Volvotad 850 Workshop Manual

Workshop Manual
Group 21-26
TAD540-2 VE
TAD550-2 VE
TAD570-2 VE
TAD840-3 VE
TAD850-3 VE
TAD870-3 VE
Table of Content
General Information
00-0 General ............................................................................................. 3
Specifications
03-0 General Specifications ................................................................... 9
03-2 Specifications, Engine .................................................................. 11
03-21 Engine ....................................................................................... 35
03-22 Lubrication System ................................................................. 45
03-23 Fuel System .............................................................................. 45
03-25 Inlet and Exhaust System ....................................................... 46
03-26 Cooling System ........................................................................ 46
Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 47
Special tools
08-2 Special Service Tools ................................................................... 51
Engine
21-0 Engine Complete, General ........................................................... 55
Fitting the Fixture ............................................................................... 55
Engine Disassembly .......................................................................... 58
Engine Assembly ............................................................................... 65
21-1 Cylinder Head ................................................................................ 75
21-4 Valve Mechanism ........................................................................ 100
21-5 Timing Gears and Shaft .............................................................. 113
21-6 Crank Mechanism ....................................................................... 137
Lubricating and Oil System

22-1 Oil pump and Line ....................................................................... 147
22-2 Oil filter ........................................................................................ 149
22-3 Oil cooler ..................................................................................... 156
Fuel System
23-0 Fuel System, General ................................................................. 158
23-3 Fuel Feed Pump and Filter ......................................................... 159
23-7 Injectors and Delivery Pipes ...................................................... 188
23-9 Miscellaneous ............................................................................. 207
Inlet and Exhaust System

25-1 Inlet and Exhaust Manifolds ...................................................... 210
25-4 Emission Control, Catalytic Converter ..................................... 219
25-5 Turbo and supercharger ............................................................ 230
25-6 Air Cleaner, Throttle Housing .................................................... 246
25-8 Emission After-Treatment .......................................................... 248
Cooling System
26-0 Cooling System, General ........................................................... 267
26-1 Radiator, Heat Exchanger .......................................................... 271
26-2 Coolant Pump, Thermostat ........................................................ 277
26-3 Fan, Fan Shroud .......................................................................... 294
Alternator, Charge Regulator
47705010 03-2018 © AB VOLVO PENTA 1

32-1 Alternator ..................................................................................... 300
Starting System
33-1 Starter Motor ............................................................................... 306
Index ......................................................................................................... 309
References to Service Bulletins ............................................................ 311
2 47705010 03-2018 © AB VOLVO PENTA

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

costs arising as a result of failure to follow the above
mentioned standards.
47705010 03-2018 © AB VOLVO PENTA 3

00-0 General
Repair instructions
Introduction Our Mutual Responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the
mounted in a workholding fixture. Maintenance work technical specification may dramatically increase the
is often carried out in situ, in which case - if nothing environmental impact of an otherwise reliable
else is indicated - using the same working methods system. It is therefore critical that the stated wear
as the workshop. tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information. maintenance schedule must be followed.
Some systems, e.g. fuel systems, often require
DANGER! special expertise and test equipment. A number of
components are factory-sealed, for among other
WARNING! things environmental reasons. Warranty-sealed
components may not be worked on without
CAUTION! authorization to perform such work.
IMPORTANT!, NOTE! Remember that most chemical products, incorrectly
are by no means comprehensive since not everything used, are harmful to the environment. Volvo Penta
can be foreseen as service work is carried out in the recommends the use of biodegradable degreasers
most varied of circumstances. We call attention to whenever components are cleaned, unless otherwise
risks that may occur due to incorrect handling during specified in the Service Manual. When working
work in a well-equipped workshop using working outdoors, take especial care to ensure that oils and
methods and tools tried and tested by us. wash residues etc. are correctly properly for
destruction.
The service manual describes work operations
carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta Tightening torque
Special Tools are designed to ensure the safest and Tightening torques for vital fasteners that must be
most rational working methods possible. It is applied using a torque wrench are indicated in the
therefore the responsibility of anyone using tools or Service Manual, chapter Tightening torques and in
working methods other than those we recommend to the Manual's work descriptions. All torque indications
ensure that no risk of personal injury or mechanical apply to clean threads, bolt heads and mating faces.
damage is present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user
required for fasteners, the correct type will be
instructions may be in force for the tools and
indicated in the job description.
chemicals mentioned in the Service Manual. These
rules must always be observed, so there are no
special instructions about this in the workshop
Torque, angle tightening
manual. When torque/angle tightening, the fastener is
tightened to a specified torque, and tightening then
By following these basic recommendations and using continues through a pre-determined angle.
common sense it is possible to avoid most of the risks
involved in the work. A clean workplace and a clean Example: For 90° angle tightening, the fastener is
product will eliminate many risks of personal injury turned an additional 1/4 turn in one sequence, after
and malfunction. the specified tightening torque has been achieved.
Above all, when working on fuel systems, hydraulic
systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.
4 47705010 03-2018 © AB VOLVO PENTA

00-0 General
Lock nuts Anaerobic agents.

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

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

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

sealants used in product manufacture are indicated. Always use chloroprene rubber gloves (gloves for
The same sealants, or sealants with equivalent chemicals handling) and goggles. Handle the
properties, must be used for maintenance work. removed seal in the same way as corrosive acid. All
A service technician should have a basic knowledge residue, including ash, can be highly corrosive. Never
of how sealing compounds are handled, and are able use compressed air to blow clean.
to assess the condition of existing seals. Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under running
Make sure that mating surfaces are dry and free from water before removing them.
oil, grease, paint and anti-corrosion agent before
applying sealant or locking fluid. Always follow the The following seals are most probably made from
manufacturer's instructions regarding applicable fluorocarbon rubber:
temperatures, hardening times and such.
Seal rings for the crankshaft, camshaft, idler shafts.
Two basic types of compound are used:
O-rings, regardless of where they are installed. O-
RTV preparations (Room Temperature rings for cylinder liner sealing are almost always
Vulcanizing). made of fluorocarbon rubber.
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV Please note that seals which have not been
sealants are completely visible when the part has exposed to high temperature can be handled
been removed. Old RTV sealant must be removed normally.
before the component is sealed again. Use
denatured alcohol.
47705010 03-2018 © AB VOLVO PENTA 5

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 which is
fastened by a bolt or such on a (light grey) engine /
transmission body.
P0015623
Focus arrows pointing at object. Sometimes it

contains number of items, e.g. three bolts.
When this symbol is used on a series of bolts it is
expected that the service technician tighten the bolts
in a logical sequence.
NOTICE! If an arrow with the text “x3” is pointing at

P0015699 only one item, e.g. a bolt, it still applies to the other
1 Focus two alike items (the two other bolts) highlighted in the
(blue) illustration.
2 Fastenings
(red)
3 Body
(light grey) P0015627
4 Background This symbol gives a positioning number to an object,

(white) e.g. 2, which is also mentioned in the supplied text
information.
P0015628
The symbol in the top left shows part no. of the

positioned special tool, e.g. 9991801.
The lower symbol is used when something needs to
be replaced by a new part / kit.
The symbol on the right side is used when a part
needs to be discarded.
6 47705010 03-2018 © AB VOLVO PENTA

00-0 General
Movement Tools
P0015622
Movement arrows are used to show which direction a P0015629
component is to be moved / rotated.

One of the following symbols is used when describing
the recommended type of screwdriver.
P0015625
Symbol is used in a corner of the illustration to show

how many degrees the object shall be turned and at
which direction.
P0015630
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.
Measurements
P0015631
A drill in a specified size, duck tape and stripes may

also be shown as symbols.
P0022436
The symbols are used to show different types of

measurements.
Clearance is shown in this feeler gauge symbol.
This dial indicator symbol shows a MIN value.
47705010 03-2018 © AB VOLVO PENTA 7

00-0 General
Chemicals Units
P0015695
P0015696
Symbols can also describe when and how a chemical

Units are mentioned in the illustration when a specific
product is to be used.
value (e.g. pressure, weight or resistance etc.) is
expected.
Cleanliness
Important
P0015624
The scraper symbol suggests that a contact surface P0015005

needs to be scraped from sealant etc.
The cloth symbol suggests that the mechanic should The eye symbol is used when something needs close
clean the contact surface thoroughly or be prepared inspection or must be performed in a certain way.
for some oil spill or similar. The symbol to the right is used when several
mechanics are needed.
Sealant
Safety
P0015698
P0015697
The tube symbol shows how thick layer of sealant to
applicate. These symbols are used when a certain safety related
The clock symbol is used when something needs to equipment is needed.
be done within or after a certain time.
8 47705010 03-2018 © AB VOLVO PENTA

03-0 General Specifications

General Tightening Torques
General Tightening Torques
M6 10 Nm (7.4 lbf ft)
M8 24 Nm (17.7 lbf ft)
M10 48 Nm (35.4 lbf ft)
M12 85 Nm (62.7 lbf ft)
M14 140 Nm (103.3 lbf ft)
M16 220 Nm (162.3 lbf ft)
IMPORTANT!
Check bolts which are to be re-installed. Damaged bolts,
e.g. with shear marks under heads must be scrapped.
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10 47705010 03-2018 © AB VOLVO PENTA

03-2 Specifications, Engine

Special Tightening Torques
Group 21: Engine

Main Bearing Caps
TAD8xxxVE
Tighten the bolts in sequence.
Tightening torque: 60 Nm (44.2 lbf. ft.)

Angle tightening: 90°
P0021522
TAD5xxxVE

P0021523
Conrod caps

P0021524
47705010 03-2018 © AB VOLVO PENTA 11

Frame reinforcement
TAD8xxxVE
Tighten the remaining bolts.
P0021525
TAD5xxxVE
Tighten the remaining bolts.
P0021526
12 47705010 03-2018 © AB VOLVO PENTA

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
47705010 03-2018 © AB VOLVO PENTA 13

Flywheel and timing cover
Flywheel and timing cover

Tightening torque
Screws 1-9:
Screws 10-12:
Screws 13-14:
NOTICE! Apply an approximately 2 mm (0.079”) bead

of silicon (product no. 1161231), max. 20 minutes
P0021530 before installation.
P0021528
14 47705010 03-2018 © AB VOLVO PENTA

Flywheel
P0021529
Vibration damper, crankshaft

P0021531
47705010 03-2018 © AB VOLVO PENTA 15

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

silicone bead (part no. 1161231) max. 20 minutes
before installation.
Fasten the cover with bolts 2 and 7.

Tighten until contact is established.
Tighten the bolts 2 and 7.
Tighten the bolts in the sequence 1, 3-6, 8.
16 47705010 03-2018 © AB VOLVO PENTA

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

Cylinder Head, Change, page 75.
IMPORTANT! Different angle torque tightening
procedure for the long cylinder head bolts (bearing caps,
camshaft 3, 6, 11, 14, 19 and 22) in step 4.
Tightening torque
1 Tighten the bolts 1-26 in sequence.
100 Nm (73.8 lbf. ft.)
2 Tighten bolts B1-B6.
29.5 Nm (21.8 lbf. ft.)
3 Angle tighten bolts 1-26.
90° (angle tightening)
4 Angle tighten bolts 1-26.
Short bolts 90°
Long bolts 135° (3, 6, 11, 14, 19, 22)
5 Tighten bolts B1-B6.
29.5 Nm (21.8 lbf. ft.)
6 Tighten bolt (A).
60 Nm (44.3 lbf. ft.)
7 Tighten bolt (C).
30 Nm (22.1 lbf. ft.)
47705010 03-2018 © AB VOLVO PENTA 17

TAD5xxxVE
P0021535
Tighten bolts 1-18 in sequence.

Tighten bolts B1-B4.
Tightening torque: 29.5 Nm (21.8 lbf. ft.)
Tighten the bolts 1-2, 4–5, 7–10, 12–13, 15–18 in
sequence.
Tighten the bolts 3, 6, 11, 14 in sequence.
Tighten bolts B1-B4.
29.5 Nm (21.8 lbf. ft.)
Tighten bolt (A).
Tighten bolt (C).
18 47705010 03-2018 © AB VOLVO PENTA

Bearing caps, camshaft

(camshaft and bearing caps in place)
TAD8xxxVE
Tighten the bolts 1-6 in sequence.

Tighten bolts 7-12.
Tighten bolts 7-12.
P0021536
TAD5xxxVE
Tightening torque
P0021537
47705010 03-2018 © AB VOLVO PENTA 19

Valve cover
TAD8xxxVE
Tightening torque: 24 Nm
P0024987

P0024988
20 47705010 03-2018 © AB VOLVO PENTA

TAD5xxxVE
P0024989

P0024990
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Group 22: Lubrication System

Drain plug, oil sump
NOTICE! Tighten the bolts in sequence, as illustrated.
Finish off by checking the tightening torque of bolts 1

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

P0021542
Oil cooler
NOTICE! Tighten the bolts in sequence, as illustrated.
P0021543
Filter cover:
Oil cooler:
P0021544
22 47705010 03-2018 © AB VOLVO PENTA

1 By-pass valve, oil filter

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.
47705010 03-2018 © AB VOLVO PENTA 23

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

P0021549
24 47705010 03-2018 © AB VOLVO PENTA

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
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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
26 47705010 03-2018 © AB VOLVO PENTA

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")
47705010 03-2018 © AB VOLVO PENTA 27

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
28 47705010 03-2018 © AB VOLVO PENTA

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
47705010 03-2018 © AB VOLVO PENTA 29

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
TAD570VE, TAD571VE, TAD572VE, TAD870VE,

TAD871VE, TAD872VE, TAD873VE
Dosing unit:
30 47705010 03-2018 © AB VOLVO PENTA

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
47705010 03-2018 © AB VOLVO PENTA 31

Belt Tensioner
P0021557
32 47705010 03-2018 © AB VOLVO PENTA

Group 30: Electrical System
P0019882
47705010 03-2018 © AB VOLVO PENTA 33

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 11.
34 47705010 03-2018 © AB VOLVO PENTA

Engine
Engine, General
Type designation TAD540-42VE, TAD550-52VE, TAD840-43VE, TAD850-53VE,
TAD570-72VE TAD870-73VE
No. of cylinders 4 6
Weight, dry TAD540-42VE, TAD550-52VE: TAD840-43VE, TAD850-53VE:
557 kg (1228 lbs) 707kg (1305 lbs)
TAD570-72VE: TAD870-73VE:
583 kg (1285 lbs) 737 kg (1359 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
47705010 03-2018 © AB VOLVO PENTA 35

Cylinder head
Height 119.8 mm (4.717")(1)
Max. flatness error (base plane) 0.2 mm (0.008")
1) Not machined surface.
Cylinder Head Bolts

TAD5xxVE TAD8xxVE
May be re-used (number of times.) 2
Thread size M15
Length 14 pcs: 169 mm (6.65") 20 pcs: 169 mm (6.65")
4 pcs: 221 mm (8.70") 6 pcs: 221 mm (8.70")
Cylinder Liners
Type Dry
Bore 110 mm (4.33")
Liner collar height above block plane 1.053 mm (0.04146")
Depth from block plane to liner collar 5.96 ± 0.02 mm (0.23465 ± 0.00079")
Max. height difference between liner collars 0.02 mm (0.00079")
Sealing surface height above block plane 0.04-0.10 mm (0.001575-0.003937")
No. of O-rings in upper / lower liner seal 0
36 47705010 03-2018 © AB VOLVO PENTA

Piston
Type / material M174+
Number of ring grooves 3
Piston installed in engine, distance between 0.195-0.511 mm (0.00768-0.02012")
piston - block plane
Front marking Arrow forward.
Piston, diameter 108.195 ± 0.012 mm (4.25963 ± 0.00047")
Max. play, gudgeon pin - connecting rod -
Piston rings
Number of compression rings 2
Number of oil scraper rings 1
XXX Upper compression ring
X
Type Trapezoidal profile
Height 2.806 mm
XXX (0.1105")
X
Marking Top
Gap (new ring), max -
X
X
X
X
2:nd compression ring

Type Rectangular
p0005201
Height 2.0 mm (0.1105")
Marking Top
Oil Scraper Ring
Height 2.5 mm (0.098")
Crank Mechanism
Crankshaft
Connecting rod, marking (front) FRONT
Big end bearing, radial -
clearance
201 201
End float, con rod - crankshaft -
Crankshaft, type of hardening Induction
hardened
201 201 Max./min. end float 0.05-0.14 mm
(0.0020-0.0055")
p0005212 Crankshaft, max. skew 0.005 (0.00020")
Max taper, crankshaft/ 0.006 (0.00024")
connecting rod journal
Max out-of-round, crankshaft/ 0.006 (0.00024")
connecting rod journal
47705010 03-2018 © AB VOLVO PENTA 37

A Main bearing journals

Dimension (diameter), STD 89.978-90 mm
(3.54243-3.54330")
Undersize 0.07 mm 89.908-89.93 mm
(3.53967-3.54054")
Undersize 0.25 mm 89.728-89.75 mm
R (3.53259-3.53345")
C D
Undersize 0.50 mm 89.478-89.50 mm
(3.52275-3.52361")
Undersize 0.75 mm 89.228-89.25 mm
(3.51290-3.51377")
Surface finish, main bearing Ra 0.25 mm
journal (0.00984")
B
Surface finish, radius -
p0005210
Fillet radius (R) 3.5 mm (0.138")
Circular run-out, 1-7 main bearing journals
No. 4 0.01 (0.0004")
No. 1 and 7 0.02 (0.0008")
No. 2 and 6 0.04 (0.0016")
No. 3 and 5 0.08 (0.0031")
Main bearing shells
External diameter (C) -
Thickness (D), A STD 2.5 - 0.019-0.032
(0.0984 -
0.00075-0.00126")
Above 1: dimension 0.07 2.535 (0.09980")
mm
Above 2: dimension 0.25 2.625 (0.10335")
mm
Above 3: dimension 0.50 2.750 (0.10827")
mm
Above 4: dimension 0.75 2.875 (0.11319")
mm
Main bearing, radial -
clearance, max
38 47705010 03-2018 © AB VOLVO PENTA

A Thrust bearing journal

Width (A), STD 35.4-35.406 mm
(1.39370-1.39393")
Width, oversize
R
Thrust washers (thrust bearing)
C D
Width (B), A STD 2.5 + 0.08 + 0.13 mm
(0.0984 + 0.0031 + 0.0051")
Width (B), STD B 2.5 + 0.03 + 0.08 mm
(0.0984 + 0.0012 + 0.0031")
Above 1: dimension 0.15 2.65 + 0.03 + 0.08 mm
B mm (0.1043 + 0.0012 + 0.0031")
Above 2: dimension 0.30 2.8 + 0.03 + 0.08 mm
p0005210
mm (0.1102 + 0.0012 + 0.0031")
G Big-end bearing journals

Dimension (diameter), STD 75.981-76 mm
(2.99137-2.99212")
Undersize 0.07 mm 75.911-75.93 mm
E (2.98861-2.98936")
Undersize 0.25 mm 75.731-75.75 mm
D (2.98153-2.98227")
C A Undersize 0.50 mm 75.481-75.5 mm
B (2.97168-2.97243")
Undersize 0.75 mm 75.231-75.25 mm
(2.96184-2.96259")
Surface finish, big end Ra 0.25 mm
R bearing (0.00984")
Surface finish, radius -
Width (A) -
Connecting rod big end, -
diameter (D)
p0005211
Connecting rod, length (E) -
Connecting rod small end, -
diameter (G)
Big-end bearings
STD A 2 - 0.019-0.032 (0.0787 -
0.00075-0.00126")
Above 1: dimension 0.07 2.035 (0.08012")
mm
Above 2: dimension 0.25 2.125 (0.08366")
mm
Above 3: dimension 0.50 2.250 (0.08858")
mm
Above 4: dimension 0.75 2.375 (0.09350")
mm
47705010 03-2018 © AB VOLVO PENTA 39

Camshaft
TAD5xxVE TAD8xxVE
Drive Gear wheel
Number of bearings 4 6
Shaft journal diameter, STD 34 - 0-0.016 mm (1.33858 - 0-0.00063")
Shaft journal diameters, undersize -
End float -
Camshaft lift, intake valves (tolerance) 63.8034 ± 0.04 mm (2.511937 ± 0.001575")
Camshaft lift, outlet (tolerance) 64.9626 ± 0.04 mm (2.557575 ± 0.001575")
Valves
Valves (inlet/exhaust) -
permissible grinding
Disc diameter, inlet 38 mm (1.50")
Disc diameter, outlet 35 mm (1.38")
Valve seat angle, inlet (A) 35 °
Valve seat angle, outlet (A): 44 °
Valve guide, height above 16 ± 0.2 mm
p0005201
spring plane, inlet (0.629919 ±
0.000787")
Valve guide, height above 16 ± 0.2 mm
spring plane, outlet (0.629919 ±
0.000787")
Seat angle in cylinder head, 35 °
inlet (B)
Seat angle in cylinder head, 45 °
outlet (B)
40 47705010 03-2018 © AB VOLVO PENTA

999 9696 Valve swivel diameter, inlet 7.978 mm (0.3141")

Valve swivel diameter, outlet 7.948 mm (0.3129")
998 9876 Max play, valve swivel - valve 0.4 ± 0.05 mm
guide, inlet (0.015748 ±
0.001968")
Max play, valve swivel - valve 0.5 ± 0.05 mm
guide, outlet (0.019685 ±
0.001968")
p0005207
Dimension (A) between valve 1.0 +0.25/-0.15

disk and cylinder head plane: (0.0394
Min. (A)/Wear value: Inlet +0.0098/-0.0059")
Dimension (A) between valve 1.0 +0.25/-0.15
disk and cylinder head plane: (0.0394
A Min. (A) Outlet +0.0098/-0.0059")
p0005203
Valve seat position
C Diameter (C), STD inlet 39 mm (1.535")

Diameter (C), STD outlet 36 mm (1.417")
R D Bottom radius (R): Inlet/outlet Max. 0.8 mm (0.031")
Depth (D), inlet/outlet -
P0005206
Valve seat
Diameter (A), inlet 39 mm (1.535")
Diameter (A), outlet 36 mm (1.417")
Height (B), inlet 6.95 ± 0.05 mm
(0.273621 ±
0.001968")
Height (B), outlet 6.95 ± 0.05 mm
(0.273621 ±
0.001968")
Valve springs, uncompressed 64.5 mm (2.539")
length
47705010 03-2018 © AB VOLVO PENTA 41

Check/adjust, intake/exhaust valves

TAD5xxVE
NOTICE! Cylinder (1) is on the opposite side in relation

to the engine flywheel/gearwheel.
The marking (1) should be to the left facing the cylinder

head's surface.
Valve clearance (cold engine), setting value:

Intake (Inl.): 0.4 mm / Cyl. (1) and (2).
Exhaust (Ex.): 0.5 mm / Cyl. (1) and (3).
P0022137
TAD8xxVE
NOTICE! Cylinder (1) is on the opposite side in relation

to the engine flywheel/gearwheel.
The marking (1) should be to the left facing the cylinder

head's surface.

Intake (Inl.): 0.4 mm / Cyl. (1), (3) and (5).
Exhaust (Ex.): 0.5 mm / Cyl. (1), (2) and (4).
P0022138
Adjustment, exhaust brake

For engines equipped with exhaust brake
systems:
Use 885812 Timing tool.

Adjust the piston on the exhaust brakes for cylinders
(1), (2) and (4).
Reset and (revolutions), (403°).
P0022139
42 47705010 03-2018 © AB VOLVO PENTA

Left marking facing surface on the

cylinder head
TAD5xxVE

Intake (Inl.): 0.4 mm / Cyl. (3) and (4).
Exhaust (Ex.): 0.5 mm / Cyl. (2) and (4).
P0022140
TAD8xxVE

Intake (Inl.): 0.4 mm / Cyl. (2), (4) and (6).
Exhaust (Ex.): 0.5 mm / Cyl. (3), (5) and (6).
P0022140
Adjustment, exhaust brake

For engines equipped with exhaust brake
systems:

Adjust the piston on the exhaust brakes for cylinders
(3), (5) and (6).
Reset and (revolutions), (403°).
P0022139
47705010 03-2018 © AB VOLVO PENTA 43

Timing gears
Permissible gear flank

clearance
A 0.03-0.13 mm
(0.00118-0.00512")
B 0.03-0.13 mm
(0.00118-0.00512")
C 0.03-0.13 mm
(0.00118-0.00512")
D 0.03-0.13 mm
(0.00118-0.00512")
E 0.03-0.11 mm
(0.00118-0.00433")
F 0.04-0.12 mm
(0.00157-0.00472")
G 0.03-0.11 mm
(0.00118-0.00433")
P0022179
Number of teeth
1 Crankshaft gear
39 teeth
2 Double intermediate gear, outer
78 teeth
3 Double intermediate gear, inner
36 teeth
4 Intermediate gear
56 teeth
5 Intermediate gear
37 teeth
6 Camshaft gear
36 teeth
7 Intermediate gear
65 teeth
8 Air compressor assembly gear
38 teeth
9 Fuel pump gear
39 teeth
10 Intermediate gear, oil pump
44 teeth
11 Oil pump gear
P0022180
35 teeth
44 47705010 03-2018 © AB VOLVO PENTA

Direction of rotation of transmission gear

1 Crankshaft gear. counterclockwise
2 Intermediate gear, double, counterclockwise
3 Intermediate gear, camshaft, clockwise
4 Intermediate gear, camshaft, counterclockwise
5 Camshaft gear, clockwise
6 Intermediate gear, clockwise
7 Fuel pump gear, counterclockwise
8 Air compressor assembly gear, counterclockwise
P0022210
Lubrication System
TAD5xxVE TAD8xxVE
Oil grade Refer toTechnical data (Lubrication system) in the Operator's
Manual.
Viscosity Refer toTechnical data (Lubrication system) in the Operator's
Manual.
Oil pressure, idle, operating speed, 1 bar (14.5 PSI): 1.25 bar (18.1 PSI):
min.
Oil pressure, hot engine, idling speed 1.5-3.0 bar (21.8-43.5 PSI) 1.75-3.25 bar (25.4-47.1 PSI)
Oil volume incl. oil filter, no engine 16 l (4.3 US gals) 27 l (7.1 US gals)
incline
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 operation 125 °C (257 °F)
Fuel System
Type Common rail
Fuel feed pressure < 25 kPa (3.6 PSI)
47705010 03-2018 © AB VOLVO PENTA 45

Inlet and Exhaust System

TAD5xxVE TAD8xxVE
Turbo HTT GT22 (VGT) HTT GT35V (VGT)
Max. exhaust temperature 515-525 °C (959-977 °F)
Cooling System
TAD5xxVE TAD8xxVE
Coolant, type Volvo Penta Coolant VCS (yellow).
Coolant, volume 13 l (3.4 US gals) 17 l (4.5 US gals)
Filler cap pressure valve, opening 100 kPa (14.5 PSI)
pressure
Thermostat
Type Wax
Opens at 85 °C (185 °F)
Fully open at 95 °C (203 °F)
46 47705010 03-2018 © 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, 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.
This symbol is used to inform that added information needs to be read. And where to find needed information.
This symbol is used where VODIA computer is needed,. either for fault tracing, testing or for programming.
A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.
47705010 03-2018 © AB VOLVO PENTA 47

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, Never start the engine without installing the air
! turbos, charge air pipes, starting heaters etc.) ! filter. The rotating compressor turbine in the
and hot fluids in pipes and hoses on an engine turbocharger can cause severe injury. Foreign
that 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
careless movement or a dropped tool may in the covers 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
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. From a such as degreasing agents, paints and
health standpoint, used oil is more dangerous solvents, are injurious to health. Carefully read
than new. Use protective gloves and avoid oil- the instructions on the product packaging!
soaked clothes and rags. Wash regularly, Always follow a product's safety directions, e.g.
especially before eating. Use suitable barrier use of protective mask, glasses, gloves etc.
creams to counteract drying out of the skin and Ensure that other personnel are not exposed to
to aid dirt removal. substances that are injurious to health. Ensure
good ventilation. 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.
48 47705010 03-2018 © 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
system is begun.
All fuels, as well as many chemicals, are Make sure that oil, fuel-soaked rags, and used
! flammable. Do not allow open flames or sparks ! fuel and oil filters are stored in a safe manner.
in 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
! flames or electric sparks. Never smoke in the ! components, even when using lifting devices
vicinity of the batteries; they generate hydrogen such 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
a transposition can result in serious damage to equipment used is in good condition and has the
electrical equipment. Refer to the wiring load capacity to lift the engine (engine weight
diagram. including gearbox or extra equipment). For safe
Always use protective goggles when charging handling and to avoid damaging components
and handling the batteries. Battery electrolyte fitted to the top of the engine, the engine must
contains sulfuric acid which is highly corrosive. be lifted with a correctly adjusted lifting boom.
Should the battery electrolyte come into contact All chains or wires must run parallel to each
with unprotected skin, wash it off immediately other and as perpendicular to the engine as
using soap and copious amounts of water. If you possible. If other equipment attached to the
get battery acid in your eyes, flush at once with engine has altered its center of gravity, special
copious amounts of water and seek medical lifting devices may be needed to obtain the
assistance immediately. correct balance for safe handling. Never
perform any work on an engine that is only
suspended from the lifting equipment.
47705010 03-2018 © AB VOLVO PENTA 49

The components in the electrical and fuel Exercise extreme caution when leak-detecting
! systems on Volvo Penta products are designed ! on the fuel system and testing the fuel injector
and manufactured to minimize the risk of fire nozzles. Use eye protection. The jet from a fuel
and explosion. The engine must not be run in nozzle has very high pressure and great
areas where there are explosive materials. penetration 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 Never use a high-pressure washer for cleaning
! recommended by Volvo Penta. Refer to the ! the engine.
Operator's Manual for the product in question. Pay attention to the following when using a high-
Use of fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never direct the water jet at
injectors. On a diesel engine, low grade fuel can seals, rubber hoses or electrical components.
cause the 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 When working on the engine; perform leakage
! straightened under any circumstances. Cracks ! and function test as necessary.
may occur. Damaged pipes must be replaced.
50 47705010 03-2018 © AB VOLVO PENTA

08-2 Special Service Tools

The following special tools are used when working on
the engine. The special tools can be ordered from AB
Volvo Penta by specifying each tool number.
1158957 Pliers 9809696 Connection washer 9986172 Puller

Coolant hoses (urea pump and Leakage test, cylinder head. Removal of air compressor's
air compressor). drive gear and gear removal
upon unit pump replacement.
9986485 Stand 9989876 Dial indicator 9992479 Holder for dial

Cylinder head removed, engine Cylinder liner, check height. indicator
renovation. Cylinder liner, check height.
9996049 Draining hose 9996239 Lifting tool 9996400 Slide hammer

Draining of coolant. Removal of cylinder head and Removal of injector pressure
flywheel. pipe, injectors.
9996662 Pressure testing kit 9998007 Adapter 9998256 Connection washer

Pressure testing/Leakage test, Adapter for slide hammer. Pressure testing, oil cooler.
cooling system.
47705010 03-2018 © AB VOLVO PENTA 51

9998264 Lifting tool 9998266 Connection washer 9998335 Drift

Camshaft. Leakage test, cylinder head.
9998506 Valve spring 9999696 Magnetic stand 9999737 Spacer

compressor Stand for tilt indicator. Cylinder head on rack.
Removal/installation of piston
rings.
88800011 Drift 88800014 Rotation tool 88800298 Connection

Installation of valve control. Valve adjustment, BVA unit, HP washer
pump, air compressor. EGR cooler, leakage test.
88800307 Connection 88800345 Adapter 88820006 Dial indicator (long

washer Location on engine on motor probe)
Cylinder head, leakage test - rack. Checking the clearance, engine
The ducts differ between 5 L transmission.
and 8 L.
52 47705010 03-2018 © AB VOLVO PENTA

88840269 Guide pin 88840271 Guide pin 88840272 Sleeve

Removal/installation of Rear valve, high pressure Removal of PRV valve.
flywheel. It requires two control pump.
pins. Location on rear valve on fuel
pump.
88840274 Guide pin 88840281 Guide pin 88840282 Extractor

Fuel pump installation. Two Installation of cylinder head. Crankshaft replacement (rear
control pins are required. and front).
88840288 Spacer 88840292 Fixture 88840293 Piston ring pliers

Removal of camshaft and Installation of cylinder head on Installation of pistons in cylinder
control of tilt arm axis. rack. liners.
88840296 Drift 88840316 Plate 88840406 Mounting tool

Installation of gasket on valve Fixture on engine block. Replacement of crankshaft
control. gasket (rear).
47705010 03-2018 © AB VOLVO PENTA 53

88840407 Mounting tool 88840290 Plugs

Replacement of crankshaft Used when protecting the high pressure system.
gasket (front).
88890105 Refractometer
54 47705010 03-2018 © AB VOLVO PENTA

21-0 Engine Complete, General
Fitting the Fixture

Tools:
88800345 Adapter
88840316 Plate
88840316 Plate
Bolt configuration, 5 L engine.
P0021750
Bolt configuration, 8 L engine.
P0021751
Installation, 5 L engine.
1 Remove the right belt guard; refer to Belt guard,
change, page 292.
2 Loosen the drive belt; refer to 26-1, Drive belt,
change.
3 Undo / remove:
1 Bracket, return wheel
2 Bracket, right front
3 Bracket, right rear
4 Starter motor, as per Starter Motor,
Change, page 306.
P0021752
47705010 03-2018 © AB VOLVO PENTA 55

4 Undo / remove:
- VGT actuator, connector
- Brackets
P0021753
5 Install 88840316 Plate.
P0021754
6 Install 88800345 Adapter.

Hoist the engine and attach it to the engine stand.
P0021755
56 47705010 03-2018 © AB VOLVO PENTA

Installation, 8 L engine.
1 Undo / remove:
1 Bracket, right rear
2 Starter motor,as per Starter Motor,
Change, page 306.
3 Heat shield
P0021756
2 Undo / remove:
1 Speed sensor, turbo
2 VGT actuator
3 Remove:
(Refer to Turbo, Change, page 231.)
- Remove the cable ties and the cable
harness from the cable holder.
- Remove the cable suspension brackets.
- Remove the oil return pipe with gasket.
4 Drain the coolant or reduce to below level, as per:
Coolant, Change, page 269.
P0019430
5 Remove coolant inlet line. Refer to Turbo,
Change, page 231.
6 Install 88840316 Plate.
P0021757
47705010 03-2018 © AB VOLVO PENTA 57

7 Install 88800345 Adapter.

Hoist the engine and attach it to the engine stand.
P0021758
Engine Disassembly
TAD870VE, TAD871VE, TAD872VE, TAD873VE
Tools:
885510 Plugs
885530 Rotation tool
885633 Torque multiplier
885648 Counterhold
885822 Magnetic pen
9989876 Dial indicator
9991821 Extractor
9996049 Draining hose
9996394 Support
9996400 Slide hammer
9996645 Puller
9998007 Adapter
9998675 Press tool
88800070 Wrench
Removal
Drain the engine oil.
Place the engine in the fixture; refer to Engine with
mounting and equipment, page 55.
Transmission, removal
1 Remove the flywheel casing, refer to Flywheel
cover, change, page 129.
2 Remove the cylinder head; refer to 21-1, Cylinder
Head, Removal
3 Remove the front crankshaft seal; refer to
Crankshaft Seal, Change (front), page 138.
4 Remove the rear crankshaft seal; refer to
Crankshaft Seal, Change (rear), page 143.
58 47705010 03-2018 © AB VOLVO PENTA

Lubrication oil pump, removal

5 Remove the oil pump; refer to Lubrication Oil
Pump, Change, page 147.
P0024940
6 Remove the reinforcement plate.
P0024941
7 Remove the cover.
P0024942
47705010 03-2018 © AB VOLVO PENTA 59

Pistons, removal
8 Rotate the crankshaft so that the piston cooling
nozzle is visible.
Remove the nozzle with the aid of
885822 Magnetic pen.
P0024943
9 Scrape clean around the cylinder's top dead

center edge.
Undo the screws a couple of turns. Tap the screw
heads to release the bearing.
Mark and remove the bearing cap.
Put the bearing cups in a safe place.
Press out the piston and the connecting rod.
P0024962
60 47705010 03-2018 © AB VOLVO PENTA

10 IMPORTANT! Reinstall the bearing cap on the

connecting rod to avoid damage to the dividing
plane.
Remove the remaining pistons.
Remove the retainer ring and press the piston pin
out.
Where necessary, refer to 21-3, Connecting Rod,
Check.
P0024944
Crankshaft, removal
11 Rotate the crankshaft so the marking is as
illustrated.
P0024945
47705010 03-2018 © AB VOLVO PENTA 61

12
P0024946
Remove:
• the bearing caps
• the bearing cups
• the thrust washers in the 6th bearing cap
• the crankshaft
13 Remove:
• top bearing cup
• top thrust washers
14 Wipe the bearing seats clean.
P0024963
62 47705010 03-2018 © AB VOLVO PENTA

15 IMPORTANT!
Max 2 cylinder liners may be changed on 6-
cylinder engines.
Max 1 cylinder liner may be changed on 4-
cylinder engines.
If more need to be replaced, a replacement block
must be used.
Assemble the tool 9809726 Pneumatic hydraulic
pump and install it.
Center the plate carefully in relation to the
cylinder liner.
Tighten by hand.
NOTICE! The length of the hydraulic cylinder

stroke means that the liner is pressed in by
stages.
Pressurize the cylinder and push up the liner.
P0024947
47705010 03-2018 © AB VOLVO PENTA 63

16 Hold on to the pressure rod and reduce the

pressure.
Screw the nut in.
Tighten by hand.
Repeat until the liner is released.
Remove the cylinder liner.
P0024948
64 47705010 03-2018 © AB VOLVO PENTA

Engine Assembly
Tools:
885633 Torque multiplier
885812 Timing tool
885822 Magnetic pen
9991821 Extractor
9992000 Handle
9998511 Lever
9998672 Press tool
9998673 Press tool
9998675 Press tool
9998678 Gauge rod
9998687 Compressor
9999696 Magnetic stand
88800070 Wrench
88800083 Piston ring pliers
88800129 Press tool
Cylinder liners, installation

IMPORTANT!
Max 2 liners may be changed on 6-cylinder engines.
Max 1 liner may be changed on 4-cylinder engines.
If more need to be replaced, a replacement block must
be used.
1 Clean the outside of the liner and the cylinder
bore.
2 IMPORTANT!
Check that the cylinder liner and cylinder bore are
of the same category. (0 or 1)
P0024949
47705010 03-2018 © AB VOLVO PENTA 65

3 Mark where the replacement took place using an

engraving pen.
NOTICE! Cylinder 1 is at the engine's drive belt

end.
P0024950
4 IMPORTANT!
The liner and cylinder bore must be dry on
installation.
Install the tool.
5 Center the cylinder liner carefully with the cylinder
bore using the puller plate.
6 Tension the pressure rod and plate using the nut.
Tighten by hand.
Pressurize the cylinder.
Press down the liner.
7 Hold on to the pressure rod and reduce the
pressure.
Screw the nut in.
Tighten by hand.
Repeat until the liner bottoms against the block
plane.
P0024951
66 47705010 03-2018 © AB VOLVO PENTA

8 Measure diagonally twice and calculate the

average.
Liner height tolerance above block plane:
0.04-0.10 mm (0.001575-0.003937")
P0024952
Crankshaft, installation
9 Fit new bearings.
Lubricate the bearing surfaces with engine oil.
P0024953
47705010 03-2018 © AB VOLVO PENTA 67

10 NOTICE! The crankshaft must be thoroughly

cleaned and blown dry.
Lift the crankshaft into place.

Align the marks.
P0024954
11 NOTICE! Check thrust washer class: STD A or B.
Make sure the main bearings are properly located

when the crankshaft is installed.
Install the thrust washers at the 6th main bearing;
note the position of the tang.
P0024955
68 47705010 03-2018 © AB VOLVO PENTA

P0025008
12 NOTICE! Use new screws.
Fit new bearings.

Lubricate the bearing surfaces with engine oil.
Locate the main bearing cup and thrust washers
in the bearing cap (marked "6" for the D8 and "4"
for the D5).
Install oiled main bearing screws.

Tighten the screws in sequence.
1 Tightening torque: 60 Nm (44.2 lbf ft)
2 Angle tightening: 90°
Check that the crankshaft is able to turn.
P0025049
47705010 03-2018 © AB VOLVO PENTA 69

14 Check end float. Limits: 0.05–0.14 mm.

Check thrust washer category; refer to
Administration, page 35.
P0024966
Piston rings
15
P0024967
NOTICE! The piston ring markings must face up.
Piston ring, spacing 120°.

Lubricate the big end bearings, piston and piston
rings.
Rotate the crankshaft so that the big end journals
are at BDC.
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16 Install the connecting rods.

Marking 1–4 for D5 (1 is closest to the circulation
pump)
Marking 1-6 for D8 (1 is closest to the circulation
pump)
P0024968
Install the bearing cap and align it carefully with

the connecting rod.
P0025007
18 Torque the screws and check that the crankshaft

can be rotated.
1 Tightening torque: 75 Nm (55.3 lbf·ft)
P0025050
47705010 03-2018 © AB VOLVO PENTA 71

19 Install the nozzles.
NOTICE! Use new screws.
Tightening torque: 34 Nm (25.1 lbf·ft)
P0024943
20 Apply a 2 mm (0.0787 in) bead of silicone.
NOTICE! Max 20 minutes before installation.
P0025051
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21 1 Fasten the cover with screws 2 and 7.

Tighten until contact.
2 Tighten screws 2 and 7. Tightening torque:
24 Nm (17.7 lbf ft).
3 Tighten screws 1, 3–6, 8. Tightening
torque: 24 Nm (17.7 lbf ft).
P0025052
22 D8
Install the plate.
Tightening torque: 24 Nm.
Tighten the remaining screws.
P0021525
23 D5
Install the plate.
Tighten the remaining screws.
P0021526
47705010 03-2018 © AB VOLVO PENTA 73

Lubrication oil pump, installation

24 Install the oil pump, refer to Lubrication Oil Pump,
Change, page 147.
25 Install the front crankshaft seal; refer to
Crankshaft Seal, Change (front), page 138.
Install the rear crankshaft seal; refer to
26 Install the cylinder head; refer to Cylinder Head,
Change, page 75.
P0024940
Transmission, installation
27 Install the flywheel housing; refer to Flywheel
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21-1 Cylinder Head
21-1 Cylinder Head

Cylinder Head, Change
Tools:
9986485 Stand
9996239 Lifting tool
9999737 Spacer
88840281 Guide pin
88840292 Fixture
IMPORTANT!
Clean thoroughly before removal.
IMPORTANT!
Turn off the main switch before any work is carried out.
NOTICE! Be prepared to gather up fluid.
1 Drain the coolant in accordance with Coolant,

Change, page 269.
Removal
2 Undo, remove:
- The intake pipe.
- The pressure drop indicator connector.
- The air cleaner's mounting plate.
P0022108
3 Remove the air cleaner with mounting plate.
P0022109
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21-1 Cylinder Head
4 Remove the turbo unit according to Turbo,

Change, page 231.
5 When replacing cylinder head or installation on
an unit stand:
Remove the exhaust manifold according to
Exhaust Manifold, Change, page 216.
6 For engines with air compressor (option):
Remove the air compressor; refer to Air
compressor, change, page 242.
7 Remove the inlet manifold, refer to Intake
Manifold, Change, page 210.
8 When replacing valves/cylinder head:
Remove the injectors according to Injector,
Change, page 188.
9 When installing on a unit stand:
Remove the injector delivery pipe according to
Fuel Injection Pipe, Change, page 204.
10 Remove the PTO.
P0022089
11 Remove the thermostat housing, refer to Coolant

12 Remove the upper and lower valve cover, refer

to:
- Upper valve cover, change, page 87
- Lower valve cover, change, page 93
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21-1 Cylinder Head
13 Remove the plug at the flywheel.

Install 88800014 Rotation tool.
P0019449
14 NOTICE! Turn counterclockwise, on the engine

flywheel side.
Turn the flywheel until the cylinder 1 marking

aligns with the marking on the flywheel housing.
The camshaft gear has two markings that
correspond to the markings on the flywheel.
P0019450
15 The camshaft gear has two markings that

Check that the gearwheel's marking (1)
corresponds with the surface of the left side of the
cylinder head.
If not, turn the engine flywheel one more turn.
P0019451
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21-1 Cylinder Head
16 For engines equipped with exhaust brake

systems:
Remove both of the exhaust brake systems.
P0022102
17 NOTICE! Cylinder head screws can be re-used a

maximum of 2 times.
Only remove one rocker arm bridge/bearing cap

at a time in ascending order from cylinder 1.
Check that the rocker arm rollers are immobilized
against the camshaft. If necessary, rotate the
flywheel.
1 Fully loosen the adjusting screws.
2 Remove the rocker arm bridge.
- Check the center punch mark on the screw
head.
3 Mark and then remove the valve yokes.
P0022103
18 Check that the gearwheel's marking (1)

cylinder head.
Use the 9998264 Lifting tool to lift the camshaft.
Check the camshaft, according to Camshaft,
Wear Check, page 124.
P0022104
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21-1 Cylinder Head
19 Remove the bearing halves.
P0022105
20 Remove the cylinder head screws.

Lift off the cylinder head.
NOTICE! Alternatively: Place 9996239 Lifting

tool (2) on the cylinder head and lift if off.
P0022106
21 Remove the cylinder head gasket.
P0022107
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21-1 Cylinder Head
22 The work is made easier if the cylinder head is in

9986485 Stand med 88840292 Fixture and
9999737 Spacer. Use 8 M10x90 mm screws.
23 For further work with the cylinder head, refer to:
- Valves, Removal, page 109
- 21-1, Cylinder Head, Inspection
- Valve Guides, Inspection, page 108
- 21-4, Valve Guides, Replacing
- 21-4, Valve Seat, Change
- 21-4, Valve Stem Sealings, Replace
P0022110
24 Remove the plate with the camshaft's hub and

idler wheel.
Check the lubrication hole.
Clean and replace the O-ring on the plate.
When replacing a cylinder head, transfer current
parts.
P0022111
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21-1 Cylinder Head
Installation
25 Clean the cylinder head carefully both internally
and externally before fitting.
Clean the cylinder head's and the engine block's
sealing surfaces.
26 Fit a new cylinder head gasket.
P0022117
27 Install 88840281 Guide pin (2).
P0022118
28 NOTICE! If the idler gear on the camshaft is

installed, make sure there is correct alignment
with the outlet.
Guide in the cylinder head onto the guiding pins.

Lower the cylinder head until it rests on the
cylinder head gasket.
P0022119
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21-1 Cylinder Head

maximum of 2 times.
Oil the threads and the screws' contact surface.

Screw in the cylinder head screws without
tightening.
P0022120
30 Check that the main bearings are free of errors.

Insert the bearing halves and apply the oil.
P0022121
31 Check that the flywheel housing is in line with 1's

marking.
P0019450
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21-1 Cylinder Head
32 Inspect the camshaft for wear. Refer to Camshaft,

Rotate the camshaft so that the gearwheel's
marking (1) is placed before installation.
Use the 9998264 Lifting tool to lift the camshaft
into position.
P0022116

cylinder head.
P0022115

maximum of 2 times.
Only install one rocker arm bridge/bearing cap at

a time in descending order from cylinder 6.
1 Check:
• The bearing cap and marking.
• The adjuster screws are in the fully undone
position.
- Install the rocker arm bridge/bearing cap.
2 Screw the cylinder head screw and the
bearing cap screw without tightening.
P0022114
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21-1 Cylinder Head
35 Tighten the cylinder head screws according to

Special Tightening Torques, page 11.
Mark the cylinder head screws with a center
punch mark.
P0022113
36 Check that the camshaft can be rotated.

Check that the rocker arm rollers are immobilized
flywheel.
Lubricate the valve shafts.
Reinstall the valve yoke as per the previous
marking.
P0022112
37 Install the injectors, refer to Injector,

Change, page 188.
38 For engines equipped with exhaust brake
systems:
Position the two exhaust brake systems.
P0022102
39 Adjust the valves according to Valves,

Adjustment, page 100.
40 Remove the upper and lower valve covers, refer
to:
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21-1 Cylinder Head

41 Install the thermostat housing, refer to Coolant
42 Install the PTO.
P0022089
43 Install the inlet manifold; refer to Intake Manifold,

Change, page 210.
44 Install the injector delivery pipes according to
45 For engines with air compressor (option):
Install the air compressor; refer to Air
46 Install the exhaust manifold according to Exhaust
Manifold, Change, page 216.
47 Install the turbo unit according to Turbo,
Change, page 231.
48 Install the air cleaner with the mounting plate.
P0022109
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21-1 Cylinder Head
49 Connect, install:
- The intake pipe.
- The pressure drop indicator connector.
- The air cleaner's mounting plate.
P0022108
50 Check engine oil level; fill as necessary.

51 Fill with coolant according to Coolant,
Change, page 269.
52 Turn on the main switch.
53 Start the engine and check for leaks; let the
engine run until it reaches normal working
temperature.
Allow the engine to run idle for an additional 5–10
minutes.
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21-1 Cylinder Head
Upper valve cover, change

TAD572VE
IMPORTANT!
The procedure in this description assumes that the

engine control unit will not be removed but moved to
one side complete with its harness and fuel
connection.
1 Disconnect the engine control unit.
P0019500
2 Protect the engine control unit with a plastic bag.

Move the engine control unit to one side.
P0019501
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21-1 Cylinder Head
3 Remove the crankcase ventilation pipe.
P0019502
4 Remove the valve cover with gasket.
P0019503
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21-1 Cylinder Head
Installation
5 Fit the gasket.
6 Install the valve cover.
Tightening sequence: Diagonally
7 Install the crankcase ventilation pipe.
P0019504
8 Install the engine control unit.
P0019508
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21-1 Cylinder Head
Upper valve cover, change

Removal
1 Detach the cable holder.
P0019482
2 Remove the crankcase ventilation pipe.
P0019483
3 Remove the valve cover with the upper gasket.
P0019484
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21-1 Cylinder Head
Installation
4 Fit the gasket.
P0019485

P0019486
P0019483
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21-1 Cylinder Head
7 Install the cable and holder.
P0019482
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21-1 Cylinder Head
Lower valve cover, change

TAD572VE
Removal
IMPORTANT!
1 Remove the upper valve cover; refer to Upper
valve cover, change, page 87.
2 Disconnect the connector.
P0019509
3 Loosen the connectors.
P0019510
47705010 03-2018 © AB VOLVO PENTA 93

21-1 Cylinder Head
4 Remove the lower valve cover and gasket.
P0019511
Installation
5 Fit the gasket.
P0019512
7 Install the connector.

Tightening torque: 2.2 Nm (1.6 lbf ft)
P0019510
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21-1 Cylinder Head
P0019515
9 Install the upper valve cover; refer to Upper valve

47705010 03-2018 © AB VOLVO PENTA 95

21-1 Cylinder Head
Lower valve cover, change

Removal
IMPORTANT!
1 Remove the upper valve cover; refer to Upper
2 Disconnect the cable.
P0019490
P0019491
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21-1 Cylinder Head
4 Disconnect the connectors.
P0019492
5 Engines equipped with exhaust brake

systems (VCB)
Disconnect the electrical connections to the
brake solenoid.
P0021890
6 Remove the lower valve cover and gasket.
P0019493
47705010 03-2018 © AB VOLVO PENTA 97

21-1 Cylinder Head
Installation
7 Fit the gasket.
P0019494
P0019495

Tightening torque: 2.2 Nm (1.6 lbf ft)
P0019492
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21-1 Cylinder Head
P0019497

systems (VCB)
Connect the electrical connections to the brake
solenoid.
P0021890
12 Install the cable harness.
P0019498
13 Install the upper valve cover; refer to Upper valve

47705010 03-2018 © AB VOLVO PENTA 99

21-4 Valve Mechanism

Valves, Adjustment
Tools:
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 in accordance
with: Upper valve cover, change, page 87.
P0019449
3 NOTICE! Turn counterclockwise on the engine

flywheel side.

The camshaft gear has two markings that
P0019450
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4 Check that the gearwheel marking (1)

cylinder head.
If not, rotate the engine 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 (D8 only)
3 Cylinder 3 6 Cylinder 6 (D8 only)
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Checks and adjustment, inlet valves

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

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

rocker arm. Turn the adjuster screw until the
correct clearance is obtained.
Feeler gages 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
gage can be inserted without any great
resistance; only slight resistance should be felt
when the feeler gage is moved back and forth. It
should not be possible to insert the 0.45 mm
feeler gage without resistance.
P0019455
Counterhold the adjuster screw while tightening
the locking nut.
Tightening torque: 33 Nm (24.3 lbf ft)
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Checks and adjustment, exhaust valves

Check the exhaust valve clearances for cylinders

(1), (2) and (4).
P0019456
Check
9 Check the exhaust valve clearances with the aid
P0019457
Adjustment
10 Adjust the exhaust valve clearance between the

rocker arm.
Turn the adjuster screw until the correct
clearance is obtained.

P0019458
Hold the adjuster screw still while tightening the

locking nut.
47705010 03-2018 © AB VOLVO PENTA 103


systems (VCB)
Adjustment of exhaust brake:
Use the 885812 Timing tool.
Adjust the piston on the exhaust brakes for
cylinders (1), (2) and (4).
Loosen the locking nut and adjust the screw until
zero clearance is retained.
Loosen the adjuster screw, (403°).
the locking nut.
P0022650
12 NOTICE! Turn counterclockwise on the engine

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

marking aligns with the marking on the flywheel
housing.
P0019450
13 Check that the gearwheel marking corresponds

with the surface of the left side of the cylinder
head.
If not, rotate the engine 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
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Checks and adjustment, inlet valves

Check the inlet valve clearances for cylinders (2),

(4) and (6).
P0019460
Check
15 Check the inlet valve clearances with the aid of a
feeler gage set.
P0019461
Adjustment
16 Adjust the inlet valve clearance between the

rocker arm. Turn the adjuster screw until the
correct clearance is obtained.

P0019462
locking nut.
47705010 03-2018 © AB VOLVO PENTA 105

Checks and adjustment, exhaust valves

Check the exhaust valve clearances for cylinders

(3), (5) and (6).
P0019463
Check
18 Check the exhaust valve clearances with the aid
P0019464
Adjustment
19 Adjust the exhaust valve clearance between the

rocker arm.
Turn the adjuster screw until the correct
clearance is obtained.

P0019465

locking nut.
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systems (VCB)
Adjustment of exhaust brake:
Use the 885812 Timing tool.
Adjust the piston on the exhaust brakes for
cylinders (3), (5) and (6).
Loosen the locking nut and adjust the screw until
zero clearance is retained.
Loosen the adjuster screw, (403°).
the locking nut.
P0022651
21 Remove the 88800014 Rotation tool from the

gear ring.
Install the plug.
P0019449
22 Insert plug for the flywheel mark.

23 Install the upper valve cover according to: Upper
P0019466
47705010 03-2018 © AB VOLVO PENTA 107

Valve Guides, Inspection

Tools:
Cylinder head, removed

1 See Cylinder Head, Change, page 75.
2 Remove the valve shaft seals from the valve
guides.
IMPORTANT!
The cylinder head may not be put down such that
its entire weight rests on the valve guides.
3 Put the cylinder head down with the valve discs
facing upwards.
4 Place a new valve in the valve guide with the
valve swivel end in the same plane as the edge
of the guide.
Use a suitable spacer under the valve swivel.
5 Place the dial indicator and holding fixture so that
the dial indicator tip is touching the valve disc
edge. Move the valve sideways, in the direction
of the outlet or inlet duct.
Read off the value on the dial indicator.
6 Check all valve guides.
If the readings exceed the values noted in the
specifications, the valve guide must be changed;
refer to Administration, page 35.
P0024939
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Valves, Removal
Tools:
9986485 Stand
9998506 Valve spring compressor
9999737 Spacer
88840292 Fixture
1 The work is made easier if the cylinder head is
fixated in 9986485 Stand with 88840292 Fixture
and 9999737 Spacer. Use 8 pcs. M10x90 mm
screws.
P0022110
2 NOTICE! Depending on working procedure:

Secure that the valve does not move downwards.
3 Install 9998506 Valve spring compressor.
Insert the tool in the bolt hole (M8) for upper valve
cover.
Adjust the tool's arms around the valve spring
plate.
Press down and remove the collets.
A Inlet valve
B Exhaust valve
P0022127
47705010 03-2018 © AB VOLVO PENTA 109

4 IMPORTANT!
Be careful with contact surfaces.
Remove the valve spring plate and valve springs.

Remove the valve stem seals from the valve
guides using pliers.
P0022128
5 NOTICE! Put the valves and springs in a marked

stand, to facilitate when putting them back in the
same places in the cylinder head.
P0022129
6 Remove the remaining valves in the same way as

above.
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Valves, Installation
Tools:
9998506 Valve spring compressor
88800011 Drift
88840296 Drift
1 Depending on working procedure: Secure that
the valve can be received from below.
2 Oil the valve stems and install the valves.
Install 88800011 Drift on the valve stem.
P0022133
3 Press the new oil seal over the valve guide.
NOTICE! Check that the oil seal is pressed down

all the way. Use 88840296 Drift and tap carefully
with a plastic mallet.
P0022134
47705010 03-2018 © AB VOLVO PENTA 111

4 Install the valve springs and valve spring plate.
P0022135
5 Install 9998506 Valve spring compressor.

Insert the tool in the bolt hole (M8) for upper valve
cover.
Adjust the tool's arms around the valve spring
plate.
Carefully press down and install the collets.
A Inlet valve
B Exhaust valve
P0022127
6 Install the remaining valves in the same way as

above.
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21-5 Timing Gears and Shaft

Camshaft, change
Removal
IMPORTANT!
Install and remove the spacers in turn in connection
with installing/removing the rocker arm bridge/bearing
cap.
to:
cylinder head. Refer to
P0019451
3 NOTICE! Cylinder head bolts can be re-used a

maximum of 2 times.
Only remove one rocker arm bridge/bearing cap

at a time in ascending order from cylinder 1.
NOTICE! Check that rocker arm rollers are not

clamped against the camshaft. If necessary,
rotate the flywheel.
Fully loosen the adjusting screws (1).

Remove the rocker arm bridge (2).
NOTICE! Check the center punch mark on the

screw head.
Mark and remove the valve yokes.

P0023112
47705010 03-2018 © AB VOLVO PENTA 113

4 Install 88840288 Spacer.
Tightening torque:
1 100 Nm (73.8 lbf ft)
2 90° (angle tightening)
3 90° (angle tightening)
NOTICE! Mark the screw head with a punch

mark.
P0023113
Repeat for remaining cylinders.

cylinder head.
CAUTION!
Cutting hazard! Protect your hands!
Remove the camshaft. Use 9998264 Lifting tool.

6 Remove the bearing halves.
Check:
- Collar thrust bearings
- The camshaft for wear, refer to Camshaft,
P0023114
114 47705010 03-2018 © AB VOLVO PENTA

Installation
7 Install the camshaft gearwheel.
Apply oil.
P0023115
8 Rotate the camshaft so that the gearwheel

marking (1) is correctly positioned before
installation.
Install the camshaft. Use 9998264 Lifting tool.
P0023114
47705010 03-2018 © AB VOLVO PENTA 115

9 NOTICE! Cylinder head bolts can be re-used a

maximum of 2 times.
Only install one rocker arm bridge/bearing cap at

a time in descending order from cylinder 6.
Check:
- The bearing cap and marking.
- Adjuster screws are in the completely loose
position.
Install the bolts (1, 2).
Tightening torque:
P0023116 1 Tighten screw 1.
100 Nm (73.8 lbf ft)
2 Tighten screw 2.
29.5 Nm (21.8 lbf ft)
3 Tighten screw 1.
4 Tighten screw 1.
5 Tighten screw 2.
29.5 Nm (21.8 lbf ft)
NOTICE! Mark the screw head with a punch

mark.
When transferring drive gear, camshaft, refer to

tightening torques: Special Tightening
Torques, page 11.
10 Check that rocker arm rollers are not clamped
flywheel.
Lubricate the valve stems.
Reinstall the valve yoke in accordance with the
previous marking.
P0022112
11 Adjust the valves according to Valves,

Adjustment, page 100.
12 Install the lower and upper valve cover, refer to:
116 47705010 03-2018 © AB VOLVO PENTA

Flank Clearance, Checking

Tools:
9999683 Dial indicator (short probe)
1 Check the gearwheels.
Replace worn, or by some other method,
damaged gearwheels.
The gearwheel backlash may not exceed the
permissible value, refer to permitted gear
backlash.
Permissible gear flank

clearance
A 0.03-0,13 mm
(0.00118-0.00512")
B 0.03-0,13 mm
(0.00118-0.00512")
C 0.03-0,13 mm
(0.00118-0.00512")
D 0.03-0,13 mm
(0.00118-0.00512")
E 0.03-0,11 mm
(0.00118-0.00433")
F 0.04-0,12 mm
(0.00157-0.00472")
G 0.03-0,11 mm
(0.00118-0.00433")
P0022179
47705010 03-2018 © AB VOLVO PENTA 117

2 Check the clearance A* as follows:

1 Install 9999696 Magnetic stand and
9999683 Dial indicator (short probe).
2 Put the tilt indicator's measurement tip on
the idler gearwheel A as illustrated.
3 Hold the idler gearwheel (twin wheel) and
turn the idler wheel A back and forth to
check that the gear backlash is within
specified limits.
Permissible value: A* 0,03-0,13 mm
(0.00118-0.00512")
4 Perform the same check measurements for
the remaining transmission gearwheels.
P0022211
118 47705010 03-2018 © AB VOLVO PENTA

Timing Gear, Removal

Tools:
1 Remove the EGR pipe.
to:
P0022199

P0019449
4 NOTICE! Turn counterclockwise, on the engine

flywheel side.

The camshaft gearwheel has two marks which
correspond to the mark on the flywheel.
P0019450
47705010 03-2018 © AB VOLVO PENTA 119


cylinder head.
If not, turn the engine flywheel one more turn.
6 Remove the flywheel cover/transmission cover,
according to Flywheel cover, change, page 129.
P0022115
7 Remove:
1 Camshaft gear
2 Idler gearwheel, twin (hub 1 and 2)
3 Idler gearwheel (hub 5)
4 Idler gearwheel (2), camshaft (hub 3)
P0022200
8 Remove the plate and the hub (1), (hub 4).

Remove the Idler gearwheel (2).
P0022201
120 47705010 03-2018 © AB VOLVO PENTA

Timing Gear, Installation

1 IMPORTANT!
Grease the bearing paths with engine oil for all
hubs.
Check that the oil holes are open.

Install a new O-ring.
Fit the plate onto the hub.
Check that the bolt holes align.
Fit the idler gearwheel (1).
Fit the plate and the hub (2). Note the oil
openings.
P0022204
2 Fit the idler gearwheel.
P0022205
3 NOTICE! The crankshaft wheel has a marking

and notch.
Align the idler gearwheel's markings as

illustrated. The marking on the idler gearwheel
must be between the markings on the fuel pump,
and the crankshaft's marking must be between
idler gearwheel's markings.
P0022206
47705010 03-2018 © AB VOLVO PENTA 121

4 Check that the oil holes are open. Check that the
bolt holes align.
Fit the hub (1) for the idler gearwheel.
IMPORTANT!
Check that the hub (2) is in the correct position.
The hub marking and the washer must be facing
up.
Fit the idler gearwheel's (2) markings as

illustrated. The twin marking on the idler
gearwheel (1) must be between the marking on
the idler gearwheel (2).
P0022207
5 Fit the camshaft gearwheel. The marking (1)

should corresponds with the surface on the
cylinder head's side.
P0022208
6 Torque turn the engine transmission according to

Special Tightening Torques, page 11.
122 47705010 03-2018 © AB VOLVO PENTA

7 Oil all sliding surfaces with engine oil before

installation of the flywheel cover/the transmission
cover.
8 Fit the flywheel cover/transmission cover,
according to Flywheel cover, change, page 129.
9 Fit the lower valve covers, refer to:
10 Install the ERG pipe.
P0022199
47705010 03-2018 © AB VOLVO PENTA 123

Camshaft, Wear Check

Rocker bridge removed
Put a steel rule across the camshaft lobes, parallel with

the camshaft axis, to check whether the cam profiles
show signs of wear.
Measure the wear with a feeler gauge or wire gauge.

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

Administration, page 35.
P0007013
Guidlines for replacement

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

are shown below.
Acceptable wear: Unacceptable wear:

The camshaft need not be changed. IMPORTANT!
The camshaft and associated rocker arms must be
changed.
P0003896 P0003899
P0003898 P0003897
124 47705010 03-2018 © AB VOLVO PENTA

Flywheel, Change
Tools:
88840269 Guide pin
CAUTION!
Pinch hazard. Keep fingers clear.
Removal
1 Remove the flywheel sensor.
P0020336
2 Remove two diametrically opposed bolts.
P0020337
47705010 03-2018 © AB VOLVO PENTA 125

3 Replace with locating pins 88840269 Guide pin.
P0020338
4 Attach and secure tool 9996239 Lifting tool.
P0020339
5 Remove the remaining bolts.
P0020340
126 47705010 03-2018 © AB VOLVO PENTA

6 Remove the flywheel.
P0020344
Installation
7 Clean the flywheel contact surface on the
crankshaft.
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 03-2018 © AB VOLVO PENTA 127

9 Install the bolts. Screw in the bolts without

tightening.
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
128 47705010 03-2018 © AB VOLVO PENTA

Flywheel cover, change

Removal
Engine oil drained.
1 NOTICE! Be prepared to gather up fluid.
Remove the oil filler.

Press in the lock bushing and pull out tube.
Remove the oil level sensor connector.
Remove the oil sump.
P0021766
2 Remove the starter motor according to Starter

Motor, Change, page 306.
3 Options:
Remove the air compressor according to Air
4 Remove the flywheel according to Flywheel,
Change, page 125.
5 Remove the rear crankshaft seal according to
6 Remove the PTO.
P0022089
47705010 03-2018 © AB VOLVO PENTA 129

7 Remove, loosen:
1 Coolant line, EATS-heating
2 Cabling/bracket, NOx sensor
3 Power steering pump
P0022090
8 IMPORTANT!
Working with the fuel system requests special
cleanliness.
IMPORTANT!
IMPORTANT!
Install safety plugs in open connections.
Remove, loosen: (refer to Fuel Pre-filter,

Change, page 159)
1 Return line, cylinder head.
2 Fuel return, tank.
3 Connector
4 Connection IN
P0022091
5 Connection OUT
6 Fuel pre-filter
9 Remove the fuel prefilter's bracket.
P0022092
10 Depending on procedure, secure and stabilize

the engine. Loosen the rear engine mount.
130 47705010 03-2018 © AB VOLVO PENTA

11 Install 9996239 Lifting tool.

Install 9996876 Guide pin (2 pcs).
P0022093
12 Remove the bolts.
P0022094
13 Carefully tap with a plastic mallet to break the

adhesive joint.
Loosen and remove the flywheel housing.
P0022095
47705010 03-2018 © AB VOLVO PENTA 131

Installation
14 IMPORTANT!
Clean the sealing surfaces.
NOTICE! Apply an approximately 2 mm

(0.0787”) thick string of silicon (product
no. 1161277) according to the image,
max 20 minutes before installation.
P0022096
15 Thread the flywheel housing on 9996876 Guide

pin (2 pcs).
NOTICE! Exercise caution so that the string of

sealant is not damaged during installation.
P0022097
132 47705010 03-2018 © AB VOLVO PENTA

16 Remove 9996876 Guide pin (2 pcs).

Remove 9996239 Lifting tool.
P0022093
17 Tighten the bolts in sequence, as illustrated.
Tightening torque:
Bolt: 1-9: 85 Nm (62.7 lbf. ft.)
Bolt: 10-12: 48 Nm (35.4 lbf. ft.)
P0021530
Tightening torque:
Bolt: 13, 14: 85 Nm (62.7 lbf. ft.)
P0022098
47705010 03-2018 © AB VOLVO PENTA 133

19 Install the bolts.
P0022094
20 Fit the fuel prefilter's bracket.
P0022099
21 IMPORTANT!
cleanliness.
Install: (refer to Fuel Pre-filter,

Change, page 159)
1 Fuel pre-filter
2 Connection OUT
3 Connection IN
4 Fuel return, tank.
5 Return line, cylinder head.
6 Connector
P0022100
134 47705010 03-2018 © AB VOLVO PENTA

22 Install:
1 Coolant line, EATS-heating
2 Cabling/bracket, NOx sensor
3 Power steering pump
P0022090
23 Install the PTO.
P0022089
24 Install the rear crankshaft seal according to

25 Install the flywheel according to Flywheel,
Change, page 125.
26 Options: Install the air compressor according to
Air compressor, change, page 242.
27 Install the start engine according to Starter Motor,
Change, page 306.
47705010 03-2018 © AB VOLVO PENTA 135

28 Install the oil sump.

Install the oil filler, dipstick with pipe.
Connect the connector to the oil level sensor.
P0021766

Finish off by checking the tightening torque of

bolts 1 and 2.

P0021542
30 Top up engine oil.
Start the engine.
Perform a function check.
136 47705010 03-2018 © AB VOLVO PENTA

21-6 Crank Mechanism

Gear Ring, Fywheel: Replace
1 Remove the flywheel; refer to Flywheel,
Change, page 125
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
flywheel.
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 03-2018 © AB VOLVO PENTA 137

Crankshaft Seal, Change (front)

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

system installed, different methods are used when
replacing 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 277.
2 Remove the drive belt according to Drive belt,
change, page 291.
P0020364
3 Remove the fan adapter and pulley from the

coolant pump.
P0019601
138 47705010 03-2018 © 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 03-2018 © AB VOLVO PENTA 139

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
crankshaft, 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
separated.
IMPORTANT!
The metal side of the seal ring must face inwards.
Slide the seal ring onto the tool.
P0020370
140 47705010 03-2018 © 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

correctly 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
achieved after 24 hours.
P0020372
12 Fit the vibration damper and the pulley.
P0020365
47705010 03-2018 © AB VOLVO PENTA 141


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 291.
16 Install the fan; refer to Coolant Pump,
Change, page 277.
P0019610
142 47705010 03-2018 © 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 125.
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 03-2018 © AB VOLVO PENTA 143

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

housing and the sealing surface on the
crankshaft.
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
crankshaft, 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
144 47705010 03-2018 © 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
separated.
IMPORTANT!
The metal side of the seal ring must face inwards.
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 03-2018 © AB VOLVO PENTA 145

9 Remove the tool and check that the seal is

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

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

Change, page 125.
146 47705010 03-2018 © AB VOLVO PENTA

22-1 Oil pump and Line

Lubrication Oil Pump, Change
Removal
1 Drain the engine oil.

2 Remove the oil filler.
Press in the lock bushing and pull out the tube.
Remove the oil level sensor connector.
Remove the oil sump.
P0021766
3 Remove the oil pump with delivery pipe and

suction strainer.
P0021767
4 Remove the pipes.
Installation
5 Install the pipes. Use new seals.
P0021768
47705010 03-2018 © AB VOLVO PENTA 147

6 Install the oil pump with delivery pipe and suction

strainer.
P0021767
7 Install the oil sump.

Install the oil filler and dipstick with pipe.
Connect the connector to the oil level sensor.
P0021766
8 Tighten the bolts in sequence.
Finish by checking the tightening torques of bolts

1 and 2.

P0021542
9 Top up the engine oil.

Start the engine.
Perform a function check..
148 47705010 03-2018 © 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
bearings, 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 work is in progress.
Removal
Engine oil drained.
1 Clean around the filter cover and housing.
Carefully remove the oil filter cover and filter.
2 Remove the O-ring and filter.
Let the oil drip off into a collection vessel.
P0019348
Installation
3 NOTICE! Use recommended oil.
Lubricate the new O-ring before installation.

4 Lubricate around the inner part of the sealing
surface on the new filter.
5 Install a new filter in the filter cover.
6 IMPORTANT!
Make sure the components are completely free of
dirt before installing them.
Install the filter cover.

P0019350
47705010 03-2018 © AB VOLVO PENTA 149

22-2 Oil filter
7 Install the drain plug (D) on the oil sump.

P0019354
8 NOTICE! Use recommended oil.
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 After running the engine for a few minutes, switch
it off and check the oil level.
Top up with oil as necessary.
150 47705010 03-2018 © AB VOLVO PENTA

22-2 Oil filter
Oil Filter Housing, Change

Removal
1 Drain the coolant in accordance with: Coolant,

Change, page 269.
2 Remove the fuel filter housing in accordance with:
Fuel filter housing, change, page 163.
3 Disconnect the oil pressure sensor connector.
Remove the cable ties.
P0019821
4 Remove the cable clamps.

Move the cable harness to one side.
P0019822
47705010 03-2018 © AB VOLVO PENTA 151

22-2 Oil filter
5 Unhook the fuel lines from the holder.
P0019823
6 Remove the holder.
P0019824
7 Remove the coolant output hose.

Detach the coolant pipe.
P0019825
152 47705010 03-2018 © AB VOLVO PENTA

22-2 Oil filter
8 Remove the oil filter housing.
P0019826
Installation
9 Use new O-rings.
Grease the O-rings.
P0019829
10 Install the oil filter housing in sequence, as

illustrated.
P0019830
47705010 03-2018 © AB VOLVO PENTA 153

22-2 Oil filter
11 Install the output coolant hose.

Screw to secure the flange on to the coolant pipe.
P0019825
12 Install the holder.
P0019824
13 Install the fuel lines in the holder.
P0019823
154 47705010 03-2018 © AB VOLVO PENTA

22-2 Oil filter
14 Refit the cable harness.

Install the cable clamps.
Fit cable ties.
P0019822
15 Connect the connector to the oil pressure sensor.

Fit cable ties.
P0019821
16 Install the fuel filter housing in accordance with:

Fuel filter housing, change, page 163.
17 Fill with coolant; refer to Coolant Level, Checking
and Topping Up, page 267.
18 Check that no leakage occurs.
19 Make sure that the oil level is between the MIN
and MAX marks.
47705010 03-2018 © AB VOLVO PENTA 155

22-3 Oil cooler
22-3 Oil cooler

Oil Cooler, Replace
Removal

Change, page 269.
2 Detach the oil cooler.
NOTICE! The particular oil filler arrangement can

affect how the oil cooler is removed. This
description assumes that there is free access to
the components.
P0019841
3 Remove the oil cooler.
P0019842
156 47705010 03-2018 © AB VOLVO PENTA

22-3 Oil cooler
4 Remove the O-rings.
Installation
5 Fit new O-rings.
P0019844
6 Install the oil cooler.

P0019841

9 Make sure that the oil level is between the MIN
and MAX marks.
47705010 03-2018 © AB VOLVO PENTA 157

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
necessary.
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
158 47705010 03-2018 © AB VOLVO PENTA

23-3 Fuel Feed Pump and Filter

Fuel Pre-filter, Change
IMPORTANT!
cleanliness. 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 Loosen the connector.
P0019269
2 Drain the filter.
P0019270
47705010 03-2018 © AB VOLVO PENTA 159

3 Remove the pre-filter and seal ring.

4 Remove the water separator and O-ring.
Installation
5 NOTICE! Use new component.
Lubricate the O-ring and seal ring with diesel.

Install the water separator.
6 Install the pre-filter.
Tighten the filter until it bottoms, then a further
180°.
P0019271
7 Connect the connector.
P0019269
8 Open the fuel tap and purge the fuel pre-filter in

accordance with Fuel Pre-filter,
Bleeding, page 161.
160 47705010 03-2018 © 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 03-2018 © AB VOLVO PENTA 161

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!
cleanliness.
IMPORTANT!
Removal
1 Remove the filter cover.
2 Remove the O-ring and filter.
P0022768
Installation
3 Grease the new O-ring for the filter cover.
4 If the filter housing is completely empty of fuel,
lubricate around the inner section's sealing
surface on the new filter.
5 Install a new filter in the filter cover.
6 IMPORTANT!
Make sure the components are completely free of
dirt before installing them.
Install the filter cover.

7 Purge the fuel system in accordance with Fuel
system, bleeding, page 158.
P0022769 8 Start and warm up engine. Check that no leakage
occurs.
162 47705010 03-2018 © AB VOLVO PENTA

Fuel filter housing, change

Tools:
88840290 Plugs
IMPORTANT!
cleanliness.
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 03-2018 © AB VOLVO PENTA 163

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
164 47705010 03-2018 © AB VOLVO PENTA

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

connection.
P0019661
9 Connect the pressure relief valve connector.

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

11 Vent the fuel system according to Fuel system,
bleeding, page 158.
47705010 03-2018 © AB VOLVO PENTA 165

High-Pressure Pump, Change

TAD853VE
Tools:
9986172 Puller
88840274 Guide pin
88840290 Plugs
IMPORTANT!
cleanliness.Clean thoroughly before removal.
IMPORTANT!
CAUTION!
CAUTION!
The fuel system may be under pressure.
When working on the fuel system, undo a closed
system at the first point with caution.
NOTICE! Turn off the main switch before any work is

carried out.

2 Fuel OUT (to return line)
A Control valve
B Fuel temperature sensor
P0021714
166 47705010 03-2018 © AB VOLVO PENTA

Removal
Disconnect the connectors.
P0021715
Disconnect the union.

Install the protective plug. Use kit
88840290 Plugs.
P0021716
3 Disconnect the union.
P0021717
47705010 03-2018 © AB VOLVO PENTA 167


Install protective plugs on all fuel unions. Use kit
88840290 Plugs.
P0021718

Detach the attachment points.
P0021719
6 Remove the cable clamps and cable ties.
Undo, remove:
1 Connector, pre-filter
2 Connector, oil level
3 Connector, oil pressure
Remove the screws. Carefully move the engine

control unit aside and stow it securely.
P0021720
NOTICE! The following images may differ somewhat

compared to the product to be worked on. However,
the main information is correct.
168 47705010 03-2018 © AB VOLVO PENTA

7 Remove the bracket.
P0019282
8 Remove the delivery pipe. Use an open 17 mm

socket (crowfoot wrench).
88840290 Plugs.
P0019292
9 NOTICE! Do not hold the pump by the connection

pipes.
Remove the high pressure pump and its

intermediate flange as one unit.
P0019293
10 Remove the gear wheel in accordance with High-

pressure pump gear wheel, change, page 182.
47705010 03-2018 © AB VOLVO PENTA 169

Installation
11 Install the gear wheel in accordance with High-
12 Turn the gear wheel as illustrated so that the mark
on it is aligned with the punch mark on the
intermediate flange.
13 Crank the flywheel until the cylinder 1 mark aligns
with the mark on the flywheel housing.
P0019300
14 NOTICE! Do not hold the pump by the connection

pipes.
Screw it into 88840274 Guide pin the flywheel

housing.
Make sure the gear wheel mark is aligned with the
punch mark.
Slide the pump in without turning the gearwheel.
P0019305
15 NOTICE! Use new bolts.
Screw in (1) without tightening.

Remove 88840274 Guide pin.
Tighten the bolts diagonally (1-2).

Tightening torque 24 Nm (17.7 lbf. ft.)
P0019306
170 47705010 03-2018 © AB VOLVO PENTA

Install new delivery pipes.
Adjust without tightening. Use an open 17 mm

Tightening torque 37 Nm (27.3 lbf. ft.)
P0019307
17 Fit the bracket.
P0019282
18 Bolt the engine control unit in place.
Install:
1 Connector, pre-filter
2 Connector, oil level
3 Connector, oil pressure
Secure the cable harness with fasteners.
P0021720
47705010 03-2018 © AB VOLVO PENTA 171

19 Connect the connections.
P0021719
P0021722
P0021715

Start the engine.
Perform a leakage and function check.
172 47705010 03-2018 © AB VOLVO PENTA

High-Pressure Pump, Change

Tools:
9986172 Puller
88840274 Guide pin
88840290 Plugs
IMPORTANT!
IMPORTANT!
CAUTION!
CAUTION!

carried out.

2 Fuel OUT (to main filter)
3 Fuel supply from the engine control unit cooling coil
4 Fuel OUT to return line
P0019287
47705010 03-2018 © AB VOLVO PENTA 173

Removal
1 Detach the bracket and move it aside.
P0019274
Disconnect the union.

88840290 Plugs.
P0019288
3 Install the protective plug. Use kit

88840290 Plugs.
Disconnect the connector.
P0019289
174 47705010 03-2018 © AB VOLVO PENTA

4 Disconnect the connector (1).

Disconnect the connector (2).
88840290 Plugs.
P0019290
P0019279
6 Remove the bolts. Carefully move the engine

P0019280
47705010 03-2018 © AB VOLVO PENTA 175

7 Loosen the connections (1, 2).

88840290 Plugs.
P0019291
P0019308
9 Remove the bracket.
P0019282
176 47705010 03-2018 © AB VOLVO PENTA


88840290 Plugs.
P0019292
11 NOTICE! Do not hold the pump by the delivery

pipe.
Remove the high pressure pump and its

intermediate flange as one unit.
12 Remove the gear wheel in accordance with High-
P0019293
Installation
13 Install the gear wheel in accordance with High-
14 Turn the gear wheel as illustrated so that the mark
on it is aligned with the punch mark on the
intermediate flange.
15 Crank the flywheel until the cylinder 1 mark aligns
with the mark on the flywheel housing.
P0019300
47705010 03-2018 © AB VOLVO PENTA 177

16 NOTICE! Do not hold the pump by the delivery

pipe.
Screw it into 88840274 Guide pin i n the flywheel

housing.
Make sure the gear wheel mark is aligned with the
punch mark.
Slide the pump in without turning the gearwheel.
P0019305
17 NOTICE! Use new bolts.

Remove the 88840274 Guide pin.
Tighten the bolts diagonally (1-2).

Tightening torque 24 Nm (17.7 lbf ft)
P0019306
Adjust without tightening. Use an open 17 mm

P0019307
178 47705010 03-2018 © AB VOLVO PENTA

19 Fit the bracket.
P0019282
20 Install the holder and secure the fuel lines.
P0019308
21 Install the bolts (1, 2).
P0019309
47705010 03-2018 © AB VOLVO PENTA 179

22 Install the engine control unit.
P0019280
23 Secure the harness with cable clamps and cable

ties.
P0019279
24 Install the bolts (1, 2).
P0019310
180 47705010 03-2018 © AB VOLVO PENTA

P0019311
P0019312

Start the engine.
47705010 03-2018 © AB VOLVO PENTA 181

High-pressure pump gear wheel,

change
Tools:
9986172 Puller
Removal
1 Remove the O-ring and nuts.
P0019294
2 Remove the gear wheel.
P0019295
182 47705010 03-2018 © AB VOLVO PENTA

3 Remove the intermediate flange and O-ring.
Installation
4 Fit a new O-ring on the inside of the flange.
Install the flange as illustrated.
P0019297
5 Check that the key is in the keyway.
P0019298
6 Install the gearwheel.

P0019299
47705010 03-2018 © AB VOLVO PENTA 183

MPROP valve, high-pressure pump,

change
Tools:
885812 Timing tool
88840271 Guide pin
88840290 Plugs
88890148 Torque wrench
IMPORTANT!
IMPORTANT!
CAUTION!
CAUTION!
P0019336
Removal
1 Disconnect the MPROP valve connector, high
pressure pump.
P0019275
184 47705010 03-2018 © AB VOLVO PENTA

2 IMPORTANT!
Make sure no contaminants get into the
component.
Mark the position.

Remove the MPROP valve.
Remove the O-ring.
P0019337

88840290 Plugs.
P0019338
47705010 03-2018 © AB VOLVO PENTA 185

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
186 47705010 03-2018 © 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.
47705010 03-2018 © AB VOLVO PENTA 187

23-7 Injectors and Delivery Pipes

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

carried out.
Removal
1 Remove the upper valve cover according to
Upper valve cover, change, page 87.
2 Remove the lower valve cover according to
Lower valve cover, change, page 93.
3 Remove the hollow screw from the return line on
the cylinder head.
P0019313
4 Remove the injector delivery pipe according to

188 47705010 03-2018 © AB VOLVO PENTA

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

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

88840290 Plugs.
P0019316
47705010 03-2018 © AB VOLVO PENTA 189

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-

installation.
Remove the injectors and washers.

Check that no washers remain in any of the
injector wells.

88840290 Plugs.
P0019319
190 47705010 03-2018 © 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

injectors.
47705010 03-2018 © AB VOLVO PENTA 191

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

injectors.
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

attention 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
channel on the high pressure pump side.
P0019323
192 47705010 03-2018 © AB VOLVO PENTA

17 NOTICE! When changing an injector, a new

injector code must be programmed into the
control unit; refer to the appropriate Workshop
Manual, Group 30: Electrical System. Refer to
respective injector code must (26-digit code),
which is stamped on the 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
cylinders.
P0019324
18 Lubricate the bolts.

Install bolts in the injector yokes.
Preload the bolts.

Tightening torque: (5 Nm) 3.7 lbf. ft.
P0019317
19 NOTICE! Use new components. O-ring and

injector delivery pipe.
Lubricate and install the O-ring.
P0019325
47705010 03-2018 © AB VOLVO PENTA 193

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 torque on the sleeves.

P0019314
23 Tighten the injector yokes bolts.

P0019327
24 Install the injector delivery pipes according to

194 47705010 03-2018 © AB VOLVO PENTA

25 Install the hollow screw from the return line on the

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

27 Install the upper valve cover according to: Upper
28 Bleed the fuel system according to: Fuel system,
bleeding, page 158.
Start the engine.
47705010 03-2018 © AB VOLVO PENTA 195

Common Rail, Change

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

pressure pump.
P0019275
196 47705010 03-2018 © 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

engine control unit cooling coil.
Detach the fuel supply connection (2) (from the
pre-filter) to the engine control unit cooling coil.
88840290 Plugs.
P0019277
47705010 03-2018 © AB VOLVO PENTA 197

P0019279
7 Remove the bolts and carefully move the engine

P0019280
P0019281
198 47705010 03-2018 © AB VOLVO PENTA

9 Remove the control unit mounting bracket.
P0019282

88840290 Plugs.
11 Remove the delivery pipes in accordance with
P0019283
12 Remove the common rail unit.
P0019284
47705010 03-2018 © AB VOLVO PENTA 199

Installation
13 Install the common rail unit, secure with its bolts.
14 Install the delivery pipes; refer to Fuel Injection
Pipe, Change, page 204.
P0019284

P0019285
16 Install the control unit mounting bracket.
P0019282
200 47705010 03-2018 © 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 03-2018 © AB VOLVO PENTA 201

20 Connect the fuel supply connection (1) from the

engine control unit cooling coil.
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

pressure sensor.
P0019276
202 47705010 03-2018 © AB VOLVO PENTA

23 Connect the connector to the pressure relief

valve.
P0019278

P0001900 system, bleeding, page 158.
Start the engine.
47705010 03-2018 © AB VOLVO PENTA 203

Fuel Injection Pipe, Change

Tools:
88840290 Plugs
IMPORTANT!
IMPORTANT!
CAUTION!
CAUTION!

carried out.
Removal
1 Detach the fuel return line connection from the
common rail.
88840290 Plugs.
P0019413
204 47705010 03-2018 © AB VOLVO PENTA

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

following order. 1, 2, 5, 3, 4, 6. Use an open 17
mm socket (crowfoot 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 cap nuts by hand. Check that the

clamps are parallel with the bolt holes.
P0019419
47705010 03-2018 © AB VOLVO PENTA 205

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

Use an open 17 mm socket (crowfoot wrench).
P0019417
7 Connect the fuel return line.
P0019418

Start the engine.
206 47705010 03-2018 © 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 in accordance with
Common Rail, Change, page 196.
P0019356
2 Remove the nut. Use 88840272 Sleeve.

Remove the solenoid.
P0019357
47705010 03-2018 © AB VOLVO PENTA 207

23-9 Miscellaneous
3 Remove the solenoid valve.
P0019358

88840290 Plugs.
P0019359
Installation
5 Install the O-ring.
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
208 47705010 03-2018 © AB VOLVO PENTA

23-9 Miscellaneous
6 NOTICE! Look at the installation drawing.
1 Install the solenoid.

2 Install the nut. Use 88840272 Sleeve.
3 Align the marks.
4 Torque tighten the nuts.
5 13 ±0.5°
6 Check the torque, 6-21 Nm (4.4-15.5 lbf ft)
P0019361
7 Install the common rail unit, in accordance with

Common Rail, Change, page 196.
P0019356
47705010 03-2018 © AB VOLVO PENTA 209

25-1 Inlet and Exhaust Manifolds

Intake Manifold, Change
IMPORTANT!
NOTICE! There is no e-ERG system or choke on the

TAD840-43VE andTAD850-53VE engines.
Removal
1 Undo, remove:
- Cable ties.
1 Choke, refer to Air throttle,
change, page 246.
2 Pre-heating element and electrical
connection.
3 EGR flow valve connector.
P0021732
210 47705010 03-2018 © AB VOLVO PENTA

2 Undo EGR flow valve connector for:

1 Sensor, E-EGR temperature
2 Start/stop switch, engine
3 Sensor, differential pressure
4 Sensor, charge air temperature/pressure
- Cable ties, connection for e-EGR pipe,
harness anchor points.
P0021733
3 Unfold and attach harness.

Remove the EGR Venturi tube as a unit.
Inspect and clean as necessary.
P0021734
47705010 03-2018 © AB VOLVO PENTA 211

4 IMPORTANT!
Remove the O-ring and filter; refer to Oil filter,

Change, page 149.
Cover, plug the open filter housing and make sure
that dirt and foreign particles are kept away.
Remove the mounting bolts and pressure pipe
clamp.
P0021735
5 NOTICE! Air compressor (accessory), prevents

any bolts.
Remove the inlet manifold. Lift diagonally

upwards.
P0021736
Installation
6 When replacing the inlet manifold, move the
sensor for charge air temperature/pressure.
Remove the gaskets.
Clean the contact surfaces.
Install the gaskets.
NOTICE! Use new gaskets.
P0021737
212 47705010 03-2018 © AB VOLVO PENTA

7 NOTICE! Air compressor (accessory), prevents

any bolts.
Apply locking fluid (prod. no. 1161053) on the

bolts.
P0021738
8 Apply locking fluid (prod. no. 1161053) on the

bolts.
P0021739
9 Torque tighten the inlet manifold; refer to Special

Tightening Torques, page 11.
P0021553
47705010 03-2018 © AB VOLVO PENTA 213

10 Install the mounting bolts and pressure pipe

clamp.
Install the filter cover and filter; refer to Oil filter,
Change, page 149.
P0021735
11 Install the EGR Venturi tube and EGR valve as a

unit.
Fold down the harness.
P0021734
214 47705010 03-2018 © AB VOLVO PENTA

12 Connect the EGR flow valve connector for:

1 Sensor, E-EGR temperature
2 Start/stop switch, engine
3 Sensor, differential pressure
4 Sensor, charge air temperature/pressure
- Cable ties, connection for e-EGR pipe,
harness anchor points.
P0021733
13 Connect / Install:
1 Pre-heating element and electrical
connection.
2 Choke, refer to Air throttle,
change, page 246.
3 EGR flow valve connector.
- Cable ties.
P0021740
47705010 03-2018 © AB VOLVO PENTA 215

Exhaust Manifold, Change

Removal
1 Remove the turbo according to: Turbo,
Change, page 231.
2 Remove:
1 Coolant pipe (outlet)
2 Heat protection plate
3 Bracket
P0021724
3 TAD870-873VE:
Unscrew the connection to the e-EGR cooler.
P0021725
216 47705010 03-2018 © AB VOLVO PENTA

4 TAD870-873VE:
Remove the e-EGR pipe.
P0021726
5 Remove the exhaust manifold.
NOTICE! Check that the parts do not have any

cracks or damages.
Installation
6 Apply sealing paste (part no 1161929) for the
screw joints.
7 Place the new gaskets on the sealing surface.
Install the exhaust manifold, see Special
P0021728
8 Install:
1 Bracket
2 Heat protection plate
3 Coolant pipe (outlet)
P0021729
47705010 03-2018 © AB VOLVO PENTA 217

9 TAD870-873VE:
Install the e-EGR pipe.
P0021730
10 TAD870-873VE:
Tighten the connection to the e-EGR cooler.
P0021725
11 Install the turbo according to: Turbo,

Change, page 231.
12 Start the engine.
218 47705010 03-2018 © AB VOLVO PENTA

25-4 Emission Control, Catalytic Converter
47705010 03-2018 © AB VOLVO PENTA 219

Cooler e-EGR, change

IMPORTANT!
Drain the coolant in accordance with Coolant,

Change, page 269.
NOTICE! Drain the coolant until the level is below the

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

Unscrew the NOx sensor.
P0020526
220 47705010 03-2018 © AB VOLVO PENTA

3 Remove the coolant pipe outlet.

Remove the thermal cover bracket.
P0020527
4 Remove the pipe clamp.

1 Move aside the coolant hose; the outlet
from the e-EGR radiator.
2 Remove the coolant pipe clamping ring;
inlet from the e-EGR radiator.
P0020528
5 Unscrew the EGR pipe connection.
P0020529
47705010 03-2018 © AB VOLVO PENTA 221

6 Remove the e-EGR radiator and its gaskets.

7 Clean the sealing surfaces and inspect the seal
ring.
8 Check the radiator core for visible cracks.
For radiator pressure testing, refer to Cooler e-
EGR, pressure testing, page 227.
NOTICE! If the radiator core is sooty with

significant deposits it must be cleaned internally
extremely thoroughly; refer to Cooler e-EGR,
pressure testing, page 227.
Also check the EGR pipe in connection with
cleaning.
P0020530
Installation
9 Install the e-EGR radiator and gaskets. Adjust the
coolant pipes to get the inlet into the e-EGR
radiator.
10 Install the pipe and gasket.
P0020529
11 Fit the pipe clamp.

1 Slide on the coolant outlet pipe from the e-
EGR radiator.
2 Slide on the coolant inlet pipe from the e-
EGR radiator.
P0020528
222 47705010 03-2018 © AB VOLVO PENTA

12 Install the coolant line outlet.

Install the heat shield cover bracket.
P0020527
13 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
14 Install the thermal cover.

17 Start and warm up engine. Perform a leakage and
function check.
47705010 03-2018 © AB VOLVO PENTA 223

Cooler e-EGR, change

IMPORTANT!
Removal
1 Remove the turbocharger, refer to Turbo,
Change, page 231.
2 Remove the pipe clamps.
Remove the inlet and outlet coolant pipes from
the e-EGR radiator
P0020084
3 Unscrew the EGR pipe union.
P0020085
224 47705010 03-2018 © AB VOLVO PENTA

4 Remove the e-EGR radiator and gaskets.
P0020086
5 Remove the EGR pipe.

6 Check the radiator core for visible cracks.
For radiator pressure testing, refer to Cooler e-
EGR, pressure testing, page 227.
7 If the radiator core is sooty with significant
deposits it must be cleaned internally extremely
thoroughly; refer to Cooler e-EGR,
Cleaning, page 228.
Also check the EGR pipe in connection with
cleaning.
Installation
8 Install the pipe and gasket.
P0020087
9 Install the e-EGR radiator and gaskets.

P0020088
47705010 03-2018 © AB VOLVO PENTA 225

10 Securely bolt the EGR pipe (1) in place.

Securely bolt the EGR pipe (2) in place.

P0020089
11 Slide off the coolant hoses for both inlet and

exhaust.
P0020084
12 Install the turbocharger, refer to Turbo,

Change, page 231.
14 Start and warm up engine. Perform a leakage and
function check.
226 47705010 03-2018 © AB VOLVO PENTA

Cooler e-EGR, pressure testing

Tools:
88800298 Connection washer
9996662 Pressure testing kit
1 Pressurize for 15 minutes.
NOTICE! Radiator nipples in the up position.
Radiator core, test pressure: 0.4 bar (5.8 PSI)

Radiator core, Max pressure: 0.6 bar (8.7 PSI)
47705010 03-2018 © AB VOLVO PENTA 227

Cooler e-EGR, Cleaning

Remove cooler e-EGR, according to Cooler e-EGR,

change, page 220.
Cleaning agent:
1 Degreasing agent (alternatively, use a paraffin
fraction 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
228 47705010 03-2018 © AB VOLVO PENTA

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 220.
47705010 03-2018 © AB VOLVO PENTA 229

25-5 Turbo and supercharger

Turbocharger, Inspection
1 Check that the turbocharger part number is
correct for the engine variant. The wrong
turbocharger for the engine variant might not
provide enough charge pressure, which would
reduce engine power.
2 Check that the turbocharger has the correct
compressor 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
compressor wheel and excessive end float on the
turbine 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
turbocharger 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.
230 47705010 03-2018 © AB VOLVO PENTA

Turbo, Change
Always identify and correct the cause of turbocharger

failure before fitting a new turbocharger. Check and
rectify in accordance with: Turbocharger,
Inspection, page 230.
IMPORTANT!
Change, page 269
2 Remove the exhaust pipe connection between
the turbocharger and the after-treatment system.
3 Remove the turbocharger charge air pipe.
P0019420
4 Remove the intake pipe.
P0019421
47705010 03-2018 © AB VOLVO PENTA 231

P0019422
6 Remove the pipe elbow (1) from the

turbocharger.
Remove the rubber bellows (2) from the air intake
with the connecting hose for crankcase
ventilation.
P0019424
7 Detach and lift up the heat shield.

Unscrew the NOx sensor.
P0019425
232 47705010 03-2018 © AB VOLVO PENTA

8 NOTICE! Note the clamp position.
Remove the clamp (1).

Remove the suspension bracket (2).
Lift off the pre-Cat with its connection pipe.
P0019426
9 Disconnect the exhaust manifold pressure sensor

connector.
10 Remove the exhaust pressure sensor unit.
P0019427
P0019429
47705010 03-2018 © AB VOLVO PENTA 233

12 Disconnect the connector for the turbocharger

tachometer sensor (1) and the VGT actuator (2).
P0019430
13 Release the generator cable and disconnect from

the connector.
P0021723
14 Remove the cable ties and the cable harness

from the cable suspension.
P0019431
234 47705010 03-2018 © AB VOLVO PENTA

15 Remove the cable suspension brackets.
P0019436
16 Remove the coolant inlet line.
P0019432
17 Remove the coolant outlet line.
P0019433
47705010 03-2018 © AB VOLVO PENTA 235

18 Remove the oil pressure line and its clamps.
P0019435
19 Remove the oil return pipe with gasket.
P0019434
20 Remove the turbocharger.
Installation
21 NOTICE! Use new sealings.
Install a new gasket on the exhaust manifold.

Install the turbocharger.
Tightening torque:
Bolt (1): 44 Nm (32.5 lbf ft)
Nut (2): 54 Nm (39.8 lbf ft)
P0019438
236 47705010 03-2018 © AB VOLVO PENTA

22 Install the oil return pipe with new seals on the

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

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

P0019433
47705010 03-2018 © AB VOLVO PENTA 237

25 Install the coolant inlet line.

P0019441
26 Install the cable harness suspension brackets.
P0019436
27 Install the cable harness and secure it with cable

ties.
P0019431
238 47705010 03-2018 © AB VOLVO PENTA

28 Connect the connector to the turbocharger

tachometer sensor (1) and the VGT actuator (2).
P0019430
P0019429
30 Install the alternator cable and connect its

connector.
P0021723
47705010 03-2018 © AB VOLVO PENTA 239

31 Install the exhaust pressure sensor unit.

P0019427
33 Check the sealing surface and gasket.

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

NOx sensor.
Examples of lubricants: Permatex: Anti-Seize or
Bostik Never-Seez.
P0019443
240 47705010 03-2018 © AB VOLVO PENTA

35 Install the pipe elbow (1) on the turbocharger.

Tighten the clamp.
Install the rubber bellows (2) to the air intake with
the connecting hose for crankcase ventilation.
P0019424
37 Connect the inlet pipe.
P0019421
38 Install the turbocharger charge air pipe.

39 Install the exhaust pipe connection between the
turbocharger and the after-treatment system.
40 Fill the fresh water system in accordance with
Coolant, Change, page 269.
41 Turn the main switch on.
42 Run the engine until warm and perform a
functional check with respect to any leakages.
P0019420
47705010 03-2018 © AB VOLVO PENTA 241

Air compressor, change

Tools:
1158957 Pliers
9986172 Puller
IMPORTANT!
Removal
1 Empty the compressed air system.
2 Loosen / remove the connections:
1 Air inlet
2 Air outlet
3 Control connection
- The connector for Rail pressure/
temperature.
NOTICE! Be prepared to gather up fluid. Clamp

1158957 Pliers and loosen the coolant hoses.
P0021883
3 Loosen the oil pressure line (1).

Secure in place and lift the air compressor away
with suitable lifting equipment (2).
P0021884
242 47705010 03-2018 © AB VOLVO PENTA

4 Remove the O-ring and undo the nut.
P0021885
5 Use 9986172 Puller in order to remove the air

compressor's gearwheel.
Mark, note positions. Transfer the nipples.
P0021886
Installation
6 Wash the tapered joint on the shaft and the
gearwheel with denatured alcohol.
Clean the sealing surfaces.
7 Thread on a new o-ring.
Connect the gearwheel on the axle and tighten.
Fit the nipples. Check marking.
P0021887
47705010 03-2018 © AB VOLVO PENTA 243

8 Max tightening torque:
1 Air inlet
150 Nm (111 lbf. ft.)
2 Air outlet
90 Nm (66.4 lbf. ft.)
25 Nm (18.4 lbf. ft.)
4 Coolant connection
45 Nm (33.2 lbf. ft.)
P0021888
9 Install the compressor n and the oil pressure line.
P0021889
10 Connect / Install the connections:

1 Air inlet
2 Air outlet
- The connector for Rail pressure/
temperature.
NOTICE! Install the coolant hoses. Loosen

1158957 Pliers.
11 Start the engine.
P0021883
244 47705010 03-2018 © AB VOLVO PENTA

VGT actuator, check

Checking the VGT actuator stroke

(TAD87x)
It should be possible to turn the actuator, with rod, by
hand.
Measure the length of stroke between actuator end
positions. The play must be ~25 mm.
If the actuator cannot be turned or if the length of stroke
is too short, examine the cause of this.
P0023173
Checking the VGT actuator stroke length

(TAD87x)
It should be possible to move the actuator, with rod,
up/down by hand.
Measure the length of stroke between actuator end
positions. The play must be ~13 mm.
If the actuator cannot be moved or if the length of
stroke is too short, examine the cause of this.
P0023174
47705010 03-2018 © AB VOLVO PENTA 245

25-6 Air Cleaner, Throttle Housing

Air throttle, change
CAUTION!
IMPORTANT!
Removal
1 Remove the hose between the inlet manifold and
the charge air cooler.
P0021741
2 Undo the electrical connection to the shutter

housing.
Remove the shutter housing.
P0021742
246 47705010 03-2018 © AB VOLVO PENTA

3 Check that the shutter can be turned easily from

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

Electrical system, EATS for any fault tracing and
other unit measurements.
P0015227
Installation
4 Install the shutter housing and gasket.
Connect the electrical connection to the shutter
housing.
P0021743
5 Install the hose between the inlet manifold and

charge air cooler.
P0021741
47705010 03-2018 © AB VOLVO PENTA 247

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
concerned. The essential information in the
illustrations is always correct, however.
IMPORTANT!
AdBlue/DEF and urea solutions cause corrosion
damage. 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 (such as diesel) and that
are not approved by Volvo, will cause a breakdown of
the exhaust aftertreatment system.
248 47705010 03-2018 © AB VOLVO PENTA

Electrically Heated AdBlue/DEF

Hose, Change
1 NOTICE! Wait at least 2 minutes after engine

stop so that the automatic drainage function is
depressurized before beginning to remove
components.
2 Remove the hose.
3 Install a new hose.
P0025276
4 Run the Urea pressure build up test.

Check that there are no leaks.
47705010 03-2018 © AB VOLVO PENTA 249

AdBlue/DEF Tank, Change

Tools:
stop to give the automatic drainage function time
to complete operations. Make sure the system is
components.
2 Unscrew the hexagonal cover (1).
Remove the drain screw (2) and empty the tank.
3 Remove the tank fittings; refer to Combined Tank
Unit, AdBlue/DEF Tank, Change, page 263.
P0019366
4 Hold the tank securely and remove the bolts.
P0025278
250 47705010 03-2018 © AB VOLVO PENTA

5 Lift the tank module and pull it carefully out of the

locating pins on the bracket.
P0019369
6 Remove the bolts.
P0019370
7 Remove the bolts.
P0019372
47705010 03-2018 © AB VOLVO PENTA 251

8 Remove the bolts and hose holder.
P0019373
9 Carefully pry the tank sides (1) apart and then pull
out the tank (2). Be aware that the venting hose
is attached.
10 Install the new tank in reverse order.
P0019374

252 47705010 03-2018 © AB VOLVO PENTA

AdBlue/DEF Tank, Cleaning

AdBlue/DEF contamination
If a fluid other than AdBlue/DEF is used in the system, or if the AdBlue/DEF tank is contaminated with other
material, the AdBlue/DEF system must be assessed, cleaned and tested to ensure it is functioning correctly.
This information provides general guidelines for the inspections that must be carried out and the actions that
must be taken if the AdBlue/DEF tank is contaminated.
The technician is expected to be acquainted with the SCR system and be able to judge of components can be
cleaned or must be replaced.
Inspection
Action: Checking for diesel or oil in the AdBlue/DEF solution, page 265.
Cleaning / replacement
If the tank has been contaminated by diesel, biodiesel, oil/grease, solvents or alkaline cleaning agents, the
tank fittings must be replaced and all hoses thoroughly cleaned with warm water.
Contamination < 20% Contamination > 20%

Change Change
• Pump unit • Pump unit
• Dosing unit • Dosing unit
• Tank fittings • Tank fittings
• All filters • AdBlue/DEF tank
Clean • All AdBlue/DEF hoses
• Use hot water to clean the AdBlue/DEF tank and • All filters
all AdBlue/DEF hoses.
NOTICE! Operations with contaminated AdBlue/DEF over extended periods can damage the SCR silencer. High
emissions following a complete cleaning as described above indicate a replacement of the SCR silencer may be
necessary.
47705010 03-2018 © AB VOLVO PENTA 253

1 Remove the tank module and tank fittings; refer

to steps 1–5 AdBlue/DEF Tank,
Change, page 250.
2 Flush through the tank fitting with warm water.
Replace the tank fitting filter.
P0019379
3 Remove the filler filter.

Place the cover and the unit in warm water for at
least 2 minutes.
P0019380
4 Flush the tank with hot water for at least 10

minutes.
5 Install in reverse order with a new filler filter and
breather filter.
NOTICE! Fit the drain screw.
P0019381

254 47705010 03-2018 © AB VOLVO PENTA

Exhaust Temperature Sensor,

Change
1 Disconnect the battery negative terminal.
2 Remove the cable ties.
4 Disconnect and remove the temperature sensor.
5 Screw in a new temperature sensor.
6 Connect the connector. Attach new cable ties.
7 Reconnect the battery negative terminal.
8 Start the engine. Check operation and inspect for
leaks.
9 Delete any fault codes.
P0019383
47705010 03-2018 © AB VOLVO PENTA 255

Dosing unit, change


components.
P0025288
3 Remove the hoses.
P0025276
4 Remove the dosing valve.

5 Clean the contact surfaces.
6 Install the dosage valve.
Tightening torque: 8Nm (5.9 Ibf ft)
P0025289
256 47705010 03-2018 © AB VOLVO PENTA


47705010 03-2018 © AB VOLVO PENTA 257

AdBlue/DEF-Pump Filter, Change


components.
2 Unscrew the filter cover.
P0019389
3 Remove the rubber gasket.

Pull out the filter. Use the puller (supplied with the
filter kit).
P0019390
258 47705010 03-2018 © AB VOLVO PENTA

4 Install as illustrated.
Filter cover:
Tightening torque: 20 Nm (14 Ibf ft).
P0019391

47705010 03-2018 © AB VOLVO PENTA 259

Solenoid Valve, AdBlue/DEF Tank,

Change
Tools:
1158957 Pliers
1 Pinch off the coolant hoses.
Remove the hoses.
A
p0013271
2 NOTICE! When installing the valve. Check valve

installation direction. Arrow toward tank.
P0025292
260 47705010 03-2018 © AB VOLVO PENTA

Pump Unit, Change


components.
P0025290
3 Remove the hoses.
P0019394
47705010 03-2018 © AB VOLVO PENTA 261

4 Remove the pump.

5 Install the new pump in reverse order.
P0025291

262 47705010 03-2018 © AB VOLVO PENTA

Combined Tank Unit, AdBlue/DEF

Tank, Change
Tools:
1158957 Pliers
1158957 1 NOTICE! Wait at least 2 minutes after engine

components.
p0013226
P0013226
2 Pinch off the coolant hoses (B).

3 Remove the hoses. Seal the connectors (A) in a
plastic bag.
P0019367
47705010 03-2018 © AB VOLVO PENTA 263

4 Remove the hose clamp.

Lift out the tank fitting.
5 Install the new tank fitting in reverse order.
P0025293

264 47705010 03-2018 © AB VOLVO PENTA

Checking for diesel or oil in the

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

visibility 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 03-2018 © AB VOLVO PENTA 265

Checking urea concentration in the

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

distilled water before use.
1 Remove the insertion in the tank inlet for better

visibility and access to the fluid.
2 Draw in a small amount of the liquid from the
surface 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
concentration.
• The system is very sensitive for incorrect urea
solution.
• If no level is shown in the instrument it may indicate
chemical residue, such as pure water or diesel.
P0020549
266 47705010 03-2018 © 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 03-2018 © AB VOLVO PENTA 267

Refill of empty system

NOTICE! Mix the correct amount of coolant in advance
to ensure that the cooling system is completely filled.
Refer to Administration, page 46 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.
268 47705010 03-2018 © 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 03-2018 © AB VOLVO PENTA 269

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
cooling fluid.
Refer to Administration, page 46 and Coolant
Level, Checking and Topping Up, page 267.
P0019345
270 47705010 03-2018 © AB VOLVO PENTA

26-1 Radiator, Heat Exchanger

Radiator Assembly, Change
Removal
IMPORTANT!
1 Drain the coolant, according to: Coolant,
Change, page 269.
2 Remove the the turbo pressure pipe (1) for
outgoing 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 03-2018 © AB VOLVO PENTA 271

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
272 47705010 03-2018 © 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 03-2018 © AB VOLVO PENTA 273

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
274 47705010 03-2018 © 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 03-2018 © AB VOLVO PENTA 275

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

cooling fluid. Refer to Administration, page 46
and Coolant Level, Checking and Topping
Up, page 267.
276 47705010 03-2018 © AB VOLVO PENTA

26-2 Coolant Pump, Thermostat

Coolant Pump, Change
IMPORTANT!
Because access depends on the type of cooling

system installed, different methods are used when
replacing the component.
Removal

Change, page 269.
2 Remove the coolant hoses and charge air
connections.
Remove the belt guard and fan guard, refer to
Radiator Assembly, Change , page 271.
3 IMPORTANT!
Do not allow the viscous coupling to lay flat for
more than a very short time. Its oil may run out
which will then mean that the coupling must be
changed.
P0019589
4 Disconnect the sensor cable from the engine

cable harness.
Remove the sensor bracket from the bracket on
the engine.
P0019590
47705010 03-2018 © AB VOLVO PENTA 277

5 NOTICE! Left hand thread.
Unscrew the viscous coupling together with the

fan.
P0019591
6 Remove the hose connection (1) from the coolant

pipe. (Hot circuit fluid from the turbocharger, e-
EGR radiator).
Remove the hose (2). (Connection hose to
expansion tank).
P0019592
7 Remove the crankcase ventilation connection

pipe.
Disconnect the electrical connection from the
preheater element.
P0019593
278 47705010 03-2018 © AB VOLVO PENTA


Open the preheater relay cover. Unscrew the
input nut.
Remove the engine attachment fitting.
P0019594
9 Remove the preheater relay.
P0019595
10 Remove the clamps.

Disconnect the cable.
Remove the bolts.
Remove the bracket.
P0019596
47705010 03-2018 © AB VOLVO PENTA 279

11 Remove the thermostat housing.
P0019597
12 Remove the gaskets.
P0019598
13 Remove the ventilation pipe from the separator.
P0019599
280 47705010 03-2018 © AB VOLVO PENTA

14 Unfasten the belt tensioner and restrain it with a

drift.
Remove the belt.
Check the function of the tensioner, the condition
of the pulleys and the pulley bearings.
P0019600
15 Remove the fan adapter and pulley from the

coolant pump.
P0019601
Remove the drain plug.

Empty the water pump.
P0019602
47705010 03-2018 © AB VOLVO PENTA 281

17 Remove the coolant pump.

Remove the gaskets.
P0019603
Installation
18 Install new gaskets.
P0019606
19 Install the coolant pump, refer to Special

NOTICE! First guide in the coolant pump

“ collar“ and O-ring.
P0019607
282 47705010 03-2018 © AB VOLVO PENTA

20 NOTICE! When reinstalling the existing

components.
Secure the plugs.
P0019609
21 Install the fan adapter and pulley on the coolant

pump. Tighten the bolts diagonally.
P0019610
22 Install the belt.

Release the belt tensioner and remove the drift.
Check that the belt is correctly aligned on all the
pulleys.
P0019611
47705010 03-2018 © AB VOLVO PENTA 283

23 Install the ventilation pipe between the separator

and the pipe union.
P0019599
24 Install new gaskets.

Grease the O-ring.
P0019613
25 Install the thermostat housing.

Tighten the bolts diagonally.
P0019597
284 47705010 03-2018 © AB VOLVO PENTA

26 Install the attachment fitting.

Install the bolts. Tighten them.
Clamp the cable.
Install the clamps.
P0019614
27 Install the preheater relay.
P0019595
28 Install the attachment fitting on the engine.

Install the cable with the input nut.
Close preheater relay cover.
Secure with a cable tie.
Connect the harness terminal.
P0019615
47705010 03-2018 © AB VOLVO PENTA 285


Install the electrical connection to the preheater
element.
Tighten using cable ties.
P0019616
30 Fit the hose connection (1) to the coolant pipe.

Install the hose (2).
P0019617
31 Lift the fan and carefully offer the coupling onto

the engine attachment.
NOTICE! Left hand thread.
Rotate the fan slowly clockwise (view as

illustrated) so that the threads engage. Rotate the
fan until the threads bottom and tighten so that
the coupling grips the adapter.
P0019618
286 47705010 03-2018 © AB VOLVO PENTA

32 Install the sensor bracket on the bracket on the

engine.
Connect the sensor cable harness to the engine
cable harness and secure with cable ties.
P0019590
33 Install the coolant hoses and charge air

connections.
Install the belt guard and fan guard, refer to
Radiator Assembly, Change , page 271.
34 Fill with coolant, refer to Coolant,
Change, page 269.
35 Turn the main switch on.
Start the engine. Check that no leakage occurs.
47705010 03-2018 © AB VOLVO PENTA 287

Thermostat, Change
Removal
1 Drain the coolant so that the level falls below the

thermostat; refer to Coolant, Change, page 269.
2 Disconnect the radiator hose.
P0019521
3 Remove the crankcase ventilation connection

from the valve cover.
P0019483
4 Remove the hose between the expansion tank

and thermostat housing.
P0019522
288 47705010 03-2018 © AB VOLVO PENTA

5 Remove the thermostat housing cover.

Remove the thermostat.
Installation
6 Install a new thermostat.
Install the thermostat housing cover.
P0019525
7 Install the hose between the expansion tank and

the thermostat housing.
P0019522
8 Connect the radiator hose.
P0019521
47705010 03-2018 © AB VOLVO PENTA 289

9 Install the crankcase ventilation connection on

the valve cover.
P0019483

290 47705010 03-2018 © AB VOLVO PENTA

Drive belt, change

Right belt guard removed; refer to Belt guard,
change, page 292.
Removal
CAUTION!
1 Unfasten the belt tensioner and restrain it with a

drift.
2 Remove the belt.
3 Check the function of the tensioner and the
condition 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 guard,
change, page 292.
P0019256
47705010 03-2018 © AB VOLVO PENTA 291

Belt guard, 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
292 47705010 03-2018 © AB VOLVO PENTA

47705010 03-2018 © AB VOLVO PENTA 293

26-3 Fan, Fan Shroud

Visco fan, replace
Removal
IMPORTANT! Turn off the main switch before starting
work.
1 Remove:
1 Belt guard, refer to Belt guard,
change, page 292.
2 loading air pipe
3 Fan guard
P0025012
2 Disconnect the sensor cable from the engine

harness.
Remove the bracket.
P0025019
294 47705010 03-2018 © AB VOLVO PENTA

3 Remove the fan ring.
P0025017
4 Secure the fan and fan ring with a strap.
P0025020
5 Unscrew the viscous coupling together with the

fan.
P0025021
47705010 03-2018 © AB VOLVO PENTA 295

6 Remove the fan adapter.
P0025018
7 Lift out the fan unit.
P0025016
8 Remove the viscous coupling.
P0025013
296 47705010 03-2018 © AB VOLVO PENTA

Installation
9 Install the viscous coupling.
P0025013
10 Secure the fan and fan ring with a strap.
P0025020
11 Lift in the fan unit with fan ring.
P0025011
47705010 03-2018 © AB VOLVO PENTA 297

12 Install the fan adapter.
P0025018
13 Carefully place the fan coupling onto the engine

attachment fittings.
Rotate the fan slowly until the threads grip.
Rotate the fan until the thread bottoms and
tighten.
Tightening torque: 150 Nm (110.6 lbf·ft)
P0025015
14 Install the fan ring.
P0025017
298 47705010 03-2018 © AB VOLVO PENTA

15 Fit the bracket.

Connect the sensor cable.
P0025019
16 Install:
1 Fan guard
2 loading air pipe
3 Belt guard, refer to Belt guard,
change, page 292.
P0025014
47705010 03-2018 © AB VOLVO PENTA 299

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

Change, page 231
1 Remove the turbocharger charge air pipe.
2 Remove the intake pipe.
3 Remove the heat shield.
4 Remove the pipe elbow from the
turbocharger.
5 Remove the rubber bellows from the air
intake with the connecting hose for
crankcase ventilation.
P0019406
2 Remove the right belt guard; refer to Belt guard,

change, page 292.
3 Remove the drive belt according to Drive belt,
change, page 291.
4 Disconnect the alternator cable terminals.
P0019407
300 47705010 03-2018 © AB VOLVO PENTA

32-1 Alternator
P0019408
6 Remove the alternator.
P0019409
47705010 03-2018 © AB VOLVO PENTA 301

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
302 47705010 03-2018 © AB VOLVO PENTA

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

change, page 291
11 Install the right belt guard: refer to Belt guard,
change, page 292.
12 Install components 1-5; refer to Turbo,
Change, page 231.
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.
3 Install the heat shield.
4 Install the inlet pipe.
5 Install the charge air pipe.
P0019412
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
47705010 03-2018 © AB VOLVO PENTA 303

32-1 Alternator
4 Undo the nut with a few short bursts from an

impact wrench.
Remove the belt pulley.
P0020359
304 47705010 03-2018 © AB VOLVO PENTA

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.
47705010 03-2018 © AB VOLVO PENTA 305

33-1 Starter Motor
33-1 Starter Motor

Starter Motor, Change
IMPORTANT!
Removal
1 Unscrew the nut from the starter motor plus
connection.
Move aside the main switch (+) cable (1), the
generator cable (2) and the cable split/fuse holder
(3).
P0020346
P0020347
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33-1 Starter Motor
3 Remove the starter motor.
Installation
4 Install the starter motor.
P0020348
P0020350
6 Install the starter motor cable connections 1-3.

Secure the cables with cable ties after

installation.
P0020349
47705010 03-2018 © AB VOLVO PENTA 307

Index
A Fuel Pre-filter, Change........................................... 159
About this Workshop manual..................................... 3 Fuel System..................................................... 45, 158
AdBlue/DEF Tank, Change.................................... 250 Fuel system, bleeding............................................ 158
AdBlue/DEF Tank, Cleaning.................................. 253 Fuel System, General............................................. 158
AdBlue/DEF-Pump Filter, Change......................... 258 G
Air Cleaner, Throttle Housing................................. 246 Gear Ring, Fywheel: Replace................................ 137
Air compressor, change......................................... 242 General....................................................................... 3
Air throttle, change................................................. 246 General Specifications............................................... 9
Alternator................................................................ 300 General Tightening Torques....................................... 9
Alternator, Change................................................. 300 Group 21: Engine..................................................... 11
B Group 22: Lubrication System.................................. 22
Belt guard, change................................................. 292 Group 23: Fuel System............................................ 25
Group 25: Inlet and Exhaust System........................ 29
C Group 26: Cooling System....................................... 31
Camshaft, change.................................................. 113 Group 30: Electrical System..................................... 33
Camshaft, Wear Check.......................................... 124
Checking for diesel or oil in the AdBlue/DEF H
solution................................................................... 265 High-pressure pump gear wheel, change.............. 182
Checking urea concentration in the fluid................ 266 High-Pressure Pump, Change....................... 166, 173
Combined Tank Unit, AdBlue/DEF Tank, Change. 263 I
Common Rail, Change........................................... 196 Illustrations................................................................. 6
Coolant Level, Checking and Topping Up.............. 267 Injector, Change..................................................... 188
Coolant Pump, Change.......................................... 277 Injectors and Delivery Pipes................................... 188
Coolant Pump, Thermostat.................................... 277 Inlet and Exhaust Manifolds................................... 210
Coolant, Change.................................................... 269 Inlet and Exhaust System................................. 46, 210
Cooler e-EGR, change................................... 220, 224 Intake Manifold, Change........................................ 210
Cooler e-EGR, Cleaning......................................... 228 L
Cooler e-EGR, pressure testing............................. 227 Lower valve cover, change................................. 93, 96
Cooling System................................................ 46, 267 Lubrication Oil Pump, Change............................... 147
Cooling System, General....................................... 267 Lubrication System................................................... 45
Crankshaft Seal, Change (front)............................. 138
Crankshaft Seal, Change (rear)............................. 143 M
Cylinder Head........................................................... 75 Miscellaneous......................................................... 207
Cylinder Head, Change............................................ 75 MPROP valve, high-pressure pump, change......... 184
D O
Dosing unit, change................................................ 256 Oil cooler................................................................ 156
Drive belt, change.................................................. 291 Oil Cooler, Replace................................................ 156
Oil filter................................................................... 149
E Oil Filter Housing, Change..................................... 151
Electrically Heated AdBlue/DEF Hose, Change..... 249 Oil filter, Change..................................................... 149
Emission After-Treatment....................................... 248 Oil pump and Line.................................................. 147
Emission Control, Catalytic Converter.................... 219
Engine................................................................ 35, 55 P
Engine Assembly...................................................... 65 Pressure Limiting Valve, Change........................... 207
Engine Complete, General....................................... 55 Pulley, alternator, change....................................... 303
Engine Disassembly................................................. 58 Pump Unit, Change................................................ 261
Exhaust Manifold, Change..................................... 216 R
Exhaust Temperature Sensor, Change.................. 255 Radiator Assembly, Change .................................. 271
F Radiator, Heat Exchanger...................................... 271
Fan, Fan Shroud.................................................... 294 Repair instructions.............................................. 4, 248
Fitting the Fixture...................................................... 55 S
Flank Clearance, Checking.................................... 117 Safety Information.................................................... 47
Flywheel cover, change.......................................... 129 Safety Instructions.................................................... 47
Flywheel, Change................................................... 125 Solenoid Valve, AdBlue/DEF Tank, Change.......... 260
Fuel Feed Pump and Filter..................................... 159 Special Service Tools............................................... 51
Fuel filter housing, change..................................... 163 Special Tightening Torques...................................... 11
Fuel filter, Change.................................................. 162 Specifications, Engine ............................................. 11
Fuel Injection Pipe, Change................................... 204 Starter Motor.......................................................... 306
Fuel Pre-filter, Bleeding.......................................... 161 Starter Motor, Change............................................ 306
47705010 03-2018 © AB VOLVO PENTA 309

T
Thermostat, Change............................................... 288
Timing Gear, Installation........................................ 121
Timing Gear, Removal........................................... 119
Timing Gears and Shaft......................................... 113
Turbo and supercharger......................................... 230
Turbo, Change....................................................... 231
Turbocharger, Inspection....................................... 230
U
Upper valve cover, change................................. 87, 90
V
Valve Guides, Inspection........................................ 108
Valve Mechanism................................................... 100
Valves, Adjustment................................................. 100
Valves, Installation................................................. 111
Valves, Removal.................................................... 109
VGT actuator, check............................................... 245
Visco fan, replace................................................... 294
310
References to Service Bulletins
Group No. Date Refers to
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311
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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:.........................................................................
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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 03-2018

Volvotad 850 Workshop Manual

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Workshop Manual

Safety and Other Instructions

Lubricating and Oil System

Inlet and Exhaust System

Alternator, Charge Regulator

47705010 03-2018 © AB VOLVO PENTA 1

2 47705010 03-2018 © AB VOLVO PENTA

Volvo Penta accepts no responsibility for damage or

47705010 03-2018 © AB VOLVO PENTA 3

4 47705010 03-2018 © AB VOLVO PENTA

Lock nuts Anaerobic agents.

Strength Classes Safety regulations for fluorocarbon

Sealing compounds etc. WARNING!

In each service manual section concerned, the WARNING!

47705010 03-2018 © AB VOLVO PENTA 5

Illustration colors Position

Focus arrows pointing at object. Sometimes it

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

4 Background This symbol gives a positioning number to an object,

The symbol in the top left shows part no. of the

6 47705010 03-2018 © AB VOLVO PENTA

Movement arrows are used to show which direction a P0015629

component is to be moved / rotated.

Symbol is used in a corner of the illustration to show

A symbol of a tool in a corner of the illustration is

Symbol is used to show how many revolutions the

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

The symbols are used to show different types of

47705010 03-2018 © AB VOLVO PENTA 7

Symbols can also describe when and how a chemical

The scraper symbol suggests that a contact surface P0015005

8 47705010 03-2018 © AB VOLVO PENTA

03-0 General Specifications

47705010 03-2018 © AB VOLVO PENTA 9

10 47705010 03-2018 © AB VOLVO PENTA

03-2 Specifications, Engine

Group 21: Engine

Tightening torque: 60 Nm (44.2 lbf. ft.)

Tightening torque: 60 Nm (44.2 lbf. ft.)

Tightening torque: 75 Nm (55.3 lbf. ft.)

47705010 03-2018 © AB VOLVO PENTA 11

12 47705010 03-2018 © AB VOLVO PENTA

1 Drive gear, camshaft

47705010 03-2018 © AB VOLVO PENTA 13

Flywheel and timing cover

Flywheel and timing cover

Tighten the bolts in sequence.

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

14 47705010 03-2018 © AB VOLVO PENTA

Vibration damper, crankshaft

47705010 03-2018 © AB VOLVO PENTA 15

Cover, crankshaft seal

NOTICE! Apply an approximately 2 mm (0.079”)

Fasten the cover with bolts 2 and 7.

16 47705010 03-2018 © AB VOLVO PENTA

NOTICE! Attach the cylinder head as per section

47705010 03-2018 © AB VOLVO PENTA 17

Tighten bolts 1-18 in sequence.

18 47705010 03-2018 © AB VOLVO PENTA

Bearing caps, camshaft

Tighten the bolts 1-6 in sequence.

47705010 03-2018 © AB VOLVO PENTA 19

Tighten the bolts in sequence.

20 47705010 03-2018 © AB VOLVO PENTA