Volvo Penta D16C-A/B/C/D MH, D16C-A MG Groups 21-26 Workshop Manual 459795601 – PDF DOWNLOAD

Description

Volvo Penta D16C-A/B/C/D MH, D16C-A MG Groups 21-26 Workshop Manual 459795601 – PDF DOWNLOAD

FILE DETAILS:

Volvo Penta D16C-A/B/C/D MH, D16C-A MG Groups 21-26 Workshop Manual 459795601 – PDF DOWNLOAD

Language : English
Pages : 234
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Volvo Penta D16C-A/B/C/D MH, D16C-A MG Groups 21-26 Workshop Manual 459795601 – PDF DOWNLOAD

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
/Replacement of components
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 161
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

DESCRIPTION:

Volvo Penta D16C-A/B/C/D MH, D16C-A MG Groups 21-26 Workshop Manual 459795601 – 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 contents. Check that you are using the
  correct Work- shop 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.

Standard times (Flat Rate):
Operation numbers that show in instruction headings refer to Volvo Penta Flat Rates.

IMAGES PREVIEW OF THE MANUAL:

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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