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D9
© 2017 AB VOLVO PENTA
Volvo Penta reserves the right to make changes
Printed on environmentally friendly paper
Table of Content
Safety Information ...................................................................................... 3
Spare parts - safety ................................................................................... 5
Lifting the engine – never do so alone .................................................... 10
Proper lifting equipment .......................................................................... 10
General Information .................................................................................. 11
Service Protocol ...................................................................................... 12
Preventive repair ..................................................................................... 13
Genuine Volvo Penta Parts ..................................................................... 20
Illustrations .............................................................................................. 22
Chemical products .................................................................................... 23
Chemical products .................................................................................. 23
Specifications ............................................................................................ 24
Engine Decals ......................................................................................... 24
Transmission Decals ............................................................................... 25
General Tightening Torques ................................................................... 26
Specifications .......................................................................................... 27
Engine ........................................................................................................ 29
Component location ................................................................................ 29
Maintenance Schedule ............................................................................ 31
General inspection .................................................................................. 32
General advice for electronic protection .................................................. 34
Air Filter ................................................................................................... 35
Valves, Adjustment ................................................................................. 36
Lubrication System ................................................................................... 37
When you work with Chemicals, Fuel and Lubrication Oil, Change ........ 37
Engine Oil, Level Check .......................................................................... 37
Engine oil, change ................................................................................... 39
Oil filter, Change ..................................................................................... 40
Fuel System ............................................................................................... 43
General ................................................................................................... 43
Fuel filter, Change ................................................................................... 45
Fuel pre-filter ........................................................................................... 46
Fuel system, bleeding ............................................................................. 48
Exhaust System ........................................................................................ 50
Exhaust hose .......................................................................................... 50
Turbocharger, Inspection ........................................................................ 51
Charge Air Pipe, Leakage Check ............................................................ 52
Cooling System ......................................................................................... 53
Coolant Level, Checking and Topping Up ............................................... 53
Drive belt, change ................................................................................... 57
Seawater Pump, Impeller, Change ......................................................... 58
Seawater Filter, Check and Cleaning ...................................................... 60
Anodes, Check and Change ................................................................... 62
Transmission ............................................................................................. 63
Reverse Gear .......................................................................................... 63
Reverse gear, oil and filter change ...................................................... 63
Electrical Rudder Actuator ................................................................... 65
Long-Term Storage ................................................................................... 66
Storage instruction for long-term storage of new engine ........................ 66
Cleaning engine and transmission .......................................................... 69
DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.
WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious
personal injury.
CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
personal injury.
IMPORTANT:
Indicates a situation, which, if not avoided, could result in property damage.
!
This symbol is may be used on the product to call your attention to the fact that this is
safety information. Always read such information very carefully.
Make sure that warning and information symbols on the engine are clearly visible and
legible. Replace symbols that have been damaged or have been painted over.
In some cases, this symbol is used on our products and refers to important information
in the Operator’s Manual.
WARNING!
Ensure that all machine guards and safety devices are
in place and are functional.
P0024482
CAUTION!
Never use tools or products that show signs of
damage.
Fire safety
WARNING!
Fire and Explosion Risk!
Accidental spark could ignite fuel vapors.
IMPORTANT:
Used fuel and oil filters are environmentally hazardous
waste and must be taken to an approved waste
management facility for correct handling, as must any
used lubricating oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
P0024483
IMPORTANT:
Only start the engine with the air filter and protective
caps fitted. Foreign objects in the inlet line could cause
machine damage. Also make sure that no tools or other
P0024688 parts have been left next to the engine.
WARNING!
Never start the engine with the valve cover removed.
There is a risk of personal injury.
For engines with turbochargers, the rotating
compressor turbine can in addition cause serious
personal injuries.
IMPORTANT:
Never disconnect the current using the main switches
when the engine is running or by disconnecting the
battery cables.
The alternator and electronics could be damaged.
P0024484
P0024468
P0026213
IMPORTANT:
P0024485 When using a lifting device, two people are usually
required to do the work – one to take care of the lifting
device – and the other to ensure that components are
lifted clear and not damaged during the lifting
operations.
IMPORTANT:
All chains or wires must run parallel to each other and
as perpendicular to the engine as possible. If other
equipment attached to the engine has altered its center
of gravity, special lifting devices may be needed to
obtain the correct balance for safe handling.
P0024689
Example of an adjustable lifting yoke and a lifting tool.
General Information
General information Specific terms for the U.S. market
This service and maintenance manual contains This engine is certified as being in compliance with
descriptions and instructions for the service of the federal and Californian exhaust restriction
above-mentioned Volvo Penta products in their regulations. Parts related to exhaust restrictions are
standard models. The design and servicing items may covered by the warranty commitment for exhaust
vary between different products. Applicable service restricting systems. Terms and the parts covered are
intervals and service procedures are described in the specified under "What is covered by the warranty
maintenance schedule for the product. undertaking for emissions” in “Emission Control
System Warranty Statement”. Repairs and service
The product designation, serial number and covered by the warranty are carried out by an
specification are indicated on the engine decals or authorized Volvo Penta distributor or dealer at no
type plate. This information must always be provided charge for diagnostics, labor or parts using genuine
in all correspondence concerning the product. Volvo Penta parts in all areas of the exhaust
restriction system covered by the warranty and found
The manual has been produced primarily for use in
to be defective.
Volvo Penta workshops. It is assumed that persons
using the manual have fundamental knowledge of the The use of the service and repair workshop other than
product and are capable of carrying out mechanical a Volvo Penta authorized distributor or dealer or the
and electrical work to industry standards. use of exhaust-related components from other
manufacturers than Volvo Penta do not affect the
Volvo Penta continually develops its products. We
scope of the warranty undertaking for emission-
therefore reserve the right to make changes.
restricting systems. If emission-related components/
All of the information in the manual is based on
items are included in scheduled service, such parts
product data available when the manual was
are marked with a diamond (♦) in the maintenance
published.
schedule and service must be carried out at the
NOTICE! The owner is responsible for ensuring that specified intervals in order to meet the requirements
scheduled maintenance is carried out. Warranty of the warranty undertaking for emission-restricting
claims to Volvo Penta may be declined if neglected systems. The full warranty terms can be found in
maintenance results in faults in the specified product. “Emission Control System Warranty Statement”.
Refer to the warranty terms supplied with the engine.
Certified engines
Explanation of the relationship between
The engine is exhaust-certified, and if it is used
in an area where exhaust emissions are regulated
service intervals and operating
by law, this places special demands on the care conditions
and maintenance of the engine. Because operating conditions may vary depending
NOTICE! Neglect or failure to follow the items on how the component is used, it is important that the
required here may invalidate the engine emissions service interval (expressed in hours or months) is not
certificate. exceeded.
This means that AB Volvo Penta will no longer be Example: 1000 hours / 24 months. Whichever is the
able to assume liability for engine specification sooner applies. If the component is used for 1000
compliance with the certified model. Volvo Penta is hours in 18 months, the service must be carried out
not responsible for damages or costs arising as a when the 1000-hour interval is reached.
result of this.
This is to retain the component’s best quality and
• Certification means that an engine type has
service life. The warranty will be void if this is not
been inspected and approved by the competent
complied with.
authorities. The engine manufacturer
guarantees that all engines made of the same Typical examples are: Propeller shaft seals operating
type are equivalent to the certified engine. in sandy waters. Air filters exposed to heavily polluted
• It is the responsibility of the user to make sure air
no intentional misuse of the engine takes place.
Action codes used in the service schedule:
• Volvo Penta maintenance and service intervals C = Cleaning
must be followed. R = Replacement
A = Adjustment
• All faults must be remedied as soon as possible.
L = Lubricate
• Only use genuine Volvo Penta replacement I = Inspection (includes where necessary also
parts or parts of the same quality as Volvo adjustment, cleaning, lubrication and replacement)
Penta replacement parts.
• The engine may not be converted or modified
in any way, except with accessories and service
kits which Volvo Penta has approved for the
engine.
• Volvo Penta recommends that service on
injection pumps, pump settings and injectors
always be carried out by a qualified workshop.
• No changes may be made to the installation of
the exhaust pipe and engine air inlet ducts.
• Any tampering with the engine will hamper EU
type-approval of the engine concerned.
• No warranty seals (if present on the product)
may be broken by unauthorized persons.
Service Protocol
To maintain the product’s functionality, the Service
Protocol must be followed. Some operations can be
carried out by the owner or other person with sufficient
technical competence, in accordance with the Service
Protocol. Please consult an authorized Volvo Penta
dealer in the event of doubt regarding how service
work should be performed.
Preventive repair
Here is an overview of the components that may be included in preventive maintenance. May vary depending on
the engine's design and construction.
These components form the basis for calculating service contracts and the costs in the service calculator in
Product Center.
Fuel system
Fuel pump
Unit injectors
P0026295
Exhaust system
Turbocharger, low-pressure
Turbocharger, high pressure
Overflow valve (Lisk)
Silencer
Diesel particulate filter (DPF), replacement
After-treatment system
Pump unit
Dosage valve
P0026296
Cooling system
Seawater pump
Coolant pump
Engine
Vibration dampers
Engine pads, kit
P0026297
Electrical system
Alternator
Starter motor
P0026298
Engine, overhaul
Here is an overview of the components that may be included in a complete overhaul. May vary depending on the
engine's design and construction.
E.g. liners may not be replaced on certain engines. In this case, cylinders must be measured to see if new pistons
can be installed or if the engine block should be replaced.
The components below provide the basis for calculating service contracts and the costs in the service calculator
in Product Center.
Engine: May be overhauled twice, after which the engine is considered spent and is replaced by a long block or
new engine.
Overhaul
Long block
Short block
Cylinder head (replacement)
Cylinder head, gasket
P0026299
P0026300
P0026301
Exhaust valve
Valve seat
P0026302
Transmission, overhaul
Here is an overview of the components that may be included in a complete overhaul/replacement. May vary
depending on the transmission's design and construction.
The components below provide the basis for calculating service contracts and the costs in the service calculator
in Product Center.
The transmission is overhauled once, then the complete unit is replaced
Overhaul, Aquamatic
Aquamatic sterndrive, replacement
Upper gear
Lower gear
P0026303
Repair, Aquamatic
Upper gear, kit
Sliding sleeve
P0026304
P0026305
Overhaul, IPS
IPS Drive, replacement
Upper gear
Lower gear
P0026306
Repair, IPS
Upper gear, kit
P0026307
P0026308
Propeller shaft
P0026309
Lube oils
Volvo Penta supplies a wide range of lubricants
developed especially for Volvo Penta engines. VDS
(Volvo Drain Specification) is a Volvo standard that
specifies Volvo’s oil grade requirements. We
recommend the use of the specified oil to ensure
engine function and a long service life.
Transmission oil
In a marine environment it is vitally important that the
correct gear lubricant is used for the product
concerned.
In Volvo Penta's extensive testing we pick out those
oils that meet our requirements for functionality and
that within the oil change intervals ensure the product’s
service life.
While oils from various suppliers meets both SAE class
(viscosity) and API class (quality), their additives often
differ. Additives can be up to 35% of the total volume,
and are crucial to how oil can handle a given water
content while still maintaining the necessary
lubricating properties. The additives also affect the
friction in, for example, the IPS unit clutch assembly.
The correct oil is crucial for the proper functioning of
the transmission.
IMPORTANT:
It is extremely important not to use other oil than
specified for the IPS unit.
Coolant
The main function of a coolant is to absorb heat from
the engine. The coolant also protects against freezing,
lime deposits and corrosion. Volvo Penta Coolant VCS
(yellow) and Volvo Penta Coolant (green) are two
completely different types of coolants, which contain
different types of inhibitors. Different types of coolants
(colors) must not be mixed.
Protection against
Mixing the freeze bursting down
concentrated coolant to:
40 % -25 °C
46 % -30 °C
54 % -38 °C
60 % -46 °C
Illustrations
P0022106
Chemical products
Chemical products
The following is a selection of Volvo Penta
recommended chemical products. The products are
available for purchase at regional Volvo Penta
dealerships. Deviations may occur in the range, see
Specifications.
For correct part numbers, refer to the Parts catalogue.
P0001869
Specifications
Engine Decals
There are type plates on the engine and its drivelines.
Some of the type plates are marked with identity
numbers. Always use this information as a reference
when ordering service and replacement parts or
contacting Volvo Penta retailers.
1 Product Designation
2 CHASSIS ID/Serial no.
3 Emission information
Transmission Decals
Rudder actuator
1 CHASSIS ID
2 Product ID
Reverse Gear
ZF and Twin Disc reverse gears have no ID marking
from Volvo Penta.
For further information about maintenance and oil
quantities, refer to the manufacturer's manual/website
for the reverse gear.
Specifications
Volvo Penta products, all markets but excluding North America
Oil quantity in engine, including filter. D9MH 425/500 at 0 degrees engine incline. 38 liters
Oil quantity in engine, including filter. D9MH 425/500 at 7 degrees engine incline. 30 liters
Oil quantity in engine, including filter. D9MG (KC/RC/HE) 46 liters
Refer to the reverse gear owner manuals for maintenance and oil quantities.
Refer to the reverse gear owner manuals for maintenance and oil quantities.
Engine
Component location
Maintenance Schedule
The Volvo Penta engine and its equipment are designed for high reliability and long life. The engine is built so as
to have minimal environmental impact. These qualities will be retained and unnecessary malfunctions avoided if
service is provided according to the maintenance schedule.
Service intervals
Service items can be found in the Service Record available for download at www.volvopenta.com.
Search under tab: Manuals.
Where both operating hours and calendar times are specified, perform the maintenance item at whichever time
is the sooner.
General inspection
General inspection
Make a habit of visually inspecting the engine and
engine compartment before the engine is started and
after operation once the engine is stopped. This will
help you to discover quickly if anything abnormal has
happened, or is about to happen.
P0026583
P0026582
P0026581
Also check:
Drive belts
Damaged wiring
Loose wiring
Loose fasteners
Exhaust hoses
Hoses/hose connections to transmissions
WARNING!
WARNING!
Air Filter
Valves, Adjustment
P0026355
Lubrication System
When you work with Chemicals,
Fuel and Lubrication Oil, Change
NOTICE! Apply barrier cream to your hands and
always use protective gloves for work which involves
contact with oil, fuel and similar. Continuous skin
contact with engine oil dries the skin and can be
hazardous.
A Oil level on the MIN marking: add oil until the level
is between min and max.
B Optimal oil level, do NOT add oil.
C Oil level at max marking; do NOT add oil.
P0028585
Removal
1 Remove the filters with the aid of filter pliers.
2 Clean around the filter attachment points.
3 Be prepared to gather up fluids.
P0026770
Installation
4 Lubricate the gasket with engine oil before
installing.
5 Install the filter. Tighten by hand until it slows up,
then tighten a further half turn.
P0026771
Fuel System
General
The fuel system has a fine filter located on the engine
as standard.
The installation almost always has a pre-filter located
in the boat; it must also be changed.
P0026772
P0026773
Fuel pre-filter
Volvo Penta fuel pre-filters are supplied in single and
double models.
Check
The double filter is fitted with a pressure gauge (A) that
indicates when it is time to replace the filter cartridges.
WARNING!
Working with or approaching a running engine is a
safety risk. Watch out for rotating components and hot
surfaces.
P0029028
Draining
Place a container under the filter. Empty the water and
sediment through the plugs (B).
P0026774
P0026775
Exhaust System
Exhaust hose
Turbocharger, Inspection
Checking the turbocharger
Cooling System
Coolant Level, Checking and
Topping Up
WARNING!
Do not open the coolant filler cap when the engine is
hot. Steam or hot fluid could spray out, causing severe
burns.
P0026776
P0026777
Emptying coolant
1 Be prepared to gather up coolant.
2 Open the expansion tank cap.
P0026778
P0026779
CAUTION!
Pinch hazard. Keep fingers clear.
Replacement
1 Remove the protective cover over the drive belt.
P0026780
Removal
1 Close the engine cooling water cock if the boat is
in the water.
2 Remove the impeller pump cover.
3 Pull out the impeller with pliers; note the direction
of rotation for installation.
4 Check the impeller. If cracks or other defects are
visible, replace the impeller.
P0026364
Installation
1 Lubricate the inside of the pump housing and the
impeller with glycerin.
2 Push the impeller in with a rotating movement in
the direction of flow, in the same direction as the
replaced impeller.
3 Install the cover; use a new O-ring.
Tightening torque: 6 Nm
4 Open the cooling water cock.
5 Start the engine. Check that no leakage occurs.
WARNING!
Risk of water entry. Close the seawater cocks before
doing any work on the seawater system.
P0026225
Transmission
Reverse Gear
Reverse gear, oil and filter change
Twin Disc
Start the engine and run it until it reaches operating
temperature.
Continue running the engine at idle and checking the
oil level using the oil dipstick.
The level should be at the max mark.
Top off as necessary and check the level as described
above.
Grease-lubricated shaft
1 Check that there is grease in the grease cup.
2 Lubricate the shaft at each service.
3 Check the shaft stuffing box. If there is any
leakage, the seal must be replaced.
4 Check the hose clamps.
P0026233
Water-lubricated shaft
Check the propeller shaft rubber sleeve if it is cracked
or leaks on launching. During the season, check for
water entering the boat through the shaft gland. If there
is any leakage, the rubber sleeve must be replaced.
P0026234
Check the oil level with the aid of the dipstick on the
side of the rudder actuator.
The oil dipstick must not be screwed down when
checking the level. The level must be between the
markings on the oil dipstick.
Tightening torque: 10 Nm
P0026316
Also check that the bolted joint is secure and that the
linkage between the actuator and rudder is not binding.
P0026317
Long-Term Storage
If the boat is not going to be used for two months or more, it is important to reduce the risk of damage to the
engine and other equipment. The following proposals contain measures to prevent freeze bursting and reduce
the formation of condensation, mold and corrosion.
IMPORTANT:
When cleaning with a high pressure washer, make sure to never aim the water jet at seals, rubber hoses or
electrical components.
Before storage
Make sure the engine cooling system is filled with
glycol.
Make sure the engine lubrication system is filled with
oil.
Pump the coolant through the seawater cooling
system. (Marine engines only)
Seal all open connections.
Remove the battery cables from the battery.
Empty the AdBlue®/DEF tank if it is filled and clean
it.
Attach a tag into the engine with information about
the date, the product's part number, type of oil used
and sign it.
During storage
The engine must be cranked 2.5 turns every 8th
month.
If the engine can be started, run it until warm.
Check that humidity is below 40%.
Check that the temperature in the storage area is
between +5°C and +30°C.
Important!
• When cleaning, always use mild detergents/
solvents.
• When cleaning the engine and engine
compartment, the alternator, idler pulley, belt
tensioner, power steering unit and all electrical
components must be covered with plastic or similar
so that detergent/solvents do not get into the parts
• Where fitted, the AC compressor must also be
protected with plastic or similar.
• When cleaning air coolers, they should be vacuum
cleaned first before flushing with warm water from
the inside out.
• Do not use a power washer on the air cooler.
• Clean the outside with a sponge/brush.
• Then flush with lukewarm water.
• When pressure washing and steam cleaning, water
pressure may not exceed 80-100 bar at the nozzle.
Maintain a distance of 100-150 mm; use a fan spray
nozzle.
• It is not permitted to came jets of water from the
pressure washer directly onto the alternator. The
electrical regulator, rectifiers, power steering units,
bellows and mechanical parts (bearings) may be
damaged and lead to serious consequential
damage.
IMPORTANT:
Coolant of a suitable chemical composition must be
used all year round to protect the engine against
internal corrosion, cavitation and freeze bursting.
This even applies when there is no risk for freeze
damage, to make sure the engine always has a
complete corrosion protection.
Checklist
Suggestions for the checklist in addition to the regular
service points:
Battery, Maintenance
WARNING!
Risk of fire and explosion. Never allow an open flame
or electric sparks near the batteries.
WARNING!
Battery electrolyte is a corrosive acid and should be
handled with care. If you spill or splash electrolyte on
any part of the body, immediately flush the exposed
area with liberal amounts of water and seek medical
attention as soon as possible.
WARNING!
Ventilate the engine compartment before working on
batteries or battery connections.
IMPORTANT:
Batteries can be damaged if they are left discharged,
and can also freeze and burst easier in cold weather.
If the engine is not going to be used for a longer period
of time, the batteries should be fully charged, trickle
charged if possible.
Care
It is important always to follow the battery
manufacturer's recommendations and instructions
when replacing and charging batteries. Instructions for
maintenance and charging may vary depending on
battery type.
Modern batteries are usually maintenance free, but
there are some recommended measures to avoid
accidents and increase battery service life:
• Keep the batteries clean and dry. Contamination
and oxide on the batteries and battery terminals can
cause stray currents, voltage drop and discharge,
especially in damp weather.
• Remove oxidation from the battery poles and
terminals using a brass brush.
• Tighten the terminals securely and grease them with
terminal grease or petroleum jelly. Loose battery
connections can cause damage to the engine
electrical system.
• Charge the batteries regularly. Batteries kept at full
charge enjoy maximum service life. The easiest way
to check whether a battery needs charging is to use
a volt meter.
Battery replacement
IMPORTANT:
Make sure that the new battery fulfills the specifications
in Technical Data. Read the information supplied with
the battery before you begin the installation.
IMPORTANT:
Do not disconnect the batteries with the engine
running.
Sensitive electrical components can be immediately
damaged.
WARNING!
Never confuse the positive and negative poles on the
batteries. Risk of arcing and explosion.
Disconnection (A)
• Remove the negative (-) cable (black).
• Remove the positive (+) cable (red).
Remove the battery.
Connection (B)
P0028239
AB Volvo Penta
SE-405 08 Göteborg, Sweden
www.volvopenta.com