Volvo Penta D16C-A B C D MH, D16C-A MG Group 21-26 Workshop Manual_459795601 – PDF DOWNLOAD

Volvo Penta D16C-A B C D MH, D16C-A MG Group 21-26 Workshop Manual_459795601 – PDF DOWNLOAD

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Volvo Penta D16C-A B C D MH, D16C-A MG Group 21-26 Workshop Manual_459795601 – PDF DOWNLOAD

Language : English
Pages : 234
Downloadable : Yes
File Type : PDF
Size: 9.78 MB

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Volvo Penta D16C-A B C D MH, D16C-A MG Group 21-26 Workshop Manual_459795601 – PDF DOWNLOAD

Introduction:

• This workshop manual contains technical data, descriptions and repair instructions for the Volvo Penta products or product versions noted in the table of contents.
• Check that you are using the correct Workshop Manual. Read the available safety information and “General information” and “Repair instructions” in the workshop manual carefully before you start to do any service work.

About the Workshop Manual:

This Workshop Manual contains technical data, descriptions and repair instructions for marine diesel engines D16C-A/B/C/D MH and D16C-A MG. The engine designation and number are noted on the number plate and engine decal. The engine designation and number must always be given in all correspondence about any product.

• The Workshop Manual is produced primarily for the use of Volvo Penta workshops and service technicians. This presupposes that persons using the manual have a fundamental knowledge of marine drive systems and can carry out the tasks of a mechanical or electrical nature associated with the trade.
• Volvo Penta constantly improves its products, and reserves the right to make modifications without prior notification. All information in this manual is based on product data which was available at the time the manual was printed. Any material changes introduced into the product or service methods after this date are notified by means of Service Bulletins.

TABLE OF CONTENTS:

Volvo Penta D16C-A B C D MH, D16C-A MG Group 21-26 Workshop Manual_459795601 – PDF DOWNLOAD

7746647………………………….. 1
7746647_US………………………..128
General Information……………. 0
General…………………… 0
Safety and Other Instructions…… 0
Safety Instructions………… 0
General………………………. 0
Engine Information, General…. 0
Troubleshooting………… 0
Test and Adjustments……. 0
Engine……………………….. 0
Crank Mechanism……………. 0
Index………………………… 0
References to Service Bulletins…. 0
7746647…………………………..132

Safety Precautions ……………………………………….. 3
General information ……………………………………… 6
About this Workshop Manual………………………….. 6
Standard times (Flat Rate)…………………………….. 6
Spare Parts…………………………………………………. 6
Certified Engines………………………………………….. 6
Service procedures ………………………………………. 7
Our Mutual Responsibility……………………………… 7
Tightening torque…………………………………………. 8
Torque-angle tightening…………………………………. 8
Lock nuts…………………………………………………….. 8
Strength Classes………………………………………….. 8
Sealant……………………………………………………….. 8
Safety rules for fluorocarbon rubber………………… 9
Special tools ………………………………………………… 10
Identification number ……………………………………. 17
Design and Function
Group 21:
Short block………………………………………………….. 18
Cylinder Head………………………………………………. 18
Cylinder Block………………………………………………. 19
Cylinder liners………………………………………………. 20
Pistons and con rods…………………………………….. 21
Crankshaft…………………………………………………… 22
Valve mechanism…………………………………………. 23
Timing gears………………………………………………… 24
Group 22:
Lubrication system……………………………………….. 25
Valves in lubrication system…………………………… 26
Piston cooling………………………………………………. 27
Group 23:
Fuel system…………………………………………………. 28
Unit injectors, working phases………………………… 30
Group 25:
Inlet and exhaust system……………………………….. 32
Turbocharger……………………………………………….. 32
Closed crankcase ventilation………………………….. 33
Group 26:
Cooling system…………………………………………….. 34
Charge air cooler………………………………………….. 35
Fault tracing …………………………………………………. 36
Location of measurement connector on engine….. 37
Actions with low charge air pressure……………….. 39
Coolant temperature too high…………………………. 40
Coolant temperature too low………………………….. 40
Coolant losses……………………………………………… 40
Instructions for operating the starter motor………. 41
Compression test…………………………………………. 42
Fuel feed pressure, checking…………………………. 44
Charge air pressure, checking………………………… 45
Charge air pipe, checking………………………………. 46
Turbocharger, checking…………………………………. 46
Exhaust back pressure, checking……………………. 47
Coolant pressure, check………………………………… 47
Seawater pressure, checking…………………………. 48
General advice
Working with chemicals, fuel and
lubrication oil……………………………………………….. 49
Before working in a boat………………………………… 49
Before lifting the engine…………………………………. 49
Actions after lifting the engine………………………… 50
General advice for pressure measurement………. 50
General advice when working on EVC engines….. 50
Electric welding……………………………………………. 51
Exposing the engine……………………………………… 52
Engine fixture, fixing……………………………………… 53
Repair Instructions
Group 21: Short block
Short block, complete overhaul………………………. 54
Cylinder head, removal………………………………….. 54
Timing gear, removing…………………………………… 65
Pistons, removal…………………………………………… 67
Crankshaft, removing……………………………………. 68
Crankshaft, assembly……………………………………. 69
Contents
2
Cylinder liners, installation……………………………… 71
Pistons, pre-assembly…………………………………… 72
Pistons, installation……………………………………….. 74
Piston cooling nozzles, installation………………….. 76
Timing gear, installation…………………………………. 77
Cylinder head, installation……………………………… 83
Camshaft, installation……………………………………. 86
Gear backlash, adjusting……………………………….. 87
Unit injector, installation…………………………………. 90
Adjustment markings…………………………………….. 91
Valves and unit injectors, adjustment………………. 92
By-pass valve oil cooler, replace……………………. 162
Piston cooling valves, replace……………………….. 162
Reduction valve, replace………………………………. 163
Safety valve, oil pressure, replace………………….. 163
Oil pressure sensor, check……………………………. 164
Pressure reduction valve, checking………………… 165
Safety valve, check………………………………………. 165
Lube oil pump, check……………………………………. 166
Lube oil pump, replace…………………………………. 166
Group 23: Fuel System
Draining, fuel gallery in cylinder head…………….. 168
Control unit, replace…………………………………….. 169
Identifying the engine control unit…………………… 170
Fuel feed pump, replace……………………………….. 171
Unit injector, replace…………………………………….. 173
Unit injector, programming the trim code…………. 178
Purging the fuel system………………………………… 180
Group 25: Inlet /Exhaust systems
Turbocharger, replace…………………………………… 181
Turbocharger, bearing clearances, check………… 184
Exhaust manifold, removal/installation……………. 186
Exhaust manifold expansion plug, change……….187
Group 26: Cooling System
Cooling system, draining………………………………. 188
Cooling system, cleaning……………………………… 190
Cooling system, filling…………………………………… 191
Cooling system, pressure testing…………………… 193
Coolant filler cap, replace……………………………… 195
Coolant pump, replace…………………………………. 196
Thermostat, function check…………………………… 197
Thermostat, replace…………………………………….. 198
Charge air cooler, removal/installation……………. 199
Charge air cooler, cleaning……………………………. 202
Charge air cooler, pressure testing………………… 203
Heat exchanger, removal and installation………… 204
Heat exchanger, cleaning……………………………… 205
Heat exchanger, pressure testing…………………… 207
Oil cooler, engine, removal/installation……………. 209
Oil cooler, engine, cleaning…………………………… 210
Oil cooler, engine, pressure testing………………… 211
Seawater pump, replace……………………………….. 212
Seawater pump, overhaul……………………………… 213
Oil cooler, reverse gear, cleaning…………………… 218
Oil cooler, reverse gear, pressure testing………… 220
Oil cooler reverse gear, thermostat replace……… 221
Drive belts, inspection………………………………….. 222
Drive belts, replace………………………………………. 222
References to Service Bulletins ……………………. 223
Alphabetical index ……………………………………….. 224
Group 21: Short block
Cylinder liner and pistons, inspection………………. 97
Cylinder liners and pistons, replace (all)…………… 99
Cylinder liner seats, inspection………………………. 105
Cylinder liner seat, milling……………………… 107/113
Crankshaft, inspection and overhaul………………. 114
Big end bearing journal, inspection………………… 115
Main bearings, replace…………………………………. 116
Big end bearings, replace (all)……………………….. 119
Flywheel, removal/installation………………………… 121
Gear ring, replace………………………………………… 123
Flywheel sensor distance, checking……………….. 124
Crankshaft seal, front, replace………………………. 126
Crankcase seal rear, replace…………………………. 127
Con rod, inspection……………………………………… 129
Gudgeon pin bushing, check measurement…….. 129
Valves, removing…………………………………………. 130
Valves, installation……………………………………….. 132
Valve seat, replace………………………………………. 133
Valve guides, inspection……………………………….. 135
Valve guides, replacing…………………………………. 136
Valve seats, grinding……………………………………. 138
Valves, grinding…………………………………………… 139
Valve stem seals, replace………………………………140
Cylinder head, pressure testing………………………142
Copper sleeve for unit injector, replace…………… 145
Camshaft, wear check………………………………….. 149
Bearing housing for camshaft, replace……………. 150
Camshaft sensor distance, checking………………. 151
Timing gear, replace…………………………………….. 153
Group 22: Lubrication System
Working with chemicals, fuel and
lubrication oil………………………………………………. 160
Overview, control valves……………………………….. 160
Overflow valve for by-pass filter, replace…………. 161
Overflow valve for full-flow filters, replace………… 16