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Volvo Penta Md2010 20 30 40 Workshop Manual




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Workshop Manual A
Engine MD2020 MD2030 MD2040
Workshop Manual
Marine engines
MD201OABC MD202OABC MD203OABC
data Repair njection pump 9 I
njection pump 54
Wear tolerances 15 Adjustment of injection angle 55
Tightening torque 17 Adjustment of speed 57
Feed pump 58
Fuel filter 59
Special tools 18
Bleeding of fuel system 59
I njector Checking of injector
of engine 19
Cooling system
Engine body Description
24 Repair instructions Refrigerants
63
Cylinder head 25 Checking of refrigerant level 64
Valves valve mechanism 28 Cleaning 65
Cylinder block pistons connecting rods 34 Circulation pump 66
Timing gears 40 Sea water pump 66
Camshaft 44 Replacing the thermostat 67
Crank mechanism 46 Checking the thermostat system
Electrical 51 Description
68
Repair instructions I mportant info 70
Oil pump 52 Starting with auxiliary battery 71
Replacing the oil filter 52 glow plug charging system 72
Cleaning the oil channels 52 Alternator 74
Starter motor 76
Electrical components 78
Fuel system Wiring diagram
53 Extra equipment 87
Note
The data given in this Workshop Manual refers in general to
engines in both A B and C versions unless otherwise stated
Safety Precautions
I ntroduction
This Workshop Manual contains technical specifica
0 Check that the warning or information labels on
the product are always clearly visible Replace
tions descriptions and instructions for the repair of the l abels which have been damaged or painted
over
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 Pre Engines with turbocharger TC Never start the
cautions Genera Information and Repair Instruc engine without installing the air cleaner ACL
tion sections of this Workshop Manual carefully filter The rotating compressor in the Turbo can
cause serious personal injury Foreign objects
I mportant
entering the intake ducts can also cause me
chanical damage
I n this book and on the product you will find the follow
i ng special warning symbols
WARNING Possible danger of personal injury Never use start spray products or similar when
Q extensive damage to property or serious me
chanical malfunction if the instructions are not
starting the engine They may cause an explo
sion in the inlet manifold Danger of personal in
followed jury
I MPORTANT Used to draw your attention to
something that can cause damage or malfunc
IL Avoid opening the filler cap for engine coolant
tions on a product or damage to property
system freshwater cooled engines when the
Note Used to draw your attention to important informa engine is still hot Steam or hot coolant can
tion that will facilitate the work or operation in spray out Open the filler cap slowly and release
progress the pressure in the system Take great care if a
cock plug or engine coolant line must be re
Below is a summary of the risks involved and safety moved from a hot engine Steam or hot you should always observe or carry out
can spray out in any operating or servicing the engine
I mmobilize the engine by turning off the power Hot oil can cause burns Avoid getting hot oil on
supply to the engine at the main switch switch the skin Ensure that the lubrication system is
es and lock it them in the OFF position before not under pressure before carrying out any work
starting work Set up a warning notice at the en Never start or operate the engine with the oil fill
gine control point or helm er cap removed otherwise oil could be ejected
As a general rule all service operations must be I Stop the engine and close the sea cock before
carried out with the engine stopped However carrying out operations on the engine cooling
system
some work for example certain adjustments re
quire that the engine is running when they are
carried out Approaching an engine which is op
erating is a safety risk Loose clothing or long Only start the engine in a area If
hair can fasten in rotating parts and cause seri operating the engine in an enclosed area en
ous personal injury If working in proximity of an sure that there is exhaust ventilation leading out
engine which is operating careless movements of the engine compartment or workshop area to
or a dropped tool can result in personal injury remove exhaust gases and crankcase ventila
Take care to avoid contact with hot surfaces ex tion emissions
haust pipes Turbocharger TC air intake pipe
start element etc and hot liquids in lines and
hoses on an engine which is running or which
has just been stopped Reinstall all protective
parts removed during service operations before
starting the Always use protective glasses or goggles when
carrying out work where there is a risk of splin
O Ensure that rags soaked in oil or fuel and used
fuel or oil filters are stored safely Rags soaked
ters grinding sparks acid splashes or where i n oil can spontaneously ignite under certain cir
other chemicals are used The eyes are ex cumstances Used fuel and oil filters are envi
tremely sensitive an injury could result in blind ronmentally dangerous waste and must be de
ness posited at an approved site for destruction
together with used lubricating oil fuel paint remnants solvent degreasing agents
and waste from washing parts
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 dry
ness and eczema and other skin problems can Never expose a battery to naked flame or elec
then occur Used oil is more dangerous than trical sparks Never smoke in proximity to the
fresh oil from a health aspect Use protective batteries The batteries give off hydrogen gas
gloves and avoid oil soaked clothes and shop during charging which when mixed with air can
rags Wash regularly especially before eating form an explosive gas oxyhydrogen This gas
There are special skin creams which counteract i s easily ignited and highly volatile Incorrect
drying out of the skin and make it easier to clean connection of the battery can cause a single
off dirt after work is completed 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
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 Always ensure that the Plus positive and Mi
paint and solvents are dangerous to health nus negative battery leads are correctly in
Read the instructions on the product packaging stalled on the corresponding terminal posts on
carefully Always follow the safety precautions the batteries Incorrect installation can result in
for the product for example use of protective serious damage to the electrical equipment Re
mask glasses gloves etc Make sure that other fer to the wiring diagrams
personnel are not exposed to hazardous chemi
cals for example in the air Ensure good ventila
tion in the work place Follow the instructions
Always use protective goggles when charging
provided when disposing of used or leftover
and handling the batteries Battery electrolyte
chemicals
contains sulfuric acid which is highly Should the battery electrolyte come into
contact
with unprotected skin wash off immediately us
Excercise extreme care when leak detecting on i ng plenty of water and soap If battery acid
the fuel system and testing the fuel injector jets comes in contact with the eyes immediately
Use eye protection The jet from a fuel injector flush with plenty of water and obtain medical as
nozzle is under extremely high pressure and sistance at once
has great penetrative energy so the fuel can
penetrate deep into the body tissue and cause
serious personal injury Danger of blood poison
Turn the engine off and turn off the power at the
i ng
main switches before carrying out work on the
electrical system
All fuels and many chemical substances are
flammable Do not allow naked flame or sparks
Clutch adjustments must be carried out with the
i n the vicinity Fuel certain thinner products and
engine stopped
hydrogen from batteries can be extremely flam
mable 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
General this Workshop Manual
This Workshop Manual contains technical specifica The service intervals and maintenance descriptions and instructions for the repair
of the ures recommended by Volvo Penta must be engines in standard format MD2010 l owed
MD2020 MD2030 MD2040 This Workshop Manual
can show operations carried out on any of the engines Only Volvo Penta Genuine Spare Parts intended
li sted above As a result the illustrations and pictures in for the certified engine version must be used
the manual that show certain parts on the engines do
not in some cases apply to all the engines listed How Service of injection pumps pump settings and
ever the repair and service operations described are in i njectors shall always be conducted by an aut
all essential details the same Where they are not the horised Volvo Penta this is stated in the manual and where the differ
ence is considerable the operations are described sep The engine must not be rebuilt or modified in any
arately The Engine Designations and Engine Number way with the exception of the accessories and
can be found on the product plate Please always in service kits that Volvo Penta has developed for
clude both the engine designation and the engine the in all
I nstallation adjustments on exhaust pipes and
The Workshop Manual is produced primarily for the use supply air channels for the engine Volvo Penta workshops and service technicians
For ventilation channels must not without due care
this reason the manual presupposes a certain basic
be conducted since this can influence of marine propulsion systems and that the
can carry out the work de
scribed to a general standard of engineering compet Seals must not be broken by unauthorised per
ence sonnel
Volvo Penta products are under a continual process and we therefore reserve all rights regard I MPORTANT Use only Volvo Penta Genuine
i ng changes and All the information in Q Spare Parts The use of non genuine parts
this manual is based on product avail i mplies that AB Volvo Penta will no longer
able at the time the book was published Any essential assume for compliance of the
changes or modifications introduced into production or engine with the certified versions All types
updated or revised service methods introduced after the of damage or costs resulting from the use of
date of publication will be provided in the form of Ser
non genuine Volvo Penta spare parts for the
vice Bulletins
product in question will not be regulated by
Volvo parts for the electrical and fuel systems
are subject to various national safety requirements for
example the United States Coast Guard Safety Volvo Penta Original Spare Parts meet Any type of damage which is the result of
using replacement parts that are not original Volvo Pen
ta replacement parts for the product in question will not
be covered under any warranty or guarantee provided
by AB Volvo engines
For engines certified for national and regional legislation the manufacturer undertakes to en
sure compliance with such environmental both new engines and engines is use The product
must comply with the approved example on For Volvo Penta as the manufacturer to be able ac
cept for the compliance of engines in use
with the set environmental requirements the for service and spare parts must be
5
Repair instructions and methods
The working methods described in the Workshop Man Our joint apply to work carried out in a workshop The engine
has been removed from the boat and is installed in an Every engine consists of many systems and fixture Unless otherwise stated ents
that work together If one component deviates from
work which can be carried out with the engine in place the technical this can have dramatic con
follows the same working method sequences on the environmental impact of the engine
even if it is otherwise in good running order It is symbols used in this Workshop Manual for full fore critical that the stated wear tolerances
are of the symbols refer to the section Safety served that systems which can be adjusted are WARNING
rectly set up and that only Volvo Penta Original Parts
are used on the engine The stated service intervals in
AL I MPORTANT
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 are factory sealed for environmental and product spe
cific reasons Under no circumstances attempt to ser
are not in any way comprehensive since it is impossible vice or repair a sealed component unless the service
to predict every circumstance under which service work technician carrying out the work is authorized to do so
or repairs may be carried out Volvo Penta AB can only
i ndicate the risks considered likely to occur as a result Bear in mind that most of the chemicals used around
of incorrect working methods in a wellequipped work boats are harmful to the environment if used using working methods and tools tested by
Volvo Volvo Penta recommends the use of AB degreasing agents for all cleaning of engine
compon
ents unless otherwise stated in the Workshop Manual
All operations described in the Workshop Manual for When working onboard a boat make a special point of
which there are Volvo Penta Special Tools available preventing oil waste water from washing components
assume that these tools are used by the service techni entering the bilges i nstead remove all such waste for
cian or person carrying out the repair Volvo Penta Spe safe disposal at an approved site for destruction
cial Tools have been specifically developed to ensure
as safe and rational working methods as possible It is
therefore the of the person or persons us Tightening torques
i ng other than Volvo Penta Special Tools or Penta working methods as described in a Work The correct tightening torques for critical joints
which
shop Manual or Service Bulletin to acquaint them must be tightened using a torque wrench are listed un
selves of the risk of personal injury or actual mechan der Technical Tightening Torques
ical damage or malfunction that can result from failing to and stated in the method descriptions in the Workshop
use the prescribed tools or working method Manual All tightening torques apply to cleaned threads
bolt heads and mating surfaces Tigthening torques
I n some cases special safety precautions and user in stated are for lightly oiled or dry threads Where may be required in order to use the
tools and l ocking or sealing agents are required for mentioned in the Workshop Manual Always j oints this is stated in both the
operation description and
follow these precautions as there are no specific in i n Tightening Torques Where no tightening torque is
structions given in the Workshop Manual stated for a joint use the general tightening torques ac
By following these basic and using cording to the tables below The tightening torques stat
common sense it is possible to avoid most of the risks ed are a guide and the joint does not have to be tight
i nvolved in the work A clean work place and a clean ened using a torque will eliminate many risks of personal injury and
engine all when working on the fuel system engine lub Dimension Tightening system air intake system Turbocharger unit
Nm seals and seals it is extremely important to ob
serve the highest standards of cleanliness and avoid M5 6 4
dirt or foreign objects entering the parts or systems M6 10 7
since this can result in reduced service life or M8 25 18
M 1 0 50 37
M12 80 59
M14 140 torque with Protractor tight Make sure that mating surfaces are dry and free from
oil grease paint and agent before apply
ening angle tightening
i ng sealant or locking fluid Always follow the using both a torque setting and a protractor turers instructions for use regarding temperature
range
angle requires that first the recommended torque is ap curing time and any other instructions for the using a torque wrench and then the
recommended Two different basic types of agent are used on the en
angle is added according to the protractor scale Ex gine and these are
ample a 90 protractor tightening means that the joint is
tightened a further 14 turn in one operation after the RTV agent Room temperature vulcanizing Used for
stated tightening torque has been applied gaskets sealing gasket joints or coating gaskets RTV
i s visible when a part has been disassembled old RTV
must be removed before resealing the joint
Lock nuts The following RTV agents are mentioned in the Service
Manual Loctite 574 Volvo Penta PN 8408791 Per
Do not reuse lock nuts that have been removed during matex No 3 Volvo Penta PN 11610995 operations as these have reduced ser Nr 77
Old sealant can be removed using life when reused use new nuts when assem spirits in all cases
bling or reinstalling For lock nuts with a plastic insert
Anaerobic agents These agents cure in an absence of
such as Nylock the tightening torque stated in the ta
air They are used when two solid parts for example
ble is reduced if the Nylock nut has the same head
cast components are installed facetoface without a
height as a standard hexagonal nut without plastic in
gasket They are also commonly used to secure plugs
sert Reduce the tightening torque by 25 for bolt size
threads in stud bolts cocks oil pressure switches and
8 mm or larger Where Nylock nuts are higher or of
so on The cured material is glasslike and it is therefore
the same height as a standard hexagonal nut the
colored to make it visible Cured anaerobic agents torques given in the table apply
extremely resistant to solvents and the old agent cannot
be removed When reinstalling the part is carefully de
greased and then new sealant is classes The following anaerobic agents are mentioned in the
Bolts and nuts are divided up into different classes of Workshop Manual Loctite 572 white Loctite 241
strength the class is indicated by the number on the blue
bolt head A high number indicates stronger material
for example a bolt marked 109 indicates a higher
Note Loctite is the registered trademark of Loctite Corparation
strength than one marked 88 It is therefore important Permatex the registered trademark of the Permatex bolts removed during the disassembly of
a bolted
j oint must be reinstalled in their original position the joint If a bolt must be replaced check in
the replacement parts catalogue to make sure the cor
rect bolt is number of sealants and locking liquids are used on
the engines The agents have varying properties and
are used for different types of jointing strengths oper
ating temperature ranges resistance to oil and and for the different materials and gap sizes
i n the engines
To ensure service work is correctly carried out it is im
portant that the correct sealant and locking fluid type is
used on the joint where the agents are required
I n this Volvo Penta Workshop Manual the user will find
that each section where these agents are applied in
production states which type was used on the service operations use the same agent or an al
ternative from a different
7
Safety rules for fluorocarbon rubber
Fluorocarbon rubber is a common material in seal
rings for shafts and in Orings for example
When fluorocarbon rubber is subjected to high above 300C572F hydrofluoric acid
can be formed which is highly corrosive Skin con
tact can give severe chemical burns Splashes in
your eyes can give severe chemical burns If in the fumes your lungs can be f WARNING Be very careful when working on
engines which have been exposed to high tem
peratures eg overheating during a seizure or
fire Seals must never be cut with an oxyacet
ylene torch or be burned up afterwards in an
uncontrolled manner
Always use gloves made of chloroprene rubber
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 rubber
Seal rings for the crankshaft camshaft irrespective of where they are 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 Technical designation
MD2010 MD2020 MD2030 M D2040
Number of cylinders 2 3 3 3
Cylinder diameter 67 mm 67 mm 75 mm 84 mm
2637 in 2637 in 2952 in 3307 in
Stroke length 64 mm 64 mm 72 mm 90 mm
2519 in 2519 in 2834 in 3543 in
Swept volume total 045 litres 068 litres 095 litres 150 litres
2746 cuin 4149 cuin 5797 cuin 9153 cuin
Power see sales literature
I dling speed 850 25 rpm 850 25 rpm 850 25 rpm 850 25 speedhigh idling
3900 25 rpm 3900 25 rpm 3900 25 rpm 3900 25 ratio 2351
2351 231 pressure with starter motor speed 3000 kPa 3000 kPa 3000 kPa 3000 kPa
435 psi 435 psi 435 psi 435 psi
Firing order cyl No 2 and 3 closest
to flywheel 12 123 123 of rotation see from front
Clockwise Clockwise Clockwise permissible angle backwards during operation 20 200
200 20
Max side angle during operation 30 30 30 30
Valve clearance idle cold engine
i nlet and outlet 020 mm 020 mm 020 mm 020 mm
0078 in 0078 in 0078 in 0078 in
Weight engine without oil and water 98 kg 116 kg 129 kg 179 kg
2159lb 2555lb 2842lb 3943 Ib
Max permissible counter pressure in exhaust pipe 20 kPa 20 kPa 20 kPa 20 kPa
29 psi 29 psi 29 psi 29 MD2010
M D2030 M D2040
M Aluminium alloy Aluminium alloy Aluminium alloy
Height total in mm 5904559095 6557565625 87668774
23242326 in 25812583 in 34513454 in
Height from gudgeon pin centre to piston top in mm 3304533095 3557535625 47664774
13001302 in 14001402 in 18761879 in
Piston clearance in mm 00480082 0042500665 00380072
00180032 in 00160026 in 00140028 in
Front marking MD2010 MD2020 The arrow alt F mark on piston top should be turned forwards
MD2030 MD2040 The SHIBAURA mark in the piston should be turned forwards
The pistons for certain engines also have an arrow in front
of the gudgeon pin hole which should point rings
MD2010 M D2030 M D2040
M rings
Number 2 2 2
Top compression ring height in mm 147149 147149 197199
05780586 in 05780586 in 07750783 in
2nd compression ring height in mm 147149 197199 147149
05780586 in 07750783 in 05780586 in
Oil ring
Number 1 1 1
Height in mm 297299 397399 390398
011691177 in 015621570 in 15351566 in
ec nrcal data
MD2010 M D2030 M D2040
M D2020
Piston ring gap in cylinder measured in mm
top compression ring 013025 015027 020035
00510098 in 00590106 in 00780137 in
2nd compression ring 010022 012024 020040
00390118 in 00470094 in 00780157 in
Oil ring 010030 020035 020040
00390118 in 00780137 in 00780157 in
Piston ring clearance in groove measured in mm
top compression ring 006010 006010 00650110
00230039 in 00230039 in 00250043 in
2nd compression ring 005009 005009 00130035
00190035 in 00190035 in 00050013 in
oil ring 002006 002006 00300130
00070023 in 00070023 in 00110051 pins
MD2010 M D2030 MD2040
M gudgeon pin gudgeon bushing in mm 00130030 00060023 00100027
00050011 in 00020009 in 00030005 in
Gudgeon pin gudgeon pin hole in mm 0004 0008 0004 0006 0001 0011
0001 0003 in in 00003 0004 in
Gudgeon pin diameter in mm 1899619002 2099821002
74787481 in 82668268 in in
Gudgeon bushings int diameter in mm 1901519026 2101021021
74867490 in 82718275 in in
Gudgeon pin holes diameter in piston in mm 1899819004 2099821004
74797481 in 82668269 in head
M D2010 MD2030 MD2040
M D2020
Height in mm 549551 646654 697703
21612169 in 25432574 in 27442767 in
Valve seats inlet diameter in mm 25352545 30353045 36353645
99801001 in 11941198 in 14311435 in
Outlet diameter in mm 21852195 26852695 32353245
86028641 in in in
Depth in mm 205215 225235 205215
08070846 in 08850925 in 08070846 with bearing
MD2010 M D2020 M D2030 M bearing cups for main and
big end axial clearance in mm 0103 01 03 005030 0104
00390118 in 00390118 in 00190118 in 00390157 in
Main bearing in mm No 1 00350072 00350072 00390106 00440116
00130028 in 00130028 in 00150041 in 00170045 in
No 2 00550092 00350072 00390106 00440116
00210036 in 00130028 in 00150041 in 00170045 in
No 3 00550092 00390092 00440102
00210036 in 00150036 in 00170040 in
Technical data
Main bearing
Main bearing journals
MD2010 in mm standard bearing journal No 1 4296442975
i n i n
No 2 4596445975 i n i n
No 3
undersize No 1 025 mm 4276042786 0098 i n i n
i n
050 mm 4251042536 0196 i n i n i n
undersize No 2 025 mm 4576445790 0098 i n i n
i n
050 mm 4551445540 0196 i n i n i n
undersize No 3 025 mm 0098 i n
i n
050 mm 0196 i n
i n
M D2030 in mm standard bearing journal No 1 4596445975
i n i n
No 2 4596445975 i n i n
No 3 4596445975 i n i n
undersize No 1 025 mm 4585445934 0098 i n i n
i n
050 mm 4560445684 0196 i n i n i n
undersize No 2 025 mm 4585445934 0098 i n i n
i n
050 mm 4560445684 0196 i n i n i n
undersize No 3 025 mm 4571445725 0098 i n i n
i n
050 mm 4546445475 0196 i n i n i n
Bigend bearing journals
MD2010 MD2020 MD2030 M D2040
Bigend bearing radial clearance in mm 00310068 00350083 00350085
00120026 i n 00130032 i n 00130033 i n
Bearing journal length in mm 15651655 17701860 19702060
61616515 i n 69687322 i n 77558110 i n
Diameter in mm standard 3496434975 3896438975
i n i n i n
undersize 025 mm 3471434725 3871438725 0098 i n i n
i n i n
050 mm 3446434475 3846438475 0196 i n i n i n i
Technical bearing shells
MD2010 MD2020 MD2030 in mm standard 14841497 14821495
05840589 i n 05830588 i n
oversize 025 mm 16091622 16071620
0098 i n 06330638 i n 06320637 i n
050 mm 17341747 17321745
0196 i n 06820687 i n 06810687 i rods
MD2010 MD2020 M D2030 M D2040
Fitted with replaceable bearing gudgeon bushings bearing position 2100021021 2300023021
82678275 i n 90559063 i n i n
Bearing shells bearing position 1901519026 2101021021
74867490 i n 08278275 i n i n
Gudgeon bushing 1901519026 2101021021
74867490 i n 82718275 i n i n
Axial clearance connecting rod crankshaft 00310079 00350083 00350083
00120031 i n 00130032 i n 00130032 i n
Timing M D2010 M D2020 MD2030 MD2040
Drive Gear wheel Gear wheel Gear wheel Gear wheel
Number of bearings 3 3 3 3
Valve times
i nlet valves open BTDC 13
130 13
close ABDC 430 43
430 40
outlet valves open BBDC 430 430 430 46
close ATDC 130 130 130 10
Valve MD2010 MD2020 M D2030 M diameter in mm
59605975 694695 69556970
23462352 i n 27322736 i n 27382744 i n
Valve disc edge in mm 09251075 09251075 09251075
03640423 i n 03640423 i n 03640423 i n
Clearance in mm valve spindle guide 00450072 00500075 003006
00170028 00190029 i n 00110023 i n
Seat angle in cylinder head 45
45 0 45
Valve clearance in mm cold engine 020 020 020
0078 i n 0078 i n 0078 i diameter in mm 59405955 694695
694695
23382344 i n 27322736 i n 27322736 i n
Valve disc edge in mm 09251075 09251075 09251075
03640423 i n 03640423 i n 03640423 i n
Clearance in mm valve spindle guide 00450072 00500075 00500075
00170028 i n 00190029 i n 00190029 i n
Seat angle in cylinder head 45 450 45
Valve clearance in mm cold engine 020 020 020
0078 i n 0078 i n 0078 i n
Technical data
Valve springs MD2010 MD2020 MD2030
MD2040
Length in mm in uncompressed 33l299 33l299 35l377 35l377
with 794 N 5856 ftlbf compression 304 1196 304 1196
with 677 N 4993 ftlbf compression 283 1114 283 1114
Push rods
Length in mm in total 146 146 157 19581962
5748 5748 6181 Outer diameter in mm in 63
63 63 6264
2480 2480 2480 Rocker mechanism
Rocker shaft diameter in mm 11651167 11651167 11651167 11651167
45864594 in 45864594 in 45864594 in 45864594 in
Clearance in mm rocker shaft bushing 00320068 00320068 00320068 00320068
00120026 in 00120026 in 00120026 in 00120026 in
Lubrication system
MD2010 MD2020 MD2030 MD2040
Oil pressure in kPa hot engine at running speed 150500 150500 150500 150500
21773 lbfin t 21773 lbfin z 21773 lbfin z 21773 lbfint
Oil pressure in kPa idling 50150 50150 50150 50150
72522 lbfin z 72522 lbfin z 72522 lbfin z z
Relief valve opening pressure in kPa 294490 294490 294490 245345
42671 lbfin 42671 lbfin t 42671 lbfin z 34450 lbfin z
Oil inner outer impeller 001015 mm 001015 mm 001015 mm 001015 mm
00040059 in 00040059 in 00040059 in 00040059 in
Axial clearance impeller cover 001015 mm 001015 mm 001015 mm 001015 mm
00040059 in 00040059 in 00040059 in 00040059 in
Oil quality as per API system CD CD CD CD
Viscosity at 5 to 50C 23 to 122F SAE 15W40 SAE 15W40 SAE 15W40 SAE 15W40
SAE 20W50 SAE 20W50 SAE 20W50 SAE 20W50
Max Oil volume incl oil filter
no engine tilt version AB 18 litres 34 litres 43 litres 64 litres
19 US quarts 36 US quarts 45 US quarts 67 US quarts
no engine tilt version C 19litres 28 litres 35 litres 57 litres
20 US quarts 30 US quarts 37 US quarts 60 US quarts
Min Oil volume incl oil filter
no engine tilt version AB 15 litres 30 litres 32 litres 55 litres
16 US quarts 32 US quarts 34 US quarts 58 US quarts
no engine tilt version C 13 litres 21 litres 27 litres 45 litres
17 US quarts 22 US quarts 29 US quarts 48 US quarts
Note Temperatures with stable ambient MD2010 MD2020
MD2030 MD2040
I njection sequence 12 123 123 123
Feed pump max induction height in m ft 08 262 08 262 08 262 08 262
Feed pressure in kPa lbfinz 1525 2136 1525 2136 1525 2136 1525 2136
I njection pump
M D2010 M D2020 MD2030 MD2040
Start of injection crankshaft position 255 1 255 1 225110 210 10
BTDC BTDC BTD C 3 BTDC 5
277 1 2151 1901
BTD C 2
BTDC 4 BTD C 67
Pump element diameter in mm in 45 1771 45 1771 55 2165 55 length in mm in
62362 62362 62362 72755
up to and including engine number 5101311299 4
from engine number 510101939 7
MD2040C
from engine number 5101311300 5
MD2040AB product number 868748
up to and including engine number 510101938 6
MD2040B product number 868778
Technical MD2010 MD2020 MD2030 pressure checking
113123 MPa 113123 MPa 113123 MPa 152162 MPa
115125 kpcm 2 115125 kpcm2 115125 kpcm 2 2 155165 kpcm 2 2
16391784 lbfin 2 16391784 lbfin 2 16391784 lbfin 22052347 pressure adjustment 118 MPa 118 MPa 118 MPa
157 MPa
120 kpcm 2 120 kpcm2 120 kpcm2 160 kpcm2
1711 lbfint 1711 lbfint 1711 lbfint 2276 valve diameter 35 mm 35 mm 6mm
4mm
01378 in 01378 in 02362 in 01575 in
Journal diameter 1 mm 1 mm 1 mm 1 mm
00394 in 00394 in 00394 in 00394 in
Jet angle 4 4 4 system
MD2010 MD2020 MD2030 MD2040
Type Overpressure closed cooling system
Fresh water system volume approx vers AB 21 litres 30 litres 40 litres 69 litres
22 US quarts 32 US quarts 42 US quarts 73 US quarts
Fresh water system volume approx vers C 23 litres 29 litres 45 litres 67 litres
24 US quarts 31 US quarts 48 US quarts 71 US number 1 st 1st 1st
1 st
Thermostat begins to open at 750 2C 75 2C 82 2C 82 2C
167 4F 167 4F 179 4F 179 4F
fully open at 87C 189F 87C 189F 95C 203F 95C valves lifting height 6 mm 6mm
8 mm 8 mm
02362 in 02362 in 03150 in 03150 system
M D2010 MD2020 MD2030 MD2040
System voltage 12V 12V 12V 12V
Fuses 15A 15A 15A 15A
Battery capacity starter battery 70 Ah 70 Ah 70 Ah 70 Ah
Glow plug
rated voltage 105V 105V 105V 105V
current 69 A 69 A 69 A 69
M D2010 MD2020 MD2030 MD2040
Output voltage at 20C 68F 142 015 V 142 015 V 142 015 V 142 015 V
Max current 60 A 60 A 60 A 60 A
Power approx 840 W 840 W 840 W 840 W
Suppressor capacitor 22 F 22 hF 22 hF 22 F
Voltage regulator type YV 77 YV 77 YV 77 YV 77
Starter motor
M D2010 MD2020 MD2030 motor power approx 07 kW 07 kW 12 kW
20 kW
Engine speed with connected starter motor
approx 340 rpm 300 rpm 285 rpm 265 rpm
Note refers to engine with timing gears and at approx 20C
Technical data
Wear tolerances
Note Unless otherwise stated the given values refer to all pressure at starter motor speed min 200 rpm min 25 kpcm2 3556 clearance
max 025 mm 0098 rings
Piston ring clearance in rings max 025 mm 0098 in
Oil ring max 015 mm 0059 in
Piston ring gap in cylinder max 10 mm 0393 pins
Gudgeon pin MD2020 min 1898 mm 7472 in
MD2030 min 2098 mm 8259 in
MD2040 min 2798 mm 11015 gudgeon pin bushing max 008
mm 0031 in
gudgeon pin hole max 002 mm 0007 max 012 mm
0047 top plane max 012 mm 0047 in
Cylinder MD2020 max 672 mm 26456 in
02 mm 00787 in oversize max 677 mm 26653 in
05 mm 01969 in oversize max 682 mm 26850 in
MD2030 max 752 mm 29606 in
05 mm 01969 in oversize max 757 mm 29803 in
10 mm 03937 in oversize max 762 mm 30000 in
MD2040 max 842 mm 33149 in
05 mm 01969 in oversize max 847 mm 33346 in
10 mm 03937 in oversize max 852 mm 33543 in
Technical max 006 mm 00236 deviation on 100 mm 3937 in measured length max
015 mm 00590 on 100 mm 3937 in measured length max 02 mm 00787 in
Axial clearance crankshaft connecting rod max 07 mm 02755 valve clearance inlet and outlet cold engine max 05
mm 01968 in
Maximum permitted valve clearance before adjustment must be carried MD2020 MD2040 min 31 mm 12204 in
MD2030 min 40 mm 15748 in
Brush length min 115 mm 4527 in
Brush spring tension MD2010 MD2020 MD2040 min 88 N 20 lbf
Brush spring tension MD2030 min 137 N 30 lbf
Technical data
Tightening torque in Nm ftlbf
MD2010 M D 2030 M D2040
M D head 3540 258295 5053 369391 9095 bearing
top to bottom bearing cap steel 2530 184221 2530 184221 5055 369405
aluminium 2025 147184 2025 147184
Main bearing cap to cylinder block 2530 184221 2530 184221 5055 369405
2530 bearing 2126 155192 3035 221258 5055 housing 1317 96125
4755 347406 1317 housing 2429 177214 2429 177214 2429
7080 516590 6070 443516 6070 coupling 912 6688 912 6688 912 plate for flywheel
housing 2429 177214 2429 177214 2429 strainer oil pump 913 6696 913 6696
913 plate 912 6686 912 6686 912 913
6696 913 6696 913 plug sump 3040 221295 3040 221295 3040 gear casing
912 6686 912 6686 912 pulley 90100 6674 120130 8696 280340
206250
I njection pump 913 6696 913 6696 913 bracket rocker shaft 2025
147184 2025 147184 2025 cover 1012 7486 1012 7486 812 oil pipe cylinder head
1013 7496 1013 7496 1 013 7496
I njector 6070 443516 8085 590627 6070 pipe 2025
147184 2025 147184 1525 valve holder 3539 258288 4045 295332 4045 valve
6070 443516 6070 443516 6070 screw max fuel volume 2025 147184 2025 147184 2025 screw
speed 1317 96125 1317 96125 plug 1520 110147
1520 110147 15127611 0147
Oil pressure relay 1520 110147 1520 110147 1520 temperature relay 2530
184221 2530 184221 2530 184221
Oil pressure sensor 1520 110147 1520 110147 1520 temperature sensor 1520
110147 1520 110147 1520 110147
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 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
8852246 Engine fixture The tool should be supplemented with 4 pcs pin
screws 4799714 4 pcs nuts 9710955 4 pcs screws 9709643
M10x140 4 pcs screws 9553116 M8x140 4 pcs washers
9601485 M10 4 pcs washers 9601410 M8 and the arms
from engine fixture 99925208 Overhaul stand
8569279 Measuring plastic disposable item
95100608 99991796 Key for dismantling of fuel and oil filters
8852519 Adapter for measuring compression pressure MD2030
8852527 Adapter for measuring compression pressure MD2010 MD2020
and MD2040 Presentation
General Design differences engine versions
The engines are inline 4stroke marine diesel engines This Workshop Manual applies to all engines MD2010
fitted with top valves MD2010 has two cylinders while 2040 A B C
MD2020 MD2030 and MD2040 have three cylinders The most important differences are
The engines are of the prechamber type and equipped
with glow plugs which are activated before and during
starting MD201040A MD201040B
The engines are fitted with thermostat regulated fresh MD201040B has
water cooling The cooling system is divided into a Unipolar electrical system
fresh water and a sea water system The sea water
cools the fresh water system via a heat exchanger The fly wheel cover and the transmission reverse
Lubricating takes place by means of an oil pressure gear or Sdrive are electrically insulated from the
system where an oil pump presses oil to all the lubrica engine
tion point The oil system is provided with a replaceable
oil filter of the fullflow type
MD201040B MD201040C
The fuel system is protected from impurities by a re MD201040C has
placeable fine filter
Heat exchangers with improved cooling performan
ce and extended expansion volume
Deeper and narrower oil sump
Reinforced generator mountings for 2010 and 2020
Common oil filter for 201040
Positioning of rating plates
VOLVO
ausan asseraBLY vxUYeo x nCCOXnnxR i0 x x
PENTA
XXXXXXX XXX 4
C nvvxoR nl
n m
XXXX 1 XXXX 5
XXXXXXXXXX2 VOLVO XXXX 1 XXX XXX 3
XXX XXX 3 XXX XXX 7 PEP7TA XXXXXXXXXX 2
Engine and transmission decal Engine plate
1 Product designation 5 Product designation
2 Serial number 6 Serial number
3 Product number 7 Product number
4 Certification number 8 Gear ratio
2 3
17 16 15 14 13
MD201OAB MS2L MD2010AB MS2L
17 16 15 14 13
MD203OAB MS2A MD203OAB MS2A
1 2 3
MD204OAB MS2L
1 Cap for replenishing of refrigerant 13 Sea water pump
2 Expansion tank 14 I njection pump
3 Relay box with fuses 15 Oil filter
4 Flexible suspension 16 Feed pump with hand pump
5 Starter motor 17 Oil cooler reverse gear
6 Alternator 18 Folding propeller
7 Oil dipstick reverse gearSdrive 19 Refrigerant intake Sdrive
8 Cap for oil dipstick reverse gearSdrive 20 Refrigerant cock sea water Sdrive
9 Fuel filter 21 Oil drain Sdrive
1 0 Cap for oil engine 22 Zinc anode zinc ring
11 Oil dipstick engine 23 Earthing relay for starter motor and
12 Air filterAir intake glow plug
Note When running in freshwater the magnesium anode
magnesium ring should be used
6 4 5 4
17 16 15 14 13
MD2010C MS2L MD2010C MS2L
1 2 3 78 9 12 10 11
22 21
MD2020C 120S MD2020C 120S
6 4 5 4
MD2030C MS2A MD2030C MS2A
3 7 8 12 9 10 11
6 4 5 4 17 16 15
MD2040C MS2L MD2040C MS2L
1 Cap for replenishing of refrigerant 14 I njection pump
2 Expansion tank 15 Oil filter
3 Relay box with fuses 16 Feed pump with hand pump
4 Flexible suspension 17 Oil cooler reverse gear
5 Starter motor 1 8 Folding propeller
6 Alternator 1 9 Refrigerant intake Sdrive
7 Oil dipstick reverse gearSdrive 20 Refrigerant cock sea water Sdrive
8 Cap for oil dipstick reverse gearSdrive 21 Oil drain Sdrive
9 Fuel filter 22 Zinc anode zinc ring
1 0 Cap for oil engine
11 Oil dipstick engine
Note When running in freshwater the magnesium anode
12 Air filterAir intake
magnesium ring should be used
1 3 Sea water pump
Engine Crank mechanism
head The crankshaft is journaled in three main bearings
MD2010 or four main bearings other engines The
The cylinder head is manufactured of specially alloyed axial bearing on MD2040 consists of loose thrust wash
cast iron It is provided with replaceable valve seats for ers placed at the rear main bearing On the other en
the inlet valves gines the rear main bearing cap is made of aluminium
The cylinder head is screwed onto the cylinder block and serves as thrust washers The crankshaft is screws The tightening of the cylinder
head should and dynamically balanced and has induction hardened
be done in three stages bearing surfaces At the front the crankshaft is fitted with
a key joint and at the rear with a flange on which the fly
wheel is block
The cylinder block is cast in one piece of specially al
l oyed cast iron
Main and bigend bearings
The main and bigend bearings consist of steel shells
li ned with bearing metal The bearings are piston rings milled and ready for installation Two oversizes are
available as spare parts
The pistons are manufactured of a lightweight metal al
l oy They are fitted with three piston rings chromium Note The thrust washers for the crankshafts axial bear
plated two compression rings and an oil ring i ng are not available in injection pump is driven from the front part of the
camshaft by means of two or three separate cams de Connecting rods
pending on the number of cylinders The connecting rods have Isections The piston bolt end
The feed pump is driven via an eccentric cam from the is for lubrication of the gudgeon pin
rear of the gears Flywheel
The timing gears consists of cylindrical gears with be The flywheel is screwed on a flange on the rear of the
velled cogs crankshaft It is statically balanced and fully camshaft and sea water pump are driven
from the The starter ring is shrunk onto the gear via an intermediate gear The engines A flexible coupling with damper element of
rubber is
oil pump is built into the intermediate wheel and is dri
screwed on the flywheel The coupling transfers the
ven via this Regulator weights are suspended in the force to the reverse edge of the camshaft
Engine body
Repair of cylinder head
1 Remove both battery leads Close the fuel cocks
2 Close the bottom valve and drain off the water in
the sea and fresh water system
3 Release the hose to the heat exchanger from the
sea water pump Release the exhaust pipe from
the exhaust hook
Fig 9 Dismantling of expansion tank with heat ex
changer
4 Release the thick rubber hose under the heat ex 1 Heat exchanger complete
changer Note the hose is filled with refrigerant 2 MD2010 MD2020 Spring
Release the thin hose from the refrigerant pump 3 MD2o10 MD2020 9
Remove the expansion tank complete with heat ex
changer
MD2010 MD2020 Remove the spring thermostat
5 MD2010 MD2020 remove the drive belt for the al
and rubber seal from the heat exchanger housing
pump Remove the alternator
and clamp
10 MD2010 MD2020 MD2030
Remove the induction manifold
MD2040
6 Release the relay box from the heat exchanger Remove the inlet pipe complete with air filter
housing and hang it up
11 Release the delivery pipe at the injection pump
7 Release the electric cables to the oil pressure relay and injectors Lift off the delivery pipes together
and to the refrigerant temperature relay and sensor Protect the connections from impurities
where MD2040 remove the cover at the front on the heat 12 Remove the nut at the top of respective injectors
exchanger housings righthand side Remove the and lift off the fuel leak pipe
spacer ring thermostat and rubber seal
Engine body
V U
u u
2 r
11601
CAP 2
MD2010 2020 M D2030 M D2040
Fig 10 Dismantling of injectors
1 Injector 3 Heat shield MD2030
2 Copper gasket 4 Insert MD20102030 Fig 12 Dismantling of oil pressure pipe cylinder
block cylinder headrocker Unscrew the injectors Use a long socket 80 mm
16 Remove the oil pressure pipe between the cylinder
MD2010 MD2020 MD2030 22 mm
block and cylinder head rocker mechanism on
MD2040 27 mm
MD2040
Remove the copper gaskets under the injectors
MD2030 Remove the heat shields 3 Fig 10
17 Remove the valve cover built together with the in
MD2010 MD2020 MD2030 Remove the inserts l et pipe on MD2010 MD2020 and MD2030
4 and the lower copper Release the electric cable to the glow plug Re
move the conductor rail and unscrew the glow plug
Fig 13 Dismantling of rocker mechanism MD2040
1 Rocker mechanism 3 Valve caps
2 Pull rods
18 Release the nuts from the rockers bearing brack
ets Remove the rocker mechanism 1 Fig 13 and
pull rods 2 Remove the valve caps 3 MD2040
from the valve stem
Fig 11 Dismantling of circulation pump
19 Release the cylinder head screws in several sta
15 MD2010 MD2020 MD2030 Remove the circula ges
tion pump Note Begin in the middle of the cylinder head and
MD2030 Note The pump must be releasedre release the screws in a circle outwards
moved before the cylinder head is released The Lift off the cylinder head
pump can otherwise be broken Remove the spring
and Engine of cylinder head
I nspection of cylinder head
The flatness tolerance for the cylinder head is max 012
mm 00472 Check in six positions AF as per Fig
15 and 16 Use a feeler gauge and a ruler the sides of
which are precision rubbed as per DIN Fig 14 Dismantling the valves
1 Valve lock 4 Valve Fig 15 Checking of cylinder head flatness
2 Valve spring washer 5 Valve cap
3 Valve spring
MD2040 and later versions of MD2010 2020 2030
1 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
2 Clean all parts Observe special care with the
channels for oil and Fig 16 Checking of cylinder head flatness
3 Remove residual soot and impurities from the cylin
der heads sealing surfaces
Note Do not use use steel brush to clean the cylin
der head screw threads or under the screw heads I 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 of valve seat Grinding of valves and valve seats
1 Use a valve spring tensioner and dismantle the
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
2 Clean the 17 A distance between cylinder head plane and
valve seat should be replaced when the distance
A in Fig 17 measured with a new valve exceeds
18 mm 0708
1 Remove the old valve seat by heating it up with a
gas jet 600700C 11121292F diagonally
over the seat
Allow the cylinder head to cool approx 35 minu Fig 18 Checking of valve spindle wear
tes in the air Carefully tap out the seat with Diameter mm I nlet Outlet
mandrel check that the cylinder head is not dama
ged MD2010 MD2020 590 mm 590 mm
2322 in 2322 in
Alternatively the valve seat can be milled out MD2030 MD2040 689 mm 684 mm
check that the cylinder head is not damaged 2712 in 2692 in
Check the wear on the valve spindle Measure the
diameter with a micrometer at points I II and III as
2 Clean the seat housing in the cylinder head care per Fig 18
fully Check the head for cracking
3 Cool down the new seat with liquid nitrogen or the
li ke to minus 6070C 140158F and heat up the
cylinder head to approx 60100C Press the seat in the head Use a hydraulic press
10001500 kp 22043307 lbf and suitable
Work the seats to the correct angle and width Fig 19 Valve disc edge
4 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 05 mm 019 in the valve
should be scrapped see Fig 19 The same ap
plies to valves with crooked valve
Engine body
5 Check the wear on the valve guides see Check 8 Fit the seals valves valve springs spring washers
i ng of valve guides before the valve seats are valve lock and valve caps See Assembly of cylin
treated der head on page 31
150
Checking of valve guides
Fig 20 Grinding of valve seat
Fig 22 Clearance valve valve guide cylinder head
A Max 25 mm 0984 in
6 Ream or grind the valve seats Fig 20 Grind of Calculate the clearance between the valve spindle and
j ust enough material so that the valve seat has the valve guide
right shape and a good mating surface
Wear tolerances
I nlet valve max clearance 020 mm 0078 in
Outlet valve max clearance 025 mm 0098 in
Note Since the valve guides are treated directly in the cylin
der head this must be replaced when the clearance is exces
low sive even when the valve is new
Fig 21 Checking of valve the valve seat when the distance A in Fig 21
measured with a new valve exceeds 18 mm 0708 in
For replacement of the valve seat inlet see seats are grind down so that the distance be
t ween the cylinder head plane and the valve disc
surface A is
MD2O10 MD2020 070090 mm 02750354 in
MD2030 MD2040 085115 mm 03340452 in
7 Grind in the valves with grinding paste and check
the contact with marker dye
Engine body
Checking of valve springs Renovating the rocker mechanism
Check that the springs do not show any signs of 1 MD2O10 MD2020 MD2030 Remove the screws
damage 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
Max 20 mm 0787 in withdrawing tool can be used
rjrq p 1
Fig 23 Checking of the valve springs on a level surface and check
the linearity with a st square Fig 23
Fig 25 Dismantling of rocker mechanism MD2040
2 Dismantle the rocker mechanism Remove the
rockers springs and washers
3 Clean the parts Observe special care with the
rocker shafts oil channels and oil holes in the rock
Fig 24 Spring tester
Fig 26 Measuring of rocker shaft
Place the spring in a spring tester and check its length
both compressed and springs should maintain the values given in Tech 4 Check the wear on the rocker shaft with a data
ter Fig 26 Diameter min 1157 mm 4555 in
Engine body
Fitting of cylinder head
Fig 27 Clearance rocker rocker shaft
Fig 28 Fitting of valve stem seals
5 Check that the rocker bearing surfaces are not out
ofround worn 1 Press down new valve stem steals on the valve
guides
Calculate the clearance between the rocker and
shaft The clearance must not exceed 02 mm Note MD2030 and MD2040 have different seals
0078 in for the guides for the inlet and outlet valves
Check that the ball pins spherical part is not defor
med 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 val
ve must not be unevenly worn or concave Adjust
ment for minor wear can be made in a grinding
machine C
Note MD2O102030 A new type of rocker includ
i ng valve cap has been introduced as from engine
number
MD2010 5101202984
MD2020 5101308898
M D2030 5101465653 00
Only the new type of rocker is available as a spare
part If one or several of the older type of rocker 2
need to be replaced all the rockers must be re
Fig 29 Fitting of valves
placed at once and valve caps installed on the
valve stems 1 Valve lock 3 Valve spring
2 Valve spring retainer 5 Valve cap
4 Valve
MD2040 and later versions of MD2O10 2020 2030
2 The valves should be fitted in the correct order Oil
i 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
Comparison between new and old rockers seals are not damaged
1 Earlier rocker 4 The new rocker tip
2 Earlier rocker tip 5 Valve cap 3 Fit the valve caps when all valves are fitted Ap
3 The new rocker 6 Valve plies to MD2040 and later versions of MD2O10
MD2020 MD2030 Please refer to the note below
item 5
4 Fit new plugs if these have been removed
6 Oil in the rocker mechanism and fit the different
parts
Engine body
Fitting of cylinder head 1st tightening
1 Clean the surface of the cylinder head and cylinder MD2O10 MD2020 10 Nm 740 ftlbs
block Remove any rust or soot from the screw ho MD2030 20 Nm 1480 ftlbs
l es and threads for the cylinder head screws MD2040 30 Nm 2210 ftlbs
2 Fit on the new cylinder head gasket 2nd Apply grease containing molybdenum disulphide MD2O10 MD2020
20 Nm 1480 ftlbs
on the cylinder head screws MD2030 35 Nm 2580 ftlbs
MD2040 70 Nm 5170 ftlbs
NOTE The screws are surface treated and must
not be cleaned with a steel brush Final tightening
Note I f the cylinder head is painted the mating sur MD2O10 MD2020 3540 Nm 2630 ftlbs
faces for cylinder head screws must be free from MD2030 5053 Nm 3739 ftlbs
paint otherwise the clamping force in the screw MD2040 9095 Nm 6670 ftlbs
union will be adversely affected
4 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
Fig 32 Fitting of the rocker mechanism MD2040
6 Fit the pull rods 2 valve caps 3 MD2040 and
l ater versions of 2010 20202030 and rocker
mechanism 1
7 Adjust the valve clearance as per directions on
page 34 Fit the valve cover
Fig 30 Tightening diagram MD2O10
Fig 33 Fitting of oil pressure pipe cylinder block
Fig 31 Tightening diagram MD2020 MD2030 MD2040 cylinder head rocker
8 Fit the oil pressure pipe between the block and
5 Tighten the cylinder head screws in three stages as cylinder head rocker mechanism on MD2040
per the following See tightening diagrams Fig 30 Tightening torque 1013 Nm 7496 ftlbs
Engine body
9 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 00
cable
1 Fig 35 Fitting of thermostat MD2O10 MD2020
MINK
MD2030 and expansion tank
CIRD 2
15 MD2O10 MD2020 Fit the rubber seal thermostat
3 and spring 2 in the heat exchanger housing 1
MD2010 2020 MD2030 M D2040 16 Fit the expansion tank complete with heat exchan
ger Connect the hoses to the heat exchanger
Fig 34 Fitting of injectors housing and refrigerant pump Tighten the hose
1 Injector 3 Heat shield MD2030 clips
2 Copper gasket 4 Insert Fit the copper gaskets heat shields MD2030 and
i nserts to the injectors as per
Fig 34
Fit the injectors Use socket L80 mm 315 in
key width 22 mm and 27 mm
MD2040
Tightening torque MD2O10 MD2030 MD2040
6070 Nm 443517 ftlbs
Tightening torque MD2030
8085 Nm 590627 ftlbs
Fig 36 Fitting of thermostat MD2040
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 17 MD2040 Fit the rubber seal thermostat and spacer
2025 Nm 148184 ftlbs ring in the heat exchanger housing Fit the cover
over the MD2O10 MD2020 MD2030 Fit the induction mani
fold 18 Connect the electric cables to the oil pressure re
lay and to the refrigerant temperature relay and
MD2040 Fit the inlet pipe complete with air filter
sensor where 33
Engine body
19 Fit the relay box 4 MD2020 MD2030 MD2040 Check and adjust if
20 MD2O10 MD2020 Fit the alternator and clamp Fit necessary the valve clearance for cylinder No 1
the drive belt and the clearance for the outlet valve on cylinder
No 2
Note I t should be possible to press in the belt ap
prox 10 mm 40 in between the pulleys Pull round the crankshaft 240 23 turn anticlock
wise seen from front and adjust the clearance for
21 Connect the hose to the sea water pump and tigh
cylinder No 3 and the clearance for the inlet valve
tenthe clip Connect the exhaust pipe on cylinder No 2
22 Fill with refrigerant See of refrige
ra t on page 64
23 Connect the battery cables Open the fuel cocks
and bottom valve Start the engine and check that 5 Clean the valve cover and fit it Replace the seal if
no leakage occurs damaged Test run the engine and check that no
l eakage the valves
Note The clearance must never be checked when
the engine is clearance cold engine
I nlet and outlet for all engines 020 mm 0078 in Dismantling of piston piston rings and
1 Dismantle the valve cover connecting rod
2 Turn the engine in its normal direction of rotation 1 Empty the cooling system and drain or syphon out
until both valves for cylinder No 1 are closed com the engine oil
pression position Continue turning the engine 2 Dismantle the cylinder head See Dismantling of
round until the marking of flywheel shows 0 0 cylinder head on page 25 and 26
Fig 38 Dismantling of oil strainer with induction
manifold
Fig 37 Adjusting the valves
3 MD2O10 Check and adjust if necessary the valve 3 Remove the sump and plate over the sump
clearance for cylinder No 1 Remove the oil pumps induction manifold
Pull round the crankshaft 180 12 turn clockwise There is no plate on the MD2O1040C
see from front and adjust the clearance for cylin
der No 2
Engine body
4 Turn round the crankshaft until the piston in ques I nspection and matching of piston rings
tion is in the lower turning position Dismantle the
main bearing cap with lower bearing cup Check the wear surfaces and sides Black patches on
the surfaces imply poor contact and indicate that it is
ti 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 by means of a pis
ton Replace the piston ring if the gap exceeds 10 mm
039 in
Fig 39 Dismantling of piston
5 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 pis
ton 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 Dismantle piston ring with a piston ring tongs
Fig 41 Checking of piston ring gap
Piston rings should also be replaced if there is noticea
ble wear or 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 clear
ance at a number of points with a feeler gauge
Fig 40 Dismantling of gudgeon pin
7 Remove the circlips for the gudgeon pin and dis
mantle the gudgeon pin carefully with a suitable
mandrel
Engine of piston piston rings
and connecting rod 6 Check the bigend clearance See Inspection of
crankshaft and Inspection of main and bigend
Note Check that pistons of the correct oversize are bearings on pages 46 and 47
used if the cylinders have been milled to oversize
7 Check the piston ring gap in the cylinder bore Fig
1 Fit one circlip in the piston 41 on page 35 and that the rings do not jam in the
2 Oil in the gudgeon pin and bushing piston ring grooves
Fig 49 Assembly of piston and connecting rod
MD2010 MD2020
Fig 51 Placement of piston rings
1 TOP marking
2 Oil scraper with expander spring Fig 50 Assembly of piston and connecting rod
MD2030 MD2040
3 Heat up the piston to approx 100C 212F Place
the piston and connecting rod so that the markings
correspond with Fig 49 or 50
MD2O10 MD2020 With the marking on the con
necting rods side upwards the arrow on the piston
top should be turned in the same direction as per
Fig 49 Fig 52 Fitting of oil ring MD2040
MD2030 MD2040 The marking on the connecting 1 Top scraper ring 3 Bottom scraper ring
rod and the SHIBAURA mark in the piston should 2 Expander
be turned in the same direction as per Fig 50
Push in the gudgeon pin 8 Fit the piston rings on the piston with a piston ring
NOTE The gudgeon pin should be able to be tong
pressed in easily It must not be knocked in Note The rings should be turned as per Fig 51
MD2O10 MD2020 MD2030 Fit the oil ring first
4 Fit the other circlip with the marking turned upwards The opening in
the expander spring should be placed 180 from the
5 Check that the connecting rod goes easily in the oil ring gap
gudgeon pin Engine body
MD2040 Place the expander 2 Fig 52 on page
38 to the oil scraper rings in the piston ring groove
Check that the ends on the expander do not over
l 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
Fig 53 Number marking on connecting rod and cap
Check that the scraper rings run easily in both di
rections and that the ends on the expander and the
3 Check that the marking on the piston top alt in the
rings are in the correct position Fig 52
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 the l owest number
should be fitted first to cylinder No 1 and subse
quently the connecting rod with the highest number
closest to the flywheel
The connecting rod should be turned with the mark
i ng marking turned towards the in
j ection pump camshaft side The arrow on the
piston top alt at the gudgeon pin hole should there
by point of piston in After replacing a connecting rod piston or gudg
eon pin the weight difference between the connecting
4 Fit the bearing cap and tighten the connecting rod
rod complete with piston and piston rings must not ex
screws See Technical data for tightening torque
ceed 10 g 035 oz between the different cylinders
Note The main bearing cap should be fitted so that
the numbercolour marking on the crankshaft and
cap correspond Fig 53
1 Lubricate the piston and piston rings with engine oil Undamaged connecting rod screws do not need to
and turn the rings so that the oil penetrates the pis be changed and can be refitted
ton 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 posi
tioned opposite the piston bolt or at right angles to
MD2040 Check that the ends on the expander and
scraper rings are in the correct position Fig 52
2 Place the bearing cups in their positions in the con
necting rod and cap Check that the hole in the
bearing cups comes opposite the hole in the con
necting rod Oil in the crank pin with engine oil
Engine body
Timing gears Dismantling of the timing gear
Replacement of front crankshaft seal Q WARNING If the crankshaft and camshaft are
turned without being synchronised with each
other the valves can go against the pistons and
The seal consists of a rubber ring and can be replaced be the crankshaft pulley has been removed Use a
universal extractor 1 Close the fuel cocks Remove both battery leads
1 Tap in one side of the seal so that it goes on edge
Pull out the seal with a hook 2 Close the bottom valve Release the rubber hoses
to the sea water pump and drain out the water in
the sea water system
3 Remove the sea water pump
4 Remove the drive belt for the Fig 54 Fitting of crankshaft seal
3 Oil in the new seal with fit it with a suitable man
drel
Fig 56 Dismantling of crankshaft pulley
5 Remove the pulley from the crankshaft Use a uni
versal extractor Use an adjustable spanner on the
l ug on the pulley as a counterhold when the nut is
removed
Fig 55 Fitting of crankshaft pulley 6 Remove the delivery pipe complete Release the
4 Remove the fitting tool Fit the key and crankshaft fuel house and fuel leak pipe at the injection pump
pulley
See Technical data for tightening Engine
body
Fig 59 Dismantling of circlip to cover for the oil pump
Fig 57 Dismantling of injection pump 10 Remove the circlip for the intermediate gear
1 Lock pin 2 Shims Fig 59 Take care of the sleeve washer spring
and shims
Lift off the gear complete with cover and oil pump
7 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 11 Dismantle the crankshaft gear with a universal ex
tractor
Remove the lock pin and release the regulator arm
Lift off the injection pump 12 If the camshaft gear is to be dismantled the cam
shaft must be removed complete See under head
NOTE Take care off the shims under the injec ing Dismantling of camshaft on page 44
tion pump flange
I nspection of timing gears
8 Dismantle the timing gear casing
Fig 60 Checking of gear flank 2 Clean the gears and other parts of the timing gears and
check them carefully Replace gears which are heavily
Fig 58 Timing gears basic setting worn or damaged
1 3 Camshaftgear Check the flank clearance with a feeler gauge or a dial
2 Intermediate gear gauge
Max permissible flank clearance 025 mm 0098 in
Note If the flank clearance exceeds the Pull round the engine until the markings on the tim
value all the the gears in the timing gears should be re
i ng gears correspond
placed
Engine and adjustment
WARNING I f the crankshaft and camshaft are
Q 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 import
ance for adjustment are marked as 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 62 Intermediate gear complete with oil pump
Fig 61 Circlip 7 Spring
Spring washer 8 I ntermediate gear
1 Put the key in position in the crankshaft and fit the Spring
complete with outer
crankshaft gear Shims rotor
5 Cover to oil pump
2 Fit the camshaft complete with regulator weights 9 Thrust washer
Carry out work steps to item 4 under the heading 6 I nner rotor
Fitting of camshaft on page 45
4 Grease in the oil pumps 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
Fig 61 Timing gears basic setting
1 Crankshaft gear 3 Camshaft gear
2 I ntermediate gear
Fig 63 Checking of oil pumps axial 5 Adjust the oil pumps axial clearance to 010015
mm 00390059 in Shims are available in sizes
010 015 020 and 050 mm 0039 0059 0078
and0196 in
3 Fit the thrust washer 9 Fig 62 on the intermedi
ate gears shaft journal Fit the intermediate gear as
per the markings Fig 61 6 Check the crankshaft seal in the timing gear cas
i ng and replace if necessary See under heading
NOTE Do not turn the crankshaft before the
ti ming gear casing is fitted 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 re
placed 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
11 Check the injection start crankshaft position in the
Fig 64 Fitting of timing gear casing event that a new injection pump or complete new
camshaft is fitted and if a new cylinder block is
7 used
Centre the cover in front of the oil pump
Note The hole in the cover should be in the posi Se directions under the heading Adjustment of in
tion shown in Fig 64 which it should if the mark j ection angle on pages 55 and 56
i ngs on the gear wheel coincide according to Fig
61 12 Connect the fuel hose to the injection pump
Fit the delivery pipe
8 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 tim
i 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 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
Fig 65 Fitting of injector pump
1 Lock pin 2 Shims
9 Turn the stop lever clockwise and connect the arm
to the injection pump Fit the lock pin
Engine body
14 Fit the sea water pump on the timing gear casing 6 MD2O10 MD2020 Remove the gear for the
Connect the water hoses to the pump mechanical tachometer drive
15 Fit the drive belt to the alternator Note Mechanical tachometer driving is not used by Volvo
Penta The gear must however be in position
Note If the tension is correct the belt should be
able to be pressed in approx 10 mm 40 in be
tween the pulleys
16 Open the fuel cocks Bleed the fuel system as per
the directions on page 59 Inspection of valve lifter and camshaft
17 Connect the battery leads
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
It is the condition of the valve lifters that determines
whether further checking of camshaft wear is
Camshaft the camshaft The cam for example may be skew worn in
an axial di
rection This can in less severe cases be adjusted by
1 Dismantle the cylinder head See Dismantling of grinding the cams Replace the camshaft in the event of
cylinder head on page 25 Lift out the valve lifters further damage or wear
and place them in order in a rack
Note When replacing the camshaft all the valve lifters
2 Remove the timing gear casing See under heading must be replaced
Dismantling of timing gear on pages 40 and 41
3 Remove the regulator sleeve from the Measuring the camshaft
Fig 68 Measuring the camshaft
Fig 67 Dismantling of camshaft
1 Gear 3 Cam height inlet and outlet A Fig 68
2 Lock washer MD2O10 MD2020 MD2030 min 261 mm
1027 in
4 Remove the screws for the lock plate one screw is MD2040 337 mm 1326 in
accessible through the hole in the camshaft gear Cam height B for injection pump
Fig 67 MD2O10 MD2020 min 343 mm 1350 in
5 Lift out the camshaft complete with gear and regu MD2030 338 mm 1330 in
l ator weights MD2040 418 mm 1645 in
Note Observe care so that bearings bearing races Cam height C for feed pump
or cams are not damaged MD2O10 MD2020 MD2030 min 270 mm
1062 in
On MD2030 and MD2040 the gear for the mechan MD2040 300 mm 1181 in
i cal tachometer drive must be removed together
with the camshaft Replace the camshaft if the wear tolerances are not
Engine the camshaft 4 Fit the regulator sleeve 3 Note The sleeve
should engage with the pin on the camshaft gear
Note If parts have been replaced on the camshaft the
fitting of these should take place in the order shown in Note Mechanical tachometers are not used by
Fig 69 Volvo Penta but the gear must still be put in
position
5 Check that the markings on the timing gear corre
spond Fig 58 on page 41
6 Carry out the work as per items 8 to 11 under the
heading Fitting and adjustment timing gears on
V1 page 43
410 7 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
Fig 69 Camshaft i n the correct order
1 Camshaft 5 Gear for drive of
2 Key mech tachometer
8 Fit the pull rods and rocker mechanism Tightening
3 Roller bearing 6 Camshaft gear
4 Spacer rings 7 Regulator sleeve torque see Technical data
Note Mechanical tachometers are not used by Volvo
Penta but the gear must still be put in position 9 Carry out the work as per items 6 to 8 under the
heading Fitting of cylinder head on page 32
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
Fig 70 Fitting the camshaft
1 Gear 3 2 Lock washer
1 MD2O10 MD2020 Fit the gear 1 Fig 70 for the
mechanical tachometer drive
2 Oil in the camshafts 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
3 Fit the lock washer 2 for the camshaft in the cor
rect position and tighten it Tightening torque
913 Nm 6696 ftlbs
Engine body
Crank mechanism Inspection of crankshaft
Dismantling of crankshaft Clean the crankshaft carefully in all channels after dis
mantling and inspect it very carefully to confirm removed it really need renovating
1 Dismantle the reverse gear alt Sdrive and adapter
plate and coupling flywheel and flywheel housing
2 Remove the cylinder head See under heading
Dismantling of the cylinder head on pages 25
and 26
3 Remove the valve lifters and place them in order in
a rack 1 2 1 2
4 Remove the pistons with connecting rods Carry
out the work steps to item 5 under the heading
Dismantling of piston piston rings and connecting Qum
rod on pages 34 and 35
5 Remove the timing gear casing Carry out the work
steps to item 8 and item 10 under the heading Dis
mantling of timing gears on pages 40 and 41
Fig 72 Check measurement of crankshaft
1 Check the wear and with a mi
crometer Measure the diameters AA and BB
i n items 1 and 2 See Fig 72
The max permissible conicity and on the main and bigend bearings is 005 mm
0019 in Grind the crankshaft to an appropriate
undersize if these values are exceeded Bearing
cups are available in two oversizes
2 Measure the crankshafts longitudinal curvature
distortion Place the crankshaft on a pair of V
blocks placed under the front and rear of the main
bearing journal Alternatively the shaft can be
Fig 71 Dismantling of main bearing cap braced between spikes Measuring should be car
ried out on the middle main bearing journals
Max longitudinal curvature distortion 006 mm
0023 in
6 Remove the lock screws which hold the main bear If this value is exceeded the crankshaft must be
i ng cap Fig 71 Carefully lift off the crankshaft aligned or replaced
complete with cap backwards
3 Check that the mating surfaces on crankshaft seals
Note Tape the crankshaft gear to protect the bear are not worn or damaged
i ng surfaces in the block during Remove the main bearing cap from the crankshaft
MD2040 Take care of both thrust washers in the
rear cap
Engine of the crankshaft
To achieve satisfactory results in connection with grind I nspection of front crankshaft bushing
ing the following factors should be taken into considera Check the bearing clearance between the bigend jour
tion nal and bushing Use a cylinder indicator and a micro
1 Grind the crankshaft in a crankshaft grinding ma meter
chine to the undersize as per Technical data Sur
face fineness 16 Z VVV for bearing races
B Fig 73 and recess radius are achieved by rub
bing with emery cloth No 400
Fig 74 Checking of bearing clearance
1 Measure the bushings 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 Measure the bearing journals outer diameter and
calculate the bearing clearance difference be
2 It is very important that the recess radius is the cor tween the previous measurement and the bearing
rect size j ournals max diameter
Recess radius Max bearing clearance 02 mm 0078 in
At main and bigend bearing journals
A 3 025 mm 1181 0098 in Replace the bushing if the clearance exceeds the per
At oil holes C min 2 mm 0787 in missible value Where necessary the crankshaft can be
max 5 mm 1968 in ground to an appropriate undersize and the bushing
Grinding hacks and sharp edges must be avoided can be replaced with a corresponding oversize
since these can give rise to crankshaft fracture Note Check the bearing clearance again before the
3 Clean the crankshaft well from grinding residue and crankshaft is fitted if it has been reground
other impurities Flush and clean the oil nspection of main and bigend the main and bigend bearing cups and the busing Replace worn bearings or
those with
damaged bearing 47
Engine of front crankshaft bushing 5 Check that the oil channel is open after pressing in
1 Dismantle the bushing from the cylinder block Check also the bushings inner diameter See
Technical data for size
2 Check that the bushings mating surface in the
block has no burrs or upset ends
Checking of bigend bearing clearance
Special tool 8569279 measuring plastic
The bigend bearings radial bearing clearance can be
checked by means of the measuring plastic part No
8569279 as follows
Fig 75 Marking up of oil hole
3 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
I 1
Fig 77 Application of measuring plastic
Wipe clean the bigend bearing and bigend journal
from oil Cut a piece of measuring plastic to the
same length as the bearing width and apply the
measuring plastic along the bigend journal
Fig 77
Note Avoid the oil hole
Fig 76 Fitting of the bushing 2 Fit the connecting rod and cap note markings cor
respond and tighten the crankshaft screws
4 Tightening torque see Technical data
Make sure that the bushings oil hole corresponds
with the oil channel in the cylinder block and press
i n the new bushing to the correct depth NOTE Do not turn the connecting rod or crank
NOTE The bushing should be pressed in from the shaft since this will destroy the measuring strip
front of the block and with the bevelled side of the
bushing turned forwards Fig 76
Engine body
Fig 78 Check measuring of measuring plastic
3 Remove the cap and measure the width on the
pressed out measuring plastic at the widest point Fig 79a Fitting of main bearing cap MD2O10
Use the scale which accompanies the measuring MD2020 MD2030
plastic Fig 78 1 Bigend bearing cap with 4 Main bearing cap of
bevelling cast iron
Max permissible bigend bearing clearance 2 Groove 5 Main bearing cap of
02 mm 0078 in 3 Top main bearing half aluminium
Replace the bigend bearing if the bearing clear with oil groove
ance exceeds the permissible value If necessary
the journals can be ground to an undersize and
oversize bearings fitted Bigend bearings are avail
able in two oversizes
NOTE Check the bearing clearance again before
assembly if the journals have been of the crankshaft
1 Check the cleaning of the crankshaft channels and
bearing surfaces cylinder block and cap Check
also that the bearing cups and their mating surfac 4
es have no burrs or upset ends
2 Place the main bearing in position in the cap Fig 79b Fitting of main bearing cap MD2040
Check that the lubrication holes in the top bear
1 Bigend bearing cap with 3 Top main bearing half
i ng cups come opposite the oil channels
bevelling with oil groove
3 Oil in the bearing and main bearing journals and fit 2 Groove 4 Thrust washers
the caps on the crankshaft
Note The bevelled edge 1 Fig 79a and 79b
should be turned forwards on all caps
5 Carefully lift the crankshaft in position in the cylin
4 Fit the cap which is provided with a groove as per
der block
2 Fig 79a and 79b
Note Tape the crankshaft gear before the crank
Note The bearing cups provided with an oil groove shaft is lifted in The cogs can otherwise damage
3 Fig 79a and 79b should be placed in the top
the bearing surfaces in the cylinder block
MD2O10 MD2020 MD2030 Fit aluminium caps
with integrated thrust washers at the far end fly
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
Engine body
6 Tighten the main bearing cap Tightening torque Replacement of rear crankshaft seal
see Technical data The seal consists of a rubber ring and becomes access
i 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
1 Clean the position for the sealing ring in the cylinder
block and the mating surface on the flywheel hous
Fig 80 Checking of axial Check that the axial clearance does not exceed
05 mm 0196 of gear ring on the flywheel
1 Mark up the position of the flywheel in relation to
the crankshaft to simplify fitting Dismantle the fly
wheel
2 Drill one or a couple of holes in a tooth gap on the Fig 81 Fitting of crankshaft seal
gear ring Split the ring at the drilled hole with a
chisel after which the gear ring can be removed
2 Apply an even layer of sealing compound VP no
3 Brush clean the mating surface on the flywheel with 840 879 round the flywheel housings mating sur
a steel brush face screw holes
Apply grease on the sealing lip and fit the seal
4 Heat up the new gear ring in an oven 120150C
248302F so that the gear ring becomes evenly 3 Fit the flywheel housing flywheel the flexible coup
hot all round li ng and the adapter plate
Tightening torque see Technical data
5 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
6 Clean the mating surfaces on the flywheel and
crankshaft Check the rear crankshaft seal Re
place if Fit the flywheel in the correct position guide pin on
MD2030 and MD2040
Tightening torque see Technical Lubricating Oil
filter
The engines are provided with a pressure lubricating The oil filter is of the full flow type which implies that all
system with an oil filter of the full flow type the oil is filtered before it is pressed out to the bearing
areas
The filter is placed on the righthand side of the cylinder
Oil pump block The filter element consists of folded filter paper
The oil pump is placed in the intermediate gear in the I n the bottom of the filter there is an overflow and from where it is also driven
A Fig 82 which opens and releases oil past the filter
if the insert should be blocked
The pump is of the rotor type with an inner and outer ro
tor placed eccentrically in relation to each other The in The filter is of the disposable type and is scrapped after
ner rotor has one cog less that the outer rotor use
The function of the pump is based on the increase and
decrease of the space between the outer and inner ro
tor cogs During the first part of the inner rotors the volume is increased whereby an occurs and oil is induced in through the inlet After
approx 12 turn the space is reduced and a occurs which presses out oil through 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 righthand side of the cy
li nder block in front of the oil filter Fig 82 Oil filter
The valve opens at excessive high pressure and releas A Overflow valve
es oil back to the prevent overpressure and to separate fuel vapour
steam and other gaseous combustion products the en
gine is fitted with enclosed crankcase
of the oil pressure
The oil pressure can be checked by connecting a ma
nometer with hose to the connection for the oil thread size in cylinder head 18 The oil
pressure should at running speed and temperature be
150500 kPa 155 kpcm 2 213711 lbfin 2
If the oil pressure is too high or too low the can be replaced first and then the oil again
The valve is fitted on the righthand side of the in front of the oil filter Fig 83 Fig 84 Checking of oil pump clearance
1 Inner rotor 2 Outer rotor
A Max 025 mm 0098 in
Fitting of the oil pump
When fitting the oil pump follow the items 410 and
1217 under the heading Fitting and adjustment
on pages 4244
Replacing the oil filter
A WARNING Hot oil can result in burn injuries
1 Place a collection vessel under the oil filter
2 Unscrew the oil filter and discard watch out for oil
spillage Use a filter extractor
Fig 83 Replacement of reducing valve
3 Moisten the new filters rubber gasket with oil and
check its mating surface on the bracket
Oil pump
4 Screw on the new filter by hand until the gasket
makes contact with the sealing surface and of the oil pump tighten the filter an additional 12 turn
5 Replenish if necessary the oil in the engine and
1 See under the heading Dismantling of the timing
start it Check that no leakage occurs
gears on pages 40 and 41 Carry out the work
steps 1 to 9
2 Remove the circlip for the intermediate gear Take
care of the circlip sleeve washer spring shims
and oil pump cover
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 300400 kPa 34 kpcm 2 426568 lbfint
I nspection of the oil pump i n connection with more extensive engine overhaul
Note Do not forget to clean the oil pressure pipe be
1 Check that the oil pump cover and the inner and
tween the cylinder block and cylinder head
outer rotor are not worn or damaged
Clean the drilled oil channels in the cylinder block
2 Check the clearance between the outer and inner
crankshaft and in the connecting rods with a cleaning
rotor Fig 84 Max permissible clearance
025 mm 0098 in brush
Note Contact Volvo Penta service department if the
shaft journal for the intermediate gear and oil pump
needs to be Fuel Injectors
The fuel is induced by the feed pump from the fuel tank The engines are fitted with injectors Fig 86 Each in
through a water separating prefilter accessory and j ector basically consists of a nozzle holder and a
pressed through the fine filter to the injection pump nozzle
Fig 85
When the fuel pressure has increased to the set value
Return fuel from the injectors is led through the fuel leak opening pressure the nozzle needle pin 5 pipe back to the tank
which is held pressed against its seat by the thrust
washer 6 and atomised fuel is injected into the en
gines precombustion chamber
The injectors opening pressure is determined by the
3 tension of the thrust washer which in turn is adjusted
with adjuster washers 7
Fig 85 Fuel system principle drawing
1 Fuel tank 4 Fine fuel filter
2 Prefilter 5 Injection pump
3 Feed pump 6 njection pump
The injection pump is a inline pump
placed on the righthand side of the engine The pump
i s driven via cams on the engines camshaft which di
rectly activate the pump element
Fig 86 Injector complete
1 Packing 6 Thrust washer
2 Nozzle nut 7 regulator 3 Nozzle sleeve 8 Nozzle holder
4 Spacer 9 Nut
The regulator is mechanical and works with speed 5 Nozzle needle pin
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 pumps con
trol rod via the regulator sleeve a lever and a The speed is regulated over the entire engine
speed range from low idling speed to high speed uni
versal type
Fuel filter
The fuel filter is of the disposable type The filter insert
Feed pump consists of a specially wound paper filter
The feed pump is also positioned on the righthand of
the engine and is driven via a cam on the engines
53
Fuel instructions 4 Send the pump to an authorised diesel workshop
for inspection if the workshop does not have spe
Observe the greatest possible cleanliness when work cially trained personnel with the necessary testing
i ng with the fuel system equipment
MD2o10 MD2020 MD2030 Nippondenso
MD2040 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 warranties are not longer valid if the seals
are broken by unauthorised personnel
1 Carefully wash clean the injection pump pipes and Fitting of the injection pump
the engine around the pump Check that the pump is in good condition and if so re
2 Close the fuel cocks Remove the delivery pipe quired also tested and approved before it is fitted
complete Release the fuel hose from the pump Note Do not remove the protective caps before the
Fit protective caps on all connections pipes are connected
1 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 isput in the
block
Note The correct pump setting is normally ob
tained with this method If the injection pump cam
shaft or cylinder block have been replaced the set
ting of the pump must be adjusted See next
section Adjustment of injection angle
2 Turn the stop lever clockwise and connect the
regulator arm to the control rod on the pump Fit the
l ock pin Fig 87 Screw tight the pump
3 Connect the fuel hose and fuel leak pipe to the
pump Fit the delivery pipe
4 Bleed the fuel system and test run the engine
Fig 87 Dismantling of the injection pump
1 Lock pin 2 Shims
3 Dismantle the pumps 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 Fuel of injection angle
Use a scrapped fuel pipe The pipe makes it easier
to see when the fuel begins and stops flowing out
Fit the injection pump as per the previous section with from the valve
the exception of item 1 which is changed to item 1 be
1 Place a shim 05 mm 0196 in in thickness under
the injection pump flange
Fig 90 Marking the pulley and engine block
Fig 88 Fitting of shim
1 Shim
2 Remove the front pressure valve holder from the 5 Continue turning the crankshaft slowly clockwise
i njection pump 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 BTDC a thinner
shims should be used under the injection pump
flange If the position exceeds Z BTDC a
thicker shims should be fitted instead See table
below
Engine Pos of crankshaft in
model X Y Z
I njection start
crankshaft pos
MD2010 300 245 265 245265 fod
M D2020
up to
Fig 89 5101311299 300 245 265 245265 BTDC
1 Pressure valve holder 4 Oring from
2 Spring 5 Copperwasher 5101311300 300 260 280 260280 BTDC
3 Pressure valve 6 Pump element
M D2030
up to
510101938 300 215 235 215235 BTDC
3 Remove the pressure valve and replace the pres from
sure valve holder 510101939 300 205 225 205225 BTDC
M D2040A
4 Move the throttle arm to max position Turn the MD2040B
crankshaft clockwise until the piston in cylinder No 868748 300 200 220 200220 BTDC
1 moves upwards in the compression stoke and MD2040B
fuel begins to flow out from the pressure valve po 868778
sition X in the table below The work is simplified if MD2040C 300 180 200 180200 BTDC
an approx 50 mm 2 in observation tube is fitted
on the pressure valve engine number product number
Fuel system
Note A change of shim size by 01 mm 0039 in
implies 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 02 03
04 and 05 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 1412 turn until the pressure valve
goes in the pressure valve holder Screw down the
pressure valve fully by hand until the 0ring begins
to be pressed together Tighten after this with a
17 mm Tightening torque see Technical data
WARNING The pressure valve holder must be
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
Fig 91 Measurement of piston position with dial gauge
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 MD2O10 MD2030 MD2040
MD2020
Piston pos Piston pos Piston pos
18BTDC 2317 mm 2875 mm
6 Adjustment of the injection angle can also be made 19 BTDC 2577 mm 3199 mm
by measuring the piston height with a dial gauge 20 BTDC 2851 mm 3539 mm
The table shows the crankshaft position in degrees 21 BTDC 3138 mm 3895 mm
when the piston is in a certain position in relation to 22 BTDC 3438 mm 4267 mm
BTDC 23 BTDC 3750 mm 4655 mm
24 BTDC 3636 mm 4075 mm 5058 mm
Carry out the adjustment work as per items 4 25BTDC 3937 mm 4413 mm 5477 mm
and 5
26 BTDC 4250 mm 4763 mm 5912 mm
The table shows the position of the piston In re 27 BTDC 4573 mm 5125 mm
l ation to the crankshaft angle MD2O10 MD2030 MD2040
MD 2020
Piston pos Piston pos Piston pos
18 BTDC 0912 in 1131 in
19 BT DC 1014 in 1259 in
20 BTDC 1122 in 1393 in
21 BT DC 1235 in 1533 in
22 BTDC 1353 in 1679 in
23 BTDC 1476 in 1832 in
24 BTDC 1431 in 1604 in 1991 in
25 BTDC 1550 in 1737 in 2156 in
26 BT DC 1673 in 1875 in 2327 in
27 BTDC 1800 in 2017 in
Fuel engine speed RPM 2 Warm up the engine and check the idling speed
Check that the throttle mechanism functions normally using a workshop tachometer see Technical Data
Check that the throttle arm 1 Fig moves towards low for correct idling speed
idle 2 when the throttle mechanism is in idling position
and moves towards the stop screw at wide open throttle
3 If necessary adjust to the correct idling speed
WOT 3 when the throttle mechanism is at wide open
using the adjustment screw 2
throttle WOT Adjust the throttle mechanism if neces
sary Also check that the air filter and air intake are not
blocked 4 Check gap 3 again according to point 1
I MPORTANT The engine speed RPM and
fuel quantity are factory set to give maximum
output and minimum environmental impact The Engine racing high idling speed
se settings must not be changed Warm up the engine and check the engine racing speed
Seals on the fuel injection pump may only be using a workshop tachometer when the engine has no
broken by authorised personnel Broken seals l oad at wide open throttle WOT see Technical Data
must always be resealed for correct engine racing speed
Adjust if necessary as follows
1 Slacken off the stop screw 3 so that it does not li
mit the movement of the throttle arm 1
2 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
3 Adjust the stop screw 3 so that there is a clearan
ce of 01 mm between the stop screw 3 and the
throttle arm 1 when the throttle mechanism is at
wide open throttle WOT
Feed pump
Fig 92 Setting engine speed RPM Dismantling of feed pump
1 Throttle arm
2 Adjustment screw low idling speed 1 Wash clean round the pump
3 Stop screw wide open throttle WOT
4 Adjustment screw engine racing
5 Adjustment screw maximum quantity of fuel 2 Close the fuel cocks Release the fuel connections
from the pump
3 Dismantle the feed pump from the cylinder block
Low idle speed Empty the pump of fuel
1 Check that gap 6 Fig 92 is approximately 3 mm
when the throttle mechanism is in the idling posi
tion If necessary Slacken off the locknut 7 and
adjust until the correct gap is obtained with the
screw 8
Fuel system
I njectors 7 Fit the fuel leak pipe
Replacement of injectors
8 Fit the delivery pipes Check that they do not come
1 Wash clean round the injectors skew and tighten the nuts
2 Release the delivery pipes at the injection pump Tightening torque 2025 Nm 147184 ftlbs
and at the injectors Lift off the delivery pipes to
gether
3 Remove the nut on the top of each injector and lift 9 Start the engine and check that no leakage occurs
off the fuel leak pipe
Renovating injectors
1 Clean the injector internally
2 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
3 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
4 Check the nozzle carefully with a lamp magnifier or
Fig102 Dismantling of injector i n a microscope Check the other parts also
1 Injector 3 Heat shield MD2030 5 When fitting a new nozzle it is important that pre
2 Copper packing 4 Insert serving oil is washed off the nozzle needle and
sleeve before the injector is assembled avoid skin
contact with needles slide surface
Clean the parts in pure alcohol Check that the
4 nozzle needle slides in the sleeve without sticking
Unscrew the injectors Use socket L 80 mm
6 Dip the nozzle parts in pure diesel or testing oil and
Socket width 22 mm MD2O10 2020 2040
socket width 27 mm MD2030 put the injector together Use the original thickness
of adjuster washers to set the opening pressure
Remove the copper packings under the injectors
7 Check the opening pressure jet pattern and tight
MD2030 Remove the heat shields 3 Fig 102 ness in a nozzle testing device
MD2O10 MD2020 MD2030 Remove the inserts
4 and the inner copper Fit a protective cap on the pipe connections on the
i njectors over the nozzle if the injector is not to be
fitted Fit the new injector
Tightening torque see Technical Fuel
of injectors Checking of is carried out in a nozzle testing device The Jet pressure and
tightness are the most important 1 Pump with the nozzle testing device and check the
part of the test The jet pattern is more difficult to evalu j et pattern The fuel jet should be conformed and in
ate and does not give a reliable indication of the condi li ne with the centre line of the nozzle
tion of the nozzle
2 Check that the fuel jet has a circular cross section
WARNING Observe care when testing the injec Tightness
tors so that unprotected parts of the body are not Tightness testing examines potential leakage between
hit by the fuel jet from a nozzle The jet has such the seat of the nozzle needle and the conical sealing
a powerful impact that it can penetrate into the surface of the nozzle sleeve
skin and cause blood poisoning
1 Wipe off the nozzle pin so that it is dry
2 Pump up the pressure to approx 2 MPa 20 kp
cm 2 2844 lbfint under the injectors opening pres
sure see Technical data Hold the pressure con
stant for 10 seconds and check if any fuel drips
from the nozzle pin Wet nozzles can be approved
Fit protective caps on the injectors pipe the opening pressure injector and over the nozzle heads if the injectors are not to
fitted A T
Fig 103 Adjuster washers 7 the nozzle testing devices lever slowly down with
the manometer connected until the nozzle opens and
releases the fuel Read off at that precise moment the
opening pressure
If 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 approx 1 MPa 10 kpcm 2 1422 lbfint with a
change in the thickness of the adjuster washer by
01 mm 0039 in
Cooling Sea water pump
The engines are fresh water cooled and fitted with an The sea water pump is fitted on the timing gear cooling system The system is divided
into at the front end of the engine The pump is driven via the
t wo circuits engines timing gears The pump wheel impeller is man
I n the inner circuit fresh water system the refrigerant is ufactured of rubber and is round by a circulation pump which is driven by
Note The pump wheel will become damaged if the pump
a Vbelt from the crankshaft pulley i s run dry
The fresh water system works at a certain whereby the risk of boiling is reduced at high A pressure valve opens in the filler cap if the
pressure gets higher than normal
The temperature of the refrigerant is regulated by 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
i n a heat exchanger
As extra equipment the engine can be fitted with a sep
arate expansion tank
Fig 104 Filler cap for 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 bypass pipe directly back to the induc
tion side of the pump As the engine heats up the wax
i ncreases in volume and the thermostat gradually opens
the channel to the heat exchanger at the same time as
the bypass pipe is closed
See Technical data for opening 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 40C 40F and
should be used all year round
Fig 105 Draining of the refrigerant
Note At least 40 antifreeze should be used in the sys
tem 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 1 Close the bottom cock or the cock on the S
0 drive Release the cover on the sea water pump
dangerous to consume
and let the water run out
I n the event that antifreeze is not necessary it is appropri
ate to add Volvo Penta agent 11415262 2 Release the hose from the sea water pump and
sea water filter at the reverse gear and tilt down so
that the water runs out
3 Check if there are additional cocksplugs at low
Draining of the refrigerant points on the refrigerant and exhaust pipes
Check carefully that all the water runs out
Stop the engine before draining the cooling system
The fresh water system
4 Tighten the hoses and cover to the sea water
1 Unscrew the filler cap Turn the cap to the first stop pump
and wait a moment before lifting off the cap
Pump out the boat and check that there is no
WARNING Open the filler cap very carefully if l eakage
the engine is hot Steam or hot liquid may spit
2 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
Cooling system
of the cooling system before filling up with re all the drain points and fill up with refrigerant to
the correct level See next page
Filling should be done with an idle engine The en
gine must not be started before the system is vented l
and completely filled If a heater unit is connected to the IN
engines cooling system the heat control valve must be
fully opened and the unit vented during hoses and connections and seal any leaks
Note Fill the system slowly Filling should not be
done too quickly or else air pockets can form in the sys
tem The air should be allowed to flow out through the MD opening Check the engine coolant level after run
Refrigerant level
ning the engine for some time Top up coolant if re
quired
Refrigerant temperature too low
If the refrigerant temperature is too low this may be be
cause of
Check the engine coolant level
Defective thermostat
Defective temperature sensor or instrument
WARNING Do not open the engine coolant
system filler cap when the engine is still hot ex
cept in an emergency Steam or hot coolant may
spray out
Refrigerant temperature too high
If the refrigerant temperature is too high this may be be
Turn the filler cap to the first stop and let any pressure
cause of
escape from the system before removing the cap Top
up coolant if necessary For the level Blocked sea water inlet or sea water filter
must be just under the neck of the filler opening and for Defective pump wheel in the sea water between the lower edge of the neck of
Too low refrigerant level air in the fresh water sys
the filler opening and the level spur 1 Reinstall the fill
er cap
Slipping or burst belt for the circulation pump
Defective thermostat temperature sensor or instru
If a separate expansion tank is installed optional extra
ment
the level should be between the MAX and MIN marks
Blocked cooling system
I ncorrectly set injection pump ie injection angle
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
MD 20102040AB
Refrigerant Cooling of pressure valve in
filler cap 2 Release the hose clips and remove the rubber
muffs at the front and back of the heat tool 999 6662 Pull out the insert
1 Drain off the refrigerant and connect the pressure
testing device with a nipple to one of the plugged
holes in the cooling system 3 Flush and clean the insert inside and outside
Clean also the housing
Note I f there are loose deposits in the insert a suit
2 Extend the drain hose from the filler pipe with a able steel rod can be pushed through the tubes in
hose the end of which is placed in a vessel contain the opposite direction to the flow of water
i ng water
NOTE Make sure that the rod does not damage
the tubes
3 Apply the pressure and read off the manometer
when the valve opens water bubbles in vessel
The valve should open at 09 kpcm 2 128 lbfin 2
4 Fit the insert in the heat exchanger NOTE Make
sure that the insert is positioned correctly Make
4 Remove the test equipment Fit the plug and fill up sure that the hole in the insert casing comes oppo
with refrigerant site 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 of heat the heat exchanger insert on signs of blocking 5 Fit the rubber muffs on the heat exchangers front
slow rise in refrigerant temperature and back and tighten the hose clips Connect the
hose from the sea water pump and tighten the clip
NOTE Checkclean the sea water filter first Check also
the sea water pumps impeller and sea water intake
6 Fill up with I mportant Close the bottom valve before
working on the cooling system
7 Open the bottom cock or the cock on the Sdrive
1 Drain off the water in the sea and fresh water sys and start the engine Check that no leakage occurs
tems
Fig 106 Heat exchanger insert
Cooling the circulation Drain off the refrigerant from the engine fresh wa
ter system
2 Release the alternator and remove the drive belt
MD2030 MD2040 Remove the clamp for the alter
nator
3 Remove the rubber hoses to and from the pump Fig 108 Application of sealing compound Release the electric cables to the
temperature re
l ay
3 Apply sealing compound silicon Volvo Penta part
No 11612777 on the cylinder block as per Fig
108 shaded area
Fit the refrigerant pump with a new gasket
4 MD2030 MD2040 Fit the clamp to the 5 Fit the rubber hoses at the pumps inlet and
outlet
Tighten the hose clips
6 Fit the drive belt It should be possible to press the
belt down approx 10 mm 40 in between the pul
l eys
Fig 107 MD2030 Circulation pump
7 Connect the contact piece to the temperature relay
5 Remove the pumps attachment screws and lift off
the pump 8 Fill up with refrigerant Start the engine and check
MD2030 Remove the back piece plate spring that no leakage occurs
and Replacing the pump wheel in the sea
1 Clean the mating surfaces on the pump and cylin water pump
der block
Close the bottom cock or the cock on the Sdrive
before working on the cooling system
2 MD2030 Place the thermostat and spring in the 1 Dismantle the pumps end cover and drain off the
pump Fit the back piece plate on the pump with a water in the sea water system
new Cooling system
M D2040 Fig 109 Replacing the pump wheel
2 Pull and twist out the pump wheel impeller with a
M D2030
pair of universal pliers
Fig110 Positioning of the thermostat
3 Clean the housing internally Grease in the pump 1 Cover
housing and inside of the cover with a little grease
4 Press in the new wheel with a rotational motion 3 MD2O10 MD2020 Release the exhaust pipe and
clockwise Fit the sealing washer on the outer remove the heat exchanger housing complete Re
end of the centre of the wheel move the spring and lift out the thermostat from the
housing
5 Fit the cover together with a new gasket
4 MD2040 Remove the cover 1 on the front left
hand side of the heat exchanger Remove the rub
6 Open the bottom cock or the cock on the Sdrive ber ring
Start the engine and check that no leakage occurs
Checking the thermostat
1 Check that the thermostat closes 2 Heat up water in a vessel to 68C 1 the thermostat
MD2O10 MD2020 or to 75C 167F MD2030
On MD2030 the thermostat is accessible after the
3 Submerge the thermostat in the water Check pump has been removed See under head
at least 35 minutes that the thermostat is still
i ng Replacing the circulation pump on page 66
closed
Other engines
4 Raise the temperature to boiling point 100C
1 Remove both battery leads Drain off the water in 212F Check after 35 minutes that the thermo
the fresh water system stat has opened at least 6 mm 02362 in
MD2O10 MD2020 or to 8 mm 3149 in
MD2030 MD2040
2 MD2O10 MD2020 Drain off the water in the sea
water system Remove the alternator Replace the thermostat if these are not
met NOTE If the thermostat does not close completely
the engine will run at too low a
Electrical The electrical system also includes as accessories re
l ays for the monitoring of the engines refrigerant tem
The engines are fitted with AC generators The system perature and oil is 12V
The electrical system is illustrated in two ways The wir
MD2010A 2020A 2030A and 2040A are fitted with a i ng diagram page 80 shows the wiring cable electrical system while MD201OBC 2020B
and colours
C 2030BC and 2040BC have a onepole system Where respective parts are positioned on the engine is
Note Onepole during the start procedure via an shown in the figures relay
Positioning of electrical components on the engine
Fig 111 Positioning of electrical components on the engine
1 Starter motor 8 Fuses 4 pcs
2 Earthing relay Aversion max 15A Aversion
3 Glow plug 9 Oil pressure relay
4 Alternator accessory
5 Starter relay 10 Oil pressure sensor
6 Glow relay 11 Refrigerant temperature relay
7 Fuses 4 pcs accessory
max 15A 12 Refrigerant temperature sensor
Electrical Connection of sensor system
I mportant Stop the engine and then switch off
The fuses are placed in the relay box at the rear left
hand side of the engine The fuses disconnect the cur
0 the current with the main switches before
working on the electrical system
rent when 2020A 2030A and 2040A are fitted with 1 Release the yellow sensor conductor from connec
two fuse blocks each with four fuses 15A for plus tion B on the minus 2 Splice the
conductor yellow 15 mm 2 16 2020BC 2030BC and 2040BC have and connect it to the batteries plus pole
only one fuse block with four fuses 15A for plus the electrical system after inspection and
work if one fuse has triggered by moving the cable con
nection to the next contact
Charging distributor
As an accessory the engines standard alternator can
be provided with a charging distributor Two separate
battery circuits can thereby be charged The charging distributor separates both groups from
each other so that the engines start battery is main
The relays are placed in the relay box on the rear left tained fully charged even if the accessory of the engine
are weak or almost flat
The start and glow functions are controlled via their own
switching relay These relays are identical and therefore
i f necessary can be 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 be
tween the alternators 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 charge voltage when necessary from the delivery from Volvo Penta the sensor system is Connection has
however in all carried out in connection with the installation of
the engine
Fig 112 Connection of sensor system to standard al
ternator principle drawing
1 Sensor conductor yellow 15 mm 2 16 AWG
2 Charging distributor accessory
3 Alternator
4 Fuse panel accessory
5 Starter motor
6 Main switch
7 Accessory batteries accessory
8 Start battery engine
system
I mportant information on the 3 For starting with auxiliary battery see
tions of page system
I MPORTANT Stop the engine and switch off the 4 Electric cables
current with the main switch before working on
the electrical system Never make holes in the cable insulation to conduct
measurements In a corrosive environment such as
1 Main switch
i n a boat it takes approx 2 years for thin cables to
Never break the current circuit between the altern oxidise off via the hole
ator and battery when the engine is running The If a hole must be made in the insulation it should
main switch must never be switched off before the be sealed with an appropriate glue afterwards
engine has stopped If the current is broken while
the engine is running the voltage regulator can be
destroyed and the alternator seriously damaged 5 Connection of extra equipment
For the same reason the charging circuits must not All extra equipment should be connected to a sepa
be switched over when the engine is running For rate terminal box and be fused Extra power points
simultaneous charging of two separate battery cir directly from instrument panels should be avoided
cuits it is possible to fit a Volvo Penta charging dis Permissible extra outlets are a total of max 5A
tributor to the standard alternator accessory for all instrument panels 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
l 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 before the charge clamps are re
l eased
WARNING The battery compartment must
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 oxyhydrogen gas
This gas is highly inflammable and very explos
i ve
Always use protective goggles when charging
and handing batteries
The battery electrolyte contains strongly corros
i 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 Electrical
corrosion Electric MD2020BC MD203OBC MD204OBC Remove the plus and minus leads from the
engines flywheel housing and transmission re and then remove all cables to the gearSdrive are electrically insulated from the Always
connect the welding clip to the Note the fitting sequence on the screw union which is to be welded and as close to the weld point as
Fig 113 The insulation sleeve pos 1 is only fitted on possible The clip must never be connected to the en
one of the screws optional screw gine or so that the current can pass over a bearing
Q WARNING The flywheel housing or transmission 0 On completion of welding Always connect the
reverse gear alt Sdrive must under no circum cables to the alternator before the battery leads
stances be earthed Earthing of these compo are replaced
nents can result in serious damage as a result of
galvanic 0
Repair instructions
Starting with auxiliary battery
umfi
u i WARNING The batteries especially the auxiliary
battery contain oxyhydrogen gas which is very
explosive A spark which can occur if the auxili
ary 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
1 Check that the auxiliary batterys rated voltage cor
responds to the engines system voltage 12V
2 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 eg at the main switch on the minus lead
or at the minus leads connection on the starter mo
tor 2pole electrical system or at the minus leads
connection on the engine onepole system
3 Start the engine NOTE Do not touch the con
nection during the attempt to start risk for
sparks and do not lean over any of the bat
teries
Fig 113 Electrical insulation A of the flywheel hous 4 Remove the leads in exactly the reverse order to
i ng and transmission the way they were connected NOTE The ordin
ary leads to the standard battery must absolute
1 Insulation sleeve 2 Insulation washer l y not be Washer
the battery leads Procedure
Set the multimeter for voltage testing and then connect
the multimeter between the batterys plus and minus A WARNING Disconnect the current and remove
pole Run the engine at approx 2000 rpm Read off and both battery leads before working on the charging
note the voltage over the battery poles alternator provides approx 140 V If the voltage drop during any
of the tests as per the
i tems above exceeds 02 V the lead connections must
Conduct test as follows be removed and cleaned from oxide etc Spray the con
Connect the multimeter between the alternators B and nections with a moisture repellant contact oil Volvo
B connections Universal oil part No 11613981 or the like and tight
en the connection again
Run the engine at approx 2000 rpm The provide 140144 V The total voltage drop Rectify the connections at the battery main switch
must not exceed 04 V starter motor alternator glow relay and glow drop less than 02 V
Battery leads in good condition drop more than 03 V Checking and of the al
Conduct check of battery leads ternator
Dismantle the alternators electrical connections
Spanner widths 8 and 10 mm
The alternator provides more than 144 V Remove the alternator belt Dismantle the items Checking and of alternator Spanner
widths 1 116 58 12 mm and 13 mm
and Checking of the regulator Release the voltage regulators connections at the alter
nators B connection Remove the flat pin at connec
tion B and D Remove the cap on the W connection
Bend the plastic guards attachment lugs alternately off
the alternator Release the regulators two of positive battery lead cables to the diode bridge Use longnose pliers or poke
Connect the multimeter between the alternators B out the cable lugs with a screwdriver Do not pull and the batterys plus pole
cables
Run the engine at approx 2000 rpm The voltage drop
must not exceed 02 V If the voltage drop exceeds this
value the lead connections must be rectified as per below Replacement of carbon brushes in the
After this carry out a test as per Checking of negative charging
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
Checking of negative battery lead acidfree soft the multimeter between the alternators B
connection and the batterys minus pole
Run the engine at approx 2000 rpm The voltage drop
must not exceed 02 V If the voltage drop exceeds this
value the lead connections must be rectified as per
Electrical of the regulator Dismantling the diode tool Regulator tester 8848921 I n
order to check the diode bridge and stator windings
the diode bridge should be before testing that the instruments the correct voltage Press in the button Test and Unsolder the three stator
windings Avoid that the green lamp Batt lights Replace the heat since this can damage the diodes Release the
batteries 2 pcs alkaline 9 V if the lamp does not light nuts note how the washers and nuts are fitted
The batteries are in a compartment underneath the in Check measurement of the diode Set
the multimeter in the position Diode test Be very
careful to obtain good contact with the probes during all
the testers grey cables to the the testers brown cable to the regulators yel
l ow and brown cables which should be put together dur Checking of the B diodes
ing the test Connect the measuring instruments positive probe to
one of the stator winding connections 123 Connect
the instruments negative probe to the diode plates B
Connect the testers black cable to the regulators black Read off the instrument A normal value should lie be
cable
tween 450 and 650 mV which is the voltage drop over
the diode An other value indicates a defective diode
Press the Test button and at the same time turn the Check the other B diodes by moving the from the 0 marking to the 1 marking
probe to the respective connection 123
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 in good condition ure as above The instrument should during this meas
The red and green lamps should light from 0 The red urement show a one 1 to far left If the should go off at the 1 marking
shows another value the diode is regulator Checking of the B the regulator if the red lamp lights
constantly Connect the instruments positive probe to the diode
when the rheostat is turned or if it does not light in any plates B connection and the instruments
probe to the respective stator winding connection
Note The 2 marking on the tester is not used for this
type of regulator
Read off the instrument as before A normal value
should lie between 450 and 650 mV Another value in
dicates a defective diode
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
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 3050 Q
Check also that no earth fault occurs by measuring be
tween slip ring and earth
the 13 diodes in the opposite direction of current NOTE Check first the inner resistance in the by switching the position of the positive and neg
cables When the measurement between the stator
ative probes Carry out the same measurement proced windings is carried out the measuring cables inner re
ure as above sistance eg 010 Q must be deducted from the value
instrument should during this measurement show a
one 1 to far left If the instrument shows another val Measure between all winding connections three meas
ue the diode is defective urements The resistance should lie at 010 S2
Note If any diode is defective the entire diode plate Measure also against the alternator material by con
must be replaced necting 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 mplies of the D diodes I f the instrument shows another value the stator winding
The diode plates three magnetising diodes are check is to the same principle as above
Note If any stator winding is defective the the measuring instruments positive probe to must be replaced as a complete unit
the respective connection for the stator winding 123
and the instruments negative probe to D The voltage
drop for the respective diode should be between 450
and 650 mV
Check the D diodes in the opposite direction of current
flow and switch the positions of the positive and nega
tive probes Carry out the same measuring procedure
as above The instrument should show a one 1 to far Starter motor
l eft If the instrument shown another value the diode is
defective General
The stator motor is a DC series motor The starter gear
i s controlled by a magnet and is moveable in an axial
Note If any diode is defective the entire diode plate
must be replaced direction on the rotor shaft
On engine MD2040 the starter motor is provided with a
reduction gear This enables a higher 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 the resistance between respective
Electrical of the starter motor
1 Remove both battery leads
2 Release the electric cables to the starter motor
3 Dismantle the starter motors attachment screws
and lift off the starter of the starter motor
Fig 117 Dismantling of the stator housing
1 Clean the exterior of the starter motor
5 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 Fig 118 Dismantling of the rotor
2 Remove the magnet 6 Remove the coupling arm and rotor
MD2040 The coupling arm is fitted in the gear
housing
3 Remove the protective cover from the rear bearing
shield Remove the lock ring and where appropriate
the intermediate Fig 119 Dismantling of the starter gear
7 Remove the starter gear as per Fig 119 First re
move the lock ring by tapping down the contact ring
with a suitable mandrel
MD2040 The starter gear is fitted in the gear hous
Fig 116 Dismantling of the bearing shield
i ng
4 Remove the rear bearing shield
of the starter motor Assembly of the starter on the starter motor should be handed Assembly is carried out in
the reverse order to strip
over to an authorised electrical workshop which disposes ping
over the necessary test equipment Connect and from a 12 V battery to the terminal on
the magnet and check that the starter gear is pushed
1 Test the rotor with respect to winding flashover and forward to the gear stop
failure with the test equipment for this purpose
Fitting of the starter motor
1 Place the starter motor in position in the flywheel
housing and tighten it
2 Connect the electric cables to the starter motor
See the wiring diagram on page 8086
3 Connect both battery leads
Fig 120 Checking of the 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 Electrical components
Relay box with fuses
Measure the commutator with a dial gauge Max
permissible radial distortion is 005 mm 0019 in The Aversion has two fuse blocks each with four fus
es 15A for plus and minus placed on the relay
3 Check that the commutators insulation lies at least box at lefthand rear side of the engine
02 mm 0078 in below the laminated surface Cor
rect if necessary See Fig 120 The BCversion has one fuse block
The fuses disconnect the current in the event of over
l oading
Reconnect the electrical system of a fuse has blown
4 Check the linearity of the rotor Brace the rotor be by moving the cable connection to the next contact
tween spikes and measure the radial distortion on
the rotor frame with a dial gauge Max permissible
radial distortion is 008 mm 0031 in
Note The radial distortion is half of the read value
5 Check the cogs on the starter gear Replace dam
aged gear Check also the starter gear ring if the
gear is winding
Check with a test instrument that there is no failure in the
winding If the field winding is defective it should be Fig 121 Relay box
with fuses
1 Fuse block 1 5A
2 Starter relay
3 Glow Electrical
Sensors
Oil pressure relay alarm Note Sensors are only available with De Luxe
i nstrument panels
Oil pressure sensor
Fig 122 Oil pressure type Normally open The contacts close if the
oil pressure in the engine drops below 03 015 bar
418 t 2 psi
Note Checking of the closing point should be conduct Fig 125 Oil pressure sensor
ed with falling pressure
Resistance testing Measure with falling pressure and
with instrument connected Measure with ohmmeter
class 1 at 20 C 68F
Pressure 0 bar 0 10 3 5 Q
Refrigerant temperature relay alarm
2 bar 279 psi 52 4Q
4 bar 558 psi 88 4 Q
6 bar 837 psi 124 5Q
Refrigerant temperature sensor
Fig 124 Refrigerant temperature type Normally open The contact closes if temperature rises over 95C 3C 203F Checking of the break point should be
conduct
i ng with rising Fig 126 Refrigerant temperature sensor
Resistance sensor Measure with the sensor sub
merged to the hexagonal screw for three minutes in cir
culating liquid and with the current switched on
Temp 60C 140F 1340 135 S2 t4C t72F
90C 194F 512 43 Q t4C 72F
100C 212F 385 30 S2 t40C t720F
Wiring diagram
Engine MD2010A MD2020A MD2030A MD2040A
0 0
1 Battery 9 Glow relay 16 Refrigerant temperature relay normally
2 Main switch 10 Protective diode open closes at 95C 3C 2032 Ft56F
3 Startermotor 11 Fuses 4 pcs max 15A 17 Refrigerant temperature sensor
4 Earthing relay 12 Fuses 4 pcs max 15A 18 Connector 16pole
5 Earth rail 13 Splice
6 Glow plug 14 Oil pressure relay engine normally
7 Alternator open closed at 03 bar 01 bar
8 Starter relay 15 Oil pressure sensor
MD2O10 2 pcs Other engines 3 pcs
Cable colours
BL Blue OR Orange
LBL Light blue R Red
BN Brown SB Black
LBN Light brown W White
GN Green Y Yellow
GR Grey
Cable areas in mm 2 are given after the colour code in the wiring diagram
Areas not given 10 mm 2
Dashed cables are not included from Volvo Penta
Wiring diagram
Engine MD201OBC MD202OBC MD203OBC MD204OBC
4 16 1 6 11 15 10 14 5 13
O 3 3 m
C 0 n 12
RY 25
30 87
86 85
86 85
R25 30 87 R 25
1 1
581o
1 Battery 7 Glow relay 12 Refrigerant temperature relay normally
2 Main switch 8 Fuses 4 pcs max 15A open closes at 100C t2C 212F t36F
3 Starter motor 9 Magnetising resistance 3309W 13 Refrigerant temperature sensor
4 Alternator 10 Oil pressure relay engine normally 14 Connector 16pole
5 Glow plug open closed at 03 t01 bar
6 Starter relay 11 Oil pressure sensor
MD2O10 2 pcs Other engines 3 pcs
Cable colours
BL Blue OR Orange
LBL Light blue R Red
BN Brown SB Black
LBN Light brown W White
GN Green Y Yellow
GR Grey
Cable areas in mm 2 are given after the colour code in the wiring not given 10 mm 2
Dashed cables are not included from Volvo Penta
Wiring diagram
Instrument panel alternative B
MD201OBC MD2020BC MD2030BC MD204OBC
with key switch
I 0 of
5 6 7
11 0 0 9 9
rFrP a enr G 1
4 ER
2 4 6 15 14 5 7 8 9 V 11 9 3 122 13
Return spring 1 I nstrument lighting
2 Tachometer with builtin hour counter accessory
alt blind plug
3 Connector for connection of extra warning display
II I accessory
4 Electronics unit alarm
Return spring
5 Warning lamp refrigerant temperature
6 Warning lamp oil pressure
7 Warning lamp charging
8 Control lamp glowing
9 Switch instrument lighting
10 Switch Alarm 11 Key switch
Cable colours
12 Alarm
BL Blue 13 Connector for connection of neutral position switch
BN Brown accessory
GN Green 14 1 6pole connection
GR Grey
OR Orange
R Red
SB Black
VO Violet
W White
Y Yellow
Cable areas in mm 2 are given after the colour code in the wiring diagram
Areas not given 10 mm 2
Wiring diagram
I nstrument panel alternative C
MD2010A MD2020A MD2030A MD2040A
SB 1 0
Return spring 6 9 8 7 4 1 5 2
15a15b 305019
1 I nstrument lighting BLISS15
2 Voltmeter BUY 15
3 Oil pressure gauge 2 6 5 4 14 15 8 7 3 16 9 10 12 13 1
4 Refrigerant temperature gauge
5 Warning lamp refrigerant temperature 16 17
6 Warning lamp oil pressure
7 Warning lamp charging Cable colours
8 Control lamp glowing BL Blue
9 Electronics unit alarm
BN Brown
10 Switch instrument lighting
GN Green
11 Switch alarm test
GR Grey
12 Tachometer
OR Orange
13 Key switch
R Red
14 Alarm
Connector for connection of neutral position switch SB Black
accessory VO Violet
16 2pole connection for extra panel W White
17 1 6pole connection Y Yellow
Wiring diagram
Instrument panel alternative C
MD2010BC MD2020BC MD2030BC MD204OBC
6 5
7 8 9 10 11
0 9 9 9
W a BAT OW
avw is
atir U
QC cc k
2 S u S 12 13 11 8
1 I nstrument lighting
2 Voltmeter
3 Oil pressure gauge
4 Refrigerant temperature gauge
Return spring 5 Connector for connection of extra warning display
accessory
6 Electronics unit alarm
7 Warning lamp refrigerant temperature
8 Warning lamp oil pressure
S 15815b 3050 19
9 Warning lamp charging
Cable colour
10 Control lamp glowing
BL Blue 11 Switch instrument lighting
LBL Light blue 12 Switch alarm
BN Brown 13 Tachometer with builtin hour counter accessory
LBN Light brown alt blind plug
Green 14 Key switch
GN 15 Alarm
GR Grey
16 Connector for connection of neutral position switch
OR Orange
accessory
R Red
17 16pole connection
SB Black
18 2pole connection for extra panel
VO Violet
W White Cable areas in mm 2 are given after the colour code in the wiring diagram
Y Yellow Areas not given 10 mm
Extra equipment eneral
Extra equipment which is driven with Vbets via the The following diagram shows the permissible crankshaft result in an
increased load on the takeout at a certain positioning of the pulley and It is therefore important that the axial posi
of the pulley on the crankshaft and the the equipment in relation to the crankshaft are adjus
ted to the power takeout of the extra equipment
1200
1000
0 d mm
70 80 90 100 110 120 130 140 150 200
320 330 340 350 0 10 20 30 40
310 50
290 70
280 80
270 90
260 100
250 110
240 120
230 130
220 210 200 190 180 170 160 150 140
Fig 127 MD 2010
Notes
Report form
Do you have any complaints or other comments about this manual Please make a copy of this page write your
comments down and post it to us The address is at the bottom of the page We would prefer you to write in
English or to no I ssued
Date
Name
AB Volvo Penta
Customer Support
Dept 42200
SE405 08 Gothenburg
Sweden

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