Repair Procedures - Volvo Penta D2-55 Workshop Manual

The working methods described in the Service Manual
apply to work carried out in a workshop. For this rea-
son, the engine is lifted out of the boat and mounted
on an engine support. Renovation work which does
not need the engine to be lifted out can be done in
situ, with the same work methods, unless otherwise
specified.
Warning symbols used in this Service Manual (for full
explanation of the symbols refer to the section;
"Safety Precautions" )
WARNING!
IMPORTANT!
NOTE!
are not in any way comprehensive since it is
impossible to predict every circumstance under which
service work or repairs may be carried out. For this
reason, all we can do is to point out the risks which
we believe could occur due to incorrect work in a well-
equipped workshop, using work methods and tools
tested by us.
All operations described in the Service Manual for
which there are Volvo Penta Special Tools available
assume that these tools are used when carrying out
the repair. Volvo Penta Special Tools have been
specifically developed to ensure the most safe and
rational working methods possible. It is therefore the
responsibility of anyone using other tools or other
working methods than we recommend to determine
that there is no risk of personal injury or mechanical
damage or malfunction as a result.
In some cases special safety precautions and user
instructions may be required in order to use the tools
and chemicals mentioned in the Service Manual.
These rules must always be observed, so there are no
special instructions about this in the Service Manual.
By following these basic recommendations and using
common sense it is possible to avoid most of the
risks involved in the work. A clean workplace and a
clean engine will eliminate many risks of personal
injury and engine malfunction.
Above all, when work on fuel systems, lubrication
systems, induction systems, turbocharger, bearing
caps and seals is done, it is extremely important that
no dirt or other kinds of foreign particles are able to
get in, since this would otherwise cause malfunctions
or shortened repair life.
6

Repair procedures

Our common responsibility
Each engine consists of a large number of collaborating
systems and components. Any deviation of a
component from its technical specification can
dramatically increase the environmental impact of an
otherwise good engine. For this reason, it is extremely
important that specified wear tolerances are
maintained, that systems with adjustment facilities are
correctly adjusted and that Volvo Penta Original Spares
are used for the engine. The stated service intervals in
the Maintenance Schedule must be observed.
Some systems, such as the components in the fuel
system, require special expertise and special testing
equipment for service and maintenance. Some
components are sealed at the factory, for
environmental reasons etc. It is only permissible to
work on sealed components if you are authorized to
do such work.
Remember that most chemical products, incorrectly
used, damage the environment. Volvo Penta
recommends the use of biodegradable degreasers
whenever engine components are de-greased, unless
otherwise specified in the Service Manual. When
working aboard a boat, be careful to ensure that oils,
wash residue etc. are processed for destruction, and
are not inadvertently discharged with bilge water into
the environment.
Tightening torque
The tightening torque for critical joints that shall be
tightened with a torque wrench, are listed in
"Specifications: Tightening torque" and noted in the
job descriptions in the book. All torque specifications
apply to clean screws, screw heads and mating faces.
Torque data stated apply to lightly oiled or dry
threads. Where grease, locking or sealing agents are
required for screwed joints, this is stated in both the
operation description and in "Torque". Where a
particular torque value is not specified for any faste-
ner, the general tightening torque in the table below
shall apply. The torque specification is a target value
and the fastener does not need to be tightened with a
torque wrench.
Dimension
M5
M6
M8
M10
M12
M14
Tightening torque
Nm lbf.ft
6 4.4
10 7.4
25 18.4
50 36.9
80 59.0
140 103.3