Volvo Penta 2001, 2002, 2003, 2003T Engine unit Workshop Manual_59518987 – PDF DOWNLOAD

Volvo Penta 2001, 2002, 2003, 2003T Engine unit Workshop Manual_59518987 – PDF DOWNLOAD

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Volvo Penta 2001, 2002, 2003, 2003T Engine unit Workshop Manual_59518987 – PDF DOWNLOAD

Language : English
Pages : 48
Downloadable : Yes
File Type : PDF
Size: 0.57 MB

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Volvo Penta 2001, 2002, 2003, 2003T Engine unit Workshop Manual_59518987 – PDF DOWNLOAD

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.

General Information :About this Workshop Manual :

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.

• However the repair and service operations described are in all essential details the same. Where they are not the same this is stated in the manual and where the difference is considerable the operations are described separately. The Engine Designations and Engine Number can be found on the product plate (refer to page 14). Please always include both the engine designation and the engine number in all correspondance.
• The Workshop Manual is produced primarily for the use of Volvo Penta workshops and service technicians. For this reason the manual presupposes a certain basic knowledge of marine propulsion systems and that the user can carry out the mechanical/electrical work described to a general standard of engineering competence.
• Volvo Penta products are under a continual process of development and we therefore reserve all rights regarding changes and modifications. All the information in this manual is based on product specifications available at the time the book was published. Any essential changes or modifications introduced into production or updated or revised service methods introduced after the date of publication will be provided in the form of Service Bulletins.

Replacement parts:

• Replacement parts for the electrical and fuel systems are subject to various national safety requirements, for example the United States Coast Guard Safety Regulations. Volvo Penta Original Spare Parts meet these specifications.
• Any type of damage which is the result of using replacement parts that are not original Volvo Penta replacement parts for the product in question will not be covered under any warranty or guarantee provided by AB Volvo Penta.

TABLE OF CONTENTS:

Volvo Penta 2001, 2002, 2003, 2003T Engine unit Workshop Manual_59518987 – PDF DOWNLOAD

Safety precautions …………………………………………. 2
General information ………………………………………… 5
Repair instructions …………………………………………. 6
Special tools …………………………………………………. 9
Technical data ………………………………………………. 10
Presentation ………………………………………………….. 14
Disassembly
Cylinder head ………………………………………………… 16
Transmission ………………………………………………… 17
Camshaft ……………………………………………………… 17
Pistons, connecting rods …………………………………. 18
Flywheel ………………………………………………………. 18
Crankshaft ……………………………………………………. 18
Overhaul
Cylinder head ………………………………………………… 19
Valve guides …………………………………………………. 19
Valve seats …………………………………………………… 19
Valves …………………………………………………………. 19
Valve springs ………………………………………………… 20
Rockers ……………………………………………………….. 20
Injectors ……………………………………………………….. 21
Injector sleeves …………………………………………….. 21
Assembling the cylinder head ………………………….. 22
Feed pump ……………………………………………………. 22
Camshaft ……………………………………………………… 23
Crankshaft ……………………………………………………. 24
Pistons ………………………………………………………… 24
Connecting rods …………………………………………….. 25
Thermostat …………………………………………………… 25
Sea water pump …………………………………………….. 25
Assembly
Crankshaft ……………………………………………………. 26
Pistons ………………………………………………………… 26
Flywheel ………………………………………………………. 27
Transmission ………………………………………………… 27
Control mechanism, injection pumps …………………. 28
Smoke limiter ………………………………………………… 28
Valve mechanism ………………………………………….. 30
Injection setting …………………………………………….. 30
Venting the fuel system ………………………………….. 33
Turbo compressor ………………………………………….. 34
Cooling system ……………………………………………… 38
Electrical system …………………………………………… 40
Fault tracing ………………………………………………….. 42