Volvo Penta 2002 Workshop Manual

Brand
Volvo Penta
Model
2002
Type
Workshop Manual

This manual is also suitable for

ProCarManuals.com
FOREWORD
Thi s
wor kshop
manual
cont ai ns
r epai r
i nst r uct i ons
f or
t he 2001,
2002
and
2003
engi nes
.
The
i nst r uct i ons
concer ni ng over haul i ng
descr i be
t he
most
sui t abl e
wor ki ng
met hod
usi ng
t he
speci al
t ool s
l i st ed
under
t he
headi ng
" Speci al
t ool s"
.
Bot h t he
engi ne
desi gnat i on
and
i t s
ser i al
number
must
be
cl ear l y
st at ed
i n
al l
cor r espondence
concer ni ng
t he
engi ne
and
when
or der i ng
par t s
.
We
r eser ve
t he
r i ght
t o
car r y
out
desi gn
modi f i cat i ons
and,
f or
t hi s
r eason,
t he
cont ent s
of
t hi s
manual cannot
be
r egar ded
as
bi ndi ng
.
SI
UNI T
SYSTEM
Power
i 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/ mi n
( r evol ut i ons
per
mi nut e)
Tor que
i s
gi ven
i n
Nm
( newt on
met r e)
Vol ume
i s
gi ven
i n
dm
3
( cubi c
deci met r e)
ear l i er uni t
kpm
( ki l opond
met 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 mp
. gal ( I mper i al gal l on)
ear l i er
uni t
US
gal
( Uni t ed
St at es
gal l on)
Pr essur e
i s
gi ven
i n
Pa
( Pascal )
ear l i er
uni t
kp/ cm
2
( ki l oponds
per
squar e
cent i met r e)
ear l i er
uni t
I bf / i n
2
( pounds
per
squar e
i nch)
AB
VOLVO
PENTA
Techni cal
Publ i cat i ons
Depar t ment
Uni t s
accor di ng
t o
t he
i nt er nat i onal
SI
syst em
have been
used
i n
t hi s
book
.
The
ear l i er
uni t s
ar e
gi ven
af t er
t he
SI
uni t s
.
ProCarManuals.com
Component s
gui de
.
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . .
.
. . .
.
2
DI SASSEMBLY
Cyl i nder
head
. .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . . .
3
Tr ansmi ssi on
. .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
. . . . .
.
.
.
.
.
. . .
.
. . . .
4
Pi st on,
pi st on
r ods
.
.
. . .
.
. . .
.
. . .
.
. . . . . . .
.
.
.
.
.
. . .
.
. . . .
5
Fl ywheel
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
. . . .
5
Cr ankshaf t
. . . . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . .
.
. . .
.
. . . .
5
Camshaf t
. .
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . . .
5
OVERHAUL
Di sassembl i ng
t he
cyl i nder
head
.
.
.
. . . . .
.
.
.
. . . . .
.
. . . .
7
Val ve
gui des
.
.
.
.
. . .
.
.
.
.
.
.
.
.
.
. . .
.
.
.
. . . . .
.
. . . . . . .
.
. . . .
7
Val ve
seat s
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . . . . . . .
7
Val ves
.
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
.
. .
.
. .
. .
7
Val ve
spr i ngs
. .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
. . . .
8
Rocker
ar m
mechani sm
.
.
.
.
.
. . .
.
. . . . . . .
.
.
.
.
.
. . .
.
.
.
. .
8
I nj ect or
sl eeve
.
.
. . .
.
. . .
.
.
.
.
.
. . .
.
.
.
. . . . .
.
.
.
.
.
. . .
.
.
.
.
.
8
I nj ect or s
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
. . . . .
.
.
.
.
.
. . .
.
. . .
.
8
Assembl i ng
t he
cyl i nder
head
. . .
.
.
.
. . . . .
.
. . . . . . .
.
. . .
.
9
Feed- pump
.
. . .
.
. . . . . . .
.
. . . . . . .
.
. . . . . . .
.
. . . . . . .
.
.
.
.
10
Pi st ons
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . .
.
.
.
. . . . .
.
.
.
.
11
Cr ankshaf t
.
.
.
.
.
.
.
.
.
.
.
. .
.
. . . . . . .
.
. . . . . . .
.
. . .
.
. . .
.
.
.
.
11
Camshaf t
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
.
. . .
.
.
.
.
11
Connect i ng
r ods
. . . . . . . . . . . .
.
.
.
.
.
. . .
.
. . .
.
. . . .
.
. . . .
. 12
Ther most at
.
. . .
.
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . .
.
. . . . . . .
.
. . .
13
Sea- wat er
pump
.
.
.
.
. . .
.
. . . . . . .
.
. . . . . . .
.
.
.
. . . . .
.
.
.
.
13
ASSEMBLY
I NDEX
Cr ankshaf t
.
.
. . .
.
. . .
.
. . .
.
. . .
.
. . .
.
. . . . . . .
.
.
.
.
.
. . .
.
. . .
14
Pi st ons
.
.
.
.
.
. . .
.
.
.
. . . . .
.
. . . . . . .
.
.
.
.
.
. . .
.
. . .
.
. . .
.
. . .
14
Fl ywheel
. . . . . . .
.
. . .
.
. . .
.
. . .
.
. . .
.
:
.
.
.
.
.
.
.
. . .
.
. . .
.
. . .
15
Tr ansmi 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
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
Faul t t r aci ng
scheme
. . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . .
28
Speci al
t ool s
.
. . . . . . . . . . . . .
.
. . . . . . . . . .
.
. . . . . . . . . . . . .
29
Techni cal
Dat a
.
. . . . . . . . .
.
.
.
. . . . . . . . . . . . . . . . . . . . . . . .
30
ProCarManuals.com
COMPONENTS
GUI DE
8
1
.
Exhaust
el bow
2
.
I nj ect or s
3
.
Temper at ur e
sender
4
.
El ect r i cal
di st r i but i on
box
5
.
Fuel
f i l t er
6
.
Al t er nat or
7
.
St ar t er
mot or
8
.
Dr ai nage,
cool i ng
wat er
9
.
Feed- pump
10
.
Engi ne
ser i al
number
11
.
Decompr essi on
devi ce
12
.
I nl et
ai r
si l encer
13
.
Fuel
i nj ect i on
pumps
14
.
Oi l
di pst i ck
15
.
Sea- wat er
pump
[email protected]
ProCarManuals.com
Dr ai n
of f
t he
cool i ng
wat er
and
t he
l ubr i cat i ng
oi l
f r om
t he
on
engi ne
cr adl e
p/ n
9992520
and
f i xt ur e
p/ n
884837
.
I f
t he
engi ne
i s
f r esh
wat er
cool ed,
see
page
21
.
1
.
Remove
t he
al t er nat or ,
t he
t ensi oner
br acket
and
t he
st ar t er
mot or
.
Remove
t he
connect i ons
f r om
t he
el ect r i cal
di st r i but i on
box
f r om
t he
engi ne
and
r emove
t he
box
and
t he
wi r e
har ness
.
2
.
Remove
t he
r et ur n
f uel
l i ne,
t he
f uel
pr essur e
l i nes
and
t he
i nl et
ai r
si l encer
.
I nst al l
pr ot ect i on
caps on
t he
f uel
i nj ect i on
pumps
and
i nj ect or s
.
Remove
t he
scr ew
hol di ng
t he l ever
of
t he
decompr essi on
devi ce
( 1)
and
pul l
out
t he
l ever
.
Remove
t he
val ve cover
.
DI SASSEMBLY
3
.
Remove
t he
f uel
f i l t er ,
t he
oi l
f i l t er ,
t he
f eed- pump,
t he
t her most at
housi ng
and
t he
exhaust
el bow
.
Al so
r emove
t he
sea- wat er
pump
wi t h
i t s
at t achment
t ubes
.
4
.
Remove
t he
val ve
br i dge
and
l i f t
out
t he
push
r ods
.
Remove
t he
r ubber
r i ngs
f or t heoi l
pi pe
.
Remove
t he
cyl i nder
head
and
t he
val ve
l i f t er s
.
Put t he
l i f t er s
on
a
r ack
i n
consecut i ve
or der , NOTE!Thecyl i nder
head
bol t sar e
phosphat i sed
andmustnot becl eanedwi t ha
st eel
br ush.
ProCarManuals.com
5
.
Remove
t he
f uel
i nj ect i on
pumps
.
Mar k
t he
pumps
t o
ensur e
i nst al l at i on
i n
t he
same
cyl i nder s
f r omwhi ch
t hey
wer e
r emoved
.
Take
car e
of
t he
shi ms
.
Remove
t he
scr ews
on
t he
si de of
t he
engi ne
bl ock
and
l i f t
out t he
pump
l i f t er s
.
6.
Remove
t he
pul l ey
cent er
bol t
and
pul l
of f
t he
pul l ey
usi ng
pul l er
p/ n
9992265
.
Pl ace
a
pr ot ect i on
pad bet ween
t he
pul l er
and
t he
cr ankshaf t
t o
avoi d
t he
cr ankshaf t
bei ng
damaged
.
7
.
Remove
t he
t r ansmi ssi on
cover
:
St ar t
by
r emovi ng
t he
t hr ot t l e
cont r ol
cover
.
Use a
sui t abl e
t ype
of
pl i er s
t o
r emove
t he
spr i ng
( 1)
.
Then
r emove
t he
end- ni ppl e
( 2)
and
t he spr i ng
( 3)
.
Remove
t he
oi l
pump
cover
and
mar k
t he
gear
wheel s
wi t h
a
col our - pen
bef or e
r emovi ng
t hem
.
( When
i nst al l i ng
t he
gear
wheel s,
t he
mar ked
si de
must
be
f aci ng
out war ds)
.
Remove
t he
br aci ng
pi n
of
t he
camshaf t
usi ng
t he
speci al
t ool
p/ n
884839
.
Never
r emove
t he
br aci ng
pi n
by
punchi ng
i t
out ,
t hi s
can
ver y
wel l
bend
t he
camshaf t
.
Remove
t he
scr ews
on
t he
t r ansmi ssi on
cover
and
pul l
i t
st r ai ght
out war ds
.
8
.
The
max
. - vol ume- scr ew
( 1)
and
t he
max
. - r ev- scr ew
( 2)
ar e
set
by
Vol vo
Pent a
and
must
never
be
changed
si nce
t hi s
wi l l
af f ect
t he
engi ne out put
.
9
.
Remove
t he
cont r ol
r od
.
St ar t
by
r emovi ng
t he
pl ug
at
t he
r ear of
t he
bl ock
and
t het wo
scr ews
on
t he
pump
pl ane,
hol di ng
t he
cont r ol
r od
.
ProCarManuals.com
10
.
Pul l
out t he
camshaf t
.
11
.
Remove
t he
out er
f l ywheel housi ng,
t he
f l ywheel
and
t he i nner
f l ywheel
housi ng
.
12
.
Tur n
t he
engi ne
upsi de
down
and
r emove
t he
oi l
pan
.
Be
car ef ul
as
t he
pan
i s
gl ued
.
NOTE!
The
oi l
pan
ends
al so
f unct i on
as
mai n
bear i ngs
.
13
.
Remove
t he
connect i ng
r od
bol t s
and
r emove
t he
connect i ng
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
mar ked
wi t h
f i gur es
.
ProCarManuals.com
14
.
Remove
t he
mai n
bear i ng
caps
.
The
mai n
bear i ng
caps
ar e
mar ked
wi 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
.
On
l at er
engi ne
ver si ons
an
ar r ow
i s
cast
i n
t he
separ at e
mai 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
THE CYLI NDER
HEAD
1 .
Remove
t he
" col l et s"
and
val ve
spr i ngs
usi ng
a
val ve
bow
.
Remove
t he val ves
.
Remove
t
he
val ve
st em
seal s
.
Pl ace
t he
val ves
i n
t he
pr oper
sequence
i n
a
val ve
st and
.
Val ve
gui des
2
.
Check
t he val ve
gui de
wear
by
i nser t i ng
anew
val ve
st em
i nt o
t he
gui de
.
Measur e
t he pl ay
usi ng
a
di al
i ndi cat or
.
I f
necessar y,
r epl ace t he
val ve
gui des
.
Wear
l i mi t s
:
I nl et
val ve,
max
pl ay
. .
.
.
. . . . . . .
.
. . .
0
. 15
mm
( 0
. 0059
i n)
Exhaust
val ve,
max
pl ay
. . . . . . . . . . . .
0
. 15
mm
( 0
. 0059
i n)
3
.
Use
mandr el
p/ n
5218
t o
pr ess
out t he
val ve
gui des
.
Oi l
t he
new
val ve
gui des
ext er nal l y
and
use
mandr el
p/ n
884559
t o
i nst al l
t hem
.
Pr ess
down
t he
mandr el
al l
t he
way
down
t o
t he
cyl i nder
head
.
Ream
t he
val ve
gui des
i f
necessar y
.
Val ve
seat s
and
val ves
4
.
Mi 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
mm
( 0
. 039±0
. 0039
i n)
.
Gr i nd
t he
val ves
i n
a val ve
gr i ndi ng
machi ne
.
The
angl e
( D) ,
see
Tech
.
dat a
.
I f
t he
di sc
t hi ckness
af t er
gr i ndi ng
i s
l ess
t han
1
. 0
mm
( 0
. 039
i n)
f or
nat ur al l y
aspi r at ed
engi nes
or 0
. 8
mm
( 0. 031
i n)
f or
t ur bochar ged
engi nes,
t he
val ves
must
be scr apped
.
Val ves
wi t h
bent
st ems,
or
i f
t he
measur ement
( A)
exceeds
2
. 5
mm
( 0
. 098
i n)
must
al so
be
scr apped
.
Gr i nd
t he
val ve
t i p
t owar ds
t he
r ocker s
i f
necessar y
.
Lap
i n
t he
val ves
usi ng
val ve
gr i ndi ng
past e
and
check
t he
cont act
ar ea
wi t h
mar ki ng
dye
.
ProCarManuals.com
Repl aci ng
t he
val ve
seat
exhaust
por t
2003T
Gr i nd
down
t he
val ve
di sc
of
a
di scar ded
val ve
t o j ust
bel ow
27
mm
( 1
. 063
i n)
di amet er
.
Push
t he
val ve
st em
t hr ough
t he
gui de
.
NOTE! Do
not
push
i n t oo
f ar -
t he
val ve
di sc
shoul d
be
j ust
bel ow
t he
edge
of t he
seat
.
Spot
wel d
t he
di sc
i n
pl ace
at
t hr ee poi nt s usi ng
a
el ect r i c
wel der
.
Knockout
t he seat
by
hi t t i ng
t he
val ve
gui de
wi t h
a
pl ast i c- headed
hammer
.
Cool
t he
new
seat
t o
appr ox
.
- 20°C
( - 4° F)
;
t he
cyl i nder
head
shoul d
beat
r oom
t emper at ur e
( +
20°0168°F)
.
Pl ace
t he
cool ed
seat on
t ool
884961- 4
and
knock
i t
down
unt i l
i t
bot t oms.
NOTE!
Tur n
t he seat
wi t h
t he
val ve
f ace
t owar ds
t he
t ool
.
Val ve
spr i ngs
5
.
Checkt he
f r ee
l engt h
of
t he
val ve
spr i ngs
and
t he
l engt h
when
l oaded
.
L =
Lengt h,
unl oaded
42, 5
mm
( 1
. 67323
i n
. )
L
1 =
Lengt h,
l oaded
wi t h
170±10 N
( 17±1
kp)
32
mm
( 1
. 25984
i n
. )
L
2
=
Lengt h,
l oaded
wi t h
300±20
N
( 30±3
kp)
24
mm
( 0
. 94488
i n
. )
Rocker
ar m
mechani sm
6
.
Di sassembl e
t he
r ocker
ar mmechani sm
and
cl ean
t he
par t s
.
Check
t he
wear
of
t he
shaf t
and
r ocker ar m
bush
i
ngs
.
Shoul d
t he
bushi ngs
need
t o
be
r epl aced,
uset he
mandr el
p/ n
9991867
f or t he
r emoval
and
i nst al l at i on,
( make
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 eamed
t o
a
cl ose
r unni ng
f i t
. When
i nst al l i ng
t he r ocker ar m shaf t ,
i t
must
be t ur ned
so
t hat
t he
l ubr i cat i on
hol es
ar e
f aci ng
t he
val ve- si de
.
Check
t o
make
sur e
t hat t he
r ocker
ar m
cont act
sur f ace
agai nst t he
val ve
i s
concave
.
Mi nor
adj ust ment s
ar e
made
i n
a
val ve
gr i ndi ng
machi ne
.
Oi l
t he
shaf t
and
i nst al l
t he
par t s
.
Pr essur e
t est i ng
t he
nozzl es
7
.
Check
t he
nozzl e' s
spr ay
pat t er n
at
t he
cor r ect
openi ng
pr essur e
( see
Techni cal
Dat a)
.
Check
al so t hat t he
f uel
spr ays
st op
si mul t aneousl y
and
no
dr i ppi ng
occur s
.
Adj ust
t he
openi ng- pr essur e
wi t h
adj ust ment - washer s
( 1)
bei ng
avai l abl e
i n
di f f er ent
t hi cknesses
f r om
1
mm
U3937
i n
. )
t o 1, 95
mm
(
. 076772
i n
. )
i n
st eps
of
0, 05
mm
(
. 001969
i n
. )
.
Di sassembl e
t he
i nj ect or
and
r epl ace
t he
adj ust ment - washer
agai nstat hi nneroneorat hi ckeronedependi ngon
whet her
t he
pr essur e
must
be
r educed
or
i ncr eased
.
Assembl e
t he
i nj ect or
and
check
t he
openi ng- pr essur e
and
t he
spr ay- pat t er n
.
ProCarManuals.com
I nj ect or - sl eeve
8
.
I nser t
t he
expandi ng
scr ew
on
t he
speci al
t ool
p/ n
884811
i nt o
t he
copper
sl eeve
and
t ur n
t he
scr ew
ant i - cl ockwi se
unt i l
t he
scr ew
has
st uck
i n
t he
sl eeve. Ti ght en
t he
scr ew
har d
t o
al l ow
t he
t hr eads
t o
wor k
t hemsel ves
i nt o
t he
copper
mat er i al
.
Then
i nst al l
t he
yoke
( 1)
on
t he
st ud
bol t of
t he
i nj ect or
.
Put
a
cyl i nder
head
scr ew
i n
t he
cyl i nder
head
as
a
suppor t f or t he
l eg
of
t he
yoke
.
I nst al l
t he
nut
( 2)
and
t i ght en
i t
unt i l
t he
sl eeve
i s
r emoved
.
9
.
Repl ace
t he
O- r i ng,
seal i ng
of f
bet ween
t he
sl eeve
and
t he
cyl i nder
head
.
Di p t he
new
O- r i ng
i n
soap- wat er
i n
or der
t o
f aci l i t at e
t he
i nst al l at i on
.
Oi l
t he
new
i nj ect or
sl eeve
and
i nst al l
i t ,
usi ng
speci al
t ool
p/ n
884557
.
Knock
down
t he
sl eeve
unt i l
i t
bot t oms
.
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
( make
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
f l ar i ng
t he
sl eeve
.
Remove
t he
t ool
.
Adj ust
t he
l engt h
of t he
sl eeve
out si de
t he
pl ane
of
t he
cyl i nder
head
t o
maxi mum
1
mm
(
. 03937
i n
. )
.
Assembl i ng
t he
cyl i nder
head
11
.
Cl ean
t he
cyl i nder
head
.
I f
t he
wat er
di st r i but i on
pi pe
has
been
di sassembl ed,
i t
must
be
i nst al l ed
wi t h
t he
hol es
t ur ned
as
i ndi cat ed
i n
t he
pi ct ur e
.
I nst al l
new
val ve
st em
seal i ngs
.
Oi l
t he
val ve
st ems
and
i nst al l
t he val ves
.
Make
sur e
t o
i nst al l
t he
val ves
and
t he
val ve
spr i ngs
i n
t hei r
r espect i ve
or i gi nal
posi t i ons
.
I nst al l
t he
val ve
spr i ngs
and
t he
" col l et s"
.
Use
a
val ve- bow
.
ProCarManuals.com
Reduct i on
val ve
12
.
Remove
t he
cover
of
t he r educt i on
val ve
and
check
t o
make
sur e t hat
t he
spr i ng
and
t he
pi st on
ar e
f aul t l ess
.
I f
t her e ar e
r easons
t o
suspect
a
f aul t
i n
t he
openi ng
pr essur e
of t he
r educt i on
val ve,
t hen
check
t he
dat a
of
t he spr i ng
.
See
under
" Techni cal
Dat a"
-
r educt i on val ve
.
Feed- pump
13
.
Depr ess
t he
pump
l ever
.
i f
t he
di aphr agm
of t he
pump
sounds
squeaky,
t he
di aphr agm
i s
f aul t l ess
.
Changi ng
t he
di aphr agm
14
.
Remove
t he
si x
scr ews, hol di ng
t he
upper
and
l ower
pump
housi ngs
t oget her
.
Remove
t he
pump
l ever
spr i ng
( 1)
and
r emove
t he
scr ew
( 2)
hol di ng
t he
pump
l ever
shaf t
.
15
.
Use
a
sui t abl e
pai r
of
pl i er s
and
r emovet he
pump
l ever
shaf t
.
Pul l
out
t he
l ever
and
t he
di aphr agm
.
ProCarManuals.com
Pi st ons,
cyl i nder s
21
.
Check
t he
wear
on
pi st ons, pi st on r i ngs
and
gudgeon
pi ns
.
Repl ace
t hese
i f
necessar y
.
Use
a
cyl i nder
i ndi cat or
gauge
t o
measur e
t he
cyl i nder
bor es
.
The
measur ement
of
t he
bi ggest
wear
i s
made
i mmedi at el y
beneat h
t he
edge
of
t he
upper
dead
cent er
and
cr osswi se
t he
engi ne
.
The
mea
sur ement
of
t he
smal l est
wear
i s
made
at
t he
l ower
dead
cent er
.
As
t o
t he
cyl i nder
di amet er , see
" Techni cal
Dat a"
.
Use
a
mi cr omet er
t o
measur e
t he
pi st ons
.
Pi st on
di amet er ,
see
under
" Techni cal
Dat a"
.
22
.
I nser t a
new
pi st on
r i ng i nt o
t he
cyl i nder and
measur e
t he
pi st on r i ng
gap
.
As
t o
t he
measur ement ,
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
.
Measur 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
measur ement ,
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
mar ki ng
of
t he
r i ngs
( TOP
or
t he
mar k
of
t he
manuf act ur er )
must
be
t ur ned
upwar ds
.
The
hei ght
of
t he
upper
com
pr essi on
r i ng
:
1, 75
mm
(
. 068898
i n
. )
The
hei ght
of
t he
l ower
compr essi on
r i ng
;
2, 00
mm
(
. 07874
i n
. )
.
Tur n
t he
pi st on
r i ngs
so
t hat
t he
gaps
ar e
t ur ned
120
°
f r om
each
ot her.
Connect i ng
r ods
25
.
Check
t he
connect i ng
r ods
f or
st r ai ght ness
and
t wi st i ng
.
ProCarManuals.com
26
.
Check
t he
connect i ng
r od
bushi ngs
by
usi ng
t he
gudgeon
pi n as
a
gauge
.
Ther e
must
be
no
pl ay
.
I f
t he
bushi ngs
must
be
r epl aced,
use
a
sui t abl e
mandr el
f or
t he
r emoval
and
i nst al l at i on
.
Make
sur e
t o
i nst al l
t he
bushi ng
wi t h
t he
oi l
hol e
coi nci di ng
wi t h
t hat of
t he
connect i ng
r od
.
Ream
t he
new
bushi ngs
.
The
f i t
i s
cor r ect
when
an
oi l ed
gudgeon
pi n
by
i t s
own
wei ght
can
sl owl y
sl i de
t hr ough
t he
bushi ng.
Sea- wat er
pump
27
.
The
pump
i s
equi pped
wi t h
t wo
bal l - bear i ngs
( 1)
.
When
di sassembl i ng,
r emove
t he
l ocki ng- r i ng
( 2)
i n
t he
housi ng
and
push
out t he
shaf t ,
wher eby
t he
bear i ngs
ar e
f ol l owi ng
.
Use
a
sui t abl e
mandr el
t o
r emove
t he
bear i ngs
f r om
t he shaf t
.
NOTE!
Do
not
f or get t he
spacer
sl eeve
( 3)
.
Repl ace
t he
seal i ngs
( 4)
.
NOTE!
Tur n
t he
seal i ngs
cor r ect l y
and
make
sur e
t hat
t hey
do
not
bl ock
t he
dr ai nage
hol e
i n
t he
pump- housi ng
.
Repl ace
t he
O- r i ng
( 5)
.
I nst al l
t he
bal l - bear i ngs
and t hespacersl eeve
ont o
t heshaf tand
l eave
a
di st ance
of
39, 5
mm
( 1
. 55512
i n
. )
f r om
t he shaf t
end
t o
t he
bal l - bear i ng
.
Coat
t he
shaf t
wi t h
gr ease
and
" scr ew"
i t
t hr ough
t he
seal i ngs
and
t he
O- r i ng
and
t ake
car e
not
t o
damage
t hem
.
Push
i n
t he
shaf t
as
f ar
as t o
al l ow
t he
bear i ngs
t o
bot t om
and
t hen
i nst al l
t he
l ocki ng- r i ng
( 2)
.
Checki ng
t he
t her most at s
28
.
I mmer se
t he
t her most at
i n
wat er
and,
usi ng
a
t her momet er ,
check
i f
i t
opens
at
t he
cor r ect
t emper at ur e
.
See
Techni cal
Dat a
f or openi ng t emper at ur es
.
I f
t he
t her most at
i s
f aul t y,
i t
must
be
r epl aced
.
ProCarManuals.com
Al ways
use
new
gasket s,
seal i ng
r i ngs,
seal i ng
washer s
and
l ock- washer s
.
Coat
t he
seal i ngs wi t h
gr ease
or
oi l
t hem
and
al so
oi l
al l
movi ng
par t s
pr i or t o
i nst al l i ng
t hem
.
I f
t he
engi ne
i s
f r esh- wat er
cool ed,
see
page
21
.
1
.
Heat
t he
cr ankshaf t
gear wheel
t o
appr ox
.
150°C
( 302
°
F)
pr i or
t o
t he
i nst al l at i on
.
Pl ace
t he
key
i n
t he
key- way
of
t he
cr ankshaf t
and
pr ess
on
t he
gear
wheel
.
Oi l
t he
new
mai n
bear i ng
hal ves
( wi t h
oi l
hol e)
and
i nst al l
t hem
i n
t he
bl ock
.
Put
i n
t he
cr ankshaf t
.
NOTE!
The
mai n
bear i ng
shel l
at
t he
f l ywheel
al so
f unct i ons
as a
t hr ust - bear i ng
.
ASSEMBLY
2
.
Oi l
t he
cap
bear i ng
hal ves
and
i nst al l
t hem
.
I nst al l
t he
caps
i n
accor dance
wi t h
t he
mar ki ng
i n
t he
bl ock
( 2001
has
no
i nt er medi at e
bear i ng)
.
I f
an
ar r ow
i s
cast ,
i t
shal l
poi nt
t owar ds
t he
oi l
di pst i ck
.
Ti ght eni ng t or que
f or
t he
mai 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
Nm
( 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
mar ked
wi t h an
ar r ow
t hat
poi nt s
t owar ds
t he
bel t
pul l ey
.
Use
i nst al l at i on
r i ng
884813- 7
.
Fi t
t he
caps
wi t h
t he
mar ki ng
al i gned
wi t h
t he cr ankshaf t ' s
mar ki ng
.
The
cr ankshaf t
can
be
t ur ned
i n
any
di r ect i on
t owar ds
t he pi st on
.
Ti ght eni ng
t or ques
:
St ep
1
:
25
Nm
( 2
. 5
kpm)
( 18
f t / l b)
St ep
2
:
70
Nm
( 7
. 0
kpm)
( 53
f t / l b)
4
.
I nst al l
t he
mai n
bear i ng
hal ves
i n
t he
oi l
pan
and
coat
t he
edge
of
t he
oi l
pan
wi t h
t hi n l ayer of
seal i ng
compound
p/ n
840879
.
I nst al l
t he
oi l
pan and
t i ght en
t he
oi l
pan
scr ews
and
t he
mai n
bear i ng
scr ews
al t er nat i ngl y
t o
20
Nm
( 2, 0
kpm)
( 14
. 7
f t
. l bs
. )
and
t hen
t he
mai n
bear i ng
scr ews
t o
60
Nm
( 6, 0
kpm)
( 44
. 2
f t
. l bs
. )
.
ProCarManuals.com
5
.
Repl ace
t he
f l ywheel
housi ng
seal i ng
( 1)
.
Smear
seal i ng
compound
( p/ n
840879)
on
t he
edge
bet ween
t he
f l ywheel
housi ng
and
t he
seal i ng
.
NOTE!
The
seal i ng
l i p
wi t h
a
spr i ng
shal l
be t ur ned
t owar ds
t he
engi ne
.
Make
sur e
t hat
t he
seal i ng
i s
i nst al l ed
i n
accor dance
wi t h
t he pi ct ur e
.
r
6
.
Repl ace
t he
O- r i ngs
and
i nst al l
t he
f l ywheel
housi ng
.
Ti ght eni ng
t or que
25
Nm
( 2, 5
kpm)
( 18
. 4
f t
. l bs)
.
I nst al l
t he
f l ywheel
.
Ti ght eni ng t or que 65
Nm
( 6, 5
kpm)
( 48
. 0
f t
. l bs) .
7A
.
Heat
t he
camshaf t
gear
wheel
t o
a
t emper at ur e
of
appr ox
.
150°C
( 302°F)
and use
a
sui t abl e
sl eeve
t o
i nst al l
i t
.
Check
t o
make
sur e
t hat
t he
gear
wheel
" bot t oms"
on
t he
camshaf t
.
I nst al l
t he
camshaf t
and
make
sur e
t hat
t he
mar ki ngs
on
t he
camshaf t
gear
wheel
and
on
t he
cr ankshaf t
gear
wheel
coi nci de
.
Put t he
washer
( 1)
on
t he
hub
of
t he
camshaf t gear
wheel
.
Check
t hat
al l
wei ght s
ar e
pr essed
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
camshaf t
i n
t he
t r ansmi ssi on
housi ng,
usi ng
mandr 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
mandr el
" bot t oms"
agai nst
t he
housi ng
.
I nst al l
a
new
O- r i ng
i n
t he
oi l
channel
i n
t he
bl ock
( 3
f i g
.
7A)
.
Use
a
new
gasket
and
i nst al l
t he t i mi ng
gear
cover
.
Pl ace
t he
pr essur e
sl eeve
( wi t h
t he
bear i ng
t owar ds
t he
pr essur e
washer )
i n
t he
cont r ol
ar m
l ever
.
Hol d
t he
sl eeve
i n
pl ace
by
pr essi ng
t he
l ever
t o
i t s
bot t om
posi t i on
wher e
t he
sl eeve
i s
pr essed
agai nst
t he
housi ng
.
I nst al l
t he
pi n of t he
camshaf t ,
usi ng
speci al
t ool
p/ n
884839
.
The
pi n
must
pr ot r ude
equal l y
much
on
bot h
si des
.
Under no
ci r cumst ances
ar e
you
t o
use
a
hammer
or
some
such
t ool
t o
punch
t he
pi n
i nt o
i t s
l ocat i on
wi t h
t he
ai d of a
mandr el
.
The
camshaf t
wi l l
t hen
be
bent
.
ProCarManuals.com
8
.
I nser t
t he
cont r ol
r od
t hr ough
t he
bl ack
and
i nt o
t he
t i mi ng
gear
casi ng
.
I nst al l
t he bear i ng
bal l
( 1)
i nt o
t he
cont r ol
r od
and
push
t he
cont r ol
r od
t hr ough
t he
hol e
i n
t he
cont r ol
l ever
( 2)
.
Fi t
t he
spr i ng
( 3)
and
scr ew
on
t he
end
ni ppl e
( 4)
unt i l
i t
bot t oms
( Not e!
Do
not use
any
t ool s)
.
Scr ew
i n
t he
upper
bol t s
( wi t h
copper
seal i ng
washer s)
t hat
gui de
t he
cont r ol r od
.
Then,
scr ew
t he
l ower
bol t s
t hat
hol d
t he
cont r ol
r od
i n
pl ace
i n
t he engi ne
bl ock
.
NOTE! The
l ower
bol t s
shoul d
not
have
seal i ng
washer s
.
Appl y
Per mat ex
t o
t he
t hr eads
.
Check
t hat
t he
cont r ol
r od
moves
f r eel y
.
9
.
I nst al l
t he
oi l
pump' s
gear wheel
accor di ng
t o
t he
mar ks
( f r om
t he
di sassembl y)
.
I nser t
a
new
O- r i ng
i n
t he t i mi 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
Nm
( 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
camshaf t
wi t h
mol ybdenum
di sul phi de
.
Oi l
t he
val ve
gui des
i n
t he
bl ock
and
i nst al l
t he
l i f t er s
.
Cl ean
t he
r ol l er
l i f t er s
of
t he
f uel
i nj ect i on
pumps
and
i nst al l
t hen
i n
t he
bl ock
.
Lock
t he
r ol l er
l i f t er s
wi t h
scr ews
t hr ough
t he
bl ock
af t er
t he
i nst al l at i on
( appl y
Per mat ex
t o
t he
t hr eads)
.
Check
car ef ul l y
t o
make
sur e
t hat
t he
l i f t er s
ar e
cor r ect l y
i nst al l ed
and
t hat
t hey
ar e
r unni ng
easi l y
i n
t he
gr oove
.
Regar di ng
t he
i nst al l at i on
of
t he
cyl i nder
head,
seet he
f ol l owi ng
page
.
ProCarManuals.com
2002
2003
12
.
Ti ght en
t he
t wo
gui de
scr ews
p/ n
884840
i n
t he
bl ock
and
i nst al l
t he
cyl i nder
head
gasket wi t h
t he
mar ki ng
" Top"
f aci ng
upwar ds
.
I nst al l
t he
cyl i nder
head
.
Make
sur e
t hat
t he
cont act sur f ace
f or
t he
cyl i nder
head
bol t s
ar e
f r ee
f r om
pai nt
.
Shoul d
t her e
be
pai nt
on
t he
bol t s,
t her e
i s
al ways
t he
r i sk
of
havi ng an
i nsuf f i ci er t
t i ght eni ng
f or ce
i n
t he
bol t
j oi nt
wi t h
subsequent
l eakages
as a
r esul t
.
NOTE!
The
bol t s
ar e
phospat ed,
t her ef or e
do
not
cl ean
t hem
wi t h
a
st eel - br ush
.
Coat
t he
cyl i nder
head
bol t s
wi t h
mol ybdenum
di sul phi de
and
t i ght en
t hem
i n
accor dance
wi t h
t he
di agr am,
f i r st
t o
20
Nm
( 2
. 0
kpm/ 14. 7
f t
. l bs)
and
t hen
t o
70
Nm
( 7
. 0
kpm/ 51
. 6
f t . l bs) .
13
.
I nst al l
t he
push
r ods
and
t he
r ocker
ar m
br i dge,
push
on
new
r ubber
r i ngs
t o
t he
oi l
pi pe
whi ch
i s
f i t t ed at
t he
same
t i me as
t he r ocker
ar m
br i dge
.
14
.
Val ve
cl ear ance
col d/ war m
engi ne
0
. 30
mm
(
. 01181
i n
. )
.
Tur n
t he
engi ne
i n
t he
di r ect i on of r ot at i on
unt i l
t he
val ves
i n
one
cyl i nder
ar e
" r ocki ng"
.
Then
t ur n
t he
engi ne
one
t ur n
mor e
and
adj ust
t he val ves
f or
t hi s
cyl i nder
.
Repeat
t he
pr ocedur e
f or
t he
r emai ni ng
cyl i nder s
.
Adj ust i ng
t he
f uel
i nj ect i on
pump
l ocat i on
wi t h
shi ms
15
.
i f
t he
same
bl ock
camshaf t
and
f uel
I nj ect i on
pumps
ar e
used
when
assembl i ng,
t he
f uel
i nj ect i on
pump
must
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
same
shi m
t hi ckness
as
ear l i er
.
The
so
cal l ed
sof t
shi ms,
al ways
bei ng
i nst al l ed
agai nst
t he
bl ock,
must
be
r epl aced
agai nst
new
ones
.
Car ef ul l y
cl ean
t he
cont act
sur f aces
bet ween
t he
bl ock
and
t he
f uel
i nj ect i on
pumps
and
i nst al l
shi ms
wi t h
t hi ckness
equal
t o t he
sum
of
t he
mar ki ng
on
t he
bl ock
and
t hat
on
t he
f uel
i nj ect i on
pump,
( 4)
ear l i er
mar ki ng
.
Exampl e
:
The
bl ock
mar ki ng
4 ( =
4
t ent hs
of
a
mi l l i met er )
(
. 015748
i n
. )
The
pump
mar ki ng
4
( =
4
t ent hs
of a
mi l l i met er )
(
. 015748
i n
. )
Tot al
amount
of
shi ms
=
0
. 8
mm
(
. 031496
i n
. )
I n
t hi s
case
sel ect
t wo
sof t
shi ms
0
. 2
and
0
. 3
mm
(
. 011811
i n
. )
.
Pl ace
t he
har d
shi m bet ween
t he
t wo
sof t
ones
and
i nst al l
t he
pump
.
NOTE!
Never
i nst al l
a
har d
shi m
t oget her
wi t h
anot her
har d
shi m
or
agai nst
t he
bl ock
or
t he
f uel
i nj ect i on
pump
.
Har d
shi ms
ar e
avai l abl e
i n
t hi cknesses
0
. 3,
0
. 6
and
0
. 9
mm
(
. 011811, . 02362,
. 035433
i n
.
r espect i vel y)
.
Sof t
shi ms
ar e
avai l abl e
i n
t hi cknesses
0
. 2
and
0
. 3
mm
(
. 007874
and
. 011811
i n
. )
.
ProCarManuals.com
On
l at er
ver si on
engi nes
an
O- r i ng
has
been
i nt r oduced
as a
seal
bet ween
t he
i nj ect i on
pump
and
t he
bl ock
.
Onl y
so- cal l ed
har d
shi ms
may
be
used
on
t hese
engi nes
when
shi mmi ng
.
Har d
shi ms
ar e
avai l abl e
i n
t hi cknesses
of 0
. 2
mm
( 0
. 0079
i n) ,
0
. 3
mm
( 0
. 0118
i n) ,
0
. 6
mm
( 0
. 0024
i n)
and
0
. 9
mm
( 0
. 0354
i n)
.
16
.
New
bl ock
or
camshaf t
I f
t he
bl ock
or
t he
camshaf t
ar e
r epl aced
t he
bl ock
must be
measur ed and
mar ked,
usi ng
t he
set t i ng- di sc
p/ n
884787
and
a
sl i di ng
cal i per
.
A
.
The
set t i ng- di sc
consi st s
of
t wo
r i ngs,
an
i nner
and
an
out er
.
The
i nner
r i ng
det er mi 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 amped
i n
degr ees
and
i s
f i xed
wi t h
a
pi n
( 1)
.
B
.
Mount
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)
comes
i n
t he l ar gest of
t he
f our
hol es
i n
t he
pul l ey
.
Pr ess
i n
t he
gui de
pi n
( 2)
so
t hat
t he
di sc
i s
cent er ed
and
t i ght en
t he
bol t s
.
The
set t i ng- di sc
i s
mar ked
f or
each
r espect i ve
cyl i nder
:
Mar ki ng
Denot es
Cyl i nder
1
Cyl i nder
1
( 1,
2,
3
cyl i nder
engi nes
;
Cyl i nder
2/ 2
Cyl i nder
2
( 2
cyl i nder
engi ne)
Cyl i nder
2/ 3
Cyl i nder
2
( 3
cyl i nder
engi ne)
Cyl i nder
3/ 3
Cyl i nder
3
( 3
cyl i nder
engi ne)
ProCarManuals.com
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35

Volvo Penta 2002 Workshop Manual

Brand
Volvo Penta
Model
2002
Type
Workshop Manual
This manual is also suitable for
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Other documents