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' Volvo/md5a: Volvomd5a user Volvo Md5a User Manual'



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FOREWORD
Before you start running your new Volvo Penta marine engine, you would be
advised to read through this instruction book carefully. It contains all the
information you need to run and service your engine in the best possible way.
Volvo Penta has built up an extensive service organization with service shops and
specially trained personnel at your service.
Always contact your local Volvo Penta representative for advice and when in need
ot service and parts.
We are convinced that the demands on good running economy and top
performance, which you have every right to expect of a quality product, will be met
and that your engine will serve you faithfully on many pleasant cruises.




WARRANTY
A warranty certificate is supplied with each engine. It contains the warranty
conditions for the engine and should be studied carefully.
Also included is a report card which is to be completed by the dealer or boat
seller. If our warranty is to apply, however, it is an absolute condition that the
measures given in the "Check and Service Scheme" are carried out and that your
engine and equipment are looked after according to the instructions in this
manual. When in doubt, always get in touch with an authorized Volvo Penta
dealer.
In all correspondence with your dealer and when ordering parts, state the type
designation and serial number of the engine and reverse gear (see starboard side
of engine).
                                                               CONTENTS




Presentation                                                              2

General Information                                                   3-4

Running Instructions                                                  5-6
                        Starting the engine                             5
                        Running instructions                            6
                        Shutdown procedure                              6
Technical Description                                                 7-9

Checks and Service Scheme                                               10

Checks and Service                                                  11 - 17
                        Check daily before starting                      11
                        Check every 14 days                         11 - 12
                        Service every 50 hours of operation         12 - 13
                        Service every 100 hours of operation        13 - 19
                        Laying-up and launching                     20 - 23
Fault Tracing Scheme                                                     24

Technical Data                                                      25 - 26

Wiring Diagram                                                          27

Engine Component Guide                                                  28

Index, alphabetical order                                               29




                                                                          1
PRESENTATION



    INSTRUMENT PANEL



                                1.    Switch, optional equipment
                                2.    Warning lamp, "Excess temp."
                                3.    Place for instrument ( 52 mm opt. equipment)
                                4.    Warning lamp, "No oil pressure"
                                5.    Switch, optional equipment
                                6.    Warning lamp, "No battery charging"
                                7.    Siren, "No oil pressure, excess temp."
                                8.    Key switch




                       Volvo Penta Single Control System
    CONTROL SYSTEM     For side mounting


                       1.       Control lever
                       2.       Disengaging button
                                Push in the button when the control lever is in neutral
                                and move the lever a bit forwards. Release button.
                                The lever is now used only for engine speed control.
                                To use the lever for both engine speed control and
                                gear-changing, push in the button and pull back the
                                lever to neutral.

                       N    =   Neutral
                       F = Control lever in position for running "Forward"
                       R = Control lever in position for running "Reverse"
                       T = Engine speed control




2
                                                GENERAL INFORMATION


Important information on the function of your engine:

 FUEL                   Use diesel fuel oil of quality "Autodiesel". Poorer fuel quality
                        can cause interruptions in operation.

                        Use only oil with quality CD (DS) according to the API system.
 LUBRICATING            Volvo Penta oil for diesel engines can be used with
 OIL                    advantage since it meets these quality demands. See under
                        "Technical Data" concerning the viscosity.

                        A new marine engine must be run-in with due care during the
 RUNNING-IN             first 20 hours of operation. If full output is taken out during this
                        time, it should only be done for short periods.
                        Oil change. Change the engine lubricating oil and the oil filter
                        after the engine has been run for 20 hours. See further under
                        "Checks and Service".



ENGINE SPEED                        Max. speed: 41.7 rev/sec (2500 rev/mm).
For choice of correct propeller, refer to the Volvo Penta propeller diagram. Check the
engine speed with normal load in the boat. In order to utilize the maximum performance
of the engine, an engine speed as high as possible should be chosen but not, however,
greater than 41.7 rev/sec (2500 rev/mm).
NOTE. When the boat has been in the water for some time, the speed and max. rev/mm
can drop due to marine growth on the hull. Prevent marine growth by painting the bottom
of the boat with anti-fouling paint. See under "Measures taken when launching".




                                                                                               3
    GENERAL INFORMATION


SAFETY EQUIPMENT
Irrespective of whether the boat is being used for long cruises or short bathing trips, the
boat should be equipped with the safety equipment listed below. It can, of course, be
supplemented further according to personal tastes. Investigate at regular intervals to
ensure that there is safety equipment on board and that it is in working order.

LIFE-JACKETS for all on board.
FIRE EXTINGUISHER, approved, at least one and installed where it is easy to get at.
DISTRESS ROCKETS and matches. Packed watertight.
FIRST-AID BOX
TOOLS suitable for the equipment on board.
ON BOARD KIT containing, e.g. impeller, etc.
ANCHOR with line.
RADAR REFLECTOR
RADIO for listening to, e.g., weather reports.
COMPASS which is deviated.
BOAT HOOK and paddle.
MOORING ROPES
FOG-HORN and whistle.
FLOATING ANCHOR
TORCH



PREPARATIONS BEFORE STARTING
Make sure that:
There is no FUEL LEAKAGE
There is no WATER LEAKAGE from engine and hull
There is no OIL LEAKAGE
There is no SMELL OF LP-GAS in the deep cavities in the boat or elsewhere
The OIL LEVEL is correct
There is enough FUEL for the planned voyage
The proper NAUTICAL CHARTS are on board for the planned voyage
If there are some other persons on board, make sure that some of them is able to
operate the boat.
If there are persons on board who have never been on a boat before, tell them where the
life-jackets are located and where the fire-extinguisher is placed. Also tell them anything
more you think necessary from a safety point of view. Should something unexpected
happen during the voyage, it is very often too late to tell those on board how safety
equipment works.




4
                                       RUNNING INSTRUCTIONS
STARTING THE ENGINE

              Switch on the main switch. Start the engine room fan (if
              fitted) and let it run several minutes before starting the engine.




              Open the cock for the cooling water intake.



              Disengage the engine speed control from the gear-
              changing as follows:

              Move the control lever to neutral, push in the red disengaging
              button, and move the lever slightly forwards. Release the
              button. The lever can now only operate the engine speed.
              Check to make sure that the stop control is pushed in.

              Turn the key switch one stage to the right. The warning
              lamps for battery charging and oil pressure should now go on
              and the siren should sound. Push in and turn the key further to
              the right to start the engine. Release the key when the engine
              starts.
              Hand starter. If the engine is started with the starting crank,
              the decompression handle on the rocker arm cover should first
              be folded up. Fold down this handle for running when the
              cranking has got the engine up in speed.

              Starting in cold weather is facilitated if the cold-start control
              is pulled out. Push it in again after a while.


              Check immediately after starting that the warning lamps for
              the oil pressure and battery charging are out and that the siren
              is quiet. If any of the lamps are on and the siren is
              sounding, the engine must be stopped immediately and
              an investigation made.



              Run the engine warm at rapid idle. Check to make sure that
              the cooling water flows out with the exhaust gases.
              NOTE. The key switch should always be switched on as
              long as the engine is running to ensure that there is
              battery charging.


                                                                                  5
RUNNING INSTRUCTIONS

             Reduce to idle and check that the engine is running smoothly.
             Engage the control lever for gear-changing as follows:
             Push in the red disengaging button and pull the lever back to
             neutral. Release the button. The control lever can now be
             used both for gear-changing and engine speed.


RUNNING

             The single lever control has both engine speed and
             manoeuvering functions.

             F = Forward     N = Neutral
             R = Reverse     T = Engine speed control


             To achieve good running economy, the engine should not be
             run at max. speed for a longer period.


             Make sure that the battery charging warning lamp does not
             light when the engine is running The siren will sound and the
             respective warning lamp go on if the engine temperature
             becomes excessive or the oil pressure too low.


SHUTDOWN PROCEDURE

             After shutdown the engine should be allowed to idle for a
             couple of minutes or so with the control lever in neutral.



             Stop the engine by pulling out the stop control when the
             engine is idling. Then turn back the key switch to the initial
             position.

             Switch off the main switch. NOTE. This switch must never
             be switched off until the engine has stopped.
             Close the fuel and cooling water cocks if the boat is not going
             to be used for some time.
             Check for leakage before leaving the beat.
             In cold weather and whenever there is risk of icing, the
             cooling water should he drained from the engine and reverse
             gear. See under "Laying-up and launching".
6
                                                     TECHNICAL DESCRIPTION




The MD5A is a single-cylinder, 4-stroke, marine diesel engine with direct injection and
sea-water cooling.

ENGINE ASSEMBLY
The engine block and cylinder head are made of cast iron. Cylinder angle 45o. The
cylinder liner is replaceable. The engine has overhead valves.

LUBRICATING SYSTEM
The lubricating system includes a full-flow oil filter which filters all the oil before it reaches
the lubricating points. A relief valve in the oil pump prevents the oil pressure from
becoming excessive.

ELECTRICAL SYSTEM
The engine has a starter motor and alternator with built-in rectifier. Voltage regulation is
taken care of by a transistorized regulator mounted on the alternator. The alternator
makes it possible to charge two battery circuits independent of each other if a charging
distributor (accessory) is fitted on the alternator.
A main fuse, which can easily be re-connected, is fixed to the engine. It protects the
electrical system from damage in the event of overloading. The wiring diagrams for the
engine and instrument panel are shown on page 27.


                                                                                                7
    TECHNICAL DESCRIPTION

FUEL SYSTEM
The fuel system contains a feed pump with pre-filter, fine filter, injection pump and
injector. The feed pump, which is of the diaphragm type, has also a hand priming lever.
Also fitted is a cold-start device with lever for connection of the push-pull control.

COOLING S YSTEM
The engine is sea-water cooled. The cooling system includes a sea-water pump as well
as a water distributor housing with thermostat.
The sea-water pump has an impeller of neoprene rubber driven by the camshaft via a
rubber flange.
The thermostat installed in the water distributor housing regulates the water flow so that
the water always flows through the exhaust manifold and out into the exhaust elbow
irrespective of whether the engine is cold or warm.




8
                                                 TECHNICAL DESCRIPTION


REVERSE GEAR
The Volvo Penta reverse gear, type Mono Shift (MSB) has a reduction ratio of 1.91:1.
The reduction gear is integrally built with the reverse gear. Power transmission from the
engine to the reverse gear is via a rubber flange.
The Volvo Penta patented cone clutch is used for "Forward" and "Reverse" operation and
ensures smooth and quiet engagement. Very small forces are required to operate the
reverse gear.




                                                                                            9
CHECKS AND SERVICE SCHEME

Checks and service should be regularly carried out according to the intervals given
below. Let an authorized Volvo Penta Service Shop look after your engine.


 CHECK DAILY BEFORE STARTING that
                                                                                  Page
 The oil level in the engine is between the marks on the dipstick                   11


 CHECK every 14 days that
 The oil level in the reverse gear is between the marks on the dipstick               11
 The electrolyte level in the battery is correct
 The belt tension                                                                     12


 SERVICE EVERY 50 HOURS OF OPERATION:
 Change the oil in the engine                                                         12
 Change the oil in the reverse gear                                                   13
 Check and adjust the valve clearances                                                13


 SERVICE EVERY 100 HOURS OF OPERATIONS OR AT
 LEAST ONCE EACH SEASON:
 Change the oil filter                                                               13
 Check the pulley belt                                                               14
 Check-tighten the cylinder head bolts                                               15
 Check the cooling system                                                            15
 Check the electrical system (fuses, etc.)                                           16
 Fuel system, filter, strainer, injector, venting                                 17-19


 SERVICE IN CONJUNCTION WITH LAYING-UP AND
 LAUNCHING THE BOAT
 Inhibiting scheme I. Inhibiting measures carried out with boat in the water.         20
 Inhibiting scheme II. Inhibiting measures carried out with boat on land.             21
 Service in connection with launching.                                                22




10
                                    CHECKS AND SERVICE


CHECK DAILY BEFORE STARTING
OIL LEVEL IN ENGINE
                            Each day before starting check that the
                            oil level is between the marks on the
                            dipstick. Top up with oil if necessary
                            through the oil filler hole.
                            NOTE. Do not top up above the MAX.
                            mark. Concerning choice of oil, see
                            under "Technical Data".




CHECKS every 14 days
OIL LEVEL IN REVERSE GEAR
                            Screw up the dipstick, wipe it clean and
                            insert it again without screwing it down.
                            Pull up the dipstick and check the oil
                            level which should be between the
                            marks. If necessary top up with oil
                            through the oil filler hole on the opposite
                            side of the reverse gear. Do not top up
                            above the MAX. mark.
                            Screw down the dipstick again. Note that
                            there is a sealing washer on the dipstick.
                            Concerning choice of oil, see under
                            "Technical Data".




                                                                          11
CHECKS AND SERVICE


ELECTROLYTE LEVEL IN BATTERY
The level should be between 5--10mm (3/16  3/8") above the cell plates in the
battery. If necessary top up with distilled water. IMPORTANT. Observe great care
when doing this since the electrolyte is abrasive and the gas which is formed is
explosive.

BELT TENSIONING

                                            Correct belt tension is necessary for full
                                            alternator output. The belt should be so
                                            tensioned that it can be depressed 5 mm
                                            (3/16") with the thumb midway between
                                            the pulleys.
                                            To tension the belt, first slacken the
                                            alternator retaining points, stretch the
                                            belts and tighten up the points again.
                                            A well worn or crached belt should be
                                            replaced.




SERVICE EVERY 50 HOURS OF OPERATION:
CHANGE OIL IN ENGINE


                                            With a new or newly reconditioned
                                            engine, the oil should be changed for the
                                            first time after 20 hours of operation and
                                            after that after every 50 hours of
                                            operation.
                                            Run the engine warm. Suck up the oil
                                            through the dipstick hole.
                                            Fill with oil to the correct revel. See
                                            under "Technical Data" concerning
                                            choice of oil.
                                            NOTE! Change also the oil filter (Fram
                                            Filter PH3614) at every other oil change.



12
                                                       CHECKS AND SERVICE


CHANGE OIL IN REVERSE GEAR

                                               The oil can be drained from the reverse
                                               gear by removing the plug under it or by
                                               sucking up the oil through the dipstick
                                               hole with the help of an oil scavenging
                                               pump.
                                               Fill with oil through the filler hole to the
                                               correct level on the dipstick. NOTE. Do
                                               not fill above the `MAX. mark on the
                                               dipstick. Concerning choice of oil, see
                                               under "Technical Data"




VALVE CLEARANCE
                                                The valve clearance should be checked
                                                and adjusted by authorized personal.
                                                See under "Valves", in "Technical Data".




SERVICE EVERY 100 HOURS OF OPERATION OR AT LEAST
ONCE EACH SEASON
OIL FILTER

The oil filter should be replaced for the first time after 20 hours of operation during the
running in period and subsequently at every other oil change. IMPORTANT. Before
removing the filter, switch off the main switch. Screw off and scrap the oil filter. It may
be necessary in certain cases to lift off the belt and tension out the alternator to permit
free passage for the filter.


                                                                                              13
CHECKS AND SERVICE

                     Coat the new filter rubber gasket with oil.
                     Check the area on the engine in contact
                     with the filter and screw on the filter by
                     hand until it just touches the engine. Then
                     screw the filter a further half turn, but not
                     more.
                     NOTE. Only use a genuine oil filter.
                     Start the engine, allow it to idle and
                     immediately check that the oil pressure
                     warning lamp is out.
                     Check the oil level and also for any
                     leakage round the oil filter.




CHECK THE BELT


                     Check the belt thoroughly for wear and
                     cracks. Replace it if there is any indica-
                     tion of such. To remove the belt, slacken
                     the alternator retaining points in order to
                     be able to slip the belt off. Wipe clean the
                     belt groove on the pulleys before fitting
                     the new belt. Tension the belt so that it
                     can only be depressed 5 mm (3/16") with
                     the thumb between the pulleys. After the
                     engine has been run for an hour or so,
                     re-check and if necessary adjust the belt
                     tensioning.




14
                                                    CHECKS AND SERVICE


CHECK-TIGHTEN THE CYLINDER HEAD BOLTS
                                             Authorized personal should check-tighten
                                             the bolts with a torque wrench before
                                             starting a new or newly reconditioned
                                             engine for the first time and again after it
                                             has been in operation for 20 hours.
                                             Check the valve clearance after tightening
                                             up the bolts. The bolt-tightening sequence
                                             can be seen from the adjacent illustration.
                                             Concerning the tightening torque, see
                                             under "Technical Data".


CHECK THE COOLING SYSTEM
The cooling system is functioning normally when the "Temp" lamp is out and the siren is
quiet. Excessive temperature ("Temp" goes on, the siren sounds) may be due to the
following: clogged water intake, defective impeller or flange in the sea-water pump,
faulty thermostat or temp. gauge sender. Look out for water penetration during all
work on the cooling system.


                                             The impeller can be damaged due to,
    Check and replace the impeller
                                             e.g., shortage of water. Remove the cover
                                             on the water pump. Pull out the shaft the
                                             length required in order to screw out the
                                             impeller lock bolt. Hold against the shaft
                                             and pull off the impeller. If the impeller is
                                             damaged, fit a new one. NOTE! If the
                                             shaft has been removed entirely from the
                                             pump housing, check when re-fitting it
                                             that the D-ring between the sealing rings
                                             in the housing gets onto the shaft.
                                             Tighten up the impeller with the lock bolt.
                                             If the impeller and shaft can be rotated
                                             then the flange is defective. A new flange
                                             can be fitted after the pump has been
                                             removed. Fit the cover with its gasket.




                                                                                       15
CHECKS AND SERVICE

                                    ELECTRIC SYSTEM
                                    Alternator
                                    The engine is equipped with an alternator. To
                                    ensure that the alternator with the built-on regulator
                                    functions without interruptions the following
                                    important points must be observed:
                                    1.   Never switch off the main switch until the
                                         engine has been stopped.

                                         To do otherwise would be to ruin the charging
                                         regulator.
                                    2.   Do not mix up the battery connection
                                         poles. A plus sign and a minus sign are marked
                                         on the respective poles. The minus pole is
                                         connected up to the engine body. Cable shoes
                                         should be greased and wall tightened.
                                    3.   Re-wiring between the charging circuits
                                         may not be carried out while the engine is
                                         running.

                                         Fit a Volvo Penta charging distributor
                                         (accessory) on the alternator when more than
                                         one battery is connected up.


4.   Observe the following in the event the engine is started with an auxiliary battery:

     Let the ordinary battery remain connected up. Connect the auxiliary battery to the
     ordinary battery, plus to plus and minus to minus. When the engine has started,
     remove the auxiliary battery but do not break the ordinary battery's wiring circuit.
5.   Do not use a rapid charging unit when the alternator is connected to the battery.
6.   Before doing any work on the alternator equipment first disconnect both the
     battery cables.
7.   In the event any electrical welding work is done on the engine or the installation
     components, disconnect the charging regulator cables at the alternator and
     insulate the cable ends.
8.   Check regularly the belt tension and the cable connections.




16
                                                       CHECKS AND SERVICE
Change Fuse
A fusebox is mounted on the cylinder. A fuse breaks the electrical system when the
system is overloaded. Re-connect the electrical system by transferring the cable
connection to the next fuse contact.




Starter motor and alternator
All work connected with the starter motor and alternator shoold be done by an authorized
service shop. Inspection and control should he carried out in connection with a general
inspection of the engine.



BATTERY
Checking the state of charge of the battery
The state of charge of the battery should he checked at cast once each season. This is
done by using a hydrometer which shows the specific gravity of the electrolyte, this
varying with the state of charge. (See the Technical Data.)



FUEL SYSTEM
Observe the greatest cleanliness when handling the fuel system.
IMPORTANT: Try to avoid fuel splash.


             Change fuel filter
                                              The filter element in the fuel filter should
                                              be changed at least once each season.
                                              To do this remove the filter centre screw
                                              and lift off the filter. Clean the container
                                              and contact surfaces. Fit the new filter
                                              element and its gasket. Pump up the fuel
                                              with the hand primer. Vent the fuel system.
                                              If the pumping effect is poor, turn over the
                                              engine a bit so that the drive cam alters its
                                              position.


                                                                                             17
CHECKS AND SERVICE


 Extra fuel filter
                                               If an extra fuel filter is fitted together with a
                                               water separator, check the transparent
                                               bowl to see if there is any water in the fuel.
                                               If necessary, drain the filter via the cock in
                                               the bottom of the bowl.
                                               Try to avoid fuel splash. Pump up the fuel
                                               with the hand primer and vent the system.
                                               The fuel filter element should be changed
                                               at least once a season.




 FUEL STRAINER
                                               The fuel pump on the engine has a built-in
                                               strainer which is accessible after removing
                                               the cover. Clean the strainer at least once
                                               a season.
                                               Immediately after starting the engine,
                                               check for leakage.
                                               Always vent the fuel system. See under
                                               "Venting the fuel system".




Injector
The injector should be removed once a season and handed in to a diesel shop for
cleaning and checking the opening pressure, the spray pattern and for leakage. To
remove the injector, unscrew the delivery pipe and the by-pass oil line. Fit protective caps
over the openings.
Release both the nuts over the fork holding the injector to the cylinder head and lift up the
injector. If the injector feels stiff to remove due to gumming, grip it with, e.g., polygrip
pliers and carefully rotate it back and forth while levering it up at the same time (with a
screwdriver, e.g., under the fork(. Before fitting, check to make sure the contact surface
on the injector and copper sleeve is clean. Connect up the delivery pipe and the return
line but do not tighten the delivery pipe nut at the injector. Turn over the engine with the
starter motor until fuel comes from the delivery pipe. Tighten up the delivery pipe nut and
make sure the delivery pipe cone is fitted properly. Concerning tightening torque, see
"Technical Data".

18
                                                          CHECKS AND SERVICE


Venting the fuel system
In order for the engine to be able to start, the fuel system must be vented on the following
occasions:
When changing the fine filter.                 With leakage and work on the fuel lines.
When draining through the drain hole.          When the engine has not been used for a
When cleaning the fuel pump strainer.          long time.
After running the fuel tank empty.
When installing the fuel injection pump.


Venting is as follows:
1.   Open the vent screw on the fuel filter.
2.   Pump forward the fuel with the help of the hand primer until fuel free from air bubbles
     flows out. Close the vent screw. If the pumping effect is poor, turn over the engine a
     bit so that the pump drive cam alters its position.
3.   If the fuel injection pump has been removed, or when starting an entirely new engine
     for the first time, the fuel injection pump must be vent. To do this open the vent
     screw on the pump. Pump with the hand primer until fuel free from air comes out.
     Slacken the injector delivery pipe nut and turn over the engine by means of the
     starter motor until fuel comes from the delivery pipe. Tighten up the delivery pipe nut
     and start the engine.




                                                            1.   Vent screw, fuel filter
                                                            2.   Hand primer
                                                            3.   Vent screw, injection pump
                                                            4.   Delivery pipe nut




                                                                                         19
LAYING-UP AND LAUNCHING


SERVICE IN CONNECTION WITH LAYING-UP AND
LAUNCHING THE BOAT

INHIBITING ENGINE AND REVERSE GEAR
IDLE ENGINE FOR BRIEF PERIODS WITH BOAT IN THE WATER
To prevent the engine from corrosion attacks, it must be run warm at least once every
14 days as long as the boat is in the water. If it is anticipated that the boat will not be
used for more than a month, long-term inhibiting should be carried out.


INHIBITING FOR A LONG PERIOD
An authorized service shop should test the engine and equipment before inhibiting the
engine for a long period acc. To Inhibiting Schemes I and II. A suitable procedure would
be to test the compression.


SERVICE INSTRUCTION
Inhibiting Scheme I
Carried out with the boat in the water


                      Run the engine warm.


1
                      Pump out all the oil from the engine and reverse gear.
                      Use an oil scavenging pump.



2
                      Change the oil filter. Fill the engine and reverse gear to the correct
                      level with Volvo Penta oil, which also has rustproofing properties,
                      to the correct level. The lubricating system is thereafter ready for
                      operation the next season.
                      If rustproofing oil is used, it should be of the type Esso Rustban
                      623, Sheel Ensis Oil or corresponding.
                      In this case, the oil filter should be replaced when launching.


3


20
                                             LAYING-UP AND LAUNCHING

                    Drain the fuel filter.




4
                    Disconnect the fuel pump flexible suction hose from the fuel
                    system and insert the free end in a can filled with 1/3rd Volvo
                    Penta oil or preservative oil and 2/3rds diesel fuel oil. Bleed the
                    fuel system. Let the engine run at rapid idle for about 10
                    minutes.
                    NOTE! If the fuel system has an electrically operated fuel pump,
                    it must be switched off before the engine is started.
5



Inhibiting Scheme II
Carried out with the boat on land

                    Drain the cooling water from the engine and reverse gear.
                    Check to make sure that the water runs out since impurities can
                    block the cock. Then close all cocks and re-fit the drain cock in
                    the reverse gear.
6
                    Disconnect the reverse gear suction line from the reverse gear.
                    Connect a hose with inner diameter 1/2" and, insert the free
                    hose end in a container with fresh water. Arrange to have water
                    added to the container and run the engine at idle for about 5 
                    10 minutes so that it is flushed throughout with fresh water.
                    Make sure that there is no dirt near the exhaust outlet. Drain all
                    water from the engine and reverse gear. Then close all drain
7                   points.
                    Mix a rustproofing mixture consisting of 15 - 20 litres
                    (13 Imp.qts. = 16 us qts. - 18 lmp.qts. = 21 US qts.)
                    fresh water and 2 - 4 litres (1.8 Imp.qts. = 2.0 US qts. - 3.5
                    lmp.qts. = 5.3 US qts.) rustproofing oil.
                    NOTE! Water first and then the oil.
                    Use, e.g., Esso Cutwull 40, Shell Donax C or similar. As an
                    alternative, a freeze-resistant 30 % glycol mixture can be used.
8




                                                                                     21
LAYING-UP AND LAUNCHING


                   Insert the hose into the rustproofing mixture. Start the engine
                   and allow it to idle until the mixture is finished. NOTE! The
                   water pump must never be allowed to run dry.


9
                   Since the rustproofing mixture does not provide any protection
                   against freezing, it must be drained from the engine and
                   reverse gear. Remove the cover from the cooling water pump.
                   Check to make sure the impeller is in good condition.
                   NOTE! Do not pull out the impeller if it is in good condition.
10
                   Remove the injector and hand it in to a diesel shop for cleaning
                   and checking. Inject Volvo Penta oil into the cylinder. Turn over
                   the engine several turns with the starter motor or the crank.
                   NOTE! Prevent oil splash. Fit the checked injector but do not
                   final-tighten it. It will be removed again before launching.
11
                   Clean the outside of the engine and reverse gear. Touch up any
                   bare patches on the paintwork with the same type of paint as
                   the original. Spray the electrical system components and all the
                   controls with anti-moisture spray.
12
                   Remove the battery. It needs to be maintained to prevent it from
                   being damaged.


13



Service in connection with launching

                   If Volvo Penta oil has been used, only the oil level in the engine
                   and reverse gear needs to be checked. If another type of
                   preservative oil has been used, both oil and filter must be
                   replaced. See under "Service 14 after every 50 hours of
                   operation".
14




22
                         LAYING-UP AND LAUNCHING


     Screw tight the cover with its gasket on the cooling water pump.
     Connect the hose between the cooling water intake and the
     reverse gear. Check-tighten all the hose clamps.
     Close the drain cocks.
     Clean the outside of the engine and the reverse gear.
15
     Install the battery, which should be fully charged. Grease the
     cable shoes. Connect up the battery cables. IMPORTANT! Do
     not mix up the polarity. Tighten up the cable shoes well.




16
     Remove the injector. Take measures to avoid oil splash and run
     the engine several turns so that the oil on the piston crowns is
     blown out.
     Fit the injector. See under "Tightening torques", "Technical
     Data".
17
     Launch the boat. Change the fuel-filter cartridge. Pump forward
     the fuel and vent the system. See under "Venting the fuel
     system".
18
     Start the engine. See the instructions on page 5. Run the
     engine warm with the reverse gear engaged. Check to make
     sure there is no leakage of fuel, air, water or exhaust gases .
     Check that all the controls, etc., are functioning properly.
19
     If necessary, contact authorized Volvo Penta service shops and
     let them service the engine and reverse gear according to the
     instructions in the servicing scheme.




20




                                                                       23
 FAULT TRACING SCHEME


TRACING FAULTS WITH INTERRUPTIONS IN OPERATION
The fault tracing scheme given below lists only the most usual reasons for faults that give
rise to interruptions in operation. With the help of the instructions given in this handbook,
the owner can generally remedy most of the reasons for the faults listed below. When in
doubt always contact the nearest Volvo Penta service shop.


                                                                                                      Engine becomes abnormally hot
                                         Engine does not reach correct
                                         operating speed at full throttle

                                                                            Engine runs unevenly or
  Engine does not start




                                                                            vibrates abnormally
                          Engine stops




                                                                                                                                      Reason                               See


                                                                                                                                      Main switch not switched on; flat    pp 5, 12, 16,
                                                                                                                                      battery, breakage in electric        17, 27
 X
                                                                                                                                      cables or blown fuse.


                                                                                                                                      Empty fuel tank, closed fuel         pp 17, 18
 X                        X                                                                                                           cock, blocked fuel filter


                                                                                                                                      Water, air or impurities in fuel     pp 17, 18, 19
 X                        X                                                    X

 X                        X                  X                                 X                                                      Defective injector                   pp 18, 26
                                                                                                                                      Idling speed not properly            p 25
                          X                                                    X                                                      adjusted


                                                                                                                                      Boat overloaded
                                             X

                                                                                                                                      Marine growth on boat bottom
                                             X

                                                                                                                                      Damaged propellor
                                                                               X

                                                                                                                                      Blockage in cooling water            p 15
                                                                                                      X                               intake, cooling jackets, defective
                                                                                                                                      impeller, or thermostat
24
                                                                       TECHNICAL DATA


Technical Data

General
Engine designation                                                       MD5A
                                                                         4-stroke diesel with direct
Operation                                                                injection

Number of cylinders                                                      1
Propeller shaft output kW (h.p.) at 2500 rev/min                         5.5 (7.5)
(acc. To DIN Leistung B f r Dauberbetrieb)

Max operating speed rev/min                                              2500
Bore, mm (in)                                                            84 (3.307)
Stroke, mm (in)                                                          80 (3.150)
                    3   3
Displacement, dm (in )                                                   0.443 (27)
                                 2         2
Compr. pressure, MPa (kp/cm = lbf/in )                                   200 - 220
(starter motor speed)                                                    (20 - 22 = 284 - 313)
Idling speed, rev/min approx                                             700
Direction of rotation looking at flywheel                                Clockwise
Engine inclination underway:
   Rearwards, max.                                                       15
   To the sides, max.                                                    20
Engine weight, incl. Reverse gear, kg (lb)                               111 (244)


Valves
Valve clearance, hot engine
   Inlet, mm (in)                                                        0.30 (0.0012)
   Exhaust, mm (im)                                                      0.35 (0.0014)


Reverse Gear
Type designation                                                         MSB
Reduction ratio "Forward" and "Reverse"                                  1.91:1


Lubricating System
Engine
   Oil Capacity, engine, litres (Imp.qts. = US qts.) ex cl. filter       2.0 (1.80 = 2.10)
                                                        Incl. filter     2.1 (1.85 = 2.20)
   Oil quality                                                           Diesel lubricating oil
                                                                         Service CD (DS)
   Viscosity:
            Above +10C (14F) - Volvo Penta CD Double Grade oil         SAE 20W/30
            Below +10C (14F) - Volvo Penta CD Single Grade oil         SAE 10W
   Oil pressure, hot engine
                                       2        2
            Idling speed, MPa (kp/cm = lbf/in )                          15 - 25 (1.5-2.5 = 21-35)
                                       2         2
            At full speed, MPa (kp/cm = lbf/in )                         40 - 50 (4.0-5.0 = 57-71)




                                                                                                       25
  TECHNICAL DATA



Reverse Gear
   Oil quality/Viscosity                                             See under "Engine"
   Oil capacity, litre (qt.)                                         0.55 (0.5)

Cooling System
Thermostat, starts to open at C (F)                                602 (1402)
              fully open at C (F)                                  90 (195)


Fuel System
Fuel injection pump, make & type                                     Bosch PFR1K
                                2           2
Feed pressure, MPa (kp/cm = lbf/in )                                 7.5 (0.75 = 11)
Injector, make Bosch, holder                                         KBAL 65
                           nozzle                                    DLLA 150
                                                        2       2
                           opening pressure, MPa (kp/cm = lbf/in )   1800 (180 = 2560)
Pre-injection angle, crankshaft degrees B.T.D.C.                     25 - 28
Fuel quality "Autodiesel"                                            Cet. rating minimum 45


Electrical System
Battery voltage                                                      12v
Battery capacity, standard                                           60 Ah
                   max                                               120 Ah
Starter motor                                                        0.8 kW (1.1 h.p.)
Alternator                                                           35A (420W)
Battery, electrolyte specific gravity:
                                        3
   Charging carried out at g/cm                                      1.230
                                    3
   Fully charged battery, g/cm                                       1.275 - 1.285

Tightening Torques
Cylinder head nuts, Nm (kpm = lb.ftf)                                70 (7.0 = 50)
Connecting rod bolts, Nm (kpm = lb.ftf)                              70 (7.0 = 50)
Crankshaft main bearings, Nm (kpm = lb.ftf)                          70 (7.0 = 50)
Flywheel nut, Nm (kpm = lb.ftf)                                      500 (50.0 = 362)
Injector nuts, Nm (kpm = lb.ftf)                                     10 (1.0 = 7)




26
                                                                               WIRING DIAGRAM


Cable Colour Code                 2
Marking       Colour          mm             A.W.G.
A             White           6              9
B             Black           1.5            15
B'            Black           0.6            19
B"            Black           0.75           18
C             Red             6              9
C'            Red             35             1
C"            Red             0.6            19
F             Yellow          1.5            15
G             Brown           1.5            15
H'            Blue            35             1
I             Green/Red       1.5            15
I'            Green/Red       0.75           18
J             Green           1.5            15
J'            Green           0.6            19
J"            Green           0.75           18
K             Blue/Yellow     0.75           18
L             White/Red       0.75           18
M             Blue/Red        0.75           18




List of Components                                         9.    Place for instruments, opt. equipment)

1.   Extra switch                                          10.   Rapid connector

2.   Battery charging warning lamp                         11.   Starter mot or

3.   Excessive temp. warning lamp                          12.   Alternator

4.   Low oil pressure warning lamp                         13.   Fusebox

5.   Key switch                                            14.   Main switch

6.   Siren                                                 15.   Battery

7.   Alarm unit                                            16.   Temperature sender

8.   Battery charging warning lamp (for battery circuit,   17.   Oil pressure sender
     opt. equipment)




                                                                                                          27
 ENGINE COMPONENT GUIDE


                                                       1.   Connection for manual
                                                            starting crank
                                                       2.   Fusebox
                                                       3.   Thermostat housing
                                                       4.   Decompression handle
                                                       5.   Injector
                                                       6.   Oil filler cap, engine
                                                       7.   Reverse gear water drainage
                                                       8.   Reverse gear oil drainage
                                                       9.   Engine water drainage
                                                       10. Reverse gear oil filler
                                                       11. Cooling water pump
                                                       12. Reverse gear oil dipstick
                                                       13. Fuel filter
                                                       14. Vent screw
                                                       15. Fuel hand primer
                                                       16. Engine oil dipstick
                                                       17. Oil filter




The tool kit supplied with the engine contains the following tools:
US-spanner 10-12, UP-spanner 14-16 , screwdriver, Phillips screwdriver, flat end pliers,
oil scavenging pump with hose and suction pipe as well as Allen spanners for the drive.




28
                                                                      INDEX

Alternator             7, 14, 16, 27   Lubricating oil                     3, 25

Battery                          12    Main Switch                          5, 6
Belt tensioning              12, 14
                                       Oil change                         12, 13
Charging regulator            7, 16    Oil dipstick, engine                   28
Controls                       2, 6    Oil dipstick, reverse gear             28
Cooling system                    8    Oil filter                     14, 20, 28
Cylinder head bolts              15    Oil level check                        11

De-inhibiting                    22    Preparations before starting           4
Drain cocks                      28
                                       Running                                6
Electrical system                16
Engine assembly                   7    Safety equipment                        4
                                       Sea-water pump                  8, 15, 28
Fault tracing scheme             24    Starter motor                          17
Fuel                              3    Starting                                5
Fuel filters                     17
Fuel pump                         8    Technical data                    25, 26
Fusebox                       7, 17    Thermostat                         8, 26

Hand primer            8, 17, 23, 28   Valve clearances                  13, 25
Hand starter                   5, 28   Venting the fuel system               19

Impeller                         15    W iring diagrams                      27
Inhibiting                       20
Injector                     18, 23
Instruments                   2, 27




                                                                               29


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