Volvo Penta D3 Service And Maintenance Manual

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Page 1 Service and Maintenance...
Page 3 Reversing gear ..................70 Reversing gear, oil and filter change ............ 70 Sterndrive ....................74 Valve block, oil filter, change ..............76 Sterdrive, hydraulic fluids ..............78 Sterndrive, Oil Filling ................79 Sterndrive bellows ................81 47708097 09-2023 © AB VOLVO PENTA...
Page 4 Long-Term Storage ................... 87 Storage instruction for long-term storage of new engine ......89 Cleaning engine and transmission ............91 Cold Weather Precautions ............... 93 Checklist ....................94 Battery, Maintenance ................95 Index ......................97 47708097 09-2023 © AB VOLVO PENTA...
Page 5 This chapter describes how safety precautions are If anything remains unclear or if you are unsure presented in the manual and on the product. Read of something, contact your Volvo Penta dealer for the 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 7 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. 47708097 09-2023 © 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. 47708097 09-2023 © 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 11 Cleaning the engine and components NOTICE! Follow the instructions Cleaning engine and transmission, page 91. P0026213 Cleanliness for sensitive components IMPORTANT: Observe meticulous cleanliness when handling system components. Even minimal amounts of dirt could cause a breakdown. 47708097 09-2023 © AB VOLVO PENTA...
Page 13 Volvo Penta parts in all areas of the exhaust restriction system covered by the warranty and found to be The manual has been produced primarily for use in defective.
Page 14 I = Inspection (includes where necessary also adjustment, cleaning, lubrication and replacement) • Only use genuine Volvo Penta replacement parts or parts of the same quality as Volvo Penta replacement parts. • The engine may not be converted or modified in...
Page 15 General Information more on Volvo Penta‘s website: vppn.volvo.com and Product Center for online service protocol. 47708097 09-2023 © AB VOLVO PENTA...
Page 16 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 47708097 09-2023 © AB VOLVO PENTA...
Page 17 General Information Cooling system Seawater pump Coolant pump Engine Vibration dampers Engine pads, kit P0026297 Electrical system Alternator Starter motor P0026298 47708097 09-2023 © AB VOLVO PENTA...
Page 18 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 47708097 09-2023 © AB VOLVO PENTA...
Page 19 General Information Cylinder liners, kit Main bearings, kit Big end bearings, kit Thrust washers, kit Camshaft bearings, kit P0026301 Exhaust valve Valve seat P0026302 47708097 09-2023 © AB VOLVO PENTA...
Page 20 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 47708097 09-2023 © AB VOLVO PENTA...
Page 21 General Information Overhaul, IPS IPS Drive, replacement Upper gear Lower gear P0026306 Repair, IPS Upper gear, kit P0026307 Lower gear, kit P0026308 47708097 09-2023 © AB VOLVO PENTA...
Page 23 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 24 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 25 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 47708097 09-2023 © AB VOLVO PENTA...
Page 26 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 27 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 47708097 09-2023 © AB VOLVO PENTA...
Page 28 Some of the type plates are marked with identity numbers. Always use this information as a reference when ordering service and replacement parts or contacting Volvo Penta retailers. P0030646 Serial number Engine power Emissions/CHASSIS ID 47708097 09-2023 © AB VOLVO PENTA...
Page 29 Specifications Transmission Decals Reverse gear Reverse gear ID Drive A Sterndrive ID B Shield ID P0030638 47708097 09-2023 © AB VOLVO PENTA...
Page 30 Specifications Electrical rudder actuator A Product information B CHASSIS ID C Product ID P0028178 47708097 09-2023 © AB VOLVO PENTA...
Page 31 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 32 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 33 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 34 Engine Engine Component location P0030643 Oil filter Diagnostic connector Fuel filter Oil dipstick Oil filler Draining, coolant Oil level, power steering 47708097 09-2023 © AB VOLVO PENTA...
Page 35 Engine P0030642 Exhaust bellows Drive belt Air filter Draining, condensation water Coolant Draining, seawater Seawater filter Impeller pump Crankcase filter Drive belt 47708097 09-2023 © AB VOLVO PENTA...
Page 36 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 37 The inspection applies to all components in the systems. Look especially carefully for fuel leakage at: • Injector connections • Common rail, replacement • Check all clamped items • Fuel filter • Fuel pipe/hoses • Fuel pump P0030636 47708097 09-2023 © AB VOLVO PENTA...
Page 38 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 39 ● 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. The diagnostic connector is located alongside and at the rear of the engine. 47708097 09-2023 © AB VOLVO PENTA...
Page 40 P0024905 Air Filter The engine air filter is located under the cover cap on the turbocharger intake. Replacing the air filter • Remove the engine cover (A). • Remove the hose clamp (B). P0030645 47708097 09-2023 © AB VOLVO PENTA...
Page 41 • Install the new filter. • Secure the hose clamps. • Install the cover. NOTICE! Scrap the old filter. It is not designed to be cleaned. 47708097 09-2023 © AB VOLVO PENTA...
Page 42 Remove the filter and insert a new one. • Slide the hose back into the air filter housing. Install the cover cap. NOTICE! Scrap the old filter. It is not designed to be cleaned. 47708097 09-2023 © AB VOLVO PENTA...
Page 43 Engine Camshaft Belt, Replace Replacing the cam belt is a servicing item. Note the servicing intervals for the engine. The work is specialized and must be done by workshop-trained personnel. 47708097 09-2023 © AB VOLVO PENTA...
Page 44 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 45 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 46 Drain the engine oil by first removing the oil dipstick. • Insert a hose into the pipe and suck out the oil with a vacuum pump. NOTICE! If the engine oil is hot, it will drain out faster. P0026555 P0026556 47708097 09-2023 © AB VOLVO PENTA...
Page 47 Lubrication System Oil filter, Replace Volvo Penta strongly recommends that only oil filters are used that have been approved by Volvo Penta. The wrong type of oil filter can lead to increased wear and damage, e.g. to bearings and crankshaft.
Page 48 • Start the engine. • Check that no leakage occurs. • After running the engine for a few minutes, switch it off and check the oil level. P0030648 • Top up as necessary. P0026558 47708097 09-2023 © AB VOLVO PENTA...
Page 49 Volvo Penta oil analysis Volvo Penta oil analysis provides an extensive diagnostic check on the condition of the driveline. The oil analysis provides information for example on water content, fuel content, dirt and the amount of metallic particles in the oil as a result of component wear.
Page 50 P0035441 P0035462 Figure 2 P0035463 Engine Length (L) D4/D6 900 mm (35 in) D2, D3, D5, D7, D8, D9, D11, D12, D13, 280 mm (11 in) Transmission/drive Length (L) IPS1 125 mm (5 in) IPS10 100 mm (4 in) IPS2/3/15/20/30...
Page 51 Lubrication System Figure 3 D2/D3/D5/D7/D8/D9/D11/D12/D13/D16 D4/D6 P0035464 P0035465 IPS1/IPS2/IPS3/15/20/30 IPS10 P0035466 P0035467 47708097 09-2023 © AB VOLVO PENTA...
Page 53 General Regular oil analyses provide improved insight into engine health. Test reports are available on the Volvo Penta Partner Network within 48 hours of receiving the sample at the test laboratory. To obtain permission to access the report page, please contact Volvo Penta's sales office in each country.
Page 54 8 Attach the sampling bottle to the pump and take an oil sample. Fill the bottle to 80%. Remove the bottle and attach the cap immediately. 9 Send to the laboratory chosen by Volvo Penta to get your oil analysis report. Clean the pump •...
Page 55 The fuel system has a fine filter fitted to the engine as standard. In addition, the installation often includes a pre-filter as an option. P0026559 Available Volvo Penta pre-filters are shown here. They are available either as a single filter or dual changeover filters. 47708097 09-2023 © AB VOLVO PENTA...
Page 56 Remove the connector to the sensor at the bottom of the fuel filter, so that it does not rotate. • Remove the fuel filter with the aid of a suitable filter puller. • Wipe up any fuel spills. P0026560 47708097 09-2023 © AB VOLVO PENTA...
Page 57 Lubricate the sealing surface (A) with diesel and install the new fuel filter. Tighten according to the instructions on the filter. • Reconnect the connector at the bottom. • Bleed the fuel system. P0030635 47708097 09-2023 © AB VOLVO PENTA...
Page 58 Fuel System Fuel pre-filter Volvo Penta fuel pre-filters are supplied in single and double models. Check The double filter is fitted with a pressure gauge (A) that indicates when it is time to replace the filter cartridges. Replace the filter cartridges according to maintenance schedule recommendations, or earlier if the pressure gauge shows a pressure drop of 6–10 in.
Page 59 Replace the other filter in the same way. • Open the fuel valves and put the lever in the normal operating position. Check that there are no leaks. • Repeat the procedure on the other filter. 47708097 09-2023 © AB VOLVO PENTA...
Page 60 The fuel is under very high pressure and can penetrate the skin. • Bleeding is electrical and is done by means of the button next to the filter. Depress the button for 10 seconds and the job is done. P0026561 47708097 09-2023 © AB VOLVO PENTA...
Page 61 NOTICE! If water comes out of the fuel pre-filter, the fuel tank must be drained and cleaned. NOTICE! The illustration shows a universal type of fuel pre-filter to illustrate the tightening torque of the drain screw. P0026313 47708097 09-2023 © AB VOLVO PENTA...
Page 62 There is also one or more exhaust hose at the reverse gear installation. These must also be checked to see that they are secure and not leaking or damaged. 47708097 09-2023 © AB VOLVO PENTA...
Page 63 Steam or hot fluid could spray out, causing severe burns. NOTICE! We strongly recommend that only VCS coolant approved by Volvo Penta is used NOTICE! Check the proportion of the anti-freeze protection each year, if the coolant is not being replaced.
Page 64 Check the level again when the engine has cooled. Adjust as necessary. NOTICE! The coolant contains corrosion protection additives. Do not drain the system if the engine is to be in storage for a longer period of time. 47708097 09-2023 © AB VOLVO PENTA...
Page 65 • Remove the inner drive belt (D). NOTICE! Check the function of the belt tensioners, pulleys and their bearings after the belts have been removed. Replace any pulley bearing that exhibits any slack. P0030640 47708097 09-2023 © AB VOLVO PENTA...
Page 66 Relieve the load on the belt tensioner and remove the drift. P0030640 • Check that the belt is correctly aligned on all the pulleys. • Install the protective cover if one has been installed. 47708097 09-2023 © AB VOLVO PENTA...
Page 67 Risk of water entry. Close and drain the raw water system before starting any work on the system. Clean and inspect the seawater pump and impeller cover. If it is worn, decide whether it needs to be changed. 47708097 09-2023 © AB VOLVO PENTA...
Page 68 Undo the three impeller cover attachment bolts (B). • Remove the O-ring (C). • Pull the impeller out using an impeller puller. NOTICE! Replace the impeller if the rubber is cracked or there is other damage to the impeller. P0030653 P0026565 47708097 09-2023 © AB VOLVO PENTA...
Page 69 Open the cooling water cock. • Check that there is no leakage when the engine is being started. NOTICE! The impeller may be damaged if any types of lubricant other than glycerin are used. P0026554 47708097 09-2023 © AB VOLVO PENTA...
Page 70 It must be possible to open and close the cock. Check the water hose to ensure that there are no cracks or signs of leakage. Clean the cooling water intake outer grille when the boat is on dry land. P0026225 47708097 09-2023 © AB VOLVO PENTA...
Page 71 Open the sea cock. P0030654 • 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 47708097 09-2023 © AB VOLVO PENTA...
Page 72 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 73 Pull up the dipstick again and check the level. • Top up with oil through the dipstick hole as necessary. NOTICE! Never overfill the reversing gear with oil. The level must be inside the marked area on the oil dipstick. 47708097 09-2023 © AB VOLVO PENTA...
Page 74 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 75 When changing the oil, draw it out through the dipstick hole. Quantity approx 5 liters. Also check that the bolted joint is secure and that the linkage between the actuator and rudder is not binding. P0026317 47708097 09-2023 © AB VOLVO PENTA...
Page 76 External stern drive service points. A Anode B Oil filler/Dipstick C Driveshaft bellows D Trim/Tilt pump E Oil drainage F Exhaust bellows G Anode P0030637 47708097 09-2023 © AB VOLVO PENTA...
Page 77 Transmission, Sterndrive Service points inboard on the transom shield. A Exhaust bellows B Hydraulic fluid reservoir for power steering C Drive shaft splines (greased during installation) P0030651 47708097 09-2023 © AB VOLVO PENTA...
Page 78 Remove the oil filter with bypass cover from the hydraulic valve unit and let the oil run off. Replace the oil filter and bypass cover. Tightening torque: 34 Nm P0030655 • Put the hoses back on the the pump. P0015485 47708097 09-2023 © AB VOLVO PENTA...
Page 79 Make sure that no person is near the drive while the steering wheel is rotated. 2,5 and 4 Inch screen 1. Move control to 2. Turn on the ignition. 3. THROTTLE ONLY: 6. Turn steering neutral. press and hold for at wheel until buzzer least 5 seconds. alarms. 47708097 09-2023 © AB VOLVO PENTA...
Page 80 Clean the area around the filler cap to prevent dirt from entering the system. • Remove the filler cap. The fluid must reach all the way up to the hole. • Top up as necessary. P0026745 47708097 09-2023 © AB VOLVO PENTA...
Page 81 NOTICE! At the same time take the opportunity to check the color of the fluid during the change. If the fluid is light/cloudy, water has entered and the shaft seal must be changed. P0026746 47708097 09-2023 © AB VOLVO PENTA...
Page 82 Remove the fluid pump and screw the drain plug back in. • Check the fluid level on the dipstick. • Reinstall the cover and propeller(s). P0026747 NOTICE! Fill the drive slowly to minimize the risk of air bubbles. P0026748 47708097 09-2023 © AB VOLVO PENTA...
Page 83 • When replacing the bellows check that the clamps are installed and facing in the correct direction. • Lubricate the drive shaft (splines) when the drive has been removed to replace the bellows. 47708097 09-2023 © AB VOLVO PENTA...
Page 84 Remove the propellers • Remove the outer propeller nut (A) and remove the outer propeller (B). • Remove the inner propeller nut (C) and remove the inner propeller (D). • Wipe the propeller shaft clean. P0030650 47708097 09-2023 © AB VOLVO PENTA...
Page 85 Install the propeller nut (C). Tightening torque: 60 Nm • Install the outer propeller (B). • Install the outer propeller nut (A). Tightening torque: 100 Nm • Check that the propellers can be turned easily. P0030650 47708097 09-2023 © AB VOLVO PENTA...
Page 86 NOTICE! If, for the most part, the boat is used in salt water, all the anodes must be of zinc or aluminum. If the boat is mostly used in fresh water, all the anodes must be of magnesium. 47708097 09-2023 © AB VOLVO PENTA...
Page 87 WARNING! Do not use emery cloth. Small pieces of iron oxide which are used in the emery cloth will become embedded in the aluminum and will cause severe corrosion damage. 47708097 09-2023 © AB VOLVO PENTA...
Page 88 # 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 89 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 90 • 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 91 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 92 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 47708097 09-2023 © AB VOLVO PENTA...
Page 93 The electrical regulator, rectifiers, power steering units, bellows and mechanical parts (bearings) may be damaged and lead to serious consequential damage. NOTICE! If the generator is exposed to water, it must be dried; see drying. 47708097 09-2023 © AB VOLVO PENTA...
Page 94 Drying the alternator • Blow the water away from the alternator using compressed air. • Check that the alternator charges. 47708097 09-2023 © AB VOLVO PENTA...
Page 95 Pump out the bilge water and dry off the space in the engine compartment. Ensure good ventilation during winter storage to prevent the formation of mold/ corrosion. P0026751 47708097 09-2023 © AB VOLVO PENTA...
Page 96 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 97 • 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. 47708097 09-2023 © AB VOLVO PENTA...
Page 98 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 47708097 09-2023 © AB VOLVO PENTA...
Page 99 Lubrication System........... 42 Maintenance Schedule..........34 Oil filter, Replace............45 Other Special Equipment......... 25 Painting the Drive............. 85 Preventive repair ............. 14 Propeller..............82 Reversing gear............70 Reversing gear, oil and filter change......70 47708097 09-2023 © AB VOLVO PENTA...
Page 102 AB Volvo Penta SE-405 08 Göteborg, Sweden www.volvopenta.com...

Volvo Penta D3 Service And Maintenance Manual

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