489752
32
Zoom out
Zoom in
Previous page
1/35
Next page
FOREWORD
This
workshop
manual
contains
repair
instructions
for
the 2001,
2002
and
2003
engines
.
The
instructions
concerning overhauling
describe
the
most
suitable
working
method
using
the
special
tools
listed
under
the
heading
"Special
tools"
.
Both the
engine
designation
and
its
serial
number
must
be
clearly
stated
in
all
correspondence
concerning
the
engine
and
when
ordering
parts
.
We
reserve
the
right
to
carry
out
design
modifications
and,
for
this
reason,
the
contents
of
this
manual cannot
be
regarded
as
binding
.
SI
UNIT
SYSTEM
Power
is
given
in
kW
(kilowatt)
Speed
is
given
in
rev/s
(revolutions
per
second)
earlier unit
hp
(horse-power)
earlier
unit
rev/min
(revolutions
per
minute)
Torque
is
given
in
Nm
(newton
metre)
Volume
is
given
in
dm
3
(cubic
decimetre)
earlier unit
kpm
(kilopond
metre)
earlier
unit
l
(litre)
earlier unit
lbf
ft (poundfoot)
earlier unit
Imp
. gal (Imperial gallon)
earlier
unit
US
gal
(United
States
gallon)
Pressure
is
given
in
Pa
(Pascal)
earlier
unit
kp/cm
2
(kiloponds
per
square
centimetre)
earlier
unit
Ibf/in
2
(pounds
per
square
inch)
AB
VOLVO
PENTA
Technical
Publications
Department
Units
according
to
the
international
SI
system
have been
used
in
this
book
.
The
earlier
units
are
given
after
the
SI
units
.
Components
guide
.
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . .
.
. . .
.
2
DISASSEMBLY
Cylinder
head
. .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . . .
3
Transmission
. .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
. . . . .
.
.
.
.
.
. . .
.
. . . .
4
Piston,
piston
rods
.
.
. . .
.
. . .
.
. . .
.
. . . . . . .
.
.
.
.
.
. . .
.
. . . .
5
Flywheel
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
. . . .
5
Crankshaft
. . . . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . .
.
. . .
.
. . . .
5
Camshaft
. .
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . . .
5
OVERHAUL
Disassembling
the
cylinder
head
.
.
.
. . . . .
.
.
.
. . . . .
.
. . . .
7
Valve
guides
.
.
.
.
. . .
.
.
.
.
.
.
.
.
.
. . .
.
.
.
. . . . .
.
. . . . . . .
.
. . . .
7
Valve
seats
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . . . . . . .
7
Valves
.
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
.
. .
.
. .
. .
7
Valve
springs
. .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
. . . .
8
Rocker
arm
mechanism
.
.
.
.
.
. . .
.
. . . . . . .
.
.
.
.
.
. . .
.
.
.
. .
8
Injector
sleeve
.
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
. . . . .
.
.
.
.
.
. . .
.
.
.
.
.
8
Injectors
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
. . . . .
.
.
.
.
.
. . .
.
. . .
.
8
Assembling
the
cylinder
head
. . .
.
.
.
. . . . .
.
. . . . . . .
.
. . .
.
9
Feed-pump
.
. . .
.
. . . . . . .
.
. . . . . . .
.
. . . . . . .
.
. . . . . . .
.
.
.
.
10
Pistons
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . .
.
.
.
. . . . .
.
.
.
.
11
Crankshaft
.
.
.
.
.
.
.
.
.
.
.
. .
.
. . . . . . .
.
. . . . . . .
.
. . .
.
. . .
.
.
.
.
11
Camshaft
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
11
Connecting
rods
. . . . . . . . . . . .
.
.
.
.
.
. . .
.
. . .
.
. . . .
.
. . . .
.12
Thermostat
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . .
.
. . . . . . .
.
. . .
13
Sea-water
pump
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . .
.
.
.
. . . . .
.
.
.
.
13
ASSEMBLY
INDEX
Crankshaft
.
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . . . . . .
.
.
.
.
.
. . .
.
. . .
14
Pistons
.
.
.
.
.
. . .
.
.
.
. . . . .
.
. . . . . . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
. . .
14
Flywheel
. . . . . . .
.
. . .
.
. . .
.
. . .
.
. . .
.
:
.
.
.
.
.
.
.
. . .
.
. . .
.
. . .
15
Transmission
. .
.
. . .
.
. . .
.
. . .
.
. . .
.
.
.
.
.
.
.
.
.
. . .
.
. . .
.
. . .
15
Adjusting the
valve
clearance
. . . . .
.
. . . . .
.
. . . .
.
.
.
.
.
. .
17
Checking
the
injection
angle
. . . . . .
.
. . . . .
.
. . . .
.
. . .
.
. .
17
2003
Turbo
.
.
. . .
.
. . . . . . . . . . . . . . . . .
. . . . . . . . . .
.
.
.
. . . .
21
Fresh
water
cooling
. . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . .
25
Electrical
system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
Fault tracing
scheme
. . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . .
28
Special
tools
.
. . . . . . . . . . . . .
.
. . . . . . . . . .
.
. . . . . . . . . . . . .
29
Technical
Data
.
. . . . . . . . .
.
.
.
. . . . . . . . . . . . . . . . . . . . . . . .
30
COMPONENTS
GUIDE
8
1
.
Exhaust
elbow
2
.
Injectors
3
.
Temperature
sender
4
.
Electrical
distribution
box
5
.
Fuel
filter
6
.
Alternator
7
.
Starter
motor
8
.
Drainage,
cooling
water
9
.
Feed-pump
10
.
Engine
serial
number
11
.
Decompression
device
12
.
Inlet
air
silencer
13
.
Fuel
injection
pumps
14
.
Oil
dipstick
15
.
Sea-water
pump
Halpert@Optonline.net
Drain
off
the
cooling
water
and
the
lubricating
oil
from
the
on
engine
cradle
p/n
9992520
and
fixture
p/n
884837
.
If
the
engine
is
fresh
water
cooled,
see
page
21
.
1
.
Remove
the
alternator,
the
tensioner
bracket
and
the
starter
motor
.
Remove
the
connections
from
the
electrical
distribution
box
from
the
engine
and
remove
the
box
and
the
wire
harness
.
2
.
Remove
the
return
fuel
line,
the
fuel
pressure
lines
and
the
inlet
air
silencer
.
Install
protection
caps on
the
fuel
injection
pumps
and
injectors
.
Remove
the
screw
holding
the lever
of
the
decompression
device
(1)
and
pull
out
the
lever
.
Remove
the
valve cover
.
DISASSEMBLY
3
.
Remove
the
fuel
filter,
the
oil
filter,
the
feed-pump,
the
thermostat
housing
and
the
exhaust
elbow
.
Also
remove
the
sea-water
pump
with
its
attachment
tubes
.
4
.
Remove
the
valve
bridge
and
lift
out
the
push
rods
.
Remove
the
rubber
rings
fortheoil
pipe
.
Remove
the
cylinder
head
and
the
valve
lifters
.
Put the
lifters
on
a
rack
in
consecutive
order, NOTE!Thecylinder
head
boltsare
phosphatised
andmustnot becleanedwitha
steel
brush.
5
.
Remove
the
fuel
injection
pumps
.
Mark
the
pumps
to
ensure
installation
in
the
same
cylinders
fromwhich
they
were
removed
.
Take
care
of
the
shims
.
Remove
the
screws
on
the
side of
the
engine
block
and
lift
out the
pump
lifters
.
6.
Remove
the
pulley
center
bolt
and
pull
off
the
pulley
using
puller
p/n
9992265
.
Place
a
protection
padbetween
the
puller
and
the
crankshaft
to
avoid
the
crankshaft
being
damaged
.
7
.
Remove
the
transmission
cover
:
Start
by
removing
the
throttle
control
cover
.
Usea
suitable
type
of
pliers
to
remove
the
spring
(1)
.
Then
remove
the
end-nipple
(2)
and
the spring
(3)
.
Remove
the
oil
pump
cover
and
mark
the
gear
wheels
with
a
colour-pen
before
removing
them
.
(When
installing
the
gear
wheels,
the
marked
side
must
be
facing
outwards)
.
Remove
the
bracing
pin
of
the
camshaft
using
the
special
tool
p/n
884839
.
Never
remove
the
bracing
pin
by
punching
it
out,
this
can
very
well
bend
the
camshaft
.
Remove
the
screws
on
the
transmission
cover
and
pull
it
straight
outwards
.
8
.
The
max
.-volume-screw
(1)
and
the
max
.-rev-screw
(2)
are
set
by
Volvo
Penta
and
must
never
be
changed
since
this
will
affect
the
engineoutput
.
9
.
Remove
the
control
rod
.
Start
by
removing
the
plug
at
the
rearof
the
block
and
thetwo
screws
on
the
pump
plane,
holding
the
control
rod
.
10
.
Pull
out the
camshaft
.
11
.
Remove
the
outer
flywheelhousing,
the
flywheel
and
the inner
flywheel
housing
.
12
.
Turn
the
engine
upside
down
and
remove
the
oil
pan
.
Be
careful
as
the
pan
is
glued
.
NOTE!
The
oil
pan
ends
also
function
as
main
bearings
.
13
.
Remove
the
connecting
rod
bolts
and
remove
the
connecting
rods
and
the
pistons
.
The
connecting
rod
and
the
connecting
rod
cap
are
marked
with
figures
.
14
.
Remove
the
main
bearing
caps
.
The
main
bearing
caps
are
marked
with
a figure
.
The
corresponding
figure
is
punched
into
the
block
.
Lift
out
the
crankshaft
.
On
later
engine
versions
an
arrow
is
cast
in
the
separate
main
bearing
caps
(2002,
2003)
.
Thearrow
is
to
point
towards
the
dipstick
.
THECYLINDER
HEAD
1 .
Remove
the
"collets"
and
valve
springs
using
a
valve
bow
.
Remove
the valves
.
Remove
t
he
valve
stem
seals
.
Place
the
valves
in
the
proper
sequence
in
a
valve
stand
.
Valve
guides
2
.
Check
the valve
guide
wear
by
inserting
anew
valve
stem
into
the
guide
.
Measure
the play
using
a
dial
indicator
.
If
necessary,
replace the
valve
guides
.
Wear
limits
:
Inlet
valve,
max
play
. .
.
.
. . . . . . .
.
. . .
0
.15
mm
(0
.0059
in)
Exhaust
valve,
max
play
. . . . . . . . . . . .
0
.15
mm
(0
.0059
in)
3
.
Use
mandrel
p/n
5218
to
press
out the
valve
guides
.
Oil
the
new
valve
guides
externally
and
use
mandrel
p/n
884559
to
install
them
.
Press
down
the
mandrel
all
the
way
down
to
the
cylinder
head
.
Ream
the
valve
guides
if
necessary
.
Valve
seats
and
valves
4
.
Mill
or
ream
the
valve
seats
.
The
angle
(C)
should
be
45°
(for
2003T,
30°
for
the
inlet
valve)
.
The
sealing
surface's
width
(B)
should
be
1
±0
.1
mm
(0
.039±0
.0039
in)
.
Grind
the
valves
in
a valve
grinding
machine
.
The
angle
(D),
see
Tech
.
data
.
If
the
disc
thickness
after
grinding
is
less
than
1
.0
mm
(0
.039
in)
for
naturally
aspirated
engines
or 0
.8
mm
(0.031
in)
for
turbocharged
engines,
the
valves
must
be scrapped
.
Valves
with
bent
stems,
or
if
the
measurement
(A)
exceeds
2
.5
mm
(0
.098
in)
must
also
be
scrapped
.
Grind
the
valve
tip
towards
the
rockers
if
necessary
.
Lap
in
the
valves
using
valve
grinding
paste
and
check
the
contact
area
with
marking
dye
.
Replacing
the
valve
seat
exhaust
port
2003T
Grind
down
the
valve
disc
of
a
discarded
valve
to just
below
27
mm
(1
.063
in)
diameter
.
Push
the
valve
stem
through
the
guide
.
NOTE!Do
not
push
in too
far-
the
valve
disc
should
be
just
below
the
edge
of the
seat
.
Spot
weld
the
disc
in
place
at
three points using
a
electric
welder
.
Knockout
the seat
by
hitting
the
valve
guide
with
a
plastic-headed
hammer
.
Cool
the
new
seat
to
approx
.
-20°C
(-4°F)
;
the
cylinder
head
should
beat
room
temperature
(+
20°0168°F)
.
Place
the
cooled
seat on
tool
884961-4
and
knock
it
down
until
it
bottoms.
NOTE!
Turn
the seat
with
the
valve
face
towards
the
tool
.
Valve
springs
5
.
Checkthe
free
length
of
the
valve
springs
and
the
length
when
loaded
.
L =
Length,
unloaded
42,5
mm
(1
.67323
in
.)
L
1 =
Length,
loaded
with
170±10N
(17±1
kp)
32
mm
(1
.25984
in
.)
L
2
=
Length,
loaded
with
300±20
N
(30±3
kp)
24
mm
(0
.94488
in
.)
Rocker
arm
mechanism
6
.
Disassemble
the
rocker
armmechanism
and
clean
the
parts
.
Check
the
wear
of
the
shaft
and
rockerarm
bush
i
ngs
.
Should
the
bushings
need
to
be
replaced,
usethe
mandrel
p/n
9991867
for the
removal
and
installation,
(make
sure
that
the
oil
hole
in
the
bushing
coincides
with
the
one
in
the
rocker
arm)
.
After
the
installation
the
bushings
are
reamed
to
a
close
running
fit
. When
installing
the rockerarm shaft,
it
must
be turned
so
that
the
lubrication
holes
are
facing
the
valve-side
.
Check
to
make
sure
that the
rocker
arm
contact
surface
againstthe
valve
is
concave
.
Minor
adjustments
are
made
in
a
valve
grinding
machine
.
Oil
the
shaft
and
install
the
parts
.
Pressure
testing
the
nozzles
7
.
Check
the
nozzle's
spray
pattern
at
the
correct
opening
pressure
(see
Technical
Data)
.
Check
also that the
fuel
sprays
stop
simultaneously
and
no
dripping
occurs
.
Adjust
the
opening-pressure
with
adjustment-washers
(1)
being
available
in
different
thicknesses
from
1
mm
U3937
in
.)
to 1,95
mm
(
.076772
in
.)
in
steps
of
0,05
mm
(
.001969
in
.)
.
Disassemble
the
injector
and
replace
the
adjustment-washer
againstathinneroneorathickeronedependingon
whether
the
pressure
must
be
reduced
or
increased
.
Assemble
the
injector
and
check
the
opening-pressure
and
the
spray-pattern
.
Injector-sleeve
8
.
Insert
the
expanding
screw
on
the
special
tool
p/n
884811
into
the
copper
sleeve
and
turn
the
screw
anti-clockwise
until
the
screw
has
stuck
in
the
sleeve. Tighten
the
screw
hard
to
allow
the
threads
to
work
themselves
into
the
copper
material
.
Then
install
the
yoke
(1)
on
the
stud
bolt of
the
injector
.
Put
a
cylinder
head
screw
in
the
cylinder
head
as
a
supportforthe
leg
of
the
yoke
.
Install
the
nut
(2)
and
tighten
it
until
the
sleeve
is
removed
.
9
.
Replace
the
O-ring,
sealing
off
between
the
sleeve
and
the
cylinder
head
.
Dip the
new
O-ring
in
soap-water
in
order
to
facilitate
the
installation
.
Oil
the
new
injector
sleeve
and
install
it,
using
special
tool
p/n
884557
.
Knock
down
the
sleeve
until
it
bottoms
.
10
.
Oil
theflare-tool
p/n
884283 and
insert
it
intothe
sleeve
(make
sure
that
the
dowel
is
properly
retracted)
.
Brace
the
tool
with
the
injector
yoke
.
Screw
down
the
flare-tool
as
far
as
the
shoulder
in
the
injector
sleeve
allows,
thereby
flaring
the
sleeve
.
Remove
the
tool
.
Adjust
the
length
of the
sleeve
outside
the
plane
of
the
cylinder
head
to
maximum
1
mm
(
.03937
in
.)
.
Assembling
the
cylinder
head
11
.
Clean
the
cylinder
head
.
If
the
water
distribution
pipe
has
been
disassembled,
it
must
be
installed
with
the
holes
turned
as
indicated
in
the
picture
.
Install
new
valve
stem
sealings
.
Oil
the
valve
stems
and
install
the valves
.
Make
sure
to
install
the
valves
and
the
valve
springs
in
their
respective
original
positions
.
Install
the
valve
springs
and
the
"collets"
.
Use
a
valve-bow
.
Reduction
valve
12
.
Remove
the
cover
of
the reduction
valve
and
check
to
make
sure that
the
spring
and
the
piston
are
faultless
.
If
there are
reasons
to
suspect
a
fault
in
the
opening
pressure
of the
reduction
valve,
then
check
the
data
of
the spring
.
See
under
"Technical
Data"
-
reduction valve
.
Feed-pump
13
.
Depress
the
pump
lever
.
if
the
diaphragm
of the
pump
sounds
squeaky,
the
diaphragm
is
faultless
.
Changing
the
diaphragm
14
.
Remove
the
six
screws, holding
the
upper
and
lower
pump
housings
together
.
Remove
the
pump
lever
spring
(1)
and
remove
the
screw
(2)
holding
the
pump
lever
shaft
.
15
.
Use
a
suitable
pair
of
pliers
and
removethe
pump
lever
shaft
.
Pull
out
the
lever
and
the
diaphragm
.
Pistons,
cylinders
21
.
Check
the
wear
on
pistons, piston rings
and
gudgeon
pins
.
Replace
these
if
necessary
.
Use
a
cylinder
indicator
gauge
to
measure
the
cylinder
bores
.
The
measurement
of
the
biggest
wear
is
made
immediately
beneath
the
edge
of
the
upper
dead
center
and
crosswise
the
engine
.
The
mea
surement
of
the
smallest
wear
is
made
at
the
lower
dead
center
.
As
to
the
cylinder
diameter,see
"Technical
Data"
.
Use
a
micrometer
to
measure
the
pistons
.
Piston
diameter,
see
under
"Technical
Data"
.
22
.
Inserta
new
piston
ring into
the
cylinderand
measure
the
piston ring
gap
.
As
to
the
measurement,
see
under
"Technical
Data"
.
If
necessary
increase
the
gap,
using
a
special
file
.
23
.
Measure
the
clearance
of
the
piston rings
in
the
piston
ring
grooves
.
Regarding
the
measurement,
see
under
"Technical
Data"
.
24
.
Use
piston
ring
pliers
to
install
the
piston
rings
.
The
marking
of
the
rings
(TOP
or
the
mark
of
the
manufacturer)
must
be
turned
upwards
.
The
height
of
the
upper
com
pression
ring
:
1,75
mm
(
.068898
in
.)
The
height
of
the
lower
compression
ring
;
2,00
mm
(
.07874
in
.)
.
Turn
the
piston
rings
so
that
the
gaps
are
turned
120
°
from
each
other.
Connecting
rods
25
.
Check
the
connecting
rods
for
straightness
and
twisting
.
26
.
Check
the
connecting
rod
bushings
by
using
the
gudgeon
pin as
a
gauge
.
There
must
be
no
play
.
If
the
bushings
must
be
replaced,
use
a
suitable
mandrel
for
the
removal
and
installation
.
Make
sure
to
install
the
bushing
with
the
oil
hole
coinciding
with
that of
the
connecting
rod
.
Ream
the
new
bushings
.
The
fit
is
correct
when
an
oiled
gudgeon
pin
by
its
own
weight
can
slowly
slide
through
the
bushing.
Sea-water
pump
27
.
The
pump
is
equipped
with
two
ball-bearings
(1)
.
When
disassembling,
remove
the
locking-ring
(2)
in
the
housing
and
push
out the
shaft,
whereby
the
bearings
are
following
.
Use
a
suitable
mandrel
to
remove
the
bearings
from
the shaft
.
NOTE!
Do
not
forget the
spacer
sleeve
(3)
.
Replace
the
sealings
(4)
.
NOTE!
Turn
the
sealings
correctly
and
make
sure
that
they
do
not
block
the
drainage
hole
in
the
pump-housing
.
Replace
the
O-ring
(5)
.
Install
the
ball-bearings
and thespacersleeve
onto
theshaftand
leave
a
distance
of
39,5
mm
(1
.55512
in
.)
from
the shaft
end
to
the
ball-bearing
.
Coat
the
shaft
with
grease
and
"screw"
it
through
the
sealings
and
the
O-ring
and
take
care
not
to
damage
them
.
Push
in
the
shaft
as
far
as to
allow
the
bearings
to
bottom
and
then
install
the
locking-ring
(2)
.
Checking
the
thermostats
28
.
Immerse
the
thermostat
in
water
and,
using
a
thermometer,
check
if
it
opens
at
the
correct
temperature
.
See
Technical
Data
foropeningtemperatures
.
If
the
thermostat
is
faulty,
it
must
be
replaced
.
Always
use
new
gaskets,
sealing
rings,
sealing
washers
and
lock-washers
.
Coat
the
sealings with
grease
or
oil
them
and
also
oil
all
moving
parts
prior to
installing
them
.
If
the
engine
is
fresh-water
cooled,
see
page
21
.
1
.
Heat
the
crankshaft
gearwheel
to
approx
.
150°C
(302
°
F)
prior
to
the
installation
.
Place
the
key
in
the
key-way
of
the
crankshaft
and
press
on
the
gear
wheel
.
Oil
the
new
main
bearing
halves
(with
oil
hole)
and
install
them
in
the
block
.
Put
in
the
crankshaft
.
NOTE!
The
main
bearing
shell
at
the
flywheel
also
functions
as a
thrust-bearing
.
ASSEMBLY
2
.
Oil
the
cap
bearing
halves
and
install
them
.
Install
the
caps
in
accordance
with
the
marking
in
the
block
(2001
has
no
intermediate
bearing)
.
If
an
arrow
is
cast,
it
shall
point
towards
the
oil
dipstick
.
Tighteningtorque
for
the
main
bearings
: 1st
tightening
20
N
m
(2
kpm)
(14
.7
ft
.lb),
2nd
tightening
60
Nm
(6
kpm)
(44
.2
ft
.lbs)
.
Turn
the
engine
.
3
.
Turn
the
piston
rings
so that
the
gaps
are
offset
in
relation
to
each
other
.
The
piston
crown
is
marked
withan
arrow
that
points
towards
the
belt
pulley
.
Use
installation
ring
884813-7
.
Fit
the
caps
with
the
marking
aligned
with
the crankshaft's
marking
.
The
crankshaft
can
be
turned
in
any
direction
towards
the piston
.
Tightening
torques
:
Step
1
:
25
Nm
(2
.5
kpm)
(18
ft/lb)
Step
2
:
70
Nm
(7
.0
kpm)
(53
ft/lb)
4
.
Install
the
main
bearing
halves
in
the
oil
pan
and
coat
the
edge
of
the
oil
pan
with
thin layer of
sealing
compound
p/n
840879
.
Install
the
oil
panand
tighten
the
oil
pan
screws
and
the
main
bearing
screws
alternatingly
to
20
Nm
(2,0
kpm)
(14
.7
ft
.lbs
.)
and
then
the
main
bearing
screws
to
60
Nm
(6,0
kpm)
(44
.2
ft
.lbs
.)
.
5
.
Replace
the
flywheel
housing
sealing
(1)
.
Smear
sealing
compound
(p/n
840879)
on
the
edge
between
the
flywheel
housing
and
the
sealing
.
NOTE!
The
sealing
lip
with
a
spring
shall
be turned
towards
the
engine
.
Make
sure
that
the
sealing
is
installed
in
accordance
with
the picture
.
r
6
.
Replace
the
O-rings
and
install
the
flywheel
housing
.
Tightening
torque
25
Nm
(2,5
kpm)
(18
.4
ft
.lbs)
.
Install
the
flywheel
.
Tighteningtorque 65
Nm
(6,5
kpm)
(48
.0
ft
.lbs).
7A
.
Heat
the
camshaft
gear
wheel
to
a
temperature
of
approx
.
150°C
(302°F)
anduse
a
suitable
sleeve
to
install
it
.
Check
to
make
sure
that
the
gear
wheel
"bottoms"
on
the
camshaft
.
Install
the
camshaft
and
make
sure
that
the
markings
on
the
camshaft
gear
wheel
and
on
the
crankshaft
gear
wheel
coincide
.
Put the
washer
(1)
on
the
hub
of
the
camshaftgear
wheel
.
Check
that
all
weights
are
pressed
in
so
that
the
tabs
(2)
are
inside
the
washer
.
7B
.
Install
anew
sealing
ring
for
the
camshaft
in
the
transmission
housing,
using
mandrel
p/n
884838
.
The
sealing
lip
with
thespring
is
to
beturnedtowards
the
engine
.
Press
in
the
sealing
ring
from
the
outside
until
the
mandrel
"bottoms"
against
the
housing
.
Install
a
new
O-ring
in
the
oil
channel
in
the
block
(3
fig
.
7A)
.
Use
a
new
gasket
and
install
the timing
gear
cover
.
Place
the
pressure
sleeve
(with
the
bearing
towards
the
pressure
washer)
in
the
control
arm
lever
.
Hold
the
sleeve
in
place
by
pressing
the
lever
to
its
bottom
position
where
the
sleeve
is
pressed
against
the
housing
.
Install
the
pin of the
camshaft,
using
special
tool
p/n
884839
.
The
pin
must
protrude
equally
much
on
both
sides
.
Underno
circumstances
are
you
to
use
a
hammer
or
some
such
tool
to
punch
the
pin
into
its
location
with
the
aid of a
mandrel
.
The
camshaft
will
then
be
bent
.
8
.
Insert
the
control
rod
through
the
black
and
into
the
timing
gear
casing
.
Install
the bearing
ball
(1)
into
the
control
rod
and
push
the
control
rod
through
the
hole
in
the
control
lever
(2)
.
Fit
the
spring
(3)
and
screw
on
the
end
nipple
(4)
until
it
bottoms
(Note!
Do
not use
any
tools)
.
Screw
in
the
upper
bolts
(with
copper
sealing
washers)
that
guide
the
control rod
.
Then,
screw
the
lower
bolts
that
hold
the
control
rod
in
place
in
the engine
block
.
NOTE!The
lower
bolts
should
not
have
sealing
washers
.
Apply
Permatex
to
the
threads
.
Check
that
the
control
rod
moves
freely
.
9
.
Install
the
oil
pump's
gearwheel
according
to
the
marks
(from
the
disassembly)
.
Insert
a
new
O-ring
in
the timing
gear
cover
.
Oil
the
gear
wheeland
fit
The
cover
using
a
new
sealing
ring
.
2001
10
.
Insert
thekey
for
the
pulley
in
the
crankshaft
and
install
the
pulley
.
Tightening torque 40
Nm
(4,0
kpm)
(29
.5
ft
.
Ibs)
.
11
.
Clean
the
valve
lifters
carefully
and
coa
t
the
contact
surf
ace
against
the
camshaft
with
molybdenum
disulphide
.
Oil
the
valve
guides
in
the
block
and
install
the
lifters
.
Clean
the
roller
lifters
of
the
fuel
injection
pumps
and
install
then
in
the
block
.
Lock
the
roller
lifters
with
screws
through
the
block
after
the
installation
(apply
Permatex
to
the
threads)
.
Check
carefully
to
make
sure
that
the
lifters
are
correctly
installed
and
that
they
are
running
easily
in
the
groove
.
Regarding
the
installation
of
the
cylinder
head,
seethe
following
page
.
2002
2003
12
.
Tighten
the
two
guide
screws
p/n
884840
in
the
block
and
install
the
cylinder
head
gasket with
the
marking
"Top"
facing
upwards
.
Install
the
cylinder
head
.
Make
sure
that
the
contactsurface
for
the
cylinder
head
bolts
are
free
from
paint
.
Should
there
be
paint
on
the
bolts,
there
is
always
the
risk
of
havingan
insufficiert
tightening
force
in
the
bolt
joint
with
subsequent
leakages
as a
result
.
NOTE!
The
bolts
are
phospated,
therefore
do
not
clean
them
with
a
steel-brush
.
Coat
the
cylinder
head
bolts
with
molybdenum
disulphide
and
tighten
them
in
accordance
with
the
diagram,
first
to
20
Nm
(2
.0
kpm/14.7
ft
.lbs)
and
then
to
70
Nm
(7
.0
kpm/51
.6
ft.lbs).
13
.
Install
the
push
rods
and
the
rocker
arm
bridge,
push
on
new
rubber
rings
to
the
oil
pipe
which
is
fitted at
the
same
time as
the rocker
arm
bridge
.
14
.
Valve
clearance
cold/warm
engine
0
.30
mm
(
.01181
in
.)
.
Turn
the
engine
in
the
direction of rotation
until
the
valves
in
one
cylinder
are
"rocking"
.
Then
turn
the
engine
one
turn
more
and
adjust
the valves
for
this
cylinder
.
Repeat
the
procedure
for
the
remaining
cylinders
.
Adjusting
the
fuel
injection
pump
location
with
shims
15
.
if
the
same
block
camshaft
and
fuel
Injection
pumps
are
used
when
assembling,
the
fuel
injection
pump
must
be
installed
in
their
original
positions
and
with
the
same
shim
thickness
as
earlier
.
The
so
called
soft
shims,
always
being
installed
against
the
block,
must
be
replaced
against
new
ones
.
Carefully
clean
the
contact
surfaces
between
the
block
and
the
fuel
injection
pumps
and
install
shims
with
thickness
equal
to the
sum
of
the
marking
on
the
block
and
that
on
the
fuel
injection
pump,
(4)
earlier
marking
.
Example
:
The
block
marking
4 (=
4
tenths
of
a
millimeter)
(
.015748
in
.)
The
pump
marking
4
(=
4
tenths
of a
millimeter)
(
.015748
in
.)
Total
amount
of
shims
=
0
.8
mm
(
.031496
in
.)
In
this
case
select
two
soft
shims
0
.2
and
0
.3
mm
(
.011811
in
.)
.
Place
the
hard
shimbetween
the
two
soft
ones
and
install
the
pump
.
NOTE!
Never
install
a
hard
shim
together
with
another
hard
shim
or
against
the
block
or
the
fuel
injection
pump
.
Hard
shims
are
available
in
thicknesses
0
.3,
0
.6
and
0
.9
mm
(
.011811, .02362,
.035433
in
.
respectively)
.
Soft
shims
are
available
in
thicknesses
0
.2
and
0
.3
mm
(
.007874
and
.011811
in
.)
.
On
later
version
engines
an
O-ring
has
been
introduced
as a
seal
between
the
injection
pump
and
the
block
.
Only
so-called
hard
shims
may
be
used
on
these
engines
when
shimming
.
Hard
shims
are
available
in
thicknesses
of 0
.2
mm
(0
.0079
in),
0
.3
mm
(0
.0118
in),
0
.6
mm
(0
.0024
in)
and
0
.9
mm
(0
.0354
in)
.
16
.
New
block
or
camshaft
If
the
block
or
the
camshaft
are
replaced
the
block
mustbe
measuredand
marked,
using
the
setting-disc
p/n
884787
and
a
sliding
caliper
.
A
.
The
setting-disc
consists
of
two
rings,
an
inner
and
an
outer
.
The
inner
ring
determines
the
injection
angle
for
each
respective
engine
type,
see
Technical
Data
(page
25)
.
The
injection
angle
is
stamped
in
degrees
and
is
fixed
with
a
pin
(1)
.
B
.
Mount
the setting-disc
or
the
pulley
with
two
bolts,
do
not tighten the bolts
.
Turn
the
setting-disc
so
that the
guide
pin
(2)
comes
in
the largest of
the
four
holes
in
the
pulley
.
Press
in
the
guide
pin
(2)
so
that
the
disc
is
centered
and
tighten
the
bolts
.
The
setting-disc
is
marked
for
each
respective
cylinder
:
Marking
Denotes
Cylinder
1
Cylinder
1
(1,
2,
3
cylinder
engines
;
Cylinder
2/2
Cylinder
2
(2
cylinder
engine)
Cylinder
2/3
Cylinder
2
(3
cylinder
engine)
Cylinder
3/3
Cylinder
3
(3
cylinder
engine)
C
.
Turn
cylinder
no
.
1
to
it's
injection
.
position
.
Place
the
guide
pin
(2)
in
the
setting-disc's
hole
marked
cyl
. 1 .
Turn
the
crankshaft
a
little
against
the
normal
direction of
rotation
and
thereafter
in
the
normal
rotation direction
until
the
setting-disc's
guide
pin
(2)
goes
in
the timing
cover's
hole
.
Measure
using
a
caliper
the
distance
between
the
cylinder
block
and
the
roller
lifter's
edge
(do
not
measure
on
the
roller)
.
The
distance
shouldbe
:
2001
:
55
.8
mm
(2
.1
9685
in)
2002,
2003
:
55,6
mm
(2
.18504
in)
2003T
:
55
.9
mm
(2
.2007
in)
Example
:
2001
.
If
the
measured
distance
is
55
.2
mm
(2
.17323
in)
this
means
that a
shim
with
thickness
0 .6
mm
(0
.02362
in)
is
to
be placed
between
the
caliper
and
the
block
.
2002,
2003
.
If
the
measured
distance
is
55
.0
mm
(2
.16535
in)
this
means
that
a
shim
with
thickness
0
.6
mm
(0
.02362
in)
is
to
be
placed
between
the
caliper
and
the
block.
Themeasuredshims
thickness
(in
this
example
0
.6
mm)
is
to
be
stamped
into
the
block
as
in
fig
.
15
.
The
total
shim
thickness
is
foun
d
by
adding
the
block's
measurements
and
the
pump's
marking
.
Example
The
block's
measurements
6 (=
0
.6
mm/0
.02362
in)
Thepump's
marking
2
(
=
0
.2
mm/0.007874
in)
No
.
of
shims
0
.8
mm
In
this
case
choosetwo
soft
shims
0
.2
and
0
.3
mm
(0
.007874
and
0
.011811
in
)
and one
hard
shim
of
0 .3
mm
(0
.011811
in)
.
Place
the
hard
shimbetween
the
two
soft
ones
and
refit
the
pump
.
NOTE!
A
hard
shim
must
never
be
fitted
togetherwith
another
hard
shim
or
directly
against
the
block
or
pump
.
Hard
shims
are
available
in
thicknesses
0
.3,
0
.6
and
0 .9
mm
(0
.011811,
0
.02362
and
0
.035433
in)
.
Soft
shims
are
available
in
thicknesses
0
.2
and
0
.3
mm
(0,007874
and
0
.011811
in)
.
D
.
Repeat
the
procedure
for
the
other
pumps
(2002,
2003)
in
the
same
way
as for
cylinder
1
.
The
setting-disc's
marking
is
explained
under
point B
.
17
.
Fit
the
injection
pump(s)
together
with
the
calculated
shim
thickness
.
Turn
the
engine
so
that
the
cam
for
the
pump
is
not
in
the
lifting
position
.
Check
that
the
pump's
pin locates
in
the
control rod's
groove
and
that
the
pump(s)
and
the locks
markings
coincide
(see
figure)
.
Check
after
fitting
each
pump
that
the
control
rod
operates
easily
.
Tighteningtorque
for
the
nuts
is
20
Nm
(2,0
kpm)
(14.7
ft
.lbs)
.
Connect
the
fuel
pipe
between
the
pumps
and
the
pipe
from
the
fuel
filter
to
the
injection
pump
.
NOTE!
The
hole
bolt for
the
return
hose
has
a
smaller
through-flow
channel
than
the
others
(on
later
versions
it
is
marked
'Out")
.
18
.
Install
thefeed
pump
and
thefuel
filter
.
Also
install
the
thermostat
housing
with
the
thermostat
.
NOTE!
Do
not
forget
the
lifting
eyelet
between
the
fuel
filter
and
the
thermostat
housing
.
19
.
Install
the
sea-water
pump
and
the
cooling
water
pipes
.
20
.
Install
the
injectors
and
the
return
fuel
pipe
.
Tightening
torque
for
the
injectors
20
Nm
(2,0
kpm)
(14
.7
ft
.lbs
.) .
Also
install
the
exhaust
elbow
and
the
water
pipe
between
the
thermostat
housing
and
the
exhaust
elbow
.
21
.
Fit
the
valve
cover using
a
new
gasket
.
Make
sure
that
the
round
hole
for
the
crankcase
ventilation
is in
the
right
position
.
Fit
the
decompression
device
lever
.
Fit
the
pressure
pipes
between
the
injectors
and
the
injection
pumps
.
Also
refit
the
inlet
air
silencer
.
22
.
Install
the
starter
motor,
the
alternator
and
the
alternator
V-belt
.
Also
install
the
electrical
distribution
box
and
hook-up
the
cable
harness
.
23
.
Fill
up
with
lubricating
oil
to
the
correct
level
.
Regarding
quantity
and
quality,
see
under
"Technical
Data"
.
24
.
Venting
the
fuel
system
A
.
Open
the
venting
screwon
the
fuel
filter
approx
.
4
turns
.
Watch
out
for
fuel-splashes
.
B
.
Use
the
hand-pump
to
pump
fuel
until
fuel
free
from
air
bubbles
is
coming
out
.
Close
the
venting
screw
.
C
.
Ease
off
the
fuel
pressure
pipe nuts
at
the
injectors
.
Position
the
throttle
control
in
the
position
for
full
speedand
turn the
engine
with
the
starter
motor
until
fuel
comes
out
of the
fuel
pressure
pipes
.
Tighten
the
fuel
pressure
pipe
nuts
.
2003T
Turbo-Compressor
Where
there
is
an
excessive
amount
of
smoke
in
the
exhaust
fumesor
the
engineoutputis particularlylowit may
be
that
the
turbo-compressor
is
not
functioningproperly
.
If
the
boat's
speed
through
the
water
is
gradually
decreasing,
the
boat's
bottom
should
also
be
inspected,
and
cleaned
where
necessary
.
Check
that
the
air
intake
has
not
become
clogged,
and
clean
the
intake
silender
.
Inspecting
the
Seals
Check
the
joints
between
the
turbine
housing
and
the
compressor
bearing
housing,
and between
the
compressor
bearing
housing
and
the
compressor
housing
.
Checks
Check
the
pre-injection
angle,
the
injector's
opening
pressure
and
the
spray
pattern
.
The
valve
clearance
and
compression
should
also
be
checked
.
Checking
axial
and
radial
clearance
Dismount
the
turbo-compressor
from
the
engine,
and
measure
the
rotor
unit's
axial
and
radial
clearance
.
Maximum
permissible
axial
clearance
0
.09
mm
Maximum
permissible
radial
clearance
0
.17
mm
If
wear
and
tear
has
reached
the
maximum
permissible
the
turbo-compressor
should
be
reconditioned
or
replaced
.
Make
line-up
marksbetween
the
turbine
housing,
the
bearing
housing
and
the
compressor
housing
.
Dismantle
the
compressor
housing
(1)
.
Unscrew
the
left-hand
threaded
nut
which
holds
the
compressor
wheel,
using
dollies
on
the
turbine
shaft
.
Remove
the
compressor
wheel
(2)
and
dismantle
the
turbine
housing
(3)
.
RECONDITIONING
Dismantle
the
turbine
shaft
(4)
and
the
heat
shield
.
If
the
turbine
shaft
sticks,
tapthe
end
gently
with
a
wooden
hammer
.
Unfasten
the
three
screws
which
hold
the
cover
(3)
and
screw
two
M5
screws
into
the
cover
.
Then
lift it
up
.
Take
the
oil
deflector
(7)
out
of
the
cover
.
Remove
the
packing
ring
(12)
on
the
turbine
shaft
and
the
two
packing
rings
(13)
on
the
oil
deflector
.
Clean
the
parts
carefully
.
Measuring
and
Inspection
Turbine
Wheel
and
Shaft
Unfasten
the
four
screws
which
hold
the
compression
bearing
(8)
.
Using
a
small
copper
mandrel,
tap
out
the
compression
bearing
and
the
bushing
(9)
.
Then
remove
the
circlips
(10)
inside
the
bearing
housing
and
remove
the
two
bearings
(11)
.
Check
that
the
turbine
wheel
and
shaft
are
free
from
mechanical
damage
.
The
vanes
must
not
be
worn
or
out
of
shape
.
Do
not
try
to
realign
the
vanes
.
Damaged
parts
should
be
replaced
.
Place
the
shaft
on
two
supports,
which
should
be
under
the
bearing
recesses,
and
check
the
throw
at the
end
of
the
shaft
.
The
maximum
permissible
throw
is
0
.011
mm
.
Check
the
diameter
of
the
shaft
bearing
recesses
.
The
minimum
permissible
diameter
is
7
.98
mm
.
Check
the
width
of
the
shaft
piston
ring
groove
.
Maximum
permissible
width
is
1
.29
mm
.
Compressor
Housing,
Turbine
Housing
Check
that
the
housings
are
free
from
cracks
or
other
damage
caused
by
excessive
wear
and
tear
.
Damaged
parts
should
be
replaced
.
Heat
Shield
Check
that
the
heat
shield
is
free
from
damage
caused
by
wear
and
tear,
heat
or
corrosion,
and
replace
it
if
necessary
.
Bushing,
Oil
Deflector,
Compressor
Bearing
Check
that
the
parts are free
from
wear
and
tear
and
discolouration
.
Damaged
parts
should
be
replaced
even
if
the
amount
of
wear
and
tear
is
within
the permitted
tolerances
.
Bushing
Oil
Deflector
Bearings
Check
measurement
(A),
which
should
not
be
less
than
4
.07
mm
.
Check
measurements
(B)
and
(C)
.
(B)
should
not
be
more
than
1
.31
mm,
(C)
shouldnot
be
more
than
1
.11
mm
.
Compressor
Bearing
Check
the
width
of
the
bearing,
and
replace
it if
the
amount
of
wear
and
tear
is
in
excess
of
the
permitted
tolerance
.
Minimum
permissible
width
is
3
.98
mm
.
Check
the
bearings
for
abnormal
wear
and
tear or
discolouration,
and
replacethem
where
necessary.Check
the
internal
and
external
diameters
of
all
bearings
.
The
external
diameter
should
not
be
less
than
12
.31
mm,
the
internal
diameter
should
not
be
more
than
8.04
mm
.
Bearing
Housing
Check
the
housing
for
corrosion
or
cracks
.
Check
measurements
(D)
and
(E),
and
replace
the
housing
where
necessary
.
Measurement
(D)
should
not
be
more than
12
.42
mm,
measurement
(E)
should
not
be
more
than 15
.05
mm
.
Cover
Check
measurements
(F)
and
(G)
.
and
replace
the
cover
where
necessary
.
Measurement
(F)
should
not
be
more
than
12
.45
mm,
measurement
(G)
should
not
be
more
than
10
.05
mm
.
Packing
Rings
Check
the
packing
rings
to
see
if
they
are
worn
or
out
of
shape,
and
replace
them
with
new
ones
where
necessa
ry
.
Reassembly
Grease
all
removable
parts
when
reassembling
them
.
Position
the
circlips
in
the
bearing
housing
so
that
the
openings
in
them
are
facing
towards
the
oil
outlet
.
Mount
the
packing
ring
on
the
turbine
shaft
.
Turn
the
opening
in
the
ring
so
that
it
is
facing
towards
the
oil
intake
.
Position
the
heat
shield
on
the
bearing
casing,
and
then
place
the
turbine
axle
in
the
bearing
housing
.
Mount
the
bushing
on
the
turbine
shaft
.
Grease
in
the
compressor
bearing
with
engine
oil,
and
mount
it
on
the
bearing
casing,
using
new
screws
andwashers
to
fasten
it
.
The
torque
should
be
1
.3
Nm±0
.1
.
Tighten
the
screws
to the
above
torque,
thenloosen
them
a
quarter
turn
before
tightening
them
up
to
the
correct
torque
again
.
Position
thetwo
packing
rings
on
the
oil
deflector
.
NOTE
:
The
opening
in
the
inner
ring
should
be
facing
the
oil
outlet,
that
in
the
outer
ring
should
be
facing
the
oil
intake
.
Position
the
oil
deflector
in
the
cover
.
Smear
the
edges
of
the
bearing
housing
which
come
in
touch
with
the
cover,
using
Permatex
for the
purpose
.
The
thickness
of
the
sealant
should
be
about
0
.1-0
.2
mm
.
Fitthe
cover
on
the
bearing
housing,
and
fasten
itwith
new
screws
and
washers
.
The
torque should
be
1 .3
Nm±0
.1
.
Tighten
the
screws
to
the
above
torque,
thenloosen
them
a
quarter
turn
before
tightening
them
up
to
the
correct
torque
again
.
Position
the
compressorwheel
on
the
turbine
shaft
and
fasten
it
with
the
left-hand
thread
nut
.
The
torqueshould
be
2 .0
Nm±0
.1
.
Mount
the
turbine
housing
on
the
bearing
housing
according
to
the
line-up
marks
.
Screw
the
locking
cover
into
position,
making
sure
that
the
screws
used
are not
those
for
the
compressor
housing
.
The
torque should
be
11
.0
Nm±0
.5
(M6),
26.0±1,0
(M8)
.
Smear
the
edges
of
the
bearing
housing
where
it
comes
in
touch
with
the
compressor
housing,
using
Permatex
for
the
purpose
.
The
thickness
of
the
sealant
should
be
about
0
.1-0
.2
mm
.
Then
mount
the
compressor
housing
according
to
the
line-up
marks,
and
screw
the
locking
cover
into
position
.
The
torque
should
be
4
.5
Nm±0
.5
.
Check
the
axial
and
radial
clearance
.
Maximum
permissible
axial
clearance
is
0.09
mm,
maximum
permissible
radial
clearance
is
0
.17
mm
.
Fitting
the
Turbo-Compressor
Before
fitting
the
turbo-compressor
on
the
engine,
spray
clean
engine
oil
into
the
oil
intake,
and
turn
the
turbine
shaft
so
that
the
oil is
evenly
distributed
.
Clean
the
turbo-compressor's
deliveryandreturnoillines.Changetheengineoilandthefilterforthelubricant.Besuretousethe
correct
quality
of
oil
(see
under
"Technical
Data")
.
Oil
changes
should be
carried
out
in
accordance
with
the
instructions
in
the
Manual,
in
order
to
keep
the
engine
clean
.
Clean
the
air
filter
.
FRESHWATER
COOLING
2002,
2003
Pos
21
and23
are
for
hot
water
outlet
.
1
.
Fit
the
circulation
pump
(complete
with
tensioner
bracket
and
spacer
sleeve,
position
4)
.
Tighten
the
bolts
(M8x75)
to
20
Nm
(2,0
kpm)
(14
.7
ft
.lbs),
position
1
.
2
.
Suspend
the
heat
exchanger
loosely
by
the
rear bolt
(M8x16and
spring
washer
.),
position
5
.
a)
Fit
the
pipe
(position
6)
and the
hose
(position
3)
between
the
heat
exchanger
and the
sea-water
pump, using
double
hoseclamps
(apply
soapy
water
to
the
rubber
rings,
applies
for
all
rubber
rings)
.
b)
Fit
the
pipe
between
the
heat-exchanger
and
thermostat
housing,
position
7
.
c)
Fit
the
pipe
between
the
heat-exchanger
and
the
circulation
pump,
position
8
.
3
.
Locatethe
pipes
in
the
heat-exchanger
andanddraw
it
forward
tightening
it
with
the
two
bolts
(M8x16and
spring
washers),
positions
5 and
9
.
4
.
Fit
the
pipe
between
the
heat-exchanger
and
the
exhaust
elbow,
position
10
.
NOTE!
The
holderforthe
pipe, (position
11)
and
the
lock (position
11
a)
.
5
.
Fit
the
pipe
between
the
circulation
pump
(lower
outlet)
and
the
cylinder
head,
position
12
.
6
.
Fit
the
pipe
between
the
circulation
pump
(upper
outlet)
and
the
cylinder
head,
position
13
.
7
.
Fit
the
alternator,
place
the
bolt
for
the tensioner
bracket
with
the
head
forwards
.
Put
onand
tension
the
V-belt
.
8
.
Fit
the
expansion
tank
to
the
exhaust
elbow,
position
15
.
9
.
Fit
the
hose
between
the
tank
and
the
circulation
pump
(double
pipe
)
2002
=
450
mm
(17
.7
in),
2003
=
550
mm
(21
.7
in)
(only single
hose
clamps
are
used
on
the
fresh-watersystem),
position
16
.
10
.
Fit
the
nipple,
position
17
.
11
.
Fitthe
hose
between
the
tank
and
the
thermostat
housing
(nipple 17)
:
2002
=
350
mm
(13
.8
in),
2003
=
450
mm
(17
.7
in),
position
18
.
12
.
Fit
the
plugs
in
the
exhaust
elbowand
the
cylinder
head,
positions
19
and
20
.
13
.
Fill
the
system
to
the
right
level
with
a
mixture
of
fresh
water
(50%
)
and
anti-freeze
(50%),
altematively
rust-protection
additive
(VP
accessory)
. The
fresh-water
system volumes
:
2002 = 4.0 dm2
(litre)
(0.88 Imp.
gals)
(1.1 US gals),
2003
=
5
.5
dm
3
(litre) (1
.2
Imp
.
gals)
(1
.45
US
gals)
.
INSTRUMENTPANEL
1 .
Printed
circuit
card
2
.
Rev
counter
(accessory)
3
.
Start
button
4
.
Switch
for
instrument
panel
5
.
Alarm
test
button
6
.
Alarm
Max
output
from
the
panel
=
5
A
Cable
colour
R
=
Red
PU
--
Purple
BN
=
Brown
OR
= Orange
GR
=
Grey
SB
=
Black
W
= White
Y
=
Yellow
GN
=
Green
BL
=
Blue
ENGINE
1
.
Relay
2
.
Fuse
3
.
Temp
.
alarm
sender
4
.
Oil
pressure alarm
sender
Wire
areas
in
mm
2
Wire
area
mm
2
1,0
16
1,5
14
2,5
12
10
6
26
AWG
Wiring
diagram,
alternative
A
(Standard)
Z
Wiring
diagram,
alternative
B
(De Luxe)
INSTRUMENT
PANEL
1
.
Voltmeter
2
.
Oil
pressure
gauge
3
.
Coolant
temperature
gauge
4
.
Printed
circuit
card
5
.
Alarm
test
6
.
Switch
for
instrument
lighting
7
.
Rev
.
counter
8
.
Key
switch
9
.
Alarm
Max
output
from
the
panel
:
5
A
Cable
colour
GR
=
Grey
SB
=
Black
BN
=
Brown
LBN
=
Light
brown
R
=
Red
P
=
Purple
GN
=
Green
Y
=
Yellow
W
=
White
BL
=
Blue
LBL
=
Light
blue
ENGINE
1
.
Coolant
temperature
sender
2
.
Oil
pressure
alarm
sender
3
.
Coolant
temperature
alarm
sender
4
.
pit
pressure
sender
5
.
Relay
6
.
Fuse
Wire
areas
in
mm
2
FAULT
TRACING
Engine
does
not
start
Engine
stops
Enginenot
reaching
correct
temp
at
full
rpm
Engine
runs
roughly
or
vibrates
abnormally
Engine
becomes
abnormally
hot
Fault
Stop
control
not
fully
pushed
back
.
Main
switch
:
not
switched
on
.
Flat
battery
.
Broken
electric
wires
.
Main
fuse
blown
.
"
Empty
fuel
tank,
closed
fuel
cock
or
clogged
fuel
filter
.
" " "
Water
or
impurities
in
the
fuel
.
Faulty
injectors
or
air
in
the fuel
system
.
"
Boat
abnormally
loaded,
clogged
intake
air
filter
or
marinegrowth
on
the
boat
bottom
.
Engine
not
properly
aligned
.
Propeller
damaged
.
"
Clogged
cooling
water
intake
or
water
jackets
in
the
exhaust
manifold
.
Faulty
impeller
in
sea-water
pump
.
Faulty
thermostat
.
Clogged
cooling
water
pipe
in
the
cylinder
head
.
9992265-0
884813-7
9995218-6
884557-0
884559-6
884787-3
884811-1
884823-6
884837-6
884838-4
884839-2
884840-0
1
Pulley
puller
Installation
ring
for
piston
Mandrel
for
valve guide
removal
Mandrel
for
installation
of
injector
sleeve
Mandrel
for
installation
of
valve
guide
Setting-disc
for
injection
pump
setting
Puller
for
injector
sleeve
Flaring
tool
for
injector
sleeve
Flange
for
engine
cradle
Mandrel
for
installation
of
sealing
ring
in
transmission
cover
Assembly
and
disassembly
tool
for
camshaft
pin
Guide
pin
for
cylinder
head
.
NOTE!
Two
are
required
.
TECHNICAL
DATA
Cylinder
bore
. . .
.
.
.
. . .
.
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
. . . .
.
. .
.
. . . .
.
Stroke
.
. . .
.
. . . . .
.
.
.
.
.
. . . . . . . . . . . . .
.
. . .
.
.
. .
.
. . .
.
.
.
.
.
. . .
.
.
Compression
ratio
.
.
.
. . . . . . . .
.
. . . .
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
Compression
ratio
at
starter
motor
speed
. . .
.
. . .
.
. . .
.
. . .
.
.
79
mm
(3
.11024
in)
87
mm
(3
.4252
in)
17
.5
:1
2-2
.5
MPa
(20-25
kp/cm
2
)
Direction
of
rotation
(seen
from
the
front
end)
. . . . . . . . . .
Idling
speed
. .
.
. . .
.
.
.
. . .
.
. . . . . . .
.
.
.
.
.
. . .
.
. . . . . . . . . . . . .
Oil
pressure
at
full
speed
and
warm
engine
. . . . . . .
.
. . . . .
Oil
pressure
at
idling
and
warm
engine
. . . . . . . . . . . . . . . . .
Clockwise
13-14
r/'s
(775-825
rpm)
0,35-0,40
MPa
(3,5-4,0
kp/cm2)
0,08-0,15
MPa
(0,8-1,5
kp/cm
2
)
Cylinder
block
Material
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. .
. .
. . . . . .
Special
alloy
cast
iron
Piston
ring
gap
in
the
cylinder
Upper
compression
ring
. . . . .
.
. .
.
.
.
.
.
.
. . .
.
. . . . . . . .
.
Lower
compression
ring
. . . . . . . . .
.
.
.
. . . . . . . . . . .
.
. .
.
. . . .
Oil
ring
. . . . .
.
.
. . . . .
. .
. . . . . . . . . . .
. .
. . . . . . .
.
. . . .
.
. .
.
. . . .
0,30-0,50
(0,001181--0,00197
in
.)
0,30-0,50
(0,001181-0,00197
in
.)
0,25-0,50
:0,009842-0,00197
in
.)
General
Type
designation
.
.
.
. . . . . . . . . .
.
. . . . . . . . . . . . . . . .
.
.
.
. . . .
2001
2002
2003,2003T
Number
of
cylinders
. . . .
.
.
.
.
.
.
.
. . . . . .
.
. . . . . . .
.
. . . . . . . .
1
2 3
Displacement
. .
.
.
.
.
.
. . . .
.
.
.
.
. . .
. . .
.
. .
.
. . .
. . . .
.
. . . .
, . . .
0.43
dm
3 (26
.2
cu 0.852
dm
3
(51
.9
cu
in)
1
.278
m
3
(77.99
in)
cu
in)
Cylinder
diameter,
standard
.
. . . . . . .
.
. . . . . . . .
.
.
.
. . .
. . . .
79,00-79,03
(3
.11025-3
.11142
in
.)
0,25
mm
over-size
. .
.
. . . . . . . . . . . . . . .
.
. .
.
. . . . .
.
. . . . . . . . .
79,25-79,28
(3
.12008-3
.12126
in
.)
0,50
mm
over-size
. .
.
.
.
. . . . . . . .
.
. . . .
.
. .
.
. . .
.
.
.
. . . . .
. . . .
79,50-79,53
(3
.12992-3
.1311
in
.)
Pistons
Material
. . . . . . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. .
.
.
. . .
.
. . .
.
. .
Light-alloy
Total
height
. . . .
.
. . .
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. .
78,3
m
m
(3
.08268
in
.)
Height
from
gudgeon
pin
center
to
piston
top
. . .
.
. . .
.
. .
50,3
mm
(1
.98031
in
.)
Piston
clearance
in
cylinder
.
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. .
0,09
mm
(
.00354
in
.)
Piston
in
standard
dimension
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. .
78,903-78,)17
(3,10642-3,10697
in
.)
0,25
mm
over-size
.
.
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. .
79,153-79,167
(3,11626-3,11681
in
.)
0,50
mm
over-size.......
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. .
79,403-79,417
(3,12610-3,12665
in
.)
Gudgeon
pins
Diameter
. . .
.
.
. .
.
. . . . . . . .
.
. . . . . . .
.
. . . . . . . . . . . . . . . . .
.
. .
25,995-26,000
(1,02343-1,02362
in
.)
Gudgeon
pin
bushing,
diameter
. . .
.
. . . . . . . . . . .
.
.
.
. . . . . .
26,005-26,011
(1,02382-1,02406
in .)
Clearance
gudgeon
pin
-
bushing
. . . . . . . . . . . . . .
.
. . .
0,0050-0
.0160
(0,00020-0,0063
in
.)
Piston
rings
Compression
ring,
number
.
.
.
.
.
.
. . .
.
. . . . . . . .
.
.
.
.
.
.
.
. . .
2
Oil
ring,
number
. . . . . . .
.
. . .
.
. . .
.
. . .
.
. . . . . . . .
.
.
.
.
.
. . . . .
1
The
upper
compression
ring
has
an
inlay of
chrome
.
The
piston
rings
are
available
for
standard
dimension
and
for
0,250
and
0,500
mm
oversize
(0,00984
and
0,0996)
in
.)
Piston
ring
axial
clearance
in
the
groove
Uppercompression
ring
. . . .
. . . . . . . . . . . .
.
. . . . . . . . . . . . . .
0,070-0,102
(0
.00276-0,00402
in
.)
Lower
compression
ring
. . . . . . . .
.
. . . . .
. . . . . . .
.
. . .
. . . . . .
0,050-0,082
(0,00197-0,00323
in
.)
Oil
ring
. . . . . . .
.
. .
.
. . . . . . . . .
.
. . .
.
. . . . . . . . . . . . . . . .
.
. . . . .
0,030-0,062
(0,00118-0,00244
in
.)
Crankshaft
Material
. . . . . . . . .
.
. . . . . . .
.
.
.
. . . . .
.
.
.
. . . . . .
.
.
.
. . .
.
.
.
. . .
Nodular
iron
Crankshaft
axial
clearance
.
. . .
.
. . .
.
. . .
.
. . .
.
. .
.
. . .
.
.
.
. . .
0,040-0,221
(0,00157-0,00870
in
.)
Main
bearing
radial
clearance
.
.
.
.
.
.
. . . . . . . . . .
.
. . .
.
.
.
. . .
0,040-0,092
(0,00157-0,00362
in
.)
Big-end
bearing,
radial
clearance
.
.
.
. . .
.
. . . . . .
.
.
. .
.
.
.
. . .
0,024-0,068
(0,00094-0
.00268
in
.)
1
Propeller
shaft
output
in
accordance
with
DIN
6270B
.
Main
bearing
journals
Diameter,
standard
0,250
m
m
under-size
. .
.
. . . . . . .
.
. . .
.
.
.
.
.
. . . . .
.
.
.
. . .
. .
.
0,500
mm
under-size-
. . . . . . . . .
.
. . .
59,987-60,000
(2,36169-2,36220
in
.)
59,737-59,750
(2,35185-2,35236
in
.)
59,487-59,500
(2,34200-2,34252
in .)
Big-endbearing
shells
Thickness,
standard
. . .
.
. . . . . . . . . . . .
. .
. . . . . . .
.
. . . . . .
. .
.
0,250
mm
over-size
. . .
. . . . . . . . . . . . .
. .
. . . . . . . . . . . . . .
. .
.
0,500
mm
over-size
. .
.
.
.
. . . . . . . . . . .
. .
. . . . . . .
.
. . . . . .
. .
.
1,478-1,488
(0,05819-0,05858
in
.)
1,603-1,613
(0,06311-0,06350
in
.)
1,728-1,738
(0,06803-0,06843
in
.)
Connecting
rods
Axial
clearance
at the
crankshaft
. .
.
. . .
.
. . .
.
. . .
. . .
. .
. . .
.
0,15-0,35
mm
(0,00590-0,01378
in
.)
Camshaft
Axial
clearance
. . . .
.
.
. .
.
.
.
.
.
. . .
.
. .
.
. . . .
.
. . . . . . . .
.
.
.
. . . .
Radial
clearance
in
bearings
. . .
.
. . .
.
. . .
.
Camshaft
diameter
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
. . . . . . . .
.
.
.
. . . .
Lifting
height
of
cams
.
.
. . . . . . . . .
.---
.----------
.
.
.--
. .
0,160-0,300
mm
(0,0063-0,01181
in
.)
0,020-0,075
mm
(0,000787-0,00295
in
.)
46,975-47,000
(1,8494-1,85039
in
.)
5,48-5,52
mm
(0,21575-0,21732
in
.)
Main
bearing
shells
Thickness,
standard
.
. .- - . - . . . . . . .
. . .
.
.
. . . . .
.
. . . . . .
2,987-2,997
(0,11760-0,11799
in
.)
0,250
mm
over-size
. . . . . . .
.
. . . . . . .
.
.
.
.
.
. . . . .
.
. . . . . .
.
. .
3,112-3,122
(0,12252-0,12291
in
.)
0,500
mm
over-size
. . .
.
-- - . - . . .
.
. . . . . . . . .
.
.
.
. . . . . . . . .
3,237-3,247
(0,12744-0,12783
in
.)
Big-end
journals
Diameter,
standard
.
. .
.
.
. . . . . . . . . . . . . . .
.
. . .
.
. . .
.
. . .
.
. . .
47,989-48,000
(1,88933-1,88976
in
.)
0,250
mm
aver-size
---
.
. . .
.
. . .
47,739-47
.750
(1,87949-1,87992
in
.)
0,500
m
m
over-size
.-
.--
.
.-
. . . . . . . . .
.
.
.
. . .
.
. . .
.
. . .
.
. . .
47,489-47,500
(1,86965-1,87008
in
.)
Bushing
diameter
.
.
. . .
.
. . .
.
. . . . .
.
.
.
. . .
.------------
. . .
47,02-47,05
mm
(1,85118-1,85236
in
.)
Cylinder
head
Material
. .
.
. .
.
.
.
. . .
. .
. . . . . . .
.
. . . . .
.
. . . . . . .
.
. . . . .
.
.
.
. . .
Special
alloy
cast
iron
Inlet
valves
20031
Disc
diameter
. . . . . .
.
. . . .
. . . . . . . . . . . . . . . . . .
.
. . .
.
.
.
.
.
. . .
34,4-34,6
mm
(1,35433-1
.36220
in
.)
35,8-36,0
mm
Stem
diameter
. . . . . .
.
. . . . . . . . . . . . . . . . . . .
.
.
.
. . .
.
.
.
.
.
. . .
7,955x7,970
mm
(0,31319-0,31378
in
.)
7,995-7,970
mm
Valve
seat
angle
. . .
.
. . . . . . . . . . . . . . . . . . . . . .
.
. . .
.
.
.
.
.
. . .
44°55'-44
°
85'
29°45'--30
15'
Cylinder
head
seat
angle
. . . .
.
. . . . . . . . . . . . .
.
. . .
.
.
.
.
.
. . .
45°
30°
Seat
width
in
the
cylinder
head
. . . . . . . . . . . . . . . . . .
.
.
.
. . .
appr
.
1
mm
(0,03)37
in
.)
appr
.
1
mm
!0
.03)37
in
.
Clearance,
cold/warm
engine
. . . . . . . .
.
. . . . . . . . . . . . .
. . .
.
Exhaust
valves
Disc
diameter
.
.
. .
.
. . .
.
.
----
. . . .
.
.
.
.
.
.
.
.
.
. . .
.
. . . . . . .
.
.
.
0,3
mm
(0,011811
in
.)
0
.3
mm
(0,011811
in
.)
29,9-30,1
mm
(1,14716-1,18504
in
.)
Stem
diameter
.
. .
.
.
.
.
.
.
.
.
.
. . .
.
.
.
. . .
.
.
.
. . . . .
.
. . . . . . .
.
.
.
7,950-7,465
mm
(0
.31299-0,31339
in
.)
Valve
seat
angle
.
.
. . .
.
.
.
.
.
. . .
.
.
.
. . . . .
.
.
.
. . .
.
. . . . . . .
.
.
.
44°55'-44°85'
Cylinder
head
seat
angle
-
.
. - . . .
.
. . . . .
.
.
.
. . . . . . . . . .
45
°
Seat
width-in
the
cylinder
head
.
--
.
. . .
.
.
.
.
.
. . . . . . .
.
.
.
. .
appr
.
1
mm
(0,03937
in
.)
Clearance,
cold/warm
engine
-----
.
. . .
.
.
.
.
.
. . .
.--
. .
.---
0,3
mm
(0,011811
in
.)
Valve
guides
Length,
inlet
valve
. .
.
. . . . . . . . . . .
.
.
.
. . .
.
.
.
.
.
. . .
. .
.
.
. . . .
38
mm
(1,49606
in
.)
Length,
outlet
valve
.
.
. .
.
. . . . . . . .
.
.
.
. . .
.
.
.
. . . . .
.
. .
.
. . . .
38
mm
(1,49606
i
n
.)
Inner
diameter
------------
. . . . . .
.
.
.
. . .
.
.
.
. . . . .
.
. . .
.
. . .
8,000-8,015
(0,31496-0,31555
in
.)
Height
above
spring-plane
of
cylinder
head
.
.
. . .
.
.
.
.
.
. . .
8,70-9,30
mm
(0,34252-0,36614
in
.)
Valve
springs
Length,
unloaded
. . .
.
. . . . . . . . .
.
.
.
. . .
.
.
.
. . . . . . . . . . . . .
42,5
mm
(1,67323
in
.)
Loaded
with
170±10
N
(17±1
kp)
. .
.
. . .
.
.
.
. . . . .
.
.
.
.
.
. . .
32
mm
(1
.25984
in
.)
Loaded
with
300±20
N
(30±2
kp)
. . . . . . . . . .
.
. . . . .
.
.
.
. . .
24
mm
(0,94488
in
.)
Lubricating
system
ENGINE
Oil
quantity
model
2001
.
. .
.
.
. . . .
.
.
.
.
.
1,40
dm
3
(1
.2
quarts)
Oil
quantity
model
2002
. . . .
.
. . .
.
2
.75
dm
3
(2
.42
quarts)
Oil
quantity
model
2003
. . . . . .
.
. . .
.
. . .
.
. . . . .
. .
4,10
dm
3
(3 .6
quarts)
Oil
quality
according
to
the
API-system
CD
(DS)
Viscosity
. . . . .
.
. . .
.
.
.
.
. . . . . . .
.
.
. .
.
. .
.
15
W/40
Oil
pressure,
warm
engine,
idling
speed
. . . . . . .
.
. . .
.
. . .
.
0,8-1,5
kp/cm2
(11
.37-21
.33
lbft/in
2
)
Oil
pressure,
warm
engine,
full
rpm
. .
. . . . . . . . .
.
. . .
.
. . .
.
3,5-4,0
kp/cm
2
(49
.78-56
.89
lbft/in
2
)
Lubricating
oil
pump
Type
.
.
.
.
. .
.
. . . . .
.
. . . . . . . . . . .
. . . .
. . . . . . . . . . . . .
.
.
.
. . .
.
.
Gearwheel
pump
Gear
wheel
axial
clearance
. . . . . . . . . . . . . . . . . . . . . .
.
. . .
.
.
0,025-0,065 (0,00098-0,00256
in
.)
Spring
for
reduction
valve,
length
unloaded
. . . . . .
.
. . . . .
49
mm
(1,92913
in
.)
Loaded
with
35
Nm
(3,5
kp) (25
.8
ft
.lbs
.)
. . . . . . . . . . . . . . . .
40
mm
(1,57480
in
.)
Fuel
System
Opening
pressure
.
injectors
.
. . . . .
.
.
.
. . . . . . .
.
. . . . . . .
.
. .
.
180-190
kp/cm
2
(2560-2702
lbft/in
2
)
1)
Spray
angle
. . . . . .
. .
. . . .
.
__
. . .
. .
.
.
. . . .
.
. .
.
. . .
.
.
.
.
.
. . .
150
°
Injection
angle
2001
. . . . . .
.
. . . . . .
. .
. . . . .
22±1
°
B
.T
.D
.C
Injection
angle
2002,
2003
.
. . . . . . .
.
.
.
.
.
. . .
.
. . . . . . .
. .
. . .
20+1°C
B
.T
.D-C
.
Injection
angle
2003T
.
.
. . . . . . . . . . . . . . . . . . . . .
.
. .
.
. .
23±1°
B
.T .D
.C
.
Injection
quantity
. .
. . . . . . .
.
. . .
.
. . . .
25+1
.5
mm3/stroke
at
40±5°C
(104°F±10
.6°F)
and
at
25
r/s
(1500
rpm)
pump
revs
Governor
overrun
. .
. . . . . .
.
. . .
.
. . . . . . . . . . . . .
.
. . . . . . . . . .
54
r/s
(3250
rpm)
Feed
pump
Feed
pressure
42
r/s
(2500
rpm)
. . .
.
.
.
. . . . . .
.
. . . .
.
. .
.
. .
. . . .
0,65-0,85
kp/cm
2
(9
.20-12
.10
lbf/in
2
)
Electrical
system
Battery voltage
.
.
.
.
. .
.
.
. . . . . . . . . . .
.
. . . . .
.
. . . . . . . .
.
. . . . .
12V
Battery
capacity
. .
.
.
.
.
.
. . . . .
.
. . . . . . .
.
. . . . . . . . . . : . .
.
.
.
. . . . .
Max
.
70
Ah
Starter-motor
output
2001
. . . .
.
. . .
.
.
.
.
.
. . . . .
.
. . . . .
.
-
0
.8
kW
!1
.1
H
P)
Starter-motor
output
2002
and
2003
.
.
.
.
. . . . . . . . . . .
.
. . . . . . .
1
.4
kW
(1
.9
HP)
Alternator
output
:
Voltage/max
.
current
.
.
. . . . . . . . . .
.
.
.
. . . . . . . . . .
. . .
. . . . .
14W50
Amp
Output
. . . . . . .
.
. .
.
. . . . . . . . . . . . . .
.
.
.
. . . . . . . . . . .
. .
. . . . .
700
Watts
Electrolyte
spec
.
gravity
:
Fully
loaded
battery
. . . .
. .
.
.
.
.
.
1,275--1,285
To
be
charged
at
.
.
. . . . . . .
.
. .
.
. . . . .
.
.
.
. . . . . . . . .
. .
. . . . .
1,230
Thermostat
. . . . .
.
.
.
.
.
. . . . . . . . . . . .
.
.
.
. . . . .
.
. . . . .
. .
.
.
.
.
.
Wax
thermostat
Begins
to
open
at
.
.
.
.
. . . . . . . . . . . .
.
.
.
.
.
. . . . . . .
. .
.
.
.
.
. . .
60±2`C
(140±4°F)
Fully
open
at
. .
.
.
.
.
.
.
.
. . . . .
.
. . . . . . . .
.
.
.
. . . . . . . . . .
.
.
.
.
.
.
75'C
{165
°
F1
Cooling
system
With
fresh-water
cooling
(2002,
2003)
Starts
opening
at
.
.
.
.
.
.
.
.
.
.
. . .
.
.
.
.
.
. . . . .
.
.
.
. . . . .
.
.
.
. . . . . .
74±1°C
(164±2°F)
Fully
open
at
.
.
. . .
.
.
.
.
.
.
.
.
.
. . .
.
.
.
.
.
.
. .
.
.
.
.
. . . .
87°C
(189
°
F)
Fresh-water system,
volume
2002
.
.
.
.
.
. . . . .
.
.
. .
. .
.
.
.
. .
.
. . .
4
.0
dm
3
litre)
(0
.88
Imp
.
gals)
(1 .1
US
gals)
2003_____
5
.5
dm
3
(litre)
11
.2
Imp
.
gals)
(1
.45
US
gals)
WEAR
TOLERANCES
Cylinders
To
be
bored
at
0,25
mm
wear
(0,00984
in
.)
Crankshaft
Main-
and
big-end
journals
:
Permitted
out-of-round
.
. . .
.
. .
.
. . .
.
. . .
.
. . . .
.
. . . . . . . . . . .
0,06
mm
(0,00236
in-)
Permitted
taper
. .
. . .
. .
. . .
.
.
.
.
.
. . .
.
. . .
.
.
. . .
.
. . . . . . . . .
. .
0,05
mm
(0,00197
in
.)
Max
.
axial
clearance
on
crankshaft
.
. . .
.
. . . . . . . . . . . . . . . .
0,40
mm
(0,01575
in
.)
1)
2003T
=
204-212
kp/cm2
(2900--3015
lbf/in
2
)
Camshaft
Bearing
journals,
permitted
out-of-round
. . . . . . . . . . . .
.
. .
Max
.
clearance
between
camshaft
and
bushings
. . .
.
. . . .
0,03
mm
(0,00118
in
.)
0,15
mm
(0,00590
in
.)
Valves
Max
.
clearance
between
valve
stemand
valve
guide
.
. . .
The
valve
disc
edge
must
be
at
least
0,15
mm
(0,00590
in
.)
1,5
mm
(0,05906
in
.)
Tightening
torques
Main
bearing
bolts,
1st tightening
.
.
.
.
. . . . . . . . .
.
.
.
.
.
. . . .
2nd
tightening
.
.
. . . . . . .
.
. . . . . . .
.
. . . .
Big-end
bearing
bolts
.
.
. . . . . . . . . . . . .
.
. . . . . . . . . .
.
.
.
. . . .
Flywheel
housing
bolts
. . . . . . . . . .
.
. . .
.
.
.
. . . . . . . .
.
. . . . .
.
Flywheel
bolts
. .
.
. . .
.
. . . . . . . . .
.
.
.
. . .
.
. . . . . . . . . .
.
. . .
.
.
.
Cylinder
head
bolts, 1st
tightening
. . .
.
.
.
. . . . . . . . . . . . . .
.
2nd
tightening
. .
.
. . . . . . . . . .
.
. . . . .
.
Rocker
arm
bridge
. .
.
. . . . . . .
.
. . .
.
. . .
.
.
.
. . . . . . . .
.
. . . . .
.
Fuel
injection
pumps
.
. . .
. . . .
.
.
.
.
.
. . .
.
. . . .
.
. .
.
.
.
. . . . . .
.
Pulley
.
. . . . . . . . .
.
. . .
.
. . . . .
.
.
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . . . . . . . .
Injectors
. . . . . . . . . . . .
.
. . . . . .
. .
.
.
.
.
.
.
20
20
Nm
(2,0
kpm)
(14
.7
ft
.lbs
.)
60
Nm
(6,0
kpm)
(44
.2
ft
.lbs
.)
70
Nm
(7,0
kpm)
{51
.6
ft
.lbs
.)
25
Nm
(2,5
kpm)
(18
.4
ft
.lbs
.)
65
Nm
(6,5
kpm)
(47
.)
ft
.lbs
.)
20
Nm
(2,0
kpm)
(14
.7
ft
.lbs
.)
70
Nm
(7,0
kpm)
(51
.6
ft
.lbs
.)
25
Nm
(2,5
kpm)
(18
.4
ft
.lbs
.)
25
Nm
(2,5
kpm)
(18
.4
ft
.lbs
.)
40
Nm
{4
,0
kpm)
(29
.5
ft
.lbs
.)
20
Nm
(2,0
kpm)
(14
.7 ft
.lbs
.)
32


Need help? Post your question in this forum.

Forumrules


Report abuse

Libble takes abuse of its services very seriously. We're committed to dealing with such abuse according to the laws in your country of residence. When you submit a report, we'll investigate it and take the appropriate action. We'll get back to you only if we require additional details or have more information to share.

Product:

For example, Anti-Semitic content, racist content, or material that could result in a violent physical act.

For example, a credit card number, a personal identification number, or an unlisted home address. Note that email addresses and full names are not considered private information.

Forumrules

To achieve meaningful questions, we apply the following rules:

Register

Register getting emails for Volvo Penta 2003 at:


You will receive an email to register for one or both of the options.


Get your user manual by e-mail

Enter your email address to receive the manual of Volvo Penta 2003 in the language / languages: English as an attachment in your email.

The manual is 5,27 mb in size.

 

You will receive the manual in your email within minutes. If you have not received an email, then probably have entered the wrong email address or your mailbox is too full. In addition, it may be that your ISP may have a maximum size for emails to receive.

Others manual(s) of Volvo Penta 2003

Volvo Penta 2003 Usermanual and installation guide - English - 24 pages


The manual is sent by email. Check your email

If you have not received an email with the manual within fifteen minutes, it may be that you have a entered a wrong email address or that your ISP has set a maximum size to receive email that is smaller than the size of the manual.

The email address you have provided is not correct.

Please check the email address and correct it.

Your question is posted on this page

Would you like to receive an email when new answers and questions are posted? Please enter your email address.



Info