Saturday, June23, 2018

Volvo Penta Md11c D Md17c D Workshop Manual

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Workshop Manual A
Engine unit 20
precautions 2
General Information 5
Repair instructions 6
Component guide head 10
Cylinder liner 11
Pistons conrods 11
Timing gear 12
Flywheel 13
Crankshaft 14
Camshaft cylinder head 15
Cleaning inspection 15
Valve guides 15
Valve seats 16
Valves 16
Valve springs 16
Rocker mechanism 16
Valve tappets 16
Injector sleeve 17
Injector 17
Assembling cylinder head 18
Cleaning checking crankcase 18
Replacing main bearings governor 19
Pistons liners 19
Connecting rods 20
Crankshaft 20
Camshaft 20
Oil pump 20
Feed pump 21
Thermostat 21
Sea water pump 21
Hand start 24
Flywheel 25
Timing gear 25
Cylinders cylinder liners 27
Pistons and liners 28
Cylinder head 29
Adjusting valve clearance 30
Injection pump 31
Checking control rod travel 32
Venting the fuel system 33
Checking injections angle 34
Adjusting engine speed system 35
Wiring diagram 35
Fault finding chart 36
Special tools 37
Technical data 39
Cooling system diagrammatic sketch 43
Safety Check that the warning or information decals on
This Workshop Manual contains technical data de
the product are always clearly visible and repair instructions for Volvo Penta
decals that have been damaged or or product versions contained in the con
tents list Ensure that the correct workshop literature
is being used
Read the safety information and the General Information and Repair In Never use start spray or similar to start the carefully before
starting work gine The starter element may cause an explo
sion in the inlet manifold Danger of personal in
this book and on the engine you will find the follow
ing special warning symbols
Avoid opening the filler cap for engine coolant
WARNING If these instructions are not fol system freshwater cooled engines when the
lowed there is a danger of personal injury ex engine is still hot Steam or hot coolant can
tensive damage to the product or serious me spray out Open the coolant filler cap carefully
chanical malfunction and slowly to release pressure before removing
the cap completely Take great care if a cock
IMPORTANT Used to draw your attention to plug or engine coolant line must be removed
something that can cause damage product from a hot engine It is difficult to anticipate in
malfunction or damage to property which direction steam or hot coolant can spray
NOTE Used to draw your attention to important infor
mation that will facilitate work or operations
Hot oil can cause burns Avoid skin contact
Below is a summary of the risks and safety precau with hot oil Ensure that the lubrication system
tions you should always observe or carry out when is not under pressure before commencing or servicing the engine on
it Never start or operate the engine with the
oil filler cap removed otherwise oil could be
Immobilize the engine by turning off the power ejected
supply to the engine at the main switch switch
es and lock it them in the OFF position before
starting work Set up a warning notice at the en
gine control point or helm Stop the engine and close the sea cock before
carrying out operations on the engine cooling
Generally all servicing should be carried out system
with the engine switched off Some work carry
ing out certain adjustments for example re
quires the engine to be running Approaching a
running engine is dangerous Loose clothing or Only start the engine in a area If
long hair can fasten in rotating parts and cause operating the engine in an enclosed space en
serious personal injury sure that exhaust gases and crankcase ventila
If working in proximity to a running engine care tion emissions are ventilated out of the working
less movements or a dropped tool can result in area
personal injury Avoid burns Take precautions
to avoid hot surfaces exhausts charge air pipes and starter elements etc and
liquids in supply lines and hoses when the en Always use protective goggles where there is a
gine is running or has been turned off immedi danger of pieces of metal sparks from grinding
ately prior to starting work on it Reinstall all acid or other chemicals being thrown into your
protective parts removed during service opera eyes Your eyes are very sensitive injury can
tions before starting the engine lead to loss of skin contact with oil Longterm or repeat Never allow a naked flame or electric
ed contact with oil can remove the natural oils near the batteries Never smoke in proximity to
from your skin The result can be irritation dry the batteries The batteries give off eczema and other skin problems Used oil gas during
charging which when mixed with air
is more dangerous to health than new oil Use can form an explosive gas oxyhydrogen gloves and avoid using oilsoaked gas is easily
ignited and highly volatile and rags Wash regularly especially be rect connection of the battery can cause a
fore meals Use the correct barrier cream to spark which is sufficient to cause an dry skin and to make cleaning your skin with resulting
damage Do not disturb connections when starting the engine spark
risk and do not lean over chemicals used in products engine oils glycol petrol and diesel oil Never mix up the positive and negative battery
and workshop chemicals solvents and paints terminals when installing Incorrect hazardous to health Read the instructions can result in
serious damage to electrical equip
on the product packaging carefully Always fol ment Refer to wiring diagrams
low safety instructions using breathing appar
atus protective goggles and gloves for ex Always use protective goggles when Ensure that other personnel are not and handling
batteries The battery exposed to hazardous substances contains extremely corrosive sulfuric acid If
by breathing them in for example Ensure that this comes into contact with the skin wash is good Handle used and excess mediately with
soap and plenty of water If according to instructions tery acid comes into contact with the eyes im
mediately flush with copious amounts of water
All fuels and many chemicals are inflammable and obtain medical that a naked flame or sparks cannot ig
nite fuel or chemicals Combined with air in cer Turn off the engine and turn off power at main
tain ratios petrol some solvents and hydrogen switches before carrying out work on the elec
from batteries are easily inflammable and explo trical system
sive Smoking is prohibited Ensure that ventila
tion is good and that the necessary safety pre Use the lifting eyes mounted on the have been taken before carrying out verse gear when
lifting the drive unit
welding or grinding work Always have a fire ex Always check that lifting equipment is in to hand in the workplace condition and
has sufficient load capacity to lift
the engine engine weight including reverse gear
Store oil and fuelsoaked rags and fuel and oil and any extra equipment safely In certain conditions can spontaneously ignite Used fuel and oil
To ensure safe handling and to avoid are dangerous waste and engine components on top of the engine use a
must be deposited at an approved site for de lifting beam to raise the engine All chains and
struction together with used lubricating oil con cables should run parallel to each other and as
taminated fuel paint remnants solvent de perpendicular as possible in relation to the top
greasing agents and waste from washing parts of the engine
If extra equipment is installed on the engine al
tering its center of gravity a special lifting de
vice is required to achieve the correct balance
for safe handling
Never carry out work on an engine suspended
on a hoist
Never remove heavy components alone even Always use fuels recommended by Volvo Pen
where secure lifting equipment such as secured ta Refer to the Instruction Book The use of
blocks are being used Even where lifting equip lower quality fuels can damage the engine On
ment is being used it is best to carry out the a diesel engine poor quality fuel can cause the
work with two people one to operate the lifting control rod to seize and the engine to overrev
equipment and the other to ensure that compo with the resulting risk of damage to the engine
nents are not trapped and damaged when being and personal injury Poor fuel quality can also
lifted When working onboard ensure that there lead to higher maintenance costs
is sufficient space to remove components with
out danger of injury or damage
Components in the electrical system ignition
system gasoline engines and fuel system on
Volvo Penta products are designed and con
structed to minimize the risk of fire and explo
sion The engine must not be run in areas
where there are explosive the workshop manual
This workshop manual contains technical descriptions and instructions for repairing the
standard versions of the following engines MD11C D
MD17C D The workshop manual displays the opera
tions carried out on any of the engines above As a
result the illustrations and pictures in the manual that
show certain parts on the engines do not in some
cases apply to all the engines listed above However
the repair and service operations described are the
same in all essential details Where they are not the
same this is stated in the manual and where the dif
ference is considerable the operations are Engine designations and numbers are
given on the number plate See page 9 The and number should be given in all about the engine
This Workshop Manual has been developed primarily
for Volvo Penta service workshops and qualified per
sonnel Persons using this book are assumed to have
a grounding in marine drive systems and be able to
carry out related mechanical and electrical work
Volvo Penta is continuously developing their prod
ucts We therefore reserve the right to make changes
All the information contained in this book is based on
product data available at the time of going to print
Any essential changes or modifications production or updated or revised service after the date of publication will be pro
vided in the form of Service parts for electrical and fuel systems are
subject to statutory requirements US Coast Guard
Safety Regulations for example Volvo Penta Genu
ine parts meet these requirements Any type of dam
age which results from the use of nonoriginal Volvo
Penta replacement parts for the product will not be
covered under any warranty provided by Volvo Penta
Repair working methods described in the Service Man
Our joint apply to work carried out in a workshop The en
gine has been removed from the boat and is installed Each engine consists of many connected systems
in an engine fixture Unless otherwise stated recondi and components If a component deviates from its
tioning work which can be carried out with the engine technical specification the environmental impact of an
in place follows the same working method otherwise good engine may be increased symbols occurring in the Workshop Manual
ly It is therefore vital that wear tolerances are main
for their meaning see Safety information tained that systems that can be adjusted are adjust
ed properly and that Volvo Penta Genuine Parts as
WARNING used The engine Maintenance Schedule must be fol
IMPORTANT Some systems such as the components in the fuel
system require special expertise and special testing
NOTE equipment for service and maintenance Some com
are not in any way comprehensive since it is imposs ponents are sealed at the factory for to predict every circumstance under which serv
reasons No work should be carried out on sealed
ice work or repairs may be carried out For this rea components except by authorized we can only highlight the risks that can arise Bear
in mind that most chemicals used on boats are
when work is carried out incorrectly in a wellequipped harmful to the environment if used incorrectly using working methods and tools developed
Penta recommends the use of biodegradable de
by us greasing agents for cleaning engine components un
All procedures for which there are Volvo Penta spe less otherwise stated in a workshop manual Take
cial tools in this Workshop Manual are carried out special care when working onboard that oil and
using these Special tools are developed to rational waste is taken for destruction and is not working methods and make procedures as safe
pumped into the environment with bilge water
as possible It is therefore the of any
person using tools or working methods other than the
ones recommended by us to ensure that there is no
Tightening of injury damage or malfunction resulting from
these Tightening torques for vital joints that must be
In some cases there may be special safety precau tightened with a torque wrench are listed in and instructions for the use of tools and
chemi manual Technical Data Tightening Torques and
cals contained in this Workshop Manual These spe are contained in work descriptions in this Manual All
cial instructions should always be followed if there torques apply for cleaned threads screw heads and
are no separate instructions in the Workshop Manual mating surfaces Torques apply for lightly oiled or dry
threads If lubricants locking fluid or sealing com
Certain elementary precautions and common sense
pound are required for a screwed joint this prevent most risks arising A clean workplace
will be contained in the work description and in
and engine eliminates much of the danger of injury
Tightening Torques Where no tightening torque is
and malfunction
stated for a joint use the general tightening torques
It is of the greatest importance that no dirt or foreign according to the tables below The tightening get into the fuel system lubrication system
stated are a guide and the joint does not have to be
intake system turbocharger bearings and seals tightened using a torque wrench
when they are being worked on The result can or a shorter operational life Dimension Tightening Torques
Nm lbtft
M5 6 44
M6 10 74
M8 25 184
M10 50 369
M12 80 590
M14 140 1033
In this Volvo Penta Service Manual the user will that each section where these agents are
applied in
Tightening using both a torque setting production states which type was used on the engine
and a protractor angle requires that During service operations use the same agent or an
first the recommended torque is ap alternative from a different plied using a torque wrench and then
the recommended angle is added ac Make sure that mating surfaces are dry and free from
cording to the protractor scale Ex oil grease paint and agent before ap
ample a 90 protractor tightening plying sealant or locking fluid Always follow the man
means that the joint is tightened a ufacturers instructions for use regarding temperature
further 14 turn in one operation after range curing time and any other instructions for the
the stated tightening torque has been product
applied Two different basic types of agent are used on the
engine and these are
RTV agent Room temperature vulcanizing Use for
gaskets sealing gasket joints or coating RTV agent is clearly visible when a component has
Do not reuse lock nuts that have been removed dur been dismantled old RTV must be removed before
ing dismantling as they have reduced service life the joint is resealed Old sealant can be removed us
when reused use new nuts when assembling or re ing methylated spirits in all For lock nuts with a plastic insert such as Anaerobic
agents These agents cure in an the tightening torque stated in the table is re of air They are used when two solid parts for ex
duced if the Nylock nut has the same head height as ample cast components are installed standard hexagonal nut without plastic insert Re
without a gasket They are also commonly used to
duce the tightening torque by 25 for bolt size 8 mm secure plugs threads in stud bolts cocks oil pres
or larger Where Nylock nuts are higher or of the sure switches and so on The cured material is glass
same height as a standard hexagonal nut the tighten like and it is therefore colored to make it visible
ing torques given in the table apply Cured anaerobic agents are extremely resistant to
solvents and the old agent cannot be removed When
reinstalling the part is carefully degreased and then
new sealant is and nuts are divided into different the class is indicated by the number on the
bolt head A high number indicates stronger material
for example a bolt marked 109 indicates a higher tol
erance than one marked 88 It is therefore bolts removed during the disassembly of a bolted
joint must be reinstalled in their original position the joint If a bolt must be replaced check
in the replacement parts catalogue to make sure the
correct bolt is number of sealants and locking liquids are used on
the engines The agents have varying properties and
are used for different types of jointing strengths oper
ating temperature ranges resistance to oil and and for the different materials and gap
sizes in the engines
To ensure service work is correctly carried out it is
important that the correct sealant and locking fluid
type is used on the joint where the agents are re
Component and D
1 Stop device
2 Air bleed screw injection pump
3 Injector
4 Delivery pipe nut
5 Temperature sender
6 Lockscrew crankshaft centre bearing
7 Drain cocks cooling water
8 Inspection cover
9 Oil drain plug engine
10 Oil dipstick reverse gear
11 Oil filler reverse gear
12 Oil drain plug reverse gear
13 Water drain plug reverse gear
MD11D connection hose
14 Decompression handle
certain models
15 Air filter MD11C
16 Oil filler engine
17 Pressure equalizing valve certain models
18 Air bleed screw
19 Fine filter
20 Feed pump
21 Engine speed sender
22 Oil filter
23 Oil pressure sender
24 Oil strainer and oil dipstick MD11C
25 Oil pump
26 Oil dipstick MD11D
and D
1 Fuse box MD17C
2 Decompression handle certain mo
3 Air filter
4 Oil filler
5 Air bleed screw
6 Fine filter
7 Feed pump
8 Engine speed sender
9 Oil filter
10 Stop device
11 Adjustment screw high idle speed
12 Adjustment screw low idle speed
13 Leakoff pipe
14 Lifting eye
15 Delivery pipe
16 Injector
17 Thermostat housing
18 Oil dipstick
19 Drain cocks cooling water
20 Engine type and number plate
21 Cooling water pump
off the engine cooling water lubricating oil and
any fuel in the fuel filter and fuel injection pump
Clean the outside of the engine
2B The picture shows later type of injector from and
including engine no 50989 MD11 and 16622
A fixture for securing the engine in the engine
stand 9992520 may be used to advantage
MD11 884604 MD17 884581
3 Take off the coolant pipe between the sea water
pump and the exhaust manifold Remove the
exhaust manifold wrench width 13 HEAD
2A Take off the air cleaner the leakoff oil pipe and
the delivery pipes Fit protective caps 4 Remove the valve covers Undo the oil pipes on
The picture shows earlier type of injector up to the rocker arm shafts and dismantle the rocker
and including engine no 50988 MD11 and arm bearing brackets Take out the push rods
5 Remove the eyebolt or eyebolts and nuts hold
ing the cylinder heads wrench width 19 mm
Straighten out the oil pipes slightly and lift the
cylinder heads off
7 Lift the cylinders out Remove the cylinder liners
by placing the cylinder with the bottom of the
liner on a flat support and strike the top face of
the cylinder with a rubber mallet
6A Disconnect the cables from the engine speed
sender the oil pressure switch and the altern
ator MD11 Remove the alternator bracket to
gether with the alternator The picture shows the
earlier model MD11C up to and including engine
no 52480 and MD11D from production start
MD17 Remove the cover earlier models over
the Vbelt and remove the alternator
8 MD11 Remove the inspection covers on the
crankcase 6 mm socket head MD17 Remove
the oil sump and strainer NOTE Remove the
sealing rings in the ends of the oil pump suction
6B MD11C The picture shows the later models 9 Remove the bigend bearing caps and take out
from and including engine no 52481 the connecting rods and pistons Mark the con
necting rods if this has not already been done
Remove the valve tappets
13A MD11C and MD17C Remove the carrier on the
crankshaft engines with RBreverse gear have
a carrier drive use a distance piece to protect
10 Remove the crankcase breatherhand starter the shaft Take care of the key
13B MD11D and MD17D Remove the carrier on the
crankshaft Use puller 884078 for the Remove the injection pump sea water pump use a distance piece to protect the shaft Take
feed pump and the fuel filter care of the key Earlier types of puller 884078
The Dengines have leakoff oil return pipes con can be modified by drilling three 85 mm holes
nected to the inlet union see also page 27 use the spline flange as a Take off the timing gear cover
14 Pull off the crankshaft gear with the aid of tool
884078 Remove the key the spacing washer
and the thrust Unscrew the left handed carrier screwnut on the
camshaft Pull out the cam disc and the gear 18 Remove the starter motor and its bracket
wheel together On MD11 the crankshaft can
be dismantled without taking off the camshaft
MD11 certain models Remove the belt pulley 19 Remove the oil pump
that is mounted on the flywheel MD17 Remove
the bearing Bend out the lock washer and unscrew the cent 20 MD11 Remove the front engine brackets Re
ral nut Pull off the flywheel using the puller move the bearing shield
884078 Take care of the key NOTE The nut is
pulled using 500 Nm 50 kpm 369 lbfft
23B MD11C 23C MD11D
21 Remove the locating screw for the crankshaft
Tool 884714 Hexagon 30 mm
centre bearing two in the case of MD17 Pull
the crankshaft Remove the thrust washer and lift the camshaft 24 Loosen the lock screw and remove the centrifu
out MD17 Check that the oil hole is correctly gal governor
located when Remove the oil filter the oil pressure switch and 25 Unscrew the centre bearing MD17 two bear
the oil pipes for the rocker arm mechanism ings NOTE Mark them so that they can be
MD11 Remove the oil strainer MD11C Use tool refitted in the same positions
884714 see 23B MD11D 30 mm hexagon see
VALVE Remove the injectors and fit protective caps on 29 Check the valve guides for wear by inserting a
the tips of the nozzles new valve Measure the clearance with the aid of
a dial gauge Replace the guides if necessary
Wear limits
Inlet valve
max clearance 015 mm 000591
Exhaust valve
max clearance 017 mm Remove the wear caps from the valve stems
Remove the valve springs with the aid of a
valve spring compressor Place the valves in or
der in a valve stand Take off the sealing rings
that are fitted on the valve INSPECTION
A 18 mm 0709
30 Press out the valve guides using drift 9991459
Oil the new guides externally and press them
into position with tool 884499 The tool should
be pressed right down against the cylinder head
Ream the guides if necessary with broach
Clean all parts Pay particular attention to cool
ant passages In case of doubt check for leak
age by pressure testing Water pressure 03
MPa 3 kgcm2 43 psi
33 Dismantle the rocker arm mechanism and clean
the parts Check the shaft and the bushes for
B 101 mm D 445
wear If the bushes need to be replaced the tool
884560 is used for pressing out and in Ensure
31 Mill or ream the valve seats the angle C that the oil hole in the bush coincides with that
should be 45 Check the valve guides and re in the rocker arm After having been pressed in
place them if necessary before machining the the bushes should be reamed to give an accu
seats see point 29 The width B of the sealing rate running fit Check whether the rocker arm
surface should be 101 mm surface which bears on the valve is worn Minor
adjustments can be made with the valve grind
Grind the valves in the valve grinding machine
ing machine Oil the shaft and fit the parts
The angle D should be 445 If the thickness
NOTE Fit the wear caps on the valve stems
of the edge of the disc after grinding is less than
15 mm 0059 the valve should be rejected
Discard also valves with bent stems or if the di
mension A exceeds 25 mm 010 If neces
sary grind the surface on which the rocker arm
bears Grind the valves in using grinding com
pound and check the surface contact using
marking blue
VALVE SPRINGS VALVE Check the valve spring lengths both loaded and
L Length unloaded 50 mm 1969 34 Check the valve tappets for wear The cylindri
L1 Length when loaded with cal surface should not be scored or porous The
30020 N 302 kp 666441 lbf 39 mm 1535 surface bearing on the camshaft should not be
L2 Length when loaded with rough or worn unevenly Replace the tappets if
56030 N 563 kp 123566 lbf 32 mm 126 SLEEVE correctly Place nuts or washers on
the stud
bolts so that the yoke can be clamped tightly
Drain the engine cooling water if this has not already
with the nuts Screw the tool down as far as the
been done
shoulder in the sleeve permits thus flaring the
sleeve Remove the tool
35 Remove the sleeve using the tool 884081 Push
the expanding screw down into the sleeve and
screw so that the screw expands
and grips the sleeve Tighten until the threads
bite into the copper material Fit the yoke onto
the stud bolts which hold the injector Screw on
the nut and rotate until the sleeve is removed
38 Adjust the length of the sleeve outside the plane
of the cylinder head dimension 09 mm
0035 Also check that the sleeve is correctly
fitted dimension 195 mm 0768
Remove the Oring and carefully clean the hole
in which the sleeve is to fit Grease and fit the
new Oring Oil the new sleeve and fit it using
tool 884077 Knock the sleeve in until it bot
39 Check the spray pattern at the correct opening
pressure Up to and including engine no 50988
MD11 16621 MD17
08 08 114
170 MPa 170 kpcm2 2418 0 psi
0 0
From and including engine no 50989 MD11 16622
245 08 MPa 245 08 kpcm2 3485 114 psi
0 0 0
37 Oilin the flaring tool 884085 and push it into the Also check that the fuel jets cease at
sleeve make sure that the pin is screwed back all four holes and that there is no dribble
CLEANING AND to and including engine no 50988 MD11 and including engine no 50989 MD11 42
Remove all core plugs and clean the crankcase
thoroughly Check that all channels are free
40 The opening pressure is adjusted by means of from deposits and that there are no cracks in
screwing the injector apart and replacing the ad the crankcase Refit the plugs using a sealing
justed washer 1 with a washer of suitable compound
THE CYLINDER HEAD REPLACEMENT OF MAIN Clean the cylinder head Oil the new sealing 43 Press the main bearings
out using tool 884489
rings for the inlet valves Place the pin of tool or a hydraulic press NOTE Check the positions
No 884497 in the valve guide Push the seal of the locking tongues so that the bearing is re
ring over the pin and knock the ring down care moved in the right direction Clean the oil chan
fully using the sleeve until the pin bottoms in the nels before fitting new bearings
B Oil the valve stems and smear a little grease in
the inlet valve collet grooves Place the valves
in their respective guides screw the inlet valves
in carefully so as to avoid damaging the sealing
rings Fit the valve springs with the aid of a
valve spring PISTONS LINERS
46 Check the pistons and liners for damage and
A 15 mm 006
A Measure the cylinder liners diameter at a
number of points round the circumference and at
44A Fit the two halves of the new bearing together several different heights between the top and
with an elastic cord and turn them so that the bottom dead centre positions B and C Re
locking tongues after pressing in fit into the ap place the pistons and the liners if the wear
propriate recess NOTE The halves should be amounts to 025 mm 001 or more
slightly staggered see the diagram B Measure the piston diameter A at right angles
to the gudgeon pin hole and 7 mm from the bot
tom edge Calculate the maximum and minimum
piston clearance the maximum and minimum
liner diameter minus the piston diameter
Piston clearance new 009013 mm
Press the bearings in with tool 884489 or using
a hydraulic GOVERNOR
47 Measure the piston ring gap with the new rings
If the cylinder liner is not new the measurement
should be made below the bottom dead centre
position For dimension see Technical Clean the governor Check that the weights 2
do not bind on the shaft or that there is excess
ive clearance between the shaft and the gov
ernor weights Check that the pin 1 slides free
ly in the shaft Finally inspect both the ball
bearings 3
Replace the ball bearings if they bind Check 48 Measure the piston ring clearances in the piston
that all moving parts are oiled and move freely ring grooves For dimensions see Technical
before assembling in reverse order Data
52 Check the camshaft for wear on the cams and
bearing journals Also check the wear on the
bearings The bearings are pressed into their re
cesses and must be line milled after pressing in
49 Check the connecting rods for straightness and The maximum allowable wear on journals or
twist bearings is 005 mm 0002
53 Remove the cover retaining the old gasket Re
50 Check the connecting rod bushings using the move the gearwheels the spring and the piston
gudgeon pins as gauges There should be no Clean all parts Check the reducing valve spring
noticeable play If it is necessary to replace the see Technical Data Replace any worn or dam
bushings a suitable drift should be used for aged parts
pressing in and out Ensure that the oil hole in
bushings coincides with that in the connecting
Ream the new bushings The correct fit is
achieved when an oiled gudgeon pin slides slow
ly through the bushing under its own 54A Check the axial play of the gearwheels NOTE
The old gasket should be included in the meas
urement If necessary the number of gaskets
may be increased or reduced so as to obtain a
clearance of 003015 mm The
thickness of a new gasket is 010 mm 0004
Also inspect the cover repair or replace as ne
51 Measure the big end journals and the main bear cessary if badly worn Coat the gaskets with
ing journals The outofround should not exceed sealant and refit the parts Pour a little oil into
006 mm 00024 and the taper should not ex the pump before mounting onto the engine
ceed 005 mm 0002 If these values are ex B Check the gear backlash which should be
ceeded the crankshaft should be ground to a 015035 mm using a feeler
suitable undersize see Technical Data gauge Worn gears must be PUMP SEA WATER PUMP
Replacing the impeller
58 Remove the cover Watch out for water pour
55 Undo the central screw in the cover lift out the ing through the pump With the aid to two
strainer and clean it Take out the six screws screwdrivers prise the shaft with the impeller out
holding the upper and lower parts of the pump of the housing sufficiently for the screw which
together Take out the lever spring 1 also re holds the impeller to be undone NOTE Lay
move the screw 2 some kind of protection under the screwdrivers
so that the housing is not Remove the lever shaft using a pair of
finenosed pliers Pull out the lever and the dia
phragm Fit new parts from the repair kit and re
assemble the pump
59 Take the screw out and pull the impeller off the
shaft Clean the housing internally and that the carrier MD17 is free from defects and
fit the new impeller Fit the cover together with a
new The thermostat is accessible after the thermo
stat housing on the front on the exhaust mani
fold has been taken off Watch out for water
pouring into the boat Check the opening and
closing temperatures with hot water These 60 MD11 Engine no 4615946175 and from and
should be as given in Technical Data If the including engine no 46214 Remove the cov
thermostat is faulty it should be discarded Use er The impeller can be pulled out as shown in
new sealing rings when refitting MD17 has only the picture or by using suitable pliers NOTE
one sealing ring The picture shows the earlier Protect the edge of the pump housing The shaft
type bellows thermostat Later engines are fit follows with the impeller but is stopped by a pin
ted with a wax thermostat behind the seals
61 MD17 from and including engine no 17973
and MD17 HD HE from production start
The impeller is removed as shown in picture 60
The pump is fitted with two ball bearings 3
When loosen the lock ring 2
and press out the shaft the bearings following
with the shaft Press the bearings from the
shaft using a suitable drift When assembling
the bearings are pressed onto the shaft using
drift 884742 until the shaft bottoms in the drift
The seals 1 are replaced according to point 63
Smear the shaft with grease and screw it care
fully through the sealing rings so as not to dam
age them Press in the shaft until the bearing
bottoms and fit the lock ring 2 63 Remove the sealing rings 1 and the Orings 2
earlier engines and clean the pump housing
and shaft Replace the impeller if necessary
Check that the shaft is free from burrs or
scratches Inspect the carrier MD17 NOTE A
new Oring 2 shall not be fitted
Fit new sealing rings NOTE Turn the sealing
rings the right way round and ensure that they
do not block the drainage hole in the pump
housing Smear the shaft with grease and fit it
carefully into the housing screwing it through
the sealing rings to avoid damaging the sealing rings
Locate the shaft in the housing so that the
screw hole lies outside Fit the impeller and the
Pump having open shaft The shaft has a
groove which is open at the front which is why
the impeller is assembled with the screw fitted
Push the impeller in until bottoms
Fit a new gasket into the cover and secure it
with the screws
Also check the carrier screw on the Remove the sea water pump Watch out for wa
ter pouring into the boat Take off the cover and
press out the shaft and the STARTER MD17 HAND STARTER MD11
64 Remove the cover 1 together with the drive
and shaft Knock out the pin 2 and press the
shaft out Remove the sealing ring 3
Remove the cover 4 and the screws 9 take
off the gearwheel Remove the bearing housing
8 knock out the pin 6 and pull out the sleeve
5 Take out the locking screw 7 and press out 65 Remove the oil filler pipe 2 Undo the screws
the shaft the bearings the spacer sleeve and and take the gearwheel off Knock out the lock
the sealing rings ing pin 3 and take off the sleeve 4 Take out
the locking screw 1 and press out the shaft
Fit new sealing rings and replace any parts that
the bearings the spacer sleeve and the sealing
are worn or damaged Pack the bearings in with
grease and refit the parts
Fit the new sealing rings and replace any parts
that are worn or damaged Pack the bearings in
with grease and refit the parts
new gaskets sealing rings sealing washers and
lock washers Grease or oil the sealing rings and oil
moving parts before 68 Fit the crankshaft in the crankcase Ensure that
the hole for the centre bearing locating screw
lines up with the hole in the crankcase MD11
Make sure that the lug on the thrust washer fits
into the recess in the Fit the centre bearing or bearings on the crank
shaft NOTE Turn the bearing the right way
round so that the locating screw in the crank
case fits into the hole 2 in the centre bearing 69 Replace the Oring on the centre bearing locat
1 oil passage 2 hole for locating screw ing screw Windon a little tape
and apply Permatex to the outside Screw the
locating screw in so that it bottoms properly and
then loosen it by half a turn
70 MD11 Replace both Orings on the bearing
67 MD11 Smear the two thrust washers with shield see illustration Replace the crankshaft
grease and fit one of them on the crankshaft sealing ring Stick a small piece of tape over the
turning the flat side towards the rear main bear keyway in the crankshaft and fit the bearing
ing timing gear side The other washer is fitted shield
in point 74 MD17 Stick a small piece of tape over the key
way in the crankshaft and fit a new sealing ring
74 Place the engine so that it is resting on the fly
wheel Make sure that the inner thrust washer is
correctly located Place the outer thrust washer
71 Fit the starter motor and the oil pump NOTE
on the crankshaft with the flat surface towards
Put a little oil into the pump before fitting
the main bearing Fit the distance washer with
MD11 Fit the front engine brackets the flat surface toward the thrust Fit the key and the flywheel the taper must be
perfectly clean Tightening torque 500 Nm 50 75 Fit the key for the crankshaft drive Heat the
kpm 369 lbfft Lock the nut by bending up gearwheel to about 100C 212F and fit it onto
the washer the crankshaft Check to make sure that the in
ner thrust washer does not move from its cor
rect GEAR
73 MD17 Smear both thrust washers with grease
and place one of them on the inner side of the
bearing shield turning the flat side towards the 76 Fit the camshaft and ensure that the oil pump
main bearing Ensure that the lug on the washer shaft fits into the slot in the camshaft Lock the
fits into the recess in the shield Fit the bearing screws with the lock washers MD17 Note the
shield onto the engine and tighten the screws location of the oil passage
77 Fit the camshaft drive key Heat the gearwheel 80 Fit the centrifugal governor Tighten the
to about 100C 212F and fit it so that the sockethead screw on the side NOTE Make
markings coincide Fit the camshaft key sure that the screw locates in the groove Check
that the pin 1 slides freely in the shaft MD17
Fit the sea water pump Fit the cam disc and the left hand threaded
screwnut to the camshaft Tightening torque 70
Nm 7 kpm 50 lbfft for MD11 and 320 Nm
32 kpm 231 lbfft for MD17 Check the end
play This should be 005015 mm
81A MD11C and MD17C Fit the timing gear Fit the key for the reverse gear drive in crankshaft keyway on the reverse gear
side Heat the drive to about
150C 302F and fit it onto the crankshaft Fit
the large washer and the lock washer and
tighten the screw with a torque wrench Use a
counterhold in the flywheel
Tightening torque
MD11C and D 70 Nm 7 kpm 50 lbfft
MD17C 120 Nm 12 kpm 87 lbfft
MD17D 110 Nm 11 kpm 80 lbfft
NOTE At this torque the crankshaft drive is
also completely tightened Check the crankshaft
axial play which should be 008035 mm
Bend the lock washer against 81B MD11D and MD17D Fit the timing gear cover
the head of the screw Cengines see 81A D
engines see 81 B
82 Fit the oil pipes for the rocker arm mechanism
Fit the oil pressure switch and a new oil filter
MD11 Fit the oil strainer NOTE Apply Perma
tex to the filters sealing surface and threads
and tighten the cover firmly use a torque 84 Place the sealing rings into the cylinder grooves
wrench so that no air can get in and upset the and under the liner collar 1 yellow Oring 2
lubrication NOTE Dont forget the gasket black Oring and 3 black Oring narrow
Smear the rings with grease
Tightening torque
MD11C 70 Nm 7 kpm 50 lbfft tool 884714
MD11D 120 Nm 12 kpm 87 lbfft wrench
width 30 mm AND CYLINDER Grease and fit the sealing ring yellow Oring for
each respective cylinder liner in the groove in
the crankcase 1 Place new shims on the 85 Place the liner with the collar against a support
crankcase face If the cylinder liners are not and put the cylinder onto the liner Press down
being replaced the equivalent shim thickness by hand until the collar rests against the counter
which corresponds to the figure stamped on the bore in the cylinder Make sure that the sealing
crankcase surface for each respective cylinder rings are not forced out of position during this
2 can be selected The marking can be in the operation
form of punch marks or figures which represent
110 mm 0004 If new cylinder liners are fit
ted fit one 02 mm 0008 and one 03 mm
0012 shim for each cylinder Later when
carrying out control measurements one of the
shims may be removed if necessary after
having been clipped Fit the valve tappets
88 Heat the pistons to about 100C 212F As
semble the pistons and connecting rods as
86 Fit the sealing rings for the pushrods and oil shown in the pipe channels The rings should be turned so
that the narrow edges seal against the crank
case Smear a little grease on the rings
89 Fit the piston rings using piston ring pliers It is
immaterial which way up the upper ring and the
oil scraper ring are fitted but the other rings are
marked Top
Turn the rings so that the gaps are 90 Fit the pistons with the special tool 2823 This is
the same as that used for the B20 and B30 en
87 Place the cylinders on the crankcase gines Fit piston No 1 nearest to the timing
gear NOTE The recess in the top of the piston
must come immediately under the 94 The value of 025 mm 00098
to tk in the illustration is added to the dimen
91 Fit the bigend bearing caps so that the engine sion A Dimension B is subtracted from the
markings agree NOTE New nuts and bolts result of this addition The clearance S ob
should be used when assembling tained should be 0809 mm
If necessary adjust the clearance with the
Tightening torque 65 Nm 65 kpm 47 lbfft
shims under the cylinder
Example A 440 mm 0173
B 353 mm 0139
S A025B A001B
S 112 mm
Allowable clearace 0809 mm
00315 to 00354
In this case a shims of 03 mm 0012 is removed
so that S becomes 11203 082 mm
00440012 0032
92 Press the cylinder liner down with tool 884622
and measure the distance A from the liner col
lar to the piston in the top dead centre position
See also Point 94
95 Fit new cylinder head gaskets Make sure that
the stud bolts are screwed in Measure the distance B from the downward
projecting part of the cylinder head to the seal
ing plane See also Point 94 96 Put the cylinder heads on and fit new nuts but
do not tighten them
ADJUSTING THE VALVE Fit the exhaust manifold but only tighten it up
enough to align the cylinder heads NOTE
Make sure that the gaskets are the right way
Valve clearance with the engine hot
Inlet 030 mm 00118
Exhaust 035 mm 00138
100 Turn the engine over in the correct direction of
rotation until the valves for one cylinder rock
Then turn through a further revolution and adjust
the valves for this cylinder Do the same for the
other cylinders After a trial run the valves
should be readjusted whilst the engine is still
98 Tighten the cylinder head nuts in stages of 30
80 and 110 Nm 3 8 11 kpm 22 58 80
lbfft Tighten the exhaust 101 Fit the rocker arm covers and check the decom
pression device as follows
A Remove the oil filler plugs
B Turn the engine over so that the exhaust valve
is closed
C Place the handle so that it points upwards
D Loosen the lock nut and screw the adjusting
99 Check the straightness of the push rods
screw upwards Screw the adjusting screw down
Roll the rods on a flat surface Bent push rods again so that it touches the rocker arm Screw
must be replaced down a further half turn and tighten the lock nut
Fit the push rods and the rocker arm bearing Replace the oil filler plugs
brackets Connect the oil pipes to the rocker
NOTE The decompression device is not adjustable
arm shafts
102 Fit the crankcase breather and the hand starter
where applicable
NOTE After fitting the hand starter check that
there is backlash between its gearwheel and the
drive on the camshaft in the case of MD17 the
check is made through the cover on the hand
starter If there is no clearance the number of 104A Clean the mating surfaces on the pump and the
gaskets under the hand starter is increased until timing gear cover Remove the plastic foil from
a noticeable clearance is obtained the new gasket and place the gasket on the
B Measure the distance from the timing gear cover
to the base circle of the pump cam the cam
should be turned towards the crankshaft It is
important that the distance should be 82802
mm inclusive of gasket to ensure
correct injection angle setting If the distance is
too small increase the number of gaskets Each
gasket is 020 mm 00079 thick
If the distance is too great larger rollers must
be fitted to the pump element lifters These roll
ers are available in sizes differing by 012 mm
00047 in diameter NOTE If a pump has roll
ers of different sizes the diameter of each roller
should be increased by the same MD11 Fit the inspection covers on the crank
MD17 Fit the oil strainer NOTE Oil the sealing
rings and place them on the ends of the pipe as
shown in the illustration Press the oil pipe into
the strainer housing first and then into the crank
case Fit the oil sump Tighten the plug 1 on
certain engines
105 Remove the inspection cover on the timing gear
cover and fit the injection pump Make sure that
the pin on the control rod is correctly fitted in the
governor lever
CHECKING THE CONTROL ROD A rough adjustment of the injection quantity can
be made as follows
A Measure the distance A from the timing gear 109 MD11 Fit the belt pulley on the flywheel certain
cover to the control rod when this is completely models
pressed in towards the front of the engine MD11 MD17 Fit the alternator and the Vbelt
B Repeat the measurement with the control rod in Connect all electrical cables MD17 Fit the belt
the backward position NOTE The cold starting guard earlier models
device must not be engaged when taking this
measurement With the MD17 the cold starting
device is disengaged by placing the tool 833839
on the pin C and pushing forward
C The difference between the two dimensions should
MD11 7101 mm MD17 6701 mm If there is a dimension stamped on the pump
flange this applies If necessary adjust by means
of the screw B Replace the inspection cover
110 Close the cooling water draincocks Fit the air
Fit the feed pump and the sea water pump
NOTE Dont forget to fit the carrier for the sea wa
ter pump on MD17 Mount the coolant pipe be
tween the pump and the exhaust Replace the fuel filter Fit the injectors tightening
111 Fill with lubricating oil to the correct level See
torque 20 Nm 2 kpm 145 lbfft Fit all fuel
Technical Data for quantity and grade NOTE Do
pipes and the lifting eyebolts
not fill so quickly so as to cause blockage of the
To prevent the injectors seizing it is advisable to ventilation hole 1 later models
spray them with antirust agent prior to THE FUEL SYSTEM
MD11C and MD17C
115 Unscrew the injector delivery pipe nuts push
the stop control in and set the speed control to
112 Unscrew the venting screw on the fuel filter by full revolutions Press down the cold start button
about 4 turns Watch out for fuel spillage on MD11 Turn the engine over with the starter
motor until fuel comes out of the delivery pipes
Tighten the delivery pipe nuts and start the en
MD11D and MD17D
1 Open the vent screw 1 above on the fine filter
113 Pump fuel out with the hand pump until fuel Watch out for fuel spillage Use pieces of rag
comes out without air bubbles Close the vent for example at the point of ventilation
screw If the pump does not work well turn the
2 Pump out fuel with the help of the hand pump 2
engine over slightly so as to change the position
below until the fuel comes out without air
of the pump driving cam
bubbles Close the vent screw If the pump does
not work well turn the engine over slightly so as
to change the position of the pump driving cam
Open the vent screw on the injection pump 3 above
and pump out clean fuel without air Close the vent
screw and open the return pipe screw pressure equal
izing valve one turn 4 above Pump out clean fuel
without air and close the return pipe screw Loosen
each injector delivery pipe nut and turn the engine
over with the starter motor until fuel comes out
Tighten the delivery pipe nut Start the Open the vent screw on the injector pump about
2 turns Pump with hand pump until the fuel
comes out without air bubbles Close the vent
screw while pumping
116B Feed pump 2 hand pump
CHECKING THE INJECTION ANGLE ADJUSTING ENGINE Unscrew the rear delivery pipe on the injection
pump nearest the reverse gear and fit a Wilbr
pipe or the level pipe 9993197
120A Allow the engine to warm up and then set the
low idling speed adjusting screw 2 so that di
mension A in the diagram is 14 mm 0551
B Start the engine and loosen the lock screw
1 on the lever
C Turn the lever against the stop 2 Then us
ing a screwdriver turn the governor shaft so as
to obtain a speed of 125135 rs 750810 r
min Tighten the levers lock screw in this posi
118 MD11 Set the speed control to max NOTE D Turn the lever up to the adjusting screw 3
The cold start device must not be engaged and check the high idling speed which should
MD17 Remove the inspection cover on the tim be MD11C 17C 44 rs 2640 rmin MD11D
ing gear cover Push the cold start pin forward 17D 46 rs 2760 rmin for pleasure use and 42
using the tool 833839 at the same time as the rs 2520 rmin for HD variant Adjust the speed
speed control is set to max if Turn the engine over in the direction of rotation
until the level pipe is filled with airfree fuel
Open the level screw on the Wilbr pipe so that
the level lies at 2530 mm 112 measured up
wards Turn the engine over slowly until the fuel
just begins to rise in the pipe The angle mark
ings on the flywheel should now be at 2426
BTDC Adjust the injection angle if necessary
by increasing or reducing the number of gaskets
under the injection pump
MD11 use tool 884595 MD17 mark on the belt
guard or use tool 3 When starting with the aid of an auxiliary bat
tery first check to make sure that the auxiliary
The following applies to engines fitted with alternators
battery has the same rated voltage as the
1 Never interrupt the circuit between the alternator standard battery Connect the auxiliary battery
and the battery while the engine is running to the standard battery with positive to positive
Otherwise the charging regulator will be ruined and negative to negative Remove the auxiliary
If a main switch is fitted it must not be battery when the engine has started NOTE On
switched off until the engine has stopped Other no account must the cables to the standard bat
wise no cable must be disconnected while the tery be disconnected in this operation
engine is running since this can also ruin the 4 When carrying out electrical welding on the en
charging regulator gine or installation components the charging
2 Check regularly the battery battery cables and regulator cables must first be disconnected and
cable terminals The battery poles should be insulated Both the battery cables must also be
well cleaned and the terminals tightened and wellgreased to ensure continuous function All 5 Before carrying out any
repairs on the alternator
cables in general must be and dry equipment always first disconnect both the bat
and sprayed with moisture inhibiting spray tery cables The same applies if the battery has
NOTE On no account must the batterys posi to be rapidly charged
tive and negative poles be mixed up when the 6 Never test any of the components with a screw
battery is fitted driver or similar tool against a connection to see
if there is any spark
1 Temperature gauge
2 Revolution counter
3 Charging warning lamp
4 Oil pressure warning lamp
5 Key switch
6 Switch instrument lighting
7 Switch extra equipment
8 Connector
9 Starter motor
10 Fuse box
12 Main switch
13 Engine speed sender
14 Oil pressure sender
15 Temperature sender
Symb Colour mm 2 AWG
A White 6 9
B Black 15 15
B Black 06 19
C Red 6 9
C Red 35 1
C Red 06 19
C Red 25 13
D Grey 15 15
F Yellow 15 15
G Brown 15 15
H Blue 4 11
H Blue 35 1
H Blue 15 15
J Green 15 15
J Green 06 19
Fault finding table
Engine Engine Engine does not Engine runs Engine CAUSE OF TROUBLE
does stops reach correct irregularly becomes
not start working or vibrates abnormally
speed on full abnormally hot
X Stop control not pressed in
Main switch not closed Battery
discharged Break in cable or
main fuse block
X X Fuel tank empty Fuel cock
closed Fuel filter blocked
X X X Water or impurities in fuel
Faulty injectors Air in fuel sys
X Faulty rev counter Boat loaded
abnormally Air cleaner
blocked Fouling on boat bot
X X Incorrect engine aligning Pro
peller damaged
X Obstruction in cooling water in
take or cooling jackets
Seawater pump impeller fault
Thermostat tools
833839 Tool for disengaging the cold starting device
when setting the control rod travel MD17
884077 Drift for assembling injector sleeve
884078 Puller for flywheel carrier Dengines and crank
884081 Injector sleeve 884085 Flaring tool injector sleeve
884489 Tool for removing and fitting of main 884497 Drift for assembling valve sealing rings
884499 Drift for assembling valve guides
884560 Drift for removing and fitting rocker arm bear
884742 Drift for assembling bearings onto sea water
pump shaft MD17
884714 Key for oil strainer MD11C
884581 Fixture for attaching engine to stand MD17
Use together with engine stand 9992520 and at
tachment flange 884583
884604 Fixture for attaching engine to stand MD11
Use together with engine stand 9992520 at
tachment flange 884583 and attachment screw
884579 Tool for dismantling oil MD11 Tool for checking injection pump setting
884741 MD17
884622 Pressing tool for fitting of cylinder liners
9991459 Drift for removing valve guides
9992823 Piston assembly ring standard 9993197 Level tube for injection pump setting
9994128 Valve guide designation MD11C MD11D MD17C at 417 rs 2500 rmin 17 kW 23 hp
26 kW 35 hp
at 50 rs 3000 rmin 184 kW 265 kW
25 hp 36 hp
Output2 at 383 rs 2300 rmin HDengine 15 kW 15 kW 22 kW 22 kW
20 hp 20 hp 30 hp 30 hp
MD11DMSB Output2 at 417 rs 2500 rmin 17 kW 23 hp
Number of cylinders 2 2 3 3
Bore mm in 889 mm 35
Stroke mm in 90 mm dm3 cuin 112 dm3 168 dm3
6835 cuin 10251 ratio pressure at starter motor speed
3342 rs 200250 rmin 225 MPa 2025 kpcm2 284355 of rotation viewed from flywheel
speed idling overspeed 2700 3300 2700 3300
2800 rmin 3350 rmin 2800 rmin 3350 rmin
Heavy duty engine 2500 2800 2500 2800
2600 rmin 2900 rmin 2600 rmin 2900 rmin
Low speed idling 750810 Cast iron
8890 mm mm
354 00002
cylinder bore 88788880 mm total mm in 98 mm from centre of gudgeon pin to top of piston mm
in 65 mm clearance in cylinder liner mm in 009013 mm PINS
Diameter mm in 280028004 mm pin bearing diameter mm in 2801428025 mm gudgeon pin
bearing Close running fit
PISTON rings number 3
Oil rings number 1
The upper compression ring is chrome ring axial clearance in groove
1st compression ring 008011 mm 0060092 mm 0030062 mm ring
0030062 mm ring gap measured in cylinder liner
1st compression ring 040055 mm and 3rd 030045 mm ring 025040 mm Propeller
shaft output DIN 6270 Leistung B fr Propeller shaft output for runin engines with reverse gear DIN 6270 Leistung B fr
Material Specially alloy AND axial clearance mm in 008035 mm bearings radial clearance mm in
00380100 mm bearings radial clearance mm in 00540099 mm BEARING 6664666665 mm mm undersize 0010
6639266411 mm mm undersize 0020 6613866157 mm
0762 mm undersize 0030 6588465903 mm BEARING mm in 21362145 mm mm oversize 0010 22632272 mm
mm oversize 0020 23902399 mm mm oversize 0030 25172526 mm BEARING mm in 5396653985 mm mm
undersize 0010 5371253731 mm mm undersize 0020 5345853477 mm mm undersize 0030
5320453223 mm BEARING mm in 13841391 mm mm oversize 0010 15111518 mm mm oversize 0020
16381645 mm mm oversize 0030 17651772 mm ROD
Axial clearance at crankshaft mm in 005025 mm clearance 005015 mm clearance in bearing
003009 mm journals diameter
No 1 3170031725 mm 2 4697547000 mm 3 4897549000 mm 4 MD17 5497055000 mm bearings are reamed
after pressing in
Cam lift mm in 575585 mm disc diameter 38 mm diameter mm in 79557970 mm seat angle
head seat angle 450
Seat width in cylinder head mm in ca 10 mm engine warm mm in 030 mm
Valve disc diameter mm in 34 mm diameter mm in 79507965 mm seat angle
head seat angle 450
Seat width in cylinder head mm in ca 10 mm engine warm mm in 035 mm DEVICE
Max downward pressing of exhaust valve
not adjustable on Dengines mm in 05 mm inlet mm in 59 mm mm in
52 mm diameter after assembly and reaming mm in 80 mm8015 mm above cylinder head spring
surface 18 mm valve stemguide
inlet 003006 mm exhaust 003007 mm SPRINGS
Free length unloaded 50 mm with 30020 N 302 kp 66139441 lbf 39 mm
56030 N 563 kp 123566 lbf 32 mm SYSTEM
Oil capacity engine inclination 0
For inclined engines fill oil to the upper mark on dipstick
Engine excl filter 26 dm3 44 dm3
07 US galls 06 UK galls 116 US galls 096 UK galls
incl filter 285 dm3 465 dm3
075 US galls 063 UK galls 123 US galls 102 UK galls
Engine incl RB reverse gear excl filter 30 dm3 48 dm3
079 US galls 066 UK galls 127 US galls 105 UK galls
incl filter 325 dm3 505 dm3
086 US galls 071 UK galls 133 US galls 11 UK galls
Oil quality ace to APIsystem diesel lubricating oil
service CD 10C 50F Volvo Penta CD oil Double grade SAE 20W30
under 10C 50F Volvo Penta CD oil Single grade SAE 10W
Oil pressure warm engine idle speed 0102 MPa 12 kpcm2 1428 psi
full speed 0203 MPa 23 kpcm2 2843 OIL PUMP
Type Gear
Spring for reducing valve
Free length unloaded 40 mm 158
loaded with 252 N 2502 kp 55044 lbf 34 mm 134
352 N 3502 kp 77044 lbf 315 mm 124
Axial gear clearance incl gasket 003015 mm pump manufacturer manufacturer Bosch hole diameter
4 st 027 mm pressure MPa 170 08 246 08 170 08 245 08
0 0 0 0
kpcm2 170 8 245 8 170 8 8
0 0 0 0
114 114 114 114
psi 2418 3485 24180 3485
0 0 0
Injection angle BTDC 2426 245265 2426 quantity 3536 mm3stroke at 20C 68F and 165 rs
1000 rmin pump 3334 mm3stroke at 20C 68F and 165 rs
1000 rmin pump speed
Type type Filter insert
Feed pressure at 42 rs 2520 rmin 6585 kPa 065085 kpcm2 925121 voltage 12 V
Battery capacity pleasure use starter motor battery max 70 Ah max 90 Ah
HD variant starter motor battery max 90 Ah max 90 Ah
Starter motor output
pleasure use 11 kW 147 hp 19 kW 255 hp
HD variant 19 kW 255 hp 19 kW 255 MD11C MD17C 35 A 490 W
MD11D MD17D 50 A 700 W
Battery electrolyte specific gravity
Fully charged battery 12751285 gcm3 lbin3
Battery to be recharged at 1230 gcm3 00444 type Bellows Replaceable with wax type
WAX from and including engine no 49685 15740
Begins to open at 60C 140F
Fully open at 74C 165F
HDHE engine
Begins to open at 74C 165F
Fully open at 89C 192F
WEAR liners and pistons should be replaced when
025 mm 0010 wear can be outofround on main and journals max 006 mm taper on main and journals max
005 mm crankshaft end play 045 mm stem max permissible wear 002 mm clearance
between valve stem and valve guides
Inlet valves 015 mm valves 017 mm valve disc edge shall be at least 15
mm from valve disc new valve to the cylinder
head face max 25 mm permissible wear in bearing journals
and bearings 005 mm TORQUES MD11C and D
MD17C and D
Cylinder head nuts 110 Nm 11 kpm 80 bearing 70 Nm 70 kpm 50 bearings 65 Nm 65 kpm 47 for
main bearings 40 Nm 40 kpm 29 for carrier and carrier drive on reverse gear 70 Nm 70 kpm 120 Nm 120 kpm
50 lbfft 87 110 Nm 110 kpm Deng
80 nut 500 Nm 50 kpm 369 20 Nm 20 kpm 145 for water pump 70 Nm 70 kpm 320 Nm 320
50 lbfft 231 lbfft
Cap nuts for valve cover 15 Nm 15 kpm 11 for oil filter 40 Nm 40 kpm 29 for oil strainer MD11 C
70 Nm 70 kpm
50 lbfft
MD11 D 120 Nm 120 kpm
87 lbfft
NOTE Tightening shall be carried out in 3 stages
1st stage 30 Nm 3 kpm 22 lbfft
2nd stage 80 Nm 8 kpm 58 stage 110 Nm 11 kpm 80 SKETCH
1 Reverse gear
2 Sea water pump
3 Thermostat
4 Thermostat housing
Report form
Do you have any complaints or other comments about this manual Please make a
copy of this page write your comments down and post it to us The address is at
the bottom of the page We would prefer you to write in English or to publication no Issued
Name AB Volvo Penta
Customer Support
Dept 42200
SE405 08 Gothenburg
English 091998

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