Volvo Penta MD22, TMD22, TAMD22 Marine Diesel Engine Workshop Manual Set (P/N 7738684-5)

This Volvo Penta workshop manual set covers the MD22, TMD22, and TAMD22 marine diesel engines. It combines Engine Repair (7738684-5), Technical Data (7740079-4), and Wiring Diagram (7740536-3).

• Cylinder head and valvetrain: Cylinder head removal, valve and guide replacement, valve-seat repair, camshaft service, and shim-based valve-clearance adjustment.

• Pistons and crankshaft: Piston and connecting rod assembly, bearing replacement, crankshaft inspection, cylinder-bore honing, and flywheel checks.

• Timing and fuel systems: Timing-belt replacement and tensioning, injection timing, injector fault tracing, feed-pump reconditioning, fuel-pressure testing, and bleeding.

• Lubrication and cooling: Oil-pump and relief-valve inspection, seawater-pump overhaul, thermostat testing, heat-exchanger resealing, and TAMD22P-B charge-air cooler service.

• Electrical diagnosis: Alternator fault tracing, starter-motor checks, glow-plug testing, and engine and instrument-panel wiring diagrams with connector identification.

• Turbocharger service: TMD22/TAMD22 turbocharger removal and installation, boost-pressure control valve checks, and replacement criteria.

Written primarily for Volvo Penta service workshops and qualified personnel, these manuals assume a grounding in marine drive systems and related mechanical and electrical work.

Cylinder Head and Bottom-End Repair

The repair volume explains piston height-class selection and the different piston-ring designs used in MD22L/MD22/TMD22 and TMD22P/TAMD22 engines. These distinctions help identify the correct replacement piston and ring arrangement before a rebuild.

Cylinder-head work includes valve-seat inspection, camshaft end-play checks, and the bolt-tightening diagram for the staged torque-and-angle procedure, including its final 90° turn. Oil-pump rotor-clearance checks and crankshaft bearing inspection have corresponding reference data in the separate specifications volume.

The main-bearing section warns that removing the front bearing cap with the oil pump still fitted can damage the pump joint.

Timing, Fuel Injection, and Boost Control

Bosch EPVE pump coverage includes removal and installation, dial-gauge timing checks, pump-connection illustrations, and model-specific pump-element lift specifications. It does not provide an internal injection-pump overhaul or bench-calibration procedure.

Tool references include timing-belt tension gauge 885036-4 and dial-gauge assembly 885139-6 for TMD22P/TAMD22. The belt section warns that kinking the belt can damage it and lead to engine seizure.

For certified engines, injection-pump and injector service and pump settings are reserved for authorized Volvo Penta workshops. The turbocharger section also defines a repair limit: the boost-control valve is not adjustable, and a failed valve test calls for turbocharger replacement.

Seawater Pumps and Cooling-System Variants

Cooling-circuit diagrams distinguish the earlier and later arrangements. MD22A, MD22L-A, and TMD22A use a directly driven seawater pump; MD22L-B, MD22P-B, TMD22-B, TMD22P-C, and TAMD22P-B use a belt-driven pump. Separate overhaul instructions and exploded views identify the components in each pump.

The heat exchanger, exhaust manifold, and coolant tank form a combined assembly. Oil-cooler arrangements differ by version, and the MD22L-B has no engine oil cooler. TAMD22P-B coverage adds charge-air cooler insert cleaning, inspection, and reassembly.

Electrical Tests and Wiring Coverage

The electrical section covers the Valeo A13N 147M alternator, Lucas M80R starter motor, and glow plugs. Starter brush maintenance is described; internal alternator faults and starter engagement-unit repairs are referred to specialists.

Wiring diagrams show engine circuits, both ignition-switch panel options, the instrument kit, and the diode cable for the 1.5-pole system. The separate wiring volume also contains MD2010–MD2040 circuits, SX/DP-S Power Trim wiring, and active corrosion protection. Those additional diagrams do not extend the mechanical engine-repair coverage to those models.

Follow the manual’s precautions for high-pressure fuel, rotating components, and electrical isolation.

A Preview of Valve-Clearance Specifications

These cold valve-clearance figures are a small sample of the set’s service data.

With the cylinder head tightened to the block, the covered engines’ cold clearances are 0.25–0.35 mm at the intake valves and 0.35–0.45 mm at the exhaust valves.

The manual distinguishes these targets from the limits that require adjustment: outside 0.20–0.40 mm intake or 0.30–0.50 mm exhaust.

PDF Search, Diagram Detail, and File Contents

Search and navigation: Body text and legends are searchable, while many labels within drawings and wiring diagrams are not. Engine Repair and Technical Data have no embedded bookmarks; Wiring Diagram has one untitled bookmark linking to its contents page. Small wiring labels require zooming to read clearly.

ZIP download with three printable English PDFs, totaling 184 pages: Engine Repair, 132 pages; Technical Data, 20 pages; Wiring Diagram, 32 pages. These totals already include 15 cover, blank, note, and report-form pages: six in Engine Repair, five in Technical Data, and four in Wiring Diagram.