Group: 21 Short block

Repair instructions

Workshop Manual
Volvo Penta - Engine

Part B

Welcome Aboard

Polar DC Generators and Volvo Penta marine engines are used all over the world to
day. They are used in all possible operating conditions for professional as well as lei
sure purposes.
Polar DC Marine is becoming a symbol of reliability, technical innovation, performance
and long service life. We also believe that this is what you demand and expect of your
Polar DC Marine generator.
Please read this operators manual thoroughly and consider the advice we provide on
operation and maintenance before you cast off on your voyage so that you will be en
sured of fulfilling your expectations.

59

Repair instructions

Group: 21 Short block

Cylinder head, installation

Special tools: 998 9876, 999 5192
1
Check the piston height with tools 9989876 and
9995192. Select a new cylinder head gasket, please
refer to Technical data.
Check that the valve lifters are in place.
2

Check that the engine block guide pins for the cyl
inder head are in place. Install a new cylinder head
gasket with the marking upwards.
Put the cylinder head in place. Insert the screws (1)
and torque them as in the tightening schedule, to the
torque specified in Technical Data.
3
Install the push rods (1) and valve caps (2).

60

Group: 21 Short block

Repair instructions
4
Install a new seal on the rocker arm bridge (1). Install
a new rocker arm bridge. Make sure that the push
rods and rocker arms (2) are correctly aligned.
Tighten the nuts (3) evenly to the specified torque,
please refer to the Technical Data chapter.

5
Install the oil supply pipe (1) on the cylinder head
with new seals.

6
Installing the injectors:
Apply sealant part. no. 840879 to the threads of the
two lowest screws (1).
Put new copper seals on the bottom of the cylinder
head.
Install the injectors and tighten them evenly to the
specified torque, please refer to the Technical Data
chapter.

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Repair instructions

Group: 21 Short block

Timing gear, removing

Cylinder head removed

Special tools: 885820, 885 822

1
Unscrew the seawater pump (1). Remove the end
panel (2) and the screws (3).

2
Unscrew the centre nut from the pulley. Install tool
no. 885820 on the pulley and remove it.
Remove the Woodruff key from the groove in the
shaft

3
Unscrew the injection pump (1). Lift it up until the lock
clip (2) is accessible. Undo the clip and release the
control rod (3).
4

62

Group: 21 Short block

Repair instructions
Unscrew the timing gear cover screws (1) and nut
(2). Remove the cover.
5

Undo the fuel pipe from the fuel filter (1).

Unscrew the fuel feed pump (2). Wipe up the fuel that
has run out.
6

Remove the valve lifters with magnetic tool 885822.

IMPORTANT! Mark the valve lifters so that they
are put back in the same positions. The D120
and D240 engines have some valve lifters
which are chamfered off.

63

Repair instructions

Group: 21 Short block

7
Rotate the camshaft until the socket cap screw (1)
becomes visible in the hole in the camshaft drive
gear. Unscrew the socket cap screw and hex head
screw (2). Remove the lock plate (3).
Remove the camshaft regulator sleeve (4).
Pull the camshaft out carefully.
IMPORTANT! There is a risk that the inner
camshaft bearing can be damaged by a cam
shaft lobe if it is pulled out with force.

8
Remove the circlip (1) on the oil pump shaft. Remove
all components of the oil pump. Note the spacer
washer (2) inside the oil pump gear.

9
Unscrew the remaining screws (1). Remove the tim
ing gear plate (2).
Undo the crankshaft gear (3) with a puller. Remove
the gear wheel and its Woodruff key.

64

Group: 21 Short block

Repair instructions

Timing gear, installation

1
Put the gear wheel (1) and its key on the crankshaft.
Tap the gear wheel on.
Install a new gasket and timing gear plate (2).
Tighten the inner screws (3) on the timing gear plate.

2
Carefully insert the camshaft.
IMPORTANT! If you force the camshaft in,
there is a risk that one of the cam lobes will
damage an internal bearing.
Put the lock plate (1) in position. Rotate the camshaft
until the screw hole for the socket cap screw (2) be
comes visible in the hole in the camshaft drive gear.
Screw the lock plate down.
Install the camshaft regulator sleeve (3).

3
Fit the thrust washing (1) in place.
Put the oil pump gear wheel (2) in place. Make sure
that the markings (3) on the gear wheel line up with
the markings (4) on the other gear wheels.
Check the gear flank clearance, please refer to Gear
flank clearance, checking.

65

Repair instructions

Group: 21 Short block

4
Install the pump gear (1), end washer (2), shims (3),
spring (4) and bush (5) in the oil pump gear. Put the
circlip (6) on the shaft.
NOTE! Note that the end washer (2) has a hole (7)
which must mate up with the guide pin in the timing
gear cover.
Install a new gasket on the timing cover.
NOTE! If the gasket has a center section (8), this
must be cut away.

5
Put the control rod (1) on the heel (2) in the timing
gear cover. Turn the stop arm (3) round so that the
control rod is held against the heel.

6
Install the timing gear cover at the same time as the
control rod (1) is held fixed by the stop arm (2).
Put the timing gear cover in place. Make sure that the
control rod ends up in the correct position and that
the pin (3) engages in the hole (4) in the oil pump
end washer.
Screw the timing gear cover down.

66

Group: 21 Short block

Repair instructions
7
Put a new O-ring (1) in the groove in the seawater
pump.
Install the rear end piece (2) with a new gasket and
its four screws (3).
NOTE! The longest screws must be put on the out
side (D113, D120).
Install the seawater pump and screw it in place.

8
Install the pulley key on the crankshaft.
Install the pulley and tighten it to the specified torque
with the center nut, please refer to the Technical
Data chapter.

9
Put the valve lifters in place as marked.
IMPORTANT! All valve lifters must be put back
in their old places. Not that on engine D120,
valve lifter no. 2 for cylinder 1 has one chamfer
(1). On engine D240, both valve lifters for cyl
inder 1 have one chamfer.

D1-20 A

67

Repair instructions

Group: 21 Short block

Pistons, removal

Engine oil drained. Cylinder head removed.

1
Turn the engine upside down. Undo the oil drain pipe
anchorage (1) on the cylinder head.
Unscrew the sump (2) and remove it together with
the oil drain pipe (3).
2

Unscrew the oil suction strainer (1). Remove the suc

tion pipe (2) with its O-ring.
Unscrew the bearing caps (3) for the con rods.
IMPORTANT! Note the markings on the bear
ing caps and their locations.

Press the pistons out.

NOTE! There might be a soot deposit on the top of

the cylinder bores. Remove the deposit to make it
easier to press the pistons out.

68

Group: 21 Short block

Repair instructions

Big end bearing, change

Pistons, removed
1
Remove the big end bearings (1) and put the new
ones in position.

Flat Rate: 21320

Pistons, change
1
Note the positions of the pistons in relation to the
crankshaft.
Remove the circlips (1) and press the gudgeon pin
out (2).

2
Clean the gudgeon pin bushing and check it.

3
Install a new piston in the correct position.
Press the gudgeon pin in.
Install the circlips with the lugs facing upwards.

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Repair instructions

Group: 21 Short block

Pistons, installation
1
Also refer to Assembly of pistons, piston rings and
con rod.
Install a piston ring compressor on the piston.
Lubricate the con rod bearing shells and studs with
engine oil.
2
Turn the crankshaft round so that the big end bearing
is in the lowest position for the piston to be installed.
Install the piston (1) in the bore and carefully tap it
down. The piston marking SHIBAURA must face
the injection pump side.
IMPORTANT! Make sure that the con rod studs
to not strike the crankshaft when driven down.

3
Install the big end bearing cap as marked. Torque to
23 Nm (D113, D120 or 32 Nm (D130, D240).
Check the movement of the big end bearing.
Repeat the procedure to install the remaining pistons.

70

Group: 21 Short block

Repair instructions

Crankshaft, remove

Removed pistons, flywheel and timing gear

1
Unscrew the inner timing gear plate (1).

2
Remove the rear crankshaft seal (1) from the crank
shaft.

3
Unscrew the oil pressure reduction valve.
4
Undo the screws (1) which hold the main bearing
caps.
Lift the crankshaft out.

NOTE! Tape the crankshaft gear teeth to protect the

bearing when the shaft is pulled out.

71

Repair instructions

Group: 21 Short block

Main bearings, change

Crankshaft, removed
1
Unscrew the main bearing retainers (1) and pull them
off the crankshaft.
IMPORTANT! The marking (2) on all main
bearing retainers for D120, D130 and D240
must be carefully noted to prevent incorrect
positioning during assembly. Also note the oil
holes (3) in the bearing caps.

D1-20, D1-30
2

D2-40

Drive out the main bearing bush (1) located in the en

gine block. Use a suitable mandrel and tap the bush
ing out from inside the crankcase.
3
Inspect all main bearings (1). Remove them from

their holders.
Check and measure the bearing surfaces (2) on the
crankshaft, please refer to crankshaft inspection.

72

Group: 21 Short block

Repair instructions
4
Install the new main bearings and lubricate them with
engine oil.
Install the main bearing retainers (1) on the crank
shaft in accordance with the markings (2). Torque the
screws to 23 Nm.
IMPORTANT! Put the main bearing retainers
back in their original places. The oil holes (3)
must face the corresponding holes in the en
gine block.
5

Install the main bearing bush (1) in the engine block.

IMPORTANT! Position the bushing so that its
oil hole is correctly aligned in the engine block.
The oil groove (2) in the bushing must be fur
thest in.
Tap the bushing in with a suitable mandrel (3) until it
lines up with the engine block.
Check that the oil duct is open after pressing in. Also
check the internal diameter of the bushing. For di
mensions, please refer to Technical Data.

73

Repair instructions

Group: 21 Short block

Crankshaft, assembly
1
Lift the crankshaft into place.
Align the main bearing retainer screw holes (1) be
fore the crankshaft is pressed into place.
2

Carefully tap the crankshaft into place if necessary,

and torque the main bearing retainers to 27 Nm.
Check that the crankshaft can be turned easily.
3
Install the oil pressure reduction valve with a new
seal. Torque to 64 Nm.
Install a rear crankshaft seal, please refer to Rear
crankshaft seal, changing.

74

Group: 21 Short block

Repair instructions

Flat Rate: 21661

Flywheel, change
1
Remove the engine speed sensor (1) and filter hous
ing bracket (2).
Remove the flywheel cover (3) and flexible coupling.

2
Unscrew the flywheel (1) and remove it.
Clean and check the crankshaft seal.

3
Carefully clean the crankshaft and flywheel.
Install the new flywheel and tighten it to the specified
torque, please refer to the Technical Data chapter.
Install the flexible coupling, flywheel housing, filter
housing bracket and engine speed sensor.

75

Repair instructions

Group: 21 Short block

Crankcase seal rear, change

Flywheel removed
1
Unscrew the inner timing gear plate (1).

2
Remove the rear crankshaft seal (1).
Check that the area for the crankshaft seal on the
engine block, the crankshaft and the inner flywheel
housing are cleaned.
Lubricate the lip of the seal on the new crankshaft
seal with engine oil and put the seal in place.
Apply sealant part no. 840879 all round the crank
shaft seal (2) and the camshaft cover (3).
Fix the inner flywheel plate.

76

Group: 21 Short block

Repair instructions

Flat Rate: 21672

Crankshaft seal, front, change

Special tools: 885820, 9995919
1
Undo the drive belt.
Unscrew the centre nut from the crankshaft pulley.
Install tool no. 885820 on the pulley and remove it.
Remove the Woodruff key from the groove in the
shaft

2
Insert tool no. 9995919 under the lip of the crankshaft
seal (1) and pull the seal out.
Clean the crankshaft and seal surfaces. Tape the key
groove on the crankshaft to avoid damaging the new
seal during assembly.

3
Lubricate the new crankshaft seal with engine oil and
put it on the crankshaft. Drive the seal into place with
a suitable mandrel.
Remove the tape.
4
Install the pulley key on the crankshaft.
Install the pulley and tighten it to the specified torque
with the center nut, please refer to the Technical
Data chapter.
Install and adjust the drive belt.

77

Repair instructions

Group: 21 Short block

Flat Rate: 21403

Valves, adjustment
Stationary, cold engine
1
Remove the air filter housing (1) and valve housing
(2).
2

D1-13
Crank the engine clockwise until the valves (1) for
no. 1 cylinder shift position. Then crank the engine
exactly one more turn. You can now adjust the valves
for no. 1 cylinder. Please refer to item 3 for the ad
justment procedure.
Crank the engine until the valves (2) for no. 2 cylin
der shift position. Then crank the engine exactly one
more turn. Adjust the valves for no. 2 cylinder.
D1-20, D1-30

Crank the engine clockwise until the valves for no. 1

cylinder shift position. Adjust no. 2 inlet valve (1) and
no. 3 exhaust valve (2). Please refer to item 3 for the
adjustment procedure.
Crank the engine clockwise until the valves for no. 2
cylinder shift position. Adjust no. 3 inlet valve (3) and
no. 1 exhaust valve (4).
Crank the engine clockwise until the valves for no. 3
cylinder shift position. Adjust no. 1 inlet valve (5) and
no. 2 exhaust valve (6).
D2-40
Crank the engine clockwise until the valves for no. 4

78

Group: 21 Short block

Repair instructions
cylinder shift position. Adjust no. 1 inlet and exhaust
valve (A). Please refer to item 3 for the adjustment
procedure.
Crank the engine clockwise until the valves for no. 2
cylinder shift position. Adjust no. 3 inlet and exhaust
valve (B).
Crank the engine clockwise until the valves for no. 1
cylinder shift position. Adjust no. 4 inlet and exhaust
valve (C).
Crank the engine clockwise until the valves for no. 3
cylinder shift position. Adjust no. 2 inlet and exhaust
valve (D).
3

Adjustment
Undo the locknut (1) with a ring wrench. Measure the
valve clearance (2) with a feeler gauge. Adjust the
valve clearance with the adjustment screw (3).
The correct valve clearance for all valves and en
gines is 0.2 mm.
When the correct valve clearance has been reached,
tighten the locknut (1).
4
Install the valve cover with a new seal.

Install the air filter housing.

Test run the engine and check that no oil leakage oc
curs.

79

Repair instructions

Group: 21 Short block

Flat Rate: 23641

Drive belt, change

1
Lightly loosen the lower fixing screws (1) on the alter
nator. Loosen the upper fixing nut (2).
Loosen the tension screw (3) and slacken the drive
belt. Remove the drive belt.

2
Install a new drive belt. Tension the belts with ten
sioner screw. Check the tension.
Tighten the alternator fixing nut and fixing screws.
IMPORTANT! D130, D240: Be careful to
ensure that the alternator belt is placed in the
groove closest to the alternator.

D1-30, D2-40

80

Group: 22 Lubrication system

Repair instructions

Oil pump bearing, changing

Timing gear and crankshaft removed

Special tools: 384 9639 (D1-13, D1-20), 384 9640

(D1-30, D2-40)
1
Drive out the oil pump bearing section (1) located
in the engine block. Tap it out from inside the crank
case.
2

Use special tool 384 9639 for D1-13 and D120, 384
9640 for D1-30 and D2-40.
First screw the guide pin (1) for the tool into the en
gine block.
Then put the new oil pump bearing (2) into the tool
block (3).

NOTE! It is important that the engine block surface

touching the tool is clean and even. The tool block
must be oiled.
3

Place the tool block with the bearing in place, using

the guide pin.
Tap the bearing into place until the tool bottoms on
the cylinder head.

81

Repair instructions

Group: 23 Fuel system

Injection pump, changing

1
Unscrew the stop solenoid (1).
Undo the supply pipe (2) to the injection pump.
Undo the supply pipes (3) and return fuel pipe (4).
IMPORTANT! Seal all openings in the fuel sys
tem with protective caps.

2
Unscrew the injection pump (1). Lift it up until the lock
clip (2) is accessible. Undo the clip and release the
control rod (3).
Lift the injection pump out and remove the shim.
3

82

Group: 23 Fuel system

Repair instructions
Put a new shim of the same thickness on the pump
housing. Insert the new injection pump into the hous
ing and fix the control rod with the lock clip.
Fix the oil supply pipe (1) on one of the studs (2).
Tighten the injection pump to the specified torque,
please refer to Technical Data.
Install the supply pipe (3).
5

Install the stop solenoid (1) with a new seal.

Install the fuel return pipe (2).
Install the fuel supply pipes (3) and tighten to the
specified torque, please refer to the Technical Data
chapter.

83

Repair instructions

Group: 23 Fuel system

Flat Rate: 23710

Injectors, changing

Clean round the injectors (1).

3

5
1

Undo the fuel supply pipes (2) by the injection pump

and the injectors. Lift the fuel supply pipes away to
gether.
Remove the nut (3) at the top of each injector, use
the nut (4) underneath the fuel return pipe (5) to
avoid kinking the pipe. Lift the return fuel pipe away.
Unscrew the injectors. Remove the copper seals un
der the injectors.
IMPORTANT! Seal all openings in the fuel sys
tem with protective caps.

2
Install the new injectors with new copper seals. Apply
sealant, part no. 840 879 to the two lowest threads
(1). Tightening torque, please refer to the Technical
Data chapter.
Install the new return fuel pipe, use the nut under
neath the fuel return pipe to avoid kinking the pipe.
Install the fuel supply pipes. Check that they do not
come out of alignment, and tighten the nuts. Tighten
ing torque, please refer to the Technical Data chap
ter.
3
Start the engine and check that no leakage occurs.

84

Group: 23 Fuel system

Repair instructions

Flat Rate: 23701

Renovating the injectors

1. Clean the outside of the injector.

2. Fix the injector (holder) in a vise. Unscrew the
injector nut and take the injector apart.

3 4

1. Injector nut
2. Injectors
3. Joining piece
4. Compression screw
5. Spring

6. Adjustment washers
7. Injector holder
8. Washer
9. Nut

Note. Be careful that the injector nozzle does not fall

out during disassembly.
3. Pull the injector nozzle out of the injector sleeve
and put the components in cleaning petrol (gaso
line).
Note. Make sure that the injector needles and injec
tor sleeves which belong with each other, and fit
together, are not mixed up if several injectors are
cleaned at the same time. To avoid mixing up, the
injectors should be put in an injector stand or in dif
ferent compartments.
4. Check each injector carefully with an illuminated
magnifier or an injector microscope. Also check
the other components.

5. When you install a new injector, it is important

that conservation oil is washed off the injector
needle and sleeve before the injector is assem
bled (avoid skin contact with the sliding surfaces
of the needle).

Clean the components in chemically pure petrol

(gasoline). Check that the injector needle slides
in the sleeve, with no tendency to binding.

6. Dip the injector components in pure Diesel or

testing oil, and fit the components together. Use
the original thickness of adjustment washer(s) to
set the opening pressure.
7. Check the opening pressure, jet pattern and
sealing in an injector tester.

85

Repair instructions

Group: 23 Fuel system

Injectors, testing

Testing is done in an injector tester. During the test,

the opening pressure and sealing are the most im
portant things. The spray pattern is more difficult to
assess, and does not give a reliable indication of the
injectors status.
WARNING! Be careful when testing injectors,
avoid getting the fuel jet from an injector on unprotected parts of your body. The jet has such
powerful penetration ability that it can force its
way in under your skinand cause blood poison
ing (septicemia).

Opening pressure

With the pressure gauge connected, press the injec

tor tester lever down slowly until the injector opens
and releases fuel. Read off the opening pressure at
the opening instant.
If the value read does not coincide with the specified
value, the setting must be changed. This is done with
washers.
Note. The opening pressure is increased or reduced
by about 1 MPa by a change in thickness of the
spacerby 0.1 mm.

Injectors, check
Spray pattern

1. Pump the injector tester, special tool 9999 772,

and check the injector spray pattern. The fuel jet
should be conical and in line with the centerline
of the injector. Fueldrops must not occur in the
jet.
2. Check that the fuel jet has a circular cross sec
tion.

Sealing

When sealing is checked, investigate the fuel leak

age which can occur between the injector nozzle seat
and the tapered sealing surface in the injector sleeve.
1. Wipe the injector nozzle tip dry.
2. Pump the pressure up to about 2 MPa below the
opening pressure of the injector (please refer to
Technical Data). Keep the pressure constant for
about 10 sec. and check that no fuel drips out
from the tip of the injector. Damp injectors can be
approved.
Install protective caps on the injector pipe couplings
and over the injector nozzle tips, if the injectors will
not be used at once.

86

Group: 23 Fuel system

Repair instructions

Setting the engine speed

Check that the accelerator control functions normally,

i.e. the actuator arm (1) is pressed against the low
idle stop (2) when the accelerator control is at idle,
and is pressed against the full throttle screw (3) when
the accelerator control is at full throttle. Adjust the
control if necessary. Also check that the air filter is
not blocked, and that the air inlet is not blocked.
IMPORTANT! The engines fuel volume and
speed are set at the factory to give highest
power and least environmental impact. These
settings must not be disturbed.
6
7

NOTE! Seals on injection equipment may only be

broken by authorized personnel. Seals which have
been broken must be re-sealed.

Low idle

1. Check that the gap (6) is about 3 mm when the

accelerator is in the idle position. If necessary:
Undo lock nut (7) and adjust screw (8) to give the
correct gap.
2. Warm the engine up and check the idling speed
with a tachometer (please refer to Technical data
for correct idling speed).
3. Use adjustment screw (2) to adjust to give the
correct idling speed.
4. Check the gap (3) again as in item 1.

5 4 3
1.
2.
3.
4.
5.
7.

Actuator arm
Adjustment screw, low idle
Stop screw, full throttle
Adjustment screw, racing speed
Adjustment screw, max. fuel volume
Lock nut

Racing speed (high idle)

Warm the engine up and check the racing speed with

a workshop tachometer when the engine is unloaded
at full throttle (please refer to Technical data for cor
rect racing speed).

Adjust the following as necessary

1. Loosen the stop screw (3) so that it does not limit

the movement of the actuator arm (1).
2. Run the engine without load at full throttle and
adjust the racing speed to the correct value with
adjustment screw (4). Remember to seal the
screw afterwards.
3. Adjust stop screw (3) to give a clearance of 0.1
mm between stop screw (3) and the actuator arm
(1) when the throttle control is at the full throttle
position.

87

Repair instructions

Group: 23 Fuel system

Flat Rate: 23311

Feed pump, changing

1
Put a rag under the feed pump to collect spilled fuel.
Undo the unions (1) on the feed pump.
Unscrew the feed pump (2).

2
Put a new O-ring in the feed pump.
Install the feed pump and screw it in place.
Install the fuel unions on the feed pump.

Flat Rate: 23341

88

Group: 23 Fuel system

Repair instructions

Hand pump, changing

1
Put a rag under the filter housing bracket to collect
spilled fuel. Undo the secondary filter (1). This must
be sorted as environmentally hazardous waste.
Undo the fuel unions (2).
Unscrew the hand pump (3) and remove it.

2
Put a new secondary filter in the new hand pump.

Install the hand pump on the bracket.

Screw the fuel unions tight.
Vent the fuel system, please refer to Fuel System,
Venting.

89

Repair instructions

Group: 23 Fuel system

Flat Rate: 23080

Fuel system, venting

1

Open the vent screw (1) located above the fuel filter
bracket.
NOTE! Check whether the copper washer on the
vent screw needs to be changed.
2
Press the hand pump (2) located on the fuel filter
bracket until fuel with no air bubbles comes out of the
vent screw. Keep pumping at the same time as the
vent screw is closed.
Pump another 10 strokes.
3
Wipe up the fuel that has run out.
Start the engine and check sealing.

90

Group: 26 Cooling system

Repair instructions

Coolant
Mixing
WARNING! All glycol is hazardous and pollutes
the environment. Flammable. Do not swallow it!
Mix:
40% Volvo Penta Coolant (conc. coolant)
60% water
This mixture prevents against internal corrosion,
cavitation and frost bursting down to about 28C.
(At 60% glycol concentration, the freezing point is
lowered to 54C.) Never mix more than 60% con
centrate (Volvo Penta Coolant) in the coolant. This
will give reduced frost protection and poorer cooling
effect, with a consequent risk of overheating.
IMPORTANT! The coolant must be mixed with
pure water, use distilled de-ionized water.
IMPORTANT! It is extremely important that the
correct concentration of coolant is put in the
system. Mix in a separate clean vessel before
filling the cooling system. Make sure that the
liquids mix.

Filling the coolant

Flush the cooling system clean before new coolant is

added.
Close all drain points and fill up with coolant to the
correct level.

The engine must be stationary when the cooling

system is filled, and must not be started until the
system is vented and completely filled. If a heat
ing unit is connected to the engine cooling system,
the heat control valve should be fully opened and the
installation vented during filling.
Check all hoses and joints, and rectifyany leaks.
Fill the system slowly! Filling must not be done so
fast that air locks are formed in the system. The air
should be allowed to flow out through the filling open
ing. Check the coolant level after the engine has
been run for about an hour. Top up with coolant as
necessary.

Checking the coolant level

WARNING! Do not open the filler cap when the
engine is warm, except in emergencies. Steam
or hot fluid could spray out.
Turn the filler cap to the first stop and allow any ex
cess pressure to hiss out before removing the cap
completely. Top the coolant up as necessary. The
level must be between the MAX and MIN markings.

91

Repair instructions

Group: 26 Cooling system

Pressure valve in filler cap,

checking

Special tools: 9996662

1. Drain some of the coolant and connect the pres
sure testing device to a nipple or other plugged
hole in the cooling system.
2. Extend the drain hose from the filler pipe with a
hose which ends up in a water - filled vessel.
3. Increase the pressure and read the pressure
gauge when the valve opens (water bubbles into
the vessel with the drain hose). The valve should
open at 0.075 MPa.
4. Remove the test equipment. Install the plug and
fill the engine up with coolant.

Fault causes, cooling system

Too low coolant temperature

Low coolant temperature can be caused by:

Faulty thermostat.

Faulty temperature sensor or instrument.

Low engine loading.

Excessive coolant temperature

Excessive coolant temperature (warning lamp lights

up) can be caused by:
Blocked sea water inlet or sea water filter.

Defective impeller in the sea water pump.

Too low coolant level, air in the fresh water sys

tem.

Slipping or broken vee belt for the coolant pump.

Faulty thermostat, temperature sensor or instru

ment.

Blocked cooling system.

Incorrectly set injection advance in the injection

pump.

Filler cap gasket does not seal.

Coolant losses

There are two types of coolant losses:

Coolant losses during operation.

Coolant losses after stopping a hot engine.

Coolant losses during operation can be caused by

poor sealing in the coolingsystem, or that air or com
bustion gases are forced into the cooling system and
force coolant out through the pressure cap.

92

Group: 26 Cooling system

Repair instructions

Flat Rate: 26271

Thermostat, change
1

Drain the coolant.

Undo the thermostat housing (1). Remove the O-ring
from the cap.
Remove the thermostat (2) and seal.
2

Install a new thermostat and seal.

Install the thermostat housing cover with a new
O-ring. Tighten the screws to the specified torque,
please refer to Technical Data.

3
Fill up with coolant.
Warm up, and check the sealing and coolant level.

93

Repair instructions

Group: 26 Cooling system

Heat exchanger, cleaning

Drained cooling system and sea water. Air filter
housing removed. Expansion tank and bracket
removed (D130 and D240)
1
Undo the heat exchanger end wall on the alternator
side.
Remove the exhaust pipe elbow (1) and hose clamp
(2) from the heat exchanger end wall. Remove the
exhaust pipe elbow.
Undo the other end wall (3) from the heat exchanger.

2
Take the insert out (1) and scrap it.

3
Install new O-rings (1) on the insert end wall.
Slide the insert in from the alternator side. Screw the
end wall onto the heat exchanger.
4
Install new O-rings (2) on the insert and end wall.
Screw the end wall onto the heat exchanger.
Install the exhaust pipe bend.
5
Fill up with coolant. Check the fluid level and sealing
after warming up.

94

Group: 26 Cooling system

Repair instructions

Heat exchanger/exhaust
manifold, changing
Current cut off with the main switch. Drained
cooling system and sea water. Expansion tank
and bracket removed (D130, D240).
1
Undo the hose union on the exhaust pipe elbow.
Unscrew the distribution box (1) and fold it to one
side.

2
Undo the hose connections (1).
Undo the screws (2) and carefully prise the heat ex
changer/exhaust manifold away.
Remove the gasket.

Clean the sealing surfaces of the cylinder head.

Transfer the exhaust pipe elbow to the new heat ex
changer/exhaust manifold.
Install the new heat exchanger/exhaust manifold and
gasket. Start to tighten the screws from the center
and then outwards. Torque to 10 Nm.
Install the distribution box on the exhaust manifold.

4
Install the hose unions and junction to the exhaust
pipe elbow.
Fill up with coolant.
Warm up, and check the sealing and coolant level.

95

Repair instructions

Group: 26 Cooling system

Flat Rate: 26652

Seawater pump, impeller

change
Close sea cock
1
Unscrew all screws on the cover (1).

2
Remove the impeller (1) with water pump pliers.

3
Clean the pump housing and sealing surfaces.
4
Grease the new impeller and housing. Put the impel
ler and a new gasket in the housing.
Screw the cover down.
Open the sea cock and start the engine. Check the
sealing.

96

Group: 26 Cooling system

Repair instructions

Flat Rate: 26612

Sea water pump, change

Close sea cock

1
Undo the hose connections (1) for the seawater
pump.
Undo the four screws (2) which hold the seawater
pump.

2
Remove the seawater pump and the O-ring.
Check the mating surfaces.

NOTE! Check the seawater pump gear wheel. If it is

damaged, the idler gear must be changed as well.

3
Install a new sea water pump and O-ring.
Install the screws and hose unions.
Open the sea cock and run the engine. Check the
sealing.

97

Repair instructions

Group: 26 Cooling system

Flat Rate: 26211

Coolant pump, change

1

Drain the coolant.

Undo the hose connections (1) for the coolant pump.
Loosen the tension (2) on the drive belt and remove
it.

2
Undo the temperature sensor connector (1).
Loosen the screws (2) and nut (3) which hold the
coolant pump and alternator stay (4).
Remove the coolant pump and alternator stay.
D1-13:

Also remove the spacer which is located between the

coolant pump and engine block.

3
Clean the sealing surfaces.
Transfer the temperature sensor, hose union and pul
ley to the new coolant pump.

4
Install the new coolant pump with new seals, spacer
(D113) and alternator stay.
Install and tension the drive belt.
Install the hose connections.
5
Fill up with coolant.
Warm up, and check the sealing and coolant level.

98

Group: 30 Electrical system

Repair instructions

Flat Rate: 32111

Alternator, changing
Current cut off with the main switch
1
Mark and undo all electric connections to the alterna
tor.
2
Loosen the upper fixing nut (1).
Undo the tension screw (2) to release the upper fix
ing screw (3) for the alternator.
Unscrew the lower fixing screw (4) and remove the
alternator.

3
Put the new alternator in position and tighten the
lower fixing screw. Tighten it loosely.
Put the upper fixing screw in position and lightly
tighten the upper fixing nut. Screw the tension screw
into the fixing screw.
Put the drive belt in place and tension it with the ten
sion screw.
IMPORTANT! D130, D240: Be careful to
ensure that the alternator belt is placed in the
groove closest to the alternator.

D1-30, D2-40

4
After checking the drive belt tension, tighten the low
er fixing screw and upper fixing nut.
Install the electric connections on the alternator.

99

Repair instructions

Group: 30 Electrical system

Flat Rate: 33111

Starter motor, changing

Current cut off with the main switch. Alternator
removed (D113).
1
Undo all electric connections (1) to the start solenoid.
2
Undo the screws (2) which hold the starter motor.
Lift the starter motor out.

3
Put the new starter motor in position and fix it with
the screws.
Install the electric connections on the starter motor.
4
Switch the current on and check the starter motor
function.

100

Wiring diagram

Wiring diagram

Engine

1. Battery
2. Starter motor
3. Alternator
4. Main switch
5. Glow plugs
6. Oil pressure monitor
7. Stop solenoid
8. Coolant temperature monitor
9. Coolant temperature sensor
10. Circuit breaker, 16 A
11. Starter relay
12. Glow plug relay
13. Charge sensing resistor, 33 Ohm/9W
14. Engine speed sensor

Cable colors
BL = Blue
LBL = Light blue
BN = Brown
LBN = Light brown
GN = Green
GR = Gray

OR = Orange
R
= Red
SB = Black
W = White
Y = Yellow

Cable areas in mm2 are specified after the color code in the wiring schedule.
Cable areas not specified = 1.5 mm.
Cables shown with broken lines are not supplied by Volvo Penta.

101

Wiring diagram

Instrument panel, alternative A *

* (without starter switch)

1.
2.

3.

Instrument illumination
Tachometer with build-in hours counter (optional)
Or blanking plug
Connector for connecting extra warning display (optional
equipment)
4. Electronic unit (alarm)
5. Warning lamp, coolant
temperature
6. Warning lamp, oil pressure
7. Charge warning lamp
8. Indication lamp, glow plugs
9. Starter button
10. Press switch. Instrument panel, On/Off
11. Connector for connecting extra neutral position switch
(optional equipment)
12. Semiconductor diode
13. Alarm
14. Tumbler switch. Glow plugs Alarm test/Acknowledgment
15. 16-pin connector

102

Cable colors
BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
PU = Purple
R = Red
SB = Black
W = White
Y = Yellow
Cable areas in mm2 are specified after the color
code in the wiring schedule.

Wiring diagram

Instrument panel, alternative B *

* (with starter switch)

Spring biased

Spring biased

Cable colors

BL = Blue
BN = Brown
GN = Green
GR = Gray
OR = Orange
R = Red
SB = Black
VO = Violet
W = White
Y = Yellow

1.
2.

3.

Instrument illumination
Tachometer with build-in hours counter (optional)
Or blanking plug
Connector for connecting extra warning display (optional
equipment)
4. Electronic unit (alarm)
5. Warning lamp, coolant temperature
6. Warning lamp, oil pressure
7. Charge warning lamp
8. Indication lamp, glow plugs
9. Switch, instrumentlighting
10. Switch - Alarm test/Acknowledgment
11. Key switch
12. Alarm
13. Connector for connection of neutral positionswitch (optional
equipment)
14. 16-pin connector

Cable areas in mm2 are specified after the color code in

the wiring schedule.

103

Technical data

Group 20 Technical data

General

Engine designation.................................................................. D1-13-A D1-20-A D1-30-A D2-40-A

Number of cylinders................................................................ 2
3
3
4
Cylinder diameter, mm (in)..................................................... 67 (2.64) 67 (2.64) 77 (3.03) 77 (3.03)
Stroke length, mm (in)............................................................. 72 (2.83) 72 (2.83) 81 (3.19) 81 (3.19)
Displacement, total litres (cu.in).............................................. 0.51 (31) 0.76 (46.5) 1.13 (69.1) 1.51 (92.1)
Power......................................................................................
See sales literature
Idling speed, rpm ....................................................................
850 25
Rated speed, rpm....................................................................
3200
Compression ratio................................................................... 23.5:1
23.5:1
23:1
23.5:1
Compression at 250 rpm, repair limit, kPa (psi)......................
2450 (355)
Firing order (highest cyl. No. closest to flywheel).................... 1-2
1-2-3
1-2-3
1-34-2...........................................................................................
Direction of rotation see from front..........................................
Clockwise
Max. forward inclination...........................................................
0o
Max. permissible angle backwards during operation..............
25o
Max. side angle during operation............................................
35o
Valve clearance, idle cold engine:
inlet and outlet, mm (in)........................................................
0.20 (0.008)
Weight, engine without oil and water, kg (lb)........................... 96 (212) 118 (260) 127 (280) 148 (326)
Permitted backpressure in exhaust line, kPa (psi)..................
20 (2.9)

Pistons

Material.................................................................................... Aluminium Alloy

Diameter, mm (in)
D1-13-A, D1-20-A.................................................................... 66.9375 66.9525 (2.6353 2.6359)
Service limit........................................................................ 66.7 (2.6260)
D1-30-A, D2-40-A.................................................................... 76.932 76.947 (3.0288 3.0294)
Service limit........................................................................ 76.7 (3.020)
Piston clearance to the cylinder, mm (in)
D1-13-A, D1-20-A.................................................................... 0.048 0.082 (0.0019 0.0032)
Service limit........................................................................ 0.25 (0,010)
D1-30-A, D2-40-A.................................................................... 0.0525 0.0865 (0.00210 0.00340)
Service limit........................................................................ 0.25 (0,010)
Front marking The SHIBAURA name on the inside of the

piston must be facing the fuel pump
on assembly

Piston rings

Compression ring, number...................................................... 2

Oil ring, number....................................................................... 1
Top compression ring:
Clearence between groove and ring, all engines, mm (in)..... 0.06 0.10 (0.0024 0.0039)
Service limit, all engines , mm (in)...................................... 0.25 (0.0098)
Gap of piston ring, mm (in)
D1-13-A, D1-20-A.................................................................... 0.13 0.25 (0.0051 0.0098)
D1-30-A, D2-40-A.................................................................... 0.15 0.27 (0.0059 0.0106)
Service limit, allengines, mm (in)........................................ 1.0 (0.039)
2nd compression ring:
Clearence between groove and ring, all engines, mm (in)..... 0.05 0.09 (0.0020 0.0035)
Service limit, all engines, mm (in)....................................... 0.25 (0.0098)
Gap of piston ring, mm (in)
D1-13-A, D1-20-A.................................................................... 0.10 0.22 (0.0039 0.0087)
D1-30-A, D2-40-A.................................................................... 0.12 0.24 (0.0047 0.0094)
Service limit, all engines, mm (in)....................................... 1.0 (0.039)
104

Technical data

Oil ring:
Clearence between groove and ring, all engines, mm (in)..... 0.02 0.06 (0.0008 0.0024)
Service limit, all engines..................................................... 0.15 (0.0059)
Gap of piston ring, mm (in)
D1-13-A, D1-20-A.................................................................... 0.10 0.30 (0.0039 0.0118)
D1-30-A, D2-40-A.................................................................... 0.20 0.35 (0.0079 0.0138)
Service limit, all engines..................................................... 1.0 (0.039)

Piston pins

Diameter, mm (in)
D1-13-A, D1-20-A.................................................................... 18.998 19.002 (0.7480 0.7481)
Service limit........................................................................ 18.98 (0.7472)
D1-30-A, D2-40-A.................................................................... 20.996 21.002 (0.8266 0.8269)
Service limit........................................................................ 20.98 (0.826)
Clearence between hole and pin, all engines, mm (in).......... 0.004 to +0.004 (0.00016 to +0.00016)
Service limit........................................................................ 0.02 (0.0008)

Cylinder block

Diameter of the bore in the cylinder block, mm (in):

D1-13-A, D1-20-A....................................................................
Service limit........................................................................
D1-30-A, D2-40-A....................................................................
Service limit........................................................................
Flatness of the top of the cylinder block, mm (in)....................
Service limit........................................................................

Cylinder head

Distortion of the cylinder head, mm (in)...................................

Max. service limit, mm (in)..................................................
Max. limit for regrinding the cylinder head, mm (in)...........
Selection of cylinder head gasket:
Piston height above top face of cylinder block, mm (in)..........
Choose gasket with thickness, mm (in)..............................
Piston height above top face of cylinder block, mm (in)..........
Choose gasket with thickness, mm (in)..............................

67.000 67.019 (2.6378 2.6385)

67.200 (2.6457)
77.000 77.019 (3.0310 3.0320)
77.200 (3.0390)
Less than 0.05 (0.002)
0.12 ( 0.005)

0.00 0.05 (0.000 0.002)

0.12 (0.005)
0.15 (0.006)
0.55 0.64 (0.0217 0.0252)
1.2 (0.047)
0.65 0.75 (0.0256 0.0295)
1.3 (0.051)

Rocker shaft

Diameter of the rocker shaft, mm (in):

D1-13-A, D1-20-A....................................................................
Service limit........................................................................
D1-30-A, D2-40-A....................................................................
Service limit........................................................................
Rocker arm clearance on the rocker shaft, mm (in):
D1-13-A, D1-20-A, Min. permissible clearance.......................
D1-30-A, D2-40-A, Min. permissible clearance.......................
Max. permissible clearance, all engines..................................

9.950 9.968 (0.3917 0.3924)

9.87 (0.3886)
11.65 11.67 (0.4587 0.4595)
11.57 (0.4555)
0.032 0.065 (0.00126 0.00260)
0.032 0.068 (0.00126 0.00268)
0.2 (0.008)

105

Technical data

Crankshaft

Thrust washers:
Standard thickness, mm (in).................................................... 21.85 21.95 (0.8602 0.8642)
Service limit........................................................................ 21.60 (0.8504)
NOTE! The thrust washers is machined into the holder for the main bearing
Crankshaft end play, mm (in)................................................... 0.10 0.30 (0.0040 0.0118)
Service limit........................................................................ 0.50 (0.0197)
Crankshaft deflection, mm (in)................................................ 0.30 or less (0.0011)
Service limit........................................................................ 0.06 (0.0023)
Front crankshaft bush, diameter in mm (in), bearing journal :
Standard, D1-13-A and D1-20-A......................................... 42.964 42.975 (1.69150 1.69193)
Service limit................................................................... 42.90 (1.6890)
Standard, D1-30-A and D2-40-A......................................... 47.965 47.975 (1.88830 1.88880)
Service limit................................................................... 47.90 (1.8858)
NOTE! No undersize bush bearing journals are available

Main bearing journals

D1-13-A
Diameter in mm (in), standard, bearing journal

No. 1....................................................
Service limit....................................

No. 2....................................................
Service limit....................................
NOTE! No undersize main bearing journals are available
D1-20-A
Diameter in mm (in), standard, bearing journal

No. 1 and 2..........................................
Service limit....................................

No. 3....................................................
Service limit....................................
NOTE! No undersize main bearing journals are available
D1-30-A
Diameter in mm (in), standard, bearing journal

No. 1 and 2..........................................
Service limit....................................

No. 3....................................................
Service limit....................................
NOTE! No undersize main bearing journals are available
D2-40-A
Diameter in mm (in), standard, bearing journal

No. 1, 2 and 3......................................
Service limit....................................

No. 4....................................................
Service limit....................................
NOTE! No undersize main bearing journals are available
Clearance between the main bearing and the main
bearing journal, standard clearance:
D1-13-A, Journal No. 1............................................................
D1-13-A, Journal No. 2............................................................
D1-20-A, Journals No. 1 and 2................................................
D1-20-A, Journal No. 3............................................................
D1-30-A, D2-40-A....................................................................
Service limit, all engines..........................................................

106

42.964 42.975 (1.69150 1.69193)

42.90 (1.6890)
45.948 45.959 (1.80897 1.80941)
45.90 (1.8071)

42.964 42.975 (1.69150 1.69193)

42.90 (1.6890)
45.948 45.959 (1.80897 1.80941)
45.90 (1.8071)

47.965 47.975 (1.88830 1.88880)

47.90 (1.8858)
47.954 47.965 (1.88800 1.88830)
47.90 (1.8858)

47.965 47.975 (1.88830 1.88880)

47.90 (1.8858)
47.954 47.965 (1.88800 1.88830)
47.90 (1.8858)

0.035 0.088 (0.0014

0.039 0.092 (0.0015
0.039 0.106 (0.0015
0.039 0.092 (0.0015
0.039 0.106 (0.0015
0.20 (0.0079)

0.0035)
0.0036)
0.0042)
0.0036)
0.0042)

Technical data

Connecting rod bearing journals

D1-13-A, D1-20-A
Diameter in mm (in), bearing journal
Standard........................................................................ 34.964 34.975 (1.3765 1.3770)

Service limit........................................................... 34.90 (1.3740)
NOTE! No undersize rod bearing journals are available
D1-30-A, D2-40-A
Diameter in mm (in), bearing journal
Standard........................................................................ 40.964 40.975 (1.6128 1.6132)

Service limit........................................................... 40.90 (1.6102)
NOTE! No undersize rod bearing journals are available
Clearance between the connecting rod bearing and the
connecting rod bearing journal, standard clearance:
D1-13-A, D1-20-A.................................................................... 0.031 0.079 (0.00122 0.00311)
D1-30-A, Journals No. 1 and 2................................................ 0.039 0.092 (0.00150 0.00360)
D1-30-A, Journal No. 3............................................................ 0.029 0.082 (0.00110 0.00320)
D2-40-A...................................................................................
0.039 0.092 (0.00150
0.00360)
Service limit, all engines.......................................................... 0.20 (0.0079)

Connecting rods

Piston pin bearing:

Clearance between the piston pin and the piston pin
bearing, mm (in)......................................................................
Service limit, D1-13-A, D1-20-A.........................................
Service limit, D1-30-A, D2-40-A.........................................
Connection rod bearing:
Clearance between the connecting rod bore and
the connecting rod bearing, mm (in)........................................
Service limit........................................................................

0.010 0.025 (0.00040 0.00099)

0.10 (0.004)
0.08 (0.0031)
0.10 0.30 (0.004 0.012)
0.70 (0.0276)

107

Technical data

Camshaft

Drive........................................................................................
Height of the camshaft lobe for the inlet and outlet valves,
all engines, mm (in).................................................................
Service limit........................................................................
Height of the camshaft lobe for the fuel injection pump,
all engines, mm (in).................................................................
Service limit........................................................................
Height of the camshaft lobe for the fuel priming pump,
all engines, mm (in).................................................................
Service limit........................................................................

Gear Wheel
26.955 27.010 (1.0612 1.0634)
26.5 (1.0430)
39.900 40.100 (1.5709 1.5787)
39.8 (1.5669)
27.900 28.000 (1.0984 1.1024)
27.0 (1.0630)

Valves
Inlet

Spindle diameter in mm (in).................................................... 6.955 6.970 (0.27382 0.27441)

Service limit........................................................................ 6.89 (0.271)
Valve disc edge in mm (in)...................................................... 0.925 1.075 (0.03642 0.04232)
Service limit........................................................................ 0.5 (0.02)
Valve depth below the cylinder head face in mm (in).............. 0.65 0.95 (0.0256 0.0374)
Service limit........................................................................ 1.8 (0.071)
Clearance in mm (in), valve spindle guide.............................. 0.025 0.052 (0.0010 0.0020)
Service limit........................................................................ 0.2 (0.008)
Seat angle in cylinder head..................................................... 45o
Seat contact face in cylinder head.......................................... 1.70 2.10 (0.0670 0.0830)
Service limit, mm (in).......................................................... 2.5 (0.098)
Valve lash in mm (in), cold engine........................................... 0.20 (0.008)
Outlet
Spindle diameter in mm (in).................................................... 6.940 6.950 (0.27323 0.27362)
Service limit, mm (in).......................................................... 6.84 (0.269)
Valve disc edge in mm (in)...................................................... 0.925 - 1.075 (0.03642 - 0.04232)
Service limit, mm (in).......................................................... 0.5 (0.02)
Valve depth below the cylinder head face in mm (in).............. 0.85 1.15 (0.0335 0.0453)
Service limit, mm (in).......................................................... 1.8 (0.071)
Clearance in mm (in), valve spindle guide.............................. 0.045 0.072 (0.0020 0.0030)
Service limit, mm (in).......................................................... 0.25 (0.010)
Seat angle in cylinder head..................................................... 45o
Seat contact face in cylinder head.......................................... 1.70 2.10 (0.0670 0.0830)
Service limit, mm (in).......................................................... 2.5 (0.098)
Valve lash in mm (in), cold engine........................................... 0.20 (0.008)

Valve springs

Length in mm (in) uncompressed............................................ 35.0 (1.377)

Length in mm (in) with 79.4 N (58.56 ft.lbf) compression........ 30.4 (1.196)

108

Technical data

Gear group

Max. backlash for all gears, mm (in)....................................... 0.25 (0.010)

Min. backlash for all gears, mm (in)........................................ 0.08 (0.003)

Lubrication system

Oil pressure in kPa (psi), hot engine at high idle..................... 196 441 (28.4 64)
Oil pressure in kPa (psi), hot engine at low idle...................... >48 (7)
Relief valve, opening pressure in kPa (psi)
D1-13-A, D1-20-A ................................................................ 352 448 (51 65)
D1-30-A, D2-40-A ................................................................ 304 500 (44 73)
Oil pump:
Clearance, in mm (in), inner outer rotor............................... 0.01 0.15 (0.0004 0.0059)
Service limit.......................................................................... 0.25 (0.0098)
Axial clearance between the face of oil pump cover
and the face of the idler gear, in mm (in)................................. 0.01 0.15 (0.0004 0.0059)
Service limit.......................................................................... 0.20 (0.008)
Shims available for adjustning the axial clearance, mm...... 0.10, 0.15, 0.20, 0.50
Oil quality as per API system................................................... VDS-2
ACEA E5
API CH-4
Viscosity at -5 to +50C* (+23 to +122F)*............................... SAE 15W/40
SAE 20W/50
Max. oil volume excl. oil filter, no engine tilt, litres (US gal):
D1-13-A................................................................................ 1.9 (0.50)
D1-20-A................................................................................ 2.8 (0.74)
D1-30-A................................................................................ 3.5 (0.92)
D2-40-A................................................................................ 6.5 (1.72)
Oil change interval
D1-13-A, D1-20-A, D1-30-A................................................. 200 h or 12 months
D2-40-A................................................................................ 500 h or 12 months
* Note: Temperatures with stable ambient temperature.

Fuel system

Feed pump max. suction height in m (ft)................................. 0.8 (2.62)

Feed pressure in kPa (lbf/in2) ................................................. 15 25 (2.1 3.6)

Fuel injection pump

Type ........................................................................................ In-line cassete

Start of injection, crankshaft position, B.T.D.C
D1-13-A, D1-20-A, D1-30-A ................................................... 20o 1o
D2-40-A .................................................................................. 22o 1o

D1-13-A D1-20-A D1-30-A D2-40-A
Pump element, diameter in mm (in)........................................ 5 (0.1968) 5 (0.1968) 6 (0.2362) 5.5
(0.2165)................................................................................... Stroke length in mm (in)
6.5
(0.2559) .......................................................................................6.5 (0.2559) 6 (0.2362) 6 (0.2362)
Axial clearance between the face of oil pump cover
and the face of the idler gear, in mm (in)................................. 0.01 0.15 (0.0004 0.0059)
Service limit.......................................................................... 0.20 (0.008)
Shims available for adjustning the axial clearance, mm...... 0.10, 0.15, 0.20, 0.50

109

Technical data

Injector

Opening pressure (checking), MPa (psi)

D1-13-A, D1-20-A, D2-40-A .................................................. 11.77 (1707)
D1-30-A................................................................................... 14.71 (2133)
Jet angle.................................................................................. 4o

Exhaust system

Permitted Max. back pressure in the exhaust line at rated speed,

all engines, kPa (psi)............................................................... 20 (2.9)

Cooling system

Type......................................................................................... Overpressure, closed cooling system

Fresh water system volume, approx, litres (US gal)
D1-13-A................................................................................ 2.7 (0.71)
D1-20-A................................................................................ 3.0 (0.79)
D1-30-A................................................................................ 4.1 (1.08)
D2-40-A................................................................................ 6.4 (1.69)
Thermostat, number................................................................ 1 st
Thermostat begins to open at.................................................. 90oC (194oF)
fully open at.......................................................................... 105oC (221oF)
Coolant, Glycol/water, mixing ratio.......................................... 40/60

Electrical system

System voltage........................................................................ 12 V
Fuse (automatic)..................................................................... 16 A
Battery capacity (starter battery)
D1-13-A, D1-20-A, D1-30-A .................................................. 70 Ah
D2-40-A................................................................................... 88 Ah
Glow plug:
rated voltage......................................................................... 11V
current.................................................................................. 11A

Alternator

Output voltage at +20oC (+68oF)............................................. 14,2 0,15 V

Max. current............................................................................ 115 A
Suppressor capacitor.............................................................. 2.2 mikroF

Starter motor

Starter motor, power approx.

D1-13-A, D1-20-A............................................................... 0.8 kW
D1-30-A.............................................................................. 1.1 kW
D2-40-A.............................................................................. 1.4 kW

110

Technical data

Tightening torque in Nm (ft.lbf)

Cylinder head*
D1-13-A...........................................................................................
D1-20-A...........................................................................................
D1-30-A...........................................................................................
D2-40-A...........................................................................................
Main bearing:
Bolts of the holder for the main bearing..........................................
Retaining bolts for the crankshaft...................................................
Connecting Rod:
D1-13-A, D1-20-A...........................................................................
D1-30-A, D2-40-A...........................................................................
Front housing.....................................................................................
Flywheel backplate:
D1-13-A, D1-20-A...........................................................................
D1-30-A, D2-40-A...........................................................................
Flywheel housing................................................................................
Flywheel.............................................................................................
Crankshaft pulley:
D1-13-A, D1-20-A...........................................................................
D1-30-A, D2-40-A...........................................................................
Flexible coupling.................................................................................
Suction strainer, oil pump...................................................................
Sump..................................................................................................
Drain plug, sump................................................................................
Camshaft, setscrews for retainer plate...............................................
Rocker shaft housing:
D1-13-A, D1-20-A...........................................................................
D1-30-A, D2-40-A...........................................................................
Valve mechanism cover:
Setscrews.......................................................................................
Cap nuts..........................................................................................
Rocker arm locknut............................................................................
Fuel injection pump:
Mounting nuts and screws..............................................................
Delivery valve holders.....................................................................
Pressure oil pipe (cylinder block cylinder head)...............................
Injector................................................................................................
Delivery pipe:
D1-13-A, D1-20-A, D2-40-A............................................................
D1-30-A...........................................................................................
Lock screw (max. fuel volume)...........................................................
Lock screw (speed)............................................................................
Exhaust manifold................................................................................
Fuel shutoff solenoid..........................................................................
Fuel pump:
Adjustment screw............................................................................
Mounting screws.............................................................................
Glow plug...........................................................................................
Oil pressure switch and adapter.........................................................
Coolant temperature switch................................................................
Coolant drain plug (plastic).................................................................
Coolant thermostat housing...............................................................
Oil relief valve.....................................................................................
Starter motor, contacts.......................................................................

36.5 (26.9)
36.5 (26.9)
51 (37.6)
51 (37.6)
23 (16.9)
27 (19.9)
23 (17)
32 (23.6)
10 (7.4)
25 (18.4)
50 (36.9)
25 (18.4)
74 (55)
93 (68.6)
123 (90.7)
8.5 11.5 (6.3 8.5)
11 (8)
11 (8)
34 (25)
11 (8)
9.5 (7)
23 (17)
11 (8)
10 (7.3)
14 (10)
6 (4.4)
42 (31)
12 (9)
64 (47.2)
20 (14.8)
23 (17)
13 16 (9.6 11.8)
13 16 (9.6 11.8)
10 (7.3)
17 (13)
2.5 (1.8)
6 (4.4)
11.5 (8.5)
11 (8)
27 (20)
3 (2.2)
14 (10)
64 (47)
9.8 11.8 (7.2 8.7)

* The tightening torque given is the final tightening torque.

The cylinder head should be tightened in three stages and in the correct sequence. See tightening procedure.
On assembly lubricate cylinder head setscrewes with clean oil.

111

Technical data

General tightening torques in Nm

M5...................................
M6...................................
M7...................................
M8...................................
M10.................................
M12.................................
M14.................................

5 Nm
10 Nm
17 Nm
24 Nm
50 Nm
80 Nm
130 Nm

Tightening sequence
Cylinder head
D2-40

D1-20, D1-30

D1-13

112

Technical data

Conversion table

Metric to American or UK units:

American or UK to Metric units:

To convert
from
To
Multiply by

To convert
from

To

Multiply by

cm

inch

inch

cm

2.540

Area

mm

sq.in.

0.00155

sq. in.

mm

Length

mm

inch

0.03937

foot

3.2808

0.3937

sq. ft.

10.76

inch

mm

foot

sq. ft.

25.40

0.3048

645.2

0.093

Volume

cm

cu. in.

0.06102

cu. in.

cm

liter, dm

cu. in.

61.023

cu. in.

liter, dm

0.01639

liter, dm

3.785

Power

Weight
Power

liter, dm
liter, dm
liter, dm
m

kg

kW

kW
kW

Torque

Nm

MPa

Pa

sq. ft.

imp. gallon

0.2642

lbf

0.2248

cu. ft.

lb.

hp (metric)
BTU/min

lbf ft

mm Wg

kPa

mWg

psi

in Wc

in Wg
in Wg

Energy

kJ/kWh

BTU/hph

MJ/kg

BTU/lb

Work

kJ/kg

kJ/kg

Fuel
g/kWh
consum- g/kWh
ption

1)

bhp

psi

BTU/lb

kcal/kg

g/hph
lb/hph

Inertia

kgm

lbft

Flow,
fluid

m/h

US gal/min

Flow, gas m/h

Speed

Temp.

m/s
mph

0.220

U.S. gallon

Pressure Bar
Pa

0.03531

cu.ft./min.

ft./s
knot

35.315

2.205

cu. ft.

imp. gallon
cu.ft.

lbf

56.87

BTU/min

0.738

145.038

0.102
0.004
4.0

39.37

0.697

0.430
430

0.239

0.736
0.00162
23.734

0.5886
4.403

3.281
0.869

F=9/5 x C+32

1)

bhp

lbf ft

kg

0.454

1.36
kW
kW

Nm

Bar

mm Wg

Pa

in Wg
in Wg
in Wg

4.545

0.0283

psi

psi

28.320

lb.

hp (metric)

14.5038

liter, dm

U.S. gallon

1.36

1.341

liter, dm

16.388

MPa
Pa

kPa

mWg

4.448

0.735

0.7457
0.0176

1.356

0.06895

0.006895

9.807

249.098
0.24908

0.0254

BTU/hph

kJ/kWh

BTU/lb

MJ/kg

0.00233

g/hph
lb/hph

g/kWh
g/kWh

1.36
616.78

lbft

kgm

0.042

US gal/min

m/h

0.2271

BTU/lb

kcal/kg

cu.ft./min.

ft./s
knot

C=5/9 x (F32)

kJ/kg

kJ/kg

m/h

m/s
mph

1.435

2.326

4.184

1.699

0.3048
1.1508

1) All power noted in the catalogue refers to metric horsepower.

113

Notes

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116

References to Service Bulletins

Group No.
Date Refers to
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117

Workshop Manual
Volvo Penta - Engine

North American Headquarters

Polar DC Marine
2250 Avolon Blvd
Carson, Calif 90745
USA
Contact:[email protected]

118

European Headquarters
Polar DC Marine AB
P1 2434
SE-310 50 Sloing
Sweeden
Contact:[email protected]