Volvo Penta D4 Installation and user guide

service and maintenance
D4, D6

© 2017 AB VOLVO PENTA
Volvo Penta reserves the right to make changes
Printed on environmentally friendly paper

Table of Content
Safety Information ...................................................................................... 5
Spare parts - safety ................................................................................... 7
General Information .................................................................................. 14
Service Protocol ...................................................................................... 15
Preventive repair ..................................................................................... 16
Genuine Volvo Penta Parts ..................................................................... 23
Illustrations .............................................................................................. 25
Chemical products .................................................................................... 27
Chemical products .................................................................................. 27
Special Tools ............................................................................................. 29
Other Special Equipment ........................................................................ 29
Specifications ............................................................................................ 31
Engine Decals ......................................................................................... 31
Transmission Decals ............................................................................... 32
General Tightening Torques .................................................................... 34
Specifications .......................................................................................... 35
Engine ........................................................................................................ 40
Component location ................................................................................ 41
Maintenance Schedule ............................................................................ 44
General inspection .................................................................................. 45
General advice for electronic protection .................................................. 47
Check software status ............................................................................. 48
Air Filter ................................................................................................... 48
Crankcase Ventilation, Filter Change ...................................................... 49
Compressor, oil level ............................................................................... 50
Compressor oil, Replace ......................................................................... 50
Lubrication System ................................................................................... 52
When you work with Chemicals, Fuel and Lubrication Oil, Change ........ 52
Engine Oil, Level Check .......................................................................... 52
Engine oil, Replace ................................................................................. 54
Oil filter, Replace ..................................................................................... 55
Oil topping up and level check ................................................................ 56
Fuel System ............................................................................................... 64
General ................................................................................................... 64
Fuel filter, Change ................................................................................... 65
Fuel pre-filter ........................................................................................... 66
Fuel system, bleeding ............................................................................. 68
Exhaust System ........................................................................................ 71
Exhaust hose .......................................................................................... 71
Turbocharger, Inspection ........................................................................ 72
Cooling System ......................................................................................... 74
Coolant Level, Checking and Topping Up ............................................... 74
Drive Belt, Replace ................................................................................. 77
Seawater Pump, Impeller, Change ......................................................... 80
Seawater Filter, Check and Cleaning ...................................................... 82
Anodes .................................................................................................... 84
Transmission ............................................................................................. 86
IPS ........................................................................................................... 86
IPS ....................................................................................................... 86
Oil drain, IPS ........................................................................................ 88
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Oil filter, IPS ......................................................................................... 88
Oil filler, IPS ......................................................................................... 89
IPS, oil level ......................................................................................... 89
Anode, exhaust outlet (IPS) ................................................................. 90
Propeller ............................................................................................... 91
Propeller shaft seals, replacement ....................................................... 92
Transmission: Oil strainer, inner and outer .......................................... 92
Anodes ................................................................................................. 93
Painting IPS Drives .............................................................................. 94
Reversing gear ....................................................................................... 95
Reversing gear, oil and filter change .................................................... 95
Sterndrive ............................................................................................... 99
Valve block, oil filter, change .............................................................. 101
Sterdrive, hydraulic fluids ................................................................... 103
Sterndrive, oil level ............................................................................. 104
Sterndrive, Draining ........................................................................... 107
Sterndrive, Oil Filling .......................................................................... 109
Sterndrive bellows .............................................................................. 111
Propeller ............................................................................................. 112
Checking Protective Anodes .............................................................. 113
Painting the Drive ............................................................................... 115
Long-Term Storage ................................................................................. 117
Storage instruction for long-term storage of new engine ....................... 119
Cleaning engine and transmission ........................................................ 121
Cold Weather Precautions .................................................................... 123
Checklist ................................................................................................ 125
Battery, Maintenance ............................................................................ 126
Index ......................................................................................................... 129
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Safety Information
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Safety Information
This chapter describes how safety precautions are
presented in the manual and on the product. Read the
chapter through very carefully before you start the
engine or do any maintenance or service. It has to do
with your safety; an incorrect operation can lead to
personal injury and damage to products or property. It
also gives you an introduction to the basic safety rules
for using and looking after the engine.
If anything remains unclear or if you are unsure of
something, contact your Volvo Penta dealer for
assistance.
IMPORTANT:
Always follow local safety instructions and
regulations.
Safety texts have the following order of priority:
DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.
WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT:
Indicates a situation, which, if not avoided, could result in property damage.
NOTICE! Used to draw attention to important information that facilitates work or
operations.
!
This symbol is may be used on the product to call your attention to the fact that this is
safety information. Always read such information very carefully.
Make sure that warning and information symbols on the engine are clearly visible and
legible. Replace symbols that have been damaged or have been painted over.
In some cases, this symbol is used on our products and refers to important information
in the Operator’s Manual.
Safety Information
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Most chemicals such as engine and transmission oils,
glycol, petrol and diesel oil and chemicals used in
workshops such as degreasing agents, paint and
solvents are harmful to health.
Carefully read the instructions on the product
packaging! Always follow the safety regulations, such
as the use of protective masks, goggles, gloves, etc.
Make sure that other personnel are not exposed to
substances that are hazardous to health. Ensure good
ventilation.
Manage used and leftover chemicals in the prescribed
manner.
Personal safety equipment
CAUTION!
Always use appropriate safety equipment. Personal
protective equipment does not eliminate the risk of
injury but it will reduce the degree of injury if an
accident does happen.
Some examples are ear protection, eye and face
protection, protective footwear, personal protective
equipment, head protection, protective clothing,
gloves and respirators.
WARNING!
Ensure that all machine guards and safety devices are
in place and are functional.
CAUTION!
Never use tools or products that show signs of
damage.
Protect your eyes
CAUTION!
Wear safety glasses.
Always wear safety glasses if there is a risk of
splintering, sparks and spray from the electrolyte (so-
called battery acid), or other chemicals. Your eyes are
very delicate and damage can result in loss of sight!
Protect your skin
CAUTION!
Risk of skin damage.
Avoid getting oil on your skin! Prolonged or repeated
exposure to oil can dry out the skin. Thereafter,
irritation, dryness and eczema and other skin problems
may occur.
Use protective gloves and avoid oil-soaked clothes
and rags. Wash regularly, especially before eating.
Wear suitable protective creams to prevent skin from
drying out and to facilitate cleaning.
P0024482
Safety Information
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Fire safety
WARNING!
Fire and Explosion Risk!
Accidental spark could ignite fuel vapors.
All fuels – as well as many lubricants and chemicals –
are flammable. Do not allow open flames or sparks
near them. Smoking forbidden! Hydrogen from the
batteries is also very flammable and explosive in
certain mixture with air.
Ensure that the workplace is well ventilated and take
the necessary precautions before welding or grinding
begins. Always ensure that there is a fire extinguisher
close at hand in the work area.
Spare parts - safety
WARNING!
Always use Volvo Penta genuine spare part to
minimize the risk of an explosion or fire.
Components in fuel systems and electrical systems on
Volvo Penta engines are designed and manufactured
to minimize the risk of explosions and fire, in
accordance with applicable legal requirements.
Used oils, filters and chemicals etc.
WARNING!
Risk of fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire.
Oil-soaked rags can spontaneously ignite under
certain circumstances.
IMPORTANT:
Used fuel and oil filters are environmentally hazardous
waste and must be taken to an approved waste
management facility for correct handling, as must any
used lubricating oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
Prevent start of the engine
WARNING!
Immobilize the engine by turning off the power supply
with the main switch(es) and lock it (them) in the off
position before starting work. Place a warning notice at
the main switch.
If the engine is equipped with BMS (Battery
Management System), always disconnect both battery
cables from the battery terminals.
P0024470
Safety Information
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Ventilation when running the engine
WARNING!
Only start the engine in a well-ventilated area. If
operating the engine in a closed area ensure that there
is exhaust ventilation leading out of the work area to
remove exhaust gases and crankcase ventilation
emissions.
The engine must not be operated in areas where there
are explosive materials or stored gas.
Rotating parts and hot surfaces
DANGER!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
If the engine is in operation and operates another
device, you must not, under any circumstances,
staying close to the engine.
Work on running engines is strictly prohibited. There
are however adjustments that require the engine to be
run. Approaching a running engine is a safety risk.
Loose clothing and long hair can get caught in the
rotating parts; careless movements or a dropped tool
can lead to serious personal injury.
Be careful to avoid hot surfaces (exhaust pipes,
turbochargers, charge air manifolds, start elements
etc.) and hot fluids in pipes and hoses on engines that
are running or have just stopped. Re-install all
protective covers that were removed during
maintenance work before starting the engine.
Information on the engine
IMPORTANT:
Make sure that all warning and information decals on
the product are always visible. Replace decals which
have been damaged or painted over.
P0024481
P0024808
Safety Information
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Prohibition on use of start spray
WARNING!
Never use start spray or similar agents to start an
engine. This may cause an explosion in the inlet
manifold. Risk of personal injury.
Before start of engine
WARNING!
Never start the engine if there is reason to suspect fuel
and/or gas leaks, or if there is explosive material
nearby.
IMPORTANT:
Only start the engine with the air filter and protective
caps fitted. Foreign objects in the inlet line could cause
machine damage. Also make sure that no tools or other
parts have been left next to the engine.
WARNING!
Never start the engine with the valve cover removed.
There is a risk of personal injury.
For engines with turbochargers, the rotating
compressor turbine can in addition cause serious
personal injuries.
Before any work on the electrical system
WARNING!
Always stop the engine first. Then disconnect the
current at the main switches and any external power
supply before working on the electrical system – to
minimize the risk of electrical hazards.
IMPORTANT:
Never disconnect the current using the main switches
when the engine is running or by disconnecting the
battery cables.
The alternator and electronics could be damaged.
Avoid damage to the engine control
module and other electronics
IMPORTANT:
Switch off the main switch before connecting or
disconnecting a connector.
Before any work on the cooling system
WARNING!
Stop the engine and let it cool before starting work on
the cooling system. Hot fluids and hot surfaces can
cause burns.
P0024483
P0024688
Safety Information
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Risk of water penetration/sinking
WARNING!
If a launched boat is equipped with sea water tap and
safety valve, ensure that these are closed before any
work is allowed to begin on the cooling system.
Remember to open the tap and valve before starting
the engine!
Hot coolant under pressure
CAUTION!
Hot coolant can cause burns. Avoid opening the filler
cap for the coolant when the engine is still hot. Steam
or hot coolant can spray out and system pressure is
lost.
Open the filler cap slowly, and release the pressure in
the cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose must be removed
from a hot engine.
Hot oil under pressure
CAUTION!
Hot oil can cause burns. Avoid getting hot oil on the
skin. Ensure that the lubrication system is not
pressurized before starting any work. Never start or
operate the engine without the oil filler cap is on. There
is a risk that hot oil can spray out.
At any leak detection on the fuel system
WARNING!
Wear safety goggles!
Be extremely careful when searching for leaks in the
fuel system high-pressure circuits. There is very high
pressure in the jet from pipes and injectors. The fuel
may penetrate the tissue and cause serious risk of
blood infection (septicemia).
Handling of fuel pipes
IMPORTANT:
High pressure pipes for fuel must not be bent or
straightened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.
Before any work on the fuel system —
Cleanliness
IMPORTANT:
Take great care to keep the fuel system components
clean. Even minimal amounts of dirt can cause engine
breakdown.
P0024484
P0024488
Safety Information
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Safe handling of batteries
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.
A spark caused by an incorrectly connected battery
can be sufficient for the battery to explode resulting in
serious injury and damage.
Do not touch the connections during a starting attempt.
Spark hazard! Do not lean over batteries.
Correct polarity of the batteries
IMPORTANT:
Make sure that the positive (+) and negative (–) battery
cables are correctly connected to the corresponding
battery terminals. Wrong connection may cause
severe damage to electrical equipment.
Risks of electrolyte in batteries
WARNING!
Always wear protective goggles when charging or
handling batteries.
Battery electrolyte is highly corrosive.
Rinse immediately with copious amounts of water if the
electrolyte gets in your eyes. Search directly after the
rinsing help by medical staff.
If it comes electrolyte to unprotected skin, wash
immediately with soap and water.
After finished work with the engine
IMPORTANT:
Always perform a leakage and function check.
Cleaning the engine and components
NOTICE! Follow the instructions Cleaning engine and
transmission, page 121.
Cleanliness for sensitive components
IMPORTANT:
Observe meticulous cleanliness when handling
system components.
Even minimal amounts of dirt could cause a
breakdown.
P0024468
P0026213
Safety Information
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Lifting the engine
WARNING!
Never work alone when removing heavy components,
even when using lifting devices such as locking tackle
lifts.
IMPORTANT:
When using a lifting device, two people are usually
required to do the work – one to take care of the lifting
device – and the other to ensure that components are
lifted clear and not damaged during the lifting
operations.
Proper lifting equipment
DANGER!
The existing lugs on the engine should be used for
lifting. Always check that the lifting equipment used
is in good condition and has the load capacity to lift
the engine (engine weight including transmission and
extra equipment). For safe handling and to avoid
damaging components fitted to the top of the engine,
the engine must be lifted with a correctly adjusted lifting
boom.
Never perform any work on an engine that is only
suspended from the lifting equipment.
IMPORTANT:
All chains or wires must run parallel to each other and
as perpendicular to the engine as possible. If other
equipment attached to the engine has altered its center
of gravity, special lifting devices may be needed to
obtain the correct balance for safe handling.
P0024485
P0024689
Example of an adjustable lifting yoke and a lifting tool.
General Information
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General Information
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General Information
General information
This service and maintenance manual contains
descriptions and instructions for the service of the
above-mentioned Volvo Penta products in their
standard models. The design and servicing items may
vary between different products. Applicable service
intervals and service procedures are described in the
maintenance schedule for the product.
The product designation, serial number and
specification are indicated on the engine decals or
type plate. This information must always be provided
in all correspondence concerning the product.
The manual has been produced primarily for use in
Volvo Penta workshops. It is assumed that persons
using the manual have fundamental knowledge of the
product and are capable of carrying out mechanical
and electrical work to industry standards.
Volvo Penta continually develops its products. We
therefore reserve the right to make changes.
All of the information in the manual is based on
product data available when the manual was
published.
NOTICE! The owner is responsible for ensuring that
scheduled maintenance is carried out. Warranty
claims to Volvo Penta may be declined if neglected
maintenance results in faults in the specified product.
Refer to the warranty terms supplied with the engine.
Specific terms for the U.S. market
This engine is certified as being in compliance with
federal and Californian exhaust restriction
regulations. Parts related to exhaust restrictions are
covered by the warranty commitment for exhaust
restricting systems. Terms and the parts covered are
specified under "What is covered by the warranty
undertaking for emissions” in “Emission Control
System Warranty Statement”. Repairs and service
covered by the warranty are carried out by an
authorized Volvo Penta distributor or dealer at no
charge for diagnostics, labor or parts using genuine
Volvo Penta parts in all areas of the exhaust restriction
system covered by the warranty and found to be
defective.
The use of the service and repair workshop other than
a Volvo Penta authorized distributor or dealer or the
use of exhaust-related components from other
manufacturers than Volvo Penta do not affect the
scope of the warranty undertaking for emission-
restricting systems. If emission-related components/
items are included in scheduled service, such parts
are marked with a diamond (♦) in the maintenance
schedule and service must be carried out at the
specified intervals in order to meet the requirements
of the warranty undertaking for emission-restricting
systems. The full warranty terms can be found in
“Emission Control System Warranty Statement”.
General Information
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Certified engines
The engine is exhaust-certified, and if it is used in
an area where exhaust emissions are regulated
by law, this places special demands on the care
and maintenance of the engine.
NOTICE! Neglect or failure to follow the items
required here may invalidate the engine emissions
certificate.
This means that AB Volvo Penta will no longer be able
to assume liability for engine specification
compliance with the certified model. Volvo Penta is
not responsible for damages or costs arising as a
result of this.
• Certification means that an engine type has
been inspected and approved by the competent
authorities. The engine manufacturer
guarantees that all engines made of the same
type are equivalent to the certified engine.
• It is the responsibility of the user to make sure
no intentional misuse of the engine takes place.
• Volvo Penta maintenance and service intervals
must be followed.
• All faults must be remedied as soon as possible.
• Only use genuine Volvo Penta replacement
parts or parts of the same quality as Volvo Penta
replacement parts.
• The engine may not be converted or modified in
any way, except with accessories and service
kits which Volvo Penta has approved for the
engine.
• Volvo Penta recommends that service on
injection pumps, pump settings and injectors
always be carried out by a qualified workshop.
• No changes may be made to the installation of
the exhaust pipe and engine air inlet ducts.
• Any tampering with the engine will hamper EU
type-approval of the engine concerned.
• No warranty seals (if present on the product)
may be broken by unauthorized persons.
Explanation of the relationship between
service intervals and operating
conditions
Because operating conditions may vary depending
on how the component is used, it is important that the
service interval (expressed in hours or months) is not
exceeded.
Example: 1000 hours / 24 months. Whichever is the
sooner applies. If the component is used for 1000
hours in 18 months, the service must be carried out
when the 1000-hour interval is reached.
This is to retain the component’s best quality and
service life. The warranty will be void if this is not
complied with.
Typical examples are: Propeller shaft seals operating
in sandy waters. Air filters exposed to heavily polluted
air
Action codes used in the service schedule:
C = Cleaning
R = Replacement
A = Adjustment
L = Lubricate
I = Inspection (includes where necessary also
adjustment, cleaning, lubrication and replacement)
Service Protocol
To maintain the functionality of the product Service
Protocol shall be followed. The owner or other persons
with sufficient technical competence may carry out
some measures in accordance with Service Protocol.
Contact an authorized Volvo Penta dealer in the case
of uncertainty as to how service work must be
performed.
Service Protocol contains the necessary maintenance
points for your engine in a single document. See more
on Volvo Penta‘s website: vppn.volvo.com and
Product Center for online service protocol.
General Information
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Preventive repair
Here is an overview of the components that may be included in preventive maintenance. May vary depending on
the engine's design and construction.
These components form the basis for calculating service contracts and the costs in the service calculator in
Product Center.
P0026295
Fuel system
Fuel pump
Unit injectors
P0026296
Exhaust system
Turbocharger, low-pressure
Turbocharger, high pressure
Overflow valve (Lisk)
Silencer
Diesel particulate filter (DPF), replacement
After-treatment system
Pump unit
Dosage valve
General Information
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P0026297
Cooling system
Seawater pump
Coolant pump
Engine
Vibration dampers
Engine pads, kit
P0026298
Electrical system
Alternator
Starter motor
General Information
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Engine, overhaul
Here is an overview of the components that may be included in a complete overhaul. May vary depending on the
engine's design and construction.
E.g. liners may not be replaced on certain engines. In this case, cylinders must be measured to see if new pistons
can be installed or if the engine block should be replaced.
The components below provide the basis for calculating service contracts and the costs in the service calculator
in Product Center.
Engine: May be overhauled twice, after which the engine is considered spent and is replaced by a long block or
new engine.
P0026299
Overhaul
Long block
Short block
Cylinder head (replacement)
Cylinder head, gasket
P0026300
Engine, overhaul kit
Cylinder head, overhaul kit
Gaskets, kit
Flat gaskets
Valve cover, gasket
General Information
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