Volvo Penta D4 D6 Workshop Manual Groups 20-26 – English

Description

Volvo Penta D4 D6 Workshop Manual — Groups 20 to 26

This is the Volvo Penta D4 D6 Workshop Manual Groups 20-26, the English-language service and repair manual used for the D4 and D6 marine diesel engine families. Published under document number 47700149 with a 09-2017 edition date, it covers engine mechanical work, lubrication, fuel, air and exhaust, turbocharging and supercharging, and the complete cooling system. The manual contains technical data, component descriptions, removal and installation procedures, inspection and measurement routines, tightening torques, tightening schedules, sealant specifications, and the special tools required for each job.

File Details

• Manual type: Workshop / Service Manual
• Brand: Volvo Penta
• Models covered: D4, D6
• Document number: 47700149
• Edition / date: 09-2017
• Language: English
• Page count: 308 pages
• File format: PDF

Chapters Covered

• General Information — General, Specifications, Engine specifications, Electrical specifications, Steering specifications, Safety instructions, Special service tools, Chemical products
• 20-0 Engine Information, General — Troubleshooting, Miscellaneous
• 21-0 Engine Complete, General — Engine disassembly, Engine assembly
• 21-1 Cylinder Head — Removal, Inspection, Copper sleeve replacement, Pipe connection sizing
• 21-2 Cylinder Block — Cylinder wall inspection
• 21-3 Cylinder Liner, Pistons — Piston inspection, Piston ring measurement and inspection
• 21-4 Valve Mechanism — Valve guide inspection and replacement, Valve seat and valve grinding, Valve seat change
• 21-5 Timing Gears and Shaft — Balance shaft housing overhaul (D4), Camshaft inspection, Camshaft checking and adjusting, Flywheel indication
• 21-6 Crank Mechanism — Con rod inspection, Crankshaft and bearing inspection, Crankshaft overhaul, Polygon hub replacement, Gear ring replacement, Flywheel housing indication, Flywheel housing Aquamatic
• 21-9 Miscellaneous — Compression test
• 22-0 Lubricating and Oil System, General — Engine oil pressure check
• 22-1 Oil Pump and Line — Lube oil pump inspection
• 22-3 Oil Cooler — Oil valve housing inspection
• 23-3 Fuel Feed Pump and Filter — Checking fuel pressure at the high-pressure pump, High-pressure pump change
• 23-4 Fuel Tank, Fuel Lines, Evaporator — Fuel hose supply and suction
• 23-7 Injectors and Delivery Pipes — Return flow check from injectors, Injector change
• 23-9 Miscellaneous — Pressure limiting valve change, Rail pressure sensor change, Fuel system bleeding
• 25-5 Turbo and Supercharger — Turbocharger removal, installation and inspection, Compressor housing cleaning, Mechanical supercharger fault tracing, Magnetic coupling change
• 25-9 Miscellaneous — Exhaust back pressure check, Charge air pressure check
• 26-1 Radiator, Heat Exchanger — Heat exchanger/oil cooler overhaul, Pressure testing
• 26-2 Coolant Pump, Thermostat — Circulation pump overhaul, Thermostat function check, Thermostat housing overhaul
• 26-5 Charge Air Cooler with Connections — Removal, Installation, Overhaul, Pressure testing
• 26-6 Sea Water System, Sea Water Pump — Impeller change, Seawater pump overhaul (early and later models), Seawater system pressure testing
• 26-9 Miscellaneous — Fresh water system pressure testing
• Index — References to Service Bulletins

This Volvo Penta D4 D6 Workshop Manual is built around the actual service procedures used in Volvo Penta workshops, with the illustrations and tightening schedules needed to carry them out correctly. The engine mechanical sections walk through complete disassembly and assembly of the D4 and D6, from removing the upper covers through separating the cylinder head, oil sump, flywheel housing, pistons and crankshaft. Cylinder head work includes valve guide replacement, valve seat grinding and replacement, copper sleeve replacement with the hydraulic press procedure, and cylinder head non-return valve service. The crank mechanism chapters cover main and big-end bearing inspection, crankshaft measurement and crack inspection, polygon hub replacement, and flywheel/flywheel housing indication.

Fuel system coverage is detailed and practical: checking fuel pressure at the high-pressure pump, changing the high-pressure pump, checking injector return flow with the excess fuel tester, injector replacement, and pressure limiting valve and rail pressure sensor service. The lubrication section covers oil pressure checking and lube oil pump inspection with end float and gear lash measurement. The cooling and seawater sections take the technician through heat exchanger and oil cooler overhaul and pressure testing, circulation pump overhaul, thermostat function testing, charge air cooler overhaul, and seawater pump impeller and bearing service for both early and later model pumps. Turbocharger removal, installation and inspection — including axial end float and radial clearance measurement — is covered for the D4 and D6, along with magnetic coupling replacement on supercharged engines.

Tightening Torques and Specifications

The Volvo Penta D4 D6 Workshop Manual includes the tightening torque tables that matter on these engines: main bearing bolts, connecting rod bolts, cylinder head bolts, flywheel and flywheel housing, vibration damper, polygon hub centre screw, injector yoke bolts, delivery pipes, and the torque/angle tightening sequences. General tightening torques for M6 through M16 fasteners are listed, along with the specific tightening schedules and bolt tightening sequences for the cylinder head, valve cover, balance shaft housing, reinforcement frame and oil sump. Sealant part numbers, application thickness, and open time are specified where they matter — for example the red sealant 1161059 and black sealant 888661 used on the side plate, valve cover, inlet manifold, charge air cooler, oil pan and flywheel housing. The manual also covers the marking of reused cylinder head, main bearing and connecting rod bolts.

Specifications chapters give the D4 and D6 bore, stroke, swept volume, compression ratio, firing order, weights, oil capacities and oil pressure figures, charge air pressure at various engine speeds, cooling system data, thermostat opening temperatures, seawater pump capacity, electrical system voltage and alternator output, and starter motor ratings. For technicians working on emission-certified engines, the manual also states the requirement to use Volvo Penta approved spare parts and to have injection pump, pump setting and injector work carried out by an authorised Volvo Penta workshop.

What This Manual Lets You Do

With this Volvo Penta D4 D6 Workshop Manual you can carry out full engine overhauls, top-end work, timing gear and camshaft service, crankshaft and bearing work, fuel system diagnosis and repair, injector replacement, turbocharger service, cooling system overhaul, charge air cooler and seawater pump repair, and the pressure testing routines that confirm the work is sealed and correct. It gives you the measurements, wear limits, torques and tightening sequences so bearings, cylinder heads, injectors, turbochargers and cooling components are assembled the way Volvo Penta specifies — not by guesswork.

IMAGES PREVIEW

The manual is delivered as an instant PDF download, with no shipping and no waiting. It opens on any device — workshop PC, laptop, tablet or phone — and can be printed for the bench. Keep a copy on the service computer and a printed copy in the engine bay so the torque figures and procedures are always to hand when you are working on a D4 or D6.