugs on the engine/reversing gear
and explosive when mixed with air in the correct should be used for lifting the assembly.
ratio. No smoking! Ensure that the work area is Always check that the lifting devices are in good
well ventilated and take the necessary safety condition and that they have the correct capaci-
precautions before starting welding or grinding ty for the lift (the weight of the engine plus the
work. Always ensure that there are fire extin- reversing gear and extra equipment).
guishers at hand when work is being carried out. The engine should be lifted with a customized or
adjustable lifting boom for safe handling and to
Make sure that oil and fuel soaked rags, and avoid damaging components on top of the en-
used fuel and oil filters are stored in a safe gine. All chains or cables should be parallel to
place. Rags soaked in oil can spontaneously ig- each other and should be as square as possible
nite under certain circumstances. Used fuel and to the top of the engine.
oil filters are polluting waste and must be hand- If other equipment connected to the engine has
ed to an approved waste management facility altered its center of gravity, special lifting devic-
for destruction, together with used lubrication oil, es may be needed to obtain the correct balance
contaminated fuel, paint residue, solvents, de- and safe handling.
greasers and wash residue. Never do any work on an engine which just
hangs from a lifting device.
4
Safety information
Never work alone when removing heavy engine Remember the following when washing with a
components, even when using lifting devices power washer: Never aim the water jet at seals,
such as locking tackle lifts. When using a lifting rubber hoses or electrical components. Never
device two people are usually required to do the use a power washer for engine cleaning.
work, one to take care of the lifting device and
another to ensure that components are lifted Only use the fuels recommended by Volvo Pen-
clear and not damaged during the lifting opera- ta. Refer to the Instruction Book. Use of fuels
tions. that are of a lower quality can damage the en-
When you work aboard a boat, always make gine. On a diesel engine, poor quality fuel can
sure that there is enough space for disassembly cause the control rod to bind and the engine to
where you are working, with no risk of personal overrev with resulting risk of damage to the en-
injury or material damage. gine and personal injury. Poor fuel can also lead
to higher maintenance 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.
5
General information
About this Workshop Manual Certified engines
This workshop manual contains technical data, de- When doing service and repair on emission certi-
scriptions and repair instructions for the following ma- fied engines, it is important to be aware of the fol-
rine diesel engines: D1-13, D1-20, D1-30 and D2-40. lowing:
The engine designation and number are noted on the Certification means that an engine type has been
number plate and engine decal. The engine designa- checked and approved by the relevant authority. The
tion and number must always be given in all corre- engine manufacturer guarantees that all engines made
spondence about any product. of the same type are equivalent to the certified en-
The Workshop Manual is produced primarily for the gine.
use of Volvo Penta workshops and service techni- This makes special demands on service and repair
cians. This assumes that people who use the Manual work, as follows:
have basic knowledge of marine drive systems and
can do the tasks of a mechanical or electrical nature Maintenance and service intervals recommended
associated with the trade. by Volvo Penta must be complied with.
Volvo Penta constantly improves its products, so we Only Volvo Penta original spares may be used.
reserve the right to make modifications without prior Service to injection pumps, pump settings and in-
notification. All information in this manual is based on jectors must always be done by an authorized
product data which was available up to the date on Volvo Penta workshop.
which the manual was printed. Any material changes
introduced into the product or service methods after The engine must not be converted or modified,
this date are notified by means of Service Bulletins. except for the accessories and service kits which
Volvo Penta has approved for the engine.
No installation changes to the exhaust pipe and
engine air inlet ducts may be done.
No seals on the engine may be broken by unau-
thorized persons.
6
Repair instructions
The working methods described in the Workshop Man- Our common responsibility
ual apply to work carried out in a workshop. For this
reason, the engine is lifted out of the boat and mount- Each engine consists of many interacting systems
ed on an engine support. Unless otherwise stated, re- and components. The deviation of one component
conditioning work which can be carried out with the from the technical specification can dramatically in-
engine in place follows the same working method. crease the environmental impact caused by an other-
The warning signs which occur in the workshop manu- wise good engine. For this reason, it is important that
al (please refer to Safety information for their mean- the specified wear tolerances are observed, that sys-
ings) tems which are adjustable are correctly adjusted and
that Volvo Penta Original Spares are used for the en-
gine. The stated service intervals in the Maintenance
WARNING!
Schedule must be observed.
Some systems, such as the components in the fuel
IMPORTANT!
system, require special expertise and special testing
NOTE! equipment for service and maintenance. For environ-
mental reasons etc., some components are sealed at
are not comprehensive in any way, since we can not
the factory. It is only permissible to work on sealed
of course foresee everything, because service work is
components if you are authorized to do such work.
done in highly varying circumstances. For this reason,
all we can do is to point out the risks which we believe Remember that most chemical products, incorrectly
could occur due to incorrect work in a well-equipped used, damage the environment. Volvo Penta recom-
workshop, using work methods and tools tested by mends the use of biodegradable degreasers whenever
us. engine components are de-greased, unless otherwise
All operations described in the Workshop Manual for specified in the workshop manual. When working
which there are Volvo Penta Special Tools available aboard a boat, be careful to ensure that oils, wash
assume that these tools are used when carrying out residue etc. are processed for destruction, and are not
the repair. Volvo Penta Special Tools have been spe- inadvertently discharged with bilge water into the envi-
cifically developed to ensure the most safe and ratio- ronment.
nal working methods possible. It is therefore the re-
sponsibility of anyone using other tools or other work-
ing methods than we recommend to determine that
there is no risk of personal injury or mechanical dam-
age or malfunction as a result.
In some cases special safety precautions and user in-
structions may be required in order to use the tools Torque
and chemicals mentioned in the Workshop Manual.
These rules must always be observed, so there are no The tightening torque for vital fasteners, which should
special instructions about this in the workshop manu- be tightened with a torque wrench, are listed in Tech-
al. nical Data: Special tightening torques and noted in
the job descriptions in the book. All torque specifica-
By following these basic recommendations and using- tions apply to clean screws, screw heads and mating
using common sense it is possible to avoid most of faces. Torque data stated apply to lightly oiled or dry
the risks involved in the work. A clean workplace and threads. If lubricants, locking fluids or sealants are
a clean engine will eliminate many risks of personal needed on a fastener, the type of preparation to be
injury and engine malfunction. used will be noted in the job description. For fasteners
Above all, when work on fuel systems, lubrication where specific torque values are not given, please re-
systems, induction systems, turbocharger, bearing fer to Technical data, General Tightening Torque.
caps and seals is done, it is extremely important that
no dirt or other kinds of foreign particles are able to
get in, since this would otherwise cause malfunctions
or shortened repair life.
7
Repair instructions
8
Repair instructions
9
Special tools
856 927
885 484
885 023 885 252
885 498
885 822
885 820
885 510
885 824
856 927 Measurement putty, for measuring main and big end
bearing clearance.
885 023 Valve spring compressor
885 252 Adapter for testing compression pressure
885 484 Adapter for testing compression pressure
885 498 Pressure foot, for valve compressor
885 510 Protective caps, fuel system
885 820 Puller, for pulley
885 822 Magnetic pen
885 824 Engine fixture
981 2519 Multimeter
998 6485 Equipment stand
998 8539 Compression tester
998 9876 Dial gauge
10
Special tools
9995192 9995919
999 2520
999 6662
999 9737
999 9179 999 9683 999 9696
384 9639
999 9772 384 9640
11
Design and function
Group 21 Short block
Engine, general
The D1-13, D1-20, D1-30 and D2-40 are four cycle The engines are lubricated by a pressure lubrication
marine diesel propulsion engines. They all have two system, in which an oil pump supplies oil under pres-
valves per cylinder, a high-mounted camshaft in the sure to all lubrication points.
engine block and a mechanical injection pump. Fresh water cooling uses a thermostatically controlled
The D1-13 is an in-line two cylinder engine with a total sea-water cooled heat exchanger. The sea water
swept volume of 0.51 liter. The D-20 and D1-30 are in- pump is operated by a gear train.
line three cylinder engines with total swept volumes of The crankshaft operates the coolant pump and alter-
0.76 and 1.13 liter respectively. The D2-40 is an in- nator via a drive belt.
line four cylinder engine with a total swept volume of
1.51 liter.
The D1-13 and D1-20 engines have identical pistons
with the same dimensions. The D1-30 and D2-40 en-
gines have different pistons, but of common dimen-
sions.
D1-30 engine
12
Group: 21 Short block Design and function
13
Design and function Group: 21 Short block
14
Group: 21 Short block Design and function
Engine
Product designation (1) .......................................................................................................
Serial number (2) .................................................................................................................
Product number (3) .............................................................................................................
Certification number (4) .......................................................................................................
S - drive/Reversing gear
Product designation (5) ........................................................................................................
Serial number (6) ..................................................................................................................
Product number (7) ..............................................................................................................
Gear ratio (8) ........................................................................................................................
Propeller designation ............................................................................................................
XXXXXX (7)
XXX (5) XX (8)
XXXXXXXXXX (6)
Engine plate
15
Design and function Group: 21 Short block
Engine block
The engine block is cast in one piece, from specially
alloyed cast iron. The camshaft is located in the en-
gine block.
The D1-13 has two cylinder bores, the D1-20 and
D1-30 have three and the D2-40 has four.
The D1-13 and D1-20 have the same dimension per
cylinder. The D1-30 and D2-40 have a larger, common
dimension per cylinder.
None of the engines have cylinder liners. The cylinder
walls are machined directly in the engine block.
Sump
The sump is located under the engine block and is
made from pressed sheet metal. There is an oil drain
pipe under the sump.
Camshaft
The camshaft has lobes which operate the valves, the
fuel pump and the injection pump. The camshaft is
driven by the crankshaft and gear wheels, via the oil
pump gear wheel.
Cylinder head
The cylinder head (1) is made from specially alloyed
3 cast iron.
The cylinder head has one inlet and one exhaust valve
per cylinder. These are operated by the camshaft via
valve lifters and push rods. The valves have replace-
able seats.
An injector is installed in the combustion chamber of
each cylinder. There is one glowplug per cylinder.
Valve cover
The valve cover (3) is made of aluminum and is locat-
ed above the rocker arm cover. The valve cover has
two internal sections, of which one leads inlet air down
into the cylinder head via an inlet. The other section
contains the crankcase ventilation valve.
16
Group: 21 Short block Design and function
Crankshaft
10 The crankshaft (1) is supported by main bearings (2).
The thrust bearing is integrated in the rear main bear-
ing cap (3). The crankshaft is statically and dynami-
cally balanced, and has induction hardened bearing
9 surfaces. At the front end, where the gear wheel (4) for
the timing gear and the pulley (5) for the alternator and
coolant pump are located, the crankshaft has a groove
2 for a Woodruff key. At the rear of the crankshaft, there
6 is a flange (6) to which the flywheel is attached.
8
Main and big end bearings
The main and big end bearings (7) consist of steel-
shells lined with bearing metal. The bearings are preci-
sion made and are ready to be installed.
1
Con rods
The con rods (8) have an I-section. The small end is
drilled for gudgeon pin lubrication.
Pistons
The pistons (9) are made of light metal alloy. They
3 7
have three piston rings (10). Two piston rings are com-
pression rings and one is an oil scraper ring.
17
Design and function Group: 21 Short block
Timing gear
2 The timing gear consists of cylindrical gear wheels
with helical teeth, located at the front of the engine
block. A timing gear cover (1) provides complete pro-
tection for the timing gear.
1
6 The camshaft (2) and sea water pump (3) are driven
by the crankshaft gear (4), via an idler wheel (5). The
engines lubrication pump is integral with the idler
gear, and is driven by it. The regulator weights (6) are
hung at the front of the camshaft drive and adjust the
injection pump via a mechanism in the timing gear
cover.
4
5 3
Crankcase breather
The crankcase ventilation is sealed and pressure con-
trolled with a valve and spring located in the valve
cover. When the gas pressure is higher, the valve
opens and directs the crankcase gases into the inlet
section, for combustion in the cylinders.
18
Group: 22 Lubrication system Design and function
2
1. Oil filter 6
2. Oil pressure monitor
3. Pressure reduction valve 3 4
4. Inlet pipe with strainer 5
5. Main oil duct
6. Oil pump
7. Oil supply pipe (outer) to valve mechanism
8. Crankcase ventilation, valve
19
Design and function Group: 22 Lubrication system
Oil valves
1
The lubrication pressure is limited by a reduction
valve (1). The valve is installed in the lubrication sys-
tem, just upstream of the oil filter (2). The valve opens
at high pressure and allows the oil to flow back into
the sump.
The D1-13 and D1-20 engines have a reduction valve
which opens in the interval from 352-448 kPa. On the
D1-30 and D2-40 engines, the valve opens in the inter-
2
val from 304-500 kPa.
A bypass valve located on the oil filter opens if the re-
sistance in the filter rises abnormally high. Oil supply
to the lubrication points is ensured in this way, even if
the filter is blocked, but the oil is no longer cleaned.
Oil pump
The lube oil pump is located in the idler wheel in the
timing gear, which also drives it.
Oil filter
The purpose of the oil filter is to remove contamina-
tion from the oil. The filter is a full flow filter, which
means that all the oil is filtered before it is forced out
1 into the lubrication system.
Filter insert is a folded paper filter.
There is a bypass valve (1) at the base of the filter,
which opens and allows oil to flow past the filter if the
filter insert should become blocked.
When the filter has been in use for a pre-determined
time, it must be replaced by a completely new filter.
20
Group: 23 Fuel system Design and function
Fuel system
A mechanical feed pump sucks the fuel up from the The fuel is then forced through the injector nozzles
fuel tank, possibly through a water separation filter into a pre-combustion chamber in the cylinder head at
(optional equipment), and the fuel is then forced high pressure and then enters the combustion cham-
through the secondary filter to the injection pump. bers in the pistons, where high speed air rotation con-
The injection pump, which is driven by the camshaft, tributes to even combustion. A glowplug in the pre-
then distributes fuel of specific quantity and timing to combustion chamber pre-heats the fuel mixture for
the injectors. cold starting.
Fuel which returns from the injectors is returned to the The secondary filter in the engine removes contamina-
base of the fuel tank. The air in the fuel system can tion which might be left in the fuel, despite the primary
be transported back to the fuel tank via a connection filter.
between the injection pump and the return fuel pipe.
6
3
4
1. Fuel tank
2. Pre - filter 1 2
3. Feed pump
4. Fuel filter
5. Hand pump
6. Injection pump
7. Injectors
21
Design and function Group: 23 Fuel system
Injection pump
The injection pump is a flange-mounted in-line pump
which is located on the engine block. The pump is
driven by cams on the engines camshaft, which oper-
ates the pump chambers directly.
The injection pump has the same number of pump
pistons as the engine has cylinders.
Centrifugal regulator
The regulator is mechanical, and uses regulator-
weights for engine speed sensing. It is mounted on
the front of the camshaft gear, which also drives it.
The regulator weights operate the injector pump con-
trol rod via the regulation sleeve, a lever and a regula-
tor arm. Engine speed is regulated across the en-
gines entire speed range, from low idle to high idle (all
speed type).
Injectors
The engines is provided with pintle - type injectors.
Each injector basically consists of a nozzle retainer
9 and a nozzle.
8
7 When the fuel pressure increases to the set value
6 (opening pressure), the injector needle which is held
5
3 4 pressed against its seat by the compression spring is
2 lifted and atomized fuel is injected into the precom-
1 bustion chamber of the engine.
The injector opening pressure is determined by the
1. Injector nut 6. Adjustment washers compression spring tension, which is adjusted by ad-
2. Injectors 7. Injector holder
3. Joining piece 8. Washer justment washers.
4. Compression screw 9. Nut
5. Spring
22
Group: 23 Fuel system Design and function
Feed pump
The feed pump is mounted on the outside of the en-
gine block and is driven by an eccentric on the rear of
the camshaft.
3 4 2
Fuel filter
The fuel filter (1) is of the disposable type. The filter
insert is a paper filter.
The fuel filter is located in a bracket (2) together with
a hand pump (3) and vent screw (4).
23
Design and function Group: 26 Cooling system
General
The engine is fresh water cooled and has a sealed The coolant temperature is regulated by a thermostat.
cooling system with expansion tank. The system is When the engine is cold, a thermostat directs the
subdivided into two circuits. coolant round an internal circuit in the engine. When
operating temperature begins to be reached, the cool-
In the inner circuit, the fresh watersystem, the coolant
ant is progressively directed out through the entire
is circulated by a coolant pump which is driven via a
heat exchanger, where the surplus heat is removed.
belt from the crankshaft pulley.
In the outer circuit, the sea water system, sea water
The fresh water circuit operates under a certain
is forced through by a gear-wheel driven pump with
amount of excess pressure, which reduces the risk of
rubber impeller.
boiling if the temperature rises too high. If the pres-
sure becomes higher than normal, a pressure valve The sea water system cools the engines heat ex-
opens in the filler cap on the expansion tank. changer. The sea water is returned together with the
exhaust gas, via a connection in the exhaust bend.
7 9
10 8 4
24
Group: 26 Cooling system Design and function
Thermostat
The engine is equipped with a thermostat whose sen-
sor body contains wax.
When the engine is cold, the thermostat keeps the
path to the heatexchanger closed. Coolant then pass-
es through a by-pass pipe, back directly to the suction
side of the pump. As the engine warms up, the vol-
ume of the wax increases and the thermostat progres-
sively opens the passage to the heat exchanger, at
the same time as the by - pass channel is closed.
Please refer to the Technical Data chapter for open-
ing temperatures.
The thermostat is located in a housing which is inte-
grated in the heat exchanger and exhaust manifold.
Coolant pump
The coolant pump is mounted on the engine block and
is driven by the crankshaft by means of a drive belt.
Heat exchanger
The heat exchanger is located in a housing which is
integrated with the exhaust manifold and thermostat.
Sea water passes through the heat exchanger matrix
and transfers heat from the internal cooling circuit in
the engine (fresh water system) to the outer circuit
(sea water). When the thermostat has not yet opened,
the coolant is lead through a short, uncooled passage
in the heat exchanger and back to the engine.
25
Design and function Group: 30 Electrical system
6
4 5
2
3
1
7, 8, 9
12
13 11
10
1. Glow plugs
2. Stop solenoid
3. Coolant temperature monitor
4. Coolant temperature sensor
5. Distribution box
6. Circuit breaker
7. Starter relay
8. Glowplug relay
9. Charge sensing resistor
10. Starter motor
11. Alternator
12. Oil pressure monitor
13. Engine speed sensor
26
Group: 30 Electrical system Design and function
Alternator
The alternator provides alternating current (14V/115A).
The voltage regulator on the alternator is provided with
a sensor system.
The sensor system compares the charge voltage be-
tween the alternator terminals, B+ and B-, with the
voltage across the battery positive and negative termi-
nals. The voltage regulator then compensates for any
voltage drop in the cables between the alternator and
the batteries, by increasing the charge voltage sup-
plied by the alternator as necessary.
When delivered from Volvo Penta, the sensor system
is not activated. The connection has probably been
done during engine installation, however.
Starter motor
The starter motor is a DC series motor. The starter
pinion is operated by a control solenoid and can be
slid axially on the rotorshaft.
The starter motor has a reduction gear, which makes
it possible to obtain greater torque.
The starter motor power depends on the engine it is
fitted to, please refer to the table below.
D1-13, D1-20 0.8 kW
D1-30 1.1 kW
D2-40 1.4 kW
Distribution box
Circuit breaker
A 16 A circuit breaker protects the electrical system
and cuts the current if overloaded.
If it has tripped, the electrical system is re-connected
by pressing the button on the circuit breaker in the
distribution box. Always first investigate the reason for
the overload.
Relays
The starting and glowplug functions are each con-
trolled by a switching relay. These relays are identical
and are thus mutually interchangeable. They are locat-
ed in the distribution box.
27
Design and function Group: 30 Electrical system
Electrical components
Lube oil pressure monitor - alarm
Contact type: Normally open. The contacts close if
the lube oil pressure in the engine falls below 0.5
0.15 bar.
The closing pressure should be checked with falling
pressure.
Stop solenoid
The stop solenoid is an electrical stopping device
which shuts off fuel supply at the injection pump.
Glow plugs
One glowplug per cylinder is installed in the cylinder
head. All glowplugs are electrically connected by a
busbar.
The glowplugs heat the fuel mixture during starting.
28
Repair instructions
Group 21 Short block
Please refer to Condition test, engine. 2 Remove the connector for the engine cables to
the instruments.
3 Remove the sea water connections/cool keeling
When working with chemicals, connection.
fuel and lubricating oil 4 Remove the exhaust pipe.
5 Close the fuel taps. Remove the fuel connections.
IMPORTANT! Always use protective gloves for
work which includes contact with oil, fuel etc. 6 Remove the throttle and gear shift cables.
7 Undo the propeller shaft from the reversing gear.
Constant skin contact with engine oil can be Undo the engine mounting pads from the bed and
very harmful. lift the engine out. Use the lifting lugs (1) on the
engine.
29
Repair instructions Group: 21 Short block
30
Group: 21 Short block Repair instructions
1
Connect drain hoses to the taps on the fresh water
system. Open all drain points.
The sea water system is drained by undoing hoses at
F the lowest points of the system.
2
Check that all water drains out.
F = Fresh water drain tap
Check whether the installation has any further taps or
plugs at the lowest points of the cooling water pipes
and exhaust pipe.
3
Close the taps.
4
Pump the bilges out as necessary. Check that no
leakage occurs.
1
Connect the suction pipe on the oil drain pump to the
oil drain pipe.
Suck the oil into a suitable vessel. The oil can also be
drained after the sump drain plug has been removed.
31
Repair instructions Group: 21 Short block
Use fixture 885 224 and 999 9737 to fix the engine to
engine stand 998 6485. Only fixture 885 224 is needed
for fixing to engine stand 999 2520.
Screw the fixture to the right side of the engine, as in
the illustrations.
D1-13-A
D1-20-A
D1-30-A
D2-40-A
32
Group: 21 Short block Repair instructions
9
6. Remove the oil pressure monitor (12), dipstick
(13) and oil pressure pipe (14) from the cylinder
head.
4
D1-13-A
8 6 7
33
Repair instructions Group: 21 Short block
23 24
26
11. Remove the valve cover (26), bus bar (27) and
glow plugs (28).
27
28
34
Group: 21 Short block Repair instructions
12. Remove the lower part of the valve cover (29) with
the integrated rocker arm bridge. Start by un-
screwing the two screws (30) on the edge, then
undo the rocker arm bridge nuts (31) one turn at a
time until the load on them has been relieved.
40
35
Repair instructions Group: 21 Short block
23. Remove the timing gear cover (39). Load the stop
42 arm (40) so that the springs on the inside of the
housing do not come out of position or spring out.
24. Remove the idler wheel (41) circlip. Save the
sleeve washer, spring and shims.
43 Lift away the idler wheel, complete with cover and
oil pump. Also remove the thrust washer behind
the idler wheel.
41
48 45 48 46 47 27. Turn the engine over and remove the sump, to-
gether with the external oilpipe. Remove the oil
strainer (45) and oil suction pipe (46). Remove the
oil pressure reduction valve.
36
Group: 21 Short block Repair instructions
Cylinder bore
Check that the cylinder bores are not scored or dam-
aged in other ways.
Measure the cylinder bores at the upper and lower
turning positions for the piston rings (app 10 mm and
100 mm below the engine block plane) and also in the
middle. Measurement should be done with an internal
dial gauge and both along and transverse to the en-
gine block (A and B).
For maximum permissible cylinder diameters, please
refer to Wear tolerances in Technical data.
37
Repair instructions Group: 21 Short block
38
Group: 21 Short block Repair instructions
39
Repair instructions Group: 21 Short block
40
Group: 21 Short block Repair instructions
41
Repair instructions Group: 21 Short block
42
Group: 21 Short block Repair instructions
43
Repair instructions Group: 21 Short block
44
Group: 21 Short block Repair instructions
NOTE! Make sure that the oil hole in the bush lines up
with the drilling in the con rod. Draw a line across the
hole in the con rod and the bush, with a felt tip pen.
Check that the oil duct is open after pressing.
45
Repair instructions Group: 21 Short block
46
Group: 21 Short block Repair instructions
47
Repair instructions Group: 21 Short block
48
Group: 21 Short block Repair instructions
49
Repair instructions Group: 21 Short block
4 3 2 4. Install the bearing caps (2) and tighten the con rod
screws. Tightening torque, please refer to the
Technical Data chapter. Bearing caps must be
installed so that the number markings/paint marks
on con rod and cap coincide.
Undamaged con rod screws do not need to be
changed, they can be put back again.
5. Install the oil suction pipe (3) and oil strainer (4).
Tightening torque, please refer to the Technical
Data chapter. Use a new O - ring.
50
Group: 21 Short block Repair instructions
6. Install the inner rotor (7) and the oil pump cover
(8). Install shims (9), spring (10), spring washer
(11) and lock washer (12).
9 12 7. Adjust the oil pump end float (13) to 0.10 - 0.15
10 mm. Shims (9) are available in thicknesses of
11 0.10; 0.15; 0.20 and 0.50 mm.
8. Install a new, possibly adjusted gasket for the
timing gear cover. Center the cover in front of the
oil pump.
9 Note. Check that the tubular pin (14) in the timing cov-
er can engage in the hole (15) in the oil pump cover.
Turn the cover back and forwards, and center it in the
mid position. The stop arm (16) must be turned and
13 held in place when the timing cover is installed.
51
Repair instructions Group: 21 Short block
19 21 20
52
Group: 21 Short block Repair instructions
1
Measuring the piston height,
installing the cylinder head and
other assembly
2
Also refer to Cylinder head, installation.
1. Clean the cylinder head and engine block mating
planes. Remove any rust from screw holes and
from the threads on the cylinder head screws.
2. Put the valve lifters in their original places.
Difference in height
between pistons and
engine block plane Gasket thickness
0.55 to 0.64 mm 1.2 mm
0.65 to 0.75 mm 1.3 mm
53
Repair instructions Group: 21 Short block
8. Install the push rods (6), valve caps (7) and rock-
er arm mechanism (8) with gasket. Torque the
nuts (9), please refer to Technical Data.
7 9 8 6
14
9. Install the oil supply pipe (10) between the block
13 and the rocker arm mechanism, together with the
oil pressure monitor (11). Install the oil pressure
18 reduction valve (12). Tightening torque, please re-
17
fer to Technical Data.
Turn the crankshaft round a couple of rotations.
15 10 10. Adjust the valve clearance, please refer to
Valves, adjustment.
16 19
11. Install the valve cover (13). Check that the small
ventilation hole in the crankcase ventilation cover
(14) is open.
12. Install copper gaskets for the injectors.
11 Install the injectors (15). Torque please refer to
Technical Data.
13. Install the hollow screw (16) on the injection pump
and the banjo nipple with new copper washers.
12
14. Install new copper gaskets and install the return
D1-30-A fuel pipe (17). Tighten the nuts and connect the
return pipe.
15. Install the fuel supply pipes (18), tightening
torque, please refer to Technical Data.
16. Install the coolant pump (19) with spacer (D1-13-
A) and a new gasket.
20
54
Group: 21 Short block Repair instructions
25 24
23 D1-30-A
22
39
40 27
55
Repair instructions Group: 21 Short block
1
Remove the screw (1) which holds the fuel filter brack-
et to the cylinder head.
Unscrew the valve cover.
Undo the cable (2) for the glow plugs.
2
Undo and remove the injector pipes (1). Undo and re-
move the return fuel pipe (2).
3
Undo the oil supply pipe (1) by the cylinder head.
Unscrew the injectors (2).
56
Group: 21 Short block Repair instructions
4
Remove the push rods (1) and valve caps (2). Mark
them.
Undo the cylinder head screws (3) in the opposite se-
quence to when they are tightened, please refer to
Technical Data. Remove the cylinder head and gas-
ket.
57
Repair instructions Group: 21 Short block
Valves, removing
Cylinder head removed.
1
Remove the busbar (1) and glow plugs (2).
Remove the valves (3) with a valve compressor, tool
nos. 885023 and 885498. Mark the valves.
Remove the valve seals.
Valves, installation
Special tools: 885023, 885498
1
Install the valve (1) in the cylinder head as marked.
Install a new valve seal (2), spring (3) and valve
spring washer (4).
Put the valve compressor in place. Compress the
valve spring and install the collets (5).
2
Install the glow plugs and tighten to the specified
torque, please refer to the Technical Data chapter.
Install the bus bar.
58
Group: 21 Short block Repair instructions
2
Check that the engine block guide pins for the cylinder
head are in place. Install a new cylinder head gasket
with the marking upwards.
Put the cylinder head in place. Insert the screws (1)
and torque them as in the tightening schedule, to the
torque specified in Technical Data.
3
Install the push rods (1) and valve caps (2).
59
Repair instructions Group: 21 Short block
4
Install a new seal on the rocker arm bridge (1). Install
a new rocker arm bridge. Make sure that the push
rods and rocker arms (2) are correctly aligned.
Tighten the nuts (3) evenly to the specified torque,
please refer to the Technical Data chapter.
5
Install the oil supply pipe (1) on the cylinder head with
new seals.
6
Installing the injectors:
Apply sealant part. no. 840879 to the threads of the
two lowest screws (1).
Put new copper seals on the bottom of the cylinder
head.
Install the injectors and tighten them evenly to the
specified torque, please refer to the Technical Data
chapter.
60
Group: 21 Short block Repair instructions
1
Unscrew the seawater pump (1). Remove the end pan-
el (2) and the screws (3).
2
Unscrew the centre nut from the pulley. Install tool no.
885820 on the pulley and remove it.
Remove the Woodruff key from the groove in the shaft
3
Unscrew the injection pump (1). Lift it up until the lock
clip (2) is accessible. Undo the clip and release the
control rod (3).
61
Repair instructions Group: 21 Short block
4
Unscrew the timing gear cover screws (1) and nut (2).
Remove the cover.
5
Undo the fuel pipe from the fuel filter (1).
Unscrew the fuel feed pump (2). Wipe up the fuel that
has run out.
6
Remove the valve lifters with magnetic tool 885822.
62
Group: 21 Short block Repair instructions
7
Rotate the camshaft until the socket cap screw (1) be-
comes visible in the hole in the camshaft drive gear.
Unscrew the socket cap screw and hex head screw
(2). Remove the lock plate (3).
Remove the camshaft regulator sleeve (4).
Pull the camshaft out carefully.
9
Unscrew the remaining screws (1). Remove the timing
gear plate (2).
Undo the crankshaft gear (3) with a puller. Remove
the gear wheel and its Woodruff key.
63
Repair instructions Group: 21 Short block
1
Put the gear wheel (1) and its key on the crankshaft.
Tap the gear wheel on.
Install a new gasket and timing gear plate (2).
Tighten the inner screws (3) on the timing gear plate.
2
Carefully insert the camshaft.
3
Fit the thrust washing (1) in place.
Put the oil pump gear wheel (2) in place. Make sure
that the markings (3) on the gear wheel line up with
the markings (4) on the other gear wheels.
Check the gear flank clearance, please refer to Gear
flank clearance, checking.
64
Group: 21 Short block Repair instructions
4
Install the pump gear (1), end washer (2), shims (3),
spring (4) and bush (5) in the oil pump gear. Put the
circlip (6) on the shaft.
NOTE! Note that the end washer (2) has a hole (7)
which must mate up with the guide pin in the timing
gear cover.
5
Put the control rod (1) on the heel (2) in the timing
gear cover. Turn the stop arm (3) round so that the
control rod is held against the heel.
6
Install the timing gear cover at the same time as the
control rod (1) is held fixed by the stop arm (2).
Put the timing gear cover in place. Make sure that the
control rod ends up in the correct position and that the
pin (3) engages in the hole (4) in the oil pump end
washer.
Screw the timing gear cover down.
65
Repair instructions Group: 21 Short block
7
Put a new O-ring (1) in the groove in the seawater
pump.
Install the rear end piece (2) with a new gasket and its
four screws (3).
8
Install the pulley key on the crankshaft.
Install the pulley and tighten it to the specified torque
with the center nut, please refer to the Technical
Data chapter.
9
Put the valve lifters in place as marked.
D1-20 A
66
Group: 21 Short block Repair instructions
Pistons, removal
Engine oil drained. Cylinder head removed.
1
Turn the engine upside down. Undo the oil drain pipe
anchorage (1) on the cylinder head.
Unscrew the sump (2) and remove it together with the
oil drain pipe (3).
2
Unscrew the oil suction strainer (1). Remove the suc-
tion pipe (2) with its O-ring.
Unscrew the bearing caps (3) for the con rods.
3
Press the pistons out.
NOTE! There might be a soot deposit on the top of
the cylinder bores. Remove the deposit to make it
easier to press the pistons out.
67
Repair instructions Group: 21 Short block
1
Remove the big end bearings (1) and put the new
ones in position.
Pistons, change
1
Note the positions of the pistons in relation to the
crankshaft.
Remove the circlips (1) and press the gudgeon pin out
(2).
2
Clean the gudgeon pin bushing and check it.
3
Install a new piston in the correct position.
Press the gudgeon pin in.
Install the circlips with the lugs facing upwards.
68
Group: 21 Short block Repair instructions
Pistons, installation
1
Also refer to Assembly of pistons, piston rings and
con rod.
Install a piston ring compressor on the piston.
Lubricate the con rod bearing shells and studs with
engine oil.
2
Turn the crankshaft round so that the big end bearing
is in the lowest position for the piston to be installed.
Install the piston (1) in the bore and carefully tap it
down. The piston marking SHIBAURA must face
the injection pump side.
3
Install the big end bearing cap as marked. Torque to
23 Nm (D1-13, D1-20 or 32 Nm (D1-30, D2-40).
Check the movement of the big end bearing.
Repeat the procedure to install the remaining pistons.
69
Repair instructions Group: 21 Short block
Crankshaft, remove
Removed pistons, flywheel and timing gear
1
Unscrew the inner timing gear plate (1).
2
Remove the rear crankshaft seal (1) from the crankshaft.
3
Unscrew the oil pressure reduction valve.
4
Undo the screws (1) which hold the main bearing caps.
Lift the crankshaft out.
NOTE! Tape the crankshaft gear teeth to protect the
bearing when the shaft is pulled out.
70
Group: 21 Short block Repair instructions
1
Unscrew the main bearing retainers (1) and pull them
off the crankshaft.
D2-40
2
Drive out the main bearing bush (1) located in the en-
gine block. Use a suitable mandrel and tap the bush-
ing out from inside the crankcase.
3
Inspect all main bearings (1). Remove them from their
holders.
Check and measure the bearing surfaces (2) on the
crankshaft, please refer to crankshaft inspection.
71
Repair instructions Group: 21 Short block
4
Install the new main bearings and lubricate them with
engine oil.
Install the main bearing retainers (1) on the crankshaft
in accordance with the markings (2). Torque the
screws to 23 Nm.
5
Install the main bearing bush (1) in the engine block.
72
Group: 21 Short block Repair instructions
Crankshaft, assembly
1
Lift the crankshaft into place.
Align the main bearing retainer screw holes (1) before
the crankshaft is pressed into place.
2
Carefully tap the crankshaft into place if necessary,
and torque the main bearing retainers to 27 Nm.
Check that the crankshaft can be turned easily.
3
Install the oil pressure reduction valve with a new
seal. Torque to 64 Nm.
Install a rear crankshaft seal, please refer to Rear
crankshaft seal, changing.
73
Repair instructions Group: 21 Short block
Flywheel, change
1
Remove the engine speed sensor (1) and filter hous-
ing bracket (2).
Remove the flywheel cover (3) and flexible coupling.
2
Unscrew the flywheel (1) and remove it.
Clean and check the crankshaft seal.
3
Carefully clean the crankshaft and flywheel.
Install the new flywheel and tighten it to the specified
torque, please refer to the Technical Data chapter.
Install the flexible coupling, flywheel housing, filter
housing bracket and engine speed sensor.
74
Group: 21 Short block Repair instructions
1
Unscrew the inner timing gear plate (1).
2
Remove the rear crankshaft seal (1).
Check that the area for the crankshaft seal on the en-
gine block, the crankshaft and the inner flywheel
housing are cleaned.
Lubricate the lip of the seal on the new crankshaft
seal with engine oil and put the seal in place.
Apply sealant part no. 840879 all round the crankshaft
seal (2) and the camshaft cover (3).
Fix the inner flywheel plate.
75
Repair instructions Group: 21 Short block
1
Undo the drive belt.
Unscrew the centre nut from the crankshaft pulley. In-
stall tool no. 885820 on the pulley and remove it.
Remove the Woodruff key from the groove in the shaft
2
Insert tool no. 9995919 under the lip of the crankshaft
seal (1) and pull the seal out.
Clean the crankshaft and seal surfaces. Tape the key
groove on the crankshaft to avoid damaging the new
seal during assembly.
3
Lubricate the new crankshaft seal with engine oil and
put it on the crankshaft. Drive the seal into place with
a suitable mandrel.
Remove the tape.
4
Install the pulley key on the crankshaft.
Install the pulley and tighten it to the specified torque
with the center nut, please refer to the Technical
Data chapter.
Install and adjust the drive belt.
76
Group: 21 Short block Repair instructions
Valves, adjustment
Stationary, cold engine
1
Remove the air filter housing (1) and valve housing
(2).
2
D1-13
Crank the engine clockwise until the valves (1) for no.
1 cylinder shift position. Then crank the engine exact-
ly one more turn. You can now adjust the valves for
no. 1 cylinder. Please refer to item 3 for the adjust-
ment procedure.
Crank the engine until the valves (2) for no. 2 cylinder
shift position. Then crank the engine exactly one more
turn. Adjust the valves for no. 2 cylinder.
D1-20, D1-30
Crank the engine clockwise until the valves for no. 1
cylinder shift position. Adjust no. 2 inlet valve (1) and
no. 3 exhaust valve (2). Please refer to item 3 for the
adjustment procedure.
Crank the engine clockwise until the valves for no. 2
cylinder shift position. Adjust no. 3 inlet valve (3) and
no. 1 exhaust valve (4).
Crank the engine clockwise until the valves for no. 3
cylinder shift position. Adjust no. 1 inlet valve (5) and
no. 2 exhaust valve (6).
77
Repair instructions Group: 21 Short block
D2-40
Crank the engine clockwise until the valves for no. 4
cylinder shift position. Adjust no. 1 inlet and exhaust
valve (A). Please refer to item 3 for the adjustment
procedure.
Crank the engine clockwise until the valves for no. 2
cylinder shift position. Adjust no. 3 inlet and exhaust
valve (B).
Crank the engine clockwise until the valves for no. 1
cylinder shift position. Adjust no. 4 inlet and exhaust
valve (C).
Crank the engine clockwise until the valves for no. 3
cylinder shift position. Adjust no. 2 inlet and exhaust
valve (D).
3
Adjustment
Undo the locknut (1) with a ring wrench. Measure the
valve clearance (2) with a feeler gauge. Adjust the
valve clearance with the adjustment screw (3).
The correct valve clearance for all valves and engines
is 0.2 mm.
When the correct valve clearance has been reached,
tighten the locknut (1).
4
Install the valve cover with a new seal.
Install the air filter housing.
Test run the engine and check that no oil leakage oc-
curs.
78
Group: 21 Short block Repair instructions
1
Lightly loosen the lower fixing screws (1) on the alter-
nator. Loosen the upper fixing nut (2).
Loosen the tension screw (3) and slacken the drive
belt. Remove the drive belt.
2
Install a new drive belt. Tension the belts with tension-
er screw. Check the tension.
Tighten the alternator fixing nut and fixing screws.
D1-30, D2-40
79
Repair instructions Group: 22 Lubrication system
1
Drive out the oil pump bearing section (1) located in
the engine block. Tap it out from inside the crank-
case.
2
Use special tool 384 9639 for D1-13 and D1-20, 384
9640 for D1-30 and D2-40.
First screw the guide pin (1) for the tool into the en-
gine block.
Then put the new oil pump bearing (2) into the tool
block (3).
NOTE! It is important that the engine block surface
touching the tool is clean and even. The tool block
must be oiled.
3
Place the tool block with the bearing in place, using
the guide pin.
Tap the bearing into place until the tool bottoms on
the cylinder head.
80
Group: 23 Fuel system Repair instructions
1
Unscrew the stop solenoid (1).
Undo the supply pipe (2) to the injection pump.
Undo the supply pipes (3) and return fuel pipe (4).
2
Unscrew the injection pump (1). Lift it up until the lock
clip (2) is accessible. Undo the clip and release the
control rod (3).
Lift the injection pump out and remove the shim.
81
Repair instructions Group: 23 Fuel system
3
Put a new shim of the same thickness on the pump
housing. Insert the new injection pump into the hous-
ing and fix the control rod with the lock clip.
Fix the oil supply pipe (1) on one of the studs (2).
Tighten the injection pump to the specified torque,
please refer to Technical Data.
Install the supply pipe (3).
5
Install the stop solenoid (1) with a new seal.
Install the fuel return pipe (2).
Install the fuel supply pipes (3) and tighten to the
specified torque, please refer to the Technical Data
chapter.
82
Group: 23 Fuel system Repair instructions
2
Injectors, changing
1
Clean round the injectors (1).
Undo the fuel supply pipes (2) by the injection pump
3
5 and the injectors. Lift the fuel supply pipes away to-
gether.
1
4 Remove the nut (3) at the top of each injector, use the
nut (4) underneath the fuel return pipe (5) to avoid
kinking the pipe. Lift the return fuel pipe away.
Unscrew the injectors. Remove the copper seals un-
der the injectors.
2
Install the new injectors with new copper seals. Apply
sealant, part no. 840 879 to the two lowest threads
(1). Tightening torque, please refer to the Technical
Data chapter.
Install the new return fuel pipe, use the nut underneath
the fuel return pipe to avoid kinking the pipe.
Install the fuel supply pipes. Check that they do not
come out of alignment, and tighten the nuts. Tighten-
ing torque, please refer to the Technical Data chap-
ter.
3
Start the engine and check that no leakage occurs.
83
Repair instructions Group: 23 Fuel system
84
Group: 23 Fuel system Repair instructions
Injectors, testing
Testing is done in an injector tester. During the test,
the opening pressure and sealing are the most impor-
tant things. The spray pattern is more difficult to as-
sess, and does not give a reliable indication of the
injectors status.
Opening pressure
With the pressure gauge connected, press the injector
tester lever down slowly until the injector opens and
releases fuel. Read off the opening pressure at the
opening instant.
If the value read does not coincide with the specified
value, the setting must be changed. This is done with
washers.
Injectors, check
Spray pattern
1. Pump the injector tester, special tool 9999 772,
and check the injector spray pattern. The fuel jet
should be conical and in line with the centerline of
the injector. Fuel drops must not occur in the jet.
2. Check that the fuel jet has a circular cross sec-
tion.
Sealing
When sealing is checked, investigate the fuel leakage
which can occur between the injector nozzle seat and
the tapered sealing surface in the injector sleeve.
1. Wipe the injector nozzle tip dry.
2. Pump the pressure up to about 2 MPa below the
opening pressure of the injector (please refer to
Technical Data). Keep the pressure constant for
about 10 sec. and check that no fuel drips out
from the tip of the injector. Damp injectors can be
approved.
Install protective caps on the injector pipe couplings
and over the injector nozzle tips, if the injectors will
not be used at once.
85
Repair instructions Group: 23 Fuel system
Low idle
1. Check that the gap (6) is about 3 mm when the
accelerator is in the idle position. If necessary:
Undo lock nut (7) and adjust screw (8) to give the
correct gap.
2. Warm the engine up and check the idling speed
with a tachometer (please refer to Technical data
for correct idling speed).
3. Use adjustment screw (2) to adjust to give the
correct idling speed.
4. Check the gap (3) again as in item 1.
86
Group: 23 Fuel system Repair instructions
1
Put a rag under the feed pump to collect spilled fuel.
Undo the unions (1) on the feed pump.
Unscrew the feed pump (2).
2
Put a new O-ring in the feed pump.
Install the feed pump and screw it in place.
Install the fuel unions on the feed pump.
87
Repair instructions Group: 23 Fuel system
1
Put a rag under the filter housing bracket to collect
spilled fuel. Undo the secondary filter (1). This must
be sorted as environmentally hazardous waste.
Undo the fuel unions (2).
Unscrew the hand pump (3) and remove it.
2
Put a new secondary filter in the new hand pump.
Install the hand pump on the bracket.
Screw the fuel unions tight.
Vent the fuel system, please refer to Fuel System,
Venting.
88
Group: 23 Fuel system Repair instructions
2
Press the hand pump (2) located on the fuel filter
bracket until fuel with no air bubbles comes out of the
vent screw. Keep pumping at the same time as the
vent screw is closed.
Pump another 10 strokes.
3
Wipe up the fuel that has run out.
Start the engine and check sealing.
89
Repair instructions Group: 26 Cooling system
Coolant
Mixing
Mix:
40% Volvo Penta Coolant (conc. coolant)
60% water
This mixture prevents against internal corrosion, cavi-
tation and frost bursting down to about 28C. (At
60% glycol concentration, the freezing point is low-
ered to 54C.) Never mix more than 60% concentrate
(Volvo Penta Coolant) in the coolant. This will give re-
duced frost protection and poorer cooling effect, with a
consequent risk of overheating.
Turn the filler cap to the first stop and allow any ex-
cess pressure to hiss out before removing the cap
completely. Top the coolant up as necessary. The
level must be between the MAX and MIN markings.
90
Group: 26 Cooling system Repair instructions
Coolant losses
There are two types of coolant losses:
Coolant losses during operation.
Coolant losses after stopping a hot engine.
Coolant losses during operation can be caused by
poor sealing in the cooling system, or that air or com-
bustion gases are forced into the cooling system and
force coolant out through the pressure cap.
91
Repair instructions Group: 26 Cooling system
Thermostat, change
1
Drain the coolant.
Undo the thermostat housing (1). Remove the O-ring
from the cap.
Remove the thermostat (2) and seal.
2
Install a new thermostat and seal.
Install the thermostat housing cover with a new O-
ring. Tighten the screws to the specified torque,
please refer to Technical Data.
3
Fill up with coolant.
Warm up, and check the sealing and coolant level.
92
Group: 26 Cooling system Repair instructions
1
Undo the heat exchanger end wall on the alternator
side.
Remove the exhaust pipe elbow (1) and hose clamp
(2) from the heat exchanger end wall. Remove the ex-
haust pipe elbow.
Undo the other end wall (3) from the heat exchanger.
2
Take the insert out (1) and scrap it.
3
Install new O-rings (1) on the insert end wall.
Slide the insert in from the alternator side. Screw the
end wall onto the heat exchanger.
4
Install new O-rings (2) on the insert and end wall.
Screw the end wall onto the heat exchanger.
Install the exhaust pipe bend.
5
Fill up with coolant. Check the fluid level and sealing
after warming up.
93
Repair instructions Group: 26 Cooling system
Heat exchanger/exhaust
manifold, changing
Current cut off with the main switch. Drained cool-
ing system and sea water. Expansion tank and
bracket removed (D1-30, D2-40).
1
Undo the hose union on the exhaust pipe elbow.
Unscrew the distribution box (1) and fold it to one
side.
2
Undo the hose connections (1).
Undo the screws (2) and carefully prise the heat ex-
changer/exhaust manifold away.
Remove the gasket.
3
Clean the sealing surfaces of the cylinder head.
Transfer the exhaust pipe elbow to the new heat ex-
changer/exhaust manifold.
Install the new heat exchanger/exhaust manifold and
gasket. Start to tighten the screws from the center
and then outwards. Torque to 10 Nm.
Install the distribution box on the exhaust manifold.
4
Install the hose unions and junction to the exhaust
pipe elbow.
Fill up with coolant.
Warm up, and check the sealing and coolant level.
94
Group: 26 Cooling system Repair instructions
1
Unscrew all screws on the cover (1).
2
Remove the impeller (1) with water pump pliers.
3
Clean the pump housing and sealing surfaces.
4
Grease the new impeller and housing. Put the impeller
and a new gasket in the housing.
Screw the cover down.
Open the sea cock and start the engine. Check the
sealing.
95
Repair instructions Group: 26 Cooling system
1
Undo the hose connections (1) for the seawater pump.
Undo the four screws (2) which hold the seawater
pump.
2
Remove the seawater pump and the O-ring.
Check the mating surfaces.
NOTE! Check the seawater pump gear wheel. If it is
damaged, the idler gear must be changed as well.
3
Install a new sea water pump and O-ring.
Install the screws and hose unions.
Open the sea cock and run the engine. Check the
sealing.
96
Group: 26 Cooling system Repair instructions
2
Undo the temperature sensor connector (1).
Loosen the screws (2) and nut (3) which hold the cool-
ant pump and alternator stay (4).
Remove the coolant pump and alternator stay.
D1-13:
Also remove the spacer which is located between the
coolant pump and engine block.
3
Clean the sealing surfaces.
Transfer the temperature sensor, hose union and pul-
ley to the new coolant pump.
4
Install the new coolant pump with new seals, spacer
(D1-13) and alternator stay.
Install and tension the drive belt.
Install the hose connections.
5
Fill up with coolant.
Warm up, and check the sealing and coolant level.
97
Repair instructions Group: 30 Electrical system
Alternator, changing
Current cut off with the main switch
1
Mark and undo all electric connections to the alterna-
tor.
2
Loosen the upper fixing nut (1).
Undo the tension screw (2) to release the upper fixing
screw (3) for the alternator.
Unscrew the lower fixing screw (4) and remove the al-
ternator.
3
Put the new alternator in position and tighten the lower
fixing screw. Tighten it loosely.
Put the upper fixing screw in position and lightly tight-
en the upper fixing nut. Screw the tension screw into
the fixing screw.
Put the drive belt in place and tension it with the ten-
sion screw.
4
After checking the drive belt tension, tighten the lower
fixing screw and upper fixing nut.
Install the electric connections on the alternator.
98
Group: 30 Electrical system Repair instructions
1
Undo all electric connections (1) to the start solenoid.
2
Undo the screws (2) which hold the starter motor.
Lift the starter motor out.
3
Put the new starter motor in position and fix it with the
screws.
Install the electric connections on the starter motor.
4
Switch the current on and check the starter motor
function.
99
Wiring diagram
Wiring diagram
Engine
1. Battery
2. Starter motor
3. Alternator
4. Main switch
5. Glow plugs
6. Oil pressure monitor
7. Stop solenoid
8. Coolant temperature monitor
9. Coolant temperature sensor
10. Circuit breaker, 16 A
11. Starter relay
12. Glow plug relay
13. Charge sensing resistor, 33 Ohm/9W
14. Engine speed sensor
Cable colors
BL = Blue OR = Orange
LBL = Light blue R = Red
BN = Brown SB = Black
LBN = Light brown W = White
GN = Green Y = Yellow
GR = Gray
Cable areas in mm2 are specified after the color code in the wiring schedule.
Cable areas not specified = 1.5 mm.
Cables shown with broken lines are not supplied by Volvo Penta.
100
Wiring diagram
101
Wiring diagram
102
Technical data
General
Engine designation ................................................................. D1-13-A D1-20-A D1-30-A D2-40-A
Number of cylinders ............................................................... 2 3 3 4
Cylinder diameter, mm (in) .................................................... 67 (2.64) 67 (2.64) 77 (3.03) 77 (3.03)
Stroke length, mm (in) ............................................................ 72 (2.83) 72 (2.83) 81 (3.19) 81 (3.19)
Displacement, total litres (cu.in) ............................................. 0.51 (31) 0.76 (46.5) 1.13 (69.1) 1.51 (92.1)
Power .................................................................................... See sales literature
Idling speed, rpm ................................................................... 850 25
Rated speed, rpm ................................................................... 3200
Compression ratio .................................................................. 23.5:1 23.5:1 23:1 23.5:1
Compression at 250 rpm, repair limit, kPa (psi) ...................... 2450 (355)
Firing order (highest cyl. No. closest to flywheel) ................... 1-2 1-2-3 1-2-3 1-3-4-2
Pistons
Material .................................................................................. Aluminium Alloy
Diameter, mm (in)
D1-13-A, D1-20-A ................................................................... 66.9375 66.9525 (2.6353 2.6359)
Service limit ...................................................................... 66.7 (2.6260)
D1-30-A, D2-40-A ................................................................... 76.932 76.947 (3.0288 3.0294)
Service limit ...................................................................... 76.7 (3.020)
Piston clearance to the cylinder, mm (in)
D1-13-A, D1-20-A ................................................................... 0.048 0.082 (0.0019 0.0032)
Service limit ...................................................................... 0.25 (0,010)
D1-30-A, D2-40-A ................................................................... 0.0525 0.0865 (0.00210 0.00340)
Service limit ...................................................................... 0.25 (0,010)
Front marking The SHIBAURA name on the inside of the
piston must be facing the fuel pump on assembly
Piston rings
Compression ring, number ..................................................... 2
Oil ring, number ..................................................................... 1
Top compression ring:
Clearence between groove and ring, all engines, mm (in) ...... 0.06 0.10 (0.0024 0.0039)
Service limit, all engines , mm (in) .................................... 0.25 (0.0098)
Gap of piston ring, mm (in)
D1-13-A, D1-20-A ................................................................... 0.13 0.25 (0.0051 0.0098)
D1-30-A, D2-40-A ................................................................... 0.15 0.27 (0.0059 0.0106)
Service limit, allengines, mm (in) ...................................... 1.0 (0.039)
2nd compression ring:
Clearence between groove and ring, all engines, mm (in) ...... 0.05 0.09 (0.0020 0.0035)
Service limit, all engines, mm (in) ..................................... 0.25 (0.0098)
Gap of piston ring, mm (in)
D1-13-A, D1-20-A ................................................................... 0.10 0.22 (0.0039 0.0087)
D1-30-A, D2-40-A ................................................................... 0.12 0.24 (0.0047 0.0094)
Service limit, all engines, mm (in) ..................................... 1.0 (0.039)
103
Technical data
Oil ring:
Clearence between groove and ring, all engines, mm (in) ...... 0.02 0.06 (0.0008 0.0024)
Service limit, all engines ................................................... 0.15 (0.0059)
Gap of piston ring, mm (in)
D1-13-A, D1-20-A ................................................................... 0.10 0.30 (0.0039 0.0118)
D1-30-A, D2-40-A ................................................................... 0.20 0.35 (0.0079 0.0138)
Service limit, all engines ................................................... 1.0 (0.039)
Piston pins
Diameter, mm (in)
D1-13-A, D1-20-A ................................................................... 18.998 19.002 (0.7480 0.7481)
Service limit ...................................................................... 18.98 (0.7472)
D1-30-A, D2-40-A ................................................................... 20.996 21.002 (0.8266 0.8269)
Service limit ...................................................................... 20.98 (0.826)
Clearence between hole and pin, all engines, mm (in) ........... 0.004 to +0.004 (0.00016 to +0.00016)
Service limit ...................................................................... 0.02 (0.0008)
Cylinder block
Diameter of the bore in the cylinder block, mm (in):
D1-13-A, D1-20-A ................................................................... 67.000 67.019 (2.6378 2.6385)
Service limit ...................................................................... 67.200 (2.6457)
D1-30-A, D2-40-A ................................................................... 77.000 77.019 (3.0310 3.0320)
Service limit ...................................................................... 77.200 (3.0390)
Flatness of the top of the cylinder block, mm (in) ................... Less than 0.05 (0.002)
Service limit ...................................................................... 0.12 ( 0.005)
Cylinder head
Distortion of the cylinder head, mm (in) .................................. 0.00 0.05 (0.000 0.002)
Max. service limit, mm (in) ................................................ 0.12 (0.005)
Max. limit for regrinding the cylinder head, mm (in) ........... 0.15 (0.006)
Selection of cylinder head gasket:
Piston height above top face of cylinder block, mm (in) ......... 0.55 0.64 (0.0217 0.0252)
Choose gasket with thickness, mm (in) ............................. 1.2 (0.047)
Piston height above top face of cylinder block, mm (in) ......... 0.65 0.75 (0.0256 0.0295)
Choose gasket with thickness, mm (in) ............................. 1.3 (0.051)
Rocker shaft
Diameter of the rocker shaft, mm (in):
D1-13-A, D1-20-A ................................................................... 9.950 9.968 (0.3917 0.3924)
Service limit ...................................................................... 9.87 (0.3886)
D1-30-A, D2-40-A ................................................................... 11.65 11.67 (0.4587 0.4595)
Service limit ...................................................................... 11.57 (0.4555)
Rocker arm clearance on the rocker shaft, mm (in):
D1-13-A, D1-20-A, Min. permissible clearance ....................... 0.032 0.065 (0.00126 0.00260)
D1-30-A, D2-40-A, Min. permissible clearance ....................... 0.032 0.068 (0.00126 0.00268)
Max. permissible clearance, all engines ................................. 0.2 (0.008)
104
Technical data
Crankshaft
Thrust washers:
Standard thickness, mm (in) .................................................. 21.85 21.95 (0.8602 0.8642)
Service limit ...................................................................... 21.60 (0.8504)
NOTE! The thrust washers is machined into the holder for the main bearing
Crankshaft end play, mm (in) ................................................. 0.10 0.30 (0.0040 0.0118)
Service limit ...................................................................... 0.50 (0.0197)
Crankshaft deflection, mm (in) ............................................... 0.30 or less (0.0011)
Service limit ...................................................................... 0.06 (0.0023)
Front crankshaft bush, diameter in mm (in), bearing journal :
Standard, D1-13-A and D1-20-A ........................................ 42.964 42.975 (1.69150 1.69193)
Service limit ................................................................. 42.90 (1.6890)
Standard, D1-30-A and D2-40-A ........................................ 47.965 47.975 (1.88830 1.88880)
Service limit ................................................................. 47.90 (1.8858)
NOTE! No undersize bush bearing journals are available
D1-20-A
Diameter in mm (in), standard, bearing journal
No. 1 and 2 ......................................... 42.964 42.975 (1.69150 1.69193)
Service limit .................................. 42.90 (1.6890)
No. 3 .................................................. 45.948 45.959 (1.80897 1.80941)
Service limit .................................. 45.90 (1.8071)
NOTE! No undersize main bearing journals are available
D1-30-A
Diameter in mm (in), standard, bearing journal
No. 1 and 2 ......................................... 47.965 47.975 (1.88830 1.88880)
Service limit .................................. 47.90 (1.8858)
No. 3 .................................................. 47.954 47.965 (1.88800 1.88830)
Service limit .................................. 47.90 (1.8858)
NOTE! No undersize main bearing journals are available
D2-40-A
Diameter in mm (in), standard, bearing journal
No. 1, 2 and 3 ..................................... 47.965 47.975 (1.88830 1.88880)
Service limit .................................. 47.90 (1.8858)
No. 4 .................................................. 47.954 47.965 (1.88800 1.88830)
Service limit .................................. 47.90 (1.8858)
NOTE! No undersize main bearing journals are available
105
Technical data
D1-30-A, D2-40-A
Diameter in mm (in), bearing journal
Standard ...................................................................... 40.964 40.975 (1.6128 1.6132)
Service limit ......................................................... 40.90 (1.6102)
NOTE! No undersize rod bearing journals are available
Connecting rods
Piston pin bearing:
Clearance between the piston pin and the piston pin
bearing, mm (in) ..................................................................... 0.010 0.025 (0.00040 0.00099)
Service limit, D1-13-A, D1-20-A ........................................ 0.10 (0.004)
Service limit, D1-30-A, D2-40-A ........................................ 0.08 (0.0031)
Connection rod bearing:
Clearance between the connecting rod bore and
the connecting rod bearing, mm (in) ....................................... 0.10 0.30 (0.004 0.012)
Service limit ...................................................................... 0.70 (0.0276)
106
Technical data
Camshaft
Drive ...................................................................................... Gear Wheel
Height of the camshaft lobe for the inlet and outlet valves,
all engines, mm (in) ................................................................ 26.955 27.010 (1.0612 1.0634)
Service limit ...................................................................... 26.5 (1.0430)
Height of the camshaft lobe for the fuel injection pump,
all engines, mm (in) ................................................................ 39.900 40.100 (1.5709 1.5787)
Service limit ...................................................................... 39.8 (1.5669)
Height of the camshaft lobe for the fuel priming pump,
all engines, mm (in) ................................................................ 27.900 28.000 (1.0984 1.1024)
Service limit ...................................................................... 27.0 (1.0630)
Valves
Inlet
Spindle diameter in mm (in) .................................................... 6.955 6.970 (0.27382 0.27441)
Service limit ...................................................................... 6.89 (0.271)
Valve disc edge in mm (in) ..................................................... 0.925 1.075 (0.03642 0.04232)
Service limit ...................................................................... 0.5 (0.02)
Valve depth below the cylinder head face in mm (in) .............. 0.65 0.95 (0.0256 0.0374)
Service limit ...................................................................... 1.8 (0.071)
Clearance in mm (in), valve spindle guide .............................. 0.025 0.052 (0.0010 0.0020)
Service limit ...................................................................... 0.2 (0.008)
Seat angle in cylinder head .................................................... 45o
Seat contact face in cylinder head ......................................... 1.70 2.10 (0.0670 0.0830)
Service limit, mm (in) ........................................................ 2.5 (0.098)
Valve lash in mm (in), cold engine ......................................... 0.20 (0.008)
Outlet
Spindle diameter in mm (in) .................................................... 6.940 6.950 (0.27323 0.27362)
Service limit, mm (in) ........................................................ 6.84 (0.269)
Valve disc edge in mm (in) ..................................................... 0.925 - 1.075 (0.03642 - 0.04232)
Service limit, mm (in) ........................................................ 0.5 (0.02)
Valve depth below the cylinder head face in mm (in) .............. 0.85 1.15 (0.0335 0.0453)
Service limit, mm (in) ........................................................ 1.8 (0.071)
Clearance in mm (in), valve spindle guide .............................. 0.045 0.072 (0.0020 0.0030)
Service limit, mm (in) ........................................................ 0.25 (0.010)
Seat angle in cylinder head .................................................... 45o
Seat contact face in cylinder head ......................................... 1.70 2.10 (0.0670 0.0830)
Service limit, mm (in) ........................................................ 2.5 (0.098)
Valve lash in mm (in), cold engine ......................................... 0.20 (0.008)
Valve springs
Length in mm (in) uncompressed ........................................... 35.0 (1.377)
Length in mm (in) with 79.4 N (58.56 ft.lbf) compression ....... 30.4 (1.196)
107
Technical data
Gear group
Max. backlash for all gears, mm (in) ...................................... 0.25 (0.010)
Min. backlash for all gears, mm (in) ....................................... 0.08 (0.003)
Lubrication system
Oil pressure in kPa (psi), hot engine at high idle ....................... 196 441 (28.4 64)
Oil pressure in kPa (psi), hot engine at low idle ........................ >48 (7)
Relief valve, opening pressure in kPa (psi)
D1-13-A, D1-20-A ................................................................ 352 448 (51 65)
D1-30-A, D2-40-A ................................................................ 304 500 (44 73)
Oil pump:
Clearance, in mm (in), inner outer rotor ............................... 0.01 0.15 (0.0004 0.0059)
Service limit ........................................................................ 0.25 (0.0098)
Axial clearance between the face of oil pump cover
and the face of the idler gear, in mm (in) ................................ 0.01 0.15 (0.0004 0.0059)
Service limit ........................................................................ 0.20 (0.008)
Shims available for adjustning the axial clearance, mm ........ 0.10, 0.15, 0.20, 0.50
Oil quality as per API system ................................................ VDS-2
ACEA E5
API CH-4
Viscosity at -5 to +50C* (+23 to +122F)* .............................. SAE 15W/40
SAE 20W/50
Max. oil volume excl. oil filter, no engine tilt, litres (US gal):
D1-13-A ............................................................................... 1.9 (0.50)
D1-20-A ............................................................................... 2.8 (0.74)
D1-30-A ............................................................................... 3.5 (0.92)
D2-40-A ............................................................................... 6.5 (1.72)
Oil change interval
D1-13-A, D1-20-A, D1-30-A ................................................. 200 h or 12 months
D2-40-A ............................................................................... 500 h or 12 months
* Note: Temperatures with stable ambient temperature.
Fuel system
Feed pump max. suction height in m (ft) ................................ 0.8 (2.62)
Feed pressure in kPa (lbf/in2) ................................................. 15 25 (2.1 3.6)
Pump element, diameter in mm (in) ....................................... 5 (0.1968) 5 (0.1968) 6 (0.2362) 5.5 (0.2165)
Stroke length in mm (in) ......................................................... 6.5 (0.2559) 6.5 (0.2559) 6 (0.2362) 6 (0.2362)
108
Technical data
Injector
Opening pressure (checking), MPa (psi)
D1-13-A, D1-20-A, D2-40-A .................................................... 11.77 (1707)
D1-30-A .................................................................................. 14.71 (2133)
Jet angle ................................................................................ 4o
Exhaust system
Permitted Max. back pressure in the exhaust line at rated speed,
all engines, kPa (psi) ............................................................. 20 (2.9)
Cooling system
Type ...................................................................................... Overpressure, closed cooling system
Fresh water system volume, approx, litres (US gal)
D1-13-A ............................................................................... 2.7 (0.71)
D1-20-A ............................................................................... 3.0 (0.79)
D1-30-A ............................................................................... 4.1 (1.08)
D2-40-A ............................................................................... 6.4 (1.69)
Thermostat, number ............................................................... 1 st
Thermostat begins to open at ................................................. 90oC (194oF)
fully open at ........................................................................ 105oC (221oF)
Coolant, Glycol/water, mixing ratio ......................................... 40/60
Electrical system
System voltage ...................................................................... 12 V
Fuse (automatic) .................................................................... 16 A
Battery capacity (starter battery)
D1-13-A, D1-20-A, D1-30-A .................................................... 70 Ah
D2-40-A .................................................................................. 88 Ah
Glow plug:
rated voltage ....................................................................... 11V
current ................................................................................ 11A
Alternator
Output voltage at +20oC (+68oF) ............................................. 14,2 0,15 V
Max. current ........................................................................... 115 A
Suppressor capacitor ............................................................. 2.2 mikroF
Starter motor
Starter motor, power approx.
D1-13-A, D1-20-A .............................................................. 0.8 kW
D1-30-A ............................................................................ 1.1 kW
D2-40-A ............................................................................ 1.4 kW
109
Technical data
Cylinder head*
D1-13-A ......................................................................................... 36.5 (26.9)
D1-20-A ......................................................................................... 36.5 (26.9)
D1-30-A ......................................................................................... 51 (37.6)
D2-40-A ......................................................................................... 51 (37.6)
Main bearing:
Bolts of the holder for the main bearing ........................................ 23 (16.9)
Retaining bolts for the crankshaft ................................................. 27 (19.9)
Connecting Rod:
D1-13-A, D1-20-A ......................................................................... 23 (17)
D1-30-A, D2-40-A ......................................................................... 32 (23.6)
Front housing .................................................................................... 10 (7.4)
Flywheel backplate:
D1-13-A, D1-20-A ......................................................................... 25 (18.4)
D1-30-A, D2-40-A ......................................................................... 50 (36.9)
Flywheel housing ............................................................................. 25 (18.4)
Flywheel ........................................................................................... 74 (55)
Crankshaft pulley:
D1-13-A, D1-20-A ......................................................................... 93 (68.6)
D1-30-A, D2-40-A ......................................................................... 123 (90.7)
Flexible coupling .............................................................................. 8.5 11.5 (6.3 8.5)
Suction strainer, oil pump ................................................................. 11 (8)
Sump ................................................................................................ 11 (8)
Drain plug, sump .............................................................................. 34 (25)
Camshaft, setscrews for retainer plate ............................................. 11 (8)
Rocker shaft housing:
D1-13-A, D1-20-A ......................................................................... 9.5 (7)
D1-30-A, D2-40-A ......................................................................... 23 (17)
Valve mechanism cover:
Setscrews ...................................................................................... 11 (8)
Cap nuts ........................................................................................ 10 (7.3)
Rocker arm locknut ........................................................................... 14 (10)
Fuel injection pump:
Mounting nuts and screws ............................................................ 6 (4.4)
Delivery valve holders .................................................................. 42 (31)
Pressure oil pipe (cylinder block cylinder head) ........................... 12 (9)
Injector .............................................................................................. 64 (47.2)
Delivery pipe:
D1-13-A, D1-20-A, D2-40-A .......................................................... 20 (14.8)
D1-30-A ......................................................................................... 23 (17)
Lock screw (max. fuel volume) ......................................................... 13 16 (9.6 11.8)
Lock screw (speed) .......................................................................... 13 16 (9.6 11.8)
Exhaust manifold .............................................................................. 10 (7.3)
Fuel shutoff solenoid ........................................................................ 17 (13)
Fuel pump:
Adjustment screw .......................................................................... 2.5 (1.8)
Mounting screws ........................................................................... 6 (4.4)
Glow plug .......................................................................................... 11.5 (8.5)
Oil pressure switch and adapter ...................................................... 11 (8)
Coolant temperature switch ............................................................. 27 (20)
Coolant drain plug (plastic) .............................................................. 3 (2.2)
Coolant thermostat housing ............................................................. 14 (10)
Oil relief valve ................................................................................... 64 (47)
Starter motor, contacts ...................................................................... 9.8 11.8 (7.2 8.7)
110
Technical data
M5 .................................. 5 Nm
M6 .................................. 10 Nm
M7 .................................. 17 Nm
M8 .................................. 24 Nm
M10 ................................ 50 Nm
M12 ................................ 80 Nm
M14 ................................ 130 Nm
Tightening sequence
Cylinder head
D2-40
D1-20, D1-30
D1-13
111
Technical data
Conversion table
Metric to American or UK units:
American or UK to Metric units:
To convert To convert
from To Multiply by from To Multiply by
Length mm inch 0.03937 inch mm 25.40
cm inch 0.3937 inch cm 2.540
m foot 3.2808 foot m 0.3048
Area mm sq.in. 0.00155 sq. in. mm 645.2
m sq. ft. 10.76 sq. ft. m 0.093
Volume cm cu. in. 0.06102 cu. in. cm 16.388
liter, dm sq. ft. 0.03531 cu. ft. liter, dm 28.320
liter, dm cu. in. 61.023 cu. in. liter, dm 0.01639
liter, dm imp. gallon 0.220 imp. gallon liter, dm 4.545
liter, dm U.S. gallon 0.2642 U.S. gallon liter, dm 3.785
m cu. ft. 35.315 cu.ft. m 0.0283
Power N lbf 0.2248 lbf N 4.448
Weight kg lb. 2.205 lb. kg 0.454
Power kW hp (metric) 1) 1.36 hp (metric) 1) 1.36 0.735
kW bhp 1.341 bhp kW 0.7457
kW BTU/min 56.87 BTU/min kW 0.0176
Torque Nm lbf ft 0.738 lbf ft Nm 1.356
Pressure Bar psi 14.5038 psi Bar 0.06895
MPa psi 145.038 psi MPa 0.006895
Pa mm Wg 0.102 mm Wg Pa 9.807
Pa in Wc 0.004 in Wg Pa 249.098
kPa in Wg 4.0 in Wg kPa 0.24908
mWg in Wg 39.37 in Wg mWg 0.0254
Energy kJ/kWh BTU/hph 0.697 BTU/hph kJ/kWh 1.435
Work kJ/kg BTU/lb 0.430 BTU/lb kJ/kg 2.326
MJ/kg BTU/lb 430 BTU/lb MJ/kg 0.00233
kJ/kg kcal/kg 0.239 kcal/kg kJ/kg 4.184
Fuel g/kWh g/hph 0.736 g/hph g/kWh 1.36
consum- g/kWh lb/hph 0.00162 lb/hph g/kWh 616.78
ption
Inertia kgm lbft 23.734 lbft kgm 0.042
Flow, gas m/h cu.ft./min. 0.5886 cu.ft./min. m/h 1.699
Flow,
fluid m/h US gal/min 4.403 US gal/min m/h 0.2271
Speed m/s ft./s 3.281 ft./s m/s 0.3048
mph knot 0.869 knot mph 1.1508
Temp. F=9/5 x C+32 C=5/9 x (F32)
112
Notes
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References to Service Bulletins
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Date: ................................................................
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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Gteborg
Sweden
7745200 English 032006