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    WORKS OPM NU LPubl n 773 974 84 199

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    FOREWORDThi s workshop manual contai ns repai r i nstr ucti ons f or the 2001, 2002 and 2003 enginesThe i nstr ucti ons concerni ng overhaul i ngdescri be themost sui tabl eworki ngmethodusi ngthespeci al tool s l i s ted underthe heading Speci al tool sBoththeengine desi gnat i on and i t s seri al number must be c lear l y stated i n a l l correspondence concerni ngtheengineandwhen orderi ng parts Wreserve the ri ght t o carry out desi gn modi f i cati ons and, f or this reason, t he cont ent s of th i s manual cannot be regarded asbi ndi ng

    SI UNTSYSTEMPower s gi ven i n kWki l owatt )

    Speed s gi ven i n rev/ s revol ut i ons per second

    ea r l i e r un i t hp hor se- power )

    earl i er uni t rev/mn revol ut i ons per m nut e)Torque i s gi ven i n Nmnewonmet r e)

    Vol ume s gi ven i n dmcubi c deci met r e)ea r l i e r un i t kpmki l opond met r e)

    earl i er u ni t l l i t r eea r l i e r un i t l bf f t poundfoot earl i er uni t Imp gal I mperi al gal l onear l i er uni t USgal Uni ted States gal l on)Pressure i s gi ven i n Pa Pascal )earl i er uni t kp/ cm2 ki l oponds per square cent i metr e)earl i er uni t I bf / i n2 poundsper squar e i nch)

    VOLVOPENTTechni cal Publ i cat i ons Department

    Uni t s accor di ng t o the i nt ernati onal SI systemhave been used i n t h i s book The earl i er uni ts ar e gi ven after the SI uni ts

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    Components gui de 2DS SSEM LYCyl i nder head 3Transmssion 4Pi st on pi st on rods 5Fl ywheel 5Cr ankshaf t 5Camhaft 5OVERH ULD sassembl i ng the cyl i nder head 7Val ve gui des 7Val ve seat s 7Val ves 7Val ve spr i ngs 8Rocker armmechani sm 8I nj ect or sl eeve 8I nj ect ors 8Assembl i ng the cyl i nder head 9Feed pumpPi st onsCrankshaf t CamhaftConnecti ng rods 12Thermostat 3Sea water pump 3

    I NDEX

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    COMPONENTSGUDE

    8 Exhaust el bow2 I nj ectors Temperaturesender l ectri cal di str i but i on box5 Fuel f i l t e r6 Al ternator7 Starter motor8 Drai nage cool i ng water9 Feed pump Engi ne seri al number Decompressi ondevi ce2 I nl et ai r si l encer3 Fuel i nj ect i on pumps4 O l di psti ck5 Sea water pump

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    Drai n of f the cool i ng water andthe l ubri cati ng oi l fromtheon engi necrad e p n 9992520and f i xture p n 884837 I f theengi ne i s f resh water cooled see page

    mov the al ternator the tensi oner bracket and thestarter mtor mov the connecti ons fromthe el ectri caldi s t r i but i on box fromthe engi ne and r mv the box andthe wre harness

    DI SASSEMBLY

    3 mov the f uel f i l t e r , the oi l f i l t er the feed pump thethermstat housi ng andthe exhaust el bow A so r mvthe sea water pumpwth i t s attachmnt tubes

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    5 emovethe f uel i nj ect i on pumps Mark the pumps toensure i nstal l at i on i n the samecyl i nders fromwhi ch theywere removed Take care of the shim emovethescrewson the si de of the engi ne bl ock and l i f t out the pump

    7 emovethe transmssi on cover Start by removi ng thethrott l e contro cover Use asui tabl e type of pl i ers tohe spri ng 1 Then removethe end-ni ppl e 2 andthe spri ng 3 emovethe oi l pumpcover andmark thegear wheel s wth a co our-pen before removi ng themWheni ns tal l i ng thegear wheel s the marked si demust bef aci ngoutwards emovethe braci ng pi n of the camhaftusi ng the specia t ool

    p/ n884839 Never removethei n by punchi ng t out t h i s can verywel l bend the

    camhaft emove the screws on the transmssi on coverand pul l t strai ght outwards

    8 The max. -vo um-screw 1 and themax. -rev-screw 2are set by Vol vo Pentaandmust never be changed si ncet h i s wi l l af f ect the engi ne output

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    1 ul l out the camhaft 12 Turn the engi ne upsi de downand removethe o panBe careful as thepan s gl ued NOT Theoi l panends al sofuncti on as mai n beari ngs

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    14 emovethemainbearing caps Themai nbearing capsaremarkedwth a f i gure Thecorresponding f i gure i sntothe bl ock i t out the crankshaf t nl t r engine

    v rsi ons n arrowi s cast i n theseparate mai nbearing caps2002 2 3 The arrow i s to point towards the di psti ck

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    THECYLINDERHE D Removethe col l ets and val ve spri ngs usi ng a val vebowRemove the val ves Remove the val ve stemseal s Place the val ves i n the proper sequence i n a val vestand

    Val ve guides

    3 Usemandrel p/n 5218 to press out the val ve guides O lthe newval ve guides external l y and use mandrel p/n884559to i ns tal l themPressdownthemandrel al l thewaydown t o the cyl i nder head Reamthe val ve gui des i f

    Val ve seats andval ves4 M l l or reamthe val veseats Theangl e C should be 45 f or 2003T 30 f or the i nl et val ve . The seal i ngsurface swdth B shouldbe 0 0390 0039 i n Gri nd the val vesmachi ne angl e

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    Repl aci ng theval ve seat exhaust port 2003TGri nddownthe val vedi sc of a di scarded val ve t o j ust bel ow271 . 063 i n di ameter Push the val vestemthrough thegui de NOTE Do not push i n too far - t he val ve di sc shoul d bej us t bel owthe edge of the seat Spot weld the di sc i n pl aceatthreepoi nts usi ng a el ect r i c welder Knockout the seat by

    he val vegui dewth a pl asti c-headed hammer Cool the newseat to approx 2 C- 4F ; the cyl i nderhead shoul dbeat roomtemperature +200168F) Pl acethecooled seat on tool 884961-4 and knock i t down unt il i tNOTE Turn the seat wth the val ve f ace towards thetool

    Val ve spri ngs

    Rocker armmechanism6 Dsassembl e the rocker armmechanismand clean theparts Checkthewear of theshaft and rockerarmbushi ngs.Shoul d thebushi ngs need t o be repl aced, usethemandrelp/n 9991867 for the removal and i n st a l l at i on , make suret hat theoi l hol e i n the bushi ngcoi ncides wth the one i n therocker arm Af t er t he i ns t al l at i on the bushi ngs are reamedt o a close runni ng fi t. When i nstal l i ng the rockerarm shaf t ,i t must be turned so t hat thel ubri cat i on holes ar e f acing theval ve-side Check t o makesure that the rockerarmcontactsurfaceagai nstthe val ve i s concave. Mnor adj ustments ar emadei n a val vegri ndi ng machi ne Oi l the shaft and i nsta l lthe parts

    Pressure testi ng thenozzles7 Check the nozzl e s spray pattern at the correct openi ngpressure s ee Technical Data Check al sothat the f uel spraysstop simul taneousl y and no dri ppi ngoccurs Adjust theopeni ng-pressure wth adj ustment-washers 1)

    i n di f f erent thi cknesses from13937

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    I nj ector- sl eeve8 I nsert the expandi ng screw on the special t ool p/ n884811 i nt o the copper sl eeve and turn the screw

    n t i c l o c k w i s e u n t i lthe screwhard to a l owthe threads t o wor k t hemel vesi nt o the copper materi a Then i nstal l the yoke 1 on thestud bol t of the i nj ector Put a cy i nder head screwi n thecy i nder headas a support fort he l eg of theyoke I nstal l thenut 2 and ti ghten i t unti l the sl eeve i s remved

    10 O l thefl are- tool p/n 884283 and i nsert i t i ntothe sl eevemake sure that the dowel i s properl y retracted Brace thetool wt h the i nj ector yoke Screwdownthe f l are tool as f aras the shoul der i n the i nj ector sl eeve a l ow therebyhe sl eeve emove the t ool Ad ust the l ength of thesl eeve outsi de the p ane of the cy i nder head tomaximum1. 03937 i n .

    Assemb i ng the cy i nder head C ean the cy i nder head I f the water di s t r i but i on pi pe

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    Reducti onval ve12 emove thecover of the reducti onval veandcheck tmke sure that the spri ng and the pi stonare f aul t l ess I fthere are reasons tosuspect af aul t i n theopeni ng pressureof the reducti on val ve then check the dataof thespri ngSee under Techni cal Data - reducti on val ve

    Changi ng thedi aphragm14 emove the si x screws hol di ng the upper and l owerpumphousi ngs together emove thepump l ever spri ng 1 and remove the screw 2 hol di ng the pump l evershaf t

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    16 C ean the pumphousi ng caref ul l y and r epl ace wornparts I nstal l the di aphragmand the l ever on thehaf t Then i nsert the shaft and t i ghten i t wth the

    screwAssemble the two housi ng hal ves and i nstal l theattachmnt pl ate 1 Then i nstal l the spri ng 2 andthe O r i n g 3

    Val ve l i f t e r s17 Checktheval ve l i f t er s f or wear Repl acethemf necessary

    19 Place a support under the camhaft gear and use ahydraul i c press t o remove the gear

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    Pi stons cyl i nders2 Check thewe r on pi stons pi ston ri ngs and gudgeonpi ns Repl ace these i f necessary Use a cyl i nder i ndi catorgauge t o masure the cyl i nder bores Theme surement ofthe b ggest we r i s m de i mmdiatel y beneath the edge oftheupper dead center and crosswse the eng ne Themesuremnt of the sm l est we r i s m det the l ower deadcenter As t o the cyl i nder di amter, see Techni ca DataUse a mcromter to masure the p stons Pi ston di amter,see under Techni ca Data

    22 I nsertanewp ston r i ng i nt o the cyl i nderand masurethe pi ston ri ng gap As t o the masuremnt, see underTechni ca Data I f necessary i ncrease the gap, usi ng aspe i l f i l e

    24 Use p ston r i ng pl i er s t o i nst l l the p ston ri ngs hemarki ngof the ri ngs TOP or t he mark of themanufacturer)must be turned upwards The hei ght of the upper compressi on r i ng : 75.068898 i n The hei ght of theomressi on ri ng 2 00.07874 i n Turn the

    i ngs so t h t the gaps are turned 120 f romeach

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    26 Check theconnecti ng rod bushi ngs by usi ng thei n as a gauge Theremust beno pl ay I f thebushi ngsmust be repl aced, use a sui tabl e mandrel f or the remvaland i nstal l at i on Make sure to i nst al l thebushi ngwth theo i l hol e coi nci di ngwth that of theconnecti ng rod Reamthenewbushi ngs Thef i t i s correctwhenanoi l edgudgeonpi n by i t s ownwei ght can sl owy s l i de through the

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    A ways use newgaskets, seal i ng ri ngs, seal i ng washersand l ock-washers Coat the seal i ngs wth grease or oi lthemandal so oi l a l l movingparts pri or to i ns tal l i ng themI f the engi ne i s fresh-water cool ed see page 21

    1 Heat thecrankshaft gearwheel to approx 150C 302 Fpri or to the i ns t al l at i on Place thekey i n thekey-wayof thecrankshaft and press on thegear wheel O l thenewmai nbeari nghalves w t h oi l hol e) and i nstal l themn the blockPut i n the cr ankshaf t . NOTE Themai n beari ng shel l at thef l ywheel al so functi ons as a thrust-beari ng

    SSEMBLY

    3 Turn the pi ston r i ngs so that thegaps are offset i n rel at i ontoeachother The pi ston crown i s marked wthan arrowthatpoi ntstowards the bel t pul l ey Use i ns tal l at i on r i ng 884813-7F i t the caps wth the marki ng al i gned wth the crankshaf t smarki ng The crankshaft can be turned i n any di rect i ontowards the pi stonTi ghteni ng torques Step 1 25Nm2 . 5 kpm 18Step 2 70Nm7 . 0 kpm 53 f t / l b

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    5 Repl acethe f l ywheel housi ng seal i ng 1 . Smear seal i ngcompound p/ n 840879 on theedgebetweenthef l ywheelhousi ng and the seal i ng NOTE The seal i ng l i p wth aspri ng shal l be turnedtowards the engi ne Makesure thatthe seal i ng i s i ns t al l ed i n accordance wth the pi cture

    r

    A Heat the camhaf t gear wheel to a temperature ofapprox 150C302F anduse sui tabl e sl eeve t o i nstal l t Check tomkesure that the gear wheel bottom on thecamhaf t I nstal l the camhaf t and mke sure that themarki ngs on the camhaf t gear wheel and on the

    gear wheel coi nci de Put thewasher 1 onthe hubofthe camhaf t gear wheel Check that al l weights are

    i n so that the tabs 2 are i nsi de the washer

    7B I nstal l anewseal i ng ri ng f or the camhaf t i n theousi ng, usi ng mandrel p/ n 884838 Theseal i ngl i p wth thespri ng i s tobeturnedt owards theengi ne Pressi n the seal i ng r i ng f rom the outsi de unti l the mandrelbottoms against the housi ng I ns tal l anewO ri ng i n theo i l channel i n the b ock 3 f i g 7A

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    8 I nsert the contr ol rodthroughthebl ackand i nto theti mnggear casi ng Instal l the beari ng bal l 1 i nto the contr ol rodandpush the contr ol rod through the hol e i n the contr ol l ever 2F i t the spri ng 3) andscrewon the end ni ppl e 4 unti l Note Do not use any tool s) Screwi n the upper bol ts w t h copper seal i ng washers) that gui de the control rod Then, screwthe l ower bol ts that hol d the contr ol rod i n pl acei n the engi ne bl ock NOTE The l ower bol ts shoul d not haveseal i ngwashers Appl y Permatex to the threads Check thatthe contr ol rodmoves f reel y 10 I nsert thekey f or the pul l ey i n the crankshaft and i ns ta l l

    the pul l ey Ti ghteni ng torque 404, 0 kpm 29. 5f t I bs)

    C ean the val ve l i f t e r s careful l y and coa the contactsurf ace against the camshaf t wth molybdenum

    Oi l the val vegui des i n the bl ock and i ns ta l l the l i f t e r s C ean the rol l er l i f t e r s of the f uel i nj ect i on pumps and

    hen i n the bl ock Lock the rol l er l i f t e r s wth screwsthrough the bl ock a f ter the i ns t al l a t i on appl y Permatex t othe threads) Check careful l y t o make sure that the l i f t e r sare correctl y i ns t al l ed and that they are runni ng easi l y i nthe groove

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    2003

    12 Ti ghten the two gui de screws p/ n 884840 i n the bl ockand i ns tal l the cyl i nder head gasket wth the marki ngTop faci ng upwards I ns t al l the cyl i nder head Make sure that the contact surface f or the cyl i nder headbol t s are f ree f rompa nt Should there be paint on thebol t s, there i s always the r i s k of havi ng an i nsuf f i ci er torce i n the bol t j oi nt wthsubsequent l eakages as aresul t NOTE The bol ts are phospated, therefore do notclean themwth a steel -brushCoat the cyl i nder head bol t s wthmolybdenumdi sul phi deand t i ghten themn accordance wth thedi agram f i r s t t o202 0 kpm14. 7 f t . l bs andthen to707 0 kpm51. 6ft. l bs .

    14 Va ve clearance col d/warmengi ne 0. 30. 01181i n . Turn the engi ne i n the di recti on of rotati on unt i l theva ves i n one cyl i nder are rocking Then turn theengi neone turn moreand adj ust

    the va ves f or t hi s cyl i nder he procedure f or the remai ning cyl i nders .

    Adj usti ng the f uel i nj ecti on pumpl ocati onwth shim15 i f the same bl ock camhaf t and f uel I nj ect i on pumpsare usedwhenassembl i ng, the f uel i nj ect i on pumpmustbe i ns t al l ed i n t hei r or i gi nal posi ti ons andwth the sameshimthi ckness as ear l i er . Thesocal l ed so f t shim, alwaysbei ng i ns t al l ed agai nst the bl ock, must be repacedaga nstnewones Careful l ycleanthe contact surf aces between thebl ock and the f uel i nj ect i on pumps and i ns t a l l shim wththi ckness equa to the sumof themarki ngon the bl ockandthat on the f uel i nj ect i on pump 4 ear l i er marki ng Exampl e Thebl ockmarki ng 4 =4tenths of aml l imter)

    . 015748 i n .

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    On l ate r versi on engines an O- r i ng has been i ntroduced as aseal between the i nj ect i on pumpand theb ock Only so- c al l edhard shi mmybe used on these engi nes whenshi mmngHard shi m ar e ava i l abl e i n thi cknesses of 0. 20 . 0079 i n ,0. 30 . 0118 i n , 0. 60 . 0024 i n and 0. 90 . 0354 i n

    16 ewb ock or camhaftI f the b ock or the camhaft are repl aced the b ock must bemeasured and marked, usi ng the set t i ng-d i sc p/ n 884787and a s l i di ng cal i per

    set t i ng-di sc pi n 2 coms i n the l argest of the four hol es i n the pul l eyPress i n the gui de pi n 2 so that the di sc i s centered andti ghten the bol ts The sett i ng-di sc i s mrked f or each respecti ve cyl i nder

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    C Turn cyl i nder no 1 t o i t s i nj ect i on posi t i on Pl ace thegu de pi n 2) i n the set t i ng- di sc s hol e mrked cyl 1 Turnthe crankshaft a l i t t l e against the norml di recti on of

    nd thereafter i n the norml rotati on di recti on unt i l theset t i ng- di sc s gui de pi n 2) goes i n the ti mng cover' s ho e Measure usi ng a cal i per the di stancebetween the cyl i nderb ockand the r ol l er l i f t er s edge do not masure on therol l er ) The di stance shou d be:2001 : 55. 82. 1 9685 i n)2002, 2003 55, 62 . 18504 i n)2003T 55. 92 . 2007 i n)Examl e :2001 I f the masured di stance i s 55. 22 . 17323i n) t h i smeans that a shi mwth thi ckness 0 . 60 . 02362 i n) i s t obe pl aced between the cal i per and the b ock2002, 2003 I f the masured di stance i s 55. 02 . 16535i n) t h i s means that a shi mwth thi ckness 0 60 . 02362i n) i s t o be pl aced between the cal i per and the bl ock.The masuredshi m thi ckness i n t hi s examl e0 . 6 mm i st o be st amed i n t o the b ock as i n f i g 15The tota l shi mthi ckness i s found by adding the b ock smasuremnts and the pum s mrki ngExaml eThe bl ock s measurements 6 = 0. 6 mm0. 02362 i n)The pum' s mrki ng 2 =0 . 2 mm0. 007874 i n)No of shi m 0. 8I n th is case choose two sof t shi m 0 . 2 and 0. 3

    0 . 007874 and 0. 011811 i n and one hard shi mof 0 . 30 .011811 i n) Pl ace the hard shi mbetween the two sof tones and ref i t the pump NOTE Ahard shi mmust never be

    17 F i t the i nj ect i on pum(s) together wth the cal cu atedshi mthi ckness Turn the engine so that the cam or thepump i s not i n the l i f t i ng posi ti on Check that the pum spi n l ocates i n the control rod s groove and t hat t he pum(s)and the l ocks mrki ngs co nci de see f i gure) Check af t erf i t t i ng each pump that the contro rod operates easi l y Ti ghten ng torque f or the nuts i s 202, 0 kpm 14. 7f t . l bs). Connect the f uel pi pe between the pumps and thepi pe f romhe f uel f i l t er t o the i nj ect i on pump NOTE Theho e bol t for the return hose has a sml l er through-f l owchannel than the others (on l at er versi ons i t i s marked' Out )

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    9 I n s t a l l the sea-water pumpand the cool i ng water

    Fi t the val ve cover usi ng a newgasket kesure t hatthe roundhol e f or the crankcase ven t i l a t i on i s i n the ri ghtposi t i on Fi t the decomressi ondevi ce l ever Fi t the

    i pes between the i n ject or s andthe i n j ect i on pumpsA so r e f i t the i nl et ai r si l encer

    2003T

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    23 i l l up wth l ubri cati ng oi l to the correct l evel quanti ty and qual i ty see under Techni cal Data

    24 Venti ng the fuel systemOpenthe venti ngscrewon the f uel f i l t e r approx turns Wtch out f or fuel -spl ashes

    Turbo-ComressorWerethere i s an excessi ve amount of smoke i n the x h u s tbe that theturbo-comressor i s not functi oni ngproperl y I fthe boat s speed through thewater i s gradual l y

    the boat s bottomshoul d al so be i nspected andcl eanedwherenecessary Checkthat the ai r i ntake has notbecome cl ogged and cl ean the i ntake si l ender

    I nspecti ng the Seal sCheck the

    j oi nts between the turbi nehousi ngandtheeari ng housing, and between the comressor

    beari ng housi ng and the comressor housi ng

    ChecksCheck the pre- i nj ecti on angl e, the i nj ector s openi ng

    ndthe spray pattern Theval ve cl earanceandhoul d al so be checked

    Checki ngaxi al and r adi al cl earanceDsmunt the turbo-comressor fromthe engi ne, andmasure the rotor uni t s axi al and radi al cl earance Maximumpermssi bl e axi al cl earance . 09

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    RECONDTIONNG

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    Removethe packing ri ng 12 on the turbi ne shaf t andthetwo packing ri ngs 13 on the oi l def l ector C ean the partscaref ul l y

    Measuri ngand I nspect i onTurbi neWhee and Shaft

    Unfasten the four screw whi ch ho d the comressi onbeari ng 8 Usi ng a sml l copper mndrel tap out thecomressi on beari ng and the bushi ng 9 Then removetheci rcl i ps 10 i nsi dethe beari nghousi ngandremovethetwo beari ngs 11

    Check that the turbi newheel and shaf t are free f romamge The vanesmst not be wornor out of

    shape onot t r y t o real i gn the vanes amagedpartsshoul d be repl aced

    Pl acetheshaf t ontwosupports whi ch shoul dbe the

    Comressor Housi ng Turbi ne Housi ngCheck that the housi ngs are free f romcracks or other

    aused by excessi vewear and tear amged partsshoul d be repl aced

    Heat Shi el dCheck that the heat shi el d i s f ree f romdamagecaused bywear and tear, heat or corrosi on and repl ace i t i f

    Bushi ng Oi l Def l ector , CompressorBeari ngCheck that the parts are free f romwear andtear and

    amgedparts shoul d be repl acedeven i f theamount of wear and tear i s wthi n the permtted

    Bushi ng

    Oi l Def l ector

    Check measurement A , whi ch shoul d not be l ess than4 07

    Checkmeasurements B and C B shoul d not bemorethan 3 mm C shoul d not bemore than . 11Comressor Beari ngCheck thewdth of thebeari ng andrepl ace i t i f theamountof wear and t ear i s i n excess of the permtted to eranceMnimumpermssi bl ewdth i s 3 98

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    Beari ng Housi ngCheck the housi ng f or corrosi on or cracks Check

    D and E , and repl acethe housi ngwhere Measurement D shoul dnot be

    more than 12. 42 mmmeasurement E shoul d not be morethan 15. 05mm

    CoverCheck measurement s F and G and repl ace the coverwhere necessary Measurement F shoul d not be morethan12. 45mmmeasurement G shoul d not bemorethan10 . 05mm

    Reassembl yGease al l removabl e partswhen reassembl i ng them

    he c i r c l i p s i n the beari ng housi ng so that then themare faci ng towards the oi l outl et

    Mount thepacki ngri ngon t he turbi ne

    shaf t Turnthei n the ri ng so that i t i s f aci ng towards the oi l i ntakePosi ti on the heat shi el d on the beari ng casi ng, andthen

    pl ace the turbi ne axl e i n the beari ng housi ngMount thebushi ngonthe turbi neshaft Grease i n the

    eari ng wth engi ne o i l , and mount i t on thebeari ng casi ng, usi ngnewscrews andwashers to fasten i t Thetorque shoul d be . 3 m1 Ti ghtenthe screwsto the abovetorque, then l oosen themaquarter turn bef ore ti ghteni ng themup to the correcttorque agai nPosi ti on the two packi ng ri ngs on the oi l def l ector NOTEThe openi ng i n the i nner ri ng shoul d bef aci ng the oi l

    hat i n the outer r i ng shoul dbe faci ng the oi l i ntakePosi ti on the oi l def l ector i n the cover Smear the edges ofthe beari ng housi ng whi chcome i n touch wth the cover,usi ng Permatex for the purpose Theth ckness of the seal ant shoul d be about 0. 1-0 . 2mmFi tt he cover onthe beari nghousi ng, andf asteni tw th newscrews and washers Thetorque shoul d be 1 . 3 m1 Ti ghtenthe screws to theabovetorque, then l oosenthemaquart er turn bef ore ti ghteni ng themup t o the correcttorque agai nPosi ti on the compressor wheel on the turbi ne shaf t andfasten i t wth the l ef t-handthreadnut The torque shoul dbe 2 . 0m1Mount theturbi ne housi ngon the beari ng housi ng

    to the l i ne-up marks Screwthe l ocki ng cover i n t oaki ng sure that the screws usedare not those forthe compressor housi ng The torque shoul d be 11 . 0m5 M6 , 26. 01,0 M8) Smear the edges of the beari ng housi ngwhere i t comes i ntouch wth the compressor housi ng, usi ng Permatex f orthe purpose Theth ckness of the sealant shoul d be about0. 1-0 . 2mmThenmount the compressor housi ng

    t o the l i ne-up marks, andscrewthe l ocki ng cover i n t opositi on Thetorque shoul d be 4. 5 Nm 5 Check the axi al and r adi al cl earance Maximum

    axi al cl earance i s 0.09mmmaximumpermssi bl el earance i s 0. 17mm

    F i t t i n g the Turbo- CompressorBef ore f i t t i n g the turbo- compressor on the engine, spray

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    FRESHWATERCOOLING2002, 2003Fi t theci rcul at i on pumpompl etewth tensi oner bracket andspacer sl eeve, positi on 4 . Ti ght en thebol ts 8x75) to202, 0 kpm 14. 7 f t . l b s ) , posi ti on 1 2 Suspend the heat exchanger l oosel y by the r ear bol t 8x16and spri ngwasher . positi on 5a) Fi t t he pi pe pos i t i on 6) and the hose os i t i on 3) bet ween the heat exchanger and the sea- wat er pump, usi ng

    doubl e hosecl amps appl y soapywater t o the rubber r i ngs, appl i es f or al l rubber r i ngs) b Fi t the pi pe betweenthe heat-exchanger and thermostat housi ng, positi on 7c) F i t the pi pe between the heat-exchanger and the ci rcul at i on pum positi on 83 Locate the pi pes i n theheat-exchanger andanddraw i t forward ti ghten ng i t wth the two bol ts 8x16and spri ngwashers), posi ti ons 5and 9

    4 F i t thepi pebetweentheheat-exchanger andtheexhaust el bow positi on10 NOTE Thehol derforthe pi pe, posi ti on11) and the l ock posi ti on 11 a)

    5 F i t the pi pe between the ci rcul at i on pumpower out l et ) and the cyl i nder head, positi on126 F i t the pi pe between the ci rcul at i on pumpupper out l et ) and the cyl i nder head, positi on137 F i t the al t ernat or, pl ace the bol t f or the tensi oner bracket wth the headforwards Put onand tensi on theV-bel t 8 F i t the expansi on tank to the exhaust el bow positi on159 F i t thehosebetweenthetank andthe ci rcul at i on pumpoubl e pi pe 2002 =45017. 7 i n , 2003=55021 . 7

    i n onl y singl e hose cl amps are used on the fresh-water system, positi on 16

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    INSTRUMENTP NEL Pri nted c i r c u i t card Rev counter accessoryStart button4 Sw tch f or i nstrument panel5 Al armtest button6 Al armMax output fromthe panel 5 A

    Cabl e colourR RedPU Purpl eBN BrownOR OangeGR GeySB B ackWhi teY Yel l owGN GeenBL B ue

    ENGNE Relay Fuse3 Temp al armsender4 Oi l pressure al armsender

    Wring di agram al ternativeSt andard

    Z

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    Wri ng di agram al t er nat i ve BDe Luxe

    INSTRUMENTPANEL Vol tmeter2 Ol pressure gauge3 Cool ant temperature gauge4 ri nted circuit card5 armtest6 Swtch f or i nstrument l i ght i ng7 Rev counter8 Key sw tch9 armMaxoutput fromthe panel 5A

    Cabl e colourGR =GeySB =BackBN =BrownLBN =Li ght brownR =RedP =Purpl eGN =GeenY =Yel l ow=Whi teBL =BueLBL =i ght b ue

    ENGNE

    FAULTTRACI NG

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    Engi nedoesnots t r t

    Engi nestops

    Engi ne notreachi ngcorrect tempt f u l l rpm

    Engine runsroughl y orvibrates

    Engi nebecomes n o r m l l y

    hot

    Faul t

    Stop control not f u l l y pushedback ain swtch not swtchedon l t battery Broken el ect r i cw res Mai n fuse bl own

    mpty f uel t nk closed f uel cockor cl oggedfuel f i l t er Wter or i mpuri ti es the f uel Faul ty i nj ectors or i r i n the fuelsystem

    Boat abnormal l y l oaded cl oggedi ntake i r f i l t er or mari ne growthon the boat bottom

    Engi nenot properl y al i gnedamged C ogged cool i ng water i nt ke orwater j ackets theexhaust

    Faul ty i mpel l er sea waterpump Faul ty thermostat cool i ngwater pi pe i n the

    ead

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    9992265 0

    884813 7

    9995218 6

    884557 0

    884559 6

    884787 3

    8848

    884823 6

    884837 6

    884838 4

    884839 2

    Pul l ey pul l er

    I n s t a l l a t i o n r i n g f or pi s t on

    Mandrel f or val ve gui de removal

    Mandrel f or i nst al l at i on of i nj ector sl eeve

    Mandrel f or i nst al l at i on of val vegui de

    Set t i ng di sc f or i nj ec t i on pu pset t i ng

    Pul l er f or i nj ector sl eeve

    l ar i ng tool f or i nj ec to r sl eeve

    Fl ange f or engi ne cradl e

    Mandrel f or i nst al l at i on of sea l i ng r i n g transmssi oncover

    Assembly and disassembl y tool f or camshaf t pi n

    TE HN LD TGeneral

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    Cyl i nder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressi on r a t i o . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compressi on r a t i o at starter mtor speed . . . . . . . . . . . . .

    793 . 11024 i n873 . 4252 i n)17. 5 : 12-2. 5 MPa 20-25 kp/cm

    D recti on of rotati on seen f romthe f ront end . . . . . . . . . .I d l i n g speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oi l pressure at f u l l speed andwarmengi ne. . . . . . . . . . . .Oi l pressure at i d l i n g andwarmengi ne. . . . . . . . . . . . . . . . .

    Cl ockwse13-14 r / s 775-825 rpm0,35-0, 40MPa 3,5- 4, 0 kp/cm0,08-0, 15MPa 0, 8- 1, 5 kp/cm

    Cyl i nder bl ockMateri al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speci a al l oy cast i r o n

    Pi ston ri nggap i n the cyl i nder

    Type desi gnati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001 2002 2003, 2003TNumer of cyl i nders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3Dsp acemnt . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . 0.43 dm 26 . 2 cu0. 852dm 51 . 9 cu i n 1 . 27877. 99i n) cu i n

    Cyl i nder di amter, standard . . . . . . . . . . . . . . . . . . . . . . . 79, 00-79,03 3 . 11025-3. 11142 i n 0 25ver-si ze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 25-79,28 3. 12008-3. 12126 i n 0 50ver-si ze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79,50-79,53 3. 12992-3. 1311 i n .Pi stonsMateri al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Li ght- al l oyTotal hei ght . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78,33. 08268 i n Hei ght f romgudgeon pi n center t o p ston top . . . . . . . . 50 31 . 98031 i n Pi ston cl earance i n cyl i nder . . . . . . . . . . . . . . . . . . . . . 0 09. 00354 i n Pi ston i n standard di mnsion . . . . . . . . . . . . . . . . . . . . 78,903-78, 17 3,10642-3, 10697 i n 0 25ver- si ze . . . . . . . . . . . . . . . . . . . . . . . . . . 79,153-79,167 3,11626-3,11681 i n 0 50over- si ze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79,403-79,417 3, 12610-3, 12665 i n Gudgeonp nsDamter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,995-26,000 1, 02343-1,02362 i n Gudgeonpi n bushing, di amter . . . . . . . . . . . . . . . . . . . . . 26, 005-26, 011 1, 02382-1,02406 i n .Cl earance gudgeon pi n - bushi ng . . . . . . . . . . . . . . . . . 0, 0050-0. 0160 0,00020-0,0063 i n

    Pi ston ri ngsCompressi on r i ng, numer . . . . . . . . . . . . . . . . . . . . 2Oi l ri ng, numer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1The upper compressi on r i n g has an i nl ay of chromThe p ston r i ngs are aval abl e f or standard di mnsion andf or 0,250 and 0,500versi ze 0,00984 and 0,0996i n Pi ston ri ng axia cl earance i n the grooveUpper compressi on r i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,070-0,102 0. 00276-0,00402 i n Lower compressi on r i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,050-0,082 0,00197-0,00323 i n Oi l r i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,030-0,062 0,00118-0,00244 i n

    Main beari ng j ournal sD ameter, standard 59, 987-60,000 2,36169-2,36220 i n .

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    0, 250under- si ze 0, 500nder-si ze- 59, 737-59, 750 2,35185-2,35236 i n .59, 487-59, 500 2,34200-2,34252 i n .

    B g- end beari ng shel l sThi ckness, standard 0 250ver- size 0, 500ver- size

    1, 478-1, 488 0,05819-0, 05858 i n 1, 603-1, 613 0,06311-0, 06350 i n 1, 728-1, 738 0,06803-0, 06843 i n

    Connecting rodsAxi al cl earance at the crankshaft 0, 15-0, 350,00590-0,01378 i n CamhaftAxi al cl earance Radi al cl earance i n beari ngs Camshaf t di ameter L i f t i n g hei ght of cam . - - - . - - - - - - - - - - . - -

    0, 160-0, 3000,0063-0,01181 i n 0, 020-0, 0750,000787-0,00295 i n 46, 975-47, 000 1, 8494-1, 85039 i n 5, 48-5, 520,21575-0,21732 i n .

    Main beari ng shel l sThi ckness, standard 2,987-2,997 0,11760-0,11799 i n 0, 250ver- size 3, 112-3, 122 0,12252-0,12291 i n 0 500ver- size 3, 237-3, 247 0,12744-0,12783 i n B g- end j ournal sD ameter, standard 47, 989-48, 000 1, 88933-1, 88976 i n 0, 250ver- si ze - - - 47, 739-47. 750 1, 87949-1, 87992 i n 0, 500over-si ze . - . - - . - 47, 489-47, 500 1, 86965-1, 87008 i n

    Bushi ng di ameter . - - - - - - - - - - - - 47, 02-47, 051, 85118-1, 85236 i n .Cyl i nder headMateri al Speci al al l oy cast i ronI nl et val ves 20031D sc di ameter 34, 4-34, 61, 35433-1. 36220 i n . 35, 8- 36, 0Stemdi ameter 7, 955x7, 9700, 31319-0, 31378 i n . 7, 995-7, 970Val ve seat angl e 4455 -4485 2945 - - 3015Cyli nder head seat angl e 45 30Seat wdth i n thecyl i nder head appr 10,03)37 i n appr 10. 03)37 i n C earance, col d/warmengi ne

    Exhaust val vesD sc di ameter - - - -

    0, 30, 011811 i n 0. 30, 011811 i n 29, 9-30, 11, 14716-1, 18504 i n .

    Stemdi ameter 7, 950-7, 4650. 31299-0,31339 i n Val ve seat angl e Cyli nder head seat angl e 45Seat wdth-i n the cyl i nder head - - appr 10,03937 i n C earance, col d/warmengi ne - - - - - . - - . - - - 0, 30, 011811 i n .Val veguidesLength, i nl et val ve 381, 49606 i n

    Lubri cati ng systemENGNE

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    Oi l quant i t y model 2001 . . . . . . . . 1, 40 dm 1 . 2 quartsOi l quant i t y mode 2002 . . . . . . . . 2. 75 dm 2 . 42 quartsOi l quant i t y mode 2003 . . . . . . . . . . . . . . . . . . . 4, 10 dm 3 . 6 quartsOi l qual i ty accordi ng t o the API-system CD DSVi scosi ty . . . . . . . . . . . . . . . . . . . . . . 15W40Oi l pressure, warmengi ne, i dl i ng speed . . . . . . . . . . . . 0, 8- 1, 5 kp/ cm2 11 . 37-21 . 33 l b f t / i n2Oi l pressure, warmengi ne, f u l l rpm . . . . . . . . . . . . . . . 3, 5-4 ,0 kp/cm 49. 78-56. 89 l b f t / i n 2 Lubri cati ng oi l pumpType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearwheel pumpGear wheel axi al cl ear ance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 025- 0, 065 0, 00098-0, 00256 i n Spri ng f or r educti on val ve, l ength unloaded . . . . . . . . . . . 49mm1, 92913 i n Loaded w t h 35 Nm 3, 5 kp) 25. 8 f t . l b s . . . . . . . . . . . . . . . . 401, 57480 i n .Fuel SystemOpeni ng pressure . i nj ectors . . . . . . . . . . . . . . . . . . . . . . . 180-190 kp/cm 2560-2702 l b f t / i n2)1Sprayangl e . . . . . . . . . . __ . . . . . . . . . . . . . . . . . . 150I nj ect i on angl e 2001 . . . . . . . . . . . . . . . . . 221 B T . D. CI nj ect i on angl e 2002, 2003 . . . . . . . . . . . . . . . . . . . . . . . 20+1C B T . D- C .I nj ect i on angl e 2003T . . . . . . . . . . . . . . . . . . . . . . . . . . 231BT . D . C .I nj ect i on quant i t y . . . . . . . . . . . . . . 25+1 . 5 mm/stroke at 405C 104F10 . 6 F )and at 25 r / s 1500 rpm pump revsGovernor overrun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 r / s 3250rpm

    FeedpumpFeed pressure 42 r / s 2500rpm. . . . . . . . . . . . . . . . . . . . . . . 0, 65-0, 85 kp/cm 9 . 20- 12 . 10 l b f / i n 2El ectr i cal systemBatt ery vol tage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12VBattery capaci t y . . . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . Max 70 AhSt ar t er- motor output 2001 . . . . . . . . . . . . . . . . . . . 0 8 kW1 . 1 H)St ar t er- motor output 2002 and 2003 . . . . . . . . . . . . . . . . . . . . 1 . 4 kW1 . 9 HP)Al t er nat or output :Vol tage/mx current . . . . . . . . . . . . . . . . . . . . . . . . . . . 14W50AmpOutput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700WttsEl ectrol yte spec gravi ty : Ful l y l oaded battery . . . . . . . 1, 275- - 1, 285To be charged at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 230Thermstat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wax thermost atBegi ns t o open at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602 C 1404F)Ful l y open at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 C {165 F1

    Cool i ng systemWth f r esh- wat er cool i ng 2002, 2003Starts openi ng at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741C 1642F)Ful l y open at . . . . . . . . . . . . . . . . . . . . 87C 189 F)Fresh- water system vol ume 2002 . . . . . . . . . . . . . . . . 4 0 dm l i t r e ) 0 . 88 Im gal s 1 . 1 USgal s3_____ 5 . 5 dm l i t r e ) 1 1 . 2 Im gal s 1 . 45 US gal s

    amhaftBeari ng j ournal s, permtted out-of-round 0 030 00118 i n

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    Max cl earance between camshaf t and bushi ngs 0 150 00590 i n ValvesMax cl earance between val ve stemand val ve gui deThe val ve di sc edge must be at l east

    0 150 00590 i n 1 50 05906 i n

    Ti ghteni ng torquesMai n beari ngbol t s 1st ti ghteni ng 2ndti ghteni ng Bi g-endbeari ngbol ts Fl ywheel housi ng bol ts Fl ywheel bol ts Cyl i nder head bol t s 1st ti ghteni ng 2nd ti ghteni ng Rocker armbri dge Fuel i nj ect i on pumpsPul l eyI nj ect ors

    200Nm2 0 kpm 14 . 7 f t . l bs 60Nm6 0 kpm 44. 2 f t . l bs 70Nm7 0 kpm{51 . 6 f t . l bs 25Nm2 5 kpm 18. 4 f t . l bs 65Nm6 5 kpm 47. f t . l bs 20Nm2 0 kpm 14. 7 f t . l bs 70Nm7 0 kpm 51 . 6 f t . l bs 25Nm2 5 kpm 18. 4 f t . l bs 25Nm2 5 kpm 18. 4 f t . l bs 40Nm{4 0 kpm 29. 5 f t . l bs 20Nm2 0 kpm 14. 7 f t . lbs.