Volvo Penta MD22 User Manual

Name: Volvo Penta MD22
Brand: Volvo Penta
Rating: 4 (1 reviews)

132 pages

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123

Electrical system

Instrument panel

1. Voltmeter

2. Oil pressure gauge

3. Engine coolant temperature

gauge

4. Printed circuit board

5. Button

6. Switch for instrument lighting

7. Tachometer

8. Ignition switch

9. Alarm

Default Chapter3
- Table of Contents3
Safety Information5
General Information8
Repair Instructions9
Special Tools12
Identification Numbers14
Introduction to the Engine15
Cylinder Head18
General18
Repair Instructions19
- 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 Assembly36
General36
Repair Instructions37
- 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 Assembly45
General45
Repair Instructions46
- 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 Sprocket56
General56
Repair Instructions57
- 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 Block69
General69
Repair Instructions69
- Cylinder Block, Replacement (16A-01)69
- Cylinder Block, Inspection (16A-02)71
- Cylinder Bore, Honing (16A-03)72
Engine Settings73
General73
Repair Instructions74
- St Piston at Top Dead Center of Compression Stroke (17A-01)74
- Setting the 174
- Valve Timings, Checking and Adjustment (17A-02)74
- Injection Timing, Checking / Adjusting75
Lubrication System77
General77
Repair Instructions78
- 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 System85
General85
Repair Instructions86
- Fuel Filter, Replacement (19A-01)86
- Injectors, Fault-Tracing87
- 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 System95
General95
Repair Instructions97
- Coolant, Draining (20A-01)97
- Coolant, Filling (20A-2)98
- Sea Water Circuit, Draining (20A-03)99
- Thermostat, Replacement (20A-04)100
- Thermostat, Checking100
- 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 Cover114
General114
Repair Instructions114
- Flywheel, Replacement (21A-01)114
- Ring Gear, Replacement (21A-02)114
- Flywheel Cover, Replacement (21A-03)116
Electrical System118
General118
- Generator118
- Starter Motor118
- Glow Plugs118
Repair Instructions119
- Generator, Replacement (22A-01)119
- Generator, Maintenance120
- Generator, Fault-Tracing120
- 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/Continuity123
- Glow Plugs, Function Check123
- Wiring Diagram124
Intake and Exhaust System127
- Turbocharger, Replacement127
- Boost Pressure Control Valve, Checking128

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Instruction Book41 pages

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Volvo Penta MD22 Specifications

General

Engine Type	Diesel
Number of Cylinders	4
Type	In-line
Compression Ratio	22:1
Fuel System	Indirect injection
Displacement	2.0 L
Bore	84 mm
Cooling System	Freshwater cooled

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