41 Fuel and Lubrication Systems

Workshop ManualFuel and lubrication system B 2(0) 31, 32, 41, 42, 43, 44, 300-Series Group 22 Lubrication system Group 23 Fuel system Marine engines MD31A • TMD31B, D, L-A TAMD31B, D, S.O.L.A.S, L-A, M-A, P-A, S-A AD31B, D, L-A, P-A • KAD32P TMD41B, D, L-A TAMD41B, D, S.O.L.A.S, L-A, M-A, P-A, H-A, H-B D41B, D, L-A • AD41B, D, L-A, P-A TAMD42AWJ, BWJ, WJ KAMD42A, B, P • KAD42A, B, P KAMD43P • KAD43P KAMD44P-A, P-B, P-C • KAD44P-A, P-B, P-C KAMD300-A • KAD300-A Contents Safety information ............................................... General information ............................................ Repair instruction ............................................... Special tools ....................................................... Other special equipment .................................... 2 5 6 9 9 Group 23 Fuel system Design and function ............................................ General .............................................................. EDC system ...................................................... Injection pump ................................................... Overflow valve ................................................... Smoke limiter ..................................................... Injector ............................................................... 2-spring injector ................................................. 2-spring injector with needle lift sensor ............... Feed pump ......................................................... Fuel filter ............................................................ Return fuel cooler ............................................... Repair instructions .............................................. Removing fuel injection pump ............................ Installing and setting up fuel injection pump ....... Fault-tracing fuel valve ....................................... Setting up idling speed ....................................... Replacing feed pump ......................................... Fuel feed pressure, check (31/32/41/42/43) ....... Checking Fuel supply pressure (44/300) ............ Replacing injector (31/32/41/42/43) .................... Replacing injector (44/300) ................................. Needle lift sensor, checking ............................... Reconditioning injectors ..................................... Cleaning copper sleeve ...................................... Recommendations when adjusting opening pressure, set pressure and replacing injectors .............................................. Adjusting opening pressure ................................ Replacing fuel filter ............................................ Bleeding the fuel system .................................... 24 24 24 25 25 26 27 27 28 29 29 29 30 30 32 34 35 36 36 37 39 40 42 43 43 Group 22 Lubrication system Design and function ............................................ General .............................................................. Control valves .................................................... Safety valve ....................................................... Relief valve ........................................................ Piston cooling valve ........................................... Piston cooling .................................................... Oil pump ............................................................ Oil cooler ........................................................... Oil filter .............................................................. Crankcase ventilation ......................................... Repair Instructions .............................................. General .............................................................. Engine fixture attachment .................................. Checking oil pressure ......................................... Replacing oil filter ............................................... Replacing oil pan gasket .................................... Replacing lubrication pump ................................ Reconditioning oil pump ..................................... Reconditioning oil cooler (early version) ............. Reconditioning oil cooler (late version) ............... Oil cooler, test pressurization ............................. 10 10 11 11 11 11 12 12 12 13 13 14 14 15 16 16 17 17 19 22 23 23 44 45 46 46 1 Safety Information Introduction This Workshop Manual contains technical data, descriptions and repair instructions for Volvo Penta products or product versions contained in the contents list. Ensure that the correct workshop literature is being used. Read the safety information and the Workshop Manual “General Information” and “Repair Instructions” carefully before starting work. Check that the warning or information decals on the product are always clearly visible. Replace decals that have been damaged or painted over. Never start the engine without installing the air cleaner (ACL). The rotating compressor in the turbocharger can cause serious personal injury. Foreign objects entering the intake ducts can also cause mechanical damage. Never use start spray or similar to start the engine. The starter element may cause an explosion in the inlet manifold. Danger of personal injury. Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out at the same time as the pressure which has built up is lost. Open the filler cap slowly, and release the pressure in the cooling system if the filling cap or tap has to be opened, or if a plug or coolant hose has to be removed when the engine is hot. Steam or hot coolant can stream out in an unexpected direction. Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before commencing work on it. Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected. Stop the engine and close the sea cock before carrying out operations on the engine cooling system. Important In this book and on the engine you will find the following special warning symbols. WARNING! If these instructions are not followed there is a danger of personal injury, extensive damage to the product or serious mechanical malfunction. IMPORTANT! Used to draw your attention to something that can cause damage, product malfunction or damage to property. NOTE! Used to draw your attention to important information that will facilitate work or operations. Below is a summary of the risks and safety precautions you should always observe or carry out when operating or servicing the engine. Immobilize the engine by turning off the power supply to the engine at the main switch (switches) and lock it (them) in the OFF position before starting work. Set up a warning notice at the engine control point or helm. Generally, all servicing should be carried out with the engine switched off. However, some work, for example certain adjustments require that the engine is running when they are carried out. Approaching a running engine is dangerous. Loose clothing or long hair can fasten in rotating parts and cause serious personal injury. If working in proximity to a running engine, careless movements or a dropped tool can result in personal injury. Avoid burns. Take precautions to avoid hot surfaces (exhausts, turbochargers, charge air pipes and starter elements etc.) and liquids in supply lines and hoses when the engine is running or has been turned off immediately prior to starting work on it. Reinstall all protective parts removed during service operations before starting the engine. Start the engine only in a well-ventilated area. If operating the engine in an enclosed space, ensure that exhaust gases and crankcase ventilation emissions are ventilated out of the working area. Always use protective goggles where there is a danger of pieces of metal, sparks from grinding, acid or other chemicals being thrown into your eyes. Your eyes are very sensitive, injury can lead to loss of sight! 2 Safety information Avoid skin contact with oil. Long-term or repeated contact with oil can remove the natural oils from your skin. The result can be irritation, dry skin, eczema and other skin problems. Used oil is more dangerous to health than new oil. Use protective gloves and avoid using oilsoaked clothes and rags. Wash regularly, especially before meals. Use the correct barrier cream to prevent dry skin and to make cleaning your skin easier. Most chemicals used in products (engine and transmission oils, glycol, petrol and diesel oil) and workshop chemicals (solvents and paints) are hazardous to health Read the instructions on the product packaging carefully! Always follow safety instructions (using breathing apparatus, protective goggles and gloves for example). Ensure that other personnel are not unwittingly exposed to hazardous substances (by breathing them in for example). Ensure that ventilation is good. Handle used and excess chemicals according to instructions. Be extremely careful when tracing leaks in the fuel system and testing fuel injection nozzles. Use protective goggles! The jet ejected from a fuel injection nozzle is under very high pressure, it can penetrate body tissue and cause serious injury There is a danger of blood poisoning. All fuels and many chemicals are inflammable. Ensure that a naked flame or sparks cannot ignite fuel or chemicals. Combined with air in certain ratios, petrol, some solvents and hydrogen from batteries are easily inflammable and explosive. Smoking is prohibited! Ensure that ventilation is good and that the necessary safety precautions have been taken before carrying out welding or grinding work. Always have a fire extinguisher to hand in the workplace. Store oil and fuel-soaked rags and fuel and oil filters safely. In certain conditions oil-soaked rags can spontaneously ignite. Used fuel and oil filters are environmentally dangerous waste and must be deposited at an approved site for destruction together with used lubricating oil, contaminated fuel, paint remnants, solvent, degreasing agents and waste from washing parts. Never allow a naked flame or electric sparks near the batteries. Never smoke in proximity to the batteries. The batteries give off hydrogen gas during charging which when mixed with air can form an explosive gas - oxyhydrogen. This gas is easily ignited and highly volatile. Incorrect connection of the battery can cause a spark which is sufficient to cause an explosion with resulting damage. Do not disturb battery connections when starting the engine (spark risk) and do not lean over batteries. Never mix up the positive and negative battery terminals when installing. Incorrect installation can result in serious damage to electrical equipment. Refer to wiring diagrams. Always use protective goggles when charging and handling batteries. The battery electrolyte contains extremely corrosive sulfuric acid. If this comes into contact with the skin, wash immediately with soap and plenty of water. If battery acid comes into contact with the eyes, immediately flush with copious amounts of water and obtain medical assistance. Turn off the engine and turn off power at main switch(es) before carrying out work on the electrical system. The clutch must be adjusted with the engine shut off. Use the lifting eyes mounted on the engine/reverse gear when lifting the drive unit. Always check that lifting equipment is in good condition and has sufficient load capacity to lift the engine (engine weight including reverse gear and any extra equipment installed). Use an adjustable lifting beam or lifting beam specifically for the engine to raise the engine to ensure safe handling and to avoid damaging engine parts installed on the top of the engine. All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine. If extra equipment is installed on the engine altering its center of gravity, a special lifting device is required to achieve the correct balance for safe handling. Never carry out work on an engine suspended on a hoist. 3 The use of other grades of fuel can damage the engine. Always use fuels recommended by Volvo Penta. even where secure lifting equipment such as secured blocks are being used. On a diesel engine poor quality fuel can cause the control rod to seize and the engine to overrev with the resulting risk of damage to the engine and personal injury. The engine must not be run in areas where there are explosive materials. When working on-board ensure that there is sufficient space to remove components without danger of injury or damage. one to operate the lifting equipment and the other to ensure that components are not trapped and damaged when being lifted. Damaged pipes must be replaced. Fuel delivery pipes must not be bent or straightened under any circumstances. Printed on environmentally compatible paper. Components in the electrical system and fuel system on Volvo Penta products are designed and constructed to minimize the risk of fire and explosion.Safety information Never remove heavy components alone. rubber hoses or electrical components. Even where lifting equipment is being used it is best to carry out the work with two people. Never use a high pressure washer for engine cleaning. 4 . Remember the following when washing with a high pressure washer: Never aim the water jet at seals. Poor fuel quality can also lead to higher maintenance costs. Refer to the Instruction Book. © 2001 AB VOLVO PENTA We reserve the right to make design changes and amendments without prior notice. The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified engine. it is important to be aware of the following: Certification means that an engine type has been checked and approved by the relevant authority. Where they are not the same. Any essential changes or modifications introduced into production or updated or revised service methods introduced after the date of publication will be provided in the form of Service Bulletins. this is stated in the manual. care and maintenance apply. the repair and service operations described are the same in all essential details.General Information About the workshop manual This workshop manual contains technical data. Volvo Penta is continuously developing their products. No seals may be broken by unauthorized personnel. Only Volvo Penta original spares may be used. IMPORTANT! Delayed or inferior care/maintenance. Replacement parts Replacement parts for the electrical and fuel systems are subject to statutory requirements (US Coast Guard Safety Regulations for example). All the information contained in this book is based on product data available at the time of going to print. This Workshop Manual has been developed primarily for Volvo Penta service workshops and qualified personnel. No installation changes to the exhaust pipe and engine air inlet ducts may be done. The engine designation and number should be given in all correspondence about the engine. However. We therefore reserve the right to make changes. Volvo Penta Genuine parts meet these requirements. The workshop manual displays the operations carried out on any of the engines above. Where the difference is considerable. Service to injection pumps. the operations are described separately. pump settings and injectors must always be done by an authorized Volvo Penta workshop. The engine must not be converted or modified. Damage. • • • The general advice in the instruction book about operation. This put special demands on service and repair work. Certificated engines When service or repairs are done to an emission certified engine. except for the accessories and service kits which Volvo Penta has approved for the engine. injury and/or costs which arise from this will not be compensated by Volvo Penta. the illustrations and pictures in the manual that show certain parts on the engines. The engine designation and number is indicted on the engine identification plate. and the use of non-original spares. mean that AB Volvo Penta can no longer be responsible for guaranteeing that the engine complies with the certified version. Any type of damage which results from the use of nonoriginal Volvo Penta replacement parts for the product will not be covered under any warranty provided by Volvo Penta. As a result. as follows: • • • Maintenance and service intervals recommended by Volvo Penta must be complied with. do not in some cases apply to all the engines listed above. descriptions and repair instructions for standard versions of the engine units in the 31/32/41/42/43/44/300 series. 5 . Persons using this book are assumed to have a grounding in marine drive systems and be able to carry out related mechanical and electrical work. No work should be carried out on sealed components except by authorized personnel. Certain elementary precautions and common sense can prevent most risks arising. require special expertise and special testing equipment for service and maintenance. Warning symbols occurring in the Workshop Manual (for their meaning see Safety information) WARNING! IMPORTANT! NOTE! are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out. Torques apply for lightly oiled or dry threads.ft 6 10 25 50 80 140 4. such as the components in the fuel system.Repair Instructions The working methods described in the Service Manual apply to work carried out in a workshop.0 103. locking fluid or sealing compound are required for a screwed joint this information will be contained in the work description and in “Tightening Torques” Where no tightening torque is stated for a joint use the general tightening torques according to the tables below. turbocharger. It is therefore vital that wear tolerances are maintained. Volvo Penta recommends the use of biodegradable degreasing agents for cleaning engine components. If a component deviates from its technical specification the environmental impact of an otherwise good engine may be increased significantly. Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working method. bearings and seals when they are being worked on. Joint responsibility Each engine consists of many connected systems and components. Special tools are developed to rationalize working methods and make procedures as safe as possible. Bear in mind that most chemicals used on boats are harmful to the environment if used incorrectly. damage or malfunction resulting from these. It is of the greatest importance that no dirt or foreign particles get into the fuel system. For this reason we can only highlight the risks that can arise when work is carried out incorrectly in a well-equipped workshop using working methods and tools developed by us. Some systems. Some components are sealed at the factory for environmental reasons. screw heads and mating surfaces. All torques apply for cleaned threads.4 36. that oil and waste is taken for destruction and is not accidentally pumped into the environment with bilge water.4 7. that systems that can be adjusted are adjusted properly and that Volvo Penta Genuine Parts as used. It is therefore the responsibility of any person using tools or working methods other than the ones recommended by us to ensure that there is no danger of injury. Take special care when working on-board. lubrication system. The engine has been removed from the boat and is installed in an engine fixture. The result can be malfunction or a shorter operational life.3 6 . Tightening Torques Tightening torques for vital joints that must be tightened with a torque wrench are listed in “Specifications”: “Tightening torques” and contained in the work descriptions in the Manual. All procedures for which there are Volvo Penta special tools in this Workshop Manual are carried out using these. If lubricants. The engine Maintenance Schedule must be followed. A clean workplace and engine eliminates much of the danger of injury and malfunction. These special instructions should always be followed if there are no separate instructions in the Workshop Manual. In some cases there may be special safety precautions and instructions for the use of tools and chemicals contained in this Workshop Manual. unless otherwise stated in a workshop manual.4 18. The tightening torques stated are a guide and the joint does not have to be tightened using a torque wrench. Dimension M5 M6 M8 M10 M12 M14 Tightening Torques Nm lbt.9 59. intake system. Example: a 90° protractor tightening means that the joint is tightened a further 1/4 turn in one operation after the stated tightening torque has been applied. operating temperature ranges. Strength classes Screws and nuts are divided into different strength classes. The following RTV agents are mentioned in the Service Manual: Loctite® 574. or of the same height as a standard hexagonal nut. oil pressure switches and so on. Anaerobic agents. 3. temperature range. In this Volvo Penta Service Manual the user will find that each section where these agents are applied in production states which type was used on the engine. threads in stud bolts. paint and anti-corrosion agent before applying sealant or locking fluid. Where Nylock® nuts are higher. Tow different basic types of agent are used on the engine and these are: RTV agent (Room temperature vulcanizing). For lock nuts with a plastic insert such as Nylock® the tightening torque stated in the table is reduced if the Nylock® nut has the same head height as a standard hexagonal nut without plastic insert. the class is indicated by the number on the bolt head. Volvo Penta P/N 1161099-5. They are used when two solid parts. It is therefore important that bolts removed during the disassembly of a bolted joint must be reinstalled in their original position when assembling the joint. resistance to oil and other chemicals and for the different materials and gap sizes in the engines. Lock nuts Do not re-use lock nuts that have been removed during dismantling as they have reduced service life when re-used . the tightening torques given in the table apply. Reduce the tightening torque by 25% for bolt size 8 mm or larger. curing time and any other instructions for the product. old RTV must be removed before the joint is resealed. grease. Cured anaerobic agents are extremely resistant to solvents and the old agent cannot be removed. sealing gasket joints or coating gaskets. Old sealant can be removed using denatured alcohol in all cases. A high number indicates stronger material. The following anaerobic agents are mentioned in the Service Manual: Loctite® 572 (white). Loctite® 241 (blue). NOTE! Loctite® is the registered trademark of Loctite Corporation. for example a bolt marked 10-9 indicates a higher strength than one marked 8-8. Permatex® is the registered trademark of the Permatex Corporation. Use for gaskets. Permatex® No.Repair instructions Tightening torque with Protractor tightening (angle tightening) Tightening using both a torque setting and a protractor angle requires that first the recommended torque is applied using a torque wrench and then the recommended angle is added according to the protractor scale. When reinstalling the part is carefully degreased and then new sealant is applied. are installed face-to-face without a gasket.use new nuts when assembling or reinstalling. Always follow the manufacturer’s instructions for use regarding. cocks. RTV agent is clearly visible when a component has been dismantled. for example cast components. Volvo Penta 840879-1. To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type is used on the joint where the agents are required. 7 . Permatex® No. These agents cure in an absence of air. Sealant A number of sealants and locking liquids are used on the engines. The cured material is glass-like and it is therefore colored to make it visible. If a bolt must be replaced check in the replacement parts catalogue to make sure the correct bolt is used. They are also commonly used to secure plugs. During service operations use the same agent or an alternative from a different manufacturer. 77. Make sure that mating surfaces are dry and free from oil. The agents have varying properties and are used for different types of jointing strengths. Exposing the skin to this chemical can cause serious burns. camshaft and intermediate shaft seals O rings.Repair instructions Safety precautions for Fluorine rubber Fluorine rubber is a common material in sealing rings for shafts and O rings. All remains. O rings for cylinder liner sealing are almost always fluorine rubber. • Treat removed seals in the same way as corrosive acid. • Always used chloroprene rubber gloves (gloves for handling chemicals) and protective goggles. Never use compressed air jets for blowing clean. If splashed in the eyes it can cause malignant ulcers. Wash gloves under running water before removal. The seals must never be burned off when disassembling or be burnt afterwards in anything other than a special disposal site. Breathing the fumes can damage the respiratory tract. WARNING! Take the greatest care when working on engines that have been operating at high temperatures. wherever used. even the ash can be extremely corrosive. for example an overheated engine that has seized or an engine involved in a fire. close it and stick a warning label on it. • The following seals may contain fluorine rubber: Crankshaft. Note that seals not exposed to high temperatures can be handled normally. 8 . Put old seal remnants in a plastic container. When fluorine rubber is exposed to high temperatures (over 300°C) it can release highly corrosive hydrofluoric acid. 32. 42. The final digit (after the hyphen) is a control number.Special tools In all cases where it is practical the tool number. 300) Holder for dial gauge (31. 43. for checking fuel supply pressure and boost pressure 999 6398-5 Manometer. 42. 884 635 884 895 885 131 885 139 885 199 885 263 885 289 885 301 999 6033 999 6860 884 635-4 884 895-4 885 131-3 885 139-6 885 199-0 Removal punch for oil cooler insert Lock pin for flywheel. 41. 43) Holder for injector angle dial gauge (41. has been stamped on the tool. 44. 32) 885 263-4 885 289-9 Injector sleeve extractor (44. 999 9946-8 Cylinder block fixture 998 6485-2 Unit stand 999 6065-0 Manometer. 300) Brush for cleaning bottom of copper sleeve and for sealing sleeve between copper sleeve and cylinder head Tool for pressing in Alfa reset piston (44P-A) 885 301-2 999 6033-8 Bracket for test pressurization of oil cooler (2) Other special equipment 884 954 998 6485 999 6065 999 6398 999 6662 999 6591 999 6666 999 9179 999 9946 884 954-9 Dial indicator 999 6662-4 Test pressurization equipment 999 6666-5 Nipple for checking fuel supply pressure 999 6860-4 Puller for oil pump drive 999 9179-6 Tool for removing fuel and oil filter. except for the final digit. pump setting Puller for dismantling injector nozzle (31. for checking oil pressure 999 6591-5 Nipple for checking oil pressure 9 . 42: 22042 16337.Group 22 Lubrication system Design and function General The engines are equipped with a pressurized lubrication system with a full flow oil filter. oil cooler and piston cooling (not MD31A). late version) Oil screen Oil pump Safety valve Oil cooler Oil distribution housing Relief valve Piston cooling valve Main lubrication channel. The oil pump is located at the front end of the oil sump and driven via an intermediate gear by the crankshaft. lubrication system (oil distribution housing. 2 3. early version) 1. All bearings and gudgeon pins as well as the valve mechanism and timing gear bearings are pressure lubricated. Basic diagram. 41: 22041 56849. 44: 22044 02895. 10 11 12 13 Basic diagram. On engines with the early version of the oil distribution housing the oil for piston cooling does not flow through the filter. piston cooling Piston cooling nozzle Oil filter Main lubrication channel. The turbocharger is also connected into the pressure lubrication system. 6 7 8 9. 300: from start of production. 43: 22043 02142. All oil flows from the from the oil pump pressure side via oil filter (10) through oil cooler (4) and out into the main lubrication channel. 4 5. Late versions of the oil distribution housing can be found on engines from the following engine numbers inclusive: 31: 22031 28265. Timing gears are lubricated from the intermediate gear bearing journal which is connected to the main lubrication channel via lubrication channels. lubrication Main bearings Other lubrication points 10 . 32: 22032 01697. lubrication system (oil distribution housing. The oil pump sucks up oil from the oil sump through the oil screen (1). The valve is closed at oil pressures below 2. Valve location in the oil distribution housing 6 7 Reduction valve Piston cooling valve 11 . Excess oil is directed back to the oil pan. the third (3) is mounted between the oil pump and delivery line. Opening pressure may be achieved when the engine is cold (viscous oil) or at high engine speeds (RPM). Reduction valve Relief valve (6) controls oil pressure in the engine. Opening pressure 750 kPa. Two of these (6 and 7) are located in the oil distribution housing. This stops the pistons being cooled unnecessarily.5 kPa. The valve opens if the oil pressure is too high and releases oil back to the oil pan. The valve keeps oil pressure at the correct level.Design and function Control valves Three spring-loaded valves control the oil flow in the engine. When the engine is started and idled the valve is closed. Safety valve The relief valve (3) acts to protect the pump and oil cooler in case of abnormally high oil pressures. Piston cooling valve The piston cooling valve (7) regulates the flow of oil to piston cooling. When it has circulated through the piston the oil passes through drain channels and down to the oil pan.Design and function Piston cooling The pistons are subject to very high temperatures. removes large particles from the oil before they reach the pump. Oil cooler Circulating lubricating oil transports heat away from the hottest parts of the engine and evens out temperature differences within the engine. Most of the heat from the pistons is transferred to the cylinder block via the piston rings and film of lubricating oil. piston ring and piston lining service life. The oil screen. Heat is removed from the lubricating oil in the oil cooler. Some heat is transferred to the crankcase via the connecting rods. This decreases piston temperature significantly. Oil circulates between the tubes while seawater passes through the tubes. 12 . integrated with the suction pipe. reduces the risk of the piston ring grooves sooting up and reduces oil consumption. All engines have a tubular oil cooler located on the right-hand side of the engine under the heat exchanger. Oil pump The oil pump is of the gear-wheel type. one for each cylinder. The oil is led through the channel to the top of the piston. Piston cooling oil is sprayed through fixed nozzles. into a channel on the underside of the piston. To further increase the cooling effect oil is sprayed into the piston from below. This achieves longer piston. The pump sucks oil through the oil screen and suction pipe to the pump suction side. water vapor and other gaseous combustion products. the crankcase gases are directed down to an oil trap located beneath the injection pump. the oil mist is separated by a replaceable paper filter before the crankcase gases are exhausted. The KA(M)D44/300 has a unique system. 13 . which means that all the oil is filtered before it enters the lubrication system. however.A. a pressure relief valve opens. Any oil is returned to the sump via a drain hose. and to separate fuel vapor. The KA(M)D42/43 has a similar system. the engine is equipped with a ventilation device connected to the rear of the valve housing or the rear valve lifter inspection housing. it has both a paper filter and an oil trap in the valve housing. On the KAD32 a combination of the above-mentioned systems is required.Design and function Oil filter The engine oil filter is of full flow type. Later models of 31/41/42WJ have an oil trap in the valve housing. but here the gases are directed through a rubber hose which exhausts underneath the air filter.L. On engines with early model oil distribution housings (please refer to the “General” chapter).S versions and early model versions of the 31/41/42WJ series. Crankcase ventilation To prevent excess pressure. with an oil trap in the valve housing. the oil for piston cooling does not pass the filter. which separates any oil mist before the gases are directed to the air filter via a plastic hose. The oil filter has a built-in by-pass valve to secure engine lubrication if the filter becomes blocked. In this. On all S.O. The filter element is made of folded filter paper. When this filter is blocked. In other words. Disconnect transmission cable (engines with reverse gear only).Repair Instructions General If possible a condition test should be carried out before every major service correction. remove battery terminals from the starter motor. Remove the fuel connections. 13 Drain engine oil. 6 7 8 9 Action before repairing in the boat 1 2 Cut off battery supply. Disconnect power trim wiring (Aquamatic engines only). Disconnect the engine wiring-instruments connector. Actions after lifting out the engine 12 Clean the engine IMPORTANT! Observe the following rules when cleaning with high-pressure water jets. so that the engines condition can be established and any contributory fault causes discovered. Clean the outside of the engine. Work requiring action to a seawater cooling system: Close seawater cooling cocks and drain engine coolant. 3 Work requiring action to cooling system: Close sea cock and drain coolant from the sea water and freshwater systems respectively. if the boat is in the water) 11 Remove the engine pads from their seats and lift out the engine. Remove screws on flywheel casing (Aquamatic engines only. Close the fuel cocks. A condition test requires the engine to be run so this should be carried out before removal of the engine or any components is begun. Be extremely careful that water does not penetrate engine components. WARNING! Ensure that all sea water intakes are properly closed and that water cannot enter when removing cooling system components. Disconnect the exhaust system. Disconnect the throttle cable. joints with gaskets or rubber hoses and electrical components. With the high pressure function connected the water jet must never be directed at sealed joints (shaft seals for example). For further information about the Condition Test see the Workshop Manual “Engine Body”. Action before lifting the engine out of the boat 4 5 Cut off battery supply. NOTE! Ensure that the cleaning residues are collected for destruction and do not accidentally affect the environment. 10 Remove the propeller shaft from the reverse gear (engines with reverse gear only). Disconnect sea water connections. 14 Remove reverse gear (if necessary) 14 . See also warning text under point 12. The fixture is secured to the right-hand side of the engine as illustrated below. Necessary screws: 41/42/43/44/300 series 2 screws 2 screws M12x30 mm M16x30 mm The following components must be removed from the engine before the fixture can be attached and the engine installed on the stand: Compressor (42/43/44/300 series). To avoid crushing the dip stick pipe the engine fixture must be modified slightly. heat exchanger with expansion tank. NOTE! It is important that the instructions for the number and size of screws is followed so that a secure attachment of the engine is obtained. oil cooler with oil distribution housing. front engine mounting. dipstick pipe NOTE! On later version engines the dip stick pipe cannot be removed in this position.Repair Instructions Engine fixture attachment Fixture 9999946 is used to attach the engine to unit stand 998 6485. oil pipe to turbocharger (TC). 15 . Install nipple 6591.Repair Instructions Checking oil pressure Special tools: 999 6398. If the oil temperature is too high the oil becomes less viscous and oil pressure drops. • 4 Remove the nipple and manometer. . 999 6591 1 Remove oil pressure switch on oil filter bracket (32/ 42/43/44/300). Connect manometer 6398 to the nipple . valve guides etc leaking oil) 2 The oil is too thin (incorrect viscosity) because it has been contaminated with fuel. Check the cooling system for blockages. If the oil has an abnormal soot contamination (even though oil changes have been made at the correct intervals and the correct grade of oil has been used) the cause of the fault could instead be: – – – – incorrect combustion due to fuel grade injector malfunction incorrect injection timing engine wear exceeds tolerances (piston rings. This can be detected by a pressure drop when the engine is idling or at operating temperature. • Defective oil pump Worn or leaking oil pump. • • 3 Start the engine and read off the manometer. Low oil consumption is obvious when oil burnt is replaced by fuel keeping the level constant. On other engines the oil pressure switch is located on the cylinder block behind the oil cooler. • Incorrect oil grade (viscosity) If the oil is too thick (incorrect viscosity or oil contaminated with soot particles) it will take too long for the oil pressure to rise after the engine is started. Worn main and/or crankshaft bearings Defective relief valve Defective piston cooling valve Corrective action to counter low oil pressure • Oil temperature too high. 16 Replacing oil filter Special tool: 999 9179 1 Place a container beneath the filter when removing to avoid spillage. Check that the oil pressure corresponds to the values contained in the Workshop Manual “Technical Data”. Check thermostat function. Install the oil pressure sensor. • Oil filter blocked If the oil filter is blocked the filter by-pass valve opens and the oil flow resistance in the filter becomes higher than normal. This can be because of incomplete combustion due to: – – injector malfunction incorrect injection timing The fault is most easily detected by low oil consumption. especially when the weather is cold. 2 Remove the oil pan. Tighten screws to 15 Nm. 4 Fill with engine oil and turn the engine with the starter motor (at the same time as the stop lever on the injection pump is twisted) until the oil pressure gauge gives a reading. 3 Apply oil to the gasket of the new filter. Note. oil cooler or other components in the lubrication system. Then twist a further ¾ turns. 3 Replacing oil pan gasket 1 Drain or suck out engine oil. Hand-tighten the filter until the gasket comes into contact with the filter bracket. NOTE! Do not drop the spacer washers between the panel and the engine block. 2 Clean filter bracket. Remove the oil delivery pipe and brackets from the cylinder block. This cannot be done on the KAMD/KAD44 engine as this does not have a manual stop arm on the fuel injection pump.Repair Instructions 2 Replacing lubrication pump (oil pan removed) Removing 1 Disconnect oil return and delivery pipes at the oil pump. Remove the screws for the first main bearing cap. Turn the engine with the starter motor with the stop arm activated when replacing the oil filter. 3 Install the oil pan together with a new gasket. Remove the old gasket. Remove filter using tool 9179. Clean the mating surfaces on the oil pan and cylinder block. 5 Start the engine and check for leakage around the oil filter. Remove the cylinder block reinforcement panel. 17 . Remove pipes and bracket. Repair Instructions 4 Remove the oil pump together with the main bearing cap. Use new O-rings Note. Screw main bearing cap into place on the oil pump bracket. For tightening torques see Workshop manual. Tighten screws. 18 . Remove the bearing shells from the bearing cap. Install cylinder block reinforcement panel. Tighten screws to 24 Nm. Installing 10 6 Install the oil delivery pipe in the pump and cylinder block. 9 Remove main bearing cap from the oil pump bracket. Do not forget the spacer washers between the panel and the engine block. 5 8 Lift the oil pump into position. 7 Oil and install the main bearing shells in the bearing cap. NOTE! Turn the safety valve as illustrated when installing. Install the oil pump and tighten main bearing cap screws. Check the ends of old oil delivery pipes for cracks before reinstalling. “Technical data”. Install the safety valve between the oil delivery pipe and the pump. Install the oil suction pipe bracket (splash bulkhead) NOTE! The screws have special washers (spring washer) Install the oil suction pipe with new sealing rings and fix it and the oil drain pipe with hose clamps. Only engines intended for V-drive 3 Pull oil pump sprocket from the shaft. Remove key and brass washer NOTE! There is no brass washer on late pump versions. Use puller 999 6860. NOTE! Engines intended for V-drive have a unique oil suction pipe and splash bulkhead. 19 . Remove the pump housing from the bracket.Repair Instructions 11 Reconditioning oil pump Special tools: 999 6860 1 Remove main bearing cap from the oil pump bracket. 2 Remove intermediate gear. 4 Remove the screws holding the pump housing. Replace bushings in the pump housing and bracket if the radial play between the shaft and bushing is 0.Repair Instructions 5 9 Remove impeller from housing. Clean all swarf from the pump housing and bracket.15 mm or more. 10 7 Press the bushings out of the bracket and pump housing using an appropriate drift. The pump housing must not be scratched. 11 8 Press new bushings into place in the bracket and pump housing. Check the gear flanks. Check seal between the bracket and pump housing. outside diameters and ends of impellers for wear. If there is a leakage the mating surfaces are black.034 mm). 6 Check pump housing for scratches and wear. Screw the pump housing into place on the bracket to act as a guide when reaming the bushings. Remove screws. Ream the bushings in the pump housing and bracket until they fit exactly (diameter 16. Remove pump housing from bracket. 20 .016–16. 14 Install the key.Repair Instructions 12 15 Lubricate the impellers and bushings with engine oil. For the correct play. Move the impellers to the bracket. “Technical data”. For the correct play. see Workshop Manual. There should be a 1.5±0. Reinstall the impellers in the housing. Note. Install the pump housing and tighten the screws.3 mm clearance between the bracket and gear. Check the impeller backlash with a feeler gauge. NOTE! There is no brass washer on late pump versions so do not reinstall it. “Technical data”. 21 . 13 16 Check the impeller axial play with a feeler gauge. Heat oil pump gear to 180°C ± 20°C and tap the gear onto the shaft with a plastic mallet. see Workshop Manual. Check that the impellers run easily and are not hitting the pump housing by turning the pump shaft one turn. Screw main bearing cap into place on the oil pump bracket. Tap the insert loose with tool 884 635 and a plastic mallet. NOTE! The above measurement applies to late version and early version pumps that do not have a brass washer installed.Repair Instructions 17 Reconditioning oil cooler (early version) Special tools: 884 635 1 Check that the clearance between the bracket and gear is 1. ensure that it is supported by all screws.5±0.3 mm. Tighten screws to 24 Nm. Take 4 longer M8 screws and screw these in approximately 5 mm. 2 Clean and inspect components. Use new O rings and gaskets when reinstalling. 22 . 18 Remove endplate. Tighten screws to 24 Nm. For the drain cock/nipple threads use sealing compound Loctite® 572. 19 Install intermediate gear. Position the oil cooler on the screws. Remove the insert and O-rings. 2 Remove endplate. Use a block of wood between. the other bracket is located so that the oil outlet is blocked. 2 Clean and inspect components. Carefully tap the insert loose using a rubber mallet. test pressurization Special tools: 999 6033 1 1 Remove oil cooler from the oil distribution housing. Apply a thin layer of grease to the end plate mating surfaces to the oil cooler housing before assembly.Repair Instructions Reconditioning oil cooler (later version) Oil cooler. Use new O-rings when installing. Install brackets 999 6033 on the cooler with sealing ring 471 637. 23 . Increase the pressure slowly until the manometer displays 0.6 MPa. Connect suitable test pressurization equipment to the compressed air hose and the nipple opposite the oil intake. One of the brackets is located with the nipple opposite the oil intake with sealing ring (1) between. If the pressure drops there is a leak and the oil cooler insert must be replaced. The pressure must not drop for two minutes. Excess fuel from the injectors runs back via return line (6). The main components of the EDC system are the control module. injectors and fuel lines. Excess fuel escapes back to the tank via connection (7). Fuel injection system 1 2 3 4 Feed pump Fine fuel filter Injection pump Delivery lines 5 6 7 Injector Return line Fuel return connection 24 . This regulates the quantity of fuel injected. The fuel injection pump then forces a quantity of fuel (corresponding to the power required) through delivery lines (4) to injectors (5) which atomize the fuel in the combustion chambers. This means that the return fuel flushes through (cools) the injection pump’s fuel chamber. Fuel is drawn up from the fuel tank by feed pump (1) and is forced through fine filter (2) to injection pump (3). The quantity of air available is calculated. Certain of the illustrations in this chapter have been put at our disposal be Robert Bosch AB. fuel injection pump.Group 23 Fuel system Design and function General The main components of the fuel injection system are the fuel tank and tank unit. The control module also has a built-in diagnostic function which allows service technicians to quickly find the source of faults. This evens out fuel temperature so it is the same for all the cylinders and prevents gas bubbles forming in the fuel line. Fuel filter. The control module processes the information from the sensors so that the correct quantity of fuel is injected. an electronic fuel injection pump and a number of sensors which provide the control module with information. For further information see Workshop Manual “EDC fuel injection system”. feed pump. EDC system Instead of a conventional fuel injection pump with a mechanical governor. the KA(M)D44/300 engine has an EDC (Electronic Diesel Control) system. Because the boost pressure and charge air temperature are monitored continuously there is a smoke limiter function built into the EDC system. This actuator turns an eccentric cam which acts on a control sleeve. except those for the KA(M)D44/300. If feed pressure is too high the valve opens and fuel returns to the fuel tank via the return line. The fuel shut-off system is controlled electrically with a solenoid valve. The pump mechanism is lubricated by the fuel. It limits feed pressure and ensures that the fuel injection system is bled continuously.Design and function Injection pump The injection pump is mounted on a flange and is driven by the timing gears. The position of the control sleeve determines the quantity of fuel should be injected. The pump is of the rotary type. have a centrifugal governor. All pumps. 25 . The KA(M)D44/300 engine has an electronic actuator. When the engine is stopped the fuel channel is closed. Fuel injection pump KA(M)D44/300 1 2 3 Actuator Eccentric cam Control sleeve 1 2 3 Overflow valve The overflow valve is located in the fuel injection pump. This is acted on by the pressure in the intake manifold via a pressure hose. This prevents the generation of exhaust smoke by opening the throttle rapidly at low engine speeds. until the turbocharger has enough exhaust gases to produce full charge air volume. Smoke limiter (not KA(M)D44/300) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Governor spring Governor cover Stop lever (stop limiter) Locating pin Adjuster nut Diaphragm Thrust spring Sliding rod Cone Adjustment screw. The guide pin is pressed further into the cone and the spring-loaded full load stop (1) follows it. The quantity of fuel is connected to the mass of air produced by the turbocharger. only a reduction in power. full load quantity Adjustment lever Tension lever Start lever Lever bearings 26 . If the turbocharger malfunctions or there is a reduction in charge air pressure for other reasons. The full load stop is based on a diaphragm (6). At low engine speeds. there is no increase in exhaust gases. *) KA(M)D44/300 is not equipped with a smoke limiter. The corresponding function is integrated in the Electronic Diesel Control (EDC) system. The membrane remains in its original position. allowing a greater quantity of fuel to be injected at full load.Design and function Smoke limiter All engines except for the KA(M)D44/300*) have fuel injection pumps equipped with a pressure -dependent full load stop (usually called a “Smoke limiter”). spring pressure is overcome and the sliding rod is pushed down. The diaphragm is connected to a sliding rod (8) the other end of which is conical. It transfers the movement of the diaphragm to lever (3) which acts as a stop for full load. When boost pressure reaches a certain point. Guide pin (4) runs over the conical end of the sliding rod. The full load stop limits the length of stroke of the control rod (quantity of fuel). boost pressure is not sufficient to overcome spring pressure (7). Injector 1 2 3 4 5 6 7 8 9 10 11 Hollow screw Gaskets Injector mounting Shims for setting the opening pressure Thrust spring Thrust pin Locating pin Guide Locating pin Nozzle Jet nut Injector function When the fuel pressure increases to a set value (opening pressure). The injector: • • Atomizes the fuel to ensure ignition and combustion. Check opening pressure for the first stage. KA(M)D44/300) As the heading indicates this injector has 2 thrust springs. Together with air turbulence distributes fuel in the combustion chamber so that an optimal fuel / air mixture is achieved. Workshop Manual “Technical data”. The injector opening pressure is determined by the tension of the spring which can be adjusted with shims (4). NOTE! These injector nozzles must not be reconditioned. The springs are calibrated so that a small quantity of fuel is injected into the combustion chamber first. which is pressed into its seat by the spring (5) is raised. This prolongs injection and reduces combustion noise.Design and function Injector The injectors are of the KBAL type. An exchange program is in place. Fuel is sprayed into the engine through carefully calibrated holes in the nozzle body. see. the nozzle needle (10). This increases the combustion pressure a little. For further information about the number and diameter of these holes. 2-spring injector (TAMD31S-A/41H-B. This allows two stage injection. Each injector basically comprises a nozzle holder and a nozzle (jet). The 2-spring injector also allows lower emissions when the engine is idling. 2-spring injector 1 2 3 4 5 6 7 8 9 10 11 Injector holders Shim Thrust spring Thrust pin Guide Thrust spring Adjustment pin Spring seat Shim Stop sleeve Intermediate element 12 Jet nut 27 . NOTE! These injector nozzles must not be reconditioned. When the injection begins the magnetic core. which is joined to the injector needle. The control module compares this signal with the signal from the engine speed sensor and calculates the difference between the calculated injection timing and the actual injection timing and carries out any corrections that are required. This in turn causes a voltage change in the voltage supply. By registering the change in voltage the control module can determine when the injection starts.Design and function 2-spring injector with needle lift sensor (KA(M)D44P-B/44P-C/300) The needle lift sensor is in the injector for cylinder 1. The measurement for this injector therefore represents all the injectors on the engine. An exchange program is in place. The coil is supplied with a direct current. moves upwards which causes a disturbance in the magnetic field. If the signal which represents the needle movement is missing. The needle lift sensor sends a signal to the control module when fuel injection starts. regardless of temperature variation. If at the same time there is a fault in the engine speed (RPM) sensor the engine will stop.. 2-spring injector with needle lift sensor 1 2 3 4 5 6 7 8 9 10 11 12 Injector holders Shim Thrust spring Thrust pin Guide Thrust spring Adjustment pin Spring seat Shim Stop sleeve Intermediate element Jet nut 28 . the injected fuel volume is limited and the injection timing is fixed. The needle lift sensor consists of a solenoid coil wound around a magnetic core. The cooler is the same type as that used for power steering and is loacetd on the intake water hose. it requires a supply of fuel at pressure. The feed pump has a hand pump which can be used to pump fuel to the filter and Injection pump if the engine is not running. Return fuel cooler Certain models are equipped with a return fuel cooler. 29 . The engine (camshaft) must be in the correct position for the hand pump to work. This fuel filter is disposable. This function is carried out by a feed pump located on the left-hand side of the cylinder block. Double pre-filters allow filters to be replaced while the engine is running.Design and function Feed pump If the injection pump is to work. and the filter insert is made of a spirally wound paper filter. See also “Bleeding fuel injection system” Fuel filter The engine fuel injection system has a fuel filter. The diaphragm feed pump is driven by the camshaft. A single or double (connected in parallel) water-separating pre-filter is also available as an accessory for the fuel injection system. Remove the delivery line and plug connections. 4 Removing fuel injection pump Note. If a loss of engine power is suspected take account of factors such as how fouled the hull is.Repair Instructions Instructions when working with the fuel injection system Take great care to ensure cleanliness when working with the fuel injection system. 1 Clean the fuel injection pump. When work has been carried out components must be resealed (BOSCH or VOLVO PENTA). Do NOT adjust the opening pressure or replace components in 2-spring injectors. Inspect components in a separate room intended for that purpose. the load and load distribution. Procedures that only apply to certain engines are indicated in the text (“Only applies to the KA(M)D44 engine”) for example. Do not remove the clamps. If you do not have this equipment or training. Remove oil and fuel filter and its bracket. If seals are broken by unauthorized personnel all warranties are invalid. 2 Remove the fuel line/hose between the fuel injection pump and fuel filter. No work should be carried out on sealed components except by authorized personnel. before adjusting the pump setting. Disconnect the leak-off pipe from the nozzles. Some procedures (checking injectors for example) require special equipment and training. the propeller type. This procedure applies to all engines contained in this Workshop Manual. 3 Applies to KA(M)D42/43/44/300 IMPORTANT! Some components are sealed at the factory for environmental reasons. Note. remove the pipes together. Plug fuel lines and connections before disconnecting. 30 . piping and engine around the pump. have an authorized diesel workshop carry out the work. The pipes are clamped together. Plug connections. Clean the engine before removing components such as the fuel lines. so that the authorization number (stamp number) is easily legible. Install protective caps on all connectors so that dirt cannot get into them. Replace injectors instead. 31 . 7 Remove 3 pump mounting screws.Repair Instructions 5 Does not apply to KA(M)D44/300 Remove smoke limiter hose. Note. Lift off the pump. NOTE! Do not forget to remove the support bracket under the pump! Send the pump to an authorized diesel workshop (Bosch) for inspection (if your own workshop does not have the specially trained personnel and test equipment necessary. Protect connectors from dirt. 9 Disconnect all electrical connectors on the pump. ensure that the sea cocks (reverse gear (transmission) engines) or the hose terminals on the shield (drive engines) are properly closed. 6 8 Slacken off flange screws. Remove seawater pump. WARNING! Risk of water entry. On other engines install a new O-ring on the fuel injection pump.Repair Instructions Installing and setting up fuel injection pump Special tools: 884 895. 884 954 31/32 series: 885 199 41/42/43/44P–B/44P-C/300 series: 885 139 44P–A series: 885 139. Install the bracket under the pump without tightening. Install the fuel injection pump. Do not remove plugs before the fuel and delivery lines are reinstalled. Turn the engine in the direction of rotation until the tool lug locks the flywheel. 32 . Tightening torques for flange screws 24 Nm. This reduces the risk of oil leaks. Install tool 884 895 in the flywheel housing. 885 301 1 2 Turn the pump shaft so that the hole for the flange screws corresponds to the hole in the camshaft gear (the gear can only be installed in one position). 3 Install the intermediate flange with new O-rings (applies to the 44/300 series). This may damage the cogs or engine speed (RPM) sensor (32/42/43). NOTE! If the stud bolts have been removed apply Loctite® 572 to their threads before reinstalling. IMPORTANT! Do not turn the engine with the fuel injection pump drive gear loose. Repair Instructions 4 6 Remove the center screw on the rear face of the fuel injection pump and install the dial indicator 884 954 with holders 885 139 (41/42/43/44/300 series) and 885 199 (31/32 series). oil the reset piston and install the tool on the pump. Remove the pump’s reset cover. Ensure that the indicator is pushed in 3–4 mm. 8 Reset the clock 9 Turn the engine in the direction of rotation. slacken off the pump securing nuts and turn the pump until the correct value is obtained. Applies to all engines 7 Release the locking lug on tool 884 895 and turn the engine back (against direction of rotation) approximately 30° (41/42/43/44/300 series) and approximately 45° (31/32 series) or until the clock “stops”. this is to ensure that the turning begins at “zero”. Tighten the pump and dismantle tool 885 301 (44P–A series) and reinstall the reset cover. Ensure that the clock does not move when the rotation begins. Turn clockwise (seen from the front) if value is too low (injection too late) and counter-clockwise if the value is too high (injection too early). 33 . Tighten the center screw until it reaches the bottom. 11 If the injectors need to be adjusted. Use Torx 30 tool. 10 When the locking pin “locks” the flywheel the dial indicator should be read off. Compare the read off value with Workshop manual “Technical data”. Applies only to KA(M)D44P–A 5 Screw out the center screw on tool 885 301. Fault-tracing fuel valve If the engine does not stop when the ignition switch is turned to the stop position. 13 Applies only to KA(M)D42/43/44/300 install oil and fuel filter and bracket. Use a new O-ring. check the following points. Check that the cylinder block is connected to ground (–) when the ignition switch is in its stop position on bipolar motors. 12 Install fuel and delivery lines. Use new copper washers. Does the valve click when stop is connected? Check the plunge function if necessary. 34 . 14 Connect all electrical connectors on the fuel injection pump. NOTE! Donut forget to remove tool 884 895 from the flywheel housing.Repair Instructions NOTE! The support bracket at the rear of the pump must block the cylinder block and pump before final tightening. Connect connector and listen for clicking. • • 16 Bleed fuel system. IMPORTANT! Ensure that the sea cocks (reverse gear engines) or the hose connectors on the shield (drive engines) are open. so that no tensions are introduced. The cable should be live when the engine is stopped. • Check that there is power to the stop solenoid connector when the ignition switch is in its stop position. 17 Start the engine and check for leaks. 15 Install seawater pump. 6 The engine should be at normal operating temperature. Check that the throttle arm (1) hits the maximum engine speed (RPM) stop screw (3). Run the engine with no load at wide open throttle. see Workshop Manual “Technical data”. Adjust the engine speed (RPM) as necessary by screwing the adjustment screw (2) out or in. see Workshop Manual “EDC fuel injection system”.Repair Instructions Setting up idling speed 31/32/41/42/43 series Special tools: 998 8460 High idle 5 Run engine to normal operating temperature. For engine speed (RPM). Do not use the boat’s instruments to set up engine speed. IMPORTANT! Seals may only be broken by authorized personnel. For engine speed (RPM). Adjust throttle mechanism if necessary. Adjust stop (3) if necessary to obtain the correct engine speed (RPM). 8 When work has been carried out the adjustment screw components must be resealed (BOSCH or VOLVO PENTA). 35 . When work has been carried out components must be resealed (BOSCH or VOLVO PENTA). that the throttle mechanism is operating normally (that the fuel injection pump throttle lever moves towards low idle when the throttle mechanism is moved to idling position and towards max when the throttle mechanism is moved towards wide open throttle. see Workshop Manual “Technical data”. Check the air cleaner (ACL) is not clogged. Set up engine speed using workshop tachometer 998 8460. so that the authorization number (stamp number) is easily legible. 4 Lock the adjustment screw after adjustment is complete. so that the authorization number (stamp number) is easily legible. Low idle 1 Run engine to normal operating temperature. 2 Low idle the engine and check engine speed (RPM). 3 KA(M)D44/300 series To set up the KA(M)D44/300 engines. 7 Check the engine speed (RPM) with a workshop tachometer. see the arrow on the filter cover. Connect the pipescrew to outlet side of the fuel filter. 2 Run the engine at an increased engine speed. The feed pump must be replaced. 4 Clean the feed pump’s mating surface on the cylinder block and install a new gasket.7–27. Connect banjo nipple 999 6666 to pipescrew 969 299.Repair Instructions Replacing feed pump 1 Clean around the pump. The feed pressure should be 14. *The pumps are identified using the P/N on the top of the pump housing. Check for reduced flow (a trapped line for example). drilled and threaded to M10x1 as illustrated. 3 Remove the feed pump from the cylinder block. Connect manometer 999 6065. The feed pump can not be reconditioned.5 kPa (feed pump 860 320*) respectively 30-50 kPA on TAMD41H (feed pump 3582310*) Low feed pressure can be caused by a blocked filter or defective feed pump. Disconnect fuel lines from the pump. 6 Vent fuel system. Checking fuel supply pressure 31/32/41/42/43 series Special tools 999 6065. Reduce the engine speed (RPM) to low idling speed. NOTE! Do not spill any fuel. 1 36 . pressure is measured after the fuel has passed through the fuel filter). 999 6666. Read off the pressure within 1 minute. 2 Close fuel cocks. 5 Screw feed pump into place. 7 Start the engine and check for leaks. 999 6666 VP replacement parts: 18 817 (6 x). Do not spill fuel. 191 397. 861 079 (3 x). 947 975.Repair Instructions Checking fuel supply pressure KA(M)D44/300 series Special tools: 999 6065. hose mounting 947 043 and hose clamp 943 471 at each end. 5 Disconnect the fuel line between the fuel filter and the fuel injection pump. 37 . 943 471 (2 x). 3 4 Connect an approximately 50cm long fuel hose 861 057 with a banjo nipple 861 079. Slacken off the nipples in the fuel filter and fuel injection pump. 947 043 (2 x). 969 299 1 Close the fuel cocks 2 Remove any clamps for the wiring at the timing cover for better access. Connect each end of the fuel hose to the fuel injection pump using the short pipescrews 969 299 and 2 x copper washers 18 817. 861 057 (50cm). The feed pumps must be replaced.7–27. Low feed pressure can be caused by a blocked filter or defective feed pump. Read off the pressure within 1 minute. Reduce the engine speed (RPM) to low idling speed.5 kPa (feed pump 860 320) respectively 30–50 kPa (feed pump 3582310*) The feed pressure downstream of the fuel filter should never drop below 0 kPa for any of the pumps. The feed pressure should be 14. 7 Connect manometer 999 6065 with the manometer quick-release connectors to modified tool 999 6666. * Feed pump 3582310 was introduced successively on the 44P-A series and is installed on all engines in the 44P-B/44P-C/300 series. The pumps are identified using the P/N on the top of the pump housing.Repair Instructions 6 8 Remove tool 999 6666. Connect nipple 191 397. Connect modified tool 999 6666 and the other end of the fuel hose to the fuel filter using the long pipescrews 947 975 and 3 x copper washers 18 817. None of the feed pumps can be reconditioned. 9 Open the fuel cock. Check for reduced flow (a trapped line for example). 38 . Run the engine at an increased engine speed. copper washer 18 817 and banjo nipple 861 079. 11 Install return line with new copper washers. 7 Install the delivery lines. Replace damaged delivery lines. 14 Start the engine and check for leaks. Otherwise water might get into the engine. 5 Remove the delivery line and plug connections. 13 Only applies to 42/43 series Install the oil and fuel filter and the bracket.Repair Instructions Replacing injectors 31/32/41/42/43 series Special tools: 885 131 1 Applies only to TAMD31S-S Remove the protection cover over the injectors/delivery lines 2 Clean around the injectors and pipe connectors. 8 Clean mating surface between copper sleeves and injectors. Turn the injector using a PU-15 wrench pulling it up at the same time. 39 . Tighten to: 24 Nm. 15 Applies only to TAMD31S-A Install the protection cover over the injectors/delivery lines. If the injector cannot be pulled up be hand use puller 885 131. 6 Remove nuts on injector yokes and remove. 9 Install the new injectors. 12 3 Remove the return line between injectors and plug connections. 10 Install injector yokes. NOTE!The delivery lines must under no circumstances be bent. 4 Only applies to 42/43 series Remove the fuel and oil filter and the bracket. 5 Applies only to KA(M)D44P-A Remove the valve cover. Replace damaged delivery lines. 6 Applies only to KA(M)D44P-B/44P-C/300 4 Remove the delivery line and plug connections. Separate the connector. Remove the valve cover. 40 . Inspect the valve cover gasket. 2 Remove the return line between injectors and plug connections. Remove the clip on the rubber grommet for the cable to the injector on cylinder 1. NOTE! The springs on cylinder 1 cannot be removed before the injector is removed from the cylinder head. Remove the seal against the valve cover (the Orings. If it is undamaged the gasket does not need to be changed. Carefully press the rubber grommet in using a screwdriver at the same time lifting the valve cover slightly. washer and spring) on each injector. NOTE!The delivery lines must under no circumstances be bent. Inspect the valve cover gasket. washer and spring) on each injector. 3 Remove fuel and oil filter and the bracket. Insert the cable through the hole.Repair Instructions Replacing injectors KA(M)D44/300 series Special tools: 885 263 1 Clean around the injectors and pipe connectors. Remove the seal against the valve cover (the O-rings. If it is undamaged the gasket does not need to be changed. Remove the screws for the valve cover. socket 13 mm. If the injector cannot be pulled up by hand use puller 885. 8 Clean the mating surface between the copper sleeves and the injectors. Tightening torque 24 Nm. Applies only to KA(M)D44P-B/44P-C/300 Ensure that the cut out in the sealing washer corresponds to the split pin and the injectors cable terminal (only cylinder 1) Applies only to KA(M)D44P-B/44P-C/300 Thread the washer and spring onto cylinder 1 before installing it. This is to ensure that the copper sleeves do not come up with the injector. 41 .263. Thread the lower O-ring onto the nozzle. Do not forget the lower O-ring on the nozzles. Install the nozzles. Press the springs together and install the injector yoke in position. washer and spring) on each injector. 9 10 Install the seal against the valve cover (the O-rings.Repair Instructions 7 Remove the injectors. NOTE! Ensure that the plane of the return line is as straight as possible. See “Cleaning copper sleeves”. 15 Install the oil and fuel filter and bracket. Install the retaining clip. If it is undamaged and securely fixed to the cover. In cases where the value lies outside the given range the injector must be replaced. the gasket does not need to be changed. Resistance should be 100±10 ohm at 20°C. NOTE! The gasket join is located as per Fig. Check that the cable is clear of the rocker arms through the oil filler hole. Connect an ohmmeter 998 8452 and measure the resistance between the connector pins. 16 Start the engine and check for leaks. If it needs to be replaced carry out the following: Thoroughly clean the position of the gasket. Applies only to KA(M)D44P-B/44P-C/300 Insert the cable for the injector through the valve cover. Needle lift sensor. checking (only to KA(M)D44P-B/44P-C/300) Special tools: 998 8452 Carry out a check of the needle lift sensor in injector nozzle 1 as follows: Separate the connector (see ”Injector. replacement” point 6). 42 . Apply the new gasket and allow it to harden in the silicon before installing the valve cover. Apply a thin layer of silicon P/N 116 1231-4 to the valve cover. Connect the cable to the engine cable harness. 13 Install return line with new copper washers. 14 Install the delivery lines. Inspect the valve cover gasket. Press the rubber grommet into place at the same time as the valve cover is lowered against the cylinder head.Repair Instructions 11 12 Install valve cover. Inspect using an illuminated lens or nozzle microscope. The nozzle microscope can also be used for the nozzle sleeve. 4 Assemble the injector nozzle using the same thickness of shims for opening pressure as before. Cleaning copper sleeve Special tools: 885 289 1 Press the mounting sleeve over the brush to keep it together before securing it in a drill. 7 3 Press the brush into the copper sleeve. 2 Position the mounting sleeve over the copper sleeve. After cleaning blow away dirt using compressed air. If several nozzles are being cleaned at the same time. 2 Dismantle the injector. If the seat has been pushed down replace the nozzle pin together with the nozzle sleeve. If there is no ultrasound wash available. 43 . 6 Dip the nozzle components in pure diesel to oil.Repair Instructions Reconditioning injectors (only 1-spring injectors) 1 Clean the outside of the injector. Use an ultrasound wash. ensure that pins and sleeves that belong to the injector are not mixed up. 4 Check injector nozzle carefully. 5 Check other components. To avoid mixing them up place nozzles in a nozzle rack or in different compartments. If the damage is minor grind using a nozzle grinder. Connect a power drill and clean the copper sleeve. clean at the nearest Bosch workshop. 3 Clean the injector. Keep pressure steady for 10 seconds. NOTE! On a 2-spring injector only the opening pressure for the first stage is possible to test. Spray pattern and creak are harder to judge and do not provide a clear indication of the condition of the injector. 44 . Research has shown that the pressure drop evens out at approximately 15% under opening pressure for a used spring. The injector nozzle may often operate well even though the spray pattern is imprecise. Spray pattern and creak The condition of the injector nozzle is hard to determine based on spray pattern and creak. set pressure and replacing injectors Injection takes place under extremely high pressure so that atomization and combustion is as effective as possible. To avoid replacing and adjusting injectors unnecessarily follow the instructions for inspection below. This drop in pressure is within the specified operating range. No fuel should drop off the point of the nozzle but it can be damp. These values apply to new indicators with new thrust springs. Because the set pressure of a new spring is somewhat higher than the opening pressure there is some margin for the spring to settle. set pressure and seal. but the injector will still function normally. Pump up a pressure of 2 Mpa under injector opening pressure (first stage on a 2-spring injector) with a manometer connected. Opening pressure will drop more over time. opening pressure drops by approximately 8–10 bar. Y X A1 A2 A3 A4 Opening pressure Operating period New spring Old spring 8–10 bar difference The injector operates well despite the 10% reduction in opening pressure. In the service literature we indicate set pressure in addition to opening pressure. Adjusting the injector can shorten the injector nozzle service life. This drop in pressure is normal and does not affect injector function or engine performance significantly. No judgement can be made of the spray pattern of a 2-spring injector as this is related to the test equipment used. Wipe the point of the nozzle dry.Repair Instructions Recommendations when adjusting opening pressure. Seal test A seal test checks for leakage from the injector nozzle. If there is a leak it is between the point of the nozzle needle and the conical seal surface of the nozzle sleeve. Do not inspect an injector unless there is a definite indication that it is not functioning normally (excessive exhaust emissions for example). When testing an injector the most important things to look at are opening pressure. With time opening pressure drops under that indicated for new injectors. Injector nozzle creak can only be judged on new injectors. When a new spring has settled. The spray pattern can be very different to that of a 1spring injector. Plug pipe connectors and the point of nozzle after testing. 4 Adjusting opening pressure (2-spring injectors) NOTE! These injectors must not be reconditioned. see Workshop Manual “Technical data”. A maximum of 2 shims may be used. 3 Read off opening pressure on the tester manometer. replace the spring. Slowly press the tester lever down until the injector nozzle starts to eject fuel. 1 Connect the injector to a nozzle tester. 45 . Note. 2 Pump hard several times to clean dirt and air out of the injector nozzle. Spray pattern At a pump speed of 4–6 strokes a second the spray pattern should be the same and the fuel should be atomized. If the opening pressure does not correspond with the specified value the setting can be changed by replacing the shims in the injector. If the thickest shims are not sufficient.Repair Instructions Adjusting opening pressure (1-spring injectors) Opening pressure/set pressure For opening pressure and set pressure (new spring). An exchange program is in place. This automatically bleeds the fuel injection pump. When the fuel coming out of the bleed nipple is free of air bubbles close it. Use the hand pump for approximately 30 seconds. NOTE! If the pump effect is poor. turn the engine over slightly so that the pump drive cam changes position. Hand-tighten the filter until the gasket comes into contact with the filter bracket. 46 . Then twist a further half turn. Start the engine and check for leakage around the filter. 2 Bleeding fuel system 1 Place a container beneath the fuel filter. Open the bleed nipple on the fuel filter holder. Remove the filter using tool 999 9179. 3 Bleed the fuel injection pump is it has been disassembled.Repair Instructions Replacing fuel filter Special tools: 999 9179 1 Clean the filter mounting carefully. Fill the fuel injection system by pumping the hand pump on the feed pump. 4 Bleed fuel system. 2 3 Apply oil to the gasket of the new filter. ..................................................................................................................................................................................................................................................................................................................................................................................................................................... .................. ................................................................................................................... .......................................................................................................................................................................................................................Notes 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Date Concerns ............................................................................................................ ....................................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................. ................................................................... ........................................................................... ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... ......................................................................................................................................................................... ...................................................... .......................................................................................................................................................................................................................................................................................................................................................................................................... .................................................................. ............. .................................................................................................................................................................................................................................................................................. .......................................................................................................................................... ................................ ...................................................... ........................................................................................................................ .............................................................................................................................................................................................................. ......................................................................................................................................................................................References to Service Bulletins Group No......................................................................... ............................................................................................................................................................................................................................................................................................................................................... ...................................................................................................................................................................................... ............................. ................................................................................... ............................................................................................................................................... ...................................................................................................................................................................................................................................................................................................................................................................................................................... .............................. ...................................................................................................................................................................................................... .............................................................................................................................................................................................................................................................................................................. ....... ........................................................... Refers to publication: ...................................................................................... Name: .............................. ......................................................... ........................................ .................................................................................................................................................................................................... ......................................................: ...................................... ............................................................................................................................................................................................................................................................................. write your comments down and post it to us..................... Suggestion/reasons: ........................................................................................................................ ...................................................Report form Do you have any complaints or other comments about this manual? Please make a copy of this page............................................................................................................................................................................... Publication no............................ Issued: ..................................... The address is at the bottom of the page. From: .......................................................................................................................................................................................................................... ........ 42200 SE-405 08 Göteborg Sweden ........ .................................................................................................................. Date: .............................................................................................................................................................................................................................. ..................................................................................................................................................................................................................... We would prefer you to write in English or Swedish.................................................... AB Volvo Penta Technical Information Dept........................................................................ ............................................................................................... 7741732-7 English 09-2001 .