Volvo Penta MD22 TMD22 TAMD22 Marine Engine Complete Workshop Service Repair Manual

Engine repair MD22, TMD22, TAMD22 Workshop Manual 2(0) A

1 Engine repair Marine Engines MD22 • TMD22 • TAMD22 Contents General Information Safety Information ............................................. 3 General Information .......................................... 6 Repair instructions ............................................ 7 Special tools ....................................................... 10 Identification Numbers ...................................... 12 Introduction to the engine ................................ 13 Cylinder head General ................................................................ 16 Repair Instructions Camshaft cover, replacement (12A-01) .............. 17 Valve clearance, check (12A-02) ........................ 18 Valve clearance, adjustment (12A-03) ................ 19 Front sealing ring, replacement (12A-04) ............ 21 Rear sealing ring, replacement (12A-05) ............ 22 Camshaft, replacement (12A-06) ........................ 23 Cylinder head assembly, replacement (12A-07) . 24 Valves and valve springs, replacement (12A-08) 28 Valves and valve springs, inspection (12A-09)... 29 Valve guides, inspection (12A-10) ...................... 30 Valve guides, replacement (12A-11) ................... 30 Cylinder head, inspection (12A-12) ..................... 31 Valve seats, grinding (12A-13) ............................ 32 Valve seats, replacement (12A-14) ..................... 33 Piston and connecting rod assembly General ................................................................ 34 Repair Instructions Big ends, replacement (13A-01) .......................... 35 Big ends, inspection (13A-02) ............................. 36 Piston and connecting rod assembly, replacement (13A-03) .......................................... 36 Piston rings, replacement (13A-04) ..................... 39 Piston and connecting rod, assembly / dismantling (13A-05) ......................... 40 Piston and piston rings, inspection (13A-06) ...... 41 Connecting rod, inspection (13A-07) ................... 42 Connecting rod bushing, replacement (13A-08) .. 42 Crankshaft assembly General ................................................................ 43 Repair Instructions Crankshaft pulley, replacement (14A-01) ............ 44 Front sealing ring, replacement (14A-02) ............ 45 Rear sealing ring, replacement (14A-03) ............ 47 Crankshaft axial clearance, checking (14A-04) .. 48 Thrust bearing, replacement (14A-05) ................ 48 Main bearings, replacement (14A-06) ................. 50 Main bearings, inspection (14A-07) ..................... 51 Crankshaft, replacement (14A-08) ...................... 52 Crankshaft, inspection (14A-09) ......................... 53 Timing cover and sprocket General ................................................................ 54 Repair Instructions Timing cover outer, replacement (15A-01) .......... 55 Timing belt, inspection (15A-02) ......................... 56 Timing belt, tension (15A-03) .............................. 57 Timing belt, replacement (15A-04) ...................... 58 Fuel injection pump pulley, replacement (15A-05) .......................................... 59 Camshaft pulley, replacement (15A-06) .............. 61 Crankshaft pulley, replacement (15A-07) ............ 62 Timing cover inner, replacement (15A-08) .......... 65 Cylinder block General ................................................................ 67 Repair Instructions Cylinder block, replacement (16A-01) ................. 67 Cylinder block, inspection (16A-02) .................... 69 Cylinder bore, honing (16A-03) ............................ 70

2 Engine settings General ................................................................ 71 Repair Instructions Setting the 1 st piston at top dead center of compression stroke (17A-01) .............................. 72 Valve timings, checking and adjustment (17A-02) ............................................................... 72 Injection timing, checking / adjusting .................. 73 Lubrication system General ................................................................ 75 Repair Instructions Oil filter, replacement (18A-01) ........................... 76 Oil filter adapter, replacement (18A-02) .............. 76 Oil pan, replacement (18A-03) ............................ 77 Oil screen and suction pipe, replacement (18A-04) ............................................................... 78 Oil screen and suction pipe, inspection (18A-05) ............................................................... 78 Oil pump, replacement (18A-06) ......................... 79 Oil pump, inspection (18A-07) ............................. 81 Relief valve, replacement (18A-08) ..................... 82 Relief valve, inspection (18A-09) ........................ 82 Fuel system General ................................................................ 83 Repair Instructions Fuel filter, replacement (19A-01) ......................... 84 Injectors, fault-tracing .......................................... 85 Injectors, replacement (19A-02) .......................... 85 Feed pump, replacement (19A-03) ...................... 86 Feed pump, reconditioning (19A-04) ................... 87 Fuel supply pressure, checking (19A-05) ........... 88 Fuel injection pump, replacement (19A-06) ......... 89 Idling speed, adjustment (19A-07) ...................... 91 Fuel injection system, bleeding (19A-08) ............ 92 Cooling system General ................................................................ 93 Repair Instructions Coolant, draining (20A-01) ................................... 95 Coolant, filling (20A-2) ......................................... 96 Sea water circuit, draining (20A-03) .................... 97 Thermostat, replacement (20A-04) ..................... 98 Thermostat, checking .......................................... 98 Circulation pump, replacement (20A-05) ............ 99 Sea water pump, replacement (20A-06) ............. 100 Sea water pump, reconditioning (20A-07) .......... 101 Installation and adapter plate for seawater pump, replacement (20A-08) .............................. 104 Oil cooler, replacement (20A-09) ....................... 105 Heat exchanger / manifold / coolant tank, replacement (20A-10) ......................................... 107 Heat exchanger, reconditioning (20A-11) ........... 109 Charge air cooler (CAC), reconditioning (20A-12) .............................................................. 111 Flywheel, flywheel cover General ............................................................... 112 Repair Instructions Flywheel, replacement (21A-01) ......................... 112 Ring gear, replacement (21A-02) ....................... 112 Flywheel cover, replacement (21A-03) .............. 114 Electrical system General ............................................................... 116 Generator ............................................................ 116 Starter motor ....................................................... 116 Glow plugs .......................................................... 116 Repair Instructions Generator, replacement (22A-01) ....................... 117 Generator, maintenance ..................................... 118 Generator, fault-tracing ...................................... 118 Starter motor, replacement (22B-01) ................. 119 Starter motor, maintenance (22B-02) ................. 119 Starter motor, checking (22B-03) ....................... 120 Glow plugs, replacement (22C-01) ..................... 120 Glow plugs, checking power supply / continuity 121 Glow plugs, function check ................................ 121 Wiring Diagram ................................................... 122 Intake and exhaust system Turbocharger (TC)(TMD22, TAMD22), replacement ........................................................ 125 Boost pressure control valve, checking ............. 126

3 General instructions Safety information Introduction This Workshop Manual contains descriptions and repair instructions for Volvo Penta products or product versions contained in the contents list. Ensure that the correct workshop literature is being used. Read the safety information and the Workshop Manual “General Information” and “Repair In- structions” carefully before starting work. Important In this book and on the product, you will find the following special warning symbols. WARNING! If these instructions are not followed there is a danger of personal injury, ex- tensive damage to the product or serious mechanical malfunction. IMPORTANT! Used to draw your attention to something that can cause damage, product malfunction or damage to property. NOTE! Used to draw your attention to important information that will facilitate work or operations. Below is a summary of the risks and safety precautions you should always observe or carry out when operating or servicing the engine. Immobilize the engine by turning off the power supply to the engine at the main switch (switches) and lock it (them) in the OFF position before starting work. Set up a warning no- tice at the engine control point or helm. Generally, all servicing should be carried out with the engine switched off. However, some work, certain adjustments for example, require that the engine is running when they are carried out. Approaching a running engine is dangerous. Loose clothing or long hair can catch in rotating parts and cause serious personal injury. If working in proximity to a running engine, careless movements or a dropped tool can result in personal injury. Avoid burns. Take precautions to avoid hot surfaces (exhausts, turbochargers, charge air pipes and starter ele- ments etc.) and liquids in supply lines and hoses when the engine is running or has been turned off immediately prior to starting work on it. Reinstall all protective parts removed during service operations before starting the engine. Check that the warning or information decals on the product are always clearly visible. Re- place decals that have been damaged or paint- ed over. Engines with turbochargers: Never start the engine without installing the air cleaner (ACL) filter. The rotating compressor in the turbocharger can cause serious personal injury. Foreign objects entering the intake ducts can also cause mechanical damage. Never use start spray or similar to start the engine. An explosion may occur in the inlet manifold. Danger of personal injury. Avoid opening the filler cap for the engine coolant system (freshwater cooled engines) when the engine is still hot. Steam or hot coolant can spray out. Open the coolant filler cap carefully and slowly to release the pressure before removing the cap completely. Take great care if a cock, plug or engine coolant line must be removed from a hot engine. It is difficult to anticipate in which direction steam or hot coolant can spray out. Hot oil can cause burns. Avoid getting hot oil on the skin. Ensure that the lubrication system is not under pressure before carrying out any work. Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected. Stop the engine and close the seacock valve before carrying out operations on the engine cooling system. Only start the engine in a well-ventilated area. If operating the engine in an enclosed space, ensure that exhaust gases and crankcase ventilation emissions are extracted from the workshop area.

4 General instructions Always use protective goggles where there is a danger of pieces of metal, sparks from grinding, acid or other chemicals being thrown into your eyes. Eyes are very sensitive. Injury to them can lead to the loss of sight! Avoid skin contact with oil! Long-term or re- peated contact with oil can remove the natural oils from your skin. This can result in irrita- tion, dry skin, eczema and other skin prob- lems. Used oil is more dangerous to health than new oil. Use protective gloves and avoid using oil-soaked clothes and rags. Wash regu- larly, especially before meals. Use the correct barrier cream to prevent dry skin and to make cleaning your skin easier. Most chemicals used in products (engine and transmission oils, glycol, petrol and diesel oil) and workshop chemicals (solvents and paints) are hazardous to health Read the instructions on the product packaging carefully! Always follow safety instructions (using breathing ap- paratus, protective goggles and gloves for example). Ensure that other personnel are not unwittingly exposed to hazardous substances (by inhalation for example). Ensure that ventilation is good. Handle used and excess chemicals according to the instructions. Be extremely careful when tracing leaks in the fuel system and testing fuel injection nozzles. Use protective goggles! The jet ejected from a fuel injection nozzle is under very high pressure. It can penetrate body tissues and cause serious injury Danger of blood poisoning. All fuels and many chemicals are inflammable. Ensure that a naked flame or sparks cannot ignite fuel or chemicals. Combined with air in certain ratios, petrol, some solvents and hy- drogen from batteries are easily inflammable and explosive. Smoking is prohibited! Ensure that ventilation is good and that the necessary safety precautions have been taken before carrying out welding or grinding work. Always have a fire extinguisher to hand in the workplace. Store oil and fuel-soaked rags and fuel and oil filters safely. In certain conditions, oil-soaked rags can spontaneously ignite. Replaced fuel and oil filters are environmentally harmful waste and should be disposed of at proper disposal areas together with engine and transmission oil, contaminated fuel, old paint, de- greasing agents, and cleaning residue. Never allow a naked flame or electric sparks near the batteries. Never smoke in the vicinity of the batteries. The batteries give off hydro- gen gas during charging which when mixed with air can form an explosive gas - oxyhydro- gen. This gas is easily ignited and highly vola- tile. Incorrect connection of the battery can cause a single spark which is sufficient to cause an explosion with resulting damage. Do not disturb the battery connections when starting the engine (spark risk) and do not lean over batteries. Always ensure that the positive and negative battery leads are correctly installed on the corresponding terminal posts on the batteries. Incorrect installation can result in serious damage to electrical equipment. Refer to the wiring diagram. Always use protective goggles when charging and handling the batteries. The battery elec- trolyte contains extremely corrosive sulfuric acid. If this comes into contact with the skin, wash immediately with soap and plenty of water. If battery acid comes into contact with the eyes, immediately flush with copious amounts of water and obtain medical assistance. Turn off the engine and switch off the power at the main switch(es) before carrying out work on the electrical system.

5 General instructions Use the lifting eyes mounted on the engine / reverse gear when lifting the drive unit. Always check that lifting equipment is in good condition and has sufficient load capacity to lift the engine (engine weight including reverse gear and any extra equipment installed). Use an adjustable lifting beam or lifting beam specifically for the engine to raise the engine to ensure safe handling and to avoid damaging engine parts installed on the top of the engine. All chains and cables should run parallel to each other and as perpendicular as possible in relation to the top of the engine. If extra equipment is installed on the engine, thereby altering its center of gravity, a special lifting device is required to achieve the correct balance for safe handling. Never carry out work on an engine suspended on a hoist. Never remove heavy components alone, even where secure lifting equipment such as se- cured blocks are being used. Even where lifting equipment is being used, it is best to carry out the work with two people; one to operate the lifting equipment and the other to ensure that components are not trapped and damaged when being lifted. When working on-board, ensure that there is sufficient space to remove components without danger of injury or damage. Components in the electrical system, ignition system (gasoline engines) and fuel system on Volvo Penta products are designed and con- structed to minimize the risk of fire and explosion. The engine must not be run in areas where there are explosive materials. Always use fuels recommended by Volvo Pen- ta. Refer to the Instruction Book. The use of other grades of fuel can damage the engine. On a diesel engine, poor quality fuel can cause the control rod to seize and the engine to overrev with the resulting risk of damage to the engine and personal injury. Poor fuel quality can also lead to higher maintenance costs.

6 General information Certificated engines If you own an engine certificated for any area where exhaust emissions are regulated by law, the following is important: Certification means that an engine type is inspected and approved by the authorities. The engine manufacturer guarantees that all engines manufactured of that type correspond to the certified engine. This places special requirements for maintenance and service as follows: • The maintenance and service intervals recommended by Volvo Penta must be observed. • Only genuine Volvo Penta replacement parts may be used. • The service of injection pumps and injectors or pump settings must always be carried out by an authorized Volvo Penta workshop. • The engine must not be modified in any way except with accessories and service kits approved by Volvo Penta. • No modifications to the exhaust pipes and air supply ducts for the engine room may be un- dertaken. • Seals may only be broken by authorized personnel. In addition, the general instructions contained in the Instruction Manual concerning operation, service and maintenance must be followed. IMPORTANT! Late or inadequate maintenance / service or the use of spare parts other than Volvo Penta original spare parts will invalidate AB Volvo Penta’s responsibility for the engine specification being in accordance with the certificated variant. Volvo Penta accepts no responsibility or liabil- ity for any damage or costs arising due to the above. About the workshop manual This Service Manual contains descriptions and instructions for the repair of the following engines in standard format: MD22A, MD22L-A, MD22L-B, MD22P-B, TMD22A, TMD22-A, TMD22-B, TMD22P- C, TAMD22P-B. This Service Manual can show operations carried out on any of the engines listed above. As a result, the illustrations and pictures in the manual showing certain engines components, do not in some cases apply to all the engines listed above. However, the repair and service operations described are the same in all essential details. Where they are not the same, this is stated in the manual. Where the difference is considerable, the operations are described separately. The engine designation and engine number are displayed on the identification plate (see the chapter “Identifying numbers”). The engine designation and number should be given in all correspondence about the engine. This Workshop Manual has been developed primari- ly for Volvo Penta service workshops and qualified personnel. Personnel using this book are assumed to have a grounding in marine drive systems and able to carry out the related mechanical and electrical work. Volvo Penta is continuously developing their products. We therefore reserve the right to make changes. All the information contained in this book is based on product data available at the time of going to print. Any essential changes or modifications introduced into production or updated or revised service methods introduced after the date of publication will be provided in the form of Service Bulletins. Spare parts Replacement parts for electrical and fuel systems are subject to statutory requirements (US Coast Guard Safety Regulations for example). Volvo Pen- ta Genuine parts meet these requirements. Any type of damage which results from the use of non- original Volvo Penta replacement parts for the product will not be covered under any warranty provided by Volvo Penta.

7 Repair Instructions The working methods described in the Service Man- ual apply to work carried out in a workshop. The engine has been removed from the boat and is installed in an engine fixture. Unless otherwise stated reconditioning work which can be carried out with the engine in place follows the same working meth- od. Warning symbols occurring in the Workshop Manu- al (for their meaning see Safety information) WARNING! IMPORTANT! NOTE! are not in any way comprehensive since it is impos- sible to predict every circumstance under which service work or repairs may be carried out. For this reason we can only highlight the risks that can arise when work is carried out incorrectly in a well- equipped workshop using working methods and tools developed by us. All procedures for which there are Volvo Penta special tools in this Workshop Manual are carried out using these. Special tools are developed to rational- ize working methods and make procedures as safe as possible. It is therefore the responsibility of any person using tools or working methods other than the ones recommended by us to ensure that there is no danger of injury, damage or malfunction resulting from these. In some cases there may be special safety precautions and instructions for the use of tools and chemicals contained in this Workshop Manual. These special instructions should always be followed if there are no separate instructions in the Workshop Manual. Certain elementary precautions and common sense can prevent most risks arising. A clean workplace and engine eliminates much of the danger of injury and malfunction. It is of the greatest importance that no dirt or foreign particles get into the fuel system, lubrication system, intake system, turbocharger, bearings and seals when they are being worked on. The result can be malfunction or a shorter operational life. Our Joint responsibility Every engine consists of many systems and components that work together. If one component devi- ates from the technical specifications this can have dramatic consequences on the environmental im- pact of the engine even if it is otherwise in good running order. It is therefore vital that wear toler- ances are maintained, that systems that can be adjusted are adjusted properly and that Volvo Penta Genuine Parts as used. The engine Maintenance Schedule must be followed. Certain systems (components in the fuel system for example) may require specialist expertise and test equipment. Some components are sealed at the fac- tory for environmental reasons. No work should be carried out on sealed components except by authorized personnel. Bear in mind that most chemicals used on boats are harmful to the environment if used incorrectly. Vol- vo Penta recommends the use of biodegradable de- greasing agents for cleaning engine components, unless otherwise stated in a workshop manual. Take special care when working on-board, that oil and waste is taken for destruction and is not acci- dentally pumped into the environment with bilge water. Tightening torque Tightening torques for vital joints that must be tightened with a torque wrench are listed in Workshop manual “Technical Data”: and are in certain cases contained in work descriptions in this Manual. All torques apply for cleaned threads, screw heads and mating surfaces. Torques apply for lightly oiled or dry threads. If lubricants, locking fluid or sealing compound are required for a screwed joint this information will be contained in the work description. Where no tightening torque is stated for a joint use the general tightening torques according to the ta- bles below. The tightening torques stated are a guide and the joint does not have to be tightened using a torque wrench. Dimension Tightening torques Nm M5 .................. 5 M6 .................. 10 M8 .................. 20 M10 ................ 40 M12 ................ 70 M14 ................ 115

8 General instructions Protractor tightening torques Tightening using both a torque setting and a protractor angle requires that first the recommended torque is applied using a torque wrench and then the recommended angle is added according to the protractor scale. Example: a 90° protractor tightening means that the joint is tightened a further 1/4 turn in one operation after the stated tightening torque has been applied. Locknuts Do not re-use lock nuts that have been removed during dismantling as they have reduced service life when re-used - use new nuts when assembling or reinstalling. For lock nuts with a plastic insert such as Nylock ® the tightening torque stated in the table is reduced if the Nylock ® nut has the same head height as a standard hexagonal nut without plastic insert. Reduce the tightening torque by 25% for 8 mm bolt sizes or larger. Where Nylock ® nuts are higher, or of the same height as a standard hexagonal nut, the tightening torques given in the table apply. Strength classes Screws and nuts are divided into different strength classes, the class is indicated by the number on the bolt head. A high number indicates stronger materi- al, for example a bolt marked 10-9 indicates a higher strength than one marked 8-8. It is therefore important that bolts removed during the disassembly of a bolted joint must be reinstalled in their original position when assembling the joint. If a bolt must be replaced check in the replacement parts catalogue to make sure the correct bolt is used. Sealing compound A number of sealants and locking liquids are used on the engines. The agents have varying properties and are used for different types of jointing strengths, operating temperature ranges, resistance to oil and other chemicals and for the different materials and gap sizes in the engines. To ensure service work is correctly carried out it is important that the correct sealant and locking fluid type is used on the joint where the agents are required. In this Volvo Penta Service Manual the user will find that each section where these agents are applied in production states which type was used on the engine. During service operations use the same agent or an alternative from a different manufacturer. Ensure that mating surfaces are dry and free from oil, grease, paint and anti-corrosion agent before applying sealant or locking fluid. Always follow the manufacturer’s instructions for use regarding; temperature range, curing time and any other instructions for the product. Two different basic types of agent are used on the engine. These are: RTV agent (Room temperature vulcanizing). Used for gaskets, sealing gasket joints or coating gaskets. RTV agent is clearly visible when a component has been dismantled; old RTV must be removed before the joint is resealed. The following RTV agents are mentioned in the Service Manual: Loctite ® 574, Volvo Penta 840879- 1, Permatex ® No.3, Volvo Penta P/N 1161099-5, Permatex (r) No. 77. Old sealant can be removed using denatured al- cohol in all cases. Anaerobic agents. These agents cure in an absence of air. They are used when two solid parts, for example cast components, are installed face-to-face without a gasket. Used to seal and lock plugs, stud threads, stopcocks, oil pressure sensors etc. Cured anaerobic agents are glassy and the agents are colored to make them visible. Cured anaerobic agents are extremely resistant to solvents and the old agent cannot be removed. When reinstalling the part is carefully degreased and then new sealant is applied. The following anaerobic agents are mentioned in the Service Manual: Loctite ® 572 (white), Loctite ® 241 (blue). NOTE! Loctite® is the registered trademark of Loctite Corporation, Permatex® is the registered trademark of the Permatex Corpora- tion.

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Volvo Penta MD22 TMD22 TAMD22 Marine Engine Complete Workshop Service Repair Manual

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