Volvo D1 30 Workshop Manual
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Workshop manualGroup 2126 30Group 2126 3036About this Workshop Manual6Spare parts6nes67Our common responsibility7Torque7Torqueangle tightening8Lock nuts8Strength classes88Safety rules for fluorocarbon rubber9Special tools10121616Crankshaft17Timing gear1818Lubrication oil system19Oil valves20Oil pump20Oil filter20Fuel system21222222Fuel filter23Feed pump23242525Sea water pump2525Electrical system2627Starter motor27box2728When working with chemicals fuel and lubricating oil29Before working in a boat29Before lifting the engine29Condition test engine30Compression test30Actions after lifting the engine303131Engine fixture fixing32Short block disassembly33Inspecting the engine block37Inspecting the cylinder head38Changing the valve seats38Grinding of valve and valve seats39Checking the valve guides40Renovating the rocker arm mechanism41Inspecting the crankshaft4242Inspection of main and big end bearings42Checking the big end bearing clearance43Piston ring inspection and fits4444Inspecting the con rod45Changing the gudgeon pin bushing45Assembling the piston piston rings and con rod46Camshafts and valve lifters inspection47Measuring the camshaft47Installing the crankshaft49Installing the piston in the cylinder and the oil pan50Installing the timing gear and injection pump51Flank clearance checking52head and other assembly53Table of contents 2006 AB VOLVO PENTA56Valves remo58Valves 5859Timing gear removing61Timing gear installation64Pistons removal67Big end bearing change68Pistons change6869Crankshaft remove70Main bearings change71Crankshaft assembly7374Crankcase seal rear change75Crankshaft seal front change76Valves adjustment77Drive belt change79Oil pump bearing changing80Injection pump changing81Injectors 83Injectors testing85Injectors check85Setting the engine speed86Feed pump changing87Hand pump changing88Fuel system venting8990Pressure valve in filler cap checking91Fault causes cooling system91Thermostat change92Heat exchanger cleaning93Heat exchangerexhaust manifold changing94Seawater pump impeller change95Sea water pump change96Coolant pump change97Alternator changing98Starter motor changing99100Technical data103116tents Check that you have the correct Workshopmanual before you start to do any service work Warns for the risk of personal injuryIs used to call attention to important informaBelow is a summary of the risks involved and safetysystem current with the main switchesit themcarried out with the engine stopped Somebe running however Approaching an engineIf work is done adjacent to a running engine acareless movement or a dropped tool can leadstarter heater etcbeen stopped Reinstall all protective parts rethe product are always clearly visible Replacecleaner filter The rotating compressor turbine instarting aid They may cause an explosion inthe cooling system if the filling cap or tap has tobe opened or if a plug or coolant hose has to beremoved when the engine is hot Steam or hotunder pressure before carrying out any workNever start or operate the engine with the oil filler cap removed otherwise oil could be ejectedWhen operated in a confined space exhaustfrom the engine bay or workshop areacarrying out work where there is a risk of splintremely sensitive injury could cause blindnessSafety informationgas when mixed with air This gas is easily ignitcause a single spark which is sufficient tonus negativeserious damage to the electrical equipment Reing plenty of water and soap If you get batteryTurn the engine off and turn off the power at themain switchescondition and that they have the correct capacialtered its center of gravity special lifting devices may be needed to obtain the correct balancesure to oil or exposure over a long period can reoccur Used oil is more dangerous than fresh oilfrom a health aspect Use protective gloves andwork is completedengine and transmission oils glycol petrol gasthe air Ensure good ventilation in the workthe fuel system and testing the fuel injector nozfrom a fuel injector has very high pressure andguishers at hand when work is being carried outta Refer to the Instruction Book Use of fuelsthat are of a lower quality can damage the encause the control rod to bind and the engine toNever work alone when removing heavy engineclear and not damaged during the lifting operaAbout this Workshop Manualnumber plate and engine decal The engine designaproduct data which was available up to the date onGeneral informationCertification means that an engine type has beenengine manufacturer guarantees that all engines madeOnly Volvo Penta original spares may be usedVolvo Penta has approved for the engineNo installation changes to the exhaust pipe andnot be compensated by Volvo Pentaal please refer to Safety information for their meanare not comprehensive in any way since we can notdone in highly varying circumstances For this reasonwhich there are Volvo Penta Special Tools availableing methods than we recommend to determine thatthe risks involved in the work A clean workplace andinjury and engine malfunctionAbove all when work on fuel systems lubricationcaps and seals is done it is extremely important thatand components The deviation of one componentthe specified wear tolerances are observed that systems which are adjustable are correctly adjusted andsystem require special expertise and special testingthe factory It is only permissible to work on sealedused damage the environment Volvo Penta recomspecified in the workshop manual When workingTorqueTorqueangle tighteningportant that the correct sealant and locking fluid typeVolvo Penta sealant cartridge 031 l part nopart no 8408791 tube 25 glock and seal plugs stud threads taps oil pressurenew sealant in accordance with the instructionsVolvo Penta thread locking fluid part no 11610532ber indicate stronger material For example a screwmarked 109 is stronger than one marked 88 For thisreason it is important when fasteners are dismantledshall be replaced by new ones since the locking prop the tightening torque specified in the table nut has the same nutduce the torque by 25 for screw size 8 mm or larger can beyour eyes can result in severe chemical burns If youbreathe in the fumes your lungs can be permanentlyAlways use chloroprene rubber gloves gloves forhighly corrosive Never use compressed air toof fluorocarbon rubber As the illustrations in the service literature refer toseveral engine variants certain details may differ from anyPressure foot for valve compressorMagnetic pen999 5192HSpanner for removing fueloil filtersMagnetic standGroup 21 Short blockThe D113 D120 D130 and D240 are four cyclevalves per cylinder a highmounted camshaft in theline four cylinder engine with a total swept volume ofThe D113 and D120 engines have identical pistonswith the same dimensions The D130 and D240 enGroup 21 Short blockDesign and functionDesign and functionGroup 21 Short blockD240 A with 130S sailboat driveGroup 21 Short blockDesign and functionSerial number 2S driveReversing gearSerial number 6Propeller designationXXXXXX 7XXX 5XXXXXXXXXX 6XX 8D130 D240D113 D120shown below The figures in brackets refer to the location of the identification number on the type plateDesign and functionGroup 21 Short blockThe engine block is cast in one piece from speciallyNone of the engines have cylinder liners The cylindermade from pressed sheet metal There is an oil drainThe cylinder head 1Rocker arm coverThe rocker arm cover 2islocated above the cylinder head The valve mechanism is installed underneath the cover PressurizedThe valve cover 3and is locattwo internal sections of which one leads inlet air downGroup 21 Short blockDesign and functionsion made and are ready to be installedDesign and functionGroup 21 Short blockThe timing gear consists of cylindrical gear wheelsengines lubrication pump is integral with the idlerinjection pump via a mechanism in the timing geartrolled with a valve and spring located in the valveGroup 22 Lubrication systemDesign and functionGroup 22 Lubrication systemlead through an external pipe to the valve mechanism1Oil filter2Oil pressure monitor3Pressure reduction valve4Inlet pipe with strainer5Main oil duct6Oil pump7Oil supply pipe outer8Crankcase ventilation valveDesign and functionGroup 22 Lubrication systemtem just upstream of the oil filter 2val from 304500 kPation from the oil The filter is a full flow filter whichFilter insert is a folded paper filterwhich opens and allows oil to flow past the filter if theWhen the filter has been in use for a predetermined1Circlip2Spring washer3Spring4Shim5Cap for oil pump6Inner rotor7Idler wheel with outer rotor8Thrust washerThe pump is a rotor pump with an inner rotor and anThe function of the pump is that the volume of theoccurs which forces the oil out through the outletGroup 23 Fuel systemA mechanical feed pump sucks the fuel up from theFuel which returns from the injectors is returned to thebe transported back to the fuel tank via a connection1Fuel tank2Pre filter3Feed pump4Fuel filter5Hand pump6Injection pump7Injectorsbers in the pistons where high speed air rotation conThe injection pump is a flangemounted inline pumpwhich is located on the engine block The pump isbustion chamber of the engineThe injector opening pressure is determined by the1Injector nut6Adjustment washers2Injectors73Joining piece84Compression screw9Nut5SpringThe regulator is mechanical and uses regulatorThe regulator weights operate the injector pump conspeed typeFuel filterThe fuel filter 1a hand pump 34Design and functionGroup 26 Cooling systemGroup 26 Cooling system1Sea water inlet2Sea water filter3Sea water pump4Seawater outlet5Coolant pump6Expansion tank7Heat exchangerexhaust manifold8Thermostat9Open thermostat circulation10Closed thermostat circulationThe engine is fresh water cooled and has a sealedbelt from the crankshaft pulleyamount of excess pressure which reduces the risk ofboiling if the temperature rises too high If the prescoolant round an internal circuit in the engine Whenis forced through by a gearwheel driven pump withThe sea water system cools the engines heat exexhaust gas via a connection in the exhaust bendGroup 26 Cooling systemDesign and functionThe engine is equipped with a thermostat whose senes through a bypass pipe back directly to the suctionsea waterGroup 30 Electrical systemcurrent of 115 A System voltage is 12 V and the1Glow plugs2Stop solenoid3Coolant temperature monitor4Coolant temperature sensor5Distribution box6Circuit breaker7Starter relay8Glowplug relay9Charge sensing resistor10Starter motor11Alternator12Oil pressure monitor13Engine speed sensortween the alternator terminals B and B with thenals The voltage regulator then compensates for anydone during engine installation howeverDistribution box Normally open The contacts close ifthe lube oil pressure in the engine falls below 05Coolant temperature monitor alarm Normally open The contacts close ifthe coolant temperature exceedsD113 D120105D130 D240110Resistance testing measured with the sensor imTemp 60C1340 135 90C512 43 C385 30 The sensor is located on the flywheel housing andwhich changes with the speed of the engineat the injection pumpGlow plugscF40T1UVGroup 21 Short blockA condition test should be done before each major1Turn the main switch off2Clean the outside of the engine Make sure that wash residue is collectedfor destruction and does not inadvertently end up3The work includes the following actions on thethe coolant from the sea water and fresh water Make sure that all sea water inletsare securely closed so that water can not findits way in during disassembly of cooling systemBoat removed from the water1Turn the battery isolator off undo the battery con2Remove the connector for the engine cables to3Remove the sea water connectionscool keeling4Remove the exhaust pipe5Close the fuel taps Remove the fuel connections6Remove the throttle and gear shift cables7Undo the propeller shaft from the reversing gearlift the engine out Use the lifting lugs 1Repair instructionsGroup 21 Short block1Clean the engine Remember the following whenside engine components When a power washerrubber hoses or electrical components2Drain the engine oil3Remove the reversing gear as necessaryA compression test is done which shows the sealingthe engine in a simple reliable mannerWarm the engine up then stop itRemove all the injectors and test each of the cylObserve the greatest possibleLow combustion pressure in all cylinders indicateshas lower compression pressure than the others theInstall a compression gauge 998 8539 in the adapterGroup 21 Short blockRepair instructionsFFresh water drain tap Remove the expansion tank filler cap andclose the hull fitting before draining the cooling sys Open the pressure cap very carefulThe sea water system is drained by undoing hoses atand exhaust pipeSuck the oil into a suitable vessel The oil can also beRepair instructionsGroup 21 Short blockGroup 21 Short blockRepair instructionsObserve the greatest possibletem Plug the unions in the fuel system with1Remove the induction silencer 12Undo the expansion tank 23Remove the electronic box 4ble harness Undo the engine speed sensor 5 Note the way that the cable harness is4Remove the alternator 65Remove the heat exchangerexhaust manifold 96Remove the oil pressure monitor 1213147Remove the fuel filter bracket 1517between the fuel filter feed pump and union inRepair instructionsGroup 21 Short block8Remove the fuel supply pipes 18fuel pump and injector use the nut underneath the9Remove the return fuel pipe 1910Unscrew the stop solenoid 21nuts on the pump Turn the stop lever clockwise Be careful when disassemblingits leveror injection pump has been changed11Remove the valve cover 26272324Group 21 Short blockRepair instructions12Remove the lower part of the valve cover 29undo the rocker arm bridge nuts 31time until the load on them has been relieved13Prepare a stand marked with cylinder numbers If be put back in their original17Undo the screws 32when they are tightened please refer to Techni18Remove the valve lifters out of the engine block be put back in The D120 and D240 engines have some19Remove the flywheel cover 3323Undo the center nut 35pulley 36820 Use the fly20Remove the flywheel 3722Remove the inner flywheel housing 38crankshaft sealRepair instructionsGroup 21 Short block23Remove the timing gear cover 39arm 40housing do not come out of position or spring out24Remove the idler wheel 41oil pump Also remove the thrust washer behind25Remove the locking plate 42 Be careful to avoid damaging the bearings26Remove the timing gear plate 4427Turn the engine over and remove the sump together with the external oilpipe Remove the oilstrainer 45and oil suction pipe 4628Scrape away the line of carbon at the top of the Check the markings on the big end bearing29Remove the locking screws 48Group 21 Short blockRepair instructionsis not warped in the same way as for the cylinderMeasure the cylinder bores at the upper and lowermiddle Measurement should be done with an internalFor maximum permissible cylinder diameters pleaseRepair instructionsGroup 21 Short blockIf warpage above the permissible level is found thefound or if the cylinder head has blow lines no speCheck the valve seats and check that the studs areFBE1Remove the old valve seat by heating it with aLet the cylinder heat cool for 3 5 min in the airThen carefully tap the seat out with a mandrelcheck that the cylinder head is not damagedThe valve seat can also be milled out check that2Carefully clean the valve seat bed in the cylinder3Cool the new valve seat with carbon dioxide snowetc to minus 60704Seat the seat into the cylinder head Use a hy5Machine the seats to the correct angle and widthGroup 21 Short blockRepair instructions1Check valve stem wear Measure the diameter2Grind the valves in a valve grinding machinemust be scrapped3Check valve guide wear please refer to Checking4Mill the valve guides When machined only re Do not grind so much that the valve depth exceeds the permissible value Please refer to ChangMill new seats down so far that the distance besurface C5Grind the valves in with grinding paste and checkRepair instructionsGroup 21 Short block1Put the cylinder head on the bench and putvalves in the valve guides2Measure the wear with a dial gauge andExhaust valve max clearance 025 mmNote Since the valve guides are machined directly in the cylinance is too great even when the valve is newGroup 21 Short blockRepair instructions1Remove the plug at the front of the rocker armmoved before the shaft is pulled out2Disassemble the rocker arm mechanism Remove3Clean the components Be specially careful with4Check the wear of the rocker arm shaft with a mi5Check whether the rocker arm bearing surfacesThe lock nut should be in good condition6Oil the rocker arm shaft and disassemble the othRepair instructionsGroup 21 Short block1Check wear and ovality with a micrometer Meaand big end bearings is 005 mm Change the2Measure lengthwise crookedness in the crankIf these values are exceeded the crankshaft3Check that the crankshaft seal mating surfaces1Measure the inner diameter of the bushing at2Measure the outer diameter of the bearing journalbetween the former measurement and the maxGroup 21 Short blockRepair instructionsSpecial tools 856927 measurement puttychecked by means of measurement putty part no1Wipe off any oil from the big end bearing and big2Install the con rod and bearing cap note theTightening torque please refer to the Technical3Remove the big end cap and measure the width ofRepair instructionsGroup 21 Short block1Remove the piston rings with piston ring pliers2Remove the gudgeon pin circlips and remove the3Check that the rings do not bind in the piston ring4Check the piston ring gap Slide the ring down using ais any noticeable wear or out of roundness infore disassemblyOil consumption is also of decisive importance forthe point in time when a piston ring change should5Check the clearance in the piston ring groovessure the clearance at several points with a feelergauge Please refer to the Technical Data specigrooves Change the piston if it has deep grooves inmore cracks in the gudgeon pin hole If any suchinder and pistonmum permissible value or if the piston diameter isGroup 21 Short blockRepair instructions1Check the con rods for cracking straightness and2Use a new gudgeon pin and measure the straighttion 015 mm on 100 mm measured length3Measure con rod twist Max deviation1Press the old bush out2Press the new bush in Make sure that the oil hole in the bush lines up3Broach the bush and measure the con rod with an4Check the end float between the con rod andAlso check the gudgeon pin bushes Please referRepair instructionsGroup 21 Short blockAssembling the piston piston1Install one of the circlips in the piston2Oil the gudgeon pin and gudgeon ring bush3Warm the piston to about 100C Place the pistonand con rod so that the markings line upSlide the gudgeon pin in It should be possible to slide the gudgeon pin4Install the other circlip5Check that the con rod does not move stiffly in6Check the big end bearing clearances Please refer to Inspecting the crankshaft and Inspecting7Check the piston ring gap in the cylinder bores8Install the piston rings on the pistons using pisInstall the oil scraper ring first Put the expansionton ring groove with the location dowel Aboth ends of the spring Check that the ends of discentre piston ring pair so that the marking facesto eachGroup 21 Short blockRepair instructionsCheck with a steel rule surfaces against the camshaft are convex or flat Ifthat the surface is not worn on the other hand It isthe condition of the valve lifters which determinesthe valve lifters do not have large areas of pittingmetal loosen from the hardened surface Lifters andcurves are not abnormally worn The cams could beobliquely worn in an axial direction for examplelifters must be changedCam height inlet and exhaustCam height B for injection pumpRepair instructionsGroup 21 Short blockNot acceptable wearnot acGroup 21 Short blockRepair instructionsInstalling the crankshaft1Check the cleanliness of the crankshaft drillings2Put the main bearings in their places in the bearing cap 3Oil the bearings and the main bearing journals andfered edges must face forwards on all bearingthe location of the bearing caps4Torque the bearing caps please refer to the5Carefully lift the crankshaft into place in the engine block Align the main bearing retainer screwholes 1 Tape the crankshaft gear before lifting thefrom damaging the front bearing seat6Torque the main bearing caps in the engine blockTightening torque please refer to the Technical7Check that the end float does not exceed 05 mmand dial gauge 998 9876Repair instructionsGroup 21 Short block After changing the crankshaft piston or gud1Lubricate the pistons and piston rings with engineoil beside the rings so that the oil finds its wayinto the piston ring grooves Turn the piston ringsso that the piston ring gaps are aligned at a 902Put the bearing shells in their places in the con3Check that the markings on the piston crown orUse a piston ring compressor 1 Make sure that the con rod studsto not strike the crankshaft when driven downThe con rod with the must be ingoes closest to the flywheel4Install the bearing caps 2installed so that the number markingspaint marksUndamaged con rod screws do not need to be5Install the oil suction pipe 34Tightening torque please refer to the Technical Do not press the oil suction pipe6Install the sump together with a new gasketTightening torque please refer to the TechnicalGroup 21 Short blockRepair instructions1Install the timing gear plate 12Oil the camshaft bearing surfaces and carefullylift the camshaft 2 Be careful to avoid damaging the bearings3Install lock plate 34Put the key in place in the crankshaft and install The components must be oiled be Make sure that the gear wheel5Install the thrust washer 5gear cover has been installed6Install the inner rotor 77Adjust the oil pump end float 138Install a new possibly adjusted gasket for the Check that the tubular pin 14er can engage in the hole 15Turn the cover back and forwards and center it in themid position The stop arm 169Check that the starter spring 17regulator arm 18regulator arm through the hole in the engine block7Turn the stop arm 19arm 20Repair instructionsGroup 21 Short block Be careful to ensure that the shimgasket8Torque the injection pump please refer to the9Install a new front crankshaft seal please refer to2120Group 21 Short blockRepair instructionsother assembly1Clean the cylinder head and engine block matingfrom the threads on the cylinder head screws2Put the valve lifters in their original places Please refer to Timing gear assembly for the positions of the valve lifters3Put the new cylinder head gasket in place withpins 2 The new gasket must be of the same thick If a piston con rod crankshaft or engine blockhas been changed new measurement must be done4Dip the cylinder head screws in engine oil and The screws are phosphated andmust not be cleaned with a steel wire brush If5Put the cylinder head in place6Torque the cylinder head screws 3Tightening schedule and torque please refer toTechnical Data7Install the glowplugs 45Repair instructionsGroup 21 Short block8Install the push rods 679Install the oil supply pipe 10and the rocker arm mechanism together with theoil pressure monitor 1110Adjust the valve clearance please refer to11Install the valve cover 13ventilation hole in the crankcase ventilation cover12Install copper gaskets for the injectors13Install the hollow screw 1614Install new copper gaskets and install the returnfuel pipe 1715Install the fuel supply pipes 1816Install the coolant pump 19D11317Install the rear crankshaft seal seat in the enginehousing Install the rear crankshaft seal 2018Apply an even layer of sealant VP no 840 879Group 21 Short blockRepair instructions19Install the inner flywheel housing 22to Technical Data for tightening torque Then inhousing 252620Install the dipstick 2720Install the fuel filter bracket 28and feed pump 2921Install the heat exchangerexhaust manifold 3022Install the starter motor 323323Install the expansion tank with fixing yoke 3524Connect all coolant hoses 36clamps and brackets25Install the electronic box 3726Install the induction silencer 3827Remove the engine fixture and install the engine28Install a new oil filter 4029Install the engine in the boat Connect the remainRepair instructionsGroup 21 Short blockUnscrew the valve cover Seal all openings in the fuel sysUnscrew the injectors 2 Seal all openings on the injectorswith protective capshave screws which must be undone Carefully priseGroup 21 Short blockRepair instructionsRepair instructionsGroup 21 Short blockValves removingValves installationInstall a new valve seal 23Put the valve compressor in place Compress theGroup 21 Short blockRepair instructionsSpecial tools 998 9876 999 5192Check the piston height with tools 9989876 andrefer to Technical dataCheck that the valve lifters are in placehead are in place Install a new cylinder head gasketwith the marking upwardstorque specified in Technical DataRepair instructionsGroup 21 Short blocknew sealsApply sealant part no 840879 to the threads of thePut new copper seals on the bottom of the cylinderInstall the injectors and tighten them evenly to thespecified torque please refer to the Technical DataGroup 21 Short blockRepair instructionsTiming gear removingUnscrew the seawater pump 1el 23Remove the Woodruff key from the groove in the shaftRepair instructionsGroup 21 Short blockUnscrew the fuel feed pump 2Remove the valve lifters with magnetic tool 885822 Mark the valve lifters so that theyGroup 21 Short blockRepair instructionsRotate the camshaft until the socket cap screw 1Remove the camshaft regulator sleeve 4 There is a risk that the inner camall components of the oil pump Note the spacerwasher 2Repair instructionsGroup 21 Short blockTiming gear installationCarefully insert the camshaft If you force the camshaft inthere is a risk that one of the cam lobes willPut the lock plate 1until the screw hole for the socket cap screw 2Group 21 Short blockRepair instructionsspring 45 Note that the end washer 27 If the gasket has a center section 8gear cover Turn the stop arm 3pin 34Repair instructionsGroup 21 Short block The longest screws must be put on the outwith the center nut please refer to the Technical All valve lifters must be put backGroup 21 Short blockRepair instructionsTurn the engine upside down Undo the oil drain pipe Note the markings on the bearingRepair instructionsGroup 21 Short blockPistons removedInstall a new piston in the correct positionGroup 21 Short blockRepair instructionsInstall a piston ring compressor on the pistonLubricate the con rod bearing shells and studs withdown The piston marking SHIBAURA must face Make sure that the con rod studsto not strike the crankshaft when driven downInstall the big end bearing cap as marked Torque toRepair instructionsGroup 21 Short blockUnscrew the inner timing gear plate 1Remove the rear crankshaft seal 1 Tape the crankshaft gear teeth to protect theGroup 21 Short blockRepair instructions The marking 2be carefully noted to prevent incorrect positionin the bearing capsInspect all main bearings 1Repair instructionsGroup 21 Short block Put the main bearing retainersmust face the corresponding holes in the engine Position the bushing so that itsoil hole is correctly aligned in the engine blockthest inTap the bushing in with a suitable mandrel 3Group 21 Short blockRepair instructionsAlign the main bearing retainer screw holes 1Repair instructionsGroup 21 Short blockRemove the flywheel cover 3Unscrew the flywheel 1Install the new flywheel and tighten it to the specifiedGroup 21 Short blockRepair instructionsCrankcase seal rear changeUnscrew the inner timing gear plate 1Apply sealant part no 840879 all round the crankshaftFix the inner flywheel plateRepair instructionsGroup 21 Short blockUnscrew the centre nut from the crankshaft pulley Install tool no 885820 on the pulley and remove itRemove the Woodruff key from the groove in the shaftInsert tool no 9995919 under the lip of the crankshaftseal during assemblywith the center nut please refer to the TechnicalGroup 21 Short blockRepair instructionsValves adjustmentStationary cold engineCrank the engine clockwise until the valves 1no 1 cylinder Please refer to item 3 for the adjustcylinder shift position Adjust no 2 inlet valve 1no 3 exhaust valve 2adjustment procedurecylinder shift position Adjust no 3 inlet valve 3cylinder shift position Adjust no 1 inlet valve 5Repair instructionsGroup 21 Short blockUndo the locknut 1valve clearance 2When the correct valve clearance has been reachedTest run the engine and check that no oil leakage ocGroup 21 Short blockRepair instructionsnator Loosen the upper fixing nut 2Install a new drive belt Tension the belts with tensionTighten the alternator fixing nut and fixing screws D130 D240 Be careful to engroove closest to the alternatorRepair instructionsGroup Oil pump bearing changingFirst screw the guide pin 1 It is important that the engine block surfaceTap the bearing into place until the tool bottoms onsystemRepair Seal all openings in the fuel sysLift the injection pump out and remove the shimhousing Insert the new injection pump into the housspecified torque please refer to the Technical DatasystemRepair Undo the fuel supply pipes 2 Seal all openings in the fuel syssealant part no 840 879 to the two lowest threadsInstall the new return fuel pipe use the nut underneathcome out of alignment and tighten the nuts TightenStart the engine and check that no leakage occurs1Clean the outside of the injector2Fix the injector holder Be careful that the injector nozzle does not fall3Pull the injector nozzle out of the injector sleeve Make sure that the injector needles and injectorsleeves which belong with each other and fit together4Check each injector carefully with an illuminatedthe other components5When you install a it is importantthat conservation oil is washed off the injectorgasolinethe injector needle slides in6Dip the injector components in pure Diesel or testthe opening pressure7Check the opening pressure jet pattern and seal1Injector nut6Adjustment washers2Injectors73Joining piece84Compression screw9Nut5SpringsystemRepair Testing is done in an injector tester During the testthe opening pressure and sealing are the most imporinjectors statusavoid getting the fuel jet from an injector on unprotected parts of your body The jet has suchvalue the setting must be changed This is done with The opening pressure is increased or reducedspacer by 01 mm1Pump the injector tester special tool 9999 772and check the injector spray pattern The fuel jet2Check that the fuel jet has a circular cross secWhen sealing is checked investigate the fuel leakage1Wipe the injector nozzle tip dry2Pump the pressure up to about 2 MPa below the1Loosen the stop screw 32Run the engine without load at full throttle and adjustment screw 43Adjust stop screw 3mm between stop screw 3pressed against the full throttle screw 3Low idle1Check that the gap 62Warm the engine up and check the idling speed3Use adjustment screw 2correct idling speed4Check the gap 3Warm the engine up and check the racing speed with1Actuator arm2Adjustment screw low idle3Stop screw full throttle4Adjustment screw racing speed5Adjustment screw max fuel volume7Lock nut543systemRepair Put a rag under the filter housing bracket to collectScrew the fuel unions tightsystemRepair Check whether the copper washer on the ventscrew needs to be changedbracket until fuel with no air bubbles comes out of theRepair instructionsGroup 26 Cooling system All glycol is hazardous and pollutestation and frost bursting down to about 28C Atered to 54C The coolant must be mixed with It is extremely important that thefilling the cooling system Make sure that thesystem is filled and must not be started until the If a heatingFill the system slowly Filling must not be done sorun for about an hour Top up with coolant as neces Do not open the filler cap when theengine is warm except in emergencies SteamTurn the filler cap to the first stop and allow any excess pressure to hiss out before removing the capcompletely Top the coolant up as necessary Thelevel must be between the MAX and MIN markingsGroup 26 Cooling systemRepair instructions1Drain some of the coolant and connect the pres2Extend the drain hose from the filler pipe with a3Increase the pressure and read the pressure4Remove the test equipment Install the plug andfill the engine up with coolantToo low coolant temperatureFaulty thermostatFaulty temperature sensor or instrumentLow engine loadingExcessive coolant temperature warning lamp lightsBlocked sea water inlet or sea water filterDefective impeller in the sea water pumpToo low coolant level air in the fresh water sysSlipping or broken vee belt for the coolant pumpFaulty thermostat temperature sensor or instruBlocked cooling systemIncorrectly set injection advance in the injectionFiller cap gasket does not sealThere are two types of coolant lossesCoolant losses during operationCoolant losses after stopping a hot enginepoor sealing in the cooling system or that air or combustion gases are forced into the cooling system andRepair instructionsGroup 26 Cooling systemGroup 26 Cooling systemRepair instructionsHeat exchanger cleaning2end wall onto the heat exchangerInstall new Orings 2Screw the end wall onto the heat exchangerInstall the exhaust pipe bendRepair instructionsGroup 26 Cooling systemHeat exchangerexhaustCurrent cut off with the main switch Drained coolUndo the hose union on the exhaust pipe elbowUnscrew the distribution box 1Transfer the exhaust pipe elbow to the new heat exGroup 26 Cooling systemRepair instructionsand a new gasket in the housingOpen the sea cock and start the engine Check theRepair instructionsGroup 26 Cooling systemCheck the seawater pump gear wheel If it isGroup 26 Cooling systemRepair instructionsley to the new coolant pumpD113Alternator changingUnscrew the lower fixing screw 4Put the new alternator in position and tighten the lowerfixing screw Tighten it loosely D130 D240 Be careful to engroove closest to the alternatorStarter motor changingUndo all electric connections 1Put the new starter motor in position and fix it with theBLBlueOROrangeLBLLight blueRRedBNBrownSBBlackLBNLight brownWWhiteGNGreenYGRGray are specified after the color code in the wiring scheduleCables shown with broken lines are not supplied by Volvo Penta1Battery2Starter motor3Alternator4Main switch5Glow plugs6Oil pressure monitor7Stop solenoid8Coolant temperature monitor9Coolant temperature sensor10Circuit breaker 16 A11Starter relay12Glow plug relay13Charge sensing resistor 33 Ohm9W14Engine speed sensor1Instrument illumination2Tachometer with buildin hours counter optional3Connector for connecting extra warning display optional4Electronic unit alarm5Warning lamp coolant6Warning lamp oil pressure7Charge warning lamp8Indication lamp glow plugs9Starter button10Press switch Instrument panel OnOff11Connector for connecting extra neutral position switch12Semiconductor diode13Alarm14Tumbler switch Glow plugs Alarm testAcknowledgment1516pin connectorBLBlueBNBrownGNGreenGRGrayOROrangePUPurpleRRedSBBlackWWhiteYYellow are specified after the colorInstrument panel alternative A Spring biased1Instrument illumination2Tachometer with buildin hours counter optional3Connector for connecting extra warning display optional4Electronic unit alarm5Warning lamp coolant temperature6Warning lamp oil pressure7Charge warning lamp8Indication lamp glow plugs9Switch instrumentlighting10Switch Alarm testAcknowledgment11Key switch12Alarm13Connector for connection of neutral positionswitch optional1416pin connectorBLBlueBNBrownGNGreenGRGrayOROrangeRRedSBBlackVOVioletWWhiteYYellowInstrument panel alternative B with starter switchGroup 20 Technical dataD113AD120AD130AD240ANumber of cylinders2334Cylinder diameter mm in67 26467 26477 30377 30372 28372 28381 31981 319cuin051 31076 465113 691151 921See 850 25rpm235123512312351repair limit kPa psiclosest to flywheel121231231342Direction of rotation see from frontnation025operation35 inlet and outlet mm inWeight engine without okg lb96 212118 260127 280148 326psi20 29Diameter mm in669375 669525 26353 26359it76932 0048 00525 The SHIBAURA name on the inside of the21Clearence between groove and ring all engines mm in006 010 00024 00039 mm in013 015 inClearence between groove and ring all engines mm in005 009 00020 00035engines mm in010 012 nes mm inClearence between groove and ring all engines mm in002 006 00008 00024010 020 engines18998 1898 020996 itClearence between hole and pin all engines mm in0004 to itDiameter of the bore in the cylinder block mm in67000 it77000 itmm inLess 012 000 005 mm inPiston height above top face of cylinder block mm in055 064 00217 00252Choose gasket with thickness mm inPiston height above top face of cylinder block mm in065 075 00256 00295Choose gasket with thickness mm in9950 it1165 1157 Rocker arm clearance on the rocker shaft mm inearanceearanceall engines2185 2195 2160 0 The thrust washers is machined into the holder for the main bearingin010 it 030 or less 00011itStandard D113A and D120A42964 42975 169150 1691934290 1Standard D130A and D240A47965 47975 188830 1888804790 1 No undersize bush bearing journals are availableNo 1424290 1No 2454590 1 No undersize main bearing journals are availableNo 1 and 242964 42975 169150 1691934290 1No 3454590 1 No undersize main bearing journals are availableNo 1 and 247965 47975 188830 1888804790 1No 3474790 1 No undersize main bearing journals are availableNo 1 2 and 34790 1No 4474790 1 No undersize main bearing journals are availableD113A Journal No 10035 0088 00014 00035D113A Journal No 20039 0092 00015 0003620039 0106 00015 00042D120A Journal No 30039 0092 00015 000360039 0106 00015 0004234964 3490 No undersize rod bearing journals are available40964 4090 No undersize rod bearing journals are available0031 20039 D130A Journal No 30039 0010 Service limit D113A D120A010 0004Service limit D130A D240Ain010 itGear Wheelall engines mm in26955 itall engines mm in39900 itall engines mm in27900 itValvesin6955 in0925 05 in065 Clearance in mm in0025 0052 head45Seat contact face in cylinder head170 210 00670 00830Valve lash in mm in020 0008in6940 in0925 05 in085 Clearance in mm in0045 0072 head45Seat contact face in cylinder head170 210 00670 00830Valve lash in mm in020 0008Valve springsLength in mm in with ftlbfmm inmm inOil pressure in kPa psi196 441 284 64Oil pressure in kPa psi48 7352 448 51 65304 500 44 73Clearance in mm inrotor001 015 00004 00059Axial clearance between the face of oil pump coverand the face of the idler gear in mm in001 015 00004 00059Shims available for adjustning the axial clearance mm010 015 020 050systemVDS2F19 28 35 65 200 h 500 h Temperatures with stable ambient temperaturem ftFeed pressure in kPa lbfin15 25 21 36Inli20 122 1D113AD120AD130AD240Amm in5 019685 019686 0236255 02165in65 0255965 025596 023626 02362Axial clearance between the face of oil pump coverand the face of the idler gear in mm in001 015 00004 00059Shims available for adjustning the axial clearance mm010 015 020 0501471 2133e4psi20 Fresh water system volume approx litres US gal27 30 41 64 1 stat90105Coolant Glycolwater mixing ratioSystem voltage12 V16 ABattery capacity starter battery70 88 Ah11V11AF142 015 V115 A22 mikroF08 kW11 kW14 kWTightening torque in Nm ftlbfD113A365 269D120A365 269D130A51 376D240A51 376Bolts of the holder for the main bearing23 169Retaining bolts for the crankshaft27 199D113A D120A23 17D130A D240A32 236Front housing10 74D113A D120A25 184D130A D240A50 369Flywheel housing25 18474 55D113A D120A93 686D130A D240A123 907Flexible coupling85 115 63 85Suction strainer oil pump11 811 8Drain plug sump34 25Camshaft setscrews for retainer plate11 8Rocker shaft housingD113A D120A95 7D130A D240A23 1711 8Cap nuts10 73Rocker arm locknut14 10Mounting nuts and screws6 44Delivery valve holders42 31Pressure oil pipe cylinder blockcylinder head12 964 472D113A D120A D240A20 148D130A23 17Lock screw max fuel volume13 16 96 118Lock screw speed13 16 96 118Exhaust manifold10 73Fuel shutoff solenoid17 13Adjustment screw25 18Mounting screws6 44Glow plug115 85Oil pressure switch and adapter11 8Coolant temperature switch27 20Coolant drain plug plastic3 22Coolant thermostat housing14 10Oil relief valve64 47Starter motor contacts98 118 72 87M55 NmM610 NmM717 NmM824 NmM1050 NmM1280 NmM14D120 D130Conversion tableTo convertTo convertfromToMultiply byfromToMultiply bymminchinchmmcminchinchcmmfootfootmmmsqinsq inmmmsq ftsq ftmVolumecmcu incu incmliter dmsq ftcu ftliter dmliter dmcu incu inliter dmliter dmimp gallonliter dmliter dmUS gallon02642US gallonliter dmmcu ftcuftmPowerNlbf02248lbfN4448kglb2205lbkg0454PowerkWhp metric136hp metric1360735kWbhp1341bhpkW07457kWBTUminBTUminkWTorqueNmlbf ftlbf ftNmBarpsi145038psiBar006895MPapsi145038psiMPa0006895Pamm Wg 0102mm WgPaPain Wc0004in WgPa249098kPain Wg40in WgkPa024908mWgin Wg3937in WgmWg00254BTUhph0697WorkBTUlb430BTUlbMghph0736ghphgkWh136gkWhlbhphkgmlbft23734lbftkgm0042Flow gasmhcuftmincuftminmhFlowmhUS galmin4403US galminmh02271msftsftsmsmphknotknotmphTemp1wer noted in the catalogue refers to metric horsepower113Notes114Notes115NotesReferences to Service BulletinsNoDateFromRefers to pubnPublication noDate of issueSuggestionMotivationDateNameAB Volvo PentaTechnical InformationDept 422007745200English03cF30T1UVz085249D200604060959080200PageMaker 70D201401282106560600Acrobat Distiller 705 Windowsomsl520engPMD
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