Volvo Penta MD22 - Page 2

Volvo Penta MD22

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Table of Contents

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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