Volvo Penta D2-55 Workshop Manual Download Page 1

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Workshop manual

Group 20-23, 26, 30

2(0)

D2-55, D2-75

Summary of Contents for D2-55

Page 1: ...Workshop manual Group 20 23 26 30 A 2 0 D2 55 D2 75 ...

Page 2: ......

Page 3: ...n 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 O...

Page 4: ...ul 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 ...

Page 5: ...o an approved waste management facility for destruction together with used lubrication oil contaminated fuel paint residue solvents de greasers 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 ...

Page 6: ...e 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 ...

Page 7: ...e 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 compen sated by the warranty offered by Volvo Penta Certified engines When doing service and repair on emission certified engines it is important to ...

Page 8: ...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...

Page 9: ... 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 flu...

Page 10: ... 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 pro...

Page 11: ...ller for pulleys 885 822 Magnetic pen 885 498 Pressure foot used together with valve spring compressor 885 023 981 2519 Multimeter 998 8539 Compression tester 998 9876 Dial indicator 999 5919 Puller seals 999 6662 Pressure testing equipment 999 9179 Wrench for removing fuel oil filters 999 9684 Rocker indicator 999 9696 Magnetic stand 999 9772 Injector tester 384 9641 Assembly tool for oil pump sh...

Page 12: ...arance and location of the type plates is shown below The figures in brackets refer to the location of the identification number on the type plate Engine Product designation 1 Serial number 2 Product number 3 Certification number 4 S drive Reverser Product designation 5 Serial number 6 Product number 7 Gear ratio 8 Propeller designation Engine plate Engine and transmission decal XXXXXX 7 XXX 5 XXX...

Page 13: ... HS25A 1 5 7 D2 55 A B with reverser HS25A 15 14 9 2 3 13 10 6 4 8 11 12 1 Coolant filling 2 Heat exchanger 3 Relay box with fuses 4 Alternator 5 Starter motor 6 Oil cooler reversing gear 7 Oil dipstick reverser S drive 8 Air filter Air intake 9 Oil dipstick engine 10 Oil filler engine 11 Fuel pump 12 Oil filter 13 Fuel filter 14 Injection pump 15 Sea water pump ...

Page 14: ...ir intake 9 Oil dipstick engine 10 Oil filler engine 11 Fuel pump 12 Oil filter 13 Fuel filter 14 Injection pump 15 Sea water pump 16 Cooling water inlet S drive 17 Sea cock S drive 18 Folding propeller 19 Sacrificial anodes 20 Oil drain S drive D2 55 A B with sail drive MS25S D2 55 A B with sail drive MS25S 18 16 1 3 5 17 2 4 12 8 10 7 19 20 9 13 14 15 11 ...

Page 15: ...motor 7 Oil dipstick reverser S drive 8 Air filter Air intake 9 Oil dipstick engine 10 Oil filler engine 11 Fuel pump 12 Oil filter 13 Fuel filter 14 Injection pump 15 Sea water pump 16 Cooling water inlet S drive 17 Sea cock S drive 18 Folding propeller 19 Sacrificial anodes 20 Oil drain S drive D2 55 C with sail drive 130S D2 55 C with sail drive 130S ...

Page 16: ...n and function D2 75 A with reverser HS25A D2 75 A with reverser HS25A D2 75 A with reverser MS25L 7 2 3 D2 75 A with reverser MS25L 6 1 8 5 4 15 14 17 13 16 9 10 12 11 7 2 3 9 1 8 5 4 17 16 11 15 12 6 10 13 14 ...

Page 17: ...xchanger 4 Charge air cooler 5 Turbo 6 Oil cooler reversing gear 7 Starter motor 8 Alternator 9 Oil dipstick reverser S drive 10 Air filter Air intake 11 Oil dipstick engine 12 Oil filler engine 13 Fuel pump 14 Oil filter 15 Fuel filter 16 Injection pump 17 Sea water pump 18 Cooling water inlet S drive 19 Sea cock S drive 20 Folding propeller 21 Sacrificial anodes 22 Oil drain S drive ...

Page 18: ...om specially alloyed cast iron Flywheel An elastic coupling with a rubber damping element is screwed onto the flywheel The coupling transfers the power to the reverser S drive Timing gear The timing gears comprise both straight cut and heli cal gears The camshaft and sea water pump are driven from the crankshaft gear via an idler gear The engine s lubrica tion pump is integral with the idler gear ...

Page 19: ...e crankshaft has a Woodruff key and the rear end has a flange upon which the flywheel is mounted Main and big end bearings The main and big end bearings comprise steelshells lined with bearing metal The bearings are precision made and are ready to be installed The thrust washers for the crankshaft axial bearings are not available in oversize Con rods The con rods are of I section The small end is ...

Page 20: ...transfers heat from the coolant to the sea water As extra equipment the engine can be equipped with a separate expansion tank Thermostat The engine is equipped with a thermostat whose sen sor body contains wax When the engine is cold the thermostat closes the way to the heat exchanger Coolant then passes through a by pass pipe back directly to the suction side of the pump As the engine warms up th...

Page 21: ...n by cams on the engine s cam shaft which operates the pump chambers directly Centrifugal regulator The regulator is mechanical and works with speed sensitive regulator weighs It is mounted on the front of the camshaft gear from where it is also driven The regulator weights operate the injector pump con trol rod via the regulation sleeve a lever and a regula tor arm The engine speed is regulated t...

Page 22: ...e set value opening pressure the injector needle which is held pressed against its seat by the compression spring is lifted and atomized fuel is injected into the precom bustion chamber of the engine The opening pressure of the injector is determined by the compression spring which is adjustable with shims Fuel filter The fuel filter is discardable The filter insert is a pa per filter 1 Injector n...

Page 23: ...n outer rotor eccentrically mounted in relation to each other The inner rotor has one tooth less than the outer rotor The function of the pump is that the volume of the spaces between the inner and outer gears increases and decreases During the first section of the rotation of the inner rotor the volume increases a partial vac uum occurs and oil is sucked into the inlet After about a half rotation...

Page 24: ...ressure and to separate fuel vapor water vapor and other gaseous combustion products the engine is fitted with closed crankcase ventilation Oil filter The filter is a full flow filter which means that all the oil is filtered before it is forced out into the lubrication system The filter element consists of folded filter paper There is a bypass valve A at the base of the filter which opens and allo...

Page 25: ...ly closed so that water cannot find its way in during disassembly of cooling system sub components Actions before lifting the engine from the boat 1 Lift the boat ashore 2 Disconnect battery power remove battery con nection on the starter motor 3 Disconnect the engine instrument cable harness connector 4 Disconnect the sea water connection keel cooling connection 5 Remove the exhaust system 6 Clos...

Page 26: ...wer compression pressure than the others the reason can be poor valve sealing broken piston rings or a damaged cylinder head gasket Insert adapter nos 885 484 and 885 252 in the injec tor hole Install a compression gauge 998 8539 in the adapter and carry out the compression test Engine fixture fixing Special tools 885 485 998 6485 or 856 927 Use fixture 885 485 to attach the engine to overhaul sta...

Page 27: ... Remove the exhaust bend 1 2 Remove the induction silencer 2 3 Remove the turbo 3 with associated oil return pipe only D2 75 4 Remove the electronics box 4 complete with ca bling 5 Remove the starter motor 5 and alternator 6 and front left engine mounting 6 Remove the coolant hoses 7 heat exchanger 8 sea water pump 9 and circulation pump 10 7 Remove the charge air cooler 11 and oil pipe to the tur...

Page 28: ... Observe the greatest possible cleanliness to avoid getting dirt in the fuel sys tem Plug the fuel pump and injector connec tions with suitable plugs for example kit number 885510 12 Remove the fuel filter and bracket 17 feed pump 18 and the nipple to the injection pump 14 18 17 19 16 15 12 13 13 Remove the injection pump 19 Remove the fix ing screws and nuts on the pump Turn the stop lever clockw...

Page 29: ... opposite tightening se quence refer to Installing cylinder head Re move the cylinder head 18 Remove the valves if these are to be re used they must be fitted in their original positions Spe cial tool magnetic pen part number 885 822 19 Remove the crankshaft sensor flywheel casing and vibration damper NOTE To reduce the risk of damage to the crankshaft sensor this should be removed before the flyw...

Page 30: ... the camshaft gear Lift out the camshaft complete with gear and regu lator weights NOTE Take care so that bearings journals and cam lobes are not damaged 26 Remove the timing gear plate 27 Invert the engine and remove the sump together with the external oil pipe Remove the oil strainer and suction pipe 28 Scrape away the carbon from the top of the cylin ders to simplify disassembly Check that the ...

Page 31: ... and 100 mm below the engine block plane and also in the middle Measurement should be done with an internal dial gauge and both along and transverse to the en gine block A and B Concerning max permitted cylinder diameter see un der Wear tolerances in Technical data 29 Remove the oil pressure valve to allow removal of the crankshaft and simplify flushing of the oil channels IMPORTANT Check that the...

Page 32: ...e brush may not be used for cleaning the cylinder head bolt threads or the underside of the bolt heads F B E A C D Inspecting the cylinder head Cylinder head warping must not exceed the value giv en in Technical data The check should be done with a feeler gauge and a straight edge Measurement is done at six positions A F If warpage above the permissible level is found the cylinder head must be cha...

Page 33: ...refully clean the valve seat bed in the cylinder head Check the cylinder head for cracks 3 Cool the new seat with dry ice or similar to minus 60 70 o C and heat the cylinder head to approx 60 100 o C 4 Press the seats into the cylinder head Use a hy draulic press and a suitable mandrel 5 Machine the seats to the correct angle and width A Grinding of valve and valve seats Special tools 885 023 885 ...

Page 34: ...he distance between the cylinder head plane and the valve head surface A is 0 65 0 95 mm 7 Grind the valves in with grinding paste and check contact with marker dye 8 Install the seals valves valve springs spring washers valve cotters and valve caps Refer to Assembly of cylinder head Checking the valve guides Special tools 999 9683 999 9696 1 Put the cylinder head on the bench and put valves in th...

Page 35: ... good condition 6 Oil the rocker arm shaft and assemble the various parts Assembly of cylinder head Special tools 885 023 885 498 1 Press the new valve stem seals onto the valve guides Note The seals for the inlet and exhaust valve guides are different The inlet valve seal has a silver spring while the exhaust valve seal s spring is black 2 The valves must be installed in the correct order Oil the...

Page 36: ...able for the engine type in question 2 Measure lengthwise crookedness in the crank shaft runout Lay the crankshaft on a pair of V blocks placed under the front and rear main bear ing journals Alternately the crankshaft can be set up between centers Measurements shall be done on the center main bearing journal s Max lengthwise crookedness runout refer to Wear tolerances If these values are exceeded...

Page 37: ...h a corresponding oversize Check the bearing play again before the crank shaft is installed if grinding has been performed Replacement of front crankshaft bush 1 Remove the bush from the cylinder block 2 Check that the bush contact surface in the hous ing has no burrs or deformities 3 Mark a line across the hole in the housing and the bush with a marker pen Oil the outside of the bush and the cont...

Page 38: ...nical Data chapter NOTE Do not rotate the con rod or crankshaft during measurement since this spoils the measurement strip 3 Remove the big end cap and measure the width of the pressed out measurement putty at the widest point Use the scale supplied with the plastigauge Max permissible big end bearing clearance please refer to the Technical Data Change the big end bearing if the bearing clearance ...

Page 39: ...ive importance for the point in time when a piston ring change should be done 5 Check the clearance in the piston ring grooves Roll the ring in its groove in the piston and mea sure the clearance at several points with a feeler gauge Please refer to the Technical Data speci fications chapter for measurements Inspection and measurement of piston and cylinder bore Check the pistons for cracks and wo...

Page 40: ...mm measured length 3 Measure any con rod twist Max deviation 0 20 mm for 100 mm measured length Replacing con rod bushes 1 Press the old bush out 2 Press the new bush in NOTE Make sure that the oil hole in the bush lines up with the drilling in the con rod Draw a line across the hole in the con rod and the bush with a felt tip pen Check that the oil duct is open after pressing 3 Broach the bush an...

Page 41: ...ngs 7 Check the piston ring gap in the cylinder bore and that the rings do not bind in the piston ring grooves 8 Install the piston rings on the pistons using pis ton ring pliers Letters or markings on ring surfac es must always be turned so that the marking fac es upwards Install the oil scraper ring first Put the expansion spring 1 for the oil scraper ring in the lower pis ton ring groove with t...

Page 42: ...cklash exceeds the permitted value then all gears in the tim ing system must be replaced Installing the crankshaft Special tools 998 9876 999 9696 1 Check the cleanliness of the crankshaft drillings and bearing surfaces engine block and bearing caps Check that the bearing shells and their beds do not have any burrs or upsets 2 Place the main bearing shell in position in the bearingcap The bearing ...

Page 43: ...ta chapter Mounting pistons in cylinders Note After replacing the crankshaft piston or gud geon pin the weight difference between con rods with piston and piston rings shall not exceed 10 g between cylinders 1 Lubricate the pistons and piston rings with engine oil beside the rings so that the oil finds its way into the piston ring grooves Turn the piston rings so that the ring gaps are displaced 9...

Page 44: ... rod bolts do not need to be changed they can be put back again 5 Mount the oil suction pipe and oil strainer Tight ening torque please refer to the Technical Data chapter Use a new O ring 6 Install the sump with a new gasket Tightening torque please refer to the Technical Data chapter Installing the camshaft The parts of the camshaft are mounted as illustrated 1 Woodruff key 5 Gear wheel 2 Camsha...

Page 45: ... pin in the timing gear cover can engage in the hole in the oil pump cover Turn the cover back and forwards and center it in the mid position The stop arm must be turned and held in place while the timing gear cover is positioned IMPORTANT The components must be oiled be fore installation IMPORTANT Make sure that the gear wheel markings coincide 2 Install the thrust washer 8 on the idler wheel sha...

Page 46: ...ata 10 Fit the key into the crankshaft and install the crankshaft pulley Tightening torque please refer to the Technical Data chapter 11 Connect the fuel hose to the injection pump 12 Check the injection timing crankshaft position in cases where a new complete camshaft has been installed or if a new cylinder block is used ä 1 Installing cylinder head 1 Clean the cylinder head and cylinder block su...

Page 47: ...ods valve caps and rocker arm mechanism with gasket Tightening torque please refer to the Technical Data chapter 9 Install the oil pressure pipe between the block and rocker arm mechanism together with the oil pres sure sensor Install the oil pressure valve Tightening torque please refer to the Technical Data chapter Turn the crankshaft round a couple of rotations 10 Adjust the valve clearances Ti...

Page 48: ...e to the turbo and charge air cool er only D2 75 Install the turbo only D2 75 21 Install the sea water pump 22 Install the fuel filter bracket and feed pump tight ening torque refer to Technical data Mount hoses and tighten hose clamps 23 Install the starter motor and alternator together with the front engine mounting 24 Connect the hose to the sea water pump and tight en the hose clamp Install th...

Page 49: ...s do not have large areas of pitting damage Pitting damage can occur for various rea sons The damage is caused when small pieces of metal loosen from the hardened surface Lifters and camshafts with minor pitting damage can be used Pitting damage seldom become worse Check that the camshaft bearing surfaces and cam curves are not abnormally worn Change the camshaft if major damage or wear occurs NOT...

Page 50: ...48 Group 21 Short block Acceptable wear The camshaft does not need to be changed Unacceptable wear NOTE Camshaft with associated rocker arms must be replaced ...

Page 51: ...at no oil leakage occurs Replace ring gear on flywheel 1 Mark the flywheel position on the crankshaft sim plifies installation Remove the flywheel 2 Drill a hole or two in a tooth root on the ring gear Crack the ring gear with a chisel at the drilled holes and remove it 3 Clean the ring gear contact surface on the fly wheel with a wire brush 4 Heat up the new ring gear in an oven 120 150o C so tha...

Page 52: ...dges and install the seal 2 Apply an even layer of sealant 840 879 around the seal 2 and camshaft 3 3 Install the flywheel the elastic coupling the adapter plate and the flywheel housing Tightening torque please refer to the Technical Data chapter Replacement of front crankshaft seal The seal consists of a rubber ring and can be replaced once the crankshaft pulley has been removed Use puller 999 5...

Page 53: ...n pump 19 Remove the fix ing screws and nuts on the pump Turn the stop le ver clockwise and carefully lift the pump to make the lock clip on the regulator arm accessible Remove the lock clip and free the regulator arm IMPORTANT Be careful when disassembling the injection pump avoid damaging or bending the lever NOTE Retain any shims from beneath the injection pump flange Use the same thickness of ...

Page 54: ...e thrust washer behind the oil pump A Inspection of oil pump 1 Check that the oil pump s cover and the outer and inner rotors are not worn or damaged 2 Check the clearance A between the inner 1 and outer 2 rotor Max permitted clearance 0 25 mm 3 Check the idler gear bearings and stub axle If necessary these shall be replaced Refer to Oil pump bearing overhaul ...

Page 55: ... 7 3 5 1 2 4 8 1 Install the thrust washer 8 on the idler wheel shaft stub Install the idler gear so that the marks align NOTE Do not turn the crankshaft before the timing gear cover has been installed 2 Install the inner rotor and cover on the oil pump Install shims spring spring washer and lock washer 3 Adjust the oil pump end float to 0 10 0 15 mm Shims are available in thicknesses 0 10 0 15 0 ...

Page 56: ...ure pipe between the cylinder block and cylinder head Clean the drilled oil channels in the cylinder block crankshaft and con rods with a cleaning brush 7 Turn the stop arm clockwise and connect to the injection pump Fit the clip NOTE Be careful to ensure that the shim that was placed underneath the injection pump flange is put back before the pump is placed in the block applies when the pump has ...

Page 57: ...engine block Then put the new oil pump bearing 2 into the tool block 3 1 Drive out the oil pump bearing section 1 located in the engine block Tap it out from inside the crankcase 3 Place the tool block with the bearing in place us ing the guide pin Tap in the bearing until the tool bottoms on the engine block NOTE It is important that the engine block sur face towards the tool is clean and even ...

Page 58: ...jection pipes and the engine closest to the pump very thoroughly 2 Close the fuel taps Remove the delivery pipes complete Release the fuel hose from the pump Fit protective plugs to all connections 3 Remove the fixing screws and nuts on the pump Turn the stop lever clockwise and carefully lift the pump to make the lock clip on the regulator arm accessible Remove the lock clip and free the regulato...

Page 59: ...m clockwise and connect the reg ulator arm to the regulator rod on the pump Fit the clip Screw the pump in place 3 Connect the fuel hose and return fuel line to the pump Install the delivery pipes 4 Prime the fuel system and test run the engine Setting injection timing 1 Remove the delivery pipes and return line If the block or the camshaft have been replaced a 0 5 mm shim shall be placed under th...

Page 60: ...linder 1 is at TDC the rocker arms on cylinder 1 should overlap Turn the crankshaft another half turn 180 in the normal direction 6 Move the actuator arm to maximum position 7 Turn the crankshaft slowly in the normal direction until the flow is 7 drops minute then read off the number of degrees on the crankshaft pulley If the value read off diverges from the value in technical data the injection t...

Page 61: ...locked IMPORTANT The engine s fuel volume and speed are set at the factory to give highest pow er and least environmental impact These set tings must not be disturbed NOTE Seals on injection equipment may only be bro ken by authorized personnel Seals which have been broken must be re sealed Low idle 1 Check that the gap 6 is about 3 mm when the accelerator is in the idle position If necessary Undo...

Page 62: ...ows Suck in the inlet IN and blow in the outlet OUT The function is normal if they seal in both cases 4 Mark the position of the cover 4 valve housing and pump housing 5 5 Remove the screws holding the cover Remove the cover and valve housing 6 Turn the membrane and piston until the pin 6 in the piston is in front of the groove in the pump housing 7 Press in the piston and membrane 7 Press the pin...

Page 63: ... mark on the pulley is at TOP if it is still poor crank the engine another revolution to TOP 3 Normally additional priming is not required Start the engine and check that no leakage occurs 4 If the engine does not start after a short attempt loosen the pressure pipes at the injectors a few turns Hold the injection pump actuator arm in it s max position and crank the engine with the start er motor ...

Page 64: ...e to a blocked strainer Note If either of the two O rings 4 are damaged they must be replaced 3 Normally additional priming is not required Start the engine and check that no leakage occurs 4 If the engine does not start after a short attempt loosen the pressure pipes at the injectors a few turns Hold the injection pump actuator arm in it s max position and crank the engine with the starter motor ...

Page 65: ... and replacement of filter insert Draining The fuel pre filter is extra equipment Put a suitable vessel underneath the filter Drain off water and contaminants through the tap plug in the bottom of the filter bowl IMPORTANT Draining should be performed first a number of hours after stopping Replacingfilterinsert Close the fuel stop cock on the tank Put a suitable vessel underneath the filter Remove...

Page 66: ...orque please refer to the Technical Data chapter 7 Install the return fuel pipe use the nut underneath the fuel return pipe to avoid kinking the pipe 8 Install the pressure pipes Check that they do not come out of alignment and tighten the nuts Tightening torque please refer to the Technical Data chapter 9 Start the engine and check that no leakage occurs 2 1 Testing of injectors Testing is done i...

Page 67: ...he fuel spray should be cone shaped and aligned with the injector center line Fuel drops shall not occur in the spray 2 Check that the fuel spray has a circular cross section Sealing When sealing is checked investigate the fuel leakage which can occur between the injector nozzle seat and the tapered sealing surface in the injector sleeve 1 Dry the injector nozzle so that it is dry 2 Pump the press...

Page 68: ...Check the injector nozzle thoroughly with a lamp magnifier or nozzle microscope Also check the other components 5 When installing a new nozzle it is important that the conserving oil is cleaned off the injector nee dle and sleeve before the injector is assembled avoid skin contact with the needle s sliding sur face Clean the components in chemically pure petrol gasoline Check that the needle slide...

Page 69: ...oolant IMPORTANT Coolant of a suitable chemical for mula must be used all year round This applies even if there is no risk for frost damage so that the engine always has complete corrosion pro tection Future warranty claims on the engine and ancil laries may be rejected if an unsuitable coolant has been used or if the instructions concerning coolant mixing have not been adhered to NOTE The anti co...

Page 70: ...crease the risk of overheating and frost damage IMPORTANT Coolant shall be mixed with pure water use distilled de ionized water The wa ter must fulfill the requirements specified by Vol vo Penta see Water quality IMPORTANT It is extremely important that the correct concentration of coolant is added to the system Mix in a separate clean vessel before filling the cooling system Make sure that the li...

Page 71: ...k if there are extra taps plugs at the cooling and exhaust systems lowest points Check carefully that all the water runs out 4 Tighten the hoses and the cover on the seawater pump Bilge pump the boat WARNING Check that there are no leaks in the seawater system Filling with coolant Flush the cooling system clean before new coolant is added Close all drain points and fill up with coolant to the corr...

Page 72: ...p ment the coolant level shall be between the MIN and MAX marks Coolant temperature too low Low coolant temperature can be caused by Faulty thermostat Faulty temperature sensor or instrument Engine running with low load Coolant temperature too high High coolant temperature warning lamp lights up can be caused by Blocked sea water inlet or sea water filter Defective impeller in the sea water pump C...

Page 73: ...ve should open at 0 09 MPa 4 Remove the test equipment Install the plug and fill the engine up with coolant Cleaning heat exchanger Clean the heat exchanger insert at any sign of block age slowly increasing coolant temperature NOTE First check clean the seawater filter Also checkthe seawater pump impeller wheel and the sea water intake IMPORTANT Close the sea cocks before work ing on the cooling s...

Page 74: ...Replacing the circulation pump Removal 1 Drain the coolant from the engine freshwater sys tem 2 Undo the alternator and remove the drive belt Re move the alternator tensioner 3 Remove the rubber hoses to and from the pump 4 Remove the electric connection from the tempera ture monitor 5 Remove the pump s fixing bolts and lift out the pump Fitting 1 Clean the contact surfaces on the pump and cyl ind...

Page 75: ...n the sea cock or tap on the S drive Start the engine and check carefully that no leakage occurs Thermostat Replacing the thermostat 1 Turn the main switch off Drain the water from the freshwater system 2 Remove the cover 1 the spacer 2 and lift out the thermostat 3 Remove the rubber ring Checking the thermostat 1 Check that the thermostat closes completely 2 Heat up water in a container to 75 o C...

Page 76: ... include as extra equip ment sensors for monitoring the engine s coolant temperature and oil pressure The electrical system is shown in two ways The wir ing diagram shows wire runs cable cross section and color Fuses The engine is equipped with a fuse block with four fus es 15A One fuse safeguards the electrical system and blows if overloaded the others are spares If a fuse blows the electrical sy...

Page 77: ...ow 1 5 mm2 2 Charge splitter extra equip 3 Alternator 4 Fuse panel extra equip 5 Starter motor 6 Main switch 7 Auxiliary batteries extra equip 8 Starting battery engine Charge splitter As extra equipment the engine s standard alternator can be fitted with a charge splitter Two independent battery circuits can in this way be charged at the same time The charge splitter separates the two cir cuits f...

Page 78: ...poles shall be kept well cleaned and the cable shoes shall always be tightened and well greased to avoid power loss Fast charging of the batteries should be avoided If fast charging must be used the batterycables shall always be disconnected first NOTE Follow the appropriate safety regulations when charging batteries During charging unscrew the cell plugs but leave them in the plug holes Ventilate...

Page 79: ...ing plane or be electrically connect ed with any other equipment i e radio naviga tion equipment rudder bathing steps etc Connection of extra equipment All extra equipment shall be connected to a separate connection box and correctly fused Extra power take offs directly from the instrument panel should be avoided The permitted extra take off is however total ly max 5A applies to all instrument pan...

Page 80: ...g Install the battery cables Fault tracing the charging system The engines are equipped with a rectified three phase delta coupled alternator of 14V 60A 840W The alternator s designation can be found on a plate on the rear of the alternator Checking and overhauling Before disassembly of the alternator is started fault tracing of the battery circuit should be performed in or der to eliminate other ...

Page 81: ...f the keyswitch or disconnect power to the instrument panel and all other consumers con nected to the starting battery 4 Set the multimeter for DC current measurement 20A Connect the multimeter between the bat tery s negative pole and the negative cable The current loss may not exceed 0 1 A with the keyswitch or instrument panel disconnected If the current loss is greater than 0 1 A Check that no ...

Page 82: ...of all cells at 25 o C Mea surement shall not be done immediately after charging or filling with battery water The acid density of a fully charged battery at 25 o C shall be 1 28 g cm3 Charge the battery if the acid density is less than 1 24 g cm3 approx 75 charged Charge at 5 6A for 10 hr WARNING The battery generates hydrogen gas which is easily ignited and highly explosive Never expose the batt...

Page 83: ...4 V The total voltage drop shall not exceed 0 4 V Voltage drop less than 0 2 V Battery leads OK Voltage drop more than 0 3 V Perform a check of the battery leads The alternator supplies more than 14 4 V See sections Checking and Fault Tracing the Al ternator and Checking the Regulator Checking the positive battery lead 1 Connect the multimeter between the alternator connection B and the battery po...

Page 84: ...ey spray the connec tions with a moisture dispersent contact oil and tight en the connections once more Treat the connections at the battery main switch starter motor alternator glow plug relay and glow plugs Alternator Checking and fault tracing the alternator 1 Remove the alternator s electrical connections Remove the alternator belt Remove the alternator 2 Undo the voltage regulator s connectio...

Page 85: ... 2 pcs alcaline 9 V if the lamp does not light The batteries are in a compart ment on the underside of the instrument Connect the tester s gray wire to the brush Connect the tester s brown wire to the regulator s yel low and brown wires which are to be held together for the test Connect the tester s black wire to the regulator s black wire Press the Test button and and at the same time turn the rh...

Page 86: ...fitted Checking the diode bridge Set the multimeter to position Diode test Be very sure that you have good probe contact for all mea surements Checking B diodes 1 Connect the multimeters positive probe to one of the stator winding s connections 1 2 3 Then connect the instruments negative probe to the di ode plate B connection Read off the instrument A normal value should be between 450 and 650 mV ...

Page 87: ... Any other value on the instrument indicates a faulty diode If any of the diodes are faulty the whole diode plate must be replaced Checking D diodes The diode plate s three magnetization diodes are checked in the same way as above 1 Connect the instrument s positive probe to each stator winding connection 1 2 3 and the negative probe to D The voltage drop for each diode should be between 450 and 6...

Page 88: ...tor body by connecting the instrument in position Ω And then measure from each winding to the body The instrument should show a one 1 with these measurements which means infinity If the instrument shows any other value the stator winding is faulty If any of the stator windings are faulty the complete stator ring must be replaced Starter motor General The starter motor is a DC series motor The star...

Page 89: ...ing Remove the locking ring and where fitted the shim s 4 Remove the rear bearing casing 5 Remove the brush plate Remove the stator hous ing from the gear housing 6 Remove the lever arm that is fitted in the gear housing and the rotor 7 Remove the starter gear that is fitted in the gear housing First remove the locking ring by striking the contact ring with a suitable sleeve ...

Page 90: ...k the straightness of the rotor Set the rotor up between centers and measure the runout of the rotor frame with a dial gauge Max runout 0 08 mm The runout is half of the indicated value 5 Check the starter gear teeth Replace damaged gears Also check the ring gear if the starter gear is damaged Field windings Check with the test instrument that there is no open circuit in the windings Faulty field ...

Page 91: ...the cable to the next fuse connec tor Always first investigate the reason for the over load Monitors Lube oil pressure monitor alarm Contact type Normally open The contacts close if the lube oil pressure in the engine drops below 0 3 0 15 bar Check of the closing point is done with falling pres sure Coolant temperature monitor alarm Contact type Normally open The contacts close if the coolant temp...

Page 92: ...ng pressure and instrument connected Measured with ohmmeter class 1 at 20o C Pressure 0 bar 10 3 5 Ω 2 bar 52 4 Ω 4 bar 88 4 Ω 6 bar 124 5 Ω Coolant temperature sensor Resistance checking measured with sensor im mersed in circulating liquid down to the hexagonal screw for 3 minutes with power connected Temp 60 o C 134 0 13 5 Ω 4 o C 90 o C 51 2 4 3 Ω 4 o C 100 o C 38 5 3 0 Ω 4 o C ...

Page 93: ...nsor 10 Fuses 4 pcs max 15A 11 Starter relay 12 Glowplug relay 13 Magnetisation resistance 14 Engine speed sensor Engine Cablecolors BL Blue LBL Light blue BN Brown LBN Light brown GN Green GR Gray OR Orange PU Purple R Red SB Black W White Y Yellow Cable cross section in mm2 is given after the color code on the wiring diagram Cross section not given 1 0 mm2 Dotted wires not included from Volvo Pe...

Page 94: ...ning lamp 8 Indication lamp glow plugs 9 Starter button 10 Press switch Instrument panel On Off 11 Connector for connecting extra neutral position switch optional equipment 12 Semiconductor diode 13 Alarm 14 Tumbler switch Glow Alarm test Acknowledge 15 16 pin connector Cablecolors BL Blue BN Brown GN Green GR Gray OR Orange PU Purple R Red SB Black W White Y Yellow Cable cross section in mm2 is g...

Page 95: ... alarm 5 Warning lamp coolant temperature 6 Warning lamp oil pressure 7 Charge warning lamp 8 Indication lamp glow plugs 9 Switch instrument lighting 10 Switch Alarm test Acknowledge 11 Key switch 12 Alarm 13 Connector for connecting neutral position switch extra equip 14 16 pin connection Cablecolors BL Blue BN Brown GN Green GR Gray OR Orange R Red SB Black VO Violet W White Y Yellow Cable cross...

Page 96: ...h instrument lighting 12 Switch Alarm test Acknowledge 13 Tachometer with built in running hours timer extra equip Or blanking plug 14 Key switch 15 Alarm 16 Connector for connecting neutral position switch extra equip 17 16 pin connector 18 2 pole connector for possible additional panel Cable cross section in mm2 is given after the color code on the wiring diagram Cross section not given 1 0 mm2 ...

Page 97: ...ht total 87 66 87 74 mm 87 66 87 74 mm Height from gudgeon pin center to piston crown 47 66 47 74 mm 47 66 47 74 mm Piston clearance 0 038 0 072 mm 0 038 0 072 mm Front marking SHIBAURA mark inside piston shall when mounted face the fuel pump D2 55 A B C D2 75 Piston rings Compression rings Quantity 2 2 Upper compression ring height 1 97 1 99 mm 1 97 1 99 mm 2nd compression ring height 1 47 1 49 m...

Page 98: ...0 044 0 102 mm 0 044 0 102 mm Main bearing journals Diameter in mm bearing journal standard no 1 2 3 4 67 957 67 970 67 957 67 970 Big end journals Big end radial clearance 0 035 0 085mm 0 035 0 085mm Lengthofbearingjournal 17 70 20 60mm 17 70 20 60mm Diameter standard 51 964 51 975mm 51 964 51 975mm Big end journal shells Thickness in mm standard 1 482 1 495 1 482 1 495 Con rods Fitted with repla...

Page 99: ...springs Length unloaded 35 mm 35 mm with 79 4 N 8 1 kp load 30 4 mm 30 4 mm Pushrods Length total 226 mm 226 mm Outer diameter 6 35 mm 6 35 mm Rocker arm mechanism Rocker arm shaft diameter 14 95 14 97 mm 14 95 14 97 mm Clearance rocker arm shaft rocker arm bush 0 030 0 093 mm 0 030 0 093 mm Lubrication system Oil pressure hot engine at operating speed 150 500 kPa 150 500 kPa Oil pressure idle 50 ...

Page 100: ...o Cooling system Type Over pressure Over pressure closed cooling system closed cooling system Freshwater system volume approx 9 5 liter 9 8 liter Thermostat qty 1 1 Thermostat starts opening at 82o 4o C 82o 4o C fully open at 95 o C 95 o C Thermostat valve lifting height 8 mm 8 mm Electrical system System voltage 12 V 12 V Fuses 15 A 15 A Battery capacity starter battery 88 Ah 88 Ah Glow plugs rat...

Page 101: ...m Clearance gudgeon pin conrod bush max 0 08 mm max 0 08 mm gudgeon pin gudgeon pin hole max 0 02 mm max 0 02 mm Cylinder head Warping max 0 12 mm max 0 12 mm Engine block Warping headplane max 0 12 mm max 0 12 mm Bore max 84 2 mm max 84 2 mm 0 5mmT D C max 84 7 mm max 84 7 mm 1 0mmT D C max 85 2 mm max 85 2 mm Crankshaft Out of straightness max 0 06 mm max 0 06 mm Conrods Straightness max deviati...

Page 102: ...haft pulley 300 Injection pump 15 Bearing block rocker arm shaft 33 Valve cover 14 Pressure oil pipe cylinder block cylinder head 12 Injectors 64 Delivery pipes 23 Pressure valve holder 42 Reduction valve 64 Locking screw max fuel volume 15 Locking screw engine speed 15 Glowplug 18 Oil pressure monitor 18 Coolant temperature monitor 27 Oil pressure sensor 18 Coolant temperature sensor 18 Thetighte...

Page 103: ... References to Service Bulletins Group No Date Refers to ...

Page 104: ... Notes ...

Page 105: ... Notes ...

Page 106: ... Notes ...

Page 107: ... write your comments on it and send it to us The address is at the bottom We would appreciate it if you were to write in English or Swedish From Refers to publication Publication no Date of issue Suggestion Motivation Date Name AB Volvo Penta Technical Information Dept 42200 SE 405 08 Göteborg Sweden ...

Page 108: ...7742969 English 08 2006 ...

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Volvo Penta D2-55, Workshop Manual

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