Download Workshop Manual For Volvo Penta D16C-A/B/C/D MH, D16C-A MG Marine Diesel Engines.

This Workshop Manual offers all the service and repair information for Volvo Penta D16C-A/B/C/D MH, D16C-A MG Marine Diesel Engines. With this in-depth & highly detailed manual you will be able to work on your vehicle with the absolute best resources available, which will not only save you money in repair bills but will also help you to look after your bussiness. The information on this manual covered everything you need to know when you want to repair or service on Volvo Penta D16C-A/B/C/D MH, D16C-A MG Marine Diesel Engines.

Models Covered:

Volvo Penta D16C-A/B/C/D MH, D16C-A MG Marine Diesel Engines

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Manual Contents:

Safety Precautions ……………………………………….. 3
General information ……………………………………… 6
About this Workshop Manual………………………….. 6
Standard times (Flat Rate)…………………………….. 6
Spare Parts…………………………………………………. 6
Certified Engines………………………………………….. 6
Service procedures ………………………………………. 7
Our Mutual Responsibility……………………………… 7
Tightening torque…………………………………………. 8
Torque-angle tightening…………………………………. 8
Lock nuts…………………………………………………….. 8
Strength Classes………………………………………….. 8
Sealant……………………………………………………….. 8
Safety rules for fluorocarbon rubber………………… 9
Special tools ………………………………………………… 10
Identification number ……………………………………. 17
Design and Function
Group 21:
Short block………………………………………………….. 18
Cylinder Head………………………………………………. 18
Cylinder Block………………………………………………. 19
Cylinder liners………………………………………………. 20
Pistons and con rods…………………………………….. 21
Crankshaft…………………………………………………… 22
Valve mechanism…………………………………………. 23
Timing gears………………………………………………… 24
Group 22:
Lubrication system……………………………………….. 25
Valves in lubrication system…………………………… 26
Piston cooling………………………………………………. 27
Group 23:
Fuel system…………………………………………………. 28
Unit injectors, working phases………………………… 30
Group 25:
Inlet and exhaust system……………………………….. 32
Turbocharger……………………………………………….. 32
Closed crankcase ventilation………………………….. 33
Group 26:
Cooling system…………………………………………….. 34
Charge air cooler………………………………………….. 35
Fault tracing …………………………………………………. 36
Location of measurement connector on engine….. 37
Actions with low charge air pressure……………….. 39
Coolant temperature too high…………………………. 40
Coolant temperature too low………………………….. 40
Coolant losses……………………………………………… 40
Instructions for operating the starter motor………. 41
Compression test…………………………………………. 42
Fuel feed pressure, checking…………………………. 44
Charge air pressure, checking………………………… 45
Charge air pipe, checking………………………………. 46
Turbocharger, checking…………………………………. 46
Exhaust back pressure, checking……………………. 47
Coolant pressure, check………………………………… 47
Seawater pressure, checking…………………………. 48
General advice
Working with chemicals, fuel and
lubrication oil……………………………………………….. 49
Before working in a boat………………………………… 49
Before lifting the engine…………………………………. 49
Actions after lifting the engine………………………… 50
General advice for pressure measurement………. 50
General advice when working on EVC engines….. 50
Electric welding……………………………………………. 51
Exposing the engine……………………………………… 52
Engine fixture, fixing……………………………………… 53
Repair Instructions
Group 21: Short block
Short block, complete overhaul………………………. 54
Cylinder head, removal………………………………….. 54
Timing gear, removing…………………………………… 65
Pistons, removal…………………………………………… 67
Crankshaft, removing……………………………………. 68
Crankshaft, assembly……………………………………. 69
Cylinder liners, installation……………………………… 71
Pistons, pre-assembly…………………………………… 72
Pistons, installation……………………………………….. 74
Piston cooling nozzles, installation………………….. 76
Timing gear, installation…………………………………. 77
Cylinder head, installation……………………………… 83
Camshaft, installation……………………………………. 86
Gear backlash, adjusting……………………………….. 87
Unit injector, installation…………………………………. 90
Adjustment markings…………………………………….. 91
Valves and unit injectors, adjustment………………. 92
Overhaul /Replacement of components
Group 21: Short block
Cylinder liner and pistons, inspection………………. 97
Cylinder liners and pistons, replace (all)…………… 99
Cylinder liner seats, inspection………………………. 105
Cylinder liner seat, milling……………………… 107/113
Crankshaft, inspection and overhaul………………. 114
Big end bearing journal, inspection………………… 115
Main bearings, replace…………………………………. 116
Big end bearings, replace (all)……………………….. 119
Flywheel, removal/installation………………………… 121
Gear ring, replace………………………………………… 123
Flywheel sensor distance, checking……………….. 124
Crankshaft seal, front, replace………………………. 126
Crankcase seal rear, replace…………………………. 127
Con rod, inspection……………………………………… 129
Gudgeon pin bushing, check measurement…….. 129
Valves, removing…………………………………………. 130
Valves, installation……………………………………….. 132
Valve seat, replace………………………………………. 133
Valve guides, inspection……………………………….. 135
Valve guides, replacing…………………………………. 136
Valve seats, grinding……………………………………. 138
Valves, grinding…………………………………………… 139
Valve stem seals, replace………………………………140
Cylinder head, pressure testing………………………142
Copper sleeve for unit injector, replace…………… 145
Camshaft, wear check………………………………….. 149
Bearing housing for camshaft, replace……………. 150
Camshaft sensor distance, checking………………. 151
Timing gear, replace…………………………………….. 153
Group 22: Lubrication System
Working with chemicals, fuel and
lubrication oil………………………………………………. 160
Overview, control valves……………………………….. 160
Overflow valve for by-pass filter, replace…………. 161
Overflow valve for full-flow filters, replace………… 161
By-pass valve oil cooler, replace……………………. 162
Piston cooling valves, replace……………………….. 162
Reduction valve, replace………………………………. 163
Safety valve, oil pressure, replace………………….. 163
Oil pressure sensor, check……………………………. 164
Pressure reduction valve, checking………………… 165
Safety valve, check………………………………………. 165
Lube oil pump, check……………………………………. 166
Lube oil pump, replace…………………………………. 166
Group 23: Fuel System
Draining, fuel gallery in cylinder head…………….. 168
Control unit, replace…………………………………….. 169
Identifying the engine control unit…………………… 170
Fuel feed pump, replace……………………………….. 171
Unit injector, replace…………………………………….. 173
Unit injector, programming the trim code…………. 178
Purging the fuel system………………………………… 180
Group 25: Inlet /Exhaust systems
Turbocharger, replace…………………………………… 181
Turbocharger, bearing clearances, check………… 184
Exhaust manifold, removal/installation……………. 186
Exhaust manifold expansion plug, change……….187
Group 26: Cooling System
Cooling system, draining………………………………. 188
Cooling system, cleaning……………………………… 190
Cooling system, filling…………………………………… 191
Cooling system, pressure testing…………………… 193
Coolant filler cap, replace……………………………… 195
Coolant pump, replace…………………………………. 196
Thermostat, function check…………………………… 197
Thermostat, replace…………………………………….. 198
Charge air cooler, removal/installation……………. 199
Charge air cooler, cleaning……………………………. 202
Charge air cooler, pressure testing………………… 203
Heat exchanger, removal and installation………… 204
Heat exchanger, cleaning……………………………… 205
Heat exchanger, pressure testing…………………… 207
Oil cooler, engine, removal/installation……………. 209
Oil cooler, engine, cleaning…………………………… 210
Oil cooler, engine, pressure testing………………… 211
Seawater pump, replace……………………………….. 212
Seawater pump, overhaul……………………………… 213
Oil cooler, reverse gear, cleaning…………………… 218
Oil cooler, reverse gear, pressure testing………… 220
Oil cooler reverse gear, thermostat replace……… 221
Drive belts, inspection………………………………….. 222
Drive belts, replace………………………………………. 222
References to Service Bulletins ……………………. 223
Alphabetical index ……………………………………….. 224

Total Pages: 234

This manual can be used by anyone from a first time owner/amateur to a professional technician. Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings. Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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Compatible: All Versions of Windows & Mac
Language: English