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Volvo Penta
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D1-20
Volvo Penta D1-20 Workshop Manual
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1
3
Table of Contents
Default Chapter
3
Table of Contents
3
Certified Engines
5
General Information
5
Spare Parts
5
Repair Instructions
6
Tightening Torques
6
Torque, Angle Tightening
6
Lock Nuts
7
Safety Regulations for Fluorocarbon Rubber
7
Sealing Compounds Etc.
7
Strength Classes
7
Illustration Colors
8
Illustrations
8
Position
8
Movement
9
Tools
9
Chemicals
10
Cleanliness
10
Sealant
10
Units
10
Specifications
11
Specifications, Engine
11
Cylinder Head
13
Tightening Sequence
13
Conversion Table
14
Technical Data
15
Engine
16
Lubrication System
22
Fuel System
23
Cooling System
24
Water Quality
24
Electrical System
25
Specifications, Electrical
25
Safety and Other Instructions
26
Safety Information
26
Safety Instructions
26
Special Service Tools
30
Design and Function
33
Engine Information, General
33
Identification Numbers
33
Engine, General
34
Camshaft
37
Cylinder Block
37
Oil Pan
37
Rocker Arm Cover
37
Con Rods
38
Crankshaft
38
Main and Big-End Bearings
38
Transmission
38
Crankcase Ventilation
39
Oil Pump
41
Oil Valves
41
Oil Filter
42
Centrifugal Regulator
44
Injection Pump
44
Injectors
44
Feed Pump
45
Fuel Filter
45
Coolant Pump
47
Seawater Pump
47
Thermostat
47
Heat Exchanger
48
Compression Test
49
Test and Adjustments
49
Repair Instructions
50
When Working with Chemicals, Fuel and Lubricating Oil
50
Before Lifting the Engine
51
Boat Removed from the Water
51
Engine Complete, General
51
Exposing the Engine
51
Fitting the Fixture
52
Engine Disassembly
53
Cylinder Head, Inspection
57
Cylinder Head, Assembly
58
Measuring Piston Height, Installing Cylinder Head and Other Assembly
58
Cylinder Head, Removal
62
Cylinder Head, Installation
64
Cylinder Block, Inspection
66
Cylinder Bore
66
Upper Block Plane
66
Cylinder Liner, Pistons
67
Piston and Cylinder Bore, Inspection and Measurement
67
Piston Rings, Measurement and Inspection
67
Pistons, Removal
68
Big End Bearing, Change
69
Pistons, Change
69
Pistons, Removed
69
Pistons, Installation
70
Pistons in Cylinders, Installation
71
Valve Mechanism
72
Valves, Adjustment
72
Cylinder Head Removed
74
Valves, Installation
74
Valves, Removal
74
Valve Guides, Inspection
75
Valve Seats and Valve, Grinding
76
Rocker Arm Mechanism, Overhaul
77
Valve Seat, Change
77
Flank Clearance, Checking
78
Timing Gear, Removal
78
Timing Gears and Shaft
78
Timing Gear, Installation
82
Camshaft, Inspection
87
Camshafts and Valve Lifters, Inspection
87
Measuring the Camshaft
87
Acceptable Wear
88
Guidelines for Replacement
88
Unacceptable Wear
88
Flywheel, Change
89
Changing the Piston Pin Bushing
90
Con Rods, Inspection
90
Crank Mechanism
90
Assembling Piston, Piston Rings and con Rod
91
Crankshaft and Bearings, Inspection
92
Inspection of Main and Big End Bearings
93
Inspection of the Crankshaft Bushing and Crankshaft Journal
93
Big End Bearing Clearance, Check
94
Crankshaft, Installation
95
Crankshaft, Removal
96
Main Bearings, Replacing
97
Crankshaft Seal, Change (Front)
99
Crankshaft Seal, Change (Rear)
100
Drive Belt, Change
101
Miscellaneous
101
Lubricating and Oil System
102
Oil Pump and Line
102
Oil Pump Bearing, Change
102
Fuel System
103
Fuel System, Bleeding
103
Fuel System, General
103
Fuel Feed Pump and Filter
104
Fuel Feed Pump, Change
104
Hand Pump, Change
104
Injection Pump, Change
105
Injection Pump, Regulator
105
Injector, Change
107
Injectors and Delivery Pipes
107
Overhauling Injectors
108
Checking Injectors
109
Opening Pressure
109
Spray Pattern
109
Testing Injectors
109
Low Idle
110
Race Revolutions (High Idle)
110
Setting Engine Rpm
110
Cooling System
111
Cooling System, General
111
Ready Mixed
111
Coolant, Mixing
112
Coolant Level, Checking and Topping up
113
Coolant, Draining
113
Checking
114
Coolant Temperature too Low
114
Excessive Coolant Temperature
114
Fault Cause
114
Pressure Valve in Filler Cap, Check
115
Heat Exchanger, Cleaning
116
Radiator, Heat Exchanger
116
Heat Exchanger/Exhaust Manifold, Change
118
Coolant Pump, Change
119
Coolant Pump, Thermostat
119
Thermostat, Change
121
Sea Water System, Sea Water Pump
122
Seawater Pump, Impeller, Change
122
Seawater Pump, Change
123
Seawater Pump, Overhaul
124
Alternator
129
Alternator, Change
129
Starting System
130
Starter Motor
130
Starter Motor, Change
130
Alphabetical Index
131
References to Service Bulletins
133
Other manuals for Volvo Penta D1-20
Operator's Manual
92 pages
Installation Instructions
8 pages
Installation Guide
24 pages
4
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Volvo Penta D1-20 Specifications
General
Engine Type
Diesel
Number of Cylinders
3
Alternator
115A
Rated RPM
3000 rpm
Cooling System
Heat exchanger
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