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2
I
ntroduction
This Workshop Manual contains technical specifica-
tions, 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 Pre-
cautions", "Genera! Information" and "Repair Instruc-
tion" sections of this Workshop Manual carefully.
I
mportant
I
n this book and on the product you will find the follow-
i
ng special warning symbols.
Q
WARNING!
Possible danger of personal injury,
extensive damage to property or serious me-
chanical malfunction if the instructions are not
followed.
4L
I
MPORTANT
!
Used to draw your attention to
something that can cause damage or malfunc-
tions on a product or damage to property.
Note!
Used to draw your attention to important informa-
tion that will facilitate the work or operation in
progress.
Below is a summary of the risks involved and safety
precautions you should always observe or carry out
when operating or servicing the engine.
I
mmobilize the engine by turning off the power
supply to the engine at the main switch (switch-
es) and lock it (them) in the OFF position before
starting work. Set up a warning notice at the en-
gine control point or helm.
As a general rule all service operations must be
carried out with the engine stopped. However,
some work, for example certain adjustments re-
quire that the engine is running when they are
carried out. Approaching an engine which is op-
erating is a safety risk. Loose clothing or long
hair can fasten in rotating parts and cause seri-
ous personal injury. If working in proximity of an
engine which is operating, careless movements
or a dropped tool can result in personal injury.
Take care to avoid contact with hot surfaces (ex-
haust pipes, Turbocharger (
TC
),
air intake pipe,
start element
etc
.)
and hot liquids in lines and
hoses on an engine which is running or which
has just been stopped. Reinstall all protective
parts removed during service operations before
starting the engine.
Safety Precautions
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Check that the warning or information labels on
the product are always clearly visible. Replace
l
abels which have been damaged or painted
over.
Engines with turbocharger (
TC
):
Never start the
engine without installing the air cleaner (
ACL
)
filter.
The rotating compressor in the Turbo can
cause serious personal injury. Foreign objects
entering the intake ducts can also cause me-
chanical damage.
Never use start spray products or similar when
starting the engine. They may cause an explo-
sion in the inlet manifold. Danger of personal in-
jury.
Avoid opening the filler cap for engine coolant
system (freshwater cooled engines) when the
engine is still hot. Steam or hot coolant can
spray out. Open the filler cap slowly and release
the pressure in the system. Take great care if a
cock, plug or engine coolant line must be re-
moved from a hot engine. Steam or hot coolant
can spray out in any direction.
Hot oil can cause burns. Avoid getting hot oil on
the skin. Ensure that the lubrication system is
not under pressure before carrying out any work.
Never start or operate the engine with the oil fill-
er cap removed, otherwise oil could be ejected.
Stop the engine and close the sea cock before
carrying out operations on the engine cooling
system.
Only start the engine in a well-ventilated area. If
operating the engine in an enclosed area en-
sure that there is exhaust ventilation leading out
of the engine compartment or workshop area to
remove exhaust gases and crankcase ventila-
tion emissions.
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