Work Shop Manual Group 20-26 - D13 PDF

Workshop Manual E
Group 20-26 2(0)
D13
Table of Content
General Information
00-0 General ............................................................................................. 3
Specifications
03-2 Specifications, Engine .................................................................... 9
03-21 Engine ....................................................................................... 32
03-22 Lubrication System ................................................................. 44
03-23 Fuel System .............................................................................. 46
03-25 Inlet and Exhaust System ....................................................... 47
03-26 Cooling System ........................................................................ 48
03-3 Specifications, Electrical .............................................................. 50
Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 53
Special tools
08-2 Special Service Tools ................................................................... 57
Chemical Products
18-0 General ........................................................................................... 65
General
20-0 Engine Information, General ........................................................ 66
Troubleshooting ................................................................................. 66
Test and Adjustments ....................................................................... 70
Engine
21-0 Engine Complete, General ........................................................... 76
Exposing the Engine ......................................................................... 76
Fitting the Fixture ............................................................................... 89
Engine Disassembly .......................................................................... 95
Engine Assembly ............................................................................. 110
21-1 Cylinder Head .............................................................................. 159
21-3 Cylinder Liner, Pistons ............................................................... 186
21-4 Valve Mechanism ........................................................................ 188
21-5 Timing Gears and Shaft .............................................................. 206
21-6 Crank Mechanism ....................................................................... 211
Lubricating and Oil System

22-1 Oil pump and Line ....................................................................... 228
22-2 Oil filter ........................................................................................ 231
22-3 Oil cooler ..................................................................................... 244
Fuel System
23-0 Fuel System, General ................................................................. 245
23-3 Fuel Feed Pump and Filter ......................................................... 250
23-7 Injectors and Delivery Pipes ...................................................... 260
Inlet and Exhaust System

25-1 Inlet and Exhaust Manifolds ...................................................... 273
25-5 Turbo and supercharger ............................................................ 298
25-6 Air Cleaner, Throttle Housing .................................................... 328
Cooling System
47701522 01-2016 © AB VOLVO PENTA 1

26-0 Cooling System, General ........................................................... 329
26-1 Radiator, Heat Exchanger .......................................................... 335
26-2 Coolant Pump, Thermostat ........................................................ 350
26-5 Charge Air Cooler with Connections ........................................ 362
26-6 Sea Water System, Sea Water Pump ........................................ 380
Alternator, Charge Regulator

32-1 Alternator ..................................................................................... 394
Starting System
33-1 Starter Motor ............................................................................... 397
Other Electrical Equipment

36-6 Monitoring and Control Systems .............................................. 400
Cables and fuses

37-1 Cables .......................................................................................... 406
Index ......................................................................................................... 417
References to Service Bulletins ............................................................ 419
2 47701522 01-2016 © AB VOLVO PENTA

00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, When carrying out service and repair on
descriptions and maintenance and repair instructions emission-certified engines, it is important to be
for standard model Volvo Penta products. A list of aware of the following:
these products may be found in the section
Specifications. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all the certified engine.
correspondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified • Maintenance and service intervals
personnel. It is assumed that any person using the recommended by Volvo Penta must be
Service Manual has a fundamental knowledge of the complied with.
product and is able to carry out mechanical and • Only spare parts approved by Volvo Penta may
electrical work to trade standard. be used.
Volvo Penta continually develops its products; we • Service on injection pumps, pump settings and
therefore reserve the right to make changes. All injectors must always be carried out by an
information in this manual is based on product data authorized Volvo Penta workshop.
which was available up to the date on which the
• The engine must not be converted or modified,
manual was printed. New working methods and
except with accessories and service kits which
significant changes introduced to the product after
Volvo Penta has approved for the engine.
this date are communicated in the form of Service
bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the
Spare parts for the electrical and fuel systems are product) may be broken by unauthorized
subject to various national safety standards. Volvo persons.
Penta Original Spare Parts meet these standards. No
damage of any kind caused by the use of spare parts The general instructions in the Operator's Manual
not approved by Volvo Penta will be compensated by concerning operation, service and maintenance
any warranty undertaking. apply.
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.
47701522 01-2016 © AB VOLVO PENTA 3

00-0 General
Repair instructions
Introduction Our mutual responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the
mounted in a holding fixture. Maintenance work is technical specification may dramatically increase the
often carried out on site, in which case – if nothing environmental impact of an otherwise reliable
else is indicated – using the same working methods system. It is therefore critical that the stated wear
as the workshop. tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only 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 . maintenance schedule must be followed.
! DANGER! Some systems, e.g. fuel systems, often require
special expertise and test equipment. A number of
! WARNING! components are factory-sealed, for among other
things environmental reasons. Warranty-sealed
! CAUTION!
components may not be worked on without
authorization to perform such work.
IMPORTANT!, NOTICE!
are by no means comprehensive since not everything Remember that most chemical products, incorrectly
can be foreseen as service work is carried out in the used, are harmful to the environment. Volvo Penta
most varied of circumstances. We call attention to recommends the use of biodegradable degreasers
risks that may occur due to incorrect handling during whenever components are cleaned, unless otherwise
work in a well-equipped workshop using working specified in the Service Manual. When working
methods and tools tried and tested by us. outdoors, take especial care to ensure that oils and
wash residues etc. are correctly properly for
The service manual describes work operations
destruction.
carried out with the aid of Volvo Penta Special Tools,
where such have been developed. Volvo Penta
Special Tools are designed to ensure the safest and
Tightening torques
most rational working methods possible. It is Tightening torques for vital fasteners that must be
therefore the responsibility of anyone using tools or applied using a torque wrench are indicated in the
working methods other than those we recommend to Service Manual, chapter Tightening torques and in
ensure that no risk of personal injury or mechanical the Manual's work descriptions. All torque indications
damage is present, or that malfunction can result. apply to clean threads, bolt heads and mating faces.
Indicated torque data apply to lightly-oiled or dry
In some cases, special safety regulations and user threads. If lubricants, locking fluids or sealants are
instructions may be in force for the tools and required for fasteners, the correct type will be noted
chemicals mentioned in the Service Manual. These in the job description.
regulations must always be followed, and no special
instructions regarding this are to be found in the
Torque, angle tightening
Service Manual.
When torque/angle tightening, the fastener is
By taking these basic precautions and using common tightened to a specified torque, and tightening then
sense it will be possible to guard against most continues through a pre-determined angle.
elements of risk. A clean workplace and a clean
product will eliminate many risks of personal injury Example: For 90° angle tightening, the fastener is
and malfunction. turned a further 1/4 turn in one sequence, after the
specified tightening torque has been achieved.
Above all, when working on fuel systems, hydraulic
systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.
4 47701522 01-2016 © AB VOLVO PENTA

00-0 General
Lock nuts Anaerobic agents.

These agents cure (harden) in the absence of air.
Removed locknuts may not be re-used; they must be These preparations are used when two solid
replaced by new ones, as locking properties are components, e.g. two cast components, are fitted
impaired or lost with re-use. together without a gasket. Common uses are also to
In the case of lock nuts with plastic inserts the lock and seal plugs, stud threads, taps, oil pressure
tightening torque indicated must be reduced if the nut monitors etc.
has the same nut height as a standard, all-metal
hexagonal nut. Hardened anaerobic preparations are glassy and for
Reduce the torque by 25% for bolt sizes of 8 mm or this reason, the preparations are colored to make
larger. them visible. Hardened anaerobic preparations are
In the case of lock nuts with plastic inserts with a high highly resistant to solvents, and old compound
nut-height (where the all-metal thread is as high as a cannot be removed. On re-assembly, it is important
standard hexagonal nut), the indicated torque to carefully degrease and wipe dry components first,
applies. before applying new sealant in accordance with the
instructions.
Strength classes
Safety regulations for fluorocarbon
Nuts and bolts are subdivided into different strength
classes. The classification is shown by a marking on rubber
the bolt head. Markings of a higher number indicate Fluorocarbon rubber is a common material in sealing
stronger material. For example, a bolt marked 10-9 is rings for shafts, and in O-rings, for example.
stronger than one marked 8-8.
When fluorocarbon rubber is exposed to high
For this reason, it is important that when bolts are temperatures (above 300°C/572°F), hydrofluoric acid
removed they are returned to their original locations can form. This is highly corrosive. Contact with the
on re-assembly. When replacing bolts check the skin can result in severe chemical burns. Splashes in
applicable Spare parts catalogue to ensure the your eyes can result in chemical wounds. If you
correct bolt is used. breathe in the fumes, your lungs can be permanently
damaged.
Sealing compounds etc.
To ensure service work is correctly carried out it is WARNING!
important that the correct type of sealants and locking Seals must never be cut with a torch, or be burnt
fluids are used on joints where such are required. afterwards in an uncontrolled manner. Risk for
poisonous gases.
In each service manual section concerned, the
sealants used in product manufacture are indicated.
The same sealants, or sealants with equivalent WARNING!
properties, must be used for maintenance work. Always use chloroprene rubber gloves (gloves for
chemicals handling) and goggles. Handle the
Make sure that mating surfaces are dry and free from removed seal in the same way as corrosive acid. All
oil, grease, paint and anti-corrosion agent before residue, including ash, can be highly corrosive. Never
applying sealant or locking fluid. Always follow the use compressed air to blow clean.
manufacturer's instructions regarding applicable Put the remains in a plastic container, seal it and
temperatures, hardening times and such. apply a warning label. Wash the gloves under running
water before removing them.
Two basic types of compound are used:
The following seals are most probably made from
RTV preparations (Room Temperature fluorocarbon rubber:
Vulcanizing).
Used most often together with gaskets, e.g. sealing Seal rings for the crankshaft, camshaft, idler shafts.
gasket joints, or are brushed on gaskets. RTV
sealants are completely visible when the part has O-rings, regardless of where they are installed. O-
been removed. Old RTV sealant must be removed rings for cylinder liner sealing are almost always
before the component is sealed again. Use made of fluorocarbon rubber.
denatured alcohol. Please note that seals which have not been
exposed to high temperature can be handled
normally.
47701522 01-2016 © AB VOLVO PENTA 5

00-0 General
Illustrations
A lot of illustrations contains standardized symbols and colors. Please refer to the following information to reduce
misunderstandings when working on an engine / transmission using this Workshop Manual.
Illustration colors Position

Most illustrations have a focused component (blue)
which is fastened by a (red) bolt or such on a (light
grey) engine / transmission body.
P0015623
Focus arrows pointing at object. Sometimes it

contains number of items, e.g. three bolts.
When this symbol is used on a series of bolts it is
expected that the service technician tighten the bolts
in a logical sequence.
NOTICE! If an arrow with the text “x3” is pointing at

P0015699 only one item, e.g. a bolt, it still applies to the other
1 Focus two alike items (the two other bolts) highlighted in the
(blue) illustration.
2 Fastenings
(red)
3 Body
(light grey) P0015627
4 Background This symbol gives a positioning number to an object,

(white) e.g. 2, which is also mentioned in the supplied text
information.
P0015628
The symbol in the top left shows part no. of the

positioned special tool, e.g. 9991801.
The lower symbol is used when something needs to
be replaced by a new part / kit.
The symbol on the right side is used when a part
needs to be discarded.
6 47701522 01-2016 © AB VOLVO PENTA

00-0 General
Movement Tools
P0015622
Movement arrows are used to show which direction a P0015629
component is to be moved / rotated.

One of the following symbols is used when describing
the recommended type of screwdriver.
P0015625
Symbol is used in a corner of the illustration to show

how many degrees the object shall be turned and at
which direction.
P0015630
A symbol of a tool in a corner of the illustration is

shown when the tool is recommended to use, e.g. a
knife or a crowbar.
P0015626
Symbol is used to show how many revolutions the

object shall be turned and at which direction.
Measurements
P0015631
A drill in a specified size, duck tape and stripes may

also be shown as symbols.
P0022436
The symbols are used to show different types of

measurements.
Clearance is shown in this feeler gauge symbol.
This dial indicator symbol shows a MIN value.
47701522 01-2016 © AB VOLVO PENTA 7

00-0 General
Chemicals Units
P0015695
P0015696
Symbols can also describe when and how a chemical

Units are mentioned in the illustration when a specific
product is to be used.
value (e.g. pressure, weight or resistance etc.) is
expected.
Cleanliness
Important
P0015624
The scraper symbol suggests that a contact surface P0015005

needs to be scraped from sealant etc.
The cloth symbol suggests that the mechanic should The eye symbol is used when something needs close
clean the contact surface thoroughly or be prepared inspection or must be performed in a certain way.
for some oil spill or similar. The symbol to the right is used when several
mechanics are needed.
Sealant
Safety
P0015698
P0015697
The tube symbol shows how thick layer of sealant to
applicate. These symbols are used when a certain safety related
The clock symbol is used when something needs to equipment is needed.
be done within or after a certain time.
8 47701522 01-2016 © AB VOLVO PENTA

03-2 Specifications, Engine

General Tightening Torques
General Tightening Torques
M6 10 Nm (7.4 lbf ft)
M8 24 Nm (17.7 lbf ft)
M10 48 Nm (35.4 lbf ft)
M12 85 Nm (62.7 lbf ft)
M14 140 Nm (103.3 lbf ft)
M16 220 Nm (162.3 lbf ft)
IMPORTANT!
Check bolts which are to be re-installed. Damaged bolts,
e.g. with shear marks under heads must be scrapped.
47701522 01-2016 © AB VOLVO PENTA 9

Special Tightening Torques
Group 21: Engine

7
5
5
7
4
5
2
1
4
3
1 2
6
3
6
6
6
P0012265
Front engine mounts, cylinder block

Stage 1: Tighten bolt 1 80 ± 15 Nm (62.69 ± 11.06 lbf ft)
Step 2: Tighten the bolts 2–4 105 ± 15 Nm (77.44 ± 11.06 lbf ft)
Stage 3: Angle tighten the bolts 2–4 in sequence 60° ± 5°
Stage 4: Tighten bolt 1 105 ± 15 Nm (77.44 ± 11.06 lbf ft)
Stage 5: Angle tighten bolt 1 60° ± 5°
Stage 6: Tighten the bolts 5 70 ± 5 Nm (51.63 ± 3.69 lbf ft)
Tighten the inverted engine bolts 6 275 ± 45 Nm (202.83 ± 33.19 lbf ft)
Tighten nut 7 300 Nm (221.27 lbf ft)
Main bearing caps

Stage 1 150 ± 20 Nm (110.6 ± 14.75 lbf ft)
Stage 2 (angle tightening) 120° ± 5°
Big end bearing cap
Stage 1 20 ± 3 Nm (14.75 ± 2.21 lbf ft)
Stage 2 60 ± 3 Nm (44.25 ± 2.21 lbf ft)
10 47701522 01-2016 © AB VOLVO PENTA

Frame reinforcement
24 22 19 18 15 14 11 10 7 6 3 2
23 21 20 17 16 13 12 9 8 5 4 1
P0005220
NOTICE! Tighten the bolts in sequence, as illustrated.

The bolts may not be reused.
Frame reinforcement
stage 1: Tighten the bolts 1–24 in sequence 45 ± 5 Nm (33.2 ± 3.69 lbf ft)
stage 2: Tighten the bolts 1–24 in sequence (angle
tightening) 60° ± 5°
Timing plate
26 27 28 29
24
25
22
21 23
16
20
19
18
17
15
1 2
4 10
5 11
6 3
12
7
8 13
P0005221
9 14
P0005222
NOTICE! Run an approx. 2 mm (0.0787 in) silicone bead

outside the groove as illustrated above, max 20 min before
installation.
Timing plate
Tighten all bolts in sequence to the following torque: 28 ± 4 Nm (20.65 ± 2.95 lbf ft)
47701522 01-2016 © AB VOLVO PENTA 11

Timing gear wheels
5 1
3 8
7 4
4
2 6
3
3 1
6
5 4
2
3
5
1
7 2
6
5 4 2
1
P0012311
1 Drive gear, crankshaft 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

2 Idler wheel, bull gear outer:
Stage 1 25 ± 3 Nm (18.44 ± 2.21 lbf ft)
NOTICE! Tighten in the sequence illustrated.
3 Intermediate gear, adjustable:

Stage 1 35 ± 4 Nm (25.81 ± 2.95 lbf ft)
4 Drive gear, camshaft (incl. vibration damper):

Stage 1 45 ± 5 Nm (33.19 ± 3.69 lbf ft)
5 Intermediate gear 140 ± 10 Nm (103.3 ± 7.38 lbf ft)

6 Drive gear, power steering and fuel feed pump 100 ± 10 Nm (73.76 ± 7.38 lbf ft)
7 Seawater pump 200 Nm (147.51 lbf ft)
12 47701522 01-2016 © AB VOLVO PENTA

Flywheel and timing cover

10 11
8 9
6 7
2 3
4 5
P0005224
P0005225
NOTICE! Run an approx. 2 mm (0.0787 in) silicone bead as

illustrated above, max 20 min before installation.
Flywheel housing
Tighten all bolts in sequence to the following torque:
M14 bolts 140 ± 20 Nm (103.3 ± 14.75lbf ft)
M10 bolts 48 ± 8 Nm (35.4 ± 5.9 lbf ft)
M8 bolts 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
47701522 01-2016 © AB VOLVO PENTA 13

Timing Gear Cover, Upper
P0005226
4
5
2 1
P0005290
P0005227
3

in the illustrations, max 20 min before installation.
Tighten the contact surfaces carefully.
Install the cover in two stages:

stage 1: Fasten the cover with bolts 1 and 2. Use the
special tool to press the cover into position 4 ± 1 Nm (2.95 ± 0.738 lbf ft)
stage 2: Tighten the bolts in sequence, as illustrated 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
14 47701522 01-2016 © AB VOLVO PENTA

Flywheel
6 8
10
4 12
2 14
13 1
11 3
9 5
7
P0005228
Flywheel
stage 2: (angle tightening) 120° ± 10°
NOTICE! Carefully check that the flange is clean and dry.

Tighten the bolts in sequence, as illustrated.
Cover, crankshaft seal
4 5
6
3
2 7
1 8
P0005229 P0005230

illustrated above, max 20 min before installation.
Cover, crankshaft seal:
stage 1: Fasten the cover with bolts 2 and 7 and tighten
until it makes contact
stage 2: Tighten the bolts 2 and 7 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
stage 3: Tighten the bolts in the sequence 1, 3–6, 8 as
illustrated. 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
47701522 01-2016 © AB VOLVO PENTA 15

Vibration damper, crankshaft

1
10
3
8
5
7
4
9
P0005231 2
Vibration damper:
NOTICE! The vibration damper 8.8 bolts may not be re-
used.
Cylinder head
36 35 28 27 22 21 15 16 23 24 31 32
13 9 6 1 3 7 11
14 10 4 2 5 8 12
38 37 30 29 18 17 19 20 25 26 33 34
P0005232
NOTICE! The cylinder head must be installed according to

the “Installation” section in Cylinder Head,
Change, page 159.
Cylinder head
stage 2 (angle tightening) 120° ± 5°
16 47701522 01-2016 © AB VOLVO PENTA

Bearing caps, camshaft/rocker arm shaft
1 2 3 4 5 6 7
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
1 6
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
2 7
1 2 3 4 5 6 7
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
3 8
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
4 9
14/8 15/9 16/10 17/11 18/12 19/13 20 14/8 15/9 16/10 17/11 18/12 19/13 20
5 10
P0005233
Camshaft: (camshaft and bearing caps in place)

stage 1: Tighten bolts 1–7 40 ± 3 Nm (29.50 ± 2.21 lbf ft)
stage 2: (with shorter extra bolts); tighten bolts 8–13 and
20 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
stage 3: Angle tighten screws 1–7 90° ± 5°
stage 4: Remove the extra bolts 8–13 and 20
Rocker arm shaft: (rocker arm shaft in place)

stage 5: Tighten bolts 8–13 and 20 in stages in the
sequence 11, 10, 12, 9, 13, 8, 20 60 ± 5 Nm (44.25 ± 3.69 lbf ft)
stage 7: Angle tighten bolts 14–19 120° ± 5°
stage 8: Undo bolts 8–13
stage 10: Angle tighten bolts 8–13 and 20 120° ± 5°
47701522 01-2016 © AB VOLVO PENTA 17

Valve adjustment
P0012312
Locking nut, unit injector (1), injector adjuster screw 52 ± 4 Nm (38.35 ± 2.95 lbf ft)
Locking nut (2), valve adjuster screw: 38 ± 4 Nm (28.03 ± 2.95 lbf ft)
Valve Cover
17
13 12 11 10 1 15 16 18
19
14
9 8 7 6 2 3 4 5 20
p0005236
Valve Cover
Tighten the bolts in sequence, as illustrated 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
18 47701522 01-2016 © AB VOLVO PENTA

Group 22: Lubrication System

Oil sump
3 A 1
4 B 2
P0012321
Oil sump (material: plastic)

Fasten the oil sump with bolts A and B and torque them
to 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
Tighten the bolts outwards from the center in the
sequence 1–4 as illustrated above 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
Finish off by checking the torque of bolts A and B 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
47701522 01-2016 © AB VOLVO PENTA 19

Oil cooler
1 3
4 2
P0005238
NOTICE! Tighten the bolts diagonally and finish off by

tightening the first bolts again.
Oil cooler, attachment bolts 27 ± 4 Nm (19.91 ± 2.95 lbf ft)
A C B
2 3
4 1
D
p0005239
Oil cooler cover

Install the cover on the engine block and fasten bolt A in the
oval hole.
Press the cover toward the water pump housing with an
installation tool and install bolt B.
Check that the cover is in position; refer to the service
instruction.
Install bolts C and D and torque them 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
Tighten the cover bolts outwards from the center in the
sequence 1–4 as illustrated above 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
Finish off by checking the torque of bolts C and D 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
20 47701522 01-2016 © AB VOLVO PENTA

4
3
P0012322
Oil filter housing (with charge air cooler)

Thermostat valve or pressure valve, oil cooler, bolt (1) M6 standard bolt torque
Safety valve, oil pressure, plug (2) 50 ± 5 Nm (36.88 ± 3.69 lbf ft)
Nipple (3) 55 ± 5 Nm (40.57 ± 3.69 lbf ft)
Plug (4) 24 ± 4 Nm (17.70 ± 2.95 lbf ft)
P0012323
Oil filter housing (above heat exchanger)

Overflow valve, oil filter, plug (1) 55 ± 5 Nm (40.57 ± 3.69 lbf ft)
47701522 01-2016 © AB VOLVO PENTA 21

Group 23: Fuel System

Unit injector
p0005241
Yoke, unit injector

First tightening (only when replacing copper sleeve):
stage 1 20 + 5 / – 0 Nm (14.75 + 3.69 / – 0 lbf ft)
NOTICE! Loosen the yoke bolt before the second

tightening.
Second tightening:
stage 1 20 + 5 / – 0 Nm (14.75 + 3.69 / – 0 lbf ft)
22 47701522 01-2016 © AB VOLVO PENTA

P0012337
Bolts (1) for adapter incl. fuel pump 24 ± 2 Nm (17.7 ± 1.48 lbf ft)
P0012338
Bolts (1) for fuel pump (installed on adapter) 8 + 2 / – 0 Nm (5.90 + 1.48 / – 0 lbf ft)
47701522 01-2016 © AB VOLVO PENTA 23

Bypass valve / fuel line brackets
A
H
H
F F
H C
H
F
D D
D D
B
F B B
B
H
P0012340
Fuel line brackets, tightening torques:

A 18 ± 3 Nm (13.28 ± 2.21 lbf ft)
B 20 ± 3 Nm (14.75 ± 2.21 lbf ft)
(C) Brackets 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
[standard torque]
D 26 ± 3 Nm (19.18 ± 2.21 lbf ft)
E 30 ± 4 Nm (22.13 ± 2.95 lbf ft)
F 35 ± 5 Nm (25.81 ± 3.69 lbf ft)
G 40 ± 5 Nm (29.50 ± 3.69 lbf ft)
H 48 ± 5 Nm (35.40 ± 3.69 lbf ft)
24 47701522 01-2016 © AB VOLVO PENTA

Group 25: Inlet and Exhaust System

Intake Manifold
11 10 2 3 6 7
P0012341 12 9 1 4 5 8
Intake Manifold
Torque the bolts 24 ± 4 Nm (17.7 ± 2.95 lbf ft)
M10 plug, inlet manifold 20 ± 3 Nm (14.75 ± 2.21 lbf ft)
47701522 01-2016 © AB VOLVO PENTA 25

Exhaust Manifold
1 3 5 7 9 11
2 4 6 8 10 12
P0012342
Exhaust Manifold with Turbo Valve Housing (only D13B-A/H and inboard engine D13B-C/L, D13C4-A)
Stage 1:
Tighten all the bolts until they make contact (5 ± 1.5 Nm) [3.69 ± 1.11 lbf ft]
Stage 2:
Torque bolts 5, 8 and 6, 7 50 ± 4 Nm (36.9 ± 2.95 lbf ft)
Torque bolts 1, 4 and 9, 12 10 ± 1.5 Nm (7.38 ± 1.11 lbf ft)
Stage 3:
Torque bolts 10 and 11 48 ± 4 Nm (35.4 ± 2.95 lbf ft)
Exhaust Manifold (only D13B-B/D/E/F/G/J/K/M/N, D13C1-A, D13C2-A, D13C3-A and IPS engine D13B-C/L,
D13C4-A)
Stage 1:
Tighten all the bolts until they make contact (5 ± 1.5 Nm) [3.69 ± 1.11 lbf ft]
Stage 2:
Torque bolts 1, 4 and 5, 8 and 9, 12 10 ± 1.5 Nm (7.38 ± 1.11 lbf ft)
Stage 3:
26 47701522 01-2016 © AB VOLVO PENTA

Turbo
Turbo – Wastegate valve (only D13B-A/C/G/H/K/L,
D13C2-A, D13C4 twin turbo)
Tighten the bolts (1) and

nuts (2) 60 Nm (44.3 lbf ft)
P0018807
Low pressure turbo (only D13B-A/C/G/H/K/L, D13C2-

A, D13C4 twin turbo)
Stage 1:
Tighten the nuts in the
sequence illustrated 15 Nm (11.1 lbf ft)
Stage 2:
P0018808
High pressure turbo (all engines)
Stage 1:
Stage 2:
P0018809
47701522 01-2016 © AB VOLVO PENTA 27

Clamps (1), Y-pipe – Wastegate valve (only D13B-A/

C/G/H/K/L, D13C2-A, D13C4 twin turbo)
Tighten the nuts 20 Nm (14.8 ±2.95 lbf ft)
Clamps (2), Y-pipe – high pressure turbo (only D13B-

A/C/G/H/K/L, D13C2-A, D13C4 twin turbo)
P0018816 Stage 1:
Tighten the bolts 10 Nm (7.4 lbf ft)
Stage 2:
Loosen the bolts 180°
Stage 3:
Tighten the bolts 10 Nm (7.4 lbf ft)
Group 26: Cooling System

Refer to General Tightening Torques, page 9.
28 47701522 01-2016 © AB VOLVO PENTA

Engine, General
NOTICE! Because the illustrations in the maintenance
literature are used for different engine variants, certain
details may vary compared to the actual model
concerned. The essential information is always
correct, however.
D13B-A MP, D13B-B MP, D13B-C MP, D13B-

D MP, D13B-G MP, D13B-H MP, D13B-E MH,
D13B-F MG, D13B-J MP, D13B-K MP, D13B-
L MP, D13B-M MP, D13B-N MH, D13C1-A MP,
Type designation D13C2-A MP, D13C3-A MP, D13C4-A MP
Number of cylinders 6
Cylinder diameter, std 131 mm (5.16 in)
Stroke 158 mm (6.22 in)
Cylinder volume 12.78 liter (779.9 in3)
Injection sequence 1–5–3–6–2–4
Compression ratio:
• D13B-A/C/G/H/K/L MP, D13C2-A, D13C4-A 16,5:1
• D13B-B/D/J/M MP, D13C1-A, D13C3-A 16,7:1
• D13B-E/N MH, D13B-F MG 18,5:1
Compression:
• D13B-A/B/C/D/G/H/J/K/L/M MP, D13C1-A, D13C2-A, 3.7 MPa (537 psi)
D13C3-A, D13C4-A
• D13B-E/N MH 3.5 MPa (508 psi)
Low idle:
• D13B-A/B/C/D/G/H/J/K/L/M MP, D13C1-A, D13C2-A, 600 rpm(1)
D13C3-A, D13C4-A
• D13B-E/N MH 550-800 rpm
High idle:
• D13B-A/B/C/D/G/H/J/K/L/M MP, D13C1-A, D13C2-A, 2000 rpm (neutral position)(2)
D13C3-A, D13C4-A
• D13B-E/N MH Rating 1: 1800 rpm
Rating 2: 1900 rpm
• D13B-F MG 1500 / 1800 rpm
Dry weight, engine without reverse gear:
• D13B-A/C/G/H/K/L MP, D13C2-A, D13C4-A 1560 kg (3439 lbs)
• D13B-B/D/J/M MP, D13B-E/N MH, D13C1-A, D13C3-A 1450 kg (3197 lbs)
• D13B-F MG 1325 kg (2921 lbs)
1. Adjustable in engine speed range 550–700 rpm.

2. 2370 rpm with drive engaged.
47701522 01-2016 © AB VOLVO PENTA 29

Location of Sensors
Refer to the tightening torques on the following page.
30 47701522 01-2016 © AB VOLVO PENTA

1 Coolant temperature sensor 22 ± 3 Nm (16.23 ± 3.21 lbf ft)

2 Fuel pressure sensor 30 ± 5 Nm (22.13 ± 3.69 lbf ft)
3 Charge pressure sensor / Charge air temperature sensor 2x M6 standard bolt torque
4 Tachometer sensor, camshaft M6 standard bolt torque
5 Tachometer sensor, flywheel M6 standard bolt torque
6 a Auxiliary stop switch (D13B-A/B/G/H/J/K, D13C1-A,
D13C2-A only)
b Emergency stop switch (D13B-C/D/E/F/L/M/N,
D13C3-A, D13C4-A only)
7 Level alarm for water separator (D13B-A/B/G/H/J/K,
D13C1-A, D13C2-A only) 18–25 Nm (13.28 ± 18.44 lbf ft)
8 Coolant level sensor insertable type
9 Oil level and oil temperature sensor M6 and M8 standard bolt torque
10 Oil pressure sensor 30 ± 5 Nm (22.13 ± 3.69 lbf ft)
11 Crankcase sensor 30 ± 5 Nm (22.13 ± 3.69 lbf ft)
12 a Exhaust temperature sensor (D13B-C/D/E/F/L/M/N,
D13C3-A, D13C4-A only)
b Exhaust temperature alarm (D13B-A/B/G/H/J/K,
D13C1-A, D13C2-A only) 45 ± 5 Nm (33.19 ± 3.69 lbf ft)
13 Seawater pressure sensor (D13B-C/D/E/F/L/M/N, D13C3-
A, D13C4-A only) 30 ± 5 Nm (22.13 ± 3.69 lbf ft)
14 Freshwater pressure sensor (D13B-C/D/E/F/L/M/N,
D13C3-A, D13C4-A only) 30 ± 5 Nm (22.13 ± 3.69 lbf ft)
47701522 01-2016 © AB VOLVO PENTA 31

Engine
Technical Data
Engine body
Cylinder head
Max unevenness (bottom surface) 0.1 mm (0.00394 in)
Cylinder Head Bolts

No./cylinder head 38
Thread dimension M16
Length 200 mm (7.87 in)
Cylinder block
Length 1052 mm (41.41 in)
Height, upper block plane-crankshaft center 422 mm (16.61 in)
Height, lower block plane-crankshaft center 120 mm (4.72 in)
Cylinder Liner
Type Wet, replaceable
Sealing surface height above block plane 0.15–0.21 mm (0.00591–0.00827 in)
No. of seal rings per cylinder liner 1+3
Piston
Height above cylinder block plane, steel pistons 0.1 (min)–0.7 (max) mm [0.00394–0.0276 in]
No. of ring grooves 3
Front marking Forward pointing arrow
32 47701522 01-2016 © AB VOLVO PENTA

Piston rings
XXX
X
XXX
X
X
X
X
X
p0005201
Compression Rings
Quantity 2
Piston ring clearance in groove:
upper compression ring (trapezoid profile)
lower compression ring 0.09–0.14 mm (0.00354–0.00551 in)
Piston ring gap, measured at ring opening:
upper compression ring 0.40–0.55 mm (0.0157–0.0217 in)
Wear tolerance < 0.65 mm (0.0256 in)
lower compression ring 1.30–1.50 mm (0.0512–0.0591 in)
Wear tolerance < 1.65 mm (0.065 in)
Oil Scraper Ring

Quantity 1
Marking Up (color marking to left of gap)
Piston ring clearance in groove 0.05–0.10 mm (0.00197–0.00394 in)
Piston ring gap, measured at ring opening 0.40–0.65 mm (0.0157–0.0256 in)
Wear tolerance < 0,80 mm (0.0315 in)
47701522 01-2016 © AB VOLVO PENTA 33

Valve mechanism
Valves
p0005201
Valve head, diameter:

Inlet 42 mm (1.654 in)
Outlet 40 mm (1.575 in)
Valve stem, diameter:
Inlet / exhaust 8 mm (0.315 in)
Valve seat angle (A):
Inlet 24,5° ± 0,2°
Outlet 39,5°
Seat angle in cylinder head (B):
Inlet 25°
Outlet 40°
p0005203
Specifications Min (A) Wear value

Dimension (A) between valve head and cylinder head
plane:
Inlet 1.0 mm Max 1.7 mm
(0.0394 in) (0.0669 in)
Outlet 1.35 mm Max 2.1 mm
(0.0531 in) (0.0827 in)
34 47701522 01-2016 © AB VOLVO PENTA

Valve clearance, cold engine, setting value:

Inlet 0.2 mm (0.00787 in)
Outlet 0.8 mm (0.0315 in)
Valve seats
B
p0005205
Outer diameter (A): Standard Oversize

Inlet 45.1 mm
(1.7756 in) 45.3 mm (1.7835 in)
Outlet 43.1 mm
(1.6968 in) 43.3 mm (1.7047 in)
Height (B):
Inlet 7.55 mm
(0.2972 in)
Outlet 7.5 mm
(0.2952 in)
47701522 01-2016 © AB VOLVO PENTA 35

Valve seat position
R D
p0005206
Diameter (C): Standard Oversize

Inlet 45.2 (1.7795 in)
[0/+0.025 mm]
45.0 mm (1.772 in) (0/+0.000984 in)
Outlet 43.2 (1.7008 in)
[0/+0.025 mm]
43.0 mm (1.693 in) (0/+0.000984 in)
Depth (D):
Inlet 11.8 ± 0.13 mm (0.4645
± 0.005118 in)
Outlet 11.2 ± 0.13 mm (0.4409
± 0.005118 in)
Seat bottom radius (R):
Inlet / exhaust max 0.8 mm (0.0315 in)
Valve guides
999 9696
998 9876
p0005207
Length:
Inlet / exhaust 83.5 mm (3.287 in)
Inner diameter:
Inlet / exhaust 8 mm (0.315 in)
Height above cylinder head spring plane:
Inlet / exhaust 24.5 ± 0.2 mm (0.9645 ± 0.00787 in)
Wear value (See figure)

Clearance, valve stem guide:(1)
Inlet max 0.7 mm (0.0276 in)
Outlet max 0.7 mm (0.0276 in)
1) The dimension is calculated for the measurement method described in the service literature; refer to Valve Guides,
Inspection, page 193.
36 47701522 01-2016 © AB VOLVO PENTA

Rocker Arm
Wear values
Bearing play (1) max 0.1 mm (0.00394 in)
Roller cam follower, clearance (2) max 0.1 mm (0.00394 in)
Valve springs
Inlet / outlet
Length uncompressed 73.8 mm (2.9055 in)
47701522 01-2016 © AB VOLVO PENTA 37

Engine Transmission
Timing gear wheels
1 Drive gear, crankshaft
2 Intermediate gear: outer gearwheel, inner
gearwheel
3 Intermediate gear (adjustable)
4 Drive gear, camshaft
5 Intermediate gear
6 Drive gear, power steering pump and fuel feed
pump
7 Drive gear, lubrication oil pump
8
8 Seawater pump
P0012463
Gear lash, adjustable intermediate gear to camshaft drive

gear 0.05–0.15 mm (0.00197–0.00591 in)
Gear lash, oil pump 0.05–0.40 mm (0.00197–0.0157 in)
Gear lash, other 0.05–0.17 mm (0.00197–0.00669 in)
Radial clearance for intermediate gear max 0.05 mm (0.00197 in)
38 47701522 01-2016 © AB VOLVO PENTA

Camshaft
Camshaft drive gearwheel
No. of bearings 7
Diameter, bearing journals, standard 69.97–70.00 mm (2.755–2.756 in)
Diameter, bearing journals, undersize:
0.25 mm (0.00984 in) 69.72–69.78 mm (2.745–2.747 in)
0.50 mm (0.0197 in) 69.47–69.53 mm (2.735–2.737")
0.75 mm (0.0295 in) 69.22–69.28 mm (2.725–2.728 in)
Permissible wear, entire camshaft profile max 0.1 mm (0.00394 in)
Unit injector, stroke 18 mm (0.709 in)
Wear value
Max end float 0.24 mm (0.00945 in)
Bearing, max permissible radial wear 0.1 mm (0.00394 in)
Camshaft Bearings
Camshaft bearing thickness, standard 1.92 mm (0.0756 in)
Oversize dimension:
0.25 mm (0.00984 in) 2.04 mm (0.0803 in)
0.50 mm (0.0197 in) 2.17 mm (0.0854 in)
0.75 mm (0.0295 in) 2.29 mm (0.0902 in)
47701522 01-2016 © AB VOLVO PENTA 39

Crank Mechanism
Crankshaft
Wear value
Crankshaft end float(1) max 0.4 mm (0.01575 in)
Machining value
Ovality of main bearing journals and connecting rod journal max 0.006 mm (0.0002362 in)
Center main bearing runout max 0.15 mm (0.00591 in)
1) Dimensions refer to greased components.
Main bearing journals
P0005849
Diameter (Ø) standard 108.0 mm (4.252 in)

Undersize dimension:
0.25 mm (0.00984 in) 107.75 mm (4.242 in)
0.50 mm (0.0197 in) 107.50 mm (4.232 in)
1.00 mm (0.0394 in) 107.00 mm (4.213 in)
Surface fineness, main bearing journals Ra 0.25 (9.84·10–6 in)
Surface fineness, radius Ra 0.4 (1.575·10–5 in)
Width, thrust bearing journal (A) standard 47.0 mm (1.850 in)
Oversize dimension:
0.2 mm (0.00787 in), thrust bearing 0.1 mm (0.00394 in) 47.2 mm (1.858 in)
Fillet radius (R) 4.0 mm (0.1575 in)
40 47701522 01-2016 © AB VOLVO PENTA

Thrust washers (thrust bearing)
R
C D
B
p0005210
Width (B) standard 3.18 mm (0.1252 in)

Oversize dimension:
0.1 mm (0.00394 in) 3.28 mm (0.1291 in)
0.2 mm (0.00787 in) 3.38 mm (0.1331 in)
0.3 mm (0.0118 in) 3.48 mm (0.1370 in)
Main bearing cup

Thickness (D) standard 2.48 mm (0.0976 in)
Oversize dimension:
0.25 mm (0.00984 in) 2.61 mm (0.1028 in)
0.50 mm (0.0197 in) 2.74 mm (0.1079 in)
1.00 mm (0.0394 in) 2.98 mm (0.1173 in)
47701522 01-2016 © AB VOLVO PENTA 41

Big-end journals
C A
B
p0005211
Diameter (Ø) 99.0 mm (3.898 in)

Undersize dimension:
0.25 mm (0.00984 in) 98.75 mm (3.8878 in)
0.50 mm (0.0197 in) 98.50 mm (3.8779 in)
0.75 mm (0.0295 in) 98.25 mm (3.8681 in)
1.00 mm (0.0394 in) 98.00 mm (3.8583 in)
1.25 mm (0.0492 in) 97.75 mm (3.8484 in)
Surface fineness, big-end journals Ra 0.25 (9.84·10–6 in)
Surface fineness, radius Ra 0.4 (1.575·10–5 in)
Width (A) 57.0 mm (2.244 in)
Fillet radius (R) 4.0 mm (0.1575 in)
Connecting rod big end, diameter (D) 103.84 mm (4.0882 in)
Connecting rod, length (E) 259,0 mm (10.1968 in)
Connecting rod small end, diameter (G) 58.0 mm (2.2835 in)
Connecting rod bearing cup

Thickness (C) standard 2.39 mm (0.0941 in)
Oversize dimension:
0.25 mm (0.00984 in) 2.51 mm (0.09882 in)
0.50 mm (0.0197 in) 2.64 mm (0.10394 in)
1.00 mm (0.0394 in) 2.89 mm (0.1138 in)
42 47701522 01-2016 © AB VOLVO PENTA

Connecting rod
Marking:
201 201
”FRONT” on the connecting rod faces forward.
The connecting rod and bearing caps are
marked in pairs with a three-digit serial number
(see illustration).
201 201
p0005212
Wear value (1)

End float, connecting rod–crankshaft max 0.35 mm (0.01378 in)
Connecting rod bearing, radial clearance max 0.1 mm (0.00394 in)
1) Dimensions refer to greased components.
Flywheel, installed
Runout, measured radius 150 mm (5.905 in) < 0.20 mm (0.0787 in)
Flywheel housing, installed

Runout for contact surface max 0.2 mm (0.0787 in)
Radial play for steering max 0.26 mm (0.01024 in)
47701522 01-2016 © AB VOLVO PENTA 43

Lubrication System
Technical Data
Oil
Oil change volume 45 liter 11.89 US gals
Oil volume between min and max markings 8 liter 2.11 US gals
Oil Pressure
Operating rpm (above 1400 rpm) 300–550 kPa 43.5–79.8 psi
Cold engine (1400 rpm) –650 kPa –94.3 psi
Low idle (min) min 200 kPa min 29.0 psi
Piston cooling pressure, hot engine (1400 rpm) min 200 kPa min 29.0 psi
Oil temperature
Max oil temperature in oil sump 130 °C 266 °F
44 47701522 01-2016 © AB VOLVO PENTA

Oil filter
Number
Full flow filter 2
Bypass filter 1
Oil valves
1 Thermostat valve, oil
cooler
Opening temperature 105–107 °C
(221–224.6 °F)
2 Safety valve, block
3 Bypass valve, full flow
filter
Spring, free length 69 mm (2.717 in)
Compressed 13–15 N
(2.9–3.4 lbf) 40 mm (1.575 in)
47701522 01-2016 © AB VOLVO PENTA 45

Fuel System
Technical Data
NOTICE! For the below-mentioned values, fuel is
required to fulfill the requirements specified in 03-0,
Fuel and Oils.
Feed pump
Feed pressure at:
600 rpm 100 kPa 14.5 PSI
1200 rpm 300 kPa 43.5 PSI
full load 300 kPa 43.5 PSI
Bypass valve
Opening pressure 300–550 kPa 43.5–79.8 PSI
Unit injector
Pre-load
Tighten the adjuster screw to zero-clearance against
the camshaft. Then turn 4 flats; see illustration.
46 47701522 01-2016 © AB VOLVO PENTA

Inlet and Exhaust System

Technical Data
Pressure drop indicator
The pressure drop indicator control lamp lights up at a

pressure drop relative to ambient air pressure of: 50 ± 5 kPa 7.25 ± 0.7 PSI
47701522 01-2016 © AB VOLVO PENTA 47

Cooling System
Technical Data
Pressure cap
p0012569
Pressure valve opens at 75 kPa (10.88 PSI)
Thermostat
Number 1
Opening temperature: < 82 °C (179.6 °F)
By-pass valves, heat exchanger

Spring force on front valve 34 ±4 N (7.6 ±0.9 lbf.)
Spring force on rear valve 76 ±8 N (17.1 ±1.8 lbf.)
48 47701522 01-2016 © AB VOLVO PENTA

Coolant
There are two different types of coolant:
Engines manufactured
- between 5/3/2009-6/6/2010 must use Volvo Penta
Coolant.
- from 6/7/2010 must use Volvo Penta Coolant VCS.
Type Volvo Penta Coolant

Color Green
Contains Ethylene glycol and anti-corrosion additives
Mix with Water (According to ASTM D4985)
Mixture proportions (Conc. coolant/water)(1) 40/60, freezing point -28 °C (-18.4 °F)
Type Volvo Penta Coolant VCS

Color Yellow
Contains Ethylene glycol and anti-corrosion additives
Mix with Water (According to ASTM D4985)
Mixing proportions (conc. coolant/water)(1) 40/60, freezing point -24 °C (-11.2 °F)
IMPORTANT!
Do not mix different kinds of coolant.
Refill quantity
Coolant quantity (engine, radiator and hoses): 60 liter (63.40 quart)
1. Volvo Penta recommends “Ready Mixed” coolant.
47701522 01-2016 © AB VOLVO PENTA 49

03-3 Specifications, Electrical

Electrical System
Sensor
Exhaust temperature sensor

Ω Temperature Impedance Impedance
766,8 Rnom Rdiff
(°C) (°F) (Ω) (∆Ω)
–40 –40 169.7 ± 1.9
554,1 0 32 200.5 ± 1.9
25 77 219.6 ± 1.9
50 122 238.5 ± 1.9
349,0 100 212 275.9 ± 1.9
275,9 200 392 349.0 ± 1.9
200,5 300 572 419.7 ± 3.1
169,7
400 752 488.1 ± 4.0
500 932 554.1 ± 4.9
600 1112 617.8 ± 5.6
-40 0 50 100 200 300 400 500 600 700 800 850 °C
700 1292 679.2 ± 6.3
P0013090
800 1472 738.2 ± 6.9
850 1562 766.8 ± 7.2
Coolant temperature sensor

Temperat Impedanc Impedance Impedanc
Ω ure e Rmin Rnom e Rmax
45313 (°C) (°F) (Ω) (Ω) (Ω)

–40 –40 40490 45313 50136
–30 –22 23580 26114 28647
–20 –4 14096 15462 16827
26114 –10 14 8642 9377 10152
0 32 5466 5896 6326
10 50 3542 3792 4043
15462 R Min
20 68 2351 2500 2649
R Nom
R Max
25 77 1941 2057 2173
5896
30 86 1615 1707 1798
2500
40 104 1118 1175 1231
-40 -20 0 20 40 60 80 100 C 50 122 798 834 870
p0005217
60 140 573 596 618
70 158 421 435 451
80 176 313 323 332
90 194 237 243 250
100 212 182 186 191
110 230 140 144 148
120 248 109 113 116
130 266 86 89 93
140 284 68 71 74
Charge air temperature sensor
50 47701522 01-2016 © AB VOLVO PENTA

Ω Temperat Impedanc Impedance Impedanc

ure (1) e Rmin Rnom e Rmax
45303
(°C) (°F) (Ω) (Ω) (Ω)
–40 –40 40730 45303 50314
–35 –31 30908 34273 37953
–30 –22 23603 26108 28829
–25 –13 18142 19999 22023
–20 –4 14055 15458 16970
–15 5 10945 12000 13144
15458 –10 14 8595 9395 10261
–5 23 6801 7413 8074
0 32 5420 5895 6403
5895
2499 5 41 4343 4711 5106
1174 10 50 3504 3791 4100
15 59 2842 3068 3310
P0013091
20 68 2323 2499 2690
25 77 1916 2056 2207
30 86 1591 1706 1827
35 95 1318 1411 1510
40 104 1100 1174 1254
45 113 927.0 987.4 1051
50 122 783.1 833.8 886.3
55 131 661.2 702.7 746.6
60 140 561.6 595.4 631.4
65 149 480.2 508.2 537.8
70 158 412.1 435.6 460.3
75 167 354.4 374.1 394.9
80 176 306.0 322.5 339.8
85 185 265.7 279.5 294.0
90 194 231.5 243.1 255.4
95 203 202.7 212.6 223.0
100 212 178.0 186.6 195.4
105 221 156.2 163.8 171.6
110 230 137.5 144.2 151.0
115 239 121.4 127.3 133.4
120 248 107.5 112.7 118.0
125 257 95.55 100.2 104.9
130 266 85.13 89.28 93.52
1. ± 1 °C (1.8 °F)
47701522 01-2016 © AB VOLVO PENTA 51

Oil level / -temperature sensor

Temperature Impedance Rnom Impedance Rdiff
(°C) (°F) (Ω) (∆Ω)
25 77 1520 ± 126.0
60 140 377.9 ± 23.5
90 194 139.7 ± 6.6
100 212 103.6 ± 4.4
120 248 59.6 ± 2.0
130 266 46.1 ± 1.4
Camshaft sensor / flywheel sensor

Distance to gearwheel 1.1 ± 0.4 mm (0.0433 ± 0.01575 in)
Crankcase sensor
Crankcase pressure, normal value < 1.0 kPa (0.145 PSI)
52 47701522 01-2016 © AB VOLVO PENTA

05-1 Safety Instructions

Safety Information
This Service Manual contains repair instructions,
descriptions and technical data for products or product
designs from Volvo Penta. Ensure that you are using
the correct service manual.
Read the safety information below and the service manual section About this Workshop manual and Repair
instructions carefully before repair and service work is begun.
!
This symbol is used in the service manual and on the product, to call attention to the
fact that this is safety information. Always read such information very carefully.
Safety texts in the manual have the following order of priority:
DANGER!
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING!
Indicates a hazardous situation which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT!
Is used to draw your attention to something that may cause minor damage or a minor
malfunction to the product or property.
NOTICE! Is used to draw your attention to important information that will facilitate the
work or operation in progress.
This symbol is used on certain operations to indicate the following:

This operation requires prior theoretical and/or instructor led training before attempting.
Contact your local training organization for further information.
A compilation of safety precautions that must be taken and risks which must be paid attention to is
presented in the following pages.
47701522 01-2016 © AB VOLVO PENTA 53

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply to the engine at the main switch ! engine is hot. Steam or hot coolant can spray
(switches) and lock it (them) in the off position out and system pressure will be lost. Open the
before starting work. Post a warning notice at filler cap slowly, and release the pressure in the
the main circuit breaker. cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed when the engine is hot.
As a rule, all service operations must be carried Hot oil can cause burns. Avoid skin contact with
! out with the engine stopped. However, some ! hot oil. Ensure that the lubrication system is not
work, such as adjustments, will require the under pressure before any work is begun.
engine to be running. Approaching an engine Never start or operate the engine with the oil
which is running is a safety risk. Bear in mind filler cap removed, because of the risk of oil
that loose clothing or long hair can fasten in ejection.
rotating parts and cause serious personal
injury.
Be aware of hot surfaces (exhaust pipes, Never start the engine without installing the air
! turbos, charge air pipes, starting heaters etc.) ! filter. The rotating compressor turbine in the
and hot fluids in pipes and hoses on an engine turbocharger can cause severe injury. Foreign
that is running or has just stopped. objects entering the intake ducts can also cause
If work is done adjacent to a running engine, a mechanical damage. Install all protective
careless movement or a dropped tool may in the covers before the engine is started.
worst case lead to personal injury.
Ensure that the warning symbols or information Only start the engine in a well-ventilated space.
! decals on the product are always clearly visible. ! When running in a confined space, exhaust
Replace decals which have been damaged or fumes and crankcase gases must be led away
painted over. from the engine bay or workshop area.
Avoid getting oil on your skin! Protracted or The majority of chemicals e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. From a such as degreasing agents, paints and
health standpoint, used oil is more dangerous solvents, are injurious to health. Carefully read
than new. Use protective gloves and avoid oil- the instructions on the product packaging!
soaked clothes and rags. Wash regularly, Always follow a product's safety directions, e.g.
especially before eating. Use suitable barrier use of protective mask, glasses, gloves etc.
creams to counteract drying out of the skin and Ensure that other personnel are not exposed to
to aid dirt removal. substances that are injurious to health. Ensure
good ventilation. Handle used and leftover
chemicals in the prescribed manner.
Stop the engine and turn off the electrical supply Clutch adjustments must be carried out with the
! at the main switch(es) before carrying out work ! engine stopped.
on the electrical system.
54 47701522 01-2016 © AB VOLVO PENTA

Always use protective glasses or goggles when Never start the engine with the valve cover
! carrying out work where a risk of splinters, ! removed. There is a risk of personal injury.
grinding sparks, splashes from acid or other
chemicals is present. Your eyes are extremely
sensitive; injury may cause blindness!
Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the sea cock / cooling
water inlet valve before work on the cooling
system is begun.
All fuels, as well as many chemicals, are Make sure that oil, fuel-soaked rags, and used
! flammable. Do not allow open flames or sparks ! fuel and oil filters are stored in a safe manner.
in their vicinity. Gasoline, some thinners, and Rags soaked in oil can spontaneously ignite
hydrogen gas from batteries are extremely under certain circumstances. Used fuel and oil
flammable and explosive when mixed with air in filters are environmentally hazardous waste
the correct proportions. No Smoking! Ensure and must be handed to an approved waste
that the work area is well ventilated and take the management facility for destruction, as must
necessary safety precautions before welding or any used lubrication oil, contaminated fuel,
grinding work is begun. Always ensure that paint residue, solvents, degreasers and wash
there are fire extinguishers close at hand in the residue.
work area.
Batteries must never be exposed to open Never work alone when removing heavy
! flames or electric sparks. Never smoke in the ! components, even when using lifting devices
vicinity of the batteries; they generate hydrogen such as locking tackle lifts. When using a lifting
gas when charged, which is explosive when device, two people are usually required to do
mixed with air. This gas is easily ignited and the work - one to take care of the lifting device
highly explosive. A spark, which can be caused and the other to ensure that components are
by incorrect battery connection, is sufficient to lifted clear and not damaged during the lifting
cause a battery to explode and cause damage. operations.
Do not touch the connections during start

attempts. Sparking hazard! Do not lean over
batteries.
Never transpose the positive (+) and negative The existing lugs on the engine should be used
! (-) battery posts when installing batteries. Such ! for lifting. Always check that the lifting
a transposition can result in serious damage to equipment used is in good condition and has the
electrical equipment. Refer to the wiring load capacity to lift the engine (engine weight
diagram. including gearbox or extra equipment). For safe
Always use protective goggles when charging handling and to avoid damaging components
and handling the batteries. Battery electrolyte fitted to the top of the engine, the engine must
contains sulfuric acid which is highly corrosive. be lifted with a correctly adjusted lifting boom.
Should the battery electrolyte come into contact All chains or wires must run parallel to each
with unprotected skin, wash it off immediately other and as perpendicular to the engine as
using soap and copious amounts of water. If you possible. If other equipment attached to the
get battery acid in your eyes, flush at once with engine has altered its center of gravity, special
copious amounts of water and seek medical lifting devices may be needed to obtain the
assistance immediately. correct balance for safe handling. Never
perform any work on an engine that is only
suspended from the lifting equipment.
47701522 01-2016 © AB VOLVO PENTA 55

The components in the electrical and fuel Exercise extreme caution when leak-detecting
! systems on Volvo Penta products are designed ! on the fuel system and testing the fuel injector
and manufactured to minimize the risk of fire nozzles. Use eye protection. The jet from a fuel
and explosion. The engine must not be run in nozzle has very high pressure and great
areas where there are explosive materials. penetration power. Fuel can force its way deep
into body tissue and cause severe injury. There
is a risk of blood poisoning (septicemia).
Only use fuels and lubricating oils Never use a high-pressure washer for cleaning
! recommended by Volvo Penta. Refer to the ! the engine.
Operator's Manual for the product in question. Pay attention to the following when using a high-
Use of fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never direct the water jet at
injectors. On a diesel engine, low grade fuel can seals, rubber hoses or electrical components.
cause the control rod to bind and the engine to
over-rev, with the risk of engine damage and
personal injury as a result. Low fuel and oil
grades may result in high service, maintenance
and repair costs.
Fuel delivery pipes must not be bent or When working on the engine; perform leakage
! straightened under any circumstances. Cracks ! and function test as necessary.
may occur. Damaged pipes must be replaced.
56 47701522 01-2016 © AB VOLVO PENTA

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.
P0004337 P0006780
P0002947
9996398 Manometer 1678297 Spacer 9990210 Valve spring

Adjusting e.g. lubricating oil For use with compressor
pressure. 9996398 Manometer.
P0006822
P0006765
P0006269
9988539 Compression meter 9990006 Puller 9990013 Slide hammer
P0006793
P0006785
P0007591
21461107 Guide pin 9990166 Mounting tool 9990185 Lifting tool

Used for cleaning heat Crankshaft seal. Lifting rocker arm bridge.
exchangers.
P0004328
P0006779
P0006784
9990192 Puller 9992000 Handle 9993590 Rotation tool

Crankshaft seal. Replacement of e.g. crankshaft As a counterhold or for rotating
seal. gearwheels.
47701522 01-2016 © AB VOLVO PENTA 57

p0004329
p0004330
9996049 Draining hose 9996394 Support 9996395 Support

Cooling system, draining. Support leg for 9996645 Puller. Support leg for 9996645 Puller.
P0006791
P0004331
P0004332
9992479 Holder for dial 9996400 Slide hammer 9996645 Puller

indicator For use with cylinder liners.
For use with 9989876 Dial
indicator.
P0004348
P0004333
p0006803
9996666 Nipple 9998007 Adapter 9998248 Adapter

For use with e.g. For use with 9996400 Slide Compression test (6 pcs.
9996398 Manometer. hammer. required).
P0006805
P0004349
9998249 Protective sleeve 9998251 Protection plug 9998339 Manometer

Protects removed injectors. Plugs hole for removed Checking charge air pressure.
injectors.
P0006773 P0001878
9990156 Adapter 9998267 Guide sleeve 9999179 Extractor oil filter

Adapter to 9998251 Protection Timing plate. Removal of filters.
plug.
58 47701522 01-2016 © AB VOLVO PENTA

P0004580 P0006814
P0006818
9998493 Hose 9998599 Cleaning kit 9998494 Hose

Used for pressure testing. Used for measuring fuel feed
The tool kit includes:
pressure.
- 9808570 Brush
- 9808616 Extender
- 9998580 Protective
sleeve.
P0006816
P0006767 P0002793
9998487 Sleeve 88800021 Drift 88800083 Piston ring pliers

Removal of filters. Removal of crankshaft seal. Installation of piston rings.
P0006806
P0006761
9998250 Sealing ring 9986173 Puller 88800387 Puller

Cylinder head fuel ducts (the kit Removal of sleeve. Removal of sleeve.
contains 12 pcs.).
P0006795
P0010363 p0006801
88800196 Drift 9990174 Drift 9998246 Drift

Installation of sleeve. Valve springs. Valve springs.
47701522 01-2016 © AB VOLVO PENTA 59

P0001872
P0004276 p0006800
88800151 Drift 3849613 Pressure testing kit 9996441 Cover, with

Valve stem seals. Pressure testing cooling system. connecting nipple
Pressure testing cooling system.
P0010357 P0010358
P0006804
9996662 Pressure testing kit 88800117 Plate 9998674 Adapter

Pressure testing cooling system. For use with 88800345 Adapter. Removal of camshaft cap.
P0010359
P0010361 P0010360
9996966 Press tool 3883671 Protective sleeve 3883672 Protective sleeve

Holds cylinder liner in place. O-ring for injector. O-ring for injector.
P0010362
P0010365
P0010364
9992955 Plate 88800031 Measuring tool 9998598 Sleeve

Removal of cylinder liner. Shimming of sensors. Removal of safety valve cover.
P0006778
9994034 Drift 9990165 Guide sleeve 884167 Drift

Used when assembling Valve stem seals. Used when assembling
seawater pump. seawater pump.
60 47701522 01-2016 © AB VOLVO PENTA

p0006802
P0007585
88800345 Adapter 885519 Guide pin 9996239 Lifting tool

For use with 88800117 Plate. Aligning inlet manifold. 2 pcs. required.
P0006764
P00068115
P0006813
9998264 Lifting tool 885810 Fixture 9998601 Fixture

Lifting the camshaft. Installation of upper timing Installation of upper timing
cover. cover.
P0006782
P0006792
9998531 Piston ring 9809726 Pneumatic hydraulic 9809729 Hydraulic cylinder

compressor pump Valves and valve guides.
Fitting rings to pistons. Valves and valve guides.
P0006788
P0006789
P0006786
9990176 Press tool 9996159 Adapter 88800064 Drift

Valves and valve guides. For 9809729 Hydraulic cylinder. Valve guides.
P0006790 p0006796 P0006794
88800127 Drift 88800147 Drift 9992670 Hand pump

Valve guides. Valve guides. Alternative to
9809726 Pneumatic hydraulic
pump .
P0006776
9990160 Fixture 22518599 Slide hammer 22632322 Puller

Cylinder head.
47701522 01-2016 © AB VOLVO PENTA 61

9998599 Cleaning kit

Cleaning kit for unit injector. Contains:
• 959239 Screw M10

• 9808570 Brush, white
• 9998580 Sleeve with holder and O-ring
• 276948 O-ring set
• 9808634 Brush kit, contains:
- Storage box
- Holder
- Holder
- Handle
- 9808614 Brush, yellow 10 pcs
- 9808617 Wire brush, narrow
- 9808618 Wire brush, coarse
62 47701522 01-2016 © AB VOLVO PENTA

Other Equipment
The following miscellaneous equipment is used when
working on the engine. The equipment can be ordered
from AB Volvo Penta by specifying the number
indicated.
Orig
in
al
P0004344
P0002936 P0002930
885510 Plugs 885633 Torque multiplier 1159794 Torque wrench

For use with e.g. fuel pressure For use with e.g. the crankshaft.
lines.
P0004342
P0004343
P0002784
885648 Counterhold 885812 Timing tool 885822 Magnetic pen

For use with 885633 Torque
multiplier.
P0001859
P0001879 P0001875
9998511 Lever 9999696 Magnetic stand 9989876 Dial indicator

For use with 9989876 Dial
indicator.
10
0
20
0
20
p0013445
P0001881 P0006823
9999683 Dial indicator (short 885811 Timing tool 1158957 Pliers

probe)
Checking gear lash
measurement.
47701522 01-2016 © AB VOLVO PENTA 63

Aluminum foil tape; classified, type-approved

machines only.
Use new aluminum foil tape part # 3819448 for
replacement in cases where tape is removed from
around oil and fuel connections, and must be replaced.
The aluminum foil tape is intended to screen off spray
from oil and fuel systems.
64 47701522 01-2016 © AB VOLVO PENTA

18-0 General
18-0 General
Chemical products
828250 Grease 1141570 Sealant 1161277 Glue
1161346 Corrosion 1698135 Lubricant

protection
47701522 01-2016 © AB VOLVO PENTA 65

20-0 Engine Information, General
Troubleshooting
Start / stop, symptoms
Engine doesn't start, starter motor is engaged 1
Engine doesn't start, starter motor doesn't engage 2
Engine starts then stops 3
Engine stopped during normal opperation 4
Engine starts but does not stop 5
Performance and comfort, symptoms

Engine is percived as low-powered 6
Engine exhaust smoke is black 7
Engine exhaust smoke is blue or white 8
Engine vibrates 9
Cooling system, symptoms

Engine does not reach normal operating temperature 10
Engine ovehheat 11
Coolant disapears from the system 12
Lubrication system, symptoms

Engine oil pressure low at idle 13
Engine oil pressure low at normal operation 14
High oil consumption 15
1 Check: 3 Check:
- Air inlet and air filter - For air in the fuel system
- Fuel feed, from tank to engine (incl. filter) - Fuel feed, from tank to engine (incl. filter)
- Stop device (control and solenoid) - Air inlet and air filter
- Fuel quality and water content - Regulator, injection pump and stop device
for function
2 Check: - Fuel quality and water contentl
- Voltage at the starter motor (during start)
4 Check:
- Voltage on switch (“50”) at starter motor
- For air in the fuel system
- The engine can be turned by hand
- Fuel feed, from tank to engine (incl. filter)
- Starter motor
66 47701522 01-2016 © AB VOLVO PENTA

5 Check: 11 Check:
- Stop switch function - Low coolant level
- Pressure cap on expansion tank
6 Check:
- Seawater intake, filter and hoses
- Hull and propellers for fouling and damage
- Impeller
- Boat weight
- Exhaust pipe for corrosion and leaks
- Fuel feed
- Thermostat
- Air inlet and air filter
- Heat exchanger
- Alternator charging capacity
- Too high engine oil level 12 Check:
- Turbo - Leakage hoses and clamps
- Pressure cap on expansion tank
7 Check:
- Hot water connections
- Air inlet and air filter
- Pressure test the cooling system
- Engine Oil Level
- That the engine does run on all cylinders 13 Check:
8 Check: - Idling speed
- Engine oil, level and consumption - Engine Oil Level
- Coolant, level and consumption - Oil quality (viscosity, fuel concentration)
- Pressure sensor (verify with manometer)
9 Check:
- Flexible engine mounting
14 Check:
- Idling speed is not too low
- Engine Oil Level
- Propeller and propeller shaft deformity
- Oil quality (viscosity, fuel concentration)
- That the engine does run on all cylinders
- Pressure sensor (verify with manometer)
10 Check: 15 Check:
- Thermostat - Leakage hoses and clamps
- Too low load on the engine - Crankcase ventilation function
- Too high heatexchange from cooling water - Oil quality (viscosity)
outlet (e.g. water heaters)
47701522 01-2016 © AB VOLVO PENTA 67

Fault tracing of the cooling system

Hot engine
1 Low coolant level (low level alarm)
2 Slipping circulating pump drive belt (too long
change intervals or splash of lubricant, either oil or
grease)
3 Blocked seawater filter / seawater inlet
4 Impeller, seawater pump
5 Dirt in the heat exchanger inlet (impeller debris)
6 Blocked cooling system (wrong glycol, mixture,
deploy cleaning kit)
7 Sticking priority valves (open or closed)
8 Blocked heat exchanger (seawater or fresh water)
9 Sticking thermostat (closed)
10 Circulating pump (impeller damaged or slipped
from shaft)
The first overheating alarm is for charge air

temperature and then high engine temperature.
For reverse gear overheating, refer to item 7.
Cold engine
1 Low engine loading
2 Leaky cold start valve (open, same as open
thermostat)
3 Sticking thermostat (open)
68 47701522 01-2016 © AB VOLVO PENTA

Charge Pressure, Troubleshooting

Boost pressure too low
1 Electrical wastegate / by-pass valve fault (fault
code)
2 Poor cooling to charge air cooler (fault code; refer
to Cooling system)
3 Blocked air filter (check for any exhaust leakage)
4 Exhaust manifold leakage, wastegate / by-pass
valve, turbocharger or flexible pipe (deformation to
plastic covers, soot particles on the engine or a
clogged air filter are signs of exhaust leakage)
5 Check turbine inlet (dirty)
6 Check turbocharger inlet (blocked by oil mist, soot
or dirt)
7 Check boost pressure sensor (check boost
pressure with manometer)
8 Leakage on air pressure side (charge air cooler or
charge air pipe)
9 Check turbocharger bearings (if the inlet turbine
has touched turbine housing)
10 Wastegate valve sticking, fully open (heavy
exhaust smoke)
Boost pressure too high

1 Wastegate valve sticking, will not open (excessive
boost pressure alarm, reduced engine power)
Boost pressure is adjusted upwards automatically

even if the turbocharger is not providing full boost
pressure (through an upward adjustment of fuel
quantity until the smoke limiting level is reached).
Check for exhaust leaks before installing the heat

shield.
In the event of difficulties in locating the exhaust leak:
Run the engine for a couple of minutes without heat
shields; shut down the engine and listen for where air
might be heard (whistling) when seawater forces
exhaust gases back.
47701522 01-2016 © AB VOLVO PENTA 69

Test and Adjustments

Compression Test
The fuel system shall be emptied and the rocker bridge
removed, see Draining, Fuel Duct in Cylinder
Head, page 246.
Tools:
9988539 Compression meter
9990185 Lifting tool
9998248 Adapter
9998249 Protective sleeve
Removal
1 IMPORTANT!
9998248 Make sure that the area around the unit injectors
is clean before they are removed.
Remove the unit injectors, see Unit Injector,
Replace, page 260 and mount the unit injector
protection (9998249 Protective sleeve). Clean
the copper sleeves as needed with
9998599 Cleaning kit.
2 Fit all(1) adapters (6 pcs), tool 9998248 Adapter,
to the cylinder head and pull them on with the
P0004964 injector retainers.
3 Oil valve caliper, cam shaft ridges and the rocker
bridge.
4 Fit the rocker bridge with 9990185 Lifting tool.
Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft
support bearing. Torque the rocker bridge as
specified in Engine, General, page 29. Use
torque wrench.
5 Install the middle piece and the oil pipe to the
rocker bridge.
6 Check the valve clearance, see Valves and Unit
P0004965
Injectors, Adjustment, page 188, for all valves as
specified in Engine, General, page 29.
1. This in order to avoid repeating removal/refitting of rocker bridge

and unit injector and performing valve adjustment six times.
70 47701522 01-2016 © AB VOLVO PENTA

7 Remove both control wires from the starter motor

control connector (the two thin cables).
Connect one of the two free connectors on the
control connector to ground.
8 Connect the other connector to a switch, which in

turn is connected to the positive (plus) connection
on the starter motor.
9 Connect tool 9988539 Compression meter to

9998248 Adapter on the first cylinder.
998 8539 10 NOTICE! Do not run the engine for more than 15
seconds at a time with intervals of 60 seconds.
Run the engine with the starter motor until the

compression meter needle has stopped (max
compression reading).
Read the value.
Move the compression meter to the next cylinder.
P0004968 999 8248
Repeat the test on all cylinders.
11 Remove the middle piece and the oil pipe for the
rocker bridge.
12 Remove the rocker bridge screws equally in
stages so that it is not bent.
Remove the bolts and carefully lift off the rocker
bridge using 9990185 Lifting tool.
47701522 01-2016 © AB VOLVO PENTA 71

13 Remove all adapters, tool 9998248 Adapter from

9998248 all cylinders.
P0004964
Installation
14 Mount the unit injectors and new o-rings, see the
Installation section in chapter Unit Injector,
Replace, page 260.
15 Fit the rocker bridge with 9990185 Lifting tool.
Torque the screws evenly along the rocker arm to
avoid that the rocker arm bends or warps.
Make sure that guide pins fit in the camshaft
support bearing. Torque the rocker bridge as
specified in Engine, General, page 29. Use
torque wrench.
16 Install the middle piece and the oil pipe to the
rocker bridge.
17 Adjust valves and unit injectors, see Valves and
P0004965
Unit Injectors, Adjustment, page 188.
18 Check and if needed change the valve cover
bearing. Install the valve cover.
19 Re-install the fuel lines. Use new sealings.
20 Vent the fuel system, see Fuel system,
bleeding, page 245.
72 47701522 01-2016 © AB VOLVO PENTA

Charge Pressure, Troubleshooting

Charge Air Pressure, Check
Tools:
9998339 Manometer
9998493 Hose
9996666 Nipple
1 Connect the nipple with hose and pressure gauge
to the measuring point on the inlet manifold; refer
to Charge Air Pressure, Check, page 327.
2 Compare this pressure with the pressure that can
be read with the VODIA tool; refer to “Workshop
manual, EMS 2”.
If the two measurements show different values,
the pressure sensor is faulty and must be
changed.
Exhaust system, inspection

1 Check that the exhaust system is a Volvo Penta
original part.
2 Check whether the exhaust system has been
modified, or has bends or damage that prevent
exhaust gas from flowing out.
If the exhaust system is not a Volvo Penta original
part, or has been modified, has bends or damage,
the exhaust back pressure may be too high,
which will reduce engine power.
Charge air cooler, checking

1 Check the charge air cooler for damage to the
cells and connections.
If there is any damage, change the charge air
cooler.
2 Check the charge air cooler and radiator for inner
clogging.
If there is any clogging, clean in accordance with
Charge Air Cooler, External Cleaning.
Inlet manifold, inspection

1 Check that the inlet pipes are clean inside, and
undamaged. Crushed, damaged or dirty inlet
pipes can reduce the charge pressure.
Charge air pipes, checking

1 Inspect the charge air pipes for visible cracks and
external damage.
2 Check that there is no oil in the charge air pipes.
If the pipes are damaged or the union seal rings
leak, the charge pressure will be too low and
engine performance will be affected.
If the pipes are contaminated with oil on the
inside, this indicates oil leakage in the
47701522 01-2016 © AB VOLVO PENTA 73

turbocharger turbine shaft seal. In this case, the

turbocharger should be changed as a unit.
IMPORTANT!
If there is oil in charge air pipes and charge air
hoses, the charge air cooler and all pipes and
hoses in the charge air system must be very
thoroughly cleaned inside, before the engine is
started.
Charge Air Cooler, External

Cleaning
Remove guards as necessary, to access the cooler.
Clean with water and a mild detergent. Use a soft
brush. Be careful not to damage the radiator matrix.
Re-install the components.
IMPORTANT!
Do not use a high pressure power washer.
74 47701522 01-2016 © AB VOLVO PENTA

Charge Air Pipe, Leakage Check

1 Inspect the charge air pipes for visible cracks and
external damage.
2 Check that there is no oil in the charge air pipes.
If the pipes are damaged or the union seal rings
leak, the charge pressure will be too low and
engine performance will be affected. If the pipes
are contaminated with oil on the inside, this
indicates oil leakage in the turbocharger turbine
shaft seal. In this case, the turbocharger should
be changed as a unit.
NOTICE! If there is any oil in the charge air pipes and

charge air hoses, the charge air cooler and all pipes
and hoses in the charge air system must be cleaned
very carefully before the engine is started.
NOTICE! In the charge air cooler(1) there is a so called

"overflow hole" to drain condensation out of the charge
air cooler. This hole can also indicate if there are any
oil- or coolant leakages.
1. The information is concerning the front charge air cooler on

engines with twin turbocharger.
47701522 01-2016 © AB VOLVO PENTA 75

21-0 Engine Complete, General
Exposing the Engine

1 NOTICE! Be prepared to gather up fluid.
Drain the coolant; refer to Coolant,

Draining, page 329.
p0013390
2 Drain the engine oil.

3 Shut the fuel valves between the tank and the fuel
feed pump.
Undo the fuel connections to and from the fuel

pump.
Undo the lower cooling coil connection.
76 47701522 01-2016 © AB VOLVO PENTA

5 Remove the covers (1 and 2) and the belt guard

(3).
6 NOTICE! Where necessary and possible, install

the engine fixture.
Carry out component removal according to

Engine with mounting and
equipment, page 89.
47701522 01-2016 © AB VOLVO PENTA 77

7 Remove the lower cooling pipes and cooling

hose(s).
8 Remove the inlet manifold; refer to Intake

Manifold, Change, page 289.
9 Remove the charge air pipe (1) from the inlet

manifold.
P0012281
10 Remove the CCV unit.
78 47701522 01-2016 © AB VOLVO PENTA

11 Remove the intermediate piece (1) for the CCV

unit and pressure sensor.
Disconnect the harness terminals (2) for the oil
pressure and crankcase pressure sensors.
12 D13B-A/C/G/H/K/L, D13C2-A, D13C4-A only

(twin turbocharger)
Remove the rear turbocharger; refer to Low
Pressure Turbo, Change, page 298
13 Remove the by-pass line and oil hose to the
turbocharger.
14 Remove the rear charge air cooler; refer to Front

Charge Air Cooler, Change, page 362
15 Remove the high pressure turbocharger; refer to
Low Pressure Turbo, Change, page 298.
16 Remove the front charge air cooler; refer to Front
Charge Air Cooler, Change, page 362
17 Remove the exhaust manifold; refer to Exhaust
47701522 01-2016 © AB VOLVO PENTA 79

18 Remove the bracket.
19 Remove the starter motor; refer to Starter Motor,

Change, page 397.
20 Remove the water pipe.

(twin turbocharger)
Remove the coolant hose to the rear
turbocharger.
80 47701522 01-2016 © AB VOLVO PENTA

22 Remove the two oil pipes.

Remove the oil line bracket; refer to Oil Leading
Bracket, Change, page 236.
23 Remove the brackets and the heat shield.
24 Remove the seawater pump.
47701522 01-2016 © AB VOLVO PENTA 81

25 Remove the alternator, the belt and the

attachment stay; refer to Alternator,
Change, page 394.
26 Remove the venting pipe and the water pipe.
27 Disconnect the harness terminal (1) to the coolant

temperature sensor.
Remove stub connection (2).
Remove the water distribution pipe (3).
82 47701522 01-2016 © AB VOLVO PENTA

28 D13B-A/B/G/H/J/K, D13C1-A, D13C2-A only

Remove the clamp securing the wire harness.
Disconnect the PCU harness terminals and
flywheel sensor.
Remove the PCU.
29 D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A only

Disconnect the Power module harness terminals,
the emergency stop switch and flywheel sensor
(3).
Remove the Power module (1) and emergency
stop switch (2).
30 Remove the oil filter bracket by unscrewing the

four outlets on the attachment plate and undoing
the harness terminals and wire harness clamps.
Remove the mountaing attachments for the heat
exchanger.
47701522 01-2016 © AB VOLVO PENTA 83

31 Remove the lifting plate.
32 Remove the wire harness; refer to Cable Trunk,

Change, page 406.
Port side wire harness.
Starboard side wire harness.
84 47701522 01-2016 © AB VOLVO PENTA

33 Remove the front engine mount.
Port side
Starboard side
47701522 01-2016 © AB VOLVO PENTA 85

Cable description
The illustrations on the following two show how wire
harnesses and hoses are positioned on the engine.
When changing harness, refer to Cable Trunk,
Change, page 406.
IMPORTANT!
When work on the engine is finished, wire harnesses
and hoses that were removed must be reinstalled
exactly as illustrated. Incorrect installation will result in
vibration damage.
D13B-A/B/G/H/J/K, D13C1-A, D13C2-A (following

page)
A PCU (Power Control Unit), behind the air filter,
communicates with the engine control unit. There are
contacts for eleven sensors. The stop button is above
the oil filter housing on the port side. The engine control
unit (ECU) is located behind the heat exchanger on the
port side.
D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A (two

pages on)
A Power module behind the air filter communicates
with the engine control unit. There are contacts for
twelve sensors. The stop button is located above the
Power module. The engine control unit (ECU) is
located behind the heat exchanger on the port side.
86 47701522 01-2016 © AB VOLVO PENTA

D13B-A/B/G/H/J/K, D13C1-A, D13C2-A, port side
D13B-A/B/G/H/J/K, D13C1-A, D13C2-A, starboard side
47701522 01-2016 © AB VOLVO PENTA 87

D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A, port side
D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A, starboard side
88 47701522 01-2016 © AB VOLVO PENTA

Fitting the Fixture

Tools:
88800345 Adapter
88800117 Plate
Heat exchanger removed; refer to Heat exchanger,

change, page 335.
Engine control unit removed; refer to Engine
Control Unit (ECU), Replace, page 400.
All fuel pump connections plugged.
1 Remove the engine control unit bracket.
Undo the clamp.

Remove the fuel line from the fuel pump.
3 Remove the pipe between the CCV unit(1) and

turbocharger.
1. CCV = Closed Crankcase Ventilation
47701522 01-2016 © AB VOLVO PENTA 89

4 Remove the cable ties holding the wire harness.
5 Remove the water pipe between the thermostat

and the heat exchanger.
6 Remove the fuel filter bracket; refer to Fuel filter

housing, change, page 252.

Remove the fuel pipe (1) and (2).
90 47701522 01-2016 © AB VOLVO PENTA

8 Remove the engine harness holder.
9 Install 88800117 Plate and fasten it with the bolts

supplied.
M8x30 (6 pcs)
M8x45 (3 pcs)
10 Attach 88800345 Adapter to the plate and fasten

it.
Hoist the engine and attach it to the engine stand.
47701522 01-2016 © AB VOLVO PENTA 91

Engine Fixture, Removal

Tools:
88800345 Adapter
88800117 Plate
1 Lower the engine from the engine stand.
Remove 88800345 Adapter and 88800117 Plate
from the engine.
NOTICE! Install the bolts in their intended places

on the plate.
2 Install the engine harness holder.
3 Install fuel pipe (2) and (1).

Tighten the clamps.
92 47701522 01-2016 © AB VOLVO PENTA

4 Install the water pipe.
5 Install the fuel filter bracket; refer to Fuel filter

6 Place the wire harness in the holder.

Clamp the harness.
7 Install the pipe between the CCV unit and the

turbocharger.
47701522 01-2016 © AB VOLVO PENTA 93

8 Install the fuel line.
9 Install the engine control unit bracket.

Secure the wire harness with clamps.
10 Install the engine control unit; refer to Engine

Control Unit (ECU), Replace, page 400.
Install the heat exchanger; refer to Heat
exchanger, change, page 335.
Vent the fuel system; refer to Fuel system,
bleeding, page 245.
94 47701522 01-2016 © AB VOLVO PENTA

Engine Disassembly
Timing Gear, Removal
Cylinder head removed; refer to 21-1, Cylinder
Head, Removal.
Tools:
9993590 Rotation tool
9998511 Lever
9998267 Guide sleeve
1 Remove the front engine mount.
P0010123
2 Remove the oil sump bolts and remove the sump.
47701522 01-2016 © AB VOLVO PENTA 95

3 Remove the starter motor.
P0010157
4 Remove the fuel pump with drive unit; refer to

Fuel Feed Pump, Change, page 256.
P0004300
5 Remove the flywheel sensor.

6 Rotate the flywheel to the zero mark. Check that
the crankshaft marking is at TDC.
Remove the flywheel bolts. Use
9993590 Rotation tool as a counterhold while
undoing the bolts.
Hoist the flywheel using suitable lifting eyes.
P0010159
96 47701522 01-2016 © AB VOLVO PENTA

7 Remove the lower timing gear cover bolts on the

starter motor side (2 pcs.).
P0010160
8 Remove the bolts on the fuel pump side (6 pcs.).
P0010161
9 Remove the remaining timing gear cover bolts.

Install lifting eyes and connect the lifting tool.
P0010162
47701522 01-2016 © AB VOLVO PENTA 97

10 Use 9998511 Lever to loosen the cover from the

intermediate plate on the fuel pump side.
P0010163
11 Use the pry bar in the same way on the starter

motor side.
P0010164
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12 Lift away the cover. Check which gear requires

replacing. The large gear (double gear) must not
be separated; it is always replaced complete. If
the oil pump gear requires replacing, remove the
fuel pump; refer to Lubrication Oil Pump,
Change, page 228.
13 Check that the crankshaft gear marking

corresponds to the double gear.
P0010180
47701522 01-2016 © AB VOLVO PENTA 99

14 Check that the camshaft gear marking

corresponds to the timing gear plate hole.
P0010181
15 Remove the lower intermediate gear.

Remove the double gear (Allen bolts at center).
16 Remove the intermediate gear.
17 NOTICE! Before the timing gear plate is

removed, two pcs. 9998267 Guide sleeve must
be installed on the engine block (tighten to 60 Nm
(44 lbf.ft)). This is to ensure that the plate is
replaced in exactly the same position.
It is now possible to remove the timing gear plate.

Remove all bolts. Using a pry bar, carefully prise
the plate free (held in place by sealant), but do
not prise such that the guide sleeves are budged
9998267 or damaged
P0010184
100 47701522 01-2016 © AB VOLVO PENTA

18 Remove the two bolts retaining the crankshaft

gear.
Remove the crankshaft gear using a suitable
puller. Place a larger washer beneath the puller
bolt to protect its thread from damage.
19 Clean the plate thoroughly on both sides. Clean
the engine block and cylinder head sealing
surfaces, but do not remove the plate guide
sleeves.
P0010185
Lube Oil Pump, Removal

1 Remove the oil pump; refer to Lubrication Oil
Pump, Change, page 228.
P0010153
Pistons, Removal
Tools:
885822 Magnetic pen
1 Remove the carbon uppermost in the cylinder
bore.
Make sure the press tool cannot touch the pistons
when the pistons are removed.
9996966
P0010048
47701522 01-2016 © AB VOLVO PENTA 101

2 Remove the piston cooling nozzles with the aid of

885822 Magnetic pen.
P0010126
3 Check that the connecting rods are marked; mark

the position if more than one is removed from the
engine.
P0010127
4 Undo the connecting rod bolts a couple of turns.

Tap the bolt heads so that the bearing cap is freed
from the connecting rod.
1
P0010128
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5 Remove the bolts entirely. Hold the connecting

rod in place and lift the bearing cap away at the
same time. Take care of the bearing cup if it does
not stay in place in the cap.
P0010129
6 Press out the piston with the connecting rod and

catch it under the engine. Make sure it does not
fall out and become damaged.
The connecting rod separation plane surface is
very sensitive and must not be exposed to impact
or knocks.
P0010130
7 Replace the bearing cap on the connecting rod

immediately to protect the separation plane
surfaces.
8 Remove the remaining pistons the same way.
P0012701
47701522 01-2016 © AB VOLVO PENTA 103

9 Remove one retainer ring for the piston pin and

press the pin out.
P0012702
10 Inspect the connecting rod; refer to Connecting

Rod, Check, page 187.
P0012703
104 47701522 01-2016 © AB VOLVO PENTA

Cylinder Liners, Removal

Tools:
9992955 Plate
9996645 Puller
9996394 Support
9996395 Support
1 Turn the engine so that the crankshaft is at the
bottom.
2 Remove the press tool holding the liner to be
removed.
P0010134
3 Assemble the tools 9992955 Plate,

9996645 Puller and 9996394 Support.
9996645 9996394
9992955
P0010135
47701522 01-2016 © AB VOLVO PENTA 105

4 Insert the tools in the liner to be removed. Make

sure the plate ends up directly under the liner.
Screw down on the nut so that the liner is drawn
up.
P0010136
5 If the liner does not come free when it has

reached the puller, release the nut sufficiently for
spacer 9996395 to be installed. Continue to pull
the liner up until it is free.
6 Lift out the liner with the tool and then remove the
9996395
tool from the liner.
7 Remove the remaining liners the same way.
8 Inspect the liners; refer to Cylinder Liner and
Pistons, Inspection, page 186.
P0010137
9 Remove the liner O-rings from the engine block.

Check the O-ring grooves for corrosion or any
other damage.
P0010138
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Crankshaft, Removal
Tools:
9990114 Puller
9990013 Slide hammer
1 Remove the crankshaft belt pulleys; refer to Drive
Belt, Change, page 358, 32-1, Alternator Belt,
Change.
2 Remove the crankshaft seal holder.
P0010156
3 Remove the main bearing cap bolts.

Use 9990114 Puller together with 9990013 Slide
hammer to rock the main bearing caps loose.
Keep the main bearing halves safe.
4 Remove the front engine mounts if they were not
removed earlier.
Attach a suitable lifting strap to the front and rear
end of the crankshaft according to the following
steps.
P0010165
47701522 01-2016 © AB VOLVO PENTA 107

5 Crank the crankshaft so that the timing mark ends

up exactly as illustrated. The crankshaft can only
be removed in this position.
Insert a bolt in the top hole in the timing gear.
P0010167
6 In the same manner, insert a bolt into the other

end of the shaft and attach the lifting strap.
P0010168
7 Lift the crankshaft and make sure that the

connecting rods and main bearing cups do not
come out with the crankshaft.
P0010169
108 47701522 01-2016 © AB VOLVO PENTA

8 Remove the thrust washers.

Remove the main bearing cups and wipe the
bearing seats dry. Fit new bearings.
Make sure the tabs fit into the notch in the bearing
seat and that the oil holes correspond to each
other.
Oil the bearings with engine oil.
P0010170
47701522 01-2016 © AB VOLVO PENTA 109

Engine Assembly
Crankshaft, Installation
Tools:
885811 Timing tool
885633 Torque multiplier
885648 Counterhold
9999696 Magnetic stand
9989876 Dial indicator
9998511 Lever
1 Inspect the crankshaft; refer to Crankshaft,
Inspection, page 223.
2 Check that the crankshaft is clean, that all bearing
surfaces are fault free and that the oil channels
are open. Install the crankshaft gear with a new
O-ring. Suspend the crankshaft in a lifting strap;
refer to Crankshaft, Removal, page 107.
Lubricate all bearing surfaces with engine oil.
3 Lower the crankshaft carefully into position. Align
the gearwheel markings with each other.
IMPORTANT!
Make sure that no connecting rod ends up in the
wrong position. The connecting rod separation
planes are very sensitive.
P0010167
4 When the crankshaft has been lowered onto the

main bearings, check that they are still correctly
positioned.
Install the thrust washers so that the locator tabs
end up in the intended notches.
P0010171
110 47701522 01-2016 © AB VOLVO PENTA

5 Wipe the main bearing caps dry and install new

bearings. Lubricate the bearing surfaces with
engine oil.
Install the thrust washers on the center main
bearing cap (fit the locator tab into the notch). The
center cap has a groove that must fit against a
locator tab in the engine block.
P0010172
6 Install the cap according to the marking. Use the

bolts to guide the caps straight. Tighten the bolts
so that the caps are pulled down onto the engine
block.
Check that the crankshaft can be rotated.
Torque and angle tighten the main bearing cap
bolts using 885811 Timing tool, 885633 Torque
multiplier and 885648 Counterhold according to
Special Tightening Torques, page 10.
Check once more that the crankshaft can be
rotated
P0010173
7 Check crankshaft end float with the aid of

9999696 Magnetic stand and 9989876 Dial
indicator.
Use 9998511 Lever move the crankshaft back
and forth. Read off the value on the dial indicator
and compare to Technical Data, page 32.
8 Install new bearings in the connecting rods and
big end bearing caps and install all connecting
rods; refer to Pistons, Removal, page 101.
Check that it is still possible to rotate the
crankshaft
9 Install the piston cooling nozzles if they were
removed.
P0010174
47701522 01-2016 © AB VOLVO PENTA 111

10 Remove the front crankshaft seal from the cover.

Clean the cover and engine block where the
cover is to be installed.
Apply sealant to the cover; refer to Special
Tightening Torques, page 10.
Install the cover and tighten the bolts in
sequence; refer to Special Tightening
Torques, page 10.
11 Install a new crankshaft seal and belt pulley; refer
to Crankshaft Seal, Change (front), page 211.
P0005229
4 5
6
3
2 7
1 8
P0005230
Cylinder Liner, Installation

Tools:
9996966 Press tool
9992479 Holder for dial indicator
9998511 Lever
9992955 Plate
1 Check the engine block liner seat for damage. If
the liner seat is damaged it must be repaired.
P0010139
112 47701522 01-2016 © AB VOLVO PENTA

2 Install the liner without O-rings and press the liner

down using two 9996966 Press tool.
P0010134
3 Measure the height between the liner and the

cylinder block plane. Measure the height of the
liner in two places, diagonal to each other.
Calculate the average of the two measurements.
For correct liner height above block plane, refer
to specifications. If the liner height is outside
specified tolerances, the liner seat must be
repaired (milled).
Always measure the highest point on the liner
sealing surface. Mark the liner's position with a
felt pen in order to re-install it in the exact same
position.
P0006964
P0006965
47701522 01-2016 © AB VOLVO PENTA 113

4 Remove the press tool and pull out the liner.

Clean the O-ring grooves in the engine block.
Lubricate new O-rings and insert them in the
grooves in the engine block; black uppermost,
then purple in the lower groove. Use the oil
supplied.
Install the O-ring on the cylinder liner.
Oil the lower part of the cylinder liner with the
lubricating oil supplied.
P0010140
5 Press the liner down according to the earlier

marking; if necessary use 9992955 Plate, a
suitable socket and 9998511 Lever against a
cylinder head bolt.
Press the liner down using two 9996966 Press
tool.
6 Install the remaining liners the same way
P0006967
A Cylinder head bolts

B 9998511 Lever
C Socket
D 9992955 Plate
Pistons, Installation
Tools:
9996966 Press tool
9998531 Piston ring compressor
1 Rotate the crankshaft so that the big end journal
for the piston to be installed ends up as low as
possible.
Remove the two press tools for the liner where
the piston is to be installed.
114 47701522 01-2016 © AB VOLVO PENTA

2 Lift the piston into place with the piston ring clamp
and connecting rod (big end bearing lubricated).
Make sure the piston is facing the right direction
(so that the connecting rod is in the right position
on the crankshaft). Tap down the piston with a
hammer shaft.
Remove the piston ring clamp when the piston is
below it.
Re-install the press tools for the cylinder liner.
Press down the piston so that the connecting rod
touches the crankshaft.
Install the big end bearing caps and align it
precisely with the crankshaft (big end bearing
oiled). Install the bolts.
P0010146
Torque the bolts and check that the crankshaft
can be rotated.
3 Install the remaining pistons the same way.
4 Clean the piston cooling nozzles and check that
they are not damaged.
Install the nozzles using new bolts. Check that the
nozzles are aimed directly at the piston oil cooling
hole.
P0010126
Lube Oil Pump, Installation

1 Install the oil pump, reinforcing plate, pipe and
suction strainer; refer to Lubrication Oil Pump,
Change, page 228.
P0010153
47701522 01-2016 © AB VOLVO PENTA 115

Timing Gear, Installation

Tools:
9999683 Dial indicator (short probe)
1 Apply a 2 mm (0.08") bead of sealant just outside
the groove on the timing plate, max 20 min. before
installation.
P0005221
27 28 29 2 Align the plate with the guide sleeves. Install all

26
24 the bolts and tighten them in sequence according
25 to Special Tightening Torques, page 10.
22
21 23
16
20
19
18
17
15
1 2
4 10
5 11
6 3
12
7
8 13
9 14
P0005222
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3 Install a new O-ring under the holder. Remove

9998267 Guide sleeve.
P0010186
4 Install a new O-ring on the crankshaft and

lubricate it.
Lubricate the inside of the gearwheel with the
same lubricant. Fit the gearwheel locator pin into
the crankshaft hole and make sure the oil pump
gear meshes with the crankshaft gear.
Install the bolts and tighten them alternately so
that the gearwheel is not skewed. Torque
according to Special Tightening
Torques, page 10.
P0010187
5 Clean the upper intermediate gear hub. Check

the oil holes are open.
Fit the washer onto the guide sleeve. Check that
the bolt holes align.
P0010186
47701522 01-2016 © AB VOLVO PENTA 117

6 Fit the hub onto the engine by aligning the guide

sleeve. Lubricate the thrust bearing with engine
oil.
P0010189
7 Check that the bearing is fault free. Lubricate the

bearing with engine oil.
Install the intermediate gear turned so that the
bearing is located outward.
8 Check that the lubricating hole in the plate is
open. Lubricate the rear of the plate.
P0010190
9 Fit the plate onto the centering guide and install

the bolts. Tighten the bolts until they touch.
Check that the gearwheel rotates easily.
P0010191
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10 Check the double gear bearing.

Align the marking on the double gear with the
marking on the crankshaft. Align the upper
intermediate gear teeth and fit the locator pin into
the center hole. Turn the hub so the bolt holes
align.
Install the bolts and tighten according to Special
P0010192
11 Install the lower intermediate gear.
P0010324
47701522 01-2016 © AB VOLVO PENTA 119

12 Install the camshaft gear without the oscillation

damper. Align the marking with the hole in the
timing plate.
Allow suitable spacers under the bolts to act as a
replacement for the vibration damper.
P0010193
13 Adjust the gear lash measurement as follows:

Undo the bolts to the upper intermediate gear so
that it is moveable. Check by rotating the
camshaft gear back and forth.
When the camshaft gear is rotated clockwise until
it stops the intermediate gear is moved to the left
so that a large gear lash measurement between
the camshaft gear and the intermediate gear is
obtained.
When the camshaft gear is rotated
counterclockwise until it stops the intermediate
gear is moved to the right so that a no gear lash
measurement between the camshaft gear and
the intermediate gear is obtained.
In order to adjust gear lash to the correct value,
insert a 0.10 mm (0.0039") feeler gauge between
the gearwheels and rotate the camshaft gear
P0010325
clockwise until it stops. Then tighten the
intermediate gear bolts and remove the feeler
gauge.
120 47701522 01-2016 © AB VOLVO PENTA

9999683 14 Check gear lash measurement using

9999683 Dial indicator (short probe) and
9999696 Magnetic stand. The upper intermediate
gear must be held secure when checking gear
lash. Compare with Technical Data, page 32.
9999696 Torque the bolts to the upper intermediate gear;
refer to Special Tightening Torques, page 10.
P0010544
15 Remove the bolts and spacers from the camshaft

gear.
Install the vibration damper, bolts and washer.
Tighten the bolts; refer to Special Tightening
Torques, page 10.
16 Remove the crankshaft seal from the flywheel
housing. Clean the flywheel housing contact
surfaces. Check that the locator sleeves are in
place.
P0010056
17 Apply a 2 mm (0.08") bead of sealant according

to Special Tightening Torques, page 10 (must be
torqued within 20 min).
P0005224
47701522 01-2016 © AB VOLVO PENTA 121

10 11 18 Lift the cover into place and align the guide

sleeves. Install all the bolts and torque according
8 9 to Special Tightening Torques, page 10 (M14 first
according to chart).
19 Inspect the flywheel. Where necessary, replace
6 7 the ring gear; refer to Gear Ring, Fywheel:
Replace, page 208.
1
2 3
4 5
P0005225
20 Install a new crankshaft seal; refer to Crankshaft

Seal, Change (rear), page 218. Install the
flywheel.
Check the flywheel with regard to distortion; refer
to Flywheel, Indication, page 207.
21 Install the flywheel sensor with a new seal; refer
to Sensors, Adjustment.
P0010159
22 Install the fuel pump with drive unit and new seal.
Install new fuel line seals.
P0004300
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23 Fit the starter motor along with its gasket and

washers.
P0010157
24 Clean the oil sump thoroughly. Check to see if the

oil sump rubber seal requires replacement.
Cut away excess sealant from the front
crankshaft seal cover. Cut away excess sealant
from the timing plate and the flywheel housing.
Apply new sealant to the joints and install the oil
sump within 20 min.
P0010147
25 Install the oil filler with attachment and the oil

dipstick.
47701522 01-2016 © AB VOLVO PENTA 123

26 Install the front engine mount and tighten the bolts

according to Special Tightening
Torques, page 10.
27 Install the cylinder head according to 21-1,
Cylinder Head, Installation.
124 47701522 01-2016 © AB VOLVO PENTA

Reassembly, Complete Engine

Proceed from assembled, basic engine
1 Attach the front lifting lug to the cylinder head.
2 Attach the rear lifting lug (1).

Attach the bracket plate (2) to the right side.
3 Install the rear engine mount.
47701522 01-2016 © AB VOLVO PENTA 125

4 Install the front right engine mount.

Install the center front engine mount.
5 Install the front left engine mount (1).

Install the alternator attachment (2).
Torque all engine mount bolts; refer to Group 21:
Engine, page 10.
6 Install the inlet pipe.

For seal replacements, refer to Intake Manifold,
Change, page 289.
126 47701522 01-2016 © AB VOLVO PENTA

7 Install the thermostat and thermostat cover.

For thermostat checks, refer to Thermostat,
Function Check, page 360.
For cold start valve checks refer to Cold Start
Valve, Check and Change, page 361
8 Install the oil line bracket with gasket.
NOTICE! Do not use sealant.

(twin turbocharger)
Install the two holders for the rear charge air
cooler.
47701522 01-2016 © AB VOLVO PENTA 127

10 Install the exhaust manifold with two seal rings for

the cooling water plus six exhaust gaskets.
NOTICE! The exhaust gaskets are marked on the

side that must face the manifold.
Use washers underneath the nuts and install new

nuts. These must not be tightened yet as torquing
takes place when the valve housing with the
turbocharger is installed.
NOTICE! The exhaust manifold can be tightened

directly for all single turbo engines and IPS twin
turbo engines.
The illustration shows an engine with a twin turbocharger.
11 Install the wire harness with attachment brackets.

Install the fuel pipes located behind the wire
harnesses.
The illustration shows the harness for a D13B-A/B/G/H/J/K, D13C1-

A, D13C2-A engine.
12 Install the large attachment bracket.

Next install the rails that secure the wire
harnesses below the inlet manifold.
The illustration shows a D13B-A/B/G/H/J/K, D13C1-A, D13C2-A

engine.
128 47701522 01-2016 © AB VOLVO PENTA

13 Clamp the wire harness that runs forward.

Install the relays on the holders and secure the
diode to the alternator attachment with a clamp.
14 Insert the injector harness into the cylinder head.

Check the grommet O-ring and lubricate if
needed.
Bolt the grommet fast and clamp the wiring for the
temperature sensor and waste gate valve.
15 Connect the injector wiring and clamp the wire

harness. Use VP original cable ties that are oil
and heat resistant.
47701522 01-2016 © AB VOLVO PENTA 129


Install the PCU.
Connect the PCU harness terminals and flywheel
sensor.
D13B-C/D/E/F/L/M/N, D13C3-A, D13C4-A only

Install the Power module (1) and emergency
stop switch (2).
Connect the Power module harness terminals,
(3).
17 Secure the wire harness with clamps down to the

starter motor and connect the camshaft sensor.
130 47701522 01-2016 © AB VOLVO PENTA

18 Check the valve cover gasket.

Install the valve cover (1).
D13B-A/C/G/H/K/L, D13C2-A, D13C4-A only

Install the heat shield (2) above the manifold.
19 Make sure the fuel lines are clamped correctly.
20 Install the fuel lines on the front of the cylinder

head and clamp the line below the lifting lug.
The illustration to the left shows the fuel line on

engines of earlier model.
47701522 01-2016 © AB VOLVO PENTA 131

The illustration to the left shows the fuel line on

engines of later model.
21 Run the fuel line as illustrated and bolt the by-

pass valve to the alternator attachment.
22 Secure the line with clamps.
132 47701522 01-2016 © AB VOLVO PENTA

23 Install the fuel filter bracket.

Install the fuel lines (1).
Install a new fuel filter.
Connect the harness terminal to the fuel pressure
sensor (2).
D13B-A/B/G/H/J/K, D13C1-A, D13C2-A only

Connect the water-in-fuel sensor harness
terminal (3).

engine.
24 Install the cylinder head fuel line and clamp it

secure on the suction pipe with the two clamps.

engine.
25 Install the fuel pump and connect the fuel lines.
47701522 01-2016 © AB VOLVO PENTA 133

26 Install the timing cover.

Install the heat exchanger attachment plate and
the hand pump.
Install and secure the fuel lines with clamps.
27 Install the engine control unit attachment plate

(1).
Clamp the wire harness secure (2).
28 Install the engine control unit.

Connect the fuel lines to the cooling duct.
134 47701522 01-2016 © AB VOLVO PENTA

29 Connect the harness terminals and secure the

wire harness with clamps.
30 Install the intermediate piece (1) for the CCV unit

and pressure sensor.
Connect the harness terminals (2) for the oil
31 Install the CCV unit.
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32 Install and clamp the CCV unit pipe secure.

Secure the harness with a cable tie.

engine.
33 Install the hose between the valve cover and CCV

unit.
Secure the hose with clamps and clamp the cable
using a cable tie.

engine.
34 Install the front heat exchanger attachment.

Install the oil filler on the attachment.
136 47701522 01-2016 © AB VOLVO PENTA

35 Install the oil filter bracket and attachment to the

upper plastic cover.
36 Align and fit the oil pipes to the oil line bracket.
37 Clamp the pipes and fasten the wire harnesses to

the upper pipe with cable ties.
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38 Install new oil filters.
39 Install the starter motor.

Make sure the insulation washers are in position
under the nuts and between the starter motor and
engine.
Connect the starter motor wiring.

Install the Y-pipe bracket.
Secure the wire harness with a cable tie.
D13B-B/D/E/F/J/M/N, D13C1-A, D13C3-A only

Secure the wire harness to the lower oil pipe,
above the flywheel, using a cable tie.
The illustration shows a D13B-A/C/G/H/K/L, D13C2-A, D13C4-A

engine.
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41 Install the water pump inlet pipe.

Do not tighten the lower bolts yet.
42 Install the water pipe to the manifold. Use VP

lubricant part # 1698135-8 for the seals.
43 Install the water pump temperature sensor

connector.
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44 Install the water pump.
45 Connect and tighten the pipe to the water pump.

Next tighten the lower water pipe bolt.
46 Install the hub and vibration damper and pulley to

the crankshaft.
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47 Install the water pipe (front) to the charge air

cooler.

Connect the water pipe for the rear charge air
cooler to the front pipe.

Install the cooling water hose to the rear
turbocharger.
NOTICE! Turn the hose the correct way as the

banjo nipples have different sizes.
47701522 01-2016 © AB VOLVO PENTA 141


Install the pipe for the rear charge air cooler.

Clamp the rear turbocharger cooling water hose
with the aid of the plastic holder to the water and
oil pipes.
52 Install the lower cooling pipe to the water pump.
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53 Install the upper cooling pipe to the thermostat

cover.
54 Install the rear heat exchanger bolt.
NOTICE! Leave a gap of arounbd 10 mm (0.4")

below the bolt head.
55 Lift the heat exchanger into place and guide the

rear bolt (1) into the rear attachment plate.
Install the remaining bolts.
Install the inlet pipe (2) from the thermostat to the
heat exchanger.
Install the valves (3) to the water outlet below the
heat exchanger.
NOTICE! The valves have guide pins so that they

cannot be mixed up or turned the wrong way.
Install the oil dipstick attachment fitting (4).
47701522 01-2016 © AB VOLVO PENTA 143

56 Install the seawater pump.

Install the oil hose from the by-pass filter and
secure it using cable ties.
57 Install the drip pan beneath the filter and attach

the holders.
58 Install the heat exchanger seawater inlet pipe.
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59 Install the heat exchanger seawater outlet.
60 Install the reverse gear oil cooler beneath the

heat exchanger
61 Install the alternator (or alternators) with

attachment.
Install the belt and check belt tension.
Install the alternator (or alternators).
47701522 01-2016 © AB VOLVO PENTA 145


(twin turbocharger)
Check the sealing surface on the wastegate
valve.
Check the tightening of the fasteners holding the
waste gate housing to the turbocharger.

(single turbocharger)
Check the sealing surface on the turbocharger.
The illustration shows a turbocharger with waste gate (D13B-A/C/G/

H/K/L, D13C2-A, D13C4-A, twin turbocharger).
63 D13B-A/C/H/L, D13C4-A Inboard engines only

Lift the valve housing with the turbocharger and
align it with the studs.
Install washers and new nuts.
Torque the manifold and turbocharger according
to Group 25: Inlet and Exhaust System, page 25.
Install the by-pass pipe on the side of the cylinder
head.
Install the coolant temperature sensor.
Install the bleeding pipe against the thermostat
housing, by-pass housing and to the pipe from the
exhaust manifold.

(twin turbocharger)
Clean and check the rear charge air cooler hose
connections and hoses.
Check the pipes where the hoses connect. Make
sure the hose clamps are positioned on the hoses
as illustrated.

(twin turbocharger)
Lift up the charge air cooler and slide the hoses
on the cooling pipes.
Fasten the charge air cooler using all bolts.
146 47701522 01-2016 © AB VOLVO PENTA


(twin turbocharger)
Remember the stays and spacers in front of the
engine.

(twin turbocharger)
Tighten the hose clamps into position as
ullustrated (in order to tighten/loosen them once
the engine is assembled).
Check that coolant pipes and hoses do not chafe
against anything behind the charge air cooler.

(twin turbocharger)
Install the oil return pipe to the turbocharger.
IMPORTANT!
The pipe must be pressed firmly into the engine
block. This is made easier when the new seal is
lubricated with VP lubricating oil part # 1698135-8
before installing on the pipe, and by greasing the
hole in the engine block before the pipe is pressed
into place.
Install the pipe with the locking clip.
69 D13B-B/D/E/F/J/M/N, D13C1-A, D13C3-A only

Install the coolant line.
IMPORTANT!
lubricated with VP lubricating oil part # 1698135-8
before installing on the pipe, and by greasing the
hole in the engine block before the pipe is pressed
into place.
Install the pipe with the locking clip.
47701522 01-2016 © AB VOLVO PENTA 147


(twin turbocharger)
Put the side of the heat shield in position.

(twin turbocharger)
Put the lower part of the heat shield in position.

(twin turbocharger)
Install the two bolts and spacers (1) that hold the
shield to the manifold. Do not tighten the bolts
fully.
Install the bolts that fasten the heat shield side to
its lower part. Clamp the oil hose with the center
bolt (2). Do not tighten the bolts fully.
73 Install the turbocharger bearing cooling water

hoses (1).

(twin turbocharger)
Install the oil pipe (2) from the wastegate valve to
the oil sump and connect the electrical terminals.
Clamp the oil pipe to the oil cooler cover.
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(twin turbocharger)
Install the turbocharger and wastegate valve oil
hoses.
Use a cable tie to hold the wastegate valve oil
hose to the turbocharger oil return pipe.

(twin turbocharger)
Install the heat shield but do not tightent the bolts
fully.
Check that the Y-pipe bolts fit into the holder.
NOTICE! The heat shield may require moving in

some direction for the Y-pipe bolts to fit.
Therefore the heat shield bolts are not tightened
until the Y-pipe is installed.

(twin turbocharger)
Install the Y-pipe (1) and fit the bolts. Do not
tighten the bolts fully.
Install the flex pipes (2) with new seal washers.
Install the clamps and fasten them.
NOTICE! Note the location of the clamps.
Tighten the Y-pipe bolts.

Tighten all heat shield bolts.
NOTICE! Do not forget the bolts to the front or the

two with spacers located on the underside up by
the manifold.

(twin turbocharger)
Install the upper part of the heat shield.
NOTICE! It should be installed later if checks are

to be made for any gas leaks after a test start.
47701522 01-2016 © AB VOLVO PENTA 149


(twin turbocharger)
Check the Y-pipe sealing surface and install a
new gasket.
Install the rear turbocharger.
Fit the water hoses to the turbocharger.
Connect the oil return pipe (1) to the
turbocharger.
NOTICE! Use VP lubricating oil part # 1698135-8

on the seal ring that fits against the flywheel
housing to facilitate oil pipe installation.
Connect the oil line (2) to the turbocharger and

clamp it to the lifting lug.

(twin turbocharger)
Tighten the two bolts (1) to the lower turbocharger
heat shield.
Clamp the water hose (2) to the oil return pipe.

(twin turbocharger)
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(twin turbocharger)
Install the boost air pipe.

(twin turbocharger)
Install the air filter holder (1).
Clamp the rubber stub hose (2) to the
turbocharger.
Install the CCV unit pipe and fasten the clamps.

(twin turbocharger)
Install the air filter housing.
47701522 01-2016 © AB VOLVO PENTA 151


(twin turbocharger)
Install the cover (1) above the turbocharger and
tighten the clamps (2) to the rubber stub hose.
85 Connect the charge air pipe to the inlet manifold.

Junction pipes and O-rings must be installed on
the charge air pipe.
NOTICE! Installation is facilitated if the O-rings

are lubricated with VP lubricating oil part #
1698135-8.
86 Install a spacer sleeve (1) on the long stud.

Make sure the hose clamps (2) are in position on
the charge air cooler hoses and that the hoses
are free from defects.
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87 Lift the charge air cooler and align it with the

studs.
Slide on the radiator hoses and the upper boost
air pipe once the charge air cooler is pressed into
place.
Install the nuts on the studs but do not tighten
them yet. The charge air cooler needs to be
somewhat moveable in order to facilitate
installation of the boost air pipe from the
turbocharger.
Check that the charge air cooler drainage hole
isn’t clogged.

(twin turbocharger)
Install the boost air pipe between the
turbocharger and the charge air cooler.
Fasten the boost air pipe and then fasten the
charge air cooler.
89 Install the attachment fitting.

Fasten the hose clamps to the charge air cooler
cooling hoses.
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(twin turbocharger)
Install the boost air pipe from the rear charge air
cooler to the turbocharger.

Install the oil feed line and coolant line.

Install the wastegate valve hose.
Secure the hose with clamps.
154 47701522 01-2016 © AB VOLVO PENTA


Make sure there is no contamination in the charge
air cooler or boost air pipe.

Make sure there is no contamination in the pipe
from the air filter.
Install the pipe between the air filter and the
turbocharger.
Install the exhaust connection.

Install the two air filter holders.
Clamp the rubber stub hose between the
turbocharger and the air filter.
Fasten the clamps on the rubber stub connection.
The illustration shows a D13B-D/E/F/M/N, D13C3-A engine
47701522 01-2016 © AB VOLVO PENTA 155


Install the top and bottom intermediate panel. The
top intermediate panel must be aligned with a
metal tag on the bottom intermediate panel and
fastened with two bolts.

Install the bottom and top heat insulation mat.
NOTICE! Check that the insulation mats are lying

correctly against the turbo. Fit in the middle mat
piece between the wastegate valve and the turbo.

Align the bottom plastic cover.
156 47701522 01-2016 © AB VOLVO PENTA


Install the two bolts against the intermediate
panel.
Install the other bolts.

Align the top plastic cover with insulation mats on
the turbo.
NOTICE! Check that the insulation mats are lying

correctly against the turbo. If needed, push down
the insulation mats from behind (between the
upper bracket and the turbo) so that the whole
turbo surface is being insulated.
Install all the bolts.
102 Install the expansion tank.
NOTICE! Do not forget the attachment fitting

under the rear retaining bolts.
Install the coolant level sensor connector.
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103 Install the hose / pipe (later mod.) to the lower

coolant pipe and clamp the hose to the CCV unit.
104 Install and secure the venting pipe with clamps.
P0012669
105 Install the battery cable connectors and connect
to the starter motor.
106 Install the belt guard and other covers.
Fill the cooling system. Vent and test pressure
again.
Top up engine oil.
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21-1 Cylinder Head
21-1 Cylinder Head

Cylinder Head, Change
Tools:
885810 Fixture
885822 Magnetic pen
9990006 Puller
9990156 Adapter
9996966 Press tool
9998251 Protection plug
9998601 Fixture
9998674 Adapter
9999683 Dial indicator (short probe)
Oil and coolant drained.
Removal
IMPORTANT!
Work on the fuel system demands exceptional
cleanliness.
Install protective plugs in open connections.
Cylinder head fuel channels empty; refer to

Draining, Fuel Duct in Cylinder Head, page 246.
1 Carry out component removal with the engine in
a stand. Refer to Engine with mounting and
equipment, page 89.
2 Remove the inlet manifold; refer to Intake
3 Remove the charge air cooler; refer to Front
Charge Air Cooler, Change, page 362.
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21-1 Cylinder Head
4 Remove the turbocharger; refer to Low Pressure

Turbo, Change, page 298.
D13B-B/D/E/F/J/M/N only (single

turbocharger)
Remove the pipe between the air filter and the
turbocharger.
D13B-A/C/G/H/K/L only (twin turbocharger)

Remove the Y-pipe and the two flex pipes.
All engines
Heat shields removed.
5 Remove the exhaust manifold; refer to Exhaust

6 Remove the water pipes.
7 Remove the thermostat cover and thermostat;

refer to Thermostat, Change, page 353.
8 Remove the venting pipe.
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21-1 Cylinder Head
9 Disconnect harness terminal to the coolant

temperature sensor.
Remove the stub connection.
10 D13B-A/B/G/H/J/K only
Disconnect the PCU harness terminals and
flywheel sensor.
Remove the PCU.
11 D13B-C/D/E/F/L/M/N only
Disconnect the Power module harness terminals,
(3).
Remove the Power module (1) and emergency
stop switch (2).
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21-1 Cylinder Head
12 Remove the lifting attachment and bracket plate.
13 Remove the fuel return line and cable fasteners.
14 Remove the fuel line.
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21-1 Cylinder Head
15 Remove the valve cover.
16 Disconnect the injector connectors.

Cut away the cable ties and carefully pull the
harness out through the harness grommet.
17 NOTICE! Seal below intermediate piece and on

the pipe.
Remove the intermediate piece for rocker arm

lubrication.
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21-1 Cylinder Head
18 Remove the camshaft sensor and then the upper

timing cover.
19 Remove the flywheel housing plugs. Fit

9993590 Rotation tool and a ratchet handle.
Turn the engine until the flywheel marking is at 0.
20 IMPORTANT!
Make sure the camshaft is at TDC.
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21-1 Cylinder Head
21 Remove the rocker arm shaft. Undo the bolts

alternately so the shaft is not bent.
22 Adjust the rocker arm holders.

Lift away the rocker arm bridge using
9990185 Lifting tool.
23 IMPORTANT!
Note the location of the components.
Mark and then remove the valve yokes.
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21-1 Cylinder Head
24 IMPORTANT!
Protect the components from knocks and
impacts.
Remove the vibration damper and camshaft gear.
25 Remove the camshaft cap bolts.

Check that the caps are marked.
26 Remove the caps. Use 9996400 Slide hammer

and 9998674 Adapter.
Place the bearing caps to one side with the upper
bearing halves in the correct order.
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21-1 Cylinder Head
27
CAUTION!
Cutting hazard! Protect your hands!
Use 9998264 Lifting tool to lift the camshaft.
28 Clean around the unit injectors and unscrew the

injector yoke bolts.
29 Remove the unit injectors. Use 9990006 Puller

and 9990013 Slide hammer.
Check that the seal washers (steel washers)
come out with the injectors. If one is still in the
copper sleeve, remove it using 885822 Magnetic
pen.
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21-1 Cylinder Head
30 NOTICE! Dirt particles may cause the unit

injectors to fail. Clean as necessary.
Mark the injectors and fit 9998249 Protective

sleeve to them.
31 Insert 9998251 Protection plug in the cylinder

head.
Remove the remaining injectors the same way.
32 Remove the bearing bracket with bearing shells

and place them together with the respective
camshaft cap, upper bearing half.
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21-1 Cylinder Head
33 Remove the bolt and washer.
34 Crank the crankshaft so that the timing gear is in

the same position as illustrated to get the bolt
through the gear wheel.
Remove the bolts that hold the intermediate plate
against the cylinder head. Only remove the four
upper bolts from the timing gear.
35 Remove the cylinder head bolts.
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21-1 Cylinder Head
36 NOTICE! Place washers between the cylinder

head and lifting chains to protect the cylinder
head sealing surface.
Use two lifting chains, tool 9996239 Lifting tool,

to lift away the cylinder head.
Remove the cylinder head gasket.
37 Install 9996966 Press tool.
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21-1 Cylinder Head
Installation
38 Clean the mating surface, the cylinder block
sealing surfaces and the cylinder head.
39 Checker liner height; refer to Cylinder Liner,
Installation, page 112.
40 Install a new cylinder head gasket and align it with
the liners.
Tighten the two bolts and washers.
41 Dip the full length of the cylinder head bolts in VP

corrosion inhibitor, part # 1161346.
P0012738
42 NOTICE! The components must be installed

within the specified time after the application of
sealant.
Apply sealant outside the transmission cover

groove.
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21-1 Cylinder Head
43 Install bolt and washer (1). The bolt may only be

screwed in a few turns.
Lower the cylinder head into position.
Make sure the washer (1) ends up outside the
engine block edge. Then tighten the bolt so that
the washer pulls the cylinder head sideways until
it touches the two washers (2) on the engine block
side.
44 Leave a 5–10 mm (0.2–0.4") gap (A) to the timing

plate.
45 Install a bolt in the upper timing gear and tighten

it so that the cylinder head is pulled toward the
timing plate.
Undo the bolt approx one turn.
The cylinder head is now in the correct position to
be fastened by the cylinder head bolts.
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21-1 Cylinder Head
46 Install the cylinder head bolts.
NOTICE! Tighten the bolts in sequence as

illustrated; refer to “Cylinder head” in Special
47 Timing plate
Tighten the bolts in sequence.
Tightening torque: 28 Nm (20.65 lbf.ft.).
Idler gear
To be tightened according to spec after gear lash
adjustment.
48 Install the camshaft bearing brackets as marked

on the cylinder head; make sure they abut the
cylinder head.
Place the bearing shells in the bearing brackets.
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21-1 Cylinder Head
49 Crank the engine using 9993590 Rotation tool so

that the flywheel is set exactly to zero according
to the marking on the flywheel housing.
50
CAUTION!
Inspect the camshaft with regard to wear; refer to

Camshaft, Wear Check, page 206.
Install 9998264 Lifting tool.
51 Rotate the camshaft to TDC.
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21-1 Cylinder Head
52 Oil the bearing shells and the install bearing caps

on their respective bearing brackets as marked.
Fasten the bearing caps to the torque specified in
“Bearing caps, camshaft” in Special Tightening
Torques, page 10.
Check that the camshaft can be rotated while the
bearing caps are being tightened.
53 IMPORTANT!
Make sure the camshaft is at TDC on the flywheel
marking.
Install the camshaft gear so that the locator pin

aligns with the hole in the camshaft and the gear
marking facing the hole in the timing plate.
P0010053
54 Install three bolts with suitable spacers in the gear

and tighten them.
P0010054
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21-1 Cylinder Head
55 Undo the bolts to the upper intermediate gear so

that it is moveable. Check by rotating the
camshaft gear back and forth.
When the camshaft gear is rotated clockwise until
it stops the intermediate gear is moved to the left
so that a large gear lash measurement between
the camshaft gear and the intermediate gear is
obtained. When the camshaft gear is rotated
counterclockwise until it stops the intermediate
gear is moved to the right so that a no gear lash
measurement between the camshaft gear and
the intermediate gear is obtained.
In order to adjust gear lash to the correct value,
insert a 0.10 mm (0.0039") feeler gauge between
the gearwheels and rotate the camshaft gear
counterclockwise until it stops. Then tighten the
intermediate gear bolts and remove the feeler
gauge.
56 Check gear lash measurement using

9999683 Dial indicator (short probe) and
9999696 Magnetic stand.
Hold the intermediate gear still and turn the
camshaft gear back and forth and compare the
result with the specified gear lash measurement.
Refer to Special Tightening Torques, page 10.
Tighten the bolts to the upper intermediate gear.
Tightening torques
Stage 1: 35 Nm (25.81 lbf.ft.)
Stage 2: (angle tightening) 120° ±5°
Remove the bolts and spacers from the camshaft

gear.
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21-1 Cylinder Head
57 Install the vibration damper, bolts and washer.
Drive gear, camshaft (incl. vibration damper)

Stage 1: 45 Nm (33.19 lbf.ft.)
Stage 2: (angle tightening) 90° ±5°
58 NOTICE! The components must be installed

sealant.
Apply sealant as illustrated.
59 Fit the rubber seals and install the upper timing

gear cover (refer to the next step).
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21-1 Cylinder Head
60 Install the cover with the two bolts located in the

oval holes. Torque to 4 Nm (3 lbf.ft.).
61 Fit 885810 Fixture and 9998601 Fixture. Press

down the cover so that it aligns with the height of
the upper side of the cylinder head.
62 Install the remaining bolts.

Tighten the bolts in sequence.
Remove the press tools.
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21-1 Cylinder Head
63 Install the camshaft sensor and heat shield; refer

to Sensors, Adjustment, page 209.
64 NOTICE! Fit injectors one at a time in order to

prevent dirt from entering the fuel channels.
Remove 9998251 Protection plug with

9990156 Adapter and 9996400 Slide hammer.
65 Clean the copper sleeve using 9998599 Cleaning

kit; refer to Sleeve for unit injector,
replace, page 266.
66 Remove the unit injector from the protective
sleeve.
Replace the O-rings on the unit injector by using
3883671 Protective sleeve and
3883672 Protective sleeve.
Lubricate the O-rings with diesel.
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21-1 Cylinder Head
67 Fit a new seal washer (steel washer) on the

injector sealing surface.
IMPORTANT!
The steel washer must be replaced with a new
one every time an injector is installed.
Install the injector and injector yoke. Turn the

injector so that the wiring connections are in
between the valve springs.
For tightening torque, refer to Special Tightening
Torques, page 10.
Install the remaining unit injectors in the same
way.
68 Install the valve yoke according to the marking.
69 Lubricate the valve yokes and the unit injector ball

seats.
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21-1 Cylinder Head
70 Install the rocker arm bridge. Guide all rocker

arms so that they assume the correct positions.
Remove the lifting tool from the rocker arm
bridge.
71 Install the rocker arm shaft bolts.

Check that the valve yokes are positioned
correctly on the valve stem.
Tighten the bolts alternately so that the rocker
arm shaft is not bent. Make sure the shaft locates
on the bearing cap guide sleeves.
Fasten the rocker arm shaft to the torque
specified in “Bearing caps, rocker arm shaft” in
72 Install the rocker arm lubrication valve housing

and oil pipe.
NOTICE! The sealing on the bottom of the

housing and on the pipe.
Adjust the valves and unit injectors; refer to

Valves and Unit Injectors,
Adjustment, page 188.
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21-1 Cylinder Head
73 Install the harness for the injectors.

Secure using oil resistant cable ties, VP part #
983472.
74 Install the valve cover.


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21-1 Cylinder Head
76 Install the fuel return line.

77 Fit the lifting attachment and bracket plate.
78 D13B-A/B/G/H/J/K only
Install the PCU.
Connect the PCU harness terminals and flywheel
sensor.
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21-1 Cylinder Head
79 D13B-C/D/E/F/L/M/N only
Install the Power module (1) and emergency stop
switch (2).
Connect the Power module harness terminals,
(3).
80 Connect the coolant temperature sensor harness

terminal.
Install the stub connection.
81 Install the thermostat cover and thermostat; refer

to Thermostat, Change, page 353.
82 Install the venting pipe.
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21-1 Cylinder Head
83 Install the water pipes.
84 Install the exhaust manifold; refer to Exhaust

85 Install the turbocharger; refer to Low Pressure

D13B-B/D/E/F/J/M/N only (single

turbocharger)
turbocharger.
D13B-A/C/G/H/K/L only (twin turbocharger)

Install the Y-pipe and the two flex pipes.
All engines
Install the heat shield.
86 Install the charge air cooler; refer to Front Charge
Air Cooler, Change, page 362.
87 Install the inlet manifold; refer to Intake Manifold,
Change, page 289.
88 Carry out component installation and remove the
engine from the stand. Refer to Engine Fixture,
Removal, page 92.
Finishing off
89 Check engine oil level; top up as necessary.
90 Fill with coolant; refer to Technical
Data, page 48.
91 Open the sea cock.
92 Switch on power.
93 Start the engine and check for any leaks.
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21-3 Cylinder Liner, Pistons

Cylinder Liner and Pistons,
Inspection
Clean the cylinder liners carefully before
inspection and measurement.
IMPORTANT!
The piston and cylinder liner sets are only available as
a single, complete unit.
Cylinder Liner
Measurement of cylinder liner wear can be done with
the liner installed in the cylinder block.
NOTICE! The cylinder liners must be taken out of the

engine block, to do a careful crack check.
1 Measure the cylinder liners with a cylinder

indicator. In order to obtain the greatest possible
accuracy in the wear measurement, the cylinder
liner must first be set up with a gauge ring or
micrometer. Use the original diameter of the
cylinder liner as the base value.
2 Measure the cylinder liner at top and bottom dead
centers, and at several places vertically.
P0006962
At each measurement location, measurement
must be lengthwise and crosswise in relation to
the engine.
3 If wear is greater than 0.45–0.50 mm, a new
complete lining kit must be used (piston, liner,
piston rings, piston pin and seals).
Oil consumption also affects when cylinder liners
must be changed.
4 Remove the cylinder liner and do a crack check.
Be specially careful when checking the liner
collars.
The Magnaflux method may be used for this
check.
Pistons
5 Check for worn piston ring grooves, damaged
retainer ring grooves, cracks and other damage
to the pistons.
If the piston has deep scratches on its skirt, the
piston (liner kit) must be scrapped. The same
applies if the piston has one or more cracks in the
piston pin hole or in the bottom of the combustion
chamber.
Crack tests must be done using the chalk powder
method.
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Connecting Rod, Check

Important consideration when removing/installing
fracture-split connecting rods.
Installing a NEW connecting rod:

Carefully fix the connecting rod in a vise with soft jaw
pads.
Undo the connecting rod bolts a few turns and carefully

tap the bearing cap with a plastic faced hammer until
it loosens.
The split line can be difficult to find when the

connecting rod is assembled.
When the cap is separated from the connecting rod, it

may occur that a chip is missing or comes loose. This
does not affect the function of the connecting rod
adversely.
Handle the connecting rod and bearing cap carefully.

If any strike marks occur on the split line, this may
affect strength after torquing.
IMPORTANT!
If the connecting rod or bearing cap are damaged,
change the connecting rod.
Connecting Rod Bushing, Check up

1 Check the connecting rods for cracking,
straightness and twist before any piston pin bush
replacement. Scrap the connecting rod if it is
cracked, bent or twisted.
When the piston pin bush is changed, the bush
must be machined (trapezoid piston pin end).
When the clearance is correct, an oiled piston pin
should slowly slide through the bush under its
own weight.
3 IMPORTANT!
2 Regarding max. allowed straightness and twist
deviations, refer to Technical Data, page 32.
P0006994 P0006995
2 Use a new piston pin and measure the

straightness of the connecting rod, using a fixture.
3 Measure connecting rod twist.
47701522 01-2016 © AB VOLVO PENTA 187

21-4 Valve Mechanism

Valves and Unit Injectors,
Adjustment
Shield above forward turbocharger removed.
Shields above the filter bracket and forward charge
air cooler removed.
1 Undo the five expansion tank bolts so that the
tank can be moved a little.
2 Remove the CCV unit hose (1) from the valve

1 cover.
P0012534
3 Remove the coolant system venting hose clamp

(1). This is done to be able to move the hose aside
1 to gain more space when removing the valve
cover.
P0012535
188 47701522 01-2016 © AB VOLVO PENTA

4 Remove the valve cover bolts (20 pcs.).

Remove the valve cover.
5 Remove the flywheel housing plug.

Insert 9993590 Rotation tool in order to crank the
engine with the aid of a ratchet handle.
6 Crank the engine with the ratchet handle until the

nearest marking arrives between the markings on
the camshaft cap.
Adjust the valves and unit injectors on the cylinder
that is marked by the camshaft marking.
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The illustration to the left shows the inlet valves

marked with thicker lines.
P0012527
7 Adjust the inlet valves according to Valve

mechanism, page 34.
Fasten with the nut.
8 Adjust the exhaust valves according to Valve
mechanism, page 34.
Fasten with the nut.
9 Adjust the unit injectors by first undoing the
adjuster screw until there is play between the
rocker arm and unit injector.
Tighten the screw until the play disappears; use
fingers to feel when the roller can no longer be
moved against the camshaft.
Turn the adjuster screw down 240° (4 flats) and
lock it with the nut.
10 Mark the rocker arms that have been adjusted.

Crank the engine until the next camshaft marking
and adjust the valves for the next cylinder.
Repeat until the valves for all cylinders have been
adjusted.
11 Check to see if the valve cover gasket needs to
be changed.
Clean the cylinder head valve cover sealing
surface.
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Install the 20 bolts and tighten according to Group
21: Engine, page 10.
13 Install the coolant system venting hose clamp (1).
P0012535
14 Align the expansion tank and tighten the bolts (3

pcs.).
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15 Install the CCV unit hose (1).

1
P0012536
16 Remove 9993590 Rotation tool used to crank the

engine and re-install the plug.
Re-install covers on engine.
192 47701522 01-2016 © AB VOLVO PENTA

Valve Guides, Inspection

Tools:
Cylinder head removed

Refer to removal in Cylinder Head,
Change, page 159.
1 Remove the valve stem seals from the valve
guides.
2
IMPORTANT!
The cylinder head must not be put down so its
entire weight rests on the valve guides (see
illustration).
Put the cylinder head on the bench with the valve
discs facing upwards.
3 Place a new valve in the valve guide with the
valve stem end in the same plane as the edge of
the guide. Use a suitable counterhold under the
valve stem.
4 Place tool 9989876 Dial indicator and tool
999 9696
9999696 Magnetic stand, so that the dial indicator
tip is touching the valve disc edge.
998 9876 Move the valve sideways, in the direction of the
exhaust or inlet duct. Read off the value on the
dial gauge.
5 Check all valve guides.
If the measurement values exceed the values
noted in the specifications, the valve guide must
be changed; refer to Technical Data, page 32.
p0005207
47701522 01-2016 © AB VOLVO PENTA 193

Valve Guides, Replacing

Cylinder head removed.
NOTICE! If the valve seats must also be changed, this

must be done before the valve guides are removed.
CAUTION!
Risk of eye injury. Eye protection required.
Option 1
Tools:
9809726 Pneumatic hydraulic pump
9809729 Hydraulic cylinder
9990176 Press tool
9996159 Adapter
88800147 Drift
88800062 Drift
Optional tools
Tools:
9992670 Hand pump
Note: 9992670 is alternative to 9809726.
Removal
999 2670 980 9729 1 Install tool 9990176 Press tool into the cylinder
980 9726 head retaining bolt holes.
NOTICE! Put washers between the nuts and the

cylinder head plane.
999 0176 2 Tighten the nuts of the tool.
999 6159 3 Install tool 9996159 Adapter in the hydraulic
888 00147 cylinder.
4 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool and press out the valve guide
using tool 88800147 Drift
and9809726 Pneumatic hydraulic pump ,
alternatively 9992670 Hand pump.
5 Press the other valve guides out in the same way.
p0003637
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Installation
6 Heat the cylinder head with hot water while
cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
IMPORTANT!
Wear protective goggles when pressing.
999 2670 980 9729 7 Press in the valve guide for the inlet valve using
980 9726 tool 88800062 Drift. Press in the exhaust valve
guide using the same tool.
8 Press until the tool bottoms against the cylinder
head plane.
9 Remove the tool from the cylinder head.
999 0176
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
999 6159
Option 2
888 00062
p0011273
Tools:
9992000 Handle
88800147 Drift
88800062 Drift
NOTICE! If the valve seats must also be changed, this

must be done before the valve guides are removed.
CAUTION!
47701522 01-2016 © AB VOLVO PENTA 195

Removal
NOTICE! Take out the valve guides from beneath the
cylinder head.
1 Tap out the valve guides with tool 88800147 Drift

together with 9992000 Handle.
2 Tap the other valve guides out in the same way.
Installation
3 Heat the cylinder head with hot water while
cooling the valve guides with e.g. carbon dioxide
snow.
Lubricate the cylinder head valve guides with
engine oil.
CAUTION!
4 Tap in the valve guide for the inlet valve using tool
88800062 Drift. Tap in the exhaust valve guide
using the same tool.
5 Tap until the tool bottoms against the cylinder
999 2000 head plane.
6 Repeat the procedure for the remaining valve
guides.
IMPORTANT!
After the valve guides have been changed, the cylinder
head must be cleaned carefully to prevent dirt particles
from getting into the fuel and oil ducts. Contamination
may cause failure or malfunction of the unit injectors.
P0011274 888 00062
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Valves, Removal
Work is made easier if the cylinder head is fixed in an

equipment stand using tool 88800058 Stand. Use 4
pcs. bolts M8 x 25.
NOTICE! It is important that the greatest possible

cleanliness is observed during work on the cylinder
head. Dirt particles in the fuel ducts can cause failure
or malfunction of the unit injectors.
Alternative 1
Tools:
9809729 Hydraulic cylinder
P0006996 88800058 Stand
9990174 Drift
9992670 Hand pump
9996159 Adapter
9998246 Drift
Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2
Tools:
9990210 Valve spring compressor
Alternative 1
1 Fit tool 9809729 Hydraulic cylinder into tool
9990176 Press tool.
2 Install tool 9996159 Adapter and tool
9998246 Drift (inlet) or tool 9990174 Drift (outlet)
on the hydraulic cylinder. Place the tool in the
holes for the cylinder head retaining bolts.
Tighten the tool nuts.
3 Connect tool 9809726 Pneumatic hydraulic pump
(alternatively 9992670 Hand pump).
4 Press the valve spring washer down and remove
the collets.
NOTICE! Check that the tool does not damage

the unit injector electrical connector, if the injector
is left in place.
NOTICE! Put the valves and springs in a marked

stand, to facilitate putting components back in the
same places in the cylinder head.
5 Remove the remaining valves in the same way as
above, using the press tool.
6 Remove the oil seals from the valve guides.
47701522 01-2016 © AB VOLVO PENTA 197

Alternative 2
Tools:
1 Lay the cylinder head on a flat, clean surface.
Make sure the cylinder head is not damaged
when the valves are to be removed.
2 Fit tool 9990210 Valve spring compressor in the
unit injector hole. Fix the tool in the bolt hole for
the unit injector yoke, M10 x 30.
3 Place the moving part of the tool over the valve
spring to be removed. Screw down the “wing nut”
on the tool until the valve washer has been
pressed down so far that the collets can be
removed.
NOTICE! Put the valves and springs in a marked

P0006997
stand, to facilitate putting components back in the
same places in the cylinder head.
4 Remove the remaining valves in the same way as
above.
5 Remove the oil seals from the valve guides.
198 47701522 01-2016 © AB VOLVO PENTA

Valves, Installation
Alternative 1
Tools:
9990174 Drift
9990176 Press tool
9992670 Hand pump
9996159 Adapter
9998246 Drift
88800151 Drift
Note: 9992670 Hand pump is alternative to

9809726 Pneumatic hydraulic pump .

Alternative 2
Tools:
1 Oil the valve stems and install the valves.
Oil the oil seals.
2 Install tool 9990165 Guide sleeve on the valve
stem and press the new oil seals down over the
valve guides.
NOTICE! Check that the oil seals are pressed

down properly. If necessary, use 88800151 Drift
and tap carefully with a plastic mallet.
P0006998
Alternative 1
3 Install the valve caliper guide pins.
Install the springs and valve spring washers.
Carefully press down the valve spring washer and
install the collets. Use tool 9990176 Press tool
together with 9809726 Pneumatic hydraulic
pump , 9996159 Adapter and 9998246 Drift (inlet)
or 9990174 Drift (outlet), in the same way as for
Valves, Removal.
47701522 01-2016 © AB VOLVO PENTA 199

Alternative 2
Tools:
1 Alternatively, tool 9990210 Valve spring
compressor may be used instead of the hydraulic
cylinder, in the same way as for Valves, Removal.
P0006997
200 47701522 01-2016 © AB VOLVO PENTA

Valve Seats and Valve, Grinding
For valve sealing angles, refer to Technical

Data, page 32.
NOTICE! Spare part valve seats are already

machined, and do not need further grinding.
Valve seat, grinding

1 Before the valve seats are ground, the valve
P0007076 guides must be checked and changed if wear
tolerances have been exceeded.
2 When grinding valve seats, do not remove an
unnecessary amount of material; only remove
enough material to give the valve seat the correct
shape and a good mating surface.
25
3 Grind new seats down so far that the dimension
24,5 between the cylinder head plane and the valve
disc surface, is in accordance with specifications;
refer also to Technical Data, page 32.
4 Check the valve seat angle with a valve seat
gauge, once the seat mating surface has been
coated with a thin layer of marker dye.
P0010244
Inlet valve
40
39,5
P0010245
Exhaust valve
47701522 01-2016 © AB VOLVO PENTA 201

NOTICE! Spare part valves are already machined, and

do not need further grinding.
NOTICE! The sealing surface must be ground as little

as possible; however, enough to grind away all
damage.
Valves, grinding
1 Check dimension (A). If the dimension is greater
than the wear tolerance as specified in Technical
Data, page 32, the valve must be changed.
NOTICE! Always change a valve with a bent

valve stem.
2 Check valve sealing with marker dye. If there is
any leakage, grind the valve seat again; refer to
Valve Seat, Grinding, then do a new check.
Once the results of grinding are acceptable, the
valve and seat may be lapped in with fine grinding
P0007000 paste.
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Valve Seat, Change

Cylinder head and valves removed.
Tools:
9992479 Holder for dial indicator
1 The valve seats must be changed if a satisfactory
seal cannot be obtained or when the distance (A)
exceeds the value stated in the specification;
refer to Technical Data, page 32.
P0007000
2 Grind the head off an old valve and weld it onto

the valve seat. Use a MAG welder, or a
conventional arc welder (with a stainless welding
electrode).
IMPORTANT!
Carefully cover the other surfaces on the cylinder head
to prevent any weld spatter from fastening.
P0007001
P0007002
47701522 01-2016 © AB VOLVO PENTA 203

3 Place a suitable socket over the valve/valve guide

and carefully tap the valve seat out.
IMPORTANT!
Be careful not to damage the cylinder head.
CAUTION!
4 Clean the seat bed carefully and check the
cylinder head for cracks.
5 Measure the diameter of the valve seat bed in the
cylinder head. Determine whether a standard or
oversize dimension valve seat must be used.
Carry out any necessary machining to the valve
P0007003
seat bed; refer to Technical Data, page 32.
6 Cool the seat in carbon dioxide snow between –

60 °C (–76 °F) and –70 °C (–94 °F) and heat the
cylinder head by flushing with hot water, or by
some other method.
Install the new valve seat using a drift.
NOTICE! Align the seat with the seat angle facing

the tool. Check sealing against the valve.
P0007004
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Valve Stem Sealings, Replace

Tools:
Removal
1 Disconnect all current to the engine, by switching
off the main switch.
2 Remove the unit injectors; refer to the removal
section in Unit Injector, Replace, page 260.
3 NOTICE! The piston must be at top dead center
when the valves are removed. This is to prevent
the valves from falling down into the cylinder. Use
tool 9993590 Rotation tool.
4 Compress the valve springs for no. 1 cylinder.
Use tool 9990210 Valve spring compressor.
5 Remove the valve washers, valve springs and
collets.
6 Remove the old valve stem seals.
Installation
7 Lubricate the valve stem with engine oil.
Fit tool 9990165 Guide sleeve to the valve stem.
88800151 Thread the new seal on and put it over the
mandrel. Slide tool 88800151 Drift over the valve
stem and tap the seal down carefully with a plastic
mallet.
8 Install the valve springs, valve spring washers
and collets. Carefully tap with a plastic mallet to
make sure the collets end up in the right position.
9 Transfer the valve spring compressor to no. 6
cylinder and repeat the tasks as above. Then
crank the engine so that no.3 and no.4 cylinder
P0011236
are at TDC.
Repeat the procedure. Then continue with
cylinders 2 and 5.
NOTICE! The piston must be at top dead center

when the valves are removed. This is to prevent
the valves from falling down into the cylinder. Use
tool 9993590 Rotation tool.
10 Install the unit injectors; refer to the installation
section in Unit Injector, Replace, page 260.
11 Adjust the valves and unit injectors; refer to
Valves and Unit Injectors, Adjustment, page 188.
12 Vent the fuel system; refer to Fuel system,
bleeding, page 245. Perform a function and
leakage check.
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21-5 Timing Gears and Shaft

Camshaft, Wear Check
Rocker bridge removed.
Put a steel rule across the camshaft lobes, parallel with

the camshaft axis, to check whether the cam profiles
have been worn.
Measure the wear with a feeler gauge or wire gauge.

Alternatively, a digital caliper gauge can be used.
Compare the measured values with those specified in

Technical Data, page 32.
P0007013
Guidelines for replacement
In normal conditions, unevenness may occur on the
surface of engine camshaft lobes. This does not mean
that the camshaft has to be changed. These marks do
not have any negative influence on either engine
performance or the durability of the engine and its
components.
Examples of acceptable wear and unacceptable wear

are shown below.
Lighter scratches: Hard wear:

The camshaft does not need to be changed. IMPORTANT!
The camshaft and associated rocker arms must be
changed.
P0003896 P0003899
P0003898 P0003897
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Camshaft Bearing Housing,

Replace
The factory-installed bearing housings are machined
with the cylinder head and are therefore not
replaceable. If a bearing housing is damaged the
complete cylinder head must be replaced.
P0007018
Flywheel, Indication
Flywheel exposed; refer to Timing Gear,
Removal, page 95.
Tools:
1 Install 9993590 Rotation tool in order to rotate the
flywheel.
2 Install 9999696 Magnetic stand and 9989876 Dial
indicator with the measuring tip against the
999 9696 flywheel at a measuring radius of around 150 mm
(5.9”).
Rotate the flywheel at least one revolution and
check the min and max deflections on the dial
indicator. The value should not exceed 0.20
mm (0.0079”).
998 9876
3 If the distortion is greater, and this is not the result
of a damaged surface where the dial indicator is
applied, remove the flywheel and check that there
is no waste material or damage to the contact
flange on the flywheel and crankshaft.
Clean the flanges or change the flywheel if it is
damaged.
P0010194
Torque the bolts; refer to Special Tightening
Torques, page 10.
4 Check using the dial indicator and magnetic stand
again.
Remove the tool.
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Gear Ring, Fywheel: Replace

Flywheel removed.
1 Drill 1–2 holes between teeth on the ring gear.
Split the gear ring at the drilled hole, using a cold
chisel. Lift the gear ring away from the flywheel.
2 Brush the flywheel contact surface clean with a
steel wire brush.
P0006979
3 Heat the new gear ring up to 180–200°C (356–

392 °F) with a welding torch or in an oven. The
gear ring must be evenly heated. Be careful not
to heat the gear ring up far with annealing as a
result.
Check the heat by polishing the ring bright at
several places. Stop heating when the polished
surfaces become blued.
P0006980
4 Put the heated gear ring onto the flywheel and tap
it into place with a soft mandrel and hammer.
Leave the gear ring to cool.
P0006981
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Sensors, Adjustment
Sensor removed.
Tools:
88800031 Measuring tool
1 If the camshaft sensor needs to be adjusted,
rotate the crankshaft so that one tooth on the
camshaft vibration damper is centered in front of
the sensor hole.
2 Remove any shims beneath the sensor.
Clean the tool's contact surface on the engine.
3 Insert 88800031 Measuring tool without
88800031 tightening the lock screw.
press in the tool firmly so that it is in contact with
the cover. Press in the center part of the tool until
it contacts the gearwheel and tighten the lock
screw.
Rove the tool and inspect the center section
position in its sleeve.
P0010198
4 Determine further actions according to the

following:
If the center section of the tool is entirely below

the sleeve's upper edge, no shims are required.
P0010219
If only the center section upper surface is above

the sleeve's top edge, one shim is required.
P0010218
47701522 01-2016 © AB VOLVO PENTA 209

If the two center section surfaces are above the

sleeve's top edge, two shims are required.
P0010220
5 Install the sensor with a new seal and any shims.
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21-6 Crank Mechanism

Crankshaft Seal, Change (front)
Tools:
9990192 Puller
9992000 Handle
88800021 Drift
Removal
1 Drain the coolant; refer to Coolant,
Draining, page 329.
2 Remove the belt guard; refer to 26-3, Belt
Guard.
3 Remove the belts. For the drive belt, refer to Drive
Belt, Change, page 358.
For the alternator belt, refer to Alternator,
Change, page 394.
4 Remove the automatic belt tensioner.
P0013386
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5 Where necessary, use tool 9993590 Rotation

tool as a counterhold.
P0004786
6 IMPORTANT!
The oscillation damper may not be exposed to
thrusts or blows.
7 Remove the oscillation damper.
P0014303
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8 Carefully knock and wiggle the hub off.
P0014304
Alternative 1, seal removal

9 Fit tool 88800021 Drift.
10 Drill two holes Ø3.5 mm in the seal with the aid of
the guide hole in the tool. Bush grease on the drill
to prevent dirt from getting into the engine.
11 Screw in two suitable sheet metal screws (1),
length approx. 50 mm, through the holes in the
tool, so that they fasten firmly in the seal.
12 Fit two long-threaded M10x60 bolts (2) and screw
them in until the seal releases.
P0004789
Alternative 2, seal removal

13 NOTICE! Incline the tool to ensure that the
crankshaft is not damaged.
Assemble tool 9996400 Slide hammer and tool

9990192 Puller.
Remove the old seal by tapping in a puller inside
the seal and pulling it out with a slide hammer.
P0004790
Installation
9992000 Handle
88800021 Drift.
47701522 01-2016 © AB VOLVO PENTA 213

14 Check that the plastic ring is correctly in place in

the new seal.
NOTICE! If the plastic ring is not in place in the

new seal, the seal ring may be damaged and
must not be used.
15 Clean the crankshaft sealing surface and cover.
Check that these are damage free.
16 Install the new seal ring and plastic ring onto the
crankshaft journal.
P0004791
17 Press the seal toward the cover by hand.
P0004792
214 47701522 01-2016 © AB VOLVO PENTA

18 Remove the plastic ring.
P0004793
19 Carefully tap in the new seal until it bottoms

against the crankshaft journal. Remove the tool.
20 Make sure that the crankshaft, belt pulleys and
hub mating surfaces are clean and damage free.
21 Fit the inner belt pulley / vibration damper.
22 Install the outer belt pulley.
23 Install the hub.
P0004794
47701522 01-2016 © AB VOLVO PENTA 215

24 Where necessary, use tool 9993590 Rotation

tool as a counterhold.
P0004786
25 NOTICE! Make sure that the contact surfaces are

clean.
Fit in the bolting holes and knock the hub on.
P0014304
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26 Install the oscillation damper.

27 Torque the oscillation damper bolts according to
specifications: Refer to General Tightening
Torques, page 9.
P0014303
28 Install the belt tensioner.

29 Install the alternator belt: Refer to Alternator,
Change, page 394.
30 Install the drive belt: Refer to Drive Belt,
Change, page 358.
31 Ensure the belts track in their grooves.
32 Install the belt guard: Refer to 26-3, Belt Guard.
33 Refill with coolant: Refer to Coolant Level,
Checking and Topping Up, page 331.
P0013386
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Crankshaft Seal, Change (rear)

Tools:
9990166 Mounting tool
9990192 Puller
Removal
1 Remove the flywheel sensor.
P0004796
218 47701522 01-2016 © AB VOLVO PENTA

2 Remove all bolts from the flywheel, with the

exception of the upper bolt.
3 Install lifting eyes and straps to the flywheel.
NOTICE! Lock the lifting device.

4 Remove the last bolt and lift away the flywheel.
P0004795
5 Fit 9996400 Slide hammer and 9990192 Puller

Check that the tools are free from burrs and
grime.
6 NOTICE! Be careful not to damage the
crankshaft. Incline the tool inwards to ensure a
good grip in the seal.
Knock out the seal.
P0004954
47701522 01-2016 © AB VOLVO PENTA 219

Installation
9990166 Mounting tool
7 NOTICE! Clean the seal seat in the flywheel
housing and the sealing surface on the
crankshaft.
NOTICE! Ensure that the plate locates correctly

on the crankshaft guide pin and bottoms firmly
against the crankshaft before the bolts are
tightened.
Fit 9990166 Mounting tool onto the crankshaft

and screw it in place.
8 Fit the spacer ring to the pin bolt.
NOTICE! The spacer ring determines how far in

the seal must be.
P0004960
9 The seal is supplied with a plastic installation ring.

The plastic ring must not be removed from the
seal.
P0004957
220 47701522 01-2016 © AB VOLVO PENTA

10 Install the seal without removing the installation

ring.
P0004959
11 Install the cover together with its handle.

Press in the seal by rotating the handle.
NOTICE! When the cover bottoms the seal is in

the correct position.
12 Remove the tool and the installation ring.
P0004958
47701522 01-2016 © AB VOLVO PENTA 221

13 Offer the flywheel into place and fit the key in the
keyway.
Install one bolt to render the lift safe.
14 Install the remainder of the bolts.
Torque according to specifications: Refer to
General Tightening Torques, page 9.
P0004795
15 Install the flywheel sensor.
P0004796
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Crankshaft, Inspection
The crankshaft is induction hardened.
Inspect the crankshaft very carefully to avoid

unnecessary overhaul.
The following applies when the need for overhaul is
checked:
1 Clean the crankshaft carefully.
Measure the bearing journals' out-of-round, wear
and taper. Refer to Technical Data, page 32 for
specifications.
2 Check whether there is any surface damage on
the bearing journals. If there is any damage on
the surface layer, the shaft must be re-ground.
3 Place the shaft pair of V-blocks, under 1st and 7th
main bearing journals. Alternatively, hold the
crankshaft between the two centers.
4 Measure crankshaft axial displacement (throw)
on the 4th main bearing.
For maximum permissible values, refer to
Technical Data, page 32.
IMPORTANT!
Crankshaft straightening is not permitted.
5 Check for cracks before and after any grinding.
Magnetic powder testing is used for this test, i.e.
fluorescent powder which is viewed under ultra-
violet light.
47701522 01-2016 © AB VOLVO PENTA 223

Main bearing, Change

Oil pan removed
The method describes replacement of main bearings

with the crankshaft in place in the engine
Tools:
9990114 Puller
Removal
1 Fit tool 9993590 Rotation tool.
P0006884
2 Remove the oil suction pipe and oil pump.

Remove the bracing frame.
P0013021
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3 Remove one bearing cap.
P0006970
4 Remove the upper main bearing shell by putting

a pin in the crankshaft oil hole and rolling the
bearing shell out by turning the crankshaft in the
direction of rotation with tool 9993590 Rotation
tool.
5 Clean and check the bearing seat, bearing cap,
shaft journal and bearing shell.
If the bearing has seized, the reason must be
determined before a new bearing is installed.
6 Check that the correct bearing dimension is used
when the bearing shells are changed.
NOTICE! If case of uncertainty, check in

Technical Data, page 32 which oversize
P0006971
dimensions are available.
Installation
7 Lubricate the shaft journal and the new bearing
shells with engine oil.
8 Install the upper bearing shell by turning the
crankshaft using tool 9993590 Rotation tool
against the direction of rotation with the pin in the
oil hole.
NOTICE! Check that the pressed-out bearing

shell heel is correctly aligned in the bearing seat
cutout.
Make sure that the upper bearing shells (those to

be located in the engine block) are equipped with
oil holes.
P0006972
NOTICE! Remove the pin when done.
47701522 01-2016 © AB VOLVO PENTA 225

9 Fit the main bearing cap together with the lower

bearing shell.
NOTICE! The main bearing caps are asymmetric

and can only be installed in one position. Note the
main bearing cap numbers showing their
locations if several caps are removed
simultaneously.
Torque the caps in two steps as specified; refer

to Technical Data, page 32.
10 Change the other bearing shells, one a time, in
the same way as the first one. Each time a
P0006973
changed is made, check that the crankshaft does
not seize by turning it using tool 9993590 Rotation
tool.
11 Check crankshaft end float and replace the thrust
washers if the clearance is too great or if the thrust
washers are damaged.
NOTICE! Measure the end float with a dial gauge.

Thrust bearings are available in a number of
oversize dimensions. Refer to Technical
Data, page 32 for oversize dimensions and axial
play.
The crankshaft thrust bearing is located in the

center main bearing.
12 Use a narrow plastic or wood stick to remove the
thrust bearing washers from the cylinder block
bearing seat.
NOTICE! The thrust washers can only be placed

in one position.
P0006974
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13 Check the axial play of the crankshaft when all

main bearing caps have been torqued; refer to
Technical Data, page 32 for specification.
14 Install the bracing frame and torque according to
the tightening chart; refer to Technical
Data, page 32.
15 Install the oil pump and oil suction pipe.
16 Remove tool 9993590 Rotation tool from the
flywheel housing and install the cover.
17 Install the oil pan.
P0006975 Add oil and change the oil filter.
Check the oil pressure.
47701522 01-2016 © AB VOLVO PENTA 227

22-1 Oil pump and Line

Lubrication Oil Pump, Change
Engine oil drained.
Removal
1 Remove the oil level sensor connector (1).
Remove the oil filler (2) with attachment and the
oil dipstick (3).
NOTICE! The the oil filler and oil dipstick may be

3 located on either the port or starboard side; see
illustration.
2 2 Remove the oil sump (4) bolts and remove the
sump.
3 Only D13B-A/C/G/H/K/L, D13C2-A, D13C4-A
(twin turbo)
Remove the wastegate valve oil return pipe from
the sump.
4 Remove the oil filters.
1
P0012707
5 Remove the suction strainer and the pipe to the

pump. Remove the delivery pipe from the pump.
Remove the connection pipe.
P00112708
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6 Remove the reinforcement plate.
CAUTION!
P0010536
7 Remove the oil pump.
P0010536
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Installation
8 Install the oil pump by meshing the gearwheels
and tightening the bolts.
9 Install the reinforcement plate with new bolts.
CAUTION!
P0010536
10 Use new seals for all pipes.

Install the delivery pipe from the pump. Install the
connection pipe.
Tighten all bolts to the reinforcement plate in the
sequence and torques according to Special
Install the suction strainer and pipe to the oil
pump.
P00112708
11 Clean the oil sump thoroughly. Check to see if the

oil sump rubber seal requires replacement.
Cut away excess sealant from the front
crankshaft seal cover. Cut away excess sealant
from the timing plate and the flywheel housing.
Apply new sealant to the joints and install the oil
sump within 20 min.
12 Tighten the oil sump bolts and install the engine
mount and tighten according to Special
Install new oil filters. Fill with engine oil.
P0010147
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22-2 Oil filter
22-2 Oil filter

Oil filter, Change
Engine oil drained.
Tools:
9999179 Extractor oil filter
1 Check that a hose is connected to the drip pan
and is led down to a suitable container.
2 Use 9999179 Extractor oil filter to remove the oil
filter.
3 Check that the filter sealing surfaces are clean.
Lubricate the new filter rubber seals with engine
oil.
Install the filters and tighten them according to the
instructions on the filters.
4 Clean the drip pan.
Reinstall the engine oil drain plug.
5 Fill with engine oil; refer to Technical
Data, page 44.
p0012233
6 Start the engine and check that there is oil
pressure.
Check that no leakage is present.
7 Stop the engine and check the oil level after a
couple of minutes.
47701522 01-2016 © AB VOLVO PENTA 231

22-2 Oil filter
Oil Pressure Sensor, Check

Tools:
9996398 Manometer
9996666 Nipple
1 Clean around the plug.
Remove the plug and the copper washer.
2 Install 9996666 Nipple.
3 Install 9996398 Manometer.

4 Start the engine and check the oil pressure.
Replace the oil pressure sensor if the pressure
does not correspond to the manometer.
232 47701522 01-2016 © AB VOLVO PENTA

22-2 Oil filter
5 Remove 9996398 Manometer and

9996666 Nipple.
6 Install the plug together with a new copper
washer.
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22-2 Oil filter
Oil Filter Bracket, Change

Removal
Remove the by-pass line (1) from the filter

bracket.
Remove the oil hose (2) to the turbocharger from
the filter bracket.
Undo the nut (3) from the oil pipe.
2 Remove the front adapter from the filter housing.
3 Undo the nut (4) from the other oil pipe.
234 47701522 01-2016 © AB VOLVO PENTA

22-2 Oil filter
4 Remove the oil filters.

Refer to Oil filter, Change, page 231.
5 Remove the filter bracket.
Installation
6 Install a new filter bracket.
7 Install new oil filters; refer to Oil filter,
Change, page 231.
8 Install the components (steps 1–3) in reverse
order.
9 Start the engine and check oil system function
and integrity.
10 Switch the engine off and check the oil level.
47701522 01-2016 © AB VOLVO PENTA 235

22-2 Oil filter
Oil Leading Bracket, Change

Removal
1 Clean the oil filter bracket and surrounding
surfaces.
2 Remove the front oil pipe (1) located between the
oil cooler and filter bracket. Remove the oil hose
(2) to the turbocharger.
3 Only D13B-A/C/G/H/K/L, D13C2-A, D13C4-A
(twin turbo)
Remove the oil hose (3) to the by-pass valve.
4 Remove the rear oil pipe located between the oil
cooler and filter bracket.
P0012711
5 Remove the two oil pipes between the cover (1)

and the oil filter housing.
Remove the covers (1 and 2).
NOTICE! The covers (2) does not have the same

threads.
6 Remove the bolts on the filter bracket (7 pcs.).
Remove the bracket.
Remove the gasket.
2
P0012712
Installation
7 Move over the parts that are to be reused to the
new bracket.
P0012713
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22-2 Oil filter
8 Thoroughly clean the engine block contact

surfaces for the bracket.
IMPORTANT!
Sealant may absolutely not be used. The use of
sealant may result in engine breakdown.
P0010003
9 Install a new gasket and screw in the lower front

bolt a couple of turns.
P0010004
10 Lift up the back edge of the sea; and suspend the

bracket from the front bolt (1). Fit a bolt (2) to the
rear end.
Install the remaining bolts and tighten them.
P0012714
47701522 01-2016 © AB VOLVO PENTA 237

22-2 Oil filter
11 Install the front and rear pipes to the oil cooler with
new seals. Install the hose to the turbocharger
with a new seal.
Install the two oil pipes between the cover (1) and
the oil filter housing.
Install the covers (1 and 2).
NOTICE! The covers (2) does not have the same

threads.
Clamp the hose to the waste gate controller.

2
1
Only D13B-A/C/G/H/K/L, D13C2-A, D13C4-A
(twin turbo)
Install the oil hose (3) to the by-pass valve.
P0012715 12 Replenish or change the oil.
13 Start the engine and check oil system function
and integrity.
14 Switch the engine off and check the oil level.
238 47701522 01-2016 © AB VOLVO PENTA

22-2 Oil filter
Safety Valve, Oil Pressure, Replace

Tools:
9998598 Sleeve
1 Clean round the safety valve.
2 Remove the safety valve cover using
9998598 Sleeve.
3 Remove the safety valve and make sure the
sealing in the end comes with it. The sealing can
stick against the block and remain in the hole.
Check that there is no dirt on the valve sealing
surface on the engine block.
P0010334
4 Install a new O-ring on the valve cover. Brush a

little grease on the valve sealing and press it in
place so that it is secure.
P0010335
5 Install the valve half way into the cover.
P0010336
47701522 01-2016 © AB VOLVO PENTA 239

22-2 Oil filter
6 Guide the valve into the engine block and fasten

the cover. The cover should be easy to screw
down all the way until the O-rings bottom.
Tighten according to Special Tightening
Torques, page 10.
7 Start the engine and check that no oil leakage is
present.
P0010334
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22-2 Oil filter
Piston Cooling Oil Pressure, Check

Tools:
9996398 Manometer
9996666 Nipple
1 Clean around the plug.
Remove the plug and the seal washer.

Start the engine.
Check that no oil leakage is present.
4 Check the piston cooling oil pressure.
Compare with Technical Data, page 44.
If the piston cooling oil pressure is faulty despite
a correct oil system pressure in the engine, the oil
filter bracket on the engine block must be
changed. The valves that control piston cooling
cannot be changed separately.
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22-2 Oil filter
5 Remove 9996398 Manometer and

9996666 Nipple.
Install the plug with a new seal washer.
Start the engine and check that no oil leakage is
present.
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22-2 Oil filter
Bypass Valve, Oil Filter Bypass,

Replace
Cover above oil filter bracket removed.
1 Clean round the overflow valve.
Remove the plug, seal washer, spring and valve
body.
2 Clean and check the components.
P0011860
3 Clean and check the seal seat in the oil filter

bracket.
4 Replace damaged components and install with a

new seal washer.
Start the engine, check function and that no
leakage is evident.
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22-3 Oil cooler
22-3 Oil cooler

Thermostat Oil Cooler, Change
1 Clean the surface around the thermostat.
P0010338
2 Remove the thermostat housing bolts. Remove

the thermostat and O-ring.
P0010339
3 Check that there is no dirt in the oil ducts.

Clean the O-ring groove.
4 Install a new O-ring in the groove. Install a new
thermostat.
Tighten the bolts.
5 Start the engine and check that no oil leakage is
present.
P0010340
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23-0 Fuel System, General

Fuel system, bleeding
1 Check that there is sufficient fuel in the tank, and
that any fuel taps are open.
2 Open the nipple on the front fuel connection.
Connect a drain hose.
P0011865
3 Purge the fuel system by pumping with the hand

pump(1) (1) until fuel without air bubbles flows.
Close the nipple and secure the hand pump.
4 Start the engine and allow it to idle fast for about
10 minutes.
5 Perform a leakage and function check.
1. Screw out the hand pump handle before usage. Fasten the handle
after usage.
47701522 01-2016 © AB VOLVO PENTA 245

Draining, Fuel Duct in Cylinder Head

Protective covers removed.
1 Clean the fuel connections on the fuel filter
bracket and at the venting nipple.
p0011863
2 Remove the tie wrap and disconnect the electrical

connector (1) from the fuel pressure sensor (2).
Undo the center fuel connection (3) on the fuel
2 filter bracket.
NOTICE! Put a rag under the connection to

collect spilled fuel.
1
3
p0011864
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3 Remove the rubber cap from the venting nipple.

Check that the venting nipple is fully clean from
dirt and paint flakes, both inside and out.
4 Connect a clean hose to the venting nipple.
Open the nipple and blow air in the hose so that
fuel flows out at the disconnected fuel lines at the
fuel filter bracket. Blow until only air comes out of
the fuel line.
Close the venting nipple and remove the hose.
5 The fuel ducts in the cylinder head are now empty
and the unit injectors can be removed without fuel
running into any of the cylinders.
6 Replace the rubber cap on the venting nipple.
P0011865
7 Re-install the fuel connections on the filter

bracket with new seals.
reconnect the pressure sensor electrical
connector.
Attach a new tie wrap to the harness.
p0011863
47701522 01-2016 © AB VOLVO PENTA 247

Bypass Valve Fuel System, Replace

Empty the cylinder head fuel channels; refer to
1 Clean around the overflow valve.
2 Undo the the oil pressure sensor harness
terminal (1).
Remove the bracket bolt (2) located below the
overflow valve.
3 Put a rag under the overflow valve (3) to collect

spilled fuel.
Remove the valve.
4 Clean the sealing surfaces and install a new valve

with new seals.
Torque the bolts according to specifications; refer
to the Group 23: Fuel System section in Special
p00112239
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5 Re-install the bracket bolts (2).

Re-install the harness terminal (1) to the oil
pressure sensor.
6 Bleed the fuel system; refer to Fuel system,

bleeding, page 245.
Start the engine and check that there are no fuel
leaks present.
Check the fuel pressure.
47701522 01-2016 © AB VOLVO PENTA 249

23-3 Fuel Feed Pump and Filter

Engine Fuel Filter Replacement
NOTICE! Be prepared to collect fluid.
1 Clean the fuel filter bracket.

2 Drain the water separator by firstly open the tap
carefully.
Loosen the filter 1-2 turns from the bracket to
empty it.
p0012233
3 Close any sea cock and remove the water pipe

between the seawater pump and the heat
exchanger.
Remove the water separator connectors.
4 Remove the drip pan attachment fitting in order to
move the water separator a little. Remove the
water separator and the fuel filter.
5 Clean the filter sealing surfaces on the bracket.
Install a new filter according to the instructions on
the filter.
6 Clean the water separator and install it. Re-install
the drip pan and attachment fitting. Clean the drip
pan.
Connect the water separator connectors.
250 47701522 01-2016 © AB VOLVO PENTA

7 Vent the fuel system by pumping with the hand

pump (1). Venting then takes place by air in the
filter being forced out through the return line.
8 If the entire fuel system has been emptied, open
the venting nipple at the front of the cylinder head
and pump with the hand pump until fuel runs out.
Close the nipple.
9 Continue to pump with the hand pump so that the
remainder of the air is forced out through the
return line.
1 10 Re-install the water pipe and open any sea cock.

Start the engine and check that no oil or water
leakage is present.
P0012235
Fuel Feed Pressure, Check

Tools:
9996398 Manometer
9998494 Hose
1 Clean the fuel system venting nipple (1) and the
surrounding area.
Bar Remove the nipple.
2 Install the nipple that belongs to (2) that belongs
to 9998494 Hose and tighten it.
9998494
3 Install the hose on the nipple.
9996398 4 Install 9996398 Manometer on the hose.
Start the engine and check the fuel pressure.
5 If the fuel pressure differs between the
manometer and the electronic sensor, replace
1 2
the electronic sensor.
If the fuel pressure is too low according to both,
replace the fuel filter.
The overflow valve governs the pressure
available in the system (any surplus is released
to the return line). Fuel pump condition also
determines the pressure supplied to the system.
6 Remove the manometer, hose and nipple.
Re-install the venting nipple and protective cap.
P0011869
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Fuel filter housing, change

Removal
NOTICE! The main switch must be in the off position
before work is begun.
1 Remove the cover.
Drain the water separator.
p0012233
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3 NOTICE! Close the seawater inlet.
Where it exists, remove the seawater pressure

sensor connector.
Remove the water pipe between the seawater
pump and the heat exchanger.
Where it exists, remove the water separator
connectors.
Remove the drip pan.
4 Remove the hose from the expansion tank.
47701522 01-2016 © AB VOLVO PENTA 253

5 IMPORTANT!
Carefully clean before removal.
NOTICE! Be prepared to gather up fluid.
Remove the water separator and the fuel filter.
6 Remove the tie wrap and disconnect the electrical

connector (1) from the fuel pressure sensor (2).
Remove the fuel return line (3) from the bracket.
NOTICE! This hollow screw has an integrated

bleeding nipple.
254 47701522 01-2016 © AB VOLVO PENTA

7 Remove the pump pressure line (4).

Remove the inlet line (5).
8 Unscrew the bracket.
Installation
9 Transfer any parts that are to be reused to the
new bracket.
10 Install a new fuel filter.
11 Install the components in the reverse order.
12 Purge the fuel system, refer to the Fuel system,
bleeding, page 245 section.
13 Start the engine and check fuel system integrity.
47701522 01-2016 © AB VOLVO PENTA 255

Fuel Feed Pump, Change

Removal
1 Close any sea cocks.
2 Undo the two seawater outlet bolts (1) and
remove it from the heat exchanger.
3 Clean the fuel pump and fuel lines, and the fuel
pump drive device.
4 Place a recovery container under the pump. Undo

the fuel lines at the pump and allow the fuel to run
out into the container.
Remove the bolts that attach the entire unit to the
engine.
5 Lift away the pump and drive.
P0004300
6 Remove the bolts that attach the pump to the

drive device.
Remove the pump.
P0010541
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7 Retain the intermediate piece to the drive.

Check that the drive bearings feel serviceable
and that the gearwheel is not damaged.
P0010543
Installation
8 Install a new O-ring for the pump.
Install the intermediate piece.
P0010542
9 Install the new pump. Turn the gearwheel so that

the intermediate piece fits against the pump and
tighten the pump bolts; refer to General
P0010541
10 Clean the sealing surfaces and install a new O-

ring on the drive unit.
P0010540
47701522 01-2016 © AB VOLVO PENTA 257

11 Clean the engine sealing surface.
P0010539
12 Install the fuel pump on the engine by meshing

the gearwheel with the timing and then tightening
the bolts.
Install the fuel lines with new seals.
13 Vent the fuel system; refer to Fuel system,
bleeding, page 245.
P0004300
14 Check the sacrificial anode and install the

seawater outlet (1) on the heat exchanger.
15 Open any sea cocks.
16 Start the engine and check that no leakage is
present (seawater, oil or fuel).
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Hand Pump, Change

Removal
1 Clean the hand pump (1) and its fuel connections.
Close any fuel taps from the tank.
2 Place a recovery container under the pump to
collect fuel spills.
3 Undo the fuel lines from the pump.
Remove the oil pump bolts and remove the pump
Installation
4 Install the new pump with the two retaining bolts

and tighten them. The pump must be somewhat
moveable.
5 Install the oil lines with new seals and tighten
them.
6 Tighten the pump retaining bolts.
7 Open any fuel taps.
Vent the fuel system if it was emptied completely.
Start the engine and check that no fuel leakage
is present.
47701522 01-2016 © AB VOLVO PENTA 259

23-7 Injectors and Delivery Pipes

Unit Injector, Replace
Tools:
9988539 Compression meter
9990006 Puller
9998248 Adapter
The tool kit 9998599 Cleaning kit includes:

– 9808570 Brush
– 9808616 Extender
– 9998580 Protective sleeve
For valves and unit injector adjustment; refer to Valves

and Unit Injectors, Adjustment, page 188.
Removal
1 Remove the ventilation pipe and valve cover.
2 Undo the connectors to the unit injectors and oil
valve.
P0012716
3 Remove the rocker arm lubrication valve and oil

pipe.
Undo the rocker arm bridge bolts in stages, equal
amounts each time, to avoid bending the rocker
shaft.
P0012717
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4 Install 9990185 Lifting tool and adjust the holes

for the rocker arms (to keep the rocker arms
together for each cylinder). The higher holders
must be used
Lift the rocker arm bridge away. Make sure the
pistons in the exhaust rocker arms and the
adjuster screw ball do not fall out.
P0004965
5 Mark and remove the valve yokes.

6 Empty the cylinder head fuel channels; refer to
7 Remove the bolts for the unit injector retaining
yoke.
6
P0012717
8 Rock a unit injector loose using 9990006 Puller

9990013 and 9990013 Slide hammer.
Check that the seal washer (steel washer) comes
out with the injector. If it is still in the copper
sleeve, remove it using 885822 Magnetic pen.
9990006 IMPORTANT!
The seal washer must always be replaced when
installing an injector.
P0001370
47701522 01-2016 © AB VOLVO PENTA 261

9 Put the injector in 9998249 Protective sleeve.
999 8249
P0010041
10 Insert 9998251 Protection plug in the cylinder

head.
999 8251
Clean the copper sleeves thoroughly with the aid
of 9998599 Cleaning kit.
P0010042
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Installation
9990156 Adapter
11 Remove the protective plug for one unit injector
(where necessary use 9990156 Adapter and
9996400 Slide hammer).
9996400
9990156
P0010061
12 Remove the injector from the protective sleeve.

Replace the unit injector O-rings (use
3883671 Protective sleeve and
3883672 Protective sleeve) and install a new
steel washer on the injector sealing surface.
IMPORTANT!
The steel washer must be replaced every time an
injector is installed.
Install the injector and injector yoke. Turn the
injector so that the wiring connections are exactly
opposite the valve springs.
Install the retaining bolt and tighten according to
13 Install the remaining injectors the same way.
P0010062
47701522 01-2016 © AB VOLVO PENTA 263

14 Put the valve yoke back in accordance with the

previous marking.
P0012717
15 Lubricate the valve yokes and the unit injector ball

seats.
Lift the rocker arm bridge into place. Guide all
rocker arms so they arrive in the correct positions.
Make sure that the exhaust rocker arm pistons
and the adjuster screw balls are in place.
Remove the lifting tool from the rocker arm
bridge. Install the rocker arm shaft bolts. Check
that the valve calipers are positioned correctly on
the valve stem.
Tighten the bolts alternately so that the rocker
P0004965
arm shaft is not bent. Make sure the shaft guides
the locator sleeves on the bearing caps.
Tighten the bolts; refer to Special Tightening
Torques, page 10.
16 Install the valve and rocker arm lubrication oil pipe
with new seals.
17 Adjust the valves and unit injectors; refer to
Valves and Unit Injectors, Adjustment, page 188.
P0012717
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18 Install the connectors to the unit injectors and oil

valve. Clamp the wire harness under the valve
cover with original cable ties (heat and oil
resistant).
6
P0012716
19 Install the valve cover. Replace gasket as

17 necessary. Tighten according to Special
13 12 11 10 1 15 16 18
19 20 Vent the fuel system; refer to Fuel system,

bleeding, page 245.
14
9 8 7 6 2 3 4 5 20
p0005236
47701522 01-2016 © AB VOLVO PENTA 265

Sleeve for unit injector, replace

Unit injector removed; refer to Unit Injector,
Replace, page 260.
Tools:
1159794 Torque wrench
9986173 Puller
9996049 Draining hose
9998250 Sealing ring
88800196 Drift
88800387 Puller
88800460 Sleeve
IMPORTANT!
Working with the fuel system requests special
cleanliness.
1 Drain the coolant with the aid of a hose, tool
9996049 Draining hose; refer to Coolant,
Draining, page 329.
2 If necessary, remove tool 9998251 Protection
plug.
P0019120
3 Clean carefully round the sleeve.

Install 2 seal rings, tool 9998250 Sealing ring, to
prevent dirt from getting into the fuel ducts when
the sleeve is removed.
P0019121
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4 The puller marking (A) should be visible when the

support ring (2) is fitted. If the marking is not
visible it may be difficult to remove the sleeve.
Press the puller (1) down to the sleeve bottom.

Refer to the arrow marking.
Install the support ring (2).
Miscellaneous:
- 9998250 Sealing ring, 2 pcs (3)
- Expander (4)
- Sleeve (5)
- Nut (6)
P0019122
5 Press 88800387 Puller to the bottom of the

sleeve.
Tighten the nut (1) sufficiently hard to hold the
puller in place; apply moderate force and use the
tool (2) as a counterhold.
P0019123
6 Alternative 1
88800460 Sleeve facilitates work instead of

puller 9986173 (Alt2).
Remove the sleeve from 88800387 Puller and

slide it over 88800460 Sleeve.
P0021199
47701522 01-2016 © AB VOLVO PENTA 267

NOTICE! Tighten the bolt moderately.
Install the sleeve with bolt (1). Screw down to the

end position towards the puller (2).
P0021200
Counterhold the screw puller (2) and screw the

sleeve nut (1) until the sleeve releases.
P0021201
268 47701522 01-2016 © AB VOLVO PENTA

Pull up the puller and sleeve.
A misshapen sleeve can be difficult to remove.

If this is the case, remove the puller and find a
new grip for the expander.
Install the support ring and make a new attempt.
P0021202
7 Alternative 2
Insert 9986173 Puller.

Screw down until the puller lugs meet the
support ring.
P0019124
Screw until the sleeve releases and the puller

and sleeve can be removed.
NOTICE! A misshapen sleeve can be difficult to
remove. If this is the case, remove the puller and
find a new grip for the expander. Install the
support ring and make a new attempt.
P0019125
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8 Use cleaning kit, tool 9998599 Cleaning kit and a

power drill before fitting the new sleeve.
Install tool 9998580 Protective sleeve in the
injector hole and secure it with a holder.
IMPORTANT!
Tool 9998580 Protective sleeve must be used to
prevent dirt from getting into the fuel duct.
9 Clean the cylinder head walls for the sleeve with
part no. 9808618.
P0007010
10 Clean the sleeve seat using brush no. 9808614

together with the handle and holders.
P0007011
11 Clean the cylinder head holes with brush no.

999 8580 9808617.
980 8617 12 Remove tool 9998580 Protective sleeve. Make

sure the O-ring is removed.
13 Check that the piston is at BDC.
IMPORTANT!
This must be done so that tool no. 9808617 does
not damage the piston due to its length.
P0007012
14 Always use the new version sleeve with two

grooves at the upper edge when replacing.
IMPORTANT!
The steel gasket supplied with the new sleeve
must be used when installing the unit injector.
Lubricate the O-ring on the sleeve with soapy
water.
IMPORTANT!
Always use a new O-ring.
P0010239
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15 Fit the sleeve to 88800196 Drift.

The steel gasket may not be used when installing
the sleeve. It may only be used when installing
the unit injector.
Oil the pin on the tool.
NOTICE! The tool only fits the new version

sleeve.
88800196
P0003616
88800196 16 Fit 88800196 Drift together with the sleeve to the

cylinder head. Make sure the sleeve bottoms in
the cylinder head.
Install the unit injector yoke.
Use tool 1159794 Torque wrench to press in the
sleeve; torque 80 Nm (59 lbf ft).
P0003617
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88800196 17 Pull the tap onto 88800196 Drift through the

sleeve tip by holding the tap and turning the nut.
Remove 88800196 Drift.
P0003618
18 Remove 9998250 Sealing ring (2 pcs).

19 Install the unit injectors with washer; refer to Unit
Injector, Replace, page 260.
20 Put the valve yokes back according to the
markings.
21 Install the rocker arm bridge and check the
clearance of the valves and unit injectors.
23 Fill up with coolant and check that no leakage
occurs. Also refer to Coolant Level, Checking and
Topping Up, page 331.
9998250
P0003619
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25-1 Inlet and Exhaust Manifolds

Exhaust Manifold, Change
Coolant drained.
Charge air cooler(s) removed; refer to Front
Charge Air Cooler, Change, page 362.
Turbocharger(s) removed; refer to Low Pressure
Y-pipe removed (D13B-A/C/G/H/K/L, D13C2-A,
D13C4-A only, twin turbocharger).
Heat shields removed.
Removal
1 Remove the coolant venting hose (1).
Remove the coolant temperature sensor
connector (2).
2 Remove the stub connection attached to the

cylinder head.
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3 Remove the water pipes connected to the

manifold top and bottom sides.
IMPORTANT!
It is recommended that a lever is used because
the water pipes can be fixed firmly. Be careful to
avoid the pipes from getting damaged.
4 Remove the manifold nuts. Pull out and remove

the manifold.
Installation
5 Install two new manifold seals. Check that the
manifold's other sealing surfaces are fault free.
6 Check that the cylinder head sealing surfaces are

fault free.
Install new exhaust gaskets.
NOTICE! The gaskets have markings that show

which side must face the manifold.
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7 Lift the manifold and align it with the studs. Make

sure that nothing is pinched when it is slid into
position.
D13B-A/H and inboard engine D13B-C/L,

D13C4-A
Tighten the nuts lightly. Torque tightening takes
place after the turbocharger and wastegate valve
are installed.
D13B-B/D/E/F/G/J/K/M/N, D13C1-A, D13C2-A,

D13C3-A and IPS engine D13B-C/L, D13C4-A
Torque the manifold according to 03-2, Group 25:
Inlet and exhaust system.

(twin turbocharger)
Check that the manifold sealing surface against
the wastegate valve is fault free. Install a new
gasket.

Check that the manifold sealing surface against
the turbocharger is fault free. Install a new gasket.
Install the by-pass housing.
(twin turbocharger)
Check the sealing surface on the wastegate
valve. Check the tightening of the fasteners
holding the waste gate housing to the
turbocharger; replace any gasket first.

Check the sealing surface on the turbocharger.
The illustration shows a turbocharger with by-pass valve (D13B-

A/C/G/H/K/L, D13C2-A, D13C4-A, twin turbocharger).
9 Lift the valve housing with turbo and align it with

the studs.
D13B-A/H and inboard engine D13B-C/L,

D13C4-A
Torque the manifold and turbocharger according
to Group 25: Inlet and Exhaust System, page 25.
D13B-G/K, D13C2-A and IPS engine D13B-

C/L, D13C4-A
Torque the valve housing against the manifold.
D13B-B/D/E/F/J/M/N, D13C1-A, D13C3-A

(single turbo)
Torque the turbo against the manifold.
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All engines
Install the stud connection that attaches to the
cylinder head in front of the manifold.
Install both water connections between the
manifold and water pump. Use new sealings and
lubricate with Forminol.
Install the coolant temperature sensor.
(twin turbocharger)
Clean and check the rear charge air cooler hose
connections and hoses.
Check the pipes where the hoses connect. Make
sure the hose clamps are positioned on the hoses
as illustrated.

(twin turbocharger)
Lift up the charge air cooler and slide the hoses
on the cooling pipes.
Fasten the charge air cooler using all bolts.

(twin turbocharger)
Remember the stays and spacers in front of the
starter motor.
276 47701522 01-2016 © AB VOLVO PENTA


(twin turbocharger)
Tighten the hose clamps into position as
ullustrated (in order to tighten/loosen them once
the engine is assembled).
Check that coolant pipes and hoses do not chafe
against anything behind the charge air cooler.

(twin turbocharger)
IMPORTANT!
The oil return pipe must be pressed firmly into the
engine block. This is made easier when the new
seal is lubricated with VP lubricating oil part #
1698135-8 before installing on the pipe, and by
greasing the hole in the engine block before the
pipe is pressed into place and attached with
locking clip.

IMPORTANT!
lubricated with VP lubricating oil part #
1698135-8 before installing on the pipe, and by
greasing the hole in the engine block before the
pipe is pressed into place and attached with
locking clip.
(twin turbocharger)
Put the side of the heat shield in position.
47701522 01-2016 © AB VOLVO PENTA 277


(twin turbocharger)
Put the lower part of the heat shield in position.

(twin turbocharger)
Install the two bolts and spacers (1) that hold the
shield to the manifold. Do not tighten the bolts
fully.
Install the bolts that fasten the heat shield side to
its lower part. Clamp the oil hose with the center
bolt (2). Do not tighten the bolts fully.
18 Install the turbocharger bearing cooling water

hoses (1).

(twin turbocharger)
Install the oil pipe (2) from the wastegate valve to
the oil sump and connect the electrical terminals.
Clamp the oil pipe to the oil cooler cover.

(twin turbocharger)
Install the turbocharger and wastegate valve oil
hoses.
Use a cable tie to hold the wastegate valve oil
hose to the turbocharger oil return pipe.
278 47701522 01-2016 © AB VOLVO PENTA


(twin turbocharger)
Install the heat shield but do not tightent the bolts
fully.
Check that the Y-pipe bolts fit into the holder.
NOTICE! The heat shield may require moving in

some direction for the Y-pipe bolts to fit.
Therefore the heat shield bolts are not tightened
until the Y-pipe is installed.

(twin turbocharger)
Install the Y-pipe (1) and fit the bolts. Do not
tighten the bolts fully.
Install the flex pipes (2) with new seal washers.
Install the clamps and fasten them.
Tighten the Y-pipe bolts.
NOTICE! Special torque, please refer to the

installation instruction.
Tighten all heat shield bolts.
NOTICE! Do not forget the bolts to the front or the

two with spacers located on the underside up by
the manifold.
(twin turbocharger)
NOTICE! It should be installed later if checks are

to be made for any gas leaks after a test start.
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(twin turbocharger)
Check the turbo sealing surface on the Y-pipe
and install a new gasket.
NOTICE! Special torque, please refer to the

installation instruction.
Fit the water hoses to the turbocharger.

Connect the oil return pipe (1) to the
turbocharger.
NOTICE! Use VP lubricating oil part # 1698135-8

on the seal ring that fits against the flywheel
housing to facilitate oil pipe installation.
Connect the oil line (2) to the turbocharger and

clamp it to the lifting lug.
(twin turbocharger)
Tighten the two bolts (1) to the lower turbocharger
heat shield.
Clamp the water hose (2) to the oil return pipe.

(twin turbocharger)
280 47701522 01-2016 © AB VOLVO PENTA


(twin turbocharger)
Install the boost air pipe.

(twin turbocharger)
Install the air filter holder (1).
Clamp the rubber stub hose (2) to the
turbocharger.

(twin turbocharger)
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(twin turbocharger)
Install the cover (1) above the turbocharger and
tighten the clamps (2) to the rubber stub hose.
30 Connect the boost air pipe to the inlet manifold.

Junction pipes and O-rings must be installed on
the boost air pipe.
NOTICE! Installation is facilitated if the O-rings

are lubricated with VP lubricating oil part #
1698135-8.
31 Install a spacer sleeve (1) on the long stud.

Make sure the hose clamps (2) are in position on
the charge air cooler hoses and that the hoses
are free from defects.
Check that the drain hole is ok.
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32 Lift the charge air cooler and align it with the

studs.
Slide on the radiator hoses and the upper boost
air pipe once the charge air cooler is pressed into
place.
Install the nuts on the studs but do not tighten
them yet. The charge air cooler needs to be
somewhat moveable in order to facilitate
installation of the boost air pipe from the
turbocharger.

(twin turbocharger)
There is an intermediate pipe with sealing rings
between the turbo connection pipe and the
charge air cooler
Remove and change / lubricate the rings to get a
better mountability.
When the charge air pipe is tightened against the
cooler and the connection pipe is tightened
against the turbo with the V-clamp both the
handles shall be tightened. Note the position of
these (the oblong hole upwards).
Fasten the boost air pipe and then fasten the
charge air cooler.
34 Install the attachment fitting.

Fasten the hose clamps to the charge air cooler
cooling hoses.
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(twin turbocharger)
Install the boost air pipe from the rear charge air
cooler to the turbocharger.

Install the oil feed line and coolant line.

Install the wastegate valve hose.
284 47701522 01-2016 © AB VOLVO PENTA


Make sure there is no contamination in the charge
air cooler or boost air pipe.
Install the charge air pipe (with an intermediate
pipe with O-rings for flexibility) between the

Make sure there is no contamination in the pipe
from the air filter.
turbocharger.

Install the two air filter holders.
Clamp the rubber stub hose between the
turbocharger and the air filter.
Fasten the clamps on the rubber stub connection.
The illustration shows a D13B-D/E/F/M/N, D13C3-A engine
47701522 01-2016 © AB VOLVO PENTA 285


Install the rear heat insulation.

Align the bottom plastic cover with the
intermediate panel and installed front insulation.

Install the two bottom bolts.
286 47701522 01-2016 © AB VOLVO PENTA


Fasten the top intermediate panel. It must be
aligned with a metal tag on the bottom
intermediate panel.

Align the top plastic cover with the insulation and
tighten all bolts.
NOTICE! Do not forget the attachment fitting

under the rear retaining bolts. Do not forget the
lower bolt right above the heat exchanger.
Install the coolant level sensor connector.
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48 Install the hose / pipe to the lower coolant pipe

and clamp the hose to the CCV unit.
49 Install and secure the venting pipe with clamps.
P0012669
50 Install the battery cable connectors and connect

to the starter motor.
51 Install the belt guard and other covers.
Fill the cooling system. Vent and test pressure
again.
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Intake Manifold, Change

Tools:
885519 Guide pin
IMPORTANT!
The main switch must be in the off position before work
is begun.
Removal
1 Remove the cover.
2 Remove the covers (1 and 2) and the belt guard

(3).
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3 Drain the coolant; refer to Coolant,

Draining, page 329.
Undo the hose clamps.
Remove the level sensor connector.
Remove the expansion tank.
4 Remove the water pipe between the thermostat

and the heat exchanger.
NOTICE! Pull the pipe forward for better access.
5 Remove the fuel filter bracket; refer to Fuel filter

6 Remove the oil filter bracket; refer to Oil Filter
7 Remove the hose between the valve cover and
CCV unit.
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8 Undo the attachment plate for the oil filter bracket

and fold the attachment plate carefully forward,
down toward the heat exchanger.
9 Disconnect the harness terminal from the charge

air sensor and undo the clamps.
10 Remove the inlet manifold.

Transfer any parts that are to be reused to the
new inlet manifold.
47701522 01-2016 © AB VOLVO PENTA 291

Installation
11 Inspect and clean the sealing surfaces on the
cylinder head and inlet manifold.
12 Install two pcs. 885519 Guide pin on the cylinder

head.
13 The pipe can be re-used several times if it is not

damaged. If it is damaged it must be scratched
off.
NOTICE! The components must be installed

sealant.
Apply a thin bead of sealant part # 1161771 in the

groove. Brush out the sealant.
292 47701522 01-2016 © AB VOLVO PENTA

14 Press the new seal into the groove.
15 Guide the inlet manifold onto the guide pins and

fasten it.
Tightening torque: 24 ±4 Nm (17.7 ±2.95 lbf.ft.)
47701522 01-2016 © AB VOLVO PENTA 293

17 Fasten the attachment plate.
18 Install the crankcase ventilation hose.
19 Connect the water pipe.
20 Install the fuel filter bracket; refer to Fuel filter

21 Install the oil filter bracket; refer to Oil Filter
294 47701522 01-2016 © AB VOLVO PENTA


Install the level sensor connector.
Connect the hoses and fasten using hose
clamps.
23 Install the covers (1 and 2) and the belt guard (3).
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24 Install the cover.
25 Top up with coolant; refer to Coolant Level,

Checking and Topping Up, page 331.
26 Turn the main switch on.
Start the engine.
Perform function and leakage checks.
296 47701522 01-2016 © AB VOLVO PENTA

Exhaust manifold expansion plug,

change
Type A
1 Remove the exhaust manifold, see Exhaust
2 Remove the expansion plugs.
NOTICE! E.g. use a bolt to pull out the plugs.

3 Clean surfaces around expansion plugs
thoroughly.
Apply 1161099 Sealant.
4 Press in the expansion plug 2.5 ±0.5 mm (A),
according to the pictures.
Use a press sleeve (1) with diameter Ø 22 mm
(B).
P0021213
P0021363
Type B
Tightening torque: 60 Nm (44.3 lbf. ft.)
P0022064
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25-5 Turbo and supercharger

Turbocharger, Inspection
1 Check that the turbocharger part number is
correct for the engine variant. The wrong
turbocharger for the engine variant might not
provide enough charge pressure, which would
reduce engine power.
2 Check that the turbocharger has the correct
compressor housing. If the wrong compressor
housing is installed on the turbocharger, the
compressor wheel might have been damaged or
have too much clearance between wheel and
housing. In both cases, charge air pressure will
be too low.
3 Remove the inlet manifold from the turbocharger.
4 Check the turbocharger for damage to the
compressor wheel and excessive end float on the
turbine shaft.
5 If there is any damage on the compressor wheel
or excessive end float on the turbine shaft, the
turbocharger must be changed as a unit.
6 Remove the exhaust pipe (muffler) from the
turbocharger and check the turbine disc.
7 Check the turbine wheel for damage. If the turbine
wheel is damaged, the turbocharger must be
changed as a unit.
Low Pressure Turbo, Change

D13B-A MP, D13B-C MP, D13B-G MP, D13B-H MP,
D13B-K MP, D13B-L MP, D13C2-A MP, D13C4-A MP
Removal
1 The shield above the rear turbocharger (low
pressure turbocharger) must be removed.
Open the clamp.
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2 Undo the two bolts to remove the shield.
3 Remove the top heat shield.
4 Undo the two bolts and remove the bottom heat

shield.
Remove the exhaust stub from the turbocharger.
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5 Remove the cover (1).

Remove the air filter housing (2) and the CCV
1 unit.
2
P0011910
6 Remove the pressure pipe between the

P0011918
7 Remove the oil supply line (1) and the clamps.

Remove the coolant hose (2).
300 47701522 01-2016 © AB VOLVO PENTA

8 Remove the oil return pipe (1) and the tie wrap.
Remove the bottom coolant hose (2).
9 Undo the nuts and remove the turbocharger

spacers.
Lift away the turbocharger.
10 Check the studs.

Clean the sealing surface and install a new
turbocharger gasket.
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Installation
11 Inspect and make sure there is no fouling in the
charge air cooler.
Inspect/clean the charge air cooler inlet pipe.
12 Make sure there is no fouling in the exhaust

manifold.
13 Install the turbocharger.

Install spacers and tighten the nuts; refer to
Group 25: Inlet and Exhaust System, page 25.
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14 Install the bottom coolant connection with new

seals.
Install the oil return pipe with new seals on the
engine block and turbocharger.
15 Fill the turbocharger with new, clean engine oil

and install the oil supply line (1) with new seals.
Secure the line by clamping it to the engine lifting
eye.
Install the top coolant connection (2) with new
seals.
16 Install a tie wrap on the oil return pipe for the top
coolant connection.
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17 Install the pipe between the turbocharger and the

charge air cooler.
P0011918
18 Check that the air filter and stub connection are

clean internally.
1 Install the air filter housing (2) and stub
2
connection.
NOTICE! Do not fasten the clamp for the

turbocharger. A shield plate must also be secured
by the clamp.
Install the pipe to the CCV unit.

Install the cover (1) above the filter.
P0011910
19 Install the exhaust stub to the turbocharger.

Install the bottom heat shield using two bolts; do
not tighten them.
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20 Install the top heat shield vertically from above;

the heat shield must be guided in between the
plates. Align it with the bottom heat shield.
21 Install all of the top heat shield bolts, then fasten

the two latches.
Tighten all the bolts.
22 Screw in the two bottom heat shield bolts.
23 Put the heat shield in position.

Insert the two bolts without tightening them.
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24 Insert the clamp by turning it so that it ends up

above the tabs that hold the protection plate in
place.
Press the clamp together and guide the studs in;
install the nuts.
NOTICE! Install the clamp so that the stud points

back underneath the turbocharger for best
accessibility.
Tighten the nuts and make sure the clamp is in

the right position.
Tighten the two heat shield bolts.
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High Pressure Turbo, Replace

1 Remove the rear turbocharger cover by first
removing the two bolts.
2 Undo the clamp. The clamp must be fully open.

Lift away the cover.
3 Remove the upper heat shield from the rear

turbocharger.
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4 Remove the cover from the front turbocharger.
5 Remove the heat shield from the front

turbocharger.
6 Remove the charge air pipe to the turbocharger.
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7 Remove the charge air pipe from the

turbocharger.
NOTICE! The pipe is most easily removed as a

unit by undoing the V-clamp from the
turbocharger and the bolts in the charge air
cooler.
8 Remove the water and oil supply lines on the

upper part of the turbocharger.
9 Remove the water and oil return pipes beneath

the turbocharger.
Also remove the hose clamp.
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10 It is necessary to remove the water connection

extension in order to remove the oil return line.
11 Remove the bolts from the side of the heat shield.

Remove the bolts and spacers underneath.
12 Remove the bolts and pull out the heat shield

under the turbocharger. It is possible to remove
the heat shield side downwards.
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13 Remove the wastegate connector. Also remove

the oil return connection from the wastegate (it
may be necessary to remove the protection
cover).
14 Remove the clamp.

Remove the oil supply line from the oil filter
holder.
15 Remove the bellows.
NOTICE! Note the clamp positions.
Use two pliers to compress the bellows in order

to remove them.
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16 Remove the wastegate valve housing nuts and

washers.
Lift away the turbocharger and wastegate valve
housing.
The illustration shows a D13B-A/H and an inboard D13B-C/L,

D13C4-A engine.
17 Remove the bolts and spacers that hold the

turbocharger and wastegate valve together.
NOTICE! On later D13B-A/H engine models the

Allen head bolts have been replaced by external
torx bolts and different spacers. Volvo Penta
recommends switching to the new bolts and
spacers in connection with repairs.
Separate the turbo and valve.
18 Transfer any components to the new valve

housing or turbocharger.
Install the turbocharger and valve housing with a
new steel gasket.
Torque tighten the bolts; refer to Group 25: Inlet
and Exhaust System, page 25.
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19 Inspect the exhaust manifold bolts and sealing

surface. Install a new steel gasket.
Make sure there is no fouling in the exhaust
manifold or the Y-manifold to the rear
turbocharger.
20 Install the turbocharger and valve housing.
NOTICE! On later D13B-A/H engine models the

earlier nuts and washers have been replaced by
copper-plated nuts without washers. Volvo Penta
recommends switching to the new nuts in
connection with repairs.
Torque tighten the nuts; refer to Group 25: Inlet

and Exhaust System, page 25.
21 Inspect the shape of the bellows and clean their

sealing surface.
Use new seals for the bellows.
Begin with the narrow bellows. Check that the
clamps are correctly turned.
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22 Make sure the bellows and the seals are centered

when the clamps are installed and tightened.
Inspect the clamp positions and torque tighten;
refer to Group 25: Inlet and Exhaust
System, page 25.
23 Make sure the clamps are located to the left of the

bellows position.
Install the large bellows with new seals.
Center the bellows and seals once the clamps are
installed and tightened.
Inspect the clamp positions.
24 Inspect all the clamp positions; refer to Group 25:

Inlet and Exhaust System, page 25.
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25 Install the heat shield below the turbocharger.

Screw in the two bolts beneath the bellows, but
do not tighten them.
26 Screw in the two bolts with spacers beneath the

heat shield.
Tighten all bolts.
27 Install the heat shield end plate and tighten the

two bolts.
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28 Install the wastegate valve connector and secure

it with a cable tie.
Install the oil return line to the valve.
Attach the heat shield with a metal clamp (if it was
removed during disassembly).
29 Attach the clamp to the oil return line.

Attach the oil supply line with a new seal to the oil
filter holder.
30 Attach the oil return line to the turbocharger with

a new seal.
Attach the extension and the lower water
connection.
Attach the clamp to the oil supply line. Attach a
cable tie to the oil return line and the wastegate
oil supply line.
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31 Fill the turbocharger with new, clean engine oil.

Attach the oil and water lines to the upper part of
the turbocharger.
32 Check that there is no fouling in the charge air

cooler, the charge air pipe or the connection pipe
from the turbocharger.
Attach the charge air pipe from the turbocharger.
When tightening the V-clamp, make sure the
flanges are centered.
It is necessary to remove the holders that hold
together the upper and lower charge air pipe
sections.
33 Attach the charge air pipe to the turbocharger.
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34 Test start the engine to check for the presence of

exhaust leaks.
Install the heat shield above the turbocharger.
35 Install the cover above the front turbocharger.
36 Install the heat shield above the rear

turbocharger. The protection housing is
positioned by lowering it in a straight line from
above between the front protection plates.
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37 Install the bolts; make sure that the rear hooks

fasten, then tighten the bolts.
38 Install the upper shield and install the two bolts

but do not tighten them yet.
39 Install the open clamp by turning it so that it fits

over the tabs that hold the protection plate in
place.
Press the clamps together and install the nut and
bolt. Tighten the nut and check that the clamp is
in the correct position.
Tighten the two protection plate bolts.
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Turbo, Change
D13B-B MP, D13B-D MP, D13B-E MH, D13B-F MG,
D13B-J MP, D13B-M MP, D13B-N MH, D13C1-A MP,
D13C3-A MP
Cooling system drained; refer to Coolant,

Draining, page 329
Removal
1 Remove the heat shield and covers, if fitted.
Remove the exhaust pipe.
2 Remove the plastic heat shield and the heat

insulation around the turbocharger.
3 Remove the pipe between the air filter and the

turbocharger.
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4 Remove the charge air pipe between the

5 Remove the hose on the valve for the wastegate

valve.
Cut away the tie wraps.
6 Remove the coolant hoses to the turbocharger.

Remove the oil supply hose to the turbocharger.
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7 Remove the oil return pipe from the turbocharger.
8 Remove the nuts and spacers from the

turbocharger.
Lift away the turbocharger.
9 Check the sealing surface on the manifold.

Check the turbocharger studs.
Check that there is no fouling in the manifold and
install a new turbocharger gasket.
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Installation
10 Transfer any components to the new
turbocharger.
Lift the turbocharger into position and install
spacers and new nuts; refer to Group 25: Inlet and
Exhaust System, page 25.
11 Install the oil return pipe to the turbocharger.

12 Install the oil supply line and coolant line.
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13 Install the wastegate valve hose.

14 Make sure there is no fouling in the charge air

cooler or boost air pipe.
Install the charge air pipe (with an intermediate
pipe between two O-rings) between the
turbocharger and charge air cooler.
Grease both intermediate pipe O-rings.
15 Make sure there is no fouling in the pipe from the

air filter.
turbocharger.
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16 Install the rear heat insulation.
17 Align the bottom plastic cover with the

18 Install the two bottom bolts.
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19 Fasten the top intermediate panel. It must be

intermediate panel.
20 Align the top plastic cover with the insulation and

tighten all bolts.
21 Install the other covers.

Fill the cooling system and check that no leakage
is present.
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Charge Air Pressure, Check

Protective covers (where fitted) removed
Tools:
9996666 Nipple
9998339 Manometer
9998493 Hose
1 Clean around the plug (1) and remove it.
Remove the seal washer if it does not come away
with the plug.
P0012245

9996666 Where necessary 9998493 Hose may be used
between the nipple and the manometer.
4 test run the engine at full load in order to check
max boost air pressure.
9998339 5 Remove 9998339 Manometer and
9996666 Nipple.
6 Install the plug (1) with a new seal washer.
P0012246
Wastegate valve, cleaning

Tools:
22632322 Puller
The wastegate valve can be disassembled for

cleaning.
Undo the throttle side (1) from the valve by pressing it

sideways towards the shaft opening (2).
Use 22518599 Slide hammer and 22632322 Puller.
Note the spring washer position.
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25-6 Air Cleaner, Throttle Housing
P0018853
25-6 Air Cleaner, Throttle Housing

Air Filter, Change
1 Remove the air filter cover (2).
2 Pull out the filter insert.
The illustration shows and engine with a twin turbocharger.
3 Clean inside the housing. Check that there is no

dirt where air passes in to the turbocharger.
4 Install a new filter.
NOTICE! Press the filter home firmly.

5 Install the cover (1).
328 47701522 01-2016 © AB VOLVO PENTA

26-0 Cooling System, General

Coolant, Draining
Tools:
WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.
1 Connect 9996049 Draining hose to the drain

valve (1).
NOTICE! Make sure a suitable recovery

container is in place under the hose.
2 Remove the filler cap from the expansion tank.
2 Connect a suitable hose (2) to the nipple next to
the engine mount and open the nipple when the
1 water has stopped running from the drain valve
9996049 hose.
NOTICE! A pump could be useful when draining

the coolant.
p0011892
3 Connect a hose to the charge air cooler nipple

and open the nipple.
p0011893
47701522 01-2016 © AB VOLVO PENTA 329

4 Connect a hose to the nipple (1) on the underside

of the oil cooler cover and open the nipple.
Cooling System, Cleaning

WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammable.
Cooling performance is reduced by deposits in the

radiator and cooling galleries. The cooling system
should be cleaned out when the coolant is changed.
IMPORTANT!
Cleaning must not be done if there is any risk of the
cooling system freezing, since the cleaning solution
does not have antifreeze properties.
IMPORTANT!
It is extremely important that the correct concentration
and volume of coolant is added to the system. Mix in a
separate clean vessel before filling the cooling system.
Make sure that the liquids mix.
1 Drain the cooling system. Refer to Coolant,
Draining, page 329.
2 Put a hose into the expansion tank filling hole and
flush with clean water, according to specifications
in Technical Data, page 48, until the water
draining out is completely clear.
3 Should there still be some contamination left after
flushing for a long time, cleaning may be done
with coolant. Otherwise, continue as in stage 8
below.
4 Fill the cooling system with 15-20% mixture of
concentrated coolant. Use only Volvo Penta
recommended concentrated coolant mixed with
clean water.
5 Drain the coolant after 1–2 days of operation.
Remove the filler cap and the lower radiator hose
if necessary to increase emptying speed.
To prevent suspended material from settling back
in the system, emptying should be done rapidly,
within 10 minutes, without the engine having
been at a standstill for a long time.
6 Flush the system immediately and thoroughly
with clean hot water to prevent dirt from settling
330 47701522 01-2016 © AB VOLVO PENTA

on the inner surfaces. Flush until the water

running out is completely clean. Make sure that
any heater controls are set to full heating during
emptying.
7 Should contamination still remain after a long
period of flushing, a clean-out may be done using
Volvo Penta radiator cleaner, followed by
treatment with Volvo Penta neutralizer. Carefully
follow the instructions on the package.
Otherwise, continue as in stage 8 below.
8 When the cooling system is completely free from
contamination, close the drain taps and plugs.
9 Refill with new, Volvo Penta-recommended
cooling fluid. Refer to Technical Data, page 48
and Coolant Level, Checking and Topping
Up, page 331.
Coolant Level, Checking and

Topping Up
WARNING!
hot, except in emergencies, this could cause serious
personal injury. Steam or hot fluid could spray out.
IMPORTANT!
Filling of coolant must be performed with the engine
stopped. Fill slowly, to allow air to flow out.
Coolant Level, Checking and Topping Up

IMPORTANT!
Only use the coolant recommended by Volvo Penta.
1 Open the filler cap.
Check that the coolant level is above the MIN
mark on the expansion tank.
2 Top up with coolant as required, so that the level
is between the MIN and MAX marks.
47701522 01-2016 © AB VOLVO PENTA 331

Filling a completely empty system

1 Mix a sufficient quantity of coolant in a vessel
before filling. Note that if a heating system, water
heater or similar is connected to the engine
cooling system, a correspondingly greater
quantity of coolant will be required. Refer to
Technical Data, page 48 for the correct coolant
volume.
2 Also make sure that any heating system, water
heater or similar connected to the engine cooling
system is vented (open the heater regulator
valve).
3 Fill coolant through the filler opening in the
expansion tank.
Fill slowly, to allow displaced air to flow out
through the filler opening.
NOTICE! The system can with advantage be

filled through the drain valve using a pump. The
P0009751 system will be filled faster and air bleeded better.
In such case, fill until the level in the expansion
tank is at MAX and then start and warm up the
engine.
4 Fill coolant to the lower rim of the filler pipe.
5 Start the engine and let it idle untill it has reached
operating temperature.
IMPORTANT!
Do not let the engine work under load until the
system is vented and completely filled.
6 Stop the engine and let it cool. Check the coolant
level.
7 Top up.
Cooling System, Pressure Testing

Alternative 1
WARNING!
burns.
Tools:
3849613 Pressure testing kit
1 Check that all hoses and clamps are undamaged
and intact.
2 Check the coolant level in the expansion tank.
3 Replace the filler cap on the expansion tank with
a suitable cover from 3849613 Pressure testing
kit.
332 47701522 01-2016 © AB VOLVO PENTA

4 Connect the pump and pump up a pressure of 70

kPa (0.7 bar).
5 Pressure must not drop for a two minute test
period, for the cooling system to be regarded as
being free from leakage.
6 Release the excess pressure and remove the
pressure testing unit.
P0010195
Install the regular filler cap.
8 Start the engine and check that no leakage
occurs.
Alternative 2
WARNING!
burns.
Tools:
9996441 Cover, with connecting nipple
and intact.
3 Replace the filler cap with 9996441 Cover, with
connecting nipple. Connect 9996662 Pressure
testing kit to the cap. Connect compressed air to
the equipment and open the cock. Adjust the
pressure to 70 kPa (0.7 bar) with the adjuster
knob. Then close the tap.
5 Release the excess pressure and remove the
pressure testing unit.
Install the regular filler cap.
P0010196
occurs.
Alternative 3
WARNING!
burns.
Tools:
and intact.
47701522 01-2016 © AB VOLVO PENTA 333

3 Connect 9996662 Pressure testing kit to

9996049 Draining hose and close the cock.
Connect the hose to the engine drain valve (1).
Open the cock and adjust the pressure to 70 kPa
(0.7 bar) with the adjuster knob. Then close the
tap.
1 5 Open the cock and increase the pressure until the
filler cap opens (must correspond to opening
pressure according to Technical Data, page 48).
Reduce the pressure to 50 kPa (0.5 bar) and then
increase to 70 kPa (0.7 bar) and check that
pressure is maintained.
P0010197
6 Remove the compressed air connection. Open
the control valve so that the pressure drops and
shut the cock when coolant runs into the drain
hose.
Remove the drain hose from the engine. Then
remove the drain hose from the test equipment
and empty the coolant from the hose.
Re-install the rubber plug in the engine drain
valve.
occurs.
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26-1 Radiator, Heat Exchanger

Heat exchanger, change
Draining, page 329.
Removal
2 Empty seawater using the drain tap.
NOTICE! There is also a tap in the oil cooler on

later models.
3 Remove the heat exchanger seawater inlet pipe.
4 Remove the seawater outlet from the heat

exchanger.
47701522 01-2016 © AB VOLVO PENTA 335

5 Remove the two clamps (1) for the filter drip pan.
Remove the drip pan (1).
Remove the hot water pipe (3) that runs from the
engine.
3 1
2
P0012406
6 Undo the two bolts (1) and remove the oil dipstick
attachment fitting.
Undo the three bolts (2) and remove the reverse
gear oil cooler.
NOTICE! To avoid oil spill the oil cooler should be

removed from the heat exchanger but still be
connected to the hoses on the oil side.
IMPORTANT!
Do not bend the oil hoses too much. They can get
damaged.
7 Remove the rear valve (1) and the narrow hose.

Remove the front valve (2) and the pipe with the
hose.
8 Undo the two bolts located below the front of the

heat exchanger.
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9 Remove the two heat exchanger bolts (1) located

underneath the fuel system hand pump.
Unscrew the bolt (2) above the hand pump a
couple of turns.
10 Pull out the heat exchanger and lift it away. Be

careful when handing the sheet metal.
CAUTION!
Sharp edges. Wear gloves or use a shop cloth to
protect your hands.
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Installation
11 Check that the top bolt at the back of the heat
exchanger is in position.
Do not screw in the bolt too far; a play of around
10 mm (0.39") below the bolt head is advisable.
12 Lift the heat exchanger onto the front attachment
fitting and at the same time guide the rear bolt (2)
into the slot in the rear attachment plate.
Insert the two bottom bolts (1) in the rear
attachment fitting.
13 Insert the front bolts.

Tighten the rear bolts first and then the front bolts.
14 Check the condition and function of the valves.

The spring force in the valves is extremely
important for cooling system function.
The valves have different spring forces in order to
control water flow through the engine cooling
system. Refer to By-pass valves, Heat
Exchanger, Check and Change, page 340.
15 NOTICE! Make sure the valve O-rings are fault
free.
Install the pipe and hose and then the front valve
(2).
The valve has a guide pin so that it cannot be
mistaken or turned to face the wrong way.
Install the rear valve (1) and install the narrow
hose at the same time.
This valve also has a guide pin so that it cannot
be mistaken or turned to face the wrong way.
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16 Check that the oil cooler O-rings are in place and

fault free.
NOTICE! The O-rings are located in the heat

exchanger.
Screw in the three bolts (2) and install the reverse

gear oil cooler.
Install the oil dipstick attachment fitting (1).
17 Check that the engine hot water pipe seal is (3)

fault free and fasten the pipe.
Install the filter drip pan (2) and the drip pan
attachment fittings (1).
3 1
2
P0012406
18 Check the condition of the zinc anode.

Install the seawater outlet and check that the
drain tap is closed.
19 Check the condition of the zinc anode.

Install the heat exchanger seawater inlet pipe.
20 Open any sea cocks.

is present.
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By-pass valves, Heat Exchanger,

Check and Change
Cooling system drained.
1 Remove the front (2) and rear (1) valves.
2 In order to check the spring force in the cooling

system valves they can be load tested on a
weighing scale. At 5 mm (0.2") open a given
weight will be displayed on the weighing scale.
The values are completely different for the two
valves; they are fitted with guide pins so that they
cannot be installed in the wrong position or face
the wrong way.
Check also that the valve disc is complete and
that the valve spindle does not jam in its steering.
3 Check that the center pin has the same height as

the housing in an unladen (closed) valve.
4 Place the valve on a suitable spacer.

Position a washer or similar that is 5 mm (0.2")
thick on top of the valve.
Place everything on a weighing scale and zero
the scale.
NOTICE! Make a note of the weight if the scale

cannot be zeroed.
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5 Press the valve down so until the center pin is

level with the 5 mm (0.2") spacer washer.
Read the weighing scale value and compare with
technical data, please refer to Technical
Data, page 48.
NOTICE! If the scale cannot be zeroed, subtract

the value that was noted before the valve was
pressed down.
6 If either valve's opening pressure does not

correspond to technical data the valve must be
replaced.
Install the valves with new seals.
Fill the cooling system.
Check function that no leakage is evident.
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Heat Exchanger, Cleaning

Heat exchanger removed; refer toHeat exchanger,
change, page 335.
Tools:
21461107 Guide pin
The heat exchanger cleaning procedure described

here entails viewing the heat exchanger from the front
with the three bolt holes illustrated as the reference
point.
IMPORTANT!
Seals and plates must be assembled in a given order
and be turned to face the right way otherwise both
function and watertight integrity will be jeopardized.
P0016330
1 Loosen the bolts (1-10) max one turn.

Continue to undo each bolt in sequence one turn
at a time until all the bolts are removed.
P0016331
342 47701522 01-2016 © AB VOLVO PENTA

2
CAUTION!
Sharp edges. Wear gloves or use a shop cloth to
protect your hands.
Lift off the cover.

3 NOTICE! Number the plates using a marker pen.
P0016332
4 Mark the top plate (1) and lay it and its unique seal
to one side.
P0016333
5 Number and remove the plates (2-45) together

with their rubber seals.
P0016334
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6 Wash all plates and seals thoroughly under

running water. Use a soft brush.
Make scrupulously sure that there is no dirt
between the rubber seals and the plates.
P0016335
7 Wash the bottom attachment plate.

Check if the seals need to be replaced.
P0016336
8 Check the oil cooler seals.

Check the water outlet pipe seal.
P0016337
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9 Install 21461107 Guide pin in the outer spacer

pipes.
P0016338
10 Install the unique seals according to Seals for

bottom plate and top plate (three pages on in this
section).
P0016339
11 NOTICE! The flat sides of the seals must face the

plate.
Install the seals on the other plates (2-44). Make

sure that all of the attachment lug seals are
properly positioned.
P0016340
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12 Install all cooling plates according to Cooling

plates and installation order (next page).
Begin with the base plate (A) and seal as

illustrated.
P0016341
13 Clean the top cover and check the seal.

Grease the bolt threads and the undersides of the
bolt heads.
Install the bolts except where the locating pins are
located.
Guide the top cover onto the two locating pins.
Tighten the screws to contact.
P0016332
14 Tighten the bolts one turn at a time in sequence

around the cover. The bolts must be tightened
evenly so that the top cover is pressed down
straight.
Remove the locating pins when the cover has

been pressed down sufficiently far for their
removal. Install the bushes and the bolts. Tighten
the two bolts until they touch.
Continue to tighten the bolts one turn at a time in

sequence until the cover is completely pressed
down on all spacer tubes.
15 Install the heat exchanger; refer to Heat
exchanger, change, page 335.
P0016331
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Cooling plates and installation order
A 1 pc base plate (# 45).

The pattern points to the right.
Note the position of the sealed hole.
NOTICE! Unique seals.
B 13 pcs finely patterned cooling plates.

Must be turned so that the pattern on every
second plate points left.
(# 44,42,40,38,36,34,32,30,28,26,24,22,20).
B 12 pcs finely patterned cooling plates.

second plate points right.
(# 43,41,39,37,35,33,31,29,27,25,23,21)
C 1 pc intermediate plate (#19).

Note the position of the sealed hole.
D 9 pcs coarsely patterned cooling plates.

second plate points left.
(# 18,16,14,12,10,8,6,4,2)
D 8 pcs coarsely patterned cooling plates.

second plate points right.
(# 17,15,13,11,9,7,5,3)
E 1 pc top plate (#1).

Note the position of the sealed holes.
NOTICE! Unique seals.
P0016342
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Seals for bottom plate and top plate

This method shows how the seal must be modified to
fit the base plate / top plate.
1 Modify 2 seals to make 1 seal for the base plate /
top plate.
Cut the seal along the dotted line as illustrated.
P0016343
2 Scrap the upper part of the seal.
P0016344
3 NOTICE! No attachment lugs may be present on

the seals. Cut away the attachment lugs.
Repeat the procedure for more seal halves.
P0016345
4 Place the two cut seal halves facing each other

on the plate.
P0016346
348 47701522 01-2016 © AB VOLVO PENTA

Image showing base plate (45)

5 The seal must be glued using Volvo Penta part #
1161277.
Run a bead of glue above and below the join

where the two seal halves meet. Apply glue at the
points illustrated. Wipe away excess glue.
Wait > 30 minutes before installing to give the

glue time to dry.
P0016347
Image showing top plate (1)
P0016348
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26-2 Coolant Pump, Thermostat

Coolant Pump, Change
Draining, page 329.
Belt guard and drive belt removed; refer to Drive

Belt, Change, page 358.
1 Remover the belt tensioner (1).
2 Remove the coolant pump.
3 Clean the sealing surface.
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4 Where appropriate transfer the pulley (1) to the

new coolant pump (2).
5 Install a new sealing ring on the pump.
6 Install the coolant pump carefully behind the

water pipe.
NOTICE! Make sure the seal does not come

away from the pump.
Tighten the bolts.
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7 Check the pulleys and belt tensioner bearings.

Install the belt tensioner (1).
Then screw on the charge air cooler nut.
Install the remaining bolts.
8 Install the drive belt and check belt tensioner

function.
Fill with coolant and check watertight integrity.
Install the belt guard.
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Thermostat, Change
Drain the coolant so that the level falls below the
thermostat; refer to Coolant, Draining, page 329.
1 Remove the protective covers from the front
turbocharger (1) and remove the front plastic
1
cover (2).
2
P0012279
2 Remove the pipe (1) from the charge air cooler to

the expansion tank.
remove the rubber hose clamp (2) from the
charge air pipe.
1
P0012280
3 Remove the charge air pipe (1) from the inlet pipe
and pull it out from the charge air cooler.
P0012281
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4 Remove the banjo bolt (1) from the thermostat

cover.
Remove the pipe (2) from the thermostat cover.
5 Remove the bolt (1) that fastens the charge air

cooler to the thermostat cover.
Remove the thermostat cover bolts and remove
the thermostat cover.
6 Remove the thermostat using suitable pliers.
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7 Clean the sealing surfaces on the cylinder head.
8 Clean the sealing surfaces on the thermostat

cover.
9 Check that the spring-loaded valve works.
Install a new O-ring at the valve.
10 Install the thermostat with a new seal.
47701522 01-2016 © AB VOLVO PENTA 355

11 Instal the thermostat cover.

Install the bolt (1) to the charge air cooler.
12 Install the banjo bolt (1) with new seals and install
the pipe (2) with a new seal.
13 Inspect the O-rings to the charge air cooler.

Lubricate the O-rings with Forminol.
Install the charge air pipe (1) with a new inlet pipe
gasket.
P0012281
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14 Fit the pipe (1) between the charge air cooler and
the expansion tank and the hose (2) from the
thermostat cover.
Use new seals.
1 Install the clamps for the pipes and hoses.
P0012356
15 Add coolant.
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Drive Belt, Change

1 Remove the belt guard.
2 Release the belt tensioner using a hinged wrench
handle.
3 Remove the belt.
4 Check the function of the tensioner, the condition
of the pulleys and the idler wheel bearings.
5 Install the belts and release the tensioner.

Check that the belt ends up in the center of the
idler wheel pulley.
6 Check that the belt is correctly aligned on all the

pulleys.
7 Install the belt guard.
p0012242
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Belt Tensioner, Change

Belt guard removed.
Drive belt removed; refer to Drive Belt,

Change, page 358.
Removal
1 Undo the three bolts that retain the belt tensioner
and return wheel. Remove the unit.
2 Unbolt the return wheel or tensioner, or replace
the complete unit.
P0013386
Installation
3 Install the tensioner complete with attachment.
Align the guide pin on the attachment to the
installation hole and tighten the bolts.
Check the condition of the drive belts.
4 Re-install the belts; refer to Drive Belt,
Change, page 358.
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Thermostat, Function Check

Remove the thermostat, see Thermostat,
Change, page 353.
1 Place the thermostat in a big pot with water and
heat it to the opening temperature as specified in
Engine, General, page 29.
P0005072
Closed thermostat.
2 If the thermostat does not open at specified

temperature, it should be replaced.
3 Install the thermostat, see Thermostat,
Change, page 353.
NOTICE! Always use a new seal, even if the

thermostat is not replaced.
P0005073
Open thermostat.
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Cold Start Valve, Check and Change

An open (sticking) cold start valve may present the
same symptoms as an open thermostat.

Draining, page 329.
1 Remove the plug that conceals the cold start
valve.
2 Use snipe nosed pliers to feel if the cold start

valve is sticking. The spring force can be felt by
pulling at the valve center pin.
The valve spring must close the valve when the
pin is released.
3 Use strong snipe nosed pliers if the valve is to be

removed. The valve is threaded into the
thermostat cover.
When installing the valve it must be held perfectly
straight in order to be threaded correctly.
If it is screwed in skewed it will be installed cross
p0012366 threaded. The valve will not be able to be screwed
down to its correct position, which means that the
valve will not seat properly.
4 Install the plug.
5 Fill the cooling system.

Check valve function.
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26-5 Charge Air Cooler with Connections

Front Charge Air Cooler, Change
Cooling system drained, refer to Coolant,

Draining, page 329.
1 Remove cover over the turbo and front engine
cover.
Remove the cover above the front charge air
cooler.
2 Remove the retainer for the covers.
3 Remove clamp for turbocharger.

Remove the two upper screws holding charge air
pipes together.
362 47701522 01-2016 © AB VOLVO PENTA

4 Remove screws holding charge air pipe and

charge air cooler together. Remove the charge air
pipe.
5 Remove pipe and clamp from the charge air

cooler.
Loosen hose clamps from charge air cooler
connections.
6 Remove lower located nuts holding charge air

cooler in place.
Remove the upper screws of the charge air
cooler.
Pull the charge air cooler out in a straight line.
Make sure hoses are released from the charge
air cooler.
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7 Check that charge air cooler hoses are flawless.

Check that o-rings for connection pipe end are
flawless.
8 Place charge air cooler on the lower studs and

press the cooler against the connection pipe.
Lubricate the O-rings.
Fit the connection pipe end to the charge air pipe
and steer in cooling water hoses.
NOTICE! Make sure there are clamps on hoses.
Press the charge air cooler in place and attach

upper screws and nuts on studs.
Tighten screws and nuts.
9 Attach the pipe to the banjo screw with new

sealings.
Attach clamp to the pipe.
Tighten clamps.
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10 Attach new sealings on charge air pipe. Check

that sealing surfaces are clean and flawless.
Check the O-ring in the connection pipe.
Fit pipe in its position.
NOTICE! For easier installation, remove the

intermediate pipe and lubricate the O-rings with
Forminol.
11 Attach screws to charge air cooler and tighten.
12 Check that the connection is in proper position.

Mount clamp and tighten the screw.
Attach the two screws to the links holding charge
air pipe together.
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13 Install the retainer for engine covers.

14 Fill the cooling system and check that no leakage
occurs.
15 Attach the cover over the front charge air cooler.

Attach the plastic cover and then the cover over
the turbocharger.
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Rear Charge Air Cooler, Change

Cooling system drained.
Removal
1 Switch off battery power.
Remove the turbocharger cover.
2 Loosen the attachment frames (1) for the battery
connections.
1
P0011896
3 Remove the charge air pipe (1) between the

1
P0011897
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4 Remove the charge air pipe between the charge

air cooler and the front turbocharger.
5 Undo the hose clamps and hoses on the rear of

the charge air cooler.
NOTICE! For better access, remove the oil hoses

from the turbocharger and wastegate valve.
6 Remove the charge air cooler retaining bolts.

Pull the charge air cooler out so that the hoses at
the back are released.
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Installation
7 Install the charge air cooler hoses and position
the hose clamps as illustrated to facilitate
tightening.
8 Check that the coolant pipes are clean and

undamaged.
Grease the pipes externally, and the pipes
internally, with rubber lubricant 1698135-8.
9 Lift up the charge air cooler and align the hoses

with the pipes. Push it in so that the hoses slide
onto the pipes.
Insert the charge air cooler retaining bolts and
tighten them.
Feel to make sure the pipes have entered the
hoses correctly and that the pipes are not chafing
against anything. Tighten the hose clamps.
10 Fill the cooling system and check that no leakage
is present.
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11 Install the oil hoses to the turbocharger and

wastegate with new seals.
12 Clean the charge air pipe and install new seals.

Install the pipe to the front turbocharger.
13 Install the pipe (1) to the rear turbocharger.
1
P0011897
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14 Install the attachment frames (1) for the battery

connections. Check that the cables do not chafe
against anything.
1
P0011896
15 Install the turbocharger cover.
47701522 01-2016 © AB VOLVO PENTA 371

Charge Air Cooler, Replace

D13B-B MP, D13B-D MP, D13B-E MH, D13B-F MG,
D13B-J MP, D13B-M MP, D13B-N MH, D13C1-A MP,
D13C3-A MP

Draining, page 329
Removal
1 Remove the heat shield and covers, if fitted.
2 Remove the plastic heat shield and the heat

insulation around the turbocharger.
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3 Remove the charge air pipe between the

4 Remove the attachment fitting (1) from the front

cover.
Remove the valve (2) and wastegate control
hose.
5 Remove the pipe and clamp from the charge air

cooler.
Undo the charge air cooler water connection hose
clamps.
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6 Remove the upper bolts on the charge air cooler.

Remove the lower charge air cooler retaining
nuts.
Pull the charge air cooler out straight. Make sure
the hoses release from the charge air cooler.
374 47701522 01-2016 © AB VOLVO PENTA

Installation
7 Transfer any necessary components to the new
charge air cooler.
8 Check that the charge air cooler hoses are
undamaged.
Check that the O-rings to the stub connection are
undamaged.
9 Fit the charge air cooler onto the lower studs.

Guide the stub connection into the charge air pipe
and guide in the cooling water hoses.
NOTICE! Make sure there are hose clamps on

the hoses.
Press the charge air cooler into position; install

the upper bolts and screw the nuts onto the studs.
Tighten them.
10 Install the pipe to the banjo bolt using new seals.

Install the pipe clamp.
Tighten the hose clamps.
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11 Install new charge air pipe seals.

Check that the sealing surfaces are clean and
undamaged.
Align the pipe and fasten it.
NOTICE! For easier installation, remove the

intermediate pipe and lubricate the O-rings.
12 Install the attachment fitting (1) for the front cover.

Install the valve (2) and wastegate control hose.
13 Install the rear heat insulation.
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14 Align the bottom plastic cover with the

15 Install the two bottom bolts.
16 Fasten the top intermediate panel. It must be

intermediate panel.
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17 Align the top plastic cover with the insulation and

tighten all bolts.
18 Install the other covers.

is present.
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Reverse gear oil cooler, change

Draining, page 329.
1 Undo the attachment fitting on the heat
exchanger for the engine oil dipstick.
Undo the oil hoses from the oil cooler.
Remove the oil cooler bolts and remove it.
2 Remove the O-rings located under the heat

exchanger.
NOTICE! The O-rings are pressed into grooves;

use a sharp awl to remove them.
3 Clean the grooves. Lubricate and press in new O-

rings.
Lift the new oil cooler into position. Insert the bolts
and tighten them.
Install the oil dipstick attachment fitting.
Install the oil hoses to the reverse gear.
4 Fill the engine cooling system.
Check the reverse gear oil level.
Start the engine and check that no oil and water
leakage is present.
Check the cooling system coolant level; check the
reverse gear oil level and function.
47701522 01-2016 © AB VOLVO PENTA 379

26-6 Sea Water System, Sea Water Pump

Seawater Pump, Impeller, Change
Tools:
1 Close the sea cocks.
2 Remove the seawater pump cover.
P0011878
3 Remove the rubber washer (1) from the pump

shaft.
P0011879
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4 Use a suitable puller to remove the impeller.
5 If the impeller lacks rubber parts, remove the pipe

that runs to the heat exchanger.
p0011881
6 Clean the heat exchanger inlet.

7 Inspect the pump housing internally and clean as
necessary. Check the condition of the shaft and
the cover.
p0011882
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8 Remove the protective cover (1) in order to be

able to crank the engine.
9 Fit 9993590 Rotation tool and a ratchet handle.

10 Grease the impeller, the inside of the pump
housing and the shaft with the lubricant supplied.
11 Crank the engine clockwise (raise the ratchet

handle) at the same time as the impeller is
pressed into the pump so that the splines grip the
pump shaft.
Press in the impeller at the same time as the
engine is cranked until the impeller is fully in the
pump housing.
P0012259
382 47701522 01-2016 © AB VOLVO PENTA

NOTICE! M8 stud with washers and nut can be

used with advantage.
12 Install the rubber washer (1) in the center of the

impeller and install a new O-ring in the housing
groove.
P0011879
13 Install the cover and tighten the bolts.
P0011878
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14 Check the zinc anode and re-install the heat

exchanger pipe.
p0011881
15 Remove the cranking tool and re-install the

protective cover (1).
16 Open the sea cocks.

Start the engine and check that no oil leakage is
present.
384 47701522 01-2016 © AB VOLVO PENTA

Seawater Pump, Change

Tools:
Removal
2 Remove the pipe between the pump and the heat
exchanger.
p0011881
3 Check for evidence of contamination in the heat

exchanger inlet pipe.
4 Remove the water inlet to the pump.
p0011882
5 Clean around the pump attachment fittings.

Remove the oil hose and its tie wraps.
47701522 01-2016 © AB VOLVO PENTA 385

6 Undo the three pump nuts (1).
P0012261
7 Lift away the pump.

It may be necessary to remove the pumps
connection fittings first (depending on the engine
version).
P0012262
8 If the gear wheel is to be removed:

Undo the nut and use a suitable puller to remove
the gear wheel.
Transfer any water connections.
P0012263
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Installation
9 Install a new O-ring on the pump before putting it
in place.
P0012263
10 Clean the engine sealing surface.
11 Lift the pump in place and crank the engine

9993590 Rotation tool to get the timing gear to
mesh with the gear wheel on the pump..
Tighten the nuts.
Remove the tool and install the protective cover.
47701522 01-2016 © AB VOLVO PENTA 387

12 Install the oil hose with new seals.
13 Secure the oil hose with a tie wrap (1).
14 Check the zinc anode. Replace as necessary.

Lubricate the O-ring in the water pipe rear end.
Install the water pipe to the heat exchanger.
15 Install the water inlet to the pump.
Open the seawater valve, if present.
16 Start the engine and check that no oil or water
leakage is present.
p0011881
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Seawater Pump, Overhaul

Remove the seawater pump; refer to Seawater Pump,
Change, page 385.
NOTICE! The numbers in brackets refer to the

illustration two pages ahead.
Tools:
884167 Drift
9994034 Drift
Disassembly
1 Mark the positions of the pipe bends in relation to
the pump housing. Remove the pipe bends.
2 Remove the the seawater pump cover together
with the O-ring. Remove the rubber washer (19)
from the impeller. Pull out the impeller with an
impeller puller.
3 Undo the cam bolt (5). Remove the cam disc (3)
and the wear ring (7).
4 Mark the position of the pump housing in relation
to the bearing housing. Undo the four bolts and
carefully pull out the pump housing. Remove the
pump housing (4), support washer (6) and shaft
seal (8) from the pump shaft.
5 Tap the ceramic ring (9) with rubber cover out
from the pump housing. Use a suitable socket.
6 Remove the deflector ring (10) from the shaft.
7 Pull the gear wheel off using a universal puller.
47701522 01-2016 © AB VOLVO PENTA 389

8 Remove the bearing retainer ring (15) from the

bearing housing and pull the shaft and bearing
out.
9 Pull the bearings off the shaft using a universal

puller.
10 Tap the seal ring (11) out of the bearing housing

with a suitable socket.
11 Inspect all components. Change worn or
damaged components.
390 47701522 01-2016 © AB VOLVO PENTA

Assembly
12 Grease the seal ring (11) with water-resistant
grease (Volvo Penta part # 828250) and tap it into
the bearing housing.
NOTICE! Put the old support washer (6) over the

ring to protect it. The side of the seal with the
spring must face inwards towards the bearing
housing.
13 Install the inner bearing retainer rings on the

pump shaft and press on the bearings.
NOTICE! 884167 Drift may be used.
Or the bearing may be heated to approx 100 °C

(212 °F) and then tapped into position.
Fill the bearings with grease (after they have
cooled).
1 Cover 10 Deflector ring

2 O-ring 11 Seal ring
3 Cam disc 12 Ball bearing
4 Pump housing 13 Bearing retainer
5 Bolt ring
6 Support washer 14 Bearing housing
7 Wear ring 15 Bearing retainer
8 Shaft seal with carbon ring
ring 16 Pump shaft
9 Ceramic ring with rubber 17 Gear wheel
cover 18 Impeller
19 Rubber washer
47701522 01-2016 © AB VOLVO PENTA 391

14 Install the pump shaft with bearing in the bearing

housing. Install the outer bearing retainer ring
(15).
15 Install the gear wheel and fasten it.

Tightening torque: 200 ±30 Nm
(147.5 ±22.1 lbf.ft.).
16 Fit the deflector ring (10) on the shaft closest to

the bearing housing.
17 Moisten the rubber cover and install the ceramic
ring (9) and rubber cover in the pump housing.
NOTICE! The sealing surfaces in the seal must

not come into contact with grease or be touched
by bare fingers. Put a piece of clean plastic foil on
a hammer handle and carefully press the ceramic
ring into place.
18 Install the pump housing on the bearing housing,
as previously marked, without tightening it.
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19 Carefully place the shaft seal (8) on the pump

shaft and press down the sleeve and carbon ring
until contact is made with the fixed ceramic ring
in the housing.
NOTICE! 9994034 Drift may be used.

20 Install the support washer (6) above the seal;
install the wear ring (7).
21 Fasten the pump housing to the bearing housing
to the standard torque of 24 Nm (17.7 lbf.ft.).
22 Install the cam disk (3) and fasten it. Use white
sealant.
23 Grease the pump housing with water resistant
grease (Volvo Penta part # 828250).
NOTICE! The impeller may be put in hot water

before installation to facilitate installation.
24 Press the impeller in with a rotating movement
(counterclockwise).
NOTICE! Screw a stud into the shaft stub and

press the impeller in with the aid of a nut and
washer.
25 Install the rubber washer (spline seal) on the end
of the impeller. Install the cover with a new O-ring
and fasten it to the standard torque of 10 Nm (7.4
lbf.ft.).
26 Install the pipe bends on the pump housing in
accordance with the previous markings.
47701522 01-2016 © AB VOLVO PENTA 393

32-1 Alternator
32-1 Alternator
Alternator, Change
Removal
2 Remove the belt guard and drive belt.
3 Disconnect the harness from the alternator.
4 Remove the alternator retaining bolts.
394 47701522 01-2016 © AB VOLVO PENTA

32-1 Alternator
5 Remove the upper bolt to the alternator

attachment fitting and undo the lower bolt.
Lift the alternator away.
Installation
6 Check that all four plastic bushings are in place.
7 Install the generator and attachment stay.
8 Install the alternator cables and the positive

terminal protective cap.
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32-1 Alternator
9 Inspect the belt and the belt tensioner

Install the belts.
10 Check belt tracking on the idler wheel.

Install the belt guard.
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33-1 Starter Motor
33-1 Starter Motor

Starter Motor, Change
2 Remove the bracket (1) with the electrical
connection boxes.
1
P0011896
3 Remove the following cables from the starter

motor
- Two heavy cables and one light cable from
the negative terminal
- Two heavy cables and one light cable from
the positive terminal
- Disassemble the harness terminal for the
harness to the control relay.
4 Remove the three starter motor bolts.

5 Lift the starter motor out.
47701522 01-2016 © AB VOLVO PENTA 397

33-1 Starter Motor
6 Transfer components as required when replacing

the starter motor.
NOTICE! Do not forget the insulating bushes for

the nuts and the plastic disc between the starter
motor and engine.
7 Install the starter motor and tighten the nuts.

Check that the insulating bushings are in place
underneath the nuts.
8 Connect the electrical cables to the starter motor

positive and negative terminals.
Connect the control relay harness terminal.
398 47701522 01-2016 © AB VOLVO PENTA

33-1 Starter Motor
9 Install the bracket (1) with the electrical

connection boxes.
Check that the cables are properly fastened and
do not chafe against anything.
10 Switch on battery power and check function.
1
P0011896
47701522 01-2016 © AB VOLVO PENTA 399

36-6 Monitoring and Control Systems

Engine Control Unit (ECU), Replace
Removal
2 Remove the two lower engine control unit bolts.
Remove the two attachment bracket bolts.
3 Move the engine control unit down approx 10 mm

(0.39").
4 Remove the harness clamps (1) and disconnect
the connectors (2).
5 NOTICE! The Breakout box can now be

connected.
It is necessary to clean around the fuel

connections when removing the engine control
unit.
6 Remove the six bolts on the cooling loop to loosen
it from the attaching bracket.
7 Remove the engine control unit.
If the engine control unit is to be changed the
bracket for the upper attachment points and the
fuel ducts must be removed and transferred.
400 47701522 01-2016 © AB VOLVO PENTA

Installation
8 Connect the fuel pipes with new seals.
9 Connect the connectors (2) and screw on the

harness clamps (1).
10 Lift up the engine control unit and install the

retaining bolts.
11 Vent the fuel system if the fuel lines have been

removed.
47701522 01-2016 © AB VOLVO PENTA 401

PCU, Replace
D13B-A MP, D13B-B MP, D13B-G MP, D13B-H MP,
D13B-J MP, D13B-K MP, D13C1-A MP, D13C2-A MP
Protective covers (where fitted) removed.
Removal
1 Undo the clamp closest to the filter.
The image shows a D13B-A/G/H/K engine (twin turbocharger).
2 Undo the two filter housing nuts and remove the

filter.
NOTICE! Alternatively loosen the bolt that is

tightening the clamp under the filter.
3 Undo the four PCU unit bolts.

Disconnect the harness connections to the PCU.
The Breakout box can now be connected or the
PCU replaced.
Installation
4 Install the harness connectors on the PCU and
screw in the four bolts.
402 47701522 01-2016 © AB VOLVO PENTA

5 Check that there is no dirt in the filter or in the filter

rubber stub connection.
6 Press the filter into the rubber stub connection
and align the studs.
Screw on the two nuts.
7 Tighten the clamp on the rubber stub connection.
The image shows a D13B-A/G/H/K engine (twin turbocharger).
8 For any necessary PCU software

reprogramming, refer to Service handbook,
Group 30 Electrical system, EVC.
Check the function of the PCU.
47701522 01-2016 © AB VOLVO PENTA 403

Power Module, Replace

D13B-C MP, D13B-D MP, D13B-E MH, D13B-F MG,
D13B-L MP, D13B-M MP, D13B-N MH, D13C3-A MP,
D13C4-A MP
Protective covers (where fitted) removed.
Removal
1 Undo the clamp closest to the filter.
The image shows a D13B-C/L engine (twin turbocharger).
2 Undo the two filter housing nuts and remove the

filter.
NOTICE! Alternatively loosen the bolt that is

tightening the clamp under the filter.
404 47701522 01-2016 © AB VOLVO PENTA

3 Screw in the three Power module bolts.

Disconnect the harness connections from the
Power module.
Change the Power module.
Installation
4 Install the harness connectors on the Power
module and screw in the three bolts.
5 Check that there is no dirt in the filter or in the filter

rubber stub connection.
6 Press the filter into the rubber stub connection
and align the studs.
Screw on the two nuts.
7 Tighten the clamp on the rubber stub connection.
The image shows a D13B-C/L engine (twin turbocharger).
8 Check the function of the Power module.
47701522 01-2016 © AB VOLVO PENTA 405

37-1 Cables
37-1 Cables
Cable Trunk, Change
In order to replace the wire harness it will be necessary
to remove or undo much of the engine's equipment
first.
If the wire harness is being replaced because of a short
circuit the cause must be remedied before
replacement.
Requirements
• Battery power disconnected.
• Cooling system drained; refer to Coolant,
Draining, page 329.
• All protective covers removed.
• Air filter housing and air filter housing holder
removed.
• Alternator and alternator bracket loosened to allow
outward movement.
• Heat exchanger removed; refer to Heat exchanger,
change, page 335.
• Water pipe between the thermostat and heat
exchanger removed.
• Oil filters removed.
1 Remove the bolt and clamp to the crankcase
ventilation pipe.
406 47701522 01-2016 © AB VOLVO PENTA

37-1 Cables
2 Remove the venting pipe (1) to the (front) charge

air cooler.
Remove the boost air pipe (2) between the (front)
charge air cooler and the inlet manifold.
3 Undo the expansion tank attachment bolts so that

it can be moved a little.
Remove the valve cover.
(twin turbocharger)
Remove the rear turbocharger; refer to Low
Pressure Turbo, Change, page 298
Remove the upper heat shield from the front
turbocharger.

Remove the pipe between the air filter and the
turbocharger.
(twin turbocharger)
Remove the Y-pipe and the two flex pipes.
47701522 01-2016 © AB VOLVO PENTA 407

37-1 Cables

(twin turbocharger)
Remove the heat shield beneath the Y-pipe.
7 Clip away the cable ties and remove the wire

harness clamps.
Disconnect all harness terminals and cable
shoes.
Remove the wire harness.
8 Take the new wire harness and thread the part (1)
that leads to the injectors behind the return fuel
hoses that run down to the overflow valve.
Also run the part (2) of the wire harness with
harness terminals for the engine control unit
behind the positive and negative cables to the
altenator.
Connect the coolant level sensor harness
terminal (3).
Secure the wire harness behind the return fuel
line using clamps.
9 Thread the wiring to the injectors through the

holes in the cylinder head and tighten the
grommet.
Clamp the wiring to the temperature sensor and
waste gate valve.
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37-1 Cables
10 Run the harness up to the waste gate valve;

connect and clamp it.
11 Connect and clampt the coolant temperature

sensor harness.
12 Connect and clamp the injector wiring.
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37-1 Cables
13 Run that part of the harness that connects to the

engine control unit.
Connect the harness terminals (1) to the oil
NOTICE! The upper sensor is for oil pressure and

the lower one for crankcase pressure.
Connect the harness terminals (2) to the

alternator and diode.
Install the relay holders.
14 Connect and clamp the engine control unit wire

harness.
Connect the connector on the cable (1) that runs
to the oil level sensor.

Connect the cable to the water separator. Clamp
the wire harness to the holder and to the harness
for the alternator cables.
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37-1 Cables
16 Connect the harness terminal (1) to the fuel

pressure sensor.
Connect the harness terminal (2) for the boost
pressure/temperature sensor.
Clamp the harness.

Lay the harness on the holders and run the cables
(1) up to the circuit breakers and stop button.
Attach cable ties (2) to the wire harness holders.

Lay the harness on the holders and run the cables
(1) up to the circuit breakers.
Attach cable ties (2) to the wire harness holders.

engine.
18 Connect and clamp the wire harness.

engine.
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37-1 Cables
19 Locate the wire harness beneath the crank case

ventilation pipe attachment.
Bolt the four outlets to the attachment plate.
Secure the two loose harness terminals to the
pipe attachment using cable ties.

Connect harness terminals to the PCU and clamp
the wire harness.
Connect the crankshaft sensor connector.

Connect the harness terminal (1) to the
emergency stop button.
Connect the Power module connector (2) and
clamp the wire harness.
Connect the crankshaft sensor connector (3).
412 47701522 01-2016 © AB VOLVO PENTA

37-1 Cables
21 Run the wire harness down to the start motor.

Connect the camshaft sensor connector.
Secure the harness with a cable tie.

engine.
22 Clamp the wire harness that runs down to the

starter motor.
23 Connect the cables to the starter motor and the

positive connection.
24 Check that the wire harness is not in contact with

any sharp edges.
Add cable ties where necessary.
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37-1 Cables

(twin turbocharger)
Install the heat shield.

(twin turbocharger)
Install the Y-pipe with flex pipes and new gaskets.

Torque the Y-pipe attachment bolts; refer to
General Tightening Torques, page 9.

(twin turbocharger)
Install the heat shield above the Y-pipe.
Do not forget the cable ties on the water hose and
oil return line.

turbocharger.

(twin turbocharger)
Install the heat shield to the rear turbocharger.
29 Check the valve cover seal. Replace as
necessary.
Install the valve cover.
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37-1 Cables
Torque tighten the bolts; refer to Group 21:

Engine, page 10.
30 Install the crank case ventilation hose.
Fasten the expansion tank.
31 Install the boost air pipe (2) and the venting pipe
(1) to the charge air cooler.
32 Install the bolt and clamp to the crankcase

ventilation pipe.
33 Install new oil filters.
34 Install the water pipe (1) between the thermostat

and heat exchanger.
Install the alternator (or alternators) and
attachment. Make sure the isolator washers are
in the correct positions.
Check the belt tensioner (2) and idler pulley.
Install the drive belt.
47701522 01-2016 © AB VOLVO PENTA 415

37-1 Cables
35 Install the heat exchanger, oil filter drip pan and

the connection pipe.
36 Install the holder for the air filter housing.
Connect the crank case ventilation pipe to the air
filter stub hose.
With the exhaust bend installed, connect the
exhaust temperature alarm (loacted at the
exhaust elbow outlet, where the exhaust gases
are mixed with seawater) to the wire harness.

With the exhaust bend installed, connect the
exhaust temperature sensor (located on the pipe
between the exhaust elbow outlet and (rear)
turbocharger) to the wire harness.
38 Install all protective covers.
Fill the cooling system.
Check the oil level.
Check all electrical functions.
39 After engine start, check that no leakage is
present (oil, coolant, seawater or fuel).
Check the oil level one more time.
416 47701522 01-2016 © AB VOLVO PENTA

Index
A Engine Complete, General....................................... 76
About this Workshop manual..................................... 3 Engine Control Unit (ECU), Replace...................... 400
Air Cleaner, Throttle Housing................................. 328 Engine Disassembly................................................. 95
Air Filter, Change................................................... 328 Engine Fixture, Removal.......................................... 92
Alternator................................................................ 394 Engine Fuel Filter Replacement............................. 250
Alternator, Change................................................. 394 Engine Information, General.................................... 66
Engine Transmission................................................ 38
B Engine, General....................................................... 29
Belt Tensioner, Change.......................................... 359 Exhaust manifold expansion plug, change............. 297
Bypass Valve Fuel System, Replace..................... 248 Exhaust Manifold, Change..................................... 273
Bypass Valve, Oil Filter Bypass, Replace.............. 243 Exposing the Engine................................................ 76
By-pass valves, Heat Exchanger, Check and
Change................................................................... 340 F
Fault tracing of the cooling system........................... 68
C Fitting the Fixture...................................................... 89
Cable description...................................................... 86 Flywheel, Indication................................................ 207
Cable Trunk, Change............................................. 406 Front Charge Air Cooler, Change........................... 362
Cables.................................................................... 406 Fuel Feed Pressure, Check.................................... 251
Camshaft Bearing Housing, Replace..................... 207 Fuel Feed Pump and Filter..................................... 250
Camshaft, Wear Check.......................................... 206 Fuel Feed Pump, Change...................................... 256
Charge Air Cooler with Connections...................... 362 Fuel filter housing, change..................................... 252
Charge Air Cooler, External Cleaning...................... 74 Fuel System..................................................... 46, 245
Charge Air Cooler, Replace................................... 372 Fuel system, bleeding............................................ 245
Charge Air Pipe, Leakage Check............................. 75 Fuel System, General............................................. 245
Charge Air Pressure, Check................................... 327
Charge Pressure, Troubleshooting.................... 69, 73 G
Chemical products.................................................... 65 Gear Ring, Fywheel: Replace................................ 208
Cold Start Valve, Check and Change..................... 361 General........................................................... 3, 65, 66
Compression Test.................................................... 70 General Tightening Torques....................................... 9
Connecting Rod Bushing, Check up...................... 187 Group 21: Engine..................................................... 10
Connecting Rod, Check......................................... 187 Group 22: Lubrication System.................................. 19
Coolant Level, Checking and Topping Up.............. 331 Group 23: Fuel System............................................ 22
Coolant Pump, Change.......................................... 350 Group 25: Inlet and Exhaust System........................ 25
Coolant Pump, Thermostat.................................... 350 Group 26: Cooling System....................................... 28
Coolant, Draining.................................................... 329 H
Cooling System................................................ 48, 329 Hand Pump, Change.............................................. 259
Cooling System, Cleaning...................................... 330 Heat exchanger, change........................................ 335
Cooling System, General....................................... 329 Heat Exchanger, Cleaning..................................... 342
Cooling System, Pressure Testing......................... 332 High Pressure Turbo, Replace............................... 307
Crank Mechanism............................................ 40, 211 I
Crankshaft Seal, Change (front)............................. 211 Illustrations................................................................. 6
Crankshaft Seal, Change (rear)............................. 218 Injectors and Delivery Pipes................................... 260
Crankshaft, Inspection............................................ 223 Inlet and Exhaust Manifolds................................... 273
Crankshaft, Installation........................................... 110 Inlet and Exhaust System................................. 47, 273
Crankshaft, Removal.............................................. 107 Intake Manifold, Change........................................ 289
Cylinder Head......................................................... 159
Cylinder Head, Change.......................................... 159 L
Cylinder Liner and Pistons, Inspection................... 186 Location of Sensors.................................................. 30
Cylinder Liner, Installation...................................... 112 Low Pressure Turbo, Change................................ 298
Cylinder Liner, Pistons........................................... 186 Lube Oil Pump, Installation.................................... 115
Cylinder Liners, Removal....................................... 105 Lube Oil Pump, Removal....................................... 101
Lubrication Oil Pump, Change............................... 228
D Lubrication System................................................... 44
Draining, Fuel Duct in Cylinder Head..................... 246
Drive Belt, Change................................................. 358 M
Main bearing, Change............................................ 224
E Monitoring and Control Systems............................ 400
Electrical System...................................................... 50
Engine................................................................ 32, 76 O
Engine Assembly.................................................... 110 Oil cooler................................................................ 244
Engine body............................................................. 32 Oil filter................................................................... 231
Oil Filter Bracket, Change...................................... 234
47701522 01-2016 © AB VOLVO PENTA 417

Oil filter, Change..................................................... 231 Valves, Installation................................................. 199
Oil Leading Bracket, Change................................. 236 Valves, Removal.................................................... 197
Oil Pressure Sensor, Check................................... 232 W
Oil pump and Line.................................................. 228 Wastegate valve, cleaning..................................... 327
Other Equipment...................................................... 63
P
PCU, Replace......................................................... 402
Piston Cooling Oil Pressure, Check....................... 241
Pistons, Installation................................................ 114
Pistons, Removal................................................... 101
Power Module, Replace......................................... 404
R
Radiator, Heat Exchanger...................................... 335
Rear Charge Air Cooler, Change........................... 367
Reassembly, Complete Engine.............................. 125
Repair instructions...................................................... 4
Reverse gear oil cooler, change............................. 379
S
Safety Information.................................................... 53
Safety Instructions.................................................... 53
Safety Valve, Oil Pressure, Replace...................... 239
Sea Water System, Sea Water Pump.................... 380
Seawater Pump, Change....................................... 385
Seawater Pump, Impeller, Change........................ 380
Seawater Pump, Overhaul..................................... 389
Sensors, Adjustment.............................................. 209
Sleeve for unit injector, replace.............................. 266
Special Service Tools............................................... 57
Special Tightening Torques...................................... 10
Specifications, Electrical........................................... 50
Specifications, Engine ............................................... 9
Starter Motor.......................................................... 397
Starter Motor, Change............................................ 397
T
Technical Data................................. 32, 44, 46, 47, 48
Test and Adjustments............................................... 70
Thermostat Oil Cooler, Change.............................. 244
Thermostat, Change............................................... 353
Thermostat, Function Check.................................. 360
Timing Gear, Installation........................................ 116
Timing Gear, Removal............................................. 95
Timing Gears and Shaft......................................... 206
Troubleshooting........................................................ 66
Turbo and supercharger......................................... 298
Turbo, Change....................................................... 320
Turbocharger, Inspection....................................... 298
U
Unit Injector, Replace............................................. 260
V
Valve Guides, Inspection........................................ 193
Valve Guides, Replacing........................................ 194
Valve Mechanism................................................... 188
Valve mechanism..................................................... 34
Valve Seat, Change............................................... 203
Valve Seats and Valve, Grinding............................ 201
Valve Stem Sealings, Replace............................... 205
Valves and Unit Injectors, Adjustment.................... 188
418 47701522 01-2016 © AB VOLVO PENTA

References to Service Bulletins
Group No. Date Refers to
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Publication No.:.............................................................Date of issue:......................................................................
Proposal/Motivation:.................................................................................................................................................
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Date:..............................................................
Name:............................................................
AB Volvo Penta
Service Communication
Dept. CB22000
SE-405 08 Gothenburg
Sweden
47701522 English 01-2016

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Workshop Manual E

Group 20-26 2(0)

Safety and Other Instructions

Lubricating and Oil System

Inlet and Exhaust System

47701522 01-2016 © AB VOLVO PENTA 1

Alternator, Charge Regulator

Other Electrical Equipment

Cables and fuses

2 47701522 01-2016 © AB VOLVO PENTA

Volvo Penta accepts no responsibility for damage or

47701522 01-2016 © AB VOLVO PENTA 3

4 47701522 01-2016 © AB VOLVO PENTA

Lock nuts Anaerobic agents.

47701522 01-2016 © AB VOLVO PENTA 5

Illustration colors Position

Focus arrows pointing at object. Sometimes it

NOTICE! If an arrow with the text “x3” is pointing at

4 Background This symbol gives a positioning number to an object,

The symbol in the top left shows part no. of the

6 47701522 01-2016 © AB VOLVO PENTA

Movement arrows are used to show which direction a P0015629

component is to be moved / rotated.

Symbol is used in a corner of the illustration to show

A symbol of a tool in a corner of the illustration is

Symbol is used to show how many revolutions the

A drill in a specified size, duck tape and stripes may

The symbols are used to show different types of

47701522 01-2016 © AB VOLVO PENTA 7

Symbols can also describe when and how a chemical

The scraper symbol suggests that a contact surface P0015005

8 47701522 01-2016 © AB VOLVO PENTA

03-2 Specifications, Engine

47701522 01-2016 © AB VOLVO PENTA 9

Special Tightening Torques

Group 21: Engine

Front engine mounts, cylinder block

Main bearing caps

10 47701522 01-2016 © AB VOLVO PENTA

NOTICE! Tighten the bolts in sequence, as illustrated.

NOTICE! Run an approx. 2 mm (0.0787 in) silicone bead

47701522 01-2016 © AB VOLVO PENTA 11

Timing gear wheels

1 Drive gear, crankshaft 24 ± 4 Nm (17.7 ± 2.95 lbf ft)

3 Intermediate gear, adjustable:

4 Drive gear, camshaft (incl. vibration damper):

5 Intermediate gear 140 ± 10 Nm (103.3 ± 7.38 lbf ft)

12 47701522 01-2016 © AB VOLVO PENTA

Flywheel and timing cover

NOTICE! Run an approx. 2 mm (0.0787 in) silicone bead as

47701522 01-2016 © AB VOLVO PENTA 13

Timing Gear Cover, Upper

NOTICE! Run an approx. 2 mm (0.0787 in) silicone bead as

Install the cover in two stages:

14 47701522 01-2016 © AB VOLVO PENTA

NOTICE! Carefully check that the flange is clean and dry.

Cover, crankshaft seal

NOTICE! Run an approx. 2 mm (0.0787 in) silicone bead as

47701522 01-2016 © AB VOLVO PENTA 15

Vibration damper, crankshaft

NOTICE! The cylinder head must be installed according to

16 47701522 01-2016 © AB VOLVO PENTA

Bearing caps, camshaft/rocker arm shaft