6
The working methods described in the Service 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.
Warning symbols occurring in the Workshop Manual
(for their meaning see
Safety information
)
WARNING!
IMPORTANT!
NOTE!
are not in any way comprehensive since it is impos-
sible to predict every circumstance under which servi-
ce work or repairs may be carried out. For this reason
we can only highlight the risks that can arise when
work is carried out incorrectly in a well-equipped work-
shop using working methods and tools developed by
us.
All procedures for which there are Volvo Penta special
tools in this Workshop Manual are carried out using
these. Special tools are developed to rationalize wor-
king methods and make procedures as safe as pos-
sible. It is therefore the responsibility of any person
using tools or working methods other than the ones re-
commended by us to ensure that there is no danger of
injury, damage or malfunction resulting from these.
In some cases there may be special safety precau-
tions and instructions for the use of tools and chemi-
cals contained in this Workshop Manual. These speci-
al instructions should always be followed if there are
no separate instructions in the Workshop Manual.
Certain elementary precautions and common sense
can prevent most risks arising. A clean workplace and
engine eliminates much of the danger of injury and
malfunction.
It is of the greatest importance that no dirt or foreign
particles get into the fuel system, lubrication system,
intake system, turbocharger, bearings and seals when
they are being worked on. The result can be malfunc-
tion or a shorter operational life.
otherwise good engine may be increased significantly.
It is therefore vital that wear tolerances are maintai-
ned, that systems that can be adjusted are adjusted
properly and that Volvo Penta Genuine Parts as used.
The engine Maintenance Schedule must be followed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance. Some com-
ponents are sealed at the factory for environmental re-
asons. No work should be carried out on sealed com-
ponents except by authorized personnel.
Bear in mind that most chemicals used on boats are
harmful to the environment if used incorrectly. Volvo
Penta recommends the use of biodegradable degrea-
sing agents for cleaning engine components, unless
otherwise stated in a workshop manual. Take special
care when working on-board, that oil and waste is ta-
ken for destruction and is not accidentally pumped
into the environment with bilge water.
Tightening torques
Tightening torques for vital joints that must be tighte-
ned with a torque wrench are listed in workshop manu-
al “Technical Data”: “Tightening Torques” and are con-
tained in work descriptions in this Manual. All torques
apply for cleaned threads, screw heads and mating
surfaces. Torques apply for lightly oiled or dry th-
reads. If lubricants, locking fluid or sealing compound
are required for a screwed joint this information will be
contained in the work description and in “Tightening
Torques” Where no tightening torque is stated for a
joint use the general tightening torques according to
the tables below. The tightening torques stated are a
guide and the joint does not have to be tightened
using a torque wrench.
Dimension Tightening Torques
Nm
M5 .................................................. 6
M6 .................................................. 10
M8 .................................................. 25
M10 ................................................ 50
M12 ................................................ 80
M14 ................................................ 140
Repair Instructions
Our joint responsibility
Each engine consists of many connected systems
and components. If a component deviates from its
technical specification the environmental impact of an
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