Volvo Penta D3-160i-B Marine Engine Full Service Repair

Workshop Manual 2(0) A D3-110i-B, D3-130i-B D3-160i-B, D3-190i-B D3-130A-B, D3-160A-B, D3-190A-B

Workshop manual Group 21–26 Marine engines D3-110i-B, D3-130i-B, D3-160i-B, D3-190i-B D3-130A-B, D3-160A-B, D3-190A-B Contents Safety information .................................................. 4 Introduction ............................................................ 4 Important ............................................................... 4 General information ............................................... 7 About this Workshop Manual ................................. 7 Standard times (Flat Rate) ..................................... 7 Spare parts ............................................................ 7 Certified engines .................................................... 7 Repair instructions ................................................. 8 Our common responsibility ..................................... 8 Torque ................................................................... 8 Torque-angle tightening .......................................... 9 Lock nuts ............................................................... 9 Strength classes .................................................... 9 Sealant .................................................................. 9 Safety rules for Fluorocarbon Rubber ................... 10 Special tools ........................................................ 11 Other special equipment ...................................... 14 Location of engine signs ..................................... 15 Design and function Group 21: Short block ....................................... 16 Engine, general .................................................... 16 Engine block ........................................................ 17 Sump ................................................................... 17 Cylinder head ....................................................... 17 Camshaft ............................................................. 17 Valve housing / inlet manifold .............................. 17 Crankshaft ........................................................... 18 Pistons ................................................................ 18 Timing gear .......................................................... 19 Crankcase breather .............................................. 19 Group 22: Lubrication system ........................... 20 Oil grades ............................................................ 20 Lubrication system, function description .............. 21 Oil valves ............................................................. 22 Oil pump .............................................................. 22 Oil filter ................................................................ 22 Group 23: Fuel system ....................................... 23 Fuel system, function description ........................ 23 Injection pump ..................................................... 24 Distribution manifold ............................................. 24 Injectors ............................................................... 25 Fuel filter housing ................................................. 25 Group 25: Inlet and exhaust system ................. 26 Inlet and exhaust system, function description .............................................. 26 Turbocharger ........................................................ 27 VNT (Variable Nozzle Turbocharger) .................... 28 Group 26: Cooling system ................................. 29 Cooling system, function description .................... 29 Thermostat .......................................................... 30 Circulation pump .................................................. 30 Sea water pump ................................................... 30 Intercooler ............................................................ 31 Heat exchanger .................................................... 31 Oil cooler ............................................................. 32 Oil cooler, steering servo ..................................... 32 Group 64: Servo system .................................... 33 Servo system ...................................................... 33 Servo pump ......................................................... 33 Fault tracing ......................................................... 34 Symptoms and possible causes .......................... 34 Malfunctions ........................................................ 35 Blockage .............................................................. 35 Inspection of return flow from injectors ................. 36

Service work ......................................................... 37 Compression test ................................................. 37 Engine oil, changing ............................................. 38 Oil filter, change ................................................... 39 Fuel filter, change ................................................ 40 Venting the fuel system ....................................... 41 Air filter, change ................................................... 42 Cooling system, draining ...................................... 43 Sea water system, cleaning and conserving ........ 44 Fresh water system, pressure testing .................. 45 Cooling system, filling .......................................... 46 Sea water pump, impeller, change ....................... 48 Drive belt/Alternator belts, inspection ................... 49 Drive belt/Alternator belts, change ....................... 49 Cam belt, change ................................................. 50 Repair instructions ............................................... 55 When working with chemicals, fuel and lubrication oil ................................................. 55 Before lifting the engine ....................................... 55 Before working in a boat ....................................... 55 Actions after lifting the engine .............................. 55 Checking the engine fixture ................................. 56 Engine, full overhaul Disassembly, engine .......................................... 58 Cover ................................................................... 58 Exhaust manifold and turbocharger ...................... 58 Fuel filter and housing .......................................... 58 Intercooler, brackets and dipstick ........................ 59 Engine cables ...................................................... 59 Drive belt ............................................................. 60 Sea water pump ................................................... 60 Servo pump, jockey wheel, left-hand engine mounting ................................................... 60 Alternator ............................................................. 61 Mounting bracket ................................................. 61 Vacuum regulator ................................................. 61 Sensors and monitors .......................................... 62 Starter motor ........................................................ 62 Fuel leakage hose ................................................ 62 Delivery pipes ...................................................... 63 High pressure pump ............................................. 63 Distribution manifold ............................................. 63 Vacuum pump ...................................................... 64 Injectors ............................................................... 64 Valve cover/inlet manifold .................................... 64 Timing gear .......................................................... 65 Circulation pump .................................................. 68 Oil pump .............................................................. 68 Cylinder head ....................................................... 68 Flywheel with cover and coupling ......................... 70 Oil filter housing ................................................... 72 Oil cooler ............................................................. 72 Sump ................................................................... 73 Oil suction pipe .................................................... 73 Piston cooling nozzles ......................................... 73 Pistons and con rods ........................................... 74 Crankshaft ........................................................... 74 Assembly, engine .............................................. 74 Classification of main bearings ............................ 76 Crankshaft ........................................................... 78 Piston rings .......................................................... 78 Piston cooling nozzles, pistons, con rods ............ 79 Flywheel, seal ring, clutch and flywheel housing ............................................ 79 Oil suction pipe and sump .................................... 80 Oil cooler ............................................................. 82 Oil pump .............................................................. 82 Toothed belt pulley ............................................... 83 Cylinder head ....................................................... 84 Valve cover .......................................................... 88 Circulation pump .................................................. 88 Timing gear .......................................................... 89 Injectors ............................................................... 93 Distribution manifold ............................................. 93 High pressure pump ............................................. 93 Fuel supply pipes and fuel leakage hose .............. 94 Fuel union ............................................................ 94 Vacuum pump ...................................................... 94 Plug, hot water outlet ........................................... 95 Oil filter housing ................................................... 95 Mounting bracket ................................................. 95 Drive belt/Alternator belt ....................................... 96 Vacuum regulator ................................................. 97 Starter motor ........................................................ 97 Sensors and cables ............................................. 97 Intercooler and dipstick ........................................ 98 Fuel filter housing ................................................. 98 Exhaust pipe with turbocharger ............................ 99 Fixture, right engine mounting .............................. 99 Coolant pipe ........................................................ 100 Heat exchanger ................................................... 100 Oil pipe, turbocharger .......................................... 100 Exhaust pipe elbow ............................................. 101 Expansion tank ................................................... 101 Hose connections, air filter housing .................... 101 Cover .................................................................. 101

Overhaul / Change components Group 21: Short block ...................................... 102 Flywheel, change ................................................ 102 Gear ring, change ................................................ 105 Crankcase seal, rear, change .............................. 106 Crankshaft seal, front, change ............................ 109 Cylinder head, change ......................................... 110 Cylinder head gasket, measurement ................... 129 Crankshaft, locking ............................................. 131 Cam belt, change ........................ see “Service work” Group 22: Lubrication system .......................... 132 When working with chemicals, fuel and lubrication oil ................................................ 132 Oil pump, change ................................................ 132 Oil filter housing, change ..................................... 134 Lube oil pressure, check ..................................... 135 Group 23: Fuel system ...................................... 136 Engine control unit, changing .............................. 136 Injection pump, changing .................................... 138 Injectors and fuel supply pipes, change .............. 139 Pressure limiting valve ........................................ 143 Fuel suction pressure, checking .......................... 144 Fuel pressure sensor, change ............................. 145 Group 25: Inlet and exhaust system ................ 146 Turbocharger, inspection ..................................... 146 Turbo, replacing .................................................. 148 Exhaust manifold, change ................................... 150 Group 26: Cooling system ................................ 152 Coolant pump, change ........................................ 152 Thermostat, function check/change .................... 153 Sea water pump, change ..................................... 154 Seawater pump, impeller change ... see “Service work” Sea water pump, seal, change ............................ 155 Coolant temperature sensor, replacing ................ 157 Heat exchanger, pressure testing ........................ 158 Heat exchanger, replacing ................................... 159 Heat exchanger, cleaning/renovation ................... 161 Oil cooler, steering servo, change ....................... 162 Intercooler, pressure testing ................................ 163 Intercooler, change ............................................. 164 Intercooler, cleaning/renovation ........................... 166 Oil cooler, engine, change ................................... 167 Group 30: Electrical (other) .............................. 168 Alternator, changing ............................................ 168 Starter motor, changing ....................................... 169 Technical data ..................................................... 170 General ............................................................... 170 Short block ......................................................... 170 Inlet and exhaust system .................................... 171 Fuel system ........................................................ 171 Lubrication system .............................................. 172 Cooling system ................................................... 172 Electrical system ................................................ 173 Wiring diagram .................................................... 174 Torque ................................................................ 175 Conversion table ................................................. 177 References to Service Bulletins ......................... 178 Alphabetical register ........................................... 179

4 Introduction This workshop manual contains technical data, descriptions and repair instructions for the Volvo Penta products or product versions noted in the table of contents. Check that you have the correct Workshop Manual for your engine. Read the available safety information, “General Infor- mation” and “Repair Instructions” in the workshop manual before you start to do any service work. Important In this book and on the product you will find the following special warning symbols. WARNING! Warns for the risk of personal injury, major damage to product or property, or serious malfunctions if the instruction is ignored. IMPORTANT! Is used to call attention to things which could cause damage or malfunctions to product or property. NOTE! Is used to call attention to important information, to facilitate work processes or operation. Below is a summary of the risks involved and safety precautions you should always observe or carry out when operating or servicing the engine. Make it impossible to start the engine by cutting system current with the main switch(es) and lock it (them) in the off position before starting service work. Set up a warning notice by the helm station. As a general rule all service operations must be carried out with the engine stopped. Some tasks, such as adjustments, need the engine to be running, however. Approaching an engine which is operating is a safety hazard. Remem- ber that loose clothing or long hair can fasten in rotating parts and cause serious personal injury. If work is done adjacent to a running engine, a careless movement or a dropped tool can lead to personal injury in the worst case. Take care to avoid contact with hot surfaces (exhaust pipes, Turbocharger, air intake pipe, starter heater etc.) and hot fluids in pipes and hoses in an engine which is running or has just been stopped. Reinstall all protective parts removed during service work before starting the engine. Check that the warning or information labels on the product are always clearly visible. Replace labels which have been damaged or painted over. Never start the engine without installing the air cleaner filter. The rotating compressor turbine in the turbocharger can cause severe injury. For- eign objects entering the intake ducts can also cause mechanical damage. Never use start spray or similar products as a starting aid. They may cause an explosion in the inlet manifold. Danger of personal injury. Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and the system pressure will be lost. Open the filler cap slowly, and release the pressure in the cooling system if the filling cap or tap has to be opened, or if a plug or coolant hose has to be removed when the engine is hot. Steam or hot coolant might spray out in an unexpected direc- tion. Safety information

Safety information 5 Exercise extreme care when leak detecting on the fuel system and testing the fuel injector nozzles. Use eye protection. The jet which comes from a fuel injector has very high pressure and considerable penetration ability. Fuel can force its way deep into body tissue and cause severe injury. Danger of blood poisoning (septicemia). All fuels, and many chemicals, are flammable. Do not allow naked flame or sparks in the vicini- ty. Petrol (gasoline), some thinners and hydrogen gas from batteries are extremely flammable and explosive when mixed with air in the correct ratio. No Smoking! Ensure that the work area is well ventilated and take the necessary safety precautions before starting welding or grinding work. Always ensure that there are fire extin- guishers at hand when work is being carried out. Make sure that oil and fuel soaked rags, and used fuel and oil filters are stored in a safe place. Rags soaked in oil can spontaneously ig- nite under certain circumstances. Used fuel and oil filters are polluting waste and must be hand- ed to an approved waste management facility for destruction, together with used lubrication oil, contaminated fuel, paint residue, solvents, degreasers and wash residue. Batteries must never be exposed to open flames or electric sparks. Never smoke close to the batteries. The batteries generate hydrogen gas when charged, which forms an explosive gas when mixed with air. This gas is easily ignit- ed and highly volatile. A spark, which can be caused by incorrect battery connection, can cause a single spark which is sufficient to cause an explosion with resulting damage. Do not move the connections when you attempt to start the engine (risk of arcing), and do not stand and lean over one of the batteries. Always ensure that the Plus (positive) and Mi- nus (negative) battery cables are correctly in- stalled on the corresponding terminal posts on the batteries. Incorrect installation can result in serious damage to the electrical equipment. Re- fer to the wiring diagram. Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before carrying out any work. Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected. Stop the engine and close the sea cocks before doing any work on the cooling system. Only start the engine in a well- ventilated area. When operated in a confined space, exhaust fumes and crankcase gases must be ventilated from the engine bay or workshop area. Always use protective glasses or goggles when carrying out work where there is a risk of splin- ters, grinding sparks, acid splashes or where other chemicals are used. Your eyes are extremely sensitive, injury could cause blindness! Avoid getting oil on your skin! Repeated exposure to oil or exposure over a long period can result in the skin becoming dry. Irritation, dryness and eczema and other skin problems can then occur. Used oil is more dangerous than fresh oil from a health aspect. Use protective gloves and avoid oil soaked clothes and rags. Wash regularly, es- pecially before eating. There are special skin creams which counteract drying out of the skin and make it easier to clean off dirt after work is completed. Most chemicals intended for the product (e.g. engine and transmission oils, glycol, petrol (gasoline) and diesel oil) or chemicals for workshop use (e.g. degreasers, paints and solvents) are hazardous. Read the instructions on the product packaging with care! Always follow the safety precautions for the product (for example use of protective mask, glasses, gloves etc.). Make sure that other personnel are not inadvertently exposed to hazardous chemicals, for example in the air. Ensure good ventilation in the work place. Follow the instructions provided when dis- posing of used or leftover chemicals.

Safety information 6 Never work alone when removing heavy engine components, even when using lifting devices such as locking tackle lifts. When using a lifting device two people are usually required to do the work, one to take care of the lifting device and another to ensure that components are lifted clear and not damaged during the lifting operations. When you work aboard a boat, always make sure that there is enough space for disassembly where you are working, with no risk of personal injury or material damage. Components in the electrical and fuel systems on Volvo Penta products have been designed to minimize the risks of explosion and fire. The engine must not be run in areas where there are explosive materials. Remember the following when washing with a power washer: Never aim the water jet at seals, rubber hoses or electrical components. Never use a power washer for engine cleaning. Only use the fuels recommended by Volvo Pen- ta. Refer to the Instruction Book. Use of fuels that are of a lower quality can damage the engine. On a diesel engine, poor quality fuel can cause the control rod to bind and the engine to overrev with resulting risk of damage to the engine and personal injury. Poor fuel can also lead to higher maintenance costs. Always use protective goggles when charging and handling the batteries. Battery electrolyte contains sulfuric acid which is highly corrosive. Should the battery electrolyte come into contact with unprotected skin wash off immediately using plenty of water and soap. If you get battery acid in your eyes, flush at once with a generous amount of water, and get medical assistance at once. Turn the engine off and turn off the power at the main switch(es) before carrying out work on the electrical system. Clutch adjustments must be carried out with the engine stopped. The existing lugs on the engine/reversing gear should be used for lifting the assembly. Always check that the lifting devices are in good condition and that they have the correct capaci- ty for the lift (the weight of the engine plus the reversing gear and extra equipment). The engine should be lifted with a customized or adjustable lifting boom for safe handling and to avoid damaging components on top of the engine. All chains or cables should be parallel to each other and should be as square as possible to the top of the engine. If other equipment connected to the engine has altered its center of gravity, special lifting devices may be needed to obtain the correct balance and safe handling. Never do any work on an engine which just hangs from a lifting device. © 2006 AB VOLVO PENTA We reserve the right to make modifications without prior notice. Printed on environmentally compatible paper.

7 About this Workshop Manual This workshop manual contains technical data, descriptions and repair instructions for the following marine diesel engines: D3-110i-B, D3-130i-B, D3-160i-B, D3-190i-B, D3-130A-B, D3-160A-B, D3-190A-B. The engine designation and number are noted on the number plate and engine decal. The engine designation and number must always be given in all corre- spondence about any product. The Workshop Manual is produced primarily for the use of Volvo Penta workshops and service techni- cians. This assumes that people who use the Manual have basic knowledge of marine drive systems and can do the tasks of a mechanical or electrical nature associated with the trade. Volvo Penta constantly improves its products, so we reserve the right to make modifications without prior notification. All information in this manual is based on product data which was available up to the date on which the manual was printed. Any material changes introduced into the product or service methods after this date are notified by means of Service Bulletins. Spare parts Spare parts for electrical- and fuel systems are sub- ject to various national safety requirements, such as U.S. Coast Guard Safety Regulations. Volvo Penta Original Spare Parts meet these specifications. Any damage, occasioned by use of non--original Volvo Penta spares for the product, will be not be compen- sated by the warranty offered by Volvo Penta. General information Certified engines When doing service and repair on emission certified engines, it is important to be aware of the following: Certification means that an engine type has been checked and approved by the relevant authority. The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified engine. This makes special demands on service and repair work, as follows: – Maintenance and service intervals recommended by Volvo Penta must be complied with. – Only by Volvo Penta approved spare parts may be used. – Service to injection pumps, pump settings and injectors must always be done by an authorized Volvo Penta workshop. – The engine must not be converted or modified, except for the accessories and service kits which Volvo Penta has approved for the engine. – No installation changes to the exhaust pipe and engine air inlet ducts may be done. – No seals on the engine may be broken by unau- thorized persons. The general advice in the instruction book about operation, care and maintenance applies. IMPORTANT! Late or inadequate maintenance/ service or the use of spare parts other than by Volvo Penta approved spare parts will invalidate AB Volvo Penta’s responsibility for the engine specification being in accordance with the cer- tificated variant. Volvo Penta accepts no responsibility or liability for any damage or costs arising due to the above. Standard times (Flat Rate) In instructions where operation numbers are found in the headings, this is a reference to the Volvo Penta standard times list (“Flat Rate”).

8 The working methods described in the Workshop Man- ual apply to work carried out in a workshop. For this reason, the engine is lifted out of the boat and mount- ed on an engine support. Unless otherwise stated, re- conditioning work which can be carried out with the engine in place follows the same working method. The warning signs which occur in the workshop manual (please refer to “Safety information” for their mean- ings). WARNING! IMPORTANT! NOTE! are not comprehensive in any way, since we can not of course foresee everything, because service work is done in highly varying circumstances. For this reason, all we can do is to point out the risks which we believe could occur due to incorrect work in a well-equipped work shop, using work methods and tools tested by us. All operations described in the Workshop Manual for which there are Volvo Penta Special Tools available assume that these tools are used when carrying out the repair. Volvo Penta Special Tools have been spe- cifically developed to ensure the most safe and ratio- nal working methods possible. It is therefore the responsibility of anyone using other tools or other working methods than we recommend to determine that there is no risk of personal injury or mechanical damage or malfunction as a result. In some cases special safety precautions and user instructions may be required in order to use the tools and chemicals mentioned in the Workshop Manual. These rules must always be observed, so there are no special instructions about this in the workshop manual. By following these basic recommendations and using common sense it is possible to avoid most of the risks involved in the work. A clean workplace and a clean engine will eliminate many risks of personal injury and engine malfunction. Above all, when work on fuel systems, lubrication systems, induction systems, turbocharger, bearing caps and seals is done, it is extremely important that no dirt or other kinds of foreign particles are able to get in, since this would otherwise cause malfunctions or shortened repair life. Our common responsibility Each engine consists of many interacting systems and components. The deviation of one component from the technical specification can dramatically in- crease the environmental impact caused by an otherwise good engine. For this reason, it is important that the specified wear tolerances are observed, that systems which are adjustable are correctly adjusted and that Volvo Penta Original Spares are used for the engine. The stated service intervals in the Maintenance Schedule must be observed. Some systems, such as the components in the fuel system, require special expertise and special testing equipment for service and maintenance. For environmental reasons etc., some component s are sealed at the factory. It is only permissible to work on sealed components if you are authorized to do such work. Remember that most chemical products, incorrectly used, damage the environment. Volvo Penta recom- mends the use of biodegradable degreasers whenever engine components are de-greased, unless otherwise specified in the workshop manual. When working aboard a boat, be careful to ensure that oils, wash residue etc. are processed for destruction, and are not inadvertently discharged with bilge water into the environment. Torque The tightening torque for vital fasteners, which should be tightened with a torque wrench, are listed in “Tech- nical Data: Special tightening torques” and noted in the job descriptions in the book. All torque specifications apply to clean screws, screw heads and mating faces. Torque data stated apply to lightly oiled or dry threads. If lubricants, locking fluids or sealants are needed on a fastener, the type of preparation to be used will be noted in the job description. For fasteners where specific torque values are not given, please refer to “Technical data, General Tightening Torque”. Repair instructions

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Volvo Penta D3-160i-B Marine Engine Full Service Repair

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