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Volvo Engine Repair Instructions

Mar. 28, 2018


Repair instructions


Each product comprises a large number of interacting systems and components. A deviation from the technical specification may dramatically increase the environmental impact of an otherwise reliable system. It is therefore critical that the stated wear tolerances be correctly set up and that only Volvo Penta Original Parts are used. The intervals in the care and maintenance schedule must be followed.


Some systems, e.g. fuel systems, often require special expertise and test equipment. A number of components are factory-sealed, for among other things environmental reasons. Warranty-sealed components may not be worked on without authorization to perform such work.

 

Remember that most chemical products, incorrectly used, are harmful to the environment. Volvo Penta recommends the use of biodegradable degreasers whenever components are cleaned, unless otherwise doors, take especial care to ensure that oils and wash residues etc. Are correctly property for destruction.

 

Tightening torques


Tightening torques for vital fasteners that must be applied using a torque wrench are indicated in the service manual, chapter tightening torques and in the manuals work descriptions. All torque indications apply to clean threads, bolt heads and mating faces. Indicated torque data apply to lightly-oiled or dry threads. If lubricants, locking fluids or sealants are required for fasteners, the correct type will be noted in the job description.

 

Torque, angle tightening


When torque/angle tightening, the fasterner is tightened to a specified torque, and tightening then continues through a pre-determined angle.

Example: For 90° angle tightening, the fastener is turned a further 1/4 turn in one sequence, after the specified tightening torque has been achieved.

 

Lock nuts


Removed locknuts may not be re-used, they must be replaced by new ones, as locking properties are impaired or lost with re-use.

In the case of lock nuts with plastic inserts the tightening torque indicated must be reduced if the nut has the same nut height as a standard, all-metal hexagonal nut.

Reduce the torque by 25% for bolt size of 8 mm or larger.

In the case of lock nuts with plastic inserts with a high nut-height ( where the all-metal threads is as high as a standard hexagonal nut), the indicated torque applies.

 

Strength classes


Nuts and bolts are subdivided into different strength classes. The classification is shown by a marking on the bolt head. Markings of a higher number indicate stronger material. For example, a bolt marked 10-9 is stronger than one marked 8-8.

For this reason, it is important that when bolts are removed they are returned to their original locations on re-assembly. When replacing bolts check the applicable spare parts catalogue to ensure the correct bolt is used.

Sealing compounds etc

To ensure service work is correctly carried out it is important that the correct type of sealants and locking fluids are used on joints where such are required.

In each service manual section concerned, the sealants used in product manufacture are indicated. The same sealants, or sealants with equivalent properties, must be used for maintenance work.

Make sure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturers instructions regarding applicable temperatures, hardening times and such.

 

Two basic types of compound are used:


RTV preparations (room temperature vulcanizing)

Used most often together with gaskets, e.g. sealing gasket joints, or are brushed on gaskets. RTV sealants are completely visible when the part has been removed. Old RTV sealant must be removed before the components is sealed again. Use denatured alcohol.

Anaerobic agents.

These agents cure (harden) in the absence of air. These preparations are used when two solid components, e.g. two cast components, are fitted together without a gasket. Commom uses are also to lock and seal plugs, stud threads, taps, oil pressure monitors etc.

Hardened anaerobic preparations are glassy and for this reason, the preparations are colored to make them visible. Hardened anaerobic preparations are highly resistant to solvents, and old compound can not be removed. On re-assembly, it is important to carefully degrease and wipe dry components first, before applying new sealant in accordance with the instructions.

 

Safety regulations for fluorocarbon rubber


Fluorocarbon rubber is a common material in sealing rings for shafts, and in O-rings, for example.

When fluorocarbon rubber is exposed to high temperatures (above 300°/572°), hydrofluoric acid can form. This is highly corrosive. Contact with the skin can result in severe chemical burns. Splashes in your eyes can results in chemical wounds. If you breathe in the fumes, your lungs can be permanently damaged.

 

Warning!


Seals must never be cut with a torch, or be burnt afterwards in an uncontrolled manner. Risk for poisonous gases.

Warning!

Always use chloroprene rubber gloves (gloves for chemicals handling) and goggles. Handle the removed seal in the same way as corrosive acid. All residue, including ash, can be highly corrosive. Never use compressed air to blow clean.

Put the remains in a plastic container, seal it and apply a warning label. Wash the gloves under running water before removing them.

 

The following seals are most probably made from fluorocarbon rubber.

Seal rings for the crankshaft, camshaft, idler shafts.

O-rings, regardless of where they are installed. O-rings for cylinder liner sealing are almost always made of fluorocarbon rubber.

Please note that seals which have not been exposed to high temperature can be handled normally.


We supply 68KW to 600KW diesel generator set with Volvo Penta diesel engine. 


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