Workshop Manual - 21-26 - TAD1150... 47705010 - EN47705020 - US - PDF

Workshop Manual I
Group 21-26 2(0)
TAD1140VE, TAD1141VE, TAD1142VE,

TAD1170VE, TAD1171VE, TAD1172VE
Content
General Information
00-0 General ................................................................................................ 3
Specifications
03-2 Specifications, Engine ....................................................................... 9
03-21 Engine .............................................................................................. 26
03-22 Lubrication System ........................................................................ 33
03-23 Fuel System ..................................................................................... 34
03-25 Inlet and Exhaust System .............................................................. 36
03-26 Cooling System ............................................................................... 36
03-3 Specifications, Electrical ................................................................. 37
Electrical System ...................................................................................... 37
Safety and Other Instructions

05-1 Safety Instructions ........................................................................... 38
Special tools
08-2 Special Service Tools ....................................................................... 42
Chemical Products
18-0 General .............................................................................................. 48
General
20-0 Engine Information, General ............................................................ 49
Test and Adjustments .............................................................................. 49
Engine
21-0 Engine Complete, General ............................................................... 55
Fitting the Fixture ...................................................................................... 55
Engine Disassembly ................................................................................. 57
Engine Assembly ...................................................................................... 67
21-1 Cylinder Head .................................................................................... 76
21-3 Cylinder Liner, Pistons ................................................................... 104
21-4 Valve Mechanism ............................................................................ 106
21-5 Timing Gears and Shaft ................................................................. 127
21-6 Crank Mechanism ........................................................................... 154
Lubricating and Oil System

22-0 Lubricating and Oil System, General ............................................ 162
22-1 Oil pump and Line .......................................................................... 165
22-2 Oil filter ............................................................................................ 170
22-3 Oil cooler ......................................................................................... 179
Fuel System
23-0 Fuel System, General ..................................................................... 184
23-3 Fuel Feed Pump and Filter ............................................................. 188
23-7 Injectors and Delivery Pipes .......................................................... 200
23-8 Control System, ECM, Data Sets ................................................... 212
Inlet and Exhaust System

25-0 Inlet and Exhaust System, General ............................................... 214
25-1 Inlet and Exhaust Manifolds .......................................................... 215
25-4 Emission Control, Catalytic Converter ......................................... 225
47705020 05-2015 © AB VOLVO PENTA 1

25-5 Turbo and supercharger ................................................................ 233
25-6 Air Cleaner, Throttle Housing ........................................................ 241
25-8 Emission After-Treatment .............................................................. 243
Cooling System
26-0 Cooling System, General ............................................................... 278
26-2 Coolant Pump, Thermostat ............................................................ 284
Alternator, Charge Regulator

32-1 Alternator ......................................................................................... 292
Starting System
33-1 Starter Motor ................................................................................... 298
Alphabetical index .................................................................................. 303
References to Service Bulletins ............................................................ 305
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00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, descrip- When carrying out service and repair on emis-
tions and maintenance and repair instructions for sion-certified engines, it is important to be aware
standard model Volvo Penta products. A list of these of the following:
products may be found in the section Specifica-
tions. 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 corre- the certified engine.
spondence 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 person- • Maintenance and service intervals recom-
nel. It is assumed that any person using the Service mended by Volvo Penta must be complied with.
Manual has a fundamental knowledge of the product • Only spare parts approved by Volvo Penta may
and is able to carry out mechanical and electrical be used.
work to trade standard.
• Service on injection pumps, pump settings and
Volvo Penta continually develops its products; we injectors must always be carried out by an
therefore reserve the right to make changes. All infor- authorized Volvo Penta workshop.
mation in this manual is based on product data which
• The engine must not be converted or modified,
was available up to the date on which the manual was
except with accessories and service kits which
printed. New working methods and significant
Volvo Penta has approved for the engine.
changes introduced to the product after 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 prod-
Spare parts for the electrical and fuel systems are uct) may be broken by unauthorized persons.
subject to various national safety standards. Volvo
Penta Original Spare Parts meet these standards. No The general instructions in the Operator's Manual
damage of any kind caused by the use of spare parts concerning operation, service and maintenance
not approved by Volvo Penta will be compensated by apply.
any warranty undertaking.
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.
47705020 05-2015 © AB VOLVO PENTA 3

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 tech-
mounted in a holding fixture. Maintenance work is nical specification may dramatically increase the
often carried out on site, in which case – if nothing environmental impact of an otherwise reliable sys-
else is indicated – using the same working methods tem. It is therefore critical that the stated wear toler-
as the workshop. ances 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.
! DANGER! Some systems, e.g. fuel systems, often require spe-
cial expertise and test equipment. A number of com-
! WARNING! ponents are factory-sealed, for among other things
environmental reasons. Warranty-sealed compo-
! CAUTION!
nents may not be worked on without authorization to
perform such work.
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remember that most chemical products, incorrectly
can be foreseen as service work is carried out in the used, are harmful to the environment. Volvo Penta
most varied of circumstances. We call attention to recommends the use of biodegradable degreasers
risks that may occur due to incorrect handling during whenever components are cleaned, unless otherwise
work in a well-equipped workshop using working specified in the Service Manual. When working out-
methods and tools tried and tested by us. doors, take especial care to ensure that oils and wash
residues etc. are correctly properly for destruction.
The service manual describes work operations car-
ried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Spe-
Tightening torques
cial Tools are designed to ensure the safest and most Tightening torques for vital fasteners that must be
rational working methods possible. It is therefore the applied using a torque wrench are indicated in the
responsibility of anyone using tools or working meth- Service Manual, chapter Tightening torques and in
ods other than those we recommend to ensure that the Manual's work descriptions. All torque indications
no risk of personal injury or mechanical damage is apply to clean threads, bolt heads and mating faces.
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 noted
instructions may be in force for the tools and chemi- in the job description.
cals mentioned in the Service Manual. These regu-
lations must always be followed, and no special
Torque, angle tightening
instructions regarding this are to be found in the Serv-
ice Manual. When torque/angle tightening, the fastener is tight-
ened to a specified torque, and tightening then con-
By taking these basic precautions and using common tinues through a pre-determined angle.
sense it will be possible to guard against most ele-
ments of risk. A clean workplace and a clean product Example: For 90° angle tightening, the fastener is
will eliminate many risks of personal injury and mal- turned a further 1/4 turn in one sequence, after the
function. 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 impor-
tance that dirt and foreign objects are kept away, as
malfunctions or shortened service intervals may oth-
erwise result.
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00-0 General
Lock nuts Anaerobic agents.

These agents cure (harden) in the absence of air.
Removed locknuts may not be re-used; they must be These preparations are used when two solid compo-
replaced by new ones, as locking properties are nents, e.g. two cast components, are fitted together
impaired or lost with re-use. without a gasket. Common uses are also to lock and
In the case of lock nuts with plastic inserts the tight- seal plugs, stud threads, taps, oil pressure monitors
ening torque indicated must be reduced if the nut has etc.
the same nut height as a standard, all-metal hexag-
onal nut. Hardened anaerobic preparations are glassy and for
Reduce the torque by 25% for bolt sizes of 8 mm or this reason, the preparations are colored to make
larger. them visible. Hardened anaerobic preparations are
In the case of lock nuts with plastic inserts with a high highly resistant to solvents, and old compound can-
nut-height (where the all-metal thread is as high as a not be removed. On re-assembly, it is important to
standard hexagonal nut), the indicated torque carefully degrease and wipe dry components first,
applies. before applying new sealant in accordance with the
instructions.
Strength classes
Safety regulations for fluorocarbon
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking on rubber
the bolt head. Markings of a higher number indicate Fluorocarbon rubber is a common material in sealing
stronger material. For example, a bolt marked 10-9 is rings for shafts, and in O-rings, for example.
stronger than one marked 8-8.
When fluorocarbon rubber is exposed to high tem-
For this reason, it is important that when bolts are peratures (above 300°C/572°F), hydrofluoric acid
removed they are returned to their original locations can form. This is highly corrosive. Contact with the
on re-assembly. When replacing bolts check the skin can result in severe chemical burns. Splashes in
applicable Spare parts catalogue to ensure the cor- your eyes can result in chemical wounds. If you
rect bolt is used. breathe in the fumes, your lungs can be permanently
damaged.
Sealing compounds etc.
To ensure service work is correctly carried out it is WARNING!
important that the correct type of sealants and locking Seals must never be cut with a torch, or be burnt
fluids are used on joints where such are required. afterwards in an uncontrolled manner. Risk for
poisonous gases.
In each service manual section concerned, the seal-
ants used in product manufacture are indicated. The
same sealants, or sealants with equivalent proper- WARNING!
ties, must be used for maintenance work. Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles. Handle the
Make sure that mating surfaces are dry and free from removed seal in the same way as corrosive acid. All
oil, grease, paint and anti-corrosion agent before residue, including ash, can be highly corrosive. Never
applying sealant or locking fluid. Always follow the use compressed air to blow clean.
manufacturer's instructions regarding applicable Put the remains in a plastic container, seal it and
temperatures, hardening times and such. apply a warning label. Wash the gloves under running
water before removing them.
Two basic types of compound are used:
The following seals are most probably made from flu-
RTV preparations (Room Temperature Vulcaniz- orocarbon rubber:
ing).
Used most often together with gaskets, e.g. sealing Seal rings for the crankshaft, camshaft, idler shafts.
gasket joints, or are brushed on gaskets. RTV seal-
ants are completely visible when the part has been O-rings, regardless of where they are installed. O-
removed. Old RTV sealant must be removed before rings for cylinder liner sealing are almost always
the component is sealed again. Use denatured alco- made of fluorocarbon rubber.
hol.
Please note that seals which have not been
exposed to high temperature can be handled nor-
mally.
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00-0 General
Illustrations
A lot of illustrations contains standardized symbols and colors. Please refer to the following information to reduce
misunderstandings when working on an engine / transmission using this Workshop Manual.
Illustration colors Position

Most illustrations have a focused component (blue)
which is fastened by a (red) bolt or such on a (light
grey) engine / transmission body.
P0015623
Focus arrows pointing at object. Sometimes it con-

tains number of items, e.g. three bolts.
NOTICE! If an arrow with the text “x3” is pointing at

only one item, e.g. a bolt, it still applies to the other
two alike items (the two other bolts) highlighted in the
P0015699
illustration.
1 Focus
(blue)
2 Fastenings
(red)
3 Body
(light grey)
4 Background
P0015627
(white)
This symbol gives a positioning number to an object,
e.g. 2, which is also mentioned in the supplied text
information.
P0015628
The symbol to the left shows part no. of the positioned

special tool, e.g. 9991801.
The symbol on the right side is used when something
needs to be replaced by a new part / kit.
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00-0 General
Movement Tools (continuence)
P0015622
Movement arrows are used to show which direction a

component is to be moved / rotated.
P0015625
Symbol is used in a corner of the illustration to show

how many degrees the object shall be turned and at
P0015630
which direction.
A symbol of a tool in a corner of the illustration is
shown when the tool is recommended to use, e.g. a
knife or a crowbar.
P0015626
Symbol is used to show how many revolutions the

object shall be turned and at which direction.
Tools
P0015631
A drill in a specified size, duck tape and stripes may

also be shown as symbols.
P0015629
One of the following symbols is used when describing

the recommended type of screwdriver.
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00-0 General
Chemicals Units
P0015695
Symbols can also describe when and how a chemical

product is to be used.
Cleanliness
P0015696
Units are mentioned in the illustration when a specific

value (e.g. pressure, weight or resistance etc.) is
expected.
Important
P0015624
The scraper symbol suggests that a contact surface

needs to be scraped from sealant etc.
The cloth symbol suggests that the mechanic should
clean the contact surface thoroughly or be prepared
for some oil spill or similar.
Sealant
P0015005
The eye symbol is used when something needs close

inspection or must be performed in a certain way.
The symbol to the right is used when several mechan-
ics are needed.
Safety
P0015698
The tube symbol shows how thick layer of sealant to

applicate.
The clock symbol is used when something needs to
be done within or after a certain time.
P0015697
These symbols are used when a certain safety related

equipment is needed.
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03-2 Specifications, Engine

Tightening torques
General Tightening Torques Nm (lbf.ft) Angle tightening
M6 standard bolt 10 ±1.5 (7.4 ±1) –
M8 standard bolt 24 ±4 (17.7 ±3) –
M10 standard bolt 48 ±8 (35.4 ±61) –
M12 standard bolt 85 ±15 (62.7 ±11) –
M14 standard bolt 140 ±25 (103.3 ±18) –
M16 standard bolt 220 ±35 (162 ±26) –
NOTICE! Inspect bolts that will be re-installed.

Damaged bolts with e.g. shear marks under the
heads, must be scrapped.
Special Tightening Torques

Group 21: Engine
Front Engine Mountingcylinder block 275 ±45 (203 ±33) –
Front Engine Mountingforward 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°
Stiffening plate / stiffening frame (cylinder block) 48 ±8 (35.4 ±6) –

NOTICE! Tighten the screws in sequence, from
the center outwards.
Lifting eye, front

Stage 1 30 ±3 (22.1 ±2) –
Stage 2 – 80°±5°
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Standard valve mechanism Tightening tor-

que
1 Adjustment, exhaust 38 Nm (28.0")
2 Preload, injector 52 Nm (38.4")
3 Adjustment, inlet 38 Nm (28.0")
P0020122
VCB mechanism Tightening tor-

que
1 Adjustment, exhaust yoke 38 Nm (28.0")
2 Preload, injector 52 Nm (38.4")
3 Adjustment, inlet 38 Nm (28.0")
P0020123
10 47705020 05-2015 © AB VOLVO PENTA

Group 22: Lubrication System

Nm (lbf.ft) Angle tightening
Oil Sump 24 ±4 (17.7 ±3) –
NOTICE! Tighten the screws 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 diag-
onally)
Stage 1 35 ±5 (26 ±5) –
Stage 2 35 ±5 (26 ±5) –
Group 23: Fuel System

Feed pump – intermediate housing / power steer- 24 ±4 (17.7 ±3) –
ing pump
Intermediate housing / power steering pump – fly- 30 ±6 (22.1 ±4) –
wheel housing
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 sec-

ond 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 40 ±4 (29.5 ±3) –

Hollow screw M4 35 ±4 (25.8 ±3) –
Riser, cylinder head front (M16) 50 ±4 (36.9 ±3) –
47705020 05-2015 © AB VOLVO PENTA 11

Piston Cooling Nozzles

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 sus-
pected, 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

Turbo 48 ±8 (35.4 ±6)(1) –
1) Note. Tighten the bolts diagonally. Finally tighten the first bolt again to the same torque.
Control valve, e-EGR:

Stage 1 25 Nm (18.4 lbf. ft.)
Stage 3 Loosen the bolts ≈ −90°
12 47705020 05-2015 © AB VOLVO PENTA

P0020780
1 Under pressure sensor, air filter. Clamp. 8 e-EGR control valve

2 Camshaft position sensor Apply paste for fixture, part no. 1161929.
Tightening torque: 8 Nm (5.9 lbf. ft.) Install bolts with spacers.
3 Pre-NOx sensor (TAD1170-72VE) Tighten the e-EGR control valve in the following
Tightening torque: 50 Nm (36.9 lbf. ft.) steps:
4 Air throttle (TAD1150-52VE, TAD1170-72VE)
1 25 Nm (18.4 lbf. ft.)
5 Coolant level sensor. Plug model.
6 Wastegate valve 2 53 Nm (39.1 lbf. ft.)
7 Coolant temperature sensor 3 Loosen the bolts ≈ −90°
Tightening torque: 22 Nm (16.2 lbf. ft.)
4 25 Nm (18.4 lbf. ft.)
5 53 Nm (39.1 lbf. ft.)
9 Oil pressure sensor
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P0020781
10 Crankcase pressure sensor 13 Auxiliary stop

Tightening torque: 25 Nm (18.4 lbf. ft.) 14 Fuses
11 Air inlet pressure/intake manifold temperature 15 Oil level/temperature sensor
sensor Tightening torque: 8 Nm (5.9 lbf. ft.)
Tightening torque: 8 Nm (5.9 lbf. ft.) 16 Water in fuel switch
12 Flywheel position sensor Tightening torque: 2 Nm (1.5 lbf. ft.)
Tightening torque: 8 Nm (5.9 lbf. ft.) 17 Fuel pressure sensor
14 47705020 05-2015 © AB VOLVO PENTA

Tightening Schedules
Cylinder head
23
13 25 9 21 6 18 1 15 3 19 7 23
14
P0012814 10 4 2 5 8 12
26 22 16 17 20 24
Tightening torques: Nm (lbf.ft) Angle tightening

Stage 1 60 ±10 (44.3 ±7) –
Step 2 (check tightening) 60 ±10 (44.3 ±7) –
Stage 3 – 120°±5°
Stage 4 – 90°±5°
Core plug, cylinder head 60 ±10 (44.3 ±7) –

Locking nut, valve adjustment:
Stage 1 Tighten until contact –
Stage 2 – 60°±5°
Valve Cover
9 10
12 11 1 7 8
13
16
6
15 14 2 3 4 5
P0004253

Tightening torques 24 ±4 (17.7 ±3) –
47705020 05-2015 © AB VOLVO PENTA 15

Timing gear plate
Apply silicone to the back of the cylinder head and cyl- Tighten the bolts in numerical order.
inder block.

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

a diameter of approx. 2 mm (0.079").
16 47705020 05-2015 © AB VOLVO PENTA

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

1. Crankshaft gear 24 ±4 (17.7 ±3) –
2. Intermediate gear, double

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

Tighten the bolts in the numerical order illustrated.
Stage 1 35 ±4 (25.8 ±3) –
Stage 2 – 120°±5°
4. Camshaft gear / vibration damper

Tighten the bolts in the numerical order illustrated.
Stage 1 45 ±4 (33.2 ±3) –
Stage 2 – 90°±5°
5. Drive, power steering pump / fuel feed pump 100 ±10 (73.8 ±7) –
6. Drive gear, PTO (power take-off) 200 +50 (147.5 +36.9) –
47705020 05-2015 © AB VOLVO PENTA 17

Flywheel Housing
35 6 Nm
P0002437
165 10 Nm

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

M12 110 ±5 (81.1 ±4) –
M14 165 ±10 (121.7 ±7) –
Timing gear cover, upper

4
2 5
1
3

18 47705020 05-2015 © AB VOLVO PENTA

Flywheel
NOTICE! Make sure that the flange is clean and dry.

Stage 1 60 ±5 (44.3 ±4) –
Stage 2 – 120°±10°
Cover, front crankshaft seal
NOTICE! Apply a bead of sealant (part # 1161231)*

with a diameter of approx. 2 mm (0.079"); see illustra-
tion.
* Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).

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

12
10 1
8 3
6 5
4 7
2 9
P0002978 11


Stage 1 45 ±5 (33.2 ±3) –
Stage 2 – 90°±5°
NOTICE! Tighten the bolts in the numerical order illus-

trated.
NOTICE! The vibration damper's 8.8 bolts may NOT be
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

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Housing, safety valve

Valve housing, lubrication system

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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 sequence on re-assembly.

Stage Tighten bolts 1–7 25 ±3 (18.4 ±2) –
1:
Stage Tighten bolts 9, 11, 13 90 ±5 (66.4 ±4) –
2: Start with bolt 11.
NOTICE! Tighten the bolts in stages to ensure
that the rocker arm shaft bottoms against the
bearing housing without bending the shaft.
Stage Tighten bolts 8, 10, 12, 14 60 ±5 (44.3 ±4) –
3:
Stage Undo bolts 9, 11, 13 – –
4:
Stage Tighten bolts 9, 11, 13 60 ±5 (44.3 ±4) –
5:
Stage Tighten bolts 1–7 – 90°±5°
6:
Stage Tighten bolts 8-14 – 100°±5°
7:
22 47705020 05-2015 © AB VOLVO PENTA

Intake manifold
P0002679

13 11 1 9 7 5 3
14 12 2 10 8 6 4
P0002979

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 temperature 12 ±2 (8.9 ±1.5) –
Exhaust manifold
7 1 9 3 11 5
2 8 4 10 4 12
P0008554

Stage Tighten bolts (in numerical order) until they 5 ±1.5 (3.7 ±1.1) –
1: touch
Stage 2 Tighten bolts 7–12 in the sequence 7–8–9– 10 ±1.5 (7.4 ±1.1) –
10–11–12
Stage 3 Tighten bolts 1 through 12 in numerical 48 ±8 (35.4 ±6) –
order
47705020 05-2015 © AB VOLVO PENTA 23

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.
24 47705020 05-2015 © AB VOLVO PENTA

Engine, General
Type designation TAD1140-TAD1142VE
TAD1150-TAD1152VE
TAD1170-TAD1172VE
No. of cylinders 6
Weight, dry 1072 kg (2363 lbs)
Stroke 152 mm (5.98”)
Displacement 10.84 l (2.86 US gals)
Bore 123 mm (4.84”)
Firing order 1-5-3-6-2-4
Direction of rotation (seen from front) Counter-clockwise
Low idle 600 rpm
Wide open throttle range
TAD1170-TAD1172VE 2250 rpm
Rating 4 -
Rating 5 -
Number of valves per cylinder 4
Compression ratio 17.0:1
Compression stroke pressure, starter motor cranking 40 kPa (5.8 lbf. ft.)
47705020 05-2015 © AB VOLVO PENTA 25

Engine
Group 21: Engine
Cylinder head
Type 6 cylinders
Height, min. 135 mm (5.31")
Max. flatness error (base plane) 0.4 mm (0.0157")
Cylinder Head Bolts

May be re-used 5 times
Thread size M16 x 2
Cylinder liner / cylinder

Type Wet, replaceable
Bore 123 +0.03 mm (4.84 +0.00118")
Liner collar height above block plane 0.14-0.21 mm (0.0055-0.0083")
Depth from block plane to liner collar 11 +0.04/-0.01 mm (0.43 +0.00157/-0.00039")
No. of O-rings in upper / lower liner seal 3 pcs
Pistons
Type / material Monosteel S103
Number of ring grooves 3 pcs
Front marking Arrow points forward
Height above engine block plane 0.15-0.65 mm (0.0059-0.0256")
Piston rings
Quantity 3 pcs
Upper compression ring, type Full keystone
Upper compression ring, height 3.5 mm (0.138") (nominal value)
Upper compression ring, marking Top
Upper compression ring, gap (new ring), max 0.3-0.45 mm (0.0118-0.0177")
2nd compression ring, type Taper face
2nd compression ring, height 2.5 -0.005/-0.03 mm (0.098 -0.0002/-0.00118")
2nd compression ring, marking Top
Oil ring, height 3.5 -0.01/-0.03 mm (0.138 -0.00039/-0.00118")
Crankshaft
Type of hardening Induction hardened
Length 1066 mm (42.0")
End float(1) 0.07-0.31 mm (0.0028-0.0122")
Ovality of main and big-end bearings, max 0.01 mm (0.0004")
Taper on main and big end bearings, max 0.01 mm (0.0004")
Center main bearing runout, max 0.15 mm (0.00591")
1. Measurements apply to lubricated components.
26 47705020 05-2015 © AB VOLVO PENTA

P0005849
Main bearing journals

Diameter, standard 108 mm (4.25")
Undersize:
0.25 mm (0.0098") 107.85-107.87 mm (4.2460-4.2468")
0.50 mm (0.0197") 107.73-107.75 mm (4.2413-4.2421")
0.75 mm (0.0295") 107.60-107.62 mm (4.2362-4.2370")
1.00 mm (0.0394") 107.48-107.50 mm (4.2315-4.2323")
1.25 mm (0.0492") 107.35-107.37 mm (4.2264-4.2272")
Surface finish, main bearing journal Ra 0.25 (0.0098")
Surface finish, radius Ra 0.4 (0.0157")
Width thrust bearing journal (A) standard 42 mm (1.654")
Oversize:
0.2 mm (0.0079"), thrust bearing 0.1 mm (0.0039") 42.17-42.22 mm (1.6602-1.6622")
Fillet radius (R) 4.5 mm (0.177")
47705020 05-2015 © AB VOLVO PENTA 27

R
C D
B
p0005210
Thrust washers (thrust bearings)

Width (B) standard 3.2 mm (0.1260")
Oversize:
0.1 mm (0.0039") 3.2-3.3 mm (0.1260-0.1299")
0.2 mm (0.0079") 3.3-3.4 mm (0.1299-0.1.339")
0.3 mm (0.0118") 3.4-3.5 mm (0.1339-0.1.378")
Main bearing shells

External diameter (C) 113 mm (4.45")
Thickness (D) standard 2.5 mm (0.098")
Oversize:
0.25 mm (0.0098") 2.6-2.7 mm (0.102-0.106")
0.50 mm (0.0197") 2.7-2.8 mm (0.106-0.110")
0.75 mm (0.0295") 2.8-2.9 mm (0.110-0.114")
1.00 mm (0.0394") 2.9-3.0 mm (0.114-0.118")
1.25 mm (0.0492") 3.1-3.2 mm (0.122-0.126")
Main bearing, radial clearance, max 0.11 mm (0.0043")
28 47705020 05-2015 © AB VOLVO PENTA

C A
B
p0005211
Big end bearing journals

Diameter 88 mm (3.46")
Undersize:
0.25 mm (0.0098") 87.85-87.87 (3.4587-3.4594")
0.50 mm (0.0197") 87.73-87.75 (3.4539-3.4547")
0.75 mm (0.0295") 87.60-87.62 (3.4488-3.4496")
1.00 mm (0.0394") 87.48-87.50 (3.4441-3.4449")
1.25 mm (0.0492") 87.35-87.37 (3.4390-3.4398")
Surface finish, big end bearing Ra 0.25 (0.0098")
Surface finish, radius Ra 0.4 (0.0157")
Width (A) 54 mm (2.13")
Fillet radius (R) 4.5 mm (0.177")
Big end journal shells

External diameter (C) 91 mm (3.58")
Thickness (D) 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")
0.75 mm (0.0295") 2.7-2.8 mm (0.1063-0.1102")
1.00 mm (0.0394") 2.8-2.9 mm (0.1102-0.1142")
1.25 mm (0.0492") 3.0-3.1 mm (0.1181-0.1220")
Connecting rod big end, diameter (D) 90.83 mm (3.5760")
Connecting rod
Length, center-center (E) 225 mm (8.86")
Piston pin bush internal diameter (G) 54 mm (2.13")
Big end bearings, radial clearance, max 0.03 mm ()
47705020 05-2015 © AB VOLVO PENTA 29

Marking
FRONT on the connecting rod faces forwards.
The connecting rods and caps are marked in pairs with
a serial number (see illustration).
P0020566
Valves
Valve head diameter:
Inlet 40 mm (1.57")
Exhaust 38 mm (1.50")
Max play, valve stem - valve guide:
Inlet 0.5 mm (0.0197")
Exhaust 0.5 mm (0.0197")
Valve guide, diameter:
Inlet 8 mm (0.315")
Valve guide, height above spring plane:
Inlet 24.5 ±0.5 mm (0.964 ±0.0197")
Exhaust 16.5 ±0.5 mm (0.650 ±0.0197")
Valve springs, uncompressed length:
Outer valve springs 73-74 mm (2.87-2.91")
Inner valve springs 70-71 mm (2.76-2.80")
Valve clearance
Standard mechanism
Cold engine, setting value:
Inlet 0.2 mm ±0.05 (0.0079”)
Exhaust 0.8 mm ±0.05 (0.0315”)
VCB mechanism
Cold engine, setting value:
Inlet 0.2 mm ± 0.05 (0.0079”)
Exhaust 1.6 mm ± 0.05 (0.0315”)
30 47705020 05-2015 © AB VOLVO PENTA

Valve seats
Outer diameter (A):
Inlet, standard 42 mm (1.65")
Exhaust, standard 40 mm (1.57")
Inlet, oversize 42.1 mm (1.657")
Exhaust, oversize 40.1 mm (1.579")
Height (B):
Inlet 7.3 mm (0.287")
Exhaust 6.4 mm (0.252")
B
A
P0020572
Valve seat angle (A):

Inlet 29.5°
Exhaust 29.5°
Seat angle in cylinder head (B):
Inlet 30°
Exhaust 30°
47705020 05-2015 © AB VOLVO PENTA 31

Valve seat position

Diameter (C):
Inlet 42 mm (1.65")
Depth (D):
Inlet 11.5 mm (0.453")
Exhaust 9.9 mm (0.390")
Seat base radius (R):
Inlet, max. 0.8 mm (0.0315")
Exhaust, max. 0.8 mm (0.0315")
Camshaft
Camshaft setting check(1) cold engine and valve clearance
= 0.
Inlet valve for cylinder 1 must be open at flywheel position
6 after TDC 1.7 ±0.4 mm (0.067 ±0.0157")
Propulsion type Gear wheel
Number of bearings 7 pcs
Diameter, bearing journals, standard 69.97-70.00 mm (2.7547-2.7559")
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")
Valve lift:
Inlet 13.1 mm (0.5157")
Exhaust 12 mm (0.4724")
Permissible wear, full cam profile 0.1 mm (0.0039")
Unit injector, stroke 13 mm (0.5118")
Max end float 0.24 mm (0.0094")
Max permissible ovality (with new bearings) 0.05 mm (0.0020")
Bearing, max permissible wear on diameter 0.05 mm (0.0020")
1) During this check, the timing gear must be turned in the correct direction (clockwise seen from the front) to take up all gear
lash.
Camshaft Bearings
Camshaft bearing thickness, standard 1.92 mm (0.0756")
Oversize:
0.25 mm (0.0098") 2.04 mm (0.0803")
0.50 mm (0.0197") 2.17 mm (0.0854")
0.75 mm (0.0295") 2.29 mm (0.0902")
32 47705020 05-2015 © AB VOLVO PENTA

Timing gears
Gear wheel:
1 Drive gear, camshaft
2 Engine PTO (accessory)
3 Intermediate gear, double drive, outer
Intermediate gear, double drive, inner
4 Drive gear, crankshaft
5 Drive gear, lubrication oil pump
6 Drive gear, steering servo and fuel feed pump
7 Intermediate gear, power steering pump
8 Drive gear, air compressor
9 Intermediate gear, adjustable
P0020594
Gear Lash 0.05-0.17 mm (0.0020-0.0067")

Idler wheel stub shaft, diameter 100 mm (3.94")
Idler wheel bush, diameter 100 mm (3.94")
Radial clearance for intermediate gear, max 0.05 mm (0.0020")
Lubrication System
Oil pressure limits
X Engine speed (rpm)

Y Oil pressure (kPa)
A Warning level
B Alarm level
P0020595
Oil volume incl. oil filter, no engine incline 37 l (9.8 US gals)
47705020 05-2015 © AB VOLVO PENTA 33

Fuel System
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 entail a power loss of up to 5% and an
increase in fuel consumption of around 2–3 %.
Fuel pressure limits

Y Fuel pressure (kPa)
A Warning level
P0020596
Type of fuel system Unit injector

Overflow valve, opening pressure 400-550 kPa (58.0-79.8 psi)
34 47705020 05-2015 © AB VOLVO PENTA

Pre-load 3–4 flats

(0.75 ±0,1 mm / 0.0295 ±0.0039")
Adjust the unit injector rocker arm to zero clear-
ance against the camshaft. Then tighten the
adjuster screw a further 3-4 flats (180°-240°).
Location of unit injector trim code(1)
P0020652
1. Note: The trim code specifies individual unit injector tolerances

for the engine control unit. In the example illustrated the trim code is
27547C9M3.
47705020 05-2015 © AB VOLVO PENTA 35

Inlet and Exhaust System

Charge air pressure limits

Y Absolute pressure, charge air cooler (kPa)
A Warning level
B Alarm level
P0020651
Turbo
Type Holset CTT HX40
End float, turbine shaft 0.127 mm (0.0050")
Radial clearance, compressor disc 0.508 mm (0.0200")
Exhaust temperature, max 492 ºC (917.6 ºF).
Cooling System
Type Overpressure (sealed system)
Coolant type: Volvo Penta Coolant VCS

Color Yellow
Contains Ethylene glycol and anti-corrosion additives
Mix with Water (according to ASTM D4985)
Mixture proportions (Conc. coolant/water)(1) 40/60, freezing point -24 °C (-11.2 °F)
Coolant volume:
Engine only 17 liters (4.5 US gallons)
Including radiator and hoses 21 liters (5.5 US gallons)
Filler cap pressure valve opens at 75 kPa (10.9 psi)
Thermostat:
Opens at 82 ºC (179.6 ºF).
Fully open at 92 ºC (197.6 ºF).
1. Volvo Penta recommends “Ready Mixed” coolant.
36 47705020 05-2015 © AB VOLVO PENTA

03-3 Specifications, Electrical
03-3 Specifications, Electrical
Electrical System
System voltage 24 V (6.7 bhp)
Alternator , make Bosch
Alternator, max voltage / current 110 V / 150 A
Starter motor, output:
Standard 5.5 kW (6.7 bhp)
Start / Stop 7 kW (6.7 bhp)
Cranking speed with starter motor engaged 100 rpm
47705020 05-2015 © AB VOLVO PENTA 37

05-1 Safety Instructions

Safety Information
This Service Manual contains repair instructions,
descriptions and technical data for products or product
designs from Volvo Penta. Ensure that you are using
the correct service manual.
Read the safety information below and the service manual section About this Workshop manual and Repair
instructions carefully before repair and service work is begun.
!
This symbol is used in the service manual and on the product, to call attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will 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 draw your attention to something that may cause minor damage or a minor
malfunction to the product or property.
NOTICE! Is used to draw your attention to important information that will facilitate the
work or operation in progress.
This symbol is used on certain operations to indicate the following:

This operation requires prior theoretical and/or instructor led training before attempting.
Contact your local training organization for further information.
A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.
38 47705020 05-2015 © AB VOLVO PENTA

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed when the engine is hot.
As a rule, all service operations must be carried Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.
Be aware of hot surfaces (exhaust pipes, tur- Never start the engine without installing the air
! bos, charge air pipes, starting heaters etc.) and ! filter. The rotating compressor turbine in the tur-
hot fluids in pipes and hoses on an engine that bocharger can cause severe injury. Foreign
is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective cov-
careless movement or a dropped tool may in the ers before the engine is started.
worst case lead to personal injury.
Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.
Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and trans-
! repeated exposure to oil can cause skin to ! mission oils, glycol, gasoline, and diesel oil,
become dry. Irritation, dryness, eczema and together with chemicals for workshop use such
other skin problems may then result. From a as degreasing agents, paints and solvents, are
health standpoint, used oil is more dangerous injurious to health. Carefully read the instruc-
than new. Use protective gloves and avoid oil- tions on the product packaging! Always follow a
soaked clothes and rags. Wash regularly, espe- product's safety directions, e.g. use of protec-
cially before eating. Use suitable barrier creams tive mask, glasses, gloves etc. Ensure that
to counteract drying out of the skin and to aid other personnel are not exposed to substances
dirt removal. that are injurious to health. Ensure good venti-
lation. Handle used and leftover chemicals in
the prescribed manner.
Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.
47705020 05-2015 © AB VOLVO PENTA 39

Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause 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 sea cock / cooling
water inlet valve before work on the cooling sys-
tem is begun.
All fuels, as well as many chemicals, are flam- Make sure that oil, fuel-soaked rags, and used
! mable. Do not allow open flames or sparks in ! fuel and oil filters are stored in a safe manner.
their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.
Batteries must never be exposed to open Never work alone when removing heavy com-
! flames or electric sparks. Never smoke in the ! ponents, even when using lifting devices such
vicinity of the batteries; they generate hydrogen as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.
Do not touch the connections during start

attempts. Sparking hazard! Do not lean over
batteries.
Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting equip-
a transposition can result in serious damage to ment used is in good condition and has the load
electrical equipment. Refer to the wiring dia- capacity to lift the engine (engine weight includ-
gram. ing gearbox or extra equipment). For safe han-
Always use protective goggles when charging dling and to avoid damaging components fitted
and handling the batteries. Battery electrolyte to the top of the engine, the engine must be
contains sulfuric acid which is highly corrosive. lifted with a correctly adjusted lifting boom. All
Should the battery electrolyte come into contact chains or wires must run parallel to each other
with unprotected skin, wash it off immediately and as perpendicular to the engine as possible.
using soap and copious amounts of water. If you If other equipment attached to the engine has
get battery acid in your eyes, flush at once with altered its center of gravity, special lifting devi-
copious amounts of water and seek medical ces may be needed to obtain the correct bal-
assistance immediately. ance for safe handling. Never perform any work
on an engine that is only suspended from the
lifting equipment.
40 47705020 05-2015 © AB VOLVO PENTA

The components in the electrical and fuel sys- Exercise extreme caution when leak-detecting
! tems on Volvo Penta products are designed and ! on the fuel system and testing the fuel injector
manufactured to minimize the risk of fire and nozzles. Use eye protection. The jet from a fuel
explosion. The engine must not be run in areas nozzle has very high pressure and great pene-
where there are explosive materials. tration power. Fuel can force its way deep into
body tissue and cause severe injury. There is a
risk of blood poisoning (septicemia).
Only use fuels and lubricating oils recom- Never use a high-pressure washer for cleaning
! mended by Volvo Penta. Refer to the Operator's ! the engine.
Manual for the product in question. Use of fuels Pay attention to the following when using a high-
that are of a lower grade may damage the pressure washer on components other than the
engine, the injection pump and the injectors. On actual engine: Never direct the water jet at
a diesel engine, low grade fuel can cause the seals, rubber hoses or electrical components.
control rod to bind and the engine to over-rev,
with the risk of engine damage and personal
injury as a result. Low fuel and oil grades may
result in high service, maintenance and repair
costs.
Fuel delivery pipes must not be bent or straight-

! ened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
47705020 05-2015 © AB VOLVO PENTA 41

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.
P0004343
P0006764
P0006823
885810 Fixture 885811 Timing tool 885822 Magnetic pen
p0013445
P0002930 P0002784
885633 Torque multiplier 885648 Counterhold 1158957 Pliers
P0004344 P0001872 P0006782
1159794 Torque wrench 3849613 Pressure testing kit 9809726 Pneumatic hydraulic
pump
P0006792 P0006761
9809729 Hydraulic cylinder 9986173 Puller 9986485 Stand
42 47705020 05-2015 © AB VOLVO PENTA

P0001875 P0006269 P0006765
9989876 Dial indicator 9990006 Puller 9990013 Slide hammer
p00006766
P0006768
9990107 Connection washer 9990113 Drift 9990114 Puller
P0011608 P0006769 P0006770
9990117 Cone 9990118 Cone 9990123 Pressure testing kit
P0004314 P0006774
9990124 Nipple 9990156 Adapter 9990157 Press tool
P0006776 P0006777 P0006795
9990160 Fixture 9990164 Fixture 9990174 Drift
P0006786
P0006793 P0002789
9990176 Press tool 9990185 Lifting tool 9990192 Puller
47705020 05-2015 © AB VOLVO PENTA 43

P0004328
P0006780
P0006791
9990210 Valve spring com- 9992000 Handle 9992479 Holder for dial indi-
pressor cator
P0006794 P0006781
9992670 Hand pump 9992873 Nipple 9996049 Draining hose
p0004329
P0006788
p0006802
9996159 Adapter 9996239 Lifting tool 9996394 Support
P0004331
p0004330 P0002947
9996395 Support 9996398 Manometer 9996400 Slide hammer
p0006800 P0004332 P0006804
9996441 Cover, with connect- 9996645 Puller 9996662 Pressure testing kit
ing nipple
P0010359
p0006801
9996666 Nipple 9996966 Press tool 9998246 Drift
44 47705020 05-2015 © AB VOLVO PENTA

P0006805 P0006806 P0006808
9998249 Protective sleeve 9998250 Sealing ring 9998251 Protection plug
P0006813 P0004349
9998264 Lifting tool 9998267 Guide sleeve 9998339 Manometer
P0006816 P0004580 P0001859
9998487 Sleeve 9998493 Hose 9998511 Lever
P0006814 P00068115
9998580 Protective sleeve 9998599 Cleaning kit 9998601 Fixture

10
0
20
0
20
P0010358 P0001878 P0001881
9998674 Adapter 9999179 Extractor oil filter 9999683 Dial indicator (short
probe)
P0001879 P0012166
9999696 Magnetic stand 88800011 Drift 88800014 Rotation tool
47705020 05-2015 © AB VOLVO PENTA 45

P0010364
P0006767
88800021 Drift 88800022 Mounting tool 88800031 Measuring tool
P0006789
P0002793 p0006796
88800062 Drift 88800083 Piston ring pliers 88800147 Drift
P0006809
P0010363
88800151 Drift 88800196 Drift 88800218 Extractor plate
P0012151 P00013450
88800318 Piston ring com- 88800387 Puller 88890105 Refractometer

pressor
88800460 Sleeve
46 47705020 05-2015 © AB VOLVO PENTA

9998599 Cleaning kit

Rengöringssats för enhetsinsprutare. Består av:
• 959239 Skruv M10

• 9808570 Borste, vit
• 9998580 Hylsa med hållare samt o-ring
• 276948 O-ringssats
• 9808634 Borstsats, består av:
- Förvaringslåda
- Hållare
- Hållare
- Skaft
- 9808614 Borste, gul 10 st
- 9808617 Stålborste, smal
- 9808618 Stålborste, grov
47705020 05-2015 © AB VOLVO PENTA 47

18-0 General
18-0 General
Chemical products
P0001869 P0016363
828250 Grease 1161053 Thread locking 1161231 Sealant
P0001870
1161277 Glue 1161771 Sealant 1161929 Lubricant
48 47705020 05-2015 © AB VOLVO PENTA

20-0 Engine Information, General
Test and Adjustments

Cooling System, Pressure Testing
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.
Alternative 1:
Tools:
9996441 Cover, with connecting nipple
9996662 Pressure testing kit
1 Check that all hoses and clamps are undamaged.
2 Check that the tap on the reducing valve is
screwed out.
3 Replace the filler cap on the expansion tank with
9996441 Cover, with connecting nipple.
Connect the pressure test device to the nipple on
the cover.
P0010196
4 Connect the pressure test device to the com-

pressed air system and open tap (B). Adjust the
reducing valve (A) so that the manometer shows
a pressure of 70 kPa (10.2 PSI). Close the cock
(B).
The pressure may not drop within two minutes for
the cooling system to be considered free from
leaks.
NOTICE! Repeat the pressure test if there is any

doubt about whether the cooling system leaks or
not.
5 Shut off the compressed air after pressure test-
ing.
P0006859
Release excess pressure in the system by
unscrewing the valve on the reducing valve and
opening tap (B).
6 Remove the pressure testing device.
7 Check the coolant level in the expansion tank.
Install the regular filler cap.
Start the engine and check that no leaks are
present.
47705020 05-2015 © AB VOLVO PENTA 49

8 Start the engine. Check that no leakage occurs.
Alternative 2:
Tools:
9996049 Draining hose
1 Check that all hoses and clamps are undamaged
and intact.
3 Connect 9996662 Pressure testing kit to
9996049 Draining hose and close the cock. Con-
nect 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 For the cooling system to be considered free from
leaks, pressure may not drop during a two-
minute test period.
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 pres-
sure 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.
50 47705020 05-2015 © AB VOLVO PENTA

Alternative 3:
Tools:
and intact.
a suitable cover from 3849613 Pressure testing
kit.
4 Connect the pump and pump up a pressure of 70
kPa (0.7 bar).
5 For the cooling system to be considered free from
leaks, pressure may not drop during a two-
minute test period.
6 Release the excess pressure and remove the
pressure testing unit.
7 Check the coolant level in the expansion tank. Fit
P0010195
the regular filler cap.
47705020 05-2015 © AB VOLVO PENTA 51

Cylinder Head, Pressure Testing

Tools:
9996239 Lifting tool
9986485 Stand
9990160 Fixture
9990107 Connection washer
9990164 Fixture
Checking the pressure test unit

Check pressure testing device 9990123 Pressure test-
ing kit before it is taken into service:
1 Connect the pressure testing device to the com-
pressed air mains.
2 Set the pressure gauge to 100 kPa (14.5 PSI)
using the reducing valve. The knob can be locked
with a retainer ring moved axially.
P0006858
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 reducing valve and
open the tap.
P0007006
52 47705020 05-2015 © AB VOLVO PENTA

Pressure Testing
Cylinder head removed.
For all lifts of the cylinder head use 2 lifting chains, tool
9996239 Lifting tool; refer to 21-1, Cylinder Head,
Removal.
1 Wash the cylinder head in a washing bath.
2 Fit the cylinder head to an assembly stand, tool
9986485 Stand with the aid of 9990160 Fixture
and 4 bolts, M8 x 25.
3 Clean the mating surfaces on the cylinder head.
4 Fit seal plates, tool 9990164 Fixture to the cylin-
der head using the cylinder head bolts and M18
nuts (14 pcs. required).
5 Fit connection washer, tool 9990107 Connection
washer onto the thermostat housing seat. Secure
the washer with a G-clamp; see illustration.
P0007007 Leave the side cover in place.
6 Leave the temperature sensor in place.
Plug any coolant connections for the compressor.
7 Connect the pressure gauge hose to connection
washer, tool 9990107 Connection washer.
8 Remove the cylinder head including fixture from
the assembly stand.
Remove the fixture.
9 Put the cylinder head in a water bath, +70 °C
(+158 °F).
10 Connect air to the pressure testing unit.
Open the shut-off valve.
11 Adjust the reducing valve knob so that pressure
gauge shows a pressure of 50 kPa (7.25 psi).
Maintain the pressure for 1 minute.
12 Raise the pressure to 150 kPa (21.76 PSI). Lock
P0007008 the reducing valve knob with the retainer ring.
Close the shut-off valve.
13 After 1 to 2 minutes, check whether the pressure
has dropped, or if bubbles of air can be seen in
the water bath.
If bubbles are visible, check seal plates and
inspect the cylinder head for any cracks.
14 Unscrew the knob on the reducing valve to relieve
the pressure in the cylinder head, and open the
tap.
15 Take the cylinder head out of the water bath.
Attach the fixture.
Secure the cylinder head in the assembly stand.
47705020 05-2015 © AB VOLVO PENTA 53

16 Blow the cylinder head dry. Be extra thorough

with the fuel channels.
IMPORTANT!
Make sure no dirt gets into the fuel channels, as
this may cause damage to the unit injectors.
17 Remove all the sealing washers and any plugs
installed for the pressure testing.
18 Remove the cylinder head including fixture from
the assembly stand.
Remove the fixture.
P0006858
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21-0 Engine Complete, General
Fitting the Fixture

Engine Fixture, Installation
IMPORTANT!
Turn off the main switch before any work is carried out.
IMPORTANT!
Working with the fuel system requests special cleanli-
ness.
NOTICE! Be prepared to gather up fluid.
P0020666
1 Remove the fuel lines (1) from the cooling loop.

Plug all fuel unions.
2 Remove the engine control unit (2) with cooling
loop; refer to Control Unit, Replace page 212.
3 Disconnect the harness from the starter motor
and sensor (the rear harness). Remove the
holder (3) for the relay and stop button.
4 Undo the fuel unions (4) to the feed pump; refer
to Fuel Feed Pump, Change page 197.
47705020 05-2015 © AB VOLVO PENTA 55

Remove the servo pipe from the power steering

pump.
5 Remove the fuel filter housing (5); refer to Fuel
filter housing, change page 193.
Remove the fuel hose and the engine block
attachment.
6 Remove the separator/crankcase ventilation (6).
P0009967
7 Remove the compressor (7) according to Com-

pressor, Change.
8 Remove the oil line to the separator turbine.
P0020667
9 Fit 88800146 Fixture and 88800345 Adapter

10 Install the engine with the fixture on the assembly
stand.
P0020668
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Engine Disassembly
Lube Oil Pump, Removal
1 Remove the oil pump; refer to Lubrication Oil
Pump, Change page 165.
P0010153
47705020 05-2015 © AB VOLVO PENTA 57

Pistons, Removal
Tools:
885822 Magnetic pen
1 Remove the carbon uppermost in the cylinder
bore.
Make sure the press tool cannot touch the pistons
when the pistons are removed.
9996966
P0010048
2 Remove the piston cooling nozzles with the aid of

885822 Magnetic pen.
P0010126
3 Check that the connecting rods are marked; mark

the position if more than one is removed from the
engine.
P0010127
58 47705020 05-2015 © AB VOLVO PENTA

4 Undo the connecting rod bolts a couple of turns.

Tap the bolt heads so that the bearing cap is freed
from the connecting rod.
1
P0010128
5 Remove the bolts entirely. Hold the connecting

rod in place and lift the bearing cap away at the
same time. Take care of the bearing cup if it does
not stay in place in the cap.
P0010129
6 Press out the piston with the connecting rod and

catch it under the engine. Make sure it does not
fall out and become damaged.
The connecting rod separation plane surface is
very sensitive and must not be exposed to impact
or knocks.
P0010130
47705020 05-2015 © AB VOLVO PENTA 59

7 Replace the bearing cap on the connecting rod

immediately to protect the separation plane sur-
faces.
8 Remove the remaining pistons the same way.
P0010131
9 Remove one retainer ring for the piston pin and

press the pin out.
P0010132
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10 Inspect the connecting rod; refer to Connecting

Rod, Check page 105.
P0010133
Cylinder Liners, Removal

Tools:
9996394 Support
9996395 Support
9996645 Puller
88800218 Extractor plate
1 Turn the engine so that the crankshaft is at the
bottom.
2 Remove the press tool holding the liner to be
removed.
P0010134
47705020 05-2015 © AB VOLVO PENTA 61

3 Assemble 88800218 Extractor plate together with

9996645 Puller and 9996394 Support.
P0021024
4 Insert the tools in the liner to be removed. Make

sure the plate ends up directly under the liner.
Screw down on the nut so that the liner is drawn
up.
Pull the cylinder liner out of the block.
P0010136
5 If the liner does not come free when it has

reached the puller, release the nut sufficiently to
allow installation of spacer 9996395 Support.
Continue to pull the liner up until it is free.
Lift out the liner with the tool and then remove the
9996395 tool from the liner. Remove the remaining liners
in the same way.
Inspect the liners; refer to Cylinder Liner and Pis-
tons, Inspection page 104.
P0010137
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6 Remove the liner O-rings from the engine block.

Check the O-ring grooves for corrosion or any
other damage.
P0010138
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Crankshaft, Removal
Tools:
9990114 Puller
9990013 Slide hammer
1 Remove the crankshaft belt pulleys; refer to 26-2,
Drive Belts, 32-1, Alternator Belt, Change.
2 Remove the crankshaft seal holder.
P0010156
3 Remove the main bearing cap bolts.

Use 9990114 Puller together with 9990013 Slide
hammer to rock the main bearing caps loose.
Keep the main bearing halves safe.
4 Remove the front engine mounts if they were not
removed earlier.
Attach a suitable lifting strap to the front and rear
end of the crankshaft according to the following
steps.
P0010165
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5 Crank the crankshaft so that the timing mark ends

up exactly as illustrated. The crankshaft can only
be removed in this position.
Insert a bolt in the top hole in the timing gear.
P0010167
6 In the same manner, insert a bolt into the other

end of the shaft and attach the lifting strap.
P0010168
7 Lift the crankshaft and make sure that the con-

necting rods and main bearing cups do not come
out with the crankshaft.
P0010169
47705020 05-2015 © AB VOLVO PENTA 65

8 Remove the thrust washers.

Remove the main bearing cups and wipe the
bearing seats dry. Fit new bearings.
Make sure the tabs fit into the notch in the bearing
seat and that the oil holes correspond to each
other.
Oil the bearings with engine oil.
P0010170
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Engine Assembly
Crankshaft, Installation
Tools:
885811 Timing tool
885633 Torque multiplier
885648 Counterhold
9999696 Magnetic stand
9989876 Dial indicator
9998511 Lever
1 Inspect the crankshaft; refer to Crankshaft,
Inspection page 158.
2 Check that the crankshaft is clean, that all bearing
surfaces are fault free and that the oil channels
are open. Install the crankshaft gear with a new
O-ring. Suspend the crankshaft in a lifting strap;
refer to Crankshaft, Removal page 64.
Lubricate all bearing surfaces with engine oil.
3 Lower the crankshaft carefully into position. Align
the gearwheel markings with each other.
IMPORTANT!
Make sure that no connecting rod ends up in the
wrong position. The connecting rod separation
planes are very sensitive.
P0010167
4 When the crankshaft has been lowered onto the

main bearings, check that they are still correctly
positioned.
Install the thrust washers so that the locator tabs
end up in the intended notches.
P0010171
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5 Wipe the main bearing caps dry and install new

bearings. Lubricate the bearing surfaces with
engine oil.
Install the thrust washers on the center main
bearing cap (fit the locator tab into the notch). The
center cap has a groove that must fit against a
locator tab in the engine block.
P0010172
6 Install the cap according to the marking. Use the

bolts to guide the caps straight. Tighten the bolts
so that the caps are pulled down onto the engine
block.
Check that the crankshaft can be rotated.
Torque and angle tighten the main bearing cap
bolts using 885811 Timing tool, 885633 Torque
multiplier and 885648 Counterhold according to
03-2, Special Tightening Torques.
Check once more that the crankshaft can be
rotated
P0010173
7 Check crankshaft end float with the aid of

9999696 Magnetic stand and 9989876 Dial indi-
cator.
Use 9998511 Lever move the crankshaft back
and forth. Read off the value on the dial indicator
and compare to Group 21: Engine page 26.
8 Install new bearings in the connecting rods and
big end bearing caps and install all connecting
rods; refer to Pistons, Removal page 58.
Check that it is still possible to rotate the crank-
shaft
9 Install the piston cooling nozzles if they were
removed.
P0010174
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10 Remove the front crankshaft seal from the cover.

Clean the cover and engine block where the
cover is to be installed.
Apply sealant to the cover; refer to 03-2, Special
Tightening Torques.
Install the cover and tighten the bolts in
sequence; refer to 03-2, Special Tightening Tor-
ques.
11 Install a new crankshaft seal and belt pulley; refer
to Crankshaft Seal, Change (front) page 154.
P0005229
4 5
6
3
2 7
1 8
P0005230
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Cylinder Liner, Installation

Tools:
9990157 Press tool
9992479 Holder for dial indicator
9996966 Press tool
9998511 Lever
88800083 Piston ring pliers
88800218 Extractor plate
88800318 Piston ring compressor
1 Inspect the engine block liner seat for damage. If
the liner seat is damaged it must be repaired.
P0010139
2 Install the liner without O-rings and press the liner

down using two 9996966 Press tool.
P0010134
70 47705020 05-2015 © AB VOLVO PENTA

3 Fit 9989876 Dial indicator onto 9992479 Holder

for dial indicator.
Place the holder with dial gauge across the cyl-
inder liner.
Zero the dial indicator with a couple of millimeters'
pre-load to the engine block plane.
4 Measure the height between the liner and the cyl-
inder block plane. Measure the height of the liner
in two places, diagonal to each other.
Calculate the average of the two measurements.
For correct liner height above the block plane,
refer to specifications in 03-21, Engine body. If
the liner height is outside specified tolerances,
the liner seat must be repaired (milled).
Always measure the highest point on the liner
sealing surface. Mark the liner's position with a
felt pen in order to re-install it in the exact same
position.
5 Remove 9996966 Press tool and pull out the liner.

Lay out the cylinder liners in the same sequence
that they were installed, together with any adjust-
ing spacers.
Clean the O-ring grooves in the engine block.
P0010140
Lubrication and location of O-rings

6 NOTICE! The purple seal ring must seat in the
lowest groove
Lubricate new O-rings and insert them in the

grooves in the engine block; black uppermost,
then purple in the lower groove. Use the oil sup-
plied.
Install the O-ring on the cylinder liner.
Oil the lower part of the cylinder liner with the
lubricating oil supplied.
P0006966
47705020 05-2015 © AB VOLVO PENTA 71

Without spacers
7 IMPORTANT!
Do not put sealing compound around the entire
liner; leave a 2 mm (0.08") gap.
When the cylinder liner is fitted without spacers,

an even bead of about 0.8 mm (0.03") of sealing
compound must be applied to the underside of
the cylinder liner collar.
With spacers
8 IMPORTANT!
Sealant must not be used between the spacers
and the cylinder liner collar.
If the liner is installed with spacers, apply the

sealant bead to the cylinder block liner seat.
NOTICE! After applying 1161231 Sealant, the

liner must be installed within 5 minutes.
P0006918
9 If the cylinder head cannot be installed and tor-

qued within 5 minutes, the liner must be held to
the engine block with two 9990157 Press tool.
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).
72 47705020 05-2015 © AB VOLVO PENTA

10 Lubricate the piston pin, piston bush and the pis-

ton bearing seat with engine oil.
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 in the piston pin. 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.
P0006921
11 Install the piston rings. Use 88800083 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 control ring is symmetrical and
can face either way.
P0006968
12 Lubricate the piston and piston rings with engine

oil.
Check that the piston ring openings are stag-
gered 120° in relation to each other.
NOTICE! Connecting rods must be installed in

their original positions. The arrow on the piston
and the “FRONT” marking on the connecting rod
must face forwards. Use 88800318 Piston ring
compressor.
P0006923
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Pistons, Installation
Tools:
88800318 Piston ring compressor
9996966 Press tool
1 Rotate the crankshaft so that the big end journal
for the piston to be installed ends up as low as
possible.
Remove the two press tools for the liner where
the piston is to be installed.
2 Lubricate the bearing shells and bearing journals
with engine oil.
3 Lift the piston into place with 88800318 Piston
ring compressor and the connecting rod (big end
bearing lubricated). Make sure the piston is facing
the right direction (so that the connecting rod is in
the right position on the crankshaft).
Tap down the piston with a hammer shaft.
Remove the piston ring clamp when the piston is
below it.
Re-install 9996966 Press tool for the cylinder
liner.
Press down the piston so that the connecting rod
touches the crankshaft.
Install the big end bearing cap and align it pre-
cisely with the crankshaft (big end bearing oiled).
P0010146
Install the bolts.
Torque the bolts and check that the crankshaft
can be rotated.
4 Install the remaining pistons the same way.
5 Clean the piston cooling nozzles and check that
they are not damaged. Install the nozzles using
new bolts.
Check that the nozzles are aimed directly at the
piston oil cooling hole.
P0010126
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Lube Oil Pump, Installation

1 Install the oil pump, reinforcing plate, pipe and
suction strainer; refer to Lubrication Oil Pump,
Change page 165.
P0010153
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21-1 Cylinder Head
21-1 Cylinder Head

Cylinder Head, Removal
Tools:
885822 Magnetic pen
9990006 Puller
9996966 Press tool
9998249 Protective sleeve
9998251 Protection plug
9998674 Adapter
88800014 Rotation tool
IMPORTANT!
ness.
IMPORTANT!
Clean thoroughly before removal.
IMPORTANT!
Install safety plugs in open connections.
1 Switch off main power.
2 Drain the coolant according to Coolant,
Change page 283.
3 Remove the turbocharger according to Turbo,
Change page 233.
4 Drain the fuel duct according to Draining, Fuel
Duct in Cylinder Head page 186.
5 1 Remove the clamp on the charge air pipe
on the charge air cooler.
2 Remove the e-EGR mixing chamber; refer
to EGR mixing chamber,
change page 230.
3 Remove the e-EGR pipe from the mixing
chamber; refer to Control valve e-EGR,
change page 225.
P0020987
6 Unscrew the electrical connection from the pre-

heater element.
Remove the pre-heater element from the inlet
manifold.
76 47705020 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
7 Undo / remove:
- Cable ties.
1 Hose union for the PWM valve.
2 Crankcase pressure sensor electrical con-
nector
3 Crankcase ventilation connection from the
valve cover.
4 Charge air pressure sensor from the inlet
manifold.
5 The pipe (closed crankcase ventilation)
6 Pre-heater element relay.
P0020988
8 Remove the bolts to the harness channel conduit

below the inlet manifold.
Remove the center section of the harness chan-
nel.
P0020989
9 Undo / remove:
1 The pressure drop indicator connector.
2 The flywheel sensor connector.
3 The air cleaner with attachment plate.
P0020990
47705020 05-2015 © AB VOLVO PENTA 77

21-1 Cylinder Head
10 Remove the coolant connections to the compres-

sor.
P0020991
11 Drain the fuel duct according to Draining, Fuel

Duct in Cylinder Head page 186.
12 Remove the IN/OUT fuel connections on the cyl-
inder head.
P0020996
13 Remove the inlet manifold.

14 Undo / remove:
1 The EGR valve harness terminal.
2 Coolant pipe, expansion tank.
3 Hose union, engine heater (option).
4 Hose union, expansion tank.
5 Connection pipe
6 Thermostat cover and thermostat; refer to
Thermostat, Change page 287.
7 Lifting eye
P0020992
78 47705020 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
15 Undo / remove:
1 Oil pipe and return pipe; refer to Control
valve e-EGR, change page 225.
2 Exhaust manifold; refer to Exhaust Mani-
fold, Change page 215.
3 Harness terminal and camshaft sensor.
P0020993
16 Remove the valve cover; refer to Valve cover,

change page 101.
17 Disconnect the injector connectors.
Cut off cable ties and remove the cable harness
from the cable holder.
Remove the cable holders.
Remove the center piece for lubrication of the
rocker arm bridge, together with the delivery pipe.
NOTICE! Make sure the seal under the center

piece does not fall into the timing gear cover.
P0020994
18 Remove the harness bush and carefully pull the

harness out through the cylinder head.
P0020995
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21-1 Cylinder Head
19 Crank the engine in its direction of rotation.

Use 88800014 Rotation tool.
P0020125
20 Crank the engine to camshaft TDC and check that

the mark on the flywheel is at zero.
P0020997
21 Remove the upper timing gear cover.
P0020998
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21-1 Cylinder Head
22 Remove the upper timing gear casing and

remove the rubber seals.
P0012728
23 Remove the camshaft gear and vibration damper

bolts.
Remove the vibration damper.
IMPORTANT!
Make sure the vibration damper is protected from
impact and shocks.
Remove the camshaft gear.
P0012729
24 Remove the rocker bridge bolts alternately to

avoid uneven load.
P0020999
47705020 05-2015 © AB VOLVO PENTA 81

21-1 Cylinder Head
25 NOTICE! Make sure the pistons in the exhaust

rocker arms and the adjuster screw ball do not fall
out when the rocker arm bridge is lifted.
Install 9990185 Lifting tool and adjust the rocker

arm holders. This is done to keep the rocker arms
for each cylinder together. Use the higher hold-
ers.
Lift the rocker arm bridge away.
P0004965
26 Mark and then remove the valve yokes.
6
5
4
3
P0010035 2
27 Remove the camshaft cap bolts.

Check that the caps are marked.
P0010038
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21-1 Cylinder Head
28 Use 9996400 Slide hammer and

9998674 Adapter to rock the caps loose.
999 6400
999 8674
P0010039
29 Use 9998264 Lifting tool to lift the camshaft.
CAUTION!
999 8264 Cutting hazard! Protect your hands!
Remove the unit injector bolts.
P0010040
P0010040
30 Rock a unit injector loose using 9990006 Puller

9990013 and 9990013 Slide hammer.
Check that the seal washer (steel washer) comes
out with the injector. If it is still in the copper
sleeve, remove it using 885822 Magnetic pen.
9990006 NOTICE! The seal washer must always be

replaced when installing an injector.
P0001370
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21-1 Cylinder Head
31 Insert the injector into 9998249 Protective

sleeve.
999 8249
P0010041
32 Insert 9998251 Protection plug into the cylinder

head.
999 8251
Remove the remaining injectors the same way.
P0010042
33 Crank the engine and remove the two bolts (1)

through the timing gear wheel.
Remove the bolts (2) holding the intermediate
plate against the cylinder head.
Remove the three upper bolts (3) from the timing
gear hub.
P0006893
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21-1 Cylinder Head
34 Remove the cylinder head bolts.
P0010046
35 Wipe away engine oil that has collected in cavities

underneath the camshaft to prevent oil from run-
ning down into the coolant duct when the cylinder
head is lifted away.
36 Fit two 9996239 Lifting tool to the cylinder head
and lift it away.
999 6239 NOTICE! Because of the timing gear sealant, it
may be necessary to carefully prise the cylinder
head free.
Lower the cylinder head onto a clean surface.
IMPORTANT!
The sealing surface must not be damaged.
P0010047
37 Remove the cylinder head gasket.

Fit 9996966 Press tool to keep the liners in place.
Make sure the press tools are not able to damage
the pistons if these must be removed.
9996966
P0010048
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21-1 Cylinder Head
Cylinder Head, Installation

Tools:
885810 Fixture
9990156 Adapter
9996966 Press tool
9998601 Fixture
9999683 Dial indicator (short probe)
1 Clean the cylinder head carefully both internally
and externally before fitting.
NOTICE! Dirt particles may cause the unit injec-

tors to fail. Clean the unit injector copper sleeves.
Refer to Sleeve for unit injector,
replace page 205.
Install the protective plugs immediately after

cleaning.
Clean the cylinder head and the engine block
sealing surfaces and cut away excess sealant.
2 Remove 9996966 Press tool holding the cylinder
liners in place.
9996966
P0010048
3 Immerse the cylinder head bolts fully in rustproof-

ing agent.
Place the bolts on a net to let the excess drip off.
P0006938
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21-1 Cylinder Head
4 Apply a 2 mm (0.787") bead of sealant to the back

of the cylinder head.
NOTICE! The cylinder head bolts must be tor-

qued within 20 minutes of sealant application.
P0006939
5 Fit a new cylinder head gasket.
6 Lower the cylinder head until it rests on the cylin-

der head gasket.
Maintain a distance to the transmission plate of
5-10 mm (0.197-0.394"). Locating pins make sure
the cylinder head aligns with the engine block.
Slide the cylinder head toward the transmission
plate.
P0006940
47705020 05-2015 © AB VOLVO PENTA 87

21-1 Cylinder Head
7 Screw a bolt in the upper intermediate gear hub

(1) into the cylinder head in order to pull the cyl-
inder head towards the timing gear plate.
Screw in five M8 screws in the transmission plate
(2).
Torque the bolts (1) and (2) as specified in Tight-
ening Schedules page 15.
Undo all bolts (1) and (2) about one turn.
NOTICE! The cylinder head is now in the correct

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.
P0006941
8 Install the cylinder head bolts and torque accord-

ing to the specifications in Tightening Sched-
ules page 15.
Use a torque multiplier for angle tightening.
9 Torque the five M8 bolts in the transmission plate

(2) according to the specifications in Tightening
Schedules page 15.
Crank the engine so that the two M8 bolts (1) can
be installed through the upper intermediate gear.
Tighten according to the specifications in Tight-
Install the remaining two M10 bolts (3) into the
upper intermediate gear, without tightening.
P0006893
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21-1 Cylinder Head
10 Clean the surface of sealant as illustrated.
NOTICE! Cut away the sealant.
P0006942
Camshaft, Installation
11 Inspect the camshaft for wear. Refer to Camshaft,
Wear Check page 148.
12 Clean the surfaces on the bearing blocks and cyl-
inder head.
Install the camshaft bearing brackets as marked
on the cylinder head and make sure they abut the
cylinder head. # 7 by the timing gear.
Place the bearing shells in the bearing blocks and
lubricate the bearing shells with engine oil.
13 Crank the engine using 88800014 Rotation tool
so that the flywheel is set exactly to zero accord-
ing to the marking on the flywheel housing.
P0020125
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21-1 Cylinder Head
14 Check that the cam bearings are fault free and

correctly installed in the caps.
Use 9998264 Lifting tool to lift the camshaft into
999 8264 position.
CAUTION!
Cutting hazard! Protect your hands!
P0010040
P0010040
15 Rotate the camshaft so that the guide hole faces

straight up.
Install the caps according to the markings.
Install M10X80 bolts instead of the rocker arm
bridge.
Tighten the bearing caps according to Tightening
Schedules page 15
Check that the camshaft can be rotated.
P0010052
16 The camshaft TDC mark must be centered

between the marks on the bearing block.
P0020997
90 47705020 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
17 IMPORTANT!
Tighten the bolts in stages to ensure that the
rocker arm shaft bottoms against the bearing
housing without bending the shaft.
NOTICE! Use a suitable spacer on the rocker arm

side.
Oil the bearing shells and install thrust bearing

caps on the respective bearing blocks. Use a suit-
able spacer on the rocker arm side.
- Torque bolts 1-7 according to step 1 in
Tightening Schedules page 15.
- Torque bolts 9, 11 and 13 according to step
2 in Tightening Schedules page 15.
P0021000
18 Install the camshaft drive without the vibration

damper; use nuts for spacers.
Place the gear so that the reference hole in the
timing gear plate is between the gear markings.
If necessary, remove the bolts on the upper inter-
mediate gear.
Temporarily tighten two bolts with low torque,
max 10 Nm (7.38 lbf. ft.).
P0010053
Flank Clearance, Checking

9999683 19 IMPORTANT!
It is important to check gear lash in order to pre-
vent serious engine problems.
Use 9999696 Magnetic stand and 9999683 Dial

9999696 indicator (short probe) to check gear lash.
Hold the intermediate gear secure and turn the
camshaft gear back and forth to check that gear
lash is within specified limits; refer to Group 21:
Engine page 26.
If gear lash is correct, tighten the intermediate
gear bolts according to step 2 in Tightening
Schedules page 15.
Remove the bolts and spacers from the camshaft
gear. Install the inlet manifold and tighten accord-
ing to the specifications in Tightening Sched-
P0010055
ules page 15.
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21-1 Cylinder Head
Flank Clearance, Adjustment

20 Loosen the bolts (1) in the upper intermediate
gear.
Check that the upper bolts are not tightened.
P0006946
21 Place a 0.1 mm (0.00394") feeler gauge on the

pressure side.
Turn the camshaft gear against the feeler gauge.
Torque the upper intermediate gear according to
step 1 in Tightening Schedules page 15.
Remove the feeler gauge.
P0006947
22 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 with gear lash specifications; refer
to Group 21: Engine page 26
If gear lash is correct, torque the upper intermedi-

ate gear (1) bolts according to step 2 in Tightening
Schedules page 15.

gear. Fit the vibration damper and torque accord-
ing to specifications in Tightening Sched-
ules page 15.
P0006948
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21-1 Cylinder Head
23 Apply a 2 mm (0.08") bead of 1161231 Sealant to

the upper timing gear cover contact surface, as
illustrated.
P0013011
24 Fit new rubber seals and install the upper timing

gear casing.
P0006949
25 Only fit the bolts (1) and tighten by hand.
NOTICE! The holes are oblong to allow the cover

to be pressed down against the rubber seal.
P0006950
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21-1 Cylinder Head
26 Press the cover down using 885810 Fixture and

88510 9998601 Fixture so that the cylinder head and the
upper timing gear cover sealing surfaces are
aligned.
Fit the remaining bolts (2). Tighten according to
the specifications in Tightening Sched-
ules page 15.
NOTICE! The timing gear casing must be instal-

led and torqued within 20 minutes of sealant
application.
P0012751
9998601
P0012752
27 Install the camshaft sensor and adjust it accord-

ing to Sensors, Adjustment page 152
Unit injector, Installation

28 NOTICE! Install one injector at a time.
Remove 9998251 Protection plug with

9990156 Adapter and 9996400 Slide hammer.
Fit new seal rings to the unit injectors. Lubricate
the rings with diesel oil.
Install the injector and fixing yoke. Center the
injector so that it does not touch the valve springs.
Tighten according to Tightening torques page 9.
P0006890
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21-1 Cylinder Head
29 Reinstall the valve yokes in their original posi-

tions.
NOTICE! Make sure that the yokes are directly

above the valve stems.
Lubricate valve yokes and camshaft.

Remove the temporary bolts and spacers on the
camshaft cap.
P0006953
30 Install the rocker arm bridge using a hoist. Make

sure that the guide pins fit into the rocker arm
shaft.
Guide all rocker arms so that they end up in the
correct positions. Make sure that the exhaust
rocker arm pistons and the adjuster screw balls
are in place.
Remove the lifting tool from the rocker arm

bridge. Install the rocker arm shaft bolts.
Check that the valve yokes are positioned cor-
P0004965
rectly on the valve stem. Tighten the bolts alter-
nately so that the rocker arm shaft is not bent.
Make sure the shaft locates on the bearing cap
guide sleeves.
Torque the bolts alternately along the rocker arm

shaft as specified in Tightening Sched-
ules page 15.
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21-1 Cylinder Head
31 Slide new O-rings over the oil supply pipe to the

rocker arm bridge.
Insert the pipe in the center piece and install the
center piece and pipe.
Check that the O-rings on the pipe and the ring
under the center piece are correctly aligned.
P0006883
32 Adjust the valves and unit injectors; refer to

Valves and Unit Injectors, Adjustment page 106.
33 Fit the cable holders.
Pull the cable harness through the cylinder head
to the unit injectors and connect them. Fasten the
harness in the cable holder using oil and heat-
resistant cable ties.
Bolt the center piece in place.
P0020994
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21-1 Cylinder Head
34 Bolt the harness bush place.
P0020995
35 Install the valve cover: Refer to Valve cover,

change page 101.
36 Install the exhaust manifold (1); refer to Exhaust
Manifold, Change page 215.
Install the oil pipe and return pipe (2); refer to
Control valve e-EGR, change page 225.
P0021013
37 Install:
1 Connection pipe
2 Hose union, expansion tank.
3 Hose union, engine heater (option).
4 The EGR valve harness terminal.
5 Thermostat cover and thermostat; refer to
Thermostat, Change page 287.
6 Coolant pipe, expansion tank.
7 Lifting eye.
P0021012
38 Install the inlet manifold; refer to Intake Manifold,

Change page 218.
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21-1 Cylinder Head
39 Install the IN/OUT fuel connections on the cylin-

der head.
P0020996
40 Install the coolant connections to the compressor.
P0020991
41 Install the bolts to the harness channel conduit

below the inlet manifold.
Install the center section of the harness channel.
P0020989
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21-1 Cylinder Head
42 Install:
1 Hose union for the PWM valve.
2 Crankcase pressure sensor electrical con-
nector
3 Crankcase ventilation connection from the
valve cover.
4 Charge air pressure sensor from the inlet
manifold.
5 The pipe (closed crankcase ventilation)
6 Pre-heater element relay.
• Cable ties.
P0021009
43 Install:
P0021010
44 Install the electrical connection to the pre-heater

element.
Install the pre-heater element from the inlet mani-
fold.
45 Install the e-EGR mixing chamber (1); refer to
EGR mixing chamber, change page 230.
Install the e-EGR pipe (2) from the mixing cham-
ber; refer to Control valve e-EGR,
change page 225.
Fit the clamp on the charge air pipe (3) on the
charge air cooler.
P0021011
46 Install the turbocharger according to Turbo,

Change page 233.
47 Check engine oil level; fill as necessary.
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21-1 Cylinder Head
48 Fill with coolant according to Coolant Level,

Checking and Topping Up page 279.
49 Start the engine and check for leaks; let the
engine run until it reaches normal working tem-
perature.
Let it run an additional 5-10 minutes at idle.
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21-1 Cylinder Head
Valve cover, change

Removal
1 Remove the crankcase ventilation connection
from the valve cover.
Disconnect the crankcase pressure sensor.
P0020178
2 Remove the valve cover with gasket.
P0020179
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21-1 Cylinder Head
Installation
3 1 Remove the gasket.
2 Clean along the gasket groove.
3 Check whether the valve cover gasket
needs to be changed. Clean the gasket.
4 Clean the sealing surfaces.
5 Fit the gasket.
P0020180
NOTICE! Remove any sealant from the joint

between the cylinder head and the upper timing
gear cover.
P0020181
5 NOTICE! The components must be installed

within the specified time after the application of
sealant.
Apply an even, 2 mm bead of sealant along the

mating surface between the upper timing gear
cover and the cylinder head.
The valve cover must be installed within 20

minutes of sealant application.
P0020182
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21-1 Cylinder Head
6 Install the cover, tighten the bolts in sequence

and torque them.
P0020183
7 Tighten the bolts in sequence, as illustrated:

P0020184
8 Install the crankcase ventilation connection on

the valve cover.
Connect the crankcase pressure sensor electrical
connector.
P0020178
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21-3 Cylinder Liner, Pistons

Cylinder Liner and Pistons,
Inspection
Clean the cylinder liners carefully before inspec-
tion 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 indi-

cator. 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 cyl-
inder 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 com-
plete 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 col-
lars.
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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Connecting Rod, Check

Important consideration when removing/installing
fracture-split connecting rods.
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 split line can be difficult to find when the connect-

ing rod is assembled.
When the cap is separated from the connecting rod, it

may occur that a chip is missing or comes loose. This
does not affect the function of the connecting rod
adversely.
Handle the connecting rod and bearing cap carefully.

If any strike marks occur on the split line, this may
affect strength after torquing.
IMPORTANT!
If the connecting rod or bearing cap are damaged,
change the connecting rod.
Connecting Rod Bushing, Check up

1 Check the connecting rods for cracking, straight-
ness and twist before any piston pin bush
replacement. Scrap the connecting rod if it is
cracked, bent or twisted.
When the piston pin bush is changed, the bush
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.
3 IMPORTANT!
2 Regarding max. allowed straightness and twist devia-
tions, refer to Group 21: Engine page 26.
P0006994 P0006995
2 Use a new piston pin and measure the straight-

ness of the connecting rod, using a fixture.
3 Measure connecting rod twist.
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21-4 Valve Mechanism

Valves and Unit Injectors,
Adjustment
There are two types of valve mechanisms:
- Standard valve mechanism page 107.
- Valve mechanism equipped with VCB (Volvo Com-
pression Brake) page 110.
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Standard valve mechanism

Tools:
1 Remove the valve cover; refer to Valve cover,
change page 101.
2 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 marked on

the camshaft is centered between the marks on
the bearing cap when adjustment is carried out.
P0020124
Valves and Unit Injectors, Adjustment

3 Crank the engine in the direction of rotation to the
next camshaft marking. Use 88800014 Rotation
tool.
P0020125
47705020 05-2015 © AB VOLVO PENTA 107

4 Adjust valves and injectors for each cylinder

together.
P0020126
5 NOTICE! Adjust the screw on the inlet valve and

exhaust valve until the feeler gauge can be
moved with a degree of resistance.
6 Adjust inlet valve clearance between the rocker
arm and the valve yoke to 0.2 mm (0.0079") with
the aid of a feeler gauge.
Tighten according to the specifications in 03-2,
Special Tightening Torques.
Check the valve clearance. Mark the rocker arm
once the valve is adjusted.
Adjust the clearance for the exhaust valve and
unit injector.
P0020127
7 Check the valve clearance for the exhaust valves

with the aid of a feeler gauge. Adjust as neces-
sary. The clearance must be 0.8 mm (0.0315”).
Tighten the locking nut.
P0020128
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8 Adjust the unit injector preload by loosening the

adjuster screw until a clearance is obtained on the
injector.
Adjust the screw until the clearance disappears
(by feel until the roller can no longer be rotated).
Tighten the adjuster screw a further 240° (4 flats).
9 Tighten the adjuster screw locking nut as per
specifications in 03-2, Special Tightening Tor-
ques.
P0020129
10 Adjust the remaining valves and unit injectors as

described above.
11 Remove 88800014 Rotation tool from the gear
ring.
Install the valve cover according to Valve cover,
change page 101.
47705020 05-2015 © AB VOLVO PENTA 109

Valve mechanism equipped with

VCB (Volvo Compression Brake)
Tools:
1 Remove the valve cover.
2 Timing marks
NOTICE! Marks 1–6 apply to inlet valve and unit

injector adjustments.
The marks V1-V6 apply to exhaust valve adjust-
ment.
It is important that the line marked on the cam-

shaft is centered between the marks on the bear-
ing cap when adjustment is carried out.
P0020168
Valves and Unit Injectors, Adjustment

3 Crank the engine in the direction of rotation to the
next camshaft marking. Use 88800014 Rotation
tool.
P0020125
110 47705020 05-2015 © AB VOLVO PENTA

4 In this case, camshaft position indicates adjust-

ment of: 1 = Inlet and injector rocker arm, cyl-
inder 1.
Adjust the inlet valves and injectors for for each

cylinder together.
P0020169
5 Adjust inlet valve clearance between the valve

yoke and the rocker arm thrust sleeve valve yoke
to 0.2 mm (0.0079") with the aid of a feeler gauge.
Refer to the Valve mechanism section in Group
21: Engine page 26.
Tighten according to the specifications in 03-2,

Check the valve clearance. Mark the rocker arm

once the valve is adjusted.
P0020170
6 Adjust the unit injector preload by loosening the

adjuster screw until a clearance is obtained on the
injector.
Adjust the screw until the clearance disappears
(by feel until the roller can no longer be rotated).
Tighten the adjuster screw a further 240° (4 flats).
Tighten the adjuster screw locking nut as per

specifications in 03-2, Special Tightening Tor-
ques.
P0020171
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7 Crank the engine to the next camshaft marking

for adjusting the exhaust valves.
In this case, camshaft position indicates adjust-

ment of: V3 = Inlet and VCB rocker arm, cylin-
der 3.
P0020172
8 Press down on the rocker arm as illustrated.
NOTICE! If the rocker arm gives, pull on its piston

spring while the rocker arm is pressed down so
that it makes contact with the valve spindle.
NOTICE! Use a strong metal wire or hooked

screwdriver to pull on the spring.
P0020173
9 NOTICE! Only perform if the rocker arm gives.
NOTICE! Use a strong metal wire or hooked

screwdriver to pull on the spring.
P0020174
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10 Check the valve clearance for the exhaust valves

with the aid of a feeler gauge.
The clearance must be 1.6 mm (0.063”).
P0020175
11 IMPORTANT!
Make sure no loose parts fall into the camshaft
drive.
NOTICE! Use a wrench on the yoke as a coun-

terhold during removal.
If the shims must be replaced, undo the screw on

the yoke while holding the yoke fast with a wrench
so that the valves are not bent.
P0020176
12 Calculate the thickness of the new spacer.

Based on the measured value, calculate how
thick the new spacers must be.
A maximum of two spacers may be used.

If two spacers are used, they must have more or
less the same thickness.
NOTICE! Spacers are available with thicknesses

in 0.05 mm increments. The thickness is stamped
on the spacer.
P0020177
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13 Insert the spacer and tighten the locking nut as

per specifications in 03-2, Special Tightening Tor-
ques.
P0020176
14 Follow the same procedure on the remaining

valves and unit injectors.
15 Remove 88800014 Rotation tool from the gear
ring.
16 Install the valve cover according to Valve cover,
change page 101.
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Valve Guides, Inspection

Tools:
Cylinder head removed

Refer to removal in 21-1, Cylinder Head, Change.
1 Remove the valve stem seals from the valve
guides.
2
IMPORTANT!
The cylinder head must not be put down so its
entire weight rests on the valve guides (see illus-
tration).
Put the cylinder head on the bench with the valve
discs facing upwards.
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 tool 9989876 Dial indicator and tool
999 9696
9999696 Magnetic stand, so that the dial indicator
tip is touching the valve disc edge.
998 9876 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 measurement values exceed the values
noted in the specifications, the valve guide must
be changed; refer to Group 21: Engine page 26.
p0005207
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Valve Guides, Replacing

Cylinder head removed.
NOTICE! If the valve seats must also be changed, this

must be done before the valve guides are removed.
CAUTION!
Risk of eye injury. Eye protection required.
Option 1
Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990176 Press tool
9996159 Adapter
88800147 Drift
88800062 Drift
Optional tools
Tools:
9992670 Hand pump
Note: 9992670 is alternative to 9809726.
Removal
999 2670 980 9729 1 Install tool 9990176 Press tool into the cylinder
980 9726 head retaining bolt holes.
NOTICE! Put washers between the nuts and the

cylinder head plane.
999 0176 2 Tighten the nuts of the tool.
999 6159 3 Install tool 9996159 Adapter in the hydraulic cyl-
888 00147 inder.
4 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool and press out the valve guide
using tool 88800147 Drift and9809726 Pneu-
matic hydraulic pump , alternatively
9992670 Hand pump.
5 Press the other valve guides out in the same way.
p0003637
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Installation
6 Heat the cylinder head with hot water while cool-
ing the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
IMPORTANT!
Wear protective goggles when pressing.
999 2670 980 9729 7 Press in the valve guide for the inlet valve using
980 9726 tool 88800062 Drift. Press in the exhaust valve
guide using the same tool.
8 Press until the tool bottoms against the cylinder
head plane.
9 Remove the tool from the cylinder head.
999 0176
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
999 6159
Option 2
888 00062
p0011273
Tools:
9992000 Handle
88800147 Drift
88800062 Drift
NOTICE! If the valve seats must also be changed, this

must be done before the valve guides are removed.
CAUTION!
47705020 05-2015 © AB VOLVO PENTA 117

Removal
NOTICE! Take out the valve guides from beneath the
cylinder head.
1 Tap out the valve guides with tool 88800147 Drift

together with 9992000 Handle.
2 Tap the other valve guides out in the same way.
Installation
3 Heat the cylinder head with hot water while cool-
ing the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
CAUTION!
4 Tap in the valve guide for the inlet valve using tool
88800062 Drift. Tap in the exhaust valve guide
using the same tool.
5 Tap until the tool bottoms against the cylinder
999 2000 head plane.
6 Repeat the procedure for the remaining valve
guides.
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
P0011274 888 00062
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Valves, Removal
Work is made easier if the cylinder head is fixed in an

equipment stand using tool 9990160 Fixture. Use 4
pcs. bolts M8 x 25.
NOTICE! It is 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.
Alternative 1
Tools:
9809729 Hydraulic cylinder
P0006996 9990160 Fixture
9990174 Drift
9992670 Hand pump
9996159 Adapter
9998246 Drift
Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2
Tools:
9990210 Valve spring compressor
Alternative 1
1 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool.
2 Install tool 9996159 Adapter and tool
9998246 Drift (inlet) or tool 9990174 Drift (outlet)
on the hydraulic cylinder. Place the tool in the
holes for the cylinder head retaining bolts.
Tighten the tool nuts.
3 Connect tool 9809726 Pneumatic hydraulic pump
(alternatively 9992670 Hand pump).
4 Press the valve spring washer down and remove
the collets.
NOTICE! Check that the tool does not damage

the unit injector electrical connector, if the injector
is left in place.
NOTICE! Put the valves and springs in a marked

stand, to facilitate putting components back in the
same places in the cylinder head.
5 Remove the remaining valves in the same way as
above, using the press tool.
6 Remove the oil seals from the valve guides.
47705020 05-2015 © AB VOLVO PENTA 119

Alternative 2
Tools:
1 Lay the cylinder head on a flat, clean surface.
Make sure the cylinder head is not damaged
when the valves are to be removed.
2 Fit tool 9990210 Valve spring compressor in the
unit injector hole. Fix the tool in the bolt hole for
the unit injector yoke, M10 x 30.
3 Place the moving part of the tool over the valve
spring to be removed. Screw down the “wing nut”
on the tool until the valve washer has been
pressed down so far that the collets can be
removed.
NOTICE! Put the valves and springs in a marked

P0006997
stand, to facilitate putting 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.
120 47705020 05-2015 © AB VOLVO PENTA

Valves, Installation
Alternative 1
Tools:
88800011 Drift
9990174 Drift
9990176 Press tool
9992670 Hand pump
9996159 Adapter
9998246 Drift
Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2
Tools:
Alternative 1
1 Oil the valve stems and install the valves.
Oil the oil seals.
2 Install tool 88800011 Drift 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.
3 Install the valve caliper guide pins.
Install the springs and valve spring washers.
Carefully press down the valve spring washer and
install the collets. Use tool 9990176 Press tool
together with 9809726 Pneumatic hydraulic
pump , 9996159 Adapter and 9998246 Drift (inlet)
or 9990174 Drift (outlet), in the same way as for
Valves, Removal.
47705020 05-2015 © AB VOLVO PENTA 121

Alternative 2
Tools:
1 Alternatively, tool 9990210 Valve spring com-
pressor may be used instead of the hydraulic cyl-
inder, in the same way as for Valves, Removal.
P0006997
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Valve Seat, Change

Cylinder head and valves removed.
Tools:
9992479 Holder for dial indicator
1 The valve seats must be changed if a satisfactory
seal cannot be obtained or when the distance (A)
exceeds the value stated in the specification;
refer to Group 21: Engine page 26.
P0007000
2 Grind the head off an old valve and weld it onto

the valve seat. Use a MAG welder, or a conven-
tional arc welder (with a stainless welding elec-
trode).
IMPORTANT!
Carefully cover the other surfaces on the cylinder head
to prevent any weld spatter from fastening.
P0007001
P0007002
47705020 05-2015 © AB VOLVO PENTA 123

3 Place a suitable socket over the valve/valve guide

and carefully tap the valve seat out.
IMPORTANT!
Be careful not to damage the cylinder head.
CAUTION!
4 Clean the seat bed carefully and check the cylin-
der 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 to the valve
P0007003
seat bed; refer to Group 21: Engine page 26.
6 Cool the seat in carbon dioxide snow between –

60 °C (–76 °F) and –70 °C (–94 °F) and heat the
cylinder head by flushing with hot water, or by
some other method.
Install the new valve seat using a drift.
NOTICE! Align the seat with the seat angle facing

the tool. Check sealing against the valve.
P0007004
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Valve Stem Sealings, Replace

Tools:
88800011 Drift
88800151 Drift
1 Switch off all electrical power to the engine at the
main switch.
Removal
2 Remove the unit injectors; refer to the Removal
section in Injector, Change page 200.
NOTICE! The pistons must be at top dead center

when the valves are removed. This is to prevent
the valves from falling into the cylinder. Use
88800014 Rotation tool.
Compress the valve springs for # 1 cylinder. Use

9990210 Valve spring compressor.
3 Remove the valve washers, valve springs and
collets.
4 Remove the old valve stem seals.
Installation
5 Lubricate the valve stem with engine oil.
Fit 88800011 Drift to the valve stem.
Thread the new seal on and put it over the man-
drel.
P0021043
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6 Slide 88800151 Drift over the valve stem and tap

the seal down carefully with a plastic mallet.
88800151
P0011236
7 Install the valve springs, valve spring washers

and collets.
Carefully tap with a plastic mallet to make sure
the collets end up in the right position.
8 Transfer the valve spring compressor to cylinder
# 6 and repeat the above procedure.
Then crank the engine so that cylinders 3 and 4
are at TDC.
Repeat the procedure. Then continue with cylin-
ders 2 and 5.
9 Install the unit injectors; refer to the Installation
section in Injector, Change page 200.
10 Adjust valves and unit injectors; refer to Valves
and Unit Injectors, Adjustment page 106
11 Bleed the fuel system; refer to Fuel system,
bleeding page 184.
Perform a leakage and function check.
126 47705020 05-2015 © AB VOLVO PENTA

21-5 Timing Gears and Shaft

Timing Gear, Removal
Tools:
9998267 Guide sleeve
9998511 Lever
1 Undo / remove:
P0020990
2 Remove the oil sump; refer to Lubrication Oil

Pump, Change page 165.
P0010454
3 Remove the starter motor; refer to Starter Motor,

Change page 298.
P0020000
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4 Remove the bolts on the starter motor side.
P0021033
5 Remove the fuel pump with drive unit; refer to

Fuel Feed Pump, Change page 197.
P0021034
6 Remove the timing gear cover's two caps.

Alternatively, remove the air compressor.
P0010158
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7 Remove the bolts on the fuel pump side.
P0021035
8 Remove the valve cover according to Valve

cover, change page 101.
9 Crank the engine to camshaft TDC and check that
the mark on the flywheel is at zero. Use
88800014 Rotation tool.
P0020997
10 Disconnect the injector connectors.

Cut off cable ties and remove the cable harness
from the cable holder.
Remove the cable holders.
P0021036
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11 Remove the harness bush and carefully pull the

harness out through the cylinder head.
P0020995
12 Remove the upper timing gear cover.
P0021037
13 Remove the upper timing gear casing and

remove the rubber seals.
P0012728
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14 Remove the vibration damper.
IMPORTANT!
impact and shocks.
Bolt on the crankshaft gear using spacers.
P0021038
15 Remove the flywheel bolts.

Lift the flywheel away using suitable lifting eyes.
P0010159
16 Remove the old crankshaft seal; refer to Crank-

shaft Seal, Change (rear) page 156.
17 Remove the remaining timing gear cover bolts.
Install lifting eyes and connect the lifting tool.
P0010162
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18 Use 9998511 Lever to release the cover from the

intermediate plate.
P0010163
19 Lift away the cover.

Check which gears need replacing.
The large gear (double drive) may not be split but
must always be replaced whole.
If the oil pump gear needs replacing, remove the
oil pump; refer to Lubrication Oil Pump,
Change page 165.
1 Drive gear, camshaft gear
2 Upper intermediate gear, adjustable
3 Intermediate gear, Double gear
4 Intermediate gear, power steering pump
and fuel pump
5 Drive gear, crankshaft gear
6 Drive gear, lubrication oil pump
7 Take-off: Drive gear, power steering pump
and fuel pump
8 Accessories: Drive gear, air compressor
P0021039 9 Accessories: Drive gear, power take-off
(auxiliary equipment)
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20 Check that the crankshaft gear marking corre-

sponds to the double gear.
P0010180
21 Check that the camshaft gear marking corre-

sponds to the timing gear plate hole.
P0010181
22 Remove the lower intermediate gear.

Remove the double gear (Allen bolts at center).
Remove the upper intermediate gear.
P0010182
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23 NOTICE! Before the timing gear plate is

removed, two pcs 9998267 Guide sleeve must be
installed on the engine block (tighten to 60 Nm
(44 lbf.ft)). This is to make sure the plate is
replaced in exactly the same position.
It is now possible to remove the timing gear plate.

Remove all bolts.
Using a pry bar, carefully prise the plate free (held
in place by sealant), but do not prise such that the
9998267 guide sleeves are dislodged or damaged.
P0010184
24 Remove the two bolts retaining the crankshaft

gear.
Remove the crankshaft gear using a suitable
puller.
Place a larger washer beneath the puller bolt to
protect its thread from damage.
Clean the plate thoroughly on both sides.
Clean the engine block and cylinder head sealing
surfaces, but do not remove the plate guide
sleeves.
P0010185
25 Remove the camshaft gear.
P0021040
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26 Remove the upper chain guide.
P0021041
27 Clean the timing gear plate, the crankshaft con-

tact surface and the cylinder head front.
NOTICE! Only remove the timing gear plate if

absolutely necessary.
P0021042
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Timing Gear, Installation

Tools:
885810 Fixture
9998601 Fixture
Timing gear plate, installation

1 NOTICE! The timing gear plate must be installed
within 20 minutes of applying the sealant.
Apply a 2 mm (0.08") bead of sealant on the

engine block and the cylinder head, as illustrated.
P0021050
2 Align the plate with the guide sleeves.

Install all the bolts and tighten them in the follow-
ing order:
P0021051
136 47705020 05-2015 © AB VOLVO PENTA

3 Lubricate the gear contact surface.
P0021049
4 Install a new O-ring on the crankshaft and lubri-

cate it. Lubricate the inside of the gearwheel with
the same lubricant.
Fit the gearwheel locator pin into the crankshaft
hole and make sure the oil pump gear meshes
with the crankshaft gear.
Install the bolts and tighten them alternately so
that the gearwheel is not skewed.
Torque according to the specifications in Tight-
P0010187
5 Clean the upper intermediate gear hub.

Check the oil holes are open.
Fit the washer onto the guide sleeve.
Check that the bolt holes align.
P0010186
47705020 05-2015 © AB VOLVO PENTA 137

6 Fit the hub onto the engine by aligning the guide

sleeve.
Lubricate the thrust bearing with engine oil.
P0010189
7 Check that the bearing is fault free. Lubricate the

bearing with engine oil.
Install the intermediate gear such that the bearing
is located outermost.
Check that the plate lubricating hole is open.
Lubricate the rear of the plate.
P0010190
8 Fit the plate onto the centering guide and install

the bolts. Tighten the bolts until contact.
Check that the gearwheel rotates easily.
P0010191
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9 Make sure that the marking for top dead center

(TDC) on the camshaft is between the markings
on the bearing cap.
P0020997
10 Install the camshaft gear without the vibration

damper.
Align the marking with the hole in the timing gear
plate.
Allow suitable spacers under the bolts to act as a
replacement for the vibration damper.
P0010193
11 Adjust the gear lash according to the sections

Flank Clearance, Checking and Flank Clearance,
Adjustment in the Cylinder Head, Installa-
tion page 86 chapter.
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12 Check the double gear bearing.

Align the marking on the double gear with the
marking on the crankshaft.
Mesh the upper intermediate gears and fit the
locator pin into the center hole.
Turn the hub so the bolt holes align.
Install the bolts and tighten according to the spec-
ifications in Tightening Schedules page 15.
P0010192
13 Install the lower intermediate gear.
P0010324
14 Apply a 2 mm (0.08") bead of sealant according

to Tightening Schedules page 15.
NOTICE! Must be torqued within 20 min.
P0005224
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10 11 15 Lift the cover into place and align the guide

sleeves.
8 9 Install all the bolts and torque according to Tight-
NOTICE! M14 bolts first as per the chart.

6 7
2 3
4 5
P0005225
16 Inspect the flywheel.

Where necessary, replace the ring gear; refer to
Gear Ring, Fywheel: Replace page 151.
17 Install a new crankshaft seal; refer to Crankshaft
Seal, Change (rear) page 156
Install the flywheel.
Check the flywheel with regard to distortion; refer
to Flywheel, Indication page 150
P0010159
18 Install the bolts on the starter motor side.
P0021033
47705020 05-2015 © AB VOLVO PENTA 141

19 Install the bolts on the fuel pump side.
P0021035
20 IMPORTANT!
impact and shocks.

gear.
Install the vibration damper.
For tightening torque, refer to Tightening Sched-
ules page 15.
P0021038
21 Apply a 2 mm (0.08") bead of 1161231 Sealant to

the upper timing gear cover contact surface, as
illustrated.
P0013011
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22 Fit new rubber seals and install the upper timing

gear casing.
P0006949
23 Only fit the bolts (1) and tighten by hand.
NOTICE! The holes are oblong to allow the cover

to be pressed down against the rubber seal.
P0006950
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24 Press the cover down using 885810 Fixture and

88510 9998601 Fixture so that the cylinder head and the
upper timing gear cover sealing surfaces are
aligned.
Fit the remaining bolts (2).
Tighten according to the specifications in Tight-
NOTICE! The timing gear casing must be instal-

led and torqued within 20 minutes of sealant
application.
P0012751
9998601
P0012752
25 Install the camshaft sensor and adjust it accord-

ing to Sensors, Adjustment page 152
P0010060
26 Check, and where necessary adjust, valves and

unit injectors according to Valves and Unit Injec-
tors, Adjustment page 106.
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27 Fit the cable holders.

Pull the cable harness through the cylinder head
to the unit injectors and connect them.
Fasten the harness in the cable holder using oil
and heat-resistant cable ties.
P0021036
28 Bolt the harness bush place.
P0020995
29 Fit the valve cover; refer to Valve cover,

change page 101
30 Install the oil sump; refer to Lubrication Oil Pump,
Change page 165.
P0010454
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31 Install the starter motor; refer to Starter Motor,

Change page 298.
P0020000
32 Install the fuel pump with drive unit; refer to Fuel

Feed Pump, Change page 197.
P0021034
33 Fit the timing gear cover's two caps.

Alternatively, install the air compressor.
P0010158
146 47705020 05-2015 © AB VOLVO PENTA

34 Install:
P0020990
35 Fill with new engine oil.

36 Start the engine and check for leaks; let the
engine run until it reaches normal working tem-
perature.
Let it run an additional 5-10 minutes at idle.
37 Check engine oil level; fill as necessary.
47705020 05-2015 © AB VOLVO PENTA 147

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 signs of wear.
Measure the wear with a feeler gauge or wire gauge.

Alternatively, a digital caliper gauge may be used.
Compare the measured values with those specified in

Group 21: Engine page 26.
P0007013
Guidlines 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 per-
formance or the durability of the engine and its com-
ponents.
Examples of acceptable wear and unacceptable wear

are shown below.
Acceptable wear: Unacceptable wear:

The camshaft need not be changed. IMPORTANT!
The camshaft and associated rocker arms must be
changed.
P0003896 P0003899
P0003898 P0003897
148 47705020 05-2015 © AB VOLVO PENTA

Camshaft Bearing Housing,

Replace
The factory-installed bearing housings are machined
together with the cylinder head, and may therefore not
be moved from one cylinder head to another.
Therefore, the first time one or more bearing housings

are replaced, all bearing housings must be replaced so
that the positions of the bearing housings can be
aligned. Bearing housings may then be replaced indi-
vidually.
P0007018
The holes for the guide sleeves are oval in the replace-
ment housings, which allows radial adjustment of the
center bearing housing and axial adjustment of the
front and rear bearing housings.
If a replacement housings are installed, mark them with

their numbers so they can be put back in the same
place as before, if they need to be removed.
P0007019
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Flywheel, Indication
Flywheel exposed; refer to Timing Gear, Removal.
Tools:
1 Install 88800014 Rotation tool in order to rotate
the flywheel.
2 Install 9999696 Magnetic stand and 9989876 Dial
indicator with the measuring tip against the fly-
999 9696 wheel at a measuring radius of around 150 mm
(5.9”).
Rotate the flywheel at least one revolution and
check the min and max deflections on the dial
indicator. The value should not exceed 0.20
mm (0.0079”).
998 9876
3 If the distortion is greater, and this is not the result
of a damaged surface where the dial indicator is
applied, remove the flywheel and check that there
is no waste material or damage to the contact
flange on the flywheel and crankshaft.
Clean the flanges or change the flywheel if it is
damaged.
P0010194
Torque the bolts; refer to 03-2, Special Tightening
Torques.
4 Check using the dial indicator and magnetic stand
again.
Remove the tool.
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Gear Ring, Fywheel: Replace

1 Remove the flywheel.
2 Drill 1-2 holes between teeth on the ring gear.
Split the ring gear at the drilled hole(s), using a
cold chisel; lift the ring gear away from the fly-
wheel.
3 Brush the flywheel contact surface clean with a
steel wire brush.
P0020333
4 Heat the new gear ring to 180-200 °C (356–392

°F).
The ring gear must be evenly heated.
P0020334
5 The bevel must face out.

Ring gear–flywheel gap: 0-0.2 mm (0-0.008")
Put the heated ring gear onto the flywheel and tap
it into place with a soft drift and hammer.
P0020335
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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.
3 Insert 88800031 Measuring tool without tighten-
88800031 ing 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 posi-
tion 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
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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.
47705020 05-2015 © AB VOLVO PENTA 153

21-6 Crank Mechanism

Crankshaft Seal, Change (front)
Tools:
9990118 Cone
9990192 Puller
9992000 Handle
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.
154 47705020 05-2015 © AB VOLVO PENTA

4 Check that the tools are undamaged, to prevent

damage to the seal.
NOTICE! No lubrication. It must be installed com-

pletely 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 cor-
rectly installed.
P0004794
6 Install the vibration damper and pulley. Tighten

according to 03-2, Special Tightening Torques.
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Crankshaft Seal, Change (rear)

Tools:
9990113 Drift
9990117 Cone
9990192 Puller
9992000 Handle
Removal
1 Remove the flywheel according to 21-5, Fly-
wheel, Change.
2 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.
P0020200
3 NOTICE! Check for damage on the guide or drift

as they may damage the seal.
Fit the 9990117 Cone to the 9990113 Drift.
P0020201
156 47705020 05-2015 © AB VOLVO PENTA

Installation
4 Install the seal on 9990113 Drift, via
9990117 Cone.
Remove 9990117 Cone.
P0020202
5 NOTICE! No lubrication. It must be installed com-

pletely dry.
Fit 9992000 Handle to 9990113 Drift.
P0020203
6 Tap in the new seal until it bottoms against the

crankshaft gear.
P0020204
7 Remove the tool and check that the seal is cor-

rectly installed.
If needed, use two bolts to pull the tool out.
8 Install the flywheel according to: 21-5, Flywheel,
Change.
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Crankshaft, Inspection
The crankshaft is induction hardened.
Inspect the crankshaft very carefully to avoid unnec-

essary overhaul.
The following applies when the need for overhaul is
checked:
1 Clean the crankshaft carefully.
Measure the bearing journals' out-of-round, wear
and taper. Refer to Group 21: Engine page 26 for
specifications.
2 Check whether there is any surface damage on
the bearing journals. If there is any damage on
the surface layer, the shaft must be re-ground.
3 Place the shaft pair of V-blocks, under 1st and 7th
main bearing journals. Alternatively, hold the
crankshaft between the two centers.
4 Measure crankshaft axial displacement (throw)
on the 4th main bearing.
For maximum permissible values, refer to Group
21: Engine page 26.
IMPORTANT!
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 which is viewed under ultra-
violet light.
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Main bearing, Change

Oil pan removed
The method describes replacement of main bearings

with the crankshaft in place in the engine
Tools:
9990114 Puller
Removal
1 Fit tool 88800014 Rotation tool.
P0006884
2 Remove the oil suction pipe and oil pump.

Remove the bracing frame.
P0010124
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3 Remove one bearing cap.
P0006970
4 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 tool 88800014 Rotation
tool.
5 Clean and check the bearing seat, bearing cap,
shaft journal and bearing shell.
If the bearing has seized, the reason must be
determined before a new bearing is installed.
6 Check that the correct bearing dimension is used
when the bearing shells are changed.
NOTICE! If case of uncertainty, check in Group

21: Engine page 26 which oversize dimensions
P0006971
are available.
Installation
7 Lubricate the shaft journal and the new bearing
shells with engine oil.
8 Install the upper bearing shell by turning the
crankshaft using tool 88800014 Rotation tool
against the direction of rotation with the pin in the
oil hole.
NOTICE! Check that the pressed-out bearing

shell heel is correctly aligned in the bearing seat
cutout.
Make sure that the upper bearing shells (those to

be located in the engine block) are equipped with
oil holes.
P0006972
NOTICE! Remove the pin when done.
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9 Fit the main bearing cap together with the lower

bearing shell.
NOTICE! The main bearing caps are asymmetric

and can only be installed in one position. Note the
main bearing cap numbers showing their loca-
tions if several caps are removed simultaneously.
Torque the caps in two steps as specified; refer

to Group 21: Engine page 26.
10 Change the other bearing shells, one a time, in
the same way as the first one. Each time a
changed is made, check that the crankshaft does
P0006973
not seize by turning it using tool 88800014 Rota-
tion tool.
11 Check crankshaft end float and replace the thrust
washers if the clearance is too great or if the thrust
washers are damaged.
NOTICE! Measure the end float with a dial gauge.

Thrust bearings are available in a number of over-
size dimensions. Refer to Group 21:
Engine page 26 for oversize dimensions and axial
play.
The crankshaft thrust bearing is located in the

center main bearing.
12 Use a narrow plastic or wood stick to remove the
thrust bearing washers from the cylinder block
bearing seat.
NOTICE! The thrust washers can only be placed

in one position.
P0006974
13 Check the axial play of the crankshaft when all

main bearing caps have been torqued; refer to
Group 21: Engine page 26 for specification.
14 Install the bracing frame and torque according to
the tightening chart; refer to Group 21:
Engine page 26.
15 Install the oil pump and oil suction pipe.
16 Remove tool 88800014 Rotation tool from the fly-
wheel housing and install the cover.
17 Install the oil pan.
P0006975 Add oil and change the oil filter.
Check the oil pressure.
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22-0 Lubricating and Oil System, General

Engine Oil Pressure, Check
Tools:
9992873 Nipple
9996398 Manometer
9998493 Hose
Where incorrect oil pressure sensor readings are sus-

pected, check the oil pressure with an external pres-
sure sensor.
There is a plug in the engine block located behind the
control unit.
1 Check the oil pressure with an external pressure
gauge and compare values with the specification
in Administration page 33.
2 Remove the control unit to get to the plug.
3 Fit 9998493 Hose, 9992873 Nipple and
9996398 Manometer.
4 Start the engine and check the oil pressure.
- If the oil pressure reading shows pressure to
be below the specified minimum, continue
fault tracing by checking the oil filters.
- If the oil pressure reading from an external
pressure sensor shows pressure to be
within limits while the engine's regular pres-
sure sensor does not, replace the pressure
sensor.
5 Remove the hose, nipple and pressure gauge.
6 Install the plug and bolt on the control unit.
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Oil pressure safety valve, change

Engine oil drained.
Removal
1 Remove the oil filler pipe and the oil dipstick.
Remove the oil level sensor connector.
P0010122
2 Remove the oil sump.
P0010454
3 Unscrew the valve housing cover and remove the

safety valve.
P0021052
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Installation
4 Install the new safety valve.
Install and tighten the valve housing cover.
5 Clean the oil sump.
Check the rubber seal.
Cut away excess sealant from the front crank-
shaft seal cover.
Cut away excess sealant from the timing gear
plate and the flywheel housing.
Apply new sealant to the joints and install the oil
sump within 20 min.
6 Fit the oil sump.
Tighten the oil sump bolts according to Tightening
torques page 9.
P0010454
7 Attach the oil dipstick tube to the bracket.

Install the oil filler pipe and the wiring to the oil
level sensor.
Fill with engine oil.
8 Start the engine.
Check the oil pressure and check for leakage.
P0010122
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22-1 Oil pump and Line

Lubrication Oil Pump, Change
Engine oil drained.
Removal
1 Remove the oil filler pipe and the oil dipstick.
Remove the oil level sensor connector.
P0010122
2 Remove the oil sump.
P0010454
3 Remove the suction strainer and the pipe to the

pump.
P0021014
47705020 05-2015 © AB VOLVO PENTA 165

4 Remove the delivery pipe from the pump.
P0021015
5 Remove the two bolts on either side of the pipe

flange.
P0021016
6 Remove the main bearing cap together with the

oil pump.
P0021017
166 47705020 05-2015 © AB VOLVO PENTA

7 Unbolt the oil pump from the main bearing cap.
P0021018
Installation
8 IMPORTANT!
Clean the contact surface.
Install the oil pump on the main bearing cap.

Check that the tab on the bearing is in the notch
in the bearing seat and that the oil holes corre-
spond to each other.
Lubricate the bearing shell with engine oil.
P0021019
9 Install the oil pump by meshing the gearwheels

and tightening the main bearing cap.
Tightening torque:
1 150 Nm (110 lbf. ft.)
2 120 °
P0021017
47705020 05-2015 © AB VOLVO PENTA 167

10 Fit the pipe flanges.
P0021016
11 Fit the delivery pipe to the oil pump.
P0021020
12 Install the suction strainer and pipe to the oil

pump.
P0021021
13 Clean the oil sump.

Check the rubber seal. Cut away excess sealant
from the front crankshaft seal cover. Cut away
excess sealant from the timing gear plate and the
flywheel housing.
Apply new sealant to the joints and install the oil
sump within 20 min.
168 47705020 05-2015 © AB VOLVO PENTA

14 Fit the oil sump.

Tighten the oil sump bolts according to Tightening
torques page 9.
P0010454
15 Attach the oil dipstick tube to the bracket.

Install the oil filler pipe and the wiring to the oil
level sensor.
Fill with engine oil.
P0010122
16 Start the engine. Check the oil pressure and

check for leakage.
47705020 05-2015 © AB VOLVO PENTA 169

22-2 Oil filter
22-2 Oil filter

Oil filter, Change
Tools:
9998487 Sleeve
9999179 Extractor oil filter
Removal
1 Drain the engine oil.
2 Clean around the filter bracket and remove the
2
filters. Use 9998487 Sleeve or 9999179 Extractor
oil filter.
P0004307
170 47705020 05-2015 © AB VOLVO PENTA

22-2 Oil filter
Installation
3 Clean the sealing surface for the oil filter seal and
neighboring surfaces on the console.
4 NOTICE! Use recommended oil.
Lightly lubricate the new oil filter's rubber gaskets

(1).
Fill the new the filters with engine oil.
5 Tighten the filters by hand until they touch the
bracket contact surface (2).
Tighten them by hand another 3/4 to one full turn
(3) (or what the filter marking stipulates).
P0019995
6 NOTICE! Use recommended oil.
Re-install the drain plug.

Fill with the requisite quantity of oil; refer to the
service record for the engine type concerned.
7 Start the engine.
8 Switch the engine off and check the oil level after
a few minutes. Top up with oil as necessary.
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22-2 Oil filter
Oil Filter Bracket, Change

Removal
IMPORTANT!
Protect against dirt while work is in progress.
1 Disconnect the pressure sensor connector.

Remove the wastegate control hose.
Remove the bracket with the NOx sensor.
Remove the cable ties.
P0020685
2 Clean the oil filter housing and the engine block

mating surfaces.
Remove the oil supply line (1) to the turbocharger.
Unscrew the oil pipe (2).
Pull the pipe out of the EGR control valve.
Remove the oil return pipe.
NOTICE! Plug the oil supply line connection to

the oil filter housing.
P0020686
172 47705020 05-2015 © AB VOLVO PENTA

22-2 Oil filter
3 Remove the oil filters.
P0020687
4 Remove the bracket.

Remove the gasket.
P0020688
5 IMPORTANT!
Clean the sealing surfaces.
Remove the oil pipes from the oil cooler cover.
P0020689
47705020 05-2015 © AB VOLVO PENTA 173

22-2 Oil filter
Installation
6 Install the oil pipes to the oil cooler cover.
7 IMPORTANT!
Sealant may absolutely not be used. The use of
sealant may result in engine breakdown.
Move over the parts for re-use to the new bracket.
P0020690
8 Install the oil filter bracket with a new gasket and

fit the oil pipes into their unions.
P0020688
9 Install a new oil filter and a new bypass filter (1).

Follow the instructions on the filter.
P0020691
174 47705020 05-2015 © AB VOLVO PENTA

22-2 Oil filter
10 Fit the oil supply line (1) to the turbo.

Connect the oil pipes the e-EGR control valve.
Connect the oil pipes (2) to the filter bracket and
tighten them.
P0020686
11 Install the bracket with the NOx sensor.

Install the wastegate control hose.
Connect the pressure sensor connector.
Attach new cable ties.
12 Replenish or change the oil.
13 Start the engine;check oil system function and
check for leaks.
14 Switch the engine off and check the oil level.
P0020692
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22-2 Oil filter
Oil filter bracket valves, change

Bypass valve oil filter, replacement
1 Remove the pressure pipe to the turbocharger.
2 Clean the area around the overflow valve.
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.
6 Tighten the turbocharger pressure pipe.
7 Start the engine and check for leaks.
P0021053
Bypass valve, full flow oil filter, replace

1 Clean the area around the overflow valve.
2 Remove the valve and clean the valve seat in the
oil filter bracket.
3 Fit the new the valve with a new seal ring and
tighten the nut.
P0021054
Reduction valve, change

1 Clean the area around the reducing valve.
2 Remove the reducing valve.
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 the new valve with a new seal ring.
Check that the internal seal does not come loose
when the valve is installed.
Install a new O-ring.
P0021055
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22-2 Oil filter
Piston cooling valve - opening valve,

replacement
1 Clean around the filter bracket and the piston
cooling valve.
2 Remove the opening valve.
3 Clean the valve seat in the filter bracket.
4 Fit the new valve with a new seal ring.
P0021056
Piston cooling valve - control valve,

replacement
1 Remove the oil filter bracket; refer to Oil Filter
Bracket, Change page 172.
2 Clean around the filter bracket and the piston
cooling valve.
3 Remove the control valve.
4 Clean the valve seat in the filter bracket.
5 Fit a new valve with a new seal ring.
6 Install the oil filter bracket; refer to Oil Filter
Bracket, Change page 172.
P0021057
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22-2 Oil filter
Bypass valve, oil cooler

1 Clean the area around the bypass valve.
2 Remove the bypass valve.
housing.
4 Fit the new valve with a new O-ring.
P0021058
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22-3 Oil cooler
22-3 Oil cooler

Oil Cooler, Replace
Drain the coolant according to Coolant,
Change page 283.
Removal
1 Remove the turbocharger charge air pipe.
Remove the heat shield.
P0020043
2 Remove the e-EGR control valve according to

Control valve e-EGR, change page 225.
Change page 233.
4 Remove the radiator hose (1) for the air compres-
sor (option).
Remove the hose (2) from the engine heater
(option).
5 Remove the exhaust manifold according to
Exhaust Manifold, Change page 215.
P0020695
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22-3 Oil cooler
6 Remove the oil cooler cover.

7 Remove the oil pipes from the oil cooler cover.
P0020696
8 Remove the oil cooler cover plate.
P0009973
9 Remove the oil cooler.
P0009974
10 Remove the two seal rings.
P0009975
11 Clean all sealing surfaces.
P0009976
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22-3 Oil cooler
12 Install a new front seal.
P0009977
Installation
13 Install new seal rings on the oil cooler.
P0009975
14 Install the oil cooler.

1 3 Tighten the bolts diagonally and finish off by tight-
ening the first bolts again.
4 2
P0005238
15 Install the oil cooler plate.
P0009973
47705020 05-2015 © AB VOLVO PENTA 181

22-3 Oil cooler
16 1 Remove gasket.
2 Clean along the gasket groove.
4 Install a new gasket.
Apply a thin bead of sealant (part # 1161771) in

the groove, max 20 min before the cover is instal-
P0010538 led.
Press the new seal into the groove.
Make sure the seal's flat surface ends up at the
bottom of the groove.
17 Install the oil pipes.
Install the bolt (1) which will end up behind the

water pump in the cover.
Lift the cover into place.
Fit a bolt (2).
Press the cover forward and fit another bolt.

Install the remaining bolts and tighten them
according to the chart.
P0020697
18 88800022 Mounting tool may make installation

easier
P0020698
Tightening chart
19 Install the cover on the engine block and install
88800022 Mounting tool with bolt A.
A C B Press the cover against the water pump housing.
2 3
Fit bolt B.
Check that the cover is in position.
Install and tighten bolts C and D to standard tor-
que.
Tighten the cover bolts outwards from the center
4 in the sequence 1–4.
1
D Finish off by checking the torque of bolts C and
p0005239 D.
20 Install the exhaust manifold according to Exhaust
Manifold, Change page 215.
182 47705020 05-2015 © AB VOLVO PENTA

22-3 Oil cooler
21 Install the radiator hose (1) for the air compressor

(option).
Install the hose (2) to the engine heater (option).
22 Install the turbocharger; refer to Turbo,
Change page 233
23 Install the exhaust pipe e-EGR; refer to Control
P0020695
24 Install the charge air pipe.

Install the heat shield.
P0020043
25 Fill the cooling system, pressure test and check

for leaks. Refer to Cooling System, Pressure
Testing page 49.
26 Check the engine oil level and top up if necessary.
47705020 05-2015 © AB VOLVO PENTA 183

23-0 Fuel System, General

Fuel system, bleeding
Check that there is sufficient fuel in the tank, and that
any fuel taps are open.
1 Free the hand pump from the fuel filter bracket.
P0019904
2 Open the nipple on the front fuel connection.

Connect a drain hose.
P0019905
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3 Purge the fuel system by pumping with the hand

pump until fuel flows.
P0019889
4 Close the venting nipple and remove the drainage

hose.
P0019905
5 Secure the hand pump.
P0019904
6 Start the engine and allow it to idle for about 10

minutes.
7 Perform a leakage and function check.
47705020 05-2015 © AB VOLVO PENTA 185

Draining, Fuel Duct in Cylinder Head

IMPORTANT!
ness.
IMPORTANT!
1 Clean the fuel connections.

2 Loosen and fold down the fuel inlet supply line
into a vessel.
Let the fitting remain in the filter.
P0021113
3 Loosen and fold the return line away from the

spacer.
P0021114
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4 Install a nipple (1), e.g. part. no. 941749. Use a

suitable hose (2).
P0021116
5 IMPORTANT!
Make sure that no dirt gets into the fuel duct.
Let the hoses hang down into a vessel.
Blow out the fuel into the vessel, through the fuel
duct inside the cylinder head (from inlet supply
line).
P0021117
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23-3 Fuel Feed Pump and Filter

Fuel Pre-filter, Change
IMPORTANT!
ness.
IMPORTANT!
CAUTION!
Risk of skin damage.
Removal
1 If there is a heater on the water separator, dis-
connect the heating element connector.
Disconnect the water separator sensor connec-
tor.
P0019891
2 Undo the drain nipple in the base of the water

separator.
Drain the filter.
NOTICE! Remove the plug on the water separa-

tor housing to allow the fuel to run out more easily.
3 Reinstall the plug and tighten the drain nipple.
P0019892
188 47705020 05-2015 © AB VOLVO PENTA

4 Remove the pre-filter together with the lower sec-

tion of the water separator. Use an oil filter
wrench.
P0019893
5 Remove the lower section of the water separator

and O-ring from the filter.
Keep the filter in a suitable container.
P0019894
6 Clean the lower section of the water separator

and the contact surfaces.
Check that the strainer and drain hole in the lower
section are not clogged.
P0019895
47705020 05-2015 © AB VOLVO PENTA 189

Installation
7 Lubricate the O-ring and seal ring with diesel.
Install a new O-ring.
Install the lower part of the water separator.
P0019894
8 Screw the filter onto the filter bracket by hand until

the rubber seal touches the mating surface. Then
tighten a further half turn, no more.
P0019893
9 Connect the connectors (poss. connector for the

heater element).
10 Purge the fuel system according to Fuel system,

bleeding page 184.
P0019891
190 47705020 05-2015 © AB VOLVO PENTA

Fuel filter, Change

IMPORTANT!
ness.
IMPORTANT!
CAUTION!
Risk of skin damage.
Removal
1 Clean around the fuel filter.
2 Remove the fuel filter with the aid of a suitable
filter puller. Let the fuel drip off into a collection
vessel.
3 Clean around the filter housing sealing surface.
P0019888
Installation
4 NOTICE! Do not fill the new filter with fuel before
installation. There is a risk of system contamina-
tion that may cause malfunction or damage.
Lubricate the seal with diesel and install the new

fuel filter. Torque the filter according to the
instructions on the filter.
47705020 05-2015 © AB VOLVO PENTA 191

5 NOTICE! No nipple need be opened.
Pump the hand pump around 200–300 strokes; a

resistance will be felt in the hand pump when
purging is complete.
P0019889
6 Start and warm up engine.

Fuel Feed Pressure, Check

Tools:
9990124 Nipple
9996666 Nipple
9998339 Manometer
1 Install tool:
1 9998339 Manometer
2 9996666 Nipple
3 9990124 Nipple
2 Check that the fuel feed pressure is according to
specifications: Refer to Administration page 25.
3 Remove the tool.
Install new fuel line seals.
P0005070
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Fuel filter housing, change

IMPORTANT!
Take great care to keep fuel system unions clean.
Even minimal amounts of dirt can cause engine break-
down.
Removal
1 Switch off battery power.
2 Thoroughly clean the fuel filter bracket, fuel hoses
and unions, and the area around the bracket.
3 Drain the pre-filter and water separator. Remove
both fuel filters.
Remove the electrical connectors to the pressure
sensor and water sensor.
P0009988
4 Remove the return fuel line from the bracket.

Remove the pump supply line from the bracket.
P0009989
47705020 05-2015 © AB VOLVO PENTA 193

5 Remove the inlet line to the bracket. Remove the

pump line from the bracket. Remove the bracket's
rear attachment bolt.
Retain the rubber bushing located behind the
bracket. Remove the supply line banjo bolt.
P0009990
6 Remove the two remaining bracket bolts. Retain

the rubber bushings located behind the bracket.
Lift away the bracket.
P0009989
Installation
7 Move over any parts that are to be reused to the
new bracket.
p0009992
194 47705020 05-2015 © AB VOLVO PENTA

8 Install two retaining bolts and the rubber bushings

to the bracket (the lower one and the front one).
P0009989
9 Install and tighten the supply line banjo bolt with

new seals. Install the rubber bushing and the
bracket's rear bolt.
P0009990
10 Install the upper fuel lines with new seals.
P0009989
47705020 05-2015 © AB VOLVO PENTA 195

11 Install new fuel filters and connect the connector.

Vent the fuel system. Start the engine and check
fuel system integrity.
P0009994
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Fuel Feed Pump, Change

IMPORTANT!
ness.
IMPORTANT!
IMPORTANT!
Install safety plugs in open connections.
Removal
1 Close any fuel cocks between the tank and fuel
feed pump, to avoid unnecessary fuel spills.
2 Clean thoroughly around the fuel feed pump and
its connections.
3 NOTICE! Be prepared to gather up fluid.
Remove fuel connections to the fuel feed pump

and allow the fuel to flow out into a suitable con-
tainer.
NOTICE! Plug the lines. Mark the suction and

pressure lines.
P0019964
4 Remove the fuel feed pump.
P0019965
47705020 05-2015 © AB VOLVO PENTA 197

Installation
5 Lubricate and install a new O-ring.
Check the dog clutch.
P0019966
6 Install the intermediate link.

Rotate the fuel feed pump shaft so that the key
slots into the dog clutch.
P0019967
7 Install the fuel pump.

P0019969
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8 IMPORTANT!
Mark the suction and pressure lines.
Install the sealing washers.

Tighten the fuel connections.
P0019968
9 NOTICE! No nipple need be opened.
Pump the hand pump around 200–300 strokes; a

resistance will be felt in the hand pump when
purging is complete.
Repeat purging if the engine is difficult to start.
P0019889
10 Start the engine.

47705020 05-2015 © AB VOLVO PENTA 199

23-7 Injectors and Delivery Pipes

Injector, Change
Tools:
9990006 Puller
9998599 Cleaning kit includes:

- 9808570 Brush
- 9808616 Extender
- 9998580 Protective sleeve
For adjusting valves and unit injectors; refer to Valves

and Unit Injectors, Adjustment page 106.
NOTICE! When reinstalling, use new seals.
NOTICE! When replacing a unit injector, a new injector

code must be programmed into the control unit. Refer
to the applicable ”Service Manual, Group 30, EMS
2.3”. The injector code is stamped on the unit injector.
Removal
1 Remove the valve cover according to Valve
cover, change page 101.
2 Detach the electric connectors from the unit injec-
tors.
Cut the cable ties holding the cable harness and
move it to one side.
P0006879
200 47705020 05-2015 © AB VOLVO PENTA

3 Remove the fuel supply pipe and the rocker arm

bridge lubrication oil supply union.
P0006883
4 NOTICE! VCB: Make sure the pistons in the

exhaust rocker arms and the adjuster screw ball
do not fall out. Secure the exhaust rocker arm
D9
D11 pistons with cable ties or similar.
D16 D9 Undo the rocker arm bridge bolts incrementally by
D9
D11 D11 D9 equal amounts each time, to avoid bending the
D16 D16 D11 rocker shaft.
D16
Carefully lift away the rocker arm bridge using
9990185 Lifting tool.
P0006887
47705020 05-2015 © AB VOLVO PENTA 201

5 Mark and remove the valve yokes.
P0006888
6 Empty the fuel channel in the cylinder head; refer

to Draining, Fuel Duct in Cylinder
Head page 186.
7 Clean around the unit injector for removal.
8 Remove the unit injector yoke bolts.
9990013 Fit 9990006 Puller onto the injector.
9 Put the puller fork in the groove in the injector and
lock the arm with the screw on the side.
Fasten the puller by turning the screw down
against the injector ball seat.
9990006 Attach a 9990013 Slide hammer and remove the
injector.
P0001370
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10 Mark the injectors and fit 9998249 Protective

sleeve to the injector.
11 Fit 9998251 Protection plug into the unit injector
location in the cylinder head if the new unit injec-
tor is not fitted right away.
P0006890
12 Install 9998580 Protective sleeve and clean thor-

oughly using 9808570 Brush and
9808616 Extender from tool kit 9998599 Clean-
ing kit.
P0005063
Installation
13 Read and note the unit injector trim code and the
cylinder it is installed in to make programming
easier.
14 Fit new seal rings to the unit injectors.
Lubricate the O-rings with diesel.
P0005064
47705020 05-2015 © AB VOLVO PENTA 203

15 Fit the yoke to the unit injector and center it

between the valve springs.
Torque the bolts according to specifications; refer
to 03-2, Special Tightening Torques.
16 Install the valve yokes.
P0005066
17 Oil the valve yoke and camshaft lobes with engine

oil.
Lift the rocker arm bridge into place with the aid
D9
D11 of 9990185 Lifting tool.
D16 Check that the guide pins are in the correct posi-
D9 D9 tions on the bearing caps.
D11 D11 D9
D16 D16 D11 NOTICE! Remove the exhaust rocker arm piston
D16
restraints.
18 Tighten alternately, to avoid bending the rocker
shaft.
Torque the rocker arm bridge bolts so that the
shaft rests on the bearing brackets. Refer to 03-2,
19 Install new seal rings on the oil supply pipe and
union.
P0006887
Put a thin layer of petroleum jelly on the pipe seal
rings and connect the pipe to the union.
20 Fit the union and tighten according to 03-2, Spe-
cial Tightening Torques.
21 Adjust valves and unit injectors; refer to Valves
and Unit Injectors, Adjustment page 106.
22 Connect the wiring to the unit injectors.
23 Check that there is no dirt in the cylinder head oil
channel.
24 Install the valve cover according to Valve cover,
change page 101.
25 Bleed the fuel system; refer to Fuel system,
bleeding page 184.
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Sleeve for unit injector, replace

Unit injector removed; refer to 23-7, Unit Injector,
Replace.
Tools:
1159794 Torque wrench
9986173 Puller
9998250 Sealing ring
88800196 Drift
88800387 Puller
88800460 Sleeve
IMPORTANT!
ness.
1 Drain the coolant with the aid of a hose, tool
9996049 Draining hose; refer to 26-0, Draining
the Cooling System.
2 If necessary, remove tool 9998251 Protection
plug.
P0019120
3 Clean carefully round the sleeve.

Install 2 seal rings, tool 9998250 Sealing ring, to
prevent dirt from getting into the fuel ducts when
the sleeve is removed.
P0019121
47705020 05-2015 © AB VOLVO PENTA 205

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

support ring (2) is fitted. If the marking is not visi-
ble it may be difficult to remove the sleeve.
Press the puller (1) down to the sleeve bottom.

Refer to the arrow marking.
Install the support ring (2).
Miscellaneous:
- 9998250 Sealing ring, 2 pcs (3)
- Expander (4)
- Sleeve (5)
- Nut (6)
P0019122
5 Press 88800387 Puller 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
88800460 Sleeve facilitates work instead of

puller 9986173 (Alt2).
Remove the sleeve from 88800387 Puller and

slide it over 88800460 Sleeve.
P0021199
206 47705020 05-2015 © AB VOLVO PENTA

NOTICE! Tighten the bolt moderately.
Install the sleeve with bolt (1). Screw down to the

end position towards the puller (2).
P0021200
Counterhold the screw puller (2) and screw the

sleeve nut (1) until the sleeve releases.
P0021201
47705020 05-2015 © AB VOLVO PENTA 207

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.
P0021202
7 Alternative 2
Insert 9986173 Puller.

Screw down until the puller lugs meet the sup-
port ring.
P0019124
Screw until the sleeve releases and the puller

and sleeve can be removed.
NOTICE! 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 sup-
port ring and make a new attempt.
P0019125
208 47705020 05-2015 © AB VOLVO PENTA

8 Use cleaning kit, tool 9998599 Cleaning kit and a

power drill before fitting the new sleeve.
Install tool 9998580 Protective sleeve in the injec-
tor hole and secure it with a holder.
IMPORTANT!
Tool 9998580 Protective sleeve must be used to
prevent dirt from getting into the fuel duct.
9 Clean the cylinder head walls for the sleeve with
part no. 9808618.
P0007010
10 Clean the sleeve seat using brush no. 9808614

together with the handle and holders.
P0007011
11 Clean the cylinder head holes with brush no.

999 8580 9808617.
980 8617 12 Remove tool 9998580 Protective sleeve. Make

sure the O-ring is removed.
13 Check that the piston is at BDC.
IMPORTANT!
This must be done so that tool no. 9998688 does
not damage the piston due to its length.
P0007012
14 Always use the new version sleeve with two

grooves at the upper edge when replacing.
IMPORTANT!
The steel gasket supplied with the new sleeve
must be used when installing the unit injector.
Lubricate the O-ring on the sleeve with soapy
water.
IMPORTANT!
Always use a new O-ring.
P0010239
47705020 05-2015 © AB VOLVO PENTA 209

15 Fit the sleeve to 88800196 Drift.

The steel gasket may not be used when installing
the sleeve. It may only be used when installing
the unit injector.
Oil the pin on the tool.
NOTICE! The tool only fits the new version

sleeve.
88800196
P0003616
88800196 16 Fit 88800196 Drift together with the sleeve to the

cylinder head. Make sure the sleeve bottoms in
the cylinder head.
Install the unit injector yoke.
Use tool 1159794 Torque wrench to press in the
sleeve; torque 80 Nm (59 lbf ft).
P0003617
210 47705020 05-2015 © AB VOLVO PENTA

88800196 17 Pull the tap onto 88800196 Drift through the

sleeve tip by holding the tap and turning the nut.
Remove 88800196 Drift.
P0003618
18 Remove 9998250 Sealing ring (2 pcs).

19 Install the unit injectors with washer; refer to 23-7,
Unit Injector, Replace.
20 Put the valve yokes back according to the mark-
ings.
21 Install the rocker arm bridge and check the clear-
ance of the valves and unit injectors.
22 Install the valve cover.
23 Fill up with coolant and check that no leakage
occurs. Also refer to Coolant Level, Checking and
Topping Up page 279.
9998250
P0003619
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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 con-
trol system. If the measurements of the cable harness
show defects, it is highly likely that the control unit is
fault free. Refer to the “Service Manual, EMS 2”.
! WARNING!
Faulty individual control unit settings may result in
injury to persons or damage to the engine. For infor-
mation about reprogramming and reading of software,
refer to “Service manual, EMS 2”
IMPORTANT!
Exchange of control units between engines, during
fault tracing or repair, must never be performed under
any circumstances.
1 Clean thoroughly around the control unit fuel con-
nections.
2 Disconnect power from the engine by disconnect-
ing the negative battery terminal.
3 Remove the lower part of the crankcase breather
pipe.
4 Remove the upper and lower cable harness
clamps.
5 Remove the control unit cable harness by moving
the connector block retaining clips outwards.
6 Remove the upper and lower fuel connections to
the cooling element; plug the fuel lines.
7 Remove the control unit retaining bolts and
remove the control unit.
P0010470
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8 Transfer the cooling element to the new control

unit. Make sure that the surface between the
cooling element and the control unit is clean.
9 Install the new control unit.
10 Connect the upper and lower fuel connections to
the cooling element with new sealing washers.
11 Install the harness and clamps.
12 Install the crank case breather lower pipe.
13 Bleed the fuel system. Refer to Fuel system,
bleeding page 184.
Start the engine and check for error codes. Refer
to the “Service Manual, EMS 2”.
P0010470
47705020 05-2015 © AB VOLVO PENTA 213

25-0 Inlet and Exhaust System, General
25-0 Inlet and Exhaust System, General

Charge Air Pipe, Leakage Check
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, the charge pressure will be too low and
engine performance will be affected. If the pipes
are contaminated with oil on the inside, this indi-
cates oil leakage in the turbocharger turbine shaft
seal. In this case, the turbocharger should be
changed as a unit.
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.
214 47705020 05-2015 © AB VOLVO PENTA

25-1 Inlet and Exhaust Manifolds

Exhaust Manifold, Change
Removal
Change page 233.
2 Remove the e-EGR control valve; refer to Control
3 Remove the clamp and undo the pipe connection,
e-EGR.
P0020658
4 Remove the exhaust manifold.
P0020659
Exhaust manifold inspection

5 In case of inspection:
Dismantle the exhaust manifold.
Check that the components have no cracks or
damage.
P0020660
47705020 05-2015 © AB VOLVO PENTA 215

6 Clean the mating surfaces and install the gaskets

as illustrated.
NOTICE! Apply assembly paste (part # 1161929)

around the exhaust manifold insertion surfaces at
the connections.
Assemble the exhaust manifold.
P0020661
Installation
7 Apply assembly paste (part # 1161929) for fas-
teners.
8 Place the gaskets on the sealing surface.
Install the exhaust manifold.
P0020662
9 Torque the exhaust manifold in the following

stages:
1 Torque bolts 1, 8, 3, 10, 5, 12
2 Torque bolts 2, 7, 4, 9, 6, 11, 1, 8, 3, 10, 5,
12
P0020663
216 47705020 05-2015 © AB VOLVO PENTA

10 Check the pipe connection gasket, e-EGR.
P0020664
11 Secularly clamp the pipe connection.
P0020658
12 Install the e-EGR control valve; refer to Control

13 Install the turbocharger according to Turbo,
Change page 233.
14 Start the engine and perform a function check.
47705020 05-2015 © AB VOLVO PENTA 217

Intake Manifold, Change

IMPORTANT!
IMPORTANT!
ness.
Removal
1 Loosen, fold away or remove:
1 Connection for crankcase ventilation.
2 Closed crankcase ventilation pipe.
3 Hose connection for PWM valve.
4 Return fuel pipe.
P0021101
218 47705020 05-2015 © AB VOLVO PENTA

P0021102
- Stripes.
1 Electrical connector for crankcase pres-

sure sensor.
2 Charge air pipe.
3 Connector for air inlet pressure sensor.
4 Connector to preheat element.
5 Cover for cable duct.

- Stripes.
1 Relay box for preheat element.
2 Air throttle, see Air throttle,
change page 241.
3 EGR mixing chamber, see EGR mixing
chamber, change page 230.
4 Preheat element and electrical connection.
P0021103
47705020 05-2015 © AB VOLVO PENTA 219

4 Remove the air filter bracket bolts.
P0021104
5 Remove the intake manifold.
P0021105
220 47705020 05-2015 © AB VOLVO PENTA

Installation
6 Clean the sealing surfaces on the cylinder head
and intake manifold.
P0021106
7 Apply a 2 mm (0.0787 in) thick bead of sealant

(part no. 1161231) in the groove.
P0021107
8 NOTICE! The planar surface of the sealing shall

be against the bottom of the groove.
Install the new silicone sealing in the groove.
P0021108
47705020 05-2015 © AB VOLVO PENTA 221

9 Install two pieces of 885519 Guide pin on the cyl-

inder head.
Guide the intake manifold onto the guide pins.
P0021109
10 Tighten the intake manifold.
P0021105
11 Tighten the air filter bracket bolts.
P0021104
222 47705020 05-2015 © AB VOLVO PENTA

12 Install:
1 Preheat element and electrical connection.
2 Relay box for preheat element.
3 EGR mixing chamber, see EGR mixing
chamber, change page 230.
4 Air throttle, see Air throttle,
change page 241.
- Stripes.
P0021110
13 Install:
P0021111
1 Cover for cable duct.

2 Connector to preheat element.
3 Connector for air inlet pressure sensor.
4 Electrical connector for crankcase pres-
sure sensor.
5 Charge air pipe.
- Stripes.
47705020 05-2015 © AB VOLVO PENTA 223

14 Install:
1 Return fuel pipe.
2 Closed crankcase ventilation pipe.
3 Connection for crankcase ventilation.
4 Hose connection for PWM valve.
- Stripes.
P0021112
15 Turn the main switch on.

16 Start the engine.
Perform a function check.
224 47705020 05-2015 © AB VOLVO PENTA

25-4 Emission Control, Catalytic Converter

Control valve e-EGR, change
Removal
NOTICE! Turn off the main switch before any work is
carried out.
1 Suspend and secure the exhaust elbow and pipe

elbow (1). Alternatively, remove them.
Undo the attachment bolts. Remove the support
bracket (2).
P0021025
2 Disconnect the harness terminal.

Remove the cable ties.
P0019060
3 If necessary, remove the control valve electrical

connection and the cable ties.
P0019061
47705020 05-2015 © AB VOLVO PENTA 225

Unscrew the oil pipe (1).

Pull the pipe out of the EGR control valve.
Remove the oil return pipe (2).
P0021026
5 NOTICE! No gasket replacement; exercise cau-

tion.
Undo the bolts a few turns and carefully tap the

valve with a plastic mallet until it comes loose.
Remove the control valve.
P0021027
226 47705020 05-2015 © AB VOLVO PENTA

Installation
6 NOTICE! Clean the sealing surfaces.
Check that the valve gaskets are undamaged.
P0021028
7 Apply joint sealant, part # 1161929.

Install the bolts and spacers.
Torque the e-EGR control valve as according to
Tightening torques page 9.
P0021029
8 Connect the oil pipes (1) and (2) to the control

valve.
P0021030
47705020 05-2015 © AB VOLVO PENTA 227

9 Connect and tighten the oil pipes.
P0021031
10 Where necessary, connect the control valve elec-

trical connection and attach new cable ties.
P0019061
11 Connect the harness terminal.

Attach new cable ties.
P0019060
228 47705020 05-2015 © AB VOLVO PENTA

12 Install the support bracket.
P0021032
13 Install the exhaust elbow and pipe elbow (1).

Tighten the attachment bolts (2).
Install the clamps and fasten them.
P0021025

NOTICE! If there is exhaust leakage from the

control valve, repeat valve torque tightening
steps 3-5 and carry out follow-up checks.
47705020 05-2015 © AB VOLVO PENTA 229

EGR mixing chamber, change

carried out.
NOTICE! Do not attempt to force the pipe into position

by bending, twisting or extending the bellows.
Removal
1 Remove the shutter housing; refer to Air throttle,
change page 241.
2 Undo the EGR pipe from the EGR mixer.
P0020665
3 Disconnect (1) the electrical connection from the

pre-heater relay.
Disconnect (2) the pre-heater element cable ter-
minals from the alternator.
Remove the bolts from the EGR mixer.
P0019055
230 47705020 05-2015 © AB VOLVO PENTA

4 Slide the EGR mixer and the pre-heater element

away sideways at the same angle as the EGR
pipe.
Remove the gaskets.
P0019056
Installation
5 NOTICE! Clean the sealing surfaces.
6 Install the gaskets and the pre-heater element.
Slide the EGR mixer sideways back into position
at the same angle as the EGR pipe.
P0019057
7 Install the EGR mixer bolts.
Torque the bolts diagonally in pairs in stages.

Stage 1: 10 Nm (7.4 lbf. ft.)
Fit pre-heater element connections (1) and (2).
P0019055
47705020 05-2015 © AB VOLVO PENTA 231

8 Bolt the EGR pipe to the EGR mixer.
P0020665
9 Install the shutter housing; refer to Air throttle,

change page 241.
232 47705020 05-2015 © AB VOLVO PENTA

25-5 Turbo and supercharger

Turbocharger, Inspection
1 Check that the turbocharger part number is cor-
rect for the engine variant. The wrong turbo-
charger for the engine variant might not provide
enough charge pressure, which would reduce
engine power.
2 Check that the turbocharger has the correct com-
pressor housing. If the wrong compressor hous-
ing is installed on the turbocharger, the compres-
sor wheel might have been damaged or have too
much clearance between wheel and housing. In
both cases, charge air pressure will be too low.
3 Remove the inlet manifold from the turbocharger.
4 Check the turbocharger for damage to the com-
pressor wheel and excessive end float on the tur-
bine shaft.
5 If there is any damage on the compressor wheel
or excessive end float on the turbine shaft, the
turbocharger must be changed as a unit.
6 Remove the exhaust pipe (muffler) from the tur-
bocharger and check the turbine disc.
7 Check the turbine wheel for damage. If the turbine
wheel is damaged, the turbocharger must be
changed as a unit.
Turbo, Change
Always identify and correct the cause of turbocharger
failure before fitting a new turbocharger. Check and
rectify according to: Turbocharger, Inspec-
tion page 233.
Removal
1 Drain the coolant according to: Coolant,
Change page 283.
2 Remove the exhaust pipe connection pipe
between the turbocharger and the aftertreatment
system.
47705020 05-2015 © AB VOLVO PENTA 233

3 Remove the turbocharger charge air pipe.

P0020043
4 Remove the heat shield brackets.
P0020044
5 1 Remove the inlet pipe from the air filter.

2 Remove the pipe bend from the turbo-
charger.
3 Remove the bracket and clamp and lift
away the pipe connection to the exhaust
pipe .
P0020045
234 47705020 05-2015 © AB VOLVO PENTA

6 Remove the rubber bellows from the air intake

with the connecting hose for crankcase ventila-
tion.
P0020046
7 Undo and lift up the heat shield.

Remove the NOx sensor, wiring and holder.
P0020047
8 IMPORTANT!
Remove the oil return pipe with gasket.

Remove the oil supply line.
Remove the intermediate piece for the NOx sen-
sor.
Remove the waste gate actuator hose.
P0020048
47705020 05-2015 © AB VOLVO PENTA 235

9 Remove the nuts and spacers from the turbo-

charger.
Lift away the turbocharger.
Remove the gasket.
P0020049
Installation
10 Check the sealing surface on the manifold.
11 New turbocharger:
Fit new studs in the turbocharger with the long
thread toward the manifold.
Install a new gasket on the exhaust manifold.

Lift the turbocharger into position.
Install the spacer sleeves and nuts, and fasten
the turbocharger.
P0020050
12 Tightening sequence: Diagonally 1–4
Tightening torque:
P0020051
236 47705020 05-2015 © AB VOLVO PENTA

13 NOTICE! Use new seals.
1 Fit oil return pipe.

Fill the turbocharger with new, clean engine

oil.
2 Install the oil supply line.
Install the intermediate piece for the NOx

sensor.
Connect the waste gate actuator hose.
P0020052
14 Install the heat shield.

15 Install the NOx sensor, wiring and holder.
Pull down the heat shield and secure it with cable
ties.
P0020053
16 Install the rubber bellows on the air intake with the

connecting hose to the crankcase ventilation.
P0020046
47705020 05-2015 © AB VOLVO PENTA 237

17 1 Bolt on the bracket and clamp the pipe con-

nection to the exhaust pipe.
2 Fit the pipe bend to the turbo.
3 Attach the inlet pipe to the air filter.
P0020054
18 Install the heat shield brackets.
P0020044
19 Install the heat shield.

Install the charge air pipe.
P0020043
20 Install the exhaust pipe connection pipe between

the turbocharger and the aftertreatment system.
21 Fill with new cooling fluid recommended by Volvo
Penta as per: Coolant Level, Checking and Top-
ping Up page 279.
238 47705020 05-2015 © AB VOLVO PENTA

Turbocharger, bearing clearances

check
Axial clearance- and end float are normally only
checked during overhaul, when you want to measure
the amount of wear in the unit.
Checking the end float
Tools:
1 Place the magnetic stand 9999696 Magnetic
stand with dial indicator 9989876 Dial indicator in
a suitable position.
Put the measurement tip on the center of the
shaft.
9989876
P0012191 9999696
2 Press in the exhaust turbine (A) by hand. Zero the

dial gauge.
B
A 3 Press in the compressor turbine (B) by hand.
Read the end float on the dial gauge. Permissible
P0012192
end float: Max. 0.127 mm (0.0050").
Replace / overhaul the turbocharger if the wear
tolerances are exceeded.
47705020 05-2015 © AB VOLVO PENTA 239

Radial clearance, check

Tools:
9999683 Dial indicator (short probe)
1 Attach the 9999683 Dial indicator (short probe) to
the 9999696 Magnetic stand. Position the meas-
urement tip on the compressor wheel.
9999683 2 Press the compressor wheel down at the same
time as the other end of the shaft (the turbine end)
is moved upwards. Zero the dial indicator.
3 Move the compressor wheel upwards, at the
same time as the other end of the shaft is pressed
down. Read off the radial clearance on the dial
indicator. Then rotate the shaft 90° and repeat the
measurement.
9999696 NOTICE! Ensure that the shaft is not rotated dur-

ing measurement.
Permissible radial clearance (compressor

wheel): Max. 0.508 mm (0.0200").
Replace the turbocharger if the wear limits have
been exceeded
P0004364
240 47705020 05-2015 © AB VOLVO PENTA

25-6 Air Cleaner, Throttle Housing

Air throttle, change
CAUTION!
Pinch hazard. Keep fingers clear.
IMPORTANT!
Removal
1 Remove the hose between the inlet manifold and
the charge air cooler.
2 Remove the electrical connection to the shutter
housing.
P0019046
3 Remove the shutter housing.
P0019047
47705020 05-2015 © AB VOLVO PENTA 241

4 Check that the shutter can be turned easily from

fully open to closed.
Press the shutter to the closed position and

release it. The valve is spring loaded and must
return to its default position (fully open).
NOTICE! Refer to Service handbook, Group 30

Electrical system, EATS for any fault tracing and
other unit measurements.
P0015227
Installation
5 Install the shutter housing and gaskets.
6 Fit the electrical connection to the shutter hous-
ing.
7 Install the hose between the inlet manifold and
charge air cooler.
P0019048
242 47705020 05-2015 © AB VOLVO PENTA

25-8 Emission After-Treatment

Repair instructions
NOTICE! Because the illustrations in the maintenance

literature are used for different engine variants, certain
details may vary compared to the actual model con-
cerned. The essential information in the illustrations is
always correct, however.
IMPORTANT!
AdBlue/DEF and urea solutions cause corrosion dam-
age. Do not remove AdBlue/DEF hoses, urea hoses or
electrical wiring during normal service or when moving
a component. Tools that have come into contact with
AdBlue/DEF or urea solution must be cleaned.
CAUTION!
Gloves must be changed. Take off contaminated
clothes.
WARNING!
In the case of any contact with eyes or skin the affected
area must be thoroughly rinsed with lukewarm water.
If you inhale any fumes, make sure you breathe fresh
air.
NOTICE! Always plug AdBlue/DEF and urea hoses in

order to avoid dirt in the AdBlue/DEF system, and any
crystallization of AdBlue/DEF.
NOTICE! Clean the AdBlue/DEF system before any

type of work is done to avoid dirt.
IMPORTANT!
Fluids other than AdBlue/DEF, and that are not
approved by Volvo, will cause a breakdown of the
exhaust aftertreatment system.
47705020 05-2015 © AB VOLVO PENTA 243

Electrically Heated AdBlue/DEF

Hose, Change
1 Stop the engine.
NOTICE! Wait at least two minutes before remov-

ing the AdBlue/DEF hoses so that automatic
drainage of the AdBlue/DEF system can proceed
and for the AdBlue/DEF system to de-pressurize.
2 Disconnect the battery negative terminal.
P0019364
3 Remove the cable tie from the AdBlue/DEF hoses

and electrical cables and expose the AdBlue/DEF
hose.
4 We recommend covering the connector with a

plastic bag to avoid spilling AdBlue/DEF.
5 Install the new AdBlue/DEF hose and check that
the connections are properly fitted and locked.
6 Connect the heater cable terminals.
7 Attach new cable ties.
p0013222
244 47705020 05-2015 © AB VOLVO PENTA

8 Reconnect the battery negative terminal.

9 Switch on the ignition and allow the pump to build
up pressure in the hoses. Check that no leakage
occurs.
10 Perform a function test and delete any fault
codes.
P0019365
47705020 05-2015 © AB VOLVO PENTA 245

AdBlue/DEF Tank, Change

Tools:
1158957 Pliers
Removal
1 Stop the engine.
NOTICE! Wait until the pump unit has stopped

running as it usually performs automatic empty-
ing of the AdBlue/DEF hoses.
3 Place a receptacle underneath the tank.
NOTICE! Use approved safety equipment and

receptacle.
P0019364
4 Undo the filler cap (1) and remove the drain plug
(2).
Empty the AdBlue/DEF from the tank.
P0019366
246 47705020 05-2015 © AB VOLVO PENTA

5 Remove the AdBlue/DEF hoses from the tank fit-

ting and seal the connectors (A) in a plastic bag.
6 Pinch off flow in both coolant hoses (B) using
1158957 Pliers on each hose.
Remove the hoses.
P0019367
1158957
p0013226
p0013222
7 Hold the tank secure and remove the bolts.
P0019368
47705020 05-2015 © AB VOLVO PENTA 247

8 Lift the tank and pull it carefully out of the locating

pins on the bracket.
P0019369
9 Undo the bolts and remove the stainless steel

sheet.
P0019370
10 Remove the bolts to the LT module and undo the

hose clamp to the tank fitting.
Carefully lift the tank fitting out of the tank.
P0019371
248 47705020 05-2015 © AB VOLVO PENTA

11 Remove the bolts.
P0019372
12 Remove the bolts and hose holder.
P0019373
13 Carefully prize the tank sides (1) apart and then

pull out the tank (2). Be aware that the venting
hose is attached.
P0019374
47705020 05-2015 © AB VOLVO PENTA 249

Installation
14 Carefully prize the tank sides (1) apart and install
the new tank (2).
P0019375
15 Install the bolts and hose holder.
P0019373
16 Install the bolts.
P0019372
250 47705020 05-2015 © AB VOLVO PENTA

17 Insert the tank fitting with the LT module.
P0019376
18 Install the stainless steel sheet.
P0019370
19 Suspend the tank module from the locating pins.
NOTICE! Make sure no hoses or cables get

pinched.
P0019377
47705020 05-2015 © AB VOLVO PENTA 251

P0019368
21 Install the AdBlue/DEF hoses and coolant hoses.

Check that the connections are properly attached
and locked.
22 Remove 1158957 Pliers.
23 Fill with AdBlue/DEF.
24 Top off coolant as necessary.
P0019378

up pressure in the hoses.
Check that no leakage occurs.
codes.
P0019365
IMPORTANT!
Fluids other than AdBlue®/DEF, and that are not
NOTICE! Care for equipment and the remaining

AdBlue®/DEF solution.
p0013225
252 47705020 05-2015 © AB VOLVO PENTA

AdBlue/DEF Tank, Cleaning

Tools:
1158957 Pliers
CAUTION!
Gloves must be changed. Take off contaminated
clothes.
1 Stop the engine.

P0019364
3 Place a receptacle underneath the tank.

receptacle.
4 Undo the filler cap (1) and remove the drain plug
(2).
Empty the AdBlue/DEF from the tank.
P0019366

Remove the hoses.
P0019367
47705020 05-2015 © AB VOLVO PENTA 253

1158957
p0013226
p0013222
7 Hold the tank secure and remove the bolts.
P0019368
8 Support the tank and pull it carefully out of the

locating pins on the bracket.
P0019369
254 47705020 05-2015 © AB VOLVO PENTA


P0019371
10 Flush the AdBlue/DEF line clean using hot water

and clean the strainer.
NOTICE! Always replace a damaged strainer.
P0019379
11 Remove the filler cap and undo the filler assem-

bly.
P0019380
47705020 05-2015 © AB VOLVO PENTA 255

12 Immerse the filler cap and filler assembly in a

water bath for at least 2 minutes.
13 Flush the tank with hot water for at least 10

minutes.
NOTICE! Make sure that the tank is completely

drained of water afterwards.
P0019381
14 Install the filler assembly.
P0019382
256 47705020 05-2015 © AB VOLVO PENTA

15 Insert the tank fitting with the LT module.
P0019376
16 Suspend the tank module from the locating pins.
NOTICE! Make sure no hoses or cables get

pinched.
P0019377
P0019368
47705020 05-2015 © AB VOLVO PENTA 257


and locked.
19 Remove the hose pinchers.
20 Fill with Adblue/DEF.
21 Top off coolant as necessary.
22 Change the AdBlue/DEF-Pump filter, see
AdBlue/DEF-Pump Filter, Change page 264.
P0019378

codes.
P0019365
IMPORTANT!
Fluids other than AdBlue®/DEF, and that are not

p0013225
258 47705020 05-2015 © AB VOLVO PENTA

Exhaust Temperature Sensor,

Change
P0019364
2 Remove the cable tie.

3 Undo the connector.
4 Undo the temperature sensor.
5 Screw in a new temperature sensor.
6 Install the connector. Attach new cable ties.
P0019383

8 Start the engine. Check for leaks; check function.
9 Delete any fault codes.
P0019365
47705020 05-2015 © AB VOLVO PENTA 259

Dosing unit, change

Removal
1 Stop the engine.
NOTICE! Wait at least two minutes before remov-

ing the AdBlue/DEF hoses so that automatic
drainage of the AdBlue/DEF system can proceed
and for the AdBlue/DEF system to de-pressurize.
CAUTION!
Hot surfaces can cause burns.
P0019364
3 Remove the AdBlue/DEF hoses and seal the con-

nectors in a plastic bag.
P0019384
p0013222
260 47705020 05-2015 © AB VOLVO PENTA

4 Remove the connector.
NOTICE! Make sure the connector does not

become contaminated with AdBlue/DEF fluid.
P0019385
5 Remove the bolts.

6 Remove the dosing unit.
P0019386
47705020 05-2015 © AB VOLVO PENTA 261

Installation
7 Clean the contact surface.
8 NOTICE! Grease the bolts with water resistant
grease. E.g. 828250 Grease.
P0019387
10 Connect the connector.
P0019388
11 Install the AdBlue/DEF hoses.
P0019384
262 47705020 05-2015 © AB VOLVO PENTA


P0019365

p0013225
47705020 05-2015 © AB VOLVO PENTA 263

AdBlue/DEF-Pump Filter, Change

D11 4f JP, TAD1170VE, TAD1171VE, TAD1172VE
1 Stop the engine.

ing of the AdBlue®/DEF hoses.
P0019364
3 Place a receptacle under the filter cover.

4 Undo the filter cover

receptacle.
P0019389
264 47705020 05-2015 © AB VOLVO PENTA

5 Use the puller (supplied with the filter kit) to pull

out the filter by first pressing it into the filter hole
until it clicks.
6 Pull out the filter.
P0019390
7 Install the new filter (1).

Install the rubber gasket (2).
Screw on the filter cover (3).
P0019391
47705020 05-2015 © AB VOLVO PENTA 265

8 Tighten the cover.

Tightening torque: 20 (+5) Nm (14.8 +3.68 Ibf.
ft.)
P0019392

P0019365

p0013225
266 47705020 05-2015 © AB VOLVO PENTA

Solenoid Valve, AdBlue/DEF Tank,

Change
Tools:
1158957 Pliers
Removal
1 Cut power to the engine by disconnecting the
negative battery terminal.
P0019364
2 Clamp 1158957 Pliers (A) on both coolant hoses

on either side of the solenoid valves so that cool-
ant does not run out.
NOTICE! The hose connections are available in

A different designs.
A
p0013271
3 Remove the electrical connection from the sole-

noid valve.
4 Remove the coolant hoses from the solenoid
valve.
5 Remove the solenoid valve retaining bolts.
Remove the solenoid valve.
P0013270
47705020 05-2015 © AB VOLVO PENTA 267

Installation
6 Install the solenoid valve.
Install the solenoid valve retaining bolts.
7 Install the electrical connection.
8 Install the coolant hoses. Secure them with hose
clamps.
P0013270
9 Remove 1158957 Pliers (A) from the coolant

hoses.
A
p0013271
P0019365
268 47705020 05-2015 © AB VOLVO PENTA

Pump Unit, Change

Removal
1 Stop the engine.

P0019364
3 Remove the harness terminal
P0019393
47705020 05-2015 © AB VOLVO PENTA 269

4 Remove the AdBlue/DEF hoses and seal the con-

nectors in a plastic bag.
NOTICE! Use approved safety equipment.
P0019394
p0013222
5 Remove the pump unit.
NOTICE! Make sure the electrical connection

does not become contaminated with AdBlue/DEF
fluid.
P0019395
270 47705020 05-2015 © AB VOLVO PENTA

Installation
6 Install the new pump unit and fasten it with the
bolts.
P0019395
7 Install the AdBlue/DEF hoses.
P0019394
8 Install a new harness terminal and make sure the

connection lock clicks.
P0019393
47705020 05-2015 © AB VOLVO PENTA 271


P0019365

p0013225
272 47705020 05-2015 © AB VOLVO PENTA

Combined Tank Unit, AdBlue/DEF

Tank, Change
Tools:
1158957 Pliers
Removal
1 Stop the engine.

P0019364
47705020 05-2015 © AB VOLVO PENTA 273


Remove the hoses.
P0019367
1158957
p0013226
p0013222

P0019371
274 47705020 05-2015 © AB VOLVO PENTA

Installation
6 Insert the new tank fitting with the LT module.
P0019376

and locked.
8 Remove 1158957 Pliers.
P0019378

codes.
P0019365

p0013225
47705020 05-2015 © AB VOLVO PENTA 275

Checking for diesel or oil in the

AdBlue/DEF solution
1 Remove the insertion in the tank inlet for better vis-

ibility and access to the fluid.
P0019380
2 Dip the indicating paper in the AdBlue/DEF solution

in the tank by halves.
3 Attach the indicating paper to a suitable stick to
reach down to the surface.
Evaluation
• If there is diesel or oil in the fluid, the dipped part of
the paper will turn dark blue.
• As small amount of diesel as down to 0,5 % can be
detected.
• Most of the diesel will stay on the surface of the
P0020548 AdBlue/DEF solution, but traces of diesel can be
found throughout the entire tank.
• The system is very sensitive for incorrect
AdBlue/DEF solution.
276 47705020 05-2015 © AB VOLVO PENTA

Checking urea concentration in the

fluid
Tools:
88890105 Refractometer
NOTICE! Rinse the test equipment carefully with dis-

tilled water before use.
1 Remove the insertion in the tank inlet for better vis-

ibility and access to the fluid.
2 Draw in a small amount of the liquid from the sur-
face using the pipette.
Use a clean hose as extension to the pipette if tank
level is low.
P0019380
3 Apply a drop on the viewer of the instrument

(88890105 Refractometer).
Evaluation
• The level must be exactly on the line for correct con-
centration.
• The system is very sensitive for incorrect urea sol-
ution.
• If no level is shown in the instrument it may indicate
chemical residue, such as pure water or diesel.
P0020549
47705020 05-2015 © AB VOLVO PENTA 277

26-0 Cooling System, General

Cooling System, Cleaning
WARNING!
All coolant is hazardous and harmful to the environ-
ment. Do not consume. Coolant is flammable.
Cooling performance is reduced by deposits in the

radiator and cooling galleries. The cooling system
should be cleaned out when the coolant is changed.
IMPORTANT!
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have antifreeze properties.
IMPORTANT!
It is extremely important that the correct concentration
and volume of coolant is added to the system. Mix in a
separate clean vessel before filling the cooling system.
Make sure that the liquids mix.
1 Drain the cooling system. Refer to 26-0, Draining
the Cooling System.
2 Put a hose into the expansion tank filling hole and
flush with clean water, according to specifications
in 03-26, Technical Data, until the water draining
out is completely clear.
3 Should there still be some contamination left after
flushing for a long time, cleaning may be done
with coolant. Otherwise, continue as in stage 8
below.
4 Fill the cooling system with 15-20% mixture of
concentrated coolant. Use only Volvo Penta rec-
ommended concentrated coolant mixed with
clean water.
5 Drain the coolant after 1–2 days of operation.
Remove the filler cap and the lower radiator hose
if necessary to increase emptying speed.
To prevent suspended material from settling back
in the system, emptying should be done rapidly,
within 10 minutes, without the engine having
been at a standstill for a long time.
6 Flush the system immediately and thoroughly
with clean hot water to prevent dirt from settling
on the inner surfaces. Flush until the water run-
ning out is completely clean. Make sure that any
heater controls are set to full heating during emp-
tying.
7 Should contamination still remain after a long
period of flushing, a clean-out may be done using
Volvo Penta radiator cleaner, followed by treat-
ment with Volvo Penta neutralizer. Carefully fol-
low the instructions on the package. Otherwise,
continue as in stage 8 below.
8 When the cooling system is completely free from
contamination, close the drain taps and plugs.
278 47705020 05-2015 © AB VOLVO PENTA

9 Refill with new, Volvo Penta-recommended cool-

ing fluid. Refer to 03-26, Technical Data and
Coolant Level, Checking and Topping
Up page 279.
Coolant Level, Checking and

Topping Up
Tools:
IMPORTANT!
Only use Volvo Penta recommended coolant.
CAUTION!
Avoid opening the filler cap for engine coolant system
(freshwater cooled engines) when the engine is still
hot. Steam or hot coolant can spray out as system
pressure is lost.
NOTICE! Use suitable safety equipment when working

with the system.
1 NOTICE! Only open the filler cap (1). Do not open

the pressure cap (2).
2 Check that the coolant level is above the MIN
mark on the expansion tank.
Top up with coolant as required, so that the level
is between the MIN and MAX marks.
P0019914
47705020 05-2015 © AB VOLVO PENTA 279

Filling a completely empty cooling system

NOTICE! Mix the correct amount of coolant in advance
to ensure that the cooling system is completely filled.
Refer to 03-26, Technical Data for the correct coolant
quantity.
IMPORTANT!
Do not start the engine until the system is purged and
completely filled.
NOTICE! If a heating unit is connected to the engine

cooling system, the heat control valve must be opened
and the installation vented during filling.
1 Check that all drain points are closed.

2 Open the filler cap (1). Do not open the pressure
cap (2).
3 Top up with coolant so that the level is between
the MIN and MAX marks.
4 Start the engine when the cooling system has
been completely filled and vented.
Open any venting nipples a short while after start-
ing, to allow trapped air to escape.
5 Run the engine at idle.
Increase engine speed somewhat after five
minutes. Increase for three minutes.
6 Check the coolant level.
7 Start the engine.
P0019914 Run it until it reaches operating temperature
(thermostat open).
8 Check the coolant level.
Adjust the level as required.
Cooling System, Pressure Testing

Alternative 1
WARNING!
burns.
Tools:
and intact.
a suitable cover from 3849613 Pressure testing
kit.
280 47705020 05-2015 © AB VOLVO PENTA

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.
P0010195
8 Start the engine and check that no leakage
occurs.
Alternative 2
WARNING!
burns.
Tools:
9996441 Cover, with connecting nipple
and intact.
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.
P0010196
occurs.
Alternative 3
WARNING!
burns.
Tools:
and intact.
47705020 05-2015 © AB VOLVO PENTA 281

3 Connect 9996662 Pressure testing kit to

9996049 Draining hose and close the cock. Con-
nect 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.
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 pres-
sure 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.
occurs.
282 47705020 05-2015 © AB VOLVO PENTA

Coolant, Change
Tools:
CAUTION!
Avoid opening the filler cap for engine coolant system
(freshwater cooled engines) when the engine is still
hot. Steam or hot coolant can spray out as system
pressure is lost.
NOTICE! Use suitable safety equipment when working

with the system.
1 NOTICE! Do not open the pressure cap (2).
Remove the filler cap (1).

2 Open all drain points.
NOTICE! There may be other taps or plugs at the

lowest points of the coolant system.
P0019914
3 Connect 9996049 Draining hose.

Connect a drainage vessel.
Empty the radiator.
NOTICE! The drain nipples are situated under the

radiator on the right side of the engine block.
4 Remove the tool.
Close any taps.
5 Refill with new, Volvo Penta-recommended cool-
ing fluid.
Refer to 03-26, Technical Data and Coolant
Level, Checking and Topping Up page 279.
P0019915
47705020 05-2015 © AB VOLVO PENTA 283

26-2 Coolant Pump, Thermostat

Coolant Pump, Change
carried out.
Removal
1 Drain the coolant; refer to Coolant,
Change page 283.
2 Remove the belt guard.
3 Free the belt tensioner for the coolant pump.
Remove the belt and put it aside.
Remove the coolant pump belt pulley.
P0019960
Remove the coolant pump.
P0019961
284 47705020 05-2015 © AB VOLVO PENTA

Installation
P0019962
6 Install a new coolant pump seal.

Use petroleum jelly to hold the seal in place dur-
ing installation.
P0019963
7 Fit the coolant pump with seal. Torque the screws

as specified; refer to 03-2, Special Tightening
Torques.
P0019961
47705020 05-2015 © AB VOLVO PENTA 285

8 Install the belt pulley.

Free the belt tensioner and fit the belt.
P0019960
9 Install the belt guard.

10 Fill with coolant; refer to Coolant Level, Checking
and Topping Up page 279.
Start the engine. Check that no leakage occurs.
286 47705020 05-2015 © AB VOLVO PENTA

Thermostat, Change
Removal
1 Disconnect the radiator hose.
P0020014
2 Remove the EGR pipe heat shield bolts.

Slide the plate up a little to unbolt the connection
pipe.
P0020015
3 Remove the thermostat housing connection pipe.
P0020016
47705020 05-2015 © AB VOLVO PENTA 287

4 Remove the thermostat housing cover.
P0020017
5 Remove the thermostat.

6 Clean the mating surfaces for the thermostat and
the thermostat housing cover.
P0020018
288 47705020 05-2015 © AB VOLVO PENTA

Installation
7 Install the new thermostat and a new gasket.
P0020019
8 Install the thermostat housing cover.
P0020017
9 Install the thermostat housing connection pipe.
P0020016
47705020 05-2015 © AB VOLVO PENTA 289

10 Slide the plate down and tighten the EGR pipe

heat shield bolts.
P0020020
11 Connect the radiator hose.
P0020014
12 Fill with coolant; refer to Coolant Level, Checking

and Topping Up page 279.
14 Pressure test the cooling system; refer to Cooling
System, Pressure Testing page 280.
290 47705020 05-2015 © AB VOLVO PENTA

Thermostat, Function Check

Remove the thermostat, see Thermostat,
Change page 287.
1 Place the thermostat in a big pot with water and
heat it to the opening temperature as specified in
Administration page 25.
P0005072
Closed thermostat.
2 If the thermostat does not open at specified tem-

perature, it should be replaced.
3 Install the thermostat, see Thermostat,
Change page 287.
NOTICE! Always use a new seal, even if the ther-

mostat is not replaced.
P0005073
Open thermostat.
47705020 05-2015 © AB VOLVO PENTA 291

32-1 Alternator
32-1 Alternator
Alternator, Change
carried out.
Removal
1 Remove the right belt guard.
P0019906
2 Remove the drive belt according to Drive Belt,

Change page 296.
3 Undo the alternator body connection (1) (starter
motor).
Undo the alternator body connection (2) (pre-
heater element).
P0019907
292 47705020 05-2015 © AB VOLVO PENTA

32-1 Alternator
4 Undo B1+ positive alternator connection (starter

motor).
P0019908
5 Disconnect the connector (1) (multifunction reg-

ulator).
Undo B2+ cable connection (2) (pre-heater
relay).
P0019909
6 Remove the alternator.
P0019910
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32-1 Alternator
Installation
7 Install the insulating bushing.
Install the alternator and tighten the two attach-
ment bolts and nuts.
P0019911
8 Connect B2+ cable connection (1) (pre-heater

relay).
Attach the connector to the terminal (2).
Secure it to the cable clip using cable ties.
P0019912
9 Connect B1+ positive alternator connection

(starter motor).
P0019908
294 47705020 05-2015 © AB VOLVO PENTA

32-1 Alternator
10 Connect the alternator body connection (1) (pre-

heater element).
Connect the alternator body connection (2)
(starter motor).
P0019913
11 Install the drive belt according to Drive Belt,

Change page 296.
12 Install the right belt guard
P0019906
47705020 05-2015 © AB VOLVO PENTA 295

32-1 Alternator
Drive Belt, Change

CAUTION!
Removal
1 Remove the fan guards and fan ring round the
cooling fan.
2 NOTICE! Fit a 1/2" socket drive to the belt ten-
sioner (1).
Free the belt tensioner, pass the drive belt round

the fan blades and remove it.
3 Check the function of the tensioner, the condition
of the pulleys and the idler wheel bearings.
P0019870
Installation
4 Pass the new drive belt over the fan.
Free the belt tensioner and fit the belt.
5 Check that the belt is correctly aligned on all the
pulleys.
6 Install the fan guard and fan ring round the cooling
fan.
296 47705020 05-2015 © AB VOLVO PENTA

32-1 Alternator
Alternator Belt, Change

CAUTION!
Removal
1 Remove the fan guards and fan ring round the
cooling fan.
sioner (1).
Free the belt tensioner and lift the water pump

drive belt off.
sioner (2).
Free the belt tensioner and lift the alternator drive

belt off.
4 Check the function of the tensioner and the con-
dition of the pulleys and the idler pulley bearings.
P0019871
Installation
5 Pass the new alternator drive belt over the fan.
Free the belt tensioner (2) and fit the belt.
6 Free the belt tensioner (1).
Lift the water pump drive belt back into place.
P0019871
7 Install the fan guard and fan ring round the cooling
fan.
47705020 05-2015 © AB VOLVO PENTA 297

33-1 Starter Motor
33-1 Starter Motor

Starter Motor, Change
Removal
1 IMPORTANT!
Turn off the main switch before any work is car-
ried out.
2 Remove the cable from the negative terminal.
P0019364
3 Remove the battery cables from the starter motor.
P0019996
4 Remove the cable ties.

Disconnect and move aside the alternator cables.
P0019997
298 47705020 05-2015 © AB VOLVO PENTA

33-1 Starter Motor
5 Disconnect and move aside the cables to the

cable split/fuse holder.
P0019998
6 Disconnect the connector.
P0019999
7 Remove the starter motor.
P0020000
Installation
8 Clean the mating surface on the flywheel hous-
ing.
9 Re-install all wiring and cables to their original
locations.
47705020 05-2015 © AB VOLVO PENTA 299

33-1 Starter Motor
10 Fit the gasket over the studs.

Install the starter motor with the insulating bush-
ings. The starter motor must be fully electrically
insulated from the flywheel housing.
Check as necessary using a multimeter between

flange bolts, studs and the starter motor casting.
NOTICE! Other engine electrical systems must

be disconnected when measuring to avoid incor-
rect values.
The resistance must be more than: 1 MΩ.
P0020001
11 Connect the connector.
P0020002
12 Connect the respective cables to the cable split/

fuse holder.
P0019998
300 47705020 05-2015 © AB VOLVO PENTA

33-1 Starter Motor
13 Connect the alternator cables.
P0020003
14 Tighten using cable ties.
P0020004
15 Fasten the cable shoes – positive cable first, neg-

ative cable last.
P0019996
16 IMPORTANT!
Check that the wiring and cables do not chafe
against the starter motor or engine block.
Check that all wiring and cables are properly
secured.
47705020 05-2015 © AB VOLVO PENTA 301

33-1 Starter Motor
17 Connect the cable to negative terminal.

P0019365
302 47705020 05-2015 © AB VOLVO PENTA

Alphabetical index
A Engine Complete, General....................................... 55
About this Workshop manual..................................... 3 Engine Disassembly................................................. 57
AdBlue/DEF Tank, Change.................................... 246 Engine Fixture, Installation....................................... 55
AdBlue/DEF Tank, Cleaning.................................. 253 Engine Information, General.................................... 49
AdBlue/DEF-Pump Filter, Change......................... 264 Engine Oil Pressure, Check................................... 162
Air Cleaner, Throttle Housing................................. 241 Exhaust Manifold, Change..................................... 215
Air throttle, change................................................. 241 Exhaust Temperature Sensor, Change.................. 259
Alternator................................................................ 292 F
Alternator Belt, Change.......................................... 297 Fitting the Fixture...................................................... 55
Alternator, Change................................................. 292 Flywheel, Indication................................................ 150
C Fuel Feed Pressure, Check.................................... 192
Camshaft Bearing Housing, Replace..................... 149 Fuel Feed Pump and Filter..................................... 188
Camshaft, Wear Check.......................................... 148 Fuel Feed Pump, Change...................................... 197
Charge Air Pipe, Leakage Check........................... 214 Fuel filter housing, change..................................... 193
Checking for diesel or oil in the AdBlue/DEF Fuel filter, Change.................................................. 191
solution................................................................... 276 Fuel Pre-filter, Change........................................... 188
Checking urea concentration in the fluid................ 277 Fuel System.................................................... 34, 0
Chemical products.................................................... 48 Fuel system, bleeding............................................ 184
Combined Tank Unit, AdBlue/DEF Tank, Change. 273 Fuel System, General............................................. 184
Connecting Rod Bushing, Check up...................... 105 G
Connecting Rod, Check......................................... 105 Gear Ring, Fywheel: Replace................................ 151
Control System, ECM, Data Sets........................... 212 General........................................................ 3, 48, 0
Control Unit, Replace............................................. 212 I
Control valve e-EGR, change................................. 225 Illustrations................................................................. 6
Coolant Level, Checking and Topping Up.............. 279 Injector, Change..................................................... 200
Coolant Pump, Change.......................................... 284 Injectors and Delivery Pipes................................... 200
Coolant Pump, Thermostat.................................... 284 Inlet and Exhaust Manifolds................................... 215
Coolant, Change.................................................... 283 Inlet and Exhaust System................................ 36, 0
Cooling System............................................... 36, 0 Inlet and Exhaust System, General........................ 214
Cooling System, Cleaning...................................... 278 Intake Manifold, Change........................................ 218
Cooling System, General....................................... 278
Cooling System, Pressure Testing................... 49, 280 L
Crank Mechanism.................................................. 154 Lube Oil Pump, Installation...................................... 75
Crankshaft Seal, Change (front)............................. 154 Lube Oil Pump, Removal......................................... 57
Crankshaft Seal, Change (rear)............................. 156 Lubricating and Oil System, General...................... 162
Crankshaft, Inspection............................................ 158 Lubrication Oil Pump, Change............................... 165
Crankshaft, Installation............................................. 67 Lubrication System................................................... 33
Crankshaft, Removal................................................ 64 M
Cylinder Head........................................................... 76 Main bearing, Change............................................ 159
Cylinder Head, Installation....................................... 86
O
Cylinder Head, Pressure Testing............................. 52
Oil cooler................................................................ 179
Cylinder Head, Removal.......................................... 76
Oil Cooler, Replace................................................ 179
Cylinder Liner and Pistons, Inspection................... 104
Oil filter................................................................... 170
Cylinder Liner, Installation........................................ 70
Oil filter bracket valves, change............................. 176
Cylinder Liner, Pistons........................................... 104
Oil Filter Bracket, Change...................................... 172
Cylinder Liners, Removal......................................... 61
Oil filter, Change..................................................... 170
D Oil pressure safety valve, change.......................... 163
Dosing unit, change................................................ 260 Oil pump and Line.................................................. 165
Draining, Fuel Duct in Cylinder Head..................... 186
P
Drive Belt, Change................................................. 296
Pistons, Installation.................................................. 74
E Pistons, Removal..................................................... 58
EGR mixing chamber, change............................... 230 Pump Unit, Change................................................ 269
Electrical System...................................................... 37
R
Electrically Heated AdBlue/DEF Hose, Change..... 244
Radial clearance, check......................................... 240
Emission After-Treatment....................................... 243
Repair instructions.............................................. 4, 243
Emission Control, Catalytic Converter.................... 225
Engine............................................................. 26, 0 S
Engine Assembly...................................................... 67 Safety Instructions.................................................... 38
47705020 05-2015 © AB VOLVO PENTA 303

Sensors, Adjustment.............................................. 152
Sleeve for unit injector, replace.............................. 205
Solenoid Valve, AdBlue/DEF Tank, Change.......... 267
Special Service Tools............................................... 42
Specifications, Electrical........................................... 37
Specifications, Engine ............................................... 9
Starter Motor.......................................................... 298
Starter Motor, Change............................................ 298
T
Test and Adjustments............................................... 49
Thermostat, Change............................................... 287
Thermostat, Function Check.................................. 291
Tightening Schedules............................................... 15
Timing Gear, Installation........................................ 136
Timing Gear, Removal........................................... 127
Timing Gears and Shaft......................................... 127
Turbo and supercharger......................................... 233
Turbo, Change....................................................... 233
Turbocharger, bearing clearances check............... 239
Turbocharger, Inspection....................................... 233
V
Valve cover, change............................................... 101
Valve Guides, Inspection........................................ 115
Valve Guides, Replacing........................................ 116
Valve Mechanism................................................... 106
Valve mechanism equipped with VCB (Volvo
Compression Brake)............................................... 110
Valve Seat, Change............................................... 123
Valve Stem Sealings, Replace............................... 125
Valves and Unit Injectors, Adjustment.................... 106
Valves, Installation................................................. 121
Valves, Removal.................................................... 119
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References to Service Bulletins
Group No. Date Refers to
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305
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Do you have any comments or other viewpoints concerning this manual? Make a
copy of this page, and write down your comments and send them to us. The ad-
dress is at the bottom of the page. We would prefer you to write in Swedish or
English.
From:...............................................................................
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Concerns publication:...............................................................................................................................................
Publication No.:.............................................................Date of issue:......................................................................
Proposal/Motivation:.................................................................................................................................................
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.................................................................................................................................................................................
Date:..............................................................
Name:............................................................
AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
47705020 English 05-2015

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Workshop Manual I

Group 21-26 2(0)

TAD1140VE, TAD1141VE, TAD1142VE,

Safety and Other Instructions

Lubricating and Oil System

Inlet and Exhaust System

47705020 05-2015 © AB VOLVO PENTA 1

Alternator, Charge Regulator

2 47705020 05-2015 © AB VOLVO PENTA

Volvo Penta accepts no responsibility for damage or

47705020 05-2015 © AB VOLVO PENTA 3

Above all, when working on fuel systems, hydraulic

4 47705020 05-2015 © AB VOLVO PENTA

Lock nuts Anaerobic agents.

47705020 05-2015 © AB VOLVO PENTA 5

Illustration colors Position

Focus arrows pointing at object. Sometimes it con-

NOTICE! If an arrow with the text “x3” is pointing at

The symbol to the left shows part no. of the positioned

6 47705020 05-2015 © AB VOLVO PENTA

Movement Tools (continuence)

Movement arrows are used to show which direction a

Symbol is used in a corner of the illustration to show

Symbol is used to show how many revolutions the

A drill in a specified size, duck tape and stripes may

One of the following symbols is used when describing

47705020 05-2015 © AB VOLVO PENTA 7

Symbols can also describe when and how a chemical

Units are mentioned in the illustration when a specific

The scraper symbol suggests that a contact surface

The eye symbol is used when something needs close

The tube symbol shows how thick layer of sealant to

These symbols are used when a certain safety related

8 47705020 05-2015 © AB VOLVO PENTA

03-2 Specifications, Engine

NOTICE! Inspect bolts that will be re-installed.

Special Tightening Torques

Main Bearing Caps:

Conrod caps (tightened diagonally):

Stiffening plate / stiffening frame (cylinder block) 48 ±8 (35.4 ±6) –

Lifting eye, front

47705020 05-2015 © AB VOLVO PENTA 9

Standard valve mechanism Tightening tor-

VCB mechanism Tightening tor-

10 47705020 05-2015 © AB VOLVO PENTA

Group 22: Lubrication System

Group 23: Fuel System

Yoke, unit injector:

Note: Loosen the fixing yoke bolt before the sec-

With re-used copper sleeve

Locking nut for adjuster screw, unit injector:

Hollow screw M16 40 ±4 (29.5 ±3) –

47705020 05-2015 © AB VOLVO PENTA 11

Piston Cooling Nozzles

IMPORTANT! Faulty piston cooling will cause the pistons to

Group 25: Inlet and Exhaust System

Control valve, e-EGR:

12 47705020 05-2015 © AB VOLVO PENTA

1 Under pressure sensor, air filter. Clamp. 8 e-EGR control valve

47705020 05-2015 © AB VOLVO PENTA 13

10 Crankcase pressure sensor 13 Auxiliary stop

14 47705020 05-2015 © AB VOLVO PENTA

Tightening torques: Nm (lbf.ft) Angle tightening