Volvo Penta D1 Series Service Manual Download Page 34

Page: 34 / 90

D2-50/55/60/75

Air filter

Draining coolant, engine block

Hand pump, fuel filter

Oil filter

Filling coolant/expansion level

Draining engine oil

Engine oil filler

Impeller pump, seawater

Drive belt, alternator/water pump

Fuel filter

Dipstick, engine oil

Drain seawater on the other side of the engine; the
drain is mounted on the heat exchanger.

P0030933

Engine

47708114 06-2021 © AB VOLVO PENTA

Summary of Contents for D1 Series

Page 1: ...serviceand maintenance D1 D2 ...

Page 2: ... 2017 AB VOLVO PENTA Volvo Penta reserves the right to make changes Printed on environmentally friendly paper ...

Page 3: ...ication System 40 When you work with Chemicals Fuel and Lubrication Oil Change 40 Engine Oil Level Check 40 Engine oil Replace 42 Oil filter Replace 43 Fuel System 46 General 46 Fuel filter Change 47 Fuel system bleeding 48 Exhaust System 51 Exhaust hose 51 Cooling System 52 Coolant Level Checking and Topping Up 52 Drive Belt Replace 55 Seawater Pump Impeller Change 57 Seawater Filter Check and Cl...

Page 4: ...Cold Weather Precautions 80 Checklist 82 Battery Maintenance 83 Index 85 2 47708114 06 2021 AB VOLVO PENTA ...

Page 5: ...f not avoided result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury IMPORTANT Indicates a situation which if not avoided could result in property damage NOTICE Used to draw attention to important inf...

Page 6: ...ective footwear personal protective equipment head protection protective clothing gloves and respirators WARNING Ensure that all machine guards and safety devices are in place and are functional CAUTION Never use tools or products that show signs of damage Protect your eyes CAUTION Wear safety glasses Always wear safety glasses if there is a risk of splintering sparks and spray from the electrolyt...

Page 7: ...osions and fire in accordance with applicable legal requirements Used oils filters and chemicals etc WARNING Risk of fire Store fuel soaked rags and other flammable material so that there is no danger of them catching fire Oil soaked rags can spontaneously ignite under certain circumstances IMPORTANT Used fuel and oil filters are environmentally hazardous waste and must be taken to an approved was...

Page 8: ...e Work on running engines is strictly prohibited There are however adjustments that require the engine to be run Approaching a running engine is a safety risk Loose clothing and long hair can get caught in the rotating parts careless movements or a dropped tool can lead to serious personal injury Be careful to avoid hot surfaces exhaust pipes turbochargers charge air manifolds start elements etc a...

Page 9: ...tating compressor turbine can in addition cause serious personal injuries Before any work on the electrical system WARNING Always stop the engine first Then disconnect the current at the main switches and any external power supply before working on the electrical system to minimize the risk of electrical hazards IMPORTANT Never disconnect the current using the main switches when the engine is runn...

Page 10: ... on the skin Ensure that the lubrication system is not pressurized before starting any work Never start or operate the engine without the oil filler cap is on There is a risk that hot oil can spray out At any leak detection on the fuel system WARNING Wear safety goggles Be extremely careful when searching for leaks in the fuel system high pressure circuits There is very high pressure in the jet fr...

Page 11: ... electrolyte in batteries WARNING Always wear protective goggles when charging or handling batteries Battery electrolyte is highly corrosive Rinse immediately with copious amounts of water if the electrolyte gets in your eyes Search directly after the rinsing help by medical staff If it comes electrolyte to unprotected skin wash immediately with soap and water After finished work with the engine I...

Page 12: ... the load capacity to lift the engine engine weight including transmission and extra equipment For safe handling and to avoid damaging components fitted to the top of the engine the engine must be lifted with a correctly adjusted lifting boom Never perform any work on an engine that is only suspended from the lifting equipment IMPORTANT All chains or wires must run parallel to each other and as pe...

Page 13: ...arranty terms supplied with the engine Specific terms for the U S market This engine is certified as being in compliance with federal and Californian exhaust restriction regulations Parts related to exhaust restrictions are covered by the warranty commitment for exhaust restricting systems Terms and the parts covered are specified under What is covered by the warranty undertaking for emissions in ...

Page 14: ...gine air inlet ducts Any tampering with the engine will hamper EU type approval of the engine concerned No warranty seals if present on the product may be broken by unauthorized persons Explanation of the relationship between service intervals and operating conditions Because operating conditions may vary depending on how the component is used it is important that the service interval expressed in...

Page 15: ...asis for calculating service contracts and the costs in the service calculator in Product Center P0026295 Fuel system Fuel pump Unit injectors P0026296 Exhaust system Turbocharger low pressure Turbocharger high pressure Overflow valve Lisk Silencer Diesel particulate filter DPF replacement After treatment system Pump unit Dosage valve General Information 47708114 06 2021 AB VOLVO PENTA 13 ...

Page 16: ...P0026297 Cooling system Seawater pump Coolant pump Engine Vibration dampers Engine pads kit P0026298 Electrical system Alternator Starter motor General Information 14 47708114 06 2021 AB VOLVO PENTA ...

Page 17: ...hould be replaced The components below provide the basis for calculating service contracts and the costs in the service calculator in Product Center Engine May be overhauled twice after which the engine is considered spent and is replaced by a long block or new engine P0026299 Overhaul Long block Short block Cylinder head replacement Cylinder head gasket P0026300 Engine overhaul kit Cylinder head ...

Page 18: ...P0026301 Cylinder liners kit Main bearings kit Big end bearings kit Thrust washers kit Camshaft bearings kit P0026302 Exhaust valve Valve seat General Information 16 47708114 06 2021 AB VOLVO PENTA ...

Page 19: ...ow provide the basis for calculating service contracts and the costs in the service calculator in Product Center The transmission is overhauled once then the complete unit is replaced P0026303 Overhaul Aquamatic Aquamatic sterndrive replacement Upper gear Lower gear P0026304 Repair Aquamatic Upper gear kit Sliding sleeve P0026305 Lower gear kit General Information 47708114 06 2021 AB VOLVO PENTA 1...

Page 20: ...P0026306 Overhaul IPS IPS Drive replacement Upper gear Lower gear P0026307 Repair IPS Upper gear kit P0026308 Lower gear kit General Information 18 47708114 06 2021 AB VOLVO PENTA ...

Page 21: ...P0026309 Propeller shaft General Information 47708114 06 2021 AB VOLVO PENTA 19 ...

Page 22: ...ervice life While oils from various suppliers meets both SAE class viscosity and API class quality their additives often differ Additives can be up to 35 of the total volume and are crucial to how oil can handle a given water content while still maintaining the necessary lubricating properties The additives also affect the friction in for example the IPS unit clutch assembly The correct oil is cru...

Page 23: ...coolant is available for purchase ready diluted Mixing the concentrated coolant Protection against freeze bursting down to 40 25 C 46 30 C 54 38 C 60 46 C NOTICE It is important to use coolant with a concentration of 40 60 in the cooling system even where there is no risk of freezing The coolant also prevents corrosion and deposits A mixture with a concentration above 60 will impair antifreeze pro...

Page 24: ...mission P0022106 Highlighted components blue Fastener red Assembly light gray Background white Special tools yellow Seals green as of 06 2018 Other types of symbols used in the images are divided into the following categories Safety Important Cleanliness Position Movement Measured value Tools Chemicals Sealant Units General Information 22 47708114 06 2021 AB VOLVO PENTA ...

Page 25: ...rchase at regional Volvo Penta dealerships Deviations may occur in the range see Specifications For correct part numbers refer to the Parts catalogue P0001869 Thread locking fluid Corrosion protection Sealant Engine oil Transmission oil IPS synthetic gear lubricant VCS Coolant Grease ATF oil Chemical products 47708114 06 2021 AB VOLVO PENTA 23 ...

Page 26: ...al equipment and tools to be used when working with the engine For some operations service points special tools are required in order to carry out the work in a correct manner 3889988 Adapter 22767251 Hose Special Tools 24 47708114 06 2021 AB VOLVO PENTA ...

Page 27: ...ines Some type plates are marked identity numbers This information should always be used as a reference when ordering service and replacement parts or when contacting Volvo Penta retailers A Engine ID B Engine Transmission Address C CHASSIS ID Engine D Certification P0030924 Specifications 47708114 06 2021 AB VOLVO PENTA 25 ...

Page 28: ...Transmission Decals Reverse gear A Reverse gear ID B CHASSIS ID reverse gear S Drive ID P0030930 Specifications 26 47708114 06 2021 AB VOLVO PENTA ...

Page 29: ...ard bolt 24 M10 standard bolt 48 M12 standard bolt 85 M14 standard bolt 140 M16 standard bolt 220 NOTICE Check the bolts intended for installation Damaged bolts with e g shear marks under the heads must be scrapped Specifications 47708114 06 2021 AB VOLVO PENTA 27 ...

Page 30: ...il SAE 15W 40 Part number 23219282 1 liter The HS 25 reverse gear uses ATF Dextron transmission oil Part number 1161995 5 liters Coolant VCS yellow concentrated Part number 22567295 Part number 22567307 5 liters 210 liters Coolant VCS yellow ready mixed Part number 22567314 Part number 22567340 5 liters 210 liters Coolant volume empty system D1 13 D1 20 D1 30 D2 40 D2 50 D2 75 2 7 liters 3 liters ...

Page 31: ... 40 Part number 23219282 0 26 gallons The HS 25 reverse gear uses ATF Dextron transmission oil Part number 3851039 1 32 gallons Coolant VCS yellow concentrated Part number 22567295 Part number 22567307 1 32 gallons 55 47 gallons Coolant VCS yellow ready mixed Part number 22567314 Part number 22567340 1 32 gallons 55 47 gallons Coolant volume empty system D1 13 D1 20 D1 30 D2 40 D2 50 D2 75 0 71 ga...

Page 32: ... and coolant leakages loose bolts worn or poorly tensioned drive belts loose cable connections damaged electrical cables and hoses This inspection only takes a few minutes but can prevent serious malfunctions and expensive repairs WARNING Risk of fire Remove all accumulations of fuel oil and grease when detected on the engine or in the engine room WARNING If an oil fuel or coolant leak is detected...

Page 33: ...ipstick engine oil H Oil filter D Engine oil filler I Draining engine oil E Expansion tank cooling water J Drive belt alternator water pump K Impeller pump seawater Drain seawater on the other side of the engine the drain is mounted on the heat exchanger P0030923 Engine 47708114 06 2021 AB VOLVO PENTA 31 ...

Page 34: ...ng coolant expansion level H Draining engine oil D Engine oil filler I Impeller pump seawater E Drive belt alternator water pump J Fuel filter K Dipstick engine oil Drain seawater on the other side of the engine the drain is mounted on the heat exchanger P0030933 Engine 32 47708114 06 2021 AB VOLVO PENTA ...

Page 35: ...vailable for download at www volvopenta com Search under tab Manuals Extended service intervals The interval between engine oil changes may be extended in certain circumstances To determine whether the service interval may be extended Volvo Penta s conditions for extended service intervals must be met and an oil analysis performed see Lubrication System page 45 The Volvo Penta dealer has further i...

Page 36: ... This inspection only takes a few minutes but can prevent serious malfunctions and expensive repairs The images are generic and applicable to all engine installations They show only a selection of components and systems The inspection applies to all components in the systems Look especially carefully for fuel leakage at P0026583 Injector connections Common rail replacement Check all clamped items ...

Page 37: ...items Also check Drive belts Damaged wiring Loose wiring Loose fasteners Exhaust hoses Hoses hose connections to transmissions WARNING Accumulations of fuel oil and grease on the engine or in the engine compartment are a fire hazard and must be removed as soon as they are discovered WARNING If you discover a leakage of oil fuel or coolant investigate the cause and fix the fault before starting the...

Page 38: ... the engine is running Switch off the main switches or disconnect the battery cables when fast charging the batteries NOTICE It is not necessary to switch off the main switches during normal maintenance charging Only batteries may be used for start help A jump start unit is able to supply very high voltage which may damage the control unit and other electronics Take extreme care so that the harnes...

Page 39: ... around the filter connection Remove the bolt at the bottom of the filter Remove the pump by pulling it straight out Install the new filter Secure the hose clamps Install the lower bolt NOTICE Scrap the old filter It cannot be cleaned Engine 47708114 06 2021 AB VOLVO PENTA 37 ...

Page 40: ...5 Replacing the air filter Remove the hose clamp Remove the filter Install the new filter Secure the hose clamps NOTICE Scrap the old filter It is not designed to be cleaned Engine 38 47708114 06 2021 AB VOLVO PENTA ...

Page 41: ...ce is a servicing item Note the servicing intervals for the engine Detailed instructions are available in the workshop manual NOTICE When adjusting the valve clearance the engine must be cold P0026752 Engine 47708114 06 2021 AB VOLVO PENTA 39 ...

Page 42: ...ication A high oil level leads to increased oil consumption and may cause clogging of the silencer and or the closed crankcase ventilation A low oil level may lead to seizing pistons engine wear and engine overheating Oil level check hot engine Make sure the engine is level Stop the engine wait a at least 15 minutes and then measure the level Oil level check cold engine recommended Make sure the e...

Page 43: ...e MIN marking add oil until the level is between min and max B Optimal oil level do NOT add oil C Oil level at max marking do NOT add oil NOTICE Never add too much engine oil Lubrication System 47708114 06 2021 AB VOLVO PENTA 41 ...

Page 44: ...in the pipe below the dipstick holder Connect a vacuum pump and draw the oil out through the pipe NOTICE If the engine oil is hot it will drain out faster NOTICE Hand the old oil in to a re cycling station P0026753 Lubrication System 42 47708114 06 2021 AB VOLVO PENTA ...

Page 45: ... Volvo Penta be used The wrong type of oil filter can lead to increased wear and damage e g to bearings and crankshaft Removal Clean around the filter Undo the filter using filter pliers Be prepared to gather up oil spills P0026754 Lubrication System 47708114 06 2021 AB VOLVO PENTA 43 ...

Page 46: ...it slows up and then a further half turn Fill with the required volume of oil see Specifications page 28 Start the engine Check that no leakage occurs Stop the engine and check the oil level after a few minutes Top up as necessary P0030926 P0030925 P0026757 Lubrication System 44 47708114 06 2021 AB VOLVO PENTA ...

Page 47: ...wear Thanks to early warning signs given by oil analysis preventive maintenance and component replacement can be planned so that unplanned shutdowns can be avoided Some engines allow the oil change intervals to be extended There are two different service records available for these engines Refer to the Volvo Penta Product Center In order to find out more about Volvo Penta Oil Analysis we recommend...

Page 48: ...s a fine filter fitted to the engine as standard Furthermore the installation often has a pre filter whose insert must also be changed The illustration shows a typical fuel pre filter P0026758 Fuel System 46 47708114 06 2021 AB VOLVO PENTA ...

Page 49: ...s will enter the system and cause malfunctions or damage Clean around the fuel filter Remove the fuel filter with the aid of a suitable filter puller Wipe up any fuel spills Lubricate the sealing surface A with diesel and install the new fuel filter Torque tighten the filter in accordance with the instructions on the filter or else until it tightens up and then a further turn Bleed the fuel system...

Page 50: ... fuel pump to bleed The fuel is under very high pressure and can penetrate the skin Vent with the hand pump above the filter Open the vent screw A Pump by hand until fuel flows out without any air bubbles Close the vent screw P0030918 Fuel System 48 47708114 06 2021 AB VOLVO PENTA ...

Page 51: ...pre filter Draining the fuel pre filter Place a recovery container under the filter to collect fuel spills Open the drain screw A at the bottom and the vent screw B on top Check that it clean fuel is coming out Close the drain screw A and the vent screw B NOTICE The drain screw A is made of plastic do not tighten it too far Screw until a slight resistance is felt and then tighten no more than 1 4 ...

Page 52: ...Pre filter Disassemble the fuel pre filter according to the figure with the pass through bolt in its center Fuel System 50 47708114 06 2021 AB VOLVO PENTA ...

Page 53: ...erse gear S Drive Inspect the exhaust hose Check that it has no cracks or leaks exhaust cooling water If there is any leakage replace the hose Check that all hose clamps are tightened Exhaust System 47708114 06 2021 AB VOLVO PENTA 51 ...

Page 54: ...NOTICE Check the protection capacity freezing point of the anti freeze every year if the coolant is not being replaced Check the fluid level in the expansion tank when the engine is cold Top up with coolant as necessary In the case of D1 D2 40 engines check the level against the mark on the outside of the vessel In the case of D2 50 55 60 75 engines check the level beneath the radiator cap P002676...

Page 55: ...drain on the side and refill with new coolant Start the engine and let it idle for a few minutes to vent Switch the engine off and check the level NOTICE If the boat has a heating element connected to the engine cooling system it must also be drained when changing the engine coolant NOTICE Hand in the old coolant to a recycling station for disposal P0026762 Cooling System 47708114 06 2021 AB VOLVO...

Page 56: ... in the expansion tank When the cooling system is filled start the engine and let it idle for a few minutes Open any venting nipples for a while to allow trapped air to escape Increase engine speed to 1600 1700 rpm and run for a few more minutes Stop the engine and let it cool down Then check the coolant level Start the engine Start the engine again and run it until it reaches normal operating tem...

Page 57: ...13 20 30 D2 40 Undo the bolts A and C Move the alternator toward the engine by screwing in bolt B and free the belt Replace the belt Tension the alternator belt by screwing bolt B until a play of about 3 4 mm is achieved Next tighten the bolts A and C P0030921 Cooling System 47708114 06 2021 AB VOLVO PENTA 55 ...

Page 58: ...belt Replace the belt Tighten the alternator belt until a play of about 3 4 mm is achieved Tighten the bolts Belt tensioning D1 and D2 engines all Check the drive belt after operation when the belt is hot It should be possible to depress the drive belt about 3 4 mm between the pulleys P0030932 Cooling System 56 47708114 06 2021 AB VOLVO PENTA ...

Page 59: ...lace if there is damage to the cover or the rubber Otherwise change the impeller at the intervals in the maintenance schedule Also check the water hoses to and from the impeller pump If they are dry swollen or show other signs of damage they must be replaced with new ones NOTICE The illustration shows the impeller pump on D2 50 55 60 75 engines The position is the same on D1 13 20 30 D2 40 engines...

Page 60: ...the inside of the pump housing and the impeller with glycerin Push the impeller in with a rotating movement in the direction of flow the same direction as the replaced impeller Install the cover use a new gasket Tightening torque 6 Nm Open the cooling water cock Start the engine Check that there are no leaks when the engine is started NOTICE The impeller may be damaged if any types of lubricant ot...

Page 61: ...Remove the sealing plate B Lift out the insert C and clean it Install in the reverse order and tighten the cover by hand Open the sea cock and check that there are no leaks when the engine is being started NOTICE Check the hose clamps are tight and water hose s undamaged Cooling water intake Check the cooling water cock operation at every service It must be possible to open and shut the cock for e...

Page 62: ... the valve housing over First insert the membrane and then the gasket Screw the cover down If the cover is screwed on too tightly the valve may stop working Tightening torque 2 Nm Install the vacuum valve onto the hoses Open the sea cock Check that there is no leakage when the engine starts NOTICE There are different versions of the vacuum valve but they all operate on the same principle P0030654 ...

Page 63: ...lass viscosity and API class quality their additives often differ Additives can be up to 35 of the total volume and are crucial to how oil can handle a given water content while still maintaining the necessary lubricating properties The additives also affect friction in the clutch package The correct oil is crucial for the proper functioning of the transmission NOTICE For reverse gear comply with ...

Page 64: ...5A A A L HS25 A C NOTICE Reverse gear designs differ During oil changes HS25 engines have oil filters that must be replaced Not all reverse gears have oil filters P0026766 P0026232 Transmission Reversing gear 62 47708114 06 2021 AB VOLVO PENTA ...

Page 65: ...e Lubricate the gasket O ring on the new filter with a thin film of oil HS25 Install the new oil filter HS25 Fill with new oil Check the level using the dipstick Start the engine and run it at 1500 rpm for a few minutes engage a gear forward reverse Stop the engine and check the oil level again Top up as necessary NOTICE Oil in accordance with Specifications page 28 P0030647 Transmission Reversing...

Page 66: ...uring the season for leakage of water into the boat through the stuffing box if so the rubber sleeve must be changed If the boat is fitted with a Volvo Penta propeller shaft the propeller shaft seals must be purged and lubricated Immediately before launching Press approximately 1 4 teaspoonful of water resistant grease into the seal Purge the seal glands by pressing them together at the same time ...

Page 67: ...folding function may seize Also lubricate the propeller shaft splines with water resistant grease Folding propeller Remove the screws E Pull out the spindles A Grease the folding propeller spindles A propeller blade attachment Remove the center bolt D Remove B and C Pull off the entire propeller unit Grease the propeller shaft splines with water resistant grease Install in reverse order For tighte...

Page 68: ...er B and the propeller cone A Remove the propeller and the spacer sleeve Clean and apply grease part 828250 on the propeller shaft Install the spacer sleeve and the propeller on the propeller shaft Tighten the propeller cone A to 70 Nm P0031801 Early model P0031088 Late model P0031089 Transmission Sterndrive 66 47708114 06 2021 AB VOLVO PENTA ...

Page 69: ...nstall the lock washer B and the new bolt C Tighten the bolt to 20 Nm Fold up at least 2 of the 3 lock tabs to secure the bolt P0031090 P0031091 Transmission Sterndrive 47708114 06 2021 AB VOLVO PENTA 67 ...

Page 70: ...otection deteriorates due to anode oxidization Even new anodes may have some surface oxidation Therefore always clean and polish them with an emery cloth before launching Replacement of anodes Clean the contact surfaces on the new anode Install and tighten the halves so that they make good contact with the surface of the drive each other Transmission Sterndrive 68 47708114 06 2021 AB VOLVO PENTA ...

Page 71: ...aning the anode This will impair the galvanic function of the anode NOTICE If the boat is mostly used in salt water the anodes must be of zinc or aluminum If the boat is mostly used in fresh water the anodes must be of magnesium Transmission Sterndrive 47708114 06 2021 AB VOLVO PENTA 69 ...

Page 72: ...evere corrosion damage When the primer coating is thin or the surface is unpainted it must first be coated with primer part 1141562 Drying time 8 12 hours Then apply a final coat The spare parts catalog and the Volvo Penta accessories catalog specify the part numbers for surface treatment products Also apply anti fouling NOTICE Use a locally recommended anti fouling paint on the drive gear S drive...

Page 73: ...ging oil with the boat in the water Draw the oil through the pipe on the side of the drive using a vacuum pump Fill with new oil P0026767 P0026768 Transmission Sterndrive 47708114 06 2021 AB VOLVO PENTA 71 ...

Page 74: ... Check the level using the dipstick in the filler hole The level must be between the markings on the dipstick top up as necessary P0026769 Transmission Sterndrive 72 47708114 06 2021 AB VOLVO PENTA ...

Page 75: ... Tightening torque 10 Nm Top up oil through the dipstick hole Check the level and top up as necessary NOTICE Hand the old oil in to a re cycling station Replacing the rubber bellows Check and replace the rubber bellows for the S Drive according to the intervals in the maintenance schedule When replacing refer to the installation instructions in the rubber bellows packaging P0030920 P0030922 Transm...

Page 76: ...arate tank if preferred If B0 fuel is not available fuel additives with anti corrosion and anti oxidation properties may be mixed in the fuel to protect the fuel system during storage Engines that use diesel fuel with a FAME content greater than 10 even if additives are used must not be placed in long term storage FAME Biodiesel B0 Diesel with 0 FAME B10 Diesel with 10 FAME Drain water from the pr...

Page 77: ...zing temperatures For cleaning the engine and transmission see the next section Touch up any paint damage with Volvo Penta original paint or paint of the same quality If necessary cover the engine air intake and exhaust pipe Always ensure good ventilation in the engine compartment in order to prevent the formation of mold and corrosion if possible leave hatches open After storage Replace filters b...

Page 78: ...r more than 8 months Before storage Make sure the engine cooling system is filled with glycol Make sure the engine lubrication system is filled with oil Pump the coolant through the seawater cooling system Marine engines only Seal all open connections Remove the battery cables from the battery Empty the AdBlue DEF tank if it is filled and clean it Attach a tag into the engine with information abou...

Page 79: ...eze properties top off as necessary Should be replaced Fuel filter Air filter AdBlue DEF filter Air filter AdBlue DEF tank Fill the AdBlue DEF tank Seawater pump impeller Marine engines only Anodes for the seawater system Marine engines only Start the engine and let it idle a while without a load Check that there are no oil fuel or coolant leaks Run the engine until warm Change the engine oil and ...

Page 80: ...ent the alternator idler pulley belt tensioner power steering unit and all electrical components must be covered with plastic or similar so that detergent solvents do not get into the parts Where fitted the AC compressor must also be protected with plastic or similar When cleaning air coolers they should be vacuum cleaned first before flushing with warm water from the inside out Do not use a power...

Page 81: ...r where fluid has seeped into the absorbent deep tears tears wider than the width of tape holes or cracked edges the entire damaged unit must be replaced Tears that can be covered widthwise by tape must be repaired using approved aluminum tape After the wash check that no small rocks or other debris has adhered to the belts and are able to penetrate them when the engine is started Drying the alter...

Page 82: ...out otherwise residual water may cause freeze bursting The risk of freeze bursting can be reduced by running the engine when on land with a mixture of 40 coolant and 60 fresh water through the sea water system before the engine is switched off Connect a garden hose to the impeller pump the sea water hose from the intakes and put the other end into a bucket of the glycol mixture Start the engine an...

Page 83: ...D1 13 20 30 D2 40 Heat exchanger drain D2 50 55 60 75 Heat exchanger drain P0030919 P0030931 Long Term Storage 47708114 06 2021 AB VOLVO PENTA 81 ...

Page 84: ...eck the rudder drive and propeller s Start the engine every six months If the boat will be out of the water for 6 8 months or more the engine must be started and warmed up every six months as follows Check the engine oil level Check the oil level in the drive or reverse gear Check the coolant level Connect the battery cables to the batteries fully charged Take the impeller out of the seawater pump...

Page 85: ...w the battery manufacturer s recommendations and instructions when replacing and charging batteries Instructions for maintenance and charging may vary depending on battery type Modern batteries are usually maintenance free but there are some recommended measures to avoid accidents and increase battery service life Keep the batteries clean and dry Contamination and oxide on the batteries and batter...

Page 86: ... confuse the positive and negative poles on the batteries Risk of arcing and explosion Disconnection A Remove the negative cable black Remove the positive cable red Remove the battery Connection B Put the new battery in place Attach the positive cable red to the battery s positive terminal Tightening torque 6 Nm Attach the negative cable black to the battery s negative terminal Tightening torque 6...

Page 87: ... Tightening Torques 27 Genuine Volvo Penta Parts 20 I Illustrations 22 L Long Term Storage 74 Lubrication System 40 M Maintenance Schedule 33 O Oil filter Replace 43 Other Special Equipment 24 P Painting the Drive 70 Preventive repair 13 Propeller 65 R Reversing gear 61 Reversing gear oil and filter change 61 S Safety Information 3 S drive 70 Seawater Filter Check and Cleaning 59 Seawater Pump Imp...

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Page 90: ...47708114 English AB Volvo Penta SE 405 08 Göteborg Sweden www volvopenta com ...

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