Volvo Penta D2-55, D2-75 Workshop Manual
Workshop manual
Group 20-23, 26, 30
A
2(0)
D2-55, D2-75
Marine engine
D2-55 A/B/C • D2-75 A
Safety Precautions .............................................. 2
General information ............................................ 5
Special tools ....................................................... 9
Design and function ............................................ 10
Location of engine type signs ................................ 10
Engine introduction ............................................... 11
Component description .......................................... 16
Repair instructions .............................................. 23
General ................................................................. 23
Engine fixture, fixing ............................................. 24
Compression test .................................................. 24
Group 21: Short block
Short block, disassembly ...................................... 25
Inspecting the engine block ................................... 29
Upper block plane ................................................. 29
Cylinder bore ......................................................... 29
Cylinder head, overhaul ......................................... 30
Cylinder head, disassembly .................................. 30
Cylinder head, inspection ...................................... 30
Valve seat, replace ............................................... 31
Valves and valve seats, grinding........................... 31
Valve guides, check .............................................. 32
Rocker arm mechanism, overhaul ......................... 33
Cylinder head, assembly ....................................... 33
Crankshaft, inspection .......................................... 34
Main and big-end bearings, inspection .................. 34
Crankshaft bush, front, inspection ......................... 35
Crankshaft bush, front, replace ............................. 35
Crank bearing play, check ..................................... 36
Piston rings, inspection and adjustment ................ 37
Piston and cylinder bore, inspection and
measurement ........................................................ 37
Con rods, inspection ............................................. 38
Con rod bush, replace ........................................... 38
Piston, piston rings and con 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
Oil pump bearing, overhaul ...................................... 55
Group 23: Fuel system
Injection pump ...................................................... 56
Setting injection timing .......................................... 57
Setting the engine speed....................................... 59
Feed pump ............................................................ 60
Venting the fuel system ........................................ 61
Fuel filter, replace ..................................................... 63
Fuel pre-filter, drain and replace .............................. 63
Injectors ................................................................ 64
Group 26: Cooling system
Fresh water system .............................................. 67
Coolant ................................................................. 68
Draining coolant ........................................................ 69
Filling with coolant ................................................ 69
Checking the coolant level .................................... 70
Cleaning heat exchanger ....................................... 71
Circulation pump ................................................... 72
Sea water pump .................................................... 73
Thermostat ........................................................... 73
Group 30: Electrical system
Description ............................................................ 74
Important information concerning
the electrical system ......................................... 76
Fault tracing, glow plugs, charging system............ 78
Alternator .............................................................. 82
Starter motor ......................................................... 86
Electrical components ........................................... 89
Wiring diagrams .................................................... 92
Group 20: Technical data
Technical data ...................................................... 96
Wear tolerances .................................................... 100
Tightening torque .................................................. 101
Contents
2
Safety Precautions
Introduction
This Service Manual contains technical data, descriptions and repair instructions for the Volvo Penta products or product versions noted in the table of contents. Check that you have the correct Workshop
Manual for your engine.
Read the available safety information, General Information and Repair Instructions in the Service Manual
before you start to do any service work.
Important
In this book and on the product you will find the following special warning symbols.
WARNING! Possible danger of personal injury,
extensive damage to property or serious mechanical malfunction if the instructions are not
followed.
IMPORTANT! Used to draw your attention to
something that can cause damage or malfunctions on a product or damage to property.
NOTE! Used to draw your attention to important information that will facilitate the work or operation in
progress.
Below is a summary of the risks involved and safety
precautions you should always observe or carry out
when operating or servicing the engine.
Immobilize the engine by turning off the power
supply to the engine at the main switch (es) and
lock it (them) turned off before starting work. Set
up a warning notice by the helm station.
As a general rule all service operations must be
carried out with the engine stopped. Some work,
such as adjustments, need the engine to be running, however. Approaching an engine which is
running is a safety risk. Remember that loose
clothing or long hair can fasten in rotating parts
and cause serious personal injury.
If work is done adjacent to a running engine, a
careless movement or a dropped tool can lead,
in the worst case, to personal injury. Be careful
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.
Never start the engine without installing the air
cleaner filter. The rotating compressor turbine in
the turbocharger can cause severe injury. Foreign objects entering the intake ducts can also
cause mechanical damage.
Never use start spray or similar products as a
starting aid. They may cause an explosion in
the inlet manifold. Danger of personal injury.
Avoid opening the coolant filling cap when the engine is hot. Steam or hot coolant can spray out
and the system pressure will be lost. Open the
filler cap slowly, and release the pressure in the
cooling system if the filling cap or tap has to be
opened, or if a plug or coolant hose has to be removed when the engine is hot. Steam or hot coolant might spray out in an unexpected direction.
Hot oil can cause burns. Avoid skin contact with
hot oil. Ensure that the lubrication system is not
under pressure before carrying out any work.
Never start or operate the engine with the oil filler cap removed, otherwise oil could be ejected.
Stop the engine and close the sea cocks before
doing any work on the cooling system.
Only start the engine in a well- ventilated area.
When operated in a confined space, exhaust
fumes and crankcase gases must be ventilated
from the engine bay or workshop area.
Always use protective glasses or goggles when
carrying out work where there is a risk of splin-
ters, grinding sparks, acid splashes or where
other chemicals are used. Your eyes are extremely sensitive, injury could cause blindness!
3
Safety Precautions
Avoid getting oil on your skin! Repeated exposure to oil or exposure over a long period can re-
sult in the skin becoming dry. Irritation, dryness
and eczema and other skin problems can then
occur.
Used oil is more dangerous than fresh oil from a
health aspect. Use protective gloves and avoid
oil-soaked clothes and rags. Wash regularly, especially before eating. There are special skin
creams which counteract drying out of the skin
and make it easier to clean off dirt after work is
completed.
Most chemicals intended for the product (e.g.
engine and transmission oils, glycol, petrol (gas-
oline) and diesel oil) or chemicals for workshop
use (e.g. degreasers, paints and solvents) are
hazardous. Read the instructions on the product
packaging with care! Always follow the safety
precautions for the product (for example use of
protective mask, glasses, gloves etc.). Make
sure that other personnel are not inadvertently
exposed to hazardous chemicals, for example in
the air. Ensure good ventilation in the work
place. Follow the instructions provided when disposing of used or leftover chemicals.
Exercise extreme care when leak detecting on
the fuel system and testing the fuel injector noz-
zles. Use eye protection. The jet from a fuel
nozzle has very high pressure and great penetration power. Fuel can force its way deep into
body tissue and cause severe injury. Danger of
blood poisoning (septicemia).
All fuels, and many chemicals, are flammable.
Do not allow naked flame or sparks in the vicini-
ty. Petrol (gasoline), some thinners and hydrogen gas from batteries are extremely flammable
and explosive when mixed with air in the correct
ratio. No Smoking! Ensure that the work area is
well ventilated and take the necessary safety
precautions before starting welding or grinding
work. Always ensure that there are fire extinguishers at hand when work is being carried out.
Make sure that oil and fuel soaked rags, and
used fuel and oil filters are stored in a safe
place. Rags soaked in oil can spontaneously ignite under certain circumstances. Used fuel and
oil filters are polluting waste and must be handed to an approved waste management facility
for destruction, together with used lubrication oil,
contaminated fuel, paint residue, solvents, degreasers 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. A spark, which can be
caused by incorrect battery connection, can
cause a single spark which is sufficient to
cause an explosion with resulting damage. Do
not move the connections when you attempt to
start the engine (risk of arcing), and do not
stand and lean over one of the batteries.
Always ensure that the Plus (positive) and Minus (negative) battery cables are correctly in-
stalled on the corresponding terminal posts on
the batteries. Incorrect installation can result in
serious damage to the electrical equipment. Refer to the wiring diagram.
Always use protective goggles when charging
and handling the batteries. Battery electrolyte
contains sulfuric acid which is highly corrosive.
Should the battery electrolyte come into contact
with unprotected skin wash off immediately using plenty of water and soap. If you get battery
acid in your eyes, flush at once with a generous
amount of water, and get medical assistance at
once.
Turn the engine off and turn off the power at the
main switch(es) before carrying out work on the
electrical system.
Clutch adjustments must be carried out with the
engine stopped.
The existing lugs on the engine/reversing gear
should be used for lifting the assembly.
Always check that the lifting equipment used is
in good condition and has the load capacity to
lift the engine (engine weight including gearbox,
if fitted, and any extra equipment).
Use an adjustable lifting beam or lifting beam
specifically for the engine to raise the engine to
ensure safe handling and to avoid damaging engine parts installed on the top of the engine. All
chains and cables should run parallel to each
other and as perpendicular as possible in relation to the top of the engine.
If other equipment connected to the engine has
altered its center of gravity, special lifting devises may be needed to obtain the correct balance
and safe handling.
Never carry out work on an engine suspended
on a hoist.
4
Never work alone when removing heavy engine
components, even when using lifting devices
such as locking tackle lifts. When using a lifting
device two people are usually required to do the
work, one to take care of the lifting device and
another to ensure that components are lifted
clear and not damaged during the lifting operations.
When you work aboard a boat, always make
sure that there is enough space for disassembly
where you are working, with no risk of personal
injury or damage to materials.
Components in the electrical and fuel systems
on Volvo Penta products have been designed to
minimize the risks of explosion and fire. The engine must not be run in areas where there are
explosive materials.
Fuel delivery pipes must not be bent or straightened 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 Penta. Refer to the Operator’s Manual. Use of fuels
that are of a lower quality can damage the engine. On a diesel engine, poor quality fuel can
cause the control rod to bind and the engine to
over-rev with resulting risk of damage to the engine and personal injury. Poor fuel can also lead
to higher service costs.
Safety Precautions
© 2006 AB VOLVO PENTA
We reserve the right to make modifications without prior notice.
Printed on environmentally compatible paper.
5
General information
About this Service Manual
This Service Manual contains technical data, descriptions and repair instructions for the standard version of
engine unit D2-55.
The Service Manual can illustrate tasks done on any of
the engines noted above. This means that the illustrations and photographs which clarify certain details might
not correspond with other engines in some cases. Repair methods are however in general, identical. If this is
not the case, this will be noted and important differences will be shown separately. The engine designation and
engine number are given on a type plate (see page 14).
The engine designation and number must always be given
in all correspondence about an engine.
The Service Manual is produced primarily for the use of
Volvo Penta workshops and service technicians. This
assumes that people who use the Manual have basic
knowledge of marine drive systems and can do the tasks
of a mechanical or electrical nature associated with the
trade.
Volvo Penta constantly improves its products, so we
reserve the right to make modifications without prior
notification. All information in this manual is based on
product data which was available up to the date on which
the manual was printed. Any material changes introduced
into the product or service methods after this date are
notified by means of Service Bulletins.
Spare parts
Spare parts for electrical and fuel systems are 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 compensated by the warranty offered by Volvo Penta.
Certified engines
When doing service and repair on emission certified
engines, it is important to be aware of the following:
Certification means that an engine type has been
checked and approved by the relevant authority. The
engine manufacturer guarantees that all engines made
of the same type are equivalent to the certified engine.
This makes special demands on service and repair
work, as follows:
● Care and Service intervals recommended by Volvo
Penta must be followed.
● Only Volvo Penta original spare parts may be
used.
● Service to injection pumps, pump settings and in-
jectors must always be performed by an authorized
Volvo Penta workshop.
● The engine must not be converted or modified, ex-
cept for the accessories and service kits that Volvo Penta has approved for the engine.
● No installation changes to the exhaust pipe and
engine air inlet ducts may be made.
● Any anti-tamper seals on the engine may not be
broken by unauthorized persons.
The general advice in the instruction book about operation, care and maintenance, applies.
IMPORTANT! Neglected or poorly performed
care/service, as well as use of non-original
spare parts, entails that AB Volvo Penta can no
longer guarantee that the engine conforms to the
certified model.
Damage, injury and/or costs which arise from
this will not be compensated by Volvo Penta.
6
Repair procedures
The working methods described in the Service Manual
apply to work carried out in a workshop. For this reason, the engine is lifted out of the boat and mounted
on an engine support. Renovation work which does
not need the engine to be lifted out can be done in
situ, with the same work methods, unless otherwise
specified.
Warning symbols used in this Service Manual (for full
explanation of the symbols refer to the section;
“Safety Precautions”
)
WARNING!
IMPORTANT!
NOTE!
are not in any way comprehensive since it is
impossible to predict every circumstance under which
service work or repairs may be carried out. For this
reason, all we can do is to point out the risks which
we believe could occur due to incorrect work in a wellequipped workshop, using work methods and tools
tested by us.
All operations described in the Service Manual for
which there are Volvo Penta Special Tools available
assume that these tools are used when carrying out
the repair. Volvo Penta Special Tools have been
specifically developed to ensure the most safe and
rational working methods possible. It is therefore the
responsibility of anyone using other tools or other
working methods than we recommend to determine
that there is no risk of personal injury or mechanical
damage or malfunction as a result.
In some cases special safety precautions and user
instructions may be required in order to use the tools
and chemicals mentioned in the Service Manual.
These rules must always be observed, so there are no
special instructions about this in the Service Manual.
By following these basic recommendations and using
common sense it is possible to avoid most of the
risks involved in the work. A clean workplace and a
clean engine will eliminate many risks of personal
injury and engine malfunction.
Above all, when work on fuel systems, lubrication
systems, induction systems, turbocharger, bearing
caps and seals is done, it is extremely important that
no dirt or other kinds of 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 specified wear tolerances are
maintained, that systems with adjustment facilities are
correctly adjusted and that Volvo Penta Original Spares
are used for the engine. The stated service intervals in
the Maintenance Schedule must be observed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance. Some
components are sealed at the factory, for
environmental reasons etc. It is only permissible to
work on sealed components if you are authorized to
do such work.
Remember that most chemical products, incorrectly
used, damage the environment. Volvo Penta
recommends the use of biodegradable degreasers
whenever engine components are de-greased, unless
otherwise specified in the Service Manual. When
working aboard a boat, be careful to ensure that oils,
wash residue etc. are processed for destruction, and
are not inadvertently discharged with bilge water into
the environment.
Tightening torque
The tightening torque for critical joints that shall be
tightened with a torque wrench, are listed in
”Specifications: Tightening torque” and noted in the
job descriptions in the book. All torque specifications
apply to clean screws, screw heads and mating faces.
Torque data stated apply to lightly oiled or dry
threads. Where grease, locking or sealing agents are
required for screwed joints, this is stated in both the
operation description and in “Torque”. Where a
particular torque value is not specified for any fastener, the general tightening torque in the table below
shall apply. The torque specification is a target value
and the fastener does not need to be tightened with a
torque wrench.
Dimension Tightening torque
Nm lbf.ft
M5 6 4.4
M6 10 7.4
M8 25 18.4
M10 50 36.9
M12 80 59.0
M14 140 103.3
7
Repair instructions
Torque-angle tightening
With torque/angle tightening, the fastener is tightened
to the specified torque, and tightening then continues
through a pre-determined angle. Example: for 90°
angle tightening, the fastener is turned a further 1/4
turn in one sequence, after the specified tightening
torque has been achieved.
Lock nuts
Disassembled locknuts shall not be re-used, they
shall be replaced by new ones, since the locking
properties are impaired or lost when the nut is used
several times. For locknuts with plastic inserts, i.e.
Nylock® the tightening-torque given in the table shall be
reduced if the Nylock®-nut has the same nut height as
a standard all-metal hex-nut. Reduce the torque by
25% for screw size 8 mm or larger. Where Nylock
®
nuts are higher, i.e. the metallic thread is of the same
height as a standard hexagonal nut, the torque given
in the table apply.
Strength classes
Screws and nuts are sub-divided into different
strength classes. Classification is indicated by
markings on the screw head. A marking with higher
number indicates stronger material. For example, a
screw marked 10-9 is stronger than one marked 8-8.
For this reason, when fasteners are removed, it is
important that the screws are put back in the correct
places when they are re-installed. If a screw must be
replaced, check in the spare parts catalogue to make
sure the correct screw is used.
Sealant
Several different types of sealant and locking fluids
are used on the engine. The properties of the
preparations differ, and they are intended for different
strengths of fastener, temperature, resistance to oil
and other chemicals, and for the different materials
and gap thicknesses found in the engine.
To ensure service work is correctly carried out it is
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 fluids are used, it is
important that the surfaces are free from oil, grease,
paint and rust-protection, and that they are dry.
Always follow the manufacturer’s instructions for use
regarding temperature range, curing time and any other instructions for the product.
Two different basic types of agent are used on the
engine. These are:
RTV preparations (Room Temperature Vulcanizing).
Used for gaskets, sealing gasket joints or coating
gaskets. RTV is visible when a part has been
disassembled; old RTV must be removed before
resealing the joint.
The following RTV preparations are mentioned in the
workshop manual: Loctite® 574, Silicone GE
RTV1473W, Permatex® No. 3, Volvo Penta 11610995, Permatex® No 77. Old sealant can be removed
using denatured alcohol in all cases.
Anaerobic agents. These agents cure in the absence
of air. These preparations are used when two solid
components, such as two cast components, are fitted
together without a gasket. Common uses are also to
lock and seal plugs, stud threads, taps, oil pressure
monitors etc. Hardened anaerobic preparations are
glassy and for this reason, the preparations are
colored to make them visible. Hardened anaerobic
preparations are highly resistant to solvents, and old
compound can not be removed. On re-installation,
degrease carefully and then apply new sealant.
The following anaerobic preparations are mentioned in
the workshop manual: Loctite® 572 (white color).
NOTE: Loctite® is a registered trademark belonging to the Loctite
Corporation, Permatex® is a registered trademark belonging to the
Permatex Corporation.
8
Repair instructions
Safety rules for
Fluorocarbon rubber
Fluorocarbon rubber is a common material in seal
rings for shafts, and in O-rings, for example.
When fluorocarbon rubber is subjected to high temperatures (above 300°C), hydrofluoric acid can be formed, which is highly corrosive. Contact with the skin
can result in severe chemical burns. Splashes in your
eyes can result in severe chemical burns. If you breathe in the fumes, your lungs can be permanently
damaged.
WARNING! Be very careful when working on
engines which have been exposed to high
temperatures, e.g. overheating during a seizure
or fire. Seals must never be cut 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 provided with a warning label. Wash the
gloves under running water before removing them.
The following seals are most probably made from
fluorocarbon rubber:
Seal rings for the crankshaft, camshaft and drive
shafts.
O-rings, regardless of where they are installed. Orings for cylinder liner sealing are almost always made
of fluorocarbon rubber.
Note that seals which have not been subjected to
high temperature can be handled normally.
9
Special tools
Wherever feasible, the tool numbers have been punched on the tools.
856 927
885 252
885 820 9812519
999 6662
999 9179
384 9641
885 485
856 927 Plastigauge, for measuring main and big-
end bearing play
884 892 Regulator tester
885 023 Valve spring compressor
885 252 Adapter for testing compression pressure
885 484 Adapter for testing compression pressure
885 485 Engine fixture for overhaul stand
885 820
1)
Puller 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 shaft
998 6485 or 999 2520 Overhaul stand
1)
This tool is used with one or more of Volvo Penta’s older products
998 8539
885 822
999 9772
998 9876
999 9696
998 6485 or 999 2520
999 9683
884 892
885 484885 023
885 498
999 5919
10
Design and function
Location of information decals and type plates
There are type plates on the engine and transmission, marked with identification numbers. This information must
always be used a reference when spare parts are ordered. The appearance 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)
XXXXXXXXXX (6)
XX (8)
S-drive and reversing gear sign
11
Design and function
Engine introduction
D2-55 A/B with reverser MS25L
5
3 2
D2-55 A/B with reverser MS25L
13 12
15
6 11
1
14
7
8
10 9
4
D2-55 A/B with reverser 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
12
Design and function
1. Coolant filling
2. Heat exchanger
3. Relay box with fuses
4. Alternator
5. Starter 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 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
13
Design and function
18
16
1
3
5
17
2
4
12
8
10
7
19 20
9
13 14
15
11
1. Coolant filling
2. Heat exchanger
3. Relay box with fuses
4. Alternator
5. Starter 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
14
Design and function
D2-75 A with reverser HS25A D2-75 A with reverser HS25A
D2-75 A with reverser MS25L
7
23
D2-75 A with reverser MS25L
6
1
8
5
4
15 14
17
13
16
9
10
12 11
7
23
9
1
8
5
4
17
16
11
15
12
6
10
13 14
15
Design and function
D2-75 A with sail-drive 150S
20
18
19
14
10
12
9
21 22
11
15
16
17
13
D2-75 A with sail-drive 150S
7
23
1
8
5
4
1. Coolant filling
2. Relay box with fuses
3. Heat exchanger
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
16
Design and function
Component description
Cylinder head
The cylinder head is made from specially alloyed cast
iron. It has replaceable valve seats for inlet and exhaust valves on D2-55 A/B/C and for exhaust valves
on D2-75 A.
Engine block
The cylinder block is cast in one piece from 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 helical gears.
The camshaft and sea water pump are driven from the
crankshaft gear via an idler gear. The engine’s lubrication pump is integral with the idler gear, and is driven
by it. Regulator weights are suspended on the front of
the camshaft gear.
17
Design and function
Camshaft
The camshaft is of conventional design with eight
lobes that operate the pushrods and valves.
Crankshaft
The crankshaft is suspended in five main bearings.
Axial thrust is taken up by separate thrust washers
placed on the rear main bearing. The crankshaft is
statically and dynamically balanced, and has induction hardened bearing surfaces. The front end of the
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 drilled
for gudgeon pin lubrication.
Pistons, piston rings
The pistons are made from aluminum alloy. They are
fitted with three piston rings (chrome plated) – two
compression rings and an oil ring.
18
Design and function
Cooling system, general
The engine is fresh water cooled with a closed cooling
system. The system is divided into two circuits.
In the inner circuit, the fresh watersystem, coolant is
pumped around by a circulation pump, driven via a
belt from the crankshaft pulley.
The fresh water system works under pressure, thus
reducing the risk of boiling if the temperature becomes
high. If the pressure becomes excessive, a pressure
valve opens in the filler cap.
The coolant temperature is regulated by a thermostat.
The flow in the sea water system is accomplished by
a gear-driven impeller pump.
The heat exchanger 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 sensor 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, the volume of the wax increases and the thermostat progressively opens the passage to the heat exchanger, at
the same time as the by-pass channel is closed.
Please refer to the “Technical Data” chapter for opening temperatures.
Sea water pump
The sea water pump is driven by the gears in the timing gear. The impeller (pump wheel) is made from rubber and is replaceable.
NOTE! The impeller will be damaged if the pump is run
dry.
19
Design and function
Fuel system, general
The fuel is sucked from the fuel tank by the feed
pump, through a water separator/pre-filter (extra
equip.) and is pressed through a fine filter to the injection pump.
Return fuel from the injectors is fed through return fuel
lines, back to the tank.
Injection pump
The injection pump is an in-line flange mounted pump.
The pump is driven by cams on the engine’s camshaft, which operates the pump chambers directly.
Centrifugal regulator
The regulator is mechanical and works with speedsensitive 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 control rod via the regulation sleeve, a lever and a regulator arm. The engine speed is regulated throughout the
entire range, from low idle to high idle (all-speed type).
1. Fuel tank 5. Fuel fine filter
2. Primary filter 6. Injection pump
3. Water separator 7. Injectors
4. Feed pump
20
Design and function
Feed pump
The feed pump is driven by an eccentric on the camshaft rear end. The pump on D2-55 A/B is also
equipped with a manual hand pump.
Injectors
The engines is provided with pintle - type injectors.
Each injector basically consists of a nozzle retainer
and a nozzle.
When the fuel pressure increases to the 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 precombustion 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 paper filter.
1. Injector nut 6. Adjustment shims
2. Injectors 7. Injector holder
3. Joining piece 8. Washer
4. Compression screw 9. Nut
5. Spring
1
2
3
4
5
6
7
8
9
21
Design and function
Lubrication system, general
The engine has a pressurized lubrication system with
full-flow oil filter.
Oil pump
The lubrication pump is located within the idler gear on
the timing gears, from where it is also driven.
The pump is a rotor pump, with an inner rotor and an
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 vacuum occurs and oil is sucked into the inlet. After
about a half rotation, the volume is reduced and a
pressure occurs, which forces the oil out through the
outlet.
22
Design and function
Reduction valve
The lubricating oil pressure is limited by a reduction
valve. The valve is located in the lubricating system
just before the oil filter. The valve opens with high
pressure and allows the oil to flow back into the sump.
Crankcase breather
To prevent over-pressure 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 allows oil to flow past the filter if the
filter insert should become blocked.
A
D2-55A/B/C
D2-75A
23
General
A condition test should be done before each major
service activity, if possible, to determine the general
condition of the engine and discovery any concurrent
fault causes. A condition test requires the engine to
be run, so this should be done before the engine or
any engine components are disassembled.
Please refer to “Condition test, engine”.
Repair instructions
Measures before overhaul in boat
1 Remove battery power.
2 Clean the outside of the engine.
NOTE! Make sure that wash residue is collected
for destruction and does not inadvertently end up
in the water. Also refer to the warning text under
“Actions after lifting the engine”.
3 Work involving the cooling system: Close the sea
cocks and drain the coolant from the sea water
and fresh water systems.
WARNING! Make sure that all sea water inlets
are securely 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 Close the fuel stopcocks. Remove the fuel con-
nections.
7 Disconnect the throttle and gearshift wires.
8 Disconnect the propshaft from the reverser. Undo
the engine mounting pads from the bed and lift the
engine out.
Actions after lifting the engine
1 Clean the engine.
IMPORTANT! Remember the following when
washing with a power washer: Be extremely
careful when cleaning, to avoid getting water inside engine components. When a power washer
is used, the water jet must never be aimed at
seals, such as shaft seals, joints with gaskets,
rubber hoses or electrical components.
2 Drain the engine oil.
3 Remove the reverser (if required).
24
Repair instructions
Condition test, engine
Compression test
Special tools: 885 484, 885 252 and 998 8539
A compression test is done, which shows the sealing
of the cylinders and valves, to assess the condition of
the engine in a simple, reliable manner.
• Warm the engine up, then stop it.
• Remove all the injectors and test each of the cylin-
ders in turn.
IMPORTANT! Observe the greatest possible
cleanliness, to avoid getting dirt in the fuel sys-
tem. Plug the connections for the disassembled
injectors and fuel pipes.
The compression pressure shall be read off at normal
starter motor speed, refer to “Technical data”.
Low combustion pressure in all cylinders indicates
worn cylinder bores and piston rings. If one cylinder
has lower 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 injector 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
stand 998 6485 or 856 927.
The fixture is attached to the right side of the engine
as illustrated below.
NOTE! It is important that the instructions regarding
number of attachment bolts and sizes are followed to
ensure secure engine attachment.
Bolts required:
1 pcs M10 x 35 mm
3 pcs M14 x 1.5 x 35 mm
Before the engine fixture can be mounted and the engine attached to the overhaul stand, the right front engine mounting, oil dipstick tube, oil cooler with oil filter
and turbo oil pipe (D2-75), must be removed from the
engine.
25
Group 21 Short block
Short block, disassembly
Special tools: 885 510, 885820, 885822
Empty the oil and water from the engine.
Lift the engine with a suitable lifting device. Installing
the engine fixture, please refer to “Engine fixture, fixing”.
1. 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 cabling.
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 turbo (only D2-75).
6
2
3
1
5
4
9
11
10
8
7
7
7
26
Group 21 Short block
8. Remove (13) oil pressure monitor and oil pressure
pipe (12) to the cylinder head.
9. Remove the fuel lines (14) between the injection
pump, fuel filter and feed pump.
WARNING! Observe the greatest possible
cleanliness in work on the fuel system. Watch
out for fuel spillage, diesel oil is hazardous on
repeated skin contact.
10. Remove the supply pipes (15) between the fuel
pump and injectors, use the nut on the return fuel
line as a counterhold so as not to bend the pipes.
Remove the fuel supply pipes and put them on a
clean, dry surface.
11. Remove the return fuel pipe (16) and the injectors.
IMPORTANT! Observe the greatest possible
cleanliness, to avoid getting dirt in the fuel sys-
tem. Plug the fuel pump and injector connections 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 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 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 shims when
re-installing, unless the camshaft, engine block or injection pump have been changed.
27
Group 21 Short block
14. Remove the rocker cover, power rail and glow
plugs.
15. Remove the lower part of the rocker cover with integrated rocker arm bridge. Start by unscrewing
the two M6 screws at the outer edge, then loosen
the rocker arm bridge nuts half a turn at a time,
until the rocker arms are no longer under load.
16. Prepare a stand, marked with cylinder numbers. If
the rocker arms, valve caps, pushrods and valve
lifters are to be re-used, these must be fitted in
their original positions.
Lift the push rods and valve caps out and put in
them in number sequence in the marked stand.
17. Loosen the bolts in the opposite tightening sequence (refer to “Installing cylinder head”). Remove the cylinder head.
18. Remove the valves, if these are to be re-used,
they must be fitted in their original positions. Special 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 flywheel
casing is removed.
20. Mark the position of the flywheel on the crankshaft. Remove the flywheel.
22. Remove the inner flywheel casing and the rear
shaft seal.
23. Remove the pulley, use special tool 885 820 and
3 pcs. M10x40 mm bolts. Remove the timing gear
cover. Load the stop arm so that the springs on
the inside of the housing do not come out of position or spring out.
18
17
16
15
14
1312
11
10
98
7
6
54
3
2
1
28
Group 21 Short block
24. Remove the idler lock ring. Save the sleeve washer, spring and shims.
Lift away the idler gear complete with cover and
oil pump. Note the thrust washer behind the oil
pump.
25. Remove the camshaft and gear. Remove the
screws from the locking plate, the screws are accessible through a hole in 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 cylinders to simplify disassembly. Check that the conrod caps are marked so that they can be reassembled correctly.
Remove the con rod caps and push out the pistons.
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