Volvo Penta D3-110 130 160 190i-B, D3-130160190A-B Workshop Manual_42535554 – PDF DOWNLOAD

Volvo Penta D3-110i-B, D3-130i-B D3-160i-B, D3-190i-B D3-130A-B, D3-160A-B, D3-190A-B Workshop Manual_42535554 – PDF DOWNLOAD

FILE DETAILS:

Volvo Penta D3-110i-B, D3-130i-B D3-160i-B, D3-190i-B D3-130A-B, D3-160A-B, D3-190A-B Workshop Manual_42535554 – PDF DOWNLOAD

Language : English
Pages : 186
Downloadable : Yes
File Type : PDF
Size: 4 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Volvo Penta D3-110i-B, D3-130i-B D3-160i-B, D3-190i-B D3-130A-B, D3-160A-B, D3-190A-B Workshop Manual_42535554 – PDF DOWNLOAD

D3-110i-B, D3-130i-B
D3-160i-B, D3-190i-B
D3-130A-B, D3-160A-B, D3-190A-B

About this Workshop Manual :

This workshop manual contains technical data, descriptions and repair instructions for the following marine diesel engines: D3-110i-B, D3-130i-B, D3-160i-B, D3-190i-B, D3-130A-B, D3-160A-B, D3-190A-B. 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 assumes that people who use the Manual have basic knowledge of marine drive systems and can do the tasks of a mechanical or electrical nature associated with the trade.
• Volvo Penta constantly improves its products, so we reserve the right to make modifications without prior notification. All information in this manual is based on product data which was available up to the date on which the manual was printed. Any material changes introduced into the product or service methods after this date are notified by means of Service Bulletins.

Standard times (Flat Rate)
In instructions where operation numbers are found in
the headings, this is a reference to the Volvo Penta
standard times list (“Flat Rate”).

Spare parts :Spare parts for electrical- and fuel systems are subject to various national safety requirements, such as U.S. Coast Guard Safety Regulations. Volvo Penta Original Spare Parts meet these specifications. Any damage, occasioned by use of non–original Volvo Penta spares for the product, will be not be compensated by the warranty offered by Volvo Penta.

TABLE OF CONTENTS:

Volvo Penta D3-110i-B, D3-130i-B D3-160i-B, D3-190i-B D3-130A-B, D3-160A-B, D3-190A-B Workshop Manual_42535554 – PDF DOWNLOAD

Safety information ………………………………………….. 4
Introduction …………………………………………………… 4
Important ……………………………………………………… 4
General information ……………………………………….. 7
About this Workshop Manual …………………………… 7
Standard times (Flat Rate) ………………………………. 7
Spare parts …………………………………………………… 7
Certified engines ……………………………………………. 7
Repair instructions…………………………………………. 8
Our common responsibility ………………………………. 8
Torque …………………………………………………………. 8
Torque-angle tightening …………………………………… 9
Lock nuts ……………………………………………………… 9
Strength classes ……………………………………………. 9
Sealant ………………………………………………………… 9
Safety rules for Fluorocarbon Rubber ………………. 10
Special tools ……………………………………………….. 11
Other special equipment ……………………………….. 14
Location of engine signs ………………………………. 15
Design and function
Group 21: Short block ………………………………… 16
Engine, general ……………………………………………. 16
Engine block ……………………………………………….. 17
Sump …………………………………………………………. 17
Cylinder head ………………………………………………. 17
Camshaft ……………………………………………………. 17
Valve housing / inlet manifold ………………………… 17
Crankshaft ………………………………………………….. 18
Pistons ………………………………………………………. 18
Timing gear …………………………………………………. 19
Crankcase breather ………………………………………. 19
Group 22: Lubrication system ……………………… 20
Oil grades …………………………………………………… 20
Lubrication system, function description ………….. 21
Oil valves ……………………………………………………. 22
Oil pump …………………………………………………….. 22
Oil filter ………………………………………………………. 22
Group 23: Fuel system ………………………………… 23
Fuel system, function description …………………… 23
Injection pump …………………………………………….. 24
Distribution manifold ……………………………………… 24
Injectors ……………………………………………………… 25
Fuel filter housing …………………………………………. 25
Group 25: Inlet and exhaust system …………….. 26
Inlet and exhaust system,
function description ………………………………………. 26
Turbocharger ……………………………………………….. 27
VNT (Variable Nozzle Turbocharger) ……………….. 28
Group 26: Cooling system …………………………… 29
Cooling system, function description ……………….. 29
Thermostat …………………………………………………. 30
Circulation pump ………………………………………….. 30
Sea water pump …………………………………………… 30
Intercooler …………………………………………………… 31
Heat exchanger ……………………………………………. 31
Oil cooler ……………………………………………………. 32
Oil cooler, steering servo ………………………………. 32
Group 64: Servo system ……………………………… 33
Servo system ……………………………………………… 33
Servo pump ………………………………………………… 33
Fault tracing ………………………………………………… 34
Symptoms and possible causes …………………….. 34
Malfunctions ……………………………………………….. 35
Blockage …………………………………………………….. 35
Inspection of return flow from injectors …………….. 36
Service work ………………………………………………… 37
Compression test …………………………………………. 37
Engine oil, changing ……………………………………… 38
Oil filter, change …………………………………………… 39
Fuel filter, change ………………………………………… 40
Venting the fuel system ………………………………… 41
Air filter, change …………………………………………… 42
Cooling system, draining ……………………………….. 43
Sea water system, cleaning and conserving …….. 44
Fresh water system, pressure testing ……………… 45
Cooling system, filling …………………………………… 46
Sea water pump, impeller, change ………………….. 48
Drive belt/Alternator belts, inspection ………………. 49
Drive belt/Alternator belts, change ………………….. 49
Cam belt, change …………………………………………. 50
Repair instructions……………………………………….. 55
When working with chemicals, fuel
and lubrication oil …………………………………………. 55
Before lifting the engine ………………………………… 55
Before working in a boat ………………………………… 55
Actions after lifting the engine ………………………… 55
Checking the engine fixture …………………………… 56
Engine, full overhaul
Disassembly, engine…………………………………… 58
Cover …………………………………………………………. 58
Exhaust manifold and turbocharger …………………. 58
Fuel filter and housing …………………………………… 58
Intercooler, brackets and dipstick …………………… 59
Engine cables ……………………………………………… 59
Drive belt ……………………………………………………. 60
Sea water pump …………………………………………… 60
Servo pump, jockey wheel, left-hand
engine mounting …………………………………………… 60
Alternator ……………………………………………………. 61
Mounting bracket …………………………………………. 61
Vacuum regulator …………………………………………. 61
Sensors and monitors …………………………………… 62
Starter motor ……………………………………………….. 62
Fuel leakage hose ………………………………………… 62
Delivery pipes ……………………………………………… 63
High pressure pump ……………………………………… 63
Distribution manifold ……………………………………… 63
Vacuum pump……………………………………………… 64
Injectors ……………………………………………………… 64
Valve cover/inlet manifold ……………………………… 64
Timing gear …………………………………………………. 65
Circulation pump ………………………………………….. 68
Oil pump …………………………………………………….. 68
Cylinder head ………………………………………………. 68
Flywheel with cover and coupling ……………………. 70
Oil filter housing …………………………………………… 72
Oil cooler ……………………………………………………. 72
Sump …………………………………………………………. 73
Oil suction pipe ……………………………………………. 73
Piston cooling nozzles ………………………………….. 73
Pistons and con rods ……………………………………. 74
Crankshaft ………………………………………………….. 74
Assembly, engine ………………………………………. 74
Classification of main bearings ………………………. 76
Crankshaft ………………………………………………….. 78
Piston rings …………………………………………………. 78
Piston cooling nozzles, pistons, con rods ………… 79
Flywheel, seal ring, clutch
and flywheel housing …………………………………….. 79
Oil suction pipe and sump ……………………………… 80
Oil cooler ……………………………………………………. 82
Oil pump …………………………………………………….. 82
Toothed belt pulley ……………………………………….. 83
Cylinder head ………………………………………………. 84
Valve cover …………………………………………………. 88
Circulation pump ………………………………………….. 88
Timing gear …………………………………………………. 89
Injectors ……………………………………………………… 93
Distribution manifold ……………………………………… 93
High pressure pump ……………………………………… 93
Fuel supply pipes and fuel leakage hose ………….. 94
Fuel union …………………………………………………… 94
Vacuum pump ……………………………………………… 94
Plug, hot water outlet ……………………………………. 95
Oil filter housing …………………………………………… 95
Mounting bracket …………………………………………. 95
Drive belt/Alternator belt ………………………………… 96
Vacuum regulator …………………………………………. 97
Starter motor ……………………………………………….. 97
Sensors and cables ……………………………………… 97
Intercooler and dipstick …………………………………. 98
Fuel filter housing …………………………………………. 98
Exhaust pipe with turbocharger ………………………. 99
Fixture, right engine mounting ………………………… 99
Coolant pipe ………………………………………………..100
Heat exchanger ……………………………………………100
Oil pipe, turbocharger ……………………………………100
Exhaust pipe elbow ………………………………………101
Expansion tank ……………………………………………101
Hose connections, air filter housing ………………..101
Cover …………………………………………………………101
Overhaul / Change components
Group 21: Short block ………………………………..102
Flywheel, change …………………………………………102
Gear ring, change…………………………………………105
Crankcase seal, rear, change…………………………106
Crankshaft seal, front, change ……………………….109
Cylinder head, change …………………………………..110
Cylinder head gasket, measurement ……………….129
Crankshaft, locking ………………………………………131
Cam belt, change …………………… see “Service work”
Group 22: Lubrication system ……………………..132
When working with chemicals, fuel
and lubrication oil …………………………………………132
Oil pump, change …………………………………………132
Oil filter housing, change……………………………….134
Lube oil pressure, check ……………………………….135
Group 23: Fuel system ………………………………..136
Engine control unit, changing …………………………136
Injection pump, changing ………………………………138
Injectors and fuel supply pipes, change …………..139
Pressure limiting valve ………………………………….143
Fuel suction pressure, checking……………………..144
Fuel pressure sensor, change ………………………..145
Group 25: Inlet and exhaust system …………….146
Turbocharger, inspection ……………………………….146
Turbo, replacing …………………………………………..148
Exhaust manifold, change ……………………………..150
Group 26: Cooling system …………………………..152
Coolant pump, change ………………………………….152
Thermostat, function check/change ………………..153
Sea water pump, change……………………………….154
Seawater pump, impeller change … see “Service work”
Sea water pump, seal, change ……………………….155
Coolant temperature sensor, replacing …………….157
Heat exchanger, pressure testing ……………………158
Heat exchanger, replacing ……………………………..159
Heat exchanger, cleaning/renovation ……………….161
Oil cooler, steering servo, change …………………..162
Intercooler, pressure testing …………………………..163
Intercooler, change ………………………………………164
Intercooler, cleaning/renovation ………………………166
Oil cooler, engine, change ……………………………..167
Group 30: Electrical (other) …………………………168
Alternator, changing ……………………………………..168
Starter motor, changing …………………………………169
Technical data ……………………………………………..170
General ………………………………………………………170
Short block …………………………………………………170
Inlet and exhaust system ………………………………171
Fuel system ………………………………………………..171
Lubrication system ……………………………………….172
Cooling system ……………………………………………172
Electrical system …………………………………………173
Wiring diagram …………………………………………….174
Torque ……………………………………………………….175
Conversion table ………………………………………….177
References to Service Bulletins …………………….178
Alphabetical register …………………………………….179