Page 1 Workshop Manual Group 21-26 TAD540-2 VE, TAD550-2 VE TAD570-2 VE, TAD580-3 VE TAD840-3 VE, TAD850-3 VE TAD870-3 VE, TAD880-4 VE TAD880-2GE...
Page 3: Table Of Contents
25-6 Air Cleaner, Throttle Housing ............ 272 Cooling System 26-0 Cooling System, General ............274 26-1 Radiator, Heat Exchanger ............278 26-2 Coolant Pump, Thermostat ............284 26-3 Fan, Fan Shroud ................300 Alternator, Charge Regulator 47705010 06-2020 © AB VOLVO PENTA...
Page 4 32-1 Alternator ..................306 Starting System 33-1 Starter Motor ................312 Index ......................315 References to Service Bulletins ............317 47705010 06-2020 © AB VOLVO PENTA...
Page 5: General Information
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 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 RTV exposed to high temperature can be handled sealants are completely visible when the part has normally. been removed. Old RTV sealant must be removed before the component is sealed again. Use denatured alcohol. 47705010 06-2020 © AB VOLVO PENTA...
Page 8 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 47705010 06-2020 © AB VOLVO PENTA...
Page 9: General Specifications
General Tightening Torques 10 Nm 24 Nm 48 Nm 85 Nm 140 Nm 220 Nm IMPORTANT! Check screws which are to be re-installed. Damaged bolts with e.g. shear marks under the heads, must be scrapped. 47705010 06-2020 © AB VOLVO PENTA...
Page 10: Specifications, Engine
Tighten the bolts in sequence. Tightening torque: 60 Nm (44.2 lbf. ft.) Angle tightening: 90° Angle tightening: 90° P0021523 Conrod caps Tighten the bolts in sequence. Tightening torque: 75 Nm (55.3 lbf. ft.) Angle tightening: 90° P0021524 47705010 06-2020 © AB VOLVO PENTA...
Page 11 Tighten the remaining bolts. Tightening torque: 24 Nm (17.7 lbf. ft.) P0021525 TAD5xxxVE Tighten the bolts in sequence. Tightening torque: 24 Nm (17.7 lbf. ft.) Tighten the remaining bolts. Tightening torque: 24 Nm (17.7 lbf. ft.) P0021526 47705010 06-2020 © AB VOLVO PENTA...
Page 12 Idler wheel (dual) 63 Nm (46.5 lbf. ft.) Drive gear, air compressor 225 Nm (166.0 lbf. ft.) Idler wheel, adjustable: 63 Nm (46.5 lbf. ft.) Drive gear, fuel feed pump 59 Nm (43.5 lbf. ft.) P0021527 47705010 06-2020 © AB VOLVO PENTA...
Page 13 Tightening torque: 48 Nm (35.4 lbf. ft.) Bolts 13-14: Tightening torque: 85 Nm (62.7 lbf. ft.) NOTICE! Apply an approximately 2 mm (0.079”) bead of silicon (product no. 1161231), max. 20 minutes before installation. P0021530 P0021528 47705010 06-2020 © AB VOLVO PENTA...
Page 14 03-2 Specifications, Engine Flywheel Tighten the bolts in sequence. Tightening torque: 190 Nm (140.1 lbf. ft.) P0021529 Vibration damper, crankshaft Tighten the bolts in sequence. Tightening torque: 110 Nm (81.1 lbf. ft.) P0021531 47705010 06-2020 © AB VOLVO PENTA...
Page 15 Tighten until contact is established. Tighten the bolts 2 and 7. Tightening torque: 24 Nm (17.7 lbf. ft.) Tighten the bolts in the sequence 1, 3-6, 8. Tightening torque: 24 Nm (17.7 lbf. ft.) 47705010 06-2020 © AB VOLVO PENTA...
Page 16 Long bolts 135° (3, 6, 11, 14, 19, 22) 5 Tighten bolts B1-B6. 29.5 Nm (21.8 lbf. ft.) 6 Tighten bolt (A). 60 Nm (44.3 lbf. ft.) 7 Tighten bolt (C). 30 Nm (22.1 lbf. ft.) 47705010 06-2020 © AB VOLVO PENTA...
Page 17 Long bolts: 135° (3, 6, 11, 14) 5 Tighten bolts B1-B4. 29.5 Nm (21.8 lbf. ft.) 6 Tighten bolt (A). Tightening torque: 60 Nm (44.3 lbf. ft.) 7 Tighten bolt (C). Tightening torque: 30 Nm (22.1 lbf. ft.) 47705010 06-2020 © AB VOLVO PENTA...
Page 18 Tightening torque: 29.5 Nm (21.8 lbf. ft.) Tighten bolts 1-4 in sequence. Angle tightening: 90° Tighten bolts 1-4 in sequence. Angle tightening: 135° P0021537 Tighten bolts 5-8 in sequence. Tightening torque: 29.5 Nm (21.8 lbf. ft.) 47705010 06-2020 © AB VOLVO PENTA...
Page 19 03-2 Specifications, Engine Valve cover TAD8xxxVE Tighten the bolts in sequence. Tightening torque: 24 Nm P0024987 Tighten the bolts in sequence. Tightening torque: 24 Nm P0024988 47705010 06-2020 © AB VOLVO PENTA...
Page 20 03-2 Specifications, Engine TAD5xxxVE Tighten the bolts in sequence. Tightening torque: 24 Nm P0024989 Tighten the bolts in sequence. Tightening torque: 24 Nm P0024990 47705010 06-2020 © AB VOLVO PENTA...
Page 21 NOTICE! Tighten the bolts in sequence, as illustrated. Tightening torque: 48 Nm (35.4 lbf. ft.) P0021543 Filter cover: Tightening torque: 40 Nm (29.5 lbf. ft.) Oil cooler: Tightening torque: 12 Nm (8.9 lbf. ft.) P0021544 47705010 06-2020 © AB VOLVO PENTA...
Page 22 Tightening torque: 24 Nm (17.7 lbf. ft.) TAD5xxxVE 1 Step 1: Tighten the bolts. Tightening torque: 7 Nm (5.2 lbf. ft.) 2 Step 2: P0021546 Tighten the bolts. Tightening torque: 10 Nm (7.4 lbf. ft.) 47705010 06-2020 © AB VOLVO PENTA...
Page 23 2 Step 2: Tighten the bolts. Tightening torque: 24 Nm (17.7 lbf. ft.) P0021547 TAD5xxxVE Tightening torque: 26 Nm (19.2 lbf. ft.) P0021548 Piston cooling nozzles Tightening torque: 34 Nm (25.1 lbf. ft.) P0021549 47705010 06-2020 © AB VOLVO PENTA...
Page 24 2 Yoke bracket, injectors (pre-load) Tightening torque: 5 Nm (3.7 lbf. ft.) 3 Sleeve, injector delivery pipe, injectors Tightening torque: 75 Nm (55.3 lbf. ft.) 4 Yoke bracket, injectors Tightening torque: 57 Nm (42.0 lbf. ft.) P0021551 47705010 06-2020 © AB VOLVO PENTA...
Page 25 Tighten the coupling nuts by hand. Check that the clamps are parallel with the bolt holes. P0019419 Stage 2: Install the bolts and tighten. P0019414 Stage 3: Torque tighten the cap nuts. Tightening torque: 37 Nm (27.3 lbf. ft.) P0019417 47705010 06-2020 © AB VOLVO PENTA...
Page 26 45 ±1° (angle tightening) 5 Coil, pressure relief valve Stage 1: 15 Nm (11.1 lbf. ft.) Stage 2: 13 ±0.5° (angle tightening) P0019361 1. Check the torque, 60-180 Nm (44.3-132.8") 2. Check the torque, 65-140 Nm (47.9-103.3") 47705010 06-2020 © AB VOLVO PENTA...
Page 27 2 Fuel OUT (to return line) 3 Fuel OUT (to common rail) A Control valve B Fuel temperature sensor P0021714 Gear wheel, high pressure pump, nut: Tightening torque: 65 Nm (47.9 lbf. ft.) P0019299 47705010 06-2020 © AB VOLVO PENTA...
Page 28 Tightening sequence: 1-18 Tightening torque: 30 Nm (22.1 lbf. ft) P0021553 TAD5xxxVE Bolt 1. Tightening sequence: 2-9 Tightening torque: 6 Nm (4.4 lbf. ft) Tightening sequence: 1-12 Tightening torque: 30 Nm (22.1 lbf. ft) P0021554 47705010 06-2020 © AB VOLVO PENTA...
Page 29 Control valve, e-EGR Torque the e-EGR control valve as follows: Stage 1: 25 Nm Stage 2: 53 Nm Stage 3: Undo the bolts ≈ −90° Stage 4: 25 Nm Stage 5: 53 Nm P0030907 47705010 06-2020 © AB VOLVO PENTA...
Page 30 Bolts 1-8 Tightening torque: 48 Nm (35.4 lbf. ft.) P0019608 Thermostat Tightening sequence: Diagonal Nipple, thermostat housing: Tightening torque: 20 Nm (14.8 lbf. ft.) P0019525 Adapter, fan: Tightening torque: 150 Nm (110.6 lbf. ft.) P0019618 47705010 06-2020 © AB VOLVO PENTA...
Page 31 03-2 Specifications, Engine Belt Tensioner Tightening torque: 60 Nm (44.3 lbf. ft.) P0021557 47705010 06-2020 © AB VOLVO PENTA...
Page 33 Tightening torque: 20 Nm (14.8 lbf. ft.) EGR temperature sensor Tightening torque: 45 Nm (33.2 lbf. ft.) 10 Fuel pressure/temperature sensor (common rail) Refer to the section Group 23 - Fuel System in Chapter Special Tightening Torques, page 8. 47705010 06-2020 © AB VOLVO PENTA...
Page 34: Engine
5.96 ± 0.02 mm (0.23465 ± 0.00079") Max. height difference between liner collars 0.02 mm (0.00079") Sealing surface height above block plane 0.04-0.10 mm (0.001575-0.003937") No. of O-rings in upper / lower liner seal 47705010 06-2020 © AB VOLVO PENTA...
Page 35 Crankshaft, type of hardening Induction hardened Max./min. end float 0.05-0.14 mm (0.0020-0.0055") Crankshaft, max. skew 0.005 (0.00020") p0005212 Max taper, crankshaft/ 0.006 (0.00024") connecting rod journal Max out-of-round, crankshaft/ 0.006 (0.00024") connecting rod journal 47705010 06-2020 © AB VOLVO PENTA...
Page 36 2.5 - 0.019-0.032 (0.0984 - 0.00075-0.00126") Above 1: dimension 0.07 2.535 (0.09980") Above 2: dimension 0.25 2.625 (0.10335") Above 3: dimension 0.50 2.750 (0.10827") Above 4: dimension 0.75 2.875 (0.11319") Main bearing, radial clearance, max 47705010 06-2020 © AB VOLVO PENTA...
Page 37 Big-end bearings STD A 2 - 0.019-0.032 (0.0787 - 0.00075-0.00126") Above 1: dimension 0.07 2.035 (0.08012") Above 2: dimension 0.25 2.125 (0.08366") Above 3: dimension 0.50 2.250 (0.08858") Above 4: dimension 0.75 2.375 (0.09350") 47705010 06-2020 © AB VOLVO PENTA...
Page 38 0.000787") Valve guide, height above 16 ± 0.2 mm spring plane, outlet (0.629919 ± 0.000787") Seat angle in cylinder head, 35 ° inlet (B) Seat angle in cylinder head, 45 ° outlet (B) 47705010 06-2020 © AB VOLVO PENTA...
Page 39 39 mm (1.535") Diameter (A), outlet 36 mm (1.417") Height (B), inlet 6.95 ± 0.05 mm (0.273621 ± 0.001968") Height (B), outlet 6.95 ± 0.05 mm (0.273621 ± 0.001968") Valve springs, uncompressed 64.5 mm (2.539") length 47705010 06-2020 © AB VOLVO PENTA...
Page 40 For engines equipped with exhaust brake systems: Use 885812 Timing tool. Adjust the piston on the exhaust brakes for cylinders (1), (2) and (4). Reset and (revolutions), (403°). Tightening torque: 15 Nm (11.1 lbf. ft.) P0022139 47705010 06-2020 © AB VOLVO PENTA...
Page 41 For engines equipped with exhaust brake systems: Use 885812 Timing tool. Adjust the piston on the exhaust brakes for cylinders (3), (5) and (6). Reset and (revolutions), (403°). Tightening torque: 15 Nm (11.1 lbf. ft.) P0022139 47705010 06-2020 © AB VOLVO PENTA...
Page 42 The [English] text in the following table is intended to facilitate harness identification. Cold side Top P0030629 Harness interface bracket Fuse Holder 15A / 25A Boost Air Temp/Press Power connection Throttle Pre-heat sensor Injector connection 47705010 06-2020 © AB VOLVO PENTA...
Page 43 03-2 Specifications, Engine Cold side P0030630 Fuel Pressure Rail temp / pressure Oil Pressure MPROP EMS B EMS A Oil / Level Temperature 47705010 06-2020 © AB VOLVO PENTA...
Page 44 03-2 Specifications, Engine Front side P0030631 Coolant level switch Coolant temperature Waste gate Pre-heat Visco 47705010 06-2020 © AB VOLVO PENTA...
Page 45 03-2 Specifications, Engine Hot side P0030632 Starter motor relay eEPG EGR valve (Lisk) Alternator connection Alternator 47705010 06-2020 © AB VOLVO PENTA...
Page 46 03-2 Specifications, Engine Rear side P0030633 Air filter Exhaust pressure Crank Camshaft 47705010 06-2020 © AB VOLVO PENTA...
Page 47 The [English] text in the following table is intended to facilitate harness identification. Cold side Top P0031630 Harness interface bracket EMS A EMS B Power / Fuse Connection Exhaust pressure Injector connection Pre-heat sensor Throttle Charge Air/Temp 47705010 06-2020 © AB VOLVO PENTA...
Page 48 03-2 Specifications, Engine Cold side P0031626 Stop Button Fuse 15A/25A Diagnose Engine Interface EATS Rail temp / pressure Fuel Pressure Oil Pressure MPROP WIF (Water in Fuel) Oil Level / Temp 47705010 06-2020 © AB VOLVO PENTA...
Page 49 03-2 Specifications, Engine Front side P0031627 Coolant level switch Waste gate Coolant temperature Pre-heat EGR valve Electric fan (Visco) 47705010 06-2020 © AB VOLVO PENTA...
Page 50 03-2 Specifications, Engine Hot side P0031628 Starter motor relay eEPG Alternator connection Alternator 47705010 06-2020 © AB VOLVO PENTA...
Page 52 10 Intermediate gear, oil pump: 44 teeth 11 Oil pump gear: 35 teeth 12 Power steering pump wheel (accessory): 30 teeth 13 Intermediate gear, power take-off (PTO, accessory): 41 teeth 14 Power take-off (PTO, accessory): 39 teeth P0022180 47705010 06-2020 © AB VOLVO PENTA...
Page 53 5 Camshaft gear, clockwise 6 Intermediate gear, clockwise 7 Fuel pump gear, counterclockwise 8 Air compressor assembly gear, counterclockwise 9 Power steering pump wheel, clockwise 10 Intermediate gear, power take-off, clockwise 11 Power take-off wheel, counterclockwise P0022210 47705010 06-2020 © AB VOLVO PENTA...
Page 54: Lubrication System
19 l (5.0 US gals) Max. 13,5 l (3.6 US gals) 24 l (6.4 US gals) Max oil temperature during operation 125 °C (257 °F) Fuel System Type Common rail Fuel feed pressure < 25 kPa (3.6 PSI) 47705010 06-2020 © AB VOLVO PENTA...
Page 55: Inlet And Exhaust System
17 l (4.5 US gals) Filler cap pressure valve, opening 75 / 100 kPa pressure Check opening pressure at the filler cap. Thermostat Type Opens at 85 °C (185 °F) Fully open at 95 °C (203 °F) 47705010 06-2020 © AB VOLVO PENTA...
Page 56: Safety Instructions
This workshop manual contains repair instructions, descriptions and technical data for products or product drawings from Volvo Penta. Check that you have the correct workshop manual. Read the safety information below and the section About this Workshop manual and Repair instructions carefully before beginning any work with repairs or service.
Page 57 Turn off the engine and disconnect the power at Only make connection adjustments with the the main switch(es) before starting work on the engine switched off. electrical system. 47705010 06-2020 © AB VOLVO PENTA...
Page 58 Never carry out any work on an engine that is only suspended by lifting equipment. 47705010 06-2020 © AB VOLVO PENTA...
Page 59 05-1 Safety Instructions The components in the electrical and fuel Take extreme care when searching for fuel systems on Volvo Penta products are designed system leaks and testing fuel injector nozzles. and manufactured to minimize the risk of fire Wear safety goggles. The jet from a nozzle is and explosion.
Page 61: Special Tools
08-2 Special Service Tools 08-2 Special Service Tools The following special tools are used when working on the engine. The special tools can be ordered from AB Volvo Penta by specifying each tool number. 1158957 Pliers 9809696 Connection washer 9986172 Puller Coolant hoses (urea pump and Leakage test, cylinder head.
Page 62 88800307 Connection 88800345 Adapter 88820006 Dial indicator (long washer Location on engine on motor probe) Cylinder head, leakage test - rack. Checking the clearance, engine The ducts differ between 5 L transmission. and 8 L. 47705010 06-2020 © AB VOLVO PENTA...
Page 63 Installation of pistons in cylinder control of tilt arm axis. rack. liners. 88840296 Drift 88840316 Plate 88840406 Mounting tool Installation of gasket on valve Fixture on engine block. Replacement of crankshaft control. gasket (rear). 47705010 06-2020 © AB VOLVO PENTA...
Page 64 08-2 Special Service Tools 88840407 Mounting tool 88840290 Plugs Replacement of crankshaft Used when protecting the high pressure system. gasket (front). 88890105 Refractometer 47705010 06-2020 © AB VOLVO PENTA...
Page 65: Engine Complete, General
Loosen the drive belt; refer to 26-1, Drive Belt, Change. Undo / remove: 1 Bracket, return wheel 2 Bracket, right front 3 Bracket, right rear 4 Starter motor, as per Starter Motor, Change, page 312. P0021752 47705010 06-2020 © AB VOLVO PENTA...
Page 66 21-0 Engine Complete, General Undo / remove: - VGT actuator, connector - Brackets P0021753 Install 88840316 Plate. P0021754 Install 88800345 Adapter. Hoist the engine and attach it to the engine stand. P0021755 47705010 06-2020 © AB VOLVO PENTA...
Page 67 - Remove the oil return pipe with gasket. Drain the coolant or reduce to below level, as per: Coolant, Change, page 276. Remove coolant inlet line. Refer to Turbo, P0019430 Change, page 251. Install 88840316 Plate. P0021757 47705010 06-2020 © AB VOLVO PENTA...
Page 68: Engine Disassembly
Remove the cylinder head; refer to 21-1, Cylinder Head, Removal Remove the front crankshaft seal; refer to Crankshaft Seal, Change (front), page 147. Remove the rear crankshaft seal; refer to Crankshaft Seal, Change (rear), page 154. 47705010 06-2020 © AB VOLVO PENTA...
Page 69 21-0 Engine Complete, General Lubrication oil pump, removal Remove the oil pump; refer to Lubrication Oil Pump, Change, page 158. P0024940 Remove the reinforcement plate. P0024941 Remove the cover. P0024942 47705010 06-2020 © AB VOLVO PENTA...
Page 70 Undo the screws a couple of turns. Tap the screw heads to release the bearing. Mark and remove the bearing cap. Put the bearing cups in a safe place. Press out the piston and the connecting rod. P0024962 47705010 06-2020 © AB VOLVO PENTA...
Page 71 Remove the remaining pistons. Remove the retainer ring and press the piston pin out. Where necessary, refer to 21-3, Connecting Rod, Check. P0024944 Crankshaft, removal Rotate the crankshaft so the marking is as illustrated. P0024945 47705010 06-2020 © AB VOLVO PENTA...
Page 72 • the bearing cups • the thrust washers in the 6th bearing cap • the crankshaft Remove: • top bearing cup • top thrust washers Wipe the bearing seats clean. P0024963 47705010 06-2020 © AB VOLVO PENTA...
Page 73 Center the plate carefully in relation to the cylinder liner. Tighten by hand. NOTICE! The length of the hydraulic cylinder stroke means that the liner is pressed in by stages. Pressurize the cylinder and push up the liner. P0024947 47705010 06-2020 © AB VOLVO PENTA...
Page 74 21-0 Engine Complete, General Hold on to the pressure rod and reduce the pressure. Screw the nut in. Tighten by hand. Repeat until the liner is released. Remove the cylinder liner. P0024948 47705010 06-2020 © AB VOLVO PENTA...
Page 75: Engine Assembly
88800129 Press tool Cylinder liners, installation Clean the outside of the liner and the cylinder bore. IMPORTANT! Check that the cylinder liner and cylinder bore are of the same category. (0 or 1) P0024949 47705010 06-2020 © AB VOLVO PENTA...
Page 76 Screw the nut in. Tighten by hand. Repeat until the liner bottoms against the block plane. P0024951 Measure diagonally twice and calculate the average. Liner height tolerance above block plane: 0.04– 0.10 mm (0.001575–0.003937”) P0024952 47705010 06-2020 © AB VOLVO PENTA...
Page 77 21-0 Engine Complete, General Crankshaft, installation Fit new bearings. Lubricate the bearing surfaces with engine oil. P0024953 NOTICE! The crankshaft must be thoroughly cleaned and blown dry. Lift the crankshaft into place. Align the marks. P0024954 47705010 06-2020 © AB VOLVO PENTA...
Page 78 NOTICE! Use new bolts. Fit new bearings. Lubricate the bearing surfaces with engine oil. Locate the main bearing cup and thrust washers in the bearing cap (marked "6" for the D8 and "4" for the D5). 47705010 06-2020 © AB VOLVO PENTA...
Page 79 1 Tightening torque: 60 Nm (44.2 lbf ft) 2 Angle tightening: 90° 3 Angle tightening: 90° Check that the crankshaft is able to turn. P0025049 Check end float. Limits: 0.05-0,14 mm. Check thrust washer category; refer to Administration, page 32. P0024966 47705010 06-2020 © AB VOLVO PENTA...
Page 80 P0024967 NOTICE! The piston ring markings must face up. Piston ring, spacing 120°. Lubricate the big end bearings, piston and piston rings. Rotate the crankshaft so that the big end journals are at BDC. 47705010 06-2020 © AB VOLVO PENTA...
Page 81 Install the bearing cap and align it carefully with the connecting rod. P0025007 Torque the screws and check that the crankshaft can be rotated. 1 Tightening torque: 75 Nm (55.3 lbf·ft) 2 Angle tightening: 90° P0025050 47705010 06-2020 © AB VOLVO PENTA...
Page 82 21-0 Engine Complete, General Install the nozzles. NOTICE! Use new bolts. Tightening torque: 34 Nm (25.1 lbf. ft.) P0024943 Run a 2 mm (0.0787"), Silicon bead. NOTICE! Max 20 minutes before installation. P0025051 47705010 06-2020 © AB VOLVO PENTA...
Page 83 Tightening torque: 24 Nm. Tighten the remaining bolts. Tightening torque: 24 Nm. P0021525 Install the plate. Tighten the bolts in sequence. Tightening torque: 24 Nm. Tighten the remaining bolts. Tightening torque: 24 Nm. P0021526 47705010 06-2020 © AB VOLVO PENTA...
Page 84 Install the rear crankshaft seal; refer to Crankshaft Seal, Change (rear), page 154. Install the cylinder head; refer to Cylinder Head, Change, page 83. P0024940 Transmission, installation Install the flywheel housing; refer to Flywheel cover, change, page 138. 47705010 06-2020 © AB VOLVO PENTA...
Page 85: Cylinder Head
Drain the coolant in accordance with Coolant, Change, page 276. Removal Undo, remove: - The intake pipe. - The pressure drop indicator connector. - The air cleaner's mounting plate. P0022108 Remove the air cleaner with mounting plate. P0022109 47705010 06-2020 © AB VOLVO PENTA...
Page 86 P0022089 Remove the thermostat housing, refer to Coolant Pump, Change, page 284. Remove the upper and lower valve cover, refer - Upper valve cover, change, page 95 - Lower valve cover, change, page 102 47705010 06-2020 © AB VOLVO PENTA...
Page 87 Check that the gearwheel's marking (1) corresponds with the surface of the left side of the cylinder head. If not, turn the engine flywheel one more turn. P0019451 47705010 06-2020 © AB VOLVO PENTA...
Page 88 Check that the gearwheel's marking (1) corresponds with the surface of the left side of the cylinder head. Use the 9998264 Lifting tool to lift the camshaft. Check the camshaft, according to Camshaft, Wear Check, page 133. P0022104 47705010 06-2020 © AB VOLVO PENTA...
Page 89 Remove the bearing halves. P0022105 Remove the cylinder head screws. Lift off the cylinder head. NOTICE! Alternatively: Place 9996239 Lifting tool (2) on the cylinder head and lift if off. P0022106 Remove the cylinder head gasket. P0022107 47705010 06-2020 © AB VOLVO PENTA...
Page 90 - 21-4, Valve Stem Sealings, Replace P0022110 Remove the plate with the camshaft's hub and idler wheel. Check the lubrication hole. Clean and replace the O-ring on the plate. When replacing a cylinder head, transfer current parts. P0022111 47705010 06-2020 © AB VOLVO PENTA...
Page 91 NOTICE! If the idler gear on the camshaft is installed, make sure there is correct alignment with the outlet. Guide in the cylinder head onto the guiding pins. Lower the cylinder head until it rests on the cylinder head gasket. P0022119 47705010 06-2020 © AB VOLVO PENTA...
Page 92 Screw in the cylinder head screws without tightening. P0022120 Check that the main bearings are free of errors. Insert the bearing halves and apply the oil. P0022121 Check that the flywheel housing is in line with 1's marking. P0019450 47705010 06-2020 © AB VOLVO PENTA...
Page 93 The bearing cap and marking. • The adjuster screws are in the fully undone position. - Install the rocker arm bridge/bearing cap. 2 Screw the cylinder head screw and the bearing cap screw without tightening. P0022114 47705010 06-2020 © AB VOLVO PENTA...
Page 94 Change, page 203. For engines equipped with exhaust brake systems: Position the two exhaust brake systems. P0022102 Adjust the valves according to Valves, Adjustment, page 109. Remove the upper and lower valve covers, refer 47705010 06-2020 © AB VOLVO PENTA...
Page 95 268. Install the exhaust manifold according to Exhaust Manifold, Change, page 231. Install the turbo unit according to Turbo, Change, page 251. Install the air cleaner with the mounting plate. P0022109 47705010 06-2020 © AB VOLVO PENTA...
Page 96 Change, page 276. Turn on the main switch. Start the engine and check for leaks; let the engine run until it reaches normal working temperature. Allow the engine to run idle for an additional 5–10 minutes. 47705010 06-2020 © AB VOLVO PENTA...
Page 97 Disconnect the engine control unit. P0019500 Protect the engine control unit with a plastic bag. Move the engine control unit to one side. P0019501 47705010 06-2020 © AB VOLVO PENTA...
Page 98 21-1 Cylinder Head Remove the crankcase ventilation pipe. P0019502 Remove the valve cover with gasket. P0019503 47705010 06-2020 © AB VOLVO PENTA...
Page 99 21-1 Cylinder Head Installation Fit the gasket. Install the valve cover. Tightening sequence: Diagonally Install the crankcase ventilation pipe. P0019504 Install the engine control unit. P0019508 47705010 06-2020 © AB VOLVO PENTA...
Page 100 21-1 Cylinder Head Upper valve cover, change TAD840VE, TAD841VE, TAD842VE, TAD843VE, TAD850VE, TAD851VE, TAD852VE, TAD853VE, TAD870VE, TAD871VE, TAD872VE, TAD873VE, TAD880VE, TAD881VE, TAD882VE, TAD883VE, TAD884VE Removal Detach the cable holder. P0019482 Remove the crankcase ventilation pipe. P0019483 47705010 06-2020 © AB VOLVO PENTA...
Page 102 21-1 Cylinder Head Installation Fit the gasket. P0019485 Install the valve cover. Tightening sequence: Diagonally P0019486 Install the crankcase ventilation pipe. P0019483 47705010 06-2020 © AB VOLVO PENTA...
Page 104 Removal IMPORTANT! Turn off the main switch before any work is carried out. Remove the upper valve cover; refer to Upper valve cover, change, page 95. Disconnect the connector. P0019509 Loosen the connectors. P0019510 47705010 06-2020 © AB VOLVO PENTA...
Page 105 21-1 Cylinder Head Remove the lower valve cover and gasket. P0019511 Installation Fit the gasket. Install the valve cover. P0019512 Install the connector. Tightening torque: 2.2 Nm (1.6 lbf ft) P0019510 47705010 06-2020 © AB VOLVO PENTA...
Page 106 21-1 Cylinder Head Install the connector. P0019515 Install the upper valve cover; refer to Upper valve cover, change, page 95. 47705010 06-2020 © AB VOLVO PENTA...
Page 107 Removal IMPORTANT! Turn off the main switch before any work is carried out. Remove the upper valve cover; refer to Upper valve cover, change, page 95. Disconnect the cable. P0019490 Disconnect the connector. P0019491 47705010 06-2020 © AB VOLVO PENTA...
Page 108 21-1 Cylinder Head Disconnect the connectors. P0019492 Engines equipped with exhaust brake systems (VCB) Disconnect the electrical connections to the brake solenoid. P0021890 Remove the lower valve cover and gasket. P0019493 47705010 06-2020 © AB VOLVO PENTA...
Page 109 21-1 Cylinder Head Installation Fit the gasket. P0019494 Install the valve cover. P0019495 Install the connector. Tightening torque: 2.2 Nm (1.6 lbf ft) P0019492 47705010 06-2020 © AB VOLVO PENTA...
Page 110 Engines equipped with exhaust brake systems (VCB) Connect the electrical connections to the brake solenoid. P0021890 Install the cable harness. P0019498 Install the upper valve cover; refer to Upper valve cover, change, page 95. 47705010 06-2020 © AB VOLVO PENTA...
Page 111: Valve Mechanism
NOTICE! Turn counterclockwise on the engine flywheel side. Turn the flywheel until the cylinder 1 marking aligns with the marking on the flywheel housing. The camshaft gear has two markings that correspond to the markings on the flywheel. P0019450 47705010 06-2020 © AB VOLVO PENTA...
Page 112 • The exhaust valves for cylinders (1), (2) and (4). P0019451 P0019452 A Inlet valve Cylinder 1 Cylinder 4 Cylinder 2 Cylinder 5 (D8 only) B Exhaust valve Cylinder 3 Cylinder 6 (D8 only) 47705010 06-2020 © AB VOLVO PENTA...
Page 113 It should not be possible to insert the 0.45 mm feeler gage without resistance. P0019455 Counterhold the adjuster screw while tightening the locking nut. Tightening torque: 33 Nm (24.3 lbf ft) 47705010 06-2020 © AB VOLVO PENTA...
Page 114 It should not be possible to insert the 0.55 mm feeler gage without resistance. P0019458 Hold the adjuster screw still while tightening the locking nut. Tightening torque: 33 Nm (24.3 lbf ft) 47705010 06-2020 © AB VOLVO PENTA...
Page 115 If not, rotate the engine flywheel one more turn. Marking left facing surface of the cylinder head: • The Inlet valves for cylinders (2), (4) and (6). • The exhaust valves for cylinders (3), (5) and (6). P0019459 47705010 06-2020 © AB VOLVO PENTA...
Page 116 It should not be possible to insert the 0.45 mm feeler gage without resistance. P0019462 Hold the adjuster screw still while tightening the locking nut. Tightening torque: 33 Nm (24.3 lbf ft) 47705010 06-2020 © AB VOLVO PENTA...
Page 117 It should not be possible to insert the 0.55 mm feeler gage without resistance. P0019465 Hold the adjuster screw still while tightening the locking nut. Tightening torque: 33 Nm (24.3 lbf ft) 47705010 06-2020 © AB VOLVO PENTA...
Page 118 P0022651 Remove the 88800014 Rotation tool from the gear ring. Install the plug. P0019449 Insert plug for the flywheel mark. Install the upper valve cover according to: Upper valve cover, change, page 95. P0019466 47705010 06-2020 © AB VOLVO PENTA...
Page 119 Read off the value on the dial indicator. Check all valve guides. If the readings exceed the values noted in the specifications, the valve guide must be changed; refer to Administration, page 32. P0024939 47705010 06-2020 © AB VOLVO PENTA...
Page 120 Secure the cylinder head in the stand. Use 8 M10x90 mm bolts. P0022110 Fit the tool. Adjust the tool's arms around the valve spring plate. Press down and remove the collets. P0022127 A Inlet valve B Exhaust valve 47705010 06-2020 © AB VOLVO PENTA...
Page 121 Remove the valve stem seals. NOTICE! Put the valves and springs in a marked stand, to facilitate when putting them back in the same places in the cylinder head. P0026810 Remove the remaining valves. 47705010 06-2020 © AB VOLVO PENTA...
Page 122 • Valve stem guide sleeve P0026812 Press the new oil seal over the valve guide. NOTICE! Check that the oil seal is pressed down all the way. Tap carefully with a plastic mallet. P0022134 47705010 06-2020 © AB VOLVO PENTA...
Page 123 Insert the tool in the bolt hole (M8) for upper valve cover. Adjust the tool's arms around the valve spring plate. Carefully press down and install the collets. A Inlet valve B Exhaust valve Install the remaining valves. P0022127 47705010 06-2020 © AB VOLVO PENTA...
Page 124: Timing Gears And Shaft
Mark and remove the valve yokes. P0023112 Fit the tool. Tightening torque: 1 100 Nm 2 90° (angle tightening) 3 90° (angle tightening) NOTICE! Mark the screw head with a punch mark. Repeat for remaining cylinders. P0023113 47705010 06-2020 © AB VOLVO PENTA...
Page 125 Remove the camshaft. Remove the bearing halves. Check: • Collar thrust bearings • The camshaft for wear, refer to Camshaft, Wear Check, page 133. When transferring the drive wheel, see: Special P0023114 Tightening Torques, page 8 47705010 06-2020 © AB VOLVO PENTA...
Page 126 21-5 Timing Gears and Shaft Installation Install the camshaft gearwheel. Apply oil. P0023115 Rotate the camshaft so that the gearwheel marking (1) is correctly positioned before installation. Install the camshaft. P0023114 47705010 06-2020 © AB VOLVO PENTA...
Page 127 Reinstall the valve yoke as per the earlier marking. P0022112 Adjust the valves; refer to Valves, Adjustment, page 109. Install; see . Lower valve cover, change, page 102 Upper valve cover, change, page 95 47705010 06-2020 © AB VOLVO PENTA...
Page 128 Permissible gear flank clearance A 0.03-0,13 mm (0.00118-0.00512") B 0.03-0,13 mm (0.00118-0.00512") C 0.03-0,13 mm (0.00118-0.00512") D 0.03-0,13 mm (0.00118-0.00512") E 0.03-0,11 mm (0.00118-0.00433") F 0.04-0,12 mm (0.00157-0.00472") G 0.03-0,11 mm (0.00118-0.00433") P0022179 47705010 06-2020 © AB VOLVO PENTA...
Page 129 A back and forth to check that the gear backlash is within specified limits. Permissible value: A* 0,03-0,13 mm (0.00118-0.00512") 4 Perform the same check measurements for the remaining transmission gearwheels. P0022211 47705010 06-2020 © AB VOLVO PENTA...
Page 130 NOTICE! Turn counterclockwise, on the engine flywheel side. Turn the flywheel until the cylinder 1 marking aligns with the marking on the flywheel housing. The camshaft gearwheel has two marks which correspond to the mark on the flywheel. P0019450 47705010 06-2020 © AB VOLVO PENTA...
Page 131 2 Idler gearwheel, twin (hub 1 and 2) 3 Idler gearwheel (hub 5) 4 Idler gearwheel (2), camshaft (hub 3) P0022200 Remove the plate and the hub (1), (hub 4). Remove the Idler gearwheel (2). P0022201 47705010 06-2020 © AB VOLVO PENTA...
Page 132 Align the idler gearwheel's markings as illustrated. The marking on the idler gearwheel must be between the markings on the fuel pump, and the crankshaft's marking must be between idler gearwheel's markings. P0022206 47705010 06-2020 © AB VOLVO PENTA...
Page 133 (2). P0022207 Fit the camshaft gearwheel. The marking (1) should corresponds with the surface on the cylinder head's side. P0022208 Torque turn the engine transmission according to Special Tightening Torques, page 8. 47705010 06-2020 © AB VOLVO PENTA...
Page 134 Fit the flywheel cover/transmission cover, according to Flywheel cover, change, page 138. Fit the lower valve covers, refer to: - Lower valve cover, change, page 102 - Upper valve cover, change, page 95 Install the ERG pipe. P0022199 47705010 06-2020 © AB VOLVO PENTA...
Page 135 Examples of acceptable wear and unacceptable wear are shown below. Acceptable wear: Unacceptable wear: The camshaft need not be changed. IMPORTANT! The camshaft and associated rocker arms must be changed. P0003899 P0003896 P0003897 P0003898 47705010 06-2020 © AB VOLVO PENTA...
Page 136 21-5 Timing Gears and Shaft Flywheel, Change Tools: 9996239 Lifting tool 88840269 Guide pin CAUTION! Pinch hazard. Keep fingers clear. Removal Remove the flywheel sensor. P0020336 Remove two diametrically opposed bolts. P0020337 47705010 06-2020 © AB VOLVO PENTA...
Page 137 21-5 Timing Gears and Shaft Replace with locating pins 88840269 Guide pin. P0020338 Attach and secure tool 9996239 Lifting tool. P0020339 Remove the remaining bolts. P0020340 47705010 06-2020 © AB VOLVO PENTA...
Page 138 P0020344 Installation Clean the flywheel contact surface on the crankshaft. Check the crankshaft seal. P0020341 Check the position of the crankshaft guide pins in relation to the flywheel locating holes. Install the flywheel. P0020342 47705010 06-2020 © AB VOLVO PENTA...
Page 139 Install the bolts. Screw in the bolts without tightening. Remove the guide pins and lifting tool. P0020343 Tighten the bolts in the sequence i as llustrated. Tightening torque: 190 Nm (140 lbf. ft.) P0020345 Install the flywheel sensor. P0020336 47705010 06-2020 © AB VOLVO PENTA...
Page 140 Remove the air compressor according to Air compressor, change, page 268. Remove the flywheel according to Flywheel, Change, page 134. Remove the rear crankshaft seal according to Crankshaft Seal, Change (rear), page 154. Remove the PTO. P0022089 47705010 06-2020 © AB VOLVO PENTA...
Page 141 2 Fuel return, tank. 3 Connector 4 Connection IN 5 Connection OUT P0022091 6 Fuel pre-filter Remove the fuel prefilter's bracket. P0022092 Depending on procedure, secure and stabilize the engine. Loosen the rear engine mount. 47705010 06-2020 © AB VOLVO PENTA...
Page 142 21-5 Timing Gears and Shaft Install 9996239 Lifting tool. Install 9996876 Guide pin (2 pcs). P0022093 Remove the bolts. P0022094 Carefully tap with a plastic mallet to break the adhesive joint. Loosen and remove the flywheel housing. P0022095 47705010 06-2020 © AB VOLVO PENTA...
Page 143 1161277) according to the image, max 20 minutes before installation. P0022096 Thread the flywheel housing on 9996876 Guide pin (2 pcs). NOTICE! Exercise caution so that the string of sealant is not damaged during installation. P0022097 47705010 06-2020 © AB VOLVO PENTA...
Page 144 Tightening torque: Bolt: 1-9: 85 Nm (62.7 lbf. ft.) Bolt: 10-12: 48 Nm (35.4 lbf. ft.) P0021530 Tighten the bolts in sequence, as illustrated. Tightening torque: Bolt: 13, 14: 85 Nm (62.7 lbf. ft.) P0022098 47705010 06-2020 © AB VOLVO PENTA...
Page 145 Working with the fuel system requests special cleanliness. Install: (refer to Fuel Pre-filter, Change, page 170) 1 Fuel pre-filter 2 Connection OUT 3 Connection IN 4 Fuel return, tank. 5 Return line, cylinder head. 6 Connector P0022100 47705010 06-2020 © AB VOLVO PENTA...
Page 146 Crankshaft Seal, Change (rear), page 154. Install the flywheel according to Flywheel, Change, page 134. Options: Install the air compressor according to Air compressor, change, page 268. Install the start engine according to Starter Motor, Change, page 312. 47705010 06-2020 © AB VOLVO PENTA...
Page 147 Finish off by checking the tightening torque of bolts 1 and 2. Drain plug (D), oil sump: Tightening torque: 60 Nm (44.3 lbf. ft.) Top up engine oil. P0021542 Start the engine. Perform a function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 148: Crank Mechanism
Heat the new ring gear to 180-200 °C (356–392 °F). The ring gear must be evenly heated. P0020334 Fit the heated ring gear onto the flywheel and tap it into place with a soft drift and hammer. P0020335 47705010 06-2020 © AB VOLVO PENTA...
Page 149 Removal Remove the fan; refer to Coolant Pump, Change, page 284. Remove the drive belt; see Drive Belt, Change, page 298. Remove the fan adapter and pulley from the coolant pump. P0019601 47705010 06-2020 © AB VOLVO PENTA...
Page 150 21-6 Crank Mechanism Remove the vibration damper and pulley. P0020365 Later model of crankshaft seal (A) Earlier model of crankshaft seal (B) P0027309 47705010 06-2020 © AB VOLVO PENTA...
Page 151 Adjust the arms 88840282 Extractor and fit the hook clamps around the metal edge of the seal. Slowly pull the seal off. P0020366 NOTICE! Remove all sealant residue from the crankshaft. NOTICE! Clean the sealing surfaces. P0020367 47705010 06-2020 © AB VOLVO PENTA...
Page 152 Fit puller 88840489 (A) and adjust the gripping jaws around the inner ring of the seal. Tighten the adjusting bolts and keep the tool in position. P0027272 47705010 06-2020 © AB VOLVO PENTA...
Page 153 (A) of the puller. 1 Forward (toward shaft): Hooks release Back (away from shaft): Hooks grip 2 Tension nut 3 Pull off the seal's inner ring. P0027271 Remove the crankshaft’s seal outer ring. P0027275 47705010 06-2020 © AB VOLVO PENTA...
Page 154 Place over the crankshaft seal. P0027276 Install the inner part if the fitting tool. Press the seal in until the cover touches the bottom. Hold in position for at least 10 s. P0027273 47705010 06-2020 © AB VOLVO PENTA...
Page 155 Install the fan adapter and pulley on the coolant pump Tightening sequence: Diagonally Install the drive belt according to: Drive Belt, Change, page 298. Install the fan; refer to Coolant Pump, Change, page 284. P0019610 47705010 06-2020 © AB VOLVO PENTA...
Page 156 1 Reversible arms for front and rear seals 2 Hook clamp for rear crankshaft seal replacement 3 Hook clamp for front crankshaft seal replacement 4 Pin 5 Lock screw 6 Pressure plate (for rear crankshaft seal) P0020364 47705010 06-2020 © AB VOLVO PENTA...
Page 157 Remove all sealant residue from the crankshaft. NOTICE! Clean the seal seat in the flywheel housing and the sealing surface on the crankshaft. P0020375 Late model Seal, front A Seal, rear (B) Adapter. rear (C) Thrust plate (D) P0027310 47705010 06-2020 © AB VOLVO PENTA...
Page 158 Adjust the arms on the tool and fit the hook clamps around the metal rim (B). 1 Forward (toward shaft): Hooks release Back (away from shaft): Hooks grip 2 Tension nut 3 Pull off the inner ring of the seal. P0027312 47705010 06-2020 © AB VOLVO PENTA...
Page 159 Install the inner part if the fitting tool. Apply the crankshaft seal. Press the seal in until the cover touches the bottom. Hold in position for at least 10 s. Install; see Flywheel, Change, page 134. P0027313 47705010 06-2020 © AB VOLVO PENTA...
Page 160: Oil Pump And Line
Press in the lock bushing and pull out the tube. Remove the oil level sensor connector. Remove the oil sump. P0021766 Remove the oil pump with delivery pipe and suction strainer. P0021767 Remove the pipes. Installation Install the pipes. Use new seals. P0021768 47705010 06-2020 © AB VOLVO PENTA...
Page 161 Finish by checking the tightening torques of bolts 1 and 2. Drain plug (D), oil sump: Tightening torque: 60 Nm (44.3 lbf ft) P0021542 Top up the engine oil. Start the engine. Perform a function check.. 47705010 06-2020 © AB VOLVO PENTA...
Page 162: Oil Filter
Install a new filter in the filter cover. IMPORTANT! Make sure the components are completely free of dirt before installing them. Install the filter cover. Tightening torque: 40 Nm (29.5 lbf ft) P0019350 47705010 06-2020 © AB VOLVO PENTA...
Page 163 P0019355 Start the engine. Check that no leakage occurs. After running the engine for a few minutes, switch it off and check the oil level. Top up with oil as necessary. 47705010 06-2020 © AB VOLVO PENTA...
Page 164 Remove the fuel filter housing in accordance with: Fuel filter housing, change, page 174. Disconnect the oil pressure sensor connector. Remove the cable ties. P0019821 Remove the cable clamps. Remove the cable ties. Move the cable harness to one side. P0019822 47705010 06-2020 © AB VOLVO PENTA...
Page 165 22-2 Oil filter Unhook the fuel lines from the holder. P0019823 Remove the holder. P0019824 Remove the coolant output hose. Detach the coolant pipe. P0019825 47705010 06-2020 © AB VOLVO PENTA...
Page 166 22-2 Oil filter Remove the oil filter housing. P0019826 Installation Use new O-rings. Grease the O-rings. P0019829 Install the oil filter housing in sequence, as illustrated. P0019830 47705010 06-2020 © AB VOLVO PENTA...
Page 167 22-2 Oil filter Install the output coolant hose. Screw to secure the flange on to the coolant pipe. P0019825 Install the holder. P0019824 Install the fuel lines in the holder. P0019823 47705010 06-2020 © AB VOLVO PENTA...
Page 168 Fuel filter housing, change, page 174. Fill with coolant; refer to Coolant Level, Checking and Topping Up, page 274. Check that no leakage occurs. Make sure that the oil level is between the MIN and MAX marks. 47705010 06-2020 © AB VOLVO PENTA...
Page 169: Oil Cooler
Detach the oil cooler. NOTICE! The particular oil filler arrangement can affect how the oil cooler is removed. This description assumes that there is free access to the components. P0019841 Remove the oil cooler. P0019842 47705010 06-2020 © AB VOLVO PENTA...
Page 170 Tightening torque: 12 Nm (8.9 lbf ft) P0019841 Fill with coolant; refer to Coolant Level, Checking and Topping Up, page 274. Check that no leakage occurs. Make sure that the oil level is between the MIN and MAX marks. 47705010 06-2020 © AB VOLVO PENTA...
Page 171: Fuel System
Repeat the operation as many times as necessary. Start the engine and let it run at high idle for at least 5 minutes before speed is increased. Perform a leakage and function check. P0019266 47705010 06-2020 © AB VOLVO PENTA...
Page 172: Fuel Feed Pump And Filter
The use of the wrong type of fuel filter may damage the fuel injection circuit. Use only fuel filters approved by the manufacturer. CAUTION! Risk of skin damage. NOTICE! Be prepared to gather up fluid. Removal Loosen the connector. P0019269 Drain the filter. P0019270 47705010 06-2020 © AB VOLVO PENTA...
Page 173 Install the pre-filter. Tighten the filter until it bottoms, then a further 180°. P0019271 Connect the connector. P0019269 Open the fuel tap and purge the fuel pre-filter in accordance with Fuel Pre-filter, Bleeding, page 172. 47705010 06-2020 © AB VOLVO PENTA...
Page 174 Operate the hand pump by pumping it until fuel flows without air bubbles. Tighten the nipple while the fuel flows. Remove the hose. Tighten the nipple. Tightening torque 3.5 Nm (2.6 lbf. ft.) Install the cap. P0019268 47705010 06-2020 © AB VOLVO PENTA...
Page 175 Install the filter cover. Tightening torque: 25 Nm (18.4 lbf ft) Purge the fuel system in accordance with Fuel system, bleeding, page 169. Start and warm up engine. Check that no leakage P0022769 occurs. 47705010 06-2020 © AB VOLVO PENTA...
Page 176 Disconnect the pressure relief valve connector. Disconnect the fuel pressure sensor connector. Remove the cable ties. P0019657 NOTICE! Clean the area around the delivery pipe connection on the high pressure pump before starting any work. 47705010 06-2020 © AB VOLVO PENTA...
Page 177 Install safety plugs on all fuel connections. Use kit 88840290 Plugs. P0019658 Remove the fuel filter housing. P0019659 Installation Move the bracket and sensor over to the new fuel filter housing if needed. Install the fuel filter housing. P0019660 47705010 06-2020 © AB VOLVO PENTA...
Page 178 Connect the pressure relief valve connector. Connect the fuel pressure sensor connector. Install the cable ties. P0019662 Open the cock on the return line to the tank. Vent the fuel system according to Fuel system, bleeding, page 169. 47705010 06-2020 © AB VOLVO PENTA...
Page 179 The fuel system may be under pressure. When working on the fuel system, undo a closed system at the first point with caution. P0019336 Removal Disconnect the MPROP valve connector, high pressure pump. P0019275 47705010 06-2020 © AB VOLVO PENTA...
Page 180 23-3 Fuel Feed Pump and Filter IMPORTANT! Make sure no contaminants get into the component. Mark the position. Remove the MPROP valve. Remove the O-ring. P0019337 Install the protective plug. Use kit 88840290 Plugs. P0019338 47705010 06-2020 © AB VOLVO PENTA...
Page 181 Insert 88840271 Guide pin. Tighten by hand. P0019339 Lubricate a new O-ring (1) and fit it onto the oil cooler housing (2). NOTICE! Use a recommended oil. P0019340 Install the MPROP valve. Note the positioning. P0019341 47705010 06-2020 © AB VOLVO PENTA...
Page 182 Tightening torque: 9 Nm (6.6 lbf. ft.) P0019342 Connect the connector to the MPROP valve, high pressure pump. P0019275 Turn on the main switch. Start and warm up engine. Perform a function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 183: Injection Pump, Regulator
NOTICE! Turn off the main switch before any work is carried out. High pressure pump, fuel connections: 1 Fuel IN (from main filter) 2 Fuel OUT (to return line) 3 Fuel OUT to common rail A Control valve B Fuel temperature sensor P0021714 47705010 06-2020 © AB VOLVO PENTA...
Page 184 NOTICE! Be prepared to gather up fluid. Disconnect the connectors. P0021715 NOTICE! Be prepared to gather up fluid. Disconnect the union. Install the protective plug. Use kit 88840290 Plugs. P0021716 Disconnect the union. P0021717 47705010 06-2020 © AB VOLVO PENTA...
Page 185 Remove the screws. Carefully move the engine control unit aside and stow it securely. P0021720 NOTICE! The following images may differ somewhat compared to the product to be worked on. However, the main information is correct. 47705010 06-2020 © AB VOLVO PENTA...
Page 186 NOTICE! Do not hold the pump by the connection pipes. Remove the high pressure pump and its intermediate flange as one unit. P0019293 Remove the gear wheel in accordance with 23-3, High-pressure pump gear wheel, change. 47705010 06-2020 © AB VOLVO PENTA...
Page 187 Slide the pump in without turning the gearwheel. P0019305 NOTICE! Use new bolts. Screw in (1) without tightening. Remove 88840274 Guide pin. Screw in (2) without tightening. Tighten the bolts diagonally (1-2). Tightening torque 24 Nm (17.7 lbf. ft.) P0019306 47705010 06-2020 © AB VOLVO PENTA...
Page 188 Tightening torque 37 Nm (27.3 lbf. ft.) P0019307 Fit the bracket. P0019282 Bolt the engine control unit in place. Install: 1 Connector, pre-filter 2 Connector, oil level 3 Connector, oil pressure Secure the cable harness with fasteners. P0021720 47705010 06-2020 © AB VOLVO PENTA...
Page 189 Connect the connections. P0021722 Connect the connector. P0021715 Purge the fuel system in accordance with Fuel system, bleeding, page 169. Turn on the main switch. Start the engine. Perform a leakage and function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 190 1 Fuel IN (from main filter) 2 Fuel OUT (to main filter) 3 Fuel supply from the engine control unit cooling coil 4 Fuel OUT to return line 5 Fuel OUT to common rail P0019287 47705010 06-2020 © AB VOLVO PENTA...
Page 191 NOTICE! Be prepared to gather up fluid. Disconnect the union. Install safety plugs on all fuel connections. Use kit 88840290 Plugs. P0019288 Install the protective plug. Use kit 88840290 Plugs. Disconnect the connector. P0019289 47705010 06-2020 © AB VOLVO PENTA...
Page 192 Install safety plugs on all fuel connections. Use kit 88840290 Plugs. P0019290 Remove the cable clamps and cable ties. P0019279 Remove the bolts. Carefully move the engine control unit aside and stow it securely. P0019280 47705010 06-2020 © AB VOLVO PENTA...
Page 193 23-6 Injection Pump, Regulator Loosen the connections (1, 2). Install safety plugs on all fuel connections. Use kit 88840290 Plugs. P0019291 Remove the holder. P0019308 Remove the bracket. P0019282 47705010 06-2020 © AB VOLVO PENTA...
Page 194 Turn the gear wheel as illustrated so that the mark on it is aligned with the punch mark on the intermediate flange. Crank the flywheel until the cylinder 1 mark aligns with the mark on the flywheel housing. P0019300 47705010 06-2020 © AB VOLVO PENTA...
Page 195 Tightening torque 24 Nm (17.7 lbf ft) P0019306 NOTICE! Use new component. Install new delivery pipes. Adjust without tightening. Use an open 17 mm socket (crowfoot wrench). Tightening torque 37 Nm (27.3 lbf ft) P0019307 47705010 06-2020 © AB VOLVO PENTA...
Page 196 23-6 Injection Pump, Regulator Fit the bracket. P0019282 Install the holder and secure the fuel lines. P0019308 Install the bolts (1, 2). P0019309 47705010 06-2020 © AB VOLVO PENTA...
Page 197 23-6 Injection Pump, Regulator Install the engine control unit. P0019280 Secure the harness with cable clamps and cable ties. P0019279 Install the bolts (1, 2). P0019310 47705010 06-2020 © AB VOLVO PENTA...
Page 198 Connect the connector. P0019311 Connect the connections. P0019312 Purge the fuel system in accordance with Fuel system, bleeding, page 169. Turn on the main switch. Start the engine. Perform a leakage and function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 199 23-6 Injection Pump, Regulator High-pressure pump gear wheel, change Tools: 9986172 Puller Removal Remove the O-ring and nuts. P0019294 Remove the gear wheel. P0019295 47705010 06-2020 © AB VOLVO PENTA...
Page 200 Install the flange as illustrated. Tightening torque: 24 Nm (17.7 lbf ft) P0019297 Check that the key is in the keyway. P0019298 Install the gearwheel. Tightening torque 65 Nm (47.9 lbf ft) Install a new O-ring. P0019299 47705010 06-2020 © AB VOLVO PENTA...
Page 201 The fuel system may be under pressure. When working on the fuel system, undo a closed system at the first point with caution. P0019336 Removal Disconnect the MPROP valve connector, high pressure pump. P0019275 47705010 06-2020 © AB VOLVO PENTA...
Page 202 23-6 Injection Pump, Regulator IMPORTANT! Make sure no contaminants get into the component. Mark the position. Remove the MPROP valve. Remove the O-ring. P0019337 Install the protective plug. Use kit 88840290 Plugs. P0019338 47705010 06-2020 © AB VOLVO PENTA...
Page 203 Insert 88840271 Guide pin. Tighten by hand. P0019339 Lubricate a new O-ring (1) and fit it onto the oil cooler housing (2). NOTICE! Use a recommended oil. P0019340 Install the MPROP valve. Note the positioning. P0019341 47705010 06-2020 © AB VOLVO PENTA...
Page 204 Tightening torque: 9 Nm (6.6 lbf. ft.) P0019342 Connect the connector to the MPROP valve, high pressure pump. P0019275 Turn on the main switch. Start and warm up engine. Perform a function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 205: Injectors And Delivery Pipes
Remove the lower valve cover in accordance with Lower valve cover, change, page 102. Remove the hollow screw from the return line on the cylinder head. P0019313 Remove the injector delivery pipes in accordance with Fuel Injection Pipe, Change, page 219. 47705010 06-2020 © AB VOLVO PENTA...
Page 206 23-7 Injectors and Delivery Pipes Remove sleeves 1 -6. P0019314 Remove the injector delivery pipes using 9996400 Slide hammer and 9998007 Adapter. P0019315 Install safety plugs on all fuel connections. Use kit 88840290 Plugs. P0019316 47705010 06-2020 © AB VOLVO PENTA...
Page 207 NOTICE! Mark the injector locations for re- installation. Remove the injectors and washers. Check that no washers remain in any of the injector wells. Install protective plugs on all fuel unions. Use kit 88840290 Plugs. P0019319 47705010 06-2020 © AB VOLVO PENTA...
Page 208 23-7 Injectors and Delivery Pipes Plug the holes. Install protective plugs on all fuel unions. Use kit 88840290 Plugs. P0019320 Remove the washer and O-ring. P0019321 Repeat the same procedure on the other injectors. 47705010 06-2020 © AB VOLVO PENTA...
Page 209 Install the injectors. Position the injectors so that the installation hole is turned to face the injector delivery pipe inlet channel on the high pressure pump side. P0019323 47705010 06-2020 © AB VOLVO PENTA...
Page 210 Lubricate the bolts. Install the bolts into the injector yoke. Preload the bolts. Tightening torque: 5 Nm (3.7 lbf. ft.) P0019317 NOTICE! Use new components: O-ring and injector delivery pipe. Lubricate and install the O-ring. P0019325 47705010 06-2020 © AB VOLVO PENTA...
Page 211 Tightening torque: 75 Nm (55.3 lbf. ft.) P0019314 Tighten the injector yoke bolts. Tightening torque: 57 Nm (42.0 lbf. ft.) P0019327 Install the injector delivery pipes in accordance with Fuel Injection Pipe, Change, page 219. 47705010 06-2020 © AB VOLVO PENTA...
Page 212 Install the upper valve cover in accordance with: Upper valve cover, change, page 95. Purge the fuel system in accordance with: Fuel system, bleeding, page 169. Turn on the main switch. Start the engine. Perform a leakage and function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 213 When working on the fuel system, undo a closed system at the first point with caution. Removal Detach the diagnostics panel and move it aside. P0019274 Disconnect the control valve connector, high pressure pump. P0019275 47705010 06-2020 © AB VOLVO PENTA...
Page 214 Remove the fuel supply connection (1) from the engine control unit cooling coil. Detach the fuel supply connection (2) (from the pre-filter) to the engine control unit cooling coil. Install protective plugs on all fuel unions. Use kit 88840290 Plugs. P0019277 47705010 06-2020 © AB VOLVO PENTA...
Page 215 23-7 Injectors and Delivery Pipes Remove the cable clamps and cable ties. P0019279 Remove the bolts and carefully move the engine control unit aside and stow it securely. P0019280 Remove the holder. P0019281 47705010 06-2020 © AB VOLVO PENTA...
Page 216 (crowfoot wrench). Install protective plugs on all fuel unions. Use kit 88840290 Plugs. Remove the delivery pipes in accordance with Fuel Injection Pipe, Change, page 219. P0019283 Remove the common rail unit. P0019284 47705010 06-2020 © AB VOLVO PENTA...
Page 217 Install the delivery pipes; refer to Fuel Injection Pipe, Change, page 219. P0019284 NOTICE! Use new component. Install new delivery pipes. Tightening torque 37 Nm (27.3 lbf ft) P0019285 Install the control unit mounting bracket. P0019282 47705010 06-2020 © AB VOLVO PENTA...
Page 218 23-7 Injectors and Delivery Pipes Install the holder. P0019281 Bolt the engine control unit in place. P0019280 Secure the harness with cable clamps and cable ties. P0019279 47705010 06-2020 © AB VOLVO PENTA...
Page 219 Connect the fuel supply connection (2) (from the pre-filter) to the engine control unit cooling coil. P0019286 Connect the connector to the control valve, high pressure pump. P0019275 Connect the connector to the common rail pressure sensor. P0019276 47705010 06-2020 © AB VOLVO PENTA...
Page 220 Connect the connector to the pressure relief valve. P0019278 Purge the fuel system in accordance with Fuel system, bleeding, page 169. P0001900 Turn on the main switch. Start the engine. Perform a leakage and function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 221 NOTICE! Turn off the main switch before any work is carried out. NOTICE! Be prepared to gather up fluid. Removal Detach the fuel return line connection from the common rail. Install protective plugs on all fuel unions. Use kit 88840290 Plugs. P0019413 47705010 06-2020 © AB VOLVO PENTA...
Page 222 Install in the following order. 1, 4, 5, 3, 2, 6. Install the delivery pipes between the common rail and the injector delivery pipes. Tighten the cap nuts by hand. Check that the clamps are parallel with the bolt holes. P0019419 47705010 06-2020 © AB VOLVO PENTA...
Page 223 Use an open 17 mm socket (crowfoot wrench). P0019417 Connect the fuel return line. P0019418 Purge the fuel system in accordance with Fuel system, bleeding, page 169. Turn on the main switch. Start the engine. Perform a leakage and function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 224: Miscellaneous
When working on the fuel system, undo a closed system at the first point with caution. Tools: 885812 Timing tool 88840272 Sleeve 88840290 Plugs Removal Remove the common rail unit in accordance with Common Rail, Change, page 211. P0019356 47705010 06-2020 © AB VOLVO PENTA...
Page 225 23-9 Miscellaneous Remove the nut. Use 88840272 Sleeve. Remove the solenoid. P0019357 Remove the solenoid valve. P0019358 Install the protective plug. Use kit 88840290 Plugs. P0019359 47705010 06-2020 © AB VOLVO PENTA...
Page 226 Tightening torque: 15 Nm (11.1 lbf ft) 5 13 ±0.5° Use 885812 Timing tool. 6 Check the torque, 6-21 Nm (4.4-15.5 lbf ft) P0019361 Install the common rail unit, in accordance with Common Rail, Change, page 211. P0019356 47705010 06-2020 © AB VOLVO PENTA...
Page 227: Inlet And Exhaust Manifolds
NOTICE! There is no e-ERG system or choke on the TAD840-43VE andTAD850-53VE engines. Removal Undo, remove: - Cable ties. 1 Choke, refer to Air throttle, change, page 272. 2 Pre-heating element and electrical connection. 3 EGR flow valve connector. P0021732 47705010 06-2020 © AB VOLVO PENTA...
Page 228 4 Sensor, charge air temperature/pressure - Cable ties, connection for e-EGR pipe, harness anchor points. P0021733 Unfold and attach harness. Remove the EGR Venturi tube as a unit. Inspect and clean as necessary. P0021734 47705010 06-2020 © AB VOLVO PENTA...
Page 229 Remove the inlet manifold. Lift diagonally upwards. P0021736 Installation When replacing the inlet manifold, move the sensor for charge air temperature/pressure. Remove the gaskets. Clean the contact surfaces. Install the gaskets. NOTICE! Use new gaskets. P0021737 47705010 06-2020 © AB VOLVO PENTA...
Page 230 Apply locking fluid (prod. no. 1161053) on the bolts. P0021738 Apply locking fluid (prod. no. 1161053) on the bolts. P0021739 Torque tighten the inlet manifold; refer to Special Tightening Torques, page 8. P0021553 47705010 06-2020 © AB VOLVO PENTA...
Page 231 Install the mounting bolts and pressure pipe clamp. Install the filter cover and filter; refer to Oil filter, Change, page 160. P0021735 Install the EGR Venturi tube and EGR valve as a unit. Fold down the harness. P0021734 47705010 06-2020 © AB VOLVO PENTA...
Page 232 P0021733 Connect / Install: 1 Pre-heating element and electrical connection. 2 Choke, refer to Air throttle, change, page 272. 3 EGR flow valve connector. - Cable ties. P0021740 Turn on the main switch. 47705010 06-2020 © AB VOLVO PENTA...
Page 233 TAD880VE, TAD881VE, TAD882VE, TAD883VE, TAD884VE Removal Remove the turbo according to: Turbo, Change, page 251. Remove: 1 Coolant pipe (outlet) 2 Heat protection plate 3 Bracket P0021724 TAD870-873VE: Unscrew the connection to the e-EGR cooler. P0021725 47705010 06-2020 © AB VOLVO PENTA...
Page 234 Apply sealing paste (part no 1161929) for the screw joints. Place the new gaskets on the sealing surface. Install the exhaust manifold, see Special Tightening Torques, page 8. P0021728 Install: 1 Bracket 2 Heat protection plate 3 Coolant pipe (outlet) P0021729 47705010 06-2020 © AB VOLVO PENTA...
Page 235 25-1 Inlet and Exhaust Manifolds TAD870-873VE: Install the e-EGR pipe. P0021730 TAD870-873VE: Tighten the connection to the e-EGR cooler. P0021725 Install the turbo according to: Turbo, Change, page 251. Start the engine. Perform a function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 236: Emission Control, Catalytic Converter
Drain the coolant in accordance with Coolant, Change, page 276. NOTICE! Drain the coolant until the level is below the e-EGR radiator. Removal Remove the thermal cover. P0020525 Undo and lift up the heat shield. Unscrew the NOx sensor. P0020526 47705010 06-2020 © AB VOLVO PENTA...
Page 237 Remove the pipe clamp. 1 Move aside the coolant hose; the outlet from the e-EGR radiator. 2 Remove the coolant pipe clamping ring; inlet from the e-EGR radiator. P0020528 Unscrew the EGR pipe connection. P0020529 47705010 06-2020 © AB VOLVO PENTA...
Page 238 Tightening torque: 60 Nm (44.3 lbf ft) P0020529 Fit the pipe clamp. 1 Slide on the coolant outlet pipe from the e- EGR radiator. 2 Slide on the coolant inlet pipe from the e- EGR radiator. P0020528 47705010 06-2020 © AB VOLVO PENTA...
Page 239 P0020526 Install the thermal cover. Fill with coolant; refer to Coolant Level, Checking and Topping Up, page 274. Turn on the main switch. Start and warm up engine. Perform a leakage and function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 240 NOTICE! Be prepared to gather up fluid. Removal Remove the turbocharger, refer to Turbo, Change, page 251. Remove the pipe clamps. Remove the inlet and outlet coolant pipes from the e-EGR radiator P0020084 Unscrew the EGR pipe union. P0020085 47705010 06-2020 © AB VOLVO PENTA...
Page 241 Also check the EGR pipe in connection with cleaning. Installation Install the pipe and gasket. P0020087 Tightening torque: 60 Nm (44.3 lbf ft) Install the e-EGR radiator and gaskets. Tightening torque: 48 Nm (35.4 lbf ft) P0020088 47705010 06-2020 © AB VOLVO PENTA...
Page 242 Slide off the coolant hoses for both inlet and exhaust. P0020084 Install the turbocharger, refer to Turbo, Change, page 251. Turn on the main switch. Start and warm up engine. Perform a leakage and function check. 47705010 06-2020 © AB VOLVO PENTA...
Page 243 88800298 Connection washer 9996662 Pressure testing kit Pressurize for 15 minutes. NOTICE! Radiator nipples in the up position. Radiator core, test pressure: 0.4 bar (5.8 PSI) Radiator core, Max pressure: 0.6 bar (8.7 PSI) 47705010 06-2020 © AB VOLVO PENTA...
Page 244 Repeat with some cleaning agent. Turning cooler on tap and rinse. Make sure the cooler is flushed through thoroughly, until clean water comes out of the cooler. P0020092 47705010 06-2020 © AB VOLVO PENTA...
Page 245 Blow dry air through the e-EGR cooler in an upright position until the cooler is dry. P0020093 Inspect that the cooling element is clean and free from grime and other contaminants. P0020094 Install cooler e-EGR, according to Cooler e-EGR, change, page 234. 47705010 06-2020 © AB VOLVO PENTA...
Page 246 25-4 Emission Control, Catalytic Converter Control valve e-EGR, change TAD580VE, TAD581VE, TAD582VE, TAD583VE NOTICE! Be prepared to collect fluid. Removal Disconnect the connector. Remove the cable ties. Remove the oil pipes. P0031642 47705010 06-2020 © AB VOLVO PENTA...
Page 247 Stage 1: 25 Nm (18.4 lbf ft) Stage 2: 53 Nm (39.1 lbf ft) Stage 3: Undo the bolts -90° Stage 4: 25 Nm (18.4 lbf ft) Stage 5: 53 Nm (39.1 lbf ft) P0031640 47705010 06-2020 © AB VOLVO PENTA...
Page 248 25-4 Emission Control, Catalytic Converter Connect and tighten the oil pipes. Connect the harness terminal. Attach new cable ties. P0031641 47705010 06-2020 © AB VOLVO PENTA...
Page 249 25-4 Emission Control, Catalytic Converter Control valve e-EGR, change TAD880VE, TAD881VE, TAD882VE, TAD883VE, TAD884VE NOTICE! Be prepared to collect fluid. Removal Disconnect the connector. Remove the cable ties. Unscrew the oil pipe. P0030628 47705010 06-2020 © AB VOLVO PENTA...
Page 250 Stage 1: 25 Nm (18.4 lbf ft) Stage 2: 53 Nm (39.1 lbf ft) Stage 3: Undo the bolts -90° Stage 4: 25 Nm (18.4 lbf ft) Stage 5: 53 Nm (39.1 lbf ft) P0030626 47705010 06-2020 © AB VOLVO PENTA...
Page 251 25-4 Emission Control, Catalytic Converter Connect and tighten the oil pipes. Connect the harness terminal. Attach new cable ties. P0030627 47705010 06-2020 © AB VOLVO PENTA...
Page 252: Turbo And Supercharger
Bear in mind: • Oil accumulation in the intake system downstream of the turbocharger may indicate a worn turbocharger. • Heavy carbon deposits on the turbine blades may indicate a worn turbocharger. 47705010 06-2020 © AB VOLVO PENTA...
Page 253 Drain the coolant in accordance with: Coolant, Change, page 276 Remove the exhaust pipe connection between the turbocharger and the after-treatment system. Remove the turbocharger charge air pipe. P0019420 Remove the intake pipe. P0019421 47705010 06-2020 © AB VOLVO PENTA...
Page 254 Remove the pipe elbow (1) from the turbocharger. Remove the rubber bellows (2) from the air intake with the connecting hose for crankcase ventilation. P0019424 Detach and lift up the heat shield. Unscrew the NOx sensor. P0019425 47705010 06-2020 © AB VOLVO PENTA...
Page 255 Remove the clamp (1). Remove the suspension bracket (2). Lift off the pre-Cat with its connection pipe. P0019426 Disconnect the exhaust manifold pressure sensor connector. Remove the exhaust pressure sensor unit. P0019427 Remove the thermal cover. P0019429 47705010 06-2020 © AB VOLVO PENTA...
Page 256 Disconnect the connector for the turbocharger tachometer sensor (1) and the VGT actuator (2). P0019430 Release the generator cable and disconnect from the connector. P0021723 Remove the cable ties and the cable harness from the cable suspension. P0019431 47705010 06-2020 © AB VOLVO PENTA...
Page 257 25-5 Turbo and supercharger Remove the cable suspension brackets. P0019436 Remove the coolant inlet line. P0019432 Remove the coolant outlet line. P0019433 47705010 06-2020 © AB VOLVO PENTA...
Page 258 Remove the turbocharger. Installation NOTICE! Use new sealings. Install a new gasket on the exhaust manifold. Install the turbocharger. Tightening torque: Bolt (1): 44 Nm (32.5 lbf ft) Nut (2): 54 Nm (39.8 lbf ft) P0019438 47705010 06-2020 © AB VOLVO PENTA...
Page 259 Fill the turbocharger with new, clean engine oil. Then install the oil supply line and clamps. Tightening torque: 26 Nm (19.2 lbf ft) P0019440 Install the upper coolant connection (outlet). Tightening torque: 38 Nm (28.0 lbf ft) P0019433 47705010 06-2020 © AB VOLVO PENTA...
Page 260 25-5 Turbo and supercharger Install the coolant inlet line. Tightening torque: 38 Nm (28.0 lbf ft) P0019441 Install the cable harness suspension brackets. P0019436 Install the cable harness and secure it with cable ties. P0019431 47705010 06-2020 © AB VOLVO PENTA...
Page 261 25-5 Turbo and supercharger Connect the connector to the turbocharger tachometer sensor (1) and the VGT actuator (2). P0019430 Install the thermal cover. P0019429 Install the alternator cable and connect its connector. P0021723 47705010 06-2020 © AB VOLVO PENTA...
Page 262 Install the unit with suspension bracket (2). P0019442 Brush lubricant onto the threads and install the NOx sensor. Examples of lubricants: Permatex: Anti-Seize or Bostik Never-Seez. Tightening torque: 50 Nm (36.9 lbf ft) P0019443 47705010 06-2020 © AB VOLVO PENTA...
Page 263 Fill the fresh water system in accordance with Coolant, Change, page 276. Turn the main switch on. Run the engine until warm and perform a functional check with respect to any leakages. P0019420 47705010 06-2020 © AB VOLVO PENTA...
Page 264 • pipe connector for the exhaust pipe • exhaust brake P0031635 Undo / remove: • oil pipe • hoses, wastegate actuator • oil pipe, EGR P0031634 47705010 06-2020 © AB VOLVO PENTA...
Page 265 Install the oil return pipe (1). Stage 1: Tightening torque: 12 Nm Stage 2: Tightening torque: 24 Nm Fill the turbocharger with new, clean engine oil. Install: • oil supply line (2) • hose, wastegate actuator P0031632 47705010 06-2020 © AB VOLVO PENTA...
Page 266 Stage 2: 12 Nm • pipe between the air filter and the turbocharger • pipe and pipe elbow between the turbocharger and charge air cooler Fill with coolant according to Coolant, Change, page 276. P0031631 47705010 06-2020 © AB VOLVO PENTA...
Page 267 • exhaust brake NOTICE! Be prepared to collect fluid. Clamp on 1158957 and remove the coolant hoses. P0030623 Undo / remove: • oil pipe • hoses, wastegate actuator • hose, SCR P0030622 47705010 06-2020 © AB VOLVO PENTA...
Page 268 Stage 1: Tightening torque: 12 Nm Stage 2: Tightening torque: 24 Nm Install the hose, EGR. Fill the turbocharger with new, clean engine oil. Install: • oil supply line • hose, wastegate actuator P0030619 47705010 06-2020 © AB VOLVO PENTA...
Page 269 P0030620 Install: • Exhaust pipe/silencer • Heat shield Run the engine until warm and perform a functional check with respect to any leakages. 47705010 06-2020 © AB VOLVO PENTA...
Page 270 NOTICE! Be prepared to gather up fluid. Clamp 1158957 Pliers and loosen the coolant hoses. P0021883 Loosen the oil pressure line (1). Secure in place and lift the air compressor away with suitable lifting equipment (2). P0021884 47705010 06-2020 © AB VOLVO PENTA...
Page 271 Clean the sealing surfaces. Thread on a new o-ring. Connect the gearwheel on the axle and tighten. Tightening torque: 225 Nm (166 lbf. ft.) Fit the nipples. Check marking. P0021887 47705010 06-2020 © AB VOLVO PENTA...
Page 272 Connect / Install the connections: 1 Air inlet 2 Air outlet 3 Control connection - The connector for Rail pressure/ temperature. NOTICE! Install the coolant hoses. Loosen 1158957 Pliers. Start the engine. Perform a function check. P0021883 47705010 06-2020 © AB VOLVO PENTA...
Page 273 Measure the length of stroke between actuator end positions. The play must be ~13 mm. If the actuator cannot be moved or if the length of stroke is too short, examine the cause of this. P0023174 47705010 06-2020 © AB VOLVO PENTA...
Page 274: Air Cleaner, Throttle Housing
Turn off the main switch before any work is carried out. Removal Remove the hose between the inlet manifold and the charge air cooler. P0021741 Undo the electrical connection to the shutter housing. Remove the shutter housing. P0021742 47705010 06-2020 © AB VOLVO PENTA...
Page 275 P0015227 Installation Install the shutter housing and gasket. Connect the electrical connection to the shutter housing. P0021743 Install the hose between the inlet manifold and charge air cooler. P0021741 Turn on the main switch. 47705010 06-2020 © AB VOLVO PENTA...
Page 276: Cooling System
26-0 Cooling System, General Coolant Level, Checking and Topping Up IMPORTANT! Only use coolant recommended by Volvo Penta. CAUTION! Avoid opening the filler cap for engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out as system pressure is lost.
Page 277 Start the engine. Run it until it reaches operating temperature (thermostat open). Check the coolant level. Adjust the level as required. Carry out a follow-up check of the coolant level after approx 1 hour's operation. 47705010 06-2020 © AB VOLVO PENTA...
Page 278 Remove the filler cap (1). P0019343 Open all drain points. NOTICE! There may be other taps or plugs at the lowest points of the coolant system Connect 9996049 Draining hose. Connect a drainage vessel. Empty the radiator. P0019344 47705010 06-2020 © AB VOLVO PENTA...
Page 279 Check that all coolant drains out. Remove the tool. Close any taps. Refill with new, Volvo Penta-recommended cooling fluid. Refer to Administration, page 53 and Coolant Level, Checking and Topping Up, page 274. P0019345 47705010 06-2020 © AB VOLVO PENTA...
Page 280: Radiator, Heat Exchanger
Remove the coolant hose (2), coolant outlet to the radiator. Remove the hose (3) between the radiator and expansion tank. P0019573 Remove the right belt guard. Remove the right fan protection. P0019574 47705010 06-2020 © AB VOLVO PENTA...
Page 281 Remove the left belt guard. Remove the left fan protection. Remove the pipe elbow. P0019576 Remove the hose between the expansion tank and thermostat housing side cover. Remove the connector to coolant level sensor, expansion tank. P0019577 47705010 06-2020 © AB VOLVO PENTA...
Page 282 Remove the coolant hose, coolant inlet (from the radiator). Loosen the upper radiator stay. P0019578 Connect the radiator to a hoisting device. Loosen the lower bracket. P0019579 Release the cooler for further work. Remove the fan ring. P0019580 47705010 06-2020 © AB VOLVO PENTA...
Page 283 Align the radiator over the frame and upper bracket. P0019580 Bolt on the radiator at the top and at the bottom bracket. P0019581 Fit the fan ring. Install the coolant hose, coolant inlet (from the radiator). P0019582 47705010 06-2020 © AB VOLVO PENTA...
Page 284 Install the pipe elbow. P0019576 Install the charge air pipe (1) from the charge air cooler and pipe elbow. Install the filler hose (2) between the expansion tank and coolant inlet coolant pipe. P0019575 47705010 06-2020 © AB VOLVO PENTA...
Page 285 Install the coolant hose (2), coolant outlet to the radiator. Install the hose (3) between the radiator and expansion tank. P0019573 Refill with new, Volvo Penta recommended cooling fluid. Refer to Administration, page 53 and Coolant Level, Checking and Topping Up, page 274. Turn on the main switch.
Page 286: Coolant Pump, Thermostat
Its oil may run out which will then mean that the coupling must be changed. P0019589 Disconnect the sensor cable from the engine cable harness. Remove the sensor bracket from the bracket on the engine. P0019590 47705010 06-2020 © AB VOLVO PENTA...
Page 287 (Hot circuit fluid from the turbocharger, e- EGR radiator). Remove the hose (2). (Connection hose to expansion tank). P0019592 Remove the crankcase ventilation connection pipe. Remove the cable ties. Disconnect the electrical connection from the preheater element. P0019593 47705010 06-2020 © AB VOLVO PENTA...
Page 288 Remove the cable ties. Open the preheater relay cover. Unscrew the input nut. Remove the engine attachment fitting. P0019594 Remove the preheater relay. P0019595 Remove the clamps. Disconnect the cable. Remove the bolts. Remove the bracket. P0019596 47705010 06-2020 © AB VOLVO PENTA...
Page 289 26-2 Coolant Pump, Thermostat Remove the thermostat housing. P0019597 Remove the gaskets. P0019598 Remove the ventilation pipe from the separator. P0019599 47705010 06-2020 © AB VOLVO PENTA...
Page 290 P0019600 Remove the fan adapter and pulley from the coolant pump. P0019601 NOTICE! Be prepared to gather up fluid. Remove the drain plug. Empty the water pump. P0019602 47705010 06-2020 © AB VOLVO PENTA...
Page 291 Remove the coolant pump. Remove the gaskets. P0019603 Installation Install new gaskets. P0019606 Install the coolant pump, refer to Special Tightening Torques, page 8. NOTICE! First guide in the coolant pump “ collar“ and O-ring. P0019607 47705010 06-2020 © AB VOLVO PENTA...
Page 292 Install the fan adapter and pulley on the coolant pump. Tighten the bolts diagonally. P0019610 Install the belt. Release the belt tensioner and remove the drift. Check that the belt is correctly aligned on all the pulleys. P0019611 47705010 06-2020 © AB VOLVO PENTA...
Page 293 26-2 Coolant Pump, Thermostat Install the ventilation pipe between the separator and the pipe union. P0019599 Install new gaskets. Grease the O-ring. P0019613 Install the thermostat housing. Tighten the bolts diagonally. P0019597 47705010 06-2020 © AB VOLVO PENTA...
Page 294 P0019614 Install the preheater relay. P0019595 Install the attachment fitting on the engine. Install the cable with the input nut. Close preheater relay cover. Secure with a cable tie. Connect the harness terminal. P0019615 47705010 06-2020 © AB VOLVO PENTA...
Page 295 Rotate the fan slowly clockwise (view as illustrated) so that the threads engage. Rotate the fan until the threads bottom and tighten so that the coupling grips the adapter. Tightening torque: 150 Nm (110.6 lbf ft) P0019618 47705010 06-2020 © AB VOLVO PENTA...
Page 296 Install the belt guard and fan guard, refer to Radiator Assembly, Change , page 278. Fill with coolant, refer to Coolant, Change, page 276. Turn the main switch on. Start the engine. Check that no leakage occurs. 47705010 06-2020 © AB VOLVO PENTA...
Page 297 Drain the coolant so that the level falls below the thermostat; refer to Coolant, Change, page 276. Disconnect the radiator hose. P0019521 Remove the crankcase ventilation connection from the valve cover. P0019483 Remove the hose between the expansion tank and thermostat housing. P0019522 47705010 06-2020 © AB VOLVO PENTA...
Page 298 Remove the thermostat. Installation Install a new thermostat. Install the thermostat housing cover. Tightening sequence: Diagonally P0019525 Install the hose between the expansion tank and the thermostat housing. P0019522 Connect the radiator hose. P0019521 47705010 06-2020 © AB VOLVO PENTA...
Page 299 26-2 Coolant Pump, Thermostat Install the crankcase ventilation connection on the valve cover. P0019483 Fill with coolant; refer to Coolant Level, Checking and Topping Up, page 274. Check that no leakage occurs. 47705010 06-2020 © AB VOLVO PENTA...
Page 300 Install the belt. Release the belt tensioner and remove the drift. Check that the belt is correctly aligned on all the pulleys. Install the belt guard; refer to Belt guard, change, page 299. P0019256 47705010 06-2020 © AB VOLVO PENTA...
Page 301 26-2 Coolant Pump, Thermostat Belt guard, change Right belt guard Removal Remove the belt guard. Installation Install the belt guard. P0019257 Left belt guard Removal Remove the belt guard. Installation Install the belt guard. P0019258 47705010 06-2020 © AB VOLVO PENTA...
Page 302: Fan, Fan Shroud
IMPORTANT! Turn off the main switch before starting work. Remove: 1 Belt guard, refer to Belt guard, change, page 299. 2 loading air pipe 3 Fan guard P0025012 Disconnect the sensor cable from the engine harness. Remove the bracket. P0025019 47705010 06-2020 © AB VOLVO PENTA...
Page 303 26-3 Fan, Fan Shroud Remove the fan ring. P0025017 Secure the fan and fan ring with a strap. P0025020 Unscrew the viscous coupling together with the fan. P0025021 47705010 06-2020 © AB VOLVO PENTA...
Page 304 26-3 Fan, Fan Shroud Remove the fan adapter. P0025018 Lift out the fan unit. P0025016 Remove the viscous coupling. P0025013 47705010 06-2020 © AB VOLVO PENTA...
Page 305 26-3 Fan, Fan Shroud Installation Install the viscous coupling. P0025013 Secure the fan and fan ring with a strap. P0025020 Lift in the fan unit with fan ring. P0025011 47705010 06-2020 © AB VOLVO PENTA...
Page 306 Carefully place the fan coupling onto the engine attachment fittings. Rotate the fan slowly until the threads grip. Rotate the fan until the thread bottoms and tighten. Tightening torque: 150 Nm (110.6 lbf·ft) P0025015 Install the fan ring. P0025017 47705010 06-2020 © AB VOLVO PENTA...
Page 307 26-3 Fan, Fan Shroud Fit the bracket. Connect the sensor cable. P0025019 Install: 1 Fan guard 2 loading air pipe 3 Belt guard, refer to Belt guard, change, page 299. P0025014 47705010 06-2020 © AB VOLVO PENTA...
Page 308: Alternator
P0019406 Remove the right belt guard; refer to Belt guard, change, page 299. Remove the drive belt according to Drive Belt, Change, page 298. Disconnect the alternator cable terminals. P0019407 47705010 06-2020 © AB VOLVO PENTA...
Page 309 32-1 Alternator Disconnect the connector. P0019408 Remove the alternator. P0019409 47705010 06-2020 © AB VOLVO PENTA...
Page 310 Lower attachment bolt (2), 85 Nm (62.7 lbf. ft.) P0019410 Connect the connector. P0019408 Install the alternator cable connections. Tightening torque: Negative terminal (1), 10 Nm (7.4 lbf. ft.) Positive terminal (2), 12 Nm (8.9 lbf. ft.) P0019411 47705010 06-2020 © AB VOLVO PENTA...
Page 311 2 Install the pipe elbow on the turbocharger. 3 Install the thermal cover. 4 Install the inlet pipe. 5 Install the turbocharger charge air pipe. P0019412 Turn on the main switch. 47705010 06-2020 © AB VOLVO PENTA...
Page 312 Clean the nut and the alternator shaft. Mark the position of the nut in relation to the alternator shaft. P0020358 Undo the nut with a couple of bursts from an impact wrench. Remove the belt pulley. P0020359 47705010 06-2020 © AB VOLVO PENTA...
Page 313 Alternative 2 Torque socket Alternative 3 (M17) Angle tighten the nut 40° Tightening torque: M16: 95 Nm M17: 118 Nm P0020360 The markings must be aligned. P0020358 Install the generator. Fit the drive belt. 47705010 06-2020 © AB VOLVO PENTA...
Page 314: Starter Motor
Turn off the main switch before any work is carried out. Removal Unscrew the nut from the starter motor plus connection. Move aside the main switch (+) cable (1), the generator cable (2) and the cable split/fuse holder (3). P0020346 Disconnect the connector. P0020347 47705010 06-2020 © AB VOLVO PENTA...
Page 315 Install the starter motor. P0020348 Connect the connector. P0020350 Install the starter motor cable connections 1-3. Tightening torque: 18 Nm (13.3 lbf ft) Secure the cables with cable ties after installation. P0020349 Turn on the main switch. 47705010 06-2020 © AB VOLVO PENTA...
Page 317: Index
Timing Gears and Shaft......... 122 Turbo and supercharger......... 250 Turbo, Change........251, 262, 265 Gear Ring, Fywheel: Replace........ 146 Turbocharger, Inspection........250 General............... 3 General Specifications..........7 General Tightening Torques........7 Upper valve cover, change......... 95, 98 47705010 06-2020 © AB VOLVO PENTA...
Page 318 Valve Guides, Inspection........117 Valve Mechanism........... 109 Valves, Adjustment..........109 Valves, Installation..........120 Valves, Removal............ 118 VGT actuator, check..........271 Visco fan, replace........... 300...
Page 319: References To Service Bulletins
References to Service Bulletins Group No. Date Refers to ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 321 From: ......................................................................................Refers to publication: ....................................Publication No.: ........... Date of issue: ......................Proposal/motivation: ....................................................................................................................................................................................................................................................................................................................................................................................................Date: ......................... Signed: ......................AB Volvo Penta Service Communication Dept. CB22000 SE-405 08 Göteborg Sweden...

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