VOLVO PENTA D3 MARINE ENGINE SERVICE REPAIR MANUAL 

This manual covers the following model(s): 

D3-200A-G 


In this manual you have the following chapters: 

Safety information 
Introduction 
Important 
General information 
About this Workshop Manual 
Standard times (Flat Rate) 
Spare parts 
Certified engines 
Repair instructions 
Our common responsibility 
Torque 
Torque-angle tightening 
Lock nuts 
Strength classes 
Sealant 
Safety rules for Fluorocarbon Rubber 
Special tools 
Other special equipment 
Location of engine signs 
Design and function 
Group 21: Short block 
Engine, general 
Engine block 
Sump 
Cylinder head 
Camshaft 
Valve housing / inlet manifold 
Crankshaft 
Pistons 
Timing gear 
Crankcase breather 
Group 22: Lubrication system 
Oil grades 
Lubrication system, function description 
Oil valves 
Oil pump 
Oil filter 
Group 23: Fuel system 
Fuel system, function description 
Injection pump 
Distribution manifold 
Injectors 
Fuel filter housing 
Group 25: Inlet and exhaust system 
Inlet and exhaust system, 
function description 
Turbocharger 
VNT (Variable Nozzle Turbocharger) 
Group 26: Cooling system 
Cooling system, function description 
Thermostat 
Circulation pump 
Sea water pump 
Intercooler 
Heat exchanger 
Oil cooler 
Oil cooler, steering servo 
Group 64: Servo system 
Servo system 
Servo pump 
Fault tracing 
Symptoms and possible causes 
Malfunctions 
Blockage 
Inspection of return flow from injectors 
Service work 
Compression test 
Engine oil, changing 
Oil filter, change 
Fuel filter, change 
Venting the fuel system 
Air filter, change 
Cooling system, draining 
Sea water system, cleaning and conserving 
Fresh water system, pressure testing 
Cooling system, filling 
Sea water pump, impeller, change 
Drive belt/Alternator belts, inspection 
Drive belt/Alternator belts, change 
Cam belt, change 
Repair instructions 
When working with chemicals, fuel 
and lubrication oil 
Before lifting the engine 
Before working in a boat 
Actions after lifting the engine 
Checking the engine fixture 
Engine, full overhaul 
Disassembly, engine 
Cover 
Exhaust manifold and turbocharger 
Fuel filter and housing 
Intercooler, brackets and dipstick 
Engine cables 
Drive belt 
Sea water pump 
Servo pump, jockey wheel, left-hand 
engine mounting 
Alternator 
Mounting bracket 
Vacuum regulator 
Sensors and monitors 
Starter motor 
Fuel leakage hose 
Delivery pipes 
High pressure pump 
Distribution manifold 
Vacuum pump 
Injectors 
Valve cover/inlet manifold 
Timing gear 
Circulation pump 
Oil pump 
Cylinder head 
Flywheel with cover and coupling 
Oil filter housing 
Oil cooler 
Sump 
Oil suction pipe 
Piston cooling nozzles 
Pistons and con rods 
Crankshaft 
Assembly, engine 
Classification of main bearings 
Crankshaft 
Piston rings 
Piston cooling nozzles, pistons, con rods 
Flywheel, seal ring, clutch 
and flywheel housing 
Oil suction pipe and sump 
Oil cooler 
Oil pump 
Toothed belt pulley 
Cylinder head 
Valve cover 
Circulation pump 
Timing gear 
Injectors 
Distribution manifold 
High pressure pump 
Fuel supply pipes and fuel leakage hose 
Fuel union 
Vacuum pump 
Plug, hot water outlet 
Oil filter housing 
Mounting bracket 
Drive belt/Alternator belt 
Vacuum regulator 
Starter motor 
Sensors and cables 
Intercooler and dipstick 
Fuel filter housing 
Exhaust pipe with turbocharger 
Fixture, right engine mounting 
Coolant pipe 
Heat exchanger 
Oil pipe, turbocharger 
Exhaust pipe elbow 
Expansion tank 
Hose connections, air filter housing 
Cover 
Overhaul / Change components 
Group 21: Short block 
Flywheel, change 
Gear ring, change 
Crankcase seal, rear, change 
Crankshaft seal, front, change 
Cylinder head, change 
Cylinder head gasket, measurement 
Crankshaft, locking 
Cam belt, change 
Group 22: Lubrication system 
When working with chemicals, fuel 
and lubrication oil 
Oil pump, change 
Oil filter housing, change 
Lube oil pressure, check 
Group 23: Fuel system 
Engine control unit, changing 
Injection pump, changing 
Injectors and fuel supply pipes, change 
Pressure limiting valve 
Fuel suction pressure, checking 
Fuel pressure sensor, change 
Group 25: Inlet and exhaust system 
Turbocharger, inspection 
Turbo, replacing 
Exhaust manifold, change 
Group 26: Cooling system 
Coolant pump, change 
Thermostat, function check/change 
Sea water pump, change 
Seawater pump, impeller change 
Sea water pump, seal, change 
Coolant temperature sensor, replacing 
Heat exchanger, pressure testing 
Heat exchanger, replacing 
Heat exchanger, cleaning/renovation 
Oil cooler, steering servo, change 
Intercooler, pressure testing 
Intercooler, change 
Intercooler, cleaning/renovation 
Oil cooler, engine, change 
Group 30: Electrical (other) 
Alternator, changing 
Starter motor, changing 
Technical data 
General 
Short block 
Inlet and exhaust system 
Fuel system 
Lubrication system 
Cooling system 
Electrical system 
Wiring diagram 
Torque 
Conversion table 
References to Service Bulletins 
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