service and maintenance

16L industry
 © 2017 AB VOLVO PENTA
Volvo Penta reserves the right to make changes
Printed on environmentally friendly paper
 Table of Content
Safety Information ...................................................................................... 2
Spare parts - safety ................................................................................... 4
General Information .................................................................................. 10
Service Protocol ....................................................................................... 12
Preventive repair ...................................................................................... 13
Genuine Volvo Penta Parts ...................................................................... 17
Illustrations ............................................................................................... 18
Chemical products .................................................................................... 19
Chemical products ................................................................................... 19
Specifications ............................................................................................ 20
Engine Decals .......................................................................................... 20
General Tightening Torques ..................................................................... 21
Specifications ........................................................................................... 22
Engine ........................................................................................................ 24
Component location ................................................................................. 24
Maintenance Schedule ............................................................................ 28
General inspection ................................................................................... 29
General advice for electronic protection .................................................. 31
Check software status ............................................................................. 32
Air Filter ................................................................................................... 32
Crankcase ventilation .............................................................................. 33
Air filter Compressor, filter replace ........................................................... 34
Valves, Adjustment .................................................................................. 34
Lubrication System ................................................................................... 35
When you work with Chemicals, Fuel and Lubrication Oil, Change ........ 35
Engine Oil, Level Check .......................................................................... 35
Engine oil, Replace .................................................................................. 37
Oil filter, Replace ...................................................................................... 39
Fuel System ............................................................................................... 46
General .................................................................................................... 46
Fuel Pre-filter, Replace ............................................................................ 47
Fuel filter, Change .................................................................................... 51
Fuel system, bleeding .............................................................................. 53
Exhaust System ........................................................................................ 56
Turbocharger, Inspection ......................................................................... 56
Charge Air Pipe, Leakage Check ............................................................ 58
SCR System ............................................................................................ 59
Nox-sensor Pre/Post SCR ....................................................................... 62
Cooling System ......................................................................................... 63
Coolant Level, Checking and Topping Up ................................................ 63
Coolant Filter, Replace ............................................................................ 68
Coolant Pump (Electric), Replace ............................................................ 70
Drive Belt, Replace .................................................................................. 71
Long-Term Storage ................................................................................... 75
Storage instruction for long-term storage of new engine ......................... 77
Cleaning engine and transmission ........................................................... 79
Checklist .................................................................................................. 81
Battery, Maintenance ............................................................................... 82
Index ........................................................................................................... 85

47709832 09-2023 © AB VOLVO PENTA 1

Safety Information
This chapter describes how safety precautions are If anything remains unclear or if you are unsure
presented in the manual and on the product. Read of something, contact your Volvo Penta dealer for
the chapter through very carefully before you start the assistance.
engine or do any maintenance or service. It has to do
with your safety; an incorrect operation can lead to IMPORTANT:
personal injury and damage to products or property. Always follow local safety instructions and
It also gives you an introduction to the basic safety regulations.
rules for using and looking after the engine.

Safety texts have the following order of priority:

DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.

WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious
personal injury.

CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
personal injury.

IMPORTANT:
Indicates a situation, which, if not avoided, could result in property damage.

NOTICE! Used to draw attention to important information that facilitates work or

operations.

!
This symbol is may be used on the product to call your attention to the fact that this is
safety information. Always read such information very carefully.

Make sure that warning and information symbols on the engine are clearly visible and
legible. Replace symbols that have been damaged or have been painted over.

In some cases, this symbol is used on our products and refers to important information
in the Operator’s Manual.

2 47709832 09-2023 © AB VOLVO PENTA

 Safety Information

Most chemicals such as engine and transmission

oils, glycol, petrol and diesel oil and chemicals used
in workshops such as degreasing agents, paint and
solvents are harmful to health.

Carefully read the instructions on the product

packaging! Always follow the safety regulations, such
as the use of protective masks, goggles, gloves, etc.
Make sure that other personnel are not exposed to
substances that are hazardous to health. Ensure good
ventilation.

Manage used and leftover chemicals in the prescribed

manner.

Personal safety equipment

CAUTION!
Always use appropriate safety equipment. Personal
protective equipment does not eliminate the risk of
injury but it will reduce the degree of injury if an
accident does happen.

Some examples are ear protection, eye and face

protection, protective footwear, personal protective
equipment, head protection, protective clothing,
gloves and respirators.

WARNING!
Ensure that all machine guards and safety devices are
in place and are functional.
P0024482

CAUTION!
Never use tools or products that show signs of
damage.

Protect your eyes

CAUTION!
Wear safety glasses.

Always wear safety glasses if there is a risk of

splintering, sparks and spray from the electrolyte (so-
called battery acid), or other chemicals. Your eyes are
very delicate and damage can result in loss of sight!

Protect your skin

CAUTION!
Risk of skin damage.

Avoid getting oil on your skin! Prolonged or repeated

exposure to oil can dry out the skin. Thereafter,
irritation, dryness and eczema and other skin problems
may occur.

Use protective gloves and avoid oil-soaked clothes

and rags. Wash regularly, especially before eating.
Wear suitable protective creams to prevent skin from
drying out and to facilitate cleaning.

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Safety Information

Fire safety
WARNING!
Fire and Explosion Risk!
Accidental spark could ignite fuel vapors.

All fuels – as well as many lubricants and chemicals

– are flammable. Do not allow open flames or sparks
near them. Smoking forbidden! Hydrogen from the
batteries is also very flammable and explosive in
certain mixture with air.

Ensure that the workplace is well ventilated and take

the necessary precautions before welding or grinding
begins. Always ensure that there is a fire extinguisher
close at hand in the work area.
P0024470

Spare parts - safety

WARNING!
Always use Volvo Penta genuine spare part to
minimize the risk of an explosion or fire.

Components in fuel systems and electrical systems on

Volvo Penta engines are designed and manufactured
to minimize the risk of explosions and fire, in
accordance with applicable legal requirements.

Used oils, filters and chemicals etc.

WARNING!
Risk of fire.
Store fuel soaked rags and other flammable material
so that there is no danger of them catching fire.

Oil-soaked rags can spontaneously ignite under

certain circumstances.

IMPORTANT:
Used fuel and oil filters are environmentally hazardous
waste and must be taken to an approved waste
management facility for correct handling, as must any
used lubricating oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.

Prevent start of the engine

WARNING!
Immobilize the engine by turning off the power supply
with the main switch(es) and lock it (them) in the off
position before starting work. Place a warning notice
at the main switch.
If the engine is equipped with BMS (Battery
Management System), always disconnect both battery
cables from the battery terminals.

4 47709832 09-2023 © AB VOLVO PENTA

 Safety Information

Ventilation when running the engine

WARNING!
Only start the engine in a well-ventilated area. If
operating the engine in a closed area ensure that
there is exhaust ventilation leading out of the work area
to remove exhaust gases and crankcase ventilation
P0024481 emissions.

The engine must not be operated in areas where there

are explosive materials or stored gas.

Rotating parts and hot surfaces

DANGER!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
If the engine is in operation and operates another
device, you must not, under any circumstances,
staying close to the engine.
P0024808
Work on running engines is strictly prohibited. There
are however adjustments that require the engine to
be run. Approaching a running engine is a safety risk.
Loose clothing and long hair can get caught in the
rotating parts; careless movements or a dropped tool
can lead to serious personal injury.

Be careful to avoid hot surfaces (exhaust pipes,

turbochargers, charge air manifolds, start elements
etc.) and hot fluids in pipes and hoses on engines
that are running or have just stopped. Re-install
all protective covers that were removed during
maintenance work before starting the engine.

Information on the engine

IMPORTANT:
Make sure that all warning and information decals on
the product are always visible. Replace decals which
have been damaged or painted over.

47709832 09-2023 © AB VOLVO PENTA 5

Safety Information

Prohibition on use of start spray

WARNING!
Never use start spray or similar agents to start an
engine. This may cause an explosion in the inlet
manifold. Risk of personal injury.

P0024483

Before start of engine

WARNING!
Never start the engine if there is reason to suspect
fuel and/or gas leaks, or if there is explosive material
nearby.

IMPORTANT:
Only start the engine with the air filter and protective
caps fitted. Foreign objects in the inlet line could cause
machine damage. Also make sure that no tools or other
P0024688 parts have been left next to the engine.

WARNING!
Never start the engine with the valve cover removed.
There is a risk of personal injury.
For engines with turbochargers, the rotating
compressor turbine can in addition cause serious
personal injuries.

Before any work on the electrical system

WARNING!
Always stop the engine first. Then disconnect the
current at the main switches and any external power
supply before working on the electrical system – to
minimize the risk of electrical hazards.

IMPORTANT:
Never disconnect the current using the main switches
when the engine is running or by disconnecting the
battery cables.
The alternator and electronics could be damaged.

Avoid damage to the engine control

module and other electronics
IMPORTANT:
Switch off the main switch before connecting or
disconnecting a connector.

Before any work on the cooling system

WARNING!
Stop the engine and let it cool before starting work on
the cooling system. Hot fluids and hot surfaces can
cause burns.

6 47709832 09-2023 © AB VOLVO PENTA

 Safety Information

Hot coolant under pressure

CAUTION!
Hot coolant can cause burns. Avoid opening the filler
cap for the coolant when the engine is still hot. Steam
or hot coolant can spray out and system pressure is
lost.

Open the filler cap slowly, and release the pressure in

the cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose must be removed
from a hot engine.

Hot oil under pressure

CAUTION!
Hot oil can cause burns. Avoid getting hot oil on
the skin. Ensure that the lubrication system is not
pressurized before starting any work. Never start or
operate the engine without the oil filler cap is on. There
is a risk that hot oil can spray out.

At any leak detection on the fuel system

WARNING!
Wear safety goggles!
Be extremely careful when searching for leaks in the
fuel system high-pressure circuits. There is very high
pressure in the jet from pipes and injectors. The fuel
may penetrate the tissue and cause serious risk of
P0024488
blood infection (septicemia).

Handling of fuel pipes

IMPORTANT:
High pressure pipes for fuel must not be bent or
straightened under any circumstances. Cracks may
occur. Damaged pipes must be replaced.

Before any work on the fuel system —

Cleanliness
IMPORTANT:
Take great care to keep the fuel system components
clean. Even minimal amounts of dirt can cause engine
breakdown.

Safe handling of batteries

WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.

A spark caused by an incorrectly connected battery

can be sufficient for the battery to explode resulting in
serious injury and damage.

Do not touch the connections during a starting attempt.

Spark hazard! Do not lean over batteries.

47709832 09-2023 © AB VOLVO PENTA 7

Safety Information

Correct polarity of the batteries

IMPORTANT:
Make sure that the positive (+) and negative (–) battery
cables are correctly connected to the corresponding
battery terminals. Wrong connection may cause
severe damage to electrical equipment.

P0024468

Risks of electrolyte in batteries

WARNING!
Always wear protective goggles when charging or
handling batteries.
Battery electrolyte is highly corrosive.

Rinse immediately with copious amounts of water if the

electrolyte gets in your eyes. Search directly after the
rinsing help by medical staff.

If it comes electrolyte to unprotected skin, wash

immediately with soap and water.

After finished work with the engine

IMPORTANT:
Always perform a leakage and function check.

Cleaning the engine and components

NOTICE! Follow the instructions Cleaning engine and
transmission, page 79.

P0026213

Cleanliness for sensitive components

IMPORTANT:
Observe meticulous cleanliness when handling
system components.
Even minimal amounts of dirt could cause a
breakdown.

Lifting the engine

WARNING!
Never work alone when removing heavy components,
even when using lifting devices such as locking tackle
lifts.

P0024485

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 Safety Information

IMPORTANT:
When using a lifting device, two people are usually
required to do the work – one to take care of the lifting
device – and the other to ensure that components
are lifted clear and not damaged during the lifting
operations.

Proper lifting equipment

DANGER!
The existing lugs on the engine should be used for
lifting. Always check that the lifting equipment used
is in good condition and has the load capacity to
lift the engine (engine weight including transmission
and extra equipment). For safe handling and to avoid
damaging components fitted to the top of the engine,
the engine must be lifted with a correctly adjusted lifting
boom.
Never perform any work on an engine that is only
suspended from the lifting equipment.

IMPORTANT:
All chains or wires must run parallel to each other and
as perpendicular to the engine as possible. If other
equipment attached to the engine has altered its center
of gravity, special lifting devices may be needed to
obtain the correct balance for safe handling.

P0024689
Example of an adjustable lifting yoke and a lifting tool.

47709832 09-2023 © AB VOLVO PENTA 9

General Information

General Information
General information Specific terms for the U.S. market
This service and maintenance manual contains This engine is certified as being in compliance
descriptions and instructions for the service of the with federal and Californian exhaust restriction
above-mentioned Volvo Penta products in their regulations. Parts related to exhaust restrictions are
standard models. The design and servicing items may covered by the warranty commitment for exhaust
vary between different products. Applicable service restricting systems. Terms and the parts covered are
intervals and service procedures are described in the specified under "What is covered by the warranty
maintenance schedule for the product. undertaking for emissions” in “Emission Control
System Warranty Statement”. Repairs and service
The product designation, serial number and covered by the warranty are carried out by an
specification are indicated on the engine decals or authorized Volvo Penta distributor or dealer at no
type plate. This information must always be provided charge for diagnostics, labor or parts using genuine
in all correspondence concerning the product. Volvo Penta parts in all areas of the exhaust restriction
system covered by the warranty and found to be
The manual has been produced primarily for use in
defective.
Volvo Penta workshops. It is assumed that persons
using the manual have fundamental knowledge of the The use of the service and repair workshop other
product and are capable of carrying out mechanical than a Volvo Penta authorized distributor or dealer
and electrical work to industry standards. or the use of exhaust-related components from
other manufacturers than Volvo Penta do not affect
Volvo Penta continually develops its products. We
the scope of the warranty undertaking for emission-
therefore reserve the right to make changes.
restricting systems. If emission-related components/
All of the information in the manual is based
items are included in scheduled service, such parts
on product data available when the manual was
are marked with a diamond (♦) in the maintenance
published.
schedule and service must be carried out at the
NOTICE! The owner is responsible for ensuring specified intervals in order to meet the requirements
that scheduled maintenance is carried out. Warranty of the warranty undertaking for emission-restricting
claims to Volvo Penta may be declined if neglected systems. The full warranty terms can be found in
maintenance results in faults in the specified product. “Emission Control System Warranty Statement”.
Refer to the warranty terms supplied with the engine.

10 47709832 09-2023 © AB VOLVO PENTA

 General Information

Certified engines
Explanation of the relationship between
The engine is exhaust-certified, and if it is used in
an area where exhaust emissions are regulated
service intervals and operating
by law, this places special demands on the care conditions
and maintenance of the engine. Because operating conditions may vary depending
NOTICE! Neglect or failure to follow the items on how the component is used, it is important that the
required here may invalidate the engine emissions service interval (expressed in hours or months) is not
certificate. exceeded.
This means that AB Volvo Penta will no longer Example: 1000 hours / 24 months. Whichever is the
be able to assume liability for engine specification sooner applies. If the component is used for 1000
compliance with the certified model. Volvo Penta is hours in 18 months, the service must be carried out
not responsible for damages or costs arising as a when the 1000-hour interval is reached.
result of this.
This is to retain the component’s best quality and
• Certification means that an engine type
service life. The warranty will be void if this is not
has been inspected and approved by
complied with.
the competent authorities. The engine
manufacturer guarantees that all engines made Typical examples are: Propeller shaft seals operating
of the same type are equivalent to the certified in sandy waters. Air filters exposed to heavily polluted
engine. air
• It is the responsibility of the user to make sure
Action codes used in the service schedule:
no intentional misuse of the engine takes place.
C = Cleaning
• Volvo Penta maintenance and service intervals R = Replacement
must be followed. A = Adjustment
L = Lubricate
• All faults must be remedied as soon as possible.
I = Inspection (includes where necessary also
• Only use genuine Volvo Penta replacement adjustment, cleaning, lubrication and replacement)
parts or parts of the same quality as Volvo Penta
replacement parts.
• The engine may not be converted or modified in
any way, except with accessories and service
kits which Volvo Penta has approved for the
engine.
• Volvo Penta recommends that service on
injection pumps, pump settings and injectors
always be carried out by a qualified workshop.
• No changes may be made to the installation of
the exhaust pipe and engine air inlet ducts.
• Any tampering with the engine will hamper EU
type-approval of the engine concerned.
• No warranty seals (if present on the product)
may be broken by unauthorized persons.

47709832 09-2023 © AB VOLVO PENTA 11

General Information

Service Protocol
To maintain the functionality of the product Service
Protocol shall be followed. The owner or other persons
with sufficient technical competence may carry out
some measures in accordance with Service Protocol.
Contact an authorized Volvo Penta dealer in the
case of uncertainty as to how service work must be
performed.

Service Protocol contains the necessary maintenance

points for your engine in a single document. See
more on Volvo Penta‘s website: vppn.volvo.com and
Product Center for online service protocol.

IMPORTANT:

TWD1683VE
Normal service interval for TWD1683VE is 1000 h.

Recommendation
For fuel consumption in excess of 65 l/h, Volvo
Penta recommends an oil change interval of 500h or
alternatively follow the procedure for extended service
intervals with oil analysis.

12 47709832 09-2023 © AB VOLVO PENTA

 General Information

Preventive repair
Here is an overview of the components that may be included in preventive maintenance. May vary depending
on the engine's design and construction.
These components form the basis for calculating service contracts and the costs in the service calculator in
Product Center.

Fuel system
Fuel pump
Unit injectors

P0026295

Exhaust system
Turbocharger, low-pressure
Turbocharger, high pressure
Overflow valve (Lisk)
Silencer
Diesel particulate filter (DPF), replacement

After-treatment system
Pump unit
Dosage valve

P0026296

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General Information

Cooling system
Coolant pump

Engine
Vibration dampers

P0026297

Electrical system
Alternator
Starter motor

P0026298

14 47709832 09-2023 © AB VOLVO PENTA

 General Information

Engine, overhaul
Here is an overview of the components that may be included in a complete overhaul. May vary depending on
the engine's design and construction.
E.g. liners may not be replaced on certain engines. In this case, cylinders must be measured to see if new pistons
can be installed or if the engine block should be replaced.
The components below provide the basis for calculating service contracts and the costs in the service calculator
in Product Center.

Engine: May be overhauled once, after which the engine will be regarded as spent and will be replaced by a
“long block” or a new engine.

Overhaul
Long block
Short block
Cylinder head (replacement)
Cylinder head, gasket

P0026299

Engine, overhaul kit

Cylinder head, overhaul kit
Gaskets, set
Flat gaskets
Valve cover, gasket

P0026300

47709832 09-2023 © AB VOLVO PENTA 15

General Information

Cylinder liners, set

Main bearings, set
Big end bearings, set
Thrust washers, set
Camshaft bearings, set

P0026301

Exhaust valve
Valve seat

P0026302

16 47709832 09-2023 © AB VOLVO PENTA

 General Information

Genuine Volvo Penta Parts

Volvo Penta products are designed and manufactured
to achieve the highest quality. All parts are
manufactured so that together they provide the best
possible reliability. Therefore we always recommend
the use of Genuine Volvo Penta Parts, as they
are manufactured based on the same stringent
specifications as the factory-installed parts in Volvo
Penta drivelines.

Lube oils
Volvo Penta supplies a wide range of lubricants
developed especially for Volvo Penta engines. VDS
(Volvo Drain Specification) is a Volvo standard
that specifies Volvo’s quality requirements. We
recommend the use of the specified oil to ensure
engine function and a long service life.

Coolant
The main function of a coolant is to absorb heat from
the engine. The coolant also protects against freezing,
lime deposits and corrosion. Volvo Penta Coolant VCS
(yellow) and Volvo Penta Coolant (green) are two
completely different types of coolants, which contain
different types of inhibitors. Different types of coolants
(colors) must not be mixed.

If the concentrated coolant must be diluted with

water, the water's chemical composition may impair
the corrosion protection. In areas with high levels of
sodium and calcium in tap water, the coolant must be
diluted with distilled water. Alternatively, Volvo Penta
coolant is available for purchase ready diluted.

Protection against
Mixing the freeze bursting down
concentrated coolant to:
40 % -25 °C
46 % -30 °C
54 % -38 °C
60 % -46 °C

NOTICE! It is important to use coolant with a

concentration of 40-60 % in the cooling system even
where there is no risk of freezing. The coolant also
prevents corrosion and deposits. A mixture with
a concentration above 60 % will impair antifreeze
protection.

47709832 09-2023 © AB VOLVO PENTA 17

General Information

Illustrations

Colors used in illustrations

• Highlighted components
Most illustrations include a highlighted component
(blue)
which is secured by a bolt or similar as part of a (light
gray) engine or transmission. • Fastener
(red)
• Assembly
(light gray)
• Background
(white)
• Special tools
(yellow)
• Seals
(green)
(as of 06/2018)

P0022106

Other types of symbols used in the images are

divided into the following categories:
• Safety
• Important
• Cleanliness
• Position
• Movement
• Measured value
• Tools
• Chemicals
• Sealant
• Units

18 47709832 09-2023 © AB VOLVO PENTA

 Chemical products

Chemical products
Chemical products
A selection of Volvo Penta recommended chemical
products is shown below. Also refer under
Specifications.

P0001869

Thread locking fluid Corrosion protection Sealant

Engine oil VCS Coolant Grease

47709832 09-2023 © AB VOLVO PENTA 19

Specifications

Specifications
Engine Decals
There are type plates on the engine, and in the case
of marine applications, also on the drive-lines. Some
of the type plates are marked with identity numbers.
Always use this information as a reference when
ordering service and replacement parts or contacting
Volvo Penta retailers.

P0030332

A Product information
B Emissions information
C CHASSIS ID
D Engine information

20 47709832 09-2023 © AB VOLVO PENTA

 Specifications

General Tightening Torques

Bolt Nm
M6 standard bolt 10
M8 standard bolt 24
M10 standard bolt 48
M12 standard bolt 85
M14 standard bolt 140
M16 standard bolt 220
NOTICE! Check the bolts intended for
installation Damaged bolts with e.g. shear
marks under the heads, must be scrapped.

47709832 09-2023 © AB VOLVO PENTA 21

Specifications

Specifications

Volvo Penta products, all markets excluding North America

Oil quantity in engine, including filter 48 liters
TAD1640–1672VE/GE
TWD1643–1673GE
TWD1683VE/GE

VDS–4.5 SAE10W–30
Part number: 23068339 5 liters
Part number: 17488420 20 liters
Part number: 17488431 208 liters
TWD1683VE/GE
VDS-4.5 SAE15W-40
Engine oil. Part number: 23909459 1 liter
Engine oil. Part number: 23909460 5 liters
Engine oil. Part number: 23909461 20 liters
Engine oil. Part number: 23909462 208 liters
TAD1640–1672VE/GE
TWD1643–1673GE

Coolant, VCS yellow, concentrated

Part number: 22567295 5 liters
Part number: 22567307 210 liters
Coolant, VCS yellow, ready-mixed
Part number: 22567314 5 liters
Part number: 22567340 210 liters
Volume ready-mixed VCS yellow coolant, (engine + standard radiator + hoses) 37 liters
TAD1640–1672VE
TWD1683VE
Volume ready-mixed VCS yellow coolant, (engine + standard radiator + hoses + 54 liters
expansion tank)
TAD1640–1651GE
Volume ready-mixed VCS yellow coolant, (engine + standard radiator + hoses + 48 liters
expansion tank)
TWD1643–1683GE

Volumes may differ if the installation has extra coolers/

radiators connected.

NOTICE! Old model engines have green coolant,

which must NOT be mixed with newer VCS yellow
coolant. Check that the engine is using the same type.

NOTICE! Yellow and red Volvo Penta ATF Dextron III

oil may be mixed without causing any problems.

22 47709832 09-2023 © AB VOLVO PENTA

 Specifications

Volvo Penta products for North America

Oil quantity in engine, including filter 12.68 gallons
TAD1640–1672VE/GE
TWD1643–1673GE
TWD1683VE/GE

VDS–4.5
Part number: 23219282 1 US quart
Part number: 23219274 1 US gallon
Part number: 23219264 5 gallons
Part number: 23219260 55 gallons
Part number: 23219246 330 gallons

Coolant, VCS yellow, concentrated

Part number: 22567295 1 US gallon
Part number: 22567307 55.47 gallons
Coolant, VCS yellow, ready-mixed
Part number: 22567314 1 US gallon
Part number: 22567340 55.47 gallons
Volume ready-mixed VCS yellow coolant, (engine + standard radiator + hoses) 9.78 gallons
TAD1640–1672VE
TWD1683VE
Volume ready-mixed VCS yellow coolant, (engine + standard radiator + hoses + 8.72 gallons
expansion tank).
TAD1640–1651GE
Volume ready-mixed VCS yellow coolant, (engine + standard radiator + hoses + 12.68 gallons
expansion tank)
TWD1643–1683GE

Volumes may differ if the installation has extra coolers/

radiators connected.

NOTICE! Old model engines have green coolant,

which must NOT be mixed with newer VCS yellow
coolant. Check that the engine is using the same type.

NOTICE! Yellow and red Volvo Penta ATF Dextron III

oil may be mixed without causing any problems.

47709832 09-2023 © AB VOLVO PENTA 23

Engine

Engine
Component location

P0028644

TAD
A Drive belts E Oil dipstick
B Purging, fuel F Fuel filter
C Diagnostic connector G Fuel pre-filter
D Oil filler

24 47709832 09-2023 © AB VOLVO PENTA

 Engine

P0028646

TAD
A Air filter E Engine block drain
B Turbocharger F Bottom plug, oil drainage
C Expansion tank, coolant G HD radiator drain
D Oil filter H Drain, std radiator

47709832 09-2023 © AB VOLVO PENTA 25

Engine

P0028645

TWD
A Purging, fuel F Oil dipstick
B Diagnostic connector G Fuel filter
C Air filter H Fuel pre-filter
D Drive belts I Oil drain pump
E Oil filler

26 47709832 09-2023 © AB VOLVO PENTA

 Engine

P0028647

TWD
A High pressure turbocharger E Oil filter
B Low pressure turbocharger F Coolant drain, engine
C Expansion tank, coolant G Coolant drain, radiator
D Coolant drain

47709832 09-2023 © AB VOLVO PENTA 27

Engine

Maintenance Schedule
The Volvo Penta engine and its equipment are designed for high reliability and long life. The engine is built so as
to have minimal environmental impact. These qualities will be retained and unnecessary malfunctions avoided if
service is provided according to the maintenance schedule.

Service intervals
Service items can be found in the Service Record available for download at www.volvopenta.com.
Search under tab: Manuals.

Extended service intervals

The interval between engine oil changes may be extended in certain circumstances. To determine whether the
service interval may be extended, Volvo Penta's conditions for extended service intervals must be met and an oil
analysis performed, see , page 42.
The Volvo Penta dealer has further information.

Where both operating hours and calendar times are specified, perform the maintenance item at whichever time
is the sooner.

28 47709832 09-2023 © AB VOLVO PENTA

 Engine

General inspection
General inspection
Make a habit of visually inspecting the engine and
engine compartment before the engine is started and
after operation once the engine is stopped. This will
help you to discover quickly if anything abnormal has
happened, or is about to happen.

This inspection only takes a few minutes, but can

prevent serious malfunctions and expensive repairs.

The images are generic and applicable to all

engine installations. They show only a selection of
components and systems.
The inspection applies to all components in the
systems.

Look especially carefully for fuel leakage at:

Injector connections
Fuel sensors
Check all clamped items
Fuel filter
Fuel pipe/hoses
Fuel pump

P0028649

47709832 09-2023 © AB VOLVO PENTA 29

Engine

Oil leaking turbocharger connections, oil pipes/hoses, oil

sensors, oil filter and oil sump.
Check all clamped items.

P0028650

Coolant leakage on the coolant pump, expansion tank,

coolant cooler, oil cooler, charge air cooler, coolant
sensors, coolant hoses.
Check all clamped items.

P0028651

Also check:
Drive belts
Damaged wiring
Loose wiring
Loose fasteners
Exhaust hoses
Hoses/hose connections to transmissions

WARNING!

Accumulations of fuel, oil and grease on the engine or

in the engine compartment are a fire hazard and must
be removed as soon as they are discovered.

WARNING!

If you discover a leakage of oil, fuel or coolant,

investigate the cause and fix the fault before starting
the engine to avoid the risk of fire.

30 47709832 09-2023 © AB VOLVO PENTA

 Engine

General advice for electronic

protection
The following advice must be complied with to ● Never switch off the current at the main switch when
avoid damage to the engine control unit and other the engine is running.
electronics. ● Never disconnect a battery cable when the engine
is running.
IMPORTANT: ● Switch off the main switches or disconnect the
Switch off the main switch before connecting or battery cables when fast-charging the batteries.
disconnecting a connector.
● NOTICE! It is not necessary to switch off the main
switches during normal maintenance charging.
● Only batteries may be used as a starting aid. A jump
start unit is able to supply very high voltage which
may damage the control unit and other electronics.
● Take extreme care so that the harness terminals
do not come into contact with oil, water or dirt if a
connector is removed from a sensor.

The diagnostic connector is located at the side of the

engine.

47709832 09-2023 © AB VOLVO PENTA 31

Engine

Check software status

These readings depend on the type of installation and
are carried out using the VODIA diagnostics tool.

• Reading and resetting parameters.

• Reading and erasing any fault codes (DTC).
P0024905 • Resetting service intervals (EVC2).

Air Filter

The engine air filter is connected to the turbocharger

inlet pipe.

Replacing the air filter

• Open the fasteners and remove the cover.
• Remove the filter by pulling/rocking it straight out.
• Wipe clean around the attachment point.
• Install the new filter.
• Install the cover and close the fasteners.
NOTICE! Scrap the old filter. It is not designed to be
cleaned.

P0028664

32 47709832 09-2023 © AB VOLVO PENTA

 Engine

Crankcase ventilation

Crankcase separator
• Requires no service.

P0028665

47709832 09-2023 © AB VOLVO PENTA 33

Engine

Air filter Compressor, filter replace

NOTICE! Universal image - filter types may differ.

• Remove the hose clamp.

• Remove the air filter.
• Install a new filter.
• Tighten the hose clamp.
Tightening torque: 5 Nm

P0026927

Valves, Adjustment

Adjusting valve clearance is a task intended for

workshop-trained personnel. Refer to the Workshop
Manual.

Note the interval in the maintenance schedule for your

engine.

P0027051

34 47709832 09-2023 © AB VOLVO PENTA

 Lubrication System

Lubrication System
When you work with Chemicals,
Fuel and Lubrication Oil, Change
NOTICE! Apply barrier cream to your hands and
always use protective gloves for work which involves
contact with oil, fuel and similar. Continuous skin
contact with engine oil dries the skin and can be
hazardous.

Engine Oil, Level Check

NOTICE! It is very important that engine oil be kept at
a suitable level for correct engine lubrication.

A high oil level leads to increased oil consumption

and may cause clogging of the silencer and/or the
closed crankcase ventilation.

A low oil level may lead to seizing pistons, engine

wear and engine overheating.

Oil level check, hot engine.

• Make sure the engine is level.
• Stop the engine; wait a at least 15 minutes and then
measure the level.

Oil level check, cold engine. (recommended)

• Make sure the engine is level.
• Oil level measurement is most reliable before the
engine is started

Check that the oil level is between the dipstick's min

and max markings.

47709832 09-2023 © AB VOLVO PENTA 35

Lubrication System

A Oil level on the MIN marking: add oil until the level
is between min and max.
B Optimal oil level, do NOT add oil.
C Oil level at max marking; do NOT add oil.

P0028585

NOTICE! Never add too much engine oil.

36 47709832 09-2023 © AB VOLVO PENTA

 Lubrication System

Engine oil, Replace

Change the engine oil and filter within the
recommended service intervals.

P0028666

Drain the engine oil by connecting a pump to the oil

dipstick hole and drawing out the oil.

P0026944

47709832 09-2023 © AB VOLVO PENTA 37

Lubrication System

Alternatively, permanently connect a hand pump to the

bottom plug (recommended).

NOTICE! If the engine oil is hot, it will drain out faster.

38 47709832 09-2023 © AB VOLVO PENTA

 Lubrication System

Oil filter, Replace

We strongly recommend that only oil filters approved

by Volvo Penta are used.
An incorrect type of oil filter can lead to increased wear
and damage, for example to bearings and crankshaft.

P0027053

Removal

• Remove the oil filters with a universal puller.

• Clean around the filter attachment on the filter
housing.

P0027054

47709832 09-2023 © AB VOLVO PENTA 39

Lubrication System

Installation

• Lubricate the new O-ring with engine oil before

installing.

P0028667

• Fit the new filters.

P0028668

40 47709832 09-2023 © AB VOLVO PENTA

 Lubrication System

• Tighten according to the instructions on the filters.

P0027029

• Fill with the required amount of oil; refer to

Specifications, page 22.
• Start the engine.
• Check that no leakage occurs.
• Stop the engine and check the oil level after a few
minutes.
• Top up as necessary.

P0027056

47709832 09-2023 © AB VOLVO PENTA 41

Lubrication System

Volvo Penta oil analysis

Volvo Penta oil analysis provides an extensive diagnostic check on the condition of the driveline. The oil analysis
provides information for example on water content, fuel content, dirt and the amount of metallic particles in the oil
as a result of component wear.
Thanks to early warning signs given by oil analysis, preventive maintenance and component replacement can be
planned, so that unplanned shutdowns can be avoided.
Some engines allow the oil change intervals to be extended. There are two different service schedules available
for these engines. Refer to the Volvo Penta Product Center
In order to find out more about Volvo Penta Oil Analysis, we recommend our on-line training.

P0035460

P0024907

IMPORTANT:
This kit and its accompanying instructions have been developed for Volvo Penta's service workshops, boat builders,
machine manufacturers and other authorized workshops that have staff with qualified professional training. The
assembly instructions are intended for professionals only and are not intended for use by laypeople. Volvo Penta
assumes no liability whatsoever for damage to materials or persons that may occur if the assembly instructions
are not followed or if the work is carried out by non-professionally trained personnel.

42 47709832 09-2023 © AB VOLVO PENTA

 Lubrication System

Figure 1

P0035441 P0035462

Figure 2

P0035463

Engine Length (L)

D5, D8, D11, D13, D16 280 mm (11 in)

47709832 09-2023 © AB VOLVO PENTA 43

Lubrication System

Figure 3
D5, D8, D11, D13, D16

P0035464

Read the instructions before starting work. Check that all parts are included in the package. Illustrations can
be used for several different instructions. Therefore, objects in illustrations may differ from the installation in
progress. However, the main information is correct.

Designation Quantity Figure Position

Oil sampling bottle and postage packaging 5 1 1
Hose, reel, 100 m (328 ft) 1 1 2
Vacuum pump 1 1 3
Plastic bag 1 1 4
Not included in the kit intended for the U.S.
Installation instructions 1

General
Regular oil analyses provide improved insight into engine health.
Test reports are available on the Volvo Penta Partner Network within 48 hours of receiving the sample at the test
laboratory.
To obtain permission to access the report page, please contact Volvo Penta's sales office in each country.
NOTICE! The oil analysis is carried out to give recommendations. It can never replace service according to the
maintenance schedule.

44 47709832 09-2023 © AB VOLVO PENTA

 Lubrication System

Sampling instructions
1 Start the engine and run until it reaches normal operating temperature.
2 Stop the engine and wait 15 minutes before taking the oil sample.
3 Cut off a suitable length of hose.
Use the oil dipstick as measurement of length (L). Mark the dipstick length on the hose. The length (+) is
needed to connect the hose to the pump. See figure 2
IMPORTANT!
Before cutting the hose, make sure that it fits in the tube of the dipstick.
4 Fit the hose into the upper part of the vacuum pump. Let the hose protrude approximately 40 mm (1.6").
5 Attach the sampling bottle to the pump.
6 Insert the sampling hose into the dipstick tube.
Locate the length marking (L) on the hose.
Take the sample halfway between the oil surface and the bottom of the oil sump.
7 Pump up oil to flush the pipe.
Release the O-ring to break the vacuum and stop the oil flow.
Remove the sampling bottle and empty it. Ensure that the oil is collected in an environmentally friendly way.
8 Attach the sampling bottle to the pump and take an oil sample.
Fill the bottle to 80%. Remove the bottle and attach the cap immediately.
9 Send to the laboratory chosen by Volvo Penta to get your oil analysis report.

Clean the pump

• • Cut off the hose above the pump and pull the hose out of the pump from the opposite side to keep the
pump free of oil.
• Wipe the pump with a lint-free cloth or paper.
Apply a thin layer of silicone grease to both O-rings.
If necessary, use compressed air for cleaning.
• Assemble the vacuum pump and test its operation.
IMPORTANT:
Do not clean the pump with diesel, gasoline or detergents.

Additional orders through the spare parts system:

• Part number 21616535 (A kit that contains: Sampling bottles, vacuum pump, plastic hose, plastic tool bag
and instructions).
NOTICE! The plastic tool bag is not included in the version of the kit intended for the United States.
• Part number 21616560 (Hose reel, 100 meters, 328 feet).
NOTICE! See VPPN/Services/Volvo Penta oil analysis for oil wear limits.

47709832 09-2023 © AB VOLVO PENTA 45

Fuel System

Fuel System
General

The fuel system has a fine filter (A) and a pre-filter (B).

P0028669

46 47709832 09-2023 © AB VOLVO PENTA

 Fuel System

Fuel Pre-filter, Replace

CAUTION!
Risk of skin damage.

NOTICE! Be prepared to gather up fluid.

Removal

• Remove the water separator sensor connector.

P0027058

• Undo the drain nipple in the base of the water

separator. Drain the filter.
• Reinstall the drain nipple and tighten securely.

P0024714

47709832 09-2023 © AB VOLVO PENTA 47

Fuel System

• Remove the pre-filter together with the lower section

of the water separator. Use a universal puller for the
oil filter.

• Remove the lower section of the water separator

and O-ring from the filter.

P0028697

48 47709832 09-2023 © AB VOLVO PENTA

 Fuel System

• Clean the lower section of the water separator and

the contact surfaces. Check that the strainer and
drain hole in the lower section are not clogged.

Installation

• Install a new O-ring. Lubricate the seal with diesel.

• Install the lower part of the water separator.

P0028670

47709832 09-2023 © AB VOLVO PENTA 49

Fuel System

• Lubricate the sealing surface with diesel and screw

the new filter onto the filter bracket by hand until the
seal touches the sealing surface.
• Then tighten a further 1/2 turn.

P0028671

• Connect the connector.

• Open the fuel tap and vent the fuel pre-filter; refer to
Fuel system, bleeding, page 53.
• Check for leakage.

P0027058

50 47709832 09-2023 © AB VOLVO PENTA

 Fuel System

Fuel filter, Change

IMPORTANT!
Protect against dirt while work is in progress.

NOTICE! Be prepared to gather up fluid.

Removal

• Remove the fuel filter with the aid of a suitable filter

puller. Let the fuel drip off into a collection vessel.
• Clean around the filter housing sealing surface.

P0027061

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Fuel System

Installation
NOTICE! Do not fill the new filter with fuel before
installation; there is a risk that contamination may
cause malfunctions.

• Lubricate the sealing surface with diesel and

install the new fuel filter. Tighten according to the
instructions on the filter.

P0028672

• Purge by hand using the pump on top of the bracket

as described in Fuel system, bleeding, page 53.
• Start the engine and check for leaks.

P0027063

52 47709832 09-2023 © AB VOLVO PENTA

 Fuel System

Fuel system, bleeding

CAUTION!
Never disconnect a fuel line or component after the fuel
pump to bleed. The fuel is under very high pressure
and can penetrate the skin.

NOTICE! Check that there is sufficient fuel in the tank,

and that any fuel taps are open.

• Free the hand pump from the fuel filter bracket.

P0027065

• Open the bleed nipple and attach a hose.

• Connect a hose and a bottle/receptacle to the other
end of the hose to collect fuel during bleeding.

P0027066

47709832 09-2023 © AB VOLVO PENTA 53

Fuel System

• Purge the fuel system by pumping with the hand

pump until fuel flows without air bubbles.

P0027063

• Close the nipple.

Tightening torque: 3.5 Nm
• Remove the hose and fit the protective rubber cover.

P0027066

54 47709832 09-2023 © AB VOLVO PENTA

 Fuel System

• Tighten the fuel pump handle.

• Wipe dry any spilled fuel.
• Start the engine and let it idle.
• Check that no leakage occurs.

P0027065

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Exhaust System

Exhaust System
Turbocharger, Inspection

TAD

Inspecting the turbocharger and charge air pipe

• Remove the protective grille.

• Remove the inlet pipe from the turbo.

• Remove the exhaust pipe from the turbocharger.
• Check the turbocharger with regard to damage to
the compressor and turbine wheels.
• In the case of damage, replace the turbocharger in
its entirety.

NOTICE! We recommend that turbocharger

replacement be carried out by a Volvo Penta
workshop.

P0028673

56 47709832 09-2023 © AB VOLVO PENTA

 Exhaust System

TWD
Inspecting the turbocharger and charge air pipe

• Remove the protective grille.

P0028674

• Remove the inlet pipe from the turbo.

• Remove the exhaust pipe from the turbocharger.
• Check the turbocharger with regard to damage to
the compressor and turbine wheels.
• In the case of damage, replace the turbocharger in
its entirety.

NOTICE! We recommend that turbocharger

replacement be carried out by a Volvo Penta
workshop.

P0028675

47709832 09-2023 © AB VOLVO PENTA 57

Exhaust System

Charge Air Pipe, Leakage Check

TAD
Inspect the charge air hose connections, hoses and
clamps with regard to cracks, leakage and other damage.
Replace as necessary.

TWD
Inspect the charge air hose connections, hoses and
clamps with regard to cracks, leakage and other damage.
Replace as necessary.

P0028676

Draining condensation water

Check that it is possible to drain the condensate through
the nipples (A).

P0028677

58 47709832 09-2023 © AB VOLVO PENTA

 Exhaust System

SCR System
Engines with SCR have filters that must be replaced.
Check the replacement intervals in the service
schedule for your engine.

NOTICE! Illustrative images of components.

Installations may differ between models.

• The pump unit filter.

P0029170

• Filter for air to the AdBlue/DEF tank.

P0029171

47709832 09-2023 © AB VOLVO PENTA 59

Exhaust System

• Filter for combined tank unit

NOTICE! Different variants of combined tank units and
filters may occur.

P0035090

Replacing the filter for the AdBlue/DEF pump

NOTICE! Maintain a high level of cleanliness when

working with the SCR system. Wipe clean around
covers and connections before beginning work. Make
sure the filter and gaskets do not come into contact
with dirty surfaces before installation.

• Switch off the engine. Wait until the pump unit has
stopped as it always performs a hose emptying
sequence.
• Disconnect the battery’s minus pole.
• Place a collection vessel under the filter cover.

P0026516

• Loosen the filter cover.

P0026517

60 47709832 09-2023 © AB VOLVO PENTA

 Exhaust System

• Use a puller (supplied with the filter kit) to pull out the
filter by pressing it into the filter hole until it clicks.
• Pull out the filter.

P0019390

• Install the new filter (A).

Install the rubber gasket (B).
Screw the filter cover (C) back on.

P0028678

47709832 09-2023 © AB VOLVO PENTA 61

Exhaust System

• Tighten the cover.

Tightening torque: 20 +5 Nm

P0026519

• Re-connect the battery negative terminal.

• Start the engine. Check operation and inspect for
leaks.
• Delete any fault codes.

P0026520

NOTICE! Take appropriate care of equipment and

surplus AdBlue/DEF solution.

p0013225

Nox-sensor Pre/Post SCR

When fault tracing or replacing components in the
aftertreatment system, refer to the EATS System
workshop manual.

62 47709832 09-2023 © AB VOLVO PENTA

 Cooling System

Cooling System
Coolant Level, Checking and
Topping Up
The engine's internal cooling system makes sure the
engine works at the right temperature. It is a closed
system that must always be filled with a mixture of
concentrated coolant and water in order to protect
the engine against internal corrosion, cavitation and
bursting due to freezing.

NOTICE! Different kinds of coolant may not be mixed.

WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

TAD

• Check the coolant level in the expansion tank.

• Top up with coolant as required (A), so that the level
is between the MIN and MAX marks.

P0028679

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Cooling System

TWD

• Check the coolant level in the expansion tank.

• Top up with coolant as required (A), so that the level
is between the MIN and MAX marks.

P0028680

64 47709832 09-2023 © AB VOLVO PENTA

 Cooling System

Replacing coolant

• Open the filler cap (A).

P0028681

• TAD: Connect a drain hose and drain the coolant

out of the radiator.

P0026914

• TWD: Connect the drain hose and drain the coolant

from the radiators (2 systems).

P0028682

47709832 09-2023 © AB VOLVO PENTA 65

Cooling System

• Connect a drain hose to the engine block and drain

the coolant from the engine. Use a receptacle to
collect the coolant.
• Remove the hoses and close the nipples/taps.
• Refill with new, Volvo Penta-recommended coolant.
NOTICE! Cooling performance is reduced by deposits
in the radiator and cooling galleries. The cooling
system should be cleaned when coolant is replaced.
Cooling system cleaning is described in the Workshop
literature.

NOTICE! Check anti-freeze protection every year, if

the coolant is not replaced.

P0027068

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 Cooling System

Filling a completely empty system

Mix the coolant in advance, to ensure the cooling
system is filled with the correct mixture, (applies to
concentrated coolant).

If a heating unit is connected to the engine cooling

system, its valves must be opened and the installation
vented during filling.

NOTICE! The engine may not be started before the

system is full.

• Check that all drain points are closed.

• Open the filler cap (A).
• Top up and check that the coolant level is between
the MIN and MAX marks on the expansion tank.
• Start the engine when the cooling system has been
filled and vented.
• Open any venting nipples shortly after starting the
engine, to allow trapped air to escape.
• Run the engine at idle a while.
• Increase engine revolutions for a few minutes. Stop
the engine and check the coolant level.
• Run the engine until the thermostat opens. Check
the level again when the engine has cooled. Top up
as necessary.

P0028681
NOTICE! Only fill coolant when the engine is cold and
stopped. Fill slowly, to allow air to flow out.

P0028680

47709832 09-2023 © AB VOLVO PENTA 67

Cooling System

Coolant Filter, Replace

If the engine has a coolant filter, the latter must be
replaced; refer to the service interval for the engine
concerned in the maintenance schedule.

• Shut the filter housing valve.

• Clean around the filter and remove it.
• Lubricate the new filter gasket with petroleum jelly
or soapy water.
• Tighten the filter until the gasket touches and then
tighten a further one half turn.
• Open the tap on the filter housing.
• Start the engine and check for leaks.

NOTICE! When working on an engine to which more

than five liters of new coolant are added, always install
a new coolant filter.

P0028690

68 47709832 09-2023 © AB VOLVO PENTA

 Cooling System

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Cooling System

Coolant Pump (Electric), Replace

• Drain the cooling water.

• Remove:
hoses
connector
pump
• Install:
pump
connector
hoses
• Fill coolant.

P0031228

70 47709832 09-2023 © AB VOLVO PENTA

 Cooling System

Drive Belt, Replace

Drive belt, water pump

NOTICE! Always replace belts that are greasy, worn

or damaged.

Removal
CAUTION!
Pinch hazard. Keep fingers clear.

TAD
• Clear a space in front of the engine. Remove
the engine fan guard, cooling fan and fan ring. If
necessary, also remove the radiator assembly.
• Insert a tool in the belt tensioner.
• Relieve the load on the belt tensioner and remove
the belt.
• Check the function of the belt tensioner and idler
wheel bearings. Replace the idler wheel if there is
play in the bearings.

P0028693

TWD

P0028694

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Cooling System

Installation
TAD
• Insert a tool in the belt tensioner.
• Relieve the load on the belt tensioner and install the
new belt.
• Deploy the belt tensioner and check that the belt is
correctly aligned on all pulleys.
• Install the fan guards, fan, fan ring and the radiator
assembly if this has been removed.

P0028693

TWD Check
The drive belt has an automatic belt tensioner and
does not need to be adjusted.

P0028694

72 47709832 09-2023 © AB VOLVO PENTA

 Cooling System

Drive belt, alternator

Removal
CAUTION!
Pinch hazard. Keep fingers clear.

TAD
• Clear a space in front of the engine. Remove
the engine fan guard, cooling fan and fan ring. If
necessary, also remove the radiator assembly.
• Insert a tool into the belt tensioner (A).
• Relieve the load on the belt tensioner (A) and lift
away the water pump drive belt.
• Insert a tool into the belt tensioner (B).
• Relieve the load on the belt tensioner (B) and lift off
the generator drive belt.
• Check the function of the belt tensioner and idler
wheel bearings. Replace the idler wheel if there is
play in the bearings.

P0028695

TWD

P0028696

47709832 09-2023 © AB VOLVO PENTA 73

Cooling System

Installation
TAD
• Insert a tool into the belt tensioner (B) and relieve
the load on the belt tensioner.
• Install the new generator belt.
• Deploy the belt tensioner (B).
• Check that the alternator belt is correctly aligned on
all the pulleys.
• Relieve the load on the belt tensioner (A) and fit the
drive belt onto the water pump.
• Deploy the belt tensioner (A) and check that the
water pump belt is correctly aligned on all pulleys.
• Install the fan guards, fan and fan ring around the
cooling fan and radiator assembly if this has been
removed.

P0028695

TWD Check
The drive belt has an automatic belt tensioner and
does not need to be adjusted.

P0028696

74 47709832 09-2023 © AB VOLVO PENTA

 Long-Term Storage

Long-Term Storage
The engine and other equipment should be conserved to avoid damage during extended lay-ups (4-8 months or
longer). Conservation protects the engine against freezing and corrosion damage.

The checklist below covers the most important points for the engine. Before decommissioning the engine for an
extended period, we recommend checks for any maintenance or repairs.

IMPORTANT:
Washing with a power washer: Never aim the water jet at radiators, charge air cooler, seals, rubber hoses or
electrical components.

For layups up to 8 months:

• • Change engine oil and oil filter as specified.
• The fuel system must be protected during storage
to prevent internal oxidation and corrosion.
Start and run the engine with FAME-free fuel before
storage.
Run the engine for at least 10 minutes to allow the
fuel to reach all parts of the fuel injection system.
FAME = Biodiesel
B0 = Diesel with 0% FAME
B10 = Diesel with 10% FAME
• If B0 fuel is not available, fuel additives with anti-
corrosion and anti-oxidation properties may be
mixed in the fuel to protect the fuel system during
storage.
Engines that use diesel fuel with a FAME level
greater than 10%, (even if additives are used) must
not be placed in long-term storage.
• Drain water from the pre-filter to reduce the risk of
bacterial growth.
Drain water, dirt and sludge from the fuel filter and
fuel tank. Fill the fuel tank completely to prevent
condensation.
Use the recommended B0 fuel. Fuels with a FAME
-content greater than 10% may not be used as
storage fuel.
• Check that the coolant has the requisite antifreeze
qualities. Top up as necessary.
• Disconnect the battery cables; clean and charge
the batteries. Maintenance charge the batteries
while the equipment is in storage. An insufficiently
charged battery can freeze and burst.
• Cleaning the exterior of the engine, see, Cleaning
engine and transmission, page 79.
• Touch up paint damage with Volvo Penta original
paint or paint of the equivalent quality.
• Attach a tag into the engine with information about
the date, type of conservation and the conservation
oils used.
• Cover the air filter, exhaust pipe and engine as
necessary.

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Long-Term Storage

Recommissioning

• Replace fuel filters before starting the engine.

Keep extra filters available as FAME may cause
microbial growth that blocks the fuel filter.
• Check the drive belts.
• Check the condition of all rubber hoses.
• Check the hose clamps.
• Check the coolant level and anti-freeze. Top up as
necessary.
• Connect the fully-charged batteries.
• Remove the covers from the air filter and exhaust
pipe.
• Start the engine and let it idle with no load for a short
while.
• Check that there are no oil, fuel or coolant leaks.

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 Long-Term Storage

Storage instruction for long-term

storage of new engine

Applies to installed and non-installed

engines

The engines must be laid up in a warm,

temperature-controlled store.
The temperature should be between +5°C and
+30°C.
Storage outdoors is strictly prohibited.
Humidity should be below 40%.
We recommend that you:
– Unpack the engine, remove the plastic wrap.
– Use the plastic bag as dust protection; leave it
loose for good ventilation.
– Do not use wax as protection in case the engine
must be started during storage.

If the engine must be stored for more than 8

months

Before storage
Make sure the engine cooling system is filled with
glycol.
Make sure the engine lubrication system is filled with
oil.
Pump the coolant through the seawater cooling
system. (Marine engines only)
Seal all open connections.
Remove the battery cables from the battery.
Empty the AdBlue®/DEF tank if it is filled and clean
it.
Attach a tag into the engine with information about
the date, the product's part number, type of oil used
and sign it.

During storage
The engine must be cranked 2.5 turns every 8th
month.
If the engine can be started, run it until warm.
Check that humidity is below 40%.
Check that the temperature in the storage area is
between +5°C and +30°C.

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Long-Term Storage

Before the engine enters service.

Uncover the engine or vacuum the system until dry.
This is in order to prevent remaining glycol mixture
from contaminating the environment.
Hand the glycol mixture to a waste management
facility as hazardous waste.
Clean the engine as necessary.
Check:
– Drive belts
– Hoses
– Clamps
Check the oil level in the engine and top off as
necessary.
Make sure the coolant has adequate antifreeze
properties; top off as necessary.
Should be replaced:
– Fuel filter
– Air filter
– AdBlue®/DEF filter
– Air filter AdBlue®/DEF tank
– Fill the AdBlue®/DEF tank
– Seawater pump impeller (Marine engines only)
– Anodes for the seawater system. (Marine engines
only)
Start the engine and let it idle a while without a load.
Check that there are no oil, fuel or coolant leaks.
Run the engine until warm.
Change the engine oil and oil filter.

Checklist, long term storage

Date Product part number Type of conservation Signature and date of checks

Month Checks during storage

8,
16,
24,
32,
40,

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 Long-Term Storage

Cleaning engine and transmission

Including the engine encapsulation and all

hatches
• A clean engine compartment minimizes the risk of
overheating and wear damage.
• Prior to every engine compartment wash, a visual
inspection must be carried out to identify any fluid
or exhaust leakages.
• Following each wash, all hoses and bellows must be
inspected visually to identify any leakages, cracks
or chafing.
• Following each wash, electrical harnesses must
be visually inspected to identify any damage to
insulation, cable jackets or clamping.
• Battery, alternator, power steering unit and starter
motor cables must be inspected extra carefully.
• Any damage to hoses, bellows, grommets or
electrical harnesses must be reported immediately.

Important!
• When cleaning, always use mild detergents/
solvents.
• When cleaning the engine and engine
compartment, the alternator, idler pulley, belt
tensioner, power steering unit and all electrical
components must be covered with plastic or similar
so that detergent/solvents do not get into the parts
• Where fitted, the AC compressor must also be
protected with plastic or similar.
• When cleaning air coolers, they should be vacuum
cleaned first before flushing with warm water from
the inside out.
• Do not use a power washer on the air cooler.
• Clean the outside with a sponge/brush.
• Then flush with lukewarm water.
• When pressure washing and steam cleaning, water
pressure may not exceed 80-100 bar at the nozzle.
Maintain a distance of 100-150 mm; use a fan spray
nozzle.
• It is not permitted to came jets of water from
the pressure washer directly onto the alternator.
The electrical regulator, rectifiers, power steering
units, bellows and mechanical parts (bearings) may
be damaged and lead to serious consequential
damage.

NOTICE! If the generator is exposed to water, it must

be dried; see drying.

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Long-Term Storage

• Wash using a flat fan nozzle when cleaning sound

absorbent.
• To maintain the fire prevention and sound
dampening qualities of the absorbent as per the
sound certificate, no damage to the absorbent
may be repaired with the aid of patches or the
puzzle principal i.e. by covering any damage with
new absorbent (patch). Accordingly, in the case of
major damage or where fluid has seeped into the
absorbent (deep tears, tears wider than the width of
tape; holes or cracked edges), the entire damaged
unit must be replaced.
• Tears that can be covered widthwise by tape, must
be repaired using approved aluminum tape.
• After the wash, check that no small rocks or other
debris has adhered to the belts and are able to
penetrate them when the engine is started.

Drying the alternator

• Blow the water away from the alternator using
compressed air.
• Check that the alternator charges.

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 Long-Term Storage

Checklist
Suggestions for the checklist in addition to the regular
service items.

Check/action
• Check for leakage: oil/fuel/water/exhaust.
• Check – Hoses and hose clamps.
• Inspection of cable connections.
• Cleaning of battery terminals; remove any oxide.
Check the electrolyte level.
• Clean the engine and engine compartment.
• Inspection/cleaning the fuel tank.
• Function check of other electrical systems.
• External cleaning of the radiator/radiator assembly.
Start the engine every six months
If the engine is to be laid up for 6-8 months or more, it
should be started and warmed up every six months as
follows:
• Check the engine oil level.
• Check the coolant level.
• Connect the battery cables to the batteries (fully
charged).
• Start the engine and run it for 2-3 minutes.
• Switch off the engine.
• Detach the battery cables.
• Check the engine compartment for any
condensation.
• Ensure good ventilation.

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Long-Term Storage

Battery, Maintenance
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.

WARNING!
Battery electrolyte is a corrosive acid and should be
handled with care. If you spill or splash electrolyte on
any part of the body, immediately flush the exposed
area with liberal amounts of water and seek medical
attention as soon as possible.

WARNING!
Ventilate the engine compartment before working on
batteries or battery connections.

IMPORTANT:
Batteries can be damaged if they are left discharged,
and can also freeze and burst easier in cold weather.
If the engine is not going to be used for a longer period
of time, the batteries should be fully charged, trickle
charged if possible.

Care
It is important always to follow the battery
manufacturer's recommendations and instructions
when replacing and charging batteries. Instructions
for maintenance and charging may vary depending on
battery type.
Modern batteries are usually maintenance free, but
there are some recommended measures to avoid
accidents and increase battery service life:
• Keep the batteries clean and dry. Contamination
and oxide on the batteries and battery terminals can
cause stray currents, voltage drop and discharge,
especially in damp weather.
• Remove oxidation from the battery poles and
terminals using a brass brush.
• Tighten the terminals securely and grease them with
terminal grease or petroleum jelly. Loose battery
connections can cause damage to the engine
electrical system.
• Charge the batteries regularly. Batteries kept at full
charge enjoy maximum service life. The easiest way
to check whether a battery needs charging is to use
a volt meter.

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 Long-Term Storage

Battery replacement
IMPORTANT:
Make sure that the new battery fulfills the specifications
in Technical Data. Read the information supplied with
the battery before you begin the installation.

IMPORTANT:
Do not disconnect the batteries with the engine
running.
Sensitive electrical components can be immediately
damaged.

WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

Disconnection (A)
• Remove the negative (-) cable (black).
• Remove the positive (+) cable (red).
Remove the battery.

Connection (B)

Put the new battery in place.

• Attach the positive cable (red) to the battery's
positive terminal. Tightening torque: 6 Nm.
• Attach the negative cable (black) to the battery's
negative terminal. Tightening torque: 6 Nm.

NOTICE! Hand in the old battery to a waste

management facility.

P0028239

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Index
A Specifications..................................................... 20, 22
Air Filter.................................................................... 32 Storage instruction for long-term storage of new
Air filter Compressor, filter replace........................... 34 engine....................................................................... 77

B T
Battery, Maintenance................................................ 82 Turbocharger, Inspection.......................................... 56

C V
Charge Air Pipe, Leakage Check............................. 58 Valves, Adjustment................................................... 34
Check software status.............................................. 32 W
Checklist................................................................... 81 When you work with Chemicals, Fuel and
Chemical products.................................................... 19 Lubrication Oil, Change............................................ 35
Cleaning engine and transmission........................... 79
Component location................................................. 24
Coolant Filter, Replace............................................. 68
Coolant Level, Checking and Topping Up................ 63
Coolant Pump (Electric), Replace............................ 70
Cooling System........................................................ 63
Crankcase ventilation............................................... 33
D
Drive Belt, Replace................................................... 71
E
Engine...................................................................... 24
Engine Decals.......................................................... 20
Engine Oil, Level Check........................................... 35
Engine oil, Replace.................................................. 37
Exhaust System....................................................... 56
F
Fuel filter, Change.................................................... 51
Fuel Pre-filter, Replace............................................. 47
Fuel System............................................................. 46
Fuel system, bleeding.............................................. 53
G
General advice for electronic protection................... 31
General Information.................................................. 10
General inspection................................................... 29
General Tightening Torques..................................... 21
Genuine Volvo Penta Parts...................................... 17
I
Illustrations............................................................... 18
L
Long-Term Storage................................................... 75
Lubrication System................................................... 35
M
Maintenance Schedule............................................. 28
N
Nox-sensor Pre/Post SCR........................................ 62
O
Oil filter, Replace...................................................... 39
P
Preventive repair ..................................................... 13
S
Safety Information...................................................... 2
SCR System............................................................. 59
Service Protocol....................................................... 12
Spare parts - safety.................................................... 4

47709832 09-2023 © AB VOLVO PENTA 85

 47709832 English

AB Volvo Penta
SE-405 08 Göteborg, Sweden
www.volvopenta.com