Volvo Md11c D 17c D Manual

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Workshop Manual A Engine unit 20 MD11C D MD17C D ContentsSafety precautions 2General Information 5Repair instructions 6Component guide head 10Cylinder liner 11Pistons conrods 11Timing gear 12Flywheel 13Crankshaft 14Camshaft cylinder head 15Cleaning inspection 15Valve guides 15Valve seats 16Valves 16Valve springs 16Rocker mechanism 16Valve tappets 16Injector sleeve 17Injector 17Assembling cylinder head 18Cleaning checking crankcase 18Replacing main bearings 18Centrifugal governor 19Pistons liners 19Connecting rods 20Crankshaft 20Camshaft 20Oil pump 20Feed pump 21Thermostat 21Sea water pump 21Hand start 24Flywheel 25Timing gear 25Cylinders cylinder liners 27Pistons and liners 28Cylinder head 29Adjusting valve clearance 30Injection pump 31Checking control rod travel 32Venting the fuel system 33Checking injections angle 34Adjusting engine speed 34Electrical system 35Wiring diagram 35Fault finding chart 36Special tools 37Technical data 39Cooling system diagrammatic sketch 43 1Safety Check that the warning or information decals onThis 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 overtents list Ensure that the correct workshop literatureis being usedRead the safety information and the WorkshopManual General Information and Repair In Never use start spray or similar to start the enstructions 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 following 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 outNOTE Used to draw your attention to important infor mation that will facilitate work or operations Hot oil can cause burns Avoid skin contactBelow is a summary of the risks and safety precau with hot oil Ensure that the lubrication systemtions you should always observe or carry out when is not under pressure before commencing workoperating 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 wellventilated 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 turbochargers 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 sight2Avoid skin contact with oil Longterm or repeat Never allow a naked flame or electric sparksed contact with oil can remove the natural oils near the batteries Never smoke in proximity tofrom your skin The result can be irritation dry the batteries The batteries give off hydrogenskin eczema and other skin problems Used oil gas during charging which when mixed with airis more dangerous to health than new oil Use can form an explosive gas oxyhydrogen Thisprotective gloves and avoid using oilsoaked gas is easily ignited and highly volatile Incorclothes and rags Wash regularly especially be rect connection of the battery can cause afore 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 batteryeasier connections when starting the engine spark risk and do not lean over batteriesMost chemicals used in products engine oils glycol petrol and diesel oil Never mix up the positive and negative batteryand workshop chemicals solvents and paints terminals when installing Incorrect hazardous to health Read the instructions can result in serious damage to electrical equipon the product packaging carefully Always fol ment Refer to wiring diagramslow safety instructions using breathing apparatus protective goggles and gloves for ex Always use protective goggles when chargingample Ensure that other personnel are not and handling batteries The battery exposed to hazardous substances contains extremely corrosive sulfuric acid Ifby breathing them in for example Ensure that this comes into contact with the skin wash imventilation is good Handle used and excess mediately with soap and plenty of water If batchemicals according to instructions tery acid comes into contact with the eyes im mediately flush with copious amounts of waterAll fuels and many chemicals are inflammable and obtain medical that a naked flame or sparks cannot ignite fuel or chemicals Combined with air in cer Turn off the engine and turn off power at maintain ratios petrol some solvents and hydrogen switches before carrying out work on the elecfrom batteries are easily inflammable and explo trical systemsive Smoking is prohibited Ensure that ventilation 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 unitwelding or grinding work Always have a fire ex Always check that lifting equipment is in goodtinguisher to hand in the workplace condition and has sufficient load capacity to lift the engine engine weight including reverse gearStore oil and fuelsoaked rags and fuel and oil and any extra equipment safely In certain conditions oilsoakedrags 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 amust be deposited at an approved site for de lifting beam to raise the engine All chains andstruction together with used lubricating oil con cables should run parallel to each other and astaminated fuel paint remnants solvent de perpendicular as possible in relation to the topgreasing 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 3 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 manualThis workshop manual contains technical specification descriptions and instructions for repairing thestandard versions of the following engines MD11C DMD17C D The workshop manual displays the operations carried out on any of the engines above As aresult the illustrations and pictures in the manual thatshow certain parts on the engines do not in somecases apply to all the engines listed above Howeverthe repair and service operations described are thesame in all essential details Where they are not thesame this is stated in the manual and where the difference is considerable the operations are Engine designations and numbers aregiven on the number plate See page 9 The and number should be given in all correspondence about the engineThis Workshop Manual has been developed primarilyfor Volvo Penta service workshops and qualified personnel Persons using this book are assumed to havea grounding in marine drive systems and be able tocarry out related mechanical and electrical workVolvo Penta is continuously developing their products We therefore reserve the right to make changesAll the information contained in this book is based onproduct data available at the time of going to printAny essential changes or modifications introducedinto production or updated or revised service after the date of publication will be provided in the form of Service parts for electrical and fuel systems aresubject to statutory requirements US Coast GuardSafety Regulations for example Volvo Penta Genuine parts meet these requirements Any type of damage which results from the use of nonoriginal VolvoPenta replacement parts for the product will not becovered under any warranty provided by Volvo Penta 5Repair working methods described in the Service Man Our joint apply to work carried out in a workshop The engine has been removed from the boat and is installed Each engine consists of many connected systemsin an engine fixture Unless otherwise stated recondi and components If a component deviates from itstioning work which can be carried out with the engine technical specification the environmental impact of anin 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 mainfor 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 lowed IMPORTANT Some systems such as the components in the fuel system require special expertise and special testingNOTE equipment for service and maintenance Some comare 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 sealedice work or repairs may be carried out For this rea components except by authorized personnelson we can only highlight the risks that can arise Bear in mind that most chemicals used on boats arewhen work is carried out incorrectly in a wellequipped harmful to the environment if used incorrectly Volvoworkshop using working methods and tools developed Penta recommends the use of biodegradable deby us greasing agents for cleaning engine components unAll procedures for which there are Volvo Penta spe less otherwise stated in a workshop manual Takecial tools in this Workshop Manual are carried out special care when working onboard that oil andusing 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 wateras possible It is therefore the responsibility of anyperson using tools or working methods other than theones recommended by us to ensure that there is no Tightening torquesdanger of injury damage or malfunction resulting fromthese Tightening torques for vital joints that must beIn some cases there may be special safety precau tightened with a torque wrench are listed in workshoptions and instructions for the use of tools and chemi manual Technical Data Tightening Torques andcals contained in this Workshop Manual These spe are contained in work descriptions in this Manual Allcial instructions should always be followed if there torques apply for cleaned threads screw heads andare no separate instructions in the Workshop Manual mating surfaces Torques apply for lightly oiled or dry threads If lubricants locking fluid or sealing comCertain elementary precautions and common sense pound are required for a screwed joint this informationcan prevent most risks arising A clean workplace will be contained in the work description and inand engine eliminates much of the danger of injury Tightening Torques Where no tightening torque isand malfunction stated for a joint use the general tightening torquesIt 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 beintake system turbocharger bearings and seals tightened using a torque wrenchwhen they are being worked on The result can bemalfunction 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 10336 angle In this Volvo Penta Service Manual the user will findtightening 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 manufacturer 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 anticorrosion 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 hasDo not reuse lock nuts that have been removed dur been dismantled old RTV must be removed beforeing dismantling as they have reduced service life the joint is resealed Old sealant can be removed uswhen 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 absenceNylock the tightening torque stated in the table is re of air They are used when two solid parts for exduced if the Nylock nut has the same head height as ample cast components are installed facetofacea standard hexagonal nut without plastic insert Re without a gasket They are also commonly used toduce the tightening torque by 25 for bolt size 8 mm secure plugs threads in stud bolts cocks oil presor larger Where Nylock nuts are higher or of the sure switches and so on The cured material is glasssame height as a standard hexagonal nut the tighten like and it is therefore colored to make it visibleing 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 classesScrews and nuts are divided into different the class is indicated by the number on thebolt head A high number indicates stronger materialfor example a bolt marked 109 indicates a higher tolerance than one marked 88 It is therefore importantthat bolts removed during the disassembly of a boltedjoint must be reinstalled in their original position whenassembling the joint If a bolt must be replaced checkin the replacement parts catalogue to make sure thecorrect bolt is usedSealantsA number of sealants and locking liquids are used onthe engines The agents have varying properties andare used for different types of jointing strengths operating temperature ranges resistance to oil and otherchemicals and for the different materials and gapsizes in the enginesTo ensure service work is correctly carried out it isimportant that the correct sealant and locking fluidtype is used on the joint where the agents are re 7Component guideMD11C 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 engine10 Oil dipstick reverse gear11 Oil filler reverse gear12 Oil drain plug reverse gear13 Water drain plug reverse gear MD11D connection hose14 Decompression handle certain models15 Air filter MD11C16 Oil filler engine17 Pressure equalizing valve certain models18 Air bleed screw19 Fine filter20 Feed pump21 Engine speed sender22 Oil filter23 Oil pressure sender24 Oil strainer and oil dipstick MD11C25 Oil pump26 Oil dipstick MD11D MD11D8MD17C and D 1 Fuse box MD17C 2 Decompression handle certain mo dels 3 Air filter 4 Oil filler 5 Air bleed screw 6 Fine filter 7 Feed pump 8 Engine speed sender 9 Oil filter10 Stop device11 Adjustment screw high idle speed12 Adjustment screw low idle speed13 Leakoff pipe14 Lifting eye15 Delivery pipe16 Injector17 Thermostat housing18 Oil dipstick19 Drain cocks cooling water20 Engine type and number plate21 Cooling water pump MD17D off the engine cooling water lubricating oil andany fuel in the fuel filter and fuel injection pumpClean the outside of the engine 2B The picture shows later type of injector from and including engine no 50989 MD11 and 16622 MD171 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 mmCYLINDER HEAD2A 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 16621 MD1710 CYLINDERS CYLINDER LINERS5 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 PISTONS AND CONNECTING RODS6A 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 pipe6B 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 11TIMING GEAR 13A MD11C and MD17C Remove the carrier on the crankshaft engines with RBreverse gear have a carrier drive use a distance piece to protect10 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 flywheel11 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 template12 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 washer1215 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 gearwheel16 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 13CRANKSHAFT 23B MD11C 23C MD11D21 Remove the locating screw for the crankshaft Tool 884714 Hexagon 30 mm centre bearing two in the case of MD17 Pull the crankshaft outCAMSHAFT22 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 GUIDES26 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 00066927 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 guidesCLEANING 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 999412828 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 15VALVE SEATS AND VALVES ROCKER ARM MECHANISMA max 25 mm 010 C 45 33 Dismantle the rocker arm mechanism and clean the parts Check the shaft and the bushes forB 101 mm 00400004 D 445 wear If the bushes need to be replaced the tool 884560 is used for pressing out and in Ensure31 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 00400004 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 blueVALVE SPRINGS VALVE TAPPETS32 Check the valve spring lengths both loaded and unloadedL Length unloaded 50 mm 1969 34 Check the valve tappets for wear The cylindriL1 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 beL2 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 tightlyDrain the engine cooling water if this has not already with the nuts Screw the tool down as far as thebeen done shoulder in the sleeve permits thus flaring the sleeve Remove the tool35 Remove the sleeve using the tool 884081 Push the expanding screw down into the sleeve and screw anticlockwise 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 INJECTORS36 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 toms 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 MD17 245 08 MPa 245 08 kpcm2 3485 114 psi 0 0 037 Oilin the flaring tool 884085 and push it into the Also check that the fuel jets cease simultaneously at sleeve make sure that the pin is screwed back all four holes and that there is no dribble afterwards 17 Crankcase CLEANING AND INSPECTIONUp to and including engine no 50988 MD11 16621MD17From and including engine no 50989 MD11 16622MD17 42 Remove all core plugs and clean the crankcase thoroughly Check that all channels are free40 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 BEARINGS41A 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 sleeveB 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 compressor18 PISTONS LINERS 46 Check the pistons and liners for damage and wear A 15 mm 006 A Measure the cylinder liners diameter at a number of points round the circumference and at44A 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 00035000544B 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 Data45 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 19CONNECTING RODS CAMSHAFT 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 in49 Check the connecting rods for straightness and The maximum allowable wear on journals or twist bearings is 005 mm 0002 OIL PUMP 53 Remove the cover retaining the old gasket Re50 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 rod 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 00010006 The thickness of a new gasket is 010 mm 0004 Also inspect the cover repair or replace as ne51 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 00060014 using a feeler suitable undersize see Technical Data gauge Worn gears must be replaced20FEED PUMP SEA WATER PUMP Replacing the impeller 58 Remove the cover Watch out for water pour55 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 damaged56 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 gasket57 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 2161 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 disassembling 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 themReplacing the sealing rings Locate the shaft in the housing so that the screw hole lies outside Fit the impeller and the screw 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 camshaft62 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 impeller22HAND STARTER MD17 HAND STARTER MD1164 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 rings 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 andlock washers Grease or oil the sealing rings and oilmoving 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 crankcase66 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 threadsealing 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 bearing67 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 ring24 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 washer71 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 positionTIMING GEAR73 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 2577 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 carrier78 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 00020006 81A MD11C and MD17C Fit the timing gear cover79 Fit the key for the reverse gear carriercarrier drive in crankshaft keyway on the reverse gear side Heat the carriercarrier 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 00030014 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 B2682 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 A MD11D 120 Nm 12 kpm 87 lbfft wrench width 30 mm BCYLINDERS AND CYLINDER LINERS83 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 27 PISTONS AND LINERS 88 Heat the pistons to about 100C 212F As semble the pistons and connecting rods as86 Fit the sealing rings for the pushrods and oil shown in the illustration 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 staggered 90 Fit the pistons with the special tool 2823 This is the same as that used for the B20 and B30 en87 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 nozzle28 94 The value of 025 mm 00098 corresponding to tk in the illustration is added to the dimen91 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 0031500354 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 440025353 112 mm 01730010139 0044 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 CYLINDER HEAD92 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 properly93 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 29 ADJUSTING THE VALVE CLEARANCE97 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 round 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 hot98 Tighten the cylinder head nuts in stages of 30 80 and 110 Nm 3 8 11 kpm 22 58 80 lbfft Tighten the exhaust manifold 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 adjusting99 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 on the Dengines30 FUEL INJECTION PUMP102 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 cover 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 3260008 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 amount103 MD11 Fit the inspection covers on the crank case 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 31CHECKING THE CONTROL ROD TRAVEL106 A rough adjustment of the injection quantity can be made as followsA 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 VbeltB 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 forwardC The difference between the two dimensions should be MD11 7101 mm 02800004 MD17 6701 mm 02640004 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 cleaner107 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 manifold108 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 SYSTEMMD11C and MD17C 115 Unscrew the injector delivery pipe nuts push the stop control in and set the speed control to112 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 gine MD11D and MD17D 116A 1 Open the vent screw 1 above on the fine filter113 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 engine114 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 33CHECKING THE INJECTION ANGLE ADJUSTING ENGINE SPEED117 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 tion118 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 necessary119 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 auxiliaryThe following applies to engines fitted with alternators battery has the same rated voltage as the1 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 charging2 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 disconnected wellgreased to ensure continuous function All 5 Before carrying out any repairs on the alternator cables in general must be welltightened 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 WIRING LIST 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 motor10 Alternator11 Fuse box12 Main switch13 Engine speed sender14 Oil pressure sender15 Temperature sender16 BatteryWIRING CODESymb Colour mm 2 AWGA White 6 9B Black 15 15B Black 06 19C Red 6 9C Red 35 1C Red 06 19C Red 25 13D Grey 15 15F Yellow 15 15G Brown 15 15H Blue 4 11H Blue 35 1H Blue 15 15J Green 15 15J Green 06 19 35Fault 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 throttle 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 tem X Faulty rev counter Boat loaded abnormally Air cleaner blocked Fouling on boat bot tom 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 shaft 884081 Injector sleeve extractor 884085 Flaring tool injector sleeve 884489 Tool for removing and fitting of main bearings 884497 Drift for assembling valve sealing rings 884499 Drift for assembling valve guides 884560 Drift for removing and fitting rocker arm bear ings 884742 Drift for assembling bearings onto sea water pump shaft MD17 37 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 884623 884579 Tool for dismantling oil filter884595 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 dimension 9993197 Level tube for injection pump setting 9994128 Valve guide designation MD11C MD11D MD17C MD17DOutput1 at 417 rs 2500 rmin 17 kW 23 hp 26 kW 35 hpat 50 rs 3000 rmin 184 kW 265 kW 25 hp 36 hpOutput2 at 383 rs 2300 rmin HDengine 15 kW 15 kW 22 kW 22 kW 20 hp 20 hp 30 hp 30 hpMD11DMSB Output2 at 417 rs 2500 rmin 17 kW 23 hpNumber of cylinders 2 2 3 3Bore mm in 889 mm 35Stroke mm in 90 mm dm3 cuin 112 dm3 168 dm3 6835 cuin 10251 ratio pressure at starter motor speed3342 rs 200250 rmin 225 MPa 2025 kpcm2 284355 psiDirection of rotation viewed from flywheel ClockwiseHigh speed idling overspeed 2700 3300 2700 3300 2800 rmin 3350 rmin 2800 rmin 3350 rminHeavy duty engine 2500 2800 2500 2800 2600 rmin 2900 rmin 2600 rmin 2900 rminLow speed idling 750810 rminCYLINDER LINERSMaterial Cast iron 0005Diameter 8890 mm mm 0010 354 00002 cylinder bore 88788880 mm total mm in 98 mm 3858Height from centre of gudgeon pin to top of piston mm in 65 mm 2559Piston clearance in cylinder liner mm in 009013 mm PINSDiameter mm in 280028004 mm pin bearing diameter mm in 2801428025 mm gudgeon pin bearing Close running fitPISTON rings number 3Oil rings number 1The upper compression ring is chrome platedPiston ring axial clearance in groove1st compression ring 008011 mm 0060092 mm 0030062 mm ring 0030062 mm ring gap measured in cylinder liner1st compression ring 040055 mm 00157002172nd and 3rd 030045 mm 0011800177Oil ring 025040 mm 00100001571 Propeller shaft output DIN 6270 Leistung B fr Dauerbetrieb2 Propeller shaft output for runin engines with reverse gear DIN 6270 Leistung B fr Dauerbetrieb 39 MD11C MD11D MD17C MD17DCYLINDER HEADMaterial 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 260386260461 0762 mm undersize 0030 6588465903 mm 2593925946MAIN 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 RODAxial clearance at crankshaft mm in 005025 mm clearance 005015 mm clearance in bearing 003009 mm journals diameterNo 1 3170031725 mm 1248012490No 2 4697547000 mm 1849418504No 3 4897549000 mm 1928119291No 4 MD17 5497055000 mm 2164221654The bearings are reamed after pressing inCam lift mm in 575585 mm disc diameter 38 mm 149606Stem diameter mm in 79557970 mm seat angle 445Cylinder head seat angle 450Seat width in cylinder head mm in ca 10 mm engine warm mm in 030 mm 0011840Exhaust MD11C MD11D MD17C MD17DValve disc diameter mm in 34 mm 133858Stem diameter mm in 79507965 mm seat angle 445Cylinder head seat angle 450Seat width in cylinder head mm in ca 10 mm engine warm mm in 035 mm DEVICEMax downward pressing of exhaust valvenot adjustable on Dengines mm in 05 mm 001969VALVE GUIDESLength inlet mm in 59 mm 232283exhaust mm in 52 mm 204724Bore diameter after assembly and reaming mm in 80 mm8015 mm above cylinder head spring surface 18 mm valve stemguide inlet 003006 mm 000118000236 exhaust 003007 mm SPRINGSFree length unloaded 50 mm 196850loaded with 30020 N 302 kp 66139441 lbf 39 mm 1535432 56030 N 563 kp 123566 lbf 32 mm SYSTEMOil capacity engine inclination 0For 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 gallsEngine 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 gallsOil quality ace to APIsystem diesel lubricating oilservice CD 10C 50F Volvo Penta CD oil Double grade SAE 20W30under 10C 50F Volvo Penta CD oil Single grade SAE 10WOil pressure warm engine idle speed 0102 MPa 12 kpcm2 1428 psifull speed 0203 MPa 23 kpcm2 2843 psiLUBRICATION OIL PUMPType GearSpring for reducing valveFree length unloaded 40 mm 158 loaded with 252 N 2502 kp 55044 lbf 34 mm 134 352 N 3502 kp 77044 lbf 315 mm 124Axial gear clearance incl gasket 003015 mm pump manufacturer BoschInjector manufacturer Bosch hole diameter 4 st 027 mm 001063opening pressure MPa 170 08 246 08 170 08 245 08 0 0 0 0 kpcm2 170 8 245 8 170 8 8 245 0 0 0 0 114 114 114 114 psi 2418 3485 24180 3485 0 0 0Injection angle BTDC 2426 245265 2426 quantity 3536 mm3stroke at 20C 68F and 165 rs 1000 rmin pump speedHDvariant 3334 mm3stroke at 20C 68F and 165 rs 1000 rmin pump speed 41FINE FILTER MD11C and D MD17C and DType SpinonEarlier type Filter insertFEED PUMPFeed pressure at 42 rs 2520 rmin 6585 kPa 065085 kpcm2 925121 psiELECTRICAL SYSTEMBattery voltage 12 VBattery capacity pleasure use starter motor battery max 70 Ah max 90 AhHD variant starter motor battery max 90 Ah max 90 AhStarter 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 WBattery electrolyte specific gravity Fully charged battery 12751285 gcm3 0046000464 lbin3 Battery to be recharged at 1230 gcm3 00444 lbin3COOLING type Bellows Replaceable with wax type WAX from and including engine no 49685 15740 Begins to open at 60C 140F Fully open at 74C 165FHDHE engine Begins to open at 74C 165F Fully open at 89C 192FWEAR liners and pistons should be replaced when025 mm 0010 wear can be outofround on main and bigendbearing journals max 006 mm taper on main and bigendbearing journals max 005 mm 000197Max crankshaft end play 045 mm stem max permissible wear 002 mm 000079Max clearance between valve stem and valve guidesInlet valves 015 mm 000591Exhaust valves 017 mm 000669The valve disc edge shall be at least 15 mm 0059Distance from valve disc new valve to the cylinderhead face max 25 mm permissible wear in bearing journalsand bearings 005 mm TORQUES MD11C and D MD17C and DCylinder head nuts 110 Nm 11 kpm 80 lbfftCentre bearing 70 Nm 70 kpm 50 lbfftBigend bearings 65 Nm 65 kpm 47 lbfftShield for main bearings 40 Nm 40 kpm 29 lbfftScrew for carrier and carrier drive on crankshaftfor reverse gear 70 Nm 70 kpm 120 Nm 120 kpm Ceng 50 lbfft 87 lbfft 110 Nm 110 kpm Deng 80 lbfftFlywheel nut 500 Nm 50 kpm 369 lbfftInjectors 20 Nm 20 kpm 145 lbfftCarrier for water pump 70 Nm 70 kpm 320 Nm 320 kpm 50 lbfft 231 lbfftCap nuts for valve cover 15 Nm 15 kpm 11 lbfftNipple for oil filter 40 Nm 40 kpm 29 lbfftCover 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 stages1st stage 30 Nm 3 kpm 22 lbfft2nd stage 80 Nm 8 kpm 58 lbfftFinal stage 110 Nm 11 kpm 80 lbfftCOOLING SKETCH 1 Reverse gear 2 Sea water pump 3 Thermostat 4 Thermostat housing 43 Notes 44 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 SwedishFrom Refers to publication Publication no Issued Date Name AB Volvo Penta Customer Support Dept 42200 SE405 08 Gothenburg Sweden77393411 English 091998

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