Repair Instructions - Volvo Penta MD22 Workshop Manual

The working methods described in the Service Man-
ual apply to work carried out in a workshop. The en-
gine has been removed from the boat and is in-
stalled in an engine fixture. Unless otherwise stated
reconditioning work which can be carried out with
the engine in place follows the same working meth-
od.
Warning symbols occurring in the Workshop Manu-
al (for their meaning see Safety information)
WARNING!
IMPORTANT!
NOTE!
are not in any way comprehensive since it is impos-
sible to predict every circumstance under which
service work or repairs may be carried out. For this
reason we can only highlight the risks that can arise
when work is carried out incorrectly in a well-
equipped workshop using working methods and
tools developed by us.
All procedures for which there are Volvo Penta spe-
cial tools in this Workshop Manual are carried out
using these. Special tools are developed to rational-
ize working methods and make procedures as safe
as possible. It is therefore the responsibility of any
person using tools or working methods other than
the ones recommended by us to ensure that there is
no danger of injury, damage or malfunction resulting
from these.
In some cases there may be special safety precau-
tions and instructions for the use of tools and chem-
icals contained in this Workshop Manual. These
special instructions should always be followed if
there are no separate instructions in the Workshop
Manual.
Certain elementary precautions and common sense
can prevent most risks arising. A clean workplace
and engine eliminates much of the danger of injury
and malfunction.
It is of the greatest importance that no dirt or for-
eign particles get into the fuel system, lubrication
system, intake system, turbocharger, bearings and
seals when they are being worked on. The result can
be malfunction or a shorter operational life.

Repair Instructions

Our Joint responsibility
Every engine consists of many systems and com-
ponents that work together. If one component devi-
ates from the technical specifications this can have
dramatic consequences on the environmental im-
pact of the engine even if it is otherwise in good
running order. It is therefore vital that wear toler-
ances are maintained, that systems that can be ad-
justed are adjusted properly and that Volvo Penta
Genuine Parts as used. The engine Maintenance
Schedule must be followed.
Certain systems (components in the fuel system for
example) may require specialist expertise and test
equipment. Some components are sealed at the fac-
tory for environmental reasons. No work should be
carried out on sealed components except by author-
ized personnel.
Bear in mind that most chemicals used on boats are
harmful to the environment if used incorrectly. Vol-
vo Penta recommends the use of biodegradable de-
greasing agents for cleaning engine components,
unless otherwise stated in a workshop manual.
Take special care when working on-board, that oil
and waste is taken for destruction and is not acci-
dentally pumped into the environment with bilge wa-
ter.
Tightening torque
Tightening torques for vital joints that must be tight-
ened with a torque wrench are listed in Workshop
manual "Technical Data": and are in certain cases
contained in work descriptions in this Manual. All
torques apply for cleaned threads, screw heads and
mating surfaces. Torques apply for lightly oiled or
dry threads. If lubricants, locking fluid or sealing
compound are required for a screwed joint this in-
formation will be contained in the work description.
Where no tightening torque is stated for a joint use
the general tightening torques according to the ta-
bles below. The tightening torques stated are a
guide and the joint does not have to be tightened us-
ing a torque wrench.
Dimension Tightening torques
M5 ..................
M6 .................. 10
M8 .................. 20
M10 ................ 40
M12 ................ 70
M14 ................ 115
Nm
5
7