Workshop Manual

Group 20-26

D9
 Table of Content

General Information
00-0 General ............................................................................................. 3

Specifications
03-2 Specifications, Engine .................................................................... 7
03-21 Engine ....................................................................................... 21
03-22 Lubrication System ................................................................. 33
03-23 Fuel System .............................................................................. 36
03-25 Inlet and Exhaust System ....................................................... 38
03-26 Cooling System ........................................................................ 40
03-3 Specifications, Electrical .............................................................. 43
Electrical System ............................................................................... 43

Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 44

Special tools
08-2 Special Service Tools ................................................................... 49

Chemical Products
18-0 General ........................................................................................... 56

General
20-0 Engine Information, General ........................................................ 57
Troubleshooting ................................................................................. 61
Test and Adjustments ....................................................................... 65
20-9 Miscellaneous ............................................................................... 78

Engine
21-0 Engine Complete, General ........................................................... 80
Exposing the Engine ......................................................................... 80
Fitting the Fixture ............................................................................... 85
Engine Disassembly .......................................................................... 86
Engine Assembly ............................................................................. 104
21-3 Cylinder Liner, Pistons ............................................................... 134
21-4 Valve Mechanism ........................................................................ 143
21-5 Timing Gears and Shaft .............................................................. 153
21-6 Crank Mechanism ....................................................................... 172

Lubricating and Oil System

22-0 Lubricating and Oil System, General ........................................ 183
22-1 Oil pump and Line ....................................................................... 190
22-3 Oil cooler ..................................................................................... 193

Fuel System
23-0 Fuel System, General ................................................................. 196
23-3 Fuel Feed Pump and Filter ......................................................... 198
23-7 Injectors and Delivery Pipes ...................................................... 201
23-8 Control System, ECM, Data Sets ............................................... 212

Inlet and Exhaust System

25-0 Inlet and Exhaust System, General ........................................... 215
25-1 Inlet and Exhaust Manifolds ...................................................... 216

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 25-5 Turbo and supercharger ............................................................ 221

Cooling System
26-0 Cooling System, General ........................................................... 224
Check and Fault Trace ..................................................................... 227
26-1 Radiator, Heat Exchanger .......................................................... 230
26-2 Coolant Pump, Thermostat ........................................................ 236
26-5 Charge Air Cooler with Connections ........................................ 239
26-6 Sea Water System, Sea Water Pump ........................................ 246

Alternator, Charge Regulator

32-1 Alternator ..................................................................................... 258
Index ......................................................................................................... 261
References to Service Bulletins ............................................................ 263

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00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, When carrying out service and repair on
descriptions and maintenance and repair instructions emission-certified engines, it is important to be
for standard model Volvo Penta products. A list of aware of the following:
these products may be found in the section
Specifications. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all the certified engine.
correspondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified • Maintenance and service intervals
personnel. It is assumed that any person using the recommended by Volvo Penta must be
Service Manual has a fundamental knowledge of the complied with.
product and is able to carry out mechanical and • Only spare parts approved by Volvo Penta may
electrical work to trade standard. be used.
Volvo Penta continually develops its products; we • Service on injection pumps, pump settings and
therefore reserve the right to make changes. All injectors must always be carried out by an
information in this manual is based on product data authorized Volvo Penta workshop.
which was available up to the date on which the
• The engine must not be converted or modified,
manual was printed. New working methods and
except with accessories and service kits which
significant changes introduced to the product after
Volvo Penta has approved for the engine.
this date are communicated in the form of Service
bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the
Spare parts for the electrical and fuel systems are product) may be broken by unauthorized
subject to various national safety standards. Volvo persons.
Penta Original Spare Parts meet these standards. No
damage of any kind caused by the use of spare parts The general instructions in the Operator's Manual
not approved by Volvo Penta will be compensated by concerning operation, service and maintenance
any warranty undertaking. apply.

IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.

Volvo Penta accepts no responsibility for damage or

costs arising as a result of failure to follow the above
mentioned standards.

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00-0 General

Repair instructions
Introduction Our Mutual Responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the
mounted in a workholding fixture. Maintenance work technical specification may dramatically increase the
is often carried out in situ, in which case - if nothing environmental impact of an otherwise reliable
else is indicated - using the same working methods system. It is therefore critical that the stated wear
as the workshop. tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information. maintenance schedule must be followed.
Some systems, e.g. fuel systems, often require
DANGER! special expertise and test equipment. A number of
components are factory-sealed, for among other
WARNING! things environmental reasons. Warranty-sealed
components may not be worked on without
CAUTION! authorization to perform such work.
IMPORTANT!, NOTE! Remember that most chemical products, incorrectly
are by no means comprehensive since not everything used, are harmful to the environment. Volvo Penta
can be foreseen as service work is carried out in the recommends the use of biodegradable degreasers
most varied of circumstances. We call attention to whenever components are cleaned, unless otherwise
risks that may occur due to incorrect handling during specified in the Service Manual. When working
work in a well-equipped workshop using working outdoors, take especial care to ensure that oils and
methods and tools tried and tested by us. wash residues etc. are correctly properly for
destruction.
The service manual describes work operations
carried out with the aid of Volvo Penta Special Tools,
Tightening torque
where such have been developed. Volvo Penta
Special Tools are designed to ensure the safest and Tightening torques for vital fasteners that must be
most rational working methods possible. It is applied using a torque wrench are indicated in the
therefore the responsibility of anyone using tools or Service Manual, chapter Tightening torques and in
working methods other than those we recommend to the Manual's work descriptions. All torque indications
ensure that no risk of personal injury or mechanical apply to clean threads, bolt heads and mating faces.
damage is present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user required for fasteners, the correct type will be
instructions may be in force for the tools and indicated in the job description.
chemicals mentioned in the Service Manual. These
rules must always be observed, so there are no Torque, angle tightening
special instructions about this in the workshop
manual. When torque/angle tightening, the fastener is
tightened to a specified torque, and tightening then
By following these basic recommendations and using continues through a pre-determined angle.
common sense it is possible to avoid most of the risks
involved in the work. A clean workplace and a clean Example: For 90° angle tightening, the fastener is
product will eliminate many risks of personal injury turned an additional 1/4 turn in one sequence, after
and malfunction. the specified tightening torque has been achieved.

Above all, when working on fuel systems, hydraulic

systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.

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 00-0 General

Lock nuts Anaerobic agents.

These agents cure in the absence of air. These
Removed lock nuts may not be re-used; they must be preparations are used when two solid components,
replaced by new ones, as locking properties are e.g. two cast components, are fitted together without
impaired or lost with re-use. a gasket. Common uses are also to lock and seal
In the case of lock nuts with plastic inserts, the plugs, stud threads, taps, oil pressure monitors etc.
tightening torque indicated must be reduced if the nut
has the same nut height as a standard, all-metal Hardened anaerobic preparations are vitreous and
hexagonal nut. for this reason, the preparations are colored to make
Reduce the torque by 25% for bolt sizes of 8 mm or them visible. Hardened anaerobic preparations are
larger. highly resistant to solvents, and old compound
In the case of lock nuts with plastic inserts with a high cannot be removed. On re-assembly, it is important
nut-height (where the all-metal thread is as high as a to carefully degrease and wipe dry components first,
standard hexagonal nut), the indicated torque before applying new sealant in accordance with the
applies. instructions.

Strength Classes Safety regulations for fluorocarbon

Nuts and bolts are grouped into different strength rubber
classes. Their classification is shown by a marking on Fluorocarbon rubber is a common material in seal
the bolt head. Markings of a higher number indicate rings for shafts, and in O-rings, for example.
stronger material. For example, a bolt marked 10-9 is
stronger than one marked 8-8. When fluorocarbon rubber is exposed to high
temperatures (above 300°C/572°F), hydrofluoric acid
For this reason, it is important that when bolted joints can form. This is highly corrosive. Contact with the
are removed they are returned to their original skin can result in severe chemical burns. Splashes in
locations on re-assembly. When replacing bolts, your eyes can result in corrosive wounds. If you
check the applicable Spare parts catalog to ensure breathe in the fumes, your lungs can be permanently
the correct bolt is used. damaged.

Sealing compounds etc. WARNING!

To ensure service work is correctly carried out, it is Seals must never be cut with a torch, or be burnt
important that the correct type of sealants and locking afterwards in an uncontrolled manner. Risk for
fluids are used on joints where such are required. poisonous gases.

In each service manual section concerned, the WARNING!

sealants used in product manufacture are indicated. Always use chloroprene rubber gloves (gloves for
The same sealants, or sealants with equivalent chemicals handling) and goggles. Handle the
properties, must be used for maintenance work. removed seal in the same way as corrosive acid. All
A service technician should have a basic knowledge residue, including ash, can be highly corrosive. Never
of how sealing compounds are handled, and are able use compressed air to blow clean.
to assess the condition of existing seals. Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under running
Make sure that mating surfaces are dry and free from water before removing them.
oil, grease, paint and anti-corrosion agent before
applying sealant or locking fluid. Always follow the The following seals are most probably made from
manufacturer's instructions regarding applicable fluorocarbon rubber:
temperatures, hardening times and such.
Seal rings for the crankshaft, camshaft, idler shafts.
Two basic types of compound are used:
O-rings, regardless of where they are installed. O-
RTV preparations (Room Temperature rings for cylinder liner sealing are almost always
Vulcanizing). made of fluorocarbon rubber.
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV Please note that seals which have not been
sealants are completely visible when the part has exposed to high temperature can be handled
been removed. Old RTV sealant must be removed normally.
before the component is sealed again. Use
denatured alcohol.

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00-0 General

Illustrations

Colors used in illustrations

1 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. 2 Fastener
(red)
3 Assembly
(light gray)
4 Background
(white)
5 Special Tools
(yellow)
6 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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 03-2 Specifications, Engine

03-2 Specifications, Engine

Tightening torques
General Tightening Torques Nm (lbf.ft) Angle tightening
M6 standard bolt 10 (7.4) –
M8 standard bolt 24 (17.7) –
M10 standard bolt 48 (35.4) –
M12 standard bolt 85 (62.7) –
M14 standard bolt 140 (103.3) –
M16 standard bolt 220 (162) –
NOTICE! Check bolts that are to be re-
installed. Damaged bolts, e.g. with shear
marks under heads must be scrapped.

Special Tightening Torques

Group 21 - Engine
Front Engine Mounting, cylinder block 275 ±45 (203 ±33) –
Front Engine Mounting, forward engine mount 150 ±30 (111 ±22) –

Main Bearing Caps:

Stage 1 150 ±20 (111 ±15) –
Stage 2 – 120° ±5°

Conrod caps (tightened diagonally):

Stage 1 20 ±3 (15 ±2) –
Stage 2 35 ±3 (26 ±2) –
Stage 3 – 90° ±5°

Reinforcement plate / reinforcement frame 48 ±8 (35.4 ±6) –

(cylinder block)
NOTICE! Tighten the bolts in sequence from
the center outwards.

Lifting eye, front

Stage 1 30 ±3 (22.1 ±2) –
Stage 2 – 80° ±5°
Lifting eye, rear:
M12 100 ±5 (73.8 ±4) –

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03-2 Specifications, Engine

Group 22 - Lubrication System

Nm (lbf.ft) Angle tightening
Oil Sump 24 ±4 (17.7 ±3) –
NOTICE! Tighten the bolts in sequence from the
center outwards.
Drain plug, oil sump 60 ±5 (44.3 ±4) –
Bracket, lubrication oil pump / main bearing cap 24 ±4 (17.7 ±3) –
Oil strainer, attachment bolts 24 ±4 (17.7 ±3) –
Oil cooler, attachment bolts (tighten the bolts
diagonally)
Stage 1 35 ±5 (26 ±5) –
Stage 2 35 ±5 (26 ±5) –

Group 23 - Fuel System

Feed pump – intermediate housing / power 24 ±4 (17.7 ±3) –
steering pump
Intermediate housing / power steering pump – 30 ±6 (22.1 ±4) –
flywheel housing

Fixing yoke, unit injector:

With new copper sleeve
First tightening:
Stage 1 20 +5/0 (14.8 +4/0) –
Stage 2 – 180° ±5°

Note: Loosen the fixing yoke bolt before the

second tightening.
Second tightening:
Stage 1 20 +5/0 (14.8 +4/0) –
Stage 2 – 60° ±5°

With re-used copper sleeve

Stage 1 20 +5/0 (14.8 +4/0) –
Stage 2 – 60° ±5°

Locking nut for adjuster screw, unit injector:

Stage 1 Tighten until contact –
Stage 2 – 45° ±5°

Hollow screw M16 x 1.5 48 ±8 (35.4 ±6) –

Hollow screw M10 x 1 18 ±3 (13.3 ±2) –

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 03-2 Specifications, Engine

Piston Cooling Nozzles

Nm (lbf.ft) Angle tightening
Attachment bolt 24 ±4 (17.7 ±3) –
IMPORTANT! Faulty piston cooling will cause the pistons
to seize.
If piston cooling nozzle damage or deformation is
suspected, the nozzle must be replaced (also applies to
new nozzles).
Always check that the piston cooling nozzles are correctly
seated in the cylinder block holes concerned, that their
attachment plates are flat against the block and that the
nozzles are aimed at the notches in the pistons.
If piston cooling nozzles are not correctly installed, the
engine will immediately break down under load.

P0008064

Group 25 - Inlet and Exhaust System

Nm (lbf.ft) Angle tightening
Turbo 48 ±8 (35.4 ±6)(1) –
1) Note: Tighten the bolts diagonally. Finally tighten the first bolt again to the same torque.

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03-2 Specifications, Engine

Tightening Schedules
Cylinder head

Tightening torques: Nm (lbf.ft) Angle tightening

Step 1 60 ±10 (44.3 ±7) –
Step 2 (check tightening) 60 ±10 (44.3 ±7) –
Step 3 – 120°±5°
Step 4 – 90°±5°

Core plug, cylinder head 60 ±10 (44.3 ±7) –

Locking nut, valve adjustment:
Step 1 Tighten until contact –
Step 2 – 60°±5°

Valve Cover
9 10
12 11 1 7 8
13

16
6
15 14 2 3 4 5
P0004253

Nm (lbf.ft) Angle tightening

Tightening torques 24 ±4 (17.7 ±3) –

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 03-2 Specifications, Engine

Timing gear plate

Apply silicone to the back of the cylinder head and Tighten the bolts in numerical order.
cylinder block.

Nm (lbf.ft) Angle tightening

Tightening torques 24 ±4 (17.7 ±3) –

NOTICE! Apply a bead of sealant (part #

1181231) with a diameter of approx. 2 mm
(0.079").

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03-2 Specifications, Engine

Transmission
4 5 1

3 7
3
4
8
1 6
2
3
5
2 4
6
3 1

5 6

2 4

1
5

Nm (lbf.ft) Angle tightening

1. Crankshaft gear 24 ±4 (17.7 ±3) –

2. Intermediate gear, bull gear

Apply locking fluid 1161053 to the bolts and
tighten in the numerical order illustrated.
Step 1 35 ±4 (25.8 ±3) –
Step 2 – 60°±5°

3. Intermediate gear, adjustable

Tighten the bolts in the numerical order
illustrated.
Step 1 35 ±4 (25.8 ±3) –
Step 2 – 120°±5°

4. Camshaft gear / vibration damper

Tighten the bolts in the numerical order
illustrated.
Step 1 45 ±4 (33.2 ±3) –
Step 2 – 90°±5°

5. Drive, power steering pump / fuel feed 100 ±10 (73.8 ±7) –
pump

6. Drive gear, seawater pump 200 +50 (147.5 +36.9) –

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 03-2 Specifications, Engine

Flywheel Housing

35 6 Nm

P0002437
165 10 Nm

NOTICE! Apply a bead of sealant (part # 1161231)* with a

diameter of approx. 2 mm (0.079"); see illustration.

Tightening torques: Nm (lbf.ft) Angle tightening

M8 35 ±6 (25.8 ±4) –
M12 110 ±5 (81.1 ±4) –
M14 165 ±10 (121.7 ±7) –

Timing gear cover, upper

2 5

1
3

Nm (lbf.ft) Angle tightening

Tightening torques 24 ±4 (17.7 ±3) –

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03-2 Specifications, Engine

Flywheel

NOTICE! Make sure that the flange is clean and

dry.

Tightening torques: Nm (lbf.ft) Angle tightening

Step 1 60 ±5 (44.3 ±4) –
Step 2 – 120°±10°

Flywheel sensor
Flywheel (flywheel housing): 1.1 ±0.4 mm (0.0433 ±0.0157")
— distance to flywheel

Cover, front crankshaft seal

NOTICE! Apply a bead of sealant (part # 1161231)*
with a diameter of approx. 2 mm (0.079"); see
illustration.
* Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).

Tightening torques: Nm (lbf.ft) Angle tightening

Stage 1: Tighten all bolts by
hand (start with bolts 2
and 7)
Step 2 Tighten bolts 2 and 7 24 ±4 (17.7 ±3) –
Step 3 Tighten all bolts 1–8 24 ±4 (17.7 ±3) –

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 03-2 Specifications, Engine

Vibration Damper (crankshaft)

12
10 1

8 3

6 5

4 7

2 9
P0002978 11

NOTICE! Apply a bead of sealant (part #

1161231)* with a diameter of approx. 2 mm
(0.079"); see illustration.

Tightening torques: Nm (lbf.ft) Angle tightening

Step 1 45 ±5 (33.2 ±3) –
Step 2 – 90°±5°

NOTICE! Tighten the bolts in the numerical

order illustrated.
The 8.8 bolts on the oscillation damper may
NOTbe re-used.

Lubrication oil cooler, cover

3, 6 8 10 12 1, 14 16 18 20 22

24
4

7 9 11 13
5 15 25
P0004254 2, 17 19 21 23

Nm (lbf.ft) Angle tightening

Tightening torques 24 ±4 (17.7 ±3) –

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03-2 Specifications, Engine

Housing, safety valve

Nm (lbf.ft) Angle tightening

Tightening torques 48 ±8 (35.4 ±6) –

Valve housing, lubrication system

Nm (lbf.ft) Angle tightening

Tightening torques 25 ±5 (18.4 ±4) –

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 03-2 Specifications, Engine

Bearing caps, camshaft/rocker arm shaft

If the rocker arm shaft has been loosened or removed,
only the bolts that retain the shaft need be tightened
according to the schedule on re-assembly.

Nm (lbf.ft) Angle tightening

Stage 1: Tighten bolts 1–7 25 ±3 (18.4 ±2) –
Stage 2: Tighten bolts 9, 11, 13 90 ±5 (66.4 ±4) –
Start with bolt 11.
NOTICE! Tighten the bolts in stages
to ensure that the rocker arm shaft
bottoms against the bearing housing
without the shaft bending.
Stage 3: Tighten bolts 8, 10, 12, 14 60 ±5 (44.3 ±4) –
Stage 4: Undo bolts 9, 11, 13 – –
Stage 5: Tighten bolts 9, 11, 13 60 ±5 (44.3 ±4) –
Stage 6: Tighten bolts 1–7 – 90°±5°
Stage 7: Tighten bolts 8-14 – 100°±5°

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03-2 Specifications, Engine

Intake manifold

P0002679

NOTICE! Apply a bead of sealant (part # 1161231) with

a diameter of approx. 2 mm (0.079"); see illustration.

13 11 1 9 7 5 3

14 12 2 10 8 6 4
P0002979

Tightening torques: Nm (lbf.ft) Angle tightening

Tighten bolts 1 through 14 in numerical order 24 ±4 (17.7 ±3) –
Plug, (M10) 20 ±3 (14.8 ±2) –
Sensor, charge air pressure / charge air 12 ±2 (8.9 ±1.5) –
temperature

Exhaust manifold

Tightening torques: Nm (lbf.ft) Angle tightening

Stage 1: Tighten bolts (in numerical order) 5 ±2 (3.7 ±1.5) –
until they touch
Step 2 Tighten bolts 1 through 12 in 25 ±5 (18.4 ±4) –
numerical order
Step 3 Tighten bolts 1 through 12 in 52 ±5 (38.4 ±4) –
numerical order

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 03-2 Specifications, Engine

Engine harness

1. Rubber clamp 3. Rubber clamp (when oil level 4. Holder (part # 8131393)*
2. Strap monitor not fitted) 5. Strap (part # 983472)*

* IMPORTANT! Use only Volvo Penta original tension straps and holders under the valve cover for clamping the wiring to the unit injectors.
These parts are specially designed to resist oil and high temperatures.

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03-2 Specifications, Engine

General
Engine designation D9A2A: D9–425, D9–MH,
D9–MG
D9A2C: D9–425, D9–MH
D9A2E: D9–425, D9–MH
Number of cylinders 6
Cylinder bore 120 mm (4.724")
Stroke 138 mm (5.433")
Cylinder volume, total 9.36 liter (571.2 in3)
Number of valves per cylinder 4
Compression ratio 20,2:1
Firing order
(cyl. # 6 closest to flywheel) 1–5–3–6–2–4
Direction of rotation Clockwise
(seen from front)
Power See applicable Sales Guide
Low idle 550 rpm
(propulsion engine)
adjustable within range 500–750 rpm
HE 1150 kg (2535 lbs)(1)
Weight (dry) MG, MH Cooling system KC 1125 kg (2480 lbs)(2)
RC 1065 kg (2348 lbs)(3)
Full throttle range (propulsion engines):
Rating 1 1800–2200 rpm
Rating 2 1800–2200 rpm
Rating 3 1800–2200 rpm
Rating 4 2400–2650 rpm
Rating 5 2400–2650 rpm
1) Applies to engines with heat exchangers.
2) Applies to engines in keel cooled version.
3) Applies to engines with radiator cooling.

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 03-2 Specifications, Engine

Engine designation D9A2A: D9–500, D9–575

D9A2B: D9–500, D9–575
D9A2D: D9–500, D9–575
D9A2F: D9–500, D9–575
Number of cylinders 6
Cylinder bore 120 mm (4.724")
Stroke 138 mm (5.433")
Cylinder volume, total 9.36 liter (571.2 in3)
Number of valves per cylinder 4
Compression ratio (D9–500, D9–575):
D9A2A 17,4:1
D9A2B, D9A2D, D9A2F 16,5:1
Firing sequence (cyl. # 6 closest to flywheel) 1–5–3–6–2–4
Direction of rotation (seen from front) Clockwise
Power See applicable Sales Guide
Low idle (propulsion engine) 550 rpm
adjustable within range 500–750 rpm
Weight (dry) R3–5 1075 kg (2370 lbs)
Full throttle range:
Rating 5 2300–2600 rpm

Engine
Engine body
Cylinder head

Type One common cylinder head for all cylinders

(overhead camshaft)
Length 996 mm (39.212")
Width 410 mm (16.142")
Height 135 mm (5.315")
Max. flatness error (base plane) 0.4 mm (0.0157")

Cylinder Head Bolts

Quantity 26
Thread size M16 x 2
Length 200 mm (7.874")

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03-2 Specifications, Engine

Cylinder block
Length 967 mm (38.071")
Height, upper block plane – crankshaft center (A) 379 mm (14.921")
Height, lower block plane – crankshaft center (B) 120 mm (4.724")

P0003958

Cylinder Liners
Type Wet, replaceable
Cylinder diameter (oversize not available) 120.00–120.02 mm
(4.724–4.725")
Height, total 250 mm (9.842")
Sealing surface height above block plane 0.15–0.20 mm
(0.0059–0.0079")
Number of O-rings, upper liner seal 1
Number of O-rings, lower liner seal 2
0.15-0.20 mm

P0008664

Pistons
Materials Aluminum
Piston installed in engine, height above engine block 0.15–0.65 mm
plane (0.0059–0.0256")
Number of ring grooves 3
Front marking Arrow towards front

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 03-2 Specifications, Engine

Gudgeon pins
Diameter 54 mm (2.1260")

Piston rings
Compression Rings
Quantity 2
Marking To face up
Piston ring clearance in groove:
upper compression ring Trapezoid profile
lower compression ring 0.09–0.14 mm (0.00354–0.00551")
Piston ring gap, measured at ring opening:
upper compression ring 0.40–0.55 mm (0.0157–0.0217")
max ring gap (wear tolerance) 0.65 mm (0.0256")
lower compression ring 0,80-1,00 mm (0,0315-0,0394")
max ring gap (wear tolerance) 1.65 mm (0.065")

Oil Scraper Ring

Quantity 1
Marking To face up
Piston ring clearance in groove 0.05–0.10 mm (0.00197–0.00394")
Piston ring gap, measured at ring opening 0.30–0.55 mm (0.0118–0.0217")
max ring gap (wear tolerance) 0.70 mm (0.0276")

XXX
X

XXX
X
X
X
X
X

p0008656

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03-2 Specifications, Engine

Timing gears

2
8
3

4
7
5
P0002538

1. Drive gear, camshaft 84 teeth

2. Intermediate gear, adjustable 73 teeth
3. Intermediate gear, bull drive outer 72 teeth
Intermediate gear, bull drive, inner 56 teeth
4. Drive gear, crankshaft 54 teeth
5. Drive gear, lubrication oil pump 23 teeth
6. Intermediate gear, power steering pump and 37 teeth
seawater pump
7. Drive gear, power steering and fuel feed pump 31 teeth
8. Drive wheel, seawater pump 42 teeth

Gear lash measurement 0.05–0.17 mm (0.0020–0.0067")

Idler wheel stub shaft, diameter 100 mm (3.9370")
Idler wheel bush, diameter 100 mm (3.9370")
Radial clearance for intermediate gear max 0.05 mm (0.0020")

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 03-2 Specifications, Engine

Valve mechanism
Camshaft
Checking camshaft timing
cold engine and valve clearance = 0
Inlet valve for cylinder 1 must be open at flywheel
position 6 after TDC 1.3 ±0.3 mm (0.0512 ±0.0118")
Note: During this check, the timing gear must be
turned in the correct direction (clockwise seen from
the front) to take up all gear lash.
NOTICE! Do not forget to re-adjust the valve
clearance to the correct value after the check.

Drive Gear wheel

No. of bearings 7
Diameter, bearing journals, standard 69.97-70.00 mm (2.7547-2.7559")
NOTICE! Only check values, not for machining.
Diameter, bearing journals, undersize dimension:
0.25 mm (0.0098") 69.72-69.78 mm (2.7449-2.7472")
0.50 mm (0.0197") 69.47-69.53 mm (2.7350-2.7374")
0.75 mm (0.0295") 69.22-69.28 mm (2.7252-2.7276")
Max permissible out-of-round (with new bearings) 0.05 mm (0.0020")
Bearing, max permissible wear on diameter 0.05 mm (0.0020")
Max end float 0.24 mm (0.0094")
Valve lift:
Inlet 13 mm (0.5118")
Exhaust 12 mm (0.4724")
Permitted wear between base circle and max lift:
Inlet max 0.1 mm (0.0039")
Exhaust max 0.1 mm (0.0039")
Unit injector max 0.1 mm (0.0039")
Unit injector, stroke 13 mm (0.5118")

Camshaft Bearings
Camshaft bearing thickness, standard 1.92 mm (0.0756")
Oversize:
0.25 mm (0.0098") 2.05 mm (0.0807")
0.50 mm (0.0197") 2.17 mm (0.0854")
0.75 mm (0.0295") 2.30 mm (0.0906")

Camshaft sensors
Camshaft (timing cover):
distance to gearwheel, vibration damper 1.1 ±0.4 mm (0.0433 ±0.0157")

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03-2 Specifications, Engine

Valves
Valve head, diameter:
Inlet 38 mm (1.496")
Exhaust 38 mm (1.496")
Valve stem, diameter:
Inlet 8 mm (0.3150")
Exhaust 8 mm (0.3150")

P0016622

Valve seat angle:

Inlet 29.5°
Exhaust 29.5°
Valve seat angle in cylinder head:
Inlet 30°
Exhaust 30°

P0008718

Dimension (A) between valve head and cylinder head

plane (check value):
Inlet min 0.95 mm (0.0374")
Exhaust min 1.25 mm (0.0492")
NOTICE! When valve seats are changed, valves must
also be changed.

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 03-2 Specifications, Engine

Valve clearance (cold engine), setting value:

Inlet 0.45 mm (0.0177")
Exhaust 0.50 mm (0.0197")
Valve clearance, (cold engine), check value:
Inlet 0.40 – 0.50 mm (0.0157–0.0197")
Exhaust 0.45 – 0.55 mm (0.0177–0.0217")

Valve seats

Outer diameter (A)

Standard:
Inlet 40.0 mm (1.5748")
Exhaust 41.0 mm (1.6142x")
Height (B):
Inlet 7.4 mm (0.2913")
Exhaust 7.4 mm (0.2913")

Valve seat position

Diameter (C) standard:

Inlet 40.0 mm (1.5748")
Exhaust 41.0 mm (1.6142")
Depth (D):
Inlet 11.5 mm (0.4528")
Exhaust 11.9 mm (0.4685")
Seat base radius (R):
Inlet max 0.8 mm (0.0315")
Exhaust max 0.8 mm (0.0315")

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03-2 Specifications, Engine

Valve guides
Length:
Inlet 83.5 mm (3.287")
Exhaust 83.5 mm (3.287")
Inner diameter:
Inlet 8 mm (0.3150")
Exhaust 8 mm (0.3150")
Height above cylinder head spring plane:
Inlet 24.5 ±0.5 mm (0.9646 ±0.0197")
Exhaust 16.5 ±0.5 mm (0.6496 ±0.0197")
Clearance, valve stem – guide:(1)
Inlet max 0.2 mm (0.0079")
Exhaust max 0.2 mm (0.0079")
1) Note: Dimensions have been calculated for the measurement method described in the ”Valve guides, inspection” section.

Valve springs
Inlet / Exhaust
Outer valve springs:
Uncompressed length 73.8 mm (2.9055")
With load 590 N (132.6 lbf) 58.4 mm (2.2992")
With load 1150 N (258.5 lbf) 45.3 mm (1.7835")
Coil bound length, max 38.5 mm (1.5157")

Inner valve spring:

Uncompressed length 70.5 mm (2.7756")
With load 328 N (73.7 lbf) 54.4 mm (2.1417")
With load 630 N (141.6 lbf) 41.3 mm (1.6260")
Coil bound length, max 36.5 mm (1.4370")

Rocker arms
Bearing clearance max 0.08 mm (0.0031")
Roller cam follower, clearance max 0.1 mm (0.0039")

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 03-2 Specifications, Engine

Crank Mechanism
Crankshaft
Crankshaft end float* 0.07 – 0.31 mm (0.0028 – 0.0122")
Main bearings, radial clearance* 0.11 mm (0.0043")
Max permissible out-of-round on main and crankshaft 0.01 mm (0.0004")
journals
Max permissible taper on main and crankshaft 0.02 mm (0.0008")
journals
Max permissible runout 0.15 mm (0.0059")

* Note: Dimensions apply to oiled components.

Main bearing journals

NOTICE! Only check values; not for machining.

Diameter (Ø) standard 108.0 mm (4.2520")
Undersize:
0.25 mm (0.0098") 107.73–107.75 mm (4.2413–4.2421")
0.50 mm (0.0197") 107.48–107.50 mm (4.2315–4.2323")
1.00 mm (0.0394") 106.98–107.00 mm (4.2118–4.2126")
Surface finish, main bearing journal Ra 0.25
Surface finish, radius Ra 0.4
Width, thrust bearing journal (A) standard 42 mm (1.6535")
Oversize:
0.2 mm (0.0079"), thrust bearing 0.1 mm 42.17–42.22 mm (1.660–1.662")
0.4 mm (0.0157"), thrust bearing 0.2 mm 42.37–42.42 mm (1.668–1.670")
0.6 mm (0.0236"), thrust bearing 0.3 mm 42.57–42.62 mm (1.676–1.678")
Fillet radius (R) 4.5 mm (0.1772")

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03-2 Specifications, Engine

Thrust washers (thrust bearings)

Width (B) standard 3.18 mm (0.1252")
Oversize:
0.1 mm (0.0039") 3.28 mm (0.1291")
0.2 mm (0.0079") 3.38 mm (0.1331")
0.3 mm (0.0118") 3.48 mm (0.1370")

Main bearing shells

Outer diameter (C) 113 mm (4.4488")
Thickness (D) standard 2.5 mm (0.0984")
Oversize:
0.25 mm (0.0098") 2.6–2.7 mm (0.1024–0.1063")
0.50 mm (0.0197") 2.7–2.8 mm (0.1063–0.1102")
1.00 mm (0.0394") 2.9–3.0 mm (0.1142–0.1181")

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 03-2 Specifications, Engine

Big-end bearing journals

NOTICE! Only check values; not for machining.
Diameter (Ø) standard 88 mm (3.4646")
Undersize:
0.25 mm (0.0098") 87.85–87.87 mm)
(3.4587–3.4594")
0.50 mm (0.0197") 87.73–87.75 mm
(3.4539–3.4547")
1.00 mm (0.0394") 87.48–87.50 mm
(3.4441–3.4449")
Surface finish, big end bearing journal Ra 0.25
Surface finish, radius Ra 0.4
Width (A) 54 mm (2.1260")
Fillet radius (R) 4.5 mm (0.1772")

Big-end journal shells

Thickness (B) standard 2.4 mm (0.0945")
Oversize:
0.25 mm (0.0098") 2.5–2.6 mm
(0.0984–0.1024")
0.50 mm (0.0197") 2.6–2.7 mm
(0.1024–0.1063")
1.00 mm (0.0394") 2.8–2.9 mm
(0.1102–0.1142")

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03-2 Specifications, Engine

Con rods
Length, center – center 225 mm (8.858")
Piston pin bush internal diameter (D) 54 mm (2.1260")
End float, connecting rod – crankshaft, max.* 0.35 mm (0.0138")
Big end bearing, radial clearance, max.* 0.10 mm (0.0039")
Straightness, max deviation on 100 mm measured 0.06 mm (0.0024")
length
Twist, max deviation on 100 mm measured length 0.15 mm (0.0059")

* Note: Dimension applies to oiled components.

Marking
”FRONT” on shaft faces Forward
Connecting rods and caps are marked in pairs by a
three-digit serial number (see illustration).

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 03-2 Specifications, Engine

Lubrication System
Oil grade (1) Sulfur content in fuel, by weight
up to 0.5% 0.5–1.0% more than 1.0% (2)
Oil change interval: Reached first in operation
VDS-3 500 hours or 12 months. 200 hours or 12 100 hours or 12 months.
months.
VDS-2 and ACEA E7 (3)(4)
VDS-2 and Global DHD-1 200 hours or 12
400 hours or 12 months. 100 hours or 12 months.
VDS-2 and API CH-4 months.
VDS-2 and API CI-4
VDS and ACEA E3, (5) 150 hours or 12
300 hours or 12 months. 75 hours or 12 months.
VDS and API CG-4, (6) months.

1) Lowest recommended oil grade. Lubricating oils with higher grades may always be used.
2) If sulfur content is >1.0 % by weight, oil with TBN >15 must be used.
3) Lubricating oil must fulfill both requirements.
4) ACEA-E7 has replaced ACEA E5. However, ACEA E5 may be used if the grade is still available.
5) ACEA E3 may be replaced by ACEA E4, E5 or E7.
6) API CG-4 may be replaced by API CI-4.

NOTICE! Mineral based oil, either fully or semi-synthetic, may be used on condition that it complies with the quality
standards above.

VDS = Volvo Drain Specification

ACEA = European Automobile Manufacturers' Association
Global DHD = Global Diesel Heavy Duty
API = American Petroleum Institute
TBN = Total Base Number

All engines
Select viscosity according to the adjacent table
(Temperature values refer to stable ambient air
temperatures).

Viscosity

* SAE 5W/30 refers to synthetic or semi-synthetic oils.

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03-2 Specifications, Engine

Oil system total volume

Including 3 filters
D9-MH:
no engine incline 46 liter (12.2 US gals)
volume difference, min– max 12 liter (3.2 US gals)
Other D9 engines through engine # x0090157603:(1)
no engine inclination 31 liters (8.2 US gallons)
volume difference, min– max 4 liter (1.1 US gals)
engine incline 6° 24 liters (6.3 US gallons)
volume difference, min– max 4 liters (1.1 US gallons)
Other engines:
no engine inclination 38 liters (10.0 US gallons)
volume difference, min– max 4 liters (1.0 US gallons)
engine incline 7° 30 liters (7.9 US gallons)
volume difference, min– max 4 liters (1.1 US gallons)

Lube oil pump

Type Gear pump

Engine Oil Pressure

Operating rpm (above 1100 rpm) 450-760 kPa (65.3-110.2 psi)
Low idle (propulsion engine) min 300 kPa (43.5 psi)

Engine Oil Temperature

Warm engine in operation, (coolant temperature 75–
95°C / 167–203°F) 90-115°C (194-239°F)

Engine Oil Filter

Full flow filter, quantity 2
(tighten ¾ – 1 turn after contact)
By-pass filter, quantity 1
(tighten ¾ – 1 turn after contact)
1) Note: The first digit (x) indicates place of manufacture (factory) and may be a 1 or a 7.

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 03-2 Specifications, Engine

Oil Valves
1. Safety valve, lubricating oil pressure
Opening pressure 860 kPa (124.7 psi)
Marking Violet

2. Thermostat valve, oil cooler

Opening temperature 116°C (241°F)

3. By-pass valve, full flow oil filter

Opening pressure 110 kPa (16.0 psi)
Spring, free length 68.8 mm (2.709")
compressed 13–15 N (2.9–3.4 lbf) 40 mm (1.575")

4. Relief valve, lubricating oil pressure

Opening pressure 480 kPa (69.6 psi)(1)
570 kPa (82.7 psi)(2)
Marking Blue(1)
Black(2)
1) Applies to D9–MH, D9–MG and other D9 engines through engine # x09163095.Note: The first digit (x) indicates place of
manufacture (factory) and may be a 1 or a 7.
2) Applies from engine # x009163096 (but notD9–MH or D9–MG).

5. By-pass valve, full flow oil filter

Opening pressure 570 kPa (82.7 psi)
Spring, free length 21.8 mm (0.858")
with load 40 ±3.5 N (9.0 ±0.8 lbf) 15 mm (0.591")

6. Piston cooling valve

Opening pressure 300 kPa (43.5 psi)
Spring, free length 122 mm (4.803")
with load 94 ±10 N (21.1 ±2.2 lbf) 62 mm (2.441")

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03-2 Specifications, Engine

Fuel System

P0008768

Fuel specification
Fuel must comply with national and international standards for commercially supplied fuels, such
as:
EN 590 (with nationally adapted environmental and cold weather requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: According to current legislation in the country concerned.

Low sulfur content fuel (urban diesel in Sweden and city diesel in Finland) may cause up to 5% power loss and a fuel
consumption increase of around 2–3 %.

Injection sequence 1–5–3–6–2–4

Feed pump
Feed pressure after fuel filter at:
600 rpm min. 400 kPa (58 psi)
1200 rpm. min. 400 kPa (58 psi)
full load min. 400 kPa (58 psi)

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 03-2 Specifications, Engine

Bypass valve
Opening pressure 400–550 kPa (58–79.8 psi)

Unit injectors

Pre-load 3–4 flats (0.75 ±0,1 mm / 0.0295 ±0.0039")

Adjust the unit injector rocker arm to zero clearance against the camshaft. Then tighten the adjuster screw a
further 3-4 flats (180°-240°).

Location of unit injector trim code(1)

P0001354

1. Note: The trim code specifies individual unit injector tolerances

for the engine control unit. In the example illustrated the trim code
is ”5D008A”.

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03-2 Specifications, Engine

Inlet and Exhaust System

Turbo
Make and type:
D9A2A MH/MG, D9A2B MH/MG, D9A2C MH Borg Warner K29
Other D9A2A, D9A2B, D9A2D Borg Warner K31
Cooling Coolant and lubricating oil
Lubrication Pressure lubrication from engine
End float, turbine shaft max 0.15 mm (0.0059")
Radial clearance, turbine disc shaft (turbine side): 0.45-0.95 mm (0.0177-0.0374")

P0008995

Wastegate valve, check values: (1)

D9 MH, MG, R3 pressure setting 2.39 ±0.02 bar
(34.66 ±0.29 psi)
valve movement (A) 2.87 ±0.2 mm
(0.1130 ±0.0079")
Other R 4–5, pressure setting 2.55 ±0.02 bar
(36.98 ±0.29 psi)
valve movement (A) 1.05 ±0.2 mm
(0.0413 ±0.0079")
1) NOTE! This is only a functional check of membrane and valve and may not be used for setting. The wastegate valve may
not be adjusted. If faults are discovered, the complete turbocharger unit must be changed. A wrongly adjusted valve may cause
engine breakdown. The engine warranty will cease to be valid if the valve has been adjusted.

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 03-2 Specifications, Engine

Charge air pressure and exhaust temperatures

Charge air pressure, (measured at the engine inlet pipe) at 100% load and full throttle.
Exhaust back pressure 10 kPa (1.45 psi). If full power cannot be achieved, the pressure will be considerably lower.
Charge air pressures in the following table to be read with a tolerance of ±15 kPa (±2.1 psi).
(100 kPa = 14.5 psi)
Exhaust temperatures taken at rated power.
Temperature of inlet air +27°C (80.6°F) and exhaust back pressure 10 kPa (1019 mm / 40.118" water column /
1.45 psi).

D9 MG (HE/KC) (1) Charge air pressure Exhaust Temperature

Power – ISO HE KC HE KC
Standard Power
1500 rpm. 154 kPa (22.3 psi) 156 kPa (22.6 psi) 460°C (860°F) 448°C (838°F)
1800 rpm 170 kPa (24.7 psi) 170 kPa (24.7 psi) 420°C (788°F) 415°C (779°F)
Power – Overload
Power (2)
1500 rpm. — — 479°C (894°F) 472°C (882°F)
1800 rpm — — 468°C (874°F) 468°C (874°F)

D9 MG (RC) (1)
Power – ISO RC RC
Standard Power
1500 rpm 154 kPa (22.3 psi) 462°C (864°F)
1800 rpm 167 KpA (24.2 psi) 432°C (810°F)
Power – Overload
Power (2)
1500 rpm — 482°C (900°F)
1800 rpm — 472°C (882°F)
1) HE = Engine fitted with heat exchanger. KC = Keel-cooled engine. RC = Engine fitted with radiator.
2) 110% of ISO Standard Power.

D9 (other engines)
Power – Rating 1 (300/355)
1800 rpm 167 kPa (24.2 psi) 393°C (739°F)
Power – Rating 1 (355)
2200 rpm 153 kPa (22.2 psi) 387°C (729°F)
Power – Ratings 2 and 3 (425)
2200 rpm 173 kPa (25.1 psi) 478°C (892°F)
Power – Ratings 4 and 5 (500)
2600 rpm 197 kPa (28.6 psi) 429°C (804°F)
Power – Rating 5 (575)
2500 rpm 216 kPa (31.3 psi) 507°C (945°F)

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03-2 Specifications, Engine

Exhaust back pressure

Max permissible back pressure in exhaust line at max 15 kPa (2.18 psi),
power (max operating rpm) 1530 mm (60.236") water column

Pressure drop indicator, air filter

Indication level (under pressure) 508 mm (20.00") water column

Cooling System
General
Type Overpressure (sealed system)
Pressure valve opens at
Check the opening pressure at the filler cap. 75 / 100 kPa
Coolant volume, approx. 39 liters (10.3 US gals)(1)

Thermostat
Type Piston thermostat
Quantity 1
The starts to open at 84–88°C (183–190°F)(2)
thermostat
fully open at 94-98°C (201-208°F)(2)
starts to open at 80–84°C (176–183°F)(3)
fully open at 90-94°C (194-201°F)(3)

Coolant Pump
Type Belt-driven centrifugal pump
600 rpm 80 kPa (11.6 psi)
1000 rpm 140 kPa (20.3 psi)
1800 rpm 270 kPa (39.2 psi)
2300 rpm 340 kPa (49.3 psi)
1) Note. Incl. heat exchanger (HE).
2) Applies through engine # 168195.
3) Applies from engine # 16896.

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 03-2 Specifications, Engine

Coolant
”Volvo Penta Coolant, Ready Mixed” Ready-mixed coolant
Consists of 40% ethylene glycol with corrosion inhibiting additives
and 60% water
Protects against freezing down to approx. –28°C (–18°F)
Alternative:
”Volvo Penta Coolant” Concentrated coolant
Consists of Ethylene glycol + corrosion inhibiting additives
Color Blue-
green

Mixture ratio Concentrated Mix with water(1)(2) Protects

coolant against
freezing
down to
approx.
60% –28°C (–
40% 18°F)
50% -40°C
50% (-40°F)
40% -54°C
60%(3) (-65°F)

Water quality
ASTM D4985:
Total solid particles < 340 ppm
Total hardness: < 9.5° dH
Chloride < 40 ppm
Sulfate < 100 ppm
pH value 5.5-9
Silica (as per ASTM D859) < 20 mg SiO2/l
Iron (as per ASTM D1068) < 0.10 ppm
Manganese (as per ASTM D858) < 0.05 ppm
Conductivity (as per ASTM D1125) < 500 µS/cm
Organic content, CODMn (acc. ISO8467) < 15 mg KMnO4/l

Seawater Pump
Type Rubber impeller
Pressure after seawater pump:
600 rpm 20 kPa (2.9 psi)
1000 rpm 35 kPa (5.1 psi)
1800 rpm 55 kPa (8.0 psi)
2300 rpm 70 kPa (10.2 psi)
1) IMPORTANT! The concentrated coolant must be mixed with clean water. Use distilled – deionized water. The water must
fulfill the demands specified in ASTM D4985 (see under heading "Water quality" below). Volvo Penta Coolant (ethylene glycol)
must not be mixed with other types of glycol.
2) IMPORTANT! A coolant mixture with at least 40% concentrate (Volvo Penta Coolant) must be used all year round, even if
there is no risk for freezing. This is to ensure that the engine is adequately protected against corrosion and cavitation damage.

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03-2 Specifications, Engine

3) Never mix more than 60% concentrate (Volvo Penta Coolant) in the coolant. A higher concentration causes reduced cooling
effect with the risk of overheating and gives less frost protection.

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 03-3 Specifications, Electrical

03-3 Specifications, Electrical

Electrical System

System voltage 24 V
Battery capacity 2 pcs. series connected 12 V,
max 180 Ah
System voltage 12 V
Battery capacity 2 pcs. parallel connected 12 V,
max 180 Ah
Battery electrolyte specific gravity at +25°C (77°F):
fully-charged battery 1.28 g/cm3 (1.24 g/cm3)(1)
0.0462 lb/in3 (0.0448 lb/in3)(1)
re-charge battery at 1.24 g/cm3 (1.20 g/cm3)(1)
0.0448 lb/in3 (0.0434 lb/in3)(1)

Alternator
Voltage/ current 28 V / 80 A

Alternative:
Voltage/ current 14 V / 115 A

Starter motor
Voltage/ output 24 V / 5.5 kW

Alternative:
Voltage/ output 12 V / 5.5 kW

1. Note: Applies to batteries with tropical acid.

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05-1 Safety Instructions

05-1 Safety Instructions

Safety Information
This workshop manual contains repair instructions,
descriptions and technical data for products or product
drawings from Volvo Penta. Check that you have the
correct workshop manual.

Read the safety information below and the section About this Workshop manual and Repair instructions
carefully before beginning any work with repairs or service.

!
In the workshop manual and on the product, this symbol is used to call your attention to the fact that this is safety
information. Always read such information very carefully.
Warning texts in the manual 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!
Is used to make you aware of something that may cause minor damage or a minor malfunction to the product or
property.

NOTICE! Is used to make you aware of important information that will facilitate the work or operation in progress.

This symbol is used on certain functions to indicate the following:

This operation requires prior theoretical and/or instructor led training before attempting.Contact your local training
organization for further information.

This symbol informs you that supplemental information needs to be read. And where necessary information can
be found.

This symbol is used when a VODIA computer is needed, either for troubleshooting, testing or programming.

A compilation of safety precautions that must be taken and risks which you must be aware of is presented
in the following pages.

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 05-1 Safety Instructions

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply with the main switch(es) and lock it ! engine is hot. Steam or hot coolant may spray
(them) in the off position before starting work. out and the system can lose pressure. Open the
Place a warning notice at the main switch. 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 has to be
removed while the engine is hot.

As a general rule, all service operations must be Hot oil can cause burn injuries. Avoid exposing
! carried out with the motor stopped. However, ! your skin to hot oil. Make sure that the
some work, such as adjustments, will require lubrication system is not under pressure before
the engine to be running. Approaching a any work is begun. Never start or run an engine
running engine is a safety risk. Remember that without the oil filler cap in place. Hot oil under
loose clothing and long hair can fasten in pressure can spray out.
rotating parts and cause serious personal
injury.

Be aware of hot surfaces (exhaust pipes, Never start the engine without the air filter in
! turbocharger, charge air pipe, starting heaters, ! place. The rotating compressor turbine in the
etc.) and hot liquids in supply lines and hoses turbocharger can cause severe injury. Foreign
on an engine that is running or has just stopped. objects entering the intake ducts can also cause
A careless movement or a dropped tool may, in mechanical damage. Install all protective
the worst case, result in personal injury when covers before starting the engine.
working in the vicinity of a running engine.

Make sure that all warning and information Only start the engine if the surrounding
! decals on the product are always visible. ! ventilation is satisfactory. When operating in a
Replace decals that have been damaged or confined space, exhaust fumes and crankcase
painted over. gases must be led away from the engine
compartment or workshop area.

Avoid getting oil on the skin! Protracted or The majority of chemicals, e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. Used oil is such as degreasing agents, paints and
more dangerous than fresh oil from a health solvents, are health hazards. Carefully read the
aspect. Use protective gloves and avoid oil- instructions on the product packaging! Always
soaked clothes and rags. Wash regularly, follow the safety directions for a product, e.g.
especially before eating. Use suitable with regard to use of protective mask, glasses,
protective creams to counteract skin dryness gloves, etc. Make sure that other personnel are
and to aid dirt removal. not exposed to substances that are health
hazards. Ensure good ventilation. Handle used
and leftover chemicals in the prescribed
manner.

Turn off the engine and disconnect the power at Only make connection adjustments with the
! the main switch(es) before starting work on the ! engine switched off.
electrical system.

47703722 01-2020 © AB VOLVO PENTA 45

05-1 Safety Instructions

Always wear protective goggles if there is a risk Never start the engine with the valve cover
! of splinters, sparks and splashes from acid or ! removed. There is a risk of personal injury.
other chemicals. Your eyes are extremely
sensitive, injury to them could result in
blindness!

Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the seacock/cooling
water inlet valve before starting work on the
cooling system.

All fuels, and many chemicals, are flammable. Make sure that rags soaked in oil or fuel and
! Never allow open flames or electrical sparks in ! used fuel and oil filters are stored safely. Oil-
the their vicinity. Gasoline, certain solvents and soaked rags may ignite spontaneously in
hydrogen from batteries are extremely certain conditions. Used fuel and oil filters are
flammable and explosive in the right environmentally hazardous waste and must be
concentration in air. No smoking! Ensure the taken to an approved waste management
work area is well ventilated and take the facility for correct handling, as must any used
necessary safety precautions before welding or lubricating oil, contaminated fuel, paint residue,
grinding work is begun. Always ensure that solvents, degreasers and wash residue.
there are fire extinguishers close at hand in the
work area.

Batteries must never be exposed to open Never work alone when dismantling heavy
! flames or electrical sparks. Never smoke in the ! components, even when using lifting equipment
vicinity of the batteries. During charging they such as lifting devices with lockable blocks. Two
generate hydrogen gas, which is explosive people are usually required when using a lifting
when mixed with air. This gas mixture is easily device; one to operate the lifting device and the
ignited and highly explosive. A spark, which can other to make sure the components do not
be caused by incorrect battery connection, is collide with objects and suffer damage during
enough to cause the battery to explode and the hoist.
cause serious damage.

Do not touch the connections during a starting

attempt. Spark hazard! Do not lean over
batteries.

Never mistake the positive (+) for the negative Use the loops on the engine when lifting it.
! (-) battery pole when installing batteries. ! Always check that the hoisting equipment is in
Incorrect pole connections can result in serious good condition and has the capacity to lift the
damage to electrical equipment. Refer to the engine (engine weight including gearbox and
wiring diagram. any auxiliary equipment installed). The engine
Always wear protective goggles when charging must be lifted with a properly adjusted lifting
or handling the batteries. The battery electrolyte boom to ensure safe handling and avoid
contains sulfuric acid which is highly corrosive. damage to components fitted to the top of the
Rinse immediately with plenty of water and engine. All chains or wires must run parallel to
soap if battery electrolyte comes into contact each other and be as perpendicular to the
with unprotected skin. If you get battery acid in engine as possible. If the engine has equipment
your eyes, flush at once with a generous fitted that alters its center of gravity, special
amount of water, and get medical assistance at lifting devices may be required to achieve the
once. correct balance for safe handling. Never carry
out any work on an engine that is only
suspended by lifting equipment.

46 47703722 01-2020 © AB VOLVO PENTA

 05-1 Safety Instructions

The components in the electrical and fuel Take extreme care when searching for fuel
! systems on Volvo Penta products are designed ! system leaks and testing fuel injector nozzles.
and manufactured to minimize the risk of fire Wear safety goggles. The jet from a nozzle is
and explosion. The engine must not be under very high pressure and has great
operated in areas where there are explosive penetration power. Fuel can penetrate deep
materials or gases. into body tissue and cause severe injury. There
is a risk of blood poisoning (septicemia).

Only use fuels and lubricating oils as Never use a high-pressure washer to clean the
! recommended by Volvo Penta. Refer to the ! engine.
operator's manual for the product concerned. Pay attention to the following when using a high-
Using fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never aim the water jet at seals,
injectors. In the case of diesel engines, low- rubber hoses or electrical components.
quality fuel may cause the control rod to stick
and the engine to overrev with the risk of engine
damage and personal injury as a result. Low-
quality fuel and oils may lead to higher service,
maintenance and repair costs.

Under no circumstances may fuel pipes be bent When overhauling an engine, perform leakage
! or straightened. Cracks may occur. Damaged ! and functional checks as necessary.
pipes must be replaced.

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05-1 Safety Instructions

48 47703722 01-2020 © AB VOLVO PENTA

 08-2 Special Service Tools

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools may be ordered from AB Volvo
Penta by specifying the number indicated.

P0006764
P0011602 P0008418

827861 Spacer 885810 Fixture 9809667 Thread tap

Fixing tool for upper timing gear
casing

P0006782

P0008420

9809668 Extractor 9998666 Adapter 9809726 Pneumatic hydraulic

Sealing washer for temperature pump
sensor during cylinder head Valves and valve guides
pressure testing

P0006792 P0006269

9809729 Hydraulic cylinder 9990006 Puller 9990113 Drift

Valves and valve guides For unit injectors Tool, removal of rear crankshaft
seal

P0012151 P0012152 P0012153

9990044 Piston ring 9990105 Plate 9990106 Plate

compressor Sealing washer for cylinder head Sealing washer for thermostat
pressure testing housing

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08-2 Special Service Tools

p00006766
P0006768 P0011608

9990107 Connection washer 9990114 Puller 9990117 Cone

Connection washer for Puller for main bearing cap Cone, installation, rear crankshaft
thermostat housing for cylinder seal
head pressure testing

P0006774
P0006786
P0006773

9990156 Adapter 9990157 Press tool 9990176 Press tool

Adapter for 9998251 Protection Press tool for removal/installing
plug valve springs and valve guides

P0006793 P0006779
P0006780

9990185 Lifting tool 9990192 Puller 9990210 Valve spring

Lifting tool for rocker arm bridge For rear crankshaft seal, used compressor
with 9996400 Slide hammer

P0012157 P0012158 P0012159

9991801 Standard handle 9991821 Extractor 9992000 Handle

Flywheel bearing, replacement

P0012160 P0006784 P0006788

9992564 Drift 9993590 Rotation tool 9996159 Adapter

p0004329

p0006802 p0004330

9996239 Lifting tool × 2 9996394 Support × 2 9996395 Support × 2

Lifting chain, removal/installation Removal of cylinder liner
of cylinder head and flywheel
housing.

50 47703722 01-2020 © AB VOLVO PENTA

 08-2 Special Service Tools

9996545
P0012163 p0006800

9996400 Slide hammer 9996441 Cover, with 9996545 Extractor

connecting nipple
For cooling system leakage test

P0004332 P0010359
p0006801

9996645 Puller 9996966 Press tool × 7 9998246 Drift

Puller for cylinder liner Press for cylinder liners. Tool for removing/installing valve
springs

p0006803 P0006805 P0006806

9998248 Adapter 9998249 Protective sleeve × 6 9998250 Sealing ring × 2

Adapter for measuring cylinder Protective sleeve for unit injector. Seal ring for fuel duct in cylinder
compression head when replacing copper
sleeves.

P0006808 P0006810 P0006813

9998251 Protection plug × 6 9998252 Thread cutting tool 9998264 Lifting tool
Protective plug for cylinder head. For removing copper sleeve to Lifting yoke for camshaft
unit injector

P0012168 P0011615 P00068115

9998511 Lever 9998601 Fixture

Fixing tool for upper timing gear
casing

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08-2 Special Service Tools

P0012166

P0012154 P0006767

88800003 Fixture 88800011 Drift 88800021 Drift

Used together with 88800146 Guide sleeve for valve stem seal Removal of front crankshaft seal
Fixture

P0012156 P0006789 P0012171

88800058 Stand 88800062 Drift 88800063 Drift

Fixture, cylinder head

P0012173 P0006819 P0012172

88800146 Fixture 88800102 Drift 88800083 Piston ring pliers

Used together with 88800003
Fixture

P0011610
p0006796

88800147 Drift 88800513 Drift 9993625 Adapter plate

Attachment plate for cranking tool

52 47703722 01-2020 © AB VOLVO PENTA

 08-2 Special Service Tools

P0025196 P0025164

88800501 Mounting tool 88800502 Puller

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08-2 Special Service Tools

Other Special Equipment

The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.

P0007588 P0007589 P0012145

885536 Plug 885539 Plug 3849613 Pressure testing kit

P0006822

P0012150

9986485 Stand 9988539 Compression meter 9989876 Dial indicator

P0012161

P0006770

9990123 Pressure testing kit 9992670 Hand pump 9996049 Draining hose

54 47703722 01-2020 © AB VOLVO PENTA

 08-2 Special Service Tools

P0012164 P0006804

9996398 Manometer 9996591 Nipple 9996662 Pressure testing kit

Pressure gauge with quick-
connector, 1.5 MPa

P0012167

P0012165 P0004349

9996666 Nipple 9998339 Manometer 9998493 Hose

Connection nipple for checking
pressure

P0006814

*9998599 Cleaning kit * Contains

Cleaning kit for unit injector. - 9808607 Retainer - 9808616 Extender
- 9808613 Retainer - 9808617 Brush
- 9808614 Brush - 9808618 Brush
- 9808615 Retainer - 9998580 Protective
sleeve

VODIA

P0012170 p0006796
p0008375

9999696 Magnetic stand 88800147 Drift 88820047 VODIA, diagnostic

tool

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18-0 General

18-0 General
Chemical products

P0001869

85145750 Thread locking 1161346 Corrosion protection 1161231 Sealant

56 47703722 01-2020 © AB VOLVO PENTA

 20-0 Engine Information, General

20-0 Engine Information, General

Engine Decals

1 2 UNIT INJECTOR SYSTEM

UNIDADES INJETORAS
CAUTION UNIDADES INYECTORAS
CUIDADO UP TO
ATÉ
ATENCÓN HASTA DE
100 VOLTS

9 3

Part no 888130

4
X X X
PART NO./CHASSIS ID.
T- (CALL OFF IDENTITY)

S E R IA L N O
DESIGNATION - STAR -

ASSEMBLY FACTORY 2

Y Y

8 LOOSEN AND RETIGHTEN

6
TO 30 Nm

BELT CHANGE:
TORQUE 20Nm SEE OWNERS MANUAL

1 Sales decal(1) *Warranty decal, engine

2 Warning decal Product designation (1)
3 exhaust emission decal(2) Serial number (2)
4 Certification plate Specification number (3)
5 Reverse gear plate
6 Engine control unit(3) *Warranty decal, transmission
7 Warning decal Product designation (6)
8 Alternator belt routing(4) Serial number (7)
9 Warranty decal* Specification number (8)
1) not for aftermarket information
2) EPA
3) Applies to EVC
4) On inside of guard

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20-0 Engine Information, General

Component location.
1 2 3 4 5 6

P0011609
Rating 3-5
12
P0004635
11 10 9 8 7

13 14 1 Coolant filler cap

2 Auxiliary stop button
3 Crankcase ventilation filter
4 Fuel filter
5 Oil filter
6 By-pass filter
7 Seawater pump
8 Oil dipstick
9 Oil filler cap
10 Control Unit
11 Heat exchanger
P0004636 16 15
12 Alternator
13 Turbocharger
14 Air filter
15 Charge air cooler
16 Starter motor

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 20-0 Engine Information, General

Location of Sensors

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20-0 Engine Information, General

1 Sensor, coolant level

2 Sensor, crankcase pressure
3 Stop button and fuses
4 Sensor, combined charge air pressure/charge air temperature
5 Sensor, combined oil pressure and oil temperature (engine)
6 DC/DC converter
7 Sensor, fuel pressure
8 Sensor, water in fuel
9 Sensor, coolant temperature
10 Sensor, lubricating oil level (accessory)
11 Engine control unit
12 Sensor, camshaft position
13 Sensor, flywheel position
14 Sensor, oil pressure
15 Sensor, piston cooling pressure

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 20-0 Engine Information, General

Troubleshooting
A number of symptoms and possible causes of engine
malfunctions are described in the table below.

IMPORTANT!
Read about safety measures for care and
maintenance in the Safety information section before
starting work.

Symptoms and possible causes

The diagnostics button indicator blinks Engine cannot be stopped

Refer to the Service handbook “(Group 23) EMS 2” 2, 5
Starter motor does not crank Starter motor cranks slowly
1, 2, 3, 4, 5, 6, 7, 24 1, 2
Starter motor cranks normally but engine does not Engine starts but stops again
start 8, 9, 10, 11, 13
8, 9, 10, 11
Engine does not reach correct operating speed at full Engine runs unevenly
throttle 10, 11
9, 10, 11, 12, 13, 21, 25, 26
High fuel consumption Black exhaust smoke
12, 13, 15, 25 12, 13
Lubrication oil pressure too low Coolant temperature too high
16 17, 18, 19, 20
Coolant temperature too low No charge, or poor charge
20 2, 23
Blue or white exhaust smoke
14, 15, 22

1. Discharged batteries 14. Coolant temperature too high

2. Poor contact/open circuit in cables 15. Coolant temperature too low
3. Main switch turned off 16. Oil level too low
4. Cable harness box fuse broken 17. Coolant level too low
5. Faulty ignition switch 18. Air in the coolant system
6. Faulty main relay 19. Faulty circulation pump
7. Faulty starter motor/solenoid 20. Defective thermostat
8. Lack of fuel: 21. Blocked charge air cooler
– fuel taps closed 22. Oil level too high
– fuel tank empty/wrong tank connected 23. Alternator drive belt slipping
9. Blocked fuel filter/pre-filter (because of 24. Water entry into engine
contamination, or paraffin fraction separation in fuel 25. High back pressure in exhaust system
at low temperature). 26. Cable break in ”Pot+” to controls
10. Air in the fuel system
11. Water/contaminants in fuel
12. Faulty unit injector
13. Insufficient air supply to engine:
– blocked air filter
– air leakage between turbocharger and engine inlet
manifold
– fouled compressor section in turbocharger
– faulty turbocharger
– poor engine bay ventilation

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20-0 Engine Information, General

Malfunctions
If there is a malfunction, first check the following items:
• Check that the coolant level is between the
markings on the expansion tank (at 20°C). If the
level in the expansion tank is too low, top up and
start the engine. If the coolant disappears, there is
internal or external leakage.
• Check that the coolant is not contaminated.
If the coolant is contaminated, this signifies internal
leakage (oil) or that the cooling system has a
blockage (deposits).
Blockage in the cooling system is caused by one or
more of the following factors:
• The coolant has not been changed at the specified
intervals.
• Incorrect mixture of coolant and water.
• • Contaminated water has been used.

Blockage
Is often caused by high coolant temperature, internal
or external blockage of the cooling system, or a
combination of both. If the cooling system is blocked,
it must be cleaned. Refer to Cooling System,
Cleaning, page 224
• Internal contamination: Check that the heat
exchanger and/or charge air cooler are not blocked.
• Internal or external leakage in the cooling system:
Check for leaks in the system.
• Coolant circulation: Check that coolant circulates by
letting the engine run at high speed. Also check the
expansion tank to see that coolant circulates. This
can be an indication of a fault in the cooling system.
• Thermostat: Check thermostat function. Drain
enough coolant to allow the thermostat to be
removed. Check the thermostat; refer to
Thermostat, Function Check, page 237

Start / stop, symptoms

Engine doesn't start, starter motor is engaged 1
Engine doesn't start, starter motor doesn't engage 2
Engine starts then stops 3
Engine stopped during normal operation 4
Engine starts but does not stop 5

Performance and comfort, symptoms

Engine is perceived as low-powered 6
Engine exhaust smoke is black 7
Engine exhaust smoke is blue or white 8
Engine vibrates 9

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 20-0 Engine Information, General

Cooling system, symptoms

Engine does not reach normal operating temperature 10
Engine overheat 11
Coolant disappears from the system 12

Lubrication system, symptoms

Engine oil pressure low at idle 13
Engine oil pressure low at normal operation 14
High oil consumption 15

1 Check: 3 Check:
- Air inlet and air filter - For air in the fuel system
- Fuel feed, from tank to engine (incl. filter) - Fuel feed, from tank to engine (incl. filter)
- Stop device (control and solenoid) - Air inlet and air filter
- Fuel quality and water content - Regulator, injection pump and stop device
for function
2 Check: - Fuel quality and water contentl
- Voltage at the starter motor (during start)
4 Check:
- Voltage on switch (“50”) at starter motor
- For air in the fuel system
- The engine can be turned by hand
- Fuel feed, from tank to engine (incl. filter)
- Starter motor

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20-0 Engine Information, General

5 Check: 11 Check:
- Stop switch function - Low coolant level
- Pressure cap on expansion tank
6 Check:
- Seawater intake, filter and hoses
- Hull and propellers for fouling and damage
- Impeller
- Boat weight
- Exhaust pipe for corrosion and leaks
- Fuel feed
- Thermostat
- Air inlet and air filter
- Heat exchanger
- Alternator charging capacity
- Too high engine oil level 12 Check:
- Turbo - Leakage hoses and clamps
- Pressure cap on expansion tank
7 Check:
- Hot water connections
- Air inlet and air filter
- Pressure test the cooling system
- Engine Oil Level
- That the engine does run on all cylinders 13 Check:
8 Check: - Idling speed
- Engine oil, level and consumption - Engine Oil Level
- Coolant, level and consumption - Oil quality (viscosity, fuel concentration)
- Pressure sensor (verify with manometer)
9 Check:
- Flexible engine mounting
14 Check:
- Idling speed is not too low
- Engine Oil Level
- Propeller and propeller shaft deformity
- Oil quality (viscosity, fuel concentration)
- That the engine does run on all cylinders
- Pressure sensor (verify with manometer)

10 Check: 15 Check:
- Thermostat - Leakage hoses and clamps
- Too low load on the engine - Crankcase ventilation function
- Too high heat exchange from cooling water - Oil quality (viscosity)
outlet (for example, water heaters)

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 20-0 Engine Information, General

Test and Adjustments

Instructions for operating the
starter motor

Alternative 1 operate the starter motor

directly by the engine.
1 Remove both control wires from the starter motor
control relay. Connect one of the now unused
connections on the starter relay to the negative
terminal (–) on the starter motor.

-
p0011843
+

2 Connect a switch (e.g. part No. 843684) with at

least 2.5 mm2 (0,1 in.2) cross-section cable
between the other terminal on the starter relay
and the positive terminal (+) on the starter motor
+ solenoid.

NOTICE! There is a risk of high short-circuit

current if wrongly connected
- IMPORTANT! Do not operate the starter motor
for intervals longer than 15 seconds. Then let the

+ - batteries and starter motor rest for a few minutes

before operating again(1)
3 After completed starter motor operation:
Remove the switch with cables. Replace the two
thin wires on the starter motor control relay.
P0011844

1. The cover of the starter motor may not get hot (max. 100°C /
212°F).

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20-0 Engine Information, General

Alternative 2, operate the starter motor

from the control panel
1 Before you operate the starter motor from the
ignintion key/starter button

IMPORTANT! Remove the two speed sensors

before operating the starter motor. The engine
control unit will then not receive a signal and the
engine will not start.

NOTICE! Save any spacer washers (shims) and

fix them to their sensor, to facilitate re-assembly.
Refit the speed sensors after completion.

NOTICE! Make sure that the shims are mounted

with the correct sensors.

Compression Test
The fuel system shall be emptied and the rocker bridge
removed, see 23-0, Draining, Fuel Duct in Cylinder
Head.

Tools:
9988539 Compression meter
9990185 Lifting tool
9998248 Adapter
9998249 Protective sleeve
9998599 Cleaning kit

Removal
1 IMPORTANT!
9998248 Make sure that the area around the unit injectors
is clean before they are removed.
Remove the unit injectors, see Unit Injector,
Replace, page 201 and mount the unit injector
protection (9998249 Protective sleeve). Clean
the copper sleeves as needed with
9998599 Cleaning kit.
2 Fit all(1) adapters (6 pcs), tool 9998248 Adapter,
to the cylinder head and pull them on with the
P0004964 injector retainers.
3 Oil valve caliper, cam shaft ridges and the rocker
bridge.

1. This in order to avoid repeating removal/refitting of rocker bridge

and unit injector and performing valve adjustment six times.

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 20-0 Engine Information, General

4 Fit the rocker bridge with 9990185 Lifting tool.

Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft
support bearing. Torque the rocker bridge as
specified in Administration, page 20. Use torque
wrench.
5 Install the middle piece and the oil pipe to the
rocker bridge.
6 Check the valve clearance, see Valves and Unit
P0004965
Injectors, Adjustment, page 143, for all valves as
specified in Administration, page 20.

7 Remove both control wires from the starter motor

control connector (the two thin cables).
Connect one of the two free connectors on the
control connector to ground.

8 Connect the other connector to a switch, which in

turn is connected to the positive (plus) connection
on the starter motor.

9 Connect tool 9988539 Compression meter to

9998248 Adapter on the first cylinder.
998 8539 10 NOTICE! Do not run the engine for more than 15
seconds at a time with intervals of 60 seconds.

Run the engine with the starter motor until the

compression meter needle has stopped (max
compression reading).
Read the value.
Move the compression meter to the next cylinder.
P0004968 999 8248
Repeat the test on all cylinders.

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20-0 Engine Information, General

11 Remove the middle piece and the oil pipe for the
rocker bridge.
12 Remove the rocker bridge screws equally in
stages so that it is not bent.
Remove the bolts and carefully lift off the rocker
bridge using 9990185 Lifting tool.
13 Remove all adapters, tool 9998248 Adapter from
9998248 all cylinders.

P0004964

Installation
14 Mount the unit injectors and new o-rings, see the
Installation section in chapter Unit Injector,
Replace, page 201.
15 Fit the rocker bridge with 9990185 Lifting tool.
Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft
support bearing. Torque the rocker bridge as
specified in Administration, page 20. Use torque
wrench.
16 Install the middle piece and the oil pipe to the
rocker bridge.
17 Adjust valves and unit injectors, see Valves and
P0004965
Unit Injectors, Adjustment, page 143.
18 Check and if needed change the valve cover
bearing. Install the valve cover.
19 Re-install the fuel lines. Use new sealings.
20 Vent the fuel system, see 23-0, Fuel system,
bleeding.

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 20-0 Engine Information, General

Fuel Feed Pressure, Check

Tools:
9996666 Nipple
9998339 Manometer
9998493 Hose

IMPORTANT! Clean nipple and hose carefully before

they are connected to the fuel system. The unit
injectors are sensitive and can easily be damaged by
contamination.
1 Clean the fuel filter bracket carefully.
2 Remove the purging nipple and fit
9996666 Nipple. Connect 9998493 Hose and
999 8339
9998339 Manometer.
3 Make sure the control lever is in neutral.
4 Start the engine and run at approx. 1000 rpm until
the feed pressure on the manometer has
stabilized.
5 Compare the measured max. feed pressure with
999 8493 that given in Administration, page 36. The
measured value is the feed pressure after the
filter.
6 Remove the measurement equipment and purge
the fuel system after completion. Refer to
Draining, Fuel system, page 196

P0004624

NOTICE! Low feed pressure can be the result of a

blocked fuel filter, a defective overflow valve or a
defective feed pump.

NOTICE! The overflow valve may not be adjusted.

Replace the valve if necessary.

Charge air pipe, checking

1 Check the charge air pipes for visible cracks and
external damage.
2 Check that there is no oil in the charge air pipes.
If the pipes are damaged or the union seal rings
leak, the charge pressure will be too low and
engine performance will be affected.
If the pipes are internally contaminated with oil,
there is probably an oil leak from the turbocharger
shaft seal. In such a case, the turbo should be
overhauled or replaced complete.

NOTICE! If there is any oil in the charge air pipes and

charge air hoses, the charge air cooler and all pipes
and hoses in the charge air system must be cleaned
very carefully before the engine is started.

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20-0 Engine Information, General

Turbocharger, check
1 Check that the turbocharger part number
corresponds to the engine variant. The wrong
turbo can give low charge pressure and reduce
the engine power.
2 Check that the correct compressor housing is
fitted to the turbocharger. If the wrong
compressor housing has been fitted, the
compressor turbine may have been damaged or
there may be too much clearance between
turbine and housing. In both cases the charge air
pressure will be too low.
3 Remove the air filter and exhaust pipe from the
turbocharger.
4 Check the compressor turbine and exhaust
turbine for damage. If there is damage, the turbo
should be overhauled or replaced complete.
5 Check the turbine shaft’s axial and radial
clearances, according to “Turbocharger, bearing
clerance check.” If the bearing play is too great,
the turbo should be overhauled or replaced
complete.

Charge Air Pressure, Check

Tools:
9996666 Nipple
9998339 Manometer
9998493 Hose
9996398 Manometer
1 Fit 9996666 Nipple on top of the inlet manifold.
Connect 9998493 Hose and
9998339 Manometer (or 9996398 Manometer) to
the nipple.
2 Run the engine at full power (max. operational
speed) and read off the charge air pressure. If full
power cannot be developed, the pressure will be
considerably lower. Refer to the
Administration, page 38.
3 Compare the pressure with the pressure that can
be read off with the VODIA tool. If the two
measurements show different values, the
pressure sensor is faulty and must be changed.

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Actions with low charge air

pressure
1 Air inlet Check that the ventilation inlet to the
engine room is large enough. Please refer to the
installation instructions.
2 Air filter Check that the air filter is not blocked
and that the correct filter inserts are in use.
Change filter inserts as necessary.
3 Sealing The inlet and exhaust manifolds and
other unions must not have any leaks. Also check
that the joints between the compressor bearing
housing and turbine and the compressor housing
itself seal correctly.
4 Turbocharger Check that the rotor shaft does
not bind and that the exhaust turbine or
compressor turbine do not rub against this
housings. Turn the wheel, firstly with light
pressure, then after displacing the shaft axially. If
the turbine is stiff to turn, the turbocharger must
be changed or overhauled as soon as possible.
Check the turbines for damage. If the engine is
operated in dusty or oily air every day, regular
P0011848 cleaning of the compressor housing and
compressor turbine is recommended. A fouled
compressor section can cause low charge air
pressure.
The compressor section can be cleaned with the
unit installed, as follows:
Remove the compressor housing. Clean the
compressor housing, compressor turbine and
end wall in white spirit or equivalent substance.
Install the compressor housing and tighten the V-
clamp.
Measure the charge air pressure again.
5 Charge air cooler Check that the charge air
cooler is not blocked. Clean as necessary.
6 Exhaust back pressure Check that the back
pressure in the exhaust system is not too great in
the finished installation. Refer to Exhaust Back
Pressure, Check, page 72.
7 Fuel feed pressure Replace the fuel filter if
required. There shall be no fuel leakage. Check
that no air comes into the system on the suction
side.
8 Unit injectors Check the cables and that the
correct unit injectors are used.
9 Engine condition Check the valve clearance
and cylinder pressure.

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Exhaust Back Pressure, Check

Tools:
9996591 Nipple
9996398 Manometer
9998339 Manometer
1 Fit 9996591 Nipple to the exhaust pipe. Connect
9996398 Manometer (or 9998339 Manometer) to
the nipple.
2 Run the engine at full power (max. operating
999 6398 speed) for a sufficient time to stabilize the value
being checked. Check that the back pressure
does not exceed the permissible value. Refer to
Administration, page 38.

999 6591

P0004627

Coolant

Coolant temperature too high

Excessive coolant temperature can be caused by:
• Blocked seawater filter / seawater system
• Worn impeller in seawater pump
• Faulty temperature gauge
• Low coolant level
• Blocked heat exchanger
• Faulty thermostat
• Blocked cooling system

Coolant temperature too low

Low coolant temperature can be caused by:
• Faulty temperature gauge
• Faulty thermostat

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Coolant losses
There are two types of coolant losses:
• Coolant losses during operation.
• Coolant losses from a hot, stopped engine.
Coolant losses during operation can be caused by poor
sealing in the cooling system, or that air or combustion
gases are forced into the cooling system and force
coolant out through the pressure cap. The fault can be
caused by a leaky cylinder head gasket.
Coolant losses after stopping a hot engine are
generally due to a faulty pressure valve in the filler cap.

Cooling System, Pressure Testing

Alternative 1
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

Tools:
3849613 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Replace the filler cap on the expansion tank with
a suitable cover from 3849613 Pressure testing
kit.
4 Connect the pump and pump up a pressure of 70
kPa (0.7 bar).
5 Pressure must not drop for a two minute test
period, for the cooling system to be regarded as
being free from leakage.
6 Release the excess pressure and remove the
pressure testing unit.
7 Check the coolant level in the expansion tank.
P0010195
Install the regular filler cap.
8 Start the engine and check that no leakage
occurs.

Alternative 2
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

Tools:
9996441 Cover, with connecting nipple
9996662 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.

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2 Check the coolant level in the expansion tank.

3 Replace the filler cap with 9996441 Cover, with
connecting nipple. Connect 9996662 Pressure
testing kit to the cap. Connect compressed air to
the equipment and open the cock. Adjust the
pressure to 70 kPa (0.7 bar) with the adjuster
knob. Then close the tap.
4 Pressure must not drop for a two minute test
period, for the cooling system to be regarded as
being free from leakage.
5 Release the excess pressure and remove the
pressure testing unit.
6 Check the coolant level in the expansion tank.
Install the regular filler cap.
P0010196
7 Start the engine and check that no leakage
occurs.

Alternative 3
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

Tools:
9996662 Pressure testing kit
9996049 Draining hose
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Connect 9996662 Pressure testing kit to
9996049 Draining hose and close the cock.
Connect the hose to the engine drain valve (1).
Open the cock and adjust the pressure to 70 kPa
(0.7 bar) with the adjuster knob. Then close the
tap.
4 Pressure must not drop for a two minute test
period, for the cooling system to be regarded as
being free from leakage.

1 5 Open the cock and increase the pressure until the

filler cap opens (must correspond to opening
pressure according to 03-26, Technical Data).
Reduce the pressure to 50 kPa (0.5 bar) and then
increase to 70 kPa (0.7 bar) and check that
pressure is maintained.

P0010197
6 Remove the compressed air connection. Open
the control valve so that the pressure drops and
shut the cock when coolant runs into the drain
hose.
Remove the drain hose from the engine. Then
remove the drain hose from the test equipment
and empty the coolant from the hose.
Re-install the rubber plug in the engine drain
valve.
7 Check the coolant level in the expansion tank.

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8 Start the engine and check that no leakage

occurs.

Cylinder Head, Pressure Testing

Checking the pressure test unit

Tools:
9990123 Pressure testing kit
9996239 Lifting tool
9986485 Stand
9990160 Fixture
9990107 Connection washer
9990106 Plate
9998666 Adapter
1 Connect the pressure testing device to a
compressed air line.
2 Use the reduction valve to set the pressure gauge
to 100 kPa; the knob can be locked with a lock
ring that is moved axially.

3 Close the shut-off valve. The pressure on the

pressure gauge must not fall for 2 minutes for the
device to be regarded as reliable.
4 Unscrew the knob on the reduction valve and
open the tap.

P0007006

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Pressure testing
Cylinder head removed.

For all cylinder head lifts use 2 pcs 9996239 Lifting

tool; refer to Engine with mounting and
equipment, page 80

Tools:
9996239 Lifting tool
9986485 Stand
9990105 Plate
1 Wash the cylinder head in a bath.
2 Secure the cylinder head in 9986485 Stand with
the aid of 9990160 Fixture and 4 bolts, M8x25.
3 Clean the cylinder head mating surfaces.
4 Fit 9990105 Plate to the cylinder head using the
cylinder head bolts and M16 nuts (14 required).
5 Install 9990107 Connection washer at the
thermostat housing location. Secure the washer
with a clamp as illustrated.
6 Fit 9990106 Plate to the thermostat housing as
necessary.
7 Fit 9998666 Adapter (9809699) in the
temperature sensor hole. Plug any coolant
connections for the compressor.

8 Connect the manometer hose to

9990107 Connection washer.
9 Remove the cylinder head including fixture from
the assembly stand. Remove the fixture.
10 Immerse the cylinder head in a water bath, +70° C
(158° F)
11 Connect air to the pressure testing unit. Open the
shut-off valve.
12 Adjust the reducing valve knob so that the
manometer shows a pressure of 50 kPa (0.5 bar).
Maintain the pressure for 1 minute.
13 Raise the pressure to 150 kPa (0.5 bar). Lock the
reduction valve knob with the locking ring. Close
the shut-off valve.
14 After 1-2 minutes, check whether the pressure
has dropped, or if bubbles of air can be seen in
the water bath. If you see bubbles, check seal
plates and inspect the cylinder head for any
cracks.

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15 Unscrew the knob on the pressure reduction

valve to release the pressure in the cylinder head
and open the tap.
16 Take the cylinder head out of the water bath.
Attach the fixture. Secure the cylinder head in the
assembly stand.
17 Blow the cylinder head dry. Be extra thorough
with the fuel channels.

NOTICE! Make sure that no dirt enters the fuel

channels; this can damage the unit injectors.

18 Remove all the sealing washers and any plugs

installed for the pressure testing
19 Remove the cylinder head including fixture from
the assembly stand. Remove the fixture.

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20-9 Miscellaneous
General advice when working on
EVC engines
General advice when working on EVC engines
The following advice must be followed to avoid
damage to the engine control unit and other
electronics.
IMPORTANT! The system must be without power and
the starter key(s) be in position 0 when the
connector(s) for the engine control unit are
disconnected or reconnected. Turn off the power with
the main switches.
• Never disconnect the power with the main switches
when the engine is running.
• Never disconnect the battery cables when the
engine is running.
• Turn off the main switches or disconnect the battery
cables when fast-charging the batteries.
• NOTICE! The main switches do not need to be
turned off during normal charging.
Only batteries may be used as starting help. Starting
devices can create over-voltage and damage the
engine control unit and other electronics.
• When performing electric welding, refer to Electrical
Welding, page 79.
• If damage is discovered in a cable harness the two
36-pin connectors for the engine control unit and the
8-pin connector between the engine and the EVC
system must be disconnected.
• Be careful to ensure that the connector pins do not
come into contact with oil, water or dirt if a connector
is undone.

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Electrical Welding
IMPORTANT! Disconnect the connectors from the
engine control unit and the 8-pin connector for the PCU
before starting electric welding.
IMPORTANT! The system must be disconnected from
power and the starter key(s) must be in position 0 when
the engine control unit connectors are disconnected or
connected.
1 Disconnect power at the main switch(es).
Disconnect the connectors from the engine
control unit (move the locking bar (1) backwards
and remove the connector). Refer to the figures
or more detailed instructions in Control Unit,
Replace, page 212.

2 2 Disconnect the 8-pin connector from the PCU(1)

3 Disconnect the alternator connector.
4 Always connect the welder earth clamp to the
component to be welded, or as close as possible
1
to the weld site. The clamp must never be
connected to the engine or in such a way that
current can pass through a bearing.
P0011895

IMPORTANT! After welding is completed, the

disconnected components, such as alternator cables
and battery cables must be connected in the correct
order.

1. Applies if the engine is still in the boat.

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21-0 Engine Complete, General

Exposing the Engine

Tools:
88800003 Fixture
88800146 Fixture
1 Disconnect electrical power to the engine
2 Drain the coolant, refer to Draining the Cooling
System, page 224 and pump out the engine oil.
3 Drain the fuel into a suitable container.
4 Remove the protective cover from the electrical
center and remove the crankcase ventilation
pipe, crankcase ventilation filter and associated
hoses.

5 Unscrew the expansion tank and release the

connections to the coolant level sensor.

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6 Remove and plug the electronic unit's fuel hoses

and remove the electronic unit and it's
connections.

7 Remove the belt guard and loosen the fixture that

holds the hoses between the heat exchanger and
charge air cooler and also the pipe between the
fresh water pump and heat exchanger.
Remove the hose between the charge air cooler
and heat exchanger.
Remove the pipe from the heat exchanger and
fresh water pump.
Remove the pipe and cover for the thermostat
and remove the thermostat.
Remove the hose between the heat exchanger
and exhaust elbow.

8 Remove the heat exchanger, (five bolts).

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9 Undo the cable harness clips from the electronic

unit fixture.
Remove the fixture for the electronic unit and
remove the oil filler pipe and dipstick tube.
Undo the return fuel pipe from the electronic unit
fixture.

10 NOTICE! As necessary and if possible, fit

88800146 Fixture together with 88800003 Fixture

888 00146

888 00003

P0004357

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11 Remove the turbocharger heat shields as well as

the air filter and fixtures.
Release the clips from the turbocharger pipe and
hoses from the charge air cooler pipe.
Release the turbocharger pipe and hoses from
the engine.
Release the clamp between the turbocharger and
the charge air cooler.
Undo the turbocharger nuts and lift off the
turbocharger.

12 Remove the charge air cooler pipe.

Remove the front intake pipe.
Remove the clamp for the rear hose connection
on the charge air cooler. Remove the charge air
cooler's lower attachment fitting.
Remove the bolts from the charge air cooler, start
with the rearmost bolt and then the center bolt and
finally the forward bolt. Then lift the charge air
cooler away.

13 Remove the cooling hose between the seawater

pump and the reverse gearbox oil cooler.
Remove the reverse gear oil cooler.

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14 Remove the seawater pump.

Remove the engine cable harness and electrical
center fixture.
Remove the alternator.
Remove the right-rear lifting eye.

15 Remove the heat shield fixture plate and manifold

with water pipes.

16 Remove fuel and oil filter brackets with

associated pipes and hoses.

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Fitting the Fixture

Engine Fixture, Installation
Tools:
9986485 Stand
88800003 Fixture
88800146 Fixture

1 Engine exposed and coolant drained.

2 Remove electrical center protective cover.
3 Remove the expansion tank.
4 Undo and plug fuel hoses to the control unit.
Remove the control unit.
5 Remove the heat exchanger.
6 Remove the fixture from the control unit and
remove the cable clamps from the fixture.
7 Install 88800003 Fixture together with
88800146 Fixture on the side of the engine as
illustrated. Use the bolts marked (12.9): M8 x 35
888 00146 (2 pcs), M8 x 55 (5 pcs)
8 Install the engine and fixture to the installation
stand 9986485 Stand.

888 00003

P0004357

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Engine Disassembly
Tools:
9996239 Lifting tool
9996400 Slide hammer
9998249 Protective sleeve
9998251 Protection plug
9990013 Slide hammer
9990006 Puller
9998511 Lever
9990160 Fixture
9993590 Rotation tool
9996394 Support
9996545 Extractor
9990114 Puller
9998511 Lever
88800218 Extractor plate

Cylinder head, removal

The engine exposed, coolant, oil and fuel drained.
1 Remove the front lifting eye.
2 Remove charge air pressure sensor (1) and tape
over the intake manifold opening.
3 Remove the coolant sensor (2).

P0011359

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4 Protect the charge air pressure sensor by fitting

a protective sleeve (1), or place a clean plastic
bag over the sensor and close the bag's opening
around the cable harness.

P0011360

5 Remove fuel line clamps from the intake pipe.

6 Remove the fuel lines from the cylinder head at
the front and rear edges. Place protective plugs
in the holes and cover the hose ends so that they
are well protected, to prevent dirt from entering
the fuel system.
7 The inlet manifold must be removed if
9990160 Fixture is to be used. Remove all bolts
and remove the intake manifold using
9998511 Lever against the reinforcement
bosses.

NOTICE! The inlet manifold may be hard to

remove due to sealant.
8 Remove the valve cover.

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9 Clean around the unit injectors and remove their

contacts. Remove cable holders together with
cable harness. Cut off cable ties and remove the
cable harness from the cable holder.

10 Remove the intermediate piece for rocker bridge

lubrication, together with the delivery pipe.

NOTICE! Make especially sure the seal under the

intermediate piece does not fall into the timing
gear cover!

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11 Remove the harness bush (1) bolt and carefully

pull the harness out through the cylinder head.

IMPORTANT!
Remove the bolt, not the cable bush.
1
12 Remove the camshaft sensor (2) and save any
shims. If the flywheel housing must be removed,
also remove the flywheel sensor (3). Mark the
sensors and the location of any spacers.
2
3

P0002689

13 Early model (> 153201 - w0727 K-10594-66)

Remove the flywheel housing plugs and fit
9993590 Rotation tool or remove the starter
motor and fit 9993625 Adapter plate and
9993590 Rotation tool. Check the markings on
the attachment plate for correct assembly.

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14 Later model
Remove the cover plate from the flywheel
housing and attach 9993590 Rotation tool.

P0016287

15 Early model (> 153201 - w0727 K-10594-66)

Turn the engine to camshaft TDC and check that
the mark on the flywheel is at zero.

Later model
Turn the engine to camshaft TDC.

16 Remove the upper timing gear cover and remove

the rubber seals.

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17 Remove the camshaft drive together with the

vibration damper.

NOTICE! The vibration damper is very sensitive

to shocks.

18 Remove the rocker bridge bolts alternately to

avoid uneven load.
19 Lift away the rocker arm bridge using
9990185 Lifting tool.
20 Mark and remove the floating valve yokes.

NOTICE! If only the unit injectors are to be

replaced, the fuel duct must be emptied; refer to
Unit Injector, Replace, page 201.

21 Clean around the unit injectors and unscrew the

injector yoke bolts. Remove the unit injectors one
at a time.

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22 Pull out the injector with the aid of 9990006 Puller

and 9990013 Slide hammer.

P0006889

23 Insert 9998251 Protection plug into the cylinder

head immediately after removal. Mark the
injectors and fit 9998249 Protective sleeve to the
injector.

NOTICE! Check that the tools are clean.

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24 Crank the engine so that the two the bolts (1) can
be reached through the timing gear wheel.

25 Place a clean rag in front of the drive to prevent

bolts from falling into the timing housing.

NOTICE! When the engine is cranked, the rag

must be removed.
26 Remove the remaining four bolts (2). Remove the
three upper bolts (3) from the timing gear hub.

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27 Remove the camshaft cap with the aid of the tool

9990192 Puller and 9996400 Slide hammer

28 Lift the camshaft carefully using 9998264 Lifting

tool.
29 Loosen the bearing brackets by tapping them
carefully with a plastic mallet. Remove the
bearing brackets with the lower bearing halves
and put them in the right order together with their
respective camshaft bearing caps, upper bearing
halves and bolts.

NOTICE! The camshaft bearing brackets are

held by guide pins marked 1-7.

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30 Remove the cylinder head bolts. Use two lifting

chains 9996239 Lifting tool to carefully lift away
the cylinder head.

NOTICE! Place washers between the cylinder

head and lifting chains to protect the cylinder
head sealing surface.

31 Remove the cylinder head gasket and clean the

contact surface on the cylinder block thoroughly.

NOTICE! Secure all cylinder liners using

9996966 Press tool.

32 Remove the starter motor if not done previously.

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33 Remove the front pipe between filter bracket and

oil cooler. Remove oil filter bracket and the rear
pipe complete.

P0011361

34 Remove coolant pump together with the coolant

housing and bracket.

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35 Turn the engine up 45°, if it is installed in the

stand. Remove the bolts for belt pulley/vibration
damper. Carefully tap and rock the hub and belt
pulleys to get them loose.

NOTICE! Do not separate the belt pulley and

vibration damper.

Lift off the vibration damper and belt pulleys.

36 Undo the bolts and remove the cover for the front
crankshaft seal with a crowbar at the
reinforcements shown.

37 Remove the oil cooler casing together with the oil

cooler.

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38 Remove fuel pump and servo pump complete.

39 Remove the engine mountings.

P0004300

40 Remove the oil level sensor terminal and remove

the oil pan.
41 Remove the connecting pipe and the oil strainer
complete with bypass valve and pipe
connections.
42 Remove bracing frame.

Early model

Later model

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Pistons, removal
43 Remove the piston cooling nozzle. Turn the
engine using 9993590 Rotation tool so that all
become accessible, two at a time.

IMPORTANT!
Remove the piston cooling nozzles before removing
the pistons. Damaged nozzles can cause extensive
engine damage.

P0006911

44 Remove big end bearing caps and bearing shells;

note any markings.
45 Turn the engine 90° if it is installed in
9986485 Stand.
46 Press the piston so far out that the piston rings
are outside the edge of the cylinder liner. Use a
hammer handle or other wooden object. Lift the
piston and connecting rod out.
47 Remove the retainer ring from the piston and
press out the piston pin. Disassemble the
connecting rod and piston.
48 Mark the connecting rod and piston, if they are to
be installed in the same cylinder at assembly.

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49 Mark the cylinder liner position in the block before

it is removed to facilitate correct placement if
reinstalled.
50 Attach 88800218 Extractor plate, and support
legs 9996394 Support, on 9996545 Extractor.
51 Move plate down through the cylinder and place
it in correct position under the cylinder liner. Pull
the cylinder liner out of the block, using the puller.
If necessary, extend the support legs with
9996395 Support.
52 Remove the cylinder liner sealing rings.

Timing gears, removal

53 Remove the flywheel sensor, if not done
previously.
54 Attach 9996239 Lifting tool to the flywheel with
two bolts. Remove the flywheel.

CAUTION!
Pinch hazard. Keep fingers clear.

The flywheel weighs about 40 kg (88 lbs).

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55 Remove the bolts in the flywheel casing and

remove the flywheel casing using lifting eyes and
lifting straps.

56 Remove the lubricating oil pump and the rear

main bearing cap. Use 9990114 Puller together
with 9996400 Slide hammer; refer to Main
Bearing, Replace, page 165.

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57 Remove the lower intermediate gear (4).

58 1 Camshaft drive gear
2 upper intermediate gear
3 intermediate gear, dual
4 lower intermediate gear
5 crankshaft gear
6 oil pump drive gear
7 drive gear for fuel feed pump/servo pump
8 drive gear, seawater pump

59 Remove the two Allen bolts on the crankshaft

drive (5) and remove the drive using a suitable
puller.

NOTICE! To protect the puller thread, place a

thick washer between the threaded shaft and the
crankshaft.
60 Remove the six socket head cap bolts in the hub
of the bull drive (3) and remove it complete.
61 Remove the upper intermediate gear (2).

NOTICE! Save the spacer plate behind the gear

and note how it is installed.
62 Remove the timing gear plate and clean both
sides.

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Crankshaft, removal
63 Remove the main bearing caps. (Rear thrust
bearing caps have been removed together with
the oil pump.)
64 Lift the crankshaft out carefully.

NOTICE! The crankshaft weighs about 80 kg.

65 Remove plugs, bolts and remaining brackets
before washing the engine block.
66 Clean the contact surfaces on parts to be
reinstalled.

P0016665

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Engine Assembly
Tools:
1161231 Sealant
9998511 Lever
9996966 Press tool
9990044 Piston ring compressor
1161346 Corrosion protection
9993590 Rotation tool
885810 Fixture
9998601 Fixture
88800218 Extractor plate

Crankshaft, installation
1 Inspect the crankshaft; refer to Crankshaft,
Inspection, page 180
2 Check the crankshaft ducts, the bearing shell
seats, the engine block and bearing caps.
3 Install new main bearing shells.
4 Put the bearing shells in their respective places
in the engine block and bearing caps. Make sure
that the bearing shells and caps are undamaged.

NOTICE! Make sure that the upper bearing shells

that fit in the cylinder block have oil holes.
5 Lubricate the bearing pins and bearing shells with
engine oil and carefully lift the crankshaft into
position.
6 Install the thrust washers for the center main
bearing, thrust bearing. The thrust washers can
only be placed in one position.
7 Install the main bearing caps with the lower
bearing shells. The bearing caps are asymmetric
and can only be installed one way. The center
bearing cap (by the thrust bearing) has a cutout,
which must be aligned to fit over the guide pin.

NOTICE! Note the bearing cap markings. 1-7.

8 Oil the main bearing bolts. Allow excess oil to run
off before installation. Tighten according to
Tightening torques, page 7 and Tightening
Schedules, page 10.
9 Install the front cover by the belt pulley without a
seal.
10 Install the seal.

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Timing gears, installation

NOTICE! Lubricate the inside of the gears before
installation.

11 Apply a 2 mm (0.08") bead of 1161231 Sealant

on the engine block as illustrated. Torque within
20 minutes of sealant being applied.
12 Install the timing gear plate. Use new bolts
pretreated with locking compound. Tighten
according to Tightening torques, page 7 and
Tightening Schedules, page 10.

NOTICE! Make sure that the plate is aligned with

the bottom of the block.

NOTICE! Torque within 20 minutes of sealant

being applied.
13 Oil the spacer plate and place it together with the
upper intermediate gear (2). Tighten with low
torque, max 10 Nm (7.4 lbf.ft).

14 Install a new O-ring on the crankshaft.

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15 Install the crankshaft gear (5) and torque the Allen

bolts according to Tightening torques, page 7 and
Tightening Schedules, page 10.

1 Camshaft drive gear

2 upper intermediate gearövre mellanhjul
3 bull drive
4 lower intermediate gear
5 crankshaft gear
6 oil pump drive gear
7 drive gear for fuel feed pump/servo pump
8 drive gear, seawater pump

16 Install the bull drive kit (3) with the hole marking
between the two hole markings on the crankshaft
drive.

NOTICE! The bull drive inner and outer gears

have different gear pitches. For the camshaft to
be set correctly, the markings must be correct.

Tighten the bolts according to Tightening

torques, page 7 and Tightening
Schedules, page 10.

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17 Install the bottom intermediate gear (4) with a new

O-ring.
18 Install the lubricating oil pump together with the
rear main bearing.
19 Screw two bolts into the crankshaft drive to
receive a crowbar for cranking the crankshaft
when required.

P0006928

20 Apply new 1161231 Sealant to the flywheel

housing, against the engine block.

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21 Install the flywheel housing. Check that the

housing is flat against the engine block.

22 Install a new crankshaft seal.

23 Install the bracing frame and tighten according to
Tightening torques, page 7 and Tightening
Schedules, page 10. Refer to 21-5, Flywheel,
Indication.

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Cylinder liner, fitting

24 Inspect the cylinder liner and pistons; refer to
Cylinder Liner and Pistons,
Inspection, page 134
25 Lubricate the sealing rings, using the lubricant
supplied with the liner kit, and install them on the
cylinder liners.

NOTICE! The purple seal ring must seat in the

lowest groove.

26 When the cylinder liner is installed without shims,

an even bead 0.8 mm (0.0315") of sealing
compound 1161231 Sealant must be applied to
the underside of the cylinder liner collar.

NOTICE! Do not put sealant around the entire

liner; leave a 2 mm (0.08 in.) gap.

If the liner is fitted with adjustment shims, the

sealant compound bead should be placed on the
cylinder block liner seat.

NOTICE! Sealing compound must not be used

between the adjusting shims and the cylinder
liner collar.

Without spacer NOTICE! The liner must be installed within 5

minutes of sealing compound application.

P0016682
With spacer

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27 Screw one of the cylinder head bolts in place (A).

Place 88800218 Extractor plate above the
cylinder liner together with a suitable spacer (B).
Press the liner down using 9998511 Lever and
secure it with 9996966 Press tool.

Piston, pre-fitting
28 Install one of the retainer rings on the new piston.
29 Oil the piston pin, the piston bearing seat and the
piston pin bush with engine oil.

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30 Install the connecting rod so that the arrow on the

piston and the connecting rod's 'Front' marking
face the same way. Press in the piston pin.

NOTICE! It should be easy to press the piston pin

in; it must not be driven in.

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31 Install the other retainer ring.

32 Check that the piston pin does not move stiffly in
the small end, and the piston can be moved
easily.

IMPORTANT! Always use 88800083 Piston ring

pliers when installing or removing piston rings.
The oil scraper rings are especially brittle and
easily damaged.

NOTICE! The two upper piston rings are marked with

letters or punch marks. The mark must face upwards.

P0006922

33 Align the piston ring gaps staggered about 120°

around the piston. However, the piston ring gaps
must not end up directly over the piston pin.

NOTICE! New cylinder liner kits are supplied

complete with pistons and piston rings.
34 Install the bearing shells in the connecting rod.

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Pistons, installing
35 Oil the cylinder liner, bearing shells and big end
bearing journals.
36 Remove 9996966 Press tool temporarily while
the pistons are installed.
37 Use 9990044 Piston ring compressor and guide
the piston and piston rings down into the cylinder.
Make sure the connecting rod does not damage
the crankshaft bearing journal.

IMPORTANT! Take care; do not open the piston

rings too far. The oil scraper rings are particularly
brittle and are easily damaged.

IMPORTANT! The piston ring compressor may

not be opened when the piston has been placed
in the tool, the piston rings can be damaged.
P0016683 Press out the piston first, before opening the tool.
38 Re-install 9996966 Press tool. All cylinder liners
must be locked with the press tool in order to
prevent movement between the cylinder liner and
engine block when the engine is cranked.

39 Install the bearing caps with their bearing halves.

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Piston cooling nozzle, installing

40 Blow the piston cooling nozzle clean and check
that it is undamaged.

IMPORTANT! Faulty piston cooling will cause the

pistons to seize. If piston cooling nozzle damage
or deformation is suspected, the nozzle must be
replaced (also applies to new nozzles).
41 Install piston cooling nozzle.

IMPORTANT! Check that the nozzle sits

correctly in the hole in the cylinder block and is
directed towards the recess in the piston and that
the retaining plate lies flat against the block. If the
piston cooling nozzle is not correctly installed, the
engine will immediately seize when loaded.
P0006911 42 Tighten according to Tightening torques, page 7
and Tightening Schedules, page 10.

IMPORTANT!
The piston cooling nozzle retaining screw has a
friction coating and may only be used once.
43 Mount the bracing frame and connecting pipes.
Tighten according to Tightening torques, page 7
and Tightening Schedules, page 10.
44 Install the oil strainer complete with bypass valve
and pipe connections. Tighten according to
Tightening torques, page 7 and Tightening
Schedules, page 10.

Early model

Later model

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45 Apply a 2 mm (0.080") bead of 1161231 Sealant

on the parting planes between the transmission
gear casing and the lower part of the engine
block, and at the front belt pulley casing. Install
the oil sump and tighten according to Tightening
torques, page 7 and Tightening
Schedules, page 10.

NOTICE! Install the oil sump within 20 minutes of

sealant application.
46 Connect the contact to the oil level sensor.

47 Install the fuel pump and servo pump complete.

P0006906

48 Install oil cooler together with oil cooler cover.

Refer to Oil Cooler, Replace, page 193.

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49 Install coolant pump together with the coolant

housing and bracket.
50 Install the belt pulley and the vibration damper.

51 Install oil filter bracket and the rear pipe complete.

Install the front pipe between filter bracket and oil
cooler cover.

NOTICE! Use new gaskets.

52 Install the front engine mounts.

P0011511

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Cylinder head, installation

53 Clean the cylinder head carefully both internally
and externally before fitting.

IMPORTANT! Dirt particles may cause the unit

injectors to fail.
54 Clean the unit injector copper sleeves, see Unit
Injector, Replace, page 201. Install protection
plugs immediately after cleaning.
55 Remove 9996966 Press tool holding the cylinder
liners in place.
56 Carefully clean the cylinder head and the engine
block sealing surfaces and cut away excess
sealant.

NOTICE! Do not pull away dry sealant.

57 Dip the cylinder head bolts completely into

1161346 Corrosion protection. Then place the
bolts on a net to let the excess drip off.

58 Apply a 2 mm (0.080”) bead of 1161231 Sealant

to the back of the cylinder head.

NOTICE! The cylinder head bolts must be

torqued within 5 minutes of sealant application.
59 Install a new cylinder head gasket.

NOTICE! Convex embossments prevent damage

to the rubber seals.

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60 Lower the cylinder head until it rests on the

cylinder head gasket. Maintain a distance to the
timing gear plate of 5–10 mm (0.2–0.4"). Locating
pins ensure that the cylinder head will be aligned
with the engine block.

5-10mm

p0011512

61 Place a clean rag in front of the drive to prevent

bolts from falling into the timing housing.

NOTICE! The rag must be removed before the

engine is cranked.
62 Place a bolt in the upper intermediate gear hub
(1) into the cylinder head, so you can pull the
cylinder head towards the timing gear plate.
Screw four M8 bolts into the transmission plate
(2).
63 Torque the bolts (1) and (2) as specified in
Tightening torques, page 7 and Tightening
Schedules, page 10. Use new bolts pre-treated
with 85145750 Thread locking. Undo all bolts (1)
and (2) about one turn.

NOTICE! The cylinder head is now in the correct

P0016810 position for fastening and must not be moved. If
the cylinder head is moved, the bolts must once
again be torqued and loosened as above.
64 Install the cylinder head bolts and torque them
according to Tightening torques, page 7 and
Tightening Schedules, page 10. Use a torque
amplifier for angle tightening.
65 Torque the four M8 bolts in the transmission plate
(2) as specified in Tightening torques, page 7 and
Tightening Schedules, page 10.
66 Turn the engine so that the two M8 bolts (1) can
be installed through the upper intermediate gear.
Tighten according to Tightening torques, page 7
and Tightening Schedules, page 10.
P0006893 67 Install the remaining two M10 bolts (3) into the
upper intermediate gear, without tightening.

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68 Clean the surface of sealant as illustrated.

NOTICE! Cut away the sealant.

69 Remove the lifting tool from the cylinder head.

Camshaft, installation
70 Inspect the camshaft as regards wear. Refer to
Camshaft, Wear Check, page 153.
71 Clean the surfaces on the bearing blocks and
cylinder head.
72 Install the camshaft bearing brackets as marked
on the cylinder head; make sure they abut the
cylinder head.
73 Place the bearing shells in the bearing blocks and
lubricate the bearing shells with engine oil.
74 Early model (> 153201 - w0727 K-10594-66)
Crank the engine using 9993590 Rotation tool so
that the flywheel is set exactly to zero according
to the marking on the flywheel housing.

9993590 Rotation tool is installed directly on the

starter motor or, if the starter motor is removed,
together with 9993625 Adapter plate

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75 Later model
Remove the cover plate from the flywheel
housing and attach 9993590 Rotation tool.

P0016287

P0016289

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76 Carefully lift the camshaft in place. Make sure that

the guide pin on the camshaft drive points straight
up. The camshaft TDC mark must be in the
middle of the markings on bearing bracket # 7.

NOTICE! The camshaft lobes are sharp.

77 Oil the bearing shells and install bearing caps on
the bearing brackets.

NOTICE! Use a suitable spacer on the rocker arm

side.

1 Torque bolts 1-7 according to step

Tightening torques, page 7 and Tightening
Schedules, page 10.
2 Torque bolts 8, 11, 14 (with spacers)
according to Tightening torques, page 7
and Tightening Schedules, page 10.

78 Place the gear so that the reference hole in the

timing gear plate is between the gear markings.
79 Install the camshaft drive without the vibration
damper; use nuts for spacers. Temporarily
tighten two bolts with low torque, max 10 Nm (7.4
lbl.ft).

Gear lash, adjustment

80 Remove the 2 lower bolts in the adjuster wheel.
Check that the upper bolts are not tightened.
81 Place a 0.1 mm (0.004 in.) feeler gauge on the
pressure side, at the centerline between the two
gears. Press the camshaft drive against the feeler
gauge. Tighten according to Tightening
torques, page 7 and Tightening
Schedules, page 10. Remove the feeler gauge.

P0006947

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82 Check the clearance as follows: Fix the adjuster

wheel. Place a dial indicator on the camshaft
drive, as illustrated. Turn the gear back and forth
and compare the result against the gear lash
measurement specification in Engine
body, page 21.
83 If gear gear lash is correct, torque the
intermediate gear (1) bolts according to
Tightening torques, page 7 and Tightening
Schedules, page 10.
84 Install the vibration damper and torque as
specified in Tightening torques, page 7 and
Tightening Schedules, page 10.

85 Apply a 2 mm (0.8 in.) bead of 1161231 Sealant

to the upper timing gear cover contact surface, as
illustrated.

P0016816

86 Install the rubber seals and install the upper

timing gear cover.

87 Only fit the bolts (1) and tighten by hand. The

holes are oblong so that the cover can be pressed
down against the rubber seal.

P0006950

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88 Remove the attachment bracket for the

intermediate piece. Press the cover down using
885810
885810 Fixture and 9998601 Fixture so that the
cylinder head and the upper timing gear cover
sealing surfaces are aligned. Refit the other bolts
(2). Tighten according to Tightening
torques, page 7 and Tightening
Schedules, page 10.

NOTICE! The timing gear cover must be installed

and torqued within 20 minutes of sealant
application.

P0002637

89 Install the camshaft sensor and adjust it

according to Camshaft Sensor Distance,
Check, page 156.

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Unit injector, installation

NOTICE! To prevent dirt from entering the fuel ducts,
it is recommended that injectors be installed one at a
time.

90 Remove 9998251 Protection plug with

9990156 Adapter and 9996400 Slide hammer.
91 Install new sealing rings to the unit injectors.
Lubricate the O-rings with diesel. Install injectors
and retaining yokes. Center the injector so that it
does not touch the valve springs. Tighten
according to Tightening torques, page 7 and
Tightening Schedules, page 10.

92 Reinstall the floating yokes in their original

positions.

NOTICE! Make sure that the yoke is directly above the

valve stem. The oval hole must be turned away from
the camshaft.

93 Lubricate valve yoke and camshaft.

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94 Remove the temporary bolts and spacers.

95 Install the rocker arm bridge. Torque the bolts
alternately along the rocker arm shaft as specified
in Tightening torques, page 7 and Tightening
Schedules, page 10.
96 Pull the cable harness to the unit injectors through
the cylinder head and connect to the terminals.
97 Slide new O-rings over the oil supply pipe for the
rocker arm bridge. Insert the pipe in the
intermediate piece and install the intermediate
piece with pipe. Check that the O-rings on the
pipe and ring under the intermediate piece are
positioned correctly. Install the cable holder and
attach the harness using oil resistant, heat
resistant cable ties.

NOTICE! Make sure the harness is not too close

to the gear.

Timing marks
The engine has markings (1-6 for the respective
cylinders) for adjusting inlet and outlet valves and unit
injectors.

NOTICE! It is important that the line marked on the

camshaft is centered between the two marks on the
bearing cap when adjustment is carried out.

P0006955

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Valves and injectors, adjustment

Adjust valves and injectors for the respective cylinders
at the same time.

98 Turn the engine to the next camshaft marking.

99 Remove the adjuster screws for the current
cylinder rocker arm so that they do not contact the
valve yokes or unit injectors.
100 Adjust the valve clearance between rocker arm
and valve yoke as specified in Tightening
torques, page 7 and Tightening
Schedules, page 10. Tighten the locking nut
according to Tightening torques, page 7 and
Tightening Schedules, page 10.

Check the valve clearance. Mark the rocker arm when

the valve has been adjusted.
101 Adjust the unit injector rocker arm to zero
clearance. Tighten the adjuster screw a further
3-4 flats (180°-240°). Tighten the nut on the
adjuster screw according to Tightening
torques, page 7 and Tightening
Schedules, page 10.
102 Adjust remaining valves and unit injector as per
the above.

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103 Connect the fuel lines to the cylinder head.

104 Apply a 2 mm (0.080”) bead of 1161231 Sealant
to parting plane (A) between the timing gear
casing and the cylinder head.
105 Install the valve cover. Tighten the bolts
according to Tightening torques, page 7 and
Tightening Schedules, page 10.

NOTICE! The valve cover must be installed within

20 minutes of sealant application.

P0006950

106 Apply a 2 mm (0.080”) bead of 1161231 Sealant

to the inlet manifold. Install the inlet manifold and
tighten according to Tightening torques, page 7
P0006959
and Tightening Schedules, page 10.

NOTICE! The inlet manifold must be installed within 20

minutes of sealant application.

107 Install the charge air pressure sensor and the

coolant sensor.
108 Install the clamps that hold the fuel lines on the
intake pipe.
109 Install the front lifting eye.
110 Install the alternator and starter motor.
111 Remove fixture and replace the parts that were
removed.
112 Install the drive belts, fan, alternator and
tensioning devices.

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Reassembly, Complete Engine

1 Install fuel and oil filter brackets with associated
pipes and hoses.

P0003853

2 Install manifold with associated water pipe and

the heat shield fixture plate.
3 Install the right rear lifting eye.
4 Install the electrical center fixture and the engine
cable harness.
5 Install the alternator and connect alternator
cables.

P0003854

6 Install the seawater pump.

P0003856

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7 Install the reverse gearbox oil cooler.

8 Install the cooling hose between the sea water
pump and the reverse gearbox oil cooler.

P0003857

9 Install the charge air cooler and it's lower fixture.

Tighten the clamp for the rear hose connection on
the charge air cooler.
Install the rubber gasket to the pipe stub between
the charge air cooler and the turbocharger.

NOTICE! Make sure that the sealing lip points

downwards and that the lower sealing cone is
pushed forwards.
Apply Vaseline to the rubber gasket to simplify
installation.
P0016818

P0016819

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10 Install the front intake pipe.

11 Install the charge air cooler pipe.
12 Install a new gasket between the manifold and the
turbocharger.
Hang the turbocharger on its studs and align the
oil drainage pipe with the engine block while
adjusting the clamp between the turbocharger
and charge air cooler, so that it doesn't get
pinched.
13 Install the turbocharger nuts and the bolt for the
connection joint.
Check that the oil drain pipe has not slipped out
of the engine block.

14 Install the clamps for the turbocharger pipe and

hoses to the charge air cooler pipe, and fit the
turbocharger hoses.

P0003859

15 Mount the fixture for the electronic unit together

with the oil filler pipe and dipstick tube. Install the
return fuel pipe to the electronic unit fixture.
Install the cable harness clips to the electronic
unit fixture.

P0003860

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16 Install the heat exchanger.

P0003861

17 Install the thermostat and cover, together with the

pipe between the thermostat and the heat
exchanger.

P0003862

18 Align the pipe between the fresh water pump and

the heat exchanger. Loosely fit the bolts for the
cooling pipe attachment.
Tighten the pipe to the heat exchanger.
Tighten the bolts for the pipe attachment.
Install the pipe between the charge air cooler and
the expansion tank.
Install the belt guard.
Install the hose between the heat exchanger and
exhaust elbow.

P0003863

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19 Connect the control unit connections and close

the locking attachments.
Install the control unit protective casing together
with the control unit. Check that the grounding
braid is properly mounted.
Install the fuel lines to the control unit cooling coil.

P0003864

20 Install the expansion vessel and connect the

coolant level sensor connection block.
28 28

28 28

P0003865

21 Install the crankcase ventilation filter and pipes.

Install the crankcase ventilation pipe seal to the
pipe before fitting it to the valve cover.

P0003866

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22 Install the electrical center protective casing.

23 Install two new inserts in the air filter housing and
install the air filter fixture and air filter.
24 Install the turbocharger heat shields.
25 Fill with coolant according to
Administration, page 40, and Cooling system,
filling, page 225.
26 Replace oil filter. Fill with engine oil according to
Administration, page 33
27 Change the fuel filter. Purge the fuel system
according to Fuel system, bleeding, page 197
28 Start the engine and let it run until it reaches
normal working temperature. Let it idle another
5-10 minutes. When the idle is even, the cylinder
balancing system has set the correct amount of
fuel for the unit injectors.

NOTICE! Do not connect any power consuming

devices (e.g. p.t.o.) while cylinder balancing is being
performed. Check that no leakage occurs.

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21-3 Cylinder Liner, Pistons

Cylinder Liner and Pistons,
Inspection
Clean the cylinder liners carefully before
inspection and measurement.

IMPORTANT!
Cylinder liners and pistons are classed together. This
means that cylinders and liners must not be mixed.

The piston and cylinder liner sets are only available as

a single, complete unit.

Cylinder Liner
Measurement of cylinder liner wear can be done with
the liner installed in the cylinder block.

NOTICE! The cylinder liners must be taken out of the

engine block, to do a careful crack check.

1 Measure the cylinder liners with a cylinder

indicator. In order to obtain the greatest possible
accuracy in the wear measurement, the cylinder
liner must first be set up with a gauge ring or
micrometer. Use the original diameter of the
cylinder liner as the base value.
2 Measure the cylinder liner at top and bottom dead
centers, and at several places vertically.
P0006962
At each measurement location, measurement
must be lengthwise and crosswise in relation to
the engine.
3 If wear is greater than 0.45–0.50 mm, a new
complete lining kit must be used (piston, liner,
piston rings, piston pin and seals).
Oil consumption also affects when cylinder liners
must be changed.
4 Remove the cylinder liner and do a crack check.
Be specially careful when checking the liner
collars.
The Magnaflux method may be used for this
check.

Pistons
5 Check for worn piston ring grooves, damaged
retainer ring grooves, cracks and other damage
to the pistons.
If the piston has deep scratches on its skirt, the
piston (liner kit) must be scrapped. The same
applies if the piston has one or more cracks in the
piston pin hole or in the bottom of the combustion
chamber.
Crack tests must be done using the chalk powder
method.

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Cylinder Liner and Pistons, Replace

(all)

Tools:
9993590 Rotation tool
9993625 Adapter plate
9996645 Puller
9996394 Support
9996395 Support
9989876 Dial indicator
9992479 Holder for dial indicator
9990157 Press tool
1161231 Sealant
9990044 Piston ring compressor

Removal
IMPORTANT!

It is important to remove the piston cooling nozzle

before the piston is removed. Damaged nozzles can
cause extensive engine damage.

1 Remove the protective cover in the flywheel

housing and install 9993590 Rotation tool, or
remove the starter motor and install
9993625 Adapter plate. Turn the crankshaft to
gain access to the bolts on the connecting rod for
removal.

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2 Remove main bearing cap and bearing shells.

3 Remove the piston together with the connecting
rod.
IMPORTANT!
Replace the bearing cap on the connecting rod to
avoid damaging the parting surface, as this is
very sensitive.

4 Pull the cylinder liner out of the block using,

88800218 Extractor plate 9996645 Puller and
9996394 Support. If necessary, extend using
9996395 Support
5 Remove the cylinder liner seal rings.

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6 Remove the retainer ring from the piston and

press out the piston pin. Remove the piston from
the connecting rod.
7 Clean the sealing surfaces in the cylinder block
and the seal ring grooves. Do not use scrapers or
other tools that can damage the sealing surfaces.

Installation
8 Check the cylinder block liner seat for damage. If
liner collar milling is necessary, refer to “Cylinder
liner seat, milling”. Fit the cylinder liner without
seal rings. Secure it using two 9996966 Press tool
9 Fit dial indicator 9989876 Dial indicator in
9992479 Holder for dial indicator. Place the
holder with dial indicator across the cylinder liner.
Zero the dial indicator with a couple of millimeters'
pre-load to the engine block plane.

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10 Measure the height between the cylinder liner

and the cylinder block plane.
Measure the height of the liner at two places,
diagonally opposite each other.
Calculate the average of the two measurements.
For correct liner height above block plane, see
specifications.
If liner height above block plane is outside
specified tolerance, the liner collar in the cylinder
block should be milled. See 'Cylinder liner seat,
milling'

NOTICE! Always measure at the highest point of

the sealing surface. Mark the liner position in the
cylinder block with felt pen, so that it is replaced
in the same position during installation. Repeat
the procedure for the remaining cylinder liners.

11 Remove 9996966 Press tool Pull the cylinder

liner out of the block. Place the cylinder liners in
the same sequence that they were installed,
together with any adjusting spacers.

12 Lubricate the seal rings using the lubricant

supplied with the liner kit and install the seal rings
on the cylinder liners.

NOTICE! The purple seal ring must sit in the

lowest groove

P0006966

13 When the cylinder liner is fitted without shims, run

an even, approx 0.8 mm (0.03 in.) bead of sealant
on the underside of the cylinder liner collar.

NOTICE! Do not run sealant around the entire

liner; leave a 2 mm (0.08 in.) gap.

Without spacer

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 21-3 Cylinder Liner, Pistons

14 If the liner is installed with shims, run the sealant

bead on the cylinder block liner seat.

NOTICE! Sealant must not be used between the

shims and the cylinder liner collar.

NOTICE! After applying 1161231 Sealant the

liner must be installed within 5 minutes. If the
cylinder head cannot be installed and torqued
within 5 minutes, the liner must be held to the
engine block with two 9990157 Press tool.

P0006918
Without spacer

15 Install one of the cylinder head bolts (A). Place

88800218 Extractor plate(D) above the cylinder
liner together with an appropriate spacer (C) and
press the cylinder liner down using
9998511 Lever B).

16 Lubricate the piston pin, piston bush and the

piston bearing seat with engine oil.

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21-3 Cylinder Liner, Pistons

17 Install the connecting rod in the piston with the

mark 'FRONT' on the connecting rod and the
arrow on the piston facing the same direction.
Press the piston pin in.
Install the retainer rings.

NOTICE! It must be possible to press the piston

pin in without much force. If resistance is too
great, the piston may need to be heated. The
connecting rod should turn freely on the piston
pin.

18 Install the piston rings. Use piston ring pliers. The

piston ring gaps must be staggered evenly in
relation to each other. The gap in the oil control
ring must be diametrically opposite the gap in the
spring underneath.

NOTICE! Both the upper piston rings are marked

with letters or dots. The markings must face
upward. The oil scraper ring is symmetrical and
can face either way.

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 21-3 Cylinder Liner, Pistons

19 Lubricate the piston and piston rings with engine

oil. Check that the piston ring gaps are staggered
in relation to each other.
20 Install the piston together with the connecting rod.

NOTICE! The connecting rods must be installed

in their original positions. The arrow on the
pistons and the 'FRONT' marking on the
connecting rod must face forwards. Use
9990044 Piston ring compressor

NOTICE! Temporarily remove the press tools

when the piston is installed. Put the press tools
back when the piston is in place.
21 Lubricate the bearing journal and bearing shells
with engine oil. Install the big end bearing shells.
Check that they are correctly aligned in the con
rods and bearing caps. Install the big end bearing
caps in accordance with the markings, and
tighten to the specified torque.
22 Clean the piston cooling nozzle and check that it
is undamaged. Install the nozzle and tighten to
the specified torque.

NOTICE! Make sure that the nozzle is aimed at the

cutout in the piston.

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21-3 Cylinder Liner, Pistons

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 21-4 Valve Mechanism

21-4 Valve Mechanism

Valves and Unit Injectors,
Adjustment

NOTICE! Adjust valves and injectors for the respective

cylinders at the same time.

Timing marks
The camshaft has marks (1–6 for the respective
cylinders) for adjusting inlet and exhaust valves and
the unit injectors.

NOTICE! It is important that the line on the camshaft

is between the markings on the bearing cap when the
adjustment is made.

Adjustment

Tools:
9993590 Rotation tool
1 Remove the cover plugs / cover plate from the
flywheel housing and attach 9993590 Rotation
tool.
Crank the engine to the nearest camshaft
marking.
2 Remove the adjuster screws for the current
cylinder rocker arm so that they do not contact the
valve yokes or injectors.

P0016287
The picture is showing an engine of later model.

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3 Adjust the valve clearance between rocker arm

and valve yoke as specified inEngine
body, page 21. Angle tighten the locking nut 60°
± 5° after contact. Check the valve clearance
again. Mark the rocker arm once the valve is
adjusted.

4 Adjust the injector rocker arm to zero clearance.

Tighten the adjusting screw an additional 3–4
flats (180°–240°). Angle tighten the locking nut
45° ± 5° after contact.
5 Adjust the remaining valves and injectors in the
same way.
6 Connect the fuel lines to the cylinder head.

P0011933

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7 Apply a 2 mm (0.079") bead of 1161231 Sealant

A to the mating surface (A) between the timing gear
cover and the cylinder head.
IMPORTANT!
A
Cut away excess sealant with a sharp knife. Do
not pull it off!
8 Install the valve cover and tighten the bolts to 24
± 4 Nm (17.7 ± 3 lbf.ft). See Tightening
torques, page 7.

NOTICE! The valve cover must be installed within

20 minutes of sealant application.

P0011934

Valve Guides, Inspection

Tools:
9989876 Dial indicator
9999696 Magnetic stand
1 Remove the valve stem seals from the valve
guides.
2 2. Put the cylinder head on the bench with the
valve discs facing upwards.

IMPORTANT! The cylinder head must not be put down

such that its entire weight rests on the valve guides (1)
(see figure under item 4).
3 Place a new valve in the valve guide with the
valve stem end in the same plane as the edge of
the guide. Use a suitable counterhold under the
valve stem.
4 Place 9989876 Dial indicator and
9999696 Magnetic stand so that the dial indicator
tip is touching the valve disc edge. Move the valve
sideways, in the direction of the exhaust or inlet
duct. Read off the value on the dial gauge.
5 Check all valve guides. If the readings exceed the
values noted in the specifications, the valve guide
must be changed. Refer to Engine
1 body, page 21.

P0003886

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Valve Guides, Replacing

Cylinder head removed, valves removed.

IMPORTANT!
If the valve seats must also be changed, do so before
the valve guides are removed.

Tools:
9990176 Press tool
9996159 Adapter
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
88800062 Drift
88800063 Drift
88800147 Drift

Removal
1 Install 9809729 Hydraulic cylinder in
9990176 Press tool.
2 WARNING!
Risk of eye injury. Eye protection required.

Fit 9996159 Adapterin the hydraulic cylinder and

press out the valve guide using 88800147 Drift
and 9809726 Pneumatic hydraulic pump .
Press the other valve guides out in the same way.

Installation
3 Lubricate the valve guides on the outside with
engine oil before installation.
4 WARNING!
Risk of eye injury. Eye protection required.

Cooling valve guides Press in the inlet valve

guides with tool 88800062 Drift. Press the
exhaust valve in using 88800063 Drift. Press until
the tool bottoms against the cylinder head plane.
IMPORTANT!
After the valve guides have been changed, the
cylinder head must be cleaned to prevent
particles from entering the fuel and oil ducts.
Contamination may cause failure or malfunction
of the unit injectors.

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Valves, Removal
NOTICE! It is very important that the greatest possible
cleanliness is observed during work on the cylinder
head. Dirt particles in the fuel ducts can cause failure
or malfunction of the unit injectors.

Tools:
9990160 Fixture
9990210 Valve spring compressor
827861 Spacer

The work will be easier if the cylinder head is held in

an assembly stand with 9990160 Fixture. Use four
M8x25 bolts.

1 Lay the cylinder head on a flat, clean surface.

Make sure that the cylinder head is not damaged
when the valves are removed.
2 Install 9990210 Valve spring compressor in in the
unit injector hole.
Attach the tool in the hole for the unit injector
yoke; 827861 Spacer allows the use of a regular
bolt.
3 Put the moving part of the tool over the valve
spring to be removed. Screw the tool "wing nut"
down until the valve washer has been pressed
down far enough for the collets to be removed.

NOTICE! Put the valves and springs in marked

stands, to make it easier to put components back
in the same places in the cylinder head.
4 Remove the remaining valves in the same way as
above.
5 Remove the oil seals from the valve guides.

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Valves, Installation
Tools:
9990210 Valve spring compressor
9809729 Hydraulic cylinder
9990176 Press tool
9996159 Adapter
9998246 Drift
9998335 Drift

Alternative 1
Oil the valve stems and install the valves.

Lubricate the oil seals.

1 Install tool # 9998335 on the valve stem and press
the new oil seals down over the valve guides.

NOTICE! Check that the oil seals are pressed down

properly.

NOTICE! Valve springs must be centered straight

above the valve guide during installation.

2 Install the springs and valve spring washers.

Carefully press down the valve spring washer and
install the collets. Use 9990176 Press tool
together with 9809729 Hydraulic cylinder,
9996159 Adapter and 9998246 Drift in the same
way as for disassembly.

Alternative 2
Alternatively 9990210 Valve spring compressor may
be used instead of the hydraulic cylinder, in the same
way as for disassembly.

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 21-4 Valve Mechanism

Valve Stem Sealings, Replace

Tools:
9998335 Drift
9990210 Valve spring compressor
9993590 Rotation tool
1 Disconnect all current to the engine, by switching
off the main switch.
2 Remove the unit injectors; refer to Unit Injector,
Replace, page 201.
3 NOTICE! The piston must be at top dead center
when the valves are removed. This is to prevent
the valves from falling down into the cylinder. Use
9993590 Rotation tool.
4 Compress the valve springs for # 1 cylinder. Use
9990210 Valve spring compressor.
5 Remove the collets, washer and valve springs.
6 Remove the old valve spring seals.
7 Lubricate the valve stem with engine oil. Fit
9998335 Drift to the valve stem. Thread the new
seal on and put it over the mandrel.

NOTICE! Valve springs must be centered straight

above the valve guide during installation.
8 Fit the valve springs, washers and collets. To
ensure the collets arrive in the correct positions,
carefully tap with a plastic faced mallet.
9 Transfer the valve spring compressor to # 6
cylinder and repeat the procedures described
above. Then crank the engine so that # 3 and # 4
cylinder are at TDC. Repeat the procedure. Then
continue with cylinders 2 and 5.

NOTICE! The piston must be at top dead center

when the valves are removed. This is to prevent
the valves from falling down into the cylinder. Use
9993590 Rotation tool.
10 Install the unit injectors; refer to Unit Injector,
Replace, page 201.
11 Adjust the valves and unit injectors; refer to
"Valves and unit injectors, adjustment".
12 Bleed the fuel system. Perform a function and
leakage check.

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21-4 Valve Mechanism

Valve Seat, Change

Cylinder head and valves removed
1 The valve seats must be replaced if a perfect seal
cannot be achieved or when the distance “A”
exceeds the value shown in the specification.
Refer to Engine body, page 21.

2 Grind the head off an old valve and weld it onto

the valve seat. Use a MAG welder, or a
conventional arc welder (with a stainless steel
welding electrode).
IMPORTANT! Carefully cover other cylinderhead
surfaces so that any weld splatter cannot stick.

3 Place a suitable socket over the valve/valve guide

and carefully tap the valve seat out.

NOTICE! Be careful not to damage the cylinder

head.

NOTICE! Wear safety goggles.

4 Clean the seat bed carefully and check the
cylinder head for cracks.
5 Measure the diameter of the valve seat bed in the
cylinder head. Determine whether a standard or
oversize dimension valve seat must be used.
Carry out any necessary machining on the valve
seat bed. Refer to Engine body, page 21.

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 21-4 Valve Mechanism

6 Cool the seat in dry ice to between –60°C and –

70°C and warm the cylinder head by flushing it
with hot water, or by some other method. Install
the valve seat using a mandrel.

NOTICE! Align the seat with the seat angle facing

the tool.

Valve Seat, Grinding

NOTICE! Spare part valve seats are already
machined, and do not need further grinding.

Inlet valve

1 Before the valve seats are ground, the valve

guides must be checked and changed if the wear
tolerances have been exceeded.
2 When grinding valve seats, do not remove an
unnecessary amount of material; only remove
enough material to give the valve seat the correct
shape and a good mating surface.
3 Grind new seats down so far that the dimension
between the cylinder head plane and the valve
disc surface, measured with a new valve, is in
accordance with the specification.

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21-4 Valve Mechanism

4 Check the valve seat angle with a valve seat

gauge, once the seat mating surface has been
coated with a thin layer of marker dye.

Exhaust valve

Valves, Grinding
Refer to Valve Seat, Grinding, page 151 for valve
sealing angles.

NOTICE! Spare part valves are already machined, and

do not need further grinding.

NOTICE! Grind the sealing surface as little as possible,

just enough to grind away all damage.

1 Check the dimension (A) on valve head edge. If

the dimension is less than the wear tolerance as
specified in Valve Seat, Grinding, page 151, the
valve must be replaced.

NOTICE! Always change a valve with a bent valve

stem.

2 Check valve sealing with marker dye. In the case

of a poor seal further valve seat grinding is
necessary; refer to Valve Seat,
Grinding, page 151, after which a new check must
be carried out.
Once the results of grinding are acceptable, the
valve and seat may be lapped in with fine grinding
paste.

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 21-5 Timing Gears and Shaft

21-5 Timing Gears and Shaft

Camshaft, Wear Check
Rocker bridge removed

Put a steel rule across the camshaft lobes, parallel with

the camshaft axis, to check whether the cam profiles
show wear.

Measure the wear with a feeler gauge or wire gauge.

Alternatively, a digital caliper gauge can be used.

Compare the readings with those specified in

"Technical Data".

Guidelines for replacement

In normal conditions, unevenness may occur on the
surface of engine camshaft lobes. This does not mean
that the camshaft must be changed. These marks do
not have any negative influence on either engine
performance or the durability of the engine and its
components.

Examples of acceptable wear and unacceptable wear

are shown below.

Acceptable wear Unacceptable wear

The camshaft need not be changed NOTICE! The camshaft and associated rocker arms must be
changed.

P0003896 P0003897

P0003898 P0003899

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Camshaft Bearing Housing,

Replace
The factory-fit bearing housings are machined
together with the cylinder head, and may therefore not
be moved from one cylinder head to another.

Consequently, the first time one or more bearing

housings require replacement, all bearing housings
must be replaced so that their positions can be aligned.
From then on, bearing housings may be changed
individually since the spare part variant differs from the
production variant.

The holes for the guide sleeves are oval in the

replacement housings, which allows radial adjustment
of the center bearing housing and axial adjustment of
the front and rear bearing housings.

If replacement housings are installed, mark them with

numbers so they can be put back in the same place as
before, if they must be removed.

Sensors, Adjustment
Sensor removed.

Tools:
88800031 Measuring tool
1 If the camshaft sensor needs to be adjusted,
rotate the crankshaft so that one tooth on the
camshaft vibration damper is centered in front of
the sensor hole.
2 Remove any shims beneath the sensor.
Clean the tool's contact surface on the engine.

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3 Insert 88800031 Measuring tool without

88800031 tightening the lock screw.
press in the tool firmly so that it is in contact with
the cover. Press in the center part of the tool until
it contacts the gearwheel and tighten the lock
screw.
Rove the tool and inspect the center section
position in its sleeve.

P0010198

4 Determine further actions according to the

following:

If the center section of the tool is entirely below

the sleeve's upper edge, no shims are required.

P0010219

If only the center section upper surface is above

the sleeve's top edge, one shim is required.

P0010218

If the two center section surfaces are above the

sleeve's top edge, two shims are required.

P0010220

5 Install the sensor with a new seal and any shims.

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21-5 Timing Gears and Shaft

Camshaft Sensor Distance, Check

1 Crank the engine so that a tooth on the camshaft
drive is aligned with the cam shaft sensor hole on
the upper timing gear cover.
2 Slide the installation tool retainer ring so that it sits
in the middle of the tool.
3 Place the tool in the camshaft sensor hole and
press it in carefully until it touches the vibration
damper tooth.
P0006982

A 4 Remove the tool and measure the distance

between the sensor contact surface and the end
of the tool. Note the reading (A).

P0006983

5 Place the sensor in the tool and measure the

distance between the sensor contact surface and
the end of the tool (B).
6 Calculate the existing sensor distance (D) as
follows:
D = A - (B + 20)
Example:
Distance (A) = 28.2 mm (1.11 in.)
Distance (B) = 8 mm (0.31 in.)
D = 28.2 - (8 +20)mm (1.11 in. - (0.31 in.+ 0.79
P0006984 in.))
D = 0.2 mm (0.01 in.)
7 Compare the value with correct value as per
“Technical data.” Adjust as needed using shims.
Install the sensor together with any shims.

Clearance measured Adjusting shims, number Part #

0.2 to 1.0 mm (0.01 till 0.04 in.) — —
– 0.3 to 0.3 mm (– 0.01 – 0.01 in.) 1 1677894
– 0.6 to – 0.3 mm (- 0.02 – 0.01 in.) 2 1677894

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 21-5 Timing Gears and Shaft

Timing Gear, Replace

Valve cover, wiring, upper timing gear casing,
camshaft sensor, oil filter holder including fuel
filter with bracket and oil pan removed.

Removal

Tools:
9996239 Lifting tool
1 Remove the flywheel sensor.
2 Turn the engine to camshaft TDC and check that
the mark on the flywheel is at “0”.
3 Bolt 9996239 Lifting tool to the flywheel. Remove
the flywheel

NOTICE! Crush risk. Protect hands.

4 Remove the starter motor, rear lifting eyes, and

the fuel pump together with the servo pump, the
cover and any rear engine mounts.
5 Remove the flywheel housing bolts. Remove the
cover using lifting eyes and lifting strap.

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6 Remove the lower intermediate gear (4).

7 Remove the Allen head bolts on the crankshaft
drive (5) and remove the drive with the aid of
puller 11159911.
8 To protect the puller thread, place a thick washer
between the threaded shaft and the crankshaft.
9 Remove the upper intermediate gear (2).

NOTICE! Save the spacer plate behind the drive

and note how it is installed.
10 Remove the camshaft gear (1).
11 Remove the timing gear plate and clean both
sides.

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 21-5 Timing Gears and Shaft

Installation

Tools:
1161231 Sealant
9998601 Fixture
885810 Fixture

NOTICE! Lubricate the inside of the gears before

installation.

1 Apply a 2 mm thick bead of 1161231 Sealant on

the engine block and the cylinder head, as
illustrated.
2 Install the timing gear plate. Use new bolts that
are pre-treated with locking compound. Tighten
according to Tightening torques, page 7 and
Tightening Schedules, page 10.

NOTICE! Make sure that the plate is aligned with

the bottom of the block.

NOTICE! Torque within 20 minutes of sealant

being applied.

3 Oil the spacer plate and place it together with the

upper intermediate gear (2). Tighten with low
torque, max 10 Nm (7.4 lbf.ft).

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4 Install a new O-ring on the crankshaft.

5 Install the camshaft gear (5) and torque the Allen
bolts according to Tightening torques, page 7 and
Tightening Schedules, page 10.

6 Install the bull drive kit (3) with the hole marking
between the two hole markings on the crankshaft
drive.

NOTICE! The bull drive inner and outer gears

have different gear pitches. For the camshaft to
be set correctly, the markings must be correct.
Tighten the bolts according to Tightening
torques, page 7 and Tightening
Schedules, page 10.

7 Install the bottom intermediate gear (4) with a new

O-Ring.
8 Install the lubricating oil pump together with the
rear main bearing.
9 Screw two bolts into the crankshaft drive to
receive a crowbar for rotating the crankshaft as
required.

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 21-5 Timing Gears and Shaft

10 Fit the camshaft drive without the vibration

damper; use nuts for spacers.
11 Place the gear so that the reference hole in the
timing gear plate is between the gear markings.
Tighten two bolts temporarily to low torque, max
10 Nm.
12 Remove the 2 lower bolts in the adjuster wheel.
Check that the upper bolts are not tightened.

P0006944

13 Place a 0.1 mm (0.004 in.) feeler gauge on the

pressure side. Turn the camshaft drive counter-
clockwise. This will move the adjustable
intermediate gear to the correct position. Torque
the adjustable intermediate gear per step 1 in
Tightening Schedules, page 10 and the play
according to the previous item. Remove the feeler
gauge.

14 Fix the adjuster wheel. Place a dial indicator on

the camshaft drive, as illustrated. Turn the gear
back and forth and compare the result against the
gear lash specification in Engine body, page 21.
15 If the gear lash is correct; torque the intermediate
gear (1) bolts according to step 2 in Tightening
Schedules, page 10.

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16 Apply 1161231 Sealant to the flywheel housing,

against the engine block.

17 Remove the seal. Install the flywheel housing.

Check that the housing is flat against the engine
block. See ”Flywheel housing, checking for
warp”.

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18 Install a new crankshaft seal.

19 Install the flywheel and torque as specified in
Technical data. Refer to 21-5, Flywheel,
Indication.
20 Install the vibration damper and tighten according
to Tightening torques, page 7 and Tightening
Schedules, page 10.

P0006907

21 Apply a 2 mm (0.08 in.) thick bead of

1161231 Sealant to the upper timing gear cover
contact surface, as illustrated.

22 Fit the rubber seals and install the upper timing

gear cover.

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21-5 Timing Gears and Shaft

23 Only fit the bolts (1) and tighten by hand. (The

holes are oblong so that the cover can be pressed
down against the rubber seal.)

P0006950

24 Remove the attachment bracket for the center

piece. Press the cover down using
885810
885810 Fixture and 9998601 Fixture so that the
cylinder head and the upper timing gear cover
sealing surfaces are aligned. Install the remaining
bolts. Tighten according to Tightening
torques, page 7 and Tightening
Schedules, page 10.

P0002637

NOTICE! The timing gear cover must be installed and

torqued within 20 minutes of sealant application.

25 Install the camshaft sensor and adjust according

to Camshaft Sensor Distance, Check, page 156.

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Main Bearing, Replace

Oil sump and starter motor removed.

The method describes replacement of main bearings

with the crankshaft in place in the engine.

1 Removal
Install9993625 Adapter plate and
9993590 Rotation tool
2 Remove the connecting pipe plus oil suction and
oil pressure pipes with the bracket.

3 Remove the bracing frame.

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4 Remove the oil pump together with the rear main

bearing cap.
5 Remove the upper main bearing shell by putting
a pin in the crankshaft oil hole and rolling the
bearing shell out by turning the crankshaft in the
direction of rotation with 9993590 Rotation tool.
6 Clean and check the bearing seat, bearing cap,
shaft journal and bearing shells. If the bearing has
seized, the reason must be determined before a
new bearing is installed.
7 Check that the correct bearing dimension is used
when the bearing shells are changed.

NOTICE! If case of uncertainty, refer to Technical

data for available oversize dimensions.

Installation
8 Lubricate the shaft journal and the new bearing
shells with engine oil.
9 Install the upper bearing shell by turning the
crankshaft using 9993590 Rotation tool against
the direction of rotation with the pin in the oil hole.

NOTICE! Check that the pressed bearing shell

heel is correctly aligned in the bearing seat
cutout. Make sure that the upper bearing shells
(those for location in the engine block) are the
ones with oil holes.

NOTICE! Remove the pin when done.

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10 Fit the main bearing cap together with the lower

bearing shell.

NOTICE! Main bearing caps are asymmetric and

can only be installed in one position.
Note the main bearing cap numbers – which
indicate their positions – if more than one bearing
cap has been removed at the same time.
Torque the caps in two steps, according to
Tightening torques, page 7 and Tightening
Schedules, page 10.
11 Replace the other bearing shells, one a time, in
the same manner. Each time a change is made,
check that the crankshaft does not seize by
turning it using 9993590 Rotation tool.

12 Check crankshaft end float and replace the thrust

washers if the float is excessive or if the thrust
washers are damaged.

NOTICE! Measure end float with a dial gauge.

The thrust bearings are available in a number of
oversize dimensions. Refer to Engine
body, page 21 for oversize dimensions and end
float.
13 The crankshaft thrust bearing pin is located in the
middle main bearing.

14 Use a narrow plastic or wooden handle to remove

the thrust bearing washers in the cylinder block
bearing seat.

NOTICE! The thrust washers can only be placed

in one position.

P0001900

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15 Check crankshaft end float when all main bearing

caps have been torqued; refer to Technical data
for specification.
16 Install the bracing frame and tighten according to
Tightening torques, page 7 and Tightening
Schedules, page 10.
17 Fit the oil pump, delivery pipe, oil suction pipe and
the overflow pipe.
18 Remove 9993590 Rotation tool from the flywheel
housing and install the cover.
Install the oil sump and starter motor.

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Flywheel, Change
Tools:
9993590 Rotation tool
9996239 Lifting tool
9993625 Adapter plate
1 Remove the flywheel sensor.
2 Turn the engine to camshaft TDC and check that
the marks on the flywheel are at zero.
3 Remove the cover under the starter motor and
install 9993590 Rotation tool and if required
9993625 Adapter plate.
4 Fix tool 9996239 Lifting toolto the flywheel with
two bolts. Remove the flywheel retaining bolts;
use the cranking tool as a counterhold. Lift the
flywheel away.
5 Clean the flywheel mating surface.
6 Clean the flywheel. Check that the tracking
surfaces for the flywheel sensor are clean.
7 Check that the flywheel guide pin is correctly
inserted into the crankshaft. Check for damage.
8 Lift the flywheel into position and install the
retaining bolts.
9 Torque the attachment bolts according to
Tightening torques, page 7 and Tightening
Schedules, page 10. Use 9993590 Rotation tool
as a counterhold.
10 Remove the cranking tool and re-install the cover.
11 Check the flywheel sensor distance; refer to
Flywheel Sensor Distance, Check, page 171 and
install the flywheel sensor.

Flywheel Bearing, Replace

Tools:
9991801 Standard handle
9992564 Drift
9991821 Extractor

Flywheel bearing, replacement

Flywheel removed (recommended):
1 Measure the bearing position on the flywheel.
2 Press the bearing out using a hydraulic press.
Use 9991801 Standard handle and
9992564 Drift.
3 Clean the flywheel and check for damage. Press
the new bearing into the measured position with
the aid of 9991801 Standard handle and
9992564 Drift.

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21-5 Timing Gears and Shaft

Flywheel not removed:

1 Measure the bearing position on the flywheel.
2 Remove the old bearing with the aid of
9991821 Extractor.
3 Tap the new bearing into the measured position
with the aid of 9991801 Standard handle and
9992564 Drift.

Gear Ring, Replace

Flywheel removed.
1 Drill 1–2 holes between two teeth on the ring gear.
Split the ring gear at the drilled hole, using a cold
chisel. Lift the gear ring away from the flywheel.
2 Brush the flywheel contact surface clean with a
steel wire brush.

P0006979

3 Heat the new gear ring to 180 - 200°C ( 356 –

392°F) with a welding torch or in an oven. The ring
gear must be evenly heated. Be careful not to
heat the gear ring too much and anneal it.
Check the heat by polishing the ring bright at
several places. Stop heating when the polished
surfaces blue.

P0006980

4 Put the heated ring gear onto the flywheel and tap
it into place with a soft mandrel and hammer.
Allow the ring gear to cool.

P0006981

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 21-5 Timing Gears and Shaft

Flywheel Sensor Distance, Check

Tools:
9993590 Rotation tool
9993625 Adapter plate
1 Install 9993590 Rotation tool and if necessary
9993625 Adapter plate. Turn the flywheel to 0°.
2 Remove the flywheel sensor.
3 Slide the installation tool retainer ring so that it sits
around the middle of the tool.

4 Fit the tool in the sensor hole and carefully press

the tool in until it touches the flywheel.
5 Remove the tool and measure the distance
between the retainer ring and the end of the tool.
Note the reading (A).

6 Put the sensor in the tool and measure the

distance between the sensor bracket mating
surface and the end of the tool. Note the reading
(B).
7 Calculate the existing sensor distance (D) as
follows:
D = A – (B + 20) mm. (20mm = 0.79 in)
Example:
Distance A = 28.2 mm (1.11 in)
Distance B = 8 mm (0.31 in)
D = 28.2 – (8 + 20) mm (D= 1.11 — (0.31 + 0.79)
D = 0.2 mm (D= 0.01 in)
Compare the distance with correct value in
“Technical data.” As required; adjust using shims,
thickness 0.6 mm.
8 Install the sensor on the flywheel housing
together with any shims.
9 Remove cranking tool and install the cover.

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21-6 Crank Mechanism

21-6 Crank Mechanism

Crankshaft Seal, Change (front)
Tools:
9990118 Cone
9990192 Puller
9992000 Handle
9996400 Slide hammer
88800021 Drift
1 Remove the crankshaft pulley and vibration
damper (12 bolts).

2 Drive the seal out with extractor 9990192

together with slide hammer 9996400.
3 Clean the seal seat in the flywheel housing and
the mating surface on the crankshaft.

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 21-6 Crank Mechanism

4 Check that the tools are undamaged, to prevent

damage to the seal.

NOTICE! No lubrication. It must be installed

completely dry.

Install cone 9990118 on the tool.

Install the seal on tool 88800021 via 9990118.
Remove tool 9990118.

5 Then install extension 9992000 on 88800021 and

carefully tap the new seal in until the tool bottoms
against the crankshaft.
Remove the tool and check that the seal is
correctly installed.

6 Install the vibration damper and pulley. Tighten

according to Tightening torques, page 7 and
Tightening Schedules, page 10.

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21-6 Crank Mechanism

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 21-6 Crank Mechanism

Crankshaft Seal, Change (front)

Applies to:

D9 Marine SN7009195516–

Tools:
88800501 Mounting tool
88800502 Puller

Removal
1 Adjust the arms 88800501 Mounting tool and
attach the tool.
Setting diameter: use A. Ø 151 Front seal D9
1 Forward: Hooks release
Backward: Hooks grip
2 Tension nut
3 Slowly pull out the seal.

P0025163

Installation
Important! The metal side of the seal ring must face
inward.
2 Slide the seal ring onto the tool.
Screw the assembly tool with the seal onto the
crankshaft.
Press the seal in until the cover touches the
bottom. Hold in position for at least 3 seconds.

P0025195

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21-6 Crank Mechanism

3 Reference dimension for a correctly installed

seal.

P0025197

Crankshaft Seal, Change (rear)

Flywheel removed.

Tools:
9990113 Drift
9990117 Cone
9992000 Handle
9996400 Slide hammer
9990192 Puller
1 Hammer out the seal using 9990192 Puller
together with 9996400 Slide hammer.
Clean the seal seat in the flywheel housing and
the mating surface on the crankshaft.

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 21-6 Crank Mechanism

2 NOTICE! Check for damage on the guide or drift;

this may damage the seal.

NOTICE! No lubrication. It must be installed

completely dry.

Fit 9990117 Cone onto 9990113 Drift.

Install the seal on 9990113 Drift via
9990117 Cone.
Remove 9990117 Cone.

3 Install 9992000 Handle on 9990113 Drift and tap

in the new seal until the tool bottoms against the
crankshaft drive.
4 Remove the tool and check that the seal is
correctly installed. If needed, use two bolts to pull
the tool out.

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21-6 Crank Mechanism

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 21-6 Crank Mechanism

Crankshaft Seal, Change (rear)

Applies to:

D9 Marine SN7009195516 —

Tools:
88800502 Puller
88800561 Mounting tool

Removal
1 Adjust the arms 88800502 Puller and attach the
tool.
Setting diameter: use B. Ø 170 Rear seal D9.
1 Forward: Hooks release
Backward: Hooks grip
2 Tension nut
3 Slowly pull out the seal.

P0025163

Installation
Important! The metal side of the seal ring must face
inward.
2 Slide the seal ring onto the tool.
Screw the assembly tool with the seal onto the
crankshaft.
Press the seal in until the cover touches the
bottom. Hold in position for at least 3 seconds.

P0025193

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21-6 Crank Mechanism

3 Reference dimension for a correctly installed

seal.

P0025172

Crankshaft, Inspection
The crankshaft is induction hardened.

Inspect the crankshaft very carefully to avoid

unnecessary overhaul.
The following applies when determining the need for
overhaul:
1 Clean the crankshaft thoroughly. Measure
bearing journal ovality, wear and taper. Refer to
“Technical Data”.
2 Check for surface damage on the bearing
journals. If there is any damage to the surface
layer, the shaft must be re-ground.
3 Place the shaft on pair of V-blocks, under # 1 and
7 main bearing journals. Alternatively, hold the
crankshaft between the two centers.
4 Measure crankshaft runout (throw) at # 4 main
bearing. For max permissible value, refer to
Engine body, page 21.

NOTICE! Crankshaft straightening is not permitted.

5 Check for cracks before and after any grinding.

Magnetic powder testing is used for this test, i.e.
fluorescent powder that is viewed under ultra-
violet light.

Connecting Rod, Check

Important to remember when removing/installing a
"fracture-split" connecting rod.

Installing a NEW connecting rod

Carefully fix the connecting rod in a vise with soft jaw
pads.

Undo the connecting rod bolts a few turns and carefully

tap the bearing cap with a plastic faced hammer until
it loosens.

The parting line can be difficult to find when the con rod
is assembled. When the cap is separated from the

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 21-6 Crank Mechanism

connecting rod, a chip may be missing or come loose.

This entails no impairment of connecting rod function.

Handle the connecting rod and bearing cap carefully.

Any impact marks that occur on the parting line may

affect strength after torquing.

NOTICE! Clean the connecting rod with compressed

air only, never with a rag or similar.

IMPORTANT! Replace the connecting rod if the rod or

cap is damaged.

IMPORTANT! Reinstall the bearing caps on the

connecting rods to avoid damage to the parting
surface, since this is very delicate.

Connecting Rod Bushing, Check up

1 Check the connecting rods for cracking,
straightness and twist before any piston pin bush
replacement.
Scrap the connecting rod if it is cracked, bent or
twisted.
When the pin bush is changed it must be
machined (trapezoid piston pin end).
When the clearance is correct, an oiled piston pin
should slowly slide through the bush under its
own weight.
IMPORTANT!For max permissible deviation
from straightness and twist, refer to “Technical
data”.
2 Use a new gudgeon pin and measure the
straightness of the connecting rod using a fixture.
3 Measure connecting rod twist.

P0008163

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21-6 Crank Mechanism

Big end bearing, Change (all)

Tools:
9993625 Adapter plate
9993590 Rotation tool

Oil sump, oil suction pipe and bracing frame removed.

Removal
1 Fit 9993590 Rotation tool and 9993625 Adapter
plate as required. Rotate the flywheel until the
bearing caps on connecting rods 1 and 6 are in
position for bolt removal.
2 Mark and remove the bearing caps on connecting
rods 1 and 6.
3 Remove the bearing shells and clean the
connecting rod and cap bearing seats.

NOTICE! Make sure the bearing caps are installed on

the same connecting rod.

4 Check the bearing journals and bearing caps.

5 Measure the shaft journals; if any value exceeds
the maximum permissible, the crankshaft must
be removed and repaired. Installation

Installation
6 Fit the new the bearing shells and check that the
bearing size is correct. Make sure the bearing
shell guide pin fits properly in the connecting rod
notch.
7 Lubricate the bearing shells and the big end
journals. Install the bearing caps and tighten
according to Tightening torques, page 7 and
Tightening Schedules, page 10.
8 Turn the flywheel so that connecting rods 5 and
2 are in position to remove the bolts and repeat
items 2-6.
9 Turn the flywheel so that connecting rods 3 and
4 are in position for bolt removal and repeat items
2-6.
10 Check that no big end bearing binds.
11 Remove the cranking tool from the flywheel
housing and install the cover.

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 22-0 Lubricating and Oil System, General

22-0 Lubricating and Oil System, General

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

Overview Control Valve

5 1 Safety valve, oil pressure (purple marking)

4 2 Overflow valve (not used)

3 By-pass valve oil cooler
2
4 Pressure limiting valve (blue marking)
5 Overflow valve, oil filter (only applies to marine
genset; others are plugged).
6 Opening valve for piston cooling Overview, Control
valves
7 Control valve for piston cooling
3
7
6

P0002599
1

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22-0 Lubricating and Oil System, General

Pressure Limiting Valve, Change

1 Clean the area around the pressure limiting valve
(1).
2 Remove the pressure limiting valve.
3 Clean the valve contact surface in the oil filter
housing. Check that the old seal is not still in
place.
4 Check that the color marking on the new valve
matches the old.
5 Fit a new sealing ring and install the valve (blue
marking). Check that the internal seal does not
come loose when the valve is installed. Tighten
according to Tightening torques, page 7 and
Tightening Schedules, page 10.
6 Start the engine and check for leaks.
7 Fit a new O-ring and cover

Bypass Valve, Oil Filter Bypass,

Replace
1 Remove the pressure pipe to the turbocharger.
2 Clean the area around the overflow valve (1).
3 Remove the overflow valve.
4 Clean the valve contact surface in the oil filter
housing.
5 Fit the new the valve with a new seal ring and
tighten the nut as specified in Tightening
torques, page 7 and Tightening
Schedules, page 10.
6 Tighten the turbocharger pressure pipe.
7 Start the engine and check for leaks.

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 22-0 Lubricating and Oil System, General

Safety Valve, Oil Pressure, Replace

1 Remove dipstick bracket.
2 Disconnect the oil level sensor and remove the
cable harness from the holders on the oil pan.
3 Drain the oil and remove the oil pan.
4 Clean the area around the valve (1) and remove
it.
5 Clean the valve contact surface.
6 Check that the color marking on the new valve
matches the old. Fit the new coolant pipe sealing
rings and torque according to Tightening
torques, page 7.
7 Check the oil pan seal. Install oil pan, dipstick and
oil level sensor cable
8 Fill with motor oil and start the engine. Check that
no leakage occurs. Check the oil pressure.

Piston Cooling Valves, Replace

1 Clean around the oil filter bracket and the piston
cooling valves.
2 Remove the filter bracket.
3 Remove both piston cooling valves, the control
valve (2) and the opening valve (1).
4 Clean valve seats in the oil filter bracket.
5 Fit new valves with new sealing ring, torque as
specified in Tightening torques, page 7
6 Re-install the oil filter bracket, with new gasket
and new sealing rings.
7 Start the engine and check for leaks.

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22-0 Lubricating and Oil System, General

Bypass Valve Oil Filter, Change

1 Clean the area around the oil cooler by-pass
valve (1).
2 Remove the valve and clean the valve seat in the
oil filter bracket.
3 Fit a new valve with a new seal ring. Tighten
according to Tightening torques, page 7
4 Start the engine and check for leaks.

Checking the Pressure Limiting

Valve
1 Check that the pressure relief valve features a
blue color marking.

P0011382

2 Check that the valve is not damaged and its

function unimpaired. Install the seal ring before
the valve is installed. Press in the valve poppet
(1) with a blunt object and check that it does not
seize and that it seals against the seat (2).

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Safety Valve, Check

Oil sump removed.
1 Check that the safety valve features a purple
color marking.
2 Check that the valve is not damaged and its
function unimpaired. Press in the valve poppet (1)
with a blunt object and check that it does not seize
and that it seals against the seat (2).

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22-0 Lubricating and Oil System, General

Oil Pressure Sensor, Check

IMPORTANT!
If the oil pressure-piston cooling reading via
88820047 VODIA, diagnostic tool is suspect, check the
oil pressure using an external pressure sensor .

Removal
1 Remove the pressure sensor.
2 Install 9992873 Nipple with 9996398 Manometer
and 9998493 Hose
3 Start the engine and check the oil pressure to the
Administration, page 33.
If the oil pressure is not within specified
parameters, fault trace using Oil filter, checks.
If the oil pressure is within tolerances with the
external sensor and the regular engine sensor
shows a pressure outside tolerances, change the
sensor.

P0004655

Installation
4 Turn off engine
5 Remove 9996398 Manometer and
9992873 Nipple
6 Install the piston cooling oil pressure sensor.

NOTICE! Use a new seal.

Finishing off
7 Check engine oil level; top up as necessary.
8 Start the engine and carry out a leakage check.

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 22-0 Lubricating and Oil System, General

Piston cooling oil pressure, check

IMPORTANT!
If the oil pressure-piston cooling reading in VODIA is
suspected as being faulty, check the oil pressure via
an external pressure sensor.

Removal

Tools:
9992873 Nipple
9996398 Manometer
1 Remove the piston cooling oil pressure sensor.
2 Install 9992873 Nipple with 9996398 Manometer
3 Start the engine and check the oil pressure
against the specifications in Technical data.
If oil pressure is not within the specified range:
commence fault tracing "Oil filter, checks".
If the oil pressure is within tolerances with the
external sensor and the regular engine sensor
shows a pressure outside tolerances, change the
sensor.

P0011980

Installation
4 Turn off engine
5 Remove 9996398 Manometer and
9992873 Nipple
6 Install the piston cooling oil pressure sensor.

NOTICE! Use a new seal.

Finishing off
7 Check engine oil level; top up as necessary.
8 Start the engine and carry out a leakage check.

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22-1 Oil pump and Line

22-1 Oil pump and Line

Oil Pump, Check
1 Remove the oil pump. Refer to Lubrication Oil
Pump, Change, page 190
2 Check the pump drive gear.

NOTICE! If the reason for the fault is traced to

poor oil quality, clean the oil system thoroughly
before new oil is filled.

Lubrication Oil Pump, Change

1 Pump out the engine oil. Remove the oil filler pipe.
Remove terminal to the oil level sensor. Remove
the oil dipstick tube from the bracket. Remove the
oil pan.

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 22-1 Oil pump and Line

2 Remove the 4 bolts that hold the oil pipes to the

engine. Remove the oil pipes, the oil strainer and
the bracket together.

Early model

Late model

3 Remove the bolts from the main bearing cap.

Remove the oil pump together with the main
bearing cap.

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22-1 Oil pump and Line

4 Remove the oil pump from the main bearing cap.

5 Clean the oil suction pipe and the oil delivery pipe.
Check that there is no damage.
6 Remove and clean the oil strainer. Check that
there is no damage.
7 Install the new oil pump on the main bearing cap
and torque the bolts as per Tightening
torques, page 7.
8 Clean the main bearing cap and lubricate the
main bearing with oil. Fit thrust bearing caps
together with oil pump. Make sure that the gears
mesh with the crankshaft drive. Tighten the bolts
as per Tightening torques, page 7
P0003901
9 Assemble the oil pipes and the oil strainer on the
bracket with new oil seals. The strainer must be
installed so that it faces to the engine front end.
Tighten the bolts as per Tightening
torques, page 7
10 Assemble the oil pipes with the oil pump. Tighten
the bolts as per Tightening torques, page 7
11 Check if the seal needs replacing. Install the oil
pan.
12 Attach the oil dipstick tube to the bracket. Install
oil filler pipe and the wiring to the oil level sensor.
Top up with engine oil.
13 Start the engine. Check the oil pressure and
check for leakage.

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 22-3 Oil cooler

22-3 Oil cooler

Oil Cooler, Replace

Removal
1 Drain the coolant; refer to Draining the Cooling
System, page 224.
2 Remove the turbocharger; refer to Turbo,
Change, page 221.
3 Remove the charge air cooler with associated
pipes and hoses; refer to Charge Air Cooler,
Replace, page 242.
4 Clean around the oil pipe connections.
5 Remove the oil pressure sensor connector block
6 Remove the front oil pipe, plug the oil filter
housing.

P0002749
7 Remove the cover bolts and the rear oil pipe. Lift
out the cover and plug the oil filter housing.
8 Remove the oil cooler from the casing.

Installation
1 Clean the cover contact surface on the engine
block.
2 Install the oil cooler in the casing with new rubber
gaskets. Torque the bolts as specified in
Technical data.
3 Install new gaskets in the casing and in the water
pump housing.
4 Lift the casing in place and install the rear oil pipe
with new O-rings. Check that the cover's rubber
gasket remains in its groove.
5 Install a bolt in the oblong hole and press the
casing, using appropriate tool, against the water
pump housing.
6 Install the cover bolts and torque according to
Tightening torques, page 7.
7 Install the front oil pipe with new O-rings.
8 Install the oil pressure sensor connector block;
install the cable in the clips.
9 Install the charge air cooler; refer to Charge Air
Cooler, Replace, page 242.
10 Install the turbocharger unit. Refer to Turbo,
Change, page 221.
11 Add coolant. Refer to Cooling system,
filling, page 225.

NOTICE! If the oil cooler has leaked engine oil into the
cooling system, the coolant filter must be replaced and
the cooling system cleaned. Refer to Cooling System,
Cleaning, page 224.

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22-3 Oil cooler

12 Start the engine and check for leakage when it

has reached normal temperature. Check coolant
level.

Oil Cooler, Pressure Testing

Tools:
9996662 Pressure testing kit
9996845 Screw clamp
1 Remove the oil cooler. Refer to Oil Cooler,
Replace, page 193”.
2 Clean the oil cooler coolant side with water-
soluble degreaser. Clean the oil side of the oil
cooler with degreaser.
3 Check 9996662 Pressure testing kit before it is
taken into service. Refer to Cylinder Head,
Pressure Testing, page 75
4 Install 9996845 Screw clamp and check that they
are placed correctly.

5 Check that the pressure reducing valve knob on

9996662 Pressure testing kitis fully opened and
that the manometer is at zero. Connect the
pressure testing device to a 9996845 Screw
clamp
6 Lower the oil cooler into a vessel containing water
at room temperature. Increase the pressure to
250 kPa (2.5 bar) with the knob on the reduction
valve. Wait at least one minute.

NOTICE! If an even stream of air bubbles comes from

the oil cooler matrix, there is leakage and the oil cooler
must be changed.

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 22-3 Oil cooler

Bypass Valve, Oil Cooler, Replace

1 Clean the area around the bypass valve (1) and
remove it. Clean the valve seat.
2 Fit the new valve with a new seal ring. Tighten
according to Tightening torques, page 7.
3 Start the engine and check for leaks.

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23-0 Fuel System, General

23-0 Fuel System, General

Draining, Fuel system
1 Close the main fuel valve on the fuel feed line
from the fuel tank.
2 Clean carefully around the fuel pump unions.
3 Place a vessel under the fuel pump and loosen
the outlet line from the fuel pump.

4 Place a vessel under the electronic unit and clean

carefully around the lower fuel line union.
5 Loosen the inlet line on the fuel pump and loosen
the line on the inlet to the electronic unit cooling
coil.

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 23-0 Fuel System, General

6 Place a vessel under the fuel filter and open the

water separator drain tap. Open the venting
nipple.
7 The fuel filter is empty when no more fuel runs out
of the water separator. Close the venting nipple
and the water separator valve.
8 Replace seals and fit the fuel line to the electronic
unit cooling coil.
9 Replace seals and fit the lines to the fuel pump
input and output.

NOTICE! The fuel in the cylinder head fuel duct must

be drained if the unit injectors are to be removed.

Fuel system, bleeding

1 Remove the rubber protective cover, fit a rubber
hose and open the venting nipple located on the
top of the fuel filter bracket.
2 Pump on the hand pump located on the filter
bracket, until fuel flows without any air bubbles
from the venting nipple. Keep pumping while
closing the venting nipple. Continue pumping
until the engine fuel system is full of fuel. When
all the air is removed, pumping becomes heavier.
Remove the hose and replace the rubber cap.
3 Wipe up the fuel that has run out. Start the engine
and check for leaks.

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.

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23-3 Fuel Feed Pump and Filter

23-3 Fuel Feed Pump and Filter

Hand Pump, Change

Removal
1 Clean around the fuel line unions. Disconnect the
fuel line unions from the fuel feed pump and plug
the lines and pump connections.
2 Remove the fuel filter and water separator.
3 Remove the hand pump.

Installation
1 Install a hand pump.
2 Fit the fuel filter and water separator.
3 Fit the fuel line fittings to the hand pump.
4 Purge the fuel system according to Fuel system,
bleeding, page 197.

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 23-3 Fuel Feed Pump and Filter

Engine Fuel Filter Replacement

WARNING!
Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they cannot cause fire.

IMPORTANT!
Do not fill the new filter with fuel before installation.
There is a risk of system contamination that may cause
malfunction or damage.
1 Clean round the fuel filter.
2 Remove the fuel filter. Use an appropriate filter
puller. Collect any spilled fuel in a suitable vessel.
3 Clean around the filter housing sealing surface.
4 Lubricate the seal with diesel fuel and install the
new fuel filter. Torque the filter according to the
instructions on the filter.
5 Bleed the fuel system; refer to Fuel system,
bleeding, page 197.

Fuel Feed Pump, Change

Removal
1 Close any fuel cocks between tank and feed
pump, to avoid unnecessary fuel spills.
2 Clean thoroughly around the feed pump and its
connections.
3 Place a suitable container under the feed pump
and remove the fuel line banjo bolts.

NOTICE! Plug the lines! Note suction and pressure.

4 Remove the feed pump together with the servo

pump.
5 Remove the feed pump from the servo pump, 3
torx bolts.

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23-3 Fuel Feed Pump and Filter

6 Remove the feed pump by carefully pulling the

pump straight out, making sure that the
interconnection on the servo pump shaft does not
come out with it.

P0004300

Installation
7 Replace O-ring on the servo pump flange and
check that the interconnection (A) is in its groove
on the servo pump shaft.
8 Install the feed pump on the servo pump, facilitate
installation by turning the servo pump shaft so
A that it fits in its groove in the interconnection.
Tighten the bolts according to Tightening
torques, page 7.
9 Install feed pump/servo pump on the engine.
10 Replace the sealing washers, remove the plugs
P0012091
and install the fuel lines.
11 Open the fuel cocks; check that the drain nipple
is closed. Vent the fuel system. Refer to the Fuel
system, bleeding, page 197 section.
12 Start the engine and check for function and
leakage.

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 23-7 Injectors and Delivery Pipes

23-7 Injectors and Delivery Pipes

Unit injector, programming of trim
code
Tools:
88820052 VODIA, diagnostic tool

After a unit injector has been replaced a new trim code

(1) for the cylinder concerned must be programmed into
the engine control unit.

Programming takes place with the aid of the VODIA

tool, (refer to the Service handbook “Group 30
Electrical system”.

P0001354

Unit Injector, Replace

Tools:
9990006 Puller
9990013 Slide hammer
9998249 Protective sleeve
9998580 Protective sleeve
1 Remove the valve cover.
2 Detach the electric connectors from the unit
injectors. Cut the cable ties holding the cable
harness and move it to one side.

1. Note. The trim code defines the tolerances for the unit injector in
question for the engine control unit.

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23-7 Injectors and Delivery Pipes

3 Remove the fuel supply pipe and the rocker arm

bridge lubrication oil supply union.
4 Undo the rocker arm bridge bolts incrementally by
equal amounts each time, to avoid bending the
rocker shaft. Carefully lift away the rocker arm
bridge using 9990185 Lifting tool.
5 Mark and remove the floating valve yokes.
6 Clean around the fuel unions before
disconnecting them.
7 Release the hose on the fuel filter bracket at the
filter outlet. Lead the hose down into a suitable
vessel.
8 Release the return line from the front of the
cylinder head.
9 Use a suitable hose and blow air through the
cylinder head fuel duct. The fuel in the fuel duct
will flow out into the vessel. The unit injectors can
then be removed without fuel running into the
cylinders.

NOTICE! Take care not to get impurities in the fuel

duct.

10 Fit the return line.

11 Fit the fuel hose between the filter bracket and the
cylinder head.
12 Remove the unit injector yoke bolts. Fit
9990013 9990006 Puller onto the injector. Put the puller
fork in the groove in the injector and lock the arm
with the screw on the side. Fix the puller by
screwing the screw down towards the ball hole in
the injector. Attach a 9990013 Slide hammer and
9990006 remove the injector.
13 Install 9998249 Protective sleeve on the removed
injector.

P0001370

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 23-7 Injectors and Delivery Pipes

14 Install 9998580 Protective sleeve and clean

thoroughly using 9808570 Brush and
9808616 Extender.

15 Installation
Fit new sealing rings to the unit injectors.
Lubricate the O-rings with diesel.

P0012381

16 Install the unit injector yoke and center it between

the valve springs. Torque the bolts according to
Tightening torques, page 7.
17 Attach the connector; press it in until a distinct
click is heard.
18 Install the valve yoke; lubricate the valve yoke
and camshaft lobes with engine oil.

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23-7 Injectors and Delivery Pipes

19 Lift the rocker arm bridge into place with the aid
of 9990185 Lifting tool. Check that the guide pins
are in the correct positions on the bearing caps.
Tighten the rocker arm bolts to the values
specified in Tightening torques, page 7so that the
shaft rests on the bearing supports.

NOTICE! Tighten alternately according to

Tightening Schedules, page 10to avoid bending
the rocker shaft.
20 Clean the cylinder head where the union is
installed, and check that there is no foreign
material in the cylinder head oil duct. Install new
seal rings on the oil supply pipe and union. Put a
thin layer of petroleum jelly on the pipe seal rings
and connect the pipe to the union.
21 Install the union and tighten according to
Tightening torques, page 7.
22 Adjust valves and unit injectors; refer to Valves
and Unit Injectors, Adjustment, page 143.
23 Install the cable harness to the unit injectors and
the valve cover.
24 Bleed the fuel system; refer to . Fuel system,
bleeding, page 197

Sleeve for unit injector, replace

Unit injector removed

Tools:
9998251 Protection plug
9998250 Sealing ring
9998580 Protective sleeve
9998599 Cleaning kit
9996049 Draining hose
88800513 Drift
9986173 Puller
88800196 Drift
88800387 Puller
88800460 Sleeve

IMPORTANT!Working with the fuel system requests

special cleanliness.
1 Drain the coolant with the aid of 9996049 Draining
hose; refer to Draining the Cooling
System, page 224. Mark and remove the valve
yokes.

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 23-7 Injectors and Delivery Pipes

2 Remove the protective plug.

P0019120

3 Clean carefully around the sleeve.

Install 2 seal rings to prevent dirt from entering the
fuel ducts when the sleeve is removed.

P0019121

4 The puller marking (A) should be visible when the

support ring (2) is fitted. If the marking is not
visible it may be difficult to remove the sleeve.
Press the puller (1) down to the sleeve bottom;
see arrow marking.
Install the support ring (2).
- 9998250 Seal ring, 2 pcs (3)
- Expander (4)
- Sleeve (5)
- Nut (6)

P0019122

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23-7 Injectors and Delivery Pipes

5 Push the tool down to the bottom of the sleeve.

Tighten the nut (1) sufficiently hard to hold the
puller in place; apply moderate force and use the
tool (2) as a counterhold.

P0019123

6 Alternative 1
Remove the sleeve from 88800387 Puller and fit
88800460 Sleeve.

P0021199

7 NOTICE! Tighten the bolt moderately.

Install the sleeve with bolt (1).

Screw down to the end position towards the puller
(2).

P0021200

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 23-7 Injectors and Delivery Pipes

8 Counterhold the screw puller (2) and screw the

sleeve nut (1) until the sleeve releases.

P0021202

9 Pull up the puller and sleeve.

A misshapen sleeve can be difficult to remove. If
this is the case, remove the puller and find a new
grip for the expander.
Install the support ring and make a new attempt.

P0021201

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23-7 Injectors and Delivery Pipes

10 Alternative 2
Install the puller.
Screw down until the puller lugs meet the support
ring.

P0019124

11 Screw until the sleeve releases and the puller and

sleeve can be removed.
A misshapen sleeve can be difficult to remove. If
this is the case, remove the puller and find a new
grip for the expander.
Install the support ring and make a new attempt.

P0019125

12 Use tool 9998599 Cleaning kit and a power drill

before fitting the new sleeve.
Install tool 9998580 Protective sleeve in the
injector hole and secure it with a holder.
IMPORTANT! Tool no. 9998580 Protective
sleeve must be used to prevent dirt from entering
the fuel duct.
13 Clean the cylinder head walls using 9808618.

P0030396

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 23-7 Injectors and Delivery Pipes

14 Clean the sleeve seat using Brush 9808614

together with the handle and holders.

P0030397

15 Clean the cylinder head hole with Brush 9808617.

16 Remove tool 9998580 Protective sleeve. Make
sure the O-ring is removed.
17 Check that the piston is at BDC.
IMPORTANT! This must be done so that tool no.
9808617, due to its length, does not damage the
piston.

P0030398

18 Lubricate the tap with graphite paste 85134750.

P0025230

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23-7 Injectors and Delivery Pipes

19 1 Fit the sleeve to the expander tool.

Lubricate the O-rings with soapy water.
2 Use the unit injector yoke to steady the tool.
Tightening torque: 80 Nm (59 lbf ft)
3 Run the tap down through the tip of the
sleeve.
20 Remove the expander tool.

P0025231

21 Remove the seal ring, (2 pcs).

22 Install the unit injectors with washer; refer to Unit
Injector, Replace, page 201.
23 Reinstall the valve yokes according to the
markings.
24 Install the rocker arm bridge. Check play on
valves and unit injectors.
25 Install the valve cover.
26 Fill up with coolant and check that no leakage
occurs.

P0030395

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23-8 Control System, ECM, Data Sets

23-8 Control System, ECM, Data Sets

Control Unit, Replace
NOTICE! Before the control unit is replaced and any
warranty claim made, all checks in the check list must
be performed, to exclude any defect in the engine
control system. If cable harness readings show
defects, it is highly likely that the control unit is fault
free. See 'Workshop Manual, (Group 23) EMS 2'

CAUTION!
Faulty individual adjustments in the control unit can
result in personal injury and engine damage.

NOTICE! For information about reprogramming and

reading of software refer to 'Service manual, EMS 2'

IMPORTANT!
Under no circumstances may control units ever be
switched between engines during fault tracing or
repair.
1 Clean thoroughly around the control unit fuel
connections.
2 Switch off power to the engine by disconnecting
the negative battery terminal.
3 Place a collection vessel under the control unit
and loosen the fuel lines from the control unit
cooling coil. Plug the lines and cooling coil.
4 Remove the control unit's protective casing.

5 Remove the control module cable harness by

moving the connector block retaining clips
outwards. Loosen connections.
6 Transfer the cooling element to the new control
unit. Make sure that the surface between the
cooling element and the control unit is clean.
7 Fit the new control unit to the cooling coil. Torque
according toTightening torques, page 7.

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 23-8 Control System, ECM, Data Sets

8 Connect the control unit connections and close

the retaining clips.

9 Fit the control unit protective casing with bolts.

10 Fit the fuel lines to the control unit cooling coil.

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23-8 Control System, ECM, Data Sets

11 Bleed the fuel system; refer to Fuel system,

bleeding, page 197. Start the engine and check
for error codes. Refer to 'Service Manual, EMS 2'

Identifying the engine control unit

(EVC)

Identification is done via the CHASSIS ID number.

IMPORTANT!
The CHASSIS ID number on the decal on the control
unit must coincide with the CHASSIS ID number on the
decal on the protective cover over the engine, and the
decals on the PCU and HCU.

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 25-0 Inlet and Exhaust System, General

25-0 Inlet and Exhaust System, General

Exhaust system, checking
1 Check if the exhaust system has dents or damage
that might obstruct the flow of exhaust gases. If
the exhaust system is damaged, exhaust back
pressure may be too high, which can reduce
engine power.

Intake Manifold, Checking

1 Check that the inlet pipes are clean inside, and
undamaged. Crushed, damaged or dirty inlet
pipes can reduce the charge pressure.

Charge air pipe, checking

1 Inspect the charge air pipes for visible cracks and
external damage.
2 Check that there is no oil in the charge air pipes.
If the pipes are damaged or the union seal rings
leak, charge pressure will be too low and engine
performance will be affected. If the pipes are
contaminated with oil internally, this indicates oil
leakage in the turbocharger turbine shaft seal. In
this case, the turbocharger must be changed as
a unit.

NOTICE! If there is oil in charge air pipes and charge

air hoses, the charge air cooler and all pipes and hoses
in the charge air system must be very thoroughly
cleaned internally, before the engine is started.

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25-1 Inlet and Exhaust Manifolds

25-1 Inlet and Exhaust Manifolds

Exhaust Manifold, Change

Removal
1 Drain the cooling system. Refer to Draining the
Cooling System, page 224.
2 Remove the air filter holder with air filter, the
exhaust pipe and the heat shield from the
turbocharger.
3 Remove the turbocharger oil and water lines from
the charge air cooler pipe and from the engine.
4 Remove the clamp between the charge air cooler
and the turbocharger.
5 Remove the turbocharger bolts and lift it off.

6 Remove the pipe between the charge air cooler

and the forward intake pipe.
7 Loosen the hose clamps from the front and rear
of the charge air cooler remove the front hose.
8 Disconnect the lower attachment fitting from the
charge air cooler and engine block.
9 Remove the two rear charge air cooler bolts.
10 Holding up the front of the charge air cooler,
remove the front bolt and then lift off the charge
air cooler.
11 Loosen the reverse gear oil cooler for better
access to the lifting eye bolts.
12 Remove the lifting eye.
13 Remove the heat shield attachment plate.
14 Remove the water pipe between the manifold and
the fresh water pump.
15 Remove the manifold nuts and carefully lift away
the manifold.

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 25-1 Inlet and Exhaust Manifolds

Installation
1 Install new O-rings on the manifold. Check that
the manifold and cylinder head mating surfaces
are clean. Fit new manifold gaskets.
2 Slide the manifold onto the studs and screw on
the nuts. Tighten according to Tightening
torques, page 7
3 Install the pipe between the manifold and the
fresh water pump.

4 Install the heat shield attachment plate.

5 Install the lifting eye.

6 Install the reverse gear oil cooler.

7 Position the charge air cooler, connect the rear

coolant hose and loosely fit the front charge air
cooler retaining bolt.
8 Install the remainder of the charge air cooler bolts
and tighten the front charge air cooler bolt.
9 Install the lower charge air cooler attachment
fitting.
10 Install the forward hose to the front of the charge
air cooler. Tighten the hose clamps at the front
and rear of the charge air cooler.
11 Install a new O-ring on the pipe between the
charge air cooler and the forward intake pipe and
install the pipe.

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25-1 Inlet and Exhaust Manifolds

12 Install a new gasket and O-ring on the

turbocharger stub connection and fit it to the
charge air cooler. Make sure the stub connection
is correctly fitted. Hang the clamp on the stub
connection.

13 Install a new gasket for the connection to the oil

drain pipe between the turbocharger and engine
block. Install the pipe to the turbocharger and fit
the bolts. Do not tighten the bolts.
14 Install a new gasket between the manifold and
turbocharger and hang the turbocharger on the
manifold. Screw on a nut so that the turbocharger
cannot fall off the studs. Be careful so that the
clamp for the stub connection is not damaged.
15 Install new O-rings and guide the oil drain pipe
into the engine block.
16 Check that the clamp for the stub connection
between the turbo and charge air cooler is not
damaged. Fit the nuts to the turbocharger and
tighten.
17 Fit the bolt for the stub connection clamp and
tighten.

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 25-1 Inlet and Exhaust Manifolds

18 Check that the O-ring for the turbocharger oil

drain pipe on the engine block is correctly
positioned and tighten the pipe bolts on the turbo.
19 Attach the turbocharger oil drain pipe clamp to the
pipe between the charge air cooler and the intake
pipe.
20 Replace the O-ring and fit the turbocharger oil
hose and then fit the hose clamps to their
attachment fitting.
21 Replace gaskets and fit the turbocharger coolant
hose. Attach the hose between the turbocharger
and fresh water pump with a clamp to the
attachment fitting for the pipe between the charge
air cooler and the forward intake pipe.
22 Fit the exhaust pipe, turbocharger heat shield and
air filter holder and air filter.
23 Fill with coolant according to specification. Refer
to Administration, page 40 and Cooling system,
filling, page 225.
24 Start the engine and carry out a function and
leakage check.

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25-1 Inlet and Exhaust Manifolds

Exhaust manifold expansion plug,

change

Type A
1 Remove the exhaust manifold, see Exhaust
Manifold, Change, page 216.
2 Remove the expansion plugs.

NOTICE! E.g. use a bolt to pull out the plugs.

3 Clean surfaces around expansion plugs
thoroughly.
Apply 1161099 Sealant.
4 Press in the expansion plug 2.5 ±0.5 mm (A),
according to the pictures.
Use a press sleeve (1) with diameter Ø 22 mm
(B).

P0021213

P0021363

Type B
Tightening torque: 60 Nm (44.3 lbf. ft.)

P0022064

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 25-5 Turbo and supercharger

25-5 Turbo and supercharger

Turbo, Change
Always identify and correct the cause of turbocharger
failure before fitting a new turbocharger.

Satisfactory turbocharger function is conditional upon

the good condition of engine lubrication and intake
systems, i.e. that oil and filter changes are completed
as scheduled, that the right kind of oil is used and that
the air filter is managed correctly.

A first action should therefore be engine oil checks and

oil filter replacement if needed, and preferably running
the engine a few minutes with the new oil before the
new turbocharger unit is installed.

Blow any rust and soot flakes out of the exhaust

manifold when the turbocharger is replaced. Soot
flakes can damage the turbine wheel in the new unit.

It is also important to clean the intake line from the air

filter. Debris from a failed turbine wheel may remain
and cause instant breakdown of the new turbocharger.
1 Removal
Remove the air filter holder with air filter, the
exhaust pipe and the heat shield from the
turbocharger.
2 Empty the freshwater system; refer to Draining
the Cooling System, page 224
3 Remove the oil and water lines from the
turbocharger.
4 Remove the clamp for the stub connection
between the charge air cooler and the
turbocharger.

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25-5 Turbo and supercharger

5 Remove the turbocharger bolts and lift it off.

Installation
1 Fit a new gasket and O-ring on the turbocharger
stub connection and connect it to the charge air
cooler. Make sure the stub connection is correctly
fitted. Hang the clamp onto the stub connection.
2 Fit a new gasket for the connection to the oil drain
pipe between the turbo and engine block. Fit the
pipe to the turbocharger and install the bolts. Do
not tighten the bolts.
3 Fit a new gasket between the manifold and
turbocharger and hang the turbocharger on the
manifold. Screw on a nut so that the turbocharger
cannot fall off the studs. Take care so that the stub
connection clamp is not damaged.
4 Fit a new O-ring and guide the oil drain pipe into
the engine block.
5 Check that the clamp for the turbocharger and
charge air cooler is not damaged. Fit the nuts to
the turbocharger and tighten them.
6 Fit the stub connection clamp bolt.
7 Check that the turbocharger oil drain pipe gasket
on the engine block is correctly positioned and
tighten the pipe bolts on the turbo.
8 Attach the turbocharger oil drain pipe to the pipe
between the charge air cooler and the intake pipe
with a clamp. Install a new O-ring and install the
turbocharger oil hose and fasten the hose clamp.
9 Install new gaskets and the turbocharger water
hose. Attach the hose between the turbocharger
and fresh water pump with a clamp to the
attachment fitting for the pipe between the charge
air cooler and the intake pipe..
10 Fit the exhaust pipe, turbocharger heat shield and
air filter holder and air filter.
11 Fill with coolant according to specification. Refer
to Administration, page 40 and Cooling system,

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 25-5 Turbo and supercharger

filling, page 225. Start the engine and carry out

function and leakage checks.

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26-0 Cooling System, General

26-0 Cooling System, General

Draining the Cooling System
WARNING!
Do not open the coolant filler cap when the engine is
hot, except in emergencies, as this could cause
serious personal injury. Steam or hot fluid could spray
out.

NOTICE! Before draining the cooling system, remove

the expansion tank cap. Engine cooling systems must
not be drained on engines that are to be conserved or
stored. The coolant contains additives that protect
against corrosion

P0002755
1 Open all drain points. Drain the coolant from the
radiator and engine block
2 Check that all coolant drains out. Deposits may
be found inside the drain tap/plug which need to
be cleared away. There is otherwise a risk that
coolant remains causing severe damage.
3 Close any cocks completely and fit rubber plugs.

P0002756

Cooling System, Cleaning

WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.

1 Empty the cooling system; refer to Draining the

Cooling System, page 224 and flush with clean
water.
2 Close all open cocks and fill the cooling system
with a mixture of radiator cleaner and pure water.
See instruction enclosed with cleaning kit.
3 Drain the cooling system again as described
above and flush the system with a mix of
neutralizer and pure water. See instruction
enclosed with cleaning kit.

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 26-0 Cooling System, General

4 Add new coolant when the cooling system is

completely free from contamination. Cooling
system, filling, page 225

Cooling system, filling

WARNING!
Do not open the coolant filler cap when the engine is
hot, except in emergencies, as this could cause
serious personal injury. Steam or hot fluid could spray
out.

NOTICE! If a large volume of coolant must be filled,

the system should be pressure tested; refer to Cooling
System, Pressure Testing, page 73

NOTICE! Filling should be done with the engine

stopped. Mix the correct volume of coolant in advance,
to ensure the system is filled. To avoid air locks forming
in the system, do not fill too quickly. Air should be able
to flow out through the filler and the venting nipples.
Only use the coolant and mixture ratio recommended
by Volvo Penta.

NOTICE! Do not start the engine until the system is

vented and completely filled.

1 coolant up to the white level pipe under the filler

cap.
2 Start the engine and let it run until it reaches
normal operating temperature and the thermostat
has opened.
3 Stop the engine, check coolant level and top up
with coolant as needed.

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26-0 Cooling System, General

Coolant level sensor, change

Removal
1 Remove the coolant level sensor connector block
from the expansion vessel.
2 Remove the coolant level sensor by carefully
pulling the level sensor straight down.

Installation
1 Install the coolant level sensor by pressing the
level sensor up through the hole in the expansion
tank until it fastens.
2 Reconnect the level sensor harness terminal.

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 26-0 Cooling System, General

Coolant temperature sensor,

replacing

Freshwater system, removal

1 Drain the cooling system. Refer to Draining the
Cooling System, page 224.
2 Disconnect the temperature sensor harness
terminal.
3 Remove the temperature sensor.

Freshwater system, installation

1 Install the temperature sensor with a new O-ring.
2 Connect the temperature sensor harness
terminal.
3 Fill with coolant according to specification. Refer
to Tightening torques, page 7, Tightening
Schedules, page 10 and Cooling system,
filling, page 225.
4 Start the engine and check for leaks. Pressurize
the cooling system; refer to Cooling System,
Pressure Testing, page 73.

Check and Fault Trace

Charge Air Cooler, Pressure Testing
Tools:
885536 Plug
885539 Plug
3849613 Pressure testing kit
1 Remove the charge air cooler.

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26-0 Cooling System, General

2 Fit an expander plug, medium (used together with

3849613 Pressure testing kit) in each union and
connect pump, part of 3849613 Pressure testing
kit, to the expander plug. Pump the pressure up
to 150 kPa (1.5 bar).
3 Immerse the charge air cooler in a water bath.
Make sure the charge air cooler is completely full
of water and that no air is left inside.
4 Pressure test the charge air cooler for 5 minutes
and check that no air leaks from the it.
5 Repeat the pressure test several times leakage is
suspected.
6 Install the intercooler.

Alternative pressure test method

Tools:
3849613 Pressure testing kit
885539 Plug
885536 Plug
1 Install 885536 Plug and 885539 Plug as
illustrated. Connect the hand pump, part of
3849613 Pressure testing kit.
2 Pump up to a pressure of 100 kPa. (1 bar) In order
to determine that the charge air cooler and unions
seal correctly, the pressure must not fall for two
minutes.

NOTICE! If the pressure falls, check that no leakage

occurs at the charge air cooler unions. Spray or brush
water and dish washing liquid on the unions to
determine that there is no leakage.

3 If the pressure falls and it has been determined

that the unions do not leak, the charge air cooler
must be overhauled. Repeat the pressure test
after the overhaul.

Pressure testing of heat exchanger

Option 1

Tools:
885536 Plug
885539 Plug
3849613 Pressure testing kit

NOTICE! If leakage is suspected, the heat exchanger

must be pressure tested before being replaced.

1 Remove the heat exchanger.

2 Fit an expander plug, medium (used together with
3849613 Pressure testing kit) in each union and
connect the pump to the expander plug. Pump the
pressure up to 150 kPa (1.5 bar).

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 26-0 Cooling System, General

3 Immerse the heat exchanger in a water bath.

Make sure the heat exchanger is completely full
of water and that no air is left inside.
4 Pressure test the heat exchanger for 1 minute
and check that no air comes out of the water
channel or from the joints.
5 Repeat the pressure test several times if leakage
is suspected.

Option 2

Tools:
885536 Plug
885539 Plug
3849613 Pressure testing kit
1 Install 885536 Plug and 885539 Plug as
illustrated. Connect the hand pump
3849613 Pressure testing kit.

NOTICE! If the pressure falls, check that no leakage

occurs at the heat exchanger unions. Spray or brush
water and washing up liquid on the unions to determine
that there is no leakage.

2 Pump to a pressure of 100 kPa, (1 bar). In order

to determine that the heat exchanger and unions
seal correctly, pressure may not fall for two
minutes.
3 If the pressure falls and the unions have been
determined not to leak, the heat exchanger must
be overhauled. Repeat the pressure test after the
overhaul.
4 Install the heat exchanger.

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26-1 Radiator, Heat Exchanger

26-1 Radiator, Heat Exchanger

Heat exchanger, change

Removal
1 Drain the cooling system. Refer to Draining the
Cooling System, page 224.
2 Remove the expansion tank; refer to 26-0,
Expansion Tank, Change.
3 Close the sea cock.
4 Loosen the hose between the heat exchanger
and exhaust system, from the heat exchanger.
5 Remove the belt guard.

6 Remove the cooling pipe attachment fitting.

7 Remove the cooling pipe from the heat
exchanger and fresh water pump.
8 Loosen the hose clamps on the hose between the
heat exchanger and charge air cooler.
9 Lift away the pipe and hose complete with the
attachment fitting.
10 Remove the pipe between the charge air cooler
and the thermostat.

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 26-1 Radiator, Heat Exchanger

11 Remove the electronic unit bolts; let the electronic

unit hang free.
12 Remove the heat exchanger (4 bolts underneath
and 1 bolt above).

Installation
1 Lift the heat exchanger into place and install the
retaining bolts. (4 bolts underneath and 1 bolt
above).
2 Install the electronic unit.

3 Fit the pipe between the heat exchanger and

thermostat by first pressing the pipe into the
thermostat. Make sure the seal is correctly fitted.
4 Install the cooling pipe to the heat exchanger by
first loosely fitting the bolts, then aligning the seal
and finally tightening the bolts.

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26-1 Radiator, Heat Exchanger

5 Install the coolant pipe attachment fitting.

6 Install the cooling pipe between the fresh water
pump and heat exchanger by first pressing the
pipe into the fresh water pump end plate. Make
sure the seal is correctly fitted.
7 Install the cooling pipe to the heat exchanger by
first loosely fitting the bolts, then aligning the seal
and finally tightening the bolts.
8 Install the hose clamps and hose between the
charge air cooler and heat exchanger.
9 Fit the hose between the heat exchanger and
exhaust system and tighten the hose clamps.
10 Install the belt guard.
11 Open the bottom valve for the sea water intake
and check for leaks.
12 Install the expansion tank; refer to 26-0,
Expansion Tank, Change.
13 Fill with coolant according to
Administration, page 40, and . Cooling system,
filling, page 225

Heat exchanger, cleaning

Heat exchanger removed.
4 1 Remove the rear cover panel and the O-ring from
the heat exchanger. Note where the indicator
hole is located on the cover panel for easier
reassembly.
Remove the intermediate plate inside the rear
cover panel and its O-ring.
Remove the front cover panel and its O-ring. Note
where the indicator hole is located on the cover
panel for easier reassembly.
Extract the heat exchanger insert.
7
NOTICE! The insert can only be pressed out
forwards, since it has a flange on the front edge.
2 Clean the entire length of the heat exchanger
insert. Use fresh water and suitable brushes.
Flush the pipes and brush until no more loose
particles appear in the flushing water. Also flush
and clean the heat exchanger housing and end
panels.
6 3 Check the zinc anodes in the end panels.
Replace the anodes if more than 50% of their
5 original size has been eroded. If not, clean the
7 zinc anodes to remove the oxide layer before re-
installing them.

IMPORTANT!
Use an emery cloth for cleaning. Do not use steel
2 tools, since this can impair the galvanic
P0002762 3 protection. Make sure there is good metallic
contact between the anode and the cover panels.

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 26-1 Radiator, Heat Exchanger

9 4 Install the insert in the heat exchanger housing

with new O-rings. Make sure the insert is correctly
installed.
Install the front end panel with a new O-ring.
Install the intermediate plate with a new O-ring.
Make sure that the indicator hole faces upwards.
Refit the rear end panel with a new O-ring.
Install the heat exchanger according to Heat
exchanger, change, page 230.

11
P0002763 10

Expansion Tank, Change

Removal
1 Drain the cooling system of coolant. Refer to
Draining the Cooling System, page 224.
2 Remove the cover from the electrical center and
the crankcase ventilation pipe.
3 Loosen the upper hose clamp on the hose
between the expansion tank and the heat
exchanger.
4 Unplug the connector from the level sensor in the
expansion tank.

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26-1 Radiator, Heat Exchanger

5 Remove the vent pipe from the expansion tank.

6 Remove the expansion tank retaining bolts.
Retain the sleeve from the lower bolt.
7 Lift off the expansion tank.

Installation
1 Align the expansion tank connection to the heat
exchanger and fit the upper bolts first
2 Put the sleeve on the lower rear bolt and install it.
Then tighten all the bolts.

3 Tighten the hose clamp at the connection

between the expansion tank and heat exchanger.
4 Install the vent hose.
5 Reconnect the level sensor harness terminal.
6 Fit an O-ring on the crankcase ventilation pipe
and align the pipe. Install the pipe. Refit the
electrical center cover.
7 Fill with coolant according to specification. Refer
to Tightening torques, page 7, Tightening
Schedules, page 10 and Cooling system,
filling, page 225
8 Start the engine and check for leaks. Pressurize
the cooling system; refer to Cooling System,
Pressure Testing, page 73.

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 26-1 Radiator, Heat Exchanger

47703722 01-2020 © AB VOLVO PENTA 235

26-2 Coolant Pump, Thermostat

26-2 Coolant Pump, Thermostat

Coolant Pump, Change
IMPORTANT!
Disconnect power or use some other means to prevent
the engine from being started during work.

Removal
1 Drain the coolant into a suitable recovery
container; refer to Draining the Cooling
System, page 224
2 Remove the drive belt guard, remove the
alternator and release the drive belt. Remove the
alternator belt.
3 Undo the coolant pipe attachment bolts and pull
the attachment to one side.
4 Remove the coolant pump.

Installation
5 Fit the coolant pump with seal. Use petroleum
jelly to hold the seal in place during installation.
Tighten the bolts according to the specification in
Tightening torques, page 7.
6 Install the coolant pipe attachment.
7 Fit the drive belt. Make sure the belt is properly
positioned and then tighten it; refer to Alternator
Belt, Replace, page 259.
8 Install the engine drive belt guard.
9 Refill the engine coolant; refer to Cooling system,
filling, page 225.
10 Start the engine and let it run until it reaches
normal operating temperature. Check that no
leakage is present. Top up with coolant as
necessary.

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 26-2 Coolant Pump, Thermostat

Thermostat, Function Check

1 Remove the thermostat; refer to Thermostat,
Change, page 238.
2 Put the thermostat in a large pot full of water and
heat up to the temperature at which it should open
according to Administration, page 40.
3 If the thermostat does not open at the specified
temperature, replace it.

Closed thermostat

4 Install the thermostat; refer to Thermostat,

Change, page 238.

Open thermostat

NOTICE! Always use a new seal, even if the

thermostat is not replaced.

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26-2 Coolant Pump, Thermostat

Thermostat, Change
1 Drain the cooling system. Refer to Draining the
Cooling System, page 224.
2 Clean the area around the thermostat housing.
Remove the coolant hose from the heat
exchanger and disconnect it from the cylinder
head.
3 Remove the thermostat and clean the inside of
the housing.
4 Install a new thermostat and seal.
5 Install the thermostat housing and tighten
according to the specifications in Tightening
torques, page 7 and Tightening
Schedules, page 10. Attach the coolant pipe.
6 Refill the cooling system. Refer to Cooling
system, filling, page 225.
7 Start the engine and check for leaks. Pressurize
the cooling system; refer to Cooling System,
Pressure Testing, page 73.

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 26-5 Charge Air Cooler with Connections

26-5 Charge Air Cooler with Connections

Reverse gear oil cooler, change

Removal
1 Close the seacock and drain the seawater
system; refer to Draining the Cooling
System, page 224.
2 Position a recovery container under the reverse
gear oil cooler and disconnect the hose
connections from the oil cooler and the reverse
gear hoses.

3 Remove the reverse gear oil cooler retaining bolts

and lift it off.

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26-5 Charge Air Cooler with Connections

Installation
1 Put the reverse gear oil cooler in place and screw
in the bolts loosely.
2 Connect the oil cooler hoses and tighten the bolts
and clamps. Connect the hoses to the reverse
gear.
3 Open the seacock. Start the engine and carry out
a function and leakage check.

Reverse gearbox oil cooler,

cleaning
1 Close the seacock and drain the seawater
system; refer to Draining the Cooling
System, page 224. Remove the oil cooler; refer
to Reverse gear oil cooler, change, page 239.
8 2 Remove the rear cover panel and O-ring from the
7 oil cooler.
6
3 Remove the front cover panel and O-ring from the
oil cooler.
4 Note the marking on the oil cooler insert and pull
out the insert together with the O-ring.
P0002765
5 Clean the oil cooler inside and out. Clean the oil
channels with degreaser.
6 Rinse the oil and coolant pipes with fresh water;
blow the oil cooler clean with compressed air (or
let it stand and drip dry).
7 Fit a new O-ring on the oil cooler insert and press
the insert into the oil cooler.
8 Fit a new O-ring to the oil cooler front cover panel
and install the panel.
9 Fit a new O-ring to the oil cooler rear cover panel
and install the panel.
10 Install the oil cooler; refer to Reverse gear oil
cooler, change, page 239.

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 26-5 Charge Air Cooler with Connections

Reverse gearbox, oil cooler

thermostat, replacing

Removal
1 Position a recovery container under the reverse
gear oil cooler and disconnect the oil cooler hose
so that any oil can run into the container.
2 Remove the thermostat cover from the reverse
gear oil cooler.
3 Remove the thermostat. Installation

P0011534

Installation
1 Fit a new O-ring and thermostat in the reverse
gear oil cooler.
2 Fit a new O-ring and thermostat cover on the
reverse gear oil cooler.
3 Connect the hoses to the reverse gear oil cooler.

P0011533

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26-5 Charge Air Cooler with Connections

Charge Air Cooler, Replace

Removal
1 Close the bottom valve, drain the seawater
system and remove the air filter casing.
2 Remove the three attachment clamps for the oil
and water pipes. Do not remove the pipes from
the turbocharger or the engine.

3 Remove the bolts from the pipe between the

charge air cooler and intake pipe.
4 Loosen the clamp from the pipe and remove the
pipe.
5 Remove the coolant pipe attachment fitting
clamps at the front of the engine. Loosen the hose
clamps on the charge air cooler intake and outlet
pipes. Remove the hose from the front of the
charge air cooler.

6 Remove the stub connection clamp bolt between

the charge air cooler and the turbocharger.
7 Disconnect the lower attachment fitting from the
charge air cooler and engine block.
8 Remove the two rear charge air cooler bolts.
9 Lift up the front of the charge air cooler and
unscrew the front retaining bolt.
10 Lower the front part of the charge air cooler so
that it comes loose from the turbocharger and
remove the stub connection.
11 Move the charge air cooler forwards so that it
comes loose from the rear hose.
12 Lift out the charge air cooler backwards.

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 26-5 Charge Air Cooler with Connections

Installation
1 Position the charge air cooler by moving it
forwards in front of the oil and water hoses to the
turbocharger and engine. Install a new gasket
and O-ring on turbocharger stub connection and
fit it to the charge air cooler. Make sure the stub
connection is correctly fitted.

2 Connect the charge air cooler to the reverse gear

oil cooler hose.
3 Hang the clamp onto the connecting pipe end.
4 Fit the front bolt for the charge air cooler.
5 Align the stub connection with the turbo and fit the
clamp.
6 Install the remainder of the charge air cooler bolts
and tighten the front charge air cooler bolt.
7 Install the lower attachment fitting to the charge
air cooler and engine block.
8 Install the coolant hose to the charge air cooler
and the coolant pipe attachment fitting clamps.

9 Fit a new O-ring on the pipe between the charge

air cooler and the forward intake pipe.
10 Attach the oil and water pipes clamps to the pipe
between the charge air cooler and the intake pipe.
Check that the oil return pipe has not slid out of
the engine block.
11 Install the air filter housing. Turn the air filter
housing downwards so that it is in contact with the
stop; fit the clamp.
12 Open the bottom valve for sea water intake and
fill with coolant according to
Administration, page 40.
13 Start the engine and check for leaks.

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26-5 Charge Air Cooler with Connections

Carge air cooler, cleaning

Cleaning
1 Remove the charge air cooler; refer to Charge Air
Cooler, Replace, page 242.
2 Remove the forward cover panel and O-ring from
the charge air cooler and the forward
4 intermediate plate with O-ring.
5
3 Remove the rear cover panel with O-ring.

1 4 Pull the charge air cooler insert with O-ring

backwards out of the charge air cooler housing.
If necessary, place a wooden block or other
2 suitable counterhold on a hard surface. The
counterhold must be narrow enough to pass
3 through the charge air cooler front section. Now
lift the charge air cooler at its back end and press
the insert forwards towards the counterhold. Be
careful not to damage the insert.
P0002766
5 Clean the charge air cooler both inside and out.
Clean the air passages with degreaser. Flush
both air and coolant channels with fresh water
and blow the cooler dry with compressed air. (or
let it stand and drip dry). Pressure test the insert
if leakage is suspected.
6 Check the zinc anodes in the cover panels.
Replace the anodes if they are less than 50% of
their original size. Otherwise clean the anodes so
that the oxidized surface is removed before
refitting.

IMPORTANT!
Use an emery cloth for cleaning. Do not use steel tools,
since this can impair the galvanic protection. Make
sure there is good metallic contact between the anode
and the cover panels.

Installation
1 Fit a new O-ring on the charge air cooler insert
and press the insert into the charge air cooler
housing from behind.
2 Install a new O-ring and fit the rear cover panel.
2 1 3 Install a new O-ring and intermediate plate to the
charge air cooler forward section.
4 Install a new O-ring and fit the forward cover
panel.
5 Install the charge air cooler; refer to Charge Air
4 Cooler, Replace, page 242.
3

P0002767

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 26-5 Charge Air Cooler with Connections

Reverse gear, oil cooler, pressure

testing
Tools:
885536 Plug
885539 Plug
3849613 Pressure testing kit
1 Remove the reverse gear oil cooler.
2 Fit an expander plug, medium (used together with
3849613 Pressure testing kit) in each union and
connect pump, part of 3849613 Pressure testing
kit, to the expander plug. Pump the pressure up
to 1.5 bar (150 kpa).
3 Immerse the reverse gear oil cooler in a water
bath. Make sure the reverse gear oil cooler is
completely full of water and that no air is left
inside.
4 Pressure test the reverse gear oil cooler for 1
minute and check that no air leaks from the water
channels or from the joints.
5 Repeat the test several times if leakage is
suspected.
6 If the pressure falls and it has been determined
that the unions do not leak, the reverse gear oil
cooler must be overhauled. Repeat the pressure
test after the overhaul.

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26-6 Sea Water System, Sea Water Pump

26-6 Sea Water System, Sea Water Pump

Seawater Pump, Change

Removal
1 Close the sea cock and drain the seawater
system according to Draining the Cooling
System, page 224.
2 NOTICE! Be prepared to gather up fluid.

Remove the water connections on the seawater

pump.
3 Remove the seawater pump.

4 Remove the water intake.

5 Install the water intake on the new seawater
pump.

Installation
6 Install the seawater pump with a new o-ring.
Install the water connections to the seawater
pump.
7 Finishing off
Open the sea cock. Start the engine and check
for any leaks.

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 26-6 Sea Water System, Sea Water Pump

Seawater Pump, Overhaul

Tools:
884167 Drift
9992071 Drift
9994034 Drift

Removal
Remove the seawater pump according to ““Seawater
pump, replacement”

Place the seawater pump in e.g. a vise (tighten against

the adapter).

Seawater pump
1. Adapter 14. O-ring
2. Ball bearing 15. O-ring
3. Pump housing 16. Plug
4. Cam disc 17. Retainer ring
5. Guide pin 18. Retainer ring
6. Cover 19. Cam bolt
7. Gear wheel 20. Shaft
8. Nut (M20) 21. Deflector ring
9. Bolt 22. Spring washer
10. Bolt 23. Wear ring
11. Impeller 24. Support washer
12. Shaft seal - kit 25. Retainer ring
13. Flat ring

1 Remove the the seawater pump cover together

with the O-ring.

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26-6 Sea Water System, Sea Water Pump

2 Pull out the impeller with a suitable universal

puller.

3 Remove the cam bolt, O-ring and cam disc.

4 Remove the wear ring.

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 26-6 Sea Water System, Sea Water Pump

5 Remove the retainer ring and support washer.

6 Remove the shaft seal from the pump shaft.

7 Undo the nut, use a universal drive with a long 12-

point socket (14 mm) as a counterhold.

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26-6 Sea Water System, Sea Water Pump

8 Pull off the gear wheel using a suitable puller.

If necessary, heat the front of the gear wheel
around the center with a heat gun for a minute or
so.

NOTICE! Be prepared to catch it.

9 Remove the retainer rings in the bearing housing.

10 Remove the adapter.

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 26-6 Sea Water System, Sea Water Pump

11 Remove the O-ring.

12 Tap or press out the shaft and bearings.

NOTICE! Be prepared to catch them.

13 Press the bearing from the shaft using mandrel

884167.

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26-6 Sea Water System, Sea Water Pump

14 Tap the seal ring out of the bearing housing and

the deflector ring from the pump housing.

Installation
15 Grease the deflector ring with waterproof grease
(Volvo Penta part # 828250) and tap it into the
pump housing with the aid of mandrel 999 2071.

16 Grease the seal ring with waterproof grease

(Volvo Penta part # 828250) and tap it into the
bearing housing.

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 26-6 Sea Water System, Sea Water Pump

17 Press on the bearing using mandrel 884167.

18 Tap or press in the shaft and bearings.

Note: Mandrel 884167 may be used.

19 Install the retainer rings in the bearing housing.

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26-6 Sea Water System, Sea Water Pump

20 Install the O-ring.

21 Install the adapter.

Tightening torque: 50 Nm

22 Install the gear wheel and fasten it.

Tightening torque: 200 ±30 Nm.

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 26-6 Sea Water System, Sea Water Pump

23 Place the shaft seal on the pump shaft and press

the seal down against the deflector ring in the
housing.

24 Install the support washer and retainer ring over

the seal.

25 Install the wear ring.

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26-6 Sea Water System, Sea Water Pump

26 Install the cam bolt, O-ring and cam disc.

Tighten to 10 Nm.

27 Grease the pump housing and the inside of the

cover with water resistant grease (Volvo Penta
part # 828250). Press in the impeller.

28 Install the cover and O-ring.

Tighten to 10 Nm.

Install the seawater pump according to Seawater

pump, replacement

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 26-6 Sea Water System, Sea Water Pump

Seawater Pump, Impeller, Change

Removal
1 WARNING!
Risk of water entry. Close and drain the raw water
system before starting any work on the system.
2 Remove the cover from the seawater pump.

3 Pull out the impeller with a universal impeller

puller.
4 Check the impeller. If cracks or other defects are
visible, the impeller must be replaced.
5 Clean and inspect the seawater pump and
impeller cover. If it is worn, the complete pump
must be replaced.

Installation
1 Grease the pump housing and the inside of the
cover with a little glycerin. The impeller wheel will
be easier to work with if it is placed in hot water
before installation.
2 Press the impeller in with a rotating movement
(take the direction of rotation into consideration).
The pump shaft is equipped with an internal
thread (M8); screw a stud into the shaft journal
and press in the impeller with the aid of a nut and
washer. Install the cover with a new O-ring.
3 Check that all pump hoses are installed. If it is
suspected that parts from a broken impeller have
carried over into the system, remove the reverse
gear oil cooler rear cover plate and clean out the
cooler.
4 Open the sea cock and check for leaks.

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32-1 Alternator

32-1 Alternator
Alternator, Change

Removal
1 Turn off the main circuit breaker and check that
the engine is without power.
2 Note how the cables are run and remove the
cables from the alternator.
3 Remove the belt guard.
4 Turn the belt tensioner upward with the aid of a
socket wrench in the belt tensioner square fitting
(½").
5 Remove the alternator belt.
6 Remove the lower and upper alternator bolts.
7 Remove the alternator.

Installation
1 In order to re-install the alternator, the rear spacer
must first be pressed backwards a little. Fit the
alternator to its attachment points. Make sure the
washers and plastic seals are correctly fitted.
2 Install the lower and upper alternator bolts.
Tighten the lower bolt to 20 Nm (15 lbf ft).
Tighten the upper bolt to 25 Nm (19 lbf ft).
3 Install the alternator belt; make sure the belt grips
in the pulley grooves.
4 Install the belt guard.
5 Turn the main switch on.
6 Start the engine and perform a function check.

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 32-1 Alternator

Alternator Belt, Replace

IMPORTANT! Always replace a drive belt that appears
worn or cracked.

Removal
1 Turn off the main circuit breaker and check that
the engine has no power.
2 Remove the belt guard.
3 Turn the belt tensioner upward with the aid of a
socket wrench in the belt tensioner square fitting
(½").
4 Remove the alternator belt.

Installation
1 Hold up (release) the belt tensioner.
2 Install the alternator belt (as illustrated). Make
sure the belt grips in the pulley grooves.
3 Install the belt guard.
4 Turn the main switch on.
5 Start the engine and perform a function check.

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Index
A Engine Decals.......................................................... 57
About this Workshop manual..................................... 3 Engine Disassembly................................................. 86
Actions with low charge air pressure........................ 71 Engine Fixture, Installation....................................... 85
Alternator................................................................ 258 Engine Fuel Filter Replacement............................. 199
Alternator Belt, Replace......................................... 259 Engine Information, General.................................... 57
Alternator, Change................................................. 258 Exhaust Back Pressure, Check................................ 72
Exhaust manifold expansion plug, change............. 220
B Exhaust Manifold, Change..................................... 216
Big end bearing, Change (all)................................. 182 Exhaust system, checking...................................... 215
Bypass Valve Oil Filter, Change............................. 186 Expansion Tank, Change....................................... 233
Bypass Valve, Oil Cooler, Replace........................ 195 Exposing the Engine................................................ 80
Bypass Valve, Oil Filter Bypass, Replace.............. 184
F
C Fitting the Fixture...................................................... 85
Camshaft Bearing Housing, Replace..................... 154 Flywheel Bearing, Replace..................................... 169
Camshaft Sensor Distance, Check........................ 156 Flywheel Sensor Distance, Check.......................... 171
Camshaft, Wear Check.......................................... 153 Flywheel, Change................................................... 169
Carge air cooler, cleaning...................................... 244 Fuel Feed Pressure, Check...................................... 69
Charge Air Cooler with Connections...................... 239 Fuel Feed Pump and Filter..................................... 198
Charge Air Cooler, Pressure Testing..................... 227 Fuel Feed Pump, Change...................................... 199
Charge Air Cooler, Replace................................... 242 Fuel System..................................................... 36, 196
Charge air pipe, checking................................. 69, 215 Fuel system, bleeding............................................ 197
Charge Air Pressure, Check..................................... 70 Fuel System, General............................................. 196
Check and Fault Trace........................................... 227
Checking the Pressure Limiting Valve.................... 186 G
Chemical products.................................................... 56 Gear Ring, Replace................................................ 170
Compression Test.................................................... 66 General........................................................... 3, 56, 57
Connecting Rod Bushing, Check up...................... 181 General advice when working on EVC engines....... 78
Connecting Rod, Check......................................... 180 H
Control System, ECM, Data Sets........................... 212 Hand Pump, Change.............................................. 198
Control Unit, Replace............................................. 212 Heat exchanger, change........................................ 230
Coolant..................................................................... 72 Heat exchanger, cleaning....................................... 232
Coolant level sensor, change................................. 226 I
Coolant Pump, Change.......................................... 236 Identifying the engine control unit........................... 214
Coolant Pump, Thermostat.................................... 236 Illustrations................................................................. 6
Coolant temperature sensor, replacing.................. 227 Injectors and Delivery Pipes................................... 201
Cooling System................................................ 40, 224 Inlet and Exhaust Manifolds................................... 216
Cooling System, Cleaning...................................... 224 Inlet and Exhaust System................................. 38, 215
Cooling system, filling............................................. 225 Inlet and Exhaust System, General........................ 215
Cooling System, General....................................... 224 Instructions for operating the starter motor.............. 65
Cooling System, Pressure Testing........................... 73 Intake Manifold, Checking...................................... 215
Crank Mechanism............................................ 29, 172
Crankshaft Seal, Change (front)..................... 172, 175 L
Crankshaft Seal, Change (rear)..................... 176, 179 Location of Sensors.................................................. 59
Crankshaft, Inspection............................................ 180 Lubricating and Oil System, General...................... 183
Cylinder Head, Pressure Testing............................. 75 Lubrication Oil Pump, Change............................... 190
Cylinder Liner and Pistons, Inspection................... 134 Lubrication System................................................... 33
Cylinder Liner and Pistons, Replace (all)............... 135 M
Cylinder Liner, Pistons........................................... 134 Main Bearing, Replace........................................... 165
D Miscellaneous........................................................... 78
Draining the Cooling System.................................. 224 O
Draining, Fuel system............................................. 196 Oil cooler................................................................ 193
E Oil Cooler, Pressure Testing.................................. 194
Electrical System...................................................... 43 Oil Cooler, Replace................................................ 193
Electrical Welding..................................................... 79 Oil Pressure Sensor, Check................................... 188
Engine................................................................ 21, 80 Oil pump and Line.................................................. 190
Engine Assembly.................................................... 104 Oil Pump, Check.................................................... 190
Engine body............................................................. 21 Other Special Equipment......................................... 54
Engine Complete, General....................................... 80 Overview Control Valve.......................................... 183

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P
Piston cooling oil pressure, check.......................... 189
Piston Cooling Valves, Replace............................. 185
Pressure Limiting Valve, Change........................... 184
Pressure testing of heat exchanger........................ 228
R
Radiator, Heat Exchanger...................................... 230
Reassembly, Complete Engine.............................. 128
Repair instructions...................................................... 4
Reverse gear oil cooler, change............................. 239
Reverse gear, oil cooler, pressure testing.............. 245
Reverse gearbox oil cooler, cleaning..................... 240
Reverse gearbox, oil cooler thermostat, replacing. 241
S
Safety Information.................................................... 44
Safety Instructions.................................................... 44
Safety Valve, Check............................................... 187
Safety Valve, Oil Pressure, Replace...................... 185
Sea Water System, Sea Water Pump.................... 246
Seawater Pump, Change....................................... 246
Seawater Pump, Impeller, Change........................ 257
Seawater Pump, Overhaul..................................... 247
Sensors, Adjustment.............................................. 154
Sleeve for unit injector, replace.............................. 204
Special Service Tools............................................... 49
Specifications, Electrical........................................... 43
Specifications, Engine ............................................... 7
T
Test and Adjustments............................................... 65
Thermostat, Change............................................... 238
Thermostat, Function Check.................................. 237
Tightening Schedules............................................... 10
Tightening torques...................................................... 7
Timing Gear, Replace............................................ 157
Timing gears............................................................. 24
Timing Gears and Shaft......................................... 153
Troubleshooting........................................................ 61
Turbo and supercharger......................................... 221
Turbo, Change....................................................... 221
Turbocharger, check................................................ 70
U
Unit injector, programming of trim code................. 201
Unit Injector, Replace............................................. 201
V
Valve Guides, Inspection........................................ 145
Valve Guides, Replacing........................................ 146
Valve Mechanism................................................... 143
Valve mechanism..................................................... 25
Valve Seat, Change............................................... 150
Valve Seat, Grinding.............................................. 151
Valve Stem Sealings, Replace............................... 149
Valves and Unit Injectors, Adjustment.................... 143
Valves, Grinding..................................................... 152
Valves, Installation................................................. 148
Valves, Removal.................................................... 147
W
When you work with Chemicals, Fuel and
Lubrication Oil, Change.......................................... 183

262
 References to Service Bulletins

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AB Volvo Penta
Global Aftermarket
Dept. CB22000
SE-405 08 Gothenburg
Sweden
47703722 English 01-2020