6
Repair instructions
The working methods described in the Service Ma-
nual apply to work carried out in a workshop. The
engine has been removed from the boat and is in-
stalled in an engine fixture. Unless otherwise stated
reconditioning work which can be carried out with
the engine in place follows the same working
method.
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 impos-
sible to predict every circumstance under which ser-
vice work or repairs may be carried out. For this rea-
son 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.
All procedures for which there are Volvo Penta spe-
cial tools in this Workshop Manual are carried out
using these. Special tools are developed to rational-
ize working methods and make procedures as safe
as possible. 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, damage or malfunction resulting
from these.
In some cases there may be special safety precau-
tions and instructions for the use of tools and chem-
icals contained in this Workshop Manual. These spe-
cial instructions should always be followed if there
are no separate instructions in the Workshop Man-
ual.
Certain elementary precautions and common sense
can prevent most risks arising. A clean workplace
and engine eliminates much of the danger of injury
and malfunction.
It is of the greatest importance that no dirt or foreign
particles get into the fuel system, lubrication sys-
tem, intake system, turbocharger, bearings and
seals when they are being worked on. The result
can be malfunction or a shorter operational life.
Our joint responsibility
Each engine consists of many connected systems
and components. If a component deviates from its
technical specification the environmental impact of an
otherwise good engine may be increased significantly.
It is therefore vital that wear tolerances are main-
tained, that systems that can be adjusted are adjusted
properly and that Volvo Penta Genuine Parts as used.
The engine Maintenance Schedule must be followed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance. Some com-
ponents are sealed at the factory for environmental
reasons. No work should be carried out on sealed
components except by authorized personnel.
Bear in mind that most chemicals used on boats are
harmful to the environment if used incorrectly.
Volvo Penta recommends the use of biodegradable
degreasing agents for cleaning engine components,
unless otherwise stated in a workshop manual. Take
special care when working on-board, that oil and
waste is taken for destruction and is not accidentally
pumped into the environment with bilge water.
Tightening torques
Tightening torques for vital joints that must be
tightened with a torque wrench are listed in workshop
manual “Technical Data”: “Tightening Torques” and are
contained in work descriptions in this Manual. All tor-
ques apply for cleaned threads, screw heads and
mating surfaces. Torques apply for lightly oiled or dry
threads. If lubricants, locking fluid or sealing com-
pound are required for a screwed joint this information
will be contained in the work description and in “Tight-
ening Torques” Where no tightening torque is stated for
a joint use the general tightening torques according to
the tables below. The tightening torques stated are a
guide and the joint does not have to be tightened using
a torque wrench.
Dimension Tightening Torques
Nm lbt.ft
M5 6 4,4
M6 10 7,4
M8 25 18,4
M10 50 36,9
M12 80 59,0
M14 140 103,3
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