service and maintenance

D9
 © 2017 AB VOLVO PENTA
Volvo Penta reserves the right to make changes
Printed on environmentally friendly paper
 Table of Content
Safety Information ...................................................................................... 2
Lifting the engine – never do so alone ...................................................... 9
Proper lifting equipment ............................................................................ 9
General Information .................................................................................. 10
Illustrations .............................................................................................. 13
Chemical products .................................................................................... 16
Chemical products .................................................................................. 16
Specifications ............................................................................................ 17
Engine Decals ......................................................................................... 17
Transmission Decals ............................................................................... 18
General Tightening Torques ................................................................... 19
Specifications .......................................................................................... 20
Engine ........................................................................................................ 22
Maintenance Schedule ............................................................................ 22
General inspection .................................................................................. 22
Component location ................................................................................ 23
General advice for electronic protection .................................................. 25
Air Filter ................................................................................................... 26
Valves, Adjustment ................................................................................. 27
Lubrication System ................................................................................... 28
When you work with Chemicals, Fuel and Lubrication Oil, Change ........ 28
Engine oil, change ................................................................................... 28
Oil filter, Change ..................................................................................... 29
Oil Analysis ............................................................................................. 31
Fuel System ............................................................................................... 32
General ................................................................................................... 32
Fuel filter, Change ................................................................................... 34
Fuel pre-filter ........................................................................................... 35
Fuel system, bleeding ............................................................................. 37
Exhaust System ........................................................................................ 39
Exhaust hose .......................................................................................... 39
Turbocharger, Inspection ........................................................................ 40
Charge Air Pipe, Leakage Check ............................................................ 41
Cooling System ......................................................................................... 42
Coolant Level, Checking and Topping Up ............................................... 42
Drive belt, change ................................................................................... 46
Seawater Pump, Impeller, Change ......................................................... 47
Seawater Filter, Check and Cleaning ...................................................... 50
Zinc Anodes, Check and Change ........................................................... 52
Transmission ............................................................................................. 53
General ................................................................................................... 53
Reverse Gear .......................................................................................... 54
Reverse gear, oil and filter change ...................................................... 54
Electrical Rudder Actuator ................................................................... 56
Long-Term Storage ................................................................................... 57
Cold Weather Precautions ...................................................................... 58
Checklist .................................................................................................. 59
Battery, Maintenance .............................................................................. 60
Index ........................................................................................................... 63

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Safety Information
This chapter describes how safety precautions are If anything remains unclear or if you are unsure of
presented in the manual and on the product. Read the something, contact your Volvo Penta dealer for
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.

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 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 spare parts with the same quality as
genuine Volvo Penta parts 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.

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 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
It is a rule that no work should be performed on a
running engine. However, there is some adjustment
work requiring the engine to run. It is a security risk to
come near a running engine. Loose clothing or long
hair can get caught in rotating parts, careless
movements or a dropped tool can result in serious
injury.

Be careful to avoid hot surfaces (exhausts,

turbochargers, manifolds for the charge air and starter
elements etc.) and hot liquids in pipes and hoses on
engines running or has just been turned off. Refit all
guards removed during service operations 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.

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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.

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 Safety Information

Risk of flooding/sinking
WARNING!
If a launched boat is equipped with sea water tap and
safety valve, ensure that these are closed before any
work is allowed to begin on the cooling system.
Remember to open the tap and valve before starting
the engine!

P0024484

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 must be
opened – or if a plug or a 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.

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Safety Information

Safe handling of batteries

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

A spark caused by an incorrectly connected battery

can be enough for the battery to explode with serious
injuries.

Do not touch the connections during start attempts.

Sparking hazard! Do not lean over batteries.

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

IMPORTANT:
Never use a high pressure washer for cleaning of
engine or engine components.

P0024486

Cleanliness for sensitive components

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

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 Safety Information

Lifting the engine – never do so

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

IMPORTANT:
P0024485 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.

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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 conformity with
descriptions and servicing instructions for the above- Federal and California emission control regulations.
mentioned standard model Volvo Penta products. The emissions control parts are covered by the
The design and servicing items may vary between Emission Control System Warranty. Covered parts
different products. The applicable service intervals and conditions are listed under “What is covered by
and servicing procedures are described in the the Emission Warranty” in the “Emission Control
Maintenance Schedule for the product. System Warranty Statement”. Repairs and service
covered by the warranty will be performed by an
The product designation, serial number and authorized Volvo Penta distributor or dealer with no
specification are indicated on the engine decals or charge for parts or labor, including diagnosis, using
type plate. This information must always be included Volvo Penta parts for any part of the emission control
in all correspondence regarding the product. system covered by the warranty and found defective.
The Manual is produced primarily for the use of Volvo Use of a service or repair facility that is not a Volvo
Penta’s service workshops. It is assumed that any Penta authorized distributor or dealer, or use of non-
person using the Service Manual has a fundamental Volvo Penta emission-related components, will not
knowledge of the product and is able to carry out void or limit coverage of the Emission Control System
mechanical and electrical work to trade standard. Warranty. If emission related components/items are
included in the scheduled service, then such parts are
Volvo Penta continually develops its products. We
marked in the service protocol with a diamond (♦) and
therefore reserve the right to make changes.
the service must be performed at prescribed time
All information in this Manual is based on product data
intervals for compliance with the Emission Control
that was available at the time the Manual was
System Warranty. For the complete warranty
published.
conditions, see the “Emission Control System
NOTICE! The owner is responsible for ensuring that Warranty Statement”.
all scheduled maintenance is performed. Volvo Penta
warranty claims can be refused if a failure to carry out
maintenance results in a defect in the indicated
product. Refer to the Warranty Terms that are
supplied with the engine.

10 47709542 10-2017 © AB VOLVO PENTA

 General Information

Certified engines Maintenance Schedule

The engine is emissions-certified, and if it is used To maintain the product’s functionality, the
in an area where exhaust emissions are regulated Maintenance Schedule must be followed. Some
by law, this places special demands on the care operations can be carried out by the owner or other
and maintenance of the engine. person with sufficient technical competence, in
accordance with the Maintenance Schedule. Please
NOTICE! Neglect or failure to follow the items consult an authorized Volvo Penta dealer in the event
required here may invalidate the engine emissions of doubt regarding how service work should be
certificate. performed. Servicing items are marked in the
This means that AB Volvo Penta will no longer be Schedule. The Service Protocol is available on the
able to assume liability for the engine specification Volvo Penta website via the Product Center search
being in accordance with the certified model. Volvo function:
Penta is not responsible for damages or costs arising “Search Publications“
as a result of this.
• Certification means that an engine type has
been inspected and approved by the relevant
authority. The engine manufacturer guarantees
that all engines made of the same type are
equivalent to the certified engine.
• It is the responsibility of the operator/user to
ensure that no intentional misuse of the engine
takes place.
• Volvo Penta maintenance and service intervals
must be followed.
• All malfunctions should be addressed as quickly
as possible.
• We strongly recommend the use of genuine
Volvo Penta parts or parts with the same quality
as Volvo Penta parts.
• The engine must not be converted or modified
in any way, except for the accessories and
service kits which Volvo Penta has approved for
the engine.
• No changes to the installation of the exhaust
pipe and engine air inlet ducts may be made.
• No warranty seals (if present on the product)
may be broken by unauthorized persons.

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General Information

Genuine Volvo Penta parts Genuine Volvo Penta coolant

Volvo Penta products are designed and made to The main function of a coolant is to absorb heat from
achieve the highest quality. All parts are made so that the engine. The coolant also protects against
together they provide the best possible reliability. We freezing, lime deposits and corrosion. Volvo Penta
therefore recommend that It is advisable to always Coolant VCS (yellow) and Volvo Penta Coolant
use Volvo Penta original spare parts, which are (green) are two completely different types of coolant,
manufactured to the same rigorous specifications as which contain different types of inhibitor. Different
the factory-fitted parts comprising Volvo Penta types of coolants (colors) must not be mixed.
drivelines.
If you need to dilute concentrated coolant with water
yourself, the chemical composition of the water may
Genuine Volvo Penta engine oil impair the corrosion protection. In areas with high
levels of calcium and sodium in tap water the coolant
Volvo Penta supplies a wide range of lubricants must be diluted with distilled water. Alternatively,
developed especially for Volvo Penta engines. VDS Volvo Penta coolant is available for purchase ready
(Volvo Drain Specification) is a Volvo standard, diluted.
specifying Volvo’s requirements concerning oil
grade. For the engine's operation and long life, it is NOTICE! It is important to use the 40–60 %
recommended to use the specified oil. concentration of coolant in the cooling system, even
if there is no risk of freezing. The coolant also
prevents corrosion and deposits. A mixture with a
concentration above 60 % will impair frost protection.

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 General Information

Illustrations
Many illustrations contain standardized symbols and
colors. Please refer to the following information, to
avoid misunderstandings when using this manual to
assist in working on an engine or transmission.

Colors used in illustrations

Most illustrations include a highlighted component
(blue) and that is secured by a (red) bolt or similar as
part of a (light gray) engine or transmission.
1 Highlighted components
(blue)
2 Fastener
(red)
3 Assembly
(light gray)
P0015699
4 Background
(white)

Position
Arrows that point to items. Sometimes a number next
to an arrow can, for example, indicate three screws.
When this symbol is used on a number of bolts, the
service technician is expected to tighten the bolts in
that logical order.
P0015623
NOTICE! If an arrow with the text“ x3“ points to only
one item (e.g. a screw), this also applies to the two
other items (the two remaining screws) that are
indicated in the illustration.

This symbol indicates a location number for an item

(e.g. 2), which is also specified in the associated
textual information.
P0015627

The symbol to the left shows the part no. for the located
special tool, e.g. 9991801.
The lower symbol is used when something needs to be
replaced by a new part./kit.
The symbol to the right is used when an item must be
scrapped.

P0015628

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General Information

Movement Important

P0015622

Movement arrows are used to show in which direction

a component to be moved or rotated. P0015005

An eye symbol is used when something needs close

visual inspection or must be performed in a certain
way.
The symbol at the right is used when several
mechanics are needed.

Safety

P0015625

This symbol is used in the corner of an illustration to

show how many degrees the object must be turned,
and in which direction.

P0015697

These symbols are used when certain safety related

equipment is required.

P0015626

This symbol is used to show how many turns the

object must be rotated and in which direction.

14 47709542 10-2017 © AB VOLVO PENTA

 General Information

Chemicals Units

P0015695
P0015696

Symbols can also indicate when and how a chemical

Units are mentioned in the illustration when a specific
product is to be used.
value (e.g. pressure, weight, resistance, etc.) is
expected.
Cleanliness
Sealant

P0015624
P0015698
A scraping symbol recommends that sealant residue,
etc. should be scraped off a contact surface to clean A tube symbol indicates the thickness of a bead of
it. sealant.
A symbol with a rag recommends that the mechanic A clock symbol is used when something needs to be
cleans the contact surface thoroughly, or that a rag is done within or after a certain time period.
used to protect against a possible spill of oil or other
liquid.

47709542 10-2017 © AB VOLVO PENTA 15

Chemical products

Chemical products
Chemical products
Shown below is a selection of Volvo Penta
recommended chemical products. See also
Specifications.

P0001869

Grease
85145750 Thread locking 828250 1161231 Sealant

Engine oil VDS-4, 15W-40 Gear lubricant VCS Coolant

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 Specifications

Specifications
Engine Decals
There are type plates on the engine and its drivelines.
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.

1 Product Designation
2 CHASSIS ID/Serial no.
3 Emission information

47709542 10-2017 © AB VOLVO PENTA 17

Specifications

Transmission Decals
Rudder actuator

1 CHASSIS ID
2 Product ID

Reverse Gear
ZF and Twin Disc reverse gears have no ID marking
from Volvo Penta.
For further information about maintenance and oil
quantities, refer to the manufacturer's manual/website
for the reverse gear.

NOTICE! Informational image, reverse gear; designs

differ between manufacturers/models.

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 Specifications

General Tightening Torques

Bolt Nm (lbf. ft.)
M6 standard bolt 10 (7.4)
M8 standard bolt 24 (17.7)
M10 standard bolt 48 (35.4)
M12 standard bolt 85 (62.7)
M14 standard bolt 140 (103.3)
M16 standard bolt 220 (162)
NOTICE! Inspect bolts that will be re-installed.
Damaged bolts with e.g. shear marks under
the heads, must be scrapped.

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Specifications

Specifications
Volvo Penta products, all markets excluding North America
Oil quantity in engine, including filter. D9MH 425/500 at 0 degrees engine incline. 38 liters (10.04 US
gallons)
Oil quantity in engine, including filter. D9MH 425/500 at 7 degrees engine incline. 30 liters (7.93 US
gallons)
Oil quantity in engine, including filter. D9MG (KC/RC/HE) 46 liters (12.15 US
gallons)

Engine oil. Part number: 22305989 (1 liter)

Engine oil. Part number: 22305990 (5 liter)
Engine oil. Part number: 22305991 (208 liter)

Refer to the reverse gear owner manuals for maintenance and oil quantities.

Oil, rudder actuator: ATF/Dextron. Part number: 3851039

Oil quantity, rudder actuator. 5 liters (1.3 US gallons)

Coolant, VCS yellow, concentrated. Part number: 22567295 (5 liter)

Coolant, VCS yellow, ready mixed. Part number: 22567314 (5 liter)
Coolant volume D9MG empty system (HE). 39 liters (10.3 US
gallons)
Coolant volume D9MH empty system. 39 liters (10.3 US
gallons)

Propeller shaft grease. Part number: 1141644 (400 gram tube)

Coolant volumes may differ if the installation has extra

coolers / radiators connected.
Engine oil volume differs depending on installation
angle (incline).

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 Specifications

Volvo Penta products for North America

Oil quantity in engine, including filter. D9MH 425/500 at 0 degrees engine incline. 10.04 US gallons (38
liters)
Oil quantity in engine, including filter. D9MH 425/500 at 7 degrees engine incline. 7.93 US gallons (30
liters)
Oil quantity in engine, including filter. D9MG (KC/RC/HE) 12.15 US gallons (46
liters)

Engine oil. Part number: 40005011 (1 US quart)

Engine oil. Part number: 40005012 (1 US gallon)
Engine oil. Part number: 40005013 (5 US gallon)
Engine oil. Part number: 40005014 (55 US gallon)

Refer to the reverse gear owner manuals for maintenance and oil quantities.

Oil, rudder actuator: ATF/Dextron. Part number: 3851039

Oil quantity, rudder actuator. 1.3 US gallons (5 liters)

Coolant, VCS yellow, concentrated. Part number: 21485012 (1 US gallon)

Coolant, VCS yellow, ready mixed. Part number: 21485014 (1 US gallon)
Coolant volume D9MG empty system (HE). 10.3 US gallons (39
liters)
Coolant volume D9MH empty system. 10.3 US gallons (39
liters)

Propeller shaft grease. Part number: 3809449 (500 gram tube)

Coolant volumes may differ if the installation has extra

coolers / radiators connected.
Engine oil volume differs depending on installation
angle (incline).

47709542 10-2017 © AB VOLVO PENTA 21

Engine

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.
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.

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.

Look especially carefully for oil, fuel and coolant

leakages, loose bolts, worn or poorly-tensioned drive
belts, loose cable connections, damaged electrical
cables and hoses. This inspection only takes a few
minutes, but can prevent serious malfunctions and
expensive repairs.

WARNING!
Risk of fire.
Remove all accumulations of fuel, oil and grease when
detected on the engine or in the engine room.

WARNING!
If an oil, fuel or coolant leak is detected, the cause must
be investigated and the fault rectified before the engine
is started.

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 Engine

Component location

1 Expansion tank, cooling water 7 Fuel filter

2 Diagnostic connector 8 Impeller pump, seawater
3 Hand pump, fuel 9 Draining engine oil
4 Bleed nipple, fuel 10 Coolant drain, heat exchanger
5 Engine oil filler, R3-5 11 Seawater drain, heat exchanger
6 Dipstick, engine oil, R3-5 12 Anode, heat exchanger

47709542 10-2017 © AB VOLVO PENTA 23

Engine

13 Oil filter (3 pcs) 19 Draining coolant, engine block

14 Draining, seawater 20 Draining, seawater
15 Turbocharger 21 Oil filler, R1-2
16 Air filter 22 Dipstick, engine oil, R1-2
17 Drive belt 23 Draining engine oil
18 Draining, coolant 24 Anode, charge air cooler

24 47709542 10-2017 © AB VOLVO PENTA

 Engine

General advice for electronic

protection
The following advice must be complied with to
avoid damage to the engine control unit and other
electronics.
IMPORTANT:
Switch off the main switch before connecting or
disconnecting a connector.

• Never switch off the current at the main switch when

the engine is running;
• Never disconnect a battery cable when the engine
is running.
• Switch of the main switches or disconnect the
battery cables when fast-charging the batteries.
• NOTICE! It is not necessary to switch off the main
switches during normal maintenance charging.
• Only batteries may be used as a start 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.

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Engine

Air Filter

The engine air filter is located on the turbocharger inlet

pipe.

Replacing the air filter

1 Undo the clamps on the cover (1) and to the inner

filter attachment (3).
2 Remove the old filters (2 pcs), outer and inner.
Wipe clean around the attachments so that no dirt
can enter when the new filters are installed.
3 Install the new filters, inner and outer and secure
them with twist clamps as illustrated.

NOTICE! Discard the old filters. They are not intended

to be cleaned.

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 Engine

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.

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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, change

1 The pipe for connection to the oil drain (1) is
located on the edge of the oil sump next to the
attachment for the oil dipstick.
2 Remove the plug, connect a vacuum pump and
draw out the oil.
3 Reinstall the plug on completion.

The illustration shows the installation at the back of the

engine for ratings 3-4 and on the side for ratings 1-2.

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

NOTICE! Hand the old oil in to a re-cycling station.

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 Lubrication System

Oil filter, Change

We strongly recommend that only oil filters approved
by Volvo Penta be used.
The wrong type of oil filter can lead to increased wear
and damage, e.g. to bearings and crankshaft.

Removal
Oil filter removal
1 Remove the filters with the aid of filter pliers.
2 Clean around the filter attachment points.
3 Be prepared to gather up fluids.

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Lubrication System

Installation
4 Lubricate the gasket with engine oil before
installing.
5 Re-install the filter. Tighten by hand until it slows
up, then tighten a further half turn.

6 Fill with the required amount of oil; refer to

Specifications. R3-4 are filled at the back above
the flywheel.

7 Fill oil on R1-2 at the side of the engine, level with

the charge air cooler.
8 Start the engine.
9 Check that no leakage occurs.
10 After a few minutes, switch off the engine and
check the oil level.
11 Top up as necessary.

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 Lubrication System, Oil Analysis

Oil Analysis
Volvo Penta oil analysis
Volvo Penta oil analysis provides an extensive
diagnostic check on the driveline condition. 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 records
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.

47709542 10-2017 © AB VOLVO PENTA 31

Fuel System

Fuel System
General
The fuel system has a fine filter fitted to the engine as
standard.
The installation almost always has a pre-filter installed
in the boat; it must also be changed.

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 Fuel System

Volvo Penta sells pre-filters. They are available either

as a single filter or dual changeover filters.

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Fuel System

Fuel filter, Change

WARNING!
Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they cannot cause fire.

Do not fill the new filter with fuel before installation.

There is a risk that contaminants will enter the system
and cause operational disruptions or damage.
1 Close the fuel tap(s).
2 Place a collection vessel underneath the filter to
avoid fuel spillage.
3 Undo the sensor connector (1).
4 Relieve the pressure inside the filter by opening
the drain tap (2) at the bottom of the water
separator.
5 Clean around the filter housing sealing surface.
6 Remove the fuel filter; use a suitable filter puller.
7 Unscrew the water separator from the filter and
clean it internally.
8 Lubricate the rubber gasket with diesel and install
the new fuel filter.
9 Tighten the filter according to the instructions on
the filter (until stiff and then a further 1/2 turn).
10 Reconnect the connector to the water sensor (1).
Install the water separator and close the drain
cock.
11 Open the main fuel tap.
12 Open the vent screw and pump out fuel using the
hand pump.
Refer to: Fuel system venting.
13 Close the vent screw when fuel flows without
bubbles.
14 Start the engine and check that there are no
leaks.

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 Fuel System

Fuel pre-filter
Volvo Penta fuel pre-filters are supplied in single and
double models.

Checks
The double filter is fitted with a pressure gauge 1 that
indicates when it is time to replace the filter cartridges.

The filter cartridges must be replaced according to

maintenance schedule recommendations, or earlier if
the pressure gauge shows a pressure drop of 6–10 in.
Hg at idle or 16–20 in. Hg at full rpm/engine load.
WARNING!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.

Draining
Place a vessel under the filter. Empty the water and
sediment through the plugs (2).

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Fuel System

Replacing filter cartridges

Double filter cartridges can be replaced while the
engine is running, by shutting off the fuel flow to one
filter holder at a time.

Fuel flow is controlled by moving the lever (1) to the

following positions:
A Normal operating position (both filters connected).
B Left filter cartridge can be replaced.
C Right filter cartridge can be replaced.
D Both filters shut off.

If the engine is stopped, begin by shutting the fuel taps

at the tank before replacing the filters. If the engine is
running the fuel flow to the filter to be replaced must be
shut off using the lever (1).

1 Place a vessel under the filters and shut off the filter
to be replaced.
2 Undo the T-bolt (2) and remove the cover (3).
3 Carefully remove the cartridge with a turning
movement.
4 Empty the water and sediment through the drain
hole (4).
5 Insert a new filter cartridge and fill the holder with
clean fuel.
6 Replace the cover gasket and the T-bolt O-ring.
Moisten the gasket and the O-ring with fuel before
they are installed.
7 Install the cover and tighten it by hand.
8 Dry up any fuel spills.
9 Replace the other filter in the same way.
10 Open the fuel taps and put the lever in the normal
operating position. Check that there are no leaks.

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 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.

The fuel system must be vented when the fuel filter is

changed or if the fuel tank has been run dry and the
pump has drawn air into the system.

NOTICE! The venting procedure with the hand pump

(2) and the bleed nipple (1) is the same regardless of
the type of filter installed.

1 Place a suitable container beneath the fuel filter

to collect any fuel spillage during replacement.
2 Remove the protective cap from the bleed nipple
(1). Connect a transparent hose. Feed the hose
into the container to avoid fuel spillage.
3 Open the bleed nipple (1) and pump fuel with the
hand pump (2) until the fuel is free from bubbles.
4 Close the bleed nipple (1).
Tightening torque: 3.5 Nm (2.6 lbf·ft)
5 Start the engine. If the engine runs unevenly,
there may be air in the system. Open the bleed
nipple while the engine is running to expel
remaining air.
6 Close the nipple (1). Remove the hose and fit the
protective cap.
7 Check that no leakage occurs.

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Fuel System

Drain the water trap.

1 Place a suitable container beneath the fuel filter

to collect any fuel spillage during replacement.
2 Open the cock (3) and drain the water and dirt
from the water trap (4). Pump using the hand
pump (2) until clean fuel flows out.
3 Close the stop cock (3).

NOTICE! If dirt is discharged when draining, remove

the lower part (4) and clean it internally.

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 Exhaust System

Exhaust System
Exhaust hose

Inspect the exhaust hose for wear and signs of

leakage. Replace the exhaust hose if it has cracks or
appears damaged.

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Exhaust System

Turbocharger, Inspection
Checking the turbocharger

1 Remove the turbocharger cover.

2 Remove the exhaust fan and air filter holder from

the turbocharger.

3 Check the turbocharger with regard to damage to

the compressor and turbine wheels. If
undamaged, reinstall everything in reverse order.

NOTICE! In the case of damage to the compressor/

turbine wheels, the complete turbocharger must be
replaced. We recommend this work be carried out by
a Volvo Penta workshop.

40 47709542 10-2017 © AB VOLVO PENTA

 Exhaust System

Charge Air Pipe, Leakage Check

Check the boost air pipe hose connection with regard

to cracks or leaks; also check the condition of the
clamps. Replace as necessary.

If the connections leak, boost pressure will be too low

and engine performance will be impaired.

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Cooling System

Cooling System
Coolant Level, Checking and
Topping Up
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.

NOTICE! Only use coolants that comply with Volvo

Coolant Specification (VCS) standard: 418-0001.

NOTICE! Check the protection capacity (freezing

point) of the anti-freeze every year, if the coolant is not
being replaced.

Check the fluid level in the expansion tank when the

engine is cold. Top up with coolant as necessary.

The level mark is located under the radiator cap.

42 47709542 10-2017 © AB VOLVO PENTA

 Cooling System

Emptying the cooling water

1 Be prepared to gather up coolant.
2 Open the expansion tank cap.

3 Connect hoses and be ready to gather up coolant.

Open the drain points on the engine block, water
pump, heat exchanger and charge air cooler and
drain the coolant.
4 The cooling system must be cleaned/flushed;
refer to Flushing the cooling system.

NOTICE! If the boat has a heating element connected

to the engine cooling system, it must also be drained
when changing the engine coolant.

NOTICE! Hand in the old coolant to a recycling station

for disposal.

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Cooling System

Flushing the cooling system

To avoid a drop in cooling performance due to deposits
and debris, the engine cooling system must be flushed
with clean water when coolant is replaced.
1 Drain the old coolant; leave all drain points/valves
open.
2 Put a hose into the filler hole in the expansion tank
and flush with freshwater.
3 Flush until clean water runs out of the drain
points.
4 Turn off the water.
5 Close the drain points when water stops running
through.
6 Refill with new ready mixed coolant; see Filling an
empty system.

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 Cooling System

Filling an empty system

NOTICE! Dilute the coolant in advance to ensure the
cooling system is filled with the correct concentration
(applies to concentrated coolant). Do not start the
engine until the system is completely filled.

NOTICE! If a heating unit is connected to the engine

cooling system, the heat control valve for the system
must be opened and the installation vented during
filling.

1 Check that all drain points are closed.

2 Fill with coolant until the level is above the MIN
mark in the expansion tank.
3 When the cooling system is filled, start the engine
and let it idle for a few minutes.
4 Open any venting nipples for a while to allow
trapped air to escape.
5 Increase engine revolutions a little for a few
minutes.
6 Stop the engine and let it cool down. Then check
the coolant level.
7 Check the level one more time once the engine is
warmed through and its thermostat has opened.

NOTICE! In the case of long term storage of the

engine, the cooling system must not be drained. The
coolant contains corrosion protection additives.

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Cooling System

Drive belt, change

Check belt condition regularly.
Always change the belt if it is damaged or cracked.
The drive belt has an automatic belt tensioner and
does not need to be adjusted.

CAUTION!
Pinch hazard. Keep fingers clear.

Replacement
1 Remove the protective cover over the drive belt.

2 Insert a socket drive into the square socket on the

belt tensioner. Take the load off the belt tensioner
and lock it in position by inserting a screwdriver
or similar tool into the gap created.
3 Remove the drive belt.
4 Check tension pulley bearings. Replace them if
there is any play.
5 Fit the new drive belt and release the belt
tensioner.
6 Check that the belt is positioned correctly in the
grooves.
7 Put the protective cover back over the drive belt.

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 Cooling System

Seawater Pump, Impeller, Change

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

Clean and inspect the seawater pump’s internal and

external components such as the impeller and impeller
cover. Replace if there is damage to the cover or the
rubber. Otherwise change the impeller at the intervals
in the maintenance schedule.

Also check the water hoses to and from the impeller

pump. If they are dry, swollen or show other signs of
damage, they must be replaced.

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Cooling System

Disassembly
1 Close the engine cooling water cock if the boat is
in the water.
2 Remove the covers from the impeller pump.
3 Pull out the impeller with pliers; note the direction
of rotation for reinstallation.
4 Check the impeller. If cracks or other defects are
visible, the impeller must be replaced.

48 47709542 10-2017 © AB VOLVO PENTA

 Cooling System

Installation
1 Lubricate the inside of the pump housing and the
impeller with glycerin.
2 Push the impeller in with a rotating movement in
the direction of flow, in the same direction as the
replaced impeller.
3 Install the cover with a new O-ring.
Bolt tightening torque is 6 Nm (4.4 lbf·ft).
4 Open the cooling water cock.
5 Start the engine. Check that no leakage occurs.

NOTICE! The impeller may be damaged if any types

of lubricant other than glycerin are used.

NOTICE! The impeller will be easier to work with if it is

placed in hot water before installation.

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Cooling System

Seawater Filter, Check and Cleaning

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

If a seawater filter is fitted to the engine it must be

cleaned according to the maintenance schedule.
If the waters where the boat is used contain a lot of
contamination, seaweed etc., check the filter more
often than specified in the maintenance schedule,
otherwise there is a risk of clogged filters causing the
engine to overheat.

NOTICE! Informational image, water filter. There may

be differences between different models.

1 Close the sea cock.

2 Unscrew the cover (1).
3 Lift out the insert and clean it.
4 The glass vessel must (2) not be removed!
5 Reassemble in the reverse order and tighten the
cover. Grease the gasket with silicone-based
grease.
6 Open the sea cock and check that there are no
leaks when the engine is being started.

NOTICE! At the same time, check that the hose clamps

are secure and that hoses and connections are
undamaged.

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 Cooling System

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

Cooling water intake

Check the cooling water cock operation at every
service.
It must be possible to open and shut the cock for e.g.
impeller maintenance.

Clean the cooling water intake outer grille when the

boat is on dry land.

NOTICE! At the same time, check that the hose clamps

are secure and coolant hose is undamaged.

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Cooling System

Zinc Anodes, Check and Change

WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

1 Close the sea cock.

2 Open the heat exchanger and charge air cooler
drain cocks(1) and drain the seawater.
Check that the O-rings/gaskets are in good
condition; if not, change them.
3 Remove the zinc anode (2).
4 Change it if less than half of its original mass
remains.
IMPORTANT:
Use emery paper. Do not use a wire brush or other
steel tools when cleaning, as these may damage the
galvanic protection.

5 Make sure there is good metal-to-metal contact

between the anode and the casting.
6 Close the drain cock (1).
7 Open the sea cock before starting the engine.
8 Check that there are no leaks.

NOTICE! Because the heat exchanger and charge air

cooler end plates on newer engines are made of
plastic, there are no anodes to replace.

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 Transmission

Transmission
General
Gear lubricant
In a marine environment it is vitally important that the
correct gear lubricant is used for the product
concerned.

While oils from various suppliers meets both SAE class

(viscosity) and API class (quality), their additives often
differ. Additives can be up to 35% of the total volume,
and are crucial to how oil can handle a given water
content while still maintaining the necessary
lubricating properties.

The correct oil is crucial for the proper functioning of

the transmission.

NOTICE! Always follow the manufacturer's

recommended intervals for oil change and
maintenance instructions for your reverse gear. Also
check the manufacturer's recommended oil type,
grade and volume at oil changes.

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Transmission, Reverse Gear

Reverse Gear
Reverse gear, oil and filter change

Service reverse gears according to the manufacturer’s

recommendations.

The reverse gears are hydraulic and the lubrication

system is equipped with an oil filter and oil cooler.
Check the oil level regularly.

NOTE! Informational image, reverse gear. Designs

differ between manufacturers. Check the manual/
owner's manual regarding applicable maintenance
intervals for the reverse gear.

Check the oil level

ZF
Start the engine and run it until it reaches operating
temperature.
Stop the engine, wait two minutes before checking the
level.
Pull out the dipstick and wipe it dry.
Re-insert the dipstick.
Pull up the dipstick again and check the level.
The level must be between the max and min markings.
Top off as necessary and check the level as described
above.

Twin Disc
Start the engine and run it until it reaches operating
temperature.
Continue running the engine at idle and checking the
oil level using the oil dipstick.
The level should be at the max mark.
Top off as necessary and check the level as described
above.

NOTICE! Never overfill the reversing gear with oil.

54 47709542 10-2017 © AB VOLVO PENTA

 Transmission, Reverse Gear

Grease-lubricated shaft
1 Check that there is grease in the grease cup.
2 Lubricate the shaft at each service.
3 Check the shaft stuffing box. If there is any
leakage, the seal must be replaced.
4 Check the hose clamps.

Water-lubricated shaft
Check the propeller shaft rubber sleeve if it is cracked
or leaks on launching. During the season, check for
water entering the boat through the shaft gland. If there
is any leakage, the rubber sleeve must be replaced.

The rubber sleeve on the propeller shaft must be

vented when the boat is launched. Vent the sleeve by
squeezing its mouth (where the shaft emerges)
together while at the same time pressing the shaft
lightly downwards.

We recommend injecting 1/4 teaspoon of water

resistant grease in on launching,

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Transmission, Reverse Gear

Electrical Rudder Actuator

Check the oil level with the aid of the dipstick on the
side of the rudder actuator.
Screw the dipstick down when checking the level. The
level must be between the markings on the dipstick.

NOTICE! The oil dipstick is made of plastic, do not

tighten it too much.
Tightening torque: 10 Nm (7.4 lbf·ft)

Changing the oil in the rudder actuator

Oil change intervals according to the maintenance
schedule. When changing the oil, draw it out through
the oil dipstick hole.
Quantity approx 5 liters (1.3 US gallons).

Also check that the bolted joint is secure and that the
linkage between the actuator and rudder is not binding.

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 Long-Term Storage

Long-Term Storage
If the boat is not going to be used for two months or more, it is important to reduce the risk of damage to the
engine and other equipment. The following proposals contain measures to prevent condensation and reduce the
prevention of frost weathering and reduce the formation of condensation, mold and corrosion.

IMPORTANT:
When cleaning with a high pressure washer, make sure to never aim the water jet at seals, rubber hoses or
electrical components. Never use a high pressure washer for engine cleaning.

• Check that the coolant offers sufficient frost

protection. Check the level and top up as
necessary.

• Drain all the remaining seawater from the cooling

system, (heat exchanger, charge air cooler,
impeller pump, hoses containing sea water).
• Remove the impeller from the seawater pump.
Store the impeller in a sealed plastic bag and keep
cool.
• Empty and clean the fuel tank if it contains water
or dirt. Then fill the fuel tank with fuel to avoid
condensation.
• Disconnect the battery cables; clean and charge
the batteries. Trickle charge the batteries while the
boat is laid up.
Please note that a poorly charged battery may
burst as a result of freezing if stored at freezing
temperatures.
• Cover the alternator with a plastic bag. Clean the
outside of the engine with a cleaning product from
a boat accessory store using a sponge/brush.
Rinse with lukewarm water afterwards, (do not use
a high pressure washer). Wet vacuum the keelson
and dry off.
• Touch up any paint damage with Volvo Penta
original paint or paint of the same quality.
• If necessary, cover the engine, air intake and
exhaust pipe.
• Always ensure good ventilation in the engine
compartment in order to prevent the formation of
mold and corrosion (if possible, leave hatches
open).

NOTICE! It is easier to discover leaks and damage and

reduce the formation of corrosion and mold in a dry,
clean engine room.

NOTICE! Attach a note on the engine/the filters with the

date and type of oil that has been used so it is easier to
remember what has been carried out when it is time to
launch.

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Long-Term Storage

Cold Weather Precautions

If the engine bay cannot be kept free from frost, the

seawater system must be drained and the freshwater
system coolant must have sufficient antifreeze to
prevent frost bursting.

IMPORTANT:
Coolant of a suitable chemical composition must be
used all year round to protect the engine against
internal corrosion, cavitation and freeze bursting.
This even applies when there is no risk for freeze
damage, to make sure the engine always has a
complete corrosion protection.

• Drain the seawater from the heat exchanger,

exhaust manifold and the charge air cooler and
drain the water to the impeller pump (arrows).
• Make sure all water drains out, otherwise residual
water may cause freeze bursting.

The risk of freeze bursting can be reduced by running

the engine with a mixture of 40% coolant and 60%
fresh water through the seawater system before the
engine is switched off.

Ensure good ventilation during winter storage to

prevent the formation of mold/corrosion.

NOTICE! Once the engine is drained of seawater/salt

water, check that it does not get onto the alternator,
fuel pump or other parts susceptible to corrosion. If it
is not possible to avoid this, carefully flush with fresh
water and make sure it is properly dried up afterwards.

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 Long-Term Storage

Checklist
Suggestion for the checklist in addition to the regular
service points:

Checks/actions when taking the boat out of the

water
• Checking for leakage: fuel/water/exhaust.
• Checking the hose clamps.
• Checking the cable connections.
• Inspecting the through-hull fittings/cocks.
• Checking the cooling water cock: opening/closing.
Replace it if it is stuck.
• Cleaning off fouling growth (drive/hull/propellers).
• Cleaning the battery terminals, removing oxide.
Check the electrolyte level.
• Clean the engine and engine compartment.
• Clean the fuel tank.
• To empty/replacement of fuel pre-filter.
• Functional check of other electrical systems.
• Check the rudder, drive and propeller(s).
Start the engine every six months
If the boat is left out of the water for 6-8 months or more,
the engine should be started and warmed up every six
months as follows:
• Check the engine oil level.
• Check the oil levels in the drive or reverse gear.
• Check the coolant level.
• Check the battery cables to the batteries (fully
charged).
• Take the impeller out of the seawater pump, or
connect cooling water via a hose to the intake.
• Start the engine and run it for 2-3 minutes with the
gearshift in the neutral position.
• Stop the engine.
• Rotate the sterndrive or reverser output shafts by
hand for 2-3 turns.
• 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 battery or 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 poles 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)
1 Remove the nut and remove the negative cable (-)
(black).
2 Remove the nut and remove the positive cable (+)
(red).

Remove the battery.

Connection (B)

Put the new battery in place.

1 Connect the positive cable (red) to the battery
positive terminal and tighten the nut.
2 Connect the negative cable (black) to the battery
negative terminal and tighten the nut.

NOTICE! Hand in the old battery to a waste

management facility.

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Index
A Transmission Decals................................................ 18
Air Filter.................................................................... 26 Turbocharger, Inspection......................................... 40

B V
Battery, Maintenance............................................... 60 Valves, Adjustment................................................... 27

C W
Charge Air Pipe, Leakage Check............................. 41 When you work with Chemicals, Fuel and
Checklist................................................................... 59 Lubrication Oil, Change............................................ 28
Chemical products.................................................... 16 Z
Cold Weather Precautions....................................... 58 Zinc Anodes, Check and Change............................. 52
Component location................................................. 23
Coolant Level, Checking and Topping Up................ 42
Cooling System........................................................ 42
D
Drive belt, change.................................................... 46
E
Electrical Rudder Actuator........................................ 56
Engine...................................................................... 22
Engine Decals.......................................................... 17
Engine oil, change.................................................... 28
Exhaust hose............................................................ 39
Exhaust System....................................................... 39
F
Fuel filter, Change.................................................... 34
Fuel pre-filter............................................................ 35
Fuel System............................................................. 32
Fuel system, bleeding.............................................. 37
G
General............................................................... 32, 53
General advice for electronic protection................... 25
General Information.................................................. 10
General inspection................................................... 22
General Tightening Torques..................................... 19
I
Illustrations............................................................... 13
L
Lifting the engine – never do so alone....................... 9
Long-Term Storage.................................................. 57
Lubrication System................................................... 28
M
Maintenance Schedule............................................. 22
O
Oil Analysis............................................................... 31
Oil filter, Change....................................................... 29
P
Proper lifting equipment............................................. 9
R
Reverse gear, oil and filter change........................... 54
S
Safety Information...................................................... 2
Seawater Filter, Check and Cleaning....................... 50
Seawater Pump, Impeller, Change.......................... 47
Specifications..................................................... 17, 20
T
Transmission............................................................ 53

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 47709542 English 10-2017

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