Volvo Penta D2-55/D2-75 Marine Engines OEM Service & Repair Manual

Workshop manual Group 20-23, 26, 30 A 2(0) D2-55, D2-75

Marine engine D2-55 A/B/C • D2-75 A Safety Precautions .............................................. 2 General information ............................................ 5 Special tools ....................................................... 9 Design and function ............................................ 10 Location of engine type signs ................................ 10 Engine introduction ............................................... 11 Component description .......................................... 16 Repair instructions .............................................. 23 General ................................................................. 23 Engine fixture, fixing ............................................. 24 Compression test .................................................. 24 Group 21: Short block Short block, disassembly ...................................... 25 Inspecting the engine block ................................... 29 Upper block plane ................................................. 29 Cylinder bore ......................................................... 29 Cylinder head, overhaul ......................................... 30 Cylinder head, disassembly .................................. 30 Cylinder head, inspection ...................................... 30 Valve seat, replace ............................................... 31 Valves and valve seats, grinding ........................... 31 Valve guides, check .............................................. 32 Rocker arm mechanism, overhaul ......................... 33 Cylinder head, assembly ....................................... 33 Crankshaft, inspection .......................................... 34 Main and big-end bearings, inspection .................. 34 Crankshaft bush, front, inspection ......................... 35 Crankshaft bush, front, replace ............................. 35 Crank bearing play, check ..................................... 36 Piston rings, inspection and adjustment ................ 37 Piston and cylinder bore, inspection and measurement ........................................................ 37 Con rods, inspection ............................................. 38 Con rod bush, replace ........................................... 38 Piston, piston rings and con rods, installation ....... 39 Camshaft, measurement ....................................... 40 Timing gear assembly, inspection ......................... 40 Crankshaft, installation .......................................... 40 Piston, installation in cylinder ................................ 41 Camshaft, installation ........................................... 42 Cylinder head, installation ..................................... 44 Valve lifters, inspection ......................................... 47 Valves, adjustment ............................................... 49 Flywheel, replace ring gear .................................... 49 Crankshaft seal, rear, replace ............................... 50 Crankshaft seal, front, replace .............................. 50 Group 22: Lubrication system Oil pump ............................................................... 51 Oil channels .......................................................... 54 Oil pump bearing, overhaul ...................................... 55 Group 23: Fuel system Injection pump ...................................................... 56 Setting injection timing .......................................... 57 Setting the engine speed ....................................... 59 Feed pump ............................................................ 60 Venting the fuel system ........................................ 61 Fuel filter, replace ..................................................... 63 Fuel pre-filter, drain and replace .............................. 63 Injectors ................................................................ 64 Group 26: Cooling system Fresh water system .............................................. 67 Coolant ................................................................. 68 Draining coolant ........................................................ 69 Filling with coolant ................................................ 69 Checking the coolant level .................................... 70 Cleaning heat exchanger ....................................... 71 Circulation pump ................................................... 72 Sea water pump .................................................... 73 Thermostat ........................................................... 73 Group 30: Electrical system Description ............................................................ 74 Important information concerning the electrical system ......................................... 76 Fault tracing, glow plugs, charging system ............ 78 Alternator .............................................................. 82 Starter motor ......................................................... 86 Electrical components ........................................... 89 Wiring diagrams .................................................... 92 Group 20: Technical data Technical data ...................................................... 96 Wear tolerances .................................................... 100 Tightening torque .................................................. 101 Contents

2 Safety Precautions Introduction This Service Manual contains technical data, descriptions and repair instructions for the Volvo Penta products or product versions noted in the table of contents. Check that you have the correct Workshop Manual for your engine. Read the available safety information, General Infor- mation and Repair Instructions in the Service Manual before you start to do any service work. Important In this book and on the product you will find the following special warning symbols. WARNING! Possible danger of personal injury, extensive damage to property or serious mechanical malfunction if the instructions are not followed. IMPORTANT! Used to draw your attention to something that can cause damage or malfunctions on a product or damage to property. NOTE! Used to draw your attention to important information that will facilitate the work or operation in progress. Below is a summary of the risks involved 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 (es) and lock it (them) turned off before starting work. Set up a warning notice by the helm station. As a general rule all service operations must be carried out with the engine stopped. Some work, such as adjustments, need the engine to be running, however. Approaching an engine which is running is a safety risk. Remember that loose clothing or long hair can fasten in rotating parts and cause serious personal injury. If work is done adjacent to a running engine, a careless movement or a dropped tool can lead, in the worst case, to personal injury. Be careful with hot surfaces (exhaust pipes, turbos, charge air pipes, starting heaters etc.) and hot fluids in pipes and hoses on an engine which is running or which has just stopped. Always refit shields that have been removed for service work before starting the engine. Check that the warning or information labels on the product are always clearly visible. Replace labels which have been damaged or painted over. Never start the engine without installing the air cleaner filter. The rotating compressor turbine in the turbocharger can cause severe injury. For- eign objects entering the intake ducts can also cause mechanical damage. Never use start spray or similar products as a starting aid. They may cause an explosion in the inlet manifold. Danger of personal injury. Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out and the system pressure will be lost. Open the filler cap slowly, and release the pressure in the cooling system if the filling cap or tap has to be opened, or if a plug or coolant hose has to be removed when the engine is hot. Steam or hot coolant might spray out in an unexpected direction. Hot oil can cause burns. Avoid skin contact with hot oil. 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 sea cocks before doing any work on the cooling system. Only start the engine in a well- ventilated area. When operated in a confined space, exhaust fumes and crankcase gases must be ventilated from the engine bay or workshop area. Always use protective glasses or goggles when carrying out work where there is a risk of splin- ters, grinding sparks, acid splashes or where other chemicals are used. Your eyes are extremely sensitive, injury could cause blindness!

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

4 Never work alone when removing heavy engine components, even when using lifting devices such as locking tackle lifts. When using a lifting device two people are usually required to do the work, one to take care of the lifting device and another 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 where you are working, with no risk of personal injury or damage to materials. 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. Fuel delivery pipes must not be bent or straight- ened under any circumstances. Damaged pipes must be replaced. Remember the following when washing with a power washer: Never aim the water jet at seals, rubber hoses or electrical components. Never use a power washer for engine cleaning. Only use the fuels recommended by Volvo Pen- ta. Refer to the Operator’s Manual. Use of fuels that are of a lower quality can damage the engine. On a diesel engine, poor quality fuel can cause the control rod to bind and the engine to over-rev with resulting risk of damage to the engine and personal injury. Poor fuel can also lead to higher service costs. Safety Precautions © 2006 AB VOLVO PENTA We reserve the right to make modifications without prior notice. Printed on environmentally compatible paper.

5 General information About this Service Manual This Service Manual contains technical data, descriptions and repair instructions for the standard version of engine unit D2-55. The Service Manual can illustrate tasks done on any of the engines noted above. This means that the illustra- tions and photographs which clarify certain details might not correspond with other engines in some cases. Re- pair methods are however in general, identical. If this is not the case, this will be noted and important differenc- es will be shown separately. The engine designation and engine number are given on a type plate (see page 14). The engine designation and number must always be given in all correspondence about an engine. The Service Manual is produced primarily for the use of Volvo Penta workshops and service technicians. This assumes that people who use the Manual have basic knowledge of marine drive systems and can do the tasks of a mechanical or electrical nature associated with the trade. Volvo Penta constantly improves its products, so we reserve the right to make modifications without prior notification. All information in this manual is based on product data which was available up to the date on which the manual was printed. Any material changes introduced into the product or service methods after this date are notified by means of Service Bulletins. Spare parts Spare parts for electrical and fuel systems are subject to various national safety requirements such as the US Coast Guard Safety Regulations. Volvo Penta Original Spare Parts meet these specifications. No damage whatever, occasioned by use of non-original Volvo Penta spares for the product, will be compensated by the warranty offered by Volvo Penta. Certified engines When doing service and repair on emission certified engines, it is important to be aware of the following: Certification means that an engine type has been checked and approved by the relevant authority. The engine manufacturer guarantees that all engines made of the same type are equivalent to the certified engine. This makes special demands on service and repair work, as follows: ● Care and Service intervals recommended by Volvo Penta must be followed. ● Only Volvo Penta original spare parts may be used. ● Service to injection pumps, pump settings and injectors must always be performed by an authorized Volvo Penta workshop. ● The engine must not be converted or modified, ex- cept for the accessories and service kits that Vol- vo 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 operation, care and maintenance, applies. IMPORTANT! Neglected or poorly performed care/service, as well as use of non-original spare parts, entails that AB Volvo Penta can no longer guarantee that the engine conforms to the certified model. Damage, injury and/or costs which arise from this will not be compensated by Volvo Penta.

6 Repair procedures The working methods described in the Service Manual apply to work carried out in a workshop. For this reason, the engine is lifted out of the boat and mounted on an engine support. Renovation work which does not need the engine to be lifted out can be done in situ, with the same work methods, unless otherwise specified. Warning symbols used in this Service Manual (for full explanation of the symbols refer to the section; “Safety Precautions”) WARNING! IMPORTANT! NOTE! are not in any way comprehensive since it is impossible to predict every circumstance under which service work or repairs may be carried out. For this reason, all we can do is to point out the risks which we believe could occur due to incorrect work in a well- equipped workshop, using work methods and tools tested by us. All operations described in the Service Manual for which there are Volvo Penta Special Tools available assume that these tools are used when carrying out the repair. Volvo Penta Special Tools have been specifically developed to ensure the most safe and rational working methods possible. It is therefore the responsibility of anyone using other tools or other working methods than we recommend to determine that there is no risk of personal injury or mechanical damage or malfunction as a result. In some cases special safety precautions and user instructions may be required in order to use the tools and chemicals mentioned in the Service Manual. These rules must always be observed, so there are no special instructions about this in the Service Manual. By following these basic recommendations and using common sense it is possible to avoid most of the risks involved in the work. A clean workplace and a clean engine will eliminate many risks of personal injury and engine malfunction. Above all, when work on fuel systems, lubrication systems, induction systems, turbocharger, bearing caps and seals is done, it is extremely important that no dirt or other kinds of foreign particles are able to get in, since this would otherwise cause malfunctions or shortened repair life. Our common responsibility Each engine consists of a large number of collaborating systems and components. Any deviation of a component from its technical specification can dramatically increase the environmental impact of an otherwise good engine. For this reason, it is extremely important that specified wear tolerances are maintained, that systems with adjustment facilities are correctly adjusted and that Volvo Penta Original Spares are used for the engine. The stated service intervals in the Maintenance Schedule must be observed. Some systems, such as the components in the fuel system, require special expertise and special testing equipment for service and maintenance. Some components are sealed at the factory, for environmental reasons etc. It is only permissible to work on sealed components if you are authorized to do such work. Remember that most chemical products, incorrectly used, damage the environment. Volvo Penta recommends the use of biodegradable degreasers whenever engine components are de-greased, unless otherwise specified in the Service Manual. When working aboard a boat, be careful to ensure that oils, wash residue etc. are processed for destruction, and are not inadvertently discharged with bilge water into the environment. Tightening torque The tightening torque for critical joints that shall be tightened with a torque wrench, are listed in ”Specifications: Tightening torque” and noted in the job descriptions in the book. All torque specifications apply to clean screws, screw heads and mating faces. Torque data stated apply to lightly oiled or dry threads. Where grease, locking or sealing agents are required for screwed joints, this is stated in both the operation description and in “Torque”. Where a particular torque value is not specified for any fastener, the general tightening torque in the table below shall apply. The torque specification is a target value and the fastener does not need to be tightened with a torque wrench. Dimension Tightening torque Nm lbf.ft M5 6 4.4 M6 10 7.4 M8 25 18.4 M10 50 36.9 M12 80 59.0 M14 140 103.3

7 Repair instructions Torque-angle tightening With torque/angle tightening, the fastener is tightened to the specified torque, and tightening then continues through a pre-determined angle. Example: for 90° angle tightening, the fastener is turned a further 1/4 turn in one sequence, after the specified tightening torque has been achieved. Lock nuts Disassembled locknuts shall not be re-used, they shall be replaced by new ones, since the locking properties are impaired or lost when the nut is used several times. For locknuts with plastic inserts, i.e. Nylock ® the tightening-torque given in the table shall be reduced if the Nylock ® -nut has the same nut height as a standard all-metal hex-nut. Reduce the torque by 25% for screw size 8 mm or larger. Where Nylock ® nuts are higher, i.e. the metallic thread is of the same height as a standard hexagonal nut, the torque given in the table apply. Strength classes Screws and nuts are sub-divided into different strength classes. Classification is indicated by markings on the screw head. A marking with higher number indicates stronger material. For example, a screw marked 10-9 is stronger than one marked 8-8. For this reason, when fasteners are removed, it is important that the screws are put back in the correct places when they are re-installed. If a screw must be replaced, check in the spare parts catalogue to make sure the correct screw is used. Sealant Several different types of sealant and locking fluids are used on the engine. The properties of the preparations differ, and they are intended for different strengths of fastener, temperature, resistance to oil and other chemicals, and for the different materials and gap thicknesses found in the engine. 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 Service Manual, the user will find that each section where these agents are applied in production states which type was used on the engine. In service work, the same preparations or preparations of corresponding properties, but of other makes, shall be used. When sealants and locking fluids are used, it is important that the surfaces are free from oil, grease, paint and rust-protection, and that they are dry. 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 preparations (Room Temperature Vulcanizing). Used for gaskets, sealing gasket joints or coating gaskets. RTV is visible when a part has been disassembled; old RTV must be removed before resealing the joint. The following RTV preparations are mentioned in the workshop manual: Loctite ® 574, Silicone GE RTV1473W, Permatex ® No. 3, Volvo Penta 1161099- 5, Permatex ® No 77. Old sealant can be removed using denatured alcohol in all cases. Anaerobic agents. These agents cure in the absence of air. These preparations are used when two solid components, such as two cast components, are fitted together without a gasket. Common uses are also to lock and seal plugs, stud threads, taps, oil pressure monitors etc. Hardened anaerobic preparations are glassy and for this reason, the preparations are colored to make them visible. Hardened anaerobic preparations are highly resistant to solvents, and old compound can not be removed. On re-installation, degrease carefully and then apply new sealant. The following anaerobic preparations are mentioned in the workshop manual: Loctite ® 572 (white color). NOTE: Loctite® is a registered trademark belonging to the Loctite Corporation, Permatex® is a registered trademark belonging to the Permatex Corporation.

8 Repair instructions Safety rules for Fluorocarbon rubber Fluorocarbon rubber is a common material in seal rings for shafts, and in O-rings, for example. When fluorocarbon rubber is subjected to high temperatures (above 300°C), hydrofluoric acid can be for- med, which is highly corrosive. Contact with the skin can result in severe chemical burns. Splashes in your eyes can result in severe chemical burns. If you brea- the in the fumes, your lungs can be permanently damaged. WARNING! Be very careful when working on engines which have been exposed to high temperatures, e.g. overheating during a seizure or fire. Seals must never be cut with a flame torch during disassembly, or burned in uncontrolled circumstances afterwards. • Always use gloves made of chloroprene rubber (gloves for handling chemicals) and protective goggles. • Handle the removed seal in the same way as corrosive acid. All residue, including ash, can be highly corrosive. Never use compressed air to blow anything clean. • Put the remains in a plastic jar which is sealed and provided with a warning label. Wash the gloves under running water before removing them. The following seals are most probably made from fluorocarbon rubber: Seal rings for the crankshaft, camshaft and drive shafts. O-rings, regardless of where they are installed. O- rings for cylinder liner sealing are almost always made of fluorocarbon rubber. Note that seals which have not been subjected to high temperature can be handled normally.

Volvo Penta D2-55/D2-75 Marine Engines OEM Service & Repair Manual

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