Volvo 2003T Service Manual

Engine unitWorkshop Manual2(0)A2001, 2002, 2003, 2003T

8General instructionsDuring service operations use the same agent or analternative from a different manufacturer.Make sure that mating surfaces are dr

9Special tools9992265-0 Pulley puller884813-7 Installation ring for piston9995218-6 Mandrel for valve guide removal884557-0 Mandrel for installation o

10Technical dataGeneralType designation... 2001 2002 2003Output1) at 53 r/s (3200 rpm) ...

11Piston ring gap in the cylinderUpper compression ring ... 0.30 – 0.50 mm (0.001181 – 0.00197 in.)Lower c

12Valve guidesLenght, inlet valve ... 38 mm (1.49606 in.)Lenght, outlet valve...

13Injected quantity ... 25±1,5 mm3/stroke at 40±5°C (104°F ±10.6°F)and at 1500 rpm pump revsGov

142001/MS2V 2003/MS2B-R2003T/MS2B-R2002/120-SType platePresentation

15All engines in the 2000 range are four stroke dieselswith direct injection and separate injection pumps foreach cylinder. In the 2000 range, the 200

16Disassembly1Drain off the cooling water and the lubricating oil fromthe engine. Clean the engine and fit it on engine cradlep/n 9992520 and fixture

17Disassembly123216. Remove the pulley center bolt and pull off the pulleyusing puller p/n 9992265. Place a protection pad be-tween the puller and the

18Disassembly11. Remove the outer flywheel housing, the flywheeland the inner flywheel housing.12. Turn the engine upside down and remove the oilpan.

19OverhaulThe cylinder head1. Remove the “collets” and valve springs using a valvebow. Remove the valves. Remove the valve stem seals.Place the valves

20OverhaulReplacing the valve seat, exhaust port *Grind down the valve disc of a discarded valve to justbelow 27 mm (1.063 in) diameter. Push the valv

21Overhaul112Pressure testing the nozzles7. Check the nozzle´s spray pattern at the correctopening pressure (see Technical Data). Check alsothat the f

22Overhaul12Assembling the cylinder head11. Clean the cylinder head. If the water distributionpipe has been disassembled, it must be installed withthe

23Overhaul12315. Use a suitable pair of pliers and remove the pumplever shaft. Pull out the lever and the diaphragm.16. Clean the pump housing careful

24OverhaulCrankshaft20. Remove the gear wheel. Use a prong puller. Cleanthe crankshaft. Measure the crank- and main bearingpins. The eccentricity must

25123445OverhaulConnecting rods25. Check the connecting rods for straightness andtwisting.26. Check the connecting rod bushings by using thegudgeon pi

26AssemblyAlways use new gaskets, sealing rings, sealing wash-ers and lock-washers. Coat the sealings with greaseor oil them and also oil all moving p

27Assembly21315. Replace the flywheel housing sealing (1). Smearsealing compound (p/n 840879) on the edge betweenthe flywheel housing and the sealing.

1Safety precautions ... 2General information ... 5Repair in

28AssemblyControl mechanism, injection pumps8. Control mechanism, design1. Injection pumps2. Roller lifter3. Control screw, roller lifter4. Control ro

29Assemblyhousing apart using a screwdriver in the grooveprovided, at the same time as you hold the leaf spring(19) out to allow the full load limiter

30(4)44200120022003, 2003TMounting the cylinder head12. Tighten the two guide screws p/n 884840 in theblock and install the cylinder head gasket with

31Assembly12a2bcalled soft shims, always being installed against theblock, must be replaced against new ones. Carefullyclean the contact surfaces betw

32AssemblyC. Turn cylinder no. 1 to it’s injection position.Place the guide pin (2b) in the setting-disc’s holemarked cyl. 1. Turn the crankshaft a li

33Assembly19. Install the sea-water pump and the cooling waterpipes.20. Install the injectors and the return fuel pipe. Tight-ening torque for the inj

342003T Turbo CompressorWhere there is an excessive amount of smoke in theexhaust fumes or the engine output is particularly lowit may be that the tur

35Turbo compressorReconditioning4. Make line-up marks between the turbine housing,the bearing housing and the compressor housing. Dis-mantle the compr

36Turbo compressor6. Unfasten the four screws which hold the compres-sion bearing (8). Using a small copper mandrel, tapout the compression bearing an

37Turbo compressorBearings16. Check the bearings for abnormal wear and tear ordiscolouration, and replace them where necessary.Check the internal and

2Safety PrecautionsIntroductionThis Workshop Manual contains technical specifica-tions, descriptions and instructions for the repair ofthe Volvo Penta

38Cooling systemCooling system 2001, 2002, 2003Sea water cooled (standard)1. Thermostat2. Distribution manifold3. Sea water pumpCooling system 2003TFr

39Cooling systemFresh water coolingAccessory 2002, 20031. Fit the circulation pump (complete with tensionerbracket and spacer sleeve, position 4). Tig

40Electrical systemInstrument panel, alternative «A»Instrument panel1. Printed circuit card2. Rev. counter (accessory)3. Start button4. Instrument pan

41Instrument panel1. Voltmeter2. Oil pressure gauge3. Coolant temperature gauge4. Printed circuit card5. Alarm test6. Switch for instrument lightning7

42Fault tracingEngine Engine Engine Engine Engine Faultdoes not stops not reaching runs roughly becomesstart full rpm or vibrates abnormallyabnormally

43...

44Notes

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7730974-8 English 08-2000

3Safety precautionsAlways use protective glasses or goggles whencarrying out work where there is a risk of splin-ters, grinding sparks, acid splashes

4Safety precautionsUse the lifting eyes fitted on the engine/reversegear when lifting the drive unit. Always checkthat the lifting equipment used is i

5General InformationAbout this Workshop ManualThis Workshop Manual contains technical specifica-tions, descriptions and instructions for the repair of

6General instructionsRepair instructions and methodsThe working methods described in the Workshop Man-ual apply to work carried out in a workshop. The

7General instructionsStrength classesBolts and nuts are divided up into different classes ofstrength; the class is indicated by the number on thebolt