This service manual contains repair instructions, descriptions and technical data for products or product designs from Volvo Penta. Ensure that you are using the correct service manual.
Read the safety information below and the service manual section about this workshop manual and repair instructions carefully before repair and service work is begun.
Immobilize the engine by turning off the power supply to the engine at the main switch and lock it in the off position before starting work. Post a warning notice at the main circuit breaker.
As a rule, all service operations must be carried out with the engine stopped. However, some work, such as adjustments, will require the engine to be running. Approaching an engine which is running is a safety risk. Bear in mind that loose clothing or long hair can fasten in rotating parts and cause serious personal injury.
Be aware of hot surfaces (exhaust pipes, turbos, charge air pipes, starting heaters etc.) and hot fluids in pipes and hoses on an engine that is running or has just stopped.
If work is done adjacent to a running engine, a careless movement or a dropped tool may in the worst case lead to personal injury.
Ensure that the warning symbols or information decals on the product are always clearly visible. Replace decals which have been damaged or painted over.
Avoid getting oil on your skin! Protracted or repeated exposure to oil can cause skin to become dry. Irritation, dryness, eczema and other skin problems may then result. From a health standpoint, used oil is more dangerous than new. Use protective gloves and avoid oilsoaked clothes and rags. Wash regularly, especially before eating. Use suitable barrier creams to counteract drying out of the skin and to aid dirt removal.
Stop the engine and turn off the electrical supply at the main switches before carrying out work on the electrical system.
Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and system pressure will be lost. Open the filter cap slowly, and release the pressure i the cooling system if the filter cap or valve has to be opened, or if a plug or coolant hose has to be removed when the engine is hot.
Hot oil can cause burns. Avoid skin contact with hot oil. Ensure that the lubrication system is not under pressure before any work is begun.
Never cap removed, because of the risk of oil ejection.
Never start the engine without installing the air filter. The rotating compressor turbine in the turbocharger can cause severe injury. Foreign objects entering the intake ducts can also cause mechanical damage. Install all protective covers before the engine is started.
Only start the Volvo engine in a well-ventilated space. When running in a confined space, exhaust fumes and crankcase gases must be led away from the engine bay or workshop area.
The majority of chemicals e.g. engine and transmission oils, glycol, gasoline, and diesel oil, together with chemicals for workshop use such as decreasing agents, paints and solvents, are injurious to health. Carefully read the instructions on the product packaging! Always follow a product’s safety directions e. g use of protective mask, glasses, gloves etc. Ensure that other personnel are not exposed to substances that are injurious to health. Ensure good ventilation. Handle used and leftover chemicals in the prescribed manner.
Clutch adjustments must be carried out with the engine stopped.
Always use protective glasses or goggles when carrying out work where a risk of splinters, grinding sparks, splashes from acid or other chemicals is present. Your eyes are extremely sensitive, injury may cause blindness.
Never use start has or similar products as a starting aid. They may cause an explosion in the inlet manifold. Danger of personal injury.
All fuels, as well as many chemicals, are flammable. Do not allow open flames or sparks in their vicinity. Gasoline, some thinners, and hydrogen gas from batteries are extremely flammable and explosive when mixed with air in the correct proportions. No smoking! Ensure that the work area is well ventilated and take the necessary safety precautions before welding or grinding work is begun. Always ensure that there are fire extinguishers close at hand in the work area.
Batteries must never be exposed to open flames or electric sparks. Never smoke in the vicinity of the batteries, they generate hydrogen gas when charged, which is explosive when mixed with air. This gas is easily ignited and highly explosive. A spark, which can be caused by incorrect battery connection, is sufficient to cause a battery to explode and cause damage.
Do not touch the connections during start attempts. Sparking hazard! Do not lean over batteries.