Volvo MD2010, MD2020, MD2030, MD2040 Workshop Manual

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Workshop Manual

Engine

2(0)

MD2010, MD2020, MD2030, MD2040



Workshop Manual

Marine engines

MD201OA/B/C

Technical data

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

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

connecting rods

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•

MD203OA/B/C

Contents

Repair instructions

njection pump

15 17

25 28

34 40 44

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

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

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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.

52 52

Note!

Electrical system

Description I

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

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72 74

76 78

80 87

Safety Precautions

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.

mportant

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

ng special warning symbols.

WARNING!

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

followed.

MPORTANT

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

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):

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

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

)

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,

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.

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-

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

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

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

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 -

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-

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

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.



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-

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.

•

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.

MPORTANT!

Spare Parts.

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:

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!

MPORTANT!

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

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-

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.

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

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

oints this is stated in both the operation description and

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

M-1

M12

M14

bilges;i

nstead remove all such waste for

torques

Torques

50 37

80 59

140

Where no tightening torque is

Torques

apply to cleaned threads,

torques

ft.Ibs

103

acstat-

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-

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.

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,

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

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.

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



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!

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

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:

nlet and outlet

Weight, engine without oil and water

Max. permissible counter pressure in exhaust pipe..



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



>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 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

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*,



MD2010,MD2020 MD2030,MD2040

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



Piston rings

Compression rings: Number Top compression ring, height in mm

2nd compression ring, height in mm

Oil ring: Number Height in mm



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)

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

ec nrcal data

Piston ring gap in cylinder measured in mm,

top compression ring

2nd compression ring

Oil ring



Piston ring clearance in groove measured in mm

top compression ring

2nd compression ring

oil ring

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



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



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)

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)

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

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)

0.055-0.092 (.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-.0040 in)

Main bearing

Main bearing journals

Diameter in mm, standard, bearing journal

undersize, No. 1

undersize, No.

No. 1

No.2

No.3

0.25mm (.0098in)

0.50 (.0196in)

0.25mm (.0098in)

0.50mm (.0196in)

0.25mm (.0098in)

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.

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



(0098in)

0.50mm (.0196in)



No. 1

No.2

No.

0.25mm (.0098in)

0.50mm (.0196

0.25mm (.0098in)

0.50

(0196in)

0.25mm (.0098in)

0.50mm (.0196in)



M D2030



45.964-45.975 (1.8096-1.8100in)

45.854-45.934 (1.8052-1.8084in)

45.604-45.684

(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)

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)

Technical data

Big-end bearing shells

Thickness in mm,

standard

oversize



0.25mm

(.0098

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:

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)

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

13 430

430 130

Gear wheel

(.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)

0.035-0.083

(.0013-.0032in)

MD2030 MD2040

Gear wheel

13 430 430

130

Gear wheel

16°

40° 46°

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



MD2010,MD2020

5.960-5.975 (.2346-.2352in)

0.925-1.075 (.0364-.0423in)



0.045-0.072 (.0017-.0028)

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)

(.0364-.0423in)

0.03-0.06

(.0011-.0023in)

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

(.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)

(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)

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

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

njection sequence

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

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

from engine number 5101311300

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)

from engine number 510101939

MD2040A/B product number 868748

MD2040B product number 868778

MD2020 MD2030 MD2040

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

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

22.51±10 B.T.D. C

21.5°±1° B.T.D.C

5.5 (.2165)

21.0°

B.T.D.C

19.0°±1°

B.T.D. C

5.5 (.2165) 7(.2755)

MD2040C

±10

6,7

Technical data

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)

(0.0394 in) 4°

MD2010

2.1 litres

2.2 US quarts

2.3 litres

2.4 US quarts

1639-1784 lbf/in

11.8 MPa 120 kp/cm 1711 lbf/int

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

mm (0.0394 in) 4°

MD2020

Overpressure, closed cooling system

3.0 litres

3.2 US quarts

2.9 litres

3.1 US quarts

MD2030

11.3-12.3 MPa

1639-1784 lbf/in22205-2347 lbf/in

11.8 MPa 120 kp/cm 1711 lbf/int

6mm

(0.0394 in) 4°

MD2030 MD2040

4.0 litres

4.2 US quarts

4.5 litres

4.8 US quarts

MD2040

15.2-16.2 MPa

15.7 MPa 160 kp/cm

2276 lbf/int 4mm

(0.0394 in)

6.9 litres

7.3 US quarts

6.7 litres

7.1 US quarts

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



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

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).



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. 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)

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)

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

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



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)

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)



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

OF)

885252-7

Key for dismantling of fuel and oil filters.

Adapter for measuring compression pressureMD2030

Adapter for measuring compression pressure and

MD2040

MD2010

MD2020



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

Product designation

Serial number

Product number

Certification number

a,usan asseraBLY

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

VOLVO PEP7TA

Product designation

Serial number

Product number

Gear ratio

vxUYeo~xnCCOXnnxR' i0•xx

nvvxoR'nl

TO;

XXXX

(1)XXX

XXXXXXXXXX (2)

Engine plate

XXXXXXX'XXX

(

4)m.~

XXX (3)



Presentation

2 3

MD201OA/B & MS2L

16 15

MD2010A/B & MS2L



Presentation

MD203OA/B & MS2A

MD204OA/B & MS2L

17 1615

MD203OA/B & MS2A

Cap for replenishing of refrigerant

Expansion tank

Relay box with fuses

Flexible suspension

Starter motor

Alternator

Oil dipstick, reverse gear/S-drive

Cap for oil dipstick, reverse gear/S-drive

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.



Presentation

5 4

MD2010-C & MS2L

16 1514

MD2010-C & MS2L

7 8

9 12 10 11

MD2020-C & 120S

2 2

MD2020-C & 120S



Presentation

MD2030-C & MS2A

8 12

10 11

MD2040-C & MS2L

Cap for replenishing of refrigerant

Expansion tank

Relay box with fuses

Flexible suspension

Starter motor

Alternator

Oil dipstick, reverse gear/S-drive

Cap for oil dipstick, reverse gear/S-drive

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.

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-

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

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

Remove both battery leads. Close the fuel cocks.

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

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

the exhaust hook.

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

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

ternator/refrigerant pump. Remove the alternator and clamp.

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

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.

10.

11.

Dismantling of expansion tank with heat ex-

changer

Heat exchanger complete

MD2010,MD2020

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

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.



Engine body

MD2010,-2020

601

CAP

M D2030

M D2040

Fig. 10. Dismantling of injectors

1. Injector

Copper gasket

13.

Unscrew the injectors. Use a long socket, 80 mm.

MD2010,MD2020,MD2030 MD2040

= 27 mm.

Heat shield (

MD2030

4. Insert (MD2010-2030)

= 22 mm

Remove the copper gaskets under the injectors.

MD2030:Remove the heat shields (3, Fig. 10).

MD2010,MD2020,MD2030:Remove the inserts

(4) and the lower copper washers.

)

Fig. 12. Dismantling of oil pressure pipe (cylinder

block - cylinder head/rocker mechanism)

16.

Remove the oil pressure pipe between the cylinder

block and cylinder head (rocker mechanism on

MD2040

17.

Remove the valve cover (built together with the inl

et pipe on

MD2010,MD2020

and

MD2030

14.

Release the electric cable to the glow plug. Remove the conductor rail and unscrew the glow plug.

Fig. 11. Dismantling of circulation pump

15.

MD2010,MD2020,MD2030:Remove the circula-

tion pump.

MD2030:Note. The pump must be released/re-

moved

before

the cylinder head is released. The

pump can otherwise be broken. Remove the spring and thermostat.

Fig. 13. Dismantling of rocker mechanism (

Rocker mechanism 3. Valve caps

Pull rods

Release the nuts from the rockers' bearing brack-

18. ets. Remove the rocker mechanism (1, Fig. 13) and

pull rods (2). Remove the valve caps (3, from the valve stem.

19.

Release the cylinder head screws in several stages.

Note: Begin in the middle of the cylinder head and release the screws in a circle outwards.

Lift off the cylinder head.

MD2040

)



Engine body

Stripping of cylinder head

Fig. 14. Dismantling the valves

Valve lock

Valve spring washer5.Valve cap*

Valve spring

*MD2040

and later versions

Valve

MD2010,2020, 2030

nspection of cylinder head

The flatness tolerance for the cylinder head is max. 0.12 mm (.00472"). Check in six positions ("A-F" as per Fig.

15 and 16). Use a feeler gauge and a ruler the sides of

which are precision rubbed as per DIN 874/Normal.

Fig. 15. Checking of cylinder head flatness

Remove the valves and valve springs. Press the springs together with a valve spring tensioner and remove the valve lock. Place the valves in order in a marked valve rack. Remove the valve stem seals.

Clean all parts. Observe special care with the channels for oil and refrigerant.

Remove residual soot and impurities from the cylinder head's sealing surfaces.

Note:

Do not use use steel brush to clean the cylin-

der head screw threads or under the screw heads.

Fig. 16. Checking of cylinder head flatness

f the flatness is not within the permissible tolerance the

cylinder head should be replaced. If leakage or blow marks are confirmed it is not necessary to check for flat-

ness since the cylinder head must be replaced.

Check the valve seats and that the pin screws are tight.

For replacement of the valve seats (inlet) see next page.



Engine body

Replacement of valve seat

Fig. 17. A = distance between cylinder head plane and

valves.

The valve seat should be replaced when the distance "A" in Fig. 17 measured with a

1.8 mm (.0708").

Remove the old valve seat by heating it up with a gas jet (600-700°C / 1112-1292°F) diagonally

over the seat.

Allow the cylinder head to cool approx. 3-5 minutes in the air. Carefully tap out the seat with

mandrel (check that the cylinder head is not damaged).

Alternatively the valve seat can be milled out (check that the cylinder head is not damaged).

new

valve exceeds

Grinding of valves and valve seats

Use a valve spring tensioner and dismantle

valve lock. Remove the valve spring washers, springs and aloes. Place the parts in the correct

order in a valve rack. Remove the valve stem seals.

Clean the parts.

Fig. 18. Checking of valve spindle wear

Diameter mm:

MD2010, MD2020

MD2030, MD2040

nlet

5.90 mm 5.90 mm (.2322 in)

6.89 mm 6.84 mm (.2712 in)

the

Outlet

(.2322 in)

(.2692 in)

Clean the seat housing in the cylinder head carefully.

Check the head for cracking.

Cool down the new seat with liquid nitrogen or the li

ke to minus 60-70°C (140-158°F) and heat up the

cylinder head to approx. 60-100°C (140-212°F).

Press the seat in the head. Use a hydraulic press (1000-1500 kp / 2204-3307 lbf) and suitable

mandrel.

Work the seats to the correct angle and width.

Check the wear on the valve spindle. Measure the diameter with a micrometer at points I, II and III as

per Fig. 18.

Fig. 19. Valve disc edge

Grind the valves in a valve grinding machine

Grind the sealing surface as little as possible, just so that it is "clean". If the the valve disc edge after

grinding is less than 0.5 mm (.019 in) the valve

should be scrapped (see Fig. 19). The same applies to valves with crooked valve spindles.

2 8

Check the wear on the valve guides (see "Checki

ng of valve guides") before the valve seats are

treated.

150

Fig. 20. Grinding of valve seat

Fit the seals, valves, valve springs, spring washers, valve lock and valve caps. See "Assembly of cylin-

der head" on page 31.

Checking of valve guides*

Engine body

A= Max. 2.5 mm (.0984 in)

Ream or grind the valve seats (Fig. 20). Grind of j

ust enough material so that the valve seat has the

right shape and a good mating surface.

Fig. 21. Checking of valve seat

Replace the valve seat when the distance "A" in Fig. 21, measured with a new valve, exceeds 1.8 mm (.0708 in).

For replacement of the valve seat (inlet) see previous page.

Fig. 22. Clearance, valve - valve guide (cylinder head)

Calculate the clearance between the valve spindle and

valve guide.

Wear tolerances:

nlet valve, max. clearance

Outlet valve, max. clearance

Note:

Since the valve guides are treated directly in the cylin-

der head this must be replaced when the clearance is excessive, even when the valve is new.



0.20 mm (.0078 in)



0.25 mm (.0098 in)

New seats are grind down so that the distance be-

ween the cylinder head plane and the valve disc

t surface "A" is:

MD2O10, MD2020: 0.70-0.90 mm (.0275-.0354 in) MD2030,

MD2040:0.85-1.15 mm (.0334-.0452 in)

Grind in the valves with grinding paste and check the contact with marker dye.

2 9



Engine body

Checking of valve springs

Check that the springs do not show any signs of damage.

Max. 2.0 mm (.0787 in)

Fig. 23. Checking of linearity

Place the valve springs on a level surface and check the linearity with a st square (Fig. 23).

Renovating the rocker mechanism

MD2O10, MD2020, MD2030: Remove the screws

at the front and rear of the rocker shaft.

MD2040: Screw in a M8 screw in the threaded hole i

n the front edge of the rocker shaft. Fix the screw

head in a vice and pull out the rocker shaft (alt. a withdrawing tool can be used).

jrq

Iry~

Fig. 25. Dismantling of rocker mechanism (MD2040)

-1

100

pso

Fig. 24. Spring tester

Place the spring in a spring tester and check its length

both compressed and uncompressed.

The springs should maintain the values given in "Technical data".

Dismantle the rocker mechanism. Remove the rockers, springs and washers.

Clean the parts. Observe special care with the rocker shaft's oil channels and oil holes in the rock-

ers.

Fig. 26. Measuring of rocker shaft

Check the wear on the rocker shaft with a micrometer (Fig. 26). Diameter min. 11.57 mm (.4555 in).

3 0



Engine body

Fitting of cylinder head

Fig. 27. Clearance rocker - rocker shaft

Fig. 28. Fitting of valve stem seals

Check that the rocker bearing surfaces are not out-

of-round worn.

Calculate the clearance between the rocker and shaft. The clearance must not exceed 0.2 mm

(.0078 in).

Check that the ball pin's spherical part is not deformed or worn. The threads should be undamaged

on the pin and lock nut. The locknut should be in good condition.

The mating sphere of the rockers (against the valve) must not be unevenly worn or concave. Adjustment for minor wear can be made in a grinding

machine.

Note: MD2O10-2030. A new type of rocker (includi

ng valve cap) has been introduced as from engine

number:

MD2010: 5101202984 MD2020: 5101308898

M D2030: 5101465653

Only the new type of rocker is available as a spare part. If one or several of the older type of rocker need to be replaced, all the rockers must be replaced at once, and valve caps installed on the

valve stems.

Press down new valve stem steals on the valve

guides.

Note:

MD2030 and MD2040 have different seals

for the guides for the inlet and outlet valves.

Fig. 29. Fitting of valves

Valve lock

Valve spring retainer5.

Valve

MD2040 and later versions of MD2O10, 2020, 2030

Valve spring Valve cap*

Comparison between new and old rockers

Earlier rocker 4. The new rocker tip

Earlier rocker tip

The new rocker

Oil in the rocker mechanism and fit the different

5. Valve cap

6. Valve

parts.

The valves should be fitted in the correct order. Oil

n the valve spindles and fit the valve in its guide.

Place the valve spring and retainer in position and press the spring together with a valve spring ten-

sioner. Fit the valve lock.

Note:

Observe care when fitting the valves and

compressing the springs so that the valve stem

seals are not damaged.

Fit the valve caps when all valves are fitted. (Ap-

3. plies to MD2040 and later versions of MD2O10,

MD2020, MD2030 (Please refer to the note below i

tem 5)).

Fit new plugs if these have been removed.

Engine body

Fitting of cylinder head

Clean the surface of the cylinder head and cylinder block. Remove any rust or soot from the screw hol

es and threads for the cylinder head screws.

Fit on the new cylinder head gasket.

Apply grease containing molybdenum disulphide on the cylinder head screws.

NOTE! The screws are surface treated and must not be cleaned with a steel brush.

Note:If the cylinder head is painted the mating sur-

faces for cylinder head screws must be free from paint, otherwise the clamping force in the screw

union will be adversely affected.

Check that the tubular pins (guides) are fitted in the block. Place the two rear cylinder head screws in the cylinder head and fit the head.

1st tightening

MD2O10. MD2020 MD2030 MD2040

 

2nd tightening

MD2O10, MD2020 MD2030 MD2040

 

Final tightening

MD2O10, MD2020 MD2030

MD2040

 



10 Nm (7.40 ft.lbs)

20 Nm (14.80 ft.lbs) 30 Nm (22.10 ft.lbs



20 Nm (14.80 ft.lbs) 35 Nm (25.80 ft.lbs)

70 Nm (51.70 ft.lbs)



35-40 Nm (26-30 ft.lbs) 50-53 Nm (37-39 ft.lbs) 90-95 Nm (66-70 ft.lbs)

Fig. 30. Tightening diagram, MD2O10

Fig. 31. Tightening diagram MD2020, MD2030, MD2040

Fig. 32. Fitting of the rocker mechanism (MD2040)

Fit the pull rods (2), valve caps (3, MD2040 and

ater versions of 2010, 2020,2030) and rocker

mechanism (1).

Adjust the valve clearance as per directions on page 34. Fit the valve cover.

Fig. 33. Fitting of oil pressure pipe (cylinder block -

cylinder head / rocker mechanism)

Tighten the cylinder head screws in three stages as per the following. See tightening diagrams Fig. 30-

31.

Fit the oil pressure pipe between the block and cylinder head (rocker mechanism on MD2040).

Tightening torque 10-13 Nm (7.4-9.6 ft.lbs).



Engine body

MD2O10, MD2020: Fit the circulation pump.

MD2030: Fit the circulation pump and thermostat and spring (see Fig. 35).

10.

Fit the glow plug, Tightening torque: see Technical data. Fit the conductor rail and connect the electric

cable.

MINK

CIRD

MD2010,

11.

-2020

1. Injector

Copper gasket

Fit the copper gaskets, heat shields (MD2030) and

nserts (MD2O10-MD2030) to the injectors as per

Fig. 34.

Fit the injectors. Use socket L=80 mm (3.15 in),

key width = 22 mm (MD2O10-MD2030), and 27 mm

(

MD2040).

Tightening torque MD2O10, MD2030, MD2040: 60-70 Nm (44.3-51.7 ft.lbs)

Tightening torque MD2030: 80-85 Nm (59.0-62.7 ft.lbs).

MD2030

Fig. 34. Fitting of injectors

Heat shield (MD2030)

4. Insert (MD2O10-2030)

M D2040

Fig. 35. Fitting of thermostat (MD2O10, MD2020,

MD2030) and expansion tank.

15.

MD2O10, MD2020: Fit the rubber seal, thermostat (3) and spring (2) in the heat exchanger housing (1)

16. Fit the expansion tank complete with heat exchanger. Connect the hoses to the heat exchanger

housing and refrigerant pump. Tighten the hose clips.

12.

Put on new copper gasket and fit the fuel leak pipe. Tighten the nuts and connect the return pipe.

13. Fit the delivery pipe complete. Tightening torque 20-25 Nm (14.8-18.4 ft.lbs).

14.

MD2O10, MD2020, MD2030: Fit the induction manifold.

MD2040: Fit the inlet pipe complete with air filter.

Fig. 36. Fitting of thermostat (MD2040)

17.

MD2040: Fit the rubber seal, thermostat and spacer ring in the heat exchanger housing. Fit the cover

over the thermostat.

18.

Connect the electric cables to the oil pressure rel

ay, and to the refrigerant temperature relay and

sensor (where appropriate).

3 3



Engine body

19. Fit the relay box.

20.

MD2O10, MD2020: Fit the alternator and clamp. Fit the drive belt.

Note:It should be possible to press in the belt ap-

prox. 10 mm (.40 in) between the pulleys.

21.

Connect the hose to the sea water pump and tighten'the clip. Connect the exhaust pipe.

22. Fill with refrigerant. See "Replenishment of refrigera t on page 64.

23.

Connect the battery cables. Open the fuel cocks and bottom valve. Start the engine and check that

no leakage occurs.

Adjusting the valves

Note! The clearance must never be checked when

the engine is running.

Valve clearance (cold engine):

nlet and outlet for all engines: 0.20 mm (.0078 in).

Dismantle the valve cover.

Turn the engine in its normal direction of rotation until both valves for cylinder No. 1 are closed (com-

pression position). Continue turning the engine round until the marking of flywheel shows 0

MD2020. MD2030. MD2040:

Check and adjust if

necessary the valve clearance for cylinder No. 1, and the clearance for the outlet valve on cylinder

No. 2.

Pull round the crankshaft 240° (2/3 turn) anti-clock-

wise

(seen from front) and adjust the clearance for

cylinder No. 3 and the clearance for the inlet valve on cylinder No. 2.

Clean the valve cover and fit it. Replace the seal if damaged. Test run the engine and check that no l

eakage occurs.

Dismantling of piston, piston rings and

connecting rod

Empty the cooling system and drain or syphon out

the engine oil.

Dismantle the cylinder head. See "Dismantling of

cylinder head" on page 25 and 26.

Fig. 37. Adjusting the valves

MD2O10:

Check and adjust if necessary the valve

clearance for cylinder No. 1.

Pull round the crankshaft 180° (1/2 turn) clockwise (see from front) and adjust the clearance for cylinder No. 2.

3 4

Fig. 38. Dismantling of oil strainer with induction manifold

Remove the sump and plate` over the sump. Remove the oil pump's induction manifold.

There is no plate on the MD2O10-40C.

Turn round the crankshaft until the piston in question is in the lower turning position. Dismantle the

main bearing cap with lower bearing cup.

Fig. 39. Dismantling of piston

Place a pair of plastic hoses as protection over the connecting rod screws. Carefully tap up the con-

necting rod with piston far enough so that the piston rings are released from the cylinder bore. Lift off

the piston together with the connecting rod.

Note:

Scrape off the soot strip in the top part of the

cylinder bore to simplify dismantling.

Engine body

nspection and matching of piston rings

Check the wear surfaces and sides. Black patches on the surfaces imply poor contact and indicate that it is

me to change the piston rings. The oil consumption is

also a critical factor as to when a piston ring should be replaced.

Check the piston ring gap (Fig. 41). Push down the ring

below the lower turning position

ton. Replace the piston ring if the gap exceeds 1.0 mm (.039 in).

by means of a pis-

Dismantle piston ring with a piston ring tongs.

Fig. 40. Dismantling of gudgeon pin

Remove the mantle the gudgeon pin carefully with a suitable mandrel.

circlips

for the gudgeon pin and dis-

Fig. 41. Checking of piston ring gap

Piston rings should also be replaced if there is noticeable wear or out-of-roundness in the cylinders since the rings seldom have the same position as they had before

dismantling.

Check the piston ring gap also on new rings.

See "Technical data" for size info.

Check the clearance in the piston ring groove. Roll the ring in its groove in the piston and measure the clearance at a number of points with a feeler gauge.

3 5



Engine body

Assembly of piston, piston rings

and connecting rod

Note:

Check that pistons of the correct oversize are

used if the cylinders have been milled to oversize.

Fit one circlip in the piston.

Oil in the gudgeon pin and bushing.

Fig. 49. Assembly of piston and connecting rod

(

MD2010, MD2020)

Check the big-end clearance. See "Inspection of crankshaft" and "Inspection of main and big-end

bearings" on pages 46 and 47.

Check the piston ring gap in the cylinder bore (Fig.

7. 41 on page 35) and that the rings do not jam in the

piston ring grooves.

Fig. 50. Assembly of piston and connecting rod

(

MD2030, MD2040)

Heat up the piston to approx. 100°C (212°F). Place the piston and connecting rod so that the markings

correspond with Fig. 49 or 50.

MD2O10, MD2020:

necting rod's side upwards the arrow on the piston top should be turned in the same direction as per

Fig. 49.

MD2030, MD2040:

rod and the "SHIBAURA" mark in the piston should be turned in the same direction as per Fig. 50.

Push in the gudgeon pin.

NOTE!

The gudgeon pin should be able to be

pressed in easily. It must not be knocked in.

Fit the other circlip.

Check that the connecting rod goes easily in the gudgeon pin bearing.

With the marking on the con-

The marking on the connecting

Fig. 51. Placement of piston rings

TOP marking

Oil scraper with expander spring (MD2O10-2030)

Fig. 52. Fitting of oil ring (MD2040)

1. Top scraper ring3. Bottom scraper ring

2. Expander

Fit the piston rings on the piston with a piston ring

tong.

Note:

The rings should be turned as per Fig. 51.

MD2O10, MD2020,

(

with the marking turned upwards). The opening in

the expander spring should be placed 180° from the oil ring gap.

MD2030:Fit the oil ring first

Engine body

MD2040:

38) to the oil scraper rings in the piston ring groove. Check that the ends on the expander do not over-

ap each other. Fit the top scraper ring (1) over the

the expander. Put in one end of the ring in the groove and hold it in place with your thumb. Push the ring in position with your other thumb.

Fit the lower scraper ring (3) in the same way.

Check that the scraper rings run easily in both directions and that the ends on the expander and the rings are in the correct position (Fig. 52).

Place the expander (2, Fig. 52 on page

Fig. 53. Number marking on connecting rod and cap

Check that the marking on the piston top, piston and on the connecting rod, correspond with

Fig. 53.

Use a piston ring compressor and fit the piston with connecting rod in the respective cylinder, beginning

with cylinder No. 1 (first).

Note:

The connecting rod with thelowest number should be fitted first (to cylinder No. 1) and subsequently the connecting rod with the highest number

closest to the flywheel.

The connecting rod should be turned with the marki

ng (number/colour marking) turned "towards the in-

jection pump" (camshaft side). The arrow on the

piston top by point forwards.

alt. at

the gudgeon pin hole should there-

alt. in

the

Fitting of piston in cylinder

Note:

After replacing a connecting rod, piston or gudg-

eon pin the weight difference between the connecting rod complete with piston and piston rings must not exceed 10 g (0.35 oz) between the different cylinders.

Lubricate the piston and piston rings with engine oil

and turn the rings so that the oil penetrates the piston ring groove. Turn the piston rings so that the

piston ring gaps are divided by 900 from each other.

Note:

Make sure that no piston ring gap is positioned opposite the piston bolt or at right angles to i

MD2040:

scraper rings are in the correct position (Fig. 52).

Place the bearing cups in their positions in the con-

2. necting rod and cap. Check that the hole in the

bearing cups comes opposite the hole in the connecting rod. Oil in the crank pin with engine oil.

Check that the ends on the expander and

Fit the bearing cap and tighten the connecting rod screws. See "Technical data" for tightening torque.

Note: The main bearing cap should be fitted so that the number/colour marking on the crankshaft and cap correspond (Fig. 53).

Undamaged connecting rod screws do not need to

be changed and can be re-fitted.

Engine body

Timing gears

Replacement of front crankshaft seal

The seal consists of a rubber ring and can be replaced

after the crankshaft pulley has been removed. Use a universal extractor.

Tap in one side of the seal so that it goes on edge. Pull out the seal with a hook.

Fig. 54. Fitting of crankshaft seal

Dismantling of the timing gear

WARNING!

turned without being synchronised with each other the valves can go against the pistons and

be damaged.

Close the fuel cocks. Remove both battery leads.

Close the bottom valve. Release the rubber hoses to the sea water pump and drain out the water in

the sea water system.

Remove the sea water pump.

Remove the drive belt for the alternator.

If the crankshaft and camshaft are

Oil in the new seal with fit it with a suitable mandrel.

Fig. 55. Fitting of crankshaft pulley

Remove the fitting tool. Fit the key and crankshaft pulley.

See Technical data for tightening torque.

Fig. 56. Dismantling of crankshaft pulley

Remove the pulley from the crankshaft. Use a universal extractor (Use an adjustable spanner on the

ug on the pulley as a counterhold when the nut is

removed)

Remove the delivery pipe complete. Release the fuel house and fuel leak pipe at the injection pump.



Engine body

Fig. 59. Dismantling of circlip to cover for the oil pump

Fig. 57. Dismantling of injection pump

Lock pin

Release the injection pump. Turn the stop lever clockwise and carefully lift up the pump so that the l

ock pin to the regulator arm is accessible (Fig. 57).

Remove the lock pin and release the regulator arm. Lift off the injection pump.

NOTE! Take care off the shims under the injec-

tion pump flange.

Shims

10.

Remove the circlip for the intermediate gear

(

Fig. 59). Take care of the sleeve washer, spring

and shims.

Lift off the gear complete with cover and oil pump.

11.

Dismantle the crankshaft gear with a universal extractor.

12. If the camshaft gear is to be dismantled the camshaft must be removed complete. See under head-

ng "Dismantling of camshaft" on page 44.

Dismantle the timing gear casing.

Fig. 58. Timing gears, basic setting

Crankshaftgear

2. Intermediate gear

Pull round the engine until the markings on the timi

ng gears correspond.

Camshaftgear

nspection of timing gears

Fig. 60. Checking of gear flank clearance

Clean the gears and other parts of the timing gears and check them carefully. Replace gears which are heavily

worn or damaged.

Check the flank clearance with a feeler gauge or a dial gauge.

Max. permissible flank clearance: 0.25 mm (.0098 in).

Note: If the flank clearance exceeds the permissible value all the the gears in the timing gears should be replaced.



Engine body

Fitting and adjustment

WARNING!

turned without being synchronised with each other the valves can go against the pistons and be damaged.

Note: The gears in the timing gears which are of importance for adjustment are marked as follows:

Crankshaft gear - the intermediate gear is marked with

a punch mark and the intermediate gear - camshaft gear with a circle opposite the tooth and tooth gap (Fig. 61).

Put the key in position in the crankshaft and fit the

crankshaft gear.

Fit the camshaft complete with regulator weights.

Carry out work steps to item 4 under the heading "Fitting of camshaft" on page 45.

f the crankshaft and camshaft are

319

Fig. 62. Intermediate gear complete with oil pump

Circlip

Spring washer

Spring

Shims

Cover to oil pump

nner rotor

Grease in the oil pump's inner rotor (6, Fig 62) and housing (outer rotor, 8).

Fit the inner rotor and cover to the oil pump. Fit the shims, spring, spring washer and lock washer as per Fig. 62.

Spring

ntermediate gear

complete with outer

rotor

Thrust washer

Fig. 61. Timing gears, basic setting

Crankshaft gear

ntermediate gear

Fit the thrust washer (9, Fig. 62) on the intermediate gear's shaft journal. Fit the intermediate gear as

per the markings (Fig. 61).

NOTE! Do not turn the crankshaft before the

ming gear casing is fitted.

4 2

Camshaft gear

Fig. 63. Checking of oil pump's axial clearance

Adjust the oil pump's axial clearance to 0.10-0.15 mm (.0039-.0059 in). Shims are available in sizes

0.10; 0.15; 0.20 and 0.50 mm (.0039, .0059, .0078 and.0196 in)

Check the crankshaft seal in the timing gear casi

ng, and replace if necessary. See under heading

"Replacement of front crankshaft seal" on page 40.



Engine body

NOTE! Make sure that the shims which were placed under the injection pump flange are replaced in position before the pump is placed in the cylinder block (applicable where the pumps has

been removed).

10.

Tighten the timing gear casing and injection pump.

Tightening torque: see Technical data.

Fig. 64. Fitting of timing gear casing

Check the injection start (crankshaft position) in the event that a new injection pump or complete new

camshaft is fitted and if a new cylinder block is

Centre the cover in front of the oil pump.

Note: The hole in the cover should be in the posi-

tion shown in Fig. 64 (which it should if the marki

ngs on the gear wheel coincide according to Fig.

61).

used.

Se directions under the heading "Adjustment of in-

ection angle" on pages 55 and 56.

12.

Connect the fuel hose to the injection pump.

Fit the delivery pipe.

Place the timing gear casing in position with a new

Tightening torque: see Technical data.

gasket. Observe care so that the crankshaft seal is not damaged.

Check that the start spring is in position in the timi

ng gear casing and is connected to the regulator

arm (link arm). Put in the regulator through the hole in the cylinder block.

Note:

Check that the tubular pip in the timing gear casing can engage in the hole in the oil pump cover. Turn the cover backwards and forwards and

centre it in mid position.

Fig. 65. Fitting of injector pump

Lock pin

Turn the stop lever clockwise and connect the arm

to the injection pump. Fit the lock pin.

Shims

Fig. 66. Fitting of crankshaft pulley

13.

Put the key in position in the crankshaft and fit the crankshaft pulley.

Tightening torque: see Technical data.



Engine body

14. Fit the sea water pump on the timing gear casing. Connect the water hoses to the pump.

15. Fit the drive belt to the alternator.

Note: If the tension is correct the belt should be able to be pressed in approx. 10 mm (.40

ween the pulleys.

16.

Open the fuel cocks. Bleed the fuel system as per

the directions on page 59.

17.

Connect the battery leads.

Camshaft

Dismantling the camshaft

Dismantle the cylinder head. See "Dismantling of cylinder head" on page 25. Lift out the valve lifters

and place them in order in a rack.

Remove the timing gear casing. See under heading "Dismantling of timing gear" on pages 40 and 41.

Remove the regulator sleeve from the camshaft.

be-

MD2O10, MD2020: Remove the gear for the mechanical tachometer drive*.

Note: Mechanical tachometer driving is not used by Volvo Penta. The gear must, however, be in position.

nspection of valve lifter and camshaft

NOTE! If the lifter is worn over the lift surface the lifter must be scrapped. The "dike" shows that the lifter has

not rotated. A dark stripe on the outer lift surface shows, however, that the surface is not worn.

t is the condition of the valve lifters that determines

whether further checking of camshaft wear is necessary.

The cam for example may be skew worn in an axial direction. This can in less severe cases be adjusted by

grinding the cams. Replace the camshaft in the event of further damage or wear.

Note:

When replacing the camshaft all the valve lifters

must be replaced.

Fig. 67. Dismantling of camshaft

Gear

Lock washer

Remove the screws for the lock plate (one screw is accessible through the hole in the camshaft gear),

Fig. 67.

Lift out the camshaft complete with gear and regul

ator weights.

Note:

Observe care so that bearings, bearing races

or cams are not damaged.

On MD2030 and MD2040 the gear for the mechani

cal tachometer drive* must be removed together

with the camshaft.

Regulatorsleeve

Measuring the camshaft

Fig. 68. Measuring the camshaft.

Cam height (inlet and outlet) "A", Fig. 68.

MD2O10, MD2020, MD2030:

MD2040:

Cam height "B" (for injection pump)

MD2O10, MD2020: MD2030:

MD2040:

Cam height "C" (for feed pump)

MD2O10, MD2020, MD2030:

MD2040:

Replace the camshaft if the wear tolerances are not maintained.



 



min. 34.3 mm (1.350 in)



min. 26.1 mm

(1.027 in)

33.7 mm (1.326 in)

33.8 mm (1.330 in)

41.8 mm (1.645 in)

min. 27.0 mm

(1.062 in)

30.0 mm (1.181 in)

4 4



Engine body

Fitting the camshaft

Note: If parts have been replaced on the camshaft the fitting of these should take place in the order shown in

Fig. 69.

Fig. 69. Camshaft

Camshaft

Key

Roller bearing

Spacer rings

* Note: Mechanical tachometers are not used by Volvo

Penta, but the gear must still be put in position.

Gear for drive of mech. tachometer*

Camshaft gear

Regulator sleeve

Fit the regulator sleeve (3). Note: The sleeve should engage with the pin on the camshaft gear.

Note: Mechanical tachometers are not used by .

Volvo Penta, but the gear must still be put in position.

Check that the markings on the timing gear correspond (Fig. 58 on page 41).

Carry out the work as per items 8 to 11 under the heading "Fitting and adjustment (timing gears) on

page 43.

Lubricate the mating surface on the valve lifters to the camshaft with molybdenum disulphide and oil in

the guides in the cylinder block. Fit the valve lifters

n the correct order.

Fit the pull rods and rocker mechanism. Tightening torque, see Technical data.

Carry out the work as per items 6 to 8 under the heading "Fitting of cylinder head" on page 32.

Fig. 70. Fitting the camshaft

Gear

Lock washer

MD2O10, MD2020: Fit the gear (1, Fig. 70) for the mechanical tachometer drive*.

Oil in the camshaft's bearing races and carefully lift the camshaft in position complete with gear and

regulator weights (together with the gear (1) for the mechanical tachometer drive* on MD2030 and

M D2040.

Note: Observe care so that bearings, bearing races or cams are not damaged.

Fit the lock washer (2) for the camshaft in the correct position and tighten it. Tightening torque: 9-13

(6.6-9.6 ft.lbs).

Regulatorsleeve

10.

Adjust the valve clearance as per the direction of page 34. Fit the valve cover.

Tightening torque, see Technical data.

11.

Carry out the work as per items 12 to 17 under the heading "Fitting and adjustment (timing gears) on

pages 43 and 44.

4 5



Engine body

Crank mechanism

Dismantling of crankshaft

(engine removed)

Dismantle the reverse gear alt. S-drive and adapter plate and coupling, flywheel and flywheel housing.

Remove the cylinder head. See under heading "Dismantling of the cylinder head" on pages 25

and 26.

Remove the valve lifters and place them in order in

a rack.

Remove the pistons with connecting rods. Carry out the work steps to item 5 under the heading "Dismantling of piston, piston rings and connecting

rod" on pages 34 and 35.

Remove the timing gear casing. Carry out the work steps to item 8 and item 10 under the heading "Dismantling of timing gears" on pages 40 and 41.

Fig. 71. Dismantling of main bearing cap

Remove the lock screws which hold the main beari

ng cap (Fig. 71). Carefully lift off the crankshaft

complete with cap backwards.

Note:

Tape the crankshaft gear to protect the bear-

ng surfaces in the block during dismantling.

nspection of crankshaft

Clean the crankshaft carefully in all channels after dismantling and inspect it very carefully to confirm whether

it really need renovating.

Qum

Fig. 72. Check measurement of crankshaft

Check the wear and out-of-roundness with a mi-

crometer. Measure the diameters "A-A" and "B-B"

n items "1" and "2" (See Fig. 72).

The max. permissible conicity and out-of-roundness on the main and big-end bearings is 0.05 mm

(.0019 in). Grind the crankshaft to an appropriate undersize if these values are exceeded. Bearing

cups are available in two oversizes.

Measure the crankshafts longitudinal curvature (distortion). Place the crankshaft on a pair of Vblocks placed under the front and rear of the main

bearing journal. Alternatively the shaft can be braced between spikes. Measuring should be carried out on the middle main bearing journal(s).

Max. longitudinal curvature (distortion): 0.06 mm (.0023 in).

If this value is exceeded the crankshaft must be

aligned or replaced.

Check that the mating surfaces on crankshaft seals are not worn or damaged.

Remove the main bearing cap from the crankshaft.

MD2040: Take care of both thrust washers in the rear cap.

4 6

Grinding of the crankshaft

To achieve satisfactory results in connection with grind-

ng the following factors should be taken into considera-

tion:

Grind the crankshaft in a crankshaft grinding machine to the undersize as per "Technical data". Sur-

face fineness 1.6 Z ( (B, Fig. 73) and recess radius are achieved by rubbing with emery cloth No. 400.

VVV

) for bearing races

Engine body

nspection of front crankshaft bushing

Check the bearing clearance between the big-end journal and bushing. Use a cylinder indicator and a micrometer.

Fig. 74. Checking of bearing clearance

Measure the bushing's inner diameter at points 1 and 2 as per Fig. 72 on page 46. Measure in two

directions ("A" and "B") at each point.

Fig. 73. Checking of recess radius

2.It is very important that the recess radius is the correct size.

Recess radius:

- At main and big-end bearing journals,

"A" = 3 ± 0.25 mm (.1181 ±.0098 in)

- At oil holes, "C" = min. 2 mm (.0787 in),

max. 5 mm (.1968 in).

Grinding hacks and sharp edges must be avoided since these can give rise to crankshaft fracture.

Clean the crankshaft well from grinding residue and other impurities. Flush and clean the oil channels.

Measure the bearing journal's outer diameter and calculate the bearing clearance (difference be-

ween the previous measurement and the bearing

ournal's max. diameter).

Max. bearing clearance: 0.2 mm (.0078 in).

Replace the bushing if the clearance exceeds the per-

missible value. Where necessary the crankshaft can be ground to an appropriate undersize and the bushing can be replaced with a corresponding oversize.

Note:

Check the bearing clearance again before the

crankshaft is fitted if it has been re-ground.

nspection of main and big-end bearings

Check the main and big-end bearing cups and the front crankshaft busing. Replace worn bearings or those with damaged bearing surfaces.

Engine body

Replacement of front crankshaft bushing

Dismantle the bushing from the cylinder block.

Check that the bushing's mating surface in the block has no burrs or upset ends.

Fig. 75. Marking up of oil hole

Draw a line over the hole in the block and bushing with a marker pen (Fig. 75). Oil in the outside of the

bushing and its mating surface in the block.

Check that the oil channel is open after pressing in.

Check also the bushing's inner diameter. See

"Technical data" for size.

Checking of big-end bearing clearance

Special tool: 856927-9 (measuring plastic)

The big-end bearing's radial bearing clearance can be checked by means of the measuring plastic (part. No.

856927-9) as follows:

I'-

Fig. 76. Fitting of the bushing

Make sure that the bushing's oil hole corresponds with the oil channel in the cylinder block and press

n the new bushing to the correct depth.

NOTE!

The bushing should be pressed in from the

front of the block and with the bevelled side of the

bushing turned forwards (Fig. 76).

Fig. 77. Application of measuring plastic

Wipe clean the big-end bearing and big-end journal from oil. Cut a piece of measuring plastic to the same length as the bearing width and apply the measuring plastic along the big-end journal

(Fig. 77).

Note:

Avoid the oil hole.

Fit the connecting rod and cap (note markings correspond) and tighten the crankshaft screws.

Tightening torque, see Technical data.

NOTE! Do not turn the connecting rod or crankshaft since this will destroy the measuring strip.

4 8



Engine body

025

038 031

076

Fig. 78. Check measuring of measuring plastic

Remove the cap and measure the width on the pressed out measuring plastic at the widest point.

Use the scale which accompanies the measuring

plastic (Fig. 78).

Max. permissible big-end bearing clearance:

0.2 mm (.0078 in).

Replace the big-end bearing if the bearing clearance exceeds the permissible value. If necessary the journals can be ground to an undersize and

oversize bearings fitted. Big-end bearings are available in two oversizes.

NOTE!

Check the bearing clearance again before

assembly if the journals have been ground.

Fitting of the crankshaft

Check the cleaning of the crankshaft channels and bearing surfaces, cylinder block and cap. Check also that the bearing cups and their mating surfac-

es have no burrs or upset ends.

Place the main bearing in position in the cap.

Check that the lubrication holes in the top bear-

ng cups come opposite the oil channels.

Oil in the bearing and main bearing journals and fit

3. the caps on the crankshaft.

Note :

The bevelled edge (1, Fig. 79a and 79b)

should be turned forwards on all caps.

Fit the cap which is provided with a groove as per

2, Fig. 79a and 79b.

Note:

The bearing cups provided with an oil groove

(3, Fig. 79a and 79b) should be placed in the

cap.

MD2O10, MD2020, MD2030: Fit (

with integrated thrust washers) at the

wheel side).

MD2040: Place both thrust washers in the lower

cap at the far end (flywheel side) and with the oil

groove turned towards the crankshaft.

aluminium

far end

top

caps

(fly-

Fig. 79a. Fitting of main bearing cap MD2O10,

MD2020, MD2030

Big-end bearing cap with4.Main bearing cap of bevelling

Groove

Top main bearing half

cast iron

Main bearing cap of aluminium

with oil groove

Fig. 79b. Fitting of main bearing cap MD2040

Big-end bearing cap with3.Top main bearing half bevelling

Groove

Carefully lift the crankshaft in position in the cylin-

with oil groove

Thrust washers

der block.

Note:

Tape the crankshaft gear before the crankshaft is lifted in. The cogs can otherwise damage the bearing surfaces in the cylinder block.

4 9

Engine body

Tighten the main bearing cap. Tightening torque, see Technical data.

Fig. 80. Checking of axial clearance

Check that the axial clearance does not exceed

0.5 mm (.0196 in).

Replacement of rear crankshaft seal

The seal consists of a rubber ring and becomes accessi

ble after the adapter plate at the back of the flywheel

housing, the flexible coupling, flywheel* and flywheel housing have been removed.

*Note:

Mark up the position of the flywheel in relation to

the crankshaft (simplified fitting).

Clean the position for the sealing ring in the cylinder

block and the mating surface on the flywheel housi

ng.

Replacement of gear ring on the flywheel

Mark up the position of the flywheel in relation to the crankshaft (to simplify fitting). Dismantle the flywheel.

Drill one or a couple of holes in a tooth gap on the gear ring. Split the ring at the drilled hole with a

chisel, after which the gear ring can be removed.

Brush clean the mating surface on the flywheel with a steel brush.

Heat up the new gear ring in an oven (120-150°C/ 248-302°F) so that the gear ring becomes evenly hot all round.

Place the heated gear ring on the flywheel and drive on with a hammer and soft mandrel. The gear

ring should then cool in the free air.

Clean the mating surfaces on the flywheel and crankshaft. Check the rear crankshaft seal. Re-

place if necessary.

Fig. 81. Fitting of crankshaft seal

Apply an even layer of sealing compound (VP no. 840 879) round the flywheel housing's mating surface (screw holes).

Apply grease on the sealing lip and fit the seal.

Fit the flywheel housing, flywheel, the flexible coup-

ng, and the adapter plate.

Tightening torque, see Technical data.

Fit the flywheel in the correct position (guide pin on

MD2030 and MD2040).

Tightening torque, see Technical data.

Lubricating system

General

The engines are provided with a pressure lubricating system with an oil filter of the full flow type.

Oil pump

The oil pump is placed in the intermediate gear in the transmission, and from where it is also driven.

The pump is of the rotor type with an inner and outer rotor placed eccentrically in relation to each other. The in-

ner rotor has one "cog" less that the outer rotor.

The function of the pump is based on the increase and decrease of the space between the outer and inner rotor cogs. During the first part of the inner rotor's rotation

speed the volume is increased, whereby an

sure

occurs and oil is induced in through the inlet. After

approx. 1/2 turn the space is reduced and a pressure condition occurs which presses out oil through the

outlet.

underpres-

Reducing valve

The oil pressure is limited by a reducing valve. The valve is placed in the lubricating system just in front of

the oil filter and is fitted on the right-hand side of the cyli

nder block in front of the oil filter.

The valve opens at excessive high pressure and releases oil back to the sump.

Oil filter

The oil filter is of the full flow type which implies that all

the oil is filtered before it is pressed out to the bearing areas.

The filter is placed on the right-hand side of the cylinder

block. The filter element consists of folded filter paper.

n the bottom of the filter there is an overflow valve

(A, Fig. 82) which opens and releases oil past the filter if the insert should be blocked.

The filter is of the disposable type and is scrapped after

use.

Fig. 82. Oil filter

Overflow valve

Crankcase ventilation

To prevent overpressure and to separate fuel vapour, steam and other gaseous combustion products, the engine is fitted with enclosed crankcase ventilation.



Lubrication system

Repair instructions

Checking of the oil pressure

The oil pressure can be checked by connecting a manometer with hose to the connection for the oil pressure

contact (thread size in cylinder head = 1/8"). The oil pressure should at running speed and temperature be 150-500 kPa (1.5-5 kp/cm2,

If the oil pressure is too high or too low the reducing

valve can be replaced first and then the oil pressure checked again.

The valve is fitted on the right-hand side of the cylinder block in front of the oil filter (Fig. 83).

21.3-71.1 lbf/in2).

Fig. 84. Checking of oil pump clearance

1. Inner rotor A.

Max 0.25 mm (.0098 in)

Outer rotor

Fitting of the oil pump

When fitting the oil pump follow the items 4-10 and 12-17 under the heading "Fitting and adjustment"

(transmission) on pages 42-44.

Fig. 83. Replacement of reducing valve

Oil pump

Dismantling of the oil pump

See under the heading "Dismantling of the timing gears" on pages 40 and 41. Carry out the work steps 1 to 9.

Remove the circlip for the intermediate gear. Take

care of the circlip, sleeve washer, spring. shims

and oil pump cover.

nspection of the oil pump

Check that the oil pump cover and the inner and outer rotor are not worn or damaged.

Check the clearance between the outer and inner rotor (Fig. 84). Max. permissible clearance

0.25 mm (.0098 in).

Note.

Contact Volvo Penta service department if the

shaft journal for the intermediate gear and oil pump

needs to be replaced.

Replacing the oil filter

WARNING!

Place a collection vessel under the oil filter.

Unscrew the oil filter and discard (watch out for oil

spillage). Use a filter extractor.

Moisten the new filter's rubber gasket with oil and check its mating surface on the bracket.

Screw on the new filter by hand until the gasket makes contact with the sealing surface, and then tighten the filter an additional 1/2 turn.

Replenish if necessary the oil in the engine and start it. Check that no leakage occurs.

Hot oil can result in burn injuries.

Oil channels

Clean up and flush the oil channels in the engine with cleaning liquid and then with steam or flushing oil at a pressure of 300-400 kPa (3-4 kp/cm2,

n connection with more extensive engine overhaul.

Note:

Do not forget to clean the oil pressure pipe be-

tween the cylinder block and cylinder head.

Clean the drilled oil channels in the cylinder block, crankshaft and in the connecting rods with a cleaning brush.

42.6-56.8 lbf/int)



Fuel system

General

The fuel is induced by the feed pump from the fuel tank through a water separating pre-filter (accessory) and

pressed through the fine filter to the injection pump (Fig. 85).

Return fuel from the injectors is led through the fuel leak pipe/return pipe back to the tank.

Fig. 85. Fuel system, principle drawing

Fuel tank

Pre-filter

Feed pump

njection pump

The injection pump is a flange-mounted in-line pump

placed on the right-hand side of the engine. The pump i

s driven via cams on the engine's camshaft which di-

rectly activate the pump element.

Fine fuel filter

5. Injection pump

6. Injector

Centrifugal regulator

The regulator is mechanical and works with speed sensing regulator weights. It is fitted at the front on the

camshaft gear from where it is also driven.

The regulator weights activate the injection pump's control rod via the regulator sleeve, a lever and a regulator

arm. The speed is regulated over the entire engine speed range, from low idling speed to high speed (universal type).

Feed pump

The feed pump is also positioned on the right-hand of the engine and is driven via a cam on the engine's camshaft.

njectors

The engines are fitted with injectors (Fig. 86). Each in-

jector basically consists of a nozzle holder and a

nozzle.

When the fuel pressure has increased to the set value (opening pressure) the nozzle needle (pin) (5) lifts

which is held pressed against its seat by the thrust washer (6) and atomised fuel is injected into the en-

gine's precombustion chamber.

The injector's opening pressure is determined by the tension of the thrust washer, which in turn is adjusted

with adjuster washers (7).

Fig. 86. Injector, complete

Packing

Nozzle nut

Nozzle sleeve

Spacer

Nozzle needle (pin)

Thrust washer

Adjusterwashers

Nozzle holder

Nut

Fuel filter

The fuel filter is of the disposable type. The filter insert consists of a specially wound paper filter.

5 3



Fuel system

Repair instructions

Observe the greatest possible cleanliness when worki

ng with the fuel system.

njection pump

Send the pump to an authorised diesel workshop*

for inspection if the workshop does not have spe-

cially trained personnel with the necessary testing equipment.

'MD2o10, MD2020, MD2030: Nippondenso.

MD2040: Bosch.

Dismantling of the injection pump

NOTE! Repair work on the injection pump which may change its setting should only be carried out

by specially trained mechanics which have the requisite equipment at their disposal.

Engine warranties are not longer valid if the seals are broken by unauthorised personnel.

Carefully wash clean the injection pump, pipes and the engine around the pump.

Close the fuel cocks. Remove the delivery pipe complete. Release the fuel hose from the pump.

Fit protective caps on all connections.

Fitting of the injection pump

Check that the pump is in good condition, and if so required also tested and approved before it is fitted.

Note:

Do not remove the protective caps before the

pipes are connected.

Fig. 87. Dismantling of the injection pump

Lock pin

Shims

Put the injection pump in the cylinder block.

NOTE! Make sure that the shims which were placed under the injection pump flange are put

back in place before the pump is'put in the block.

Note:

The correct pump setting is normally obtained with this method. If the injection pump, camshaft or cylinder block have been replaced the set-

ting of the pump must be adjusted. See next section, "Adjustment of injection angle":

Turn the stop lever clockwise and connect the regulator arm to the control rod on the pump. Fit the

ock pin (Fig. 87). Screw tight the pump.

Connect the fuel hose and fuel leak pipe to the pump. Fit the delivery pipe.

Bleed the fuel system and test run the engine.

Dismantle the pump's attachment screws and nuts.

Turn the stop lever clockwise and carefully lift up the pump so that the lock pin to the regulator arm

becomes accessible (Fig. 87).

Remove the lock pin and release the regulator arm.

NOTE! Take care of the shims under the injec-

tion pump flange when the pump is lifted off the cylinder block.

5 4



Fuel system

Adjustment of injection angle

Fit the injection pump as per the previous section with

the exception of item 1 which is changed to item 1 be-

ow.

Place a shim 0.5 mm (.0196 in) in thickness under the injection pump flange.

Fig. 88. Fitting of shim

1. Shim

Remove the front pressure valve holder from the i

njection pump.

Use a scrapped fuel pipe. The pipe makes it easier to see when the fuel begins and stops flowing out from the valve.

Fig. 90. Marking the pulley and engine block

Continue turning the crankshaft slowly clockwise until the fuel stops flowing out from the pressure

valve holder. Check the position of the crankshaft to the marking on the pulley and engine block at

this point. See Fig. 90.

If the position is after "Y°" (B.T.D.C.) a thinner

shims should be used under the injection pump flange. If the position exceeds "Z°" (B.T.D.C.) a

thicker shims should be fitted instead. (See table below).

Fig. 89.

1. Pressure valve holder4.

Spring

Pressure valve

Remove the pressure valve and replace the pres-

sure valve holder.

Move the throttle arm to max. position. Turn the crankshaft clockwise until the piston in cylinder No.

moves upwards in the compression stoke and

fuel begins to flow out from the pressure valve (position X in the table below). The work is simplified if

an approx. 50 mm (2 in) "observation tube" is fitted on the pressure valve.

O-ring Copperwasher

Pump element

Engine Pos. of crankshaft in

model

MD2010 30,0 24,5 26,5

njection start,

crankshaft pos.

24,5-26,5° f.o.d.

M D2020

up to 5101311299

30,0 24,5 26,5

24,5-26,5° B.T.D.C.

from

5101311300

30,0 26,0 28,0

26,0-28,0° B.T.D.C.

M D2030

up to

510101938

30,0

21,5

23,5

21,5-23,5° B.T.D.C.

from * 510101939

30,0 20,5 22,5

20,5-22,5° B.T.D.C.

M D2040A

MD2040B

**868748

30,0

20,0

22,0

20,0-22,0° B.T.D.C.

MD2040B

**868778

MD2040C

engine number

30,0

18,0

- product number

20,0

18,0-20,0° B.T.D.C.

5 5

Fuel system

Note:

A change of shim size by 0.1 mm (.0039 in)

mplies that the injection start is moved approx. 1 °.

An increase in shim size reduces the injection angle and conversely a decrease in shim size in-

creases the angle.

Shims are available in the following sizes: 0.2, 0.3,

0.4 and 0.5 mm (.0078, .0118, .0157 and .0196 in).

NOTE! In the event that no shims are required, li

quid sealing compound should be used.

Replace the pressure valve. Screw in the pressure valve holder by hand. If the pressure valve holder will not go in, screw the holder backwards and for-

wards quickly 1/4-1/2 turn until the pressure valve

goes in the pressure valve holder. Screw down the pressure valve fully by hand until the 0-ring begins

to be pressed together. Tighten after this with a

17 mm spanner.

Tightening torque, see Technical data.

WARNING!

screwed in by hand so that it is possible to feel

that the pressure valve goes correctly into the valve holder. Never use force to screw the valve

holder down since this can damage the pressure valve. If the pressure valve cannot be turned in

the valve holder the pump must be dismantled

and the same method applied with the pump in a completely horizontal position.

The pressure valve holder must be

Fig. 91. Measurement of piston position with dial gauge

Adjustment of the injection angle can also be made

by measuring the piston height with a dial gauge.

The table shows the crankshaft position in degrees when the piston is in a certain position in relation to

B.T.D.C.

Carry out the adjustment work as per items 4 and 5.

The table shows the position of the piston In rel

ation to the crankshaft angle ('B.T.D.C.).

MD2O10, MD2020

Crankshaftangle

18°B.T.D.C.

19° B.T.D.C. 20° B.T.D.C. 21 'B.T.D.C.

22° B.T.D.C. 23° B.T.D.C. 24° B.T.D.C. 25°B.T.D.C.

B.T.D.C.

26 27°BT.D.C.

Crankshaftangle

18° BT.D.C.

19°BT. D.C. 20° BT.D.C.

21° BT. D.C. 22° BT.D.C. 23° BT.D.C.

24° BT.D.C..1431 in. 25° BT.D.C..1550 in. 26° BT. D.C..1673 in. 27° BT.D.C..1800 in.

Piston pos.

3.636 mm

3.937 mm

4.250 mm 4.763 mm

4.573 mm

MD2O10, MD 2020

Piston pos. Piston pos. Piston pos.

MD2030 MD2040

Piston pos.

2.317 mm

2.577 mm

2.851 mm

3.138 mm 3.895 mm

3.438 mm 4.267 mm

3.750 mm

4.075 mm

4.413 mm

5.125 mm

MD2030 MD2040

0912 in.

1014 in.

. .1122 in.

1235 in. 1353 in.

. .

1476 in.

1604 in.

1737 in. 1875 in.

. .

2017 in.

Piston pos.

2.875 mm

3.199 mm

3.539 mm

4.655 mm

5.058 mm

5.477 mm

5.912 mm

1131 in.

1259 in.

1393 in.

1533 in.

1679 in.

1832 in.

1991 in.

2156 in.

2327 in.

5 6

Fuel

system

Setting engine speed (RPM)

Check that the throttle mechanism functions normally. Check that the throttle arm (1) (Fig. moves towards low

dle (2) when the throttle mechanism is in idling position and moves towards the stop screw at wide open throttle (

WOT) (3) when the throttle mechanism is at wide open

throttle (WOT). Adjust the throttle mechanism if neces-

sary. Also check that the air filter and air intake are not blocked.

MPORTANT!

fuel quantity are factory set to give maximum output and minimum environmental impact. The-

se settings must not be changed

Seals on the fuel injection pump may only be broken by authorised personnel. Broken seals must always be resealed

The engine speed (RPM) and

Warm up the engine and check the idling speed

using a workshop tachometer (see Technical Data

for correct idling speed).

3.If

necessary, adjust to the correct idling speed

using the adjustment screw (2).

Check gap (3) again according to point 1.

Engine racing (high idling speed)

Warm up the engine and check the engine racing speed using a workshop tachometer when the engine has no

oad at wide open throttle (WOT) (see Technical Data

for correct engine racing speed).

Adjust if necessary as follows:

Slacken off the stop screw (3) so that it does not limit the movement of the throttle arm (1).

Run the engine with no load at wide open throttle

(

WOT) and adjust to the correct rev speed using

the adjustment screw (4) (remember to reseal the screw).

Fig. 92. Setting engine speed (RPM)

Throttle arm

Adjustment screw, low idling speed

Stop screw, wide open throttle (WOT)

Adjustment screw, engine racing

Adjustment screw, maximum quantity of fuel

Low idle speed

Check that gap (6) (Fig. 92) is approximately 3 mm

when the throttle mechanism is in the idling position. If necessary: Slacken off the locknut (7) and

adjust until the correct gap is obtained with the screw (8).

Adjust the stop screw (3) so that there is a clearance of 0.1 mm between the stop screw (3) and the

throttle arm (1) when the throttle mechanism is at wide open throttle (WOT).

Feed pump

Dismantling of feed pump

Wash clean round the pump.

Close the fuel cocks. Release the fuel connections from the pump.

Dismantle the feed pump from the cylinder block. Empty the pump of fuel.



Fuel system

njectors

Fit the fuel leak pipe.

Replacement of injectors

Wash clean round the injectors.

Release the delivery pipes at the injection pump and at the injectors. Lift off the delivery pipes to-

gether.

Remove the nut on the top of each injector and lift off the fuel leak pipe.

Fig.102. Dismantling of injector

1. Injector

2. Copper packing

Unscrew the injectors. Use socket, L = 80 mm.

Socket width = 22 mm (MD2O10, 2020, 2040),

socket width = 27 mm (MD2030)

Remove the copper packings under the injectors.

MD2030: Remove the heat shields (3, Fig. 102).

MD2O10, MD2020, MD2030: Remove the inserts (4) and the inner copper washers.

3. Heat shield (MD2030)

4. Insert (MD2O10-2030)

Fit the delivery pipes. Check that they do not come

skew, and tighten the nuts.

Tightening torque: 20-25 Nm (14.7-18.4 ft.lbs).

Start the engine and check that no leakage occurs.

Renovating injectors

Clean the injector internally.

Place the injector (holder) in a vice. Unscrew the nozzle nut and take the injector apart.

Note:

Observe care when taking it apart so that the

nozzle needle does not drop out.

Pull out the nozzle needle from the nozzle sleeve and place the parts in cleaning petrol.

Note:

Make sure that the nozzle needles and nozzle sleeves which belong together and are adjusted to each other are not mixed up if several nozzles are

cleaned together. To avoid confusion the nozzles . should be placed in a nozzle rack or in different

compartments.

Check the nozzle carefully with a lamp magnifier or

4. i

n a microscope. Check the other parts also.

When fitting a

5. serving oil is washed off the nozzle needle and

sleeve before the injector is assembled (avoid skin contact with needle's slide surface).

Clean the parts in pure alcohol. Check that the nozzle needle slides in the sleeve without sticking.

Dip the nozzle parts in pure diesel or testing oil and

put the injector together. Use the original thickness of adjuster washer(s) to set the opening pressure.

Check the opening pressure, jet pattern and tightness in a nozzle testing device.

new nozzle it is important that pre-

Fit a protective cap on the pipe connections on the i

njectors over the nozzle if the injector is not to be

fitted immediately.

Fit the new injector.

Tightening torque: see Technical data.

Fuel system

Testing of injectors

Testing is carried out in a nozzle testing device. The opening pressure and tightness are the most important

part of the test. The jet pattern is more difficult to evaluate and does not give a reliable indication of the condi-

tion of the nozzle.

WARNING!

tors so that unprotected parts of the body are not hit by the fuel jet from a nozzle. The jet has such a powerful impact that it can penetrate into the skin and cause blood poisoning.

Observe care when testing the injec-

Adjusting the opening pressure, injector

Checking of injectors

Jet pattern

Pump with the nozzle testing device and check the

et pattern. The fuel jet should be conformed and in

ne with the centre line of the nozzle.

Check that the fuel jet has a circular cross section.

Tightness

Tightness testing examines potential leakage between the seat of the nozzle needle and the conical sealing surface of the nozzle sleeve.

Wipe off the nozzle pin so that it is dry.

Pump up the pressure to approx. 2 MPa (20 kp/

cm2,

284.4 lbf/int) under the injector's opening pres-

sure (see Technical data). Hold the pressure constant for 10 seconds and check if any fuel drips from the nozzle pin. Wet nozzles can be approved.

Fit protective caps on the injector's pipe connections and over the nozzle heads if the injectors are not to be fitted immediately.

Fig. 103. Adjuster washers (7), injector

Press the nozzle testing device's lever slowly down with the manometer connected until the nozzle opens and

releases the fuel. Read off at that precise moment the opening pressure.

f the value read off does not correspond with the pre-

scribed value the setting must be changed. This is done with adjuster washers (Fig. 103).

Note: The opening pressure increases or diminishes with approx. 1 MPa (10 kp/cm2,

change in the thickness of the adjuster washer by

0.1

mm (.0039 in).

142.2 lbf/int) with a

Cooling system

General

The engines are fresh water cooled and fitted with an enclosed cooling system. The system is divided into

wo circuits.

n the inner circuit (fresh water system) the refrigerant is

pumped round by a circulation pump which is driven by a V-belt from the crankshaft pulley.

The fresh water system works at a certain overpressure, whereby the risk of boiling is reduced at high tem-

peratures. A pressure valve opens in the filler cap if the pressure gets higher than normal.

The temperature of the refrigerant is regulated by a thermostat.

The percolation in the sea water system is handled by a gear driven pump of the blade type.

Heat is transferred from the refrigerant to the sea water

n a heat exchanger.

As extra equipment the engine can be fitted with a separate expansion tank.

Sea water pump

The sea water pump is fitted on the timing gear housing

at the front end of the engine. The pump is driven via the engine's timing gears. The pump wheel (impeller) is manufactured of rubber and is replaceable.

The pump wheel will become damaged if the pump

Note:

s run dry.

Fig. 104. Filler cap for refrigerant

Thermostat

The engines are provided with a thermostat, the sensor

body of which contains wax.

When the engine is cold the thermostat keeps the chan-

nel to the heat exchanger closed. The refrigerant then passes via a a by-pass pipe directly back to the induc-

tion side of the pump. As the engine heats up the wax

ncreases in volume and the thermostat gradually opens the channel to the heat exchanger, at the same time as the by-pass pipe is closed.

See "Technical data" for opening temperatures.

6 2



Cooling system

Repair instructions NOTE! Close the bottom valve before working on the

cooling system.

Refrigerant

The refrigerant has the twin purpose of protecting the cooling system from freezing and preventing corrosion.

Antifreeze Use a mixture of 50 % Volvo Penta antifreeze (glycol) and

50 % pure water (as neutral as possible). This mixture prevents freezing down to approx. -40°C (-40°F) and

should be used all year round.

Fig. 105. Draining of the refrigerant

Note: At least 40 % antifreeze should be used in the system to ensure satisfactory corrosion protection.

Mix the antifreeze with water in a separate vessel before filling the cooling system.

For replenishment of the refrigerant see the instruction on page 64.

The sea water system Watch out for the penetration of water in the boat!

WARNING! Antifreeze is hazardous to health

(dangerous to consume).

Close the bottom cock or the cock on the S-

1. drive. Release the cover on the sea water pump and let the water run out.

n the event that antifreeze is not necessary it is appropri-

ate to add Volvo Penta anti-corrosion agent 1141526-2.

Draining of the refrigerant

Stop the engine before draining the cooling system. The fresh water system

Unscrew the filler cap. Turn the cap to the first stop and wait a moment before lifting off the cap.

WARNING! Open the filler cap very carefully if

the engine is hot. Steam or hot liquid may spit out.

Connect a hose to the drain cock. Open the cock

and drain out the refrigerant in a vessel. Hand in the mixture to a recovery station if it is

not to be used again. Never pollute the water.

Release the hose from the sea water pump and

2. sea water filter at the reverse gear and tilt down so

that the water runs out.

Check if there are additional cocks/plugs at low

points on the refrigerant and exhaust pipes. Check carefully that all the water runs out.

Tighten the hoses and cover to the sea water

pump.

Pump out the boat and check that there is no l

eakage.

Cooling system

Replenishment of refrigerant

Flush the cooling system before filling up with refrigerant.

Close all the drain points and fill up with refrigerant to the correct level. See next page.

Filling should be done with an idle engine.

gine must not be started before the system is vented and completely filled. If a heater unit is connected to the engine's cooling system the heat control valve must be

fully opened and the unit vented during filling.

Check hoses and connections and seal any leaks.

Note: Fill the

done too quickly or else air pockets can form in the system. The air should be allowed to flow out through the

filling opening. Check the engine coolant level after run-

ning the engine for some time. Top up coolant if re-

quired.

system slowly!

Filling should not be

The en-

Check the engine coolant level

WARNING!

system filler cap when the engine is still hot except in an emergency Steam or hot coolant may

spray out.

Turn the filler cap to the first stop and let any pressure escape from the system before removing the cap. Top

up coolant if necessary. For MD2O10-204OA/B the level must be just under the neck of the filler opening and for MD2O10-2040C between the lower edge of the neck of

the filler opening and the level spur (1). Reinstall the filler cap.

a separate expansion tank is installed (optional extra)

the level should be between the MAX and MIN marks.

Do not open the engine coolant

MD 2010-2040C

Refrigerant level

Refrigerant temperature too low

If the refrigerant temperature is too low this may be because of:

Defective thermostat.

Defective temperature sensor or instrument.

Refrigerant temperature too high

If the refrigerant temperature is too high this may be be-

cause of:

Blocked sea water inlet or sea water filter.

Defective pump wheel in the sea water pump.

Too low refrigerant level, air in the fresh water system.

Slipping or burst belt for the circulation pump.

Defective thermostat, temperature sensor or instrument.

Blocked cooling system.

ncorrectly set injection pump, i.e. injection angle.

MD 2010-2040A/B

Refrigerant level

6 4

Refrigerant loss

There are two types of refrigerant loss:

Refrigerant loss when running.

Refrigerant after stopping with a hot engine.

Refrigerant loss when running may be because the cooling system is not tight or because air or combustion

gases have been forced into the system.



Cooling system

Checking of pressure valve in filler cap

Special tool:

Drain off the refrigerant and connect the pressure

testing device with a nipple to one of the plugged

holes in the cooling system.

Extend the drain hose from the filler pipe with a hose the end of which is placed in a vessel contain-

ng water.

Apply the pressure and read off the manometer when the valve opens (water bubbles in vessel).

The valve should open at 0.9 kp/cm

Remove the test equipment. Fit the plug and fill up with refrigerant.

999

6662

(12.8 lbf/in2).

Release the hose clips and remove the rubber muffs at the front and back of the heat exchanger. Pull out the insert.

Flush and clean the insert inside and outside. Clean also the housing.

Note:

f there are loose deposits in the insert a suit-

able steel rod can be pushed through the tubes in the opposite direction to the flow of water.

NOTE! Make sure that the rod does not damage the tubes.

Fit the insert in the heat exchanger.

sure that the insert is positioned correctly. Make

sure that the hole in the insert casing comes opposite the hole in the housing and that the vent hole

comes upwards. The insert is marked with "UP".

Place the insert so that its extruding parts are equal at the front and back.

NOTE! Make

Cleaning of heat exchanger

Fit the rubber muffs on the heat exchanger's front

Clean the heat exchanger insert on signs of blocking (slow rise in refrigerant temperature).

NOTE! Check/clean the sea water filter first. Check also

the sea water pump's impeller and sea water intake.

mportant!

working on the cooling system.

Drain off the water in the sea and fresh water sys-

tems.

Close the bottom valve before

5. and back and tighten the hose clips. Connect the

hose from the sea water pump and tighten the clip.

Fill up with refrigerant.

Open the bottom cock or the cock on the S-drive

7. and start the engine. Check that no leakage occurs.

Fig. 106. Heat exchanger insert

Cooling system

Replacing the circulation pump

Dismantling

Drain off the refrigerant from the engine (fresh wa-

ter system).

Release the alternator and remove the drive belt.

MD2030, MD2040: Remove the clamp for the alternator.

Remove the rubber hoses to and from the pump.

Release the electric cables to the temperature rel

ay.

Fig. 108. Application of sealing compound (silicon)

Apply sealing compound (silicon, Volvo Penta part No. 1161277-7) on the cylinder block as per Fig. 108, shaded area.

Fit the refrigerant pump with a new gasket.

MD2030, MD2040: Fit the clamp to the alternator.

Fig. 107. MD2030. Circulation pump

Remove the pump's attachment screws and lift off the pump.

MD2030: Remove the back piece (plate), spring, and thermostat.

Fitting

Clean the mating surfaces on the pump and cylinder block.

MD2030: Place the thermostat and spring in the pump. Fit the back piece (plate) on the pump with a

new gasket.

Fit the rubber hoses at the pump's inlet and outlet. Tighten the hose clips.

Fit the drive belt. It should be possible to press the belt down approx. 10 mm (.40 in) between the pul-

eys.

Connect the contact piece to the temperature relay.

Fill up with refrigerant. Start the engine and check that no leakage occurs.

Replacing the pump wheel in the sea

water pump

Close the bottom cock, or the cock on the S-drive before working on the cooling system.

Dismantle the pump's end cover and drain off the

water in the sea water system.



Cooling system

Fig. 109. Replacing the pump wheel

Pull and twist out the pump wheel (impeller) with a pair of universal pliers.

Clean the housing internally. Grease in the pump

3. housing and inside of the cover with a little grease.

Press in the new wheel with a rotational motion (clockwise). Fit the sealing washer on the outer

end of the centre of the wheel.

Fit the cover together with a new gasket.

Open the bottom cock, or the cock on the S-drive. Start the engine and check that no leakage occurs.

M D2040

M D2030

Fig.110. Positioning of the thermostat

Cover

MD2O10, MD2020: Release the exhaust pipe and

3. remove the heat exchanger housing complete. Re-

move the spring and lift out the thermostat from the housing.

MD2040: Remove the cover (1) on the front left-

4. hand side of the heat exchanger. Remove the rub-

ber ring.

MD2O10-2020

Thermostat

Replacing the thermostat

Note:

On MD2030 the thermostat is accessible after the

circulation pump has been removed. See under headi

ng "Replacing the circulation pump" on page 66.

Other engines:

Remove both battery leads. Drain off the water in

1. the fresh water system.

MD2O10, MD2020: Drain off the water in the sea

water system. Remove the alternator.

Checking the thermostat

Check that the thermostat closes completely.

Heat up water in a vessel to 68°C 1 154.4°F (

MD2O10, MD2020), or to 75°C / 167°F (MD2030,

MD2040).

Submerge the thermostat in the water. Check after at least 3-5 minutes that the thermostat is still

closed.

Raise the temperature to boiling point (100°C / 212°F). Check after 3-5 minutes that the thermo-

stat has opened at least 6 mm /.02362 in (

MD2O10, MD2020), or to 8 mm /.3149 in

(

MD2030, MD2040).

Replace the thermostat if these specifications are not met. NOTE! If the thermostat does not close completely

the engine will run at too low a temperature.

6 7

Electrical system

General The engines are fitted with AC generators. The system

voltage is 12V.

MD2010A, -2020A, -2030A and -2040A are fitted with a 1,5-pole* electrical system, while MD201OB/C, 2020B/

C, 2030B/C and 2040B/C have a one-pole system.

Note: One-pole during the start procedure via an

earthing relay.

Positioning of electrical components on the engine

The electrical system also includes as accessories re-

ays for the monitoring of the engine's refrigerant tem-

perature and oil pressure.

The electrical system is illustrated in two ways. The wir-

ng diagram (page 80) shows the wiring, cable areas

and colours. Where respective parts are positioned on the engine is

shown in the figures below.

Fig. 111. Positioning of electrical components on the engine

Starter motor

Earthing relay (A-version)

Glow plug

Alternator

Starter relay

Glow relay

Fuses (4 pcs), max. 15A (+)

Fuses (4 pcs), max. 15A (-) (A-version)

Oil pressure relay, (accessory)

10.

Oil pressure sensor

11.

Refrigerant temperature relay (accessory)

12.

Refrigerant temperature sensor

Electrical system

Fuses

The fuses are placed in the relay box at the rear lefthand side of the engine. The fuses disconnect the cur-

rent when overloaded.

MD2010A, -2020A, -2030A and -2040A

two fuse blocks each with four fuses (15A) for plus (+) and minus (-) .

MD201OB/C, -2020B/C, -2030B/C and -2040B/C

only one fuse block with four fuses (15A) for plus (+).

Re-connect the electrical system, after inspection and work, if one fuse has triggered by moving the cable connection to the next contact.

are fitted with

have

Relays

The relays are placed in the relay box on the rear lefthand of the engine.

The start and glow functions are controlled via their own switching relay. These relays are identical and therefore

f necessary can be interchanged.

Connection of sensor system

mportant! Stop the engine and then switch off

the current with the main switches before working on the electrical system.

Release the yellow sensor conductor from connection B+ on the alternator.

Splice the conductor (yellow, 1.5 mm2, and connect it to the batteries' plus pole (+).

16 AWG)

Charging distributor

As an accessory the engine's standard alternator can be provided with a charging distributor. Two separate

battery circuits can thereby be charged simultaneously.

The charging distributor separates both groups from

each other so that the engine's start battery is main-

tained fully charged even if the "accessory batteries"

are weak or almost flat.

Alternator

Voltage regulator with sensor system

The voltage regulator to the standard alternator (14V/ 60A) is provided with a sensor system.

The sensor system compares the charge voltage between the alternator's connections B+ and 13- with that between the batteries' plus and minus poles. The volt-

age regulator then compensates any voltage drop in the cables between alternator and batteries by increasing the charge voltage when necessary from the alternator.

On delivery from Volvo Penta the sensor system is not activated. Connection has, however, in all probability been carried out in connection with the installation of

the engine.

Fig. 112. Connection of sensor system to standard alternator, principle drawing

Sensor conductor (yellow, 1.5 mm

Charging distributor (accessory)

Alternator

Fuse panel (accessory)

Starter motor

Main switch

Accessory batteries (accessory)

Start battery (engine)

16 AWG)

6 9



Electrical system

For starting with auxiliary battery, see instruc-

mportant information on the

3. tions of page 71.

electrical system

MPORTANT!

current with the main switch before working on the electrical system.

Main switch

Never break the current circuit between the alternator and battery when the engine is running. The main switch must never be switched off before the

engine has stopped. If the current is broken while the engine is running the voltage regulator can be destroyed and the alternator seriously damaged.

For the same reason the charging circuits must not be switched over when the engine is running. For

simultaneous charging of two separate battery circuits it is possible to fit a Volvo Penta charging distributor to the standard alternator (accessory).

Batteries

Never switch the batteries plus and minus poles when fitting the batteries. This can result in serious

damage to the electrical equipments. Compare with the wiring diagram. The battery poles should be

well cleaned and the lead lugs always tight and well greased to ensure good contact.

Quick charging of batteries should be avoided. If quick charging must be used, then both battery

eads should always be removed first.

NOTE! Follow the relevant safety instructions when charging batteries. During charging the cell plugs

should be unscrewed but remain in the plug holes. Ventilate well, especially if the batteries are charged in a closed room. Always switch off the

charging current l

eased.

Stop the engine and switch off the

before

the charge clamps are re-

Electric cables

Never make holes in the cable insulation to conduct measurements. In a corrosive environment such as i

n a boat it takes approx. 2 years for thin cables to

oxidise off via the hole.

a hole must be made in the insulation, it should

be sealed with an appropriate glue afterwards.

Connection of extra equipment

All extra equipment should be connected to a sepa-

rate terminal box and be fused. Extra power points

directly from instrument panels should be avoided.

Permissible extra outlets are a (for all instrument panels together).

total of max. 5A

WARNING!

never be exposed to a naked flame or electrical sparks. Never smoke in the vicinity of batteries.

Hydrogen gas develops during charging which when mixed with air forms This gas is highly inflammable and very explos-

ve.

Always use protective goggles when charging and handing batteries.

The battery electrolyte contains strongly corrosi

ve sulphuric acid. In the event of skin contact, wash with soap and plenty of water. If battery acid gets in your eyes, rinse immediately with plenty of water and contact a doctor immediately.

The battery compartment must

oxyhydrogen

gas.

Electrical system

Galvanic corrosion

MD201OB/C, MD2020B/C, MD203OB/C, MD204OB/C

The engine's flywheel housing and transmission (reverse gear/S-drive) are electrically insulated from the

engine. Note the fitting sequence on the screw union (Fig. 113). The insulation sleeve pos. 1 is only fitted on

one of the screws (optional screw).

WARNING!

(reverse gear alt. S-drive) must under no circumstances be earthed. Earthing of these components can result in serious damage as a result of

galvanic corrosion.

The flywheel housing or transmission

-umfi

~ i

Electric welding

Remove the plus and minus leads from the batteries, and then remove all cables to the alternator.

Always connect the welding clip to the component which is to be welded and as close to the weld point as

possible. The clip must never be connected to the en-

gine or so that the current can pass over a bearing.

On completion of welding:

cables to the alternator are replaced.

Always connect the

before

the battery leads

Repair instructions

Starting with auxiliary battery

WARNING!

battery) contain oxyhydrogen gas which is very explosive. A spark, which can occur if the auxiliary battery is incorrectly connected, is sufficient to

cause the battery to explode and result in injury.

Note: If the start battery has frozen it must be thawed first before a start attempt is made with the auxiliary

battery. Check that the battery is not damaged before connecting it again.

The batteries (especially the auxiliary

Fig. 113. Electrical insulation (A) of the flywheel hous-

ng and transmission

1. Insulation sleeve2. Insulation washer

Washer

Check that the auxiliary battery's rated voltage corresponds to the engine's system voltage (12V).

Connect the red auxiliary lead (+) to the auxiliary battery and then to the flat battery. Then connect

the black auxiliary lead (-) to the auxiliary battery, and finally to a point some distance from the flat

batteries,

or at the minus lead's connection on the starter motor (2-pole electrical system), or at the minus lead's connection on the engine (one-pole system).

Start the engine.

nection during the attempt to start (risk for sparks) and do not lean over any of the bat-

teries.

Remove the leads in exactly the reverse order to

the way they were connected.

ary leads to the standard battery must absolute-

y not be disconnected.

e.g. at the main switch on the minus lead

NOTE! Do not touch the con-

NOTE! The ordin-

Electrical system

Checking the battery leads

Set the multimeter for voltage testing and then connect the multimeter between the battery's plus and minus

pole. Run the engine at approx. 2000 rpm. Read off and note the voltage over the battery poles.

The alternator provides approx. 14.0 V:

Conduct test as follows:

Connect the multimeter between the alternator's B+ and

B- connections.

Run the engine at approx. 2000 rpm. The alternator should provide 14.0-14.4 V. The total voltage drop

must not exceed 0.4 V.

Voltage drop less than 0.2 V:

Battery leads in good condition.

Voltage drop more than 0.3 V:

Conduct check of battery leads.

The alternator provides more than 14.4 V:

See items "Checking and troubleshooting of alternator" and "Checking of the regulator".

Checking of positive battery lead

Connect the multimeter between the alternator's B+ connection and the battery's plus pole.

Run the engine at approx. 2000 rpm. The voltage drop must not exceed 0.2 V. If the voltage drop exceeds this

value the lead connections must be rectified as per the

"Procedure" below.

After this carry out a test as per "Checking of negative battery charging".

Checking of negative battery lead

Connect the multimeter between the alternator's Bconnection and the battery's minus pole (-).

Run the engine at approx. 2000 rpm. The voltage drop must not exceed 0.2 V. If the voltage drop exceeds this

value the lead connections must be rectified as per the "Procedure" below.

Procedure

WARNING!

both battery leads before working on the charging circuit.

If the voltage drop during any of the tests as per the

tems above exceeds 0.2 V the lead connections must

i be removed and cleaned from oxide etc. Spray the con-

nections with a moisture repellant contact oil (Volvo

Universal oil, part. No. 1161398-1) or the like and tight-

en the connection again.

Rectify the connections at the battery, main switch,

starter motor, alternator, glow relay and glow plug.

Disconnect the current and remove

Alternator

Checking and troubleshooting of the alternator

Dismantle the alternator's electrical connections.

Spanner widths 8 and 10 mm.

Remove the alternator belt. Dismantle the alternator. Spanner widths 1 1/16"; 5/8"; 12 mm and 13 mm.

Release the voltage regulator's connections at the alternator's B+ connection. Remove the flat pin at connec-

tion B+ and D+. Remove the cap on the W connection.

Bend the plastic guard's attachment lugs alternately off the alternator. Release the regulator's two connection cables to the diode bridge. Use long-nose pliers or poke

out the cable lugs with a screwdriver. Do not pull the

cables!

Replacement of carbon brushes in the

alternator

Unscrew the voltage regulator. Unscrew the brush hold-

er.

Check the length of the carbon brushes. Replace the

brushes if they are 5 mm (.1968 in) or shorter. Carbon

and holder are replaced as one unit. Unsolder the con-

nection cables and solder on the new ones with an

acid-free soft solder.

Electrical system

Checking of the regulator

Special tool: Regulator tester 884892-1

Check before testing that the instrument's batteries

have the correct voltage. Press in the button "Test" and

check that the green lamp ("Batt.") lights. Replace the

batteries (2 pcs alkaline, 9 V) if the lamp does not light.

The batteries are in a compartment underneath the instrument.

Connect the tester's grey cables to the carbon.

Connect the tester's brown cable to the regulator's yell

ow and brown cables which should be put together dur-

ng the test.

Connect the tester's black cable to the regulator's black

cable.

Press the "Test" button and at the same time turn the rheostat from the "0" marking to the "1" marking.

Regulator in good condition

The red and green lamps should light from "0". The red

amp should go off at the "1" marking.

Dismantling the diode bridge

n order to check the diode bridge and stator windings

the diode bridge should be dismantled.

Unsolder the three stator windings. Avoid excessive heat since this can damage the diodes. Release the

nuts (note how the washers and nuts are fitted).

Check measurement of the diode bridge

Set the multimeter in the position "Diode test". Be very careful to obtain good contact with the probes during all

measurements.

Checking of the B+ diodes

Connect the measuring instrument's positive probe to one of the stator winding connections (1-2-3). Connect the instrument's negative probe to the diode plate's B+.

Read off the instrument. A normal value should lie between 450 and 650 mV, which is the voltage drop over the diode. An other value indicates a defective diode.

Check the other B+ diodes by moving the positive probe to the respective connection (1-2-3).

Check the B+ diodes in the opposite direction of current flow by switching the position of the positive and neg-

ative probes. Carry out the same measurement procedure as above. The instrument should during this measurement show a one "1" (to far left). If the instrument

shows another value the diode is defective.

Faulty regulator

Replace the regulator if the red lamp lights constantly when the rheostat is turned, or if it does not light in any position.

Note:

The "2" marking on the tester is not used for this

type of regulator.

Check measurement of rotor winding

After the regulator and carbon brushes have been re-

moved it is possible to measure the resistance of the ro-

tor.

Set the measuring instrument in position Q. Make sure

that the probes have good contact between the slip

rings. The resistance of the rotor should be 3.0-5.0 Q.

Check also

tween slip ring and earth.

that no earth fault occurs by measuring be-

Checking of the B- diodes

Connect the instrument's positive plate's B- connection and the instrument's negative

probe

to the respective stator winding connection

(1-2-3)

Read off the instrument as before. A normal value should lie between 450 and 650 mV. Another value in-

dicates a defective diode.

probe

to the diode

7 5

Electrical system

Check the 13- diodes in the opposite direction of current flow by switching the position of the positive and neg-

ative probes. Carry out the same measurement procedure as above.

The instrument should during this measurement show a

one "1" (to far left). If the instrument shows another value the diode is defective.

Note: If any diode is defective the entire diode plate must be replaced.

Checking of the D+ diodes

The diode plate's three magnetising diodes are check according to the same principle as above.

Connect the measuring instrument's positive probe to the respective connection for the stator winding (1-2-3) and the instrument's negative probe to D+. The voltage

drop for the respective diode should be between 450 and 650 mV.

NOTE!

cables. When the measurement between the stator windings is carried out the measuring cable's inner re-

sistance (e.g. 0.10 Q) must be deducted from the value obtained.

Measure between all winding connections (three measurements). The resistance should lie at 0.10 S2.

Measure also against the alternator material by connecting the instrument in position S2. Measure between

the respective winding and the material. The instrument should during this measurement show a one "1" (which

I i

Note: If any stator winding is defective the stator must be replaced as a complete unit.

Check first the inner resistance in the measuring

mplies infinite).

f the instrument shows another value the stator winding

s defective.

Check the D+ diodes in the opposite direction of current flow and switch the positions of the positive and negative probes. Carry out the same measuring procedure

as above. The instrument should show a one "1" (to far l

eft). If the instrument shown another value the diode is

defective.

Note: If any diode is defective the entire diode plate must be replaced.

Check measurement of the stator windings

When the diode bridge is removed it is possible to measure the stator windings with the multimeter set to

the "Buzzer" position.

Measure the resistance between respective windings.

Starter motor

General

The stator motor is a DC series motor. The starter gear i

s controlled by a magnet and is moveable in an axial

direction on the rotor shaft.

On engine MD2040 the starter motor is provided with a reduction gear. This enables a higher torque.

7 6

Dismantling of the starter motor

Remove both battery leads.

Release the electric cables to the starter motor.

Dismantle the starter motor's attachment screws and lift off the starter motor.

Stripping of the starter motor

Clean the exterior of the starter motor.

Electrical system

Fig. 117. Dismantling of the stator housing

Remove the brush holder plate. Remove the stator housing from the rotor and front bearing shield; on

2040 from the gear housing.

Fig. 115. Stripping of the starter motor

Remove the magnet.

Remove the protective cover from the rear bearing shield. Remove the lock ring and where appropriate

the intermediate washer(s).

Fig. 116. Dismantling of the bearing shield

Fig. 118. Dismantling of the rotor

Remove the coupling arm and rotor.

MD2040: The coupling arm is fitted in the gear housing.

Fig. 119. Dismantling of the starter gear

Remove the starter gear as per Fig. 119. First remove the lock ring by tapping down the contact ring with a suitable mandrel.

MD2040: The starter gear is fitted in the gear housi

ng.

Remove the rear bearing shield.

Electrical system

nspection of the starter motor

Troubleshooting on the starter motor should be handed

over to an authorised electrical workshop which disposes over the necessary test equipment.

Test the rotor with respect to winding flash-over and failure with the test equipment for this purpose.

Fig. 120. Checking of the commutator

Check that the mating surfaces for the electric brushes on the commutator are smooth and free

from dirt and oil. If the commutator is damaged or burnt it can be polished with sandpaper No. 500 or

600.

Measure the commutator with a dial gauge. Max. permissible radial distortion is 0.05 mm (.0019 in).

Check that the commutator's insulation lies at least

0.2 mm (.0078 in) below the laminated surface. Correct if necessary. See Fig. 120.

Check the linearity of the rotor. Brace the rotor between spikes and measure the radial distortion on

the rotor frame with a dial gauge. Max. permissible radial distortion is 0.08 mm (.0031 in).

Note:

The radial distortion is half of the read value.

Check the cogs on the starter gear. Replace damaged gear. Check also the starter gear ring if the

gear is damaged.

Assembly of the starter motor

Assembly is carried out in the reverse order to stripping.

Connect + and - from a 12 V battery to the terminal on the magnet and check that the starter gear is pushed forward to the gear stop.

Fitting of the starter motor

Place the starter motor in position in the flywheel housing and tighten it.

Connect the electric cables to the starter motor. See the wiring diagram on page 80-86.

Connect both battery leads.

Electrical components

Relay box with fuses

The A-version has two fuse blocks each with four fus-

es (15A) for plus (+) and minus (-) placed on the relay box at left-hand rear side of the engine.

The B/C-version has one fuse block.

The fuses disconnect the current in the event of over-

oading.

Re-connect the electrical system of a fuse has blown by moving the cable connection to the next contact.

Field winding

Check with a test instrument that there is no failure in the

winding. If the field winding is defective it should be re-

placed.

7 8

Fig. 121. Relay box with fuses

Fuse block + (1 5A)

Starter relay

Glow relay

Electrical system

Relays

Oil pressure relay - alarm

Fig. 122. Oil pressure relay

Contact type:

oil

pressure in the engine drops below 0.3 ± 0.15 bar

(4.18 t 2 psi).

Note:

Checking of the closing point should be conduct-

ed with

Refrigerant temperature relay -

falling

Normally open. The contacts close if the

pressure.

alarm

Sensors

Note:

Sensors are only available with "De Luxe"

nstrument panels.

Oil pressure sensor

Fig. 125. Oil pressure sensor

Resistance testing:

with instrument connected. Measure with ohmmeter class 1 at +20° C (+68°F)

Pressure

0 bar (0:

2 bar (27.9 psi):

4 bar (55.8 psi):

6 bar (83.7 psi):

Measure with falling pressure and

10 +3 /-5 Q

52 ±4Q

88 ± 4 Q

124 ±5Q

Fig. 124. Refrigerant temperature relay

Contact type:

refrigerant temperature rises over 95°C ± 3°C (203°F ±

5.6°F).

Note:

Checking of the break point should be conduct-

ng with

Normally open. The contact closes if the

rising temperature.

Refrigerant

temperature sensor

Fig. 126. Refrigerant temperature sensor

Resistance sensor:

merged to the hexagonal screw for three minutes in circulating liquid and with the current switched on.

Temp. 60°C (+140°F):

90°C (+194°F):

100°C (+212°F):

Measure with the sensor sub-

134.0 ±13.5 S2

51.2 ±4.3 Q

38.5 ±3.0 S2

(t4°C, t7.2°F) (t4°C, ±7.2°F) (t40C, t7.20F)

7 9

Wiring diagram

Engine MD2010A, MD2020A, MD2030A, MD2040A

Battery

Main switch

Startermotor

Earthing relay

Earth rail

Glow plug*

Alternator

Starter relay

MD2O10:

2 pcs. Other engines:

Glow relay

10.

Protective diode

11.

Fuses (4 pcs), max. 15A (+)

12.

Fuses (4 pcs), max. 15A (-)

13.

Splice

14.

Oil pressure relay, engine (normally open, closed at

15.

Oil pressure sensor

3 pcs

0.3

16.

17.

18.

bar ±0.1 bar

Cable colours

= LBL = BN = LBN =

GN = GR =

Blue Light blue Brown Light brown

Green Grey

OR R SB

W Y

Orange

Red

Black White

Yellow

Cable areas in mm2are given after the colour code in the wiring diagram.

Areas not given=1.0 mm2.

Dashed cables are not included from Volvo Penta.

Refrigerant temperature relay (normally open, closes at 95°C

±3°C, 203,2

°Ft5.6°F ) Refrigerant temperature sensor Connector, 16-pole

16



Wiring diagram

Engine MD201OB/C, MD202OB/C, MD203OB/C, MD204OB/C

416

15 10

5 13

0 n

30 87

-85

R25

R/Y 2.5

863085

R25

R 2.5



1 1

581o

R10

Battery

Main switch

Starter motor

Alternator Glow plug*

Starter relay

10.

11.

MD2O10: 2 pcs. Other engines: 3 pcs

Cable colours

Blue OR LBL = BN LBN =

GN = GR =

Cable areas in mm

Light blue

Brown

Light brown W

Green

Grey

R SB

are given after the colour code in the wiring diagram.

Areas not given = 1.0 mm2.

Dashed cables are not included from Volvo Penta.

Glow relay Fuses (4 pcs), max. 15A (+)

Magnetising resistance (330/9W) Oil pressure relay, engine (normally

open, closed at 0.3 t0.1 bar) Oil pressure sensor

Orange

Red Black

White Yellow

12.

Refrigerant temperature relay (normally open, closes at 100°C t2°C, 212°F t3.6°F)

Refrigerant temperature sensor

13.

14.

Connector, 16-pole



9



Wiring diagram

nstrument panel, alternative "B"

MD201OB/C, MD2020B/C, MD2030B/C, MD204OB/C

(with key switch)

®®0of

RIM

0 0 (9 (9

rFr>P

enr

R,a

W/S8 so

•

Return spring

Cable colours

BL BN GN GR

OR R SB VO W Y

•

Blue Brown Green

Grey Orange Red Black

Violet White Yellow

57 8

V 11

122

Return spring

II I

nstrument lighting

Tachometer with built-in hour counter (accessory),

alt. blind plug

Connector for connection of extra warning display

(accessory)

Electronics unit (alarm)

Warning lamp, refrigerant temperature

Warning lamp, oil pressure

Warning lamp, charging

Control lamp, glowing

Switch, instrument lighting

10.

Switch -Alarm test/Acknowledging

11.

Key switch Alarm

12. Connector for connection of neutral position switch

13. (accessory)

6-pole connection

14.

Cable areas in mm

Areas not given=

are given after the colour code in the wiring diagram.

1.0 mm



Wiring diagram

nstrument panel, alternative "C"

MD2010

A, MD2020A, MD2030A, MD2040A

SB 1 0

61+

Return spring

III

$ 15a15b 305019

1.Instrument lighting

Voltmeter Oil pressure gauge

Refrigerant temperature gauge

Warning lamp, refrigerant temperature

5. Warning lamp, oil pressure

Warning lamp, charging Control lamp, glowing

Electronics unit, alarm

10.

Switch, instrument lighting

11.

Switch - alarm test

12.

Tachometer

13.

Key switch

14.

Alarm Connector for connection of neutral position switch

15. (accessory) 2-pole connection (for extra panel)

16.

17.16-pole connection

BLISS15

n©

BUY 1.5

Cable colours

•

R SB

•

145

Blue Brown Green Grey Orange Red Black Violet

White Yellow

16910

12 13

8 5



Wiring diagram

nstrument panel, alternative "C"

MD2010B/C, MD2020B/C, MD2030B/C, MD204OB/C

Return spring

Cable colour

BL LBL BN LBN

GN GR OR R SB VO W Y

S 15815b 3050 19

Blue Light blue

•

Brown Light brown Green

•

Grey

•

Orange

•

Red

•

Black

•

Violet White

•

Yellow

•

0 (9 (9 (9

+ - +

BAT

&OW

RIM

w/Sa

A-

1.Instrument lighting

Voltmeter Oil pressure gauge

Refrigerant temperature gauge

Connector for connection of extra warning display (accessory)

Electronics unit (alarm)

Warning lamp, refrigerant temperature

Warning lamp, oil pressure

Warning lamp, charging

10.

Control lamp, glowing

11.

Switch, instrument lighting

12.

Switch - alarm test/Acknowledging Tachometer with built-in hour counter (accessory),

13. alt. blind plug

14.

Key switch

15.

Alarm

16.

Connector for connection of neutral position switch (accessory)

17.

16-pole connection

18.

2-pole connection (for extra panel)

Cable areas in mm2are given after the colour code in the wiring diagram.

Areas not given=

1.0 mm

12 13

avw is

atir

8 6



Extra equipment (accessories)

eneral

Extra equipment which is driven with V-bet*,s via the engine's crankshaft result in an increased load on the

crankshaft. It is therefore important that the axial position of the pulley on the crankshaft and the positioning of the equipment in relation to the crankshaft are adjus-

ted to the power takeout of the extra equipment.

R (N)

1200

1000

800

The following diagram shows the permissible power

takeout at a certain positioning of the pulley and extra equipment.

700

600

500

i i

400

300

200

310°

300°

290°

280°

270°

70 80

320°

100 110 120 130 140 150

330°340° 350°

0°

10°

20°

30°

d (mm)

200

40°

50°

60°

70°

80°

90°

260°

250°

240°

230°

220°

210°200°

190° 180° 170°

Fig. 127. MD 2010.

160° 150°

100°

110°

120°

130°

140°

8 7



Notes

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

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

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English or Swedish.

From:



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

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



ssued:

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

Date:

Name:

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Customer Support

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Sweden



Volvo MD2010, MD2020, MD2030, MD2040 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual