Wednesday, March29, 2017

Volvo Md5a Workshop Manual

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Publ No 3061
Dec diesel engine
ENGINE workshop manual contains repair instructions for the MD5A marine diesel engine The overhauling describe the most suitable working method to
be used with the special tools listed under
the heading Special tools
Both the engine designation and its serial number must be clearly stated in all concerning the
engine and when ordering spare parts We reserve the right to carry out design modifications and for this
reason the contents of this manual cannot he regarded as binding
Technical Information NEW UNITS OF MEASUREMENT
Technicians have long since tried to establish an standardized system of
measurements In 1960 a decision was made to use a system called SI Systme dUnites To a large extent this system is based on earlier
systems but the units have been
made uniform so that no conversions are necessary
The SIsystem is now being applied within industry in Europe This manual contains the new SI
units The units used previously however are also stated but in brackets
The new units are
Output is slated in kW kilowatts
earlier unit hp Torque is stated in NM earlier unit kpm Engine speed is stated in rs revolutions per
earlier unit rpm revolutions per minute
Displacement and volumes are stated in dm cubic decimetres
earlier unit l litres
Pressure is stated in Pa Pascal
earlier unit kpcm kiloponds per square Reproduction permitted if source
system thermostat housing cylinder head 3
Flywheel fuel injector pump 4
Oil pump transmission cover governor 5
Lubricating oil pump camshaft cylinder 6
Crankshaft cylinder liner camshaft bearing oil pump seawater pump 79
Feed pump 9 11
Fuel filter crankshaft governor piston 12 13
Valve guides nozzle sleeve 14 15
Valves valve seats rocker mechanism injector 15 16
Hand start mechanism camshaft liner crankshaft 18
Cylinder camshaft governor oil pump transmission cover 20
Adjustment of control rod travel assembling
flywheel cover 20 21
Oil sump cylinder head feed cover 22
Fuel filter injector thermostat 22
Flywheel generator valve adjustment 24
Checking injection angle 25
Bleeding the fuel system electrical system 26
Wiring diagram system 28
Special tools 29
Technical data 30 33
1 Connection for hand start
2 Fuse box
3 Thermostat housing
4 Decompression lever
5 Injector
6 Oil filler Cap engine
7 Water drain tap gearbox
8 Oil drain plug gearbox
9 Water drain tap engine
10 Oil filler gearbox
11 Seawater pump
12 Dipstick gearbox
13 Fuel filter
14 Bleed screw
15 Hand pump fuel
16 Dipstick engine
17 Oil Repair Drain the cooling water and the oil from the engine Clean 3 Remove the rocker cover and the
fuel pipe between afterwards Loosen the water hose between the pump and the injector and unscrew the rocker gear Note
gearbox and the sea water pump and remove the gearbox Pull the rocker gear straight up since it is centred with a
guide pin 1 The other hole 2 is an oil Remove the generator and its drive belt starter motor 4 Remove the pushrods 1 remove the cylinder head
fuel filter and fuel pump with the drainoff pipe be careful of the cylinder head gasket Take care of the washers 2 under
fuel spillage coolant water pump with hose and thermostat the dipstick temperature and oil pressure and discard the oil filter
5 Remove the flywheel nuts Spanner jaw width 55 mm 7 Remove the cover for the injection pump Note The
2 532 Use a wooden shaft or something similar as a bracket for the cold start is fixed with one of the force in the flywheel spokes
Take care of the spring under the cover
6 Fit tool 884078 to the flywheel Afterwards screw in the 8 Prise the lower ball joint free from the pump with a
centre screw on the tool until the flywheel loosens Remove the pump screws Position the ball in the centre 11 Remove the governor by
loosening the hexagonal set
and remove the pump screw 1 the governor and the gear wheel can then be
Remove the sump and then the transmission cover 13 12 Remove the screw and the locking washer for the
screws The lifting eye is fixed one of the screws The cover gearbox drive flange on the crankshaft and remove the
is centralised by guide pins flange with a puller Use counter force Remove the key
13 Remove the lubricating oil pump Discard the gasket 15 Remove the gearwheel on the camshafts flywheel side
4 screws Then remove the camshaft and the Remove the cover flywheel side 10 screws The cover
is centred with guide pins The screws by the guide pins are 16 Mark and remove the bearing cap on the crankshaft and
fitted with thick washers carefully knock out the piston through the Remove the main bearing caps Take care of
the axial 19 Bearing replacement Press out the camshaft bearings if
thrust bearings 1 on the transmission side Lift the crankshaft they are damaged or if the wear is too great see technical
out and the bearing shells afterwards and then the axial data Clean the bearing housings and ensure that the oil
bearing halves channels are clean Press in the new bearings so that the oil
holes face the corresponding oil channels in the block When
the bearings are pressed in position they are to be reamed
see technical data
20 Remove the gearwheels nuts and pull off the gearwheel
18 Mark the cylinder liners position in the cylinder so that with a puller The gearwheel sits on a key take care of this
the same position can be obtained during assembly key
Remove the cylinder liner Use tool 884551 Use the long
screw and its nut from the tool 884231 MD21MD32 See
page 29 Special tools Discard the 0ring Afterwards remove
the 0rings in the block which provide a seal for the and then remove the valve lifters Wash all the parts
and replace those damaged
21 Remove the steel wire which holds the filter Remove Overhauling the seawater pump
and clean the wire gauze thoroughly Afterwards remove the 23 The seawater pump is a round flange type pump which
six screws which hold the cover in position Discard the means that it can be fitted in a position best suited to the
gasket coolant water hoses The new pump is fitted with an 0ring
which forms a seal against the Remove the gearwheel from the housing Remove the 24 Remove the cover 6 screws Change the impeller with
split pin for the reduction valve Remove washer 1 spring 2 the help of two screwdrivers or something similar Note
and piston 3 Clean and replace damaged parts Assemble Protect the edges of the pump housing See the figure Prise
the lubricating oil pump in the reverse order Note Fit a new out the impeller with the screwdrivers so far that the screw
gasket 4 between the housing and the cover Fix the wire becomes visible
mesh 5 in position with the steel wire 6 and finally lay the key
in position and tighten the gearwheel 7
25 Unscrew the screw and withdraw the impeller from the 27 Fit new sealing rings Note The sealing rings must face
shaft If the sealing rings are to be replaced the shaft and the right way see that they do not block the drain hole in the
the impeller can be removed and the screw subsequently pump housing Smear grease on the shaft and fit it
in the housing Screw it through the sealing rings so that
they will not be damaged Place the shaft so far into the
housing that the hole for the screw is visible Fit the impeller
and screw in the screw Then carefully press in the impeller
so that it touches bottom Place a new gasket on the cover
and tighten the cover with the six Remove the sealing rings 1 and the 0ring 2 earlier Overhauling the feed pump
engines and clean the housing and the shaft Note The 28 Depress the pumps lever see fig If the pump creaks
pump must be removed from the engine Check that there then it is sound If it is unserviceable the diaphragm must be
are no abrasions on the shaft Note A new 0ring is not to be replaced which is done in the following
29 Remove the covers centre screw remove the filter 1 31 Depress the diaphragm and shake the pump arm
and clean it spindle out until the pump arm is free Then remove the
diaphragm from the Remove the six screws which hold the upper and lower 32 Remove screw 1 and withdraw the manual pump arm 2
pump halves together Remove the pumps spring and undo and replace spring 3 if it is broken Note Be careful of the
screw 2 which holds the pump arm spindle rubber seal which is pressed into the housing
33 Clean the pump housing carefully and replace worn Refit the manual pump arm Press in the diaphragm 35 Remove the circlip
with circlip pliers Then remove the
and connect the pump arm to the diaphragm centre pin gear drive Use a press or a gear puller Clean the
Then push the spindle in and tighten it with the screw Note crankshaft and carry out control measurements of all the
Do not forget the washer under the screw bearing surfaces Grind the shaft where necessary See
Lay the gauze filter on the upper housing and screw the technical data
cover and the gasket tight Press in the pump arm 3
assemble the two housing halves and fit the spring retainer 2
on the mechanical pump arm 3 Note that the spring retainer
can only be fitted one way Replace the spring next and the
0ring 4 which provides a seal for the filter
34 When the filter insert is changed the centre screw 1 is 36 Place the key in the crankshafts key slot Heat the
removed allowing the filter holder to be removed Afterwards gearwheel to approximately 1000C 2120F no more and
remove the filter insert by lifting the plastic loop 4 Wash the press it onto the crankshaft Note The marking on the
filter holder clean and fit a new filter Fit a new packing gearwheel shall face outwards Refit the circlip on the
washer 5 and refit the holder to the cover with the centre
37 Clean the governor Check to see if the weights 2 grip 39 Mark the piston and the connecting rod Remove the
on their spindle or if there is too much movement between circlips Press out the gudgeon pin with a drift The piston
the spindle and the governor weight Afterwards check that can be heated first to ease removal
the pin 1 slides easily in the spindle Finally check both the
ball bearings 3 Replace the ball bearings if they are tight
Check that all the movable parts move easily lubricate and
refit them in the reverse Remove the piston rings with the help of piston ring 40 Press the bush out of the connecting rod if it is worn or
pliers Clean the piston and be particularly careful about the damaged Then knock out the connecting rod screws Note
piston ring grooves The screws must always be changed when the connecting
rod has been 12
41 Knock new screws in place and press a new bush in the 43 Fit the piston rings with the help of piston ring rod Ensure that the
lubricating hole 1 in the bush Start with the oil scraper ring in the lowest groove The oil
aligns with the hole in the connecting rod Ream or diamond scraper ring can be fitted either way Continue with the
drill the bush to an accurate free fit Check that the gudgeon compression ring which is marked TOP on one side This
pin slides through the bush due to its own weight See also marking shall face upwards when fitted The piston ring with
the technical data Fit one of the circlips and oil the gudgeon the chromium insert is fitted last and can be fitted either way
pin and connecting rod bush Heat the piston 700C 1580F and assemble the piston and
the connecting rod according to the marking Note The
gudgeon pin must be able to be pressed in easily Fit the
other circlip
Cylinder head
42 Control the dimensions of the piston with a micrometer 44 Remove the collets the collars and the valve at right angles to the gudgeon pin
holes at the with the help of a valve spring compressor Remove the
pistons lower edge Afterwards check the new rings play in valves Remove the valve seal from the inlet valve Burnt
the piston ring grooves See technical data valves are discarded if worn too much and damaged seats
are to ne machined when necessary See technical data
The valves and valve seats are to be ground together so that
the mating surfaces provide a complete seal
Replacing valve guides Nozzle sleeve
45 The valve guides must be replaced if there is too much 47 Remove the injector sleeve with tool 884541 Insert the
play between the valve stem and the valve guide See expanding screw in the nozzle sleeve and screw data Press out the valve guides with
tool 884538 wise until the screw has expanded and gripped the sleeve
Tighten hard so that the threads bite into the copper Fit the
yoke onto the studs which hold the nozzle Screw on the nut
and tighten until the sleeve is New valve guides are fitted with tool 884549 Use a 48 Remove the 0ring which provides a seal between the
press This tool gives the guide the right height above the sleeve and the cylinder head Clean carefully and dry with
cylinder heads valve spring seat surface Check the dimen compressed air and then dip the new 0ring in a soap
sion A this must be 9 mm 03543 in when the guide is solution to facilitate assembly Lubricate and fit the new
pressed into place nozzle sleeve with tool 884557 Knock in the sleeve until it
reaches Lubricate the mandrel tool 884537 and insert the tool Valve and valve seat grinding
into the sleeve Ensure that the centre screw is sufficiently 51 Machine the valve seats by milling or grinding Place some nuts or several washers
on the Grind no more than is necessary to give the seat the correct
studs so that the yoke can be tightened in place with the shape and a good mating surface The seat angle C shall be
fixing nuts Screw in the mandrel as far as the mating face of 45 and the width B approximately 1 mm 00394 in The
the sleeve allows The mandrel is then withdrawn Remove width is adjusted with a 39 and a 60 miller respectively or
the tool a grinding disc Clean the valves and grind them in a
machine The valves face angle D shall be 445 The
sealing surface is ground no more than is necessary to
clean it If less than 1 mm 00394 in is left on the valve
edge it is to be discarded Likewise the valve is discarded if
the valve stern is not straight or if dimension A exceeds 25
mm 00984 in Note If this dimension is exceeded even if
a new valve is fitted the cylinder head must be Adjust the length of sleeve protruding from the cylinder
head face length is 09 mm 00354 in and check that the
sleeve is correctly fitted dimension 195 mm 07677 in
Rocker mechanism
52 Remove the circlip from the rocker shaft and remove the
rocker arms Clean the parts Be particularly careful when
cleaning the rocker shaft oil channels 3 and the rocker arms
oil hole see also fig 53
53 Check the wear on the rocker shaft Also check that the Pressure testing the adjustment screws spherical part is neither deformed 55 Check
the shape of the jets at an opening pressure of
nor worn The threads on the screw and the locknut must be 185 kpcm 2 2631 psi Also check that the fuel
discontinues at all four holes and that no
Oval rocker arm bushes are to be replaced Pressing in and subsequent drops appear
out is performed with drift 884560 Press the bush in so that
the oil hole assumes the position shown in the figure The
bush is reamed to a light push fit after it has been pressed
in Lubricate the shaft and assemble the rocker Fit the rubber seal 1 on the inlet valve Use tool 884497 Adjustment of opening pressure
Oil the valve sterns before they are inserted in their 56 The opening pressure is adjusted with valve guides Afterwards fit the valve
springs washer 1 which is available in thicknesses between 1 mm
collars and collets with the help of a valve compressor 00394 inl and 195 mm 00768 in with a difference of
005 00020 in mm between each size Dismantle the
nozzle and replace the washer with a thinner or thicker
washer depending on whether the pressure is to be reduced
or increased Assemble the nozzle and check the opening
pressure and jet shape Continue until a satisfactory result is
Flywheel cover and hand starting mechanism that the transmission cover must be machined since the
57 Unscrew nut 1 and remove it and washer 2 holding the new camshaft gear is thicker than the earlier gear and
hand starting gearwheel 3 Then remove the gearwheel from consequently there is not enough space for it in the
the shaft A Knock the shaft out from the cover Loosen the transmission cover The axial guide face distance A must be
set screw 5 which holds the spacer washer and knock out the filed down by 3mm 01181 in
spacer washer when the bearings 7 has been key 8 slide off the spacer ring 9 and pull off ball
bearing 10 after which seal 11 can be pulled off Note If only
the seal 11 is to be changed pin 12 can be knocked out after
which the seal can be removed
If the camshaft is damaged this means that the camshaft
gear must be replaced in this case as well This also means
that the axial guide face must be filed down by 3 mm
01181 in
58 Replace damaged parts and reassemble the pin seal
ball bearing and spacer ring on the shaft Fit the spacer
washer into the cover and tighten it in position with the set
screw Note Ensure that the spacer washers groove faces
the locking screws centre Fit the shaft in the cover Place the
key in position and then the ball bearing Fit the it with a washer and nut Knock out seal 1 from the
flywheel cover Press in a new seal 60 If the transmission cover is damaged and
must be
replaced this means that even the camshaft and the
camshaft gear must be replaced The replacement is
necessary because the axial guide in the new transmission
cover is shortened by 3 mm 01181 in which in turn
means that the camshaft will have an axial play of 3 mm
01181 in
The camshaft camshaft gear and transmission cover are
as of engine no 1076 inclusive When
changing camshaft gears of a later type the camshaft shall
be pressed out of the camshaft gear
Take care of the key Check the camshaft for wear See the
technical data
Place the key in the camshaft and press on the camshaft
gear The distance from the camshaft end to the camshaft
gears hub must be 136 mm 5354 in See In such cases on engines with engine nos a camshaft gear change is necessary the camshaft
must be changed as well A new camshaft gear cannot be
fitted to an early type of camshaft Furthermore this means
63 Place the main bearing halves with the oil channel holes
61 Check that the liner is not scratched and that it is in in the block Then place the axial bearing halves in condition otherwise Fit new
0rings 1 in the block 2 Turn the oil grooves 1 and a new 0ring 2 on the cylinder liner Turn the mark
on the liner which was made during dismantling to the mark
on the block Lubricate the 0rings and fit the liner Be careful
not to damage the When the cylinder liner is fitted in the block the height of 64 Oil both the bearing halves and place the crankshaft in
the liner outside the block must be measured The height position Fit the main bearing shells in the bearing housings
must not exceed 005 mm 00020 in and must not be less and place the axial bearings with the oil grooves 001 mm 00004 in otherwise there is a
risk that a Fit the bearing housing so that the indentation in the housing
leak can occur faces the same way as the indentation in the bearing half
already in the block Tighten the bearing housing with a
torque of 70 Nm 7 kpm 50 Lbft
65 Remove any wear edges in the cylinder liner Oil the 67 Fit the camshaft with the camshaft gear Align the liner and fit the piston in
the block Use a piston ring on the crankshaft gear and the camshaft gear
sleeve or tool 9992176 Turn the piston so that the in the piston crown faces the nozzle side
66 Oil and fit the big end bearing shells in the bearing half
68 Fit the governor Tighten it in position with the set screw
Turn mark to the correct position and fit the bearing torque 70 Nm 7 kpm 50Lbft on the side See that it goes into the groove
69 Fit the gearwheel on the camshafts opposite end 71 Fit a new gasket for the transmission cover Afterwards
fit the transmission cover Fix the lifting eye with the upper
Adjustment of control rod travel
72 Fit a new gasket and fit the injector pump Press on the
ball end of the control arm Measure and check that the
control rod travel is correctly adjusted The same as prior to
dismantling The measurement must be carried out with a
new gasket Set the control at full throttle Press down the
plunger to bottom position Note that the cold start must not
be engaged during measurement The exact amount
injected can only be determined when checking in a test
Fit the oil pump Note the different screw Release the plunger 8 mm 03150 in and measure the 75 If the engine smokes abnormally the centre screw
distance from the transmission cover face to the adjusting the cover can be loosened and the adjusting screw can be
screws contact point on the control arm adjusted until the engine runs smoke free See the technical
data for the correct injection Measure the adjusting screws length and adjust any 76 Fit a new gasket and fit the flywheel cover Be careful so
eventual deviation so that the plunger stops when released 8 that the sealing ring is not damaged Trim the excessive
mm Screw down the cover afterwards gasket
77 Fit a p lane packing and then fit the sump Note On 79 Replace the tappet rods and fit the rocker engines a rubber seal was used This is
to be Check that the guide pin in the cylinder head goes into the
replaced by a plane packing hole in the rocker
80 Lubricate the oil filter rubber seal Screw in the oil filter
78 Lubricate and replace the valve lifters Fit a new cylinder so far that the rubber seal first contacts the engine body
head gasket and then the cylinder head Place the washers Afterwards screw in the filter a further half turn Note
under the nuts and tighten the nuts in three stages to 70 Nm Tighten by hand Then fit the feeder pump Use a new 0ring
between the pump and the engine
7 kpm 50Lbft See the tightening stage 10 Nm 1 kpm stage 40 Nm 4 kpm stage 70 Nm 7 kpm 22
81 Fit the fuel filter Place sealing rings on both sides of the 83 Connect the injector pipe the temperature and oil
fuel pipe unions pressure
Thermostat testing
82 Fit the injector The tightening torque 10 Nm 1 kpm 84 Lower the thermostat into hot water and check with a
7Lbft Then connect the fuel drain pipe Note Place thermometer if the thermostat opens and closes correctly at
sealing rings on both sides of the pipe unions the right temperature It should start to open at 600C 140 0F
and should be fully open at 900C 194 0F If the thermostat is
defective it must be replaced Clean the thermostat and fit a
new gasket 1 Place the thermostat in the engine and fit the
thermostat housing Then fit the water pump and connect the
coolant water hose
85 Place the key for the gearbox connecting drive on the 87 Fit the starter motor and the alternator Note Place on the gearbox side Heat the
connecting drive spacer tube correctly and assemble the belt tensioner Fit
and fit it onto the crankshaft Lock the drive with the large and tension the drive belt so that it can be depressed 34
washer and the lockwasher Tighten the screw with a torque mm in with normal thumb The tightening torque is 70 Nm 7 kpm a counter force Bend
the lockwasher up against the
screw head Tappet adjustment
88 Turn the flywheel until both tappets function Turn the
86 Place the key for the flywheel in the crankshafts key flywheel a further complete turn and adjust the tappets The
slot Fit and tighten the flywheel Use a counter force in the clearance is 030 mm 00118 in for the inlet valve nearest
flywheel and 035 mm 100138 in for the exhaust valve
spokes of the flywheel The tightening torque is 500 Nm 50
when the engine is hot Fit the rocker box cover and a new
kpm 362Lbft Spanner jaw width is 55 mm 2 532
ANGLE CONTROL 91 Open the level valve 1 on the measuring apparatus so
89 A Wilbr tube is used when checking the injection angle that the level lies 25 30 mm 1 2 316 from the bottom
Fit the Wilbr tube on the pressure pipe nipple Turn the engine in the rotation direction until compression is
90 Rotate the engine in the correct direction until the level 92 If the injection angle does not meet the 1 is full with airfree fuel
value the number of washers 1 between the pump housing
and the transmission cover is increased or decreased until
the correct value is obtained One washer gives a difference
in injection angle of approximately 1
93 Fit the exhaust elbow and the gearbox Use new
gaskets Check that the rubber damper is not damaged ELECTRICAL SYSTEM
The following applies to engines fitted with alternators
1 Do not break the electrical circuit between the
alternator and the battery when the engine is running
If a main switch is fitted it must therefore not be
turned off until the engine is stopped
No lead must be disconnected when the engine is
running since this can irreparably damage the charging
2 The battery battery cable and cable terminals are to be
checked regularly The battery poles are to be properly
clean and the cable terminals are to be tight and well
greased so that a break in the circuit cannot occur All
other cables are to be properly connected no loose
connections must occur The batterys positive and
negative connections must on no condition be exchanged
when the battery is connected
3 When starting with an auxiliary battery check first that it
BLEEDING THE FUEL SYSTEM has the same rated voltage as the standard battery
94 Fuel system bleeding is always carried out in the Connect the auxiliary battery with positive to positive and
following cases When the microfilter is changed when negative to negative Remove the auxiliary battery when
draining via the drain plug when cleaning the gauze in the the engine has started Notel The cables to the standard
fuel pump when the fuel tank has run dry when fitting an battery must on no condition be pump after leaks in or repairs on the fuel
when the engine has been out of use for a long time 4 When carrying out electrical welding on the engine or
Bleeding is carried out as follows associated installation parts the charging the air bleed screw 1 in the
microfilter Pump up fuel cable must be disconnected and insulated first After
using the hand pump 2 until clean airfree fuel runs out wards both the battery cable terminals can be the air bleed screw If the pump
effect is poor rotate 5 When carrying out repairs on the generator both battery
the engine until the pumps drive cam assumes another cable terminals must always be disconnected The If the injector pump has been
dismantled or when applies if the battery is given a quick charge
the engine is to be started for the first time after injection pump must be bled Open the air bleed screw 3 6 Never test a connection with a
screwdriver or similar tool
on the injection pump Pump the hand pump 2 until airfree to see if it sparks
fuel runs out Loosen the pressure connection 4 and rotate
the engine with the starter motor until fuel runs out from the
pressure pipe Tighten the pressure connection and start Diagram
Cable Colour mm2 AWG Circuit explanation
A White 6 9 1 Extra switch
B Black 15 15 2 Charging control lamp
B Black 06 19 3 Temperature warning lamp
B Black 075 18 4 Oil pressure warning lamp
C Red 6 9 5 Key switch
C Red 35 1 6 Warning unit
C Red 06 19 7 Screw
F Yellow 15 15 8 Charging control lamp for secondary battery
G Brown 15 15 circuit extra equipment
H Blue 35 1 9 Place for instruments extra equipment
I GreenRed 15 15 10 Snap connection
I GreenRed 075 18 11 Starter motor
J Green 15 15 12 Alternator
J Green 06 19 13 Fusebox
J Green 075 18 14 Main switch
K BlueYellow 075 18 15 Battery
L WhiteRed 075 18 16 Temperature sender
M BlueRed 075 18 17 Oil pressure sender
The fault finding chart given below only covers the most common faults which occur
The engine does not reach
The engine runs rough or
the correct speed at full
The engine becomes
vibrates will not start
abnormally hot
Engine stops
X Main switch not connected flat battery cable
See para A
X X Empty fuel tank fuel tap closed blocked fuel
See para B
X X X Water air or impurities in the fuel
See para B
X X X X Faulty injector
See para C
X Boat abnormally loaded boat bilge fouled with See para C
X X Propeller damaged See para E
X Clogged coolant water intake cooling vanes See para F
defective pump wheel or Check the charge state of the battery with the help of a
hydrometer which shows the specific gravity of the D To obtain
the best operational economy the acid This varies according to the state of the
speed should be at least 300 rpm less that the
charge see the technical data See furthermore maximum
obtainable during extended running system p 26
Note If the boat has been in the water a considerable
time the maximum obtainable engine speed can
B Change the microfilter by unscrewing the hexagonal decrease due
to growth on the hulls underside Use
head on the filter holders base The microfilter and its growth
inhibiting bottom paint
holder are of a discardable type which means that the old Check and
clean the hull is discarded and a new one fitted Check that the
face of the cover is completely clean and that the filter E Check that
the propeller blades are whole If any of the
packing is undamaged Screw the new filter by hand until propeller
blades are damaged the propeller should be
the packing contacts the cover Then tighten the filter a changed A
propeller blade can be out of line twisted
further half turn There is a drain plug in the bottom of the this is very
difficult to detect Place the propeller on a flat
filter holder for draining water and impurities in the fuel surface and
measure the blades If any blade is twisted
Bleed the fuel system after draining and after a filter the
propeller should be and then check for the cover on the feed pump and clean the pre
F Check the coolant system from the point of view of
filter in diesel oil Refit the filter with the notches upward leakage
blockage etc
and fit an undamaged packing and tighten the cover Check that
the thermostat opens at the correct the fuel system
ture The thermostat can be taken out when the
Check and drain when necessary the extra fuel filter if thermostat
housing has been dismantled See also
one is fitted Look out for spilled fuel paragraph 84
The pump impeller in the sea water pump is made of
C Check the injector with reference to opening pressure neoprene
rubber and can be damaged when the and jet shape It is recommended that these
supply is cut off for instance if there is a blockage in the
checks be carried out after a maximum operation time of sea water
intake Paragraphs 2327 should be followed
400 hours or once per season See also paragraphs 55 when changing
a pump impeller and sealing rings Note
and 56 If the boat
is in the water the sea cock must be closed
before the sea water is dismantled Do not forget to open
the cock again
Special tools for the MD5A
Part No Drift for pressing out valve Drift for pressing in valve Drift for pressing in injector Tool for removing
injector Drift for copper Tool for removing cylinder and
nut Drift for removing rocker arm Drift for fitting rubber valve Nipple Nipple for compression pressure
TECHNICAL DIN at 40 rs 2500 rpm MD5A
No of cylinders 55 kW 75 bhp
Bore 1
Stroke 84 mm 331 total 80 mm
315 ratio 0443dm 3 27 cu pressure at starter motor speed
rotation viewed from flywheel 20 22kpcm 2 11 144 159 psi
Idling speed Clockwise
92 108 rs 550 650 liner wet diameter standard mm in
84000 84015 33071 height mm in
Height from gudgeon pin centre to piston crown mm in clearance mm in 490 4905 19291
available as standard mm in 0081 0114 00032 00045
83901 83919 33032 pins
Diameter mm in
Inner diameter of gudgeon pin bush mm in 25996 26000 10235 between gudgeon pin and bush mm in 25999
26004 10236 10237
0001 0008 000004 rings
Number of compression rings
Number of oil rings 2
The upper compression ring has a chromium insert 1
Axial piston ring compression ring mm in
Lower compression ring mm in 0070 0102 00028 00040
Oil scraper ring mm in 0050 0082 00020 00032
0030 0062 00012 ring gap in compression ring mm in
Lower compression ring mm in 030 050 00118 00197
Oil scraper ring mm in 030 050 00118 00197
025 050 00098 clearance end float mm in
Main bearings radial clearance mm in 005 030 00020 00118
Big end bearing radial clearance mm in 0040 0096 00016 00038
0040 0096 00016 00038
Main bearing standard mm undersized 0250 mm in 53987 54000 21255 undersized 0500 mm in
53737 53750 21156 21161
53487 53500 21058 21063
Main bearing standard mm 0250 mm in 1968 1980 00775 0500 mm in
2093 2105 00824 00829
2218 2230 00873 00878
1 Measured with a Moto Meter nipple 884535 and fixture 884543
rod standard mm in 50987 51000 20074 undersized 0250 mm in 50737 50750 19975
undersized 0500 mm in 50487 50500 19877 19882
Big end bearing standard mm in 1768 1780 00696 0250 mm in 1893 1905
00745 0500 mm in 2018 2030 00794 rod
Axial clearance end float at crankshaft mm in 005 020 00020 clearance end float mm in 054 082 00213
clearance in bearings mm in 0025 0075 00010 diameter mm in 39975 40000 1 5738 1
diameter mm in 46975 47000 18494 height mm in 58 diameter
mm in 40025 40050 15758 diameter mm in 47025 47050 18514 valve
Valve disc diameter mm in 349 351 13740 13819
Valve stem diameter mm in 7955 7970 031 32 031 38
Valve seat angle 455 see fig page 15
Seat angle in cylinder head 45
Seat width in cylinder head mm in ca 1 clearance hot mm in 030 valve
Valve disc diameter mm in 279 281 10984 11063
Valve stem diameter mm in 7925 7940 03120 03126
Valve seat angle 445 see fig page 15
Seat angle in cylinder head 45
Seat width in cylinder head mm in ca 1 clearance hot mm in 035 00 138
Valve inlet valve mm in 52 exhaust valve mm in 52
diameter mm in 8000 8015 03150 above cylinder blocks spring face mm in 1065 1135 04193
valve stemvalve guide inlet valve mm in 0030 0060 000 12 valve stemvalve guide outlet valve mm in 0060 0090 0 0024 0 0035
Valve unloaded mm in 425 with a force of 170 N 17 kp 375 lb mm in 32 with a
force of 300 N 30 kp 66 lb mm in 24 system
Engine oil capacity ex filter Imp qts US qts 20 din3 17 21
Engine oil capacity inc filter Imp qts US qts 21 din3 18 22
Oil quality according to API system CD DS
1st alternative Above 100C 5Q0 F Volvo Penta oil
Double grade SAE 20W30
Below 100C 500F Volvo Penta oil Single grade SAE l0W
2nd alternative Viscosity above 100Cj500F SAE 20
Viscosity below 100 50 F SAE 10
Oil pressure hot engine idling kplcm 2 psi 15 25 kplcm 2 21 36
Oil pressure hot engine full throttle kplcm 2 psi 40 50 kplcm 2 57 71
oil MANN W 77 or FRAM oil pump
Type Gear pump
Spring for pressure reduction valve Length unloaded
mm in 40 with 25 N 25 kp 55 lb mm in 34 with 35
N 35 kp 77 lb mm in 315 axial clearance including packing mm in 0010 0130 pump Bosch
PFR 1K 70A Bosch holder KBAL 65
Nozzle DLLA 150
Hole diameter mm in Four 023 pressure new nozzle kpcm 2 psi 185 2631
Nozzle angle angle 25 28
Fuel quantity injected 31 min3stroke at 333 rs 2000 rpm
Micro Filter
Type Bosch 0 450 015 003
Filter element Bosch 1 457 431 324
Feed pump
Type Pierburg PE 15672
Feed pressure at 42 rs 2500 rpin kpcm 2 psi 065 085 92 voltage 12 V
Battery capacity Max 60 Ah
Alternator rating max 35 A
Starter motor rating 081 kW 11 hp
Battery electrolyte spec gray Fully charged battery 1275 1285 gcm 3
Charging to be carried out at 1230 gcm 3
Cooling Bellows to open at0C 0F 60 140
Fully open at 0C 0F 90 194
WEAR when worn or if the engine has an oil consumption mm in 025 and big end ovality mm in
006 conicity mm in 005 00020
Max axial clearance end float mm in 036 journals permissible ovality tom in 003 00012
Max clearance between camshaft and bearings mm in 015 clearance between valve guide and valve stem mm 016
disc edge mm thickness mm in 10 00394
head nuts 70 Nm 7 kpm head studs 20 Nm 2 kpm for a gearbox
drive on crankshaft 80 Nm 8 kpm 58 nut 500 Nm 50 kpm end connecting rod
bearings 70 Nm 7 kpm pump drive 60 Nm 6 kpm bearings
70 Nm 7 kpm 50 Lbtt
Nuts for injector holder 10 Nm 1 kpm torque for cylinder head nuts
Note The tightening must be done in three stages
First stage 10 Nm 1 kpm 7Lbft
Second stage 40 Nm 4 kpm 29Lbft
Final stage 70 Nm 7 kpm 33

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