VOLVO PENTA D2-55 D2-75 MARINE FACTORY WORKSHOP SERVICE REPAIR MANUAL Marine engine D2-55 A/B/C D2-75 A D2 55 D2 75 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