Volvo MD2010, MD2020, MD2030, MD2040 Workshop Manual

Workshop Manual

A

Engine

2(0)

MD2010, MD2020, MD2030, MD2040

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Workshop Manual

Marine engines

MD201OA/B/C

Technical data

I

njection pump
Wear tolerances
Tightening torque

Special tools

Presentation

Description of engine

Engine body

Description
Repair instructions:
Cylinder head
Valves. valve mechanism

Cylinder block, pistons.
Timing gears
Camshaft
Crank mechanism

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MD202OA/B/C

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connecting rods

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MD203OA/B/C

Contents

Repair instructions

9

I

njection pump

15
17

18

19

24

25
28

34
40
44

46

Adjustment of injection angle
Adjustment of speed

Feed pump
Fuel filter

Bleeding of fuel system
I

njector

Checking of injector

Cooling system

Description
Repair instructions

Refrigerants

Checking of refrigerant level
Cleaning

Circulation pump

Sea water pump
Replacing the thermostat

Checking the thermostat

•

MD204OA/B/C

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54
55
57

58
59

59
60
61

62

63
64
65

66
66

67
67

Lubricating system

Description
Repair instructions

Oil pump
Replacing the oil filter

Cleaning the oil channels

Fuel system

Description

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The data given in this Workshop Manual refers in general to
engines in both A, B and C versions unless otherwise stated.

51

52
52

52

53

Note!

Electrical system

Description
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mportant info

Starting with auxiliary battery
Troubleshooting, glow plug, charging

Alternator
Starter motor

Electrical components

Wiring diagram

Extra equipment

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system

68
70

71

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72
74

76
78

80
87

1

Safety Precautions

I

ntroduction

This Workshop Manual contains technical specifica­tions, descriptions and instructions for the repair of the

Volvo Penta products or product types described in the
Table of Contents. Check that you have the correct

Workshop Manual for your engine.

Before starting work on the engine read the "Safety Pre­cautions", "Genera! Information" and "Repair Instruc-

tion" sections of this Workshop Manual carefully.

I

mportant

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n this book and on the product you will find the follow-

i

ng special warning symbols.

WARNING!

Q

extensive damage to property or serious me­chanical malfunction if the instructions are not

followed.

I

MPORTANT

4L

something that can cause damage or malfunc-

tions on a product or damage to property.

Note!

Used to draw your attention to important informa-

tion that will facilitate the work or operation in
progress.

Below is a summary of the risks involved and safety
precautions you should always observe or carry out

when operating or servicing the engine.

Possible danger of personal injury,

!

Used to draw your attention to

0

Check that the warning or information labels on
the product are always clearly visible. Replace
l

abels which have been damaged or painted

over.

Engines with turbocharger (TC):

0

engine without installing the air cleaner (

filter.

The rotating compressor in the Turbo can

cause serious personal injury. Foreign objects

entering the intake ducts can also cause me-

chanical damage.

Never use start spray products or similar when
starting the engine. They may cause an explo­sion in the inlet manifold. Danger of personal in-

jury.

Avoid opening the filler cap for engine coolant

IL

system (freshwater cooled engines) when the
engine is still hot. Steam or hot coolant can

spray out. Open the filler cap slowly and release

the pressure in the system. Take great care if a
cock, plug or engine coolant line must be re-

moved from a hot engine. Steam or hot coolant

can spray out in any direction.

Never start the

ACL

)

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0

mmobilize the engine by turning off the power
supply to the engine at the main switch (switch­es) and lock it (them) in the OFF position before

starting work. Set up a warning notice at the en­gine control point or helm.

As a general rule all service operations must be
carried out with the engine stopped. However,
some work, for example certain adjustments re-

quire that the engine is running when they are
carried out. Approaching an engine which is op­erating is a safety risk. Loose clothing or long
hair can fasten in rotating parts and cause seri-

ous personal injury. If working in proximity of an
engine which is operating, careless movements
or a dropped tool can result in personal injury.

Take care to avoid contact with hot surfaces (ex-

haust pipes, Turbocharger (TC),
start element

hoses on an engine which is running or which
has just been stopped. Reinstall all protective

parts removed during service operations before
starting the engine.

etc.)and hot liquids in lines and

air intake pipe,

I&

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Hot oil can cause burns. Avoid getting hot oil on
the skin. Ensure that the lubrication system is

not under pressure before carrying out any work.
Never start or operate the engine with the oil fill­er cap removed, otherwise oil could be ejected.

Stop the engine and close the sea cock before
carrying out operations on the engine cooling

system.

Only start the engine in a well-ventilated area. If
operating the engine in an enclosed area en­sure that there is exhaust ventilation leading out

of the engine compartment or workshop area to
remove exhaust gases and crankcase ventila­tion emissions.

2

Always use protective glasses or goggles when
carrying out work where there is a risk of splin-

ters, grinding sparks, acid splashes or where
other chemicals are used. The eyes are ex­tremely sensitive, an injury could result in blind-

ness!

Avoid getting oil on the skin! Repeated expo-

0

sure to oil or exposure over a long period can
result in the skin becoming dry. Irritation, dry­ness and eczema and other skin problems can
then occur. Used oil is more dangerous than
fresh oil from a health aspect. Use protective
gloves and avoid oil soaked clothes and shop

rags.

Wash regularly, especially before eating.
There are special skin creams which counteract
drying out of the skin and make it easier to clean
off dirt after work is completed.

Many chemicals used on the product (for ex-

ample engine and transmission oils, glycol,
gasoline and diesel oil), or chemicals used in
the workshop (for example degreasing agents,
paint and solvents) are dangerous to health.

Read the instructions on the product packaging

carefully! Always follow the safety precautions
for the product (for example use of protective

mask, glasses, gloves
personnel are not exposed to hazardous chemi-

cals, for example in the air. Ensure good ventila­tion in the work place. Follow the instructions

provided when disposing of used or leftover
chemicals.

Excercise

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the fuel system and testing the fuel injector jets.

Use eye protection. The jet from a fuel injector
nozzle is under extremely high pressure and

has great penetrative energy, so the fuel can
penetrate deep into the body tissue and cause
serious personal injury. Danger of blood poison­i

ng.

extreme care when leak detecting on

etc

.).

Make sure that other

O

2L

0

A

Ensure that rags soaked in oil or fuel and used
fuel or oil filters are stored safely. Rags soaked

i

n oil can spontaneously ignite under certain cir­cumstances. Used fuel and oil filters are envi­ronmentally dangerous waste and must be de-

posited at an approved site for destruction
together with used lubricating oil, contaminated
fuel, paint remnants, solvent, degreasing agents
and waste from washing parts.

Never expose a battery to naked flame or elec­trical sparks. Never smoke in proximity to the
batteries. The batteries give off hydrogen gas

during charging which when mixed with air can
form an explosive gas -

i

s easily ignited and highly volatile. Incorrect

connection of the battery can cause a single

spark which is sufficient to cause an explosion
with resulting damage. Do not shift the connec-

tions when attempting to start the engine (spark

risk) and do not lean over any of the batteries.

Always ensure that the Plus (positive) and Mi-

nus (negative) battery leads are correctly in-

stalled on the corresponding terminal posts on
the batteries. Incorrect installation can result in

serious damage to the electrical equipment. Re­fer to the wiring diagrams.

Always use protective goggles when charging

and handling the batteries. Battery electrolyte

contains sulfuric acid which is highly corrosive.

Should the battery electrolyte come into contact

with unprotected skin wash off immediately us-

i

ng plenty of water and soap. If battery acid

comes in contact with the eyes, immediately
flush with plenty of water and obtain medical as-

sistance at once.

Turn the engine off and turn off the power at the

main

switch(es)before carrying out work on the

electrical system.

oxyhydrogen.This gas

All fuels and many chemical substances are

0

flammable. Do not allow naked flame or sparks
i

n the vicinity. Fuel, certain thinner products and
hydrogen from batteries can be extremely flam­mable and explosive when mixed with air.

Smoking is not to be permitted in the vicinity!
Ensure that the work area is well ventilated and
take the necessary safety precautions before
starting welding or grinding work. Always en-

sure that there are fire extinguishers at hand
when work is being carried out.

Clutch adjustments must be carried out with the
engine stopped.

3

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General Information

About this Workshop Manual

This Workshop Manual contains technical specifica­tions, descriptions and instructions for the repair of the

following engines in standard format:MD2010

MD2020,MD2030,MD2040.This Workshop Manual

can show operations carried out on any of the engines
li

sted above. As a result the illustrations and pictures in

the manual that show certain parts on the engines, do
not in some cases apply to all the engines listed. How­ever the repair and service operations described are in
all essential details the same. Where they are not the

same this is stated in the manual and where the differ­ence is considerable the operations are described sep­arately. The Engine Designations and Engine Number
can be found on the product plate. Please always in­clude both the engine designation and the engine

number in all correspondance

The Workshop Manual is produced primarily for the use
of Volvo Penta workshops and service technicians. For

this reason the manual presupposes a certain basic
knowledge of marine propulsion systems and that the

user can carry out themechanical/electrical
scribed to a general standard of engineering compet­ence.

Volvo Penta products are under a continual process of
development and we therefore reserve all rights regard-

i

ng changes and modifications. All the information in
this manual is based on product specifications avail­able at the time the book was published. Any essential

changes or modifications introduced into production or
updated or revised service methods introduced after the
date of publication will be provided in the form of Ser-

vice Bulletins.

.

,

work de-

Replacement parts

Replacement parts for the electrical and fuel systems
are subject to various national safety requirements, for
example the United States Coast Guard Safety Regula-

tions. Volvo Penta Original Spare Parts meet these
specifications. Any type of damage which is the result of
using replacement parts that are not original Volvo Pen­ta replacement parts for the product in question will not

be covered under any warranty or guarantee provided
by AB Volvo Penta.

•

The service intervals and maintenance proced-

ures recommended by Volvo Penta must be fol­l

owed.

•

Only Volvo Penta Genuine Spare Parts intended
for the certified engine version must be used.

•

Service of injection pumps, pump settings, and
i

njectors, shall always be conducted by an aut-

horised Volvo Penta workshop.

•

The engine must not be rebuilt or modified in any
way, with the exception of the accessories and

service kits that Volvo Penta has developed for

the engine.

•

I

nstallation adjustments on exhaust pipes and

supply air channels for the engine compartment
(ventilation channels) must not, without due care,
be conducted since this can influence exhaust
emissions.

•

Seals must not be broken by unauthorised per­sonnel.

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MPORTANT!

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Spare Parts.

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mplies that AB Volvo Penta will no longer
assume responsibility for compliance of the
engine with the certified versions.

of damage or costs resulting from the use of

non genuine Volvo Penta spare parts for the
product in question will not be regulated by

Volvo Penta.

Use only Volvo Penta Genuine

The use of non genuine parts

All types

Certified engines

For engines certified for national and regional environ­mental legislation the manufacturer undertakes to en-

sure compliance with such environmental requirements

for both new engines and engines is use. The product

must comply with the approved example on certifica-

tion. For Volvo Penta as the manufacturer to be able ac­cept responsibility for the compliance of engines in use
with the set environmental requirements, the following

requirements for service and spare parts must be ful-

filled:

5

Repair instructions and methods

The working methods described in the Workshop Man­ual apply to work carried out in a workshop. The engine

has been removed from the boat and is installed in an
engine fixture. Unless otherwise stated reconditioning
work which can be carried out with the engine in place

follows the same working method.

Warning symbols used in this Workshop Manual (for full
explanation of the symbols refer to the section; "Safety

Precautions")

WARNING!

A

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MPORTANT!

AL

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. Volvo Penta AB can only

i

ndicate the risks considered likely to occur as a result
of incorrect working methods in a well-equipped work­shop using working methods and tools tested by Volvo

Penta AB.

All operations described in the Workshop Manual for
which there are Volvo Penta Special Tools available
assume that these tools are used by the service techni-

cian or person carrying out the repair. Volvo Penta Spe­cial Tools have been specifically developed to ensure
as safe and rational working methods as possible. It is

therefore the responsibility of the person or persons us-

i

ng other than Volvo Penta Special Tools or approved

Volvo Penta working methods (as described in a Work­shop Manual or Service Bulletin), to acquaint them-

selves of the risk of personal injury or actual mechan­i

cal damage or malfunction that can result from failing to

use the prescribed tools or working method.

I

n some cases special safety precautions and user in-

structions may be required in order to use the tools and
chemicals mentioned in the Workshop Manual. Always
follow these precautions as there are no specific in-

structions given in the Workshop Manual.

By following these basic recommendations and using
common sense it is possible to avoid most of the risks

i

nvolved in the work. A clean work place and a clean

engine will eliminate many risks of personal injury and
engine malfunction.

Above all when working on the fuel system, engine lub­rication system, air intake system, Turbocharger unit,
bearing seals and seals it is extremely important to ob­serve the highest standards of cleanliness and avoid

dirt or foreign objects entering the parts or systems,
since this can result in reduced service life or malfunc-

tions.

Our joint responsibility

Every engine consists of many systems and compon­ents that work together. If one component deviates from

the technical specifications this can have dramatic con-

sequences on the environmental impact of the engine
even if it is otherwise in good running order. It is there-

fore critical that the stated wear tolerances are ob-

served, that systems which can be adjusted are cor­rectly set up and that only Volvo Penta Original Parts
are used on the engine. The stated service intervals in

the Maintenance Schedule must be followed.

Some systems, such as the components in the fuel sys-

tem, require special expertise and special testing equip-

ment for service and maintenance. Some components

are factory sealed for environmental and product spe­cific reasons. Under no circumstances attempt to ser-

vice or repair a sealed component unless the service
technician carrying out the work is authorized to do so.

Bear in mind that most of the chemicals used around
boats are harmful to the environment if used incorrectly.
Volvo Penta recommends the use of bio-degradable

degreasing agents for all cleaning of engine compon­ents unless otherwise stated in the Workshop Manual.
When working onboard a boat make a special point of

preventing oil, waste water from washing components
entering the
safe disposal at an approved site for destruction.

Tightening

The correct tighteningtorquesfor critical joints which

must be tightened using a torque wrench are listed un­der "Technical Specifications - Tightening
and stated in the method descriptions in the Workshop

Manual. All tighteningtorques
bolt heads and mating surfaces.Tigthening

stated are for lightly oiled or dry threads. Where grease,
l

ocking or sealing agents are required for screwed

j

oints this is stated in both the operation description and

i

n "Tightening
stated for a joint use the general tighteningtorques
cording to the tables below. The tighteningtorques
ed are a guide and the joint does not have to be tight-

ened using a torque wrench.

Dimension Tightening torque

M5

M6

M8

M-1

0

M12

M14

bilges;i

nstead remove all such waste for

torques

Torques

Nm

10

25

50 37

80 59

140

".

Where no tightening torque is

6

Torques

apply to cleaned threads,

torques

ft.Ibs

4

7

18

103

"

ac­stat-

6

Tightening torque with Protractor tight­ening (angle tightening)

Tightening using both a torque setting and a protractor

angle requires that first the recommended torque is ap­plied using a torque wrench and then the recommended
angle is added according to the protractor scale. Ex­ample: a 90° protractor tightening means that the joint is

tightened a further 1/4 turn in one operation after the
stated tightening torque has been applied.

Lock nuts

Do not re-use lock nuts that have been removed during

dissassembly

vice life when re-used - use new nuts when assem­bling or reinstalling. For lock nuts with a plastic insert
such as

ble is reduced if the
height as a standard hexagonal nut without plastic in­sert. Reduce the tightening torque by 25% for bolt size

8 mm or larger. Where
the same height as a standard hexagonal nut, the
tightening

operations as these have reduced ser-

Nylock®

the tightening torque stated in the ta-

torques

Nylock®

given in the table apply.

nut has the same head

Nylock®

nuts are higher, or of

Strength classes

Bolts and nuts are divided up into different classes of
strength; the class is indicated by the number on the

bolt head. A high number indicates stronger material,
for example a bolt marked 10-9 indicates a higher
strength than one marked 8-8. It is therefore important

that bolts removed during the disassembly of a bolted
j

oint must be reinstalled in their original position when
assembling the joint. If a bolt must be replaced check in
the replacement parts catalogue to make sure the cor-

rect bolt is used.

Make sure that mating surfaces are dry and free from
oil,

grease, paint and anti-corrosion agent before apply-

i

ng sealant or locking fluid. Always follow the manufac­turer's instructions for use regarding temperature range,
curing time and any other instructions for the product.

Two different basic types of agent are used on the en­gine and these are:

RTV

agent (Room temperature vulcanizing). Used for

gaskets, sealing gasket joints or coating gaskets.

i

s visible when a part has been disassembled; old

must be removed before resealing the joint.

The following

Manual:
matex® No. 3, Volvo Penta P/N 1161099-5,

Nr

77. Old sealant can be removed using

spirits in all cases.

Anaerobic agents. These agents cure in an absence of

air.

They are used when two solid parts, for example

cast components, are installed face-to-face without a

gasket. They are also commonly used to secure plugs,

threads in stud bolts, cocks, oil pressure switches and

so on. The cured material is glass-like and it is therefore

colored to make it visible. Cured anaerobic agents are

extremely resistant to solvents and the old agent cannot
be removed. When reinstalling the part is carefully de­greased and then new sealant is applied.

The following anaerobic agents are mentioned in the
Workshop Manual:

(blue).

Note:

Loctite®is the registered trademark of

Permatex® the registered trademark of the

RTV

agents are mentioned in the Service

Loctite®574, Volvo Penta P/N 840879-1,

methylated

Loctite®572 (white), Loctite®

Loctite

Permatex

RTV

Permatex®

241

Corparation

Corporation.

RTV

Per-

,

Sealant

A number of
the engines. The agents have varying properties and
are used for different types of jointing strengths, oper-

ating temperature ranges, resistance to oil and other

chemicals and for the different materials and gap sizes

i

n the engines.

To ensure service work is correctly carried out it is im­portant that the correct sealant and locking fluid type is
used on the joint where the agents are required.

I

n this Volvo Penta Workshop Manual the user will find

that each section where these agents are applied in
production states which type was used on the engine.

During service operations use the same agent or an al-

ternative from a different manufacturer.

sealants

and locking liquids are used on

7

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Safety rules for fluorocarbon rubber

Fluorocarbon rubber is a common material in seal
rings for shafts, and in O-rings, for example.

When fluorocarbon rubber is subjected to high tem-

peratures (above

can be formed, which is highly corrosive. Skin con­tact can give severe chemical burns. Splashes in

your eyes can give severe chemical burns. If you
breathe in the fumes, your lungs can be permanently

damaged.

300°C/572°F),hydrofluoric acid

WARNING!

f

4

engines which have been exposed to high tem­peratures,

fire.

Seals must never be cut with an oxyacet­ylene torch, or be burned up afterwards in an
uncontrolled manner.

Always use gloves made of

•

(gloves for handling chemicals) and protective
goggles.

Handle the removed seal in the same way as

•

corrosive acid. All residue, including ash, can be
highly corrosive. Never use compressed air to
blow anything clean.

Put the remains in a plastic box which is sealed

•

and provided with a warning label. Wash the
gloves under running water before removing

them.

The following seals are probably made from fluoro­carbon rubber:

Seal rings for the crankshaft, camshaft, intermediate
shafts.

O-rings irrespective of where they are installed.
O-rings for cylinder liner sealing are almost always
made from fluorocarbon rubber.

Note that seals which have not been subjected to
high temperature can be handled normally.

Be very careful when working on

e.g

.

overheating during a seizure or

chloroprene

rubber

8

Technical data

General

Engine designation
Number of cylinders

Cylinder diameter

Stroke length

Swept volume, total

Power, see sales literature
I

dling speed

Deregulation speed/high idling
Compression ratio
Compression pressure with starter motor speed

Firing order (cyl. No. 2 and 3 closest

to flywheel)

Direction of rotation see from front
Max. permissible angle backwards during operation
Max. side angle during operation
Valve clearance, idle cold engine:

i

nlet and outlet

Weight, engine without oil and water

Max. permissible counter pressure in exhaust pipe..

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MD2010 MD2020 MD2030

2
67 mm
(2.637 in) (2.637 in) (2.952 in)
64 mm 64 mm 72 mm

(2.519 in) (2.519 in) (2.834 in)

0.45 litres
(27.46

cu.in

850 ±25 rpm 850 ±25 rpm
3900 ±25 rpm 3900 ±25 rpm 3900 ±25 rpm 3900 ±25 rpm

23.5:1

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>3000 kPa
(>435 psi)

1-2
Clockwise Clockwise

20°
30° 30°

0.20 mm
(.0078 in) (.0078 in) (.0078 in) (.0078 in)
98 kg 116 kg 129 kg 179 kg
(215.9lb) (255.5lb) (284.2lb)

20 kPa
(2.9 psi)

3 3
67 mm 75 mm

0.68 litres

)

(41.49

cu.in

)

23.5:1
>3000 kPa >3000 kPa

(>435 psi)

1-2-3 1-2-3

0

20

0.20 mm

20 kPa
(2.9 psi)

0.95 litres
(57.97

cu.in

)

850 ±25 rpm 850 ±25 rpm

23:1 22:1

(>435 psi)

Clockwise

0

20
30° 30°

0.20 mm 0.20 mm

20 kPa

(2.9 psi)

M D2040

3
84 mm

(3.307 in)

90 mm

(3.543 in)

1.50 litres
(91.53

cu.in

>3000 kPa
(>435 psi)

1-2-3
Clockwise
20°

(394.3 Ib)
20 kPa

(2.9 psi)

)

Pistons

Material

Height, total in mm

Height from gudgeon pin centre to piston top in mm

Piston clearance in mm:

Front marking*,

*

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MD2010,MD2020
MD2030,MD2040

The pistons for certain engines also have an arrow in front
of the gudgeon pin hole which should point forwards.

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Piston rings

Compression rings:
Number
Top compression ring, height in mm

2nd compression ring, height in mm

Oil ring:
Number
Height in mm

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MD2010

M D2020

Aluminium alloy

59.045-59.095

(2.324-2.326 in)

33.045-33.095 35.575-35.625
(1.300-1.302 in) (1.400-1.402 in)

0.048-0.082
(.0018-.0032 in) (.0016-.0026 in)
The arrow alt. "F" mark on piston top should be turned forwards

The "SHIBAURA" mark in the piston should be turned forwards

MD2010

M D2020

2 2 2

1.47-1.49 1.47-1.49 1.97-1.99
(0578-.0586 in)

1.47-1.49
(.0578-.0586 in)

1

2.97-2.99
(.01169-1177 in)

M D2030 M D2040

Aluminium alloy

65.575-65.625
(2.581-2.583 in)

0.0425-0.0665

M D2030 M D2040

(.0578-.0586 in) (.0775-.0783 in)

1.97-1.99 1.47-1.49
(.0775-.0783 in) (.0578-.0586 in)

1 1

3.97-3.99
(.01562-.1570 in) (.1535-.1566 in)

Aluminium alloy

87.66-87.74
(3.451-3.454 in)

47.66-47.74
(1.876-1.879 in)

0.038-0.072
(.0014-.0028 in)

3.90-3.98

9

ec nrcal data

Piston ring gap in cylinder measured in mm,

top compression ring

2nd compression ring

Oil ring

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Piston ring clearance in groove measured in mm

top compression ring

2nd compression ring

oil ring

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Gudgeons pins

Clearance, gudgeon pin - gudgeon bushing in mm

Gudgeon pin - gudgeon pin hole in mm

Gudgeon pin diameter in mm

Gudgeon bushing's int. diameter in mm

Gudgeon pin hole's diameter in piston in mm

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MD2010

M D2020

0.13-0.25
(.0051-.0098 in)

0.10-0.22
(.0039-.0118 in)

0.10-0.30
(.0039-.0118 in)

0.06-0.10

(.0023-.0039 in)

0.05-0.09

(.0019-.0035 in)

0.02-0.06

(.0007-.0023 in)

MD2010

M D2020



0.013-0.030

(.0005-.0011 in)

-0.004- +0.008
(-.0001- +.0003 in)

18.996-19.002

(.7478-.7481 in)

19.015-19.026

(.7486-.7490 in)

18.998-19.004

(.7479-7481 in)

M D2030 M D2040

0.15-0.27
(.0059-.0106 in)

0.12-0.24
(.0047-.0094 in)

0.20-0.35 0.20-0.40
(.0078-.0137 in)

0.06-0.10

(.0023-.0039 in)

0.05-0.09

(.0019-.0035 in)

0.02-0.06

(.0007-.0023 in)

M D2030

0.006-0.023
(.0002-.0009 in) (.0003-.0005 in)

-0.004- +0.006
(-.0001-+.0002 in)

20.998-21.002

(.8266-.8268 in) (1.1021-1.1023 in)

21.010-21.021

(.8271-.8275 in)

20.998-21.004 27.999-28.005

(.8266-.8269 in)

0.20-0.35
(.0078-.0137 in)

0.20-0.40

(.0078-.0157 in)

(.0078-.0157 in)

0.065-0.110

(.0025-.0043 in)

0.013-0.035

(.0005-.0013 in)

0.030-0.130

(.0011-.0051 in)

MD2040

0.010-0.027

-0.001- +0.011
(-.00003- +.0004 in)

27.994-28.000

28.010-28.021
(1.1027-1.1031 in)

(1.1023-1.1025 in)

Cylinder head

Height in mm

Valve seats (inlet outlet)

I

nlet, diameter in mm

Outlet diameter in mm

Depth in mm









Crankshaft with bearing

(Replaceable bearing cups for main and
big end bearings)

Crankshaft, axial clearance in mm

Main bearing, radial

clearance in mm, No. 1

10

No. 2

No. 3









M D2010
M D2020

54.9-55.1
(2.161-2.169 in)

25.35-25.45

(.9980-1.001 in)

21.85-21.95

(.8602-.8641 in)

2.05-2.15

(.0807-.0846 in)

MD2010

0.1-0.3
(.0039-.0118 in)

0.035-0.072
(.0013-.0028 in)

0.055-0.092
(.0021-.0036 in)

M D2020

0.1

-0.3

(.0039-.0118 in)

0.035-0.072
(.0013-.0028 in)

0.035-0.072
(.0013-.0028 in)

0.055-0.092
(.0021-.0036 in)

MD2030

64.6-65.4
(2.543-2.574 in)

30.35-30.45
(1.194-1.198 in)

26.85-26.95
(1.0570-1.0610 in) (1.2736-1.2775 in)

2.25-2.35
(.0885-.0925 in)

M D2030

0.05-0.30 0.1-0.4
(.0019-.0118 in)

0.039-0.106
(.0015-.0041 in)

0.039-0.106 0.044-0.116

(.0015-.0041 in)

0.039-0.092 0.044-0.102

(.0015-.0036 in)

MD2040

69.7-70.3
(2.744-2.767 in)

36.35-36.45
(1.431-1.435 in)

32.35-32.45

2.05-2.15
(.0807-.0846 in)

M D2040

(.0039-.0157 in)

0.044-0.116

(.0017-.0045 in)

(.0017-.0045 in)

(.0017-.0040 in)

Main bearing

Main bearing journals

Diameter in mm, standard, bearing journal

undersize, No. 1

undersize, No.

undersize, No.

2

3

No. 1

No.2

No.3

0.25mm
(.0098in)

mm

0.50
(.0196in)

0.25mm
(.0098in)

0.50mm
(.0196in)

0.25mm
(.0098in)

mm

0.50
(.0196in)

Technical data

MD2010 MD2020



















42.964-42.975 42.964-42.975
(1.6915-1.6919in)

45.964-45.975 42.964-42.975
(1.8096-1.8100in)

-

42.760-42.786 42.760-42.786
(1.6834-1.6844in)

42.510-42.536
(1.6736-1.6746in)

45.764-45.790
(1.8017-1.8027in)

45.514-45.540
(1.7918-1.7929in)

(1.6915-1.6919in)

(1.8096-1.8100in)

45.964-45.975
(1.8096-1.8100in)

(1.6834-1.6844in)

42.510-42.536
(1.6736-1.6746in)

42.760-42.786
(1.6834-1.6844in)

42.510-42.536
(1.6736-1.6746in)

45.764-45.790
(1.8017-1.8027in)

45.514-45.540
(1.7918-1.7929in)

Diameter in mm, standard, bearing journal

undersize, No. 1

undersize, No.

undersize, No.

2

3

Big-end bearing

Big-end bearing journals

Big-end bearing, radial clearance in mm

Bearing journal length in mm

Diameter in mm, standard

undersize, 0.25





mm

(0098in)

0.50mm
(.0196in)



No. 1

No.2

No.

0.25mm
(.0098in)

0.50mm
(.0196

0.25mm
(.0098in)

0.50

mm

(0196in)

0.25mm
(.0098in)

0.50mm
(.0196in)



M D2030



3



i

n)



45.964-45.975
(1.8096-1.8100in)

45.964-45.975
(1.8096-1.8100in)

45.964-45.975
(1.8096-1.8100in)

45.854-45.934
(1.8052-1.8084in)

45.604-45.684

i

(1.7954-1.7985

45.854-45.934
(1.8052-1.8084in)

45.604-45.684
(1.7954-1.7985in)

:....

45.714-45.725
(1.7997-1.8001in)

45.464-45.475
(1.7899-1.7903in)

MD2010,MD2020 MD2030

0.031-0.068
(.0012-.0026in)

15.65-16.55
(.6161-.6515in)

34.964-34.975
(1.3765-1.3769in)

34.714-34.725
(1.3666-1.3671in)

34.464-34.475
(1.3561-1.3572in)

n)

MD2040

67.900-67.970
(2.6732-2.6759

67.900-67.970
(2.6732-2.6759in)

67.960-67.986
(2.6755-2.6766in)

67.650-67.720
(2.6633-2.6661

67.400-67.470
(2.6535-2.6562in)

67.650-67.720
(2.6633-2.6661in)

67.400-67.470
(2.6535-2.6562in)

67.710-67.736
(2.6657-2.6667in)

67.460-67.486
(2.6559-2.6569in)

M D2040

0.035-0.083
(.0013-.0032in)

17.70-18.60 19.70-20.60
(.6968-.7322in)

38.964-38.975
(1.5340-1.5344in)

38.714-38.725
(1.5240-1.5246in)

38.464-38.475
(1.5143-1.5147in)

0.035-0.085
(.0013-.0033in)

(.7755-.8110in)

51.964-51.975
(2.0458-2.0463in)

51.714-51.725

(2.0359-2.0364in)

51.464-51.475

(2.0261-2.0266in)

i

n)

i

n)

1

1

Technical data

Big-end bearing shells

Thickness in mm,

standard

oversize



0.25mm

n)

(.0098

i

0.50

mm ............................

(.0196in)

Connecting rods

Fitted with replaceable bearing shells.
Diameter, gudgeon bushing's bearing position

Bearing shell's bearing position

Gudgeon bushing





Axial clearance, connecting rod -crankshaft

Timing gears

Camshaft

Drive



Number of bearings
Valve times:

i

nlet valves open B.T.D.C

close A.B.D.C
outlet valves open B.B.D.C
close A.T.D.C











MD2010,MD2020 MD2030

,

MD2040

1.484-1.497 1.482-1.495
(.0584-.0589in)

1.609-1.622
(.0633-.0638in)

1.734-1.747
(.0682-.0687

MD2010,MD2020



21.000-21.021
(.8267-.8275in)

i

n)

M D2030 M D2040

23.000-23.021
(.9055-.9063in)

19.015-19.026 21.010-21.021

(.7486-.7490in)

(.0827-.8275in)

19.015-19.026 21.010-21.021

(.7486-.7490in)



0.031-0.079

(.0012-.0031in)

(.8271-.8275in)

0.035-0.083
(.0013-.0032in)

M D2010 M D2020

Gear wheel

3

0

13
430

430
130

Gear wheel

3

0

13

0

43

0

43

0

13

(.0583-.0588in)

1.607-1.620
(.0632-.0637in)

1.732-1.745
(.0681-.0687in)

30.500-30.516
(1.2007-1.2014in)

28.010-28.021
(1.1027-1.1031in)

28.010-28.021
(1.1027-1.1031in)

0.035-0.083

(.0013-.0032in)

MD2030 MD2040

Gear wheel

3

0

13
430
430

130

Gear wheel

3

16°

40°
46°

0

10

Valve system
Valves

Inlet

Spindle diameter in mm

Valve disc edge in mm

Clearance in mm, valve spindle guide

Seat angle in cylinder head

Valve clearance in mm, cold engine

Outlet

Spindle diameter in mm

Valve disc edge in mm

Clearance in mm, valve spindle guide

Seat angle in cylinder head
Valve clearance in mm, cold engine

1

2













MD2010,MD2020

5.960-5.975
(.2346-.2352in)

0.925-1.075
(.0364-.0423in)





0.045-0.072
(.0017-.0028)

0

45

0.20
(.0078in)

5.940-5.955
(.2338-.2344in)

0.925-1.075
(.0364-.0423in)



0.045-0.072
(.0017-.0028in)
45°



0.20
(.0078in)

M D2030 M D2040

6.94-6.95
(.2732-.2736in)

6.955-6.970
(.2738-.2744in)

0.925-1.075 0.925-1.075
(.0364-.0423in)

0.050-0.075
(.0019-.0029in)

0

45

(.0364-.0423in)

0.03-0.06

(.0011-.0023in)

0

45

0.20 0.20
(.0078in)

6.94-6.95
(.2732-.2736in)

0.925-1.075
(.0364-.0423in)

(.0078in)

6.94-6.95

(.2732-.2736in)

0.925-1.075
(.0364-.0423in)

0.050-0.075 0.050-0.075
(.0019-.0029in)

450

(.0019-.0029in)

45°

0.20 0.20
(0078in)

(.0078in)

Technical data

Valve springs

Length in mm (in) uncompressed

with 79.4 N (58.56 ft.lbf) compression
with 67.7 N (49.93 ft.lbf) compression







Push rods

Length in mm (in), total

Outer diameter in mm (in)





Rocker mechanism

Rocker shaft, diameter in mm

Clearance in mm, rocker shaft - bushing





Lubrication system

Oil pressure in kPa, hot engine at running speed

Oil pressure in kPa, idling

Relief valve, opening pressure in kPa

Oil pump:
Clearance, inner - outer impeller

Axial clearance, impeller - cover

Oil quality as per API system

Viscosity at -5 to +50°C* (+23 to +122°F)*

Max. Oil volume incl. oil filter:

no engine tilt (version A/B)

no engine tilt (version C)

Min. Oil volume incl. oil filter:
no engine tilt (version A/B)

no engine tilt (version C)

*

Note: Temperatures with stable ambient temperature.





















MD2010

33(l.299)

-

MD2020 MD2030

33(l.299) 35(l.377)

30.4 (1.196)

28.3 (1.114) 28.3 (1.114)

146
(5.748)

146

157

(5.748) (6.181)

6.3 6.3 6.3
(.2480) (.2480)

11.65-11.67

11.65-11.67

(.4586-.4594 in) (.4586-.4594 in)

(.2480)

11.65-11.67
(.4586-.4594 in) (.4586-.4594 in)

0.032-0.068 0.032-0.068 0.032-0.068

(.0012-.0026 in) (.0012-.0026 in)

MD2010

MD2020

150-500 150-500

(21.7-73 lbf/in

50-150
(7.25-22 lbf/in z)

t)

(21.7-73 lbf/in z)

50-150 50-150

(7.25-22 lbf/in z)

294-490 294-490
(42.6-71 lbf/in')

(42.6-71 lbf/int)

0.01-0.15 mm 0.01-0.15 mm

(.0004-.0059 in)

(.0004-.0059 in) (.0004-.0059 in)

0.01-0.15 mm 0.01-0.15 mm

(.0004-.0059 in)

CD

SAE 15W/40.

SAE 20W/50

1.8 litres

(1.9 US quarts)

1.9-litres
(2.0 US quarts)

1.5 litres
(1.6 US quarts)

1.3 litres
(1.7 US quarts)

(.0004-.0059 in) (.0004-.0059 in)
CD

SAE 15W/40.
SAE 20W/50

3.4 litres
(3.6 US quarts)

2.8 litres
(3.0 US quarts)

3.0 litres

(3.2 US quarts)

2.1 litres

(2.2 US quarts)

(.0012-.0026 in) (.0012-.0026 in)

MD2030

150-500 150-500
(21.7-73 lbf/in z)

(7.25-22 lbf/in z)

294-490 245-345

(42.6-71 lbf/in z)

0.01-0.15 mm

0.01-0.15 mm

CD
SAE 15W/40.
SAE 20W/50

4.3 litres
(4.5 US quarts)

3.5 litres
(3.7 US quarts)

3.2 litres
(3.4 US quarts)

2.7 litres
(2.9 US quarts)

MD2040

35(l.377)

30.4 (1.196)

-

195.8-196.2

(7.709-7.724)

6.2-6.4
(.2441-0.2520)

11.65-11.67

0.032-0.068

MD2040

(21.7-73

lbf/int)

50-150
(7.25-22lbf/in z)

(34.4-50 lbf/in z)

0.01-0.15 mm

(.0004-.0059 in)

0.01-0.15 mm

(.0004-.0059 in)
CD

SAE 15W/40.
SAE 20W/50

6.4 litres
(6.7 US quarts)

5.7 litres
(6.0 US quarts)

5.5 litres

(5.8 US quarts)

4.5 litres

(4.8 US quarts)

Fuelsystem

I

njection sequence

Feed pump max. induction height in m (ft)
Feed pressure in kPa (lbf/inz)

I

njection pump

Start of injection, crankshaft position

........................................................................

Pump element, diameter in mm (in)
stroke length in mm (in)

'

up to and including engine number 5101311299

2

from engine number 5101311300

3

up

to and including engine number 510101938







MD2010

1-2



0.8 (2.62) 0.8 (2.62) 0.8 (2.62)
15-25 (2.1-3.6) 15-25 (2.1-3.6)

M D2010 M D2020



25.5° ±1°
B.T.D.C



4.5 (.1771)

6(.2362)

4

from engine number 510101939

5

MD2040A/B product number 868748

6

MD2040B product number 868778

MD2020 MD2030 MD2040

1-2-3

1-2-3

1-2-3

0.8 (2.62)

15-25 (2.1-3.6) 15-25 (2.1-3.6)

MD2030 MD2040

25.5° +1°
B.T.D.C'

1 °

±

27.7°
B.T.D. C

2

4.5 (.1771)
6(.2362) 6(.2362)

22.51±10
B.T.D. C

21.5°±1°
B.T.D.C

3

4

5.5 (.2165)

21.0°

B.T.D.C

19.0°±1°

B.T.D. C

5.5 (.2165)
7(.2755)

7

MD2040C

±10

5

6,7

13

Technical data

I

njector

Opening pressure (checking)

Opening pressure (adjustment)

Needle valve, diameter

Journal diameter

Jet angle











Cooling system

Type



Fresh water system volume, approx (vers. A/B).

Fresh water system volume, approx (vers. C) ....

MD2010 MD2020

11.3-12.3 MPa 11.3-12.3 MPa
115-125 kp/cm2115-125 kp/cm2115-125 kp/cm2155-165 kp/cm

1639-1784 lbf/in

11.8 MPa

120 kp/cm
1711 lbf/int

3.5 mm
(0.1378 in)

1

mm

(0.0394 in)
4°

MD2010

2.1 litres

2.2 US quarts

2.3 litres

2.4 US quarts

2

1639-1784 lbf/in

2

11.8 MPa
120 kp/cm
1711 lbf/int

3.5 mm
(0.1378 in) (0.2362 in) (0.1575 in)

1

mm
(0.0394 in)
4°

MD2020

Overpressure, closed cooling system

3.0 litres

3.2 US quarts

2.9 litres

3.1 US quarts

2

MD2030

11.3-12.3 MPa

2

1639-1784 lbf/in22205-2347 lbf/in

11.8 MPa
120 kp/cm
1711 lbf/int

6mm

1

mm

(0.0394 in)
4°

MD2030 MD2040

4.0 litres

4.2 US quarts

4.5 litres

4.8 US quarts

2

MD2040

15.2-16.2 MPa

15.7 MPa
160 kp/cm

2276 lbf/int
4mm

1

mm

(0.0394 in)

40

6.9 litres

7.3 US quarts

6.7 litres

7.1 US quarts

2

2

2

Thermostat, number
Thermostat begins to open at

Thermostat valve's lifting height



fully open at

Electrical system

System voltage
Fuses



Battery capacity (starter battery)
Glow plug:

rated voltage
current







Alternator

Output voltage at +20°C (+68°F)
Max. current

Power approx
Suppressor capacitor

Voltage regulator type









1

st











750±2°C

(167° ±4°F)
87°C (189°F) 87°C (189°F)
6 mm
(0.2362 in) (0.2362 in) (0.3150 in)

M D2010

12V 12V
15A 15A

70 Ah

10.5V 10.5V 10.5V

6.9 A

M D2010

14.2 ±0.15 V
60 A
840 W 840 W

2.2 µF 2.2 hF 2.2 hF
YV 77

1st
75° ±2°C
(167° ±4°F)

6mm

MD2020

70 Ah 70 Ah 70 Ah

6.9 A

MD2020

14.2 ±0.15 V 14.2 ±0.15 V 14.2 ±0.15 V

60 A 60 A 60 A

YV 77

1st
82° ±2°C
(179° ±4°F)
95°C (203°F)
8 mm

MD2030

12V
15A

6.9 A 6.9 A

MD2030

840 W

YV 77 YV 77

1

st

82° ±2°C
(179° ±4°F)

95°C (203°F)
8 mm
(0.3150 in)

MD2040

12V
15A

10.5V

MD2040

840 W

2.2 µF

Starter motor

Starter motor, power approx
Engine speed* with connected starter motor,

approx



Note:

refers to engine with timing gears and at approx. +20°C (+68°F).

1

4



M D2010

0.7 kW

340 rpm

MD2020

0.7 kW

300 rpm

MD2030

1.2 kW

285 rpm

MD2040

2.0 kW

265 rpm

Wear tolerances

Note:

Unless otherwise stated the given values refer to all engines.

General

Compression pressure at starter motor speed (min. 200 rpm) ....

Pistons

Piston clearance

Piston rings

Piston ring clearance in groove:
Compression rings

Oil ring



Piston ring gap in cylinder







Technical data

min. 25 kp/cm2(355.6 lbf/int)

max. 0.25 mm (.0098 in)

max. 0.25 mm (.0098 in)
max. 0.15 mm (.0059 in)
max. 1.0 mm (.0393 in)

Gudgeon pins

Gudgeon pin diameter:

MD2010
MD2030
MD2040

Clearance, gudgeon pin - bushing

.

MD2020




gudgeon pin - hole





Cylinder head

Distortion



Cylinder block

Distortion (top plane)

Cylinder diameter

MD2010.MD2020

0.2 mm (.00787 in) oversize

0.5 mm (.01969 in) oversize

MD2030

MD2040



0.5 mm (.01969 in) oversize

1.0 mm (.03937 in) oversize


0.5 mm (.01969 in) oversize

1.0 mm (.03937 in) oversize





min. 18.98 mm (.7472 in)
min. 20.98 mm (.8259 in)

min. 27.98 mm (1.1015 in)












max. 0.08 mm (.0031 in)
max. 0.02 mm (.0007 in)

max. 0.12 mm (.0047 in)

max. 0.12 mm (.0047 in)

max. 67.2 mm (2.6456 in)
max. 67.7 mm (2.6653 in)

max. 68.2 mm (2.6850 in)
max. 75.2 mm (2.9606 in)
max. 75.7 mm (2.9803 in)

max. 76.2 mm (3.0000 in)
max. 84.2 mm (3.3149 in)

max. 84.7 mm (3.3346 in)
max. 85.2 mm (3.3543 in)

1

5

Technical data

Crankshaft

Curvature



max. 0.06 mm (.00236 in)

Connecting rods

Linearity, deviation on 100 mm (3.937 in) measured length
Distortion on 100 mm (3.937 in) measured length

Axial clearance, crankshaft - connecting rod







max. 0.15 mm (.00590 in)
max. 0.2 mm (.00787 in)

max. 0.7 mm (.02755 in)

Valves

Max. valve clearance*, inlet and outlet (cold engine)

*

Maximum permitted valve clearance before adjustment must be carried out



max. 0.5 mm (.01968 in)

Starter motor

Commutator diameter:

MD2010.MD2020.MD2040
MD2030

Brush length
Brush spring tension
Brush spring tension





MD2010.MD2020.MD2040
MD2030







min. 31 mm (1.2204 in)
min. 40 mm (1.5748 in)

min. 11.5 mm (.4527 in)
min. 8.8 N (2.0 lbf)
min. 13.7 N (3.0 lbf)

1

6

Technical data

Tightening torque in

Cylinder head*
Main bearing:

top to bottom bearing cap (steel)
(aluminium)
Main bearing cap to cylinder block

Big-end bearing
End-plate/flywheel housing
Flywheel housing

Flywheel
Flexible coupling
Adapter plate for flywheel housing
Suction strainer, oil pump

Bottom plate
Sump



Drain plug, sump

Timing gear casing
Crankshaft pulley

I

njection pump

Bearing bracket, rocker shaft
Valve cover

Pressure oil pipe (cylinder block-cylinder head).
I

njector

Delivery pipe
Pressure valve holder

Relief valve
Lock screw (max. fuel volume)
Lock screw (speed)

Glow plug
Oil pressure relay
Refrigerant temperature relay

Oil pressure sensor
Refrigerant temperature sensor

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































Nm

MD2010

M D 2020

-

35-40 (25.8-29.5)

25-30 (18.4-22.1)

;



20-25 (14.7-18.4)
25-30 (18.4-22.1)

21-26 (15.5-19.2)

13-17 (9.6-12.5)
24-29 (17.7-21.4)
70-80 (51.6-59.0)

9-12 (6.6-8.8)

24-29 (17.7-21.4)

9-13 (6.6-9.6) 9-13 (6.6-9.6)

9-12 (6.6-8.6) 9-12 (6.6-8.6)

9-13 (6.6-9.6) 9-13 (6.6-9.6)

30-40 (22.1-29.5)

9-12 (6.6-8.6) 9-12 (6.6-8.6)

90-100 (66-74)

9-13 (6.6-9.6) 9-13 (6.6-9.6)

20-25 (14.7-18.4)

10-12 (7.4-8.6) 10-12 (7.4-8.6)

10-13 (7.4-9.6)

60-70 (44.3-51.6)

20-25 (14.7-18.4)

35-39 (25.8-28.8)

60-70 (44.3-51.6)
20-25 (14.7-18.4) 20-25 (14.7-18.4)

13-17 (9.6-12.5)

15-20 (11.0-14.7)

15-20 (11.0-14.7)
25-30 (18.4-22.1) 25-30 (18.4-22.1)

15-20 (11.0-14.7)

15-20 (11.0-14.7)

50-53 (36.9-39.1)

25-30 (18.4-22.1)
20-25 (14.7-18.4)

25-30 (18.4-22.1)

30-35 (22.1-25.8)
47-55 (34.7-40.6) 13-17 (9.6-12.5)

24-29 (17.7-21.4)
60-70 (44.3-51.6)
9-12 (6.6-8.8)

24-29 (17.7-21.4)

30-40 (22.1-29.5)

120-130 (86-96)

20-25 (14.7-18.4)

10-13 (7.4-9.6)

80-85 (59.0-62.7)
20-25 (14.7-18.4)
40-45 (29.5-33.2)
60-70 (44.3-51.6) 60-70 (44.3-51.6)

13-17 (9.6-12.5)
15-20 (11.0-14.7)

15-20 (11.0-14.7)

15-20 (11.0-14.7)
15-20 (11.0-14.7)

(ft.lbf)

M D 2030

M D2040

90-95 (66.4-70.1)

50-55 (36.9-40.5)

50-55 (36.9-40.5) **
25-30 (18.4-22.1)***

50-55 (36.9-40.5)

24-29 (17.7-21.4)
60-70 (44.3-51.6)

9-12 (6.6-8.8)
24-29 (17.7-21.4)
9-13 (6.6-9.6)

9-12 (6.6-8.6)
9-13 (6.6-9.6)

30-40 (22.1-29.5)
9-12 (6.6-8.6)
280-340 (206-250)
9-13 (6.6-9.6)

20-25 (14.7-18.4)

8-12 (5.9-8.6
1

0-13 (7.4-9.6)

60-70 (44.3-51.6)

15-25 (11.0-18.4)

40-45 (29.5-33.2)

20-25 (14.7-18.4)

13-17(9.6-12.5)
1512'76"(11. 0-14.7)

15-20 (11.0-14.7)

25-30 (18.4-22,1)

15-20 (11.0-14.7)
15-20 (11.0-14.7)

-

The tightening torque given under respective engine is the final tightening torque.
The cylinder head should be tightened in three stages and in the correct sequence.

See tightening torque diagram on page 32.
Grease in the cylinder head screw threads with grease containing molybdenum disulphide.

**

Hexagonal screws
Rear cap (socket head screws)

1

7

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Special tools

Note. If necessary, the workshop should be equipped with 2 deep (minimum 80 mm) hexagonal sockets, 22 mm and
27mm, for removing the injectors. These sockets can be obtained from a well stocked tool supplier and are not

stocked by Volvo Penta.

885224-6

9992520-8

856927-9

9510060-8

Engine fixture. The tool should be supplemented with 4 pcs pin
screws 479971-4, 4 pcs nuts 971095-5, 4 pcs screws 970964-3

(

M10x140), 4 pcs screws 955311-6 (M8x140), 4 pcs washers

960148-5 (M10), 4 pcs washers 960141-0 (M8) and the arms

from engine fixture 885050-5.

Overhaul stand

Measuring plastic (disposable item)

Multimeter

9999179-6

885251-9

10

OF)

885252-7

1

8

Key for dismantling of fuel and oil filters.

Adapter for measuring compression pressureMD2030

Adapter for measuring compression pressure
and

MD2040

.

MD2010

.

,

MD2020

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Presentation

General

The engines are in-line, 4-stroke, marine diesel engines
fitted with top valves.

MD2020,MD2030

The engines are of the pre-chamber type and equipped
with glow plugs which are activated before and during

starting.

The engines are fitted with thermostat regulated fresh

water cooling. The cooling system is divided into a
fresh water and a sea water system. The sea water

cools the fresh water system via a heat exchanger.

Lubricating takes place by means of an oil pressure
system where an oil pump presses oil to all the lubrica­tion point. The oil system is provided with a replaceable

oil filter of the full-flow type.

The fuel system is protected from impurities by a re­placeable fine filter.

MD2010

and

MD2040

has two cylinders, while

have three cylinders.

Design differences, engine versions

This Workshop Manual applies to all engines
2040 A, B, C

The most important differences are:

MD2010-40A

MD2010-40B

=*

MD2010-40B has:

•

Unipolar electrical system

•

The fly wheel cover and the transmission (reverse

gear or S-drive) are electrically insulated from the
engine

MD2010-40B=MD2010-40C

MD2010-40C has:

•

Heat exchangers with improved cooling performan­ce and extended expansion volume

•

Deeper and narrower oil sump

•

Reinforced generator mountings for 2010 and 2020

•

Common oil filter for 2010-40

MD2010

-

Positioning of rating plates

VOLVO

PENTA

XXXX(1)
XXXXXXXXXX(2)

XXX XXX (3)

Engine and transmission decal

1.

Product designation

2.

Serial number

3.

Product number

4.

Certification number

a,usan asseraBLY

Tx

XXXX (5)
XXXXXXXXXX(6)
XXX XXX (7)

C.

VOLVO
PEP7TA

5.

Product designation

6.

Serial number

7.

Product number

8.

Gear ratio

vxUYeo~xnCCOXnnxR' i0•xx

n

nvvxoR'nl

TO;

XXXX

(1)XXX

XXXXXXXXXX (2)

Engine plate

XXXXXXX'XXX

'

(

4)m.~

XXX (3)

.

..

0

1

9

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Presentation

2 3

MD201OA/B & MS2L

17

16 15

MD2010A/B & MS2L

14

13

2

0



Presentation

MD203OA/B & MS2A

1

2

MD204OA/B & MS2L

17 1615

MD203OA/B & MS2A

3

14

13

1.

Cap for replenishing of refrigerant

2.

Expansion tank

3.

Relay box with fuses

4.

Flexible suspension

5.

Starter motor

6.

Alternator

7.

Oil dipstick, reverse gear/S-drive

8.

Cap for oil dipstick, reverse gear/S-drive

9.

Fuel filter

10.Cap for oil replenishment, engine

11.

Oil dipstick, engine

12.

Air filter/Air intake

13.

Sea water pump

14.Injection pump

15.

Oil filter

16.

Feed pump (with hand pump)

17.

Oil cooler, reverse gear

18.

Folding propeller

19.

Refrigerant intake, S-drive
Refrigerant cock (sea water), S-drive

20.

21.

Oil drain, S-drive

22.

Zinc anode (zinc ring)*

23.

MD201OA-2040A: Earthing relay (for starter motor and
glow plug)

Note: When running in freshwater the magnesium anode
(

magnesium ring) should be used.

2

1

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Presentation

2

6

4

5 4

MD2010-C & MS2L

1

2

17

16 1514

13

MD2010-C & MS2L

3

7 8

9 12 10 11

MD2020-C & 120S

2 2

22

21

MD2020-C & 120S

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Presentation

2

6

4

5

4

MD2030-C & MS2A

3

4

6

5

4

7

17

MD2030-C & MS2A

8 12

9

16

10 11

15

MD2040-C & MS2L

1.

Cap for replenishing of refrigerant

2.

Expansion tank

3.

Relay box with fuses

4.

Flexible suspension

5.

Starter motor

6.

Alternator

7.

Oil dipstick, reverse gear/S-drive

8.

Cap for oil dipstick, reverse gear/S-drive

9.

Fuel filter

10.Cap for oil replenishment, engine

11.

Oil dipstick, engine

12.

Air filter/Air intake

13.Sea water pump

MD2040-C & MS2L

14.Injection pump

15.

Oil filter

16.

Feed pump (with hand pump)

17.

Oil cooler, reverse gear

18.Folding propeller

19.Refrigerant intake, S-drive

20.

Refrigerant cock (sea water), S-drive

21.

Oil drain, S-drive

22.

Zinc anode (zinc ring)*

Note:

When running in freshwater the magnesium anode

(

magnesium ring) should be used.

2

3

Engine body

Description

Cylinder head

The cylinder head is manufactured of specially alloyed

cast iron. It is provided with replaceable valve seats for

the inlet valves.

The cylinder head is screwed onto the cylinder block
with screws. The tightening of the cylinder head should

be done in three stages.

Cylinder block

The cylinder block is cast in one piece of specially al­l

oyed cast iron.

Pistons, piston rings

The pistons are manufactured of a light-weight metal al­l

oy. They are fitted with three piston rings (chromium-

plated) - two compression rings and an oil ring.

Crank mechanism

Crankshaft

The crankshaft is journaled in three main bearings
(

MD2010),or four main bearings (other engines). The

axial bearing onMD2040 consists of loose thrust wash­ers placed at the rear main bearing. On the other en-

gines the rear main bearing cap is made of aluminium
and serves as thrust washers. The crankshaft is statically
and dynamically balanced and has induction hardened

bearing surfaces. At the front the crankshaft is fitted with
a key joint and at the rear with a flange on which the fly­wheel is attached.

Main and big-end bearings

The main and big-end bearings consist of steel shells
li

ned with bearing metal. The bearings are precision
milled and ready for installation. Two oversizes are
available as spare parts.

Note:

The thrust washers for the crankshaft's axial bear-

i

ng are not available in oversize.

Camshaft

The injection pump is driven from the front part of the
camshaft by means of two or three separate cams (de-

pending on the number of cylinders).

The feed pump is driven via an eccentric cam from the

rear of the camshaft.

Timing gears

The timing gears consists of cylindrical gears with be­velled cogs.

The camshaft and sea water pump are driven from the
crankshaft gear via an intermediate gear. The engine's

oil pump is built into the intermediate wheel and is dri­ven via this. Regulator weights are suspended in the

front edge of the camshaft gear.

2 4

Connecting rods

The connecting rods have I-sections. The piston bolt end

i

s through-drilled for lubrication of the gudgeon pin.

Flywheel

The flywheel is screwed on a flange on the rear of the
crankshaft. It is statically balanced and fully processed.

The starter ring is shrunk onto the flywheel.

A flexible coupling with damper element of rubber is
screwed on the flywheel. The coupling transfers the

force to the reverse gear/S-drive.



Engine body

Repair instructions

Cylinder head

Dismantling of cylinder head

1.

Remove both battery leads. Close the fuel cocks.

2.

Close the bottom valve and drain off the water in
the sea and fresh water system.

3.

Release the hose to the heat exchanger from the
sea water pump. Release the exhaust pipe from

the exhaust hook.

2

4.

Release the thick rubber hose under the heat ex­changer.
Release the thin hose from the refrigerant pump.

5.

MD2010,MD2020:remove the drive belt for the al-

ternator/refrigerant pump. Remove the alternator
and clamp.

6.

Release the relay box from the heat exchanger
housing and hang it up.

7.

Release the electric cables to the oil pressure relay
and to the refrigerant temperature relay and sensor
(

where appropriate).

(Note:

the hose is filled with refrigerant).

Fig. 9.

9.

10.

11.

Dismantling of expansion tank with heat ex-

changer

1.

Heat exchanger complete

2.

MD2010,MD2020

3.

MD2o10,

Remove the expansion tank complete with heat ex-

changer.

MD2010,MD2020

and rubber seal from the heat exchanger housing.

MD2010,MD2020,MD2030

Remove the induction manifold.

MD2040

Remove the inlet pipe complete with air filter.

Release the delivery pipe at the injection pump
and injectors. Lift off the delivery pipes together.
Protect the connections from impurities.

:

:

Remove the spring, thermostat

MD2020

:

Spring

:

Thermostat

:

8.

MD2040:remove the cover at the front on the heat

exchanger housing's right-hand side. Remove the
spacer ring, thermostat and rubber seal.

12.

Remove the nut at the top of respective injectors
and lift off the fuel leak pipe.

2

5