VOLVO PENTA D3 Marine Engine Service Repair Manual

VOLVO PENTA D3 MARINE ENGINE SERVICE REPAIR MANUAL

This manual covers the following model(s):

• D3-110i-B
• D3-130i-B
• D3-160i-B
• D3-190i-B
• D3-130A-B
• D3-160A-B
• D3-190A-B

In this manual you have the following chapters:

• Safety information
• Introduction
• Important
• General information
• About this Workshop Manual
• Standard times (Flat Rate)
• Spare parts
• Certified engines
• Repair instructions
• Our common responsibility
• Torque
• Torque-angle tightening
• Lock nuts
• Strength classes
• Sealant
• Safety rules for Fluorocarbon Rubber
• Special tools
• Other special equipment
• Location of engine signs
• Design and function
• Group 21: Short block
• Engine, general
• Engine block
• Sump
• Cylinder head
• Camshaft
• Valve housing / inlet manifold
• Crankshaft
• Pistons
• Timing gear
• Crankcase breather
• Group 22: Lubrication system
• Oil grades
• Lubrication system, function description
• Oil valves
• Oil pump
• Oil filter
• Group 23: Fuel system
• Fuel system, function description
• Injection pump
• Distribution manifold
• Injectors
• Fuel filter housing
• Group 25: Inlet and exhaust system
• Inlet and exhaust system, function description
• Turbocharger
• VNT (Variable Nozzle Turbocharger)
• Group 26: Cooling system
• Cooling system, function description
• Thermostat
• Circulation pump
• Sea water pump
• Intercooler
• Heat exchanger
• Oil cooler
• Oil cooler, steering servo
• Group 64: Servo system
• Servo system
• Servo pump
• Fault tracing
• Symptoms and possible causes
• Malfunctions
• Blockage
• Inspection of return flow from injectors
• Service work
• Compression test
• Engine oil, changing
• Oil filter, change
• Fuel filter, change
• Venting the fuel system
• Air filter, change
• Cooling system, draining
• Sea water system, cleaning and conserving
• Fresh water system, pressure testing
• Cooling system, filling
• Sea water pump, impeller, change
• Drive belt/Alternator belts, inspection
• Drive belt/Alternator belts, change
• Cam belt, change
• Repair instructions
• When working with chemicals, fuel and lubrication oil
• Before lifting the engine
• Before working in a boat
• Actions after lifting the engine
• Checking the engine fixture
• Engine, full overhaul
• Disassembly, engine
• Cover
• Exhaust manifold and turbocharger
• Fuel filter and housing
• Intercooler, brackets and dipstick
• Engine cables
• Drive belt
• Sea water pump
• Servo pump, jockey wheel, left-hand engine mounting
• Alternator
• Mounting bracket
• Vacuum regulator
• Sensors and monitors
• Starter motor
• Fuel leakage hose
• Delivery pipes
• High pressure pump
• Distribution manifold
• Vacuum pump
• Injectors
• Valve cover/inlet manifold
• Timing gear
• Circulation pump
• Oil pump
• Cylinder head
• Flywheel with cover and coupling
• Oil filter housing
• Oil cooler
• Sump
• Oil suction pipe
• Piston cooling nozzles
• Pistons and con rods
• Crankshaft
• Assembly, engine
• Classification of main bearings
• Crankshaft
• Piston rings
• Piston cooling nozzles, pistons, con rods
• Flywheel, seal ring, clutch and flywheel housing
• Oil suction pipe and sump
• Oil cooler
• Oil pump
• Toothed belt pulley
• Cylinder head
• Valve cover
• Circulation pump
• Timing gear
• Injectors
• Distribution manifold
• High pressure pump
• Fuel supply pipes and fuel leakage hose
• Fuel union
• Vacuum pump
• Plug, hot water outlet
• Oil filter housing
• Mounting bracket
• Drive belt/Alternator belt
• Vacuum regulator
• Starter motor
• Sensors and cables
• Intercooler and dipstick
• Fuel filter housing
• Exhaust pipe with turbocharger
• Fixture, right engine mounting
• Coolant pipe
• Heat exchanger
• Oil pipe, turbocharger
• Exhaust pipe elbow
• Expansion tank
• Hose connections, air filter housing
• Cover
• Overhaul / Change components
• Group 21: Short block
• Flywheel, change
• Gear ring, change
• Crankcase seal, rear, change
• Crankshaft seal, front, change
• Cylinder head, change
• Cylinder head gasket, measurement
• Crankshaft, locking
• Group 22: Lubrication system
• When working with chemicals, fuel and lubrication oil
• Oil pump, change
• Oil filter housing, change
• Lube oil pressure, check
• Group 23: Fuel system
• Engine control unit, changing
• Injection pump, changing
• Injectors and fuel supply pipes, change
• Pressure limiting valve
• Fuel suction pressure, checking
• Fuel pressure sensor, change
• Group 25: Inlet and exhaust system
• Turbocharger, inspection
• Turbo, replacing
• Exhaust manifold, change
• Group 26: Cooling system
• Coolant pump, change
• Thermostat, function check/change
• Sea water pump, change
• Seawater pump, impeller change
• Sea water pump, seal, change
• Coolant temperature sensor, replacing
• Heat exchanger, pressure testing
• Heat exchanger, replacing
• Heat exchanger, cleaning/renovation
• Oil cooler, steering servo, change
• Intercooler, pressure testing
• Intercooler, change
• Intercooler, cleaning/renovation
• Oil cooler, engine, change
• Group 30: Electrical (other)
• Alternator, changing
• Starter motor, changing
• Technical data
• General
• Short block
• Inlet and exhaust system
• Fuel system
• Lubrication system
• Cooling system
• Electrical system
• Wiring diagram
• Torque
• Conversion table
• References to Service Bulletins
• Alphabetical register