Volvo Penta 2001, 2002, 2003, 2003T Workshop Manual
FOREWORD
wor kshop
Thi s
The
i nst r uct i ons
t he
headi ng
Bot h t he
when
or der i ng
r eser ve
We
bi ndi ng
.
UNI T
SI
Uni t s
accor di ng
Power
Tor que
i s
ear l i er uni thp( hor se- power )
ear l i er uni t
ear l i er uni t
Pressur e
ear l i er
ear l i er
manual
" Speci al
engi ne
i s
desi gnat i on
par t s
t he
r i ght
gi ven
i nkW( ki l owat t )
gi ven
kpm
l bf
i s
gi ven
uni t
kp/ cm
uni t
I bf / i n2( pounds
cont ai ns
concer ni ng over haul i ng
t ool s"
.
t o
car r y
SYSTEM
i nt er nat i onalSIsyst em
t o
t he
i n
Nm
( newt on
( ki l opond
f t ( poundf oot )ear l i er uni t
( Pascal )
i n
Pa
2
( ki l oponds
.
and
out
met r e)
per
r epai r
i t s
ser i al
desi gn
met r e)
per
squar e
i nst r uct i ons
descr i be
number
modi f i cat i ons
squar e
cent i met r e)
i nch)
f or
t he 2001,
t he
most
sui t abl e
mustbecl ear l y
and,
f or
t hi s
have been
I mp
used
i n
Speed
Vol ume
. gal ( I mper i al gal l on)
2002
wor ki ng
st at ed
r eason,
t hi s
ear l i er
ear l i er
ear l i er
and
2003
met hod
i n
al l
cor r espondence
t he
cont ent soft hi s
book.The
i s
gi ven
uni t
r ev/ mi n
i s
gi ven
uni tl( l i t r e)
uni t
US
ear l i er
i n
r ev/ s
i ndm3
gal
engi nes
usi ng
Techni cal
uni t s
( r evol ut i ons
( r evol ut i ons
( cubi c
( Uni t ed
.
t he
speci al
concer ni ng
manual cannotber egar ded
Publ i cat i ons
ar e
deci met r e)
St at es
gi ven
per
t ool s
AB
af t er
per
second)
mi nut e)
gal l on)
l i st ed
t he
VOLVO
Depar t ment
t he
engi ne
PENTA
SI
under
and
uni t s
as
.
I NDEX
Component s
DI SASSEMBLY
Cyl i nder
Tr ansmi ssi on
Pi st on,
Fl ywheel
Cr ankshaf t
Camshaf t
OVERHAUL
Di sassembl i ng
Val ve
Val ve
Val ves......
Val ve
Rocker
I nj ect or
I nj ect or s....
Assembl i ng
Feed- pump.. . ... . . . . . ... . . . . . ... . . . . . ... . . . . . .....
Pi st ons...... . ....... . ... . . . . . ... . . . . . ..... . . . .....
Cr ankshaf t..
Camshaf t.... . ....... . ....... . ....... . ....... . .....
Connect i ng
Ther most at.. . ....... . ... . . . . . ... . . . . . ... . . . . . ... . .
Sea- wat er
gui de..
head
. ... . ... . .....
. ... . ... . ....... . ..... . . . ....... . ... . . .
pi st on
. . ... . .
. . . . ... . ... . ....... . ... . . . . . ... . ... . ... . . .
. ... . ... . ... . ....... . .....
..... . ........... . ..... . . . ... . . . . . ... . . .
gui des
seat s.. . ....... . ....... . ... . . . . . ... . . . . . . . . . . .
. . ....... . ... . ... . ....... . .....
spr i ngs
. ....... . ....... . ....... . ... . ... . ... . . .
ar m
mechani sm...... . ... . . . . . ....... . ..... .
sl eeve..
. . ....... . ....... . ..... . . . ....... . ... . ..8
t he
...
r ods
pump....
. . ....... . ... . . . . . ... . . . . . ... . .
.
. . ....... . ....... . ... . . .
r ods..
. . ... . ... . ... . . . . . ....... . ... . . .
... . ....... . ....... . ... . ... . ... . . .
...
. . .
...
.
.
.
t he
cyl i nder
. . ... . ....... . ..... . . . ....... . .....
cyl i nder
.
...
.
. . . . . . . . . . . ....... . ... . ... . . ... . . .
head.... . . . ..... . . . ... . . .
... .
head
. . ..... . . . ... . . . . . ... . ..9
.
.
. . . . . . ... . . . . . ... . ... . .....
. .
. . ... . . . . . ... . . . . . ..... . . . .....
. . ... . . .
.
. .
. .
. 12
.
2
3
4
5
5
5
5
7
7
7
7
8
8
8
.
10
11
11
11
13
13
ASSEMBLY
Cr ankshaf t..
Pi st ons...... . ..... . . . ... . . . . . ....... . ... . ... . ... . .
Fl ywheel
Tr ansmi ssi on
Adj ust i ng t he
Checki ng
2003
Tur bo..
Fr esh
El ect r i cal
Faul t t r aci ng
Speci al
Techni cal
. . ... . ... . ... . ... . ... . . . . . ....... . ... . .
. . . . . . ... . ... . ... . ... . ..:........ . ... . ... . .
. ... . ... . ... . ... . ........... . ... . ... . .
val ve
cl ear ance
t he
i nj ect i on
. . ... . . . . . . . . . . . . . . . .
wat er
cool i ng
syst em
scheme
t ool s.. . . . . . . . . . . . ... . . . . . . . . ... . . . . . . . . . . . .
Dat a.. . . . . . . . ..... . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . ... . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . ... . . . . . . . . . . . .
. . . . ... . . . ... . . ....... .
angl e
. . . . . ... . . . ... . . ... . ... .
. . . . . . . . . ..... . . .
14
14
15
15
17
17
21
25
26
28
29
30
COMPONENTS
8
GUI DE
1
.Exhaust
2.I nj ect or s
3.Temper at ur e
4
.El ect r i cal
5
.Fuel
6.Al t er nat or
7
8
9.Feed- pump
10
11
12
13
14.Oi l
15
f i l t er
Engi ne
di pst i ck
mot or
ser i al
ai r
si l encer
i nj ect i on
.St ar t er
.Dr ai nage,
.
.Decompr essi on
.I nl et
.Fuel
.Sea- wat er
el bow
sender
di st r i but i on
cool i ng
number
devi ce
pumps
pump
box
wat er
Halpert@Optonline.net
Dr ai n
on
engi ne
engi ne
of f
t he
i s
cool i ng
cr adl e
f r esh
p/ n
wat er
wat er
9992520
cool ed,
and
t he
and
see
l ubr i cat i ng
f i xt ur e
p/ n
page21.
DI SASSEMBLY
oi l
f r om
t he
.
I f
884837
t he
1.Remove
st ar t er
di st r i but i on
wi r e
t he
t he
al t er nat or ,
mot or.Remove
box
f r om
har ness
.
t he
t he
engi ne
connect i ons
t he
t ensi oner
and
r emove
br acket
f r om
t he
t he
and
t he
el ect r i cal
box
and
3.Remove
t her most at
t he
sea- wat er
t he
f uel
housi ng
pump
f i l t er ,
and
wi t h
t he
t he
exhaust
i t s
oi l
f i l t er ,
el bow.Al so
at t achment
t he
f eed- pump,
t ubes
t he
r emove
.
2
.
Remove
t he
i nl et
t he l everoft he
l ever.Remove
t he
ai r
si l encer.I nst al l
pumps
r et ur n
f uel
l i ne,
and
i nj ect or s
decompr essi on
t he
val ve cover
t he
f uel
pr ot ect i on
.
Remove
devi ce
.
pr essur e
caps on
t he
scr ew
and
( 1)
t he
pul l
l i nes
f uel
hol di ng
out
and
t he
and
l i f t
out
t he
push
r ods
t he
r ack
.
cyl i nder
Remove
i n
consecut i ve
or der , NOTE!Thecyl i nder
head
bol t sar e
phosphat i sed
andmustnot becl eanedwi t ha
st eel
br ush.
4.Remove
i nj ect i on
head
t he
and
t he
r ubber
t he
val ve
r i ngs
val ve
br i dge
f or t heoi l
l i f t er s.Put t he
pi pe.Remove
l i f t er sona
5.Remove
ensur e
wer e
on
t he
.
t he
f uel
i nst al l at i on
r emoved.Take
si de of
t he
i nj ect i on
i n
t he
car eoft he
engi ne
same
bl ock
pumps.Mar k
cyl i nder s
shi ms.Remove
and
f r omwhi ch
l i f t
out t he
t he
pumps
t he
pump
t hey
scr ews
l i f t er s
7.Remove
t hr ot t l e
t he spr i ng
gear
( When
f aci ng
usi ng
t o
camshaf t.Remove
and
t he
t r ansmi ssi on
cont r ol
t he
wheel s
i nst al l i ng
out war ds).Remove
t he
pi nbypunchi ng
pul l
cover.Use a
spr i ng
( 1).Then
( 3).Remove
wi t hacol our - pen
t he
speci al
i t
st r ai ght
t ool
t he
out war ds
cover:St ar tbyr emovi ng
sui t abl e
r emove
t he
oi l
gear
wheel s,
t he
884839.Never
p/ n
i t
out ,
scr ewsont he
.
pump
t he
br aci ng
t hi s
t ypeofpl i er s
t he
end- ni ppl e
cover
bef or e
mar ked
pi noft he
can
ver y
t r ansmi ssi on
and
r emovi ng
si de
r emove
wel l
t he
t o
r emove
( 2)
and
mar k
t he
t hem
must
camshaf t
t he
br aci ng
bend
t he
cover
.
be
6.
Remove
usi ng
pul l er
t he
pul l er
damaged
and
.
t he
p/ n
t he
pul l ey
cent er
9992265.Pl ace
cr ankshaf t
t o
bol t
avoi d
and
a
pr ot ect i on
t he
pul l
of f
pad bet ween
cr ankshaf t
t he
pul l ey
bei ng
8.The
ar e
t hi s
9.Remove
t he
set
wi l l
r ear of
hol di ng
max
by
t he
. - vol ume- scr ew
Vol vo
Pent a
af f ect
t he
engi ne out put
t he
cont r ol
t he
bl ock
cont r ol
( 1)
and
t he
and
must
never
.
r od.St ar tbyr emovi ng
and
r od
t het wo
.
scr ewsont he
max
. - r ev- scr ew
changed
be
t he
pump
si nce
pl ug
pl ane,
( 2)
at
10.Pul l
out t he
camshaf t
.
12.Tur n
Be
f unct i onasmai n
t he
engi ne
car ef ulast he
upsi de
pan
i s
bear i ngs
gl ued
down
.
NOTE!
.
and
r emove
The
oi l
pan
t he
oi l
ends
pan
al so
.
11
.
Remove
t he i nner
t he
f l ywheel
out er
f l ywheel housi ng,
housi ng
t he
f l ywheel
.
and
13.Remove
r ods
connect i ng
t he
r od
and
cap
connect i ng
t he
pi st ons
ar e
mar ked
r od
.
The
bol t s
and
connect i ng
wi t h
f i gur es
r emove
r od
.
t he
and
t he
connect i ng
t he
mai n
14.Remove
ar e
mar ked
i nt o
t he
ver si ons
( 2002,
an
2003).The ar r ow
wi t h
bl ock.Li f t
ar r ow
bear i ng
a f i gur e.The
out
i s
cast
i n
i s
t he
t he
t o
caps.The
cor r espondi ng
cr ankshaf t.On
separ at e
poi nt
mai n
mai n
t owards
bear i ng
f i gur e
l at er
bear i ng
t he
di pst i ck
caps
i s
engi ne
punched
caps
.
3.Use
t he
new
884559
down
mandr el
val ve
i nst al l
t o
t o
t he
.
p/ n
gui des
t hem.Press
cyl i nder
5218
t o
pr ess
ext er nal l y
head.Ream
down
out t he
and
t he
mandr el
t he
val ve
use
val ve
gui des.Oi l
mandr el
al l
t he
gui des
p/ n
way
i f
necessar y
THE CYLI NDER
1 .
Remove
bow.Remove
Pl ace
st and
.
t he
t he
" col l et s"
t he val ves.Removethe
val ves
i n
HEAD
and
t he
val ve
pr oper
spr i ngs
val ve
sequence
usi ng
a
st em
i naval ve
val ve
seal s
.
Val ve
gui des
2.Check
i nt o
t he
necessar y,
Wear
l i mi t s
I nl et
val ve,
Exhaust
t he val ve
gui de.Measur e
r epl ace t he
val ve,
:
max
pl ay
max
gui de
pl ay
wearbyi nser t i ng
gui des
usi ng
.
t he pl ay
val ve
. ...
. . . . . . ... . .0. 15
. . . . . . . . . . . .0. 15
anew
a
di al
val ve
i ndi cat or.I f
mm
( 0
mm
( 0
. 0059
. 0059
st em
i n)
i n)
Val ve
seat s
and
4.Mi l lorr eam
( f or
2003T,
30°
( B)
shoul dbe1±0. 1
i n
a val ve
t he
f or
bent
i n)
r ocker s
past e
gr i ndi ng
di sc
t hi ckness
nat ur al l y
engi nes,
st ems,ori f
must
al sobescr apped.Gr i nd
i f
necessar y.Lap
and
check
val ves
t he
val ve
f or
t he
machi ne.The
af t er
aspi r at ed
t he
t he
t he
seat s.The
i nl et
val ve).The
mm
( 0
. 039±0
gr i ndi ng
engi nes
val ves
must
measur ement
i n
t he
cont act
ar ea
angl e
( C)
seal i ng
sur f ace' s
. 0039
i n).Gr i nd
angl e
( D) ,
see
t han
i s
l ess
or 0
. 8
be scr apped.Val ves
( A)
t he
val ves
wi t h
1
. 0
mm
( 0. 031
exceeds2. 5
val ve
t i p
usi ng
mar ki ng
shoul dbe45°
wi dt h
t he
val ves
Tech.dat a.I f
mm
( 0
. 039
i n)
f or
wi t h
t ur bochar ged
mm
( 0
. 098
t owards
val ve
gr i ndi ng
dye
.
i n)
t he
Repl aci ng
Gr i nd
27
mm
gui de.NOTE! Do
j ust
t hr ee poi nt s usi ngael ect r i c
Cool
head
cool ed
t ool
down
( 1
bel ow
t he
t he
shoul d
seat on
NOTE!
.
t he
. 063
t he
val ve
new
t he
beat
Tur n
val ve
seat
exhaust
val ve
di scofa
i n)
di amet er
not
edge
gui de
seat
t ool
r oom
.
push
i n t oo
of t he
seat.Spot
wi t hapl ast i c- headed
t o
appr ox.- 20°C
t emper at ur e
884961- 4
t he seat
di scar ded
Push
wel der.Knockout
and
wi t h
por t
2003T
t he
val ve
f ar -
t he
wel d
( - 4°F);t he
( +
20° 0168° F).Pl ace
knock
i t
t he
val ve
val ve
st em
val ve
t he
hammer
down
f ace
t o j ust
t hr ough
di sc
di sc
i n
t he seat
unt i l
t owards
bel ow
shoul d
pl ace
by
.
cyl i nder
i t
bot t oms.
t he
be
hi t t i ng
t he
t he
Rocker
6
par t s.Check
Shoul d
p/ n
t hat
r ocker
t oacl ose
at
i t
val ve- si de
sur f ace
made
t he
ar m
.
Di sassembl e
t he
9991867
t he
oi l
ar m)
must
be t ur nedsot hat
agai nst t he
i naval ve
par t s
.
mechani sm
t he
t he
wearoft he
bushi ngs
f or t he
hol e
i n
.
Af t er
r unni ng
.
Check
gr i ndi ng
r ocker
need
r emoval
t he
bushi ng
i nst al l at i on
t he
f i t
. When
t o
make
val ve
ar mmechani sm
shaf t
and
t ober epl aced,
and
i nst al l at i on,
coi nci des
t he
i nst al l i ng
t he
l ubr i cat i on
sur e
t hat t he
i s
concave.Mi nor
machi ne.Oi l
and
cl ean
r ocker ar m
wi t h
bushi ngs
t he r ocker ar m shaf t ,
hol es
r ocker
t he
bushings
uset he
shaf t
mandr el
( make
t he
one
ar e
ar e
f aci ng
ar m
adj ust ment s
and
r eamed
cont act
i nst al l
sur e
i n
t he
.
t he
t he
ar e
Val ve
spr i ngs
5.Checkt he
when
l oaded
L =
Lengt h,
L
1 =
Lengt h,
( 1
. 25984
L2=
Lengt h,
( 0
. 94488
f r ee
l engt h
.
unl oaded
l oaded
i n
. )
l oaded
i n
. )
t he
val ve
of
42, 5
mm
wi t h
170±10 N
wi t h
300±20N( 30±3
spr i ngs
( 1
. 67323
i n
( 17±1
and
. )
kp)
kp)
t he
l engt h
32
24
mm
mm
Pressur e
7.Check
pr essur e
st op
Adj ust
bei ng
i n
i n
whet her
Assembl e
t he
t est i ng
t he
( see
si mul t aneousl y
t he
avai l abl e
. )
t o 1, 95
. ).Di sassembl e
t he
t he
spr ay- pat t er n
t he
nozzl es
nozzl e' s
Techni cal
openi ng- pr essur e
mm(. 076772
pr essur e
i nj ect or
spr ay
Dat a)
andnodr i ppi ng
i n
di f f er ent
t he
i nj ect or
and
.
i n
must
pat t er natt he
Check
al so t hat t he
.
wi t h
adj ust ment - washer s
t hi cknesses
. )
i n
st eps
and
r epl ace
be
r educed
check
t he
cor r ect
occur s
.
f r om1mm
of
0, 05
t he
openi ng- pr essur e
openi ng
f uel
U3937
mm(. 001969
adj ust ment - washer
or
i ncr eased
spr ays
( 1)
agai nstat hi nneroneorat hi ckeronedependi ngon
.
and
I nj ect or - sl eeve
8.I nser t
884811
t he
i nt o
st ud
cyl i nder
nut
scr ew
t he
bol t of
( 2)
and
t he
expandi ng
i nt o
t he
har d
copper
t he
headasa
t i ght en
scr ew
copper
t o
mat er i al.Then
i nj ect or.Putacyl i nder
sl eeve
al l ow
t he
suppor t f or t he
unt i l
i t
t he
on
and
t hr eads
i nst al l
l egoft he
sl eeve
t he
t ur n
t o
t he
i s
wor k
head
r emoved
speci al
t he
t ool
scr ew
t hemsel ves
( 1)
yoke
scr ew
yoke.I nst al l
.
on
i n
p/ n
ant i - cl ockwi se
t he
t he
t he
10.Oi l
t hef l ar e- t ool
( make
sur e
unt i l
t he
scr ew
has
st uck
i n
t he
sl eeve. Ti ght en
t ool
as
t he
sl eeve
1
mm
wi t h
t hat
t he
i nj ect or
shoul der
t he
sl eeve.Remove
out si de
(
. 03937
t he
dowel
i n
t he
t he
pl aneoft he
i n
. )
.
p/ n
884283 and
i s
pr oper l y
yoke.Scr ew
i nj ect or
t he
t ool.Adj ust
i nser t
r et r act ed).Brace
down
sl eeve
cyl i nder
i t
i nt ot he
t he
f l ar e- t oolasf ar
al l ows,
t he
head
t her eby
l engt h
t o
sl eeve
t he
f l ar i ng
of t he
maxi mum
9.Repl ace
t he
cyl i nder
t o
f aci l i t at e
and
i nst al l
sl eeve
unt i l
t he
O- r i ng,
head.Di p t he
t he
i nst al l at i on.Oi l
i t ,
usi ng
speci al
i t
bot t oms
seal i ng
new
t ool
.
of f
bet ween
O- r i ng
i n
t he
p/ n
884557.Knock
t he
soap- wat er
new
i nj ect or
sl eeve
down
and
i n
or der
sl eeve
t he
Assembl i ng
11.Cl ean
has
been
t ur nedasi ndi cat ed
seal i ngs.Oi l
sur e
t o
r espect i ve
t he
" col l et s".Useaval ve- bow
t he
cyl i nder
t he
cyl i nder
di sassembl ed,
t he
val ve
i nst al l
t he
or i gi nal
i n
val ves
posi t i ons.I nst al l
head
head.I f
t he
st ems
t he
i t
mustbei nst al l ed
pi ct ur e.I nst al l
and
and
t he
.
wat er
di st r i but i on
new
i nst al l
t he val ves.Make
val ve
spr i ngs
t he
val ve
wi t h
spr i ngs
t he
val ve
i n
pi pe
hol es
st em
t hei r
and
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