Workshop Manual A Engine unit 2 0 MD6A MD7AAB Volvo PentaCustomer SupportDept 42200SE405 08 Workshop Manual Marine diesel engines MD6A MD7A ContentsSafety Precautions 2General information 5Repair methods 8MD7A 9Repair instructions 10Electrical system 30Special Tools 34Technical Data 35 1Safety Check that the warning information decals onThis workshop manual contains technical data the product are always clearly and repair instructions for Volvo Penta Replace decals that have been damaged orproducts or product versions contained in the contents painted overlist Ensure that the correct workshop literature is beingused Engine with turbocharger Never start the enRead the safety information and the Workshop gine without installing the air cleaner ACLManual 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 thefollowing 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 coolantNOTE Used to draw your attention to important line must be removed from a hot engine It isinformation that will facilitate work or operations difficult to anticipate in which direction steam or hot coolant can spray outBelow is a summary of the risks and safety precautionsyou should always observe or carry out when operating Hot oil can cause burns Avoid skin contactor 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 wellventilated 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 turbochargers 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 2Always use protective goggles where there is a Store oil and fuelsoaked rags and fuel anddanger of pieces of metal sparks from oil filters safely In certain conditions oilgrinding acid or other chemicals being thrown soaked rags can spontaneously ignite Usedinto 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 withAvoid skin contact with oil Longterm or used lubricating oil contaminated fuel paintrepeated contact with oil can remove the remnants solvent degreasing agents andnatural oils from your skin The result can be waste from washing dry skin eczema and other skinproblems Used oil is more dangerous to health Never allow a naked flame or electric sparksthan new oil Use protective gloves and avoid near the batteries Never smoke in proximityusing oilsoaked clothes and rags Wash to the batteries The batteries give offregularly especially before meals Use the hydrogen gas during charging which whencorrect 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 theMost 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 damageand workshop chemicals solvents and paints Do not disturb battery connections whenare hazardous to health Read the instructions starting the engine spark risk and do noton the product packaging carefully Always fol lean over batterieslow safety instructions using breathing apparatus protective goggles and gloves for exam Never mix up the positive and negativeple Ensure that other personnel are not battery terminals when installing exposed to hazardous substances installation can result in serious damage toby breathing them in for example Ensure that electrical equipment Refer to is good Handle used and excess according to instructions Always use protective goggles whenBe extremely careful when tracing leaks in the charging and handling batteries The batteryfuel system and testing fuel injection nozzles electrolyte contains extremely corrosiveUse protective goggles The jet ejected from a sulfuric acid If this comes into contact withfuel injection nozzle is under very high pres the skin wash immediately with soap andsure it can penetrate body tissue and cause plenty of water If battery acid comes intoserious injury There is a danger of blood contact with the eyes immediately flush withpoisoning copious amounts of water and obtain medical assistanceAll fuels and many chemicals are that a naked flame or sparks cannot ig Turn off the engine and turn off power atnite fuel or chemicals Combined with air in cer main switches before carrying out work ontain ratios petrol some solvents and hydrogen the electrical systemfrom batteries are easily inflammable andexplosive Smoking is prohibited Ensure that Clutch adjustments must be carried out is good and that the necessary the engine turned offsafety precautions have been taken beforecarrying out welding or grinding work Alwayshave a fire extinguisher to hand in theworkplace 3Use the lifting eyes mounted on the enginere When working onboard ensure that there isverse 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 liftthe engine engine weight including reverse Components in the electrical system ignitiongear and any extra equipment installed system gasoline engines and fuel systemTo ensure safe handling and to avoid on Volvo Penta products are designed anddamaging engine components on top of the constructed to minimize the risk of fire andengine use a lifting beam to raise the engine explosion The engine must not be run inAll chains and cables should run parallel to areas where there are explosive materialseach other and as perpendicular as possible inrelation to the top of the engine Always use fuels recommended by VolvoIf extra equipment is installed on the engine al Penta Refer to the Instruction Book The usetering its center of gravity a special lifting de of lower quality fuels can damage thevice is required to achieve the correct balance engine On a diesel engine poor quality fuelfor safe handling can cause the control rod to seize and theNever carry out work on an engine suspended engine to overrev with the resulting risk ofon a hoist damage to the engine and personal injury Poor fuel quality can also lead to higherNever remove heavy components alone even maintenance costswhere secure lifting equipment such assecured blocks are being used Even wherelifting equipment is being used it is best to carryout the work with two people one to operatethe lifting equipment and the other to ensurethat components are not trapped and damagedwhen being lifted 4General the workshop manual Certified enginesThis workshop manual contains technical specifica The manufacturer guarantees that certified new andtion descriptions and instructions for repairing the currently operational engines meet national and restandard versions of the following engines gional environmental regulations in Lake TAMD31L TAMD31P AD31L AD31P for example The product must be the same as theKAD32P TAMD41H TAMD41M TAMD41P AD41P example approved for certification purposes So thatTAMD42WJ KAMD42A KAMD42B KAMD42P Volvo Penta as a manufacturer can guarantee thatKAD42A KAD42B KAD42P KAMD43P KAD43P currently operational engines meet KAD44P The workshop manual displays regulations the following service and replacementthe operations carried out on any of the engines part requirements must be observedabove As a result the illustrations and pictures in themanual that show certain parts on the engines do The Service Intervals and maintenance operationsnot in some cases apply to all the engines listed recommended by Volvo Penta must be observedabove However the repair and service are the same in all essential details Only Volvo Penta genuine replacement parts inWhere they are not the same this is stated in the tended for the certificated engine may be usedmanual and where the difference is considerable theoperations are described separately Engine The servicing of ignition timing and fuel and numbers are given on the number systems gasoline or injector pumps pump setplate See Workshop manual Group 21 Engine page tings and injectors diesel must always be carried15 The engine designation and number should be out be an authorized Volvo Penta workshopgiven in all correspondence about the engine The engine must not be modified in any way apartThis Workshop Manual has been developed primarily from with accessories and service kits developedfor Volvo Penta service workshops and qualified per for it by Volvo Pentasonnel Persons using this book are assumed tohave a grounding in marine drive systems and be No modifications to the exhaust pipes and airable to carry out related mechanical and electrical supply ducts for the engine room ducts may be undertaken as this may effect ex haust emissionsVolvo Penta is continuously developing their products We therefore reserve the right to make chang Seals may only be broken by authorized persones All the information contained in this book is based nelon product data available at the time of going to printAny essential changes or modifications introduced IMPORTANT Use only Volvo Penta Genuineinto production or updated or revised service Partsmethods introduced after the date of publication will Use of nonoriginal AB Volvo Penta sparebe 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 requirements Any type of damage resulting from the use ofReplacement parts nonoriginal Volvo Penta replacement parts for the product will not be covered under any warReplacement parts for electrical and fuel systems are ranty provided by AB Volvo Pentasubject 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 VolvoPenta 5Repair methodsThe working methods described in the Service Our joint apply to work carried out in a workshop Theengine 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 ofengine in place follows the same working method an otherwise good engine may be increased significantly It is therefore vital that wear symbols occurring in the Workshop Manual are maintained that systems that can be adjustedfor 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 testingNOTE equipment for service and maintenance Some comare 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 sealedservice work or repairs may be carried out For this components except by authorized we can only highlight the risks that can arisewhen work is carried out incorrectly in a well Bear in mind that most chemicals used on boats areequipped workshop using working methods and tools harmful to the environment if used incorrectly Volvodeveloped by us Penta recommends the use of biodegradable de 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 us special care when working onboard that oil anding 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 waterpossible It is therefore the responsibility of any person using tools or working methods other than the Tightening torquesones recommended by us to ensure that there is no Tightening torques for vital joints that must be tightdanger of injury damage or malfunction resulting ened with a torque wrench are listed in workshopfrom these manual Technical Data Tightening Torques and are contained in work descriptions in this Manual AllIn some cases there may be special safety precau torques apply for cleaned threads screw heads andtions and instructions for the use of tools and chemi mating surfaces Torques apply for lightly oiled or drycals contained in this Workshop Manual These spe threads If lubricants locking fluid or sealing comcial instructions should always be followed if there pound are required for a screwed joint thisare 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 tighteningcan prevent most risks arising A clean workplace torques stated are a guide and the joint does notand engine eliminates much of the danger of injury have to be tightened using a torque wrenchand malfunction Dimension Tightening TorquesIt is of the greatest importance that no dirt or foreign Nm lbtftparticles get into the fuel system lubrication system M5 6 44intake system turbocharger bearings and seals M6 10 74when they are being worked on The result can be M8 25 184malfunction or a shorter operational life M10 50 369 M12 80 590 M14 140 1033 6Tightening angle To ensure service work is correctly carried out it istightening 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 manufacturer 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 anticorrosion agent before ap tightening torque has been plying sealant or locking fluid applied Always follow the manufacturers instructions for use regarding temperature range curing time and any other instructions for the Two different basic types of agent are used on theDo not reuse lock nuts that have been removed dur engine and these areing dismantling as they have reduced service lifewhen reused use new nuts when assembling or re RTV agent Room temperature vulcanizing Use forinstalling For lock nuts with a plastic insert such as gaskets sealing gasket joints or coating gasketsNylock the tightening torque stated in the table is RTV agent is clearly visible when a component hasreduced if the Nylock nut has the same head height been dismantled old RTV must be removed beforeas a standard hexagonal nut without plastic insert the joint is resealedReduce the tightening torque by 25 for bolt size 8mm or larger Where Nylock nuts are higher or of The following RTV agents are mentioned in the Servthe 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 casesScrews and nuts are divided into different strength Anaerobic agents These agents cure in an absenceclasses the class is indicated by the number on the of air They are used when two solid parts for exambolt head A high number indicates stronger material ple cast components are installed facetoface withfor example a bolt marked 109 indicates a higher out a gasket They are also commonly used to setolerance 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 glasslikeof a bolted joint must be reinstalled in their original and it is therefore colored to make it visible Curedposition 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 Whenmake 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 241A number of sealants and locking liquids are used on bluethe engines The agents have varying properties andare 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 sizes in the engines Recess for starting crank2 Oil filling engine3 Sealed crankcase ventilation4 Intake silencer5 Connection fuel inlet6 Feed pump7 Reduction reverse gear MS red 19118 Control lever reverse gear9 Oil filling reverse gear10 Oil pressure contact11 Lubricating oil filter12 Fuel filter14 Watercooled exhaust manifold15 Decompression handle16 Injectors17 Temperature sender18 Cooling water outlet19 Thermostat housing20 Throttle lever21 Stop lever22 Fuel injection pump23 Oil dipstick engine24 Fuel return line connection25 Seawater pump26 Oil dipstick reverse gear 8MD7A1 Oil dipstick and oil filling reverse gear2 Cover cooling water pump3 Bleedscrew fine filter4 Fine filter5 Decompression handle6 Pressure pipe nut7 Temperature sender8 Injector9 Thermostat housing10 Oil filling engine11 Hand start12 Cooling water drain engine13 Fuel injection pump14 Oil dipstick engine15 Cooling water drain reverse gear16 Air cleaner and intake silencer17 Sender rev counter18 Fuel pump with hand pump19 Cooling water inlet reduction gear20 Oil drain reverse gear reduction gear21 Warner low oil pressure22 Oil filter 9Repair the cooling water and oil from the engine Then 3 Remove the thermostat housing 2 bolts and theclean the outside of the engine Remove the reverse hose clamp under the housing Take thegear 4 bolts thermostat out of the exhaust manifold Note the small Oring which seals against the exhaustRemoval manifold1 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 splash2 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 105 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 pump6 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 119 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 gasket10 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 1213 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 gear14 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 screwdriver 1317 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 con18 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 1421 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 key22 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 1525 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 desired26 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 refitted 16Cylinder head 31 Replacing the valve guides With excessive clearance between the valve29 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 etc30 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 17Removing the nozzle sleeves Installing the valves33 Insert the expander screw on tool 884541 into 35 Thoroughly clean the cylinder head valve guides the copper sleeve and screw anticlockwise 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 valves34 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 00001034 a Oil the spreader tool mm 0000004 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 pump37 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 simultaneously at all four holes does not the diaphragm must be replaced This and there is no dripping afterwards is done as the opening pressure38 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 1941 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 342 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 20Overhauling the seawater pump 47 Remove the sealing rings 2 and the 0ring 1 earlier engines and clean the pump body and45 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 shaft46 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 21Checking the thermostat 51 Oil and fit the bearing halves in the caps Place the caps according to the marking on the block49 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 0 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 manifold 52 Turn the piston rings so that their respective gaps are apart from each other The piston top isINSTALLING THE ENGINE marked with Front and should point towards the flywheel NOTE Fit the connecting rod which is50 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 outwards 2253 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 pins54 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 2357 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 fitted58 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 2461 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 out62 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 2565 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 bolts66 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 2669 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 engine70 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 2773 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 fig 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 2 374 Fit the fuel pipes between the injection pump and the injectors NOTE Check to make sure that the brake pipes are properly installed see Fig 76 Adjust the valves as follows Rotate the flywheel until both valves on a cylinder rock Turn the flywheel one further75 Adjusting the BOSCH injection pump turn and adjust the valves for this cylindera 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 blockb 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 pumpc Tighten the nutsd 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 coincidee Fit the inspection cover with the rubber gasket 2877 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 connect78 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 flywheel 81 Fill the engine and reverse gear with oil Concer ning the oil quantity and quality see under Technical Data 29Electrical 3 When starting with the help of a helper battery82 The following applies to engines fitted with first check that the helper battery has the same alternators rated current as the standard one Connect the1 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 cables2 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 disconnected wellcleaned and the cable terminals always 5 In the event of repairs to the alternator welltightened 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 welltightened 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 sparksFig 82 Wiring diagram for the MD6A with startgenerator no rev counter and temp gaugeCable Marking 1 Starter button 2 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 Startgenerator 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 30Fig 83 Wiring diagram for late prod Type MD6A1 Key switch2 Instrument panel switch3 Temperature gauge4 Warning light for low oil pressure5 Rev counter6 Warning light charging Switch optional equipment8 Terminal board9 Warning light charging alternator Optional Equipment10 Battery11 Main switch12 Alternator Optional Equipment14 Charging regulator15 Fuse16 Temperature sender17 Rev counter18 Oil pressure sender19 Other electrical equipment 31Wiring Diagram MD7ACABLE MARKINGDes Colour mm 2 AWGA White 6 9B Black 15 15B Black 06 19B Black 075 18C Red 6 9C Red 35 1C Red 06 19F Yellow 15 15G Brown 15 15H Blue 4 11H Blue 35 1I Greenred 075 18J Green 15 15J Green 06 18J Green 075 18K Blueyellow 075 18L Whitered 075 18M Bluered 075 18Position List2 Charging warning light3 Warning light for high temperature4 Warning light for low oil pressure5 Key switch 12 Alternator6 Siren 13 Fuse7 Alarm unit 14 Main switch9 Place for instrument extra equipment 15 Battery10 Terminal board 16 Temperature sender11 Starter motor 17 Oil pressure sender 32FAULT TRACING Bleeding the fuel system To ensure that the engine starts the fuel system mustThe faulttracing scheme below includes only those be bled on the following occasions 1 When changingfaults 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 beenA 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 propellerB 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 33Special ToolsPart No 34Technical DataTechnical Data designation MD6AOutput DIN at 40 revsec 2400 revmm 74 kW 10 hpNumber of cylinders 2Bore 70 mm 27560Stroke 82 mm 32283 3Capacity ratio 1871 2 2 1Compression pressure at starter motor speed 2325 kpcm 327355 lbfin Direction of rotation viewed towards flywheel speed 12 revsec 700 revmin 2 2Oil pressure hot engine 4 kpcm 57 lbfin 2 2Oil pressure idling hot engine 08 kpcm 11 lbfin Cast ironBore standard 7000070019 mm 27560275660500 mm 0020 oversize 7050070519 mm total 81 mm 319Height from gudgeon pin centre to piston crown 51 mm 200Piston clearance in cylinder 00860130 mm standard 6988969914 mm 27515275250500 mm 0020 oversize 7038970414 mm pinsDiameter 279975280025 mm pin bushing diameter 280125280225 mm gudgeon pin bushing 00100025 mm rings number 2Oil scraper ring number 1Upper compression ring has chromium liningPiston rings are available for standard size and 0500 mm0020 oversizePiston ring clearance in groove axiallyUpper compression ring 00620113 mm compression ring 00370087 mm 0001500034Oil scraper ring 00370089 mm ring gap in cylinderUpper compression ring 02790406 mm compression ring 02030330 mm 0008000130Oil scraper ring 03500480 mm Nodular ironCrankshaft axial clearance 008031 mm 0003100122Main bearing radial clearance 00260075 mm rod radial clearance 00260075 mm 00010000301 Measured with Moto Meter nipple 884535 and yoke 884543 35Main bearing standard 4998450000 mm 19679196850300 mm undersize 4968449700 mm 19560195670600 mm undersize 4938449400 mm 1944219449Main bearing standard 17301737 mm 00681006840300 mm oversize 20302037 mm 00800008020600 mm oversize 23302337 mm rod standard 4998450000 mm 19679196850300 mm undersize 4968449700 mm 19560195670600 mm undersize 4938449400 mm rod standard 17301737 mm 00681006840300 mm oversize 20302037 mm 00800008020600 mm oversize 23302337 mm rodsEnd play at crankshaft 025050 mm play 01600300 mm clearance in bearing 00170083 mm diameter 4399244008 mm 1732017326Lift height of cams 548552 mm diameter 4402544075 mm headMaterial Specialalloy cast ironIntake valvesDisc diameter 288290 mm 1133811417Stem diameter 79387960 mm seat angle head seat angle 30Width of seat in cylinder head approx 1 mm 0040Clearance hot engine 030 mm 0012Exhaust valvesDisc diameter 263265 mm 1035410433Stem diameter 79387960 mm seat angle head seat angle 30Width of seat in cylinder head approx 1 mm 0040Clearance hot engine 030 mm 0012Valve guides 43 mm 16930Length intake valve 49 mm 1 9291Length exhaust valve 80008022 mm 0315003158Bore 107110 mm above cylinder head spring face 00400084 mm valve stemguide 36Valve springsLength offload 47 mm 1 8504Loaded with 150 N 15 kp 33 Ibf 30 mm 11811Loaded with 230 N 23 kp 50 lbf 21 mm capacity excl filter 28 litres 25 Impqts 29 US qtsOil capacity incl filter 30 litres 26 lmpqts 32 US qtsOil quality acc to APIsystem CD DS 0 0Viscosity above 10 C 50 F SAE 30 0 0Viscosity below 10 C 50 F SAE 20W 2 2Oil pressure hot engine idling speed 081 5 kpcm 11 42 1 3 Ibfin 2 2Oil pressure hot engine full speed 3540 kpcm 5057 lbfin Reverse gearOil Same as for engine 3Oil capacity din qts red 11 04 04 3Oil capacity din qts red 191 1 05505Combi reduction gearReduction gear same oil compartment as mechanism and propeller hub Lubricating grease Shell Alvania EP2 or oil ACDELCO 1530838 type SALubricating oil pumpType Gear wheel pumpRelief valve spring Length offload 45 mm 17717Loaded with 15 N 15 kp 33 lbf 40 mm 15748Loaded with 46 N 46 kp 10 Ibf 29 mm 11417Axial clearance of gear wheels incl gasket 00480084 mm 0002000033Fuel systemFuel injection pump make Bosch 0 460 302 006Injectors make Bosch holders 0 431 112 001Nozzles 0 433 171 001Hole diameter Four 022 mm 00087 2 2Opening pressure 180 kpcm 2560 Ibfin Spray angle 150Advance angle 12 3Injection quantity 20 mm stroke at 317 revsec 1900 revminMax speed 408425 revsec 24502550 revminFine filterType Bosch 0 450 133 001Filter insert Bosch 1 457 434 0611Feed pumpType Pierburg PE 15672 2 2Feed pressure at 40 revsee 2400 revmm 065085 kpcm 92120 lbfin 37Electrical systemBattery voltage 12 VBattery capacity Max 60 Bosch 0 010 350 004Generator output max 135WGenerator output continuous 90 WStarter motor output 074kW 1 hp 3Battery electrolyte specific gravity Fully charged batter 12751285 gcm 3When charging has to be carried out 1230 gcmCooling Bellows thermostat 0 0Starts opening at 60 C 140 F 0 0Fully open at 74 C 165 FWEAR with wear or if engine has abnormal 025 mm bearing and connecting rod outofroundness 006 mm 00024Permitted taper 005 mm 00020Max axial play on crankshaft 036 mm journals permitted outofroundness 003 mm 00012Max clearance between camshaft and bushings 015 mm 00060ValvesMax clearance between valve stem and guide 016 mm 00063Edge of valve disc should be mm 10 mm TORQUES Nm Kpm LbftfCylinder head nuts 70 7 51Cylinder head stud bolts 20 2 14Bolt for flange on crankshaft 70 7 50Flywheel nut 180 18 130Connecting rod bolts 50 5 36Water pump flange 60 6 43Main bearings 50 5 36Nuts for fork for injectors 8 08 58Tightening scheme for cylinder head nuts 38Technical Data designation MD7AOutput at flywheel DIN at 43 revsec 2600 revmm 10 kW 134 hpNumber of cylinders 2Bore 76 mm 29921Stroke 82 mm 32283 3Capacity 0744 dmCompression ratio 171 2 2Compression pressure at starter motor speed 225 MPa 2025 kpcm 284355 lbfin Direction of rotation viewed towards flywheel speed 1113 revsec 650780 revmin 2 2Oil pressure full speed hot engine 035040 MPa 3540 kpcm 5057 lbfin 2 2Oil pressure idling hot engine 008015 MPa 0815 kpcm 1121 lbfin Cast ironBore standard 76007603 mm 2992129933025 mm 0010 oversize 76257628 mm 3002030032050 mm 0020 oversize 76507653 mm total 764 mm 30079Height from gudgeon pin centre to piston crown 514 mm 20236Piston clearance in cylinder 00730118 mm standard diameter 7591275927 mm 2988329893025 mm 0010 oversize 7616276177 mm 2998529991050 mm 0020 oversize 7641276427 mm pinsDiameter 2800028004 mm pin bushing diameter 280125280225 mm gudgeon pin bushing 0008500230 mm rings number 2Oil scraper ring number 1The upper compression ring is chromium linedPiston rings are available for standard size 0250 mm0010 and 0500 mm 0020 oversizePiston ring clearance in groove axiallyUpper compression ring 00700102 mm compression ring 00500082 mm 0002000030Oil scraper ring 00300062 mm ring gap in cylinderUpper compression ring 030050 mm 001200020Lower compression ring 030050 mm 001200020Oil scraper ring 025050 mm Nodular ironCrankshaft axial clearance 00800313 mm 0003200123Main bearing radial clearance 00260075 mm bearings radial clearance 00260075 mm 0001000030 39Main bearing standard 4998450000 mm 1 9679196850300 mm 00120 undersize 4968449700 mm 19560195670600 mm 00236 undersize 4938449400 mm 1944219449Main bearing standard 17301737 mm 00681006840300 mm 00120 oversize 18801 887 mm 00740007430600 mm 00236 oversize 20302037 mm standard 4998450000 mm 19679196850300 mm 00120 undersize 4968449700 mm 19560195670600 mm 00236 undersize 4938449400 mm standard 17301737 mm 00681006840300 mm 00120 oversize 18801887 mm 00740007430600 mm 00236 oversize 20302037 mm rodsEnd play at crankshaft 025050 mm play 01600300 mm clearance in bearing 001 80083 mm diameter 4399244008 mm 1 732017326Lift height of cams 548552 mm diameter 4402644075 mm 1 headMaterial Specialalloy cast ironIntake valvesDisc diameter 324326 mm 1275612835Stem diameter 79557970 mm seat angle 45 15 45 45Cylinder head seat angle 45Width of seat in cylinder head approx 1 mm 0040Clearance hot engine 030 mm 0012Exhaust valvesDisc diameter 274276 mm 1078710866Stem diameter 79507965 mm seat angle 45 15 45 45Cylinder head seat angle 45Width of seat in cylinder head approx 1 mm 0040Clearance hot engine 030 mm 0012Valve guidesLength intake valve 38 mm 1 4961Length exhaust valve 38 mm 1 4961Bore 808015 mm above cylinder head spring face 885915 mm valve valve 003006 mm valve 00350065 mm 0001400026 40Valve springsLength offload 425 mm 16732Loaded with 17010 N 171 kp 3752 lbf 32 mm 12598Loaded with 30020 N 302 kp 6645 lbf 24 mm capacity excl filter 28 litres 25 lmpqts 29 US qtsOil capacity incl filter 30 litres 26 lmpqts 32 US qtsOil quality ace to APIsystem CD DS 0 0Viscosity above 10 C 50 F SAE 20 W 0 0Viscosity below 10 C 50 F SAE 10 W 2 2Oil pressure hot engine idling speed 0815 kpcm 11 421 3 lbfin 2 2Oil pressure hot engine full speed 3540 kpcm 5057 lbfin Reverse gearOil Same as for engine 3Oil capacity din qts red 11 04 04 3Oil capacity din qts red 1911 055 05Combi reduction gearReduction gear Same oil compartment as mechanism and propeller hub Lubricating grease Shell Alvania EP2 or oil pumpType Gear wheel pumpRelief valve spring Length offload 45 mm 1 7717Loaded with 15 N 15 kp 33 lbf 40 mm 15748Loaded with 46 N 46 kp 10 lbf 29 mm 1 1417Axial clearance of gear wheels incl gasket 00480084 mm 0002000033Fuel systemFuel injection pump make Bosch Up to engine no 19999 0 460 302 008Fuel injection pump CAV From engine no 20000 0 3222 F070Injectors make Bosch holders 0 431 112 001Nozzles 0 433 171 009Hole diameter Four 023 mm 00091 2 2Opening pressure 185193 kpcm 26312744 lbfin 0Spray angle 150 CAdvance angle Bosch pump 11 1 btdcAdvance angle CAV pump 14 01 btdcInjection quantity Bosch pump 1805 mgstroke at 43 revsec 2580 quantity CAV pump 17505 mgstroke at 43 revsec 2580 revmmFeed pumpType Pierburg PE 15672 2 2Feed pressure at 42 revsec 2500 revmm 065085 kpcm 92120 lbfin 41Electrical systemBattery voltage 12 VBattery capacity Max 120 AhStarter motor Bosch 0 001 311 115Starter motor output 11 kW 148 hpAlternator SEV Marchal 70 output 490W 35A 3Battery electrolyte specific gravity Fully charged battery 12751285 gcm 3When charging has to be carried out 1230 gcmCooling Bellows thermostat 0 0Starts opening at 60 C 140 F 0 0Fully open at 74 C 165 FWEAR for wear or if engine has abnormal fuel consumption 025 mm bearing and connecting rod outofroundness 006 mm 00024Permitted taper 005 mm 00020Max axial play on crankshaft 040 mm journals permitted outofroundness 003 mm 00012Max clearance between camshaft and bushings 015 mm 00060ValvesMax clearance between valve stem and guide 015 mm 00060Edge of valve disc should be mm 10 mm torques Nm Kpm Lbf ftCylinder head nuts 70 7 51Cylinder head stud bolts 20 2 14Bolt for flange on crankshaft 70 7 51Flywheel nut 180 18 130Connecting rod bolts 70 7 51Water pump flange Bosch fuel injection pump 60 6 43Water pump flange CAV fuel injection pump 80 8 58Main bearings 50 5 36Nuts for fork for injectors 8 08 58Bolt for intermediate gear transmission 70 7 51Starter motor bolt 70 7 51Bolt front engine mounting 45 45 33Bolt rear engine mounting 45 45 33Tightening scheme for cylinder head nuts 42 Longitudinal section Cross section43