Workshop Manual Engine unit A 2(0) 2001, 2002, 2003, 2003T
Engine unit 2001, 2002, 2003, 2003T Index Safety precautions ................................................. 2 General information ................................................ 5 Repair instructions ................................................. 6 Special tools .......................................................... 9 Technical data ....................................................... 10 Presentation ........................................................... 14 Disassembly Cylinder head ...
Safety Precautions Introduction This Workshop Manual contains technical specifications, descriptions and instructions for the repair of the Volvo Penta products or product types described in the Table of Contents. Check that you have the correct Workshop Manual for your engine. Before starting work on the engine read the "Safety Precautions", "General Information" and "Repair Instruction" sections of this Workshop Manual carefully.
Safety precautions Always use protective glasses or goggles when carrying out work where there is a risk of splinters, grinding sparks, acid splashes or where other chemicals are used. The eyes are extremely sensitive, an injury could result in blindness! Avoid getting oil on the skin! Repeated exposure to oil or exposure over a long period can result in the skin becoming dry. Irritation, dryness and eczema and other skin problems can then occur.
Safety precautions Use the lifting eyes fitted on the engine/reverse gear when lifting the drive unit. Always check that the lifting equipment used is in good condition and has the load capacity to lift the engine (engine weight including reverse gear and any extra equipment installed). Use an adjustable lifting beam or lifting beam specifically for the engine to raise the engine to ensure safe handling and to avoid damaging engine parts installed on the top of the engine.
General Information About this Workshop Manual Certificated engines This Workshop Manual contains technical specifications, descriptions and instructions for the repair of the following engines in standard format: 2001, 2002, 2003, 2003T. This Workshop Manual can show operations carried out on any of the engines listed above. As a result the illustrations and pictures in the manual that show certain parts on the engines, do not in some cases apply to all the engines listed.
General instructions Repair instructions and methods The working methods described in the Workshop Manual apply to work carried out in a workshop. The engine has been removed from the boat and is installed in an engine fixture. Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working method.
General instructions Tightening torque with Protractor tightening (angle tightening) Tightening using both a torque setting and a protractor angle requires that first the recommended torque is applied using a torque wrench and then the recommended angle is added according to the protractor scale. Example: a 900 protractor tightening means that the joint is tightened a further 1/4 turn in one operation after the stated tightening torque has been applied.
General instructions During service operations use the same agent or an alternative from a different manufacturer. Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturer’s instructions for use regarding temperature range, curing time and any other instructions for the product. Two different basic types of agent are used on the engine and these are: RTV agent (Room temperature vulcanizing).
Special tools 9992265-0 Pulley puller 884813-7 Installation ring for piston 9995218-6 Mandrel for valve guide removal 884557-0 Mandrel for installation of injector sleeve 884559-6 Mandrel for installation of valve guide 884787-3 Setting-disc for injection pump seeing 884811-1 Puller for injector sleeve 884823-6 Flaring tool for injector sleeve 884837-6 Flange for engine cradle 884838-4 Mandrel for installation of sealing ring in transmission 884839-2 Assembly and disassembly tool for ca
Technical data General Type designation .......................................................... 2001 2002 2003 Output1) at 53 r/s (3200 rpm) ........................................ Output1) at 53 r/s (3200 rpm) 2003T ............................. 6.6 kW (9.0 hp) 13.2 kW (18.0 hp) 20.6 kW (28.0 hp) 33.1 kW (45.0 hp) Number of cylinders ..................................................... 1 2 3 3 Displacement ............................................................... 0.43 dm .........
Technical Data Piston ring gap in the cylinder Upper compression ring ............................................... Lower compression ring ............................................... Oil ring ......................................................................... 0.30 – 0.50 mm (0.001181 – 0.00197 in.) 0.30 – 0.50 mm (0.001181 – 0.00197 in.) 0.25 – 0.50 mm (0.009842 – 0.00197 in.) Crankshaft Material ........................................................................
Technical data Valve guides Lenght, inlet valve ........................................................ Lenght, outlet valve ...................................................... Inner diameter .............................................................. Height above spring plane of cylinder head .................. Clearance valve stem – valve guide: Inlet valve ................................................................. Outlet valve ..............................................................
Technical data Governor overrun ......................................................... 25±1,5 mm3/stroke at 40±5°C (104°F ±10.6°F) and at 1500 rpm pump revs 3250 rpm Turbo charger (2003T) Boost pressure at full load / 3200 rpm, 20°C (68°F) ...... 100 – 120 kPa (14.5 – 17.4 psi) Feed pump Feed pressure at 2500 rpm .......................................... 0.65 – 0.85 kp/cm2 (9.20 – 12.10 psi) Injected quantity ..........................................................
Presentation 2001/MS2V 2003/MS2B-R Type plate 2002/120-S 14 2003T/MS2B-R
All engines in the 2000 range are four stroke diesels with direct injection and separate injection pumps for each cylinder. In the 2000 range, the 2001 has a single cylinder, the 2002 has twin cylinders, and the 2003 has three cylinders. The 2003 is also available with turbocharging, and then has the designation 2003T. The engines are of modular construction, with many common components, so in most cases they have the same repair data and service methods.
Disassembly Drain off the cooling water and the lubricating oil from the engine. Clean the engine and fit it on engine cradle p/n 9992520 and fixture p/n 884837. 3. Remove the fuel filter, the oil filter, the feed-pump, the thermostat housing and the exhaust elbow. Also remove the sea-water pump with its attachment tubes. 1. Remove the alternator, the tensioner bracket and the starter motor.
Disassembly 1 2 8. The max.-volume-screw (1) and the max.-rev-screw (2) are set by Volvo Penta and must never be changed since this will affect the engine output. 6. Remove the pulley center bolt and pull off the pulley using puller p/n 9992265. Place a protection pad between the puller and the crankshaft to avoid the crankshaft being damaged. 3 9. Remove the control rod. Start by removing the plug at the rear of the block and the two screws on the pump plane, holding the control rod. 2 1 7.
Disassembly 11. Remove the outer flywheel housing, the flywheel and the inner flywheel housing. 13. Remove the connecting rod bolts and remove the connecting rods and the pistons. The connecting rod and the connecting rod cap are marked with figures. 12. Turn the engine upside down and remove the oil pan. Be careful as the pan is glued. NOTE! The oil pan ends also function as main bearings. 14. Remove the main bearing caps. The main bearing caps are marked with a figure.
Overhaul 3. Use mandrel p/n 9995218 to press out the valve guides. Oil the new valve guides externally and use mandrel p/n 884559 to install them. Press down the mandrel all the way down to the cylinder head. Ream the valve guides if necessary. The cylinder head 1. Remove the “collets” and valve springs using a valve bow. Remove the valves. Remove the valve stem seals. Place the valves in the proper sequence in a valve stand. Valve guides 2.
Overhaul Replacing the valve seat, exhaust port * Grind down the valve disc of a discarded valve to just below 27 mm (1.063 in) diameter. Push the valve stem through the guide. Do not push in too far - the valve disc should be just below the edge of the seat. Spot weld the disc in place at three points using a MAG electric welder. Knock out the seat by hitting the valve guide with a plastic-headed hammer. Valve springs 5. Check the free length of the valve springs and the length when loaded.
Overhaul 1 Pressure testing the nozzles 7. Check the nozzle´s spray pattern at the correct opening pressure (see Technical Data). Check also that the fuel sprays stop simultaneously and no dripping occurs. Adjust the opening-pressure with adjustment-washers (1) being available in different thicknesses from 1 mm (.03937 in.) to 1.95 mm (.076772 in.) in steps of 0.05 mm (.001969 in.).
Overhaul Assembling the cylinder head 11. Clean the cylinder head. If the water distribution pipe has been disassembled, it must be installed with the holes turned as indicated in the picture. Install new valve stem sealings. Oil the valve stems and install the valves. Make sure to install the valves and the valve springs in their respective original positions. Install the valve springs and the “collets”. Use a valve-bow. Feed-pump 13. Depress the pump lever.
Overhaul Valve lifters 17. Check the valve lifters for wear. Replace them if necessary. 15. Use a suitable pair of pliers and remove the pump lever shaft. Pull out the lever and the diaphragm. 3 2 1 Camshaft 18. Check the camshaft for wear on cams and bearing races. Also check the wear of the bearings. The bearings are pressed into their locations and must be line bored after the installation. 16. Clean the pump housing carefully and replace worn parts.
Overhaul Crankshaft 20. Remove the gear wheel. Use a prong puller. Clean the crankshaft. Measure the crank- and main bearing pins. The eccentricity must not exceed 0.06 mm (.002362 in.) and the taper 0.05 mm (.001969 in.). Should these values be exceeded, the crankshaft must be ground to a suitable underdimension, see under “Technical Data”. 22. Insert a new piston ring into the cylinder and measure the piston ring gap. As to the measurement, see under “Technical Data”.
Overhaul 4 4 5 1 3 2 Connecting rods 25. Check the connecting rods for straightness and twisting. Sea-water pump 27. The pump is equipped with two ball-bearings (1). When disassembling, remove the locking-ring (2) in the housing and push out the shaft, whereby the bearings are following. Use a suitable mandrel to remove the bearings from the shaft. NOTE! Do not forget the spacer sleeve (3). Replace the sealings (4).
Assembly Always use new gaskets, sealing rings, sealing washers and lock-washers. Coat the sealings with grease or oil them and also oil all moving parts prior to installing them. 1. Heat the crankshaft gear wheel to approx. 150°C (302°F) prior to the installation. Place the key in the key-way of the crankshaft and press on the gear wheel. Oil the new main bearing halves (with oil hole) and install them in the block. Put in the crankshaft.
Assembly 1 3 2 1 5. Replace the flywheel housing sealing (1). Smear sealing compound (p/n 840879) on the edge between the flywheel housing and the sealing. NOTE! The sealing lip with a spring shall be turned towards the engine. Make sure that the sealing is installed in accordance with the picture. 7A. Heat the camshaft gear wheel to a temperature of approx. 150°C (302°F) and use a suitable sleeve to install it. Check to make sure that the gear wheel “bottoms” on the camshaft.
Assembly 1 5 2 4 7 3 10 8 9 6 Control mechanism, injection pumps 8. Control mechanism, design 1. Injection pumps 2. Roller lifter 3. Control screw, roller lifter 4. Control rod 5. Control screw, control rod 6. Centrifugal weights, fuel volume control 7. Control arm 8. Max. engine speed screw 9. Max. volume screw 10. End nipple, control rod The 2003T-B has a smoke limiter, which maximises the fuel volume to suit the turbo boost pressure.
Assembly housing apart using a screwdriver in the groove provided, at the same time as you hold the leaf spring (19) out to allow the full load limiter to loosen from the volume screw (9). The outer part of the smoke limiter housing, including the spring, piston and volume screw, can now be removed. Unscrew the holder (17) (internal 8 mm socket) and press it out of the smoke limiter housing, after which the diaphragm (12) can be undone and can be changed.
Assembly Mounting the cylinder head 2001 2002 13. Install the push rods and the rocker arm bridge, push on new rubber rings to the oil pipe which is fitted at the same time as the rocker arm bridge. 14. Valve clearance cold/warm engine should be 0.30 mm (.01181 in.). Turn the engine in the direction of rotation until the valves in one cylinder are “rocking”. Then turn the engine one turn more and adjust the valves for this cylinder. Repeat the procedure for the remaining cylinders.
Assembly called soft shims, always being installed against the block, must be replaced against new ones. Carefully clean the contact surfaces between the block and the fuel injection pumps and install shims with thickness equal to the sum of the marking on the block and that on the fuel injection pump, (4) earlier marking. Example: The block has the marking 4 (= 4 tenths of a millimeter /.015748 in.) The pump marking is 4 (= 4 tenths of a millimeter /.015748 in.) Total amount of shims = 0.8 mm (.031496 in.
Assembly D. Repeat the procedure for the other pumps (2002, 2003) in the same way as for cylinder 1.The setting-disc’s marking is explained under point B. C. Turn cylinder no. 1 to it’s injection position. Place the guide pin (2b) in the setting-disc’s hole marked cyl. 1. Turn the crankshaft a little against the normal direction of rotation and thereafter in the normal rotation direction until the setting-disc’s guide pin (2b) goes in the timing cover’s hole.
Assembly 19. Install the sea-water pump and the cooling water pipes. 22. Install the starter motor, the alternator and the alternator V-belt. Also install the electrical distribution box and hook-up the cable harness. 20. Install the injectors and the return fuel pipe. Tightening torque for the injectors 20 Nm (14.7 ft.lbs.). Also install the exhaust elbow and the water pipe between the thermostat housing and the exhaust elbow. 23. Fill up with lubricating oil to the correct level.
Turbo compressor 2003T Turbo Compressor 1. Inspecting the Seals Where there is an excessive amount of smoke in the exhaust fumes or the engine output is particularly low it may be that the turbo is not functioning properly. If the boat’s speed through the water is gradually decreasing, the boat’s bottom should also be inspected, and cleaned where necessary. Check that the air intake has not become clogged, and clean the intake silencer. Messure the supercharging pressure under full load at 3200 rpm.
Turbo compressor Reconditioning 4. Make line-up marks between the turbine housing, the bearing housing and the compressor housing. Dismantle the compressor housing (1). Unscrew the left-hand threaded nut which holds the compressor wheel, using dollies on the turbine shaft. Remove the compressor wheel (2) and dismantle the turbine housing (3). 5. Dismantle the turbine shaft (4) and the heat shield. If the turbine shaft sticks, tap the end gently with a wooden hammer.
Turbo compressor 9. Check the diameter of the shaft bearing recesses. The minimum permissible diameter is 7.98 mm (0.3141 in). Check the width of the shaft piston ring groove. Maximum permissible width is 1.29 mm (0.0507 in). Compressor Housing, Turbine Housing 10. Check that the housings are free from cracks or other damage caused by excessive wear and tear. Damaged parts should be replaced. Heat Shield 6. Unfasten the four screws which hold the compression bearing (8).
Turbo compressor Bearings 16. Check the bearings for abnormal wear and tear or discolouration, and replace them where necessary. Check the internal and external diameters of all bearings. The external diameter should not be less than 12.31 mm (0.48464 in), the internal diameter should not be more than 8.04 mm (0.31653 in). Reassembly Grease all removable parts when reassembling them. Position the circlips in the bearing housing so that the openings in them are facing towards the oil outlet.
Cooling system Cooling system 2001, 2002, 2003 Sea water cooled (standard) 1 1. Thermostat 2. Distribution manifold 3. Sea water pump 2 3 Cooling system 2003T Sea water system 1. Exhaust pipe 2. Heat exchanger 3. Oil cooler 4. Sea water pump 5. Reversing gear 1 2 Fresh water system 1. Heat exchanger 2. Expansion tank 3. “By-pass” pipe (water flow with closed thermostat) 4. Thermostat 5. Circulation pump 6. Distribution manifold 7.
Cooling system Fresh water cooling Accessory 2002, 2003 1. Fit the circulation pump (complete with tensioner bracket and spacer sleeve, position 4). Tighten the bolts (M8x75) to 20 Nm (14.7 ft.lbs), position 1. 7. Fit the alternator, place the bolt for the tensioner bracket with the head forwards. Put on and tension the V-belt. 2. Suspend the heat exchanger loosely by the rear bolt (M8x16 and spring washer), position 5.
Electrical system Instrument panel, alternative «A» Instrument panel 1. Printed circuit card 2. Rev. counter (accessory) 3. Start button 4. Instrument panel switch 5. Alarm test 6. Alarm Max. output from the panel : 5 Amp Cable GR SB BN LBN R PU GN Y W BL LBL color = Grey = Black = Brown = Light brown = Red = Purple = Green = Yellow = White = Blue = Light blue Wire areas mm2 1,0 1,5 2,5 10 AWG 17 15 13 7 Engine 1. Relay 2. Fuse 3. Coolant temp. alarm switch 4.
Electrical system Instrument panel, alternative «B» Instrument panel 1. Voltmeter 2. Oil pressure gauge 3. Coolant temperature gauge 4. Printed circuit card 5. Alarm test 6. Switch for instrument lightning 7. Rev. counter 8. Key switch 9. Alarm Max. output from the panel : 5 Amp Cable GR SB BN LBN R PU GN Y W BL LBL color = Grey = Black = Brown = Light brown = Red = Purple = Green = Yellow = White = Blue = Light blue Wire areas mm2 1,0 1,5 2,5 10 AWG 17 15 13 7 Engine 1.
Fault tracing Engine does not start Engine stops Engine not reaching full rpm Engine runs roughly or vibrates abnormally Engine becomes abnormally hot Stop control not fully pushed back. Main switch not switched on. Flat battery. Broken electric wires. Main fuse blown. ● ● ● ● ● Empty fuel tank, closed fuel cock or clogged fuel filter. ● ● Water or impurities in the fuel. Faulty injectors or air in the fuel system.
References to service bulletins Group No. Date Concerns ......................................................................................................................................................................................... ......................................................................................................................................................................................... ................................................................................
Notes 44
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7730974-8 English 08-2000
