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Summary of Contents for Volvo Penta D5A T
- Page 1 Workshop Manual Technical Data 2(0) D5A T, D5A TA D7A T, D7A TA, D7C TA...
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Page 3: Table Of Contents
Technical data Marine engines D5A T, D5A TA, D7A T, D7A TA, D7C TA Contents Safety information ..........2 General information ..........5 Repair instructions ..........6 Technical data ............9 General ..............9 Cylinder head ............10 Cylinder liners ............10 Cylinder head gasket .......... -
Page 4: Safety Information
This workshop manual contains technical data, de- on the product are always visible. Replace any scriptions and repair instructions for the Volvo Penta stickers that have been damaged or painted products or product variants listed in the table of con- over. - Page 5 Safety information Avoid skin contact with oil. Long-term or repea- Batteries should never be exposed to an open ted skin contact with oil can lead to the skin lo- flame or electric spark. Never smoke near the sing its natural oils, resulting in irritation, drying, batteries.
- Page 6 Components in the electrical, ignition (gasoline engines) and fuel systems of Volvo Penta pro- ducts are designed and manufactured to minimi- ze the risk of explosion and fire. The engine should not be used in explosive environments.
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Page 7: General Information
D5A T, D5A TA, D7A T, D7A TA and D7C TA. binds itself to ensure that both new engines and those in use meet the environmental requirements. The... -
Page 8: Repair Instructions
(see “Safety Information” for meaning) hered to, that systems that are adjustable are kept correctly set and that Volvo Penta Original Parts are WARNING! used for the engine. The times specified in the main- tenance schedule for the engine must be followed. - Page 9 Safety information Torque-tightening angle Sealants With torque-tightening angle, the screw fixing is tight- Several different types of sealant and locking com- ened to a specified torque and then turned further pound are used in the engine. The products have dif- through a specified angle.
- Page 10 Safety information Safety instructions for fluorocarbon rubber Always use neoprene gloves (gloves for handling Fluorocarbon rubber is a common material, for example ● chemicals) and goggles. in axle sealing rings and O-rings. Handle a seal that has been removed in the same When fluorocarbon rubber is subjected to high tempera- ●...
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Page 11: Technical Data
Technical data Technical data General Engine model D5A T D5A TA D7A T D7A TA D7C TA Direction of rotation, seen from flywheel end ......Counter- Counter- Counter- Counter- Counter- clockwise clockwise clockwise clockwise clockwise Number of cylinders ........4 Cylinder diameter, mm (in.) ...... -
Page 12: Cylinder Head
Technical data Cylinder head Type ............Common cylinder head for all cylinders. Max. permitted deviation from flat (bottom face), mm (in.) D5 .............. 0.085 (0.0033) D7 .............. 0.125 (0.0049) Cylinder head bolts Thread size ..........M14 Quantity x length, mm (in.) D5 .............. -
Page 13: Cylinder Head Gasket
Technical data Cylinder head gasket Measuring piston height over the face of the cylinder block A dial gauge with a fixture (special tool 999 8678) is required for this measure- ment. The piston is above the face of the cylinder block, at top dead center. •... -
Page 14: Crank Mechanism
Technical data Crankshaft Crank mechanism Crankshaft, length ........973.2 mm (38.31”) Crankshaft, axial play 0.1 – 0.3 mm (0.004 – 0.012”) Main bearings, radial play ....0.03 – 0.092 mm (0.0012 – 0.0036”) Max. permitted ovality of crankshaft journals and big-end journals ......0.01 mm (0.0004”) Max. - Page 15 Technical data Big-end bearing journals Diameter for machining (G), -0.02 standard ............. 68 -0.0008” (2.68” Undersize: 0.25 mm (0.0098”) ......... 67.75 -0.02 -0.0008” (2.6673” -0.02 0.5 mm (0.02”) ........67.5 (2.6575” -0.0008” Width of axial journal (H) ......35.5 ±0.02 ±0.0008”...
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Page 16: Connecting Rods
Technical data Connecting rods ±0.06 Length, center to center (L) ..... 210 (8.27” ±0.0024” Inside diameter of connecting rod bushing, Ø (M) ........ 42.04 +0.01 +0.0004” (1.655” Wear ..........0.08 mm (0.003”) When changing a bushing: +0.02 diameter of hole in connecting rod, Ø ..45.5 (1.79”... -
Page 17: Pistons
Technical data Pistons Number of piston ring grooves ......... 3 Combustion chambers: Diameter Ø ..........71 ±0.1 ±0.004” (2.79” ±0.1 Depth ............. 16.66 ±0.004” (0.656” Diameter Ø of gudgeon pin ......42 -0.006 (1.65” -0.0002” Piston marking Fit the pistons as shown in the diagram. The crank- shaft symbol should by facing towards the flywheel. -
Page 18: Camshaft
Technical data Camshaft Camshaft type ............A Drive, timing gears ........Gear wheel Number of bearings D5 ................. 5 D7 ................. 7 Camshaft bearings, diameter, Ø: +0.054 Standard: ..........65 +0.00213” (2.56” Wear tolerance: .......... 65.08 mm (2.5622”) +0.012 Camshaft bearings, thickness ..... 1.988 (0.07827”... -
Page 19: Valve Mechanism
Technical data Valve mechanism Valves Stem diameter Ø (A): -0.015 Inlet ............. 8.98 -0.0006” (0.3535” -0.015 Exhaust ..........8.96 (0.3527” -0.0006” Edge of valve head (B): Inlet, min............ 2.1 mm (0.08”) Exhaust, min..........1.8 mm (0.07”) Valve head diameter Ø (C): ±0.1 Inlet ............ - Page 20 Technical data Valve seats Width of valve seat: Inlet ........... 2.8 mm (0.11”) Ø A Exhaust ..........2.2 mm (0.09”) Outside diameter Ø (A): -0.02 Inlet ............ 49.09 -0.0008” (1.933” -0.02 Exhaust ..........43.06 (1.695” -0.0008” Height (B): ±0.1 Inlet ............7.5 (0.29”...
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Page 21: Lubrication System
Technical data Lubrication system Grade of oil Sulfur content of fuel (percentage by weight) Up to 0.5 % 0.5 – 1.0 % over 1.0 % Oil change intervals: Whichever comes first VDS–2 ACEA: E3-96, E4-99, E5-99 500 hrs or 12 months 250 hrs or 12 months 125 hrs or 12 months API: CF, CF–4... -
Page 22: Oil Capacity
D7 ..........80 kPa (11.6 psi) Oil pressure at running temperature for the oil (min. 248°F (120° C)): D5A T ........440 kPa (63.8 psi) D5A TA ........390 kPa (56.6 psi) D7A T ........450 kPa (65.3 psi) D7A TA ........350 kPa (50.7 psi) D7C TA ........ -
Page 23: Fuel Specification
Technical data Fuel specification The fuel must conform to national and international standards for commercial fuel, for example: EN 590 with environmental and low temperature specifications meeting national regulations. ASTM D 975 Nos. 1-D and 2-D JIS KK 2204 Sulfur content: In line with current legislation in the particular country. NOTE! Fuel with an extremely low sulfur content (for example Citydiesel in Sweden and Finland) can cause a loss of power of approximately 5% and lead to an increase in fuel consumption of approximately 2-3%. -
Page 24: Cooling System
The mixture specified below also provides complete corrosion protection. Seawater cooling A mixture of at least 40% Volvo Penta antifreeze (gly- col) and water (to ASTM D4985 specification) should be used. The mixture protects against damage due to freezing down to approximately -40°F (-40°C), and... -
Page 25: Injector Pumps
Technical data Injector pumps Manufacturer ........... Bosch Model ............PF 33 L Measurement A: ......... 54 mm (2.13”) Measurement L ........ 143 mm (5.63”) Min. length L : (A/100+143)-143 mm ... >0 mm Opening pressure: ...... 27.5 MPa (3988 psi) Maximum pressure: D5 ........... -
Page 26: Determining Shim Thickness When Changing An Injector Pump
, is obtained from table 2. S NOTE! This formula is applicable when changing JUST an injector pump. Calculation 1 Explanation Factor D5A T, D5A TA, D7A T, D7A TA, D7C TA Cylinder no.: XXX Cyl: 1 Cyl: 2 Cyl: 3... -
Page 27: Determining Shim Thickness For When An Injector Valve Should Open
NOTE! After determining shim thickness, a new EP code MUST ALWAYS be produced using “Calculation 3,” so that any later pump changes will be done correctly. Calculation 2.1 Explanation Factor D5A T, D5A TA, D7A T, D7A TA, D7C TA Cylinder no.: XXX Cyl: 1 Cyl: 2 Cyl: 3... -
Page 28: Determining The Corrected Fitting Measurement
→ → → → → EP code The new EP code is obtained from table 3.2 E Calculation 3.1 Explanation Factor D5A T, D5A TA, D7A T, D7A TA, D7C TA Cylinder no.: XXX Cyl: 1 Cyl: 2 Cyl: 3... - Page 29 Technical data Table 2 Shim thickness Theoretical thickness Shim thickness Theoretical thickness ”T ” (mm) ”T ” (mm) ”S ” (mm) ”S ” (mm) 0,95–1.049 3,05–3,149 1,05–1,149 3,15–3,249 1,15–1,249 3,25–3,349 1,25–1,349 3,35–3,449 1,35–1,449 3,45–3,549 1,45–1,549 3,55–3,649 1,55–1,649 3,65–3,749 1,65–1,749 3,75–3,850 1,75–1,849 3,85–3,949 1,85–1,949...
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Page 30: Regulator
Technical data Regulator The engine speed regulator is a mechanical, variable-speed model with centrifugal weights. NOTE! The regulator is specially installed for every engine. This means that the regulator can not be swapped between engines. An incorrectly set regulator can lead to the engine not meeting the specified emission and per- formance requirements. -
Page 31: Inlet And Exhaust Systems
Permitted axial play, max.: ......0.14 mm (0.0055”) Exhaust back pressure, max.: ...... 7.5 kPa (1.09 psi) Turbo pressure Exhaust temperature °C °F D5A T, Rating 1 1,900 rpm ..........93 13.4 2,300 rpm ..........129 18.7 D5A T, Rating 2 1,900 rpm ..........115 16.7 2,300 rpm .......... -
Page 32: Tightening Torque
Technical data Tightening torque General tightening torques (lbf.ft.) M6: Standard bolt, type 8.8 ........10 ±1.5 ±1.1 M8: Standard bolt, type 8.8 ........25 ±4 ±3 ±8 ±6 M10: Standard bolt, type 8.8 ........50 ±9 ±7 M12: Standard bolt, type 8.8 ........80 M14: Standard bolt, type 8.8 ........ - Page 33 (37) Stage 2: ............130 (96) Stage 3: ............90° angle tightening Tightening sequence for cylinder head bolts D5A T / D5A TA D7A T / D7A TA / D7C TA Group 22: Lubrication system ±2 ±1 Oil cooler, fixing bolts ..........21 Oil cooler, banjo bolt Stage 1: ..............
- Page 34 Technical data Tightening torque (lbf.ft.) Group 23: Fuel system Bolt, regulator, intermediate gear ...... 21 (15) ±2 ±1 Bolt, control rod sleeve ........10 ±1.5 ±1.1 Bolt, engine speed regulator ......17 Flange bolt, injector pump Stage 1: Initial tightening ........5 Stage 2: ..............
- Page 35 Technical data Tightening torque (lbf.ft.) Group 26: Cooling system Thermostat housing ..........42 (31) ±2 ±1 Thermostat holder ..........21 ±2 ±1 Level switch, coolant ..........25 Coolant housing ............. 21 ±2 ±1 ±2 ±1 Pulley, coolant pump ..........21 Coolant pipe, T-piece to engine body .....
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Page 36: References To Service Bulletins
References to service bulletins Group Date Subject .......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - Page 37 Notes Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
- Page 38 Notes Notes ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
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Page 39: Report Form
From: ....................................................................Refers to publication: ............................. Publication no: ............... Date of issue: ..............Suggestion/Motivation: ..................................................................................................................................................................................................................................................................................................................Date: ..............Name: .............. AB Volvo Penta Customer Support Dept. 42200 SE-405 08 Göteborg Sweden...
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