Volvo Penta 2002 Workshop Manual

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Publ nr 77309748 41990WORKSHOP MANUAL VOLVO workshop manual contains repair instructions for the 2001 2002 and 2003 enginesThe instructions concerning overhauling describe the most suitable working method using the special tools listed underthe heading Special tools Both the engine designation and its serial number must be clearly stated in all correspondence concerning the engine andwhen ordering partsWe reserve the right to carry out design modifications and for this reason the contents of this manual cannot be regarded asbinding AB VOLVO PENTA Technical Publications DepartmentSI UNIT SYSTEMUnits according to the international SI system have been used in this book The earlier units are given after the SI units Power is given in kW kilowatt Speed is given in revs revolutions per second earlier unit hp horsepower earlier unit revmin revolutions per minuteTorque 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 gallonPressure is given in Pa Pascal earlier unit kpcm 2 kiloponds per square centimetre earlier unit Ibfin 2 pounds per square inch guide head 3Transmission 4Piston piston rods 5Flywheel 5Crankshaft 5Camshaft the cylinder head 7Valve guides 7Valve seats 7Valves 7Valve springs 8Rocker arm mechanism 8Injector sleeve 8Injectors 8Assembling the cylinder head 9Feedpump 10Pistons 11Crankshaft 11Camshaft 11Connecting rods 12Thermostat 13Seawater pump 14Pistons 14Flywheel 15Transmission 15Adjusting the valve clearance 17Checking the injection angle 172003 Turbo 21Fresh water cooling 25Electrical system 26Fault tracing scheme 28Special tools 29Technical Data 30COMPONENTS GUIDE 1 Exhaust elbow 2 Injectors 3 Temperature sender8 4 Electrical distribution box 5 Fuel filter 6 Alternator 7 Starter motor 8 Drainage cooling water 9 Feedpump 10 Engine serial number 11 Decompression device 12 Inlet air silencer 13 Fuel injection pumps 14 Oil dipstick 15 Seawater pump off the cooling water and the lubricating oil from theon engine cradle pn 9992520 and fixture pn 884837 If theengine is fresh water cooled see page 21 3 Remove the fuel filter the oil filter the feedpump the thermostat housing and the exhaust elbow Also remove the seawater pump with its attachment tubes 1 Remove the alternator the tensioner bracket and thestarter motor Remove the connections from the box from the engine and remove the box andthe 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 inthe lever of the decompression device 1 and pull out the hcTNyOleiEndra pboelhts aidnmouts aswcbilethnd lbrushlever Remove the valve cover 7 Remove the transmission cover Start by removing the throttle control cover Use a suitable type of pliers to the spring 1 Then remove the endnipple 2 and remov the spring 3 Remove the oil pump cover and mark the gear wheels with a colourpen before removing them When installing the gear wheels the marked side must be facing outwards Remove the bracing pin of the camshaft using the special tool 884839 Never remove the pin by punching pnit out this can very well bend bracing the5 Remove the fuel injection pumps Mark the pumps to camshaft Remove the screws on the transmission coverensure installation in the same cylinders from which they and pull it straight outwards were removed Take care of the shims Remove the screwson the side of the engine block and lift out the pump lifters 8 The max volumescrew 1 and the max revscrew 2 are set by Volvo Penta and must never be changed since this will affect the engine output 6 Remove the pulley center bolt and pull off the pulleyusing puller pn 9992265 Place a protection pad between 9 Remove the control rod Start by removing the plug atthe puller and the crankshaft to avoid the crankshaft being the rearof the block and thetwo screws on the pump planedamaged 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 thethe 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 capsare marked with a figure The corresponding figure is into the block Lift out the crankshaft On later engine an arrow is cast in the separate main bearing caps2002 2003 The arrow is to point towards the dipstick 3 Use mandrel pn 5218 to press out the valve guides Oil the new valve guides externally and use mandrel pn 884559 to install them Press down the mandrel all the way down to the cylinder head Ream the valve guides if necsaryTHE CYLINDER HEAD1 Remove the collets and valve springs using a valvebow Remove the valves Remove the valve stem seals Place the valves in the proper sequence in a valvestand Valve seats and valves 4 Mill or ream the valve seats The angle C should be 45 for 2003T 30 for the inlet valve The sealing surfaces widthValve 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 If2 Check the valve guide wear by inserting anew valve stem the disc thickness after grinding is less than 1 0 mm 0 039 ininto the guide Measure the play using a dial indicator Ifnecessary replace the valve guides for naturally aspirated engines or 0 8 mm in for 0031 engines the valves must be scrapped Valves with limits Inlet valve max play 0 15 mm 00059 in bent stems or if the measurement A exceeds 2 5 mm 0 098 in must also be scrapped Grind the valve tip towards theExhaust valve max play 0 15 mm 0 0059 in rockers if necessary Lap in the valves using valve grinding paste and check the contact area with marking dye Rocker arm mechanism 6 Disassemble the rocker arm mechanism and clean the parts Check the wear of the shaft and rockerarm bushings Should the bushings need to be replaced usethe mandrel pn 9991867 for the removal and installation make sureReplacing the valve seat exhaust port 2003T that the oil hole in the bushing coincides with the one in theGrind down the valve disc of a discarded valve to just below rocker arm After the installation the bushings are reamed27 mm 1 063 in diameter Push the valve stem through the to a close running fit When installing the rockerarm shaftguide NOTE Do not push in too far the valve disc should be it must be turned so that the lubrication holes are facing thejust below the edge of the seat Spot weld the disc in place at valveside Check to make sure that the rocker arm contactthree points using a electric welder Knockout the seat by surface againstthe valve is concave Minor adjustments are the valve guide with a plasticheaded hammer hitng made in a valve grinding machine Oil the shaft and installCool the new seat to approx 20C 4F the cylinder the parts head should beat room temperature 200168F Place thecooled seat on tool 8849614 and knock it downtowards until it NOTE Turn the seat with the valve face botms thetool Pressure testing the nozzles 7 Check the nozzles spray pattern at the correct opening pressure see Technical Data Check also that the fuel sprays stop simultaneously and no dripping occurs Valve springs Adjust the with 15 Checkthe free length of the valve springs and the length being available in different thicknesses from 1 mm U3937when loaded in to 195 mm 076772 in in steps of 005 mm 001969L Length unloaded 425 mm 1 67323 in in Disassemble the injector and replace the 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 and 0 94488 in the spraypattern Insert the expanding screw on the special tool pn 10 Oil theflaretool pn 884283 and insert it intothe sleeve884811 into the copper sleeve and turn the screw make sure that the dowel is properly retracted Brace the Tighten tool with the injector yoke Screw down the flaretool as farthe screw hard to allow the threads to work themselves as the shoulder in the injector sleeve allows therebyinto the copper material Then install the yoke 1 on the flaring the sleeve Remove the tool Adjust the length of thestud bolt of the injector Put a cylinder head screw in the sleeve outside the plane of the cylinder head to head as a supportforthe leg of the yoke Install the 1 mm 03937 in nut 2 and tighten it until the sleeve is removed Assembling the cylinder head 11 Clean the cylinder head If the water distribution pipe has been disassembled it must be installed with the holes9 Replace the Oring sealing off between the sleeve and turned as indicated in the picture Install new valve stemthe cylinder head Dip the new Oring in soapwater 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 theirand install it using special tool pn 884557 Knock down the respective original positions Install the valve springs andsleeve until it bottoms the collets Use a valvebow Changing the diaphragm 14 Remove the six screws holding the upper and lowerReduction valve pump housings together Remove the pump lever spring12 Remove the cover of the reduction valve and check to 1 and remove the screw 2 holding the pump levermake sure that the spring and the piston are faultless If shaft there are reasons to suspect a fault in the opening pressureof the reduction valve then check the data of the spring See under Technical Data reduction valve Feedpump13 Depress the pump lever if the diaphragm of the pump 15 Use a suitable pair of pliers and removethe pump leversounds 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 wornparts Install the diaphragm and the lever on the shaft Then insert the shaft and tighten it with diaphrgm thescrew Assemble the two housing halves and install theattachment plate 1 Then install the spring 2 and the Oring 3Valve lifters17 Check the valve lifters for wear Replace them if necessary Crankshaft 20 Remove the gear wheel Use a prong puller Clean the crankshaft Measure the crankand main bearing pins The eccentricity must not exceed 006 mm 002362 in and the taper 0 05 mm 001969 in Should these values be excdCamshaft the crankshaft must be ground to a suitable Check the camshaft for wear on cams and bearing races Also check the wear of the bearings The bearings arepressed into their locations and must be line bored afterthe installation Pistons cylinders21 Check the wear on pistons piston rings and gudgeonpins Replace these if necessary Use a cylinder indicatorgauge to measure the cylinder bores The measurement ofthe biggest wear is made immediately beneath the edge ofthe upper dead center and crosswise the engine The measurement of the smallest wear is made at the lower dead 24 Use piston ring pliers to install the piston rings Thecenter As to the cylinder diameter see Technical Data marking of the rings TOP or the mark of the a micrometer to measure the pistons Piston diameter must be turned upwards The height of the upper comsee under Technical Data pression ring 175 mm 068898 in The height of the compression ring 200 mm 07874 in Turn the lower rings so that the gaps are turned 120 from each piston other22 Inserta new piston ring into the cylinderand measurethe piston ring gap As to the measurement see underTechnical Data If necessary increase the gap using aspecial file Connecting rods23 Measure the clearance of the piston rings in the piston 25 Check the connecting rods for straightness andring grooves Regarding the measurement see under Data 26 Check the connecting rod bushings by using the pin as a gauge There must be no play If the bushings 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 pump27 The pump is equipped with two ballbearings 1 When disassembling remove the lockingring 2 in thehousing and push out the shaft whereby the bearings arefollowing Use a suitable mandrel to remove the bearingsfrom the shaft NOTE Do not forget the spacer sleeve 3Replace the sealings 4 NOTE Turn the sealings correctlyand make sure that they do not block the drainage hole inthe pumphousing Replace the 5 Install the Oring ostlpheacvrn lastnhdef veadistance of 395 mm 1 55512 in from the shaft end to theballbearing Coat the shaft with grease and screw itthrough the sealings and the Oring and take care not todamage them Push in the shaft as far as to allow thebearings to bottom and then install the lockingring 2Checking the thermostats28 Immerse the thermostat in water and using a check if it opens at the correct temperature thermo SeeTechnical Data foropening temperatures If the thermostat isfaulty it must be replaced ASSEMBLYAlways use new gaskets sealing rings sealing washersand lockwashers Coat the sealings with grease or oilthem and also oil all moving parts prior to installing them If the engine is freshwater cooled see page 21 3 Turn the piston rings so that the gaps are offset in relation1 Heat the crankshaft gearwheel to approx 150C 302 F to each other The piston crown is marked with an arrow thatprior to the installation Place the key in the keyway of the points towards the belt pulley Use installation ring 8848137 crankshaft and press on the gear wheel Oil the new main Fit the caps with the marking aligned with the halves with oil hole and install them in the block marking The crankshaft can be turned in any directionPut in the crankshaft NOTE The main bearing shell at the towards the piston flywheel also functions as a thrustbearing Tightening torques Step 1 25 Nm 2 5 kpm 18 ftlb Step 2 70 Nm 7 0 kpm 53 ftlb2 Oil the cap bearing halves and install them Install the 4 Install the main bearing halves in the oil pan and coatcaps in accordance with the marking in the block 2001 has the edge of the oil pan with thin layer of sealing pn 840879 Install the oil pan and tighten the oilcompund panno intermediate bearing If an arrow is cast it shall pointtowards the oil dipstick Tightening torque for the main screws and the main bearing screws alternatingly to 20 Nmbearings 1st tightening 20 N m 2 kpm 14 7 ft lb 2nd 20 kpm 147 ft lbs and then the main bearing screws totightening 60 Nm 6 kpm 44 2 ft lbs Turn the engine 60 Nm 60 kpm 44 2 ft lbs 5 Replace the flywheel housing sealing 1 Smear sealing 7A Heat the camshaft gear wheel to a temperature ofcompound pn 840879 on the edge between the flywheel approx 150C 302F and use a suitable sleeve to install it housing and the sealing NOTE The sealing lip with a Check to make sure that the gear wheel bottoms on thespring shall be turned towards the engine Make sure that camshaft Install the camshaft and make sure that thethe 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 thepncamshaft 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 Oring in the oil channel in the block 3 fig 7A Use a new gasket and install the timing gear cover Place the pressure sleeve with the bearing towards the pressure washer in the control arm lever Hold the sleeve in place by pressing the lever to its bottom position where the sleeve is pressed against the housing Install the pin of the camshaft using special tool 884839 The pin must6 Replace the Orings and install the flywheel housing pn equally much on both sides Under no circumstances torque 25 Nm 25 kpm 18 4 ft lbs are you to use a hammer or some such tool to punch theInstall the flywheel Tightening torque 65 Nm 65 kpm pin into its location with the aid of a mandrel The camshaft48 0 ftlbs will then be bent 8 Insert the control rod through the black and into the timinggear casing Install the bearing ball 1 into the control rod andpush 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 botmswith copper sealing washers that guide the control rod Then screw the lower bolts that hold the control rod in placein the engine block NOTE The lower bolts should not havesealing washers Apply Permatex to the threads Check thatthe control rod moves freely 10 Insert the key for the pulley in the crankshaft and install the pulley Tightening torque 40 Nm 40 kpm 29 5 ft Ibs 11 Clean the valve lifters carefully and coa t the contact surf ace against the camshaft with molybdenum disulphe Oil the valve guides in the block and install the lifters Clean the roller lifters of the fuel injection pumps and then in the block Lock the roller lifters with screws 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 20019 Install the oil pumps gearwheel according to the marksfrom the disassembly Insert a new Oring in the timinggear cover Oil the gear wheel and fit The cover using a new Regarding the installation of the cylinder head seethesealing ring page folwing 14 Valve clearance coldwarm engine 0 30 mm 01181 in Turn the engine in the direction of rotation until the valves in one cylinder are rocking Then turn the engine one turn more and the valves for this cylinder the procedure adjust for the remaining cylinders Repat200312 Tighten the two guide screws pn 884840 in the blockand install the cylinder head gasket with the markingTop facing upwards Install the cylinder head Make sure that the contact surface for the cylinder headbolts are free from paint Should there be paint on thebolts there is always the risk of having an insufficiert force in the bolt joint with subsequent leakagestighen as aresult NOTE The bolts are phospated therefore do notclean them with a steelbrush Coat the cylinder head bolts with molybdenum disulphideand tighten them in accordance with the diagram first to20 Nm 2 0 kpm147 ft lbs and then to 70 Nm 7 0 kpm516ftlbs Adjusting the fuel injection pump location with shims 15 if the same block camshaft and fuel Injection pumps are used when assembling the fuel injection pump must be installed in their original positions and with the same shim thickness as earlier The so called soft shims always being installed against the block must be replaced against new ones Carefully clean the contact surfaces between the block and the fuel injection pumps and install shims with thickness equal to the sum of the marking on the block and that on the fuel injection pump 4 earlier marking Example The block marking 4 4 tenths of a millimeter 015748 in The pump marking 4 4 tenths of a millimeter 015748 in Total amount of shims 0 8 mm 031496 in In this case select two soft shims 0 2 and 0 3 mm 011811 in Place the hard shim between the two soft ones and install the pump NOTE Never install a hard shim together with another hard shim or against the block or the fuel pump Hard shims are available in thicknesses 03 injecto13 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 mmsame time as the rocker arm bridge 007874 and 011811 in On later version engines an Oring has been introduced as aseal between the injection pump and the block Only socalledhard shims may be used on these engines when shimming Hard shims are available in thicknesses of 0 2 mm 0 0079 in0 3 mm 0 0118 in 0 6 mm 0 0024 in and 09 mm 0 0354 in 16 New block or camshaft settingdisc pin 2 comes in the largest of the four holes in the pulley If the block or the camshaft are replaced the block must be Press in the guide pin 2 so that the disc is centered andmeasured and marked using the settingdisc pn 884787 tighten the bolts and a sliding caliper The settingdisc is marked for each respective cylinder A The settingdisc consists of two rings an inner and an Marking Denotesouter The inner ring determines the injection angle foreach respective engine type see Technical Data page 25 Cylinder 1 Cylinder 1 1 2 3 cylinder engines The injection angle is stamped in degrees and is fixed with Cylinder 22 Cylinder 2 2 cylinder enginea pin 1 Cylinder 23 Cylinder 2 3 cylinder engineB Mount the settingdisc or the pulley with two bolts do Cylinder 33 Cylinder 3 3 cylinder enginenot tighten the bolts Turn the so that the guide 17 Fit the injection pumps together with the calculated shim thickness Turn the engine so that the cam for theC Turn cylinder no 1 to its injection position Place the pump is not in the lifting position Check that the pumpsguide pin 2 in the settingdiscs hole marked cyl 1 Turn pin locates in the control rods groove and that the pumpsthe 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 settingdiscs guide pin 2 goes in the timing covers hole Tightening torque for the nuts is 20 Nm 20 kpm 147Measure using a caliper the distance between the cylinder ftlbs Connect the fuel pipe between the pumps and theblock and the roller lifters edge do not measure on the pipe from the fuel filter to the injection pump NOTE Theroller hole bolt for the return hose has a smaller throughflow channel than the others on later versions it is markedThe distance should be Out 2001 55 8 mm 21 9685 in2002 2003 556 mm 2 18504 in2003T 55 9 mm 2 2007 inExample 2001 If the measured distance is 55 2 mm 2 17323 in thismeans that a shim with thickness 0 6 mm 0 02362 in is tobe placed between the caliper and the block 2002 2003 If the measured distance is 55 0 mm 2 16535in this means that a shim with thickness 06 mm 0 02362in is to be placed between the caliper and the blockThe measured shims thickness in this example 0 6 mm isto be stamped into the block as in fig 15The total shim thickness is found by adding the and the pumps marking ExampleThe blocks measurements 6 0 6 mm002362 inThe pumps marking 2 0 2 mm0007874 inNo of shims 0 8 mmIn this case choose two soft shims 0 2 and 0 3 mm0 007874 and 0 011811 in and one hard shim of 0 3 mm0 011811 in Place the hard shim between the two softones and refit the pump NOTE A hard shim must never befitted together with another hard shim or directly againstthe block or pump Hard shims are available in thicknesses 0 3 0 6 and 0 9 mm0 011811 0 02362 and 0 035433 in Soft shims are available in thicknesses 0 2 and 0 3 mm0007874 and 0 011811 in 18 Install thefeed pump and thefuel filter Also install the thermostat housing with the thermostat NOTE Do notD Repeat the procedure for the other pumps 2002 2003 forget the lifting eyelet between the fuel filter and thein the same way as for cylinder 1 housing thermosaThe settingdiscs 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 seawater pump and the cooling water pies20 Install the injectors and the return fuel pipe Tightening 22 Install the starter motor the alternator and thetorque for the injectors 20 Nm 20 kpm 147 ft lbs Also alterno and Vbelt Also install the electrical distribution boxinstall the exhaust elbow and the water pipe between the hookup the cable harness thermostat housing and the exhaust elbow 2003T Where there is an excessive amount of smoke in the ilptoawrcuy ma be that the is not functioning properly If the boats speed through the water is gradually decrasing the boats bottom should also be inspected and cleaned where necessary Check that the air intake has not become clogged and clean the intake silender Inspecting the Seals joints between the turbine housing and the Check thebearing housing and between the compressor compres bearing housing and the compressor housing Checks Check the preinjection angle the injectors opening and the spray pattern The valve clearance and presu should also be checked compresin23 Fill up with lubricating oil to the correct level Regardin quantity and quality see under Technical Data Checking axial and radial clearance Dismount the from the engine and measure the rotor units axial and radial clearance Maximum permissible axial clearance 0 09 mm24 Venting the fuel systemA Open the venting screw on the fuel filter approx 4 turns Watch out for fuelsplashes B Use the handpump to pump fuel until fuel free from airbubbles 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 Positnturn the engine with the starter motor until fuel comes outof the fuel pressure pipes Tighten the fuel pressure pipenuts Maximum permissible radial clearance 0 17 mm If wear and tear has reached the maximum permissible the should be reconditioned or replaced lineup marks between the turbine housing the Dismantle the turbine shaft 4 and the heat shield If thebearing housing and the compressor housing Dismantle turbine shaft sticks tap the end gently with a woodenthe compressor housing 1 Unscrew the lefthand Unfasten the three screws which hold the cover hamer 3threaded nut which holds the compressor wheel using and screw two M5 screws into the cover Then lift it up dollies on the turbine shaft Remove the compressor wheel Take the oil deflector 7 out of the cover 2 and dismantle the turbine housing 3 Compressor Housing Turbine Housing Check that the housings are free from cracks or other caused by excessive wear and tear Damaged damge parts should be replaced Heat Shield Check that the heat shield is free from damage caused by wear and tear heat or corrosion and replace it if necsary Bushing Oil Deflector the four screws which hold the compression Bearingbearing 8 Using a small copper mandrel tap out thecompression bearing and the bushing 9 Then remove Check that the parts are free from wear and tear andthe circlips 10 inside the bearing housing and remove the Damaged parts should be replaced even if discoluratn thetwo bearings 11 amount of wear and tear is within the permitted the packing ring 12 on the turbine shaft and thetwo packing rings 13 on the oil deflector Clean the partscarefully Measuring and Wheel and ShaftCheck that the turbine wheel and shaft are free from damage The vanes must not be worn or out mechanil ofshape Do not try to realign the vanes Damaged partsshould be replaced Bushing Check measurement A which should not be less than 407 mm Oil Deflector Check measurements B and C B should not be more than 1 31 mm C should not be more than 1 11 mm Compressor Bearing Check the width of the bearing and replace it if the amount of wear and tear is in excess of the permitted tolerance Minimum permissible width is 398 mm Place the shaft on two supports which should be under thebearing recesses and check the throw at the end of the Bearingsshaft The maximum permissible throw is 0 011 mm Check the bearings for abnormal wear and tear orCheck the diameter of the shaft bearing recesses The is 798 etCnhcksary e permissible diameter mm Check the width minu of internal and external diameters of all bearings The extrnalthe shaft piston ring groove Maximum permissible width diameter should not be less than 12 31 mm the internalis 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 Nm01 Tighten the screws to the above torque then loosen them a quarter turn before tightening them up to the correct torque again Position the two packing rings on the oil deflector NOTE The opening in the inner ring should be facing the oil that in the outer ring should be facing the oil intake 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 10 2 mm Check the housing for corrosion or cracks Check Fitthe cover on the bearing housing and fasten itwith new D and E and replace the housing where more than measurnt necsary screws and washers The torque should be 1 3 Nm0 1 Measurement D should not be 12 42 mmmeasurement E should not be more than 15 05 mm Tighten the screws to the above torque then loosen them a quarter turn before tightening them up to the correct torque again Position the compressor wheel on the turbine shaft and fasten it with the lefthand thread nut The torque should be 2 0 Nm0 1 Mount the turbine housing on the bearing housing acording to the lineup marks Screw the locking cover into making sure that the screws used are not those positn for the compressor housing The torque should be 11 0 Nm0 5 M6 26 010 M8 Smear the edges of the bearing housing where it comes in touch with the compressor housing using Permatex for the purpose The thickness of the sealant should be about 0 10 2 mm Then mount the compressor housing acording to the lineup marks and screw the locking cover into position The torque should be 4 5 Nm0 5 Check the axial and radial clearance Maximum permisbl axial clearance is 0 09 mm maximum permissible clearance is 0 17 mm measurements F and G and replace the coverwhere necessary Measurement F should not be morethan 12 45 mm measurement G should not be more than Fitting the 05 mm Before fitting the on the engine spray clean engine oil into the oil intake and turn the turbine shaft so that the oil is evenly distributed Clean the Rings correct quality of oil see under Technical Data OilCheck 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 ryFRESHWATER COOLING 2002 2003 1 Fit the circulation pump complete with tensioner bracket and spacer sleeve position 4 Tighten the bolts M8x75 to 20 Nm 20 kpm 147 ft lbs position 1 2 Suspend the heat exchanger loosely by the rear bolt M8x16 and spring washer position 5 a Fit the pipe position 6 and the hose position 3 between the heat exchanger and the seawater pump using double hose clamps apply soapy water to the rubber rings applies for all rubber rings b Fit the pipe between the heatexchanger and thermostat housing position 7 c Fit the pipe between the heatexchanger and the circulation pump position 8 3 Locate the pipes in the heatexchanger 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 heatexchanger and the exhaust elbow position 10 NOTE The holderforthe pipe position 11 and the lock position 11 a 5 Fit the pipe between the circulation pump lower outlet and the cylinder head position 12 6 Fit the pipe between the circulation pump upper outlet and the cylinder head position 13 7 Fit the alternator place the bolt for the tensioner bracket with the head forwards Put on and tension the Vbelt 8 Fit the expansion tank to the exhaust elbow position 15 9 Fit the hose between the tank and the circulation pump double pipe 2002 450 mm 17 7 in 2003 550 mm 21 7 in only single hose clamps are used on the freshwater system position 16 10 Fit the nipple position 17 11 Fitthe hose between the tank and the thermostat housing nipple 17 2002 350 mm 13 8 in 2003 450 mm 17 7 in position 18 12 Fit the plugs in the exhaust elbow and the cylinder head positions 19 and 20 13 Fill the additive system with right level The a mixture system freshwater of fresh water 50 volumes 2002 and antifreeze 40 dm2 litre 088 50 altematively Imp gals 11 rustpoecin US gals 2003 5 5 dm 3 litre 1 2 Imp gals 1 45 US gals Pos 21 and 23 are for hot water outlet Wiring diagram alternative A Printed circuit card2 Rev counter accessory3 Start button4 Switch for instrument panel5 Alarm test button6 AlarmMax output fromthe panel 5 ACable colourR RedPU PurpleBN BrownOR OrangeGR GreySB BlackW WhiteY YellowGN GreenBL Blue ZENGINE1 Relay2 Fuse3 Temp alarm sender4 Oil pressure alarm senderWire areas in mm 2Wire areamm 2 AWG10 1615 1425 1210 626 Wiring diagram alternative B De LuxeINSTRUMENT PANEL1 Voltmeter2 Oil pressure gauge3 Coolant temperature gauge4 Printed circuit card5 Alarm test6 Switch for instrument lighting7 Rev counter8 Key switch9 AlarmMax output fromthe panel 5 ACable colourGR GreySB BlackBN BrownLBN Light brownR RedP PurpleGN GreenY YellowW WhiteBL BlueLBL Light blueENGINE1 Coolant temperature sender2 Oil pressure alarm sender3 Coolant temperature alarm sender4 pit pressure sender5 Relay6 FuseWire areas in mm 2 FAULT TRACINGEngine Engine Engine not Engine runs Engine Faultdoes stops reaching roughly or becomesnot correct temp vibrates abnormal ystart 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 seawater manifold pump Faulty thermostat Cloged cooling water pipe in the head cylinder 199922650 Pulley puller8848137 Installation ring for piston99952186 Mandrel for valve guide removal8845570 Mandrel for installation of injector sleeve8845596 Mandrel for installation of valve guide8847873 Settingdisc for injection pump setting8848111 Puller for injector sleeve8848236 Flaring tool for injector sleeve8848376 Flange for engine cradle8848384 Mandrel for installation of sealing ring in transmission cover Assembly and disassembly tool for camshaft Guide pin for cylinder head NOTE Two are requid General TECHNICAL DATAType designation 2001 2002 of cylinders 1 2 3Displacement 0 43 dm 3 26 2 cu 0 852 dm 3 51 9 cu in 1 278 m 3 77 99 in cu inCylinder bore 79 mm 3 11024 inStroke 87 mm 3 4252 inCompression ratio 17 5 1Compression ratio at starter motor speed 22 5 MPa 2025 kpcm 2 Direction of rotation seen from the front end speed 1314 rs 775825 rpmOil pressure at full speed and warm engine 035040 MPa 3540 kpcm2Oil pressure at idling and warm engine 008015 MPa 0815 kpcm 2 Cylinder blockMaterial Special alloy cast ironCylinder diameter standard 79007903 3 110253 11142 in 025 mm oversize 79257928 3 120083 12126 in 050 mm oversize 79507953 3 129923 1311 in height 783 m m 308268 in Height from gudgeon pin center to piston top 503 mm 1 98031 in Piston clearance in cylinder 009 mm 00354 in Piston in standard dimension 789037817 310642310697 in 025 mm oversize 7915379167 311626311681 in 050 mm oversize 7940379417 312610312665 in Gudgeon pinsDiameter 2599526000 102343102362 in Gudgeon pin bushing diameter 2600526011 102382102406 in Clearance gudgeon pin bushing 000500 0160 00002000063 in Piston ring number 2Oil ring number 1The upper compression ring has an inlay of chrome The piston rings are available for standard dimension andfor 0250 and 0500 mm oversize 000984 and 00996in Piston ring axial clearance in the grooveUpper compression ring 00700102 0 00276000402 in Lower compression ring 00500082 000197000323 in Oil ring 00300062 000118000244 in Piston ring gap in the cylinderUpper compression ring 030050 0001181000197 in Lower compression ring 030050 0001181000197 in Oil ring 025050 0009842000197 in Nodular ironCrankshaft axial clearance 00400221 000157000870 in Main bearing radial clearance 00400092 000157000362 in Bigend bearing radial clearance 00240068 0000940 00268 in 1 Propeller shaft output in accordance with DIN 6270B Main bearing standard 5998760000 236169236220 in 0250 m m undersize 5973759750 235185235236 in 0500 mm undersize 5948759500 234200234252 in Main bearing standard 29872997 011760011799 in 0250 mm oversize 31123122 012252012291 in 0500 mm oversize 32373247 012744012783 in Bigend standard 4798948000 188933188976 in 0250 mm aversize 4773947 750 187949187992 in 0500 m m oversize 4748947500 186965187008 in Bigend bearing standard 14781488 005819005858 in 0250 mm oversize 16031613 006311006350 in 0500 mm oversize 17281738 006803006843 in Connecting rodsAxial clearance at the crankshaft 015035 mm 000590001378 in CamshaftAxial clearance 01600300 mm 00063001181 in Radial clearance in bearings 00200075 mm 0000787000295 in Camshaft diameter 4697547000 18494185039 in Lifting height of cams 548552 mm 021575021732 in Bushing diameter 47024705 mm 185118185236 in Cylinder headMaterial Special alloy cast ironInlet valves 20031Disc diameter 344346 mm 1354331 36220 in 358360 mmStem diameter 7955x7970 mm 031319031378 in 79957970 mmValve seat angle 445544 85 294530 15Cylinder head seat angle 45 30Seat width in the cylinder head appr 1 mm 00337 in appr 1 mm 0 0337 in Clearance coldwarm engine 03 mm 0011811 in 0 3 mm 0011811 in Exhaust valvesDisc diameter 299301 mm 114716118504 in Stem diameter 79507465 mm 0 31299031339 in Valve seat angle 458Cylinder head seat angle 45 Seat widthin the cylinder head appr 1 mm 003937 in Clearance coldwarm engine 03 mm 0011811 in Valve guidesLength inlet valve 38 mm 149606 in Length outlet valve 38 mm 149606 i nInner diameter 80008015 031496031555 in Height above springplane of cylinder head 870930 mm 034252036614 in Valve springsLength unloaded 425 mm 167323 in Loaded with 17010 N 171 kp 32 mm 1 25984 in Loaded with 30020 N 302 kp 24 mm 094488 in Lubricating quantity model 2001 140 dm 3 1 2 quartsOil quantity model 2002 2 75 dm 3 2 42 quartsOil quantity model 2003 410 dm 3 36 quartsOil quality according to the APIsystem CD DSViscosity 15 W40Oil pressure warm engine idling speed 0815 kpcm2 11 3721 33 lbftin2 Oil pressure warm engine full rpm 3540 kpcm 2 49 7856 89 lbftin 2 Lubricating oil pumpType Gearwheel pumpGear wheel axial clearance 00250065 000098000256 in Spring for reduction valve length unloaded 49 mm 192913 in Loaded with 35 Nm 35 kp 25 8 ft lbs 40 mm 157480 in Fuel SystemOpening pressure injectors 180190 kpcm 2 25602702 lbftin21Spray angle 150Injection angle 2001 221 B T D CInjection angle 2002 2003 201C BT DC Injection angle 2003T 231 BT D C Injection quantity 251 5 mm3stroke at 405C 104F10 6F and at 25 rs 1500 rpm pump revsGovernor overrun 54 rs 3250 rpmFeed pumpFeed pressure 42 rs 2500 rpm 065085 kpcm 2 9 2012 10 lbfin 2 Electrical systemBattery voltage 12VBattery capacity Max 70 AhStartermotor output 2001 08 kW 1 1 H PStartermotor output 2002 and 2003 1 4 kW 1 9 HPAlternator output Voltagemax current 14W50 Amp Output 700 spec gravity Fully loaded battery 12751285 To be charged at 1230Thermostat Wax to open at 602C 1404FFully open at 75C 165 F1Cooling systemWith freshwater cooling 2002 2003Starts opening at 741C 1642FFully open at 87C 189 FFreshwater system volume 2002 40 dm 3 litre 0 88 Imp gals 1 1 US gals 2003 55 dm 3 litre 11 2 Imp gals 1 45 US galsWEAR be bored at 025 mm wear 000984 in CrankshaftMain and bigend journals Permitted outofround 006 mm 000236 inPermitted taper 005 mm 000197 in Max axial clearance on crankshaft 040 mm 001575 in 1 2003T 204212 kpcm2 29003015 lbfin 2 journals permitted outofround 003 mm 000118 in Max clearance between camshaft and bushings 015 mm 000590 in ValvesMax clearance between valve stem and valve guide 015 mm 000590 in The valve disc edge must be at least 15 mm 005906 in Tightening torquesMain bearing bolts 1st tightening 20 Nm 20 kpm 14 7 ft lbs 2nd tightening 60 Nm 60 kpm 44 2 ft lbs Bigend bearing bolts 70 Nm 70 kpm 51 6 ft lbs Flywheel housing bolts 25 Nm 25 kpm 18 4 ft lbs Flywheel bolts 65 Nm 65 kpm 47 ft lbs Cylinder head bolts 1st tightening 20 Nm 20 kpm 14 7 ft lbs 2nd tightening 70 Nm 70 kpm 51 6 ft lbs Rocker arm bridge 25 Nm 25 kpm 18 4 ft lbs Fuel injection pumps 25 Nm 25 kpm 18 4 ft lbs Pulley 40 Nm 4 0 kpm 29 5 ft lbs Injectors 20 Nm 20 kpm 14 7 ftlbs

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