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FOREWORD Thisworkshop manualcontains repair instructionsforthe2001, 2002 and2003engines. Theinstructionsconcerning overhauling describethemostsuitableworkingmethodusingthespecialtoolslistedunder the heading "Special tools". Boththeengine designationand itsserialnumbermustbe clearlystated inallcorrespondenceconcerningtheengineand when ordering parts. We reserve the right to carry out design modifications and, for this reason, the contents of this manual cannot be regarded as binding. AB VOLVO PENTA Technical Publications Department SI UNIT SYSTEM Units according to the international SI system have been used in this book. The earlier units are given after the SI units. Power is given in kW (kilowatt) Speed is given in rev/s (revolutions per second) earlier unit hp (horse-power) earlier unit rev/min (revolutions per minute) Torque is given in Nm (newton metre) Volume is given in dm3 (cubic decimetre) earlier unit kpm (kilopond metre) earlier unit l (litre) earlier unit lbf ft (poundfoot) earlier unit Imp. gal (Imperial gallon) earlier unit US gal (United States gallon) Pressure is given in Pa (Pascal) earlier unit kp/cm2 (kiloponds per square centimetre) earlierunitIbf/in2(poundspersquare inch) Componentsguide..................................2DISASSEMBLYCylinderhead.......................................3Transmission.......................................4Piston,pistonrods..................................5Flywheel............................................5Crankshaft..........................................5Camshaft...........................................5OVERHAULDisassemblingthecylinderhead.....................7Valveguides........................................7Valveseats.........................................7Valves..............................................7Valvesprings.......................................8Rockerarmmechanism.............................8Injectorsleeve......................................8Injectors............................................8Assemblingthecylinderhead........................9Feed-pump........................................10Pistons............................................11Crankshaft.........................................11Camshaft..........................................11Connectingrods...................................12Thermostat........................................13Sea-waterpump...................................13ASSEMBLYINDEXCrankshaft.........................................14Pistons............................................14Flywheel........................:..................15Transmission......................................15Adjustingthevalveclearance.......................17Checkingtheinjectionangle........................172003Turbo........................................21Freshwatercooling................................25Electricalsystem...................................26Faulttracingscheme...............................28Specialtools.......................................29TechnicalData.....................................30 Halpert@Optonline.net DISASSEMBLY Drain offthecoolingwaterandthe lubricating oilfromthe on engine cradle p/n 9992520 and fixture p/n 884837 . If the engine is fresh water cooled, see page 21 . 3. Remove the fuel filter, the oil filter, the feed-pump, the thermostat housing and the exhaust elbow. Also remove the sea-water pump with its attachment tubes. 1 . Remove the alternator, the tensioner bracket and the starter motor. Remove the connections from the electrical distribution box from the engine and remove the box and the wire harness. 2. Removethe return fuel line, the fuel pressure lines and 4. Remove the valve bridge and lift out the push rods. the inlet air silencer. Install protection caps on the fuel the rubber rings fortheoil pipe . Remove Remove thecylinder pumps and injectors. injection head and the valve lifters . Put the lifters on a rack in Remove the screw holding the lever of the decompression device (1) and pull out the consecutiveorder, TheheadNOTE!boltsphosphatisedaremustnot cleanedawithsteelbrush. cylinderandbelever. Remove the valve cover. 5. Remove the fuel injection pumps. Mark the pumps to ensure installation in the same cylinders from which they wereremoved.Takecareoftheshims.Removethescrews on the side of the engine block and lift out the pump . lifters 7. Remove the transmission cover: Start by removing the throttle control cover. Use a suitable type of pliers to the spring (1) . Then removeremove the end-nipple (2) and the spring (3). Remove the oil pump cover and mark the gear wheels with a colour-pen before removing them. (When installing the gear wheels, the marked side must be facingoutwards).Removethebracing pinofthecamshaft using the special tool 884839. Never remove the p/nbracing pin by punching it out, this can very well bend the camshaft. Remove the screws on the transmission cover and pull it straight outwards. 8. The max.-volume-screw (1)andthemax.-rev-screw (2) are set by Volvo Penta and must never be changed since this will affect the engine output. 6. Remove the pulley center bolt and pull off the pulley 9. Remove the control rod . Start by removing the plug at using puller p/n 9992265. Place a protection pad between therearoftheblockandthetwoscrewsonthepump plane, the pullerandthecrankshafttoavoidthecrankshaftbeing holding the control rod. damaged. 10. Pull out the camshaft. 12. Turn the engine upside down and remove the oil pan. Becarefulasthepan isglued.NOTE!Theoilpanendsalso function as main bearings. 11 .Removetheouterflywheelhousing, theflywheeland 13.Removetheconnectingrodboltsandremovethe theinner flywheelhousing . rodsandthepistons.Theconnectingrodandconnectingthe connecting rod cap are marked with figures. 14. Removethemainbearingcaps.Themainbearingcaps aremarkedwithafigure .Thecorrespondingfigureis intotheblock .punched Liftoutthecrankshaft.Onlaterengine versionsanarrow iscast intheseparatemainbearingcaps (2002, 2003). The arrow is to point towards the dipstick. THE CYLINDER HEAD 1 . Remove the "collets" and valve springs using a valve bow. Remove the valves . Remove the valve stem seals. Place the valves in the proper sequence in a valve stand . Valve guides 2. Check the valve guide wear by inserting anew valve stem into the guide. Measure the play using a dial indicator. If necessary, replace the valve guides. Wear limits: Inletvalve,maxplay . . . . . . . . . . . . . . . 0.15mm(0.0059 in) Exhaustvalve,maxplay . . . . . . . . . . . . 0.15mm(0.0059in) 3. Use mandrel p/n 5218 to press out the valve guides . Oil the new valve guides externally and use mandrel p/n 884559toinstallthem.Pressdownthemandrelalltheway down to the cylinder head. Ream the valve guides if . necessary Valve seats and valves 4. Mill or ream the valve seats. The angle (C) should be 45 (for2003T,30 forthe inlet valve). The sealingsurface'swidth (B) should be 1 0.1 mm (0.0390.0039 in). Grind the valves in a valve grinding machine. The angle (D), see Tech. data. If thediscthicknessaftergrinding islessthan 1.0mm(0.039 in) fornaturallyaspiratedenginesor0.8mm in)for (0.031 engines, the valves must be scrapped turbocharged .Valveswith bentstems,orifthemeasurement(A)exceeds2.5mm(0.098 in) must also be scrapped. Grind the valve tip towards the rockers if necessary. Lap in the valves using valve grinding pasteandcheckthecontactareawithmarkingdye. Replacing the valve seat exhaust port 2003T Grind down the valve disc of a discarded valve to just below 27 mm(1 .063 in) diameter. Push the valve stem through the guide. NOTE! Do not push in too far-the valve disc should be justbelowtheedgeofthe seat.Spotweldthedisc inplaceat threepointsusing aelectricwelder.Knockouttheseat by the valve guide with a plastic-headed hammer.hitting Cool the new seat to approx. -20C (-4F); the cylinder headshouldbeatroomtemperature(+200168F).Placethe cooled seat on tool 884961-4 and knock it down until it towards . NOTE! Turn the seat with the valve face bottoms the tool. Valve springs 5. Checkthefreelengthofthevalvespringsandthelength when loaded. L =Length,unloaded42,5mm(1.67323in.) L1 = Length, loaded with 17010 N (171 kp) 32 mm (1.25984 in .) L2 = Length, loaded with 30020 N (303 kp) 24 mm (0.94488 in.) Rocker arm mechanism 6. Disassemble the rocker arm mechanism and clean the parts .Checkthewear oftheshaftand rockerarm bushings. Should the bushings need to be replaced, usethe mandrel p/n 9991867 for the removal and installation, (make sure thattheoilholeinthebushingcoincideswiththeone inthe rocker arm) . After the installation the bushings are reamed to a close running fit. When installing the rockerarm shaft, itmustbeturned sothatthelubricationholes are facingthe valve-side.Checktomakesurethatthe rockerarmcontact surface againstthe valve is concave. Minor adjustments are made in a valve grinding machine. Oil the shaft and install the parts. Pressure testing the nozzles 7. Check the nozzle's spray pattern at the correct opening pressure(seeTechnicalData) .Checkalsothatthe fuelsprays stop simultaneously and no dripping occurs. Adjust the opening-pressure with adjustment-washers (1) beingavailableindifferentthicknessesfrom 1mmU3937 in.)to1,95 mm (.076772in.)instepsof0,05mm (.001969 in .) . Disassemble the injector and replace the adjustment-washeragainstorthickerdependinga aaone oneoneon thinner whether the pressure must be reduced or increased . Assemblethe injectorandchecktheopening-pressureand the spray-pattern . Injector-sleeve 8. Insert the expanding screw on the special tool p/n 884811 into the copper sleeve and turn the screw anti-clockwiseuntilthestuckin. screwhasthesleeveTighten the screw hard to allow the threads to work themselves into the copper material. Then install the yoke (1) on the stud bolt of the injector. Put a cylinder head screw in the cylinderheadasasupportforthelegoftheyoke. Installthe nut (2) and tighten it until the sleeve is removed. 9 . Replace the O-ring, sealing off between the sleeve and the cylinder head . Dip the new O-ring in soap-water in order to facilitate the installation. Oil the new injector sleeve andinstall it,usingspecialtoolp/n884557 .Knockdownthe sleeve until it bottoms. 10 . Oil theflare-tool p/n 884283 and insert it intothe sleeve (make sure that the dowel is properly retracted). Brace the tool with the injector yoke. Screw down the flare-tool as far as the shoulder in the injector sleeve allows, thereby flaring the sleeve. Remove the tool . Adjust the length of the sleeveoutsidetheplane ofthecylinderheadtomaximum 1mm (.03937 in .) . Assembling the cylinder head 11 . Clean the cylinder head. If the water distribution pipe has been disassembled, it must be installed with the holes turned as indicated in the picture. Install new valve stem sealings. Oil the valve stems and install the valves. Make sure to install the valves and the valve springs in their respective original positions. Install the valve springs and the "collets" . Use a valve-bow. Reduction valve 12.Removethecoverofthereduction valveandcheck to make sure that the spring and the piston are faultless . If there are reasonstosuspectafault intheopeningpressure of the reduction valve, then check the data of the spring. See under "Technical Data" -reduction valve. Changing the diaphragm 14. Remove the six screws, holding the upper and lower pump housings together. Remove the pump lever spring (1) and remove the screw (2) holding the pump lever shaft. Feed-pump 13. Depress the pump lever. if the diaphragm of the pump 15. Use a suitable pair of pliers and removethe pump lever sounds squeaky, the diaphragm is faultless. shaft. Pull out the lever and the diaphragm. 16. Clean the pump housing carefully and replace worn parts. Install the diaphragm and the lever on the shaft.Theninserttheshaftandtighten itwithdiaphragmthe screw. Assemble the two housing halves and install the attachmentplate(1).Theninstallthespring(2)andthe O-ring(3). Valve lifters 17.Checkthevalveliftersforwear.Replacethem ifneces sary. Camshaft 18.Checkthecamshaftforwearoncamsandbearing ra ces.Alsocheckthewearofthebearings.Thebearingsare pressed into their locations and must be line bored after the installation. 19. Place a support under the camshaft gear and use a hydraulic press to remove the gear. Crankshaft 20. Removethegearwheel.Useaprongpuller.Cleanthe crankshaft.Measurethecrank-and mainbearing pins. The eccentricitymustnotexceed 0.06mm(.002362 in.)andthe taper0.05 mm(.001969in.) .Shouldthesevaluesbeexceeded, the crankshaft must be ground to a suitable under-dimension,see"Technical.underData" Pistons, cylinders 21 . Checkthewearonpistons,pistonrings andgudgeon pins . Replace these if necessary. Use a cylinder indicator gaugeto measure the cylinder bores. The measurement of thebiggestwearismadeimmediatelybeneath the edge of theupperdeadcenterandcrosswisetheengine.Themea surement of the smallest wear is made at the lower dead center. As to the cylinder diameter, see "Technical Data". Use amicrometertomeasurethepistons. Pistondiameter, see under "Technical Data". 22. Inserta new piston ring into the cylinderand measure the piston ring gap. As to the measurement, see under "Technical Data" . If necessary increase the gap, using a special file . 24. Use piston ring pliers to install the piston rings. The markingoftherings(TOP orthemarkofthemanufacturer) must be turned upwards. The height of the upper com pression ring : 1,75 mm (.068898 in .) The height of the compression ring ; 2,00mm (.07874 in.).Turn the lower rings so that the gaps are turned 120 from eachpiston . other Connecting rods 23.Measuretheclearanceofthepistonrings inthepiston 25.Checktheconnectingrodsforstraightnessand ring grooves. Regarding the measurement, see under.twisting "Technical Data". 26. Check the connecting rod bushings by using the pin as a gauge. There must be no play.gudgeon Ifthe bushings must be replaced, use a suitable mandrel for the removal and installation. Make sure to install the bushing with the oil hole coinciding with that of the connecting rod . Ream thenewbushings.Thefitiscorrectwhenanoiledgudgeon pin by its own weight can slowly slide through the . bushing Sea-water pump 27. The pump is equipped with two ball-bearings (1) . When disassembling, remove the locking-ring (2) in the housing and push out the shaft, whereby the bearings are following. Use a suitable mandrel to remove the bearings from the shaft. NOTE! Do not forget the spacer sleeve (3). Replace the sealings (4). NOTE! Turn the sealings correctly and make sure that they do not block the drainage hole in the pump-housing . Replace the (5) . Install the O-ring ball-bearingsandthesleevetheanda spacerontoshaft leavedistanceof39,5mm(1.55512 in .)from the shaft endtothe ball-bearing . Coat the shaft with grease and "screw" it through the sealings and the O-ring and take care not to damage them. Push in the shaft as far as to allow the bearings to bottom and then install the locking-ring (2). Checking thethermostats 28 . Immerse the thermostat in water and, using a check if it opens at the correct temperature.thermometer, See TechnicalDataforopeningtemperatures.Ifthethermostatis faulty, it must be replaced. ASSEMBLY Always use new gaskets, sealing rings, sealing washers and lock-washers. Coat the sealings with grease or oil themandalso oilallmovingpartspriorto installingthem. If the engine is fresh-water cooled, see page 21 . 1 . Heatthecrankshaftgearwheeltoapprox.150C(302F) priortotheinstallation.Placethekeyinthekey-wayofthe crankshaft and press on the gear wheel. Oil the new main bearinghalves(with oilhole)andinstallthemintheblock. Put in the crankshaft. NOTE! The main bearing shell at the flywheel also functions as a thrust-bearing . 3. Turnthepistonringssothat thegapsareoffsetinrelation toeachother.Thepistoncrownismarkedwithan arrowthat pointstowardsthebeltpulley.Useinstallationring884813-7. Fit the caps with the marking aligned with the crankshaft's marking. The crankshaft can be turned in any direction towards the piston. Tightening torques: Step 1:ft/lb) 25Nm (2.5kpm)(18Step2 : 70Nm(7.0kpm)(53ft/lb) 4. Install the main bearing halves in the oil pan and coat 2. Oil the cap bearing halves and install them. Install the the edge of the oil pan with thin layer of sealing caps inaccordancewiththemarkingintheblock(2001 has Install the oil pan and tighten the oil pan no intermediate bearing) . If an arrow is cast, it shall point p/n 840879.compound towardsthe oildipstick.Tighteningtorque forthemain screwsandthemainbearingscrewsalternatinglyto20Nm (2,0kpm) (14.7 ft.lbs .)andthenthemainbearingscrewsto bearings:1st tightening20Nm(2kpm)(14.7 ft.lb),2nd tightening60Nm(6kpm)(44.2ft.lbs) .Turntheengine . 60Nm(6,0kpm)(44.2ft.lbs.). 5.Replacetheflywheelhousingsealing(1). Smearsealing compound (p/n840879) ontheedgebetweentheflywheel housing and the sealing. NOTE! The sealing lip with a springshallbeturned towardstheengine.Makesurethat the sealing is installed in accordance with the picture. r 6. Replace the O-rings and install the flywheel housing . Tighteningtorque25Nm(2,5kpm)(18.4 ft.lbs). Install the flywheel. Tightening torque 65 Nm (6,5 kpm) (48.0 ft.lbs). 7A. Heat the camshaft gear wheel to a temperature of approx. 150C (302F) and use a suitable sleeve to install it . Checktomakesure thatthegearwheel "bottoms"onthe camshaft. Install the camshaft and make sure that the markings on the camshaft gear wheel and on the crankshaft gearwheelcoincide.Putthe washer (1)onthehubof the camshaft gear wheel. Check that all weights arepressed in so that the tabs (2) are inside the washer. 7B. Install anew p/n sealing ring for the camshaft in the housing, using mandrel 884838. transmission The sealing lipwiththespring istobeturnedtowards theengine.Press in the sealing ring from the outside until the mandrel "bottoms" against the housing . Install a new O-ring in the oil channel in the block (3 fig . 7A) . Use a new gasket and install the timing gear cover. Place thepressuresleeve (withthebearingtowards thepressure washer) in the control arm lever. Hold the sleeve in place by pressing the lever to its bottom position where the sleeve ispressedagainstthehousing. Installthepinofthe camshaft, using special tool 884839. The pin must p/n Undernocircumstances equally much on bothsides.protrude are you to use a hammer or some such tool to punch the pinintoitslocationwiththeaidofa mandrel.Thecamshaft will then be bent. 8. Insertthecontrolrodthroughtheblackandintothetiming gearcasing.Installthebearing ball (1)intothecontrolrodand push the control rod through the hole in the control lever (2) . Fit the spring (3) and screw on the end nipple (4) until it bottoms (Note! Do not use any tools). Screw in the upper bolts (with copper sealing washers) that guide the control rod . Then,screwthelowerboltsthatholdthecontrolrod inplace in the engine block. NOTE! The lower bolts should not have sealing washers. Apply Permatex to the threads. Check that the control rod moves freely. 10. Insertthekey forthepulleyinthecrankshaftandinstall the pulley. Tightening torque 40 Nm (4,0 kpm) (29.5 ft .Ibs). 11 . Clean the valve lifters carefully and coa t the contact surface against the camshaft with molybdenum disulphide . Oil the valve guides in the block and install the lifters. Clean the roller lifters of the fuel injection pumps and then in the block.install Lock the roller lifters with screws through the block after the installation (apply Permatex to the threads). Check carefully to make sure that the lifters are correctly installed and that they are running easily in the groove. 9. Installtheoilpump'sgearwheelaccordingtothemarks 2001 (from the disassembly) . Insert a new O-ring in the timing gearcover.OilthegearwheelandfitThecoverusinganew Regardingtheinstallationofthecylinderhead,seethe sealing ring. page.following 12. Tighten the two guide screws p/n 884840 in the block and install the cylinder head gasket with the marking "Top" facing upwards. Install the cylinder head . Make sure that the contact surface for the cylinder head bolts are free from paint. Should there be paint on the bolts,there isalwaystheriskofhavingan insufficiert forceinthe boltjointwithsubsequentleakagestighteningasa result. NOTE! The bolts are phospated, therefore do not clean them with a steel-brush. Coat the cylinder head bolts with molybdenum disulphide and tighten them in accordance with the diagram, first to 20Nm(2.0 kpm/14.7 ft.lbs)andthen to70Nm(7.0 kpm/51.6 ft.lbs). 13. Install the push rods and the rocker arm bridge, push on new rubber rings to the oil pipe which is fitted at the same time as the rocker arm bridge. 14. Valve clearance cold/warm engine 0.30 mm (.01181 in .) . Turn the engine in the direction of rotation until the valves in one cylinder are "rocking". Then turn the engine one turn more and the valves for this cylinder. adjustRepeat the procedure for the remaining cylinders. Adjusting the fuel injection pump location with shims 15. if the same block camshaft and fuel Injection pumps are used when assembling, the fuel injection pump must be installed in their original positions and with the same shimthickness as earlier.Thesocalled softshims,always being installed against the block, must be replaced against newones.Carefullycleanthecontactsurfacesbetweenthe block and the fuel injection pumps and install shims with thicknessequaltothe sum ofthemarkingontheblockand that on the fuel injection pump, (4) earlier marking . Example: Theblockmarking4(= 4tenthsofamillimeter) (.015748 in.) Thepumpmarking4(= 4tenthsof a millimeter) (.015748 in.) Totalamountofshims=0.8mm (.031496in.) Inthiscaseselecttwosoftshims0.2and0.3mm(.011811 in .) . Place the hard shim between the two soft ones and install the pump. NOTE! Never install a hard shim together withanotherhardshim oragainsttheblockorthefuel pump.injection Hard shims are available in thicknesses 0.3, 0.6and0.9mm(.011811,.02362, .035433in .respectively). Soft shims are available in thicknesses 0.2 and 0 .3 mm (.007874 and .011811 in .) . On later version engines an O-ring has been introduced as a sealbetweentheinjectionpumpandtheblock. Onlyso-called hard shims may be used on these engines when shimming. Hardshimsareavailable inthicknessesof0.2mm(0.0079 in), 0.3mm(0.0118in),0.6mm (0.0024in)and0.9mm (0.0354in). 16. New block or camshaft setting-disc If the block or the camshaft are replaced the block must be measured and marked, using the setting-disc p/n 884787 and a sliding caliper. A. The setting-disc consists of two rings, an inner and an outer. The inner ring determines the injection angle for eachrespectiveenginetype,seeTechnicalData(page25). The injection angle is stamped in degrees and is fixed with a pin (1) . B . Mount the setting-disc or the pulley with two bolts, do not tighten the bolts. Turn the so that the guide pin (2) comes in the largest of the four holes in the pulley. Press in the guide pin (2) so that the disc is centered and tighten the bolts . The setting-disc is marked for each respective cylinder: Marking Denotes Cylinder 1 Cylinder 1 (1, 2, 3 cylinder engines ; Cylinder 2/2 Cylinder 2 (2 cylinder engine) Cylinder 2/3 Cylinder 2 (3 cylinder engine) Cylinder 3/3 Cylinder 3 (3 cylinder engine) C. Turn cylinder no. 1 to it's injection. position. Place the guide pin (2) in the setting-disc's hole marked cyl . 1 . Turn the crankshaft a little against the normal direction of andthereafter in the normal rotation direction untilrotation the setting-disc's guide pin (2) goes in the timing cover's hole. Measureusing a caliperthedistancebetweenthecylinder block and the roller lifter's edge (do not measure on the roller). The distance should be: 2001 :55.8mm (2.19685 in) 2002, 2003: 55,6 mm (2.18504 in) 2003T:55.9mm (2.2007 in) Example: 2001 . Ifthemeasureddistance is55.2mm(2.17323in)this meansthata shimwiththickness0.6 mm(0.02362 in) isto be placed between the caliper and the block. 2002,2003.Ifthemeasureddistance is55.0mm(2.16535 in) this means that a shim with thickness 0.6 mm (0.02362 in) is to be placed between the caliper and the block. Themeasuredshimsthickness (inthisexample0.6mm) is to be stamped into the block as in fig . 15. The total shim thickness is found by adding the block's measurements and the pump's marking. Example The block's measurements 6 (= 0.6 mm/0.02362 in) The pump's marking 2 (= 0 .2 mm/0.007874 in) No. of shims 0.8mm In thiscasechoosetwo softshims0.2and0.3mm (0.007874and0.011811in)andone hardshim of 0.3 mm (0.011811 in) . Place the hard shim between the two soft onesandrefitthepump.NOTE!Ahardshimmustneverbe fitted together with another hard shim or directly against the block or pump. Hardshimsareavailableinthicknesses0.3,0.6and 0.9 mm (0 .011811, 0.02362 and 0.035433 in) . Softshimsareavailableinthicknesses 0.2and 0.3mm (0,007874 and 0 .011811 in). D. Repeat the procedure for the other pumps (2002, 2003) in the same way as for cylinder 1 . The setting-disc's marking is explained under point B . 17. Fit the injection pump(s) together with the calculated shim thickness. Turn the engine so that the cam for the pump is not in the lifting position. Check that the pump's pin locates inthecontrol rod's grooveand that the pump(s) and the locks markings coincide (see figure). Check after fitting each pump that the control rod operates easily. Tightening torque for the nuts is 20 Nm (2,0 kpm) (14.7 ft.lbs). Connect the fuel pipe between the pumps and the pipe from the fuel filter to the injection pump. NOTE! The hole bolt for the return hose has a smaller through-flow channel than the others (on later versions it is marked 'Out"). 18. Installthefeedpumpandthefuelfilter.Alsoinstallthe thermostat housing with the thermostat . NOTE! Do not forget the lifting eyelet between the fuel filter and the housing .thermostat 21. Fitthevalvecoverusing anewgasket.Makesurethat the round hole for the crankcase ventilation is in the right position . Fit the decompression device lever. Fit the pressure pipes between the injectors and the injection pumps. Also refit the inlet air silencer. 19. Install the sea-water pump and the cooling water . pipes 20. Installtheinjectorsandthereturnfuelpipe.Tightening torquefortheinjectors20Nm(2,0kpm)(14.7 ft.lbs.). Also install the exhaust elbow and the water pipe between the thermostat housing and the exhaust elbow. 22. Install the starter motor, the alternator and the V-belt. Also install the electrical distribution boxalternator and hook-up the cable harness. 23. Fill up with lubricating oil to the correct level .Regarding quantity and quality, see under "Technical Data". 24. Venting the fuel system A.Opentheventingscrewon thefuelfilterapprox .4turns . Watch out for fuel-splashes. B . Use the hand-pump to pump fuel until fuel free from air bubbles is coming out. Close the venting screw. C . Ease off the fuel pressure pipe nuts at the injectors. Position the throttle control in the position for full speed and turn the engine with the starter motor until fuel comes out of the fuel pressure pipes. Tighten the fuel pressure pipe nuts. 2003T Turbo-Compressor Wherethere isanexcessiveamount ofsmoke inthe exhaustfumestheengineisit oroutputparticularlylowmay bethattheturbo-compressorisnotfunctioningproperly.If the boat's speed through the water is graduallydecreasing, the boat's bottom should also be inspected, and cleanedwherenecessary.Checkthattheairintakehasnot become clogged, and clean the intake silender. Inspecting the Seals jointsbetween the turbine housing and the Check thecompressor bearing housing, and between the compressor bearing housing and the compressor housing. Checks Check the pre-injection angle, the injector's opening and the spray pattern. The valve clearance andpressure should also be checked.compression Checking axial and radial clearance Dismount the turbo-compressor from the engine, and measure the rotor unit's axial and radial clearance . Maximum permissible axial clearance 0 .09 mm Maximum permissible radial clearance 0 .17 mm Ifwearand tearhas reachedthemaximum permissiblethe turbo-compressor should be reconditioned or replaced . RECONDITIONING Makeline-upmarksbetween theturbinehousing,the Dismantletheturbineshaft(4)andtheheatshield.Ifthe bearinghousingandthecompressorhousing .Dismantle turbineshaftsticks,tapthe endgentlywithawooden the compressor housing (1). Unscrew the left-hand . Unfasten the three screws which hold the cover (3) hammer threaded nut which holds the compressor wheel, using and screw two M5 screws into the cover. Then lift it up. dolliesontheturbineshaft.Removethecompressorwheel Taketheoildeflector(7)outofthecover. (2) and dismantle the turbine housing (3). Unfasten the four screws which hold the compression bearing (8). Using a small copper mandrel, tap out the compression bearing and the bushing (9). Then remove thecirclips (10) insidethebearinghousingandremove the two bearings (11) . Remove the packing ring (12) on the turbine shaft and the two packing rings (13) on the oil deflector. Clean the parts carefully. Measuring and Inspection Turbine Wheel and Shaft Check that the turbine wheel and shaft are free from damage.mechanical The vanes must not be worn or out of shape. Do not try to realign the vanes. Damaged parts should be replaced . Placethe shaftontwosupports, which should be underthe bearing recesses, and check the throw at the end of the shaft.Themaximum permissiblethrow is0.011mm. Checkthediameteroftheshaftbearingrecesses.The is 7.98 permissible diameter mmminimum .Checkthewidth of theshaftpistonringgroove.Maximumpermissiblewidth is 1.29mm. Compressor Housing, Turbine Housing Check thatthehousingsarefreefromcracks orother caused by excessive wear and tear. Damaged damage parts should be replaced. Heat Shield Checkthattheheatshield isfreefromdamagecausedby wear and tear, heat or corrosion, and replace it ifnecessary . Bushing, Oil Deflector, Compressor Bearing Check that the parts are free from wear and tear and .Damagedpartsshouldbereplacedeven ifdiscolourationthe amount of wear and tear is within the permitted . tolerances Bushing Check measurement (A), which should not be less than 4.07 mm. Oil Deflector Check measurements (B) and (C). (B) should not be more than 1 .31 mm, (C) should not be more than 1 .11 mm. Compressor Bearing Checkthewidthofthebearing,andreplaceit iftheamount of wear and tear is in excess of the permitted tolerance. Minimumpermissiblewidth is3.98mm. Bearings Check the bearings for abnormal wear and tear or discolouration,andreplacewhere.the themnecessaryCheckinternal and external diameters of all bearings. Theexternal diametershouldnotbelessthan 12.31mm,theinternal diameter should not be more than 8.04 mm. Bearing Housing Checkthehousing forcorrosion orcracks.Check (D)and (E),andreplacethehousingwheremeasurementsnecessary more than .Measurement(D)shouldnotbe 12.42mm, measurement(E)shouldnotbemorethan15.05mm. Cover Check measurements (F)and (G).and replacethe cover where necessary. Measurement (F) should not be more than12.45mm,measurement (G)should notbemorethan 10.05mm. Packing Rings Check the packing rings to see if they are worn or out of shape, and replace them with new ones wherenecessa ry. Reassembly Greaseallremovablepartswhenreassemblingthem. the circlips in the bearing housing so that the Position in them are facing towards the oil outlet.openings Mountthepackingring shaft.Turntheopening on the turbine in the ring so that it is facing towards the oil intake. Position the heat shield on the bearing casing, and then place the turbine axle in the bearing housing. Mountthebushingontheturbineshaft.Greaseinthe bearing with engine oil, and mount it oncompressor the bearingcasing,usingnewscrewsandwasherstofasten it. The torque should be 1 .3 Nm0.1 . Tightenthescrewsto the abovetorque,thenloosen them a quarter turn before tightening them up to the correct torque again. Positionthetwo packingringsontheoildeflector.NOTE: Theopeningintheinnerringshouldbefacingthe oil outlet, that intheouterringshouldbefacingtheoilintake. Position the oil deflector in the cover. Smear the edges of the bearing housing which come in touch with the cover, using Permatex for the purpose. Thethicknessofthesealantshouldbeabout0.1-0.2mm. Fitthe coveronthe bearinghousing, andfasten itwith new screwsandwashers.Thetorqueshould be 1.3 Nm0.1. Tightenthescrewstotheabovetorque,thenloosen them a quarter turn before tightening them up to the correct torque again. Position the compressor wheel on the turbine shaft and fasten it with the left-hand thread nut. The torque should be 2.0 Nm0.1. Mounttheturbine housing on the bearing housingaccording to the line-up marks. Screw the locking cover into making sure that the screws used are not thoseposition, for the compressor housing . The torque should be 11 .0 Nm0.5 (M6), 26.01,0 (M8). Smeartheedgesofthebearinghousingwhere itcomesin touch with the compressor housing, using Permatex for thepurpose.Thethicknessofthesealantshouldbeabout 0.1-0.2mm.Thenmountthecompressorhousingaccording to the line-up marks, and screw the locking cover into position.Thetorqueshould be 4.5Nm0.5. Check the axial and radial clearance . Maximumpermissible axialclearance is0.09 mm,maximum permissible clearance is 0.17mm.radial Fitting the Turbo-Compressor Before fitting the turbo-compressor on the engine, spray clean engine oil into the oil intake, and turn the turbine shaftsothatthe oil is evenlydistributed.Cleanthe turbo-compressor'sdeliverylinesengineand andandfor. ..sureuseoil oiloilBetothe thethethethereturnChangefilterlubricant correct quality of oil (see under "Technical Data"). Oil changes should be carried out in accordance with the instructions intheManual, inordertokeeptheengineclean. Clean the air filter . FRESHWATER COOLING 2002, 2003 1 . Fitthecirculationpump(completewithtensionerbracketandspacersleeve,position4).Tightenthebolts(M8x75)to 20Nm(2,0kpm)(14.7ft.lbs),position1 . 2. Suspend the heat exchanger loosely by the rear bolt (M8x16 and spring washer.), position 5. a) Fit the pipe (position 6) and the hose (position 3) between the heat exchanger and the sea-water pump, using double hose clamps (apply soapy water to the rubber rings, applies for all rubber rings). b) Fit the pipe between the heat-exchanger and thermostat housing, position 7. c) Fit the pipe between the heat-exchanger and the circulation pump, position 8. 3. Locate the pipes in the heat-exchanger and and draw it forward tightening it with the two bolts (M8x16 and spring washers), positions 5 and 9. 4. Fitthepipebetweentheheat-exchangerandtheexhaustelbow,position10.NOTE!Theholderforthepipe,(position 11) and the lock (position 11 a). 5. Fit the pipe between the circulation pump (lower outlet) and the cylinder head, position 12. 6. Fit the pipe between the circulation pump (upper outlet) and the cylinder head, position 13. 7. Fit the alternator, place the bolt for the tensioner bracket with the head forwards. Put on and tension the V-belt . 8. Fit the expansion tank to the exhaust elbow, position 15. 9. Fitthehosebetweenthetankandthecirculationpump(doublepipe )2002=450mm(17.7in),2003=550mm(21.7 in) (only single hose clamps are used on the fresh-water system), position 16. 10. Fit the nipple, position 17. 11 . Fitthehosebetweenthetankandthethermostathousing(nipple17) :2002=350mm(13.8in),2003=450mm(17.7 in), position 18 . 12. Fit the plugs in the exhaust elbow and the cylinder head, positions 19 and 20 . 13. Fillthesystemtotherightlevelwithamixtureoffreshwater(50% )andanti-freeze(50%),altemativelyrust-protection additive (VP accessory). The fresh-water system volumes: 2002 = 4.0 dm2 (litre) (0.88 Imp. gals) (1.1 US gals), 2003=5.5dm3 (litre) (1 .2Imp. gals) (1.45USgals). Pos 21 and 23 are for hot water outlet. Wiring diagram, alternative A (Standard) INSTRUMENTPANEL 1 . Printed circuit card 2. Rev counter (accessory) 3. Start button 4. Switch for instrument panel 5. Alarm test button 6. Alarm Max output from the panel = 5A Cable colour R = Red PU --Purple BN = Brown OR = Orange GR = Grey SB = Black W = White Y = Yellow GN = Green BL = Blue Z ENGINE 1 . Relay 2 . Fuse 3 . Temp. alarm sender 4 . Oil pressure alarm sender Wire areas in mm2 Wire area mm2 AWG 1,0 16 1,5 14 2,5 12 10 6 Wiring diagram, alternative B (De Luxe) INSTRUMENT PANEL 1 . Voltmeter 2. Oil pressure gauge 3. Coolant temperature gauge 4. Printed circuit card 5. Alarm test 6. Switch for instrument lighting 7. Rev.counter 8. Key switch 9. Alarm Max output from thepanel: 5A Cable colour GR = Grey SB = Black BN = Brown LBN Light brown = R = Red P = Purple GN = Green Y = Yellow W = White BL = Blue LBL = Light blue ENGINE 1 . Coolant temperature sender 2. Oil pressure alarm sender 3. Coolant temperature alarm sender 4. pit pressure sender 5. Relay 6. Fuse Wire areas inmm2 FAULTTRACING Engine Engine Engine not Engine runs Engine does stops reaching roughly or becomes not correct temp vibrates abnormally start at full rpm abnormally hot " " " " " " Fault Stop control not fully pushed back. Main switch: not switched on . Flat battery. Broken electric wires. Main fuse blown. Empty fuel tank, closed fuel cock or clogged fuel filter. Water or impurities in the fuel . Faulty injectors or air in the fuel system . Boat abnormally loaded, clogged intake air filter or marine growth on the boat bottom . Engine not properly aligned. damaged.Propeller Clogged cooling water intake or waterjackets intheexhaust . manifold Faulty impeller in sea-water pump. Faulty thermostat.Clogged cooling water pipe in the head.cylinder 9992265-0 884813-7 9995218-6 884557-0 884559-6 884787-3 884811-1 884823-6 884837-6 884838-4 884839-2 884840-0 Pulley puller Installation ring for piston Mandrel for valve guide removal Mandrel for installation of injector sleeve Mandrel for installation of valve guide Setting-disc for injection pump setting Puller for injector sleeve Flaring tool for injector sleeve Flange for engine cradle Mandrel for installation of sealing ring in transmission cover Assembly and disassembly tool for camshaft pin Guide pin for cylinder head. NOTE! Two arerequired . TECHNICALDATACylinderbore............................................ Stroke.................................................. Compressionratio...................................... Compressionratioatstartermotorspeed................. 79mm(3.11024in) 87mm(3.4252in) 17.5:12-2.5MPa(20-25kp/cm2) Directionofrotation(seenfromthefrontend).......... Idlingspeed.......................................... Oilpressureatfullspeedandwarmengine............. Oilpressureatidlingandwarmengine................. Clockwise13-14r/'s(775-825rpm) 0,35-0,40MPa(3,5-4,0kp/cm2) 0,08-0,15MPa(0,8-1,5kp/cm2) CylinderblockMaterial..............................................SpecialalloycastironPistonringgapinthecylinderUppercompressionring........................... Lowercompressionring............................... Oilring............................................... 0,30-0,50(0,001181--0,00197in.) 0,30-0,50(0,001181-0,00197in.) 0,25-0,50:0,009842-0,00197in.) GeneralTypedesignation.....................................200120022003,2003TNumberofcylinders..................................123Displacement.....................................,...0.43dm3(26.2cu0.852dm3(51.9cuin)1.278m3(77.99in)cuin) Cylinderdiameter,standard...........................79,00-79,03(3.11025-3.11142in.) 0,25mmover-size.....................................79,25-79,28(3.12008-3.12126in.) 0,50mmover-size.....................................79,50-79,53(3.12992-3.1311in.) PistonsMaterial..............................................Light-alloyTotalheight...........................................78,3mm(3.08268in.) Heightfromgudgeonpincentertopistontop..........50,3mm(1.98031in.) Pistonclearanceincylinder............................0,09mm(.00354in.) Pistoninstandarddimension..........................78,903-78,)17(3,10642-3,10697in.) 0,25mmover-size.....................................79,153-79,167(3,11626-3,11681in.) 0,50mmover-size.....................................79,403-79,417(3,12610-3,12665in.) GudgeonpinsDiameter.............................................25,995-26,000(1,02343-1,02362in.) Gudgeonpinbushing,diameter........................26,005-26,011(1,02382-1,02406in.) Clearancegudgeonpin-bushing..................0,0050-0.0160(0,00020-0,0063in.) PistonringsCompressionring,number............................2Oilring,number......................................1Theuppercompressionringhasaninlayofchrome. Thepistonringsareavailableforstandarddimensionandfor0,250and0,500mmoversize(0,00984and0,0996) in.) PistonringaxialclearanceinthegrooveUppercompressionring...............................0,070-0,102(0.00276-0,00402in.) Lowercompressionring...............................0,050-0,082(0,00197-0,00323in.) Oilring...............................................0,030-0,062(0,00118-0,00244in.) CrankshaftMaterial..............................................NodularironCrankshaftaxialclearance.............................0,040-0,221(0,00157-0,00870in.) Mainbearingradialclearance..........................0,040-0,092(0,00157-0,00362in.) Big-endbearing,radialclearance.......................0,024-0,068(0,00094-0.00268in.) 1PropellershaftoutputinaccordancewithDIN6270B. MainbearingjournalsDiameter,standard0,250mmunder-size.............................. . ... 0,500mmunder-size-............. 59,987-60,000(2,36169-2,36220in.) 59,737-59,750(2,35185-2,35236in.) 59,487-59,500(2,34200-2,34252in.) Big-endbearingshellsThickness,standard................................... 0,250mmover-size................................... 0,500mmover-size................................... 1,478-1,488(0,05819-0,05858in.) 1,603-1,613(0,06311-0,06350in.) 1,728-1,738(0,06803-0,06843in.) ConnectingrodsAxialclearanceatthecrankshaft.......................0,15-0,35mm(0,00590-0,01378in.) CamshaftAxial . clearance...... . .................................. Radialclearanceinbearings............ Camshaftdiameter.................................... Liftingheightofcams............---.----------...--.. 0,160-0,300mm(0,0063-0,01181in.) 0,020-0,075mm(0,000787-0,00295in.) 46,975-47,000(1,8494-1,85039in.) 5,48-5,52mm(0,21575-0,21732in.) MainbearingshellsThickness,standard...--.-........................2,987-2,997(0,11760-0,11799in.) 0,250mmover-size...................................3,112-3,122(0,12252-0,12291in.) 0,500mmover-size....---.-.........................3,237-3,247(0,12744-0,12783in.) Big-endjournalsDiameter,standard....................................47,989-48,000(1,88933-1,88976in.) 0,250mmaver-size---........47,739-47.750(1,87949-1,87992in.) 0,500mmover-size.-.--..-...........................47,489-47,500(1,86965-1,87008in.) Bushingdiameter......................------------...47,02-47,05mm(1,85118-1,85236in.) CylinderheadMaterial..............................................SpecialalloycastironInletvalves20031Discdiameter.........................................34,4-34,6mm(1,35433-1.36220in.)35,8-36,0mmStemdiameter........................................7,955x7,970mm(0,31319-0,31378in.)7,995-7,970mmValveseatangle......................................4455'-4485'2945'--3015' Cylinderheadseatangle..............................4530 Seatwidthinthecylinderhead........................appr.1mm(0,03)37in.)appr.1mm!0.03)37in. Clearance,cold/warmengine.......................... ExhaustvalvesDiscdiameter..........----........................... 0,3mm(0,011811in.)0.3mm(0,011811in.) 29,9-30,1mm(1,14716-1,18504in.) Stemdiameter........................................7,950-7,465mm(0.31299-0,31339in.) Valveseatangle......................................4455'-4485' Cylinderheadseatangle-..-......................45 Seatwidth-inthecylinderhead.--.....................appr.1mm(0,03937in.) Clearance,cold/warmengine-----.............--...---0,3mm(0,011811in.) ValveguidesLength,inletvalve....................................38mm(1,49606in.) Length,outletvalve...................................38mm(1,49606in.) Innerdiameter------------............................8,000-8,015(0,31496-0,31555in.) Heightabovespring-planeofcylinderhead.............8,70-9,30mm(0,34252-0,36614in.) ValvespringsLength,unloaded...................................42,5mm(1,67323in.) Loadedwith17010N(171kp)......................32mm(1.25984in.) Loadedwith30020N(302kp)......................24mm(0,94488in.) Lubricating system ENGINE Oilquantitymodel2001 . . . . . . . . . . . . .. Oilquantitymodel2002 . . . . . . . .. Oilquantitymodel2003 .. .. .. . . .. . .. . . . ... . . . Oil quality according to the API-system Viscosity ..... . ... . . . . .. . . .. ....... . . Oil pressure, warm engine, idling speed. . . . . . . . . . . . . . . . Oilpressure,warmengine,fullrpm . . . . . . . . . . . . . . . . . . . . Lubricating oil pump Type. . . . .. . ..... . ........... .... ............. . . . ... .. Gearwheelaxialclearance .. .. .. .. .. .. .. .. .. .. .. . . .. .. Spring for reduction valve, length unloaded . . . . . . . . . . . . Loadedwith35Nm(3,5kp)(25.8ft.lbs.) . . . . . . . . . . . . . . . . Fuel System Openingpressure.injectors . . .. .. . . . . .. ... . . .. .. .. . . .. . Sprayangle...... . . .... .__... . . . . .... . .. . ... . . . . . ... Injectionangle2001 .. . ... . . .. . .. . . . .. . . Injectionangle2002,2003 . .. .. . .. . . . . . . .. ... .. . .. . . . .. Injectionangle2003T . . ..................... . .. . .. Injectionquantity . . . .. . . .. . . .. . .. .. Governoroverrun . . . .. . .. . .. . . . .. .. .. .. .. .. . .. . .. ... .. Feed pump Feedpressure42r/s(2500rpm). .. . . . .. . ... .. .. . . .. . . . . .. . Electrical system Batteryvoltage. . . . . . . . ........... . ..... . ........ . ..... Batterycapacity.. . . . . . ..... . ....... . .......... :.. . . . ..... Starter-motoroutput2001 ... . . . .. . . . . . . .. .. . .. . .. . Starter-motoroutput2002and2003. . . . . . . . . . . . . . . . . . . . . . . Alternator output: Voltage/max.current. . .. ... .. . .. . . . .. . ... .. .. . . . . .. .. Output ....... . .. . .............. . . . ........... . . ..... Electrolyte spec. gravity: Fully loaded battery. . . . . . . . . . . Tobechargedat. . ....... . .. . ..... . . . ......... . . ..... Thermostat..... . . . . . ............ . . . ..... . ..... . . . . . . . Beginstoopenat. . . . ............ .. . . . ....... .. . . . . ... Fullyopenat.. . . . . . . . ..... . ........ . . . .......... . . . . . . Cooling system With fresh-water cooling (2002, 2003) Startsopeningat . . . . . . . . . . ... . . . . . ..... .. . ..... . . . ...... Fullyopenat..... ............ .... . . . . ........ Fresh-watersystem, volume2002 . . . . . . . . . . . . . . . . . . . . . . . . . 2003_____ WEAR TOLERANCES Cylinders To be bored at 0,25 mm wear (0,00984 in.) Crankshaft Main-and big-end journals: Permittedout-of-round . .. . . .. . . .. . .. . . ... . ... .. .. ... . . Permittedtaper . . ... . . ... . . . . . ... . ... . .... .......... .. Max.axialclearanceoncrankshaft . .. . . .. .. ... .. .. ... . . 1) 2003T = 204-212 kp/cm2 (2900--3015 lbf/in2) 1,40 dm3 (1 .2 quarts) 2.75dm3 (2.42quarts) 4,10 dm3 (3.6 quarts) CD (DS) 15 W/40 0,8-1,5kp/cm2 (11.37-21.33lbft/in2) 3,5-4,0 kp/cm2 (49.78-56.89 lbft/in2) Gearwheel pump 0,025-0,065 (0,00098-0,00256 in .) 49 mm (1,92913 in.) 40mm(1,57480 in.) 180-190 kp/cm2 (2560-2702 lbft/in2)1) 150 221 B.T.D.C . 20+1C B.T .D-C 231B.T.D .C. 25+1.5mm3/stroke at405C(104F10.6F) and at 25 r/s (1500 rpm) pump revs 54 r/s (3250 rpm) 0,65-0,85kp/cm2 (9.20-12.10lbf/in2) 12V Max. 70Ah 0.8kW !1.1HP) 1.4 kW (1 .9 HP) 14W50 Amp 700 Watts 1,275--1,285 1,230 Wax thermostat 602`C (1404F) 75'C {165 F1 741C (1642F) 87C (189 F) 4.0 dm3 litre) (0 .88 Imp. gals) (1 .1 US gals) 5.5 dm3 (litre) 11 .2 Imp. gals) (1 .45 US gals) 0,06 mm (0,00236 in-) 0,05 mm (0,00197 in.) 0,40 mm (0,01575 in.) Camshaft Bearing journals, permitted out-of-round . . . . . . . . . . . . . . . Max. clearance between camshaft and bushings . . . . . . . . Valves Max. clearance between valve stem and valve guide . . . . The valve disc edge must be at least Tightening torques Mainbearingbolts,1sttightening.. . . . . . . . . . . . . . . . . . . . . . 2ndtightening . . .. .. .. . ... .... . . .. .. Big-endbearingbolts .... .. .. .. .. .. . . .. .. .. .. .. . . . .. .. Flywheelhousingbolts... .. .. . .. . .. . . .... .. .. .. . . .. .. . Flywheelbolts .. . .. . . . ... .. .. . . . . .. . . .. .. .. .. .. . . .. ... Cylinderheadbolts,1st tightening . . . . .. . . . . . . . . . . . . . . . 2ndtightening . . . . ... .. .. .. . . .. .. . Rockerarmbridge . . . . ... .. . . . .. . .. . . .... .. .. .. . . .. .. . Fuelinjectionpumps . . .. ... . . . .. . .. . . . ... .. . . . . .. .. .. . Pulley . ......... . ... . ..... .. . ... . . . . . ... . ... . ......... Injectors............ . ...... .. . . . . . . 0,03mm (0,00118 in.) 0,15mm (0,00590 in.) 0,15mm (0,00590 in.) 1,5mm (0,05906 in.) 20 2020Nm (2,0kpm)(14.7 ft.lbs .) 60Nm(6,0kpm)(44.2 ft.lbs.) 70Nm (7,0kpm){51.6 ft.lbs .) 25Nm(2,5kpm)(18.4 ft.lbs.) 65Nm(6,5kpm)(47.) ft.lbs.) 20Nm(2,0kpm)(14.7 ft.lbs.) 70 Nm (7,0 kpm) (51 .6 ft .lbs .) 25Nm (2,5kpm)(18.4ft.lbs .) 25Nm (2,5kpm)(18.4ft.lbs.) 40Nm{4,0kpm)(29.5 ft.lbs.) 20Nm (2,0kpm)(14.7 ft.lbs.)