Volvo Penta D1-13, 20, 30 | D2-40 Service Workshop Manual

INSTALLATION MANUAL
Safety precautions
General information
Conversion factors
Special tools
Installation drawings
Engine installation
Engine inclination
Flexible shaft seal
Rigid shaft seal
Fitting of reverse gear and S-drive
S-drive insulation
Rubber mounts
Propeller shaft system
Front end power take-off
Cooling system
Exhust system
Engine room ventilation
Soundproofing
Fuel system
Electrical system
Connection of battery cables
Controls
S-drive installation
Preparation
Cutting and fiberglassing of engine bed
Installation of drive and engine
Fitting of the rubber seal
Installation of propeller
Oil quality and filling

WORKSHOP MANUAL:
General Information
Engine Specifications,
Design and Function
Test and Adjustments
Repair Instructions
Engine
Lubrication System
Fuel System
Cooling System
Electrical secifications,
Electrical System
Safety Instructions
Special tools

ENGINE:
Short block, disassembly
Inspection, component change, overhaul and
assembly of the short block engine
Inspecting the engine block
Inspecting the cylinder head
Changing the valve seats
Grinding of valve and valve seats
Checking the valve guides
Renovating the rocker arm mechanism
Inspecting the crankshaft
Inspection of the and crankshaft bushing and
crankshaft journal
Inspection of main and big end bearings
Checking the big end bearing clearance
Piston ring inspection and fits
Inspection and measurement of piston and cylinder bore
Inspecting the con rod
Changing the gudgeon pin bushing
Assembling the piston, piston rings and con rod
Camshafts and valve lifters, inspection
Measuring the camshaft
Installing the crankshaft
Installing the piston in the cylinder and the oil pan
Installing the timing gear and injection pump
Flank clearance, checking
Measuring the piston height, installing the cylinder ead and other assembly
Cylinder head removal & installation
Valves removal & installation
Timing gear removal & installation
Pistons, removal
Big end bearing, change
Pistons, change
Pistons, installation
Crankshaft, remove
Main bearings, change
Crankshaft, assembly
Flywheel, change
Crankcase seal rear, change
Crankshaft seal, front, change
Valves, adjustment
Drive belt, change

LUBRICATING & OIL SYSTEM:
Lubrication oil system
Oil pump and Line
Oil valves
Oil filter

FUELSYSTEM:
Fuel system General
Injection pump
Centrifugal regulator
Injectors
Fuel filter
Feed pump
Hand pump
Delivery Pipes

COOLING SYSTEM:
Cooling System General
Pressure valve in filler cap, checking
Fault causes, cooling system
Thermostat, change
Heat exchanger, cleaning
Heat exchanger/exhaust manifold, changing
Seawater pump, impeller change
Radiator
Heat Exchanger
Coolant Pump
Thermostat
Sea Water System
Sea Water Pump

ELECTRICAL SYSTEM:
General information
Spare parts
Repair instructions
Torque
Special tools
The MDI system
Component location
Component description:
MDI:
Switch, oil pressure, engine
Sensor, coolant temperature
Sensor, engine speed (flywheel)
Stop solenoid
Glow plugs
Starter motor
Alternator

Repair Instructions:
General advice
Fault tracing of cables and connectors
Starter motor
Checking battery voltage
Checking alternator brushes
Checking the charging system
Checking the instruments

MALFUNCTIONS:
Oil pressure (engine) warning
Check MDI output for oil pressure switch
Coolant temperature warning
Check MDI output for coolant temperature sensor
Check coolant temperature sensor
Multilink fault
Check speed sensor, flywheel
Check NMEA 2000 Gateway LED
Fuel level warning
Check fuel level sensor
Button panel fault
Check button panel
Stop solenoid fault
Check stop solenoid
Start / preheat warning
Battery warning
Check alternator excitation voltage
Wiring diagram
Pin configuration, MDI
Electrical system
Alternator
Starter motor
Technical data

SAILBOAT DRIVE WORKSHOP MANUAL:
Safety information
General information
Repair instructions
Special tools
Other special equipment
Design and function
Gear change principle
Upper gear housing
Lower gear housing

Repair instructions
Upper gear, renovation:
Disassembly
Inspection
Gear mechanism, renovation
Upper gear, assembly
Upper gear, final assembly
Shift mechanism, adjustment

Lower gear, renovation:
Disassembly
Assembly
Gear wheels 130S, shimming
Gear wheels 150S, shimming
Pinion gear 130S, shimming
Pinion gear 150S, shimming
Final assembly

Upper and lower gear housing, assembly:
Pressure testing
Rubber bushing, change
Painting

Shimming, quick reference guide:
Shim calculation, lower gear housing 130S
Shim calculation, lower gear housing 150S
Shim calculation, lower gear housing
Shim table, upper gear housing
Troubleshooting
Technical data
Torque settings