Volvo Penta TMD22 Wartungshandbuch Seite 3
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1
Engine repair
Marine Engines
MD22 • TMD22 • TAMD22
Contents
General Information
Safety Information ............................................. 3
General Information .......................................... 6
Repair instructions ............................................ 7
Special tools ....................................................... 10
Identification Numbers ...................................... 12
Introduction to the engine ................................ 13
Cylinder head
General ................................................................ 16
Repair Instructions
Camshaft cover, replacement (12A-01) .............. 17
Valve clearance, check (12A-02) ........................ 18
Valve clearance, adjustment (12A-03) ................ 19
Front sealing ring, replacement (12A-04) ............ 21
Rear sealing ring, replacement (12A-05) ............ 22
Camshaft, replacement (12A-06) ........................ 23
Cylinder head assembly, replacement (12A-07) . 24
Valves and valve springs, replacement (12A-08) 28
Valves and valve springs, inspection (12A-09)... 29
Valve guides, inspection (12A-10) ...................... 30
Valve guides, replacement (12A-11) ................... 30
Cylinder head, inspection (12A-12) ..................... 31
Valve seats, grinding (12A-13) ............................ 32
Valve seats, replacement (12A-14) ..................... 33
Piston and connecting rod assembly
General ................................................................ 34
Repair Instructions
Big ends, replacement (13A-01) .......................... 35
Big ends, inspection (13A-02) ............................. 36
Piston and connecting rod assembly,
replacement (13A-03) .......................................... 36
Piston rings, replacement (13A-04)..................... 39
Piston and connecting rod,
assembly / dismantling (13A-05) ......................... 40
Piston and piston rings, inspection (13A-06) ...... 41
Connecting rod, inspection (13A-07) ................... 42
Connecting rod bushing, replacement (13A-08) .. 42
Crankshaft assembly
General................................................................ 43
Repair Instructions
Crankshaft pulley, replacement (14A-01)............ 44
Front sealing ring, replacement (14A-02) ............ 45
Rear sealing ring, replacement (14A-03) ............ 47
Crankshaft axial clearance, checking (14A-04) .. 48
Thrust bearing, replacement (14A-05) ................ 48
Main bearings, replacement (14A-06) ................. 50
Main bearings, inspection (14A-07)..................... 51
Crankshaft, replacement (14A-08) ...................... 52
Crankshaft, inspection (14A-09) ......................... 53
Timing cover and sprocket
General................................................................ 54
Repair Instructions
Timing cover outer, replacement (15A-01).......... 55
Timing belt, inspection (15A-02) ......................... 56
Timing belt, tension (15A-03) .............................. 57
Timing belt, replacement (15A-04) ...................... 58
Fuel injection pump pulley,
replacement (15A-05) .......................................... 59
Camshaft pulley, replacement (15A-06) .............. 61
Crankshaft pulley, replacement (15A-07)............ 62
Timing cover inner, replacement (15A-08) .......... 65
Cylinder block
General................................................................ 67
Repair Instructions
Cylinder block, replacement (16A-01) ................. 67
Cylinder block, inspection (16A-02) .................... 69
Cylinder bore, honing (16A-03)............................ 70
- Workshop Manual 1
- Engine repair 3
- Safety information 5
- Protractor tightening torques 10
- Locknuts 10
- Strength classes 10
- Sealing compound 10
- General instructions 11
- Special tools 12
- APPROVAL NO: 14
- Engine presentation 15
- General information 16
- Cylinder head 18
- Valve clearance, check 20
- (12A-02) 20
- Valve clearance, adjustment 21
- (12A–03) 21
- Front sealing ring 23
- (12A-05) 24
- Camshaft, replacement 25
- (12A-06) 25
- Cylinder head assembly 26
- Valves and valve springs 30
- Valve guides, inspection 32
- (12A-10) 32
- Valve guides, replacement 32
- (12A-11) 32
- Cylinder head, inspection 33
- (12A-12) 33
- Valve seat, grinding (12A-13) 34
- Valve seat, replacement 35
- (12A-14) 35
- Piston and connecting rod 36
- Piston and connecting rod as 38
- Big ends, inspection (13A-02) 38
- Piston rings, replacement 41
- (13A-04) 41
- (13A-05) 42
- Piston and piston rings 43
- Connecting rod, inspection 44
- (13A-07) 44
- Connecting rod bushing 44
- (13A-08) 44
- Crankshaft assembly 45
- (14A-03) 49
- Crankshaft axial clearance 50
- Thrust bearing, replacement 50
- (14A-05) 50
- Main bearings, replacement 52
- (14A-06) 52
- Crankshaft, replacement 53
- (14A-08) 53
- Main bearings, inspection 53
- (14A-07) 53
- Crankshaft, inspection 55
- (14A-09) 55
- Timing cover and sprocket 56
- Timing belt, inspection 58
- (15A-02) 58
- Timing belt, tension (15A-03) 59
- (15A-04) 60
- Timing belt, replacement 60
- Fuel injection pump pulley 61
- Timing cover and drive 62
- Camshaft pulley, replacement 63
- (15A-06) 63
- (15A-07) 64
- Timing cover inner, replace 67
- Cylinder block 69
- Cylinder block, inspection 71
- (16A-02) 71
- Engine settings 73
- Lubrication system 77
- Oil pan, replacement (18A-03) 79
- Oil screen and suction pipe 80
- (18A-04) 80
- Oil pump, replacement 81
- (18A-06) 81
- Oil pump, inspection (18A-07) 83
- Relief valve, replacement 84
- (18A-08) 84
- Relief valve, inspection 84
- (18A-09) 84
- Fuel system 85
- Injectors, fault-tracing 87
- Injectors, replacement 87
- (19A-02) 87
- Feed pump, replacement 88
- (19A-03) 88
- Feed pump, reconditioning 89
- (19A-04) 89
- Fuel supply pressure 90
- Fuel injection pump, replace 91
- Fuel injection system 92
- Idling speed, adjustment 93
- (19A-07) 93
- (19A-08) 94
- Coolant, filling (20A-2) 98
- Sea water circuit, draining 99
- (20A-03) 99
- Thermostat, replacement 100
- (20A-04) 100
- Thermostat, checking 100
- (20A-05) 101
- Circulation pump, replacement 101
- Sea water pump, replacement 102
- (20A-06) 102
- Sea water pump, recondition 103
- Cooling system 104
- Special tools: 885038 106
- Oil cooler, replacement 107
- (20A-09) 107
- Heat exchanger / manifold / 109
- (20A-10) 109
- (20A-11) 111
- Charge air cooler (CAC), re 113
- Flywheel, flywheel cover 114
- Ring gear, replacement 115
- (21A-01) 115
- Flywheel cover, replacement 116
- Electrical system 118
- Repair Instructions 119
- Generator, maintenance 120
- Generator, fault-tracing 120
- Starter motor, replacement 121
- (22B-01) 121
- Starter motor, maintenance 121
- (22B-02) 121
- Starter motor, checking 122
- (22B-03) 122
- Glow plugs, replacement 122
- (22C-01) 122
- Glow plugs, checking power 123
- Glow plugs, function check 123
- Wiring Diagram 124
- Intake and exhaust system 127
- Boost pressure control valve 128
- Report form 131
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