Volvo 2001, Workout Manual

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Page 2: ... binding SI UNIT SYSTEM Power is given in kW kilowatt Speed is given in rev s revolutions per second earlier unit hp horse power earlier unit rev min revolutions per minute Torque is given in Nm newton metre Volume is given in dm3 cubic decimetre earlier unit kpm kilopond metre earlier unit l litre earlier unit lbf ft poundfoot earlier unit Imp gal Imperial gallon earlier unit US gal United States...

Page 3: ...m mechanism 8 Injector sleeve 8 Injectors 8 Assembling the cylinder head 9 Feed pump 10 Pistons 11 Crankshaft 11 Camshaft 11 Connecting rods 12 Thermostat 13 Sea water pump 13 ASSEMBLY INDEX Crankshaft 14 Pistons 14 Flywheel 15 Transmission 15 Adjusting the valve clearance 17 Checking the injection angle 17 2003 Turbo 21 Fresh water cooling 25 Electrical system 26 Fault tracing scheme 28 Special t...

Page 4: ...nder 4 Electrical distribution box 5 Fuel filter 6 Alternator 7 Starter motor 8 Drainage cooling water 9 Feed pump 10 Engine serial number 11 Decompression device 12 Inlet air silencer 13 Fuel injection pumps 14 Oil dipstick 15 Sea water pump Halpert Optonline net ...

Page 5: ...ir silencer Install protection caps on the fuel injection pumps and injectors Remove the screw holding the lever of the decompression device 1 and pull out the lever Remove the valve cover DISASSEMBLY 3 Remove the fuel filter the oil filter the feed pump the thermostat housing and the exhaust elbow Also remove the sea water pump with its attachment tubes 4 Remove the valve bridge and lift out the ...

Page 6: ...he spring 1 Then remove the end nipple 2 and the spring 3 Remove the oil pump cover and mark the gear wheels with a colour pen before removing them When installing the gear wheels the marked side must be facing outwards Remove the bracing pin of the camshaft using the special tool p n 884839 Never remove the bracing pin by punching it out this can very well bend the camshaft Remove the screws on t...

Page 7: ... housing 12 Turn the engine upside down and remove the oil pan Be careful as the pan is glued NOTE The oil pan ends also function as main bearings 13 Remove the connecting rod bolts and remove the connecting rods and the pistons The connecting rod and the connecting rod cap are marked with figures ...

Page 8: ... bearing caps are marked with a figure The corresponding figure is punched into the block Lift out the crankshaft On later engine versions an arrow is cast in the separate main bearing caps 2002 2003 The arrow is to point towards the dipstick ...

Page 9: ...tall them Press down the mandrel all the way down to the cylinder head Ream the valve guides if necessary Valve seats and valves 4 Mill or ream the valve seats The angle C should be 45 for 2003T 30 for the inlet valve The sealing surface s width B should be 1 0 1 mm 0 039 0 0039 in Grind the valves in a valve grinding machine The angle D see Tech data If the disc thickness after grinding is less t...

Page 10: ...the shaft and rockerarm bushings Should the bushings need to be replaced usethe mandrel p n 9991867 for the removal and installation make sure that the oil hole in the bushing coincides with the one in the rocker arm After the installation the bushings are reamed to a close running fit When installing the rockerarm shaft it must be turned so that the lubrication holes are facing the valve side Che...

Page 11: ...it using special tool p n 884557 Knock down the sleeve until it bottoms 10 Oil theflare tool p n 884283 and insert it intothe sleeve make sure that the dowel is properly retracted Brace the tool with the injector yoke Screw down the flare tool as far as the shoulder in the injector sleeve allows thereby flaring the sleeve Remove the tool Adjust the length of the sleeve outside the plane of the cyl...

Page 12: ...he spring See under Technical Data reduction valve Feed pump 13 Depress the pump lever if the diaphragm of the pump sounds squeaky the diaphragm is faultless Changing the diaphragm 14 Remove the six screws holding the upper and lower pump housings together Remove the pump lever spring 1 and remove the screw 2 holding the pump lever shaft 15 Use a suitable pair of pliers and removethe pump lever sh...

Page 13: ...he camshaft for wear on cams and bearing ra ces Also check the wear of the bearings The bearings are pressed into their locations and must be line bored after the installation 19 Place a support under the camshaft gear and use a hydraulic press to remove the gear Crankshaft 20 Remove the gear wheel Use a prong puller Clean the crankshaft Measure the crank and main bearing pins The eccentricity mus...

Page 14: ...nserta new piston ring into the cylinderand measure the piston ring gap As to the measurement see under Technical Data If necessary increase the gap using a special file 23 Measure the clearance of the piston rings in the piston ring grooves Regarding the measurement see under Technical Data 24 Use piston ring pliers to install the piston rings The marking of the rings TOP or the mark of the manuf...

Page 15: ... mandrel to remove the bearings from the shaft NOTE Do not forget the spacer sleeve 3 Replace the sealings 4 NOTE Turn the sealings correctly and make sure that they do not block the drainage hole in the pump housing Replace the O ring 5 Install the ball bearingsandthespacersleeveontotheshaftandleavea distance of 39 5 mm 1 55512 in from the shaft end to the ball bearing Coat the shaft with grease ...

Page 16: ...an arrow is cast it shall point towards the oil dipstick Tightening torque for the main bearings 1st tightening 20 N m 2 kpm 14 7 ft lb 2nd tightening 60 Nm 6 kpm 44 2 ft lbs Turn the engine 3 Turn the piston rings so that the gaps are offset in relation to each other The piston crown is marked with an arrow that points towards the belt pulley Use installation ring 884813 7 Fit the caps with the m...

Page 17: ... hub of the camshaft gear wheel Check that all weights are pressed in so that the tabs 2 are inside the washer 7B Install anew sealing ring for the camshaft in the transmission housing using mandrel p n 884838 The sealing lip with the spring is to beturned towards the engine Press in the sealing ring from the outside until the mandrel bottoms against the housing Install a new O ring in the oil cha...

Page 18: ... the marks from the disassembly Insert a new O ring in the timing gear cover Oil the gear wheel and fit The cover using a new sealing ring 2001 10 Insert the key for the pulley in the crankshaft and install the pulley Tightening torque 40 Nm 4 0 kpm 29 5 ft Ibs 11 Clean the valve lifters carefully and coa t the contact surface against the camshaft with molybdenum disulphide Oil the valve guides in...

Page 19: ...lves for this cylinder Repeat the procedure for the remaining cylinders Adjusting the fuel injection pump location with shims 15 if the same block camshaft and fuel Injection pumps are used when assembling the fuel injection pump must be installed in their original positions and with the same shim thickness as earlier The so called soft shims always being installed against the block must be replac...

Page 20: ... an inner and an outer The inner ring determines the injection angle for each respective engine type see Technical Data page 25 The injection angle is stamped in degrees and is fixed with a pin 1 B Mount the setting disc or the pulley with two bolts do not tighten the bolts Turn the setting disc so that the guide pin 2 comes in the largest of the four holes in the pulley Press in the guide pin 2 s...

Page 21: ...shims 0 2 and 0 3 mm 0 007874 and 0 011811 in and one hard shim of 0 3 mm 0 011811 in Place the hard shim between the two soft ones and refit the pump NOTE A hard shim must never be fitted together with another hard shim or directly against the block or pump Hard shims are available in thicknesses 0 3 0 6 and 0 9 mm 0 011811 0 02362 and 0 035433 in Soft shims are available in thicknesses 0 2 and 0...

Page 22: ...at housing and the exhaust elbow 21 Fit the valve cover using a new gasket Make sure that the round hole for the crankcase ventilation is in the right position Fit the decompression device lever Fit the pressure pipes between the injectors and the injection pumps Also refit the inlet air silencer 22 Install the starter motor the alternator and the alternator V belt Also install the electrical dist...

Page 23: ...rbo compressor is not functioning properly If the boat s speed through the water is gradually decreasing the boat s bottom should also be inspected and cleaned where necessary Check that the air intake has not become clogged and clean the intake silender Inspecting the Seals Check the joints between the turbine housing and the compressor bearing housing and between the compressor bearing housing a...

Page 24: ...sor wheel using dollies on theturbine shaft Remove the compressor wheel 2 and dismantle the turbine housing 3 RECONDITIONING Dismantle the turbine shaft 4 and the heat shield If the turbine shaft sticks tap the end gently with a wooden hammer Unfasten the three screws which hold the cover 3 and screw two M5 screws into the cover Then lift it up Take the oil deflector 7 out of the cover ...

Page 25: ... Compressor Housing Turbine Housing Check that the housings are free from cracks or other damage caused by excessive wear and tear Damaged parts should be replaced Heat Shield Check that the heat shield is free from damage caused by wear and tear heat or corrosion and replace it if necessary Bushing Oil Deflector Compressor Bearing Check that the parts are free from wear and tear and discolouratio...

Page 26: ...ousing which come in touch with the cover using Permatex for the purpose The thickness of the sealant should be about 0 1 0 2 mm Fitthe cover on the bearing housing and fasten itwith new screws and washers The torque should be 1 3 Nm 0 1 Tighten the screws to the above torque then loosen them a quarter turn before tightening them up to the correct torque again Position the compressor wheel on the ...

Page 27: ...olderforthe pipe position 11 and the lock position 11 a 5 Fit the pipe between the circulation pump lower outlet and the cylinder head position 12 6 Fit the pipe between the circulation pump upper outlet and the cylinder head position 13 7 Fit the alternator place the bolt for the tensioner bracket with the head forwards Put on and tension the V belt 8 Fit the expansion tank to the exhaust elbow p...

Page 28: ... button 6 Alarm Max output from the panel 5 A Cable colour R Red PU Purple BN Brown OR Orange GR Grey SB Black W White Y Yellow GN Green BL Blue ENGINE 1 Relay 2 Fuse 3 Temp alarm sender 4 Oil pressure alarm sender Wire areas in mm 2 Wire area mm 2 1 0 16 1 5 14 2 5 12 10 6 26 AWG Wiring diagram alternative A Standard Z ...

Page 29: ...for instrument lighting 7 Rev counter 8 Key switch 9 Alarm Max output from the panel 5 A Cable colour GR Grey SB Black BN Brown LBN Light brown R Red P Purple GN Green Y Yellow W White BL Blue LBL Light blue ENGINE 1 Coolant temperature sender 2 Oil pressure alarm sender 3 Coolant temperature alarm sender 4 pit pressure sender 5 Relay 6 Fuse Wire areas in mm2 ...

Page 30: ...ectric wires Main fuse blown Empty fuel tank closed fuel cock or clogged fuel filter Water or impurities in the fuel Faulty injectors or air in the fuel system Boat abnormally loaded clogged intake air filter or marine growth on the boat bottom Engine not properly aligned Propeller damaged Clogged cooling water intake or waterjackets in the exhaust manifold Faulty impeller in sea water pump Faulty...

Page 31: ...e removal Mandrel for installation of injector sleeve Mandrel for installation of valve guide Setting disc for injection pump setting Puller for injector sleeve Flaring tool for injector sleeve Flange for engine cradle Mandrel for installation of sealing ring in transmission cover Assembly and disassembly tool for camshaft pin Guide pin for cylinder head NOTE Two are required ...

Page 32: ...ight 78 3 m m 3 08268 in Height from gudgeon pin center to piston top 50 3 mm 1 98031 in Piston clearance in cylinder 0 09 mm 00354 in Piston in standard dimension 78 903 78 17 3 10642 3 10697 in 0 25 mm over size 79 153 79 167 3 11626 3 11681 in 0 50 mm over size 79 403 79 417 3 12610 3 12665 in Gudgeon pins Diameter 25 995 26 000 1 02343 1 02362 in Gudgeon pin bushing diameter 26 005 26 011 1 02...

Page 33: ...1 87949 1 87992 in 0 500 m m over size 47 489 47 500 1 86965 1 87008 in Bushing diameter 47 02 47 05 mm 1 85118 1 85236 in Cylinder head Material Special alloy cast iron Inlet valves 20031 Disc diameter 34 4 34 6 mm 1 35433 1 36220 in 35 8 36 0 mm Stem diameter 7 955x7 970 mm 0 31319 0 31378 in 7 995 7 970 mm Valve seat angle 44 55 44 85 29 45 30 15 Cylinder head seat angle 45 30 Seat width in the...

Page 34: ...10 6 F and at 25 r s 1500 rpm pump revs Governor overrun 54 r s 3250 rpm Feed pump Feed pressure 42 r s 2500 rpm 0 65 0 85 kp cm2 9 20 12 10 lbf in2 Electrical system Battery voltage 12V Battery capacity Max 70 Ah Starter motor output 2001 0 8 kW 1 1 H P Starter motor output 2002 and 2003 1 4 kW 1 9 HP Alternator output Voltage max current 14W50 Amp Output 700 Watts Electrolyte spec gravity Fully ...

Page 35: ...ng bolts 1st tightening 2nd tightening Big end bearing bolts Flywheel housing bolts Flywheel bolts Cylinder head bolts 1st tightening 2nd tightening Rocker arm bridge Fuel injection pumps Pulley Injectors 20 20 Nm 2 0 kpm 14 7 ft lbs 60 Nm 6 0 kpm 44 2 ft lbs 70 Nm 7 0 kpm 51 6 ft lbs 25 Nm 2 5 kpm 18 4 ft lbs 65 Nm 6 5 kpm 47 ft lbs 20 Nm 2 0 kpm 14 7 ft lbs 70 Nm 7 0 kpm 51 6 ft lbs 25 Nm 2 5 kp...