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Reassembly - DB Moteurs

1. 0 40 0 0157 Replacing camshaft bushings Install the bushings in the crankcase then secure them in place with the set screws Before tightening the screws be sure that the screw holes in the bush ings and crankcase are aligned and that the oil holes in the bushings are aligned with those leading to the oil gallery in the crankcase Use a wide bushing as the bearing for the rear section and insert it in the correct attitude 2 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Reassembly Install the rear plate 1 Apply sealant to the rear plate mounting surface of the crankcase then place the packing in posi tion Apply the same sealant to the packing then install the rear plate 2 Replace the dowel pins if worn or if the rear plate has been replaced 3 Make sure that the lower end of the rear plate is flush with the bottom of the crankcase Cut off the excess of the packing neatly along the edge of the plate Crank the engine 1 Install the bolts M22 x 1 5 mm 0 87 x 0 059 in to the viscous damper mounting holes 2 Using these bolts turn the crankshaft with a bar to bring the No 1 cylinder piston to the top dead center Install idler gear shafts Drive the idler gear shaft in using a guide bolt Tight en idler gear shaft mounting bolts to specified torque Install camshaft 1 Insert the camshaft into the cylinder block then install the thrust plate 2 Tighten
2. 3 180 0 12520 Thickness of center 0 75 0 0295 mm in Nominal Value 3 375 0 12287 Assembly Standard 3 347 to 3 360 0 13177 to 0 13228 Service Limit 3 305 0 13012 Thickness of center 1 00 0 0394 mm in Nominal Value 3 500 0 13780 Assembly Standard 3 472 to 3 485 0 13669 to 0 13720 Service Limit 3 430 0 13504 NOTE Replace bearings if worn down to service limit Regrind crankpins and use undersize bearings if necessary 26 Plus d informations sur www dbmoteurs fr Flywheel Face runout mm in Assembly Standard 0 285 0 0112 to less Radial runout mm in Assembly Standard 0 127 0 0050 or less Injection pump accessory drive Bearing bore inside diameter mm in Nominal Value 90 3 54 Assembly Standard 89 987 90 022 3 54279 3 54417 Bearing bore inside diameter mm in Nominal Value 100 3 94 Assembly Standard 99 987 100 022 3 93649 3 93787 Bearing Outside diameter mm in Nominal Value 90 3 54 Assembly Standard 89 985 90 000 3 54272 3 54331 Bearing Outside diameter mm in Nominal Value 100 3 94 Assembly Standard 99 985 100 000 3 93642 3 93701 Bearing Inside diameter mm in Nominal Value 45 1 77 Assembly Standard 44 988 to 45 000 1 77118 to 1 77165 Bearing Ins
3. Main bearing cap bolt Side bolt Main bearing cap Main bearing lower Thrust bearing Crankshaft Main bearing upper Thrust bearing Slinger front Slinger rear Crankshaft gear Check valve Piston cooling nozzle Crankcase Plus d informations sur F D s Look for O n m OO w gt Scale damage cracks clogged oil holes Wear scratching pitting scoring Stripped threads Wear Clogged oil hole Check valve movement Scoring pitting flaking chipping cracks corrosion Wear chipping abnormal tooth contact Wear Cracking Stripped threads 117 www dbmoteurs fr Group 21 Engine Body 11 Turning the crankcase upside down Use such lifting tool as a chain block and shackles to play the crankcase on its side Then add slings to the crankcase and turn it upside down Weight Approx 1000 kg 2205 Ib Removing the main bearing caps 1 Unscrew the cap bolts and side bolts Remove the main bearing cap using cap removers injec tor remover or a chain block use 2 eye bolts M27 x 1 5 mm 1 06 x 0 059 in 2 Remove the thrust bearings from the No 7 bear ing cap Do not damage the thrust bearings Removing the crankshaft 1 Remove the front upper halves of the thrust bear ings by rotating them slowly 2 Carefully lift the crankshaft off the crankcase keeping it horizontal
4. 70 2 76 Assembly standard 70 020 70 040 2 75669 2 75747 Service limit 70 070 2 75866 Replacing connecting rod bushings 1 Use the Connecting rod bushing installer A to re move 1 the bushing for replacement as shown 2 When installing a new bushing 2 align the oil holes in the bushing and connecting rod 3 After installing the bushing measure it and ream to correct size if necessary Insert the piston pin and make sure that the pin rotates freely without rattling Connecting rods bend 1 and twist 2 Measure C and L If the measurement at C is larger than 0 05 mm 0 0020 in per 100 mm 3 9 in of L straighten the rod with a press NOTE To inspect for bend and twist install the cap to the connecting rod then tighten the cap bolts to the specified torque To inspect the rod bend when assembled with the piston place the piston on a surface plate Insert a round bar of the same diameter as the crank pin into the big end bore then measure heights A and B of the bar Connecting rod bend C D mm in Assembly standard 0 05 100 max 0 0020 3 9 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Inspecting connecting rod large end bearings Inspect each bearing shell for flaking scratching sei zure pitting and other defects If any defects are found replace the shell Measuring connecting rod end play Install the connecting rod to its crank pin then
5. 0 c cesceeeeeeseeeeeeeees 45 INSPOCHON ssisssssssrrnareeetennnes na 132 Standard eyebolts cccccceeeeeeeeeeeseeeseteeeseees 45 Reassembly 132 Standard union nuts cccceeeeeeeeeeeeeeeeeeeeeeeeees 46 Oil Cooler and Thermostat 133 High pressure fuel injection pipes ee 46 Inspectii ess rate cies Obtenir 134 Sealants and Lubricants Table 47 Re assemblsss sereine E 134 Sp cial TOQIS siririna iernut 48 Determination of overhaul timing ee 51 Plus d informations sur www dbmoteurs fr Oil Filter Filter Alarm Relief Valve Left Side Cooler and Thermostat 135 Inspection 135 Reassembly eee eeeeccceeeeeeeeseceeeeeeeseseeeeeeeeneeneees 135 Group 23 Fuel System 136 PUT FIGS 58 eme amener 136 Reassembly 137 Fuel Injectors sanati a ptet 138 Inspection and Adjustment 139 Reassembly re 141 Fuel Injection PUMP ssessssssrsessersrnrensrrrrnrensrnnnnn 142 Inspection 147 FREASSOMDIY roiete NARE E 150 Adjustment of Injection Timing eee 159 FOO PUMI assise eects ender eee 161 RRASSOMDIy eee eeeeccceeeeeeeeneceeeeeeeneseeeeneeeeeeneees 162 VeQOSUUING sariro Ea E S 162 PSG Woodward Governor and Driv
6. PEPEE A CAUTION PERFORM SAFETY MAINTENANCE Wel Bs WITH REFERENCE TO OPERATION AND MAINTENANCE MANUAL 45A93 51600 5 pJ e HOT WATER MAY A 2e CAUSE BURNS DU NOT REMOVE RADIATOR CAUTION ta HOT SURFACES MAY CAUSE BURN HOT SURFACE MAY CAUSE BURNS CAUTION DO NOT TOUCH HOT SURFACE 45A93 59900 Plus d informations sur www dbmoteurs fr General information General Information About the Workshop Manual This Workshop Manual contains technical information descriptions and instructions for the standard versions of the D25A and D30A engines The engine designation and numbers are to be found on the engine identification plate refer to section Identification numbers The motor designation and number should always be given during all correspondence with Volvo Penta The Workshop Manual is primarily produced for Volvo Penta service workshops and their qualified personnel It is therefore assumed that persons using this manual have a basic knowledge of marine drive systems and are able to carry out the related mechanical and electrical nature Volvo Penta is continuously developing their prod ucts We therefore reserve the right to make changes All the information contained in this book is based on product data available prior to publication Any essential changes or modifications in production or updated or re vised service methods introduced after publication will b
7. Assembly Standard 85 C 185 F NOTE Check in atmospheric pressure 34 Plus d informations sur www dbmoteurs fr Sea water pump Impeller Repair Limit Replace if cracked Pump seals Repair Limit Replace if water leaks Bearing Repair Limit Replace if worn excessively Holder bearing bore inside diameter mm in Nominal value 90 3 54 Assembly Standard 89 975 90 010 3 54232 3 54362 Service Limit 90 013 3 54381 Bearing Outside diameter mm in Nominal value 90 3 54 Assembly Standard 90 000 90 015 3 54330 3 54389 Bearing Inside diameter mm in Nominal value 30 1 18 Assembly Standard 29 990 30 000 1 18071 1 18110 Bearing Inside diameter mm in Nominal value 40 1 57 Assembly Standard 39 988 40 000 1 57433 1 57480 Shaft bearing journal mm in Nominal value 30 1 18 Assembly Standard 30 002 30 012 1 18118 1 18157 Service Limit 29 995 1 18090 Shaft bearing journal mm in Nominal value 40 1 57 Assembly Standard 40 002 40 013 1 57488 1 57531 Service Limit 39 995 1 57460 Maintenance Standards 35 Plus d informations sur www dbmoteurs fr Maintenance Standards Fuel system Fuel injector Valve opening pressure MPa kgf cm psi Nominal value 3
8. Install the other connecting rod to the crank pin Temporarily tighten the cap bolts of the rod in stalled later then press it squarely toward the rod already installed by tapping Move the large end of this rod in the thrust direction Make sure that the rod has correct end play insert feeler gauges while tightening Tighten the cap bolts to the specified torque NOTE Tighten connecting rod cap bolts according to the angle method Tighten to 245 N m 25 kgf m 181 lbf ft then 60 more Use feeler gauges to measure the end play of the connecting rod Make sure that the end play is equal on both top and bottom sides of the crank pin AN IMPORTANT Before installing the cylinder head measure the protrusion of the piston Make sure that the measurement is correct 2 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Viscous damper and front gears Disassembly 1 Crankshaft pulley Viscous damper Pulley water pump amp alternator drive Front oil seal a A WwW ND Front cover Plus d informations sur www dbmoteurs fr Look for A Worn belt groove B Cracks oil leakage C D E Worn belt groove Worn lip wear deterioration Cracks defective dowel pin hole 103 Group 21 Engine Body Viscous damper 1 Attach a sling to the viscous damper Unscrew the mounting bolts pA 2 Screw the jack bolts M14x1 5 40 mm 0 55 x la 0 059 1 57 in into the t
9. 1 Install the nozzle on the nozzle tester Operate the handle of the tester at a rate of about 1 stroke per setond to observe the pressure at which fuel is being injected If the pressure is out of stan dard adjust it Injection pressure MPa kgf cm2 psi Assembly Standard 34 32 34 81 350 355 4979 5050 A WARNING Never touch the spray hole of the in jection nozzle during injection testing 2 To adjust injection pressure remove the set screw from the nozzle holder loosen the cap nut and then turn the adjusting screw To increase the injection pressure tighten the screw To de crease the injection pressure loosen the screw 3 After completing the adjustment tighten the set screw and the cap nut to the specified torque 4 Re check the injection pressure to be sure that it is correct Spray pattem 1 When you are testing the injection pressure in spect each nozzle for clogged or leaking holes Also examine the spray pattem If the nozzle is faulty wash or replace it 2 When tested on the nozzle tester the nozzle should spray fuel from all ten holes at the same time in a straight cone of 160 degrees The spray should tonsist of finely atomized fuel particles without large droplets The spray should termi nate without dripping at the top 139 Plus d informations sur www dbmoteurs fr Group 23 Fuel System 14 Washing or replacing the nozzle 1 The nozzle is spring loaded Remove the
10. 4 000 0 15748 Assembly Standard 3 967 to 3 980 0 15618 to 0 15669 Service Limit 3 925 0 15453 NOTE Replace bearings if worn down to service limit Regrind crankpins and use undersize bearings if worn beyond service limit Crankcase Flatness of gasket surface mm in Assembly Standard 0 1 0 004 or less Repair Limit 0 2 0 008 NOTE Reface if necessary Main bearing bore diameter mm in Nominal Value 147 5 79 Assembly Standard 147 000 to 147 025 5 78739 to 5 78837 Service Limit 147 035 5 78877 30 Plus d informations sur www dbmoteurs fr Inlet and exhaust system Turbocharger TD13 Inside diameter of bearing fitted housing section mm in Nominal Value 30 1 18 Service Limit 30 006 1 18134 Bearing outside diameter mm in Service Limit 29 876 1 17622 Bearing inside diameter mm in Service Limit 18 050 0 71063 Bearing length mm in Service Limit 17 440 0 68661 Shaft journal diameter mm in Nominal Value 18 0 709 Service Limit 17 996 0 70850 Shaft deflection mm in Service Limit 0 015 0 00059 Ring gap clearance mm in Standard Clearance 0 05 to 0 25 0 00197 to 0 00984 Shaft amp turbine wheel and turbine housing clearance mm in Standard Clearance 0 29 to 0 91 0 01142 to 0
11. O 0 O O O O O O0 16 Testing Airtightness test Plug the discharge port Apply air pressure of 0 2 MPa 2 kgf cm 28 4 psi to the suction port immerse the pump in diesel fuel and check for air leakage bub bles Feed pump test Testing conditions Fuel pipe mm in Outside diameter 15 mm 0 59 in Inside diameter 13 mm 0 51 in Length 2000 mm 78 7 in Cam mm in Lift per revolution 12 mm 0 47 in Run the pump under the above conditions and mea sure the discharge start time Feed pump discharge start at 100 rpm sec Assembly Standard 20 sec or less Priming pump suction capacity Discharge fuel completely from the feed pump in the testing conditions described in the feed pump test Then operate the priming pump at a rate of 60 to 100 strokes per minute and count the number of pumping operations required for fuel to reach the pump Priming pump discharge start strokes Assembly Standard 30 or less Feed rate test Open the valve on the discharge side in the testing conditions described in the feed pump test Operate the pump and measure the amount of oil fed during the first 15 seconds Feed rate at 500 rpm cm cu in 15 sec Assembly Standard 1100 67 1 or more 2 Plus d informations sur www dbmoteurs fr Group 23 Fuel System PSG Woodward Governor and Drive Disassembly PSG governor Packing Dr
12. 0 20 0 29 2 0 2 9 28 to 43 Repair limit 0 10 1 0 14 or lower at idling speed NOTE Oil temp 60 to 70 C 140 to 158 F Valve timing 2 mm 0 8 in clearance valve side cold Nominal Value Inlet valve opens 2 5 BTDC 2 crank angle Inlet valve closes 13 ABDC 2 crank angle Exh valve opens 26 BBDC 2 crank angle Exh valve closes 10 5 BTDC 2 crank angle NOTE Values are only for checking valve timing and are different from the actual ones Valve clearance cold mm in Inlet valves Standard Clearance 0 6 0 024 Exhaust valves Standard Clearance 0 8 0 031 Injection timing Nominal Value XX BTDC 1 crank angle NOTE XX varies according to specifications Refer to caution plate on No 1 rocker cover 22 Plus d informations sur www dbmoteurs fr Engine main parts Valves Valve stem diameter mm in Nominal Value 10 0 39 Assembly Standard 9 940 to 9 960 0 39134 to 0 39213 Service Limit 9 910 0 39016 NOTE The same for both inlet and exhaust valves Valve guide inside diameter mm in Nominal Value 10 0 39 Assembly Standard 10 000 to 10 015 0 39370 to 0 39429 Service Limit 10 060 0 39606 NOTE The same for both inlet and exhaust valves Valve seat angle A Nominal Value 30 Valve depth B mm in
13. 37 3 67 2 82 2 Delivery valve spring mm in Free length A Assembly Standard 18 0 71 Perpendicularity B Service Limit 0 6 0 024 Length under test force mm in Assembly standard 14 15 0 56 Test force N kgf Ibf Assembly standard 51 6 61 4 5 26 6 26 11 60 13 80 Camshaft thrust clearance mm in Standard Clearance 0 02 to 0 06 0 00079 to 0 00236 Resistance in rack movement Assembly Standard 500 g 1 102 Ib NOTE Make sure rack moves smoothly Total rack stroke should be 36 mm 1 42 in Injection start interval Assembly Standard 60 0 5 NOTE Camshaft angle Nozzle valve opening pressure MPa Bar psi Assembly Standard 34 3 343 4978 75 Feed pressure MPa Bar psi Assembly Standard 0 16 1 6 22 76 37 Plus d informations sur www dbmoteurs fr Maintenance Standards PSG governor drive Diameter of case bore drive shaft side bearing section mm in Nominal Value 52 2 05 Assembly Standard 51 988 52 018 2 04677 2 04795 Drive shaft side bearing Outside diameter mm in Nominal Value 52 2 05 ae Assembly Standard 51 987 52 000 2 04673 2 04742 Inside diameter mm in Nominal Value 25 0 98 Assembly Standard 24 990 25 000 0 98386 0 98425 Drive shaft diam bearifig secti f mm in Nominal Value 25 0 98 Assembly Standard 25 002 25 011 0 9843
14. Installing the oil deflector Apply engine oil to both sides of the thrust ring and in stall Then install the oil deflector with the baffle fac ing down 18 8 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Assembling the insert sub assembly 1 Install the finger sleeve and the piston ring in the insert A IMPORTANT Do not expand the piston ring ex cessively or twist the ends when installing on the finger sleeve A IMPORTANT Apply Moly Disulfide to the piston ring installed on the finger sleeve then install on the insert carefully so as to avoid piston ring damage 2 After installing the above parts irrstall the sub as sembly in the bearing housing 26 Installing the snap ring Install the snap ring with the tapered side face up in the bearing housing Make sure you install the snap ring correctly NOTE Lightly drive both ends of the snap ring using a screwdriver and hammer to securely insert the ring into the groove on the bearing housing Make sure the screwdriver does not hit the bearing housing 189 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System 19 Turbine wheel and housing clearance Set a dial gauge on the end face of the shaft amp turbine wheel Read the dial gauge indication while moving the shaft amp turbine wheel in the axial direction If the dial gauge indication deviates from the assem bly standard disa
15. Nominal value 0 Assembly Standard 2 0 0 2 0 008 0 008 Repair Limit 1 0 0 039 Seat width C mm in Nominal value 2 3 0 091 Assembly Standard 2 15 to 2 45 0 0846 to 0 0965 Repair Limit 2 8 0 110 Valve margin D mm in Nominal Value 3 0 0 12 Assembly Standard 2 8 3 2 0 110 to 0 126 NOTE Refacing permissible up to 2 5 0 098 Cylinder head bore and valve seat diameter mm in Nominal Value 60 2 36 Assembly Standard 0 070 0 130 0 00276 0 00512 NOTE minus indicates interference Valve springs Free length A mm in Assembly standard 73 2 87 Service limit 71 2 80 Perpendicularity B mm in Service limit 2 2 0 087 at end Length under test force mm in Assembly standard 66 0 2 6 Test force N kgf Ibf Assembly standard 289 319 29 45 to 32 55 65 to 72 Plus d informations sur www dbmoteurs fr Maintenance Standards W i 23 Maintenance Standards Valve push rods Deflection mm in Assembly Standard 0 5 0 020 maximum Service Limit 0 5 0 020 Rockers Rocker bushing inside diameter mm in Nominal Value 36 1 42 Assembly Standard 36 000 to 36 040 1 41732 to 1 41889 Service Limit 36 090 1 42086 Rocker shaft diameter mm
16. WITH REFERENCE TO OPERATION AND 93 51600 MAINTENANCE MANUAL 45 HOT WATER MAY CAUSE BURNS DU NOT REMOVE RADIATOR CAUTI 0 N CAP UNDER HOT CONDITIONS 45493 50600 Plus d informations sur www dbmoteurs fr Safety information Warning labels D25A D30A MT The engine carries Warning Labels at places where you are required to pay special attention Please read them carefully and make sure you understand the content of each label and the meaning of their position 1 Make sure the labels are legible If you find any letter or picture illegible in a label remove soil from the label or replace it Clean the label with cloth and water or cleanser Do not use organic solvent or gasoline this would dissolve the label s adhesive and cause the label to fall off If any label is damaged lost or illegible replace it When replacing a label make sure the new label is identical to the old one For new labels please contact your dealer WARNING BE CAREFUL OF ROTATING BELT DO NOT PUT FINGERS NEA ROTATING BELT asno3 s Q WARNING il OIL MIST IS q Y FLAMMABLE AND lt EXPLOSIVE DO NOT OPEN INSPECTION COVER WITHIN 10 MINUTES AFTER ENGINE STOP 4 45093 51300 5 WARNING TURNING CAN CAUSE SEVERE NY PERSONAL INJURY BE SURE NO DANGER AROUND MOVING PARTS BEFORE TURNING e KEEP TURNING DEVICE OR BAR IN OFF POSI TION WHEN NOT IN USE
17. Workshop Manual EH 2 0 D25A MS D25A MT D30A MS D30A MT Plus d informations sur www dbmoteurs fr Plus d informations sur www dbmoteurs fr Marine Engines D25A amp D30A MS MT Content Safety Information 5 Adjustment and Benchtesting 52 IntOdUCtION iiion 5 Valve Clearance ccccceceeseceeeeeeeeeeeeeeneeeeenieeeeee 52 IMPOTANT kisiera nn ne 5 Fuel system bleeding 55 Warning labels D25A D30A MS ose 8 Fuel injection timing 57 Warning labels D25A D30A MT ossee 9 Speed Setting 2eme fees 59 General Information cccceeeeeeeeeeeeeeteeeeeeeees 10 Measure V belt deflection 60 About the Workshop Manual 10 Bench testing jasseiccceesvessencce de cacsanneoeaseadsncetexetentecs 61 Spare parts 10 Engine auxiliaries removal and installation 62 Certified engines ccccccececeeeeeeeeeeteeeeeeneeeeteaes 10 Engine Auxiliaries Installation 69 Repair instructions 11 Group 21 Engine Body n 73 Our joint responsibility 11 Cylinder heads and valve mechanism 73 How to Use This Manual 1
18. bled in correct orientation Therefore put align ment marks with a punch or marker Remove the compressor cover 1 Put the turbocharger on a workbench with the compressor cover down Unscrew the bolts and remove the lockplates 2 Lightly tap around the compressor cover with a soft faced hammer to remove the cover Also re move the o ring from the bearing housing Remove the compressor wheel A IMPORTANT Handle the compressor wheel and turbine wheel with care during disassembly and assembly Vanes can easily bend when dropped or hit 1 Fasten the flange of the turbine housing in a vise and install the bearing housing to the turbine housing with the v clamp 2 Hold the boss of the shaft amp turbine wheel and re move the lock nut holding the compressor wheel NOTE The lock nut has left handed threads 3 While holding the turbine wheel with one hand turn the compressor wheel lightly with the other hand and remove 169 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Removing the snap ring NOTE Use only snap ring pliers to remove snap rings NOTE Put your thumb on the snap ring to prevent it from flying out in case the pliers lose grip Removing the insert and oil deflector 1 Using two screwdrivers gently pry out the insert from the bearing housing 2 Separate the finger sleeve together with the pis ton ring from the insert 3 Remove the o ring the o
19. 11 Install governor drive Fit the o ring to the mounting flange of the drive case to wich the drive shaft and gear have been installed and install the case to the rear plate Tighten the case mounting bolts to the specified torque Install the flywheel 1 Install the flywheel Check that all dowel pins en ter their holes 2 Coat the threads and the bolt bearing surface of the flywheel mounting bolts with engine oil Tight en the bolts to the specified torque Inspect the face and radial runouts of the flywheel Install the pickup 1 Turn the engine to position a tooth of the ring gear at the center of the pickup mounting hole 2 Screw the pickup gently into the hole by hand When the pickup touch the gear tooth loosen it 1 turn then tighten the lock nut to secure the pickup in place NOTE Installing the pickup too close to the teeth may result in too strong a signal Install oil pump and oil strainer Measure the backlash between crankshaft gear and oil pump drive gear adjust with shims if necessary Install the oil sump Apply sealant to the joint surface of the oil sump and place the packing on the sump Apply the same seal ant to the packing and mount the sump on the crank case Tighten the bolt uniformly to specified torque 6 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Crankcase Crankshaft and Main bearings Disassembly ON DOA BR WD ee L BR amp D
20. 2 Remove control bracket 3 and speed control knob as a set 65 Plus d informations sur www dbmoteurs fr Auxiliaries removal and installation 66 Remove governor oil filter 1 Remove oil pipes 1 2 and 3 2 Remove oil filter 4 3 Remove oil tank bracket 5 oil tank stay 6 and stay 7 Remove the governor 1 Remove governor drain pipe 1 2 Remove control links 2 and 3 as a set 3 Remove control lever 4 and lever bracket 5 4 Remove governor mounting bolts and governor 6 Remove fuel pipes 1 Remove fuel leak off pipes 1 2 Disconnect six fuel pipes 2 and six leak connec tors 3 3 Disconnect and remove leak off pipes 4 5 6 and 7 NOTE Cover the openings of the injection pump and nozzle inlet connectors with rubber caps to prevent dust from entering the system Plus d informations sur www dbmoteurs fr 1 2 3 4 2 Auxiliaries removal and installation Remove fuel injection pump Remove the two lubrication oil pipes 1 Remove the coupling cover 2 Remove tcoupling joint nut 3 Unscrew pump mounting screw 4 With the cou pling attached to the injection pump side remove the injection pump 5 by pulling it towards the front using a stick to give leverage Weight approx 60 kg 132 Ib Unscrew bracket mounting bolts and remove the bracket 6 Remove stop solenoid 1 Disconnect linkage 1 Remove lev
21. Lubrication system Oil pump Cover and case Sealant ccceeeeees refer to parts catalogue How to use ee Coat both sides of packing Cooling system Fresh water pump Oil seal Lubricant s s s Engine oil How to use eee Coat lip of inner seal Fresh water pump Unit seal Lubricant s s s Coolant How to use Coat floating seat Sea water pump Unit seal Lubricant 0 Grease How to use Apply to surface that contacts bushing Sea water pump Oil seal Lubricant c Grease How to USE eee Apply to hollow part and lip of oil seal 47 Plus d informations sur www dbmoteurs fr Special tools Special Tools gt A 885423 885422 885391 885410 E go 885413 885386 885452 885414 885396 885443 885420 885423 Rocker bushing tool 885452 Ring pliers 885422 Cylinder head lifting 885425 Cylinder liner remover 885391 Valve spring pusher 885414 Piston ring tool 885410 Valve guide remover 885396 Idler bushing puller 885413 Valve guide and seal installer 885443 Piston installer 885386 Valve lapper 885420 Connection rod bushing installer 48 Plus d informations sur www dbmoteurs fr 885421 885409 885445 885447 885446 885424 885446 885421 885409 ZB D 885424 885439 885441 Compression gauge adaptor Compression gauge To remove install injection pump gear and waterpump shaft pulley nut Tool for lifting piston Waterpump pliers Imp
22. Plus d informations sur www dbmoteurs fr Plus d informations sur www dbmoteurs fr Plus d informations sur www dbmoteurs fr Plus d informations sur www dbmoteurs fr Plus d informations sur www dbmoteurs fr Plus d informations sur www dbmoteurs fr 7742854 8 English 05 2003
23. Safety switch A Wear of gear damage 2 Magnetic switch assembly B Play and unsmooth rotation 3 Rear bracket C Adhesion of brush particles irregular 4 Brush holder assembly wear brush movement in holder 5 Yoke assembly D Wear of gear 6 Armature assembly E Surface roughness seizure wear and damage 7 Center bracket 8 Shift lever assembly 9 Front bracket oO Pinion case 4 _ Pinion clutch assembly 206 Plus d informations sur www dbmoteurs fr Group 30 Electrical System 1 Remove the safety switch wires and cables and the magnetic switch assembly 2 Unscrew the through bolts and the brush holder mounting screws Remove the rear bracket 3 Remove the brushes from the brush holder as sembly and then remove the yoke 4 Pull out the armature assembly 07 2 Plus d informations sur www dbmoteurs fr Group 30 Electrical System 20 5 Remove the center bracket 6 Remove the lever pin inner housing and shift le ver from the pinion case 7 Using a jig remove the pinion stopper then re move the overrunning clutch from the pinion shaft NOTE To remove the shaft bearing for replacement use a bearing puller as shown in the drawing 8 Plus d informations sur www dbmoteurs fr Group 30 Electrical System Inspection and Repair Magnetic Switch Testing the magnetic switch coil 1 Test the pressure coil and holding coil for an open ciruit The coils ar
24. high engine performance Inspecting piston ring grooves Check the piston ring grooves for wear and damage replace the piston if necessary Pay special attention to the Ni resist insert in the top groove A for cracks Plus d informations sur www dbmoteurs fr Group 21 Engine Body Piston Rings Measuring piston ring gaps Place the rings in the new or master cylinder liner Measure the gap of each ring If the service limit is exceeded replace all the rings on that piston NOTE Use a piston to place the piston ring in the lin er by pushing it squarely Piston ring gap Top ring mm in 4 N y N y j N Standard clearance 0 6 0 8 0 024 0 031 Service limit 2 0 0 079 Piston ring gap Second ring mm in Standard clearance 0 6 0 8 0 024 0 031 Service limit 2 0 0 079 Piston ring gap Oil ring mm in Standard clearance 0 3 0 45 0 012 0 018 Service limit 2 0 0 079 95 Plus d informations sur www dbmoteurs fr Group 21 Engine Body me lt 100 3 9 0 05 0 0020 100 3 9 96 0 05 0 0020 Connecting Rods Bearings and Bushings Measuring connecting rod bushing inside diameter Measure the inside diameter of each bushing in two directions and on two locations see picture If the service limit is exceeded replace the bushing Connection rod bushing inside diameter mm in Normal value
25. 0 20 0 0039 to 0 0079 Service Limit 0 4 0 0157 Drive gear and driven gear clearance mm in Nominal Value 60 2 36 Standard Clearance 0 100 to 0 148 0 00394 to 0 00583 Clearance 0 Tip clearance 0 35 0 0138 Gear end clearance in case mm in Nominal Value 72 5 2 854 Standard Clearance 0 040 to 0 116 0 00157 to 0 00457 Clearance 006 0 21 0 0083 NOTE Remove the cover packing width of 0 04 0 0016 for mesurement Shaft diameter mm in Nominal Value 25 0 98 Assembly Standard 24 947 to 24 960 0 98216 to 0 98268 Service Limit 24 900 0 98031 Bushing inside diameter mm in Nominal Value 25 0 98 Assembly Standard 25 000 to 25 021 0 98425 to 0 98508 Service Limit 25 100 0 98819 Safety valve Valve opening pressure MPa Bar psi Assembly Standard 1 37 0 10 13 7 1 0 199 14 Spring set length load mm in N kgf Ibf Assembly Standard 67 2 2 64 384 38 2 86 4 Relief valve Valve opening pressure MPa Bar psi Assembly Standard 0 46 4 6 66 8 Oil thermostat Temperature at which valve starts opening Assembly Standard 80 to 84 C 176 to 183 F Temperature at which valve lift more than 11 mm 0 43 in Assembly Standard 95 C 203 F Piston cooling nozzle Valve opening pressure MPa Bar psi Assembly Standard 0 2
26. 000 50 025 1 96850 1 96848 Service limit 50 060 1 97086 Idler gear shaft diameter mm in Nominal value 50 1 97 Assembly standard 49 950 49 975 1 96653 1 96752 Service limit 49 900 1 96456 Idler gear end play Measure the end play with feeler gauges or dial gauge If the idler gear end play exceeds the service limit replace the thrust plate Idler gear end play mm in Standard clearance 0 2 0 4 0 008 0 016 Service limit 0 6 0 024 Replace idler bushing 1 Use the Idler bushing puller to remove the bush ing 2 Install a new bushing to the gear by pressing it until the end face of the bushing is 1 mm 0 04 in A recessed from that of the gear boss 3 After installing the bushing make sure that its in side diameter is within the assembly standard If not ream the bushing to the correct diameter 0 4 Ra 0 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Camshafts and Camshaft Bushings Measure cam lift Use a micrometer to measure the diameters of A and B on each cam to determine the reduction in cam lift If the cam lift is less than the service limit re place the camshaft Cam lift A B mm in Assembly standard 9 197 9 297 0 36209 0 36602 Service limit 8 45 0 3327 Measuring camshaft deflection If the deflection exceeds the repair limit straighten the cams
27. 03583 Shaft end play mm in Assembly Standard 0 075 to 0 135 0 00295 to 0 00531 Turbine backplate and turbine wheel clearance mm in Standard Clearance 0 55 to 1 15 0 02165 to 0 05315 Maintenance Standards 31 Plus d informations sur www dbmoteurs fr Maintenance Standards Turbocharger TD15 Inside diameter of bearing fitted housing section mm in Nominal Value 34 1 34 Service Limit 34 016 1 33921 Bearing outside diameter mm in Service Limit 33 882 1 33393 Bearing inside diameter mm in Service Limit 19 929 0 78460 Bearing length mm in Service Limit 19 440 0 76535 Shaft journal mm in Nominal Value 20 0 79 Service Limit 19 863 0 78201 Shaft deflection mm in Service Limit 0 015 0 00059 Ring gap clearance mm in Standard Clearance 0 05 to 0 20 0 00197 to 0 00787 Shaft amp turbine wheel and turbine housing clearance mm in Standard Clearance 0 63 to 1 18 0 02480 to 0 04646 Shaft end play mm in Assembly Standard 0 075 to 0 135 0 00295 to 0 00531 Turbine backplate and turbine wheel clearance mm in Standard Clearance 0 85 to 1 35 0 03346 to 0 04528 32 Plus d informations sur www dbmoteurs fr Lubrication system Oil Pump Backlash between drive gear and driven gear mm in Assembly Standard 0 10 to
28. 098 194 19 8 143 350 35 7 258 M20 x 2 5 0 79 x 0 098 272 27 7 200 489 49 9 361 M22 x 2 5 0 87 x 0 098 363 37 0 268 653 66 6 482 M24 x 3 0 94 x 0 12 468 47 7 345 843 86 0 622 M27 x 3 1 06 x 0 12 686 70 0 506 1236 126 0 911 Standard eyebolts Thread Strength classification diameter x pitch 4T mm in Nm kpm Ibf ft M8 x 1 25 0 31 x 0 049 8 1 0 8 0 1 5 8 0 72 M10 x 1 25 0 39 x 0 049 15 2 1 5 0 2 10 8 1 45 M12 x 1 25 0 47 x 0 049 25 3 2 5 0 3 18 1 2 17 M14 x 1 5 0 55 x 0 059 34 4 3 5 0 4 25 3 2 89 M16 x 1 5 0 63 x 0 059 44 5 4 5 0 5 32 5 3 62 M18 x 1 5 0 71 x 0 059 7445 7 5 0 5 54 2 3 62 M20 x 1 5 0 79 x 0 059 98 10 10 0 1 0 72 3 7 23 M24 x 1 5 0 94 x 0 059 147 15 15 0 1 5 108 5 10 8 M27 x 3 1 06 x 0 12 226 20 23 0 2 0 166 3 14 5 Dry 45 Plus d informations sur www dbmoteurs fr General information Standard union nuts Cap nut size Strength classification Nominal diameter x pitch diameter mm in Nm kpm Ibf ft M14 x 1 5 0 55 x 0 059 39 4 29 63 M16 x 1 5 0 63 x 0 059 49 5 36 80 M20 x 1 5 0 79 x 0 059 78 8 58 100 M22 x 1 5 0 87 x 0 059 98 10 72 120 M27 x 1 5 1 06 x 0 059 157 16 116 150 M30 x 1 5 1 18 x 0 059 196 20 145 180 M30 x 1 5 1 18 x 0 059 196 20 145 200 M33 x 1 5 1 30 x 0 059 245 25 181 220 M36 x 1 5 1 42 x 0 059 294 30 217 254 Dry High pressure fuel injection pipes Cap nut size Strength classification diameter x pitch mm in Nm kpm Ibf ft M12 x 1 5 0 49 x 0 05
29. 2 Install the Eye nut to the stud bolt and lift up the cylinder head assembly Locate the head aligning its holes with the dowel pins and keep the head being slightly separated from the cylinder Apply engine oil to the threads and bearing surfaces of head bolts then wipe off the excessive oil before tightening 3 Tighten the cylinder head bolts with the specified torque in the order shown in the drawing Plus d informations sur www dbmoteurs fr Group 21 Engine Body Tightening cylinder head bolts 1 2 Place the Head bolt plate on the cylinder head Tighten each head bolt to 294 N m 30 kgfm 217 Ibfft torque initial torque The head bolt plate has graduations at 30 inter vals Place a reference point mark on each head bolt Tighten each bolt 30 After tightening all bolts turn each bolt another 30 totally 60 After tightening all cylinder heads loosen all bolts and retighten again according to 1 4 Installing the rocker case 1 Insert the water outlet connector fully into the rocker case Install the rocker case so it meets the dowel pins Tighten the rocker case mounting bolts to the specified torque Insert the water outlet connector by sliding it from the next rocker case after coating the O ring with grease Install the snap ring Installing valve bridges and caps 1 Coat the bridge guides with engine oil A then install the bridges to the guides with the adjusting scre
30. 3 6 2 4 Example After checking and adjusting the cylinder No 1 turn the engine 120 and check and adjust the cylin der No 5 Cylinder No 1 5 3 6 2 4 Timing O 120 240 360 480 600 53 Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting 54 How to use the Turning Gear 1 Loosen the two bolts securing the shaft lock plate and remove the plate from the shaft groove 2 Push in the shaft all the way to the TURN posi tion 3 Put a socket to the hexagonal end of the shaft and turn the shaft with a ratchet handle for turn ing 4 After turning the engine pull the shaft back to the RUN position secure the shaft with the locking device and tighten the plate bolts Make sure the plate is secured properly A WARNING Before starting the engine make sure the turning gear is in the RUN position and is locked Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting Fuel system bleeding Prime the fuel filters and fuel injection pump in the fol lowing sequence Bleeding the Fuel filter 1 Put the fuel filter switching cock in the left filter bleed position and loosen the left air vent plug 2 Turn the priming pump plunger counterclockwise to unlock the mechanism 3 Move the plunger up and down until fuel free of air flows out then tighten the air vent plug 4 Put the fuel filter switching cock in the neutral po sition and repeat the procedure with t
31. 6795 NOTE Meaure diameter perpendicular to pin at piston skirt Weight difference between pistons in one engine Assembly Standard 10 g 0 35 oz NOTE Only one type of piston available for service replacement Pin bore diameter mm in Nominal Value 70 2 76 Assembly Standard 70 002 to 70 015 2 75598 to 2 75649 Service Limit 70 040 2 75747 Protrusion mm in Assembly Standard 0 06 to 0 65 0 0024 to 0 0256 NOTE From the cylinder block Piston rings Gaps Top ring mm in Assembly Standard 0 6 to 0 8 0 024 to 0 031 Service Limit 2 0 0 079 NOTE If gauge is not available the general value can be obtained at the cylinder bore Gaps Second ring mm in Assembly Standard 0 6 to 0 8 0 024 to 0 031 Service Limit 2 0 0 079 NOTE If gauge is not available the general value can be obtained at the cylinder bore Gaps Oil ring mm in Assembly Standard 0 3 to 0 45 0 012 to 0 018 Service Limit 2 0 0 079 NOTE If gauge is not available the general value can be obtained at the cylinder bore Piston pins Diameter mm in Nominal Value 70 2 76 Assembly Standard 69 987 70 000 2 75539 to 2 75590 Service Limit 69 970 2 75472 Maintenance Standards 25 Plus d informations sur www dbmoteurs fr Maintenance Standards Connecting rods Bush
32. 717 8 730 0 14634 0 14685 Service limit 3 675 0 14468 Main bearing thickness center 0 75 0 0295 mm in Nominal value 3 875 0 15256 Assembly standard 3 842 3 855 0 15126 0 15177 Service limit 3 800 0 14961 Main bearing thickness center 1 00 0 0394 mm in Nominal value 4 000 0 15748 Assembly standard 3 967 3 980 0 15618 0 15669 Service limit 3 925 0 15453 NOTE Four undersizes are available for the main bearings 0 25 mm 0 0098 in 0 50 mm 0 0197 in 0 75 mm 0 0295 in and 1 00 mm 0 0394 Replace main bearings If the thickness exceeds the service limit either re place the main bearings as above or refinish the crankshaft and use undersize bearings 4 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Crankcase Flatness of gasket surface Measure flatness with a straight edge and feeler gauges If the warpage exceeds the assembly stan dard reface the gasketed surfaces with a surface grinder Crankcase gasket surface flatness mm in Assembly standard 0 1 0 004 max Repair limit 0 2 0 008 NOTE Do not grind the crankcase more than neces sary to remove warpage Excessive grinding can cause the piston protrusion to exceed assembly stan dard Main bearing bore diameter Secure the end bearing cap to the specified torque and measure the bore dia
33. B mm in Nominal Value 9 247 0 36405 Assembly Standard 9 197 to 9 297 0 36209 to 0 36602 Service Limit 8 45 0 3327 Deflection mm in Assembly Standard 0 05 0 0020 or less Repair Limit 0 08 0 0031 NOTE Deflection at center bushing measured with both ends supported Repair or replace if necessary Journal diameter mm in Nominal Value 84 3 31 Assembly Standard 83 92 to 83 94 3 3039 to 3 3047 Service Limit 83 87 3 3020 Camshaft bushing inside diameter as installed in crank case mm in Nominal Value G84 3 31 Assembly Standard 84 00 to 84 035 3 30708 to 3 30846 Service Limit 84 10 3 3110 NOTE Replace bushings and ream them if necessary End play mm in Nominal Value 8 0 3 Assembly Standard 0 10 to 0 25 0 0039 to 0 0098 Service Limit 0 40 0 0157 NOTE Replace thrust bearing if necessary 28 Plus d informations sur www dbmoteurs fr Crankshaft Crankshaft pin diameter mm in Nominal Value 125 4 92 Assembly Standard 0 050 0 070 0 00197 0 00276 Repair Limit 0 110 0 00433 Crankshaft journal diameter mm in Nominal Value 140 5 51 Assembly Standard 0 050 0 070 0 00197 0 00276 Repair Limit 0 110 0 00433 Journal and crankpin center
34. Clearance 0 85 1 35 0 03346 0 04528 Installing the turbine housing 1 Check the mounting direction of the turbine hous ing then install on the bearing housing 2 Apply Moly Disulfide to the threads of the bolt and tighten to the specified torque Installing the diffuser 1 Apply grease to the diffuser and install the bear ing housing 2 Install the diffuser 191 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Installing the compressor cover Check the mounting direction of the compressor cov er then install Installing the V clamp Install the V clamp to the compressor cover and tap around it with a soft faced hammer for more than times and tighten to the specified torque 19 2 Plus d informations sur www dbmoteurs fr Group 26 Cooling System Group 26 Cooling System pat Disassembly Nut washer Water pump pulley key Snap ring CoverRing O ring Impeller Unit seal ON O 01 R OND Spacer o ring Fresh Water Pump Oil seal 10 Bearing Snap ring Water pump shaft Bearing Oil seal Case Look for A Rotation B Wear deterioration of lip C D E F Corrosion feathering Wear damage of belt groove Wear damage Corrosion cracks damage 193 Plus d informations sur www dbmoteurs fr Group 26 Cooling System 19 Fresh water pump Touch the drain port located at the bottom
35. No work should be carried out on sealed components except by authorized personnel Bear in mind that most chemicals used on boats are harmful to the environment if used incorrectly Volvo Penta recommends the use of biodegradable degreasing agents for cleaning engine components unless otherwise stated in a workshop manual Take special care when working on board that oil and waste is taken for destruc tion and is not accidentally pumped into the environment with bilge water 11 Plus d informations sur www dbmoteurs fr General information How to Use This Manual 1 12 Parts in illustrations are numbered to correspond with references to these numbers in text Items or conditions to be inspected during disas sembly are listed in the disassembled views Maintenance standards for inspection and repair are described in text where relevant For a quick summary of maintenance standards refer to sec tion Maintenance Standards of this manual The sequence in which parts are to be reassem bled is summarized below each assembled view Such as Tightening torque under wet conditions is indicat ed as wet in text drawings and tables When so indicated apply engine oil to the threaded por tion of the fastener Unless indicated as wet the tightening torque should be dry Terms used in this manual Before you read this manual note that the following special terms are used in dimensional and other specifica
36. One spark from connecting the batteries incorrectly is sufficient to cause the battery to explode and cause injury Do not touch the connection when starting risk of spark and do not lean over the batteries Never confuse the plus and minus terminals when fitting the batteries This can cause seri ous damage to the electrical equipment Check the wiring diagram Always use protective glasses when charging and handling batteries The battery electrolyte contains strongly corrosive sulphuric acid Upon contact with the skin wash with soap and plen ty of water If battery acid gets into the eyes rinse immediately with water and contact a doctor without delay Stop the engine and turn off the power with the main switch switches before working on the electrical system The clutch should be adjusted when the engine is idle Plus d informations sur www dbmoteurs fr A Use the lifting hooks mounted on the engine re versing gear when lifting the drive unit Always check that the lifting equipment is in good con dition and has the correct capacity for the lift weight of engine plus reversing gear and extra equipment where appropriate For safe handling and to avoid damaging the components mounted on top of the engine the engine should always be lifted with a lifting bar adjusted to the engine All chains or wires should run in parallel with each other and as perpendicular to the top of the engine as possi ble Special
37. a stationary engine However some proce inlet pipe can also damage the machine dures e g certain adjustments require the en gine to be running Approaching an engine that Z Never use starter spray or the like Risk of in is running is a safety risk Remember that loose the inlet pipe Risk of personal injury clothes or long hair can fasten in rotating parts and cause severe injury AN Avoid opening the coolant filler cap when the A careless movement or dropped tool while working in the vicinity of an engine that is run ning can in the worst case lead to injury Ob serve caution with hot surfaces exhaust pipe turbo charge air pipe starter element etc and hot fluids in the lines and hoses of an engine that is running or has just been stopped Refit all guards dismantled during service work be fore starting the engine engine is hot Steam or hot coolant can spray out and built up pressure will be lost Open the filler cap slowly and release the overpressure in the cooling system if the filler cap or cock must be opened or if a plug or coolant pipe must be removed when the engine is hot Steam or hot coolant can flow out in an unpredicted direction Plus d informations sur www dbmoteurs fr Safety information A gt D Hot oil can cause burn injuries Avoid skin con tact with hot oil Make sure that the oil system is not pressurised before working on it Never start or run the engine with the oil filler cap re
38. damage to the pinion and control rack during the installation of the plunger assem bly NOTE If the stopper plate is not used during plunger assembly installation the teeth on the pinion hit the teeth on the rack causing rough edges that hinder smooth rack movement Hold the flange of the barrel with both hands and press down the plunger assembly until the bot tom side of the flange contacts the stopper plate Remove the stopper plate and lower the plunger assembly by serching the correct meshing slow ly Do not apply excessive forte to press down the plunger assembly If the plunger assembly is jammed turn the flange by jiggling back and forth then press down Insert standard barrel shims thickness 1 0 mm 0 04 in under each barrel flange and align the reference mark on the barrel flange with the alignment mark 1 5 mm 0 06 in diameter hole on the pump case ZN IMPORTANT In each cylinder insert barrel shims of the same thickness one in front and one in back Do not use two or more shims at one location If the shim thickness varies in the front and back of a cylinder the rack may not move smoothly causing hunting or other prob lems Install washers on the barrel bolts and screw the bolts snug Then using a torque wrench tighten the bolts progressively and evenly to 78 to 83 N m 8 0 to 8 5 kgf m 58 to 61 Ibf ft 155 Plus d informations sur www dbmoteurs fr Group 23 Fuel System 7 Rem
39. dimension 139 43 139 45 5 4894 5 4901 Roundness 0 Dia Diff 0 01 0 0004 max Cylindricity a Dia Diff 0 02 0 0008 max Journal diam undersize 0 75 0 0295 mm in Finishing dimension 139 18 139 20 5 4795 5 4803 Roundness 0 Dia Diff 0 01 0 0004 max Cylindricity Dia Diff 0 02 0 0008 max Journal diam undersize 1 00 0 0394 mm in Finishing dimension 138 93 138 95 5 4697 5 4705 Roundness 0 Dia Diff 0 01 0 0004 max Cylindricity ow Dia Diff 0 02 0 0008 max Grinding the crankshaft Refinish the crankshaft according to the dimensions of the undersize main bearing and connecting rod bearing When grinding the crank pins and journals be sure to produce the same fillet radius as the original They should have a hardness of 590 Vickers Hardness Number If necessary re harden the crank pins and journals and inspect them for cracks by conducting a Magnaflux magnetic particle test After grinding fin ish the journals and crank pins to 0 2 Ra 0 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Measuring crankshaft end play 1 Install the thrust bearings in position then secure the bearing cap Under this condition measure the end play If the end play exceeds the stan dard clearance replace the thrust bearings 2 If the end play still exceeds the repair limit even after the new thrust bearings have been installed
40. in Nominal Value 36 1 42 Assembly Standard 35 966 to 35 991 1 41598 to 1 41697 Service Limit 35 940 1 41496 Cylinder heads Cylinder head Flatness of gasket surface mm in Assembly Standard 0 03 0 0012 or less Repair Limit 0 07 0 0028 Service Limit 0 50 0 0197 NOTE Reface if necessary Thickness of gasket when tightened mm in Nominal Value 1 8 0 07 Assembly Standard 1 77 to 1 83 0 0697 to 0 0720 Cylinder liners Inside diameter mm in Nominal Value 170 6 69 Assembly Standard 170 000 to 170 040 6 69290 to 6 69447 Repair Limit 170 200 6 70078 Service Limit 170 500 6 71259 Roundness mm in Assembly Standard 0 02 0 0008 or less Cylindricity mm in Assembly Standard 0 02 0 0008 or less Squareness of flange lower face to liner center line mm in Assembly Standard 0 03 0 0012 or less Protrusion of cylinder liner at flange mm in Assembly Standard 0 11 to 0 20 0 0043 to 0 0089 Pistons and cylinderheads Clearance between piston top and cylinder head mm in Standard Clearance 1 22 to 1 95 0 0480 to 0 0768 24 Plus d informations sur www dbmoteurs fr Pistons Outside diameter mm in Nominal Value 170 6 69 Assembly Standard 169 76 to 169 80 6 6835 to 6 6850 Service Limit 169 66 6
41. installed in the pump case and remove the bellows 2 Remove the set screw from the back side of the pump case and pull out the control rack NOTE After removing the set screw conduct a color check or magnaflux inspection to make sure there are no cracks NOTE Do not remove the rack bushing unless nec essary Removing tappets Hook a wire to two small holes 4 mm 0 16 in dia on the upper side of the tappet and pull out the tap pet 4 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Removing the camshaft 1 Unscrew four front cover mounting bolts and re move the front cover and bearing outer race 2 Tilt the pump case sideways and remove two center bearing mounting bolts 3 Strike the camshaft on the drive side end with a soft hammer to remove the camshaft and center bearing 4 Remove the bearing inner races from both ends of the camshaft Removing the rear cover Remove the rear cover mounting bolts Insert the tips of screwdrivers into the notch located on the side of the rear cover and pry out Remove the shim 145 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Disassembling plunger 1 Mount the plunger assembly on the plunger spring compression jig 4829 1 00200 2 Press the knob on the jig to tompress the plunger spring then remove the plunger holder jig 3 Loosen the compression of the plunger spring gradually and remove the lower spr
42. lifting equipment may be required to ensure the right balance and safe handling if other equipment connected to the engine alters its centre of gravity Never work on an engine supported only by lift ing equipment Never work alone when heavy components are to be dismantled even when safe lifting e g lockable block and tackle equipment is used In most cases two persons are required even when lifting equipment is used one to handle the equipment and one to make sure that com ponents are not damaged When working on board a boat always make sure in advance that there is sufficient space to allow dismantling in situ without the risk of personal injury or materi al damage A A A Safety information WARNING The components in the electrical system and fuel system on Volvo Penta prod ucts are designed and manufactured to mini mise the risks of explosion and fire The engine must not be run in environments surrounded by explosive media Pressure pipes must not bent turned or ex posed to other strain Replace damaged pres sure pipes Observe the following when cleaning with high pressure wash Never point the jet of water at seals rubber hoses or electrical components Never use the high pressure function when washing the engine Always use Volvo Penta recommended fuel See the instruction manual The use of inferior quality fuel could damage the engine The use of inferior fuel in a diesel engine could ca
43. lip for damage and be sure to po sition correctly in the housing 2 Apply asmear of grease to the surface of the oil seal to be fitted into the housing bore 3 Use an oil seal driver shown to guide the seal lip and drive the outer diameter squarely To avoid damage to the oil seal and leaking never ham mer on it directly Driving oil seals onto shafts 1 Apply a smear of grease to the oil seal lip 2 Use an oil seal guide of the type shown when driving the oil seal over the stepped portion splines threads or key way to prevent damage to the oil seal lip O rings Dt NZ Use an O ring guide to install an O ring over stepped parts splines threads or key way to prevent damage to the ring Apply a smear of grease to the O ring be fore installation 14 Plus d informations sur www dbmoteurs fr General information Bearings 1 When installing a rolling bearing be sure to push the inner or outer race by which the bearing is fit ted Be sure to use a bearing driver like the one shown 2 Whenever possible use a press to minimize shock to the bearing and to assure proper instal lation CY ene A L Bend lock plates against the flats of the nuts or bolt heads as shown OO 7 99 2 Split Pins and Spring Pins Generally split pins are to be replaced once dis turbed Insert the pin fully and spread it properly Drive each spring pin into position to hold it in
44. moved due to the risk of ejecting oil Stop the engine and close the bottom valve be fore working on the cooling system Only start the engine in a well ventilated area Exhaust fumes and crankcase gases should be bled out of the engine compartment or work shop when working in closed environments Always use protective glasses for work where there is a risk of splintering sparks or splash ing of acid or other chemicals The eyes are ex tremely sensitive and an injury could cause blindness Avoid skin contact with oil Prolonged or fre quent skin contact with oil can degrease the skin resulting in irritation drying out eczema and other skin complaints Used oil is more dangerous than new oil from a health care point of view Use protective gloves and avoid oil drenched clothes and rags Wash your hands regularly especially before meals Use special hand cream to counteract drying out and to simplify cleaning the skin The majority of chemicals intended for the prod uct e g engine and timing gear oils glycol petrol and diesel oil or chemicals for workshop use e g degreasing agent enamels and sol vents are hazardous to health Read the in structions on the pack carefully Always follow the given safety instructions e g the use of breathing protection protective glasses or gloves etc Make sure that other personnel are not exposed to hazardous substances e g by inhaling the air Make sure there is adequ
45. of the pump with your finger If the port is leaking water check the condition of the unit seal If it is leaking oil the oil seal is defective Remove the impeller 1 Remove the snap ring the water pump pliers then remove the cover 2 Remove the impeller with the impeller remover Remove the water pump shaft 1 Remove the snap ring from the front bearing 2 Drive the pump shaft out towards the gear side complete with bearing using a press or a soft hammer NOTE Be careful not to damage the pump shaft or the impeller when removing the impeller fron the shaft A Plus d informations sur www dbmoteurs fr Group 26 Cooling System Inspection Water pump Measure the inside diameter of the pump case bore to which the bearing outer race is fitted Measure the diameter of the pump shaft on which the bearing in ner race is fitted If the bearing case or shaft is worn replace it Inside diameter of pump case bearing mm in Nominal value 80 3 15 Assembly standard 79 988 80 018 3 14913 3 15031 Service limit 80 025 3 15058 Pump case bore diameter mm in Nominal value 90 3 54 Assembly standard 89 987 90 022 3 54279 8 54417 Service limit 90 025 3 54428 Bearing Diameter mm in Nominal value 80 3 15 Assembly standard 79 985 80 000 3 14902 3 14961 Bearing Diameter mm in Nominal value
46. packing Valve cotter Valve rotator Valve spring Stem seal Valve Cylinder head gasket Tappet Look for TAS IONMOoOowxz Cracks oil leaks deterioration Cracks damage carbon and scale deposits Wear Damaged threads Wear clogged oil hole Distortion cracks Matching wear Worn stem or face corrosion damage or carbon deposits Cracks damage deterioration rubber parts cracked Worn ends distortion Worn cam contact face or sliding surface Replace gasket 73 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 74 Removing fuel injector assemblies 1 Remove the fuel inlet connector and the nozzle gland 2 Use the Nozzle remover to remove the injector assembly Take out the gasket if it is left behind in the cylinder head 3 Store the injector and the inlet connector as a set to avoid swapping A IMPORTANT Do not damage the nozzle Removing the rockershaft assemblies 1 Loosen the adjusting screw of each rocker 2 Store the shaft assembly and mounting bolts to gether as a set Disassembling rockershaft assemblies Arrange the disassembled rockers in the order re moved so you can install them in that order at reas sembly This will ensure the same rockershaft clear ance as before Remove the valve bridge Remove the valve bridge and bridge cap NOTE Do not drop the bridge cap or other parts into the crankcase through the push rod hole Plus d informations
47. pin by wiping with a cloth then coat it with engine oil Pistons for right bank cylinders Turn the crankshaft in the normal direction until the number stamped on the damper A of the cylinder to which the piston is to be installed is at the position of approximately 50 before top dead center Connecting rod bearing upper shells Install the upper shell of the bearing in the rod by fit ting its locating lug in the lug groove of the rod A Coat the inside surface of the shell with engine oil Make sure the oil holes in the rod and bearing are aligned Inserting pistons 1 Put the connecting rod in the cylinder liner and carefully rest the piston on top of the crankcase Z IMPORTANT Make sure the arrow mark above the CAM arrow A on top of the piston points towards the camshaft B A IMPORTANT When placing the connecting rod in the liner have another service man to ob serve the rod through the inspection hole to keep it away from the oil cooling nozzle Do not rotate the piston 0 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 2 Coat the piston rings with engine oil then position the ring gaps as shown A Joint of coil spring B Gap of top compression ring C Gap of second compression ring D Gap of oil ring 3 Hold the compression ring portion of the piston and carefully insert the piston into the cylinder lin er NOTE Do not pinch your fingers between the oil rin
48. place after later installation of parts has been completed 15 Plus d informations sur www dbmoteurs fr General information Presentation D25A D30A MS D25A D30A MS 1 Fuel filters Oil cooler Fuel injection pump Governor oil filter Manual stop lever Governor Stop solenoid Oil dipstick oO N OO a A WwW PD Fuel feed pump 10 Oil filler cap 11 Fresh water pump 12 Lifting eye 13 Intake air silencer 14 Turbocharger 15 Charge air cooler 16 Alternator 17 By pass filter for engine oil 18 Oil filters 19 Engine oil drain pipe 20 Starter motor 16 Plus d informations sur www dbmoteurs fr General information Presentation D25A D30A MT 1 a N OO oa A WB ND oO N 11 D25A D30A MT Fuel filters Oil cooler Fuelinjection pump Governor oil filter Manual stop lever Governor Stop solenoid Oil dipstick Fuel feed pump Oil filler cap Fresh water pump Lifting eye Intake air silencer Turbocharger Charge air cooler Heat exchanger By pass filter for engine oil Oil filters Starter motor Engine oil drain pipe Sea water pump Alternator 17 Plus d informations sur www dbmoteurs fr General information Identification numbers D25A D30A Type plates with identification numbers can be found on the engine and the transmission or generator This infor mation must always be used as
49. replace the bearings with the next oversize bear ings There are three sizes for the thrust bear ings 0 25 mm 0 0098 in 0 50 mm 0 0197 in 0 75 mm 0 0295 in NOTE Generally the rear journal is likely to wear more rapidly than the front journal This means that replacement of the rear thrust bearings will generally be sufficient Thrust bearing journal length A mm in Nominal value 66 000 66 030 2 6000 2 6012 Crankshaft end play mm in Standard Clearance 0 20 0 40 0 0079 0 0157 Service limit 0 50 0 0197 Crankshaft Journal grinding dimensions oversize thrust bearings 0 25 0 0098 mm in Oversizes for Journal or Thrust bearings 66 25 2 6083 Oversizes for Journal and Thrust bearings 66 50 2 6181 Tolerance n se 0 03 0 0 0012 0 0 50 0 0197 mm in Oversizes for Journal or Thrust bearings 66 50 2 6181 Oversizes for Journal and Thrust bearings 67 00 2 6378 Tolerance n 0 03 0 0 0012 0 0 75 0 0295 mm in Oversizes for Journal or Thrust bearings 66 75 2 6280 Oversizes for Journal and Thrust bearings 67 50 2 6575 Tolerance 006 0 03 0 0 0012 0 121 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 12 Measuring crankshaft deflection Support the crankshaft on its journals in V blocks then measure the deflection at the center journal with a dial gauge Depending on the amou
50. sur www dbmoteurs fr Group 21 Engine Body Removing the rocker cases 1 Remove the snap ring of the water outlet connec tor Slide the connector towards the snap ring 2 Unscrew the rocker case mounting bolts then re move the rocker case from the cylinder head Removing cylinder head assemblies 1 Each cylinder head is located relative to the crankcase with dowel pins Use the Eye nut to lift the head off the crankcase at a slant Cylinder head weight approx 35 kg 77 Ib 2 Remove the cylinder head gasket AN IMPORTANT Do not damage the cylinder head or crankcase surfaces when you remove the gasket with a screwdriver or other tool Removing valves and valve springs Use the valve spring pusher to compress the valve spring squarely then remove the valve cotters NOTE If the valves are to be reused do not change the combination of the valve seat and valve guide Removing studs guides etc Do not remove the nozzle gland mounting studs or the bridge guide from the cylinder head unless abso lutely necessary If any of these parts have been re moved apply thread adhesive to the threads when in stalling it or a new part to the cylinder head 75 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 76 Inspection and Repair Rocker Bushings and Rockershaft 1 Measuring rocker bushing inside diameter and rockershaft diameter If the measurement ex ceeds the service limit replace t
51. the alignment marks made during disassembly Install the lock plates Install the lock plates to the compressor cover Install the turbine housing Mount the turbine housing on the bearing housing and be sure to follow the alignment marks made dur ing disassembly Installing the V clamp Install the V clamp to the compressor cover and tap around it with a soft faced hammer for more than 3 times and tighten to the specified torque 179 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Turbocharger TD15 Disassembly V clamp Compressor cover Diffuser O ring Lock nut Compressor wheel Snap ring Insert Finger sleeve Piston ring O ring Oil deflector Thrust ring compressor CONOARWN gt reer De yer on gt 9 180 14 15 16 17 18 19 20 21 22 23 24 25 26 Thrust bearing Thrust ring turbo Bolt Turbine housing Shaft and turbine wheel Piston ring Turbine backplate Bearing Snap ring Snap ring Bearing Snap ring Bearing housing Look for Ow nmo TO Wear Thrust face wear Vane distortion damage rubbing contact on back face and gas erosion Rubbing contact with compressor wheel Rubbing contact with turbine wheel cracks and distortion Vane distortion damage rubbing contact on back face and gas erosion and damage to ring grooves Rubbing contact with turbine wheel and damage Damage to bearing bore gas erosion and distorti
52. to center distance mm in Nominal Value 90 3 54 Assembly Standard 0 1 0 004 Parallelism between journals and crankpins mm in Assembly Standard 0 01 0 0004 or less at pin length Repair Limit 0 03 0 0012 Roundness of journals and crankpins mm in Assembly Standard 0 01 0 0004 or less in diameters Repair Limit 0 03 0 0012 Cylindricity of journals and crankpins mm in Assembly Standard 0 02 0 0008 or less in diameters Repair Limit 0 03 0 0012 Fillet radius of crankpins mm in Nominal Value 7 0 28 Assembly Standard 7 0 7 2 0 268 0 276 Fillet radius of journals mm in Nominal Value 7 0 28 Assembly Standard 7 0 7 2 0 268 0 276 Hardness of journals and crankpins Assembly Standard Hv gt 620 Angularity Assembly Standard 0 20 Deflection mm in Assembly Standard 0 04 0 0016 or less Repair Limit 0 10 0 0039 NOTE Repair or replace if necessary Thrustbearing journal length mm in Nominal Value 66 2 60 Crankshaft end play mm in Nominal Value 66 2 60 Assembly Standard 0 20 to 0 40 0 0079 to 0 0157 Service Limit 0 50 0 0197 1 18 0 0465 crank shaft width Maintenance Standards NOTE Replace thrust bearings if worn down to service limit Use oversize thrust bearings if worn beyond
53. with diesel fuel 4 Coat the valve face with engine oil then lap the valve again 5 Check the valve face for contact NOTE Do not permit the compound to come in con tact with the valve Stern NOTE Use a compound of 120 to 150 mesh for initial lapping and a compound finer than 200 mesh for fin ish lapping NOTE Mixing the compound with a small amount of engine oil will facilitate coating Valve spring clearance and free length Measure the free length and clearance of each valve spring If the free length or clearance perpendiculari ty exceeds the service limit replace the spring Free length A mm in Assembly standard 73 2 87 Service limit 71 2 80 Perpendicularity B mm in Service limit 2 2 0 087 at end Length under test force mm in Assembly standard 66 0 2 6 Test force N kgf Ibf Assembly standard 289 319 29 45 to 32 55 65 to 72 81 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 82 Bridge to rotator clearance 1 When clearance is less than 1 5 mm 0 059 in check the valve stem top for cupping If the stem top is badly cupped replace the valve to obtain more than 1 5 mm 0 059 in clearance 2 Check the condition of the bridge cap Replace it if it is badly worn Tappets and Push Rods Inspecting cam contact faces of tappets Replace the tappets if their cam contact faces are ab nor
54. 0 000 1 18071 1 18110 Bearing inside diameter mm in Nominal value 40 1 57 Assembly standard 39 988 40 000 1 57433 1 57480 Shaft diam at bearing position mm in Nominal value 30 1 18 Assembly standard 30 002 30 012 1 18118 1 18157 Service limit 29 995 1 18090 Shaft diam at bearing position mm in Nominal value 40 1 57 Assembly standard 40 002 40 013 1 157488 1 57531 Service limit 39 995 1 57460 201 Plus d informations sur www dbmoteurs fr Group 26 Cooling System Reassembly Reassembly sequence 9 0 l el 13 im I t N F O a Was 2 Plus d informations sur www dbmoteurs fr Ca Group 26 Cooling System 1 Install the oil seal squarely to the holder using a jig and a hammer NOTE Always replace the oil seal at reassembly 2 Apply grease to the hollow section and the lip of the oil seal A 3 Install the cam to the casing and tighten the screw to the specified torque The contact surfac es must be coated with ThreeBond 1102 4 Install the unit seal to the bushing by striking with a hammer making sure the unit seal remains square to the bushing during installation The contact surface must be coated with ThreeBond 1102 NOTE Be sure to replace the unit seal with a new part 203 Plus d informations sur
55. 0 0008 max Repair limit 0 03 0 0012 Pin amp Journal fillet radius mm in Nominal value 7 0 28 Assembly standard 7 0 0 276 0 008 Pin amp Journal hardness Assembly standard Hv gt 620 119 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 12 Grinding dim for undersize crankshaft Crankpin diam undersize 0 25 0 0098 mm in Finishing dimension 124 68 124 70 4 9087 4 9094 Roundness 0 Dia Diff 0 01 0 0004 max Cylindricity Dia Diff e 0 02 0 0008 max Crankpin diam undersize 0 50 0 0197 mm in Finishing dimension 124 43 124 45 4 8988 4 8996 Roundness 0 Dia Diff 0 01 0 0004 max Cylindricity Dia Diff 0 02 0 0008 max Crankpin diam undersize 0 75 0 0295 mm in Finishing dimension 124 18 124 20 4 8890 4 8898 Roundness 0 Dia Diff 0 01 0 0004 max Cylindricity oe Dia Diff 0 02 0 0008 max Crankpin diam undersize 1 00 0 0394 mm in Finishing dimension 123 93 123 95 4 8791 4 8799 Roundness 0 Dia Diff 0 01 0 0004 max Cylindricity Dia Diff 0 02 0 0008 max Journal diam undersize 0 25 0 0098 mm in Finishing dimension 139 68 139 70 5 4992 5 5000 Roundness 0 Dia Diff 0 01 0 0004 max Cylindricity a Dia Diff 0 02 0 0008 max Journal diam undersize 0 50 0 0197 mm in Finishing
56. 06 1 18134 Bearing Measure bearing outside diameter If the measured diameter is less than the service limit replace the bearing Bearing inside diameter mm in Service Limit 29 876 1 17622 Measure bearing inside diameter If the measured diameter exceeds the service limit replace the bearing Bearing inside diameter mm in Service Limit 18 050 0 71063 Measuring bearing length If the measured length is less than the service limit replace the bearing Bearing length mm in Service Limit 17 440 0 68661 2 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Shaft amp turbine wheel Measure journal diam of shaft amp turbine wheel If the measured diameter is less than the service limit replace the shaft amp turbine wheel Shaft journal diameter mm in Service Limit 17 996 0 70850 Measure shaft deflection 1 Set a dial gauge at a location next to the thread ed section of the shaft and measure shaft deflec tion If the deviation indicated by the dial gauge exceeds the service limit replace the shaft amp tur bine w heel IMPORTANT If the shaft is bent replace Do not attempt to correct the bend 2 Ifthe surface of the shaft journal is rough mount the shaft on a lathe and gently polish the surface using 400 sandpaper and engine oil while rotat ing at 300 600 min Shaft deflec
57. 2 0 8MM attached to the No 1 rocker cover Check it before FIRING ORDER f k M inspection Bring the piston for No 1 cylinder to top 1 5 3 6 2 4 i FUEL INJECTION TIMING dead center on compression stroke as follows 2 8 RR _ VALVE CLEARANCE COLD ae DI IYA LY I 1 Turn the engine in the normal direction to align the timing mark 1 6 on the damper with the pointer as shown 2 Remove the No 1 rocker cover and make sure the inlet and exhaust valves for No 1 cylinder have some clearance If these valves have no clearance turn the engine once again to align the timing mark 1 6 NOTE Do not confuse the No 1 cylinder with No 6 When the piston for the No 1 cylinder is in the above mentioned position its inlet and exhaust valve are seated presenting some clearance 3 Turn back the engine approximately 60 degrees and turn it in the normal direction slowly until the specified timing indicated on the caution plate aligns with the pointer 4 To ensure proper injection timing make sure that the timing mark B on the coupling flywheel 2 A aligns with the pointer A on the fuel injection lg pump 57 Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting Adjust fuel injection timing 1 Make sure the timing mark indicated on the cau tion plate is aligned with the pointer with the pis ton for the cylinder at top dead center on com pression stroke 2 Loo
58. 2 Inspection and Repair 76 Terms used in this manual 12 REASSOMDIy sssri E 83 Disassembly and Reassembly 13 Cylinder liners Pistons and Connecting rods 87 Presentation D25A D30A MS seee 16 Inspection and Repair 90 Presentation D25A D30A MT seese 17 Reassembly asrina 99 Identification numbers D25A D30A 18 Viscous damper and front gears eee 103 Specification D25A D30A n e 19 Rassemblement ducetveeersereendecn ene 105 Maintenance Standards Table 22 Flywheel Timing gears Camshaft and Oilpan 106 G n raliste san a da aaaeeeaa 22 Inspection and Repair 109 Engine main parts 23 FREASSOMDIY issues 113 Reassembly 0 eeeecetneeeeeeeeeenneeeeeeeeeeneeeeeeeeeeaaes 27 Crankcase Crankshaft and Main bearings 117 Inlet and exhaust system ccceeesteeeeeeeetaees 31 Inspection and Repair 119 Lubrication system 33 Reassembly 126 Cooling system 34 Group 22 Lubrication system 128 Fuel SVSTON assessment ass 36 Oil Pump and Safety Valve ceeeeeeeeeeeeees 128 Electric Syste cs ccvcssetensnevecreseuenteceessvesctevereyeenesses 39 INSPECTION murran S oR amentes 129 Tightening torques D25A ceecee 41 Reassembly n 131 Tightening torques D30A aec 43 Relief valve cceeeeeeeeeectceeeeeeeeeenneeeeeeeeeenneeeeeenee 132 Standard Bolts and Nuts
59. 3 Remove the rear upper halves of the thrust bear ings on the crankcase Removing the piston cooling nozzles Do not remove the nozzles unless such defects as clogging are observed NOTE Tighten the piston cooling nozzle to the speci fied torque when reassembling 8 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Inspection and Repair Crankshaft Crank pin and crank journal diameters 1 Using a micrometer measure the crank pin A and crank journal B diameters If the repair limit is exceeded grind them to the next lower size 0 25 mm 0 0098 in 0 50 mm 0 0197 in 0 75 mm 0 0295 in or 1 00 mm 0 0394 in NOTE If the 1 00 mm 0 0394 in undersize jour nals and crank pins exceed the repair limit replace the crankshaft 2 Measure the crank pins and journals to determine the roundness and cylindricity Crank pin diameter A mm in Nominal value 125 4 92 Assembly standard 0 050 0 070 0 00197 0 00276 Repair limit 0 110 0 00433 Crank journal diameter A mm in Nominal value 140 5 51 Assembly standard 0 050 0 070 0 00197 0 00276 Repair limit 0 110 0 00433 Pin amp Journal roundness mm in Assembly standard Dia diff 0 01 0 0004 max Repair limit 0 03 0 0012 Pin amp Journal cylindricity mm in Assembly standard Dia Diff 0 02
60. 3 0 98468 Case bore diam idler shaft side bearing section mm in Nominal Value 47 1 85 Assembly Standard 46 989 47 014 1 84996 1 85094 0008 Idler shaft side bearing diamet Outside diameter mm in Nominal Value 47 1 85 Assembly Standard 46 988 47 000 1 84992 1 85039 Inside diameter mm in 940 Too Nominal Value 20 0 79 Assembly Standard 19 990 20 000 0 78701 0 78740 Idler shaft diam bearing section mm in Nominal Value 20 079 h Assembly Standard 20 002 20 011 0 78749 0 78783 38 Plus d informations sur www dbmoteurs fr Electric system Starter Diameter of commutator mm in Nominal Value O43 1 69 Service Limit 42 1 65 Runout of commutator mm in Assembly Standard 0 06 0 0024 or less Service Limit 0 10 0 0039 Mica depth in commutator mm in Assembly Standard 0 7 0 9 0 028 0 035 Service Limit 0 2 0 0079 Height of brushes mm in Assembly Standard 21 22 0 83 0 87 Service Limit 13 0 51 Tension of brush springs N kgf Ibf Nominal Value 44 13 4 5 10 Assembly Standard 39 23 49 03 4 0 5 0 9 11 Service Limit 39 23 4 0 9 maximum Armature shaft diameter rear mm in Nominal Value 14 0 55 Assembly Standard 13 941 13 968 0 54886 0 54992 R
61. 4 32 350 4977 Assembly Standard 34 32 to 34 81 350 to 355 4977 to 5048 Spray cone angle Nominal value 160 NOTE Check nozzle with a hand tester at fuel oil temperature 20 C 68 F Replace the nozzle if the spray pattern is still bad after washing in clean fuel oil Feed pump Feed pump discharge start time Assembly Standard 20 sec or less Priming pump discharge start Assembly Standard No of pumping operations 30 strokes or less Feed pump feed rate pump at 600 rpm Assembly Standard 900 cm 54 9 cu in 15 sec 36 Plus d informations sur www dbmoteurs fr Maintenance Standards Injection pump Overall clearance at tappet roller mm in Service Limit 0 2 0 00787 Wear of contact surface between tappet and plunger mm in Service Limit 0 2 0 00787 Outside diameter at contact surface of camshaft oil seal mm in Nominal value 35 1 378 Assembly Standard 34 963 to 34 938 1 37649 to 1 37551 Service Limit 34 800 1 37001 Camshaft deflection mm in Assembly Standard 0 05 0 00197 Repair Limit 0 15 0 00591 Plunger Spring mm in Free length A mm in Assembly Standard 70 8 2 787 Perpendicularity B mmlin Service Limit 1 8 0 071 Length under test force mm in Assembly standard 60 0 2 36 Test force N kgf Ibf Assembly standard 299 366 30 5
62. 409 in 2 Heat the gear to the range 180 to 200 C 356 to 392 F Do not heat the gear above 200 C 392 F 3 Drive the rear crankshaft gear onto the crank shaft by tapping the end face of the gear lightly with a copper hammer Be sure the crankshaft dowel pin enters the notch in the gear ZN IMPORTANT Install the gear to the crankshaft until it contacts the collar Lv IMPORTANT Do not mistake the direction of gear installation 123 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 12 Main Bearing Bearing surfaces Inspect each bearing shell for abnormal contact such as scratching corrosion flaking etc Also check for signs of poor seating in the bore of the crankcase or bearing cap Bearing thickness Use a ball point micrometer to measure the center of each hearing shell If the service limit is exceeded on any of the shells replace the upper and lower shells as a set Main bearing thickness center STD mm in Nominal value 3 500 0 138 Assembly standard 3 467 3 480 0 13650 0 13701 Service limit 3 425 0 13484 Main bearing thickness center 0 25 0 0098 mm in Nominal value 3 625 0 14272 Assembly standard 3 592 3 605 0 14142 0 14193 Service limit 3 550 0 13976 Main bearing thickness center 0 50 0 0197 mm in Nominal value 3 750 0 14764 Assembly standard 3
63. 6 to 0 32 2 6 to 3 2 88 to 47 Maintenance Standards 33 Plus d informations sur www dbmoteurs fr Maintenance Standards Cooling system Fresh water pump Bearing bore inside diameter mm in Nominal value 80 3 15 Assembly Standard 79 998 80 018 3 14913 3 15031 Service limit 80 025 3 15058 Bearing bore inside diameter mm in Nominal value 90 3 54 Assembly Standard 89 987 90 022 3 54279 8 54416 Service limit 90 025 3 54428 NOTE Same as the bearing cover Bearing Outside diameter mm in Nominal value 80 3 15 Assembly Standard 79 985 80 000 3 14902 3 14961 Bearing Outside diameter mm in Nominal value 90 3 54 Assembly Standard 89 985 90 000 3 54272 8 54331 Bearing Inside diameter mm in Nominal value 40 1 57 Assembly Standard 39 988 40 000 1 57433 1 57480 Shaft bearing journal diameter mm in Nominal value 40 1 57 Assembly Standard 40 002 40 013 1 57488 1 57531 Service limit 39 995 1 57492 Vane front face clearance mm in Nominal value 0 72 0 028 Standard Clearance 0 14 to 1 3 0 006 to 0 051 Thermostat Temperature at which valve starts opening Assembly Standard 71 2 C 159 8 3 6 F NOTE Check in atmospheric pressure Temperature at which valve lift is more than 11 mm 0 43 in
64. 9 3945 4 0 5 29 3 6 M14 x 1 5 0 55 x 0 059 49 5 5 0 5 36 3 6 M18 x 1 5 0 71 x 0 059 59 1 6 1 0 43 7 2 Dry 46 Plus d informations sur www dbmoteurs fr Sealants and Lubricants Table Engine main parts Cylinder head sealing caps Sealant uo refer to parts catalogue How to USE Coat holes in crankcase Water outlet connectors Rocker case Lubricant s es Grease How to USE Grease O ring joint Cylinder liners Sealant or lubricant Engine Oil How to USE Grease O ring joint Front plate gear case oil pan and crankcase Sealant uo refer to parts catalogue How to use ee Coat three face mating portions only Rear plate gear case oil pan and crankcase Sealant iaee refer to parts catalogue How to use Coat three face mating portions only Crankcase plugs Sealant Loctite How to use eee Apply to threads Oil pan and crankcase Sealant uo refer to parts catalogue How to use Coat three face mating portions only Front plate front gear case and timing gear case Sealant eee refer to parts catalogue Oil Seals Lubricant s es Engine oil How to Use eee Coat lip of each oil seal Drive case Sealant uo refer to parts catalogue How to use e eee Apply to flange surface Cylinder head gasket Sealant uo refer to parts catalogue How to use eee Apply around tappet chambers General information
65. 90 3 54 Assembly standard 89 985 90 000 3 54272 8 54331 Bearing Inside diameter mm in Nominal value 40 1 57 Assembly standard 39 988 40 000 1 57433 1 57480 Bearing Inside diameter mm in Nominal value 40 1 57 Assembly standard 40 002 40 013 1 57488 1 57531 Diameter of pump shaft mm in Nominal value 55 2 17 Assembly standard 55 011 55 024 2 16578 2 16629 Service limit 39 995 1 57460 195 Plus d informations sur www dbmoteurs fr Group 26 Cooling System Reassembly Reassembly sequence G 0 9 0 0 0 0 90 9 0 0 0 9 0 0 NOTE Replace O rings unit seal and oil seal at reassembly NOTE Install the bearings to the shaft with sideplates on the oil side 1 Use the oil seal installer to press fit oil seal into case Apply grease to the lip surface of the oil N seal B A N 2 Install bearing s to the water pump shaft by strik ing with a hammer Make sure the shield plate A of each bearing faces the oil seal side 3 Use the unit seal installer to press fit unit seal into case NOTE If the unit seal is removed at disassembly re place it at reassembly NOTE Apply sealant to the periphery A of the unit seal 4 Install the shaft to the case by striking with a hammer Install the snap ring to secure it in place 19 6 Plus d informations sur www dbmoteurs fr Group 26 Cooling System 5
66. Of cylind rs 22 38ursssnnaslenis 6 Arrangement eee eeeeeeeseeeeeeeeeeeeeeseeeneeeenseeeeeneeaeneeees in line Combustion type siie Direct injection Valve mechanism sesseseessesreerirsrerirsriserrrrresrrsrrs Overhead Cylinder bore mm fin 170 6 70 Cylinder stroke mm iN n se eenen 180 7 10 Displacement litres U S gal eeeeeeeeeeeeeeeeeees 24 51 6 47 Compression ratio 14 0 1 Firing Ordefsisssessienintsnmistnneninmnmnmentints 1 5 3 6 2 4 Rotational direction Counterclockwise as viewed from flywheel Engine support method 4 point support Weight Dry without marine gear kg Ib D25A MS D25A MT D30A MS D30A MT Te 2320 51 15 2900 6395 2420 5335 3000 6615 Engine main parts Cylinder liner type oo eee eeeseeeeeeeeeteaceseeeeeneeeneneees Wet type Piston rings Compression rings PCS eccececeeeeeeeeeeeeeeeeeaeeseeeeeaees 2 Oil ring w expander PCS eeeeeeeeeeeeseeeeeeeeeteeteeeeenees 1 Valve timing when warm Inlet valve Inlet valve Exhaust valve open BTDC 37 close ABDC 44 open BBDC 57 Exhaust valve close ATDC 24 Fuel system Fuel JIS K2204 cael idl rss TYPE 1 TYPE 2 TYPE 3 ASTM D975 Na RMS Ad No 1 D No 2 D BS 2869 eieiei aaea e ae a EATEN CLASS A1 CLASS A2 DINS TOOT aora DIESEL FUEL ISO8217 a a E DMX CLASS Injection pump Model Ea E E ET PS6 type Manu
67. Plus d informations sur www dbmoteurs fr Group 21 Engine Body 94 N N N N N y Measuring piston pin bore diameter Using calipers or a cylinder gauge measure the pis ton pin bore diameter If the service limit is exceeded replace the piston Piston pin bore diameter mm in Normal value 70 92 76 Assembly standard 70 002 70 015 2 75598 2 75649 Service limit 70 040 2 75747 Measuring piston protrusion Measure the protrusion height from cylinder head to piston head of each piston at top dead center If it is not within standards for piston protrusion measure ment inspect the clearance of the parts 1 Set the dial gauge to zero 0 on top of the crank case and measure the protrusion at four places on top of the piston head Average the four mea surements to determine the protrusion 2 Subtract the piston protrusion from the thickness of the cylinder head gasket as installed to deter mine the clearance between the piston top and cylinder head Piston protrusion mm in Assembly standard 0 06 60 0 065 0 0024 to 0 0256 Cylinder head gasket thickness mm in Assembly standard 1 77 to 1 83 0 0697 to 0 0720 Piston top and cylinder head clearance mm in Assembly standard 1 22 to 1 95 0 0480 to 0 0768 A IMPORTANT Keep the piston protrusion within assembly standard range to prevent the valves from stamping on the piston and to maintain
68. TANT Always read the Service Bulletins to learn about changes in procedures and or technical data NOTE Pay attention to the marks on assemblies components and parts for positions or directions Put on your own marks if necessary to aid reassembly NOTE Carefully check each part for faults during removal or cleaning Signs of abnormal wear will tell if parts or assemblies are functioning improperly NOTE Use assembly bins to keep the parts in order of removal and lay down disassembled or cleaned parts in the order in which they were removed This will save you time at reassembly NOTE Wash all engine parts except oil seals O rings rubber seals etc in cleaning solvent and dry them with compressed air NOTE Use a torque wrench to tighten parts when specified tightening torques are required NOTE Use only good quality lubricating oils and greases Be sure to apply a coat of oil grease or sealant be fore reassembly to parts as specified NOTE Replace all gaskets and packing Apply appropriate amount of adhesive or liquid gasket when required NOTE Always apply high temperature anti seizing compound to bolts and nuts that are exposed to high tem peratures e g exhaust manifold turbo charger exhaust flanges etc 13 Plus d informations sur www dbmoteurs fr General information Oil Seals When installing oil seals carefully observe the follow ing points Driving oil seals into housings Check the seal
69. Use the oil seal installer to press fit oil seal into case Make sure the oils seal surface is flush with the case face Apply grease to the lip surface A of the oil seal 6 Install the floating seat A of the unit seal to the impeller and install the impeller to the pump shaft by striking with a hammer Make sure end faces are flush B 197 Plus d informations sur www dbmoteurs fr Group 26 Cooling System Thermostats Disassembly Thermostat cover Packing Snap ring Thermostat Thermostat seal oar D Thermostat case 19 Look for A Deteriorated worn cracked B Replace packing C Worn cracked Inspection Heat the thermostat in the water Measure the temper ature when the valve opens Measure it again when the valve lift is 11 mm 0 43 in Replace if not within standard Opening temp C F Assembly standard 71 2 159 8 3 6 Valve lift 11 mm 0 43 in temp C F Assembly standard 85 185 NOTE Stir the water to maintain even temperatures during the test NOTE Confirm the valve opening temperature stamped on its mounting flange 8 Plus d informations sur www dbmoteurs fr Group 26 Cooling System Heat Exchanger Disassembly Look for 1 Cover A Pipes clogged leaks 2 Packing B Change if less than 50 3 Cover remains 4 O ring 5 Zinc rod 6 Element 7 Body Inspection Cleaning of element 1 While pouring running water ont
70. a reference when ordering service and spare parts Sae ETE A A A ET E A E A E I T Froductdesignat OM iis secccccnnee ite cecennnte sid cecmagadeasctevecunestadce AANE AAAA ACANOR REEERE Serial and basic engine number sise Product number wss osonni a D aazceainvng meade veassucen ss assauesnuns dada td a dor e de sean Certification IMO aenean aa tanta cnveda aes das en de na asset tete e ana sers a cn unies tete D cal part NO airian enaa an here RERE aa ten idem dr dents Ee meme d serte APPROVAL NO eraa EIEEE OEE ARLE OA A Transmission Generator iii Product d signation 5 5 srasieue sruranatesiesemmeseeete sa manne te EAR nr lie ann eaaa ar er etai amer esta grd S TALNUMO T aaeei e de reaa aE ae e aE dde soso ns nn ne cons DU a shee eE area arni eaaa Product number ersen aneen a aimer aa a ads ends dda cs ess qbnnns sey Ma reed eee she dote fase g e HN 41 amp M th Ow ont eter sag a Tana Lz 9 6 G OY aad 0 ONIHIA WLU 0 ST WU O Fat BUAEATILACLANG LU TI09 I9NVAVI19 JATVA aadis T3SMA14d 1431 MAIA LNONA Li LES eva us GA CHEH FE Re Fm Re LHOR ey D a Caution plate WOLVO PENTA Serial No Spec No Lo Manufactured by Mitubishi Heavy Industries Lid Sagamihara Japan for VOLVO PENTA Plus d informations sur www dbmoteurs fr General information Specification D25A D30A General specification Walao le AEE E E T Water cooled 4 stroke turbocharged diesel with intercooler No
71. ace of the shaft journal is rough mount the shaft on a lathe and gently polish the surface using 400 sandpaper and engine oil while rotat ing at 300 600 min Shaft deflection mm in Service Limit 0 015 0 00059 Insert Measure piston ring end gap Install a new piston ring squarely in the insert then measure the piston ring end gap If the end gap devi ates from the assembly standard replace the insert Ring end gap mm in Assembly Standard 0 05 0 20 0 00197 0 00787 185 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Reassembly Reassembly sequence 6 6 0 0 oo oc 2L0 0 0 0 D D 0 0 D D O O NOTE Always replace the following parts at disassembly 4 O ring 9 Piston ring 11 O ring 19 Piston ring A IMPORTANT If vanes are damaged or cracked do not reuse the part A IMPORTANT After reinstalling the overhauled turbocharger crank the engine to lubricate moving parts of the turbo 18 6 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Install shaft amp turbine wheel and bearing O 1 Install the bearing housing the snap rings and M the bearing on the turbine side and the snap ring 6 A AAH on the compressor side NOTE Use only snap ring pliers to install snap rings After installing the snap ring rotate it with a finger to make sure it rotates smoothly NOTE Apply engine oil to the outside and ins
72. andard 46 988 47 000 1 84992 1 85039 Inside diameter Nominal Value 20 0 79 Assembly Standard 19 990 20 000 0 78701 0 78740 Idler shaft diam mm in Nominal Value 20 0 79 Assembly Standard 20 002 20 011 0 78748 0 78783 4 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Reassembly Reassembly Sequence O 0 0 9 0 0 0 0 0 0 0 0 0 165 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Group 25 Inlet and Exhaust System Air Cooler Disassembly Look for Manifold cover A Replace packing Air cooler cover Packing Air cooler element Plate Packing Air cooler case AN OO O1 5 WD Packing 166 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Inspection Cleaning air cooler 1 Remove dirt built up from the air cooler by direct ing high pressure air of max press 0 29 to 0 49 MPa 3 to 5kgf cm 43 to 71 psi in the opposite direction of the air flow Inspect the cooler for cor rosion and cracks 2 Wash the fresh water or salt water pipes in water and caustic soda lime then remove scale depos its by inserting a 3 mm 1 8 in bar into each pipe Inspecting air cooler for air tightness Immerse the air cooler in water then apply high pres sure air max press 0 39 MPa 4 kgf cm 57 psi to the coolant side to inspect for air leaks NOTE Kee
73. ap ring 4 and move connector 5 to wards the cylinder head to disconnect it from the heat exchanger 4 Remove coupling 6 to disconnect from the ex haust manifold 63 Plus d informations sur www dbmoteurs fr Auxiliaries removal and installation 5 Remove four bolts to disconnect from the air cooler 7 6 Unscrew heat exchanger mounting bolts and re move the heat exchanger 8 Remove belt covers and heat exchanger bracket 1 Remove left and right belt covers 1 2 Remove heat exchanger bracket 2 Remove air cooler Remove the manifold cover 1 remove also the air cooler 2 and air cooler cover as a set 64 Plus d informations sur www dbmoteurs fr Auxiliaries removal and installation Remove exhaust manifold Unscrew manifold mounting bolts and remove mani fold 1 and gasket 2 NOTE When installing the manifold place each gas ket with its side marked as MANIFOLD facing the manifold Remove fresh water pump and tension pulley 1 Loosen tension pulley and remove the v belt 1 2 Unscrew tension pulley mounting bolts and re move the pulley 3 3 Unscrew fresh water pump mounting bolts and remove the pump 2 Remove fuel filter 1 Remove joint 1 2 Remove fuel pipes 2 and 3 2 Remove fuel filter 4 and bracket 5 Remove the speed control knob 1 Remove the lock nut from the governor lever 1 to disconnect control cable 2 from the lever
74. ate ventilation Handle consumed and surplus chemicals in the prescribed manner Observe extreme caution when tracing fuel leaks in fuel systems and when testing fuel noz zles Wear protective glasses The jet from a fuel nozzle has a very high pressure and pene trating force The fuel can penetrate deeply into bodily tissue and cause serious injury Risk of blood poisoning A All fuels as well as many chemicals are inflam mable Make sure no naked flames or sparks can cause ignition Petrol certain thinners and hydrogen from batteries are extremely inflam mable and explosive when mixed with air Smoking is prohibited Ventilate well and take the necessary precautions before welding or grinding in the immediate vicinity Always have a fire extinguisher handy in the workshop Make sure that rags drenched in oil and petrol including old fuel and lubricant filters are stored safety Oil drenched rags can in certain condi tions self ignite Old fuel and oil filters are envi ronmentally hazardous waste and together with spent lubricant contaminated fuel paint resi due solvent degreasing agent and suds should be handed in to a waste handling unit for destruction Batteries must never be exposed to naked flames or electrical sparks Never smoke in the vicinity of batteries Hydrogen develops when batteries are charged which in combination with air forms an explosive gas This gas is highly inflammable and very explosive
75. case for surface scratches dents cracks and damage If critical flaws are found re place with a new part O rings and bellow Replace O rings gaskets and below with new ones once disturbed 149 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Reassembly Reassembly sequence 206 80 670766 00 0 0 0 00 0 0 0 60 0 0 0 0 O 0 0 0 0 0 O O NOTE The reassembly of the jam nut 4 and subsequent steps should be performed after the parts are mount ed on the engine and adjusted properly 15 0 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Assembling the bearing and front cover 1 Install the O ring and bearing outer race on the front cover 2 Install the front cover on the pump case by strik ing with a hammer 3 Tighten the front cover mounting bolts Assembling the camshaft center bearing 1 Install the bearing inner race on the camshaft by striking with a hammer 2 Lay the pump case on its side 3 Place the center bearing on the camshaft and in sert the shaft into the pump case 4 Slowly rotate the camshaft and align the bolt hole in the center bearing with the bolt hole in the pump case then tighten the mounting bolt 151 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Assembling the rear cover 1 2 Install the bearing outer race on the rear cover Install the O ring and shim on the rear cover and instal
76. d control lever to max speed mea sure engine rpm 2 If max speed is out of the specified range reset with the governor set bolt 2 3 Manually change the engine speed to test the governor response its ability to sense changes in speed and adjust it promptly to nominal speed Correcting hunting 1 If the engine hunts adjust with the needle valve 3 Open the needle valve counterclockwise 2 to 3 rotations until the engine hunts Keep it hunting for 30 seconds until air is vented from the governor 2 Slowly close the valve until the hunting stops NOTE If the needle is closed too far speed regula tion with respect to changes in load will be delayed Keep the valve backed off at least 1 4 rotation from the fully closed position 3 Seal all set bolts 59 Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting Q GR NS y ote 60 Measure V belt deflection Measure the deflection of the belt Apply approxi mately 98 to 147 N 10 to 15 kgf 22 to 33 Ibf force midway between the pulleys The deflection should be approximately 10 to 15 mm 0 4 to 0 6 in Adjust the belt if the deflection is not correct Alternator 1 Loosen all the bolts securing the alternator 2 Turn the turn buckle 2 to adjust the belt tension 4 While maintaining this condition tighten all the mounting bolts 4 to secure the alternator Raw water pump 1 Loosen all the bolts securing th
77. e 163 IMSPOCTOMN 5 Seed vcketetdeseudies a aaaeei 164 FREASSOMDIY sus sister een 165 Group 25 Inlet and Exhaust System 0010 166 Alt COOIGF es int ain 166 Mepa tiO ensinaram 167 Turbocharger TD13 eeens 168 Disassembly rss ssrrcisstrereunmeuns 169 Inspection 172 FRREASSOMDIY ss envies 174 Turbocharger TD15 neneeese 180 DISASSOIMDIY sereevecseeecett tepectveent were veeneeeeeerianthes 181 INSPOCHON rer srssnneerr ee amener tisse etienne 184 Reassembly oe eee eeeeeeeeeeeeeneeeeeeeeteenaeeeeeeetenaees 186 Group 26 Cooling System 193 Fresh Water Pump eeeseeeeeeeeeesteeeeeeeeenaaees 193 INSPOCTION seniestes sise ne amet moe 195 Reassembly 196 Thermostais siosaia ARER 198 Heat Exchanger 199 Raw Water Pump standard rubber impeller 200 INSPOCHON nicnn nannaa 201 Reassembly 202 Group 30 Electrical System 206 SJ ee 206 Inspection and Repair 209 Reassembly 2 ee eeeecccceeeeeeeeeeeeeeeeeseseeseneeeeenenes 213 Alternator nr 216 Inspection and repair 217 Reass mhlVs issue aR nE min 217 Plus d informations sur www dbmoteurs fr Safety information Safety Information Introduction The Manual contains technical data descriptions and repair instructions fo
78. e communicated by means of Service Bulletins Spare parts Spare parts for the electrical and fuel systems are subject to different national safety requirements e g U S Coast Guard Safety Regulations Volvo Penta Genuine Spare Parts comply with these requirements All types of damage resulting from the use of non genuine Volvo Penta spare parts for the product in question will not be reg ulated by the warranty undertakings of Volvo Penta Certified engines For service and repair on an engine certificated for any area where exhaust emissions are regulated by law the following is important Certification means that an engine type is inspected and approved by the authorities The engine manufacturer guarantees that all engines manufactured of that type correspond to the certified engine This places special requirements on maintenance and service as follows e The maintenance and service intervals recommended by Volvo Penta must be observed e Only genuine Volvo Penta replacement parts may be used e The service of injection pumps and injectors or pump settings must always be carried out by an authorized Volvo Penta workshop e The engine must not be modified in any way except with accessories and service kits approved by Volvo Penta e No modifications to the exhaust pipes and air supply ducts for the engine may be undertaken e Seals may only be broken by authorized personnel Otherwise the general instructions contained in the Opera
79. e open circuited if there is no continuity between the M terminal of the mag netic switch and the case Resistance 1 4 ohms approx 2 Apply voltage of 24 volts between the M terminal of the magnetic switch and the case Now push in the plunger by hand When you release your hand the plunger should not be attracted Testing magnetic switch contact points Measure the load current flowing through the starter If the voltage drop between terminals B and M ex ceeds 0 3 volts per 100 amperes clean or replace the contact points If the starter switch is tumed to OFF during voltage measurement the battery voltage is directly applied to the voltmeter This can damage the voltmeter Al ways turn the starter switch to ON before measuring the voltage then turn it OFF after measuring the volt age A IMPORTANT Do not apply 24 V on terminals to test the magnetic switch movement 209 Plus d informations sur www dbmoteurs fr Group 30 Electrical System 21 Armature Measuring the armature runout Measure the runout with a dial gauge If the deflection exceeds the assembly standard repair or replace the armature Armature deflection mm in Assembly Standard 0 05 0 00197 Inspecting the commutator 1 Check the condition of the commutator surface If it is rough polish it with 400 to 600 sandpaper Check the commutator for runout with a dial gauge Replace the commutator if the deflection exceeds the
80. e tension pulley 3 2 Loosen the lock nut 5 on the adjusting bolt 6 and fasten the bolt to tighten the belt 3 While maintaining this condition tighten all the mounting bolts 4 to secure the alternator Plus d informations sur www dbmoteurs fr Bench testing An overhauled engine should be performance tested on a dynamometer This test is also for breaking in the major running parts of the engine To test the en gine follow these procedures Start Up 1 Check levels in radiator oil pan and fuel tank Prime the fuel and cooling systems 2 Crank the engine for about 10 seconds to permit lubricating oil to circulate through the engine NOTE Do not supply fuel to the engine place the stop lever in stop position 3 Move the speed control lever slightly in the direc tion of increasing fuel injection turn the starter switch to START to start the engine Do not move the control lever to full fuel injection position 4 After the engine starts let it idle under no load by operating the speed control lover Inspection after Start Up After starting up the engine check the following points If you find anything wrong immediately stop the engine and investigate the cause 1 Lubricating oil pressure should be 0 49 to 0 64 Mpa 5 to 6 5 kgf cm2 71 to 92 psi at rated speed or over 0 20 to 0 29 Mpa 2 to 3 kgf cm2 28 to 43 psi at idling speed 2 Coolant temperature should be 71 to 85 C 165
81. ect Valve Timing It is not necessary to inspect the valve timing provi ded that all match marks on the timing gears are aligned Inspect the timing for verification as ex plained below Valve timing diagrams A Standard B with 2 mm 0 08 in valve clearance added 1 Inlet valve opens 2 Inlet valve closes 3 Exhaust valve opens 4 Exhaust valve closes Use a 2 mm 0 08 in feeler gauge add 2 mm 0 08 in clearance to the inlet and exhaust valves of the No 1 cylinder Then insert a 0 05 mm 0 020 in feel er gauge between the bridge cap and rocker Slowly turn the crankshaft to find the position where the feel er gauge is firmly gripped the valve starts opening and the position where the gauge is released the valve starts closing Check that these positions coin cide with the angular positions shown in the valve tim ing diagram B Install the timing gear case 1 Apply engine oil to the lip section of the oil seal Install the oil seal in the case Clearance A should be 1 mm 0 04 in NOTE Make sure the oil seal is flush with the end face of the case 2 Apply sealant to gear case surface Mount the packing Apply sealant to packing 3 Replace dowel pins if worn or if gear case has been replaced 4 Tighten gear case mounting bolts evenly to the specified torque Cut off excess packing along the edge of the crankcase 115 Plus d informations sur www dbmoteurs fr Group 21 Engine Body
82. ed threads 87 www dbmoteurs fr Group 21 Engine Body NY SU we oT rar ne SSS SSS 88 Removing connecting rod caps Open the inspection hatches remove the connecting rod caps For identification mark the removed con necting rod bearing with cylinder number and upper or lower shell IMPORTANT Handle bearings with care Removing pistons Preparations Use a cloth or oil paper to remove all carbon deposits from the upper areas of the cylinder liner Carbon de posits make it difficult to pull the piston out Removing pistons 1 Turn the crankshaft to bring the piston assembly from which the connecting rod cap has been re moved to top dead center 2 Turn the crankshaft in reverse until the crank pin comes off the connecting rod and the bolt hole of the rod is visible through the inspection hatch on the side of the crankcase 3 Cover a bar with a cloth for protection Put the tip of the bar under the bottom of the big end of the connecting rod and pry the bar slightly down wards using the crank pin as a fulcrum This will push the piston assembly upwards NOTE If you insert the turning bar too far you may not be able to pry the piston assembly upwards In sert the bar 10 to 20 mm 0 39 to 0 79 in beyond the big end Plus d informations sur www dbmoteurs fr Group 21 Engine Body 4 Turn the crankshaft a little at a time to raise the crank pin fulcrum while pu
83. eller remover 885455 885451 885439 885441 885440 885428 885455 Special tools 885451 885428 To remove oil and water pump plate and flywheel Nozzle tester To remove and install snap ring To remove and install snap ring To remove and install snap ring Injection coupling gauge 49 Plus d informations sur www dbmoteurs fr Special tools X 885426 885435 885430 885431 o g 885448 885429 885432 885450 A 885449 885399 885407 885408 885426 To install front oil seal 885432 Spacer for liner pusher head bolt 885435 To installa rear oil seal 885450 Measure crankcase counter bore depth 885430 Valve seat cutter shaft 885449 To tighten cylinder head bolts 885431 Valve seat cutter 885399 Installation of fan drive oil seal 885448 Liner pusher 885407 Installation of fan drive bearing 885429 Bolt for liner pusher 885408 Installation of fan drive beaing 50 Plus d informations sur www dbmoteurs fr Overhaul Instructions Determination of overhaul timing In most cases the engine should be overhauled when the engine s compression pressure is low Other factors that indicate the necessity of engine overhaul are A Decreased power Increased fuel consumption Increased engine oil consumption Increased blow by gas volume through the breather due to abrasion of liner and piston rings Decreased engine oil pressure Gas leakage due to poor seating of inlet and exhaust valves Starting problems rommogd W I
84. embly Standard 28 5 0 5 V Field coil resistance at 20 C 68 F Assembly Standard 7 3 to 8 6 W 40 Plus d informations sur www dbmoteurs fr General information Tightening torques D25A Thread Torque Description Diam xPitch Nm kpm Ibf ft Notes M Thread Cylinder Head 22 x 2 5 539 55 398 a b c Cylinder head nozzle gland studs 14 x 2 0 69 78 7 8 51 58 Rocker case 12 x 1 25 108 11 80 Rocker shaft 14 x 2 0 147 15 108 Rocker arm lock nuts 12 x 1 25 64 6 5 47 Bridge lock nuts 10 x 1 25 55 5 6 40 Camshaft gear 12 x 1 25 127 13 94 Camshaft thrust plate 12x 1 25 59 6 43 Main bearing caps 22 x 2 5 490 50 362 a Hanger 12 x 1 25 108 11 80 Piston cooling nozzle 12x 1 75 34 3 5 25 d Timing gear case 16 x 1 5 216 22 159 Rear plate 12 x 1 25 108 11 80 Oil pan 12x 1 25 59 6 43 Front mounting bracket 12 x 1 25 108 11 80 Rear mounting bracket 16 x 1 5 216 22 159 Connecting rod bearing caps 22Xx1 5 539 55 398 a e Flywheel 22x1 5 539 55 398 a Viscous damper 22x1 5 490 50 362 Rear idler shaft 12 x 1 25 108 11 80 Rear idler shaft thrust plate 10 x 1 25 29 3 22 Exhaust manifold V clamp nuts 8 x 1 25 19 6 2 14 5 Exhaust manifold mounting bolts 1 4 x 28 9 0 9 6 5 UNF Exhaust pipe V clamps 10 x 1 5 98 10 72 Oil pump 12 x 1 25 108 11 80 Oil pump cover 10x1 25 26 3 39 7 2 7 4 1 18 32 Fresh water pump 12 x 1 25 59 6 43 Fresh water pump shaft pulley nuts 24x 1 5 245 25 181 For alternator drive a Wet apply lubrication oi
85. emperature where the valve opens then mea sure it again when the valve lift is 11 mm 0 43 in Replace the thermostat if temperatures are not within standard Temperature for valve opening C F Assembly Standard 80 84 176 183 2 Temp for 11 mm 0 43 in valve lift C F Assembly Standard 95 203 A IMPORTANT Stir the oil to maintain even tem peratures during the test A IMPORTANT At reassembly confirm the valve opening temperature stamped on its mounting flange Reassembly Reassembly is the reverse procedure of disassembly 1 Replace packing and O rings for reassembly 2 Before reassembly clean the oil paths of the oil cooler cover and other parts with cleaning sol vent Use compressed air to remove dust and cleaning solvent before reassembly 4 Plus d informations sur www dbmoteurs fr Group 22 Lubrication System Oil Filter Disassembly Look for 1 Oil filter cartridge type 4 Cover 6 O ring 8 Cock A Clogging cracks 2 Cover 5 Packing 7 Pin 9 Filter bracket 3 Packing Inspection Inspect the oil filter When replacing filter element sample about 500 cm 30 5 in of oil and look for metal particles If particles are found unfold the pleats of the element and check the color and shape of the particles to identify the cause Reassembly Reassembly is the reverse procedure of disassembly 1 Clean oil paths of the filter bracket etc with cleaning solvent Use c
86. ent it from flying out in case the pliers lose grip 18 2 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Removing the insert and oil deflector 1 Using two screwdrivers gently pry out the insert from the bearing housing 2 Separate the finger sleeve together with the pis ton ring from the insert 3 Remove the o ring the oil deflector the compres sor thrust ring the thrust bearing and the turbo thrust ring from the bearing housing Removing the shaft amp turbine wheel 1 Remove the bolts and lock plates 2 While gripping the shaft of the shaft amp turbine wheel with one hand hold the bearing housing with the other hand and slowly remove the shaft amp turbine wheel from the turbine housing 3 Turn the bearing housing turbine wheel face up and place it on the compressor cover Remove the shaft and turbine wheel the piston ring the turbine backplate and the bearing compressor side Removing the snap ring and bearing A IMPORTANT Remove the snap ring with care and make sure not to damage the inside sur face of the bearing house or the seal turbine side of the piston ring Place the bearing housing on a workbench with the compressor side face up Then remove the 3 snap rings and the bearing 183 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System 18 Inspection Bearing housing Measure inside diameter of bearing f
87. epair Limit B10 925 0 39 9 0098 Armature shaft diameter front mm in Nominal Value 25 0 98 Assembly Standard 25 002 25 011 0 98433 0 98468 Reapir Limit B25 028 0 98 9 0098 Armature shaft deflection mm in Assembly Standard 0 06 0 00236 Maintenance Standards 39 Plus d informations sur www dbmoteurs fr Maintenance Standards Pinion shaft diameter rear mm in Nominal Value 30 1 8 Assembly Standard 30 002 to 30 011 1 18118 to 1 1853 Reapir Limit B30 10 011 1 18 0 0043 Pinion shaft diameter front mm in Nominal Value 19 0 75 Assembly Standard 18 90 to 18 94 0 7441 to 0 7457 Reapir Limit B19 006 0 75 0 00236 Metal Pinion Nominal Value 19 0 75 Assembly Standard 19 000 to 19 033 0 7480 to 0 7493 Reapir Limit G19 208 0 75 0 00130 Service Limit 0 25 0 0098 NOTE Clearance between shaft and metal End play of armature mm in Assembly Standard 0 3 to 0 7 0 012 to 0 028 End play of pinion shaft mm in Assembly Standard 0 2 to 0 8 0 008 to 0 031 Alternator Output current 27 V 2500 rpm At 2500 rpm Assembly Standard 30 A or higher when cold At 5000 rpm Assembly Standard 35 A or higher when hot Regulator adjusting voltage alternator at 5000 rpm load at 5 A or lower Ass
88. er bracket 2 together with the stop per lever Unscrew stop solenoid mounting bolts and re move stop solenoid 3 Remove the solenoid bracket 4 Remove oil cooler Remove oil cooler 1 and cover 2 as a set 67 Plus d informations sur www dbmoteurs fr Auxiliaries removal and installation 68 Remove oil filters Remove two oil filters 1 and oil by pass filter 2 Unscrew filter bracket mounting bolts and remove bracket 3 Remove oil emergency pipe 4 Remove oil filter adaptor 5 Remove the alternator 1 Loosen lock nuts 1 left handed thread and lock nut 2 Turn adjusting rod and remove the V belt 2 Remove the adjusting rod and attached parts as a set 3 Unscrew alternator bracket mounting bolts and remove bracket 4 and alternator 5 as a set Remove the starter Remove starters 1 by unscrewing the starter mount ing bolts Plus d informations sur www dbmoteurs fr Auxiliaries removal and installation Engine Auxiliaries Installation To install the engine auxiliaries follow the removal procedures in reverse After installation service them as fol lows 1 Refill the engine with the recommended oil up to the specified level Refill the cooling system with coolant For easy engine starting pour engine oil for the governor into the oil filter from its vent plug Check each pipe connection for oil or coolant leaks Prime the fuel system oa F oe N I
89. er liner protrusion 8 If the value is less than the assembly standard insert a shim under the collar of the cylinder liner Measuring step height of cylinder liner collar 1 Place a dial gauge on the rim of the liner collar and set the indicator to 0 zero 2 Measure the cylinder liner step at four locations and obtain the average Cylinder liner step height mm in Assembly standard 0 16 0 24 0 006 0 010 3 Ifthe average is less than the assembly standard or if the step has sectional chipping replace the cylinder liner 91 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Z A Le sr Z a A A A A YZ ZA L N 92 Cylinder liner shim Insert a shim between the cylinder liner and the crankcase NOTE Select the shim that achieves the largest pro trusion within the assembly standard range Replace cylinder liners 1 Use the Cylinder liner remover to remove the cyl inder liner from the crankcase 2 Coat the O rings with engine oil to prevent twist ing and attach them to the new cylinder liner A black o ring B red o ring Carefully insert the liner into the bore of the crankcase 3 Lightly tap liner on the top with the installer so it rests on its flange on the counterbore in the crankcase After seating the liner tap on it sever al times more to secure the proper seating N IMPORTANT After installing the liners on all bore
90. esting brush spring tension Brush spring tension N kgf Ibf Assembly Standard 39 23 49 03 4 0 5 0 9 11 Service Limit 39 23 4 0 9 maximum 211 Plus d informations sur www dbmoteurs fr Group 30 Electrical System Safety Switch Connect the safety switch as shown and check the starter and safety switch operations 1 Connect the R terminal to the battery minus side 2 Turn the switch on and check that the starter tums 3 After step 2 above is completed if you remove the R terminal from the battery minus side or if you connect the terminal to the battery plus side after removal make sure you stop the start er operation AN IMPORTANT When you are making con nections pay special attention to the bat tery s polarity 21 2 Plus d informations sur www dbmoteurs fr Group 30 Electrical System Reassembly Reassembly sequence 1 Install the center bracket overrunning clutch and pinion stopper to the pinion shaft Insert the shaft in position by tapping it with a soft head mallet 2 Install the shift lever and pinion shaft to the front bracket by aligning the matching mark on the shifi lever 3 Install the armature and yoke to the center brack et making sure that the dowel pin enters its hole 4 Install the brushes and brush holders 213 Plus d informations sur www dbmoteurs fr Group 30 Electrical System NOTE Ins
91. ew part Camshaft deflection mm in Assembly Standard 0 05 0 00197 Repair Limit 0 15 0 00591 Bearing Check the bearing for flaking abnormal abrasion and noise If damage is found replace with a new part 8 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Plunger and delivery valve springs 1 Check the surface of each spring for scratches and rust 2 Using a square measure the perpendicularity gap B at the upper end of the spring If the measurement exceeds the service limit re N place the spring Plunger Spring mm in Free length A Assembly Standard 70 8 2 787 Perpendicularity B Service Limit 1 8 0 071 Q C Length under test force mm in Assembly standard 60 0 2 36 Test force N kgf Ibf Assembly standard 299 366 30 5 37 3 67 2 82 2 Delivery valve spring mm in Free length A Assembly Standard 18 0 71 Perpendicularity B Service Limit 0 6 0 024 Length under test force mm in Assembly standard 14 15 0 56 Test force N kgf Ibf Assembly standard 51 6 61 4 5 26 6 26 11 60 13 80 Valve holders 1 Check the contacting surfaces of injection pipe and delivery valve on each valve holder for scratches 2 Ifthe contact surfaces are scratched replace the valve holder since surface scratches can cause fuel leakage Pump case Check the pump
92. f the bearing to each bearing cap Install the thrust bearings to the No 7 bearing cap with the oil groove side of the bearing facing out From the front side of the crankcase hearings No 1 to No 7 are stamped on the caps Install the caps with these numbers and FRONT mark on the front of the crankcase Coat the threads of the metal cap bolts with en gine oil then temporarily tighten the bolts Use a softhead mallet to drive in the metal caps evenly Bearing cap bolts 1 Temporarily tighten the bearing cap coated with engine oil Tighten the four bolts progressively and evenly to the specified torque Tighten the left and right side bolts progressively and evenly to the specified torque Make sure that the crankshaft rotates smoothly Crankshaft end play Tighten No 1 through No 6 bearing cap bolts and side bolts to the specified torque with the No 7 cap bolt temporarily tightened then mea sure the end play After tightening the No 7 cap bolts make sure that the end play is correct Confirm that all cap bolts and side bolts are tight ened to the specified torque 127 Plus d informations sur www dbmoteurs fr Group 22 Lubrication System Group 22 Lubrication system Disassembly Support Oil pipe Oil strainer Safety valve Pump cover Bushing Drive gear ON OA FWD Oil pump gear Oil Pump and Safety Valve Driven gear 10 11 12 13 14 15 Nu
93. facturer cccccssecccccceecsssssseeeeeecessssssseeeeeeeeees Mitsubishi Heavy Industries Ltd Plunger outside diam mm iN neeesser 17 0 67 Plunger lead mm IN neeese Counterclockwise left hand 35 1 38 lead Cam lift mm in eeeeeeeeeeeeeeeeeeeeseaeeteaeeeaee 15 0 59 Fuel feed pump MOSM acces sanesa ea ae eaa Enia Zexel Ma ufatture eaea ae aaa RE TEE Zexel Cami lift mi M ccsseccccetascscezeztis sexe secaassestasenssseraxteataces 12 0 47 Governor Control SYSTEM 15 seccscest isceideladtin ctietadateniadveasseessentteast Woodward Hydraulic PSG 19 Plus d informations sur www dbmoteurs fr General information Fuel system cont Fuel injector TYPO E E E A Hole type ManulaGturer siirinsesi ieira ienaa Zexel No of Spray NOleSii wcscii nineties shine 10 Spray hole diameter mm in 0 325 0 013 Spray angle deg 160 Injection press Mpa kgf cm psi ceeeeeeeeeeee 34 82 to 34 81 350 to 355 4979 to 5050 Fuel filter TYPO E E Aenea det Paper element cartridge changeover spin on type Oil system Lubricating type iiaiai aiina aani Forced circulation type pressure feed by oil pump Engine oil Standard CF oil API service classification or better Engine oil volume Oil sump liter U S gal 140 37 0 approx Complete engine liter U S gal 160 42 3 approx Oil pump VG Sarre Ain fencing ried Gear pump Delivery capacit
94. formations sur www dbmoteurs fr Group 21 Engine Body Reassembly Reassembly is done in the reverse order of disas sembly Pistons and connecting rods 1 The piston pin is clearance fitted to the piston To facilitate pin insertion heat the piston with a pis ton heater or in hot water 2 Coat the piston pin with engine oil then insert it in position through the connecting rod 3 Install the connecting rod to the piston with the matching marks on the large end on the camshaft side 4 Use the Ring pliers to install the snap rings in the grooves of the piston Make sure that the rings are not fatigued and that they fit in the grooves properly NOTE Position the ends of both snap rings at the bottom of the pin bore Piston rings 1 Use the Piston ring tool to install the piston rings on the piston A IMPORTANT The top piston ring and second piston ring are marked RH and the oil ring is marked R near the gap Install the rings with these marks upwards Faulty mounting will cause excessive oil consumption and overheating 2 Install the oil ring with its gap positioned at 180 from the coil spring joint 1 Aull LTS SNS Q A A 99 Plus d informations sur www dbmoteurs fr Group 21 Engine B UZZZZ LLG LCL LLC LOO L OA 10 ody DT L2277ZZZZZZZZZZZZZZ1 CA Preparation before installing pistons Clean the cylinder liner bore surface and crank
95. g and cylinder liner Insert the piston slowly not to damage the oil ring 4 Coat the rings with engine oil and clamp them using the Piston installer Coat the inside surface of the installer with engine oil 5 Lightly tap on the piston head with a soft head mallet to insert the piston into the cylinder liner If the piston will not go into the liner move the large end of the connecting rod back and forth through the crankcase inspection hole 6 Make sure that the upper shell of the bearing is properly positioned in the big end of the connect ing rod Installing connecting rod cap bolts 1 Place the connecting rod bearing on the connect ing rod fitting its lug in the lug groove Coat the threads of the cap bolts and the inside surface of the lower shells of the connecting rod bearing with engine oil 2 Install each cap in position Hold the upper end of the cap then tighten the bolt at the lower end first This will help prevent the cap from dropping into the oil pan Coat the threads and bearing sur faces of the bolts with engine oil then tighten the bolts temporarily 101 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 10 3 Touch the joint between the cap and rod Make sure that the cap is fit in place and tighten the bolts to the specified torque ZN IMPORTANT Make sure that the matching 5 marks on the cap and rod are on the same side and show the same number
96. groove on the shaft amp turbine wheel 4 When installing the shaft amp turbine wheel mount ed with the piston ring in the bearing housing po sition the ring on the shaft so that there is a small space A at the ring end gap side B and a large space C on the other side Then insert the shaft amp turbine wheel while rotating A IMPORTANT Do not expand the piston ring ex cessively or twist the ends when installing on the shaft amp turbine wheel A IMPORTANT Do not apply excessive forte with out tentering the shaft properly during the instal lation of the shaft amp turbine wheel NOTE After installing the piston ring in the ring groove apply Moly Disulfide to the ring before as sembly 5 Hold the shaft end and tum the assembly over so the compressor side faces up Install the bearing on the compressor side and then mount the bear ing housing in the turbine housing and fasten the v clamp temporarily 175 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System D Install the thrust bearing Apply engine oil to both sides of the thrust ring and thrust bearing To install the thrust bearing align the notch with the groove pin Install the O ring Apply grease to the O ring and install Install the oil deflector Apply engine oil to both sides of the thrust ring and in stall Then install the oil deflector with the baffle fac ing down 17 6 Plus d informations sur ww
97. h the cen ter of the hole i e the connector should never touch the walls of the hole in the cylinder head IMPORTANT The anti seizing compound must be high temp resistant and must not cover the nozzle holes 4 Install all fuel lines to the inlet connectors with a loose fit When all inlet connectors are installed and aligned tighten nozzle gland mounting nut to the specified torque 5 Tighten the fuel inlet connector to the specified torque 6 Align all high pressure fuel lines in such a way that they fit in their clamps with the least possible strain 7 Tighten high pressure fuel pipes to fuel inlet con nectors to the specified torque 86 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Cylinder liners Pistons and Connecting rods Disassembly Bolt Connecting rod cap Connecting rod bearing lower shell Top compression ring Second compression ring Oil ring Snap ring Piston pin ONourownr Piston Oo Connecting rod _ _ Connecting rod bushing D Connecting rod bearing Plus d informations sur Look for A Wear scratches damage B Fatigue C Scratches cracks damage wear carbon deposits on outside surface D Cracks clogged oil hole E Scratches wear on inside surface rust on outside surface F Damage G Wear scratches discolored inside surface H Scratches seizure wiping out of overlay on both sides I Damag
98. haft with a press or replace it with a new one AN IMPORTANT Set up a dial gauge on the cam shaft then turn the camshaft Take one half of the gauge indication as the deflection Camshaft deflection mm in Assembly standard 0 05 0 0020 max Repair limit 0 08 0 0031 Measuring camshaft journal diameters Use a micrometer to measure each camshaft journal in two directions at right angles to each other If the diameter exceeds the service limit replace the cam shaft Camshaft journal diameter mm in Nominal value G84 3 31 Assembly standard 83 92 83 94 3 3039 3 3047 Service standard 83 87 3 3020 Measuring camshaft bushing inside diameter Use a cylinder gauge to measure the inside diameter of the camshaft bushings fitted to the crankcase If the inside diameter exceeds the service limit replace the bushings Camshaft bushing inside diameter mm in Nominal value 84 3 31 Assembly standard 84 000 84 035 3 30708 3 30846 Service limit 84 10 3 3110 111 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 11 Measuring camshaft end play Use a dial gauge to measure the end play of the cam shaft to which the camshaft gear is installed If the end play exceeds the service limit replace the thrust plate Camshaft end play mm in Standard clearance 0 10 0 25 0 0039 0 0098 Service limit
99. han the ones recommended by us to ensure that there is no danger of injury damage or malfunction resulting from these In some cases there may be special safety precautions and instructions for the use of tools and chemicals con tained in this Workshop Manual These special instructions should always be followed if there are no separate in structions in the Workshop Manual Certain elementary precautions and common sense can prevent most risks arising A clean workplace and en gine eliminates much of the danger of injury and malfunction It is of the greatest importance that no dirt or foreign particles get into the fuel system cooling system lubrication system intake system turbocharger bearings and seals when they are being worked on The result can be mal function or a shorter operational life Our joint responsibility Each engine consists of many connected systems and components If a component deviates from its technical specification the environmental impact of an otherwise good engine may be increased significantly It is therefore vital that wear tolerances are maintained that systems that can be adjusted are adjusted properly and that Volvo Penta Genuine Parts as used The engine Maintenance Schedule must be followed Some systems such as the components in the fuel system require special expertise and special testing equip ment for service and maintenance Some components are sealed at the factory for environmental reasons
100. he bushing or shaft Rocker bushing inside diameter mm in Normal Value 36 1 42 Assembly Standard 36 000 36 040 1 41732 1 41889 Service limit 36 090 1 42086 Rockershaft diameter mm in Normal Value 36 1 42 Assembly Standard 35 966 35 991 1 41598 1 41697 Service limit 35 940 1 41496 Replacing rocker bushings Use the Rocker bushing tool to remove the rocker bushings for replacement NOTE Press a new bushing into the rocker from the chamfered side 1 of the bore NOTE Align the oil holes in the bushing and rocker NOTE Check bushing joint mark 2 Plus d informations sur www dbmoteurs fr aS LLLLLLL fp y N LLLLLLLLL DEERE ERE UUE DAA 1 DLA ERA CL COR LLL LLL ly X 21 SR TR VE Oh TE A EE MBER ZA G Group 21 Engine Body Valve Guide and Valve Stems Measure valve stem and valve guide The valve guide wears more rapidly at its ends than at any other location Measure the inside diameter of the guide at its ends in two directions If the service limit is exceeded replace the guide Valve stem diameter mm in Normal Value 10 0 39 Assembly Standard 9 940 9 960 0 39134 0 39213 Service limit 9 910 0 39016 Valve guide inside diameter mm in Normal Value 10 0 39 Assembly Standard 10 000 10 015 0 39370 0 39429 Service li
101. he other fuel filter 55 Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting Bleeding the fuel injection pump 1 Loosen the air vent cock on the fuel injection pump about 1 5 turns 2 Pump the priming pump to start the flow of fuel through the system 3 When fuel without visible bubbles comes out of the air vent cock lock the priming pump cap while holding it down Tighten the air vent cock NOTE Be sure to lock the priming pump cap before tightening the air vent plugs and cock If not the cap will not return to the original position due to pressure in the priming pump 4 Tighten the priming pump cap by hand until the tightening force increases normally this occurs after approximately 70 to 90 degrees Mark this position on the priming pum 5 Tighten the priming pump cap an additional 120 to150 degrees using a wrench ZA IMPORTANT If the priming pump cap is tight ened too much more than 240 degrees in to tal the top of the pump might be damaged A IMPORTANT If the pump cap is not tightened properly engine vibration may cause excessive wear to the internal threads of the pump This may cause the priming pump cap to eject and oil to flow out leading to engine failure and dam age to the installation 56 Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting Fuel injection timing T The injection timing is indicated on the caution plate rit 0 6MM 17
102. he snap rings 2 Remove the piston pin to separate the piston from the connecting rod 3 If it is difficult to pull out the pin heat the piston with a piston heater or in hot water to expand the pin bore 89 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 90 Inspection and Repair Cylinder Liners Inside diameter Measure the inside diameter of each liner in two di rections parallel and transverse to the piston pin at three positions top worn position middle and low If measurements exceed the service limit replace the liner Cylinder liner side diameter mm in Normal value 170 6 69 Assembly standard 170 000 170 040 6 69290 6 69447 Service limit 170 500 6 71259 Measuring cylinder liner protrusion Measure the protrusion of each liner at its flange with a dial gauge NOTE The method of measuring the protrusion of an used liner differs from that of newly installed one Cylinder liner protrusion at flange A mm in Assembly standard 0 11 0 20 0 0043 0 0079 ZN IMPORTANT If the protrusion is less than the assembly standard the gasket will fail to seal the bore resulting in gas leakage When cylinder head has just been removed 1 Clean the gasketed surface of the crankcase and the top of the liners 2 Secure the top of the liner uniformly at four plac es with the Liner pusher and the Bolts NOTE Use the Head bolt space
103. heel evenly then remove the flywheel Weight Approx 140 kg 309 Ib A IMPORTANT When you remove the flywheel do not drop it or bump it against a hard object A IMPORTANT The ring gear is bolt mounted to the flywheel Do not remove the gear except when it has to be replaced Governor and injection pump drives Unscrew the mounting bolts and remove the governor drive and injection pump drive case NOTE Be careful not to damage the gear teeth Remove the timing gear case 1 Attach slings to the timing gear case 2 Unscrew the timing gear case mounting bolts 3 Remove the timing gear case by lifting it up and pulling it away from the engine until it separates from the dowel pins NOTE Keep the timing gear case suspended and do not damage the oil seal Weight Approx 85 kg 187 Ib Measure backlash and end play Measure the backlash and end play of each gear to obtain data to evaluate need of parts replacement 107 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 10 Remove idler gears Align the pointer with the mark for top dead center of piston no 1 in compression stroke Remove the thrust plate mounting bolts and the idler gear Remove the idler shaft Remove the idler shaft mounting bolts Install two jack bolts M10 x 1 25 mm 0 39 x 0 049 in in the holes for shaft removal Screw the bolts evenly to remove the idler shaft Remove camshaft gears Unscrew the camshaf
104. hreads evenly then re move the viscous damper Weight Approx 50 kg 110 Ib SSSSSSSSSSSS he DR X DR es I e Water pump and alternator drive pulley Remove the crankshaft pulley by screwing the two jack bolts M12 x 1 25 mm 0 47 x 0 049 in evenly into the pulley Front cover Unscrew the front cover mounting bolts and remove the Icover Be careful not to damage the oil seal Viscous damper inspection and repair Check the viscous damper for cracks deformations or cracks leakage of silicone oil discolored or peel ing paint due to excessive heat Replace it with a new one after 8000 to 12000 hours of service even when no defect is observed NOTE Damper may also be sent to authorized Volvo Penta workshop for inspection 10 A Plus d informations sur www dbmoteurs fr Group 21 Engine Body Reassembly A Installing the front cover 1 Apply engine oil to the lip section of the oil seal Install the oil seal in the front cover Clearance A should be 1 mm 0 04 in NOTE Make sure the oil seal is flush with the end face of the oil seal installation hole of the front cover 2 Apply sealant to the front cover mounting surface of the crankcase then place the packing in posi tion Apply the same sealant to the packing then install the front cover 3 Replace the dowel pins if worn or if the front plate has been replaced 4 Make sure that the lower end of the front
105. ication e Tighten connecting rod caps according to the angle method tighten to 245 Nm 25 kpm 181 Ibf ft then tighten 60 more f Left handed thread g Apply Moly Disulfide to thread h Tighten the lock nut to 49 Nm 5 kpm 36 Ibf ft firs then loosen it completely Retighten to 14 7 Nm 1 5 kpm 0 8 Ibf ft then tighten 80 3 more i Tighten the lock nut to 69 Nm 7 kpm 51 Ibf ft then loosen it completely Apply Loctite No 962T to the threads Retighten to 9 8 Nm 1 kpm 7 2 lbf ft then tighten 90 3 more 44 Plus d informations sur www dbmoteurs fr General information Standard Bolts and Nuts Fine threads Thread Strength classification diameter x pitch 7T 10 9 mm in Nm kpm Ibf ft Nm kpm Ibf ft M10 x 1 25 0 39 x 0 049 33 3 4 25 60 6 1 44 M12 x 1 25 0 47 x 0 049 60 6 1 44 108 11 0 80 M14 x 1 5 0 55 x 0 059 97 9 9 72 176 17 9 129 M16 x 1 5 0 63 x 0 059 145 14 8 107 262 26 7 193 M18 x 1 5 0 71 x 0 059 210 21 4 155 378 38 5 278 M20 x 1 5 0 79 x 0 059 291 29 7 215 524 53 4 386 M22 x 1 5 0 87 x 0 059 385 39 3 284 694 70 8 512 M24 x 1 5 0 94 x 0 059 487 49 7 359 878 89 5 647 M27 x 3 1 06 x 0 12 738 75 3 544 1328 135 5 980 Coarse threads M8 x 1 25 0 31 x 0 049 17 1 7 12 30 3 1 22 M10 x 1 5 0 39 x 0 059 32 3 3 24 58 5 9 43 M12 x 1 75 0 47 x 0 069 57 5 8 42 102 10 4 75 M14 x 2 0 55 x 0 079 93 9 5 69 167 17 0 123 M16 x 2 0 63 x 0 079 139 14 2 103 251 25 6 185 M18 x 2 5 0 71 x 0
106. ide diameter mm in Nominal Value 50 1 97 Assembly Standard 49 988 to 50 000 1 96803 to 1 96850 Drive shaft bearing journal diameter mm in Nominal Value 45 1 77 Assembly Standard 45 002 to 45 013 1 77173 to 1 77216 Drive shaft bearing journal diameter mm in Nominal Value 50 1 97 Assembly Standard 50 002 to 50 013 1 96858 to 1 96901 Damper Radial runout at periphery mm in Assembly Standard 0 5 0 020 or less Service Limit 1 5 0 059 Radial runout at periphery mm in Assembly Standard 0 5 0 020 or less Service Limit 1 5 0 059 Maintenance Standards 27 Plus d informations sur www dbmoteurs fr Maintenance Standards Timing gears Backlash mm in Assembly Standard 0 12 to 0 18 0 0047 to 0 0071 Repair Limit 0 30 0 0118 Service Limit 0 50 0 0197 Idle gear shaft bushing inside diameter mm in Nominal value 50 1 97 Assembly standard 50 000 50 025 1 96850 1 96848 Service limit 50 060 1 97086 Idle gear shaft diameter mm in Nominal value 50 1 97 Assembly standard 49 950 49 975 1 96653 1 96752 Service limit 49 900 1 96456 Idle gear end play mm in Standard clearance 0 2 0 4 0 008 0 016 Service limit 0 6 0 024 Camshaft Cam lift A
107. ide sur faces of the bearing before installation C 2 Place the bearing housing on the compressor 4 cover and install the turbine backplate 3 Insert the piston ring into the groove on the shaft A amp turbine wheel B 4 When installing the shaft amp turbine wheel mount o ed with the piston ring in the bearing housing po sition the ring on the shaft so that there is a small space A at the ring end gap side B and a large space C on the other side Then insert the shaft amp turbine wheel while rotating A IMPORTANT Do not expand the piston ring ex cessively or twist the ends when installing on the shaft amp turbine wheel A IMPORTANT Do not apply excessive forte with out tentering the shaft properly during the instal lation of the shaft amp turbine wheel NOTE After installing the piston ring in the ring groove apply Moly Disulfide to the ring before as sembly 5 Hold the shaft end and tum the assembly over so the compressor side faces up Install the bearing on the compressor side and then mount the bear ing housing on the turbine housing and fasten the bolt temporarily 187 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System D Installing the thrust bearing Apply engine oil to both sides of the thrust ring and thrust bearing To install the thrust bearing align the notch with the groove pin Installing the O ring Apply grease to the O ring and install
108. il deflector the compres sor thrust ring the thrust bearing and the turbo thrust ring from the bearing housing Remove the v clamp Loosen the v clamp with a socket wrench and dis lodge the clamp from its position 17 0 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Removing the shaft amp turbine wheel 1 Remove the bolts and lock plates 2 While gripping the shaft of the shaft amp turbine wheel with one hand hold the bearing housing with the other hand and slowly remove the shaft amp turbine wheel from the turbine housing 3 Turn the bearing housing turbine wheel face up and place it on the compressor cover Remove the shaft and turbine wheel the piston ring the turbine backplate and the bearing compressor side Removing the snap ring and bearing LA IMPORTANT Remove the snap ring with care and make sure not to damage the inside sur face of the bearing house or the seal turbine side of the piston ring Place the bearing housing on a workbench with the compressor side face up Then remove the 3 snap rings and the bearing 171 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System 17 Inspection Bearing housing Measure inside diameter of bearing fitted section If the measured diameter exceeds the service limit replace the bearing housing Inside diam bearing fitted section mm in Service Limit 30 0
109. ing inside diameter mm in Nominal Value 70 2 76 Assembly Standard 70 020 70 040 2 75669 to 2 75747 Service Limit 70 070 2 75866 Bend and twist mm in Assembly Standard 0 05 100 0 0020 3 9 or less End play rod and crankpin widths mm in Nominal Value 67 2 64 Assembly Standard 0 2 0 6 0 008 to 0 016 Service Limit 1 0 0 039 Weight difference between connecting rods in one engine Assembly Standard 30 g 1 06 oz NOTE All connecting rods in one engine must be with the same classification letter Big end bore diameter mm in Nominal Value 131 5 16 Assembly Standard 131 000 to 131 025 5 15747 to 5 15845 Service Limit 131 050 5 15944 NOTE To be measured in combination with caps Roundness less than 0 1 mm 0 004 in service limit Connecting rod bearings Thickness of center STD mm in Nominal Value 3 000 0 11811 Assembly Standard 2 972 to 2 985 0 11701 to 0 11752 Service Limit 2 930 0 11535 Thickness of center 0 25 0 0098 mm in Nominal Value 3 125 0 12303 Assembly Standard 3 097 to 3 110 0 12193 to 0 12244 Service Limit 3 055 0 12028 Thickness of center 0 50 0 0197 mm in Nominal Value 3 250 0 12795 Assembly Standard 3 222 to 3 235 0 12685 to 0 12736 Service Limit
110. ing seat plunger and plunger spring from the barrel A IMPORTANT Handle plungers carefully to pre vent damage and scratches Z IMPORTANT Place the removed plungers in a tray with clean diesel fuel do not change the original combinations of plungers and barrels 4 Remove the barrel from the plunger spring com pression jig then remove the upper spring seat pinion and O ring 14 6 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Inspection NOTE After disassembly wash parts in clean diesel oil Replace defective or damaged parts Plungers and barrels 1 Inspect the lead section and tip of each plunger for wear scratches discoloration and erosion 2 After washing with clean diesel fuel check each plunger by tilting approximately 15 and lifting it approximately 30 to 35 mm 1 18 to 1 38 in as Go shown in the diagram The plunger must fall smoothly on its own weight Change the plunger position by turning it slightly and check again Re peat this test two or three times for each plunger 3 If the plunger falls too quickly or sticks before it reaches the bottom replace the plunger and bar rel as a set Delivery valves 1 In each delivery valve inspect the valve seat and C i sliding surfaces for scratches and check contact ing surface to the barrel ji 2 Wash parts with clean diesel oil Lift the valve and let it fall making sure that it slides down a smoothly to
111. itted section If the measured diameter exceeds the service limit replace the bearing housing Inside diam bearing fitted section mm in Service Limit 34 016 1 33921 Bearing Measure bearing outside diameter If the measured diameter is less than the service limit replace the bearing Bearing inside diameter mm in Service Limit 33 882 1 33393 Measure bearing inside diameter If the measured diameter exceeds the service limit replace the bearing Bearing inside diameter mm in Service Limit 19 929 0 78460 Measuring bearing length If the measured length is less than the service limit replace the bearing Bearing length mm in Service Limit 19 44 0 76535 4 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Shaft amp turbine wheel Measure journal diam of shaft amp turbine wheel If the measured diameter is less than the service limit replace the shaft amp turbine wheel Shaft journal diameter mm in Service Limit 19 863 0 78201 Measure shaft deflection 1 Set a dial gauge at a location next to the thread ed section of the shaft and measure shaft deflec tion If the deviation indicated by the dial gauge exceeds the service limit replace the shaft amp tur bine w heel IMPORTANT If the shaft is bent replace Do not attempt to correct the bend 2 Ifthe surf
112. ive case O ring Idler gear Snap ring Idler shaft Washer bolt Bearings NN O O1 WD 10 Drive gear _ _ Snap ring 12 Drive shaft 13 Snap ring 14 Bearings Plus d informations sur Look for A Rotation B Wear C D Wear of spline Wear of teeth 163 www dbmoteurs fr Group 23 Fuel System 16 Inspection Inspection of bearings Rotate each bearing to check for rotation Replace a bearing which fails to rotate smoothly Check the fit of the bearings on the drive shaft and idler shaft Re place the shaft or bearings whichever are badly worn Check the fit of bearings in the drive case and replace a worn part Case bore diam drive shaft side mm in Nominal Value 52 2 05 Assembly Standard 51 988 52 018 2 04677 2 04795 Drive shaft side bearing mm in Outside diameter Nominal Value 52 2 05 Assembly Standard 51 987 52 000 2 04673 2 04742 Inside diameter Nominal Value 25 0 98 Assembly Standard 24 990 25 000 0 98386 0 98425 Drive shaft diam mm in Nominal Value 25 0 98 Assembly Standard 25 002 25 011 0 98433 0 98468 Case bore diam idler shaft side mm in Nominal Value 47 1 85 Assembly Standard 46 989 to 47 014 1 84996 to 1 85094 Idler shaft side bearing diameter mm in Outside diameter Nominal Value 47 1 85 Assembly St
113. l and installation 72 Stop solenoid Adjustment 1 Supply power to solenoid 1 contracted 2 Loosen nuts 2 and 3 3 Rotate rod 4 to adjust the clearance between le ver 5 and follower 6 to be from 0 5 to 1 0 mm 0 020 to 0 039 in 4 Tighten nuts 2 and 3 Inspection 1 Cut off power to solenoid 1 extended 2 After adjusting the exhaust temperature run the engine at high idling speed 3 Supply electric current to solenoid 1 contracted condition 4 After the engine stops completely check to make sure the distance between the rack end surface and pump case end surface is 68 to 69 mm 2 68 to 2 72 in on both banks NOTE It should be noted that the engine may not stop if the distance between the rack end surface and pump case is 70 mm 2 76 in or more NOTE When adjusting the adjusting rod make sure the rack moves without interference If the rack does not move smoothly the governor cannot operate properly Plus d informations sur www dbmoteurs fr Group 21 Engine Body Group 21 Engine Body Cylinder heads and valve mechanism Disassembly Rocker cover Fuel inlet connector Nut washer Injection nozzle gland Injection nozzle Gasket O ring Adjusting screw Bolt 10 Rocker 11 Spacer 12 Rockershaft 13 Bridge cap 14 Valve bridge D o NO DUB NE Push rod Rocker case Water outlet connector Cylinder head bolt Cylinder head Inlet port
114. l the rear cover on the pump case Camshaft thrust clearance 1 Set a dial gauge on the end surface of the cam shaft and measure end play using the Cam thrust ejector Camshaft thrust end play mm in Assembly Standard 0 02 0 06 0 00079 0 00236 2 If the measured clearance deviates from the as sembly standard increase or decrease the shim thickness to make adjustment 3 Tum the camshaft to make sure if it rotates smoothly Installing tappets 1 Install the tappet roller and roller bearing in each tappet and insert the tappet pin in each assem bly 2 Apply lubricating oil to each part 3 After the assembly make sure the roller rotates smoothly without sticking 4 Install tappets in the pump case by positioning 15 each tappet so the falt faces of the tappet engag es securely with the stopper pin 2 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Assembling plunger assemblies NOTE Wash each part with clean diesel fuel before assembly Use new O rings and apply grease to the O rings to prevent damage during assembly Install the O rings in the sequence of A B andC 1 Install three O rings on each barrel 2 Install the pinion and upper spring seat on each barrel by tapping with a hammer Make sure the pin inserted in the barrel is positioned at the notch of the upper spring seat 3 Set the assembly of the barrel pinion upper spring seat on the plunger spring compressio
115. l to the threads of the nut and bolt b 2 step tightening method c Tighten cylinder head bolts according to the angle method tighten to 294 Nm 30 kpm 217 Ibf ft then tighten 60 more d Extremely important to use torque wrench in tightening the piston cooling nozzles Failure to do so may result in excessive tightening torque which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubrication e Tighten connecting rod caps according to the angle method tighten to 245 Nm 25 kpm 181 Ibf ft then tighten 60 more 41 Plus d informations sur www dbmoteurs fr General information Thread Torque Description Diam xPitch Nm kpm Ibf ft Notes M Thread Sea water pump cam screw 10x1 25 15 7 21 6 1 6 2 2 11 6 15 9 Sea water pump casing 8 x 1 25 7 4 9 8 0 75 1 0 5 42 7 23 Sea water pump cover 8 x 1 25 7 4 9 8 0 75 1 0 5 42 7 23 Sea water pump drive gear nut 24 x 2 0 191 201 19 5 20 5 141 148 Injection pump 12 x 1 25 108 11 80 Injection pump bracket 12 x 1 25 108 11 80 Injection pump drive case 12 x 1 25 108 11 80 Injection pump gear nuts 30 x 1 5 392 40 289 Injection pump laminate plate 12 x 1 25 103 113 10 5 11 5 76 83 Injection pump flywheel nuts 24x 1 5 392 40 289 Injection pump coupling shaft 14x 1 5 167 177 17 18 123 130 Tighten the slit part Injection pump plunger assembly 12x 1 25 78 83 8 8 5 58 61 Injection pump delivery valve holder 30 x 1 5 235 255 24 26 174 188 Injection noz
116. ly standard 99 985 100 000 3 93642 3 93701 Bearing inside diameter mm in Nominal value 45 1 77 Assembly standard 44 988 45 000 1 77118 1 77165 Bearing inside diameter mm in Nominal value 50 1 97 Assembly standard 9 988 50 000 1 96803 1 96850 Drive shaft bearing diameter mm in Nominal value 45 1 77 Assembly standard 45 002 45 013 1 77173 1 77216 Drive shaft bearing diameter mm in Nominal value 50 1 97 Assembly standard 50 002 50 013 1 96858 1 96901 109 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 11 Timing gear backlash To measure the backlash between the gears set up a dial gauge so that it contacts the pitch circle of the gear to measure If a dial gauge is not available mea sure the backlash by inserting feeler gauges between the gear teeth If the backlash exceeds the service limit replace the worn gears Timing gear backlash mm in Standard clearance 0 12 0 18 0 0047 0 0071 Repair limit 0 30 0 0118 Service limit 0 50 0 0197 Idler gears bushings and shafts Measure idler gear bushing inside diameter and idler gear shaft diameter If the service limit is exceeded replace the bushing or shaft whichever is worn Idler gear bushing inside diameter mm in Nominal value 50 1 97 Assembly standard 50
117. make sure the pointer located on the pump case end surface aligns with the stamped line on the fly wheel If they are not aligned stamp a new line on the flywheel at the pointer position Point a flashlight from the top of the pump case and look through the deflector bolt hole and check the position of the upper end of the plung er Rotate the camshaft until the upper end of the plunger closes the barrel suction hole With the camshaft in this position the pointer should align with the stamped line on the flywheel If not change the shims so the pointer aligns with the line NOTE Increase of shim thickness retards injec tion timing and decrease of shim thickness ad vances injection timing A IMPORTANT Never use more than one shim on each side Use shims of the same thickness on both sides of the cylinder 159 Plus d informations sur www dbmoteurs fr Group 23 Fuel System 16 Adjustment of injection intervals 1 For cylinder No 2 and subsequent cylinders use the injection start timing of cylinder No 1 as the reference point and check the injection start inter vals on the angle scale on the pump tester ac cording to the injection sequence 2 Ifthe injection intervals deviate from the specifi cation make adjustment by adjusting the thick ness of the barrel shims in the same way for pre stroke adjustment NOTE Injection start intervals 45 0 5 Adjustment of Injection Volume 1 Install a f
118. mally worn Measuring valve pushrod deflection If the deflection exceeds the assembly standard re place the push rods Push rod deflection mm in Assembly standard Less than 0 5 0 020 max Cylinder Head Measuring head gasket flatness of surface Use a straight edge and feeler gauges to measure warping on each cylinder head If warping exceeds the repair limit reface the gasket surface with a sur face grinder Flatness mm in Assembly standard lt 0 03 0 0012 Repair limit 0 07 0 0028 Service limit 0 50 0 0197 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Reassembly Reassembly sequence Reverse the order of disassembly Installing tappets Insert tappets coated with engine oil into the tappet holes and make them seat softly on the camshaft Installing cylinder head gaskets 1 Clean the gasketed surfaces of the cylinder head and crankcase thoroughly with a solvent or de greasing solution 2 Apply a thin coat of Three Bond 1211 to areas 5 to 8 mm 0 197 to 0 315 in from the periphery of the head gasket around tappet holes and oil pas sage holes on both sides of the head gasket to areas indicated in the diagram on the right Spread the liquid gasket with a finger to a thick ness of 0 2 to 0 5 mm 0 008 to 0 020 in NOTE Liquid gasket should be applied to areas indi cated in the diagram on the right Do not apply an ex ce
119. mbly Standard 2 15 2 45 0 0846 0 0965 Repair limit 2 8 0 110 Valve margin thickness D mm in Assembly Standard 2 8 3 2 0 110 0 126 Repair limit refacing 2 5 0 098 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Refacing the valve face If the valve face is badly worn reface it with a valve refacer NOTE Set a valve refacer at an angle of 30 NOTE Grind the valve as little as possible If the margin seems to exceed the repair limit as a result of grinding replace the valve Refacing valve seats 1 Use the Valve seat cutter or a valve seat grinder to reface the valve seat After refacing grind the seat lightly using 400 grade sandpaper inserted between the cutter and valve seat 2 Lap the valve in the valve seat NOTE Cut or grind the valve seat only as needed for refacing NOTE Replace the valve seat if the seat width is more than the repair limit as a result of wear or cut ting NOTE Replace the valve seat if the valve sinkage exceeds the repair limit after refacing Replacing valve seats 1 Weld a stud 1 to the valve seat 2 Insert a shaft 3 into the valve guide holder from the up per side of the cylinder head Drive the seat off the head as shown NOTE When you weld the stud do not permit splat ter to come in contact with the machined surfaces of the cylinder head 79 Plus d informations sur www dbmoteurs fr Group 21 Engi
120. meter in the three direc tions Main bearing bore diameter mm in Nominal value 147 5 79 Assembly standard 147 000 147 025 5 78739 5 78837 Service Limit 147 035 5 78877 125 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 12 Reassembly Reassembly is done in the reverse order of disas sembly Main bearing 1 Install each upper shell of the main bearing in the crankcase by fitting its locating lug in the lug groove The oil holes in the bearings and crank case Will be aligned when the bearings are in stalled in this way 2 Lightly coat the inside surface of the shells with engine oil Installing thrust bearings 1 Install the thrust bearings to the No 9 bearing seat of the crankcase with the oil groove side of the bearings facing out 2 After installing the crankshaft install the inner thrust hearing with the oil groove facing inside the crankcase Crankshaft 1 Wash the crankshaft with cleaning solvent and dry it with compressed air NOTE After washing the crankshaft make sure that the oil holes are clean and not clogged 2 Hold the crankshaft horizontally with a hoist then carefully put it on the crankcase 3 Lightly coat the journals with engine oil 6 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Main bearings Main bearing caps 1 2 7 3 CLI 4 5 1 Fit the lower shell o
121. mit 10 060 0 39606 Replacing valve guides and stem seals 1 Use the Valve guide remover to remove the valve guide for replacement 2 Use the Valve guide seal installer to install slowly a new guide with a press Z N IMPORTANT The installation depth for the valve guide is specified so use the Valve guide seal installer to secure the correct depth A IMPORTANT Do not apply any oil or sealant to the surface of the stem seal that comes in con tact with the valve guide When installing the stem seal apply lub oil to valve stem to ensure initial lubrication of the stem seal lip A IMPORTANT Use a new stem seal whenever removed 77 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 78 Valves and Valve Seats Inspecting the valve Coat the valve face lightly with red lead Use the Valve lapper to inspect the valve contact with its seat If the contact is not uniform or if the valve is defec tive or if the repair limit is exceeded repair or replace the valve and valve seat NOTE Inspect the valve face after the inspection or replacement of the valve guide NOTE When you press the valve coated with red lead into the valve seat do not rotate the valve A Good contact B Bad contact Valve seat mm in Angle A Assembly Standard 30 Valve sinkage depth B Assembly Standard 0 2 0 2 0 008 0 008 Repair limit 1 0 0 039 Width C Asse
122. n jig Insert the jig stopper in the pinion tooth sec tion missing tooth section This stopper posi tions the missing tooth section for prevention of incorrect engagement with rack of the pinion to the center of the inspection hole in the upper spring seat 153 Plus d informations sur www dbmoteurs fr Group 23 Fuel System 4 Align the flange section of the plunger properly with the plunger seating section of the pinion us ing a screwdriver 5 Press down the knob of the jig to insert the plung er into the plunger seating section of the pinion then screw the plunger holder to the threaded section of the plunger head Installing the control rack 1 Insert the control rack in the pump case making sure the F mark on the end surface or the threaded section is positioned on the driven side then tighten the set screw to 21 Nom 2 1 kgf m 15 Ibf ft 2 Look through the cylinder from the upper side of the pump case and move the control rack so the thick tooth three times thicker than other teeth for prevention of incorrect engagement with pin ion is positioned at the center of the cylinder in the pump case 15 4 Plus d informations sur www dbmoteurs fr L Group 23 Fuel System Installing plunger assemblies 1 Position the cam at the bottom dead center in the cylinder to which the plunger assembly is in stalled Place the Stopper plate 1 on top of the pump case to prevent
123. ncreased noise from engine parts Abnormal color of exhaust gas after warm up Anyone or a combination of these symptoms may indicate that engine overhaul is required Item D requires spe cial consideration because decreased pressure due to wear of the cylinder liner and the piston rings is one of the most obvious signs that the engine requires overhauling Test the compression pressure Some items listed above are not directly related to the need of an engine overhaul B and G are more likely to be affected substan tially by e Injection volume of the fuel injection pump e Fuel injection timing e Wear of injection pump plunger e Fitting of the injection nozzle e Condition of equipment battery starter or alternator Testing the compression pressure Measure the compression pressure at regular inter vals to obtain correct data If the compression pres sure is lower than the repair limit overhaul the en gine 1 Remove the injector from the cylinder to be mea sured Attach the compression gauge adapter A to the adapter and connect compression gauge B 2 Crank the engine Read the compression pres sure with the engine running at specified speed Compression pressure Mpa Bar psi Assembly Standard 2 85 28 5 263 min Repair Limit 2 30 23 0 185 max A IMPORTANT Measure the compression pres sure on all cylinders NOTE Compression pressure varies with engine speed Measure
124. ne Body 80 2 Before inserting a new valve seat measure the inside diameter of the cylinder head bore and the outside diameter of the valve seat to make sure that clearance fit is within clearance standards Valve seat dimensions mm in Cylinder head bore diameter A Nominal value 60 000 60 030 2 36220 2 36338 Valve seat diameter A Nominal value 60 100 60 130 2 36614 2 36732 Cylinder head bore Valve seat clearance standard clearance 0 070 0 130 0 00276 0 00512 B Nominal value 3 6 0 142 C Nominal value 8 0 0 315 D Nominal value 11 6 11 7 0 4567 0 4606 A minus indicates interference 3 Chill the valve seat in liquid nitrogen 70 C 274 F for more than 4 minutes with the cylinder head kept at normal temperature or heat the cyl inder head to 80 to 100 C 176 to 212 F with the valve seat chilled in ether or alcohol contain ing dry ice 4 Use the Installer to install the valve seat Plus d informations sur www dbmoteurs fr Group 21 Engine Body Lapping valves in valve seats Be sure to lap the valves in the valve seats after the seats has been replaced 1 Coat the valve face lightly with a lapping com pound 2 Lap the valve in the seat using the valve lapper Raise the valve off the seat then rotate the valve only a partial turn and strike it against the seat 3 Wash off the compound
125. ness 97 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 98 Serration on connecting rod big end Inspect the serration on connecting rod big end by conducting a Magnaflux magnetic particle test If cracking or damage is found replace the connecting rod Connecting rod bearing thickness Use a ball point micrometer to measure the center of each bearing shell If the thickness exceeds the ser vice limit on the upper or lower shell replace both shells as a set Connecting rod bearing thickness STD mm in Nominal value 3 000 0 11811 Assembly standard 2 9 72 2 985 0 11701 0 11752 Service limit 2 930 0 11535 Bearing thickness 0 25 0 0098 mm in Nominal value 3 125 0 12303 Assembly standard 3 097 3 110 0 12193 0 12244 Service limit 3 055 0 12028 Bearing thickness 0 50 0 0197 mm in Nominal value 3 250 0 12795 Assembly standard 3 222 3 235 0 12685 0 12736 Service limit 3 180 0 12520 Bearing thickness 0 75 0 0295 mm in Nominal value 3 375 0 13287 Assembly standard 3 347 3 360 0 13177 0 13228 Service limit 3 305 0 13012 Bearing thickness 1 00 0 0394 mm in Nominal value 3 500 0 13780 Assembly standard 3 472 3 485 0 13669 0 13720 Service limit 3 430 0 13504 Plus d in
126. njection pump and mount the pump on the pump assembly stand 4 Remove the couplings laminated plates cross coupling flywheel and feed pump NOTE When removing the flywheel mounting nut in sert turning bar into the turning bar hole located at the flywheel periphery in order for the flywheel to avoid slipping Removing delivery valves Remove delivery valve holders Remove the spring seat delivery valve spring delivery valve and valve seat from each valve holder NOTE Place each pair of delivery valve and valve seat in clean diesel fuel Do not swap the original combinations of delivery valves and valve seats 143 Plus d informations sur www dbmoteurs fr Group 23 Fuel System 14 Removing plunger assemblies 1 Position the tam at the bottom dead center in the cylinder from which the plunger assembly is re moved 2 Remove the deflector bolt located on the back side of the pump case A IMPORTANT Be sure to remove the deflector before removing the plunger assembly If the plunger assembly is removed without removing the deflector bolt first damage results in the de flector bolt and plunger assembly 3 Screw the Plunger holder 48291 00301 in the threaded hole on the upper end of the plunger 4 Loosen two barrel bolts altemately and lift the plunger assembly and remove Removing the control rack 1 Dislodge the bellows from the grooves of the con trol rack and rack bushing
127. nstallation of the fuel injection pump is described below After installing the fuel injection pump be sure to in spect and adjust the injection timing Refer to Section 1 3 of Chapter 5 Adjustments and Bench Testing Fuel Injection Pump Installations 1 Turn the crankshaft in normal direction to align the timing mark 1 6 on the viscous damper with the pointer NOTE Verify the injection timing by referring to the caution plate attached to the No 1 rocker cover 2 Move the No 1 cylinder inlet and exhaust valve rocker arms to make sure that they are not being pushed up by the push rods 3 Turn the crankshaft about 60 in reverse Turn it a little at a time in the normal direction to align the timing mark on the damper with the pointer 4 Install the coupling to the injection pump then align the pointer 1 on the pump case with mark 2 on the coupling 69 Plus d informations sur www dbmoteurs fr Auxiliaries removal and installation 5 Connect the pump drive coupling 3 to the drive shaft Loosen the coupling mounting bolts 6 Putthe pump case on the pump bracket then tighten the mounting bolts 4 temporarily 7 Connect the fuel pipe and the oil pipe to the injec tion pump 8 Tighten the two coupling bolts 5 temporarily 9 Insert the side of the Injection coupling gauge A marked with GO to determine clearance B be tween the flywheel and coupling then tighten the bolt
128. nt of deflection repair the crankshaft by grinding or straightening with a press If the deflection exceeds the repair limit re place the crankshaft Crankshaft deflection mm in Assembly standard 0 04 0 0016 max Repair limit 0 10 0 0039 Replace the oil seal slinger Replace the slinger if it is pitted scratched or distort ed enough to cause oil leaks Remove the Slinger Use a gear puller to remove the slinger from the crankshaft Install the Slinger 1 Identify the front slinger and the rear slinger and pay attention to their attitudes A Front B Rear 1 Front cover 2 Timing gear case 3 Oil seal 4 Slinger 2 Use a slinger installer to install the heated above 110 C 230 F slinger to the crankshaft until it contacts the gear AN IMPORTANT If the slinger has stopped before it touches the gear tap the center or shoulder of the installer with a copper hammer 2 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Replace the crankshaft gear Remove the Gear Use a gear puller to remove the gear from the crank shaft NOTE Do not remove the gear by hitting it with a hammer Install the Gear 1 Before installing the crankshaft gear measure the inside diameter of the crankshaft gear to be sure that the fit is within the specified value Front side 0 106 0 171 mm 0 00417 0 00673 in Rear side een 0 274 0 358 mm 0 01079 0 01
129. o the outer sur face of the element clean with a wire brush Check the element for corrosion and tears 2 Insert a stick into the pipe and remove deposits 199 Plus d informations sur www dbmoteurs fr Group 26 Cooling System Raw Water Pump standard rubber impeller Disassembly Cover O ring Impeller Casing gasket plate gasket Bushing unit seal Slinger Nut spring washer Gear oN Oo OF oN os Snap ring Shaft key Bearing o Oil seal 12 Holder 13 Cam _ k 200 Plus d informations sur www dbmoteurs fr Group 26 Cooling System Inspection Inspect mounted pump Touch the drain port located at the bottom of the pump with your finger If the port is leaking water check the condition of the unit seal If it is leaking oil the oil seal is defective Bearing dimensions Measure the dimensions of the bearing installation sections of the sea water pump holder and shaft If excessive wear or damage is observed replace the bearing holder and shaft Inside diameter at bearing position mm in Nominal value 90 3 54 Assembly standard 89 975 90 011 3 54232 3 54369 Service limit 90 013 3 54381 Bearing outside diameter mm in Nominal value 90 3 54 Assembly standard 90 000 90 015 3 54330 3 54389 Bearing inside diameter mm in Nominal value 30 1 57 Assembly standard 29 990 3
130. older Spring seat oO Delivery valve spring _ Delivery valve assembly mh N Deflector bolt _h ao Barrel bolt washer A Plunger assembly Oo Barrel shim O Bellows mk N Set screw _h Control rack 14 26 27 28 29 30 31 32 33 34 35 Tappet Front cover O ring bearing outer race Bolt Camshaft Center bearing Bearing inner race Rear cover oil seal bearing outer race Shim Lower spring seat Plunger Plunger spring Upper spring seat Pinion O ring Barrel Pump case Rack bushing Look for A O moo w i On 257 gt Damage of threads Fatigue Seat contacting surface Contact surface Wear and cracks on teeth worn sliding surfaces Ridges caused by abrasion cracks Wear scratches Erosion Damage and scratches on bushing contact surfaces cracks Wear scratches discoloration corrosion erosion Wear Rack sliding resistance wear of teeth Cracking Damage and scratches on key grooves and seal contact surfaces wear of cam surface Rotation condition Pitching roller surface roughness 2 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Preparing for disassembly 1 Hold the pump assembly stand with a vice 2 Remove the drain plug from the bottom of the pump and drain oil from the case 3 Clean the outer surface of the i
131. ompressed air to dry and remove dust Replace packings and O rings Mount the oil filter element on the bracket before installation 135 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Group 23 Fuel System Fuel Filters Disassembly Look for Filter element A Cracks damaged threads Bolt Cover O ring Pin Cock Fuel filter bracket Packing OM NAAR YD a Air vent plug 136 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Reassembly Reassembly sequence D 0 0 0 0 0 0 0 To install the filter clean the mounting surface and apply fuel oil to the gasket After bringing the gasket into con tact with the sealing surface of the bracket tighten the filter with your hand about one half to three quarters of a full tum Bleed the filter NOTE After installing the fuel filter on the engine start the engine and look for leaks 137 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Fuel Injectors 4 3 D s Disassembly Look for 1 Cap nut gasket A Fatigue damage length 2 Adjusting screw B Wear damage 3 O ring C Carbon deposits clogged spray 4 Retaining nut hole sticking needle valve 5 Nozzle 6 Spacer 7 Pushrod nozzle spring spring seat 8 O ring 9 Nozzle holder 10 Fuel inlet connector 13 8 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Inspection and Adjustment Injection pressure
132. on of tur bine side flange Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Disassembly Preparing for disassembly Mount the turbine housing In a vice by clamping at the flange AN IMPORTANT Clamp the flange securely to pre vent the turbine housing from loosening or mov ing during work Removing the compressor cover A IMPORTANT The compressor cover bearing housing and turbine housing must be reassem bled in correct orientation Therefore put align ment marks with a punch or marker 1 Loosen the V clamp using a socket wrench 2 Lightly tap around the compressor cover with a soft faced hammer to remove the cover Removing the diffuser 1 Lightly tap around the diffuser with a soft faced hammer to remove the diffuser 2 Remove O ring from the bearing housing 181 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Removing the compressor wheel A IMPORTANT Handle the compressor wheel and turbine wheel with care during disassembly and assembly Vanes can easily bend when dropped or hit 1 While holding the boss of the shaft amp turbine wheel remove the lock nut fastening the com pressor wheel 2 While holding the turbine wheel with one hand turn the compressor wheel lightly with the other hand and remove Removing the snap ring NOTE Use only snap ring pliers to remove snap rings NOTE Put your thumb on the snap ring to prev
133. on pump coupling shaft 14x 1 5 167 177 17 18 123 130 Tighten the slit part Injection pump plunger assembly 12x 1 25 78 83 8 8 5 58 61 Injection pump delivery valve holder 30 x 1 5 235 255 24 26 174 188 Injection nozzle gland nut 14x 1 5 98 10 72 Injection nozzle chip nut 28 x 1 5 177 196 18 20 130 145 Nozzle holder cap nuts 14x 1 5 69 78 7 8 51 58 Injection nozzle set screw 10x 1 5 34 44 3 5 4 5 25 33 Injection nozzle inlet connector 16 x 1 5 64 74 6 5 7 5 47 54 Injection pipes 18x1 5 49 69 5 7 36 51 Fuel filter air vent plug 7 8 9 8 0 8 1 0 5 8 7 2 Fuel rack control lever 8 x 1 25 25 2 5 18 b Governor drivecase 12x 1 25 108 11 80 Starter 12 x 1 25 59 6 43 Turbocharger compressor wheel nut 11 x 1 0 FD138 f g h Turbocharger V clamp 7 8 9 8 0 8 1 0 5 8 7 2 FD13 g Turbocharger compressor wheel nut 1 2 x 20 FD15 UNF f i Turbocharger turbine housing 10x1 5 25 28 2 6 2 9 19 21 FD15 g Turbocharger V clamp 9 8 10 8 1 0 1 1 7 2 8 0 FD15 g a Wet apply lubrication oil to the threads of the nut and bolt b 2 step tightening method c Tighten cylinder head bolts according to the angle method tighten to 294 Nm 30 kpm 217 Ibf ft then tighten 60 more d Extremely important to use torque wrench in tightening the piston cooling nozzles Failure to do so may result in excessive tightening torque which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubr
134. or overhauling the engine Preparation 1 Shut off the fuel supply and disconnect the starting system from the engine 2 Loosen the drain cocks on the left rear side of crankcase and drain coolant 3 Loosen the oil pan drain plug and drain engine oil Oil capacity 160 42 3 U S gals Whole engine A WARNING Hot engine oil can cause personal injury if it contacts the skin Be careful when draining the oil 1 Engine Auxiliaries Removal Remove turbocharger Remove turbocharger oil supply pipe 1 and drain pipe 2 2 Remove exhaust duct 3 and turbocharger 4 fT Remove raw water pump J 1 Remove turbocharger oil supply pipe 1 and wo df oo ND mY TM 2 DOME TA 5 6 K CN Wi Y al a ZEYH Sy By 62 Plus d informations sur drain pipe 2 Remove raw water pipe 3 from raw water pump Remove pipe bracket 4 and remove raw water pipe 5 Unscrew raw water pump mounting bolts and dis mount the pump 6 www dbmoteurs fr Auxiliaries removal and installation Remove breather and oil filler 1 Remove hose clamps and rubber hose 1 2 Remove cam cover 2 with breather pipe at tached 3 Remove side cover 3 with breather pipe at tached 4 Remove oil filler 4 Remove heat exchanger 1 Remove coupling 1 and dismount water pipe 2 from the fresh water pump 2 Remove water pipe 3 from the heat exchanger 3 Remove sn
135. ove the Plunger holder Make sure the con 15 trol rack slides and strokes smoothly A IMPORTANT Move the rack after installing each plunger assembly to make sure it moves smoothly sliding resistance 4 9 N 0 5 kgf 1 10 IbfJ or less At the same time check to make sure the total rack stroke is 36 mm 1 42 in Control rack sliding resistance 1 After the pump assembly is completed attach a spring balancer to the control rack and make sure the control rack moves smoothly over the entire stroke Control rack sliding resistance N kgf Ibf Assembly Standard 4 9 0 5 1 10 or less After making sure the rack sliding resistance is lower than the standard value install the deflector bolts on the pump case to 41 N m 4 2 kgfem 30 Ibf ft Assembling delivery valves 1 In each barrel install delivery valve valve spring spring seat and valve holder in that order Apply grease to a new O ring to prevent 0 ring from damage then install the O ring on each valve holder Using a torque wrench tighten the valve holders to 235 to 255 N m 24 to 26 kgfam 174 to 188 lbfaft 6 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Installing the bellows Insert the protrusions on the bellows into the grooves on the control rack and rack bushing and install the bellows Installing the flywheel Install the flywheel making sure it aligns with the woodruff key of the camshaft then
136. p 12 x 1 25 108 11 80 Oil pump cover 10x1 25 26 3 39 7 2 7 4 1 18 32 Fresh water pump 12 x 1 25 59 6 43 Fresh water pump shaft pulley nuts 24 x 1 5 245 25 181 For alternator drive a Wet apply lubrication oil to the threads of the nut and bolt b 2 step tightening method c Tighten cylinder head bolts according to the angle method tighten to 294 Nm 30 kpm 217 Ibf ft then tighten 60 more d Extremely important to use torque wrench in tightening the piston cooling nozzles Failure to do so may result in excessive tightening torque which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubrication e Tighten connecting rod caps according to the angle method tighten to 245 Nm 25 kpm 181 Ibf ft then tighten 60 more 43 Plus d informations sur www dbmoteurs fr General information Thread Torque Description Diam xPitch Nm kpm Ibf ft Notes M Thread Sea water pump cam screw 10x1 25 15 7 21 6 1 6 2 2 11 6 15 9 Sea water pump casing 8 x 1 25 7 4 9 8 0 75 1 0 5 42 7 23 Sea water pump cover 8 x 1 25 7 4 9 8 0 75 1 0 5 42 7 23 Sea water pump drive gear nut 24 x 2 0 191 201 19 5 20 5 141 148 Injection pump 12 x 1 25 108 11 80 Injection pump bracket 12 x 1 25 108 11 80 Injection pump drive case 12 x 1 25 108 11 80 Injection pump gear nuts 30 x 1 5 392 40 289 Injection pump laminate plate 12 x 1 25 103 113 10 5 11 5 76 83 Injection pump flywheel nuts 24x 1 5 392 40 289 Injecti
137. p record of the water air temperatures using infrared temp gun to determine when the cooler needs cleaning 167 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Turbocharger TD13 Disassembly aAnNnoaroaonr a ok on 16 V clamp Turbine housing Lock plate Compressor cover O ring Lock nut Compressor wheel Snap ring Insert Piston ring Finger sleeve O ring Oil deflector 14 15 16 17 18 19 20 21 22 23 24 25 Thrust ring compressor Thrust bearing Thrust ring turbo Shaft and turbine wheel Piston ring Turbine backplate Bearing Snap ring Snap ring Bearing Snap ring Bearing housing Look for A B C Wear Thrust face wear Vane distortion damage rubbing contact on back face and gas erosion Rubbing contact with compressor wheel Rubbing contact with turbine wheel cracks and distortion Vane distortion damage rubbing contact on back face and gas erosion and damage to ring grooves Rubbing contact with turbine wheel and damage Damage to bearing bore gas erosion and distortion of turbine side flange 8 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Disassembly Remove the turbine housing Remove the V clamp and the turbine housing in that order from the turbocharger AN IMPORTANT The compressor cover bearing housing and turbine housing must be reassem
138. plate is flush with the bottom of the crankcase Cut off the excess of the packing neatly along the edge of the plate When the Pointer is out of place To determine the top dead center on the compression stroke of No 1 6 cylinder for example bring the mark on the flywheel to where it is at an equal distance from the marks stamped on the timing gear case Installing Pulleys and damper Tighten the pulley and damper mounting bolts to the specified torque 105 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 10 Flywheel Timing gears Camshaft and Oilpan Disassembly Oil pan Oil strainer oil pipe oil pump Flywheel Injection pump drive Governor drive Timing gear case oil seal Thrust plate Idler gear Idler shaft Camshaft gear OMNOAR WD i i O Thrust plate N Camshaft wo Rear plate h P Nozzle plate Look for Damage wear Clogged oil hole Loss of overlay wear Clogged oil hole Cracks Faulty bearing operation damaged seal Cracks Cracks damaged dowel pin hole Worn lip damage deterioration Loss of overlay wear Damaged gear wear FRe n M OD gt Stripped threads 6 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Remove the flywheel 1 Attach a sling to the flywheel 2 Unscrew the mounting bolts 3 Screw the two jack bolts into the holes in the fly w
139. r the designated Volvo Penta engines or engine versions Make sure that the correct workshop literature is used Read the following safety information and the General Information and Repair Instructions in the Workshop Man ual carefully before starting service work Important The following special warning symbols are used in the Workshop Manual and on the engine WARNING Warns of risk of bodily injury serious damage to product or property or that a serious malfunc tion can occur if the instructions are not followed A IMPORTANT Used to attract attention to things that can cause damage or malfunction to product or prop erty NOTE Used to attract attention to important information to simplify work procedures or handling The following list provides an overview of the risks and cautionary procedures that should always be observed A Prevent the engine from being started by dis A Make sure that the warning or information de connecting the power with the main switch cals on the product are always clearly visible switches and locking it them in the discon Replace labels that have been damaged or nected position Post warning signs stating painted over Work in progress in every position from wich the engine can be started ZA Never start the engine unless the air filter is fit ted The rotating compressor wheel in the turbo AN Maintenance and service should be performed can cause severe injury Foreign objects in the on
140. rature rises to 70 90 C 158 194 F 3 Measure oil pressure at idling speed and at maxi mum speed 4 Ifthe relief valve setting differs from the assembly standard remove the oil pipe and adjust the set ting by inserting shims between the adapter and the spring Relief valve setting at max rpm MPa Bar psi Assembly Standard 0 49 0 64 4 9 6 4 71 1 92 4 Relief valve opening pressure MPa Bar psi Assembly Standard 0 46 4 6 66 86 NOTE If the setting can not be adjusted with shims replace the relief valve and spring Reassembly Reassembly is done in the reverse order of disas sembly NOTE Replace O rings at reassembly 13 2 Plus d informations sur www dbmoteurs fr Group 22 Lubrication System Oil Cooler and Thermostat Look for A Clogging rupture cracks B Replace O ring C Replace packing 133 Plus d informations sur www dbmoteurs fr Group 22 Lubrication System 13 Inspection Inspect oil cooler Test the oil path with compressed air of 1 47 MPa 1 47 Bar 213 psi for damage or cracks in the ele ment If there is any leakage replace the element Inspect oil thermostat 1 Inspect the oil thermostat seal for deterioration and cracks If any are found replace the seal 2 Refer to the drawing on the right that shows the correct direction for seal installation 3 Operation testing Immerse the thermostat in engine oil then measure the t
141. repair limit 29 Plus d informations sur www dbmoteurs fr Maintenance Standards Main bearing Thickness of center STD mm in Nominal Value 3 500 0 138 Assembly Standard 3 467 to 3 480 0 13650 to 0 13701 Service Limit 3 425 0 13484 NOTE Replace bearings if worn down to service limit Regrind crankpins and use undersize bearings if worn beyond service limit Thickness of center 0 25 0 0098 mm in Nominal Value 3 625 0 14272 Assembly Standard 3 592 to 3 605 0 14142 to 0 14193 Service Limit 3 550 0 13976 NOTE Replace bearings if worn down to service limit Regrind crankpins and use undersize bearings if worn beyond service limit Thickness of center 0 50 0 0197 mm in Nominal Value 3 750 0 14764 Assembly Standard 3 717 to 3 730 0 14634 to 0 14685 Service Limit 3 675 0 14468 NOTE Replace bearings if worn down to service limit Regrind crankpins and use undersize bearings if worn beyond service limit Thickness of center 0 75 0 0295 mm in Nominal Value 3 875 0 15256 Assembly Standard 3 842 to 3 855 0 15126 to 0 15177 Service Limit 3 800 0 14961 NOTE Replace bearings if worn down to service limit Regrind crankpins and use undersize bearings if worn beyond service limit Thickness of center 1 00 0 0394 mm in Nominal Value
142. rs when tightening the Line pushers using head bolts 3 Setup the dial gauge at the top face of the crank case then set the gauge pointer to zero 0 4 Measure the protrusion at four places at the flange of the liner Take the average of the four measurements 5 If the average is less than the assembly stan dard insert a shim under the collar of the cylinder liner Plus d informations sur www dbmoteurs fr Group 21 Engine Body When replacing cylinder liner 1 Remove the cylinder liner Refer to section Re place cylinder liners and observe the cylinder liner contacting surface to the crankcase 2 Ifthe cylinder liner contacts the crankcase only on one side use a rotary grinder to grind the surface to keep the differences of depth in four positions within 0 05 mm 0 0020 in 3 Use the Projection plate B and measure the counter bore depth of the crankcase in four po sitions and obtain the average 4 Subtract the Projection plate thickness from the measured counter bore depth to obtain the ac tual counter bore depth from the top surface of the crankcase Crankcase counter bore depth A mm in Assembly standard 14 00 14 05 0 5500 0 5520 5 Measure the thickness of the cylinder liner collar Thickness of cylinder liner collar mm in Assembly standard 14 16 14 20 0 5563 0 5579 7 Subtract the crankcase ridge depth from the cyl inder liner collar thickness This value is the cylin d
143. s MPa kgf cm psi Assembly Standard 1 37 0 10 1441 0 199 14 0 Safety valve spring set length set force mm N in kgf Ibf Assembly Standard 67 2 384 2 64 39 2 86 4 Measure crankshaft gear and oil pump driven gear backlash If backlash exceeds assembly standard adjust it with shims Crankshaft gear idler gear backlash mmlin Assembly Standard 0 11 0 38 0 0043 0 0150 0 Plus d informations sur www dbmoteurs fr Reassembly Reassembly sequence O O 0 o NOTE Coat the pump parts with engine oil before in stalling them Apply a thick coat of engine oil to the threads and seating faces of nuts and bolts except flange nuts before tightening tightening NOTE Degrease idler gear nut and spindle and apply Loctite 262 to their threads before tightening them to the specified torque NOTE Replace o rings when refitting oil pipe and strainer Group 22 Lubrication System 131 Plus d informations sur www dbmoteurs fr Group 22 Lubrication System Relief valve Disassembly Schematic 1 Adapter o ring 4 Relief valve A Pressure adjusting shim D Drain 2 Stopper 5 Sleeve B To turbocharger E Normal pressure 3 Spring 6 Plate C From main bearing F High pressure Inspection Test relief valve setting 1 Connect a pressure gauge to the oil pressure sensor send out port PT 1 8 on the oil cooler cover 2 Run the engine until oil tempe
144. s test the liner fitting for water tightness by applying water under pressure NOTE Check all liners to be sure its protrusion is within assembly standards Plus d informations sur www dbmoteurs fr Group 21 Engine Body Pistons Inspecting the piston outside surfaces Check the combustion surfaces and inside surfaces of the pin bosses Replace the piston if any defects are found Measuring piston diameter Measure the diameter of each piston perpendicular A to the piston pin and 30 mm 1 18 in below the center of the piston pin B If the service limit is ex ceeded replace the piston If any pistons have to be replaced select new pistons so that weight difference in an engine is within assembly standards Piston diameter mm in Normal value 170 S6 69 Assembly standard 169 76 169 80 6 6835 6 6850 Service limit 169 66 6 6795 Weight difference in an engine g oz Assembly standard 10g 0 35 max Information stamped on top of each piston A Part no B Engine front side mark C Piston weight Measuring piston pin diameter Using a micrometer measure the outside diameter of each piston pin If the measurement exceeds the ser vice limit replace the pin Piston pin outside diameter mm in Nominal value 70 2 76 Assembly standard 69 987 70 000 2 75539 2 75590 Service limit 69 970 2 75472 93
145. s to specified torque NOTE Only the side marked with GO should fit into the gap If not loosen the bolt and readjust the clear ance Flywheel and coupling clearance mmlin Standard clearance 49 0 25 1 93 0 010 10 Tighten the pump mounting bolt 4 firmly Be sure that the coupling mark B aligns with the A pump case pointer A Tighten the two connect ing nuts 5 to specified torque 11 Tighten the shaft tightening bolt 6 of the cou pling to specified torque NOTE Coupling damage or wrong injection timing can be caused by improper tightening of bolts 70 Plus d informations sur www dbmoteurs fr Auxiliaries removal and installation Adjust injection quantities of pumps 1 Check to make sure the output shaft of the gover nor is positioned on the side marked with 0 no injection side 2 Install governor lever 1 at an angle of 10 3 Install link 2 make sure that the installation length is 62 0 7 mm 2 4 0 028 in 4 Install the rod 3 while adjusting the length of it to achieve a distance of 67 5 68 5 mm 2 66 2 70 in between the rack end surface and pump case end surface NOTE Make sure that at least 8 mm 0 35 in of the thread of the rod and the ball joint are engaged at both ends 5 Make sure the rack stroke is approx 2mm 0 08 in when stop lever 4 is pulled fully towards STOP 71 Plus d informations sur www dbmoteurs fr Auxiliaries remova
146. sen the bolts C for the fuel injection pump coupling 3 Turn the coupling flywheel until the timing mark B on the coupling flywheel aligns with the pointer A on the fuel injection pump 4 Tighten the one nut for fuel injection pump cou pling Turn the engine to tighten the other side nut 5 Turn the engine two turns to recheck the injec tion timing for verification 58 Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting Speed setting ZN IMPORTANT When working with speed set tings stand by to stop the engine manually to avoid engine overspeed A IMPORTANT Set screw no 4 adjusts maximum fuel to engine and is factory set and should not be touched NOTE The idling speed and maximum speed are set at factory bench testing and the set bolts are sealed These settings are to be inspected and adjusted at Volvo Penta Workshops only NOTE After adjusting the governor be sure to seal the stopper Whether the seals are intact or not has bearing on the validity of claims under the warranty NOTE Prior to inspection and adjustment run the engine until coolant and oil temperature is 70 C 158 F or higher PSG Governor Check and adjust idling speed setting 1 Make sure the speed control lever is in idling po sition measure engine rpm 2 If idling speed is out of the specified range reset with the adjust screw 1 Check and adjust no load max speed setting 1 Move spee
147. service limit Commutator deflection mm in Assembly Standard 0 06 0 0024 maximum Service Limit 0 10 0 0039 2 Measure the mica depth Use a depth gauge to measure the depth of each mica undercut If the depth exceeds the repair limit re condition the mica Commutator mica depth mm in Assembly Standard 0 7 to 0 9 0 028 0 035 Repair Limit 0 2 0 0079 Testing the armature 1 Use a growler to test the armature for short cir cuits If the hacksaw blade vibrates against the core replace the armature 2 If there is continuity between the commutator and shaft replace the armature 0 Plus d informations sur www dbmoteurs fr Group 30 Electrical System Field coil Testing for open circuits 1 If there is no continuity between the M terminal of the field coil and the lead wire on the brush side replace the field coil Overrunning Clutch The clutch is in good condition if it rotates freely in one direction when tumed by hand Check the pinion teeth for wear or damage If they are damaged replace the pinion LA IMPORTANT Do not immerse the overrunning clutch in cleaning solvent to clean it Immersion in cleaning solvent Will cause grease inside the clutch to run out causing clutch parts to seize when operating Brushes Inspecting for wear Brush height mm in Assembly Standard 21 22 0 83 0 87 A Service Limit 13 0 51 B T
148. set screw and loosen the adjusting screw until it can be loosened by hand 2 Loosen the retaining nut remove the nozzle and wash the needle valve and body AN IMPORTANT When pulling out the nozzle do not damage the tip 3 Wash the nozzle in clean diesel fuel oil After washing assemble the needle valve and body in clean diesel fuel NOTE The needle valve and body are finely finished Do not change the pairing of needle valve and body when cleaning more than one nozzle atthe time 4 Tighten the retaining nut to the specified torque 5 Ifthe spray pattem is still bad after the nozzle has been adjusted and cleaned replace the nozzle NOTE New nozzle tips are coated with vaseline to preserve them Wash them in diesel fuel before you install them NOTE Avoid getting Copa slip or Molycote on the needle 0 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Reassembly Reassembly Sequence O 0 O A IMPORTANT Tighten the retaining nut to the specified torque Excessive torque on the retaining nut will cause sticky movement of the needle and will result in exhaust smoke or the needle stick NOTE Always replace all o rings at reassembly 141 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Fuel Injection Pump Disassembly Drain plug Coupling Laminated plate Cross coupling Laminated plate Flywheel Feed pump Oo Nour wn Valve h
149. shing the outer end of the bar to further raise the piston assembly A IMPORTANT Raise the piston assembly care fully so that the connecting rod don t interfere with the oil jet nozzle for piston cooling 5 When the oil ring of the piston comes out of the cylinder liner lower the piston a little and carefully rest the oil ring on the edge of the liner NOTE To avoid damage to the oil ring lower the pis ton slowly and carefully Do not rotate the piston 6 Holding the compression ring portion of the piston and carefully pull the piston from the cylinder lin er Rest its skirt on the top of the crankcase 7 Hold the piston pin portion of the piston and lift the piston assembly off the liner Using the Piston remover 1 Turn the crankshaft to bring the piston assembly to 50 after top dead center 2 Attach the Piston remover to the top of the piston Grip the handle of the remover then lift the piston and the connecting rod off the liner LA IMPORTANT Do not damage the piston when you pull it out from the cylinder liner Do not let it hit the connecting rod with its skirt Support the connecting rod to avoid the cylinder liner bore from scratching LA IMPORTANT Do not use a crane to remove pis tons and connecting rods Forces applied by cranes are far to uncontrollable Removing the piston ring Use the Piston ring tool to remove the piston rings Removing piston pins 1 Use the Ring pliers to remove t
150. ssemble and locate the cause of the problem Clearance turbine wheel and housing mm in Standard Clearance 0 63 1 18 0 02480 0 04646 Installing the compressor wheel Install the compressor wheel Tighten the lock nut to the specified torque Lock nut tightening method 1 Tighten the lock nut to torque of 69 Nem 7 kgf m 51 Ibf ft then loosen it completely Apply Loctite No 962T to the threads Retighten to a snug torque of 9 8 Nem 1 kgfm 7 2 lbf ft then turn another 90 3 Shaft amp turbine wheel axial play Set a dial gauge on the end face of the shaft amp turbine wheel Measure the amount of play while moving the compressor wheel in the axial direction If the measured play deviates from the standard val ue disassemble and locate the cause of the problem Shaft amp turbine wheel axial play mm in Assembly Standard 0 075 0 135 0 00295 0 00531 0 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Turbine wheel and backplate clearance Remove the turbine housing from the bearing housing and install the compressor cover Measure the clear ance between the turbine backplate and the back side of the turbine wheel using feeler gauges NOTE Use two feeler gauges and measure at vane tips If the clearance deviates from the assembly standard disassemble and locate the cause of the problem Turbine wheel and turbine backplate clearance mm in Standard
151. ssembly Field coil Stator Rear bracket ONnea Pr amp w D Regulator assembly 10 Rectifier assembly 11 Terminal assembly 216 Plus d informations sur www dbmoteurs fr Group 30 Electrical System Inspection and repair Stator 1 Testing the stator coil for open circuits If there is no continuity among the three lead wires replace the stator 2 Testing the stator coil for grounding If there is continuity between the coil and core replace the stator Field coil Measure resistance between the terminals of the field coil If the measured resistance deviates from the standard value replace the coil Field coil resistance Q Assembly Standard 7 3 8 6 Inspecting rectifier To check individual diodes measure resistance be tween the diode lead wire and heat sink Connect the positive test lead wire to the diode and measure resistance Then connect the negative test lead wire to the diode and measure resistance again If both measured values are close to 0 zero the cir cuit is shorted NOTE If the diode has an open circuit or is shorted it is defective and the rectifier must be replaced Reassembly Reassembly sequence 070707009 0 0 9 0 A WARNING The alternator requires no grease Keep the bearing box free of oil and grease since oil and grease can cause creeping of the bearing on the rear side ZN WARNING Heat the bearing box of the rear bracket for assembly 217
152. ssive amount of liquid gasket since it can press the head gasket O rings and cause deformation NOTE Do not allow liquid gasket to adhere within an area of 10 mm 0 394 in around the cylinder bore A this may cause gas leakage Sections B and C are very close to O rings Make sure that there is no large amount of liquid gasket on the edge at these sec tions 2 Install the gasket before the liquid gasket dries Place the gaskets on the crankcase making sure that the dowel pins enter their holes in the gas kets 83 Plus d informations sur www dbmoteurs fr Group 21 Engine Body 84 Reassembly of the cylinder heads 1 Coat the valve Stems with engine oil then insert them into the valve guides 2 Install the valve springs and rotators to the valve guides Compress each valve spring with the Valve spring pusher then install the valve cotters on the valve Stem 3 Lightly tap on the top of each valve stem with a soft faced mallet to make sure that the valve spring and cotters are properly installed Install cylinder head assemblies IMPORTANT Before you install the cylinder head assembly measure the protrusion of each piston Make sure that the protrusion is correct 1 Install the exhaust connector to the cylinder head while pushing down the exhaust connector so it touches the edge of the bolt hole NOTE Place the gasket so its MANIFOLD printed side aligns with the connector side
153. t Spindle Bushing Idler gear Bushing Pump case 128 Plus d informations sur Look for Replace o ring Cracks damage Wear Wear chipped gear teeth Weak worn or broken spring Cracks clogged strainer Ommooow gt Cracks www dbmoteurs fr Group 22 Lubrication System Inspection Measure gear backlash If the backlash exceeds the service limit replace the gears Drive gear and driven gear backlash mm in Standard Clearance 0 087 0 316 0 034 0 0124 Service Limit 0 3 0 012 Measure gear radial clearance Use feeler gauges to measure the clearance If the clearance exceeds the service limit replace the gears or case whichever is badly worn Drive gear and driven gear clearance mm in Nominal Value 60 2 36 Standard Clearance 0 100 0 196 0 00394 0 00772 Service Limit Tip clearance 0 35 0 0138 Measure pump gear end clearance Use a dial gauge to measure the clearance If the clearance exceeds the service limit replace the gears or case whichever is badly worn Pump gear end clearance mm in Nominal Value 34 0 1 34 Standard Clearance 0 050 0 114 0 00197 0 00449 Service Limit 0 25 0 0098 Measure shaft and bushing diameters 1 Check the gear teeth Replace gears if they are defective 2 Measure the gear shafts and bushings using a dial gauge If the diameter exceeds the service limi
154. t replace the parts Gear shaft diameter mm in Nominal Value 25 0 98 Assembly Standard 24 947 24 960 0 98216 0 98268 Service Limit 24 900 0 98031 Bushing inside diameter mm in Nominal Value 25 0 0 98 Assembly Standard 25 000 25 021 0 98425 0 98508 Service Limit 25 100 0 98819 129 Plus d informations sur www dbmoteurs fr Group 22 Lubrication System A 13 Replace oil pump bushings Remove A and install B oil pump bushings using the oil pump bushing tool 1 Remove the oil pump bushing as needed If it is tooo difficult to remove the bushings replace the bushings and related parts as an assembly 2 When you install the pump cover bushing place the bushing joint positions as shown in the right drawing A Pump cover B Pump case NOTE Do not align with the lubrication oil groove 3 Insert the bushing to the position shown in the drawing on the right A Pump cover depth 1 0 mm 0 04 in B Pump case depth 1 0 mm 0 04 in except at pos 1 5 mm 0 20 in C Idler gear depth 1 0 mm 0 04 in 4 After you press a new bushing into position finish its inside diameter to 25H7 2 mm 0 98H7 S jn 0 8 R Inspect the safety valve Check the valve spring of the oil pump safety valve for fatigue If excessive fatigue wear or break is found replace the valve spring Safety valve opening pres
155. t gear mounting bolts then re move the camshaft gear Remove camshafts Unscrew the thrust plate mounting bolts then pull out the camshaft from the crankcase Weight Approx 32 kg 71 Ib A IMPORTANT When pulling out the camshaft support it with a bar inserted through the cam shaft inspection hole of the crankcase to pre vent damage to the cam surfaces and bush ings 8 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Inspection and Repair Flywheel face and radial runouts Measure the runouts of the flywheel installed on the crankshaft If the runouts exceed the assembly stan dard check for loose bolts or obstacles lodged be tween the mounting faces of the flywheel and crank shaft Flywheel face runout mm in Assembly standard 0 285 0 0112 max Flywheel radial runout mm in Assembly standard 0 127 0 0050 max Injection pump drive and bearing 1 Measure inside and outside diameters of bearing fitted sections of injection pump drive 2 Check bearings drive shaft and oil seal Replace if not running smoothly or if otherwise defective 3 Check the fit of the drive shaft in the bearing and the fit of the bearing in the drive case Replace excessively worn parts Bearing outside diameter mm in Nominal value 90 3 54 Assembly standard 89 985 90 000 3 54272 Bearing outside diameter mm in Nominal value 100 3 94 Assemb
156. t to 49 Nm 5 kpm 36 Ibf ft firs then loosen it completely Retighten to 14 7 Nm 1 5 kpm 0 8 Ibf ft then tighten 80 3 more i Tighten the lock nut to 69 Nm 7 kpm 51 Ibf ft then loosen it completely Apply Loctite No 962T to the threads Retighten to 9 8 Nm 1 kpm 7 2 lbf ft then tighten 90 3 more 42 Plus d informations sur www dbmoteurs fr General information Tightening torques D30A Thread Torque Description Diam xPitch Nm kpm Ibf ft Notes M Thread Cylinder Head 22 x 2 5 539 55 398 a b c Cylinder head nozzle gland studs 14 x 2 0 69 78 7 8 51 58 Rocker case 12 x 1 25 108 11 80 Rocker shaft 14 x 2 0 147 15 108 Rocker arm lock nuts 12 x 1 25 64 6 5 47 Bridge lock nuts 10 x 1 25 55 5 6 40 Camshaft gear 12 x 1 25 127 13 94 Camshaft thrust plate 12x 1 25 59 6 43 Main bearing caps 22 x 2 5 490 50 362 a Hanger 12 x 1 25 108 11 80 Piston cooling nozzle 12x 1 75 34 3 5 25 d Timing gear case 16 x 1 5 216 22 159 Rear plate 12 x 1 25 108 11 80 Oil pan 12x 1 25 59 6 43 Front mounting bracket 12 x 1 25 108 11 80 Rear mounting bracket 16 x 1 5 216 22 159 Connecting rod bearing caps 22Xx1 5 539 55 398 a e Flywheel 22x 1 5 539 55 398 a Viscous damper 22x1 5 490 50 362 Rear idler shaft 12 x 1 25 108 11 80 Rear idler shaft thrust plate 10 x 1 25 29 3 22 Exhaust manifold V clamp nuts 8 x 1 25 19 6 2 14 5 Exhaust manifold mounting bolts 1 4 x 28 9 0 9 6 5 UNF Exhaust pipe V clamps 10 x 1 5 98 10 72 Oil pum
157. tall the positive side brush and negative side brush as shown O 5 Install the rear bracket to the yoke by aligning the matching marks Secure the brush holders with bolts then tighten the through bolts 6 Measure the end play of the armature If the end play exceeds the assembly standard adjust it on the rear side Armature end play mm in Assembly Standard 0 3 0 7 0 012 0 028 7 Liberally coat the internal gear with grease then J install the pinion shaft to the gear L AS 21 4 Plus d informations sur www dbmoteurs fr Group 30 Electrical System 8 Measure the end play of the pinion shaft If the end play exceeds the assembly standard adjust it on the internal gear side Pinion shaft end play mm in Assembly Standard 0 2 0 8 0 008 0 031 9 Install the magnetic switch Apply a voltage of 24 volts between the C and E terminals Connect the lead wire and energize the circuit between the M and E terminals within 1 setond After the pinion has shifted measure retraction length of the pin ion If the measurement is not within 2 5 to 5 5 mm CO 098 to 0 22 in use the magnetic switch adjusting screw to make adjustments 10 Secure the lead wire 11 Install the safety switch 215 Plus d informations sur www dbmoteurs fr Group 30 Electrical System Alternator Disassembly Nut washer Pulley assembly Set screw Front bracket assembly Rotor a
158. the other laminated plate Install the laminated plate to the coupling on the drive side using the wide coupling washers Tighten the flange nuts to 103 to 113 Nrn 10 5 to 11 5 kgf m 76 to 83 Ibf ft Install sets of long bushings and coupling wash ers to the laminated plate and install the laminat ed plate to the cross coupling with short bolts Tighten the short bolts to 103 to 113 N m 10 5 to 11 5 kgf m 76 to 83 Ibf ft NOTE Make sure the coupling on the drive side is positioned so that the key groove of the drive cou pling faces the black line on the flywheel as shown in the diagram 8 Plus d informations sur www dbmoteurs fr AD Group 23 Fuel System Adjustment of Injection Timing Adjustment of the prestroke After the pump assembly is completed place it on an injection pump tester and make the following adjust ments 1 Remove the deflector bolt from the back side of the pump case Remove the valve holder from cylinder No 1 counter drive side then remove the spring seat valve spring and delivery valve Set the measuring tip of a dial depth gaugeon the head of the plunger Rotate the camshaft by hand to bring the plunger to the bottom dead center by reading the indication on the depth gauge Set the depth gauge indicator to 0 Tum the camshaft in the normal operating direc tion until the dial depth gauge indicates 5 mm 0 2 in With the camshaft in this position check to
159. the compression pressure at 120 rpm NOTE The compression pressure will be slightly higher on new or overhauled engines Pressure will drop gradually by wear of parts 51 Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting Adjustment and Benchtesting Valve Clearance Check and adjust the valve clearance on a cold en gine The valve height is adjusted first and then the clearance of the rocker arm A IMPORTANT The engine must under no circum stances be running when checking and adjust ing the valve clearance since the valves can knock against the pistons and cause serious damage IMPORTANT Make sure that the stop lever is pulled out and the starter key switched off Top dead center on compression stroke 1 Turn the engine in the normal direction to align the timing mark 1 6 on the damper with the pointer as shown 2 Remove the cylinder cover and make sure the in let and exhaust valves have some clearance If the timing mark 1 6 is aligned with the pointer either the No 1 or No 6 piston is at top dead center on the compression stroke Adjust valve height A IMPORTANT Clearance between valve yoke and rotator should be min 1 5 mm 0 059 in If not interference will occur and cause the valve cones to get out of place If clearance is less than 1 5 mm 0 059 in after valve adjustment consult your dealer NOTE If the valve seats are worn one valve will dif fer from ano
160. the thrust plate mounting bolts to the specified torque 3 Check and make sure that the camshaft turns smoothly 113 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Installing camshaft gears 1 Install the camshaft gears to meet the dowel pin 2 Tighten the camshaft gear mounting bolts to the specified torque 3 After installing the camshaft gear make sure the gear rotates smoothly Installing the injection pump drive 1 Install the injection pump gear to the drive shaft then tighten it to the specified torque 2 Fit the O ring to the installation surface of the drive case and install the case to the rear plate 3 Tighten the drive case mounting bolts to the specified torque Installing idler gears Y NY O Y 0 R AT J 1 Install the idler gear by aligning its matching mark amp with that on the crankshaft gear and camshaft gear and install the thrust plate 2 Tighten the ithrust plate mounting bolts to the specified torque 3 Align the matching marks of the timing gears as the drawing show on the right 11 4 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Inspect and adjust timing gears After installing the timing gears be sure to inspect and adjust them as follows Inspect timing gear backlash and end play After installing the timing gears inspect the backlash between the gears in mesh and the end play of each gear Insp
161. the valve seat 3 If the valve sticks replace the delivery valve and valve seat as a set Tappets 1 Check each tappet roller roller bearing and tappet pin for flaking lotal wear and scratches 2 Check overall clearance of tappet taper roller roller bearing and tappet pin If the measurement exceeds the service limit replace with a new as sembly Overall clearance of tappet roller mm in Service Limit 0 2 0 00787 3 Inspect the plunger contact surface of each tap pet If the amount of wear exceeds the service limit replace with a new assembly Tappet wear of plunger contact area mm in Service Limit 0 2 0 00787 147 Plus d informations sur www dbmoteurs fr Group 23 Fuel System 14 Camshaft 1 Check the key and key groove for excessive play Also check the tapered section for scratch es and the tam surfaces for flaking local wear and scratches If damage is found replace the camshaft 2 Check the oil seal contacting surface for wear If the amount of wear exceeds the service limit re place with a new part Camshaft diam at oil seal contact area mm in Assembly Standard 34 938 34 963 1 37551 1 37649 Service Limit 34 800 1 37001 3 Support the camshaft with V blocks and mea sure runout at the center bearing section using a dial gauge If the amount of runout exceeds the repair limit correct with a press or replace with a n
162. ther in height increasing the clearance between the valve stem and yoke leading to an in creased valve clearance 1 Unscrew lock nut and adjusting screw on the valves so that there is clearance between the yoke and the valve stem 2 Press the valve yoke down Turn the adjusting screw until it touches the valve stem Turn an ad ditional 10 degrees Lock the adjusting screw with the lock nut 52 Plus d informations sur www dbmoteurs fr Adjustments and Benchtesting Valve clearance inspection 1 Check the valve clearance with feeler gauges in serted between the rocker arm and yoke cap Valve Clearance Inlet valve aaaaaaaa 0 6 mm 0 024 in Exhaust valve 0 8 mm 0 031 in 2 The clearance is correct if feeler gauge is slightly gripped between the rocker arm and the yoke cap If the feeler does not fit into the clearance exactly perform adjustments as described below Adjust valve clearance 1 Loosen the lock nut of the adjusting screw 2 Turn the adjusting screw in either direction until the feeler gauge is slightly gripped between the rocker arm and yoke cap 3 After adjusting the clearance tighten the lock nut of the adjusting screw while holding the adjusting screw in position Firing order Check and adjust the valve clearance in the firing order injection sequence turning the engine with each cylin der piston at top dead center on compression stroke Firing order 1 5
163. tighten its cap bolts to the specified torque Use feeler gaug es to measure the end play If the end play exceeds the service limit replace the connecting rod Connecting rod end play mm in Nominal value 67 2 34 Standard clearance 0 2 to 0 6 0 008 to 0 024 Service limit 1 0 0 039 Axial play over crankpin Weight difference of connecting rods in an engine When replacing connecting rods make sure that the weight difference of connecting rods in an engine is within the assembly standards below Weight difference of connecting rods g oz Assembly standard 30 1 06 NOTE Connecting rods are classified with capital let ters In one engine all connecting rods have to be of the same letter classification The classification of the connecting rods can be found on the engine plate latest models or on the connecting rods older mod els Big end bore diameter Measure the connecting rod big end bore diameter in directions 3 4 and 5 and at front and rear positions 1 and 2 as shown in the drawing To obtain the round ness value subtract the smallest measured value from the largest measured value If the diameter ex ceeds the servi Big end bore diameter mm in Nominal value 131 5 16 Assembly standard 131 000 131 025 5 15747 5 15845 Service limit 131 050 5 15944 Service limit 0 100 0 0039 Round
164. tighten the jam nut to 329 N m 40 kgf m 289 Ibf amp Installing the coupling assembly 1 Install sets of short bushings short bolts and cou pling washers in two diagonally located holes in the laminated plate LA WARNING If the coupling washer is installed in the wrong direction the laminated plate can break When the laminated plate breaks bolt damage occurs and can result in a serious acci dent NOTE Set the side of the coupling washer with a ra diused outer edge on the laminated plate 2 While making sure that the short bolts and cou pling washers installed on the laminated plate re main in place install the laminated plate to the cross coupling by screwing short bolts with long bushings and coupling washers in the remaining two holes in the laminated plate from the opposite side Tighten the short bolts to 103 to 113 N m 10 5 to 11 7 kgf m 76 to 83 Ibf ft NOTE Use a spanner type torque wrench to tighten the short bolts 157 Plus d informations sur www dbmoteurs fr Group 23 Fuel System 15 Tighten the two remaining short bolts on the lami nated plate mounted with the cross coupling to install the laminated plate securely to the fly wheel Tighten the bolts to 103 to 113 N m 10 5 to 11 5 kgf m 76 to 83 Ibf ft NOTE When tightening the short bolts be sure not to drop the coupling washers Install short bushings long bolts and coupling washers to two diagonally located holes in
165. tion mm in Service Limit 0 015 0 00059 Insert Measure piston ring end gap Install a new piston ring squarely in the insert then measure the piston ring end gap If the end gap devi ates from the assembly standard replace the insert Ring end gap mm in Assembly Standard 0 05 0 25 0 00197 0 00984 173 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Reassembly Reassembly sequence 6 oo _ 01 0 0 0 0 0 0 0 0 NOTE Always replace the following parts at disassembly 4 O ring 9 Piston ring 11 O ring 19 Piston ring A IMPORTANT If vanes are damaged or cracked do not reuse the part A IMPORTANT After reinstalling the overhauled turbocharger crank the engine to lubricate moving parts of the turbo 17 4 Plus d informations sur www dbmoteurs fr ooaoH t Group 25 Inlet and Exhaust System Install shaft amp turbine wheel and bearing 1 Install the bearing housing the snap rings and the bearing on the turbine side and the snap ring on the compressor side NOTE Use only snap ring pliers to install snap rings After installing the snap ring rotate it with a finger to make sure it rotates smoothly NOTE Apply engine oil to the outside and inside sur faces of the bearing before installation 2 Place the bearing housing on the compressor cover and install the turbine backplate 3 Insert the piston ring into the
166. tions Assembly standard Indicates the dimension of a part the dimension to be attained at the time of reassembly or the standard performance Norminal value Indicates the standard dimension of a part Repair limit A part which has reached this limit must be repaired Service limit A part which has reached this limit must be replaced Standard clearance Indicates the clearance to be obtained between mat ing parts at reassembly Plus d informations sur www dbmoteurs fr General information Disassembly and Reassembly This service manual covers recommended procedures to be followed when servicing diesel engines It also con tains information on special tools required and basic safety precautions It is the responsibility of service personnel to be familiar with these requirements precautions and potential haz ards and to discuss these points with their foreman or supervisor Study this manual carefully and observe the following general precautions to prevent serious personal injury and to avoid damage to the engine equipment and parts A WARNING Use the correct tools and instruments Serious injury or damage to the engine can result from using the wrong tools and instruments A WARNING When lifting or carrying heavy parts get someone to help you if the part is too awkward for one person to handle Use jacks and chain blocks when necessary A IMPORTANT Use an overhaul stand or work bench if necessary A IMPOR
167. top 185 F 3 Check for leakage of oil coolant fuel especially oil pipe connections for turbocharger lubrication 4 Knocking should die away as coolant tempera ture rises No other defective noise should be heard 5 Check exhaust color and for abnormal odors Adjustments and Benchtesting Bench test dynamometer conditions Summary table of bench testing conditions Step 1 Speed rpm sssaaa Idling Load No load Time min eee 5 Step 2 Speed rpm 1000 Load No load Time min eeee 5 Step 3 Speed rpm sssaaa 1200 Load No load Time min eee 10 Step 4 Speed rpm Rated LO AG sc iccssiscesscteceasezes 25 Time MiN eeeee 10 Step 5 Speed rpm Rated Load 50 Time min eeeee 10 Step 6 Speed rpm Rated Load ee 75 Time min eeee 30 Step 7 Speed rpm Rated Eoy To css 100 Time MiN eee 20 Rated speed Varies according to specifications After Bench Testing 1 Adjust valve clearance 2 Adjust injection timing 3 Re tighten external bolts and nuts 61 Plus d informations sur www dbmoteurs fr Auxiliaries removal and installation Engine auxiliaries removal and installation This section explains the procedures and tips for removal and installation of the accessories the preliminary process to go through f
168. tors manual concerning operation service and mainte nance must be followed IMPORTANT Neglected or deficient maintenance service and the use of non original spare parts will entail Volvo Penta renouncing any responsibility for the engine corresponding to the certified version Volvo Pen ta will not compensate for damage and or costs arising from the above 10 Plus d informations sur www dbmoteurs fr General information Repair instructions The working methods described in the Service Manual apply to work carried out in a workshop The engine has been removed from the boat and is installed in an engine fixture Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working method Warning symbols occurring in the Workshop Manual refer to section Safety information are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out For this reason we can only highlight the risks that can arise when work is carried out incorrectly in a well equipped workshop using working methods and tools developed by us All procedures for which there are Volvo Penta special tools in this Workshop Manual are carried out using these Special tools are developed to rationalize working methods and make procedures as safe as possible It is therefore the responsibility of any person using tools or working methods other t
169. trical system Voltage polarity i iscissteasncsehesctadzerscccsateasesseusteeveeceteceess 24V earth float Starter MANUPACtUie rei 2 5 coctscccnsidcealessadesssaspeadsenaseskeztecasipacaianes Nikko Electric Industry Pinion MOS ty Pe 245 5 Pinion shift Reduction type OUUPUL 255 nr sense sntnte men tient mini ide V KW 24 7 5 2 11 182 3 Phase alternating generator Internal IC regulator Mitsubishi Electric V A 24 35 Rated generated eceeccseeeseeseeeeeeaeeeeeeeseaeeteaeeeaees 27V 35A at 5000 rpm Regulated voltrage V 28 5 0 5 Drive belt VDO ssocssststissssasse den tesnacduiee T V belt outside circumference mm in 1250 49 General information 21 Plus d informations sur www dbmoteurs fr Maintenance Standards Maintenance Standards Table General Maximum rpm Nominal Value 5 10 higher than rated rpm Repair limit Lower or 20 higher than rated rpm NOTE Rated rpm stamped on the nameplate Check governor setting Minimum rpm Nominal value 600 to 650 rpm Compression pressure MPa Bar psi Nominal Value 2 85 28 5 263 minimum at 120 rpm Repair limit 2 30 23 0 185 or lower NOTE Oil and water temp 20 to 30 C 68 to 86 F Lube oil pressure MPa Bar psi Nominal Value 0 5 5 0 72 At idling speed
170. uel hose and the specified fuel pipe to the fuel injection pipe Adjustment conditions Nozzle holes 10 0 31 mm 0 012 in Nozz opening press 34 32 MPa 350 kgf cm 4979 psi Feed pressure MPa kgf cm psi 0 3 0 05 340 5 42 7 7 1 Fuel pipe dimensions out Oxin xL 7x2 8x817 mm 0 28x0 11x32 2 in Test fuel JIS Class 2 diesel fuel Test fuel temp 40 10 C 104 18 F 3 To adjust the injection volume loosen barrel bolts and slowly turn the barrel 4 After adjustment tighten the barrel bolts alter nately to 78 to 83 Nem 8 to 8 5 kgf m 58 to 61 lbf ft torque 0 Plus d informations sur www dbmoteurs fr Group 23 Fuel System Feed Pump Disassembly Priming pump Spring Valve Plug Spring Valve Plug Spring ONourwnr Piston Puch rod Snap ring a N Tappet 4 wo Adapter A Pump housing Plus d informations sur Look for A B C D E Scuffing rust on piston and cylinder Fatigue Dust particles Gauze filter Wash with diesel fuel Cracks damage of threads Wear of seat AN IMPORTANT Do not disassemble the gauge filter if it is clogged the filter may become twisted and damaged Remove as much dust as possible through the small holes then disassemble the gauge filter with a screwfriver 161 www dbmoteurs fr Group 23 Fuel System Reassembly Reassembly Sequence O
171. use the control rod to jam and the engine to over speed with the risk of personal injury or dam age to the machine Inferior fuel can also lead to higher maintenance costs Plus d informations sur www dbmoteurs fr Safety information Warning labels D25A D30A MS The engine carries Warning Labels at places where you are required to pay special attention Please read them carefully and make sure you understand the content of each label and the meaning of their position 1 Make sure the labels are legible If you find any letter or picture illegible in a label remove soil from the label or replace it 2 Clean the label with cloth and water or cleanser Do not use organic solvent or gasoline this would dissolve the label s adhesive and cause the label to fall off 3 If any label is damaged lost or illegible replace it When replacing a label make sure the new label is identical to the old one For new labels please contact your dealer 1 AU HN WARNING BE CAREFUL OF ROTATING BELT DO NOT PUT FINGERS NEAR ROTATING BELT WARNING il OIL MIST IS W Z FLAMMABLE AND EXPLOSIVE DO NOT OPEN INSPECTION COVER WITHIN 10 MINUTES AFTER ENGINE STOP 4693 51300 TURNING CAN CAUSE SEVERE NN PERSONAL INJURY BE SURE NO DANGER AROUND MOVING PARTS BEFORE TURNING e KEEP TURNING DEVICE OR BAR IN OFF POSI TION WHEN NOT IN USE A CAUTION PERFORM SAFETY MAINTENANCE i
172. w dbmoteurs fr Group 25 Inlet and Exhaust System Assembly of the insert sub assembly 1 Install the finger sleeve and the piston ring in the insert A IMPORTANT Do not expand the piston ring ex cessively or twist the ends when installing on the finger sleeve A IMPORTANT Apply Moly Disulfide to the piston ring installed on the finger sleeve then install on the insert carefully so as to avoid piston ring damage 2 After installing the above parts irrstall the sub as sembly in the bearing housing Install the snap ring Install the snap ring with the tapered side face up in the bearing housing NOTE Make sure you install the snap ring correctly NOTE Lightly drive both ends of the snap ring using a screwdriver and hammer to securely insert the ring into the groove on the bearing housing Make sure the screwdriver does not hit the bearing housing 177 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System 17 Turbine wheel and housing clearance Set a dial gauge on the end face of the shaft amp turbine wheel Read the dial gauge indication while moving the shaft amp turbine wheel in the axial direction If the dial gauge indication deviates from the assem bly standard disassemble and locate the cause of the problem Clearance turbine wheel and housing mm in Standard Clearance 0 29 0 91 0 01142 0 03583 Install the compressor wheel Install the compressor
173. wheel Apply Moly Disulfide to the threads of the lock nut then tighten to the speci fied torque Lock nut tightening method 1 Tighten the lock nut to torque of 49 Nem 5 kgf m 36 Ibf ft then loosen it completely 2 Retighten to a snug torque of 14 7 Nem 1 5 kgfm 10 8 lbf ft then turn another 80 3 Shaft amp turbine wheel axial play Set a dial gauge on the end face of the shaft amp turbine wheel Measure the amount of play while moving the compressor wheel in the axial direction If the measured play deviates from the standard val ue disassemble and locate the cause of the problem Shaft amp turbine wheel axial play mm in Assembly Standard 0 075 0 135 0 00295 0 00531 8 Plus d informations sur www dbmoteurs fr Group 25 Inlet and Exhaust System Turbine wheel and backplate clearance Remove the bearing housing from the turbine housing and install it in the compressor cover Measure the clearance between the turbine backplate and the back side of the turbine wheel using feeler gauges NOTE Use two feeler gauges and measure at vane tips If the clearance deviates from the assembly standard disassemble and locate the cause of the problem Turbine wheel and backplate clearance mm in Standard Clearance 0 55 1 15 0 02165 0 04528 Install the compressor cover 1 Apply grease to the o ring and install it 2 Mount the compressor cover on the bearing housing and be sure to follow
174. ws positioned on the exhaust manifold side Coat the bridge contact face of the bridge caps A with engine oil Install the caps in position be ing careful not to let them fall into the crankcase through the push rod holes Installing rocker shaft assemblies 1 Install the spacer A on the rocker shaft and mount the rockers on both sides Align the pin hole of the rocker shaft with the po sitioning pin and install the rocker shaft assem bly to the rocker case Move the rocker arm up and down to make sure that the arm is free NOTE While tightening the bracket mounting bolts temporarily install the bracket in place so the rocker tip comes in contact with the bridge caps evenly NOTE Tighten the long bolt securing the head and rocker bracket first then tighten the short bolt to the specified torque 85 Plus d informations sur www dbmoteurs fr Group 21 Engine Body Install fuel injector 1 Disconnect the fuel inlet connector from the injector assembly NOTE Always keep track of the inlet connector and injector assembly pairs so that inlet connectors are reassemblied to the same injector as before 2 Put three O rings on the injector and coat them with normal grease 3 Coat the copper gasket with anti seizing com pound and attach it to the injector Insert the in jector assembly into the cylinder head aligning its connector hole with the rocker case hole NOTE Always align the inlet connector wit
175. www dbmoteurs fr Group 26 Cooling System ____ 5 Using ajig and a hammer install the bearing to the shaft making sure the bearing remains square to the center line of the shaft 6 Install the shaft and the bearing assembly to the holder with a hammer 7 Install the snap ring to the holder 8 Install the slinger A to the holder Install the bushing B with unit seal to the holder Clean the sliding surface C on the seat side of the unit seal with ethyl alcohol then coat with turbine oil Install the seat side D onto the shaft and fasten with the snap ring E 20 A Plus d informations sur www dbmoteurs fr Group 26 Cooling System 9 Install the casing to the holder via the plate The contact surface must be coated with ThreeBond 1102 Tighten the bolts to 7 4 to 9 8 N m 0 75 to 1 0 kgf m 5 42 to 7 23 Ibf ft 10 Install the impeller to the shaft by striking with a hammer NOTE Make sure the impeller vane tips are pointed in the direction opposite to the rotational direction 11 Install the impeller cover 12 Install the O ring to the casing and mount the cover Tighten the bolts to the specified torque 13 Tighten the nut to secure the drive gear in place tightening torque 191 2 201 0 Nem 19 5 20 5 kgfem 141 0 148 3 Ibf ft 205 Plus d informations sur www dbmoteurs fr Group 30 Electrical System Group 30 Electrical System Starter Disassembly Look for 1
176. y liter U S gai 325 85 9 at engine speed 1650 rpm Relief valve TYPE isvicre irainei aeaieie Piston valve type Opening press MPa kgf cm pSi ceeeeeeeeeeeee 0 46 4 7 67 TDG SR E E TE E TE Water cooled multi plate type housed in the engine block TMD E E E E T Paper element changeover type spin on VD E E E eee Paper element type spin on LE iat Wax type Valve opening temp C F 80 to 84 176 to 183 2 Cooling system COOMNG TY D6 ERP Water cooled forced circulation Coolant capacity engine only liter U S gal D25A MS D25A MT D30A MS D30A MT A iieiaeie 50 13 2 115 30 4 55 14 5 120 31 7 TYPE iieis ar ee iaaea a aiaa Centrifugal Pump capacity liter U S gal Min sasse 800 211 Total head 0 20 MPa 20 mAq at 2925 rpm pump speed Pump drive belt type eceeeeeseeeseeeeeees V belt Outside circumference mm in 1535 60 Thermostat WY PO RP ee ee LEE EEE Wax Valve opening temp C F auessen 71 2 160 35 6 Valve fully opened C F 85 2 185 35 6 Raw water pump only on MT Typ iaeiiai oa iea airon Naia Rubber rotor Pump capacity liter U S gal Min eee 450 119 Total head 0 10 MPa 10 mAq at 1800 rpm pump speed 20 Plus d informations sur www dbmoteurs fr Inlet and exhaust system Turbocharger TYPO ste Lena hit nine lin TD13 or TD15 NO Of UNIS rss ssstrenise datesti sien tr sscestene den hentai 1 Elec
177. zle gland nut 14x 1 5 98 10 72 Injection nozzle chip nut 28 x 1 5 177 196 18 20 130 145 Nozzle holder cap nuts 14x 1 5 69 78 7 8 51 58 Injection nozzle set screw 10x 1 5 34 44 3 5 4 5 25 33 Injection nozzle inlet connector 16 x 1 5 64 74 6 5 7 5 47 54 Injection pipes 18x1 5 49 69 5 7 36 51 Fuel filter air vent plug 7 8 9 8 0 8 1 0 5 8 7 2 Fuel rack control lever 8 x 1 25 25 2 5 18 b Governor drivecase 12x 1 25 108 11 80 Starter 12 x 1 25 59 6 43 Turbocharger compressor wheel nut 11 x 1 0 FD13 f g h Turbocharger V clamp 7 8 9 8 0 8 1 0 5 8 7 2 FD13 g Turbocharger compressor wheel nut 1 2 x 20 FD15UNF f i Turbocharger turbine housing 10x1 5 25 28 2 6 2 9 19 21 FD15 g Turbocharger V clamp 9 8 10 8 1 0 1 1 7 2 8 0 FD15 g a Wet apply lubrication oil to the threads of the nut and bolt b 2 step tightening method c Tighten cylinder head bolts according to the angle method tighten to 294 Nm 30 kpm 217 Ibf ft then tighten 60 more d Extremely important to use torque wrench in tightening the piston cooling nozzles Failure to do so may result in excessive tightening torque which may cause valve malfunctions that could lead to seizing of pistons due to insufficient lubrication e Tighten connecting rod caps according to the angle method tighten to 245 Nm 25 kpm 181 Ibf ft then tighten 60 more f Left handed thread g Apply Moly Disulfide to thread h Tighten the lock nu

Reassembly - DB Moteurs

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