Volvo Penta 2001 Workshop Manual Download | Manualshive

Page: 1 / 35

background image

ProCarManuals.com

1
2
3
...
»

Summary of Contents for 2001

Page 1: ...ProCarManuals com ...

Page 2: ...s gi ven i n kW ki l owat t Speed i s gi ven i n r ev s r evol ut i ons per second ear l i er uni t hp hor se power ear l i er uni t r ev m i n r evol ut i ons per m i nut e Tor que i s gi ven i n N m newt on m et r e Vol um e i s gi ven i n dm3 cubi c deci m et r e ear l i er uni t kpm ki l opond m et r e ear l i er uni t l l i t r e ear l i er uni t l bf f t poundf oot ear l i er uni t I m p gal...

Page 3: ...sl eeve 8 I nj ect or s 8 Assem bl i ng t he cyl i nder head 9 Feed pum p 10 Pi st ons 11 Cr ankshaf t 11 Cam shaf t 11 Connect i ng r ods 12 Ther m ost at 13 Sea wat er pum p 13 ASSEM BLY I NDEX Crankshaf t 14 Pi st ons 14 Fl ywheel 15 Tr ansm i ssi on 15 Adj ust i ng t he val ve cl ear ance 17 Checki ng t he i nj ect i on angl e 17 2003 Tur bo 21 Fr esh wat er cool i ng 25 El ect r i cal syst em...

Page 4: ...r i but i on box 5 Fuel f i l t er 6 Al t er nat or 7 St ar t er m ot or 8 Dr ai nage cool i ng wat er 9 Feed pum p 10 Engi ne ser i al num ber 11 Decom pr essi on devi ce 12 I nl et ai r si l encer 13 Fuel i nj ect i on pum ps 14 Oi l di pst i ck 15 Sea wat er pum p Halpert Optonline net ProCarManuals com ...

Page 5: ...t al l pr ot ect i on caps on t he f uel injection pum ps and i nj ect or s Rem ove t he scr ew hol di ng t he l ever of t he decom pr essi on devi ce 1 and pul l out t he l ever Rem ove t he val ve cover DI SASSEM BLY 3 Rem ove t he f uel f i l t er t he oi l f i l t er t he f eed pum p t he t her m ost at housi ng and t he exhaust el bow Al so r em ove t he sea wat er pum p wi t h i t s at t ach...

Page 6: ...m ove t he end ni ppl e 2 and t he spr i ng 3 Rem ove t he oi l pum p cover and m ar k t he gear wheel s wi t h a col our pen bef or e r em ovi ng t hem W hen i nst al l i ng t he gear wheel s t he m ar ked si de m ust be f aci ng out war ds Rem ove t he br aci ng pi n of t he cam shaf t usi ng t he speci al t ool p n 884839 Never r em ove t he bracing pi n by punchi ng i t out t hi s can ver y we...

Page 7: ...i ne upsi de down and r em ove t he oi l pan Be car ef ul as t he pan i s gl ued NO TE The oi l pan ends al so f unct i on as m ai n bear i ngs 13 Rem ove t he connect i ng r od bol t s and r em ove t he connecting r ods and t he pi st ons The connect i ng r od and t he connect i ng r od cap ar e m ar ked wi t h f i gur es ProCarManuals com ...

Page 8: ... t h a f i gur e The cor r espondi ng f i gur e i s punched i nt o t he bl ock Li f t out t he cr ankshaf t O n l at er engi ne ver si ons an ar r ow i s cast i n t he separ at e m ai n bear i ng caps 2002 2003 The ar r ow i s t o poi nt t owar ds t he di pst i ck ProCarManuals com ...

Page 9: ... m andr el al l t he w ay down t o t he cyl i nder head Ream t he val ve gui des i f necessary Val ve seat s and val ves 4 M i l l or r eam t he val ve seat s The angl e C shoul d be 45 f or 2003T 30 f or t he i nl et val ve The seal i ng sur f ace s wi dt h B shoul d be 1 0 1 m m 0 039 0 0039 i n G r i nd t he val ves i n a val ve gr i ndi ng m achi ne The angl e D see Tech dat a I f t he di sc t...

Page 10: ...bushi ngs need t o be r epl aced uset he m andr el p n 9991867 f or t he r em oval and i nst al l at i on m ake sur e t hat t he oi l hol e i n t he bushi ng coi nci des wi t h t he one i n t he r ocker ar m Af t er t he i nst al l at i on t he bushi ngs ar e r eam ed t o a cl ose r unni ng f i t W hen i nst al l i ng t he r ocker ar m shaf t i t m ust be t ur ned so t hat t he l ubr i cat i on ho...

Page 11: ...ock down t he sl eeve unt i l i t bot t om s 10 Oi l t hef l ar e t ool p n 884283 and i nser t i t i nt ot he sl eeve m ake sur e t hat t he dowel i s pr oper l y r et r act ed Br ace t he t ool wi t h t he i nj ect or yoke Scr ew down t he f l ar e t ool as f ar as t he shoul der i n t he i nj ect or sl eeve al l ows t her eby flaring t he sl eeve Rem ove t he t ool Adj ust t he l engt h of t he...

Page 12: ...chni cal Dat a r educt i on val ve Feed pum p 13 Depr ess t he pum p l ever i f t he di aphr agmof t he pum p sounds squeaky t he di aphr agm i s f aul t l ess Changi ng t he di aphr agm 14 Rem ove t he si x scr ews hol di ng t he upper and l ower pum p housi ngs t oget her Rem ove t he pum p l ever spr i ng 1 and r em ove t he scr ew 2 hol di ng t he pum p l ever shaf t 15 Use a sui t abl e pai r...

Page 13: ...r wear on cam s and bear i ng r a ces Al so check t he wear of t he bear i ngs The bear i ngs ar e pr essed i nt o t hei r l ocat i ons and m ust be l i ne bor ed af t er t he i nst al l at i on 19 Pl ace a suppor t under t he cam shaf t gear and use a hydr aul i c pr ess t o r em ove t he gear Cr ankshaf t 20 Rem ove t he gear wheel Use a pr ong pul l er Cl ean t he cr ankshaf t M easur e t he cr...

Page 14: ...t o t he cyl i nder and m easur e t he pi st on r i ng gap As t o t he m easur em ent see under Techni cal Dat a I f necessar y i ncr ease t he gap usi ng a speci al f i l e 23 M easur e t he cl ear ance of t he pi st on r i ngs i n t he pi st on r i ng gr ooves Regar di ng t he m easur em ent see under Techni cal Dat a 24 Use pi st on r i ng pl i er s t o i nst al l t he pi st on r i ngs The m ar...

Page 15: ...ar i ngs f r om t he shaf t NO TE Do not f or get t he spacer sl eeve 3 Repl ace t he seal i ngs 4 NO TE Tur n t he seal i ngs cor r ect l y and m ake sur e t hat t hey do not bl ock t he dr ai nage hol e i n t he pum p housi ng Repl ace t he O r i ng 5 I nst al l t he ball bearingsandthespacersleeveontotheshaftandleavea di st ance of 39 5 m m 1 55512 i n f r om t he shaf t end t o t he bal l bear...

Page 16: ...i nt t owar ds t he oi l di pst i ck Ti ght eni ng t or que f or t he m ai n bear i ngs 1st t i ght eni ng 20 N m 2 kpm 14 7 f t l b 2nd t i ght eni ng 60 N m 6 kpm 44 2 f t l bs Tur n t he engi ne 3 Tur n t he pi st on r i ngs so t hat t he gaps ar e of f set i n r el at i on t o each ot her The pi st on cr own i s m ar ked wi t h an ar r owt hat poi nt s t owar ds t he bel t pul l ey Use i nst a...

Page 17: ... Check t hat al l wei ght s ar e pressed i n so t hat t he t abs 2 ar e i nsi de t he washer 7B I nst al l anew seal i ng r i ng f or t he cam shaf t i n t he transmission housi ng usi ng m andr el p n 884838 The seal i ng l i p wi t h t he spr i ng i s t o bet ur ned t owar ds t he engi ne Pr ess i n t he seal i ng r i ng f r om t he out si de unt i l t he m andr el bot t om s agai nst t he housi...

Page 18: ...nser t a new O r i ng i n t he t i m i ng gear cover Oi l t he gear wheel and f i t The cover usi ng a new seal i ng r i ng 2001 10 I nser t t he key f or t he pul l ey i n t he cr ankshaf t and i nst al l t he pul l ey Ti ght eni ng t or que 40 N m 4 0 kpm 29 5 f t I bs 11 Cl ean t he val ve l i f t er s car ef ul l y and coa t t he cont act sur f ace agai nst t he cam shaf t wi t h m ol ybdenum ...

Page 19: ...t t he pr ocedur e f or t he r em ai ni ng cyl i nder s Adj ust i ng t he f uel i nj ect i on pum p l ocat i on wi t h shi m s 15 i f t he sam e bl ock cam shaf t and f uel I nj ect i on pum ps ar e used when assem bl i ng t he f uel i nj ect i on pum p m ust be i nst al l ed i n t hei r or i gi nal posi t i ons and wi t h t he sam e shi m t hi ckness as ear l i er The so cal l ed sof t shi m s al...

Page 20: ... r i ng det er m i nes t he i nj ect i on angl e f or each r espect i ve engi ne t ype see Techni cal Dat a page 25 The i nj ect i on angl e i s st am ped i n degr ees and i s f i xed wi t h a pi n 1 B M ount t he set t i ng di sc or t he pul l ey wi t h t wo bol t s do not t i ght en t he bol t s Tur n t he set t i ng di sc so t hat t he gui de pi n 2 com es i n t he l ar gest of t he f our hol e...

Page 21: ...4 and 0 011811 i n and one har d shi m of 0 3 m m 0 011811 i n Pl ace t he har d shi m bet ween t he t wo sof t ones and r ef i t t he pum p NO TE A har d shi m m ust never be f i t t ed t oget her wi t h anot her har d shi mor di r ect l y agai nst t he bl ock or pum p Har d shi m s ar e avai l abl e i n t hi cknesses 0 3 0 6 and 0 9 m m 0 011811 0 02362 and 0 035433 i n Sof t shi m s ar e avai l...

Page 22: ...l bow 21 Fi t t he val ve cover usi ng a new gasket M ake sur e t hat t he r ound hol e f or t he cr ankcase vent i l at i on i s i n t he r i ght posi t i on Fi t t he decom pr essi on devi ce l ever Fi t t he pressure pi pes bet ween t he i nj ect or s and t he i nj ect i on pum ps Al so r ef i t t he i nl et ai r si l encer 22 I nst al l t he st ar t er m ot or t he al t er nat or and t he alte...

Page 23: ... f unct i oni ng pr oper l y I f t he boat s speed t hr ough t he wat er i s gr adual l y decreasing t he boat s bot t om shoul d al so be i nspect ed and cl eaned wher e necessar y Check t hat t he ai r i nt ake has not becom e cl ogged and cl ean t he i nt ake si l ender I nspect i ng t he Seal s Check t he j oi nt s bet ween t he t ur bi ne housi ng and t he compressor bear i ng housi ng and be...

Page 24: ... t he t ur bi ne shaf t Rem ove t he com pr essor wheel 2 and di sm ant l e t he t ur bi ne housi ng 3 RECO NDI TI O NI NG Di sm ant l e t he t ur bi ne shaf t 4 and t he heat shi el d I f t he t ur bi ne shaf t st i cks t ap t he end gent l y wi t h a wooden hammer Unf ast en t he t hr ee scr ews whi ch hol d t he cover 3 and scr ew t wo M 5 scr ews i nt o t he cover Then l i f t i t up Take t he...

Page 25: ...Housi ng Tur bi ne Housi ng Check t hat t he housi ngs ar e f r ee f r om cr acks or ot her damage caused by excessi ve wear and t ear Dam aged par t s shoul d be r epl aced Heat Shi el d Check t hat t he heat shi el d i s f r ee f r om dam age caused by wear and t ear heat or cor r osi on and r epl ace i t i f necessary Bushi ng Oi l Def l ect or Com pr essor Bear i ng Check t hat t he par t s ar...

Page 26: ... i n t ouch wi t h t he cover usi ng Per m at ex f or t he pur pose The t hi ckness of t he seal ant shoul d be about 0 1 0 2 m m Fi t t he cover on t he bear i ng housi ng and f ast en i t wi t h new scr ews and washer s The t or que shoul d be 1 3 N m 0 1 Ti ght en t he scr ews t o t he above t or que t hen l oosen t hema quar t er t ur n bef or e t i ght eni ng t hem up t o t he cor r ect t or ...

Page 27: ...and t he l ock posi t i on 11 a 5 Fi t t he pi pe bet ween t he ci r cul at i on pum p l ower out l et and t he cyl i nder head posi t i on 12 6 Fi t t he pi pe bet ween t he ci r cul at i on pum p upper out l et and t he cyl i nder head posi t i on 13 7 Fi t t he al t er nat or pl ace t he bol t f or t he t ensi oner br acket wi t h t he head f or war ds Put on and t ensi on t he V bel t 8 Fi t t...

Page 28: ... put f r om t he panel 5 A Cabl e col our R Red PU Pur pl e BN Br own O R O r ange G R G r ey SB Bl ack W W hi t e Y Yel l ow G N G r een BL Bl ue ENG I NE 1 Rel ay 2 Fuse 3 Tem p al ar m sender 4 Oi l pr essur e al ar m sender W i r e ar eas i n m m2 W i r e ar ea m m2 1 0 16 1 5 14 2 5 12 10 6 26 AW G W i r i ng di agr am al t er nat i ve A St andar d Z ProCarManuals com ...

Page 29: ...t i ng 7 Rev count er 8 Key swi t ch 9 Al ar m M ax out put f r om t he panel 5 A Cabl e col our G R G r ey SB Bl ack BN Br own LBN Li ght br own R Red P Pur pl e G N G r een Y Yel l ow W W hi t e BL Bl ue LBL Li ght bl ue ENG I NE 1 Cool ant t em per at ur e sender 2 Oi l pr essur e al ar m sender 3 Cool ant t em per at ur e al ar m sender 4 pi t pr essur e sender 5 Rel ay 6 Fuse W i r e ar eas i...

Page 30: ...YXWVUTSRQPONMLKJIHGFEDCBA Em pt y f uel t ank cl osed f uel cock or cl ogged f uel f i l t er W at er or i m pur i t i es i n t he f uel Faul t y i nj ect or s or ai r i n t he f uel syst em Boat abnor m al l y l oaded cl ogged i nt ake ai r f i l t er or m ar i ne gr owt h on t he boat bot t om Engi ne not pr oper l y al i gned Propeller dam aged Cl ogged cool i ng wat er i nt ake or wat er j ack...

Page 31: ...f i nj ect or sl eeve M andr el f or i nst al l at i on of val ve gui de Set t i ng di sc f or i nj ect i on pum p set t i ng Pul l er f or i nj ect or sl eeve Fl ar i ng t ool f or i nj ect or sl eeve Fl ange f or engi ne cr adl e M andr el f or i nst al l at i on of seal i ng r i ng i n t r ansm i ssi on cover Assem bl y and di sassem bl y t ool f or cam shaf t pi n G ui de pi n f or cyl i nder ...

Page 32: ...ot al hei ght 78 3 mm 3 08268 i n Hei ght f r omgudgeon pi n cent er t o pi st on t op 50 3 m m 1 98031 i n Pi st on cl ear ance i n cyl i nder 0 09 m m 00354 i n Pi st on i n st andar d di m ensi on 78 903 78 17 3 10642 3 10697 i n 0 25 m mover si ze 79 153 79 167 3 11626 3 11681 i n 0 50 m mover si ze 79 403 79 417 3 12610 3 12665 i n G udgeon pi ns Di am et er 25 995 26 000 1 02343 1 02362 i n ...

Page 33: ... over si ze 47 489 47 500 1 86965 1 87008 i n Bushi ng di am et er 47 02 47 05 m m 1 85118 1 85236 i n Cyl i nder head M at er i al Speci al al l oy cast i r on I nl et val ves 20031 Di sc di am et er 34 4 34 6 m m 1 35433 1 36220 i n 35 8 36 0 m m St em di am et er 7 955x7 970 m m 0 31319 0 31378 i n 7 995 7 970 m m Val ve seat angl e 44 55 44 85 29 45 30 15 Cyl i nder head seat angl e 45 30 Seat...

Page 34: ...00 r pm pum p r evs G over nor over r un 54 r s 3250 r pm Feed pum p Feed pr essur e 42 r s 2500 r pm 0 65 0 85 kp cm 2 9 20 12 10 l bf i n 2 El ect r i cal syst em Bat t er y vol t age 12V Bat t er y capaci t y M ax 70 Ah St ar t er m ot or out put 2001 0 8 kW 1 1 HP St ar t er m ot or out put 2002 and 2003 1 4 kW 1 9 HP Al t er nat or out put Vol t age m ax cur r ent 14W 50 Am p O ut put 700 W a...

Page 35: ...ni ng 2nd t i ght eni ng Bi g end bear i ng bol t s Fl ywheel housi ng bol t s Fl ywheel bol t s Cyl i nder head bol t s 1st t i ght eni ng 2nd t i ght eni ng Rocker ar m br i dge Fuel i nj ect i on pum ps Pul l ey I nj ect or s 20 20 N m 2 0 kpm 14 7 f t l bs 60 N m 6 0 kpm 44 2 f t l bs 70 N m 7 0 kpm 51 6 f t l bs 25 N m 2 5 kpm 18 4 f t l bs 65 N m 6 5 kpm 47 f t l bs 20 N m 2 0 kpm 14 7 f t l...

Reviews:

No comments

Related manuals for 2001

Brand: Nanni Pages: 67

Brand: Hacker Pages: 36

Brand: Champion Power Equipment Pages: 20

Brand: Nice Pages: 23

Brand: YASKAWA Pages: 447

Brand: Perkins Pages: 108

Brand: Hoval Pages: 12

Brand: SH Engines Pages: 6

Brand: DJ ENGINE Pages: 9

Brand: O.S. engine Pages: 4

Brand: Teknik Pages: 121

Brand: Grundfos Pages: 76

Brand: Franklin Electric Pages: 13

Brand: Yaroslavl Pages: 270

Brand: Mitsubishi Pages: 90

Brand: Mitsubishi Pages: 105

Brand: Nanni Pages: 191

Brand: Kärcher Pages: 137

Brands by name

0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Popular brands

Load more brands