Volvo Penta D25A MS, D25A MT D30A MS, D30A MT Workshop Manual (400569232)- PDF DOWNLOAD

Volvo Penta D25A MS, D25A MT D30A MS, D30A MT Workshop Manual (400569232)- PDF DOWNLOAD

DESCRIPTION:

D25A MS, D25A MT
D30A MS, D30A MT

Volvo Penta D25A MS, D25A MT D30A MS, D30A MT Workshop Manual (400569232)- PDF DOWNLOAD

Introduction
The Manual contains technical data, descriptions, and repair instructions for the designated Volvo Penta engines
or engine versions. Make sure that the correct workshop literature is used.
Read the following safety information and the General Information and Repair Instructions in the Workshop Manual
carefully before starting service work.
Important
The following special warning symbols are used in the Workshop Manual and on the engine.
WARNING! Warns of risk of bodily injury, serious damage to product or property, or that a serious malfunction
can occur if the instructions are not followed.
IMPORTANT! Used to attract attention to things that can cause damage or malfunction to product or property.
NOTE! Used to attract attention to important information, to simplify work procedures or handling.
The following list provides an overview of the risks and cautionary procedures that should always be observed.

General Information
About the Workshop Manual
This Workshop Manual contains technical information, descriptions, and instructions for the standard versions of
the D25A and D30A engines. The engine designation and numbers are to be found on the engine identification
plate, refer to section “Identification numbers”. The motor designation and number should always be given during
all correspondence with Volvo Penta.
The Workshop Manual is primarily produced for Volvo Penta service workshops and their qualified personnel. It
is therefore assumed that persons using this manual have a basic knowledge of marine drive systems, and are
able to carry out the related mechanical and electrical nature. Volvo Penta is continuously developing their products.
We therefore reserve the right to make changes. All the information contained in this book is based on
product data available prior to publication. Any essential changes or modifications in production or updated or revised
service methods introduced after publication will be communicated by means of Service Bulletins.
Spare parts
Spare parts for the electrical and fuel systems are subject to different national safety requirements, e.g. U.S.
Coast Guard Safety Regulations. Volvo Penta Genuine Spare Parts comply with these requirements. All types of
damage resulting from the use of non genuine Volvo Penta spare parts for the product in question will not be regulated
by the warranty undertakings of Volvo Penta.
Certified engines
For service and repair on an engine certificated for any area where exhaust emissions are regulated by law, the
following is important:
Certification means that an engine type is inspected and approved by the authorities. The engine manufacturer
guarantees that all engines manufactured of that type correspond to the certified engine.
This places special requirements on maintenance and service as follows:
● The maintenance and service intervals recommended by Volvo Penta must be observed.
● Only genuine Volvo Penta replacement parts may be used.
● The service of injection pumps and injectors or pump settings must always be carried out by an authorized
Volvo Penta workshop.
● The engine must not be modified in any way except with accessories and service kits approved by Volvo
Penta.
● No modifications to the exhaust pipes and air supply ducts for the engine may be undertaken.
● Seals may only be broken by authorized personnel.
Otherwise the general instructions contained in the Operator’s manual concerning operation, service and maintenance
must be followed.
IMPORTANT! Neglected or deficient maintenance/service and the use of non-original spare parts will entail
Volvo Penta renouncing any responsibility for the engine corresponding to the certified version. Volvo Penta
will not compensate for damage and/or costs arising from the above.

TABLE OF CONTENTS:

Volvo Penta D25A MS, D25A MT D30A MS, D30A MT Workshop Manual (400569232)- PDF DOWNLOAD

Safety Information 5
Introduction 5
Important 5
Warning labels D25A / D30A MS 8
Warning labels D25A / D30A MT 9
General Information 10
About the Workshop Manual 10
Spare parts 10
Certified engines 10
Repair instructions 11
Our joint responsibility 11
How to Use This Manual 12
Terms used in this manual 12
Disassembly and Reassembly 13
Presentation D25A/D30A MS 16
Presentation D25A/D30A MT 17
Identification numbers D25A/D30A 18
Specification D25A/D30A 19
Maintenance Standards Table 22
General 22
Engine main parts 23
Reassembly 27
Inlet and exhaust system 31
Lubrication system 33
Cooling system 34
Fuel system 36
Electric system 39
Tightening torques D25A 41
Tightening torques D30A 43
Standard Bolts and Nuts 45
Standard eyebolts 45
Standard union nuts 46
High pressure fuel injection pipes 46
Sealants and Lubricants Table 47
Special Tools 48
Determination of overhaul timing 51
Content
Oil Filter Filter Alarm Relief Valve
Left Side Cooler and Thermostat 135
Inspection 135
Reassembly 135
Group 23 Fuel System 136
Fuel Filters 136
Reassembly 137
Fuel Injectors 138
Inspection and Adjustment 139
Reassembly 141
Fuel Injection Pump 142
Inspection 147
Reassembly 150
Adjustment of Injection Timing 159
Feed Pump 161
Reassembly 162
Testing 162
PSG Woodward Governor and Drive 163
Inspection 164
Reassembly 165
Group 25 Inlet and Exhaust System 166
Air Cooler 166
Inspection 167
Turbocharger [TD13] 168
Disassembly 169
Inspection 172
Reassembly 174
Turbocharger [TD15] 180
Disassembly 181
Inspection 184
Reassembly 186
Group 26 Cooling System 193
Fresh Water Pump 193
Inspection 195
Reassembly 196
Thermostats 198
Heat Exchanger 199
Raw Water Pump(standard rubber impeller) 200
Inspection 201
Reassembly 202
Group 30 Electrical System 206
Starter 206
Inspection and Repair 209
Reassembly 213
Alternator 216
Inspection and repair 217
Reassembly 217

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