Maintenance Schedule

Your Volvo Penta engine and its equipment are designed for high reliability and long life. The engines are built to
withstand the marine enVironment, but also to have the smallest possible environmental impact. If the engine and
transmission are serviced regularly according to the schedule, these qualities will be retained and unnecessary
malfunctions will be avoided .
Warranty inspection
During the initial period of use a special warranty inspection - a First service inspection - must be carried out by
an authorized Volvo Penta workshop. Instructions regarding how this must be done can be found in the Mainte-
nance Schedule below and in the Warranty and service book.

Service program
=
FSI First Service Inspection C = Clean
=
S1 , S2, S3 Special Interval Service R = Replace
=
A - F Type of service (regular service) A = Adjustment
L = Lubrication
I = Inspection (includes, if necessary, cleaning ,
adjustment, lubrication and change)

FSI = First Service Inspection

First Service Inspection, after 50-100 running hours (1)

Inspection with VODIA (Diagnostic Tool)(2) I

Fuel pre-filter, draining water 1 contamination C
Air Filter I
Seawater filter C
Coolant level and antifreeze mixtu re I
Drive belts, belt tensioner and idler wheels I
Start and warm up engine
Engine and transmission, abnormal noises I
Engine and transmission, oil 1 fuel 1 water leakage I
1) Or within 180 days of the date of delivery, or the end of the first season , whichever comes first.
2) Readout if any fault codes and LVD

S1
Every 125-600 hours 1 at least every 12 month (1)

Engine Oil and Oil Filters 1 By-pass filter I R

1) Oil change intervals vary, depending on engine type, oil grade and sulfur content of the fuel.Change the filters during each
oil change.

S2
Oil Analysis
See dealer's information
SB 17--{}-2

S3

•
After the first 1200 hours
Valve clearance I

4770250806-2013 © AB VOLVO PENTA 37

Maintenance Schedule

A
Every 600 hours I At least every
(month)
12 24 48
Inspection with VODIA (Diagnostic Tool)(l) I • l
Fuel pre-filter, draining water 1 contamination C •
Air Filter I •
Seawater filter C •
Seawater pump, impeller and o-ring I •
Coolant level and antifreeze mixture I •
Drive belts, belt tensioner and idler wheels I •
Batteries, electrolyte level I •
Start and warm up engine
Engine and transmission, abnormal noises I • l
Engine and transmission, oil 1 fuel 1 water leakage I •
1) Readout if any fault codes and LVD

B
Every 1200 hours I At least every
(month)
12 24 48
Engine and reverse gear, inspect hoses and cable clamping I •
Air Filter R •
Impeller, Seawater Pump R •
Fuel pre-filter, filter insert R •
Fuel fine filter R •
Sacrificial anodes (charge air cooler and heat exchanger) R •
Engine and transmission, cleaning I painting I •
c
Every 2400 hours I At least every
(month)
12 24 48
Valve clearance I
Turbocharger, inspect I clean as required I •
Drive Belts R •
D
Every 8000 hours I At least every
(month)
12 24 48
Coolant VCS (yellow)(1) I R •
1) Different types of coolant must not be mixed with each other.

38 4770250806-2013 © AB VOLVO PENTA

 Maintenance
This chapter contains general technical information and instructions on how the prescribed maintenance items

•
must be carried out. Read through the instructions carefully before starting work. The times when maintenance
items must be carried are indicated in the Maintenance Schedule.
Read through the safety precautions for maintenance and service in the Safety Information page 4 chapter before
work on the engine is begun.

& WARNING!
Care and maintenance work should be done with the engine stopped unless otherwise specified. Stop the engine
before opening or removing the engine hatch/hood. Make it impossible to start the engine by removing the start
key and cutting the system voltage with the main switches.

Orientation

• 013 MG HE/CC

Expansion tank
2 Heat exchanger
3 Switch able fuel filters
4 Fuel feed pump (hand pump)
10
5 Air outlet generator
6 MCU connection box with panel
9
7 Lifting eye *4

•
8 Engine Control Unit (EMS)
9 Oil filler cap, engine
10 Seawater Pump, HE
8
11 Air Filter
12 Emergency Stop
13 Charge air cooler

•
a
\~
14 Switch able oil filters
15 By-pass filter for engine oil
16 Air inlet generator

• 16

4770250806-2013 ©AB VOLVO PENTA 39

Maintenance

013 MG KC

1 Expansion tank
2 Switch able fuel filters
3 Fuel feed pump (hand pump)
4 Air outlet generator
5 MCU connection box with panel
6 Lifting eye *4
7 Keel cooler, charge air cooler circuit
8 Engine management system (EMS)
9 Oil filler cap, engine
10 Air Filter
8 7 ,,
11 Emergency Stop
12 Charge air cooler
" /

13 Switchable oil filters

14 By-pass filter for engine oil
15 Air inlet generator

L
14 13

40 4770250806-2013 © AB VOLVO PENTA

 Maintenance

D13 MG RC

1 Expansion tank
2 Switchable fuel filters
3 Fuel feed pump (hand pump)
4 MCU connection box with panel
5 Lifting eye *4
6 Air outlet generator
7 Engine management system (EMS)
8 Oil filler cap, engine
9 Air Filter
10 Emergency Stop
11 Radiator with charge air cooler
8 6
12 Switchable oil filters
10 13 By-pass filter for engine oil
14 Air inlet generator

4770250806-2013 ©AB VOLVO PENTA 41

Maintenance

Engine, General
General inspection
Make a habit of visually checking the engine and
engine bay before starting, and after operations when
you have stopped the engine. This will help you to dis-
cover abnormalities quickly, or if something is about to
happen.
Look especially carefully for oil, fuel and coolant lea-
kages, loose bolts, worn or poorly-tensioned drive
belts, loose cable connections, damaged electrical
cables and hoses. This inspection only takes a few
minutes and can prevent serious malfunctions and
expensive repairs.
( i
\..J

& WARNING!
Accumulations of fuel, oil and grease on the engine or
in the engine room is a fire hazard and must be
removed immediately they are detected.

& WARNING!
If an oil, fuel or coolant leak is detected, the cause must
be investigated and the fault rectified before the engine
is started.
POO02455
Never direct the jet from a high-pressure washer at
seals, rubber hoses or electrical components. Never
use the high pressure setting for engine cleaning.

Air Filter, Change

1 If indicator is all red after the engine is stopped,
change the filter insert.
2 Undo the clamps and remove the lid from the filter
~)
~!~
housing.
3 Remove the old filter. Be careful to ensure that no
contamination gets into the engine.
4 Install a new air filter and tighten the lid.
5 Reinstate the pressure drop indicator by pressing
in the indicator button.

IMPORTANT!
Scrap the old filter. It must not be cleaned.
POO03091

42 4770250806-2013 © AB VOLVO PENTA

.. _-_._----
 Maintenance

Drive Belt and Alternator Belt,

Inspection

• Inspections must be carried out after operations, while

the belts are hot.
You should be able to depress the alternator belt and
the drive belt about 3-4 mm between the pulleys.
The alternator belts and drive belts have automatic belt
tensioners and do not need to be adjusted.
Check the ccndition ofthe drive belts. Replace as nec-
essary; refer to Alternator Belt, Change page 43 and
Drive Belt, Change page 44.

Alternator Belt, Change

IMPORTANT!
Always replace a drive belt that seems worn or is
cracked.
1 Disconnect the main switch(es) and check that the
engine is not connected to system voltage.
2 Remove the fan guard and fan ring round the cool-
ing fan.
3 Remove the belt guard.
4 Place a 1/2" square wrench in the belttensioner (1).
Lift the wrench up and lift the water pump drive belt
off.
5 Place a 1/2" square wrench in the belt tensioner (2).
Press the wrench down and remove the alternator
belt.
6 Check that the pulleys are clean and undamaged.
7 Press the 1/2" wrench in the belttensioner (2) down
and install the new alternator drive belt.
P0004319
8 Lift the 1/2" wrench in the belt tensioner (1) and re-
J install the water pump drive belt.

•• 9 Install the belt guards .

10 Install the fan guard and fan ring round the cooling
fan .
11 Start the engine and perform a function check .

..
4770250806-2013 © AB VOLVO PENTA 43
Maintenance

Drive Belt, Change

1 Disconnect the main switch(es) and check that the
engine is not connected to system voltage.
2 Remove the fan guard and fan ring round the cool-
ing fan.
o
3 Remove the belt guard.
4 Place a 1/2" square wrench in the belltensioner (1).
Lift the wrench and remove the drive belt.
5 Thread the drive belt round the fan and remove it.
6 Check that the pulleys are clean and undamaged.
7 Thread the new drive belt over the fan.
8 Lift the 1/2" wrench and install the new drive belt.
9 Install the belt guards. o
10 Install the fan guard and fan ring round the cooling
fan.
11 Start the engine and perform a function check. ~)
PO004320

44 4770250806-2013 ©AB VOLVO PENTA

 Maintenance

Lubrication System
Oil change intervals can vary depending on oil grade
and sulphur content of the fuel , please refer to Techni-
cal Data, Lubrication System.

Oil change intervals must never exceed a period of 12

months.

If you want longer oil change intervals than given in the

table Oil Grade and Oil Change Interval, the condition
of the oil must be checked by the oil manufacturers
through regular oil testing .

POOO2089

Oil level, checking and topping up

The oil level must be inside the marked area on the

dipstick (1) and should be checked daily before the first
start.

Top up the oil through the filling hole on the side of the
engine (2). Check that the correct.level has been ach-
ieved. Wait a few minutes to allow the oil to run down
into the sump.

IMPORTANT!
Do not fill up above the maximum oil level. Only use a
recommended grade of oil , please refer to Technical
Data, Lubrication System.

P0009747

4770250806-2013 © AS VOLVO PENTA 45

Maintenance

Engine Oil, Change

Always follow the recommended oil change interval.
Use a manual or electric oil drain pump (optional equip-
ment) to pump the oil out of the oil pan .
0
.&. WARNING!
Hot oil and hot surfaces can cause burns .

.&. WARNING!
Working with or going close to a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.

1 Run the engine until warm so that the oil is easier

to pump. Then stop the engine.
2 Connect a hose to the drain pump discharge(1) and
lead it to a collection vessell.
Alternative, remove the drain plug (2) and let the oil
run out into a collection vessel.
3 Open the tap (3) under the drain pump to the posi-
tion for draining engine oil (E). Suck up the oil.
4 Remove the drain hose (or install the bottom drain
plug ).
5 Replace the oil filter and by-pass filter at every oil
change; refer to the Oil Filter/By-pass Filter,
Change page 47 section .
6 Close the drain pump tap (5 ).
Fit the drain plug if it has been removed .
0
7 Fill oil to the correct level via the filler opening on
the side of the engine; refm to the Technical Data,
Lubrication System section for oil quantity.
IMPORTANT!
Use only oils of the recommended grades; refer to
the Oil Grade and Oil Change Interval section.
8 Start the engine and let it idle. Check that the low CD
oil pressure warning lamp goes out and that no
leaks are present at the filters.
@;
9 Stop the engine. Wait a felN minutes before check-
ing the oil level. Top up as needed. o
Hand the old oil in to a re-cycling station.

46 47702508 06-20B © AS VOLVO PENTA

 Maintenance

Oil Filter/By-pass Filter, Change

The oil filter and bypass filter must be replaced at every
oil change.
Remember to hand the old filters in to a re-cycling sta-
tion .

& WARNING!
Hot oil and hot surfaces can cause burns.

Place a collection vessel underneath the filter drip

tray to avoid oil spillage .
2 Clean the filter bracket.
3 Unscrew the bypass filter (1) and the oil filters (2)
with a suitable puller.

POO15633 4 Check that the mating surfaces on the filter bracket

are clean and that no remains from the old gaskets
are left.
5 Moisten the gaskets on the new filters with engine
oil.
6 Screw on the filter by hand until the rubber gasket
touches the filter bracket mating surface. Then turn
a further 3/4 to 1 turn.
7 Start the engine, run at low idle, and check that no
leakage occurs. Check the oil level after the engine
has stopped.

4770250806-2013 © AB VOLVO PENTA 47

Maintenance

Switchable oil filters

IMPORTANT!
Even though it is possible, change-over filters must not
be replaced while the engine is running except in an
emergency.
0
The engine should always be run on both filters.

1 Clean the filter holder.

2 Disconnect the filter (1) by turning the handle clock-
wise to the end position. Pull down on the knob
below the handle to release the handle.
3 Unscrew the filter and scrap it. Use a filter tool if
necessary.
4 Check that the filter holder sealing surfaces are
clean and thatthere are no gasket residues left from
the old filter.
U
5 Lubricate the rubber gasket for the new filter.

~
6 Screw on the filter by hand until the rubber gasket ',;' ,~.'J' '
just touches the filter holder sealing surface. Then
POO15686
tighten the filter a further 3/4 to 1 turn.
7 Turn the handle counterclockwise to end position
and replace the right oil filter in the same way.
8 Put the handle in the operating position, straight
down.
9 If necessary, top up the system at the first stop.
Refer to section Engine Oil, Change page 46. 0
Fuel System
Only use the grades of fuel recommended in the fuel
specification, see Technical Data, Fuel System.
Always observe the greatest cleanliness during re-
fuelling and work on the fuel system.
All work on the unit injectors of the engine must be
carried out by an authorized workshop.

& WARNING!
Fire hazard. When carrying out work on the fuel system
make sure the engine is cold. A fuel spill onto a hot
surface or an electrical component can cause a fire.
Store fuel soaked rags so that they can not cause fire.

48 4770250806-2013 © AB VOLVO PENTA

 Maintenance

Engine Fuel Filter Replacement

Stationary engine

) 1 Close the fuel valve/valves.

2 Clean the filter bracket and put a vessel under the
filter.
Remove the protective cap from the venting nip-
ple. Connect a transparent plastic hose to the
nipple and lower the hose into the vessel.

& CAUTION!
Open the tap with caution. Hot fuel can spray out in
any direction.

3 Relieve pressure inside the filter by opening the

bleeding nipple (1).
4 Unscrew the filter, use a filter wrench if needed.
5 Clean the sealing surface on the filter bracket
Make sure the new filter is absolutely clean and
that the sealing surfaces are undamaged. Mois-
ten the seals with engine oil, including the inner
rubber seal on the inside of the threaded hole in
the center of the filter.

NOTICE! Do not fill the new filter with fuel before

assembly. Contaminations may get into the system
and cause damage and malfunction.

6 Screw the new filter on by hand until the seal just

touches the mating surface. Then tighten a fur-
ther 3/4 turn.
7 Open the fuel valvelvalves.
8 Open the bleeding nipple and work the pump (2)
until air-free fuel flows out Tighten the bleeding

•• nipple while fuel is flowing out

9 Remove the hose and put the protective cap back
on the nipple.
10 Start the engine and check for leakages.

4770250806-2013 © AB VOLVO PENTA 49

 tID
~ ..

()

50 4770250806-2013 © AS VOLVO PENTA

 Maintenance

Fuel system, bleeding

The fuel system must be bled if the fuel tank has been
run dry and after a long-term stoppage.
1 Remove the protective cap from the bleed nipple
(1 ).
Connect a transparent hose to the bleed nipple.
Feed the hose to a container to avoid spillage.

"i 2 Open the bleeding nipple and pump fuel with the
r hand pump (2) until the fuel is free from bubbles.
3 Close and tighten the bleed nipple.
4 Start the engine.
If the engine runs unevenly there might be air left in
the fuel system. To empty the system of remaining
air, open the bleed nipple while the engine is run-
) ning.

L'rl. WARNING!
Hot fuel can cause burns.

L'rl. WARNING!
Working with or going close to a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.

5 Close the bleed nipple. Remove the hose and fit the
protective cap to the bleed nipple.
6 Make sure there are no leaks.

'.
)
5~

4770250806-2013 ©AB VOLVO PENTA 51

Maintenance

Fuel pre-filter
Volvo Penta fuel pre-filters are supplied in single and
double models.

Checks
The double filter is fitted with a pressure gauge 1 that
indicates when it is time to replace the filter cartridges.

The filter cartridges must be replaced according to

maintenance schedule recommendations, or earlier if
the pressure gauge shows a pressure drop of 6-1 0 in.
Hg at idle or 16-20 in. Hg at full rpm/engine load.

& WARNING!
Working with or going close to a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
pOO04926
2

Draining
Place a vessel under the filter. Empty the water and
sediment through the plugs (2).

~
ti

52 4770250806-2013 ©AB VOLVO PENTA

 Maintenance

Replacing filter cartridges

Double filter cartridges can be replaced while the

•
engine is running, by shutting off the fuel flow to one
filter holder at a time.

Fuel flow is controlled by moving the lever (1) to the

following positions:
A Normal operating position (both filters connected).
D B Left filter cartridge can be replaced.
C Right filter cartridge can be replaced.
p0004927
D Both filters shut off.

If the engine is stopped, begin by shutting the fuel taps

at the tank before replacing the filters. If the engine is

J running the fuel flow to the filter to be replaced must be

shut off using the lever (1).

1 Place a vessel under the filters and shut off the filter
to be replaced.
2 Undo the T-bolt (2) and remove the cover (3).
0 3 Carefully remove the cartridge with a turning move-
ment.
4 Empty the water and sedimentthrough the drain
hole (4).
5 Insert a new filter cartridge and fill the holder with
clean fuel.
6 Replace the cover gasket and the T-bolt O-ring.
Moisten the gasket and the O-ring with fuel before
4 they are installed.
7 Install the cover and tighten it by hand.
8 Dry up any fuel spills.

•
.,.,a.'
~'9
9 Replace the other filter in the sarne way.
10 Open the fuel taps and put the lever in the normal
operating position. Check that there are no leaks.

•
)

4770250806-2013 ©AB VOLVO PENTA 53

Maintenance

Freshwater System
The freshwater system is the engine's internal cooling {\'I
system that ensures that the engine operates at the 'v..!
correct temperature. It is a closed system that must
always be filled with a coolant mixture in order to pro-
tect the engine against intemal corrosion, cavitation
and frost bursting.

IMPORTANT!
Coolant of a suitable chemical composition must be
used all year round. This applies even when there is
no risk for frost damage, so that the engine always has
complete corrosion protection.
The use of anti-corrosion agents alone is not permitted
in Volvo Penta engines. Never use water alone as the
coolant.

The corrosion protection additives become less effec-

tive over time, which means that the coolant must be
changed at regular intervals; refer to Maintenance
Schedule. The cooling system must be flushed when-
ever the coolant is changed, refer to Freshwater sys-
tem, Flushing page 58.

Volvo Penta recommend "Volvo Penta Coolant VCS,

Ready Mixed" orthe concentrate "Volvo Penta Coolant
VCS" mixed with pure water according to specifica-
tions, see Water Quality.
POO13077
Volvo Penta Coolant VCS and VCS Ready Mixed are
based on organic acid technology (OAT). Using other
types of coolant, such as conventional or hybrid types,
can drastically reduce the heat transfer and result in
overheating of the engine.

54 4770250806-2013 © AB VOLVO PENTA

 Maintenance

Coolant, Mixing

& WARNING!

•
All coolant is hazardous and harmful to the environ-
ment. Do not consume. Coolant is flammable.

IMPORTANT!
Different types of coolant must not be mixed with each
other!

Mix: 40% "Volvo Penta Coolant" (cone.

eoolant)and 60% water
This mixture protects against internal corrosion, cavi-
tation and frost bursting down to -24°C (-11°F). At
60% glycol concentration, the freezing point is lowered
to -46°C (-51°F).
Never mix more than 60% concentrate (Volvo Penta
J Coolant) in the coolant. A greater concentration pro-
vides reduced cooling effect with the risk for overheat-
ing and reduced frost protection.

""i,
,A The coolant must be mixed with distilled, deionized
POOO2463 water. The water must fulfil the requirements specified
by Volvo Penta; refer to Water Quality.
It is extremely important that the system is filled with
the correct coolant concentration. Mix in a separate
clean vessel before filling the cooling system. Make
sure that the liquids mix.

•
•'I.
t

4770250806-2013 © AB VOLVO PENTA 55

Maintenance

Filling with coolant

.&. WARNING!
Burn hazard. Steam and hot fluid may spray out. Stop
the engine and allow it to cool before opening the filler
cap.

IMPORTANT!
Top up with the same type of coolant as already used
in the system. Different types of coolant must not be
mixed.

Topping up
Top up coolant to the correct level through the filler
opening on the expansion tank. Fill slowly, to allow air
that is displaced to flow out through the filler opening.

When filling an empty system, oriffor some reason the

coolant level has sunk sow low that it cannot be seen
through the filler opening, filling must be carried out
according to "Filling a completely empty cooling sys-
tem". 0).

Filling a completely empty cooling system Q

1 Mix a sufficient quantity of coolant in a vessel before
filling. Note that if a heating system, water heater or
similar is connected to the engine cooling system,
a correspondingly greater quantity of coolant will be
required.
2 Also make sure that any heating system, water
heater or similar connected to the engine cooling Ol)
system is vented (open the heater regulator valve).
3 Fill coolant through the filler opening in the expan-
~Ij
sion tank.
Fill slowly, to allow displaced air to flow out through
the filler opening.
t)
4 Fill coolant to the lower rim of the filler pipe.
5 Start the engine and let it idle untill it has reached
operating temperature.
IMPORTANT!
Do not let the engine work under load until the sys-
tem is vented and completely filled.
6 Stop the engine and let it cool. Check the coolant
level.
7 Top up.
U

56 4770250806-2013 © AB VOLVO PENTA

 Maintenance

Coolant, Draining

& WARNING!
Stop the engi ne and let it cool before starti ng work on
the cooling system. Hot fluids and hot surfaces can
cause burns.

& WARNING!
All coolant is hazardous and harmful to the
environment. Do not consume. Coolant is flammab le.

Drain the coolant via taps (F).

1 Remove the fi ll ing cap (1) from the expansion

tank.
J HE/KC/CC/RC F 2 Connect a hose to each drain point. Open the
RC taps and allow all the coolant to drain off into a
suitable vessel.

• Check that all coolan t really does drain out.

Deposits may need to be cleared away, inside
the drain plug(s)/tap(s) .
3 Al so drain the heating system, tap water heater
etc., if connected to the engine's freshwater sys-
tem.
4 Close all drain taps.

• 5 Collect the old coolant and hand it to a re-cycling

station for destruction.

4770250806-20 13 © AB VOLVO PENTA 57

Maintenance

Freshwater system, Flushing

The cooling system should be flushed when the cool-

ant is changed, to avoid loss of cooling performance CQ
... .
due to deposits in the cooling system.
1 Drain the coolant, please refer to section Coo/ant,
Draining page 57.
2 Put a hose into the filling hole in the heat exchanger
and flush with fresh water.
3 Flush until the water which runs out of the drain
points is clean.
4 Close all drain points when all coolant has run out.
5 Fill up with coolant, please refer to section Mainte-
nance page 56. ~.

58 47702508 06-2013 © AB VOLVO PENTA

 Maintenance

Seawater System

• The raw water system is the engine's external cooling

system and it is either a seawater system or a central
cooling system. It cools the internal cooling system in
an engine mounted or externally mounted heat
exchanger. The system is protected against galvanic
corrosion by zinc anodes located in the heat
exchanger.

& WARNING!
Risk of water entry. Close and drain the raw water sys-
tem before starting any work on the system.

•
1.•
I

4770250806-2013 © AS VOLVO PENTA 59

Maintenance

Seawater System, Draining

The seawater system must be drained in cold weather,
if there is a risk of frost, to prevent frost damage .
. t\\
~'
& WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

An alternative to draining is to keep the engine bay

above freezing temperature, by means of a fan heater
which is approved for outdoor use.

1 Close the sea cock.

2 Connect a hose to each drain tap before opening
the tap (one at a time).
3 Open the drain taps/remove the drain plugs (5) and
allow the water to run out.

Drain points:
tap under the heat exchanger
tap above seawater pump
plug below seawater pump
POO15707
IMPORTANT!
Check that all water really does drain out. Depos-
its may need to be cleared away, inside the drain
plug/tap.
4 Also drain/empty any auxiliary equipment such as
the seawater filter etc.
5 Close/install all drain taps and plugs before you
leave the boat.

60 4770250806-2013 © AS VOLVO PENTA

 Maintenance

Zinc Anodes, Check and Change

.&. WARNING!
•• Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

1 Close the seawater tap.

2 Open the heat exchanger drain tap (1) and drain off
the seawater.
3 Remove the zinc anodes (Z) (2 pcs.) from the heat
exchanger.

,
Check that the a-ring is in good condition, other-
wise change it.
4 Check the zinc anodes and change them if they
have been consumed below 1/3 of their original
size. If not, clean the zinc anodes with emery cloth
to remove the oxide layer before re-installing them.

•
IMPORTANT!
Use emery paper. Do not use a wire brush or
other steel tools when cleaning, as these may
damage the galvanic protection.
5 Install the zinc anodes. When installing, make sure
there is good metallic contact between the anode
and the casting.
6 Close the drain tap (1 ).

I 7 Open the sea cock before starting the engine.

8 Check that there are no leaks.

•
••
4770250806-2013 © AB VOLVO PENTA 61
Maintenance

Impeller, Check and Change

& WARNING!
Risk of water entry, Close the seawater cocks before IS\
doing any work on the seawater system, ViI2
1 Remove the seawater pump lid, and pull the impel-
ler out with universal impeller puller.
2 Check the impeller. If any cracks or other defects
are visible, the impeller must be changed,
3 Lubricate the pump housing and the inside of the
lid with water-resistant grease (which is not aggres-
sive to rubber), The impeller will be easier to work
with if it is put in hot water prior to fitting.
4 Press the impeller in with a circular motion (counter Iff\""',,,

clockwise). The shaft of the pump has an internal "<J.

thread (MS). Screw a stud into the end of the shaft
and press the impeller in using a washer and nut
Fit the cover, using a new O-ring.
5 Open the sea cock. ~"

IMPORTANT!
Always carry a spare impeller on board.

f2
A,
'VlY!

62 4770250S 06-2013 © AS VOLVO PENTA

 Maintenance
l
Seawater Filter, Check and Cleaning
The seawater filter is optional equipment. Volvo Penta

• offers two different seawater filters.

If the water where the boat is operated contains a lot

of contamination, weed etc., check the filter more fre-
quently than specified in the maintenance schedule.
There is otherwise a risk that the filter would be
blocked, which would make the engine overheat.

'&WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.

• 1 Close the sea cock.

2 Unscrew the cover by hand counter clockwise (1).
3 lift out the insert (2) and clean it.

•
4 If the glass vessel (3) needs cleaning from e.g.
algae fouling, this must be done from the top with
the aid of a suitable brush; use soapy water as
required. The glass vessel must (3) not be
removed!
5 Screw the cover back on (1) by ~and. The cover
threads should be brushed with silicone-based
water-proof grease, e.g. VP part # 828250, annu-

• PQ010446
ally; this will ensure that the cover does not seize
on removal.
Mineral oil based grease may not be used.
6 Open the sea cock and check for leaks.

1 Close the sea cock.

1 2 Remove the lid (1) and lift up the insert.

il 3 Clean the insert and the housing (2).

4 Install the components as in the illustration. Check
the seals. Change as necessary.

• 5 Open the sea cock and check carefully that no leak-

age occurs.

•
4770250806-2013 ©AB VOLVO PENTA 63
Maintenance

Intake Manifold, Checking the Drain

Hole
Steam may be generated during operations; it drains
via a hole atthe bottom ofthe charge air cooler. Check
that the hole is not blocked.

'&CAUTIONl
Burn hazard! Steam may evaporate through the drain
hole.

IMPORTANT!
If a large amount of coolant flows out of the drain hole,
the charge air cooler must be removed and pressure
tested.

This work must be carried out by an authorized work- ~

shop.

t2
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e1.

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64 4770250806-2013 © AB VOLVO PENTA

 Maintenance

Electrical System
The engine is equipped with a 2-pole electrical system
and an alternator. System voltage is 24V.

& WARNING!
Always stop the engine and break the current using the
main switches before working on the electrical system.
Isolate shore current to the engine block heater, bat-
tery charger or accessories mounted on the eng ine.

Power Module

• PM
The power module supplies power to the EMS and the
MCC control system . The power module (PM) protects
the system from high cu rrent with a built in over current
protection.
The status of the fuse functions are shown in the MCU
menu. Should an automatic fuse blow, repair the fault
and restart the system to reset the fuse.

POO06350

•
Main switch
IMPORTANT!
Never disconnect the current with the main switches
when the engine is running , the alternator and elec-
tronics could be damaged .

The main switches must never be switched off before

the engine has stopped. Ifthe circuit between the alter-
nator and the battery is disconnected when the engine
is running , the alternator and electronics can be dam-
aged . For the same reason the charging circuits must
never be re-connected with the engine running .
PO002576

Electrical Connections

Check that electrical connections are dry , free from

oxide, and that they are securely. tightened .

}(lj»~1f~
UnivetsaJ

o oil

POOO2479

4770250806-2013 © AB VOLVO PENTA 65

Maintenance

Battery, Maintenance
& WARNING!
Risk of fire and explosion. Never allow an open flame Itiil\.
or electric sparks near the battery or batteries. ""

P0002107
& WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

& WARNING!
The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries.
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
whas off immediately using plenty of water and soap.
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.
Iii!..\
Connecting and disconnecting the battery ""I'
Connecting
1 Connect the + cable (red) to the + pole on the bat-
tery.
2 Connect the - cable (black) to the - pole on the
battery.

Disconnecting
1 Remove the - cable (black).
2 Remove the + cable (red).

POO021OS

f2
Cleaning
A
~~;:'

Keep the batteries clean and dry. Contamination and

oxide on the batteries and battery poles can cause
stray currents, voltage drop and discharge, especially
in wet weather. Remove oxidation from the battery
tJ.
poles and terminals, using a brass brush. Tighten the
terminals securely and grease them with terminal
grease or petroleum jelly.

66 4770250806-2013 © AB VOLVO PENTA

 Maintenance

Filling
The electrolyte level should be 5-10 mm (0.2- 0.4")
above the cell plates in the battery . Top upwith distilled
water as required.

After fillin g, the battery should be charged for at least

30 minutes by running the engine at idle.

Some maintenance-free batteries have special

instructions, which must be followed .

POOO2110

•
Battery, Charging
& WARNING!
Risk of fire and explosion . Never allow an open flame
or electric sparks near the battery or batteries.

• P0002107 & WARNING!

The battery electrolyte contains extremely corrosive
sulfuric acid. Protect your skin and clothes when charg-
ing or handling batteries .
Always use protective goggles and gloves. If battery
electrolyte comes into contact with unprotected skin
whas off immediately using plenty of water and soap.

•
If battery acid comes in contact with the eyes, flush
immediately with plenty of water and obtain medical
assistance without delay.

&WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.

IMPORTANT!
Observe the instruction manual for the battery charger
carefully. To avoid the risk of electrochemical corrosion
when an external charger is connected , the battery
cables should be removed from the batteries before
the charger is connected.
Always switch off the charging current before the
charging clips are removed.

4770250806-2013 © AB VOLVO PENTA 67

Maintenance

• Charge batteries if they have become discharged.

During charging, unscrew the cell plugs but leave
them in the plug holes. Ventilate well, especially if
the batteries are charged in an enclosed space.
• If the engine is not used for a longer period of time, 0)
the batteries should be fully charged, then possibly
trickle charged (please refer to the battery manu-
facturer's recommendations). Batteries are dam-
aged by being left discharged, and can also freeze
and burst easier in cold weather.
• Special instructions apply to boost charging. Boost
charging can shorten battery life, and should there-
fore be avoided.

Electrical Welding
Remove the positive and negative cables from the bat- Iif..:..'.'
teries, then disconnect all cables connected to the .,
alternator, EMS, power module and MCC.

Always connect the welder ground clamp to the com-

ponent to be welded, and as close as possible to the
weld site. The clamp must never be connected to the
engine or in such a way that current can pass through
a bearing.

IMPORTANT!
After finished welding, re-connect the alternator termi-
nals before connecting the battery cables.

(
.;1
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68 4770250806-2013 © AB VOLVO PENTA

 1

Storage
The engine and other equipment must be laid up to prevent damage if they are not used for two months or more.

•
It is important that this is done in the correct manner, and nothing is forgotten. For this reason, we have compiled
a check list of the most important points.
Before the engine is taken out of service for a long period of time, an authorized Volvo Penta workshop should
check it over. Have any faults and deficiencies attended to, so that the equipment is in order, ready for the next
start.

& CAUTION!
Read the chapter on Maintenance before starting work. It contains instructions on how to carry out maintenance
and service operations in a safe and correct manner.

& WARNING!
Conservations oils can be flammable and dangerous to breathe. Ensure good ventilation. Use a protective face

•
mask when spraying.

IMPORTANT!
Remember the following when washing with a high pressure washer: Never aim the water jet at seals, rubber
hoses or electrical components.

• o For up to 8 month's stoppage:

Change the oil and oil filter on the engine, then warm
it up afterwards.
More than 8 month's stoppage:
Conserve the lubrication and fuel systems with con-
servation oil. Please refer section'
Storage page 70.
o Check that the coolant offers sufficient frost protec-
tion. Top up as necessary.
Alternatively, you can drain the coolant (also drain
the coolant filter).
o Drain any water and contamination from the fuel fil-
ters and fuel tank. Fill the fuel tank completely, to
avoid condensation.
o Disconnect the battery cables, clean and charge the

:1
batteries. Trickle charge the batteries while the
equipment is in storage. A poorly charged battery
can freeze and burst.
P0002089
o Clean the outside of the engine. Do not use a high
pressure washer for engine cleaning. Touch up
r8 paint damage with Volvo Penta original paint.
o Spray the components of the electrical system with
water-repellent spray.
o Check and rust-proof any control cables.

o Put a note on the engine with the date, type of con-

servation and the conservation oil used.
o Cover over the air filter, exhaust pipe and engine if
necessary.

4770250806-2013 ©AB VOLVO PENTA 69