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MD22
Volvo Penta MD22 User Manual
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122
Electrical system
Instrument panel
1
.
Printed circuit board
2
.
Switch for instrument lighting
3.
Tachometer
4
.
Starter button
5.
Button
5
.
Alarm connector
Cable color
GR
=
gray
SB
=
black
BN
=
brown
LBN
=
light brown
R=
r
e
d
PU
=
purple
G
N
=
green
W
=
white
BL
=
blue
LBL
=
light blue
OR
=
orange
Unless otherwise stated, cable cross
sections = 1.5
mm
2
Wiring Diagram
123
125
Table of Contents
Default Chapter
3
Table of Contents
3
Safety Information
5
General Information
8
Repair Instructions
9
Special Tools
12
Identification Numbers
14
Introduction to the Engine
15
Cylinder Head
18
General
18
Repair Instructions
19
Camshaft Cover, Replacement (12A-01)
19
Valve Clearance, Check (12A-02)
20
Valve Clearance, Adjustment (12A-03)
21
Front Sealing Ring, Replacement (12A-04)
23
Rear Sealing Ring, Replacement (12A-05)
24
Camshaft, Replacement (12A-06)
25
Cylinder Head Assembly, Replacement (12A-07)
26
Valves and Valve Springs, Replacement (12A-08)
30
Valves and Valve Springs, Inspection (12A-09)
31
Valve Guides, Inspection (12A-10)
32
Valve Guides, Replacement (12A-11)
32
Cylinder Head, Inspection (12A-12)
33
Valve Seats, Grinding (12A-13)
34
Valve Seats, Replacement (12A-14)
35
Piston and Connecting Rod Assembly
36
General
36
Repair Instructions
37
Big Ends, Replacement (13A-01)
37
Big Ends, Inspection (13A-02)
38
Piston and Connecting Rod Assembly, Replacement (13A-03)
38
Piston Rings, Replacement (13A-04)
41
Piston and Connecting Rod, Assembly / Dismantling (13A-05)
42
Piston and Piston Rings, Inspection (13A-06)
43
Connecting Rod, Inspection (13A-07)
44
Connecting Rod Bushing, Replacement (13A-08)
44
Crankshaft Assembly
45
General
45
Repair Instructions
46
Crankshaft Pulley, Replacement (14A-01)
46
Front Sealing Ring, Replacement (14A-02)
47
Rear Sealing Ring, Replacement (14A-03)
49
Crankshaft Axial Clearance, Checking (14A-04)
50
Thrust Bearing, Replacement (14A-05)
50
Main Bearings, Replacement (14A-06)
52
Main Bearings, Inspection (14A-07)
53
Crankshaft, Replacement (14A-08)
53
Crankshaft, Inspection (14A-09)
55
Timing Cover and Sprocket
56
General
56
Repair Instructions
57
Timing Cover Outer, Replacement (15A-01)
57
Timing Belt, Inspection (15A-02)
58
Timing Belt, Tension (15A-03)
59
Timing Belt, Replacement (15A-04)
60
Fuel Injection Pump Pulley, Replacement (15A-05)
61
Camshaft Pulley, Replacement (15A-06)
63
Crankshaft Pulley, Replacement (15A-07)
64
Timing Cover Inner, Replacement (15A-08)
67
Cylinder Block
69
General
69
Repair Instructions
69
Cylinder Block, Replacement (16A-01)
69
Cylinder Block, Inspection (16A-02)
71
Cylinder Bore, Honing (16A-03)
72
Engine Settings
73
General
73
Repair Instructions
74
St Piston at Top Dead Center of Compression Stroke (17A-01)
74
Setting the 1
74
Valve Timings, Checking and Adjustment (17A-02)
74
Injection Timing, Checking / Adjusting
75
Lubrication System
77
General
77
Repair Instructions
78
Oil Filter, Replacement (18A-01)
78
Oil Filter Adapter, Replacement (18A-02)
78
Oil Pan, Replacement (18A-03)
79
Oil Screen and Suction Pipe, Replacement (18A-04)
80
Oil Screen and Suction Pipe, Inspection (18A-05)
80
Oil Pump, Replacement (18A-06)
81
Oil Pump, Inspection (18A-07)
83
Relief Valve, Replacement (18A-08)
84
Relief Valve, Inspection (18A-09)
84
Fuel System
85
General
85
Repair Instructions
86
Fuel Filter, Replacement (19A-01)
86
Injectors, Fault-Tracing
87
Injectors, Replacement (19A-02)
87
Feed Pump, Replacement (19A-03)
88
Feed Pump, Reconditioning (19A-04)
89
Fuel Supply Pressure, Checking (19A-05)
90
Fuel Injection Pump, Replacement (19A-06)
91
Idling Speed, Adjustment (19A-07)
93
Fuel Injection System, Bleeding (19A-08)
94
Cooling System
95
General
95
Repair Instructions
97
Coolant, Draining (20A-01)
97
Coolant, Filling (20A-2)
98
Sea Water Circuit, Draining (20A-03)
99
Thermostat, Replacement (20A-04)
100
Thermostat, Checking
100
Circulation Pump, Replacement (20A-05)
101
Sea Water Pump, Replacement (20A-06)
102
Sea Water Pump, Reconditioning (20A-07)
103
Installation and Adapter Plate for Seawater Pump, Replacement (20A-08)
106
Oil Cooler, Replacement (20A-09)
107
Heat Exchanger / Manifold / Coolant Tank, Replacement (20A-10)
109
Heat Exchanger, Reconditioning (20A-11)
111
Charge Air Cooler (CAC), Re- Conditioning (20A-12)
113
Flywheel, Flywheel Cover
114
General
114
Repair Instructions
114
Flywheel, Replacement (21A-01)
114
Ring Gear, Replacement (21A-02)
114
Flywheel Cover, Replacement (21A-03)
116
Electrical System
118
General
118
Generator
118
Starter Motor
118
Glow Plugs
118
Repair Instructions
119
Generator, Replacement (22A-01)
119
Generator, Maintenance
120
Generator, Fault-Tracing
120
Starter Motor, Replacement (22B-01)
121
Starter Motor, Maintenance (22B-02)
121
Starter Motor, Checking (22B-03)
122
Glow Plugs, Replacement (22C-01)
122
Glow Plugs, Checking Power Supply/Continuity
123
Glow Plugs, Function Check
123
Wiring Diagram
124
Intake and Exhaust System
127
Turbocharger, Replacement
127
Boost Pressure Control Valve, Checking
128
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Volvo Penta MD22 Specifications
General
Brand
Volvo Penta
Model
MD22
Category
Engine
Language
English
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