Manuale Officina Volvo TAD870VE

Workshop Manual I
Group 21-26 2(0)
TAD570VE, TAD571VE, TAD572VE,

TAD870VE, TAD871VE, TAD872VE, TAD873VE
Content
General Information
00-0 General ................................................................................................ 2
Specifications
03-2 Specifications, Engine ....................................................................... 8
03-22 Lubrication System ........................................................................ 30
Safety and Other Instructions

05-1 Safety Instructions ........................................................................... 31
Special tools
08-2 Special Service Tools ....................................................................... 35
Engine
21-1 Cylinder Head .................................................................................... 37
21-4 Valve Mechanism .............................................................................. 51
21-5 Timing Gears and Shaft ................................................................... 59
21-6 Crank Mechanism ............................................................................. 63
Lubricating and Oil System

22-2 Oil filter .............................................................................................. 73
22-3 Oil cooler ........................................................................................... 82
Fuel System
23-0 Fuel System, General ....................................................................... 85
23-3 Fuel Feed Pump and Filter ............................................................... 86
23-7 Injectors and Delivery Pipes .......................................................... 112
23-9 Miscellaneous ................................................................................. 131
Inlet and Exhaust System

25-4 Emission Control, Catalytic Converter ......................................... 134
25-5 Turbo and supercharger ................................................................ 145
25-8 Emission After-Treatment .............................................................. 158
Cooling System
26-0 Cooling System, General ............................................................... 193
26-1 Radiator, Heat Exchanger .............................................................. 197
26-2 Coolant Pump, Thermostat ............................................................ 203
Alternator, Charge Regulator

32-1 Alternator ......................................................................................... 221
Starting System
33-1 Starter Motor ................................................................................... 227
Alphabetical index .................................................................................. 231
References to Service Bulletins ............................................................ 233
47705010 05-2015 © AB VOLVO PENTA 1

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.
2 47705010 05-2015 © AB VOLVO PENTA

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.
47705010 05-2015 © AB VOLVO PENTA 3

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.
4 47705010 05-2015 © AB VOLVO PENTA

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.
47705010 05-2015 © AB VOLVO PENTA 5

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.
6 47705010 05-2015 © AB VOLVO PENTA

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.
47705010 05-2015 © AB VOLVO PENTA 7

03-2 Specifications, Engine

General Tightening Torques
General Tightening Torques
M6 standard bolt 10 ± 1.5 Nm (7.4 ± 1.1 lbf ft)
M8 standard bolt 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
IMPORTANT!
Check bolts which are to be re-installed. Damaged bolts,
e.g. with shear marks under heads must be scrapped.
8 47705010 05-2015 © AB VOLVO PENTA

Special Tightening Torques
Group 21: Engine

TAD8xxxVE
Main Bearing Caps
NOTICE! Use new bolts.
NOTICE! Tighten the bolts in sequence, as illustrated.
Step 1: 60 Nm (44.2 lbf. ft.)

Step 2 (angle tightening): 90°
P0021522
TAD5xxxVE
P0021523
Conrod caps
NOTICE! Use new bolts.
Step 1: 75 Nm (55.3 lbf. ft.)

P0021524
47705010 05-2015 © AB VOLVO PENTA 9

TAD8xxxVE
Frame reinforcement
Tightening torque: 24 Nm (17.7 lbf. ft.)
Step 1:
Tighten the bolts in sequence, as illustrated.
Step 2:
Tighten the remaining bolts:
P0021525
TAD5xxxVE
P0021526
Timing gears
1 Drive gear, camshaft

32 Nm (23.6 lbf. ft.)
2 Idler wheel (hexagon socket head
screw)
24 Nm (17.7 lbf. ft.)
3 Idler wheel
24 Nm (17.7 lbf. ft.)
4 Idler wheel (dual)
63 Nm (46.5 lbf. ft.)
5 Drive gear, air compressor
225 Nm (166.0 lbf ft)
6 Idler wheel, adjustable
63 Nm (46.5 lbf. ft.)
7 Drive gear, fuel feed pump
59 Nm (43.5 lbf. ft.)
P0021527
10 47705010 05-2015 © AB VOLVO PENTA

Flywheel and timing cover
P0021528
P0021530
NOTICE! Apply an approximately 2 mm (0.079”) thick

string of silicon (product no. 1161231) as illustrated in
figure on left, max. 20 minutes before installation.
Tightening torque
Bolts 1-9 85 Nm (62.7 lbf. ft.)
Bolts 10-12 48 Nm (35.4 lbf. ft.)
Bolt 13, 14: 85 Nm (62.7 lbf. ft.)
Flywheel
P0021529
47705010 05-2015 © AB VOLVO PENTA 11

Vibration damper, crankshaft

P0021531
Cover, crankshaft seal
P0021533
P0021532
NOTICE! Apply an approximately 2 mm (0.079”) thick

string of silicon (product no. 1161231) as illustrated in
figure on left, max. 20 minutes before installation.
Tightening torque
Step 1:
Fasten the cover with bolts 2 and 7.
Tighten until contact is established.
Step 2:
Tighten bolts 2 and 7.
24 Nm (17.7 lbf. ft.)
Step 3:
Tighten the bolts in sequence 1, 3–6, 8 as illus-
trated.
24 Nm (17.7 lbf. ft.)
12 47705010 05-2015 © AB VOLVO PENTA

Cylinder head
TAD8xxxVE
P0021534
NOTICE! Attach the cylinder head as per section

Installation in 21-1, Cylinder Head, Change.
Tightening torque
Step 1:
Tighten bolts 1-26 in sequence, as illustrated.
100 Nm (73.8 lbf. ft.)
Step 2:
Tighten bolts B1-B6.
29.5 Nm (21.8 lbf. ft.)
Step 3:
Angle tighten bolts 1-26 in sequence.
90° (angle tightening)
Step 4:
Step 5:
29.5 Nm (21.8 lbf. ft.)
Step 6:
Tighten bolt (A).
60 Nm (44.3 lbf. ft.)
Stage 7:
Tighten bolt (C).
30 Nm (22.1 lbf. ft.)
47705010 05-2015 © AB VOLVO PENTA 13

TAD5xxxVE
P0021535
NOTICE! Attach the cylinder head as per section

Installation in 21-1, Cylinder Head, Change.
Tightening torque
Step 1:
100 Nm (73.8 lbf. ft.)
Step 2:
29.5 Nm (21.8 lbf. ft.)
Step 3:
Step 4:
Step 5:
29.5 Nm (21.8 lbf. ft.)
Step 6:
Tighten bolt (A).
60 Nm (44.3 lbf. ft.)
Stage 7:
Tighten bolt (C).
30 Nm (22.1 lbf. ft.)
14 47705010 05-2015 © AB VOLVO PENTA

Bearing caps, camshaft

(camshaft and bearing caps in place)
TAD8xxxVE
Tightening torque
Step 1:
100 Nm (73.8 lbf. ft.)
Step 2:
Tighten bolts 7-12.
29.5 Nm (21.8 lbf. ft.)
Step 3:
P0021536
Step 4:
Step 5:
Tighten bolts 7-12.
29.5 Nm (21.8 lbf. ft.)
TAD5xxxVE
Tightening torque
Step 1:
100 Nm (73.8 lbf. ft.)
Step 2:
Tighten bolts 5-8.
29.5 Nm (21.8 lbf. ft.)
Step 3:
P0021537
Step 4:
Step 5:
Tighten bolts 5-8.
29.5 Nm (21.8 lbf. ft.)
47705010 05-2015 © AB VOLVO PENTA 15

TAD5xxxVE
Valve Cover
P0021539
TAD8xxxVE
P0021538
Valve cover, lower

TAD8xxxVE TAD5xxxVE
P0021540
P0021541
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Group 22: Lubrication System

Drain plug, oil sump
Finish off by checking the tightening torque of bolts 1

and 2.
Drain plug (D), oil sump:

P0021542
Oil cooler
P0021543
Filter cover:
Oil cooler:
P0021544
47705010 05-2015 © AB VOLVO PENTA 17

1 By-pass valve, oil filter

Tightening torque: 29.4 Nm (21.7 lbf. ft.)
2 Plug
3 Plug
4 By-pass valve, oil cooler
5 Plug
6 Plug
7 Control valve
P0021545
Oil separator (standard)
Oil return pipe, turbo
TAD8xxxVE
1 Step 1:
Tighten the bolts.
2 Step 2:
Tighten the bolts.
TAD5xxxVE
1 Step 1:
Tighten the bolts.
P0021546 2 Step 2:
Tighten the bolts.
18 47705010 05-2015 © AB VOLVO PENTA

Oil line
TAD8xxxVE
1 Step 1:
Tighten the bolts.
2 Step 2:
Tighten the bolts.
P0021547
TAD5xxxVE
P0021548
Piston cooling nozzles

P0021549
47705010 05-2015 © AB VOLVO PENTA 19

Group 23: Fuel System

Fuel Filter
Fuel filter cover
P0021550
Injector
Tightening sequence
1 Connector, injectors, nut
2 Yoke bracket, injectors (pre-traction)
3 Sleeve, injector delivery pipe, injectors
4 Yoke bracket, injectors
P0021551
20 47705010 05-2015 © AB VOLVO PENTA

High-pressure pipe
TAD8xxxVE
Step 1:
Install in sequence (1, 4, 5, 3, 2, 6).
Install the delivery pipes between the common rail
and the injector delivery pipes.
Tighten the cap nuts by hand. Check that the clamps
are parallel with the bolt holes.
P0019419
Step 2:
Install the bolts and tighten.
P0019414
Step 3:
Torque tighten the cap nuts.
P0019417
47705010 05-2015 © AB VOLVO PENTA 21

Common rail
TAD8xxxVE
NOTICE! Only perform angle tightening once.
Tightening torque
1 Bolt, common rail unit.
24 Nm (17.7 lbf. ft.)
2 Cap nuts, delivery pipes
37 Nm (27.3 lbf. ft.)
3 Common rail pressure sensor(1)
Step 1:
20 Nm (14.8 lbf. ft.)
P0021552
Step 2:
15 ±1° (angle tightening)
4 Pressure limiting valve(2)
Step 1:
20 Nm (14.8 lbf. ft.)
Step 2:
45 ±1° (angle tightening)
5 Coil, pressure limiting valve
Step 1:
15 Nm (11.1 lbf. ft.)
Step 2:
13 ±0,5° (angle tightening)
P0019361
1. Check the torque 60-180 Nm (44.3-132.8")

2. Check the torque 65-140 Nm (47.9-103.3")
22 47705010 05-2015 © AB VOLVO PENTA

Fuel pump
High pressure pump, fuel connections:

1 Fuel IN (from main filter)
2 Fuel OUT (To main filter)
3 Fuel supply pre-filter, from the engine control unit
cooling coil
4 Fuel OUT to return line
5 Fuel OUT to common rail
P0019287
Gear wheel, high pressure pump, nut:

P0019299
47705010 05-2015 © AB VOLVO PENTA 23

Group 25: Inlet and Exhaust System

Intake manifold
TAD8xxxVE
A
Bolt 1. Tightening sequence: 2-13
B
Tightening sequence: 1-18
P0021553
TAD5xxxVE
A
Bolt 1. Tightening sequence: 2-9
B
P0021554
24 47705010 05-2015 © AB VOLVO PENTA

Exhaust Manifold
TAD8xxxVE
1 Step 1:
Tightening torque: 5-10 Nm (3.7-7.4 lbf. ft.)
2 Step 2:
3 Step 3:
P0021555
TAD5xxxVE
1 Step 1:
Tightening torque: 5-10 Nm (3.7-7.4 lbf. ft.)
2 Step 2:
3 Step 3:
P0021556
47705010 05-2015 © AB VOLVO PENTA 25

Group 26: Cooling System

Coolant Pump
Step 1:
Screw in bolts 1-8 without tightening.
Step 2:
Bolt A
Step 3:
Bolts 1-8
P0019608
Thermostat
Tightening sequence: Diagonal
Nipple, thermostat housing:

P0019525
Fan
Adapter, fan:
P0019618
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Belt Tensioner
P0021557
47705010 05-2015 © AB VOLVO PENTA 27

Group 30: Electrical System
P0019882
28 47705010 05-2015 © AB VOLVO PENTA

1 Sensor for coolant temperature

2 A Fuel pressure sensor
B Oil pressure sensor
3 Oil level/temperature sensor
4 A Sensor for camshaft position
B Flywheel sensor for rpm and position
5 NOx sensor, (pre-catalyst).
Tightening torque: 50Nm (36.9 lbf. ft.)
6 Turbine speed sensor
7 Sensor for exhaust manifold
Tightening torque: Standard
8 Water in fuel sensor
9 A Sensor for charge air temperature and charge air pressure
B Differential pressure transducer
C EGR temperature sensor
10 Fuel pressure/temperature sensor (Common rail)
Refer to section Group 23: Fuel System in Chapter Special Tightening Torques page 9.
47705010 05-2015 © AB VOLVO PENTA 29

Engine, General
Type designation TAD570-72VE TAD870-73VE
No. of cylinders 4 6
Weight, dry 566 kg (1247 lbs) 696 kg (1534 lbs.)
Bore 110 mm (4.33") 110 mm (4.33")
Stroke 135 mm (5.31") 135 mm (5.31")
Displacement 5.1 L (311.2 in3) 7.7 L (469.9 in3)
Number of valves per cylinder 4 4
Direction of rotation (seen from front) Clockwise Clockwise
Firing order 1-3-4-2 1-4-2-6-3-5
Compression ratio 17.5:1 17.5:1
Low idle 700 rpm 600 rpm
Lubrication System
Group 22: Lubrication System
TAD570-72VE TAD870-73VE
Oil grade Refer to Technical data (Lubrication system) in the Operator's
Manual.
Viscosity Refer to Technical data (Lubrication system) in the Operator's
Manual.
Oil pressure, hot engine, operating rpm 430 kPa (62.4 psi) 425 kPa (61.6 psi)
Oil volume incl. oil filter, no engine incline 16 l (4.3 US gals) 27 l (7.1 US gals)
Oil volume, oil sump
MIN 10 l (2.5 US gals) 19 l (5.0 US gals)
MAX 14 l (3.6 US gals) 24 l (6.4 US gals)
Max oil temperature during operations 125 °C (257 °F)
30 47705010 05-2015 © AB VOLVO PENTA

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.
47705010 05-2015 © AB VOLVO PENTA 31

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.
32 47705010 05-2015 © AB VOLVO PENTA

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.
47705010 05-2015 © AB VOLVO PENTA 33

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.
34 47705010 05-2015 © AB VOLVO PENTA

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.
9986172 Puller 88800014 Rotation tool 88840269 Guide pin

Used when removing air com- Used for valve adjustment, BVA Used when removing and
pressor drive gear and for gear assembly, HP pump, air com- installing flywheel. Two guide
removal at unit pump replace. pressor. pins needed.
88840270 Wrench 88840271 Guide pin 88840272 Sleeve

Used for injector replacement, Used for check valve, high Used when removing PRV
HP pump, common rail, PRV pressure pump. valve.
valve. Used to position the check
valve on the fuel pump.
88840274 Guide pin 88840406 Mounting tool 88840407 Mounting tool

Used for fuel pump installation. Used when replacing crank- Used when replacing crank-
Two pcs needed. shaft sealings (rear). shaft sealings (front).
88840282 Extractor 88890105 Refractometer

Used when removing crank-
shaft seal (rear and front).
47705010 05-2015 © AB VOLVO PENTA 35

88840290 Plugs
Used when protecting the high pressure system.
36 47705010 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
21-1 Cylinder Head

Upper valve cover, change
TAD570VE, TAD571VE, TAD572VE
IMPORTANT!
Turn off the main switch before any work is carried out.
The procedure in this description assumes that the

engine control unit will not be removed but moved to
one side with its harness and fuel connection. In con-
nection with control unit replacement, refer to 36-6,
Engine Control Unit (ECU), Replace.
1 Undo the cable holder and cable ties.
Remove the control unit retaining bolts.
P0019500
2 IMPORTANT!
Clean thoroughly before removal.
Protect the engine control unit by moving it to one

side, enclosing it in a plastic bag and tying the bag
shut.
P0019501
47705010 05-2015 © AB VOLVO PENTA 37

21-1 Cylinder Head
3 Remove the crankcase ventilation connection

from the valve cover.
P0019502
4 Remove the valve cover.
P0019503
38 47705010 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
Installation
5 1 Remove gasket.
2 Clean along the gasket groove.
3 Check to see if the valve cover gasket
needs to be changed.
Clean the gasket.
4 Clean the sealing surfaces.
5 Fit the gasket.
P0019504
6 Install the cover, tighten the bolts in sequence

and torque them.
P0019505
Tighten the bolts in sequence, as illustrated:

P0019506
47705010 05-2015 © AB VOLVO PENTA 39

21-1 Cylinder Head
7 Install the crankcase ventilation connection on

the valve cover.
P0019507
8 Install the control unit.

Fasten it to the harness holder and fit cable ties.
P0019508
9 Check the connections.
40 47705010 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
Upper valve cover, change

Removal
1 Loosen the cable clip.
P0019482
2 Remove the connection for crankcase ventilation

from the valve cover.
P0019483
3 Remove the valve cover with upper gasket.
P0019484
47705010 05-2015 © AB VOLVO PENTA 41

21-1 Cylinder Head
Installation
4 1 Remove gasket.
3 Check if the valve cover gasket needs to be
changed. Clean the gasket.
5 Install the gasket.
P0019485
5 Install the valve cover and tighten the bolts in

sequence and with tightening torque.
P0019486
P0019489
Tighten the bolts in numerical order according to

the picture:
42 47705010 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
6 Install the connection for the crankcase ventila-

tion to the valve cover.
P0019483
7 Install cable and cable clip.
P0019482
47705010 05-2015 © AB VOLVO PENTA 43

21-1 Cylinder Head
Lower valve cover, change

Removal
IMPORTANT!
1 Remove the upper valve cover; refer to Upper
valve cover, change page 37.
2 Remove the connector from the grommet.
P0019509
3 Unscrew the wiring from the injectors.
P0019510
44 47705010 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
4 Remove the lower valve cover.
P0019511
Installation
5 1 Remove gasket.
3 Check to see if the valve cover gasket
needs to be changed.
Clean the gasket.
5 Fit the gasket.
P0019512
6 Install the cover, tighten the bolts in sequence

and torque them.
P0019513
47705010 05-2015 © AB VOLVO PENTA 45

21-1 Cylinder Head
Tighten the bolts in sequence, as illustrated:

P0019514
7 Screw on the injector connectors.

P0019510
8 Connect the connector through the grommet.
P0019515
9 Install the upper valve cover; refer to Upper valve

cover, change page 37.
46 47705010 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
Lower valve cover, change

Removal
IMPORTANT!
1 Remove the upper valve cover, see Upper valve
2 Remove the stripes and loosen the cable from the
cover.
P0019490
3 Disconnect the connector from the lead-through.
P0019491
47705010 05-2015 © AB VOLVO PENTA 47

21-1 Cylinder Head
4 Unscrew the electrical wiring from the injectors.
P0019492
5 Remove the lower valve cover.
P0019493
Installation
6 1 Remove gasket.
3 Check if the valve cover gasket needs to be
changed. Clean the gasket.
5 Install the gasket.
P0019494
48 47705010 05-2015 © AB VOLVO PENTA

21-1 Cylinder Head
7 Install the valve cover and tighten the bolts in

sequence and with tightening torque.
P0019495
Tighten the bolts in numerical order according to

the picture:
P0019496
8 Screw the connectors onto the injectors.

P0019492
47705010 05-2015 © AB VOLVO PENTA 49

21-1 Cylinder Head
9 Connect the connector to the lead-through.
P0019497
10 Clamp the cable harness onto the valve cover

with original stripes.
P0019498
11 Install the upper valve cover, see Upper valve

50 47705010 05-2015 © AB VOLVO PENTA

21-4 Valve Mechanism

Valves, Adjustment
Tools:
88800014 Rotation tool
IMPORTANT!
NOTICE! Normal valve clearance is set when the

engine is cold, or when it has been left to cool for at
least a half hour. Oil temperature < 80 °C (176 °F).
Removal
1 Remove the upper valve cover according to:
Upper valve cover, change page 37.
2 Remove the plug by the flywheel.
Insert 88800014 Rotation tool.
P0019449
3 NOTICE! Crank counterclockwise, on the engine

flywheel side.
Crank the flywheel until the cylinder 1 mark aligns

with the mark on the flywheel housing.
The camshaft gear has two markings corre-
sponding to the marking on the flywheel.
P0019450
47705010 05-2015 © AB VOLVO PENTA 51

4 Check that the gearwheel marking (1) corre-

sponds with the surface of the left side of the cyl-
inder head.
If not, crank the flywheel one more turn.
Marking (1) facing surface of the cylinder

head:
• The Inlet valves for cylinders (1), (3) and (5).
• The exhaust valves for cylinders (1), (2) and
(4).
P0019451
P0019452
A Inlet valve 1 Cylinder 1 4 Cylinder 4

B Exhaust valve 2 Cylinder 2 5 Cylinder 5
3 Cylinder 3 6 Cylinder 6
52 47705010 05-2015 © AB VOLVO PENTA

Checks and adjustment, inlet valves

5 NOTICE! Cylinder (1) is on the opposite side in
relation to the engine flywheel/gearwheel.
Check the valve clearance on the inlet valves for

cylinders (1), (3) and (5).
P0019453
Check
6 Check the valve clearance for the inlet valves with
the aid of a feeler gauge set.
The clearance must be 0.4 ±0.05 mm.
In the value is not correct, adjust the valve.
P0019454
Adjustment
7 Adjust inlet valve clearance between the rocker
arm and the valve yoke to 0.4 ±0.05 mm with the
aid of a feeler gauge set.
Loosen the adjuster screw locking nut on the

rocker arm. Turn the adjuster screw until the right
clearance is achieved.
Feeler gauges should be used when adjusting.

One 0.40 mm, the other 0.45 mm.
Set the clearance so that only the 0.40 mm feeler
gauge can be inserted without any great resist-
ance, and only slight resistance should be felt
when the feeler gauge is pulled back and forth. It
should not be possible to insert the 0.45 mm
feeler gauge without resistance.
P0019455
Counterhold the adjuster screw while tightening
the locking nut.
47705010 05-2015 © AB VOLVO PENTA 53

Checks and adjustment, exhaust valves

8 NOTICE! Cylinder (1) is at the opposite side in
Check the valve clearance on the exhaust valves

for cylinders (1), (2) and (4).
P0019456
Check
9 Check the valve clearance for the exhaust valves
with the aid of a feeler gauge set.
P0019457
Adjustment
10 Adjust exhaust valve clearance between the
rocker arm and the valve yoke to 0.5 ±0.05 mm

rocker arm.
Turn the adjuster screw until the right clearance
is achieved.

P0019458

the locking nut.
54 47705010 05-2015 © AB VOLVO PENTA

11 NOTICE! Crank counterclockwise, on the engine

flywheel side.
Crank the flywheel one turn until the cylinder 1

mark aligns with the mark on the flywheel hous-
ing.
P0019450
12 Check that the gearwheel marking corresponds

with the surface of the left side of the cylinder
head.
If not, crank the flywheel one more turn.
Marking left facing surface of the cylinder

head:
• The Inlet valves for cylinders (2), (4) and (6).
• The exhaust valves for cylinders (3), (5) and
(6).
P0019459
47705010 05-2015 © AB VOLVO PENTA 55

Checks and adjustment, inlet valves

Check the valve clearance on the inlet valves for

cylinders (2), (4) and (6).
P0019460
Check
14 Check the valve clearance for the inlet valves with
the aid of a feeler gauge set.
P0019461
Adjustment
15 Adjust inlet valve clearance between the rocker
arm and the valve yoke to 0.4 ±0.05 mm with the
aid of a feeler gauge set.

rocker arm.
is achieved.

P0019462

the locking nut.
56 47705010 05-2015 © AB VOLVO PENTA

Checks and adjustment, exhaust valves

Check the valve clearance on the exhaust valves

for cylinders (3), (5) and (6).
P0019463
Check
17 Check the valve clearance for the exhaust valves
If the value is not correct, adjust the valve.
P0019464
Adjustment
18 Adjust exhaust valve clearance between the
rocker arm and the valve yoke to 0.5 ±0.05 mm

rocker arm.
is achieved.

P0019465

the locking nut.
47705010 05-2015 © AB VOLVO PENTA 57

19 Remove 88800014 Rotation tool from the gear

ring.
Install the plug.
P0019449
20 Insert plug for the flywheel mark.

21 Install the upper valve cover according to: Upper
valve cover, change page 37.
P0019466
58 47705010 05-2015 © AB VOLVO PENTA

21-5 Timing Gears and Shaft

Flywheel, Change
Tools:
9996239 Lifting tool
88840269 Guide pin
CAUTION!
Pinch hazard. Keep fingers clear.
Removal
1 Remove the flywheel sensor.
P0020336
2 Remove two diametrically opposed bolts.
P0020337
47705010 05-2015 © AB VOLVO PENTA 59

3 Replace with locating pins 88840269 Guide pin.
P0020338
4 Attach and secure tool 9996239 Lifting tool.
P0020339
5 Remove the remaining bolts.
P0020340
60 47705010 05-2015 © AB VOLVO PENTA

6 Remove the flywheel.
P0020344
Installation
7 Clean the flywheel contact surface on the crank-
shaft.
Check the crankshaft seal.
P0020341
8 Check the position of the crankshaft guide pins in

relation to the flywheel locating holes.
Install the flywheel.
P0020342
47705010 05-2015 © AB VOLVO PENTA 61

9 Install the bolts. Screw in the bolts without tight-

ening.
Remove the guide pins and lifting tool.
P0020343
10 Tighten the bolts in the sequence i as llustrated.

Tightening torque: 190 Nm (140 lbf. ft.)
P0020345
11 Install the flywheel sensor.
P0020336
62 47705010 05-2015 © AB VOLVO PENTA

21-6 Crank Mechanism

Gear Ring, Fywheel: Replace
1 Remove the flywheel; refer to Flywheel,
Change page 59
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
47705010 05-2015 © AB VOLVO PENTA 63

Crankshaft Seal, Change (front)

Tools:
88840407 Mounting tool
88840282 Extractor
IMPORTANT!
Because access depends on the type of cooling sys-

tem installed, different methods are used when replac-
ing the component.
Removal
88840282 Extractor
1 Reversible arms for front and rear seals
2 Hook clamp for rear crankshaft seal replacement
3 Hook clamp for front crankshaft seal replacement
4 Pin
5 Lock screw
6 Pressure plate (for rear crankshaft seal)
1 Remove the fan; refer to Coolant Pump,
Change page 203.
2 Remove the drive belt according to Drive Belt,
Change page 219.
P0020364
3 Remove the fan adapter and pulley from the cool-

ant pump.
P0019601
64 47705010 05-2015 © AB VOLVO PENTA

4 Remove the vibration damper and pulley.
P0020365
5 NOTICE! The tool arms are reversible for use

with front or rear seals.
NOTICE! The seal is bonded to the shaft and may

adhere with moderate to high strength.
NOTICE! Use a hose clamp around the arms to

prevent the hook clamps from losing their grip on
the seals.
Adjust the arms on 88840282 Extractor and fit the

hook clamps around the metal edge of the seal.
Pull out the seal slowly.
P0020366
6 NOTICE! Remove all sealant residue from the

crankshaft.
NOTICE! Clean the sealing surfaces.
P0020367
47705010 05-2015 © AB VOLVO PENTA 65

Installation
7 NOTICE! Curing will not begin until the seal is
pressed up against the sealant.
Run a bead of adhesive/sealant, part no.

21597610 around the circumference of the crank-
shaft, as illustrated.
Maintain the distance:
D5: 60.8 mm (2.39")
D8: 54.8 mm (2.16")
P0020368
8 Fit 88840407 Mounting tool onto the crankshaft

and screw it in place.
P0020369
9 IMPORTANT!
The seal ring is in two parts and may not be sep-
arated.
IMPORTANT!
The metal side of the seal ring must face out.
Slide the seal ring onto the tool.
P0020370
66 47705010 05-2015 © AB VOLVO PENTA

10 Fit the tool cover (88840407 Mounting tool) with

the screw handle.
Press in the seal until the cover bottoms against
the crankshaft seal cover.
P0020371
11 Remove the tool and check that the seal is cor-

rectly installed against the crankshaft seal cover.
Permissible clearance: ±0.15 mm (±0.0059").
Remove any sealant residues.

Curing takes 15-30 minutes. Full strength is ach-
ieved after 24 hours.
P0020372
12 Fit the vibration damper and the pulley.
P0020365
47705010 05-2015 © AB VOLVO PENTA 67

13 Tighten the bolts in sequence, as illustrated.

Tightening torque: 110 Nm (81 lbf. ft.)
P0020373
14 Install the fan adapter and pulley on the coolant

pump
Tighten the bolts diagonally.
15 Install the drive belt according to Drive Belt,
Change page 219.
16 Install the fan; refer to Coolant Pump,
Change page 203.
P0019610
68 47705010 05-2015 © AB VOLVO PENTA

Crankshaft Seal, Change (rear)

Tools:
88840406 Mounting tool
88840282 Extractor
88840282 Extractor
1 Reversible arms for front and rear seals
2 Hook clamp for rear crankshaft seal replacement
3 Hook clamp for front crankshaft seal replacement
4 Pin
5 Lock screw
6 Pressure plate (for rear crankshaft seal)
P0020364
Removal
1 Remove the flywheel according to Flywheel,
Change page 59.
2 NOTICE! The tool arms are reversible for use
with front or rear seals.
NOTICE! The seal is bonded to the shaft and may

adhere with moderate to high strength.
Adjust the arms on 88840282 Extractor and fit the

hook clamps around the metal edge of the seal.
Pull out the seal slowly.
P0020374
47705010 05-2015 © AB VOLVO PENTA 69

3 IMPORTANT!
Remove all sealant residue from the crankshaft.
NOTICE! Clean the seal seat in the flywheel

housing and the sealing surface on the crank-
shaft.
P0020375
Installation
4 NOTICE! Curing will not begin until the seal is
pressed up against the sealant.
Run a bead of adhesive/sealant, part no.

21597610 around the circumference of the crank-
shaft, as illustrated. Maintain the distance 16.2
mm (0.638").
P0020376
5 Check the position of the crankshaft guide pins in

relation to the 88840406 Mounting tool.
P0020377
70 47705010 05-2015 © AB VOLVO PENTA

6 Fit 88840406 Mounting tool onto the crankshaft

and screw it in place.
P0020378
7 IMPORTANT!
The seal ring is in two parts and may not be sep-
arated.
IMPORTANT!
The metal side of the seal ring must face out.
Slide the seal ring onto the tool.
P0020379
8 Fit the tool cover with the screw handle.

Press in the seal until the cover bottoms against
the flywheel housing.
P0020380
47705010 05-2015 © AB VOLVO PENTA 71

9 Remove the tool and check that the seal is cor-

rectly installed against the flywheel housing.
Permissible clearance: ±0.15 mm (±0.0059").
Remove any sealant residues.

Curing takes 15-30 minutes. Full strength is ach-
ieved after 24 hours.
P0020381
10 Install the flywheel according to: Flywheel,

Change page 59.
72 47705010 05-2015 © AB VOLVO PENTA

22-2 Oil filter
22-2 Oil filter

Oil filter, Change
IMPORTANT!
Risk of material damage. Use only an oil fuel filter
approved by the manufacturer.
The wrong type of oil filter can lead to damage to bear-
ings, the crankshaft and connected components as a
result of unfiltered oil entering the lubrication system.
A Volvo oil filter constantly cleans dirt, metal particles,
carbon, etc. from the oil so that only clean oil reaches
lubrication and bearing points.
IMPORTANT!
Protect against dirt while working.
NOTICE! Be prepared to gather up fluid.
Removal
Engine oil drained.
1 Clean around the filter cover and housing.
Carefully remove the oil filter cover and filter.
P0019348
2 Remove the O-ring and filter.

Let the oil drip into a collection vessel.
P0019349
47705010 05-2015 © AB VOLVO PENTA 73

22-2 Oil filter
Installation
3 NOTICE! Use recommended oil.
Lubricate the O-ring lightly before installing the

filter cover.
P0019350
Lubricate around the sealing surface on the new

filter's inner component.
P0019351
5 Install a new filter in the filter cover.

Make sure the filter seats properly in the cover.
P0019352
74 47705010 05-2015 © AB VOLVO PENTA

22-2 Oil filter
6 IMPORTANT!
Make sure that the component is clean before
installation.
Install the filter cover and filter in the bracket.

Carefully screw in the cover and check that the
O-ring does not get twisted.
Lubricate the seal again, as necessary.
Tighten the cover.

P0019353
7 Install the drain plug (D) on the oil sump.

P0019354
Fill with the requisite quantity of oil; refer to the

service record for the engine type concerned.
P0019355
9 Start the engine.

Check that no leakage occurs.
10 Switch the engine off and check the oil level after
a few minutes.
Top up with oil as necessary.
47705010 05-2015 © AB VOLVO PENTA 75

22-2 Oil filter
Oil Filter Housing, Change

Removal
1 Drain the coolant, according to: Coolant,

Change page 195.
2 Remove the fuel filter housing, according to: Fuel
filter housing, change page 93.
3 Disconnect the oil pressure sensor connector.
Remove the cable ties.
P0019821
4 Remove the cable clamps.

Loosen the harness aside.
P0019822
76 47705010 05-2015 © AB VOLVO PENTA

22-2 Oil filter
5 Unclip the fuel lines from the bracket.
P0019823
6 Remove the retainer bracket.
P0019824
7 Remove the hose for outgoing coolant.

Loosen the coolant pipe.
P0019825
47705010 05-2015 © AB VOLVO PENTA 77

22-2 Oil filter
8 Remove the oil filter housing.
P0019826
Installation
9 Clean the mating surfaces on the engine block.
P0019827
10 During reassembly of the existing oil filter; clean

the mating surfaces.
P0019828
78 47705010 05-2015 © AB VOLVO PENTA

22-2 Oil filter
11 Use new O-rings.

Lubricate the O-rings.
P0019829
12 Install the oil filter housing.
P0019826
13 Tighten the screws in numerical order as shown:

P0019830
47705010 05-2015 © AB VOLVO PENTA 79

22-2 Oil filter
14 Install the hose for outgoing coolant.

Fasten the flange to the coolant pipe.
P0019825
15 Install the retainer bracket.
P0019824
16 Install the fuel lines to the bracket.
P0019823
80 47705010 05-2015 © AB VOLVO PENTA

22-2 Oil filter
17 Position the harness.

Install the cable clamps.
Install the cable ties.
P0019822
18 Connect the oil pressure sensor connector.

P0019821
19 Install the fuel filter housing, according to: Fuel

filter housing, change page 93.
20 Top up with coolant; refer to Coolant Level,
Checking and Topping Up page 193.
21 Check that no leakage occurs.
22 Make sure that the oil level is between the MIN
and MAX marks.
47705010 05-2015 © AB VOLVO PENTA 81

22-3 Oil cooler
22-3 Oil cooler

Oil Cooler, Replace
Removal

Change page 195.
2 Unscrew the oil cooler.
NOTICE! Depending which version of oil filler

assembly can this affect the removal of the oil
cooler. This description has free access to com-
ponent.
P0019841
3 Remove the oil cooler.
P0019842
82 47705010 05-2015 © AB VOLVO PENTA

22-3 Oil cooler
4 Remove the O-rings.
P0019843
Installation
5 Clean the contact surfaces on the oil filter hous-
ing.
P0019844
6 Use new O-rings.

Lubricate the O-rings.
P0019843
47705010 05-2015 © AB VOLVO PENTA 83

22-3 Oil cooler
7 Install the oil cooler to the oil filter housing.
P0019845
8 Tighten the oil cooler.

P0019841

11 Make sure that the oil level is between the MIN
and MAX marks.
84 47705010 05-2015 © AB VOLVO PENTA

23-0 Fuel System, General
23-0 Fuel System, General

Fuel system, bleeding
1 Check that there is sufficient fuel in the tank, and
that any fuel taps are open.
2 Operate the hand pump by pumping it until it
offers resistance.
3 Wait 15 seconds.
Repeat the operation as many times as neces-
sary.
4 Start the engine and let it run at high idle for at
least 5 minutes before speed is increased.
5 Perform a leakage and function check.
P0019266
47705010 05-2015 © AB VOLVO PENTA 85

23-3 Fuel Feed Pump and Filter

Fuel Pre-filter, Change
IMPORTANT!
Working with the fuel system requests special cleanli-
ness. Clean thoroughly before removal.
IMPORTANT!
Risk of material damage.
The use of the wrong type of fuel filter may damage the
fuel injection circuit. Use only fuel filters approved by
the manufacturer.
CAUTION!
Risk of skin damage.
Removal
1 Clean around the pre-filter and the water separa-
tor.
Disconnect the connector. Remove the wire har-
ness:
P0019269
2 Undo the drain nipple.

Drain the filter.
Tighten the drain nipple.
NOTICE! Undo a pipe if necessary.
P0019270
86 47705010 05-2015 © AB VOLVO PENTA

3 Remove the pre-filter and seal ring together with

the lower section of the water separator. Use an
oil filter wrench.
P0019271
4 Remove the lower section of the water separator

and O-ring from the filter.
Keep the filter in a suitable container.
Clean the lower section of the water separator
and the contact surfaces.
P0019272
Installation
5 NOTICE! Use new component.
Lubricate the O-ring and seal ring with diesel.

Install a new O-ring.
Install the lower part of the water separator.
P0019273
47705010 05-2015 © AB VOLVO PENTA 87

6 Install the new pre-filter.

Screw the filter on by hand until it stops.
Tighten the filter until it bottoms, then a further
180-240°.
P0019271
7 Connect the connector.

Secure the wire harness.
P0019269
8 Open the fuel tap and purge the fuel pre-filter

according to Fuel pre-filter, bleeding page 89.
88 47705010 05-2015 © AB VOLVO PENTA

Fuel pre-filter, bleeding

It is only necessary to purge the fuel system following
maintenance on the system or if a fault has caused it
to run dry.
1 Remove the cover.

Lightly undo the nipple (two turns).
P0019267
2 Position a collection vessel.

Connect a transparent hose.
Operate the hand pump by pumping it until fuel
flows without air bubbles.
3 Tighten the nipple while the fuel flows.
Remove the hose.
Tighten the nipple.
Tightening torque 3.5 Nm (2.6 lbf. ft.)

4 Install the cap.
P0019268
47705010 05-2015 © AB VOLVO PENTA 89

Fuel filter, Change

IMPORTANT!
Risk of material damage. Use only a fuel filter approved
by the manufacturer. The wrong type of fuel filter may
damage the fuel injection circuit.
IMPORTANT!
ness.
IMPORTANT!
Protect against dirt while working.
Removal
1 Clean around the filter cover and housing.
Carefully remove the filter cover and filter.
P0019259
2 Remove the O-ring and filter.

Let the fuel drip off into a collection vessel.
P0019260
90 47705010 05-2015 © AB VOLVO PENTA

Installation
3 NOTICE! Lubricate with diesel.
Lubricate the O-ring before installing the filter

cover.
P0019261
4 NOTICE! Lubricate with diesel.
If the filter housing is completely empty, lubricate

around the inner section's sealing surface on the
new filter.
P0019262
5 Install a new filter in the filter cover.

Make sure the filter seats properly in the cover.
P0019263
47705010 05-2015 © AB VOLVO PENTA 91

6 IMPORTANT!
Make sure that the component is clean before
installation.
Install the filter cover and filter in the bracket.

Carefully screw in the cover and check that the
O-ring does not get twisted. Re-lubricate the seal
as necessary.
Tighten the cover to: 25 Nm (18.4 lbf. ft.)
P0019264
7 Purge the fuel system according to Fuel system,

bleeding page 85.
8 Start and warm up engine. Check that no leakage
occurs.
92 47705010 05-2015 © AB VOLVO PENTA

Fuel filter housing, change

Tools:
88840290 Plugs
IMPORTANT!
ness.
IMPORTANT!
IMPORTANT!
Risk of material damage.
Using the wrong type of fuel filter can damage the
injector circuit. Use only fuel filters approved by the
manufacturer.
WARNING!
Hot fluid. Scalding risk.
Removal
1 Close the cock on the return line to the tank.
2 Disconnect the pressure relief valve connector.
Disconnect the fuel pressure sensor connector.
P0019657
3 NOTICE! Clean the area around the delivery pipe

connection on the high pressure pump before
starting any work.
47705010 05-2015 © AB VOLVO PENTA 93

4 Remove fuel connection (1) 'fuel IN' from the fuel

feed pump and returnline (2) and let the fuel run
into a suitable vessel.
Remove fuel connection (3) 'fuel OUT' to high
pressure pump.
Install safety plugs on all fuel connections. Use kit

88840290 Plugs.
P0019658
5 Remove the fuel filter housing.
P0019659
Installation
6 Move the bracket and sensor over to the new fuel
filter housing if needed.
7 Install the fuel filter housing.
P0019660
94 47705010 05-2015 © AB VOLVO PENTA

8 Install fuel connection 1, 2, and 3.
NOTICE! Different diameter for proper connec-

tion.
P0019661
9 Connect the pressure relief valve connector.

Connect the fuel pressure sensor connector.
P0019662
10 Open the cock on the return line to the tank.

11 Vent the fuel system according to Fuel system,
bleeding page 85.
47705010 05-2015 © AB VOLVO PENTA 95

High Pressure Pump, Change

Tools:
9986172 Puller
88800014 Rotation tool
88840270 Wrench
88840274 Guide pin
88840290 Plugs
IMPORTANT!
IMPORTANT!
Install safety plugs in open connections.
CAUTION!
CAUTION!
The fuel system may be under pressure.
When working on the fuel system, undo a closed sys-
tem at the first point with caution.
NOTICE! Turn off the main switch before any work is

carried out.
High pressure pump, fuel connections:

1 Fuel IN (from main filter)
2 Fuel OUT (To main filter)
3 Fuel supply from the engine control unit cooling coil
4 Fuel OUT to return line
5 Fuel OUT to common rail
P0019287
96 47705010 05-2015 © AB VOLVO PENTA

Removal
1 Undo the diagnostics panel and move it aside.
P0019274
2 NOTICE! Clean the area around the delivery pipe

connection on the high pressure pump before
starting work.

3 Remove fuel connection 'fuel IN' from the main
filter and let the fuel run into a suitable vessel.
88840290 Plugs.
P0019288
4 Fit a protective plug over 'fuel IN' on the high

pressure pump. Use kit 88840290 Plugs.
Remove the MPROP valve connector.
P0019289
47705010 05-2015 © AB VOLVO PENTA 97

5 Remove the fuel supply connection (1) from the

engine control unit cooling coil.
Undo the fuel supply connection (2) (from the pre-
filter) to the engine control unit cooling coil.
88840290 Plugs.
P0019290
6 Remove the cable clamps and cable ties.
P0019279
7 Remove the bolts and carefully move the engine

control unit aside and stow it securely.
P0019280
98 47705010 05-2015 © AB VOLVO PENTA

8 Undo connection (1) 'fuel OUT' to the return line.

Undo connection (2) 'Fuel OUT' to the main filter.
88840290 Plugs.
P0019291
9 Remove the holder
P0019308
10 Remove the control unit mounting bracket.
P0019282
47705010 05-2015 © AB VOLVO PENTA 99

11 Remove the delivery pipe between the high pres-

sure pump and the common rail. Use
88840270 Wrench.
88840290 Plugs.
P0019292
12 NOTICE! Do not hold the pump by the connection

pipes.
Remove the high pressure pump and its inter-

mediate flange as one unit.
P0019293
13 Remove the O-ring and undo the nut.
P0019294
100 47705010 05-2015 © AB VOLVO PENTA

14 Use 9986172 Puller to remove the high pressure

pump gearwheel.
P0019295
15 Remove the intermediate flange and O-ring.
P0019296
47705010 05-2015 © AB VOLVO PENTA 101

Installation
16 Wash the tapered joint on the shaft and the gear-
wheel with denatured alcohol. Clean the contact
surfaces and sealing surfaces.
Fit a new O-ring (1) on the inside of the flange.
Turn the flange as illustrated and fit the high pres-
sure pump and intermediate flange together.
P0019297
17 Check that the key is in the keyway.
P0019298
18 Fit the gearwheel on the shaft, install the washer

and the nut.
Tightening torque 65 Nm (47.9 lbf. ft.)
Fit a new O-ring onto the intermediate flange.
P0019299
102 47705010 05-2015 © AB VOLVO PENTA

19 Turn the gearwheel so that the mark on the gear-

wheel lines up with the punch mark on the inter-
mediate flange.
See illustration.
P0019300
20 Remove the plug by the flywheel.

Insert 88800014 Rotation tool.
P0019303
21 Crank the flywheel until the cylinder 1 mark aligns

with the mark on the flywheel housing.
P0019304
47705010 05-2015 © AB VOLVO PENTA 103

22 NOTICE! Do not hold the pump by the connection

pipes.
Screw 88840274 Guide pin into the flywheel

housing.
Make sure the gearwheel mark lines up with the
punch mark.
Slide the pump in without turning the gearwheel.
P0019305
23 NOTICE! Use new bolts.
Screw in (1) without tightening.

Remove 88840274 Guide pin.
Screw in (2) without tightening.
Tighten bolts diagonally (1-2).

P0019306
24 Remove 88800014 Rotation tool.

Insert both plugs by the flywheel.
P0019303
104 47705010 05-2015 © AB VOLVO PENTA

Install a new delivery pipe between the high pres-

sure pump and the common rail.
Adjust without tightening. Use

88840270 Wrench.
P0019307
26 Install the control unit mounting bracket.
P0019282
27 Install the holder and the fuel lines.
P0019308
47705010 05-2015 © AB VOLVO PENTA 105

28 Connect connection (1) 'fuel OUT' to the return

line.
Connect connection (2) 'Fuel OUT' to the main
filter.
P0019309
29 Bolt the engine control unit in place.
P0019280
30 Secure the harness with cable clamps and cable

ties.
P0019279
106 47705010 05-2015 © AB VOLVO PENTA

31 Connect the fuel supply connection (1) from the

Connect the fuel supply connection (2) (from the
pre-filter) to the engine control unit cooling coil.
P0019310
32 Connect the harness terminal to the MPROP

valve, high pressure pump.
P0019311
33 Connect the fuel connection, 'fuel IN' from the

main filter.
P0019312

bleeding page 85.
35 Turn the main switch on.
Start the engine.
Perform a leakage and function check.
47705010 05-2015 © AB VOLVO PENTA 107

MPROP valve, high pressure pump,

change
Tools:
885812 Timing tool
88840271 Guide pin
88840290 Plugs
88890148 Torque wrench
IMPORTANT!
IMPORTANT!
CAUTION!
CAUTION!
P0019336 tem at the first point with caution.
Removal
1 Disconnect the MPROP valve connector, high
pressure pump.
P0019275
108 47705010 05-2015 © AB VOLVO PENTA

2 IMPORTANT!
Make sure no contaminants get into the compo-
nent.
Mark the position.

Remove the MPROP valve.
Remove the O-ring.
P0019337
3 Install the protective plug. Use kit

88840290 Plugs.
P0019338
47705010 05-2015 © AB VOLVO PENTA 109

Installation
4 Insert 88840271 Guide pin.
Tighten by hand.
P0019339
5 Lubricate a new O-ring (1) and fit it onto the oil

cooler housing (2).
NOTICE! Use a recommended oil.
P0019340
6 Install the MPROP valve.

Note the positioning.
P0019341
110 47705010 05-2015 © AB VOLVO PENTA

7 Press the MPROP valve firmly against the pump

when removing the tools and installing the bolts.
Remove 88840271 Guide pin.

Install new screws. Tighten by hand and then
tighten.
P0019342
8 Connect the connector to the MPROP valve, high

pressure pump.
P0019275

Start and warm up engine.
Perform a function check.
47705010 05-2015 © AB VOLVO PENTA 111

23-7 Injectors and Delivery Pipes

Injector, Change
IMPORTANT!
IMPORTANT!
CAUTION!
CAUTION!
Tools:
9996400 Slide hammer
9998007 Adapter
88840270 Wrench
88840290 Plugs

carried out.
Removal
1 Remove the upper valve cover according to
2 Remove the lower valve cover according to
Lower valve cover, change page 44.
3 Remove the hollow screw from the return line on
the cylinder head.
P0019313
4 Remove the injector delivery pipe according to

Fuel Injection Pipe, Change page 128.
112 47705010 05-2015 © AB VOLVO PENTA

5 Remove the sleeves 1 -6.
P0019314
6 Remove the injector delivery pipe with the aid of

9996400 Slide hammer and 9998007 Adapter.
P0019315
7 Install safety plugs on all fuel connections. Use kit

88840290 Plugs.
P0019316
47705010 05-2015 © AB VOLVO PENTA 113

8 Remove the injector yoke bolts.
P0019317
9 Use a 10 mm drift/screwdriver in the yoke as a

lever to prize the injector loose.
P0019318
10 NOTICE! Mark the injector locations for re-instal-

lation.
Remove the injectors and washers.

Check that no washers remain in any of the injec-
tor wells.
Install protective plugs on all fuel unions. Use kit

88840290 Plugs.
P0019319
114 47705010 05-2015 © AB VOLVO PENTA

11 Plug the hole.

88840290 Plugs.
P0019320
12 Remove the washer and O-ring.
P0019321
13 Repeat the same procedure on the other injec-

tors.
47705010 05-2015 © AB VOLVO PENTA 115

Installation
NOTICE! Clean the sealing surfaces.
NOTICE! Use new components.
14 Install a new washer and O-ring.

Fit the washer and the protective plug.
NOTICE! Lightly oil the O-ring.
P0019322
15 Repeat the same procedure on the other injec-

tors.
16 IMPORTANT!
Carefully clean away combustion residue from
the injector wells before installing the injectors.
Vacuum out dirt particles.
NOTICE! If the injectors are re-used, pay atten-

tion to the numbered locations on re-installation.
Install the injectors.

Position injectors so that the installation hole is
turned to face the injector delivery pipe inlet chan-
nel on the high pressure pump side.
P0019323
116 47705010 05-2015 © AB VOLVO PENTA

17 NOTICE! When changing an injector, a new

injector code must be programmed into the con-
trol unit; refer to the appropriate Service Hand-
book, Group 30: Electrical System. The injector
code is stamped on the unit injector.
NOTICE! Cylinder (1) is on the opposite side in

relation to the engine flywheel.
In the case of new injectors, take into account the

injector numbers and the corresponding cylin-
ders.
P0019324
18 Lubricate the bolts.

Install bolts in the injector yokes.
Preload the bolts.

P0019317
19 NOTICE! Use new components. O-ring and injec-

tor delivery pipe.
Lubricate and install the O-ring.
P0019325
47705010 05-2015 © AB VOLVO PENTA 117

20 Repeat the same procedure on the other injector

delivery pipes.
21 Align the injector delivery pipe and press in the

pipe with the guide facing up until it fits all the way
into its seat.
1 Lubricate the sleeve with Renolin PGK
680.
Install the sleeve.
2 Undo the injector yoke bolts and tighten.
P0019326
22 Check the tightening tightening torque on the

sleeves.
P0019314
23 Tighten the injector yokes bolts.

P0019327
24 Install the injector delivery pipes according to

Fuel Injection Pipe, Change page 128.
118 47705010 05-2015 © AB VOLVO PENTA

25 Install the hollow screw from the return line on the

cylinder head.
P0019328
26 Install the the lower valve cover according to:

Lower valve cover, change page 44.
27 Install the the upper valve cover according to:
28 Bleed the fuel system according to: Fuel system,
bleeding page 85.
Start the engine.
47705010 05-2015 © AB VOLVO PENTA 119

Common Rail, Change

Tools:
88840270 Wrench
88840290 Plugs
IMPORTANT!
IMPORTANT!
CAUTION!
CAUTION!
Removal
1 Undo the diagnostics panel and move it aside.
P0019274
2 Disconnect the control valve connector, high

pressure pump.
P0019275
120 47705010 05-2015 © AB VOLVO PENTA

3 Disconnect the pressure relief valve connector.
P0019278
4 Disconnect the common rail pressure sensor.
P0019276
5 Remove the fuel supply connection (1) from the

Undo the fuel supply connection (2) (from the pre-
filter) to the engine control unit cooling coil.
88840290 Plugs.
P0019277
47705010 05-2015 © AB VOLVO PENTA 121

6 Remove the cable clamps and cable ties.
P0019279
7 Remove the bolts and carefully move the engine

control unit aside and stow it securely.
P0019280
8 Remove the holder
P0019281
122 47705010 05-2015 © AB VOLVO PENTA

9 Remove the control unit mounting bracket.
P0019282
10 Remove the delivery pipe between the high pres-

sure pump and the common rail. Use
88840270 Wrench.
88840290 Plugs.
11 Remove the delivery pipes according to Fuel
Injection Pipe, Change page 128.
P0019283
12 Remove the common rail unit.
P0019284
47705010 05-2015 © AB VOLVO PENTA 123

Installation
13 Install the common rail unit and the bolts.
14 Install the delivery pipe; refer to Fuel Injection
Pipe, Change page 128.
P0019284
Install a new delivery pipe between the high pres-

sure pump and the common rail.
Adjust without tightening. Use
88840270 Wrench.
P0019285
16 Install the control unit mounting bracket.
P0019282
124 47705010 05-2015 © AB VOLVO PENTA

17 Install the holder.
P0019281
18 Bolt the engine control unit in place.
P0019280
19 Secure the harness with cable clamps and cable

ties.
P0019279
47705010 05-2015 © AB VOLVO PENTA 125

20 Connect the fuel supply connection (1) from the

Connect the fuel supply connection (2) (from the
pre-filter) to the engine control unit cooling coil.
P0019286
21 Connect the connector to the control valve, high

pressure pump.
P0019275
22 Connect the connector to the common rail pres-

sure sensor.
P0019276
126 47705010 05-2015 © AB VOLVO PENTA

23 Connect the connector to the pressure relief

valve.
P0019278

P0001900 bleeding page 85.
Start the engine.
47705010 05-2015 © AB VOLVO PENTA 127

Fuel Injection Pipe, Change

Tools:
88840270 Wrench
88840290 Plugs
IMPORTANT!
IMPORTANT!
CAUTION!
CAUTION!

carried out.
Removal
1 Undo the fuel return line connection from the
common rail.
88840290 Plugs.
P0019413
128 47705010 05-2015 © AB VOLVO PENTA

2 Remove the attachment bolts.
P0019414
3 Remove and discard the delivery pipes in the fol-

lowing order. 1, 2, 5, 3, 4, 6. Use
88840270 Wrench.

88840290 Plugs.
P0019415
P0019416
Installation
Install in the following order. 1, 4, 5, 3, 2, 6.
Install the delivery pipes between the common

rail and the injector delivery pipes.
Tighten the union nuts by hand. Check that the

clamps are parallel with the bolt holes.
P0019419
47705010 05-2015 © AB VOLVO PENTA 129

5 Install the bolts and tighten.
P0019414
6 Torque the union nuts.

Use 88840270 Wrench.
P0019417
7 Connect the fuel return line.
P0019418

bleeding page 85.
Start the engine.
130 47705010 05-2015 © AB VOLVO PENTA

23-9 Miscellaneous
23-9 Miscellaneous
Pressure Limiting Valve, Change
IMPORTANT!
IMPORTANT!
CAUTION!
CAUTION!
Tools:
885812 Timing tool
88840272 Sleeve
88840290 Plugs
Removal
1 Remove the common rail unit according to Com-
mon Rail, Change page 120.
P0019356
47705010 05-2015 © AB VOLVO PENTA 131

23-9 Miscellaneous
2 Support the common rail in a vise. Use soft jaw

pads in the vise.
Remove the nut. Use 88840272 Sleeve.
Remove the solenoid.
P0019357
3 Clean away any paint residue.

Remove the solenoid valve.
P0019358
4 Install the protective plug. Use kit

88840290 Plugs.
P0019359
132 47705010 05-2015 © AB VOLVO PENTA

23-9 Miscellaneous
Installation
5 NOTICE! Angle tightening may only be per-
formed once.
Install a new O-ring. Use the recommended

grease.
1 Install the pressure reducing solenoid
valve.
2 45 ±1° (use 885812 Timing tool).
3 Check the torque 65-140 Nm (47.9-103.3
lbf. ft.)
P0019360
6 IMPORTANT!
The joint must be tightened correctly.
NOTICE! Observe the installation drawing.
NOTICE! Angle tightening may only be per-

formed once.
1 Install the solenoid.

2 Install the nut. Use 88840272 Sleeve.
3 Align the marks.
4 Torque the nuts.
5 13 ±0.5°
P0019361 Use 885812 Timing tool.
6 Check the torque 6-21 Nm (4.4-15.5 lbf. ft.)
7 Install the common rail unit according to Common
Rail, Change page 120.
P0019356
47705010 05-2015 © AB VOLVO PENTA 133

25-4 Emission Control, Catalytic Converter

Cooler e-EGR, change
IMPORTANT!
Drain the coolant according to Coolant,

Change page 195.
NOTICE! Drain the coolant until the level is below the

e-EGR radiator.
Removal
1 Remove the heat shield.
P0020525
2 Undo and lift up the heat shield.

Unscrew the NOx sensor.
P0020526
134 47705010 05-2015 © AB VOLVO PENTA

3 Remove the coolant pipe outlet.

Remove the heat shield cover.
P0020527
4 Remove the pipe clamp.

1 Move aside the coolant hose.
2 Remove the coolant pipe clamping ring,
inlet from the e-EGR cooler.
P0020528
5 Undo the EGR pipe connection.
P0020529
47705010 05-2015 © AB VOLVO PENTA 135

6 Remove the e-EGR and gaskets.
P0020530
7 Clean the sealing surfaces and inspect the seal

ring.
P0020531
8 Check the radiator core for visible cracks.

For radiator pressure testing, refer to 25-4, Cooler
e-EGR, pressure testing.
NOTICE! If the radiator core is sooty with signifi-

cant deposits it must be cleaned internally
extremely thoroughly; refer to 25-4, Cooler e-
EGR, pressure testing.
Also check the EGR pipe in connection with
cleaning.
136 47705010 05-2015 © AB VOLVO PENTA

Installation
9 NOTICE! Clean the sealing surfaces.
10 Install the e-EGR radiator and gaskets. Adjust the
coolant pipes; insert the inlet into the e-EGR radi-
ator.
P0020532
11 Install the pipe and gasket.

P0020529
12 Fit the pipe clamp.

1 Slide on the coolant outlet pipe from the e-
EGR cooler.
2 Slide on the coolant inlet pipe from the e-
EGR cooler.
P0020528
47705010 05-2015 © AB VOLVO PENTA 137

13 Install the coolant line outlet.

Install the heat shield cover bracket.
P0020527
14 Brush lubricant onto the threads and install the

NOx sensor.
Install the heat shield.
Examples of lubricants: Permatex Anti Seize or

Bostik Never-Seez.
P0020526
15 Install the heat shield.
P0020525
16 Fill with coolant; refer to Coolant Level, Checking

and Topping Up page 193.
18 Start and warm up engine. Perform a leakage and
function check.
138 47705010 05-2015 © AB VOLVO PENTA

Cooler e-EGR, change

IMPORTANT!
Removal
1 Remove the turbo, see Turbo,
Change page 145.
2 Remove the pipe clamps.
Remove coolant hose, inlet and outlet, from
cooler e-EGR.
P0020084
3 Unscrew the EGR pipe connection.
P0020085
47705010 05-2015 © AB VOLVO PENTA 139

4 Remove cooler e-EGR with gaskets.
P0020086
5 Remove the EGR pipe.

6 Check the cooling element for visible cracks.
For cooling element pressure testing, see 25-4,
Cooler e-EGR, pressure testing.
7 If the cooling element is fouled with an indicating
dirt covering it must be cleaned thoroughly inside,
see Cooler e-EGR, Cleaning page 143.
While cleaning, also check the EGR pipe.
P0020087
140 47705010 05-2015 © AB VOLVO PENTA

Installation
Install the pipe with gasket.

P0020087
9 Install cooler e-EGR with gaskets.

P0020088
10 Screw on the EGR pipe (1).

Screw on the EGR pipe (2).

P0020089
47705010 05-2015 © AB VOLVO PENTA 141

11 Thread on the coolant hoses for inlet and

exhaust.
P0020084
12 Install the turbo, see Turbo, Change page 145.

14 Start and warm up engine. Perform a leakage and
function check.
142 47705010 05-2015 © AB VOLVO PENTA

Cooler e-EGR, Cleaning

Remove cooler e-EGR, according to Cooler e-EGR,
change page 134.
Cleaning agent:
1 Degreasing agent (alternatively, use a paraffin frac-
tion as a second choice).
2 Heavy duty alkaline cleaner for coarse industrial
cleaning. Supposedly used in bath for degreasing
of metal constructions.
Cleaning
1 Clean the e-EGR cooler by first washing through
it with degreasing or recommended cleaning
agent a couple of times.
2 Soak the radiator for 24 h in a suitable cleaning
agent.
P0020091
3 Steam clean, or rinse hot water through the

cooler, in an upright position so that dirt can flow
downward.
Repeat with some cleaning agent. Turning cooler
on tap and rinse. Make sure the cooler is flushed
through thoroughly, until clean water comes out
of the cooler.
P0020092
47705010 05-2015 © AB VOLVO PENTA 143

4 Blow dry air through the e-EGR cooler in an

upright position until the cooler is dry.
P0020093
5 Inspect that the cooling element is clean and free

from grime and other contaminants.
P0020094
6 Install cooler e-EGR, according to Cooler e-EGR,

change page 134.
144 47705010 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 housing is installed on
the turbocharger, the compressor wheel may be
damaged or have excessive clearance between
turbine 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 (silencer) from the tur-
bocharger and check the turbine wheel.
7 Inspect 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 145.
1 Drain the coolant according to: Coolant,
Change page 195
2 Remove the exhaust pipe connection between
the turbocharger and the aftertreatment system.
47705010 05-2015 © AB VOLVO PENTA 145

3 Remove the turbocharger charge air pipe.
P0019420
4 Remove the intake pipe.
P0019421
P0019422
146 47705010 05-2015 © AB VOLVO PENTA

6 Remove the pipe bend (1) from the turbocharger.

Remove the rubber bellows (2) from the air intake
with the connecting hose for crankcase ventila-
tion.
P0019424
7 Undo and lift up the heat shield.

Unscrew the NOx sensor.
P0019425
8 NOTICE! Note the clamp position.
Remove the clamp (1).

Remove the attachment bracket (2).
Lift away the pre-Cat with the connection pipe.
P0019426
47705010 05-2015 © AB VOLVO PENTA 147

9 Disconnect the exhaust manifold pressure sensor

connector.
P0019427
10 Remove the exhaust pressure sensor unit.
P0019428
P0019429
148 47705010 05-2015 © AB VOLVO PENTA

12 Disconnect the turbocharger tachometer sensor

(1) connector and the VGT actuator (2).
P0019430
13 Remove the cable ties and the cable harness

from the cable holder.
P0019431
14 Remove the cable holder brackets.
P0019436
47705010 05-2015 © AB VOLVO PENTA 149

15 Remove the coolant inlet pipe.
P0019432
16 Remove the coolant outlet pipe.
P0019433
17 Remove the oil return pipe with gasket.
P0019434
150 47705010 05-2015 © AB VOLVO PENTA

18 Remove the oil supply pipe and the clamps.
P0019435
19 Remove the nuts, bolts and spacers from the tur-

bocharger.
Lift away the turbocharger.
Remove the gasket.
P0019437
Installation
20 NOTICE! Use new sealings.
Check the sealing surface on the manifold.

Install a new gasket on the exhaust manifold.
Lift the turbocharger into position.

Install the spacer sleeves, nuts and bolts and fas-
ten the turbocharger.
Tightening torque:
Bolt (1): 44 Nm (32.5 lbf. ft.)
Nut (2): 54 Nm (39.8 lbf. ft.)
P0019438
47705010 05-2015 © AB VOLVO PENTA 151

21 Install the oil return pipe with new seals on the

engine block and turbocharger.
P0019439
22 NOTICE! Use new sealings.
Fill the turbocharger with new, clean engine oil.

Then install the oil supply pipe and clamps.
P0019440
23 Install the upper coolant connection (outlet).

P0019433
152 47705010 05-2015 © AB VOLVO PENTA

24 install the coolant inlet pipe.

P0019441
25 Install the harness holder brackets.
P0019436
26 Install the harness and secure it with cable ties.
P0019431
47705010 05-2015 © AB VOLVO PENTA 153

27 Connect the turbocharger tachometer sensor (1)

connector and the VGT actuator (2).
P0019430
P0019429
29 Install the exhaust pressure sensor unit.
P0019428
154 47705010 05-2015 © AB VOLVO PENTA

P0019427
31 Check the sealing surface and gasket.

Lift the pre-Cat and connection pipe into position.
Install the clamp (1).
Install the unit and bracket (2).
P0019442
32 Brush lubricant onto the threads and install the

NOx sensor.
Examples of lubricants: Permatex: Anti seize or
Bostik: never seize.
P0019443
47705010 05-2015 © AB VOLVO PENTA 155

33 Install the pipe bend (1) on the turbocharger.

Tighten the clamp.
Remove the rubber bellows (2) to the air intake
with the connecting hose for crankcase ventila-
tion.
P0019424
P0019422
35 Connect the inlet pipe.
P0019421
156 47705010 05-2015 © AB VOLVO PENTA

36 Install the charge air pipe.
37 Install the exhaust pipe connection between the

turbocharger and the after-treatment system.
38 Fill the fresh water system according to Coolant,
Change page 195.
40 Run the engine warm and perform a function
check for possible leakage.
P0019420
47705010 05-2015 © AB VOLVO PENTA 157

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.
158 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 159

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
160 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 161

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
162 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 163

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
164 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 165

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
166 47705010 05-2015 © AB VOLVO PENTA

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.
codes.
P0019365
IMPORTANT!
Fluids other than AdBlue®/DEF, and that are not
NOTICE! Care for equipment and the remaining

AdBlue®/DEF solution.
p0013225
47705010 05-2015 © AB VOLVO PENTA 167

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
168 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 169


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
170 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 171

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
172 47705010 05-2015 © AB VOLVO PENTA


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 179.
P0019378

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

p0013225
47705010 05-2015 © AB VOLVO PENTA 173

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
174 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 175

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
176 47705010 05-2015 © AB VOLVO PENTA

Installation
7 Clean the contact surface.
8 NOTICE! Grease the bolts with water resistant
grease. E.g. 828250 Grease.
P0019387
P0019388
11 Install the AdBlue/DEF hoses.
P0019384
47705010 05-2015 © AB VOLVO PENTA 177


P0019365

p0013225
178 47705010 05-2015 © AB VOLVO PENTA

AdBlue/DEF-Pump Filter, Change

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
47705010 05-2015 © AB VOLVO PENTA 179

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
180 47705010 05-2015 © AB VOLVO PENTA

8 Tighten the cover.

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

P0019365

p0013225
47705010 05-2015 © AB VOLVO PENTA 181

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
182 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 183

Pump Unit, Change

Removal
1 Stop the engine.

P0019364
3 Remove the harness terminal
P0019393
184 47705010 05-2015 © AB VOLVO PENTA

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
47705010 05-2015 © AB VOLVO PENTA 185

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
186 47705010 05-2015 © AB VOLVO PENTA


P0019365

p0013225
47705010 05-2015 © AB VOLVO PENTA 187

Combined Tank Unit, AdBlue/DEF

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

P0019364
188 47705010 05-2015 © AB VOLVO PENTA


Remove the hoses.
P0019367
1158957
p0013226
p0013222

P0019371
47705010 05-2015 © AB VOLVO PENTA 189

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

and locked.
8 Remove 1158957 Pliers.
P0019378

codes.
P0019365

p0013225
190 47705010 05-2015 © AB VOLVO PENTA

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.
47705010 05-2015 © AB VOLVO PENTA 191

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
192 47705010 05-2015 © AB VOLVO PENTA

26-0 Cooling System, General

Coolant Level, Checking and
Topping Up
IMPORTANT!
Only use coolant recommended by Volvo Penta.
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).
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.
P0019343
47705010 05-2015 © AB VOLVO PENTA 193

Refill of completely empty 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
volume.
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 purged during filling.
1 Check that all drain points are closed.

2 NOTICE! Only open the filler cap (1).
Do not open the pressure cap (2).
Check that the coolant level is above the MIN

mark on the expansion tank.
3 Start the engine when the cooling system has
been completely filled and purged.
Open any venting taps a short while after starting,
to allow trapped air to escape.
4 Run the engine at idle a while.
Increase engine speed to 1600-1700 rpm over
three minutes.
Check the coolant level.
P0019343
5 Start the engine.
Run it until it reaches operating temperature
(thermostat open).
Check the coolant level. Adjust the level as
required.
6 Carry out a follow-up check of the coolant level
after approx 1 hour's operation.
194 47705010 05-2015 © AB VOLVO PENTA

Coolant, Change
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.
Tools:
9996049 Draining hose
1 NOTICE! Do not open the pressure cap (2).
Remove the filler cap (1).
P0019343
2 Open all drain points.
NOTICE! There may be other taps or plugs at the

lowest points of the coolant system
3 Connect 9996049 Draining hose.
Connect a drainage vessel.
Empty the radiator.
P0019344
47705010 05-2015 © AB VOLVO PENTA 195

4 Connect 9996049 Draining hose.

Connect a drainage vessel.
Drain the engine block.
Check that all coolant drains out.

5 Remove the tool.
Close any taps.
6 Refill with new, Volvo Penta-recommended cool-
ing fluid.
Refer to 03-26, Technical Data and Coolant
Level, Checking and Topping Up page 193.
P0019345
196 47705010 05-2015 © AB VOLVO PENTA

26-1 Radiator, Heat Exchanger

Radiator Assembly, Change
Removal
IMPORTANT!
Change page 195.
2 Remove the the turbo pressure pipe (1) for out-
going charge air.
Remove the coolant hose (2), coolant outlet to the
radiator.
Remove the hose (3) between the radiator and
expansion tank.
P0019573
3 Remove the right belt guard.

Remove the right fan protection.
P0019574
47705010 05-2015 © AB VOLVO PENTA 197

4 Remove the charge air pipe (1) from the charge

air cooler and pipe elbow.
Remove the filler hose (2) between the expansion
tank and coolant inlet coolant pipe.
P0019575
5 Remove the left belt guard.

Remove the left fan protection.
Remove the pipe elbow.
P0019576
6 Remove the hose between the expansion tank

and thermostat housing side cover.
Remove the connector to coolant level sensor,
expansion tank.
P0019577
198 47705010 05-2015 © AB VOLVO PENTA

7 Loosen the fan ring.

Remove the coolant hose, coolant inlet (from the
radiator).
Loosen the upper radiator stay.
P0019578
8 Connect the radiator to a hoisting device. Loosen

the lower bracket.
P0019579
9 Release the cooler for further work.

Remove the fan ring.
P0019580
47705010 05-2015 © AB VOLVO PENTA 199

Installation
10 Thread the fan ring over the fan.
Align the radiator over the frame and upper
bracket.
P0019580
11 Bolt on the radiator at the top and at the bottom

bracket.
P0019581
12 Fit the fan ring.

Install the coolant hose, coolant inlet (from the
radiator).
P0019582
200 47705010 05-2015 © AB VOLVO PENTA

13 Install the hose between the expansion tank and

thermostat housing side cover.
Connect the connector to coolant level sensor,
expansion tank.
P0019577
14 Install the left belt guard.

Fit the left fan protection.
Install the pipe elbow.
P0019576
15 Install the charge air pipe (1) from the charge air
cooler and pipe elbow.
Install the filler hose (2) between the expansion
tank and coolant inlet coolant pipe.
P0019575
47705010 05-2015 © AB VOLVO PENTA 201

16 Install the right belt guard.

Fit the right fan protection.
P0019574
17 Install the the turbo pressure pipe (1) for outgoing

charge air.
Install the coolant hose (2), coolant outlet to the
radiator.
Install the hose (3) between the radiator and
expansion tank.
P0019573
18 Refill with new, Volvo Penta recommended cool-

ing fluid. Refer to 03-26, Technical Data and
Coolant Level, Checking and Topping
Up page 193.
202 47705010 05-2015 © AB VOLVO PENTA

26-2 Coolant Pump, Thermostat

Coolant Pump, Change
IMPORTANT!
There are different procedures for access point at

replacement of the component dependent on which
cooling system that is connected.
Removal

Change page 195.
2 Remove the radiator hoses and charge air con-
nections.
Remove belt guard and fan guard, see Radiator
Assembly, Change page 197.
3 IMPORTANT!
Do not allow the visco coupling to lay flat for more
than a moment. Oil may run out which will mean
that the coupling must be changed.
P0019589
4 Disconnect the sensor harness from to the engine

harness.
Remove the sensor bracket from the engine con-
sole.
P0019590
47705010 05-2015 © AB VOLVO PENTA 203

5 NOTICE! Left hand thread.
Unscrew the visco coupling with the fan.
P0019591
6 Remove the hose connection (1) from the coolant

pipe. (Warm-circuit fluid from the turbo, cooler e-
EGR).
Remove the hose (2). (Connection hose to the
expansion tank).
P0019592
7 Remove the the connection pipe for the crank-

case ventilation.
Remove the electrical connection from the pre-
heater element.
P0019593
204 47705010 05-2015 © AB VOLVO PENTA

8 Disconnect the harness terminal.

Open the cover of the pre-heating relay. Remove
the input nut.
Remove the engine attachment.
P0019594
9 Remove the pre-heating relay.
P0019595
10 Remove the clamps.

Loosen the harness.
Remove the screws.
Remove the support.
P0019596
47705010 05-2015 © AB VOLVO PENTA 205

11 Remove the thermostat housing.
P0019597
12 Remove the gaskets.
P0019598
13 Remove the breather pipe from the separator.
P0019599
206 47705010 05-2015 © AB VOLVO PENTA

14 Release the belt tensioner and lock it in place with

a drift.
Remove the drive belt.
Check the function of the tensioner, the condition
of the pulleys and the idler wheel bearings.
P0019600
15 Remove the fan adapter and the coolant pump

pulley.
P0019601
16 NOTICE! Be prepared to gather up fluid.
Loosen the drain plug.

Drain the coolant pump.
P0019602
47705010 05-2015 © AB VOLVO PENTA 207

17 Remove the coolant pump.

Remove the gaskets.
P0019603
Installation
P0019604
NOTICE! When remounting the existing compo-

nent.
P0019605
208 47705010 05-2015 © AB VOLVO PENTA

20 Install new gaskets.
P0019606
21 Install the coolant pump; first guide in the coolant

pump "neck" and O-ring.
P0019607
22 Tighten the screws in numerical order according

to the picture.
Stage 1 Screw in 1-8 without tightening.

Stage 2 Tightening torque, screw (A): 24 Nm
(17.7 lb. ft.)
Stage 3 Tightening torque, screw 1-8: 48 Nm
(35.4 lb. ft.)
P0019608
47705010 05-2015 © AB VOLVO PENTA 209

23 NOTICE! When remounting the existing compo-

nent.
Tighten the plug.
P0019609
24 Install the fan adapter and the coolant pump pul-

ley. Tighten the screws crosswise.
P0019610
25 Fit the belt.

Release the belt tensioner and the drift.
Check that the belt is properly aligned in the
groove and correct on all pulleys.
P0019611
210 47705010 05-2015 © AB VOLVO PENTA

26 Install the breather pipe between the separator

and the pipe connection.
P0019599
P0019612
28 Install new gaskets.

Lubricate the o-ring.
P0019613
47705010 05-2015 © AB VOLVO PENTA 211

29 Install the thermostat housing.

Tighten the screws crosswise.
P0019597
30 Install the support.

Install the screws. Tighten the screws.
Position the harness.
Install the clamps.
P0019614
31 Install the pre-heating relay.
P0019595
212 47705010 05-2015 © AB VOLVO PENTA

32 Install the engine attachment.

Install the cable to the input nut.
Close the cover to the pre-heating relay.
Fasten with cable ties.
Connect the harness terminal.
P0019615
33 Fit the the connection pipe for the crankcase ven-

tilation.
Install the electrical connection from the pre-
heater element.
Fasten with cable ties.
P0019616
34 Install the hose connection (1) to the coolant pipe.

Install the hose (2).
P0019617
47705010 05-2015 © AB VOLVO PENTA 213

35 Lift the fan and carefully offer the coupling onto

the engine attachment.
NOTICE! Left hand thread.
Rotate the fan slowly clockwise (viewed as illus-

trated) so that the threads grip. Rotate the fan
until the threads bottom and tighten so that the
coupling grips the adapter.
P0019618
36 Install the sensor bracket from the engine con-

sole.
Connect the sensor harness to the engine har-
ness and secure them with a cable tie.
P0019590
37 Refit the radiator hoses and charge air connec-

tions.
Install belt guard and fan guard, see Radiator
Assembly, Change page 197.
38 Fill with coolant; refer to: Coolant,
Change page 195.
Start the engine. Check that no leakage occurs.
214 47705010 05-2015 © AB VOLVO PENTA

Thermostat, Change
Removal
1 Drain off coolant sufficient for its level to drop

below the thermostat housing, refer to Coolant,
Change page 195.
2 Disconnect the hose from the radiator.
P0019521
3 Remove the connection for the crankcase

breather from the valve cover.
P0019483
47705010 05-2015 © AB VOLVO PENTA 215

4 Loosen the hose between the expansion tank and

thermostat housing.
P0019522
5 Remove the thermostat housing cover.

Remove the thermostat.
P0019523
6 Clean the mating surfaces of the thermostat

housing.
P0019524
216 47705010 05-2015 © AB VOLVO PENTA

Installation
7 Install a new thermostat.
Install the thermostat housing cover.
Tightening sequence: Diagonal
P0019525
8 Install the hose between the expansion tank and

thermostat housing.
P0019522
9 Connect the hose to the radiator.
P0019521
47705010 05-2015 © AB VOLVO PENTA 217

10 Fit the connection for the crankcase breather to

the valve cover.
P0019483

218 47705010 05-2015 © AB VOLVO PENTA

Drive Belt, Change

Right belt guard removed; refer to Belt protector,
change page 220.
Removal
CAUTION!
Pinch hazard. Keep fingers clear.
1 Unfasten the belt tensioner and restrain it with a

drift.
2 Remove the belt.
3 Check the function of the tensioner and the con-
dition of the pulleys and the idler pulley bearings.
P0019255
Installation
4 Install the belt.
5 Release the belt tensioner and remove the drift.
6 Check that the belt is correctly aligned on all the
pulleys.
7 Install the belt guard; refer to Belt protector,
change page 220.
P0019256
47705010 05-2015 © AB VOLVO PENTA 219

Belt protector, change

Right belt guard
Removal
1 Remove the belt guard.
Installation
2 Install the belt guard.
P0019257
Left belt guard
Removal
1 Remove the belt guard.
Installation
2 Install the belt guard.
P0019258
220 47705010 05-2015 © AB VOLVO PENTA

32-1 Alternator
32-1 Alternator
Alternator, Change
Removal
carried out.
1 Remove components 1-5; refer to Turbo,

Change page 145
1 Remove the turbocharger charge air pipe.
2 Remove the intake pipe.
4 Remove the pipe elbow from the turbo-
charger.
5 Remove the rubber bellows from the air
intake with the connecting hose for crank-
case ventilation.
P0019406
2 Remove the right belt guard; refer to Belt protec-

tor, change page 220.
3 Remove the drive belt according to Drive Belt,
Change page 219.
4 Disconnect the alternator cable terminals.
P0019407
47705010 05-2015 © AB VOLVO PENTA 221

32-1 Alternator
5 Disconnect the connector.
P0019408
6 Remove the alternator.
P0019409
222 47705010 05-2015 © AB VOLVO PENTA

32-1 Alternator
Installation
7 Install the alternator.
Tighten the two attachment bolts and nuts.
Tightening torque:
Upper attachment bolt (1), 48 Nm (35.4 lbf.
ft.)
Lower attachment bolt (2), 85 Nm (62.7 lbf.
ft.)
P0019410
P0019408
9 Install the alternator cable connections.
Tightening torque:
Negative terminal (1), 10 Nm (7.4 lbf. ft.)
Positive terminal (2), 12 Nm (8.9 lbf. ft.)
P0019411
47705010 05-2015 © AB VOLVO PENTA 223

32-1 Alternator
10 Install the drive belt according to Drive Belt,

Change page 219
11 Install the right belt guard: refer to Belt protector,
change page 220.
12 Install components 1-5; refer to Turbo,
Change page 145.
1 Install the rubber bellows on the air intake
with the connecting hose to the crankcase
ventilation.
2 Install the pipe elbow on the turbocharger.
4 Install the inlet pipe.
5 Install the charge air pipe.
P0019412
224 47705010 05-2015 © AB VOLVO PENTA

32-1 Alternator
Pulley, alternator, change

Removal
1 Remove the drive belt. / Alternator removed.
2 Clean the nut and the alternator shaft.
3 Using a marker pen, mark the position of the nut
in relation to the alternator shaft.
P0020358
4 Undo the nut with a few short bursts from an

impact wrench.
Remove the belt pulley.
P0020359
47705010 05-2015 © AB VOLVO PENTA 225

32-1 Alternator
Installation
5 Clean thread locker away from the threads with a
brush.
6 Install the pulley and first screw on the nut by
hand.
Select the tightening alternative that corresponds
to the specified torque:
Alternative 1
Use a few short bursts from an impact
wrench until the marks are aligned.
Alternative 2
Use a torque limiting socket
Alternative 3 (M17)
Angle tighten the nut 40 degrees.
Tightening torque:
P0020360 M16: 95 Nm (70 lbf. ft.)

M17: 118 Nm (87 lbf. ft.)
7 The markings must be aligned.
P0020358
8 Install the alternator.

Fit the drive belt.
226 47705010 05-2015 © AB VOLVO PENTA

33-1 Starter Motor
33-1 Starter Motor

Starter Motor, Change
IMPORTANT!
Removal
1 Unscrew the nut from starter plus terminal.
Fold aside cable (1) from the main power switch
(+), generator cable (2) and cable split / fuse
holder (3).
P0020346
2 Disconnect the connector.
P0020347
47705010 05-2015 © AB VOLVO PENTA 227

33-1 Starter Motor
3 Remove the starter motor.
P0020348
228 47705010 05-2015 © AB VOLVO PENTA

33-1 Starter Motor
Installation
4 Clean the contact surface on the flywheel hous-
ing.
5 Fasten the start motor.
P0020348
P0020350
7 Connect the cables 1-3 to the starter motor.

Secure the cables with cable ties after performed

installation.
P0020349
47705010 05-2015 © AB VOLVO PENTA 229

Alphabetical index
A I
About this Workshop manual..................................... 2 Illustrations................................................................. 5
AdBlue/DEF Tank, Change.................................... 161 Injector, Change..................................................... 112
AdBlue/DEF Tank, Cleaning.................................. 168 Injectors and Delivery Pipes................................... 112
AdBlue/DEF-Pump Filter, Change......................... 179 L
Alternator................................................................ 221 Lower valve cover, change................................. 44, 47
Alternator, Change................................................. 221 Lubrication System................................................... 30
B M
Belt protector, change............................................ 220 Miscellaneous......................................................... 131
C MPROP valve, high pressure pump, change......... 108
Checking for diesel or oil in the AdBlue/DEF O
solution................................................................... 191 Oil Cooler, Replace.................................................. 82
Checking urea concentration in the fluid................ 192 Oil filter..................................................................... 73
Combined Tank Unit, AdBlue/DEF Tank, Change. 188 Oil Filter Housing, Change....................................... 76
Common Rail, Change........................................... 120 Oil filter, Change....................................................... 73
Coolant Level, Checking and Topping Up.............. 193
Coolant Pump, Change.......................................... 203 P
Coolant Pump, Thermostat.................................... 203 Pressure Limiting Valve, Change........................... 131
Coolant, Change.................................................... 195 Pulley, alternator, change....................................... 225
Cooler e-EGR, change................................... 134, 139 Pump Unit, Change................................................ 184
Cooler e-EGR, Cleaning......................................... 143 R
Cooling System, General....................................... 193 Radiator Assembly, Change .................................. 197
Crank Mechanism.................................................... 63 Radiator, Heat Exchanger...................................... 197
Crankshaft Seal, Change (front)............................... 64 Repair instructions.............................................. 3, 158
Crankshaft Seal, Change (rear)............................... 69
S
Cylinder Head........................................................... 37
Safety Instructions.................................................... 31
D Solenoid Valve, AdBlue/DEF Tank, Change.......... 182
Dosing unit, change................................................ 175 Special Service Tools............................................... 35
Drive Belt, Change................................................. 219 Special Tightening Torques........................................ 9
E Specifications, Engine ............................................... 8
Electrically Heated AdBlue/DEF Hose, Change..... 159 Starter Motor.......................................................... 227
Emission After-Treatment....................................... 158 Starter Motor, Change............................................ 227
Emission Control, Catalytic Converter.................... 134 T
Exhaust Temperature Sensor, Change.................. 174 Thermostat, Change............................................... 215
F Timing Gears and Shaft........................................... 59
Flywheel, Change..................................................... 59 Turbo and supercharger......................................... 145
Fuel Feed Pump and Filter....................................... 86 Turbo, Change....................................................... 145
Fuel filter housing, change....................................... 93 Turbocharger, Inspection....................................... 145
Fuel filter, Change.................................................... 90 U
Fuel Injection Pipe, Change................................... 128 Upper valve cover, change................................. 37, 41
Fuel pre-filter, bleeding............................................. 89
V
Fuel Pre-filter, Change............................................. 86
Valve Mechanism..................................................... 51
Fuel system, bleeding.............................................. 85
Valves, Adjustment................................................... 51
Fuel System, General............................................... 85
G
Gear Ring, Fywheel: Replace.................................. 63
General....................................................................... 2
General Tightening Torques....................................... 8
Group 21: Engine....................................................... 9
Group 22: Lubrication System............................ 17, 30
Group 23: Fuel System............................................ 20
Group 25: Inlet and Exhaust System........................ 24
Group 26: Cooling System....................................... 26
Group 30: Electrical System..................................... 28
H
High Pressure Pump, Change.................................. 96
47705010 05-2015 © AB VOLVO PENTA 231

References to Service Bulletins
Group No. Date Refers to
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233
Report form
Do you have any complaints or other comments about this manual.

Please make a copy of this page, write your comments down and send
them to us. The address is at the bottom. We would prefer you to write in
English or Swedish.
From:.........................................................................
..................................................................................
..................................................................................
..................................................................................
Refers to publication:...................................................................................................................................
Publication No.:....................................Date of issue:..................................................................................
Proposal/motivation:....................................................................................................................................
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Date:.....................................................................................
Signed:.................................................................................
AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Göteborg
Sweden
47705010 English 05-2015

Manuale Officina Volvo TAD870VE

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Workshop Manual I

Group 21-26 2(0)

TAD570VE, TAD571VE, TAD572VE,

Safety and Other Instructions

Lubricating and Oil System

Inlet and Exhaust System

Alternator, Charge Regulator

47705010 05-2015 © AB VOLVO PENTA 1

Volvo Penta accepts no responsibility for damage or

2 47705010 05-2015 © AB VOLVO PENTA

Above all, when working on fuel systems, hydraulic

47705010 05-2015 © AB VOLVO PENTA 3

Lock nuts Anaerobic agents.

4 47705010 05-2015 © AB VOLVO PENTA

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

47705010 05-2015 © AB VOLVO PENTA 5

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

6 47705010 05-2015 © AB VOLVO PENTA

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

47705010 05-2015 © AB VOLVO PENTA 7

03-2 Specifications, Engine

8 47705010 05-2015 © AB VOLVO PENTA

Special Tightening Torques

Group 21: Engine

NOTICE! Tighten the bolts in sequence, as illustrated.

Step 1: 60 Nm (44.2 lbf. ft.)

Step 1: 75 Nm (55.3 lbf. ft.)

47705010 05-2015 © AB VOLVO PENTA 9

1 Drive gear, camshaft

10 47705010 05-2015 © AB VOLVO PENTA

Flywheel and timing cover

NOTICE! Apply an approximately 2 mm (0.079”) thick

NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque: 190 Nm (140.1 lbf. ft.)

47705010 05-2015 © AB VOLVO PENTA 11

Vibration damper, crankshaft

Tightening torque: 110 Nm (81.1 lbf. ft.)

Cover, crankshaft seal

NOTICE! Apply an approximately 2 mm (0.079”) thick

12 47705010 05-2015 © AB VOLVO PENTA

NOTICE! Attach the cylinder head as per section

47705010 05-2015 © AB VOLVO PENTA 13

NOTICE! Attach the cylinder head as per section

14 47705010 05-2015 © AB VOLVO PENTA

Bearing caps, camshaft

47705010 05-2015 © AB VOLVO PENTA 15

Tightening torque: 24 Nm (17.7 lbf. ft.)

Valve cover, lower

NOTICE! Tighten the bolts in sequence, as illustrated.

Tightening torque: 24 Nm (17.7 lbf. ft.)

16 47705010 05-2015 © AB VOLVO PENTA