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
Cam belt, change
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
Tags: d3
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
Cam belt, change
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
Tags: d3