6
Repair instructions
The working methods described in the Service Manu-
al apply to work carried out in a workshop. The engine
has been removed from the boat and is installed in an
engine fixture. Unless otherwise stated reconditioning
work which can be carried out with the engine in place
follows the same working method.
Warning symbols occurring in the Workshop Manual
(for their meaning see
Safety information)
WARNING!
IMPORTANT!
NOTE!
are not in any way comprehensive since it is impossi-
ble to predict every circumstance under which service
work or repairs may be carried out. For this reason we
can only highlight the risks that can arise when work
is carried out incorrectly in a well-equipped workshop
using working methods and tools developed by us.
All procedures for which there are Volvo Penta spe-
cial tools in this Workshop Manual are carried out us-
ing these. Special tools are developed to rationalize
working methods and make procedures as safe as
possible. It is therefore the responsibility of any per-
son using tools or working methods other than the
ones recommended by us to ensure that there is no
danger of injury, damage or malfunction resulting from
these.
In some cases there may be special safety precau-
tions and instructions for the use of tools and chemi-
cals contained in this Workshop Manual. These spe-
cial instructions should always be followed if there
are no separate instructions in the Workshop Manual.
Certain elementary precautions and common sense
can prevent most risks arising. A clean workplace
and engine eliminates much of the danger of injury
and malfunction.
It is of the greatest importance that no dirt or foreign
particles get into the fuel system, lubrication system,
intake system, turbocharger, bearings and seals
when they are being worked on. The result can be
malfunction or a shorter operational life.
Our joint responsibility
Each engine consists of many connected systems
and components. If a component deviates from its
technical specification the environmental impact of an
otherwise good engine may be increased significant-
ly. It is therefore vital that wear tolerances are main-
tained, that systems that can be adjusted are adjust-
ed properly and that Volvo Penta Genuine Parts as
used. The engine Maintenance Schedule must be fol-
lowed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance. Some com-
ponents are sealed at the factory for environmental
reasons. No work should be carried out on sealed
components except by authorized personnel.
Bear in mind that most chemicals used on boats are
harmful to the environment if used incorrectly. Volvo
Penta recommends the use of biodegradable de-
greasing agents for cleaning engine components, un-
less otherwise stated in a workshop manual. Take
special care when working on-board, that oil and
waste is taken for destruction and is not accidentally
pumped into the environment with bilge water.
Tightening torques
Tightening torques for vital joints that must be tight-
ened with a torque wrench are listed in workshop
manual “Technical Data”: “Tightening Torques” and
are contained in work descriptions in this Manual. All
torques apply for cleaned threads, screw heads and
mating surfaces. Torques apply for lightly oiled or dry
threads. If lubricants, locking fluid or sealing com-
pound are required for a screwed joint this information
will be contained in the work description and in “Tight-
ening Torques” Where no tightening torque is stated
for a joint use the general tightening torques accord-
ing to the tables below. The tightening torques stated
are a guide and the joint does not have to be tight-
ened using a torque wrench.
Dimension
Tightening Torques
Nm
lbt.ft
M5
6
4.4
M6
10
7.4
M8
25
18.4
M10
50
36.9
M12
80
59.0
M14
140
103.3
