Workshop Manual: Group 21-26

Workshop Manual
Group 21-26

D3-D/E/F/G/H
Table of Content
General Information
00-0 General ............................................................................................. 3
Specifications
03-0 General Specifications ................................................................... 9
03-2 Specifications, Engine .................................................................. 10
Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 15
Special tools
08-2 Special Service Tools ................................................................... 20
General
20-0 Engine Information, General ........................................................ 22
Design and Function ......................................................................... 24
Troubleshooting ................................................................................. 28
Engine
21-0 Engine Complete, General ........................................................... 30
Engine Assembly ............................................................................... 53
21-1 Cylinder Head ................................................................................ 55
21-5 Timing Gears and Shaft ................................................................ 83
21-6 Crank Mechanism ......................................................................... 92
Lubricating and Oil System

22-0 Lubricating and Oil System, General .......................................... 99
22-1 Oil pump and Line ....................................................................... 101
22-3 Oil cooler ..................................................................................... 103
Fuel System
23-3 Fuel Feed Pump and Filter ......................................................... 104
23-6 Injection Pump, Regulator ......................................................... 111
23-7 Injectors and Delivery Pipes ...................................................... 114
Inlet and Exhaust System

25-1 Inlet and Exhaust Manifolds ...................................................... 124
25-5 Turbo and supercharger ............................................................ 128
25-6 Air Cleaner, Throttle Housing .................................................... 140
Cooling System
26-0 Cooling System, General ........................................................... 141
26-1 Radiator, Heat Exchanger .......................................................... 143
26-2 Coolant Pump, Thermostat ........................................................ 148
26-5 Charge Air Cooler with Connections ........................................ 152
26-6 Sea Water System, Sea Water Pump ........................................ 157
Alternator, Charge Regulator

32-1 Alternator ..................................................................................... 161
Starting System
33-1 Starter Motor ............................................................................... 163
Other Electrical Equipment

36-6 Monitoring and Control Systems .............................................. 165
47702022 04-2019 © AB VOLVO PENTA 1

Cables and fuses
37-1 Cables .......................................................................................... 166
Instruments
38-6 Sensors for Indicator and Warning System ............................. 174
Steering
64-5 Power Steering ............................................................................ 180
Index ......................................................................................................... 183
References to Service Bulletins ............................................................ 185
2 47702022 04-2019 © 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.
47702022 04-2019 © 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 holding fixture. Maintenance work is technical specification may dramatically increase the
often carried out on site, 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.
! DANGER! Some systems, e.g. fuel systems, often require
special expertise and test equipment. A number of
! WARNING! components are factory-sealed, for among other
things environmental reasons. Warranty-sealed
! CAUTION!
components may not be worked on without
authorization to perform such work.
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remember that most chemical products, incorrectly
can be foreseen as service work is carried out in the used, are harmful to the environment. Volvo Penta
most varied of circumstances. We call attention to recommends the use of biodegradable degreasers
risks that may occur due to incorrect handling during whenever components are cleaned, unless otherwise
work in a well-equipped workshop using working specified in the Service Manual. When working
methods and tools tried and tested by us. outdoors, take especial care to ensure that oils and
wash residues etc. are correctly properly for
The service manual describes work operations
destruction.
carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta
Special Tools are designed to ensure the safest and
Tightening torques
most rational working methods possible. It is Tightening torques for vital fasteners that must be
therefore the responsibility of anyone using tools or applied using a torque wrench are indicated in the
working methods other than those we recommend to Service Manual, chapter Tightening torques and in
ensure that no risk of personal injury or mechanical the Manual's work descriptions. All torque indications
damage is present, or that malfunction can result. apply to clean threads, bolt heads and mating faces.
Indicated torque data apply to lightly-oiled or dry
In some cases, special safety regulations and user threads. If lubricants, locking fluids or sealants are
instructions may be in force for the tools and required for fasteners, the correct type will be noted
chemicals mentioned in the Service Manual. These in the job description.
regulations must always be followed, and no special
instructions regarding this are to be found in the
Torque, angle tightening
Service Manual.
When torque/angle tightening, the fastener is
By taking these basic precautions and using common tightened to a specified torque, and tightening then
sense it will be possible to guard against most continues through a pre-determined angle.
elements of risk. A clean workplace and a clean
product will eliminate many risks of personal injury Example: For 90° angle tightening, the fastener is
and malfunction. turned a further 1/4 turn in one sequence, after 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 47702022 04-2019 © AB VOLVO PENTA

00-0 General
Lock nuts Anaerobic agents.

These agents cure (harden) in the absence of air.
Removed locknuts may not be re-used; they must be These preparations are used when two solid
replaced by new ones, as locking properties are components, e.g. two cast components, are fitted
impaired or lost with re-use. together without a gasket. Common uses are also to
In the case of lock nuts with plastic inserts the lock and seal plugs, stud threads, taps, oil pressure
tightening torque indicated must be reduced if the nut monitors etc.
has the same nut height as a standard, all-metal
hexagonal nut. Hardened anaerobic preparations are glassy and for
Reduce the torque by 25% for bolt sizes of 8 mm or this reason, the preparations are colored to make
larger. them visible. Hardened anaerobic preparations are
In the case of lock nuts with plastic inserts with a high highly resistant to solvents, and old compound
nut-height (where the all-metal thread is as high as a cannot be removed. On re-assembly, it is important
standard hexagonal nut), the indicated torque to carefully degrease and wipe dry components first,
applies. before applying new sealant in accordance with the
instructions.
Strength classes
Safety regulations for fluorocarbon
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking on rubber
the bolt head. Markings of a higher number indicate Fluorocarbon rubber is a common material in sealing
stronger material. For example, a bolt marked 10-9 is rings for shafts, and in O-rings, for example.
stronger than one marked 8-8.
When fluorocarbon rubber is exposed to high
For this reason, it is important that when bolts are temperatures (above 300°C/572°F), hydrofluoric acid
removed they are returned to their original locations can form. This is highly corrosive. Contact with the
on re-assembly. When replacing bolts check the skin can result in severe chemical burns. Splashes in
applicable Spare parts catalogue to ensure the your eyes can result in chemical wounds. If you
correct bolt is used. breathe in the fumes, your lungs can be permanently
damaged.
Sealing compounds etc.
To ensure service work is correctly carried out it is WARNING!
important that the correct type of sealants and locking Seals must never be cut with a torch, or be burnt
fluids are used on joints where such are required. afterwards in an uncontrolled manner. Risk for
poisonous gases.
In each service manual section concerned, the
sealants used in product manufacture are indicated. WARNING!
The same sealants, or sealants with equivalent Always use chloroprene rubber gloves (gloves for
properties, must be used for maintenance work. chemicals handling) and goggles. Handle the
removed seal in the same way as corrosive acid. All
Make sure that mating surfaces are dry and free from residue, including ash, can be highly corrosive. Never
oil, grease, paint and anti-corrosion agent before use compressed air to blow clean.
applying sealant or locking fluid. Always follow the Put the remains in a plastic container, seal it and
manufacturer's instructions regarding applicable apply a warning label. Wash the gloves under running
temperatures, hardening times and such. water before removing them.
Two basic types of compound are used: The following seals are most probably made from
RTV preparations (Room Temperature fluorocarbon rubber:
Vulcanizing). Seal rings for the crankshaft, camshaft, idler shafts.
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV O-rings, regardless of where they are installed. O-
sealants are completely visible when the part has rings for cylinder liner sealing are almost always
been removed. Old RTV sealant must be removed made of fluorocarbon rubber.
before the component is sealed again. Use
denatured alcohol. Please note that seals which have not been
exposed to high temperature can be handled
normally.
47702022 04-2019 © AB VOLVO PENTA 5

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

systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.
6 47702022 04-2019 © 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.
47702022 04-2019 © AB VOLVO PENTA 7

00-0 General
Illustrations
Colors used in illustrations

1 Highlighted components
Most illustrations include a highlighted component
(blue)
which is secured by a bolt or similar as part of a (light
gray) engine or transmission. 2 Fastener
(red)
3 Assembly
(light gray)
4 Background
(white)
5 Special Tools
(yellow)
6 Seals
(green)
(as of 06/2018)
P0022106
Other types of symbols used in the images are

divided into the following categories:
• Safety
• Important
• Cleanliness
• Position
• Movement
• Measured value
• Tools
• Chemicals
• Sealant
• Units
8 47702022 04-2019 © AB VOLVO PENTA

03-0 General Specifications
03-0 General Specifications

General Tightening Torques
General Tightening Torques
M6 10 Nm
M8 24 Nm
M10 48 Nm
M12 85 Nm
M14 140 Nm
M16 220 Nm
IMPORTANT!
Check screws which are to be re-installed. Damaged bolts
with e.g. shear marks under the heads, must be scrapped.
47702022 04-2019 © AB VOLVO PENTA 9

03-2 Specifications, Engine

Technical Data
Engine, General
Inboard Aquamatic
D3-110 I D3-150 I D3-170 I D3-200 I D3-220 I D3-140 D3-170 D3-200 D3-220
No. of 5
cylinders
No. of valves 20
Displacement 2.4 l (0.63 US gallon)
Firing 1–2–4–5–3
sequence
Bore 81 mm (3.19")
Stroke 93.2 mm (3.67")
Compression 16,5:1
ratio
Idling speed 700 + 50 rpm
Engine power 81 kW 110 kW 125 kW 147 kW 162 kW 98 kW 125 kW 147 kW 162 kW
(110 hp) (150 hp) (170 hp) (200 hp) (220 hp) (133 hp) (170 hp) (200 hp) (220 hp)
High idle 3000 rpm 4000 rpm
Rating 5
Transmission HS25 HS45 SX / DPS DPS
10 47702022 04-2019 © AB VOLVO PENTA

Group 21: Engine
Main bearing classes

A template for identification is available in the
workshop manual to make sure that correct bearings
are used within the engine overhaul procedure.
Cylinder head / cylinder block

IMPORTANT!
Neither the cylinder head nor the cylinder block may be
machined.
P0010768
Bore
C-marked 81.00–81.01 mm
(3.18897-3.18936")
D-marked 81.01–81.02 mm
(3.18936-3.18975")
E-marked 81.02–81.03 mm
(3.18975-3.19015")
Cylinder head gasket

Classification Hole marking
1 5
2 4, 5
3 3, 4, 5
4 2, 3, 4, 5
5 1, 5
NOTICE! Hole A and B are only used to identify engine

type and will therefore not affect the classification.
P0015855
Classification
The following classification measurements for the
cylinder head gasket are to be used if the cylinder block
has been replaced.
To measure. see Cylinder Head, Change, page 55.
Dist., block surface- piston (TDC) Classification

0.26-0.47 mm (0.0102-0.0185") 1
0.47-0.52 mm (0.0185-0.0205") 2
0.52-0.57 mm (0.0205-0.0224") 3
0.57-0.62 mm (0.0224-0.0244") 4
0.62-0.74 mm (0.0244-0.0291") 5
P0015856
47702022 04-2019 © AB VOLVO PENTA 11

Pistons
Piston class is stamped on top of the piston.
As standard the diameter is measured 12 mm (0.47")

above the piston lower end.
C-marked (1) 80.95–80.96 mm

(3.18700-3.18739")
D-marked (1) 80.96–80.97 mm
(3.18739-3.18779")
E-marked (1) 80.97–80.98 mm
P0010770 (3.18779-3.18818")
Piston rings
Thickness Clearance
Top ring 2.0 mm -0.01–0.03 mm
(0.0787") (-0.0004–0.0012")
First ring 1.75 mm -0.01–0.03 mm
(0.0689") (-0.0004–0.0012")
Oil ring 2.0 mm -0.01–0.03 mm
(0.0787") (-0.0004–0.0012")
Piston pin
Diameter 24.985-25.0 mm
(0.9837-0.9842")
Length 66.0-66.3 mm
(2.5984-2.6102")
Valves
Inlet Exhaust
Length (A) 98.1 ±0.07 mm 97.7 ±0.15 mm
(3.862 ±0.0028") (3.846 ±0.0059")
Plate diameter 28.0 ±0.1 mm 26.2 ±0.1 mm
(B) (1.102 ±0.0039") (1.031 ±0.0039")
Shaft diameter 5.975 ±0.015 5.975 +0/-0.015
(C) mm mm
(0.235 ±0.0006") (0.235
+0/-0.0006")
Valve angle (D) 45.0 ±0.5° 45.0 +0.5/-0°
Crankshaft
Axial clearance* 0.11-0.30 mm (0.0043-0.0118")
P0010771
* To be measured with the cylinder block assembled.
Con rods
Diameter, big end 53 mm (2.09")
Diameter, small end 30 mm (1.18")
Length between centre of the ends 147 mm (5.79")
12 47702022 04-2019 © AB VOLVO PENTA

Group 22: Lubrication System

Max. oil level with oil filter 6.3 l (1.66 US gallon)
Max. oil level without oil filter 5.8 l (1.53 US gallon)
Oil pressure at D3-D/E/F/G D3-H →

Engine start 0.55-0.60 MPa (80-87 psi) 0.40-0.60 MPa (58-87 psi)
700 rpm 0.35-0.45 MPa (51-65 psi) 0.35-0.50 MPa (51-73 psi)
Valid oil pressure at a water temperature of 15 °C (59 °F) and an oil temperature of 20 °C (68 °F) at engine start.
Run engine on each rpm for five minutes to stabilize and then on 4000 rpm until normal running temperature,
115 ±10 °C (239 ±18 °F), has been reached.
Group 23: Fuel System

EDC, type Bosch EDC17
Fuel feed pump, type Electric
High pressure pump, type Bosch CP 4.2
Injectors, type Bosch CRI 3.2
When measuring injector return volume: 3000 rpm for 3 minutes. Max volume difference between injectors,
+/-20%.
Group 25: Inlet and Exhaust System

Inboard Aquamatic
D3-110 I D3-150 I D3-170 I D3-200 I D3-220 I D3-140 D3-170 D3-200 D3-220
Charge air pressure, kPa (psi)
1200 rpm 128 127 126 126 127 127 126 126 127
(18.56) (18.42) (18.27) (18.27) (18.42) (18.42) (18.27) (18.27) (18.42)
2000 rpm 199 229 230 229 230 198 230 229 230
(28.86) (33.21) (33.36) (33.21) (33.36) (28.72) (33.36) (33.21) (33.36)
2800 rpm 198 235 249 243 270 206 249 243 270
(28.72) (34.08) (36.11) (35.24) (39.16) (39.16) (36.11) (35.24) (39.16)
4000 rpm – – 239 250 274 203 239 250 274
(34.66) (36.26) (39.74) (29.44) (34.66) (36.26) (39.74)
Group 26: Cooling System

Thermostat, opens at 80 °C (176 °)
Thermostat, fully open at 94 °C (201.2 °)
Coolant volume, incl. heat exchanger 8,7 l (2.3 US gallon)
Heat exchanger Seawater cooled
Seawater pump Rubber impeller
47702022 04-2019 © AB VOLVO PENTA 13

Group 30: Electrical System

Only SOLAS engines
Use grease (part no. 1161277) when installing the
sensor for air inlet pressure / intake manifold
temperature.
NOTICE! Do not apply grease on the sealing ring.
P0022591
14 47702022 04-2019 © AB VOLVO PENTA

05-1 Safety Instructions

Safety Information
This workshop manual contains repair instructions,
descriptions and technical data for products or product
drawings from Volvo Penta. Check that you have the
correct workshop manual.
Read the safety information below and the section About this Workshop manual and Repair instructions
carefully before beginning any work with repairs or service.
!
In the workshop manual and on the product, this symbol is used to call your attention to the fact that this is safety
information. Always read such information very carefully.
Warning texts in the manual have the following order of priority:
DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.
WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious personal injury.
CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate personal injury.
IMPORTANT!
Is used to make you aware of something that may cause minor damage or a minor malfunction to the product or
property.
NOTICE! Is used to make you aware of important information that will facilitate the work or operation in progress.
This symbol is used on certain functions to indicate the following:

This operation requires prior theoretical and/or instructor led training before attempting.Contact your local training
organization for further information.
This symbol informs you that supplemental information needs to be read. And where necessary information can
be found.
This symbol is used when a VODIA computer is needed, either for troubleshooting, testing or programming.
A compilation of safety precautions that must be taken and risks which you must be aware of is presented
in the following pages.
47702022 04-2019 © AB VOLVO PENTA 15

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply with the main switch(es) and lock it ! engine is hot. Steam or hot coolant may spray
(them) in the off position before starting work. out and the system can lose pressure. Open the
Place a warning notice at the main switch. filler cap slowly, and release the pressure in the
cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed while the engine is hot.
As a general rule, all service operations must be Hot oil can cause burn injuries. Avoid exposing
! carried out with the motor stopped. However, ! your skin to hot oil. Make sure that the
some work, such as adjustments, will require lubrication system is not under pressure before
the engine to be running. Approaching a any work is begun. Never start or run an engine
running engine is a safety risk. Remember that without the oil filler cap in place. Hot oil under
loose clothing and long hair can fasten in pressure can spray out.
rotating parts and cause serious personal
injury.
Be aware of hot surfaces (exhaust pipes, Never start the engine without the air filter in
! turbocharger, charge air pipe, starting heaters, ! place. The rotating compressor turbine in the
etc.) and hot liquids in supply lines and hoses turbocharger can cause severe injury. Foreign
on an engine that is running or has just stopped. objects entering the intake ducts can also cause
A careless movement or a dropped tool may, in mechanical damage. Install all protective
the worst case, result in personal injury when covers before starting the engine.
working in the vicinity of a running engine.
Make sure that all warning and information Only start the engine if the surrounding
! decals on the product are always visible. ! ventilation is satisfactory. When operating in a
Replace decals that have been damaged or confined space, exhaust fumes and crankcase
painted over. gases must be led away from the engine
compartment or workshop area.
Avoid getting oil on the skin! Protracted or The majority of chemicals, e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. Used oil is such as degreasing agents, paints and
more dangerous than fresh oil from a health solvents, are health hazards. Carefully read the
aspect. Use protective gloves and avoid oil- instructions on the product packaging! Always
soaked clothes and rags. Wash regularly, follow the safety directions for a product, e.g.
especially before eating. Use suitable with regard to use of protective mask, glasses,
protective creams to counteract skin dryness gloves, etc. Make sure that other personnel are
and to aid dirt removal. not exposed to substances that are health
hazards. Ensure good ventilation. Handle used
and leftover chemicals in the prescribed
manner.
Turn off the engine and disconnect the power at Only make connection adjustments with the
! the main switch(es) before starting work on the ! engine switched off.
electrical system.
16 47702022 04-2019 © AB VOLVO PENTA

Always wear protective goggles if there is a risk Never start the engine with the valve cover
! of splinters, sparks and splashes from acid or ! removed. There is a risk of personal injury.
other chemicals. Your eyes are extremely
sensitive, injury to them could result in
blindness!
Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the seacock/cooling
water inlet valve before starting work on the
cooling system.
All fuels, and many chemicals, are flammable. Make sure that rags soaked in oil or fuel and
! Never allow open flames or electrical sparks in ! used fuel and oil filters are stored safely. Oil-
the their vicinity. Gasoline, certain solvents and soaked rags may ignite spontaneously in
hydrogen from batteries are extremely certain conditions. Used fuel and oil filters are
flammable and explosive in the right environmentally hazardous waste and must be
concentration in air. No smoking! Ensure the taken to an approved waste management
work area is well ventilated and take the facility for correct handling, as must any used
necessary safety precautions before welding or lubricating oil, contaminated fuel, paint residue,
grinding work is begun. Always ensure that solvents, degreasers and wash residue.
there are fire extinguishers close at hand in the
work area.
Batteries must never be exposed to open Never work alone when dismantling heavy
! flames or electrical sparks. Never smoke in the ! components, even when using lifting equipment
vicinity of the batteries. During charging they such as lifting devices with lockable blocks. Two
generate hydrogen gas, which is explosive people are usually required when using a lifting
when mixed with air. This gas mixture is easily device; one to operate the lifting device and the
ignited and highly explosive. A spark, which can other to make sure the components do not
be caused by incorrect battery connection, is collide with objects and suffer damage during
enough to cause the battery to explode and the hoist.
cause serious damage.
Do not touch the connections during a starting

attempt. Spark hazard! Do not lean over
batteries.
Never mistake the positive (+) for the negative Use the loops on the engine when lifting it.
! (-) battery pole when installing batteries. ! Always check that the hoisting equipment is in
Incorrect pole connections can result in serious good condition and has the capacity to lift the
damage to electrical equipment. Refer to the engine (engine weight including gearbox and
wiring diagram. any auxiliary equipment installed). The engine
Always wear protective goggles when charging must be lifted with a properly adjusted lifting
or handling the batteries. The battery electrolyte boom to ensure safe handling and avoid
contains sulfuric acid which is highly corrosive. damage to components fitted to the top of the
Rinse immediately with plenty of water and engine. All chains or wires must run parallel to
soap if battery electrolyte comes into contact each other and be as perpendicular to the
with unprotected skin. If you get battery acid in engine as possible. If the engine has equipment
your eyes, flush at once with a generous fitted that alters its center of gravity, special
amount of water, and get medical assistance at lifting devices may be required to achieve the
once. correct balance for safe handling. Never carry
out any work on an engine that is only
suspended by lifting equipment.
47702022 04-2019 © AB VOLVO PENTA 17

The components in the electrical and fuel Take extreme care when searching for fuel
! systems on Volvo Penta products are designed ! system leaks and testing fuel injector nozzles.
and manufactured to minimize the risk of fire Wear safety goggles. The jet from a nozzle is
and explosion. The engine must not be under very high pressure and has great
operated in areas where there are explosive penetration power. Fuel can penetrate deep
materials or gases. into body tissue and cause severe injury. There
is a risk of blood poisoning (septicemia).
Only use fuels and lubricating oils as Never use a high-pressure washer to clean the
! recommended by Volvo Penta. Refer to the ! engine.
operator's manual for the product concerned. Pay attention to the following when using a high-
Using fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never aim the water jet at seals,
injectors. In the case of diesel engines, low- rubber hoses or electrical components.
quality fuel may cause the control rod to stick
and the engine to overrev with the risk of engine
damage and personal injury as a result. Low-
quality fuel and oils may lead to higher service,
maintenance and repair costs.
Under no circumstances may fuel pipes be bent When overhauling an engine, perform leakage
! or straightened. Cracks may occur. Damaged ! and functional checks as necessary.
pipes must be replaced.
18 47702022 04-2019 © AB VOLVO PENTA

47702022 04-2019 © AB VOLVO PENTA 19

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools may be ordered from AB Volvo
Penta by specifying the number indicated.
P0002943 P0002937
885050 Fixture 885490 Sleeve 885511 Roller
P0006821
P0007588 P0007589
885531 Pressure testing kit 885536 Plug 885539 Plug
P0002930 P0007816
885633 Torque multiplier 885819 Counterhold 885820 Puller
-60
-40
-80
-20
-100
P0001875 P0002942
1158688 Torque wrench 9989876 Dial indicator 9990150 Manometer
P0007808 p0014391
9995192 Gauge rod 9995199 Drift 9995270 Pressure gauge
20 47702022 04-2019 © AB VOLVO PENTA

P0011954
9995455 Mounting tool 21433378 Nipple 9995747 Protective sleeve
P0004331
P0007809 P0002947
9995919 Extractor 9996398 Manometer 9996400 Slide hammer

P0004333
P0014392 p0014393
9996666 Nipple 9997005 Rotation tool 9997007 Lock pin
P0014451 p0014394
9997009 Brush 9997174 Mounting tool 9997217 Wrench
9997352 Adapter 9997353 Slide hammer 9997451 Mounting tool

P0004348
P0004580
9998007 Adapter 9998493 Hose 9995678 Guide sleeve
22701079 Guide sleeve
47702022 04-2019 © AB VOLVO PENTA 21

20-0 Engine Information, General

Lifting the Engine, Actions
Before lifting the engine

Boat removed from the water
1 Turn the main switch off. Undo the battery
connections to the engine.
2 Disconnect the harness terminals for the
secondary fuel filter and the trim pump. Undo the
throttle cable from the engine control unit.
Remove the box containing the engine control
unit from the bulkhead. Remove the ground cable
from the shield.
3 Remove the seawater connection.
4 Remove the exhaust pipe (baffle).
5 Aquamatic only
Drain the power steering system hydraulic oil via
the drain valve under the system oil cooler. Undo
the hydraulic connections on the steering
cylinder. Remove the power steering oil reservoir.
6 Close the fuel taps. Remove the fuel connections.
7 Disconnect the drive at the shield (if an AQ is
fitted) or disconnect the propeller shaft at the
reverse gear (inboard).
8 Undo the engine mounts from the beds and the
flywheel housing. Lift out the engine.
Actions after lifting the engine

1 Clean the engine.
IMPORTANT!
Do not use a power washer. There is a risk that
the engine components are subjected to
waterlogging.
2 Pump out the engine oil (as necessary).
22 47702022 04-2019 © AB VOLVO PENTA

Actions before working in boat

1 Switch off the current at the main switch and
check that the engine is without power.
2 Clean the outside of the engine.
NOTICE! Make sure that wash residue is

collected for disposal and does not inadvertently
end up in the environment.
3 The work includes the following actions on the
cooling system: Close the sea cocks and drain
the coolant from the seawater and fresh water
systems.
IMPORTANT!
Make sure that all seawater inlets are securely
closed so that water cannot enter the boat during
removal of cooling system sub-components.
47702022 04-2019 © AB VOLVO PENTA 23

Model Identification
There are two ways in which to identify an engine.
- A decal on the engine cover (cold side).
P0010766
- An identification plate riveted to the back of the

engine block (hot side).
P0010767
Design and Function

Group 22: Lubrication System
3 6
2
5
8
P0012383
24 47702022 04-2019 © AB VOLVO PENTA

The oil pump (1) is of the rotor (duo centric) type with Oil from the filter is distributed to the connecting rod
a flow capacity of 69 l/min (18.2 US gallon/min) at bearings via ducts in the main gallery.
4000 rpm and an oil temperature of 100 °C (212 °F),
at a pressure of 3 bar (43.5 psi). Oil is also distributed to the pistons via piston cooling
nozzles (6) below the side gallery.
The oil pump cannot be repaired but must be
exchanged if it becomes defective. The pump inner Pressure is regulated by a valve (5) that opens at
rotor is spline driven directly from the crankshaft. The 1.35 bar (19.6 psi). Oil is led up to the cylinder head,
pump has an internal safety valve that opens at 8 bar the hydraulic valve lifter roller bearings and the
(116.0 psi). camshaft via a vertical duct at the front of the block.
An oil pressure sensor (7) is located in the cylinder
Oil flows from the pump to the water-cooled oil cooler block - engine bed for monitoring.
(2) located on the right side of the oil sump.
A combined oil level/temperature sensor (8) is
The relief valve (3) is located after the oil cooler and installed in the bottom of the oil sump.
maintains oil pressure at a maximum of 5.5 bar
(79.8 psi).
Cooled oil is then fed to the oil filter (4) via an integral
pipe in the lower crankcase/engine bed.
47702022 04-2019 © AB VOLVO PENTA 25

Group 23: Fuel System
P0012207
CAUTION! The new Piezo injectors (7) are supplied from the fuel
Never disconnect a fuel line or component after the rail. One big difference compared to previous systems
fuel pump to bleed. The fuel is under very high is that the injectors have fuel pressure on the leak-off
pressure and can penetrate the skin. side.
Do not try to measure any pressure without checking *The PCV valve replaces the old security relief valve
the workshop manual! and it's main function is to stabilise the hp pressure in
the fuel rail.
The electrical feed pump (3) is controlled by the EDC It controls and manages the pressure together with
17 (1) . Fuel is sucked from the fuel tank through the the M-prop valve especially at engine deceleration.
pre-filter to the feed pump, the feed pump increases The PCV valve is fully open when it is not energised
the fuel feed pressure to approx 4 bars (p-norm 3,8 – (No Current).
4,2 bar).
This type of system is called Coupled Pressure
The fuel is then pumped through the fine filter (4) Control (CPC).
before it enter the High Pressure pump (5).
A magnetic proportional valve is mounted in the Hp

pump to regulate the expected output pressure to the
fuel rail (6).
The fuel rail is equipped with one fuel pressure sensor

(9) and one Pressure Control Valve (8)*.
26 47702022 04-2019 © AB VOLVO PENTA

Group 26: Cooling System
P0011256
The engine is fresh water cooled and Volvo type 90 Freshwater circuit
coolant must be used. The turbocharger is not water Coolant enters the engine at the front and cools the
cooled but has instead a protective cover to prevent engine block via transverse channels. The coolant is
turbocharger heat from presenting a hazard. discharged at the left rear. If coolant is still cold it
The oil is cooled by an oil cooler located at the lower, passes the thermostat directly back to the circulating
front right on the oil pan. pump and enters the engine block again. The oil
cooler is located parallel with the main return line and
Oil temperature is maintained at the correct level by
does not have a separate thermostat on the water
means of an oil thermostat. Refer to Group 22:
side. Refer to oil cooling in Group 22: Lubrication
Lubrication System, page 24.
System, page 24.
The engine has a power steering (accessory) cooler
at the rear. The exhaust manifold has its own connection at the
rear right where coolant is led through the exhaust
Seawater circuit
manifold and on to the main return line.
Seawater is drawn in by the seawater pump on the If the coolant is too hot the thermostat opens and
right side of the engine and lead through a seawater coolant is led through the heat exchanger where it is
filter before reaching the charge air cooler. After the cooled. It is then drawn into the circulating pump and
charge air cooler it passes the power steering returns to the engine block. There is an expansion
(accessory) cooler at the rear of the engine. The water tank at the front of the engine where expanded
is then led to the heat exchanger on the left side of the coolant and air are collected.
engine. The engine has three venting points: 1. Heat
Finally, seawater passes through the exhaust elbow exchanger, 2. Cylinder head (rear) and 3. Exhaust
where it cools exhaust gases and is discharged. Manifold.
47702022 04-2019 © AB VOLVO PENTA 27

Troubleshooting
Start / stop, symptoms
Engine doesn't start, starter motor is engaged 1
Engine doesn't start, starter motor doesn't engage 2
Engine starts then stops 3
Engine stopped during normal operation 4
Engine starts but does not stop 5
Performance and comfort, symptoms

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

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

Engine oil pressure low at idle 13
Engine oil pressure low at normal operation 14
High oil consumption 15
1 Check: 3 Check:
- Air inlet and air filter - For air in the fuel system
- Fuel feed, from tank to engine (incl. filter) - Fuel feed, from tank to engine (incl. filter)
- Stop device (control and solenoid) - Air inlet and air filter
- Fuel quality and water content - Regulator, injection pump and stop device
for function
2 Check: - Fuel quality and water contentl
- Voltage at the starter motor (during start)
4 Check:
- Voltage at switch (“50”) on the starter motor
- For air in the fuel system
- The engine can be turned by hand
- Fuel feed, from tank to engine (incl. filter)
- Starter motor
28 47702022 04-2019 © AB VOLVO PENTA

5 Check: 11 Check:
- Stop device (wire and solenoid) - Low coolant level
- Pressure cap on expansion tank
6 Check:
- Seawater intake, filter and hoses
- Hull and propellers for fouling and damage
- Impeller
- Boat weight
- Exhaust pipe for corrosion and leaks
- Fuel feed
- Thermostat
- Air inlet and air filter
- Heat exchanger
- Alternator charging capacity
- Too high engine oil level 12 Check:
- Turbo - Leakage hoses and clamps
- Timing, camshaft - crankshaft - Pressure cap on expansion tank
- Hot water connections
7 Check:
- Pressure test the cooling system
- Air inlet and air filter
- Engine Oil Level 13 Check:
- That the engine does run on all cylinders - Idling speed
- Timing, camshaft - crankshaft - Engine Oil Level
8 Check: - Oil quality (viscosity, fuel concentration)
- Engine oil, level and consumption - Pressure sensor (verify using a pressure
- Coolant, level and consumption gauge)
9 Check:
- Flexible engine mounting
14 Check:
- Idling speed is not too low
- Engine Oil Level
- Propeller and propeller shaft deformity
- Oil quality (viscosity, fuel concentration)
- That the engine does run on all cylinders
- Pressure sensor (verify using a pressure
gauge)
10 Check: 15 Check:
- Thermostat - Leakage hoses and clamps
- Too low load on the engine - Crankcase ventilation function
- Too high heat exchange from cooling water - Oil quality (viscosity)
outlet (for example, water heaters)
47702022 04-2019 © AB VOLVO PENTA 29

21-0 Engine Complete, General

Engine, Overhaul
Tools:
885224 Fixture
885820 Puller
9995746 Puller
Removal
Remove the cylinder head according to: Cylinder
Head, Change, page 55.
Remove the rear crankshaft seal according to:
Crankshaft Seal, Change (rear), page 92.
1 Remove the coolant pipe.
2 Remove the oil cooler according to: Oil Cooler,
Replace, page 103.
P0014642
3 Remove the engine mount on the engine hot side.

Tightening torque: M10, 60 Nm (44.3 lbf.ft.)
4 Remove the alternator according to: Alternator,
Change, page 161.
5 Remove the wire harness:
- Flywheel sensor
- B+ cable, starter motor-alternator
- Coolant temperature sensor
- Ground
- Oil level sensor
- Oil pressure sensor
P0014643 - Attachment, oil trap
30 47702022 04-2019 © AB VOLVO PENTA

6 Remove the engine mount on the engine cold

side.
P0014644
7 Fit the attachment. Use 885224 Fixture.

Install the engine in a stand.
P0014645
8 Remove the oil dipstick.

9 Remove the oil pressure sensor according to: Oil
pressure sensor, replace, page 174.
P0014646
47702022 04-2019 © AB VOLVO PENTA 31

10 Remove the distributing pipe.
Early model
When installing an early model with an O-ring,
sealant (part number 1161059) be added to the
flat surface between the O-ring and the channel.
Late model
When installing a late model with a flat gasket,
sealant must not be applied.
P0014647
11 NOTICE! Be prepared to collect fluid.
Remove the crank case ventilation oil trap.

P0014648
12 Remove the timing gear. Use 885820 Puller.

13 D3-D/E/F/G
Remove the oil pump according to: Lubrication
Oil Pump, Change, page 101.
D3-H →
Remove the cover.
14 Remove the seawater pump according to:
Seawater Pump, Change, page 159.
32 47702022 04-2019 © AB VOLVO PENTA

15 Remove the camshaft belt idler wheel.

P0014649
16 Remove the belt guard.

P0014650
47702022 04-2019 © AB VOLVO PENTA 33

17 Remove the crank case ventilation return hose.

Tightening torque: (38 Nm) 28.0 lbf. ft.
P0014651
D3-H →
Remove the pipe.
P0021311
18 Remove the oil sump.
D3-D/E/F/G D3-H →
P0014652 P0021327
34 47702022 04-2019 © AB VOLVO PENTA

19 Remove the suction strainer.
P0014653
20 D3-H →
Push the tensioner back and secure it using a 2
mm drill bit.
P0021312
21 D3-H →
Remove the chain tensioner cover.
P0021313
47702022 04-2019 © AB VOLVO PENTA 35

22 D3-H →
Remove the oil pump and chain.
P0021314
23 D3-H →
Remove the splash guard.
P0021315
24 Rotate the cylinder # 1 piston so that the piston

cooling nozzle is accessible.
Remove the cylinder # 1 piston cooling nozzle.
25 Repeat the above procedural steps for cylinders
2-5.
P0014654
36 47702022 04-2019 © AB VOLVO PENTA

26 NOTICE! Put together the bearing caps with their

respective connecting rods after removal.
IMPORTANT!
Treat contact surfaces with care.
IMPORTANT!
Note the location of components before removal.
Rotate the cylinder # 1 piston so that the bearing

cap is accessible.
Remove the bearing cap from the cylinder # 1
connecting rod.
P0014655
27 IMPORTANT!
Remove the piston together with the connecting

rod. Use 9995746 Puller.
28 Repeat the previous procedure steps for
cylinders 2-5.
P0014656
29 Remove the bolts.
P0014657
47702022 04-2019 © AB VOLVO PENTA 37

P0014658
P0014659
32 Remove the intermediate section.
P0014660
38 47702022 04-2019 © AB VOLVO PENTA

33 Remove the crankshaft bearings from the

intermediate section.
P0014661
34 CAUTION!
Heavy object. Use lifting device when installing or
removing.
Remove the crankshaft.
P0014662
35 Remove the crankshaft bearings from the

cylinder block.
P0014663
47702022 04-2019 © AB VOLVO PENTA 39

36 D3-D/E/F/G
Remove the piston cooling valve.
P0014664
D3-H →
Remove the piston cooling valve.
Tightening torque: 10 Nm (7.4 lbf. ft.)
P0021316
40 47702022 04-2019 © AB VOLVO PENTA

Installation
NOTICE! Make sure that all ducts are cleaned before
starting the installation.
37 D3-D/E/F/G
Install the piston cooling valve.
P0014664
D3-H →
Install the piston cooling valve.
P0021316
38 NOTICE! Always use new bearings.
There is an engine classification marking at the

parting line of the cylinder block/intermediate
section.
1 Classification, cylinder bore

2 Classification, cylinder block
P0014636
47702022 04-2019 © AB VOLVO PENTA 41

39 The crankshaft classification is located on the

crankshaft.
3 Classification, crankshaft
For correctly classified main bearing shells, see
Classification schedule, cylinder block /
crankshaft, page 53.
P0014637
40 IMPORTANT!
Clean the component thoroughly before
installation.
Install the crankshaft bearings in the cylinder

block.
P0014663
41 Apply engine oil to the bearing race.
P0014665
42 47702022 04-2019 © AB VOLVO PENTA

42 CAUTION!
Heavy object. Use lifting device when installing or
removing.
IMPORTANT!
Clean the component thoroughly before
installation.
Install the crankshaft.
P0014662
43 Install the crankshaft bearings in the intermediate

section.
P0014661
P0014665
47702022 04-2019 © AB VOLVO PENTA 43

D3-D/E/F/G
45 NOTICE! Make sure the surface is clean before
application.
NOTICE! Components must be installed within

the specified time after application of sealant.
D3-D/E/F/G
Apply sealant with a thickness of 1.5 mm (0.06")
to the intermediate section. Use sealant part
# 1161059
Install within 5 minutes.
P0014666
D3-H → D3-H →
Apply sealant with a thickness of 1.5 mm (0.06")
to the intermediate section. Use sealant part
# 1161771
P0021317
46 Install the intermediate section.
P0014660
44 47702022 04-2019 © AB VOLVO PENTA

47 IMPORTANT:
Apply locking fluid part # 23284156 to the sleeve.
Tightening torque for intermediate section to

engine block:
Stage 1: (20 Nm) 14.8 lbf. ft.
P0014667
48 Install the bolts.

engine block:
P0014668
49 Install the bolts.

engine block:
P0014669
47702022 04-2019 © AB VOLVO PENTA 45

50 Final tightening, crankshaft section.

engine block:
Stage 5: 110°
P0014667
51 Make sure the piston rings are installed with

120°displacement and that the gaps are not
directly above the piston pin.
P0014670
52 Make sure the piston is installed as illustrated.

Marking X = 1. cylinder bore classification
P0014671
46 47702022 04-2019 © AB VOLVO PENTA

53 Install the connecting rod bearings.
NOTICE! Bearing cups that have a black color

marking on the side must be placed in the
connecting rod.
P0014672
P0014665
55 Crank the crankshaft until cylinder # 1 is at bottom

dead center.
Place the piston in a piston ring compressor.
P0014673
47702022 04-2019 © AB VOLVO PENTA 47

56 Install the piston together with the connecting rod.

Use 9995746 Puller.
P0014674
57 IMPORTANT!
Install the bearing cap for the cylinder # 1

connecting rod.
Tightening torque:
Stage 2: 90°
P0014655
58 Install the cylinder # 1 piston cooling nozzle.

59 Repeat the previous procedure for cylinders 2-5.
P0014654
48 47702022 04-2019 © AB VOLVO PENTA

60 D3-H →
Install the splash guard.
P0021315
61 D3-H →
Install the chain and oil pump.
P0021314
62 D3-H →
Install the chain tensioner and release the spring.
P0021313
47702022 04-2019 © AB VOLVO PENTA 49

63 D3-D/E/F/G
Install the suction strainer.
P0014653
D3-H →
Install the suction strainer.
P0021319
64 D3-D/E/F/G
Install the seal ring.
P0014675
50 47702022 04-2019 © AB VOLVO PENTA

D3-D/E/F/G
application.
NOTICE! Components must be installed within

the specified time after application of sealant.
Apply sealant with a thickness of 2 mm (0.08") to

the intermediate section. Use sealant part
# 1161771
P0014676
D3-H →
P0021320
66 Fit the oil sump.

1 M7, 70 mm (2.76")
2 M7, 40 mm (1.58")
3 M7, 20 mm (0.79")
NOTICE! Align the engine block and oil sump

mating surfaces at the rear before tightening the
sump.
D3-D/E/F/G D3-H →
P0014652 P0021327
47702022 04-2019 © AB VOLVO PENTA 51

67 D3-H →
Install the oil pipe.
P0021321
68 Install in reverse order.
52 47702022 04-2019 © AB VOLVO PENTA

Engine Assembly
Classification schedule, cylinder
block / crankshaft
47702022 04-2019 © AB VOLVO PENTA 53

P0021328
1 Marking, cylinder block The marking is stamped on the engine block

2 Crankshaft, marking intermediate section (1) and crankshaft (2) as
3 Main bearing position, block illustrated. In the diagram, the first letter of the
marking provides a color value for the upper (3) and
4 Main bearing position, intermediate section
lower (4) bearing cups bearing position 1 and the
5 Position, thrust bearing (combined with main second letter provides a color value for bearing
bearing) position 2 etc. Bearing position 1 is at the front of the
engine and bearing position 6 is on the flywheel side
B Blue as illustrated (5).
R Red
Y Yellow
G Green
Rubber mountings
IMPORTANT!
When changing the rubber mountings they need to be
loaded for 24 h before the engine is aligned.
NOTICE! Only the front rubber mountings needs to be

loaded on an AQ installation.
For more information, refer to D3 Installation Manual.
P0018465
54 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
21-1 Cylinder Head

Cylinder Head, Change
Tools:
9989876 Dial indicator
9995192 Gauge rod
9995199 Drift
9995919 Extractor
9997005 Rotation tool
9997007 Lock pin
9997217 Wrench
Actions prior to working in boats; according to: Actions

before working in boat, page 23.
Top cover service position, according to: Top Cover,
Service Position, page 80.
Remove the camshaft belt, according to: Camshaft
Belt, Change, page 84.
Remove the exhaust manifold, according to: Exhaust
Manifold, Change, page 124.
Removal
1 Remove the heat shield.
P0014358
2 Remove the coolant hose between the cylinder

head and the exhaust manifold.
3 Remove the heat exchanger according to: Heat
exchanger, change, page 143.
4 Remove the high pressure pump; refer to: 23-3,
High-Pressure Pump, Change.
P0014359
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21-1 Cylinder Head
5 Remove the wire harness:

- Injectors
- Camshaft sensors
- Rail pressure sensor
- PCV valve
P0014360
6 Remove the delivery pipes.

Use 9997217 Wrench.
P0014361
56 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
7 Remove the fuel leak-off line incl. fuel supply

hose.
P0014362
8 Remove the return line.

9 IMPORTANT!
The injectors are calibrated; in order to avoid
recalibration note the injector locations.
Remove injectors according to: Injector, Cylinder

1–4, Change, page 114.
10 Remove the fuel filter; refer to: Engine Fuel Filter
Replacement, page 104.
P0014363
11 Remove the supply hose from the fuel filter

bracket.
P0014364
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21-1 Cylinder Head
12 Remove the crankcase ventilation hose.
P0014365
13 Remove the fuel filter bracket including the crank

case ventilation hose.
P0014366
14 Remove the heat exchanger bracket.
P0011331
58 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
15 Remove the attachment fitting.
P0014367
16 Remove the attachment fitting bracket.
P0014368
17 IMPORTANT!
Note the location of the components.
Remove the camshaft drive gear.

Use 9995199 Drift.
P0014369
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21-1 Cylinder Head
18 Remove the camshaft seal.

Use 9995919 Extractor.
P0014370
19 Remove the belt guard.
P0014371
20 Remove the oil filter housing from the cylinder

head.
P0014372
60 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
21 Remove the oil filler pipe.

22 Remove the vacuum pump; refer to: Vacuum
Pump, Change, page 138.
P0014373
23 Remove the venting hose at the back of the

cylinder head.
P0014374
24 Remove the rear lifting lug.
P0014375
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21-1 Cylinder Head
25 Remove the inlet manifold.
P0014376
26 Remove the bearing caps.
P0014377
27 IMPORTANT!
Remove the camshaft bearing caps.
P0014378
62 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
28 Remove the camshafts.
P0014379
29 IMPORTANT!
Remove the lifters.
P0014380
30 Install a lifting lug.
P0014381
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21-1 Cylinder Head
31 Remove the cylinder head.
P0014382
32 Remove the cylinder head gasket. Note the

gasket category.
P0014383
33 Undo the starter motor connections.

1 B+ (30)
2 Start supply (50)
P0011332
64 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
34 Remove the starter motor.
P0011333
D3-D/E/F/G
35 IMPORTANT!
Set according to marking.
IMPORTANT!
The crankshaft may only be rotated clockwise.
P0014384
D3-H →
P0021324
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21-1 Cylinder Head
36 IMPORTANT!
Set according to marking.
Use 9997005 Rotation tool.
P0014385
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21-1 Cylinder Head
Installation
37 NOTICE! The type of gasket is identified as
illustrated.
Install the cylinder head gasket.
NOTICE! Holes A and B are only to identify type

of engine and do not therefore affect
classification.
Classification Hole marking

1 5
2 4, 5
3 3, 4, 5
P0015855 4 2, 3, 4, 5
5 1, 5
NOTICE! Classification must be performed if the

cylinder block has been replaced.
P0015856
Use 9995192 Gauge rod and 9989876 Dial

indicator.
Reset 9989876 Dial indicator against surface of

the block.
Crank the engine so that the piston reaches
TDC; use 9997005 Rotation tool.
To read classification, compare the measured

value with Group 21: Engine, cylinder head
gasketin Technical Data, page 10.
P0015857
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21-1 Cylinder Head
38 Install the cylinder head.

Use new cylinder head bolts.
Tightening torque:
Step 1: (20 Nm) 14.8 lbf. ft.
Step 2: (50 Nm) 36.9 lbf. ft.
Step 3: (50 Nm) 36.9 lbf. ft.
Step 4: 120°
Step 5: 120°
P0014386
39 Remove the lifting lug.
P0014381
40 Install the lifters.
P0014387
68 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
41 NOTICE! The camshafts may not be rotated.
Install the camshafts.
P0014388
42 Install the bearing caps. Screw the camshafts

onto the surface of the bearing caps in turns from
the center and outwards.
Tightening torque: M6, (10 Nm) 7.4 lbf. ft.
P0014378
43 IMPORTANT!
Make sure the components are clean and free
from foreign objects and lubricants before
application.
Apply sealant.
Apply sealing compound part # 1161059.
Use roller.
P0014389
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21-1 Cylinder Head
44 Tightening torque: M7, (17 Nm) 12.5 lbf. ft.

45 Install the camshaft seals.
P0014377
46 Lock the camshafts in the zero position.

Use 9997007 Lock pin.
P0014390
47 Install the belt guard bolt.

P0014371
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21-1 Cylinder Head
48 Install the attachment fitting for the oil filter

housing.
P0014372
49 Install the camshaft drive gear.
NOTICE! Only tighten by hand at this time.

50 Install the camshaft belt according to: Camshaft
P0014369
51 Tighten the drive gear.

P0014369
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21-1 Cylinder Head
52 Remove the tool. Install the engine block plug.

P0014385
53 Install the starter motor.

P0011333
54 Connect the starter motor contacts.

1 B+ (30)
2 Start supply (50)
Tightening torque: (8.5 Nm) 6.3 lbf. ft.
P0011332
72 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
55 Install the cylinder head venting hose.

56 Install the vacuum pump according to: Vacuum
Pump, Change, page 138.
P0014374
57 Install the inlet manifold.

P0014376
58 Install the oil filler pipe.
P0014373
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21-1 Cylinder Head
59 Install the suspension yoke bracket.
Tightening torque:
- M8 (24 Nm) 17.7 lbf.ft.
- M10 (50 Nm) 36.9 lbf.ft.
P0014368
60 Install the suspension bracket.

P0014367
61 Install the heat exchanger bracket.
Tightening torque:
- M6 (10 Nm) 7.4 lbf. ft.
- M8 (24 Nm) 17.7 lbf. ft.
- M10 (48 Nm) 35.4 lbf. ft.
- Union nut: (38 Nm) 28.0 lbf. ft.
P0011331
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21-1 Cylinder Head
62 Install the fuel filter bracket.
Tightening torque:
- M6 (10 Nm) 7.4 lbf. ft.
- M8 (24 Nm) 17.7 lbf. ft.
P0014366
63 Install the crankcase ventilation hose.
P0014365
64 Connect the supply hose to the fuel filter bracket.

65 Install the fuel filter according to: Engine Fuel
Filter Replacement, page 104.
66 Install the injectors according to: Injector,
Cylinder 1–4, Change, page 114.
P0014364
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21-1 Cylinder Head
67 Install the fuel return hose.

Tightening torque, union nut: (38 Nm) 28.0 lbf.
ft.
P0014363
68 Install the fuel leak-off line incl. fuel supply hose.
P0014362
69 Install the high pressure fuel pipes, cylinders 1-4.
Tightening torque:
Step 1: (10 Nm) 7.4 lbf. ft.
Step 2: 60°
70 Install the high pressure pump according to: 23-3,
High-Pressure Pump, Change.
P0014361
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21-1 Cylinder Head
71 Install the wire harness:

- Injectors
- Camshaft sensors
- Rail pressure sensor, 70 Nm
- PCV valve, 85 Nm
72 Install the heat exchanger according to: Heat
P0014360
73 Fit the hose between the cylinder head and

exhaust manifold.
P0014359
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21-1 Cylinder Head
74 Install the heat shield plate.
Tightening torque:
- M7 (17 Nm) 12.5 lbf. ft.
- M8 (24 Nm) 17.7 lbf. ft.
75 Install the exhaust manifold, turbocharger,
charge air cooler and seawater pump in the
reverse order as described in: Exhaust Manifold,
Change, page 124.
76 Install the top cover according to: Top Cover,
P0014358
Finishing off
Restoring to original condition according to: Actions
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21-1 Cylinder Head
Valve cover, change
Removal
1 Remove the cover (hot side).
Tightening torque: M8, 24 Nm (17.7 Ibf.ft.)
P0011356
2 Remove the cover (cold side).

P0011357
3 Remove the center cover.

Installation
P0011358 Install in reverse order.
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21-1 Cylinder Head
Top Cover, Service Position
Removal
NOTICE! Make sure system power is switched off.
Remove the engine covers according to: Valve cover,

change, page 79.
1 Remove the support bracket by the charge air

cooler.
P0012179
2 Remove the steering unit (PCU) harness.
P0011395
80 47702022 04-2019 © AB VOLVO PENTA

21-1 Cylinder Head
3 Remove the DC/DC transducer cables.
P0012180
4 Remove all relays.
5 Remove the bracket.
P0012182
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21-1 Cylinder Head
6 Remove the attachment fittings (4 pcs.) from the

venting hoses.
P0012183
7 Remove the top plate.

Remove the top plate by pulling it up and to one
side.
P0012184
Installation
Install in reverse order.
82 47702022 04-2019 © AB VOLVO PENTA

21-5 Timing Gears and Shaft

Gear Ring, Replace
Flywheel removed.
1 Drill 1–2 holes between teeth on ring gear.
Use a cold chisel to split the ring gear at the drill
site and remove the ring.
P0005675
2 Brush the flywheel contact surface clean with a

steel wire brush.
Heat the new ring gear in an oven or with a
welding torch to max 180-200 °C (356-392 °F).
IMPORTANT!
Take care to ensure that the ring gear is evenly
heated with no hot spots that may lead to
annealing. Polish the ring gear in a number of
P0006980 places before heating begins to aid controlling the
heating process. Stop heating when these
surfaces become blued.
3 Fit the heated ring gear onto the flywheel and tap
it into place with a soft mandrel and hammer.
Let the ring gear cool in the open air.
4 Install the flywheel.
P0005677
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Camshaft Belt, Change

Tools:
885633 Torque multiplier
885819 Counterhold
Removal
Remove the drive belt according to: Drive belt,
change, page 149.
Remove the engine cowling (cold side) according to:
Valve cover, change, page 79.
1 Remove the crankcase ventilation hose.
P0011241
P0011242
84 47702022 04-2019 © AB VOLVO PENTA

3 Remove the cowling.
P0011243
4 Place the engine so that the camshaft and

crankshaft markings are aligned to the markings
on the engine.
P0011244
D3-D/E/F/G D3-H →
P0014384 P0021324
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5 Remove the vibration damper.
P0011247
6 Install 885819 Counterhold.
P0011248
7 Remove the belt pulley center bolt; use

885633 Torque multiplier.
P0011249
86 47702022 04-2019 © AB VOLVO PENTA

8 Remove the belt pulley.

9 Remove the tension pulley.
10 Remove the camshaft belt.
P0011250
Installation
11 NOTICE! Make sure the camshaft and upper
timing gear markings are aligned according to the
“zero setting” marking before installing the
camshaft.
12 Check the idler pulley before installing a new
camshaft.
Tightening torque: M8, (24 Nm) 17.7 Ibf.ft
Install a new tension pulley; only tighten finger

tight at this time.
D3-D/E/F/G D3-H →
P0014384 P0021324
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13 Install a new camshaft belt.

1 Crankshaft
2 Idler pulley
3 Upper timing gear
4 Water pump
5 Tension pulley
P0011245
14 Adjust belt tension.

Tighten the center bolt (M8) to: (24 Nm) 17.7
Ibf.ft.
P0011246
15 Install the belt pulley.
P0011251
88 47702022 04-2019 © AB VOLVO PENTA

16 Install 885819 Counterhold.
P0011248
17 Tighten the belt pulley.

Tightening torque: (20 Nm) 14.8 Ibf.ft.
P0011249
18 Rotate the engine crankshaft (clockwise) 2

revolutions, check belt tension and the markings;
adjust as necessary.
NOTICE! If adjustment is required, repeat belt

tension check.
19 Tighten the belt pulley to (300 Nm) 221.2 Ibf.ft.;
use 885633 Torque multiplier.
P0011249
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20 Remove the counterhold.
P0011248
21 Install the vibration damper; tighten the bolts in

two stages:
Stage 1 (35 Nm) 25.8 Ibf.ft

Stage 2 angle tighten 50°
P0011247
22 Install the cowling (M6 bolts).
P0011243
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23 Install the crankcase ventilation hose.
P0011241
Install the engine cowling (cold side) according to:

Install the drive belt according to: Drive belt,
change, page 149.
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21-6 Crank Mechanism

Crankshaft Seal, Change (rear)
Tools:
9995919 Extractor
9997174 Mounting tool
Removal
Remove the flywheel according to: Flywheel,
Change, page 96.
1 IMPORTANT!
Be careful with contact surfaces.
2 Remove the seal.
D3-D/E/F/G
P0010738
Installation
3 Inspect the contact surface before installation.
4 Only SOLAS engines
Apply grease (part no. 1161325) on the contact
surface.
P0010739
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5 Only SOLAS engines

Fill the groove inside the seal with grease (part
no. 1161325).
6 Install the seal.
D3-D/E/F/G
Use 9997174 Mounting tool.
D3-H →
P0010740
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Crankshaft Seal, Change (front)

Tools:
885820 Puller
9995919 Extractor
Removal
Remove the camshaft belt according to: Camshaft
1 Remove the timing gear.

Use 885820 Puller.
2 Remove the crankshaft seal.

94 47702022 04-2019 © AB VOLVO PENTA

Installation
3 Install a new seal.
47702022 04-2019 © AB VOLVO PENTA 95

Flywheel, Change
Tools:
Removal
Remove the reverse gear/stern drive.
Remove the heat exchanger according to Heat
Remove the starter motor according to Starter Motor,
Change, page 163.
1 Undo the flywheel sensor connector.

Remove the flywheel sensor.
P0010731
2 Remove the nuts behind the flywheel as

illustrated.
Remove the bolt located immediately beneath the
starter motor.
P0010732
96 47702022 04-2019 © AB VOLVO PENTA

3 Take out the dislodged bolts.

Undo the remaining bolts.
Only inboard engines:

Loosen the screws on the engine mounts'
bracket.
All engines:
Remove the flywheel housing.
P0010733
4 Remove the flywheel.
NOTICE! Heavy component.
P0010734
Installation
5 IMPORTANT!
Inspect the contact surface before installation.
Make sure the threads are clean.
6 Fixate the flywheel, use 9995678 Guide sleeve
(x3) and 22701079 Guide sleeve as illustrated.
NOTICE! The locator hole (1) must be positioned

on the crankshaft pin.
NOTICE! The tool 22701079 Guide sleeve is to

be fixated in the hole to the left of the hole marking
(1).
P0022052
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7 Install the flywheel bolts.

Remove 9995678 Guide sleeve (x3) and
22701079 Guide sleeve.
Install the remaining bolts.
Tightening torque
Step 1: (45 Nm) 33.2 lbf. ft.
Stage 2: 65°
P0022053
98 47702022 04-2019 © AB VOLVO PENTA

22-0 Lubricating and Oil System, General

Engine Oil, Change
Removal
NOTICE! Make sure the engine is at operating
temperature.
NOTICE! Remove the oil filter before draining the oil.
1 Remove the oil filter and oil dipstick.

Tightening torque, oil filter: 25 Nm (18.4 Ibf.ft.)
P0012267
2 Use a pipe to drain out the oil.

Use a suitable pumping device.
NOTICE! Make sure the oil drain-off pipe is

inserted at least 425 mm (16.7").
NOTICE! Pipe diameter is 6 mm (0.24") on early

models and 10 mm (0.39") on later models.
P0012268
Installation
Finishing off
Fill with engine oil.
Run the engine until warm.
Check the oil level; top up as necessary.
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Engine Oil Pressure, Check

Tools:
9995270 Pressure gauge
Removal
1 Remove the oil dipstick complete with tube.
P0011397
2 Remove the sensor harness.
P0011398
3 Remove the adapter.

4 Check the oil pressure, use 9995270 Pressure
gauge.
Refer to Technical Data, page 10.
Installation
P0011399
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22-1 Oil pump and Line

Lubrication Oil Pump, Change
Tools:
9995747 Protective sleeve
Removal
1 Remove the front crankshaft seal according to
Crankshaft Seal, Change (front), page 94.
2 Release the auxiliary alternator belt tensioner
and remove the belt according to Drive belt,
change, page 149.
3 Remove the lower cam belt guard.
P0014514
4 Remove the oil pump and gasket.

P0014515
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Installation
5 Install the protective sleeve, use
9995747 Protective sleeve.
P0014516

application.
Install the gasket and oil pump.

P0014517
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22-3 Oil cooler
22-3 Oil cooler

Oil Cooler, Replace
Removal
Drain the coolant according to: Coolant,
Change, page 141.
Drain the engine oil according to: Engine Oil,
Change, page 99.
1 Undo the oil cooler hoses.
P0010881
2 Remove the oil cooler.
P0010882
Installation
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23-3 Fuel Feed Pump and Filter

Engine Fuel Filter Replacement
Removal
NOTICE! Be prepared to gather up fuel.
1 Remove the fuel filter, incl. sensor.
P0011318
2 Move the sensor over to the new fuel filter.
P0011319
Installation
Finishing off
Before engine start, prime the engine for around 5 sec
to bleed the system.
104 47702022 04-2019 © AB VOLVO PENTA

Fuel Feed Pump, Change
Removal
Remove the belt guard according to: Drive belt,

change, page 149.
1 Remove the wire harness.
x2
P0010684
2 NOTICE! Be prepared to gather up fuel.
Undo the delivery pipe clamp.

Undo the delivery pipe union at the feed pump.
P0011252
47702022 04-2019 © AB VOLVO PENTA 105

3 Undo the attachment, then pull the pump forward

so that the suction line is accessible.
P0011253
4 Undo the suction line and then remove the feed

pump.
P0011254
Installation
106 47702022 04-2019 © AB VOLVO PENTA

Fuel Feed Pressure, Check

Tools:
9996666 Nipple
9998493 Hose
9996398 Manometer
Removal
Remove the cold side engine cover according to: Valve
cover, change, page 79.
1 Remove the plug from the fuel filter housing.
P0011335
2 Connect 9996666 Nipple, 9998493 Hose and

9996398 Manometer.
3 NOTICE! The engine does not need to be started
to check return pressure.
Prime the engine for 10 sec.

Check the feed pressure (during the prime).
P-Normal: 3.8-4.2 bar (55-61 psi)
P-Min: 3.5 bar (51 psi)
P-Max: 5.5 Bar (80 psi)
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P-Min
If feed pressure is below 3.5 bar (51 psi), check
the following:
• Fuel filter, according to: Engine Fuel Filter
Replacement, page 104.
• Under pressure, according to: Fuel System
Vacuum, Check, page 110.
P-Max
Excessive feed pressure may occur because the
inlet and return lines are transposed. The feed
pump has an integral safety valve with a pressure
range of 6-8 bar (87-116 psi), which means that
pressure cannot exceed 8 bar (116 psi).
NOTICE! In continual operations in the max

position there is a risk that the pump will be
damaged.
4 If the feed pressure exceeds 5.5 bar (80 psi)
check the following:
• Check return fuel pressure according to:
Fuel Return Pressure, Check, page 109.
Installation
108 47702022 04-2019 © AB VOLVO PENTA

Fuel Return Pressure, Check

Tools:
9996398 Manometer
9998493 Hose
21433378 Nipple
Removal

9996398 Manometer to the output connection on
the engine.
NOTICE! A transparent hose is recommended.
P0010737

to check return pressure.
Prime the engine with fuel for around 10 sec.

Check the return fuel pressure while doing this.
P Norm: 0-1 bar (0-14.5 psi)
P Max: 1.0 bar (14.5 psi)
3 P Max
If the return fuel pressure exceeds 1 bar
(14.5 psi), check:
1 Return fuel lines in respect of blockages.
2 Fuel line dimensions according to
specifications.
Installation
47702022 04-2019 © AB VOLVO PENTA 109

Fuel System Vacuum, Check

Tools:
9990150 Manometer
9998493 Hose
21433378 Nipple
Removal
9990150 Manometer on the suction side.
NOTICE! A transparent hose at the connection is

recommended.

to check vacuum.
Prime the engine for around 10 sec. Check the

vacuum while priming.
1 P Norm: 0 – (-)0.3 bar (0 – (-)4.35 psi)
2 P Min: -0.3 bar (-4.35 psi)
3 P-Min
If vacuum is below -0.3 bar (-4.35 psi), check:
1 Shut-off tap
2 Fuel prefilter
3 Fuel lines from tank
4 Fuel tank
5 The installation in regard to line
dimensioning.
Installation
110 47702022 04-2019 © AB VOLVO PENTA

23-6 Injection Pump, Regulator
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High-Pressure Pump, Change
Removal
Remove the heat exchanger according to: Heat

Top cover service position according to: Top Cover,
1 Remove the delivery pipe P clamp.
P0011327
2 Remove the fuel pipes.
NOTICE! Be prepared to gather up any fuel.
NOTICE! Delivery pipes must always be replaced

with new pipes once removed.
Tightening torque, delivery pipe:

Stage 1: 10 Nm (7.4 Ibf. ft.)
Stage 2: 75°
P0011326
112 47702022 04-2019 © AB VOLVO PENTA

3 Remove the inlet and return lines.
NOTICE! Be prepared to gather up any fuel.
P0011328
4 Remove the harness.
P0011329
5 Remove the high pressure pump.

Keep the drive component in a safe place.
P0011330
Installation
47702022 04-2019 © AB VOLVO PENTA 113

23-7 Injectors and Delivery Pipes

Injector, Cylinder 1–4, Change
Tools:
885490 Sleeve
9996400 Slide hammer
9997009 Brush
9997217 Wrench
9998007 Adapter
Removal
Top cover service position according to Top Cover,

1 Remove the harness to the injectors.
P0014435
2 NOTICE! Be prepared to gather up fluid.
Remove the fuel leak-off line.
P0014436
114 47702022 04-2019 © AB VOLVO PENTA

Remove the delivery pipes to cylinders 1–4. Use

885490 Sleeve and 9997217 Wrench.
P0014361
4 Remove the injector fasteners.
P0014437
5 Remove the injector. Use 9996400 Slide

hammer together with 9998007 Adapter.
P0014438
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If the injector is stuck fast:
Remove the parts from the injector (A).

Screw the 9997352 Adapter securely into the
injector.
Pull the injector out of the cylinder head using
9997353 Slide hammer.
IMPORTANT!
The component may not be reused.
P0021208
Installation
6 Make sure the area around the injector is clean.
Use 9997009 Brush.
P0014439
7 NOTICE! Use a new component.
P0014440
116 47702022 04-2019 © AB VOLVO PENTA

8 Install the injector incl. retaining bracket.

Only tighten by hand at this time.
P0014441
9 Make sure the injector has reached its clockwise

end position.
Tighten the injector; tightening torque 13 Nm
(9.6 lbf.ft.).
P0014442
10 NOTICE! Use new components.
Install the fuel delivery pipes. Use 885490 Sleeve

and 9997217 Wrench.
Tightening torque:
Injector
Step 1: 10 Nm (7.4 lbf.ft.)
Step 2: 60°
Common rail
P0014361 Step 2: 75°
Finishing off
Program the injectors according to: Trimming the
injector in D3 Workshop Manual, Group 30.
47702022 04-2019 © AB VOLVO PENTA 117

Injector, Cylinder 5, Change

Tools:
885490 Sleeve
9996400 Slide hammer
9997009 Brush
9997217 Wrench
9998007 Adapter
Removal
Top cover service position according to Top Cover,

1 Remove the harness to the injectors.
P0014435
Remove the fuel leak-off line.
P0014436
118 47702022 04-2019 © AB VOLVO PENTA

Remove the delivery pipe to cylinder 5. Use

885490 Sleeve and 9997217 Wrench.
P0014449
4 Remove the injector fasteners.
P0014437
5 Remove the injector. Use 9996400 Slide

hammer together with 9998007 Adapter.
P0014438
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If the injector is stuck fast:
Remove the parts from the injector (A).

Screw the 9997352 Adapter securely into the
injector.
Pull the injector out of the cylinder head using
9997353 Slide hammer.
IMPORTANT!
The component may not be reused.
P0021208
Installation
6 Make sure the area around the injector is clean.
Use 9997009 Brush.
P0014439
7 NOTICE! Use a new component.
P0014440
120 47702022 04-2019 © AB VOLVO PENTA

8 Install the injector incl. retaining bracket.

Only tighten by hand at this time.
P0014441
9 Make sure the injector has reached its clockwise

end position.
Tighten the injector; tightening torque 13 Nm
(9.6 lbf.ft.).
P0014442
10 NOTICE! Use new components.
Install the fuel delivery pipes. Use 885490 Sleeve

and 9997217 Wrench.
Tightening torque:
Injector
Step 2: 60°
Common rail
P0014449 Step 2: 75°
Finishing off
Program the injectors according to: Trimming the
injector in D3 Workshop Manual, Group 30.
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Rail Pressure Sensor, Change
Removal
Top cover service position according to: “(21–1) Top

cover, service position”
P0011391
2 Remove the common rail pressure sensor.
P0011392
Installation
122 47702022 04-2019 © AB VOLVO PENTA

MPROP valve, change
Removal
Remove the engine cover (cold side) according to

1 Undo the connector.
P0011393
Remove the MPROP valve.
P0011394
Installation
Check that no leakage occurs.
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25-1 Inlet and Exhaust Manifolds

Exhaust Manifold, Change
Removal
Drain the coolant according to: Coolant,
Change, page 141.
Remove the turbocharger according to: Turbo,
Change, page 136.
1 Remove the venting hoses.
P0011320
2 Remove the expansion tank.
P0011322
124 47702022 04-2019 © AB VOLVO PENTA

3 Rotate the expansion tank upwards.
P0011323
4 Disconnect the coolant level sensor connector.
P0011321
47702022 04-2019 © AB VOLVO PENTA 125

6 Remove the crank case ventilation reservoir.

Hang the reservoir and its bracket to one side.
7 Remove the seawater filter, hoses and oil filler

pipe.
8 Remove the support bracket.
126 47702022 04-2019 © AB VOLVO PENTA

9 Undo the freshwater connections.
10 Remove the exhaust manifold.
Installation
11 When replacing the exhaust manifold, transfer
the hoses (1, 2).
Tightening torque:
Banjo bolt (1) to exhaust manifold, 38 Nm (28
Ibf.ft)
Install a new gasket.

47702022 04-2019 © AB VOLVO PENTA 127

25-5 Turbo and supercharger

Turbocharger, check
1 Quick check
Stop the engine and listen to the turbocharger at
the moment it stops. The rotating components in
the turbocharger should normally stop a little later
than the engine.
If this is not the case, remove the air filter housing
and check the following items on the
turbocharger:
• That the compressor wheel rotates easily
when turned
• That the compressor wheel does not scrape
against the compressor housing
NOTICE! The turbine shaft floats on an oil film

and is thus subject to a certain amount of play.
P0010686
2 Check VNT
Check, in the following sequence:
• That the vacuum hoses between the
turbocharger and vacuum pump are intact.
• That the vacuum regulator located under the
fuel distribution pipe functions.
Switch to another vacuum regulator to check
that the original is not faulty.
• That the turbocharger control arm reaches
its end position.
Remove the hose from the turbocharger
vacuum box (1) and connect
885531 Pressure testing kit instead. Create
a vacuum of 64 ± 3 kPa. At this point the
control arm (2) on the turbocharger (VNT)
P0010687 must reach its end position.
If the control arm does not reach its end
position and the vacuum hoses and vacuum
regulator prove to be intact, change the
turbocharger.
IMPORTANT!
The control arm adjustment nut is calibrated with
the turbocharger and may not be removed. If its
position is changed, a fault code will be
generated. The engine warranty is no longer valid
if the adjuster nut is undone.
128 47702022 04-2019 © AB VOLVO PENTA

Turbocharger, cleaning
Function description:
The turbocharger is equipped with VNT technology.
The positions of the vanes in the turbine housing are
varied by means of vacuum generated by a vacuum
pump. The vacuum capsule rod is joined to a movable
ring via a lever.
1 VTG ring
2 Lever
3 Vacuum capsule
4 Vacuum circuit
5 Vacuum regulator
6 Guide rail
7 Vacuum circuit, vacuum pump
8 Vacuum capsule rod
If the lever movement is being restrained due to that it

is stuck, corrosion or else, the engine control unit
P0018726 makes a diagnosis that there is a problem with the
regulation and sets the fault code MID 128, SID 27,
FMI 1.
The two tests on the following page shall be performed

to check if the lever movement is the problem of the
fault code:
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Checking the lever movement
Tools:
3849613 Pressure testing kit
NOTICE! Spray with corrosion agent as needed.
Test 1:
1 Run the engine at idle. The lever is affected by
the vacuum capsule rod. The lever position
depends on the vacuum provided by the vacuum
circuit.
2 Watch the lever return motions and check the
time it takes for the lever to reach its initial position
(the position it has when not affected by vacuum)
when the engine is shut down. The return should
be approx. 1-1.5 seconds.
If the return time is longer it could be long enough
for the engine control unit to diagnose a fault.
Test 2:
1 Make sure the engine is not running.
P0018727 2 Connect the standard Volvo Penta vacuum pump
(3849613 Pressure testing kit) to the vacuum
capsule located at the turbocharger.
3 Pump unit the lever has moved to its end position.
4 Release the vacuum and watch the lever return
motion and check the time it takes for the lever to
reach its initial position (the position it has when
not affected by vacuum). The return time should
be approx. 1-1.5 seconds. Of the return time is
longer it could be long enough for the engine
control unit to diagnosis a fault.
If a lever movement problem is suspected after both

tests have been performed the turbocharger must be
checked (see the following page).
130 47702022 04-2019 © AB VOLVO PENTA

Checking
1 Do not change the length on the control rod.
Mark the position of the turbine housing and
compressor housing towards the bearing
housing.
P0018728
2 Remove the turbine housing and compressor

housing.
P0018729
3 Mark the VTG(1) ring towards the housing.
P0018730
1. VTG = Variable Turbine Geometry
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4 Remove the VTG ring.
NOTICE! Keep the roller wheels with shaft.
P0018731
5 Check that the guide rails are turnable.

If not, remove the guide rails.
NOTICE! Keep the bushings under the ring.
P0018732
6 Clean the guide rails.

Use universal spray and scrape carefully with a
knife.
P0018733
132 47702022 04-2019 © AB VOLVO PENTA

7 Clean the turbine side.
IMPORTANT!
Be very careful with the turbine wheel.
P0018734
8 Clean the turbine side.

Use universal spray and scrape carefully with a
knife.
P0018735
9 Clean the compressor side.
NOTICE! Keep the O-ring.
IMPORTANT!
Be very careful with the compressor wheel.
P0018736
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10 Clean the compressor side.
P0018737
Reassemble
11 Install the ring with guide rails.
Check that the guide rails are turnable.
P0018732
12 Install the VTG ring according to previous

marking.
P0018738
134 47702022 04-2019 © AB VOLVO PENTA

13 Install turbine housing according to previous

marking.
IMPORTANT!
Be very careful with the compressor wheel.
P0018739
14 Install the O-ring and compressor housing

according to previous marking.
P0018740
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Turbo, Change
Removal
Remove the charge air cooler according to: Charge Air
Cooler, Replace, page 152.
P0011237
2 Remove the exhaust pipe.
P0011238
3 Remove the vacuum hose.
P0011239
136 47702022 04-2019 © AB VOLVO PENTA

4 Remove the turbocharger.
Tightening torque:
Stud to exhaust manifold: 30 Nm (22.1 Ibf.ft)
Bolt, turbocharger: 25 Nm (18.4 Ibf.ft)
P0011240
Installation
Bolt, drain pipe/turbocharger
IMPORTANT!
This joint must be retightened after engine warm-up
otherwise there is a risk of oil leakage.
Torque: 10 Nm (7.4 Ib.ft)
P0016806
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Vacuum Pump, Change
Removal
1 NOTICE! Close the seawater intake.
Remove the seawater outlet hose.
P0010779
2 Remove the VGT valve hose.

Undo the clamp.
P0010780
138 47702022 04-2019 © AB VOLVO PENTA

3 Remove the bracket and the vacuum pump.

NOTICE! Be prepared to gather up fluids.
P0010781
Installation
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25-6 Air Cleaner, Throttle Housing
25-6 Air Cleaner, Throttle Housing

Air Filter, Change
Removal
Remove the engine cover (hot side) according to:
1 Remove the hose clamp.
P0010887
2 Remove the air filter.
Installation
P0010888 Install in reverse order.
140 47702022 04-2019 © AB VOLVO PENTA

26-0 Cooling System, General

Cooling System, Pressure Testing
Tools:
1 Unscrew the expansion tank cap.
Screw on the 885531 Pressure testing kit cap.
Connect the hand pump to the 885531 Pressure
885 531
0
100
testing kit.
2 Pump up a pressure of 100 kPa (14.5 PSI).
In order to prove correct heat exchanger and
connection sealing function, pressure may not fall
for two minutes.
NOTICE! If the pressure falls, spray or brush

water and dishwashing liquid on the connections
and hoses to determine the source of the
leakage.
3 Rectify the cause of the leakage.
Repeat pressure testing after repairs.
885 531
P0010688
Coolant, Change
Removal
NOTICE! Close the seawater inlet valve.
CAUTION!
Hot steam.
1 Open the expansion tank cap.
NOTICE! Be prepared to gather up liquid.
Open the drains for each cooling system.

1. Coolant
2. Seawater
47702022 04-2019 © AB VOLVO PENTA 141

2 NOTICE! Be prepared to gather up liquid.
Open the charge air cooler seawater drain.
3 NOTICE! Be prepared to gather up liquid.
Undo the oil cooler hose unions.

Drain the coolant.
P0010881
Installation
Install in reverse order
Finishing off
Top up fluids. Run the engine until warm.
Top up as necessary.
Check for leakage.
142 47702022 04-2019 © AB VOLVO PENTA

26-1 Radiator, Heat Exchanger

Heat exchanger, change
Precautions before working in boats, according
toActions before working in boat, page 23.
Remove the cold side engine cover according to Valve
cover, change, page 79.
1 Undo hose connections.
2 Disconnect harnesses to:
- Sensor
- Datalink
P0014468
Tightening torque:
- M6 10 Nm (7.4 lbf. ft.)
- M8 24 Nm (17.7 lbf. ft.)
P0014469
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4 Undo hose connections.
P0014470
5 Undo fasteners.
Tightening torque: M8, 24 Nm (17.7 lbf. ft.)
P0014471
6 Undo the charge air pipe clamp.

P0014472
144 47702022 04-2019 © AB VOLVO PENTA

7 Undo the heat exchanger front fasteners.

It may be necessary to move the charge air pipe
sideways to remove the rear bolts.
P0014473
8 Loosen the bolt (1) about 2 turns.

Remove the heat exchanger (2).
P0014474
Installation
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Heat exchanger, overhaul
Removal
Remove the heat exchanger according to Heat
1 Remove the insert bolts.
P0010761
2 Use the two bolts from the previous item.

Unscrew alternately.
Remove the insert.
P0010762
146 47702022 04-2019 © AB VOLVO PENTA

P0010763
Installation
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26-2 Coolant Pump, Thermostat

Coolant Pump, Change
Removal
Drain the coolant according to Coolant,
Change, page 141.
Remove the camshaft belt according to Camshaft Belt,
Change, page 84.
1 Remove the coolant pump.
P0010727

application.
Remove and discard the gasket.
P0010728
Installation
148 47702022 04-2019 © AB VOLVO PENTA

Drive belt, change
Removal
1 Remove the belt cover.
Tightening torque: M8, 24 Nm (17.7 Ibf.ft)
P0010879
2 Release belt tension (1).

Remove the belt (2).
P0010878
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3 Release belt tension (1).

Remove the belt (2).
P0010880
Installation
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Thermostat, Change
Removal
Empty the freshwater system according to: Coolant,
Change, page 141.
1 Undo the freshwater hoses.
P0014470
2 Remove the thermostat cover.

P0014527
3 Remove the thermostat, including the seals.
Installation
Finishing off
Run the engine until warm; check the coolant level.
P0014528
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26-5 Charge Air Cooler with Connections

Charge Air Cooler, Replace
Removal
Remove the engine cover (hot side) according to:
Drain the seawater from the charge air cooler
according to: Coolant, Change, page 141.
Remove the air filter according to: Air Filter,
Change, page 140.
1 Remove the oil return pipe.
P0010889

3 Remove the turbocharger heat shield.
Remove the seawater pump according to:
Seawater Pump, Change, page 159.
P0010890
152 47702022 04-2019 © AB VOLVO PENTA

4 Remove the oil pipe.
Tightening sequence:
1 Tightening torque, banjo bolt, at the
turbocharger: 25 Nm (18.4 Ibf.ft)
2 Tightening torque, banjo bolt, at the engine
block: 38 Nm (28 Ibf.ft)
P0010891
5 Undo the seawater inlet hose.
P0010892
6 Undo the charge air pipe.
P0010893
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7 Undo the seawater outlet hose.
P0010894
8 Undo the connection at the turbocharger.
NOTICE! At installation, install the silicon pipe on

the turbocharger before installing the charge air
cooler.
P0010895
9 Undo the upper attachments.
P0010896
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10 Remove the charge air cooler.

1 Tightening torque: M10, 48 Nm (35.4 Ibf.ft)
2 Tightening torque: M8, 24 Nm (17.7 Ibf.ft)
P0010897
Installation
Finishing off
Check that the seawater system is in working order.
47702022 04-2019 © AB VOLVO PENTA 155

Charge Air Cooler, Overhaul

Tools:
885536 Plug
885539 Plug
Removal
1 Remove the charge air cooler according to
Charge Air Cooler, Replace, page 152.
2 Tightening torque, end cover bolts: M8 24
Nm (17.7 lbf.ft.)
Tightening torque, pipe stub bolts: M6 10
Nm (7.4 lbf.ft.)
P0010776
Leakage test
3 Use 885531 Pressure testing kit, 885536 Plug
and 885539 Plug.
Apply a -1 bar (-14.5 psi) vacuum to the charge
air cooler.
IMPORTANT!
The vacuum must remain constant for 15
minutes. If the vacuum degrades, check for leaks.
P0010775
Installation
156 47702022 04-2019 © AB VOLVO PENTA

26-6 Sea Water System, Sea Water Pump

Seawater pump hub, overhaul
Remove the pump shaft with hub according to:
Seawater Pump, Impeller, Change, page 160.
1 Remove the lock ring and washer.
P0015534
2 Remove the seal. Use snipe nosed pliers or a

screwdriver
IMPORTANT!
Be careful with contact surfaces.
P0015535
3 Grease the outer part of the seal unit (1) with a

very thin layer of silicone grease part no.
1161325.
Press the unit into position manually. Use a long
sleeve or similar.
NOTICE! Allow no grease or similar on the

ceramic ring seal surface.
P0015536
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4 Press the spring-loaded part (1) of the seal down

far enough for the washer (2) and retainer ring (3)
to be installed.
5 Install the pump shaft with hub according to:
Seawater Pump, Impeller, Change, page 160.
P0015537
158 47702022 04-2019 © AB VOLVO PENTA

Seawater Pump, Change
Removal
Close the seawater inlet valve.
Remove the seawater pump drive belt according to:
Drive belt, change, page 149.
1 Remove the hoses.
P0010883
2 Remove the seawater pump.

P0010884
Installation
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Seawater Pump, Impeller, Change
Removal
Undo the seawater pump drive belt according to: Drive
belt, change, page 149.
1 Remove drive unit and o-ring.
2 Remove the impeller.
Installation
160 47702022 04-2019 © AB VOLVO PENTA

32-1 Alternator
32-1 Alternator
Alternator, Change
Removal
NOTICE! The main switch must be in the off position
before work is begun.
1 Undo the harness connections.

1 B+
2 Sensor cable
Tightening torque
1 Alternator B+ connection: 15 Nm (11.1
lbf.ft.)
2 Remove the power steering pump according to
Servo Steering Pump, Change, page 180.
P0014509
3 Remove the power steering pump bracket.

P0014510
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32-1 Alternator
4 Remove the alternator.

Installation
P0014511
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33-1 Starter Motor
33-1 Starter Motor

Starter Motor, Change
Removal

Top cover service position according to: Top Cover,
P0011331
2 Undo the starter motor connections.

1 B+ (30)
2 Start supply (50)
P0011332
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33-1 Starter Motor
3 Remove the starter motor.
P0011333
Installation
164 47702022 04-2019 © AB VOLVO PENTA

36-6 Monitoring and Control Systems
36-6 Monitoring and Control Systems

PCU, Replace
Removal
Remove the engine covers according to Valve cover,

change, page 79.
1 Disconnect the harness.
P0011395
2 Remove the PCU.

Tightening torque: 6 Nm (4.4 lbf.ft.)
P0011396
Installation
Program the empty PCU according to the

Programming an empty control unit section in the
relevant Service handbook, EVC, Group 30.
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37-1 Cables
37-1 Cables
Cable Trunk, Change
In order to replace the wire harness it is necessary to
remove or undo much of the engine's ancillary
equipment first. If the wire harness is being replaced
because of a short circuit the cause must be remedied
before replacement.
Preconditions:
• Battery power disconnected.
• Engine covers removed according to Valve cover,
change, page 79.
• Cooling system drained according to Coolant,
Change, page 141.
Removal
1 Remove the relays illustrated.
P0010747
2 Remove the top cover according to Top Cover,

NOTICE! Do not unbolt the PCU or DC/DC

transducer from the top cover.
3 Remove the seawater and coolant hoses from the
heat exchanger according to Heat exchanger,
change, page 143.
166 47702022 04-2019 © AB VOLVO PENTA

37-1 Cables
Installation
4 Install the bracket on the heat exchanger.
Secure the hoses from the high pressure pump
and fuel feed pump to the bottom of the bracket.
P0010743
5 Attach the starter motor harness connector.
P0010744
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37-1 Cables
6 Secure the harness to the heat exchanger with a

clamp.
P0010745
7 Attach the following connectors at the back of the

engine.
Connect the flywheel sensor (1) behind the
coolant pipe.
P0010746
8 Attach the common rail pressure sensor

connector.
P0010748
168 47702022 04-2019 © AB VOLVO PENTA

37-1 Cables
9 Attach the injector connectors.

Attach the camshaft sensor connector.
P0010749
10 Tie the wiring for cylinder #3 to the harness. Use

a cable tie and clip and secure it to the cover
below.
P0010750
11 Tie the wiring for cylinder #5 to the camshaft

sensor wire. Use a cable tie.
P0010751
12 Install the top cover according to Top Cover,

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37-1 Cables
13 Attach the oil pressure sensor connector.
P0010752
14 Secure the wire harness with a clamp as

illustrated.
Install the relays.
P0010753
15 Install the bracket on the top cover.

P0012182
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37-1 Cables
16 Secure the wire harness with a clamp as

illustrated.
P0010754
17 Connect the positive wire (1) to the alternator.
NOTICE! For Aquamatic installations: Also

connect the AQ harness; see two items ahead in
this section.
Attach connector (2) to the alternator.
P0010755
18 Connect the ground wire to the engine block.
NOTICE! For Aquamatic installations: Also

connect the negative cable from the AQ harness;
refer to the next item.
P0010756
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37-1 Cables
19 Tie the AQ harness to the engine harness. Use

cable ties as illustrated.
Figure 1:
Connect the harness to the circuit breaker.
Figure 2:
Connect the negative wire to the engine block.
Connect the positive wire to the alternator. Use
cable ties as illustrated.
P0010758
20 Attach the fuel filter connector.
P0011318
21 Attach the oil sump connector.
P0010757
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37-1 Cables
22 Connect the fuel pump wiring.
x2
P0010684
23 Attach the DC/DC transducer connector.

Attach the PCU connectors.
P0010759
Finishing off:
- Attach the seawater and coolant hoses to the heat
exchanger according to Heat exchanger,
change, page 143.
- Fill coolant according to Coolant,
Change, page 141.
- Install the engine covers according to Valve cover,
change, page 79.
- Turn battery power on.
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38-6 Sensors for Indicator and Warning System

Oil pressure sensor, replace
Removal
1 Remove the oil dipstick.
P0011397
2 Remove the oil pressure sensor harness.
P0011398
3 Remove the oil pressure sensor.
Installation
P0011400
174 47702022 04-2019 © AB VOLVO PENTA

Oil level sensor, change
Removal
Actions before working in boat, according to: Actions
Drain oil according to: 22-2, Oil filter, Change.
1 Remove the oil level sensor and the o-ring.
x3
P0010729
Installation
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Fuel temperature sensor (High-

Pressure Pump), replacing
Removal
Remove the (cold side) engine cover according to:

1 Remove the sensor.
NOTICE! Be prepared to gather up fuel.
Installation
176 47702022 04-2019 © AB VOLVO PENTA

Coolant level sensor, change
Removal
Remove the engine covers according to: Valve cover,
change, page 79.
1 Remove the venting hoses.
P0011320
P0011322
3 Rotate the expansion tank upwards.
P0011323
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4 Remove the coolant level sensor.
P0011321
Installation
178 47702022 04-2019 © AB VOLVO PENTA

Coolant temperature sensor,

change
Removal
1 Disconnect the harness.
P0011324
2 Remove the coolant temperature sensor.
P0011325
Installation
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64-5 Power Steering
64-5 Power Steering

Servo Steering Pump, Change
Tools:
1158688 Torque wrench
9995199 Drift
Removal
Remove the drive belt according to Drive belt,
change, page 149.
WARNING!
Hot fluids can be present.
NOTICE! Be prepared to gather up fluids.
1 Remove the hoses.
P0014749
2 Remove the power steering pump.

P0014750
180 47702022 04-2019 © AB VOLVO PENTA

64-5 Power Steering
3 Replace the pulley.

Use 9995199 Drift and 1158688 Torque wrench.
Tightening torque: 60 Nm (44.2 Ib.ft.)
P0014751
Installation
Top off fluid. Vent the system by repeatedly turning

hard to port and starboard a number of times.
Recheck the level.
47702022 04-2019 © AB VOLVO PENTA 181

Document No Issue Index
22602983 01
Rating Power (Hp) Rpm
R5 220 4000
R5 220 4000
Sensors Alarm Signal Range Alarm switch Alarm Level Derating level Condition/Delay
y g Derating
Boost pressure offset high boost pressure demand map boost pressure demand rpm and 20 mg/hub. 10 s Soft derate - 40 Nm/s to
0,5-4,5 V 50-400 kPa N/A + 30 kPa map + 30 kPa delay Torque derate map 1
Boost pressure offset low 0,5-4,5 V 50-400 kPa boost pressure demand map
N/A - 30 kPa N/A
Boost temperaure 4786-191 mV -40° - 130 °C 80°C See soft derate 1 combined
with Temperature derate
N/A 90°C 2s map
Coolant level switch Digital Alarm when closed Low 5,5 s
Coolant temperature 94-3310 mV -60° to 160 98°C See soft derate 2 combined
°C with Temperature derate
N/A 101°C 2s map
Rail pressure offset 0,5-4,5 V 0-15 kPa rail pressure demand map +/- rail pressure demand map + Above 740 rpm, ~1 s Soft derate - 40 Nm/s to
N/A 200 Bar /- 200 Bar Torque derate map 1
Engine Speed Cam Frequency N/A Lost sign
Engine Speed Crank Frequency N/A Lost sign
Oil Pressure 0,5-5 V 0-700 kPa Oil pressure map Soft derate - 40 Nm/s to
N/A Oil pressure map 1s Torque derate map 1
Oil level sensor PWM 0-129mm N/A <30mm N/A
Oil temperature PWM -40° - 140 °C N/A See soft derate 3 combined
with Temperature derate
N/A 130°C map
Fuel temperature 131 - 3150 mV -40° - 130 °C 12 s after engine start and See soft derate 4 combined
delay 2 s with Temperature derate
N/A 70°C 70°C map
Water In fuel switch Digital Alarm when closed Water in Fuel 30 s
Document No Issue Index
22602983 01
Torque derate map 1 rpm 700 1750 2000 5000
Nm 500 500 20 20
Soft derate 1 deg C -40 80 90 200
derate factor 1 1 0.1 0.1
Temperature derate map [mm3/stroke] derate factor[%] / speed [rpm] 800 1000 1500 1750 2000 2500 2750 3000 3200 3350 3500 3650 3800 4000 4100 4130
0.00 36.00 40.00 60.00 70.00 8.00 8.00 8.00 8.00 8.00 8.00 9.00 9.00 10.00 10.00 10.00 10.00
0.10 36.00 40.00 60.00 70.00 8.00 8.00 8.00 8.00 8.00 8.00 9.00 9.00 10.00 10.00 10.00 10.00
0.20 36.00 40.00 60.00 70.00 8.00 8.00 8.00 8.00 8.00 8.00 9.00 9.00 10.00 10.00 10.00 10.00
0.30 36.00 40.00 60.00 70.00 12.92 12.75 12.92 13.00 13.42 13.34 14.08 14.08 14.58 14.42 14.34 14.34
0.40 36.00 40.00 60.00 70.00 17.83 17.50 17.83 18.00 18.82 18.68 19.18 19.18 19.18 18.82 18.68 18.68
0.50 36.00 40.00 60.00 70.00 22.75 22.25 22.75 23.00 24.26 24.00 24.26 24.26 23.76 23.26 23.00 23.00
0.55 36.00 40.00 60.00 70.00 27.67 27.00 27.67 28.00 29.68 29.34 29.34 29.34 28.34 27.68 27.34 27.34
0.60 36.00 40.00 60.00 70.00 32.58 31.75 32.58 33.00 35.08 34.68 34.42 34.42 32.92 32.08 31.68 31.68
0.65 36.00 40.00 60.00 70.00 37.50 36.50 37.50 38.00 40.50 40.00 39.50 39.50 37.50 36.50 36.00 36.00
0.70 36.00 40.00 60.00 70.00 42.42 41.25 42.42 43.00 45.92 45.34 44.58 44.58 42.08 40.92 40.34 40.34
0.75 36.00 40.00 60.00 70.00 47.33 46.00 47.33 48.00 51.34 50.68 49.68 49.68 46.68 45.34 44.68 44.68
0.80 36.00 40.00 60.00 70.00 52.25 50.75 52.25 53.00 56.76 56.00 54.76 54.76 51.26 49.76 49.00 49.00
0.85 36.00 40.00 60.00 70.00 57.17 55.50 57.17 58.00 62.18 61.34 59.84 59.84 55.84 54.18 53.34 53.34
0.90 36.00 40.00 60.00 70.00 62.08 60.25 62.08 63.00 67.58 66.68 64.92 64.92 60.42 58.58 57.68 57.68
0.99 36.00 40.00 60.00 70.00 67.00 65.00 67.00 68.00 73.00 72.00 70.00 70.00 65.00 63.00 62.00 62.00
1.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00 85.00
Oil pressure map rpm 0 590 600 700 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
hPa 0 0 800 1000 1000 1000 1000 1000 1200 1400 1600 1800 2000 2500 3000 3000
Index
A Group 26: Cooling System................................. 13, 27
About this Workshop manual..................................... 3 Group 30: Electrical System..................................... 14
Actions before working in boat................................. 23 H
Air Cleaner, Throttle Housing................................. 140 Heat exchanger, change........................................ 143
Air Filter, Change................................................... 140 Heat exchanger, overhaul...................................... 146
Alternator................................................................ 161 High-Pressure Pump, Change............................... 112
Alternator, Change................................................. 161 I
C Illustrations................................................................. 8
Cable Trunk, Change............................................. 166 Injection Pump, Regulator...................................... 111
Cables.................................................................... 166 Injector, Cylinder 1–4, Change............................... 114
Camshaft Belt, Change............................................ 84 Injector, Cylinder 5, Change................................... 118
Charge Air Cooler with Connections...................... 152 Injectors and Delivery Pipes................................... 114
Charge Air Cooler, Overhaul.................................. 156 Inlet and Exhaust Manifolds................................... 124
Charge Air Cooler, Replace................................... 152 L
Classification schedule, cylinder block / crankshaft. 53 Lifting the Engine, Actions........................................ 22
Coolant level sensor, change................................. 177 Lubricating and Oil System, General........................ 99
Coolant Pump, Change.......................................... 148 Lubrication Oil Pump, Change............................... 101
Coolant Pump, Thermostat.................................... 148
Coolant temperature sensor, change..................... 179 M
Coolant, Change.................................................... 141 Model Identification.................................................. 24
Cooling System, General....................................... 141 Monitoring and Control Systems............................ 165
Cooling System, Pressure Testing......................... 141 MPROP valve, change........................................... 123
Crank Mechanism.................................................... 92 O
Crankshaft Seal, Change (front)............................... 94 Oil cooler................................................................ 103
Crankshaft Seal, Change (rear)............................... 92 Oil Cooler, Replace................................................ 103
Cylinder Head........................................................... 55 Oil level sensor, change......................................... 175
Cylinder Head, Change............................................ 55 Oil pressure sensor, replace.................................. 174
D Oil pump and Line.................................................. 101
Design and Function................................................ 24 P
Drive belt, change.................................................. 149 PCU, Replace......................................................... 165
E Power Steering....................................................... 180
Engine Assembly...................................................... 53 R
Engine Complete, General....................................... 30 Radiator, Heat Exchanger...................................... 143
Engine Fuel Filter Replacement............................. 104 Rail Pressure Sensor, Change............................... 122
Engine Information, General.................................... 22 Repair instructions.................................................. 4, 6
Engine Oil Pressure, Check................................... 100 Rubber mountings.................................................... 54
Engine Oil, Change.................................................. 99
S
Engine, Overhaul...................................................... 30
Safety Information.................................................... 15
Exhaust Manifold, Change..................................... 124
Safety Instructions.................................................... 15
F Sea Water System, Sea Water Pump.................... 157
Flywheel, Change..................................................... 96 Seawater pump hub, overhaul............................... 157
Fuel Feed Pressure, Check.................................... 107 Seawater Pump, Change....................................... 159
Fuel Feed Pump and Filter..................................... 104 Seawater Pump, Impeller, Change........................ 160
Fuel Feed Pump, Change...................................... 105 Sensors for Indicator and Warning System............ 174
Fuel Return Pressure, Check................................. 109 Servo Steering Pump, Change............................... 180
Fuel System Vacuum, Check................................. 110 Special Service Tools............................................... 20
Fuel temperature sensor (High-Pressure Specifications, Engine ............................................. 10
Pump), replacing ................................................... 176 Starter Motor.......................................................... 163
G Starter Motor, Change............................................ 163
Gear Ring, Replace.................................................. 83 T
General................................................................. 3, 22 Technical Data......................................................... 10
General Specifications............................................... 9 Thermostat, Change............................................... 151
General Tightening Torques....................................... 9 Timing Gears and Shaft........................................... 83
Group 21: Engine..................................................... 11 Top Cover, Service Position..................................... 80
Group 22: Lubrication System............................ 13, 24 Troubleshooting........................................................ 28
Group 23: Fuel System...................................... 13, 26 Turbo and supercharger......................................... 128
Group 25: Inlet and Exhaust System........................ 13 Turbo, Change....................................................... 136
47702022 04-2019 © AB VOLVO PENTA 183

Turbocharger, check.............................................. 128
Turbocharger, cleaning.......................................... 129
V
Vacuum Pump, Change......................................... 138
Valve cover, change................................................. 79
184
References to Service Bulletins
Group No. Date Refers to
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Date:....................................................................................
Name:..................................................................................
AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
47702022 English

Workshop Manual: Group 21-26

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Workshop Manual

Safety and Other Instructions

Lubricating and Oil System

Inlet and Exhaust System

Alternator, Charge Regulator

Other Electrical Equipment

47702022 04-2019 © AB VOLVO PENTA 1

2 47702022 04-2019 © AB VOLVO PENTA

Volvo Penta accepts no responsibility for damage or

47702022 04-2019 © AB VOLVO PENTA 3

4 47702022 04-2019 © AB VOLVO PENTA

Lock nuts Anaerobic agents.

47702022 04-2019 © AB VOLVO PENTA 5

Above all, when working on fuel systems, hydraulic

6 47702022 04-2019 © 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!

47702022 04-2019 © AB VOLVO PENTA 7

Colors used in illustrations

Other types of symbols used in the images are

8 47702022 04-2019 © AB VOLVO PENTA

03-0 General Specifications

47702022 04-2019 © AB VOLVO PENTA 9

03-2 Specifications, Engine

10 47702022 04-2019 © AB VOLVO PENTA

Group 21: Engine

Main bearing classes

Cylinder head / cylinder block

Cylinder head gasket

NOTICE! Hole A and B are only used to identify engine

Dist., block surface- piston (TDC) Classification

47702022 04-2019 © AB VOLVO PENTA 11

As standard the diameter is measured 12 mm (0.47")

C-marked (1) 80.95–80.96 mm

* To be measured with the cylinder block assembled.

12 47702022 04-2019 © AB VOLVO PENTA

Group 22: Lubrication System

Oil pressure at D3-D/E/F/G D3-H →

Group 23: Fuel System

Group 25: Inlet and Exhaust System

Group 26: Cooling System

47702022 04-2019 © AB VOLVO PENTA 13

Group 30: Electrical System

NOTICE! Do not apply grease on the sealing ring.

14 47702022 04-2019 © AB VOLVO PENTA

05-1 Safety Instructions

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

47702022 04-2019 © AB VOLVO PENTA 15

16 47702022 04-2019 © AB VOLVO PENTA

Do not touch the connections during a starting

47702022 04-2019 © AB VOLVO PENTA 17

18 47702022 04-2019 © AB VOLVO PENTA

47702022 04-2019 © AB VOLVO PENTA 19

08-2 Special Service Tools

885050 Fixture 885490 Sleeve 885511 Roller

885531 Pressure testing kit 885536 Plug 885539 Plug

885633 Torque multiplier 885819 Counterhold 885820 Puller

1158688 Torque wrench 9989876 Dial indicator 9990150 Manometer

9995192 Gauge rod 9995199 Drift 9995270 Pressure gauge

20 47702022 04-2019 © AB VOLVO PENTA

9995919 Extractor 9996398 Manometer 9996400 Slide hammer