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Volvo Penta 2002 Workshop Manual



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              Publ . nr 7730974-8
              4-1990




WORKSHOP MANUAL




          VOLVO
          PENTA
FOREWORD

This 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 correspondence 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
binding.

                                                                                                      AB VOLVO PENTA
                                                                                       Technical Publications Department




SI 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 rev/s (revolutions per second)
  earlier unit hp (horse-power)                                    earlier unit rev/min (revolutions per minute)

Torque 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 gallon)
Pressure is given in Pa (Pascal)
  earlier unit kp/cm 2 (kiloponds per square centimetre)
  earlier unit Ibf/in 2 (pounds per square inch)
                                         INDEX

Components guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DISASSEMBLY
Cylinder head . . . . .          .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .   .   .   .   3
Transmission . . . . .           .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .   .   .   .   4
Piston, piston rods              .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .   .   .   .   5
Flywheel . . . . . . . . . .     .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .   .   .   5
Crankshaft . . . . . . . .       .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .   .   .   .   5
Camshaft . . . . . . . . .       .   .   .   .   .   .   .   .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .    .   .   .   .   .   .   .   .   .   .   .   5

OVERHAUL
Disassembling the cylinder head                                                      .   .. .         ..      .. . . . . .. .. . . .. . 7
Valve guides . . . . . . . . . . . . . . . . . . .                                   .   .. .         ..      .. . . .. .. .. . . .. . 7
Valve seats . . . . . . . . . . . . . . . . . . . .                                  .   ...          ..      .. . . .. .. .. .. .. . 7
Valves . . . . . . . . . . . . . . . . . . . . . . . . .                             .   .. .         . .     .. . . .. . . .. . . .. . 7
Valve springs . . . . . . . . . . . . . . . . . .                                    .   .. .         . .     .. . . .. . . .. . . .. . 8
Rocker arm mechanism . . . . . . . .                                                 .   .
                                                                                         . .          ..      .. . . . . . . .. . . . . . 8
Injector sleeve . . . . . . . . . . . . . . . . .                                    .   .. .         ..      .. . . . . . . .. . . . . . 8
Injectors . . . . . . . . . . . . . . . . . . . . . . .                              .   .. .         ..      .. . . . . . . .. . .. . . 8
Assembling the cylinder head . . .                                                   .   .. .         ..      .. . .. . .. .. . .. . . 9
Feed-pump . . . . . . . . . . . . . . . . . . . .                                    .   ...          ..      . . . . . . . . . . . . . . 10
Pistons . . . . . . . . . . . . . . . . . . . . . . . .                              .   ...          ..      . . . . . . . . . . . . . . 11
Crankshaft . . . . . . . . . . . . . . . . . . . . .                                 .   ...          ..      . . . . . . . . . . . . . . 11
Camshaft . . . . . . . . . . . . . . . . . . . . . .                                 .   .. .         . .     . . . . . . . . . . . . . . 11
Connecting rods . . . . . . . . . . . . . . .                                         . . ..           . .     . . . . . . . . . . . . . .12
Thermostat . . . . . . . . . . . . . . . . . . . .                                   . . ..           ..      . . . . . . . . . . . . . . 13
Sea-water pump . . . . . . . . . . . . . . .                                         . . ..           ..      . . . . . . . . . . . . . . 13

ASSEMBLY
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                               14
Pistons . . . . . . . . . . . . . . . . . . . . . .                          ..      .   .    . . . .         ..      . .. .           . . .. . .              ..          14
Flywheel . . . . . . . . . . . . . . . . . . . . .                           ..      .   :    . . . .         . .     . .. .           . . .. . .              ..          15
Transmission . . . . . . . . . . . . . . . .                                 ..      .   .    . . . .         . .     . .. .           . . .. . .              ..          15
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 . . . . . . . . . . . . . . .                                 . .     .    .   . .. .          . .     . .. .           . . ... .               ..          30
COMPONENTS 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.    Feed-pump
                   10 .   Engine serial number
                   11 .   Decompression device
                   12 .   Inlet air silencer
                   13.    Fuel injection pumps
                   14 .   Oil dipstick
                   15 .   Sea-water pump
                                                        DISASSEMBLY
Drain off the cooling water and the lubricating oil from the
on engine cradle p/n 9992520 and fixture p/n 884837 . If the
engine is fresh water cooled, see page 21 .




                                                                       3 . Remove the fuel filter, the oil filter, the feed-pump, the
                                                                       thermostat housing and the exhaust elbow . Also remove
                                                                       the sea-water pump with its attachment tubes .



1 . Remove the alternator, the tensioner bracket and the
starter motor . Remove the connections from the electrical
distribution 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                                                                       consecutiveorde, hcTNyOleiEn!dra pboelhts aidnmouts aswcbilethnd l.brush
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 end-nipple (2) and       remov
                                                                 the spring (3) . Remove the oil pump cover and mark the
                                                                 gear wheels with a colour-pen 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 p/nit 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
     .                                                 lifters




                                                                 8 . The max .-volume-screw (1) and the max .-rev-screw (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 p/n 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 plane,
damaged .                                                        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
                                                            punched
versions an arrow is cast in the separate main bearing caps
(2002, 2003) . The arrow is to point towards the dipstick.
                                                                           3 . Use mandrel p/n 5218 to press out the valve guides . Oil
                                                                           the new valve guides externally and use mandrel p/n
                                                                           884559 to install them . Press down the mandrel all the way
                                                                           down to the cylinder head . Ream the valve guides if
                                                                                   .                                                necsary



THE CYLINDER HEAD
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
stand .




                                                                           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 surface's 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
                                                                                                                           (0.031
                                                                                        engines, the valves must be scrapped    . Valves with
                                                                                                                                           turbochaged
Wear limits :
Inlet valve, max play . . . . . . . . . . . . . . . 0 .15 mm (0.0059 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
                                                                      p/n 9991867 for the removal and installation, (make sure
Replacing 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      valve-side . 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 plastic-headed 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 884961-4 and knock it downtowards
                                                 until it
       . NOTE! Turn the seat with the valve face          botms the
tool .




                                                                      Pressure testing the nozzles
                                                                      7 . Check the nozzle's spray pattern at the correct opening
                                                                      pressure (see Technical Data) . Check also that the fuel sprays
                                                                      stop simultaneously and no dripping occurs .
Valve springs                                                         Adjust the opening-pressure with adjustment-washers (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 1,95 mm ( .076772 in .) in steps of 0,05 mm ( .001969
L = Length, unloaded 42,5 mm (1 .67323 in .)                          in .) . Disassemble the injector and replace the adjustment-washer odatnehrgpicks
L1 = Length, loaded with 17010 N (171 kp) 32 mm
      (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 opening-pressure and
      (0 .94488 in .)                                                 the spray-pattern .
Injector-sleeve
8 . Insert the expanding screw on the special tool p/n                                                       10 . Oil theflare-tool p/n 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
                                                         anti-clockwiseuntilshecrwshatucktinhe.slv Tighten   tool with the injector yoke . Screw down the flare-tool 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                                                                                                             flaring
                                                                                                                   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 maximum
cylinder 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 O-ring, sealing off between the sleeve and                                                   turned as indicated in the picture . Install new valve stem
the cylinder head . Dip the new O-ring in soap-water in                                                      sealings . Oil the valve stems and install the valves . Make
                                                              orde
     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 p/n 884557 . Knock down the                                               respective original positions . Install the valve springs and
sleeve until it bottoms .                                                                                    the "collets" . Use a valve-bow .
                                                               Changing the diaphragm
                                                               14 . Remove the six screws, holding the upper and lower
Reduction valve                                                pump housings together . Remove the pump lever spring
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 .




Feed-pump
13 . 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 the
attachment plate (1) . Then install the spring (2) and the O-ring (3).




Valve lifters
17. Check the valve lifters for wear . Replace them if neces
sary .




                                                                           Crankshaft
                                                                           20 . Remove the gear wheel . Use a prong puller . Clean the
                                                                           crankshaft. Measure the crank-and main bearing pins . The
                                                                           eccentricity must not exceed 0.06 mm ( .002362 in .) and the
                                                                           taper 0 .05 mm ( .001969 in .) . Should these values be excd,
Camshaft                                                                         the crankshaft must be ground to a suitable under-dimension,s.D"uaTnetdchril
18 . 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 indicator
gauge 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 manufacturer)
Use a micrometer to measure the pistons . Piston diameter,     must be turned upwards . The height of the upper com
see under "Technical Data" .                                   pression ring : 1,75 mm ( .068898 in .) The height of the
                                                                      compression ring ; 2,00 mm ( .07874 in .) . Turn the lower
                                                                      rings so that the gaps are turned 120  from each piston
                                                                    .                                                          other




22 . Inserta new piston ring into the cylinderand measure
the piston ring gap . As to the measurement, see under
"Technical 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                 .                                              twisng
"Technical Data" .
 26 . Check the connecting rod bushings by using the
        pin as a gauge . There must be no play. If the bushings
                                                           gudeon
 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
      .                                                           bushing




Sea-water pump
27 . The pump is equipped with two ball-bearings (1) .
When disassembling, remove the locking-ring (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 pump-housing . Replace the            (5) . Install the
                                   O-ring                   ball-bearingsand ostlpheacvrn lastnhdef vea
distance of 39,5 mm (1 .55512 in .) from the shaft end to the
ball-bearing . Coat the shaft with grease and "screw" it
through the sealings and the O-ring and take care not to
damage them . Push in the shaft as far as to allow the
bearings to bottom and then install the locking-ring (2).

Checking the thermostats
28 . 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 .
                                                        ASSEMBLY

Always use new gaskets, sealing rings, sealing washers
and lock-washers . Coat the sealings with grease or oil
them and also oil all moving parts prior to installing them .
If the engine is fresh-water 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 key-way of the   points towards the belt pulley . Use installation ring 884813-7 .
crankshaft and press on the gear wheel . Oil the new main         Fit the caps with the marking aligned with the crankshaft's
bearing 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 thrust-bearing .                     Tightening torques :
                                                                  Step 1 : 25 Nm (2 .5 kpm) (18
                                                                                             ft/lb)
                                                                  Step 2 : 70 Nm (7 .0 kpm) (53 ft/lb)




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
                                                                           p/n 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       (2,0 kpm) (14.7 ft .lbs .) and then the main bearing screws to
tightening 60 Nm (6 kpm) (44 .2 ft .lbs) . Turn the engine .      60 Nm (6,0 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 (p/n 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 .




  r




                                                              7B . Install anew sealing ring for thep/ncamshaft in the
                                                                         housing, using mandrel         884838 . The sealing
                                                                                                                       transmio
                                                              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 O-ring 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 O-rings and install the flywheel housing .                                    p/n
                                                                     equally much on both sides.     Under no circumstances     protude
Tightening torque 25 Nm (2,5 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 (6,5 kpm)      pin into its location with the aid of a mandrel . The camshaft
(48 .0 ft.lbs).                                               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 (4,0 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
                                                                                                                                     instal
                                                                        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 .




                                                                        2001
9 . Install the oil pump's gearwheel according to the marks
(from the disassembly) . Insert a new O-ring in the timing
gear cover . Oil the gear wheel and fit The cover using a new           Regarding the installation of the cylinder head, seethe
sealing ring .                                                                 page .                                           folwing
                                                                       14 . Valve clearance cold/warm 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 .         Repat




2003


12 . Tighten the two guide screws p/n 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 leakagestighen as a
result . NOTE! The bolts are phospated, therefore do not
clean them with a steel-brush .
Coat the cylinder head bolts with molybdenum disulphide
and tighten them in accordance with the diagram, first to
20 Nm (2 .0 kpm/14.7 ft .lbs) and then to 70 Nm (7 .0 kpm/51.6
ft.lbs).                                                               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 0.3,
                                                                                                                                   injecto
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 O-ring has been introduced as a
seal between the injection pump and the block . Only so-called
hard 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 0.9 mm (0 .0354 in) .




16. New block or camshaft setting-disc                                 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 setting-disc p/n 884787                 tighten the bolts .
and a sliding caliper .                                                The setting-disc is marked for each respective cylinder :
A . The setting-disc 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   2/2   Cylinder   2   (2 cylinder engine)
a pin (1) .
                                                                       Cylinder   2/3   Cylinder   2   (3 cylinder engine)
B . Mount the setting-disc or the pulley with two bolts, do            Cylinder   3/3   Cylinder   3   (3 cylinder engine)
not tighten the bolts . Turn the            so that the guide
                                                                         17 . Fit the injection pump(s) together with the calculated
                                                                         shim thickness . Turn the engine so that the cam for the
C . Turn cylinder no . 1 to it's injection. position . Place the         pump is not in the lifting position . Check that the pump's
guide pin (2) in the setting-disc's hole marked cyl . 1 . Turn           pin locates in the control rod's groove and that the pump(s)
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 .
setting-disc's guide pin (2) goes in the timing cover's hole .           Tightening torque for the nuts is 20 Nm (2,0 kpm) (14.7
Measure using a caliper the distance between the cylinder                ft.lbs). Connect the fuel pipe between the pumps and the
block and the roller lifter's 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 through-flow
                                                                         channel than the others (on later versions it is marked
The distance should be :
                                                                          'Out") .
2001 : 55 .8 mm (2.1 9685 in)
2002, 2003 : 55,6 mm (2 .18504 in)
2003T : 55 .9 mm (2 .2007 in)
Example :
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 0.6 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 block's
measurements and the pump's marking .
Example
The block's measurements                6 (= 0 .6 mm/0.02362 in)
The pump's marking                     2 ( = 0 .2 mm/0.007874 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
(0,007874 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 setting-disc's 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
                                                                                                                           presu .
                                                                   Also refit the inlet air silencer .

19 . Install the sea-water pump and the cooling water
     .                                                pies




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 (2,0 kpm) (14.7 ft .lbs .) . Also                                                                 alterno and
                                                                             V-belt . Also install the electrical distribution box
install the exhaust elbow and the water pipe between the              hook-up the cable harness .
thermostat housing and the exhaust elbow .
                                                                     2003T
                                                                     Turbo-Compressor
                                                                     Where there is an excessive amount of smoke in the exhaustftorumesheiosuntgp ilptoawrcuy ma

                                                                     be that the turbo-compressor is not functioning properly . If
                                                                     the boat's speed through the water is gradually decrasing,
                                                                          the boat's 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 .


                                                                     Checks
                                                                     Check the pre-injection angle, the injector's 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 turbo-compressor from the engine, and
                                                                      measure the rotor unit's 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 fuel-splashes .
B . Use the hand-pump 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
                                                            Positn
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 mm
                                                                      If wear and tear has reached the maximum permissible the
                                                                      turbo-compressor should be reconditioned or replaced .
                                           RECONDITIONING




Make line-up 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 left-hand               . 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, Compressor
Unfasten the four screws which hold the compression
                                                                   Bearing
bearing (8) . Using a small copper mandrel, tap out the
compression 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
                                                                        .                                             tolerancs
Remove the packing ring (12) on the turbine shaft and the
two packing rings (13) on the oil deflector. Clean the parts
carefully .




Measuring and Inspection
Turbine 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 .
                                                                   Bushing
                                                                   Check measurement (A), which should not be less than
                                                                   4.07 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 3.98 mm .


Place the shaft on two supports, which should be under the
bearing recesses, and check the throw at the end of the            Bearings
shaft . 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 7.98                                                                                    discolouration,andwtrhepmlac et.Cnhcksary 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 .
                                                                     Reassembly
                                                                     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
                                                                                                  the
                                                                                                    facing
                                                                                                      turbine
                                                                                                           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 Nm0.1 .
                                                                     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
                                                                                                                             outle, .
                                                                     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 .1-0 .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 mm,
measurement (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 left-hand thread nut . The torque should
                                                                     be 2 .0 Nm0 .1 .
                                                                     Mount the turbine housing on the bearing housing acording
                                                                        to the line-up 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 .01,0 (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 .1-0 .2 mm . Then mount the compressor housing acording
                                                                          to the line-up 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 .                             radil


Cover
Check 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 Turbo-Compressor
10 .05 mm .                                                          Before fitting the turbo-compressor 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
                                                                                                                             turbo-compressor'sdtus.BlfaoeCrhinbdgvcy

Packing 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
                                                                                                                              instruco .
shape, and replace them with new ones where necsa
                                                                      Clean the air filter .
  ry.
FRESHWATER COOLING 2002, 2003
 1.    Fit the circulation pump (complete with tensioner bracket and spacer sleeve, position 4). Tighten the bolts (M8x75) to
       20 Nm (2,0 kpm) (14.7 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 sea-water pump, using
           double hose clamps (apply soapy water to the rubber rings, applies for all rubber rings) .
       b) Fit the pipe between the heat-exchanger and thermostat housing, position 7 .
       c) Fit the pipe between the heat-exchanger and the circulation pump, position 8 .
 3.    Locate the pipes in the heat-exchanger 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 heat-exchanger 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 V-belt .
 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 fresh-water 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 to(VPtheaccessory).  with
                                right level The   a mixture system
                                                fresh-water  of fresh water (50%
                                                                    volumes:  2002 =) and anti-freeze
                                                                                      4.0 dm2 (litre) (0.88
                                                                                                      (50%),   altematively
                                                                                                             Imp. gals) (1.1 rust-poecin 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
                                                (Standard)

INSTRUMENTPANEL
1.     Printed circuit card
2.     Rev counter (accessory)
3.     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
                                                                     Z




ENGINE
1.    Relay
2.    Fuse
3.    Temp . alarm sender
4.    Oil pressure alarm sender




Wire areas in mm 2

Wire area
mm 2             AWG
1,0              16
1,5              14
2,5              12
10                6



26
                                         Wiring diagram, alternative B
                                                    (De Luxe)




INSTRUMENT PANEL
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 blue




ENGINE
1.    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 TRACING

Engine   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
                                                                      system .

                  "                                                   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 sea-water
                                                                                                   manifold
                                                                      pump . Faulty thermostat . Cloged
                                                                          cooling water pipe in the
                                                                             head .                         cylinder
                                                                       1




9992265-0   Pulley puller




884813-7    Installation ring for piston




9995218-6   Mandrel for valve guide removal




884557-0    Mandrel for installation of injector sleeve




884559-6    Mandrel for installation of valve guide




884787-3    Setting-disc for injection pump setting




884811-1    Puller for injector sleeve




884823-6    Flaring tool for injector sleeve




884837-6    Flange for engine cradle




884838-4    Mandrel for installation of sealing ring in transmission
            cover



            Assembly and disassembly tool for camshaft pin
884839-2




884840-0    Guide pin for cylinder head . NOTE! Two are requid
               .
General
                                                                                                     TECHNICAL DATA
Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                            .. . . . . .. .                                              2001                 2002                       2003,2003T

Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                            1                     2                        3
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . .                                                                                                                     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)
Stroke . . . . . . .     .. . . .   . .   . . .. .. .   . .. . .. . . . .. .                                      .   .    .    .        .       .       .       .       . . . .             .       .   .   .   .              87 mm (3 .4252 in)
Compression              ratio      . .   . . .. .. .   . . . . .. . . . .. .                                     .   .    .    .        .       .       .       .       . . . .             .       .   .   .   .              17 .5 :1
Compression              ratio      at     starter       motor speed                                              .   .    .    .        .       .       .       .       .. . .              .       .   .   .   .              2-2 .5 MPa (20-25 kp/cm 2 )
Direction of rotation (seen from the front end)                                                                                         .       .       .       .         ... .             .       .                          Clockwise
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                            .       .       .       .         ... .             .       .                          13-14 r/'s (775-825 rpm)
Oil pressure at full speed and warm engine . . .                                                                                        .       .       .       .         . .. .            .       .                          0,35-0,40 MPa (3,5-4,0 kp/cm2)
Oil pressure at idling and warm engine . . . . . . .                                                                                    .       .       .       .        . .. .             .       .                          0,08-0,15 MPa (0,8-1,5 kp/cm 2 )

Cylinder block
Material . . . . . . . . . .        . . . .. . .. .      . . .   .    . .. .         .       .   .   .    .       .   .    .     . .. .                          . .. .                .     ..                                Special alloy cast iron
Cylinder diameter,                  standard             . ..    .   . .. .          .       .   .   .    .       .   .    .    . . . .                         . .. .                 .    . .                                79,00-79,03 (3 .11025-3 .11142 in .)
0,25 mm over-size .                 . . . ... .. .      . ..     .   . .. .          .       .   .   .    .       .   .    .    . . ..                          . .. .                 .    . .                                79,25-79,28 (3 .12008-3 .12126 in .)
0,50 mm over-size .                 . . . . .. .. .     . ..     .   . .. .          .       .   .   .    .       .   .   .     . . ..                          . .. .                 .    . .                                79,50-79,53 (3 .12992-3 .1311 in .)

Pistons
Material . . . . . . . . . . . . . . . . . . . . . . .               . .. . . . .. .                              .. . .                 .       .       .       .       .    . .       .    .       .                         Light-alloy
Total height . . . . . . . . . . . . . . . . . . . .                 . . . . . . .. .                             .. . .                 .       .       .       .       .     . .      .    .       .                         78,3 m m (3.08268 in .)
Height from gudgeon pin center                                       to piston                                    top                    .       .       .       .       .    . .       .    .       .                         50,3 mm (1 .98031 in .)
Piston clearance in cylinder . . . . .                               . .. . . . .. .                              .. . .                 .       .       .       .       .    . .       .    .       .                         0,09 mm ( .00354 in .)
Piston in standard dimension . . .                                   . .. . . . .. .                              .. . .                 .       .       .       .       .    . .       .    .       .                         78,903-78,)17 (3,10642-3,10697 in .)
0,25 mm over-size . . . . . . . . . . . . . .                        . .. . . . .. .                              .. . .                 .       .       .       .       .     . .      .    .       .                         79,153-79,167 (3,11626-3,11681 in .)
0,50 mm over-size....... . . . . . . .                               . .. . . . .. .                              .. . .                 .       .       .       .       .    . .       .    .       .                         79,403-79,417 (3,12610-3,12665 in .)


Gudgeon pins
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                             25,995-26,000 (1,02343-1,02362 in .)
Gudgeon pin bushing, diameter. . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                                                   26,005-26,011 (1,02382-1,02406 in .)
Clearance gudgeon pin - bushing . . . . . . . . . . . . . . . . . .                                                                                                                                                            0,0050-0 .0160 (0,00020-0,0063 in .)


Piston rings
Compression ring, number . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                                               2
Oil ring, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                                   1
The upper compression ring has an inlay of chrome .
The piston rings are available for standard dimension and
for 0,250 and 0,500 mm oversize (0,00984 and 0,0996)
in .)

Piston ring axial clearance in the groove
Upper compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                                          0,070-0,102 (0 .00276-0,00402 in .)
Lower compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                                          0,050-0,082 (0,00197-0,00323 in .)
Oil ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                        0,030-0,062 (0,00118-0,00244 in .)

Piston ring gap in the cylinder
Upper compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                                                  0,30-0,50 (0,001181--0,00197 in .)
Lower compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                                          0,30-0,50 (0,001181-0,00197 in .)
Oil ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                                                                                        0,25-0,50 :0,009842-0,00197 in .)


Crankshaft

Material . . . . . . . . . . . . . . . . . . . . . . . .             .   .   .   .       .    . .     .       .    . .      .       .       .       .       .        .    .    .   .    .       .                             Nodular iron
Crankshaft axial clearance . . . . . . .                             .   .   .   .       .     . .    .       .     . .     .       .       .       .       .        .    .    .   .    .       .                             0,040-0,221 (0,00157-0,00870 in .)
Main bearing radial clearance . . . .                                .   .   .   .       .    . .     .       .    . .      .       .       .       .       .        .    .    .   .    .       .                             0,040-0,092 (0,00157-0,00362 in .)
Big-end bearing, radial clearance .                                  .   .   .   .       .     . .    .       .    . .      .       .       .       .       .        .    .    .   .    .       .                             0,024-0,068 (0,00094-0 .00268 in .)
1 Propeller shaft output in accordance with DIN 6270B .
Main bearing journals
Diameter, standard                                                                                                                                 59,987-60,000 (2,36169-2,36220 in .)
0,250 m m under-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                               . . .               59,737-59,750 (2,35185-2,35236 in .)
0,500 mm under-size- . . . . . . . . . . . . .                                                                                                     59,487-59,500 (2,34200-2,34252 in .)

Main bearing shells
Thickness, standard - - . -        .. .. . .. . . . . . . .. .. . . .. .. . . ..                                                                   2,987-2,997 (0,11760-0,11799 in .)
0,250 mm over-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                           3,112-3,122 (0,12252-0,12291 in .)
0,500 mm over-size - - . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -                                                             3,237-3,247 (0,12744-0,12783 in .)

Big-end journals
Diameter, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                        47,989-48,000 (1,88933-1,88976 in .)
0,250 mm aver-size ---                                                     . . .. . .. .                                                          47,739-47 .750 (1,87949-1,87992 in .)
0,500 m m over-size .- .-- . .- . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                             47,489-47,500 (1,86965-1,87008 in .)

Big-end bearing shells

Thickness, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                         1,478-1,488 (0,05819-0,05858 in .)
0,250 mm over-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                          1,603-1,613 (0,06311-0,06350 in .)
0,500 mm over-size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                          1,728-1,738 (0,06803-0,06843 in .)

Connecting rods
Axial clearance at the crankshaft . . . . . . . . . . . . . . . . . . . . . . .                                                                   0,15-0,35 mm (0,00590-0,01378 in .)

Camshaft
Axial clearance . . . . . . . . . . . . .         .   .   .    . .. . . .     . . . .. .. .. .. . . . . .                       . .               0,160-0,300 mm (0,0063-0,01181 in .)
Radial clearance in bearings                      .   .   .    . .. . . .     . . .                                                               0,020-0,075 mm (0,000787-0,00295 in .)
Camshaft diameter . . . . . . . . .               .   .   .    . .. . . .     . . . .. .. .. .. . . . . .                       . .               46,975-47,000 (1,8494-1,85039 in .)
Lifting height of cams . . . . . .                .   .   .   . . .---        .---------- . . .--                               . .               5,48-5,52 mm (0,21575-0,21732 in .)
Bushing diameter . . . . . . . . . .              .   .   .    .. . . . .     . . .------------ .                               . .               47,02-47,05 mm (1,85118-1,85236 in .)

Cylinder head
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                              Special alloy cast iron

Inlet valves                                                                                                                                                                    20031
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                         34,4-34,6 mm (1,35433-1 .36220 in .)    35,8-36,0 mm
Stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                           7,955x7,970 mm (0,31319-0,31378 in .)   7,995-7,970 mm
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                            4455'-44  85'                         2945'--30 15'
Cylinder head seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                    45                                     30
Seat width in the cylinder head . . . . . . . . . . . . . . . . . . . . . . . .                                                         appr . 1 mm (0,03)37 in .)              appr . 1 mm !0 .03)37 in .
Clearance, cold/warm engine . . . . . . . . . . . . . . . . . . . . . . . . . .                                                         0,3 mm (0,011811 in .)                  0 .3 mm (0,011811 in .)


Exhaust valves
Disc diameter . . . . . . . . . . ---- . . . . . . .                  .   .   .   .
                                                                                 . .. .   .   .   .   .
                                                                                                  .. ..                . . . .                    29,9-30,1 mm (1,14716-1,18504 in .)
Stem diameter . . . . . . . . . . . . . . . . . . . .                 .   .   .   .
                                                                                . ..  .   .   .   .   .
                                                                                                  .. ..                . . . .                    7,950-7,465 mm (0 .31299-0,31339 in .)
Valve seat angle . . . . . . . . . . . . . . . . . .                  .   .   .   .
                                                                                 . .. .   .   .   .   .
                                                                                                  .. ..                . . . .                                             45'-8
Cylinder head seat angle - . . - . . . . . .                          .   .   .   .
                                                                                 . .. .   .   .   .   .
                                                                                                  .. ..                                           45 
Seat width-in the cylinder head . -- .                                .   .   .   .
                                                                                 . . ..   .   .   .
                                                                                                 ... . .               . . . .                    appr . 1 mm (0,03937 in .)
Clearance, cold/warm engine ----- .                                    . .. . . . . .      . . . .-- . .                .---                      0,3 mm (0,011811 in .)


Valve guides
Length, inlet valve . . . . . . . . . .               . . .. . . . .. . . . . .            . ..       .   .   .   . . .    .    .   .             38 mm (1,49606 in .)
Length, outlet valve . . . . . . . . .                . . .. . . . .. . . . . .           . ..        .   .   .   . . .    .    .   .             38 mm (1,49606 i n.)
Inner diameter ------------ . .                       . . .. . . . .. . . . . .           . ..        .   .   .   . . .    .    .   .             8,000-8,015 (0,31496-0,31555 in .)
Height above spring-plane of                          cylinder head .                      . ..       .   .   .    . . .   .    .   .             8,70-9,30 mm (0,34252-0,36614 in .)


Valve springs
Length, unloaded . . . . . . . . . . . . . . . . .. . . . . .. .. .. .. .. .. .                                                                   42,5 mm (1,67323 in .)
Loaded with 17010 N (171 kp) . . . . . . . . . . . . . . . . . . . . . .                                                                        32 mm (1 .25984 in .)
Loaded with 30020 N (302 kp) . . . . . . . . . . . . . . . . . . . . . .                                                                        24 mm (0,94488 in .)
Lubricating system
ENGINE
Oil quantity model 2001 .                                . . . . .               .                      .. . . . . .                  1,40 dm 3 (1 .2 quarts)
Oil quantity model 2002 . . . . . . . . .                                                                                             2 .75 dm 3 (2 .42 quarts)
Oil quantity model 2003 . . . . . . . . . . . . . . . .                          ... ..                                      .        4,10 dm 3 (3.6 quarts)
Oil quality according to the API-system                                                                                               CD (DS)
Viscosity . . . . . . . . . . . . .                .. . . .                                    .                                      15 W/40
Oil pressure, warm engine,          . .. .. .. . .
                                           idling speed .                        .. ... . . . .. . .. . .                             0,8-1,5 kp/cm2 (11 .37-21 .33 lbft/in2 )
Oil pressure, warm engine, full rpm . . . . .                                    .. ... . . . .. . .. . .                             3,5-4,0 kp/cm 2 (49 .78-56 .89 lbft/in 2 )


Lubricating oil pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .         .. .. . . . . ....                             Gearwheel pump
Gear wheel axial clearance . . . . . . . . . . . . . . . .                             .. .. .. . . ....                              0,025-0,065 (0,00098-0,00256 in .)
Spring for reduction valve, length unloaded                                            .. .. .. . . .. ..                             49 mm (1,92913 in .)
Loaded with 35 Nm (3,5 kp) (25 .8 ft .lbs .) . . . .                                   .. .. .. .. .. ..                              40 mm (1,57480 in .)


Fuel System
Opening pressure . injectors . . . . . . .                    .    .   .    .. ... . .     .. .. .. . . ...                           180-190 kp/cm 2 (2560-2702 lbft/in2)1)
Spray angle . . . . . . . . . . . . . __ . . . . .            .    .   .    .. . . .. .    . .. . . . . . .. .                        150
Injection angle 2001 . . . . . . . . . . . . .                 .   .   .    .. . .                                                    221    B .T .D .C
Injection angle 2002, 2003 . . . . . . . .                     .   .    .   . . . ....     . .. . .. . . . ..                         20+1C B.T .D-C .
Injection angle 2003T . . . . . . . . . . .                   .    .    .    . . . . . .   . . . . . . . ..                           231 B.T .D .C .
Injection quantity . . . . . . .                                                            .. . . .. . .. ..                         25+1 .5 mm3/stroke at 405C (104F10 .6F)
                                                                                                                                      and at 25 r/s (1500 rpm) pump revs
Governor overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                            54 r/s (3250 rpm)


Feed pump
Feed pressure 42 r/s (2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                 0,65-0,85 kp/cm 2 (9 .20-12 .10 lbf/in 2 )

Electrical system
Battery voltage . . . . . . . . . . . . . . . . . . . . . .                 .. . . .. .. .. .. . . .. ..                              12V
Battery capacity . . . . . . . . . . . . . . . . . . . . .                  . .. .. .. ... : .. . . . .. . ..                         Max. 70 Ah
Starter-motor output 2001 . . . . . . . . . . .                             . . . .. .. . .. . .. . -                                 0.8 kW !1 .1 H P)
Starter-motor output 2002 and 2003 . .                                      . . . .. ... .. . .. . .. .. . ..                         1 .4 kW (1 .9 HP)
Alternator output :
 Voltage/max. current . . . . . . . . . . . . . . .                         .. . ... ..     .   .   .    .   .   .   .   .    .   .   14W50 Amp
 Output . . . . . . . . . . . . . . . . . . . . . . . . . . . .             .. . ... ..     .   .   .    .   .   .   .   .    .   .   700 Watts
Electrolyte spec. gravity : Fully loaded                                     battery .      .   .   .    .   .   .   .   .    .   .   1,275--1,285
 To be charged at . . . . . . . . . . . . . . . . . . .                     . . . .. ...    .   .   .    .   .   .   .   .    .   .   1,230
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . .                .. . .. . ..    .   .   .    .   .   .   .   .    .   .   Wax thermostat
Begins to open at . . . . . . . . . . . . . . . . . . .                     . . . .. ...    .   .   .   .    .   .   .   .   .    .   602`C (1404F)
Fully open at . . . . . . . . . . . . . . . . . . . . . . . .               . . . ... ..    .   .   .   .    .   .   .   .    .   .   75'C {165  F1


Cooling system
With fresh-water cooling (2002, 2003)
Starts opening at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                     741C (1642F)
Fully open at . . . . . . . . . . . . . . . . . . . . . . . .                   . . . . . .. ..                                       87C (189  F)
Fresh-water system, volume 2002 . . . . . . . . . . . . . . . . . . . . . . . . .                                                     4.0 dm 3 litre) (0 .88 Imp . gals) (1 .1 US gals)
                                           2003_____                                                                                  5.5 dm 3 (litre) 11 .2 Imp . gals) (1 .45 US gals)

WEAR TOLERANCES
Cylinders
To be bored at 0,25 mm wear (0,00984 in .)

Crankshaft
Main- and big-end journals :
Permitted out-of-round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                                0,06 mm (0,00236 in-)
Permitted taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .                                         0,05 mm (0,00197 in .)
Max . axial clearance on crankshaft . . . . . . . . . . . . . . . . . . . . .                                                         0,40 mm (0,01575 in .)
1) 2003T = 204-212 kp/cm2 (2900--3015 lbf/in 2 )
Camshaft
Bearing journals, permitted out-of-round . . . . . . . . . . . . . . .                                                            0,03 mm (0,00118 in .)
Max . clearance between camshaft and bushings . . . . . . . .                                                                     0,15 mm (0,00590 in .)

Valves
Max . clearance between valve stem and valve guide . . . .                                                                        0,15 mm (0,00590 in .)
The valve disc edge must be at least                                                                                              1,5 mm (0,05906 in .)


Tightening torques
Main bearing bolts, 1st tightening . .                           . .    . .    . .   . ..    .   . .    .   . .   .   .   . ..    20   Nm   (2,0    kpm)   (14 .7   ft .lbs .)
                               2nd tightening . .                 ..     ..     ..    ...    .    ..    .  . .    .   .   . ..    60   Nm   (6,0    kpm)   (44 .2   ft .lbs .)
Big-end bearing bolts . . . . . . . . . . . . .                  . .     . .   . .   . ..    .   . .    .   . .   .   .   . ..    70   Nm   (7,0    kpm)   {51 .6   ft .lbs .)
Flywheel housing bolts . . . . . . . . . . . .                   . .     . .   ..    . ..    .   . .    .   . .   .   .    ...    25   Nm   (2,5    kpm)   (18 .4   ft .lbs .)
Flywheel bolts . . . . . . . . . . . . . . . . . . . .           . .     . .   . .   . ..    .   . .    .   . .   .   .   ...     65   Nm   (6,5    kpm)   (47 .)   ft .lbs .)
Cylinder head bolts, 1st tightening .                            . .     . .   ..    . ..    .   . .    .   ..    .   .    ...    20   Nm   (2,0    kpm)   (14 .7   ft .lbs .)
                                  2nd tightening                 . .     . .    ..   . ..    .   . .    .   . .   .   .    ...    70   Nm   (7,0    kpm)   (51 .6   ft .lbs .)
Rocker arm bridge . . . . . . . . . . . . . . . .                . .     . .   ..    . ..    .   . .    .   . .   .   .    ...    25   Nm   (2,5    kpm)   (18 .4   ft .lbs .)
Fuel injection pumps . . . . . . . . . . . . . .                 . .     . .    ..   . ..    .    . .    . ..     .   .    ...    25   Nm   (2,5    kpm)   (18 .4   ft .lbs .)
Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . .    . .    . .    ..    . ..   .    . .    ...      .   .    .. .   40   Nm   {4 ,0   kpm)   (29 .5   ft .lbs .)
Injectors . . . . . . . . . . . . . . . . . . .                                          .   .    . .    . . .    .               20   Nm   (2,0    kpm)   (14 .7   ft.lbs.)


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