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Volvo Penta Md6a Md7a Workshop Manual




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Workshop Manual A
Engine unit 2 0
MD6A MD7A
AB Volvo Support
Dept 42200
SE405 08 Workshop Manual
Marine diesel engines
MD6A MD7A
Precautions 2
General information 5
Repair methods 8
MD7A 9
Repair instructions system 30
Special Tools 34
Technical Data 35
Safety Check that the warning information decals on
This workshop manual contains technical data the product are always clearly and repair instructions for Volvo Penta Replace
decals that have been damaged or
products or product versions contained in the contents painted over
list Ensure that the correct workshop literature is being
used Engine with turbocharger Never start the en
Read the safety information and the Workshop gine without installing the air cleaner ACL
Manual General Information and Repair The rotating compressor in the Turbo carefully before starting work cause
serious personal injury Foreign
objects entering the intake ducts can also
cause mechanical this book and on the engine you will find the
Never use start spray or similar to start the
following special warning symbols
engine The starter element may cause an
explosion in the inlet manifold Danger of
WARNING If these instructions are not
personal injury
followed there is a danger of personal injury
extensive damage to the product or serious
Avoid opening the filler cap for engine
mechanical malfunction
coolant system freshwater cooled engines
when the engine is still hot Steam or hot
IMPORTANT Used to draw your attention to
coolant can spray out Open the coolant filler
something that can cause damage product
cap carefully and slowly to release pressure
malfunction or damage to property
before removing the cap completely Take
great care if a cock plug or engine coolant
NOTE Used to draw your attention to important
line must be removed from a hot engine It that will facilitate work or operations
difficult to anticipate in which direction steam
or hot coolant can spray out
Below is a summary of the risks and safety should always observe or carry out when operating
Hot oil can cause burns Avoid skin contact
or servicing the engine
with hot oil Ensure that the lubrication
system is not under pressure before
Immobilize the engine by turning off the power
commencing work on it Never start or
supply to the engine at the main switches and
operate the engine with the oil filler cap
lock it them in the OFF position before
removed otherwise oil could be ejected
starting work Set up a warning notice at the
engine control point or helm
Stop the engine and close the sea cock
before carrying out operations on the engine
Generally all servicing should be carried out
cooling system
with the engine switched off Some work
carrying out certain adjustments for example
Only start the engine in a requires the engine to be running Approaching
area If operating the engine in an enclosed
a running engine is dangerous Loose clothing
space ensure that exhaust gases and
or long hair can fasten in rotating parts and
crankcase ventilation emissions are
cause serious personal injury
ventilated out of the working area
If working in proximity to a running engine
careless movements or a dropped tool can
result in 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 engine is running or has been
turned off immediately prior to starting work on
it Reinstall all protective parts removed during
service operations before starting the engine
Always use protective goggles where there is a Store oil and fuelsoaked rags and fuel and
danger of pieces of metal sparks from oil filters safely In certain conditions acid or other chemicals being thrown soaked rags can
spontaneously ignite Used
into your eyes Your eyes are very sensitive fuel and oil filters are can lead to loss of sight dangerous waste and must be
deposited at
an approved site for destruction together with
Avoid skin contact with oil Longterm or used lubricating oil contaminated fuel contact with oil can remove the remnants solvent
degreasing agents and
natural oils from your skin The result can be waste from washing dry skin eczema and other Used oil is more dangerous to health Never
allow a naked flame or electric sparks
than new oil Use protective gloves and avoid near the batteries Never smoke in oilsoaked clothes and rags Wash to the batteries The
batteries give especially before meals Use the hydrogen gas during charging which when
correct barrier cream to prevent dry skin and to mixed with air can form an explosive gas
make cleaning your skin easier oxyhydrogen This gas is easily ignited and
highly volatile Incorrect connection of the
Most chemicals used in products engine and battery can cause a spark which is oils glycol petrol and diesel oil to cause an explosion with
resulting damage
and workshop chemicals solvents and paints Do not disturb battery connections when
are hazardous to health Read the instructions starting the engine spark risk and do not
on the product packaging carefully Always fol lean over safety instructions using breathing appara
tus protective goggles and gloves for exam Never mix up the positive and Ensure that other personnel are not battery terminals when
installing exposed to hazardous substances installation can result in serious damage to
by breathing them in for example Ensure that electrical equipment Refer to is good Handle used and excess according to
Always use protective goggles when
Be extremely careful when tracing leaks in the charging and handling batteries The battery
fuel system and testing fuel injection nozzles electrolyte contains extremely corrosive
Use protective goggles The jet ejected from a sulfuric acid If this comes into contact with
fuel injection nozzle is under very high pres the skin wash immediately with soap and
sure it can penetrate body tissue and cause plenty of water If battery acid comes into
serious injury There is a danger of blood contact with the eyes immediately flush copious amounts
of water and obtain
medical fuels and many chemicals are that a naked flame or sparks cannot ig Turn off the engine and turn off power at
nite fuel or chemicals Combined with air in cer main switches before carrying out work on
tain ratios petrol some solvents and hydrogen the electrical system
from batteries are easily inflammable Smoking is prohibited Ensure that Clutch adjustments must be carried out is good and that the necessary
the engine turned off
safety precautions have been taken out welding or grinding work Always
have a fire extinguisher to hand in 3
Use the lifting eyes mounted on the enginere When working onboard ensure that there is
verse gear when lifting the drive unit sufficient space to remove check that lifting equipment is in good without danger of
injury or and has sufficient load capacity to lift
the engine engine weight including reverse Components in the electrical system ignition
gear and any extra equipment installed system gasoline engines and fuel system
To ensure safe handling and to avoid on Volvo Penta products are designed and
damaging engine components on top of the constructed to minimize the risk of fire and
engine use a lifting beam to raise the engine explosion The engine must not be run in
All chains and cables should run parallel to areas where there are explosive other and as perpendicular as possible in
relation to the top of the engine Always use fuels recommended by Volvo
If extra equipment is installed on the engine al Penta Refer to the Instruction Book The use
tering its center of gravity a special lifting de of lower quality fuels can damage the
vice is required to achieve the correct balance engine On a diesel engine poor quality fuel
for safe handling can cause the control rod to seize and the
Never carry out work on an engine suspended engine to overrev with the resulting risk of
on a hoist damage to the engine and personal injury
Poor fuel quality can also lead to higher
Never remove heavy components alone even maintenance costs
where secure lifting equipment such as
secured blocks are being used Even where
lifting equipment is being used it is best to carry
out the work with two people one to operate
the lifting equipment and the other to ensure
that components are not trapped and damaged
when being lifted
General the workshop manual Certified engines
This workshop manual contains technical specifica The manufacturer guarantees that certified new and
tion descriptions and instructions for repairing the currently operational engines meet national and re
standard versions of the following engines gional environmental regulations in Lake TAMD31L TAMD31P AD31L AD31P
for example The product must be the same as the
KAD32P TAMD41H TAMD41M TAMD41P AD41P example approved for certification purposes So KAMD42A KAMD42B KAMD42P
Volvo Penta as a manufacturer can guarantee that
KAD42A KAD42B KAD42P KAMD43P KAD43P currently operational engines meet KAD44P The workshop manual displays
regulations the following service and operations carried out on any of the engines part requirements must be As a result the
illustrations and pictures in the
manual that show certain parts on the engines do The Service Intervals and maintenance in some cases apply to all the engines listed
recommended by Volvo Penta must be However the repair and service are the same in all essential details Only Volvo Penta
genuine replacement parts in
Where they are not the same this is stated in the tended for the certificated engine may be used
manual and where the difference is considerable are described separately Engine The servicing of ignition timing and fuel and
numbers are given on the number systems gasoline or injector pumps pump set
plate See Workshop manual Group 21 Engine page tings and injectors diesel must always be carried
15 The engine designation and number should be out be an authorized Volvo Penta in all about the engine
The engine must not be modified in any way apart
This Workshop Manual has been developed primarily from with accessories and service kits developed
for Volvo Penta service workshops and qualified per for it by Volvo Persons using this book are assumed to
have a grounding in marine drive systems and be No modifications to the exhaust pipes and air
able to carry out related mechanical and electrical supply ducts for the engine room
ducts may be undertaken as this may effect ex
haust Penta is continuously developing their prod
ucts We therefore reserve the right to make chang Seals may only be broken by authorized person
es All the information contained in this book is based nel
on product data available at the time of going to print
Any essential changes or modifications introduced IMPORTANT Use only Volvo Penta Genuine
into production or updated or revised service introduced after the date of publication will Use of nonoriginal AB Volvo
Penta spare
be provided in the form of Service Bulletins parts will result in AB Volvo Penta being un
able to assume liability for the engine meet
ing engine certification Any type of damage resulting from the use parts
nonoriginal Volvo Penta replacement parts for
the product will not be covered under any parts for electrical and fuel systems are ranty provided by AB Volvo 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 5
Repair methods
The working methods described in the Service Our joint apply to work carried out in a workshop The
engine has been removed from the boat and is Each engine consists of many connected in an engine fixture Unless otherwise stated
and components If a component deviates from work which can be carried out with the technical specification the environmental impact of
engine in place follows the same working method an otherwise good engine may be increased
It is therefore vital that wear symbols occurring in the Workshop Manual are maintained that systems that can be adjusted
for their meaning see Safety in formation are adjusted properly and that Volvo Penta Genuine
WARNING Parts as used The engine Maintenance Schedule
must be followed
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 impossi ponents are sealed at the factory for to predict every circumstance under which
reasons No work should be carried out on work or repairs may be carried out For this components except by authorized we can only
highlight the risks that can arise
when work is carried out incorrectly in a well Bear in mind that most chemicals used on boats are
equipped workshop using working methods and tools harmful to the environment if used incorrectly by us
Penta recommends the use of biodegradable de
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 us special care when working onboard that oil and
ing these Special tools are developed to rationalize waste is taken for destruction and is not methods and make procedures as safe as
pumped into the environment with bilge It is therefore the of any per
son using tools or working methods other than the Tightening torques
ones recommended by us to ensure that there is no Tightening torques for vital joints that must be tight
danger of injury damage or malfunction resulting ened with a torque wrench are listed in workshop
from these manual Technical Data Tightening Torques and
are contained in work descriptions in this Manual All
In some cases there may be special safety precau torques apply for cleaned threads screw heads and
tions and instructions for the use of tools and chemi mating surfaces Torques apply for lightly oiled or dry
cals contained in this Workshop Manual These spe threads If lubricants locking fluid or sealing com
cial instructions should always be followed if there pound are required for a screwed joint this
are no separate instructions in the Workshop information will be contained in the work
and in Tightening Torques Where no tightening
torque is stated for a joint use the general elementary precautions and common sense torques according to the tables below The
prevent most risks arising A clean workplace torques stated are a guide and the joint does not
and engine eliminates much of the danger of injury have to be tightened using a torque wrench
and malfunction
Dimension Tightening Torques
It is of the greatest importance that no dirt or foreign Nm get into the fuel system lubrication system
M5 6 44
intake system turbocharger bearings and seals M6 10 74
when they are being worked on The result can be M8 25 or a shorter operational life
M10 50 369
M12 80 590
M14 140 1033
Tightening angle To ensure service work is correctly carried out it is
tightening important that the correct sealant and locking fluid
type is used on the joint where the agents are re
Tightening using both a torque quired
setting and a protractor angle
requires that first the In this Volvo Penta Service Manual the user will find
recommended torque is applied that each section where these agents are applied in
using a torque wrench and then production states which type was used on the
the recommended angle is engine
added according to the
protractor scale Example a During service operations use the same agent or an
9Q0 protractor tightening alternative from a different means that the joint is
tightened a further 14 turn in Make sure that mating surfaces are dry and free from
one operation after the stated oil grease paint and agent before ap
tightening torque has been plying sealant or locking fluid
applied
Always follow the instructions for use
regarding temperature range curing time and any
other instructions for the Two different basic types of agent are used on the
Do not reuse lock nuts that have been removed dur engine and these are
ing dismantling as they have reduced service life
when reused use new nuts when assembling or re RTV agent Room temperature vulcanizing Use For lock nuts with a plastic insert such as
gaskets sealing gasket joints or coating the tightening torque stated in the table is RTV agent is clearly visible when a component has
reduced if the Nylock nut has the same head height been dismantled old RTV must be removed before
as a standard hexagonal nut without plastic insert the joint is the tightening torque by 25 for bolt size 8
mm or larger Where Nylock nuts are higher or of The following RTV agents are mentioned in the Serv
the same height as a standard hexagonal nut the ice Manual Loctite 574 Volvo Penta torques given in the table apply
Permatex
No 3 Volvo Penta PN 11610995 Permatex No
77 Old sealant can be removed using classes spirits in all cases
Screws and nuts are divided into different strength Anaerobic agents These agents cure in an the class is indicated by the number on the
of air They are used when two solid parts for exam
bolt head A high number indicates stronger material ple cast components are installed facetoface with
for example a bolt marked 109 indicates a higher out a gasket They are also commonly used to se
tolerance than one marked 88 It is therefore cure plugs threads in stud bolts cocks oil that bolts removed during the disassembly
switches and so on The cured material is glasslike
of a bolted joint must be reinstalled in their original and it is therefore colored to make it visible when assembling the joint It a bolt
must be anaerobic agents are extremely resistant to check in the replacement parts catalogue to and the old agent cannot be
removed When
make sure the correct bolt is used reinstalling the part is carefully degreased and then
new sealant is The following anaerobic agents are mentioned in the
Service Manual Loctite 572 white Loctite 241
A number of sealants and locking liquids are used on blue
the engines The agents have varying properties and
are used for different types of jointing strengths oper NOTE Loctite is the registered trademark of Loctite temperature ranges resistance to
oil and other Permatex is the registered trademark of the Permatex
and for the different materials and gap siz
es in the engines
Recess for starting crank
2 Oil filling engine
3 Sealed crankcase Intake silencer
5 Connection fuel inlet
6 Feed pump
7 Reduction reverse gear MS red
1911
8 Control lever reverse gear
9 Oil filling reverse gear
10 Oil pressure contact
11 Lubricating oil filter
12 Fuel filter
14 Watercooled exhaust manifold
15 Decompression handle
16 Injectors
17 Temperature sender
18 Cooling water outlet
19 Thermostat housing
20 Throttle lever
21 Stop lever
22 Fuel injection pump
23 Oil dipstick engine
24 Fuel return line Seawater pump
26 Oil dipstick reverse gear
MD7A
1 Oil dipstick and oil filling reverse gear
2 Cover cooling water pump
3 Bleedscrew fine filter
4 Fine filter
5 Decompression handle
6 Pressure pipe nut
7 Temperature sender
8 Injector
9 Thermostat housing
10 Oil filling engine
11 Hand start
12 Cooling water drain engine
13 Fuel injection pump
14 Oil dipstick engine
15 Cooling water drain reverse gear
16 Air cleaner and intake silencer
17 Sender rev counter
18 Fuel pump with hand pump
19 Cooling water inlet reduction gear
20 Oil drain reverse gear reduction gear
21 Warner low oil pressure
22 Oil filter
Repair the cooling water and oil from the engine Then 3 Remove the thermostat housing 2 bolts and the
clean the outside of the engine Remove the reverse hose clamp under the housing Take the
gear 4 bolts thermostat out of the exhaust manifold Note the
small Oring which seals against the manifold
1 Remove the air cleaner disconnect the
alternator electric cables and the oil pressure
cable remove the alternator and the drive belts
Then remove the seawater pump the oil filter
the fuel filter and the feed pump Look out for
fuel and oil Remove the injectors and pipes as well as the
leakoff oil pipe Discard the sealing washers on
both sides of the leakoff oil pipe 4 Remove the exhaust manifold 4 bolts
5 Remove the rocker arm cover 2 nuts the intake 7 a BOSCH pump Disconnect the pipe from the
manifold 4 bolts the rocker arm 2 nuts and fuel filter and remove the nuts for the fuel
the cylinder head 9 bolts Take care of the injection pump
washers
7 b CAV pump Disconnect the pipe from the fuel
filter and remove the nuts for the fuel injection
pump
6 Remove the cover on which the water pump is
mounted NOTE Two of the five bolts are
shorter than the other three and are placed
towards the centre of the engine Take care of
the control bracket Discard the old gasket
8 Remove the nut which drives the water pump
Use the flywheel as a counterhold Remove the
fuel injection pump and the gear wheel
9 Remove the timing gear cover NOTE The small 11 Knock out the hand starter pin in the camshaft
round cover on which the fuel pump is mounted Remove the protective cover 2 bolts NOTE
has bolts with 3 different lengths The bolts for Scrap the sealing ring and fit a new one
the large casing has two lengths The two bottom
bolts are shorter than the others Carefully lever
loose the timing gear casing from its guide pins
Discard the Remove the flywheel Remove the nut and use a 12 Remove the front cover behind the flywheel 11
puller The axle is tapered and provided with a bolts Note the guide pins Carefully tap all
key Use a counterhold when releasing the nut round Replace the gasket and the sealing ring
13 Remove the sump as well as the nut and lock 15 Remove the bolt for the intermediate gear Dis
washer for the camshaft Use a counterhold on card the sealing washer 1 under the bolt Pull off
the crankshaft the intermediate gear
14 Bend down the lock washer and release the bolt 16 Check that the shaft pin 1 for the intermediate
securing the reverse gear flange to the gear is secure
crankshaft Use a counterhold NOTE Take care
of the key Lever loose the rubber damper with a
17 Remove the gearwheel for the camshaft by tap 19 Invert the engine and remove the oil strainer 2
ping the camshaft on the flywheel side with a bolts and 1 nut
plastic mallet or similar tool Lift out the shaft and
take care of the cover
20 Unscrew the bolts and remove the caps Then
carefully tap out the pistons and connecting rods
Place connection rods and caps in the same pai
ring as when removed to prevent them getting
mixed up if they are not marked NOTE Also
mark the piston and connecting rod for the re
spective cylinders see point 21 On earlier engi
nes there is no marking on the pistons and con
18 Remove the 4 bolts holding the timing gear ca necting rods During overhauling these engines
sing The casing also sits on guides Carefully le must be marked in the same way as those
ver all round and remove the casing produced later on
21 Mark the connecting rod and cap nearest the fly 23 Remove the centre nut and washer for the gear
wheel with a peener Peen as shown in Fig 21 wheel on the lubricating oil pump The shaft is ta
pered and the gear wheel sits on a key
22 Remove the main bearing caps and lubricating
oil pump
The main bearing caps are marked with a 2 or 3
The corresponding figures are punched into the 24 Remove the bolts 4 from the pump body cover
block Replace the axial bearings 1 Check that and lift off the cover Clean the body and check
the guide 2 for the caps is in good condition Lift that the gears are in good condition Replace da
out the crankshaft maged parts
25 Refit the gears as shown in the Fig below Fit 27 Check for wear on pistons piston rings and gud
the cover together with a new gasket Tighten up geon pins Replace if necessary The piston and
the 4 bolts and rotate the shaft to make sure that connecting rod must be matchfitted as shown in
it does not jam Fit the key in its groove and refit fig A Make absolutely certain that the groove
the gear wheel Fit the spring washer and tighten ring for the gudgeon pin is fitted in its groove
up the gear with the nut The piston rings are fitted with a piston ring rod
Begin with the oil ring 1 fig B in the lowest
groove Continue with the compression ring 2
Finally fit the compression ring 3 NOTE The
marking TOP must face upwards The other two
rings can be faced as Remove the bolt 1 for the relief valve and check
that the spring 2 and piston are in good
condition If there is anything suspicious about
the opening pressure of the relief valve check
the data for the spring See under Technical Crankshaft
Data Lubricating oil pump 28 Check the drive gear on the crankshaft for wear
Clean and refit the piston and spring and tighten or damage Remove the drive gear with a puller
up the bolt Remove the key and clean the shaft Check for
wear and grind the shaft if necessary See
under Technical Data Clean the engine block
and all other parts which must be 16
Cylinder head 31 Replacing the valve guides
With excessive clearance between the valve
29 Remove the valve tappets NOTE Carefully stem and valve guide the valve guide must be
machine clean the valve tappets where they replaced See under Technical Data Press
have been smoothed down 1 in order to serve out the valve guides with tool 884538
as a counterhold for the torque wrench Do not
force out the valve tappets as this could damage
the block etc
30 Remove the seals on the valve stems Remove
the valve springs with the help of a valve spring
remover Remove all the collets 1 Remove the
valves IMPORTANT Place the valves in the or
der in which they are removed Discard burnt
valves if the wear is excessive and grind valve
seats if necessary See under Technical Data
Seats and valves must be ground together so
that the contact surfaces will be absolutely tight
32 Fit new valve guides with tool 884549 Use a
press
Removing the nozzle sleeves Installing the valves
33 Insert the expander screw on tool 884541 into 35 Thoroughly clean the cylinder head valve guides
the copper sleeve and screw until and valve seats Use a small brush Check that
the screw has expanded and fastened in the the bevel on the seats is correctly ground by
sleeve Then pull hard so that the threads go into applying marking blue to the bevel on the valve
the copper material Fit the yoke on the stud disc and rotating it against the seat under light
bolts holding the injector Screw on the nut and pressure If the blue is not distributed evenly on
rotate until the sleeve is removed the entire bevel surface of the seat this indicates
a leaky valve grind the valve further and re
check until results are successful The width of
the seat should be approx 1 mm 004
Oil the valve stems before filling them in their re
spective guides IMPORTANT Make sure that
the valves and valve springs are refilled in their
original positions Place the cylinder head on its
edge and fit the valve springs and collets 2 Use
a valve spring tool Finally fit the rubber seal 1
MD6A on the intake Replacing the 0ring which seals between sleeve
and cylinder head
Dip the 0ring in soapy water before fitting it
Wash and blow clean before filling the new
injector sleeve with tool 884539 knock in the
sleeve until it bottoms Check to make sure that
the 0ring is not damaged or has moved
Checking the cylinder head level finish
36 If there is any doubt as to the level finish of the
cylinder head after carrying out repairs check as
follows
Completely disassemble the cylinder head and
clean it thoroughly Measure with the help of a
steel ruler check the ruler against a flat disc by
placing it on the cylinder head face as shown by
the arrows in the diagram below Then measure
with a feeler gauge the gap between the ruler
and the face of the cylinder head at the marked
measuring points A maximum gap of a Oil the spreader tool mm measured crisscross see
884537 and push the diagram below and 000010 mm 000
tool into the sleeve en 0004 measured laterally see diagram below
sure that the bolt is is approved If the measured gap is between
screwed back suffi 010 mm 0004 and 020 mm 0008 then the
ciently Place nuts or gap must be grinded If the gap exceeds 020
washers on the stud mm 0008 replace the cylinder head with a
bolts so that the yoke new one
can be securely attach
ed with nuts Screw the
tool down as far as the
recess in the injector
sleeve allows Thus
pressing out the sleeve
Remove the tool
the injectors Overhauling the feed pump
37 Check the spray pattern at an opening pressure 39 Exert force on the pump lever see Fig If the
2 2
of 180 kpcm 2560 Ibfin Also check that the pump squeaks then it is in good condition If it
fuel jets cease at all four holes does not the diaphragm must be replaced This
and there is no dripping afterwards is done as the opening pressure
38 Adjust the opening pressure with adjuster
washers 1 which are available in different 40 Release the cover centre screw lift out the strai
thicknesses ranging from 1 mm 004 to 195 ner 1 and clean it
mm 008 at intervals of 005 mm 0002
between each washer
Screw apart the injector and replace the adjuster
washer with a thinner or thicker one depending
on whether the pressure has to be reduced or in
creased Screw the injector together again and
check the opening pressure and spray pattern
Continue this procedure until results are satisfac
tory
41 Unscrew the six bolts holding the upper and 43 Undo the screw 1 and pull out the manual pump
lower sections of the pump body together lever 2 and replace the spring 3 if in poor condi
Remove the pump lever spring 1 and unscrew tion NOTE keep an eye on the rubber seal
the screw 2 which holds the pump lever shaft which is pressed into the body
44 Thoroughly clean the pump body and replace
worn parts
Refit the manual pump lever Press the di
aphragm in and fit the pump lever onto the di
aphragm shaft Then insert the shaft and tighten
it with the screw IMPORTANT Do not forget the
washer on the screw
Place the strainer on the upper body section and
screw tight the cover and gasket Assemble the
pump body halves and fit the retaining washer 1
for the spring 2 on the mechanical pump lever 3
42 Press down the diaphragm and shake forwards IMPORTANT The retaining washer can only be
the pump lever shaft 1 until the pump lever loo filled in one way Fit the spring and then the 0
sens Then pull the diaphragm out of the body ring 4 which seals against the engine
the seawater pump 47 Remove the sealing rings 2 and the 0ring 1
earlier engines and clean the pump body and
45 Remove the cover 6 bolts Replace the impeller shaft IMPORTANT The pump must be
with the help of two screwdrivers or similar tools removed from the engine Check to make sure
IMPORTANT Protect the edges on the pump there is no burr on the shaft NOTE A new 0ring
body See Fig below Lever out the impeller with must not be fitted
the screwdrivers so far that the bolt becomes vi
sible
48 Fit new sealing rings IMPORTANT Turn the
sealing rings so that they are in their proper
position and make sure that they do not block
the drain hole in the pump body Grease the shaft
46 Unscrew the bolt and pull the impeller off the and carefully fit it into the body Screw it through
shaft If the sealing rings also have to be repla the sealing rings but make sure the rings are not
ced the shaft can be pulled out entirely together damaged when doing so Place the shaft so far
with the impeller after which the bolt can be rele into the housing that the bolt hole is outside Fit
ased the impeller and screw in the bolt Then carefully
push in the impeller until it bottoms Place a new
gasket on the cover and tighten up with the 6
bolts
Checking the thermostat 51 Oil and fit the bearing halves in the caps Place
the caps according to the marking on the block
49 Lower the thermostat into hot water and with a Fit the remaining axial bearing halves on the
thermometer test to see whether the thermostat intermediate cap with the oil grooves facing
opens and closes at the right temperature It outwards NOTE Fit a new 0ring on the rear
0 0
should start opening at 60 C 140 F and be fully cap which is integrally built with the lubricating oil
open at 74CC 165 F If the thermostat is faulty pump The tightening torque for the main
it must be replaced Clean and fit a new rubber bearings is 50 Nm 5 kpm 36 Ibftf Turn the
gasket 1 on the thermostat Place a new 0ring 2 engine
for the water hole on the lower edge of the
thermostat housing and fit the housing on the
exhaust 52 Turn the piston rings so that their respective
gaps are apart from each other The piston top is
INSTALLING THE ENGINE marked with Front and should point towards the
flywheel NOTE Fit the connecting rod which is
50 Before installing heat the crankshaft drive gear marked with punch pops nearest the flywheel
Place the key in the key slot on the crankshaft Carefully tap the piston downwards through the
and press on the new drive gear installation tool with a wooden handle or similar
Fit new bearing shells Oil the bearings Install Place the engine on its side and tighten up the
the crankshaft Fit an axial bearing half 1 on caps Tightening torque 50 Nm 5 kpm 36
each side of the intermediate main bearing with Ibftf Lock the bolts with the lock washers
the oil grooves 2 facing 22
53 Fit the protective cover for the starting crank 55 Fit a new gasket and install the timing gear
Replace the sealing ring and gasket casing 4 bolts Tap carefully so as not to
deform the guide pins
54 Fit the camshaft Observe due care so that the 56 Fit the key in the camshaft and then the gear
sealing ring in the protective cover for the wheel Turn the gear wheel so that the figure
starting crank is not damaged Knock the which is punched on the ring gear faces
starting crank pin into the camshaft Use a tube outwards Fit the star washer and the nut on the
or similar as a counterhold camshaft Tighten up later on see Point 59
When a new engine block is used a new shaft
pin 1 for the intermediate gear must be fitted
57 Fit the intermediate gear Check that the 59 Install the fuel injection pump Use a new
punchedin figures on the crankshaft drive and gasket Fit the key on the pump shaft and install
camshaft gear wheel coincide with the marking the gear wheel IMPORTANT The figure must
on the intermediate gear face towards the figure on the intermediate gear
Tighten up the gear wheel with the nut which
also functions as a flange for the water pump
Tightening torque 60 Nm 6 kpm 43 Ibftf
Use a counterhold
Tighten the camshaft nut Remove the counter
hold
60 Fit the cylinder head gasket It can only be fitted
58 Place the large flat washer on the intermediate in one way If the stud bolts in the cylinder head
gear with the bevel facing outwards and must be replaced fit the new ones to a torque of
thereafter the steelrubber washer 1 Tighten 20 Nm 2 kpm 14 Ibffi Fit the cylinder head
with the bolt NOTE On earlier engines a plastic All the nuts must have washers under them
washer is used This must be scrapped and except the one on which the lift eyelet is filled
replaced by the steelrubber one Tightening torque 70 Nm 7 kpm 50 Ibm
NOTE Tightening is in three stages
First stage 10 Nm 1 kpm 7 Ibm
Second stage 40 Nm 4 kpm 29 Ibffi
Third stage 70 Nm 7 kpm 50 Ibm
See tightening scheme below
61 Place a new gasket on the inner timing gear 63 Place a new gasket on the water pump and fit it
cover and fit the outer timing gear casing Two with the two bolts Make sure that the groove in
short bolts are fitted at the bottom Trim off any the pump shaft engages in the flange nut
part of the gasket which sticks out
62 Fit a new gasket and cover where the water 64 Fit the cover with new gasket over the camshaft
pump is to be installed NOTE The control end NOTE The bolts have three different
bracket is fitted with one of the bolts Two bolts lengths The Fig below shows where they are
are shorter placed
65 Install the fuel pump Make sure that the 0ring 67 Fit the oil sump together with a new gasket The
is in position Use a new 0ring The pump is gasket can only be fitted in one way Begin with
installed with two inhex bolts and spring the four corner bolts for locating the sump into
washers Check that the pump squeaks by position Tighten all the bolts thoroughly
pressing in the pump lever before installing the Remove the sealing ring on the casing for the
pump on the engine Connect up the fuel hoses crankshaft flywheel side Fit a new sealing
ring Trim off any part of the oil sump gasket that
is sticking out Place a new gasket on the cover
and fit it Carefully knock on the cover until it fits
over the guide pins Tighten up the cover with
the Release the lock wire securing the lubricating oil 68 Fit the rocker arm fuel filter and fuel lines
strainer Lift out the strainer wash it and blow it NOTE Replace the fine filter insert see page
dry with compressed air Refit it and lock it with 25 Point B by turning the hex head in the
the lock wire Turn the engine and fit the bottom of the container When the installation of
complete oil strainer the engine is completed bleed the fuel system
through the bleeder screw 1 See more detailed
instructions about this on page 25 Point B
69 Fit the key for the flywheel and push on the fly 71 MD6A Install the stars generator with its
wheel Fit the thick washer and tighten up the bracket Screw tight the tensioning bar to the
flywheel with the nut Tightening torque 180 engine Earlier engines have a washer placed
Nm 18 kpm 130 lbftf Use a counterhold between the engine and bracket
through the flywheel MD7A Install the alternator with its bracket
Screw tight the tensioning bar to the Oil the oil filter rubber gasket Fit the oil filter and 72 Install the exhaust manifold Fit a new gasket
the oil pressure contact Screw in the oil filter so Check to make sure that the rubber hose for the
far that the rubber gasket just touches the cooling water is in good condition Fit the cooling
engine Then screw tight a further half turn water hose from the cooling water pump and
IMPORTANT Screw by hand tighten up the hose clamp
73 Fit the injectors and the overflow pipe 75a Adjusting the CAV fuel injection pump
Tightening torque for injectors nuts 1 8 Nm a Rotate the flywheel in a clockwise direction until
08 kpm 58 lbftf NOTE Do not forget the both the valves on No 1 cylinder are closed
new sealing washers 2 on both sides of the compression stroke
overflow pipe b Assemble the pump so that the marking coinci
des with that on the transmission housing see
c Fit on the gear wheel NOTE The figure 1 is to
be turned towards the figure 1 of the
intermediate wheel
d Bleed the air from the pump with the bleed
screws in the following order 1 2 3
74 Fit the fuel pipes between the injection pump
and the injectors NOTE Check to make sure
that the brake pipes are properly installed see
76 Adjust the valves as follows
Rotate the flywheel until both valves on a
cylinder rock Turn the flywheel one further
75 Adjusting the BOSCH injection pump turn and adjust the valves for this cylinder
a Turn over the engine until the valves in cylinder Repeat the procedure for the other cylinder
No 2 rock Continue to turn over the engine in With a hot engine the clearance should be 030
the normal direction of rotation until marking 10 mm 0012 for both the intake and exhaust
on flywheel coincides with the marking on the valves
block
b Remove the pump inspection cover and check
that the marking 1 coincides exactly with the
pointer 2 Adjustments are made by slackening
the pump securing nuts and turning the pump
c Tighten the nuts
d Check the setting by turning over the engine 14
turn in the opposite direction of rotation then
back again to the 10 marking on the flywheel
Check that the marking 1 and the pointer 2
still coincide
e Fit the inspection cover with the rubber gasket
77 Oil the rocker arm and fit the rocker arm cover 79 Fit the key in the crankshaft Heat the flange and
together with new gaskets Fit the intake fit it on the shaft Tighten it up with the bolt and
manifold and gasket and install the air cleaner the thick washer Tightening torque 80 Nm 8
Fit the ventilation hose between the rocker arm kpm 57 lbftf Bend down the thin washer over
cover and air cleaner the bolt head Fit the rubber damper
NOTE Fit the intake manifold with the flange
displaced towards the reverse gear side in order
to provide space for the air cleaner
80 Install the reverse gear and gasket and connect
78 Fit the Vbelts and tension the alternator The up the cooling water hose between the reverse
belts are properly tensioned when they can be gear and water pump Then fit the exhaust
depressed under normal thumb pressure about elbow
3 4 mm 18 Depress between the start
generator and 81 Fill the engine and reverse gear with oil Concer
ning the oil quantity and quality see under
Technical Data
3 When starting with the help of a helper battery
82 The following applies to engines fitted with first check that the helper battery has the same
alternators rated current as the standard one Connect the
1 Never break the current between the helper battery to the standard battery positive to
alternator and battery while the engine is positive and negative to negative Remove the
running If a main switch is fitted it must not helper battery when the engine has started
be switched off until the engine has stopped Note The cables to the standard battery must
Otherwise no cable must be disconnected while not be broken
the engine is running since this also can ruin 4 With electrical welding on the engine or instal
the charging regulator lation components the charging regulator cables
2 Check regularly the battery battery cables and must first be disconnected and insulated Both
cable terminals The battery poles should be the battery cables must also be wellcleaned and the cable terminals always 5
In the event of repairs to the alternator
and wellgreased to ensure equipment both battery cables must first be
continuous function All cables in general must disconnected The same applies if the battery
be there must be no loose has to be rapidly charged
connections Note On no account must the 6 Never test any of the components with a
batterys positive and negative poles be mixed screwdriver etc against a terminal to see if it
up when the battery is fitted 82 Wiring diagram for the MD6A with no rev counter and temp gauge
Cable Marking 1 Starter button
Des Colour mm AWT 2 Key switch
A Beige 25 13 3 Charging warning light
B Bl Black 15 15 4 Control light for oil pressure
C Red 25 3 5 Switch
C Red 25 13 6 Terminal board instrument panel resp engines
D Green 15 15 7 Charging regulator
D Green 25 13 8 G Brown 15 15 9 Oil pressure indicator
H Blue 15 15 10 Battery 12V max 60 Ah
H Blue 25 3 11 Main Switch
Fig 83 Wiring diagram for late prod Type MD6A
1 Key switch
2 Instrument panel switch
3 Temperature gauge
4 Warning light for low oil pressure
5 Rev counter
6 Warning light charging Switch optional equipment
8 Terminal board
9 Warning light charging alternator
Optional Battery
11 Main switch
12 Alternator Optional Charging regulator
15 Fuse
16 Temperature sender
17 Rev counter
18 Oil pressure sender
19 Other electrical 31
Wiring Diagram MD7A
CABLE MARKING
Des Colour mm
A White 6 9
B Black 15 15
B Black 06 19
B Black 075 18
C Red 6 9
C Red 35 1
C Red 06 19
F Yellow 15 15
G Brown 15 15
H Blue 4 11
H Blue 35 1
I Greenred 075 18
J Green 15 15
J Green 06 18
J Green 075 18
K Blueyellow 075 18
L Whitered 075 18
M Bluered 075 List
2 Charging warning light
3 Warning light for high Warning light for low oil pressure
5 Key switch 12 Alternator
6 Siren 13 Fuse
7 Alarm unit 14 Main switch
9 Place for instrument extra equipment 15 Battery
10 Terminal board 16 Temperature sender
11 Starter motor 17 Oil pressure sender
FAULT TRACING
Bleeding the fuel system
To ensure that the engine starts the fuel system must
The faulttracing scheme below includes only those
be bled on the following occasions 1 When which arise most often during operation
the fine filter 2 When draining through the drain plug
3 When cleaning the prefilter 4 When running scheme
fuel tank empty 5 When installing the fuel injection
Engine runs unevenly or pump 6 With leakage and when working on the fuel
right operating speed at
Engine does not reach
Engine does not start
vibrates abnormally line 7 When the engine has been stopped for a long
time Bleeding is as follows Open the bleeder screw 1
Engine becomes
abnormally hot FAULT Notes on the fine filter See Point 68 Pump forward the fuel
Engine stops
with the help of a hand primer until about 02 litre 02
full throttle
qt fuel has run out Close the bleeder screw If you
get poor pumping effect turn over the engine a bit so
that the pump drive cam alters its position If the fuel
Main switch not on
injection pump has been removed or when starting an
X flat battery broken A
entirely new engine for the first time the fuel injection
electric cables
pump must be bled Pump with the hand primer for
Empty fuel tank
about 12 minute This automatically bleeds the fuel
X X closed fuel cock B
injection pump Slacken the delivery pipe nuts for the
blocked fuel filter
injectors and turn over the engine with the start
Water air or generator until fuel comes from the delivery pipes
X X X B
impurities in fuel Tighten up the delivery pipe nuts and start the engine
X X X X Defective injectors C
Boat abnormally C Check the injectors with regard to their opening
X loaded Growth on D pressure tightness and spray pattern Max
running
boat bottom time of 400 operating hours or once a season is
X X Damaged propeller E recommended between these checks See also
Points
Clogging of cooling 37 and 38
water intake
X cooling jackets F D In order to get the best possible operating economy
defective impeller the engine speed selected should be minimum 300
or thermostat revmm below the max speed for The engine during
lengthy periods of operation When the boat has been
A Check the state of charge of the battery with the help
in the water for so time the max speed for the engine
of a hydrometer which shows the specific gravity of the can drop due to growth
on the outside of the hull Use
battery acid This will vary with the state of charge see antifouling paint Check
and clean the hull regularly
under Technical Data Also see under Electrical
system on page 23 E Check the propeller blades
If a propeller blade is
damaged the propeller must be replaced A propeller
B Replace the fine filter by turning the hex head in the
blade can also be warped something which is very
bottom of the container The fine filter and container difficult to discover
Place the propeller on a flat disc
are of the throwaway type They must be discarded and measure the blades If
a propeller blade is
and a new one installed Check that the contact warped the propeller
should be replaced
surface for the cover is absolutely clean and that the
filter gasket is in good condition Screw on the new F Check the cooling system
for leakage clogging etc
filter tight by hand until the gasket goes against the
Check to make sure the thermostat opens at the right
cover Then tighten the filter a further 12 turn The
temperature The thermostat can be removed after
bottom of the filter container has a drain plug for
having taken down the thermostat housing at the front
draining water and impurities that have accumulated in
of the exhaust manifold See also Point 49 The pump
the fuel Bleed the fuel system after draining and
body in the seawater pump is made of neoprene
replacing the filter also check for leakage
rubber which can be damaged with shortage of water
Remove the feed pump cover and clean the prefilter
eg in the event the seawater inlet is blocked
in the fuel oil Then fit the filter with the pins facing
upwards and place the gasket undamaged in position Proceed according to
Points 4548 in the event the
and tighten up the cover Bleed the fuel system impeller and sealing
rings have to be replaced NOTE
Check and if necessary drain the extra fuel filter if such If the boat is in the
water the bottom cock must be
is fitted Look out for fuel splash closed before the
seawater pump is removed But do
not forget to open the cock again
Special Tools
Part No 34
Technical Data designation MD6A
Output DIN at 40 revsec 2400 revmm 74 kW 10 hp
Number of cylinders 2
Bore 70 mm 82 mm 32283
Capacity ratio 1871
2 2 pressure at starter motor speed 2325 kpcm 327355 lbfin
Direction of rotation viewed towards flywheel speed 12 revsec 700 revmin
2 2
Oil pressure hot engine 4 kpcm 57 lbfin
2 2
Oil pressure idling hot engine 08 kpcm 11 lbfin Cast iron
Bore standard mm mm 0020 oversize mm
total 81 mm from gudgeon pin centre to piston crown 51
mm clearance in cylinder 00860130 mm standard mm mm 0020 oversize
mm pins
Diameter mm pin bushing diameter mm gudgeon pin bushing
00100025 mm rings number 2
Oil scraper ring number 1
Upper compression ring has chromium lining
Piston rings are available for standard size and 0500 mm
0020 ring clearance in groove compression ring 00620113 mm compression ring
00370087 mm scraper ring 00370089 mm ring gap in compression ring
02790406 mm compression ring 02030330 mm scraper ring
03500480 mm Nodular axial clearance 008031
mm bearing radial clearance 00260075 mm rod radial clearance 00260075 mm
Measured with Moto Meter nipple 884535 and yoke 884543
Main bearing standard mm mm undersize mm mm undersize mm
bearing standard 17301737 mm mm oversize 20302037 mm mm oversize
23302337 mm rod standard mm mm undersize mm mm undersize mm
rod standard 17301737 mm mm oversize 20302037 mm mm oversize
23302337 mm rods
End play at crankshaft 025050 mm play 01600300 mm clearance in bearing
00170083 mm diameter mm height of cams 548552 mm diameter mm
head
Material Specialalloy cast iron
Intake valves
Disc diameter 288290 mm diameter 79387960 mm seat angle
head seat angle 30
Width of seat in cylinder head approx 1 mm hot engine 030 mm valves
Disc diameter 263265 mm diameter 79387960 mm seat angle
head seat angle 30
Width of seat in cylinder head approx 1 mm hot engine 030 mm guides 43 mm
intake valve 49 mm 1 exhaust valve 80008022 mm 107110 mm
above cylinder head spring face 00400084 mm valve 36
Valve offload 47 mm 1 with 150 N 15 kp 33 Ibf 30 mm with 230 N 23 kp 50 lbf 21 mm
capacity excl filter 28 litres 25 Impqts 29 US qts
Oil capacity incl filter 30 litres 26 lmpqts 32 US qts
Oil quality acc to APIsystem CD DS
0 0
Viscosity above 10 C 50 F SAE 30
0 0
Viscosity below 10 C 50 F SAE 20W
2 2
Oil pressure hot engine idling speed 081 5 kpcm 11 42 1 3 Ibfin
2 2
Oil pressure hot engine full speed 3540 kpcm 5057 lbfin
Reverse gear
Oil Same as for engine
Oil capacity din qts red 11 04 04
Oil capacity din qts red 191 1 reduction gear same oil compartment as mechanism and propeller hub
Lubricating grease Shell Alvania EP2 or oil ACDELCO 1530838 type oil pump
Type Gear wheel pump
Relief valve spring Length offload 45 mm with 15 N 15 kp 33 lbf 40 mm with 46 N 46 kp 10 Ibf 29 mm
clearance of gear wheels incl gasket 00480084 mm system
Fuel injection pump make Bosch 0 460 302 make Bosch holders 0 431 112 001
Nozzles 0 433 171 001
Hole diameter Four 022 mm 00087
2 2
Opening pressure 180 kpcm 2560 Ibfin
Spray angle 150
Advance angle 12
Injection quantity 20 mm stroke at 317 revsec
1900 revmin
Max speed 408425 revsec 24502550 filter
Type Bosch 0 450 133 001
Filter insert Bosch 1 457 434 0611
Feed pump
Type Pierburg PE 15672
2 2
Feed pressure at 40 revsee 2400 revmm 065085 kpcm 92120 lbfin
voltage 12 V
Battery capacity Max 60 Bosch 0 010 350 004
Generator output max output continuous 90 W
Starter motor output 074kW 1 hp
Battery electrolyte specific gravity Fully charged batter 12751285 gcm
When charging has to be carried out 1230 gcm
Cooling Bellows thermostat
0 0
Starts opening at 60 C 140 F
0 0
Fully open at 74 C 165 F
WEAR with wear or if engine has abnormal 025 mm bearing and connecting rod
006 mm taper 005 mm axial play on crankshaft 036 mm
journals permitted 003 mm clearance between camshaft and bushings 015 mm clearance between valve stem and guide
016 mm of valve disc should be mm 10 mm TORQUES
Nm Kpm head nuts 70 7 51
Cylinder head stud bolts 20 2 14
Bolt for flange on crankshaft 70 7 50
Flywheel nut 180 18 rod bolts 50
5 36
Water pump flange 60 6 43
Main bearings 50 5 36
Nuts for fork for injectors 8 08 scheme for cylinder head nuts
Technical Data designation MD7A
Output at flywheel DIN at 43 revsec 2600 revmm 10 kW 134 hp
Number of cylinders 2
Bore 76 mm 82 mm 32283
Capacity 0744 ratio 171
2 2
Compression pressure at starter motor speed 225 MPa 2025 kpcm 284355 lbfin
Direction of rotation viewed towards flywheel speed 1113 revsec 650780 revmin
2 2
Oil pressure full speed hot engine 035040 MPa 3540 kpcm 5057 lbfin
2 2
Oil pressure idling hot engine 008015 MPa 0815 kpcm 1121 lbfin
Cast iron
Bore standard 76007603 mm mm 0010 oversize 76257628 mm mm 0020
oversize 76507653 mm total
764 mm from gudgeon pin centre to piston crown 514 mm clearance in cylinder 00730118
mm standard diameter mm mm 0010 oversize mm mm 0020 oversize
mm pins
Diameter mm pin bushing diameter mm gudgeon pin bushing
mm rings number 2
Oil scraper ring number 1
The upper compression ring is chromium lined
Piston rings are available for standard size 0250 mm
0010 and 0500 mm 0020 ring clearance in groove compression ring 00700102 mm compression ring
00500082 mm scraper ring 00300062 mm ring gap in compression ring
030050 mm compression ring 030050 mm scraper ring
025050 mm Nodular axial clearance 00800313 mm
bearing radial clearance 00260075 mm bearings radial clearance 00260075 mm
39
Main bearing standard mm 1 mm 00120 undersize mm mm 00236 undersize mm bearing
standard 17301737 mm mm 00120 oversize 18801 887 mm mm 00236 oversize 20302037 mm
standard 4998450000 mm mm 00120 undersize mm mm 00236 undersize mm standard
17301737 mm mm 00120 oversize 18801887 mm mm 00236 oversize 20302037 mm rods
End play at crankshaft 025050 mm play 01600300 mm clearance in bearing
001 80083 mm diameter mm 1 height of cams 548552 mm diameter mm
1 head
Material Specialalloy cast iron
Intake valves
Disc diameter 324326 mm diameter 79557970 mm seat angle
45 15 45 45
Cylinder head seat angle 45
Width of seat in cylinder head approx 1 mm hot engine 030 mm valves
Disc diameter 274276 mm diameter 79507965 mm seat angle
45 15 45 45
Cylinder head seat angle 45
Width of seat in cylinder head approx 1 mm hot engine 030 mm intake valve 38 mm 1
exhaust valve 38 mm 1 4961
Bore 808015 mm above cylinder head spring face 885915 mm valve valve
003006 mm valve 00350065 mm 40
Valve offload 425 mm with 17010 N 171 kp 3752 lbf 32 mm with 30020 N 302 kp 6645 lbf
24 mm capacity excl filter 28 litres 25 lmpqts 29 US qts
Oil capacity incl filter 30 litres 26 lmpqts 32 US qts
Oil quality ace to APIsystem CD DS
0 0
Viscosity above 10 C 50 F SAE 20 W
0 0
Viscosity below 10 C 50 F SAE 10 W
2 2
Oil pressure hot engine idling speed 0815 kpcm 11 421 3 lbfin
2 2
Oil pressure hot engine full speed 3540 kpcm 5057 lbfin
Reverse gear
Oil Same as for engine
Oil capacity din qts red 11 04 04
Oil capacity din qts red 1911 055 05
Combi reduction gear Same oil compartment as mechanism and propeller hub Lubricating
grease Shell Alvania EP2 or oil pump
Type Gear wheel pump
Relief valve spring Length offload 45 mm 1 with 15 N 15 kp 33 lbf 40 mm with 46 N 46 kp 10 lbf
29 mm 1 1417
Axial clearance of gear wheels incl gasket 00480084 mm system
Fuel injection pump make Bosch Up to engine no 19999 0 460 302 008
Fuel injection pump CAV From engine no 20000 0 3222 make Bosch holders 0 431 112 001
Nozzles 0 433 171 009
Hole diameter Four 023 mm 00091
2 2
Opening pressure 185193 kpcm 26312744 lbfin
Spray angle 150 C
Advance angle Bosch pump 11 1 angle CAV pump 14 01 quantity Bosch pump
1805 mgstroke at 43 revsec 2580 quantity CAV pump 17505 mgstroke at 43 revsec 2580
revmm
Feed pump
Type Pierburg PE 15672
2 2
Feed pressure at 42 revsec 2500 revmm 065085 kpcm 92120 lbfin
voltage 12 V
Battery capacity Max 120 Ah
Starter motor Bosch 0 001 311 115
Starter motor output 11 kW 148 SEV Marchal 70 output
490W 35A
Battery electrolyte specific gravity Fully charged battery 12751285 gcm
When charging has to be carried out 1230 gcm
Cooling Bellows thermostat
0 0
Starts opening at 60 C 140 F
0 0
Fully open at 74 C 165 F
WEAR for wear
or if engine has abnormal fuel consumption 025 mm bearing and connecting rod 006 mm taper
005 mm axial play on crankshaft 040 mm journals permitted
003 mm clearance between camshaft and bushings 015 mm clearance between valve stem and guide 015 mm of
valve disc should be mm 10 mm torques Nm Kpm Lbf ft
Cylinder head nuts 70 7 51
Cylinder head stud bolts 20 2 14
Bolt for flange on crankshaft 70 7 51
Flywheel nut 180 18 rod bolts 70
7 51
Water pump flange Bosch fuel injection pump 60 6 43
Water pump flange CAV fuel injection pump 80 8 58
Main bearings 50 5 36
Nuts for fork for injectors 8 08 58
Bolt for intermediate gear transmission 70 7 51
Starter motor bolt 70 7 51
Bolt front engine mounting 45 45 33
Bolt rear engine mounting 45 45 scheme for cylinder head nuts
Longitudinal section Cross

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