service and maintenance

13L Industry
 © 2017 AB VOLVO PENTA
Volvo Penta reserves the right to make changes
Printed on environmentally friendly paper
 Table of Content
Safety Information ...................................................................................... 3
Spare parts - safety ................................................................................... 5
General Information .................................................................................. 11
Service Protocol ...................................................................................... 12
Preventive repair ..................................................................................... 13
Genuine Volvo Penta Parts ..................................................................... 17
Illustrations .............................................................................................. 18
Chemical products .................................................................................... 19
Chemical products .................................................................................. 19
Specifications ............................................................................................ 20
Engine Decals ......................................................................................... 20
General Tightening Torques ................................................................... 21
Specifications .......................................................................................... 22
Engine ........................................................................................................ 24
Component location ................................................................................ 24
Maintenance Schedule ............................................................................ 26
General inspection .................................................................................. 27
General advice for electronic protection .................................................. 29
Check software status ............................................................................. 30
Reading Ash Load, DPF ......................................................................... 30
Air Filter ................................................................................................... 31
Crankcase Ventilation, Filter Change ...................................................... 32
Air filter Compressor, filter replace .......................................................... 33
Valves, Adjustment ................................................................................. 33
Lubrication System ................................................................................... 34
When you work with Chemicals, Fuel and Lubrication Oil, Change ........ 34
Engine Oil, Level Check .......................................................................... 34
Engine oil, change ................................................................................... 36
Oil filter, Change ..................................................................................... 38
Fuel System ............................................................................................... 42
General ................................................................................................... 42
Fuel Pre-filter, Change ............................................................................ 43
Fuel filter, Change ................................................................................... 48
Fuel system, bleeding ............................................................................. 50
Exhaust System ........................................................................................ 53
Turbocharger, Inspection ........................................................................ 53
Charge Air Pipe, Leakage Check ............................................................ 54
EGR cooler .............................................................................................. 55
SCR System ............................................................................................ 56
Nox-sensor Pre/Post SCR ...................................................................... 59
Particulate Filter Insert, Replace ............................................................. 61
Cooling System ......................................................................................... 63
Coolant Level, Checking and Topping Up ............................................... 63
Radiator Assembly, Change ................................................................... 67
Drive belt, change ................................................................................... 72
Long-Term Storage ................................................................................... 76
Storage instruction for long-term storage of new engine ........................ 78
Cleaning engine and transmission .......................................................... 80
Checklist .................................................................................................. 82
Battery, Maintenance .............................................................................. 83

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 Index ........................................................................................................... 85

2 47709849 03-2020 © AB VOLVO PENTA

Safety Information
This chapter describes how safety precautions are If anything remains unclear or if you are unsure of
presented in the manual and on the product. Read the something, contact your Volvo Penta dealer for
chapter through very carefully before you start the assistance.
engine or do any maintenance or service. It has to do
with your safety; an incorrect operation can lead to IMPORTANT:
personal injury and damage to products or property. Always follow local safety instructions and
It also gives you an introduction to the basic safety regulations.
rules for using and looking after the engine.

Safety texts have the following order of priority:

DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.

WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious
personal injury.

CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
personal injury.

IMPORTANT:
Indicates a situation, which, if not avoided, could result in property damage.

NOTICE! Used to draw attention to important information that facilitates work or

operations.

!
This symbol is may be used on the product to call your attention to the fact that this is
safety information. Always read such information very carefully.

Make sure that warning and information symbols on the engine are clearly visible and
legible. Replace symbols that have been damaged or have been painted over.

In some cases, this symbol is used on our products and refers to important information
in the Operator’s Manual.

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Safety Information

Most chemicals such as engine and transmission oils,

glycol, petrol and diesel oil and chemicals used in
workshops such as degreasing agents, paint and
solvents are harmful to health.

Carefully read the instructions on the product

packaging! Always follow the safety regulations, such
as the use of protective masks, goggles, gloves, etc.
Make sure that other personnel are not exposed to
substances that are hazardous to health. Ensure good
ventilation.

Manage used and leftover chemicals in the prescribed

manner.

Personal safety equipment

CAUTION!
Always use appropriate safety equipment. Personal
protective equipment does not eliminate the risk of
injury but it will reduce the degree of injury if an
accident does happen.

Some examples are ear protection, eye and face

protection, protective footwear, personal protective
equipment, head protection, protective clothing,
gloves and respirators.

WARNING!
Ensure that all machine guards and safety devices are
in place and are functional.
P0024482

CAUTION!
Never use tools or products that show signs of
damage.

Protect your eyes

CAUTION!
Wear safety glasses.

Always wear safety glasses if there is a risk of

splintering, sparks and spray from the electrolyte (so-
called battery acid), or other chemicals. Your eyes are
very delicate and damage can result in loss of sight!

Protect your skin

CAUTION!
Risk of skin damage.

Avoid getting oil on your skin! Prolonged or repeated

exposure to oil can dry out the skin. Thereafter,
irritation, dryness and eczema and other skin problems
may occur.

Use protective gloves and avoid oil-soaked clothes

and rags. Wash regularly, especially before eating.
Wear suitable protective creams to prevent skin from
drying out and to facilitate cleaning.

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 Safety Information

Fire safety
WARNING!
Fire and Explosion Risk!
Accidental spark could ignite fuel vapors.

All fuels – as well as many lubricants and chemicals –

are flammable. Do not allow open flames or sparks
near them. Smoking forbidden! Hydrogen from the
batteries is also very flammable and explosive in
certain mixture with air.

Ensure that the workplace is well ventilated and take

the necessary precautions before welding or grinding
begins. Always ensure that there is a fire extinguisher
close at hand in the work area.
P0024470

Spare parts - safety

WARNING!
Always use Volvo Penta genuine spare part to
minimize the risk of an explosion or fire.

Components in fuel systems and electrical systems on

Volvo Penta engines are designed and manufactured
to minimize the risk of explosions and fire, in
accordance with applicable legal requirements.

Used oils, filters and chemicals etc.

WARNING!
Risk of fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire.

Oil-soaked rags can spontaneously ignite under

certain circumstances.

IMPORTANT:
Used fuel and oil filters are environmentally hazardous
waste and must be taken to an approved waste
management facility for correct handling, as must any
used lubricating oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.

Prevent start of the engine

WARNING!
Immobilize the engine by turning off the power supply
with the main switch(es) and lock it (them) in the off
position before starting work. Place a warning notice
at the main switch.
If the engine is equipped with BMS (Battery
Management System), always disconnect both battery
cables from the battery terminals.

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Safety Information

Ventilation when running the engine

WARNING!
Only start the engine in a well-ventilated area. If
operating the engine in a closed area ensure that there
is exhaust ventilation leading out of the work area to
remove exhaust gases and crankcase ventilation
P0024481 emissions.

The engine must not be operated in areas where there

are explosive materials or stored gas.

Rotating parts and hot surfaces

DANGER!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
If the engine is in operation and operates another
device, you must not, under any circumstances,
staying close to the engine.
P0024808
Work on running engines is strictly prohibited. There
are however adjustments that require the engine to be
run. Approaching a running engine is a safety risk.
Loose clothing and long hair can get caught in the
rotating parts; careless movements or a dropped tool
can lead to serious personal injury.

Be careful to avoid hot surfaces (exhaust pipes,

turbochargers, charge air manifolds, start elements
etc.) and hot fluids in pipes and hoses on engines that
are running or have just stopped. Re-install all
protective covers that were removed during
maintenance work before starting the engine.

Information on the engine

IMPORTANT:
Make sure that all warning and information decals on
the product are always visible. Replace decals which
have been damaged or painted over.

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 Safety Information

Prohibition on use of start spray

WARNING!
Never use start spray or similar agents to start an
engine. This may cause an explosion in the inlet
manifold. Risk of personal injury.

P0024483

Before start of engine

WARNING!
Never start the engine if there is reason to suspect fuel
and/or gas leaks, or if there is explosive material
nearby.

IMPORTANT:
Only start the engine with the air filter and protective
caps fitted. Foreign objects in the inlet line could cause
machine damage. Also make sure that no tools or other
P0024688 parts have been left next to the engine.

WARNING!
Never start the engine with the valve cover removed.
There is a risk of personal injury.
For engines with turbochargers, the rotating
compressor turbine can in addition cause serious
personal injuries.

Before any work on the electrical system

WARNING!
Always stop the engine first. Then disconnect the
current at the main switches and any external power
supply before working on the electrical system – to
minimize the risk of electrical hazards.

IMPORTANT:
Never disconnect the current using the main switches
when the engine is running or by disconnecting the
battery cables.
The alternator and electronics could be damaged.

Avoid damage to the engine control

module and other electronics
IMPORTANT:
Switch off the main switch before connecting or
disconnecting a connector.

Before any work on the cooling system

WARNING!
Stop the engine and let it cool before starting work on
the cooling system. Hot fluids and hot surfaces can
cause burns.

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Safety Information

Hot coolant under pressure

CAUTION!
Hot coolant can cause burns. Avoid opening the filler
cap for the coolant when the engine is still hot. Steam
or hot coolant can spray out and system pressure is
lost.

Open the filler cap slowly, and release the pressure in

the cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose must be removed
from a hot engine.

Hot oil under pressure

CAUTION!
Hot oil can cause burns. Avoid getting hot oil on the
skin. Ensure that the lubrication system is not
pressurized before starting any work. Never start or
operate the engine without the oil filler cap is on. There
is a risk that hot oil can spray out.

At any leak detection on the fuel system

WARNING!
Wear safety goggles!
Be extremely careful when searching for leaks in the
fuel system high-pressure circuits. There is very high
pressure in the jet from pipes and injectors. The fuel
may penetrate the tissue and cause serious risk of
P0024488
blood infection (septicemia).

Handling of fuel pipes

IMPORTANT:
High pressure pipes for fuel must not be bent or
straightened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.

Before any work on the fuel system —

Cleanliness
IMPORTANT:
Take great care to keep the fuel system components
clean. Even minimal amounts of dirt can cause engine
breakdown.

Safe handling of batteries

WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.

A spark caused by an incorrectly connected battery

can be sufficient for the battery to explode resulting in
serious injury and damage.

Do not touch the connections during a starting attempt.

Spark hazard! Do not lean over batteries.

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 Safety Information

Correct polarity of the batteries

IMPORTANT:
Make sure that the positive (+) and negative (–) battery
cables are correctly connected to the corresponding
battery terminals. Wrong connection may cause
severe damage to electrical equipment.

P0024468

Risks of electrolyte in batteries

WARNING!
Always wear protective goggles when charging or
handling batteries.
Battery electrolyte is highly corrosive.

Rinse immediately with copious amounts of water if the

electrolyte gets in your eyes. Search directly after the
rinsing help by medical staff.

If it comes electrolyte to unprotected skin, wash

immediately with soap and water.

After finished work with the engine

IMPORTANT:
Always perform a leakage and function check.

Cleaning the engine and components

NOTICE! Follow the instructions Cleaning engine and
transmission, page 80.

P0026213

Cleanliness for sensitive components

IMPORTANT:
Observe meticulous cleanliness when handling
system components.
Even minimal amounts of dirt could cause a
breakdown.

Lifting the engine

WARNING!
Never work alone when removing heavy components,
even when using lifting devices such as locking tackle
lifts.

P0024485

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Safety Information

IMPORTANT:
When using a lifting device, two people are usually
required to do the work – one to take care of the lifting
device – and the other to ensure that components are
lifted clear and not damaged during the lifting
operations.

Proper lifting equipment

DANGER!
The existing lugs on the engine should be used for
lifting. Always check that the lifting equipment used
is in good condition and has the load capacity to
lift the engine (engine weight including transmission
and extra equipment). For safe handling and to avoid
damaging components fitted to the top of the engine,
the engine must be lifted with a correctly adjusted lifting
boom.
Never perform any work on an engine that is only
suspended from the lifting equipment.

IMPORTANT:
All chains or wires must run parallel to each other and
as perpendicular to the engine as possible. If other
equipment attached to the engine has altered its center
of gravity, special lifting devices may be needed to
obtain the correct balance for safe handling.

P0024689
Example of an adjustable lifting yoke and a lifting tool.

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 General Information

General Information
General information Specific terms for the U.S. market
This service and maintenance manual contains This engine is certified as being in compliance with
descriptions and instructions for the service of the federal and Californian exhaust restriction
above-mentioned Volvo Penta products in their regulations. Parts related to exhaust restrictions are
standard models. The design and servicing items may covered by the warranty commitment for exhaust
vary between different products. Applicable service restricting systems. Terms and the parts covered are
intervals and service procedures are described in the specified under "What is covered by the warranty
maintenance schedule for the product. undertaking for emissions” in “Emission Control
System Warranty Statement”. Repairs and service
The product designation, serial number and covered by the warranty are carried out by an
specification are indicated on the engine decals or authorized Volvo Penta distributor or dealer at no
type plate. This information must always be provided charge for diagnostics, labor or parts using genuine
in all correspondence concerning the product. Volvo Penta parts in all areas of the exhaust
restriction system covered by the warranty and found
The manual has been produced primarily for use in
to be defective.
Volvo Penta workshops. It is assumed that persons
using the manual have fundamental knowledge of the The use of the service and repair workshop other than
product and are capable of carrying out mechanical a Volvo Penta authorized distributor or dealer or the
and electrical work to industry standards. use of exhaust-related components from other
manufacturers than Volvo Penta do not affect the
Volvo Penta continually develops its products. We
scope of the warranty undertaking for emission-
therefore reserve the right to make changes.
restricting systems. If emission-related components/
All of the information in the manual is based on
items are included in scheduled service, such parts
product data available when the manual was
are marked with a diamond (♦) in the maintenance
published.
schedule and service must be carried out at the
NOTICE! The owner is responsible for ensuring that specified intervals in order to meet the requirements
scheduled maintenance is carried out. Warranty of the warranty undertaking for emission-restricting
claims to Volvo Penta may be declined if neglected systems. The full warranty terms can be found in
maintenance results in faults in the specified product. “Emission Control System Warranty Statement”.
Refer to the warranty terms supplied with the engine.

47709849 03-2020 © AB VOLVO PENTA 11

General Information

Certified engines
Explanation of the relationship between
The engine is exhaust-certified, and if it is used
in an area where exhaust emissions are regulated
service intervals and operating
by law, this places special demands on the care conditions
and maintenance of the engine. Because operating conditions may vary depending
NOTICE! Neglect or failure to follow the items on how the component is used, it is important that the
required here may invalidate the engine emissions service interval (expressed in hours or months) is not
certificate. exceeded.
This means that AB Volvo Penta will no longer be Example: 1000 hours / 24 months. Whichever is the
able to assume liability for engine specification sooner applies. If the component is used for 1000
compliance with the certified model. Volvo Penta is hours in 18 months, the service must be carried out
not responsible for damages or costs arising as a when the 1000-hour interval is reached.
result of this.
This is to retain the component’s best quality and
• Certification means that an engine type has
service life. The warranty will be void if this is not
been inspected and approved by the competent
complied with.
authorities. The engine manufacturer
guarantees that all engines made of the same Typical examples are: Propeller shaft seals operating
type are equivalent to the certified engine. in sandy waters. Air filters exposed to heavily polluted
• It is the responsibility of the user to make sure air
no intentional misuse of the engine takes place.
Action codes used in the service schedule:
• Volvo Penta maintenance and service intervals C = Cleaning
must be followed. R = Replacement
A = Adjustment
• All faults must be remedied as soon as possible.
L = Lubricate
• Only use genuine Volvo Penta replacement I = Inspection (includes where necessary also
parts or parts of the same quality as Volvo adjustment, cleaning, lubrication and replacement)
Penta replacement parts.
• The engine may not be converted or modified
in any way, except with accessories and service
kits which Volvo Penta has approved for the
engine.
• Volvo Penta recommends that service on
injection pumps, pump settings and injectors
always be carried out by a qualified workshop.
• No changes may be made to the installation of
the exhaust pipe and engine air inlet ducts.
• Any tampering with the engine will hamper EU
type-approval of the engine concerned.
• No warranty seals (if present on the product)
may be broken by unauthorized persons.

Service Protocol
To maintain the product’s functionality, the Service
Protocol must be followed. Some operations can be
carried out by the owner or other person with sufficient
technical competence, in accordance with the Service
Protocol. Please consult an authorized Volvo Penta
dealer in the event of doubt regarding how service
work should be performed.

The Service Protocol contains the required

maintenance points for your engine in a single
document. See more at the Volvo Penta website:
volvopenta.com.

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 General Information

Preventive repair
Here is an overview of the components that may be included in preventive maintenance. May vary depending on
the engine's design and construction.
These components form the basis for calculating service contracts and the costs in the service calculator in
Product Center.

Fuel system
Fuel pump
Unit injectors

P0026295

Exhaust system
Turbocharger, low-pressure
Turbocharger, high pressure
Overflow valve (Lisk)
Silencer
Diesel particulate filter (DPF), replacement

After-treatment system
Pump unit
Dosage valve

P0026296

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General Information

Cooling system
Coolant pump

Engine
Vibration dampers

P0026297

Electrical system
Alternator
Starter motor

P0026298

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 General Information

Engine, overhaul
Here is an overview of the components that may be included in a complete overhaul. May vary depending on the
engine's design and construction.
E.g. liners may not be replaced on certain engines. In this case, cylinders must be measured to see if new pistons
can be installed or if the engine block should be replaced.
The components below provide the basis for calculating service contracts and the costs in the service calculator
in Product Center.

Engine: May be overhauled once, after which the engine will be regarded as spent and will be replaced by a
“long block” or a new engine.

Overhaul
Long block
Short block
Cylinder head (replacement)
Cylinder head, gasket

P0026299

Engine, overhaul kit

Cylinder head, overhaul kit
Gaskets, set
Flat gaskets
Valve cover, gasket

P0026300

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General Information

Cylinder liners, set

Main bearings, set
Big end bearings, set
Thrust washers, set
Camshaft bearings, set

P0026301

Exhaust valve
Valve seat

P0026302

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 General Information

Genuine Volvo Penta Parts

Volvo Penta products are designed and manufactured
to achieve the highest quality. All parts are
manufactured so that together they provide the best
possible reliability. Therefore we always recommend
the use of Genuine Volvo Penta Parts, as they are
manufactured based on the same stringent
specifications as the factory-installed parts in Volvo
Penta drivelines.

Lube oils
Volvo Penta supplies a wide range of lubricants
developed especially for Volvo Penta engines. VDS
(Volvo Drain Specification) is a Volvo standard that
specifies Volvo’s oil grade requirements. We
recommend the use of the specified oil to ensure
engine function and a long service life.

Coolant
The main function of a coolant is to absorb heat from
the engine. The coolant also protects against freezing,
lime deposits and corrosion. Volvo Penta Coolant VCS
(yellow) and Volvo Penta Coolant (green) are two
completely different types of coolants, which contain
different types of inhibitors. Different types of coolants
(colors) must not be mixed.

If the concentrated coolant must be diluted with water,

the water's chemical composition may impair the
corrosion protection. In areas with high levels of
sodium and calcium in tap water, the coolant must be
diluted with distilled water. Alternatively, Volvo Penta
coolant is available for purchase ready diluted.

Protection against
Mixing the freeze bursting down
concentrated coolant to:
40 % -25 °C
46 % -30 °C
54 % -38 °C
60 % -46 °C

NOTICE! It is important to use coolant with a

concentration of 40-60 % in the cooling system even
where there is no risk of freezing. The coolant also
prevents corrosion and deposits. A mixture with a
concentration above 60 % will impair antifreeze
protection.

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General Information

Illustrations

Colors used in illustrations

• Highlighted components
Most illustrations include a highlighted component
(blue)
which is secured by a bolt or similar as part of a (light
gray) engine or transmission. • Fastener
(red)
• Assembly
(light gray)
• Background
(white)
• Special tools
(yellow)
• Seals
(green)
(as of 06/2018)

P0022106

Other types of symbols used in the images are

divided into the following categories:
• Safety
• Important
• Cleanliness
• Position
• Movement
• Measured value
• Tools
• Chemicals
• Sealant
• Units

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 Chemical products

Chemical products
Chemical products
A selection of Volvo Penta recommended chemical
products is shown below. Also refer under
Specifications.

P0001869

Thread locking fluid Corrosion protection Sealant

Engine oil VCS Coolant Grease

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Specifications

Specifications
Engine Decals
There are type plates on the engine, and in the case
of marine applications, also on the drive-lines. Some
of the type plates are marked with identity numbers.
Always use this information as a reference when
ordering service and replacement parts or contacting
Volvo Penta retailers.

P0030241

A Product information
B Emissions information
C CHASSIS ID
D Engine information

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 Specifications

General Tightening Torques

Bolt Nm
M6 standard bolt 10
M8 standard bolt 24
M10 standard bolt 48
M12 standard bolt 85
M14 standard bolt 140
M16 standard bolt 220
NOTICE! Check the bolts intended for
installation Damaged bolts with e.g. shear
marks under the heads, must be scrapped.

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Specifications

Specifications

Volvo Penta products, all markets but excluding North America

Oil quantity in engine, including filter. 36 liters
TAD1340VE / 1385VE:
TAD1341GE / 1355GE:

Engine oil. Part number: 23571951 1 liters

Engine oil. Part number: 23039848 5 liters
Engine oil. Part number: 23039851 20 liters
Engine oil. Part number: 23039853 208 liters

Coolant, VCS yellow, concentrated. Part number: 22567295 5 liters

Coolant, VCS yellow, concentrated. Part number: 22567307 210 liters
Coolant, VCS yellow, ready mixed. Part number: 22567314 5 liters
Coolant, VCS yellow, ready mixed. Part number: 22567340 210 liters
Quantity of ready-mixed VCS yellow coolant, (engine + standard radiator + hoses + 24 liters
expansion tank)
TAD1340VE / 1385VE:

Quantity of ready-mixed VCS yellow coolant, (engine + standard radiator + hoses + 24 liters
expansion tank)
TAD1341GE / 1355GE:

Volumes may differ if the installation has extra coolers /

radiators connected.

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 Specifications

Volvo Penta products for North America

Oil quantity in engine, including filter. 9.5 US gallons
TAD1340VE / 1385VE:
TAD1341GE / 1355GE:

Engine oil. Part number: 40005011 (1 US quart) 1 US quart

Engine oil. Part number: 40005012 (1 US gallon) 1 US gallon
Engine oil. Part number: 40005013 (5 US gallons) 5 US gallons
Engine oil. Part number: 40005014 (55 US gallons) 55 US gallons

Coolant, VCS yellow, concentrated. Part number: 21485012 1 US gallon

Coolant, VCS yellow, ready mixed. Part number: 21485014 1 US gallons
Quantity of ready-mixed VCS yellow coolant, (engine + standard radiator + hoses + 6.34 US gallons
expansion tank)
TAD1340VE / 1385VE:

Quantity of ready-mixed VCS yellow coolant, (engine + standard radiator + hoses + 6.34 US gallons
expansion tank)
TAD1341GE / 1355GE:

Volumes may differ if the installation has extra coolers /

radiators connected.

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Engine

Engine
Component location

P0030230

A Drive belts E Oil dipstick

B Purging, fuel F Fuel filter
C Diagnostic connector G Fuel pre-filter
D Oil filler

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 Engine

P0030237

A Air filter E Oil filter

B Turbocharger F Bottom plug, oil drainage
C Expansion tank, coolant G Coolant drain, HD radiator
D Coolant drain, engine block H Coolant drain, std radiator

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Engine

Maintenance Schedule
The Volvo Penta engine and its equipment are designed for high reliability and long life. The engine is built so as
to have minimal environmental impact. These qualities will be retained and unnecessary malfunctions avoided if
service is provided according to the maintenance schedule.

Service intervals
Service items can be found in the Service Record available for download at www.volvopenta.com.
Search under tab: Manuals.

Extended service intervals

The interval between engine oil changes may be extended in certain circumstances. To determine whether the
service interval may be extended, Volvo Penta's conditions for extended service intervals must be met and an oil
analysis performed, see Lubrication System, page 41.
The Volvo Penta dealer has further information.

Where both operating hours and calendar times are specified, perform the maintenance item at whichever time
is the sooner.

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 Engine

General inspection
General inspection
Make a habit of visually inspecting the engine and
engine compartment before the engine is started and
after operation once the engine is stopped. This will
help you to discover quickly if anything abnormal has
happened, or is about to happen.

This inspection only takes a few minutes, but can

prevent serious malfunctions and expensive repairs.

The images are generic and applicable to all engine

installations. They show only a selection of
components and systems.
The inspection applies to all components in the
systems.

Look especially carefully for fuel leakage at:

• Injector connections
• Pressure sensor, common rail
• Check all clamped items
• Fuel filter
• Fuel pipe/hoses
• Fuel pump

P0030234

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Engine

Oil leaking turbocharger connections, oil pipes/hoses, oil

sensors, oil filter and oil sump.
Check all clamped items.

P0030243

Coolant leakage on the coolant pump, expansion tank,

coolant cooler, oil cooler, charge air cooler, coolant
sensors, coolant hoses.
Check all clamped items.

P0030239

Also check:
Drive belts
Damaged wiring
Loose wiring
Loose fasteners
Exhaust hoses
Hoses/hose connections to transmissions

WARNING!

Accumulations of fuel, oil and grease on the engine or

in the engine compartment are a fire hazard and must
be removed as soon as they are discovered.

WARNING!

If you discover a leakage of oil, fuel or coolant,

investigate the cause and fix the fault before starting
the engine to avoid the risk of fire.

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 Engine

General advice for electronic

protection
The following advice must be complied with to ● Never switch off the current at the main switch when
avoid damage to the engine control unit and other the engine is running.
electronics. ● Never disconnect a battery cable when the engine
is running.
IMPORTANT: ● Switch off the main switches or disconnect the
Switch off the main switch before connecting or battery cables when fast-charging the batteries.
disconnecting a connector.
● NOTICE! It is not necessary to switch off the main
switches during normal maintenance charging.
● Only batteries may be used as a starting aid. A jump
start unit is able to supply very high voltage which
may damage the control unit and other electronics.
● Take extreme care so that the harness terminals do
not come into contact with oil, water or dirt if a
connector is removed from a sensor.

The diagnostic connector is located at the side of the

engine.

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Engine

Check software status

These readings depend on the type of installation and
are carried out using the VODIA diagnostics tool.

• Reading and resetting parameters.

• Reading and erasing any fault codes (DTC).
P0024905 • Resetting service intervals (EVC2).

Reading Ash Load, DPF

• This reading describes how large the ash quantity is
as a percentage. Whether the filter must be replaced
or if it will last until the next service.
P0024905 • Current condition is calculated using hours
consumed and hours remaining until the next
service in relation to the ash quantity reading.
• The reading is taken using the VODIA diagnostics
tool.
• The reading must be noted in the maintenance
schedule and saved in Product Center.

DPF filter, replacement planning

The amount of ash must be read off at the 1000 hour
service and an estimation made of how many hours
remain before the DPF filter must be replaced.
The filter must be changed when the amount of ash
reaches 80%.

P0031617

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 Engine

Air Filter

The engine air filter is connected to the turbocharger

inlet pipe.

Replacing the air filter

• Open the fasteners and remove the cover.
• Remove the filter by pulling/rocking it straight out.
• Wipe clean around the attachment point.
• Install the new filter.
• Refit the cover and close the fasteners.
NOTICE! Scrap the old filter. It is not designed to be
cleaned.

P0030240

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Engine

Crankcase Ventilation, Filter

Change

Crankcase separator
• Requires no service.

P0026321

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 Engine

Air filter Compressor, filter replace

NOTICE! Universal image - filter types may differ.

• Remove the hose clamp.

• Remove the air filter.
• Install a new filter.
• Tighten the hose clamp.
Tightening torque: 5 Nm

P0026927

Valves, Adjustment

Adjusting valve clearance is a task meant for

workshop-trained personnel. Refer to the Workshop
Manual.

Note the interval in the maintenance schedule for your

engine.

P0026355

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Lubrication System

Lubrication System
When you work with Chemicals,
Fuel and Lubrication Oil, Change
NOTICE! Apply barrier cream to your hands and
always use protective gloves for work which involves
contact with oil, fuel and similar. Continuous skin
contact with engine oil dries the skin and can be
hazardous.

Engine Oil, Level Check

NOTICE! It is very important that engine oil be kept at
a suitable level for correct engine lubrication.

A high oil level leads to increased oil consumption

and may cause clogging of the silencer and/or the
closed crankcase ventilation.

A low oil level may lead to seizing pistons, engine

wear and engine overheating.

Oil level check, hot engine.

• Make sure the engine is level.
• Stop the engine; wait a at least 15 minutes and then
measure the level.

Oil level check, cold engine. (recommended)

• Make sure the engine is level.
• Oil level measurement is most reliable before the
engine is started

Check that the oil level is between the dipstick's min

and max markings.

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 Lubrication System

A Oil level on the MIN marking: add oil until the level
is between min and max.
B Optimal oil level, do NOT add oil.
C Oil level at max marking; do NOT add oil.

P0028585

NOTICE! Never add too much engine oil.

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Lubrication System

Engine oil, change

Change the engine oil and filter within the
recommended service intervals.

P0027025

Drain the engine oil by connecting a pump to the oil

dipstick hole and drawing out the oil.

P0026944

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 Lubrication System

Alternatively, permanently connect a hand pump to the

bottom plug (recommended).

NOTICE! If the engine oil is hot, it will drain out faster.

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Lubrication System

Oil filter, Change

We strongly recommend that only oil filters approved

by Volvo Penta be used.
The wrong type of oil filter can lead to increased wear
and damage, e.g. to bearings and crankshaft.

P0027026

Removal

• Remove the oil filters using a universal puller.

• Clean around the filter attachment on the filter
housing.

P0027027

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 Lubrication System

Installation

• Lubricate the new O-ring with engine oil before

installing.

P0030090

• Fit the new filters.

P0030242

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Lubrication System

• Tighten by hand until the surfaces touch and then a

further half turn.

P0027029

• Fill with the required volume of oil; see

Specifications, page 22.
• Start the engine.
• Check that no leakage occurs.
• After running the engine for a few minutes, switch it
off and check the oil level.
• Top up as necessary.

P0030092

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 Lubrication System

Volvo Penta oil analysis

Volvo Penta oil analysis provides an extensive
diagnostic check on the driveline condition. The oil
analysis provides information for example on water
content, fuel content, dirt and the amount of metallic
particles in the oil as a result of component wear.

Thanks to early warning signs given by oil analysis,

preventive maintenance and component replacement
can be planned, so that unplanned shutdowns can be
avoided.

Some engines allow the oil change intervals to be

extended. There are two different service records
available for these engines. Refer to the Volvo Penta
Product Center

In order to find out more about Volvo Penta Oil

Analysis, we recommend our on-line training.

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Fuel System

Fuel System
General

The fuel system has a fine filter (A) and a pre-filter (B).

P0030233

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 Fuel System

Fuel Pre-filter, Change

CAUTION!
Risk of skin damage.

NOTICE! Be prepared to gather up fluid.

Removal

• Remove the water separator sensor connector.

P0027034

• Loosen the drain nipple in the base of the water

separator. Drain the filter.
• Reinstall the drain nipple and tighten securely.

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Fuel System

• Remove the pre-filter together with the lower section

of the water separator. Use a universal puller for the
oil filter.

P0027035

• Remove the lower section of the water separator

and O-ring from the filter.

P0030094

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 Fuel System

• Clean the lower section of the water separator and

the contact surfaces. Check that the strainer and
drain hole in the lower section are not clogged.

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Fuel System

Installation

• Install a new O-ring. Lubricate the seal with diesel.

• Install the lower part of the water separator.

P0030094

• Lubricate the sealing surface with diesel and screw

the new filter onto the filter bracket by hand until the
seal touches the sealing surface. Then tighten a
further 1/2 turn.

P0030231

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 Fuel System

• Connect the connector.

• Open the fuel tap and vent the fuel pre-filter; refer to
Fuel system, bleeding, page 50. Check for
leakage.

P0027034

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Fuel System

Fuel filter, Change

IMPORTANT!
Protect against dirt while work is in progress.

NOTICE! Be prepared to gather up fluid.

Removal

• Remove the fuel filter with the aid of a suitable filter

puller. Let the fuel drip off into a collection vessel.
• Clean around the filter housing sealing surface.

P0027041

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 Fuel System

Installation
NOTICE! Do not fill the new filter with fuel before
installation; there is a risk that contamination may
cause malfunctions.

• Lubricate the sealing surface with diesel and install

the new fuel filter. Tighten according to the
instructions on the filter.
• Purge the fuel system; see Fuel system,
bleeding, page 50.
• Start the engine and check for leaks.

P0030232

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Fuel System

Fuel system, bleeding

CAUTION!
Never disconnect a fuel line or component after the fuel
pump to bleed. The fuel is under very high pressure
and can penetrate the skin.

NOTICE! Check that there is sufficient fuel in the tank,

and that any fuel taps are open.

• Free the hand pump from the fuel filter bracket.

P0027043

• Open the bleed nipple on the front fuel connection

next to the valve cover and fit a hose.
• Connect a hose and a bottle/receptacle to the other
end of the hose to collect fuel when bleeding.

P0027044

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 Fuel System

• Purge the fuel system by pumping with the hand

pump until fuel flows without air bubbles.

P0027045

• Close the nipple.

Tightening torque: 3.5 Nm
• Remove the hose and fit the protective rubber cover.

P0027044

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Fuel System

• Tighten the fuel pump handle.

• Wipe dry any spilled fuel.
• Start the engine and let it idle.
• Check that no leakage occurs.

P0027043

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 Exhaust System

Exhaust System
Turbocharger, Inspection
Inspecting the turbocharger and charge air pipe

• Remove the protective grille.

• Remove the inlet pipe from the turbocharger

• Remove the exhaust pipe from the turbocharger.
• Check the turbocharger with regard to damage to
the compressor and turbine wheels.
• In the case of damage, replace the turbocharger in
its entirety.

NOTICE! We recommend that turbocharger

replacement be carried out by a Volvo Penta
workshop.

P0030244

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Exhaust System

Charge Air Pipe, Leakage Check

Inspect the condition of the charge air hose

connections and hoses for cracks, leaks and other
damage. Replace as necessary.

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 Exhaust System

EGR cooler

EGR cooler
Refer to the maintenance schedule for the engine
cleaning or replacement of the EGR cooler.
This job should be carried out by trained workshop
personnel. Refer to the workshop literature for further
information regarding the engine concerned.

NOTICE! Not all engines have EGR coolers.

NOTICE! EGR cooler shown for illustration purposes.

Design and attachment differs between different
engines.

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Exhaust System

SCR System
Engines with SCR have filters that must be replaced.
Check the replacement intervals in the maintenance
schedule for your engine.

NOTICE! Illustrative images of components.

Installations can differ between different models.

• Pump unit filter.

P0029170

• Filter for air to the AdBlue/DEF tank.

P0029171

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 Exhaust System

Replacing the filter to the AdBlue/DEF pump

NOTICE! Maintain a high level of cleanliness when

working with the SCR system. Wipe clean around
covers and connections before beginning work. Make
sure the filter and gaskets do not come into contact
with dirty surfaces before installation.

• Switch off the engine. Wait until the pump unit has
stopped as it always performs a hose emptying
sequence.
• Remove the battery’s minus pole.
• Place a collection vessel under the filter cover.

P0026516

• Undo the filter cover

P0026517

• Use a puller (supplied with the filter kit) to pull out

the filter by first pressing it into the filter hole until it
clicks.
• Pull out the filter.

P0019390

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Exhaust System

• Install the new filter (A).

Install the rubber gasket (B).
Screw the filter cover (C) back on.

P0028678

• Tighten the cover.

Tightening torque: 20 +5 Nm

P0026519

• Connect to the battery negative pole.

• Start the engine. Check operation and inspect for
leaks.
• Delete any fault codes.

P0026520

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 Exhaust System

NOTICE! Take appropriate care of equipment and

surplus AdBlue/DEF solution.

p0013225

Nox-sensor Pre/Post SCR

When fault tracing or replacing components in the
aftertreatment system, refer to the EATS System
workshop manual.

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Exhaust System

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 Exhaust System

Particulate Filter Insert, Replace

First read the instruction entitled 'Requirements when

working on the aftertreatment system' in the Operator's
Manual.

Removal
Undo the harness connector to:
• dosage valve
• exhaust temperature sensor
Remove:
• hoses
• pipe to pressure sensor

P0030077

Remove and discard the clamps.

Remove the cover.

P0030078

NOTICE! Handle the filter carefully.

Pull out the filter insert.

Remove and discard the seals.

Inspect the filter holder and remove any soot.

NOTICE! When replacing, put the removed filter in the

protective bag supplied.

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Exhaust System

P0030079

Installation
NOTICE! Use new components.

Install the filter insert.

P0030076

Grease the clamps with graphite paste.

Install the cover.
Tighten the clamps alternately.
Tightening torque:
Stage 1: 10 Nm
Stage 2: 24 Nm (small clamp), 20 Nm (large clamp)

P0030075

Install the hoses.

Install the pressure sensor pipe.
Tightening torque 30 Nm.
Connect the dosage valve harness terminal.
Connect the temperature sensor harness terminal.

P0030077

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 Cooling System

Cooling System
Coolant Level, Checking and
Topping Up
The engine's internal cooling system makes sure the
engine works at the right temperature. It is a closed
system that must always be filled with a mixture of
concentrated coolant and water in order to protect the
engine against internal corrosion, cavitation and
bursting due to freezing.

NOTICE! Different kinds of coolant may not be mixed.

WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

• Check the coolant level in the expansion tank.

• Top up with coolant as required (A), so that the level
is between the MIN and MAX marks.

P0028679

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Cooling System

Replacing coolant

• Open the filler cap (A).

P0028679

• Connect a drain hose and drain the coolant out of

the radiator. The drain nipple is located underneath
standard radiators and on the side of HD radiators.

P0026914

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 Cooling System

• Connect a drain hose to the engine block and drain

the coolant from the engine. Use a receptacle to
collect the coolant.
• Remove the hoses and close the nipples/taps.
• Refill with new, Volvo Penta-recommended coolant.
NOTICE! Cooling performance is reduced by deposits
in the radiator and cooling galleries. The cooling
system should be cleaned when coolant is replaced.
Cooling system cleaning is described in the Workshop
literature.

NOTICE! Check anti-freeze protection every year, if

the coolant is not replaced.

P0027047

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Cooling System

Filling a completely empty system

Mix the coolant in advance, to ensure the cooling
system is filled with the correct mixture, (applies to
concentrated coolant).

If a heating unit is connected to the engine cooling

system, its valves must be opened and the installation
vented during filling.

NOTICE! The engine may not be started before the

system is full.

• Check that all drain points are closed.

• Open the filler cap (A).
• Top up and check that the coolant level is between
the MIN and MAX marks on the expansion tank.
• Start the engine when the cooling system has been
filled and vented.
• Open any venting nipples shortly after starting the
engine, to allow trapped air to escape.
• Run the engine at idle a while.
• Increase engine revolutions for a few minutes. Stop
the engine and check the coolant level.
• Run the engine until the thermostat opens. Check
the level again when the engine has cooled. Top up
as necessary.

P0028679
NOTICE! Only fill coolant when the engine is cold and
stopped. Fill slowly, to allow air to flow out.

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 Cooling System

Radiator Assembly, Change

Replacing the drive belt
It may be necessary to remove the radiator assembly
to replace the drive belt.
Belt replacement can be found as a separate item after
this chapter.

IMPORTANT!
Turn off the main switch before any work is carried out.

Removal

• Drain the coolant from the radiator and the engine

(drain located underneath the std radiator and on
the side of the HD radiator).
Be prepared to gather up fluids.

P0026914

P0027048

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Cooling System

• Remove the left side hoses between the engine and

the radiator.

• Remove the left side hoses between the engine and

the radiator.

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 Cooling System

• Remove the hoses between the engine and the

expansion tank.

• Remove the fan guard and disconnect the coolant

level sensor connector. The belt guard consists of
sections.

P0030238

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Cooling System

• Remove the radiator stay between the engine and

the radiator.

• Attach the radiator to a lifting device. Undo the lower

bracket and release the radiator for further work.
• Remove the fan if the belt cannot be lifted over it.
• Now replace the drive belts; refer to Drive belt,
change, page 72.

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 Cooling System

Installation
Install the radiator assembly in reverse order.

Take the opportunity to flush the radiator and engine

clean internally. Refer to the instructions in the
workshop manual.

Fill with coolant; refer to Coolant Level, Checking and

Topping Up, page 63.

Turn the main switch On.

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Cooling System

Drive belt, change

Drive belt, water pump

NOTICE! Always replace belts that are greasy, worn

or damaged.

Removal
CAUTION!
Pinch hazard. Keep fingers clear.

• Clear a space in front of the engine. Remove the

engine fan guard, cooling fan and fan ring. If
necessary, also remove the radiator assembly.
• Insert a tool in the belt tensioner
• Relieve the load on the belt tensioner (1) and
remove the belt.
• Check the function of the belt tensioner and idler
wheel bearings. Replace the idler wheel if there is
play in the bearings.

P0030235

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 Cooling System

Installation

• Insert a tool in the belt tensioner

• Relieve the load on the belt tensioner and install the
new belt.
• Deploy the belt tensioner and also check that the
belt is correctly aligned on all pulleys.
• Install a fan guard around the cooling fan and install
the radiator assembly if this has been removed.

Check
The drive belt has an automatic belt tensioner and
does not need to be adjusted.

P0030235

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Cooling System

Drive belt, alternator

Removal
CAUTION!
Pinch hazard. Keep fingers clear.

• Clear a space in front of the engine. Remove the

engine fan guard, cooling fan and fan ring. If
necessary, also remove the radiator assembly.
• Insert a tool into the belt tensioner (A).
• Relieve the load on the belt tensioner (A) and lift
away the water pump drive belt.
• Insert a tool into the belt tensioner (B).
• Relieve the load on the belt tensioner (B) and lift off
the generator drive belt.
• Check the function of the belt tensioner and idler
wheel bearings. Replace the idler wheel if there is
play in the bearings.

P0030236

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 Cooling System

Installation

• Insert a tool into the belt tensioner (B) and relieve

the load on the belt tensioner.
• Install the new generator belt.
• Deploy the belt tensioner (B) and also check that the
alternator belt is correctly aligned on all pulleys.
• Relieve the load on the belt tensioner (A) and fit the
drive belt onto the water pump.
• Deploy the belt tensioner (A) and also check that the
water pump belt is correctly aligned on all pulleys.
• Install a fan guard around the radiator fan and install
the radiator assembly if this has been removed.

Check
The drive belt has an automatic belt tensioner and
does not need to be adjusted.

P0030236

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Long-Term Storage

Long-Term Storage
The engine and other equipment should be conserved to avoid damage during extended lay-ups (4-6 months or
longer). Conservation protects the engine against freezing and corrosion damage.

The checklist below covers the most important points for the engine. Before taking the engine out of operation for
an extended period, we recommend checks for any maintenance or repairs.

IMPORTANT:
Washing with a power washer: Never aim the water jet at radiators, charge air cooler, seals, rubber hoses or
electrical components.

For layups up to 8 months:

• The fuel system must be protected during storage
to prevent internal oxidation and corrosion.
Start and run the engine with FAME-free fuel before
storage.
Run the engine for at least 10 minutes to allow the
fuel to reach all parts of the fuel injection system.
FAME = Biodiesel
B0 = Diesel with 0% FAME
B10 = Diesel with 10% FAME
• If B0 fuel is not available, fuel additives with anti-
corrosion and anti-oxidation properties may be
mixed in the fuel to protect the fuel system during
storage.
Engines that use diesel fuel with a FAME content
greater than 10%, (even if additives are used) must
not be placed in long-term storage.
• Drain water from the pre-filter to reduce the risk of
bacterial growth.
Drain water, dirt and sludge from the fuel filter and
fuel tank. Fill the fuel tank completely to prevent
condensation.
Use the recommended B0 fuel. Fuels with a FAME
-content greater than 10% may not be used as
storage fuel.
• Change engine oil and oil filters.
• Check that the coolant has the requisite antifreeze
qualities. Top up as necessary.
• Disconnect the battery cables; clean and charge the
batteries. Maintenance charge the batteries while
the equipment is laid up. An insufficiently charged
battery can freeze and burst.
• Cleaning the outside of the engine, see Cleaning
engine and transmission, page 80.
• Touch up paint damage with Volvo Penta original
paint or paint of the equivalent quality.
• Attach a tag into the engine with information about
the date, type of conservation and the conservation
oils used.
• Cover the air filter, exhaust pipe and engine as
necessary.

See also Service bulletin: 05-2-104

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 Long-Term Storage

Recommissioning

• Replace filters before starting the engine.

Keep extra filters available as FAME may cause
microbial growth that blocks the fuel filter.
• Check the drive belts.
• Check the condition of all rubber hoses.
• Check the hose clamps.
• Check the coolant level. Top up as necessary.
• Connect the fully charged batteries.
• Remove the covers from the air filter and exhaust
pipe.
• Start the engine and let it idle with no load a short
while.
• Check that there are no oil, fuel or coolant leaks.

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Long-Term Storage

Storage instruction for long-term

storage of new engine

Applies to installed and non-installed

engines

The engines must be laid up in a warm,

temperature-controlled store.
The temperature should be between +5°C and
+30°C.
Storage outdoors is strictly prohibited.
Humidity should be below 40%.
We recommend that you:
– Unpack the engine, remove the plastic wrap.
– Use the plastic bag as dust protection; leave it
loose for good ventilation.
– Do not use wax as protection in case the engine
must be started during storage.

If the engine must be stored for more than 8

months

Before storage
Make sure the engine cooling system is filled with
glycol.
Make sure the engine lubrication system is filled with
oil.
Pump the coolant through the seawater cooling
system. (Marine engines only)
Seal all open connections.
Remove the battery cables from the battery.
Empty the AdBlue®/DEF tank if it is filled and clean
it.
Attach a tag into the engine with information about
the date, the product's part number, type of oil used
and sign it.

During storage
The engine must be cranked 2.5 turns every 8th
month.
If the engine can be started, run it until warm.
Check that humidity is below 40%.
Check that the temperature in the storage area is
between +5°C and +30°C.

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 Long-Term Storage

Before the engine enters service.

Uncover the engine or vacuum the system until dry.
This is in order to prevent remaining glycol mixture
from contaminating the environment.
Hand the glycol mixture to a waste management
facility as hazardous waste.
Clean the engine as necessary.
Check:
– Drive belts
– Hoses
– Clamps
Check the oil level in the engine and top off as
necessary.
Make sure the coolant has adequate antifreeze
properties; top off as necessary.
Should be replaced:
– Fuel filter
– Air filter
– AdBlue®/DEF filter
– Air filter AdBlue®/DEF tank
– Fill the AdBlue®/DEF tank
– Seawater pump impeller (Marine engines only)
– Anodes for the seawater system. (Marine engines
only)
Start the engine and let it idle a while without a load.
Check that there are no oil, fuel or coolant leaks.
Run the engine until warm.
Change the engine oil and oil filter.

Checklist, long term storage

Date Product part number Type of conservation Signature and date of checks

Month Checks during storage

8,
16,
24,
32,
40,

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Long-Term Storage

Cleaning engine and transmission

Including the engine encapsulation and all

hatches
• A clean engine compartment minimizes the risk of
overheating and wear damage.
• Prior to every engine compartment wash, a visual
inspection must be carried out to identify any fluid or
exhaust leakages.
• Following each wash, all hoses and bellows must be
inspected visually to identify any leakages, cracks
or chafing.
• Following each wash, electrical harnesses must be
visually inspected to identify any damage to
insulation, cable jackets or clamping.
• Battery, alternator, power steering unit and starter
motor cables must be inspected extra carefully.
• Any damage to hoses, bellows, grommets or
electrical harnesses must be reported immediately.

Important!
• When cleaning, always use mild detergents/
solvents.
• When cleaning the engine and engine
compartment, the alternator, idler pulley, belt
tensioner, power steering unit and all electrical
components must be covered with plastic or similar
so that detergent/solvents do not get into the parts
• Where fitted, the AC compressor must also be
protected with plastic or similar.
• When cleaning air coolers, they should be vacuum
cleaned first before flushing with warm water from
the inside out.
• Do not use a power washer on the air cooler.
• Clean the outside with a sponge/brush.
• Then flush with lukewarm water.
• When pressure washing and steam cleaning, water
pressure may not exceed 80-100 bar at the nozzle.
Maintain a distance of 100-150 mm; use a fan spray
nozzle.
• It is not permitted to came jets of water from the
pressure washer directly onto the alternator. The
electrical regulator, rectifiers, power steering units,
bellows and mechanical parts (bearings) may be
damaged and lead to serious consequential
damage.

NOTICE! If the generator is exposed to water, it must

be dried; see drying.

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• Wash using a flat fan nozzle when cleaning sound

absorbent.
• To maintain the fire prevention and sound
dampening qualities of the absorbent as per the
sound certificate, no damage to the absorbent may
be repaired with the aid of patches or the puzzle
principal i.e. by covering any damage with new
absorbent (patch). Accordingly, in the case of major
damage or where fluid has seeped into the
absorbent (deep tears, tears wider than the width of
tape; holes or cracked edges), the entire damaged
unit must be replaced.
• Tears that can be covered widthwise by tape, must
be repaired using approved aluminum tape.
• After the wash, check that no small rocks or other
debris has adhered to the belts and are able to
penetrate them when the engine is started.

Drying the alternator

• Blow the water away from the alternator using
compressed air.
• Check that the alternator charges.

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Checklist
Suggestions for the checklist in addition to the regular
service items.

Check/action
• Check for leakage: oil/fuel/water/exhaust.
• Check – Hoses and hose clamps.
• Inspection of cable connections.
• Cleaning of battery terminals; remove any oxide.
Check the electrolyte level.
• Clean the engine and engine compartment.
• Inspection/cleaning the fuel tank.
• Function check of other electrical systems.
• External cleaning of the radiator/radiator assembly.
Start the engine every six months
If the engine is to be laid up for 6-8 months or more, it
should be started and warmed up every six months as
follows:
• Check the engine oil level.
• Check the coolant level.
• Connect the battery cables to the batteries (fully
charged).
• Start the engine and run it for 2-3 minutes.
• Switch off the engine.
• Detach the battery cables.
• Check the engine compartment for any
condensation.
• Ensure good ventilation.

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Battery, Maintenance
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.

WARNING!
Battery electrolyte is a corrosive acid and should be
handled with care. If you spill or splash electrolyte on
any part of the body, immediately flush the exposed
area with liberal amounts of water and seek medical
attention as soon as possible.

WARNING!
Ventilate the engine compartment before working on
batteries or battery connections.

IMPORTANT:
Batteries can be damaged if they are left discharged,
and can also freeze and burst easier in cold weather.
If the engine is not going to be used for a longer period
of time, the batteries should be fully charged, trickle
charged if possible.

Care
It is important always to follow the battery
manufacturer's recommendations and instructions
when replacing and charging batteries. Instructions for
maintenance and charging may vary depending on
battery type.
Modern batteries are usually maintenance free, but
there are some recommended measures to avoid
accidents and increase battery service life:
• Keep the batteries clean and dry. Contamination
and oxide on the batteries and battery terminals can
cause stray currents, voltage drop and discharge,
especially in damp weather.
• Remove oxidation from the battery poles and
terminals using a brass brush.
• Tighten the terminals securely and grease them with
terminal grease or petroleum jelly. Loose battery
connections can cause damage to the engine
electrical system.
• Charge the batteries regularly. Batteries kept at full
charge enjoy maximum service life. The easiest way
to check whether a battery needs charging is to use
a volt meter.

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Battery replacement
IMPORTANT:
Make sure that the new battery fulfills the specifications
in Technical Data. Read the information supplied with
the battery before you begin the installation.

IMPORTANT:
Do not disconnect the batteries with the engine
running.
Sensitive electrical components can be immediately
damaged.

WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

Disconnection (A)
• Remove the negative (-) cable (black).
• Remove the positive (+) cable (red).
Remove the battery.

Connection (B)

Put the new battery in place.

• Attach the positive cable (red) to the battery's
positive terminal. Tightening torque: 6 Nm.
• Attach the negative cable (black) to the battery's
negative terminal. Tightening torque: 6 Nm.

NOTICE! Hand in the old battery to a waste

management facility.

P0028239

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Index
A S
Air Filter.................................................................... 31 Safety Information...................................................... 3
Air filter Compressor, filter replace........................... 33 SCR System............................................................. 56
B Service Protocol....................................................... 12
Battery, Maintenance............................................... 83 Spare parts - safety.................................................... 5
Specifications..................................................... 20, 22
C Storage instruction for long-term storage of new
Charge Air Pipe, Leakage Check............................. 54 engine....................................................................... 78
Check software status.............................................. 30
Checklist................................................................... 82 T
Chemical products.................................................... 19 Turbocharger, Inspection......................................... 53
Cleaning engine and transmission........................... 80 V
Component location................................................. 24 Valves, Adjustment................................................... 33
Coolant Level, Checking and Topping Up................ 63 W
Cooling System........................................................ 63 When you work with Chemicals, Fuel and
Crankcase Ventilation, Filter Change....................... 32 Lubrication Oil, Change............................................ 34
D
Drive belt, change.................................................... 72
E
EGR cooler............................................................... 55
Engine...................................................................... 24
Engine Decals.......................................................... 20
Engine oil, change.................................................... 36
Engine Oil, Level Check........................................... 34
Exhaust System....................................................... 53
F
Fuel filter, Change.................................................... 48
Fuel Pre-filter, Change............................................. 43
Fuel System............................................................. 42
Fuel system, bleeding.............................................. 50
G
General..................................................................... 42
General advice for electronic protection................... 29
General Information.................................................. 11
General inspection................................................... 27
General Tightening Torques..................................... 21
Genuine Volvo Penta Parts...................................... 17
I
Illustrations............................................................... 18
L
Long-Term Storage.................................................. 76
Lubrication System................................................... 34
M
Maintenance Schedule............................................. 26
N
Nox-sensor Pre/Post SCR........................................ 59
O
Oil filter, Change....................................................... 38
P
Particulate Filter Insert, Replace.............................. 61
Preventive repair ..................................................... 13
R
Radiator Assembly, Change .................................... 67
Reading Ash Load, DPF........................................... 30

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 47709849  English 

AB Volvo Penta
SE-405 08 Göteborg, Sweden
www.volvopenta.com