Volvo Penta D1 Service Manual
  1. Manuals
  2. Brands
  3. Volvo Penta Manuals
  4. Engine
  5. D1 Series
  6. Service manual

Volvo Penta D1 Service Manual

Hide thumbs Also See for D1:
Table of Contents

Advertisement

Quick Links

service and maintenance
D1, D2

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the D1 and is the answer not in the manual?

Questions and answers

Related Manuals for Volvo Penta D1

Summary of Contents for Volvo Penta D1

  • Page 1 D1, D2...
  • Page 2 © 2017 AB VOLVO PENTA Volvo Penta reserves the right to make changes Printed on environmentally friendly paper...

  • Page 3: Table Of Contents

    Propeller ....................65 Checking Protective Anodes ..............68 Painting the Drive ................. 70 S-drive ....................70 Long-Term Storage ................... 74 Storage instruction for long-term storage of new engine ......76 Cleaning engine and transmission ............78 47708114 06-2021 © AB VOLVO PENTA...
  • Page 4 Cold Weather Precautions ..............80 Checklist ....................82 Battery, Maintenance ................83 Index ......................85 47708114 06-2021 © AB VOLVO PENTA...

  • Page 5: Safety Information

    This chapter describes how safety precautions are If anything remains unclear or if you are unsure of presented in the manual and on the product. Read the something, contact your Volvo Penta dealer for chapter through very carefully before you start the assistance.
  • Page 6 Use protective gloves and avoid oil-soaked clothes and rags. Wash regularly, especially before eating. Wear suitable protective creams to prevent skin from drying out and to facilitate cleaning. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 7: Spare Parts - Safety

    P0024470 Spare parts - safety WARNING! Always use Volvo Penta genuine spare part to minimize the risk of an explosion or fire. Components in fuel systems and electrical systems on Volvo Penta engines are designed and manufactured to minimize the risk of explosions and fire, in accordance with applicable legal requirements.
  • Page 8 Information on the engine IMPORTANT: Make sure that all warning and information decals on the product are always visible. Replace decals which have been damaged or painted over. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 9 Switch off the main switch before connecting or disconnecting a connector. Before any work on the cooling system WARNING! Stop the engine and let it cool before starting work on the cooling system. Hot fluids and hot surfaces can cause burns. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 10 Damaged pipes must be replaced. Before any work on the fuel system — Cleanliness IMPORTANT: Take great care to keep the fuel system components clean. Even minimal amounts of dirt can cause engine breakdown. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 11 Cleaning the engine and components NOTICE! Follow the instructions Cleaning engine and transmission, page 78. P0026213 Cleanliness for sensitive components IMPORTANT: Observe meticulous cleanliness when handling system components. Even minimal amounts of dirt could cause a breakdown. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 12 P0024689 Example of an adjustable lifting yoke and a lifting tool. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 13: General Information

    Volvo Penta parts in all areas of the exhaust restriction system covered by the warranty and found The manual has been produced primarily for use in to be defective.

  • Page 14: Service Protocol

    This means that AB Volvo Penta will no longer be Example: 1000 hours / 24 months. Whichever is the able to assume liability for engine specification sooner applies. If the component is used for 1000 compliance with the certified model.

  • Page 15: Preventive Repair

    These components form the basis for calculating service contracts and the costs in the service calculator in Product Center. Fuel system Fuel pump Unit injectors P0026295 Exhaust system Turbocharger, low-pressure Turbocharger, high pressure Overflow valve (Lisk) Silencer Diesel particulate filter (DPF), replacement After-treatment system Pump unit Dosage valve P0026296 47708114 06-2021 © AB VOLVO PENTA...
  • Page 16 General Information Cooling system Seawater pump Coolant pump Engine Vibration dampers Engine pads, kit P0026297 Electrical system Alternator Starter motor P0026298 47708114 06-2021 © AB VOLVO PENTA...
  • Page 17 Engine: May be overhauled twice, after which the engine is considered spent and is replaced by a long block or new engine. Overhaul Long block Short block Cylinder head (replacement) Cylinder head, gasket P0026299 Engine, overhaul kit Cylinder head, overhaul kit Gaskets, kit Flat gaskets Valve cover, gasket P0026300 47708114 06-2021 © AB VOLVO PENTA...
  • Page 18 General Information Cylinder liners, kit Main bearings, kit Big end bearings, kit Thrust washers, kit Camshaft bearings, kit P0026301 Exhaust valve Valve seat P0026302 47708114 06-2021 © AB VOLVO PENTA...
  • Page 19 Product Center. The transmission is overhauled once, then the complete unit is replaced Overhaul, Aquamatic Aquamatic sterndrive, replacement Upper gear Lower gear P0026303 Repair, Aquamatic Upper gear, kit Sliding sleeve P0026304 Lower gear, kit P0026305 47708114 06-2021 © AB VOLVO PENTA...
  • Page 20 General Information Overhaul, IPS IPS Drive, replacement Upper gear Lower gear P0026306 Repair, IPS Upper gear, kit P0026307 Lower gear, kit P0026308 47708114 06-2021 © AB VOLVO PENTA...
  • Page 21 General Information Propeller shaft P0026309 47708114 06-2021 © AB VOLVO PENTA...

  • Page 22: Genuine Volvo Penta Parts

    IMPORTANT: It is extremely important not to use other oil than specified for the IPS unit. NOTICE! Volvo Penta will deny all warranty claims if it emerges that the wrong oil has been used in the IPS unit. NOTICE! For reverse gears, the oil change intervals and maintenance instructions recommended by the manufacturer must be adhered to.
  • Page 23 In areas with high levels of sodium and calcium in tap water, the coolant must be diluted with distilled water. Alternatively, Volvo Penta coolant is available for purchase ready diluted. Protection against...

  • Page 24: Illustrations

    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 47708114 06-2021 © AB VOLVO PENTA...

  • Page 25: Chemical Products

    Chemical products Chemical products Chemical products The following is a selection of Volvo Penta recommended chemical products. The products are available for purchase at regional Volvo Penta dealerships. Deviations may occur in the range, see Specifications. For correct part numbers, refer to the Parts catalogue.

  • Page 26: Special Tools

    There are special equipment and tools to be used when working with the engine. For some operations/ service points special tools are required in order to carry out the work in a correct manner. 3889988 Adapter 22767251 Hose 47708114 06-2021 © AB VOLVO PENTA...

  • Page 27: Specifications

    This information should always be used as a reference when ordering service and replacement parts or when contacting Volvo Penta retailers. P0030924 Engine ID Engine/Transmission/Address CHASSIS ID Engine Certification 47708114 06-2021 © AB VOLVO PENTA...

  • Page 28: Transmission Decals

    Specifications Transmission Decals Reverse gear A Reverse gear ID B CHASSIS ID reverse gear P0030930 S Drive, ID 47708114 06-2021 © AB VOLVO PENTA...

  • Page 29: General Tightening Torques

    M8 standard bolt M10 standard bolt M12 standard bolt M14 standard bolt M16 standard bolt NOTICE! Check the bolts intended for installation Damaged bolts with e.g. shear marks under the heads, must be scrapped. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 30: Specifications

    NOT be mixed with newer VCS yellow coolant. Check that the engine is using the same type. NOTICE! Yellow and red Volvo Penta ATF Dextron III oil may be mixed without causing any problems. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 31 NOT be mixed with newer VCS yellow coolant. Check that the engine is using the same type. NOTICE! Yellow and red Volvo Penta ATF Dextron III oil may be mixed without causing any problems. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 32: Engine

    Remove all accumulations of fuel, oil and grease when detected on the engine or in the engine room. WARNING! If an oil, fuel or coolant leak is detected, the cause must be investigated and the fault rectified before the engine is started. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 33 Engine oil filler Draining engine oil Expansion tank, cooling water Drive belt, alternator/water pump Impeller pump, seawater Drain seawater on the other side of the engine; the drain is mounted on the heat exchanger. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 34 Draining engine oil Engine oil filler Impeller pump, seawater Drive belt, alternator/water pump Fuel filter Dipstick, engine oil Drain seawater on the other side of the engine; the drain is mounted on the heat exchanger. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 35: Maintenance Schedule

    Engine Maintenance Schedule The Volvo Penta engine and its equipment are designed for high reliability and long life. The engine is built so as to have minimal environmental impact. These qualities will be retained and unnecessary malfunctions avoided if service is provided according to the maintenance schedule.

  • Page 36: General Inspection

    The inspection applies to all components in the systems. Look especially carefully for fuel leakage • Injector connections • Common rail, replacement • Check all clamped items • Fuel filter • Fuel pipe/hoses • Fuel pump P0026583 47708114 06-2021 © AB VOLVO PENTA...
  • Page 37 WARNING! If you discover a leakage of oil, fuel or coolant, investigate the cause and fix the fault before starting the engine to avoid the risk of fire. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 38: General Advice For Electronic Protection

    ● Take extreme care so that the harness terminals do not come into contact with oil, water or dirt if a connector is removed from a sensor. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 39: Air Filter

    Remove the bolt at the bottom of the filter. • Remove the pump by pulling it straight out. • Install the new filter. • Secure the hose clamps. • Install the lower bolt. NOTICE! Scrap the old filter. It cannot be cleaned. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 40 Replacing the air filter • Remove the hose clamp. • Remove the filter. • Install the new filter. • Secure the hose clamps. NOTICE! Scrap the old filter. It is not designed to be cleaned. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 41: Valves, Adjustment

    Adjusting valve clearance is a servicing item. Note the servicing intervals for the engine. Detailed instructions are available in the workshop manual. NOTICE! When adjusting the valve clearance, the engine must be cold. P0026752 47708114 06-2021 © AB VOLVO PENTA...

  • Page 42: Lubrication System

    Oil level check, cold engine. (recommended) • Make sure the engine is level. • Oil level measurement is most reliable before the engine is started Check that the oil level is between the dipstick's min and max markings. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 43 A Oil level on the MIN marking: add oil until the level is between min and max. B Optimal oil level, do NOT add oil. C Oil level at max marking; do NOT add oil. P0028585 NOTICE! Never add too much engine oil. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 44: Engine Oil, Replace

    Connect a vacuum pump and draw the oil out through the pipe. NOTICE! If the engine oil is hot, it will drain out faster. NOTICE! Hand the old oil in to a re-cycling station. P0026753 47708114 06-2021 © AB VOLVO PENTA...

  • Page 45: Oil Filter, Replace

    Lubrication System Oil filter, Replace Volvo Penta strongly recommends that only oil filters approved by Volvo Penta be used. The wrong type of oil filter can lead to increased wear and damage, e.g. to bearings and crankshaft. Removal • Clean around the filter.
  • Page 46 Fill with the required volume of oil; see Specifications, page 28. • Start the engine. • Check that no leakage occurs. P0030925 • Stop the engine, and check the oil level after a few minutes. • Top up as necessary. P0026757 47708114 06-2021 © AB VOLVO PENTA...
  • Page 47 There are two different service records available for these engines. Refer to the Volvo Penta Product Center In order to find out more about Volvo Penta Oil Analysis, we recommend our on-line training. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 48: Fuel System

    The fuel system has a fine filter fitted to the engine as standard. Furthermore, the installation often has a pre- filter whose insert must also be changed. The illustration shows a typical fuel pre-filter. P0026758 47708114 06-2021 © AB VOLVO PENTA...

  • Page 49: Fuel Filter, Change

    ½ turn. • Bleed the fuel system. • Replace the insert in the fuel pre-filter at the same time, if one is fitted. P0030635 47708114 06-2021 © AB VOLVO PENTA...

  • Page 50: Fuel System, Bleeding

    • Vent with the hand pump above the filter. • Open the vent screw (A). • Pump by hand until fuel flows out without any air bubbles. • Close the vent screw. P0030918 47708114 06-2021 © AB VOLVO PENTA...
  • Page 51 Screw until a slight resistance is felt and then tighten no more than 1/4 turn more. NOTICE! If water comes out of the fuel pre-filter, the fuel tank must be drained and cleaned. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 52 Fuel System Pre-filter Disassemble the fuel pre-filter according to the figure with the pass-through bolt in its center. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 53: Exhaust System

    Exhaust hose Reverse gear/S Drive: Inspect the exhaust hose. Check that it has no cracks or leaks (exhaust, cooling water). If there is any leakage, replace the hose. Check that all hose clamps are tightened. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 54: Cooling System

    Check the fluid level in the expansion tank when the engine is cold. Top up with coolant as necessary. In the case of D1-D2/40 engines, check the level against the mark on the outside of the vessel. P0026760 In the case of D2-50/55/60/75 engines, check the level beneath the radiator cap.
  • Page 55 NOTICE! If the boat has a heating element connected to the engine cooling system, it must also be drained when changing the engine coolant. NOTICE! Hand in the old coolant to a recycling station for disposal. P0026762 47708114 06-2021 © AB VOLVO PENTA...
  • Page 56 Allow to cool, and check the coolant level. NOTICE! Do not drain the system if the engine is to be in storage for a longer period of time. The coolant contains corrosion protection additives. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 57: Drive Belt, Replace

    Cooling System Drive Belt, Replace The engine has a belt that drives the alternator and the coolant pump. Belt replacement D1-13/20 — 30/D2-40 • Undo the bolts (A) and (C). • Move the alternator toward the engine by screwing in bolt (B) and free the belt.
  • Page 58 Tighten the alternator belt until a play of about 3–4 mm is achieved. Tighten the bolts. P0030932 Belt tensioning, D1 and D2 engines (all) Check the drive belt after operation, when the belt is hot. It should be possible to depress the drive belt about 3-4 mm between the pulleys.

  • Page 59: Seawater Pump, Impeller, Change

    If they are dry, swollen or show other signs of damage, they must be replaced with new ones. NOTICE! The illustration shows the impeller pump on D2-50/55/60/75 engines. The position is the same on D1-13/20/30– D2-40 engines. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 60 Open the cooling water cock. • Start the engine. Check that there are no leaks when the engine is started. NOTICE! The impeller may be damaged if any types of lubricant other than glycerin are used. P0026764 47708114 06-2021 © AB VOLVO PENTA...

  • Page 61: Seawater Filter, Check And Cleaning

    It must be possible to open and shut the cock for e.g. impeller maintenance. Clean the cooling water intake (outer grille) when the boat is on dry land. NOTICE! Check the hose clamps are tight and water hose(s) undamaged. P0026225 47708114 06-2021 © AB VOLVO PENTA...
  • Page 62 • Open the sea cock. • Check that there is no leakage when the engine starts. NOTICE! There are different versions of the vacuum valve, but they all operate on the same principle. P0026743 47708114 06-2021 © AB VOLVO PENTA...

  • Page 63: Transmission

    In a marine environment it is vitally important that the correct gear lubricant is used for the product concerned. In Volvo Penta's extensive testing, we pick out those oils that meet the requirements for functionality and which, within the oil change intervals, will ensure the product’s service life.
  • Page 64 Transmission, Reversing gear The reverse gears to D1/D2: MS15A-B/A-L MS25A-A/A-L HS25 A-C P0026766 NOTICE! Reverse gear designs differ. During oil changes, HS25 engines have oil filters that must be replaced. Not all reverse gears have oil filters. P0026232 47708114 06-2021 © AB VOLVO PENTA...
  • Page 65 Start the engine and run it at 1500 rpm for a few minutes, (engage a gear forward/reverse). • Stop the engine and check the oil level again. • Top up as necessary. NOTICE! Oil in accordance with P0030647 Specifications, page 28. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 66 If the boat is fitted with a Volvo Penta propeller shaft, the propeller shaft seals must be purged and lubricated Immediately before launching. Press approximately 1/4 teaspoonful of water resistant grease into the seal.

  • Page 67: Sterndrive

    Remove (B) and (C). • Pull off the entire propeller unit. • Grease the propeller shaft splines with water resistant grease. • Install in reverse order. P0030927 For tightening torque; refer to General Tightening Torques, page 27. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 68 Clean and apply grease part # 828250 on the propeller shaft. P0031801 Early model P0031088 Late model • Install the spacer sleeve and the propeller on the propeller shaft. • Tighten the propeller cone (A) to 70 Nm. P0031089 47708114 06-2021 © AB VOLVO PENTA...
  • Page 69 Install the lock washer (B) and the new bolt (C). • Tighten the bolt to 20 Nm. P0031090 • Fold up at least 2 of the 3 lock tabs to secure the bolt. P0031091 47708114 06-2021 © AB VOLVO PENTA...

  • Page 70: Checking Protective Anodes

    Replacement of anodes • Clean the contact surfaces on the new anode. • Install and tighten the halves so that they make good contact with the surface of the drive/each other. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 71 NOTICE! If the boat is mostly used in salt water, the anodes must be of zinc or aluminum. If the boat is mostly used in fresh water, the anodes must be of magnesium. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 72: Painting The Drive

    # 1141562. Drying time 8-12 hours. Then apply a final coat. The spare parts catalog and the “Volvo Penta accessories” catalog specify the part numbers for surface treatment products. Also apply anti-fouling.
  • Page 73 Transmission, Sterndrive Changing oil with the boat in the water • Draw the oil through the pipe on the side of the drive using a vacuum pump. P0026767 • Fill with new oil. P0026768 47708114 06-2021 © AB VOLVO PENTA...
  • Page 74 Transmission, Sterndrive • Check the level using the dipstick in the filler hole. The level must be between the markings on the dipstick; top up as necessary. P0026769 47708114 06-2021 © AB VOLVO PENTA...
  • Page 75 Replacing the rubber bellows Check and replace the rubber bellows for the S Drive according to the intervals in the maintenance schedule. When replacing, refer to the installation instructions in the rubber bellows packaging. P0030922 47708114 06-2021 © AB VOLVO PENTA...

  • Page 76: Long-Term Storage

    Fill the fuel tank with fuel to avoid condensation during storage. Use the recommended B0 fuel. • Check that the coolant offers adequate protection against freezing. Check the level and top up as necessary. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 77 • For cleaning the engine and transmission, see the next section. • Touch up any paint damage with Volvo Penta original paint or paint of the same quality. • If necessary, cover the engine, air intake and exhaust pipe.

  • Page 78: Storage Instruction For Long-Term Storage Of New Engine

    The engine must be cranked 2.5 turns every 8th month. If the engine can be started, run it until warm. Check that humidity is below 40%. Check that the temperature in the storage area is between +5°C and +30°C. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 79 Check that there are no oil, fuel or coolant leaks. Run the engine until warm. Change the engine oil and oil filter. Checklist, long term storage Date Product part number Type of conservation Signature and date of checks Month Checks during storage 47708114 06-2021 © AB VOLVO PENTA...

  • Page 80: Cleaning Engine And Transmission

    (bearings) may be damaged and lead to serious consequential damage. NOTICE! If the generator is exposed to water, it must be dried; see drying. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 81 Drying the alternator • Blow the water away from the alternator using compressed air. • Check that the alternator charges. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 82: Cold Weather Precautions

    Start the engine and let it idle. Be ready to stop as soon as the bucket is empty. Use a container to collect the coolant from the exhaust outlet and hand it in to a recycling station. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 83 Long-Term Storage D1-13/20/30 - D2-40 Heat exchanger drain P0030919 D2-50/55/60/75 Heat exchanger drain P0030931 47708114 06-2021 © AB VOLVO PENTA...

  • Page 84: Checklist

    Switch off the engine. • Rotate the stern drive or reverser output shafts by hand for 2-3 turns. • Detach the battery cables. • Check the engine compartment for any condensation. • Ensure good ventilation. 47708114 06-2021 © AB VOLVO PENTA...

  • Page 85: Battery, Maintenance

    • Charge the batteries regularly. Batteries kept at full charge enjoy maximum service life. The easiest way to check whether a battery needs charging is to use a volt meter. 47708114 06-2021 © AB VOLVO PENTA...
  • Page 86 Attach the positive cable (red) to the battery's positive terminal. Tightening torque: 6 Nm. • Attach the negative cable (black) to the battery's negative terminal. Tightening torque: 6 Nm. NOTICE! Hand in the old battery to a waste management facility. P0028239 47708114 06-2021 © AB VOLVO PENTA...

  • Page 87: Index

    Painting the Drive............. 70 Preventive repair ............. 13 Propeller..............65 Reversing gear............61 Reversing gear, oil and filter change......61 Safety Information............3 S-drive..............70 Seawater Filter, Check and Cleaning....... 59 Seawater Pump, Impeller, Change......57 47708114 06-2021 © AB VOLVO PENTA...
  • Page 90 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

This manual is also suitable for:

D2

Table of Contents

Save PDF