Volvo Penta D1-13 Workshop Manual
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Volvo Penta D1-13 Workshop Manual

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Workshop Manual
A
Group 21-26
2(0)
D1-13, D1-20, D1-30, D2-40

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Summary of Contents for Volvo Penta D1-13

  • Page 1 Workshop Manual Group 21-26 2(0) D1-13, D1-20, D1-30, D2-40...

  • Page 3: Table Of Contents

    23-7 Injectors and Delivery Pipes ............105 Cooling System 26-0 Cooling System, General ............... 109 26-1 Radiator, Heat Exchanger .............. 114 26-2 Coolant Pump, Thermostat ............117 26-6 Sea Water System, Sea Water Pump ..........120 Alternator, Charge Regulator 47701798 05-2013 © AB VOLVO PENTA...
  • Page 4 32-1 Alternator ..................127 Starting System 33-1 Starter Motor ................... 128 Alphabetical index .................. 129 References to Service Bulletins ............131 47701798 05-2013 © AB VOLVO PENTA...

  • Page 5: General

    IMPORTANT! Neglected or poorly-performed care/service and the use of spare parts not approved by Volvo Penta, will mean that AB Volvo Penta no longer guarantees that the engine conforms to the certified model. Volvo Penta accepts no responsibility for damage or costs arising as a result of failure to follow the above mentioned standards.

  • Page 6: Repair Instructions

    Volvo Penta Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and For significance, refer to Safety Information .
  • Page 7 Old RTV sealant must be removed before made of fluorocarbon rubber. the component is sealed again. Use denatured alco- hol. Please note that seals which have not been exposed to high temperature can be handled nor- mally. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 8 The symbol to the left shows part no. of the positioned special tool, e.g. 9991801. The symbol on the right side is used when something needs to be replaced by a new part / kit. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 9 Tools P0015631 A drill in a specified size, duck tape and stripes may also be shown as symbols. P0015629 One of the following symbols is used when describing the recommended type of screwdriver. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 10 The tube symbol shows how thick layer of sealant to applicate. The clock symbol is used when something needs to be done within or after a certain time. P0015697 These symbols are used when a certain safety related equipment is needed. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 11: Specifications, Engine

    NOTICE! * The final tightening torque is indicated. The cylinder head must be tightened in three stages and in the correct order: refer to the tightening procedure. Lubricate the Cylinder head mounting bolts with oil on instal- lation. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 12 9.8–11.8 Nm (7.2–8.7 lbf.ft.) General tightening torque values 5 Nm (3.7 lbf.ft.) 10 Nm (7.4 lbf.ft.) 17 Nm (12.5 lbf.ft.) 24 Nm (17.7 lbf.ft.) 50 Nm (36.9 lbf.ft.) 80 Nm (59.0 lbf.ft.) 130 Nm (95.9 lbf.ft.) 47701798 05-2013 © AB VOLVO PENTA...
  • Page 13 03-2 Specifications, Engine Tightening sequence Cylinder head D2-40 P0008160 D1-20, D1-30 P0008161 D1-13 P0008162 47701798 05-2013 © AB VOLVO PENTA...
  • Page 14 Flow, fluid US gal/min. 4,403 US gal/min. 0,2271 Speed ft./s 3,281 ft./s 0,3048 knot 0,869 knot 1,1508 Temperature °F=9/5 x °C+32 °C=5/9 x (°F–32) All power noted in the catalogue refers to metric horsepower. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 15: Technical Data

    0,20 (0.008") Weight, dry engine 96 kg (212 lbs) 118 kg (260 lbs) 127 kg (280 lbs) 148 kg (326 lbs) Permissible back pressure in exhaust line 20 kPa (2.9 PSI) 47701798 05-2013 © AB VOLVO PENTA...

  • Page 16: Engine

    0.048–0.082 mm (0.0019–0.0032") D1-30-A/B/F, D2-40-A/B/F 0.0525–0.0865 mm (0.0021–0.0034") Service limit, all engines 0.25 mm (0.010") Front marking The designation ”SHIBAURA” on the inside of the pis- ton must face the fuel pump on installation. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 17: Piston Rings

    –0.004 to +0.004 mm (–0.00016 to +0.00016") Service limit 0.02 mm (0.0008") Cylinder block Bore diameter in cylinder block: D1-13-A/B/F, D1-20-A/B/F 67.000–67.019 mm (2.6378–2.6385") Service limit 67.200 mm (2.6457") D1-30-A/B/F, D2-40-A/B/F 77.000–77.019 mm (3.0310–3.0320") Service limit 77.200 mm (3.0390") 47701798 05-2013 © AB VOLVO PENTA...
  • Page 18 D1-30-A/B/F, D2-40-A/B/F 11.65–11.67 mm (0.4587–0.4595") Service limit 11.57 mm (0.4555") Rocker arm play on rocker arm shaft: D1-13-A/B/F, D1-20-A/B/F, minimum permissible play 0.032–0.065 mm (0.00126–0.00260") D1-30-A/B/F, D2-40-A/B/F, minimum permissible play 0.032–0.068 mm (0.00126–0.00268") Maximum permissible play, all engines 0.2 mm (0.008")
  • Page 19 D1-13-A/B/F, journal #. 2 0.039–0,092 mm (0.0015–0.0036") D1-20-A/B/F, journal #. 1 and 2 0.039–0.106 mm (0.0015–0.0042") D1-20-A/B/F, journal #. 3 0.039–0,092 mm (0.0015–0.0036") D1-30-A/B/F, D2-40-A/B/F 0.039–0.106 mm (0.0015–0.0042") Service limit, all engines 0.20 mm (0.0079") 47701798 05-2013 © AB VOLVO PENTA...
  • Page 20 Service limit 26.5 mm (1.0430") Cam lobe height for fuel injection pump 39.900–40.100 mm (1.5709–1.5787") Service limit 39.8 mm (1.5669") Cam lobe height for hand fuel pump 27.900–28.000 mm (1.0984–1.1024") Service limit 27.0 mm (1.0630") 47701798 05-2013 © AB VOLVO PENTA...

  • Page 21: Valve Springs

    35.0 mm (1.377") Length at 79.4 Nm (58.56 lbf.ft) compression 30.4 mm (1.196") Gear wheel group Maximum play for all gear wheels 0.25 mm (0.0098") Minimum play for all gear wheels 0.08 mm (0.0031") 47701798 05-2013 © AB VOLVO PENTA...

  • Page 22: Lubrication System

    3.5 l (0.92 US gals) D2-40-A/B/F 6.5 l (1.72 US gals) Oil change interval: D1-13-A/B/F, D1-20-A/B/F, D1-30-A/B/F 200 hours or 12 months D2-40-A/B/F 200 hours or 12 months NOTICE! * Temperatures at stable ambient temperature. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 23: Fuel System

    11.96 MPa (1735 PSI) D1-30-A/B/F 13.9 MPa (2016 PSI) D2-40-A/B/F 14.7 MPa (2132 PSI) Jet angle 4° Exhaust System Max. permissible exhaust back pressure in exhaust line at max. rpm, all engines 20 kPa (2.9 PSI) 47701798 05-2013 © AB VOLVO PENTA...

  • Page 24: Cooling System

    Silica (acc. ASTM D859) <20 mg SiO P0002094 Iron (acc. ASTM D1068) <0.10 ppm Manganese (acc. ASTM D858) <0.05 ppm Conductivity (acc. ASTM D1125) <500 µS/cm Organic content, COD (acc. <15 mg KMnO ISO8467) 47701798 05-2013 © AB VOLVO PENTA...

  • Page 25: Specifications, Electrical

    14.2 ±0.15 V without sense 14.2 ±0.30 V Max. current 115 A Power, approx. 1,630 W Suppression capacitor 2.2 μF Starter motor Power, approx. D1-13-A/B/F, D1-20-A/B/F 0.8 kW D1-30-A/B/F 1.1 kW D2-40-A/B/F 1.4 kW 47701798 05-2013 © AB VOLVO PENTA...

  • Page 26: Safety Instructions

    This Service Manual contains repair instructions, descriptions and technical data for products or product designs from Volvo Penta. Ensure that you are using the correct service manual. Read the safety information below and the service manual section About this Workshop manual and Repair instructions carefully before repair and service work is begun.
  • Page 27 Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the at the main switch(es) before carrying out work engine stopped. on the electrical system. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 28 Never perform any work on an engine that is only suspended from the lifting equipment. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 29 05-1 Safety Instructions The components in the electrical and fuel sys- Exercise extreme caution when leak-detecting tems on Volvo Penta products are designed and on the fuel system and testing the fuel injector manufactured to minimize the risk of fire and nozzles.

  • Page 30: Special Service Tools

    Used for compression testing. Floor lock (used together with 885023 Valve spring compres- sor). P0002936 885510 Plugs 885820 Puller 885822 Magnetic pen protection plugs, fuel system. Puller, for pulley. Used for removing valve lifters. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 31 P0001878 P0001881 P0001879 9999179 Extractor oil filter 9999683 Dial indicator (short 9999696 Magnetic stand probe) Wrench for removing fuel and Used when checking valve Used e.g. for checking end oil filters. guides. float. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 32 P0007812 P0007813 P0007811 9999737 Fixture 9999772 Pressure testing kit 3849639 Mounting tool Fixture cylinder used for Used for checking injectors. Used for oil pump shaft (D1-13, 885224 Fixture to D1-20). 9986485 Stand. p0005128 P0007813 3849640 Mounting tool 88890016 Break-out cable...

  • Page 33: Engine Information, General

    Serial number (3): ........Transmission Product designation (4): ........Gear ratio (5): ........Serial number (6): ........Product number (7): ........P0007541 A Engine and transmission decal B Engine plate C Transmission plate p0007825 47701798 05-2013 © AB VOLVO PENTA...
  • Page 34 Fresh water cooling uses a thermostatically controlled The D1-13 is an in-line two cylinder engine with a total raw-water cooled heat exchanger. The raw water swept volume of 0.51 liter. The D1-20 and D1-30 are pump is operated by a gear train.
  • Page 35 20-0 Engine Information, General D1-13 with MS10A reverse gear D1-20 with MS10A reverse gear 47701798 05-2013 © AB VOLVO PENTA...
  • Page 36 20-0 Engine Information, General D1-30 with MS15A reverse gear D2-40 with 130S sailboat drive 47701798 05-2013 © AB VOLVO PENTA...
  • Page 37 The cylinder block is cast in one piece from special cast iron alloy. The camshaft is located in the engine block. The D1-13 engine has two cylinder bores, the D1-20 and D1-30 have three, and the D2-40 has four. The D1-13 and D1-20 engines have the same cylinder dimensions.
  • Page 38 The governor weights (6) are sus- pended at the front of the camshaft drive and adjust the injection pump via a mechanism in the timing gear cover. P0007835 47701798 05-2013 © AB VOLVO PENTA...

  • Page 39: Crankcase Ventilation

    When the gas pressure is higher, the valve opens and directs the crankcase gases into the inlet section, for combustion in the cylinders. P0007836 47701798 05-2013 © AB VOLVO PENTA...
  • Page 40 The oil filter is of full-flow type and is fitted with an overflow valve. Oil filter Oil pressure monitor Pressure relief valve Inlet pipe with strainer Main oil duct Oil pump Oil delivery pipe (outer) to valve mechanism Crankcase ventilation, valve 47701798 05-2013 © AB VOLVO PENTA...

  • Page 41: Oil Pump

    (2). The valve opens at high pres- sure and allows the oil to flow back into the oil pan. The D1-13 and D1-20 engines have a relief valve that opens in the 352-448 kPa (51–65 PSI) range. On D1-30 and D2-40 engines, the valve opens in the 304-500 kPa (44–73 PSI) range.

  • Page 42: Oil Filter

    The filter element consists of folded filter paper. There is a bypass valve (1) at the base of the filter, which opens and allows oil to flow past the filter ele- ment if the filter insert should become blocked. P0007860 47701798 05-2013 © AB VOLVO PENTA...
  • Page 43 A glowplug in the pre-combustion cham- ber pre-heats the fuel mixture for cold starting. The engine fine filter removes contamination which may be left in the fuel, despite the prefilter. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 44: Injection Pump

    Injector opening pressure is determined by the com- pression spring which is adjustable with shims. Injector nut Injectors Joining piece Compression screw Spring Adjustment shims Injector holder Washer 47701798 05-2013 © AB VOLVO PENTA...

  • Page 45: Feed Pump

    The fuel filter (1) is of the disposable type. The filter insert is a paper filter. The fuel filter is located in a bracket (2) together with a hand pump (3) and vent screw (4). P0007866 47701798 05-2013 © AB VOLVO PENTA...
  • Page 46 4 Raw water, outlet exhaust gas, via a connection in the exhaust bend. 5 Coolant pump 6 Expansion tank 7 Heat exchanger / exhaust manifold 8 Thermostat 9 Open thermostat - circulation 10 Closed thermostat - circulation 47701798 05-2013 © AB VOLVO PENTA...

  • Page 47: Seawater Pump

    The pump is driven by the engine timing and pumps cooling water to the engine heat exchanger. NOTICE! The impeller will be damaged if the pump is run dry. P0007939 47701798 05-2013 © AB VOLVO PENTA...

  • Page 48: Heat Exchanger

    (fresh water system) to the outer circuit (raw water). When the thermostat is closed, coolant is led through a short, uncooled passage in the heat exchanger and back to the engine. P0007940 47701798 05-2013 © AB VOLVO PENTA...

  • Page 49: Test And Adjustments

    Place the adapters 885484 Adapter and 885252 Adapter in the injector sockets. Place 9988539 Compression meter in the adapter and carry out the compression test. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 50: Repair Instructions

    IMPORTANT! Make sure that all sea water inlets are securely closed, so that water can not find its way in during disassembly of cooling system sub-components. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 51: Engine Complete, General

    When a power washer is used, the water jet must never be aimed at seals, such as shaft seals, joints with gaskets, rubber hoses or electrical components. 2 Drain the engine oil 3 Remove the reverse gear (as necessary) 47701798 05-2013 © AB VOLVO PENTA...

  • Page 52: Fitting The Fixture

    9986485 Stand. Only 885224 Fixture is required for securing in 9992520 Stand. Bolt the fixture to the right side of the engine, as illus- trated. D1-13-A/B/F D1-20-A/B/F P0007974 P0007975 D1-30-A/B/F D2-40-A/B/F P0007977 P0007976 47701798 05-2013 © AB VOLVO PENTA...

  • Page 53: Engine Disassembly

    Remove the fuel filter bracket (15) with anchor- age, feed pump (16) and feed hose by the union P0007980 (17) for the injection pump. Leave the fuel hoses between the fuel filter, feed pump and union in place. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 54 NOTICE! Retain the shim / gasket (25) located beneath the injection pump flange. Use the same thickness of shims when installing. Remove the valve cover (26), current bar (27) and the glowplugs (28). P0007984 47701798 05-2013 © AB VOLVO PENTA...
  • Page 55 Remove the inner flywheel housing (38) and rear crankshaft seal. Remove timing gear casing (39). Load the stop arm (40) so that the springs on the inside of the housing do not come out of position or spring out. P0007986 P0007987 47701798 05-2013 © AB VOLVO PENTA...
  • Page 56 Remove the locking screws (48) that hold the main bearing caps. Carefully lift the crankshaft out backwards, complete with caps. NOTICE! Tape the crankshaft gear to protect the bearing surfaces in the block during removal. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 57: Cylinder Head

    Check the valve seats and check that the studs are P0008005 firmly seated. Inspect the cylinder head for cracks. Carefully check the areas around the valve seats and the holes for the injector nozzles. P0008006 47701798 05-2013 © AB VOLVO PENTA...
  • Page 58 P0008070 Put the cylinder head in place. Difference in height between pistons and engine block plane Gasket thickness 0.55 to 0.64 mm 1.2 mm (0.0472") (0.0217–0.0252") 0.65 to 0.75 mm 1.3 mm (0.0512") (0.0255–0.0295") 47701798 05-2013 © AB VOLVO PENTA...
  • Page 59 Install the glowplugs (4) and current bar (5). P0008071 Install the push rods (6), valve caps (7) and rocker arm mechanism (8) with gasket. Torque the nuts (9); refer to Tightening torques page 9. P0008072 47701798 05-2013 © AB VOLVO PENTA...
  • Page 60 Install the delivery pipes (18). For tightening tor- D1-30-A/B/F ques, refer to Tightening torques page 9. Install the coolant pump (19) with spacer (D1-13- A/B/F) and a new gasket. Clean the rear crankshaft seal seat in the engine block and the mating surface on the inner fly- wheel housing.
  • Page 61 Group 22: Lubrication System page 20. Install the engine in the boat. Connect the remain- ing connections and controls to the engine. Open the fuel taps and the sea cock. Start the engine and check that no leakage occurs. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 62 21-1 Cylinder Head Cylinder Head, Removal Coolant drained. Air filter housing, heat exchanger and coolant pump with spacer (D1-13) removed. Remove the bolt (1) which holds the fuel filter bracket to the cylinder head. Remove the valve cover. Disconnect the cable (2) to the glow plugs.
  • Page 63 Remove the push rods (1) and valve caps (2). Mark them. Undo the cylinder head bolts (3) in reverse tight- ening sequence; refer to Tightening tor- ques page 9. Remove the cylinder head and gas- ket. P0008093 47701798 05-2013 © AB VOLVO PENTA...
  • Page 64 Put the cylinder head in place. Insert the bolts (1) and torque them according to the tightening sequence and to the specific torque; refer to Tightening torques page 9. P0008077 Put the push rods (1) and valve caps (2) in place. P0008078 47701798 05-2013 © AB VOLVO PENTA...
  • Page 65 Apply sealant part no. 840879 to the two lowest threads (1). Put new copper seals on the bottom of the cylinder head. Install the injectors and tighten them evenly to the specified torque, refer to Tightening tor- ques page 9. P0008084 47701798 05-2013 © AB VOLVO PENTA...

  • Page 66: Cylinder Block

    Measurement should be done with an internal dial gauge both longitudinally and transversely to the engine block (A and B). Concerning max. permitted cylinder diameter, refer to “Wear tolerances” in Group 21: Engine page 14. P0008004 47701798 05-2013 © AB VOLVO PENTA...

  • Page 67: Cylinder Liner, Pistons

    Then measure the cylinder bore and calculate the clearance between the cylinder and piston. Replace the piston if the clearance exceeds permitted values or if the piston diameter is lower than the per- mitted value. P0008022 47701798 05-2013 © AB VOLVO PENTA...
  • Page 68 Note the markings on the bearing caps and their locations. Press the pistons out. NOTICE! There may be a soot deposit on the top of the cylinder bores. Remove the deposit to facil- itate pressing the pistons out. P0008095 47701798 05-2013 © AB VOLVO PENTA...
  • Page 69 Press the piston pin in. Install the retainer rings with the lugs facing upwards. P0008096 Big end bearing, change Pistons, removed Remove the big end bearings (1) and put the new ones in position. P0008097 47701798 05-2013 © AB VOLVO PENTA...
  • Page 70 Install the big end bearing cap according to the mark. Tighten with 23 Nm of torque (17.0 lbf.ft) (D1-13, D1-20), or 32 Nm (23.6 lbf.ft) (D1-30, D2-40). Check the movement of the big end bearing. Repeat the procedure to install the remaining pis- tons.
  • Page 71 There is a risk that an oil duct could be blocked. Install the oil pan together with a new gasket. For tightening torques, refer to Tightening tor- ques page 9. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 72: Valve Mechanism

    Adjust no. 3 inlet valve (3) and no. 1 exhaust valve (4). Crank the engine clockwise until the valves for no. 3 cylinder overlap. Adjust no. 1 inlet valve (5) and no. 2 exhaust valve (6). P0008111 47701798 05-2013 © AB VOLVO PENTA...
  • Page 73 When the correct valve clearance has been reached, tighten the locknut (1). P0008113 Install the valve cover with a new seal. Install the air filter housing. Test run the engine and check that no oil leakage occurs. P0008114 47701798 05-2013 © AB VOLVO PENTA...
  • Page 74 Compress the valve spring with the spring clamp and install the collets (5). Install the glowplugs and tighten to the specified torque: refer to Tightening torques page 9. Install 885 498 the busbar. P0008013 47701798 05-2013 © AB VOLVO PENTA...
  • Page 75 Exhaust valve, max clearance 0.25 mm (0.010") NOTICE! Since the valve guides are machined directly in the cylinder head, the cylinder head must be changed when the clearance is too great, even when the valve is new. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 76 0.045") for the exhaust. The mating face (C) must be 45 degrees and the contact surface (D) must be 1.70-2.10 mm (0.067– 0.083"). 5 Grind the valves in with grinding paste, and check contact with marker dye. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 77 The threads on the pin and lock nut must be undam- aged. The lock nut must be in good condition. 6 Oil the rocker arm shaft and disassemble the other P0008014 components. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 78: Timing Gears And Shaft

    Refer to Group 21: Engine page 14 for min. and max. values. P0008038 Timing Gear, Removal Cylinder head removed Tools: 885820 Puller 885822 Magnetic pen Remove the raw water pump (1). Remove the end panel (2) and the bolts (3). P0008050 47701798 05-2013 © AB VOLVO PENTA...
  • Page 79 Unbolt the injection pump (1). Lift it up until the lock clip (2) is accessible. Undo the clip and release the control rod (3). P0008083 Undo the timing gear cover bolts (1) and nut (2). Remove the cover. P0008084 47701798 05-2013 © AB VOLVO PENTA...
  • Page 80 Remove the camshaft regulator sleeve (4). Pull the camshaft out carefully. IMPORTANT! There is a risk of damaging the inner camshaft bearing with a camshaft lobe if the camshaft is pulled out with force. P0008087 47701798 05-2013 © AB VOLVO PENTA...
  • Page 81 (2) inside the oil pump gear. P0008088 Undo the remaining bolts (1). Remove the timing gear plate (2). Remove the crankshaft gear (3) with a puller. Remove the gear wheel and its Woodruff key. P0008089 47701798 05-2013 © AB VOLVO PENTA...
  • Page 82 (2). Make sure that the mark- ings (3) on the gear wheel line up with the mark- ings (4) on the other gear wheels. Check the gear flank play; refer to Flank Clearance, Check- ing page 76. P0008046 47701798 05-2013 © AB VOLVO PENTA...
  • Page 83 Put the timing gear cover in place. Make sure that the control rod ends up in the correct position and that the pin (3) engages in the hole (4) in the oil pump end washer. Bolt on the timing gear cover. P0008049 47701798 05-2013 © AB VOLVO PENTA...
  • Page 84 All valve lifters must be put back in their previous places. Note that on D1-20 engines, valve lifter no. 2 for cylinder 1 has a chamfer (1). Note that on D2-40 engines, both valve lifters for cylinder 1 have a chamfer. P0007999 47701798 05-2013 © AB VOLVO PENTA...
  • Page 85 Install the thrust washer (5) on the idler wheel shaft stub. Install the idler wheel (6) in accord- ance with the markings. NOTICE! Do not turn the crankshaft before the timing gear cover has been installed. P0008040 47701798 05-2013 © AB VOLVO PENTA...
  • Page 86 Install a new front crankshaft seal; refer to Crank- shaft Seal, Change (front) page 97. Fit the key into the crankshaft and install the crankshaft pul- ley. For tightening torque, refer to Tightening tor- P0008043 ques page 9. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 87 26.5 mm (1.04”) (inlet and exhaust) Cam height B 41.8 mm (1.65”) (for injection pump) Cam height C 27.0 mm (1.06”) (for feed pump) Change the camshaft if the wear limits have been exceeded. P0008028 47701798 05-2013 © AB VOLVO PENTA...
  • Page 88 Examples of acceptable wear and unacceptable wear are shown below. Acceptable wear Unacceptable wear The camshaft does not need to be changed. NOTICE! The camshaft and associated rocker arms must be changed. P0003899 P0003896 P0003897 P0003898 47701798 05-2013 © AB VOLVO PENTA...
  • Page 89 Carefully clean the crankshaft and flywheel. Install the new flywheel and tighten it to the speci- fied torque; refer to Tightening torques page 9. Install the flexible coupling, flywheel housing, fil- ter housing bracket and engine rpm sensor. P0008105 47701798 05-2013 © AB VOLVO PENTA...

  • Page 90: Crank Mechanism

    Using a felt tip pen, draw a line across the hole in the connecting rod and the bush. Check that the oil duct is open after pressing in the new bush. Ream the bush and measure the connecting rod with an internal dial gauge. P0008024 47701798 05-2013 © AB VOLVO PENTA...
  • Page 91 Check the big end bearing clearances. Refer to Crankshaft and Bearings, Inspection page 90. Check the piston ring gap in the cylinder bore and that the rings do not bind in the piston ring grooves. P0008026 47701798 05-2013 © AB VOLVO PENTA...
  • Page 92 For max lengthwise crookedness (runout), refer to Group 21: Engine page 14. If these values are exceeded, the crankshaft must be changed. 3 Check that the crankshaft seal mating surfaces on the crankshaft are not worn or damaged. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 93 Change the bush if the clearance exceeds the per- missible value. Inspection of main and big end bearings Check the main and big end bearing shells, and the front main bearing bushing. Change worn bearing shells, or any with damaged bearing surfaces. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 94 Use the scale supplied with the plas- tigauge. For max. permissible big-end bearing play, refer to Group 21: Engine page 14. Change the big-end bearing if bearing clearance exceeds the permissible value. P0008018 47701798 05-2013 © AB VOLVO PENTA...
  • Page 95 0.5 mm (0.020"). Install the oil pressure relief valve with a new seal. Torque to 64 Nm (47.2 lbf.ft). Install a the rear crankshaft seal; refer to Crank- shaft Seal, Change (rear) page 98. P0008030 47701798 05-2013 © AB VOLVO PENTA...
  • Page 96 Unscrew the oil pressure relief valve. P0008102 Undo the bolts (1) that hold the main bearing caps. Lift the crankshaft out. NOTICE! Tape the crankshaft gear teeth to pro- tect the bearing when the shaft is pulled out. P0008103 47701798 05-2013 © AB VOLVO PENTA...
  • Page 97 (3) in the bearing caps. P0008098 D2-40 P0008029 Drive out the main bearing bush (1) located in the engine block. Use a suitable mandrel and tap the bush out from inside the crankcase. P0008099 47701798 05-2013 © AB VOLVO PENTA...
  • Page 98 Check that the oil duct is open after pressing in the new bush. Also check the internal diameter of the bush. For dimensions, refer to Group 21: Engine page 14. P0008020 47701798 05-2013 © AB VOLVO PENTA...
  • Page 99 Install the belt pulley key on the crankshaft. Install the belt pulley and tighten it to the fasten it with the center nut to the specified torque; refer P0008108 to Tightening torques page 9. Install and adjust the drive belt. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 100 Lubricate the new crankshaft seal lip with engine oil and put the seal in place. Apply sealant part no. 840879 all round the crank- shaft seal (2) and the camshaft cover (3). Fix the inner flywheel plate. P0008106 47701798 05-2013 © AB VOLVO PENTA...

  • Page 101: Miscellaneous

    Check the tension. Tighten the alternator retaining nut and retaining bolts. WARNING! D1-30, D2-40: Ensure that the alter- nator belt is placed in the groove closest to the alternator. P0008115 D1-30, D2-40 47701798 05-2013 © AB VOLVO PENTA...

  • Page 102: Oil Pump And Line

    Tap it out from inside the crankcase. P0008116 Use special tool 3849639 Mounting tool for D1-13 and D1-20 engines, and 3849640 Mounting tool for D1-30 and D2-40. First screw the guide pin (1) for the tool into the cylinder block.

  • Page 103: Fuel System, General

    Keep pumping at the same time as the bleed screw is closed. Pump another 10 strokes. Wipe dry the fuel that runs out. Start the engine and check sealing. P0008140 47701798 05-2013 © AB VOLVO PENTA...

  • Page 104: Fuel Feed Pump And Filter

    Unbolt the hand pump (3) and remove it. Put a new fine filter in the new hand pump. Install the hand pump on the bracket. Fasten the fuel unions. Bleed the fuel system; refer to Fuel system, bleeding page 101. P0008139 47701798 05-2013 © AB VOLVO PENTA...

  • Page 105: Injection Pump, Regulator

    Unbolt the injection pump (1). Lift it up until the lock clip (2) is accessible. Undo the clip and release the control rod (3). Lift the injection pump out and remove the shim. P0008083 47701798 05-2013 © AB VOLVO PENTA...
  • Page 106 Install the stop solenoid (1) with a new seal. Install the fuel return pipe (2). Install the delivery pipes (3) and tighten to the specified torque; refer to Tightening tor- ques page 9. P0008135 47701798 05-2013 © AB VOLVO PENTA...

  • Page 107: Injectors And Delivery Pipes

    Install the fuel delivery pipes. Check that they do not come out of alignment, and tighten the nuts. For tightening torque, refer to Tightening tor- ques page 9. P0008084 Start the engine and check for leaks. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 108 Dip the injector components in pure Diesel or testing oil, and fit the components together. Use the original thickness of adjustment washer(s) to set the opening pressure. Check the opening pressure, jet pattern and seal- ing in an injector tester. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 109: Checking Injectors

    Damp injectors may be approved. Fit protective plugs to the injector pipe connections and over the injector nozzles if the injectors are not to be installed immediately. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 110 Adjust stop screw (3) to give a clearance of 0.1 Adjustment screw, race revolutions mm (0.0039") between the stop screw (3) and the Adjustment screw, max. fuel volume actuator arm (1) when the throttle control is in the full throttle position. Lock nut 47701798 05-2013 © AB VOLVO PENTA...

  • Page 111: Cooling System, General

    The use of anti-corrosion agents alone is not permitted in Volvo Penta engines. Never use water alone as a substitute for coolant. IMPORTANT! •...
  • Page 112 It is extremely important that the system be filled with the correct coolant concentration. Mix in a separate clean vessel before filling the cooling system. Make sure that the liquids mix. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 113 Top up with coolant as necessary. NOTICE! It is okey to lift off and heighten the expan- P0007524 sion tank to ease the filling. Check and top up as necessary after the engine has been running warm (open thermostat). 47701798 05-2013 © AB VOLVO PENTA...
  • Page 114 Coolant losses during operation • • Coolant losses after stopping a hot engine Coolant losses during operation can be due to a leak- ing cooling system or air or combustion gases being forced into the cooling system. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 115 (water bubbles into the vessel with the drain hose). The valve should open at 75 kPa (10.9 PSI). Remove the test equipment. Install the plug and fill the engine with coolant. P0002790 47701798 05-2013 © AB VOLVO PENTA...

  • Page 116: Radiator, Heat Exchanger

    Remove the exhaust elbow (1) and hose clamp (2) from the heat exchanger end plate. Remove the exhaust elbow. Undo the other heat exchanger end plate (3). P0008143 Remove the insert (1) and clean it. p0008144 47701798 05-2013 © AB VOLVO PENTA...
  • Page 117 Install new O-rings (2) on the insert and end plate. Bolt the end plate onto the heat exchanger. Install the exhaust elbow. Fill up with coolant. Check the level and sealing after warming up. P0008145 47701798 05-2013 © AB VOLVO PENTA...
  • Page 118 Install the distribution box on the exhaust mani- fold. Install the hose unions and junction to the exhaust elbow. Fill up with coolant. Warm up the engine P0008148 and check the sealing and coolant level. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 119: Coolant Pump, Thermostat

    Belt, Change. Remove the coolant pump. Tightening torque: M6, 10 Nm (7.4 lbf.ft.) P0010727 NOTICE! Make sure the surface is clean before application. Remove and discard the gasket. P0010728 Installation Install in reverse order. 47701798 05-2013 © AB VOLVO PENTA...
  • Page 120 Clean the sealing surfaces. Transfer the temper- ature sensor, hose union and pulley to the new coolant pump. Install the new coolant pump with new seals, spacer (D1-13) and alternator stay. Install and p0008153 tension the drive belt. Install the hose connec- tions.
  • Page 121 Install the thermostat housing cover with a new O-ring. Tighten the screws to the specified tor- que, refer to Group 26: Cooling System page 22. Fill up with coolant. Warm up the engine and check the sealing and coolant level. P0008141 47701798 05-2013 © AB VOLVO PENTA...

  • Page 122: Sea Water System, Sea Water Pump

    Place the impeller and a new gasket in the hous- ing. Screw the cover down. Open the sea cock and start the engine. Check the sealing. IMPORTANT! Only glycerin may be used as an impeller lubricant. P0008150 47701798 05-2013 © AB VOLVO PENTA...
  • Page 123 If the gear wheel is damaged, the idler gear must be inspected as well. Install a new raw water pump and O-ring. Install the bolts and connect the hoses. Open the sea cock and run the engine. Check the sealing. P0008151 47701798 05-2013 © AB VOLVO PENTA...
  • Page 124 Remove the gearwheel (1) from the seawater pump shaft. Use a puller. P0018119 Remove the impeller cover (1) and gasket. Pull out the impeller (2) with the aid of polygrip pliers. Remove the wear washer (3). P0018120 47701798 05-2013 © AB VOLVO PENTA...
  • Page 125 26-6 Sea Water System, Sea Water Pump Remove the retainer ring. CAUTION! Risk of eye injury. Eye protection required. P0018121 Carefully tap out the shaft. P0018122 47701798 05-2013 © AB VOLVO PENTA...
  • Page 126 Install the retainer ring (2) and spacer sleeve (3). CAUTION! Risk of eye injury. Eye protection required. Carefully press on the second ball bearing (4). Press the first ball bearing back until it is abut the retainer ring. P0018147 47701798 05-2013 © AB VOLVO PENTA...
  • Page 127 (1) until the retainer ring groove in the pump housing is visible. P0018158 Fit the retainer ring into the groove in the seawa- ter pump housing. CAUTION! Risk of eye injury. Eye protection required. P0018121 47701798 05-2013 © AB VOLVO PENTA...
  • Page 128 Fit a new O-ring and the gearwheel (1) with a washer and nut on the seawater pump shaft. Install the seawater pump. P0018119 Finishing off Open the sea cock, or S-drive valve. Start the engine and check that no leakage occurs. 47701798 05-2013 © AB VOLVO PENTA...

  • Page 129: Alternator

    D1-30, D2-40: Ensure that the alternator belt is placed in the groove closest to the alternator. After checking the drive belt tension, tighten the lower retaining bolt and upper retaining nut. Install the electrical connections on the alternator. P0008115 47701798 05-2013 © AB VOLVO PENTA...

  • Page 130: Starter Motor

    Lift the starter motor out. Put the new starter motor in position and fasten it with the bolts. Install the electrical connections on the starter motor. Switch the current on and check the starter motor function. P0008155 47701798 05-2013 © AB VOLVO PENTA...

  • Page 131: Alphabetical Index

    Valve Guides, Inspection.......... 73 Group 23: Fuel System........21, 41 Valve Mechanism............. 70 Group 26: Cooling System......... 22, 44 Valve Seat, Change..........75 Group 30: Electrical System........23 Valve Seats and Valve, Grinding......74 Valves, Adjustment........... 70 47701798 05-2013 © AB VOLVO PENTA...
  • Page 132 Valves, Installation........... 72 Valves, Removal............72 Water Quality............22 47701798 05-2013 © AB VOLVO PENTA...

  • Page 133: References To Service Bulletins

    References to Service Bulletins Group No. Date Refers to ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 135 English. From: ...................................................................... Concerns publication: .............................. Publication No.: ............Date of issue: ..............Proposal/Motivation: ........................................................................................................................................................................................................................................................................................................................Date: ............. Name: ............AB Volvo Penta Market Communication Dept. CB22000 SE-405 08 Gothenburg Sweden...

This manual is also suitable for:

D1-30D1-20D2-40

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