Workshop Manual E

Group 20 Technical Data 2(0)

D16C-A MH, D16C-A MG

 Group 20: Technical Data

Marine Diesel Engines

D16C-A/B/C MH, D16C-A MG

Contents
Safety information ............................................................... 2
General information ................................................................ 5
Technical data:
General ............................................................................... 6
Short block .......................................................................... 7
Reciprocating components .................................................. 9
Valve mechanism ................................................................ 14
Timing gears ........................................................................ 18
Lubrication system .............................................................. 19
Fuel system ........................................................................ 22
Inlet and exhaust system .................................................... 24
Cooling system ................................................................... 26
Electrical system ................................................................. 28
Tightening torques .............................................................. 30
Tightening diagrams ............................................................ 33
Installing seals .................................................................... 45
References to Service Bulletins .......................................... 48
 Safety information

If work is done adjacent to a running engine, a

Introduction careless movement or a dropped tool can lead,
This workshop manual contains technical data, de- in the worst case, to personal injury.
scriptions and repair instructions for the Volvo Penta
Be careful with hot surfaces (exhaust pipes, tur-
products or product versions noted in the table of
bos, charge air pipes, starting heaters etc.) and
contents. Check that you have the correct Workshop
hot fluids in pipes and hoses on an engine
Manual for your engine.
which is running or which has just stopped. Re-
Read the available safety information and “General install all protective parts removed during ser-
information” and “Repair instructions” in the workshop vice operations before starting the engine.
manual carefully before you start to do any service
work.
Never start the engine with the valve cover re-
moved. Apart from the risk of spilling oil, there is
a risk of personal injury. The voltage supplied to
the unit injectors can be as high as 100 V.

Check that the warning or information labels on

the product are always clearly visible. Replace
labels which have been damaged or painted
over.

Important
In this book and on the product you will find the fol- Never start the engine without installing the air
lowing special warning symbols. cleaner filter. The rotating compressor turbine in
the turbocharger can cause severe injury. For-
WARNING! Possible danger of personal injury,
eign objects entering the intake ducts can also
extensive damage to property or serious me-
cause mechanical damage.
chanical malfunction if the instructions are not
followed.
IMPORTANT! Used to draw your attention to Never use start spray or similar products as a
something that can cause damage or malfunc- starting aid. They may cause an explosion in
tions on a product or damage to property. the inlet manifold. Danger of personal injury.

NOTE: Used to draw your attention to important infor-

mation that will facilitate the work or operation in
Avoid opening the coolant filling cap when the
progress.
engine is hot. Steam or hot coolant can spray
Below is a summary of the risks involved and safety out and the system pressure will be lost. Open
precautions you should always observe or carry out the filler cap slowly, and release the pressure in
when operating or servicing the engine. the cooling system if the filling cap or tap has to
be opened, or if a plug or coolant hose has to
Immobilize the engine by turning off the power be removed when the engine is hot. Steam or hot
supply to the engine at the main switch (switch- coolant might spray out in an unexpected direction.
es) and lock it (them) turned off before starting
work. Set up a warning notice by the helm sta-
tion. Hot oil can cause burns. Avoid skin contact with
hot oil. Ensure that the lubrication system is not
As a general rule all service operations must be under pressure before carrying out any work.
carried out with the engine stopped. Some Never start or operate the engine with the oil fill-
tasks, such as adjustments, need the engine to er cap removed, otherwise oil could be ejected.
be running, however. Approaching an engine
which is running is a safety risk. Remember that
loose clothing or long hair can fasten in rotating Stop the engine and close the sea cocks before
parts and cause serious personal injury. doing any work on the cooling system.

2
Group 20 Safety information

Only start the engine in a well- ventilated area. Used fuel and oil filters are polluting waste and
When operated in a confined space, exhaust must be handed to an approved waste manage-
fumes and crankcase gases must be ventilated ment facility for destruction, together with used
from the engine bay or workshop area. lubrication oil, contaminated fuel, paint residue,
solvents, degreasers and wash residue.
Always use protective glasses or goggles when
carrying out work where there is a risk of splin- Never expose a battery to naked flame
ters, grinding sparks, acid splashes or where or electrical sparks. Never smoke close to the
other chemicals are used. Your eyes are ex- batteries. The batteries generate hydrogen gas
tremely sensitive, injury could cause blindness! when charged, which forms an explosive gas
when mixed with air. This gas is easily ignited
Avoid getting oil on your skin! Repeated exposure and highly volatile. A spark, which can be
to oil or exposure over a long period can result in caused by incorrect battery connection, can
the skin becoming dry. Irritation, dryness and ec- cause a single spark which is sufficient to cause
zema and other skin problems can then occur. an explosion with resulting damage. Do not
Used oil is more dangerous than fresh oil from a move the connections when you attempt to start
health aspect. Use protective gloves and avoid oil- the engine (risk of arcing), and do not stand and
soaked clothes and rags. Wash regularly, espe- lean over one of the batteries.
cially before eating. There are special skin creams
which counteract drying out of the skin and make Always ensure that the Plus (positive) and Mi-
it easier to clean off dirt after work is completed. nus (negative) battery cables are correctly in-
stalled on the corresponding terminal posts on
the batteries. Incorrect installation can result in
Most chemicals intended for the product (e.g.
serious damage to the electrical equipment. Re-
engine and transmission oils, glycol, petrol
fer to the wiring diagram.
(gasoline) and diesel oil) or chemicals for work-
shop use (e.g. degreasers, paints and solvents)
Always use protective goggles when charging and
are hazardous. Read the instructions on the
handling the batteries. Battery electrolyte contains
product packaging with care! Always follow the
sulfuric acid which is highly corrosive. Should the
safety precautions for the product (for example
battery electrolyte come into contact with unpro-
use of protective mask, glasses, gloves etc.).
tected skin wash off immediately using plenty of
Make sure that other personnel are not inad-
water and soap. If you get battery acid in your
vertently exposed to hazardous chemicals, for
eyes, flush at once with a generous amount of
example in the air. Ensure good ventilation in
water, and get medical assistance at once.
the work place. Follow the instructions provided
when disposing of used or leftover chemicals.
Turn the engine off and turn off the power at the
main switch(es) before carrying out work on the
Exercise extreme care when leak detecting on electrical system.
the fuel system and testing the fuel injector noz-
zles. Use eye protection. The jet from a fuel Clutch adjustments must be carried out with the
nozzle has very high pressure and great pene- engine stopped.
tration power. Fuel can force its way deep into
body tissue and cause severe injury. Danger of The existing lugs on the engine/reversing gear
blood poisoning (septicemia). should be used for lifting the assembly.
Always check that the lifting equipment used is
All fuels, and many chemicals, are flammable. in good condition and has the load capacity to
Do not allow naked flame or sparks in the vicini- lift the engine (engine weight including gearbox,
ty. Petrol (gasoline), some thinners and hydro- if fitted, and any extra equipment).
gen gas from batteries are extremely flammable Use an adjustable lifting beam or lifting beam
and explosive when mixed with air in the correct specifically for the engine to raise the engine to
ratio. No Smoking! Ensure that the work area is ensure safe handling and to avoid damaging
well ventilated and take the necessary safety engine parts installed on the top of the engine.
precautions before starting welding or grinding All chains and cables should run parallel to
work. Always ensure that there are fire extin- each other and as perpendicular as possible in
guishers at hand when work is being carried relation to the top of the engine.
out. If other equipment connected to the engine has
altered its center of gravity, special lifting devis-
Make sure that oil and fuel soaked rags, and es may be needed to obtain the correct balance
used fuel and oil filters are stored in a safe and safe handling.
place. Rags soaked in oil can spontaneously ig- Never carry out work on an engine suspended
nite under certain circumstances. on a hoist.

3
Safety information Group 20

Never work alone when removing heavy engine Never use a power washer for engine cleaning.
components, even when using lifting devices such Remember the following when washing other
as locking tackle lifts. When using a lifting device components with a power washer: Never aim
two people are usually required to do the work, the water jet at seals, rubber hoses or electrical
one to take care of the lifting device and another components.
to ensure that components are lifted clear and not
damaged during the lifting operations.
When you work aboard a boat, always make
sure that there is enough space for disassembly Only use the fuels recommended by Volvo Penta.
where you are working, with no risk of personal Refer to the Instruction Book. Use of fuels that are
injury or damage to materials. of a lower quality can damage the engine. Poor
fuel can also lead to higher service costs.
Components in the electrical and fuel systems
on Volvo Penta products have been designed
to minimize the risks of explosion and fire. The
engine must not be run in areas where there
are explosive materials.

© 2007 AB VOLVO PENTA

We reserve the right to make modifications without prior notice.
Printed on environmentally compatible paper.

4
 General information

About this Workshop Manual Certified engines

This workshop manual contains technical data for When performing service and repair on emission
standard versions of engines D16C-A/B/C MH and D16C-A certified engines, it is important to be aware of
MG. the following:
The engine designation and number are noted on the Certification means that an engine type has been
number plate and engine decal. The engine designa- checked and approved by the relevant authority. The
tion and number must always be given in all corre- engine manufacturer guarantees that all engines made
spondence about an engine. of the same type are equivalent to the certified engine.
The Workshop Manual is produced primarily for the This places special demands on service and re-
use of Volvo Penta workshops and service techni- pair work, as follows:
cians. This assumes that people who use the Manual
● Care and Service intervals recommended by
have basic knowledge of marine drive systems and
Volvo Penta must be followed.
can perform tasks of a mechanic a l /electrical nature
associated with the trade. ● Only spare parts approved by Volvo Penta may
Volvo Penta constantly improves its products, so we be used.
reserve the right to make modifications without prior ● Service to injection pumps, pump settings and in-
notification. All information in this manual is based on jectors must always be performed by an autho-
product data which was available up to the date on rized Volvo Penta workshop.
which the manual was printed. Any material changes
● The engine must not be converted or modified,
introduced into the product or service methods after
except for the accessories and service kits that
this date are notified by means of Service Bulletins.
Volvo Penta has approved for the engine.
● No installation changes to the exhaust pipe and
engine air inlet ducts may be made.
● Any anti-tamper seals on the engine may not be
broken by unauthorized persons.

The general advice in the instruction book about op-

eration, care and maintenance, applies.
Spare parts
Spare parts for electrical- and fuel systems are sub- IMPORTANT! Neglected or poorly performed
ject to various national safety requirements such as carel /service, as well as use of non-original
the US Coast Guard Safety Regulations. Volvo Penta spare parts, entails that AB Volvo Penta can no
Original Spare Parts meet these specifications. No longer guarantee that the engine conforms to
damage whatever, occasioned by use of non-original the certified model.
Volvo Penta spares for the product in question, will be Damages and/or costs accrued due to this will
compensated by the warranty offered by Volvo Penta. not be compensated for by Volvo Penta.

5
 Technical Data

General
Type designation ................................................ D16C-A/B/C MH D16C-A MG
No. of cylinders ..................................................... 6
Bore ...................................................................... 144 mm (5.669")
Stroke ................................................................... 165 mm (6.496")
Swept volume, total .............................................. 16.12 dm3 (983.9 in3)
Power ................................................................... Please refer to the sales literature
No. of valves per cylinder ..................................... 4
Direction of rotation (seen from front) ................... Clockwise
Compression ratio ................................................ 17.5:1
Crankcase pressure, normal value,
irrespective of engine speed ................................. max. 5 kPa (0.73 psi)
Firing sequence (cyl. No. 6 closest to flywheel) .... 1–5–3–6–2–4
Low idle (propulsion engine) ................................. 600 ±10 rpm –
adjustable within the range ................................ 550 –600 rpm –
D16C-500/550/600 (rating 1):
full throttle range ................................................ 1780 –1850 rpm –
D16C-650 (rating 1):
full throttle range ................................................ 1780 –1880 rpm –
D16C-750 (rating 2):
full throttle range ................................................ 1880 –1950 rpm –
High idle:
D16C-A MG .......................................................... – 1500 or 1800 rpm
Weight, engine with heat exchanger, without
reverser, (dry) approx. .......................................... 1750 kg (3858 lbs)

6
Group 20 Technical data

Short block
Cylinder head
D16C-A/B/C MH D16C-A MG
Type ..................................................................... One cylinder head for all cylinders
(overhead camshaft)
Length .................................................................. 1194 mm (47.008")
Width .................................................................... 438 mm (17.244")
Height ................................................................... 135 mm (5.315")
Max. flatness error (base plane) ........................... 0.1 mm (0.0039")

Bolts, cylinder head

Quantity ................................................................ 38
Thread dimension ................................................. M18
Length .................................................................. 188 mm (7.402")

Cylinder block
Length .................................................................. 1156 mm (45.512")
Height, upper block plane–crankshaft center (A) . 453 mm (17.835")
Height, lower block plane–crankshaft center (B) .. 120 mm (4.724")

7
Technical data Group 20

Cylinder liners
D16C-A/B/C MH D16C-A MG
Type ..................................................................... Wet, replaceable
Height, total .......................................................... 288 mm (11.339")
Cylinder diameter (oversize not available) ............ 144 mm (5.669")
Sealing surface height above block plane ............. 0.15 –0.21 mm
(0.0059–0.0083")
Number of O-rings, upper liner seal ...................... 1
Number of O-rings, lower liner seal ...................... 2

Pistons
Piston mounted in engine, height above
cylinder block plane .............................................. 0.15 –0.65 mm
(0.0059–0.0256")
No. of ring grooves ............................................... 3
Front marking ....................................................... Arrow towards front

Gudgeon pins
Diameter ............................................................... 63 mm (2.4803")

Combustion chamber (piston ball)

Diameter (A) ......................................................... 98 mm (3.8583")
Depth (B) .............................................................. 19.35 mm (0.7618")

8
Group 20 Technical data

Piston rings
D16C-A/B/C MH D16C-A MG
Compression rings
Number ................................................................. 2
Piston ring clearance in groove:
upper compression ring .................................... Trapezoidal profile
lower compression ring, height .......................... 0.07 mm (0.0028")
max. play (wear allowance) ............................ 0.1 mm (0.0039")
Piston ring gap, measured at ring opening:
upper compression ring .................................... 0.62 mm (0.0244")
max. ring gap (wear allowance) ...................... 0.85 mm (0.0335")
lower compression ring ..................................... 1.1 mm (0.0433")
max. ring gap (wear allowance) ...................... 1.35 mm (0.0531")

Oil scraper ring

Number ................................................................. 1
Width, incl. spring ................................................. 4.55 mm (0.1791")
Piston ring clearance, vertical ............................... 0.04 mm (0.0016")
max. play ........................................................... 0.1 mm (0.0039")
Piston ring gap, measured at ring opening ........... 0.55 mm (0.0217")
max. ring gap ..................................................... 0.9 mm (0.0354")

Reciprocating components
Crankshaft
Length .................................................................. 1256 mm (49.449")
Crankshaft end float 1) ........................................... 0.15 mm (0.0059")
Main bearings radial clearance 1) .......................... 0.07– 0.14 mm
(0.0028–0.0055")
Max. permitted ovality on main- and big-end
bearing journals .................................................... 0.01 mm (0.0004")
Max. permitted taper of main- and big-end
bearing journals .................................................... 0.02 mm (0.0008")
Max. runout on center bearing .............................. 0.15 mm (0.0059")
1)
Note. Values apply to oiled components.

9
Technical data Group 20

Main bearing journals

D16C-A/B/C MH D16C-A MG
NOTE: Only check values, not for machining.
Diameter (Ø) standard .......................................... 118.0 mm (4.6457")
Undersize dimension:
0.25 mm (0.0098") ............................................ 117.75 mm (4.6358")
0.50 mm (0.0197") ............................................ 117.50 mm (4.6260")
1.00 mm (0.0394") ............................................ 117.00 mm (4.6063")
Surface finish, main bearing journal ...................... Ra 0.25
Surface finish, radius ............................................ Ra 0.4
Width thrust bearing journal (A) standard ............. 49.0 mm (1.9291")
Oversize dimension:
0.2 mm (0.0079") (thrust bearing 0.1) ............... 49.2 mm (1.9370")
0.4 mm (0.0157") (thrust bearing 0.2) ............... 49.4 mm (1.9449")
0.6 mm (0.0236") (thrust bearing 0.3) ............... 49.6 mm (1.9528")
Web flank radius (R) ............................................. 4.5 mm (0.1772")

10
Group 20 Technical data

Thrust washers (thrust bearing)

D16C-A/B/C MH D16C-A MG
Width (B) standard ............................................... 3.18 mm (0.1252")
Oversize dimension:
0.1 mm (0.0039") .............................................. 3.28 mm (0.1291")
0.2 mm (0.0079") .............................................. 3.38 mm (0.1331")
0.3 mm (0.0118") .............................................. 3.48 mm (0.1370")

Main bearing shells

Type ..................................................................... Replaceable
Outer diameter (C) ................................................ 123.12 mm (4.8472")
Thickness (D) standard ........................................ 2.51 mm (0.0988")
Oversize dimension:
0.25 mm (0.0098") ............................................ 2.64 mm (0.1039")
0.50 mm (0.0197") ............................................ 2.76 mm (0.1087")
1.00 mm (0.0394") ............................................ 3.01 mm (0.1185")

11
Technical data Group 20

Big end journals

D16C-A/B/C MH D16C-A MG
NOTE: Only check values, not for machining.
Diameter (Ø) standard .......................................... 112.0 mm (4.4094")
Undersize dimension:
0.25 mm (0.0098") ............................................ 111.75 mm (4.3996")
0.50 mm (0.0197") ............................................ 111.50 mm (4.3898")
1.00 mm (0.0394") ............................................ 111.00 mm (4.3701")
Surface finish, big end bearing journal .................. Ra 0.25
Surface finish, radius ............................................ Ra 0.4
Width, journal (A) .................................................. 60 mm (2.2322")
Web flank radius (R) ............................................. 4.5 mm (0.1772")

Big end journal shells

Thickness (B) standard ........................................ 2.35 mm (0.0925")
Oversize dimension:
0.25 mm (0.0098") ............................................ 2.48 mm (0.0976")
0.50 mm (0.0197") ............................................ 2.60 mm (0.1024")
1.00 mm (0.0394") ............................................ 2.85 mm (0.1122")
Diameter, bearing shell seat (C) ........................... 116.8 mm (4.5984")

12
Group 20 Technical data

Con rods
D16C-A/B/C MH D16C-A MG
Length center – center (D) .................................... 280 mm (11.0236")
Marking:
Conrods and bearing caps are marked with
a three-figure number (see figure).
“FRONT” on rod turned ..................................... Forwards
Big end bearing cap internal
diameter (E) .......................................................... 63.036–63.046 mm
(2.4817– 2.4821")
End float, con rod – crankshaft, max. 1) ................. 0.35 mm (0.0138")
Big end bearings, radial clearance, max. 1) ............ 0.10 mm (0.0039")
Straightness, max. deviation per 100 mm
(3.937") measured length ..................................... 0.06 mm (0.0024")
Twist, max. deviation per 100 mm (3.937")
measured length ................................................... 0.15 mm (0.0059")
1)
Values apply to oiled components.

Flywheel, installed
Max permitted runout on measured radius 150 mm
(5.905") ................................................................. 0.1 mm (0.0039")
No. of teeth on starter gear ring ............................ 153
Sensor grooves on flywheel .................................. 3 × 18

Flywheel housing, installed

Max. permitted runout for contact surface
against timing gear ............................................... 0.1 mm (0.0039")
Max. permitted radial runout for alignment against
timing gear ............................................................ 0.05 mm (0.0020")

13
Technical data Group 20

Valve mechanism
Camshaft
D16C-A/B/C MH D16C-A MG
Checking camshaft setting:
The check shall be performed with a cold en-
gine and valve clearance = 0.
Inlet valve for no.1 cylinder shall, at
flywheel position 6° a. t. d. c. have opened ........... 1.4 ±0.3 mm
(0.0551 ±0.0118")
Note. During this check, the timing gear
must be turned in the correct direction
(clockwise seen from the front) to take up all
gear backlash.
NOTE: Do not forget to adjust the valve clear-
ance back to the correct value after the check.

Drive ..................................................................... Gear wheel

No of bearings ...................................................... 7
NOTE: Only check values, not for machining.
Diameter, bearing journals, standard .................... 69.97–70.00 mm
(2.7547– 2.7559")
Diameter, bearing journals, undersize dimension:
0.25 mm (0.0098") ............................................ 69.72–69.78 mm
(2.7449–2.7472")
0.50 mm (0.0197") ............................................ 69.47–69.53 mm
(2.7350– 2.7374")
0.75 mm (0.0295") ............................................ 69.22– 69.28 mm
(2.7252– 2.7276")
Max permissible ovality (with new bearings) ......... 0.05 mm (0.0020")
Bearing, max. permissible wear on diameter ........ 0.05 mm (0.0020")
End float ............................................................... max. 0.35 mm (0.0138")
Valve lift:
Intake ................................................................ 13.7 mm (0.5394")
Exhaust ............................................................. 14.5 mm (0.5709")
Cam lobes, permitted (wear between base
circle and max. lift):
Inlet ................................................................... max. 0.1 mm (0.0039")
Exhaust ............................................................. max. 0.1 mm (0.0039")
Unit injector ....................................................... max. 0.1 mm (0.0039")
Unit injector, stroke ............................................... 18 mm (0.7087")

Camshaft bearings
Camshaft bearing thickness, standard .................. 1.92 mm (0.0756")
Oversize dimension:
0.25 mm (0.0098") ............................................ 2.05 mm (0.0807")
0.50 mm (0.0197") ............................................ 2.17 mm (0.0854")
0.75 mm (0.0295") ............................................ 2.30 mm (0.0906")
Diameter, camshaft bearing seat:
Bearings 1 to 7 .................................................. 69.97–70.00 mm
(2.7547–2.7559")

14
Group 20 Technical data

Valves
D16C-A/B/C MH D16C-A MG
Head diameter:
Intake ................................................................ 49 mm (1.9291")
Exhaust ............................................................. 46 mm (1.8110")
Stem diameter:
Inlet ................................................................... 10 mm (0.3937")
Exhaust ............................................................. 10 mm (0.3937")
Valve seat angle:
Intake ................................................................ 24.5°
Exhaust ............................................................. 44.5°
Seat angle in cylinder head:
Intake ................................................................ 25°
Exhaust ............................................................. 45°

INLET EXHAUST

Valve clearance, cold engine, setting value,

Intake ................................................................ 0.3 mm (0.0118")
Exhaust ............................................................. 0.6 mm (0.0236")
Valve clearance, cold engine, check value,
Intake ................................................................ 0.25–0.35 mm
(0.0098– 0.0138")
Exhaust ............................................................. 0.55–0.65 mm
(0.0217– 0.0256")

15
Technical data Group 20

Valve seats
D16C-A/B/C MH D16C-A MG
Outer diameter (dimension A), standard:
Intake ................................................................ 52 mm (2.0472")
Exhaust ............................................................. 49 mm (1.9291")
Outer diameter (dimension A), oversize:
Intake ................................................................ 52.2 mm (2.0551")
Exhaust ............................................................. 49.2 mm (1.9370")
Height (dimension B):
Intake ................................................................ 7.6 mm (0.2992")
Exhaust ............................................................. 7.8 mm (0.3071")
Distance from valve head to cylinder head
plane (check measurement):
Inlet ................................................................... 0.9 –1.4 mm
(0.0354– 0.0551")
wear tolerance ................................................ max. 1.5 mm (0.0591")
Exhaust ............................................................. 1.4–1.9 mm
(0.0551– 0.0748")
wear tolerance ................................................ max. 2.0 mm (0.0787")
If the distance is greater, the valve seat must be
replaced.
NOTE! When the valve seats are changed, the
valves must be changed at the same time.
As spare parts, the valve seats are fully machined
and should not need additional grinding.

Valve seat bed

Diameter (dimension C) standard:
Intake ................................................................ 52.0 mm (2.0472")
Exhaust ............................................................. 49.0 mm (1.9291")
Diameter (dimension C) oversize:
Intake ................................................................ 52.2 mm (2.0551")
Exhaust ............................................................. 49.2 mm (1.9370")
Depth (dimension D):
Intake ................................................................ 11.7 ±0.13 mm (0.4606 ±0.0051")
Exhaust ............................................................. 11.7 ±0.13 mm (0.4606 ±0.0051")
Seat bottom radius (dimension R):
Intake ................................................................ max. 0.8 mm (0.0315")
Exhaust ............................................................. max. 0.8 mm (0.0315")

16
Group 20 Technical data

Valve guides
D16C-A/B/C MH D16C-A MG
Length:
Intake ................................................................ 83.5 mm (3.287")
Exhaust ............................................................. 83.5 mm (3.287")
Inner diameter:
Intake ................................................................ 10 mm (0.3937")
Exhaust ............................................................. 10 mm (0.3937")
Height above cylinder head spring plane:
Intake ................................................................ 24.5 ±0.2 mm (0.9646 ±0.0079")
Exhaust ............................................................. 22.5 ±0.2 mm (0.8858 ±0.0079")
Clearance, valve stem – guide:
Intake ................................................................ 0.025 –0.054 mm
(0.0010–0.0021")
Wear tolerance ................................................ max. 0.9 mm 1) (0.0354") 1)
Exhaust ............................................................. 0.058 – 0.087 mm
(0.0023–0.0034")
Wear tolerance ................................................ max. 0.9 mm 1) (0.0354") 1)
1)
Max. permissible clearance between valve stem and
valve guide: (according to method in “Workshop manu-
al group 21–26, D16C; Valve guides, inspection”).

Valve springs
Inlet (single springs)
Unloaded length ................................................... 67.5 mm (2.6575")
with 522 N (117.4 lbf) load ................................. 57.0 mm (2.2441")
with 1205 N (270.9 lbf) load ............................... 43.3 mm (1.7047")
coilbound length max. ........................................ 40.3 mm (1.5866")

Exhaust (double springs)

Outer valve springs:
Unloaded length ................................................... 69.3 mm (2.7283")
with 930 N (209.1 lbf) load ................................. 54.0 mm (2.1260")
with 1813 N (407.6 lbf) load ............................... 39.5 mm (1.5551")
coilbound length max. ........................................ 37.0 mm (1.4567")
Inner valve spring:
Unloaded length ................................................... 67.0 mm (2.6378")
with 465 N (104.5 lbf) load ................................. 51.0 mm (2.0079")
with 887 N (199.4 lbf) load ................................. 36.5 mm (1.4370")
coilbound length max. ........................................ 34.0 mm (1.3386")

Rocker arms
Bearing clearance ................................................. max. 0.1 mm (0.0039")
Rocker arm roller, clearance ................................. max. 0.1 mm (0.0039")

17
Technical data Group 20

Timing gears
D16C-A MH D16C-A MG

1. Gear, camshaft ................................................ 84 teeth

2. Idler wheel, adjustable ..................................... 85 teeth
3. Idler gear, bull gear:
outer ............................................................. 84 teeth
inner ............................................................. 56 teeth
4. Crankshaft gear ............................................... 63 teeth
5. Gear, lube oil pump ......................................... 37 teeth
6. Gear, fuel pump ............................................... 36 teeth
7. Idler wheel, fuel pump ...................................... 29 teeth
8. Gear, sea water pump ..................................... 48 teeth
Backlash, adjustable idler to drive gear
camshaft ............................................................... 0.05 –0.15 mm* (0.0020–0.0059")*
Backlash, oil pump ............................................... 0.05 –0.40 mm (0.0020–0.0157")
Backlash, other ..................................................... 0.05 –0.17 mm (0.0020–0.0067")
Radial clearance for idler wheel ............................ max. 0.05 mm (0.0020")

* Note. Use a 0.10 mm feeler gauge when adjusting.

18
Group 20 Technical data

Lubrication system
D16C-A/B/C MH, D16C-A MG:
Oil grade 1) Fuel sulfur content by weight
up to 0.5% 0.5 – 1.0% more than 1.0% 2)
Oil change interval: Reached first in operation
VDS-3 500 hrs. or 12 months. 200 hrs. or 12 months. 100 hrs. or 12 months.
⎫
VDS-2 and ACEA E7 3), 4)
VDS-2 and Global DHD-1 3) ⎬ 400 hrs. or 12 months. 200 hrs. or 12 months. 100 hrs. or 12 months.
VDS-2 and API CH-4 3)
VDS-2 and API CH-4 3) ⎭

⎫
VDS and ACEA E3 3), 5) ⎬ 300 hrs. or 12 months. 150 hrs. or 12 months. 75 hrs. or 12 months.
VDS and API CG-4 3), 6) ⎭

⎫
ACEA: E3 5) ⎬ 200 hrs. or 12 months. 100 hrs. or 12 months. 50 hrs. or 12 months.
API: CG-4 6) ⎭

NOTE: Mineral based oil, as well as fully or semi-synthetic, can be used on condition that it complies with the
quality requirements above.
1)
Lowest recommended oil grade. A lubricating oil with a higher grade can always be used.
2)
With sulfur content >1.0 weight% oils with TBN >15 shall be used.
3)
The lubricating oil shall fulfil both requirements.
4)
ECEA E7 has replaced ACEA E5. ACEA E5 can however be used if oil of this grade is available.
5)
ACEA E3 can be replaced with ACEA E4, E5 or E7.
6)
API CG-4 can be replaced with API CI-4.

VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européens d’Automobiles
Global DHD = Global Diesel Heavy Duty
API = American Petroleum Institute
TBN = Total Base Number

−30 −20 −10 ±0 +10 20 30 40 o

C
Viscosity −15oC SAE 15W/40
All engines: −25oC SAE 10W/30
Select viscosity from adjacent table. ✱ SAE 5W/30
(Temperature values apply to stable outside air tem- −10oC SAE 20W/30
perature).
±0oC SAE 30
* SAE 5W/ 30 applies to synthetic or semi-synthetic oils. +10oC SAE 40
o
−22 −4 +14 32 50 68 86 104 F

19
Technical data Group 20

D16C-A/B/C MH D16C-A MG
Lube oil volume
Change volume, including changing three filters,
without regard to engine inclination .................... 55 liters (14.5 US gals)
volume difference min.– max. ............................ 10 liters (2.6 US gals)

Lube oil pressure

Operating speed (1100 rpm or higher) .................. 250 – 650 kPa (36.3–94.3 psi)
Idle (propulsion engine) ........................................ min. 160 kPa (23.2 psi)

Oil pressure, piston cooling

Operating speed (1100 rpm or higher) .................. min. 200 kPa (29.0 psi)

Oil filter
Full-flow filter, number .......................................... 2
(tightened ¾ turn after contact)
By-pass filter, number ........................................... 1
(tightened ¾–1 turn after contact)

Lube oil pump

Type ..................................................................... Gear driven

20
Group 20 Technical data

Oil valves
D16C-A/B/C MH D16C-A MG

2
1

7
5
6

4 3

1. By-pass valve (by-pass filter)

Opening pressure ................................................. 110 kPa (16.0 psi)
Spring, free length ................................................ 68.8 mm (2.709")
loaded with 13–15 N (2.9–3.4 lbf) ..................... 40 mm (1.575")

2. By-pass valve (full-flow oil filter)

Opening pressure ................................................. 110 kPa (16.0 psi)
Spring, free length ................................................ 68.8 mm (2.709")
loaded with 13–15 N (2.9–3.4 lbf) ..................... 40 mm (1.575")

3. By-pass valve, oil cooler

Opening pressure ................................................. 860 kPa (124.7 psi)
Marking ................................................................. 124

4. Opening valve, piston cooling

Opening pressure ................................................. 300 kPa (43.5 psi)
Spring, free length ................................................ 122 mm (4.803")
Loaded with 94 ±10 N (21.1 ±2.2 lbf) ................ 62 mm (2.441")

5. Control valve, piston cooling

Pressure ............................................................... 210 kPa (30.5 psi)
Spring, free length ................................................ 122 mm (4.803")
Loaded with 94 ±10 N (21.1 ±2.2 lbf) ................ 62 mm (2.441")

6. Reduction valve, lube oil pressure

Opening pressure ................................................. 480 kPa (69.6 psi)
Marking ................................................................. Blue

7. Safety valve, lube oil pressure

Opening pressure ................................................. 900 kPa (130.5 psi)
Marking ................................................................. Violet

21
Technical data Group 20

Fuel system
D16C-A/B/C MH D16C-A MG

Fuel specification
The fuel must comply with national and international standards for commercially supplied fuels, such as:
EN 590 (with nationally adapted environmental and cold weather requirements)
ASTM D 975 No 1-D and 2-D
JIS KK 2204
Sulfur content: Complying with legal requirements in each country.
Low density fuel (city diesel in Sweden and Finland) can cause a loss of up to 5% of power and an increase in fuel
consumption of about 2–3%.

Injection sequence ................................................ 1–5–3–6–2–4

Feed pump
Feed pressure after fuel filter at:
600 rpm ............................................................. min. 100 kPa (14.5 psi)
1200 rpm ........................................................... min. 280 kPa (40.6 psi)
full load .............................................................. min. 280 kPa (40.6 psi)

By-pass valve
Opening pressure ................................................. 300–550 kPa (43.5–79.8 psi)

22
Group 20 Technical data

Unit injectors
D16C-A/B/C MH, D16C-A MG

Pre-load ................................................................ 3 –4 spanner flats

(0.75 ±0.1 mm / 0.0295 ±0.0039")
Adjust the unit injector rocker arm to zero clear-
ance on the camshaft. Then tighten the adjusting
screw an additional 3 –4 spanner flats (180 –
240°).

Position of the unit injectors trim code* .................

* Note. The trim code defines each unit injector’s toler-
ances for the engine control unit.
In the illustration the trim code is “5D008A”.

23
Technical data Group 20

Inlet and exhaust system

Turbocharger
D16C-A/B/C MH D16C-A MG
Make and type ...................................................... Borg Warner S500C
Lubrication system ................................................ Pressure lubrication
Max. permissible end float .................................... 0.12 mm (0.0047")
Max. permissible run out (compressor side) ......... 0.74 mm (0.0291")
Max. permissible run out (turbine side) ................. 0.56 mm (0.0220")

Exhaust back pressure

Max. permitted back pressure in exhaust pipe at max.
power (max. operating rpm) .................................. 15 kPa (2.18 psi /
1530 mm water column /
60.236" water column)

Pressure drop indicator, air filter

Level for indication (low pressure) ........................ 508 mm water column
(20.000" water column)

24
Group 20 Technical data

Charge air pressure and exhaust temperatures

Charge air pressure, (measured in inlet manifold) at 100% load and full throttle.
Exhaust back pressure 10 kPa (1.45 psi). If full power cannot be developed, the pressure will be considerably
lower.
Charge air pressure in the following table has a tolerance of ±15 kPa (±2.1 psi).
(100 kPa = 14.5 psi).

The exhaust temperatures are measured at duty rating. Temperature of inlet air +27°C (80.6°F) and
exhaust back pressure 10 kPa (1.45 psi / 1019 mm water column / 40.118" water column).

D16C-A/B/C MH Charge air pressure Exhaust temperature

Power – Rating 1 (500)
1800 rpm .............................................................. 160 kPa (23.2 psi) 400°C (752°F)

Power – Rating 1 (550)

1800 rpm .............................................................. 180 kPa (26.1 psi) 400°C (752°F)

Power – Rating 1 (600)

1800 rpm .............................................................. 200 kPa (29.0 psi) 410°C (770°F)

Power – Rating 1 (650)

1800 rpm .............................................................. 210 kPa (30.5 psi) 420°C (788°F)

Power – Rating 2 (750)

1900 rpm .............................................................. 220 kPa (31.9 psi) 465°C (869°F)

D16C-A MG (HE/KC)*
Power – ISO Standard Power
1500 rpm .............................................................. 215 kPa (31.2 psi) 465°C (869°F)
1800 rpm .............................................................. 230 kPa (33.4 psi) 435°C (815°F)

Power – Overload Power**

1500 rpm .............................................................. – 475°C (887°F)
1800 rpm .............................................................. – 455°C (851°F)

* HE = Engine equipped with heat exchanger.

KC = Keel-cooled engine.
** 110% of ISO Standard Power.

25
Technical data Group 20

Cooling system
D16C-A/B/C MH D16C-A MG
General
Type ..................................................................... Pressurized, sealed
Pressure cap opens at .......................................... 75 kPa (10.9 psi)
Coolant volume, approx. ....................................... 56 liters* (14.8 US gals)*
* Note. Incl. heat exchanger (HE).

Thermostat
Type ..................................................................... Piston thermostat
Quantity ................................................................ 1
The thermostat starts to open at ........................... 84 – 88°C (183– 190°F)
fully open at ..................................... 94 – 98°C (201– 208°F)

Coolant filter
Number ................................................................. 1

Coolant pump
Type ..................................................................... Belt driven centrifugal pump
Pressure after coolant pump:
1200 rpm ........................................................... 150 kPa (21.8 psi) –
1500 rpm ........................................................... 220 kPa (31.9 psi) 220 kPa (31.9 psi)
1800 rpm ........................................................... 290 kPa (42.1 psi) 290 kPa (42.1 psi)
1900 rpm ........................................................... 330 kPa (47.9 psi) –

26
Group 20 Technical data

Coolant
D16C-A/B/C MH D16C-A MG
“Volvo Penta Coolant, Ready Mixed” .................... Ready-mixed coolant
Consists of ......................................................... 40% ethylene glycol with corrosion inhibiting
additives and 60% water
Protects against freezing down to approx. ......... –28°C (–18°F)
Alternative:
“Volvo Penta Coolant” .......................................... Concentrated coolant
Consists of ......................................................... Ethylene glycol + anti-corrosion additives
Color .................................................................. Blue-green

Mixture ratio ....................................................... Concentrated Mix with Provides frost

coolant water* protection down
* IMPORTANT! The concentrated coolant must be to approx.
mixed with clean water. Use distilled – deionized
water. The water must fulfill the demands specified 40% 60% –28°C (–18°F)
in ASTM D4985 (see under heading “Water quality” 50% 50% –40°C (–40°F)
below).
“Volvo Penta Coolant” (ethylene glycol) must not be 60%** 40% –54°C (–65°F)
mixed with other types of glycol.
IMPORTANT! A coolant mixture with at least 40%
concentrate (“Volvo Penta Coolant”) shall be used
all year round, even if there is no risk for freezing.
This is to ensure that the engine is adequately pro-
tected against corrosion and cavitation damage.
** Never mix more than 60% concentrate (“Volvo Penta
Coolant”) in the coolant. A higher concentration causes
reduced cooling effect with the risk of overheating and
gives less frost protection.

Water quality
ASTM D4985:
Total solid particles ............................................ < 340 ppm
Total hardness ................................................... < 9.5° dH
Chloride ............................................................. < 40 ppm
Sulfate ............................................................... < 100 ppm
pH value ............................................................ 5.5 – 9
Silica (acc. to ASTM D859) ............................... < 20 mg SiO2/l
Iron (acc. to ASTM D1068) ................................ < 0.10 ppm
Manganese (acc. to ASTM D858) ..................... < 0.05 ppm
Conductivity (acc. to ASTM D1125) ................... < 500 µS/cm
Organic content, CODMn (acc. ISO8467) ........... < 15 mg KMnO4/l

Sea water pump

Type ..................................................................... Rubber impeller
Pressure after sea water pump:
1200 rpm ........................................................... 50 kPa (7.3 psi) –
1500 rpm ........................................................... 75 kPa (10.9 psi) 75 kPa (10.9 psi)
1800 rpm ........................................................... 100 kPa (14.5 psi) 100 kPa (14.5 psi)
1900 rpm ........................................................... 105 kPa (15.2 psi) –

27
Technical data Group 20

Electrical system
D16C-A/B/C MH D16C-A MG
System voltage ..................................................... 24 V
Battery capacity .................................................... 2 series-connected 12 V, max. 220 Ah
Battery electrolyte density at +25°C (77°F):
fully charged battery ........................................... 1.28 g/cm3 (1.24 g/cm3)*
0.0462 lb/in3 (0.0448 lb/in3)*
re-charge battery at ............................................ 1.24 g/cm3 (1.20 g/cm3)*
0.0448 lb/in3 (0.0434 lb/in3)*
* Note. Applies to batteries with tropical acid.

Alternator
Make .................................................................... Bosch
Voltage/max. current capacity .............................. 28 V / 80 A
Output, approx. ..................................................... 2240 W

Starter motor
Make .................................................................... Mitsubishi 24 V / 7 kW
Brush length ......................................................... min. 11 mm (0.433")

Charge air pressure sensor

Check value .......................................................... 1.05–1.30 V at 100 kPa* (14.5 psi)*
* Note. Normal atmospheric pressure at sea level.

Speed sensor
Camshaft (timing gear cover):
distance to toothed wheel, vibration damper ...... 1.1 ±0.4 mm (0.0433 ±0.0157")
Flywheel (flywheel housing):
distance to flywheel ........................................... 1.1 ±0.4 mm (0.0433 ±0.0157")

28
Group 20 Technical data

Charge air temperature sensor Tempera- Impedance Impedance Impedance

ture (°C / °F) R min. (Ω) R nom. (Ω) R max. (Ω)
–40 / –40 45301.0 48153.0 51006.0
–30 / –22 25350.0 26854.0 28359.0
–20 / –4 14785.0 15614.0 16443.0
–10 / 14 8951.0 9426.0 9901.0
±0 / 32 5605.0 5887.0 6168.0
10 / 50 3618.7 3791.1 3963.5
20 / 68 2401.9 2510.6 2619.3
30 / 86 1644.7 1715.4 1786.2
40 / 104 1152.4 1199.6 1246.7
50 / 122 819.1 851.1 883.0
60 / 140 590.3 612.3 634.2
70 / 158 431.0 446.3 461.6
80 / 176 318.7 329.5 340.3
90 / 194 238.4 246.2 253.9
100 / 212 180.4 186.0 191.6
110 / 230 137.6 142.1 146.5
120 / 248 106.1 109.6 113.2
130 / 266 82.6 85.4 88.3

Tempera- Impedance Impedance Impedance

ture (°C / °F) R min. (Ω) R nom. (Ω) R max. (Ω)
Oil temperature sensor, engine –50/–58 89496.5 105290.0 121083.5
–40 / –40 45163.6 52394.0 59624.4
–30 / –22 23871.0 27375.0 30879.0
–20 / –4 13181.5 14945.0 16708.5
–10 / 14 7555.7 8480.0 9404.3
±0 / 32 4477.9 4981.0 5484.1
10 / 50 2747.3 3029.0 3310.7
20 / 68 1736.6 1900.0 2063.4
30 / 86 1127.3 1224.0 1320.7
40 / 104 750.0 809.1 868.2
50 / 122 510.4 547.0 583.6
60 / 140 354.5 377.9 401.3
70 / 158 251.6 266.5 281.4
80 / 176 181.4 191.2 201.0
90 / 194 133.1 139.7 146.3
100 / 212 99.2 103.6 108.0
110 / 230 75.0 78.0 81.0
120 / 248 57.6 59.6 61.6
130 / 266 44.7 46.1 47.5
140/284 34.8 36.0 37.2
150/302 27.4 28.5 29.6

29
Technical data Group 20

Tightening torques
D16C-A/B/C MH, D16C-A MG
General tightening torques
Nm (lbf.ft) Angle tightening
M6 standard screw 8.8 ......................................... 10 ±1.5 (7.4 ±1) –
M8 standard screw 8.8 ......................................... 24 ±4 (17.7 ±3) –
M10 standard screw 8.8 ....................................... 48 ±8 (35.4 ±6) –
M12 standard screw 8.8 ....................................... 85 ±15 (62.7 ±11) –
M14 standard screw 8.8 ....................................... 140 ±25 (103.3 ±18) –
M16 standard screw 8.8 ....................................... 220 ±35 (162 ±26) –

Note. Only torqued screws can be re-installed.

Torque and angle tightened/stretch-limit bolts:
8.8 ..................................................................... Should not be reused
10.9 ................................................................... Can be reused
12.9 ................................................................... Can be reused
NOTE! Check screws which are to be re-in-
stalled. Damaged screws, with marks of seizure
etc. under the heads, must be scrapped.

Special tightening torques

Group 21: Short block
Front engine mounting, cylinder block .................. 220 ±35 (162 ±26) –
Front engine mounting (M16) ............................... 220 ±35 (162 ±26) –
Rear engine mounting, flywheel housing (M16) .... 220 ±35 (162 ±26) –
Rear engine mounting, reverser (M16) ................. 220 ±35 (162 ±26) –
Cylinder head (see tightening diagram
“Cylinder head” page 33).
Locknut for adjuster screw, unit injector ................ 52 ±4 1) (38.4 ±3) 1) –
1)
Alternative: Angle tightening 45° ±5° after contact.

Valve cover (see tightening diagram

“Valve cover” page 35).
Main bearing caps:
Stage 1 .............................................................. 300 ±20 (221 ±14) –
Stage 2 .............................................................. – 120° ±5°
Conrod caps*:
Stage 1 .............................................................. 20 ±3 (14.8 ±2) –
Stage 2 .............................................................. 60 ±5 (44.3 ±4) –
Stage 3 .............................................................. – 90° ±5°
* Note. Tighten screws diagonally.

Stiffening frame, cylinder block:

(see tightening diagram “Stiffening frame,
cylinder block” page 37).

30
Group 20 Technical data

D16C-A/B/C MH, D16C-A MG

Special tightening torques
Nm (lbf.ft) Angle tightening
The camshaft bearing cap screws shall be
tightened in 5 stages:
(see tightening diagram “bearing cap, cam-
shaft /rocker arm shaft” page 34).
Timing gear plate:
(see tightening diagram “Timing gear plate”
page 35).
Timing gear drive and vibration damper, cam-
shaft:
(please refer to “Timing gear” tightening dia-
gram
page 36).
Vibration damper (crankshaft):
(see tightening diagram “Vibration damper
(crankshaft)” page 40).
Flywheel:
(see tightening diagram “Flywheel” page 40).
Flywheel housing:
Stage 1 (M14 bolts) ........................................... 160 ±20 (118 ±15) –
Stage 2 (M10 bolts) ........................................... 48 ±8 (35.4 ±6) –
Stage 3 (M8 screws) ......................................... 24 ±4 (17.7 ±3) –
Timing gear cover:
(see tightening diagram “Timing gear cover”
page 41).

Group 22: Lubrication system

Oil nozzle in timing gear ....................................... 34 ±4 (25 ±3) –
Screw, piston cooling nozzle:
(see tightening diagram “Piston cooling
nozzles” page 37).
Lube oil cooler, fixing screws:
(see tightening diagram “Lube oil cooler”
page 38).
Cover, lubrication oil cooler:
(see tightening diagram “Cover, lubrication oil
cooler” page 39).
Oil pressure pipe: (see “Oil pressure pipe” page
38).
Lube oil pump, fixing screws:
Stage 1 .............................................................. 35 ±3 (25.8 ±2) –
Stage 2 .............................................................. – 90° ±5°
Oil filter bracket:
(see tightening diagram “Oil filter bracket”
page 43).

31
Technical data Group 20

D16C-A/B/C MH, D16C-A MG

Special tightening torques
Nm (lbf.ft) Angle tightening
Group 23: Fuel system
Unit injector, fixing yoke screw:
With existing copper sleeve
Stage 1 .............................................................. 20 ±5 (14.8 ±4) –
Stage 2 .............................................................. – 60° ±5°
With new copper sleeve
First tightening:
Stage 1 .............................................................. 20 ±5 (14.8 ±4) –
Stage 2 .............................................................. – 180° ±5°
Note. Loosen the unit injector’s
fixing yoke screw before the second tightening.
Second tightening:
Stage 1 .............................................................. 20 ±5 (14.8 ±4) –
Stage 2 .............................................................. – 60° ±5°
Fuel pump ............................................................ 25 ±2 (18.4 ±1.5) –
Clamping and tightening torques for fuel lines,
see “Fuel lines” page 42.

Group 25: Inlet and exhaust system

Inlet pipe ............................................................... 24 ±4 (17.7 ±3) –
Exhaust manifold (see tightening diagram
“Exhaust manifold” page 42).
Turbocharger ........................................................ 60 ±4 (44.3 ±3) –
Lock nut, V-clamp:
compressor housing – bearing housing .............. 12.2 ±0.7 (9 ±0.5) –
turbine housing – exhaust elbow ........................ 16 ±0.7 (11.8 ±0.5) –

Group 26: Cooling system

Coolant pump:
(see tightening diagram “Coolant pump”
page 43).
Gear wheel, sea water pump ................................ 200 ±30 (148 ±22) –
Plug, by-pass valve .............................................. 55 ±5 (40.6 ±4) –
Charge air cooler* ................................................. 5 –7 (3.7–5.2) –
* IMPORTANT! The charge air cooler may not be
disassembled. Individual studs and nuts may
however be replaced.

Group 30: Electrical system

Sensor, charge air pressure / temperature ............ 12 ±2 (8.9 ±1.5) –
Other sensors ....................................................... 30 ±5 (22.1 ±4) –
Starter motor ........................................................ 60 ±6 (44.3 ±4.4) –
Starter motor, battery cables ................................ 25 ±5 (18.4 ±4) –

32
Group 20 Technical data

Tightening diagrams
D16C-A/B/C MH, D16C-A MG
Cylinder head

Nm (lbf.ft) Angle tightening

+10 +7.4
Stage 1 .............................................................. 100 – 0 (73.8 – 0 ) –
Stage 2 .............................................................. – 90° ±5°
Stage 3 .............................................................. – 90° ±5°

Cover, front crankshaft seal

4 5

2 7

1 8

Stage 1: Tighten all screws by hand.

Stage 2: Tighten screws “2” and “7” ..................... 24 ±4 Nm (17.7 ±3 lbf.ft)
Stage 3: Tighten remaining screws ....................... 24 ±4 Nm (17.7 ±3 lbf.ft)

33
Technical data Group 20

D16C-A/B/C MH, D16C-A MG

Bearing caps, camshaft / rocker arm shaft
NOTE: Tighten the screws in stages to ensure that the rocker arm shaft bottoms against the bearing housing
without bending the shaft.
If the rocker arm shaft has been loosen or removed, then only the screws holding the shaft shall be tightened
according to the diagram when refitting.

Nm (lbf.ft) Angle
Camshaft: tightening
Stage 1: (camshaft and bearing cap in place). Fit a drift to No. 7’s
bearing seat to protect the guide sleeve.
Stage 2: Tighten screws 1–7 ..................................................................... 15 ±3 (11.1 ±2) –
Stage 3: (with shorter extra screws). Tighten screws 8–13 and 20 ........... 50 ±5 (36.9 ±4) –
Stage 4: Angle tighten screws 1–7 ............................................................ – 90° ±5°
Stage 5: Remove extra screws 8–13 and 20.
Stage 6: Remove the drift from No. 7’s bearing seat.

Rocker arm shaft:

Stage 7: (rocker arm shaft in place). Tighten screws 8 –13 in stages
in the sequence 11, 10, 12, 9, 13, 8 ............................................ 50 ±5 (36.9 ±4) –
Stage 8: Tighten screws 14 –19 ................................................................. 50 ±5 (36.9 ±4) –
Stage 9: Tighten screw 20 ......................................................................... 60 ±5 (44.3 ±4) –
Stage 10: Angle tighten screws 8 –19 .......................................................... – 120° ±5°
Stage 11: Angle tighten screw 20 ................................................................ – 100° ±5°

34
Group 20 Technical data

D16C-A/B/C MH, D16C-A MG

Valve cover

Tightening torque .................................................. 24 ±4 Nm (17.7 ±3 lbf.ft)

Timing gear plate

Screws 1–26 ........................................................ 28 ±4 Nm (20.7 ±3 lbf.ft)

Screw 27 .............................................................. 60 ±8 Nm (44.3 ±6 lbf.ft)

IMPORTANT! The screws may not be reused.

35
Technical data Group 20

D16C-A/B/C MH, D16C-A MG

Timing gear

Nm (lbf.ft) Angle tightening

1. Crankshaft gear
Stage 1 ............................................................ 60 ±5 (44.3 ±3) –
Stage 2 ............................................................ – 120° ±10°
2. Idler gear, double
Tighten in sequence as illustrated.
Stage 1 ............................................................ 45 ±5 (33.2 ±3) –
Stage 2 ............................................................ – 90° ±5°
3. Idler gear, adjustable
Tighten the screws in sequence, as illustrated.
Stage 1 ............................................................ 35 ±4 (25.8 ±3) –
Stage 2 ............................................................ – 120° ±5°
4. Camshaft gear / vibration damper
Tighten the screws in sequence, as illustrated.
Stage 1 ............................................................ 45 ±5 (33.2 ±3) –
Stage 2 ............................................................ – 90° ±5°
5. Drive gear, fuel pump .................................... 100 ±10 (73.8 ±7) –
6. Drive gear, sea water pump .......................... 200 ±30 (148 ±22) –

36
Group 20 Technical data

D16C-A/B/C MH, D16C-A MG

Stiffening frame, cylinder block

Nm (lbf.ft) Angle tightening

Tightening torque:
Stage 1 ................................................................. 65 ±5 (48 ±4) –
Stage 2 ................................................................. – 90° ±5°

Piston cooling nozzles

Fixing screw ....................................... 24 ±4 Nm
(17.7 ±3 lbf.ft)

WARNING! Faulty piston cooling results in pis-

ton seizure.
If you suspect that the piston cooling nozzle
may be damaged or deformed, it should be re-
placed (applies to new nozzles as well).
Always check that the nozzle is placed correctly
in the hole in the cylinder block and is directed
towards the recess in the piston and that the re-
taining plate lies flat against the block.
If the piston cooling nozzle is not correctly in-
stalled, the engine will immediately seize when
loaded.

37
Technical data Group 20

D16C-A/B/C MH, D16C-A MG

Oil pressure pipe, oil pump
Reused oil pressure pipe
Stage 1:
Tighten the screwed joint until it bottoms
(“zero play”).
Stage 2 ................................................................. 200 ±10 Nm
(148 ±7 lbf.ft)

New oil pressure pipe

Stage 1:
Tighten the screwed joint until it bottoms
(“zero play”).
Stage 2 ................................................................. 180°

Connections, turbocharger*
Stage 1:
Tighten the screwed joint until it bottoms
(“zero play”).
Stage 2 ................................................................. 25 ±5 Nm (18.4 ±4 lbf.ft)
* Note. For coolant and lube oil respectively.

Oil cooler

Tightening torque:
Stage 1 ................................................................. 10 ±4 Nm (7.4 ±3 lbf.ft)
Stage 2* ................................................................ 27 ±4 Nm (20 ±3 lbf.ft)
* Note. Tightening sequence 1 – 2 – 3 – 4 – 1 in stage 2.

38
Group 20 Technical data

D16C-A/B/C MH, D16C-A MG

Cover, lubrication oil cooler

Tightening torque .................................................. 27 ±4 Nm (20 ±3 lbf.ft)

Lube oil pan

Tightening torque:
Lube oil pan .......................................................... 24 ±4 Nm (17.7 ±3 lbf.ft)
Drain plug ............................................................. 60 ±5 Nm (44.3 ±4 lbf.ft)

39
Technical data Group 20

D16C-A/B/C MH, D16C-A MG

Vibration damper

Tightening torque: Nm (lbf.ft) Angle tightening

NOTE! The 8.8 screws on the vibration damper
must NOT be reused.
Stage 1 ................................................................. 35 ±5 (25.8 ±4) –
Stage 2 ................................................................. 90 ±10 (66.4 ±7) –

Engine with stub-shaft .......................................... 125 ±10 (92.2 ±7) –

Flywheel

Tightening torque: Nm (lbf.ft) Angle tightening

Stage 1 ................................................................. 40 ±5 (29.5 ±4) –
Stage 2 ................................................................. 100 ±5, and 90° ±10°
(73.8 ±4, and 90° ±10°)
NOTE: Make sure that the flange is clean and dry.

40
Group 20 Technical data

D16C-A/B/C MH, D16C-A MG

Flywheel housing

Tightening torque:
Stage 1: Tighten all M14 bolts .............................. 160 ±20 Nm (118 ±15 lbf.ft)
Stage 2: Tighten all M10 bolts .............................. 48 ±8 Nm (35.4 ±6 lbf.ft)
Stage 3: Tighten all M8 screws ............................. 24 ±4 Nm (17.7 ±3 lbf.ft)

Timing gear cover

Tightening torque .................................................. 27 ±4 Nm (20 ±3 lbf.ft)

41
Technical data Group 20

D16C-A/B/C MH, D16C-A MG

Exhaust manifold

Tightening torque: Nm (lbf.ft) Angle tightening

Stage 1 ................................................................. 5 ±2 (3.7 ±1.5 lbf.ft) –
Stage 2 ................................................................. 25 ±5 (18.4 ±4 lbf.ft) –
Stage 3 ................................................................. 52 ±5 (38.4 ±4 lbf.ft) –

Fuel pipes

Tightening torque, fuel lines

A. By-pass valve ................................................. 40 ±5 Nm (29.5 ±4 lbf.ft)
B. Hollow screw (M10) ........................................ 12 ±2 Nm (8.9 ±1.5 lbf.ft)
C. Hollow screw (M16) ........................................ 40 ±5 Nm (29.5 ±4 lbf.ft)
D. Nuts, fuel shut-off valve .................................. 40 ±5 Nm (29.5 ±4 lbf.ft)

1. Plastic clips
2. Tension strap
3. Rubber clamp

42
Group 20 Technical data

D16C-A/B/C MH, D16C-A MG

Oil filter bracket

Tightening torque .................................................. 24 ±4 Nm (17.7 ±3 lbf.ft)

Coolant pump

Tightening torque: Nm (lbf.ft) Angle tightening

Stage 1* ................................................................ 24 ±4 (17.7 ±3) –
Stage 2* ................................................................ 24 ±4 (17.7 ±3) –
* Note. Tightening sequence: 1– 5– 2– 4– 6 –3.

43
Technical data Group 20

Engine cables

1. Holder (part No. 8131393)* 3. Rubber clamp

2. Tension strap (part No. 983472)* 4. Tension strap

* IMPORTANT! Use only Volvo Penta original tension straps and holders under
the valve cover for clamping the wiring for the unit injectors. These components
have been specially developed to withstand oil and high temperatures.

44
Group 20 Technical data

Installing seals
D16C-A/B/C MH, D16C-A MG
Cylinder block, rear

Apply a string of sealant, part No. 1161231* and with a diameter of about 2 mm (0.079").
* Note. Sealant 1161231 (cartridge 0.31 l), or 1161277 (tube 20 g).

Cover, front crankshaft seal

Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079").

45
Technical data Group 20

D16C-A/B/C MH, D16C-A MG

Timing gear cover

Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079").

Inlet pipe

Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079") as illustrated.

46
Group 20 Technical data

D16C-A/B/C MH, D16C-A MG

Cylinder block, underneath

Apply an even string of sealant, about 2 mm (0.079") thick, to the joints.

The figure shows the joint between the cylinder block and front crankshaft seal cover and the
flywheel housing where sealant (part No. 1161231) shall be applied.

Valve cover

Apply a string of sealant, part No. 1161231 and with a diameter of about 2 mm (0.079") to the
joint between the timing gear cover and the cylinder head.

47
 References to Service Bulletins

Group No. Date Refers to

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AB Volvo Penta
Technical Information
Dept. 42200
SE-405 08 Gothenburg
Sweden
7746641 English 04-2013