Monday, July23, 2018

Volvo Penta 2002 Workshop Manual

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Publ nr 77309748
workshop manual contains repair instructions for the 2001 2002 and 2003 engines
The instructions concerning overhauling describe the most suitable working method using the special tools listed under
the heading Special tools
Both the engine designation and its serial number must be clearly stated in all concerning the engine and
when ordering parts
We reserve the right to carry out design modifications and for this reason the contents of this manual cannot be regarded as
Technical Publications UNIT SYSTEM
Units according to the international SI system have been used in this book The earlier units are given after the SI units
Power is given in kW kilowatt Speed is given in revs revolutions per second
earlier unit hp horsepower earlier unit revmin revolutions per is given in Nm newton metre
Volume is given in dm 3 cubic decimetre
earlier unit kpm kilopond metre earlier unit l litre
earlier unit lbf ft poundfoot earlier unit Imp gal Imperial gallon
earlier unit US gal United States is given in Pa Pascal
earlier unit kpcm 2 kiloponds per square centimetre
earlier unit Ibfin 2 pounds per square inch
guide head
Piston piston rods 5
Flywheel 5
Crankshaft 5
Camshaft the cylinder head
Valve guides 7
Valve seats 7
Valves 7
Valve springs 8
Rocker arm mechanism
Injector sleeve 8
Injectors 8
Assembling the cylinder head 9
Feedpump 10
Pistons 11
Crankshaft 11
Camshaft 11
Connecting rods
Seawater pump
Pistons 14
Adjusting the valve clearance 17
Checking the injection angle 17
2003 Turbo 21
Fresh water cooling 25
Electrical system 26
Fault tracing scheme 28
Special tools 29
Technical Data GUIDE
1 Exhaust elbow
2 Injectors
3 Temperature sender
8 4 Electrical distribution box
5 Fuel filter
6 Alternator
7 Starter motor
8 Drainage cooling water
9 Feedpump
10 Engine serial number
11 Decompression device
12 Inlet air silencer
13 Fuel injection pumps
14 Oil dipstick
15 Seawater pump
off the cooling water and the lubricating oil from the
on engine cradle pn 9992520 and fixture pn 884837 If the
engine is fresh water cooled see page 21
3 Remove the fuel filter the oil filter the feedpump the
thermostat housing and the exhaust elbow Also remove
the seawater pump with its attachment tubes
1 Remove the alternator the tensioner bracket and the
starter motor Remove the connections from the box from the engine and remove the box and
the wire harness
2 Remove the return fuel line the fuel pressure lines and 4 Remove the valve bridge and lift out the push rods
the inlet air silencer Install protection caps on the fuel the rubber rings fortheoil pipe Remove the cylinder Remov
pumps and injectors Remove the screw holding injecto head and the valve lifters Put the lifters on a rack in
the lever of the decompression device 1 and pull out the pboelhts aidnmouts
aswcbilethnd lbrush
lever Remove the valve cover
7 Remove the transmission cover Start by removing the
throttle control cover Use a suitable type of pliers to
the spring 1 Then remove the endnipple 2 and remov
the spring 3 Remove the oil pump cover and mark the
gear wheels with a colourpen before removing them
When installing the gear wheels the marked side must be
facing outwards Remove the bracing pin of the camshaft
using the special tool 884839 Never remove the
pin by punching pnit out this can very well bend bracing the
5 Remove the fuel injection pumps Mark the pumps to camshaft Remove the screws on the transmission cover
ensure installation in the same cylinders from which they and pull it straight outwards
were removed Take care of the shims Remove the screws
on the side of the engine block and lift out the pump
8 The max 1 and the max revscrew 2
are set by Volvo Penta and must never be changed since
this will affect the engine output
6 Remove the pulley center bolt and pull off the pulley
using puller pn 9992265 Place a protection pad between 9 Remove the control rod Start by removing the plug at
the puller and the crankshaft to avoid the crankshaft being the rearof the block and thetwo screws on the pump
holding the control rod
10 Pull out the camshaft 12 Turn the engine upside down and remove the oil pan
Be careful as the pan is glued NOTE The oil pan ends also
function as main bearings
11 Remove the outer flywheel housing the flywheel and 13 Remove the connecting rod bolts and remove the
the inner flywheel housing rods and the pistons The connecting rod andconetig the
connecting rod cap are marked with figures
14 Remove the main bearing caps The main bearing caps
are marked with a figure The corresponding figure is
into the block Lift out the crankshaft On later engine
an arrow is cast in the separate main bearing caps
2002 2003 The arrow is to point towards the dipstick
3 Use mandrel pn 5218 to press out the valve guides Oil
the new valve guides externally and use mandrel pn
884559 to install them Press down the mandrel all the way
down to the cylinder head Ream the valve guides if
1 Remove the collets and valve springs using a valve
bow Remove the valves Remove the valve stem seals
Place the valves in the proper sequence in a valve
Valve seats and valves
4 Mill or ream the valve seats The angle C should be 45
for 2003T 30 for the inlet valve The sealing surfaces width
Valve guides B should be 1 0 1 mm 0 0390 0039 in Grind the valves
in a valve grinding machine The angle D see Tech data If
2 Check the valve guide wear by inserting anew valve stem
the disc thickness after grinding is less than 1 0 mm 0 039 in
into the guide Measure the play using a dial indicator If
necessary replace the valve guides for naturally aspirated engines or 0 8 mm in for
engines the valves must be scrapped Valves with
Inlet valve max play 0 15 mm 00059 in bent stems or if the measurement A exceeds 2 5 mm 0 098
in must also be scrapped Grind the valve tip towards the
Exhaust valve max play 0 15 mm 0 0059 in
rockers if necessary Lap in the valves using valve grinding
paste and check the contact area with marking dye
Rocker arm mechanism
6 Disassemble the rocker arm mechanism and clean the
parts Check the wear of the shaft and rockerarm bushings
Should the bushings need to be replaced usethe mandrel
pn 9991867 for the removal and installation make the valve seat exhaust port 2003T that the oil hole in the bushing
coincides with the one in the
Grind down the valve disc of a discarded valve to just below rocker arm After the installation the bushings are reamed
27 mm 1 063 in diameter Push the valve stem through the to a close running fit When installing the rockerarm shaft
guide NOTE Do not push in too far the valve disc should be it must be turned so that the lubrication holes are facing the
just below the edge of the seat Spot weld the disc in place at valveside Check to make sure that the rocker arm contact
three points using a electric welder Knockout the seat by surface againstthe valve is concave Minor adjustments are
the valve guide with a hammer hitng made in a valve grinding machine Oil the shaft and install
Cool the new seat to approx 20C 4F the cylinder the parts
head should beat room temperature 200168F Place the
cooled seat on tool 8849614 and knock it downtowards
until it
NOTE Turn the seat with the valve face botms the
Pressure testing the nozzles
7 Check the nozzles spray pattern at the correct opening
pressure see Technical Data Check also that the fuel sprays
stop and no dripping occurs
Valve springs Adjust the with 1
5 Checkthe free length of the valve springs and the length being available in different thicknesses from 1 mm U3937
when loaded in to 195 mm 076772 in in steps of 005 mm 001969
L Length unloaded 425 mm 1 67323 in in Disassemble the injector and replace the Length loaded with 17010 N 171 kp 32
1 25984 in whether the pressure must be reduced or increased
L 2 Length loaded with 30020 N 303 kp 24 mm Assemble the injector and check the and
0 94488 in the spraypattern Insert the expanding screw on the special tool pn
10 Oil theflaretool pn 884283 and insert it intothe sleeve
884811 into the copper sleeve and turn the screw make sure that the dowel is properly
retracted Brace the
Tighten tool with the injector yoke Screw down the flaretool as far
the screw hard to allow the threads to work themselves as the shoulder in the injector sleeve
allows thereby
into the copper material Then install the yoke 1 on the
the sleeve Remove the tool Adjust the length of the
stud bolt of the injector Put a cylinder head screw in the sleeve outside the plane of the cylinder
head to head as a supportforthe leg of the yoke Install the 1 mm 03937 in
nut 2 and tighten it until the sleeve is removed
Assembling the cylinder head
11 Clean the cylinder head If the water distribution pipe
has been disassembled it must be installed with the holes
9 Replace the Oring sealing off between the sleeve and turned as indicated in the picture Install
new valve stem
the cylinder head Dip the new Oring in soapwater in sealings Oil the valve stems and install
the valves Make
to facilitate the installation Oil the new injector sleeve sure to install the valves and the valve
springs in their
and install it using special tool pn 884557 Knock down the respective original positions Install the
valve springs and
sleeve until it bottoms the collets Use a valvebow
Changing the diaphragm
14 Remove the six screws holding the upper and valve pump housings together Remove the pump lever
12 Remove the cover of the reduction valve and check to 1 and remove the screw 2 holding the pump lever
make sure that the spring and the piston are faultless If shaft
there are reasons to suspect a fault in the opening pressure
of the reduction valve then check the data of the spring
See under Technical Data reduction valve Depress the pump lever if the diaphragm of the pump 15 Use a suitable pair of pliers and removethe
pump lever
sounds squeaky the diaphragm is faultless shaft Pull out the lever and the diaphragm
19 Place a support under the camshaft gear and use a
hydraulic press to remove the gear
16 Clean the pump housing carefully and replace worn
parts Install the diaphragm and the lever on the
shaft Then insert the shaft and tighten it with diaphrgm the
screw Assemble the two housing halves and install plate 1 Then install the spring 2 and the Oring lifters
17 Check the valve lifters for wear Replace them if neces
20 Remove the gear wheel Use a prong puller Clean the
crankshaft Measure the crankand main bearing pins The
eccentricity must not exceed 006 mm 002362 in and the
taper 0 05 mm 001969 in Should these values be the crankshaft must be
ground to a suitable Check the camshaft for wear on cams and bearing ra
ces Also check the wear of the bearings The bearings are
pressed into their locations and must be line bored after
the installation
Pistons cylinders
21 Check the wear on pistons piston rings and gudgeon
pins Replace these if necessary Use a cylinder to measure the cylinder bores The measurement of
the biggest wear is made immediately beneath the edge of
the upper dead center and crosswise the engine The mea
surement of the smallest wear is made at the lower dead 24 Use piston ring pliers to install the piston rings The
center As to the cylinder diameter see Technical Data marking of the rings TOP or the mark of the a micrometer to measure the pistons Piston
diameter must be turned upwards The height of the upper com
see under Technical Data pression ring 175 mm 068898 in The height of the
compression ring 200 mm 07874 in Turn the lower
rings so that the gaps are turned 120 from each piston
22 Inserta new piston ring into the cylinderand measure
the piston ring gap As to the measurement see Data If necessary increase the gap using a
special file
Connecting rods
23 Measure the clearance of the piston rings in the piston 25 Check the connecting rods for straightness and
ring grooves Regarding the measurement see under Data
26 Check the connecting rod bushings by using the
pin as a gauge There must be no play If the bushings
must be replaced use a suitable mandrel for the removal
and installation Make sure to install the bushing with the
oil hole coinciding with that of the connecting rod Ream
the new bushings The fit is correct when an oiled gudgeon
pin by its own weight can slowly slide through the
27 The pump is equipped with two ballbearings 1
When remove the lockingring 2 in the
housing and push out the shaft whereby the bearings are
following Use a suitable mandrel to remove the bearings
from the shaft NOTE Do not forget the spacer sleeve 3
Replace the sealings 4 NOTE Turn the sealings correctly
and make sure that they do not block the drainage hole in
the pumphousing Replace the 5 Install the
Oring ostlpheacvrn lastnhdef vea
distance of 395 mm 1 55512 in from the shaft end to Coat the shaft with grease and screw it
through the sealings and the Oring and take care not to
damage them Push in the shaft as far as to allow the
bearings to bottom and then install the lockingring the Immerse the thermostat in water and using a
check if it opens at the correct temperature thermo See
Technical Data foropening temperatures If the thermostat is
faulty it must be replaced
use new gaskets sealing rings sealing washers
and lockwashers Coat the sealings with grease or oil
them and also oil all moving parts prior to installing them
If the engine is freshwater cooled see page 21
3 Turn the piston rings so that the gaps are offset in relation
1 Heat the crankshaft gearwheel to approx 150C 302 F to each other The piston crown is marked with an arrow that
prior to the installation Place the key in the keyway of the points towards the belt pulley Use installation ring 8848137
crankshaft and press on the gear wheel Oil the new main Fit the caps with the marking aligned with the halves with oil hole and install them
in the block marking The crankshaft can be turned in any direction
Put in the crankshaft NOTE The main bearing shell at the towards the piston
flywheel also functions as a Tightening torques
Step 1 25 Nm 2 5 kpm 18
Step 2 70 Nm 7 0 kpm 53 ftlb
2 Oil the cap bearing halves and install them Install the 4 Install the main bearing halves in the oil pan and coat
caps in accordance with the marking in the block 2001 has the edge of the oil pan with thin layer of sealing
pn 840879 Install the oil pan and tighten the oilcompund pan
no intermediate bearing If an arrow is cast it shall point
towards the oil dipstick Tightening torque for the main screws and the main bearing screws alternatingly to 20 Nm
bearings 1st tightening 20 N m 2 kpm 14 7 ft lb 2nd 20 kpm 147 ft lbs and then the main bearing screws to
tightening 60 Nm 6 kpm 44 2 ft lbs Turn the engine 60 Nm 60 kpm 44 2 ft lbs
5 Replace the flywheel housing sealing 1 Smear sealing 7A Heat the camshaft gear wheel to a temperature of
compound pn 840879 on the edge between the flywheel
approx 150C 302F and use a suitable sleeve to install it
housing and the sealing NOTE The sealing lip with a
Check to make sure that the gear wheel bottoms on the
spring shall be turned towards the engine Make sure that
camshaft Install the camshaft and make sure that the
the sealing is installed in accordance with the picture
markings on the camshaft gear wheel and on the crankshft
gear wheel coincide Put the washer 1 on the hub of
the camshaft gear wheel Check that all weights are presd
in so that the tabs 2 are inside the washer
7B Install anew sealing ring for in the
housing using mandrel 884838 The sealing
lip with the spring is to beturned towards the engine Press
in the sealing ring from the outside until the mandrel
bottoms against the housing Install a new Oring in the
oil channel in the block 3 fig 7A
Use a new gasket and install the timing gear cover Place
the pressure sleeve with the bearing towards the pressure
washer in the control arm lever Hold the sleeve in place
by pressing the lever to its bottom position where the
sleeve is pressed against the housing Install the pin of the
camshaft using special tool 884839 The pin must
6 Replace the Orings and install the flywheel housing pn
equally much on both sides Under no circumstances torque 25 Nm 25 kpm 18 4 ft lbs are you to use a hammer or some such tool to
punch the
Install the flywheel Tightening torque 65 Nm 65 kpm pin into its location with the aid of a mandrel The camshaft
48 0 ftlbs will then be bent
8 Insert the control rod through the black and into the timing
gear casing Install the bearing ball 1 into the control rod and
push the control rod through the hole in the control lever 2
Fit the spring 3 and screw on the end nipple 4 until it
Note Do not use any tools Screw in the upper bolts botms
with copper sealing washers that guide the control rod
Then screw the lower bolts that hold the control rod in place
in the engine block NOTE The lower bolts should not have
sealing washers Apply Permatex to the threads Check that
the control rod moves freely 10 Insert the key for the pulley in the crankshaft and install
the pulley Tightening torque 40 Nm 40 kpm 29 5
ft Ibs
11 Clean the valve lifters carefully and coa t the contact
surf ace against the camshaft with molybdenum disulphe
Oil the valve guides in the block and install the lifters
Clean the roller lifters of the fuel injection pumps and
then in the block Lock the roller lifters with screws
through the block after the installation apply Permatex to
the threads Check carefully to make sure that the lifters
are correctly installed and that they are running easily in
the groove
9 Install the oil pumps gearwheel according to the marks
from the disassembly Insert a new Oring in the timing
gear cover Oil the gear wheel and fit The cover using a new Regarding the installation of the cylinder head ring
page folwing
14 Valve clearance coldwarm engine 0 30 mm 01181
in Turn the engine in the direction of rotation until the
valves in one cylinder are rocking Then turn the engine
one turn more and the valves for this cylinder
the procedure adjust
for the remaining cylinders Tighten the two guide screws pn 884840 in the block
and install the cylinder head gasket with the marking
Top facing upwards Install the cylinder head
Make sure that the contact surface for the cylinder head
bolts are free from paint Should there be paint on the
bolts there is always the risk of having an insufficiert
force in the bolt joint with subsequent as a
result NOTE The bolts are phospated therefore do not
clean them with a steelbrush
Coat the cylinder head bolts with molybdenum tighten them in accordance with the diagram first to
20 Nm 2 0 kpm147 ft lbs and then to 70 Nm 7 0 Adjusting the fuel injection pump
location with shims
15 if the same block camshaft and fuel Injection pumps
are used when assembling the fuel injection pump must
be installed in their original positions and with the same
shim thickness as earlier The so called soft shims always
being installed against the block must be replaced against
new ones Carefully clean the contact surfaces between the
block and the fuel injection pumps and install shims with
thickness equal to the sum of the marking on the block and
that on the fuel injection pump 4 earlier marking
Example The block marking 4 4 tenths of a millimeter
015748 in
The pump marking 4 4 tenths of a millimeter
015748 in
Total amount of shims 0 8 mm 031496 in
In this case select two soft shims 0 2 and 0 3 mm 011811
in Place the hard shim between the two soft ones and
install the pump NOTE Never install a hard shim together
with another hard shim or against the block or the fuel
pump Hard shims are available in thicknesses 03
13 Install the push rods and the rocker arm bridge push 0 6 and 0 9 mm 011811 02362 035433 in respectively
on new rubber rings to the oil pipe which is fitted at the Soft shims are available in thicknesses 0 2 and 0 3 mm
same time as the rocker arm bridge 007874 and 011811 in
On later version engines an Oring has been introduced as a
seal between the injection pump and the block Only shims may be used on these engines when shimming
Hard shims are available in thicknesses of 0 2 mm 0 0079 in
0 3 mm 0 0118 in 0 6 mm 0 0024 in and 09 mm 0 0354 in
16 New block or camshaft settingdisc pin 2 comes in the largest of the four holes in the pulley
If the block or the camshaft are replaced the block must be Press in the guide pin 2 so that the disc is centered and
measured and marked using the settingdisc pn 884787 tighten the bolts
and a sliding caliper The settingdisc is marked for each respective cylinder
A The settingdisc consists of two rings an inner and an
Marking Denotes
outer The inner ring determines the injection angle for
each respective engine type see Technical Data page 25
Cylinder 1 Cylinder 1 1 2 3 cylinder engines
The injection angle is stamped in degrees and is fixed with
Cylinder 22 Cylinder 2 2 cylinder engine
a pin 1
Cylinder 23 Cylinder 2 3 cylinder engine
B Mount the settingdisc or the pulley with two bolts do Cylinder 33 Cylinder 3 3 cylinder engine
not tighten the bolts Turn the so that the guide
17 Fit the injection pumps together with the calculated
shim thickness Turn the engine so that the cam for the
C Turn cylinder no 1 to its injection position Place the pump is not in the lifting position Check that the pumps
guide pin 2 in the hole marked cyl 1 Turn pin locates in the control rods groove and that the pumps
the crankshaft a little against the normal direction of and the locks markings coincide see figure Check after
and thereafter in the normal rotation direction until rotain the fitting each pump that the control rod operates easily guide pin 2 goes in the
timing covers hole Tightening torque for the nuts is 20 Nm 20 kpm 147
Measure using a caliper the distance between the cylinder ftlbs Connect the fuel pipe between the pumps and the
block and the roller lifters edge do not measure on the pipe from the fuel filter to the injection pump NOTE The
roller hole bolt for the return hose has a smaller throughflow
channel than the others on later versions it is marked
The distance should be
2001 55 8 mm 21 9685 in
2002 2003 556 mm 2 18504 in
2003T 55 9 mm 2 2007 in
2001 If the measured distance is 55 2 mm 2 17323 in this
means that a shim with thickness 0 6 mm 0 02362 in is to
be placed between the caliper and the block
2002 2003 If the measured distance is 55 0 mm 2 16535
in this means that a shim with thickness 06 mm 0 02362
in is to be placed between the caliper and the block
The measured shims thickness in this example 0 6 mm is
to be stamped into the block as in fig 15
The total shim thickness is found by adding the and the pumps marking
The blocks measurements 6 0 6 mm002362 in
The pumps marking 2 0 2 mm0007874 in
No of shims 0 8 mm
In this case choose two soft shims 0 2 and 0 3 mm
0 007874 and 0 011811 in and one hard shim of 0 3 mm
0 011811 in Place the hard shim between the two soft
ones and refit the pump NOTE A hard shim must never be
fitted together with another hard shim or directly against
the block or pump
Hard shims are available in thicknesses 0 3 0 6 and 0 9 mm
0 011811 0 02362 and 0 035433 in
Soft shims are available in thicknesses 0 2 and 0 3 mm
0007874 and 0 011811 in 18 Install thefeed pump and thefuel filter Also install the
thermostat housing with the thermostat NOTE Do not
D Repeat the procedure for the other pumps 2002 2003 forget the lifting eyelet between the fuel filter and the
in the same way as for cylinder 1 housing thermosa
The marking is explained under point B
21 Fit the valve cover using a new gasket Make sure that
the round hole for the crankcase ventilation is in the right
position Fit the decompression device lever Fit the
pipes between the injectors and the injection pumps
Also refit the inlet air silencer
19 Install the seawater pump and the cooling water
20 Install the injectors and the return fuel pipe Tightening 22 Install the starter motor the alternator and the
torque for the injectors 20 Nm 20 kpm 147 ft lbs Also alterno and
Vbelt Also install the electrical distribution box
install the exhaust elbow and the water pipe between the hookup the cable harness
thermostat housing and the exhaust elbow
Where there is an excessive amount of smoke in the ilptoawrcuy ma
be that the is not functioning properly If
the boats speed through the water is gradually decrasing
the boats bottom should also be inspected and
cleaned where necessary Check that the air intake has not
become clogged and clean the intake silender
Inspecting the Seals
joints between the turbine housing and the
Check thebearing housing and between the compressor compres
bearing housing and the compressor housing
Check the preinjection angle the injectors opening
and the spray pattern The valve clearance and presu
should also be checked compresin
23 Fill up with lubricating oil to the correct level Regardin
quantity and quality see under Technical Data
Checking axial and radial clearance
Dismount the from the engine and
measure the rotor units axial and radial clearance
Maximum permissible axial clearance 0 09 mm
24 Venting the fuel system
A Open the venting screw on the fuel filter approx 4 turns
Watch out for fuelsplashes
B Use the handpump to pump fuel until fuel free from air
bubbles is coming out Close the venting screw
C Ease off the fuel pressure pipe nuts at the injectors
the throttle control in the position for full speed and
turn the engine with the starter motor until fuel comes out
of the fuel pressure pipes Tighten the fuel pressure pipe
nuts Maximum permissible radial clearance 0 17
If wear and tear has reached the maximum permissible the
should be reconditioned or replaced
lineup marks between the turbine housing the Dismantle the turbine shaft 4 and the heat shield If the
bearing housing and the compressor housing Dismantle turbine shaft sticks tap the end gently with a wooden
the compressor housing 1 Unscrew the lefthand Unfasten the three screws which hold the cover hamer 3
threaded nut which holds the compressor wheel using and screw two M5 screws into the cover Then lift it up
dollies on the turbine shaft Remove the compressor wheel Take the oil deflector 7 out of the cover
2 and dismantle the turbine housing 3
Compressor Housing Turbine Housing
Check that the housings are free from cracks or other
caused by excessive wear and tear Damaged damge parts
should be replaced
Heat Shield
Check that the heat shield is free from damage caused by
wear and tear heat or corrosion and replace it if necsary
Bushing Oil Deflector the four screws which hold the compression
8 Using a small copper mandrel tap out bearing and the bushing 9 Then remove Check that the parts are free from wear and tear and
the circlips 10 inside the bearing housing and remove the Damaged parts should be replaced even if discoluratn the
two bearings 11 amount of wear and tear is within the permitted
the packing ring 12 on the turbine shaft and the
two packing rings 13 on the oil deflector Clean the and Wheel and Shaft
Check that the turbine wheel and shaft are free from
damage The vanes must not be worn or out mechanil of
shape Do not try to realign the vanes Damaged parts
should be replaced
Check measurement A which should not be less than
407 mm
Oil Deflector
Check measurements B and C B should not be more
than 1 31 mm C should not be more than 1 11 mm
Compressor Bearing
Check the width of the bearing and replace it if the amount
of wear and tear is in excess of the permitted tolerance
Minimum permissible width is 398 mm
Place the shaft on two supports which should be under the
bearing recesses and check the throw at the end of the The maximum permissible throw is 0 011 mm Check the bearings for
abnormal wear and tear or
Check the diameter of the shaft bearing recesses The
is 798 etCnhcksary e
permissible diameter mm Check the width
minu of internal and external diameters of all bearings The extrnal
the shaft piston ring groove Maximum permissible width diameter should not be less than 12 31 mm the internal
is 1 29 mm diameter should not be more than 8 04 mm
Grease all removable parts when reassembling them
the circlips in the bearing housing so that the Positn
in them are facing towards the oil outlet openigs
Mount the packing ring shaft Turn the openig
in the ring so that it
on is
towards the oil intake
Position the heat shield on the bearing casing and then
place the turbine axle in the bearing housing
Mount the bushing on the turbine shaft Grease in the
bearing with engine oil and mount it oncompres the
bearing casing using new screws and washers to fasten it
The torque should be 1 3 Nm01
Tighten the screws to the above torque then loosen them a
quarter turn before tightening them up to the correct
torque again
Position the two packing rings on the oil deflector NOTE
The opening in the inner ring should be facing the oil
that in the outer ring should be facing the oil intake
Position the oil deflector in the cover Smear the edges of
the bearing housing which come in touch with the cover
using Permatex for the purpose
Bearing Housing
The thickness of the sealant should be about 0 10 2 mm
Check the housing for corrosion or cracks Check Fitthe cover on the bearing housing and fasten itwith new
D and E and replace the housing where
more than measurnt necsary
screws and washers The torque should be 1 3 Nm0 1
Measurement D should not be 12 42 E should not be more than 15 05 mm Tighten the screws to the above torque then loosen
them a
quarter turn before tightening them up to the correct
torque again
Position the compressor wheel on the turbine shaft and
fasten it with the lefthand thread nut The torque should
be 2 0 Nm0 1
Mount the turbine housing on the bearing housing acording
to the lineup marks Screw the locking cover into
making sure that the screws used are not those positn for
the compressor housing The torque should be 11 0
Nm0 5 M6 26 010 M8
Smear the edges of the bearing housing where it comes in
touch with the compressor housing using Permatex for
the purpose The thickness of the sealant should be about
0 10 2 mm Then mount the compressor housing acording
to the lineup marks and screw the locking cover into
position The torque should be 4 5 Nm0 5
Check the axial and radial clearance Maximum permisbl
axial clearance is 0 09 mm maximum permissible
clearance is 0 17 mm measurements F and G and replace the cover
where necessary Measurement F should not be more
than 12 45 mm measurement G should not be more than Fitting the 05 mm Before
fitting the on the engine spray
clean engine oil into the oil intake and turn the turbine
shaft so that the oil is evenly distributed Clean the
Rings correct quality of oil see under Technical Data Oil
Check the packing rings to see if they are worn or out of changes should be carried out in accordance with the
in the Manual in order to keep the engine clean
shape and replace them with new ones where necsa
Clean the air filter
COOLING 2002 2003
1 Fit the circulation pump complete with tensioner bracket and spacer sleeve position 4 Tighten the bolts M8x75 to
20 Nm 20 kpm 147 ft lbs position 1
2 Suspend the heat exchanger loosely by the rear bolt M8x16 and spring washer position 5
a Fit the pipe position 6 and the hose position 3 between the heat exchanger and the seawater pump using
double hose clamps apply soapy water to the rubber rings applies for all rubber rings
b Fit the pipe between the and thermostat housing position 7
c Fit the pipe between the and the circulation pump position 8
3 Locate the pipes in the and and draw it forward tightening it with the two bolts M8x16 and spring
washers positions 5 and 9
4 Fit the pipe between the and the exhaust elbow position 10 NOTE The holderforthe pipe position
11 and the lock position 11 a
5 Fit the pipe between the circulation pump lower outlet and the cylinder head position 12
6 Fit the pipe between the circulation pump upper outlet and the cylinder head position 13
7 Fit the alternator place the bolt for the tensioner bracket with the head forwards Put on and tension the Vbelt
8 Fit the expansion tank to the exhaust elbow position 15
9 Fit the hose between the tank and the circulation pump double pipe 2002 450 mm 17 7 in 2003 550 mm 21 7
in only single hose clamps are used on the freshwater system position 16
10 Fit the nipple position 17
11 Fitthe hose between the tank and the thermostat housing nipple 17 2002 350 mm 13 8 in 2003 450 mm 17 7
in position 18
12 Fit the plugs in the exhaust elbow and the cylinder head positions 19 and 20
13 Fill the additive
system with
right level The a mixture system
freshwater of fresh water 50
volumes 2002 and antifreeze
40 dm2 litre 088
50 altematively
Imp gals 11 rustpoecin US gals
2003 5 5 dm 3 litre 1 2 Imp gals 1 45 US gals
Pos 21 and 23 are for hot water outlet
Wiring diagram alternative A
Printed circuit card
2 Rev counter Start button
4 Switch for instrument panel
5 Alarm test button
6 Alarm
Max output from
the panel 5 A
Cable colour
R Red
PU Purple
BN Brown
OR Orange
GR Grey
SB Black
W White
Y Yellow
GN Green
BL Blue
2 Fuse
3 Temp alarm sender
4 Oil pressure alarm areas in mm 2
Wire area
mm 2 AWG
10 16
15 14
25 12
10 6
Wiring diagram alternative B
1 Voltmeter
2 Oil pressure gauge
3 Coolant temperature gauge
4 Printed circuit card
5 Alarm test
6 Switch for instrument lighting
7 Rev counter
8 Key switch
9 Alarm
Max output from
the panel 5 A
Cable colour
GR Grey
SB Black
BN Brown
LBN Light brown
R Red
P Purple
GN Green
Y Yellow
W White
BL Blue
LBL Light Coolant temperature sender
2 Oil pressure alarm sender
3 Coolant temperature alarm sender
4 pit pressure sender
5 Relay
6 Fuse
Wire areas in mm 2
FAULT Engine Engine not Engine runs Engine Fault
does stops reaching roughly or becomes
not correct temp vibrates abnormal y
start at full rpm abnormly hot
Stop control not fully pushed
back Main switch not switched
on Flat battery Broken electric
wires Main fuse blown
Empty fuel tank closed fuel cock
or clogged fuel filter
Water or impurities in the fuel
Faulty injectors or air in the fuel
Boat abnormally loaded clogged
intake air filter or marine growth
on the boat bottom
Engine not properly aligned
damaged Propel
Clogged cooling water intake or
water jackets in the exhaust
Faulty impeller in seawater
pump Faulty thermostat Cloged
cooling water pipe in the
head cylinder
Pulley Installation ring for Mandrel for valve guide Mandrel for installation of injector Mandrel for installation of valve
Settingdisc for injection pump Puller for injector Flaring tool for injector Flange for engine Mandrel for installation of sealing
ring in transmission
Assembly and disassembly tool for camshaft Guide pin for cylinder head NOTE Two are requid
Type designation
2001 2002 of cylinders
1 2
0 43 dm
3 26 2 cu 0 852 dm 3 51 9 cu in 1 278 m 3 77 99
in cu in
Cylinder bore
79 mm 3 11024 in
87 mm 3 4252 ratio
17 5 ratio at starter motor speed
22 5 MPa 2025 kpcm 2
Direction of rotation seen from the front end
1314 rs 775825 rpm
Oil pressure at full speed and warm engine
035040 MPa 3540 kpcm2
Oil pressure at idling and warm engine
008015 MPa 0815 kpcm 2
Special alloy cast iron
Cylinder diameter standard
79007903 3 110253 11142 in
025 mm oversize
79257928 3 120083 12126 in
050 mm oversize
79507953 3 129923 1311 in
783 m m 308268 in
Height from gudgeon pin center to piston top
503 mm 1 98031 in
Piston clearance in cylinder
009 mm 00354 in
Piston in standard dimension
789037817 in
025 mm oversize
7915379167 in
050 mm
7940379417 in
Gudgeon pins
2599526000 in
Gudgeon pin bushing diameter
2600526011 in
Clearance gudgeon pin bushing
000500 0160 in
Piston ring number
Oil ring number
The upper compression ring has an inlay of chrome
The piston rings are available for standard dimension and
for 0250 and 0500 mm oversize 000984 and 00996
Piston ring axial clearance in the groove
Upper compression ring
00700102 0 in
Lower compression ring
00500082 in
Oil ring
00300062 in
Piston ring gap in the compression ring
030050 in
Lower compression ring
030050 in
Oil ring
025050 in
Nodular axial clearance
00400221 in
Main bearing radial clearance
00400092 in
Bigend bearing radial clearance
00240068 0000940 00268 in
1 Propeller shaft output in accordance with DIN 6270B
Main bearing standard
5998760000 in
0250 m m undersize 5973759750 in
0500 mm undersize 5948759500 in
Main bearing standard 29872997 in
0250 mm oversize 31123122 in
0500 mm oversize 32373247 in
Bigend standard 4798948000 in
0250 mm aversize 4773947 750 in
0500 m m oversize 4748947500 in
Bigend bearing standard 14781488 in
0250 mm oversize 16031613 in
0500 mm oversize 17281738 in rods
Axial clearance at the crankshaft 015035 mm in clearance
01600300 mm in
Radial clearance in bearings 00200075 mm in
Camshaft diameter 4697547000 in
Lifting height of cams 548552 mm in
Bushing diameter 47024705 mm in
Cylinder head
Material Special alloy cast iron
Inlet valves
Disc diameter 344346 mm 1354331 36220 in 358360 mm
Stem diameter 7955x7970 mm in 79957970 mm
Valve seat angle 445544 85 294530 15
Cylinder head seat angle 45 30
Seat width in the cylinder head appr 1 mm 00337 in appr
1 mm 0 0337 in
Clearance coldwarm engine 03 mm 0011811 in 0 3 mm
0011811 in
Exhaust valves
Disc diameter
299301 mm in
Stem diameter
79507465 mm 0 in
Valve seat angle
head seat angle
Seat widthin the cylinder head
appr 1 mm 003937 in
Clearance coldwarm engine 03 mm 0011811 in
Valve inlet valve 38 mm 149606 in
Length outlet valve 38 mm 149606 i n
Inner diameter 80008015 in
Height above springplane of cylinder head 870930 mm in
Valve unloaded 425 mm 167323 in
Loaded with 17010 N 171 kp 32 mm 1 25984 in
Loaded with 30020 N 302 kp 24 mm 094488 in quantity
model 2001 140 dm 3 1 2 quarts
Oil quantity model 2002 2 75 dm 3 2 42 quarts
Oil quantity model 2003 410 dm 3 36 quarts
Oil quality according to the APIsystem CD
15 W40
Oil pressure warm engine
idling speed 0815 kpcm2 11 3721 33 lbftin2
Oil pressure warm engine full rpm 3540 kpcm 2 49 7856 89 lbftin 2 oil
Type Gearwheel pump
Gear wheel axial clearance 00250065 in
Spring for reduction valve length unloaded 49 mm 192913 in
Loaded with 35 Nm 35 kp 25 8 ft lbs 40 mm 157480 in
Fuel pressure injectors 180190 kpcm 2 25602702 angle
angle 2001
221 B T D C
Injection angle 2002 2003 201C BT DC
Injection angle 2003T 231 BT D C
Injection quantity 251 5 mm3stroke at 405C 104F10 6F
and at 25 rs 1500 rpm pump revs
Governor overrun 54 rs 3250 rpm
Feed pump
Feed pressure 42 rs 2500 rpm 065085 kpcm 2 9 2012 10 lbfin 2
Electrical voltage 12V
Battery capacity Max 70 output 2001
08 kW 1 1 H output 2002 and 2003
1 4 kW 1 9 output
Voltagemax current 14W50 Amp
Output 700 spec gravity Fully loaded
battery 12751285
To be charged at
Wax to open at 602C open at
75C 165 F1
Cooling system
With freshwater cooling 2002 2003
Starts opening at 741C open at
87C 189 system volume 2002
40 dm 3 litre 0 88 Imp gals 1 1 US gals
2003 55 dm 3 litre 11 2 Imp gals 1 45 US gals
WEAR be bored at 025 mm wear 000984 in and bigend journals
Permitted outofround 006 mm 000236 taper
005 mm 000197 in
Max axial clearance on crankshaft 040 mm 001575 in
1 2003T 204212 kpcm2 29003015 lbfin 2 journals permitted outofround 003 mm
000118 in
Max clearance between camshaft and bushings 015 mm 000590 in clearance
between valve stem and valve guide 015 mm 000590 in
The valve disc edge must be at least 15 mm 005906 in
Main bearing bolts 1st tightening 20 Nm 20 kpm 14 7 ft lbs
2nd tightening 60 Nm 60 kpm 44 2 ft lbs
Bigend bearing bolts 70 Nm 70 kpm 51 6 ft lbs
Flywheel housing bolts 25 Nm 25 kpm 18 4 ft lbs
Flywheel bolts 65 Nm 65 kpm 47 ft lbs
Cylinder head bolts 1st tightening 20 Nm 20 kpm 14 7 ft lbs
2nd tightening 70 Nm 70 kpm 51 6 ft lbs
Rocker arm bridge 25 Nm 25 kpm 18 4 ft lbs
Fuel injection pumps 25 Nm 25 kpm 18 4 ft lbs
Pulley 40 Nm 4 0 kpm 29 5 ft lbs
Injectors 20 Nm 20 kpm 14 7 ftlbs

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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.