Volvo Penta 31 Series Workshop Manual
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Volvo Penta 31 Series Workshop Manual

Engine body
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Engine Body
2(0)
31, 32, 41, 42, 43,
44, 300 series

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Виталий
April 10, 2025

Момент затяжки гаек шейки шатуна Допустимый зазор втулки клапана

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Виталий
January 28, 2025

Допустимый зазор поршневые колец. Момент затяжки гаек шатуна.

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Summary of Contents for Volvo Penta 31 Series

  • Page 1 Workshop Manual Engine Body 2(0) 31, 32, 41, 42, 43, 44, 300 series...

  • Page 3: Table Of Contents

    Group 21 Engine Body Marine Engines MD31A • TMD31B, D, L-A TAMD31B, D, S.O.L.A.S, L-A, M-A, P-A, S-A AD31B, D, L-A, P-A • KAD32P TMD41B, D, L-A TAMD41B, D, S.O.L.A.S, L-A, M-A, P-A, H-A, H-B D41B, D, L-A • AD41B, D, L-A, P-A TAMD42AWJ, BWJ, WJ KAMD42A, B, P •...

  • Page 4: Safety Information

    Check that the warning or information decals on This Workshop Manual contains technical data, de- the product are always clearly visible. Replace scriptions and repair instructions for Volvo Penta decals that have been damaged or painted products or product versions contained in the con- over.
  • Page 5 Safety Precautions Avoid skin contact with oil. Long-term or repeat- Never allow a naked flame or electric sparks ed contact with oil can remove the natural oils near the batteries. Never smoke in proximity to from your skin. The result can be irritation, dry the batteries.
  • Page 6 Components in the electrical and fuel systems a diesel engine poor quality fuel can cause the on Volvo Penta products have been designed to control rod to seize and the engine to overrev minimize the risks of explosion and fire. The en-...

  • Page 7: General Information

    IMPORTANT! Delayed or inferior care/mainte- ed in the form of Service Bulletins. nance, and the use of non-original spares, mean that AB Volvo Penta can no longer be re- sponsible for guaranteeing that the engine complies with the certified version.
  • Page 8 Warning symbols occurring in the Workshop Manual tained, that systems that can be adjusted are adjust- (for their meaning see Safety information ) ed properly and that Volvo Penta Genuine Parts as WARNING! used. The engine Maintenance Schedule must be fol- lowed.
  • Page 9 Tightening using both a torque setting and a protrac- In this Volvo Penta Service Manual the user will find tor angle requires that first the recommended torque that each section where these agents are applied in is applied using a torque wrench and then the recom- production states which type was used on the engine.
  • Page 10 Repair instructions • Always used chloroprene rubber gloves (gloves Safety precautions for Fluorine for handling chemicals) and protective glasses. rubber • Treat removed seals in the same way as corro- sive acid. All remains, even the ash can be ex- Fluorine rubber is a common material in sealing rings tremely corrosive.

  • Page 11: Special Tools

    Special tools In all cases where it is practical the tool number, except for the final digit, has been stamped on the tool. The final digit (after the hyphen) is a control number. 884 359 884 596 884 599 884 608 884 635 884 231 / 884 551...
  • Page 12 Special tools 885 139 885 199 885 237 885 238 885 243 885257 885 260 885 261 885 263 885 274 885 289 357 8670 999 1867 9992000 999 2265 999 2268 885 301 885 289-9 Brush for cleaning bottom of copper 885 139-6 Holder for injector angle dial gauge (41, sleeve and for sealing sleeve between...
  • Page 13 Special tools 999 2479 999 2658 9992679 9995028 9995031 9995218 9995443 9995444 9996033 9996272 9996385 9996404 9996532 9996598 9996858 9996860 9996936 9998039 999 2479-7 Holder for dial test indicator when check- 999 6385-2 Drift for replacing rear crankshaft seal ing liner height 999 6404-1 Press tool for the crankshaft and poly- 999 2658-6 Puller for crankshaft drive gon hub...

  • Page 14: Other Special Equipment

    999 9946-8 Engine fixture for unit stand pressure and boost pressure 999 6398-5 Pressure gauge, for checking oil pres- sure 1. Diagram of the special tool for the Turbo The tool is not supplied by Volvo Penta but must be manufactured at your own workshop.

  • Page 15: Design And Function

    Design and Function Engines general The engines are straight 6 cylinder (31/32 series have The charge air cooler (CAC) also gives lower exhaust 4 cylinders), 4 stroke diesel engines with overhead emissions because combustion is more efficient valves. KA(M)D44/300 have 4 valve technology, because of the higher oxygen content of the intake other models conventional 2 valve technology.

  • Page 16: Location Of Identification Plates

    3. Engine Product number 4. Reverse gear-/drive designation 5. Reverse gear-/drive serial number 6. Reverse gear-/drive product number 7. Volvo Penta Part Number (P/N) 8. Pump type and version 9. BOSCH P/N 10. Engine designation and product number 11. Engine Product number 12.

  • Page 17: Engine Presentation

    Design and Function Introduction to the engine AD31L,P/DP 1 Turbocharger 11 Oil filler cap 2 Air Cleaner (ACL) 12 Dip stick 3 Expansion tank 13 Charge air cooler (CAC) 4 Heat exchanger 14 Seawater pump 5 Thermostat housing 15 Steering servo pump 6 Oil cooler 16 Injection pump 7 Lubricating oil filter...
  • Page 18 Design and Function TAMD31M,L,P/HS1 1 Terminal box with semi-automatic fuses 10 Starter motor 2 Oil filler cap 11 Turbocharger 3 Dip stick 12 Expansion tank 4 Charge air cooler (CAC) 13 Thermostat housing 5 Air Cleaner (ACL) 14 Oil cooler 6 Injection pump 15 Lubrication oil filter 7 Seawater filter...
  • Page 19 Design and Function KAD32P/DP 1 Expansion tank 11 Starter motor 2 Terminal box with semi-automatic fuses 12 Turbocharger 3 Dip stick 13 Air Cleaner (ACL) 4 Charge air cooler (CAC) 14 Compressor 5 Seawater filter 15 Oil cooler 6 Seawater pump 16 Silencer compressor 7 Injection pump 17 Heat exchanger...
  • Page 20 Design and Function AD41P/DP 1 Terminal box with semi-automatic fuses 10 Starter motor 2 Oil filler cap 11 Turbocharger 3 Charge air cooler (CAC) 12 Air Cleaner (ACL) 4 Air Cleaner (ACL) 13 Expansion tank 5 Seawater filter 14 Thermostat housing 6 Seawater pump 15 Heat exchanger 7 Injection pump...
  • Page 21 Design and Function TAMD41H,M,P/HS1 1 Terminal box with semi-automatic fuses 10 Starter motor 2 Oil filler cap 11 Turbocharger 3 Charge air cooler (CAC) 12 Air Cleaner (ACL) 4 Air Cleaner (ACL) 13 Expansion tank 5 Engine coolant temperature (ECT) 14 Heat exchanger 6 Seawater pump 15 Thermostat housing...
  • Page 22 Design and Function KAD43P/DP 1 Terminal box with semi-automatic fuses 11 Starter motor 2 Oil filler cap 12 Turbocharger 3 Oil filter 13 Air Cleaner (ACL) 4 Charge air cooler (CAC) 14 Expansion tank 5 Seawater filter 15 Compressor 6 Seawater pump 16 Heat exchanger 7 Injection pump 17 Oil cooler...
  • Page 23 Design and Function KAMD43P/HS1 1 Terminal box with semi-automatic fuses 9 Oil filter 2 Oil filler cap 10 Starter motor 3 Charge air cooler (CAC) 11 Turbocharger 4 Seawater pump 12 Air Cleaner (ACL) 5 Injection pump 13 Expansion tank 6 Generator 14 Compressor 7 Fuel filter...
  • Page 24 Design and Function TAMD42WJ 1 Terminal box with semi-automatic fuses 9 Turbocharger 2 Oil filler cap 10 Air Cleaner (ACL) 3 Charge air cooler (CAC) 11 Expansion tank 4 Injection pump 12 Heat exchanger 5 Seawater pump 13 Thermostat housing 6 Fuel filter 14 Oil filter 7 Fuel pump...
  • Page 25 Design and Function KAD44P/DP 1 Terminal box with semi-automatic fuses 11 Oil cooler, power steering 2 Oil filler cap 12 Starter motor 3 EDC-unit 13 Turbocharger 4 Oil filter 14 Air Cleaner (ACL) 5 Charge air cooler (CAC) 15 Expansion tank 6 Seawater filter 16 Compressor 7 Seawater pump...
  • Page 26 Design and Function KAMD44P/KAMD300, HS63AE 1 Terminal box with semi-automatic fuses 10 Dipstick, reverse gear. 2 Oil filler cap 11 Type plate 3 EDC-unit 12 Water-cooled exhaust elbow 4 Oil filter 13 Air Cleaner (ACL) 5 Charge air cooler (CAC) 14 Oil dipstick 6 Seawater pump 15 Topping up the engine coolant...
  • Page 27 Design and Function KAD300/DP-G 1. Sea water filter 13. Turbocharger 2. Distribution box 14. Air filter 3. Oil filler, engine 15. Dipstick, engine 4. Control unit (EDC) 16. Coolant filler 5. Oil filter, engine 17. Expansion tank 6. Intercooler 18. Supercharger 7.

  • Page 28: Component Description

    Design and Function Component specification Cylinder block The cylinder block is made of special alloy cast iron and cast in one piece. Combustion induced tensile stresses in the cylinder head screws are directed through stiffened sections between the cylinder block walls into the main bearings. The camshaft bearings are bored to the correct di- mension and aligned after installation.
  • Page 29 Design and Function Piston rings Each piston has two compression rings and an oil ring. The upper ring “A” is of the “Keystone” type (trapezi- um shaped) The keystone is molybdenum coated and should be used with the marking TOPCD upwards. The other compression ring “B”...
  • Page 30 Design and Function Valve system The valves are made of chrome-nickel steel. The valve stems are chromed. The valve seats of special steel are replaceable. The seats are available are as replacement parts as standard size and as over-sized. The over-sized seat has a 2 mm larger outer diameter and is used if new valve seats need to be cut in the cylinder head.
  • Page 31 Design and Function Main and crankshaft bearings The main and crankshaft bearings consist of indium plated leaded bronze lined steel shells. The bearings are precision manufactured and ready for installation. Three under-sizes can be obtained as replacement parts. The thrust washers for the crankshaft axial bearings are available in three over-sizes.

  • Page 32: Repair Instructions

    Repair Instructions Repair Instructions Actions before lifting the engine out of General the boat If possible a condition test should be carried out be- Take the boat out of the water. fore every major service correction, so that the engi- nes condition can be established and any contributory Cut off battery supply, remove battery terminals fault causes discovered.

  • Page 33: Engine Fixture Attachment

    Repair Instructions Engine fixture attachment Fixture 999 9946 is used to attach the engine to unit stand 998 6485. The fixture is screwed onto the engine’s right side ac- cording to the picture below. NOTE! It is important that the instructions for the number and size of screws is followed so that a se- cure attachment of the engine is obtained.

  • Page 34: Engine Condition Test

    Repair Instructions Engine condition test Removing components from the Cylinder block Compression test Removing Special tools 31/32/41/42/43 series: 999 6936 44/300 series: 885 257 A compression test indicating the cylinders and valve sealing is carried out as a easy and reliable way of judging engine condition.
  • Page 35 Repair Instructions Remove the compressor bracket and remove the Remove the lower screw from the heat exchanger- compressor. Wrench sizes 14 mm and 15 mm cylinder block strut. Wrench 17 mm. (KA(M)D32/42/43/44/300) Remove the heat exchanger and expansion tank IMPORTANT! Cover the compressor intake and complete with respective brackets.
  • Page 36 Repair Instructions Remove the oil cooler with the oil distribution housing Lift the engine with the appropriate lifting gear. Re- Wrench 12 mm. move the engine pads. Wrench 17 mm. Remove the dipstick pipe. Wrench 10 mm. Install engine fixture 999 9946. NOTE! If the dipstick pipe cannot be removed the fix- ture must be modified so that the dipstick pipe is not crimped.
  • Page 37 Repair Instructions Remove EDC unit connector. Carefully bend down the Remove fuel filter complete with electronic diesel red lock pin at the same time as the connector is control (EDC) unit (KA(M)D44/300) and bracket. pulled out (KA(M)D44/300). Wrench 14 mm. Remove fuel pipe bracket.
  • Page 38 Repair Instructions Remove the generator (GEN) electrical terminals. Remove water filter bracket. Remove the sea water Wrench 7 mm, 8 mm and 10 mm. pump and lift off the filter and pump as one unit. Wrench 12 mm. Remove the starter motor solenoid electrical ter- minals.
  • Page 39 Repair Instructions Remove the charge air cooler (CAC). Disconnect the turbocharger (TC) connector pipe, wrench 10 mm. Slacken off the support bracket at the bottom edge Remove the exhaust pipe. Socket 15 mm. Lift off the and on the inside of the CAC and the terminal to the exhaust pipe and turbocharger (TC) as one unit.
  • Page 40 Repair Instructions Remove the lifting bracket. Socket 13 mm. Remove the outer pulley on the circulation pump. Socket 12 mm. Slacken and remove the circulation pump drivebelt. Remove tension reel. Wrench 8 mm allen.

  • Page 41: Disassembling Cylinder Block

    Repair Instructions Dismantling cylinder block Removal KA(M)D44P-B/44P-C/300 Remove the clip on the rubber grommet for the cable to the injector on cylinder 1. Separate the connector. Remove circulation pump. Socket 12 mm. Remove the screws for the valve cover. Carefully press the rubber grommet in using a screwdriver at the same time lifting the valve cover slightly.
  • Page 42 Repair Instructions Remove the injectors. Use extractor 885 131 (31/32/ 41/42/43 series) and 885 263 (44/300 series). This is to ensure that the copper sleeves are not extracted as well. 31/32/41/42/43 Remove the upper valve covers. Socket 10 mm. Remove the lower part of the valve covers. Socket 13 mm.
  • Page 43 Repair Instructions Remove the vibration damper and belt pulley. Socket Remove oil feed pipe and oil delivery pipe and their 12 mm. bracket. Socket 12 mm. NOTE! The bracket screws have sprung washers which may not be mixed with the other washers. Remove the polygon hub center bolt.
  • Page 44 Repair Instructions Screw the center bolt back in loosely and without the washer Pull off the polygon hub, use puller 884 608 with 3 belt pulley screws. Remove the center screw. Remove the intermediate gear. Socket 12 mm. Remove the camshaft pulley center screw and washer.
  • Page 45 Repair Instructions Remove the inner timing cover and intermediate gear hub. Socket 12 mm. Remove the crankshaft gear with puller 999 2658. Use tool 884 895 as a counterhold. Remove the inner flywheel cover. Socket 14 mm. Remove the connecting rod cap and press out the pistons Take care not to damage the piston cooling Remove camshaft pressure washer and carefully nozzles.
  • Page 46 Repair Instructions Remove the main bearing caps and remove the crankshaft. The main bearing caps are numbered and must be reinstalled in their original positions. Socket 19 mm. Remove piston cooling nozzles. NOTE! Lock nuts should not be reused but should al- ways be replaced with new ones.

  • Page 47: Cylinder Head, Reconditioning

    Cylinder head, dismantling/ Install the plugs if they have been removed. Clean the plug seats. reassembly Apply Permatex® No. 3 or Volvo Penta 1161099-5 sealing compound. Special tools: 885 128 Insert plugs using a drift or socket. Lubricate the valve stems and install the valve in its guide.

  • Page 48: Guide Pin, Valve Yoke, Change (44/300)

    Repair Instructions Guide pin, valve yoke, change (only KA(M)D44/300) The guide pin should only be changed in cases where the guide pin has been broken. Since this task requi- res great accuracy, we recommend that the cylinder head should be removed from the engine before work starts.

  • Page 49: Cylinder Head, Leakage Check

    Repair Instructions Cylinder head, leakage check Special tools: 885 243, 885 274, 999 6662, 999 6532 WARNING! Pressure test equipment 999 6662 should be checked before use. Always follow the safety precautions. Check that the knob on the pressure test equipment relief valve is unscrewed.

  • Page 50: Cylinder Head, Inspection

    Repair Instructions Cylinder head, inspection Cracks When checking before reconditioning heat cracks can sometimes be seen between the valve seat and in- jector nozzle in engines that have a large number of operating hours. The cylinder head does not require changing because of heat cracking The crack begins at the copper injector sleeve and goes towards the valve seat position.

  • Page 51: Valve Guides, Inspection

    Repair Instructions Valve guides, inspection Special tools: 999 9683, 999 9696 Position the cylinder head on a pair of wooden blocks and install new valves in the guides. Lower the valve approximately 2 mm and check wear. 31/32/41/42/43 series: Lubricate the new guides and press them in with drift 999 5028.

  • Page 52: Valve Seat, Replacing

    Repair Instructions Valve seat, replacing Clean the seat position and check that there are no Special tools: 999 2479, 998 9876 cracks. Measure the diameter of the valve seat position. De- valve seats should be replaced when the when the cide using the measurement whether a standard or distance (A), measured to the new valve exceeds (for oversized seat is needed.

  • Page 53: Valve Seat, Grinding

    Repair Instructions Valve seat, grinding Valve, grinding Before grinding the valve guides should be checked Valves tightening angles: and replaced if the wear parameters are exceeded. When grinding the valve seat only remove the min- Inlet: 29.5° imum amount necessary to ensure that the valve Exhaust: 44.5°...

  • Page 54: Rocker Mechanism, Reconditioning

    Repair Instructions Rocker mechanism, reconditioning Special tools: 999 1867 Remove the snap rings from the rocker arm shaft and remove rocker arms, bearing supports and springs. Clean the components; be particularly careful with the oilway in the bearing supports (44/300 series) and the rocker arm shaft and rocker arms oil holes.

  • Page 55: Checking Valve Springs

    Repair Instructions Applies to 31/32/41/42/43 series Valve springs, checking Pull out the steel ring above the copper sleeve by ex- panding tool 884 931 just under the ring. NOTE! To prevent the extractor stem from damage when extracting, the crank must be held and the tight- ening carried out with a nut.

  • Page 56: Cleaning Seat For Copper Sleeve

    Repair Instructions Copper sleeve, installing Check that the lower O-ring (31/32/41/42/43 only) has Special tools 31/32/41/42/43 series: 884 945 come up with the copper sleeve and that the lower 44/300 series: 885 237 sealing point is clean. If the sealing surface is damaged or soot coated it It is important that the steel ring and the copper can be cleaned with a nylon brush.
  • Page 57 Repair Instructions Applies to 44/300 series Insert the sleeve and the tool into the cylinder head. Mount the injector mounting nut and press the pack- age with the mounting screw until the copper sleeve bottoms in the cylinder head. IMPORTANT! Note that when installing with the cylinder head mounted, the piston must not be at Top Dead Center (TDC) when the installation takes place.

  • Page 58: Cylinder Head, Installing

    Repair Instructions Cylinder head, installing Special tools: 999 2479, 999 6272 Clean the cylinder head and the cylinder block sur- face. Remove any rust and carbon from screw holes and threads of the cylinder head mounting screws. Clean threads with a tap (M12). Remove loose dirt with a vacuum cleaner or compressed air.

  • Page 59: Valves, Adjusting

    Repair Instructions Valves, adjusting Remove valve covers. When checking valve clear- ance the engine should be turned in the direction of NOTE! The clearance must never be checked with rotation. Turning is carried out using the engines poly- the engine running – the engine must be stopped – gon hub with a 24 mm socket and ratchet.
  • Page 60 Repair Instructions Press the valve yoke down. Adjust the clearance between the rocker and the valve yoke on cylinder 1. Turn the engine a third of a revolution in the direction of rotation and adjust the clearance for the yoke and rocker on cylinder 5.

  • Page 61: Cylinder Head, Reconditioning

    Repair Instructions Cylinder liner, inspection and Cylinder block, reconditioning measurement Cylinder block, inspection Inspection Clean the cylinder block thoroughly and check bear- The cylinder liner should be thoroughly cleaned before ing position, connecting rods and cap for damage. inspection and measuring. The cylinder liner must be Check that all the channels are free of deposits and removed from the cylinder block in order to carry out that the block does not have any cracks.

  • Page 62: Cylinder Liner, Honing

    Repair Instructions The honing lines must be regularly formed and evenly cut in both directions, over the whole surface. If the wear is greater than 0.25–0.30 mm the cylinder liner with piston and piston rings should be replaced. NOTE! The correct speed must be held on the honing tool in order to obtain the correct pattern.

  • Page 63: Piston And Connecting Rod, Inspection

    Repair Instructions Piston and connecting rod, Remove the gudgeon pin snap ring and press out the inspection gudgeon pin with a suitable drift. Checking piston wear Check pistons for cracks, broken piston ring carriers or worn piston ring grooves. If the piston has deep scores in the outer mantle the piston (liner kit) must be discarded.

  • Page 64: Piston, Installing

    Repair Instructions Piston, installing Position the piston and connecting rod so that the Install one snap ring in the piston. Heat the piston to front marking on the pistons (arrowed) and the num- approximately 100°C. bering on the connecting rods is in the position illus- trated.

  • Page 65: Piston Rings, Inspection And Alignment

    Repair Instructions Piston rings, inspection and Piston rings, installing alignment Install the piston rings on the piston using piston ring pliers. The oil ring (C) is installed first and can be freely turned. The opening in the expander ring is placed op- posite the oil ring gap.

  • Page 66: Lifters And Camshaft, Inspection

    Repair Instructions It has been found that the damage seldom gets Lifters and camshaft, worse. inspecting Check the camshaft bearing caps and cam lobes for wear. Cams can be unevenly worn axially. This can be adjusted in minor cases by grinding the cams.

  • Page 67: Camshaft Bearings, Replacing

    Repair Instructions Camshaft bearings, replacing Measure wear and ovalness with a micrometer. The bearings are pressed into position and must be Greatest permitted ovalness in Main and big end bored after pressing in. Replacing the camshaft bear- bearings 0.08 mm, maximum conicity 0.05 mm. ings can only be carried out when overhauling the Grind the crankshaft to a suitable undersize if these whole engine.
  • Page 68 Repair Instructions Checking for cracks Cutting damage can cause overheating cracks which can only be detected with special equipment. Any cracks and notches can be found most reliably using a magnetic powder such as Magnaglo, fluorescent powder reacting to ultraviolet light. Refer to the rele- vant equipment manufacturer’s instructions for opera- tional procedure.

  • Page 69: Crankshaft, Reconditioning

    Repair Instructions Crankshaft, reconditioning In general regrinding and realigning mean a shorter lifetime. Therefore do not regrind unless there is good reason for regrinding, measurement fault (wear, oval- ness, conicity) or such serious surface damage that grinding is not sufficient. The crankshaft main and big end bearing journals can be ground to 0.25 mm, 0.50 mm and 0.75 mm under- size.

  • Page 70: Flywheel, Replacing

    Repair Instructions Flywheel, replacing Check that the flywheel locating pin in the crankshaft is in place and undamaged. Lift the flywheel into place and install screws. Tighten the flywheel screws to 65 Nm + angle tighten 60°. Install the RPM sensor (44/300 series). Remove the screws and lift off the flywheel.

  • Page 71: Ring Gear, Replacing

    Repair Instructions Gear collar, replacing (flywheel dismounted) Locate the heated gear collar on the flywheel and knock it into position with a soft drift and hammer. Let the gear collar cool in open air. Drill 1–2 holes in a notch on the gear collar. Split the gear collar at the drilling point with a chisel and re- move the gear ring.

  • Page 72: Flywheel, Indication

    Repair Instructions Read off the value and the move the dial indicator Flywheel, indication and mounting to the opposite side of the flywheel. Special tools: 999 9696, 998 9876 The difference in value between these two indications must not exceed 0.15 mm. Position an dial gauge with the point against the fly- wheel.

  • Page 73: Flywheel Cover Reconditioning

    Repair Instructions Reassembling Flywheel housing, reconditioning Special tool: 884 596 Press on the new bearing using drift 884 596. Install snap ring. Press the shaft into the housing with drift 884 596. Ensure that the snap ring (6) locates correctly in the tool notch.

  • Page 74: Cylinder Block, Installing

    Repair Instructions Lift up the cylinder liner and install the new sealing Cylinder block installation rings as illustrated. Brush the sealing rings and lower sealing surface with soap solution. Cylinder liner, installing Special tools: 998 9876, 999 2479, 999 6272, 999 6598, 999 2000 NOTE! All mating surfaces in the block for liners and sealing rings should be thoroughly cleaned.

  • Page 75: Piston, Installing

    Repair Instructions Install new main- and thrust bearings. The main Install the big end bearing caps so that the marking bearing shells with oil ways should be install in matches the marking on the crankshaft. Oil the the cylinder block. Lubricate the bearing surfaces threads.
  • Page 76 Repair Instructions Install a new seal ring in the inner bell housing, using Install the bracket (splash plate) for the inlet pipe. mandrel 999 6385. NOTE! The screws have special washers (spring NOTE! Wipe grease, VP part no. 1161447 on the inner washer).
  • Page 77 Repair Instructions Install the camshaft intermediate drive gear as Install the inner timing cover with the intermediate marked on the gear. Tightening torque 24 Nm. gear shaft journal as a guide. If necessary use a rub- ber mallet. Clean and then oil the camshaft bearings. Carefully Install the camshaft key.
  • Page 78 Repair Instructions Install the timing gear cover with a new seal. Grease the inner edge of the seal ring lip with grease, VP part no. 1161447. Wrench size 12 mm. Early version of marking Apply molybdendisulphide to the crankshaft shaft. Heat the polygon hub to approximately 100°C and in- stall it on the shaft.
  • Page 79 Repair Instructions Install the valve lifters in their original positions in the Install the intermediate flange with new O-rings (44/ block. Clean the lifters and then oil the lifters and the 300 series). Install the fuel injection pump. Do not guides in the block.
  • Page 80 Repair Instructions Install intake manifold on cylinder head. Apply seal- ing compound Loctite® 574 to cylinder head and in- take manifold. Apply a thin even unbroken bead, bead width 3 mm. Install the front vibration damper and belt pulleys. Tightening torque 28 Nm. Socket 12 mm. A, B (B only upper edge) = Sealing compound intake manifold Install feed pump.
  • Page 81 Repair Instructions Install a new cylinder head gasket and lift the cylinder head in place. Handling, see “ Cylinder head, install- ing”. Install the push rods in their original positions. Install the nozzles. Do not forget the lower O-ring on the nozzles (44/300 series only) NOTE! Ensure that the plane of the return line is as straight as possible.
  • Page 82 Repair Instructions 31/32/41/42/43-series Install the valve cover with new gaskets. Tightening torque upper valve cover 8 Nm. Socket 10 mm, 13 Applies only to KA(M)D44P-B/44P-C/300 Ensure that the cut out in the sealing washer corre- sponds to the split pin and the injectors cable termi- nal (only cylinder 1) 44/300 series 44/300 series...
  • Page 83 Repair Instructions Install the lifting brackets. Install the thermostat Applies only to KA(M)D44P-B/44P-C/300 housing using new sealing ring. Socket 12 mm, 13 Insert the cable for the injector through the valve cov- er. Press the rubber grommet into place at the same Install the circulation pump outer pulley.

  • Page 84: Injection Timing, Setting

    Repair Instructions Applies only to KA(M)D44P-A Injection timing, setting Special tools: 884 895, 884 954 31/32 series: 885 199 41/42/43/44P-B/44P-C/300 series: 885 139 44P-A: 885 139, 885 301 Remove the pump’s reset cover. Use Torx 30 tool. Install tool 884 895 in the flywheel housing. Turn the engine in the direction of rotation until the tool lug locks the flywheel.
  • Page 85 Repair Instructions Applies to all engines Release the locking lug on tool 884 895 and turn the engine back (against direction of rotation) approx- imately 30° (41/42/43/44/300 series) and approxi- mately 45° (31/32 series) or until the clock “stops”. Reset the clock Turn the engine in the direction of rotation.
  • Page 86 Repair Instructions Install fuel and oil filters bracket. Install the generator (GEN) and generator belt. Wrench 11/16", 5/8", 12 mm, 13 mm. NOTE! Mounting for injector pipes in the bracket. Tension the generator belt. See “Checking belt ten- Wrench 10 mm, 13 mm and 17 mm. sions”.
  • Page 87 Repair Instructions Install the starboard engine bracket and where appli- Install the sea water pump, water filter with bracket cable the servo pump. Install and tension belts. See and hose to the charge air cooler (CAC) front terminal “Checking belt tensions”. and to water intake (shield).
  • Page 88 Repair Instructions Install the heat exchanger with hose connectors. Do Install the compressor (32/42/43/44/300), and tighten not tighten the clamp at the thermostat in this posi- the coolant hose clamp at the thermostat housing. tion. Wrench 15, 17 mm Wrench 14, 15 mm. Install the expansion tank and bracket and the vent- Install and tension the compressor drive belt.

  • Page 89: Drive Belts, Tensioning

    Repair Instructions Drive belts, tensioning, 31/41 series Drive belts, inspection points Alternator belt Install the air pipe compressor – air cleaner. Use new O-rings and dip them in soap solution to facilitate in- stalling the air pipe . Install air cleaner. Wrench 10, 11 mm.
  • Page 90 Repair Instructions Drive belts, tensioning 32/42/43/44 series (early model) Circulation pump belts (double V-belts) (only KA(M)D42 up to engine no. 2204208023) Applies to the following engines: 32 series up to engine number 2203202197 KA(M)D42 series, TAMD42WJ up to engine no. 2204216366 43 series up to engine number 2204303258 44 series up to engine number 2204404631 Special tools: 1159 660...
  • Page 91 Repair Instructions Circulation pump belt (Poly-Vee belt) Alternator belt Tension the belts with adjuster screw (3). The check point on the belt is at (3), right behind the edge of the poly-Vee pulley track. Tighten screws (1) and (2). The check point for the belt is at (5), mid way between Belt tension 20–25 kg (44–55.1 lb).
  • Page 92 Repair Instructions The following applies to installing a used belt. Drive belts, tensioning 32/42WJ/43/44/300 (late model) – Tension the belt to 30–35 kg (66–77.1 lb). – Turn the engine round about one turn in its direc- Applies to the following engines: tion of rotation.

  • Page 93: Checks Before Starting

    Repair Instructions Before starting Supercharger belt Fill engine oil. Check level. Fill coolant. Check level. Check oil level, compressor (KAD/KAMD 32/42/43/44/300). Check that all wiring is connected and that all ter- minals are properly fastened. Check that the wir- ing is correctly clamped so that it is not exposed to mechanical wear.
  • Page 94 References to Service Bulletins Group Date Regarding ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 95 From: ....................................................................Concerns publication: ............................. Publication No.: ............Date of issue: ..............Proposal/Motivation: ....................................................................................................................................................................................................................................................................................................................Date: ............Name: ............AB Volvo Penta Customer Support Dept. 42200 SE-405 08 Gothenburg Sweden...

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