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

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 – 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 – PDF DOWNLOAD

Language : English
Pages : 186
Downloadable : Yes
File Type : PDF

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 – 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

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 – PDF DOWNLOAD

Introduction:

• This workshop manual contains technical data, de- scriptions and repair instructions for the Volvo
  Penta products or product versions noted in the table of con- tents. Check that you have the
  correct Workshop Manual for your engine.
• Read the available safety information, “General Infor- mation” and “Repair Instructions” in the
  workshop manual before you start to do any service work.

About this Workshop Manual:

• This workshop manual contains technical data, de- scriptions and repair instructions for the
  following ma- rine 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
  designa- tion and number must always be given in all corre- spondence about any product.
• The Workshop Manual is produced primarily for the use of Volvo Penta workshops and service techni-
  cians. 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.

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