WSM 20-26 - D11 - 47714430

Workshop Manual
Group 20-26
D11C-A
Table of Content
General Information
00-0 General ............................................................................................. 3
Specifications
03-0 General Specifications ................................................................... 8
03-2 Specifications, Engine .................................................................. 12
03-21 Engine ....................................................................................... 31
03-22 Lubrication System ................................................................. 43
03-23 Fuel System .............................................................................. 44
03-25 Inlet and Exhaust System ....................................................... 45
03-26 Cooling System ........................................................................ 46
03-3 Specifications, Electrical .............................................................. 47
Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 48
Special tools
08-2 Special Service Tools ................................................................... 49
General
20-0 Engine Information, General ........................................................ 55
Test and Adjustments ........................................................................ 57
Engine
21-0 Engine Complete, General ........................................................... 60
Check and Fault Trace ....................................................................... 62
Fitting the Fixture ............................................................................... 67
Engine Disassembly .......................................................................... 68
Engine Assembly ............................................................................... 73
21-1 Cylinder Head ................................................................................ 82
21-4 Valve Mechanism .......................................................................... 99
21-5 Timing Gears and Shaft .............................................................. 102
21-6 Crank Mechanism ....................................................................... 106
Fuel System
23-0 Fuel System, General .................................................................. 110
Check and Fault Trace ..................................................................... 110
23-3 Fuel Feed Pump and Filter ......................................................... 111
23-7 Injectors and Delivery Pipes ...................................................... 115
23-8 Control System, ECM, Data Sets ............................................... 125
Inlet and Exhaust System

25-0 Inlet and Exhaust System, General ........................................... 128
25-1 Inlet and Exhaust Manifolds ...................................................... 130
25-5 Turbo and supercharger ............................................................. 136
Mechanical Compressor ................................................................. 150
25-6 Air Cleaner, Throttle Housing .................................................... 154
Cooling System
26-0 Cooling System, General ........................................................... 155
26-1 Radiator, Heat Exchanger .......................................................... 163
47714430 02-2023 © AB VOLVO PENTA 1

26-2 Coolant Pump, Thermostat ........................................................ 168
26-5 Charge Air Cooler with Connections ........................................ 171
26-6 Sea Water System, Sea Water Pump ......................................... 177
Alternator, Charge Regulator

32-1 Alternator ..................................................................................... 186
Starting System
33-1 Starter Motor ............................................................................... 188
Index ......................................................................................................... 191
References to Service Bulletins ............................................................ 193
2 47714430 02-2023 © AB VOLVO PENTA

00-0 General
About this Workshop manual
General Information Certified engines
The product designation and the serial number and When performing service and repairs on
specification are shown on the engine decal or type emission certified engines, it is important to be
plate. This information must be included in all aware of the following:
correspondence concerning the product.
Certification means that an engine type has been
Volvo Penta is constantly developing its products. All checked and approved by the relevant authority. The
information in this Manual is based on product data engine manufacturer guarantees that all engines of
that was available at the time the Manual was the same type are manufactured to correspond to the
published. certified engine.
This places special demands on service and repair
The working methods described in this manual are work, namely:
based on a workshop scenario where the product is
mounted in a work fixture. Maintenance work is often • Maintenance and service intervals
carried out in situ, in which case - if nothing else is recommended by Volvo Penta must be
indicated - using the same working methods as the complied with.
workshop. • Only replacement parts approved by Volvo
Penta may be used.
The service manual describes work operations
carried out with the aid of Volvo Penta Special Tools, • All fuel injection service must always be carried
where such have been developed. Volvo Penta out by an authorised Volvo Penta workshop.
Special Tools are designed to ensure the safest and
• The engine must not be converted or modified,
most rational working methods possible.
except with accessories and service kits which
In some cases local safety regulations and user Volvo Penta has approved for the engine.
instructions may be applicable regarding the use of • No changes to the exhaust pipe and engine air
tools and chemicals mentioned in the service manual. inlet duct installations may be made.
These rules must always be observed, so there are
no special instructions about this in the workshop • No warranty seals (where present on the
manual. product) may be broken by unauthorized
persons.
Above all, when working on fuel systems, hydraulic
systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost IMPORTANT!
importance that dirt and foreign objects are kept Neglected or poorly-performed maintenance or
away, as malfunctions or shortened service intervals service and the use of replacement parts not
may otherwise result. approved by Volvo Penta, will mean that AB Volvo
Penta no longer guarantees that the engine conforms
to the certified model.
Replacement parts
Volvo Penta accepts no responsibility for damage or
Volvo Penta Original Replacement Parts meet costs arising as a result of failure to follow the above
national safety requirements. No damage of any kind mentioned standards.
caused by the use of replacement parts not approved
by Volvo Penta will be compensated by any warranty
undertaking.
47714430 02-2023 © AB VOLVO PENTA 3

00-0 General
Colours used in images

Most images include a highlighted component which is secured by a screw or similar as part of a (light gray) engine
transmission.
NOTICE! Because the images in the maintenance literature are used for different engine variants, certain details
may vary compared to the actual model concerned. The essential information is always correct, however.
1 Component emphasized (blue)

2 Attachment fasteners (red)
3 Chassis (light grey)
4 Background (white)
5 Special tool (yellow)
6 Seals (green)
(as from June 2018)
P0030543
Other types of symbols used in

the images are divided into the
following categories:
• Safety
• Important
• Cleanliness
• Position
• Movement
• Measured value
• Tools
• Chemicals
• Sealant
• Units
4 47714430 02-2023 © AB VOLVO PENTA

00-0 General
Safety information
Read the safety information below carefully before you
start repair or service work.
This symbol is used on the product to let you know that this concerns safety information. Always read such
information very carefully.
Warnings take the following priority:
DANGER!
Indicates a dangerous situation which, if not avoided, will lead to death or serious injury.
WARNING!
Indicates a dangerous situation which, if not avoided, could lead to death or serious personal injury.
CAUTION!
Indicates a dangerous situation which, if not avoided, will lead to minor or significant injury.
IMPORTANT:
Is used to make you aware of something that may cause minor injury or a minor malfunction to the product or
property.
NOTICE! Is used to make you aware of important information that will facilitate the work or operation in progress.
This symbol is used on certain functions to indicate the following:

Performance of this operation requires prior theoretical and/or instructor-led training. Contact your local training
organization for further information.
This symbol informs you that supplemental information needs to be read. And where necessary information can
be found.
This symbol means Dangerous electrical voltage / General electrical danger.
This symbol is used when a VODIA computer is needed, either for troubleshooting, testing or programming.
This symbol is used for facilitation tips when repairing.
A compilation of safety precautions that must be taken and risks which you must be aware of is presented
in the following pages.
47714430 02-2023 © AB VOLVO PENTA 5

00-0 General
Immobilize the engine by turning off the power Avoid opening the coolant filler cap when the
supply with the main switch(es) and lock it engine is hot. Steam or hot coolant may
(them) in the off position before work is begun. spray out and with a resultant system
Place a warning notice at the main switch. pressure loss.
All maintenance and service must be carried Never start the engine without the air filter in
out on when the engine is stopped. place. The rotating compressor turbine in the
Approaching a running engine is a safety risk. turbocharger can cause severe injury.
Install all protective covers before starting
the engine.
Beware of hot surfaces and hot liquids in pipes When operating in a confined space,
and hoses on an engine that is running or has exhaust pipe fumes and crankcase gases
just been switched off. must be led away from the engine
compartment or workshop area.
Ensure good ventilation.
Make sure that all warning and information Only make connection adjustments with the
decals on the product are always visible. engine switched off.
Replace decals that have been damaged or
painted over.
Avoid getting oil on the skin! Use protective Never start the engine with the valve cover
gloves and avoid oil-soaked clothes and rags. removed. There is a risk of personal injury.
Switch off the engine and disconnect the power Stop the engine before working on the
at the main switches before starting work on the cooling system.
electrical system. Marine engines: Close the sea cock/cooling
water inlet valve before starting work on the
cooling system.
Always wear protective goggles if there is a risk Check that rags soaked in oil or fuel and
of splinters, sparks and splashes from acid or used fuel and oil filters are stored safely. Oil-
other chemicals. soaked rags may ignite spontaneously in
certain conditions.
Never use start gas or similar products as a Never work alone when dismantling heavy
starting aid. components, even if you use lifting
equipment.
Never allow open flames or electrical sparks in Take extreme care when searching for fuel
the vicinity of fuel. Always ensure that there are system leaks and testing fuel injector
fire extinguishers close at hand in the operating nozzles. Wear safety goggles.
area.
Batteries must never be exposed to open Never use a high-pressure washer to clean
flames or electrical sparks. the engine.
Pay attention to the following when using a
high-pressure washer on components other
than the actual engine: Never aim the water
jet at seals, rubber hoses or electrical
components.
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00-0 General
Always wear protective goggles when charging Only use fuels and lubricating oils as
or handling the batteries. Rinse immediately recommended by Volvo Penta.
with plenty of water and soap if battery
electrolyte comes into contact with unprotected
skin.
If you get battery acid in your eyes, flush at
once with a generous amount of water, and get
medical assistance at once.
The engine must not be operated in areas
where there are explosive materials or gases.
47714430 02-2023 © AB VOLVO PENTA 7

03-0 General Specifications

Engine Decals
There are type plates on the engine and its drivelines.
Some of the type plates are marked with identity
numbers. Always use this information as a reference
when ordering service and replacement parts or
contacting Volvo Penta retailers.
P0030522
A Product designation
B Emission information
C CHASSIS ID/Serial no.
8 47714430 02-2023 © AB VOLVO PENTA

Component location
P0036331
1. Filler cap for coolant fluid

2. Emergency stop / Extra stop
3. Crankcase ventilation filter
4. Fuel filter
5. Filler cap for lubricating oil
6. Alternator
7. Heat exchanger
8. Control Unit
9. Oil dipstick
10. Fuel pump / Servo pump
11. Seawater pump
12. Oil cooler, transmission
47714430 02-2023 © AB VOLVO PENTA 9

P0036332
13. Oil filter

14. By-pass filter
15. Charge air cooler
16. Turbocharger
17. Air filter
18. Compressor
19. Starter motor
20. Housing, control valves
21. Coolant pump
10 47714430 02-2023 © AB VOLVO PENTA

General Tightening Torques

General Tightening Torques
M6 10 Nm
M8 24 Nm
M10 48 Nm
M12 85 Nm
M14 140 Nm
M16 220 Nm
IMPORTANT!
Check screws which are to be re-installed. Damaged bolts
with e.g. shear marks under the heads, must be scrapped.
47714430 02-2023 © AB VOLVO PENTA 11

03-2 Specifications, Engine

Group 21 - Engine
Main bearing caps
NOTICE! May be reused once.
Step 1: 150 Nm
Step 2: Angle tightening 120°
P0036561
Big end bearing cap

Step 1: 20 Nm
Step 2: 35 Nm
P0037209
Stiffening plate
Tightening from the center outwards.
48 Nm
P0036563
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Oil sump
Tightening from the center outwards.
24 Nm
P0036564
Valve cover
24 Nm
P0036565
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Cylinder head
P0036752
NOTICE! May be reused twice.

Step 1: 60 Nm
Step 2: 60 Nm, check tightening
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Bearing caps, camshaft/rocker arm shaft
P0036763
1 Tightening sequence: 1-2-3-4-5-6-7

25 Nm
2 Tightening sequence: 11-9-13
90 Nm
3 Tightening sequence: 8-10-12-14
60 Nm
4 Loosen the screws 11-9-13
5 Tightening sequence: 11-9-13
60 Nm
90°
100°
47714430 02-2023 © AB VOLVO PENTA 15

Valve adjustment
Locking nut, valve adjuster screw
38 Nm
Lock nut, injector adjusting screw
52 Nm
P0036767
Timing gear casing, front
NOTICE! Apply a bead of sealant P/N 1161231 with a

diameter of approx. 2 mm, see illustration.
P0036756
Step 1: Tighten by hand

Step 2: Tighten all screws: 24 Nm
P0034657
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Oscillation damper, camshaft

Step 1: 45 Nm
P0036566
Oscillation damper, crankshaft

Step 1: 45 Nm
P0036764
Lifting eye, front

Step 1: 30 Nm
P0036567
47714430 02-2023 © AB VOLVO PENTA 17

Lifting eye, rear

100 Nm
P0036568
Engine mount, front

Against cylinder block: 275 Nm
Engine pad: 150 Nm
P0036569
Engine mount, rear

Against cylinder block: 275 Nm
Engine pad: 150 Nm
P0036570
18 47714430 02-2023 © AB VOLVO PENTA

Flywheel housing

P0036754
M8: 35 Nm
M12: 110 Nm
M14: 165 Nm
P0036571
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Timing gear plate

P0036757
Tighten the screws in numerical order.

24 Nm
P0036755
Flywheel
Step 1: 60 Nm
P0036572
20 47714430 02-2023 © AB VOLVO PENTA

Transmission
(A) Camshaft gear / oscillation damper
Step 1: 45 Nm
(B) Idler gear, adjustable

Step 1 35 Nm
Step 2 Angle tightening 120°
(C) Idler gear, double

Step 1 35 Nm
Step 2 Angle tightening 60°
(D) Crankshaft gear 24 Nm

P0036753
(E) Seawater pump, drive 200 Nm
(F) Servo pump/fuel feed pump, drive 100 Nm
Timing gear casing, upper

Tighten the bolts in sequence.

24 Nm
P0036574
47714430 02-2023 © AB VOLVO PENTA 21

Group 22 - Lubrication System

Lube oil pump
24 Nm
P0036575
Lubricating oil cooler

35 Nm
P0036576
Lubricating oil cooler, casing

24 Nm
P0036761
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Valve housing, lubrication system

25 Nm
P0036762
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Oil Valves
A Thermostat valve for oil cooler
10 Nm
B Reducing valve, lubricating oil pressure
Marking: Black
10 Nm
C Overflow valve, full flow filter / plug
55 Nm
D Control valve, piston cooling
55 Nm
E Opening valve, piston cooling
55 Nm
F Safety valve, lubricating oil pressure
55 Nm
P0036758
P0036759
P0036760
24 47714430 02-2023 © AB VOLVO PENTA

Piston cooling jet

24 Nm
P0029221
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Group 23 - Fuel System

Copper sleeve
NOTICE! Copper sleeve with 2 grooves requires

injectors with a sealing washer.
P0034664
Sleeve for injector

Tightening torque when replacing the sleeve:
Step 1: 20 Nm
Step 3: Loosening the screw
Step 4: 20 Nm
Tightening torque when reusing sleeve:
Step 1: 20 Nm
NOTICE! Once an injector has been released, a new

washer must always be used using the same mounting
method as when replacing a complete sleeve.
P0034662
26 47714430 02-2023 © AB VOLVO PENTA

Group 25 - Inlet and Exhaust System

Exhaust manifold
Step 1: Torque-tighten the screws 7-12
10 Nm
Step 2: Tighten the screws in sequence
48 Nm
P0036578
Intake manifold

Tightening torque in numerical order.

A Inlet manifold
24 Nm
B Plug
20 Nm
C Sensor, charge air pressure / charge air temperature
12 Nm
P0036765
P0036766
47714430 02-2023 © AB VOLVO PENTA 27

Turbo
48 Nm
P0036580
General
Engine designation (1) D11C1–A MP
D11C2–A MP
D11C3–A MP
D11C4–A MP
Number of cylinders 6
Cylinder diameter 123 mm
Stroke 152 mm
Cylinder volume, total 10.84 liter
Number of valves per cylinder 4
Compression ratio 16.5:1
Firing order
(cyl. no. 6 is closest to the flywheel) 1–5–3–6–2–4
Direction of rotation
(seen from front) Clockwise
Power See applicable Sales Guide
Low idle 600 rpm
Adjustable 550-800 rpm for inboard and
600-650 for IPS
Dry weight 1172 kg inboard
1329 kg IPS
Rpm Load Rating 3 2250 rpm
Rpm Load Rating 5 2500 rpm
1) Note: In the following pages engines will be designated D11 in cases where data pertains to all variants in general.
28 47714430 02-2023 © AB VOLVO PENTA

Location of Sensors
P0036337
Sensor Location
Crankcase pressure C2
Coolant level B3
Piston cooling oil pressure A4
Fuel pressure F2
Oil pressure and oil temperature F2
Flywheel position I3
Boost pressure and charge air temperature D2
Camshaft position J3
Coolant temperature M3
Lubricating oil level C5
47714430 02-2023 © AB VOLVO PENTA 29

Control valve, overview

A Thermostat, oil cooler
B Reducing valve, lubricating oil pressure
C Overflow valve, full flow plug
D Control valve, piston cooling
IMPORTANT!
For the correct part number and thus the correct
opening pressure on the valves, see Spare parts
information (EPC).
P0036341
C. Overflow valve, full flow filter
IMPORTANT!
The opening pressure and design of the valves
distinguish between standard / remote mounted oil
filters. On remote systems, the overflow valve (C) is
located in the filter retainer.
P0036339
E. Safety valve, lubricating oil pressure
P0036340
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Engine
Cylinder block(1)
Length 967 mm
Height, upper block plane - crankshaft center, min (A) 379 mm
Height, lower block plane - crankshaft center, min (B) 120 mm
P0029850
1) The cylinder block (exchange) and pistons with piston rings should be changed when the honing pattern is worn away, or
lubricating oil consumption is abnormally high
Cylinder head
Length 996 mm
Height, min. 103.8 mm
Max flatness error (base plane) 0.04 mm
Cylinder Head Bolts

No. per cylinder head
Quantity 26
(1)
Thread dimension M16 x 2

1) The screws may be re-used max 3 times
Cylinder liner
Height above cylinder block plane (H) 0.15 – 0.20 mm
Max height difference between cylinder liners 0.05 mm
47714430 02-2023 © AB VOLVO PENTA 31

Pistons
Piston mounted, height above cylinder block plane 0.05 – 0.55 mm
Gudgeon pins
Clearance, piston pin hole in connecting rod 0.056 mm
Play, piston pin - piston, max 0.048 mm
Piston rings
P0029853
Upper compression ring, piston ring gap (G) at position (L),

max 0.40 – 0.55 mm
2nd compression ring, play in piston ring groove (axial), max 0.09 – 0.14 mm
Oil ring, play in piston ring groove (axial), max 0.05 – 0.10 mm
32 47714430 02-2023 © AB VOLVO PENTA

Crank Mechanism
Crankshaft
Axial play 0.15 mm 1)
1) Dimensions apply to oiled components.
Main bearing journals
P0034818
Standard diameter (D) 108 mm

Max ovality 0.01 mm
Taper, max 0.02 mm
Fillet radius (R) 4.5 mm
Main bearing shell, standard bearing, dimension (T) 2.475 mm
P0029856
Thrust bearing pin, standard bearing, width dimension (X) 42 mm

Thrust bearing, standard bearing, dimension (T) 3.14 – 3.21 mm
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Big-end bearing journals
P0029860
Standard diameter (D) 90 mm

Max ovality 0.006 mm
Taper, max 0.01 mm
Fillet radius (R) 4 mm
Big-end journal shells

Standard bearing (T) 2.07 mm
34 47714430 02-2023 © AB VOLVO PENTA

Con rods
P0029858
Diameter (D1) 94.835 +0.015/0 mm

Diameter (D2) 54 +0.028/+0.018 mm
Length, connecting rod (L) center measurement between
(D1) and (D2) 225 mm
Flywheel
P0034830
Axial eccentricity (A), max 0.2 mm
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Valve mechanism
Camshaft
P0034822
Diameter, bearing journal 69.97-70.00 mm

Bearing journal, max ovality 0.05 mm
Axial play camshaft - bearing position, max 0.24 mm
Camshaft, lift height (H), intake 13 mm
Camshaft, lift height (H), exhaust 12 mm
Permitted wear between base circle and max lift:
Inlet / Outlet / Unit injector 0.1mm
Valves
P0034833
Inlet
Valve, seat angle (A1) 29.45°
Valve seat, seat angle (A2) 30°
Outlet
Valve, seat angle (A1) 29.45°
Valve seat, seat angle (A2) 30°
Valve stem, inlet, diameter 8 mm

Valve stem, outlet, diameter 8 mm
36 47714430 02-2023 © AB VOLVO PENTA

P0034832
Valve dimensions below cylinder casing plane (A), inlet, max 1.6 mm
Valve dimensions below cylinder casing plane (A), outlet, 0.9 mm
max
P0034829
Radial play, inlet, valve/valve guide, max 0.5 mm

Radial play, outlet, valve/valve guide, max 0.5 mm
47714430 02-2023 © AB VOLVO PENTA 37

Valve seats
P0034834
Valve seat, inlet, height (H) 7.3 mm

Valve seat, inlet, diameter (D) 42.078 mm
Valve seat, outlet, height (H) 6.4 mm
Valve seat, outlet, diameter (D) 40.068 mm
Valve seat position in cylinder head, inlet, depth (A) 11.5 mm

Position of the valve seat in the cylinder head, inlet, diameter
(B) 42 mm
Valve seat position in cylinder head, inlet, radius (R) 0.8 mm
Valve seat position in cylinder head, outlet, depth (A) 9.9 mm
Position of the valve seat in the cylinder head, outlet,
diameter (B) 40 mm
Valve seat position in cylinder head, outlet, radius (R) 0.8 mm
Valve springs
Valve spring, length, unloaded 70.5 mm
Valve spring, length, loaded with 552 N 54.4/41.3 mm
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Cable description
Cold side, from above
P0036102
Cold side
P0036103
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Front side
P0036104
Hot side
P0036105
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From rear
P0036106
Alternator – Starter motor
P0036101
P0036108
P0036107
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IPS 2.3
P0036110
D11 Marine IPS STD
P0036109
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Lubrication System
Lubricating oil, engine
Oil grade VDS 4.5
Viscosity SAE10W/30 in normal conditions
Oil volume, (including oil filter): 59 liters

Oil volume between min and max markings: 10 liters
Engine Oil Pressure

Lubrication oil pressure, idle, hot engine, min 160 kPa @ 600 rpm
Lubrication oil pressure, operating speed, warm engine, min 270 kPa @ 1900 rpm
210 kPa @ 1200 rpm
Oil temperature, loaded, max 130°C
Thermostat
Thermostat, oil cooler, starts to open 104°C
Thermostat, oil cooler, fully open 116°C
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Fuel System
Fuel system
Injection pressure 1700 ± 150 bar
Pressure from feed pump, at idle, min 400 kPa
Pressure from feed pump, operating rpm, min 500 kPa
Max permissible negative pressure to feed pump -65 kPa relative
44 47714430 02-2023 © AB VOLVO PENTA

Inlet and Exhaust System

Turbo
Axial play (A) Visual inspection with the wheels not contacting the
housing
Radial play (B), turbine wheel Visual inspection with the wheels not contacting the
housing
P0034831
Charge air pressure

Charging pressure, max rpm/load, air temp 20-25⁰C 297-315 (850hp)
Depends on the power variant
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Cooling System
Cooling system
Coolant, type VCS 40/60
Coolant, volume 38 L (engine) + 95 L (radiator)
Opening pressure of the filling cap 100 kPa
Thermostat
Starts to open at 82°C
Fully open at 94°C
Seawater Pump
Capacity 410 L/m
46 47714430 02-2023 © AB VOLVO PENTA

03-3 Specifications, Electrical
03-3 Specifications, Electrical

Electrical System
System voltage 24 V
Generator, max charging current 110 A
47714430 02-2023 © AB VOLVO PENTA 47

05-1 Safety Instructions
05-1 Safety Instructions
Cleanliness requirements
Absolute cleanliness must be observed during all work on lead free bearings.
Even very small particles can have a markedly negative effect, especially on bearings.
Particles on bearing race during assembly can lead to relatively quickly occurring bearing failures.
The product's service life is directly dependent on the level of cleanliness maintained during service and repair
work.
Remember to:
• Thoroughly clean the outside of the engine before starting work.
• Keep the immediate surroundings clean while work is in progress (in the boat or workshop).
• If possible, make sure no dirt is brought in from outside. For example, close engine compartment ventilation.
Close the doors and such to the workshop workspace.
• Make sure no 'dirty' work takes place in the vicinity, i.e. no forklift driving, spray painting, grinding or welding
etc. nearby.
• Certain spare parts may need to be cleaned before installation.
NOTICE! Roller bearings and ball bearings may never be washed but must be stored in their packaging until
installation.
• Make sure all tools are clean when working.
• Use lint-free gloves and absorbent paper.
• Canned spray-on cleaning agent may be used as necessary, but not on rubber parts.
48 47714430 02-2023 © AB VOLVO PENTA

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools may be ordered from AB Volvo
Penta by specifying the number indicated.
827861 Spacer 884167 Drift 884895 Lock pin
885527 Sleeve 885536 Plug 885539 Plug
885810 Fixture 3849613 Pressure testing kit 9809726 Pneumatic hydraulic

pump
9809729 Hydraulic cylinder 9986485 Stand 9988539 Compression meter
47714430 02-2023 © AB VOLVO PENTA 49

9989876 Dial indicator 9990006 Puller 9990013 Slide hammer
9990105 Plate 9990106 Plate 9990107 Connection washer
9990114 Puller 9990156 Adapter 9990158 Piston ring

compressor
9990176 Press tool 9990185 Lifting tool 9990192 Puller
9990210 Valve spring 9991801 Standard handle 9992479 Holder for dial
compressor indicator
50 47714430 02-2023 © AB VOLVO PENTA

9992669 Drift 9992671 Hydraulic cylinder 9993590 Rotation tool
9996049 Draining hose 9996159 Adapter 9996239 Lifting tool
9996394 Support 9996395 Support 9996400 Slide hammer
9996591 Nipple 9996645 Puller 9996662 Pressure testing kit
9996666 Nipple 9996966 Press tool 9998248 Adapter
47714430 02-2023 © AB VOLVO PENTA 51

9998249 Protective sleeve 9998250 Sealing ring 9998251 Protection plug
9998264 Lifting tool 9998339 Manometer 9998493 Hose
9998511 Lever 9998601 Fixture 9999683 Dial indicator (short

probe)
9999696 Magnetic stand 21343236 Puller 88800003 Fixture
52 47714430 02-2023 © AB VOLVO PENTA

88800058 Stand 88800062 Drift 88800063 Drift
88800083 Piston ring pliers 88800146 Fixture 88800147 Drift
88800151 Drift 88800318 Piston ring 88800387 Puller

compressor
88800422 Extractor oil filter 88800501 Mounting tool 88800502 Puller
88800513 Drift
47714430 02-2023 © AB VOLVO PENTA 53

88800550 Cleaning kit Contains:

- 9808616 Extender
- 9808607 Bracket
- 9808617 Brush
- 9808613 Bracket
- 9808618 Brush
- 9808614 Brush
- 9998580 Protective sleeve
- 9808615 Bracket
88800561 Mounting tool 88800814 Adapter 88820015 Puller
88840300 Plate 88880175 Counterhold 88880176 Guide pin
88880193 Puller 88880194 Puller
54 47714430 02-2023 © AB VOLVO PENTA

20-0 Engine Information, General

Transmission Decals
IPS unit
A Product ID
B CHASSIS ID
C Serial number
P0030529
Rudder actuator
A Product information
B CHASSIS ID
C Product ID
P0028178
47714430 02-2023 © AB VOLVO PENTA 55

Reverse gear
ZF and Twin Disc reverse gears have no ID marking
from Volvo Penta.
For further information about maintenance and oil
quantities, refer to the manufacturer's manual/website
for the reverse gear.
NOTICE! Informational image, reverse gear; designs

differ between manufacturers/models.
56 47714430 02-2023 © AB VOLVO PENTA

Test and Adjustments

Exhaust Back Pressure, Check
Tools:
9996398 Manometer
9996591 Nipple
9998493 Hose
1 Install:
• nipple P/N 9996491
• manometer P/N 9996398
• hose P/N 9998493
2 Run the engine at operating speed until the value
is stabilized.
Max exhaust back pressure: 0.15 Bar
P0036426
47714430 02-2023 © AB VOLVO PENTA 57

Cylinder Head, Pressure Testing

Tools:
9990105 Plate
9990107 Connection washer
9996662 Pressure testing kit
Insert the sealing plates P/N 9990105 on the cylinder

head.
Use the screws for the cylinder head and M16 nuts (12
pcs.).
Connect the pressure test plate P/N 9996662 on the

connecting washer P/N 9990107, raise the pressure to
1 Bar.
The pressure must not drop below 5 bar.
Water baths at 70°C can be used.
NOTICE! Make sure that no dirt gets into the fuel

P0036356
galleries, since this could damage the unit injectors.
58 47714430 02-2023 © AB VOLVO PENTA

47714430 02-2023 © AB VOLVO PENTA 59

21-0 Engine Complete, General

Engine, to set TDC
Tools:
9993590 Rotation tool
• Valve cover off.

1 Remove flywheel casing cover.
P0036071
2 Mount the cranking adapter.
P0036072
60 47714430 02-2023 © AB VOLVO PENTA

3 Turn the engine until TDC on the camshaft

matches between two markings in the camshaft
bearing cap.
P0036070
47714430 02-2023 © AB VOLVO PENTA 61

Check and Fault Trace

Cylinder Head, Check
Tools:
9989876 Dial indicator
9992479 Holder for dial indicator
9999683 Dial indicator (short probe)
9999696 Magnetic stand
1 Perform the check with a feeler gauge and a
straight edge.
If the unevenness exceeds 0.04 mm, the cylinder
head must be replaced.
P0036306
2 Valve guides, check

Lift the valve from the seat.
Max permitted play is:
• Inlet: 0.5 mm
• Outlet: 0.5 mm
P0029373
62 47714430 02-2023 © AB VOLVO PENTA

3 Valve seats, check

The valve seat should be replaced when
dimension (L) exceeds:
• Inlet: 1.6 mm
• Outlet: 0.9 mm
P0036305
4 Valve seat bed, check

Check no cracks are present.
Measure valve seat diameter (D):
• Inlet: 42 mm
• Outlet: 40 mm
P0036307
47714430 02-2023 © AB VOLVO PENTA 63

Compression Test
Tools:
9988539 Compression meter
9998248 Adapter
• Rocker arm bridge, intermediate piece and injector
removed, see 23-7, Injector, Replace
NOTICE! The engines are fitted with a ”keystone” type

upper compression ring. This type of ring requires gas
pressure to function optimally.
Measurement results with this type of compression
ring can therefore give erroneous indications.
A simpler and more reliable test can be performed with
the VODIA-tool (refer to”VODIA User guide”).
1 Fit all the adapters to the cylinder head (to avoid

repeated removal/fitting of the rocker arm bridge
and fuel injectors and adjustment of the valve
clearances six times).
2 Add rocker arm bridge and intermediate section,
see 23-7, Injector, Replace.
3 Crank the engine with the starter motor until the
needle on the compression gauge stops moving
(max. compression value) and read off the value.
Repeat the test on all cylinders.
NOTICE! Do not run the starter motor for more

than 15 seconds at a time, with a rest interval of a
few minutes.
P0036776 4 Remove adapters and re-fit the injectors, see
23-7, Injector, Replace.
64 47714430 02-2023 © AB VOLVO PENTA

Camshaft, Wear Check

Rocker bridge removed.
Put a steel rule across the camshaft lobes, parallel with

the camshaft axis, to see if the cam profiles show signs
of wear.
Compare the measured values with those specified in

Administration, page 31.
P0036775
Guidelines for replacement

In normal conditions, unevenness may be present on
the surface of the engine camshaft lobes. This does
not mean that the camshaft must be changed. These
marks do not have any negative influence on either
engine performance or the durability of the engine and
its components.
Lighter scratching: The camshaft need not be

changed.
Hard wear: The camshaft and associated rocker arms
must be changed.
47714430 02-2023 © AB VOLVO PENTA 65

Connecting Rod, Check
Check the connecting rod in respect of cracks,

straightness and twist.
IMPORTANT! If the connecting rod or bearing cap are

damaged, change the connecting rod.
Important to remember when removing/installing a

"fracture-split" connecting rod.
When the cap is removed from the connecting rod, a

chip may be missing or come loose. This entails no
impairment of connecting rod function.
Handle the connecting rod and bearing cap carefully.

Any impact marks that occur on the parting line may
affect strength after torquing.
P0036777
66 47714430 02-2023 © AB VOLVO PENTA

Fitting the Fixture

Tools:
88800003 Fixture
88800146 Fixture
1 Remove marked components.
P0036323
2 Fit the fixture.
P0036324
47714430 02-2023 © AB VOLVO PENTA 67

Engine Disassembly
Tools:
9990013 Slide hammer
9990114 Puller
9992000 Handle
9996239 Lifting tool
9996394 Support
9996395 Support
9996645 Puller
9996966 Press tool
Tools:
1 Remove marked parts.
P0036265
P0036266
P0036267
68 47714430 02-2023 © AB VOLVO PENTA

P0036268
P0036269
6 Remove:
• suction pipe (s)
• return pipe (s)
P0036270
7 Remove the stiffening plate.
P0036271
47714430 02-2023 © AB VOLVO PENTA 69

8 Remove the piston cooling nozzles.
P0036272
9 Mark and remove the bearing caps, connecting

rod and piston.
P0036273
10 Pull the cylinder liner out of the block.

Remove the cylinder liner sealing rings.
P0036274
70 47714430 02-2023 © AB VOLVO PENTA

11 Remove the flywheel.
P0036275
12 Remove the timing gear casing.
P0036276
13 Remove:
• transmission wheel
• oil pump
P0036277
47714430 02-2023 © AB VOLVO PENTA 71

14 Remove the timing gear plate.
P0036278
72 47714430 02-2023 © AB VOLVO PENTA

Engine Assembly
Tools:
9989876 Dial indicator
9992479 Holder for dial indicator
9998511 Lever
88800318 Piston ring compressor
88840300 Plate
Tools:
1 Install:
• bearing
• crankshaft
NOTICE! Lubricate bearings and crankshaft.
P0036281
2 Install the main bearing caps.

• Step 1: 150 Nm
• Step 2: Angle tightening 120°
P0036282
47714430 02-2023 © AB VOLVO PENTA 73

3 NOTICE! Apply a bead of sealant P/N 1161231

with a diameter of approx. 2 mm, see illustration.
P0036283
4 Install the timing gear plate.

Tightening torque: 24 Nm
P0036278
5 Install new seals.
P0036284
74 47714430 02-2023 © AB VOLVO PENTA

6 Insert transmission wheels according to

numerical order.
NOTICE! Install the double drive (5) so that the

marking matches the markings on the crankshaft
drive (2).
For tightening torque, see Group 21 -

Engine, page 12.
P0036285

P0036286
8 Install the timing gear casing.

• M8: 35 Nm
• M12: 110 Nm
• M14: 165 Nm
P0036276
47714430 02-2023 © AB VOLVO PENTA 75

9 Install a new crankshaft seal, see Crankshaft

Seal, Replace (rear), page 108.
NOTICE! The metal side of the seal ring must

face inward.
P0036287
10 Install the flywheel.

• Step 1: 60 Nm
P0036288

12 Install the casing.
P0036289
76 47714430 02-2023 © AB VOLVO PENTA

13 Install the crankshaft seal; refer to Crankshaft

Seal, Replace (front), page 106.
P0036290
14 Fit the cylinder liner without seal rings. Affix it with

two press tools P/N 9996966.
15 Insert the dial indicator in the retainer. Place the
retainer across the cylinder liner. Zero the
indicator with a couple of millimeters' pre-load
against the cylinder block plane (1).
Measure the height between the highest point of
the cylinder liner and the plane of the cylinder
block in two different places diagonally to each
other and calculate the average value of the
measurement results (2).
If the liner height above the block plane is outside
specified tolerances, a shim shall be used when
installing.
P0036291
16 If the cylinder liner is fitted without shims, an even,

about 0.8 mm thick bead of sealing compound P/
N 1161231 must be placed on the underside of
the cylinder liner collar.
If the cylinder liner is installed with shims, apply
the sealant bead to the cylinder block liner seat.
NOTICE! Do not put the seal around the entire

liner. Leave a 2 mm opening.
NOTICE! Sealant must not be used between the

shims and the cylinder liner collar.
NOTICE! After applying the sealant, the liner

must be installed within 20 minutes. Use pressing
tools P/N 9996966 to hold the liner in place.
P0036292
Apply the included lubricant to the sealing rings of
the liner and install the seals on the lining.
NOTICE! The violet-colored seal must be located

at the bottom of the lining.
47714430 02-2023 © AB VOLVO PENTA 77

17 Insert one of the cylinder head screws and press

the cylinder liner down with a prybar and puller
plate.
Use the appropriate spacer between plate and
prybar. Secure the liner with P/N 9996966 press
tool.
P0036293
18 Lubricate the piston pin and the piston bearing

seat with engine oil and install the connecting rod.
IMPORTANT:
The mark “FRONT” on the connecting rod and the

arrow on the piston must face the same direction.
19 Install the piston rings evenly spaced in relation to
each other. The oil scraper ring opening must be
diametrically opposite the opening in the spring.
IMPORTANT:
The marking on the upper piston rings shall face

upwards. The oil ring can be installed in both
P0036294
directions.
20 Tightening torque big end bearing cap:

• Step 1: 20 Nm
• Step 2: 35 Nm
P0036295
78 47714430 02-2023 © AB VOLVO PENTA

21 Install the piston cooling jets:

P0036272
22 Install reinforcing plate:

P0036271
23 Install:
• Suction pipe
• Return pipe
P0036270
24 Install marked parts.
P0036269
47714430 02-2023 © AB VOLVO PENTA 79

P0036268
P0036267
P0036266
P0036265
80 47714430 02-2023 © AB VOLVO PENTA

47714430 02-2023 © AB VOLVO PENTA 81

21-1 Cylinder Head
21-1 Cylinder Head

Cylinder Head, Replace
Removal
Tools:
884895 Lock pin
885810 Fixture
9990006 Puller
9990192 Puller
9998249 Protective sleeve
9998251 Protection plug
9998601 Fixture
9999683 Dial indicator (short probe)
9999696 Magnetic stand
1 Remove:
• the exhaust manifold; refer to Exhaust
Manifold, Replace, page 130
• the inlet manifold, refer to 25-1, Intake
Manifold, Replace
• the heat exchanger, refer to Heat
exchanger, Replace, page 163
• oil filter bracket, refer to 22-2, Oil Filter
Bracket, Replace
• expansion tank, refer to Expansion Tank,
Replace, page 166
• thermostat housing/thermostat, refer to
Thermostat, Replace, page 169
• starter motor, refer to Starter Motor,
Replace, page 188
2 Remove:
• fuel return line
• switch to crankcase pressure sensor
• screw to hose crankcase recirculation
P0036134
82 47714430 02-2023 © AB VOLVO PENTA

21-1 Cylinder Head
3 Remove:
• water pipe
• temperature sensor
P0036135
4 Remove the valve cover.
P0036137
5 Remove:
• contacts to unit injector(s)
• cable clips
• screw to upper timing gear casing
Thread the cabling out of the timing gear casing.
P0036136
47714430 02-2023 © AB VOLVO PENTA 83

21-1 Cylinder Head
6 Remove:
• camshaft sensor
• for upper timing gear casing
P0036138
7 Remove the camshaft gear and oscillation

damper.
NOTICE! The oscillation damper is very sensitive

to shocks.
P0036139
8 Remove screws in the timing gear plate.

Two screws behind the transmission gears are
reached by turning the engine.
9 Remove unit injectors, refer to Unit Injector,
Replace, page 115.
P0036140
84 47714430 02-2023 © AB VOLVO PENTA

21-1 Cylinder Head
10 Remove:
• camshaft bearing cap
• camshaft
• bearing brackets
NOTICE! Mark up positioning for reassembly.
P0036144
11 Remove the cylinder head.

Use 2 lifting chains to lift off the cylinder head.
P0036145
Installation
12 Clean the mating surfaces.
P0036146
47714430 02-2023 © AB VOLVO PENTA 85

21-1 Cylinder Head
13 Fit a new cylinder head gasket.
P0036147
14 Apply a 2 mm string of P/N 1161231 to the rear

edge of the cylinder head.
P0036148
15 Install the cylinder head to the engine.

Attach screws to the transmission side to pull the
cylinder head firmly against the transmission
plate so that sealant is applied.
Tightening torque: 24 Nm, then loosen screws 1
turn.
NOTICE! The cylinder head must not be moved

after this operation.
P0036149
86 47714430 02-2023 © AB VOLVO PENTA

21-1 Cylinder Head
16 Install the cylinder head, refer to Group 21 -

Engine, page 12.
P0036151
17 Mark the bolt with a bearing mark.
NOTICE! The screws may only be used 2 times.
P0036152
18 Tighten the screws in the timing gear plate.

P0036153
47714430 02-2023 © AB VOLVO PENTA 87

21-1 Cylinder Head
19 Turn engine to TDC with 9993590.

Lock the engine with 884895.
P0036154
20 Lubricate and attach the camshaft with bearing

brackets.
P0036155
21 The camshaft shall be mounted in TDC.
P0036156
88 47714430 02-2023 © AB VOLVO PENTA

21-1 Cylinder Head
22 Tighten the camshaft bearing cap, refer to Group

21 - Engine, page 12
P0036157
23 Install the camshaft gear without the oscillation

damper.
24 Loosen the two lower screws in the adjusting
wheel.
Check that the upper screws are not tightened
Place a feeler gauge on the pressure side. Press
the camshaft gear against the feeler gauge.
Tightening torque, adjustment wheel:
• 35 Nm
• 120°
Tightening torque camshaft gear:
• 45 Nm
P0037212
• 90°
25 Check the gear backlash setting, redo the step
above if backlash is not correct.
Gear backlash: 0.05-0.17mm
P0036159
47714430 02-2023 © AB VOLVO PENTA 89

21-1 Cylinder Head
26 Apply a bead of sealant P/N 1161231 with a

diameter of approx. 2 mm.
Install new gaskets.
P0036160
27 Install the timing gear casing. Fasten the casing

with two screws, loosely. The holes for the screws
are oblong.
Use tools to press down on the casing.
P0036161
28 Tighten screws in numerical order 24 Nm.
P0036162
90 47714430 02-2023 © AB VOLVO PENTA

21-1 Cylinder Head
29 Install the camshaft sensor.
P0036163
30 Install all the unit injector(s), refer to Unit Injector,

Replace, page 115.
31 Carry out Valves and Unit Injectors,
Adjustment, page 99.
P0036429
32 Add the intermediate section with oil pipe to the

rocker arm.
Attach wire harness to unit injector(s) with oil and
heat resistant cable ties.
33 Apply a strand of sealant P/N 1161231 with a
diameter of approximately 2 mm on the mating
surface between the transmission casing and
cylinder head.
P0036167
47714430 02-2023 © AB VOLVO PENTA 91

21-1 Cylinder Head
34 Refit the valve cover.

P0036168
35 Install:
• fuel return line
• switch to crankcase pressure sensor
• screw to hose crankcase recirculation
P0036134
36 Install:
• water pipe
• temperature sensor
P0036135
92 47714430 02-2023 © AB VOLVO PENTA

21-1 Cylinder Head
37 Remove the tool.

38 Install:
• starter motor, refer to Starter Motor,
Replace, page 188
• thermostat housing/thermostat, refer to
26-2, Thermostat, Replace
• expansion tank, refer to Expansion Tank,
Replace, page 166
• oil filter bracket, refer to 22-2, Oil Filter
Bracket, Replace
• the heat exchanger, refer to Heat
exchanger, Replace, page 163
P0036154
• the inlet manifold, refer to Intake Manifold,
Replace, page 133
• the exhaust manifold; refer to Exhaust
Manifold, Replace, page 130
47714430 02-2023 © AB VOLVO PENTA 93

21-1 Cylinder Head
Cylinder Head, Overhaul

Tools:
827861 Spacer
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990176 Press tool
9990210 Valve spring compressor
9991801 Standard handle
9992669 Drift
9992671 Hydraulic cylinder
9996159 Adapter
88800058 Stand
88800062 Drift
88800063 Drift
88800147 Drift
88800151 Drift
88880175 Counterhold
88880176 Guide pin
88880193 Puller
88880194 Puller
Tools:
1 Position the fixture.
P0036347
2 Remove:
• valve cotters (valve cones)
• spring washer and spring
• valves
P0036346
94 47714430 02-2023 © AB VOLVO PENTA

21-1 Cylinder Head
3 Place the valves in a stand, to allow reinstallation

in their original places.
P0029360
4 Holding the puller (A), screw the stick handle into

position.
NOTICE! The tool is identified by the number of

the expander.
P0034916
5 Insert the counterhold and screw the hydraulic

cylinder into position
IMPORTANT:
Stop pumping as soon as the seat loosens.
P0034917
47714430 02-2023 © AB VOLVO PENTA 95

21-1 Cylinder Head
6 Cool the valve seat and heat the cylinder head

Install the valve seat.
P0036360
7 Grind valves and valve seats according to

specification, refer to Administration, page 31.
NOTICE! Spare part valves are already

machined, and do not need further grinding.
P0029358
8 Remove the valve stem seals.
P0036351
96 47714430 02-2023 © AB VOLVO PENTA

21-1 Cylinder Head
9 Press out the valve guides.
NOTICE! Use only nuts on tool 9990176.
P0036345
10 NOTICE! Oil the valve guide outsides with engine

oil before installation.
Press home new valve guides.
P0036352
47714430 02-2023 © AB VOLVO PENTA 97

21-1 Cylinder Head
11 Insert a valve and tape the blue-marked area.

Install new valve stem seals.
P0036349
12 Install:
• valve cotters (valve cones)
• spring and spring washer
P0036348
98 47714430 02-2023 © AB VOLVO PENTA

21-4 Valve Mechanism

Valves and Unit Injectors,
Adjustment
Standard valve mechanism V1-V6.
Camshaft marking and valve mechanism.
P0036334
Timing marks
Marks 1–6 apply to inlet valve and unit injector
adjustment.
The marks V1-V6 apply to exhaust valve adjustment.
NOTICE! It is important that the line on the camshaft is

between the markings on the bearing cap when the
adjustment is made.
P0020168
47714430 02-2023 © AB VOLVO PENTA 99

Adjustment
Tools:
2 Fit the cranking adapter.
3 Crank the engine to the nearest camshaft
marking.
P0020169
4 Adjust the valve clearance to 0.2 mm.

Tighten the lock nuts; refer to Group 21 -
Engine, page 12.
Check valve clearance. 0.2 ± 0.05 mm.
P0020127
100 47714430 02-2023 © AB VOLVO PENTA

5 Adjust the pre-load until play is obtained. Tighten

the adjusting screw an additional 240°.
P0020129
6 Crank the engine to the next marking on the

camshaft.
7 Adjust the valve clearance to 0.8 mm.
Tighten the locking nuts, refer to Group 21 -
Engine, page 12.
Check valve clearance. 0.8 ± 0.05 mm.
8 Adjust the remaining valves and injectors in the
same way.
9 Remove the cranking adapter.
P0020172
V3 = Exhaust cylinder 3
10 Apply an even 2 mm strand of sealant between

the cylinder head and the timing gear casing.
NOTICE! The valve cover must be installed within

20 minutes of sealant application.
11 Install the valve cover.
P0037213
47714430 02-2023 © AB VOLVO PENTA 101

21-5 Timing Gears and Shaft

Camshaft Bearing Housing,
Replace
The factory-installed bearing housings are machined
together with the cylinder head, and therefore must not
be moved from one cylinder head to another.
Therefore, the first time one or more bearing housings

are replaced, they must all be replaced so that their
positions can be aligned. From then on, bearing
housings may be changed individually since the
replacement part variant differs from the production
variant.
P0036326
The holes for the guide sleeves are oval in the

replacement housings, which allows radial adjustment
of the center bearing housing and axial adjustment of
the front and rear bearing housings.
If replacement housings are installed, number them so

they can be put back in the same place as before, if
they must be removed.
P0036325
102 47714430 02-2023 © AB VOLVO PENTA

Gear Ring, Fywheel: Replace

Prerequisite flywheel removed.
1 Drill 1-2 holes in the gap between teeth on the ring
gear.
Split the gear ring using a cold chisel.
P0028593
2 Heat the gear ring.

Tap the gear ring into place using a copper drift.
P0028594
47714430 02-2023 © AB VOLVO PENTA 103

Drive Belts, Replace

1 Remove the belt protector.
P0035613
2 Place a 1/2" square wrench in the belt tensioner.

Loosen and remove the drive belt.
3 Check the function of the tensioner, the condition
of the belt pulleys and the idler pulley bearings.
4 Install a new belt.
P0035612
5 Install the belt protector.
104 47714430 02-2023 © AB VOLVO PENTA

Flywheel, Replace
• Propshaft, power transmission removed.
Tools:
1 Crank the engine to TDC.
2 Remove:
• flywheel sensor
• flywheel
P0035662
NOTICE! Use cranking adapter as a counterhold.
3 Install:
• flywheel
Tightening torque:
Step 1: 60 Nm
Step 2: 120° (angle tightening)
• flywheel sensor
47714430 02-2023 © AB VOLVO PENTA 105

21-6 Crank Mechanism

Crankshaft Seal, Replace (front)
Tools:
88800501 Mounting tool
88800502 Puller
88800814 Adapter
Removal
Remove drive belt, refer toDrive Belts,
Replace, page 104.
Remove oscillation damper / belt pulley.
1 Adjust the arms and attach the tool.
Settings: A
1 Forward: The hooks release
Back: The hooks grip
2 Tension nut
3 Slowly pull the seal off.
P0025163
Installation
Important! The metal side of the seal ring must face
inward.
2 Slide the seal ring onto the tool and screw tight.
Install:
• adapter
• the tool
Press the seal in until the cover touches the
bottom. Hold in position for at least 3 seconds.
P0036387
106 47714430 02-2023 © AB VOLVO PENTA

3 Reference dimension for a correctly installed

seal.
Install oscillation damper / belt pulley.

Install drive belt, refer toDrive Belts,
Replace, page 104.
P0036388
47714430 02-2023 © AB VOLVO PENTA 107

Crankshaft Seal, Replace (rear)

Tools:
88800502 Puller
88800561 Mounting tool
Removal
1 Setting: B
Adjust the arms and attach the tool.
1 Forward: The hooks release
Back: The hooks grip
2 Tension nut
3 Slowly pull the seal off.
P0025163
Installation
Important! The metal side of the seal ring must face
inward.
2 Slide the seal ring onto the tool.
Screw the tools with the seal onto the crankshaft.
Press the seal in until the cover touches the
bottom. Hold in position for at least 3 seconds.
P0036385
108 47714430 02-2023 © AB VOLVO PENTA

3 Reference dimension for a correctly installed

seal.
P0036386
47714430 02-2023 © AB VOLVO PENTA 109

23-0 Fuel System, General
23-0 Fuel System, General

Fuel Feed Pressure, Check
Tools:
9996666 Nipple
9998339 Manometer
9998493 Hose
1 Remove the venting nipple of the water separator
and mount the tools.
The fuel pressure shall be at least 100 kPa at 600
rpm and at least 300 kPa at 1200 rpm.
NOTICE! Low feed pressure can be the result of

a blocked fuel filter, a defective overflow valve or
a defective feed pump.
P0036300
110 47714430 02-2023 © AB VOLVO PENTA

23-3 Fuel Feed Pump and Filter

Fuel filter, Change
Tools:
88800422 Extractor oil filter
NOTICE! Be prepared to collect fluids.
1 Close the fuel tap.

2 Relieve the pressure by opening the drain tap.
Remove the WIF sensor and unscrew the water
separator.
Remove the filter.
3 Lubricate the O-rings with diesel.
NOTICE! Use a new component.
Install the filter.

Screw the filter until it has contact, then according
to the instructions on the filter.
P0036407
4 Open fuel tap.

5 Bleed the fuel system, refer to Fuel system,
bleeding, page 114.
47714430 02-2023 © AB VOLVO PENTA 111

Fuel System, Drainage

NOTICE! Be prepared to gather up fluid.
1 Disconnect the outlet hose and the inlet hose

from the fuel pump.
P0036301
2 Open the venting nipple of the water separator.
P0036304
3 Disconnect the hose to the inlet of the electronic

unit cooling coil.
P0036302
112 47714430 02-2023 © AB VOLVO PENTA

4 Remove the fuel hose between the filter and

cylinder head.
Bend out the hose place the end into a suitable
container.
P0036409
5 Put a nipple on the cylinder head.

Use a suitable hose and blow fuel through the fuel
channel.
P0036410
47714430 02-2023 © AB VOLVO PENTA 113

Fuel system, bleeding

1 Remove the cover.
Loosen the nipple slightly.
Connect a transparent hose.
2 Pump until fuel flows without air bubbles.
Tighten the nipple while the fuel flows.
3 Remove the hose.
Tighten the nipple.
Tightening torque: 3.5 Nm.
4 Install the cover.
P0036411
114 47714430 02-2023 © AB VOLVO PENTA

23-7 Injectors and Delivery Pipes

Unit Injector, Replace
IMPORTANT:
Working with the fuel system requires special
cleanliness.
Clean thoroughly before removing.
Install plugs in open connections.
CAUTION!
The fuel system may be pressurized.

When working on the fuel system, exercise caution
when disconnecting the first location in a closed
system.
Tools:
9990006 Puller
9998249 Protective sleeve
9998599 Cleaning kit
2 Remove:
• intermediate housing
• pipe
• rocker arm bridge
P0036321
47714430 02-2023 © AB VOLVO PENTA 115

3 Remove the valve caliper, note the location on the

valve calipers.
P0036320
4 Remove:
• connector
• fastening caliper
P0036312
5 Remove the injector.

Install a protective plug on the injector.
NOTICE! Mark the injector positioning.
P0036314
116 47714430 02-2023 © AB VOLVO PENTA

6 Clean the sleeve.
P0036313
P0036412
Installation
8 Lubricate the O-rings with diesel
P0036413
47714430 02-2023 © AB VOLVO PENTA 117

9 Position the injector, tightening the screw as

follows:
Tightening torque when replacing the copper
sleeve:
1 20 Nm
2 180°
3 loosen the screw
4 20 Nm
5 60°
Tightening torque when refitting the old copper
sleeve:
1 20 Nm
P0036414 2 60°
10 Install the connector.
11
NOTICE! When replacing an injector, a new

injector code must be programmed into the
control unit. The code can be found on the
injector, see photo.
P0036316
12 Install the valve calipers.

13 Lubricate the valve calipers and camshaft lobes
with engine oil.
P0036319
118 47714430 02-2023 © AB VOLVO PENTA

14 Install:
• valve
• pipes
• rocker arm bridge
For tightening torque, refer to Group 21 -
Engine, page 12.
P0036322
47714430 02-2023 © AB VOLVO PENTA 119

Sleeve for unit injector, replace

Tools:
9998250 Sealing ring
9998251 Protection plug
9998599 Cleaning kit
88800387 Puller
88800460 Sleeve
88800513 Drift
• Valve cover removed
• Rocker arm bridge and unit injector removed, refer
to 23-7, Injector, Replace.
• Cooling system drained; refer to Coolant,
Replace, page 156.
IMPORTANT!Working with the fuel system requests

special cleanliness.
IMPORTANT!Install safety plugs in open connections.
CAUTION! The fuel system may be pressurized.

Exercise caution when disconnecting the first location
in a closed system.
1 Remove any protective plugs.
P0036666
2 Install 2 seal rings to prevent dirt from entering the

fuel ducts.
P0036668
120 47714430 02-2023 © AB VOLVO PENTA

3 Press down on the puller until it bottoms out

against the injector sleeve.
Tighten the nut until the expander grips the
sleeve.
P0036661
4 Thread the sleeve over and screw on the puller.

Screw on the nut with bearing to extract the
injector sleeve.
P0036660
5 Lift out the tooling and sleeve.
P0036669
47714430 02-2023 © AB VOLVO PENTA 121

6 Use brushes from the cleaning kit, P/N 9998599

before installing a new sleeve.
Install the protective sleeve in the injector well
and affix it.
Clean the cylinder head walls.
P0030396
7 Clean the sleeve seat.
P0030397
8 Clean the cylinder head wells.

IMPORTANT! Check that the piston is in its lower
position in the cylinder to avoid damage.
P0030398
122 47714430 02-2023 © AB VOLVO PENTA

9 Lubricate the tap with engine oil.
P0025230
10 Put the injector sleeve on the drift and lubricate

the O-ring with soapy water.
P0036662
11 Press down on the mandrel and affix it with the

attachment caliper of the unit injector.
12 Run the tap down through the tip of the sleeve.
Remove the tool.
P0036665
47714430 02-2023 © AB VOLVO PENTA 123

13 Remove the seal rings.

14 Insert injector and rocker arm bridge, refer to
23-7, Injector, Replace.
15 Install the valve cover.
16 Fill coolant, refer to Coolant, Replace, page 156.
P0036668
124 47714430 02-2023 © AB VOLVO PENTA

23-8 Control System, ECM, Data Sets

Control Unit, Replace
Before replacing the component and for warranty

claims, troubleshooting according to troubleshooting
information shall be performed.
The prerequisite for a correct warranty claim process is
that all measured values in the Checklist are
completed and that a copy of the complete Checklist is
attached to the complaint.
For information about re-programming and reading out

software, refer to “Service Manual Group 30 Electrical
system”.
P0036231
1 Cut the power.

2 Close the fuel taps.
3 Disconnect the fuel lines to the control unit
cooling coil.
Plug the lines and cooling coil.
P0036230
4 Disconnect:
• control unit with wire harness
• protective cover with control unit
• wire harness clamps
• bracket and cables
47714430 02-2023 © AB VOLVO PENTA 125

5 Open the clamps and disconnect engine

connectors.
6 Transfer the cooling element to the new control
unit.
7 Install all the remaining components.
8 Open the fuel taps.
9 Bleed the fuel system, refer to 23-0, Fuel system,
bleeding.
P0036232
10 Turn the main switch on.
P0036233
126 47714430 02-2023 © AB VOLVO PENTA

Identifying the engine control unit

Identification is done via the CHASSIS ID number.
IMPORTANT!
The CHASSIS ID number on the decal on the control
unit must coincide with the CHASSIS ID number on the
decal on the protective cover over the engine, and the
decals on the PCU and HCU.
47714430 02-2023 © AB VOLVO PENTA 127

25-0 Inlet and Exhaust System, General

Compressor, oil level check
• Check that the oil level (1) is located within the

marking on the stick.
• If necessary, top up compressor oil for charge air
compressor.
P0035663
Turbocharger, check
Check:
• that no visible external damage to the compressor
wheel/turbine wheel is present.
• Press the turbine wheel/compressor wheel axially
and radiantly while rotating the shaft. No contact
between the turbine wheel or compressor wheel and
their housings may occur.
Bear in mind:
• Oil accumulation in the intake system downstream
of the turbocharger may indicate a worn
turbocharger.
P0034831 • Heavy carbon deposits on the turbine blades may
indicate a worn turbocharger.
128 47714430 02-2023 © AB VOLVO PENTA

47714430 02-2023 © AB VOLVO PENTA 129

25-1 Inlet and Exhaust Manifolds

Exhaust Manifold, Replace
• Cooling system drained; refer to Coolant,
Replace, page 156.
Removal
1 Remove the turbocharger, refer to 25-5, Turbo,
Replace.
2 Remove the charge air cooler; refer to Charge Air
Cooler, Replace, page 171.
3 Remove the lifting eye.
P0036246
4 Remove coolant pipe.
P0036245
130 47714430 02-2023 © AB VOLVO PENTA

5 Remove the exhaust manifold.
P0036247
Installation
6 Install new seals / gaskets.
P0036248
7 Install the exhaust manifold.

Engine, page 12.
P0036247
8 Install the coolant pipe.
P0036245
47714430 02-2023 © AB VOLVO PENTA 131

9 Install the lifting eye.
Install:
• charge air cooler, refer to Charge Air Cooler,
Replace, page 171.
• turbocharger, refer to Turbo, Replace, page 136.
Refill with coolant, refer to Coolant Level, Checking
and Topping Up, page 159.
P0036246
132 47714430 02-2023 © AB VOLVO PENTA

Intake Manifold, Replace
Removal
1 Drain the fresh water system, refer toCoolant,
Replace, page 156.
2 Remove expansion tank and the plastic cover of
the relay box.
P0036235
3 Detach bracket to relay box and CCV unit.

Move the bracket to one side.
P0036234
4 Remove the charge air tube and gasket towards

the inlet pipe.
P0036237
47714430 02-2023 © AB VOLVO PENTA 133

5 Remove:
• charge air pressure sensor
• inlet pipe
P0036236
Installation
6 Use sealant P/N 1161231.
P0036238
7 Install:
• inlet pipe
• charge air pressure sensor
NOTICE! The inlet pipe must be installed within
20 minutes of applying the sealant.
P0036236
134 47714430 02-2023 © AB VOLVO PENTA

8 Install the charge air pipe.

Engine, page 12.
P0036237
9 Install bracket to relay box and CCV unit.
P0036234
10 Install expansion tank and the plastic cover of the

relay box
11 Fill the fresh water system in accordance with
Coolant, Replace, page 156.
P0036235
47714430 02-2023 © AB VOLVO PENTA 135

25-5 Turbo and supercharger

Turbo, Replace
Always identify and correct the cause of turbocharger
failure before fitting a new turbocharger.
Check and rectify in accordance with: 25-5,
Turbocharger, Inspection.
Blow any rust and soot flakes out of the exhaust

manifold when replacing the turbocharger. Soot flakes
can damage the turbine rotor in the new unit.
Removal
1 Drain the freshwater cooling system, refer to
Draining the Seawater System, page 155.
2 Remove:
• exhaust pipe
• inlet pipe
• charge air pipe
P0035623
3 Remove air filters, refer to Air Filter,

Replace, page 154.
4 Remove protecting plate.
Loosen the vacuum hose.
P0035703
136 47714430 02-2023 © AB VOLVO PENTA

5 Remove the insulation.
P0035708
6 Remove the inner attaching plate.
P0035704
7 Remove the shutter housing.
P0035702
47714430 02-2023 © AB VOLVO PENTA 137

8 NOTICE! Be prepared to gather up fluid.
Remove the oil feed line.
P0035705
9 Remove the coolant line.
P0035701
10 Remove the oil return pipe.
P0035706
138 47714430 02-2023 © AB VOLVO PENTA

11 Remove:
• bracket
• charge air pipe
P0035700
12 Remove the turbocharger.
P0035707
47714430 02-2023 © AB VOLVO PENTA 139

Installation
13 Clean the sealing surface.
Install:
• washers and new nuts
• turbocharger
for tightening torque, refer to Group 21 -
Engine, page 12.
P0035699
14 Install:
• bracket
• charge air pipe
P0035700
15 Install the return oil pipe.
P0035706
140 47714430 02-2023 © AB VOLVO PENTA

16 Refit the coolant line.
P0035701
17 Install the oil supply line.
P0035705
18 Remove the shutter housing.
P0035702
47714430 02-2023 © AB VOLVO PENTA 141

19 Install the inner attachment plate.
P0035704
20 Install the insulation.
P0035708
21 Install:
• heat shield plate
• vacuum hose
P0035703
22 Install air filter, refer to Air Filter,

Replace, page 154.
142 47714430 02-2023 © AB VOLVO PENTA

23 Install:
• inlet pipe
• charge air pipe
• exhaust pipe
P0035623
Supplementary work
24 Check engine oil level, fill as necessary.
25 Top up with coolant; refer to Coolant Level,
Checking and Topping Up, page 159.
47714430 02-2023 © AB VOLVO PENTA 143

Compressor oil, Replace

1 Drain the oil:
• Unscrew the plug (2).
• Alternatively, suck out the oil with a hose
through the hole for the dipstick (1).
2 Fill with oil.
NOTICE! Use compressor oil for charge air

compressor P/N 85108974.
3 Install the plug (2).
P0035663
144 47714430 02-2023 © AB VOLVO PENTA

Drive Belt, Replace
Compressor
1 Remove the inlet manifold and charge air pipe.
P0035623
2 Remove the cable bracket; let it hang to one side.
P0035619
47714430 02-2023 © AB VOLVO PENTA 145

3 Remove the protective cover.
P0035621
4 Remove cardan covers.
P0035620
5 Remove protecting covers.
P0035622
146 47714430 02-2023 © AB VOLVO PENTA

6 NOTICE! Before removal, secure the bearing

carriers in position with tape.
Remove the propeller shaft.
P0035617
7 Relieve the load on the belt tensioner and remove

the belt. Insert an 8 mm drill.
P0035618
8 Check to see if there is play in the tension pulley

bearing.
Replace as necessary.
9 Fit a new belt.
Release the belt tensioner.
P0035616
47714430 02-2023 © AB VOLVO PENTA 147

10 Install the propeller shaft.

Tightening torque: 85 Nm.
Remove the tape.
P0035617
11 Install the protecting covers.
P0035622
12 Install the cardan covers.

Tightening torque: 50 Nm.
P0035620
148 47714430 02-2023 © AB VOLVO PENTA

13 Install the protective cover.
P0035621
14 Screw on the cable mount.
P0035619
15 Install the inlet pipe and charge air pipe.
P0035623
47714430 02-2023 © AB VOLVO PENTA 149

Mechanical Compressor
Compressor, Replace
Remove the compressor drive belt, refer to Drive Belt,
Replace, page 145.
1 Remove:
• Inlet pipe. Scrape the surface free from
sealant.
• Outlet pipe with gasket.
P0035695
2 Remove:
• Tension wheel
• Belt tensioner
P0035696
150 47714430 02-2023 © AB VOLVO PENTA

3 Unscrew the compressor.

4 Install:
• Compressor
• Belt tensioner
• Tension wheel
P0035697
5 Install:
• Outlet pipe with gasket
• Inlet pipe. Use P/N 1161231 sealant.
P0035694
6 Install the compressor drive belt, refer to Drive

belt, compressor.
47714430 02-2023 © AB VOLVO PENTA 151

Magnetic Coupling, Replace

Tools:
885527 Sleeve
21343236 Puller
88820015 Puller
Remove the compressor according to Compressor,

Replace, page 150.
Removal
1 Remove the center nut.
Use pullers to remove the pressure plate. Save
the shims located beneath the pressure plate.
P0036310
2 Bend the lock washer down.

Remove nut with special tools.
Remove the lock washer
3 Lift the solenoid clutch unit off.
Turn the retaining ring so that the opening ends
up in the groove with the wire harness. Ensure
that the harness is not twisted.
P0036309
152 47714430 02-2023 © AB VOLVO PENTA

4 Inspect the shaft journal, replace as necessary.

Loosen screws, use pullers to remove the shaft
journal
P0036308
Installation
5 Install:
• cable and turn retaining ring 45°
• solenoid clutch unit
• lock washer
Tightening torque, nuts: 80 Nm.
Bend the lock washer up.
P0036309
6 Install the pressure plate.

Check the play between pressure plate and
solenoid clutch unit. Reduce or increase shim
thickness to achieve the correct play.
Tightening torque, nuts: 22 Nm
P0036311
47714430 02-2023 © AB VOLVO PENTA 153

25-6 Air Cleaner, Throttle Housing
25-6 Air Cleaner, Throttle Housing

Air Filter, Replace
1 Remove the casing.
2 Loosen the clamp, pull off the filter.
3 Install a new filter and tighten the clamp.
4 Install the casing.
P0035661
154 47714430 02-2023 © AB VOLVO PENTA

26-0 Cooling System, General

Draining the Seawater System
WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.
1 Connect drain hoses to the drain points.

2 Open the heat exchanger drain tap.
P0035660
3 Open the drain tap of the charge air cooler.
P0035659
4 Drain the seawater.

5 Close the drain cocks.
6 Open the sea cock.
47714430 02-2023 © AB VOLVO PENTA 155

Coolant, Replace
Tools:
9996049 Draining hose
CAUTION!
Avoid opening the filler cap for engine coolant system
(freshwater cooled engines) when the engine is still
hot. Steam or hot coolant can spray out as system
pressure is lost.
NOTICE! Use suitable safety equipment when working

with the system.
1 • Open the expansion tank cap (A).

• Connect drain hoses to the drain points (X)
• Connect to a drainage vessel.
• Drain the coolant.
• Check that all the coolant drains out.
• Remove the tools.
2 Refill with new, Volvo Penta-recommended
coolant fluid.
Refer to Administration, page 46 and Cooling
system, filling, page 160.
P0035636
156 47714430 02-2023 © AB VOLVO PENTA

Cooling System, Cleaning
Internal cooling system

WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.
1 Mix cleaning liquid and neutralization liquid

according to the volume of the current cooling
system.
• Cleaning agent: Citric acid (C6H8O7) 30
grams to 1 liter of water (preferably distilled
water).
• Neutralization fluid: Bicarbonate (NaHCo3)
6 grams to 1 liter of water.
2 Drain the cooling system (all draining points and
low-placed hoses etc).
• Fill the cooling system with cleaning agent.
• Run the engine for about 8 hours with
relatively high load (to open the thermostats
fully).
• Fill the cooling system with neutralization
fluid.
• Run the engine for about 1 hour with
relatively high load.
• Fill the cooling system with approximately
10% glycol mixture.
NOTICE! Use the correct type of coolant.
Refer to the engine specifications.
• Run the engine for about 2 hours with
relatively high load.
• Fill the cooling system with ready-mixed
coolant. Refer to the engine specifications.
47714430 02-2023 © AB VOLVO PENTA 157

Cooling System, Cleaning

Flushing the cooling system
To avoid a drop in cooling performance due to deposits
and debris, the engine cooling system must be flushed
with clean water when coolant is replaced.
• Drain the old coolant; leave all drain points/valves

open. Refer to Coolant, Replace, page 156.
• Put a hose into the filler hole in the expansion tank
and flush with fresh water.
• Flush until clean water runs out of the drain points.
• Turn off the water.
• Close the drain points when water stops running out.
• Refill with new, ready-mixed engine coolant; refer to
Cooling system, filling, page 160.
P0026362
158 47714430 02-2023 © AB VOLVO PENTA

Coolant Level, Checking and

Topping Up
IMPORTANT!
Only use coolant recommended by Volvo Penta.
CAUTION!
Avoid opening the filler cap for engine coolant system
(freshwater cooled engines) when the engine is still
hot. Steam or hot coolant can spray out as system
pressure is lost.
NOTICE! Use suitable safety equipment when working

with the system.
1 Check the coolant level in the expansion tank

when the engine is cold.
2 Fill with coolant up to the white level pipe under
the filler cap. (Approx. 5 cm below the filler cap
sealing surface).
P0035631
47714430 02-2023 © AB VOLVO PENTA 159

Cooling system, filling
Filling an empty system

NOTICE! Mix the coolant in advance to ensure that the
cooling system is filled with the correct mixture. Do not
start the engine until the system is fully filled.
NOTICE! If a heating unit is connected to the engine

cooling system, the heat control valve for the system
must be opened and the installation vented during
filling.
NOTICE! Only open the filler cap.
• Check that all drain points are closed.

• Check that the coolant level is up by the white level
pipe under the filler cap.
• When the cooling system is filled, start the engine
and let it idle for a few minutes.
• Open any venting nipples for a while to allow
trapped air to escape.
• Increase engine revolutions a little for a few minutes.
• Stop the engine and let it cool down. Then check the
coolant level.
• Check the level once the engine is warmed through
and its thermostat has opened.
P0035631
NOTICE! Do not drain the system if the engine is to be

kept in storage for a longer period of time. The coolant
contains corrosion protection additives.
160 47714430 02-2023 © AB VOLVO PENTA


Charge Air Cooler, Pressure Testing
Tools:
885536 Plug
885539 Plug
1 Remove the charge air cooler; refer to Charge Air
2 Plug the coolant connections.
3 Pump up a pressure of 1 bar, pressure must not
fall during a 5 minute period.
NOTICE! If the pressure drops, troubleshoot the

leak with the aid of soapy water around
connections and seals.
4 Install the charge air cooler; refer to Charge Air
P0036117
47714430 02-2023 © AB VOLVO PENTA 161

Pressure testing of heat exchanger

Tools:
885536 Plug
885539 Plug
1 Remove the heat exchanger; refer to Heat
exchanger, Replace, page 163.
2 Plug the coolant connections.
3 Pump up a pressure of 1 bar, pressure must not
fall during a 5 minute period.
NOTICE! If the pressure drops, troubleshoot the

leak with the aid of soapy water around
connections and seals.
4 Install the heat exchanger; refer to Heat
exchanger, Replace, page 163.
P0036118
162 47714430 02-2023 © AB VOLVO PENTA

26-1 Radiator, Heat Exchanger

Heat exchanger, Replace
Close the sea cocks.
Remove the Control Unit, refer to Control Unit,

Replace, page 125
Drain the seawater system, refer to 26-6, Raw Water

System, Draining
Remove the expansion tank, refer to Expansion Tank,

Replace, page 166
1 Remove:
• seawater hose
• coolant pipe
• upper attachment
P0036076
2 • screws
• seawater hose
3 Replace the heat exchanger and refit the rest in
the reverse order.
Install the expansion tank, refer to Expansion Tank,

Replace, page 166.
P0036077
Install the Control Unit, refer to Control Unit,
Replace, page 125.
47714430 02-2023 © AB VOLVO PENTA 163

Heat exchanger, cleaning
Heat exchanger removed.
P0036100
Components Tightening torque Chemical products

1 Covers, screws 18 Nm –
2 Plug 1/2 NPF + Zinc Anode 30 Nm P/N 85145750 Thread locking
3 Plug 1/2 NPF 30 Nm P/N 85145750 Thread locking
4 Plug, M22 60 Nm P/N 85145750 Thread locking
Disassembly
• Unscrew the front and rear cover plates.
• Note the marking hole.
Remove:
• rear intermediate plate
• O-rings
• Pull the insert loose. (Pushed out forward).
• Clean the entire length of the pipe of the insert, as
well as the housing and end covers (fresh water
using appropriate brushes).
164 47714430 02-2023 © AB VOLVO PENTA

IMPORTANT!
Clean the anode with emery cloth. Do not use steel
tools, since this can impair the galvanic protection.
Make sure there is good metallic contact between the
anode and the cover panels when installing.
• Check the zinc anodes. Replace the anodes if more
than 50% of their original size has been eroded. If
not, clean the zinc anodes to remove the oxide layer
before re-installing them.
Assembly
NOTICE! Use a new component: O-rings
• Install the insert with O-rings.

• Cover plates with O-rings, rear with intermediate
plate and O-ring.
• Tighten the components.
47714430 02-2023 © AB VOLVO PENTA 165

Expansion Tank, Replace

Drain the freshwater system, refer to Coolant,
Replace, page 156.
P0035624
1 Remove:
1. Cover
2. Pipe
3. Hose clamp (disconnect hose)
4. Connector
5. Expansion tank, screws and hose clamps
2 Installation:
• Fit the tank with the top screws first.
• Connect the hose with clamps
• Place the sleeve at the lower rear screw
• Tighten all screws
166 47714430 02-2023 © AB VOLVO PENTA

3 Install:
4. Connector
3. Hose
2. Pipe
1. Cover
4 Top up with coolant; refer to Coolant Level,
Checking and Topping Up, page 159.
47714430 02-2023 © AB VOLVO PENTA 167

26-2 Coolant Pump, Thermostat

Coolant Pump, Replace
Drain the coolant; refer to Coolant, Replace, page 156.
1 Remove the drive belt.
2 Remove:
• pulley
• idler pulley
• coolant pump
P0036075
P0036073
4 Install:
• coolant pump
• pulley
• idler pulley
5 Install drive belt.
Fill coolant; refer to Coolant, Replace, page 156.
P0036074
168 47714430 02-2023 © AB VOLVO PENTA

Thermostat, Replace
Removal
1 Drain the coolant; refer to Coolant,
Replace, page 156
2 Remove the air filter, refer to Air Filter,
Replace, page 154.
3 Remove the intake manifold.
P0036111
4 Release / Remove:
• hose coupling
• connector
• coolant pipe
P0036112
47714430 02-2023 © AB VOLVO PENTA 169

5 Remove the thermostat.
P0036113
Installation
6 Install a new thermostat and seal.
7 Install:
• coolant pipe
• connector
• hose coupling
• intake manifold
8 Fill the cooling system, refer to Coolant,
Replace, page 156.
170 47714430 02-2023 © AB VOLVO PENTA

26-5 Charge Air Cooler with Connections

Charge Air Cooler, Replace
Close the sea cocks.
Removal
1 Drain the seawater system, refer to Draining the
Seawater System, page 155.
2 Drain the fresh water system, refer to Coolant,
Replace, page 156.
P0036418
4 Remove intake manifolds, loosen hose clamps

on the seawater pipe of the heat exchanger.
P0036419
47714430 02-2023 © AB VOLVO PENTA 171

5 Remove the charge air pipe.

Remove 2 screws to inner attaching plate.
P0036420
6 Remove:
• screws
• plate
P0036425
7 Remove:
• water pipe
• oil pipe
P0036421
172 47714430 02-2023 © AB VOLVO PENTA

8 Remove the charge air cooler.
P0036422
Installation
9 Install the charge air cooler
P0036422
10 Install:
• water pipe
• oil pipe
P0036423
47714430 02-2023 © AB VOLVO PENTA 173

11 Install the plate.
P0036425
12 Install the charge air pipe.
P0036420
13 Install intake manifold.
P0036424
174 47714430 02-2023 © AB VOLVO PENTA

Fill the cooling system, refer to Coolant,

Replace, page 156.
P0036418
47714430 02-2023 © AB VOLVO PENTA 175

Carge air cooler, cleaning
P0036099
Disassembly
• Unscrew the front and rear cover plates.
Remove:
• rear intermediate plate
• O-rings
• insert
Clean the insert, housing and cover plates
(degreaser, fresh water, blow the radiator dry with
compressed air).
IMPORTANT!
Check and clean the anode with emery cloth. Do not
use steel tools, since this can impair the galvanic
protection. Make sure there is good metal-to-metal
contact between the anode and the casting when
installing.
Assembly
• Install the insert with O-rings.
• Install the front cover plate with O-rings, rear with
intermediate plate and O-ring.
• Tighten:
draining nipple 30 Nm
plug (+anode) 30 Nm
176 47714430 02-2023 © AB VOLVO PENTA

26-6 Sea Water System, Sea Water Pump

Seawater Pump, Overhaul
The seawater pump removed, refer to Seawater
Pump, Replace, page 183
Tools:
884167 Drift
1 Remove:
• cover
• seal
P0036249
2 Remove:
• impeller
• cam screw with seal
• cam lobe
P0036250
47714430 02-2023 © AB VOLVO PENTA 177

3 Remove:
• wear ring
• retaining ring
• support washer
P0036251
4 Remove nut.
Use a long 12-edged socket 14 mm as a

counterhold on the shaft.
Heat the center of the gear, use pullers to remove
gear.
P0036252
5 Remove the retaining rings.
P0036253
178 47714430 02-2023 © AB VOLVO PENTA

6 Remove the adapter and seal.
P0036254
7 Knock out the shaft and bearing.

Remove shaft seal and stuffing box.
P0036255
8 Press off the bearing.
P0036256
47714430 02-2023 © AB VOLVO PENTA 179

9 Press the bearing on.
P0036257
10 Insert a new stuffing box, use drift to knock the

shaft seal down into position.
P0036258
11 Press the bearing and shaft home.
P0036261
180 47714430 02-2023 © AB VOLVO PENTA

12 Install adapter and seal.

P0036254
13 Install the retaining rings.
P0036253
14 Install the gearwheel.

Use a long 12-edged socket (14 mm) as a

counterhold on the shaft.
P0036262
47714430 02-2023 © AB VOLVO PENTA 181

15 Install:
• support washer
• retaining ring
• wear ring
P0036251
16 Apply Sealant P/N 23223194 to the back of the

cam.
Apply locking fluid P/N 85145750 to the screw.
17 Install the impeller.
P0036263
18 Fit the lid and seal.

P0036249
182 47714430 02-2023 © AB VOLVO PENTA

Seawater Pump, Replace

WARNING!
Removal
NOTICE! Be prepared to gather up liquid.
Drain the seawater system, refer to Draining the

1 Disconnect the water connections from the
seawater pump.
P0036068
2 Remove:
• connector
• seawater pump
• seawater pipe
P0036069
47714430 02-2023 © AB VOLVO PENTA 183

Installation
3 Connect the water inlet to the new seawater
pump.
Install:
• seawater pump
• seawater pipe
• seawater connections
• connector
4 Open the sea cock.
184 47714430 02-2023 © AB VOLVO PENTA

Seawater Pump, Impeller, Change

WARNING!
Drain the seawater system, refer to: Draining the

1 Remove the cover and O-ring.
P0035691
2 Pull out the impeller.
P0035693
3 Grease the pump housing and the new impeller

with glycerine (P/N 3862178).
4 Press in the impeller with a rotating movement
(clockwise).
5 Install the cover with a new O-ring (4).
Tightening torque 10 Nm.
P0035692
47714430 02-2023 © AB VOLVO PENTA 185

32-1 Alternator
32-1 Alternator
Alternator, Replace
NOTICE! The main switch must be in the off position
before starting work.
1 Remove drive belt, refer toDrive Belts,

Replace, page 104.
P0035628
2 Remove cables B- and B1+.

Disconnect the connector.
3 Remove the alternator.
4 Install:
• bushings
• alternator
Tightening torque M10: 48 Nm
Tightening torque M12: 85 Nm
5 Connect the connector.
NOTICE! Affix the wire harness using cable ties.

6 Install cabling.
• Tightening torque B1+: 14 Nm
• Tightening torque B–: 10 Nm
NOTICE! Don't forget the 6.5mm spacer under
the (B-) cable connection.
186 47714430 02-2023 © AB VOLVO PENTA

32-1 Alternator
7 Install drive belt, refer toDrive Belts,

Replace, page 104.
47714430 02-2023 © AB VOLVO PENTA 187

33-1 Starter Motor
33-1 Starter Motor

Starter Motor, Replace
IMPORTANT:
Turn off the main switch before any work is carried out.
P0035664
1 Disconnect cable connection from the negative

terminal of the battery.
2 Unscrew:
1 battery cables
2 alternator cables
3 terminal cable
(+) Yellow, Red
(-) Black
4 Connector
3 Remove the starter motor.
4 Install:
• gasket
• bushings
• starter motor
188 47714430 02-2023 © AB VOLVO PENTA

33-1 Starter Motor
5 Screw home:
• connector
• terminal cables
• alternator cables
• battery cables
Tightening torque:
(+) 18 Nm
(-) 24 Nm
6 Connect cable connection to the negative
terminal of the battery.
47714430 02-2023 © AB VOLVO PENTA 189

Index
A Flywheel, Replace.................................................. 105
About this Workshop manual..................................... 3 Fuel Feed Pressure, Check.................................... 110
Air Cleaner, Throttle Housing................................. 154 Fuel Feed Pump and Filter..................................... 111
Air Filter, Replace................................................... 154 Fuel filter, Change................................................... 111
Alternator................................................................ 186 Fuel System...................................................... 44, 110
Alternator, Replace................................................. 186 Fuel system, bleeding............................................. 114
Fuel System, Drainage........................................... 112
C Fuel System, General............................................. 110
Cable description...................................................... 39
Camshaft Bearing Housing, Replace..................... 102 G
Camshaft, Wear Check............................................ 65 Gear Ring, Fywheel: Replace................................ 103
Carge air cooler, cleaning....................................... 176 General................................................................. 3, 54
Charge Air Cooler with Connections...................... 171 General Specifications............................................... 8
Charge Air Cooler, Pressure Testing...................... 161 General Tightening Torques..................................... 11
Charge Air Cooler, Replace.................................... 171 Group 21 - Engine.................................................... 12
Check and Fault Trace..................... 62, 110, 128, 161 Group 22 - Lubrication System................................. 22
Compression Test..................................................... 64 Group 23 - Fuel System........................................... 26
Compressor oil, Replace........................................ 144 Group 25 - Inlet and Exhaust System...................... 27
Compressor, oil level check.................................... 128 H
Compressor, Replace............................................. 150 Heat exchanger, cleaning....................................... 164
Connecting Rod, Check........................................... 66 Heat exchanger, Replace....................................... 163
Control System, ECM, Data Sets........................... 125 I
Control Unit, Replace............................................. 125 Identifying the engine control unit........................... 127
Control valve, overview............................................ 30 Injectors and Delivery Pipes................................... 115
Coolant Level, Checking and Topping Up.............. 159 Inlet and Exhaust Manifolds................................... 130
Coolant Pump, Replace......................................... 168 Inlet and Exhaust System................................. 45, 128
Coolant Pump, Thermostat.................................... 168 Inlet and Exhaust System, General........................ 128
Coolant, Replace.................................................... 156 Intake Manifold, Replace........................................ 133
Cooling System................................................ 46, 155
Cooling System, Cleaning.............................. 157, 158 L
Cooling system, filling............................................. 160 Location of Sensors.................................................. 29
Cooling System, General....................................... 155 Lubrication System................................................... 43
Crank Mechanism............................................ 33, 106 M
Crankshaft Seal, Replace (front)............................ 106 Magnetic Coupling, Replace.................................. 152
Crankshaft Seal, Replace (rear)............................. 108 Mechanical Compressor......................................... 150
Cylinder Head........................................................... 82
P
Cylinder Head, Check.............................................. 62
Pressure testing of heat exchanger........................ 162
Cylinder Head, Overhaul.......................................... 94
Cylinder Head, Pressure Testing.............................. 58 R
Cylinder Head, Replace........................................... 82 Radiator, Heat Exchanger...................................... 163
D S
Draining the Seawater System............................... 155 Safety Instructions.................................................... 48
Drive Belt, Replace................................................. 145 Sea Water System, Sea Water Pump.................... 177
Drive Belts, Replace............................................... 104 Seawater Pump, Impeller, Change......................... 185
Seawater Pump, Overhaul..................................... 177
E
Seawater Pump, Replace....................................... 183
Electrical System...................................................... 47
Sleeve for unit injector, replace.............................. 120
Engine................................................................ 31, 60
Special Service Tools............................................... 49
Engine Assembly...................................................... 73
Specifications, Electrical........................................... 47
Engine Complete, General....................................... 60
Specifications, Engine ............................................. 12
Engine Decals............................................................ 8
Starter Motor.......................................................... 188
Engine Disassembly................................................. 68
Starter Motor, Replace........................................... 188
Engine Information, General.................................... 55
Engine, to set TDC................................................... 60 T
Exhaust Back Pressure, Check................................ 57 Test and Adjustments............................................... 57
Exhaust Manifold, Replace..................................... 130 Thermostat, Replace.............................................. 169
Expansion Tank, Replace....................................... 166 Timing Gears and Shaft.......................................... 102
Transmission Decals................................................ 55
F
Turbo and supercharger......................................... 136
Fitting the Fixture...................................................... 67
Turbo, Replace....................................................... 136
47714430 02-2023 © AB VOLVO PENTA 191

Turbocharger, check............................................... 128
U
Unit Injector, Replace............................................. 115
V
Valve Mechanism..................................................... 99
Valve mechanism..................................................... 36
Valves and Unit Injectors, Adjustment...................... 99
192
References to Service Bulletins
Group No. Date Refers to
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193
47714430 English

WSM 20-26 - D11 - 47714430

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Workshop Manual

Safety and Other Instructions

Inlet and Exhaust System

47714430 02-2023 © AB VOLVO PENTA 1

Alternator, Charge Regulator

2 47714430 02-2023 © AB VOLVO PENTA

47714430 02-2023 © AB VOLVO PENTA 3

Colours used in images

1 Component emphasized (blue)

Other types of symbols used in

4 47714430 02-2023 © AB VOLVO PENTA

This symbol is used on certain functions to indicate the following:

This symbol means Dangerous electrical voltage / General electrical danger.

This symbol is used for facilitation tips when repairing.

47714430 02-2023 © AB VOLVO PENTA 5

6 47714430 02-2023 © AB VOLVO PENTA

47714430 02-2023 © AB VOLVO PENTA 7

03-0 General Specifications

8 47714430 02-2023 © AB VOLVO PENTA

1. Filler cap for coolant fluid

47714430 02-2023 © AB VOLVO PENTA 9

13. Oil filter

10 47714430 02-2023 © AB VOLVO PENTA

General Tightening Torques

47714430 02-2023 © AB VOLVO PENTA 11

03-2 Specifications, Engine

NOTICE! May be reused once.

Big end bearing cap

12 47714430 02-2023 © AB VOLVO PENTA

47714430 02-2023 © AB VOLVO PENTA 13

NOTICE! May be reused twice.

14 47714430 02-2023 © AB VOLVO PENTA

Bearing caps, camshaft/rocker arm shaft

1 Tightening sequence: 1-2-3-4-5-6-7

47714430 02-2023 © AB VOLVO PENTA 15

Timing gear casing, front

NOTICE! Apply a bead of sealant P/N 1161231 with a

Step 1: Tighten by hand

16 47714430 02-2023 © AB VOLVO PENTA

Oscillation damper, camshaft

Oscillation damper, crankshaft

Lifting eye, front

47714430 02-2023 © AB VOLVO PENTA 17

Lifting eye, rear

Engine mount, front

Engine mount, rear

18 47714430 02-2023 © AB VOLVO PENTA

NOTICE! Apply a bead of sealant P/N 1161231 with a

47714430 02-2023 © AB VOLVO PENTA 19

Timing gear plate

NOTICE! Apply a bead of sealant P/N 1161231 with a

Tighten the screws in numerical order.

20 47714430 02-2023 © AB VOLVO PENTA

(B) Idler gear, adjustable

(C) Idler gear, double

(D) Crankshaft gear 24 Nm

Timing gear casing, upper

NOTICE! Apply a bead of sealant P/N 1161231 with a

Tighten the bolts in sequence.