Workshop Manual B

Fuel and lubrication system 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 ............................................... 2 Group 23 Fuel system
General information ............................................ 5
Design and function ............................................ 24
Repair instruction ............................................... 6
General .............................................................. 24
Special tools ....................................................... 9
EDC system ...................................................... 24
Other special equipment .................................... 9
Injection pump ................................................... 25
Group 22 Lubrication system Overflow valve ................................................... 25
Design and function ............................................ 10 Smoke limiter ..................................................... 26
General .............................................................. 10 Injector ............................................................... 27
Control valves .................................................... 11 2-spring injector ................................................. 27
Safety valve ....................................................... 11 2-spring injector with needle lift sensor ............... 28
Relief valve ........................................................ 11 Feed pump ......................................................... 29
Piston cooling valve ........................................... 11 Fuel filter ............................................................ 29
Piston cooling .................................................... 12 Return fuel cooler ............................................... 29
Oil pump ............................................................ 12 Repair instructions .............................................. 30
Oil cooler ........................................................... 12 Removing fuel injection pump ............................ 30
Oil filter .............................................................. 13 Installing and setting up fuel injection pump ....... 32
Crankcase ventilation ......................................... 13 Fault-tracing fuel valve ....................................... 34
Repair Instructions .............................................. 14 Setting up idling speed ....................................... 35
General .............................................................. 14 Replacing feed pump ......................................... 36
Engine fixture attachment .................................. 15 Fuel feed pressure, check (31/32/41/42/43) ....... 36
Checking oil pressure ......................................... 16 Checking Fuel supply pressure (44/300) ............ 37
Replacing oil filter ............................................... 16 Replacing injector (31/32/41/42/43) .................... 39
Replacing oil pan gasket .................................... 17 Replacing injector (44/300) ................................. 40
Replacing lubrication pump ................................ 17 Needle lift sensor, checking ............................... 42
Reconditioning oil pump ..................................... 19 Reconditioning injectors ..................................... 43
Reconditioning oil cooler (early version) ............. 22 Cleaning copper sleeve ...................................... 43
Reconditioning oil cooler (late version) ............... 23 Recommendations when adjusting
Oil cooler, test pressurization ............................. 23 opening pressure, set pressure and
replacing injectors .............................................. 44
Adjusting opening pressure ................................ 45
Replacing fuel filter ............................................ 46
Bleeding the fuel system .................................... 46

1
 Safety Information
Introduction
This Workshop Manual contains technical data, de- Check that the warning or information decals on
scriptions and repair instructions for Volvo Penta prod- the product are always clearly visible. Replace
ucts or product versions contained in the contents list. decals that have been damaged or painted over.
Ensure that the correct workshop literature is being
used. Never start the engine without installing the air
Read the safety information and the Workshop cleaner (ACL). The rotating compressor in the
Manual “General Information” and “Repair In- turbocharger can cause serious personal injury.
structions” carefully before starting work. Foreign objects entering the intake ducts can
also cause mechanical damage.

Important Never use start spray or similar to start the en-

In this book and on the engine you will find the follow- gine. The starter element may cause an explo-
ing special warning symbols. sion in the inlet manifold. Danger of personal in-
jury.
WARNING! If these instructions are not followed
there is a danger of personal injury, extensive Avoid opening the coolant filling cap when the
damage to the product or serious mechanical engine is hot. Steam or hot coolant can spray
malfunction. out at the same time as the pressure which has
built up is lost. Open the filler cap slowly, and
IMPORTANT! Used to draw your attention to release the pressure in the cooling system if the
something that can cause damage, product mal- filling cap or tap has to be opened, or if a plug or
function or damage to property. coolant hose has to be removed when the en-
gine is hot. Steam or hot coolant can stream out
NOTE! Used to draw your attention to important infor- in an unexpected direction.
mation that will facilitate work or operations.
Hot oil can cause burns. Avoid skin contact with
Below is a summary of the risks and safety precau- hot oil. Ensure that the lubrication system is not
tions you should always observe or carry out when op- under pressure before commencing work on it.
erating or servicing the engine. Never start or operate the engine with the oil fill-
er cap removed, otherwise oil could be ejected.

Immobilize the engine by turning off the power Stop the engine and close the sea cock before
supply to the engine at the main switch (switch- carrying out operations on the engine cooling
es) and lock it (them) in the OFF position before system.
starting work. Set up a warning notice at the en-
gine control point or helm.
Start the engine only in a well-ventilated area. If
Generally, all servicing should be carried out operating the engine in an enclosed space, en-
with the engine switched off. However, some sure that exhaust gases and crankcase ventila-
work, for example certain adjustments require tion emissions are ventilated out of the working
that the engine is running when they are carried area.
out. Approaching a running engine is dangerous.
Loose clothing or long hair can fasten in rotating Always use protective goggles where there is a
parts and cause serious personal injury. danger of pieces of metal, sparks from grinding,
If working in proximity to a running engine, care- acid or other chemicals being thrown into your
less movements or a dropped tool can result in eyes. Your eyes are very sensitive, injury can
personal injury. Avoid burns. Take precautions lead to loss of sight!
to avoid hot surfaces (exhausts, turbochargers,
charge air pipes and starter elements etc.) and
liquids in supply lines and hoses when the en-
gine is running or has been turned off immedi-
ately prior to starting work on it. Reinstall all pro-
tective parts removed during service operations
before starting the engine.

2
 Safety information

Avoid skin contact with oil. Long-term or repeat- Never allow a naked flame or electric sparks
ed contact with oil can remove the natural oils near the batteries. Never smoke in proximity to
from your skin. The result can be irritation, dry the batteries. The batteries give off hydrogen
skin, eczema and other skin problems. gas during charging which when mixed with air
Used oil is more dangerous to health than new can form an explosive gas - oxyhydrogen. This
oil. Use protective gloves and avoid using oil- gas is easily ignited and highly volatile. Incor-
soaked clothes and rags. Wash regularly, espe- rect connection of the battery can cause a spark
cially before meals. Use the correct barrier which is sufficient to cause an explosion with re-
cream to prevent dry skin and to make cleaning sulting damage. Do not disturb battery connec-
your skin easier. tions when starting the engine (spark risk) and
do not lean over batteries.
Most chemicals used in products (engine and
transmission oils, glycol, petrol and diesel oil) Never mix up the positive and negative battery
and workshop chemicals (solvents and paints) terminals when installing. Incorrect installation
are hazardous to health Read the instructions on can result in serious damage to electrical equip-
the product packaging carefully! Always follow ment. Refer to wiring diagrams.
safety instructions (using breathing apparatus,
protective goggles and gloves for example). En- Always use protective goggles when charging
sure that other personnel are not unwittingly ex- and handling batteries. The battery electrolyte
posed to hazardous substances (by breathing contains extremely corrosive sulfuric acid. If
them in for example). Ensure that ventilation is this comes into contact with the skin, wash im-
good. Handle used and excess chemicals ac- mediately with soap and plenty of water. If bat-
cording to instructions. tery acid comes into contact with the eyes, im-
mediately flush with copious amounts of water
Be extremely careful when tracing leaks in the and obtain medical assistance.
fuel system and testing fuel injection nozzles.
Use protective goggles! The jet ejected from a Turn off the engine and turn off power at main
fuel injection nozzle is under very high pressure, switch(es) before carrying out work on the elec-
it can penetrate body tissue and cause serious trical system.
injury There is a danger of blood poisoning.
The clutch must be adjusted with the engine
All fuels and many chemicals are inflammable. shut off.
Ensure that a naked flame or sparks cannot ig-
Use the lifting eyes mounted on the engine/re-
nite fuel or chemicals. Combined with air in cer-
verse gear when lifting the drive unit.
tain ratios, petrol, some solvents and hydrogen
Always check that lifting equipment is in good
from batteries are easily inflammable and explo-
condition and has sufficient load capacity to lift
sive. Smoking is prohibited! Ensure that ventila-
the engine (engine weight including reverse gear
tion is good and that the necessary safety pre-
and any extra equipment installed).
cautions have been taken before carrying out
Use an adjustable lifting beam or lifting beam
welding or grinding work. Always have a fire ex-
specifically for the engine to raise the engine to
tinguisher to hand in the workplace.
ensure safe handling and to avoid damaging en-
gine parts installed on the top of the engine. All
Store oil and fuel-soaked rags and fuel and oil chains and cables should run parallel to each
filters safely. In certain conditions oil-soaked other and as perpendicular as possible in rela-
rags can spontaneously ignite. Used fuel and oil tion to the top of the engine.
filters are environmentally dangerous waste and If extra equipment is installed on the engine al-
must be deposited at an approved site for de- tering its center of gravity, a special lifting de-
struction together with used lubricating oil, con- vice is required to achieve the correct balance
taminated fuel, paint remnants, solvent, de- for safe handling.
greasing agents and waste from washing parts. Never carry out work on an engine suspended
on a hoist.

3
Safety information

Never remove heavy components alone, even Fuel delivery pipes must not be bent or straight-
where secure lifting equipment such as secured ened under any circumstances. Damaged pipes
blocks are being used. Even where lifting equip- must be replaced.
ment is being used it is best to carry out the Remember the following when washing with a
work with two people; one to operate the lifting high pressure washer: Never aim the water jet at
equipment and the other to ensure that compo- seals, rubber hoses or electrical components.
nents are not trapped and damaged when being Never use a high pressure washer for engine
lifted. cleaning.
When working on-board ensure that there is suf-
ficient space to remove components without Always use fuels recommended by Volvo Pen-
danger of injury or damage. ta. Refer to the Instruction Book. The use of
other grades of fuel can damage the engine. On
Components in the electrical system and fuel a diesel engine poor quality fuel can cause the
system on Volvo Penta products are designed control rod to seize and the engine to overrev
and constructed to minimize the risk of fire and with the resulting risk of damage to the engine
explosion. The engine must not be run in areas and personal injury. Poor fuel quality can also
where there are explosive materials. lead to higher maintenance costs.

© 2001 AB VOLVO PENTA

We reserve the right to make design changes and amendments
without prior notice.
Printed on environmentally compatible paper.

4
 General Information

About the workshop manual Certificated engines

This workshop manual contains technical data, de- When service or repairs are done to an emission certi-
scriptions and repair instructions for standard ver- fied engine, it is important to be aware of the
sions of the engine units in the 31/32/41/42/43/44/300 following:
series. The workshop manual displays the operations Certification means that an engine type has been
carried out on any of the engines above. As a result, checked and approved by the relevant authority. The
the illustrations and pictures in the manual that show engine manufacturer guarantees that all engines made
certain parts on the engines, do not in some cases of the same type are equivalent to the certified engine.
apply to all the engines listed above. However, the
repair and service operations described are the same This put special demands on service and repair work,
in all essential details. Where they are not the same, as follows:
this is stated in the manual. Where the difference is
• Maintenance and service intervals recommended
considerable, the operations are described separately.
by Volvo Penta must be complied with.
The engine designation and number is indicted on
the engine identification plate. The engine designa- • Only Volvo Penta original spares may be used.
tion and number should be given in all correspond- • Service to injection pumps, pump settings and in-
ence about the engine. jectors must always be done by an authorized Vol-
This Workshop Manual has been developed primari- vo Penta workshop.
ly for Volvo Penta service workshops and qualified • The engine must not be converted or modified, ex-
personnel. Persons using this book are assumed to cept for the accessories and service kits which
have a grounding in marine drive systems and be Volvo Penta has approved for the engine.
able to carry out related mechanical and electrical
• No installation changes to the exhaust pipe and
work.
engine air inlet ducts may be done.
Volvo Penta is continuously developing their prod-
• No seals may be broken by unauthorized personnel.
ucts. We therefore reserve the right to make chang-
es. All the information contained in this book is The general advice in the instruction book about oper-
based on product data available at the time of going ation, care and maintenance apply.
to print. Any essential changes or modifications in-
IMPORTANT! Delayed or inferior care/mainte-
troduced into production or updated or revised serv-
nance, and the use of non-original spares, mean
ice methods introduced after the date of publication
that AB Volvo Penta can no longer be responsi-
will be provided in the form of Service Bulletins.
ble for guaranteeing that the engine complies
with the certified version.
Damage, injury and/or costs which arise from
Replacement parts this will not be compensated by Volvo Penta.
Replacement parts for the electrical and fuel sys-
tems are subject to statutory requirements (US
Coast Guard Safety Regulations for example). Volvo
Penta Genuine parts meet these requirements. Any
type of damage which results from the use of non-
original Volvo Penta replacement parts for the prod-
uct will not be covered under any warranty provided
by Volvo Penta.

5
 Repair Instructions

The working methods described in the Service Manual

apply to work carried out in a workshop. The engine
Joint responsibility
has been removed from the boat and is installed in an Each engine consists of many connected systems
engine fixture. Unless otherwise stated reconditioning and components. If a component deviates from its
work which can be carried out with the engine in place technical specification the environmental impact of an
follows the same working method. otherwise good engine may be increased significantly.
Warning symbols occurring in the Workshop Manual It is therefore vital that wear tolerances are main-
(for their meaning see Safety information) tained, that systems that can be adjusted are adjust-
ed properly and that Volvo Penta Genuine Parts as
WARNING! used. The engine Maintenance Schedule must be fol-
lowed.
IMPORTANT! Some systems, such as the components in the fuel
system, require special expertise and special testing
NOTE! equipment for service and maintenance. Some com-
are not in any way comprehensive since it is impossi- ponents are sealed at the factory for environmental
ble to predict every circumstance under which service reasons. No work should be carried out on sealed
work or repairs may be carried out. For this reason we components except by authorized personnel.
can only highlight the risks that can arise when work Bear in mind that most chemicals used on boats are
is carried out incorrectly in a well-equipped workshop harmful to the environment if used incorrectly. Volvo
using working methods and tools developed by us. Penta recommends the use of biodegradable degreas-
All procedures for which there are Volvo Penta special ing agents for cleaning engine components, unless
tools in this Workshop Manual are carried out using otherwise stated in a workshop manual. Take special
these. Special tools are developed to rationalize work- care when working on-board, that oil and waste is tak-
ing methods and make procedures as safe as possi- en for destruction and is not accidentally pumped into
ble. It is therefore the responsibility of any person us- the environment with bilge water.
ing tools or working methods other than the ones rec-
ommended by us to ensure that there is no danger of
injury, damage or malfunction resulting from these.
Tightening Torques
In some cases there may be special safety precau-
tions and instructions for the use of tools and chemi- Tightening torques for vital joints that must be tight-
cals contained in this Workshop Manual. These spe- ened with a torque wrench are listed in “Specifica-
cial instructions should always be followed if there are tions”: “Tightening torques” and contained in the work
no separate instructions in the Workshop Manual. descriptions in the Manual. All torques apply for
cleaned threads, screw heads and mating surfaces.
Certain elementary precautions and common sense
Torques apply for lightly oiled or dry threads. If lubri-
can prevent most risks arising. A clean workplace and
cants, locking fluid or sealing compound are required
engine eliminates much of the danger of injury and
for a screwed joint this information will be contained in
malfunction.
the work description and in “Tightening Torques”
It is of the greatest importance that no dirt or foreign Where no tightening torque is stated for a joint use the
particles get into the fuel system, lubrication system, general tightening torques according to the tables be-
intake system, turbocharger, bearings and seals when low. The tightening torques stated are a guide and the
they are being worked on. The result can be malfunc- joint does not have to be tightened using a torque
tion or a shorter operational life. 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

6
 Repair instructions

To ensure service work is correctly carried out it is im-

Tightening torque with portant that the correct sealant and locking fluid type
Protractor tightening is used on the joint where the agents are required.
In this Volvo Penta Service Manual the user will find
(angle tightening) that each section where these agents are applied in
Tightening using both a torque setting and a protractor production states which type was used on the engine.
angle requires that first the recommended torque is During service operations use the same agent or an
applied using a torque wrench and then the recom- alternative from a different manufacturer.
mended angle is added according to the protractor
scale. Example: a 90° protractor tightening means Make sure that mating surfaces are dry and free from
that the joint is tightened a further 1/4 turn in one oper- oil, grease, paint and anti-corrosion agent before ap-
ation after the stated tightening torque has been ap- plying sealant or locking fluid.
plied. Always follow the manufacturer’s instructions for use
regarding; temperature range, curing time and any oth-
er instructions for the product.
Tow different basic types of agent are used on the en-
Lock nuts gine and these are:
Do not re-use lock nuts that have been removed dur- RTV agent (Room temperature vulcanizing). Use for
ing dismantling as they have reduced service life gaskets, sealing gasket joints or coating gaskets.
when re-used - use new nuts when assembling or rein- RTV agent is clearly visible when a component has
stalling. For lock nuts with a plastic insert such as Ny- been dismantled; old RTV must be removed before
lock® the tightening torque stated in the table is re- the joint is resealed.
duced if the Nylock® nut has the same head height as
The following RTV agents are mentioned in the Serv-
a standard hexagonal nut without plastic insert. Re-
ice Manual: Loctite® 574, Volvo Penta 840879-1, Per-
duce the tightening torque by 25% for bolt size 8 mm
matex®
or larger. Where Nylock® nuts are higher, or of the
same height as a standard hexagonal nut, the tighten- No. 3, Volvo Penta P/N 1161099-5, Permatex® No. 77.
ing torques given in the table apply. Old sealant can be removed using denatured alcohol
in all cases.
Anaerobic agents. These agents cure in an absence
of air. They are used when two solid parts, for exam-
Strength classes ple cast components, are installed face-to-face with-
Screws and nuts are divided into different strength out a gasket. They are also commonly used to secure
classes, the class is indicated by the number on the plugs, threads in stud bolts, cocks, oil pressure
bolt head. A high number indicates stronger material, switches and so on. The cured material is glass-like
for example a bolt marked 10-9 indicates a higher and it is therefore colored to make it visible. Cured
strength than one marked 8-8. It is therefore important anaerobic agents are extremely resistant to solvents
that bolts removed during the disassembly of a bolted and the old agent cannot be removed. When reinstall-
joint must be reinstalled in their original position when ing the part is carefully degreased and then new seal-
assembling the joint. If a bolt must be replaced check ant is applied.
in the replacement parts catalogue to make sure the The following anaerobic agents are mentioned in the
correct bolt is used. Service Manual: Loctite® 572 (white), Loctite® 241
(blue).

Sealant NOTE! Loctite® is the registered trademark of Loctite Corporation,

Permatex® is the registered trademark of the Permatex Corpora-
tion.
A number of sealants and locking liquids are used on
the engines. The agents have varying properties and
are used for different types of jointing strengths, oper-
ating temperature ranges, resistance to oil and other
chemicals and for the different materials and gap siz-
es in the engines.

7
Repair instructions

Safety precautions for Fluorine

rubber
Fluorine rubber is a common material in sealing rings • Treat removed seals in the same way as corro-
for shafts and O rings. sive acid. All remains, even the ash can be ex-
When fluorine rubber is exposed to high temperatures tremely corrosive. Never use compressed air jets
(over 300°C) it can release highly corrosive hy- for blowing clean.
drofluoric acid. Exposing the skin to this chemical • Put old seal remnants in a plastic container,
can cause serious burns. If splashed in the eyes it close it and stick a warning label on it. Wash
can cause malignant ulcers. Breathing the fumes can gloves under running water before removal.
damage the respiratory tract. The following seals may contain fluorine rubber:
WARNING! Take the greatest care when work- Crankshaft, camshaft and intermediate shaft seals
ing on engines that have been operating at high O rings, wherever used. O rings for cylinder liner seal-
temperatures, for example an overheated engine ing are almost always fluorine rubber.
that has seized or an engine involved in a fire.
The seals must never be burned off when disas-
sembling or be burnt afterwards in anything oth- Note that seals not exposed to high temperatures
er than a special disposal site. can be handled normally.

• Always used chloroprene rubber gloves (gloves

for handling chemicals) and protective goggles.

8
 Special tools
In all cases where it is practical the tool number, except for the final digit, has been stamped on the tool, The final
digit (after the hyphen) is a control number.

884 635 884 895 885 131 885 139 885 199

885 263 885 289 885 301 999 6033 999 6860

884 635-4 Removal punch for oil cooler insert 885 263-4 Injector sleeve extractor (44, 300)
884 895-4 Lock pin for flywheel, pump setting 885 289-9 Brush for cleaning bottom of copper
885 131-3 Puller for dismantling injector nozzle (31, sleeve and for sealing sleeve between
32, 41, 42, 43) copper sleeve and cylinder head

885 139-6 Holder for injector angle dial gauge (41, 885 301-2 Tool for pressing in Alfa reset piston
42, 43, 44, 300) (44P-A)

885 199-0 Holder for dial gauge (31, 32) 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

998 6485-2 Unit stand 999 6666-5 Nipple for checking fuel supply pressure
999 6065-0 Manometer, for checking fuel supply 999 6860-4 Puller for oil pump drive
pressure and boost pressure 999 9179-6 Tool for removing fuel and oil filter.
999 6398-5 Manometer, for checking oil pressure 999 9946-8 Cylinder block fixture
999 6591-5 Nipple for checking oil pressure

9
 Group 22 Lubrication system
Design and function

General
The engines are equipped with a pressurized lubrica- sump through the oil screen (1). All oil flows from the
tion system with a full flow oil filter, oil cooler and from the oil pump pressure side via oil filter (10)
piston cooling (not MD31A). On engines with the early through oil cooler (4) and out into the main lubrica-
version of the oil distribution housing the oil for piston tion channel.
cooling does not flow through the filter. Late versions All bearings and gudgeon pins as well as the valve
of the oil distribution housing can be found on engines mechanism and timing gear bearings are pressure
from the following engine numbers inclusive: lubricated. The turbocharger is also connected into
31: 22031 28265, 32: 22032 01697, 41: 22041 56849, the pressure lubrication system.
42: 22042 16337, 43: 22043 02142, 44: 22044 02895,
300: from start of production. Timing gears are lubricated from the intermediate gear
bearing journal which is connected to the main
The oil pump is located at the front end of the oil lubrication channel via lubrication channels.
sump and driven via an intermediate gear by the
crankshaft. The oil pump sucks up oil from the oil

Basic diagram, lubrication system (oil distribution housing, Basic diagram, lubrication system (oil distribution housing,
early version) late version)
1. Oil screen
2 Oil pump
3. Safety valve
4 Oil cooler
5. Oil distribution housing
6 Relief valve
7 Piston cooling valve
8 Main lubrication channel, piston cooling
9. Piston cooling nozzle
10 Oil filter
11 Main lubrication channel, lubrication
12 Main bearings
13 Other lubrication points

10
 Design and function

Control valves
Three spring-loaded valves control the oil flow in the
engine. Two of these (6 and 7) are located in the oil
distribution housing, the third (3) is mounted between
the oil pump and delivery line.

Safety valve
The relief valve (3) acts to protect the pump and oil
cooler in case of abnormally high oil pressures.
The valve opens if the oil pressure is too high and
releases oil back to the oil pan. Opening pressure
may be achieved when the engine is cold (viscous oil)
or at high engine speeds (RPM).
Opening pressure 750 kPa.

Reduction valve
Relief valve (6) controls oil pressure in the engine.
The valve keeps oil pressure at the correct level.
Excess oil is directed back to the oil pan.

Valve location in the oil distribution

Piston cooling valve housing
The piston cooling valve (7) regulates the flow of oil to 6 Reduction valve
piston cooling. The valve is closed at oil pressures 7 Piston cooling valve
below 2.5 kPa. When the engine is started and idled
the valve is closed. This stops the pistons being
cooled unnecessarily.

11
Design and function

Piston cooling
The pistons are subject to very high temperatures.
Most of the heat from the pistons is transferred to the
cylinder block via the piston rings and film of
lubricating oil. Some heat is transferred to the
crankcase via the connecting rods.
To further increase the cooling effect oil is sprayed
into the piston from below. This decreases piston
temperature significantly.
This achieves longer piston, piston ring and piston
lining service life, reduces the risk of the piston ring
grooves sooting up and reduces oil consumption.
Piston cooling oil is sprayed through fixed nozzles,
one for each cylinder, into a channel on the underside
of the piston. The oil is led through the channel to the
top of the piston. When it has circulated through the
piston the oil passes through drain channels and down
to the oil pan.

Oil pump
The oil pump is of the gear-wheel type. The pump
sucks oil through the oil screen and suction pipe to
the pump suction side.
The oil screen, integrated with the suction pipe,
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. Heat is
removed from the lubricating oil in the oil cooler.
All engines have a tubular oil cooler located on the
right-hand side of the engine under the heat
exchanger. Oil circulates between the tubes while
seawater passes through the tubes.

12
 Design and function

Oil filter
The engine oil filter is of full flow type, which means
that all the oil is filtered before it enters the lubrication
system. On engines with early model oil distribution
housings (please refer to the “General” chapter), the
oil for piston cooling does not pass the filter, however.
The filter element is made of folded filter paper.
The oil filter has a built-in by-pass valve to secure
engine lubrication if the filter becomes blocked.

Crankcase ventilation
To prevent excess pressure, and to separate fuel
vapor, water vapor and other gaseous combustion
products, the engine is equipped with a ventilation
device connected to the rear of the valve housing or
the rear valve lifter inspection housing.
On all S.O.L.A.S versions and early model versions of
the 31/41/42WJ series, the oil mist is separated by a
replaceable paper filter before the crankcase gases
are exhausted. When this filter is blocked, a pressure
relief valve opens.
Later models of 31/41/42WJ have an oil trap in the
valve housing, which separates any oil mist before the
gases are directed to the air filter via a plastic hose.
The KA(M)D42/43 has a similar system, with an oil
trap in the valve housing, but here the gases are
directed through a rubber hose which exhausts
underneath the air filter.
On the KAD32 a combination of the above-mentioned
systems is required. In other words, it has both a
paper filter and an oil trap in the valve housing.
The KA(M)D44/300 has a unique system. In this, the
crankcase gases are directed down to an oil trap
located beneath the injection pump. Any oil is returned
to the sump via a drain hose.

13
 Repair Instructions

General Action before lifting the engine out of the

boat
If possible a condition test should be carried out
before every major service correction, so that the 4 Cut off battery supply, remove battery terminals
engines condition can be established and any from the starter motor.
contributory fault causes discovered. A condition test 5 Disconnect the engine wiring-instruments
requires the engine to be run so this should be carried connector. Disconnect power trim wiring
out before removal of the engine or any components (Aquamatic engines only).
is begun.
6 Disconnect sea water connections.
For further information about the Condition Test see
7 Disconnect the exhaust system.
the Workshop Manual “Engine Body”.
8 Close the fuel cocks. Remove the fuel
connections.
9 Disconnect the throttle cable. Disconnect
transmission cable (engines with reverse gear
only).
10 Remove the propeller shaft from the reverse gear
(engines with reverse gear only). Remove screws
on flywheel casing (Aquamatic engines only, if
Action before repairing in the boat the boat is in the water)
1 Cut off battery supply. 11 Remove the engine pads from their seats and lift
2 Clean the outside of the engine. out the engine.

NOTE! Ensure that the cleaning residues are

collected for destruction and do not accidentally
affect the environment. See also warning text Actions after lifting out the engine
under point 12. 12 Clean the engine
3 Work requiring action to cooling system: Close
sea cock and drain coolant from the sea water IMPORTANT! Observe the following rules when
and freshwater systems respectively. cleaning with high-pressure water jets. Be
extremely careful that water does not penetrate
Work requiring action to a seawater cooling
engine components. With the high pressure
system: Close seawater cooling cocks and drain
function connected the water jet must never be
engine coolant.
directed at sealed joints (shaft seals for
example), joints with gaskets or rubber hoses
WARNING! Ensure that all sea water intakes
and electrical components.
are properly closed and that water cannot enter
when removing cooling system components. 13 Drain engine oil.
14 Remove reverse gear (if necessary)

14
 Repair Instructions

Engine fixture attachment

Fixture 9999946 is used to attach the engine to unit

stand 998 6485.
The fixture is secured to the right-hand side of the
engine as illustrated below.
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.
Necessary screws:
41/42/43/44/300 series
2 screws M12x30 mm
2 screws 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), heat exchanger
with expansion tank, oil cooler with oil distribution
housing, front engine mounting, oil pipe to
turbocharger (TC), dipstick pipe
NOTE! On later version engines the dip stick pipe
cannot be removed in this position. To avoid crushing
the dip stick pipe the engine fixture must be modified
slightly.

15
Repair Instructions

If the oil has an abnormal soot contamination (even

Checking oil pressure though oil changes have been made at the correct
Special tools: 999 6398, 999 6591 intervals and the correct grade of oil has been used)
the cause of the fault could instead be:
1 – incorrect combustion due to fuel grade
Remove oil pressure switch on oil filter bracket (32/ – injector malfunction
42/43/44/300). On other engines the oil pressure
– incorrect injection timing
switch is located on the cylinder block behind the oil
cooler. – engine wear exceeds tolerances (piston rings,
valve guides etc leaking oil)

The oil is too thin (incorrect viscosity) because it has

2
been contaminated with fuel. This can be because of
incomplete combustion due to:
– injector malfunction
– incorrect injection timing
The fault is most easily detected by low oil
consumption. Low oil consumption is obvious when oil
burnt is replaced by fuel keeping the level constant.
• 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
detected by a pressure drop when the engine is
idling or at operating temperature.

Install nipple 6591. Connect manometer 6398 to the

nipple . • Defective relief valve

• Defective piston cooling valve

3
Start the engine and read off the manometer. Check • Defective oil pump
that the oil pressure corresponds to the values Worn or leaking oil pump.
contained in the Workshop Manual “Technical Data”.

• Worn main and/or crankshaft bearings

4
Remove the nipple and manometer. Install the oil
pressure sensor.

Corrective action to counter low oil

pressure
• Oil temperature too high.
If the oil temperature is too high the oil becomes
less viscous and oil pressure drops. Check the Replacing oil filter
cooling system for blockages. Check thermostat Special tool: 999 9179
function.
• Incorrect oil grade (viscosity) 1
If the oil is too thick (incorrect viscosity or oil Place a container beneath the filter when removing to
contaminated with soot particles) it will take too avoid spillage.
long for the oil pressure to rise after the engine is
started, especially when the weather is cold.

16
 Repair Instructions

2
Replacing lubrication pump
(oil pan removed)

Removing
1
Disconnect oil return and delivery pipes at the oil
pump.

2
Clean filter bracket. Remove filter using tool 9179.

3
Apply oil to the gasket of the new filter. Hand-tighten
the filter until the gasket comes into contact with the
filter bracket. Then twist a further ¾ turns.

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. Remove the oil delivery pipe and brackets from the
Note. Turn the engine with the starter motor with the cylinder block. Remove pipes and bracket.
stop arm activated when replacing the oil filter, oil
cooler or other components in the lubrication system.
This cannot be done on the KAMD/KAD44 engine as 3
this does not have a manual stop arm on the fuel
injection pump.

5
Start the engine and check for leakage around the oil
filter.

Replacing oil pan gasket Remove the cylinder block reinforcement panel.

NOTE! Do not drop the spacer washers between the

1 panel and the engine block.
Drain or suck out engine oil.
Remove the screws for the first main bearing cap.

2
Remove the oil pan. Remove the old gasket. Clean
the mating surfaces on the oil pan and cylinder block.

3
Install the oil pan together with a new gasket. Tighten
screws to 15 Nm.

17
Repair Instructions

4 8
Remove the oil pump together with the main bearing Lift the oil pump into position. Install the oil pump and
cap. Remove the bearing shells from the bearing cap. tighten main bearing cap screws. Tighten screws. For
tightening torques see Workshop manual, “Technical
data”.
5

Install cylinder block reinforcement panel. Do not

forget the spacer washers between the panel and the
Remove main bearing cap from the oil pump bracket. engine block.

Installing
10

Install the oil delivery pipe in the pump and cylinder

block. Use new O-rings
Note. Check the ends of old oil delivery pipes for
cracks before reinstalling.
Screw main bearing cap into place on the oil pump
bracket. Tighten screws to 24 Nm. Install the safety valve between the oil delivery pipe
and the pump.

NOTE! Turn the safety valve as illustrated when

installing.
7
Oil and install the main bearing shells in the bearing
cap.

18
 Repair Instructions

11
Reconditioning oil pump
Special tools: 999 6860

1
Remove main bearing cap from the oil pump bracket.

2
Remove intermediate gear.

3
Install the oil suction pipe bracket (splash bulkhead)

NOTE! The screws have special washers (spring was-

her)

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

Pull oil pump sprocket from the shaft. Use puller 999
6860. Remove key and brass washer

NOTE! There is no brass washer on late pump

versions.

NOTE! Engines intended for V-drive have a unique oil

suction pipe and splash bulkhead.
4

Remove the screws holding the pump housing.

Remove the pump housing from the bracket.

19
Repair Instructions

5 9

Remove impeller from housing.

6 Screw the pump housing into place on the bracket to

act as a guide when reaming the bushings.
Check pump housing for scratches and wear. Check
seal between the bracket and pump housing. If there
is a leakage the mating surfaces are black. The pump
housing must not be scratched. 10
Check the gear flanks, outside diameters and ends of
impellers for wear.
Replace bushings in the pump housing and bracket if
the radial play between the shaft and bushing is 0.15
mm or more.

Ream the bushings in the pump housing and bracket

until they fit exactly (diameter 16.016–16.034 mm).
Press the bushings out of the bracket and pump
housing using an appropriate drift.

11
8 Remove screws. Remove pump housing from bracket.
Press new bushings into place in the bracket and Clean all swarf from the pump housing and bracket.
pump housing.

20
 Repair Instructions

12 15

Lubricate the impellers and bushings with engine oil.

Reinstall the impellers in the housing.

Move the impellers to the bracket. Install the pump

housing and tighten the screws. Check that the
13 impellers run easily and are not hitting the pump
housing by turning the pump shaft one turn.

16

Check the impeller axial play with a feeler gauge.

For the correct play, see Workshop Manual,
“Technical data”.

14

Install the key.

NOTE! There is no brass washer on late pump

versions so do not reinstall it.

Heat oil pump gear to 180°C ± 20°C and tap the gear
onto the shaft with a plastic mallet.
Check the impeller backlash with a feeler gauge. For
Note. There should be a 1.5±0.3 mm clearance
the correct play, see Workshop Manual, “Technical
between the bracket and gear.
data”.

21
Repair Instructions

17
Reconditioning oil cooler
(early version)

Special tools: 884 635

Check that the clearance between the bracket and

gear is 1.5±0.3 mm.

NOTE! The above measurement applies to late

version and early version pumps that do not have a
brass washer installed.

18 Remove endplate. Take 4 longer M8 screws and

screw these in approximately 5 mm. Position the oil
cooler on the screws, ensure that it is supported by all
screws. Tap the insert loose with tool 884 635 and a
plastic mallet.
Remove the insert and O-rings.

2
Clean and inspect components. Use new O rings and
gaskets when reinstalling. For the drain cock/nipple
threads use sealing compound Loctite® 572.

Screw main bearing cap into place on the oil pump

bracket. Tighten screws to 24 Nm.

19

Install intermediate gear. Tighten screws to 24 Nm.

22
 Repair Instructions

Reconditioning oil cooler Oil cooler, test pressurization

Special tools: 999 6033
(later version)

Remove oil cooler from the oil distribution housing.

Install brackets 999 6033 on the cooler with sealing
ring 471 637. One of the brackets is located with the
nipple opposite the oil intake with sealing ring (1)
between, the other bracket is located so that the oil
outlet is blocked.

Remove endplate. Carefully tap the insert loose using

a rubber mallet. Use a block of wood between.

2
Clean and inspect components. Use new O-rings
when installing. Apply a thin layer of grease to the end
plate mating surfaces to the oil cooler housing before
Connect suitable test pressurization equipment to the
assembly.
compressed air hose and the nipple opposite the oil
intake. Increase the pressure slowly until the
manometer displays 0.6 MPa. The pressure must not
drop for two minutes. If the pressure drops there is a
leak and the oil cooler insert must be replaced.

23
 Group 23 Fuel system
Design and function

General EDC system

The main components of the fuel injection system are Instead of a conventional fuel injection pump with a
the fuel tank and tank unit, feed pump, Fuel filter, fuel mechanical governor, the KA(M)D44/300 engine has
injection pump, injectors and fuel lines. an EDC (Electronic Diesel Control) system.
Fuel is drawn up from the fuel tank by feed pump (1) The main components of the EDC system are the
and is forced through fine filter (2) to injection pump control module, an electronic fuel injection pump and
(3). Excess fuel escapes back to the tank via a number of sensors which provide the control module
connection (7). This means that the return fuel flushes with information.
through (cools) the injection pump’s fuel chamber. The control module processes the information from
This evens out fuel temperature so it is the same for the sensors so that the correct quantity of fuel is
all the cylinders and prevents gas bubbles forming in injected.
the fuel line.
Because the boost pressure and charge air
The fuel injection pump then forces a quantity of fuel temperature are monitored continuously there is a
(corresponding to the power required) through delivery smoke limiter function built into the EDC system. The
lines (4) to injectors (5) which atomize the fuel in the quantity of air available is calculated. This regulates
combustion chambers. the quantity of fuel injected.
Excess fuel from the injectors runs back via return The control module also has a built-in diagnostic
line (6). function which allows service technicians to quickly
Certain of the illustrations in this chapter have been put at our disposal find the source of faults.
be Robert Bosch AB.
For further information see Workshop Manual “EDC
fuel injection system”.

Fuel injection system

1 Feed pump 5 Injector
2 Fine fuel filter 6 Return line
3 Injection pump 7 Fuel return connection
4 Delivery lines

24
 Design and function

Injection pump
The injection pump is mounted on a flange and is
driven by the timing gears. 1
The pump is of the rotary type. All pumps, except
those for the KA(M)D44/300, have a centrifugal 2
governor. The KA(M)D44/300 engine has an electronic
actuator. This actuator turns an eccentric cam which
acts on a control sleeve. The position of the control
sleeve determines the quantity of fuel should be
injected.
The fuel shut-off system is controlled electrically with
a solenoid valve. When the engine is stopped the fuel
channel is closed.
The pump mechanism is lubricated by the fuel. 3

Fuel injection pump KA(M)D44/300

1 Actuator
2 Eccentric cam
3 Control sleeve

Overflow valve
The overflow valve is located in the fuel injection
pump. It limits feed pressure and ensures that the fuel
injection system is bled continuously.
If feed pressure is too high the valve opens and fuel
returns to the fuel tank via the return line.

25
Design and function

Smoke limiter
All engines except for the KA(M)D44/300*) have fuel
injection pumps equipped with a pressure -depend-
ent full load stop (usually called a “Smoke limiter”).
This prevents the generation of exhaust smoke by
opening the throttle rapidly at low engine speeds.
The full load stop limits the length of stroke of the
control rod (quantity of fuel), until the turbocharger
has enough exhaust gases to produce full charge air
volume. The full load stop is based on a diaphragm
(6). This is acted on by the pressure in the intake
manifold via a pressure hose. The diaphragm is con-
nected to a sliding rod (8) the other end of which is
conical. Guide pin (4) runs over the conical end of
the sliding rod. It transfers the movement of the dia-
phragm to lever (3) which acts as a stop for full
load.
At low engine speeds, boost pressure is not suffi-
cient to overcome spring pressure (7). The mem-
brane remains in its original position. When boost
pressure reaches a certain point, spring pressure is
overcome and the sliding rod is pushed down. The
guide pin is pressed further into the cone and the
spring-loaded full load stop (1) follows it, allowing a
greater quantity of fuel to be injected at full load. The
quantity of fuel is connected to the mass of air pro-
duced by the turbocharger.
If the turbocharger malfunctions or there is a reduc-
tion in charge air pressure for other reasons, there
is no increase in exhaust gases, only a reduction in
power.
*) KA(M)D44/300 is not equipped with a smoke limiter. The corre-
sponding function is integrated in the Electronic Diesel Control
(EDC) system.

Smoke limiter (not KA(M)D44/300)

1 Governor spring
2 Governor cover
3 Stop lever (stop limiter)
4 Locating pin
5 Adjuster nut
6 Diaphragm
7 Thrust spring
8 Sliding rod
9 Cone
10 Adjustment screw, full load quantity
11 Adjustment lever
12 Tension lever
13 Start lever
14 Lever bearings

26
 Design and function

Injector
The injectors are of the KBAL type. Each injector ba-
sically comprises a nozzle holder and a nozzle (jet).
The injector:
• Atomizes the fuel to ensure ignition and com-
Injector
bustion.
1 Hollow screw
• Together with air turbulence distributes fuel in 2 Gaskets
the combustion chamber so that an optimal fuel 3 Injector mounting
/ air mixture is achieved. 4 Shims for setting the
opening pressure
5 Thrust spring
Injector function 6 Thrust pin
When the fuel pressure increases to a set value 7 Locating pin
(opening pressure), the nozzle needle (10), which is 8 Guide
pressed into its seat by the spring (5) is raised. 9 Locating pin
10 Nozzle
Fuel is sprayed into the engine through carefully cal-
11 Jet nut
ibrated holes in the nozzle body. For further informa-
tion about the number and diameter of these holes,
see, Workshop Manual “Technical data”.
The injector opening pressure is determined by the
tension of the spring which can be adjusted with
shims (4).

2-spring injector
(TAMD31S-A/41H-B, KA(M)D44/300)
2-spring injector
As the heading indicates this injector has 2 thrust
springs. This allows two stage injection. 1 Injector holders
2 Shim
The springs are calibrated so that a small quantity of 3 Thrust spring
fuel is injected into the combustion chamber first. 4 Thrust pin
This increases the combustion pressure a little. This 5 Guide
prolongs injection and reduces combustion noise. 6 Thrust spring
7 Adjustment pin
The 2-spring injector also allows lower emissions
8 Spring seat
when the engine is idling. 9 Shim
Check opening pressure for the first stage. 10 Stop sleeve
11 Intermediate ele-
NOTE! These injector nozzles must not be recondi- ment
tioned. An exchange program is in place. 12 Jet nut

27
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 repre-
sents all the injectors on the engine. The needle lift
sensor sends a signal to the control module when
fuel injection starts.
The control module compares this signal with the
signal from the engine speed sensor and calculates
the difference between the calculated injection tim-
ing and the actual injection timing and carries out
any corrections that are required.
If the signal which represents the needle movement
is missing, the injected fuel volume is limited and
the injection timing is fixed.. If at the same time
there is a fault in the engine speed (RPM) sensor
the engine will stop.
The needle lift sensor consists of a solenoid coil
wound around a magnetic core. The coil is supplied
with a direct current, regardless of temperature vari-
ation. When the injection begins the magnetic core,
which is joined to the injector needle, moves up-
wards which causes a disturbance in the magnetic
field. 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.

NOTE! These injector nozzles must not be recondi-

tioned. An exchange program is in place.

2-spring injector with needle

lift sensor
1 Injector holders
2 Shim
3 Thrust spring
4 Thrust pin
5 Guide
6 Thrust spring
7 Adjustment pin
8 Spring seat
9 Shim
10 Stop sleeve
11 Intermediate element
12 Jet nut

28
 Design and function

Feed pump
If the injection pump is to work, it requires a supply
of fuel at pressure. This function is carried out by a
feed pump located on the left-hand side of the cylin-
der block. The diaphragm feed pump is driven by the
camshaft.
The feed pump has a hand pump which can be used
to pump fuel to the filter and Injection pump if the en-
gine is not running.

The engine (camshaft) must be in the correct posi-

tion for the hand pump to work. See also “Bleeding
fuel injection system”

Fuel filter
The engine fuel injection system has a fuel filter.
This fuel filter is disposable, and the filter insert is
made of a spirally wound paper filter.
A single or double (connected in parallel) water-sep-
arating pre-filter is also available as an accessory
for the fuel injection system. Double pre-filters allow
filters to be replaced while the engine is running.

Return fuel cooler

Certain models are equipped with a return fuel cool-
er. The cooler is the same type as that used for
power steering and is loacetd on the intake water
hose.

29
 Repair Instructions
1
Instructions when working
Clean the fuel injection pump, piping and engine
with the fuel injection system around the pump.
Take great care to ensure cleanliness when working
with the fuel injection system. Clean the engine before 2
removing components such as the fuel lines. Install
protective caps on all connectors so that dirt cannot Remove the fuel line/hose between the fuel injection
get into them. Inspect components in a separate room pump and fuel filter. Disconnect the leak-off pipe from
intended for that purpose. the nozzles. Plug connections.

Some procedures (checking injectors for example)

require special equipment and training. If you do not
have this equipment or training, have an authorized 3
diesel workshop carry out the work.
Applies to KA(M)D42/43/44/300
Do NOT adjust the opening pressure or replace
components in 2-spring injectors. Replace
injectors instead.
If a loss of engine power is suspected take account of
factors such as how fouled the hull is, the propeller
type, the load and load distribution, before adjusting
the pump setting.

IMPORTANT! Some components are sealed at

the factory for environmental reasons. No work
should be carried out on sealed components
except by authorized personnel.

If seals are broken by unauthorized personnel all

warranties are invalid. When work has been Remove oil and fuel filter and its bracket.
carried out components must be resealed
(BOSCH or VOLVO PENTA), so that the
authorization number (stamp number) is easily
legible. 4

Removing fuel injection pump

Note. Plug fuel lines and connections before
disconnecting.
This procedure applies to all engines contained in this Remove the delivery line and plug connections.
Workshop Manual.
Note. The pipes are clamped together. Do not remove
Procedures that only apply to certain engines are the clamps, remove the pipes together.
indicated in the text (“Only applies to the KA(M)D44
engine”) for example.

30
 Repair Instructions

5 8
Does not apply to KA(M)D44/300
Remove smoke limiter hose.

Slacken off flange screws.

Disconnect all electrical connectors on the pump.

Note. Protect connectors from dirt.

Remove 3 pump mounting screws. 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
Remove seawater pump. have the specially trained personnel and test
equipment necessary.
WARNING! Risk of water entry, ensure that the
sea cocks (reverse gear (transmission) engines)
or the hose terminals on the shield (drive
engines) are properly closed.

31
Repair Instructions

2
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, 885 301

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).
Tightening torques for flange screws 24 Nm. Install
the bracket under the pump without tightening.

Install the intermediate flange with new O-rings

(applies to the 44/300 series). On other engines install
a new O-ring on the fuel injection pump. Install the
fuel injection pump.

NOTE! If the stud bolts have been removed apply

Loctite® 572 to their threads before reinstalling. This
reduces the risk of oil leaks.

Do not remove plugs before the fuel and delivery lines

are reinstalled.
IMPORTANT! Do not turn the engine with the
fuel injection pump drive gear loose, This may
damage the cogs or engine speed (RPM)
sensor (32/42/43). Install tool 884 895 in the flywheel housing. Turn the
engine in the direction of rotation until the tool lug
locks the flywheel.

32
 Repair Instructions

4 6

Remove the center screw on the rear face of the fuel Screw out the center screw on tool 885 301, oil the
injection pump and install the dial indicator 884 954 reset piston and install the tool on the pump.
with holders 885 139 (41/42/43/44/300 series) and 885 Tighten the center screw until it reaches the bottom.
199
(31/32 series). Ensure that the indicator is pushed
in 3–4 mm. Applies to all engines
7
Applies only to KA(M)D44P–A Release the locking lug on tool 884 895 and turn the
5 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”.

8
Reset the clock

9
Turn the engine in the direction of rotation. Ensure
that the clock does not move when the rotation
begins, this is to ensure that the turning begins at
“zero”.
Remove the pump’s reset cover. 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”.

11
If the injectors need to be adjusted, slacken off the
pump securing nuts and turn the pump until the
correct value is obtained. 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).
Tighten the pump and dismantle tool 885 301 (44P–A
series) and reinstall the reset cover.

33
Repair Instructions

NOTE! The support bracket at the rear of the pump

must block the cylinder block and pump before final
Fault-tracing fuel valve
tightening, so that no tensions are introduced. If the engine does not stop when the ignition switch is
turned to the stop position, check the following points.
NOTE! Donut forget to remove tool 884 895 from the
• Check that there is power to the stop solenoid
flywheel housing.
connector when the ignition switch is in its stop
position. The cable should be live when the
engine is stopped.
12
• Connect connector and listen for clicking. Does
Install fuel and delivery lines. Use new copper the valve click when stop is connected? Check
washers. the plunge function if necessary.
• Check that the cylinder block is connected to
13 ground (–) when the ignition switch is in its stop
Applies only to KA(M)D42/43/44/300 position on bipolar motors.

install oil and fuel filter and bracket.

14
Connect all electrical connectors on the fuel injection
pump.

15
Install seawater pump. Use a new O-ring.

IMPORTANT! Ensure that the sea cocks

(reverse gear engines) or the hose connectors
on the shield (drive engines) are open.

16
Bleed fuel system.

17
Start the engine and check for leaks.

34
 Repair Instructions

High idle
Setting up idling speed
5
31/32/41/42/43 series Run engine to normal operating temperature.

Special tools: 998 8460

6
The engine should be at normal operating
temperature.
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.
Adjust throttle mechanism if necessary.
Check the air cleaner (ACL) is not clogged.
Set up engine speed using workshop tachometer 998
8460. Do not use the boat’s instruments to set up
engine speed.
Run the engine with no load at wide open throttle.
IMPORTANT! Seals may only be broken by Check that the throttle arm (1) hits the maximum
authorized personnel. When work has been engine speed (RPM) stop screw (3).
carried out components must be resealed
(BOSCH or VOLVO PENTA), so that the
7
authorization number (stamp number) is easily
legible. Check the engine speed (RPM) with a workshop
tachometer. Adjust stop (3) if necessary to obtain the
correct engine speed (RPM). For engine speed (RPM),
Low idle see Workshop Manual “Technical data”.
1
Run engine to normal operating temperature. 8
When work has been carried out the adjustment screw
2 components must be resealed (BOSCH or VOLVO
PENTA), so that the authorization number (stamp
Low idle the engine and check engine speed (RPM). number) is easily legible.
For engine speed (RPM), see Workshop Manual
“Technical data”.

KA(M)D44/300 series
To set up the KA(M)D44/300 engines, see Workshop
Manual “EDC fuel injection system”.

Adjust the engine speed (RPM) as necessary by

screwing the adjustment screw (2) out or in.

4
Lock the adjustment screw after adjustment is
complete.

35
Repair Instructions

Replacing feed pump

1
Clean around the pump.

2
Close fuel cocks. Disconnect fuel lines from the
pump.

3
Remove the feed pump from the cylinder block.

4
Clean the feed pump’s mating surface on the cylin-
der block and install a new gasket.

5
Screw feed pump into place.

6
Vent fuel system.
Connect banjo nipple 999 6666 to pipescrew 969
7 299, drilled and threaded to M10x1 as illustrated.
Connect the pipescrew to outlet side of the fuel fil-
Start the engine and check for leaks. ter, see the arrow on the filter cover. pressure is
measured after the fuel has passed through the fuel
filter).
NOTE! Do not spill any fuel.
Connect manometer 999 6065.

2
Run the engine at an increased engine speed. Re-
duce the engine speed (RPM) to low idling speed.
Read off the pressure within 1 minute.
Checking fuel supply pressure The feed pressure should be 14.7–27.5 kPa (feed
pump 860 320*) respectively 30-50 kPA on TAMD41H
31/32/41/42/43 series (feed pump 3582310*)
Special tools 999 6065, 999 6666. Low feed pressure can be caused by a blocked filter
or defective feed pump. Check for reduced flow (a
1 trapped line for example).
The feed pump can not be reconditioned. The feed
pump must be replaced.
*The pumps are identified using the P/N on the top of the pump
housing.

36
 Repair Instructions

4
Checking fuel supply pressure
KA(M)D44/300 series
Special tools: 999 6065, 999 6666
VP replacement parts: 18 817 (6 x), 191 397, 861 057
(50cm), 861 079 (3 x), 943 471 (2 x), 947 043 (2 x),
947 975, 969 299

1
Close the fuel cocks

2
Remove any clamps for the wiring at the timing cov-
er for better access.

Connect an approximately 50cm long fuel hose 861

057 with a banjo nipple 861 079, hose mounting 947
043 and hose clamp 943 471 at each end.

Disconnect the fuel line between the fuel filter and the
fuel injection pump. Do not spill fuel.
Slacken off the nipples in the fuel filter and fuel in-
jection pump.

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.

37
Repair Instructions

6 8

Remove tool 999 6666. Connect nipple

191 397, copper washer 18 817 and banjo nipple 861
079.

7
Connect manometer 999 6065 with the manometer
quick-release connectors to modified tool 999 6666.

9
Open the fuel cock.
Run the engine at an increased engine speed. Re-
duce the engine speed (RPM) to low idling speed.
Read off the pressure within 1 minute. The feed
pressure should be 14.7–27.5 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.
Low feed pressure can be caused by a blocked filter
or defective feed pump. Check for reduced flow (a
trapped line for example).
None of the feed pumps can be reconditioned. The
feed pumps must be replaced.
* 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.
Connect modified tool 999 6666 and the other end of
the fuel hose to the fuel filter using the long pipe-
screws 947 975 and 3 x copper washers 18 817.

38
 Repair Instructions

8
Replacing injectors
Clean mating surface between copper sleeves and
injectors.
31/32/41/42/43 series
9
Special tools: 885 131
Install the new injectors.
1
Applies only to TAMD31S-S 10
Remove the protection cover over the injectors/delive- Install injector yokes. Tighten to: 24 Nm.
ry lines
11
2 Install return line with new copper washers.
Clean around the injectors and pipe connectors.
12
3 Install the delivery lines.
Remove the return line between injectors and plug
connections.
13
Only applies to 42/43 series
4
Install the oil and fuel filter and the bracket.
Only applies to 42/43 series
Remove the fuel and oil filter and the bracket.
14
Start the engine and check for leaks.
5
Remove the delivery line and plug connections.
15
NOTE!The delivery lines must under no circum-
Applies only to TAMD31S-A
stances be bent. Replace damaged delivery lines.
Install the protection cover over the injectors/delivery
lines.
6
Remove nuts on injector yokes and remove.

Turn the injector using a PU-15 wrench pulling it up at

the same time. If the injector cannot be pulled up be
hand use puller 885 131. Otherwise water might get
into the engine.

39
Repair Instructions

6
Replacing injectors
KA(M)D44/300 series
Special tools: 885 263

1
Clean around the injectors and pipe connectors.

2
Remove the return line between injectors and plug
connections.

3
Remove fuel and oil filter and the bracket.
Applies only to KA(M)D44P-B/44P-C/300
4 Remove the clip on the rubber grommet for the cable
to the injector on cylinder 1. Separate the connector.
Remove the delivery line and plug connections.

NOTE!The delivery lines must under no circum-

stances be bent. Replace damaged delivery lines.

Remove the screws for the valve cover. Carefully

press the rubber grommet in using a screwdriver at
Applies only to KA(M)D44P-A the same time lifting the valve cover slightly. Insert
the cable through the hole. Remove the valve cover.
Remove the valve cover. Remove the seal against Remove the seal against the valve cover (the O-
the valve cover (the O-rings, washer and spring) on rings, washer and spring) on each injector.
each injector.
Inspect the valve cover gasket. If it is undamaged NOTE! The springs on cylinder 1 cannot be removed
the gasket does not need to be changed. before the injector is removed from the cylinder
head.

Inspect the valve cover gasket. If it is undamaged

the gasket does not need to be changed.

40
 Repair Instructions

7 10
Remove the injectors. If the injector cannot be pulled
up by hand use puller 885.263. This is to ensure that
the copper sleeves do not come up with the injector.

8
Clean the mating surface between the copper
sleeves and the injectors. See “Cleaning copper
sleeves”.

Install the seal against the valve cover (the O-rings,

washer and spring) on each injector.

Install the nozzles. Do not forget the lower O-ring on

the nozzles.

NOTE! Ensure that the plane of the return line is as

straight as possible.

Tightening torque 24 Nm, socket 13 mm.

Applies only to KA(M)D44P-B/44P-C/300
Ensure that the cut out in the sealing washer corre-
sponds to the split pin and the injectors cable termi-
nal (only cylinder 1)

Applies only to KA(M)D44P-B/44P-C/300

Thread the washer and spring onto cylinder 1 before
installing it. Press the springs together and install
the injector yoke in position. Thread the lower O-ring
onto the nozzle.

41
Repair Instructions

11 12
Install valve cover.

13
Install return line with new copper washers.

14
Install the delivery lines.

15
Install the oil and fuel filter and bracket.

Inspect the valve cover gasket. If it is undamaged

16
and securely fixed to the cover, the gasket does not
need to be changed. If it needs to be replaced carry Start the engine and check for leaks.
out the following:
Thoroughly clean the position of the gasket. Apply a
thin layer of silicon P/N 116 1231-4 to the valve cover.
Apply the new gasket and allow it to harden in the
silicon before installing the valve cover.

NOTE! The gasket join is located as per Fig.

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). Connect an ohmmeter 998 8452 and meas-
ure the resistance between the connector pins. Re-
sistance should be 100±10 ohm at 20°C.
In cases where the value lies outside the given
range the injector must be replaced.
Applies only to KA(M)D44P-B/44P-C/300
Insert the cable for the injector through the valve cov-
er. Press the rubber grommet into place at the same
time as the valve cover is lowered against the cylinder
head. Install the retaining clip. Connect the cable to
the engine cable harness.
Check that the cable is clear of the rocker arms
through the oil filler hole.

42
 Repair Instructions

Reconditioning injectors Cleaning copper sleeve

Special tools: 885 289
(only 1-spring injectors)
1 1
Clean the outside of the injector.

2
Dismantle the injector. If several nozzles are being
cleaned at the same time, ensure that pins and
sleeves that belong to the injector are not mixed up.
To avoid mixing them up place nozzles in a nozzle
rack or in different compartments.

3 Press the mounting sleeve over the brush to keep it

together before securing it in a drill.
Clean the injector.
Use an ultrasound wash. If there is no ultrasound
wash available, clean at the nearest Bosch workshop. 2

4
Check injector nozzle carefully. Inspect using an
illuminated lens or nozzle microscope. The nozzle
microscope can also be used for the nozzle sleeve. If
the seat has been pushed down replace the nozzle pin
together with the nozzle sleeve. If the damage is
minor grind using a nozzle grinder.

5
Check other components.
Position the mounting sleeve over the copper sleeve.
6
Dip the nozzle components in pure diesel to oil. 3

Press the brush into the copper sleeve. Connect a

power drill and clean the copper sleeve.

4
Assemble the injector nozzle using the same
After cleaning blow away dirt using compressed air.
thickness of shims for opening pressure as before.

43
Repair Instructions

When a new spring has settled, opening pressure

Recommendations when drops by approximately 8–10 bar.
adjusting opening pressure, Opening pressure will drop more over time, but the
injector will still function normally.
set pressure and replacing
Research has shown that the pressure drop evens out
injectors at approximately 15% under opening pressure for a
used spring. This drop in pressure is within the
Injection takes place under extremely high pressure
specified operating range.
so that atomization and combustion is as effective as
possible. With time opening pressure drops under that
indicated for new injectors. Seal test
This drop in pressure is normal and does not affect A seal test checks for leakage from the injector
injector function or engine performance significantly. nozzle. If there is a leak it is between the point of the
Adjusting the injector can shorten the injector nozzle nozzle needle and the conical seal surface of the
service life. nozzle sleeve.
To avoid replacing and adjusting injectors Wipe the point of the nozzle dry. Pump up a pressure
unnecessarily follow the instructions for inspection of 2 Mpa under injector opening pressure (first stage
below. on a 2-spring injector) with a manometer connected.
Do not inspect an injector unless there is a Keep pressure steady for 10 seconds. No fuel should
definite indication that it is not functioning drop off the point of the nozzle but it can be damp.
normally (excessive exhaust emissions for
example).
Spray pattern and creak
When testing an injector the most important things to
look at are opening pressure, set pressure and seal. The condition of the injector nozzle is hard to
determine based on spray pattern and creak.
NOTE! On a 2-spring injector only the opening pressu- Injector nozzle creak can only be judged on new
re for the first stage is possible to test. injectors.
Spray pattern and creak are harder to judge and do The injector nozzle may often operate well even
not provide a clear indication of the condition of the though the spray pattern is imprecise. No judgement
injector. can be made of the spray pattern of a 2-spring injector
as this is related to the test equipment used. The
In the service literature we indicate set pressure in
spray pattern can be very different to that of a 1-
addition to opening pressure. These values apply to
spring injector.
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.

Y Opening pressure
X Operating period
A1 New spring
A2 Old spring
A3 8–10 bar difference
A4 The injector operates well despite the 10% reduction
in opening pressure.

44
 Repair Instructions

Adjusting opening pressure Opening pressure/set pressure

For opening pressure and set pressure (new spring),
(1-spring injectors) see Workshop Manual “Technical data”.

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. Plug pipe connectors and the point of
nozzle after testing.

1
Connect the injector to a nozzle tester.
Adjusting opening pressure
(2-spring injectors)
2
NOTE! These injectors must not be reconditioned. An
Pump hard several times to clean dirt and air out of
exchange program is in place.
the injector nozzle.
Slowly press the tester lever down until the injector
nozzle starts to eject fuel.

3
Read off opening pressure on the tester manometer.

If the opening pressure does not correspond with the

specified value the setting can be changed by
replacing the shims in the injector.

Note. A maximum of 2 shims may be used. If the

thickest shims are not sufficient, replace the spring.

45
Repair Instructions

Replacing fuel filter Bleeding fuel system

Special tools: 999 9179
1
1
Clean the filter mounting carefully.

Place a container beneath the fuel filter.

Open the bleed nipple on the fuel filter holder.
Remove the filter using tool 999 9179.
2
3 Fill the fuel injection system by pumping the hand
pump on the feed pump. When the fuel coming out of
Apply oil to the gasket of the new filter. Hand-tighten
the bleed nipple is free of air bubbles close it.
the filter until the gasket comes into contact with the
filter bracket. Then twist a further half turn. NOTE! If the pump effect is poor, turn the engine over
slightly so that the pump drive cam changes position.
4
Bleed fuel system. Start the engine and check for 3
leakage around the filter.
Bleed the fuel injection pump is it has been
disassembled. Use the hand pump for approximately
30 seconds. This automatically bleeds the fuel
injection pump.

46
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 References to Service Bulletins

Group No. Date Concerns

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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Göteborg
Sweden
7741732-7 English 09-2001