Volvo Penta TMD22 Instrukcja Obsługi

Engine repairMD22, TMD22, TAMD22Workshop Manual2(0)A

8General instructionsProtractor tightening torquesTightening using both a torque setting and a protrac-tor angle requires that first the recommended t

98Cooling systemThermostat, replacement(20A-04)1Drain the cooing system so that the coolant level isbelow the position of the thermostat and disconnec

99Cooling systemCirculation pump, replacement(20A-05)1Disconnect the battery.2Drain the coolant circuit, operation 20A-01.3Disconnect the suction pipe

100Cooling systemSea water pump, replacement(20A-06)Applies to MD22A, MD22L-A, TMD22ANOTE! If the installation plate and adapter plate forthe sea wate

101Cooling systemSea water pump, replacement(20A-06)Applies to MD22L-B, MD22P-B, TMD22-B,TMD22P-C, TAMD22P-B1Drain the sea water circuit, operation 20

102Cooling system2Remove the end cover (B13) and the gasket (B14).3Remove the rubber plug (B12) from the end of theimpeller (B11).4Carefully remove th

103Cooling systemSea water pump, recondition-ing (20A-07)Applies to MD22L-B, MD22P-B, TMD22-B,TMD22P-C, TAMD22P-B1Remove the pump, operation 20A-06.2R

104Cooling systemInstallation and adapter platefor sea water pump, replace-ment (20A-08)Special tools: 885038Applies to MD22A, MD22L-A, TMD22A1Remove

105Cooling systemOil cooler, replacement(20A-09)Applies to MD22A, MD22L-A, TMD22AThe pipes in the oil cooler do not usually needcleaning because the c

106Cooling systemOil cooler, replacement(20A-09)Applies to MD22P-B, TMD22-B, TMD22P-C,TAMD22P-BThe oil cooler may need cleaning because the cool-ant w

107Cooling systemHeat exchanger / manifold /coolant tank, replacement(20A-10)Applies to MD22A, MD22L-A, TMD22A1Drain the coolant circuit, operation 20

9General instructionsSafety precautions for FluorinerubberFluorine rubber is a common material in sealingrings for shafts and O rings.When fluorine ru

108Cooling system12Connect the sea water intake and outlet pipes to theheat exchanger. The output pipe must be pushed inso that the end of the pipe is

109Cooling system6Place a new manifold gasket in position over theguide pins in the cylinder head (A1). You do notneed to use any sealing compound. Ch

110Cooling system6Check the components for signs of damage and re-place if necessary.7Slide the sleeve (A1) on the end of the insert untilthe insert i

111Cooling systemHeat exchanger, reconditioning(20A-11)Applies to MD22L-B, MD22P-B, TMD22-B,TMD22P-C, TAMD22P-B1Drain the sea water circuit, operation

112Flywheel, flywheel coverGeneralThe motor may be equipped with a back plate ofaluminum or soft carbon steel or a flywheel cover ofcast iron. Marine

113Flywheel, flywheel cover8Check the axial run-out on the flywheel surface (B).The axial run-out must not be greater than 0.03 mmas a total reading o

114Flywheel, flywheel coverFlywheel cover, replacement(21A-3)Special tools: 8850301Remove the drive components from the rear end ofthe engine.2Remove

115Flywheel, flywheel cover12Install the flywheel and the drive adapter for the re-verse gear, operation 21A-01. Check that the guidepins are correctl

116Electrical systemComponent descriptionGeneratorThe Valeo A13N 147M generator is driven from thecrankshaft pulley with a single drive belt. The gen-

117Electrical systemRepair InstructionsGenerator, replacement(22A-01)To prevent damage to the diodes and resistance,the following instructions must be

10Special tools885 026884 9558858 018885 019885 020885 021885 022885 023885 024 885 025Special tools884955-6 Dial gauge assembly885018-2 Installation

118Electrical systemGenerator, maintenance1Check that the drive belt is not worn and that thebelt tension is correct.2Keep the generator clean. When c

119Electrical systemStarter motor, replacement(22B-01)1Disconnect the battery.2Disconnect the starter motor cables.3Slacken off the mountings and remo

120Electrical systemStarter motor, checking(22B-03)Check that the battery is charged.Switch on the lamps and engage the ignition switch.If no lamps ar

121Electrical systemGlow plugs, checking powersupply/continuity1Connect a 12 V test lamp between the battery posi-tive pole and ground to check that t

122Electrical systemInstrument panel1. Printed circuit board2. Switch for instrument lighting3. Tachometer4. Starter button5. Button5. Alarm connector

123Electrical systemInstrument panel1. Voltmeter2. Oil pressure gauge3. Engine coolant temperaturegauge4. Printed circuit board5. Button6. Switch for

124Electrical systemEngine1. Engine coolant temperaturesensor2. Coolant temperature switch3. Oil pressure sensor4. Pre-heating5. Relay6. Ground fuse7.

125Intake and exhaust systemTurbocharger, replacement(only TMD, TAMD)Removing and installing1Clean the turbocharger (TC) carefully.2Remove the air fil

126Intake and exhaust system13Install the exhaust elbow for the turbocharger (TC)if required. Check that the mating surfaces on theelbow and the turbo

127Notes...

11Special tools885 036885 035885 034885 033885 032885 139885 041885 038885 037885032-3 Protective socket for front stuffing box,crankshaft.885033-1 In

128Notes...

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7738684-5 English 04-1999

12Identifying numbersYour engine and transmission has identification plates with identification numbers. This information should al-ways be quoted whe

1314151 234191718MD22L/120S1. Coolant filler2. Heat exchanger3. Pipe for oil scavenging pump4. Oil filter5. Starter motor6. Generator7. Injection pump

1423457MD22P/MS2518, 19211711 1213 141510982017111213 1415109820TMD22/MS223457TMD22P/HS2512118, 19171112131415109820211918234571General information

155671 2 3 425262724 11 12 13 14 15 16 1710181992122823TAMD22P/SX1. Turbo (TMD, TAMD)2. Coolant filler3. Heat exchanger4. Oil

16Cylinder headCylinder headGeneralThe carbon deposits in a diesel engine are smalland therefore the number of operational hours donot give an indicat

17Cylinder headRepair InstructionsCamshaft cover, replacement(12A-01)Special tools: 8850251Remove the screws securing the camshaft coverfront flange t

18Check that the groove in the camshaft cover andthe mating surfaces on the cylinder head and coverare clean. Apply a 2mm bead of silicon in the outer

19Cylinder headValve clearance, adjustment(12A–03)Special tools: 885024, 885025, 885037If when checking valve clearance, operation 12A-02, it appears

20Cylinder head8Adjust each valve lifter in the following order: Re-move the valve lifter (A1) and remove the shim(A2), located on top of the valve sp

21Cylinder headFront sealing ring,replacement (12A-04)Special tools: 885026, 885018, 8850371Disconnect the battery2Remove the screw from the adjustmen

22Cylinder headRear sealing ring, replacement(12A-05)Special tools: 885019, 885020, 8850381Remove the seawater pump and the drive housingand remove th

23Cylinder headCamshaft, replacement(12A-06)Special tools: 8850371Disconnect the battery2Remove the screw from the adjustment hole on thetop of the fr

24Cylinder head15Check the fuel injection pump adjustment, opera-tions 17A-03.16Install the cap of the timing cover, operation 15A-01. Install the scr

25Cylinder head10Remove the injectors, operation 19A-02 and theglow plugs, operation 22C-01 to prevent any possi-ble damage to the tips.11Remove the s

26Cylinder headEnsure that the adjustment drifts are installedthrough the camshaft cover into the adjustment holein the camshaft. Install the cylinder

27Cylinder head35Fill the engine coolant system. See operation 20A-02.36Connect the battery.37Bleed the fuel injection system, operation 19A-08.38Star

1Engine repairMarine EnginesMD22 • TMD22 • TAMD22ContentsGeneral InformationSafety Information ... 3General

28Cylinder headValves and valve springs,replacement (12A-08)Special tools: 8850231Remove the cylinder head, operations 12A-07.2Remove the seawater pum

29Cylinder head13Use the valve spring tensioner to compress thevalve spring and the install the valve cotter (B1).Ensure that the valve spring is pres

30Cylinder headValve guides, inspection(12A-10)Special tools: 885021, 885022Check the valve guides for wear. The maximumplay between the valve stem an

31Cylinder headCylinder head, inspection(12A-12)1Remove the cylinder head assembly, operations12A-07.2Remove the thermostat housing.3Remove the seawat

32Cylinder headValve seat, grinding (12A-13)1If the valve guide is worn it should be replaced, op-eration 12A-11.2Install the locating pin in the valv

33Cylinder headValve seat, replacement(12A-14)1Install a new valve guide, operation 12A-11.2Work a small segment from the inside of one side ofthe val

34Piston and connecting rodGeneralThe combustion chamber on the upper side of thepiston has a special ”swirl lip” to provide an effec-tive fuel – air

35Repair InstructionsBig ends, replacement(13A-01)1Drain engine oil.2Remove the oil pan, operation 18A-033Remove the oil screen and extractor pipe, op

36Piston and connecting rod10Clean, lubricate and install the lower bearing shell inthe cap. Ensure that the guide lug is slid well intothe cut out (A

37Piston and connecting rod7Remove the big end bearing cap and the connectingrod bearing caps, operation 13A-01. Keep the bear-ing shells with the rel

2Engine settingsGeneral...71Repair InstructionsSetting the 1st piston at top dead center

38Piston and connecting rod15Slide the piston and connecting rod through the cyl-inder bore and down to the big end journal. Turn theconnecting rod so

39Piston and connecting rodPiston rings, replacement(13A-04)Remove the piston rings with an appropriate pistonring pliers Separate the ring gap just s

40Piston and connecting rodPiston and connecting rod,assembly / dismantling(13A-05)1Remove the piston rings, operation 13A-04.2Remove the snap rings h

41Piston and connecting rod8Place the connecting rod with piston upside down.The locating lug (B2) on the connecting rod must beon the same side as th

42Piston and connecting rodConnecting rod, inspection(13A-07)1Check the connecting rods for deformation, seeWorkshop Manual “Technical Data”.2Check th

43Crankshaft assemblyGeneralThe crankshaft is made of ductile cast iron. It hasintegral balancing weights and five main bearingjournals.The axial play

44Repair InstructionsCrankshaft pulley, replacement(14A-01)1Disconnect the battery.2Remove the generator (GEN) drive belt, operation22A-02.3Remove the

45Crankshaft assemblyFront sealing ring,replacement (14A-02)Special tools: 885031, 885032, 885033, 8850371Disconnect the battery2Remove the screw from

46Crankshaft assembly11Install protective socket 885032 (C1) on the crank-shaft. Lubricate the new sealing ring with fresh en-gine oil. Insert the sea

47Crankshaft assemblyRear sealing ring, replacement(14A-03)Special tools: 885030, 885034, 8850351Disconnect the battery2Remove the drive components fr

3General instructionsSafety informationIntroductionThis Workshop Manual contains descriptions andrepair instructions for Volvo Penta products or prod-

48Crankshaft assemblyLocate the ring (C1) from tool 885035 on the crank-shaft flange with the correct side of the ring towardsthe sealing ring. If the

49Crankshaft assemblyRemove the screws for the central main bearingand remove the bearing cap assembly with thethree lower thrust washer halves (B). P

50Crankshaft assemblyMain bearings, replacement(14A-06)(with crankshaft installed)If the front bearing is to be removed the oil pumpmust also be remov

51Crankshaft assembly10Check the mounting screws for wear and deforma-tion and replace them if required. Lightly lubricatethe threads with engine oil.

52Crankshaft assembly11Check that all the big end caps are marked with thenumber of the relevant cylinder. Remove the capsand the lower big end shells

53Crankshaft assemblyApply sealing compound in the groove on each sideof the front and rear main bearing cap (A). Apply thesealing compound until it f

54Timing cover and sprocketGeneralThe drive pulleys are installed on the camshaft (A1)and the fuel injection pump (A2). These pulleys aredriven by a t

55Repair InstructionsTiming cover outer,replacement (15A-01)1Disconnect the battery.2Remove the generator (GEN) drive belt, operation22A-03.3Remove th

56Timing cover and driveTiming belt, inspection(15A-02)Special tools: 8850361Remove the inspection hatch from the upper side ofthe timing cover (A).2M

57Timing cover and driveTiming belt, tension (15A-03)Special tools: 885036, 8850371Install the adjustment drifts on the camshaft and fly-wheel, operat

4General instructionsAlways use protective goggles where there isa danger of pieces of metal, sparks fromgrinding, acid or other chemicals being throw

58Timing cover and driveTiming belt, replacement(15A-04)Special tools: 8850371Disconnect the battery.2Remove the screw over the adjustment hole in the

59Timing cover and drive16Install the cap of the timing cover, operation 15A-01and install the inspection hatch.17Install the mounting screw in the ad

60Timing cover and drive7Check the pulley for wear, cracks and other dam-age. Replace it if required.8Check that the key is correctly installed in the

61Timing cover and driveCamshaft pulley, replacement(15A-06)Special tools: 885027, 885029, 8850371Disconnect the battery.2Remove the screw over the ad

62Timing cover and drive14Turn the crankshaft two revolutions to ensure thatthere is nothing preventing free movement15Install the cap of the timing c

63Timing cover and driveInsert the thin end spacer piece in the crankshaft(A1). Install the main tool 885027 (B) on the pulleyusing the mounting screw

64Timing cover and drive17Slide the (A8) into the keygroove to a depth of 5 mmmeasured from the pulley front end plate.NOTE! It is important that all

65Timing cover and driveTiming cover inner, replace-ment (15A-08)Special tools: 885037, 885027, 8850291Disconnect the battery.2Remove the screw over t

66Timing cover and drive12Remove the fuel injection pump pulley, operation15A-05 and the camshaft pulley, operation 15A-06.13Install the crankshaft pu

67Cylinder blockGeneralThe cylinder block is made of cast iron with sideswhich extend below the crankshaft for maximumsupport. The cylinder bore is ma

5General instructionsUse the lifting eyes mounted on the engine /reverse gear when lifting the drive unit.Always check that lifting equipment is in go

68Cylinder block10Remove the cylinder head assembly, operations12A-07.11Remove the oil pump, operation 20A-11.12Remove the oil filter/ separator unit.

69Cylinder block27Install the cylinder head assembly, operation 12A-07.28Install the fuel filter, injectors and fuel injectionpump, see section 19.29I

70Cylinder blockIf the cylinder bores are damaged or worn morethan 0.15 mm, measured in the diameter, the borecan be bored out and honed to 0.50 mm, d

71Engine settingsGeneralThe installation holes for the adjustment drifts are inthe flywheel and in the front camshaft bearing jour-nal. When these hol

72Repair InstructionsSetting the 1st piston at topdead center of the compres-sion stroke (17A-01)Special tools: 8850371Disconnect the battery and rem

73Engine settings8Check the fuel injection pump adjustment, opera-tions 17A-03.9Remove the adjustment drifts and turn the enginetwo revolutions to ens

74Engine settings5If the read out is not within 0.05 mm of the correctsetting, disconnect the fuel delivery lines from thepump. Use a wrench to preven

75Lubrication systemGeneralThe oil pump is located around the front end of thecrankshaft, the pumps inner rotor is driven by a keyin the crankshaft. T

76Lubrication systemRepair InstructionsOil filter, replacement (18A-01)1Place a container under the filter to collect anyspilled fluid.27Check that th

77Lubrication system5Oil pan, replacement (18A-03)1Drain the oil. Remove the dip stick. Disconnect thecrankcase ventilation return pipe.2Arrange a sup

6General informationCertificated enginesIf you own an engine certificated for any areawhere exhaust emissions are regulated by law,the following is im

78Lubrication systemOil screen and suction pipe,replacement(18A-04)The oil screen is an integrated part of the suctionpipe. No regular service is requ

79Lubrication systemOil pump, replacement(18A-06)Special tools: 885032, 8850371Disconnect the battery2Remove the screw from the adjustment hole on the

80Lubrication system13Clean the crankshaft and the protective socket885032-3 and lightly lubricate with fresh engine oil.Install the protective socket

81Lubrication systemOil pump, inspection (18A-07)If the rotors are so damaged that it affects the oilpump capacity, the whole oil pump must be re-plac

82Lubrication systemRelief valve, replacement(18A-08)The relief valve is installed on the left side of thepump and can be replaced as a unit. The pres

83Fuel systemGeneralAll engines are equipped with Bosch fuel injectionpump. These pumps have mechanical engine speedregulator.The injectors are suppli

84Fuel injection systemRepair InstructionsFuel filter, replacement(19A-01)1Carefully clean the outside of the fuel filter unit.Slacken off the bleed s

85Fuel injection systemInjectors, fault-tracingA faulty injector can cause engine misfires.To find the faulty injector, run the engine at highidling s

86Fuel injection systemFeed pump, replacement(19A-03)1Remove the fuel lines from the supply pump.2Remove the screw from the adjustment hole on thetop

87Fuel injection systemFeed pump, reconditioning(19A-04)1Clean the outside of the supply pump.2Make a mark straight across the flanges on both thepump

7Repair InstructionsThe working methods described in the Service Man-ual apply to work carried out in a workshop. The en-gine has been removed from th

8811Install the diaphragm in position above the bottompump half with the connecting arm fin upwards to-wards the slit in the control arm. Ensure that

89Fuel injection systemFuel injection pump, replace-ment (19A-06)Special tools: 885027, 885029, 8850371Disconnect the battery.2Position the piston in

90Fuel injection system9Check that the key is correctly installed on thepump shaft. Install the fuel injection pump in posi-tion with the locknuts suf

91Fuel injection system19Run the engine and check for any leakage. Checkthat the idle speed is correct, operation 19A-07.20If a new fuel injection pum

92Fuel injection systemFuel injection system, bleeding(19A-08)If air has entered the fuel injection system it mustbe removed before the engine is star

93Cooling systemGeneralThe engine has two cooling circuits. The closed cir-cuit is filled with coolant which is used for coolingthe cylinder block and

94Cooling systemMD22L-B, MD22P-B, TMD22-B, TMD22P-C, TAMD22P-B5. Freshwater pump6. Sea water pump7. Outlet bend8. Charge air cooler (only TAMD22)1. Cy

95Cooling systemRepair InstructionsCoolant, draining (20A-01)Applies to MD22L-B, MD22P-B, TMD22-B,TMD22P-C, TAMD22P-BWARNING! Do not drain coolant whe

96Cooling systemRemove the bleed plug from the hot water connec-tion (B1) or the plug (B2) on the heat exchanger.2Remove the filler cap (B3) from the

97Cooling systemSea water circuit, draining(20A-03)Applies to MD22A, MD22L-A, TMD22A1Check that the seacock is closed.2Disconnect both hoses from the