Workshop Manual E

Groups 21–26 2(0)

D16C-A MH, D16C-A MG

 Groups 21–26
Marine diesel engines
D16C-A MH, D16C-A MG

Contents
Safety Precautions .............................................. 3 Group 26:
General information ............................................ 6 Cooling system ................................................... 34
About this Workshop Manual .............................. 6 Charge air cooler ................................................ 35
Standard times (Flat Rate) .................................. 6 Fault tracing ......................................................... 36
Spare Parts ........................................................ 6 Location of measurement connector on engine .... 37
Certified Engines ................................................ 6 Actions with low charge air pressure .................. 39
Service procedures ............................................. 7 Coolant temperature too high ............................. 40
Our Mutual Responsibility ................................... 7 Coolant temperature too low ............................... 40
Tightening torque ................................................ 8 Coolant losses .................................................... 40
Torque-angle tightening ...................................... 8 Instructions for operating the starter motor ......... 41
Lock nuts ............................................................ 8 Compression test ............................................... 42
Strength Classes ................................................ 8 Fuel feed pressure, checking .............................. 44
Sealant ............................................................... 8 Charge air pressure, checking ............................ 45
Safety rules for fluorocarbon rubber ................... 9 Charge air pipe, checking ................................... 46
Special tools ........................................................ 10 Turbocharger, checking ...................................... 46
Identification number .......................................... 17 Exhaust back pressure, checking ....................... 47
Coolant pressure, check ..................................... 47
Design and Function Seawater pressure, checking ............................. 48
Group 21:
General advice
Short block ......................................................... 18
Working with chemicals, fuel and
Cylinder Head ..................................................... 18
lubrication oil ....................................................... 49
Cylinder Block .................................................... 19
Before working in a boat ..................................... 49
Cylinder liner ...................................................... 20
Before lifting the engine ...................................... 49
Pistons and con rods .......................................... 21
Actions after lifting the engine ............................. 50
Crankshaft .......................................................... 22
General advice for pressure measurement ......... 50
Valve mechanism ............................................... 23
General advice when working on EVC engines ... 50
Timing gear ........................................................ 24
Electric welding .................................................. 51
Group 22:
Exposing the engine ........................................... 52
Lubrication system ............................................. 25
Engine fixture, fixing ........................................... 53
Valves and lubrication system ............................ 26
Piston cooling ..................................................... 27 Repair Instructions
Group 23: Group 21: Short block
Fuel system ........................................................ 28 Short block, complete overhaul .......................... 54
Unit injectors, working phases ............................ 30 Cylinder head, removal ....................................... 54
Group 25: Timing gear, removing ........................................ 65
Inlet and exhaust system .................................... 32 Pistons, removal ................................................. 67
Turbocharger ...................................................... 32 Crankshaft, removing ......................................... 68
Sealed crankcase ventilation .............................. 33 Crankshaft, assembly ......................................... 69
Contents
Cylinder liners, installation .................................. 71
Pistons, pre-assembly ........................................ 72
Pistons, installation ............................................. 74
Piston cooling nozzles, installation ..................... 76
Timing gear, installation ...................................... 77
Cylinder head, installation ................................... 83
Camshaft, installation ......................................... 86
Gear backlash, adjusting .................................... 87
Unit injector, installation ...................................... 90
Adjustment markings .......................................... 91
Valves and unit injectors, adjustment ................. 92
Overhaul / Replacement of components
Group 21: Short block
Cylinder liner and pistons, inspection ................. 97
Cylinder liners and pistons, replace (all) ............. 99
Cylinder liner seats, inspection .......................... 105
Cylinder liner seat, milling .......................... 107/113
Crankshaft, inspection and overhaul .................. 114
Big end bearing journal, inspection .................... 115
Main bearings, replace ...................................... 116
Big end bearings, replace (all) ........................... 119
Flywheel, removal/installation ............................ 121
Gear ring, replace .............................................. 123
Flywheel sensor distance, checking .................. 124
Crankshaft seal, front, replace ........................... 126
Crankcase seal rear, replace ............................. 127
Con rod, inspection ............................................ 129
Gudgeon pin bushing, check measurement ...... 129
Valves, removing ............................................... 130
Valves, installation ............................................. 132
Valve seat, replace ............................................ 133
Valve guides, inspection .................................... 135
Valve guides, replacing ..................................... 136
Valve seats, grinding ......................................... 138
Valves, grinding ................................................. 139
Valve stem seals, replace .................................. 140
Cylinder head, pressure testing ......................... 142
Copper sleeve for unit injector, replace ............. 145
Camshaft, wear check ....................................... 149
Bearing housing for camshaft, replace .............. 150
Camshaft sensor distance, checking ................. 151
Timing gear, replace .......................................... 153
Group 22: Lubrication System
Working with chemicals, fuel and
lubrication oil ...................................................... 160
Overview, control valves .................................... 160
Overflow valve for by-pass filter, replace ........... 161
Overflow valve for full-flow filter, replace ........... 161
© 2007 AB VOLVO PENTA
We reserve the right to make modifications. Printed on environmentally compatible paper.
2
By-pass valve oil cooler, replace ....................... 162
Piston cooling nozzles, replace ......................... 162
Reduction valve, replace ................................... 163
Safety valve, oil pressure, replace ..................... 163
Oil pressure sensor, inspection ......................... 164
Pressure reduction valve, checking ................... 165
Safety valve, check ........................................... 165
Lube oil pump, check ......................................... 166
Lube oil pump, replace ...................................... 166
Group 23: Fuel System
Draining, fuel gallery in cylinder head ................ 168
Control unit, replace .......................................... 169
Identifying the engine control unit ...................... 170
Fuel feed pump, replace .................................... 171
Unit injector, replace .......................................... 173
Unit injector, programming the trim code ........... 178
Purging the fuel system ..................................... 180
Group 25: Inlet / Exhaust systems
Turbocharger, replace ....................................... 181
Turbocharger, bearing clearance, check ........... 184
Exhaust manifold, removal/installation ............... 186
Group 26: Cooling System
Cooling system, draining ................................... 187
Cooling system, cleaning ................................... 189
Cooling system, filling ........................................ 190
Cooling system, pressure testing ....................... 192
Coolant filler cap, replace .................................. 194
Coolant pump, replace ...................................... 195
Thermostat, function check ............................... 196
Thermostat, replace ........................................... 197
Charge air cooler, removal/installation ............... 198
Charge air cooler, cleaning ................................ 201
Charge air cooler, pressure testing .................... 202
Heat exchanger, removal and installation .......... 203
Heat exchanger, cleaning .................................. 204
Heat exchanger, pressure testing ...................... 206
Oil cooler, engine, removal/installation .............. 208
Oil cooler, engine, cleaning ............................... 209
Oil cooler, engine, pressure testing ................... 210
Seawater pump, replace .................................... 211
Seawater pump, overhaul .................................. 212
Oil cooler, reverse gear, cleaning ...................... 217
Oil cooler, reverse gear, pressure testing .......... 219
Oil cooler reverse gear, thermostat replace ....... 220
Drive belts, inspection ....................................... 221
Drive belts, replace ............................................ 221
References to Service Bulletins ........................ 222
Alphabetical index .............................................. 223
 Safety Precautions
Introduction
This workshop manual contains technical data, de-
scriptions and repair instructions for the Volvo Penta
products or product versions noted in the table of
contents. Check that you are using the correct Work-
shop Manual.
Read the available safety information and “General
information” and “Repair instructions” in the workshop
manual carefully before you start to do any service
work.
Important
In this book and on the product you will find the fol-
lowing special warning symbols.
WARNING! Serious risk of personal injury, ex-
tensive damage to property or serious mechani-
cal malfunction if this instruction is not followed.
IMPORTANT! Used to draw your attention to
something that may cause damage or malfunc-
tion to the product or damage to property.
NOTE: Used to draw your attention to important in-
formation that will facilitate the work or operation in
progress.
In order to provide an overview of the risks and safety
measures that shall always be observed and carried
out, we have listed them as follows:
Immobilize the engine by turning off the power
supply to the engine at the main switch
(switches) and lock it (them) turned off before
starting work. Place a warning notice at the helm
station.
As a 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 run-
ning is a safety risk. Remember that loose cloth-
ing 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,
in the worst case, to personal injury.
Be careful with hot surfaces (exhaust pipes, tur-
bos, charge air pipes, starting heaters etc.) and
hot fluids in pipes and hoses on an engine which
is running or which has just stopped. Reinstall all
protective covers removed during service
operations before starting the engine.
Never start the engine with the valve cover re-
moved. Apart from the risk of spilling oil, there is
a risk of personal injury. The voltage supplied to
the unit injectors can be as high as 100 V.
Ensure that the warning or information decals on
the product are always clearly visible. Replace
decals which have been damaged or painted
over.
Never start the engine without installing the air
filter. The rotating compressor turbine in the tur-
bocharger can cause severe injury. Foreign ob-
jects 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 en-
gine is hot. Steam or hot coolant can spray out
and the system pressure will be lost. Open the fill-
er 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 re-
moved when the engine is hot. Steam or hot cool-
ant might spray out in an unexpected direction.
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 fill-
er cap removed, otherwise oil could be ejected.
Stop the engine and close the sea cocks before
doing any work on the cooling system.
3
Safety Precautions
Only start the engine in a well-ventilated area.
When running 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 a risk of splinters, grind-
ing sparks, splashes from acid or other chemi-
cals are present. Your eyes are extremely sensi-
tive, injury can cause blindness!
Avoid getting oil on your skin! Protracted or re-
peated exposure to oil can cause skin to be-
come dry. Irritation, dryness, eczema and other
skin problems may then result.
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. Use suitable barrier
creams to counteract drying out of the skin and
to aid dirt removal.
Most chemicals intended for the product (e.g.
engine and transmission oils, glycol, gasoline
and diesel) or chemicals for workshop use (e.g.
degreasers, paints and solvents) are hazardous.
Carefully read the instructions on the product
packaging! Always follow the safety precautions
for the product (e.g. use of protective mask,
glasses, gloves etc.). Make sure that other per-
sonnel are not inadvertently exposed to hazard-
ous substances, e.g. by inhaling fumes. Ensure
good ventilation. Follow the instructions provided
when disposing of used or leftover chemicals.
Exercise extreme caution when leak detecting
on the fuel system and testing the fuel injector
nozzles. Use eye protection. The jet from a fuel
nozzle has very high pressure and great pene-
tration power. 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 flames or sparks in the vicin-
ity. Gasoline, some thinners and hydrogen gas
from batteries are extremely flammable and ex-
plosive when mixed with air in the correct ratio.
No Smoking! Ensure that the work area is well
ventilated and take the necessary safety precau-
tions before starting welding or grinding work.
Always ensure that there are fire extinguishers
close at hand in the work area.
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.
4
Used fuel and oil filters are polluting waste and
must be handed to an approved waste manage-
ment facility for destruction, together with used
lubrication oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
Never expose a battery to naked flame or electrical
sparks. Never smoke close to the batteries. The
batteries generate hydrogen gas when charged,
which is explosive when mixed with air. This gas is
easily ignited and highly explosive. A spark, which
can be caused by incorrect battery connection, is
sufficient to cause a battery to explode and cause
further damage. Do not shift the connections when
attempting to start the engine (spark risk) and do
not lean over any of the batteries.
Never transpose the positive (+) and negative (–
) battery posts when installing batteries. Such a
transposition can result in serious damage to
electrical equipment. Refer to the wiring dia-
gram.
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 us-
ing plenty of water and soap. If you get battery
acid in your eyes, flush at once with a generous
amount of water, and seek medical assistance
immediately.
Stop the engine and turn off electrical supply at
the main switch(es) before carrying out work on
the electrical system.
Clutch adjustments must be carried out with the
engine stopped.
Use the lifting eyes mounted on the engine / re-
verse gear when lifting the drive train.
Always check that the lifting equipment used is
in good condition and has the load capacity to lift
the engine (engine weight including reverse gear
and any extra equipment).
Use an adjustable lifting beam or lifting beam
specifically for the engine to raise the engine to
ensure safe handling and to avoid damaging en-
gine parts installed on the top of the engine. All
chains and cables should run parallel to each
other and as perpendicular as possible in rela-
tion to the top of the engine.
If other equipment connected to the engine has
altered its center of gravity, special lifting devis-
es may be needed to obtain the correct balance
for safe handling.
Never carry out work on an engine suspended
on a hoist.
 Safety Precautions

Never work alone when removing heavy engine Never use a power washer for engine cleaning.
components, even when using lifting devices Remember the following when washing other
such as locking tackle lifts. When using a lifting components with a power washer: Never aim
device two people are usually required to do the the water jet at seals, rubber hoses or electrical
work, one to take care of the lifting device and components.
another to ensure that components are lifted
clear and not damaged during the lifting opera-
Only use the fuels recommended by Volvo
tions.
Penta. Refer to the Operator’s Manual. Use of
When working aboard a boat, always make sure
fuels that are of a lower quality can damage the
ahead of time that there will be enough space to
engine. On a diesel engine, poor quality fuel can
allow for disassembly, without risk of personal
cause the control rack to bind and the engine to
injury or damage to materials.
over-rev with resulting risk of engine damage
and personal injury. Poor fuel can also lead to
Components in the electrical and fuel systems higher service costs.
on Volvo Penta products have been designed to
minimize the risks of explosion and fire. The en-
gine must not be run in areas where there are
explosive materials.

5
 General Information
About the Workshop Manual
This Workshop Manual contains technical data, de-
scriptions and repair instructions for marine diesel en-
gines D16C-A MH and D16C-A MG.
The engine designation and number are noted on the
number plate and engine decal. The engine designa-
tion 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 presupposes that persons using the man-
ual have a fundamental knowledge of marine drive
systems and can carry out the tasks of a mechanical
or electrical nature associated with the trade.
Volvo Penta constantly improves its products, and re-
serves the right to make modifications without prior
notification. All information in this manual is based on
product data which was available at the time the man-
ual was printed. Any material changes introduced into
the product or service methods after this date are no-
tified by means of Service Bulletins.
Standard times (Flat Rate)
Operation numbers that show in instruction headings
refer to Volvo Penta Flat Rates.
Spare Parts
Spare parts for electrical- and fuel systems are sub-
ject to various national safety requirements such as
the US Coast Guard Safety Regulations. Volvo Penta
Original Spare Parts meet these specifications. No
damage whatever, occasioned by use of spare parts
other than by Volvo Penta approved spare parts for
the product, will be compensated by the warranty of-
fered by Volvo Penta.
6
Certified engines
When performing 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 places special demands on service and re-
pair work, as follows:
● Care and Service intervals recommended by
Volvo Penta must be followed.
● Only spare parts approved by Volvo Penta may be
used.
● Service to injection pumps, pump settings and in-
jectors must always be performed by an autho-
rized Volvo Penta workshop.
● The engine must not be converted or modified,
except for the accessories and service kits that
Volvo Penta has approved for the engine.
● No installation changes to the exhaust pipe and
engine air inlet ducts may be made.
● Any anti-tamper seals on the engine may not be
broken by unauthorized persons.
The general advice in the instruction book about op-
eration, care and maintenance, applies.
IMPORTANT! Neglected or poorly performed
care /service, as well as use of spare parts other
than by Volvo Penta approved spare parts, en-
tails that AB Volvo Penta can no longer guaran-
tee that the engine conforms to the certified
model.
Damages and /or costs accrued due to this will
not be compensated for by Volvo Penta.
 Repair Instructions
The working methods described in the Workshop
Manual apply to work carried out in a workshop. For
Our Mutual Responsibility
this reason, the engine is lifted out of the boat and Each engine consists of a large number of collaborat-
mounted on an equipment stand. Overhaul work ing systems and components. Any deviation of a
which does not need the engine to be lifted out can component from its technical specification can dra-
be done in situ, with the same work methods, unless matically increase the environmental impact of an
otherwise specified. otherwise good engine. It is therefore of utmost im-
portance that wear tolerances are maintained, that
The warning signs which occur in the workshop man-
the system that is adjustable has the correct settings
ual (please refer to “Safety information” for their
and that spare parts recommended by Volvo Penta
meanings).
are used on the engine. The stated service intervals
in the Maintenance Schedule must be observed.
WARNING!
Some systems, such as the components in the fuel
system, require special expertise and special testing
IMPORTANT! equipment for service and maintenance. Due to envi-
ronmental requirements, some components are
NOTE: sealed from the factory. It is only permissible to work
on sealed components if you are authorized to do
are not in any way comprehensive since it is impossi- such work.
ble to predict every circumstance under which service Remember that most chemical products, incorrectly
work or repairs may be carried out. For this reason, all used, are harmful to the environment. Volvo Penta
we can do is to point out the risks which we believe recommends the use of biodegradable degreasers
could occur due to incorrect work in a well-equipped whenever engine components are de-greased, un-
workshop, using work methods and tools tested by us. less otherwise specified in the Workshop Manual.
All operations described in the Workshop Manual are When working aboard a boat, be careful to ensure
carried out using special Volvo Penta tools wherever that oils, wash residue etc. are processed for destruc-
such are available. Volvo Penta Special Tools have tion, and are not inadvertently discharged with bilge
been developed to ensure the most safe and rational water into the environment.
working methods possible. It is therefore the respon-
sibility of anyone using other tools or other working
methods than those we recommend to ensure that
there is no risk of personal injury or mechanical dam-
age or malfunction as a result.
In some cases special safety precautions and user in-
structions 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 Manu-
al.
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 in-
jury and engine malfunction.
Especially during work on the fuel system, lubricating
system, inlet system, turbocharger, bearings and
seals, it is of the utmost importance that dirt and con-
taminants of any sort, do not enter the system, other-
wise malfunction or shortened repair lifespan can re-
sult.

7
General advice
Tightening 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 specifica-
tions 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 fasten-
ers where specific torque values are not given,
please refer to “Technical data: General tightening
torques”. General torque specifications are target val-
ues and the fastener does not need to be tightened
with a torque wrench.
Torque-angle tightening
In torque/angle tightening, the fas-
tener is tightened to the specified
torque, and tightening then contin-
ues through a pre-determined an-
gle. For example; for 90° angle
tightening, the joint is turned a fur-
ther 1/4 turn in one sequence, after
the specified tightening torque has
been achieved.
Lock nuts
Disassembled locknuts shall not be re-used, they
shall be replaced by new ones, since the locking
properties are impaired or lost when the nut is used
several times. For locknuts with plastic inserts, i.e.
Nylock®, the tightening torque shall be reduced if the
Nylock® nut has the same nut-height as a standard
all-metal hexagonal nut. Reduce the torque by 25%
for screw size 8 mm or larger. For Nylock® nuts with a
greater nut-height (where the all-metal thread is as
high as a standard hexagonal nut), the stated torque
applies.
8
Strength classes
Screws and nuts are sub-divided into different
strength classes. The classification is shown by a
marking on the bolt head. Markings of a higher num-
ber indicate stronger material. For example, a bolt
marked 10-9 has greater strength than a bolt marked
8-8. It is therefore important when dismantling bolted
joints, that the bolts are used in the same places when
reinstalled. If a bolt must be replaced, check in the
spare parts catalogue to make sure the correct bolt is
obtained.
Sealant
The sealants and locking fluids noted below shall be
used on the engines covered by this manual.
To ensure service work is correctly carried out it is
important that the correct sealant and locking fluid
type is used on the joint where the agents are re-
quired.
Agents used during manufacture are those specified
in the applicable sections of the Workshop Manual.
In service work, the same preparations or prepara-
tions with corresponding properties, but of other
makes, shall be used.
When sealants and locking fluids are used, it is im-
portant that the surfaces are free from oil, grease,
paint and rust-protection, and that they are dry. Al-
ways follow the manufacturer’s instructions for use
regarding temperature range, curing time and any
other instructions for the product.
Two different basic types of agent are used on the
engine. These are:
RTV preparations (Room Temperature Vulcanizing).
Used for gaskets, sealing gasket joints or coating
gaskets. RTV is visible when a part has been disas-
sembled; old RTV must be removed before resealing
the joint.

The following RTV preparations are used on the en-
gine:
Volvo Penta sealant (silicone, cartridge 0.31 l, part
No. 116 1231, or tube 20 g., part No.116 1277) and
part No. 840879 (tube 25 g).
Remove old sealant with denatured alcohol.
Anaerobic agents. These agents cure in the absence
of air. These preparations are used when two solid
components, such as two cast components, are fitted
together without a gasket. Common uses are also to
lock and seal plugs, stud threads, taps, oil pressure
monitors etc.
Hardened anaerobic preparations are glassy and for
this reason, the preparations are colored to make
them visible.
Hardened anaerobic preparations are highly resistant
to solvents, and the old compound cannot be re-
moved. On re-assembly, it is important to degrease
components carefully first, wipe off and apply new
sealant in accordance with the instructions.
The following anaerobic preparations are used on the
engines:
Volvo Penta locking fluid (part No. 116 1053).
Safety Precautions for
Fluorocarbon Rubber
Fluorocarbon rubber is a common material in sealing
rings for shafts, and in O-rings, for example.
When fluorocarbon rubber is subjected to high tem-
peratures (above 300°C), hydrofluoric acid can be
formed, which is highly corrosive. Contact with the
skin can result in severe chemical burns. Splashes in
your eyes can result in severe chemical burns. If you
breathe in the fumes, your lungs can be permanently
damaged.
NOTE: As the illustrations in the service literature refer to
several engine variants, certain details may differ from any
particular engine. The essential information in the illustra-
tions is always correct, however.
General advice
WARNING! Be very careful when working on
engines which have been exposed to high
temperatures, e.g. overheating during a seizure
or fire. Seals must never be cut with a flame
torch during disassembly, or burned in uncon-
trolled circumstances afterwards.
● Always use gloves made of chloroprene rubber
(gloves for handling chemicals) and protective
goggles.
● Handle the removed seal in the same way as cor-
rosive acid. All residue, including ash, can be
highly corrosive. Never use compressed air to
blow anything clean.
● Put the remains in a plastic jar which is sealed
and provided with a warning label. Wash the
gloves under running water before removing
them.
The following seals are most probably made from flu-
orocarbon rubber:
Seal rings for the crankshaft, camshaft, idler shafts.
O-rings, regardless of where they are installed.
O-rings for cylinder liner sealing are almost always
made of fluorocarbon rubber.
Note that seals which have not been subjected to
high temperature can be handled normally.
9
 Special Tools
Special tools in the catalogue are divided into three categories:
– “Special tools category 1” (pages 10–14) comprises tools for the most common jobs (for i.e. a “mobile” work-
shop).
– “Special tools category 2” (page 15) comprise the tools which can be used as alternatives (hydraulic tools) and
tools for the tasks which are normally done in a larger workshop.
– “Other special equipment” (page 16) comprises tools where alternative equipment of a similar type can al-
ready be available in the workshop.

Special tools category 1

885 381 885536 885539 885810

3838620 3838621 3838622 3838623

383 8619 999 0006 999 0013

885 381 Sealing washers for pressure testing VODIA consists of:
heat exchangers or reverse gear oil 3838620 VODIA – hand computer (PDA) with
coolers SD-card.
885536 Expanding plug for pressure testing of 3838621 VODIA – docking station. Used with
charge air cooler VODIA PDA (3838620).
3838622 VODIA – cable with connector.
885539 Expanding plug for pressure testing of Used together with docking station
charge air cooler (3838621) on the engine communi-
885810 Fixing tool for the timing gear cover cation outlet.
383 8619 VODIA, complete diagnostics tool 3838623 VODIA – Adaptor EDC with external
power supply. Used with docking
station 3838621 and cable 3838622
connected to the engine’s 2-pin out-
let.
999 0006 Extractor for unit injector
999 0013 Slide hammer. Used together with
999 0006 and 999 0114

10
 Special Tools

999 0107 999 0114 999 0156 999 0157

999 0158 999 0164 9990166

999 0185 999 0192 999 0210 999 2000

999 0107 Sealing washer for thermostat housing 999 0166 Tool for mounting the rear crankshaft seal
when pressure testing the cylinder head 999 0185 Lifting tool for the rocker arm shaft
999 0114 Extractor for main bearing cap. Used 999 0192 Extractor for the rear crankshaft seal
with 999 0013 (alt. method). Used with 999 6400
999 0156 Adaptor (M16 /M10). Used together with 999 0210 Tool for removing and installing valve
999 6400 springs
999 0157 Press tool 1) for cylinder liner (7 pcs 999 2000 Handle for drifts 999 0183, 999 0184 re-
required) spectively 999 8238
999 0158 Piston ring compressor
999 0164 Sealing washer for pressure testing the
cylinder head

1)
Supplied individually.

11
Special Tools

999 2479 999 3590 999 6049 999 6394 2) 999 6395 2)

999 6398 999 6400 1) 999 6441 999 6591 999 6645 1)

999 6662 1) 999 6666 999 6845 999 6963

999 2479 Holder for dial indicator 999 6441 Cover with connecting nipple for cooling
999 3590 Cranking tool system leakage test
999 6049 Drain hose for coolant (fits cylinder block 999 6591 Connecting nipple (1/8"-27 NPSF) for
nipple) pressure monitoring
999 6394 Spacer 1) for removing cylinder liner 999 6645 Cylinder liner extractor
999 6395 Spacer 1) for removing cylinder liner 999 6662 Pressure testing device
999 6398 Manometer with quick-release connector 999 6666 Connecting nipple (M10 x 1) for pressure
(1.6 MPa) monitoring
999 6400 Slide hammer for removal of sealing 999 6845 Screw clamp 1) for oil cooler pressure
plug 999 8251 for cylinder head. 2) To- testing, motor (2 pcs required)
gether with 999 0192 also for removal of 9996963 Plate for removal or clamping of cylinder
camshaft caps or for removal of rear liner
crankshaft seal

1)
Supplied individually.
2)
Used together with adapter 999 0156.

12
 Special Tools

999 8248 999 8249 999 8250 999 8251

980 9667
980 9668

(998 7009)
(980 9746)

999 8252 999 8253 999 8264

999 8339 999 8487 999 8511 999 8517

999 8248 Adapter 1) for measurement of compres- 999 8253 Extractor for copper sleeves for unit in-
sion pressure (6 pcs required) jectors. Consists of:
999 8249 Protective sleeve 1) for unit injector (6 980 9668 Extractor for copper sleeve for unit-
pcs required) injector (M9)
980 9746 Extractor (M8). Not used
999 8250 Sealing ring 1) for fuel gallery in cylinder
head (2 pcs required) 999 8264 Lifting yoke for camshaft
999 8251 Sealing plug 1) for cylinder head (6 pcs 999 8339 Manometer with quick-release connector
required) (600 kPa)
999 8252 Thread cutting tool. Consists of: 999 8487 Socket for removing oil filter
980 9667 Thread cutting tool (M9) for removal 999 8511 Crowbar
of copper sleeves for unit injectors 999 8517 Tool for testl/installation of flywheel or
998 7009 Thread cutting tool (M8). Not used camshaft sensor position

1)
Supplied individually.

13
Special Tools

980 8618 980 8617

276948 999 8580

980 8570

980 8614

959239

999 8599 999 8601 999 8629 999 9179 1)

888 00011 888 00021 888 00064 888 00083 888 00102

888 00127 888 00137 888 00151

999 8599 Cleaning kit for unit injectors. Consists of: 888 00011 Guide sleeve for valve stem seal
276948 O-ring kit (replaces 999 0165)
959 239 Bolt M10 888 00021 Drift for fitting front crankshaft seal
980 8570 Brush, white
888 00064 Drift for fitting valve guides
999 8580 Sleeve
(inlet)
Holder
980 8634 Brush kit. Consists of: 888 00083 Piston ring pliers
980 8614 Brush, yellow (10 pcs) 888 00102 Expander tool (Ø 7.8 mm / 0.307") for
Holder (2 pcs) copper sleeve for unit injectors (replaces
Handle 999 8688)
980 8617 Wire brush, thin 888 00127 Drift for fitting valve guides
980 8618 Wire brush, course
(exhaust)
999 8601 Fixing tool for the timing gear cover
888 00137 Drift for removing valve guides (replaces
999 8629 Lifting eye 1) (2 pcs required) 999 0184)
999 9179 Filter extractor 888 00151 Drift for fitting valve stem seals

1)
Supplied individually.

14
 Special Tools

Special tools category 2

980 9726 980 9729 980 9771 980 9772 981 2524

999 0160 999 0174 999 0176 999 2670

999 6159 999 8246 888 00003 888 00123

980 9726 Pneumatic hydraulic pump (alt. to 999 0176 Press tool for removing and installing
999 2670) valve springs and valve guides
980 9729 Hydraulic cylinder for replacement of cyl- 999 2670 Manual hydraulic pump (alt. to 980 9726)
inder-liner and valve guides 999 6159 Dowel for hydraulic cylinder 999 6161
980 9771 Extension for 9812524 9998246 Tool for removing and installing valve
980 9772 Spacer for 9812524 springs, inlet
981 2524 Milling tool for cylinder liner seats 888 00003 Adapter for engine fixture 1)
999 0160 Fixture for attaching cylinder head to as- 888 00123 Engine fixture 1) (plate). Used with
sembly stand 88800003
999 0174 Tool for removing and installing valve
springs, exhaust

1)
Note Replaces 999 0143.

15
Special Tools

Other special equipment

885 633 885 648 885 811 885 812 115 9794

384 9613 998 6485 998 8539 1) 998 9876 1)

999 8493 999 9683 999 9693 1) 999 9696 1)

885633 Torque multiplier, 1/2"– 3/4" 998 8539 Compression gauge

885648 Counterhold for Torque multiplier 998 9876 Dial indicator
885811 Protractor, 3/4" 999 8493 Hose for pressure measurement
885812 Protractor, 1/2" 999 9683 Dial indicator
115 9794 Torque wrench, 3/8" (10 –100 Nm) 9999693 Diagram sheet for 998 8539
3849613 Pressure testing equipment, cooling 9999696 Magnetic stand
system
998 6485 Assembly stand

16
 Identification numbers

Location of engine signs and decals*

* Note. Some signs /decals do not appear on certain engine variants.

1. Engine decal 8. Engine designation and en- Identification decal,

2. Warning decal gine serial number (punched engine control unit (6)
on cylinder block) Chassis ID number (1)
3. Exhaust emission decal (EPA)
9. Warning decal Serial number, engine (2)
4. Identification decal, engine
control unit
5. Engine sign (classified engine) Engine decal (1) Type sign engine (8)
6. Identification decal, engine Engine designation (1) 1. Engine designation
control unit Serial number (2) 2. Serial number
7. Type plate, engine Specification number (3) 3. Specification number
(six last figures)

17
 Design and Function
Group 21: Short block

Cylinder Head
The cylinder head is cast in one piece from a cast
iron alloy to provide a stable bearing for the overhead
camshaft.
The thermostat housing is integrated in the cylinder
head (A).
The cylinder head has separate inlet and outlet chan-
nels with crossflow for each cylinder (B).
The fuel channel to the unit injectors has been drilled
lengthwise through the cylinder head and has a ring-
shaped space around each unit injector (C).
The oil pressure to the rocker arm mechanism can be
fed through the channel in plug (D).
For camshaft and rocker arm lubrication, a channel
has been drilled centrally in the left side of the cylin-
der head (E).
The valve guides are manufactured of alloyed cast
iron. All valve guides are equipped with valve stem
seals (oil seals). The valve seats are replaceable.

18
Group 21: Short block
Cylinder Block
The cylinder block is made of cast iron and cast in
one piece. The sides of the cylinder block are arched
around each cylinder, for high stiffness and good
sound damping.
All lubricating oil channels have been machined di-
rectly in the block. There are two longitudinal oil chan-
nels. The piston cooling channel on the right side and
the main lube oil channel on the left side. The chan-
nels are plugged front and back. The rear face also
has a channel for oil supply to the timing gear.
A bracing frame is fitted to the underside of the block
to reduce vibration and thereby also engine noise.
The oil pan is made from plastic and is attached with
spring loaded bolts. The seal between block and oil
pan consists of a rubber strip, in one piece, placed in
a groove in the sump.
Design and Function
The main bearing caps are aligned by pressed-in
sleeves in the cylinder block (1). To prevent incorrect
mounting, the caps are numbered 1–7 and have cast
bosses on both block (2) and caps (3). The underside
of the bearing caps are also marked with arrows,
which should be turned towards the engine’s inlet side.
The cylinder head gasket is made from steel. The
gasket incorporates vulcanized rubber seals for oil
and coolant channels. The gasket has also a number
of convex embossings* to allow the cylinder head to
slide on the gasket during installation, and to prevent
damaging the rubber rings in the gasket.
* Note. During installation, the cylinder head is lowered onto the
guide pins in the cylinder block at a small distance from the tim-
ing gear plate. After this, the cylinder head is pulled horizontally
towards the timing gear plate. When the cylinder head is in
place, it is tightened against the cylinder block and the emboss-
ings in the gasket are flattened.
19
Design and Function
Cylinder liner
The cylinder block is equipped with wet, replaceable
cylinder liners that are centrifugally cast of cast iron
alloy.
The coolant space around the cylinder liners is sealed
against the cylinder block with three sealing rings.
20
Group 21: Short block
The upper part is sealed by a ring below the liner col-
lar.
The lower part of cylinder liner is sealed using two
rubber rings. The top one, closest to the coolant, is
black and the lower one towards the oil side is purple.
Group 21: Short block
Pistons and con rods
The pistons are of aluminum and have three piston
rings.
The upper compression ring is a “Keystone” type
while the second compression ring is rectangular.
The lower ring is a spring-loaded oil scraper ring.
Design and Function
The con rods are forged and the lower big end is
“fracture-split” i.e. divided through a flat unmachined
surface. The upper end features a pressed-in bushing
that is lubricated via a drilled channel in the connect-
ing rod.
21
Design and Function
Crankshaft
The crankshaft is drop forged in one piece, and the
bearing surfaces are induction hardened for in-
creased strength and reduced risk of cracking.
The crankshaft has 7 main bearings with each big
end bearing located between two main bearings. The
thrust washers are located on the center main bear-
ing. Both the main and big end bearings have steel
shells which are plated with lead /nickel and lined with
lead bronze.
The crankshaft can be ground to all under-sizes with-
out re-hardening.
The crankshaft has an integrated hub for the timing
gear drive (at the rear) and for the oscillation damper /
belt pulley (at the front).
On the front edge of the cylinder block there is a cov-
er with a Teflon seal that seals against the front end
of the crankshaft. The seal has an external felt liner
that acts as a dust seal.
The vibration damper housing contains a freely rotat-
ing steel ring which serves as an inertial mass. The
space between the steel ring and the damper housing
22
Group 21: Short block
is filled with highly viscous silicone oil. Oscillations
are damped out by the oil, which evens out the pul-
sating motion of the crankshaft and the even move-
ment of the steel ring.
The crankshaft gear is fitted to the rear end of the
crankshaft. A guide dowel in the gear fits into the
crankshaft, so that it cannot be incorrectly mounted.
The end of the crankshaft has an O-ring that seals
between the crankshaft and the timing gears.
The timing gears are surrounded by the combined
timing gear cover / flywheel cover. A Teflon seal seals
between the cover and the crankshaft.
The crankshaft guide dowel extends back into the fly-
wheel, which therefore can only be mounted in one
position. The flywheel bolts are tightened through the
crankshaft gear, against the crankshaft.
The flywheel has a number of machined grooves for
the engine control system’s speed /position sensor.
Lubrication is via separate oil ways in the cylinder
block to each main bearing and from there via oil
ways to the nearest big end journal.
Group 21: Short block
Valve mechanism
The camshaft is overhead, and is induction hardened.
The bearing journals can be ground and fitted with re-
placeable bearing shells.
The camshaft is supported in seven bearing housings
that are line bored and numbered 1–7 seen from the
front of the engine. The rear bearing is also the thrust
bearing.
The camshaft has three lobes per cylinder. One for
the inlet valves, one for the exhaust valves, and a
lobe in the middle for the unit injector.
The camshaft gear is installed on the rear flange of
the camshaft with a hydraulic oscillation damper on
the outside. Both the camshaft gear and the oscilla-
tion damper have holes for a guide dowel mounted in
the camshaft, to prevent incorrect assembly. There
are teeth on the oscillation damper, which generate
signals in the camshaft sensor.
There is a flange with the camshaft marking in front of
the rear bearing housing (numerical marking 1– 6 and
TDC).* TDC is used for the basic camshaft setting
and should be between the two marks on the bearing
housing when the flywheel is at the 0° mark. The nu-
merical markings are used for adjusting the valves
and injectors.
* Note. TDC = “Top Dead Center”.
Design and Function
A rocker arm shaft with rocker arms supported on
pressed-in surface treated steel bushes is bolted to
the camshaft bearing caps. A valve yoke transfers the
rocker arm movement to the valves. The rocker arm
has a roller in contact with the camshaft, and a ball
socket and adjuster screw in contact with the valve
yoke.
The exhaust valves are operated via the valve yoke
using a guide pin while the inlet valves are operated
via a floating valve yoke (without guide pin)*.
The exhaust valves have double valve springs.
The valve guides are made from cast iron alloy and
the valve seats from steel. Both are replaceable as
spares.
All valve guides have valve stem seals.
* Note. Valve yokes without the guide pin (inlet) should be located
with the oval hole facing away from the camshaft.
23
Design and Function
Timing gear
The timing gears are located at the rear of the engine
on a 6 mm thick steel plate, bolted to the cylinder
head and engine block, and fixed with two guide
sleeves and a guide pin. All gear wheels have helical
teeth and are nitride hardened.
The crankshaft gear (5) also works as a spacer be-
tween the crankshaft flange and the flywheel. It is
screwed on with 12 pass-through bolts and fixed to
the crankshaft with two Allen screws and a guide pin.
Above the crankshaft gear is a bull drive (3) consist-
ing of two gears screwed together. The gear wheels
are pre-installed on a hub journalized on two conical
roller bearings. The inner gear wheel drives the upper
(adjustable) idler gear (2) which in turn drives the
camshaft gear wheel (1) and is journalized on a bush
in the hub.
24
Group 21: Short block
1. Camshaft gear
2. Upper idler gear
3. Bull drive
4. Lower idler gear
5. Crankshaft gear
6. Drive gear, lube-oil pump
7. Drive gear, fuel pump
The backlash shall be adjusted between the upper
idler gear (2) and the camshaft gear wheel (1) when
the timing gears have been serviced.
The camshaft gear (1) is bolted to the camshaft
flange and located with a guide pin. An oscillation
damper is mounted outside the camshaft gear. The
oscillation damper has teeth for the camshaft sensor.
The lower idler gear (4) is journalized in a double-row
ball bearing and drives the fuel pump. The gear is
fastened with a bolt that runs through the flywheel
cover and is threaded into the cylinder block.
Gear (7) drives the fuel pump.
The oil pump drive gear (6) is driven directly from the
crankshaft gear.
 Group 22: Lubrication System
The engine is pressure lubricated by a gear pump
connect to the engine’s timing gears. The oil flow is
controlled by 7 valves.
The lubricating oil pump is driven directly by the
crankshaft gear and supplies pressurized oil to two
full-flow filters and a by-pass filter. The by-pass filter
has low flow and a high degree of filtration.
Two channels are drilled along the cylinder block,
where the one in the left side of the block is the lubri-
cating oil channel that supplies all bearings on the
crank mechanism with oil. The lubricating oil channel
is plugged at both the front and rear.
The other channel (on the right side of the block) is
the piston cooling duct, which provides the pistons
with oil for lubrication and cooling. The piston cooling
channel is plugged at both ends.
All bearings in the cylinder head are lubricated from
the hollow rocker bridge connected with the cylinder
block via a cast channel located centrally in the block.
The oil pump housing is made from aluminum. The
pump is driven directly by the crankshaft gear. The oil
pump housing and the two pump gears are matched
and cannot be exchanged separately. The pump gear
shafts are journalized directly in the oil pump housing.
Suction and delivery pipes are made of steel and are
sealed against the pump cover and the oil distribution
housing with rubber seals.
The pump housing is screwed into the cylinder block
foot and acts as a bracket for the suction strainer,
which is also secured to the bracing frame. The lube
oil pump safety valve is located in the filter housing.
The oil cooler is of the flat plate type and is located on
the right of the engine, on the inside of the cooling
jacket side cover. The oil cooler is immersed in cool-
ant.
25
Design and Function
1
7
5
6
4 3
Valves and lubrication system
1. Overflow valve for by-pass filter
The overflow valve opens (>1.1 bar / 15.9 psi) if the
filter becomes blocked and secures the oil supply to
the turbocharger.
2. Overflow valve for full-flow oil filter
The overflow valve opens (>2.1 bar / 30.4 psi) if the
filter becomes blocked and thereby secures lubrica-
tion.
3. By-pass valve for oil cooler
When the pressure drop across the oil cooler is high,
i.e. after starting when the oil temperature is low, the
by-pass valve opens and oil passes by the oil cooler.
When the oil temperature rises and pressure drop
across the oil cooler falls (< 3.0 bar / 43.5 psi), the
valve closes and oil passes through the oil cooler be-
fore it is forced out into the lubrication system.
4. Piston cooling valve
The piston cooling valve opens when engine revs
have increased to slightly above idle.
26
Group 22: Lubrication System
2
Oil then flows via the control valve (5) through the pis-
ton cooling channel to the six piston cooling nozzles.
From them, the oil is sprayed up to the pistons and
then drains back to the lube oil system.
5. Control valve for piston cooling
The control valve (5) maintains the piston cooling
pressure at a constant level once the piston cooling
valve has opened.
6. Pressure reduction valve, lube oil pressure
The reduction valve controls the oil pressure by open-
ing at too high a pressure and feeding the excess oil
back to the oil pan. The valves is a unitary valve and
is marked blue.
7. Safety valve, lube oil pressure
The safety valve opens when oil pressure is too high
and the oil escapes back to the oil sump. The valve is
a unitary valve and is marked purple.
Group 22: Lubrication System
5 4
Piston cooling
Oil for the piston cooling is filtered through the full-
flow filters, and is controlled by two spring loaded
sleeve valves.
The piston cooling valve (4) senses the oil pressure
and is directly connected to the filtered oil channel.
The valve is a spring-loaded sleeve valve that opens
and closes the oil flow to the piston cooling (opens
above 2.5 bar / 36.3 psi, closes below 2.5 bar / 36.3
psi).
The control valve (5) provides a constant piston cool-
ing pressure independent of engine speed.
Design and Function
The valve is a spring-loaded sleeve valve. Oil enters
through the lower chamber and passes the hole in the
wall to the upper chamber. The pressure from the oil
that is led upwards via the channel pushes the sleeve
down. The sleeve waist controls the flow through the
wall and thus the piston cooling pressure, which is
held constant.
The pistons are cooled via cavity cooling. Oil is
sprayed vertically up a channel in the piston via the
piston cooling nozzles in the cylinder block. The oil
then continues up to a circular channel in the top of
the piston and is drained back to the oil pan.
27
 Group 23: Fuel System
There is an electronically controlled unit injector for
each cylinder, which works at a very high pressure.
The pressure is generated mechanically from the over-
head camshaft, via the rocker arms. The injection is
controlled electronically from the engine control unit.
The fuel feed pump (1) sucks fuel from the tank
through the fuel pre-filter (2) and past the fuel shut-off
valve (3) to the feed pump suction side. The feed
pump then pumps the fuel to the filter housing (4),
through the fine filter and via the fuel shut-off valve up
to the cylinder head fuel channel (5). The fuel channel
supplies each unit injector (6) with fuel via a ring-
shaped space around each injector. The overflow
valve (7) controls the fuel pressure to the injectors.
There is a built-in purging valve in the overflow valve.
Any air in the system flows together with a small
amount of fuel back to the tank via the fuel line (8).
Fuel is fed out of the front of the cylinder head and
further via the fuel shut-off valve, through the overflow
valve (11) up to the filter housing where it is mixed
with the fuel from the suction side before it is fed back
to the feed pump.
28
There are two valves in the fed pump. The safety
valve (10) allows the fuel to flow back to the suction
side if the pressure is too high (i.e if the fuel filter is
blocked). The check valve (9) opens when the hand
pump (12) on the fine filter housing is used.
When the fuel shut-off valve (3) is activated, the fuel
flow changes direction so that the feed pressure to
the cylinder head fuel channel quickly drops and the
engine stops.
IMPORTANT! Observe the greatest possible
cleanliness when working on the fuel system. Al-
ways clean the engine thoroughly before starting
any repair work. Always fit protective plugs
when connections are removed, to prevent con-
taminants from entering the fuel system. Store
removed parts in sealed plastic bags until they
are reinstalled.
IMPORTANT! Please refer to “Instructions for
operating the starter motor” on page 41, if the
engine needs to be cranked by the starter motor
for some reason without risking an inadvertent
start.
NOTE: For specifications, please refer to “Tech-
nical Data”.
Group 23: Fuel System
A. The unit injector is a combination of an injection
pump and an injector that works at a much higher
pressure than an ordinary injector. The opening
pressure is approx. 320 bar (4641 psi) and the
working pressure can be up to 2000 bar (29007
psi).
The injection timing and the volume of fuel to be
injected is determined by the engine control unit,
which sends signals to solenoid fuel valves built
into the unit injectors. The pressure force in the
unit injector is taken from a lobe on the camshaft
via a rocker arm.
B. The fuel filter housing has a hand pump for purg-
ing the fuel system. Draining water takes place
by hand at the water trap on the fuel pre-filter. A
built-in check valve in the pump prevents the fuel
from flowing back when the engine is shut-down.
C. The gear-type feed pump is driven from the
crankshaft by an idler gear. High feed pressure is
needed to ensure complete filling of the unit injec-
tors. The flow must be sufficient to even out any
temperature differences in the cylinder head fuel
channel.
Design and Function
D. The engine control unit is attached to the engine
via four vibration absorbing rubber mounts.
The control unit receives continuous information
from a number of sensors on the engine, to allow
it to calculate the fuel volume and timing for injec-
tion. Control signals to the unit injector fuel valves
are sent via electric cables. The control unit
stores any faults and divergences which occur in
the system. Intermittent faults are also stored so
that they can be traced at a later date.
E. Excess fuel form the overflow valve is mixed with
fuel from the suction side of the filter housing and
is fed back to the feed pump.
The feed pressure to the fuel system is controlled
by a bypass valve that is integrated in a hollow
screw, located in the return line from the cylinder
head. Opening pressure is 400 –550 kPa (58 –
79.8 psi). The high feed pressure is required to
ensure complete filling of the unit injectors. The
bypass valve also has an integrated purging
valve that automatically purges the system, al-
lowing a small volume of fuel back to the tank.
29
Design and Function Group 23: Fuel System

Unit injectors, working phases

The working sequence of the unit injector can be
divided into four phases:
● Filling phase
● Leak-off phase
● Injection phase
● Pressure reduction phase

The pump piston always forces the same amount of

fuel back and forwards through the injector. It is only
when the fuel valve is closed that the pressure is built
up and injection takes place. The duration and timing
of the impulse signal determines the volume of fuel
injected and its timing.

Filling phase
During the filling phase, the pump piston (1) travels
towards its upper position. The highest point on the
camshaft lobe is passed and the rocker is on the way
down towards the camshaft base circle.
The fuel valve (3) is open, since the solenoid valve is
1 not powered. Fuel from the fuel channel in the cylin-
der head can therefore flow past the fuel valve and
into the unit injector’s pump cylinder.
3 Filling continues until the pump piston reaches its up-
per position.
1. Pump piston
2. Injector needle
3. Fuel gallery
2

Leak-off phase
The leak-off phase starts when the camshaft has
come to the position where the cam lobe operates the
rocker and starts to press the pump piston (1) down.
1 The fuel can now flow backwards through the fuel
valve (3) and back into the fuel duct.
The leak-off phase continues for as long as the fuel
3 valve is open.

1. Pump piston
2. Injector needle
3. Fuel gallery 2

30
Group 23: Fuel System Design and Function

Injection phase
The injection phase starts when the solenoid valve is
activated by the control unit, and the fuel valve (3)
closes.
1 The camshaft lobe continues to press the pump pis-
ton (1) down, via the rocker arm. Since the passage
through the fuel valve is closed, pressure quickly
builds up. The pressure lifts the injector needle and
injection takes place.
3 The injection phase continues for as long as the fuel
valve is closed.

1. Pump piston
2. Injector needle
3. Fuel gallery

Pressure reduction phase

The pressure reduction phase starts when the engine
control unit considers that the engine has received
the fuel it needs. The control unit then cuts the elec-
tric impulse to the solenoid valve, the fuel valve
opens and the fuel flows back out to the fuel channel.
This means that the pressure quickly falls below the
1 injector opening pressure, the injector needle closes
and injection is terminated.
Please note that it is the position of the fuel valve,
1. Pump piston
3
(closed or open), which determines when injection will
2. Injector needle
start and finish.
3. Fuel gallery
The time that the fuel valve is closed determines the
amount of fuel injected for each pump stroke.
2

31
 Group 25: Inlet and exhaust system

Turbocharger
The turbocharger is driven by the exhaust gas which When the compressor wheel rotates, air is sucked in
passes through the exhaust turbine housing on its via the air filter. Air is compressed and pressed into
way out of the exhaust system. the engine cylinders after it first has been cooled by
The exhaust flow makes the exhaust turbine rotate passing through the charge air cooler.
and drives the compressor turbine, which is mounted
on the same shaft. The compressor turbine is located
in a housing that is connected between the air filter
and the charge air cooler/engine inlet manifold.

32
Group 25: Inlet/Exhaust systems Design and Function

1 Closed crankcase ventilation

(option)
The engine can be supplied with closed crankcase
ventilation. In these cases, the engine is equipped
with a separator and a centrifugal oil separator that is
2 driven by the engine oil pressure.
The separator separates oil from the oil mist in the
crankcase gases before the gases are recirculated to
the engine.

4
1. Uncleaned crankcase gases from the engine
2. Filtered crankcase gas is returned to the engine
3. Lube oil under pressure to operate the oil separator
4. Lube oil returned to the oil pan

33
 Group 26: Cooling System

Flow diagram for engine with heat exchanger

1. Coolant pump 6. Exhaust manifold 11. Heat exchanger
2. Oil cooler, engine 7. Turbocharger 12. Priority valve
3. Piston thermostat 8. Charge air cooler 13. Oil cooler, reverse
4. By-pass valve 9. Expansion tank gear (extra equip.)
5. Cylinder block/head 10. Seawater pump

Cooling System
The engine cooling system is divided into two sepa-
rate circuits.
The engine’s internal cooling system is a closed
freshwater system, with a piston thermostat which
regulates the coolant temperature.
The coolant from the heat exchanger is pumped by
the coolant pump into the cylinder block distribution
jacket on the right side of the block. Some of the cool-
ant is pressed into the cylinder liner lower cooling
jacket. The greatest quantity of coolant is pressed up-
wards through the oil cooler and then to the liner up-
per cooling jacket. The return coolant from the liner
jacket also flows to the cylinder head.
All coolant flows via the thermostat to the heat ex-
changer or back to the coolant pump, depending on
the engine temperature.
A spring-loaded by-pass valve (“cold start valve”) is
located on the front of the cylinder head.
mined coolant pressure and allows a certain amount
of coolant to bypass the thermostat. The coolant in
the air charge cooler is thus able to circulate and
overheating of the cooler is thus avoided.
The seawater system is the engine’s external cooling
system. In the heat exchanger, heat is transferred
from the internal cooling circuit in the engine (fresh-
water system) to the outer circuit (seawater).
A priority valve controls the coolant flow through the
heat exchanger. 1)
The engine can also be equipped with hull cooling.
The coolant circulates in the closed system, driven by
the engine coolant pump (engine circuit), or with the
assistance of a separate impeller pump located on
the flywheel cover (charge air cooling circuit).
1)
The greatest part of the heat exchanger capacity is used to cool
the engine. The rest of the capacity cools the coolant further be-
fore it is passed on through the charge air cooler.

Under heavy engine loading and with a cold engine

(thermostat closed), the valve opens at a pre-deter-

34
Group 26: Cooling System Design and Function

Charge air cooler

In the charge air cooler, the heat from the induction
air is transferred to the engine freshwater system.
The cooler is located above the flywheel cover at the
rear of the engine.
The inlet air passes the charge air cooler after
compression in the turbocharger. The charge air cool-
er reduces the temperature of the air, thus improving
cylinder filling considerably, since the volume of the
air is reduced. More air (oxygen) can then be pressed
into the engine cylinders and burn a larger volume of
fuel in each working cycle. I.e. the power is in-
creased. Charge air cooling also contributes to lower-
ing the thermal loading on the engine.

1 3

Engine adapted for hull cooling

1. To hull cooler (engine circuit)
2. From hull cooler (engine circuit)
3. To hull cooler (charge air cooler circuit)
4. From hull cooler (charge air cooler circuit)

35
 Fault Tracing
A number of symptoms and possible causes of engine malfunctions are described in the table below.

Symptoms and possible causes

The diagnostics button indicator blinks Refer to workshop manual

“Group 30, Electrical system”

Engine cannot be stopped 2, 4, 5, 7

Starter motor does not rotate 1, 2, 3, 4, 5, 6, 8, 9, 10, 11, 37, 40, 43

Starter motor rotates slowly 1, 2

Starter motor rotates normally but the engine does not

star t/is difficult to start 12, 13, 14, 15, 39, 40, 41

Engine starts but stops again 12, 13, 14, 15, 20, 40

Engine does not reach correct operating speed at full throttle 13, 14, 15, 16, 17, 18, 19, 20, 21,
24, 34, 38, 40, 42

Engine runs roughly 14, 15, 42

Engine vibrates 25

High fuel consumption 16, 17, 19, 22, 38

Black exhaust smoke 20

Blue or white exhaust smoke 22, 35, 44

Lubrication oil pressure too low 23

Coolant temperature too high 26, 27, 28, 29, 30, 31, 32, 33

Coolant temperature too low 32

No, or poor charge 2, 36

1. Flat batteries 17. Fouling on hull/propeller 30. Blocked seawater inlet/lines/filter

2. Poor contact /open circuit in wiring 18. Cables for unit injector damaged 31. Defective impeller in the sea water
3. Main switch turned off (open circuit) pump
4. One of the fuses in the distribution 19. Faulty unit injector 32. Defective thermostat
box has blown 20. Insufficient air supply to engine: 33. Blocked heat exchanger / cooler
5. Faulty ignition lock – blocked air filter 34. Blocked charge air cooler
6. Control lever is not in neutral- – air leakage between turbocharger 35. Too high oil level
position/helm station not activated and engine inlet pipe 36. Alternator drive belt slips
7. Faulty stop relay – fouled compressor section in 37. Water entry into engine
8. Faulty main relay turbocharger
38. High back pressure in exhaust sys-
– faulty turbocharger
9. Faulty starter relay tem
– poor engine bay ventilation
10. Faulty starter motor relay 39. Faulty engine speed sensor
21. Excessive coolant temperature
11. Faulty starter motor/solenoid 40. Stored fault codes*
22. Coolant temperature too low
12. Lack of fuel: 41. Check valve in fuel line (suction
23. Lube oil level too low/faulty oil pump
– fuel stopcocks closed side) leaks
24. Defect i v e /faulty propeller
– fuel tank wrong tank selected 42. Check valve in feed pump leaks
25. Faulty engine mounting
13. Blocked fuel fine/pre-filter (caused 43. Check that the extra stop button is in
by contamination or fuel stratification 26. Coolant level too low the RUN position (not depressed)
at low temperature) 27. Air in the freshwater system 44. Faulty piston ring seals in the turbo-
14. Air in the fuel system 28. Faulty circulation pump charger
15. Water / contaminants in fuel 29. Closed seawater inlet
* Note. Refer to workshop manual “Group
16. Boat abnormally loaded 30, Electrical system” for further informa-
tion.

36
 Troubleshooting /Tests and adjustments

Location of measurement outlets

The figures below and on the next page show where mea-
surement equipment can be connected to the engine.

1. Charge air pressure/temp. after
charge air cooler (1/8"-27 NPSF).
Note. Upper plug has M10 x 1
thread.
2. Seawater temp./pressure (pump de-
livery side) (1/8"-27 NPSF).
3. Fuel supply pressure (before filter).
Drill and thread a hole (M10 x 1) in a
hollow bolt (part No. 190713).
Fit the bolt to the inlet of the fuel fil-
ter.
4. Fuel supply pressure (after filter).
Remove the purging nipple on the
filter bracket (M10 x 1).
5. Seawater temp/pressure (pump suc-
tion side) (1/8"-27 NPSF).
6. Lube oil pressure/temp (M12 x 1.5 in
block). 1/8"-27 NPSF if reduction
nipple (part No. 947899) is used.
7. Crankcase pressure (M16 x 1.5).

37
Troubleshooting /Tests and adjustments
8. Exhaust back pressure/temperature
(1/8"-27 NPSF).
9. Negative pressure, air filter. The
pressure drop indicator is omitted
(1/8"-27 NPSF).
* Note. Plug missing on earlier engines.
38
10. Piston cooling oil pressure. Remove
the sensor and angled nipple
(1/8"-27 NPSF).
11. Charge air pressure/temp. before
charge air cooler (1/8"-27 NPSF).*
12. Coolant pressure/temperature.
Classified engine (M18 x 1.5).
13. Coolant pressure/temperature.
Non-classified engine (M18 x 1.5).
 Troubleshooting /Tests and adjustments

Actions with low charge air

pressure
1. Air inlet
Check that the ventilation inlet to the engine room
is large enough. Please refer to the installation in-
structions.

2. Air filter
Check that the air filter is not blocked (pressure
drop indicator shows red) and that the correct fil-
ter is in use. Change filter as necessary.

3. Sealing
The inlet and exhaust manifolds and other unions
must not have any leaks. Also check that the
joints between the compressor bearing housing
and turbine and the compressor housing itself
seal correctly.

4. Turbocharger
Check that the rotor shaft does not bind and that
the exhaust turbine or compressor turbine do not
rub against this housings. Turn the wheel, firstly
with light pressure, then after displacing the shaft
axially. If the turbine is stiff to turn, the turbo-
charger must be changed or overhauled as soon
as possible. Check the turbines for damage.
If the engine is operated in dusty or oily air every
day, regular cleaning of the compressor housing
and compressor turbine is recommended. A
fouled compressor section can cause low charge
air pressure.
The compressor section can be cleaned with the
unit installed, as follows:
Remove the compressor housing. Clean the
compressor housing, compressor turbine and
end wall in white spirit or equivalent substance.
Install the compressor housing and tighten the V-
clamp to 12.2 ±0.7 Nm (9 ±0.5 lbf.ft).
Measure the charge air pressure again.

5. Charge air cooler

Check that the charge air cooler is not blocked.
Clean as necessary, according to the instruction
on page 201.

39
Troubleshooting /Tests and adjustments

6. Exhaust back pressure

Check that the back pressure in the exhaust sys-
tem is not too great in the finished installation.
Refer to “Exhaust back pressure, checking” on
page 48.
7. Feed pressure
Replace the fuel filter if required. There shall be
no fuel leakage. Check that no air comes into the
system on the suction side.
8. Unit injector
Check the cables and that the correct unit injector
is used.
Coolant temperature too high
Excessive coolant temperature can be caused by:
● Blocked seawater filter
● Worn impeller or seawater pump
● Faulty temperature gauge
● Low coolant level
● Blocked heat exchanger
● Faulty thermostat
● Blocked cooling system

9. Engine condition
Check the valve clearance and cylinder pressure.

Coolant temperature too low

Low coolant temperature can be caused by:
● Faulty temperature gauge
● Faulty thermostat

Coolant losses
There are two types of coolant losses:
● Coolant losses during operation.
● Coolant losses from a hot, stopped engine.
Coolant losses during operation can be caused by
poor sealing in the cooling system, or that air or com-
bustion gases are forced into the cooling system and
force coolant out through the pressure cap. The fault
can be caused by a leaky cylinder head gasket.
Coolant losses after stopping a hot engine are gener-
ally due to a faulty pressure valve in the filler cap.

40
 Troubleshooting /Tests and adjustments

Instructions for operating the

starter motor
1
Remove the two thin wires from the starter motor
control relay.
Connect one of the now unoccupied control relay ter-
minals to the negative terminal (–) on the starter motor.

2
Connect a switch (e.g. part No. 843 684) with at least
2.5 mm2 cross-section cable between the other termi-
nal on the starter relay and the positive terminal (+)
on the starter motor solenoid.
WARNING! There is a risk of high short-circuit
current if wrongly connected.

NOTE: Do not operate the starter motor for intervals

longer than 15 seconds. Then let the batteries and
starter motor rest for a few minutesr* before operating
again.
* Note. The cover of the starter motor may not get hot (max. 100°C).

After completed starter motor operation:

3
Remove the switch with cables. Replace the two thin
wires on the starter motor control relay.

If the engine is cranked with the starter motor via

the ignition switch/starter button:
IMPORTANT! To ensure that the engine can-
not start, the following instructions must be
followed carefully.

Remove the two engine speed sensors (the control

unit does not receive a signal then, and the engine
cannot start).
NOTE: Save any spacer washers (shims) and fix
them to their sensor, to facilitate re-assembly.

Refit the speed sensors after completion.

NOTE: Make sure that the shims are mounted with
the correct sensors.

41
Troubleshooting /Tests and adjustments

21002

Compression test
Fuel system empty* and rocker arm bridge
removed
* NOTE: Empty the fuel channel in the cylinder head. Refer to
“Draining, fuel channel in cylinder head” on page 168.

Special tools:
Lifting device ............................................. 999 0185
Adapter (6 pcs) .......................................... 999 8248
Compression gauge .................................. 999 8539

NOTE: The engines are fitted with a “keystone” type

upper compression ring. This type of ring requires
gas pressure to function optimally. Measurement re-
sults with this type of compression ring can therefore
give faulty indications.
A simpler and more reliable test can be performed
with the VODIA-tool (refer to “VODIA User guide”).

1
Remove the unit injectors and clean the copper
sleeves as necessary.
IMPORTANT! Make sure that the area around
the unit injectors is clean before they are re-
moved.

2
Fit all the adapters (999 8248) to the cylinder head (to
avoid repeated removal/fitting of the rocker arm
bridge and unit injectors and adjustment of the valve
clearances six times).

3
Oil the valve yokes, camshaft lobes and rocker
bridge.

4
Lift the rocker bridge into place with lifting tool
999 0185.
NOTE: The marks (D16) on the tool shall be directly
in front of the rocker shaft fixing points on the engine.
Tighten the bolts alternately along the rocker shaft to
prevent bending or skewing the shaft.
Check that the rocker shaft fits properly onto the
guide sleeves on the camshaft bearing blocks.
Tighten the rocker bridge according to the tightening
diagram in “Technical data”.

42
 Troubleshooting /Tests and adjustments

5
Mount the intermediate part and oil pipe to the rocker
bridge.

6
Check the valve clearances for all valves according to
the specification in “Technical data”.

7
Connect a switch to the starter motor. Refer to “In-
structions for operating the starter motor” on page 41.

8
Connect compression gauge 998 8539 to adapter
999 8248 on the first cylinder.

9
Crank the engine with the starter motor until the nee-
dle on the compression gauge stops moving (max.
compression value) and read off the value.
Repeat the test on all the other cylinders.
NOTE: Do not run the starter motor for more than
15 seconds at once, with a rest of a few minutes.

10
Remove the intermediate part and the oil pipe from
the rocker bridge.

11
Undo all the rocker bridge bolts (equal amounts, in
turns) so that the bridge is not bent.

12
Remove the bolts and carefully lift away the rocker
bridge with lifting tool 999 0185.
NOTE: The marks (D16) on the tool shall be directly
in front of the rocker shaft fixing points on the engine.

13
Drain the fuel channel in the cylinder head, see
“Draining, fuel channel in cylinder head” in chapter
“Overhaul/Replacing components”.

43
Troubleshooting /Tests and adjustments

14
Remove adaptors 999 8248 from all cylinders.

15
Install the unit injectors with new O-rings, refer to
“Unit injector, replace”
Install the rocker shaft.
NOTE: Torque the bolts evenly along the rocker shaft
to avoid that the rocker arm bends or warps.
Adjust the valves and unit injectors, refer to “Valves
and unit injectors, adjustment”

16
Purge the fuel system, refer to “Fuel system, purging”
on page 180.

Fuel feed pressure, checking

Special tools:
Connecting nipple ..................................... 999 6666
Hose ......................................................... 999 8493
Manometer ............................................... 999 8339

IMPORTANT! Clean nipple and hose carefully

before they are connected to the fuel system.
The unit injectors are sensitive and can easily be
damaged by contamination.

1
Clean the fuel filter bracket carefully.

2
Remove the purging nipple and fit nipple 999 6666.
Connect hose 999 8493 and manometer 999 8339.

3
Make sure the control lever is in neutral.

4
Start the engine and run at approx. 1000 r.p.m. until
the feed pressure on the manometer has stabilized.

44
 Troubleshooting /Tests and adjustments

5
Compare the measured max. feed pressure with that
given in “Technical data”.
The measured value is the feed pressure after the fil-
ter.

6
Remove the measurement equipment and purge the
fuel system after completion. Refer to “Fuel system,
purging” on page 180.

Note. Low feed pressure can be the result of a

blocked fuel filter, a defective overflow valve or a de-
fective feed pump.
NOTE: The overflow valve may not be adjusted. Re-
place the valve if necessary.

25502

Charge air pressure, checking

Special tools:
Connecting nipple ..................................... 999 6591
Hose ......................................................... 999 8493
Manometer ............................................... 999 8339*
* Note. As an alternative, manometer 999 6398 can be used.

1
Fit nipple 999 6591 on the front of the inlet manifold
(lower connection). Connect hose 999 8493 and ma-
nometer 999 8339 (or 999 6398) to the nipple.

2
Run the engine at full power (max. operational
speed) and read off the charge air pressure. If full
power cannot be developed, the pressure will be con-
siderably lower.
Refer to the “Technical Data” chapter for the charge
air pressure.

3
Compare the pressure with the pressure that can be
read off with the VODIA tool.
If the two measurements show different values, the
pressure sensor is faulty and must be changed.

45
Troubleshooting /Tests and adjustments

Charge air pipes, checking 25507

1 Turbocharger, checking
Check the charge air pipes for visible cracks and ex-
ternal damage. 1
Check that the turbocharger part number corre-
sponds to the engine variant. The wrong turbo can
2 give low charge pressure and reduce the engine pow-
Check that there is no oil in the charge air pipes. If er.
the pipes are damaged or the union seal rings leak,
the charge pressure will be too low and engine perfor-
mance will be affected. 2
Check that the correct compressor housing is fitted to
If the pipes are internally contaminated with oil, there
the turbocharger. If the wrong compressor housing
is probably an oil leak from the turbocharger shaft
has been fitted, the compressor turbine may have
seal. In such a case, the turbo should be overhauled
been damaged or there may be too much clearance
or replaced complete.
between turbine and housing. In both cases the
NOTE: If there is any oil in the charge air pipes and charge air pressure will be too low.
charge air hoses, the charge air cooler and all pipes
and hoses in the charge air system must be cleaned
very carefully before the engine is started. 3
Remove the air filter and exhaust pipe from the turbo-
charger.

4
Check the compressor turbine and exhaust turbine
for damage. If there is damage, the turbo should be
overhauled or replaced complete.

5
Check the turbine shaft’s axial and radial clearances,
according to instructions on page 184 –185. If the
bearing play is too great, the turbo should be over-
hauled or replaced complete.

46
 Troubleshooting /Tests and adjustments

Exhaust back pressure,

checking
Special tools:
Manometer ............................................... 999 6398*
Connection nipple ..................................... 999 6591
* Note. As an alternative, manometer 999 8339 can be used.

1
Fit nipple 999 6591 to the exhaust bend. Connect ma-
nometer 999 6398 (or 999 8339) to the nipple.

2
Run the engine at full power (max. operating speed)
for a sufficient time to stabilize the value being
checked.
Check that the back pressure does not exceed the
permissible value. Refer to “Technical Data” in the
workshop manual.

26001

Coolant pressure, check

Special tools:
Connecting nipple ...................................... 999 6666
Manometer ................................................ 999 8339
Hose .......................................................... 999 8493

1
Drill and tap a hole (M10 x 1) in a plug “A”
(M18 x 1.5 – part No. 982293). Fit the plug with a
copper washer (part No. 947624) to the cylinder
block’s right side above the oil filter bracket (refer to
figure).

2
Fit nipple 999 6666 to the plug and connect hose
999 8493 and manometer 999 8339.
WARNING! Coolant will flow out when the plug
in the engine block is undone. Warning for burns
if the engine is hot.

3
Run the engine at full operating speed and read off
the coolant pressure. Refer to “Technical data” in the
workshop manual for coolant pressure.

47
Troubleshooting /Tests and adjustments

Seawater pressure, checking

Special tools:
Manometer ............................................... 999 6398*
Connection nipple ..................................... 999 6591
* Note. As an alternative, manometer 999 8339 can be used.

Pressure side, pump

1
Fit nipple 999 6591 to the coolant pipe between the
seawater pump and the heat exchanger. Connect
manometer 999 6398 (or 999 8339).
WARNING! Seawater in the heat exchanger will
flow out when the plug in the seawater pipe is
undone. Seawater can also flow in if the impeller
is faulty.

2
Run the engine at full operating speed and read off
the seawater pressure. Refer to “Technical data” in
the workshop manual for seawater pressure.

48
 General advice

General advice Before lifting the engine

1
When working with chemicals, Remove battery power. Undo the connections from
the starter motor.
fuel and lubricating oil
IMPORTANT! Lubricate hands with a barrier 2
cream and always use protective gloves during Disconnect the engine and instrument wiring connec-
work where you risk contact with oil, fuel, etc. tor block(s).
Continuous skin contact with engine oil dries
your skin and can be hazardous. 3
Remove the seawater or hull cooling connections.

4
Remove the exhaust system.

5
Close the fuel stopcocks.
Remove the fuel connections.
Before working in a boat
1 6
Disconnect power at the main switch and check that Undo the two cable connections from the connection
the engine is without power. box and the wiring to the reverse gear.

2 7
Clean the outside of the engine. Disconnect the propshaft from the reverse gear.
NOTE: Make sure that wash residue is collected for Undo the engine mounting pads from the bed and lift
destruction and does not inadvertently end up in the the engine out.
water.

3
Work involving the cooling system:
Close the sea cocks and drain the coolant from the
seawater- and freshwater systems.
WARNING! Make sure that all seawater inlets
are securely closed, so that water cannot find its
way in during removal of cooling system compo-
nents.

49
General advice

Actions after lifting the engine General advice when working

1 on EVC engines
Clean the engine.
WARNING! Remember the following when
washing with a power washer: Be extremely
careful when cleaning, to avoid getting water in-
side engine components. When a power washer
is used, the water jet must never be aimed at
seals, such as shaft seals, joints with gaskets,
rubber hoses or electrical components.
The following advice must be followed to avoid
damage to the engine control unit and other elec-
tronics.
IMPORTANT! The system must be without pow-
er and the starter key(s) be in position 0 when
the connector(s) for the engine control unit are
disconnected or reconnected. Turn off the power
with the main switches.

● Never disconnect the power with the main switch-

2 es when the engine is running.
Pump out the engine oil (if required).
● Never disconnect the battery cables when the en-
gine is running.
3
Remove the reverse gear (if required). ● Turn off the main switches or disconnect the
battery cables when fast-charging the batteries.
NOTE: The main switches do not need to be
turned off during normal charging.

● Only batteries may be used as starting help. Start-

ing devices can create over-voltage and damage
the engine control unit and other electronics.

● When performing electric welding, refer to the in-

structions under heading “Electrical welding” on
the following page.
General advice for pressure ● Be careful to ensure that the connector pins do not
come into contact with oil, water or dirt if a
measurement connector is undone.

999 6398 999 6591 999 6666 999 8339

999 8493

The same hoses and nipples are used to check oil,

water and fuel pressure. Clean the tools carefully be-
fore pressure testing.
IMPORTANT! Be specially careful before check-
ing the fuel feed pressure. The unit injectors are
sensitive and can easily be damaged by con-
tamination.

50
 General advice

Electric welding
IMPORTANT! Disconnect the connectors from
the engine control unit and the 8-pin connector
for the PCU before starting electric welding.

IMPORTANT! The system must be disconnect-

ed from power and the starter key(s) must be in
position 0 when the engine control unit connec-
tors* are disconnected or connected*.

1
Disconnect power at the main switch(es). Disconnect
the connectors from the engine control unit (move the
locking bar (1) backwards and remove the connec-
tor).
Refer to the figures or more detailed instructions un-
der the “Control unit, replace” heading on page 169.

2
Remove the connector from the “power module”.

3
Disconnect the 8-pin connector from the PCU*.
* Note. Applies if the engine is still in the boat.

4
Disconnect the alternator connector.

5
Always connect the welder earth clamp to the compo-
nent to be welded, or as close as possible to the weld
site. The clamp must never be connected to the en-
gine or in such a way that current can pass through a
bearing.
IMPORTANT! After welding is completed, the
disconnected components, such as alternator
cables and battery cables must be connected in
the correct order.

51
Exposing the engine

Exposing the engine

During general overhaul

1
Drain the coolant, refer to “Cooling system, draining”
on page 187.
Pump the engine oil out.

2
Close the fuel stopcocks between the tank and feed
pump.

3
Remove the protective cover from the fuel pump/fuel
shut-off valve. Undo the connections to and from the
fuel pump and let the fuel run into a suitable contain-
er.

4
Remove the fuel filter and oil filler tube.

5
Remove the reverse gear, any pumps and other an-
cillaries from the engine. Refer to instructions on
page 211 when removing the seawater pump*.

6
Remove the air filter.

7
Remove the cabling (with general overhaul), alterna-
tor, etc.
Note. Mark the cables and associated monitors/sen-
sors to simplify reassembly.

8
Remove the charge air cooler*. Refer to “Charge air
cooler, removal and installation” on page 198.

9
Remove the heat exchanger*. Refer to “Heat ex-
changer, removal and installation” on page 203.

10
Remove the control unit (with general overhaul). Re-
fer to “Control unit, replacing” on page 169.
* Note. Points 3 –9 apply if the engine is to be mounted on an
overhaul stand.
The charge air cooler, heat exchanger, control unit and sea
water pump do not need to be removed if only the cylinder
head is to be removed.

52
 Installing, fixture

Engine fixture, fixing

Special tools:
Overhaul stand ......................................... 998 6485
Adapter for engine fixture ......................... 888 00003
Engine fixture (plate) ................................ 888 00123

1
Remove the electrical connection box and the heat
exchanger.

2
Loosen the cabling to the control unit and remove the
control unit. Refer to “Control unit, replacing” on page
169.

3
Remove the fuel and electrical connections. Lift off
the fuel filter bracket together with the filters.
Cover all fuel connections.

4
Bolt engine fixture 888 00123 in place on the engine’s
left side, together with adapter 888 00003 (see figure).
Use the bolts supplied:
M8 x 45 (2 pcs.).
M8 x 55 (1 pcs.).
M12 x 50 (4 pcs.).

5
Bolt the fixture/engine to overhaul stand 998 6485.

53
General overhaul Group 21: Short block

Short block, general overhaul

Cylinder head, removal
The engine exposed and installed on stand, cool-
ant and fuel drained.

1
Remove the rear lifting eyes.

2
Remove the heat shield from the turbocharger if this
was not done during “Exposing the engine”.
IMPORTANT! The insulation around the turbine
housing may not be compressed, since this seri-
ously reduces the heat insulation.
Note. Refer to “Turbocharger, replace” on page 181
for more detailed instructions about removing the tur-
bocharger.

3
Undo the turbocharger pressure oil connection and
coolant connections (2 pcs) on the cylinder block.
Remove the oil drain pipe.
Cover all openings.

5
Remove the nuts and spacers holding the turbo-
charger to the exhaust pipe and lift it away.
WARNING! The heat shield between the turbine
housing and the compressor housing has sharp
edges. Cutting risk.
Cover all openings on the turbo.
Note. The turbocharger weighs about 30 kg (66 lbs).

6
Remove the exhaust pipe. Refer to the instruction on
the page 186.

54
Group 21: Short block General overhaul

7
Remove the flywheel sensor and camshaft sensor as
well as cabling to the starter motor and other sensors.

8
1 Undo the fuel connections (1) to the cylinder head
and plug the connectors.

9
Remove the valve cover and crankcase ventilation.

10
Clean around the unit injectors and remove the elec-
trical connectors. Remove the cable holders together
with the cables.
Cut the tie-wraps and remove the cables from the
holders.

55
General overhaul Group 21: Short block

1 11
Remove the bolt (1) from the cable feed-through and
carefully extract the cabling from the cylinder head.

12
Undo the coolant sensor connector, hoses to the ex-
pansion vessel and the rest of the cabling and lift it
away.

13
Remove the fuel return lines from the front of the cyl-
inder head and plug the connections.

14
The inlet manifold must be removed if fixture
999 0160 for the cylinder head is to be used. Remove
all bolts and loosen the manifold using crowbar
999 8511 on the reinforcing bosses.

15
Remove the thermostat housing and thermostat, and
the front lifting eye.

16
Remove the bolts from the coolant pipe and the hose
clamp from the coolant hose.
Remove the coolant by-pass valve from the front of
the cylinder head.

56
Group 21: Short block General overhaul

17
Remove the timing gear cover and remove the rubber
seals.

18
Remove the center piece for lubrication of the rocker
bridge, together with the delivery pipe.

19
Remove the cover plug from the flywheel cover and
install cranking tool 999 3590.

57
General overhaul Group 21: Short block

20
Crank the engine to “TDC” on the camshaft. Check
that the mark on the flywheel is at “0°”.

21
Remove the camshaft gear together with the oscilla-
tion damper.
IMPORTANT! The oscillation damper must not
be subjected to blows or impacts.

22
Undo all the rocker bridge bolts (equal amounts, in
turns) so that the bridge is not bent.

23
Remove the bolts and carefully lift away the rocker
bridge with lifting tool 999 0185.
NOTE: The marks (D16) on the tool shall be directly
in front of the rocker shaft fixing points on the engine.

58
Group 21: Short block General overhaul

24
Mark the valve yokes and remove them.

25
Clean around the unit injectors and unscrew the bolts
for the injector yokes.
Remove the unit injectors, one at a time.

26
Extract the injectors using tool 999 0006 and slide
hammer 999 0013.

27
Fit sealing plug 999 8251 in the cylinder head immedi-
ately after removal.
Mark the injectors and fit protective sleeves
999 8249 to the injectors.
NOTE: Check that the tools are clean.

59
General overhaul Group 21: Short block

28
Remove the camshaft bearing caps using tools
999 0192 and 999 6400.

29
Lift the camshaft carefully using tool 9998264.

30
Loosen the bearing blocks by carefully tapping them
with a plastic hammer.
Remove the bearing blocks with the lower bearing
halves and put them in the right order together with
their respective camshaft bearing caps, upper bear-
ing halves and bolts.
NOTE: The camshaft bearing blocks are held in place
by guide pins and are marked 1–7.

31
Turn the engine so that the two bolts (1) can be
reached through the timing gear wheel.

60
Group 21: Short block General overhaul

32
Place a rag in front of the gear to prevent the bolts
falling into the timing gear housing.
Remove the two bolts (1).
NOTE: When the engine is turned, the rag must be
removed.

33
Remove the remaining five bolts (2).
Remove the other three screws (3) from the timing
gear hub.

34
Remove the cylinder head bolts.
Use 2 lifting chains 999 6239 to carefully lift away the
cylinder head. Alternatively, lifting eyes and lifting
straps can be used.
NOTE: Place washers between the cylinder head and
lifting chains to protect the cylinder head sealing sur-
face.

35
Remove the cylinder head gasket and clean contact
surface on the cylinder block thoroughly.
NOTE: Secure all cylinder liners with tools 999 0157.

61
General overhaul Group 21: Short block

36
Remove the starter motor.

37
Remove the oil filter complete with bracket.

38
Remove the cover from above the oil cooler. Remove
the oil cooler and extract the seals.

62
Group 21: Short block General overhaul

39
Remove both coolant pipes and the coolant pump.

40
Remove the belt pulley bolts/oscillation damper.
Carefully tap and rock the hub and belt pulley to get
them loose.
NOTE: Do not lever between the belt pulley and oscil-
lation damper.
Lift the oscillation damper.
IMPORTANT! The oscillation damper must not
be subjected to blows or impacts.

41
Remove the bolts and remove the cover for the front
crankshaft seal with a crowbar at the point indicated.

1 42
Remove the tensioner roller and the front engine
mountings, together with the belt tensioner on the
right side of the engine, 6 bolts (1).

63
General overhaul Group 21: Short block

43
Remove the alternator with it’s fixture, together with
the belt tensioner.

44
Remove the engine mounting and dipstick.

45
Remove the fuel pump complete with intermediate
housing.

46
Undo the connector from the oil level sensor and re-
move the oil pan.

47
Remove the oil strainer complete with pipe connec-
tions.

48
Remove the bracing frame.

64
Group 21: Short block General overhaul

Timing gear, removing

49
IMPORTANT! Remove the flywheel sensor to
avoid damaging it with the flywheel during disas-
sembly. Remove and save any shims.

50
Bolt lifting chain 999 6239 to the flywheel.
Remove the bolts and lift off the flywheel.

WARNING! Crushing hazard. The flywheel

weighs about 65 kg (143 lbs).

51
Undo the flywheel housing bolts. Remove the housing
using lifting eyes and lifting strap.

52
Remove the lube oil pump with it’s gear.

65
General overhaul Group 21: Short block

1. Gear, camshaft
2. Idler wheel, adjustable
3. Idler gear, bull gear
4. Crankshaft gear
5. Gear, lube oil pump
6. Gear, fuel pump
7. Idler wheel, fuel pump
8. Drive, seawater pump

53
Remove the fuel pump idler gear (7).

54
Remove the two bolts in the crankshaft gear (4) and
remove the gear using a suitable puller.
NOTE: Place a thick washer between the threaded rod
and the crankshaft to protect the thread from the puller.

55
Undo the six Allen bolts from the hub of the bull drive
(3) and remove the complete gear.

56
Remove the upper (adjustable) idler gear (2).
NOTE: Save the spacer plate behind the drive and
note how it is installed.

57
Remove the timing gear plate (if an oil leak has been
discovered). Clean the timing gear plate and the rear
of the cylinder head.

IMPORTANT! The timing gear plate should only

be removed if absolutely necessary!

66
Group 21: Short block General overhaul

Pistons, removal
58
Remove the piston cooling nozzles. Crank the engine
with tool 999 3590 so that they are accessible (two at
a time).

WARNING! It is important to remove the pis-

ton cooling nozzles before the pistons are re-
moved. Damaged nozzles can cause exten-
sive engine damage.

59
Remove the big end bearing cap and bearing shell,
note the markings.

60
Rotate the engine 90° if it is mounted on overhaul
stand 9986485.

61
Push out the pistons so that the piston rings come
outside the cylinder liner (use a hammer handle or
other wooden object).
Lift the piston and con rod out.

IMPORTANT! Reinstall the bearing caps on the

connecting rods to avoid damage to the mating
surface, since this is very delicate.

62
Remove the circlip from the piston and push out the
gudgeon pin. Disassemble connecting rod and piston.
NOTE: Mark the con rod and piston so that they can
be installed in the same cylinder on assembly.

67
General overhaul Group 21: Short block

63
Mark the positions of the cylinder liners in the block
with a marker pen before removing them. The liner can
then be placed in the correct position on reassembly.

64
Fit puller plate 999 6963 and support legs 999 6394
on puller 999 6645.

65
Guide the plate down through the cylinder and placer
it in the correct position beneath the cylinder liner.
Pull the cylinder liner out of the block, using the ex-
tractor. If necessary, extend the support legs with
999 6395.

66
Remove the cylinder liner seals.

Crankshaft, removing
67
Remove the main bearing caps, if not already done.

68
Group 21: Short block General overhaul

68
Carefully lift out the crankshaft.
NOTE: The crankshaft weighs about 80 kg (176 lbs).

69
Before washing the cylinder block, all plugs, bolts and
remaining brackets must be removed.

70
Clean the contact surfaces of parts that are to be re-
used.

Crankshaft, assembly
71
Inspect the crankshaft, refer to “Crankshaft, inspec-
tion” on page 114.

72
Check the crankshaft oil ways and contact surfaces
for the bearing shells as well as the cylinder block
and bearing caps.

73
Install new main bearing shells.

74
Position the bearing shells in the correct places in the
cylinder block and bearing caps. Make sure that bear-
ing shells or caps are not damaged.
NOTE: Make sure that the upper bearing shells to be
fitted into the cylinder block have oil holes.

69
General overhaul Group 21: Short block

75
Lubricate the bearing journals and shells with engine
oil and carefully lift the crankshaft into place.

76
Install the thrust bearings on the center main bearing.
The thrust washers can only be placed in one position.

77
Install the main bearing caps onto the lower bearing
shells. The bearing caps are asymmetric and can
only be installed one way. The center bearing cap
(with the thrust bearing) has a recess that is to be
turned so that it passes over the guide pin.
NOTE: Note the markings on the bearing caps, 1–7.

78
Oil the main bearing bolts. Allow excess oil to run off
before installation.
Tighten the main bearing bolts in two stages.
Stage 1: 300 ±20 Nm (221 ±14 lbf.ft).
Stage 2: Angle tighten 120° ±5°.
NOTE: Check that the crankshaft does not bind.

79
Install the front cover by the belt pulley and install a
new seal. Refer to “Crankshaft seal front, replace” on
page 126.
NOTE: No lubrication. This should be installed com-
pletely dry.

70
Group 21: Short block General overhaul

Cylinder liners, installation

80
Inspect cylinder liner and pistons, see “Cylinder liner
and pistons, inspection”

81
Lubricate the sealing rings, using the lubricant sup-
plied with the liner kit, and install them on the cylinder
liners.
NOTE: The purple seal ring fits in the lowest groove.

82
In cases where the cylinder liner is installed without a
spacer, an even 0.8 mm (0.031") wide bead of seal-
ant (1161231) is applied to the underside of the cylin-
der liner collar.
NOTE: Do not put the seal around the entire liner.
Leave a 2 mm (0.079") opening.
If the liner is fitted with an adjustment spacer, the
sealant compound bead should be placed on the cyl-
inder block liner seat.
Without spacer NOTE: Sealant must not be used between the adjust-
ing spacers and the cylinder liner collar.
NOTE: The liner must be installed within 20 minutes
of the sealant application.

With spacer

71
General overhaul Group 21: Short block

83
Screw in one of the cylinder head bolts (A).
Place tool 999 6963 above the cylinder liner together
with a suitable spacer (B).
Press the liner down with crowbar 999 8511 and se-
cure it with tool 999 0157.

Pistons, pre-assembly
84
Install a circlip in the new piston.

85
Oil the gudgeon pin, piston bearing hole and con rod
bush with engine oil.

86
Mount the con rod so that the piston arrow and the
con rod “Front” mark point in the same direction.
Press in the gudgeon pin.
NOTE: The gudgeon pin should enter easily, it must
not be knocked in.

87
Fit the other circlip.

88
Check that the gudgeon pin does not bind in the con
rod bush and that the piston can move easily.

72
Group 21: Short block General overhaul

IMPORTANT! Always use piston ring pliers

888 00083 when fitting / removing piston rings.
The oil scraper rings are particularly brittle and
can easily be damaged.

NOTE: The two upper piston rings are marked with

letters or point marks. The mark shall face upwards.

89
Place the piston ring gaps offset about 120° on the
piston. The piston ring openings must not end up di-
rectly over the gudgeon pin, however.
NOTE: New cylinder lining kits are delivered com-
plete with pistons and piston rings.

90
Install the big end bearing shells in the con rods and
bearing caps.

73
General overhaul Group 21: Short block

Pistons, installation
91
Install cranking tool 9993590.
Crank the flywheel until the crankshaft comes into po-
sition to install each con rod.

92
Remove clamping tool 999 0157 temporarily while the
pistons are being installed.

93
Oil the cylinder liners, bearing shell surfaces and
crankshaft journals. Install the piston and con rod with
the arrow and FRONT markings facing forwards. Use
tool 9990158 and carefully guide the piston down into
the cylinder liner. Check that the connecting rod does
not damage the crankshaft bearing journal.
IMPORTANT! Be careful. The oil scraper rings
are brittle and can easily be damaged.
The piston ring compressor must not be opened
once the piston has been placed in the tool,
since the piston rings could then be easily dam-
aged. Always press the piston out first, before
the tool is opened.

94
Refit the clamping tools 999 0157. All cylinder liners
must be locked with clamping tools to prevent move-
ment between the cylinder liner and the cylinder block
when the engine is cranked.

95
Clean the contact surfaces on the con rod and bear-
ing cap carefully before assembly.
Check carefully that the bearing cap contact
surface matches the con rod contact surface.

74
Group 21: Short block General overhaul

96
Oil the bearing shells and install the bearing caps so
that the markings on the con rod and bearing cap co-
incide.
NOTE: The bearing caps are numbered for each con
rod. The markings on the con rod and bearing cap
must face the same way.
Make sure that the bearing shell guide pin is correctly
located in the con rod cutout, and that the oil holes in
the con rod and bearing shell line up.
Mount the con rod bearing caps according to their
markings and tighten the bolts diagonally.
Tightening torque:
Stage 1: 20 ±3 Nm (14.8 ±2 lbf.ft).
Stage 2: 60 ±5 Nm (44.3 ±4 lbf.ft).
Stage 3: Angle tighten 90° ±5°.
NOTE: Nut runners may not be used for tightening the
can rod bolts. This could damage the mating surfaces.

97
Crank the flywheel until the crankshaft comes into po-
sition to install more con rods and repeat the proce-
dure.

98
Check that none of the big end bearings binds.

75
General overhaul Group 21: Short block

Piston cooling nozzles, installation

99
Blow clean the piston cooling nozzles and check that
they are not damaged.
WARNING! Faulty piston cooling causes seizure.
If you suspect that a piston cooling nozzle may
be damaged or deformed, it should be replaced
(applies to new nozzles as well).

100
Install each piston cooling nozzle with a new bolt and

new O-ring. Tightening torque: 24 ±4 Nm (17.7 ±3

lbf.ft).
NOTE: The piston cooling nozzle retaining screw has
a friction coating and may only be used once.
WARNING! Always check that each piston cool-
ing nozzle is placed correctly in its hole in the
engine block, that the retaining plate lies flat
against the block and that the nozzle is directed
towards the recess in the piston.
If the piston cooling nozzle is not correctly in-
stalled, the engine will immediately seize when
loaded.

101
Install the bracing frame. Tighten the screws in two
stages.
Stage 1: 65 ±5 Nm (48 ±4 lbf.ft).
Stage 2: Angle tightening 90° ±5°.

76
Group 21: Short block General overhaul

Timing gear, installation

NOTE: Lubricate the bearing surfaces of the gears
before assembly.

102
Apply an approx. 2 mm (0.079") wide bead of sealant
(part No. 1161231) to the cylinder block as illustrated.
Note. Use a marker pen to mark up where the seal-
ant should be applied.

103
Install the timing gear plate if it has been removed.
IMPORTANT! Use new bolts that are treated
with locking fluid.
Tighten the bolts to 28 ±4 Nm (20.7 ±3 lbf.ft) (M8),
and 60 ±8 Nm (44.3 ±6 lbf.ft) (other bolts). Refer to
the torque schedule in “Technical Data”.
NOTE: Torque within 20 minutes after sealant has
been applied.

101
Oil the spacer plate and place it together with the up-
per (adjustable) idler gear (2). Tighten to a low torque
(max. 10 Nm / 7.4 lbf.ft).

104
Fit a new O-ring to the crankshaft.

105
Install the crankshaft gear (4) and tighten the Allen
bolts in two stages.
Stage 1: 60 ±5 Nm (44.3 ±4 lbf.ft).
Stage 2: Angle tighten 120° ±10°.
NOTE: Make sure that the mating surfaces on crank-
shaft and gear are clean and flawless.

77
General overhaul Group 21: Short block

1. Gear, camshaft
2. Idler wheel, adjustable
3. Idler gear, bull gear
4. Crankshaft gear
5. Gear, lube oil pump
6. Gear, fuel pump
7. Idler wheel, fuel pump
8. Gear, seawater pump

106
Place two screws in the crankshaft gear so you can
attach a crowbar and thus be able to turn the crank-
shaft as needed.

107
Install the bull-gear (3) with the mark in between the
two marks on the crankshaft gear.
NOTE: The inner and outer gears have different
pitches. For the camshaft to be set correctly, the
markings must be correct.
Tighten the bolts in two stages.
Stage 1: 45 ±5 Nm (33.2 ±3 lbf.ft).
Stage 2: Angle tighten 90° ±5°.
Refer to the torque schedule in “Technical Data”.

108
Install the idler gear (7) for the fuel pump with a new
O-ring.

78
Group 21: Short block General overhaul

109
Install the lube oil pump.

110
Remove the old crankshaft seal from the flywheel
cover.
Apply sealant (part No. 1161231) to the flywheel cov-
er contact surface on the cylinder block.

111
Install the flywheel cover and tighten the bolts in three
stages. Check that the cover aligns with the under
edge of the cylinder block.
Stage 1: Tighten all M14 bolts to 160 ±20 Nm
(118 ±15 lbf.ft).
Stage 2: Tighten all M10 bolts to 48 ±8 Nm
(35.4 ±6 lbf.ft).
Stage 3: Tighten all M8 bolts to 24 ±4 Nm
(17.7 ±3 lbf.ft).
Refer to the torque schedule in “Technical Data”.

112
Install a new crankshaft seal. Refer to “Crankshaft
seal rear, replace” on page 127.
NOTE: No lubrication. This should be installed com-
pletely dry.

79
General overhaul Group 21: Short block

113
Install the flywheel and tighten the bolts in two stages.
NOTE: Make sure that the flange is clean and dry.
Stage 1: 40 ±5 Nm (29.5 ±4 lbf.ft).
Stage 2: 100 ±5 Nm (73.8 ±4 lbf.ft), and then
angle tightening 90° ±10°.
Refer to the torque schedule in “Technical Data”.

114
Remove the old crankshaft seal from the front cover.
Apply sealant to the front cover and install it. Torque
the screws to 24 ±4 Nm (17.7 ±3 lbf.ft).
Refer to the torque schedule in “Technical Data”.
NOTE: Torque within 20 minutes after sealant has
been applied.
Note. Ensure that the under edge of the cover aligns
with the under edge of the cylinder block.

115
Install a new front crankshaft seal. Refer to “Crank-
shaft seal front, replace” on page 126.
NOTE: No lubrication. The seal should be installed
completely dry.

116
Fit the belt pulley and the oscillation damper and
tighten in two stages.
NOTE: The 8.8 bolts on the oscillation damper must
NOT be reused.
Stage 1: 35 ±5 Nm (25.8 ±4 lbf.ft).
Stage 2: 90 ±10 Nm (66.4 ±7 lbf.ft) (125 ±10 Nm*
(92.2 ±7 lbf.ft)*).
Refer to the torque schedule in “Technical Data”.
IMPORTANT! The oscillation damper must not
be subjected to blows or impacts.
* Note. Applies to engines with a “stubshaft” at the front.

117
Install the oil suction strainer with pipe.

118
Cut away any remains of sealant and apply new seal-
ant on the surfaces between the cylinder block and,
the front cover and the flywheel cover.

80
Group 21: Short block General overhaul

119
Install the oil pan.

120
Install the dipstick with new O-rings.

121
Install the fuel pump complete with intermediate
housing.

122
Install the coolant pump.

123
Install the front engine mounts together with the belt
tensioner and the tensioning wheel on the right side
of the engine.

124
Install the alternator with attachment and belt tension-
er on the left side of the engine.

125
Clean and install new sealing rings in the cylinder
block. Bolt the oil cooler in place in two stages.
Stage 1: 10 ±4 Nm (7.4 ±3 lbf.ft).
Stage 2: 27 ±4 Nm* (20 ±3 lbf.ft)*.
* Note. Tightening sequence 1 –2 –3 –4 –1 in stage 2.

81
General overhaul Group 21: Short block

126
Install the oil cooler cover with a new O-ring and
torque as specified in “Technical data”.
Note. Check that the cover rubber gasket remains in
it’s groove.

127
Install the oil filter bracket with new gasket and new
oil filters.

128
Install the starter motor.

129
Install the coolant pipe with new O-rings.

82
Group 21: Short block General overhaul

Cylinder head, installation

130
Clean the cylinder head thoroughly inside and out be-
fore installing.
NOTE: Dirt particles can destroy the unit injectors.

131
Clean the unit injector copper sleeves. Refer to “Cop-
per sleeve for unit injector, replace” on page 145.
Install sealing plugs immediately after cleaning.

132
Remove clamping tools 999 0157 that are holding the
cylinder liners in place.

133
Carefully clean the cylinder head and the cylinder
block sealing surfaces. Remove old sealant.

134
Dip the full length of the cylinder head screws in cor-
rosion inhibitor (part No. 1161346).
Then place the screws on a net to let excess drip off.

135
Apply a 2 mm (0.079") thick string of sealant on the
back side of the cylinder block.
NOTE: The cylinder head screws must be torqued
within 20 minutes after sealant application.

136
Install a new cylinder head gasket.
NOTE: Convex embossings prevent damage to the
rubber seals.
NOTE: Check that the coolant pipe is in place.

83
General overhaul Group 21: Short block

137
Lower the cylinder head until it rests on the cylinder
head gasket.
Maintain a distance to the timing gear plate of 5–10 mm
(0.20–0.40"). Guide pins ensure that the cylinder head
aligns with the cylinder block.

138
Slide the cylinder head against the timing gear plate.

139
Place a rag in front of the drive to prevent bolts from
falling into the timing gear housing.
(0.20–0.40")
NOTE: The rag must be removed before the engine
is to be cranked.

140
Place a bolt (M12) in the upper idler gear hub (1) into
the cylinder head, so you can pull the cylinder head
towards the timing gear plate.
Screw in 5 bolts (M8) in the timing gear plate (2).

141
Tighten the bolts (1) and (2) according to the specifi-
cation in “Technical data”.
Unscrew all bolts (1) and (2) about one turn.
NOTE: The cylinder head is now in the correct posi-
tion to be secured and must not be moved. If the cyl-
inder head is moved from its position, the tightening
sequence above must be repeated.

84
Group 21: Short block General overhaul

142
Install the cylinder head bolts and tighten in three
stages. Refer to the torque schedule in “Technical
Data”.
NOTE: The bolt tightening sequence should prefera-
bly be marked with a felt tip pen on the cylinder head.
Use a torque multiplier when angle tightening.
Stage 1: 100 +10 +7.4
– 0 Nm (73.8 – 0 lbf.ft)
Stage 2: Angle tighten 90° ±5°.
Stage 3: Angle tighten 90° ±5°.

143
Torque the five M8 bolts in the transmission plate (2)
as specified in “Technical data.”
* Note. Refer to figure on previous page.

144
Crank the engine so that the two M8 bolts (3) can be
installed through the upper idler gear. Tighten accord-
ing to the specification in “Technical data”.

145
Place the remaining M12 bolts (4) into the upper idler
gear, without tightening.

146
Tighten the coolant pipe in the cylinder head.

147
Clean the surface from sealant as illustrated.
IMPORTANT! Cut away the excess sealant. Do
not pull it off.

85
General overhaul Group 21: Short block

Camshaft, installation
148
Check the camshaft for wear. Refer to “Camshaft,
checking for wear.”

149
Clean surfaces on bearing blocks and the cylinder
head.

150
Install the camshaft bearing blocks as marked, make
sure that they rest against the cylinder head. No. 7 at
the timing gears.

151
Place the bearing shells in the bearing blocks and lu-
bricate the bearing shells with engine oil.

152
Crank the engine with cranking tool 999 3590 so that
the flywheel is exactly at the zero mark on the fly-
wheel cover.

153
Carefully lift the camshaft in place. Make sure the
hole for the guide pin on the camshaft gear is upper-
most. The camshaft TDC mark shall be between the
marks on No. 7 bearing block.
WARNING! Camshaft lobes are sharp.

86
Group 21: Short block General overhaul

154
Install the camshaft gear without the oscillation damp-
er. Use nuts as spacers.
Place the gear so that the reference hole in the timing
gear plate lies between the gear markings. If neces-
sary, loosen the bolts on the upper idler gear.
Temporarily tighten the bolts to a low torque (max.
10 Nm / 7.4 lbf.ft).

155
Clean the surfaces of the bearing caps and oil the
bearing shells.
Install the bearing caps on the respective bearing
blocks.
NOTE: Use a suitable spacer on the rocker side.
Tighten bolts 1–7 according to stage 1 in the Work-
shop Manual “Technical data”.
Torque screws 8, 11, 14 (with spacers) as in stage 2
in “Technical data”.

Backlash, adjustment
156
Loosen bolts (1) in in the upper idler gear. Check that
the upper bolts are not tightened.

87
General overhaul Group 21: Short block

157
Place a 0.10 mm feeler gauge on the pressure side.
Turn the camshaft gear against the feeler gauge.
Tighten the upper idler gear according to stage 1 in
Workshop Manual “Technical data”.
Remove the feeler gauge.

158
Check the backlash as follows:
Fix the adjustable idler gear.
Place a dial indicator on the camshaft gear as illus-
trated.
Turn the gear back and forth and measure the back-
lash. The backlash should be 0.05–0.15 mm
(0.0020–0.0059").

159
If gear backlash is correct; torque the screws on the
idler gear (1) as per stage 2 in “Technical data”.

160
Fit the oscillation damper and tighten in two stages.
Stage 1: 45 ±5 Nm (33.2 ±3 lbf.ft).
Stage 2: Angle tighten 90° ±5°.
Refer to the torque schedule in “Technical Data”.
IMPORTANT! The oscillation damper must not
be subjected to blows or impacts.

161
Apply an approx. 2 mm (0.079") wide bead of sealant
(part No. 1161231) to the timing gear cover contact
surface as illustrated.

88
Group 21: Short block General overhaul

162
Install the rubber seal and mount the timing gear cov-
er.

163
Only fit bolt (1) and tighten by hand.
Note. The hole is elongated so that the cover can be
pressed down onto the rubber seal.

164
Press the cover down with tools 885810 and
999 8601 so that the cylinder head and the upper tim-
ing gear cover sealing surfaces are aligned.
Install the remaining bolts (2), upper figure. Torque
the screws to 27 ±4 Nm (20 ±3 lbf.ft).
Refer to the torque schedule in “Technical Data”.
NOTE: The timing gear cover must be installed and
torqued within 20 minutes after sealant application.

165
Install the camshaft sensor. Refer to “Camshaft sen-
sor distance, check” on page 151.

89
General overhaul Group 21: Short block

Unit injector, installation

NOTE: Install one unit injector at a time.
166
Remove the sealing plugs 999 8251 with adapter
999 0156 and slide hammer 999 6400.

167
Fit new sealing rings on the unit injectors. Lubricate
the rings with diesel oil.
Install injectors and retaining yokes. Center the in-
jector so it does not touch the valve springs.
Tighten the unit injector as follows.
NOTE: Different tightening torques are used, depend-
ing on whether the unit injector copper sleeve has
been replaced or not.
New copper sleeve:
First tightening
Stage 1: 20 ±5 Nm (14.8 ±4 lbf.ft).
Stage 2: Angle tighten 180° ±5°.
Note. Undo the bolt for the unit injector fixing yoke
before the second tightening.
Second tightening
Stage 1: 20 ±5 Nm (14.8 ±4 lbf.ft).
Stage 2: Angle tighten 60° ±5°.

Old copper sleeve:

Stage 1: 20 ±5 Nm (14.8 ±4 lbf.ft).
Stage 2: Angle tighten 60° ±5°.

168
Re-install the valve yokes in their original positions.
NOTE: Make sure that the yoke is directly above the
valve stem.

169
Oil the valve yoke and camshaft lobes with engine oil.

170
Remove the temporary bolts with spacers on the
camshaft bearing caps.

90
Group 21: Short block General overhaul

171
Lift the rocker bridge into place with lifting tool
999 0185.
NOTE: The marks (D16) on the tool shall be directly
in front of the rocker shaft fixing points on the engine.
Tighten the bolts alternately along the rocker shaft to
prevent bending or skewing the shaft.
Check that the rocker shaft fits properly onto the
guide sleeves on the camshaft bearing blocks.
Tighten the rocker bridge according to the tightening
diagram in “Technical data”.

172
Thread new O-rings over the oil supply pipe for the
rocker arm bridge. Put the pipe in the joining piece
and install the joining piece with pipe. Check that the
O-rings on the pipe and the ring under the joining
piece are correctly aligned.
Install the cable holder.

Timing marks
The camshaft has marks (1–6 for the respective cyl-
inders) for adjusting intake and outlet valves and the
unit injectors.
NOTE: It is important that the line on the camshaft is
between the marks on the bearing cap when making
the adjustment.

91
General overhaul Group 21: Short block

21403

Valves and unit injectors,

adjustment
Note. Adjust valves and injectors for the respective
cylinders at the same time.

173
Crank the engine to the closest camshaft mark.

174
Screw the adjustment screw down so it rests against
the valve stem and thereafter an additional sixth turn
(60°).
NOTE: When the adjustment screw is turned down,
the yoke must simultaneously be pressed down so it
touches the valve stem. It is very important that the
pressure is brought to bear as close to the adjust-
ment screw as possible, see illustration.

175
Adjust the valve clearance between rocker arm and
valve yoke as specified in “Technical data”.
Tighten the locknut and recheck the valve clearance.
Mark the rocker arm when the valve has been adjust-
ed.

92
Group 21: Short block General overhaul

176
Adjust the unit injector rocker arm to zero clearance.
Tighten the adjusting screw an additional 3 – 4 flats
(180°– 240°).
Tighten the locknut to 52 ±4 Nm* (38.4 ±3 lbf.ft)*.
* Alternative: Angle tightening 45° ±5° after contact.

177
Adjust the remaining valves and unit injectors in a
corresponding way.

178
Apply a 2 mm (0.079") wide bead of sealant
(1161231) to the inlet manifold.
Install the inlet manifold. Tightening torque: 24 ±4 Nm
(17.7 ±3 lbf.ft).
NOTE: The inlet manifold must be installed and tight-
ened within 20 minutes after applying the sealant.

179
Carefully pull the cables for the unit injectors into the
cylinder head. Lubricate the O-ring and press the
adapter into the cylinder head. Tighten the cable tran-
sition on the cylinder head.

180
Connect the connector to each unit injector. Press in
until you hear a “click”.

93
General overhaul Group 21: Short block

181
Fix the cabling on the holder with Volvo Penta original
clips.

IMPORTANT! Use only Volvo Penta origi-

nal* clips (part No. 983472) and holder (part
No. 8131393) under the valve cover for
clamping the cables to the unit injectors.

* Note. These components have been specially developed to with-

stand oil and high temperatures.

182
Install the rear lifting eye.

183
Install sensors for flywheel, camshaft and oil pressure
and cables to the starter motor.

184
Connect the fuel lines to the cylinder head and torque
as specified in “Technical data”.

185
Apply a 2 mm (0.079") thick bead of sealant to the
plane (A) between the timing gear casing and the cyl-
inder head.

186
Install the valve cover and tighten the bolts to
24 ±4 Nm (17.7 ±3 lbf.ft). Refer to the torque sched-
ule in “Technical Data”.

94
Group 21: Short block General overhaul

NOTE: The valve cover must be installed within

20 minutes after sealant application.
187
Locate the gaskets on the studs. Turn the gasket so
that the side with the text “MANIFOLD SIDE” is facing
the exhaust manifold.
Install the exhaust manifold and tighten it in three
stages.
Stage 1: 5 ±2 Nm (3.7 ±1.5 lbf.ft).
Stage 2: 25 ±5 Nm (18.4 ±4 lbf.ft).
Stage 3: 52 ±5 Nm (38.4 ±4 lbf.ft).
Refer to the torque schedule in “Technical Data”.

188
Install the turbocharger without tightening it. Refer to
“Turbocharger, installation” on page 183.
IMPORTANT! The insulation around the turbine
housing may not be compressed, since this seri-
ously reduces the heat insulation.

189
Install the thermostat housing and tighten alternately.
Install the front lifting eye.

190
Install the coolant pipe with new sealing rings and
tighten alternately.

95
General overhaul Group 21: Short block

191 197
Remove the engine fixture and replace the removed Install, as required, the oil separator (extra equip.) for
parts. the crankcase ventilation.

192 198
Install the drive belts and protective shields. Put a new filter in the air filter housing and install it.

193
Install the connections to and from the fuel pump. In-
stall the protective cover over the fuel pump/fuel shut-
off valve.
194
Install the charge air cooler. Refer to “Charge air cool-
er, removal and installation” on page 198.
195
Install the charge air pipe between the turbocharger
and charge air cooler. Install the insulation around the
pipe.
196
Install the heat exchanger. Refer to “Heat exchanger,
removal and installation” on page 203.
199
Connect the exhaust pipe to the exhaust elbow.
200
Replace the oil filter and fill the engine with lubricating
oil.
201
Fill the engine with coolant. Refer to “Cooling system,
filling” on page 190.
202
Replace the fuel filter. Open fuel cocks and purge the
fuel system. Refer to “Fuel system, purging” on page
180.
203
Start the engine and let it run until it reaches normal
operating temperature. Let it run an additional 5 –10
minutes at idle. When the idle is even, the cylinder
balancing system has set the correct amount of fuel
for the unit injectors.
NOTE: Do not connect any power consuming device
(e.g. power take-offs) while cylinder balancing is un-
derway.
Check that no leakage occurs.

96
Overhaul / Replacement of components
Group 21: Short block

Cylinder liners and pistons,

inspection
Clean the cylinder liners carefully before inspection
and measurement.
NOTE: Cylinder liners and pistons are matched to-
gether. This means that pistons and liners must not
be mixed.
Pistons and cylinder liners are only supplied as com-
plete units for spare part purposes.

Cylinder liner
Measurement of cylinder liner wear can be done with
the liner installed in the cylinder block.
NOTE: In order to thoroughly check for cracks, the
cylinder liner must be removed from the cylinder
block.

1
Measure the cylinder liner wear with a cylinder indica-
tor. In order to obtain the greatest possible accuracy in
the wear measurement, the cylinder liner must first be
set up with a gauge ring or micrometer. Use the origi-
nal diameter of the cylinder liner as the base value.

2
Measure the cylinder liner at the end of travel of the
top piston ring, and at several places along its travel.
At each measurement location, the measurement
should be taken in the engine length -as well as cross
direction.

3
If the wear is greater than 0.45 – 0.50 mm (0.0177 –
0.0197"), a new complete liner kit shall be used (pis-
ton, liner, piston rings, gudgeon pin and seals).
Oil consumption also has a bearing on when the cyl-
inder liners should be changed.

97
Overhaul/Replacement Group 21: Short block

4
Extract the cylinder liner and perform a crack test. Be
specially careful when checking the liner collars. The
Magnaflux method can be used for this check.

Pistons
5
Check for worn piston ring grooves, damaged circlip
grooves, cracks and other damage to the pistons.
If the pistons have deep scratches on the skirts, the
pistons (liner kit) must be scrapped. The same ap-
plies if the piston has one or several cracks in the
gudgeon pin hole or in the bottom of the combustion
chamber.
A crack test should be done using the chalk flour pro-
cess.

98
Group 21: Short block Overhaul/Replacement

Cylinder liners and pistons,

replace
(all)
Special tools:
Cranking tool ............................................ 999 3590
Puller ........................................................ 999 6645
Spacer ...................................................... 999 6394
Spacer ...................................................... 999 6395
Puller plate ............................................... 999 6963
Press tools (7pcs) ..................................... 999 0157
Mandrel .................................................... 999 6599
Prying tool ................................................ 999 8511
Piston ring compressor ............................. 999 0158
Piston ring pliers ....................................... 88800083
Other special equipment:
Torque wrench (10 –100 Nm) ................... 115 9794
Torque wrench (40 –340 Nm) ................... 115 9795
Dial gauge ................................................ 999 9876
Holder ....................................................... 999 2479

Removal
Cylinder head, oil pan, bracing frame and piston
cooling nozzles removed

WARNING! It is important to remove the pis-

ton cooling nozzles before the pistons are re-
moved. Damaged nozzles can cause exten-
sive engine damage.

1
Remove the protective cover from the flywheel casing
and fit cranking tool 999 3590.
Turn the crankshaft so you can access the bolts on
the connecting rod that is to be removed.

99
Overhaul/Replacement Group 21: Short block

2
Remove the con rod bearing cap and bearing shell.

3
Remove the piston and con rod.

IMPORTANT! Reinstall the bearing caps on the

connecting rods to avoid damage to the mating
surface, since this is very delicate.

4
Extract the cylinder liner from the block using puller
plate 999 6963, puller 999 6645 and spacer 999 6394.
Extend if required with spacer 999 6395

5
Remove the cylinder liner sealing rings.

6
Remove the circlip from the piston and push out the
gudgeon pin.
Remove the piston from the connecting rod.

7
Clean the sealing surfaces in the cylinder block and
the grooves for the sealing rings. Do not use scrapers
or other tools that can damage the sealing surfaces.

8
Check the liner position. Refer to “Cylinder liners,
checking” on page 105.

100
Group 21: Short block Overhaul/Replacement

Installation
NOTE: Check the liner heights before the cylinder lin-
ers are installed. Refer to “Cylinder liners, checking”
on page 105.

9
Check the cylinder block liner seat for damage. In
case of damage, the cylinder liner seat must be re-
conditioned. Refer to “Cylinder liner, milling” on pages
107/113.
Fit cylinder liner, without sealing rings. Fix it with two
press tools 999 0157.

10
Put the dial indicator 998 9876 in holder 999 2479.
Place the holder with the dial indicator across the cyl-
inder liner.
Zero the dial gauge with a couple of millimeter pre-
load to the plane of the cylinder block.

11
Measure the height difference between the cylinder
liner and cylinder block plane.
Measure the liner height at two different, diagonally
opposite places.
Calculate the average of the two measurements. For
correct liner height above block plane, see specifica-
tions. If the liner height above block plane is outside
specified tolerance, the liner collar in the cylinder
block should be milled.

NOTE: Always measure on the highest point of the

sealing surface. Mark the liner position in the cylinder
block with an India ink pen, so that it is placed in the
same position during installation. Repeat the proce-
dure for the remaining cylinder liners.

12
Remove the press tools 999 0157. Extract the cylin-
der liner from the block.

Place the cylinder liners in the same sequence that

they were installed, together with any adjusting spac-
ers.
13
Lubricate the sealing rings, using the lubricant sup-
plied with the liner kit, and install them on the cylinder
liners.

NOTE: The purple seal ring fits in the lowest groove

101
Overhaul/Replacement Group 21: Short block

14
When the cylinder liner is fitted without spacers, an
even, approx. 0.8 mm (0.031") thick bead of sealant
(art. nr 1161231) should be applied on the underside
of the cylinder liner collar.
NOTE: Do not put the seal around the entire liner.
Leave a 2 mm (0.079") opening.

15
If the liner is fitted with spacers, the sealant bead
should be placed on the cylinder block liner seat.

NOTE: Sealant must not be used between the adjust-

ing spacers and the cylinder liner collar.

16
NOTE: After applying the sealant, the liner must be
installed within 20 minutes.
NOTE: If the cylinder head cannot be installed and
torqued within 20 minutes, the liner must be clamped
to the cylinder block with two press tools 999 0157 so
that the sealant hardens in the correct position.

17
Install one of the bolts (A) for the cylinder head. Place
the plate 999 6963 above the cylinder liner together
with a suitable spacer (B). Press the liner down with
crowbar 999 8511.

18
Oil the gudgeon pin, piston bearing hole and con rod
bush with engine oil.

102
Group 21: Short block Overhaul/Replacement

19
Install the connecting rod in the piston with the mark
“FRONT” on the connecting rod and the arrow on the
piston turned in the same direction.
Press the gudgeon pin in.

NOTE: You should be able to press the gudgeon pin

in without much force. If the resistance is too much,
the piston may need to be heated. The connecting
rod should turn freely on the gudgeon pin.
Install the circlips.

20
Install the piston rings.
IMPORTANT! Always use piston ring pliers
888 00083 when fitting piston rings. The oil
scraper rings, especially, are brittle and are eas-
ily damaged.
The piston ring openings must be evenly spaced in
relation to each other.
The opening in the oil scraper ring must be diametri-
cally opposite the opening in the spring underneath.

NOTE: The two upper piston rings are marked with

letters or point marks. The markings should be turned
up. The oil scraper ring is symmetrical and can face
either way.

21
Lubricate the piston and the piston rings with engine
oil. Check that the piston ring openings are offset
120° in relation to each other.

22
Install the piston together with the con rod.

NOTE: Connecting rods shall be installed in their re-

spective original positions. The arrow on the pistons
and the “FRONT” marking on the con rod must face
forwards. Use piston ring compressor 999 0158.
Temporarily remove the press tools when the piston
is installed. Put the press tools back when the piston
is in place.

103
Overhaul/Replacement Group 21: Short block

23
Oil the crankshaft journal and bearing shells with en-
gine oil. Install the big end bearing shells. Check that
they are correctly aligned in the con rods and bearing
caps.
Mount the con rod bearing caps according to their
markings and tighten the bolts diagonally.
Tightening torque:
Stage 1: 20 ±3 Nm (14.8 ±2 lbf.ft).
Stage 2: 60 ±5 Nm (44.3 ±4 lbf.ft).
Stage 3: Angle tighten 90° ±5°.

24
Blow the piston cooling nozzle clean and check that it
is undamaged. Install the new piston cooling nozzle
with new bolts. Tightening torque: 24 ±4 Nm (17.7 ±3
lbf.ft).

NOTE: The piston cooling nozzle retaining screw has

a friction coating and must only be used once.
WARNING! Faulty piston cooling results in pis-
ton seizure.
If you suspect that the piston cooling nozzle may
be damaged or deformed, it should be replaced
(applies to new nozzles as well). Always check
that each piston cooling nozzle is placed cor-
rectly in its hole in the engine block, that the re-
taining plate lies flat against the block and that
the nozzle is directed towards the recess in the
piston.
If the piston cooling nozzle is not correctly in-
stalled, the engine will immediately seize when
loaded.

104
Group 21: Short block Overhaul/Replacement

Cylinder liner seats, inspection

If the cylinder liner seat is damaged, this is rectified
by milling the liner shelf. The material which is re-
moved by milling is compensated by using spacers,
which are available in different thicknesses.

Special tools:
Holder for dial gauge ................................. 999 2479
Press tool .................................................. 999 0157

1
Make sure that the old seals in the engine block and
the cylinder liner, where appropriate, have been re-
moved, and that the sealing surfaces are carefully
cleaned.
Use a brass brush and cleaning fluid 1161440. Scrap-
ing tools may not be used.

2
Assess the scope of any damage.

3
Install the cylinder liner without sealing rings and bolt
in place with two press tools 9990157.

105
Overhaul/Replacement Group 21: Short block

4
Mount the tools as illustrated. Zero the dial gauge
against the engine block plane.

5
Measure the liner height at two different places, and
calculate the amount that needs to be milled away
(thickness of the adjustment spacers). Aim to use the
least possible number of spacers.
NOTE: Always measure on the highest point of the
sealing surface.
Refer to “Technical Data” for sealing surface height.
Mark the position of the liner in the engine block so
that it is put in the same position during installation.

106
Group 21: Short block Overhaul/Replacement

21307

Cylinder liner seat, milling

Liner removed (shimming included)

Special tools:
Fixing tool* .................................................. 999 0157
Holder for dial gauge .................................. 999 2479
Spacer (2 pcs) ............................................ 999 6394
Spacer (2 pcs) ............................................ 999 6395
Puller .......................................................... 999 6645
Plate for cylinder liner ................................. 999 6963
* Note. 2 pcs required for each cylinder liner.

Other special equipment:

Spacer ........................................................ 980 9772
Milling tool ................................................... 981 2524
Dial gauge .................................................. 998 9876
981 2524 Milling tool for cylinder liner seats
1. Feed sleeve (vertical feed) 7. Centering roller
2. Lock screw 8. Spindle
3. Scale ring 9. Cutter
4. Electromagnet 10. Switch (electro magnet)
5. Locking brace 11. Crank
6. Feed ring (horizontal feed) 1
Remove the cylinder liner and clean the liner seat in
the block. Please refer to the instructions on pages 68
and 105.

2
Install the new cylinder liner without sealing rings in
the block. Fix it with two press tools 999 0157.

3
Mount dial indicator 998 9876 in holder 999 2479.
Place the holder with dial gauge right across the cyl-
inder liner.
Zero the dial gauge with a couple of millimeters’ pre-
load to the plane of the engine block.

107
Overhaul/Replacement Group 21: Short block

4
Measure the height difference between the cylinder
liner and cylinder block plane.
Measure the height of the liner at two places, diago-
nally to each other. Calculate the average of the two
measurements.
NOTE: Always measure on the highest point of the
sealing surface.
Mark the position of the cylinder liner in the block with
a marker pen before it is removed. This will allow the
liner to be installed in the correct position if re-installed.

5
Remove the press tools. Pull the cylinder liner out of
the engine block as illustrated.

6
Three thicknesses of adjustment spacers are available
for adjusting cylinder liner height: 0.20 mm, 0.30 mm
and 0.50 mm (0.0079", 0.0118" and 0.0197").

7
Calculate the amount that the liner seat needs to be
machined, so that when the adjustment spacer is in-
stalled, the correct liner height above the block plane
will be achieved (0.15 – 0.21 mm / 0.0059 –0.0083")
in the example below.
NOTE: Always attempt to end up in the upper toler-
ance range.
Machine the liner seat as little as possible, and use
the least number of adjustment spacers possible.

Example:
Correct liner height above
block plane ........................... 0.21 mm (0.0083")
Less measured value .......... – 0.12 mm (–0.0047")
Difference ............................ 0.09 mm (0.0035")

Thickness of spacers ........... 0.20 mm (0.0079")

Less difference .................... – 0.09 mm (–0.0035")
Machining required .............. 0.11 mm (0.0043")

108
Group 21: Short block Overhaul/Replacement

8
Use a suitable size of cutter and check that it is un-
damaged.
Hold up the locking brace and install the cutter. The
toothed surface must face the electromagnet and the
centering roller on the side of the spindle marked “R”.

9
If the adjacent cylinders have the liners fitted, spacer
980 9772 must be used.
Spacer height is 4 mm (0.16"). If the liner height is
higher, the adjacent liners must be removed.
NOTE: Check that the spacer and the cylinder head
plane are carefully cleaned.

NOTE: When the cylinder liner beside the timing gear

plate is milled, the milling tool must be extended. Re-
fer to “Cylinder liner, milling” on pages 107/113.

10
Place the milling cutter 981 2524 so that it is some-
what displaced with respect to the cylinder center.

109
Overhaul/Replacement Group 21: Short block

11
Turn the switch to “1” so that the electromagnet is ac-
tivated. Screw the feed sleeve up so that the cutter
passes freely over the liner shelf.

12
Press the locking brace down and put the centering
roller against the cylinder liner wall, where the dis-
tance to the wall is greatest.
Release the locking brace and move the switch to be-
tween position “1” and “2”.
NOTE: Do not allow the switch to go all the way to
position “2”. The magnetism would then disappear
completely.

110
Group 21: Short block Overhaul/Replacement

13
Center the tool by turning the crank clockwise at the
same time as the horizontal feed ring is held still.
The tool will now move round the liner seat, since it
was placed with an offset in relation to the center of
the cylinder.
If the centering roller looses contact with the liner seat
wall – turn backwards (counter clockwise), at the
same time as the horizontal feed ring is kept still, until
the centering roller is in contact again.
Continue until the tool movements stop and the cen-
tering roller has light contact with the liner seat wall.

14
Move the switch to position “1” when the tool is cor-
rectly centered.

15
Press the brace down and move the cutter so that it
moves across the liner shelf plane, without contacting
the wall of the liner seat.

16
Turn the crank and the vertical feed sleeve clockwise
until the cutter comes into light contact with the liner
shelf plane.
Zero, and lock the scale ring.

17
Press the brace down and move the cutter so that its
tip moves just inside the edge of the liner shelf (inner
diameter).

18
Turn the vertical feed ring clockwise so that the cutter
starts to machine the liner shelf.
NOTE: Do not feed more than 0.05 mm (0.0020") for
the first cut, to check that the cutter works evenly
across the entire surface.
After which, max. 0.15 mm (0.0059").

111
Overhaul/Replacement Group 21: Short block

19
Machine the liner shelf by turning the crank clockwise
at the same time as the horizontal feed ring is held
still.
The cutter will then machine the liner shelf plane from
the inner diameter and outwards towards the outer
wall of the liner seat.
Turn the crank carefully and allow the ring to slide
slightly between your fingers, when the cutter reach-
es the wall of the liner shelf. This makes it possible to
stop precisely when the cutter reaches the wall.
NOTE: Do not force the crank backwards (counter
clockwise), since this can damage the cutter.
Repeat this procedure until the desired dimension
has been reached.

20
Release the electromagnet by moving the switch to
position “2” and remove the milling tool.

21
Clean the liner seat carefully. Install the new cylinder
liner without seal rings, but with the selected adjust-
ment spacer, and re-measure the liner height above
the block plane, as in points 2 –4.
NOTE: Fix the cylinder liner with two press tools
999 0157.

22
If the cylinder liner height above the engine block plane
is within tolerances – install the liner with sealing rings.
Refer to “Cylinder liner, installing” on page 71.

112
Group 21: Short block Overhaul/Replacement

21377

Cylinder liner seat, milling

Beside the timing gear plate (shimming included)

Special tools:
Fixing tool* ................................................. 999 0157
Holder for dial gauge ................................. 999 2479
Spacer (2 pcs) ........................................... 999 6394
Spacer (2 pcs) ........................................... 999 6395
Puller ......................................................... 999 6645
Plate for cylinder liner ................................ 999 6963
* Note. 2 pcs required for each cylinder liner.

Other special equipment:

Extension ................................................... 980 9771
Spacer ....................................................... 980 9772
Milling tool .................................................. 981 2524
Dial gauge ................................................. 998 9876

1
Remove the plate underneath the milling tool by re-
moving the three Allen screws.

2
Fit the extension (extension kit 980 9771) to the cutter
and screw in place.

3
Clean the spacer (extension kit 980 9771) carefully
and fit it to the cylinder block. Fasten with the screws.

4
Perform the milling work as described in the “Cylinder
liner seat, milling” procedure on page 107.

113
Overhaul/Replacement Group 21: Short block

Crankshaft, inspection and

overhaul
The crankshaft is induction hardened.

Inspection
Inspect the crankshaft very carefully to avoid unnec-
essary overhaul.
The following applies when the need for overhaul is
checked:

A. Clean the crankshaft carefully. Measure the bear-

ing journals’ out-of-round, wear and taper. Refer
to “Technical Data”.
B. Investigate whether surface damage occurs on
the bearing races. If there is any damage on the
surface layer, the shaft must be re-ground.
C. Measure lengthwise crookedness in the crank-
shaft (runout).
The crankshaft should be placed on either a pair
of V blocks, under 1st and 7th main bearing jour-
nals.
Or: Set the crankshaft up between centers.
Measurement should be done on the 4:th main
bearing.
Refer to the “Technical Data” chapter for permis-
sible values.
It is not permissible to straighten the crank-
shaft.
D. A crack test shall be performed before and after
any grinding. To check, use a magnetic powder
test, i.e. fluorescent powder which can be seen
under ultraviolet light.

Overhaul
1
Inspection according to points A – D on the previous
page.

2
Grinding to undersize according to specification.
When grinding is done, it is important that fillet radii
and transitions from fillet radii are kept within the
specified dimensions.
IMPORTANT! Grinding of the center main bear-
ing journal requires special care as far as the
measurement “A” is concerned. Refer to “Width
of thrust bearing journal” in the “Technical Data”
chapter.

114
Group 21: Short block Overhaul/Replacement

3
If sharp edges are formed at the oil way inlet holes
during grinding, the edges must be removed with a
small grindstone or emery cloth.

4
Check that there are no grinding burns on the shaft.

5
Check lengthwise crookedness of the crankshaft
(runout). Refer to point C on the previous page.

6
Perform a crack test. Refer to point D on the previous
page.

7
Lapping the bearing journals. Check that the surface
evenness requirement for bearing races and radii has
been met. Refer to “Technical Data”.

8
After grinding, any grinding swarf and contamination
must be carefully cleaned off the shaft (including the
oil ways).

Big end bearing journal,

inspection
1
Check the big end journals and bearing shells.
If any bearing has seized, the reason must be discov-
ered before a new bearing shell is installed.

2
Check the measurements of the big end bearing jour-
nals for taper and ovality. If any of the values exceed
the maximum permissible values, the crankshaft must
be removed and rectified.
Refer to “Technical data”.
Also check if the crankshaft is standard or undersize
if there is doubt.

115
Overhaul/Replacement Group 21: Short block

Main bearings, replace

Oil pan removed
The method describes replacement of main bear-
ings with the crankshaft in place in the engine

Special tools:
Cranking tool ............................................. 999 3590
Puller ......................................................... 999 0114
Slide hammer ............................................ 999 6400

Removal
1
Install cranking tool 999 3590.

2
Remove the oil suction pipe and lube oil pump.
Remove bracing frame.

3
Remove one main bearing cap.

116
Group 21: Short block Overhaul/Replacement

4
Remove the upper bearing shell by placing a pin in
the crankshaft oil hole and roll the bearing shell out
by turning the crankshaft in the direction of rotation
using cranking tool 999 3590.

5
Clean and check the bearing seat, bearing cap, shaft
journal and bearing shell.
If the bearing has seized, the reason must be discov-
ered before a new bearing is installed.

6
Check that the correct bearing dimension is used
when the bearing shells are changed.
NOTE: If you are uncertain, check in “Technical data”
which oversize dimensions are available.

Installation
7
Oil the shaft journal and the new bearing shells with
engine oil.

8
Install the upper bearing shell by turning the crank-
shaft using tool 999 3590 against the direction of rota-
tion with the pin in the oil hole.
NOTE: Check that the shoulder pressed out of the
bearing shell is placed correctly in the bearing seat
recess.
Be careful to make sure that the upper bearing shells
(the ones that should be put in the engine block) are
the ones with oil holes.
NOTE: Remove the pin when done.

9
Fit the main bearing cap together with the lower bear-
ing shell.
NOTE: The main bearing caps are asymmetric and
can only be installed in one position. Write down the
main bearing cap numbers that show their place-
ments if several caps have been removed simulta-
neously.
Torque the bearing caps in two steps, as specified in
“Technical data.”

10
Change the other bearing shells, one a time, in the
same way as the first one. Check after every replace-
ment, that the crankshaft does not bind by turning it
using the cranking tool 999 3590.

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Overhaul/Replacement Group 21: Short block

11
Check the crankshaft axial play and replace the thrust
washers if the clearance is too big or if the thrust
washers are damaged.
NOTE: Axial play is measured using a dial indicator.
The thrust bearings are available in a number of over-
size dimensions. Refer to “Technical data” for over-
size dimensions and axial play.

12
The crankshaft thrust washers are located on the
center main bearing.

13
Use a narrow plastic or wood stick to remove the
thrust bearing washers in the cylinder block bearing
seat.
NOTE: The thrust bearings can only be placed in one
position.

14
Check the axial play of the crankshaft when all main
bearing caps have been torqued. Refer to “Technical
data” for the specification.

15
Install bracing frame and torque as specified in “Tech-
nical data.”

16
Install the lube oil pump and oil suction pipe.

17
Remove cranking tool 999 3590 from the flywheel
cover and fit the protective plug.

18
Install the oil pan.
Add oil and replace oil filter.
Check the oil pressure.

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Group 21: Short block Overhaul/Replacement

Big end bearings, replace (all)

Oil pan, oil suction pipe and bracing frame removed

Special tools:
Cranking tool ............................................. 999 3590

Removal
1
Fit cranking tool 999 3590 in the flywheel cover and
turn the flywheel until the bearing caps on connecting
rod 1 and 6 are in a position where you can remove
the bolts.

2
Mark and remove bearing caps on connecting rods 1
and 6.
NOTE: Be careful not to damage the surfaces.

3
Remove the bearing shells and clean the bearing
seat and bearing cap.
NOTE: Make sure the bearing caps are installed on
the same connecting rod.

4
Check the bearing journals and bearing shells.

5
Check the measurements of the bearing journals. If
any of the values exceed the maximum permissible
values, the crankshaft must be removed and rectified.

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Overhaul/Replacement Group 21: Short block

Installation
6
Fit the new bearing shells and check that the bearing
size is correct. Make sure the bearing shell guide pins
is aligned with the connecting rod recess.

7
Oil the bearing shells and crankshaft journals.
Fit the bearing caps and torque the screws as speci-
fied in “Technical data.”

8
Turn the flywheel so that connecting rods 5 and 2 are
in position to remove the bolts and repeat points 2–7.

9
Turn the flywheel so that connecting rods 3 and 4 are
in position to remove the bolts and repeat points 2–7.

10
Check that none of the big end bearings bind.

11
Remove the cranking tool from the flywheel casing
and install the cover.

12
Install the bracing frame, oil suction pipe and oil pan.
Add oil and replace oil filter.
Check the oil pressure.

120
Group 21: Short block Overhaul/Replacement

21661

Flywheel, removal /installation

Reverse gear removed
Special tools:
Cranking tool ............................................. 999 3590
Lifting chain ............................................... 999 6239

Removal
1
IMPORTANT! Remove the flywheel sensor to
avoid damaging it with the flywheel during disas-
sembly. Remove and save any shims.

2
Mount cranking tool 999 3590 in the flywheel cover.

3
Bolt the lifting chain 999 6239 to the flywheel with two
bolts.
Remove the flywheel retaining screws, Use the
cranking tool as counterhold.
Lift the flywheel away.
WARNING! Crushing hazard. The flywheel
weighs about 65 kg (143 lbs).

121
Overhaul/Replacement Group 21: Short block

Installation
4
Clean the mating face of the crankshaft against the
flywheel very carefully.

5
Clean the mating face of the flywheel against the
crankshaft very carefully and check that the surface
where the sensor grooves are located is completely
free from contamination.

6
Check that the flywheel guide pin in the crankshaft is
in position and is undamaged.

7
Install the flywheel and tighten the bolts in two stages.
NOTE: Make sure that the flange is clean and dry.
Stage 1: 40 ±5 Nm (29.5 ±4 lbf.ft).
Stage 2: 100 ±5 Nm (73.8 ±4 lbf.ft), and then
angle tightening 90° ±10°.
Refer to the torque schedule in “Technical Data”.
Use cranking tool 999 3590 as counterhold.

9
Remove cranking tool and install the cover.

10
Check the distance between the flywheel sensor and
the flywheel. Refer to “Flywheel sensor distance,
checking” in the next section. Install the flywheel sen-
sor.

122
Group 21: Short block Overhaul/Replacement

21687

Gear ring, replace

Reverse gear and flywheel removed
1
Drill 1– 2 holes at an internal tooth base on the gear
ring.
Split the gear ring at the drilled hole, using a cold
chisel and lift the gear ring away from the flywheel.

2
Clean the ring gear contact surface on the flywheel
with a wire brush.

3
Heat up the new gear ring to 180–200°C (356–392°F)
with a welding torch or in an oven. The gear ring must
be evenly heated. Be careful not to heat the gear ring
up too far and anneal it.
Check the heat by polishing the ring bright at several
places. Stop heating when the polished surfaces
have become blued.

4
Put the heated gear ring onto the flywheel and tap it
into place with a soft mandrel and hammer.
Leave the gear ring to cool.

123
Overhaul/Replacement Group 21: Short block

Flywheel sensor distance,

checking
Special tools:
Cranking tool ............................................. 999 3590
Setting tool ................................................ 999 8517

1
Fit cranking tool 9993590 and crank the flywheel to 0°.

2
Remove the speed sensor from the flywheel cover.
Remove and save any shims.

3
Move the locking ring on the setting tool so that it is
located round the center of the tool.

4
Fit the tool in the sensor hole and press the tool in
with care until it touches the flywheel.

5
Remove the tool and measure the distance between
the locking ring and the end of the tool.
Write down the value measured (A).

124
Group 21: Short block Overhaul/Replacement

6
Place the sensor in the tool and measure the distance
between the sensor bracket contact surface and the
end of the tool.
Note the value measured (B).

7
Calculate the existing sensor distance (D) as follows:

Metric: Imperial:
D = A – (B + 20) mm D = A – (B + 0.787) in.

Example:
Distance A = 28.2 mm Distance A = 1.110"
Distance B = 8 mm Distance B = 0.315"
D = 28.2 – (8 + 20) mm D = 1.110 –(0.315 + 0.787)"
D = 0.2 mm D = 0.008"

Compare the distance with the correct value:

1.1 ±0.4 mm (0.043 ±0.016").
The measured distance can be increased to the cor-
rect value by putting spacer washers (part No.
1677894 thickness 0.6 mm / 0.024") between the
sensor and the flywheel cover.

8
Install the engine speed sensor on the flywheel cover
together with any spacer washers.

9
Remove the cranking tool from the flywheel cover and
install the cover.

125
Overhaul/Replacement Group 21: Short block

21672

Crankshaft seal, front, replace

Special Tools
Slide hammer ........................................... 999 6400
Puller ........................................................ 999 0192
Mandrel .................................................... 888 00021
Handle ...................................................... 999 2000

1
Extract the seal with tool 999 0192 together with the
slide hammer 999 6400.

2
Clean the seal seat in the cover and the sealing sur-
face on the crankshaft.

3
Check that the tools are undamaged, to prevent dam-
age to the seal.

4
Mount the seal with drift 888 00021.
NOTE: No lubrication. This should be installed com-
pletely dry.

5
Mount the handle 999 2000 on 888 00021 and careful-
ly tap in the new seal until the tool bottoms against
the crankshaft.
Remove the tool and check that the seal is correctly
installed.

6
Install the oscillation damper and belt pulley.
Tighten the bolts as follows:
Stage 1: 35 ±5 Nm (25.8 ±4 lbf.ft).
Stage 2: 90 ±10 Nm (66.4 ±7 lbf.ft).
Refer to the torque schedule in “Technical Data”.

Note. The following applies to engines with a “stub-

shaft” at the front: 125 ±10 Nm (92.2 ±7 lbf.ft).

126
Group 21: Short block Overhaul/Replacement

Crankshaft seal rear, replace

Flywheel removed

Special tools:
Slide hammer ............................................ 999 6400
Fitting tool .................................................. 999 0166
Puller ......................................................... 999 0192
Mandrel ..................................................... 999 2000

1
Apply tools 999 6400 and 999 0192 to the old seal by
pressing in or knocking in with the slide hammer.
NOTE: Protect the crankshaft by leaning the tool in-
ward and so that you get a good grip on the seal.
Knock out the seal with the tool.

2
Clean the seal seat in the flywheel cover (timing gear
cover) and sealing surface on the crankshaft (sealing
surfaces should be completely clean and dry).

3
Place the tool on the crankshaft and tighten with the
bolts. Make sure that the plate on the tool is touching
the crankshaft before tightening it.
The washer should be placed on the center screw as
spacer. It determines how far the seal is pressed into
the cover.

127
Overhaul/Replacement Group 21: Short block

4
Fit the plastic ring that holds the new seal and fit the
cover with the screw handle.

5
Press in the seal using the tool. The seal is in the cor-
rect position when the cover bottoms on the tool.
NOTE: No lubricants may be used and surfaces shall
be clean.

6
Remove the tool.

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Group 21: Short block Overhaul/Replacement

Con rod, inspection

Important consideration when removing /install-
ing “fracture-split” connecting rods.
Fitting a NEW connecting rod:
Carefully fix the con rod in a vise with soft jaw pads.
Undo the con rod bolts a few turns and carefully tap
the bearing cap with a plastic faced hammer until it
loosens.
The parting line can be difficult to find when the con
rod is assembled.
When the cap is separated from the con rod, it may
occur that a chip is missing or comes loose. This
does not affect the function of the con rod at all.
Handle the con rod and bearing cap carefully. If any
dents occur on the parting line, this can affect the
strength after torquing.
IMPORTANT! Replace connecting rod if the rod
or cap is damaged.

Gudgeon pin bushing, check

measurement
1
Check the con rods for cracking, straightness and
twist before considering changing the gudgeon pin
bush. Discard the connecting rod if it is cracked, bent
or twisted.
When the gudgeon pin bush has been changed, the
bush must be machined (trapezoid shaped gudgeon
pin end).
When the clearance is correct, an oiled gudgeon pin
2 3 should slowly slide through the bush under its own
weight.
IMPORTANT! Regarding max. allowed straight-
ness and twist deviation, see “Technical data”.

2
Use a new piston pin and measure the connecting
rod straightness in a fixture.

3
Measure con rod twist.

129
Overhaul/Replacement Group 21: Short block

Valves, removing
Special tools:
Fixture ....................................................... 999 0160
Hydraulic cylinder ...................................... 980 9729
Press tool .................................................. 999 0176
Pin ............................................................. 999 6159
Mandrel, inlet ............................................. 999 8246
Mandrel, exhaust ....................................... 999 0174
Hydraulic pump (pneumatic) ...................... 980 9726
or (manual) ...................... 999 2670

Work will be simplified if the cylinder head is attached

to an assembly stand with fixture 999 0160. Use four
bolts M8 x 25.
NOTE: It is important to maintain complete cleanli-
ness when working on the cylinder head. Dirt parti-
cles in the fuel ducts can cause failure or malfunction
of the unit injectors.

Alternative 1
1
Fit hydraulic cylinder 980 9729 in press tool 999 0176.

2
Fit pin 999 6159 and tool 999 8246 (inlet) or 999 0174
(exhaust) on the hydraulic cylinder. Put the tool in the
holes for the cylinder head fixing bolts.
Tighten the nuts of the tool.

3
Connect hydraulic pump 980 9726 (or 999 2670).

4
Press the valve spring washer down and remove the
collets.
WARNING! Use protective goggles.

NOTE: Check that the tool does not damage the unit
injector connector, if the injector is left in place.
NOTE: Put the valves and springs in a marked stand,
to so that the components can be put back in the
same places in the cylinder head.

130
Group 21: Short block Overhaul/Replacement

5
Remove the remaining valves using the press tool in
the same way.

6
Remove the valve stem seals from the valve guides.

Alternative 2
Special tools:
Press tool .................................................. 999 0210

1
Place the cylinder head on a clean, flat surface.
NOTE: Make sure that the cylinder head is not
scratched when the valves are removed.

2
Fit press tool 999 0210 in the unit injector hole. Fix the
tool in the screw hole for the unit injector fixing yoke,
M10 x 30.

3
Put the moving part of the tool over the valve spring
to be removed. Screw down the “wing nut” on the tool
until the valve washer has been pressed down so far
that the collets can be removed.
WARNING! Use protective goggles.

NOTE: Place valves and springs in a marked rack to

facilitate reinstallation at the same place in the cylin-
der head.

4
Remove the remaining valves in the same way as
above.

5
Remove the valve stem seals from the valve guides.

131
Overhaul/Replacement Group 21: Short block

Valves, installation
Special tools:
Hydraulic cylinder ..................................... 980 9729
Press tool ................................................. 999 0176
Adapter ..................................................... 999 6159
Tool, inlet .................................................. 999 8246
Tool, exhaust ............................................ 999 0174
Hydraulic pump (pneumatic) ..................... 980 9726
or (manual) ..................... 999 2670
Valve spring compressor .......................... 999 0210
Guide sleeve ............................................ 888 00011
Mandrel .................................................... 888 00151

Alternative 1
1
Oil the valve stems and install the valves.
Oil the valve stem seals.

2
Place guide sleeve 888 00011 on the valve stem and
press the new valve stem seal down over the valve
guide.

3
Tap the valve stem seal down carefully with tool
888 00151.
NOTE: Check that the seals are pressed down proper-
ly.

4
Mount the guide pin for the valve yoke (exhaust).
Fit the valve springs and valve spring washers.
NOTE: Exhaust valves have double springs.
Carefully press down the valve spring washer and in-
stall the collets. Use press tool 999 0176 together with
hydraulic cylinder 980 9729, pin 999 6159 and tool
999 8246 (inlet) or 999 0174 (exhaust) in the same
way as with disassembly.
WARNING! Use protective goggles.

Alternative 2
Alternatively, tool 999 00210 an be used instead of
the hydraulic cylinder, in the same way as with disas-
sembly.

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Group 21: Short block Overhaul/Replacement

21405, 21406

Valve seat, replace

Cylinder head and valves removed

Special tools:
Holder for dial gauge ................................. 999 2479
Dial gauge ................................................. 999 9876

1
The valve seats should be replaced if you cannot get
perfect sealing or when the distance “A” exceeds the
value shown in the specification. Refer to “Technical
Data”.

2
Grind the head off an old valve and weld it onto the
valve seat. Use a MAG welder, or a conventional arc
welder (with a stainless welding electrode).
IMPORTANT! Carefully cover other cylinder
head surfaces so that any weld splatter will not
stick.

3
Place an appropriate socket over the valve/valve
guides and tap out the valve seat carefully.
NOTE: Be careful not to damage the cylinder head.
NOTE: Use protective goggles.

133
Overhaul/Replacement Group 21: Short block

4
Clean the seat bed carefully and check the cylinder
head for cracks.

5
Measure the diameter of the valve seat bed in the cyl-
inder head. Investigate whether a standard or over-
size dimension valve seat should be used.
Do any machining needed on the valve seat bed. Re-
fer to “Technical Data”.

6
Cool the seat in dry ice to between –60°C and –70°C
(–76°F and –94°F) and heat the cylinder head by
hosing it with hot water or some other suitable source
of heat.
Press in the valve seat in with a mandrel.
NOTE: Turn the seat with the seat angle towards the
tool.

134
Group 21: Short block Overhaul/Replacement

21410

Valve guides, inspection

Cylinder head removed

Special tools:
Dial indicator .............................................. 998 9876
Magnetic stand .......................................... 999 9696

1
Remove the valve stem seals from the valve guides.

2
Place the cylinder head on the workbench with the
valve heads facing up.
IMPORTANT! The cylinder head must not be
put down so its entire weight rests on the valve
guides (see figure).

3
Place a new valve in the valve guide with the valve
stem end in the same plane as the edge of the guide.
Use a suitable counterhold under the valve stem.

4
Place dial gauge 998 9876 with magnetic stand
999 9696 so that the probe presses against the edge
of the valve head.
Move the valve sideways in the direction of the outlet-
and intake ducts. Read off the value on the dial
gauge.

5
Check all valve guides. If the measurement values
exceed the values noted in the specifications, the
valve guide must be changed. Refer to “Technical
Data”.

135
Overhaul/Replacement Group 21: Short block

21411, 21412

Valve guides, replacing

Cylinder head removed

NOTE: If the valve seats are also going to be changed,

this must be done before the valve guides are re-
moved.

Special tools:
Pin ............................................................ 999 6159
Hydraulic cylinder ..................................... 980 9729
Press tool ................................................. 999 0176
Mandrel, for disassembly .......................... 888 00137
Mandrel, for installation (inlet) ................... 888 00064
Mandrel, for installation (exhaust) ............. 888 00127
Hydraulic pump (pneumatic) ..................... 980 9726
or (manual) ...................... 999 2670

Removal
Note. The valve guides are pressed out from under-
neath the cylinder head.

1
Mount hydraulic cylinder 980 9729 in tool 999 0176.

2
Mount pin 999 6159 in the hydraulic cylinder and
press out the valve guides with mandrel 888 00137
and hydraulic pump 980 9726 or 999 2670.
WARNING! Use protective goggles.

Press the other valve guides out in the same way.

136
Group 21: Short block Overhaul/Replacement

Installation
3
Oil the holes for the valve guides in the cylinder head
with engine oil before installation.

4
Heat the cylinder head with hot water and cool the
valve guides with e.g. dry ice at the same time.
Press in the valve guides with tool 888 00064
(inlet), or. 888 00127 (exhaust).
Press until the tool bottoms against the cylinder head
plane.
WARNING! Use protective goggles.

5
Remove the tool and check that the valve guides
have the correct height above the cylinder head
plane. For the relevant measurement, refer to “Tech-
nical data”.

IMPORTANT! Clean the cylinder head and blow

clean the fuel and oil ways thoroughly after re-
placing the valve guides. Contamination can
damage or cause malfunction of the unit
injectors.

137
Overhaul/Replacement Group 21: Short block

Valve seat, grinding

Special tools:
Dial indicator .............................................. 998 9876
Stand for dial gauge .................................. 999 2479

The valve seats should be replaced when dimension

(A), measured with a new valve, exceeds the value
given in the specification. See “Technical data”.
NOTE: Spare part valve seats are already machined,
and should not need further grinding.
When the valve seats are replaced, the valves must
also be replaced.

1
Before the valve seats are ground, the valve guides
should be checked and changed if the wear toleranc-
es have been exceeded.

2
When the valve seats are ground, do not remove an
unnecessary amount of material, only remove enough
material to give the valve seat the correct shape and
a good mating surface.
Inlet valve
3
Grind new seats down so that the dimension between
the cylinder head plane and the valve head surface is
in accordance with the specification. Refer to “Techni-
cal Data”.

4
Check the valve seat angle with a valve seat gauge,
once the seat mating surface has been coated with a
thin layer of marker dye.

Exhaust valve

138
Group 21: Short block Overhaul/Replacement

21401, 21402

Valves, grinding
Special tools:
Dial indicator .............................................. 998 9876
Stand for dial gauge .................................. 999 2479

If the measurement (A), (measured with a new valve)

exceeds the wear tolerance, the valve (or valve and
valve seat) shall be replaced.
The wear tolerance is given in the specification. See
“Technical data”.
NOTE: Grind the sealing surface as little as possible.
But enough to remove all damage.
NOTE: Spare part valve seats are already machined,
and should not need further grinding.

1
Check the distance from valve head to the cylinder
head plane (A). If the measurement exceeds the
wear tolerance, the valve must be replaced.
NOTE: Always change a valve with a bent stem.

2
Check valve sealing with marker dye. Grind the valve
seat again if it does not seal properly. Refer to “Valve
seat, grinding” on the previous page.
Inlet valve And then check the sealing again.
Lap the valve and seat with a fine grinding paste once
the sealing results are approved.

Exhaust valve

139
Overhaul/Replacement Group 21: Short block

Valve stem seals, replace

Special tools:
Guide sleeve ............................................ 888 00011
Valve spring compressor .......................... 999 0210
Cranking tool ............................................ 999 3590
Mandrel .................................................... 888 00151

1
Remove power from the engine by turning off the
main switch.

2
Remove the unit injectors. Refer to “Unit injector,
change”.

3
NOTE: The piston must be at TDC when the valves
are removed. This is to prevent the valves from falling
down into the cylinder. Use cranking tool 999 3590.

4
Press down the valve springs for cylinder no.1. Use
tool 999 0210.

5
Remove the valve spring washers, valve springs and
collets.

6
Remove the old valve stem seals.

7
Oil the valve stems and valve stem seals.
Place the guide sleeve 888 00011 on the valve stem
and press the new valve stem seal down over the
valve guide.

140
Group 21: Short block Overhaul/Replacement

8
Tap the valve stem seal down carefully with tool
888 00151.
NOTE: Check that the seals are pressed down proper-
ly.

9
Install the valve spring washers, valve springs and
collets. Carefully tap with a plastic faced mallet to put
the collets in the correct positions.

10
Transfer the valve spring compressor to No. 6 cylin-
der and repeat the procedure above. Then crank the
engine so that No. 3 and No. 4 cylinder are at TDC.
Repeat the procedure. Then continue with cylinders 2
and 5.
NOTE: The piston must be at TDC when the valves
are removed. This is to prevent the valves from falling
down into the cylinder. Use cranking tool 999 3590.

11
Install the unit injectors. Refer to “Unit injector, re-
place”.

12
Adjust the valves and unit injectors. Refer to “Valves
and unit injectors, adjusting”.

13
Purge the fuel system. Perform a function and leak-
age check.

141
Overhaul/Replacement Group 21: Short block

21111

Cylinder head, pressure

testing
Special tools:
Overhaul stand .......................................... 998 6485
Connection washer .................................... 999 0107
Fixture ....................................................... 999 0160
Seal plates ................................................. 999 0164
Lifting chain* (2 required) ........................... 999 6239
Pressure testing device ............................. 999 6662
* Note. Use 2 lifting chains 9996239 for all lifting of the cylinder
head. Refer to “Cylinder head, removal”.

Pressure testing unit, checking

Check the pressure testing device 999 6662 before
using it, as follows:

1
Connect the pressure testing device to the workshop
compressed air system. Set the pressure gauge to
100 kPa (14.5 psi) with the reduction valve.
Note. The knob on the reduction valve can be locked
with a lock ring which is moved axially.
NOTE: Always observe the relevant safety rules.

2
Close the shut-off tap. The pressure on the pressure
gauge must not fall during 2 min. for the pressure
testing unit to be regarded as being reliable.

3
Check that the knob on the reduction valve is
screwed out.

142
Group 21: Short block Overhaul/Replacement

Pressure testing the cylinder head

Cylinder head removed

1
Wash the cylinder head in a wash bay.

2
Fit the cylinder head to an assembly stand 998 6485
using fixture 999 0160 and 4 bolts (M8 x 25).

3
Clean contact surfaces on the cylinder head.

4
Fit seal plates 999 0164 on the cylinder head using
the cylinder head bolts and M18 nuts (14 needed).

5
Fit connection washer 9990107 onto the thermostat
housing seat. Fix the washer with a G-clamp, see figure.
Leave the air filter bracket in place.

6
Leave the coolant temperature sensor in place.
Plug the coolant connections to the turbocharger.

7
Connect the hose from the pressure testing device to
the connection washer 999 0107.

8
Release the cylinder head, with fixture, from the over-
haul stand.
Remove the fixture.

9
Lower the cylinder head into a water bath (+70°C /
158°F).

10
Connect air to the pressure testing device.
Open the shut-off valve.

143
Overhaul/Replacement Group 21: Short block

11
Adjust the pressure reduction valve knob so that
pressure gauge shows a pressure of 50 kPa (7.3 psi).
Maintain the pressure for 1 minute.

12
Raise the pressure to 150 kPa (21.8 psi). Lock the re-
duction valve knob with the locking ring.
Close the shut-off valve.

13
Check after 1– 2 minutes if the pressure has dropped
or if there are bubbles in the water bath.
If you see bubbles, check seal plates and inspect the
cylinder head for any cracks.

14
Eliminate excess pressure in the cylinder head by un-
screwing the valve on the reduction valve.

15
Take the cylinder head up out of the water bath.
Attach the fixture.
Mount the cylinder head in the overhaul stand.

16
Blow the cylinder head dry. Be extra particular with
the fuel channels.
NOTE: Make sure that no dirt gets into the fuel chan-
nels, since this could damage the unit injectors.

17
Remove the sealing plates, connection washer and
any plugs fitted for the pressure test

18
Release the cylinder head, with fixture, from the over-
haul stand.
Remove the fixture.

144
Group 21: Short block Overhaul/Replacement

Copper sleeve for unit injector,

replace
Unit injector removed

Special tools:
Thread cutting tool .................................... 980 9667
Cranking tool ............................................ 999 3590
Seal ring ................................................... 999 8250
Sealing plug .............................................. 999 8251
Thread cutter ............................................ 999 8252
Puller ........................................................ 999 8253
Cleaning kit ............................................... 999 8599
Expander .................................................. 888 00102

1
Drain the coolant. Refer to “Cooling system, draining”
on page 187.

2
Remove the sealing plug 999 8251.

3
Install 2 sealing rings, 999 8250 in order to prevent
dirt from entering the fuel channels when the copper
sleeve is removed.
NOTE: Ensure that the piston is in its lower position.

4
Grease the thread cutter 980 9667 in order to prevent
swarf from falling into the cylinder.
Screw the tap at least 20 mm (0.8") into the copper
sleeve with tool 999 8252.
NOTE: Use thread cutter 980 9667.

5
Remove the tool 999 8252 and thread cutter.

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Overhaul/Replacement Group 21: Short block

6
Check that the pin 980 9668 is installed on 999 8253.
Screw in the pin on tool 9998253 at least 15 mm
(0.6") into the copper sleeve. Remove the copper
sleeve by turning the nut at the same time as the pin
is held tight.

7
Use cleaning kit 999 8599 and an electric drill before
fitting the new copper sleeve.
Mount sleeve 999 8580 in the injector well and fix it
with the holder (the “ears” must be cut off to get the
tool to fit).
NOTE: Sleeve 980 8580 must be used to prevent dirt
entering the fuel channel.

8
Clean the cylinder head walls for the copper sleeve
with 980 8618.

9
Clean the copper sleeve seat with brush 980 8614 to-
gether with handle and holder.

146
Group 21: Short block Overhaul/Replacement

10
Clean the cylinder head hole with brush 980 8617.

11
Remove tool 999 8580.

12
Check that the piston is in its lower position in the cyl-
inder.
NOTE: This should be done so that tool 888 00102
does not damage the piston due to its length.

13
Lubricate the new sealing ring on the copper sleeve
with soapy water.

14
Place the copper sleeve on tool 888 00102.

15
Oil the pin on tool 888 00102. Lubricate between nut
and tool.

16
Press the copper sleeve down carefully so that the
expansion tool locates against the area for the unit in-
jector (edge) in the cylinder head. Check that the cop-
per sleeve “bottoms” in the cylinder head.
Install the unit injector yoke and tighten it.

147
Overhaul/Replacement Group 21: Short block

17
Enlarge the copper sleeve with a drift by screwing on
the nut while the spindle is held steady until the en-
larging drift has been pulled all the way through.
NOTE: After fitting new copper sleeve, follow instruc-
tions for torquing of unit injector yoke in “Technical
data”.

18
Remove the sealing rings 999 8250.

19
Install the unit injector. Refer to “Unit injector, replace”.

20
Reinstall the valve yoke according to the marks.

21
Install the rocker bridge and check the clearance of
the valves and unit injectors.

22
Install the valve cover and tighten the bolts to 24 ±4
Nm (17.7 ±3 lbf.ft). Refer to the torque schedule in
“Technical Data”.

23
Fill up with coolant and check that no leakage occurs.

148
Group 21: Short block Overhaul/Replacement

Camshaft, wear check

Rocker bridge removed

Place a steel ruler above the lobes in the camshaft’s

lengthwise direction in order to check if the cam pro-
files are worn.
Measure the wear with a feeler gauge or wire gauge.
Alternatively, a digital caliper gauge can be used.
Compare the measured values with those specified in
“Technical Data”.

Guidlines for replacement

In normal conditions, un-evenness may occur on the
camshaft lobes in the engine. This does not mean
that the camshaft has to be changed. These marks
do not have any negative influence on either engine
performance or durability of the engine and its com-
ponents.
Examples of acceptable wear and unacceptable
wear are shown below.

Acceptable wear
The camshaft does not need to be changed.

149
Overhaul/Replacement Group 21: Short block

NOT acceptable wear

NOTE: Camshaft with associated rocker arms must
be replaced.

Bearing housing for camshaft,

replace
The production-installed bearing housings are ma-
chined together with the cylinder head, and can there-
fore not be moved from one cylinder head to another
one.
Therefore, the first time one or more bearing hous-
ings are replaced, all bearing housings must be re-
placed so that the positions of the bearing housings
can be aligned. Bearing housings can then be re-
placed individually.

The holes for the guide sleeves are oval in the re-
placement housings, which allows radial adjustment
of the middle bearing housing and axial adjustment of
the front and rear bearing housings.
1 If a replacement housings are installed, mark them
with their numbers, so they can be put back in the
same place as before, if they have to be removed.
2– 6

150
Group 21: Short block Overhaul/Replacement

Camshaft sensor distance,

checking
Special tools:
Cranking tool ............................................. 999 3590
Setting tool ................................................ 999 8517

1
Remove the engine speed sensor from the timing
gear cover. Remove and save any shims.

2
Crank the engine until a tooth on the oscillation damp-
er is directly in front of the hole for the camshaft sen-
sor in the timing gear cover.

3
Move the locking ring on the setting tool so that it is
located round the center of the tool.

4
Place tool 999 8517 in the camshaft sensor hole and
press gently so that it touches the tooth on the oscilla-
tion damper.

5
Remove the tool and measure the distance between
the locking ring and the end of the tool.
Write down the value measured (A).

6
Place the sensor in the tool and measure the distance
between the sensor contact surface and the end of
the tool.
Note the value measured (B).

151
Overhaul/Replacement Group 21: Short block

7
Calculate the existing sensor distance (D) as follows:
Metric: Imperial:
D = A – (B + 20) mm D = A – (B + 0.787) in.

Example:
Distance A = 28.2 mm Distance A = 1.110"
Distance B = 8 mm Distance B = 0.315"
D = 28.2 – (8 + 20) mm D = 1.110 –(0.315 + 0.787)"
D = 0.2 mm D = 0.008"

Compare the distance with the correct value:

1.1 ±0.4 mm (0.043 ±0.016").
The measured distance can be increased to the cor-
rect value by putting spacer washers (part No.
D = Clearance in mm 2 = Toothed wheel 1677894, thickness 0.6 mm / 0.024") between the
sensor and the timing gear cover.
1 = Spacer washer 3 = Camshaft sensor

8
Install the sensor together with any shims.

152
Group 21: Short block Overhaul/Replacement

Timing gear, replace

Special tools:
Lifting chain ............................................... 999 6239
Lifting eyes (2 pcs) .................................... 999 8629

Valve cover, cable harness, timing gear cover,

camshaft sensor, oil pan, and oil pump removed.

Removal
1
IMPORTANT! Remove the flywheel sensor to
avoid damaging it with the flywheel during disas-
sembly. Remove and save any shims.

2
Crank the engine to “TDC” on the camshaft. Check
that the mark on the flywheel is at “0°”.

3
Bolt lifting chain 999 6239 to the flywheel.
Remove the bolts and lift off the flywheel.
WARNING! Crushing hazard. The flywheel
weighs about 65 kg (143 lbs).

4
Remove the protective covers, starter motor, rear lift-
ing eye, fuel pump complete with intermediate hous-
ing and possibly the rear engine mount.

153
Overhaul/Replacement Group 21: Short block

5
Undo the flywheel cover bolts. Remove the cover us-
ing lifting eyes and lifting strap.

6
Remove the fuel pump idler gear (7).

7
Remove the oscillation damper and camshaft gear
(1).

IMPORTANT! The oscillation damper must not

be subjected to blows or impacts.

WARNING! Never turn the crankshaft or

camshaft when the timing gear wheels
have been removed, if the rocker arm
bridge is in place.
Pistons and valves might come into con-
tact with each other and be damaged.

8
Remove the two bolts in the crankshaft gear (4) and
remove the gear using a suitable puller.
NOTE: Place a thick washer between the threaded rod
and the crankshaft to protect the thread from the puller.

9
Undo the six Allen bolts from the hub of the bull drive
(3) and remove the complete gear.

10
Remove the upper (adjustable) idler gear (2).
NOTE: Save the spacer plate behind the drive and
note how it is installed.

11
Remove the timing gear plate and clean both sides.

1. Gear, camshaft
2. Idler wheel, adjustable
3. Idler gear, bull gear
4. Crankshaft gear
5. Gear, lube oil pump
6. Gear, fuel pump
7. Idler wheel, fuel pump
8. Gear, seawater pump

154
Group 21: Short block Overhaul/Replacement

Installation
NOTE: Lubricate the bearing surfaces of the gears
before assembly.

1
Apply an approx. 2 mm (0.079") wide bead of sealant
(part No. 1161231) to the cylinder block as illustrated.
Note. Use a marker pen to mark up where the seal-
ant should be applied.

2
Install the timing gear plate if it has been removed.
IMPORTANT! Use new bolts that are treated
with locking fluid.
Tighten the bolts to 28 ±4 Nm (20.7 ±3 lbf.ft) (M8),
and 60 ±8 Nm (44.3 ±6 lbf.ft) (other bolts). Refer to
the torque schedule in “Technical Data”.
NOTE: Torque within 20 minutes after sealant has
been applied.

3
Oil the spacer plate and place it together with the up-
per (adjustable) idler gear (2). Tighten to a low torque
(max. 10 Nm / 7.4 lbf.ft).

4
Fit a new O-ring to the crankshaft.

5
Install the crankshaft gear (4) and tighten the Allen
bolts in two stages.
Stage 1: 60 ±5 Nm (44.3 ±3 lbf.ft).
Stage 2: Angle tighten 120° ±10°.
NOTE: Make sure that the mating surfaces on crank-
shaft and gear are clean and flawless.

6
Install the bull-gear (3) with the mark in between the
two marks on the crankshaft gear.
NOTE: The inner and outer gears have different
pitches. For the camshaft to be set correctly, the
markings must be correct.
Tighten the bolts in two stages.
Stage 1: 45 ±5 Nm (33.2 ±3 lbf.ft).
Stage 2: Angle tighten 90° ±5°.
Refer to the torque schedule in “Technical Data”.

155
Overhaul/Replacement Group 21: Short block

7
Install the idler gear (7) for the fuel pump with a new
O-ring.

8
Install the lube oil pump.

9
Place two screws in the crankshaft gear so you can
attach a crowbar and thus be able to turn the crank-
shaft as needed.

10
Install the camshaft gear (1) without the oscillation
damper. Use nuts as spacers.

11
Place the gear so that the reference hole in the timing
gear plate lies between the gear markings.
Temporarily tighten the bolts to a low torque (max.
10 Nm / 7.4 lbf)).

12
1 Loosen the two lower bolts (1) for the adjustable idler
gear. Check that the upper bolts are not tightened.

13
Place a 0.10 mm (0.004") feeler gauge on the pres-
sure side. Turn the camshaft gear against the feeler
gauge.
Tighten the upper (adjustable) idler gear to 35 ±4 Nm
(25.8 ±3 lbf.ft) (stage 1).
Refer to the torque schedule in “Technical Data”.
Remove the feeler gauge.

156
Group 21: Short block Overhaul/Replacement

14
Check the backlash as follows:
Fix the upper (adjustable) idler gear.
Place a dial indicator on the camshaft gear as illus-
trated.
Turn the gear back and forth and measure the back-
lash. The backlash should be 0.05 –0.15 mm
(0.0020 – 0.0059").

15
If gear backlash is correct: Angle tighten the idler
gear bolts 90° ±5° (stage 2).
Refer to the torque schedule in “Technical Data”.

16
Remove the old crankshaft seal from the flywheel
cover.
Apply sealant (part No. 1161231) to the flywheel cov-
er contact surface on the cylinder block.

17
Install the flywheel cover and tighten the bolts in three
stages. Check that the cover aligns with the under
edge of the cylinder block.
Stage 1: Tighten all M14 bolts to 160 ±20 Nm
(118 ±15 lbf.ft).
Stage 2: Tighten all M10 bolts to 48 ±8 Nm
(35.4 ±6 lbf.ft).
Stage 3: Tighten all M8 bolts to 24 ±4 Nm
(17.7 ±3 lbf.ft).
Refer to the torque schedule in “Technical Data”.

18
Install a new crankshaft seal. Refer to “Crankshaft
seal rear, replace” on page 127.
NOTE: No lubrication. The seal should be installed
completely dry.

157
Overhaul/Replacement Group 21: Short block

19
Install the flywheel and tighten the bolts in two stages.
NOTE: Make sure that the flange is clean and dry.
Stage 1: 40 ±5 Nm (29.5 ±4 lbf.ft).
Stage 2: 100 ±5 Nm (73.8 ±4 lbf.ft), and then
angle tightening 90° ±10°.
Refer to the torque schedule in “Technical Data”.
Install the flywheel sensor with any spacers. See
“Flywheel sensor distance, checking” on page 124.

20
Fit the camshaft oscillation damper and tighten the
bolts in two stages.
Stage 1: 45 ±5 Nm (33.2 ±4 lbf.ft).
Stage 2: Angle tighten 90° ±5°.
Refer to the torque schedule in “Technical Data”.
IMPORTANT! The oscillation damper must not
be subjected to blows or impacts.

21
Apply an approx. 2 mm (0.079") wide bead of sealant
(part No. 1161231) to the timing gear cover contact
surface as illustrated.

22
Install the rubber seal and mount the timing gear cov-
er.

158
Group 21: Short block Overhaul/Replacement

23
Only fit bolt (1) and tighten by hand.
Note. The holes are oblong so that you can press the
casing down towards the rubber seal.

24
Press the cover down with tools 885810 and
999 8601 so that the cylinder head and the upper tim-
ing gear cover sealing surfaces are aligned.
Refit the other bolts (2).
Torque the screws to 27 ±4 Nm (20 ±3 lbf.ft). Refer
to the torque schedule in “Technical Data”.
NOTE: The timing gear cover must be installed and
torqued within 20 minutes after sealant application.

25
Install the camshaft sensor with any spacers. Refer to
“Camshaft sensor distance, check” on page 151.

26
Reinstall other components that were removed.

159
 Group 22: Lubrication System

1
Overview, control valves
1. Overflow valve for by–pass filter
2. Bypass valve for full-flow filter
3. Bypass valve for oil cooler (marked “124”)
4. Piston cooling valve
5. Control valve for piston cooling
6. Reduction valve, lube oil pressure (blue color)
7. Safety valve, lube oil pressure (purple color)
7
5
6

4 3

160
Group 22: Lubrication System Overhaul/Replacement

Overflow valve for

by-pass filter, replace
1
Undo the pressure line to the turbocharger.

2
Clean the area around the overflow valve.

3
Remove the overflow valve (1).

4
Clean the valve contact surface in the oil filter hous-
ing.

5
Fit the new the valve with a new seal ring and tighten
the plug to 55 ±5 Nm (40.6 ±4 lbf.ft).

6
Tighten the pressure line to the turbocharger.

7
Start the engine and check that no leakage occurs.

Overflow valve for full-flow

filters, replace
1
Clean the area around the overflow valve.

2
Remove the valve (2) and clean the valve seat in the
filter bracket.

3
Fit a new valve with a new sealing ring.
Tighten the plug to 55 ±5 Nm (40.6 ±4 lbf.ft).

4
Start the engine and check that no leakage occurs.

161
Overhaul/Replacement Group 22: Lubrication System

By-pass valve oil cooler,

replace
1
Clean the area around the bypass valve and remove it.
Clean the valve seat.

2
Install the new valve (3) with a new O-ring.
Install the cover with a new O-ring. Tightening torque
10 ±2 Nm (7.4 ±1.5 lbf.ft).

3
Start the engine and check that no leakage occurs.

Piston cooling valves, replace

4
1
Clean around the oil filter bracket and the piston cool-
ing valves.

2
5 Remove the filter bracket.

3
Remove the piston cooling valves (4) and control
valve (5).

4
Clean valve seats in the filter bracket.

5
Install new valves with new sealing rings. Tighten the
plugs to 55 ±5 Nm (40.6 ±4 lbf.ft).

6
Re-install the filter bracket, with new gasket and new
sealing rings. Tightening torque: 24 ±4 Nm (17.7 ±3
lbf.ft).
Refer to the torque schedule in “Technical Data”.

7
Start the engine and check that no leakage occurs.

162
Group 22: Lubrication System Overhaul/Replacement

6 Reduction valve, replace

1
Clean the area around the reduction valve.

2
Remove the reduction valve (6).

3
Clean the valve contact surface in the oil filter hous-
ing. Check that the old seal is not still in place.

4
Fit the new valve with a new sealing ring. Check that
the ring does not come loose when the valve is in-
stalled.
Install the cover with a new O-ring. Tightening torque
10 ±2 Nm (7.4 ±1.5 lbf.ft).

5
Start the engine and check that no leakage occurs.

Safety valve, oil pressure,

replace
1
Clean the area around the valve (7) and remove it.
7

2
Clean the valve contact surface.

3
Fit the new valve with a new sealing ring. Check that
the ring does not come loose when the valve is in-
stalled.
Install the cover with a new O-ring. Tightening torque
10 ±2 Nm (7.4 ±1.5 lbf.ft).

4
Start the engine and check that no leakage occurs.

163
Overhaul/Replacement Group 22: Lubrication System

Oil pressure sensor, inspection

Special tools:
Hose .......................................................... 999 8493
Nipple ........................................................ 999 6598
Manometer ................................................ 999 6398

The pressure sensor is located in the cylinder block

behind the heat exchanger. Refer to “Location of
measurement connections” on page 37.

1
Remove the oil pressure sensor and fit nipple (part
No. 847899) together with a copper washer.

2
Mount nipple 999 6598, hose 999 8493 and manome-
ter 999 6398.

3
Start the engine and check the oil pressure.
If the measurement shows that the pressure is below
the minimum value specified in “Technical data”, con-
tinue troubleshooting by checking/replacing the oil fil-
ter.
Replace the pressure sensor if the measurement
shows that the pressure is within tolerance but di-
verges from the engine’s ordinary pressure sensor.

4
Remove the manometer, hose and nipples.

5
Install the oil pressure sensor and connect the wires.

164
Group 22: Lubrication System Overhaul/Replacement

Pressure reduction valve,

checking
1
Check that the reduction valve is blue in color.

2
Check that the valve is not damaged, which would im-
pair its function.
Press in the valve poppet (1) with a blunt object and
check that it does not seize and that it seals against
the seat (2).

Safety valve, check

1
Check that the safety valve features a purple color
marking.

2
Check that the valve is not damaged, which would im-
pair its function.
Press in the valve poppet (1) with a blunt object and
check that it does not seize and that it seals against
the seat (2).

165
Overhaul/Replacement Group 22: Lubrication System

Lube oil pump, check

1
Remove the lube oil pump. Refer to “Lube oil pump,
replace”

2
Check the pump gear.
NOTE: If the reason for the fault can be traced to
poor oil quality, clean the oil system thoroughly before
new oil is filled.

22111

Lube oil pump, replace

1
Pump out the engine oil.
Remove the oil filler pipe.
Remove terminal to the oil level sensor.
Remove the dip stick pipe from the bracket.
Remove the oil pan.

2
Remove the bolts holding the oil pipe to the engine.
Remove the oil pipes, the oil strainer and the bracket
together.

3
Remove the lube oil pump bolts and remove the
pump.

4
Clean the oil suction pipe and the oil delivery pipe.
Check for damage.

5
Remove and clean the oil strainer. Check for dam-
age.

166
Group 22: Lubrication System Overhaul/Replacement

6
Install the new lube oil pump.
Make sure that the teeth fit into the camshaft gear.
Tighten the bolts in two stages.
Stage 1: 35 ±3 Nm (25.8 ±2 lbf.ft).
Stage 2: 90° ±5°.

7
Install the oil pressure pipe with a new seal. Tighten
the union in the cylinder block until it bottoms (“zero
play”).
Reused oil pressure pipe
Tighten the union to 200 ±10 Nm (148 ±7 lbf.ft).

New oil pressure pipe

Angle tighten the union 180°.

8
Install the connection pipe and the oil strainer on the
bracket with new oil seals. The strainer should be in-
stalled so that it points to the engine’s front edge.
Torque the screws as specified in “Technical data”.

9
Assemble the oil pipe with the lube oil pump.
Torque the screws as specified in “Technical data”.

10
Check if the seal needs replacing.
Install the oil pan and tighten the bolts to 24 ±4 Nm
(17.7 ±3 lbf.ft).

11
Fasten the dipstick tube to the bracket.
Install oil filler pipe and the wiring connector to the oil
level sensor.
Top the engine oil up as specified. Refer to “Techni-
cal Data”.

11
Start the engine. Check the oil pressure and check
for leakage.

167
 Group 23: Fuel System

Draining, fuel channel in

cylinder head
1
Clean around the fuel unions on the cylinder head
and fuel filter bracket.

2
Loosen the fuel lines from the rear connection (I) on
the fuel shut-off valve.
Pull out the hose and place it in a suitable container.

3
Loosen the fuel return hoses from the front of the cyl-
inder head.

4
Mount a suitable nipple (M16 x 1.5) in the cylinder
head. Use a suitable hose and blow fuel through the
fuel channel, so that it runs out into the container.

IMPORTANT! Make sure that you do not get dirt

in the fuel channel.

168
Group 23: Fuel System Overhaul/Replacement

34300

Control unit, replace

NOTE: Before the control unit is replaced and any
warranty claim made, all checks in the check list
should be performed, to exclude any defect in the en-
gine control system. If the measurements of the cable
harness show defects, it is highly likely that the con-
trol unit is OK. Refer to Workshop Manual “Group 30
Electrical system”.

WARNING! Exchange of control units between

engines, during fault tracing or repair, must nev-
er be performed under any circumstances (with-
out re-programming).

WARNING! Faulty individual adjustments of the

control unit may result in damage to persons or
the engine. For information about re-program-
ming and reading out software Refer to Work-
shop Manual “Group 30 Electrical system”.

1
NOTE: Cut the power with the main switch.
IMPORTANT! The system must be without pow-
er and the starter key(s) be in position 0 when
the connector(s) for the engine control unit are
disconnected or reconnected.

2
Remove upper and lower cable harnesses clamps.

3
Loosen the cabling from the control unit. Move the
locking loop (1) backwards and remove the appropri-
ate connector.

4
Remove the screws holding the control unit and re-
move it.

5
Install the new control unit.

6
Connect the cables to the control unit. Lock each
connector by moving the locking loop (2) forwards.
Tighten the clamps.

169
Overhaul/Replacement Group 23: Fuel System

7
Perform an auto-configuration. Refer to Workshop
Manual “Group 30 Electrical system”.
NOTE: The engine can not be started until auto-con-
figuration has been performed.*
* Note. When the engine control unit is replaced (or re-pro-
grammed), fault codes MID 187, PSID 17 and MID 164, PSID 99
“Data bus network, configuration fault” will be generated.

8
Start the engine and perform a function check.
If the new engine control unit has recently been pro-
grammed:
Check if any new fault codes related to the engine
control system appear after start.

Identifying the engine control unit

Identification is done via the CHASSIS ID number.
IMPORTANT! The CHASSIS ID number on the
decal on the control unit must coincide with the
CHASSIS ID number on the decal on the protec-
tive cover over the engine, and the decals on
the PCU and HCU.

170
Group 23: Fuel System Overhaul/Replacement

23311

Fuel feed pump, replace

Removal
1
Close the fuel stopcocks between the tank and feed
pump.

2
Remove the protective cover from the fuel pump/fuel
shut-off valve. Clean thoroughly around the feed
pump and its connections.

3
Place a suitable container under the feed pump and
remove the fuel line banjo screws.
NOTE: Plug the lines! Note suction or pressure, re-
spectively.

4
Remove the feed pump complete with intermediate
housing.

5
Remove the feed pump from the intermediate hous-
ing (3 torx-bolts).
Remove the pump by carefully pulling it straight out.
Make sure that the intermediate part (A) of the shaft
does not come out as well.

171
Overhaul/Replacement Group 23: Fuel System

Installation
6
Check that the intermediate part (A) is in the grove in
the shaft end.
Mount the feed pump on the intermediate housing
with a new O-ring. Simplify assembly by turning the
pump shaft so that it slots into the groove in the inter-
mediate part.
Tighten the bolts to 25 ±2 Nm (18.4 ±1.5 lbf.ft).

7
Install the feed pump complete with intermediate
housing on the engine.

8
Connect the fuel lines. Use new sealing washers.
Install the protective cover.

9
Open the fuel stopcocks and purge the fuel system.
Refer to “Fuel system, purging” on page 180.

10
Start the engine and check that no leakage occurs.

172
Group 23: Fuel System Overhaul/Replacement

23710

Unit injector, replace

Special tools:
Puller ......................................................... 999 0006
Slide hammer ............................................ 999 0013
Lifting tool .................................................. 999 0185
Protective sleeve ....................................... 999 8249
Sealing plug ............................................... 999 8251
Cleaning kit ................................................ 999 8599

Removal
1
Remove the valve cover.

2
Remove the unit injector connector blocks.

3
Remove the fuel supply pipe and the joining piece
that supplies oil to the rocker arm bridge.

4
Undo all the rocker bridge bolts (equal amounts, in
turns) so that the bridge is not bent.

5
Remove the bolts and carefully lift away the rocker
bridge with lifting tool 999 0185.
NOTE: The marks (D16) on the tool shall be directly
in front of the rocker shaft fixing points on the engine.

6
Mark up and remove the valve yoke for the unit injec-
tor to be changed.

7
Drain the fuel channel in the cylinder head. Refer to
“Draining, fuel channel in cylinder head” on page 168.

173
Overhaul/Replacement Group 23: Fuel System

NOTE: Clean very thoroughly around the unit

injector to be replaced.

9
IMPORTANT! Drain off some of the coolant be-
fore the unit injector is removed. If the unit injec-
tor is stuck, there is a risk that the copper sleeve
could come with it, which would risk getting wa-
ter in the engine.

10
Remove the bolts for the unit injector fixing yoke.
Place puller 999 0006 on the injector.
Put the puller fork in the groove in the injector and
lock the arm with the screw on the side. Hold the pull-
er by turning the screw down against the injector’s
ball cup.
Apply the slide hammer 999 0013 and release the in-
jector.

11
Put protective sleeve 999 8249 over the removed in-
jector.

12
Mount a sealing plug 999 8251 in the unit injector hole
if the unit injector is not to be mounted again directly.
IMPORTANT! Very clean conditions are re-
quired!

13
Clean the unit injector hole in the cylinder head.
Use cleaning kit 999 8599. Mount the sleeve 999 8580
in the injector well and hold with holder 980 8607.
Clean carefully with brush 980 8570 and extension
980 8616.

174
Group 23: Fuel System Overhaul/Replacement

Installation
NOTE: Note the trim code of the new unit injector and
the cylinder involved, before installation.
The code consists of six characters and is noted on
the unit injector (the trim code is “5D008A” in the fig-
ure above).

Note. Once a unit injector has been changed, the

new trim code for the relevant cylinder must be pro-
grammed into the engine control module. Refer to
“Unitinjector, programming of trim code” on page 178.

13
Install new seal rings on the unit injectors and check
that they are correctly located.
Lubricate the rings with diesel oil.
Upper O-ring – large diameter
Lower O-ring – small diameter

14
Install the unit injector and yoke. Center the unit in-
jector between the valve springs.
Tighten the unit injector as follows.
NOTE: Different tightening torques are used, depend-
ing on whether the unit injector copper sleeve has
been replaced or not.
New copper sleeve:
First tightening
Stage 1: 20 ±5 Nm (14.8 ±4 lbf.ft).
Stage 2: Angle tighten 180° ±5°.
Note. Undo the bolt for the unit injector fixing yoke
before the second tightening.
Second tightening
Stage 1: 20 ±5 Nm (14.8 ±4 lbf.ft).
Stage 2: Angle tighten 60° ±5°.

Old copper sleeve:

Stage 1: 20 ±5 Nm (14.8 ±4 lbf.ft).
Stage 2: Angle tighten 60° ±5°.

175
Overhaul/Replacement Group 23: Fuel System

15
Connect the connector block to the unit injector.
Press it in until a clear “click” is heard.
Fit a new cable clip if required.

IMPORTANT! Use only Volvo Penta origi-

nal* clips (part No. 983472) and holder (part
No. 8131393) under the valve cover for
clamping the cables to the unit injectors.
* Note. These components have been specially developed to with-
stand oil and high temperatures.

16
Re-install the valve yokes in their original positions.
Note. Valve yokes without the guide pin (inlet) should
be located with the oval hole facing away from the
camshaft.

17
Oil the valve yoke and camshaft lobes with engine oil.

18
Lift the rocker bridge into place with lifting tool
999 0185.
Tighten the bolts alternately along the rocker shaft to
prevent bending or skewing the shaft.
Check that the rocker shaft fits properly onto the
guide sleeves on the camshaft bearing blocks.
Tighten the rocker bridge according to the tightening
diagram in “Technical data”.

176
Group 23: Fuel System Overhaul/Replacement

19
Clean the cylinder head where the center piece is in-
stalled, and check that there is no rubbish in the cylin-
der head oil way.
Install new seal rings on the oil supply pipe and cen-
ter piece. Put a thin layer of Vaseline on the seal
rings for the pipe and install the pipe in the joining
piece.

20
Mount the center piece and tighten the bolts.

21
Adjust the valves and unit injectors. Refer to “Valves
and injectors, adjusting” on page 92.

22
IMPORTANT! Cut away excess sealant with a
sharp knife. Do not pull it off!
Apply a string of sealant 1161231 and with a diameter
of 2 mm to the joint between the timing gear cover
and the cylinder head.
NOTE: The valve cover must be installed within
20 minutes after applying the sealant.

23
Install the valve cover and tighten the bolts to 24 ±4
Nm (17.7 ±3 lbf.ft). Refer to the torque schedule in
“Technical Data”.

24
Purge the fuel system. Refer to “Fuel system, purg-
ing” on page 180.

177
Overhaul/Replacement Group 23: Fuel System

Unit injector, programming of

trim code
Special tools:
VODIA ....................................................... 3838619

Once a unit injector has been changed, a new trim

code* for the relevant cylinder must be programmed
into the engine control module. This is done by
means of the VODIA tool.
* Note. The trim code defines each unit injector’s tolerances for
the engine control unit.

1
Connect VODIA and turn on the power to the engine.

2
Go into menu “Service and Maintenance” in VODIA.

3
Select “Parameter, programming”.

4
Press on “Play”.

5
Select the cylinder number where the new unit injec-
tor is mounted.

6
Enter the trim code for the new unit injector and press
“OK”.
Note. Each unit injector has a unique trim code. The
code consists of six characters and is noted on the
unit injector (the trim code is “5D008A” in the figure).

178
Group 23: Fuel System Overhaul/Replacement

7
Close “Parameter, programming”.

8
VODIA will ask you to “Turn off the main switch”, then
follow the instructions.

9
Programming must be reported to Volvo Penta within
28 days.
Log on to Volvo Penta Partner Network’s home-
page:

http://www.vppn.com

10
Select “VODIA” in the left menu.

11
Select “Report software” in the left menu.

12
Follow the instructions concerning “Report software/
parameter”. Click on “Report software/parameter”.

179
Overhaul/Replacement Group 23: Fuel System

23080

Purging the fuel system

Stationary engine

1
Clean around the purging nipples on the fuel filter
bracket. Remove the protective covers from the purg-
ing nipples

2
Connect a transparent plastic tube between the vent-
ing nipples (1) on the fuel filter bracket and a collec-
tion vessel.
Open the purging nipple for one of the filters.
Pump with the hand pump (2) until air-free fuel flows
out. Tighten the venting nipple while fuel is flowing out.
Vent the other filter in the same way.

3
Remove the hoses and replace the protective covers
on the purging nipples.

4
Run the engine at idle for a few minutes to remove
any remaining air from the system.

5
Perform a leakage and function check.

After filter replacement under power

1
Remove the protective cover from one of the purging
nipples (1) and open the nipple ½ –1 turn.
WARNING! Hot fuel can cause burns.

2
Lift the handle (3) and turn it slowly to the purging po-
sition (B). This allows a limited flow of fuel to the filter,
which drives the air out through the purging nipple.
Tighten the purging nipple while air-free fuel is flowing
out.

3
Purge the other filter in the same way.
Turn the handle to the running position (N). Check
that no leakage occurs.

180
Group 25: Inlet / Exhaust systems

25512

Turbocharger, replace
Always find out and rectify the reasons for why the
turbocharger has failed, before a new turbocharger is
installed.
One condition for satisfactory functioning of the turbo-
charger is that the engine’s oil system and inlet sys-
tem are kept in good condition, i.e. that oil changes
and filter changes are done at specified times, the
right grade of oil is used and the air filter is correctly
maintained.
A first remedy should be checking the engine oil and
replace the oil filters if needed, and preferably running
the engine a few minutes with the new oil before the
new turbo unit is installed.
Blow out any rust- and soot flakes from the exhaust
manifold when replacing the turbocharger. Flakes of
soot can damage the exhaust turbine on the new unit.
It is important that the inlet pipe from the air filter is
also cleaned. Pieces from a failed turbine wheel can
remain in place and cause instant destruction of the
new turbocharger.

Removal
1
Drain some of the coolant. Refer to “Cooling system,
draining” on page 187.

2
Remove the air filter.

3
Remove the heat shield from the turbocharger.
IMPORTANT! The insulation around the turbine
housing may not be compressed, since this seri-
ously reduces the heat insulation.

181
Overhaul/Replacement Group 25: Inlet/Exhaust systems

4
Remove the heat insulation from around the turbine
housing exhaust pipe flange and between the turbine
housing and the exhaust elbow.

5
Remove the insulation from the charge air pipe. Loos-
en the fixing bolts for the charge air pipe’s two rear
fixtures somewhat.

6
Loosen the clamp on the compressor housing and
loosen the fixing bolts for the charge air pipe’s front
fixture.

7
Undo the turbocharger pressure oil connection and
coolant connections (2 pcs) on the cylinder block.
Remove the oil drain pipe.

8
Where required, remove the exhaust temperature
sensor from the exhaust elbow and hang it up in a
protected place.

9
Loosen the exhaust elbow from the exhaust pipe and
loosen the clamp on the turbine housing. Remove the
exhaust elbow.

10
Remove the nuts and spacers holding the turbo-
charger to the exhaust manifold and lift it away.
WARNING! The heat shield between the turbine
housing and the compressor housing has sharp
edges. Cutting risk.
Note. The turbocharger weighs about 30 kg (66 lbs).

11
Remove the lube oil lines and coolant lines from the
turbocharger.

182
Group 25: Inlet/Exhaust systems Overhaul/Replacement

Installation
IMPORTANT! The insulation around the turbine
housing may not be compressed, since this seri-
ously reduces the heat insulation.

1
Clean the contact surfaces.

2
Connect the coolant hoses to the bearing housing.
WARNING! The heat shield between the turbine
housing and the compressor housing has sharp
edges. Cutting risk.

3
Place a new gasket on the exhaust manifold and in-
stall the turbocharger without tightening it. Use spac-
ers and new bolts.
Tightening torque: 60 ±4 Nm (44.3 ±3 lbf.ft).
Note. The turbocharger weighs about 30 kg (66 lbs).

4
Fit the return oil pipe. Check that the old seal is not
left in place and that the new one ends up in correct
position. Tighten the turbocharger.

5
Fill the turbocharger bearing housing with clean en-
gine oil via the pressure oil hose connection.
NOTE: Make sure no contaminants enter the connec-
tion. Use a strainer when filling.

6
Connect the pressure oil hose between the bearing
housing and oil filter bracket.

7
Connect the coolant hoses to the cylinder block and
to the cylinder head.

8
Connect the exhaust elbow to the turbine housing
and tighten the V-clamp.
Tightening torque: 16 ±0.7 Nm (11.8 ±0.5 lbf.ft).

183
Overhaul/Replacement Group 25: Inlet/Exhaust systems

9
Install the heat insulation around the turbine housing
exhaust pipe flange and between the turbine housing
and the exhaust elbow.
At the same time, check that the heat shield is not
damaged.

10
Install the charge air pipe and insulation around it.

11
Install the heat shield over the turbocharger.

12
Install the air filter.

13
Start the engine and check that no leakage occurs.

Turbocharger, bearing
clearance, check
Axial clearance- and end float are normally only
checked during overhaul, when you want to measure
the amount of wear in the unit.

Checking the end float

Special tools:
Dial indicator .............................................. 998 9876
Magnetic stand .......................................... 999 9696

1
Place the magnetic stand 999 9696 with dial indicator
998 9876 in a suitable position.
Put the measurement tip on the center of the shaft.

184
Group 25: Inlet/Exhaust systems Overhaul/Replacement

2
Press in the exhaust turbine (A) by hand. Zero the
dial gauge.

3
Press in the compressor turbine (B) by hand. Read
the end float on the dial gauge.

Permissible end float: Max. 0.12 mm (0.0047").

Replace/overhaul the turbocharger if the wear toler-

ances are exceeded.

Checking the radial clearance

Special tools:
Dial gauge ................................................. 999 9683
Magnetic stand .......................................... 999 9696

1
Mount the dial indicator 999 9683 on the magnetic
stand. Put the measurement tip on the round surface
on the compressor turbine’s locknut.

2
Press the compressor turbine down at the same time
as the other end of the shaft (the exhaust turbine end)
is moved upwards. Zero the dial gauge.

3
Move the compressor turbine upwards, at the same
time as the other end of the shaft is pressed down.
Read off the radial clearance on the dial gauge. Then
rotate the shaft 90° and repeat the measurement.
NOTE: Be careful to ensure that the shaft is not rotat-
ed during measurement.

Permissible radial clearance (compressor side):

Max. 0.74 mm (0.0291").
Permissible radial clearance (exhaust turbine side):
Max. 0.56 mm (0.0220").

Replace/overhaul the turbocharger if the wear toler-

ances are exceeded.

185
Overhaul/Replacement Group 25: Inlet/Exhaust systems

Exhaust manifold, removal /

installation
Removal
1
Remove the turbocharger as instructed on page 181.

2
Remove the coolant connections to and from the ex-
haust manifold.

3
Remove the charge air pipe fixture.

4
Remove the nuts from the exhaust manifold and lift
away the manifold

Installation
1
Install the exhaust manifold with new gaskets and
O-rings.

2
Assemble the remaining parts in reverse order.

3
Fill the engine with coolant. Refer to “Cooling system,
filling” on page 190.

4
Start the engine and check that no leakage occurs.

186
 Group 26: Cooling System

Engine with heat exchanger

Cooling system, draining
NOTE: Close the bottom cock in the boat and remove
the expansion tank filler cap before draining the cool-
ing system.
On engines which are to be laid up or put in storage,
the engine cooling system should not be drained. The
coolant contains corrosion-inhibiting additives.
WARNING! Avoid opening the coolant filling cap
when the engine is hot. Steam or hot coolant
might spray out in an unexpected direction.
Open the filler cap slowly, and release the pres-
sure in the cooling system if the filling cap or tap
has to be opened, or if a drain plug has to be re-
moved when the engine is hot.

1
Open all drain taps /nipples. Drain the coolant with
drain hoses.
F F S S* F
Note. Drain hose 999 6049 can be connected to the
nipple on the right side of the cylinder block.

2
IMPORTANT! Check that all water drains out.
Deposits may be found inside the drain plug/tap,
and need to be cleared away. There is otherwise
a risk that water could remain and cause severe
damage.
Check whether the installation has any further taps or
plugs at the lowest points of the cooling water pipes
and exhaust pipe.

F FF V
F = Drain tap for coolant (freshwater)
S = Drain tap for seawater
V = Purging tap
* Note. Applies to the seawater pump cover.

187
Overhaul/Replacement Group 26: Cooling System

Hull-cooled engine 3
Remove the cover on the seawater pump and the
cover on any auxiliary pump. In addition, open the
drain tap on the reverse gear oil cooler (as required).

4
Close the taps, mount the plugs and covers to the
coolant pump and any auxiliary pumps.

5
Pump out the bilges as required. Check that there is
no leakage before you leave the boat.

F* F

F F V
F = Drain tap for coolant (freshwater)
V = Purging tap
* Note. Applies to the pump cover in the charge air
cooler circuit.

188
Group 26: Cooling System Overhaul/Replacement

26000

Cooling system, cleaning

Cleaning kit ................................... part No. 1141658

WARNING! Chemicals for the cooling system

are a health hazard (do not ingest).

1
Close the sea cock(s) and empty the cooling system.
Refer to “Cooling system, draining”, page 187.

2
Flush the freshwater and seawater systems with
fresh water.

3
Fill the fresh water side with a mixture of radiator
cleaner (kit no. 1141658) and fresh water (please re-
fer to the instruction included with the kit).
NOTE: As an alternative, the freshwater system can
be filled with a mixture of 15 –20% Volvo Penta glycol
and water that is drained after 1– 2 days running.

4
Drain the freshwater system. Then flush the fresh wa-
ter side with a mixture of neutralizer (kit no. 1141658)
and fresh water (please refer to the instruction includ-
ed with the kit).

5
If any contamination is still left, repeat the cleaning
procedure until the system is completely free from
contamination.

6
Fill up with new coolant when the fresh water system
is completely free from contamination.
IMPORTANT! Use a coolant mixture recom-
mended by Volvo Penta. Refer to the “Coolant”
heading in the “Technical Data” chapter.
IMPORTANT! A coolant mixture with at least 40%
concentrate (“Volvo Penta Coolant”) shall be used
all year round, even if there is no risk for freezing.
This is to ensure that the engine is adequately pro-
tected against corrosion and cavitation damage.

NOTE: Mix the correct volume in advance, to ensure

that the system is filled.

189
Overhaul/Replacement Group 26: Cooling System

Cooling system, filling

WARNING! Open the coolant filling cap (and
purging tap) with great care when the engine is
hot. Steam or hot coolant could spray out.
IMPORTANT! Only use the coolant and mixture
ratio recommended by Volvo Penta.
IMPORTANT! Do not start the engine until the
system is purged and completely filled.

1
NOTE: Filling should be done with the engine station-
ary.
Mix the correct volume of coolant in advance, to en-
sure that the system is filled. Please note that if a
heating system, water heater etc. is connected to the
engine cooling system, a correspondingly greater
amount of coolant will be needed.

2
Remove the filler cap on the expansion tank and fill
up with Volvo Penta recommended coolant mixture.*
* Refer to the “Technical Data” chapter for coolant, “Cooling
system”.

3
Purge the system while filling by removing the filling
cap on the thermostat housing (1) and opening the
purging tap (2) on the front of the cylinder head.
Fill up slowly, to allow the air that is displaced is al-
lowed to flow out. Also ensure that the heating sys-
tem, tap water heater etc. if connected to the engine
cooling system, are also purged (open the heater
control valve).

4
Fit the cover to the opening on the thermostat hous-
ing when the coolant reaches up to the edge of the
opening.
NOTE: In unfavorable conditions (engine inclined) the
coolant may not reach up to this opening. Fill with
coolant to the maximum level in this opening (1) if this
should occur.

190
Group 26: Cooling System Overhaul/Replacement

5
Close the purging tap(s) as soon as air-free coolant
flows out.

6
Fill with coolant to approx. 5 cm (2") below the filler
cap sealing surface.

7
Wait approx. 5 minutes so that the remaining air in
the engine can be evacuated. Top up with coolant as
necessary.

8
Fit the filler cap. Start the engine and let it idle approx.
10 minutes. Check the level and top up as necessary.
WARNING! Be careful when opening the cool-
ant filler cap when the engine is hot. Steam or
hot fluid may spray out.

9
Run the engine with a low load until the normal work-
ing temperature is reached (thermostat opens).
IMPORTANT! The engine must not be run at full
load until the system has been purged and com-
pletely filled.

10
Stop the engine and let it cool down. Check the cool-
ant level. Refill as required, up to approx. 5 cm (2")
under the filler cap sealing surface in the expansion
tank.

191
Overhaul/Replacement Group 26: Cooling System

26001

Cooling system, pressure

testing
WARNING! Be careful when opening the cool-
ant filler cap when the engine is hot. Steam or
hot coolant could spray out.

Alternative 1:
Special tools:
Cover with connecting nipple ..................... 999 6441
Pressure testing device ............................. 999 6662

Check the pressure testing device 999 6662 before

using it. Refer to the instruction on the page 142.

1
Check that all hoses and clamps are undamaged.

2
Check that the tap on the reduction valve is screwed
out.

3
Replace the filler cap on the expansion tank with cov-
er 999 6441. Connect the pressure testing device to
the nipple on the cover.

4
Connect the pressure-testing device to the workshop
compressed air system and open the cock (B). Adjust
the pressure reduction valve (A) so that pressure
gauge shows a pressure of 70 kPa (10.2 psi). Close
the cock (B).

5
The pressure must not drop during two minutes for
the cooling system to be considered free from leaks.

NOTE: Repeat the pressure testing if you are uncer-

tain whether the cooling system leaks or not.

192
Group 26: Cooling System Overhaul/Replacement

6
Shut off the compressed air after completed testing.
Eliminate excess pressure in the system by unscrew-
ing the valve on the reduction valve.

7
Remove the pressure testing device.

8
Check the coolant level in the expansion tank.
Install the ordinary filler cap.

9
Start the engine and check that no leakage occurs.

Alternative 2:
Special tools:
Pressure-testing equipment ....................... 885531

1
Check that all hoses and clamps are undamaged.

2
Check the coolant level in the expansion tank.

3
Replace the coolant filler cap on the expansion tank
with cap from the pressure testing equipment
885531. Connect the pressure testing equipment to
the nipple on the cover.

4
Pump up a pressure of 70 kPa (10.2 psi).

193
Overhaul/Replacement Group 26: Cooling System

5
The pressure must not drop during two minutes for
the cooling system to be considered free from leaks.

NOTE: Repeat the pressure testing if you are uncer-

tain whether the cooling system leaks or not.

6
Release the excess pressure and remove the pres-
sure testing unit.

7
Check the coolant level in the expansion tank. Install
the ordinary filler cap.

8
Start the engine and check that no leakage occurs.

Coolant filler cap, replace

NOTE: Always change the coolant filler cap on an en-
gine that has been overheated. The pressure relief
valve in the cap (plastic cap) might have been dam-
aged by the heat.

194
Group 26: Cooling System Overhaul/Replacement

26211

Coolant pump, replace

Removal
1
Disconnect power at the main switch and check that
the engine is without power.

2
Drain the coolant into a suitable container. Refer to
“Cooling system, draining”

3
Remove the drive belt shield that is installed above
the coolant pump.

4
Remove the coolant pump drive belt by placing a pull-
ing handle (A) in the belt tensioner and releasing the
belt tension.
Remove the drive belt from the coolant pump.

5
Remove the coolant pump and its seal. Press the belt
tensioner down so it is easier to access the lower
screw in the coolant pump. Allow screw “1” to stay in
the housing.

Installation
6
Install the coolant pump with a new seal.
Note. Use petroleum jelly to hold the seal in place
during installation. The screw “1” must be in place in
the housing during installation.
Tighten the bolts in two stages.
Stage 1: 24 ±4 Nm (17.7 ±3 lbf.ft).
Stage 2: 24 ±4 Nm (17.7 ±3 lbf.ft).
Note. Tightening sequence 1–5 –2 –4 –6 –3 in both
stages. Refer to the tightening diagram on the follow-
ing page.

195
Overhaul/Replacement Group 26: Cooling System

7
Install the coolant pump drive belt.

8
Install the belt shield.

9
Fill the engine with coolant. Refer to “Cooling system,
filling” on page 190.

10
Start the engine and let it run until it reaches normal
operating temperature.
Check that no leakage occurs. Top up with coolant as
necessary.

26273

Thermostat, function check

1
Remove the thermostat, see “Thermostat, replacing”.

2
Place the thermostat in a large pot of water and heat
it to the opening temperature as specified in “Techni-
cal data, Thermostat”.
Closed thermostat
3
If the thermostat does not open at specified tempera-
ture, replace it.

4
Install the thermostat. Refer to “Thermostat, replacing”.
NOTE: Always use a new seal, even if the thermostat
is not replaced.

Open thermostat

196
Group 26: Cooling System Overhaul/Replacement

26271

Thermostat, replace
1
Drain the cooling system. Refer to “Cooling system,
draining” on page 187.

2
Clean the area around the thermostat housing.
Remove the coolant hose from the thermostat hous-
ing and unscrew it from the cylinder head.

3
Remove the thermostat (1) and clean the inside of the
housing.

4
Install a new thermostat with a new sealing ring.

5
Install the thermostat housing and tighten.
Install the coolant pipe and tighten.

6
At the same time, check that the by-pass valve does
not bind.
Unscrew the plug (2) and check that the valve (3) can
be moved.
Tighten the plug to 55 ±5 Nm (40.6 ±4 lbf.ft).

7
Fill the engine with coolant. Refer to “Cooling system,
filling” on page 190.

8
Start the engine and check that no leakage occurs.
Pressure test the cooling system. Refer to “Cooling
system, pressure testing” on page 192.

197
Overhaul/Replacement Group 26: Cooling System

25060

Charge air cooler, removal and

installation
1
Disconnect power at the main switch and check that
the engine is without power.

2
Close the sea cock(s) and empty the cooling system.
Refer to “Cooling system, draining” on page 187.

3
Remove the cover from the intake pipe connection to
the charge air cooler.

4
Undo the coolant connections beneath the charge air
cooler.

5
Undo the purging hose on the top of the charge air
cooler.

6
Undo the charge air pipe from the turbocharger at the
connection to the charge air cooler.

7
Remove the emergency stop button.

198
Group 26: Cooling System Overhaul/Replacement

8
Remove the connections to the crankcase ventilation
(as required).

9
Undo the charge air pipe connection to the intake
pipe and lift the charge air cooler away, complete with
bracket.
NOTE: Be careful to prevent contamination from get-
ting into the engine’s intake pipe.

199
Overhaul/Replacement Group 26: Cooling System

10
If the charge air cooler is to be replaced, remove it
from the bracket.

Install the components in reverse order.

200
Group 26: Cooling System Overhaul/Replacement

25061

Charge air cooler, cleaning

The charge air cooler is connected to the fresh water
system. This means that the water side is cleaned
when the engine cooling system is cleaned. Refer to
“Cooling system, cleaning” on page 189.
Note. Water can condense in the charge air cooler
during operation. The condensation water is drained
via a hose on a nipple behind the charge air cooler’s
intake pipe connection flange.
WARNING! If a large amount of water flows out
of the drain hose, from the intake pipe, the
charge air cooler must be removed and pres-
sure tested.

1
Check that the drain nipple is not blocked.

2
Close the sea cock(s) and empty the cooling system.
Refer to “Cooling system, draining”, page 187.

3
Remove the charge air cooler. Refer to “Charge air
cooler, removal/installation” on page 198.
NOTE: Be careful to prevent contamination from get-
ting into the engine’s intake pipe.

4
Clean the charge air cooler internally and externally.
Clean the air passages with degreaser. Rinse both
the air- and coolant pipes with fresh water blow the
charge air cooler clean with compressed air (or leave
it to drain off).
IMPORTANT! The charge air cooler must not be
disassembled.

5
Install the charge air cooler. Refer to the instruction
on the previous page.

6
Fill with coolant according to specification. Refer to
“Cooling system, filling”, page 190.

7
Start the engine and do a function and sealing check.

201
Overhaul/Replacement Group 26: Cooling System

Charge air cooler, pressure

testing
Special tools:
Pressure-testing equipment ....................... 885531
Expansion plug .......................................... 885536
Expansion plug .......................................... 885539

1
Close the sea cock(s) and drain the cooling system.
Refer to “Cooling system, draining”, page 187.

2
Remove the charge air cooler. Refer to “Charge air
cooler, removal/installation” on page 198.
NOTE: Pressure testing can be performed with the
frame and bracket in place (not illustrated).

Leakage test, water side

3
Fit expansion plugs 885536 and 885539 on the
charge air cooler. Connect hand pump 885531 to ex-
pansion plug 885536.
Plug the union for the purging hose.

4
Pump up the pressure to 150 kPa (1.5 bar / 21.8 psi).

5
Lower the charge air cooler into a water bath. Make
sure that the air loop is fully filled with water and that
no air is left inside.

6
Pressure test the charge air cooler for 1 minute and
check that no air comes out of the air loop or from the
joints.

7
Repeat the leakage check a few times to be sure that
there is no suspicion of leakage.

202
Group 26: Cooling System Overhaul/Replacement

26112, 26000

Heat exchanger, removal and

installation
1
Close the sea cock(s) and drain the coolant from the
seawater and freshwater systems. Refer to “Cooling
system, draining” on page 187.

2
Remove the electrical box with fixing plate.

3
Loosen both coolant connections on the top of the
heat exchanger.

4
Loosen the connection to the priority valve beneath
the heat exchanger.

5
Loosen the connection flange on the front of the heat
exchanger.

6
Loosen the connection pipe from the seawater pump
at the rear of the heat exchanger.

7
Remove the upper fixing bolts (4 pcs).

8
Remove the lower fixing bolts (4 pcs).

9
Lift out the heat exchanger, forwards – outwards.

Install the components in reverse order.

203
Overhaul/Replacement Group 26: Cooling System

Heat exchanger, cleaning

The water side is cleaned when the engine cooling
system is cleaned. Refer to “Cooling system, clean-
ing” on page 189.

1
Close the sea cock(s) and drain the cooling system.
Refer to “Cooling system, draining”, page 187.

2
Remove the heat exchanger. Refer to “Heat exchang-
er, removal and installation” on the previous page.
NOTE: The heat exchanger insert (seawater side)
can also be cleaned with the heat exchanger still on
the engine, once the two end pieces have been re-
moved.

3
Remove the end pieces from the heat exchanger.
(First remove the bolts on the end pieces, then the
two screws for the insert).

4
Remove the O-rings (2 pcs at the front, one at the
rear) and press the insert out.
NOTE: The insert can only be pressed out backwards
since it has a flange at the rear edge.
The insert can also be pressed out of the housing by
screwing two M10 bolts into the threaded holes in the
flange.

5
Clean the entire length of the heat exchanger piping.
Use fresh water and suitable brushes. Flush the pipes
and keep brushing until no more loose particles come
away with the water. Also flush and clean the outside
of the insert. Also clean the housing and the end caps.

204
Group 26: Cooling System Overhaul/Replacement

6
Check the zinc anodes in the end piece. Replace the
anodes if more than 50% of their original size has
been eroded. If not, clean the zinc anodes to remove
the oxide layer before re-installing them.
IMPORTANT! Clean with Emery paper. Do not
use steel tools, since this could impair the gal-
vanic protection.
Make sure there is good metallic contact between the
anode and the end piece.

7
Install the insert in the housing with new sealing rings.

8
Install the end pieces, using new seal rings.

205
Overhaul/Replacement Group 26: Cooling System

26010

Heat exchanger, pressure

testing
Special tools:
Sealing washers ........................................ 885 381*
Pressure-testing device ............................. 999 6662

* Note. Cut off part of the rubber seal on the sealing washer with-
out connection nipple (dotted area on the figure below). The
washer would otherwise catch on the end piece and cause leak-
age.

1
Close the sea cock(s) and drain the cooling system.
Refer to “Cooling system, draining”, page 187.

2
Remove the heat exchanger. Refer to “Heat exchang-
er, removal and installation” on page 203.

3
Check the pressure testing device 999 6662 before
using it. Refer to the instruction on the page 142.

Fresh water side

4
Mount sealing washers 885 381 as illustrated. Use the
existing screws.
Install a cover* over the remaining opening in the
heat exchanger housing.
* Note. Use cover (part No.3827303) with O-ring (part No.
925255) together with two bolts (part No. 946173), (M8 x 20)
during pressure testing.

206
Group 26: Cooling System Overhaul/Replacement

5
Connect the pressure testing equipment 999 6662 to
the workshop air supply and fill with air to 150 kPa
(1.5 bar / 21.8 psi).

6
Lower the heat exchanger into a water bath. Make
sure that the water channel that is not pressurized is
completely filled with water.

7
Pressure test the heat exchanger for 1 minute and
check that no air comes out of the water channel or
from the joints.

8
Repeat the pressure test if you suspect leakage.

Seawater side
9
Mount the pressure plates 885 381 with seals as illus-
trated. Use the existing screws.
Connect the pressure testing equipment 999 6662 to
the workshop air supply and fill with air to 150 kPa
(1.5 bar / 21.8 psi).

10
Lower the heat exchanger into a water bath. Make
sure that the water channel that is not pressurized is
completely filled with water.

11
Pressure test the heat exchanger for 1 minute. Check
that no air comes out of the water ducts or from the
joints.

12
Repeat the pressure test if you suspect leakage.

207
Overhaul/Replacement Group 26: Cooling System

22311

Oil cooler, engine, removal/

installation
Removal
1
Drain the coolant. Refer to “Cooling system, draining”
on page 187.

2
Clean around the cover over the oil cooler.

3
Undo the bolts and remove the cover over the oil cool-
er.

4
Remove the oil cooler from the cylinder block.

5
Remove the oil cooler seal rings and the gasket in the
cover over the oil cooler. Clean the mating surfaces
on the cover.

6
Clean and pressure test the oil cooler. Refer to the in-
structions on pages 209 – 210.

Installation
1
Clean and install new sealing rings in the cylinder
block. Bolt the oil cooler in place in two stages.
Stage 1: 10 ±4 Nm (7.4 ±3 lbf.ft).
Stage 2: 27 ±4 Nm* (20 ±3 lbf.ft)*.
* Note. Tightening sequence 1 –2 –3 –4 –1 in stage 2.

2
Put a new seal in the cover and lift it into place.
Torque the screws to 27 ±4 Nm (20 ±3 lbf.ft).
Refer to the torque schedule in “Technical Data”.
Note. Check that the cover rubber gasket remains in
it’s groove.

208
Group 26: Cooling System Overhaul/Replacement

3
Check the oil level and top up as required. Concern-
ing oil, see specification in “Technical data”.

4
Fill with coolant according to specification. Refer to
“Technical Data” and “Cooling system, filling” on page
190.
NOTE: If the oil cooler leaked oil into the cooling sys-
tem, the system must be cleaned before filling. Refer
to “Cooling system, cleaning” on page 189.

5
Start the engine and perform a leakage check.

22312

Oil cooler, engine, cleaning

The oil cooler is connected to the fresh water system.
This means that the water side is cleaned when the
engine cooling system is cleaned. Refer to “Cooling
system, cleaning” on page 189.

1
Remove the oil cooler. Refer to “Oil cooler, removal/
installation” on the previous page.

2
Clean the oil cooler internally and externally. Clean
the oil channels with degreaser. Rinse both the oil-
and coolant pipes with fresh water blow the oil cooler
clean with compressed air (or leave it to drain off).

209
Overhaul/Replacement Group 26: Cooling System

22312

Oil cooler, engine, pressure

testing
Special tools:
Pressure testing device ............................. 999 6662
G-clamp (2 required) ................................. 999 6845

1
Remove the oil cooler. Refer to “Oil cooler engine,
removal/ installation” on page 208.

2
Clean the oil cooler. Please refer to previous section:
“Oil cooler, engine, cleaning”.

3
Check the pressure testing device 999 6662 before
using it. Refer to the instruction on the page 142.

4
Mount G-clamps 999 6845 and check that they are fit-
ted correctly.

5
Check that the pressure reduction valve knob on the
pressure testing device 999 6662 is fully opened and
that the pressure gauge shows 0.
Connect the pressure testing device to a G-clamp
999 6845.

6
Lower the oil cooler into a vessel containing water at
room temperature.
Increase the pressure to 250 kPa (2.5 bar / 36.3 psi)
with the knob on the reduction valve.
Wait at least one minute.
NOTE: If an even stream of air bubbles come from
the oil cooler element, it leaks and the oil cooler must
be replaced.

210
Group 26: Cooling System Overhaul/Replacement

26213

Seawater pump, replace

1
Close the sea cock(s) and drain the sea water sys-
tem. Refer to “Cooling system, draining” on page 187.

2
Remove the water connections from the seawater
pump.

3
Remove the water pipe between the seawater pump
and the heat exchanger.

4
Remove the seawater pump.

5
Fix the old seawater pump in a vice etc. Remove the
nut from the timing gear wheel and pull the gear off
with a suitable puller. Install the timing gear wheel on
the new seawater pump.
Tightening torque: 200 ±30 Nm (148 ±22 lbf.ft).

6
Install the new seawater pump with a new O-ring.
NOTE: Check that the O-ring is properly aligned
when installing.

7
Install the water pipe between the seawater pump
and the heat exchanger, using new seal rings.
NOTE: Grease the seal for the heat exchanger with lu-
bricant (part No. 1141699) to make installation easier.

8
Install the water inlet and the clamp on the seawater
pump. Use a new O-ring.

211
Overhaul/Replacement Group 26: Cooling System

26214

Seawater pump, overhaul

Seawater pump removed

Disassembly
Note. The figures in brackets refer to the figure on
page 214.

1
Mark up the positions of the pipe bends in relation to
the pump housing. Remove the pipe bends.

2
Remove the cover over the seawater pump together
with the O-ring. Pull the impeller out with a suitable
universal puller. Remove the rubber washer (2) from
the pump.

3
Remove the cam screw (12), cam disk (5) and wear
ring (6).

4
Mark up the position of the pump housing in relation
to the bearing housing. Undo the four bolts and care-
fully pull the pump housing. Remove the pump hous-
ing (10), support washer (8) and shaft seal (9) from
the pump shaft.

5
Tap out the shaft seal’s ceramic ring with rubber cov-
er from the pump housing. Use a suitable socket.

6
Remove the deflector ring (13) from the shaft.

7
Pull the gear wheel off with a universal puller.

212
Group 26: Cooling System Overhaul/Replacement

8
Remove the lock ring (20) in the bearing housing and
push the shaft out with bearing.

9
Pull the bearings off the shaft with a universal puller.

10
Tap the seal ring (16) out of the bearing housing with
a suitable socket.

11
Inspect all parts. Change worn or damaged compo-
nents.

213
Overhaul/Replacement Group 26: Cooling System

Assembly
1
Grease the sealing ring (16) with water-resistant
grease (Volvo Penta part No. 828250) and tap it into
the bearing housing.
Note. Put the old support washer (8) over the ring to
protect it. The side of the seal with the spring should
face inwards towards the bearing housing.

2
Install the inner circlips on the pump shaft and press
the bearings on. Note. Drift 884167 can be used.
Or the bearing can be heated to approx. 100°C
(212°F) and then be tapped into place.
Fill the bearings with grease (after they have cooled).

1. Cover 12. Screw

2. Rubber washer 13. Deflector ring
3. Impeller 14. Bearing housing
4. O-ring 15. O-ring
5. Cam disc 16. Seal ring
6. Wear ring 17. Ball bearing
7. Pin 18. Circlips
8. Support washer 19. Ball bearing
9. Shaft seal, compl. 20. Circlip
10. Pump housing 21. Pump shaft
11. Plug 22. Gear wheel

214
Group 26: Cooling System Overhaul/Replacement

3
Install the pump shaft with bearing in the bearing
housing. Install the outer circlip (20).

4
Install the gear wheel and tighten it.
Tightening torque: 200 ±30 Nm (148 ±22 lbf.ft).

5
Place the deflector ring (13) on the shaft close to the
bearing housing.

6
Wet the rubber cover for the shaft seal ’s ceramic ring
and mount in the pump housing.
NOTE: The sealing surfaces of the seal must not
come into contact with grease or be touched by fin-
gers. Put a piece of clean plastic foil on a hammer
handle and carefully press the ceramic ring into
place.

7
Install the pump housing on the bearing housing, as
previously marked, without tightening it.

215
Overhaul/Replacement Group 26: Cooling System

8
Carefully place the shaft seal (9) on the pump shaft
and press the sleeve with carbon ring until contact is
made with the fixed ceramic ring in the housing.
Note. Drift 999 4034 can be used.

9
Mount the support washer (8) over the seal and wear
ring (6).

10
Tighten the pump housing on the bearing housing
with standard torque 24 Nm (18 lbf.ft).

11
Mount the cam disc (5) and tighten. Use white sealant
(Volvo Penta part. no. 1141570).

12
Grease the pump housing and inside of the cover
with water-resistant grease (Volvo Penta part No.
828250).
Note. The impeller can be put in hot water before in-
stallation, to facilitate installation.

13
Press the impeller in with a rotating movement (anti-
clockwise).
NOTE: The pump shaft has an internal thread (M8).
Screw a stud into the spindle stub and press the im-
peller in with a nut and washer.

14
Install the rubber washer (spline seal) on the end of
the impeller. Install the cover with a new O-ring and
torque it to standard torque 10 Nm (7.4 lbf.ft).

15
Install the pipe bends on the pump housing in accor-
dance with the previous markings.

NOTE: Check that the O-ring (15) is properly aligned

when installing the pump on the engine.

216
Group 26: Cooling System Overhaul/Replacement

44272

Oil cooler, reverse gear,

cleaning
(Note: Oil cooler is extra equipment)

NOTE: The oil cooler insert (seawater side) can also

be cleaned with the oil cooler still on the engine, once
the sea cock has been closed and the two end pieces
have been removed.

1
Close the sea cock(s) and drain the sea water sys-
tem. Refer to “Cooling system, draining” on page 187.

2
Loosen the oil hoses to and from the oil cooler.

3
Loosen the cooling water connections to and from the
oil cooler.

4
Loosen the fixing bolts and lift the oil cooler away.
NOTE: Empty the oil into a suitable collection vessel.

5
Remove the cover over the thermostat. Remove the
thermostat.

6
Remove both end pieces and press out the insert.

217
Overhaul/Replacement Group 26: Cooling System

7
Wash the insert in white spirit etc., and blow it clean
with compressed air. (or leave it to drain). Clean the
insides of the tubes and the end walls of the insert
with suitable brushes. Also clean the housing.

8
Assemble the parts in reverse order. Use new seal
rings.

9
Open the sea cock(s). Start the engine and perform a
leakage check.

10
Check the oil level in the reverse gear. Top the oil up
as specified, if necessary. Please refer to the instruc-
tion manual for the relevant engine.

218
Group 26: Cooling System Overhaul/Replacement

Oil cooler, reverse gear,

pressure testing
(Oil cooler is extra equipment)

Note. If there is any suspicion of leakage, oil cooler

must be pressure tested before it is changed.

Special tools:
Pressure plate .................................... 885381
Pressure testing device ...................... 999 6662
Pressure plate (A) .............................. Refer to Note*
* Note. A pressure plate clad in rubber with the dimensions illus-
trated must be made up in your own workshop

1
Remove the reverse gear’s oil cooler. Refer to “Cool-
ing system, reverse gear, cleaning” on page 217.

2
Check the pressure testing device 999 6662 before
using it. Refer to the instruction on the page 142.

3
Mount a pressure plate with quick-release coupling
from kit 885381 on the horizontal connection as illus-
trated. Use the existing bolts (M8) on each side of the
oil cooler.
Connect the pressure testing equipment 999 6662 to
the workshop air supply and fill with air to 150 kPa
(1.5 bar / 21.8 psi).

4
Mount a suitable pressure plate (A) on the vertical
connection.

5
Lower the oil cooler into a water bath. Make sure that
the oil way is fully filled with water and that no air is
left inside.

6
Pressure test the oil cooler for 1 minute and check
that no air comes out of the oil channel or from the
joints.

7
Repeat the test several times if leakage is suspected.

219
Overhaul/Replacement Group 26: Cooling System

Oil cooler reverse gear,

thermostat replace
(Oil cooler is extra equipment)

1
Position a collection vessel under the oil cooler and
so that any oil can run out into the vessel.

2
Remove the thermostat cover and extract the thermo-
stat.

3
Install the new thermostat* in the oil cooler with a new
O-ring.
* Note. The thermostat opens at 70°C (158°F).

4
Install the thermostat cover with a new O-ring.

220
Group 26: Cooling System Overhaul/Replacement

Drive belts, inspection

Check belts after running when they are warm.
IMPORTANT! Always replace a drive belt that
seems worn or is cracked.

Drive belts, replace

1
Disconnect power at the main switch and check that
the engine is without power.

2
Remove the belt cover.

3
Put a 1/2" square key on the belt tensioner (1).
Relieve the belt tensioner by lifting the key.
Remove the drive belt.

4
Put a 1/2" square key on the belt tensioner (2).
Relieve the belt tensioner by lifting the key.
Remove the alternator belt.

5
Check that the belt pulleys are clean and undam-
aged.

6
Lift the 1/2" square key on the belt tensioner (2) and
fit the new alternator belt.

7
Lift the 1/2" square key on the belt tensioner (1) and
fit the new coolant pump belt.

8
Install the belt cover.

9
Start the engine and perform a function check.

221
 References to Service Bulletins

Group No. Date Refers to

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222
 Contents
A Cylinder Block ...................................................... 19
About the Workshop Manual ................................ 6
Actions after lifting the engine ............................... 50
Actions with low charge air pressure .................... 39
B Cylinder head, removal ......................................... 54
Backlash, adjustment ........................................... 87
Bearing housing for camshaft, replace ................. 150
Before lifting the engine ........................................ 49
Before working in a boat ....................................... 49
Big end bearing journal, inspection ....................... 115
Big end bearings, replace (all) .............................. 119
By-pass valve oil cooler, replace .......................... 162
C Design and Function ............................................. 18
Camshaft sensor distance, checking .................... 151
Camshaft, refitting ................................................ 86
Camshaft, wear check .......................................... 149
Certified engines ................................................... 6
Charge air cooler .................................................. 35
Charge air cooler, cleaning ................................... 201
Charge air cooler, pressure testing ....................... 202
Charge air cooler, removal/installation .................. 198
Charge air pipes, checking ................................... 46
Charge air pressure, checking .............................. 45
Closed crankcase ventilation ................................ 33
Compression test ................................................. 42
Con rod, inspection ............................................... 129
Control unit, replace ............................................. 169
Coolant filler cap, replace ..................................... 194
Coolant losses ...................................................... 40
Coolant pressure, check ....................................... 47
Coolant pump, replace .......................................... 195
Coolant temperature too high ............................... 40
Coolant temperature too low ................................. 40
Cooling System .................................................... 34
Cooling system, cleaning ...................................... 189
Cooling system, draining ...................................... 187
Cooling system, filling ........................................... 190
Cooling system, pressure testing .......................... 192
Copper sleeve for unit injector, replace ................ 145
Crankshaft seal rear, replace ................................ 127
Crankshaft seal, front, replace .............................. 126
Crankshaft ............................................................ 22
Crankshaft, assembly ........................................... 69
Crankshaft, inspection and overhaul ..................... 114
Crankshaft, removing ........................................... 68
Cylinder Head ....................................................... 18
Cylinder head, installation ..................................... 83
Cylinder head, pressure testing ............................ 142
Cylinder liner seat, milling ..............................107/113
Cylinder liner seats, inspection ............................. 105
Cylinder liner ........................................................ 20
Cylinder liners and pistons, inspection .................. 97
Cylinder liners and pistons, replace (all) ............... 99
Cylinder liners, installation .................................... 71
D
Draining, fuel channel in cylinder head ................. 168
Drive belts, inspection .......................................... 221
Drive belts, replacing ............................................ 221
E
Electric welding..................................................... 51
Engine fixture, fixing ............................................. 53
Exhaust back pressure, checking ......................... 47
Exhaust manifold, removal/installation .................. 186
Exposing the engine ............................................. 52
F
Fault tracing .......................................................... 36
Flywheel sensor distance, checking ..................... 124
Flywheel, removal/installation ............................... 121
Fuel feed pressure, checking ................................ 44
Fuel feed pump, replace ....................................... 171
Fuel system .......................................................... 28
G
Gear ring, replace ................................................. 123
General advice for pressure measurement ........... 50
General advice when working on EVC engines .... 50
General Information .............................................. 6
Gudgeon pin bushing, check measurement .......... 129
H
Heat exchanger, cleaning ..................................... 204
Heat exchanger, pressure testing ......................... 206
Heat exchanger, removal and installation ............. 203
I
Identification numbers ........................................... 17
Identifying the engine control unit ......................... 170
Inlet / Exhaust systems .......................................... 32
Instructions for operating the starter motor ........... 41
223
Alphabetical register

L Seawater pump, overhaul ..................................... 212

Location of measurement connectors Seawater pump, replacing .................................... 211
on engine .............................................................. 37 Short block ........................................................... 18
Lock nuts .............................................................. 8 Short block, general overhaul ............................... 54
Lube oil pump, check ............................................ 166 Spare parts ........................................................... 6
Lube oil pump, replace ......................................... 166 Special Tools ........................................................ 10
Lubrication System ............................................... 25 Standard times (Flat Rate) .................................... 6
M Strength classes ................................................... 8
Main bearings, replacing ....................................... 116 T
O Thermostat, function check .................................. 196
Oil cooler reverse gear, thermostat replace .......... 220 Thermostat, replacing ........................................... 197
Oil cooler, engine, cleaning .................................. 209 Tightening torque .................................................. 8
Oil cooler, engine, pressure testing ...................... 210 Timing gear .......................................................... 24
Oil cooler, engine, removal/installation ................. 208 Timing gear, installation ........................................ 77
Oil cooler, reverse gear, cleaning ......................... 217 Timing gear, removing .......................................... 65
Oil cooler, reverse gear, pressure testing ............. 219 Timing gear, replace ............................................. 153
Oil pressure sensor, inspection ............................ 164 Timing marks ........................................................ 91
Our Mutual Responsibility ..................................... 7 Torque-angle tightening ........................................ 8
Overflow valve for by-pass filter, replace .............. 161 Turbocharger ........................................................ 32
Overflow valve for full-flow filter, replace ............... 161 Turbocharger, bearing clearance, check .............. 184
Overhaul/Replacement of components ................. 97 Turbocharger, checking ........................................ 46
Overview, control valves ....................................... 160 Turbocharger, replace .......................................... 181
P U
Piston cooling nozzles, installation ....................... 76 Unit injector, installation ........................................ 90
Piston cooling valves, replace .............................. 162 Unit injector, programming the trim code .............. 178
Piston cooling ....................................................... 27 Unit injector, replace ............................................. 173
Pistons and con rods ............................................ 21 Unit injectors, working phases .............................. 30
Pistons, installation ............................................... 74 V
Pistons, pre-assembly .......................................... 72 Valve guides, inspection ....................................... 135
Pistons, removal ................................................... 67 Valve guides, replacing......................................... 136
Purging the fuel system ........................................ 180 Valve mechanism ................................................. 23
R Valve seat, replace ............................................... 133
Reduction valve, checking .................................... 165 Valve seats, grinding ............................................ 138
Reduction valve, replace ...................................... 163 Valve stem seals, replace ..................................... 140
References to Service Bulletins ............................ 222 Valves and unit injectors, adjustment ................... 92
Repair Instructions ............................................... 7/54 Valves in lubrication system ................................. 26
S Valves, grinding .................................................... 139
Safety Precautions ............................................... 3 Valves, installation ................................................ 132
Safety rules for fluorocarbon rubber ..................... 9 Valves, removal .................................................... 130
Safety valve, check .............................................. 165 W
Safety valve, oil pressure, replace ........................ 163 When working with chemicals,
Sealant ................................................................. 8 fuel and lubrication oil ........................................... 49
Seawater pressure, checking ............................... 48

224
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Suggestion / Motivation: .........................................................................................................................................

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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7746647 English 03– 2007