Volvo Penta D2-55 | D2-75 and Sailboat Drives Service Workshop Manual

Workshop Service and Repair Manual for the D2-55 & D2-75 Volvo Penta engines This full workshop manual set covers every component, service and repair procedure including the MS25 and S130 – S150 Sailboat drives in full Volvo Penta factory specification with clear concise step by step photographs and technical drawings for the D2 engines and Drives with torque setting values throughout where required for fasteners, below is an exhaustive list of the items covered within this set.
This is the most comprehensive service manual set available as used by marine engineers and boatyards the world over.

For Engines:
D2-55 & D2-75

For Sailboat drives:
MS25S, MS25S-r
130S-A, 130SR-A, 130S-B,
130SR-B, 130S-C, 130SR-C
150S-A, 150SR-A, 150S-B,
150SR-B, 150S-C, 150SR-C

D2-55 & D2-75 ENGINE WORKSHOP MANUAL

Safety Precautions
General Information
Special Tools
Design And Function
Location Of Engine – Type Signs
Engine Introduction
Component Description
Repair Instructions
General
Engine Fixture, Fixing
Compression Test

GROUP 1 SHORT BLOCK
Short Block, Disassembly
Inspecting The Engine Block
Upper Block Plane
Cylinder Bore
Cylinder Head, Overhaul
Cylinder Head, Disassembly
Cylinder Head, Inspection
Valve Seat, Replace
Valves And Valve Seats, Grinding
Valve Guides, Check
Rocker Arm Mechanism, Overhaul
Cylinder Head, Assembly
Crankshaft, Inspection
Main And Big-end Bearings, Inspection
Crankshaft Bush, Front, Inspection
Crankshaft Bush, Front, Replace
Crank Bearing Play, Check
Piston Rings, Inspection And Adjustment
Piston And Cylinder Bore, Inspection And
Measurement
Con Rods, Inspection
Con Rod Bush, Replace
Piston, Piston Rings And Con Rods, Installation
Camshaft, Measurement
Timing Gear Assembly, Inspection
Crankshaft, Installation
Piston, Installation In Cylinder
Camshaft, Installation
Cylinder Head, Installation
Valve Lifters, Inspection
Valves, Adjustment
Flywheel, Replace Ring Gear
Crankshaft Seal, Rear, Replace
Crankshaft Seal, Front, Replace

GROUP 2 LUBRICATION SYSTEM
Oil Pump
Oil Channels
Oil Pump Bearing, Overhaul
Group 23: Fuel System
Injection Pump
Setting Injection Timing
Setting The Engine Speed
Feed Pump
Venting The Fuel System
Fuel Filter, Replace
Fuel Pre-filter, Drain And Replace
Injectors
Group 26: Cooling System
Fresh Water System
Coolant
Draining Coolant
Filling With Coolant
Checking The Coolant Level
Cleaning Heat Exchanger
Circulation Pump
Sea Water Pump
Thermostat

GROUP 3 ELECTRICAL SYSTEM
Description
Important Information Concerning
The Electrical System
Fault Tracing, Glow Plugs, Charging System
Alternator
Starter Motor
Electrical Components
Wiring Diagrams

GROUP 0 TECHNICAL DATA
Technical Data
Wear Tolerances
Tightening Torque

D2 ENGINE 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
Exhaust System
Engine Room Ventilation
Soundproofing
Fuel System
Electrical System 1
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
References To Service Bulletins

SAILBOAT DRIVES WORKSHOP MANUAL S130 – S150
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 And Lower Gear Housing, Disassembly
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

SAILBOAT DRIVES WORKSHOP MANUAL MS25S – MS25S-R
General Information
About The Workshop Manual
Spare Parts
Repair Instructions
Tightening Torque
Torque-angle Tightening
Lock Nuts
Strength Classes
Sealants
Safety Rules For Fluorocarbon Rubber
Special Tools
Other Special Equipment
Chemicals
Design And Function
Powertrain
Upper Gear Housing
Lower Gear Housing
Disassembly – Upper And Lower Gear Housings
Repair – Upper Gear Housing
Repair – Lower Gear Housing
Pressure Testing
Painting Of The Drive
Technical Data
References To Service Bulletins