Volvo Penta D1 13 D1 20 D1 30 D2 40 Engine Group 21-26 30 Workshop Manual 345777913 – PDF DOWNLOAD

Volvo Penta D1 13 D1 20 D1 30 D2 40 Engine Group 21-26 30 Workshop Manual 345777913 – PDF DOWNLOAD

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Volvo Penta D1 13 D1 20 D1 30 D2 40 Engine Group 21-26 30 Workshop Manual 345777913 – PDF DOWNLOAD

Language : English
Pages : 120
Downloadable : Yes
File Type : PDF
Size: 1.79 MB

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Volvo Penta D1 13 D1 20 D1 30 D2 40 Engine Group 21-26 30 Workshop Manual 345777913 – PDF DOWNLOAD

Introduction:

• This workshop 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 workshop manual before you start to do any service work.

About this Workshop Manual :

This workshop manual contains technical data, descriptions and repair instructions for the following marine diesel engines: D1-13, D1-20, D1-30 and D2-40. The engine designation and number are noted on the number plate and engine decal. The engine designation and number must always be given in all correspondence about any product. The Workshop 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.

TABLE OF CONTENTS:

Volvo Penta D1 13 D1 20 D1 30 D2 40 Engine Group 21-26 30 Workshop Manual 345777913 – PDF DOWNLOAD

Safety information …………………………………………………… 3
General information ………………………………………………… 6
About this Workshop Manual ………………………………….. 6
Spare parts …………………………………………………………… 6
Certified engines …………………………………………………… 6
Repair instructions …………………………………………………. 7
Our common responsibility …………………………………….. 7
Torque …………………………………………………………………. 7
Torque-angle tightening …………………………………………. 8
Lock nuts ……………………………………………………………… 8
Strength classes ……………………………………………………. 8
Sealant ………………………………………………………………… 8
Safety rules for fluorocarbon rubber …………………………… 9
Special tools …………………………………………………………. 10
Design and function
Group 21 Short block
Engine, general …………………………………………………… 12
Engine block ………………………………………………………. 16
Cylinder head ……………………………………………………… 16
Crankshaft ………………………………………………………….. 17
Timing gear ………………………………………………………… 18
Crankcase breather …………………………………………….. 18
Group 22 Lubrication system
Lubrication oil system ………………………………………….. 19
Oil valves ……………………………………………………………. 20
Oil pump …………………………………………………………….. 20
Oil filter ………………………………………………………………. 20
Group 23 Fuel system
Fuel system ………………………………………………………… 21
Injection pump …………………………………………………….. 22
Centrifugal regulator ……………………………………………. 22
Injectors ……………………………………………………………… 22
Fuel filter …………………………………………………………….. 23
Feed pump …………………………………………………………. 23
Group 26 Cooling system
Cooling system …………………………………………………… 24
Thermostat …………………………………………………………. 25
Heat exchanger …………………………………………………… 25
Sea water pump ………………………………………………….. 25
Coolant pump ……………………………………………………… 25
Group 30 Electrical system
Electrical system …………………………………………………. 26
Alternator ……………………………………………………………. 27
Starter motor ……………………………………………………….. 27
Distribution box …………………………………………………… 27
Electrical components ………………………………………….. 28
Repair instructions
When working with chemicals, fuel and lubricating oil 29
Before working in a boat ………………………………………. 29
Before lifting the engine ……………………………………….. 29
Condition test, engine ………………………………………….. 30
Compression test ………………………………………………… 30
Actions after lifting the engine ……………………………….. 30
Cooling system, draining ……………………………………… 31
Engine oil, draining/changing ……………………………….. 31
Engine fixture, fixing …………………………………………….. 32
Group 21 Short block
Short block, disassembly ……………………………………… 33
Inspection, component change, overhaul and
assembly of the short block engine ………………… 37-53
Inspecting the engine block ………………………………….. 37
Inspecting the cylinder head …………………………………. 38
Changing the valve seats …………………………………….. 38
Grinding of valve and valve seats ………………………….. 39
Checking the valve guides …………………………………… 40
Renovating the rocker arm mechanism ………………….. 41
Inspecting the crankshaft ……………………………………… 42
Inspection of the and crankshaft bushing and
crankshaft journal ………………………………………………… 42
Inspection of main and big end bearings. ………………. 42
Checking the big end bearing clearance: ………………. 43
Piston ring inspection and fits ……………………………….. 44
Inspection and measurement of piston and cylinder
bore. ………………………………………………………………….. 44
Inspecting the con rod ………………………………………….. 45
Changing the gudgeon pin bushing ………………………. 45
Assembling the piston, piston rings and con rod. …….. 46
Camshafts and valve lifters, inspection ………………….. 47
Measuring the camshaft ……………………………………….. 47
Installing the crankshaft ……………………………………….. 49
Installing the piston in the cylinder and the oil pan ….. 50
Installing the timing gear and injection pump ………….. 51
Flank clearance, checking ……………………………………. 52
Measuring the piston height, installing the cylinder
head and other assembly …………………………………….. 53
Continued on next page
Cylinder head, removal ………………………………………… 56
Valves, removing …………………………………………………. 58
Valves, installation ………………………………………………. 58
Cylinder head, installation ……………………………………. 59
Timing gear, removing …………………………………………. 61
Timing gear, installation ……………………………………….. 64
Pistons, removal ………………………………………………….. 67
Big end bearing, change ……………………………………… 68
Pistons, change …………………………………………………… 68
Pistons, installation ……………………………………………… 69
Crankshaft, remove ……………………………………………… 70
Main bearings, change ………………………………………… 71
Crankshaft, assembly …………………………………………… 73
Flywheel, change ………………………………………………… 74
Crankcase seal rear, change ………………………………… 75
Crankshaft seal, front, change ………………………………. 76
Valves, adjustment ………………………………………………. 77
Drive belt, change ……………………………………………….. 79
Group 22 Lubrication system
Oil pump bearing, changing …………………………………. 80
Group 23 Fuel system
Injection pump, changing ……………………………………… 81
Injectors, changing ………………………………………………. 83
Injectors, testing ………………………………………………….. 85
Injectors, check …………………………………………………… 85
Setting the engine speed ……………………………………… 86
Feed pump, changing ………………………………………….. 87
Hand pump, changing …………………………………………. 88
Fuel system, venting ……………………………………………. 89
Group 26 Cooling system
Coolant ………………………………………………………………. 90
Pressure valve in filler cap, checking …………………….. 91
Fault causes, cooling system ………………………………… 91
Thermostat, change …………………………………………….. 92
Heat exchanger, cleaning …………………………………….. 93
Heat exchanger/exhaust manifold, changing ………….. 94
Seawater pump, impeller change ………………………….. 95
Sea water pump, change ……………………………………… 96
Coolant pump, change ………………………………………… 97
Group 30 Electrical system
Alternator, changing …………………………………………….. 98
Starter motor, changing ………………………………………… 99
Wiring diagram ……………………………………………………. 100
Technical data …………………………………………………….. 103
References to Service Bulletins …………………………… 116