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' Volvo/md5a: Volvomd5a Workshop Manual Volvo Md5a Workshop Manual'



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Publ No 3061 Dec 1975WORKSHOP diesel engine ENGINE workshop manual contains repair instructions for the MD5A marine diesel engine The overhauling describe the most suitable working method to be used with the special tools listed underthe heading Special toolsBoth the engine designation and its serial number must be clearly stated in all correspondence concerning theengine and when ordering spare parts We reserve the right to carry out design modifications and for thisreason the contents of this manual cannot he regarded as binding AB VOLVO PENTA Technical Information Department NEW UNITS OF MEASUREMENT Technicians have long since tried to establish an standardized system of measurements In 1960 a decision was made to use a system called SI Systme International dUnites To a large extent this system is based on earlier systems but the units have been made uniform so that no conversions are necessary The SIsystem is now being applied within industry in Europe This manual contains the new SI units The units used previously however are also stated but in brackets The new units are Output is slated in kW kilowatts earlier unit hp horsepower Torque is stated in NM Newtonmetres earlier unit kpm kilopondmetres Engine speed is stated in rs revolutions per second earlier unit rpm revolutions per minute 3 Displacement and volumes are stated in dm cubic decimetres earlier unit l litres Pressure is stated in Pa Pascal 2 earlier unit kpcm kiloponds per square centimetre Reproduction permitted if source system thermostat housing cylinder head 3Flywheel fuel injector pump 4Oil pump transmission cover governor 5Lubricating oil pump camshaft cylinder 6Crankshaft cylinder liner camshaft bearing oil pump seawater pump 79Feed pump 9 11Fuel filter crankshaft 11Centrifugal governor piston 12 13Valve guides nozzle sleeve 14 15Valves valve seats rocker mechanism injector 15 16Hand start mechanism camshaft liner crankshaft 18Cylinder camshaft governor 19Lubricating oil pump transmission cover 20Adjustment of control rod travel assembling flywheel cover 20 21Oil sump cylinder head feed cover 22Fuel filter injector thermostat 22Flywheel generator valve adjustment 24Checking injection angle 25Bleeding the fuel system electrical system 26Wiring diagram 27Faulttracing system 28Special tools 29Technical data 30 33 Presentation 1 Connection for hand start 2 Fuse box 3 Thermostat housing 4 Decompression lever 5 Injector 6 Oil filler Cap engine 7 Water drain tap gearbox 8 Oil drain plug gearbox 9 Water drain tap engine 10 Oil filler gearbox 11 Seawater pump 12 Dipstick gearbox 13 Fuel filter 14 Bleed screw 15 Hand pump fuel 16 Dipstick engine 17 Oil filter2 Repair Drain the cooling water and the oil from the engine Clean 3 Remove the rocker cover and the fuel pipe between theexternally afterwards Loosen the water hose between the pump and the injector and unscrew the rocker gear Notegearbox and the sea water pump and remove the gearbox Pull the rocker gear straight up since it is centred with a guide pin 1 The other hole 2 is an oil channel2 Remove the generator and its drive belt starter motor 4 Remove the pushrods 1 remove the cylinder head andfuel filter and fuel pump with the drainoff pipe be careful of the cylinder head gasket Take care of the washers 2 underfuel spillage coolant water pump with hose and thermostat the nutshousing dipstick temperature and oil pressure sensorsUnscrew and discard the oil filter 35 Remove the flywheel nuts Spanner jaw width 55 mm 7 Remove the cover for the injection pump Note The2 532 Use a wooden shaft or something similar as a bracket for the cold start is fixed with one of the screwscounter force in the flywheel spokes Take care of the spring under the cover6 Fit tool 884078 to the flywheel Afterwards screw in the 8 Prise the lower ball joint free from the pump with acentre screw on the tool until the flywheel loosens screwdriver49 Remove the pump screws Position the ball in the centre 11 Remove the governor by loosening the hexagonal setand remove the pump screw 1 the governor and the gear wheel can then be withdrawn10 Remove the sump and then the transmission cover 13 12 Remove the screw and the locking washer for thescrews The lifting eye is fixed one of the screws The cover gearbox drive flange on the crankshaft and remove theis centralised by guide pins flange with a puller Use counter force Remove the key afterwards 513 Remove the lubricating oil pump Discard the gasket 15 Remove the gearwheel on the camshafts flywheel side 4 screws Then remove the camshaft and the gearwheel14 Remove the cover flywheel side 10 screws The coveris centred with guide pins The screws by the guide pins are 16 Mark and remove the bearing cap on the crankshaft andfitted with thick washers carefully knock out the piston through the cylinder617 Remove the main bearing caps Take care of the axial 19 Bearing replacement Press out the camshaft bearings ifthrust bearings 1 on the transmission side Lift the crankshaft they are damaged or if the wear is too great see technicalout and the bearing shells afterwards and then the axial data Clean the bearing housings and ensure that the oilbearing halves channels are clean Press in the new bearings so that the oil holes face the corresponding oil channels in the block When the bearings are pressed in position they are to be reamed see technical data Oilpump 20 Remove the gearwheels nuts and pull off the gearwheel18 Mark the cylinder liners position in the cylinder so that with a puller The gearwheel sits on a key take care of thisthe same position can be obtained during assembly keyRemove the cylinder liner Use tool 884551 Use the longscrew and its nut from the tool 884231 MD21MD32 Seepage 29 Special tools Discard the 0ring Afterwards removethe 0rings in the block which provide a seal for the cylinderliner and then remove the valve lifters Wash all the partsand replace those damaged 721 Remove the steel wire which holds the filter Remove Overhauling the seawater pumpand clean the wire gauze thoroughly Afterwards remove the 23 The seawater pump is a round flange type pump whichsix screws which hold the cover in position Discard the means that it can be fitted in a position best suited to thegasket coolant water hoses The new pump is fitted with an 0ring which forms a seal against the engine22 Remove the gearwheel from the housing Remove the 24 Remove the cover 6 screws Change the impeller withsplit pin for the reduction valve Remove washer 1 spring 2 the help of two screwdrivers or something similar Noteand piston 3 Clean and replace damaged parts Assemble Protect the edges of the pump housing See the figure Prisethe lubricating oil pump in the reverse order Note Fit a new out the impeller with the screwdrivers so far that the screwgasket 4 between the housing and the cover Fix the wire becomes visiblemesh 5 in position with the steel wire 6 and finally lay the keyin position and tighten the gearwheel 7 825 Unscrew the screw and withdraw the impeller from the 27 Fit new sealing rings Note The sealing rings must faceshaft If the sealing rings are to be replaced the shaft and the right way see that they do not block the drain hole in thethe impeller can be removed and the screw subsequently pump housing Smear grease on the shaft and fit it in the housing Screw it through the sealing rings so that they will not be damaged Place the shaft so far into the housing that the hole for the screw is visible Fit the impeller and screw in the screw Then carefully press in the impeller so that it touches bottom Place a new gasket on the cover and tighten the cover with the six screws26 Remove the sealing rings 1 and the 0ring 2 earlier Overhauling the feed pumpengines and clean the housing and the shaft Note The 28 Depress the pumps lever see fig If the pump creakspump must be removed from the engine Check that there then it is sound If it is unserviceable the diaphragm must beare no abrasions on the shaft Note A new 0ring is not to be replaced which is done in the following mannerfitted 929 Remove the covers centre screw remove the filter 1 31 Depress the diaphragm and shake the pump armand clean it spindle out until the pump arm is free Then remove the diaphragm from the housing30 Remove the six screws which hold the upper and lower 32 Remove screw 1 and withdraw the manual pump arm 2pump halves together Remove the pumps spring and undo and replace spring 3 if it is broken Note Be careful of thescrew 2 which holds the pump arm spindle rubber seal which is pressed into the housing 1033 Clean the pump housing carefully and replace worn Refit the manual pump arm Press in the diaphragm 35 Remove the circlip with circlip pliers Then remove theand connect the pump arm to the diaphragm centre pin gear drive Use a press or a gear puller Clean theThen push the spindle in and tighten it with the screw Note crankshaft and carry out control measurements of all theDo not forget the washer under the screw bearing surfaces Grind the shaft where necessary SeeLay the gauze filter on the upper housing and screw the technical datacover and the gasket tight Press in the pump arm 3assemble the two housing halves and fit the spring retainer 2on the mechanical pump arm 3 Note that the spring retainercan only be fitted one way Replace the spring next and the0ring 4 which provides a seal for the engineFuel filter34 When the filter insert is changed the centre screw 1 is 36 Place the key in the crankshafts key slot Heat theremoved allowing the filter holder to be removed Afterwards gearwheel to approximately 1000C 2120F no more andremove the filter insert by lifting the plastic loop 4 Wash the press it onto the crankshaft Note The marking on thefilter holder clean and fit a new filter Fit a new packing gearwheel shall face outwards Refit the circlip on thewasher 5 and refit the holder to the cover with the centre 11Centrifugal governor37 Clean the governor Check to see if the weights 2 grip 39 Mark the piston and the connecting rod Remove theon their spindle or if there is too much movement between circlips Press out the gudgeon pin with a drift The pistonthe spindle and the governor weight Afterwards check that can be heated first to ease removalthe pin 1 slides easily in the spindle Finally check both theball bearings 3 Replace the ball bearings if they are tightCheck that all the movable parts move easily lubricate andrefit them in the reverse orderPiston38 Remove the piston rings with the help of piston ring 40 Press the bush out of the connecting rod if it is worn orpliers Clean the piston and be particularly careful about the damaged Then knock out the connecting rod screws Notepiston ring grooves The screws must always be changed when the connecting rod has been dismantled 1241 Knock new screws in place and press a new bush in the 43 Fit the piston rings with the help of piston ring rod Ensure that the lubricating hole 1 in the bush Start with the oil scraper ring in the lowest groove The oilaligns with the hole in the connecting rod Ream or diamond scraper ring can be fitted either way Continue with thedrill the bush to an accurate free fit Check that the gudgeon compression ring which is marked TOP on one side Thispin slides through the bush due to its own weight See also marking shall face upwards when fitted The piston ring withthe technical data Fit one of the circlips and oil the gudgeon the chromium insert is fitted last and can be fitted either waypin and connecting rod bush Heat the piston 700C 1580F and assemble the piston andthe connecting rod according to the marking Note Thegudgeon pin must be able to be pressed in easily Fit theother circlip Cylinder head42 Control the dimensions of the piston with a micrometer 44 Remove the collets the collars and the valve springsMeasure at right angles to the gudgeon pin holes at the with the help of a valve spring compressor Remove thepistons lower edge Afterwards check the new rings play in valves Remove the valve seal from the inlet valve Burntthe piston ring grooves See technical data valves are discarded if worn too much and damaged seats are to ne machined when necessary See technical data The valves and valve seats are to be ground together so that the mating surfaces provide a complete seal 13Replacing valve guides Nozzle sleeve45 The valve guides must be replaced if there is too much 47 Remove the injector sleeve with tool 884541 Insert theplay between the valve stem and the valve guide See expanding screw in the nozzle sleeve and screw data Press out the valve guides with tool 884538 wise until the screw has expanded and gripped the sleeve Tighten hard so that the threads bite into the copper Fit the yoke onto the studs which hold the nozzle Screw on the nut and tighten until the sleeve is removed46 New valve guides are fitted with tool 884549 Use a 48 Remove the 0ring which provides a seal between thepress This tool gives the guide the right height above the sleeve and the cylinder head Clean carefully and dry withcylinder heads valve spring seat surface Check the dimen compressed air and then dip the new 0ring in a soapsion A this must be 9 mm 03543 in when the guide is solution to facilitate assembly Lubricate and fit the newpressed into place nozzle sleeve with tool 884557 Knock in the sleeve until it reaches bottom1449 Lubricate the mandrel tool 884537 and insert the tool Valve and valve seat grindinginto the sleeve Ensure that the centre screw is sufficiently 51 Machine the valve seats by milling or grinding themunscrewed Place some nuts or several washers on the Grind no more than is necessary to give the seat the correctstuds so that the yoke can be tightened in place with the shape and a good mating surface The seat angle C shall befixing nuts Screw in the mandrel as far as the mating face of 45 and the width B approximately 1 mm 00394 in Thethe sleeve allows The mandrel is then withdrawn Remove width is adjusted with a 39 and a 60 miller respectively orthe tool a grinding disc Clean the valves and grind them in a machine The valves face angle D shall be 445 The sealing surface is ground no more than is necessary to clean it If less than 1 mm 00394 in is left on the valve edge it is to be discarded Likewise the valve is discarded if the valve stern is not straight or if dimension A exceeds 25 mm 00984 in Note If this dimension is exceeded even if a new valve is fitted the cylinder head must be changed50 Adjust the length of sleeve protruding from the cylinderhead face length is 09 mm 00354 in and check that thesleeve is correctly fitted dimension 195 mm 07677 in Rocker mechanism 52 Remove the circlip from the rocker shaft and remove the rocker arms Clean the parts Be particularly careful when cleaning the rocker shaft oil channels 3 and the rocker arms oil hole see also fig 53 1553 Check the wear on the rocker shaft Also check that the Pressure testing the nozzlestappet adjustment screws spherical part is neither deformed 55 Check the shape of the jets at an opening pressure ofnor worn The threads on the screw and the locknut must be 185 kpcm 2 2631 psi Also check that the fuel sprayundamaged discontinues simultaneously at all four holes and that noOval rocker arm bushes are to be replaced Pressing in and subsequent drops appearout is performed with drift 884560 Press the bush in so thatthe oil hole assumes the position shown in the figure Thebush is reamed to a light push fit after it has been pressedin Lubricate the shaft and assemble the rocker mechanism54 Fit the rubber seal 1 on the inlet valve Use tool 884497 Adjustment of opening pressureOil the valve sterns before they are inserted in their 56 The opening pressure is adjusted with valve guides Afterwards fit the valve springs washer 1 which is available in thicknesses between 1 mmcollars and collets with the help of a valve compressor 00394 inl and 195 mm 00768 in with a difference of 005 00020 in mm between each size Dismantle the nozzle and replace the washer with a thinner or thicker washer depending on whether the pressure is to be reduced or increased Assemble the nozzle and check the opening pressure and jet shape Continue until a satisfactory result is obtained 16 Flywheel cover and hand starting mechanism that the transmission cover must be machined since the57 Unscrew nut 1 and remove it and washer 2 holding the new camshaft gear is thicker than the earlier gear andhand starting gearwheel 3 Then remove the gearwheel from consequently there is not enough space for it in thethe shaft A Knock the shaft out from the cover Loosen the transmission cover The axial guide face distance A must beset screw 5 which holds the spacer washer and knock out the filed down by 3mm 01181 inspacer washer when the bearings 7 has been removedRemove key 8 slide off the spacer ring 9 and pull off ballbearing 10 after which seal 11 can be pulled off Note If onlythe seal 11 is to be changed pin 12 can be knocked out afterwhich the seal can be removed If the camshaft is damaged this means that the camshaft gear must be replaced in this case as well This also means that the axial guide face must be filed down by 3 mm 01181 in58 Replace damaged parts and reassemble the pin sealball bearing and spacer ring on the shaft Fit the spacerwasher into the cover and tighten it in position with the setscrew Note Ensure that the spacer washers groove facesthe locking screws centre Fit the shaft in the cover Place thekey in position and then the ball bearing Fit the it with a washer and nut Knock out seal 1 from theflywheel cover Press in a new seal afterwards 60 If the transmission cover is damaged and must be replaced this means that even the camshaft and the camshaft gear must be replaced The replacement is necessary because the axial guide in the new transmission cover is shortened by 3 mm 01181 in which in turn means that the camshaft will have an axial play of 3 mm 01181 in The camshaft camshaft gear and transmission cover are interchangable as of engine no 1076 inclusive When changing camshaft gears of a later type the camshaft shall be pressed out of the camshaft gear Take care of the key Check the camshaft for wear See the technical data Place the key in the camshaft and press on the camshaft gear The distance from the camshaft end to the camshaft gears hub must be 136 mm 5354 in See figCamshaft59 In such cases on engines with engine nos 1001075where a camshaft gear change is necessary the camshaftmust be changed as well A new camshaft gear cannot befitted to an early type of camshaft Furthermore this means 17ASSEMBLING 63 Place the main bearing halves with the oil channel holes61 Check that the liner is not scratched and that it is in in the block Then place the axial bearing halves in positiongood condition otherwise Fit new 0rings 1 in the block 2 Turn the oil grooves 1 outwardsoff and a new 0ring 2 on the cylinder liner Turn the markon the liner which was made during dismantling to the markon the block Lubricate the 0rings and fit the liner Be carefulnot to damage the 0rings62 When the cylinder liner is fitted in the block the height of 64 Oil both the bearing halves and place the crankshaft inthe liner outside the block must be measured The height position Fit the main bearing shells in the bearing housingsmust not exceed 005 mm 00020 in and must not be less and place the axial bearings with the oil grooves outwardsthan 001 mm 00004 in otherwise there is a risk that a Fit the bearing housing so that the indentation in the housingleak can occur faces the same way as the indentation in the bearing half already in the block Tighten the bearing housing with a torque of 70 Nm 7 kpm 50 Lbft 1865 Remove any wear edges in the cylinder liner Oil the 67 Fit the camshaft with the camshaft gear Align the markscylinder liner and fit the piston in the block Use a piston ring on the crankshaft gear and the camshaft gearsleeve or tool 9992176 Turn the piston so that the in the piston crown faces the nozzle side66 Oil and fit the big end bearing shells in the bearing half 68 Fit the governor Tighten it in position with the set screwTurn mark to the correct position and fit the bearing halfTightening torque 70 Nm 7 kpm 50Lbft on the side See that it goes into the groove 19 369 Fit the gearwheel on the camshafts opposite end 71 Fit a new gasket for the transmission cover Afterwards fit the transmission cover Fix the lifting eye with the upper screw Adjustment of control rod travel 72 Fit a new gasket and fit the injector pump Press on the ball end of the control arm Measure and check that the control rod travel is correctly adjusted The same as prior to dismantling The measurement must be carried out with a new gasket Set the control at full throttle Press down the plunger to bottom position Note that the cold start must not be engaged during measurement The exact amount injected can only be determined when checking in a test bench70 Fit the oil pump Note the different screw lengths2073 Release the plunger 8 mm 03150 in and measure the 75 If the engine smokes abnormally the centre screw ondistance from the transmission cover face to the adjusting the cover can be loosened and the adjusting screw can bescrews contact point on the control arm adjusted until the engine runs smoke free See the technical data for the correct injection amount74 Measure the adjusting screws length and adjust any 76 Fit a new gasket and fit the flywheel cover Be careful soeventual deviation so that the plunger stops when released 8 that the sealing ring is not damaged Trim the excessivemm Screw down the cover afterwards gasket 2177 Fit a p lane packing and then fit the sump Note On 79 Replace the tappet rods and fit the rocker engines a rubber seal was used This is to be Check that the guide pin in the cylinder head goes into thereplaced by a plane packing hole in the rocker mechanism 80 Lubricate the oil filter rubber seal Screw in the oil filter78 Lubricate and replace the valve lifters Fit a new cylinder so far that the rubber seal first contacts the engine bodyhead gasket and then the cylinder head Place the washers Afterwards screw in the filter a further half turn Noteunder the nuts and tighten the nuts in three stages to 70 Nm Tighten by hand Then fit the feeder pump Use a new 0ring between the pump and the engine7 kpm 50Lbft See the tightening sequenceFirst stage 10 Nm 1 kpm 7LbftSecond stage 40 Nm 4 kpm 29LbftThird stage 70 Nm 7 kpm 50Lbft 2281 Fit the fuel filter Place sealing rings on both sides of the 83 Connect the injector pipe the temperature and oilfuel pipe unions pressure transmitters Thermostat testing82 Fit the injector The tightening torque 10 Nm 1 kpm 84 Lower the thermostat into hot water and check with a7Lbft Then connect the fuel drain pipe Note Place thermometer if the thermostat opens and closes correctly atsealing rings on both sides of the pipe unions the right temperature It should start to open at 600C 140 0F and should be fully open at 900C 194 0F If the thermostat is defective it must be replaced Clean the thermostat and fit a new gasket 1 Place the thermostat in the engine and fit the thermostat housing Then fit the water pump and connect the coolant water hose 2385 Place the key for the gearbox connecting drive on the 87 Fit the starter motor and the alternator Note Place thecrankshaft on the gearbox side Heat the connecting drive spacer tube correctly and assemble the belt tensioner Fitand fit it onto the crankshaft Lock the drive with the large and tension the drive belt so that it can be depressed 34washer and the lockwasher Tighten the screw with a torque mm 0118101575 in with normal thumb pressurewrench The tightening torque is 70 Nm 7 kpm 50LbftUse a counter force Bend the lockwasher up against thescrew head afterwards Tappet adjustment 88 Turn the flywheel until both tappets function Turn the86 Place the key for the flywheel in the crankshafts key flywheel a further complete turn and adjust the tappets Theslot Fit and tighten the flywheel Use a counter force in the clearance is 030 mm 00118 in for the inlet valve nearest flywheel and 035 mm 100138 in for the exhaust valvespokes of the flywheel The tightening torque is 500 Nm 50 when the engine is hot Fit the rocker box cover and a newkpm 362Lbft Spanner jaw width is 55 mm 2 532 ANGLE CONTROL 91 Open the level valve 1 on the measuring apparatus so89 A Wilbr tube is used when checking the injection angle that the level lies 25 30 mm 1 2 316 from the bottomFit the Wilbr tube on the pressure pipe nipple Turn the engine in the rotation direction until compression is felt90 Rotate the engine in the correct direction until the level 92 If the injection angle does not meet the prescribedtube 1 is full with airfree fuel value the number of washers 1 between the pump housing and the transmission cover is increased or decreased until the correct value is obtained One washer gives a difference in injection angle of approximately 1 2593 Fit the exhaust elbow and the gearbox Use newgaskets Check that the rubber damper is not damaged ELECTRICAL SYSTEM IMPORTANT The following applies to engines fitted with alternators 1 Do not break the electrical circuit between the alternator and the battery when the engine is running If a main switch is fitted it must therefore not be turned off until the engine is stopped No lead must be disconnected when the engine is running since this can irreparably damage the charging regulator 2 The battery battery cable and cable terminals are to be checked regularly The battery poles are to be properly clean and the cable terminals are to be tight and well greased so that a break in the circuit cannot occur All other cables are to be properly connected no loose connections must occur The batterys positive and negative connections must on no condition be exchanged when the battery is connected 3 When starting with an auxiliary battery check first that itBLEEDING THE FUEL SYSTEM has the same rated voltage as the standard battery94 Fuel system bleeding is always carried out in the Connect the auxiliary battery with positive to positive andfollowing cases When the microfilter is changed when negative to negative Remove the auxiliary battery whendraining via the drain plug when cleaning the gauze in the the engine has started Notel The cables to the standardfuel pump when the fuel tank has run dry when fitting an battery must on no condition be pump after leaks in or repairs on the fuel piping when the engine has been out of use for a long time 4 When carrying out electrical welding on the engine orBleeding is carried out as follows associated installation parts the charging regulatorsOpen the air bleed screw 1 in the microfilter Pump up fuel cable must be disconnected and insulated first Afterusing the hand pump 2 until clean airfree fuel runs out wards both the battery cable terminals can be removedClose the air bleed screw If the pump effect is poor rotate 5 When carrying out repairs on the generator both batterythe engine until the pumps drive cam assumes another cable terminals must always be disconnected The sameposition If the injector pump has been dismantled or when applies if the battery is given a quick chargethe engine is to be started for the first time after renovationthe injection pump must be bled Open the air bleed screw 3 6 Never test a connection with a screwdriver or similar toolon the injection pump Pump the hand pump 2 until airfree to see if it sparksfuel runs out Loosen the pressure connection 4 and rotatethe engine with the starter motor until fuel runs out from thepressure pipe Tighten the pressure connection and start DiagramCable Colour mm2 AWG Circuit explanationA White 6 9 1 Extra switchB Black 15 15 2 Charging control lampB Black 06 19 3 Temperature warning lampB Black 075 18 4 Oil pressure warning lampC Red 6 9 5 Key switchC Red 35 1 6 Warning unitC Red 06 19 7 ScrewF Yellow 15 15 8 Charging control lamp for secondary batteryG Brown 15 15 circuit extra equipmentH Blue 35 1 9 Place for instruments extra equipmentI GreenRed 15 15 10 Snap connectionI GreenRed 075 18 11 Starter motorJ Green 15 15 12 AlternatorJ Green 06 19 13 FuseboxJ Green 075 18 14 Main switchK BlueYellow 075 18 15 BatteryL WhiteRed 075 18 16 Temperature senderM BlueRed 075 18 17 Oil pressure sender 27 FAULT TRACINGThe fault finding chart given below only covers the most common faults which occur The engine does not reach The engine runs rough or the correct speed at full The engine becomes vibrates will not start FAULT Note abnormally hot Engine stops throttle X Main switch not connected flat battery cable See para A disconnected X X Empty fuel tank fuel tap closed blocked fuel See para B filter X X X Water air or impurities in the fuel See para B X X X X Faulty injector See para C X Boat abnormally loaded boat bilge fouled with See para C weedgrowth X X Propeller damaged See para E X Clogged coolant water intake cooling vanes See para F defective pump wheel or thermostatA Check the charge state of the battery with the help of ahydrometer which shows the specific gravity of the D To obtain the best operational economy the enginebattery acid This varies according to the state of the speed should be at least 300 rpm less that thecharge see the technical data See furthermore maximum obtainable during extended running system p 26 Note If the boat has been in the water a considerable time the maximum obtainable engine speed canB Change the microfilter by unscrewing the hexagonal decrease due to growth on the hulls underside Usehead on the filter holders base The microfilter and its growth inhibiting bottom paintholder are of a discardable type which means that the old Check and clean the hull is discarded and a new one fitted Check that theface of the cover is completely clean and that the filter E Check that the propeller blades are whole If any of thepacking is undamaged Screw the new filter by hand until propeller blades are damaged the propeller should bethe packing contacts the cover Then tighten the filter a changed A propeller blade can be out of line twisted further half turn There is a drain plug in the bottom of the this is very difficult to detect Place the propeller on a flatfilter holder for draining water and impurities in the fuel surface and measure the blades If any blade is twistedBleed the fuel system after draining and after a filter the propeller should be changedchange and then check for the cover on the feed pump and clean the pre F Check the coolant system from the point of view offilter in diesel oil Refit the filter with the notches upward leakage blockage etcand fit an undamaged packing and tighten the cover Check that the thermostat opens at the correct temperaBleed the fuel system ture The thermostat can be taken out when theCheck and drain when necessary the extra fuel filter if thermostat housing has been dismantled See alsoone is fitted Look out for spilled fuel paragraph 84 The pump impeller in the sea water pump is made ofC Check the injector with reference to opening pressure neoprene rubber and can be damaged when the watertightness and jet shape It is recommended that these supply is cut off for instance if there is a blockage in thechecks be carried out after a maximum operation time of sea water intake Paragraphs 2327 should be followed400 hours or once per season See also paragraphs 55 when changing a pump impeller and sealing rings Noteand 56 If the boat is in the water the sea cock must be closed before the sea water is dismantled Do not forget to open the cock again 28Special tools for the MD5APart No Drift for pressing out valve guides884549 Drift for pressing in valve guides884557 Drift for pressing in injector sleeve884541 Tool for removing injector sleeve884537 Drift for copper sleeve884551 Tool for removing cylinder andnut Drift for removing rocker arm bush884497 Drift for fitting rubber valve seal884543 Nipple fixture884535 Nipple for compression pressure measurement 29 TECHNICAL DIN at 40 rs 2500 rpm MD5ANo of cylinders 55 kW 75 bhpBore 1Stroke 84 mm 331 inDisplacement total 80 mm 315 inCompression ratio 0443dm 3 27 cu inCompression pressure at starter motor speed 1651Direction rotation viewed from flywheel 20 22kpcm 2 11 144 159 psiIdling speed Clockwise 92 108 rs 550 650 liner wet diameter standard mm in 84000 84015 33071 height mm inHeight from gudgeon pin centre to piston crown mm in 7730315Piston clearance mm in 490 4905 19291 19311Pistons available as standard mm in 0081 0114 00032 00045 83901 83919 33032 33039Gudgeon pinsDiameter mm inInner diameter of gudgeon pin bush mm in 25996 26000 10235 10236Clearance between gudgeon pin and bush mm in 25999 26004 10236 10237 0001 0008 000004 00003Piston ringsNumber of compression ringsNumber of oil rings 2The upper compression ring has a chromium insert 1Axial piston ring clearanceUpper compression ring mm inLower compression ring mm in 0070 0102 00028 00040Oil scraper ring mm in 0050 0082 00020 00032 0030 0062 00012 00024Piston ring gap in cylinderUpper compression ring mm inLower compression ring mm in 030 050 00118 00197Oil scraper ring mm in 030 050 00118 00197 025 050 00098 clearance end float mm inMain bearings radial clearance mm in 005 030 00020 00118Big end bearing radial clearance mm in 0040 0096 00016 00038 0040 0096 00016 00038Main bearing standard mm inDiameter undersized 0250 mm in 53987 54000 21255 21260Diameter undersized 0500 mm in 53737 53750 21156 21161 53487 53500 21058 21063Main bearing standard mm inOversized 0250 mm in 1968 1980 00775 00780Oversized 0500 mm in 2093 2105 00824 00829 2218 2230 00873 008781 Measured with a Moto Meter nipple 884535 and fixture 884543 30Connecting rod standard mm in 50987 51000 20074 20079Diameter undersized 0250 mm in 50737 50750 19975 19980Diameter undersized 0500 mm in 50487 50500 19877 19882Big end bearing standard mm in 1768 1780 00696 00701Oversized 0250 mm in 1893 1905 00745 00750Oversized 0500 mm in 2018 2030 00794 rodAxial clearance end float at crankshaft mm in 005 020 00020 clearance end float mm in 054 082 00213 00323Radial clearance in bearings mm in 0025 0075 00010 00030Camshaft diameter mm in 39975 40000 1 5738 1 5748Camshaft diameter mm in 46975 47000 18494 18504Lifting height mm in 58 02283Bearing diameter mm in 40025 40050 15758 15768Bearing diameter mm in 47025 47050 18514 18524Inlet valveValve disc diameter mm in 349 351 13740 13819Valve stem diameter mm in 7955 7970 031 32 031 38Valve seat angle 455 see fig page 15Seat angle in cylinder head 45Seat width in cylinder head mm in ca 1 00394Tappet clearance hot mm in 030 00118Outlet valveValve disc diameter mm in 279 281 10984 11063Valve stem diameter mm in 7925 7940 03120 03126Valve seat angle 445 see fig page 15Seat angle in cylinder head 45Seat width in cylinder head mm in ca 1 00394Tappet clearance hot mm in 035 00 138Valve guidesLength inlet valve mm in 52 20472Length exhaust valve mm in 52 20472Inner diameter mm in 8000 8015 03150 03156Height above cylinder blocks spring face mm in 1065 1135 04193 04469Clearance valve stemvalve guide inlet valve mm in 0030 0060 000 12 00024Clearance valve stemvalve guide outlet valve mm in 0060 0090 0 0024 0 0035Valve springsLength unloaded mm in 425 16732Loaded with a force of 170 N 17 kp 375 lb mm in 32 12598Loaded with a force of 300 N 30 kp 66 lb mm in 24 systemEngine oil capacity ex filter Imp qts US qts 20 din3 17 21Engine oil capacity inc filter Imp qts US qts 21 din3 18 22Oil quality according to API system CD DS1st alternative Above 100C 5Q0 F Volvo Penta oilDouble grade SAE 20W30Below 100C 500F Volvo Penta oil Single grade SAE l0W2nd alternative Viscosity above 100Cj500F SAE 20Viscosity below 100 50 F SAE 10Oil pressure hot engine idling kplcm 2 psi 15 25 kplcm 2 21 36Oil pressure hot engine full throttle kplcm 2 psi 40 50 kplcm 2 57 71 31Lubrication oil MANN W 77 or FRAM oil pumpType Gear pumpSpring for pressure reduction valve Length unloadedmm in 40 15748Loaded with 25 N 25 kp 55 lb mm in 34 13386Loaded with 35 N 35 kp 77 lb mm in 315 12402Gears axial clearance including packing mm in 0010 0130 0000400051Fuel systemInjector pump Bosch PFR 1K 70A 43111Injector Bosch holder KBAL 65Nozzle DLLA 150Hole diameter mm in Four 023 00091Opening pressure new nozzle kpcm 2 psi 185 2631Nozzle angle angle 25 28Fuel quantity injected 31 min3stroke at 333 rs 2000 rpmMicro FilterType Bosch 0 450 015 003Filter element Bosch 1 457 431 324Feed pumpType Pierburg PE 15672Feed pressure at 42 rs 2500 rpin kpcm 2 psi 065 085 92 121Electrical systemBattery voltage 12 VBattery capacity Max 60 AhAlternator rating max 35 AStarter motor rating 081 kW 11 hpBattery electrolyte spec gray Fully charged battery 1275 1285 gcm 3Charging to be carried out at 1230 gcm 3Cooling Bellows to open at0C 0F 60 140Fully open at 0C 0F 90 194WEAR linerReplaced when worn or if the engine has an abnormallyhigh oil consumption mm in 025 and big end ovality mm in 006 conicity mm in 005 00020Max axial clearance end float mm in 036 journals permissible ovality tom in 003 00012Max clearance between camshaft and bearings mm in 015 00059ValvesMax clearance between valve guide and valve stem mm 016 00063inValve disc edge mm thickness mm in 10 00394 32TIGHTENING head nuts 70 Nm 7 kpm 50LbftCylinder head studs 20 Nm 2 kpm 14LbftScrew for a gearbox drive on crankshaft 80 Nm 8 kpm 58 LbftFlywheel nut 500 Nm 50 kpm 362LbftBig end connecting rod bearings 70 Nm 7 kpm 50LbftWater pump drive 60 Nm 6 kpm 43LbftMain bearings 70 Nm 7 kpm 50 LbttNuts for injector holder 10 Nm 1 kpm torque for cylinder head nuts Note The tightening must be done in three stages First stage 10 Nm 1 kpm 7Lbft Second stage 40 Nm 4 kpm 29Lbft Final stage 70 Nm 7 kpm 50Lbft 333435

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