Volvo Penta 2001 2002 2003 2003T Marine Engines Service & Repair Manual

WORKSHOP MANUAL Publ . n r 7730974-8 4-1990 VOLVO PENTA

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

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 consecutiveorder, NOTE!Thecylinderheadboltsarephosphatisedandmustnot becleanedwithasteelbrush.

5 . Remove the fuel injection pumps . Mark the pumps to ensure installation in the same cylinders from which 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 pad between the puller and the crankshaft to avoid the crankshaft being damaged . 7 . Remove the transmission cover : Start by removing the throttle control cover . Use a 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 engine output . 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 flywheel housing, 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) . The arrow is to point towards the dipstick.

THE CYLINDER 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 .) L1= Length, loaded with 170±10 N (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 arm mechanism and clean the parts . Check the wear of the shaft and rockerarm bushings. 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 .

Volvo Penta 2001 2002 2003 2003T Marine Engines Service & Repair Manual

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